I

STC75
Truck crane Safety code

Hunan SANY Auto Hoisting Machinery Co., Ltd.


Hunan SANY Auto Hoisting Machinery Co., Ltd.
Address: SANY Industry Town, Changsha Jinzhou Development Zone, Hunan, China
Postal Code: 410600 http://www.sanyauto.com.cn Tel: 0086-731-85831153
Fax: 0086-731-84031999.523
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Preface
Hunan SANY Auto Hoisting Machinery Co., Ltd. sincerely thanks you for purchasing SANY
fully-hydraulic truck crane. SANY is dedicated to providing you with first-rate products,
first-rate quality and first-rate service.
This Safety Manual contains the detailed information and instructions for the operation,
installation, maintenance and repair items about STC75 truck crane.
In order to ensure the high-efficiency performance of the truck crane, we strongly
recommend that you read and understand this Maintenance Manual carefully before
operation.
It is also recommended that you keep this guide within reach during operation. Only when
you completely understand the Users Guide can you operate the machine expertly and safely.
Thank you for your trust in SANY, and sincerely wish you great success in your business.
Special Notes:
Person who operates the truck crane must be the experienced workman having been
trained. If the operator is the person having not been trained, the operator shall bear the
responsibility for any accident.
The safety devices of truck crane must be inspected periodically to ensure their
normal performance. Once found, any abnormality should be fed back to after-sales
service personnel of our company. For any serious hidden safety trouble, the machine
should be shut down.
This Users Guide must be put at an easily reachable position in the operating room
of superstructure for the operators reference. The user can contact us for any question
regarding this Users Guide.

Incorrect operation of the crane may result in fatal accident
Wrong operation of a crane may cause death or serious injury
Cranes must be operated by authorized, trained professionals
All the technical safety regulations, operating manuals are all based on the intended use
of cranes.
The intended use of truck crane
Crane's intended use is limited to vertical movements of the non-attachment load whose
weight and gravity center are known.
For this reason, the lifting crane wire rope should be equipped with the hook or hook block
recognized by Sany, and the truck crane can only be operated within the allowed operation
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configuration range.
Truck crane can be operated only with the corresponding driving or operating load
diagram map regardless of load. Besides, the operation of truck crane must comply with the
appropriate operating instructions given in the crane configuration in a safe condition.
Any other use or the use out of range is not the intended use.
Part of the intended use should also comply with safety regulations, conditions, premises,
crane configuration and operating steps which are specified in crane documents (e.g.
operation manual, operating load chart, operating plan).
If damage appears due to the non-intended use or improper use of cranes, we will not
bear any responsibility, while the related risks should be undertaken by crane owners,
operators and users themselves.
Non-intended use
Non-intended use refers to:
Operate not in accordance with the permitted configuration specified in the operation
load chart.
Operate not in accordance with the permitted extension radius and rotation range
specified in the operation load chart.
Select the inconsistent load value with the actual crane configuration.
Select the unmatched load moment limiter code with the actual crane configuration.
Operate crane when the switches of load torque limiter and lifting limiter are off.
Extension radius increases with the disconnection of load torque limiter , for example,
the diagonal drag load.
Outrigger pressure will act as an anti-rollover security feature.
Adopt the equipment or accessories that are not recognized by crane.
Use cranes in the sports field or recreation area, especially bungee jumping spot.
Drive crane on the road whose axle load and size are not suitable for crane traveling.
When traveling, equipment is located in the position which is not suitable for driving
crane.
Use horizontal adjustment device, outrigger or outrigger cylinder to push, pull or lift
loads.
Push, pull or lift load with slewing, pitch and flexible organization.
Loosen the tied-up objects with crane.
Using cranes for a long time loading and unloading of materials.
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Sudden release of cranes (crawl or dumping operation).
Use cranes when there is change in the load weight(for example, carry out load
operation on the container hanging on the hook).
Cranes can not be used
By (for example) cutting blowpipe load weight and unknown gravity to loosen the
truss load.
Have others to follow by driving.
Transport personnel with operation room when crane is traveling.
Transport personnel with lifting equipment and load thereof.
Transport personnel through the container (boom loaders) without the appropriate
safety board's written approval.
Transport load with chassis.
Operate crane under a dual-hook with no auxiliary equipment.
Loading and unloading of extended material.
The person who carries out operation, assembly and maintenance of cranes must read
and follow the safety manual operation.
Safety Equipment
Please pay particular attention to the built-in crane safety equipment, and always monitor their
function. Once safety equipment does not work or not work properly, please stop the operation
of the crane.
Please bear it in mind!
Safety is the most important
This crane is manufactured in accordance with applicable crane manufacturing and driving
regulations and has obtained approval from the relevant authorities.
Danger
Accessories
The critical danger may appear if the non-original accessories are adopted!
The malfunction of crane and the critical danger may appear if the non-original
accessories are adopted!
Components of crane may be damaged!
Crane can only be operated with original accessories!
It is forbidden to operate crane with non-original accessories!
Danger
Both the crane license and quality guarantee will fail!
Both the crane license and quality guarantee will fail once the components of crane have
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been modified, refit and replaced (e.g. dismantle components or install non-original
components).
Do not modify original components!
Do not dismantle original components!
Do use the original components for SANY crane!
Definition of direction data
Forward traveling refers that the cab is located forward when crane is traveling.
Rearward traveling refers that the tail light is at front when carne is traveling.
Front, rear, left and right of crane refer the four directions when cab and boom are in the
same direction. The front always refers to where the cab is located.
Front, rear, left and right of cab refer to the four directions of carne chassis. The cab is
always located at front.
Front, rear, left and right of operation room refer to the four directions of superstructure.
The front always refers to the direction where boom is located.

