Manual de Operacion y Servicios

8/13/2019 Manual de Operacion y Servicios

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STT2OOTOWER CRANE

II. OPERATION & SERVGE MANUAL

2410P164Fushun Yongmao Construetion [l,4ae hinery flo,, tid,


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STT2Oi) ]'OWER CIIANf, OPERATIONAND SERVICE NTANUAI,

Table of contents


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TO\IIR CF.T.\..E ERECTION ]\IA\IJA,

,t) T;5.006.455.00 I 5 0U

62 onr

40 3 60i. r r.t I f-l r- --.1

l. Characteristic parameterl0r

=E;1qE

.0000

0.00

R Fall R(c,"",) C(max)I ,n l4rql *5.0q I slo.oo I lc_s.oo ls.1q 9Llqlil l I r0J.oo I 5.r .oo ] iolq I 5.r

1o-oo lro.too ls(ro.oo I lo.

155

IV t6 5l r0.00II 3A.24 5.00ry 17.45 l0 00IT 3t.6650

5.00IV )7.67 I0.00II 32.35t?33.91{35.085.00

4S403530

,0.u0l 5.0010.00VIIEl

ff.-n

5.uU_r .9lJ5.00

-I{30 00l0l5.0010.005.00 J.o0 i5

uo l 5o


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TOWER CRANE ERECTTON ['IANUAL

3n1

,i",,ilsa r11""

rogelafs

,Fg-t9

O -"*a* "* t" service Reaction lorce oui ofservice ':;r'l

Mechanisms main characteristic parametersFreestanding height (withortr counterwand base bllast erghl)

M

0 - 57 m/min

(s

22

5.04.01.5

0 - 57 m^nin0 - 0.7 rpmo - 0.? lpt

45L[v25855t.Fv25

1090m>1090m*

5Rl-cv12.5 - 25 rn/min


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TOWI.]R CRANI OPER{TIO]AND SERVICtr I\IANUAL2. Safety rules

2.I The regulation of correct usell) It is forbidden to use the tower crane which has not passed the performance test;2) Acco.ding to the technical regulation and method of use, the crane must be used inits good condition. Pay more attention to the safety to prevent the dangerous

Eliminate all kinds ofmallunctions in time which may cause the safety accident;3) Operate the tower crane in specified scope oltemperahre: (_20.C_+40.C);4) Qremte d1e tower crane in specified limit of wind speed (the max. rvind speed for

opemting is 20m,/s, the max. wind speed out ofservice is 42mls);5) Obserue the regulation in operation manual and regulation related to serr,.ice and

maintenance.2.2 Safety measures1) The operator should read the operation rules before operating the to\\,er crane:2) The operator should always remember every safety measure and recognize the

hazard, meanwhile the operation rules should be visible;3) It\ forbidden lor the operator to be rvith Iong hair, wearing robe or wearingjeweiry;4) Often read the rvaming board about safety and prevcnting from hazard;5) lf the crane is in abnormal condition, stop oper.ation immediately and report it to

the interested personl6) It is forbidden 1o change or add any pa s of the cranc, unless the tower cranemanulacturer permitted;7) Service, lubricate and debug the tower crane according to the cyole specihed inoperation ll,]anual;

8) The crane operalor should know the position ol fire pr-oofing equiprnenl, a1]d graspthe method of using it.


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TO\ ER CRANE OPER{'IloN AND SlRVlCll I\IANU^L

l-r"r*nn*'"ctingandtheirqualif ications

I

II1

II

1) The tower crane mustsbe operated by qualihed person;

2) The crane operator must be trained There musl bea specific regulation about the

ability of driver' erectol' maintenance and sewice person;3) Crane operatols shoutd clari their responsibility' and make

them know thal they

shor'cl refuse all the orders which act against the safety;

4) The experience


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TOWf,R CRANE OPEIIA]]ON AND SERVICE IlIANIJAf,2) In servicea). The driver should operate the crane in the cabin;b). Test the motion ofeach mechanism with no load and low speed;c). It is forbidden to use any operating mode which may threaten the tower cranesafety;d). Before traveling, drive the jib to the center line ofthe track;e). It is ibrbidden to pass the load over the person when the crane is in service;0. It requires someone to guide when the load is out ofthe sight ofthe driver;g). It is forbidden to sling overload out ofthe specified radius;h). It is forbidden to sling heavy load when the load has not been hang tirmly;i). It is forbidden to canting pull the load;j). It is lorbidden to sling the load which has fixed to the ground;k). It is lorbidden to stop normal motion by emergency stop bulton; it only can beused in exceptional case which may threaten the safety;l), lt is lorbidden to use limiter and brake as an normal stop device;rn). It is forbidden to shoft-circuit, change and adjust the safety device, or obstruct itsnormal operation;n) when the max. wind speed is less than 20,r/s, the road should be iower than rm2/t.

Stop working ifthe wind speed reaches to 20mls;o) Make sure that there is no obstacle enters into jib slewing area after the tower.crane traveling;p) lfthe crane operation is in bad condition, stop immediately and send somebody torepair;q) Make sure that there is enough distance between the tower crane and ai.eleclricwire;


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FTOWERCRANE OPEI{ATTON AND Sf,RVICE MANUAL

3) After one daY's work:a). Lift the hook below the limit point'

meanwhile it is forbidden to leave any load onthe hook;

b). Drive the trolley close to the mast;c). Starting up the wealher-vane effect;d. Grip the clamp rail devices on the trackle). Cut off the power supply and

locked'2.5 Maintenance and fault clearance during the tower crane operation1) Debug, maintenance and check-up each pa ofthe crane according to the method

and cycle specified in operation manual; and replace some pafis and devicesaccording to the regulation;

2l If it needs to service and maintenancethe tower crane with powel'off' adopt

necessary measures to prevent false starting of the crane' First' lock the powersupply panel and take off the key' Second' hang warning plate on the panel;

3) If it needs to dismantle some safety devices during service and mintenance' afterthis. il should be assembled and readjusted'

2la

bcde

2

a

b

c


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2,6 Instruction for special dangerousl) When operating tower crane near the air line, there should be enough distancebetween the tower crane and air line.a). Once the tower cmne connected with the air line, the driver should stay in the cab,to prevent from getting an electric shock;

b). Drive the crane out ofdangerous zone at once;c). Noti the person around don,t close to the crane;d). Cut oflthe power supply which comected with the air line;e). Don't leave the tower crane unless you can confi.- that the erectric wire has been

cut off2) Maintenance of the electrical equipment only can bc cauied out by qualilied

electrician or trainee which is supervised by a qualified clectrician accordins tothe electrical rules.a) Thc tower crane must be cut olf the electricity during mainlenance and repaimeanwhile set up a waming plate of ,,manned operation, prohibit switch on,, onthe obvious position of power supply panel, then earlh or sho circuit the powerline (afler this, do please clismantle the eaflhing ancl short circuit line):b) The electdcal equiprnent of tower crane should be checked periodically. Ifdiscover some hidden clanger, such as connection loosen, elcctr.ical wire earlhing,component breakage, etc, it must be eliminated in time:c) Ifit [rust carry ou1 li'e-\yire work, tl.rere should [.e someone to r]ronitor. so that thernain powel supply can be cut olI.in emergency situation.

.I'O\YER CRTINE OI'T]R,{TION AND SERYTCtr r\IANI]A,


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TOWER CRANEOPERATION AND SERVTCE MANUAL

2.? IlYtlraulic sYstem"r. O.,r,n" *'*sional or experienced person

can operate the hydraulic systeul

b). Periodicallv check every kind of conduct tt'i.t"tl'-,lj- ::::ffi:;check up the oil leak and extemal mlfunction' if so' eliminate tleak maY oause damage and frre);

c). Release the component pressure according to the relevantregulations before

rePairing'd). tnstall the hydraulic pipe line correctly Do not conect

the high and low pressure

interfaces in reverse Meanrvhile' the joint length and qual of theflexible pipe

should meet the requiretnent:e). Hold the oil quantity and quality in the oil box'


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TOWTR CR,{NE OPERATION AND Sf, RYICE I\IANUAL

3. Operation


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TOWER CRANE OPERATION AND SERVICEMANUAL

Important notice: - . t . -, ]La i-"rqllation and;;ra debug must be made upon finishing the installationthe tower crane' The tower rane can only be

put into servicel*-*U o' lo*l safety authorities with the issuance of license'

erectionwhen it

o

i::::"#:iver must be e qualiried person who has trained bv authoritatiboard of labor or specified units and passed the exam'The driver must opelate' service and maintenance

the crane correctly' It is import

for reducing failure, improving device availability,avoiding loss of working time

prolonging service life of equipment'Incorect operating will resutt in damage of all electric motors'

reducers' dr

brakes and wire ropes' even the iniegral steel construcdonWhat is more' it

cause serious mechanical accident and result in personnelloss'

3.2 OPeration highlights1) The control panel is finishing equipment lt must be careful

when operating i

2) The control lever must be operated slowly whenstarting or stopping'

3) Change shift one by one' it is forbidden to eet over shlft ,--4) It is forbidden to disobey sequential operation when stoppi"g

to*" uttbt5) The control lever should tum to zero position gradua

when actuating

making reverse movement Operate until the mechanism completelystoppe

6) lt is forbidden to operate the crane which safety device has a failure'unso

or inaccurate' fuilhenore it is forbidden to pick off or sealed the safety,de^t'^ **edta


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TOWf,R CRANf, OPEMTIONAND Sf,RVICf, MANI'Af,forbidden to operate the crane with failure.

8) The driver is entitled to refuse the command which against the safty rules.9) The driver must master the moment curve, the max. load, the min. load (at the jib

end) and the load under hook in random radius.3.3 Operation instruction3.3.1 Startinga) Check the tower crane before everyday stading according to the instruction

regulation. Ifthere is any problem, repo it and it is not allowed to start anv more.b) Switch on the main power supply and press down the start button.c) Test the working condition of all mechanisms with no load and low speed, check

the limit devices of al1 mechanisms.d) Check that whether all safety devices are integrated and acting reliable.3.3.2 Operating the hoisting wincha) Confirm the lifting load radius according to the moment curve (or table).b) Estimate the weight of lifting load- Lift the load 1m high slowly in small radius.* Move the load forward slowly by changing radius oftrolley with low speed.* Stop forward movement when moving to the position of moment limiter.- Confirm rhe radius of rrolley stopping posirion.

