QY25D Truck Crane

Operator’s Manual

Edition 1 7, 2014
 Operator’s Manual for Truck Crane

To Users
起
重
机 appreciates your selection of ZOOMLION truck crane for your application.
Zoomlion
说
明 should operate the crane unless they read and understand the information in this manual.
No one

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
起
重
DANGER,机 WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this
说
manual to show important instructions. In this manual, the labels follow the paragraph or item they
明
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
起
重
机
To Users .............................................................................................................................................. I
说
明
Safety Instructions ............................................................................................................................ II

Chapter 1 Description of Crane

1.1 Model and name plates .................................................................................................... 1-1

1.1.1 Model .................................................................................................................... 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 model and its manufacturer...................................................................... 1-2
1.1.6 Engine code, name plate and their locations ....................................................... 1-2
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 Technical data ..................................................................................................... 1-10
1.3.3 Work parameters ................................................................................................ 1-13
1.3.4 Lifting capacity tables ......................................................................................... 1-14
1.3.5 Lifting height chart .............................................................................................. 1-22
1.3.6 Working areas .................................................................................................... 1-25

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 ................................................................................................. 2-5
2.3 Break-in instructions ......................................................................................................... 2-6
2.4 General safety technical guidelines .................................................................................. 2-7
2.4.1 Requirements of the crane operator, rigger and signalman ................................. 2-7
2.4.2 Selecting an operating site ................................................................................... 2-9
2.4.3 Supporting .......................................................................................................... 2-11
2.4.4 Working conditions ............................................................................................. 2-12

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 Operator’s Manual for Truck Crane

2.4.5 Points for attention for safe operation ................................................................ 2-16

2.5 Hand signals ................................................................................................................... 2-19
起
重
Chapter
机3 Operation – Crane Chassis
说
3.1 Driver’s cab ....................................................................................................................... 3-1
明
3.1.1 Overview ............................................................................................................... 3-1
3.1.2 Steering wheel assy. ............................................................................................. 3-3
3.1.3 Instrument panel assy. and display unit................................................................ 3-6
3.1.4 Media player ....................................................................................................... 3-19
3.1.5 Gear lever ........................................................................................................... 3-20
3.1.6 Parking brake hand lever.................................................................................... 3-20
3.1.7 Air horn button .................................................................................................... 3-20
3.1.8 Foot pedal (R): Engine control............................................................................ 3-20
3.1.9 Foot pedal (M): Service brake ............................................................................ 3-20
3.1.10 Foot pedal (L): Clutch ....................................................................................... 3-20
3.1.11 Crane lighting .................................................................................................... 3-21
3.1.12 Door, driver's cab .............................................................................................. 3-22
3.1.13 Seats in driver's cab ......................................................................................... 3-23
3.1.14 Attachments ...................................................................................................... 3-23
3.2 Before starting up the vehicle ......................................................................................... 3-25
3.2.1 Prerequisites ....................................................................................................... 3-25
3.2.2 General checks before setting off ....................................................................... 3-25
3.2.3 General checks at vehicle start up ..................................................................... 3-26
3.3 Driving the crane............................................................................................................. 3-27
3.3.1 Starting and stopping the engine ........................................................................ 3-27
3.3.2 Transmission operation ...................................................................................... 3-29
3.3.3 Clutch operation ................................................................................................. 3-30
3.3.4 Steering operation .............................................................................................. 3-31
3.3.5 Brake operation .................................................................................................. 3-31
3.3.6 PTO operation .................................................................................................... 3-33
3.3.7 Towing................................................................................................................. 3-34
3.4 Points for attention .......................................................................................................... 3-36
3.4.1 Road driving ....................................................................................................... 3-36
3.4.2 Crane movements in off-road conditions ............................................................ 3-37
3.4.3 Park the vehicle .................................................................................................. 3-37
3.4.4 Emergency stop on the roadway ........................................................................ 3-37

IV QY25D531R Truck Crane

 Operator’s Manual for Truck Crane

Chapter 4 Operation – Crane Superstructure

起
4.1 Operator’s cab .................................................................................................................. 4-1
重
机 4.1.1 Overview............................................................................................................... 4-1
说
4.1.2 Control panel ........................................................................................................ 4-2
明
4.1.3 Control levers ....................................................................................................... 4-7
4.1.4 Engine control pedal ............................................................................................. 4-8
4.1.5 Operator's seat ..................................................................................................... 4-8
4.2 Computer system ............................................................................................................. 4-9
4.3 Starting up the crane ...................................................................................................... 4-10
4.3.1 Checks before starting up .................................................................................. 4-10
4.3.2 Starting and stopping the engine ........................................................................ 4-11
4.4 Safety devices ................................................................................................................ 4-12
4.4.1 Level gauge ........................................................................................................ 4-12
4.4.2 Angle indicator .................................................................................................... 4-12
4.4.3 Hoisting limit switch ............................................................................................ 4-13
4.4.4 Lowering limit switch .......................................................................................... 4-15
4.4.5 Hydraulic safety devices ..................................................................................... 4-15
4.4.6 Emergency off button ......................................................................................... 4-17
4.5 Crane operation .............................................................................................................. 4-18
4.5.1 Preparations for crane operation ........................................................................ 4-18
4.5.2 Outrigger ............................................................................................................. 4-19
4.5.3 Derricking ........................................................................................................... 4-27
4.5.4 Telescoping......................................................................................................... 4-29
4.5.5 Lifting / lowering.................................................................................................. 4-31
4.5.6 Slewing ............................................................................................................... 4-36
4.5.7 Simultaneous crane movements ........................................................................ 4-38
4.5.8 Rope reeving ...................................................................................................... 4-41

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 ....................................................................................................... 5-6
5.2.4 Dismantling ........................................................................................................... 5-7
5.2.5 Reeving in the auxiliary hoist rope ....................................................................... 5-8
5.2.6 Connection of hoisting limit switch ....................................................................... 5-8

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 Operator’s Manual for Truck Crane

5.3 Rooster sheave............................................................................................................... 5-10

5.3.1 Assembly ............................................................................................................ 5-10
起
重 5.3.2 Dismantling ......................................................................................................... 5-11
机
说6 Additional Equipment
Chapter
明
6.1 Air conditioning in driver's cab .......................................................................................... 6-1
6.1.1 Operating methods ............................................................................................... 6-1
6.2 Air conditioning in operator's cab ..................................................................................... 6-4
6.2.1 Air conditioning ..................................................................................................... 6-4

Chapter 7 Transportation and Storage

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

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

VI QY25D531R Truck Crane

Operator’s Manual for Truck Crane

Chapter 1 Description of Crane

 Operator’s Manual for Truck Crane

Description of Crane
Chapter 1 Description of Crane

1.1起Model and name plates

重
1.1.1
机 Model
说
Model in engineering industry: QY25D
明
Chassis model: ZLJ5331JQZ

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.

汽 车 起 重 机
TRUCK CRANE
品牌及型号 Trade Mark & Model 中 联 牌 Q Y 25D
产品特征号 Product Characteristic Code Q Y 25D 531R
最大额定起重量 Max. Rated Lifting Capacity 25000 kg
发动机型号 Engine Model W P 10.270
发动机额定功率 Engine Rated Power 199 kW
发动机最大净功率 Max. Engine Net Power 197 kW
最大允许总质量 Max. Authorized Total Mass 32400 kg
整车整备质量 Complete Vehicle Kerb Mass 32270 kg
外形尺寸(长×宽×高) Overall Dimensions 13000 m m× 2550 m m× 3500 mm
车辆识别代号 VIN L5E6B3D3××A××××××
出厂编号 Production No.
生产日期 Production Date 年(Y.) 月(M.)
制造国 Production Country 中国 China
中联重科股份有限公司制造
MANUFACTURER:ZOOMLION HEAVY INDUSTRY SCIENCE & TECHNOLOGY CO.,LTD.

Figure 1-1 Name plate of crane

汽车起重机专用底盘
TRUCK CRANE SPECIAL PURPOSE CHASSIS
品牌及型号 Trade Mark & Model 中联牌Z L J 5 3 31 J Q Z
产品特征号 Product Characteristic Code ZLJ5331JQ ZD 3R
最大允许总质量 Max. Authorized Total Mass 33000 kg
整车整备质量 Complete Vehicle Kerb Mass 11700 kg
发动机型号 Engine Model W P 10.270
发动机额定功率 Engine Rated Power 199 kW
发动机最大净功率 Max. Engine Net Power 197 kW
车辆识别代号 VIN L5E6B3D3××A××××××
出厂编号 Production No.
生产日期 Production Date 年(Y.) 月(M.)
制造国 Production Country 中国 China

中联重科股份有限公司制造
MANUFACTURER:ZOOMLION HEAVY INDUSTRY SCIENCE & TECHNOLOGY CO.,LTD.

Figure 1-2 Name plate of chassis

QY25D531R Truck Crane 1-1

 Operator’s Manual for Truck Crane
Description of Crane

1.1.3 Name plates installation locations

The name plate of crane is installed on the right side of operator’s cab.
起name plate of chassis is installed on the right longitudinal beam of chassis frame.
The
重
For exact installation locations, please refer to Figure 1-3.
机
说
明
10 20
0 10 20
30
30
40

50
60
60
70
70 80
80

Crane name plate Chassis name plate VIN

Figure 1-3 Name plate locations

1.1.4 Vehicle identification number (VIN) and its locations

The VIN of QY25D is L5E6B3D3××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 1-3.

1.1.5 Engine model and its manufacturer

Engine model: WP10.270
Manufacturer: WEICHAI POWER Co., Ltd.

1.1.6 Engine code, name plate and their locations

As for WP10.270 engine:
The engine code is stamped on the right part of engine near the gear chamber.
The engine name plate is installed on left part of engine.
The exact locations are shown in Figures 1-4 and 1-5.
Note: Have the above engine data available when communicating with us.

1-2 QY25D531R Truck Crane

 Operator’s Manual for Truck Crane

Description of Crane
起
重
机
说
明

Engine code

Figure 1-4 Engine code location

Engine name plate

Figure 1-5 Engine name plate location

QY25D531R Truck Crane 1-3

 Operator’s Manual for Truck Crane
Description of Crane

1.2 Crane components and product description

1.2.1 Crane components
起
1.2.1.1重Crane chassis
机
说
7
明

5
4

8
3
9
2
10
1
11

12
13
14

15

Figure 1-6 Main components of crane chassis

Pos. Description Pos. Description

1 Engine housing 9 Toolbox

2 Driver’s cab 10 Rear axle

3 Exhaust system 11 Intermediate axle

4 Platform 12 Guard rail

5 Propeller shaft 13 Front outrigger box

6 Chassis frame assy. 14 Air intake system

7 Spare tire 15 Front axle

8 Rear outrigger box

1-4 QY25D531R Truck Crane

 Operator’s Manual for Truck Crane

Description of Crane
1.2.1.2 Complete vehicle

起
重
机
说
明 1
2

3 14
4
20 50
0 10 3040

6070
80

5 13
6 12
11
10

9
8

Figure 1-7 Main components of complete vehicle

Pos. Description Pos. Description

1 Telescopic boom 8 Slewing gear

2 Length sensor 9 Operator’s cab

3 Angle sensor 10 Derricking gear

4 Jib 11 Auxiliary hook

th
5 Auxiliary winch 12 The 5 outrigger

6 Main winch 13 Special purpose chassis

7 Outrigger 14 Main hook

QY25D531R Truck Crane 1-5

 Operator’s Manual for Truck Crane
Description of Crane

1.2.2 Product description

1.2.2.1 Crane chassis

起
重
Driver's The low-mounted sheet steel semi-cab offers a comfortable and functional
机cab
说 working environment.
明 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 manually operated windows
– Air conditioning
– 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 single-plate clutch

Transmission 8-speed mechanical transmission with contrate gear output

Main and auxiliary transmissions are with a synchronizer.

Suspension Front axle with longitudinal leaf spring suspension, and rear axle with leaf
spring + equalizer beam + thrust rod suspension
Tandem-axle balanced suspension is applied.

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

Description of Crane
1.2.2.2 Crane superstructure

Operator's cab The sheet steel cab offers a comfortable and functional working
起
重 environment.
机 The cab has the following features:
说 – Sliding door
明
– Adjustable seat with headrest
– Manual 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.
Built-in slide blocks with compensation technology applied have the
guidance capability and lifting capacity improved.
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, manual proportional control, with proportional

speed-regulating system
Driven by the quadruple gear pump

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

QY25D531R Truck Crane 1-7

 Operator’s Manual for Truck Crane
Description of Crane

1.2.3 Boom
It includes main boom and jib.
起
The 重boom has five parts to it: 1 basic boom and 4 telescopic sections.
Main机 boom length: 10.6 m – 40.0 m
Jib说 length: 8 m
明
When the fully extended main boom is fitted with jib (3 offsets: 5°, 17° and 30°), the boom
length L is 48 m (40 m + 8 m).