SANY Auto Hoisting Machinery Co., Ltd.








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Content
Preface ......................................................................................................................................
Statement...................................................................................................................................
1-1 Basic regulation...................................................................................................................
1-1-1 Marks of Safety Prompt ............................................................................................
1-1-2 Traffic regulation......................................................................................................................................9
1-1-3 Running-in regulation of new truck...........................................................................
1-2 Specification and Requirements on Crane Operation.........................................................
1-2-1 Requirements on Properly Using the Crane.............................................................
1-2-2 Examples of Results Due to Improper Usage ..........................................................
1-2-3 Requirements on Crane Owner and Other Authorized Relevant Personnel ............
1-2-4 Requirements on Crane Driver.................................................................................
1-2-5 Requirements on Crane Signaler .............................................................................
1-2-6 Operation Planning...................................................................................................
1-3 Safety Techenical Specifications .........................................................................................
1-3-1 Worksite Requirements ............................................................................................
1-3-2 Overall Supporting....................................................................................................
1-3-3 Precautions for Lifting...............................................................................................
1-3-4 Safety measures check.................................................................................................................................30
1-3-5Connection with ground .................................................................................................................................30
1-3-6 Load connecting with ground........................................................................................................................32
1-3-7Welding of loading..........................................................................................................................................33
1-4 Safety Device ......................................................................................................................
1-4-1 Moment Limiter.........................................................................................................
1-4-2 Three-layer Overrelaxing Protector ..........................................................................
1-4-3 Sytem master switch ................................................................................................
1-4-4 Choke alarm of the hydraulic oil filter .......................................................................
1-5 Safety in Power Utilization...................................................................................................
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1-5-1 Countermeasures against electric shock of crane ...................................................
1-5-2 Preventive measures against blast of storage battery .............................................
1-5-3 Proper welding..........................................................................................................




































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Special Statement:
For any damage owing to the offence against the safety regulations or the omission, the
manufacturer shall not bear any responsibility.
For any damage owing to the addition or refitting of components, the manufacturer shall
not bear any responsibility.
If you have to conduct the operation that doesnt conform to the safety regulations, please
consult the manufacturer or the agency of this equipment.
1 Basic Rules
1.1 Marks of Safety Prompt
Working and maintenance safety should be paid much attention to. Because the crane can lift
weights to a high position, casualty may be caused owing to the offence against the safety
regulations or the omission by the driver, section chief, dispatcher and people on site, resulting
in serious damage to crane or loss of property.
To remind the workers to notice the dangerous operation methods and maintenance
procedures, much safety information is provided in this manual. Each piece of safety
information consists of a safety prompt mark and a prompt word, indicating a dangerous
severity.














This safety prompt mark indicates
attention is needed!
Please notice that it concerns your safety! To avoid
possible injury, please follow the safety message

Danger
It indicates indirect danger!
Please notice that serious casualty may be caused
if this message is ignored.

Warning
It indicates potential danger!
Please notice that serious casualty may be caused
if this message is ignored.

Caution
It indicates potential danger!
Please notice that slight or moderate injury may be
caused if this message is ignored.
Caution Without a safety prompt mark, it
indicates that if this message is ignored, the
property may be endangered.
Attention: It calls for careful operation and
maintenance.
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The safety information described in this manual is just to provide the qualified drivers with
safety operation instructions. It is impossible for the manufacturer to foresee all the possible
dangers on working site, so the problems on safety should be in the charge of crane drivers
and owners.
There may be stricter regulations in local regions and local governments on crane operation; if
there are any conflicts with them, the stricter regulations prevail.

In the traveling on road, the hook and sheave shall be kept out of the visual field of the
driver.
1.2 Traffic regulation
SANY truck crane is designed and manufactured in accordance with regulations specified
in China Traffic Law; so it has gained recognition from related authorities. In fact, the traveling
of truck crane should comply with related traffic regulation of the country.
According to the traffic regulation, the loading for single-axle should not exceed 12tons.
Therefore, it is forbidden to have the single-axle of SANY truck crane to bear over 12-ton
loading. Any result from violative operation should be accepted by customers!

In the traveling, no person other than the driver is permitted to stay in the operating
room of superstructure.

Drivers eyesight should not be disturbed by hook sheave when driving.
1.3 Running-in of new truck