&umate the weight of load according to moment characteristic diagram (table) andradius.

c) Use the min. lifting speed before the wire rope tightened up.d) u"" -"'- qrc lnln. loucr.in. .no,l \^ h^n t^,,,-"-., r^^r


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TOI{ER CRANE OPERATION AND SERVICE MANUAL

@ load raking off rhe ground) or be over

n l**rir"trtt is allowable in normal lifting' use the rated speed of rnotor instead ofmedium sPeed'

g) The speed u'as selected as per the weight of load Heavy loadselecte low speed

(PV) and light load selecte high speed (GV)'h) Stop moving before operating the stroke limiter'i) Don't Put the hook on ground'j) Loosen the wire rope slowly to avoid rope winding when placing

load'

3.3.3 Operating the slewing mechanisma) Select the slewing speed according to the shift to be reached'

b) Every time use the max' speed as long as theangle allowed'

c) If the slewing mechanism suddenlv changes its speed' t rn"l "":::l:- ,,;;;;" t-ing So acceleration and deceleradon operation mu$ be dograduallY.

d) It is forbidden to siop the jib by slewing brake' It should decelerate firs andth

release the control lever' so that the brake can brakein minor slewing speed'

e) The slewing brake can only be used in windy condition' which can keepjib in

position.f When s'lewing the iib, it is recommended to operate the

movement at the same time' to avoid distofling of theconvenieni for the rope swivel to work'

lifting or lo1{ewire roPe and

,- limiter stad to work'


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TO\YER CRANE OPERAT'ION AND SERVICE MANUA,3.3.4 Operating the trolleying wincha) The trolley speed is selected by the distance ofthe trolley.b) It must accelerate or decelerate gradually to avoid swing when suddenly changingthe shift oftrolley operation.c) Stop the trolley movement before operating the trolley limiter3.3.5 Operating the traveling mechanisma) The traveling speed is selected by the distance oftraveling.b) In order to ensure the tower crane safety, when it travels in the track, the trolley

must be at the jib foot; if operating in the track curve, beside keep the trolley in thejib foot, it must travel with low speed. Meanwhile it is forbidden to keep the jibfacing toward the inside ofcurve track.

c) Belore traveling to the end ofthe track, the tower crane operation must be stopped.d) There are two brakes in the traveling motot one of them used fbr buffering anddecelerating, the other used for stopping the cmne movement which via 6-gseconds time delay after powering off and automatically baked. After the controllever return to zero, the crane can still run a few meters, so this operation shouldbe done in advance.

e) Attention during crane traveling:* Wam people to leave the dangerous areas by hailer;* Observe that ifthere are sorre obstacles on the track:- It is forbidden to make the cable pileup or pull too tight.D wh"n tow.,".ane traveling, the jib *rust be in the centerline ofthe track.


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TO\NER CRANE OPERaT"'" nn' "'*uttu ttnnu*

I*u,,ont during operation].4 precautions ourru vr-- -- ^-^-- is: _20C-+40C, theThe \Yorking environmental temperature

of tower crane is: -2(

rnut. t*'ting ''nrl speed is 20m/s antl rvorking gratte is A4'3.4.1 Each time before operation ^-- i-.erfect condition'l, ,*. ** tn"t tne power supply' cables and switches are in pelfecb) Make sure that each pin' f'oft and split pin are in

normal condition' restrict the jib

sleu'ing fieely (release the weather-vaneeffect)'

c) Make sure that the counter-weight blocks and baseballasts are fixed hrmly'

d) Check the hoisting and trolleying wire ropes , 1^...i-a 'e1 Check the lubricating condition ofhoisting reducer

and slerving rtng'

0 Switch on the Power suPPlY'g) Test all mechanisms with no load and

checknecessary, readusted it'

h) If rhe rvorking height of towel crane is beyondinstalled ll the wind speed exceeds 20m/s' it canthen the tower crane must stop $'orking'

3.4.2 During operationa) Never Iifl load beyond the pern.ritted radius'blrever pull load in an oblique dilcction'c) When entering into the cabin' check that whether the extinguisher'

instruction plate

and warning Plate are in Placed) Chcck that \\'hether the haiiet' is in perfect condition'.-t. .,.,hich fixed on the ground'

each mechanism' brake and limiter' if

50m, an anemoscoPe must besent audible and visual alarm


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TOWER CRANf, OP]RATION AND Sf,RVICE MAN I IA I,J:-i Special notice: If hear some abnoflnal noise, stop operating the tower crane

immediately, and inform to the site supervisor; if the wind speed reaches to 20mls,and sent audible and visual alarm, it must stop working; ifthe load is out ofe sightof the driver, there must be someone as a guide; never cancel any safety device oradjust at random witout authorization.3.4.3 Each time after operationa) Lift the hook to the top endb) Drive the trolley to the jib foot, staf the weather-vane and brake device, to make

the jib slewing freely (weather-vane effect). If power off manual operate thisdevice. For traveling spe of tower crane, anchor the crane by 4 rail clampingdevices.

' lNote: The weather-vane effect, that is to say, above the upper slewing of the towercrane ca.n slew freely, it can reduce the windward area automdtically. Thus the,. crane driver must start the weather-vane effect after he is off duty.

I Tum off the main power supply switch and take the measures against rain.ss down the emergency stop button, and cut offthe power supply.

liii:


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TOWER CRANE OPERATION AND SERVICEMANUAL

3.4.4 Periotlical insPection3.4.4.l Electricity

-n"*:,"1'"ml::Xlifi illiltJfiI'ff ::t'Xffi LH"; i"'r't4"'"u 1o:;;;,*-'*r't"**r,::H',i:ililJJrt:,:"1,condition. and connectlng wlrerlur

lnspection item After eachefection

Check the rax value oftower crane supply voltage

sr.""r tt ut *h"thffi :ffi i[T.*l.--'------'-.'--**.*"*-:""11'::lrt::X:'":,::'*'*o

Check the earth resistance of tower crane

Check the insulation resismnce of electric equipment

Check the insulation resistance of otoritch contact inCheck the contact coffi of sw

been tightened uP


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TOWER CIIANE OPERATION:1ND SI]RYICE ] TA'UAL3.-1.1..:. achinery

Inspection item

Metalstructure

Mechanicalparls

Check the worn out ofwearing plate Trolleying winchTraveling mechanismHoisting winchSlewing mechanismCheck the oil level ofreducer Trolleying winchfraveling mechanisrr

Check the hook, hook pin and clamping plateAdjust the tensile force oftrolley wire rope

Check the wire rope and jointCheck that whether the swing pulley is in periectcondition

chcck that whether the prcr enr ru isl hook atfrxing point othoo[ "rIr'i, p.ri..i JYrii,t',\ 'lccr( lhe autornalic locking der ice in 2,4 lall ordoublc lrolley loc[ing device

+l-iv],,

-

ViVast vefticality and levelnessVisual inspection ofgear ring boltTighten up of slewing gear ring bolt

_ -Vi,sual inspection rhe fishplare connecron on',Tlllo-T3^r, ,1,9: counrerjib and fixing plare onbase plate, iir"t'uoing piri.iptit pil;;?ffii:Detect the crack ofsection steel and check theweld jointAdjust and check thebrake with max. load

Traveling mechanism

Hoisting winchSlewing mechanismTrolleying winchHoistins winchSlewing mechanism

Cable drun.rIlydraulic push rod

Othes


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TOWER CRAN OPERAIION AND SERVICE MANUAL

3.4.4 3 SafetY devices

Inspection item

Load limiter

After eacherection

Moment limiterHoisting limiterSlewing limiter

TrolleYing limiterTraveling limiter

Prevent roPe broken devicesPrevent shaft broken devices


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.I'OWI]R C&{NT OPI,]RA]'IO\ AND Sf,RVICI IIIANUAf ,3.4.4.4 Lubrication

Inspeclion item CycleAfter eacherection One month

Hoistingwinch

SlewingimechanismIIl

LlTroJleyingI winchIl

guide pulley ofhoisting wire ropebearing or axle box ofhoisting drum

lubricate the grooved clutch geart all thrust bearing ofprevent twist_- qri"" lor hoisting hook

hoisting wire ropethe prevent twisr device of wire ropefor iib endslewing ring

extemal gear ring vbearing of drumtrolley guide pulley

wlre ropeThe tensioner or tension spring ofthewire rope

hook assem b1yTraveling

mechanismgear ring on driving bogie wheelrollel support ofdriven bogie and. nrotorball eear ring lor track curr c device

I Cable drumfsc---l---.devi.,I Hre";i-iL prvot joint _iL Track J

bearing ofdrumpin. spring. inion. prevenr ropebroken device

cabin cloor, tumed-doorwhecl rirr.r side olthe bogie


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IOWER CRANE' OPERATION AND SERVICENTANUAL

3'5 OPeration;a;';*-' *"el lavout and opertins

method

There are lefi control panel unO 'igl't "ont'ot panelon both side of the seat (they are

also catled ioYstick) fthe ioystick. (See Figure oflever operating)t here is a control lever in the cente u' "'- -'catrin

tsHl

TrolleY inHoistingLocking Posilio11

Co-nirol console for hoisting side RiqhtI Let Controt consote

tor siewing sioei DAvr l, , _oRG-, ii ot

ILD_:i..I i _-^,'.- il.iLH

XRFSivgr) lo)I

,o*"*,,

RG : Slewing leltrvards RD Slewing right\ardsTra{elling fo(wards: ( Traveling tYPe )

DAV : Trolley outTrarelling ba':k

TAR : ( Travelling tDARLH

TAVI,D.x : Lo$e ng ,.\1r^'iinP Dosition li

I -.. lr ',l


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TOWER CRANE OPERATIONAND SRVCE ]TIANUALON THE LEFT CONTROL PANEL:

1). Parallel connection button SII. Graphical symbol , ryith functions asfollorvs:The button is used in the special case such as telescoping, changing iall, and so on.when move the trolley to the jib foot or raise the hook to limited position, the limitedswitch cut ofl Press the button SH so as to continue moving the trolley to the jib rootof the crane tower or making the hoist hook to a highest position until finishing the

functions as follows:In the windy working circumstance and the speed of the wind is under 20mls, it,snecessary to hoist a load in fixed point. As the button w.as pressed, apply the slewingbake, which made jib fixed in place well and truly. But the plgmise is to stop the iib

Th"control lever can switch in various directions as shown in Fig.2_3_1. The trolleymoves ahead DVA as push the lever ahead, in reverse, DAR . There are three shiftsrespectively for moving forwards and backwads the jib slew to the left RG as pushthe lever towards left RD. In reverse. The lever can be pushed at random towards leftor dght without limit of shift. The bigger the turning angle of the lever. is, the fastere speed of slewing will be. The lever can also pushed in oblique direction (to becontolled in the form of x) which drive both the trolleying and slewing operate in 2diection at the same tire.