30°
Jib length: 8.0 m 5° 17°

Main boom length (fully Main boom length (fully

extended): 40.0 m extended): 40.0 m

Main boom
length (fully
retracted):
10.6 m

Figure 1-8 Boom lengths

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 Operator’s Manual for Truck Crane

Description of Crane
1.3 Technical data
1.3.1 Overall view
起
重 Unit: Metric mm
机
说
明 0 10 20
30
40

50
60 70
80

3500
12° 220 20°
240
2720 1350 4325 2055 (2310)
13000x2550
a

R 3385 2440 2920

4200
2550
6100

0
2 59
R1
0
0 00
0

R1
40
R8

5360

2040 1830
2550
c d
c d

Figure 1-9 Overall view

QY25D531R Truck Crane 1-9

 Operator’s Manual for Truck Crane
Description of Crane

1.3.2 Technical data

Table 1-1 Technical data
起
重 Item Value Remarks
机
说 Max. rated lifting capacity kg 25000
明 Max. load moment of basic
kN.m 1029
boom
Max. load moment of main
kN.m 564
boom (fully extended)
Max. lifting height of basic
m 11.1
boom
Max. lifting height of main These parameters
m 40.5
boom (fully extended) do not include
Work
deflection of boom
performance Max. lifting height of jib m 48.5
and jib.
Max. hoist rope speed th
m/min 120 Drum 4 layer
(main winch)
Max. hoist rope speed nd
m/min 100 Drum 2 layer
(auxiliary winch)

Boom derricking up time s 40

Boom telescoping out time s 80

Slewing speed r/min 0 – 2.2

Max. driving speed km/h 78

Max. gradeability % 37

Turning diameter m ≤ 22

Min. ground clearance mm 235

Limits for exhaust pollutants Comply with ECE R49

Driving
and smoke related standards (EURO IV)
Oil consumption per hundred
L 35
kilometers

Front / rear overhang angle ° 20 / 12

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

1-10 QY25D531R Truck Crane

 Operator’s Manual for Truck Crane

Description of Crane
Table 1-1 Technical data (continued)

Item Value Remarks

起
Deadweight in driving
重 kg 32400
机 condition
说
Complete vehicle kerb mass kg 32270
明
Mass
Front axle load kg 6500

Rear axle load kg 25900

Overall dimensions
mm 13000 × 2550 × 3500
(L × W × H )

Outrigger spread (L) m 5.36

Fully extended: 6.1,

Outrigger spread (W) m intermediately
extended: 4.2

Main boom length m 10.6 – 40

Boom angle ° -2 – 80

Dimensions Jib length m 8

Offset ° 5, 17, 30

Front / rear overhang mm 2055 / 2720

Number of axles 3

Wheelbase mm 4325 + 1350

Front mm 2040
Treads
Rear mm 1830 / 1830

Tail slewing radius mm 3385

Model WP10.270

6-cylinder in line,
Type turbo-charged,
inter-cooling
Engine Fuel type Light diesel oil

Displacement ml 9726

Rated power / RPM kW/r/min 199 / 2200

Max. torque / RPM N.m/r/min 1100 / 1200 – 1600

QY25D531R Truck Crane 1-11

 Operator’s Manual for Truck Crane
Description of Crane

Table 1-1 Technical data (continued)

Item Value Remarks

起
重 Model 8JS118TB-B
机
Mechanical stepped
说 Type
明 speed change
Mechanical manual
Operating method
operation
Transmission 8 forward and 1
Number of speeds
reverse speeds
Forward speeds:
11.40/7.94/5.63/4.06/2
Speed ratio
.81/1.96/1.39/1.00,
reverse speed: 11.35

Steering type Steering wheel

Outer diameter of
mm 480
steering wheel

Steering column Universal coupling

Steering Model PY-ZJ120C-Z/Y

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

Steering Model QC20/15-WP10-ZL

pump Type Gear type

Drive type 6×4

Drive axle
Speed ratio 5.92

Number of leaf springs (front / rear) 12 / 10

Cab capacity 2

Fuel tank capacity L 250

Hydraulic oil tank capacity L 500

1-12 QY25D531R Truck Crane

 Operator’s Manual for Truck Crane

Description of Crane
1.3.3 Work parameters

1.3.3.1 Max. support strength per outrigger

起
When the crane is working within the rated lifting capacities, the max. support strength per
重
机
outrigger is 30 tons.
说
1.3.3.2
明 Hook

Table 1-2 Hook configuration

Model Number of pulley Max. reeving Weight Remarks

25 tons 4 8 285 kg Straight shank with single hook

3 tons - 1 105 kg

1.3.3.3 Rope specification

Table 1-3 Rope specification

Standard
Type of rope Specification Length
code
4V×39S+5FC-17.0-1870-
Main hoist rope GB 8918-2006 190000 mm
left-hand ordinary lay
4V×39S+5FC-17.0-1870-
Auxiliary hoist rope GB 8918-2006 120000 mm
left-hand ordinary lay

1.3.3.4 Standard rope reevings

Table 1-4 Standard rope reevings for various boom lengths

Boom length 10.6 m 10.6 m – 18 m 18 m – 29 m 29 m – 40 m 40 m + 8.0 m

Reeving 8 6 4 3 1

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) The max. permissible lifting capacity of single wire rope is 4000 kg.

QY25D531R Truck Crane 1-13

 Operator’s Manual for Truck Crane
Description of Crane

1.3.4 Lifting capacity tables

This crane is provided with several lifting capacity tables. The operator should select proper
起 lifting load referring to resp. lifting capacity tables according to actual working conditions.
rated
重
机
说
明

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 Operator’s Manual for Truck Crane

Description of Crane
Table 1-5 Lifting capacity table

Unit: kg
起
重 Main boom
机
Radius
说
明
(m) Outriggers and telescoping cylinder I fully extended, over sides and rear

10.6 m 14.3 m 18.0 m 23.5 m 29.0 m 34.5 m 40.0 m

3.0 25000 23000
3.5 25000 23000 19500
4.0 24500 22500 19000 14500
4.5 22500 22000 18000 14500
5.0 21000 19500 16500 14000
5.5 18500 18000 15500 13000 10800
6.0 16500 16300 14500 12000 10200
6.5 14500 14500 13500 11500 9800
7.0 13000 13000 12500 11000 9400 7800
7.5 12000 12000 11500 9800 9000 7400
8.0 11200 11200 11000 9500 8500 7000
9.0 9100 9000 8500 7600 6600 6000
10.0 7500 7400 7600 7000 6200 5500
11.0 6200 6200 6800 6200 5600 5100
12.0 5200 5800 5600 5200 4800
13.0 4300 5000 5200 4700 4400
14.0 3600 4300 4600 4400 4000
15.0 3600 4000 4000 3800
16.0 3100 3500 3600 3400
18.0 2300 2700 2900 2900
20.0 2050 2300 2400
22.0 1500 1750 1900
24.0 1100 1300 1450
26.0 950 1050
28.0 700 800
30.0 620
I 0 3.7 7.4 7.4 7.4 7.4 7.4
II 0 0 0 5.5 11.0 16.5 22.0
Reeving 8 6 6 4 4 3 3
Hook 25 tons

QY25D531R Truck Crane 1-15

 Operator’s Manual for Truck Crane
Description of Crane

Table 1-6 Lifting capacity table

Unit: kg
起
重 Main boom
机
Radius
说 Outriggers fully extended and telescoping cylinder I intermediately extended,
明
(m)
over sides and rear
10.6 m 14.3 m 19.8 m 25.3 m 30.8 m 36.3 m
3.0 25000 23000
3.5 25000 23000
4.0 24500 22500 14000
4.5 22500 22000 14000
5.0 21000 19500 14000 10600
5.5 18500 18000 13000 10400
6.0 16500 16300 12000 10000
6.5 14500 14500 11500 9600 7600
7.0 13000 13000 11000 9200 7600
7.5 12000 12000 10000 8800 7200
8.0 11200 11200 9800 8500 6800 6000
9.0 9100 8500 7600 6500 6000
10.0 7500 7600 6800 6200 5400
11.0 6200 6600 6200 5600 5000
12.0 5600 5600 5000 4800
13.0 4800 5200 4700 4300
14.0 4000 4400 4200 4000
15.0 3400 3850 3900 3800
16.0 2800 3200 3500 3300
18.0 2600 2900 2900
20.0 1800 2250 2250
22.0 1300 1800 1800
24.0 1200 1300
26.0 900 1000
28.0 650 750
30.0
I 0 3.7 3.7 3.7 3.7 3.7
II 0 0 5.5 11.0 16.5 22.0
Reeving 8 6 4 4 3 3
Hook 25 tons

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Description of Crane
Table 1-7 Lifting capacity table

Unit: kg
起
重 Main boom
机
Radius
说 Outriggers fully extended and telescoping cylinder I fully retracted, over
明(m)
sides and rear
10.6 m 16.1 m 21.6 m 27.1 m 32.6 m
3.0 25000 14000
3.5 25000 14000
4.0 24500 14000 10400
4.5 22500 14000 10400
5.0 21000 14000 10400
5.5 18500 13000 10400 7500
6.0 16500 12000 10000 7500
6.5 14500 11500 10000 7200
7.0 13000 11000 10000 7000
7.5 12000 9800 9800 6800 6000
8.0 11200 9500 9500 6600 5700
9.0 8200 8800 6300 5400
10.0 7400 8200 5800 5100
11.0 6500 7300 5100 4700
12.0 5500 6300 4500 4200
13.0 4700 5500 4200 3900
14.0 3800 4800 3950 3500
15.0 4200 3700 3200
16.0 3600 3500 3000
18.0 2800 2900 2600
20.0 2500 2200
22.0 1900 1700
24.0 1500 1300
26.0 1000
28.0
30.0
I 0 0 0 0 0
II 0 5.5 11.0 16.5 22.0
Reeving 8 6 4 3 3
Hook 25 tons

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Description of Crane

Table 1-8 Lifting capacity table

Unit: kg
起
重 Main boom
机
Radius
说 Outriggers intermediately extended and telescoping cylinder I fully extended,
(m)明
over sides and rear
10.6 m 14.3 m 18.0 m 23.5 m 29.0 m 34.5 m 40.0 m
3.0 25000 23000
3.5 22000 22000 19000
4.0 20000 20000 19000 14000
4.5 18000 18000 16500 14000
5.0 15000 15000 15000 12000
5.5 12500 12500 12300 11500 10200
6.0 10000 10200 10300 10900 9500
6.5 9000 8800 8700 9500 9000
7.0 7800 7600 7500 8200 8000 7500
7.5 6500 6500 6500 7100 7500 7000
8.0 6000 4500 5500 6300 6300 6300
9.0 3500 4300 4900 5300 5700 5500
10.0 2800 3300 3900 4300 4600 5000
11.0 2500 3100 3500 3800 4000
12.0 1800 2500 2900 3100 3400
13.0 1400 2000 2300 2600 2800
14.0 1000 1600 1900 2100 2400
15.0 1200 1500 1800 2000
16.0 9000 1200 1500 1700
18.0 800 1000 1100
20.0 700 800
22.0
I 0 3.7 7.4 7.4 7.4 7.4 7.4
II 0 0 0 5.5 11.0 16.5 22.0
Reeving 8 6 6 4 4 3 3
Hook 25 tons

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Description of Crane
Table 1-9 Lifting capacity table

Unit: kg
起
重 Main boom
机
Radius
说 Outriggers and telescoping cylinder I intermediately extended, over sides
明
(m)
and rear
10.6 m 14.3 m 19.8 m 25.3 m 30.8 m 36.3 m
3.0 25000 23000
3.5 22000 22000
4.0 20000 20000 14000
4.5 18000 18000 14000
5.0 15000 15000 14000 10200
5.5 12500 12500 12500 10200
6.0 10000 10200 10900 10000
6.5 9000 8800 9200 9500 7500
7.0 7800 7600 8000 8500 7200
7.5 6500 6500 7000 7500 7000
8.0 6000 4500 6100 6500 6800 5800
9.0 3500 4800 5200 5500 5500
10.0 2800 3800 4200 4500 4800
11.0 3000 3300 3700 4000
12.0 2300 2800 3100 3300
13.0 1800 2200 2600 2800
14.0 1400 1900 2100 2300
15.0 1100 1500 1800 2000
16.0 850 1200 1500 1700
18.0 750 1000 1100
20.0 800
22.0
I 0 3.7 3.7 3.7 3.7 3.7
II 0 0 5.5 11.0 16.5 22.0
Reeving 8 6 4 4 3 3
Hook 25 tons

