ZOOMLION ZCC1600HD (160t) CRAWLER CRANE

TECHNICAL SPECIFICATIONS

ZCC1600HD/27Y

Edition 1
 Zoomlion ZCC1600HD (160t) Crawler Crane

Technical Specifications
ZCC1600HD/27Y

1. Overall dimensions and major technical parameters ....................................................... 2

1.1. Overall dimensions of the crane ............................................................................................. 2

1.2. Major technical parameters ................................................................................................... 3

1.3. Illustrations of operating modes ............................................................................................ 4

2. Technical instructions............................................................................................................... 5

2.1. Power unit ............................................................................................................................... 5

2.2. Hydraulic system ..................................................................................................................... 5

2.3. Electrical system ...................................................................................................................... 5

2.4. Hoisting mechanism ................................................................................................................ 5

2.5. Derricking mechanism............................................................................................................. 6

2.6. Slewing mechanism ................................................................................................................. 6

2.7. Counterweight ......................................................................................................................... 7

2.8. Operator’s cab ......................................................................................................................... 7

2.9. Crawling mechanism ............................................................................................................... 7

2.10. Safety devices .......................................................................................................................... 8

2.11. Boom...................................................................................................................................... 10

2.12. Hook ....................................................................................................................................... 10

3. Working radius and lifting capacity charts........................................................................ 11

3.1. Operating mode S.................................................................................................................. 11

3.2. Lifting capacity charts (operating mode S) ........................................................................... 13

3.3. Lifting capacity charts (operating mode SH-1; main hook used; with tip boom on) .......... 14

3.4. Lifting capacity charts (operating mode SH-2; auxiliary hook used) ................................... 15

4. Dimensions of components in transport ........................................................................... 16

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1. Overall dimensions and major technical parameters

1.1. Overall dimensions of the crane

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1.2. Major technical parameters

Major technical parameters

Items Unit Values Notes

Max. lifting moment t×m 960
Max. lifting capacity t 160
Main boom length m 12～60
Single rope speed of H1 m/min 0～140 The 5th layer
Diameter of rope for H1 mm 26
Max. single rope tension of H1 t 13.5
Single rope speed of H2 (high-speed
m/min 0～91 The 3rd layer
lowering winch)
Diameter of rope for H2 mm 32
Max. single rope tension of H2 t 25
Single rope speed of derricking
m/min 0～78 The 5th layer
mechanism
Diameter of rope for derricking
mm 22
mechanism
Slewing speed rpm 0～2.2
Crawling speed km/h 0～1.85
Model WP12G430E300
Rated power / rotational speed kW/rpm 316/1900

Engine Max. output torque / rotational

Nm/rpm 2060/(1000～1400)
speed
CHINA III for non-road
Emission standard /
mobile machinery
Gradeability ％ 30
Average ground pressure of basic boom
MPa 0.11
operating mode
With A-frame and
Dimensions of basic machine in
mm 12460×3200×3280 main boom
transport L×W×H
tilting-back support
Weight of basic machine in transport t 37.4
Counterweight / central ballast t 57/20
Basic boom with
Dead weight of the crane t 154
main hook
Distance between two tracks × contact
mm 6000×7205×950
length of track × width of track pad
Note: The value of ground pressure is the mean value of the operating mode with the basic boom.
The actual maximum ground pressure is determined according to the actual operating mode.

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1.3. Illustrations of operating modes

Code Operating mode Boom combination

S Main boom 12m～60m
SH-1 Main boom + tip boom (primary hook) 12m～60m
SH-2 Main boom + tip boom (auxiliary hook) 12m～60m

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2. Technical instructions

2.1. Power unit

Weichai electronic-injection diesel engine: WP12G430E300

Rated power / rotational speed: 316kW/1900r/min

Maximum output torque / rotational speed:260Nm/1000~1400r/min

Emission standard: CHINA III for non-road mobile machinery

Volume of fuel oil tank: 700L (guarantee sufficient working hours)

2.2. Hydraulic system

Hydraulic pumps: main pumps are two open plunger pumps that are energy-saving, stable and

reliable and are used to drive winches and the crawling mechanism. The slewing pump is an open

plunger pump. Three gear pumps are used for auxiliary operations and heat dissipation of the

hydraulic system.

Control system: a pilot hydraulic proportional control system with a load feedback system; two

cross-shaped hydraulic joysticks and a dual foot-operated crawling control valve are used for

controlling different executive components.

Actuator: the hoisting winch motor is a variable plunger pump with large displacement, featuring

high speed and high stability.