aforementioned job.2) Slewin lrake lockin

Thee ^.-, ..__ -' roctrn* tnechanisrn and zero protective devices lor preventing the lever


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TOWER CRANE OPERATONAND SERVICE MANUAL

-* "r*rls"t* rn"*-l""" which is likely to run mechanisms and resulaccidents. The power supply cannot be started if the lever is not in neutral (zeposition. Take hold of the lever as shown in figure and press locking pin up whnger, then push the lever' Before pressing Iocking pin' it was strictly forbiddepush the lever lest parts was destroyed'The levers on both the left control panel and the right control panel have the funcof auto-reset (returning zero)'THE RIGHT CONTROL PANEL IS EQUIPPED WITH:Power supply button (also horn button') symbol ; warning light VOIbreak button (emergency button) O' To begin with' tum the emergency buttotherighttillitwassprungout.ThenpresstheporversupplyStartbutton.Theposupply of the towet crane was stafied (main contactor P of electrical control paStartwork)whilethehomhootingandwaminglrghtshining.Whenpressthebreabutton (the emergency button) O' the power supply is hrmed off (main contactoelectrical control panel A is released)' The break button cannot reset (1umautomatically.Ifrequired,turnittotherightuntilitspringsupbyitself'PIeSSbutton to cut off current when the crane is out of service or to meet the emrequirement such as the contactor attaching mechanism is out of control oreurergency requiring current break'As shown on the panel, the lever can be pushed in accordance * '" inst*X", that is the lever can not be pushed in oblique direction' Push the lever foto lower the hook.lwhen the lever is nushed to the left or to the right (TAV TAR)' the travelling


25/148

to

A

TOWf,R CRANN OPER,{TIONAND SERVICE ] IANUA,olthe crane is effected. But for the anchorage or climbing crane, there is no such kindofcontrol lever installed. And no control circuit is set on the panel.(2) . Precautions during the operationl) Obserue the safety operation regulations strictly during the operation. The

operation which might influence the safety of the crane is absolutely forbidden.For example, raise a load buried in the ground; slings (rope clamps) are not in linewith relative requirement or is damaged; the load is not bundled or colligaredfirmly; raise a load in oblique direction or operating after drinking; and so on.

2) During all mechanisms operation, it was forbidden to use lower shift for a longtime (not exceed 10 seconds according to the regulation), the shifts should beinueased or reduced gradually, the time between two shifts should not less than1-1.5 seconds. During lifting operation switch tleqrently between shift 4 adshift 5 is not permitl.ed lest the parl will be destroyed. It is impodant thal nufturegood operating habit. When move the trolley, do your best to switch from shift 1to shift 2 then shift 3 and in the slewing operation the contlol of the lever isrequired to be handled harmoniously.In any case: It is absolutely forbidden to operate in reverse direction (makereturn) suddenly or to press brake button forcibly during the running of thejib.

3) Set the tower crane in the state of weather vane whenever tl.ris shift,s operation isfinished.

4) Duing rhe operation, provicled that the crane falls into the trouble, please call onservice man o[ the rnender in 1i o Tt ic f^rhi1. i^ /r1r^rqi rhe crap r.,irh


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TO1{EB CBANE OPEBATION AND Sf,RVICEMANUAL

-'"::::':,*,.::::":

;:::":::J;J;''"'-* sDMo' tro,ev re'lrucer RDMO'overroad

limiter SLCIIPY hoist speed limiter SLCIIGV)'it is absolute forbidden to

moalify their a'Iiustments' which is adjusted wellanl truly during their initial

installation and calibration'5) Lubricate your crane during operation in accordance

with relevant regulaiions

(SEE CIIAPTER ' '"U 'o"'"t RULES OF TIIECRANE)' Pav special

afiendon to the lubdcation and wom state ofthe steelwire ropes (SEE CIIAPTER

I1B, CODE FOR INSTALLATION' EXAMINATION ANDDISCARD OF

STEEL WIRE ROPE FOR CRANE)(3). OPeration of weather vane

(unlock the slewing brake) rq_rs which situate in tht)wt,"ntt,'"ctaneisoutofsewice,plessthebuftonfolls 2s,w

side of electrical control panel IIF (inside the operators cabin)'the indicator lam

of weather vane lights up' ^ ,r+tt iqtime,t,, ;:,;'l,: l::;-;;; ,*", 'v means of the break bufton o At this time'slewing brake is unlocked (in released state)' At last'

cut off the main pow

suPPlY of the crane'3) Unlock the slewing brake

mechanism) 'manually (in release state) (see chapter 7B slew


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TOWf,R CRANE OPERATION AND SDRVICE MANUAL

4. Power supply and schematic diagram

4.1 Power supply.. ........._...............48-z4.1.1 Power supply ........................48_z4. 2 Lightning protection and earthing Earthing.......................................4B_44. 3 Power supply capacity and supply voltage requirement ...................48_64. 4 How to see electrical schematic diagrams......................................... 48_64. 5 Electrical schematic diagram symbol................................................48-7

l.:,4. 6 Electrical schematic diagram figure ................................................48-10


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.TO\YER CRANI] OPER'TIIONAND ERVICE NTANUAL

4.1 Po\ler suPPlY4.1.1 Pott"t tupPlYInstall the eleclrical equipment of tower crane according to the national

standard

requitement ST series to\\'er orane meet the relevant regulationsin design and

manufacture. the management regulation of power supply use on iobsiteand the

requiretrents of TN-S three-phase five-wire system or TT three-phase four-wires.vstem power supply The jobsite porver supply must meet the national

construction

department requirements' the po\\'er supply use requirement "third classdistribution

and two class protection" The iblloiDg system diagram is for your reference:

Jib site3U0V 50t{Z mainelectdcal or TT 1\-Sor TT^ k^\TN.S

pael

Branchsitcl'tho\

Note:1) Both the branch electrical control panel

air swiiches and leakage ptoteciors'and branch switch box are equipped wi

2) The operaLing parameter of leakage protector in branch switch box: {3OmA3) The user can select the installation method of TN-S or TT according to the

loca

supply network acltninistralive regulations'4) All the devices beiore A box (i[cluding cable) should be prepared by user'


29/148

TOWER CRANE OPf,RTIONAND SERYICE MANUALConnection mode ofpower supply entering into A box3

TN-S TTtower crane must be earthed properl no matter which mode of power

Ll L2 L3 PEN Ll L2 L3 PE


30/148

TOWER CRANE OPER{'TION AND ERVICEMANUAL

]Q;-gn'ni'eP'otectionandearthins;"..:"'",::-:":,::::::ilIiJ.::.,'..*iX',:lXil-:protection shall be taken into'n,*n". .o*oon"nts and personnel' he above special condition with lightning rotloqoipping the crane :t":,1:-1* recommended aiming at protection' or takeor surge suppressor " "t:-:'";;n according to the actual conilition'

necessar) measures "tt*Y:*.:l:.;"" .rr, ""t,n"t t"clude a fuse nor the coreAttentiotr: The earth conducttof a switch or a cable'There are three tyPes of eafihing:

A. The earth substanceeither use


31/148

TOWf,R CRANE oPERATIoNAA,D sERvicE bIANUALIn above earthing methods, the copper conductor ,""0o, "o-rr[--ilubstance should be more than 25mm2. ffthe soil conduction is poor, buried sodiumchloride (salt) in the soil and pour some water. For traveling type oftower crale, each section of rails must be electrical cormected, and the two rails must be electricalconnected. The earth esistance is less than 4.


32/148

TOWERCRANE OPERATION AND SERVTCE MANUAL

rhe requirement power voltage ' tl ::::'":)"1."1.r" ,r,, power voltasefhe requirement power Yurlo- -,ard; s0fl7,l60*T,,3g0v+5%. This power voltagecEr38 and china National standard: t':"1 : ^-::;" the tower crane. If the realJJ;;" ,"*rinal voltage of Panel A during operatins the tower;"-"r';"""=' ', ,"-- t:^",:i;: ::::" :; :::':H: :i::::til;should be insPected and adjusta xiSLChGV

Cicuit-breake (C*,..lransformer)LMOSLD

;".:: ru9ue switch(lor\er_r9sI9 -)Hook Limjt "h ,Flefre" f91 ion) In*r -U.it -l*rc,r,"JLanlem_--.----Liitswircfi GIeh Fo o\.el&dtil@L S\df.. M* i""d f"-doadlimite)SLChPVosition)

odrery Checking elayRejay (dow"\ Lfa ---_:--C(ltunfo.lloifokrhke..-StpplyCrllccforhvE dmorff ,ssor'=-Electic Cotactor for lo* *.d _rrrrolorLPV

Relay (up)l LPVlr*t

--''a.Y llnd shifr )-=--Relay (Jrd shirRebv r.

LRaGV Lontactor(for high speerl motor,ssralo-I)Resistrncc con tor (eri",s, .",-rr.rr4.) I

l,Ra2i +.-l ' \ 'ur snrft) lcsislance coDtaclor (enelgy consutnerrake)----=- ) LRa


34/148

'TOWER CRANE OPER-$ION AND SERVICE TTANUAL

DecriPtionrtactor for Iow sPeed motor's stalo

DescriptionRelay (4th shift)lRelay (5th shift)

-

Supply Cotactor (do*fl)

SymbolCo

SYbolxL41 LRaPV El""t i" "ontu"to. for high sPeeI,GVxL5 I*t*o, fo, high sPeed motor'stator

Resistance contactol for first sectionLGVlLD

Supply Contactor (uP) T,1LHHoist Relay (Parallel) t,2 esistance Contactol

for seconSH

Resistance Contactor for third sectioControl tansformer

ln"]l|,"n T1*".* --\Hoisting low sp"ed motor

lTiming resistance of electric moto

JTiming esistance for brake motorJControl transforme

Relay for short-circuited resistanceRelay for short-circited resistancelHoistine brake

L3CXL2TSLCXL3

LMGVLFsResistance I,MPVRf1, Rf)lesistance (pressre sellsitive)Control tansformerAutotansfomerAnemoscoPe looP\_-

Ilfrolley forward switch

R1-R23GF 1--F6TSl

TS2TS3Protectio switchReductio Trolley backward Switc

lReduction trotlcy forward switch

FADiRXDAISDAV

I(olley backward switchIrolley limit SwitchSupply mntactor for Iow speed trolleySupply contactor for low sPeedIt.ollev

RXDAVSDArReduction switch for fixed diusRDMOSMSwitch for fixed load vadable radiSDMODMV Y'

XDArPanel sNitch for trolle}r torwar"I* ro. r,o,,"r oud*'oPanel s$'itch fot niddle Ered rol{