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Description of Crane

Table 1-10 Lifting capacity table

Unit: kg
起
重 Main boom
机
Radius
说 Outriggers intermediately extended and telescoping cylinder I fully
明
(m)
retracted, over sides and rear
10.6 m 16.1 m 21.6 m 27.1 m 32.6 m
3.0 25000 14000
3.5 22000 14000
4.0 20000 14000 10200
4.5 18000 14000 10200
5.0 15000 14000 10200
5.5 12500 13000 10200 7500
6.0 10000 11000 10000 7500
6.5 9000 10000 10000 7200
7.0 7800 8300 9000 7000
7.5 6500 7400 7800 6800 5800
8.0 6000 6500 6800 6400 5500
9.0 5000 5500 5800 5000
10.0 4000 4500 4900 4300
11.0 3600 3800 4100 4100
12.0 3000 3000 3500 3700
13.0 2500 2500 3000 3100
14.0 2200 2500 2700
15.0 1900 2100 2300
16.0 1600 1800 2000
18.0 900 1000 1500
20.0 700 1100
22.0
I 0 0 0 0 0
II 0 5.5 11.0 16.5 22.0
Reeving 8 6 4 3 3
Hook 25 tons

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Description of Crane
Table 1-11 Lifting capacity table

Unit: kg
起
Main boom + jib
重
机 Outriggers fully extended
Boom
说 40.0 m + 8.0 m
明
angle
5° 17° 30°
Over sides and rear Over sides and rear Over sides and rear
80° 3000 2200 1600
78° 2900 2150 1600
76° 2800 2100 1500
74° 2650 2000 1450
72° 2450 1850 1400
70° 2250 1750 1350
68° 2100 1600 1300
66° 1900 1500 1250
64° 1650 1400 1200
62° 1450 1250 1050
60° 1200 1100 950
58° 1000 900 800
56° 850 750 650
54° 700 600 500
52° 570 5200 470
50° 430 410 400
1 reeving
3 tons hook

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 Operator’s Manual for Truck Crane
Description of Crane

1.3.5 Lifting height chart

起
重 52
80° 75° 70°
机 40.0m +8m 65°
30°
说 48 17° 60°
明 5°
55°
44
50°
40.0m
40
45°
34.5m
36

Lifting
32
height 29.0m 40°
(m)
28
35°
23.5m
24
30°
18.0m
20
25°
14.3m
16
20°
10.6m
12

4 8 12 16 20 24 28 32 36

Working radius (m)

Figure 1-10 Lifting height chart

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Description of Crane
CAUTION
(1) The sliding beams must be extended (to a uniform length on both sides) to the
起
extent stated in the lifting capacity tables. All wheels must be raised clear of the
重
机 ground.
说
(2) When you set up the 5
th
outrigger, the values in the lifting capacity tables are
明
suitable for 360° full range operation.

(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: 285 kg, auxiliary hook:
105 kg) and slings.

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

(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) If the actual boom length and working radius are between two adjacent values given
in the lifting capacity table, you should use the interpolation method to determine
the rated lifting capacity. The rated lifting capacity displayed on the load moment
limiter is for reference.
(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 (700 kg).
(7) The maximum lifting capacity for the rooster sheave is 3000 kg. If the rated lifting
capacity found out in the lifting capacity table is less than 3000 kg according to the
actual working conditions, the lifting capacity found out in the table should be
referred to.
For example:
The rated lifting capacity is 3000 kg when the crane is working with 18 m long main
boom under 6.5 m working radius.

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 Operator’s Manual for Truck Crane
Description of Crane

The rated lifting capacity is 2050 kg if the crane is working with 28.4 m long main
boom under 20 m working radius.
(8) During operation, do not lift a load with both the main hook and auxiliary hook
起
重simultaneously.
机
说
明 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.

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Description of Crane
1.3.6 Working areas

起 Over front
重 Over sides and rear
机
说
明

Figure 1-11 Working areas

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Operator’s Manual for Truck Crane

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

Safety Guidelines
crane on roads!
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 safety 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

a) The locations of safety signs are as shown in Figure 2-1.
b) Points for attention:
1) The signs for all the potential danger referred in the Operator's Manual have been
stuck on specified positions. Do not move the signs without permission!
2) 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.

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1 2

起
重
机
说
明
Safety Guidelines

3 4 5 6 7 (3) 8 (7)
a Erectly left side

Operator’s cab
(4)

Hydraulic oil tank

Engine housing
°C
F

(6) 9 (9)

b Other sides

Figure 2-1 Overview of the safety signs on the machine

1 Exit
紧急出口
EXIT

2 No standing under the boom.

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 Operator’s Manual for Truck Crane

3 Keep clear of moving outriggers.

危 险
DANGER

起
重
机
说
明

Safety Guidelines
4 Be careful in the working radius.

5 Caution – Risk of falling.

注 意
CAUTION

6 Caution – Swinging Load

注 意
CAUTION

7 Prohibited – No Access Only

Authorized Personnel 警 告
WARNING

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8 Fire extinguisher

起
重
机
说
明
Safety Guidelines

9 Burn Hazard: Contact with hot

surfaces can cause burns. 警 告
WARNING

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2.2 Planning crane operation

起
In addition to a perfectly working crane and a well-trained crew, crane operation planning is an
重
important principle of safe crane operation.
机
The crane operator must obtain or receive the necessary information in a timely fashion before
说
明
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.
Based 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
重 can extend crane service life, increase work reliability and save energy consumption.
机attention to the following items during the break-in period:
Pay
说
a) During initial crane operation (less than 100 operating hours), you must follow the below
明
Safety Guidelines

instructions during this time period:

– The work load and work speed must not be too high.
– The maximum lifting capacity should not be larger than 80% of the rate one.
– Do not operate the crane at a speed that is more than the maximum limits.
b) Do not drive the crane at the 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) When the vehicle is driving for the first 600 – 1500 km, replace the engine oil.
d) Increase the driving speed or engine RPM gradually after the first 600 km and 2000 km.
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 drum 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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2.4 General safety technical guidelines

2.4.1 Requirements of the crane operator, rigger and signalman
起
重
The primary responsibility of crane operator, rigger and signalman is to control, operate, adjust
机
the crane and conduct the operation in a manner that is safe for both themselves and others.
说
明
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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 Operator’s Manual for Truck Crane

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
physical to operate the crane safely. Be able to estimate the distance, height and
起
重clearance correctly.
k) 机Know how to administer first aid and know how to use a fire extinguisher. Know how to
说
survive in an emergency.
明
Safety Guidelines

Make sure that only the personnel who are qualified and authorized are allowed to operate the
crane.

DANGER
(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 work.

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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
起
to conduct the crane operation, but such work can only be done by one person at any time.
重
机
Qualifications for signalman:
说
a) Be qualified with the work in hearing, eyesight and reaction ability.
明

Safety Guidelines
b) Be able to estimate the distance, height and clearance correctly.
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 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
A1
For stiff or semi-solid cohesive ground:
A1 = T
T refers to the depth of ditch.
T

DANGER
If the safety distance can not 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 to the ground. In certain cases, a single outrigger has to transmit almost the entire
forces
重
weight of the crane, plus the load weight, to the ground. The ground must be able to safely
机
absorb
说 this pressure every time. If the outrigger pad area is inadequate, then it must be
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 show in Table 2-1, and it is for reference
only.

Table 2-1 Load bearing capacity of the ground

Ser. 2
Soil type Load bearing capacity (kg/cm )
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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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 the a soil test.
起
重
机
说
CAUTION
明
Only strong materials may be used for the outrigger pad bases such as properly

Safety Guidelines
dimensioned wooden timbers.
In order to ensure that 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 can not be more than 0.6°. Refer to Figure 2-2.

Figure 2-2 Inclination angle of crane

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 Operator’s Manual for Truck Crane

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
机 cases.
说
After the crane is supported, examine the following safety measures:
明
Safety Guidelines

a) The placement location has been selected in such a way that the crane can be operated
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
2
the wind pressure is 125 N/m .

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
起
Beaufort Description wind speed Effect of the wind on the land
重 speed (m/s)
(m/s)
机
说
0 Calm 0 – 0.2 0 – 0.3 No wind, smoke rises vertically
明
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 = 0.625 νs . (p represents wind pressure, unit:
2

N/m , ν s represents average instantaneous wind speed, unit: m/s)

2

K h represents height changing coefficient of wind pressure.

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 Operator’s Manual for Truck Crane

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
Height机above
≤ 10 10 – 20 20 – 30 30 – 40 40 – 50 50 – 60 60 – 70 70 – 80
说 (m)
ground
明
Safety Guidelines

Kh 1 1.13 1.32 1.46 1.57 1.67 1.75 1.83

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 higher than 2000 m, have the crane made to order.
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.

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

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2.4.4.4 Other Conditions

a) During crane operation, if the visibility is less than 200 m, do the tasks that follow:
起 1) Stop the work (safely lower the load).
重
2) Retract the boom.
机
说 3) Correctly stow the boom.
明
b) During crane operation, stop working in case of thunderbolt or rainstorm. At the same time,

Safety Guidelines
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
same time, full retract and correctly stow the boom.

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

DANGER
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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2.4.5 Points for attention for safe operation

a) Personnel must stay away from the area below
起the boom.
重
机
说
明
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 than 0.6° during
operation.
起
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.
起
重
机
说
明
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

a) Start
起
重 Hold the right arm stretched
机 vertically upwards. The palm
说
faces forwards.
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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 Operator’s Manual for Truck Crane

e) Lower the load

With arm extended downward
with a 30° angle to the body,
起
重forefinger pointing down, move
机hand in small horizontal circle.
说
明
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.

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h) Lower the load slowly

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

Safety Guidelines
i) Rotate slowly
Turn left: With right forearm
vertical, the palm of the hand
facing outwards, move forearm
horizontally and repeatedly,
fingers pointing in the direction of
rotation.
Turn right: With left forearm
vertical, the 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.

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 Operator’s Manual for Truck Crane

k) Raise boom
Arm extended, finger closed,
thumb pointing upward.
起
重
机
说
明
Safety Guidelines

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

m) Raise boom slowly

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

n) Lower boom slowly

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

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o) Extend boom
Both fists in front of body with
thumbs pointing outwards.
起
重
机
说
明

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

q) Stop
Arm extended, palm down, and
move the arm back and forth
horizontally.

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

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 Operator’s Manual for Truck Crane

s) End a movement
Cross your hands in front of your
forehead.
起
重
机
说
明
Safety Guidelines

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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

Crane Chassis
Operation –
2 6

Figure 3-1 Cab exterior

Pos. Description Pos. Description

1 Rotating beacon 5 Side turn signal

2 Corner marker light 6 Front windshield wiper

3 Door handle 7 Front combination signals

4 Mirror

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 Operator’s Manual for Truck Crane

起
重
机 1
说
明
2

3
Crane Chassis
Operation –

4 5 6 7 8

Figure 3-2 Cab interior

Pos. Description Pos. Description

1 Sun visor 5 Foot pedal (L): Clutch

2 Steering wheel assy. 6 Foot pedal (M): Service brake

3 Instrument panel assy. and display unit 7 Foot pedal (R): Engine control

4 Driver’s seat 8 Air horn switch

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 Operator’s Manual for Truck Crane

3.1.2 Steering wheel assy.

See Figure 3-3.
起
重
机
说 4
明

5
1
3
2

Crane Chassis
Operation –
Figure 3-3 Steering wheel assy.

Pos. Description Pos. Description

1 Ignition starter switch 4 Electric horn buttons

2 Steering wheel adjustment handle 5 Left-hand steering column switch

3 Steering wheel

3.1.2.1 Steering wheel adjustment handle

The height and position of the steering wheel can be adjusted to suit the driver.
You can adjust the height and position of the steering wheel when you pull the adjustment
handle on the steering column 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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 Operator’s Manual for Truck Crane

3.1.2.2 Left-hand steering column switch

See Figure 3-4.
起
重
机
说 1
明

3
4

Ⅱ
Ⅰ
2 O
J
Crane Chassis
Operation –

Figure 3-4 Left-hand steering column switch

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 2): activate turn signal (left).
b) Switch between the low beam and high beam and operate the headlamp flasher
Jog the switch upwards (in direction 3) 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) Activate the windshield wiper
Rotate the end of this steering column switch to activate the windshield wiper. The
windshield wiper has 4 stages:
J: Intermittent
I: Low speed
II: High speed
O: Off

d) Activate the windshield wiper washer system

Press the button (in position 4) on the end of this steering column switch. The washer and
wiper begin to work. They will not stop working until the button is released.

