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1. cvs a 178 078 688 CER LES 988 SES ves tts TT Its 0t pasi WS erc avs 689 608 e E Mo Ua w zy l um rmx LY T 248 89 198X 4 MA zl 88 n os cog os MUN AAMAS yeu bl T lea 4 mo L 4 EUN EUN rapoy x X 109 y 000 HOOL E0 0 ZOOL LODI SODI ON 1 Y pon 6070 100 800 S00 00 coo 20 100 000 pm E e lt e o I ye fie in vee LL j m t LIDUX A ACEO i TDA Wow 3 18 11 as Q e gt o vol 89 19 19 vey ce cal 78 1199 59 89 B 5 vil uw i a m 1 r TTT T TT T TT TP TT UU VIDA gala EA y voy E9 79 19 99 0S os 59 m ul 9 ys es zs 15 Pipe a ae cirie T RSE g A Hats n y Ald hold 29 190 T A A r AA gus Us DM O 12419 EM 68 18 jp 3 SH NN OS AAA Y ey AER tras c ea Li v 8 600 A33H CER LSS 956 95 188 66 TIS 168 098 678 878 LYS 978 678 TYS eny Ml j 8 9 s rle z k Td A u IN YH WH ON 3 95 8 es 78 IS 1 Y Qe N wj 4 e
2. Table 10 6 3 2 fall Hoisting moment Trolley moment limiter SM limiter SLMO SDMO RDMO Lf X Y W L L D m 10N ON CON m m m Li 74 2700 2970 6000 37 3 41 0 59 70 3000 3300 6000 38 5 42 3 56 1 64 3700 4070 6000 41 9 46 1 51 I 60 4000 4400 6000 42 0 46 2 48 54 4600 5060 6000 42 7 46 9 43 50 5300 5830 6000 44 8 49 3 40 44 6000 6600 6000 44 0 44 0 35 40 6000 6600 6000 40 0 40 0 32 Table 10 6 4 4 fall Hoisting moment Trolley moment limiter DM limiter SLMO SDMO RDMO Lf X Y W L L D m 10N GON CION m m m E 74 2200 2420 120008 20 2 22 2 59 I 70 2500 2750 112000 20 7 22 8 56 i 64 3200 3520 12000 223 24 5 SI di 60 3500 3850 12000 22 1 24 3 48 54 4100 4510 12000 22 3 24 5 43 50 4800 5280 12000 232 25 5 40 44 6500 7150 12000 25 9 28 5 35 40 7500 8250 112000 26 4 29 0 32 10B 13 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 7 Anemoscope 10 7 1 Technical specifications 10 7 1 1 Power voltage 48VAc 50Hz 10 7 1 2 Starting wind speedx1 5m s 10 7 1 3 Dial gauge lt 3 10 7 2 Operating environment temperature 10 7 2 1 Wind speed sensor 40 50 C 0 100 RH 10 7 2 2 Dial gauge 20 4 50 C 0 70 RH 10 7 3 Working principles and instructions for use 10 7 3 1 Working principles The wind
3. SH 205 24m H m H m H m e 19 63 14 20 63 34 s 20 61 24 P 5044 19 60 34 pA 64 19 58 24 1757 14 l 57 34 Em 57 19 5924 16 54 14 17 54 34 55 55 17 52 24 1851 14 16 51 34 SH Ba 197 5m33 19 4924 14 48 14 15 48 34 133 24m 32 52 19 46 24 13 45 14 14 45 34 45 45 14 43 24 12 42 14 13 42 34 44 44 44 13 40 24 1139 14 12 39 34 42 121 5m42 _ 142 12 37 24 10 36 14 11 36 34 OH zio zi 10 1134 24 9 33 14 10 33 34 SERE 33 33 33 10 31 24 8 30 14 9 30 34 32 32 32 32 9 28 24 2x2m 7 27 14 8 27 34 30 85 5m 30 30 85 5m 30 alan on 2 2 0x2 0m 29 m 29 29 m 59 L69B1 6 24 14 7 24 34 pet 28 28 28 2x2m 7 22 24 5121 14 2x2m 6 21 34 1691 Do 51 al 51 L69B1 6 19 24 4 18 14 L69B1 5 18 34 20 20 20 20 E 3 15 14 co A 1534 49 5m18 495m1B 49 5m18 d8 SNE elo Z Sas 16 18 18 18 1 94 E 2 934 k x i 5 ES 1 1 6 34 4 4 4 4 FL leon 3 4 F2 Sem EZA ED ED CE YZ86X o EB amp HN F2 182t 222t F1 118t 130t F3 126t 173t B 95t B 107t Reaction force in service ll Reaction force out of service Mechanisms main characteristic parameters y and base ballast weight Freestanding height without counter weight Name Code m min t m min t Kw Hoisting O 55LFV30B 0 44 6 0 0 22 12 0 630m 55 0 53 4 0 0 27 8 0 gt 630m SSLFV30BB 0 88 17 0 44 3 5 Trolleying lt 0 7 5DFVO8 0 69 7 5 yes
4. C 1L000 M31 811 LUI 91 SII vit ELI TL 22 OL 601 801 geil 9EI AOZZOY zoil 901 pol oeil SEI pol i 41 85 L 98 gs 0 ys ES ts IS 98 e e gd AA IN AJA U 100 790 X J zs wo qx J Do yen n byl vv by DET LY l Bey ILL i ea SER Jake Jn il SM l 901 9011 POLE MOD EO ZOL IOL 0071 NOD ZOOL 900 SOOL FOTO NOD 0 OL 2001 NOOO 1070 MOD 00 OL N00 N 1 did 907 SOT POT 807 000 WZ 007 WI Olt 60 80 1421 90 SO POT SO ZO 10 00 WO OLO 600 900 100 900 S00 900 800 200 100 000 yoo e 1 1 i 1 e9 e e ee e nt e e 9 9 e e e e 9 y y cu ing Wy oas amp o fd Td dd W W ele 8 00 0l DAN 0 0 0 0 0 o bd 4 L4 L4 O Tu E E um fofu Tufo Je fe To fo EP ERI Jo W To Te Te Tu Toe Te je ul lu u 9L TS 1 f III PL LI LE PE LIL I I II IT 1 i ot l i i fo iodo Tr p e Ww 10 Te Tse I 19 SE y FF LALALALALALA LA LA TENE rey amp ye ms qu WIS Wu 7A9497S LABUIIS AdU9TS ows HS sx lex lex zx cx lay VI e d mu GIA A i Y a a e e e e e e E 12200 A4 M1 O M Ed d bd Od WW ON VA OW WE X S S S SS v B B uo o om do
5. 1 Lift the load V with low speed PV then hoist up with high speed 2 Adjusting bolt 1 until the bolt head touches the inching switch 2 3 Lower the load and add 10 to the load Lift it gt gt with low speed then try to hoist up with high i speed At this moment it shouldn t be obtain the high speed the five shift otherwise if should be readjusted eAdjusting the max load limiter SLCHPV 1 Lift the load X with low speed 2 Adjusting bolt 3 until the bolt head touches the inching switch 4 3 Lower the load and add 10 to the load Lift it with low speed If the load can be lifted readjusted it Il id Note For various load V W X and Y see Table 10 6 2 10B 12 en version 2 0 Load table for max working load limiter 12t TOWER CRANE OPERATION AND SERVICE MANUAL Table 10 6 2 Load limiter for high speed limiting Overload limiter SLChGVI LChGV2 SLChPV MV V W V W X Y ION GON GON GON 10N 10N V 3 4000 4400 1750 1925 6000 6600 n 8000 8800 3500 3850 12000 13200 Adjusting load and radius table for the moment limiter 12t
6. 13B 12 13 4 5 Dismantling and installing of terminal plate 13B 16 13B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 1 Every kind of lubricating symbols Table 13 1 1 symbols International standard or main characteristic T12032 16 3 industry lithium based grease HL 20 20 gear oil 2 aircraft grease ZL45 2 N100 gear oil MIL L 2105B SAE80 VOIO3242 Used in the country with cold weather Compound calcium base MOS2 4 32 antiwear hydraulic oil in winter 46 antiwear hydraulic oil in summer GAISA o OS MIL L 2105B SAE 90 JOIO3255 Used in the country with hot or comfort weather 13B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 2 General instruction Table 13 2 1 M When startig N Oil level V Draining R Fill up G Lubricating 13 2 1 Running in period Carry out the first draining of oil in the reducer after 450 working hours 13 2 2 Using the grease gun 1 Grease all the connecting pieces without grease nipples such as door and trap door hinges joystick locks and hinges of the safety devices 2 In order to avoid any impurity getting into the oil when checking the oil level and draining clean the parts which located around the plugs 3 The oil quantities shown in this manual are only for the user s reference it is essential that the oil reaches to
7. 9B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 9 4 2 Although the oil box has been filled up with oil some of them getting into the cylinder when it start up so it need to add some hydraulic oil until it reaches to the upper limit of level gauge Check the cleanliness of hydraulic oil every six month or after 2000 hours running According to the specific circumstances it can be checked in advance If the oil is milkiness freezing and dirt it must be replaced In order to protect the seal ring of cylinder wipe the dirty bodies on piston rod The hydraulic pump should be covered well with plastic material after work with the purpose to protect the oil quality and prolong the service life 9 4 3 Check that whether the oil is curdle if it didn t work for a long time Operate the hydraulic system every two or three months with no load which will protect the pump valve and cylinder 9 4 4 If the oil is milkiness freezing and dirt it must be replaced The cylinder must be cleaned when replacing the oil and checked that some place have rusted It so get rid of the rust first then add the new oil 9 4 5 Check the oil quality before everyday work It must be maintenance periodically A Never adjust the throttle valve with load Otherwise it may occur serious accident 9B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 9 5 The common failures and troubleshooting 1 The cylinder shakes heavily when it lo
8. DI cM 50 h wo 450 h 900 h 1900h 13B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 3 1 Maintenance on trolley winch The following rules should be strictly observed to do any kind of maintenance on trolley winch The operator must fasten the safety rope When carry out maintenance the brake the operator must ride on the motor 13 3 2 Maintenance on hook The bearing on the traverse beam of the hook must be greased every 200 hours using calcium based grease C Oil symbol lt amp M IN SS 350 h Se uat MN 13B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 3 3 Maintenance on rope twist protector 13 3 4 Greasing the wire ropes The wire ropes must be greased every 6 months or when they seem to be dry or tend to oxidize We recommended that lubricate them using 10 mechanical lubrication In case of long time no using of the wire rope it should be grease Detailed information please see fixing and testing rules for wire rope 13B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 3 5 Maintenance on hydraulic pump station M when starti
9. Symbol Description Symbol Description i nd R Hosting brake XD2 Joystick control trolley 2 resistance switch rd PG VAL XD3 Joystick control trolley 3 switch LVeM Hoisting blower fan RDMo REOUCMOR Switch ee radius PTC Hoisting thermistor SDMo Sei Tor io load variable radius LTS Hoisting control RDv Trolley forward transformer deceleration switch TSDi TSDil FanDi PLCDi Small breaker SDv Trolley forward stop switch BS thermostat RDr Trolley o deceleration switch XKM Hoisting main relay SDr Trolley Park ward RUP switch KM Hosting main LO Auto lubricating system contactor control button LFa Hosting brake LOW Auto lubricating system oil contactor level switch lm Fan S Auto lubricating system cycle switch PLC PXperammapie DFa Trolley brake contactor controller XI X2 X3 Obstacle light DFaK Trolley brake relay MHR Hoisting sensor AOK GU lubricating syter relay MDR Trolley sensor SD Parallel connection relay SLCL Proving ring sensor BZK Buzzer relay MONITOR Indicator LMM Power supply for indicator DFS Trolley brake DFV Trolley FC converter Trolley energy R consumption XRGil Realy for weathvane effect resistance DM Trolley motor XRG12 Relay Or vehe ane effect RFs1 RFs2 Coil for slewing brake TSR Control transformer 4B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Symbol Description Symbol Description GiFal GiFa2 Coil for weathervane TSD Control transf
10. acc CE UL E HILL HO T EOT 00 00 10 1 WOO 0 LL CO IL 10 11 00 LL 10701 90701 6070 70 Ol EX co e o ad oe zLf zko E ena y g UNE f ing 02 og 0o 09 do 06 am am y y n ON N E N c 7 A L 1 ul WI 16 16 081 9 901 9 161 6 01 6 081 v 71 4 6y1 8 e77 8y1 7 221 2 Ly1 171 4 1 30 1 811 LLI 091 681 861 0 1 671 011 8 871 691 1 811 891 9 LM 91 6 911 91 4 SII 91 y 291 2 en 191 1 211 AH 1 T 011 8 n 69 T 1L00 M1 9 l Gel vel LEI 11 un on cul rad x XN Y pay Y an manan L 841 697 9 O A 9 I Lz iv LI ila axo MX L5 841 65 he Er 72 I 72 vi ES 89 c9 v eo a9 lo je os po 8L Jez fc I I I TUTI f rra PA3H YASH WAH WAT wed LAYOUT OF HOIST 31 Fan BUI 2 BU2 32 Fan Fan Braking unit Braking unit Fan 28 LDI Auto circuit breaker 8 TSDil 9 PLCDi 10 FanDi 11 EVDi 12 KMK 13 GVK 14 BzK 15 LFaK 16 CXT 17 CXD Circuit br Circuit br Circuit br Circuit br Circuit br Control Control Control Control relay relay relay relay 27 LFU 29 KM 18 PLC 19 XKM 20 LFa frequency AC conta
11. e o e e 09 BIHLIMOSH 14 ZAR E i nii 3 b dd ob k _ 800 00 BHO HOO 70 01 0 0120 0110 0 TU yy NN TETTE 0 qa VAN s je ki 4 A 1 Me up HR L 1 TET h DEL wy ul u e bbl 86 6 DR T 9s wy ul o e l as us aa JW AH X CANC AS Lar INY LeH 8 dei VEH L uu L LT AR 0 H 9 Low YES ono AH 67H 5 EX M8 Nl ET 87H p LA n LUi t I 9IH 7 PAIS S7H 1 YES lens Au 0 4 Leny _ 7 aX 7 LAYOUT OF SLEWING TROLLEY Red Redl MFA diode diode transfor transfor Circuit br Circuit br Circuit br Circuit br Circuit br Silicon controlled rectifier DLC RLC RWa Programmable logic Controller Programmable logic RFV RRa Controller Eddy current controller breaker breaker breaker Button Button AC DFV contactor frequency FIL frequency conversion conversion Weathervan FIL Filter e Light Filter H K H R H D H A socket socket socket socket H Terminal strip ELECTRIC PARTS LIST OF SLEWING TROLLEY Symbol Name Q ty TSIjTS2 Transformer 2 red redl Rectifying diode 2 RDi GtDi p i TsDi PLDi Cic Dread 8 RA DA DAI RFa DFa XRGil AC contactor 6 XRGi2 SD DFaK RFaK Control relay 4 XRGil RFa Auxiliary contact 1 H Terminal strip 25 VGi Weather vane Light 1 XGi DBO RBO Button 3 H K H R H D H A Socket 4 DLC RLC Programmable logic Controller
12. g Stop the slewing movement before slewing limiter start to work 3B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 3 4 Operating the trolleying winch a The trolley speed is selected by the distance of the trolley b It must accelerate or decelerate gradually to avoid swing when suddenly changing the shift of trolley operation c Stop the trolley movement before operating the trolley limiter 3 3 5 Operating the traveling mechanism a The traveling speed is selected by the distance of traveling 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 the jib foot it must travel with low speed Meanwhile it is forbidden to keep the jib facing toward the inside of curve track c Before traveling to the end of the track the tower crane operation must be stopped d There are two brakes in the traveling motor one of them used for buffering and decelerating the other used for stopping the crane movement which via 6 8 seconds time delay after powering off and automatically braked After the control lever return to zero the crane can still run a few meters so this operation should be done in advance e Attention during crane traveling Warn people to leave the dangerous areas by hailer Observe that if there are some obstacles on the track It is forbidden to make the cable pileup or pull
13. c Use the min lifting speed before the wire rope tightened up d Use the min lowering speed when lowering load 3B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL e Use the medium speed when start lifting after load taking off the ground or be over lifting f If the height is allowable in normal lifting use the rated speed of motor instead of medium speed g The speed was selected as per the weight of load Heavy load selecte low speed PV and light load selecte high speed GV h Stop moving before operating the stroke limiter 1 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 mechanism a Select the slewing speed according to the shift to be reached b Every time use the max speed as long as the angle allowed c If the slewing mechanism suddenly changes its speed it may cause the mast twisting and jib swing So acceleration and deceleration operation must be done gradually d It is forbidden to stop the jib by slewing brake It should decelerate first and then release the control lever so that the brake can brake in minor slewing speed e The slewing brake can only be used in windy condition which can keep jib in its position f When slewing the jib it is recommended to operate the lifting or lowering movement at the same time to avoid distorting of the wire rope and it is convenient for the rope swivel to work
14. Y8 10 00 10 07 Frequency converter Power supply terminal R L1 S L2 T L3 Motor terminal U T1 V T2 W T3 Resistor terminal B1 B2 7B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 4 RFCV slewing mechanism operating and troubleshooting 7 4 1 Notice for RFCV operating 1 In normal working condition the push button of the slewing locking arm is N O contact When telescoping and lifting load rotate the push button of the locking arm to make it close and then the brake de energize and brake When stop with full speed it was controlled by the internal circuit It must to ensure that the button only active when the slewing arm stop completely 2 Maintenance and service the slewing mechanism in regular Before the failure is eliminated it is forbidden to continue operate it Otherwise it may serious destroy the transmission parts and structures even result in serious accidents When carrying out maintenance it must cut off the power supply Note Note it is forbidden to use slewing locking jib button in full speed state with the purpose to prevent steel structure distortion 7B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 4 2 Operation part of digital actuator Name and function of the key REMOTE choose running operation Key Name Function LOCACL REMOTE key can switch the running of LOCAL LOCAL REMOTE key digital actuator and control circuit Via setting pa