Volume of hydraulic oil tank: 850L

2.3. Electrical system

DC of 24V, negative ground, two storage batteries of 200AH

Components of the electrical system: power supply, indicating lights, alarm, fan, wiper, load

moment limiter, illuminating system, video monitoring system, safety control system, etc. The

operator’s cab is equipped with an intelligent button panel. Data communication is realized through

CAN bus.

The crane is equipped with a global position system (GPS/GPRS).

2.4. Hoisting mechanism

The hoisting mechanism consists of two parts: the main hoisting mechanism and the secondary

hoisting mechanism (the one with the function of high-speed lowering)

The main hoisting winch is driven by an axial hydraulic variable-displacement piston motor

through a built-in planetary reducer. Braking of the spring on winch motor is controlled by the

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balancing valve. The drum with a double-rope groove guarantees that rope of multiple layers will not

intertwine together.

The secondary hoisting winch (H2) has the function of high-speed lowering, which enables fast

lowering of a load of 13t. It is also driven by an axial hydraulic variable-displacement piston motor

through a built-in planetary reducer.

H1 H2
th th
Rated single rope tension 13.5 (the 4 layer) 26t (the 4 layer)
Wire rope diameter 26mm 32mm
Wire rope length 355m 150m
th
Single rope speed 140m/min (the 5 layer) 91m/min (the 3rd layer)
Note: Rope length of the high-speed lowering winch (H2) can be customized
according to the needs of users. The maximum length shall not exceed 240m.

2.5. Derricking mechanism

The derricking winch is driven by an axial piston motor through a built-in planetary reducer and

brakes through the spring on the motor end.

The derricking mechanism is equipped with a ratchet pawl locking mechanism. Press the

derricking locking switch to unlock the ratchet pawl before operating the derricking winch in order to

avoid misoperation of the joystick and ensure the safety of the crane in the non-working condition.
Derricking mechanism
Rated single rope tension 99.5kN (the 2nd layer)
Wire rope diameter 22mm
Wire rope length 255m
Single rope speed 78m/min (the 5th layer)

2.6. Slewing mechanism

The slewing mechanism is composed of two hydraulic motors, two slewing reducers, control

valves and a slewing bearing. Small gear of the output shaft rotates around the slewing bearing ring

fixed on the chassis so that the slewing table makes slewing movement of 360°.

The slewing mechanism has the function of controllable free-slewing, which starts stably with

less impact.

The external gearing three-row roller-type slewing bearing provides stronger bearing capacity so

as to guarantee the stability and accuracy of slewing.

The slewing mechanism can be mechanically locked by the locking device at the front end of the

slewing table.

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2.7. Counterweight
The total weight of rear counterweight is 57t. Counterweight plates are piled up and locked by

chains. There are two types of counterweight plates: 4.8t×10 (48t in total). The counterweight base

weighs 9t.

The central ballast consists of two ballast plates of 10t (20t in total). There is a tool cabinet at the

central part of the central ballast, which is convenient for the storage of slings and maintenance tools.

2.8. Operator’s cab

The steel structure operator’s cab is 1250mm in width with tempered glasses around. It provides

broad visions. The roof and the front windows are laminated glasses. Sun shields, an adjustable seat,

wipers, a cold/warm air conditioner, various switches and a head lamp are also equipped in the cab.

The cab can be pitched up for 20°through the cab-pitching cylinder controlled by a switch in the

cab.

The cab is also equipped with a cold/warn air conditioner, a radio and a color display of 10.4’’.

Control levers and buttons are designed according to the ergonomics.

The cab can be rotated for 90°horizontally to reduce the transport width.

 Armrest boxes

Both armrest boxes are equipped with various kinds of electrical switches

 Control lever and joystick

Two cross-shaped pilot hydraulic joystick control H1, H2, slewing and derricking.

Crawling and steering are control by two levers.

Air conditioner

Air conditioner, optimized air flue and air vent are standard configurations.

2.9. Crawling mechanism

The crawling mechanism adopts dual motors and dual reducers. Crawling of the two tracks are

controlled by the two levers respectively. It is able to make such movements as crawling in a straight

line, unilateral steering, differential steering, pivot steering and crawling with a load with high

maneuverability and flexibility.

Crawling speed: 0~1.35 km/h

Gradeability: 30%

Tensioning of track: The track is tensioned by a jack, which is convenient and reliable.

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2.10. Safety devices

The crane is equipped with different types of safety and alarm devices, such as mechanical,

electronic and hydraulic devices, that guarantee the safety of the machine.