CAUTION
The wiper stops if the washer system sprays washer fluid for 15 seconds or if the
washer fluid tank is empty.

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 Operator’s Manual for Truck Crane

Do not operate the wipers on sunny days unless you spray the window with wiper
fluid.
When the temperature is below freezing, make sure that the wiper blades are not
起
重 stuck to the window before you set the wipers to ON.
机
3.1.2.3
说 Electric horn buttons
明
They are in the central area of the steering wheel. Press either of the two buttons on the left or
right side of the central area to activate the electric horn.

3.1.2.4 Ignition starter switch

The 4 positions of the switch (in clockwise direction) 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

Crane Chassis
Operation –
work.
ON The entire electrical system is electrified.
S A temporary position, use it to operate the starter. The key will return to position
“ON” automatically after being released 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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3.1.3 Instrument panel assy. and display unit

3.1.3.1 Instrument panel assy.

起
重
1 2
机
说
明

60 80 5
15 20
100 25
40 km/h 10 × 100r/min

120 30
20 5
km HOURS

0 140 0 35
Crane Chassis
Operation –

40 80 100 120 0 1/2 1 4 6 0 2 4 6 8 10 18 24 28 32

℃ 2 8 ×0.1 MPa V

0 10
×0.1 MPa

3 4 5 6 7

Figure 3-5 Instrument panel assy.

Pos. Description Pos. Description

1 Tachometer 5 Barometer

2 Odometer 6 Engine oil pressure gauge

3 Water thermometer 7 Voltmeter

4 Fuel gauge

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3.1.3.2 Instruments
1 Tachometer
起 Displays engine speed (RPM) and engine
重 60 80
operating time. 100
机 40 km/h
说
120
明 20
km
0 140

2 Odometer
Displays the speed of the crane in
15 20
kilometers per hour (km/h) when the crane 25
10 × 100r/min

Crane Chassis
Operation –
is moving and displays its total driving
30
distance. 5
HOURS

0 35

3 Water thermometer
40 80 100 120
Displays the engine coolant temperature in
degrees Celsius °C. ℃

4 Fuel gauge
Displays the fuel reserves. 0 1/2 1

5 Barometer
The two pointers resp. display the pressure 4 6
of air reservoir for the front axle and air 2 8
reservoir for the intermediate and rear axles.
0 10
×0.1 MPa

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 Operator’s Manual for Truck Crane

6 Engine oil pressure gauge

0 2 4 6 8 10
Displays the engine oil pressure when the
engine is running.
起 ×0.1 MPa
重
机
说
明

7 Voltmeter
18 24 28 32
Displays the voltage of generator during
engine running and displays the voltage of V
battery when engine stops.
Crane Chassis
Operation –

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3.1.3.3 Display unit

起 1 11
重 2 12
机
说
3 13
明

5
4 14

5 15
6 16

7 17

Crane Chassis
Operation –
8 18

9 19
10 20

Figure 3-6 Display unit

Pos. Description Pos. Description

a
Warning light Control light
1 9
Charge monitoring Emergency steering
Control light Warning light
2 10
High beam Door opened
Control light Warning light
3 11
Vehicle direction of travel left Engine coolant level low
Warning light Control light
4 12
Brake pressure low Rear fog light
Control light Control light
5 13
Longitudinal differential lock Vehicle direction of travel right
a
Warning light Control light
6 14 th
Engine coolant temperature high The 5 outrigger fully retracted
Control light Control light
7 15
Parking brake closed Transversal differential lock
Control light Warning light
8 16
Diesel engine preheating system Engine oil pressure low

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 Operator’s Manual for Truck Crane

Pos. Description Pos. Description

Control light Warning light

17 19
起Engine exhaust brake Engine error code displayed
重 a
Warning light Control light
18 机 20
说ABS defects PTO engaged
明 indicated with a are optional.
The parts

1 Warning light Charge monitoring

Illuminates:
The ignition starter switch is in position ON.
Extinguishes after engine starts:
The generator begins to charge the battery.
Crane Chassis
Operation –

CAUTION
If the warning light illuminates during engine
running, the generator is defective. Stop to
examine at once!

2 Control light High beam

Illuminates:
The high beam or headlamp flasher is ON.

3 Control light Vehicle direction of travel left

Illuminates:
The vehicle is to turn left.

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4 Warning light Brake pressure low

Illuminates:
起
重 Brake pressure is low.
机 Extinguishes:
说
Brake pressure increases to the specified value.
明

CAUTION
Do not drive the vehicle if the warning light lights
up.

5 Control light Longitudinal differential lock

Illuminates:

Crane Chassis
Operation –
The button “Longitudinal and transversal differential
locks” is switched on and the longitudinal differential
is locked.

6 Warning light Engine coolant temperature high

Illuminates:
Engine coolant temperature exceeds the maximum
permissible value.
Examine the water thermometer and bring the
vehicle to a standstill to examine the engine cooling
system.

WARNING
Do not stop the engine immediately when the
engine coolant temperature is above the
maximum limit. If you stop the engine, the
coolant temperature decreases suddenly and
damage to the engine occurs. Immediately
operate the engine at a RPM above idle to help
decrease the coolant temperature.

7 Control light Parking brake closed

Illuminates:
The parking brake is applied.
Do not start the vehicle until the parking brake is
released and the control light extinguishes.

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8 Control light Diesel engine preheating system

Illuminates:
The engine is being preheated.
起
重
机
说
明 a
9 Control light Emergency steering
Illuminates:
The ignition starter switch is in position ON.
Extinguishes:
The vehicle speed exceeds 15 km/h.
Note:
Crane Chassis
Operation –

If the vehicle is not equipped with an emergency

steering system, this control light always
extinguishes.

10 Warning light Door opened

Illuminates:
The door is opened.

WARNING
Do not drive the vehicle if the warning light lights
up!

11 Warning light Engine coolant level low

Illuminates:
Engine coolant level in expansion tank is lower than
the set value.

12 Control light Rear fog light

Illuminates:
The rear fog light is ON.

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13 Control light Vehicle direction of travel right

Illuminates:
The vehicle is to turn right.
起
重
机
说
明 a th
14 Control light The 5 outrigger fully retracted

CAUTION
Do not drive the vehicle if the control light goes
off.

15 Control light Transversal differential lock

Crane Chassis
Operation –
Illuminates:
The button “Longitudinal and transversal differential
locks” is switched on and the transversal differential
is locked.

16 Warning light Engine oil pressure low

Illuminates:
The ignition starter switch is in position ON under
normal conditions.
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!

17 Control light Engine exhaust brake

Illuminates:
Engine exhaust brake is ready for work or it is
activated.

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 Operator’s Manual for Truck Crane

a
18 Warning light ABS defects
Illuminates:
The ABS is defective.
起
重
机
说
明
19 Warning light Engine error code displayed
Illuminates and then extinguishes:
The engine works normally.
Illuminates all the time:
The engine is defective.
Bring the vehicle to a standstill and rectify it.
Crane Chassis
Operation –

It flashes out the error code after the button “Engine

fault diagnosis” is pressed and released.

20 Control light PTO engaged

Illuminates:
The PTO is engaged.

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3.1.3.4 Keyboard

起 1 2 3 4 5
重
机
说
明

Crane Chassis
Operation –
6 7 8 9 10 11

Figure 3-7 Keyboard

Pos. Description Pos. Description

Button Button
1 7
Engine fault diagnosis Front fog light
Button Button
2 8
Rear fog light Exhaust brake
Button Button
3 9
Rotating beacon Corner marker lights
Button Button
4 10
A/C fan speed Parking signal
Button Button
5 11
A/C power Longitudinal and transversal differential locks
Button
6
Engine stop

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 Operator’s Manual for Truck Crane

1 Button Engine fault diagnosis

起
Pressed and released:
重
机The warning light “Engine error code displayed” will flash out
说the error code if the warning light “Engine error code displayed”
明
or warning light “Engine defects” illuminates all the time.

2 Button Rear fog light

Pressed:
The rear fog light is ON.
Note:
Crane Chassis
Operation –

The rear fog light can be activated only when the high beam,
low beam or front fog light is activated.

3 Button Rotating beacon

Pressed:
The rotating beacon is ON.

4 Button A/C fan speed

Pressed:
Regulate the fan speed of A/C.

5 Button A/C power

Pressed:
The air conditioning works.

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6 Button Engine stop

Keep it pressed for 2 – 3 seconds:
The engine stops running.
起
重
机
说
明

7 Button Front fog light

Pressed:
The front fog light is ON.

Crane Chassis
Operation –
8 Button Exhaust brake
Pressed:
The exhaust brake is activated.

9 Button Corner marker lights

Pressed:
The corner marker light is ON.

10 Button Parking signal

Pressed:
The parking signal is ON.

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11 Button Longitudinal and transversal differential locks

Pressed:
The longitudinal and transversal differential locks are switched
起
重on.
机
说
明 CAUTION
You can operate the button only when the vehicle is
stationary.
Crane Chassis
Operation –

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3.1.4 Media player

起
重 USB SD MP3 PLAYER AUX
机 VOL - TUN -
说
明

VOL + TUN +

POW MUTE SD USB MR.CE APS.F

Rotary switch for volume SD card slot Display USB port Rotary switch for radio tune /

Crane Chassis
Operation –
adjustment / SEL / Radio SEL / Skip previous or next

Figure 3-8 Media player

1 Button Power source

POW
2 Button MUTE & MP3 play
MUTE
3 Button
Reserve radio stations / Clear MP3 memory MR.CE
4 Button
Automatic radio search / MP3 mode select APS.F
5 Rotary knob
VOL -
Volume adjustment / SEL / Radio

VOL +

6 Rotary knob
TUN -
Radio tune / SEL / Skip previous or next

TUN +

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

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3.1.5 Gear lever

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

3.1.7 Air horn button

It is located on the outside of accelerator pedal and on the right side of driver.
Depressed: Air horn alarms.
Released: Air horn stops alarming.
Crane Chassis
Operation –

3.1.8 Foot pedal (R): Engine control

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

3.1.9 Foot pedal (M): Service brake

Depressed: the vehicle decelerates or stops.

3.1.10 Foot pedal (L): Clutch

Depressed: the clutch is disengaged.

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3.1.11 Crane lighting

3.1.11.1 Front combination signals

起
重
Take the lights on the left as an example. The lights on right side are the same as the left ones.
机
For details, refer to Figure 3-9.
说
明
1 2

Crane Chassis
Operation –
6 5 4 3

Figure 3-9 Front combination signals

Pos. Description Pos. Description

1 Front low beam 4 Front width lamp

2 Front turn signal 5 Front fog light

3 Side turn signal 6 Front high beam

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 Operator’s Manual for Truck Crane

3.1.11.2 Interior illumination

The interior illumination is located at the roof of the
起 cab, including small lamp & its button and
driver's
重
door lamp & its button.
机
Small
说 lamp & its button:
The明direction of small lamp can be adjusted by
pressing its edge. The small lamp button is a
2-handed button.
Door lamp & its button:
The door lamp button is a 3-handed button:
Center position: Off
Left and right positions: On
Crane Chassis
Operation –

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.

3.1.12 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 closed.

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

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 outside

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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3.1.13 Seats in driver's cab

3.1.13.1 Seat adjustment

起
This crane is equipped with a
重
机
mechanical suspension seat, which can
说
be adjusted to suit any driver height or
明
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
1
2 Switch, adjust seat cushion angle
2

Crane Chassis
Operation –
(rear section)
3
3 Switch, adjust seat cushion angle
4
(front section)
5
4 Rotary knob, adjust stiffness
5 Switch, adjust horizontal setting

3.1.13.2 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.

3.1.14 Attachments
a) Sun visor
The sun visor is located above the 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
The toolbox 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 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.