15. gt C ee Yom telescoping cylinder oil box Hydraulic principle of telescoping system 9B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL main power supply sgh SBz T m or LEE um KM e on CT FR i electromagnet starter N motor Electrical principle of pump The combination reversal valve in the middle position H the opening P and opening T are joined together the hydraulic oil of the oil pump outputted went back to the oil box the hydraulic system is in offload condition at this moment Combination reversal valve is in the left position of figure when lifting the lever of combination reversal valve the hydraulic oil of oil pump outputted come into the big chamber via the combination reversal valve P and H the high pressure hose assembly and the hydraulic lock Open the hydraulic lock at the same time and make the piston of cylinder move downward the hydraulic oil of the small chamber flow back to the oil box via the hydraulic lock high pressure hose assembly and combination reversal valve B and T the telescoping cylinder start to telescope The telescoping speed depends on the flow of oil pump 9B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Combination reversal valve is in the right position of figure when press down the lever of combination reversal valve the
16. WWE AR es GAA GA ex The parameter of frequency converter has already been set and adjusted before leaving factory The code of frequency converter can ensure the system runs in correct stable and safe conditions The digital actuator is provided for repairing checking and setting of parameters Therefore the customer needn t to open the electric control panel during the system is working in normal condition If it is in abnormal condition check the display state of digital actuator and write down the failure code to judge and clear the fault 6B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL c The malfunction monitoring and maintenance of the frequency converter Display Explanation Causes Solution LOW ole O Aa cut 3 E da id ed Find out the reason and resolve UVI Standard 380V a 10 6 3 voltage unstable it 4 bad contact 1 power voltage too high Adjust the input voltage OV High voltage of main circuit 2 low deceleration time Set the deceleration time check higher motor heat the brake resistor circuit 1 output side earthed short o 2 EAR circuit h OC Current is 20096 of the rated gt overload with tou short Find out the reason and resolve current acceleration or deceleration it time Output side earthed current is GF 250 of the rated current Output side earthed Resolve it The ponto ewer CED As Adjust the power ON OFF abnormal UV2 The volt
17. or inaccurate furthermore it is forbidden to pick off or sealed the safety devices 7 Once discover some failure it must be stopped and checked immediately It is 3B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL forbidden to operate the crane with failure 8 The driver is entitled to refuse the command which against the safety 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 instruction 3 3 1 Starting a Check the tower crane before everyday starting according to the instruction regulation If there is any problem report it and it is not allowed to start any 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 all mechanisms d Check that whether all safety devices are integrated and acting reliable 3 3 2 Operating the hoisting winch a 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 of trolley with low speed Stop forward movement when moving to the position of moment limiter Confirm the radius of trolley stopping position Estimate the weight of load according to moment characteristic diagram table and radius
18. 1 L 8E670 A33H 676 875 176 906 676 78 67S 175 E 075 618 816 TE 918 18 TE els bes LoS Add TU A W 18 dd ld Od UN ON VA ON Q 30S 8S US 99 SS PS ES 28 IS ee e_ _e 9 9 9 9 9 AOZZIY m m BS 19 98 SS v9 t ZS IS 98 ci o ex AN to IY IY 2 A 3 4x AUN MO ZOL 007 20701 900 SOOL 9001 001 200i 1001 000 MD N 1 e je HOO 107019070160 0850 001600020 0010000000 f9 deo Ne OH AH eH mi 20 00 10 WA de j p SN vol ZOL 001 1071 6H TS 60 POL E0 QUI JO OOF M O 00 60 870 100 900 S00 00 00 200 100 000 wy 9 Ir z S le E e ee U zm T 080 1039 i vi Lo Te A S E i e ah ld d WoW 3 Ja 970 A 240 Y 9 i i 0 3 x H SH PH 1 91 SL vile ly w Sy Ww o amp 8 i 9 m amp velo ajaj aja ajr ajaj v a a UL o 6 f TTT TT TT TLE LA TTTTT OMS Ody IT LLLI M 4 OM ANA X m ER ai ul ul wl 6 is yj t rrr ly Sy ME i 9 amp joef 618 2 S Is AAAI A amp ax aax A x hl A AA MA HO am Qu E i MS My JH 8 670 A3H
19. 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Important notice A thorough debug must be made upon finishing the installation and erection of the tower crane The tower crane can only be put into service when it is approved by local safety authorities with the issuance of license 3 1 General rules The tower crane driver must be the qualified person who has trained by authoritative board of labor or specified units and passed the exam The driver must operate service and maintenance the crane correctly It is important for reducing failure improving device availability avoiding loss of working time and prolonging service life of equipment Incorrect operating will result in damage of all electric motors reducers drums brakes and wire ropes even the integral steel construction What is more it may cause serious mechanical accident and result in personnel loss 3 2 Operation highlights 1 The control panel is finishing equipment It must be careful when operating it 2 The control lever must be operated slowly when starting or stopping 3 Change shift one by one it is forbidden to get over shift 4 It is forbidden to disobey sequential operation when stopping some action 5 The control lever should turn to zero position gradually when actuating device making reverse movement Operate until the mechanism completely stopped 6 It is forbidden to operate the crane which safety device has a failure unsoundness
20. 40 thickened oil Volume of oil box 130L Motor power I5 KW Safety valve setting pressure 44 MPa Max working pressure for telescoping 40 MPa Max working pressure for lowering 6 5 MPa Balance valve pressure 2 5 MPa Oil pump capacity 23 L mm Cylinder inner diameter 0 180 mm Piston rod diameter 125 mm Max telescoping force 100t Telescoping speed 0 8 m min Return speed Adjustable in safe range Cylinder travel 1600 mm High pressure hose West Germany standard 4D 13 60 H type high pressure hose assembly 4m 9B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 9 3 Working principle Drive the oil pump by coupling after motor starting up The oil pump makes the oil from oil box to telescoping cylinder via the filter combination reversal valve and high pressure hose assembly The setting pressure between the oil pump and combination reversal valve is 44MPa the telescoping overflow valve of the combination valve is 40Mpa the lowering overflow valve is 6 5Mpa and the balance valve is 2 5Mpa before leaving factory combination reversal valve high pressure hose assembly NL pressure gauge H relief valve P Qr 40MPa ooe o E 44MPa e C Ld filter lt extra high pressure valve 4 E
21. AND SERVICE MANUAL Figure Description Figure Description TD E ix Coil for relay contactor di Delay action N C contact D X Te Coil ofa slow releasing relay r Lighting x X4 Coil of a slow operating relay A Anemoscope pa N O contact 7 Thermo sensitive resistance i T N C contact Potentiometer 4 Tus Main contacts of contactor di Rectifying diode 1 1 E E cae 2 3 phase Autotransformer Thyristor silicon controlled rectifier Plug socket Plug T Crossing without electrical Crossing junction connection CZ Earth U Pressure sensitive resistance 4B 11 en version 2 0 4 7 Wiring diagram of cable TOWER CRANE OPERATION AND SERVICE MANUAL The consumer can install the cable according to this electrical schematic diagram Xi e Ke LM Em 1 SLCHPV 17 RDMo SLCHGV1 A box X2 SDMo SLCHGV2 7 6 5 Fig 4 7 1 11 N V F i A oeey 0 M 29 hoisting D ES joystick 2 K box slweing and 4 trolleying 23 joystick AF GTM LH di Wiring diag
22. DFV frequency conversion 2 FIL Filter 2 Fan Fan 2 e A o o eRed ATVOS LH913M X4 VW DNIMYUO VEOCLA A4 X09 y IHl J0 NYYDVIO ONIYIM BH 44 st S y m Pava weis ON 000 frenan bs i 1sior 40 18108 GEMAS WOULSAOP 40 A3TTOYL ANY ONIMITS SEHHEC 38 i DERE es Safety Transformer Circuit Breaker Safety Transformer AMEKNTFA Control Cab Lighting AC 220v X AMEX N Cab Lighting Fm SS JT A Control Windscreen Wipe Mala Windscreen Wipe HRS Socket MBF Control Fan AE Fan BRI DC Power Supply 1087 CAB D333E ino jae voc wo sten niic THE CAB RG ME MES gt i Y YONGMAO NGMAO O MDR SL GL gt ES MONITOR EY P P e P 5 O gt U O Mm C o c C C C C C Q AO Im C C rT1 r r c UO SIGN DATE DISPLAY WIRING DIAGRAM LOAD D333A DATE 060629 Page of YONGMAO TOWER CRANE OPERATION AND SERVICE MANUAL 9 Hydraulic system 9 1 C
23. Proceed as described above but move the trolley to the jib foot Operate the slewing down cam 7 to depress the contact 8 and then regulate limit switch cam 9 to depress the contact 10 Adjusting the trolley in deceleration safety device RDAr and trolley in limiter SDAr drive the trolley to the jib foot Rotate cam 7 until it depresses the corresponding contact 8 then adjust limit cam 9 until it depresses the corresponding contact 10 NOTE The adjustments must be checked daily before putting the tower crane into service o B oo le 10B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 5 Moment limiter Adjust A C and D Loosen the nut 1 rotate the bolt 2 until it touches the contact 3 then close the switch contact Lock the nut 1 after exact adjustments 10B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 5 1 Purpose The tower crane is calculated and designed according to constant max load moment It is forbidden to exceed the max load moment The moment limiter is a device to inspect the hoisting and trolleying motion with rated load so as to prevent the tower crane from overturning 10 5 2 Working Principle The moment limiter which is located on the main member at the counter jib foot is composed of a pair of elastic plate three micro inching limit switches as well as installation support adjustable screw housing and so on When hoisting w
24. Should take out the stuff steel wire from the check number because can t make stuff steel wire as load steel wire The multilayer wire rope only considered its visible outer layer For the wire rope with steel core consider it as the internal strands 11B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 11 6 2 Broken wire on rope end When the wire rope breaks at rope end or around it indicates that there is high stress on this part which may be caused by incorrect installation of rope end Find out the reason for damage Cut off the broken part and fix it again if its length is allowable 11 6 3 Broken wire part focusing The rope should be discard if the broken wire part focusing within the length of wire rope less than 6d or it concentrated in one strand even if the broken wire number is less than the table listed above 11 6 4 Increase rate of broken wire rope In some events the fatigue is an important reason for rope damage The broken wire occurs after using a period of time and its broken number increases in a short time In this condition check and write down the broken wire increasing rate in order to confirm the wire rope discard date 11 6 5 Rope strand broken The rope should be discarded if the whole wire rope broekn 11 6 6 Rope diameter decreased due to the rope core broken The wire rope should be discarded when the rope diameter decreased obviously due to the fiber core damage and steel core break or inner
25. depresses the contact 7 Note Each time when transferring the tower crane to a new jobsite and before putting it into service it is essential to unscrew the plug located at the lowest part of limit switch in order to drain away the condensing water This plug must be re screwed before the tower crane transportation 10B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 4 Trolley limit switch 10 4 1 Purpose The trolley limit switch is to avoid any possible error operation and to keep a safety distance between the trolley and jib nose or between the trolley and jib foot 10 4 2 Working Principle The trolley limit switch is a device with reduction gear which driven by a pinion engaged with the drum gear ring The reduction gear of limiter drives the cams 3 6 7 and 9 to rotate which controls the circuit breaker inching switch 4 5 8 10 so as to cut off the corresponding motion See Fig 10 4 1 10 4 3 Adjustments 1 Adjusting the trolley out deceleration safety device RDAv drive the trolley to a distance of 1 5m from the jib nose buffer Rotate cam 3 until it depresses the corresponding contact 4 2 Adjusting the trolley out limit switch SDAv Drive the trolley to a distance about 20cm from the jib nose buffer Rotate cam 6 until it depresses the contact 5 Don t adjust the cam 3 any more 3 Adjusting the trolley in slewing down safety device RDAr and the trolley in limit switch SDAr
26. electrical schematic diagram 1 digital actuator operation instruction a display part of digital actuator Name and function of the key Display running mode FWD light up when co rotating REV light up when reversion SEQ light up when the running command of control circuit is effect REF light up when the frequency command of control circuit Al A2 is effect ALARM light up when appear failure or warning Display data LCD DRIVE drive mode QUICK program mode ADV advanced program mode VERIFY verify mode A TUNE self learning mode Function key Carry out parameter setting monitoring JOG running self learning mode and so on Name and function of digital actuator Important notice the charge light of frequency converter not only shows whether the power supply is switching on but also shows whether the charge has fully released after cutting off the power supply The discharge time usually lasts several minutes If not fully released it will be dangerous for the person s health So when repairing the frequency converter and its outside circuits only can touch the current carrying part after the indicator fully lighten off 6B 5 en version 2 0 b Operation part of digital actuator TOWER CRANE OPERATION AND SERVICE MANUAL Name and function of the key REMOTE choose running operation Key Name Function LOCACL REMOTE key can switch the running of LOCAL LOCAL REMOTE key digital actuator and
27. faces to the frequency converter b Install the connector first and then put the connector and cable in the fan housing c Mount the fan housing on the frequency converter Be sure that the fan housing fix on the frequency converter firmly 13B 13 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 4 4 2 Frequency converter of 18 5kW or more The cooling fan was installed on the top of frequency converter The cooling fan can be replaced without removing the frequency converter from the installation panel 13 4 4 2 1 Removing the cooling fan a Remove the terminal housing mainframe housing manipulator and front housing of frequency converter b Remove the control frame which equipped with control plate Remove all the cables which connect with the controller c Remove the cooling fan power cable connector from the drive plate which placed at the rear of the controller d Loosen the fan cover screws and pull out the fan cover from the frequency converter e Remove the cooling fan from the fan housing 13B 14 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 4 4 2 2 Mounting the cooling fan a After installing the new cooling fan install all of the parts and components according to the reverse procedure of above b When installing the cooling fan on the metal frame be sure that the airflow direction of cooling fan faces to the top of the frequency converter Airflow direction Control fram
28. lt P1 lt 85 bar 2 The min working pressure of piston rod See Fig 6 4 4A When the piston rod stroke is 2 7 0 2mm the min pressure value P2 occurs on the pressure gauge its value must 115 lt P2 lt 135 the piston rod value displayed is all the same with the value of checking of piston rod stroke 3 Adjust the system pressure is 140 3 bars j j TS Pis S S PN i cui SIE LP DTT L LIZZ TS Fig 6 4 4 6B 15 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 2 Adjust the working stroke brake release brake D First step See Fig 6 4 4B set up the pressure P 140 bar rotate part 1 until the part 2 contacts with part 3 N 2 Second step See Fig 6 4 4C release the pressure to zero reset the move parts Q2 3 Repeat the second step twice or three times 4 Set up P 140 bar See Fig 6 4 4D 5 Screw out part 1 1 2 3 4 circles See Fig 6 4 4E im Ol O 6 Rotate part 1 in idle state to C1 make it can support the static state overload C1 0 8 1 2mm See Fig 6 4 5E F If it can not support the max rated load 33 after adjustment check that the state of brake disc oil stain the state of brake pad max wearing gt 3mm replace the brake each year or working 3000 hours BEBBELEE IPY PAVN PR ANNE WAY ATL e d e AT AH Woe SAS AAAS Fig 6 4 5 6B 16 en
