Operating instructions for the XCMG QY25K Truck Crane. Operating manual of xcmg qy25K truck crane Chinese truck crane 25 ton control

1.Description of XCMG QY25k5 Truck Crane Computer

If you need spare parts for Chinese mobile cranes, go here

Torque limiter NS4900 series Electric

Using a variety of signal sensors, the limiter can
control the control of all kinds of crane functions, and also provides
load data to the crane driver. Changes in crane operation
reflected directly in numeric values.

The limiter provides the crane driver with such information,
as the length and angle of the lifting jib, height, operating amplitude, nominal and

If the control of the crane is out of the permissible range,
torque limiter НС4900 will warn the crane driver about this.
At the same time, the warning light will light up and the work of those parts will stop.
crane, which could damage the control of the system.

2. Warning

In the case when in the operation of the crane may occur
malfunctions that can lead to loss of life or equipment breakdown,
the limiter sends a special warning signal for use
auxiliary device.

However, this device cannot replace the weighted
driver's decision. The driver's experience and competent handling of the machine in accordance with
operating rules are essential conditions for safe
use of equipment.

The driver is responsible for driving safety. He must
carefully read and understand all the points in this manual.

Attention!

If the limiter works correctly, no errors are allowed in the control, thenthe information on the indicator will be as useful as possible for the driver, in order to prevent accidents with fatalities and damage to equipment, when installing the limiter, you need to carefully check whether everything is in order.

3. Description of the system

NS4900 series torque limiter can be installed on

most cranes. It is necessary to calculate the moment of force and calculate the weight
load to avoid overloading and to prevent dangerous handling.

The НС4900 system is able to calculate the length, the angle of the crane boom,
maximum lifting height, operating amplitude of the crane, rated lifting weight and
other data. The limiter by measuring these nodes is able to calculate
the value of the moment of force. When control goes beyond safe,
a warning signal appears on the LCD screen, and at the same time
the control device sends the appropriate command, informing the driver that
it is necessary to suspend work.

Functions, features and instructions for use are described below.
operation of the NS4900 series torque limiter .

4. Structuresystem we

1. The main mechanism is the central controller.

2. Box of connecting wires CAN (local area network of controllers)

3. Indicator with color liquid crystal image

4. Oil pressure switch

5. Length / angle sensor

6. Height limit switch and weight

5.Instruction to control the crane truck computer

After normal adjustment, the force limiter can work automatically, therefore the crane driver must operate guided by knowledge of the limiter system, only the field of correct adjustment can be started.

6. Functions and control method of XCMG QY25k5 truck crane computer

6.1 Pointers

1. Height limit indicator

2. Warning indicator

3. Overload indicator

A. Barcode

B. Scope of work

C. Diameter reading area (shows steel wire rope data)

D. Boom length display area

E. Range of indication of the maximum lift height for a given
position of the tap

F. Main boom angle display area

G. Range of indications of the working amplitude of the crane

H. Display area for actual load weight

I. Range of indications of rated lifting capacity

J. Level display area

K. Weight range

L. Wind speed display area

M. Time display area

N. Function button

O. Button for setting operating parameters

P. Cable Extension Adjustment Button

Q. Fault diagnosis button

R. Mute button

S. Outrigger status display area (1/2% half extended, 1: fully extended).

Note: the two rows of numeric buttons represent the corresponding given numbers.

6.2 Control method of the mobile crane computer

6.2.1 Language selection (Chinese / English)

The 4900 limiter system uses the IC4600 monitor and provides readings in both English and Chinese. When you turn on the system, by default, the readings are displayed in Chinese, if you want to set the English language, follow the instructions: Press the "functions" button of the main menu shown in Fig. 1 (in the figure designation N) and go to the "functions" menu shown in fig. 2.

Rice. 2 Function menu

Click the button shown in Figure 2 to change the Chinese language to English. To switch of English language press this button again, please note that after changing the language to English, the set language may not be saved for a long time. After the next connection to the power supply, you need to re-install the desired language. After changing the language, the panel looks like this:

Rice. 3. Menu of functions of the computer of the truck crane after turning on the English language

6.2.2 Switching the measuring system

To meet export requirements, the monitor may display metric or inch units. The default is metric units. If you need to switch the system of measures in inches, follow the instructions: Press the main menu button.

Press the button again to toggle between metric units.

Rice. 4 Function menu after switching on the measuring system in inches

6.2.3 Setting the operating parameters of the xcmg mobile crane computer

Setting the operating parameters is the setting of the restrictor parameters according to the actual operating environment of the crane. When the crane is operating, it is necessary that the indicator readings coincide with the real working environment. Before starting work according to the crane model and working environment, find the job number, the readings should be adjusted to the actual situation.

Important to remember:Correctthe setting of operating parameters is an important factor that ensures faithfulsystem and crane operation. The system and the crane can be controlled only a highly qualified specialist. Do not work on a crane if the setting of the parameters does not correspond to the real ones. Way correct installation working parameters:

When you need to adjust the limiter readings, click on the button in the main menu, and go to the menu "setting operating parameters" (Fig. 5)

Fig. 5 Menu for setting operating parameters

In this menu, by operating the digital and functional
with the buttons, you can match the operating value displayed by the indicator with the actual control state. For example, setting the operating mode 1: first press the button, while in the column "new code" will be displayed "o", press the button "1", and in the column "new code" will display "1". Press the button to confirm the set parameter and return to the main menu. If you need to set the operating mode 21: first press the button, while in the column "new code" will display "o", then press the number buttons "2" and "1" while in the column "new code" will display "21". Press the button to confirm the set parameter and return to the main menu. Press the button to cancel the set parameter. See paragraph 6.2.8 for specific parameter codes.

6.2.4 Setting the multiplicity of cable increase

The setting of the magnification is the information that is necessary in order for the limiter to set the magnification of the steel cable. Before starting the ascent, the driver must adjust the actual and displayed cable gain. Displayed and actual values are equal if:

The panel displays 1 - 16

Increase in steel rope 1 - 16

Press the button in the main menu and go to the menu "setting the multiplicity of cable increase" (Fig. 6).

Rice. 6 Menu for setting the multiplicity of cable magnification

The method of setting the multiplicity of the cable increase is similar to setting the operating parameters.

6.2.5 Information on failures in the safety system

Press the main menu button and enter the fault information menu. This menu provides information on faults (description). This information will help you with maintenance and troubleshooting.

Rice. 7. Menu with codes and information about faults

Press the "up" and "down" button to identify the DTC. Press the button to return to the main menu.

6.2.6 Setting time and date

To set the time, press number 1 in the function menu (Fig. 2) and go to the “time setting” menu.

Rice. 8 Time setting menu

To set the time, follow the instructions: By pressing the function buttons, select the object that you want to change and use the number buttons to enter the data. For example, you need to set the date to 1.05.08 and the time to 18:30. Using the buttons

"Up" and "down" move the green point to the "year" position and press the number buttons "0" and "8". Press down button to set month, press number buttons "0" and "5". Press the down button to set the number, press the number buttons "0" and "1". Press the down button to set the hour, press the number buttons "1" and "8". Press the down button to set the minutes, press the number buttons "3" and "0". Press the button to confirm the set parameters. After installation, the menu looks like this:

Rice. 9. Time setting menu

Note: after setting the time, the seconds countdown starts from "0"

6.2.7 Checking CAN status

To check the CAN status, press button 2 in the function settings menu. In this menu, the operator can check the operation of the main CAN wire. If the wire is faulty, the cause of the fault is displayed. In this case, the green square - the work of the part is normal, the yellow - the part is ready for work, the red - the malfunction of the part.

Rice. 10. CAN STATUS CHECK MENU Press the button to return to the main menu.

6.2.8 Checking the operating parameters

Press number button 3 in the main menu to enter the "check operating parameters" menu. Use the up and down buttons to scroll through the operating parameter codes. Press the button to return to the main menu.

Fig. 11 Menu for checking operating parameter codes

6.2 Setting the lower and upper limit of the angle of the mobile crane xcmg

The torque limiter system can limit the operating angle of the lifting arm, this will help the driver to maintain safe and moderate driving in the presence of obstacles (structures, bridges, high voltage lines).

Attention! The boom angle limiting system of this system has a warning function and controls all dangerous actions. When you turn on the limiter again the limit value must be set again.

6.3.1 Setting the upper limit of the angle.

Increase the boom amplitude as appropriate for the situation to the safest position. Click on the button in the main menu, on the left side of the upper limit of the boom angle value will appear. This sets the upper limit of the boom angle to the current angle position. When the limit value is increased, the indicator lights up and at the same time a warning signal sounds to remind the driver to operate the crane more safely.

Attention: the set angle of the upper limit cannot be reduced to the already setcorner of the lower limit.

6.3.2 Setting the lower angle limit

Decrease the boom amplitude to the minimum safe position as appropriate for the situation. Click on the button in the main menu, on the left side of the lower limit of the boom angle value will appear. The limiter then sets the lower boom angle limit as the current angle position. When the limit value is decreased, the indicator lights up and at the same time a warning signal sounds, reminding the driver to operate the crane more safely.

Note: the set lower angle limit cannot be increased up to the already set upper angle limit.

Example: The setting of the upper limit angle of 75º and the lower limit of 60º is shown below.

Fig. 12 Menu bar after setting upper and lower angle limits

6.3.3 Removing an angle limit

Press the numeric button "0" in the upper and lower angle limit setting menu, thus you will cancel the set angle limit.

The horn of the HC4900 system emits a warning signal in the following situations:

Exceeding the maximum rated load moment

Boom hook approached the limit height

Exceeding the working area of the crane

Restraint system problems

Management errors

Click the button on the main panel, so you can cancel the warning
beep 20S.

6.5 Description of the indicators of the xacmg auto-screen computer

6.5.1 Height limit indicator

When the weight of the height limit switch and lifting equipment is touched, the

the red indicator of the limit switch and an audible signal (buzzer) sounds, this means that the limit height is close. It is necessary to stop lifting, extending the boom, changing the amplitude. To prevent injury to people and damage to the crane, check the height limit switch systems before starting work.

Checking method:

Raise the height limiter by hand, the indicator should light up and a sound signal should appear.

Raise the lifting equipment slowly or change the amplitude, extend the boom to extend the height limit switch weight, the indicator should light up and a beep should sound. Boom lift, amplitude change, boom extension should stop.

If the buzzer and indicator did not work, the crane did not stop working, this indicates a system malfunction or a crane malfunction, it is necessary to eliminate the malfunction and only then start work.

6.5.2 Warning indicator.

When the actual bearing torque reaches 90% -100% of the rated bearing torque, the yellow indicator is lit on the screen, it means that the overload condition is near, the operator should be careful.

6.5.3 Overload indicator
When the actual bearing torque reaches 100% of the rated bearing torque, the red indicator on the screen lights up and the buzzer sounds. Also, this indicator is on when the overload indicator is malfunctioning. In this case, it is necessary to stop lifting, extending the boom, changing the amplitude.

7. Functions of the xcmg truck crane limiter

7.1 Warning

When one of the following situations occurs, the HC4900 system beeps and the indicator lights up:

Overloading the crane

The lifting mechanism of the crane is raised to the maximum height

Limiter system malfunction

When coordinated with the crane's electrical system, when a signal is given in the event of a hazardous situation, it is prohibited to perform one of the following operations:

Decrease boom amplitude

Boom extension

Raising the boom In this case, the system allows the performance of safe operations, i.e .:

Boom amplitude increase

Arrow retraction

Arrow descent.

Attention

If the setting to automatically stop the execution of limiter operations

is in working position, the automatic stop signal is received

constantly. Only the functions "not the ability to perform hazardous work",

“Performing only safe operations” is associated with the crane's electrical system,

including "safe direction measuring switch",

"Safety solenoid valve". The moment limiter itself does not accept

a decision on the hazard or safety of the line of work.

8. Maintenance and adjustment method computer truck crane

If during Maintenance or adjustment problems, contact the manufacturer.