DMVlDFa Contactor for trclley brakeDAV Suf'ply contaclor for Itolle) I XDp\


35/148

TOWER CRANE OPERATIONAND Sf,RVICE MANUAL

DescriptionPanel switch fo high speed rolleyDpV Suppl Conacror lor middle peed Relay for middle speed trolleyContactor for trolley blowerTrolley brake

JrolleJ moror DveM Motor for trolley blower1'rolley circuit beaker fo main.Gtclrcuit Motor fo telescopingRelay for rveather vane Button for weather vane effectRelay for weather vane 1 RFaSupply contactor for dghl siewing T Tcminal stipSilicon conlolled rectifi er Supply contactor for left slewingSlewing brake Temperature controiElecbo-magnetic loop for ueadr vate Brake lor slerving bow waveSignal light of rveather vane Motor for slewing blowerButton for sleq, baking RM ] Slerving motorSwitch for ieft slcwing Slewing potentiometerSwitch for right slewing Main circuit brcaker.for slewing

DAr contactor for

Brake for troile,borv rvave

Sl mbol DescriptionSLrpplyback*ard

DRaDMDDi

trolley

DGV elr\ ror ]ltsh speed trolley

Contactor for slerg brakeRD


36/148

OWER CRANE OPER'{IION NNDSERVTCE NTNNAL

4.6 Electricalschematic iliagram figure (See table 4'6-1)

liansfo nerBrake DC excitation winding

Table 4.6-1

Delay action N/O con

DescriPtionFigure lI DescriPtion Terminal striP (HF Panel)Termrnal striP (HF Panel)

Terminal striP (D Box)Terminal striP (L

Panel) V1 \ ElectricHornTerminal striP (R Box)Ovedoad Auto-break switcring off button (Emergenc'v ibulion swit"] ------ 1 Por ,er switch(Stroke switcPush-button s\\itch

Push-button switch,r*ri-"**""u,ornosuitchLLinkage switchThlee Phase squinel cage

asynchronous motor ResistaoceThree Phases rvind rotorasynchrglq1llgqDelaY action

N/C conta

Bow uave brake rryindinB DelaYaction N/O co


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TOWER CR]{Ntr OPERATION AND SERVICE MNLIAI,

DescriptionCoil for relay contactor Delay action N/C contact

Coil ofa slowreJeasing relayCoil ofa slow operating relay Anemoscope

Thermo-sensitive resistancePotentiometer

Main contacts of conactor RectiSing diode3 phase Autotransformer Thyristor(silicon controlled

Crossing junction Crossing without electrical

Pressure-sensitive resistance


38/148

TOWER CBANE OPEBATION AND SERYICE MANUAL

4,7 Wiring tliagram of cableThe consumer can install the cable according to this electrical schematic

diagram

\\\

Fig' 4'7-1Wiring diagram of cable for stationary type of tower crane


39/148

TOWER CII{NE OPER{TTONAND SERVICE MANUA,

,. Rruo " L o^ 1Dl2i rli'L qiilii

ltltk lrr

fig.4.7-2Wiring diagram of walk cable


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.TOWER CRANE OPE'RATION AND SERVICE TTANUAL

/1 Notice: )h can protect the cable, the diameter is 5mm' keeprr,3rrtailu gutt ani"d wire rope whi d j

> ^j,o+ leL> _q

bIZi,

tuEtshEi{p EE'2F

+EE.EiiPEBB


57/148

TOWER CRANE OPf,RATIONAI\'D SERI{CE MANUAL

7. Slewing mechanism (RTC)

7.1 Explanation of symbols................ -.-.-.........-......--..78-27.2 Composition of slewing mechanism and its working principle..........7B-27.3 RIC controller princip1e............... .........................7B-47.4 RIC slewing mechanism operating and troubleshooting...................7B-57.5 Slewingbrake. .........................78-77.5.1 Manual brak release.................. ........................78-77.5.2 Electric starhrp ofweathervane..... .... ...:............7B-8

.5.3 Maintenance and service of slewing brake ......................................7B-9


58/148

OWER CRAN' OPT]RATION A D SERVICEMANUAL

?.1 ExPlanation of sYmbols

Explanation: ^rrdance with the displacement required Accelerchoose the slerving speed in accoroa""" - ,- "-^- tt e iib by iorce via slewor decelerate the slewing speed gradually

Don't stop the iib by

brake, it must decelerate ti"t' "l then stop the slewing movementThe sle

brake is only used to position;" t; '"'hoisting when the windspeed is less

13m/s. If the slewing and n",.,-* *,a* are carried out atthe same time' it

pre\ enl the u ire rope from disLoning'

tj1


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The slewing mechanism is composed of torque motor and planetary reduction gear(see Fig.7.2-1). It adopts electronic variable voltage control system. Throughadjusting the torque motor stator power voltage, the eddy_cunent brake andeddy-current, the speed can be adjusted. The slewing driving system is composed of

TOWER CRANE OPf,RATION AND SERVICE MANUAL7,2 Composition of slewing mechanism and its working principle

of the eddy-current brake produces magnetic field in thethe armature when the excited coil was supplied with direct current. .lhe: incises the magnetic field so as to form potential field and the current (thatwent) is obtained. Because of the mutual action of magnetic field ofand electromagnet, produce brake moment that is directly proporlionalcurent and rotate speed of the armature. Through the frequency control

torque motor, which adopts two sets of eddy-current brakes and one set ofweathervane brakes, and planetary reduction gear. Weathervane brake can bebrake and released automatically or manually. Electromagnetic brake is released. when power on, while brake when power off When power on, the slewing brake is, {ways released. During operation, ifnecessary adopt the slewing brake to protect theirane against action of wind, under the condition of wind speed is ress than l3m/sslewing movement stops completery. At the end of each shift, make themagnetic brake work automatically or manually so that the tower craneinto the state ofweathervane effect.

ieddy-cu[ent brake armature of the motor rotates with the shaft. theair gap 61

-current braking, it can fulfill the stepless speed regulation perfectly.


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TOWER CRAN OPERATIONAND SERVICE IIIANUAL

7.4 RTC slelving mechanism operating and troubleshooting7.4.1 Notice for oPerating RTC7.4.1.i In the control loop' the slewing mechanism adopts special slewing

contro(electronic block)' which ensure that speed un or down s1bl1.:::::'n*'* o*oand s'hich prevent the crane liom emergency stop and reversion suddenly dumispla,r'. Thus it is very inpofiant that the slewing conffoller (electronic bloconrroi panel, potentiometer, power supply of erectronic block and alr parconnection ale cor-rect and

reliable'7.4.1.2 Maintenance and service the slerving mechanism in regular' Refore the fais eiiminated, it is forbidden to continue operate ii Otherwise' it may serious dethe transmission pafis and structures' even result in serious accidents7.4.2 Malfunction diagnosis and maintenance methotl of RTC ln::i:'l:ll"LT]:l:::"ffi;'; l'',,*' *"'"' irthe srewing doesn't work in ncondition, it should cut off the po'u"t t'pply first and then check the folloaspects:7,4.2.| Thetower. clane can only oPelate in single direction, aftef Stop a pertime, another direction can t''nnil.'g' uft"' a period time running' it can only oby single direction again ll this to"ndnton ot"u''"d' stop immediately and cutpower supply to check that wl]ethel two lines conr.recting between control panclectric contl'ol panel, potentiometer centre tap and earthing grip is well Therelay contact ot slerving control bloch

didn't connect well'.7.4.2.2 Theslewing speed in or.re direction is fast than the other direction;closed the slewing air breaker RDi' the slewing mechanism rotate towardirection, It Should cut off th" ,'*", .,0,,, imnrediately and c}rgck at]rhepotentiometer open wire ot open ci'cuit I, addition' lt tuvh ofut *'i,"*Measuletheresistanceofcentletaparrdslidingendbymultimeter|n,|should be \vithin 0.-50 ) , othelwise it should readjusl the zero pospotentiometer. :.-- ;^n.'lino In this condition' it shou


61/148

TOWf,R CRANE OPERATIONAND SERVICE MA^-UALon and check the motor three phase of voltage whethe loss of phase; thrce phasevoltage rvhether balance. In normal condition, the degree ofunbalance for three phase

to,

of.

voltage shouldn,t be more than 3%. Namely, the voltage of three phase output linecan't exceed l5V Ifthe declination is too high, please replace the slewing controller7.4.2.1 The sleu,ing system staft up fast and stop slowly. Check the exciting voltage ofRRa eddy-cunent, it should about 20V direct current in stop state. If the voltage is toolow, check that rvhether the altemaring voltage (4gV) ofthyristor module is too iow, if ithas no voltage, cut offthe porver supply and check the connecting line ofthis part; checkthat whether the thyristor modure damaged again, the inspection method is as follows:1) The resistance between gate G and negative pole Ksh ouid be 7-100 O.2) The resistance infinitely great between the positivepole A and negative pole K.Ifall above have no problem, please replace the slewing controller.7.4.2.5 After tIe control handle back to zeo, there is a contactor (RD or RG) stillpower on. It should power off and check the zero position of potentiometer pull outthe insertion piece belween controller and mother boad of thyristor Measure theesistance between potentiometer earthing end and sliding end by multimeter, if theresistance is infinitely great, replace the potentiometer.

r^.. ut crdrsrr ll've no voltage output. it.s the problem of controller. When all the above check is in, ]llal condition, check that whether the contacror RD or A1 end of RG have 48V

? 4'2.6 The clockwise and anticlockrvise contactor (RD or RG) no athacting. Fit.st,check that whether the cormection wire roosen or broken; next check that whether the)lltc *a of potentiometer Rp has r di rect voltage (when the handle operate), if

GK

of

tlc

ls

volho" ,._ .,olr:-' lut, ,h. operate handle condition and farther check the controller have 4gV") rr all the above check is in normal condition, please replace the slerving'' rne slewing controller and thyristor both bur out and blackening. Check thelar first, then checi( that *h"th", th" por"", supply voltage is too high. lf all theI ch.^r- .- "' ls ln normal condirion. please clrech the sleu ing conLrollcr.