Danger
Warning
Important
Danger
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No running-in has been conducted for new truck crane.
The lifting capacity cant exceed 75% of the rated load during the running-in period.
The running-in of new truck crane is an important stage that ensures the long-term traveling of
the truck crane. After the running-in period, the surface of each moving part can be fully ground
in, to prolong the service life of the chassis of truck crane. Therefore, the running-in shall be
conducted carefully for new truck crane. In addition, the truck crane shall be ensured with
normal working status before the running-in.
Precautions for Running-in:
2000km is required for the running-in of a new truck crane;
After the cold starting, dont speed up the engine promptly before the working
temperature reaches the normal value;
Drive on the flat pavement during the running-in period;
Shift gear in time and engage the clutch smoothly to avoid abrupt speed-up or
emergency brake;
Before climbing onto a slope, shift to the low gear in time, but dont keep the engine
working at a speed too low;
Check and regulate the pressure of engine oil and the normal temperature of coolant;
give attention to the temperature of transmission, rear axle, wheel hub and brake
drum at any time, and conduct adjustment or repair in case of serious heating;
After the first 50kms traveling or every time after replacement of wheel, screw down
the wheel nuts as per the specified moment;
Check the bolts and nuts of all parts, especially the bolts of cylinder head. After
300kms traveling, with the engine still under heated condition, screw down the nuts
of cylinder head in specified sequence.
During the 2000km running-in period, the traveling speed at each gear shall be
limited as follows:
Gear 1: 5km/h Gear 2: 5 km/h Gear 3: 10 km/h Gear 4:
15 km/h
Gear 5: 25 km/h Gear 6: 35 km/h Gear 7: 50 km/h Gear 8: 60
km/h
After running-in, an overall compulsory maintenance should be conducted for the
chassis of truck crane at the service station specified by our company.
2 Specification and Requirements on Crane Operation
2.1 Requirements on Properly Using the Crane
Using the crane in proper way is a primary requirement for safety operation;
Use the crane by following the crane operation conditions in Section 2.3;
Pease comply with all the safety regulations strictly;
Pay attention to potential dangers, and eliminate the troubles immediately, especially
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Fig.1.1
when they may affect safety;
Keep the safety devices well and full prepared, and in good working condition;
Have qualified staff conduct necessary check and maintenance safely and timely.
2.2 Examples of Results Due to Improper Usage
Using the crane in improper way will cause the results that:
Human lives may be endangered;
The crane may be seriously damaged;
The lifted weight may be damaged;
The crane performance may get seriously
degraded and the quality warranty may
cease to be effective.
The following operations are strictly forbidden:
Without the written permission from the
manufacturer, changing the structure of
crane and influencing its safety as a result;
Any operation in ways that may endanger operation safety;
Overloading;
Standing under the lifted load, or having the load passing over persons, as shown in
Fig. 1.1, for if there is load over the head, it may cause casualty in case of load
dropping, therefore,
never stay in the dangerous area;
never stretch your hand into driving device or crane parts when they are
working;
Dragging the load with the hook or slewing mechanism;
Drawing the load along the ground or slantways;
During operation,
setting the safety devices at improper
mode;
not using suitable load meter;
Forbidden!
Fig.1.2
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Tilting the crane;
Carrying persons on slewing platform or carrier devices, as shown in Fig.1.2for the
safety of persons who are carried by the hook or on the load will be seriously
threatened. Under such situation, they are neither able to control the motion of crane
nor able to avoid hitting or dropping, so that even a small mistake may lead to a fatal
consequence!
Commissioning or working at dangerous explosive areas, including the temporarily
explosive area in the air.








Fig.1.3
Pay attention to the following operations, which are improper:
Braking abruptly when the weight is lifted;
Drawing the weight along the ground (when slewing or traveling) as the weight has
not been lifted off the ground, for it may lead to personal injury due to overturn or
damage of the machine;
Braking or slewing too abruptly while lifting a weight, for the load may wobble due to
such operation and result in overturn, damage, dropping and otherwise, which will
endanger human safety, as shown in Fig. 1.4;
Lifting weight on uneven ground when the outriggers have not been adjusted evenly;
Binding the weight improperly;
Having the weight loosed accidentally while it is being dragged or lifted;
Tangling the hoisting rope;
Hitting the bridge, ceiling, high-voltage wire and the like, as shown in Fig. 1.5
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Fig 1.5
2.3 Requirements on Crane Owner and Other Authorized Relevant Personnel
Make sure that only the personnel who have read and understood this safety
regulations and accepted sufficient training are allowed to operate and maintain the
truck crane;
Make sure that the person operating and maintaining the truck crane is qualified and
responsible for his job;
Examine the relevant staff on their safety consciousness in working;
Stop the truck crane as soon as any trouble that affects safety is found;
Conduct corresponding checks to the crane according to local and national
regulations as well as to the manufacturers instructions;
Ensure timely maintenance and repair to the truck crane;
As to every accident of truck crane that leads to serious human injuries or property
loss, report should be made to the manufacturer or the agency;
Permit the serviceman from the manufacturer or the agency to take his safety
responsibility and check the truck crane under no restraint;
Make a plan carefully and consciously for the usage of the truck crane.
2.4 Requirements on Crane Driver
1. The truck crane can be operated only by the following personnel, including:
Operators qualified after getting relevant certificate through testing;
Personnel trained for more than half one year under the supervision of qualified
operator;
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Personnel required for maintenance or inspection;
Appointed labor safety supervisor;
No one else is allowed to access the cab.
2. The operator shall meet the following conditions:
Eighteen years old or above, and with healthy body;
With a visual acuity above 0.7 (the rectification is allowable), and without color
blindness;
With an audition meeting the specific working conditions.