1) Check the connection and integrity of all wires. If you find a faulty wire, replace it.

2) Check the connecting wire of the length sensor and the height limit switch and the wire insulation, if the insulation or wire is faulty, replace it in time.

3) Check the operation of the height limit switch.

4) Check the wire spool.

5) Check that there is no leakage from the amplitude change oil cylinder pressure sensor and the connecting pipe.

8.2 Setting the length sensor of the truck crane xcmg

If the displayed boom length is not correct, adjust as follows:

Retract the boom to the main one, check the pre-tension of the drum with the cable (the cable must be tensioned), open the outer cover of the length and angle sensor, another name is a hanging box), slowly turn the axial shaft of the length potentiometer (when rotating clockwise - increase, counterclockwise - decrease ), rotate until the actual length matches the displayed length.

8.3 Adjusting the boom angle sensor

Angle sensor and boom length sensor are installed in the same housing. When checking, first retract the boom to the main one, the displayed length should correspond to the actual one.

When doing so, check that the angle and amplitude of the boom match. If the displayed value does not match the actual value, you need to adjust the angle sensor. To do this, loosen three bolts (shown by arrows in the figure), gradually move the angle sensor body until the actual value of the angle and amplitude matches the values displayed on the screen. Then tighten the screws.

8.4 Length of sound signal

If, after turning on the engine, the indicators displayed on the screen are normal, there is no malfunction code, but the buzzer emits a long beep, it is necessary to check the serviceability of the length measurement wire, the operation of the height limit switch, the reliability of the connection of the height limiter and the boom junction box, connection of the height limiter, and check the wires for a short circuit.

8.5 The cable to be measured is difficult to remove

If, when retracting the crane boom, it becomes difficult to retract the cable to be measured, this may be caused by too little pretensioning of the spring inside the box or incorrect position of the cable in the box.

In this case, it is necessary to adjust the pre-tensioning force in the following way:

1) Remove the boom, place the boom on the frame.

2) Remove the fixed end of the cable from the boom and slowly rotate the blade,

so that the cable returns to the groove, to its original place.

3) Pre-stretch the box (turn the wire and make sure

so that the measured wire and the box rotate together).

4) Pull out the wire, secure the end to the boom.

5) If after adjustment the readings have not changed, check the serviceability of the length sensor or adjust it.

Attention!

Be careful when adjusting.

Incorrect adjustment can lead to accident or damage.

After graduation

adjustments, make sure the setting is correct again.

9. Malfunctions of the computer crane xcmg and how to fix them

If a malfunction occurs during the operation of the crane, a malfunction code will light up on the screen.

According to this code, the operator must find the cause of the malfunction and fix it.

Below is the decoding of the xcmg truck crane safety system fault codes.

Malfunction		Way eliminating
Working the amplitude is too small or boom angle too large	Amplitude exceeds the minimum amplitude set in a special table or angle below the maximum set angle. The reason is too much decrease main boom amplitudes	Reduce
Working the amplitude is too large or too small boom angle	Amplitude exceeds the maximum amplitude specified in a special table or angle below the minimum set angle. The reason is too big decrease in the amplitude of the main boom	Increase amplitude or angle to the set value.
No operating state or rotation zone not allowed	Operating state not saved code selected The main boom is in the unauthorized area.	Turn crane to the permitted work area or set the correct parameters.
Boom length is out of scope permissible length	1. The main boom is too extended, or vice versa, not fully extended. For example, the maximum shoulder length has been exceeded. 2. Adjusted the sensor lengths, e.g. cable lagged behind the disc wires 3. Problems with springs in the box of wires, e.g. broken wire	1. Extend or retract the primary boom until desired 2. Retract the boom and Check if the sensor is showing abnormal data. Open the length sensor and use a screwdriver to move up to Set elevation 3. Change the kit Spring including moving wheel. After that Adjust the sensor
Primary Boom Length Sensor Voltage Below Limit meaning	1. Breakage of the length sensor	1. Replace the sensor 2. In the DGA6.i.3 device simulate the correct meaning PDB
Oil pressure sensor voltage below limit meaning	1. Breakage of the length sensor 2.Not supported by PDB 3.Failure of electrical parts	1. Replace the sensor 2. In the DGA6.i.3 device simulate the correct meaning PDB 3.Replace the sensor
Voltage cavity oil pressure sensor below limit value	Look E12	Look E12
Primary Boom Angle Sensor Voltage Below Limit meaning	1. Broken angle sensor 2. Breakdown of electrical parts	1. Replace the sensor 2. In the DGA6.i.3 device simulate the correct meaning PDB
Measurements primary boom length sensor exceed the limit	Look E11	Look E11
Measurements of the oil pressure sensor in the cavity exceed the limit value	Look E12	Look E12
Measurements oil pressure sensor not in the cavity exceed the limit value	Look E12	Look E12
Measurements tensile force transducer exceed the limit value	Look E14	Look E14
Measurements primary boom angle sensor exceed the limit	Look E15	Look E15
Error supplying electricity to a current source	+ UB system not starting system The + UB system did not detect the equipment activation system System on / off contact error + UB	System + UB and the system current source + UB must be connected separately with a wire: system + UB and crane accumulator are connected Turn on / off + UB again
Error signaling	Breakage of the element responsible for the system program Broken Flash-EPROM	Install working software Replace main unit
Program system does not match the digital data of the crane	Not Correspondence between the LMI system program and the crane data program	Install running system program or running crane data
Not correspondence of the system program and the performance table	Not compatibility of the LMI system program and the crane performance table	Install the operating program of the system or related documents with characteristic data
Error memory (RAM)	Breaking processor (RAM) or main unit	Replace main unit
Error memory management Measurements CRC memory do not match the data	CRC memory signal error No battery charge (1kOhm,<2V) Breakdown of the main unit	Raise LMI Replace main unit battery Replace main unit
Error digital crane data	Broken Flash-EPROM	Replace main unit
Error load curve document	Invalid data stored in the digital data of the crane (load curve) Broken Flash-EPROM	Set valid data Replace main unit
Error setting the length of analog output 1, angle 1, pressure 1	Not analog output supported	Install correct Flag in DFG6.i.2
Error digital crane data	Invalid data stored in the digital data of the crane Broken Flash-EPROM	Replace main unit
Error digital data of crane movement	Invalid data stored in the digital data of the crane Broken Flash-EPROM	Restore or install valid data Replace main unit
Error when transmitting CAN bus data to CAN elements	Broken or short circuit in the CAN bus wire between the main unit and sensor Short circuit of CAN bus wire	Check connection Replace main unit Replace CAN bus wire
Error CAN bus data transmission sensor	Broken wire between main unit and sensor Failure of the CAN bus output on the main unit Broken sensor	Check connection Replace main unit Replace sensor
Error CAN bus sensor	Analog values of sensor element not supported	Replace sensor
Error data transmission CAN bus length / angle sensor	Look E62	Look E62
Error working condition	Selected operating parameters are not included in the data of the crane	Select other operating parameters Check tap program
Error determining the amplitude	Calculated the amplitude is too small	Check tap program
Code operating parameters changes following the load	Code operating parameters of the controller changes following the load	Please select code of operating parameters in the absence of load on the boom
No messages between main unit and monitor	Broken monitor cable or broken monitor CAN system malfunction	Replace monitor or cable
Active LMI action	Excess LMI processing time	Reinstall the system Check connections
A short closing switch A2B	Short circuit of wire A2B Short circuit of the connecting wire of the A2B switch	Replace switch A2B
Shutdown circuit breaker A2B	Switching off the A2B wire circuit Switching off the circuit of the connecting wire of the switch A2B	Connect or replace switch A2B Connect or replace connecting wire
Not correct operation of the A2B switch	Sensor error CAN bus delay Radiogram delay Invalid radio message ID	Replace switch A2B Replace connecting wire Replace battery Set ID in DFG6.i.2
Error	Deleting DVR settings	Again set up a registrar
Active software operation digital registrar	Excess LMI processing time	Reinstall the system Check connections
No charging	Short battery charge	Replace battery then install RTS

S14, S15-switch system pressure

S13-switch free run turn

S12-switch of elimination of limitation of rotation

S21- switch elimination of the warning that steel cables are unrolled to the end

S20- overload elimination switch

S23- heating switch (optional, for the greenhouse)

S24-ignition switch (optional, for the greenhouse)

S25-oil supply switch (optional, for the greenhouse)

S26- horn switch
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e. Relay description

Relay K0 (type JQ201S-PL0): electrical system control

Relay K2 (type JQ202S-KL0): rotation limit control

Relay K3 (type JQ202S-KL0): horn control

Relay K5 (type JQ202S-KL0): overload control

Relay K10, K9 (type JQ202S-KL0): control over the front area

Relay K6 (type JS157): monitoring the warning that steel cables are rolled up to the end

Relay K7 (type JS157): monitoring the warning that steel cables are fully extended

Relay K8 (type JS157): front area warning control

Relay K1 (type 67147): control for free rotation

Relay K4 (type 67147): boom replacement monitoring

Buzzer B2 (type FM-24V): warning that steel cables are coiled or deployed to the end

Buzzer B3 (FM-24V type): front area warning

Operating instructions

a. it is necessary to put the handles of all control devices in the middle position before turning on the main power

b, the truck crane is equipped with an overload relief switch (S20). Use this switch with care when overloading. In general, there is no need to use this switch.

(5) Diagram of electrical devices

4.2 Description of the hydraulic system

The hydraulic system of the QY 25K type truck crane adopts a variable axial piston motor system with an open metering pump, which includes a four-section gear pump and an axial piston motor with an inclined cylinder block. Divided into 2 parts: upper machine hydraulic system and lower machine hydraulic system

Lower machine hydraulic system

A gear pump with a displacement of 32 ml / r gives the oil channel pressure of the lower machine. The pressure of the overflow valve is 20 MPa. A manual multichannel transfer valve is used to control the direction of movement of the horizontal and vertical outriggers. It is possible to work on both sides of the frame. The client can make a choice for a specific situation. The 4 horizontal or vertical outriggers can be extended separately or simultaneously. The new type multi-port diverter valve with pressure limiting valve can effectively prevent the piston rod of the horizontal cylinder from bending. On cylinders, the 4 vertical outriggers have double-sided hydraulic locks to ensure that the piston rod of the vertical cylinder can roll up during lifting or extend by itself when the crane is moving.

(2) Hydraulic system of the upper machine

The control system of a hydraulic multi-port bypass valve, the main control valve of which is a sensitive proportional load multi-port bypass valve. Each transfer valve is equipped with a vibration-resistant valve, at the same time, the leading and auxiliary mechanisms with a gas valve. The hydraulic booster valve adopts imported proportional pressure reducing valve. The handle angles of the power steering valve are directly proportional to the outlet pressure, and the amount of movement of the spool is also directly proportional to the outlet pressure of the power steering valve, so that the whole machine has better creep properties. At the same time, under the action of a sensitive loading valve, the speed of movement of the actuators is not related to the load, which reduces the difficulty of the operation and facilitates the intensity of labor. The use of a variable motor as a hoist gives the whole machine the advantage of being lightly loaded at high speed and heavily loaded at low speed.

a. Description of the lifting oil channel

Maximum pump displacement: 82ml / r, variable motor displacement: 55 ml / r.

The lift oil channel uses a normally closed lift brake. When the power steering valve operating the drive mechanism is operating, the control oil exits the power steering valve and makes the hydraulic transfer valve change direction through the shuttle valve, at the same time, the pressure oil discharging from the power steering pump (3MPa) activates the lift brake through the hydraulic bypass valve thus, normal lifting work is carried out.

When the hydraulic control valve returns to the middle position, the pressure oil of the control oil channel flows from the hydraulic control valve into the tank, the hydraulic control valve returns to its initial position under the action of the return spring, and the pressure oil in the lift brake flows into the tank through the hydraulic control valve, the brake acts by means of a spring.

b, Description of the oil return duct

Maximum pump displacement: 32ml / r, dispensing axial piston motor displacement: 55 ml / r.