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 Operator’s Manual for Truck Crane

CAUTION
Set the ignition starter switch to "ACC", when you use the cigarette lighter with the engine
起
in the OFF position.
重
机
说
明
Crane Chassis
Operation –

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 Operator’s Manual for Truck Crane

3.2 Before starting up the vehicle

3.2.1
起 Prerequisites
重
a)
机 If the crane is used for the first time, make sure the crane is in proper working condition
说 (without damage or abnormalities).
明
b) 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 Serial 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.
b) Do a check of the fuel level and make sure that you have more than is necessary to

Crane Chassis
Operation –
complete the task.
c) Make sure that the parts in the steering and brake systems are flexible, safe, and reliable.
d) Do a check of the steering fluid level and the clutch fluid level and add more if below the
required level.
e) Make sure that the parts that follow are tight:
– Bolts in universal joints for steering axles
– Leaf spring bolts
– U-bolt
– Wheel bolts.
f) Examine the leaf springs for crack.
g) Examine all tires for correct pressure.
h) Examine the items that follow for damage:
– Condition of tires
– Door locks
– Doors
– Windows
– Each crane control mechanism.
i) Examine the fittings of oil pipes, air pipes and water pipes for leakage.
j) Examine the air reservoir for condensation (drain the water as necessary).
k) Examine the battery terminals for too much corrosion and make sure that the power wires
are tight.
l) Examine the level of the battery electrolyte (adjust as necessary).
m) Examine the air filter vacuum actuated indicator. If the indicator is in the red area, clean or
replace the filter element.
n) Turn the ignition starter switch to position “ON” and examine the functions of the items that
follow:
– Instruments

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 Operator’s Manual for Truck Crane

– Switches and buttons

– Lighting
– Control lights and warning lights
起
重– Wipers
机– Miscellaneous displays.
说
o) Adjust the mirrors for clear vision to the rear.
明
3.2.3 General checks at vehicle start up
Examine the controls and instruments.
a) Examine the engine oil pressure gauge.
1) Idle speed: the engine oil pressure must be more than 0.1 MPa.
2) When engine speed is 1200 r/min, the engine oil pressure must be in the range of
0.35 – 0.55 MPa.
Crane Chassis
Operation –

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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3.3 Driving the crane

3.3.1
起 Starting 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
b) Before starting the engine, make sure the following prerequisites are met:
1) Put the gear lever in neutral.
2) Apply the parking brake.

Crane Chassis
Operation –
3) Turn the ignition starter switch to position ON.
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 several
minutes Then try to start the engine again to avoid motor damage. If the
engine can not 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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 Operator’s Manual for Truck Crane

WARNING
起(1) In order to make the engine oil flow into each part of engine and raise up water
重 temperature to burn the fuel normally, it is necessary to warm up the engine
机
说 before starting.
明(2) Do not run the engine at high speed without a load during warming up.
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.
(5) The engine oil pressure should not be lower than 0.1 MPa when the engine runs
Crane Chassis
Operation –

at idle speed. With the engine warming up, the oil pressure is going to 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” and hold for 2 – 3 seconds to stop the chassis
engine.
f) Turn the ignition starter switch to position “LOCK” and pull the key out after the engine is
stopped about 30 seconds.
g) Do not keep the ignition starter switch in position ON or ACC after you park the crane. The

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 Operator’s Manual for Truck Crane

battery drains in these conditions.

h) If you park the crane on a slope, you must put the chocks before and behind the wheels to
avoid accident.
起
重
i) To prevent an accident when you park the crane in the dark, you must turn on the hazard
机 lights.
说
明 Transmission operation
3.3.2
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 3-10.

Crane Chassis
Operation –
High speed range R 51 7
3
空

direction
Forward
Low speed range 6 8
2 4

Figure 3-10 Transmission

3.3.2.1 Shifting gears

a) Always engage the first gear and push the range-change switch down on the front of the
gear lever to engage low range when driving away.
b) Always depress the clutch pedal fully when shifting gears. Push the gear lever smoothly
when shifting until the gear is engaged.
c) Both the low and the high speed ranges have a neutral position. The neutral positions are
between gears 5 and 6 in the high speed range and between gears 3 and 4 in the low
speed range. Put the gear lever in neutral in the low speed range when you park the
crane.
d) Wait until the vehicle is at a standstill before you engage the reverse gear. Failure to do so
may result in serious damage to the transmission. 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 speed range and high speed range.
Otherwise, you will shorten the service life of synchronizer of auxiliary transmission.

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 Operator’s Manual for Truck Crane

WARNING
You should use the range-change switch when you shift between gears 4 and 5.
起
f) 重When you drive downwards the slope, do not shift gear between high and low speed
机ranges.
说
g) When you hear an unusual noise in the transmission or it is hard to operate the gear lever,
明
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.

WARNING
The temperature of transmission should be between -40°C – 120°C during
Crane Chassis
Operation –

continuous working.
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 or backward 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.

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

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 Operator’s Manual for Truck Crane

CAUTION
起 Only when the compressed air pressure P is above 0.4 MPa, can the clutch be
重
completely disengaged.
机
说 Steering operation
3.3.4
明
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
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

Crane Chassis
Operation –
steering wheel in the same direction as the turn.
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 neutral to prevent an
unstable condition.

e) Decelerate the vehicle and shift to the low speed range 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.
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
with the actual driving speed. At last, depress the engine control pedal to drive at

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 Operator’s Manual for Truck Crane

normal speed.
3) Cadence brake: Depress the service brake pedal and release it. Repeat the operation
to decelerate the vehicle gradually. The operation should be very gentle.
起
重4) Rapid brake: In a sudden emergency, release the engine control pedal immediately
机 and depress the service brake pedal jerkily (sometimes apply the parking brake at the
说
same time) to bring the vehicle to a standstill as soon as possible. As a result, the
明
accident will be avoided.

CAUTION
When you make many hard brake stops, the tire, brake drum and brake lining
wear prematurely and service life of each part shortens. Use more caution
when the roads are wet or frozen.
Crane Chassis
Operation –

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.
– Press the button “Exhaust brake”.
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.

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
hand lever forwards to the unlocking position to deactivate the emergency brake.

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 Operator’s Manual for Truck Crane

CAUTION
起 (1) You can also use the emergency brake (namely parking brake) to park the
重
vehicle in normal condition or on slopes.
机
说 (2) Deactivate the emergency brake before driving.
明
3.3.5.2 Points for attention
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
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

Crane Chassis
Operation –
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 downhill, shift the gear lever to low speed 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 let the vehicle move forward
or backward when transmission is in neutral.
e) When the parking brake is used as the emergency brake, do not pull the parking 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 the PTO

See Figure 3-11.
a) Open the shutoff gate valve of hydraulic oil tank to connect the hydraulic oil tank and the oil
lines.
b) Start the engine.
c) Examine the barometer to ensure whether the air pressure is between 0.6 and 0.8 MPa
after the engine runs stably.
d) Depress the clutch pedal.
th
e) Apply the parking brake and move the gear lever to the 4 gear position.
f) Pull out the PTO switch to engage the PTO, and then the control light “PTO engaged”
lights up.
g) Slowly release the clutch pedal, and the crane is ready to work.

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 Operator’s Manual for Truck Crane

起
重
机
a c d e f g
说
明
Figure 3-11 Engaging the PTO

3.3.6.2 Disengaging the PTO

See Figure 3-12.
a) Depress the clutch pedal.
b) Press the PTO switch to deactivate the PTO, and then the control light “PTO engaged”
Crane Chassis
Operation –

extinguishes.
c) Shift to neutral.
d) Release the clutch pedal slowly, and then the crane is in non-working state.

Figure 3-12 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.

3.3.7 Towing
There is a towing coupling at both the front and rear ends of the crane. Obey the following
towing regulations:
a) Attach a strong towing rope onto the tow coupling at the front under the bumper. Start
slowly to avoid impact.

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 Operator’s Manual for Truck Crane

b) 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.

起
重 WARNING
机
说 If the engine of the towed crane cannot operate, do not tow the crane.
明
c) Shift the transmission of towed crane to neutral.
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
right half shafts.

CAUTION

Crane Chassis
Operation –
The engine exhaust brake system will be invalid if you remove the propeller shaft or
the half shaft.

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 Operator’s Manual for Truck Crane

3.4 Points for attention

3.4.1 Road driving
起
a) 重Do not skip a gear when you move through the gear cycle.
机
b) 说Stop the vehicle if there are unusual conditions with the items in the below list:
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
Crane Chassis
Operation –

repaired.
d) Examine the following instruments for functions:
– Barometer
– Engine oil pressure gauge
– Water thermometer, etc.
e) Shift to a lower gear before you drive uphill to decrease the load on the engine and
drive-line.
f) Do the items that follow before you drive downhill:
– Make sure that the brake system can stop the crane before you go onto the slope.
– Shift to the low speed range.
– 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) The engine is easily damaged by overrunning.
(2) Decelerate the crane before you downshift the transmission. When you
th
downshift from the 4 gear position, the engine RPM should be below 1500
rd
r/min. When you downshift from the 3 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 or backward after the engine is off.

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 Operator’s Manual for Truck Crane

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:
起
a) Switch on transversal and longitudinal differential locks.
重
b) Shift the gear lever to the low speed range and then engage the clutch slowly. Otherwise
机
说 crane service life will be shortened.
明
c) 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
of clearance in front and to the aft of the vehicle.

Crane Chassis
Operation –
2) Apply the parking brake. Always put the chocks before and behind the wheels on a
slope.
3) Shift the gear lever to the neutral position of low speed 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 (propeller 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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 Operator’s Manual for Truck Crane

Chapter 4 Operation – Crane Superstructure

 汽车起重机操作手册
Operator’s Manual for Truck Crane

Chapter 4 Operation – Crane Superstructure

4.1起Operator’s cab
重
4.1.1
机 Overview
说
明
1

3
4

6
9

Superstructure
Operation – Crane
10 上
8 车
操
作

Figure 4-1 Overview, operator’s cab

Pos. Description Pos. Description

1 Load moment limiter 6 Pressure gauges

2 LED acoustic control light 7 Accelerator pedal

3 Front windshield wiper 8 Door

4 Control levers 9 Operator’s seat

5 Control box 10 Air conditioning

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 Operator’s Manual for Truck Crane

4.1.2 Control panel

起
重

ENGINE
STOP
机
说
明

POWER
I
II 4

START
ENGINE
1 2 3 6
5

Figure 4-2 Control panel

Pos. Description Pos. Description

Button Button
1 4
Emergency off Engine stop
Superstructure
Operation – Crane

Switch Button
2 5
Pre-selection of telescoping cylinder I / II Engine start
Button
3 Bypass key switch 6
Power source

1 Button Emergency off

Pressed:
All superstructure movements are cut off.

2 Switch Pre-selection of telescoping cylinder I / II

Left position: I II

The telescoping cylinder I is operational.

Right position:
The telescoping cylinder II is operational.

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

3 Bypass key switch

Dangerous crane movements will be switched off when
the items below occur:
起
重 – The main or aux. winch is in the spool-up mode and
机 the hook block touches the hoisting limit switch
说
weight.
明
– The sensor senses that the winch has 3 wraps of
wire rope on it.
– The sensor senses that the load weight is beyond
the maximum limit.
– 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.

Superstructure
Operation – Crane
WARNING
Do not use the bypass key switch when you do usual 上
车
crane operations. Otherwise, there will be 操
life-threatening hazards or serious damages to 作

property.

4 Button Engine stop

Pressed and held for 1 to 2 seconds:
The engine stops. ENGINE
STOP

5 Button Engine start

Pressed:
Engine starts. ENGINE
Released after engine starts: START
The switch will return to its initial position.

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 Operator’s Manual for Truck Crane

6 Button Power source

Pressed:
Superstructure control system is energized.
起 POWER
重
机
说
明

1 2 3 4 5 6 7

Figure 4-3 Auxiliary control panel

Pos. Description Pos. Description

Superstructure
Operation – Crane

Button Button
1 5
Oil cooler Work lights on boom head
Button Button
2 6
Front windshield wiper Work lights
Button Control light
3 7
Front windshield washer system Oil cooler fan
Button
4
Roof window washer system

1 Button Oil cooler

Pressed:
The oil cooler fan works.

4-4 QY25D531R Truck Crane

 汽车起重机操作手册
Operator’s Manual for Truck Crane

2 Button Front windshield wiper

Pressed:
Switch on the front windshield wiper.
起
重
机
说
明

3 Button Front windshield washer system

Pressed:
Switch on the front windshield washer system.

Superstructure
Operation – Crane
上
车
操
4 Button Roof window washer system 作
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.

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 Operator’s Manual for Truck Crane

5 Button Work lights on boom head

Pressed:
Switch on the work lights on boom head.
起
重
机
说
明

6 Button Work lights

Position 1:
Switch on the background lighting.
Position 2:
Switch on the background lighting, work lights
on slewing table and boom.
Superstructure
Operation – Crane

7 Control light Oil cooler fan

Illuminates:
The oil cooler fan works.