62/148

To\{ER CRANE oPERATIoN AND sERvlcE M:)17.5 Slewing brake,ar'***t ot*" release (See Eig 7 5-1)7.s. r. l srart the we*:**: l-"],;.r (l ), i.e. movement A.al. Lift the manual brake release I;, ;:.;;;,"-." ,,) ""* ":::;";::;:."'.t:" -,"st on the clip(3), then-' '"t"^"" th" mut'ai brake rek"''

,1"* t.', *" t"cked by the cltn (3)'pin the clip 'sm oan rotate ft

d). The weathervane effect accomplished and the siewing mechantZ.S.t.Z n"t"u'" tt'" weather vane devicea). Lift the manual brake release lever (t)' i'e movement

A'Jr. *"c** O' "t"oted out under the spring foroe (4)'ll' o"'"""" *" *"'*"]*-*]|". ll)'tn" *"*'n"nould be standstill'd). The weathervane effect accontl'"""-- - j


63/148

TOWER CRANE OPRAT'IONAND SERVICE MANUAI,7.5.1 .3 Working principJe1. bake cgaged

2. brake released

Note: "E,, is the clearance of brake, which value must benecessary adj ust it.7.5,2 Electric staftup ofweather yaxel:r::*.,it is an electromagneric brake, which is engaged as soon as rhe cur.entut oft t has its own and independent power supply.L brake engaged

2. brake eleased

kept between 0.8- l.2nim. if


64/148

TOWERCRANE OPERATTON AND SETVICEIIANUAT'

'7 .5 .)' ^^^';"" of slewing brakcM aintenance anu >EL"''-

Note: it mustn't have any foreign bodles in thebraf(es (such as cement' sand' grea

ctc.)7.5.3.1 Unscheduled maintenanceThe maintenance should be caied out under the following

conditions:

a). lnsufflcient braking moment which is causedby worn and damage ofbrake p

b). fhe indicator light is out ofwork'7.5.3.2 Scheduled maintenancea). Maintenance the slerving br ake every 200 hou or

each month'

b). Check the clearance and brake torque as well as thewear conrlition of te

pad, teplace them ifnecessary .^.,^L o".ement, sandc). Check that thee are no loreign boclies in the brahes

(such as ce


65/148

TOWER CRANE OFERAIION AND SERVICE MANUAI,7.6 R box wiring diagram

R

L terminal board of slewing center teminal box (R box)

t tIF23 25

47.48,49,46


66/148

progressive grease Iubricating systemI . Intoduction ofprogressive (pRG) grease lubricating systemProgressive grease lubricating system consists of lubrication pump,progressive oil distributoq pipeline accessories and control unit. Whensystem supplies oir, a series ofpistons ofprogressive oir distribufor woulddo differential reciprocating motion in a certain order The oilsuccessively escapes at the indmainry depends ",,n. r,",", l"lill ::t: il:: ::"r,:::::::.T:distributor. The scope ofgrease used for system is NLGI 000-2#, workingpressure is l -300Mpa, dispiaceris r50r. 1-200 rubricutrng #:':::';:':il'::rT::::.::;distributor can be connected to three stages at most-The system can be equipped with oil indicator rod and blockage alarm soas to monitor the oil supply situation of each outlet. In case that thesystem is blocked or a certain outlet cannot supply oil, the indicator rodwill stop motion, and the alarm will emit the waming signal immediately.The motion of indicator rod alrthrough the controller. so can calry out timing and counting

According to the structure, progressive oil distributor can be divided intowo types, integration type and sliand different slice composition,"t" ''o" By choosing different structurecarry out periodica, *o,rr-",.,,"i] "j,;:,ffi:,*apprication canFeatures;1. Accurate oiling capacity;2' Regionalization performance: operation and monitoring onindividual region;


67/148

3 . SimPle malfixrctioninspeotion ;

4 Testing the malfrmction point easily;5. Repa and replace oil distributor easily'[ . Lubrication PumP1. ComPosition:

1. Motor grease pump4. Oii PiPe joint7. Tee oil-distributing block10. Motor

2. Size-changed joint block 3' Oil pipe rp8x15. Bipyramid femrle 6 Radial pressure gauge

S.Greas e filter 9' Progressive distributo

Fig' 1 Schematic of grease lubricating system2. Working PrinciPleFirst connect the outlet joint of manual grease pump shown

in:l:' 2the inlet of electric" ,'""" ';;;;;'it u"' '' rill the erease lntocontainer of electr'""t r'""t" 0*'O' *t t':,,*tl"-*^"i.lr -::'-#pump is 2L; when system supplles ,r unnrlantiFrcationall and eriodicall toe ro ressiveoildistributo


68/148

the control of controller. A series of pistons in the distributor would dodifferential reciprocating motion in a certin orde and the oilsuccessively escapes at the individual outlets. The oil capacity suppliedmainly depends on the piston stroke and section area of progressivedistributor' For working piece of double outlets, be sure not to let anyoutlet be blocked so as not to affect nomal working, otherwise thedistributor will be damaged.

i- t1. -,., ., ,,-1-.., t- -;-,. )l i

3. Operation ofauto lubricating deviceRefer to the drawing, Low switch (oir lever switch) with the function ofavoiding the device to be damaged when thee is no oil in oil drum (asFig.4), it is connected to the normal closed point ofoil drum switch (Note:no oil is the closed point, with oil is the open point).Refer to the drawing, S switch with the function of avoiding the device tobe damaged when mallinction occurs on distributor, it is connected to ahicroswitch on the distributor (as lig.5), connected to the nomal oponpoint ofthis switch, viz. on the black and yellow line.

Fig .2 Manual greasc pump Fig.3 Schematic of electrical grease lubrication


69/148

-Oil level s\ "LrL

I

le indicator

I

titrltl I 'i-. ' itallig.5: Disfibutor

Fig 4: Oil dru'

when the oil capacitv in the :1' -::":'**,i1tl"llT" "j""1 ";the limit switch controlling oil "^t:'::, :,;;;king and the buzzercontrollcr' the auto lubricating 5)5tcrrr s'r' -" Iwill alarm simulianeouslv' at e moment :" :t:-:::-" lubricatrnglr*.*lo *"' tne grease' and then restad the oPemtlon'If the auto lubricating system rvorks normally' each outlet on

distributor

will supply oil in order' the cycle switch (S) will give ofl signalafter

completing one oil supplY cycle lf there are any faults in the system'such as leakage, ",o, ., ou,,,o o,*n, making any motion time

of c}cleswitch (S) delayed to tht "on"oll"' preset alarm time (5 mins)'

the auto

lubricating syslem will uoo *tl"'** "O"r the control of controller' andthe buzzer will give "fi "*'t"'*"it"'"ously' at the moment cut

off the

auto lubricating system to inspecl the lubricating pump'


70/148

4. Mechanical performance parameter

Ml2x1.s


71/148

Ill SM-AC ControLler1 . GeneralsN4-AC is a multi-purpose :"":ffi::,:jtt:::["]::J'rl"";\r,hich can be used to controlthror'rgh simPle Pro gramming'rhis controller pos se sse s ":.,ilil t", *'[T;::: T:::T;ensure rhe accurate oil *"'. ":;r';;ition due to its high protectivealmost all kinds o[ rouph indu'grade, excelient antlvibration and anti-interference

performance'

2. Panel and keY boardA . Wiring of inner terminal

St'1-AC

^, rar R A0 A1 A2' 12 3 4 u " 'l.Terminalt.:eo*.,inptltlphaSeline.nostrictrequllellt(1,.'.zero line)'2. Terminal 3,4: Load input (pump motor or solenoid

valve etc )'

3. ltrminal 5,6: Low level signal input (The switch is closed,the

corrtroller nill give offalarrn)' :^ )4. Terminal 7,8: collnect r'vith pressure switch (NO) at

rloo( "'connect with cyclc switch (No or NC) at mode 3


72/148

5. Terminal A0, A1, A2: Output terminal of fault alarm relay.AO-Almeans Normal Close, A0_A2 means Normal Open, can beconnected with alamr or mainframe controller.

There are one 4-digit display and 3 LED lights on t}re panel.,The digitalscreen can display operation mode and program. 3 LED .lights indicaterespectively: power supply (Green), pump running @ed) and low levelalarm (Yellow).C. Key boardi

S Funct ion setting and program review.R Data store, reset and run.


73/148

TOWER CRANE OPf,RATIONAND Sf,RVICf, MANUAL8. Ilottey winch (DTC)

8. I Explanation of syrnbols

Locked rotor torqueEddy-current speed regulationVariable voltage speeJcontotTrolley winch

speed should be selected in accordance with the holley distance. It isto acceleration or deceleration gradually.


74/148

TO\ ERCRANE OPER'\TION AND ERVICE IIANUAL

8.3. Trolley bake (see fig' 7-3-1)Descriptioni It is an electromagnetic brake' which is braked when

switched off lt hasindePendent Poer suPPlY'8.3.1. \\roing principle oftrolley brake

9

1. Exciting coil4. Moving atmature7. Brahe lining2. SPling5. Fliction disk8. Screrv

3. Release nut6. Brake disk9. Protective cover

rig.8.3-lBraking: when the exciting coil switching off, the elecffomagnelic atract

disappears, lhe brake spring (2) pushes the lriction disc (5)' then the brakedisc

entets inlo hrakc statc ,,",cBr.akc rcre.se: whcn curlent enter.ing into thc exciting coil, the armature

ls at"rvhich drives the liicrion disc (5)' co*.rptess tlle spLing (2)' "nd m'L" the

b:":.c.terirs. inlo rereasing statc. fhe brake is rcady fol next brake when the

1""


75/148

TOWER CMNE OPEMTION A\TI SERVICE MANUALClearance adjustment: Remove the protective cover (9) ana _.._ (r)*r""" *disc by screw, until it lean ag;nst the cove ofthe latch. Move the disc again, and

locked it in the 3.d. At this time, the cleaace is 0.g to l.2mmbrake moment adjustment: It is already adjusted in the manufactuer.Manual brake release: Tighten the release nut (3). Do not forget to unscrew the nutwhen restarting..3.2. Maintenance

Every 200 hours or every one month once.check the cleaance and brake momeng as wefl as the wom condition ofthe brakeisc, replace it if necessary.

't replace the brake until it wom out completely.that whether there is some foreign substance in the brake (such as cement,

grease, etc).


76/148

rro\vER CRANE oPERAlloN AND st)Rvlct', NIA

relaY and contactor oftrolle

oa r0t\ a a

- ,,, iLoo r . t,=' i- o ':-'- ?-C O RD-, Ri51\ -,...oo

>Yl:; Iotlcllxlli .n.\'O t ... ::,i', r'i'.r,.i?-r j i::/, oo oo- - , t., I 't --aaa '- -:r --' \ ^i-i ioiOol ioioio o io, i r i -,r-,.-.r.-.r til rl 1"", lts r Irili'7 ' --^" ^' e K""P form"r uttracting sute. Attracting when Power on

Release when Power down

o


77/148

I

I

j_ ____.ir,

l:l


78/148

..-=l =J*lI

I

I

o


79/148


80/148

POWER TRAVELING PANEL ELECTRIC LAYOUT

14_XJPhasesequenceDotecor

I5.DI

aiswitchlo-xP 1I.RE

Cabledrumcotactor

26-Tfu1


81/148

-t-

f---t_-,-\-:_i- t ----\- l| | ral =t.J. ______-i

" i-3,


82/148

?'?9-.-6 I


83/148

'lr'liil"i; HI

I

I

iFiIl4I,l

I

3i 5 : Ia*l = " -6gs a :.-lt-L-:J al ts 9aali --.1=l

n- EC 3= = ll r l= =< a E gB.-A = llrt--l E Al9-a?-{ E=+\l .lJ:

EI.J:/:_____j1-- f=I lAEs=__ 5

j

I.. l[s

I - ---x / r-rr.rrrr - - / e alel -l )' ja_\ -,.3_I I EtI I pt l?--l?t--'r


84/148

.-1-?