29. once a week After an accident or before putting the wire rope into service again after dismounting inspect the wire rope thoroughly 11B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 11 5 Inspection places 11 5 1 General inspecting places Pay special attention to the following places although a thorough inspection on the whole length of the wire rope should be made a The places of rope running and two fixed ends of wire rope b For the rope or rope sections which reeving through the pulley block pay special attention to all the places reeving through the pulleys during hoisting when the mechanism carrying out repeated operation C The rope sections which located on the balancing pulley d The rope sections which may be worn due to external factors e Internal inspection for corrosion and fatigue The inspection results should be recorded on the equipment inspection notebook 5 2 Inspecting the drum See Fig 5 1 a Check the end places of the wire rope on the drum A Fixed P 3 pulley b Check for distortion and wear which a q Zo i point caused by sungualied enwimdng DE especially at the wire rope groove SN jumping and overlapping places c Check for broken wire rope Movable pulley d Check for corrosion of the wire rope Load e Check for distortion which caused by v adding load suddenly Fig 5 1 11 5 3 Inspecting the fixed pulley and fixed points
30. several minutes If not fully released it will be dangerous for the person s health So when repairing the frequency converter and its outside circuits only can touch the current carrying part after the indicator fully lighten off 8B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 8 5 Trolley brake The three phase asynchronous motor is the new model which designed based on the advanced technology of oversea This motor start smoothly the impact force to the equipment is very small low noise and low vibration simple structure convenient for operating and maintenance safe and reliable characteristics The electromagnet of brake parts can adjust the distance with armatures automatically 8 5 1 Structure and working principle a The structure diagram of disc brake 1 fixed brake disc 2 two side brake disc 3 disc type brake disc 4 hexagonal spline 5 small spring 6 armature 7 electromagnet 8 main spring 9 adjusting sleeve 10 lever 11 double threaded screw 12 slotted nut 13 split pin 14 rear cover 15 brake 16 spacer 8B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL b Working principle When the power supply is not switching on owing to the effect of spring 8 via armature 6 to press on the brake disc 3 the motor is in brake state When power on the electromagnet 7 generate magnetic field via the effect of spring 8 small spring 5 and the brake 15 make the arma
31. signal NE frequency converter PLC resistor i logic output XL joystick PLC programmable controller LFa brake LM hoisting frequency converter motor PG encoder Fig 6 3 1 6B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Electric control system is composed of programmable controller PLC and vector control frequency converter The software programming design can carry out the logic control AC frequency converter equipped with velocity feedback block and made of PWM with the frequency converter motor with velocity encoder AC frequency converter adjusting system of vector control and the speed ratio is 1 100 Start torque could reach to 150 at null speed and the accuracy of speed adjusting is within 0 02 Motor runs in 1 2 3 and 4 quadrants When motor runs in deceleration state it released the electric energy via brake unit to brake resistor This system software design guarantees the precise adjustment of logic control and time parameters in case of the brake work frequently It could ensure that the frequency converter equip with enough output current before the brake release and not cause free fall after releasing It also can ensure that the torque reach to 150 of rated value after releasing at null speed so as to hoist the load successfully The design could meet the requirements of every safety device for hoisting winch and enhanc
32. the capacity of transformer and the distance should be inspected and adjusted or increase the cross section of power supply conductor Type STT293 12t STT293 18t Power supply capacity 120KVA 140K VA 4 4 How to see electrical schematic diagrams In the process of installing and service it often needs to look up the electrical schematic diagram with the purpose to complete the installing and service work more quickly and accurately The schematic diagram adopt letter symbols and graphic symbols in coordinate drawing which meanings could be find in the table 4 1 1 and 4 1 2 Horizontal coordinate numbers are under every electrical schematic diagram there is a vertical line under every contactor relay coil graphic symbols which marked coordinate numbers at both sides It shows the quantity of main switch and auxiliary switch which the contactor relay used and the coordinate positions on the drawing The number on the upper right quarter shows the position of auxiliary switch contact With transverse line above the number is NC switch contact and without this line is NO switch contact Arrow marked beside the number is time relay switch and the coordinate number marked at the lower left quarter of vertical line shows the position of main switch contact When a contactor relay was in working condition look for the control position of contactor switches contact on the drawing coordinate as per number under the
33. the lower part of the oil level plug 13 2 3 Checks to be carried out before assembling and disassembling 1 Check and adjust the brakes periodically according to the recommended cycles in the manual Each time before the tower crane erection and dismantling all the mechanisms should be inspected properly 2 For fast erection and self erection tower crane it required the folded winch to installing and dismantling the jib So it is necessary to check each mechanism 3 Check the condition of brake disc each friction surface and the pins Adjust them if necessary 4 Make sure that nothing will influence the good working order of tower crane perfect motor and brake supply circuit fuses in place and in good working order flexible of the rod for manual brake release remove the nut if necessary Note The drum must be locked when carrying out the above checks Any carelessness of this warning may cause serious results 13B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 3 Maintenance schedule G lubricating N oil level R fill up E replacing H oiling P air blasting V draining checking O lifetime lubricating h hour T air hole p e AD mM Em 10 h 50 h T i e 450 h l a E UN 900 h o m 1900 h e SF e i o g e E gt oO E S S 3 A gt E Ss gt E o gt 5 N g j
34. the power ON OFF CPF05 Control circuit damaged Adjust the power ON OFF Linkage fault Power OFF then insert card CPF06 PG B2 is in poor connect condition Card damaged Replace the card Notice don t change the setting value 7B 10 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 4 4 Instructions of charge light a Fitting position Pag ii AE d ki 2 y e 5 E Ju E AAT TERIOS E L NE at IN Pila UON Il O DALE HH e TES W rwy Hbc M o ae om i b Function The charge light not only shows whether the power supply is switching on but also shows whether the charge has fully released after cutting off the power supply The discharge time usually lasts several minutes If not fully released it will be dangerous for the person s health So when repairing the frequency converter and its outside circuits only can touch the current carrying part after the indicator fully lighten off 7B 11 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 5 Slewing brake 7 5 1 Manual brake release See Fig 7 5 1 1 Start the weathervane device a Lift the manual brake release lever 1 i e movement A b Push the button 2 under the brake release lever 1 c Release the manual brake release lever 1 and make it rest on the clip 3 then the lever 1 was locked by the clip 3 pin the clip d The weathervane effect accomplished and the s
35. to start up the frequency converter running during operating Press this key to stop the frequency converter during STOP key operating EB stop Via setting parameter 02 02 it can set availability invalidation when control circuit terminal running 8B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL There are indicator lights on the left above the RUN STOP key There are three states light up flashing and light off During DB initial excitation state the RUN key is flashing and STOP key is lighting up WWE AR es GAA GA ex The parameter of frequency converter has already been set and adjusted before leaving factory The code of frequency converter can ensure the system runs in correct stable and safe conditions The digital actuator is provided for repairing checking and setting of parameters Therefore the customer needn t to open the electric control panel during the system is working in normal condition If it is in abnormal condition check the display state of digital actuator and write down the failure code to judge and clear the fault 8B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL The malfunction monitoring and maintenance of the frequency converter Display Explanation Causes Solution LOW ole O Aa cut 3 E da id ed Find out the reason and resolve UVI Standard 380V a 10 6 3 voltage unstable it 4 bad contact 1 pow
36. usos n Ero Re ES pcr ee pra eee et 11 6 The discard standard of wire rope 1 eite coca dodne 11 6 1 The quality and quantity of broken wire rope 11 6 2 Broken wire on tope end cd tote e e i 11 6 3 Broken wire partio cusco 11 6 4 Increase rate of broken wire tope laririara ln 11 6 5 Rope strand DEL las 11 6 6 Rope diameter decreased due to the rope core broken 11 6 7 Elasticity decadas 11 6 8 External and internal Wear usa 11 6 9 External and internal corrosion a TESTO DO 11 6 11 Damage which caused by heat or arc 11 7 Relevant equipment conditions for wire rope APPENDIX Common wire rope defects 11B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 11 1 Explanation Although its structure is compact and its appearance is strong the fatigue and wear of wire rope is unavoidable The fatigue and wear wire rope will damaged rapidly which may result in serious accidents both on personal and equipment if the users do not pay special attention to it The wire rope condition can be found by periodical inspection For the hoist equipment the wire rope should be taken as a kind of expendable It should be replaced once its intensity and strength reduced 11 2 Fitting the wire rope The type and specification of new wire rope should be the same as the original one If not the user must ensure that the characteristics and the capab
37. version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Coiling out table of encoder Plug Twin cable Twin cable VCC V Red Red A Yellow Blue GND 0V Black Black B Green Green A Pink Black B Gray Black Shield 6B 17 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 Slewing mechanism RFCV 7 1 Explanation of symbolSs 7B 2 7 2 Composition of slewing mechanism and its working principle 7B 2 7 3 RFCV controller principle rca 7B 4 7 4 RFCV slewing mechanism operating and troubleshooting 7B 5 T Slewing DISIKO sonni IA 7B 7 7 5 1 Manual brake Telas a 7B 7 7 5 2 Electric startup of weather vane usu ea cp er a ile E resa des 7B 8 7 5 3 Maintenance and service of slewing brake 7B 9 7 6 R box wiring ASA 7B 14 7B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 1 Explanation of symbols RFCV EE Vortex timing of slewing frequency otor power Explanation Choose the slewing speed in accordance with the displacement required Accelerate or decelerate the slewing speed gradually Don t stop the jib by force via slewing brake it must decelerate first and then stop the slewing movement The slewing brake is only used to position the jib for hoisting when the wind speed is less than 13m s If the slewing and hoisting actions are carried out at the same time it must prevent the wi
38. wire rope strand for multilayer structure 11 6 7 Elasticity decreased In some conditions generally related to the working environment the flexibility of wire rope shall decrease obviously it s not safe to use any more Generally accompany with follow conditions a The rope diameter decreased b The length of wire rope lay extended 11B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL C Lack of air gap between the wire rope and wire strand due to extrusion of each other d There is some brown dust at the wire rope sinking places e Although there is no broken wire the wire rope became hard to bent and the diameter decreased the wire rope should be discarded immediately 6 8 External and internal wear a Internal wear The internal wear was caused by friction between the wire rope and wire strand in particular the wire rope bend frequently b External wear The wear for outer layers of wire rope surface was caused by the wear of pulley and drum groove or the wear between ropes on the drums The lack of lubrication incorrect lubrication dust and sand will enlarge the wear The wire rope should be discarded if the outer layer wear reaches 40 of its diameter If the wire rope diameter decreases 7 of its nominal diameter even there is no broken wire it also should be discarded 11 6 9 External and internal corrosion a External corrosion The outer corrosion of wire rope can be observed by na
39. with the air line the driver should stay in the cab to prevent from getting an electric shock b Drive the crane out of dangerous zone at once c Notify the person around don t close to the crane d Cut off the power supply which connected with the air line e Don t leave the tower crane unless you can confirm that the electric wire has been cut off 2 Maintenance of the electrical equipment only can be carried out by qualified electrician or trainee which is supervised by a qualified electrician according to the electrical rules a The tower crane must be cut off the electricity during maintenance and repair meanwhile set up a warning plate of manned operation prohibit switch on on the obvious position of power supply panel then earth or short circuit the power line after this do please dismantle the earthing and short circuit line b The electrical equipment of tower crane should be checked periodically If discover some hidden danger such as connection loosen electrical wire earthing component breakage etc it must be eliminated in time C If it must carry out live wire work there should be someone to monitor so that the main power supply can be cut off in emergency situation 2B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 2 7 Hydraulic system a Only the professional or experienced person can operate the hydraulic system b Periodically check every kind of conduct pipe flexible pi
40. zero connecting plate the service motor cable via the cable elbow into the slip ring and connect it to the conductor clip on current conducting plate of the slip ring outer ring The marked current conducting plate connect with zero line the other three current conducting plates connect with the real line See Fig 5 3 2 the P view lip ring SG Reducer _ n TES d 5B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Locking part Flange disk Adjusting nut Wl RY DY pa 2 3 KA js N 1 NIN 7 s A D 111 A N Inspection hole tH p P view Current conducting plate full line connecting plate current conducting plate Cable elbow zero conductor connecting plate Fig 5 3 2 5B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 5 3 3 Debug of the cable drum Before the cable drum putting into service screw out the locking parts on the shell of reducer its position in reducer please see Fig 5 3 2 Check that whether the groove of adjusting nut of reducer and the installing hole of locking parts are aligned If not manual rotate the disc until the groove is aligned with the hole then insert the locking parts into the hole see Fig 5 3 3 and rotate the disc The person stands outside the drum if rotate the disk clockwise the adjusting nut under the limit of locking parts moves towards the spring and increase the output t
41. 7 50 6 21 5 05 4 48 3 80 3 43 2 98 2 72 2 39 2 20 II 37 3 6 0 6 00 6 00 5 55 4 98 4 30 3 93 3 48 3 22 2 89 2 70 70 IV 20 7 12 0 412 6 40 5 25 4 66 3 96 3 58 3 11 2 84 2 50 II 38 5 6 0 6 00 6 00 5 75 5 16 4 46 4 08 3 61 3 34 3 00 64 IV 22 3 12 0 8 43 7 03 5 83 5 19 4 42 4 01 3 49 3 20 II 41 9 6 0 6 00 6 00 6 00 5 69 4 92 4 51 3 99 3 70 60 IV 22 1 12 0 8 37 6 98 5 84 5 20 4 43 4 02 3 50 II 42 0 6 0 6 00 6 00 6 00 5 70 4 93 4 52 4 00 54 IV 22 3 12 0 8 46 7 06 5 95 5 30 4 02 4 10 II 42 7 6 0 6 00 6 00 6 00 5 80 5 02 4 60 50 IV 23 2 12 0 8 88 7 43 6 26 5 62 4 80 II 44 8 6 0 6 00 6 00 6 00 6 00 5 30 44 IV 25 9 12 0 10 10 8 50 7 17 6 50 II 44 0 6 0 6 00 6 00 6 00 6 00 40 IV 26 4 12 0 10 35 8 74 7 50 II 40 0 6 0 6 00 6 00 6 00 35 IV 26 4 12 0 10 35 8 80 II 30 0 6 0 6 00 6 00 30 IV 26 4 12 0 10 35 II 30 0 6 0 6 00 1A 1 en version 2 0 TOWER CRANE ERECTION MANUAL