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

4.1.3 Control levers

There are five control levers in the operator’s cab:
起
–
重 Control lever 1:
机 Spool main winch up / reel main winch off.
说
– Control lever 2:
明
Spool auxiliary winch up / reel auxiliary winch off.
– Control lever 3:
Derrick boom up / derrick boom down.
– Control lever 4:
Telescope boom out / telescope boom in.
– Control lever 5:
Slew to the left / slew to the right.
See Figure 4-4.

3
2

Superstructure
Operation – Crane
4
上
车
5 操
作

Figure 4-4 Control levers

Pos. Description Pos. Description

1 Free swing button 5 Control lever 3: Derricking gear

2 Horn button 6 Control lever 4: Telescoping system

3 Control lever 1: Main hoist gear 7 Control lever 5: Slewing gear

4 Control lever 2: Auxiliary hoist gear 8 Locking plate for auxiliary hoist gear

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 Operator’s Manual for Truck Crane

WARNING
Do not press the free swing button after the load is away from the ground. Otherwise,
起 will be life-threatening hazards or serious damages to property.
there
重
机
4.1.4 Engine control pedal
说
You明can depress the engine control pedal to increase the engine RPM, thus to accelerate the
slewing, derricking, telescoping and hoist movements.

4.1.5 Operator's seat

Superstructure
Operation – Crane

Seat adjustment
hand levers

Figure 4-5 Operator’s seat

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

4.2 Computer system

The load moment limiter is a computer system for controlling and monitoring mobile cranes.
起
The load moment limiter calculates data from the pressure sensors, length sensor, angle
重
sensor and other monitoring devices to judge whether the crane is in safe working conditions,
机
说
and displays the basic parameters, such as boom length, boom angle, working radius, rated
明
lifting capacity etc., on the LCD.
If the actual load reaches 90% – 100% of the rated one, the warning light lights up and 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 buzzer sends
out fast acoustic warning and all dangerous crane movements are switched off.

CAUTION
(1) The load moment limiter can prevent 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 capacity

Superstructure
Operation – Crane
table, obey the lifting capacity table.
上
(2) Make sure that the load moment limiter is set to the proper configuration before 车
操
operation. It is dangerous to set the load moment limiter incorrectly. Only the 作
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.

WARNING
The load moment limiter should only be commissioned by service technician!

For details, please refer to Operating Instructions for Load Moment Limiter attached to the
crane.

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 Operator’s Manual for Truck Crane

4.3 Starting up the crane

4.3.1 Checks
起 before starting up
重
Make
机 sure that the following prerequisites are met before starting up:
a) 说Examining the engine oil level
明
1) The machine has been leveled.
2) Pull out the oil 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.

WARNING
If the oil level is lower than the Min. mark, fill the tank with oil. Otherwise, the
engine will be damaged seriously!

b) Examining the hydraulic oil level

The oil level must be between the Min. and Max. marks on the oil dipstick.
Open the shutoff gate valve to connect the hydraulic oil tank with the oil line. See Figure
Superstructure
Operation – Crane

4-6.

Hydraulic oil tank

关
OFF

开
ON Shutoff gate valve: OFF

Shutoff gate valve: ON

Figure 4-6 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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 汽车起重机操作手册
Operator’s Manual for Truck Crane

CAUTION
起 Deaerate the fuel supply system before adding fuel.
重
If the fuel tank has been run dry, always deaerate the whole fuel supply system.
机
说 Do not run the fuel tank dry!
明
d) Examining the coolant level
Fill coolant expansion tank up to overflow on filler neck.
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 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 and greased.
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.
6) Make sure that the cable / rope drums and sensors are free of snow and ice.

Superstructure
Operation – Crane
7) Make sure that there are no loose parts on the superstructure or the telescopic boom.
上
8) Make sure that the control levers in the operator’s cab are in neutral before you 车
engage the PTO.
操
作
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 off” to switch off the engine.
b) Starting the engine
You can operate the ignition starter switch if the following prerequisites are met:
1) PTO has been engaged.
2) The transmission is in the required position.
Note:
If the button “Emergency off” is activated in an emergency, turn the switch clockwise
to remove the limitation. Otherwise, the ignition starter switch is invalid.

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 Operator’s Manual for Truck Crane

4.4 Safety devices

4.4.1 Level
起 gauge
重
A level
机 gauge is located on each side of the crane near the outrigger control mechanism.
说 the crane is horizontally aligned, the bubble in the level gauge should be in the exact
After
明
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). See Figure 4-7.
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 lifting capacity tables and lifting height chart.
Superstructure
Operation – Crane

20 30 40 50 60
10 70
0 80

20 30 40 50 60
10 70
0 80

40°

Figure 4-7 Angle indicator

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 汽车起重机操作手册
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
起
the hook block from colliding with the rope pulley.
重
When the distance detected between the hook block and the pulley is less than the safety one,
机
the hoisting limit switch is triggered and buzzer sounds. The crane movements “Spool winches
说
明
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 4-8.

Check ring
Hoisting limit

Superstructure
Operation – Crane
switch weight
Check ring 上
车
操
作
Dangerous operation
(Be switched off)
Bypassed
(Return to safe operation)

Figure 4-8 Hoisting limit switch

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

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

How to connect and install the hoisting limit switches on jib and rooster sheave:
a) When the jib is used (See Figure 4-9.):
1) Connect the connector of cable harness in jib to the connector on main boom head.
2) Connect the cable harness of jib section 2 to the cable harness of the jib adaptor if the
jib section 2 is used.

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 Operator’s Manual for Truck Crane

起
重
机
说
明

Connectors between
main boom and jib

Figure 4-9 Cable harness connection of jib

b) When the rooster sheave is used (See Figure 4-10.):

1) Remove the hoisting limit switch from the jib.
2) Connect the connectors of hoisting limit switch and rooster sheave.
3) Connect the cable harness in rooster sheave to the connector on main boom head.
Superstructure
Operation – Crane

Connectors between main boom and rooster sheave

Installation
Connectors between hoisting limit switch and rooster sheave location of
hoisting limit
switch

Figure 4-10 Cable harness connection of rooster sheave

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

4.4.4 Lowering limit switch

In order to prevent the wire rope from being spooled up automatically after being reeled off
起
completely, the lowering limit switches installed beside the winches will automatically switch off
重
the movements ”Reel off winches” if there are only 3 rope windings remaining on the winches.
机
In this case, the warning light lights up, the buzzer sounds the alarm and only the upward
说
明
movement of the hook is permitted. During commissioning and maintenance, activate the
lowering limit bypass switch to bypass the switch-off. See Figure 4-11.

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

Winch

Superstructure
Operation – Crane
Lowering limit switch
上
车
操
作

Figure 4-11 Lowering limit switch

4.4.5 Hydraulic safety devices

4.4.5.1 Relief valves in hydraulic system

The relief valves in hydraulic system can prevent the pressure in the circuit from excessively
rising, thus avoid hydraulic oil pump and hydraulic motor from being damaged and 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 stop the pressure oil in both sides of
outrigger cylinder to prevent the outrigger from retracting or extending inadvertently, and thus
ensure the safe operation of the crane.

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 Operator’s Manual for Truck 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
起
balance
重 valve in the hydraulic circuit can stop the hydraulic oil in the derricking cylinder piston
机immediately to prevent the boom from falling down inadvertently, and thus ensure the safe
side
说
operation of the crane.
明
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 stop the hydraulic oil in the telescoping cylinder piston
side immediately to prevent the telescopic sections from retracting inadvertently, 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
th th
the 5 outrigger, a pressure relay is installed on the oil cylinder for the 5 outrigger. When you
carry out a lift operation over front, the pressure relay can detect pressure of hydraulic system
th
for the 5 outrigger and send the pressure signal to the crane control system. Once the
Superstructure
Operation – Crane

th
pressure exceeds the maximum permissible value, the warning light “The 5 outrigger pressure
high” lights up and the buzzer sounds.

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

4.4.5.6 System pressure monitoring

There are three pressure gauges on the instrument console in the operator’s cab, see Figure
4-12. Functions of the pressure gauges are as follows:
Pressure gauge 1: monitor the pressure of control oil circuit.
Pressure gauge 2: monitor the pressure of oil circuit in slewing gear.
Pressure gauge 3: monitor the pressure of oil circuit in main & auxiliary winches, derricking gear
and telescoping system.

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

起
重
机
说
明

Pressure gauge 1 Pressure gauge 2 Pressure gauge 3

Figure 4-12 Pressure gauges

The maximum pressures are as follows:

Pressure of spooling up oil circuit in main / auxiliary winch: 23 MPa - 25 MPa, pressure of
reeling off oil circuit in main / auxiliary winch: 10 MPa – 12 MPa
Pressure of derricking up oil circuit: 23 MPa - 25 MP, pressure of derricking down oil circuit: 9
MPa – 12 MPa
Pressure of telescoping out oil circuit: 10 MPa – 12 MPa, pressure of telescoping in oil circuit:

Superstructure
Operation – Crane
13 MPa – 15 MPa
Pressure of slewing oil circuit: 12 MPa – 13 MPa 上
Pressure of control oil circuit: 3 MPa – 3.5 MPa 车
操
作
4.4.6 Emergency off button
The button “Emergency off” (See the figure on the right) is
fitted on the instrument console in operator’s cab.
In an emergency, push this button to immediately STOP all
crane functions. Turn the switch clockwise to bypass the
switch-off.

WARNING
Only use the button “Emergency off” in the event of a clear emergency!

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 Operator’s Manual for Truck Crane

4.5 Crane operation

4.5.1 Preparations for crane operation
起
重 sure that following checks are done before operation:
Make
机
a) 说Assess the load condition prior to lifting it.
b) 明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 signalman to make sure that nothing will hinder
Superstructure
Operation – Crane

the operation.
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 control levers 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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 汽车起重机操作手册
Operator’s Manual for Truck Crane

4.5.2 Outrigger
Both sides of the vehicle chassis frame have the items below:
起
– Accelerator control switch
重
– Outrigger control levers
机
–
说 Level gauge.
明
You can operate the control levers to extend or retract the outriggers simultaneously or
independently. See Figure 4-13.

4 3

5
7
6

Superstructure
Operation – Crane
8

上
车
操
作
Figure 4-13 Outrigger

Pos. Description Pos. Description

1 Front outrigger box 5 Outrigger control levers

2 Sliding beam 6 Level gauge

3 Vertical cylinder 7 Horizontal cylinder

4 Accelerator control switch 8 Outrigger pad

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.

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 Operator’s Manual for Truck Crane

4.5.2.1 Outrigger control levers

Outrigger control levers are shown in Figure 4-14.
起
重
机
说
明
Superstructure
Operation – Crane

2
3
4
5
6

Figure 4-14 Outrigger control levers and operating illustrations

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 movement of the cylinder.
3) Move lever 1 downwards: extend the horizontal / vertical cylinder.
c) Control lever 3: select the left rear outrigger
Control lever 4: select the right rear outrigger
Control lever 5: select the left front outrigger
Control lever 6: select the right front outrigger

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 汽车起重机操作手册
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.
起
重 2) Move levers 3, 4, 5 and 6 downwards and move lever 1 upwards or downwards:
机 extend / retract the vertical cylinders.
说 th
d) Control lever 2 : select the 5 outrigger
明
th
Move lever 2 downwards and move lever 1 upwards: retract the 5 outrigger
th
Move lever 2 downwards and move lever 1 downwards: extend the 5 outrigger.

CAUTION
During operation of outriggers, turn the accelerator control switch clockwise to increase
working speed of outriggers.

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

Superstructure
Operation – Crane
4.5.2.2 Outrigger extension
a) Remove the pins of sliding beam. 上
车
b) Do the following steps as follows: 操
作
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 sliding beams are fully extended.
4) Move the levers to neutral positions after the sliding beams are fully extended.
5) Extend the sliding beams on the other side of the crane in the same steps.
See Figure 4-15.

1
3 2
6 54

Figure 4-15 Extend horizontal cylinder

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 Operator’s Manual for Truck Crane

WARNING
The mid-position marks “ ” on sliding beams must completely exposed and the
起pins must be secured if the crane is working with outriggers intermediately
重
机extended. Otherwise, the crane may topple.
说
c) Do the following steps as follows:
明
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) Extend the vertical cylinders on the other side of the crane in the same steps.
See Figure 4-16.
Superstructure
Operation – Crane

1
2
43
65

Figure 4-16 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 (See
Figure 4-17):
1) Move levers 4 and 6 downwards slowly.
2) Slowly move lever 1 upwards and monitor the level gauge at the same time.

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

起 st
be
ext
end
ed
and
the
ma
chi
ne

lev
el.