3. The following persons are not allowed to operate the crane:
Drunkards and druggers;
Personnel having had medicine with inhibiting effect.
4. The operator shall be familiar with the following knowledge:
Before the operation, the operator shall read the Users Guide carefully to well know
the structure and technical performance of truck crane;
Operation specifications, rules and laws related to the truck crane;
Performance of safety and protection devices;
Basic knowledge regarding engine, electrical system and hydraulic system;
Command signals;
5. Responsibilities of Crane Operator and Matters Needing Attention
Crane operator should check crane function and emergency shut-off equipment
before operation, ensuring there is no obvious damage on the crane.
Pay full attention to operation, without doing any distractible things;
Once there exists potential danger, crane operator should stop the crane
immediately.
The operator must control, operate and adjust the crane to protect the workers and
equipment around the crane. Attention: 65% of the crane accidents were caused by
improper operation;
No drunkard, drugger or the personnel
having had medicine with inhibiting
effect is allowed to operate the truck
crane.
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Crane operator should ensure:
1Before supplying power to driving components, set all the control equipment to the
position of neutral gear or off-load.
2Before leaving turntable, please set control equipment to the position of neutral gear
or controlling with power supply cut off.
3After discharging control unit and do wireless control, over-operation not allowed.
Operators need to pay attention to load at any time when moving the crane; if
gripping devices may cause risk when moving at no load, pay attention to the load of
gripping devices at any time. Only under the guiders help could moving the crane
when the operator cannot see the load.
The operators must show the emergency mark under necessary condition.
The operators must guarantee the working condition under the limited parameters in
wind; when the speed is over the limited or after work, the boom should be retracted.
If the load hangs to the tools through human beings, the operators could move the
crane only when accepting clear signal from those who are appointed by guiders or
contractors. The side who takes responsibility must get common sense of signal with
operators when it is necessary to use signal. If the operator is sure that the load is
not in the right place, moving load is not allowed.
After open the load moment limiter, operators could not lift heavy objects through
retracting or extending.
The operator should be equipped with necessary personal protection; do not wear
baggy clothes, scarves, unsnapped coat or loose the skirt sleeves, to avoid being
grasped or dragged into the running parts of the crane to result in serious injury!

It will cause death for operators or helper without using safety devices.
The manufacturer must provide safety devices for the operators and other helpers.
The manufacturer must guarantee operators and other helpers to wear safety devices.
Operators and other helpers have the responsibility to take and wear safety devices.
Use individual safety devices according to related standard
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Individual safety devices including (as follows)
helmet
Protective gloves
Anti-dropping safety belt
Safety shoes
Warning closes






High-frequent accidents
It could not guarantee 100% protection even wearing safety devices.
Helmet could only provide protect for light-dropping, not for heavy-dropping
Serious death could happen at any time!
Be alarming at surrounding condition, for safety operation!

For your and others safety and interests, please operate the crane rightly and get
familiar with any possible danger in your work.
2.5 Requirements on Crane Signaler
If the crane driver cannot see the states of working device (and dangerous area) from the cab,
a signaler should be appointed. The signaler is also needed in conditions where oral
communication is inapplicable owing to loud noise.
Main responsibilities of the signaler:
1. The signaler should be able to communicate with the operator effectively;
2. The signaler should help the operator with effective and safe working, must be
familiar with these marks and signs, and should be responsible and reliable;
Danger
Warning
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3. The signaler should stand on safe position, where he can see all the working places
and can be seen by all the operators clearly;
4. The signaler must use the marks easily recognizable for the drivers;
5. The signaler must use standard command signals, unless otherwise methods like
intercom and banner are permitted.


Special Gestures

ReadyExtend the armabove the head,
with five fingers separate naturally and
hand palmsteadily facing forward.
Indicating Descending Position:
Keep five fingers straight to point
out the position for descending.
Stop: Put the forearm in front of
chest with five fingers spreading
and hand palm downward, and
wave the forearm horizontally to
one side.
Emergency Stop: Put two
forearms in front of chest with
fingers spreading and hand
palms downward, and wave the
two forearms horizontally to the
two sides at the same time.
Auxiliary Hook Required: Make a single
fist with the forearm keeping upward,
and extend the other armfor hand palm
Lifting Hook Lifted: Straighten the
forearm to upside with five fingers
separate naturally higher than the
Boom Lifted: Straighten the arm
horizontally to one side, with the
thumb upward and other fingers
holding together, and swing the
forearm upward
Boom Descended: Straighten the arm
horizontally to one side, with the thumb
downward and other fingers holding
together, and swing the forearm
downward.
Working Finished: Cross the two
forearms in front of chest, with
fingers spreading.
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Slewing the Crane: Straighten an arm forwards and horizontally, and keep the five
fingers spreading naturally. Have another arm waving horizontally in front of the chest
repeatedly.
Boom Lifted Slightly: Put a forearm in
front of chest with fingers straight and
hand palms downward. Keep the thumb
of the other hand pointing the palmand
other four fingers holding together, and
Boom Descended Slightly: Put a
forearm in front of chest with fingers
straight and hand palm upward. Keep
the thumb of the other hand pointing the
palm and other four fingers holding
together, and wave them upwards and
Gripping: Put the two forearms in front at
two sides, with the palms opposite to each
other, and swing two arms fromtwo sides
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Misunderstanding gesture causes accidents.
Both sides should have common sense of single and being clear when operating!

2.6 Operation Planning
Before driving truck crane to the worksite, the operator shall obtain or try to survey the
following information:
Working type;
Construction location (distance);
Height and width of access to worksite;
Power line above the working area (see Table 2.2 for details);
Working limitation from surrounding structures;
Weight and dimension of the load to be lifted;
Lifting and descending heights;
Bearing capacity of ground;
Only after obtaining the detailed information above, can the operator of truck crane install
the necessary lifting devices, including hook, jib and supporting pad, and get to know the
lifting conditions to choose the operating route.

In order to complete the working task favorably, the driver must get to know the
compulsory lifting conditions. Therefore, to avoid accident, the operators should
prepare very well before operation.