42. 7 5RFCV 0 0 8 rpm 2x7 5 Slewing O RTC290 0 0 8 rpm 2x145N m Traveling Gr RT 12 5 25 m min 4x2 6 5 2 please contact us 1A 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 2 Safety rules 2 1 The regulation of correct used 1 It is forbidden to use the tower crane which has not passed the performance test 2 According to the technical regulation and method of use the crane must be used in its good condition Pay more attention to the safety to prevent the dangerous Eliminate all kinds of malfunctions in time which may cause the safety accident 3 Operate the tower crane in specified scope of temperature 20 C 40 C 4 Operate the tower crane in specified limit of wind speed the max wind speed for operating is 20m s the max wind speed out of service is 50m s 5 Observe the regulation in operation manual and regulation related to service and maintenance 2 2 Safety measures 1 The operator should read the operation rules before operating the tower crane 2 The operator should always remember every safety measure and recognize the hazard meanwhile the operation rules should be visible 3 It s forbidden for the operator to be with long hair wearing robe or wearing jewelry 4 Often read the warning board about safety and preventing from hazard 5 If the crane is in abnormal condition stop operation immediately and report it to the interested person 6 It is forbidden to change or add any parts o
43. B 3 10 23 DCUM EE T AS 10B 4 10 3 Slewing limit Staller 10B 5 10 3 1 PURPOSE naea a aE OR Fe eM it 10B 5 10 3 2 Working Principle acts ida 10B 5 1033 AGI USING iioii lic pad ti 10B 6 10 4 Trolley lmit switch piane E rio SIRE e eh E Pe Verte 10B 7 MN illo 10B 7 10 4 2 Working Principle scialle 10B 7 ASIAN ia 10B 7 10 5 AA a eoo iet deo riali 10B 9 WO UN PUFDOSC aoctor pede tiun iip de med O 10B 9 10 5 2 Working Prine Plena idss 10B 9 10 5 3 NC OST initial 10B 9 OG NEO AG MITET et 10B 11 POO T P EDOSC don as NIE E 10B 11 10 6 2 Working Paciente ES ani 10B 11 TOGS xd US Eme ic ditat 10B 11 MA sane lea 10B 15 10B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 1 Introduction The safety devices of tower crane are important devices to ensure the safety of person and equipment Among the safety devices the moment limiter and the load limiter set a limit for the tower crane so as to protect it against overturning and the wire rope from breaking off After the safety devices are set don t modify their adjustments The purpose of each limit switch is to limit the motion range of each mechanism NOTE D If the top of tower crane exceeds 30m it is necessary to fit red obstacle indicator lights which remain current feed even the tower crane stopped 2 If the pivot joint height of jib foot exceeds 50m it is necessary to fit an anemoscope which send out warning to stop operation when wind speed
44. ER CRANE OPERATION AND SERVICE MANUAL The purpose of each potentiometer is as follows WI 13m s limit alarm set W2 20m s limit alarm setup W3 LED light beam gauge full range adjustment WA wide angle gauge full range adjustment WS test signal amplitude adjustment ZA i l Pt IIa an U NI _ I I x ZA 13 7AN e59 20 8 3 es x A FP Ws a 66 AS EM 3 MIS 10 sl 172 O N i i Y alarm NC 7L 0 N82 wind speed OFF ON 13 20 light limit WS 2 anemoscope lt N ff N gt D ff LV J M jj Ny Y three weather vane same direction Signal output socket Wind speed sensor 10B 15 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 11 Fixing and testing rules for wire rope Ns Explanation ton 11 2 Fitting tbe A a a ae ts SMS UE 11 2 1 Fitting new wire TODO soria eoru tas V3 Maintenance aliene WMA TASC cionado nuo aa ela LAT Daily observationen snno o UN a So e a a 11 4 2 Periodical inspection by person in charge TES InspectiOH Dide eSdasuuseqpepdte AN S espe 11 5 1 General inspecting places iii 1 32 Inspecting the dEDE aa p ts CMS pait 11 5 3 Inspecting the fixed pulley and fixed points 11 5 4 Internal inspecting of wire rope iii 11 5 5 Inspecting the wire rope endis
45. G open wire PG connection is wrong Make the connection right Power supply in normal PG no power supply Sandee Over load Reduce load Too short acceleration time Delay the acceleration time DEV Deviation of speed is to large The load speed is in locking state Check the mechanism system F1 10 F1 11is not set correct Confirm the set value OPR Poor contact of digital Check the PG signal actuator Confirm the income line CPF02 Base lockout is poor Control circuit damaged BUM NOWE ONOFF Replace the frequency converter CPF03 EFPROM is poor Control circuit damaged Adjust the power ON OFF CPF04 Control circuit damaged Adjust the power ON OFF CPF05 Control circuit damaged Adjust the power ON OFF Linkage fault Power OFF then insert card PG B2 is in poor CPF06 Pe connect condition Card damaged Replace the card Notice don t change the setting value 8B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 8 4 2 Instructions of charge light a Fitting position Control loop terminal Main loop terminal cia TIE al 4 itt TARARE EL CRA TEBEO ra eG A E Ae Ein ERI LT Cra 84 2 1 58 0 i ne zl Electrification indicate light igi Lr lal d o DAA fr y g Earthing terminal b Function The charge light not only shows whether the power supply is switching on but also shows whether the charge has fully released after cutting off the power supply The discharge time usually lasts
46. OM is poor Control circuit damaged Adjust the power ON OFF CPF04 Control circuit damaged Adjust the power ON OFF CPF05 Control circuit damaged Adjust the power ON OFF Linkage fault Power OFF then insert card PG B2 is in poor CPF06 Pe connect condition Card damaged Replace the card Notice don t change the setting value 6B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 6 4 3 Rotary encoder Rotary encoder is speed sensor which adopts technology of machinery electric and light It corresponds with different speed output pulse when motor rotating and identify the rotating direction This system adopts NO 3 signal of 90 angle difference the pulse number of A B and Z phase is 600 1024ppr the power supply voltage Vpc 5V The rotary encoder fitted on the tail of motor It must be protected seriously with the purpose to waterproof moisture proof etc The wiring diagram please see electrical schematic diagram 6 4 4 Brake The hoisting mechanism adopts both hydraulic pusher brake and flush type brake which make the work more safe and reliable 1 Pusher brake is N C brake The adjustment of hydraulic pusher brake 1 4 15 TT TUT A 1 lifting spot 2 Brake spring 3 Torque adjusting nut 4 Angle lever 5 Thruster 6 Arm 7 brake shoe 8 connecting bolt 9 tighten nut 10 balancing lever 11 interlocking pin 12 cable entry 13 compensation device 14 tighten bolt 15 clearance adjusting nut 16 han
47. STT293 TOWER CRANE II OPERATION amp SERVICE MANUAL 2008L184 Fushun Yongmao Construction Machinery Co Ltd STT293 TOWER CRANE OPERATION AND SERVICE MANUAL Table of contents l Tower eranc parameler tall iaa 1A 2 Safety rules of the tower crane ruina 2B OPEN ita 3B 4 Power supply and schematic diagram nono noconnncnnnss 4B Snell ila aida 5B 0 HOURS WITICI accra An 6B Tre Ole WITS NCC attis ib hoo enacted eu ett od tablet orto oin 7B S POMS yO AVC rr ro eal eee lien PR AA Ad 8B Attached Electric diagram 9 Hydraulic system for telescopimg ieiiis eren tree terns ees 9B TO Safe a A EN 10B 11 Fitting and inspection rules of wire rope for hoisting machinery 11B 12 Slewing DEMO sii 12B EA dva ee Du DU dein Reali 13B TOWER CRANE ERECTION MANUAL 1 Characteristic Parameter 20 2m 76 0 di 12t el eoi LC 2 7t 12t 70m f Lu2003 64m Cam 3 0 60m 172003 Sf 54m gt Ls E 50m 2003 4 6t 44m m Vim I um ma x 162m e don pri um amp st S 35m gt modien mo 7 5t gt 30m T L P2003 P2416 gt LJ2003 8 8t me Mx AN R ran 0009 Ca 39 35 40 44 50 54 60 64 70 74 74 IV 20 2 12 0
48. a Check for the broken and wear of wire rope which reeving through pulleys b Check for broken and corrosion of wire rope on fixing points as well as the wire rope sections around the balancing pulleys 11B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL c Check for distortion of wire rope d Check for the diameter of wire rope Check for places around movable pulley a Check carefully on the rope section which passing through the movable pulleys especially the rope sections around the pulleys with load b Check for broken of the wire rope and surface wear c Check for corrosion of wire rope 11 5 4 Internal inspecting of wire rope Internal damage is mainly caused by the corrosion and fatigue of wire rope Internal damage may not be discovered by external inspection even if the wire rope is nearly broken completely The person in charge should carry out the internal inspection The method of internal inspection is as follows Firmly tighten the wire ropes via two clamps with suitable dimensions Screw the clamp so that the outer layers of the wire rope are divorced from the core of wire rope When the wire rope is untwisted slightly clear the grease and chip in the rope by screwdriver The inspection items are as follows a Internal lubrication b Corrosion conditions c Wire rope impress which caused by extrusion and wear d Confirm if there are broken wire ropes Make the wire rop
49. ace the grease of reducer each year When replacing the grease screw out the locking parts clear off the dirty oil and then screw tightly the hexagonal plug add the clear grease and then screw up the locking parts 6 Keep the surface of slip ring motor and reducer clean 7 If the parts worn a lot and has already influenced its working characteristics it must be replaced at once 5B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 6 Hoisting winch C_1 LFV C BB 6 1 Explanation of symbols C LEV COBB Dual brake B Type momotor Single line pull Hoisting frequency control mechanism Motor power kw 6 2 Composition of hoisting winch The LFV hoisting winch is composed of frequency converter motor brake devices reducer drum bracket resistance box electric control panel etc See Fig 6 2 1 1 fan 2 motor 3 hydraulic pusher brake 4 reducer 5 pump 6 hydraulic clamp 7 drum 8 limiter 9 chassis Fig 6 2 1 6B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 6 3 Working principle LFV system makes the frequency of 3 phase power supply and voltage changing into adjustable power via an AC frequency converter which reaches to the frequency converter motor and drive the reducer and drum with the purpose to transport the load vertically The electrical control system diagram sees Fig 6 3 1 XL logic signal run null speed failure AAA btakesinit y interlocking
50. age of control power Replace the frequency supply is too low converter 1 loss of phase in power supply PF Mainicitouit voltage dilute 2 the phase voltage is Find out the reason and resolve unbalanced it 3 momentary power failure 1 output wire is broken LF Loss of phase for output 2 loosen of output terminal SETHISCGOHHE devices D Replace the fan 3 motor winding is broken OH The cooling fin is too hot Fan damaged Adjust the load 6B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Display Explanation Causes Solution OLI The motoris overload The rated value of motoris wrong Adjust the set value Overshoot undershoot Adjust gain OS Over speed The speed is too high Adjust circuit and gain F1 08 F1 09 is not set correct Confirm the set value PG open wire Connect the open wire PGO PG open wire PG connection is wrong Make the connection right Power supply in normal PG no power supply Sandee Over load Reduce load Too short acceleration time Delay the acceleration time DEV Deviation of speed is to large The load speed is in locking state Check the mechanism system F1 10 F1 11is not set correct Confirm the set value OPR Poor contact of digital Check the PG signal actuator Confirm the income line CPF02 Base lockout is poor Control circuit damaged BUM NOWE ONOFF Replace the frequency converter CPF03 EFPR
51. ake E controls the auxiliary brake and control the wind and unwind of cable drum 5 2 Bogie brake The two stage brake includes both soft brake and hard brake They take effect one by one RE controls the service brake E controls the auxiliary brake When stop the motion of bogie it provides a soft friction first then stable deceleration after that it bands brake and make the bogie fully stopped 5 3 Cable drum The cable drum is installed on the horizontal bracing of chassis and parallel with the rail 5 3 Features and working principle of cable drum The cable drum is composed of moment motor reducer slip ring bracket drum and roller box When the tower crane moving towards the power supply direction start up the moment motor The moment motor transfers the moment to drum via rotor disc and flange then the drum slowly rotate the cable is involved in the disc when the tower crane moving against the power supply via drawing of the cable to conquer the friction moment in the reducer which pulling the disc rotate and the cable auto exit 5B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 5 3 2 Wiring of cable drum The outer power supply cable pass through the roller box see Fig 5 3 1 as per the direction of arrow in Fig 5 3 2 to induct the drum inner ring via the inner hole of the reducer output shaft to get into the slip ring connect with three real line connecting plates of the slip ring inner ring and a
52. bolts remarked with are selected for connecting the slewing mechanism of the tower crane they must be checked weekly If the bolts become loosen please retighten it with the torque value shown in table 1 12B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 Maintenance 13 1 Every kind of lubricating symbols u c ii 13B 2 PAS AA ee ela ee ea eee ay 13B 3 13 2 1 R nning in AA A Na Re hb Reds 13B 3 13 2 2 Using the grease Bulli 13B 3 13 2 3 Checks to be carried out before assembling and disassembling 13B 3 13 3 Maintenance socio HEREIN E ori 13B 4 13 3 1 Maintenance on trolley with ois ii rent iot repete oe eren 13B 4 13 3 2 Maintenance on NOOK oil 13B 5 13 3 3 Maintenance on rope twist protector 13B 6 13 3 4 Greasing the wire ropes cst scs tortor rti qois veniet sts be oio bee to e a stet 13B 7 13 3 5 Maintenance on hydraulic pump station 13B 8 13 3 6 Greasing the rope guiding pulley ooooooccnonccnooccnoncncnnnnconnnonononnnoss 13B 8 13 3 7 Greasing the slewing ring dad a 13B 9 13 3 8 Greasing the hoisting winch i 13B 10 13 4 Maintenance and service of frequency converter 13B 10 I3 Dallynspeciona ia Col ned 13B 10 134 2 Pernodical nis ECON ode 13B 10 13 4 3 Scheduled maintenance of parts and components 13B 11 13 4 4 Replacing instructions of cooling fan
53. coil symbol 4B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 5 Electrical schematic diagram symbol see Table 4 5 1 Table 4 5 1 Symbol Description Symbol Description LI Hoisting power LFaK Hoisting brake auxiliary indicator relay GVI Hoiste high speed GVK High speed indicate relay indicator XLH Hoisting 1 shift LDi Hoisting air switch XLD Lowering 1 shift React Reactor XL2 Relay 20 shift LFV Hoisting FC converter XL3 Relay 3 shift BU1 BU2 BU3 Braking unit XL4 Relay 4 shift L PG Socket for L box to encoder XLS Relay 5 shift L SL Socket for LBox ED moment and proving ring SBO Reset button LIR SOCKetJonE box to LT resistance SH SM Short circuit hoisting LK Socket for L box to K box limiter button control wire SLMO Hoisting moment L LM Socket for L box mole control wire SLchPV Max load switch for Bz buzzer proving ring th SES OM ese ce EC Cab light switch th ova tramo mete ECB Switch for cab light switch RLH Hoisting deceleration ECDi Breaker for cab light limiter SLH Hoisting stop limiter A hailer RLD VE deceleration n Anemoscoue imiter EU Joystick control trolley SLD Lowering stop limiter XDv odas Seb Joystick control trolley LM hoisting motor XDr Li 4B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL
54. commissioning 8B 10 en version 2 0 OVWONOA jo eSed 31v9s LH9I3M WUVW ONIMVUG J 0v0 Y WVYDVIG 371dIONIYd AlddNS YIMOd CEE 612080 31va Ilva sa N td CYOXDA X LAYOUT OF ELECTRIC SUPPLY Control Circuit breaker Circuit breaker Phase detector Assemble transformer control relay H A Auto circuit breaker AC contactor Socket Terminal strip ELECTRIC PARTS LIST OF ELECTRIC SUPPLY Symbol Name Q ty TSA Transformer 1 Di Auto circuit breaker 1 TsDi TsDil Circuit breaker 2 XJ 3 Phase contactor 1 P AC contactor 1 XP Control relay 1 A Terminal strip 4 H A Socket 1 b 12200 Ad1 101 901 Sol vol 01 701 LOL vel Ul 1097 eel 8l N n N eel gii oH un ve 01 go EH que e m gla x N wit gt NU Fr cae a 41 UY UY UY mH TI DI las LV Y Y c in x j yed A A 1081 4 NAX Z ANI 11 YS HI ES Jey LI 6 e 124 _ s UA rv Lot AU olie Li 8l 1 I I DI i i i i i T PIE pa UL Ly 0 1919 ILE y VERTI C woo 290 29 290 11969 QI sold
55. control circuit Via setting parameter 02 01 it can set availability invalidation Co rotating reversion MENU MENU key PLE ad Choose each mode ESC key ESC exit key Press ESC key back to previous state JOG key i i inching Inching key during operation FWD REV key Switch the rotary direction during operating SHIFT RESET key Choose the digit of parameter setting RESET shift reset As reset key during occurring failure Choose the mode parameter number and setting value Add key add etc Use when carrying out next item and data Choose the mode parameter number and setting value Reduce key reduce etc Use when returning to the previous item and data Ensure the number of each mode parameter and DATA DATA ENTER key setting value ENTER data input When changing from one menu to next menu it can be used c RUN key Press this key to start up the frequency converter running during operating Press this key to stop the frequency converter during STOP key operating EB stop Via setting parameter 02 02 it can set availability invalidation when control circuit terminal running 6B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL There are indicator lights on the left above the RUN STOP key There are three states light up flashing and light off During DB initial excitation state the RUN key is flashing and STOP key is lighting up
