Maintenance of the electrical system .1 Inspection of the lighting system

Check for normal operation of the illumination system.

As shown in the figure on the right (e.g.: aviation lighting devices)

4.10.2 Inspection of windshield wipers in the operator's cab as well as cleaning solution

Check for normal operation of the windshield wiper weekly.

Location of sprayer is at the left rear side of the cab seat.

Add water into the sprayer constantly, and add a little cleaning agent when necessary.

4.10.3 Inspection of the video monitoring system

The monitor system is optional. If the monitor system is equipped, check for normal operation of the monitor system camera and the definition of LED image in the operator’s cab before using vehicles.

Fig. ×4-023

Fig. × 4 - 025 Incorrect

Correct

Fig. × 4 - 024

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ZCC800HWG Crawler Cranes

4.10.4 Battery inspection

Batteries must be well maintained and kept for use, because they function as the power supply of starting the engine, electrical control system, illumination and electrical auxiliary devices of the machine.

a) Store the battery (a filled and charged lead-acid battery) at the temperature ranging from 5 °C to 25 °C and in a dry, clean and ventilated environment. Do not expose the battery to direct sunshine to avoid degradation of the performance caused by high ambient temperature.

b) Do not inverse and place the battery horizontally. Do not shock and press the battery mechanically.

c) Recharge the battery in time to avoid performance degradation caused by the sulfating of the battery.

d) Do not overcharge the battery. Avoid premature failure of the battery caused by too much water loss, growth of grid and drop of diachylon.

e) Remove the batteries from the car and store them in a well-ventilated and dry place if they are used for long time (usually more than 15 days). Charge the batteries every 3-6 months (see if the indicator is black or not).

This series of lead-acid batteries for cars is the dry charged batteries produced in accordance with JIS Japan and DIN Germany. Dry charged batteries can start the car in 30 minutes after injecting the electrolyte. If possible, charging for 3 - 5 hours before use will result in a better starting performance.

Preparation before use:

a) Make sure the level of electrolyte is 10 mm higher than the minimum waterline.

b) Make sure the blow cock is crewed in case of acid leakage.

c) Check the air hole of the blow cock to ensure a smooth venting.

d) Pay attention to the positive and negative poles when connecting wires to avoid reverse connections.

Storage and maintenance:

a) The storage battery should be stored in a clean, dry, and ventilated storeroom at ambient temperature ranging from 5°C to 40°C. Be sure not to unpack the sealing bar or blow cock of the dry charged battery before use.

b) Under exceptional circumstances, the storage battery should be stored in company with electrolyte and be charged monthly through common charging method. The liquid level and density of electrolyte should also be regulated as required, and the density of electrolyte is 1.28±0.01g/cm³.

c) Do not prepare the electrolyte with river water, well water or water containing impurities. When using a battery, keep the external and wiring of the battery dry and clean.

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d) After discharging battery, charge it in time to avoid long-term idleness.

e) Open the blow cock while it is charging and screw up the blow cock before use.

f) Do not smoke and light fires at the charging site.

Exterior charging is required under the following circumstances:

a) The density of electrolyte falls to 1.170 and below.

b) Brownout.

c) Under-voltage, the voltage of the battery is under 0.8 V.

4.10.5 Inspection of the limit switch

Provide references for crane operators by real-time monitoring the working condition of the crawler crane, and displaying the condition on the moment limiter. In abnormal working condition, the crawler crane generates an alarm by an icon flashing on the system display interface, and interrupts the operations that could increase the danger.

1—Hoisting winch 1 over-winding alarm

Over-winding of the hoisting winch 1 is also known as the main hook reaching the upper limit. By this time, the corresponding alarm indication “ ” blinks in the display, along with audible alarm. Meanwhile, the “reel in” movement of hoisting winch 1 and “reel out”

movement of derricking winch will be cut automatically, and the bypass key switch operation is effective.

2—Hoisting winch 1 over-release alarm

Over-release of the hoisting winch 1 is also known as only three circles of wire ropes left on the hoisting winch 1. By this time, the corresponding alarm indication “ ” blinks in the display, along with audible alarm. Meanwhile, the “reel out” movement of hoisting winch 1 will be cut automatically, and the bypass key switch operation is effective.

3—Hoisting winch 2 over-winding alarm

Over-winding of the hoisting winch 2 is also known as the auxiliary hook reaching the upper limit. By this time, the corresponding alarm indication “ ” blinks in the display, along with audible alarm. Meanwhile, the “reel in” movement of hoisting winch 2 and

“reel out” movement of derricking winch will be cut automatically, and the bypass key switch operation is effective.

4—Hoisting winch 2 over-release alarm

Over-release of the hoisting winch 2 is also known as only three circles of wire ropes left on the hoisting winch 2. By this time, the corresponding alarm indication “ ” blinks in the display, along with audible alarm. Meanwhile, the “reel out” movement of hoisting winch 2 will be cut automatically, and the bypass key switch operation is effective.

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ZCC800HWG Crawler Cranes

5—Main boom 80° alarm

When the elevation angle of the main boom reaches 80°, and limit switch at the root of main boom is closed, the corresponding alarm indication “ ” blinks in the display, along with audible alarm. Meanwhile, the “reel in” movement of derricking winch will be cut automatically, and the bypass key switch operation is ineffective.

4.10.6 Inspection of cable terminals and dust guards

Every dismantling of the basic machine and site transport requires the inspection for whether the cable terminal is aligned and plugged tightly and whether the dust guard is well covered.

4.10.7 Prevention of electrical parts or cables from catching fires

Fire of the electrical parts or cables can be prevented, and effective measures can be taken to avoid such danger.

Precautions:

a) Inspect or exam the electrical devices of the crane regularly. Find out the cause for faults like loose connection and cable heat, etc., and troubleshoot these devices immediately.

b) Check all cables, connectors and terminals for looseness or damages (see if there is any oxides formed on both poles of the terminal or battery), and rectify all confirmed faults immediately.

c) Use the original spare parts and original fuse in compliance with the specified rigidity only.

d) Close the crane immediately in case the power fails.

e) No unauthorized replacements, supplements or modifications toward the electrical system are allowed unless approved by the manufacturer.

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