II

iL-l>-ta_=r1l E sa '-: =l:]:-la

:E


85/148

furucalLrsrameTSFUp, psdF _ Transformer 94_l2

XLIJ. XLD,'XL.l1. XL5. xr:. xrq.CXL2. CXL3Conn.ol relavrcv, rpvl. r .l ciJo.lll. LR. I R"l. I Rap\ LnirL1. L2, L:l AC contacto

CXL3

Bcaker

Middle relav

fime Aelay rilav cover

6t--.--15 iTerminal strip - ,r--- )l__l4-7--l- ,'

xI_2.SH.CXL

LFaL onnect CXI l .Connect XL2. Xii XL4. Tirne de la relayconneer sH. in"pv.-ini_ & lRar. L:. r lConnect LpVCCtLPVI. LD, iV,EH. AuxiliaryLGV]. LHBSL , BSL 1 Tonperutra" alay

rlf


86/148

=lE=*

L--Q:;; i = I'e,-------*q Ti - --

=k_--


87/148

-l-


88/148

tc

I-o6Iu-

t-t- ; **-a4alrt-=;i-rLJIl i lj illl -i i*-rv--\1-ry


89/148

==R==t++q

I

Il

' .,?f_--+,\-/\eJ..-^-sJ4l


90/148

I.{YOUT oF SLEWING/TRoLLEYTS1Transforme TS2

Transfome Red2Diodetvcl***I LisI *oLr

[]

MTCSilicon conto1ledrecifier

rsrunjrsrutlooiCircuil-brealCircuit-brealCircu;t_reaker Ir., lr..RDAC contactor

t:RC

Auxilia4

I I'/I,KSocket

IIF,DRKSocket

RedDiode

DAr DMVl DPV DMV DPV IControlrelay

DCVControlrelay

RDMControlrelay

DDiCircuit-brea

XRGjI XRGi2Controlrelay

I xnurI XRa2Controlrelay

I Rr"I

SDConroirelay

DFaCont.olrelay

DRVControlrelay

SDMConrrolrelay

RDiCircuitbre

kerAr,iliury Auxiliary Au\iliary Auxiliary Au\ilialy

XRT)

Conlrolrelay

XRG

Controlrelay

I RedFUCircuit-brea

ke

RedFUl

Circuitbreaker

FaDi

Circui brea


91/148

ELECTzuC PARTS L IST OF SLEWING/TROLLEYSymbol .--TSl Name a31II2I

ra.)rs3 TransformeT;;=:-Red. Red2RDi----GD-.-

DDifSFLTP .j"dFlrp-


92/148

CDODD6I6


93/148

u-OD(Y)CDoICJ

b-g2o

r.-o6r =U-E={il| E--F


94/148

TOWER CRANE OPEMTION AND StrRVICE MANUAL

9. .Hydraulic system

9.5 The common failures and troubleshooting................... .....-...........-...-..gI._7


95/148

TOWER CRANI] OPERA]TIONAND Sf,RVICE NIANUAL

l" n*urrn system ol ST series tower crane is con.tposed of: lrydraulic purrtelescoping cylinder' joining hose and so on'

9.1 Composition of hydrautic pump stationIt nrainl-v nrakes up of oil box' lter' motor'pressure liniting valve and pressure gauge'

oil pump, combination reversal vaiv

11

23

891011t-13

PLrrnp outline diagratn

Outline dlarvirg of Lclescoping cylinder

1. Molor2. Illectromagnetic siarter3. Combination revelsal valv4. Name Piate5. Oil box6. Temperature gauge for liq7. Oil outlct8. Lifting Point9. Hldraulic air cleanel10. High Pressure lluid con11. Low Pressre fluid conn12. Pressure relief valve13. Pressure gauge

:I

6:

4


96/148

TOWER CRNE oPERATI0N AJ{D SERVICE MANUAL

9.2 Basic technical parameter

N46 antiwea hydraulic oil or 40 thickened oilVolume of oil box

Mofor powerSafetJ ylye settirg pressureworking pressure for tetescopitg

Max. working pressure for loweringBaLrnce valve pressur.e

Oil pump capacityCylinder inner diameler O 180 mm

Piston rcd diameterMx. telescoping force

Telescoping speedReturn speed Adjustable in safe range

Cylitrder trvelprcsure hoe West Germany stadad 4D-13-60

Pressure hose ssemblv


97/148

TOWER CRANE OPERATION AND ERVICE MANUAL

9.3 Working PrinciPleDrive the oil pu[rp by coupling after motor starting up The oil pump makes the ofrom oil box to telescoping cylinder via the filter' combination reversal valve anhigh pressure hose assembly' The setting pressure between the oil pump ancombination reversal valve is 44MPa' the telescoping overflow valve of thcombination valve is 40Mpa, the lowering overflow valve is 6 5Mpa and the balanvalve is 2.5Mpa before leaving factory'

high Pressure hose assembl)combindtion re{erir \ arle

pressure gaugc l{' ' I reliefvalveP

10\lP

hl draulic air cleaner e\tra high pressure val 'e \ relescoPig cYlinderoilbox

rnolor

Hydraulic principle of telescoping system


98/148

TOWER CRANE OPEMTIONAND SERVTCE IITANUAL

the oilandand

of thebalance

lah power supplyl SBh SBz

r l\,M-a

Electrical principle of pumpThe combination eversal valve in the middle position H, the opening p and openingT are joined togetheq the hydraulic oil ofthe oil pump outputted went back to the oilbox, the hydraulic system is in oft,load condition at this moment.Combination revesal valve is in the left position of figure (when lifting the lever ofcolnbination reversal valve), the hydraulic oil ofoil pump outputted come into the bigchamber via the combination reversM rhe hydrauric rock. open,r. rr::;:::': :::"T" ::j,:j" ;,.:lfcylinder move downward; the hydraulio oil ofthe small chamber flow back to theil box via the hydraulic rock, high pressu.e hose assembry and combination reversalalve B and I the telescopins cvlGp.od.,'",,. ^"* ''''"'"''"" .ylinder start to telescope. The telescoping speed\- ,,, tc rlow ol oilpurnp.


99/148

TOWER CRANE OPERAIION AND SERVIC[ f dNUAI'ffiposition of hgure (when press down theCornbination rer ersal valve ls tnlerer of combination

revesal valve)' the hydraulic oil of oil pump outputted comeinto the small chamber via the combination reversal valve P and B' the high pressurehose assembl-v and the hydraulic lock Open the hydraulic lock at the saure time

and

make the pisto' of cyrinder move upward; the hydraulic oil of the small chamberflow back to the oil box via the hydraulic lock' high pressure hose assembly

and

combinatiou revesal valve Fl and T' the telescoping cylinder start tolower' The lowet

speed depends on the throttle valve of cylinder'

9.4 OPerating and maintenance9.4.1 Coffect connect the main power supply ol motor' Make the motor rotate

anticlockwise OPen the cover of hyclraulic air filter and fill up the clean andappointed hydraulic oil Connect the hydraulic telescoping system pipelincaccording to the hydraulic system diagram and screw up the joinl: test run andchcck that whether the h'vdrar'rlic pump is in normal condition The cylinder rraybeioggirg at beginning' tuln lelt the ailbleed screw via air bleed hole of cylinder

and

spun some oil Operate it several times' if it didn'L jogging any more' tighten upthc ailblced screrv tightwarcl; check the pressure oftelescoping overflow valve (theoverflorv varve is 40Mpa betbre reaving factory, it no needs to adrust. If necessao'it can be ad.iusted and the ovelllow valve for lorvering is 6 5Mpa)' namely obselvethe pressure $'hen the cylindel cxtends completely and retract completely Aflerrlrc ebor e rr ot k. it can hc l'trtt ing into serr ice'


100/148

TO\YER CRANI OPERATION AND SIiRVfCE ]UANUALthe

and

and

and

and

andup

(th

$f

9.4.2 Although the oil box has o" --...................."........................................-en filled up with oil, sore "r*;;;;;ylinder when it stft rp, .o it need to add some hydrauric oir until it eaches to theupper rimit of level gauge check the creanliness ofhydraulic oil every six monthor after 2000 hours,running. According to the specific circumstances, it can bechecked in advance. Ifthe oil is milkiness, freezing and dirt, it must be replaced. Inorde to protect the seal ring of cylinder, wipe the dirry bodies on piston rod. Thehydraulic pump should be covered weil with plastic materiai after work with thepulpose to protect the oil quality and prolong the selice life.9.4.3 Check that whether the oil is curdle ifit didn,t work for a long time. Operate thehydraulic system every two or three months with no load, which will protect thepump, valve and cylinder.9.4.4 If the oil is milkiness, freezing and dirt, it must be replaced. The cylinder mustbe cleaned when replacing the oil and checked that some place have rusted. It so.get rid ofthe rust first, then add the new oil.9.4.5 Check the oil qualiry belore everyday work. lr musr be mainrenanceperiodically.

A X "".,".tJethrottle valve with load. otherwise it may occur


101/148

TOWER CRANE OPERAIION AND SERVICE MANUAL

9,5 Th" "ollnoo fuilures and troubleshooting1) The cvlinder shakes heavilv when it lowering' even

caut::"::::*:*t"-**l* ,* 'r*t'"ent of throttle valve for oil retum circuit is unsuitable'Troubleshooting: Adjust the thottle valve according to the operation

manual' until i

reaches to the optimum condition' If the opening posidon of throttle valve didnalign with the screw thread' it can not be adjusted'2) The joint sleeve damagedReason:Themanufacturingprocessofsleevewasn,tensured.Troubleshooting: Replace the joint or weld' i e weld the nut and direct connectiocompletely' (At this time' the joint can't adjust the direction of oil

pipe)'

3) The cylinder continually falling downReason: Two chambers of e cylinder have residual gas left;

not well sealed; or

hydraulic oil wasn't clear'Troubleshooting:Eliminatethegasofthecylinder;ensurethesealand check valve; often check the oil cleanliness and ensure the oilthecontrolvalveofhydraulicpumpmustbeaccuratelyadjusted.

of control Pisbox well sea

The high and low pressure interface of hylraulic telescoping syscannot be overturned; it is forbidtlen to adjust the throttle valveload;itmustbecarefultoa.ljustthehighpressurethrottlevalve.