56. ctor Programmable logic AC conversion Controller contactor 21 L SL 22 L PG 23 L R 24 L LM 25 L K socket socket socket socket socket 30 React Reactor 26 L HY 33 L Terminal Strip sockel ELECTRIC PARTS LIST OF HOIST Symbol Name Q ty LTS Transformer 1 FanDi PLCDi 2 TSDi EVDi Circuit breaker 2 TSDil 1 Red Diode 1 KM 1 D AC contactor 1 XKM l CXT CXD LFaK Control relay 3 GVK KMK BzK 3 Connecting KM Auxiliary 1 BUI BU2 Braking unit 2 LFV Frequency conversion 1 PLC Programmable logic Controller 1 LDI Auto circuit breaker 1 React Reactor 1 L SL L PG 2 L K L LM 2 Socket L R 1 L HY 1 SBO Button i Fan Fan 2 1 8 670 AJ3H 71S am 018 608 806 LOS 708 908 108 06 AE 108 99 875 125 ts 99 875 vis T ops HS Sp 875 is 125 vs ris A Azz cea OH sala ii 181 Mm jia x uej T ci uf nt Ut Ut m tai i vi Iva CT Ya S x 4 Iv Iv Iv y Y 7 T 1051 b b o Jedd yead 6 g ITE JH Y q 2 l l g I rA ps Za NJi i y A Y l LN ZII Are EE y AA 9 P x li tes seem Al wu L d Ld Pu v W YV M e ut I 7 acce y J zx Y uy BE 16 16 Y 8 ol YX 08 9
57. d relesse lever 17 limit switch 6B 10 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Working principle when breaking the brake wheel brakes via spring force when power on the hydraulic pusher overcome the spring force and release the brake Adjustment of brake moment loosen nut 3 and rotate it adjust the spring length to the required requirement There is a measuring scale on one side with the purpose to get each kind of different brake moment Adjustment of the brake pad adjust nut 4 make the distance of brake pad between 0 7 1 2mm then adjust bolt 7 make the brake pad and brake wheel can be contacted uniformly Maintenance check the clearance of brake and the wearing condition of brake pad the thickness can not lt 3mm each week if necessary adjust or replace it 2 Flush type brake Flush type brake is a safe brake mechanical brake hydraulic releasing brake The brake force acted on the brake lateral plate which machining by drum flange The brake is composed of a bracket and 3 brake tongs B this brake tongs is mechanical brake and hydraulic releasing brake When the mechanism works it only can be stopped via the action of both tongs a Release brake Fill 140 bar pressure into the cavity 4 push the piston rod 5 and nut 6 move backward compress the disk spring 2 via piston rod 3 Push the temper screw 7 move backward the push rod 1 released there is no force on the brake lateral plate an
58. d the brake moment is zero b Brake Remove the pressure The disk spring 2 is no longer being compressed the spring 6B 11 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL force was acted on the brake lateral plate via piston rod 3 temper screw 7 and push rod 1 Meanwhile the piston rod 5 was fixed on the piston rod via temper screw The brake moment depends on the spring force of disk spring The brake distance depends on the position of temper screw 7 INS ASA NIN SSR 1 456222 72277 ZEE NUNN ES KI ee ae ARS NARA NNUU UE pra LVAN 6B 12 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 Hydraulic center The hydraulic center is the device which provides the power to brake and also control the brake This system is composed of motor oil pump oil filter relief valve magnet valve quick disconnect coupling pum etc The hydraulic oil is N15 as per SY 1181 76 dosage is 24L the pollution grade is 6 7 as per NAS1638 the replacing period is 12 months Brake principle Fig A When the electromagnet DT loss of electron the oil flow direction see Fig A The system pressure is nearly 0 The brake tongs brakes under the action of spring force Release brake Fig B When the electromagnet DT gain of electron the oil flow direction see Fig B The system pressure is 140 bars The brake tongs conquer the spring force via the action of hydraul
59. e n Controller Fan housing Connector 13B 15 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 4 5 Dismantling and installing of terminal plate The terminal plate can be removed without disconnecting the cables Note Always confirm that the charge indicator light off before removing the terminal plate 13 4 5 1 Removing the terminal plate a Remove the manipulator and front housing b Remove the connectors of earth wire which connected to FE or NC on the terminal plate c Loosen the mounting screws on the left and right sides of the control circuit terminals until they are in sliding state It is not necessary to remove these screws d Pull the terminal plate out in direction 2 when the screws are loosened 13 4 5 2 Mounting the terminal plate Install all of the parts and components according to the reverse procedure of removing Confirm that the terminal plate and the connector of the controller properly aligned and then insert the terminal plate Otherwise the connecting pin may be bent which can not ensure the frequency converter working in normal condition Removing of the terminal plate 13B 16 en version 2 0 Fushun Yongmao Construction Machinery Co Ltd Add No 3 Yuanda Road Shuncheng District Fushun Liaoning P R China Tel 86 0413 7648899 7649988 Fax 86 0413 7649999 Hot line 86 800 8900088 86 400 6154555 86 0413 7648989 Postcode 113126 Website www y
60. e every 200 hours or each month b Check the clearance and brake torque as well as the wear condition of the brake pad replace them if necessary c Check that there are no foreign bodies in the brakes such as cement sand grease etc 7B 14 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 6 R box wiring diagram 5 5 ue y Al ES HVeM La El PA 3 o ye ci N L Lj gi t 156 n A LFa E X HVeM e 57 58 59 R 51 54 55 56 57 58 59 61 64 65 66 69 72 terminal board of slewing center terminal box R box terminal terminal 69 TO Tl 72 F H 51 59 01 06 en version 2 0 7B 15 TOWER CRANE OPERATION AND SERVICE MANUAL 8 Trolley winch DFV 8 1 Explanation obs MD 8B 2 8 2 Composition of trolley winch and its working principle 8B 2 8 2 1 Mechanism working principle oooooconnonnnnoccnononononcconnncnnnnnnnoss 8B 3 8 2 2 Safety test signal cial 8B 3 8 2 3 Output stot lo cisci P dre crap ica Rd eere Era EXER duds 8B 3 8 3 PEC A ao 8B 3 8 4 Main components and maintenance iii 8B 4 ls TH 8B 9 8B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 8 1 Explanation of symbols ES DEV EJ EE Single line pull Trolley frequency control mechanism Motor power kw 8 2 Composition of trolley winch and
61. e its safety and stability Meanwhile it could realize the control function respectively for the max running speed and improve the working efficiency The PLC and frequency converter software had been adjusted and checked strictly before the electric control system leaving factory It is absolutely forbidden to modify it If you have any doubt please consult us 6B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 6 4 Main components and its maintenance 6 4 1 Programmable controller PLC It should be periodical checked and maintenance in order to ensure the PLC running more reliable in long time The checking and maintenance contents include check the working voltage of power supply I O terminal ambient temperature battery backup etc Item Check Parameter Power Supply scisco PEC terminal L N AC100 240V voltage lola Ambient temperature humidity 0 C 55 C ntr in ome No dirt and dust 30 85 RH I O voltage Voltage of input output terminal DC24V Fixing firm EDGE CODO wiring and terminal reliable Battery backup Whether replacing periodical Around 3 years ERR light will be lightened when the voltage of battery backup is quite low It must be replaced within a month as per the manual requirement 6B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 6 4 2 Frequency converter Adopt CIMR G7A frequency converter of current vector control the outer wiring sees the
62. e to its original state then grease This method is not applicable for the wire rope with multiple layers 11 5 5 Inspecting the wire rope end It is very dangerous if the wire rope from the fixing end fatigue and wear the same inspection should be made on other fixing devices such as rope anchor box cable clamp and so on Check if there is crack check for possible slide between rope anchor box cable clamps and wire ropes check the fixing of wire rope on the drum In any case the wire rope on the drum mustn t be less than 3 circles 11B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 11 6 The discard standard of wire rope 11 6 1 The quality and quantity of broken wire rope For wire ropes with 6 or 8 strands the broken of wire rope mostly occurs on the appearance For the wire rope with multilayer strands it mostly occurs inside the wire rope The visible broken wire ropes which must discard for the hoisting machinery Table 6 1 Mechanism working grade M3 M8 Alternate lay Lang lay The wire no of Wire rope structure outer strands Length range 6d 30d 6d 30d 6x19 7x19 6x 19 101 120 6w 19 34x7 10 19 5 10 221 240 6x37 19 38 10 19 Note 1 The working grade of tower crane mechanism is M4 2 d represents the diameter of wire rope 3 The filling wires is not the load bearing wires so it must be take out from the inspection number
63. eight or falls of tower crane it is necessary to adjust the hoisting limit switch for hoisting and lowering 1 Adjusting the hoisting limit switch for lowering SLD Lower the hook down with 2 fall or 4 fall Rotate cam 1 via corresponding adjusting screw so as to depress the corresponding contact A Here the hook stops before reaching to the ground it is forbidden to make the hook reaches to the ground with the purpose to prevent the rope unwinding from the drum At least 3 layers of rope windings should remain on the drum when the hook is at the lowest position 2 Adjusting the deceleration limit switch for lowering RLD Lower the hook down with 2 fall or 4 fall Rotate cam 2 via corresponding adjusting screw so as to depress the corresponding contact B Here the hook can stop away from the ground 6m and only can run with low speed 3 Adjusting the deceleration limit switch for hoisting RLH Hoist the hook up with 2 fall or 4 fall until the distance between the trolley and hook block is only 6m Rotate the cam 3 via corresponding adjusting screw Check the hoisting control until it depresses the corresponding contact C and only can hoist with low speed 4 Adjusting the hoisting limit switch for hoisting SLH Hoist the hook up with 2 fall or 4 fall until the distance between the trolley and hook block is only 1m Rotate the cam 4 via corresponding adjusting screw Check the hoisting control until it depresses the corre
64. er 1 loss of phase in power supply PF Main circuit voltage failure 2 the phase voltage is n i HE RASO and unbalanced CRETA 3 momentary power failure 1 output wire is broken cina LF Loss of phase for output 2 loosen of output terminal Rorlace the EE d 3 motor winding is broken P OH The cooling fin is too hot Fan damaged Adjust the load OLI The motor is overload The Pedal Of motets Adjust the set value wrong 7B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Display Explanation Causes Solution Overshoot undershoot Adjust gain OS Over speed The speed is too high Adjust circuit and gain F1 08 F1 09 is not set correct Confirm the set value PG open wire Connect the open wire PGO PG open wire PG connection is wrong Make the connection right Power supply in normal PG no power supply condition Over load Reduce load Too short acceleration time Delay the acceleration time Deviation of speed DEV istol ME The load speed is in locking Check the mechanism state system F1 10 F1 11is not set correct Confirm the set value OPR Poor contact of Check the PG signal digital actuator Confirm the income line Adjust the power ON OFF CPF02 Base lockout is poor Control circuit damaged Replace the frequency converter CPF03 EFPROM is poor Control circuit damaged Adjust the power ON OFF CPF04 Control circuit damaged Adjust
65. er voltage too high Adjust the input voltage OV High voltage of main circuit 2 low deceleration time Set the deceleration time check higher motor heat the brake resistor circuit 1 output side earthed short o 2 EAR circuit h OC Current is 20096 of the rated gt overload with tou short Find out the reason and resolve current acceleration or deceleration it time Output side earthed current is GF 250 of the rated current Output side earthed Resolve it The ponto ewer CED As Adjust the power ON OFF abnormal UV2 The voltage of control power Replace the frequency supply is too low converter 1 loss of phase in power supply PF Mainicitouit voltage dilute 2 the phase voltage is Find out the reason and resolve unbalanced it 3 momentary power failure 1 output wire is broken LF Loss of phase for output 2 loosen of output terminal SETHISCGOHHE devices D Replace the fan 3 motor winding is broken OH The cooling fin is too hot Fan damaged Adjust the load 8B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Display Explanation Causes Solution OLI The motoris overload The rated value of motoris wrong Adjust the set value Overshoot undershoot Adjust gain OS Over speed The speed is too high Adjust circuit and gain F1 08 F1 09 is not set correct Confirm the set value PG open wire Connect the open wire PGO P
66. erence Name Standard replacing period Replacing method Cooling fan 2 or 3 years Replace it Filtering electrolytic o yt 5 years Replace the capacitor after inspection capac tor Braking relay Determine after inspection Fuse 10 years Replace the fuse Capacitors on PCBs 5 years Replace the PCBs after inspection Note the standard replacing period is based on the following usage conditions Ambient temperature Yearly average of 30 C Load factor lower than 80 Operating rate lower than 12 hours day 13B 12 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 4 4 Replacing instructions of cooling fan 13 4 4 1 Frequency converter of 15kW or less The cooling fan was installed at the bottom of frequency converter If using the mounting holes at the rear of the frequency converter the cooling fan can be replaced without removing the frequency converter from the installation panel 13 4 4 1 1 Removing the cooling fan a Press down the right and left buckles of cooling fan housing as per the direction of arrows 1 then pull the fan out in the direction of arrow 2 b Pull out the cable which connected with the fan from the fan housing and disconnect the connector c Open the left and right fan housing and remove the fan from the fan housing 13 4 4 1 2 Mounting the cooling fan a Install the cooling fan in the fan housing Be sure that the airflow direction of the cooling fan
67. es on the track e Cancel the jib weathervane condition f Check that all the protective devices and safety devices are in normal condition 2B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 2 In service a The driver should operate the crane in the cabin b Test the motion of each mechanism with no load and low speed C It is forbidden to use any operating mode which may threaten the tower crane safety d Before traveling drive the jib to the center line of the track e It is forbidden to pass the load over the person when the crane is in service f It requires someone to guide when the load is out of the sight of the driver g It is forbidden to sling overload out of the specified radius h It is forbidden to sling heavy load when the load has not been hang firmly 1 It is forbidden to canting pull the load 3 It is forbidden to sling the load which has fixed to the ground k It is forbidden to stop normal motion by emergency stop button it only can be used in exceptional case which may threaten the safety 1 It is forbidden to use limiter and brake as an normal stop device m It is forbidden to short circuit change and adjust the safety device or obstruct its normal operation n When the max wind speed is less than 20m s the load should be lower than 1m t Stop working if the wind speed reaches to 20m s 0 Make sure that there is no obstacle enters into jib slewing area af
68. exceeds max limit of working speed 10B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 2 Hoisting limit switch 10 2 1 Purpose Hoisting limit switch is a device to avoid any possible error operation a To stop the hoisting up motion as soon as the pulley block comes near the jib trolley at 1 2m distance b To prevent the wire rope from completely unwinding or winding up onto the drum in the reverse direction when the pulley block is lowered 10 2 2 Working Principle See Fig 10 2 1 The limit switch which equipped with a reduction gear and located on the chassis of drum is driven either directly by the drum shaft or the pinion engaged a gear ring It drives several cams to rotate which control the circuit breakers so as to cut off the corresponding motion Note Each time when transferring the tower crane to a new jobsite and before putting it into service it is essential to unscrew the plug located at the lowest part of limit switch in order to drain away the condensing water This plug must be re screwed before the tower crane transportation 10B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 2 3 Adjustments After the tower crane reaches to the predetermined height Adjustments must be carried out with no load Control the hoisting or lowering motion and operate contact A or D manually so as to determine the contact which cuts off the control motion Note If changing the h