 Load moment limiter

It consists of a moment limiter and a digital LCD. If the lifting moment reaches 90% of the rated

moment, the warning light is on and the buzzer sends out an alarm. The crane operation can be cut

off automatically if the rated moment is reached, thus prevent an accident caused by overload and

guaranteeing the crane’s normal operation.

Data displayed on the LCD: 1, load moment ratio; 2, main boom angle; 3, main boom length; 4,

working radius; 5, actual load on the hook; 6, permissible lifting capacity; 7, the maximum permissible

height; 8, wind speed on boom head.

 Limit on hoisting height

Limit switch and limiting weight fixed on boom end are used to prevent excessive hoisting of the

hook. When the hook is hoisted to a certain height, the limit switch send out a signal and the electrical

system will automatically cut off the hoisting. Besides, the buzzer and the display in the operator’s

cab send out a sound-light alarm to avoid over-hoisting of the hook.

 Limit on main boom angle

When the main boom is derricked up to its maximum angle, the limit switch of the pivot section

will be activated, the upward derricking will be cut off, and a sound-light signal will be sent out from

the buzzer and the indicator light.

 Protective device for over-lowering of rope

The protective device will send out a signal and cut off the movement of lowering the hook when

there are only three circles of rope left on the drum. A sound-light signal will be also sent out from the

buzzer and the indicator light in the operator’s cab.

 Tilting-back support for boom

A tilting-back support, used to avoid backward tilting of the boom, is composed of nested steel

and spring.

 Slewing locking device

It is used to secure the superstructure and the undercarriage during transport. It must be

unlocked during operation.

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 ZCC1600HD/27Y

 Mousing on hook

A mousing is used to close off a hook to prevent a load from slipping off.

 Anemometer

With the electronic anemometer, real-time wind speed can be presented on the display.

 Electronic gradienter, mechanical gradienter

The electronic gradienter shows the levelness of the crane on the display, while the bubble-type

mechanical gradienter is fixed on the chassis frame.

 Aviation warning light

It is fixed on the top of the boom for warning in the upper air.

 Main boom angle indicator

Main boom angle indicator is fixed at the rear lower end of the pivot section. Operator is able to

see the elevation angle of the boom clearly from the operator’s cab.

 Rear-view mirror

One is located on the front left side of the cab and the other is on the handrail of the right hood.

 Automatic locking mechanism of ratchet wheel on the derricking winch

It is used to lock the derricking winch when the crane is stopped.

 Emergency stop button

Press this button to shut down the engine and cut off all movements in an emergency.

 Tri-color warning light

The warning light has three colors, red, yellow, and green. The loading condition of the crane can

be displayed simultaneously. Green indicates that the load rate is below 90%; yellow indicates that

the load rate ranges between 90% and 100%; red means that the load rate is beyond 100% and the

crane is overloaded.

 Slewing alarm

It gives out a sound-light alarm during slewing.

 Crawling alarm

It gives out a sound-light alarm during crawling.

 Monitoring system

Camera and video displayer are optional, through which the real-time working condition of the

hoisting winch and the blind area at the rear end of the crane can be monitored.

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2.11. Boom
 Main boom

Main boom length ranges between 12m and 60m. Components of a main boom are: a pivot

section of 6.5m, a boom head of 5.5m, intermediate sections of 3m, 6m and 9m, and a tip boom.
Pivot Intermediate Intermediate Intermediate Head
Main boom
section section of section of section of section
length (m)
(6.5m) 3m 6m 9m (5.5m)
12 1 0 0 0 1
15 1 1 0 0 1
18 1 2 0 0 1
21 1 1 1 0 1
24 1 2 1 0 1
27 1 1 2 0 1
30 1 1 1 1 1
33 1 2 1 1 1
36 1 1 2 1 1
39 1 1 1 2 1
42 1 2 1 2 1
45 1 1 2 2 1
48 1 1 1 3 1
51 1 2 1 3 1
54 1 1 2 3 1
57 1 1 1 4 1
60 1 2 1 4 1

2.12. Hook
Five types of hooks are available. Each hook has a mousing to prevent the load from slipping off.

Specification of Number of
Lifting capacity (Kg) Max. reeving
hook pulleys
160t 2377 7 14
100t 1935 5 10
80t 1713 3 6
50t 1355 2 4
25t 600 - 1

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3. Working radius and lifting capacity charts

3.1. Operating mode S

Curves of hoisting height (S/SH-1)

Unit: m

Hoisting height

Working radius

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Curves of hoisting height (SH-2)

Hoisting height

Working radius

Attention:
The main boom and the tip boom cannot work at the same time if a tip boom is fixed on.