重
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 腿
EX
ore ret on durin
Bef be lev or yed s 前支
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

机
警 N IN 水平
； the it ma
左前
W AR 车架保持 Pro
hib
FLO
, 并使 3.
支腿 上； 右 后
放下 支架 柄。 O
须先 吊臂 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

说
明

1
3 2
6 54

Figure 4-17 Level the vehicle

e) When the bubble is at the center 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,
th th
you should set up the 5 outrigger. The 5 outrigger is available for options.
th
How to extend the 5 outrigger:
1) Move lever 2 downwards.
th

Superstructure
Operation – Crane
2) Move lever 1 downwards until the 5 outrigger is 5 mm – 10 mm away from the
ground. See Figure 4-18.
上
车
操
作

1
2
43
65

th
Figure 4-18 Extend the 5 outrigger

CAUTION
Do the steps below If there is a need to adjust the outrigger height during a lift
operation:
th
(1) Retract the 5 outrigger.
(2) Adjust the outrigger height.
(3) Level the crane.
th
(4) Extend the 5 outrigger to the position where its outrigger pad is about 5 mm –
10 mm off the ground.

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

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 Operator’s Manual for Truck Crane

CAUTION
Lever 1 can return to neutral position automatically after being released, while other
起
levers should be returned manually.
重
4.5.2.3机Outrigger retraction
说
明
WARNING
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.
th
(4) Retract the 5 outrigger.
(5) Retract the vertical cylinders.
(6) Retract the sliding beams.

Do the steps that follow to retract the outriggers:

th
a) Retract the 5 outrigger (See Figure 4-19):
1) Move lever 2 downwards.
Superstructure
Operation – Crane

th
2) Move lever 1 upwards until the 5 outrigger is fully retracted.

1
3 2
6 54

th
Figure 4-19 Retract the 5 outrigger

Note:
In order to prevent potential safety hazard, such as forgetting retracting or incompletely
th th
retracting the 5 outrigger, the 5 outrigger of this crane can retract with other outriggers
synchronously.

b) Retract the vertical cylinders:

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 upwards to retract vertical cylinders completely.
4) Retract the vertical cylinders on the other side of the crane in the same steps.
See Figure 4-20.

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 汽车起重机操作手册
Operator’s Manual for Truck Crane

起
重
机
说
明 1
3 2
6 54

Figure 4-20 Retract vertical cylinder

c) Retract the sliding beams:

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 upwards to retract sliding beams completely.
4) Retract the sliding beams on the other side of the crane in the same steps.
See Figure 4-21.

Superstructure
Operation – Crane
上
车
操
作

1
3 2
6 54

Figure 4-21 Retract horizontal cylinder

d) Install the outrigger retaining pins.

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 Operator’s Manual for Truck Crane

4.5.2.4 Install and remove the outrigger pads

a) The outrigger pad is shown in Figure 4-22.
起
重
机
说
明

Vertical cylinder

Outrigger pad

Socket pin

Figure 4-22 Outrigger pad

b) Installation
Superstructure
Operation – Crane

Before you extend the outriggers, remove the socket pin from the outrigger pads and pull
out the outrigger pads. When the hole aligns with the vertical cylinder, install the socket
pin.
Weight of outrigger pad: about 35 kg.
c) 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.
th
(3) Make sure that all the outrigger pads (except the 5 outrigger pad) contact with the
ground.
th
(4) You can only extend the 5 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
th
from the ground due to excessive extending of the 5 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.

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Operator’s Manual for Truck Crane

WARNING
Do not operate the outrigger control levers in a lift operation.
起
4.5.3
重 Derricking
机
说Control lever 3 in Figure 4-4 controls the derricking gear.
明– Neutral position: stop the derricking movements.
– Move the control lever backwards.
Result:
The boom is derricked up.
– Move the control lever forwards.
Result:
The boom is derricked down.
See Figure 4-23.

Neutral

Superstructure
Operation – Crane
上
车
操
作

Figure 4-23 Control lever 3: derricking gear

The speed of derricking movement is changed by:

– Control lever 3 - how far you move the control lever forwards or backwards
– Engine control pedal - increase or decrease the engine RPMs.
Do not apply the engine control pedal when the travel distance of control lever is short.
Do not change the derricking speed rapidly.
The angle indicator and the angle detector attach to the side of the main boom. Refer to Figure
4-24. 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

起
重
机
说 20
10
0

30

明
0
0 4
05
80 70 6

Length / angle detector Angle indicator Operator’s cab

Figure 4-24 Safety devices on the main boom

WARNING
Superstructure
Operation – Crane

(1) Do all derricking movements smoothly. You can cause damage to the crane if you
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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Operator’s Manual for Truck Crane

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

Telescopic
Boom retraction Telescopic section 2 Telescopic section 3
Basic boom Telescopic section 1 section 4
rope I

Superstructure
Operation – Crane
上
车
操
作
Telescoping Telescoping Boom extension Boom retraction Boom extension
cylinder I cylinder II rope I rope II rope II

Figure 4-25 Telescoping system

Control lever 4 in Figure 4-4 controls the telescoping system.

– Neutral position: stop the telescoping movements.
– Move the control lever forwards.
Result:
The telescopic sections are telescoped out.
– Move the control lever backwards.
Result:
The telescopic sections are telescoped in.
See Figure 4-26.

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 Operator’s Manual for Truck Crane

起 Neutral
重
机
说
明

Figure 4-26 Control lever 4: telescoping system

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.
Superstructure
Operation – Crane

– 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:
– Control lever 4 - how far you move the control lever 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.
(6) The operator should strictly carry out the telescoping operation according to lifting
capacity tables. Otherwise, the crane may topple or be damaged.

WARNING
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
起
Read Lifting capacity tables and Lifting height chart in Chapter 1 before lifting / lowering
重
机
operation.
说
How to look up lifting capacity in the Lifting capacity table (See Figure 4-27):
明
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 according to Figure 4-29:
If the working radius is R 2 and main boom length is L 2 m, the lifting capacity is W 2 kg.
If the working radius is R 3 and main boom length is L 3 m, the lifting capacity is W 3 kg.

CAUTION

Superstructure
Operation – Crane
(1) Look up the corresponding lifting capacity according to actual working conditions. 上
车
(2) Observe the notes shown below the lifting capacity table. 操
作

Supposed height above Boom length: L (m)

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

Figure 4-27 Look up the lifting capacity table

CAUTION
The parameters shown in the lifting height chart do not include the deflection of main
boom.

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 Operator’s Manual for Truck Crane

Lifting capacities are changed with working radius.

Working radius without load

起
重
机
说
明

30 40 50 60
10 20 70
0 80
Superstructure
Operation – Crane

Working radius with load

Figure 4-28 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: L2 refers to main boom length. W2 refers to the rated lifting capacity.

Figure 4-29 Lifting capacity table

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Operator’s Manual for Truck Crane

4.5.5.2 Spooling up / reeling off main winch

a) Control lever 1 in Figure 4-4 controls the main winch.
起 – Neutral position: stop spooling up / reeling off main winch.
重
– Move the control lever forwards.
机
说 Result:
明 The main winch is reeled off.
– Move the control lever backwards.
Result:
The main winch is spooled up.
See Figure 4-30.

Neutral

Superstructure
Operation – Crane
上
车
操
作

Figure 4-30 Control lever 1: main hoist gear

b) The main hoist gear is working. Refer to Figure 4-31.

30405060
10 20 7080
0

Figure 4-31 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) Release the locking plate for auxiliary hoist gear.
起
重
机
说
明

Locking plate

Figure 4-32 Release the locking plate for auxiliary hoist gear

b) Control lever 2 in Figure 4-4 controls the auxiliary winch.

– Neutral position: stop spooling up / reeling off auxiliary winch.
– Move the control lever forwards.
Result:
Superstructure
Operation – Crane

The auxiliary winch is reeled off.

– Move the control lever backwards.
Result:
The auxiliary winch is spooled up.
See Figure 4-33.

Neutral

Figure 4-33 Control lever 4: auxiliary hoist gear

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Operator’s Manual for Truck Crane

c) The auxiliary hoist gear is working. Refer to Figure 4-34.

起
重
机
说
明

Figure 4-34 Auxiliary hoist gear operation

Superstructure
Operation – Crane
After you complete the movement, move the control lever to the neutral position slowly to stop
the movements.
上
The speed of the winch movement is changed by: 车
操
– Control lever – how far you move the control lever forwards or backwards 作
– Engine control pedal - increase or decrease the engine RPMs.
Spool up / reel off the winch smoothly. You can cause damage to the crane if you change
speed rapidly.
Do not apply the engine control pedal when the travel distance of control lever is short.
A warning noise sounds and a warning light illuminates if the items below occur:
– The main or aux. 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 beyond the maximum limit.
When the warning occurs, the winch operation is cut off. The crane can only work towards safe
directions till the dangerous operation is deactivated.

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

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 Operator’s Manual for Truck Crane

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:
起
重– The crane has a part of the load weight.
机– The crane connects to a load on the ground.
说
(5) Do not change quickly between "Reel off" and "Spool up". Let the winch stop before
明
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.

4.5.6 Slewing

4.5.6.1 Operation
Control lever 5 in Figure 4-4 controls the slewing gear.
– Neutral position: stop the slewing movements.
Superstructure
Operation – Crane

– Move the control lever forwards.

Result:
Slew to the right.
– Move the control lever backwards.
Result:
Slew to the left.
See Figure 4-35.

Neutral Neutral

a b

Figure 4-35 Control lever 5: slewing gear

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Operator’s Manual for Truck Crane

The speed of the slewing movement is changed by:

– Control lever 5 – how far you move the control lever forwards or backwards
– Engine control pedal - increase or decrease the engine RPM.
起
重
Do not apply the engine control pedal when the travel distance of control lever is short.
机
Do the slewing movement smoothly. You can cause damage to the crane if you change
说
speed rapidly.
明

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.

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

Superstructure
Operation – Crane
after finishing this operation. See Figure 4-36.
上
车
操
作

Slewing table

Slewing lockout device

Figure 4-36 Slewing lockout device

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 900 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.

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 Operator’s Manual for Truck Crane

(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
起
重safe.
(6)机Lubricate the slewing bearing at regular intervals.
说
明
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 10 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:
a) Make sure that you increase the engine RPM (Apply the engine control pedal).
b) 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.
Superstructure
Operation – Crane

Do not telescope the boom with a suspended load!

Table 4-1 Simultaneous crane movements

Simultaneous Illustration
Ser.
crane Operating instructions
No. Control lever Control lever
movements

a) Release the locking

plate for auxiliary hoist
gear.
b) Move the control levers
Main winch
1 and 2 to make main
1 +
winch and auxiliary
Auxiliary winch
winch initiate relevant
movements
simultaneously. See
the left figures.

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Simultaneous Illustration
Ser.
crane Operating instructions
No. Control lever Control lever
起 movements
重
机 Move the control levers 1
说 and 3 to make main winch
明 Main winch and derricking gear initiate
2 + relevant movements
Derrick simultaneously.
See the left figures.

Move the control levers 1

and 4 to make main winch
Telescope and telescoping system
3 + initiate relevant movements
Main winch simultaneously.
See the left figures.

Superstructure
Operation – Crane
Move the control levers 1
and 5 to make main winch
上
Slew and slewing gear initiate 车
操
4 + relevant movements 作
Main winch simultaneously.
See the left figures.

Move the control levers 2

and 3 to make auxiliary
Auxiliary winch winch and derricking gear
5 + initiate relevant movements
Derrick simultaneously.
See the left figures.

Move the control levers 2

and 4 to make auxiliary
Telescope winch and telescoping
6 + system initiate relevant
Auxiliary winch movements simultaneously.
See the left figures.

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Simultaneous Illustration
Ser.
crane Operating instructions
No. Control lever Control lever
起movements
重
机 Move the control levers 2
说 and 5 to make auxiliary
明 Slew winch and slewing gear
7 + initiate relevant movements
Auxiliary winch simultaneously.
See the left figures.

Move the control levers 3

and 4 to make derricking
Derrick gear and telescoping
8 + system initiate relevant
Telescope movements simultaneously.
See the left figures.
Superstructure
Operation – Crane

Move the control levers 3

and 5 to make derricking
Slew gear and slewing gear
9 + initiate relevant movements
Derrick simultaneously.
See the left figures.

Move the control levers 4

and 5 to make telescoping
Slew system and slewing gear
10 + initiate relevant movements
Telescope simultaneously.
See the left figures.