69. f the crane unless the tower crane manufacturer permitted 7 Service lubricate and debug the tower crane according to the cycle specified in operation manual 8 The crane operator should know the position of fire proofing equipment and grasp the method of using it 2B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 2 3 Personnel selecting and their qualifications 1 The tower crane musts be operated by qualified person 2 The crane operator must be trained There must be a specific regulation about the ability of driver erector maintenance and service person 3 Crane operators should clarify their responsibility and make them know that they should refuse all the orders which act against the safety 4 The experienced personnel must supervise on jobsite when the tower crane is operated by trainees or learners 5 The installing debug and maintenance of electric equipment must be operated by competent electrician 6 The debug and maintenance for each mechanism must be operated by professional person 7 The installing debug and maintenance of hydraulic devices must be operated by experienced person 2 4 The safety rules during working stage 1 Every time before starting up a Give audience to the order of jobsite supervisor b Switch on the power supply c Remove the cushion block release the rail clamping device and other fixing devices wind speed 13m s d Check that there is on obstacl
70. gize and braked which made the jib fixed in proper place Only use the brake button XRFS after the jib was fully stopped so as to prevent the tower mast from distortion The control lever in left control panel can move in various directions When push the lever forward trolley out DAV in reverse DAR When push the lever to the left the jib slewing to the left RG in reverse RD There are three shifts respectively for moving forwards and backwards while the lever can be pushed at random towards left or right without limit of shift The bigger the turning angle of the lever is the faster the speed of slewing will be The lever can also pushed in oblique direction to be controlled in the form of which drive both the trolleying and slewing operate in 2 direction at the same time 3B 13 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL The right control panel is equipped with Parallel connection button SH Graphical symbol with functions as follows The button is used in special case such as telescoping changing falls and so on When move the trolley in or raise the hook and the limiter cut off press down the button SH continue operating until the trolley reaches to the jib root or making the hook reaches to a highest position to finish the aforementioned job As shown on the panel the lever in the right control panel can be pushed in cop accordance with instead of that is to say
71. hich fixed on the ground 3B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Dm Special notice If hear some abnormal noise stop operating the tower crane immediately and inform to the site supervisor if the wind speed reaches to 20m s and sent audible and visual alarm it must stop working if the load is out of the sight of the driver there must be someone as a guide never cancel any safety device or adjust at random without authorization 3 4 3 Each time after operation a Lift the hook to the top end b Drive the trolley to the jib foot start the weather vane and brake device to make the jib slewing freely weather vane effect If power off manual operate this device For traveling type of tower crane anchor the crane by 4 rail clamping devices Note The weather vane effect that is to say above the upper slewing of the tower crane can slew freely it can reduce the windward area automatically Thus the crane driver must start the weather vane effect after he is off duty c Turn off the main power supply switch and take the measures against rain d Press down the emergency stop button and cut off the power supply 3B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 4 4 Periodical inspection 3 4 4 1 Electricity Inspection item Cycle After each erection One month Check the max value of tower crane supply voltage V Check that whether the c
72. hinery the working environment as well as the wire rope used If possible the wire rope should be cleaned and greased especially the bended and curved part of wire rope which reeled through the pulley The type of lubricating oil should be suitable to the grease which used in the wire rope factory Lack of maintenance is one of the common reasons for short life time of wire ropes especially when the machinery works in corrosive environment or the wire rope can not be greased due to some reasons caused by the limitation of operation 11 4 Inspections 11 4 1 Daily observation It is recommended to observe all the visible parts of the wire rope every working day so as to discover any damage or distortion in time Pay special attention to the part which fixed on the tower crane if any obvious change is found inform the person in charge to inspect the wire rope according to the fourth item listed below 11 4 2 Periodical inspection by person in charge The following items should be taken into account in order to determine the inspection period and inspection cycle a National statute for hoisting machinery such as GB5144 2006 Safety rules of tower crane b Types of hoisting machinery and it working environment c Working grade of hoisting machinery d The test results and the defects before e Working time of the wire rope since its initial use Ensure that the wire rope used on the tower crane was inspected at least
73. hydraulic oil of oil pump outputted come into the small chamber via the combination reversal valve P and B the high pressure hose assembly and the hydraulic lock Open the hydraulic lock at the same time and make the piston of cylinder move upward the hydraulic oil of the small chamber flow back to the oil box via the hydraulic lock high pressure hose assembly and combination reversal valve H and T the telescoping cylinder start to lower The lower speed depends on the throttle valve of cylinder 9 4 Operating and maintenance 9 4 Correct connect the main power supply of motor Make the motor rotate anticlockwise Open the cover of hydraulic air filter and fill up the clean and appointed hydraulic oil Connect the hydraulic telescoping system pipeline according to the hydraulic system diagram and screw up the joint test run and check that whether the hydraulic pump is in normal condition The cylinder maybe jogging at beginning turn left the airbleed screw via air bleed hole of cylinder and spurt some oil Operate it several times if it didn t jogging any more tighten up the airbleed screw rightward check the pressure of telescoping overflow valve the overflow valve is 40Mpa before leaving factory it no needs to adjust If necessary it can be adjusted and the overflow valve for lowering is 6 5Mpa namely observe the pressure when the cylinder extends completely and retract completely After the above work it can be putting into service
74. ic force to release brake 6B 13 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 The maintenance of clamp type brake a Check the brake tongs 1 Check the brake tongs every 200 hours or each month Stop the hoisting mechanism and check the brake tongs Carry out the following operations Check the characteristic of brake tongs Check the piston stroke Insert pressure gauge See Fig 6 4 3A Release brake set up the P 140 bar on brake tongs See Fig 6 4 3C Screw out the temper screw 3 via locking plate 2 See Fig 6 4 3D Un A 0N Re C oU WN Cancel the pressure P there is a clearance J min value Otherwise reset the pressure and screw out the adjusting rod See Fig 6 4 3E 6 Set up the P 140 bar measure the stroke C with dial gauge max value The C must is 2 7 0 2mm Otherwise replace the brake tons It is forbidden to readjust the pressure adjusting nut 5 See Fig 6 4 3F i RSNZ z EE TRA RCA IAN MS 4 MAS PRESE T AA 5 UA REE 6B 14 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL c Check the spring force of disk spring 1 Initial condition See the adjustment of brake tongs working stroke See Fig 6 4 4 install the dial gauge and pressure gauge D The initial pressure of piston rod See Fig 6 4 4A Adjust the relief valve from 0 140bar make the dial gauge shift 0 1mm read out the P1 its value must 65
75. ility of new wire rope are not lower than the original one and the new wire rope is applicable to the groove of drums and pulleys Prevent the wire rope from knotting twisting together buckling or adhering sundries Before putting the wire rope of tower crane into service the users should ensure that all kinds of devices involved with the work of wire rope are in normal working condition In order to keep the wire rope in place steadily operate the tower crane with 10 of the rated load several times 11 2 1 Fitting new wire rope 1 Completely unwind the wire rope on the clean ground and avoid any twist see Fig 2 1 If it is not possible to unwind the wire rope completely unwind it in large loops In this way it can avoid danger during enwinding the wire rope onto the drum 2 Check the length of wire rope 11B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 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 less than 3cm the tightening moment of the screw is 9mdaN 4 Hoisting up and enwind the wire rope onto the drum 4 10 circles tightly See Fig 2 2 5 Check the adjustment of limit switch and readjust it if necessary Fig 2 1 Fig 2 2 11B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 11 3 Maintenance The maintenance of wire rope depends on the purpose of hoisting mac
76. imum load It is forbidden that the working load exceeds the max load The load limiter MSWL is a safety device to prevent the tower crane from overload 10 6 2 Working Principle When passing through the proving ring pulley of hoisting wire rope the rope produces tension due to the action of load The tension was transmitted to the proving ring 9 which connects with the pulley As the load changes the proving ring begins distorting as well as the metal plate 10 which equipped with inching switches 2 4 6 and 7 and adjustable screw 1 3 5 and 8 According to the requirement of the load via proper adjustment the inching switch 2 4 6 and 7 was depressed so as to control the circuit 10 6 3 Adjustments Dew Special suggestion Confirm the rated load of tower crane before adjusting the load limiter then debug the relevant data Fig 10 6 1 1 3 5 and 8 adjustable bolt 9 proving ring 2 4 6 and 7 inching switch 10 metal plate Note 1 The tower crane should be set 2 sensitive switches and adjustable bolts 2 Except normal inspection and maintenance for the load limiter after each erection and changing falls it must be readjusted according to characteristic parameters 10B 11 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Table 10 6 1 e Adjusting the speed limiter SLCHGV
77. ith load the elastic plate began distorting the distance between the two plates became smaller due to the action of load moment If the load exceeds rated value the adjustable screw on one elastic plate depresses the switch contact which located on the other elastic plate so as to cut off the control circuit and stop the mechanism motion 10 5 3 Adjustments new Special suggestion Confirm the rated load moment of tower crane before adjusting the moment limiter then debug the relevant data f a E Light load Overload 4 A L C n i P 9 D EH d I Hd xl SLMO A Fixed radius variable load SS TT 5 SO SDMO C Fixed load variable radius RDMO D Variable radius deceleration 1 Elastic plate 2 Limit switch 3 Adjustable screw 4 Moment housing 5 Installation support Fig 10 5 1 10B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Table 10 5 1 1 Adjusting the hoisting moment limiter SLMO 1 Drive the trolley to the jib nose and lift the specified load X with rated speed in 2 falls according to the jib length adjust device A 2 Lower the load then lift a load of Y X X 10 with the lowest speed in 2 falls The inching switch SLMO will move and cut off the circuit otherwise it should be readjusted 2 Adjusting
78. its working principle Lows po yL CH l M Q O mm ee li E a AN De N zz S Na 7 N T Em m NS CEE 1 PN E tia ses da gt BT bs i m S d sel X j SUR 5 LI V A Dis dt 6 1 outer support 2 reducer 3 drum 4 motor 5 limiter 6 brake 8B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 8 2 1 Mechanism working principle ABCN XD PLC VVVF Detecting signal DFS Explanation the choice of trolley speed must be din accordance with the trolley distance It must accelerate or decelerate gradually 8 2 2 Safety test signal Fixing load changing radius the information sent at 80 of the rated radius RDMO Fixing radius changing load the information sent at the rated radius SDMO PLC program reset DBo The confirmation of frequency converter power supply DA The declutch conformation of motor PC P4 The engagement conformation of motor M M 8 2 3 Output signal The malfunction of frequency converter MA MC Overheat protection of brake resistor PC P5 8 3 PLC cont
79. ked eye The wire rope should be discarded if the surface appears pit and the wire rope became slack b Internal corrosion The wire rope should be discarded if the internal corrosion is serious 11 6 10 Distortion The wire rope can generate the visible deformation due to mechanical damage or local fatigue They are undulation cage distortion appeared in multilayer wire rope wire extruding local diameter enlarged kinking local diameter decreased part 11B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL collapsing bending and so on The wire rope should be discarded if it appeared the above conditions 11 6 11 Damage which caused by heat or arc If the surface of wire rope is in annealing condition due to the heat factor it should be discarded 11 7 Relevant equipment conditions for wire rope The drum and pulley should be checked periodically in order to keep them in normal condition The radius of pulley groove should be suitable for the nominal diameter of wire rope Notice in particular e It is forbidden to use the wire rope on mechanical drives after it damaged e It is forbidden to make the wire rope distorting which may damage the safety and service life of wire rope e Visually inspect the whole length of the wire rope every three months e Replace the wire rope if occurs the following conditions breaking down the wire rope diameter decreased due to corrosion or wear distort crushing folding k
80. l wire rope for machinery 3B 15 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 5 3 Operation of weather vane effect unlock the slewing brake 1 When the tower crane is out of service press down the button for 1S 2S which is in the side of electrical control panel HF the indicator lamp of weather vane lights up 2 Cut off the power supply of left control panel by means of the break button O At this time the slewing brake is unlocked in release state At last cut off the main power supply of the crane 3 Unlock the slewing brake manually in release state see 7B slewing mechanism 3B 16 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 Power supply and schematic diagram AL POW EE SIP oles ita 4 1 1 POSVeRSUDD laica ae Letal A A N 4 1 3 Power supply capacity and supply voltage requirement 4 1 4 How to see electrical schematic diagrams 4 1 5 Electrical schematic diagram symbol 4 1 6 Electrical schematic diagram figure 4 1 7 Wiring diagram of Cables cidad 4B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 1 Power supply 4 1 1 Power supply Install the electrical equipment of tower crane according to the national standard requirement ST series tower crane meet the relevant regulations in design and manufacture the management regulation of power supply use on jobsi