28
The solenoid valve controls the engagement of the rotary brake. When the solenoid valve has no electricity, the brake is disengaged, otherwise the brake is applied by the action

pressure oil. Therefore, during pivot operation, the operator must press the S11 switch button (3 in total) in line with the power steering control valve that controls the pivot movement.

The main oil return channel has a free run function. When the boom is pulling sideways during lifting operation, press any switch button from S13 and S17 and the turntable will adjust itself so that the plane on which the centerline wire is above the load center of gravity. Thus, it prevents the boom from bending and kinking due to lateral pull.

c, Description of oil duct with variable offset

The maximum pressure of the system is set at 8MPa during descent with a change in departure. In this position, for a smooth or reliable stop, a back-up valve is installed in the oil channel. A special decompression oil channel of the bypass valve has been designed to provide a stable pressure signal to the torque limiter.

d. Description of the telescopic oil channel

Maximum pump displacement: 50 ml / r.

There are 4 main boom segments. One telescopic cylinder is simultaneously extended with the second, third and fourth boom segments. To prevent bending of the piston drawbar due to too high pressure, a pressure limiting valve pressure of 14 MPa is set. For smooth or reliable stopping, a back-up valve is installed in the oil channel.

e. Description of the control oil channel

A gear pump with a displacement of 8 ml / r gives the pressure of the control oil channel with a hydraulic booster, the pressure of the overflow valve is 3 MPa.

A solenoid valve is installed to control the oil supply. Only if available electricity for this valve, all executive mechanisms can act, otherwise not act.

An unloading solenoid valve is installed, controlled by a torque limiter. When the magnitude of the load torque is equal or greater than the nominal value, electricity is generated at the solenoid valve, all actions that can increase the torque cannot be performed

A triple circle safety solenoid valve is installed, which will generate electricity when the leading and auxiliary lifting drums have 3 circles of steel cable left. At this time, the steel cables cannot go down further.

The pivot mechanism and the auxiliary mechanism share a single power steering control valve (located on the left armrest of the seat). Push the handle forward, the auxiliary lifting hook descends; Push the handle backwards, the auxiliary lifting hook is lifted; Push the handle to the left, the turntable turns to the left; Push the handle to the right, the turntable swivels to the right.

The telescopic mechanism and the drive train share a single power steering control valve (on the right armrest of the seat). Push the handle forward, the driving hook is lowered; Push the handle backwards, the driving lifting hook is lifted; Pushing the handle to the left is going to; Push the handle to the right, expands.

(3) Technical parameters

Operating pressure of the main oil channel: 21 MPa

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Tank capacity: 397 l.

Accuracy of the receiving oil filter: 180 µ

Oil return filter accuracy: 20 µ

Accuracy of the oil filter of the control oil channel: 10 µ

Hydraulic oil brand:

Ambient temperature ≥5℃, L-HM46

Ambient temperature -15℃ --- 5 ℃, L-HM32

Ambient temperature -15℃ --- -30 ℃, L-HV 22

Ambient temperature< -30 ℃ , aviation hydraulic oil No. 10

4.3 Starting the engine and operating the PTO

(1) Items requiring special attention during the operation

Before engaging the power take-off, ensure that all control levers in the operator's cab are in the middle position.

The procedure for engaging the power take-off is in the following table:

	Graphemics	Operation order
		Give the stop brake to the braking state
		Confirm that the selector lever and PTO switches are in the middle position (off position)
		Turn the chassis switch and turn on the engine; on cold days, warm up the engine before turning it on.

		Engage power take-off
		Slowly lower the cone pedal

This is the end of the preparation for the work of the truck crane. In winter, after starting the engine, you must first idle for about 15-20 minutes to comfortably raise the temperature.

The procedure for disengaging the power take-off is in the following table:

	Graphemics	Operation order
		Press the cone pedal all the way
		Switch off power take-off
		Lower taper pedal
		Turn off the engine
		Turn the chassis switch to the off position.

So the crane is out of order.

Attention: after turning on the power take-off, you can turn on the engine in the control cab of the upper machine with the ignition locks and turn it off with the extinguishing switch.

4.4 Outrigger Operation 10.3

Special Notes ：

Before extending the support, you must remove the pin lock.
place the hoisting machine on a firm and level ground.
The wheels should lift off the ground.
The crane should be installed horizontally to a solid platform if the ground is soft, loose then you need wooden coasters so that the tap is installed horizontally.
When the crane is installed, it is imperative that each support must be fixed so that there is no slope due to the possibility of danger.
if the support is not fully extended, the crane cannot be operated.
When the support needs to be put back in place, the pin of the lock should be inserted freely.
Support distance 4.8Х6.0m

(1) Names of outrigger parts

(2) Outrigger control lever

Attention:

a. Use the selective control lever to select the outrigger telescopic cylinder oil channel or outrigger lift cylinder oil channel.

* After completing the operation, you must immediately push the selective control lever to the middle position. In addition, it is imperative to confirm before starting work that the selective control lever is indeed in the middle position.

b, Push the # 1 outrigger telescopic cylinder oil channel or outrigger lift cylinder oil channel control lever # 1, the outrigger telescopic cylinder oil channel or outrigger lift cylinder oil channel can be extended.

(3) Extend and assemble the horizontal outriggers

Move control lever 2, 3, 4, 5 to the outrigger telescopic cylinder position, then push control lever 1 to the expansion position, then the 4 horizontal outriggers expand simultaneously. When fully extended, push all control levers to center position. When assembling the horizontal outriggers, the preparation procedure is the same, only you still need to push control lever # 1 to the collecting position.

(4) Extend and assemble the vertical outriggers

Move control lever 2, 3, 4, 5 to the outrigger lift cylinder position, then push control lever 1 to the expansion position, then the 4 vertical outriggers expand simultaneously. After the machine body has lifted and all tires are off the ground, push all control levers to center position. When assembling the vertical outriggers, the preparation procedure is the same, only you still need to push control lever # 1 to the collecting position.

Set the truck crane to a horizontal state

If, after expanding the outriggers, the truck crane is not yet horizontal, adjust it to a horizontal state in the following order:

For example: when the right side of the truck crane is too high,

a. Push the # 2 front left arm and the # 4 rear left arm from the selective control levers to the center position.

Caution: Do not inadvertently push the control lever into the outrigger lift cylinder position.

b. Slowly push control lever # 1 "outrigger telescopic cylinder or outrigger lift cylinder" to the "pick up" side, at the same time carefully observe the spirit level

c. When the spirit level is level, immediately push all selective control levers to the middle position.

Caution: Ensure that all crane tires are off the ground and that each outrigger chassis is actually in contact with the ground. 35

4.5 Gas operation

Accelerate or decelerate using static oil pressure. Depressing the accelerator pedal on the upper machine accelerates the swing, boom extension and hoist movements.

This pedal is located on the right side of the cab floor (see Map 4-10).

4.6 Hoist operation

Drive gear control handle (2):

Push the handle forward, the hook descends; Push the handle backwards, the hook is lifted. The control handle (2) and throttle will adjust the travel speed.

(2) Accessory control handle (3):

Push the handle forward, the hook descends; Push the handle backwards, the hook is lifted. The control handle (2) and throttle will adjust the travel speed.

Caution: To protect the side link when lifting, depress the free-turn momentary switch (S17) while operating the drive lift control lever (S17) so that the drive boom can swing freely and adjust to the center of gravity of the load. After the load has been lifted off the ground, the switch (S17) can be lowered.

4.7 Driving Luffing Boom Extension Operation

Note:

During boom exit and entry, slight change of boom is possible. For this on, a certain height, after a while there is a change in temperature in the hydraulic system, a slight change in the boom appears.

For example:

1.When the boom reaches 5 m, when the temperature is below 10 ℃, the exit is delayed by cho mm.

2. Since the influence of natural conditions changes the oil temperature, there is a slight change in the boom, which brings minor inconveniences, when control ： therefore

Do not allow the oil temperature to rise.
If an arbitrary reduction has occurred, it is necessary to bring the arrow back to normal.

3. Do not pull up the load, lift only vertically.

Extension control handle (2)

Pushing the control handle to the left, the boom expands, pushing to the right is going. The control stick (2) and throttle will adjust the speed.

Drive boom amplitude control handle (2)

Press the switch S18, push the handle (2) to the right, the boom descends, left-rises. The control stick and throttle will adjust the speed.

2) The relationship between the weight of the load and the tilt of the main boom when lowering the boom, the radius increases, then the carrying capacity decreases, when the boom is raised, the radius decreases, then the carrying capacity increases.

Rotary control handle (3)

Before carrying out pivoting work, first lower the mechanical lock (4) and press the switch (S11). Push the handle (3) to the right, the rotary plate turns to the right, to the left and turns to the left.

4.10 Tag Description

(1) Nameplate

The nameplate is located on the outside of the control cab door (see Map 4-11)

(2) Lift tag

Lift label is located in the control cab (see Map 4-11)

For each operating range, there is a corresponding lifting capacity and lifting height in the lifting property table. Before lifting, it is the operator's responsibility to become familiar with the weight and work area and select the appropriate operating condition. It is strictly forbidden to work outside the table.

（3） Amplitude Indicator Label (Map 4-12)

The Amplitude Label is located on the side of the boom. During lifting operation, the amplitude indicator is able to show the amplitude values for different boom lengths and different elevation angles. The permissible lifting weights and lifting heights can be determined based on the lifting capacity tag.

5.1 Secondary boom

1. It is imperative to put completely outstretched resisting legs firmly.

2. Do not stand in the direction of protrusion of the auxiliary shoulder.

3.Adequate operating time should be provided before assembling and storing the auxiliary arm.

4. In addition, the following points are strictly prohibited, otherwise the auxiliary arm may deteriorate. You need to collect and store the auxiliary arm for this manual:

a. Perform the operation lowering the shoulder when the auxiliary hook touches the apex of the auxiliary shoulder.

b. After pulling the pin for securing the auxiliary arm from the side of the driving arm, do not operate or drive the crane.

with. When mounting and assembling the secondary boom, extend the boom forward and reassemble the boom too quickly.

5. During necessary high-altitude work when assembling and storing the auxiliary arm, a ladder should be used to ensure safety.

Description of the installation and use of the auxiliary boom:

The auxiliary boom has a triangular truss structure, which has such advantages as simple structure, lightness, ease of installation, etc. We will now explain the installation and application as follows:

(1) A true secondary boom must be used when the boom outriggers are fully extended.

(2) Installing the secondary boom

a, Fully assemble the drive boom and lower it onto the rear side of the truck crane.

b, Remove burst from row 1 secondary boom, twist around row 2 burst to align secondary boom pin hole over drive boom pin hole, insert burr A.

c, Remove the row 2 burs, twist the whole secondary boom around the A to align the secondary boom hole to the primary boom hole, insert another secondary boom A. At this time, the secondary boom is 8.15 m long.

d, Spread out the yoke of the block and remove the steel cables from the block at the head of the secondary boom.

e, Pass the steel cables through the block yoke and the block at the secondary boom head

f, Turn on the power for the lifting limit switch auxiliary boom, insert the plug of the auxiliary boom and install the junction box at the head of the telescopic boom in order, install the breaker touching part lifting limit

g, Remove the hook from the auxiliary hook holder and install it.

(3) Angle 15 ° and 30 °

First set the secondary boom at 0 ° at (1), then lower the boom until the secondary boom head touches the ground. Remove burs B, insert into 15 ° or 30 ° hole and reinforce (see map 5-4, 5-5).

Here is the secondary boom in order, now you can use it.

(4) Removing the secondary boom.

After use, the auxiliary boom can be removed in the opposite order and

reinforce it to the right of the leading arrow (see Map 5-6).

The auxiliary boom is now fully assembled.

48
5.2. Rotational support

(1) Basic structure

The design of the rotary support is shown in Figure 4-5.