Table1.1 Minimum Distances Between Boom, Weights and Power Distribution Line
Voltage of Power Distribution Line V (KV) < 1 1~20 35~110 154 220 330
Min. Distance (m) 1.5 2 4 5 6 7
Caution
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3 Safety Control Specifications
3.1 Worksite Requirements
Before working, check the adorability and bearing capacity of the working ground. If the
bearing condition of ground is unknown, conduct the detection at each supporting point
and check their compressive resistance. If the pressure resistance is insufficient, apply
the steel plate or sleeper to enlarge the bearing area at the supporting points and reduce
the press applied to the ground. See Table 1.2 for the compressive strengths of various
kinds of soil, which are listed just for reference.
Table 1.2 Compressive Strengths of Various Kinds of Soil
Soil Type
Max. Compressive Strength
MPa
Uncompacted Gravel Soil 0~0.1
Dirt Road, Swamp, Wilderness 0
Gravel Ground 0.2
Slurry Ground 0
Soft Ground 0.04
Solid Ground 0.1
Semi-solid Ground 0.2
Clay soil
Hard Ground 0.4
Compacted Stratum 1.5
Natural
Ground
Rock slightly cracked
but not weathered under
favorable conditions
Stratum Composed of Rock
Blocks and Granules
3.0

It is the most important requirement for the working safety of truck crane that the
ground is solid and it can bear all kinds of loads.
3.2 Overall Supporting
When spreading the outrigger, a certain safe distance should be kept between the
outrigger and the pit, slope, ditch, excavated land or other machines.
(a) Min. Distance from Slope ----- A (see the following figure)
If outrigger pressure 12t, A=1m;
If outrigger pressure > 12t, A=2m;
Warning
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(b) Safe Distance from Pit ----- B (see the following figure)
For loose backfilled ground, B 2T (T as the depth of pit);
For solid ground, B T (T as the depth of pit);

(c) No matter how ground conditions are, the supporting plane must be horizontal, and if
necessary, a horizontal supporting surface should be shaped. In addition, dont lay any
outrigger on a hole.

(d) The level plane that supports the whole machine should be prepared with a gradient
within 0.5% and the stability of the supporting ground should be monitored during the
working.
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(e) In case of any factor that may reduce the stabilization, the boom should be retracted at
once, and only after such factor is eliminated, can the supporting be conducted again.
The factors include:
Change of ground conditions due to rain, snow water or other water sources;
Subsidence of ground at the side of outrigger;
Leakage in the outrigger oil cylinder;
Before spreading the outrigger, check if there is any obstruction around the machine;
When spreading the outrigger, observe the bubble water level meter at the base frame to
adjust the machine to a horizontal status, with the gradient of slewing supporting plane
within 0.5%.

Cranes will be overturn if inclination!
If the crane stop on the slope and boom is on the side of slope, the diameter will add. So
the slewing mechanism could not bear the superstructure, in the extreme condition, overturn
happens!
Be sure that the crane stops horizontally!
When fix outriggers, make sure that front and rear tyres of chassis are departure and then
push handle of the control valve of outriggers to the neutral position.