81. lewing mechanism can rotate freely 2 Release the weather vane device a Lift the manual brake release lever 1 i e movement A b The clip 3 ejected out under the spring force 4 c Release the manual brake release lever 1 d The weathervane effect accomplished and the slewing should be standstill A Fig 7 5 1 7B 12 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 Working principle 1 brake engaged 2 brake released E E RIE MAA er E e A T CR EI MN LE Pc SS pA Eg Note E is the clearance of brake which value must be kept between 0 8 1 2mm if necessary adjust it 7 5 2 Electric startup of weather vane Explanation it is an electromagnetic brake which is engaged as soon as the current cut off It has its own and independent power supply 1 brake engaged 2 brake released dll 7B 13 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 5 3 Maintenance and service of slewing brake Note it mustn t have any foreign bodies in the brakes such as cement sand grease etc 1 Unscheduled maintenance The maintenance should be carried out under the following conditions a Insufficient braking moment which is caused by worn and damage of brake pad b The indicator light is out of work 2 Scheduled maintenance a Maintenance the slewing brak
82. ng N oil level V draining R fill up 1 year 1800 hours Maximum Minimum Minimum Because of different working environment temperature the lubrication oil used in the hydraulic pump station should be different The user should add proper hydraulic oil according to the environment temperature Number of hydraulic oil environmenta 30 20 C 20 10 C 10 0 C 0 20 C 20 38 C 38 80 C temperature Code YC N46D YC N32 YB N32 YB N46 YB N68 YB N80 above N46D Low Mn TR UT nc n ps Rove NODE New grade paint point 5 Antiwear Antiwear Antiwear Antiwear 2 t a lic oi un QU Sa hidradhecott hydtailic dl ydraulic oil hydraulic oil hydraulic oil hydraulic oil nem 30D 208 208 304 404 gt 50H grade 13B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 3 6 Greasing the rope guiding pulley Before the rope guiding pulley putting into service fill up the grease Meanwhile add grease every 50 hours 2 lithium based grease Before greasing clean out the impurity oil on the shaft 13 7 Greasing the slewing ring Before installing the slewing ring fill up the grease Meanwhile add grease every 50 hours In case of long time no using of the slewing ring it should be greased Each time when greasing the gear ring should be fully greased until it bleed from the sealing place Turn the slewing ring slowly while greasing which can make the grease evenly The tooth surface
83. not or other damage twist distortion if the wire rope drying or oxidation using the RC oil to lubricate e Dismantling the old wire rope lower down the pulley block on fixing support loosen the wire rope from its fixing end unwind the wire rope from the drum dismantle the double bulldog of wire rope and loosen the single bulldog of wire rope but don t dismantle it 11B 10 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL APPENDIX Common wire rope defects If the wire rope damaged it must be replaced immediately The damage causes are as follows 11B 11 Individual wires bend up and protrude from the strands the wire rope serious damaged which caused by stress changing Increased diameter of a parallel enwinding wire rope results in distortion to the metal core due to abrupt change stress Corrosion and wear are often noted on the external layer of the wire rope Example of serious bending of the wire rope Basket slacking birdcage of multilayer wire rope non rotating type which caused by forced enwinding of the wire rope through narrow groove or large deflection angle en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 12 Slewing ring Periodical inspection for fastening bolt of slewing ring type 013 50 1830 101 Frequency of inspection After the initial 100 hours running of the slewing ring the pretension of the bolt should be inspected After this it should be in
84. omposition of hydraulic devices i 9B 2 9 2 Basic technical Parla 9B 3 9 3 Wotano PHI sile 9B 3 9 4 Operating and Main cas 9B 5 9 5 The common failures and troubleshooting 9B 7 9B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL The hydraulic system of ST series tower crane is composed of hydraulic pump telescoping cylinder joining hose and so on 9 1 Composition of hydraulic pump station It mainly makes up of oil box filter motor oil pump combination reversal valve pressure limiting valve and pressure gauge Motor Electromagnetic starter Combination reversal valve Name plate Oil box Temperature gauge for liquid level Oil outlet Lifting point Hydraulic air cleaner 10 High pressure fluid connection 11 Low pressure fluid connection 12 Pressure relief valve 13 Pressure gauge Pump outline diagram air bleed hole throttle valve Outline drawing of telescoping cylinder 9B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 9 2 Basic technical parameter YZ 3 YG 7 Hydraulic oil N46 antiwear hydraulic oil or
85. on f Are screws loose Tighten loose screws External terminals mounting bolts connectors etc Are connectors loose Reconnect the loose connectors Clean out any dirt and dust with dry Cooling fins Are the fins dirty or dusty air under the pressure of 39 2x10 58 8x10 Pa 4 6kg cm Clean out any dirt and dust with dry Is there any conductive dirt or oil air under the pressure of mist on the PCBs 39 2x10 58 8x10 Pa 4 6kg cm otherwise replace it PCBs Is there any abnormal noise or Cooling fan vibration or the total operating Replace the cooling fan time exceeds 20 000 hours Clean out any dirt and dust with dry Is there any dirt or dust on the f y air under the pressure of Power elements 9 Clements 39 2x10 58 8x 10 Pa 4 6kg cm Pikering Are there any disorders such as Replace the electrolytic capacitor or electrolytic i discoloration or odor frequency converter capac tor 13B 11 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 4 3 Scheduled maintenance of parts and components The frequency converter is composed of many parts and components It is necessary to carry out maintenance for these parts and components as per their usage conditions Periodical inspection standards vary depending on the frequency converter s setting environment and usage conditions The frequency converter s maintenance periods are noted below Keep them as ref
86. ongmao com cn E mail sun yongmao com cn Manufacture License of Special Equipment No TS2410592 2008
87. onnection of earth wire is in V V good condition Check the connecting condition between tracks and V between tracks and earth conductor Check the earth resistance of tower crane V Check the insulation resistance of electric equipment V Check the motion of relay in each circuit which can V protect the tower crane safety Check the insulation resistance of motor V Check the contact condition of switch contact in V circuit Check that whether the connecting terminal in each electrical panel and resistance box including the V V inner binding screw and nut is tightened up Ensure that every electrical component is in good condition and connecting wire for them has already V V been tightened up 3B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 4 4 2 Machinery Cycle Inspection item After each One erection month Mast verticality and levelness V V Visual inspection of gear ring bolt V Tighten up of slewing gear ring bolt V V Metal structure Visual inspection the fishplate connection on standard mast jib counter jib and fixing plate on V base plate including pin split pin and bolt lt Detect the crack of section steel and check the V weld joint Hoisting winch Adjust and check the Slewing mechanism brake with max load Trolleying winch Traveling mechanism Hoisting winch Check the worn out of Slewing mechanism Mechanical wea
88. op button power horn button parallel connection button RG Slewing to the left RD Slewing to the right DAR Trolley in DAV Trolley out LH Hoisting LD Lowering TAR Travelling backwards TAV Travelling forwards 3B 12 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL On the left control panel 1 Power supply button also horn button symbol warning light VOI and de energize button emergency stop button O First turn the emergency button to the right till it was sprung out Then press the power supply start button the power supply of the tower crane was started up main contactor P of electrical control panel A start work while the horn hooting and warning light shining When press the de energize button emergency stop button O the power supply is turned off main contactor P of electrical control panel A is released The de energize button cannot reset turn back automatically If required turn it to the right until it springs up by itself Press the button to cut off current when the crane is out of service or to meet the emergent requirement such as the contactor attaching mechanism is out of control or other emergency requiring current break 2 Slewing brake button XRFS Graphical symbol POE with functions as follows In the windy working circumstance and the wind speed is under 20m s it s necessary to hoist a load in fixed point As the button was pressed down the slewing brake de en ener
89. ormer G1 G2 Weathervane switch RD Left slewing contactor XRFs Lock jib button RG Right slewing contactor SRD ps ronden XRal XRa2 Brake relay imiter SRG slewing a haded RFa Slewing brake contactor limiter Slewing E PXR potentiometer XRD Left slewing auxiliary relay RRal RRa2 Vortex coil XRG Rigit slewingausiliany relay RM1 RM2 Slewing motor T Terminal board HVeMI sh HVeM2 Slewing blower fan MTC Slewing silicon controlled GT Telescoping motor RCV Slewing controller AOM Auto iO H K Socket for control wire system motor TSDi Transformer primary H D Trolleying control wire breaker socket TSDil Tian E H R1 Slewing control wire socket secondary breaker PLDi PLC power breaker H R2 Slewing control wire socket FaDi Cooling fan breaker H R3 Slewing control wire socket RedDi Diode breaker H A Socket for H box to A box DDi Trolley main breaker H DMo SOEREN LONH DOO moment RDi Slewing main breaker H AOM Bos a H Socio quio lubricating system GTDi Po I XA Start button telescoping motor Red1 Red2 rectifier VOI power indicator DA oe O Emergency stop button contactor 4B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Symbol Description Symbol Description Control lubricating AO system motor P Main power contactor contactor XTAv TENER Ed OHIO XP Main power supply rela switch P ppyreay XTAr Traveling backward TAv Traveling forward contactor switch XTGv Traveling 2 switch TAr T
90. orque by force In reverse rotate the disk anticlockwise will reduce the output torque Adjust the output repeatedly until the cable can wind successfully and avoid overheat of motor This optimum position can extend the life of reducer Pull out the locking parts screw the locking parts which sides with threaded into the hole of reducer see Fig 5 3 4 Installing direction of locking part In debug Out of debug Socke Locking part MH amata Socke Locking part Reducer housing ATI 1 ll RNY 2 Reducer housing HA Adjusting nut y id SS Adjusting nut Figure 5 3 3 Figure 5 3 4 5B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Notice 1 Switch off the power supply before opening the housing of slip ring 2 It is strictly forbidden to insert the locking parts into the nut groove in working condition 3 The grease level of the reducer should be above the center of inspection hole Service and maintenance 1 When the reducer putting into service first time after the first month the grease in the reducer must be replaced 2 Check the oil level of reducer every two month when it lowering than the center of inspection hole add grease 3 Check the tightening condition of electrical parts in slip ring every two month Make sure that they contact well and the connection of cable joint is reliable 4 After putting into service a period of time check the winding and unwinding condition of the cable drum 5 Repl
91. pe and joint so that check up the oil leak and external malfunction if so eliminate it immediately oil leak may cause damage and fire c Release the component pressure according to the relevant regulations before repairing d Install the hydraulic pipe line correctly Do not connect the high and low pressure interfaces in reverse Meanwhile the joint length and quality of the flexible pipe should meet the requirement e Hold the oil quantity and quality in the oil box 2B 6 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 Operation 3 1 General FUlEsS P 3B 2 3 2 Operation highlights oooosooessoeossocessoeessocsssoesesocecsoecesoosssseeesoossssee 3B 2 3 3 Operation instruction iii ii 3B 3 3 4 Precaution during operation ssscessseessoocssoecesooessseoesoosesseeesoossssee 3B 5 3 4 1 Each time before operation ccccscsssscccsscscssscsccsscscessscceeeees 3B 5 3 4 2 Duro operation sissi rire nana UR osas ricas 3B 5 3 4 3 Each fime after operation u eode eere en eran none zia 3B 5 3 4 4 Periodical INS PCCHOMiesssscnrcacccescsvavecsssccnesc cearsorsnacccccexastscsaicoccncasdens 3B 6 3 9 ODEPFALPTIOH ioa ten lana rina ea 3B 9 3 5 1 Control panel layout and operating method 3B 9 3 5 2 Precautions during operation vsrrrcrrrrrrrrerrrrsccesreseesececenecoo 3B 12 3 5 3 Operating method of weather vane effect 3B 13 3B
92. ram of cable for stationary type of tower crane 4B 12 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Control procedure charts for power supply A box control element electrify order explanation 50Hz 60Hz 380V Di T 48V control voltage airbreaker 50Hz 60Hz 48V CXORD CXOL CXORD left interlock desk zero position i XJ CXOL right interlock desk zero position f XJ phase protect relay starting uh ak XP door relay XP 7A P door contactor e O e XP P T break off XP and P stop FAN XP triphase power supply break down Ne EN HEP 4B 13 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 5 Traveling The composition of bogie traveling system The bogie traveling system is composed of four bogies with motor two limiters a cable drum and an electric control panel Each bogie is composed of a driving wheel and a driven wheel a reducer which directly engaged with driving wheel a dual speed squirrel cage motor and each motor equipped with two sets of brakes S 1 Working principle The speed adjustment of bogie traveling adopts four sets of dual speed motor pole changing control and each motor equipped with service brake and auxiliary brake TAv is a contactor to control moving forward TAr is a contactor to control moving backward TPv is a contactor to control first shift TGv 1s a contactor to control second shift RE controls the service br
93. rameter 02 01 it can set availability invalidation Co rotating reversion MENU MENU key PE menu key Choose each mode ESC key ESC a Press ESC key back to previous state JOG key i E 1 inching Inching key during operation FWD REV key Switch the rotary direction during operating gt SHIFT RESET key Choose the digit of parameter setting RESET shift reset As reset key during occurring failure Choose the mode parameter number and setting value Add key add etc Use when carrying out next item and data Choose the mode parameter number and setting value Reduce key reduce etc Use when returning to the previous item and data Ensure the number of each mode parameter and DATA DATA ENTER key setting value ENTER data input When changing from one menu to next menu it can be used e RUN key Press this key to start up the frequency converter running during operating Press this key to stop the frequency converter during STOP key operating EB stop Via setting parameter 02 02 it can set availability invalidation when control circuit terminal running 7B 7 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL There are indicator lights on the left above the RUN STOP key There are three states light up flashing and light off During DB initial excitation state the RUN key is flashing and STOP key is lighting up The parameter of freq
94. raveling Dackward contactor Cable drum driven Traveling at low speed E TPV motor contactor contactor Forward end limit STAv RE Cable drum relay switch STAr Backward end limit TGV Traveling high speed switch contactor TMI TM2 Traveling driving EDi Cable drum motor TM3 TM4 motor contactor TFS Traveling brake XBa Circuit breaker Control solenoid transformer XGi Weathervane button XJ Phase MEE E phase protection relay VGi Weather vane light TDi Traveling motor breaker TSA Control transformer 4B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 6 Electrical schematic diagram figure See table 4 6 1 Table 4 6 1 Description Figure Description Terminal strip HF Panel Terminal strip HF Panel Terminal strip L Panel Terminal strip D Box Terminal strip R Box ee Electric Horn button switch Switching off button Emergency i Overload Auto break switch Push button switch Power switch Stroke switch Panel Lever controlled switch contact Push button switch Three phase squirrel cage asynchronous motor Linkage switch Three phases wind rotor asynchronous motor Resistance Transformer Delay action N C contact Brake DC excitation winding Delay action N O contact Bow wave brake winding Delay action N O contact 4B 10 en version 2 0 TOWER CRANE OPERATION