The pivot support is not only a support device for the entire rotational part of the crane, but also a unit that connects the upper body of the crane to the chassis. The inner ring of the pivot bearing is fixed to the lower part of the pivot disk of the upper crane body by means of 60 bolts2 (M27) located on one circumference. The outer ring is fixed to the lower crane body with 60 bolts1 (M27) on one circumference.

(2) Items requiring special attention during operation

Swivel bolts are manufactured using 42CrMo materials, should not be replaced with plain bolts.

The torque of the bolt is 1172N.m. It is necessary to comprehensively check the torque of the bolt after operating the pivot bearing for 100 hours, then comprehensively check them every 500 hours.

Normally, it should be lubricated every 100 hours. Pour calcium radical grease (ZG-3) into the filler hole, top up each time so that the grease seeps through the seal.

d. Changes in noise and gyroscopic moment of resistance should be observed during operation. Should be dismantled and checked immediately when the unusual condition occurs.

e. The teeth should be cleaned of dust and dirt after every 10 days of operation. It needs to be greased again.

Leading and auxiliary hook

Basic construction

Drive hook design see map 5-8, auxiliary hook design see map 5-9.

Check before use

A hook is rejected in any of the following cases:

A crack and gap appeared on the surface of the hook.

The width of the hook throat is greater than 10% of the nominal size (see the tag of the leading and auxiliary hooks)

with. The value of the wear of the dangerous section is higher than 10% of the nominal size.

d, The amount of wear of the section hanging of the rope is higher than 5% of the nominal height

e, Formability and hook twist above 10 °

f, With dangerous cross-sections of the hook tail, the threaded part of the hook and the live hook, irreversible deformation occurs.

52
Coefficient change multiplicity of steel cable

Operation conditions: firmly place the supporting legs, take in the shoulder and turn to the side or back.

Forcing the hook to the ground after lowering the shoulder.

Dismantle the cable gate on the shoulder head and on the hook.

with. Remove the heavy cable stop hammer from the steel cable.

d. Remove the cable cover.

e. When changing the multiplicity factor of the steel cable, you should carry out the operation of lowering the hook, at the same time pull out the steel cable.

Note:

The position of the assembly of the heavy hammer of the rope stop is not the same in the even and odd numbers of the multiplicity factor.

(during an even number) (during an odd number)

mount a heavy hammer on a branch with a cable cover

mount a heavy hammer on a branch next to a branch with a cable cover

(2) Care should be taken that the cables do not wind up randomly.

The assembly method for the cable cover and cable holder is shown in the lower fig.

54
7.1 Torque position switch

(1) working principle

An electronic computer calculates the radius of work by the duration of the hog, the signal of the magnitude of the angles entered by different generators. It is on the basis of the signal entered by the pressure generator that the computer calculates the forces of the varioscopic cylinder, after which it calculates the lifting moment. In the end, the computer compares it with the maximum forces stored in the database, then the manipulator dictates the appropriate information.

(2) safety function

In the event that the lifting torque overloads, the circuit breaker cuts off all routes that increase the torque (extension、 wobble underneath, rise) ; only routes that contribute to torque reduction (retraction、 swing up、 lowering the hook).

(3) height limiting function (7-1)

When the load hook approaches the lift boom block (750mm), it will cause the duration generator, whose electronic resistance is 4.7k, to ground. After work＂Enclosures＂ the same decides the extension and ascent of the ascent arrow. At the same time, the power switch displays a warning light.

(4) attention events

a. Before lifting, you must carefully read the abstract and fully master it.

Despite the fact that the serial connection of this hoisting machine there is a power switch, there is also a responsibility for safe management. Before work, the driver must more or less recognize the weight of the hanging things, then determine whether they can be lifted in accordance with the graphic characteristics. The power switch is a very important setting of this machine, in no case is it allowed to be turned off, let alone prohibited movements (for example: stretching with loads). The power switch can only work effectively when the position of the load is supplied in accordance with characteristic graphemics before work.

7.2 Three-ring fuse (7-1)

When the working surface of the truck crane is slightly high, the steel cable on the drums may not be enough to sweep through. When the drums have 3 circles of steel cable left, the fuse is active, the descent operation is automatically stopped, at the same time the buzzer will sound and the warning lamp will light up that the steel cables are soon to be deployed to the end (see Map 4-2).

system pressure switch (see Map 4-1)

This safety device is designed to prevent accidental pushing of the control handles when entering or exiting. Before work, you must press the switch (-S15, -S16) to build up pressure, otherwise the system cannot work.

Hydraulic safety valve

Designed to protect too high overload pressure. After starting this valve, all actions are stopped that further increase the torque (expansion of the boom, changes in amplitude downward, lifting). They can continue those actions that reduce the lifting moment (gathering the boom, changing the amplitude upward, lowering the hook).

Hydraulic oil filter shutter warning lamp

When a blockage occurs with the hydraulic oil filter, the warning lamp comes on. At this time, it is necessary to stop working and continue it after replacement.

Amplitude indicator

The amplitude indicator is able to show the magnitude of the amplitude for different boom lengths and different elevation angles. The approved lifting weights must be determined taking into account the "Lifting table" and the "Lifting accordion" to prevent overloading and damage.

8.1 Points requiring special attention

The following are as the main points requiring special attention in the operation of the truck crane. Customers are required to carefully read and understand them to ensure safe operation.

Number	Graphemics		Note
		Conveniently read the section on starting and stopping the engine of this explanation.	Check before running
		In the preparatory phase, check the hydraulic oil position by confirming the amount of hydraulic oil has reached the required level.
		Check every detail, confirming everything is in order, if abnormal phenomena appear, it is necessary to eliminate them on time.
		When the crane is in working order, it is prohibited to carry out repairs and inspections.
		After starting the engine, slowly accelerate, let the engine raise the temperature fully.
		Before starting the unit, make sure that all control levers are in neutral.
		In order to check every control levers and actuators are in order. If there is a malfunction, it is necessary to repair it in time.
		It is necessary to carry out a preventive test over the function of the automatic torque switch in the indicated positions.
		Check all other devices (eg pressure gauge), confirming whether they can work normally.
		Turn on the power supply key and trigger actuator in the control room before use.

Number	Graphemics	Attention events	Note
		It is imperative to carry out lifting work subject to the rated lifting capacity. Phenomena such as overloading, lateral thrust, lifting loads out of order, lifting loads buried or frozen in the ground are strictly prohibited.
		Normally it is not allowed to use 2 or more than 2 mobile cranes to lift one load. If necessary, pay attention to keep the steel cables upright, all truck cranes must lift synchronously. The load of each truck crane should not exceed 80% of its rated lifting capacity.
		When calculating the used lifting amplitudes, one must take into account such a factor that in the event of a load, the working amplitude increases due to the bending of the main boom.
		It is necessary to drive the hoisting machine slowly at the initial stage.
		When lifting, keep your attention focused and do not look around or chat with others. Only act on the signals of the indicated commander, but at any time obey all stop signals issued by anyone.
		When lifting, care should be taken to observe the surrounding position to prevent accidents. When the load is in a suspended state, the operator should not leave the work station.

Number	Graphemics	Events attention	Note
		It is necessary to pay attention to the temperature of the hydraulic oil. When the temperature exceeds 80 ℃, stop the operation. The capacity of the hydraulic oil in the oil cylinder and tank changes with the oil temperature. If the high-temperature hydraulic oil makes a stretch, shortly thereafter, the hog will spontaneously draw in due to the temperature descending. .In order to resume the previous duration, it is necessary to control the unsupported beam in time.	During lifting work
		You need to pay attention to the weather forecast ： 1 When the wind rate exceeds 10m / second, stop working 2 It is necessary to stop lifting and collect to save the hog in case of thunderstorm electricity
		It is impossible to pull out a load that has not yet lifted off the ground, avoiding a god load.
		It is better to put the hoisting machine on a stubborn and level place (you need to shift strong firewood under the outrigger on soft ground).	Outrigger control
		After finishing the setting of the truck crane, the tires of the truck crane should be lifted off the ground. When settling, attention should be paid to observe the spirit level.
		It is necessary to put the outrigger in certain places, at the same time it is a little closed.

Number

Graphemics

Attention events

Note

Do not turn the controlled lever of the lifting structure intensively.

Lifting structure management

a filtration of hydraulic oil or exchange of the periodic system
Three months

Six months

. The oil must be filtered or changed every six months. The service life of the hydraulic oil should not exceed two years. If it is more than two years, it must not be used even after filtering.

Date of renting machines filtering or oil exchange

Attention:

(1) Any time the hydraulic oil is seriously contaminated, it should be cleaned or replaced promptly in accordance with JB / T9737.3 standards.- 2000.

(2) Select a suitable hydraulic oil according to the ambient temperature.

b. hydraulic oil temperature

maximum hydraulic oil temperature ---- 80 degrees

c. hydraulic oil capacity

The required capacity is approximately 370 shz.

Inspect the oil tank: Inspect the oil tank when the hoisting machine is in the preparatory state of movement. The oil position table has a scale indicating the swelling volume at different temperatures. When inspecting the oil, it must be ensured that the oil position is between the 0 scales.℃ and reaching temperature.

Barcode 0 ℃ means the minimum position, so when the oil position goes below 0℃ , the hydraulic oil must be replenished in time.

9.2 nigroh

a. periodic system

Three months

Twelve months

Since then, the oil has to be changed every twelve months.

date of delivery of machines oil change

(1) If serious contamination of the nygroha is found, exchange should not even be done before the cycle.

(2) It is necessary to frequently inspect over the hydraulic pressure, in case the oil position is lower than the required one, it should be replenished in time.

b. lifting structure

The filling volume is about 2.0 liters. When filling with grease, you can first remove the steel cables, then unscrew the filling plug and that's it.

c. Swivel mechanism

The filling volume is about 1.5 liters. When filling with grease, refer to the description of the swivel tag and oil gauge.

9.3 Lubrication

Name of the lubrication point	Lubrication intervals	Lubrication method
Leading hook pulley block	Every week	Filling with an oil syringe
Boom hoisting block	Every week	Filling with an oil syringe
Boom segment 2,3,4 block	Every week
Surfaces through which blocks of 2,3,4 boom segments pass	Every week	Smearing
Upper and lower spherical bearing cylinder of change of overhang	Every week	Filling with an oil syringe
Secondary boom pulley	Before using	Filling with an oil syringe
Lift boom rear pivot bearing	Every week	Smear, filling with an oil syringe
Swivel support	On demand 5.2	Filling with an oil syringe
	Every week	Smearing
Auxiliary lifting hook	Before using	Smearing
Steel cable	Every week	Smearing
Steel cable (for boom extension)	Every week	Smearing
Outrigger bus	Every week	Filling with an oil syringe
Lift Bearing Seat	Every week	Filling with an oil syringe

Transcript

1 XCMG QY25K Truck Crane Operation Manual

2 Catalog 1. The main purpose and advantage Main technical characteristics The appearance of the whole truck crane and its technical characteristics The main technical characteristics of the truck crane Preparation for lifting Ways to control the truck crane Electrical system Hydraulic system Engine start and PTO operation Outriggers operation Throttle operation Lifting operation Lift boom telescopic operation Lift boom change operation Swing mechanism operation Tag description Auto crane auxiliary parts Auxiliary boom Swivel support Lead and auxiliary hook Wire rope gear ratio Safety device Torque limiter Tri-circle safety switch System pressure switch Hydraulic safety valve Hydraulic warning lamp oil filter Amplitude indicator attention events attention events attention events use wa Remedy Attention to the adjustment of the cable Lubricating oil Hydraulic oil Periodic system Lubrication Static oil Frequent faults and their remedies Faults and their remedies Change of warps Bypass oil filter Line oil filter Periodic check Rail transport Appendix Gesture card Packing list