It is important to correctly support crane according to load chart to ensure safe operation.
Be carefully to watch the combination on the surface of outriggers stopping surface to ensure
normal strength transmission between outriggers.
Cranes supporting could only do when outriggers open!
Cranes may overturn.
Due to strength transmission can only be done through surface on both sides, the central
position for the width of outriggers could not realize the maximum effection of supporting. If it is
insufficient of the surface for the central position, it could cause wrong transmission.
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Connect moveable outriggers and outriggers seat through fixed shaft according to load
chart.
Completely fasten fixed shaft!
All the spreading of four moveable outriggers, cylinder of outrigger and counterweight are
accordance with load chart.
If there are only moveable outriggers near to load spreading, the crane may be overturn
when slew or place load.
Incorrectly spreading moveable outriggers cause overturn
The hanging load on hook can cause tension and distortion of wire rope, telescopic boom,
truss and zipper. If the load drop from wire rope or under this condition, hook or wire rope
disconnect, the load will suddenly release. The boom will retract quickly and the crane will be
overturn at this moment.
Although there has some hypothesis, pushing load to the other side is necessary. At this
moment cranes will overturn. When the crane inclines from the vertical direction, it will be
overturn because of momentum of boom or counterweight.
The spreading of four moveable outriggers and cylinder of outrigger must be accordance
with load chart.
3.3 Precautions for Lifting
For the first 100-hour traveling during the running-in period of new truck crane, the
working load and speed should be controlled at the medium or low level, and the lifting
capacity should be limited not more than 75% of the rated lifting capacity;
The lifting capacity must be controlled within the rated scope, and any overloading is
forbidden;
It is forbidden to draw or lift weight slantways, to lift for selecting among the articles
interlaced together, or to lift the article embedded in the earth or congealed on the ground;
Generally, it is not allowed to lift a same weight with two cranes or more, because it is very
dangerous due to serious loading unbalance. In special cases that the weight has to be
lifted in this way, the wire rope should be kept vertical. The lifting and descending of each
crane should keep synchronously with each other, and the load of each crane should not
exceed 80% of its rated capacity.
For the working reach may be enlarged due to the bend of boom under the effect of load,
the user shall consider this factor during the estimation of lifting capacity and working
scope.
The crane should be operated carefully before you get familiar with the operation.
The operator should concentrate on the work; dont watch around or chat with other
persons. The operator should have response only to the signals of commander; however,
the stop signal should be always obeyed no matter when and by whom the signal is sent.
When working, the operator should pay attention to the circumstances around the crane.
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When the load is being lifted, the operator cant get away from the working position.
The temperature of hydraulic oil should be always checked. If the oil temperature exceeds
80, the operation should be stopped at once. For the hydraulic oil in oil cylinder and
hydraulic oil tank expands due to heat and shrinks due to cold, if extending the boom
when the oil temperature is higher, the boom will retract naturally after the oil temperature
falls. For this problem, just extend the boom to recover the required length.
Dont drag the weight that has not got off the ground, and try to avoid side loading.
Pay attention to the weather forecast, and
1. Dont conduct lifting when wind speed exceeds 13.8m/s;
2. In case of strong wind or thunder, it is necessary to stop lifting and retract the boom.
Visual Ways of Judging Wind Force
Wind
Speed
Name Force Observations (on the ground)
0~0.2 Calm 0 Smoke rises vertically.
0.3~1.5 Light air 1 Direction of wind can be shown by smoke but not by wind
vanes.
1.6~3.3 Light
breeze
2 Breeze wind is felt on face; leaves rustle; ordinary wind
vane is moved by wind.
3.0~5.4 Gentle
breeze
3 Leaves and small twigs present in constant motion; wind
extends light flag.
5.5~7.9 Moderate
breeze
4 Breeze raises dust and loose paper; small branches
wobble.
8~10.7 Fresh
breeze
5 Small trees in leaf begin to sway; crested wavelets occur
on inland water.
10.8~13.8 Strong
breeze
6 Large branches present in motion; telephone wires
whistle; it is difficult to spread an umbrella.
13.9~17.1 Moderate
gale
7 Whole trees present in motion; it is inconvenient to walk
against wind.
17.2~20.7 Fresh gale 8 Twigs are broken off trees; strong resistance is felt in
walking against wind.
20.8~24.4 Strong gale 9 Slight structural damage occur (chimney pots and slates is
removed).
24.5~28.4 Whole gale 10 It is rarely experienced on land; if so, trees are uprooted
and considerable structural damage occurs.
28.5~32.6 Storm 11 It is rarely experienced on land; if so, it must be
accompanied by widespread damage.
32.7 Hurricane 12 It is rarely experienced on land; if so, devastation occurs.
It is not allowed to drag heavy object which is on the ground, avoid side load.
check before operation
Before operation, the operator must check the crane to ensure safety operation.
Checking whether it is in sufficient-supporting at horizontal position
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Checking whether input all the parameters to satisfy working load chart for the
equipment.
Ensure that no human beings or object in dangerous area of cranes.
Slewing cranes when avoiding the human beings or other objects in dangerous area could
cause accident.
It is so special for working in small work area, extended boom in diameter after
counterweight or slew cranes towards chassis.
It must give alarming signal before operating crane!
Be sure that no person or objects in dangerous area before slewing!
Checking damage with eyesight!

Accident could happen!
Stop operation as soon as possible when safety problems happened!
The following malfunctions endanger operation
Designing and supporting parts damaged(boom, outriggers and so on).
Brake of lifting mechanism couldnt work and cause load to move.
Control system malfunction.
Control lamp and alarming lamp malfunction.
Wire rope damaged.
Safety devices malfunction.
Hydraulic system leaks.
Please inform these malfunctions to related directors. It replacing operators, there is need
to tell these malfunctions to the replacer.
Side sunshine could cause distortion of boom.
Due to the different temperature at two sides of boom, it could cause side distortion of
telescopic boom to reduce bearing capacity. For example, if the difference is 30 , the
difference is 22mm for both sides of 60m telescoping boom, especially when it is narrow in
some part of telescoping boom, it could break to one side.
If use rated load, especially use truss jib, tilting truss jib or foldable jib these extended
parts of telescopic boom, before catching heavy objects, it must check crane with eyesight to
ensure no single distortion of telescopic boom caused by single sunshine.

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Parts overload could cause accident!
If single sunshine cause distortion, it will cause parts overload and cause accident.
Change the direction of crane to make the same temperature of both sides to avoid single
distortion.
Operation in thunder
(including lighting )
Stop working at once.
Put down load
If possible, retract boom and set it in safety condition.
Shut off engine.
Working near to emitter
If the working place is near to emitter, it could be on strong electromagnetism field.
Electromagnetism could cause direct or indirect dangerous to human beings and objects. For
example:
Rising temperature is harm to organic of human body.
Rising temperature could cause fire.
Form sparkle or electricity.