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3.2. Lifting capacity charts (operating mode S)

Unit: t
Boom
12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
Radius
5 160 160 160
6 160 160 160 160 156
7 136 136 133 129 125 122 119 116
8 112 112 109 107 104 102 99.8 97.5 95.3 93.2
9 93.1 93.5 93.3 91.4 89.4 87.6 85.8 84 82.3 80.6 79 77.4 76.1
10 79.1 79.5 79.7 79.5 78 76.5 75.1 73.7 72.3 70.9 69.6 68.3 67.3 66 64.8
11 68.6 69 69.2 69.3 69.1 67.9 66.7 65.5 64.3 63.2 62.1 61 60.2 59.1 58 57 56
12 60.3 60.8 61.1 61.1 61.1 60.9 59.9 58.9 57.9 56.9 55.9 55 54.3 53.4 52.4 51.5 50.7
14 48.9 49.2 49.2 49.1 49.1 49 48.8 48 47.2 46.5 45.7 45.3 44.5 43.8 43 42.3
16 40.9 40.9 40.9 40.8 40.7 40.6 40.4 40.2 39.5 38.9 38.6 38 37.3 36.7 36.1
18 34.8 34.8 34.8 34.6 34.5 34.3 34.2 34 33.7 33.5 32.9 32.4 31.8 31.3
20 30.1 30.1 30.1 30 29.8 29.7 29.5 29.3 29.2 29.3 28.9 28.4 27.9 27.4
22 26.4 26.4 26.3 26.2 26 25.8 25.6 25.5 25.6 25.4 25.2 24.7 24.3
24 23.4 23.3 23.2 23 22.8 22.7 22.5 22.6 22.4 22.2 21.9 21.7
26 20.8 20.7 20.6 20.4 20.2 20 20.1 19.9 19.7 19.4 19.2
28 18.6 18.5 18.3 18.1 17.9 18 17.8 17.6 17.3 17.1
30 16.8 16.7 16.5 16.3 16.1 16.3 16 15.8 15.5 15.3
34 13.6 13.4 13.3 13.4 13.1 12.9 12.7 12.5
38 11.2 11 11.1 10.9 10.7 10.4 10.2
42 9.4 9.1 8.9 8.6 8.4
46 7.6 7.4 7.2 7
48 6.8 6.6 6.4
52 5.2
Reeving 13 13 13 13 13 10 10 9 8 8 7 7 6 6 5 5 5

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3.3. Lifting capacity charts (operating mode SH-1; main hook used; with tip boom on)
Unit: t
Boom
12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
Radius
5 160 160 160
6 160 160 160 158 154
7 134 134 131 128 124 121 118 115
8 111 111 108 105 103 101 98.5 96.3 94.1 92
9 91.3 91.8 91.8 89.9 88 86.2 84.4 82.7 81 79.4 77.8 76.2 74.7
10 77.3 77.7 78 78 76.5 75.1 73.7 72.3 70.9 69.6 68.3 67 65.7 64.5 63.3
11 66.7 67.2 67.5 67.6 67.5 66.4 65.2 64.1 62.9 61.8 60.7 59.6 58.6 57.5 56.5 55.5 54.5
12 58.4 59 59.3 59.4 59.3 59.3 58.4 57.4 56.4 55.5 54.5 53.6 52.7 51.8 50.9 50 49.1
14 47 47.4 47.4 47.4 47.4 47.3 47.2 46.5 45.7 45 44.3 43.5 42.8 42.1 41.4 40.7
16 39 39.1 39.1 39.1 39 38.8 38.7 38.6 38 37.4 36.8 36.2 35.6 35 34.4
18 33 33 33 32.9 32.8 32.6 32.5 32.3 32.1 31.6 31.1 30.6 30.1 29.5
20 28.3 28.3 28.3 28.2 28.1 28 27.8 27.6 27.4 27.2 27.1 26.6 26.1 25.6
22 24.6 24.6 24.5 24.4 24.3 24.1 23.9 23.7 23.5 23.3 23.2 22.9 22.4
24 21.6 21.5 21.4 21.3 21.1 20.9 20.7 20.5 20.3 20.1 19.9 19.7
26 19 18.9 18.8 18.6 18.4 18.3 18 17.8 17.7 17.4 17.2
28 16.8 16.7 16.5 16.3 16.2 16 15.8 15.6 15.3 15.1
30 15 14.9 14.7 14.6 14.4 14.2 14 13.8 13.5 13.3
34 11.8 11.7 11.5 11.3 11.1 10.9 10.7 10.4
38 9.4 9.3 9.1 8.8 8.7 8.4 8.2
42 7.3 7.1 6.9 6.6 6.4
46 5.6 5.4 5.2 4.9
48 4.7 4.5 4.3
52 3.1