3 The QY type truck crane is designed for lifting and erection work in places such as factory, mine, oil field, port, construction site, etc. This car has the following advantages: 1. Hydraulic transmission. Infinitely variable speed control is carried out. Reliable performance, convenient operation. 2.The driving and auxiliary hoists are of the same type, they all use a drum internal planetary gearbox, they can supply oil with one pump or two pumps, as well as work with many speed modes, such as low speed under heavy load and high speed under light load. ... The quality of the work is very high. 3.The slewing mechanism adopts planetary reduction gear and permanently closed locking mechanism, adopts a motor to drive the spur gear, and adopts hydraulic system with buffer valve, it can realize free running rotation and slow smooth movement. 4. Safety device including torque limiter, height limiting device, support plug and spirit level. Completed lighting installation for night work. 5. The control cabin is light, spacious and comfortable, with an adjustable seat inside. A fan can be installed as desired. 6. Large selection of accessories. We offer auxiliary lifting booms, auxiliary lifting mechanism, single pulley at the end of the boom, heating device in the control cabin (for optional mounting), etc. 7.This machine has a low barycenter, reliable stability and high travel speed, which is convenient for moving quickly between work sites. 2.1 The appearance of the whole machine and their technical characteristics (1) The appearance of the whole machine is inspected in Figure 2-1. (2) Technical parameters are inspected in Table 2-1 and 2-2. (3) Primary Boom Lift Table, Table 2-3, 2-4. (4) Secondary Boom Lift Table, Table 2-5. (5) The lifting height collar is examined in Figure 2-2. (6) Distribution of the working range of the truck crane. (see Map 2-3)

5 5 Table 2-1 Main technical characteristics of the truck crane in motion Classification Article Unit Parameter Size parameter Length of the whole truck crane Width of the whole truck crane mm 2500 Height of the whole truck crane mm Base Base of the first shaft mm 1350 Base of the second shaft mm 2079 Track Front wheels (first shaft) mm 1834 Rear wheels (second and third shafts) mm Weight parameter Total weight in motion kg 6100 Energy parameter Motion parameter Shaft load front shaft kg rear shaft kg D6114ZLQ5B motor type 158/2200 Rated motor power kw / rpm 790/1400 Rated torque motor Nm / rpm 2200 Nominal motor revolution r / min 8.27 Displacement Travel speed Wrap-around diameter Maximum speed Km / h 72 Minimum stable speed Km / h 2.9 Minimum wrap-around diameter m 22.0 Wrap-around diameter of the boom head m Minimum clearance from the ground mm 260 Approach angle 16 Angle Leaving 13 Braking distance (speed 30 km per hour) m 10 Surmountable rise% 27 L 6

6 Table 2 Main technical parameters of the truck crane in work Classification Article Unit Parameter Parameters Maximum main nominal lifting weight of properties Minimum nominal operating amplitude Rotating half-diameter of the rotating stand end Operating speed parameters Noise limitation Maximum lifting moment Props distance Lifting height t 25 m 3 m Main boom kn. m 941 Maximum main boom Maximum main boom + secondary boom kn.m 439 kn.m 331 Longitudinal m 4.8 Transverse m 6.0 Main boom m 10.5 Maximum main boom Maximum main boom + secondary boom m 32.5 m 40.8 boom length Main boom m 10.4 Maximum main boom Boom Maximum Main Boom + Secondary Boom m 32 m Secondary Boom Mounting Angle Lift Boom Amplitude Change Time Lift Boom Expansion and Contraction Time Boom Raise s 75 Boom Descent s 45 Full Expansion s 100 Full Contraction s 60 Maximum rotation speed r / min 2.5 Expansion and contraction time of the props Horizontal props lower simultaneously s 35 simultaneously assemble s 30 Vertical props lower simultaneously s 40 Lifting speed Main lifting structure Auxiliary lifting structure simultaneously assemble s 35 Full load m / min 70 Idle load m / min 100 Full load m / min 60 Idle load m / min 100 Radiality of the exterior machine db (a) 118 Radius around the driver's seat db (a) 90 7

7 Table 2-3 Lifting properties of the driving boom of the QY 25 mobile crane working The outriggers are fully extended. Side and Rear Operation Range Main Boom Medium Scale Fully Expanded Fully Expanded (Reach) 10.40m Boom 17.60m Boom 24.80m Boom 32.00m Lift Capacity (kg) Lift Height (m) Lift Capacity (kg) Lift Height (m) Lift Capacity (kg) lift height (m) lift capacity lift height (kg) lift (m) increase hook weight minimum drive boom lift angle drive boom maximum lift angle 250kg

8 Table 2-4 Lifting properties of the driving boom of the QY 25 mobile crane working Outriggers are fully extended (including the fifth outrigger). Operation in 360 degrees.amplitude main boom medium scale fully extended fully extended (reach) 10.40m boom 17.60m boom 24.80m boom 32.00m lift capacity (kg) lift height (m) lift capacity (kg) lift height (m) lift capacity (kg) height Lift (m) Lift Capacity Height (kg) Lift (m) Increase Hook Weight Minimum Drive Boom Lift Maximum Drive Boom Lift 250kg

9 Table 2-5 Lifting properties of the auxiliary boom of the QY 25K mobile crane (on the side and rear side) angle of the driving boom 32 elevation of the auxiliary boom 8.15m driving compensation angle () of the boom amplitude (mm) lifting capacity (kg) amplitude (mm) lifting capacity (kg) amplitude (mm) hook weight Caution: Explanation of the lifting capacity in tables 2-3, 2-4, 2-5: 55kg lifting capacity (1) The nominal lifting capacity indicated in the table refers to the maximum lifting capacity of this mobile crane when parked on firm and firm ground. earth. This value is not more than 75% of the tipping load. (2) Ratings shown in table include hook and slingshot weights. (3) The working widths shown in Tables 2-3 and 2-4 refer to the actual value including the deflection value of the boom. Therefore, it is necessary to carry out the lifting work strictly on the basis of the working width. (4) The 75% overturning load is calculated with a wind force of 7 points (i.e. wind pressure of 125 N / m². Can be operated with a wind force of 7 points. (5) The lifting height given in Tables 2-3 and 2-4 and the amplitude indicated in Table 2-5 are comparative values. (6) The table of the lifting properties of the single pulley at the end of the boom of the QY 25K truck crane is as follows: Boom length (m) Lifting capacity (kg) With an amplitude of 4-18 m lifting capacity 2500 kg. Remaining cm . table 2-3, property of a boom with a length of 24.8 m and an amplitude of m (kg) With an amplitude of m, a lifting capacity of 2500 kg. For the rest, see table 2-3, property of a boom with a length of 32 m and an amplitude of 10 m

10 Table of properties of the leading boom of the QY 25K truck crane with semi-expansion of the outriggers working amplitude The outriggers are semi-extended (including the fifth outrigger). 360 degree operation (4.34m 4.8m) (reach) main boom 10.40m medium boom 17.60m main boom 10.40m medium boom 17.60m lift capacity (kg) lift height (m) lift capacity (kg) Lift height (m) lift capacity ( kg) Lift height (m) Lift capacity (kg) Lift height (m) Increase hook weight 250kg 11

11 12

12 13

13 2.2 Parameters of properties of the main parts of the truck crane (1) Swivel bearing Style: single row ball pivot bearing at four points contact, used as a connecting part between the upper part and the lower part of the machine. Allowed to turn 360. Type: (2) Oil pump Type: GB-kp50 / 32/32/08 Rated operating pressure: 25 MPa Peak pressure: 25 MPa (3) Swing mechanism Type: GJB17T planetary gearbox Speed ratio: 78.9 Motor: A2F28W6. 1Z4 axial piston motor (4) Lifting mechanism: (leading and auxiliary) Type: GJ T 17 W planetary gearbox Speed ratio: 45 Motor: A6V55HA2FZ10380 variable axial piston motor Steel cable type: 14NAT 4V 39S + 5FC1870 Steel cable length: 15.5 m (at the driving gear) (5) Leading boom 90 m (at the auxiliary gear) Style: one segment of the main boom and three segments of the telescopic boom, Profile in a six-sided orthodrome or in an eight-sided orthodrome. Boom length: m (minimum boom length) 32.0 m (maximum boom length) Telescopic style: single cylinder and rope, synchronous extension. (6) Secondary Lift Boom Style: Truss Secondary Boom Boom Length: 8.15m (7) Reach Cylinder Style: Single Cylinder, Reach Front Length: m (8) Telescopic Cylinder Style: Single Cylinder and Rope, Synchronous advancement. Range: 7.2 m (9) Control cab Style: made of fiberglass, safety glass installed, complete with heating device and control devices. The field of view is open. (10) Upper Machine Lead Valve Type: FYZ-36 14

14 Preparatory work before operation Two safety conditions during crane operation: the equipment must be in good working order, the personnel trained and trained. Before starting work, check the following at the work site: the type of work. Distance of the working site. Passage, passage, height, width. Finding the power line on the site (exact voltage) see table 1, how the structure of the material is laid around the construction site. Size, weight of the lifted load, the distance of the lifted and lowered load. Ground structure. After careful study, the crane operator begins the final preparation of the equipment, and the departure: hook, boom, support device, route, permission to exit. If the crane operator does not study the nature of the job, it will be difficult to complete the task. Therefore, before work, it is necessary to prepare all conditions for work in order to avoid the occurrence of an accident. Table 1 Voltage V (KV) Minimum distance (m) Distance between power line and boom.<1 1~ (V-50)+3 15

15 Electrical Applies a method of directly supplying power from the lower machine. Power style: DV24V, negative metallization, single wire system. (1) Engine management a. Starting the engine Insert the key to the ignition switch (so) and turn it clockwise to position Ⅰ, at this time the power is connected, the control system of the upper machine starts to supply power. Continue turning the key to position Ⅱ while the engine is on. Each ignition time should not be more than 5 s, the break time should not be less than 15 s. If the engine cannot be turned on 2-3 times, it is necessary to look for reasons. b. Switching off the engine Turn the key counterclockwise to position Ⅲ (STOP) and hold it after 1-25 s. The engine is off. Lower your hand, the switch returns to its original position (off). (2) Security controls a. Torque limiter (see "Operating instructions for the torque limiter") b. System pressure switch (-s14, -s15, -s16): The pressure is only generated after the switch is closed. c, Height limiting device: It includes limit switches at the end of the leading and secondary booms and a bulwark. When the center of the hook rises to a position 780 mm from the center of the boom pulley, the hook will automatically stop and the height limiting device will alert you. d. Triple-circle fuse (-a2, -A3): When the hook is lowered before there are 3 circles of steel cables, the hook will automatically stop and the triple-circle fuse will warn about this. e. Hydraulic oil filter shutter warning lamp (-H4) f. Engine check 1 Engine oil pressure too low warning lamp (-h1) 2 Water temperature too high warning lamp (-h2) (3) Electrical appliances in the cab a. Description of electrical appliances in the control cab (see Map 4-1) A) - Display (Map 4-2): systematically shows the operating and safety conditions. B) - right control device (card 4-3): control of the operating state C) left control device (card 4-4): control of the safety state D) - control panel (card 4-5): logical control element E) - fuse: 15th

16 a) - windscreen wiper b) - ceiling lamp c) - fan d) - torque limiter main motor e) - auxiliary winch selector switch (optional) b, Description of the display (1) torque limiter display (see "Operating instructions for the torque limiter torque ”) (2) power indicator light (3) engine oil pressure too low warning light (4) water temperature too high warning light (5) front outrigger overload warning light (6) hydraulic oil filter shutter warning light ( 7) indicator lamp of the front area (8) warning lamp that steel cables are rolled up soon to the end (9) warning lamp that steel cables are unrolled soon to the end (10) lamp indicating system pressure (11) lamp indicating extension 4 of the 5th and 5th boom segment (12) lamp indication of free rotation (13) lamp indication of amplitude change (14) lamp indication of telescopic state (15) lamp indication of application fifth outrigger c. Description of right control device 17

17 S17- turnover switch S16- system pressure switch S18 S19- telescopic position and amplitude change switch S5- warning lamp switch (optional) S9- cooling fan switch S6- windscreen wiper switch S1- height indicator light switch S3- work lamp switch S7-fan switch S4- lighting (instrument) switch S0- ignition switch R0-cigarette lighter S22-switch for use of the fifth outrigger (optional) S27-glass wiper for skylight (optional) d, Description of the left control device 18