Electromagnetism field could cause danger.
If working near to emitter. You must consult Sany Mobile Cranes Co., Ltd. at first.
And it is need to consult high frequency experts
Because of high frequency radiation from emitter, there is need to provide protection
according to special environment standard to operators and other workers.
1.Each crane must be connected to ground completely. To check ladder, operators cab
and wire rope with eyesight or other simple way.
2.All the people who worked on the crane or carry big metal objects, they should wear
gloves and suit that made from unconducted and synthetic materials to prevent getting
fire.
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3.) Dont be shacked when feel hot. Considering each structural parts or bracket is hot
when working.
4.The temperature of objects which have affected by high frequency radiation depends
on their size. Truck crane, trailer, and cover are hotter, comparably speaking.
5.It is forbidden to get touch with load when operating. The damage caused by burning
could severely reduce the transmission ability of cable. It is urgent to report to the
supervisor to do checking.
6.It is necessary to install insulator between boom and spreader. It is forbidden to
dismantle the insulator.
7.Do not get touch with the cable up the insulator.
8.After the load is lifting or dropping, do not get touch with the load attached on the crane
with unprotected body.
9.Put on protected clothes.
10.In order to reduce the absorption of high frequency radiation, it is better to transport
huge load horizontally if possible.
11.It must connect the load to ground or take insulated devicesplace rubber material
between object and gloveswhen need handle work.
12.Using appropriate instrument to check temperature, for example, if the voltage is
500V within I to 2cm, it is not allowed to touch this instrument.
The distance is further, the voltage is higher.
Distance: 10cm, 600V; 30cm, 2000V.
13.In order to avoid second accident, it is necessary to tie safety belt when work on the
structural object which get away from ground.
14.When dealing with inflammables, it must be away from huge metal object which could
cause fire at least 6m. Only use rubber conduit to fill fuel.
15. Report to the supervisor or safety engineer at the first time when accidents
happened.
Cranes operation with load
The operators must be sure that the crane is ready for safety preparation before operation.
All the safety system, such as load torque limiter, lifting limit switch, braking devices are in
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working condition.
It must monitor moment limiter according to cranes structure.
Do not exceed the number on the load chart.
Cranes load could not exceed the rated number on the load chart.
The operator need get to know the weight, center of gravity and size of load before
operation.
Load pullet, lifting devices and spreader are in accordance with requirements.
Notice: detract the weight of pullet blocks and spreader from the load on the chart.
example
Rated number on load chart 30.000t
weight of pullet sheaves 350kg -0.350t
weight of sling 50kg -0.050t
practical load =29.600t
Operation ceasing
If the operators must leave off the crane because of unexpected reason, it must be sure
that the crane and the surrounding are safe.

Causing death
If leaving off the crane without supervision, the crane could be in unsafe condition.
The crane could be overturn and cause death and severely property damage.
It must make crane under control.
accident (examples):
The ground sank because of heavy rain.
Ice-out
Rainstorm and thunderstorm
Mountain coast
erosion
On mobile crane
Malfunction of cylinder of outriggers
On telescoping crane
Malfunction of luffing cylinder
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Hostile damage
Must be satisfied the following condition:
No load on hook
No obstacle for transportation

It must take measure to control cranes safe by trained and qualified person if there is need to
leave off crane because of some unexpected reason.


Accidents
It must retract mechanical parts and boom if there is no condition to control crane which
have assembled.
Restart operation
The operator must check the safety system of crane before restarting operation.

Accidents
If the operator leaves off the cab even in a short time, if there is need to restart operation,
it must check and set up operating mode again.
If there is need, check operating mode and reset-up.
Be over the operation
The operator must do as follows before leaving off the crane:
Put the load on the ground and get it out of hook.
For crane with telescopic boom,
Completely retract telescopic boom and arm frame.
For crane with truss mast boom
Put down truss mast boom and dismantle it in necessary condition.
Push lever (main switch) to neutral position.
Close heater
Stop brake on chassis.
Switch engine and pull down ignition key.
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It will cause accident and bring danger if not followed those notice.
3.4 Safety measures check
The location for stopping could guarantee that the crane can travel as its possible
minimum diameter.
Sufficient bearing capacity on ground.
Keep some distance with concave and slope.
Ensure that there is no cable in the area that the crane operating.
There is no obstacle that prevents cranes necessary moving.
3.5 Connection with ground

Electric-attack could cause death
There exists electric-attack if the crane disconnects with ground.
Make sure that the crane connects with ground correctly.
It must put the crane connect to ground before operation as follow conditions:
Be near to emitter(wireless electricity, television signal emitter, wireless radio station)
Be near to high frequency converter station
The degree of thunderbolt or potential thunder will be great.
Cranes will be attached static electric, especially when there has multi-functional
supporting blocks or placed on the top of insulators.

Electric-attack could cause death.
There is potential danger of electric-attack when the crane does not connect to ground
correctly.
- Prevent static electric on the crane.
To avoid cranes with static electric, the devices as follows are needed:
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One piece of conducted ground-rod for 2m to insert under the ground.
Conducted cable for 16 mm
2
cross section.
Earthing connection or spiral nip for welding.
Obey the requirements as follows:
Should due crossover ground-rod.
Earthing resistance must be less than 0.5 ohm.
Should be right conduction connecting between the crane and ground.
Connect one end of earthing cable with 16 mm
2
cross section with ground rod putting into
earth.
The depth of ground rod into ground is at least 1.5m.
Make the surrounding earth of metal rod wetter to improve conduction ability.

The resistance of earthing depends on the materials made of ground and activeness of ground
rods surface.
Connect one end of ground connecting cable (with 16mm
2
cross section) to ground connecting
devices on the cranes.


Should be right conduction connecting between the crane and ground.
If it is possible to connect basic ground and frequent ground with smaller resistance, just
adopted this way in prior.


Electric-attack could cause death.
It will have danger of electric-attack if the crane does not connect ground correctly.
Make sure right conduction connecting between the crane and ground.