102/148

TOWER CRANE oPERATIoNAND sERvIcE MAIUA

10. Safety devices


103/148

1 0. 1 IntroductionThe safe devices of tower crane are important devices to ensure

the safety ofpersand equiPment'Among the safe devices' the moment limiter ard the load limiter

set a limit fortower crane so as to protect it against overtuming and the wire rope fiom

breakingAfter the safety devices are set' don't modi their adjustments The purpose

of etimit switch to timit the motion range of each mechanism'O. If the top of tower craneexceeds30m,itisnecessarytofitredobstacleindica

lights, which remain current feed even the tower crane stopped'O. If the pivot joint height of jib foot exceeds 50m' it.is ""::::i""::

anemoscoPe, which ."rr-d o,rt *u*i'g to stop operation when wind speed exmax. limit of working sPeed'

@. Readjust the every safety device after divert tothe new field '


104/148

TOWER CIIANE OPERATION AND SERVICE ,ft{UAL10.2 Hoisting limit switch10.2.1 PurposeHoisting limit switch is a device to avoid any possible error operation.a). To stop the hoisting-up motion as soon as the pulley block c


105/148

rr{

i

TO\tER CRAN ] OPI]RA'I'ION AND SERVICL }'IANf]AL

10.2 3 AdjustmentsAfter the torver crane reaches

to the predetermined height:Adjustmenis must be carried out with no load Control the hoisting or loweringmotion ard operate microswitch lW and 4W manually so as to detennine themicros'itch hich cuts oll the control molion (Note: If changing the height or fallof 1o\\'e1. crane, it is necessary ro adjust the hoisting limit switch for hoisting anlo\\erirg. )

-'.r, iF

3W2W

172Z4l3T2f1T

,2 1Z4Z 2Z


106/148

"rrO

Adjusfing p"o"...,

1W4Z

I l) D i.u.r"rb,-ng the housing tz) r oo,.n nut r ]rl;" ;,:":t'*'"r check and screw up 2 scews F.3) Adjus ting the h";;,;;,::" "ompretervLower rhe hook ."_, ,;; r;;, ,.

irch ror rouerins (Sr D),spihdle Iz .r, ,r,r,. .rr",a Adjusr rhe rimier ar rhe sloou uoo. before reaching ,o ,n" , o"ot"r"n. "orr".oororr*l;" , fi"::;"took eaches . *. o";;; ;;;:"*' I -2m distance. rt is rorbidden to make rheha. o, ,"u., . ,--, - .. -' ",u rre pu{pose to prevent the rope unwinriio r.^* .,

Adjusing spiudleIvficroswitch

t_| ::a ---:.-4z- - =- E

id At l.u.t , ,"r;,";;;" ;.trte

pu{pose to prevent the rope unwinding rrom thes at the lorvest posiion). *'trdings should remain on the drum (when the hool


107/148

TOWER CRANE OPERATION AND SERVTCE I1ANUAL

f "- *;*"mit switch forhoisting (SLH)

Hoist the hook up with 2-fall or 4-fa'll' until the distanceb":::::::"::::::r:t:"]-::^:;. oa*"p*u* o' and rotate cam 4r" check the hoisting conol'

until it depresses the coresponding contact 4W andthe hoisting motion stopped'

5) Scre up nut E' otherrvise it will make the memory disorder'6) Operare the hoisting u'inch and rvotk several times with no load Checkthat

whether the memory position is right lfnot' adjust it asthe above process'

7) If the position is right' screw up nut E' install the housing'8) Afte the operalion of l'inch' check the position of memory conol' so

as t'

correct it in the Proper time'"6**"''"*'st the hoisting lirnit s'itch after each erection

and changing fails


108/148

ToWf,R CMNE OPERATIONAID SERVICE MANIAL10.3 slewing limit switch10.3.1 Purpose:This device is used on the tower crane which hasn,t have slip ring. Its function focuson avoiding cable twist and damage. It,s equipped with slewing limite, and allowsthe max slewing circle is three.I 0.3.2 Working principle:Limiter has reducing device with pinion driving. pinion joggle with slewing ringdirectly. When slewing, limiter reducing device bring protruding block slewing. Anding block controls breaker (iggle switch). So the slewing can be stopped by

Fig 10.3 -l


109/148

TO\YER CRANtr OPERATTON ANT' SERVICE J\IANtNTL

10.3'3 AdjustnentsAdjustments must be carried ou1 with noslerving and opetate mict'oswitch 1W andmi.r osr'iLcll rr hich e uis olf >ler'r ing rnotion '

Control thc right slewing ot'manually so as to determine

load.4W

1iftthe

fi,4Z

3W2W

1Z2Z3Z41 423T2l1T

t lL

blc for atljusling sPindting spindle ltL It1,2 I37,

tiYe taidius

ComparirI

and micros*itch --1I Mlcros'r'itch -- ]| ,'l --llc, cam antCm1'l2T3T


110/148

TOWER CR-{NE OPf,lL{TIONAND SERVICE MANUALAdjusting process:

,' -1 17/ ,._ r,._,ii il:r)r,i42

1) D isassembling the housing of limiter, check and screw up 2 screws o.2) Loosen nut E and make it loose completely.3)Adjusting the right slewing limit switch 1br lou,ering ( SRD )Slew the jib make the cable not twist, sle.right for. half rotation ,and then adjustspindle 1Z and rotate cam I T until press relevant microsq,itch to lw, stop slewinr .4)Adjusting the deceleration limit su,itch tbr lifl slerving ( SRG )Slew right for half rotation, and adjust spindle 42 and rotate cam 4.1_, inspect o1.hoisting until press releyant microsrvitch to,lW,stop slerr,,ing.5) Screrv up nut E, otherwise it rviil make the memory disorder6) Operate the slerving winch and rvork several times with no load. Check thatwhether the memory position is right. If.not, adjust it as the above process.?) If the position is right, screw up nut lr, install the housing.8) After the operation of winch, check the position of memory control, so as tot, ,, ,n the proper time.]Ql rv"t" : Everyday adjust the crane all above before in service, when thectane diYcrt to other lieltl must [re pultr out plug of limiter lower and drain awayoholtg condensation water. Beflagai. ore the crane cut to the plug must be plugging


111/148

TOWT,RCR{NE OPf,BATION AND SERVICE T^NUAI'

f O,+ f.ott"Y limit switch10.4.1 PurPose:Trolley liritel can prevent liom operation mistake' And make the trolley

and jib foothave a safet' distance to running'10.4.2 Working Principle:Thete is a teducing device in trolley limiter; it joggles wifh the teeth

ring which is

fixed on the drum b"v a pinion Reducing device brings the protruding blockslewing'

And the protrr-rding block contrors breaker (iggre switch). so cut off therelevant

movlng.

.,i1,.. irll


112/148

I'OWI]R CRANE OI'I'IL4TION AND ERVICE MANUAI,I0,1.3 Adjustments :

is

q u-\,iji

2W1T

Cornparative table f


113/148

TOWERCRANE OPERATION AND SERYICE MANUAL

Adiusting Proces

4W-/--..a/ -- 1'\ l-/ lrr) I\,.' *-/ /4z^.-1:Y--223Z

1Z

3T

223ZT

2r-|f1) Disassembling the housing of limiter' check and screw up 2 screws F'2) Loosen nut E and make it loose completely'3) Adjusting the toliey limit switch for out (RDAV)

The trolley is apart from 1 5m for the top arm of buffe adjust spindle 22 anrotate cam 2T so as to depress the corresponding oontact 2W'

4) Adjusting the trolley limit switch for out' (SDAV)The trolley is apart from about 20cm for the top of buffer ' adjust spindle 12 anrotate cam lT so as to depless the coresponding contact lw, stop trolley and sto

3W2W

adjust for cam 2T.5) Adjusting the trolley limit switch for entad' (RDAR)

admit to the trolley for arm root, adjust spindle 32 and rotate camdepress the corresponding contact 3W'

6) Adjusting the trolley limit switch stop for entad' (SDAR)Admit to the trolley for arm root, adjust sPindle 4Z and rofale cam 4T so adepress the corresponding contact 4W, stop trolley

3T so as


114/148

TOWERCRAT OPEIL{I,ION AT{D SER\'ICE MANTJIAL7) Scew up nut E, otherwise it will make the memory disorder-8) Operate the trolley winch and work several mes with no load. Check that whetherthe memory position is right. Ifnot, adjust it as the above process.9) Ifthe position is right, screw up nut E, install the housing.10) After the operation of winch, check the posion of memory control, so as tocorrect it in the proper time.

Note : Everyday must be to adjust crane before in service.


115/148

TOWER CRANE OPERATION AND SERVICE MANUAL

10.5 Monent limiter

l.

Fig 10.5-1

:::'jff:[, rotate the bolt (2) ,ntil it touches the contact (3)' then closwitch contact. Lock the nut (1) after exact adiustments'


116/148

TO\yER CRA\-E OPERATIONAND SERVCE M^NUAL10.5.1 Purpose'Ihe tower crane is calculated and designed according to constant rIt is forbidden to exceed the max. load moment. The -o_"rra ,rr.lll load moment.inspect the hoisting and f"ll";i;g motion with rated ,oad.o ur,ottt"'is a device tocranefr.omovertuming.ruauUi1topleventthetower1 0.5-2 Working principleThe moment limiter, rvhich is located on the main member at the counter-jib foot, is:r,"1:.:"d of a pair of elastic plate, three micro_inching limit switches as well asnstallation suppoft. adjustable screw, housing und ,o on. When hoisting with load,the elastic prate began distorting (the distance between the two p-l-ates became sma,er)due to the action of load moment. If the load exceeds rated value, the adjustablescrew on one elastic plate depresses the switch contact which located on the otherelastic plate so as to cut offthe control circuit and stop the mechanism motion.10.5.3 Adjustments:-:, Specialsuggestion:Confirm the rated load moment of tower crane beibre adjusting the moment limiter,then debug the relevant data.

l

C

Lisht load Overload

fbel. Elastic plate4.Monrent housing

(i'ixed radius, variable load)(Fixed load, variable radius)(Variable radius, deceleration)

3. Adjustable screw

SLMOSDMORDMO

Ct)

i

2. Limit switch5. Ins tallalion suppolt

Fig. 10.5-J


117/148

TOWtrR CRANE OPERATIONAND SERVICE TfANUAL

Table 10 5-11. Adjusting the hoisting moment limiter SLMO1). l)rive the trolley to the jib nose and lift the speciedload X vith rated speed in 2 falls according to thejib

legth (ad.just device A)2). Lowcr the load. then lift a load of Y=X+X l0% wjth

the lowest spee


118/148

'I'OWER CR{NI] OPER TION AND SE]iVICf] ]IIANUAL10.6 Load limiter MSWLI 0.6.1 PurposeThe stuctue and hoisting winch of the tower cr.ane are calculated and designed inaccordance u,ith maximum load. It is fobidden that the wol*ing load exceeds themax. load. The load limiter MSWL is a safeq, device to prevent the towel. crane fton.roverload.I 0.6.2 Wbrking principleWhen passing though the proving ring pulley of hoisting wire rope, the ropeproduces tension due to the action of load. The tension was transmitted to the provingring (9) ich coLnects with the pulley. As the load changes, the proving ring beginsdistoting, as well as the metal plate (10) which equipped with inching switches (2,4,6 and 7) and adjustable screw (1, 3, 5 and g). According to the requirenent of theload, via proper adjustment, the inching switch (2, +,6 and 7) was depressed so as tocontrol the circuit.10.6.3 Adjustments.,.., Special suggestion:Confirm the rated load of tower crane before adjusting the load limiter, then debugthe relevant data.