18 S11-switch for elimination of rotation restriction S14, S15-system pressure switch S13-switch for free-run rotation S12-switch for elimination of rotation restriction S21-switch for elimination of the warning that steel cables are fully extended S20-switch for overload elimination S23-heating switch ( optional, for the hot house) S24-ignition switch (optional, for the hot house) S25-oil supply switch (optional, for the hot house) S26- horn switch 19

19 e. Description of the relay Relay K0 (type JQ201S-PL0): control over the electrical system Relay K2 (type JQ202S-KL0): control over the rotation limitation Relay K3 (type JQ202S-KL0): control the horn Relay K5 (type JQ202S-KL0): control over overload Relay K10, K9 (type JQ202S-KL0): monitoring the front area Relay K6 (type JS157): monitoring the warning that steel cables are rolled up to the end Relay K7 (type JS157): monitoring the warning that steel cables cables extended to the end Relay K8 (type JS157): control over the warning about the front area Relay K1 (type 67147): control over the free rotation Relay K4 (type 67147): control over the replacement of the boom Buzzer B2 (type FM-24V): warning about that steel cables are rolled up or unrolled to the end Buzzer B3 (type FM-24V): front area warning (4) Operating instructions a. it is necessary to put the handles of all control devices to the middle position before turning on the main power supply b, an overload elimination switch (s20) is supplied with the truck crane. Use this switch with care when overloading. In general, it is not necessary to use this switch c. Carefully read the "Torque Limiter Operating Instructions" before operating. (5) Wiring diagram 20

20 21

21 22

22 23

23 24

24 25

25 26

26 Hydraulic System Description The hydraulic system of the QY 25K truck crane adopts a variable axial piston motor system with an open metering pump, which includes a four-section gear pump and

27 tilt-cylinder axial piston motor. Divided into 2 parts: hydraulic system of the upper machine and hydraulic system of the lower machine (1) Hydraulic system of the lower machine A gear pump with a displacement of 32 ml / r gives the oil channel pressure of the lower machine. The pressure of the overflow valve is 20 MPa. A manual multichannel transfer valve is used to control the direction of movement of the horizontal and vertical outriggers. It is possible to work on both sides of the frame. The client can make a choice for a specific situation. The 4 horizontal or vertical outriggers can be extended separately or simultaneously. The new type multi-port diverter valve with pressure limiting valve can effectively prevent the piston rod of the horizontal cylinder from bending. On cylinders, the 4 vertical outriggers have double-sided hydraulic locks to prevent the piston rod of the vertical cylinder from collapsing during lifting or extending on its own when the crane is moving. (2) Hydraulic system of the upper machine The control system of the hydraulic multi-way diverter valve, the main control valve of which is a sensitive proportional load multi-way diverter valve. Each transfer valve is equipped with a vibration-resistant valve, at the same time, the leading and auxiliary mechanisms with a gas valve. The hydraulic booster valve adopts imported proportional pressure reducing valve. The handle angles of the power steering valve are directly proportional to the outlet pressure, and the amount of movement of the spool is also directly proportional to the outlet pressure of the power steering valve, so that the whole machine has better creep properties. At the same time, under the action of a sensitive loading valve, the speed of movement of the actuators is not related to the load, which reduces the difficulty of the operation and facilitates the intensity of labor. The use of a variable motor as a hoist gives the whole machine the advantage of being lightly loaded at high speed and heavily loaded at low speed. a. Description of lifting oil channel Maximum displacement of the pump: 82ml / r, displacement of the variable motor: 55 ml / r. The lift oil channel uses a normally closed lift brake. When the power steering valve operating the driving gear is operating, the control oil comes out of the power steering valve and makes the hydraulic transfer valve change direction through the shuttle valve, at the same time the pressure oil (3MPa) discharging from the power steering pump activates the lift brake through the hydraulic transfer valve. thus, normal lifting work is carried out. When the hydraulic control valve returns to the middle position, the pressure oil of the control oil channel flows from the hydraulic control valve into the tank, the hydraulic control valve returns to its initial position under the action of the return spring, and the pressure oil in the lift brake flows into the tank through the hydraulic control valve, the brake acts by means of a spring. b, Description of the oil return channel Maximum pump displacement: 32ml / r, dispensing axial piston motor displacement: 55 ml / r. 28

28 The solenoid valve controls the engagement of the rotary brake. When the solenoid valve has no electricity, the brake is disengaged, otherwise the brake is applied by the pressure oil. Therefore, during pivot operation, the operator must press the s11 switch button (3 in total) in line with the power steering control valve that controls the pivot movement. The main oil return channel has a free run function. When the boom is pulling sideways during lifting operation, press any switch button from S13 and S17, and the turntable will adjust itself so that the plane on which the centerline wire is above the load center of gravity. Thus, it prevents the boom from bending and kinking due to lateral pull. c, Description of oil duct with variable overhang Maximum pump displacement: 50 ml / r. The maximum pressure of the system is set at 8MPa during descent with a change in departure. In this position, for a smooth or reliable stop, a back-up valve is installed in the oil channel. A special decompression oil channel for a stable pressure signal to the torque limiter has been designed. d. Description of telescopic oil channel Maximum pump displacement: 50 ml / r. bypass valve for feeding There are 4 main boom segments. One telescopic cylinder is simultaneously extended with the second, third and fourth boom segments. To prevent bending of the piston drawbar due to too high pressure, a pressure limiting valve pressure of 14 MPa is set. For smooth or reliable stopping, a back-up valve is installed in the oil channel. e. Description of the control oil channel A gear pump with a displacement of 8 ml / r gives the pressure of the control oil channel with a hydraulic booster, the pressure of the overflow valve is 3 MPa. A solenoid valve is installed to control the oil supply. Only if there is electricity to this valve, all the actuators can act, otherwise not. An unloading solenoid valve is installed, controlled by a torque limiter. When the load torque is equal or greater than the nominal value, electricity is generated at the solenoid valve, all actions that can increase the torque cannot be performed A three-circle safety solenoid valve is installed, which will generate electricity when the driving and auxiliary lifting drums have 3 circles of steel cable. At this time, the steel cables cannot go down further. The pivot mechanism and the auxiliary mechanism share a single power steering control valve (located on the left armrest of the seat). Push the handle forward, the auxiliary lifting hook descends; Push the handle backwards, the auxiliary lifting hook is lifted; Push the handle to the left, the turntable turns to the left; Push the handle to the right, the turntable swivels to the right. The telescopic mechanism and the drive train share a single power steering control valve (on the right armrest of the seat). Push the handle forward, the driving hook is lowered; Push the handle backwards, the driving lifting hook is lifted; Pushing the handle to the left is going to; Push the handle to the right, expands. (3) Technical parameters Operating pressure of the main oil channel: 21 MPa (for the set pressure of the overflow valves, see the reference values in the principle drawing) 29 Tank capacity: 397 l.

29 Accuracy of the receiving oil filter: 180 µ Accuracy of the return oil filter: 20 µ Accuracy of the oil filter of the control oil channel: 10 µ Hydraulic oil grade: Ambient temperature 5, L-HM46 Ambient temperature, L-HM32 Ambient temperature, L-HV 22 Ambient temperature< -30, авиационное гидравлическое масло 10 30

30 31

31 4.3 Starting the engine and operating the power take-off (1) Points requiring special attention during the operation Before engaging the power take-off, make sure that all control levers in the control cab are in the middle position. (2) The procedure for engaging the power take-off is in the following table: p / p Graphemics Procedure for operation 1 Set the stop brake in braking state 2 Confirm that the selector lever and PTO switches are in the middle position (off position) 3 Turn the chassis switch and turn on the engine, on cold days it is necessary to warm up the engine before turning it on. 4 Press the cone pedal all the way 5 Turn on the power take-off 6 Slowly lower the cone pedal This is the end of the preparation for crane operation. In winter, after starting the engine, you must first idle for about minutes to comfortably raise the temperature. (3) The procedure for disengaging the power take-off is in the following table: p / p Graphemics Procedure for operation 1 Press the taper pedal all the way 2 Disengage the power take-off 3 Lower the taper pedal 4 Switch off the engine 5 Turn the chassis switch to the "off" position. So the crane is out of order. Attention: after turning on the power take-off, you can turn on the engine in the control cab of the upper machine with the ignition locks and turn it off with the extinguishing switch. 32

32 4.4 Outrigger Operation 10.3 Special Note: 1. Before the outrigger can be extended, the pin lock must be removed. 2. Place the hoisting machine on firm and level ground. 3. The wheels should lift off the ground. 4. The crane must be installed horizontally to a solid platform, if the ground is soft, loose, then wooden supports are needed so that the crane is horizontally installed. 5. When the crane is installed, it is imperative that each support be fixed so that there is no slope due to the possibility of danger. 6. If the support is not fully extended, the crane must not be operated. 7. When the support is to be put back in place, the pin of the lock should be inserted freely. 8. Distance of supports 4.8Х6.0m (1) Name of parts of outrigger support 33

33 (2) Outrigger Control Lever Caution: a. Use the selective control lever to select the outrigger telescopic cylinder oil channel or outrigger lift cylinder oil channel. * After completing the operation, you must immediately push the selective control lever to the middle position. In addition, it is imperative to confirm before starting work that the selective control lever is indeed in the middle position. b, Push the outrigger telescopic cylinder oil channel or outrigger lift cylinder oil channel control lever 1, the outrigger telescopic cylinder oil channel or outrigger lift cylinder oil channel can be extended. 34

34 (3) Extend and assemble the horizontal outriggers Push the control lever 2,3,4,5 to the outrigger telescopic cylinder position, then push the control lever 1 to the expansion position, then the 4 horizontal outriggers expand simultaneously. When fully extended, push all control levers to center position. When assembling the horizontal outriggers, the preparation procedure is the same, only you still need to push the control lever 1 to the collecting position. (4) Extend and assemble the vertical outriggers Push the control lever 2,3,4,5 to the outrigger lift cylinder position, then push the control lever 1 to the expansion position, then the 4 vertical outriggers expand simultaneously. After the machine body has lifted and all tires are off the ground, push all control levers to center position. When assembling the vertical outriggers, the preparation procedure is the same, only you still need to push the control lever 1 to the collecting position. (5) Adjust the crane to a horizontal position If, after expanding the outriggers, the crane is not yet horizontal, adjust it to a horizontal state as follows: For example: when the right side of the crane is too high, a. Push the front left control lever 2 and the rear left control lever 4 from the selective control levers to the middle position. Caution: Do not inadvertently push the control lever into the outrigger lift cylinder position. b. Slowly push the outrigger telescopic cylinder or outrigger lift cylinder control lever 1 to the pick-up side while carefully observing the spirit level c. When the spirit level is level, immediately push all selective control levers to the middle position. Caution: Ensure that all crane tires are off the ground and that each outrigger chassis is actually in contact with the ground. 35

35 4.5 Gas operation Accelerate or decelerate using static oil pressure. Depressing the accelerator pedal on the upper machine accelerates the swing, boom extension and hoist movements. This pedal is located on the right side of the cab floor (see Map 4-10). 4.6 Operation on the lifting mechanism Note during operation: 1. Only vertical lifting, do not pull on the zeil. 2. Do not jerk the handle. 3. Before lifting, make sure that the lifting mechanism is intact and working properly. (1) Drive gear control handle (2): Push the handle forward, the hook is lowered; Push the handle backwards, the hook is lifted. The control handle (2) and throttle will adjust the travel speed. (2) Accessory control handle (3): Push the handle forward, the hook is lowered; Push the handle backwards, the hook is lifted. The control handle (2) and throttle will adjust the travel speed. Caution: To protect the side link when lifting, while operating the drive lift control lever, press the free swing momentary switch (s17) so that the drive boom can swing freely and adjust according to the load. After the load has been lifted off the ground, the switch (s17) can be lowered. center of gravity 36