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3.4. Lifting capacity charts (operating mode SH-2; auxiliary hook used)
Unit: t
Boom
12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
Radius
5 25 25 25
6 25 25 25 25 25
7 25 25 25 25 25 25 25 25
8 25 25 25 25 25 25 25 25 25 25
9 25 25 25 25 25 25 25 25 25 25 25 25 25
10 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
11 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
12 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
14 26 26 25 25 25 25 25 25 25 25 25 25 25 25 25 25
16 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
18 25 25 25 25 25 25 25 25 25 25 25 25 25 25
20 25 25 25 25 25 25 25 25 25 25 25 25 25 25
22 24.6 24.6 24.5 24.4 24.3 24.1 23.9 23.7 23.5 23.3 23.2 22.9 22.4
24 21.6 21.5 21.4 21.3 21.1 20.9 20.7 20.5 20.3 20.1 19.9 19.7
26 19 18.9 18.8 18.6 18.4 18.3 18 17.8 17.7 17.4 17.2
28 16.8 16.7 16.5 16.3 16.2 16 15.8 15.6 15.3 15.1
30 15 14.9 14.7 14.6 14.4 14.2 14 13.8 13.5 13.3
34 11.8 11.7 11.5 11.3 11.1 10.9 10.7 10.4
38 9.4 9.3 9.1 8.8 8.7 8.4 8.2
42 7.3 7.1 6.9 6.6 6.4
46 5.6 5.4 5.2 4.9
50 3.9 3.7
52 3.1
Reeving 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Attention: The limit of single rope tension is not considered for the lifting capacities in the above chart.

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4. Dimensions of components in transport

Basic machine 1 piece *
Length (L) 12460 mm
Width (W) 3200 mm
Height (H) 3340 mm
Weight 37400kg

With A-frame and main

boom tilting-back support

Crawler carrier assy. 2 pieces *

Length (L) 8260 mm
Width (W) 1375 mm
Height (H) 1320 mm
Weight 15330kg

Central ballast 2 pieces

Length (L) 4480 mm
Width (W) 1280 mm
Height (H) 580 mm
Weight 10000kg

Counterweight base 1 piece

Length (L) 5570 mm
Width (W) 1700 mm
Height (H) 468 mm
Weight 9320kg

Counterweight plate 1 10 pieces

Length (L) 1500 mm
Width (W) 1700 mm
Height (H) 560 mm
Weight 4800 kg

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Main boom pivot section 1 piece *

Length (L) 6707 mm
Width (W) 2263 mm
Height (H) 1800 mm
Weight 2190kg

Main boom head 1 piece

Length (L) 6090 mm
Width (W) 2120 mm
Height (H) 2520mm
Weight 2310kg

Main boom intermediate section of 3m 2 pieces *

Length (L) 3120 mm
Width (W) 2120 mm
Height (H) 2117mm
Weight 820kg

Main boom intermediate section of 6m 1 piece *

Length (L) 6120 mm
Width (W) 2120 mm
Height (H) 2117 mm
Weight 1340kg

Main boom intermediate section of 9m 4 pieces *

Length (L) 9120 mm
Width (W) 2120 mm
Height (H) 2117mm
Weight 2080kg

Tip boom 1 piece

Length (L) 1780 mm
Width (W) 970 mm
Height (H) 1040 mm

Weight 330 kg

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Hook for 160t 1 piece *

Length (L) 2180 mm
Width (W) 810mm
Height (H) 990 mm
Weight 2340 kg

Hook for 100t 1 piece *

Length (L) 1974 mm
Width (W) 810 mm
Height (H) 916 mm
Weight 1930 kg

Hook for 80t 1 piece *

Length (L) 1900 mm
Width (W) 810 mm
Height (H) 765 mm
Weight 1710 kg

Hook for 25t 1 piece *

Length (L) 1253mm
Width (W) 450mm
Height (H) 450mm
Weight 600kg

Notes:

1. Components are presented in diagrammatic drawings that are not drawn to scale. Length is a

boundary dimension.

2. Weight of packaging is not counted in the weight above, which might be different from the actual

weight due to manufacturing error.

3. There might be improvements made on components listed above, resulting modifications in

dimensions and weight. Actual products to be delivered shall prevail.

4. Numbers of components marked * are determined by the actual need.

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