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Operator’s Manual for Truck Crane

4.5.8 Rope reeving

Before you start to change the wire rope reevings, make sure that the following preconditions
起
are fulfilled:
重
机
a) Support the crane on outriggers.
说
b) Fully retract the boom and move it to the side or rear of the crane.
明
See Figure 4-37.

a b c d

Superstructure
Operation – Crane
Figure 4-37 Rope reeving
上
Change the wire rope reevings as follows: 车
操
a) Derrick boom down and put the hook (a) on the ground. 作
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)起You must change the location of the hoisting limit switch weight if you have a
重
different number of wire rope reevings. See Figure 4-38.
机
说
明

Even reeving number Odd reeving number

Figure 4-38 Installation location of hoisting limit switch weight

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

(3) For methods of installing socket and rope clamp, please refer to Figure 4-39.

d - Rope diameter

Figure 4-39 Rope clamp installation

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Chapter 5 Equipment
 Operator’s Manual for Truck Crane

Chapter 5 Equipment

5.1起Safety technical guidelines for assembly

重
a)
机 Reeve the hoist rope between the rope pulley on the boom head and hook pulley in
说 accordance with the corresponding reevings specified in lifting capacity tables.
明
b) Assemble the counterweight plates according to lifting capacity tables.
c) If the jib is not in contact with ground during assembly and dismantling, 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
起
Jib重 is one of the important components of truck crane. With the jib assembled, the load can be
机
lifted
说 to a higher height and the working radius can be enlarged via offset changed.
The 明jib is a frame structure. Its length is 8 m. During driving, the whole jib is secured under the
boom via pins.

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 5°, 17° or 30° to the telescopic boom according to work
requirements.
Assemble the jib (Take 5° offset for example.). Refer to Figure 5-1 to Figure 5-7.
a) Take out the auxiliary hook from the hook holder.
b) Extend the outriggers and make the crane level with the level gauge.
c) Make sure there is 25 m slewing range to the slewing center.
Equipment

Figure 5-1 Non-working state

d) Remove the pin I. Install the pin I into holes I and II of U-type fork at jib end. And install
retaining clips. See Figure 5-2 and Figure 5-3.

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Pin I
起
重
机
说
明

Pin I

Figure 5-2 Pin I removal

Pin hole II Pin hole III

Pin hole I

Equipment
Figure 5-3 Pin I installation

e) Spool up the main winch till the main hook is at the closest position to the pulley on the
main boom head. Reeve the auxiliary hoist rope through the upper rope pulley on the main
boom head and through the rooster sheave. Install the auxiliary hook.
f) Attach one end of the 7.5 m long standby wire rope to the rear bracket on the left side of
basic boom and attach the other end of the rope to the auxiliary hook. Spool up or reel off
the winch to make the rope in a proper tension. See Figure 5-4.

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 Operator’s Manual for Truck Crane

起
重
机
说
明

Figure 5-4 Reeve the standby wire rope

g) Derrick up the boom to about 60°, and then telescope out the boom a little. The jib will
automatically fall off from its retaining pin. Slowly reel off the auxiliary winch till the jib is
vertical to the ground. See Figure 5-5.
Equipment

Figure 5-5 Make the jib vertical to the ground

CAUTION
Operate slowly and stably.

h) Detach the standby wire rope from the auxiliary hook. Reeve the auxiliary hoist rope
through the jib head pulley. Install the hoisting limit switch for auxiliary winch.

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 Operator’s Manual for Truck Crane

i) Stably spool up the winch (or slowly telescope out the boom) at low speed to tighten the
rope in order to make the auxiliary hook contact the jib head. Meanwhile, observe the
condition of jib. When the included angle between the jib and the main boom is about 120°,
起
重 slowly telescope out the boom till the jib is lifted. See Figure 5-6.
机
说
明

Figure 5-6 Lift the jib

CAUTION
Slowly and stably spool up the winch. Keep the jib at least 0.5 m away from the
ground.

j) When the jib reaches the required position, remove the pin II for securing the drag rod and

Equipment
the jib. Align the end of drag rod with the connecting points on the head of the telescopic
section 4. Install the pin II and the retaining clip IV. And install the pin I which is on the right
side of jib into the pin hole III. See Figure 5-7.

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 Operator’s Manual for Truck Crane

起
重
机
说
明 Pin II

Figure 5-7 Secure the drag rod

k) After you derrick up the boom to more than 60°, you can fully telescope out the boom for a
lift operation.

CAUTION
Before operation, examine the assembly and make sure that all connections are
tight.

5.2.3 Angle settings

The way of changing the offset from 5° to 17° or 30°:
a) Move the control lever 2 (referring to Figure 4-4) to reel off the auxiliary hoist rope for 2 m
Equipment

to 3 m at low speed.
b) Change offset to 17° or 30°:
1) Remove the pin and retaining clip from the pull bracket at jib end.
2) Derrick the boom up slowly until the long groove of the pull bracket aligns with the pin
hole for 17° or 30° position.
3) Install the pin and retaining clip at the point for the required offset position.
See Figure 5-8.

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 Operator’s Manual for Truck Crane

5°

起
重
机
说
明

17°

30°

Equipment
Figure 5-8 Offset positions

5.2.4 Dismantling
After you complete the jib operation, dismantle the jib in reverse order of the assemble steps.

CAUTION
(1) Assemble and dismantle the jib slowly and stably. Otherwise, the components and
parts may be damaged! Meanwhile, observe the relative position of main boom and
jib.
(2) After you dismantle the jib, you must install all the pins in position.

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5.2.5 Reeving in the auxiliary hoist rope

a) Reeve the hoist rope from the auxiliary winch through the rope guide on the basic boom.
起
b) 重Reeve the rope through rope securing tube I.
c) 机Remove the rope securing tube II and retaining clip.
d) 说Reeve the rope head through the wedge sleeve and connect with the auxiliary hook.
明
e) Install the rope securing tube II.
For details, please refer to Figure 5-9.

Rope securing tube I

Rope securing tube II

Figure 5-9 Positions of rope securing tubes

Equipment

5.2.6 Connection of hoisting limit switch

For the connection of hoisting limit switch, please refer to Figure 5-10.

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 Operator’s Manual for Truck Crane

起
重
机
说
明

Figure 5-10 Connection of hoisting limit switch

CAUTION
Before you use the jib in a lift operation, connect the cable harness of the hoisting limit
switch for the auxiliary winch and the cable harness of the jib.
Before you dismantle the jib, disconnect the cable harness of the hoisting limiting
switch for the auxiliary winch and the cable harness of the jib. Otherwise, the cable
harness may be broken!

Equipment

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 Operator’s Manual for Truck Crane

5.3 Rooster sheave

The components of the rooster sheave are as follows:
起
 重Bracket
 机Sheave spindle
说
 Sheave
明
 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 head.
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) Retract the boom fully.
b) Move the boom over sides and 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 5-11.
d) Reeve the 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.
Equipment

Top boom section

Connecting pin

Securing pin

Rooster sheave

Figure 5-11 Rooster sheave assembly

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 Operator’s Manual for Truck Crane

5.3.2 Dismantling
When it is not necessary to use the rooster sheave, make sure that it is attached to the side of
起
the top boom section head. Disassemble it in the reverse order of the assemble procedure.
重
机
说
明

Equipment

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Chapter 6 Additional Equipment

 Operator’s Manual for Truck Crane

Chapter 6 Additional Equipment

6.1起Air conditioning in driver's cab

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

Figure 6-1 Control panel, A/C

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

Footwell air supply 5 bars – stage 5

Equipment
Additional

Fresh air 6 bars – stage 6:

Front window air supply Vehicle body

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 Operator’s Manual for Truck Crane

6.1.1.2 Buttons
1 Temperature adjustment button
起
重 Pressed:
机 Increase / decrease the temperature.
说
2明 Fan speed button
Pressed:
Increase / decrease the fan speed.

3 OFF button
Pressed:
Turn off the air conditioning system.

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

5 A/C button
Pressed:
Activate the air conditioning.

6 Circulation button
Pressed:
Changeover interior / outer air circulation.

7 Front window air supply button

Pressed:
Activate the front window air supply mode.
Equipment
Additional

8 Mode button
Pressed:
Changeover different air supply modes.

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

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CAUTION
(1) Make sure that the A/C is in the OFF mode when the engine is OFF or at idle speed
起
for a long time. The battery drains in these conditions.
重
(2)
机 When you move the crane for a long distance at low speed, with the A/C in the ON
说 mode, put the transmission in a low gear. This increases the engine RPM and
明
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) Regularly (once a month) switch on the air conditioning briefly, even if cooling is
not required (e.g. in winter). This will 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 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.

Equipment
Additional

QY25D531R Truck Crane 6-3

 Operator’s Manual for Truck Crane

6.2 Air conditioning in operator's cab

In order to provide a comfortable environment, an air conditioning is available.
起
The重A/C control panel above the right window of the operator’s cab is used to adjust room
机
temperature.
说
明

Cab heater control panel

A/C control panel

Figure 6-2 Control panel locations

6.2.1 Air conditioning

The A/C control panel is above the right window of the operator’s cab.
There are two rotary switches and two control lights on the control panel. See Figure 6-3.
a) CAB COOLER POWER SWITCH
Refrigeration on / off
b) A/C FAN SPEED / MASTER SWITCH
Used to control the evaporator fan speed: OFF, HI, MID, LOW
It is also the master power to the REFRIGERATION mode function and must be ON (HI,
MID, LOW) for the functions to operate.
c) CONTROL LIGHTS
FAN POWER CONTROL LIGHT and COOL MODE CONTROL LIGHT

通风 制冷
VENTILATE COOL
CONTROL LIGHTS
Equipment
Additional

CAB COOLER POWER

LOW低
SWITCH
MIDDLE中

HIGH高 COOL制冷
关 关
OFF OFF
A/C FAN SPEED /
MASTER SWITCH

Figure 6-3 A/C control panel

6-4 QY25D531R Truck Crane

 Operator’s Manual for Truck Crane

6.2.1.1 Operating instructions

a) Refrigeration mode
起 To achieve faster cooling, first use the high fan speed. And then make the fan speed lower
重
according to the actual condition.
机
说 – Set the A/C FAN SPEED / MASTER SWITCH to position “HIGH”.
明 Result – FAN POWER CONTROL LIGHT is ON.
– After 5 minutes, set the CAB COOLER POWER SWITCH to position “COOL”.
Result – the COOL MODE control light illuminates and the refrigeration mode is ON.
b) Set the CAB COOLER POWER SWITCH to position “OFF” when you get necessary
temperature.
Result – the COOL MODE control light goes off and the compressor stops work.
When the temperature in the cab is higher than the set value:
– The COOL MODE control light lights up.
– The compressor starts automatically.
– The cooling system begins to work.
Note:
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 / MASTER SWITCH to control the evaporator fan speed:
OFF, HI, MID, LOW.
When the air conditioning is used, do not turn the CAB COOLER POWER SWITCH to
position “COOL” while the A/C FAN SPEED / MASTER 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 interval.
(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.
Equipment
Additional

(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.

QY25D531R Truck Crane 6-5

 Operator’s Manual for Truck Crane

6.2.1.2 Requirements for periodic maintenance

Table 6-1 Requirements for periodic maintenance
起
重Item Maintenance Repair interval
机
说 fan motor
Condenser Examine and repair Every quarter
明
Evaporator fan motor Examine and repair Every quarter

Every month or increase the

maintenance frequency
Condenser Examine and clean.
according to the working
conditions
Every quarter or increase
the maintenance frequency
Evaporator Examine and clean.
according to the working
conditions

Connector Make sure that the connector is set in place. Every month

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
Two different locations:
– between the water tank and fan (for the crane without condenser fan)
– on the side of vehicle (for the crane with condenser fan).
(3) Condenser fan – it is mounted with the condenser to help the hot air exchange.
Equipment
Additional

6-6 QY25D531R Truck Crane

Operator’s Manual for Truck Crane

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.
The positions (on chassis frame and slewing table) to lift the crane are shown in the Figure 7-1.
Follow applicable rules while you lift.

Lifting points

Lifting points

Figure 7-1 Lifting points

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

QY25D531R 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:
起
a) 重Lock the doors and the windows, and switch off control instruments.
b) 机Clean contamination off the crane.
说
c) Fully retract all the cylinder pistons (except vertical cylinders).
明
d) Fully extend the outriggers to lift the tires away from the ground.
e) Inflate the tires to specified pressure and put moisture-proof wooden blocks below the
tires.
f) Turn off the engine and cut off the power supply.
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) Keep the crane in a garage. If not, take measures against rain, thunder and freeze.
k) Operate the engine for more than 1 hour every three months. Examine the mechanisms at
idle speed to make sure that they operate correctly.
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.
and Storage
Transportation

7-2 QY25D531R Truck Crane