36 4.7 Driving Lift Boom Extend Operation Note: There may be minor changes to the boom during boom exiting and retracting. Therefore, at a certain height, after a while, a change in temperature occurs in the hydraulic system, a slight change in the boom appears. For example: 1. when the boom reaches 5 m, at a temperature below 10, the exit is delayed by cho mm. 2. Since the influence of natural conditions changes the oil temperature, there is a slight change in the boom, which brings minor inconveniences, when driving: therefore (1) Do not allow the oil temperature to rise. (2) If an arbitrary contraction occurs, it is necessary to bring the arrow back to normal. 3. Do not pull up the load, lift only vertically. Extend control handle (2) Push the control handle to the left, the boom expands, it is going to push to the right. The control stick (2) and throttle will adjust the speed. Note: 1. Vertical lift only, do not use the boom to pull the load on the ground. 2. Do not raise the boom above the angle limiter. (violation) 3. At the beginning and end and other changes of action, I need to slowly move and control the handle. 37

37 Drive boom amplitude control handle (2) Press switch S18, push the handle (2) to the right, the boom descends, rises to the left. The control stick and throttle will adjust the speed. 2) The relationship between the weight of the load and the tilt of the main boom when lowering the boom, the radius increases, then the carrying capacity decreases, when the boom is raised, the radius decreases, then the carrying capacity increases. Note: 1. Only vertical lifting is possible, you cannot drag the load. 2. Before operating, make sure that the supports are set at a distance appropriate to the requirement. 3. You must have free movement. 4. At the beginning, end and other actions, slowly move the control handle. 5. When we do not turn around, we must put on the braking device. 6. Before starting a turn, release the braking device. Pivot mechanism control handle (3) Before performing pivot work, first lower the mechanical lock (4) and press the switch (S11). Push the handle (3) to the right, the turntable turns to the right, to the left turns to the left Description of the tag (1) Nameplate The nameplate is located on the outside of the control cab door (see map 4-11) The content of the nameplate includes the name, type, nominal capacity of the truck crane, date release, name of the plant, etc. (2) Lift capacity label The lift capacity label is located in the cockpit (see Map 4-11) The lifting capacity label includes the QY25K Truck Crane Rated Capacity Table, QY25K Truck Crane Lifting Height and QY25K Truck Crane Working Range Drawing. For each operating range, there is a corresponding lifting capacity and lifting height in the lifting property table. Before lifting, it is the operator's responsibility to become familiar with the weight and work area and select the appropriate operating condition. It is strictly forbidden to work outside the table. 38

38 (3) Amplitude Indicator Label (Card 4-12) The Amplitude Indicator label is located on the side of the boom. During lifting operation, the amplitude indicator is able to show the amplitude values for different boom lengths and different elevation angles. The permissible lifting weights and lifting heights can be determined based on the lifting capacity tag. 39

39 5.1 Tracking boom 1. Be sure to place the trailing legs completely extended. 2. Do not stand in the direction of protrusion of the auxiliary shoulder. 3.Adequate operating time should be provided before assembling and storing the auxiliary arm. 4. In addition, the following points are strictly prohibited, otherwise the auxiliary arm may deteriorate. Collect and store the auxiliary arm for this manual: a. Perform the operation lowering the shoulder when the auxiliary hook touches the apex of the auxiliary shoulder. b. After pulling the pin for securing the auxiliary arm from the side of the driving arm, do not operate or drive the crane. with. When mounting and assembling the secondary boom, extend the boom forward and reassemble the boom too quickly. 5. During necessary high-altitude work when assembling and storing the auxiliary arm, a ladder should be used to ensure safety. Description of installation and use of the auxiliary boom: The auxiliary boom has a triangular truss structure, which has such advantages as simple structure, lightness, ease of installation, etc. Now, the installation and application will be explained as follows: (1) It is necessary to use a real auxiliary boom with full extension of the boom outriggers. (2) Installing the secondary boom a, Fully assemble the drive boom and lower it to the rear side of the truck crane. b, Remove the burst from the row 1 secondary boom, twist around the row 2 bit to align the secondary boom pin hole over the drive boom pin hole, insert bit A. c, Remove the row 2 burst, twist the whole secondary boom around the secondary boom. in order to align the secondary boom connection hole with the primary boom connection hole, insert another burs A. At this time, the length of the secondary boom is 8.15 m.

40 arrows. e, Pass the steel cables through the yoke of the block and the block at the secondary boom head f, Turn on the power for the secondary boom lifting limit switch, insert the secondary boom plug and install the junction box at the telescopic boom head in order, install the hoisting limit switch engaging part g, Remove the hook from the auxiliary hook holder and install it. (3) Angles 15 and 30 First set the secondary boom to angle 0 at (1), then lower the boom until the secondary boom head touches the ground. Remove burs B, insert into corner 15 or 30 and reinforce (see map 5-4, 5-5). Here is the secondary boom in order, now you can use it. (4) Removing the secondary boom. After use, you can remove the secondary boom in the opposite order and reinforce it to the right of the driving boom (see Map 5-6). The auxiliary boom is now fully assembled. 42

44 46

45 7

46 Pivot bearing (1) Basic structure The structure of the pivot bearing is shown in Figure 4-5.

47 The pivot support is not only a supporting device for the entire rotary part of the crane, but also a unit that connects the upper body of the crane to the chassis. The inner ring of the rotary bearing is fixed to the lower part of the rotating disc of the upper crane body by means of 60 bolts2 (m27) located on one circumference. The outer ring is fixed to the lower crane body by means of 60 bolts1 (m27) located on one circumference. (2) Items requiring special attention during operation. The turning bolts are made using 42CrMo materials, should not be replaced with simple bolts. The torque of the bolt is 1172N.m. It is necessary to comprehensively check the torque of the bolt after operating the pivot bearing for 100 hours, then comprehensively check them every 500 hours. Normally, it should be lubricated every 100 hours. Pour calcium radical grease (zg-3) into the filler hole, top up each time so that the grease seeps through the hermetic blockage. d. Changes in noise and gyroscopic moment of resistance should be observed during operation. Should be dismantled and checked immediately when the unusual condition occurs. e. The teeth should be cleaned of dust and dirt after every 10 days of operation. It needs to be greased again. 5.3 Lead and auxiliary hook (1) Basic design Lead hook design see map 5-8, auxiliary hook design see map 5-9. (2) Inspection before use The hook is rejected in any of the following cases :, A crack and break appears on the surface of the hook. 49

48, The width of the hook mouth is greater than 10% of the nominal size (see the tag on the driving and auxiliary hooks) p. The value of the wear of the dangerous section is higher than 10% of the nominal size. d, The amount of wear of the section of the rope hanging above 5% of the nominal height e, Formability and twisting of the hook above 10 f, With dangerous sections of the tail of the hook, the threaded part of the hook and the live hook, irreversible deformation occurs. 50

49 51

50 52 Changing the multiplicity factor of the steel cable Operation conditions: firmly place the supporting legs, take in the shoulder and turn to the side or back side .. Force the hook to the ground after lowering the shoulder .. Dismantle the cable gate on the head of the shoulder and on the hook. with. Remove the heavy cable stop hammer from the steel cable. d. Remove the cable cover. (during an even number) (during an odd number) e. When changing the multiplicity factor of the steel cable, you should carry out the operation of lowering the hook, at the same time pull out the steel cable.

51 53 Note: (1) The assembly position of the heavy rope stop hammer is not the same in the odd and even number of the multiplicity factor. (during an even number) (during an odd number) mount a heavy hammer on a branch with a cable cover mount a heavy hammer on a branch next to a branch with a cable cover (2) Pay attention so that the cables do not wind up randomly. (3) The assembly method of the cable cover and cable holder is shown in the lower fig.

52 torque position switch (1) principle of operation An electronic computer calculates the radius of work by the duration of the hog, the signal of the angles entered by different generators. It is on the basis of the signal entered by the pressure generator that the computer calculates the forces of the varioscopic cylinder, after which it calculates the lifting moment. In the end, the computer compares it with the maximum forces stored in the database, then the manipulator dictates the appropriate information. (2) safety function In the event that the lifting moment overloads, the power switch cuts off all the routes that increase the torque (swing at the bottom of the lift); only the routes that contribute to the reduction of the moment are saved (retract, swing up, lower the hook). (3) Height limiting function (7-1) When the load hook approaches the lift boom unit (750mm), it will cause the duration generator, whose electronic resistance is 4.7k, to ground. After the work of the "body", the same decides the extension and ascent of the ascent arrow. At the same time, the power switch displays a warning light. (4) attention events a. Before lifting, you must carefully read the abstract and fully master it. Although the series connection of this hoisting machine has a power switch, there is also a responsibility for safe control. Before work, the driver must more or less recognize the weight of the hanging things, then determine whether they can be lifted in accordance with the graphic characteristics. The power switch is a very important setting of this machine, in no case is it allowed to be turned off, let alone prohibited movements (for example: stretching with loads). The power switch can only work effectively when the position of the load is supplied in accordance with characteristic graphemics before work. 7.2 Three Circular Fuse (7-1) When the working surface of the truck crane is slightly high, the steel cable on the drums may not be enough to rewind to the end. When the reels have 3 circles of steel cable left, the fuse is active, the descent operation is automatically stopped, at the same time the buzzer will sound and the warning lamp will light up that the steel cables are soon to be deployed to the end (see Map 4-2).

53 7.3 System pressure switch (see Map 4-1) This safety device is designed to prevent the control handles from being pushed inadvertently when entering or exiting. Before work, you must press the switch (-S15, -S16) to build up pressure, otherwise the system cannot work. 7.4 Hydraulic pressure relief valve Designed to protect the overload pressure from too high. After starting this valve, all actions are stopped that further increase the torque (expansion of the boom, changes in amplitude downward, lifting). They can continue those actions that reduce the lifting moment (gathering the boom, changing the amplitude upward, lowering the hook). 7.5 Hydraulic oil filter shut-off warning lamp When a blockage occurs with the hydraulic oil filter, the warning lamp comes on. At this time, it is necessary to stop working and continue it after replacement. 7.6 Amplitude Gauge The Amplitude Gauge is able to show the magnitude of the amplitude at different boom lengths and different elevation angles. The approved lifting weights must be determined taking into account the "Lifting table" and the "Lifting accordion" to prevent overloading and damage. 55

54 8.1 Points requiring special attention The following are the main points requiring special attention during crane operation. Customers are required to carefully read and understand them to ensure safe operation. Number Schedule Attention events note 1 Conveniently read the section on starting and Checking before stopping the engine of this explanation by control 2 In the preparatory stage, check the hydraulic oil position, confirming the amount of hydraulic oil has reached the required level. 3 Check every detail, confirming everything is in order, if abnormal phenomena appear, it is necessary to eliminate them in time. 4 When the truck crane is in working order, it is prohibited to carry out repairs and inspections. 5 After starting the engine, slowly accelerate, let the engine raise the temperature fully. 6 Before starting the unit, make sure that all control levers are in neutral. 7 In order to check every control levers and actuators are in order. If there is a malfunction, it must be repaired in time. 8 It is necessary to carry out a preventive test on the function of the automatic torque switch in the indicated positions. 9 Check all other devices (eg pressure gauge), confirming whether they can work normally. 10 Turn on the power switch and start actuator in the control room before use 56

55 57 Number of graphemics Attention events note 11 It is imperative to carry out lifting work under the condition of the rated lifting capacity. Phenomena such as overloading, lateral thrust, lifting loads out of order, lifting loads buried or frozen in the ground are strictly prohibited. 12 Normally it is not allowed to use 2 or more than 2 mobile cranes to lift one load. If necessary, pay attention to keep the steel cables upright, all truck cranes must lift synchronously. The load of each truck crane should not exceed 80% of its rated lifting capacity. 13 When calculating the used lifting amplitudes, one must take into account such a factor that in the case of a load, the working amplitude increases due to the bending of the main boom. 14 It is necessary to operate the hoisting machine slowly at the initial stage. 15 Focus your attention when lifting, and do not look around or chat with others. Only act on the signals of the indicated commander, but at any time obey all stop signals issued by anyone. 16 When lifting work, care should be taken to observe the surrounding position to prevent accidents. When the load is in a suspended state, the operator should not leave the work station. during lifting work

56 58 Event graphemic number note 17 Attention must be paid to the temperature of the hydraulic oil. When the temperature exceeds 80, the operation must be stopped. The capacity of the hydraulic oil in the oil cylinder and tank changes with the oil temperature. pulls in due to the lowering of the temperature. in order to resume the previous duration, it is necessary to control the unsupported beam in time during lifting work. 18 It is necessary to pay attention to the weather forecast: 1 When the wind rate exceeds 10 meters / second, work must be stopped 2 It is necessary to stop lifting and collect the hog in case of thunderstorm electricity 19 It is impossible to pull out a load that has not yet lifted off the ground, avoiding a god load 20 Better put the hoisting machine on a stubborn and level place (you need to transfer strong firewood under the outrigger on soft ground). 21 After finishing the setting of the truck crane, the truck crane tires should be off the ground. When settling, attention should be paid to observe the spirit level. 22 It is necessary to put the outrigger in certain places, at the same time it is a little closed.