Fig. 10.6-19. proving ring

10. metal platel, 3, 5 and 8 - adjustable bolt2, 4, 6 and,7 , inching switch

NotelIt t'rre to\ver cr.ane should be set 2 sensitive switches ard adjustable bolt.s.''^(cpt normal inspection arrd rnaintenance lor the lord lilniter, afier.each erecriorr. and changing falls, it must be readjusted according to characteristic parameters.


119/148

TOWER CRANE OPT'RATION AND SDRYICE MANUALTable 10.6-1

lodiu*,r*,n" 'oeed limiter( sLcHGV )

l-.irr,. r"^ V with low speed (PV)' thenhoist uP u'ith high sPeed

.Adjusting the max' load limiter ( SLCHPV )1. Lift the load X with low sPeed'

[, *** *u a-. - '-,.,** o"tt l'""d t"'"h"t thl: r,o*.rttl. r., * " r0o to the load -:i''-=--'.-Llft it with tou speed lfthe load can oeI lilted, readlu>teo lr'1"1 tiJ'Iltll

Notci For various load V W, X and Y, see fable 10.6-2'

itl..h Yl


120/148

TOWER CIl.{NE OPf,Rd'TIONAND ERYICE MANUAL

Load table for max. working load limiter (l2t):

Adjusting load and radius table for the moment limiter (l2t):

Table t0. 6 2 l

l

Table 10

Table 10.6-4

Load limiter for high speed limiting Overload m-ite-SLChPV&{V\

(10N)w

(10N)x

(10N) (10N)2500 2500 5000 s5005000 5500 10000 11000

- 1.1'I

SNI2 ropes Hoisting limiterSLMO Trolleying limiterSDM) RDTIOLf(m) x(10N) Y(10\) w(10N) L(m) u(m) Dm)ti0 2240 2420 o000 2 36.5 75 4855 2600 2i3ii0 c001) 70 3'7.t)7 4150 3000 3 300 4000 70 31.07 1045 3500 38r0 5000 31. 60 38.06 3640 430u 4730 5000 35.50 39.05 3235 000 5500 5000 34.00 3',1.4 2830 5000 5500 5000 30.00 3t.0u 24

lfI rlllL,L

l

i

4ropesDM Hoisting IimiterSLMO _ 'frolleyilg IimitcrSDMO Rr)uoLf(m) x(10N) Y(10N) (10N) L(m) L'(-) D(n,60 1700 1870 10000 17.04 18.744 4B55 2t70 10000 tB. i6 19.97 6 .1,150 2570 r0000 18. 15 t9.965 4045 3r 70 34fJ7 10000 18. 69 20.559 36

320 3.170 ,12i7 10000 r9.09 20.99935 467t) 5 t37 10000 r8.90 20.19 2330 5570 6127 10000 18. 77 20.647 2,t l


121/148

TOWER CRANE OPERAIION AND SERVICE MANUAL

10.7 AnemoscoPern 7 I Technical sPecifications,0.r.,.,. ro*t' uoltage: 48VAc/50Hzl,0.r.,.r. ttun'n* *ind sPeed I l 5m/s:10.7.1.3. Dial gawge


122/148

TOWER CRANf, OPERATION AND SERVICE MNUAITThe purpose ofeach potentiometer is as follows:Wl - l3m/s limit alarm set;W2 - 20mls limit alarm setup;W3 - LED light beam gauge full range adjustment;W4 - wide angle gauge full range adjustrnent;W5 - test signal amptude adjustrnent;

w21 " v|t-6

IX

.20 - 13uII

6 filsI o 3.,n

oFFEoN 13r0WS-2 anemoscope

Wind speed sensor

three weather vane

Signal output socket


123/148

fOWER CRANE OPERATIONAND SERVICE MANUAL

10.8 Height indicator light1. Fo the height of tower crane top beyond 30m' tl.re tower crane should

equipped with red obstruction light on crane top and two jib ends' and ensure tporver supply should not be influenced by power failure'

2. FoI the height of tower crane jib foot pivot beyond 50m' the tower crane shobe equipped \\'ith anemoscope, when the wind speed beyond the limit speedrvorking, il should make a sound alarm'

3. When modifu the crane working condition for each time' all the safety devicshould be reviewed and readjusted'


124/148

-

TOWER CRANE OPERATION AND SERVICE MANUAL

11. tr'ixing and testing rules for wire rope

Incease rate of broken wire rope......... ..............._... 1lB_gRope strand broken ....................1lB_gRope diameter decreased due to the rope core broken.......................... 1lB,gand intemal wear.. ........ 1lB-9which caused by heat or arc .............. ...... 1lB_9t equipment conditions for wire rope . ......... l18_10

D(: Common wire rope defects


125/148

.I OWER CIANE OPT]RATION AND SERVICE I\'IANUAL

11.1 ExPlanationA1thoughitSStructureiScompactanditSappeaIanceiSSffong,thefatigueandwearofrvire roPe is unavoidable The fatigue and wear wire rope will dauraged rapidly'rvhich mal, result in serious accidents (both on personar and equipment)

if the usersdo not pa special attentiori to it'The l'ire rope condition can be found by periodicalequipment, the ire rope should be taken

as a kind ofreplaced once its intensity and strength reduced'

dl um. ^f. i-a r^rle

inspecdon. For the hoistexpendable. It should be

11.2 FitLing the wire ropeThe type and sPecification of ner'v wire rope should be the same as

the original one lfnot. the user must ensure that the characteristics ancl the capability

of new wire ropeare not lower than the originat

one and the nerv wire rope is applicable to the groove

of tlruts and pulleys ?revent the uire rope from knotting' twisting together'buck1ingot.adheringsundries.BeloIeputtingthewireropeof1owelcraneint0servicc. the users shoriid ensure that all kinds of devices involved rvith

the work of

,ire r.ope are in nomal 'orting condition ln order to l(eep the wire ropein place

steaclil'. opetate the to\ er crare with 100ofthe rated load several times'

1 i.2.1 F-itting nel rvire t'oPe1) cornplctely unu'i.td the rvile rope on the clean ground and avoid any

twist (see rig'

2-1). ll it is no1 possible to unwind the wire roPe completely' utlwind it in largeloops. Ir tlris ay it can avoid danger cluling enrvinding the wire rope onto

tho


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TOltTh CRAAts OPERATION AN SERVICE MANUAL3) Enwind the wire rope onto the drum via a sling and fasten it with bulldog grips.

The distance between the wire rope and the last bulldog grip should be not lessthan 3cm (the tightening moment of the screw is gmdaN).4) Hoisting up and enwind the wire rope onto the drum 4-10 circles tightly (See Fig.) -)\

5) Check the adjustuent of limit stch and readjust it if necessary.

.::

Fig. 2-1

Fig,2-2


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TOWER CRANE OPERAITONAND SERVICE MANUAL

li: ,H|"J:::"rwire rope depends on the purpose or hoisting machinery' the

working environment as well ut tf'" *i'" rope used lf possible' the wire rope shouldbe cleaned and greased' especially the bended and curved :un o'l *O" rope

which

reeled through the pultey tle type of lubricating oil should be suitable to the greasewhich used in the wire rope tactory Lack of rnaintenance is one of

the commonreasons fot shorl life time of wire 'op"'' "tp""iully when the machinery works

in

corrosive environment or the wire rope can not be greased dueto some reasons

caused by the limitation of operation'1 1.4 InsPections

il::i:ffi: ll."*" r *," ,isibre parts orthe wire rope every working daso as to discover any damage o' di'to'tion in time Pay sPecial attention :: :TTwhich fixed on the tower crane' if any obvious change is found''inform the person

m

charge to inspect the wire rope according to thefourth item listed below'

11.4.2 Periodical inspection by person in chargeThe lollowing items shoutd e iaken into account in order to detemine

the inspection

;:::::j:HT: r"1.'.,",''- machinery' such as GB5144-2006 "saretv rures ortower crane";

b). Types oflT oisting machinery andit working environment;

c). Working grade of hoisting machinery;d). The test results and the defects before;?.::Til: ::: ."- :::. :.?:',::::'":;" -"' '1'1"*"u a'i reas' 'ceweek. After an accident or before putting the wire rope into sel'vic

agait zlte

dismounting, inspect the wire rope thoroughly'


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TOWER CRANE OPERATIO] AND SERVIC: IIANUAI,1 1.5 Inspection places1 1.5.I Gener.al inspecting placesPay special attention to the following places although a thorough inspection onthe rvhole length of the rvire rope should be made.a.). The places ofrope running and two fixed ends ofwire rope.b), For the rope or rope sections which reeving through the pulley block, pay specialattention to all the places reeving through the pulleys during hoisting when themechanism carrying out repeated operation.c). The lope sections rvhich located on the balancing pulley.d). The rope sections rvhich may be wom due to extemal factos.e). Internal inspection lor corosion and fatigue. The inspection results should berecorded on the equipment inspection notebook.5.2 Inspecting the drum (See Fig. 5_l)a). Check the end places ofthe wire rope on

the drum.b). Check for distorlion and wear whichcaused by unqualified enwinding, n.u. . ,especiafly r rhe uire rope groovejumping an

8/13/2019 Manual de Opera

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Manual de Operacion y Servicios