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3.6 Load connecting with ground

Electric-attack could cause death.
Electric-attack could happen if the load connected ground in wrong way.
Make sure that the load connected ground correctly.
It must connect ground before operation as follows condition:
Be near to emitter(wireless electricity, television signal emitter, wireless radio station)
Be near to high frequency converter station
The degree of thunderbolt or potential thunder will be great.
Cranes will be attached static electric even it connected to the ground, especially when
the material of hook sheaves are made of synthetic material and insulated fixed devices(such
as rubber or thick rope)



Electric-attack could cause death.
There is potential danger of electric-attack when the load does not connect to ground correctly.
To prevent load with static electric.
Should be right conduction connecting between the load and ground.
To avoid load with static electric, the devices as follows are needed:
One piece of conducted ground-rod for 2m to insert under the ground.
Conducted cable for 16 mm
2
cross section.
One piece of conducted metal-rod with insulated handle for getting touch with load.
Connect one end of earthing cable with 16 mm
2
cross section with ground rod putting into
earth.
The depth of ground rod into ground is at least 1.5m.
Make the surrounding earth of metal rod wetter to improve conduction ability.

The resistance of earthing depends on the materials made of ground and activeness of ground
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rod surface.
Connect one end of ground connecting cable with 16 mm
2
cross section with metal-rod with
insulated handle.


Electric-attack could cause death!
It must grasp metal-rod with insulated handle.
Grasp metal rod with insulated handle/
Before getting touch with load in hand, use metal-rod touch load.
3.7 Welding for load

Load must be connected with ground
If it must do welding to load, it must fix screw clamp of welding parts on the welding element to
avoid conduct of wire rope, superstructure and chassis.
Damage of heated control module.
Disconnect battery and positive and negative of cable, connect positive cable on the ground
for stopping.

4 Safety Device
4.1 Moment Limiter
Before lifting operation, the operator should read carefully the Users Guide of Moment
Limiter to know well how to operate;
Though the crane is equipped with the moment limiter, the driver is responsible for the
safe operation. Before operating, the driver should generally know the weight to be lifted
and the distance between the crane and the load to be lifted, and then with reference to
the Chart of Lifting Performance, determine whether the weight can be lifted or choose
the best lifting condition.
The moment limiter is an important safety device. It is forbidden to lift any load with the
moment limiter off.
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The crane is equipped with the overload release switch, viz. the forced switch on the
moment limiter of control panel. If the crane is overloaded, the switch should be used
carefully. For any damage due to the using of forced switch, the manufacturer and the
agency shall not bear any responsibility.


The improper setting of moment limiter may lead to serious truck damage or personal
safety accident.
4.2 Three-layer Overrelaxing Protector
When only three layers are left on the drum of wire rope, the three-layer overrelaxing
protector will be activated to avoid the hook descending; meanwhile, the overrelaxing
alarm lamp will flash. The alarm can be released by raising the hook.

4.3 System Master Switch
This safety device is intended to avoid false operation resulted from touching the control
handle by mistake.
The skilled operator can make use of the master switch to conduct lifting operation.





Danger
35

















H2Alarm lamp for low fuel S2Instrument light switch
H3Alarm lamp for hot water S3Engine's hold-up switch
H4Alarm lamp of oil return blockage S4Clearance lamp switch
H6Overwinding alarm lamp S5Working Lamp Switch
H73-ring protect alarm lamp S6Wiper Switch
H8auxiliary winch working alarm lamp S9Oil Cooler Switch
H9telescopic boom working alarm lamp S10Control switch
S11telescopic/auxiliary winch convert switch S12Overwinding Releasing Switch
S13check switch S14cylinder convert switch
S8 syringe switch S15high-speed winch switch
S16overload releasing switch S17freely sliding switch
S19horn switch
4.4 Alarming of the Hydraulic Oil Filter
When there is a blockage in the oil filter of the hydraulic system, the alarm will turn red.
Working must be stopped at that time and the filter core should be replaced with a new one.
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5 Safety in Power Utilization

The operator nearby power lines must work carefully, keeping a proper distance from
the power line, or else all the personnel on or nearby the truck crane may be involved
into fatal danger. When the high-voltage spark occurs, a funnel form area of high
voltage will be shaped under and around the machine. The voltage reduces along with
the deviation from the center. It is more dangerous to be more approaching! When a
person is striding over two areas of different voltages (step voltage), the current
resulted from electric potential difference will flow through the human body.

5.1 Countermeasures against Electric Shock of Crane
Dont get away from the superstructure operating room or undercarriage cab;
Warn other persons off the crane;
Give notice to the professional for power supply to cut off the power supply.
5.2 Preventive Measures against Blast of Storage Battery
Keep spark, open fire or flame away from the top of storage battery;
Check the charge of storage battery by using a voltmeter or gravimeter but never by
placing metal to connect the two terminal posts of storage battery;
Dont charge the frozen storage battery; or else blast may occur; warm the battery to 16
first before charging it;
If a storage battery explodes, the electrolyte, which is poisonous, may spatter into eyes,
resulting in blindness;
When checking the specific gravity of electrolyte, always wear goggles;
5.3 Proper Welding
The welding must be conducted properly to protect electronic control device and bearing
from damage. When welding on a machine or engine equipped with electronic control
devices, such steps should be followed:
Shut down the engine and turn its switch to Off position;
Danger
37
Dismount the negative cable of storage battery;
Attention: Dont take the electrical components (such as electronic control module or its
sensor) or the earthing points of them as the earthing point for electric welder;
Clamp the components to be welded with the ground clamps of welder and keep the
clamp near the welding point to ensure the current from ground wire to components will
not flow through any bearing, accordingly reducing the possible damage to such parts as
transmission bearing, hydraulic components, electrical components and other parts;
Keep the wire harness away from the chips or spatters produced from welding;
Conduct the welding in accordance with the standard welding procedures.