SNOW BLADE TX150-DF254AU USER MANUAL Dear Customer! Thank you for placing your trust in this TX150 blade. Please observe the following rules: 1. Read carefully

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Terms of payment and delivery of the truck crane

For all Chinese autocarts XCMG QY25K5 one year warranty is provided.
The truck crane is available, supplied with accompanying documentation for, passport and permission to use.

Truck crane XCMG QY25K5 and XCMG technique manufactured under license from companies such as KATO and Liebherr, equipped with imported components and an engine that meets modern environmental requirements. All China XCMG truck cranes including truck crane, have a hydraulic control system, as well as a limiter for the lifted weight and free play of the crane boom cable. Truck crane ideal for lifting work up to 25 tons and working heights up to 48 meters! Using chinese truck crane when erecting a 16-storey building, you can refuse to rent a tower crane after the completion of the roof installation - all finishing materials can be supplied truck crane

Also in this section you can watch a video about Chinese XCMG truck cranes

Schematic diagram of the structure Chinese truck crane QY25K5 and hydraulic circuit diagram of Chinese XCMG QY25K5 truck crane have obtained many government patents. QY25K5 mobile cranes manufactured under licenses of such world-famous companies as KATO and Liebherr.

China truck crane QY25K5-

equipped with engines that meet the latest requirements in the field of environmental safety. Since 2008, all chassis of Chinese truck cranes XCMG QY25K5 are equipped with engines that meet the Euro-3 standard.

Using the example of the most common model - the Chinese XCMG QY25K5 truck crane - we will try to consider the design and operation features of this type of equipment.

Chinese Truck Cranes

have a low center of gravity, which provides excellent stability when driving and working with a load. The main boom consists of 5 sections and has a telescopic structure. The boom design uses an original octagonal profile. The alternating extension of the boom sections allows you to handle different loads at different heights. The main and auxiliary winches are designed for independent operation. The hydraulic system of the truck cranes is controlled by means of two joysticks on the armrest of the crane operator's seat. It accurately transmits operations to all actuators, even with light pressing of the joysticks. Automatic load balancing takes place through the use of a swing system with a free slip function. Chinese truck cranes are equipped with a highly effective safety system, which includes a limiter for the maximum lifting of a load, a limiter for the load moment and a free play of the cable, a safety control valve, a hydraulic pressure protection valve, anti-cavitation and anti-lock device, etc. All the main elements of the crane installation and chassis are made of high-strength steel. New lightweight materials used in the construction of mobile cranes allow to minimize the total weight and, therefore, increase the efficiency of use. For the convenience of working with mobile cranes, a separate crane operator's cabin is provided. It is a full-size cab with a very wide field of view. Like the driver's cab, the crane operator's cab is equipped with air conditioning.

Specifications.

EngineChinese mobile cranes XCMG QY25K5

Model	C6L280-2 (in-line, water-cooled, four-stroke, turbocharged)
Rated power	206 kW (282 hp) at 2200 rpm
Maximum torque	1170N.m / 1400rpm
Engine volume
Fuel consumption
Starting motor	24 V, 11 kW
Alternator
Batteries	12V, 170x2A / hour
Cooling system	centrifugal pump (forced circulation), fan

Lift dataChinese mobile cranes XCMG QY25K5

Max lifting capacity of XCMG QY25K5 - 25t

Nominal working radius 3 m

Maximum load moment on the main boom 961 kNm

Maximum load moment at full boom reach 450 kNm

Distance between outriggers (longitudinal) 4.8 m

Distance between outriggers (Side) 6 m

Main boom height 10.2 m

Full reach of boom 38.6 m

Full reach + jib 47.6m

Boom lifting time 75 s

Boom full extension time 150 s

Maximum swing speed 2.5 rpm

Outrigger extension time 35 s

Main winchChinese mobile cranes XCMG QY25K5

Auxiliary winch -Chinese truck crane XCMG QY25K5

Article - Chinese truck cranes manufactured by XCMG

"... two important arguments in favor of Chinese XCMG truck cranes, including XCMG QY25K5 and QY25K5 truck cranes.

1. Liebherr Technologies. All XCMG truck cranes are based on the design thought of Liebherr engineers - the WORLDWIDE renowned manufacturer of truck cranes. They are known everywhere, this is a brand. Is at least one of our brands known in the world for at least a quarter? This question is likely to be answered: “There is also KATO, I heard about Chinese XCMGs. "Klintsy"? no, I haven't heard ... "

2. Fifty countries of XCMG truck crane importers: including Russia, Iran, Indonesia, Vietnam, Saudi Arabia, Algeria, Sudan, Angora, Turkey, Brazil, Peru, Cuba. Chinese XCMG truck cranes are supplied everywhere and everywhere where there are no import restrictions to protect manufacturers - protective duties, certificates, etc. And if a Chinese XCMG truck crane could somehow be legally imported to Germany, then, perhaps, the Liebherr concern would have to move its production to China in order to compete in price - after all, the quality is comparable. This was done by BMW, which from 2019 will produce up to 70% of spare parts for its cars in China. "

XCMG article:

"...Everything XCMG truck cranes the highest quality workmanship, rightfully competing with German and Japanese quality. The export of truck cranes to Europe is stopped only by the high duties on the import of foreign-made construction equipment. But when it comes to construction outside Europe, German developers buy XCMG machinery. In particular, the construction in southern Africa - a little less than 30% of the operated special equipment - XCMG technique... XCMG truck cranes, especially the XCMG QY25K5, are widely used in Spain, Italy and Brazil.
High quality assembly with the use of high-grade steel for arrows, reliability in operation, high-tech and innovative Chinese cranes XCMG ... "

XCMG QY Chinese Truck Cranes Videos

Technical features of the China mobile crane XCMG QY

User manual

Truck crane XCMG QY25K

Catalog

The main purpose and dignity .............................................. .................................................. .........1
Main technical characteristics ............................................... .................................................. ... 3

2.1 Appearance of the whole truck crane and its technical characteristics ................................... ... ... .... ........4

2.2 Main technical characteristics of the truck crane ............................................. ......................……......13

Preparing to rise ............................................... .................................................. ................................fourteen
Ways to control the crane ..................................... .......... .................................................. ............16

4.1 Electrical system ................................................ .................................................. ............................ …… ..... 17

4.2 Hydraulic system ............................................... .................................................. ............... …… ..... 28

4.3 Starting the engine and operating the power take-off .................................. ... ... ..... ....... 32

4.4 Outrigger operation ............................................. ............................................... ……. ........... 33

4.5 Throttle operation .............................................. .................................................. .......... …… ............. 36

4.6 Lifting operation ............................................. .................................. ... ............... .... 36

4.7 Telescopic Lift Boom Operation ... ............................... ... ........ 37

4.8 Operation to change the luffing boom reach ... ............... ... ... ... .......... 37

4.9 Swing Operation ............................................. ................................... ... ........ ... ..... ..38

4.10 Description about tag .............................................. .................................................. ...............… .........… ....... 38

Auxiliary parts of the truck crane ............................................... .................................................. .......... 40

5.1 Secondary boom ............................................... .................................................. .................. ... ........ 41

5.2 Swivel bearing ............................................... .................................................. ........................ ... ............ 49

Leading and auxiliary hook .............................................. .................................................. …........50

Steel rope transmission ratio .............................................. .................................................. .... 53
Safety device ................................................ .................................................. ............... 55

7.1 Torque limiter ............................................... .................................................. ................ ... ............ 56

7.2 Three-circle fuse ............................................... .................................................. .. …… ...... 56

7.3 System pressure switch .............................................. ................................................…. .............. 57

7.4 Hydraulic safety valve .............................................. ......................... ... ................. 57

7.5 Warning lamp for hydraulic oil filter closure .................................... ... ...... ........... 57

7.6 Amplitude indicator ............................................... .................................................. ........… ............... 57

8. attention events .............................................. .................................................. ........................................... 58

8.1. attention events ……. .................................................. .................................................. ......................... 59

8.2. warp attention events .............................................. .................................................. .... 65

8.3 Attention to the settlement of the guy ............................................. .................................................. ............. 65

9. Lubricating oil …………………………………………………………………. ……………… .. …… ..67

9.1. hydraulic oil...................................……………………..... .................................................. ........ 68

9.2. periodic system ................................................ .................................................. ............................. 69

9.3. Lubrication ................................................. .................................................. .................. ………………… .......... 70

9.4 Static oil ............................................... .................................................. ......................................... 70

10 Frequent faults and their remedies .......................................... .................... 74

10.1 Malfunctions and their remedies ……………………………………………………… .. ……… 72

10.2 Change of warps ……………………………………………………………………………… .. ……… 77

10.3 Bypass oil filter …………………………………………………………………… .. ……… 81

10.4 Linear oil filter ……………………………………………………………………… .. ……… .82

11. Periodic inspection …………………………………………………………………… .. ……… ..83

12 Railway transport ............................................... .................................................. ........................ 90

13 Appendix ................................................ .................................................. .................................................. .92

14 Gesture card ............................................... .................................................. ................................ ... ............ 95

15 Packing list ............................................... .................................................. ............................. ... .......... 98

The QY type truck crane is designed for lifting and erection work in places such as factory, mine, oil field, port, construction site, etc.

A real car has the following advantages:

1.Hydraulic transmission. Infinitely variable speed control is carried out. Reliable performance, convenient operation.

2.The driving and auxiliary hoists are of the same type, they all use a drum internal planetary gearbox, they can supply oil with one pump or two pumps, as well as work with many speed modes, such as low speed under heavy load and high speed under light load. ... The quality of the work is very high.

3.The slewing mechanism adopts planetary reduction gear and permanently closed locking mechanism, adopts a motor to drive the spur gear, and adopts hydraulic system with buffer valve, it can realize free running rotation and slow smooth movement.

4. Safety device including torque limiter, height limiting device, support plug and spirit level. Completed lighting installation for night work.

5. The control cabin is light, spacious and comfortable, with an adjustable seat inside. A fan can be installed as desired.

6. Large selection of accessories. We offer auxiliary lifting booms, auxiliary lifting mechanism, single pulley at the end of the boom, heating device in the control cabin (for optional mounting), etc.

7.This machine has a low barycenter, reliable stability and high travel speed, which is convenient for moving quickly between work sites.

2.1 Appearance of the whole machine and their technical characteristics

The appearance of the entire machine is inspected in Figure 2-1.
Technical parameters are examined in Tables 2-1 and 2-2.
Primary Boom Lift Chart, Table 2-3, 2-4.
Secondary Boom Lift Chart, Table 2-5.
The lifting height collar is examined in Figure 2-2.
Distribution of the working range of the truck crane. (see Map 2-3)

THE BELL