95. re rope from distorting 7B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 2 Composition of slewing mechanism and its working principle The slewing mechanism is composed of torque motor or frequency converter motor planetary reduction gear see Fig 7 2 1 It adopts frequency converter and electronic control eddy current control system Through adjusting the motor stator power frequency and the eddy current brake voltage the speed can be adjusted The slewing driving system is composed of torque motor which adopts two sets of eddy current brakes and one set of weathervane brakes and planetary reduction gear Weathervane brake can be brake and released automatically or manually Electromagnetic brake is released when power on while brake when power off When power on the slewing brake is always released During operation if necessary adopt the slewing brake to protect the crane against action of wind under the condition of wind speed is less than 13m s and slewing movement stops completely At the end of each shift make the electromagnetic brake work automatically or manually so that the tower crane getting into the state of weathervane effect The eddy current brake armature of the motor rotates with the shaft The electromagnet of the eddy current brake produces magnetic field in the air gap 01 around the armature when the excited coil was supplied with direct current The armature incises the magnetic field so as to fo
96. ring plate Trolleying winch parts Traveling mechanism Hoisting winch Slewing mechanism Check the oil level of Trolleying winch reducer Traveling mechanism Cable drum Hydraulic push rod lt sE Check the hook hook pin and clamping plate Adjust the tensile force of trolley wire rope lt Check the wire rope and joint lt lt lt ISIK lt II ue e ee eA lt Others Check that whether the swing pulley is in perfect condition check that whether the prevent twist hook at V fixing point of hook end is in perfect condition lt Check the automatic locking device in 2 4 fall or V V double trolley locking device 3B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 4 4 3 Safety devices Cycle Inspection item Before After peak everyday changing si One month work fall Load limiter V V V Moment limiter V V V Hoisting limiter V V V V Slewing limiter V V V V Trolleying limiter V V V V Traveling limiter V V V V Prevent rope broken devices V V V V Prevent shaft broken devices V V V V 3B 10 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 4 4 4 Lubrication Cycle Inspection item ANET md One month erection guide pulley of hoisting wire rope V V bearing or axle box of hoisting drum Lo lubricate the groo
97. rm potential field and the current that is eddy current is obtained Because of the mutual action of magnetic field of eddy current and electromagnet produce brake moment that is directly proportional to excited current and rotate speed of the armature Through the frequency control and the eddy current braking it can fulfill the stepless speed regulation perfectly 7B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 1 Torque motor 2 Planetary reduction gear 3 Weathervane brake 4 Slewing ring 5 Travel limiter 6 Eddy current brake RA 6 2 b 4 aan Fig 7 2 1 7B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 3 RFCV controller principle ABCN ZA A PLC VVVF E R Control principle diagram It sends the signals to PLC by joystick the output frequency and voltage of the frequency converter is controlled by the PLC output signals and the resistance of the potentiometer On the other hand the eddy current is controlled by the output signals of the potentiometer The frequency converter and the eddy current work together to control the slewing speed to make it balanced when starting and stopping to fulfill the stepless speed regulation when accelerating and decelerating Programmable controller PLC Power supply L_N AC220V Input terminal X0 XF 0 00 0 11 Output terminal YO
98. roller Power supply L N AC220V Input terminal 0 00 0 11 Output terminal 10 00 10 07 The voltage of output point DC24V The max permissible current of output point 200mA 8B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 8 4 Main components and maintenance 8 4 1 Operation part of digital actuator Name and function of the key REMOTE choose running operation Key Name Function LOCACL REMOTE key can switch the running of LOCAL LOCAL REMOTE key digital actuator and control circuit Via setting parameter 02 01 it can set availability invalidation Co rotating reversion MENU MENU key PEL menu key Choose each mode ESC key A ESC exit key Press ESC key back to previous state JOG key E inching Inching key during operation FWD REV key Switch the rotary direction during operating gt SHIFT RESET key Choose the digit of parameter setting RESET shift reset As reset key during occurring failure Choose the mode parameter number and setting value Add key add etc Use when carrying out next item and data Choose the mode parameter number and setting value Reduce key reduce etc Use when returning to the previous item and data Ensure the number of each mode parameter and DATA DATA ENTER key setting value ENTER data input When changing from one menu to next menu it can be used e RUN key Press this key
99. se lower shift for a long time not exceed 10 seconds according to the regulation the shifts should be increased or reduced gradually the time between two shifts should be not less than 1 1 5 seconds During lifting operation the shift 4 and shift 5 are not permitted to change so frequently which may damage the mechanical parts When moving the trolley try your best to switch from shift 1 to shift 2 then shift 3 and in the slewing operation the lever control is required to be handled harmoniously In any case it is absolutely forbidden to operate in reverse direction suddenly or press down the brake button forcibly during jib slewing 3 Put the tower crane into weather vane effect when one day s work has finished 4 During operation provided that the tower crane takes into trouble please call on service man in time It is forbidden to operate the crane with malfunctions In any case for all kinds of safety devices which have adjusted corectly during their initial installation and calibration hoisting moment limiter SLMO trolleying moment limiter SDMO trolleying reducer RDMO load limiter SLCHPV limiting load speed SLCHGVI SLCHGV2 it is absolutely forbidden to modify their adjustments 5 Lubricate the crane during operation in accordance with relevant regulations see 13B Maintenance Pay special attention to the lubrication and worn state of the steel wire ropes see 11B Code for installation examination and discard of stee
100. should be cleaned every 10 days and lubricate with calcium base grease 13B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL The lubricating grease can be selected according to the following table Bear structure Working conditions Lubricating Lubricating grease position Name Consistency grade Standard code rubber seal ring for plastic isolation block low temperature normal temperature wet 40 C 60 C raceway extreme pressure lithium base grease 1 2 BG7324 1994 gear carbon calcium base grease ZG S SH0369 1992 labyrinth seal for metal isolation block High temperature and wet 40 C 140 C extreme pressure lithium base grease 1 2 GB7323 1994 raceway MOS2 complex calcium lubricating grease 2 gear 4 high temperature grease 4 SY1511 65 80 C 180 C raceway MOS2 complex calcium lubricating grease 2 gear 4 high temperature grease 4 SY1511 65 normal temperature proof seawater corrosion 50 C raceway 2 complex aluminium base grease 2 gear 4 complex aluminium base grease 4 SH0378 1992 13B 9 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 8 Greasing the hoisting winch 1 Unscrew the drain plug of reducer and fill diesel oil for cleaning reducer Tighten the plug af
101. spected every 500 hours Enough pretension should be maintained At the same time the pretension of the bolt should be inspected each time when the tower crane is to be mounted and dismounted Method of inspection make sure that the bolts to be checked are not influenced by the tension force due to load or counter weights Using a torque wrench to check the tightening torque of the bolts corresponds to the values as listed in Table 12 1 1 Occasional replacement It may happen that during an inspection one or several bolts show a tightening torque beyond the minimum and maximum torques as stated in the table In such case it will be necessary to replace part or all of the bolts Systematic replacement The screws and bolts used for the slewing ring assembly must be systematically replaced every seven years or 14000 hours Re tightening of the bolts No matter it is after the replacement of the bolts or the slewing ring is re assembled by using new bolts the tightening of the bolts should be carried out continuously and symmetrically in 180 direction Then re tighten them one more time to make sure that all the bolts on the circle have the same pretension 12B 1 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Table 12 1 1 Bolt type 10 9 Bolt diameter p mm Tightening moment N m Max Rated D20 580 520 D22 780 700 D24 10000 900 0 927 9 1500 1350 30 2000 1800 The
102. speed sensor and the dial gauge are connected with three core cables The wind speed sensor outputs the pulse signal which proportionated to the wind speed the pulse was rearranged via the circuit into DC level Then the current is magnified and fed into the gauge to show the wind speed The LED light beam gauge processes the signal via exclusive circuit which lights up 201 raster lines The alarm sounds when the wind speed exceeds the limit value 10 7 3 2 Instructions for use Before power on connect the sensor and dial gauge with the included cable Screw tightly When power on it shows the wind speed and wind force both via ft s and m s readings Green represents the operating zone yellow represents the caution zone and red represents the danger zone Set the limit value to 13 when it hoisting Set the limit value to 20 when it working When the wind speed exceeds the above limits it sent out both audible and visual alarm the relay contact began to work When the wind speed is lower than the limit value it can reset automatically 10 7 4 Adjusting and service 10 7 4 1 The circuit of the wind anemoscope has already been adjusted it is not necessary to readjust it In the event of sufficient depreciation or rough transport conditions the display can be inaccurate or the preset limit value can be biased In this case only a professional staff can open the anemoscope and adjust the corresponding potentiometer 10B 14 en version 2 0 TOW
103. sponding contact D and the hoisting motion stopped Dis 4SLH Ge 8 RLH B 2 RLD 1 SLD Fig 10 2 2 10B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 3 Slewing limit switch 10 3 1 Purpose It is provided for tower cranes without slip ring with the purpose to prevent the cables from twisting and damage The max allowable slewing circles is 3 when the slewing limiter is installed 10 3 2 Working Principle The limit switch is a device with reduction gear which driven by a pinion engaged directly with the slewing ring gear While the crane slewing the reduction gear of limiter drives the cams 4 and 6 to rotate which also controls the circuit breaker inching switch so as to stop the corresponding slewing motion at suitable position See Fig 10 3 1 10B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 3 3 Adjustments The adjustment of slewing limiter should be carried out with no load Control left slewing or right slewing motion and adjust contact A manually to determine which one cuts off the slewing movement a Adjusting the right slewing limiter SRD Slew the jib so that the cables won t be twisted Slew one and a half circles to the right then adjust the cam 4 and check its movement until it depresses the corresponding contact 5 b Adjusting the left slewing limiter SRG Slew 3 circles in the reverse direction Adjust the cam 6 until it
104. te and the requirements of TN S three phase five wire system or TT three phase four wire system power supply The jobsite power supply must meet the national construction department requirements the power supply use requirement third class distribution and two class protection The following system diagram is for your reference Nm MOT DERE ron fib sit Branch Branch m a DSe TN S electrical switch TN S A box 380V 50HZ main TN S i electrical OT TT p or TT ox or TT H ges ai panel I MES Note 1 Both the branch electrical control panel and branch switch box are equipped with air switches and leakage protectors 2 The operating parameter of leakage protector in branch switch box 250mA 3 The user can select the installation method of TN S or TT according to the local supply network administrative regulations 4 All the devices before A box including cable should be prepared by user 4B 2 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL Connection mode of power supply entering into A box A box A box L1 L2 L3 PEN L1 L2 L3 PE pe A B C PE N A B C PE TN S TT The tower crane must be earthed properly no matter which mode of power supply it adopted 4B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 2 Earthing Attention The earth conduc
105. ter draining and volatilizing 2 Fill 18 20 L gear lubricant Oil level reaching to about 1 5 of standard oil level then tighten the plug Keep the grease nipple and around clean Prevent dirty or foreign bodies getting into the oil 3 Check the oil level and add oil every 200 working hours Drain the oil after working 2400 hours clean it and then refill with oil 4 The grease nipple which outside the bearing support on the drum tail was filled up with 2 lithium based grease before leaving factory Check and fill up with this kind of grease after working 200 hours 13B 10 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 13 4 Maintenance and service of frequency converter 13 4 1 Daily inspection Check the following items in service The motor should be no abnormal noises or vibration There should be no abnormal heat generation The ambient temperature should not be too high The output current is not larger than the normal value The cooling fan on the bottom of the frequency converter should be operating in normal condition 13 4 2 Periodical inspection Check the following items when carrying out the periodical inspection Cut off the power supply when inspecting Confirm that the LCD and LED indicators lighten off and carry out the inspection after five minutes Be sure not to touch the terminal when just cutting off the power supply which may result in electric shock Item Inspection Soluti
106. ter the tower crane traveling p If the crane operation is in bad condition stop immediately and send somebody to repair q Make sure that there is enough distance between the tower crane and air electric wire 2B 3 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 After one day s work a Lift the hook below the limit point meanwhile it is forbidden to leave any load on the hook b Drive the trolley close to the mast c Starting up the weather vane effect d Grip the clamp rail devices on the track e Cut off the power supply and locked 2 5 Maintenance and fault clearance during the tower crane operation 1 Debug maintenance and check up each part of the crane according to the method and cycle specified in operation manual and replace some parts and devices according to the regulation 2 If it needs to service and maintenance the tower crane with power off adopt necessary measures to prevent false starting of the crane First lock the power supply 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 maintenance after this it should be assembled and readjusted 2B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 2 6 Instruction for special dangerous 1 When operating tower crane near the air line there should be enough distance between the tower crane and air line a Once the tower crane connected
107. the lever can not be pushed in oblique direction When pushing the lever forward the hook lowers down When pushing the lever to the left or to the right TAV TAR the tower crane travels But for the cranes with anchorage or inside climbing cranes there is no such kind of control lever and no control circuit setting on the panel There are locking devices and zero protective devices for preventing the lever from unconscious movements which is likely to run mechanisms and result in accidents The power supply cannot be started up if the lever is not in neutral zero position Take hold of the lever as shown in figure and lift the locking pin up then push the lever Before lifting the locking pin it was strictly forbidden to push the lever which may damage the mechanical parts The levers on both the left control panel and the right control panel have the same function of auto reset returning zero 3B 14 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 52 Precautions during operation 1 Observe the safety regulations strictly during operation The operation which might influence the tower crane safety is absolutely forbidden For example lift a load buried in the ground slings rope clamps are not in line with relative requirement or is damaged the load is not bundled or colligated firmly lift a load in oblique direction or operating after drinking and so on 2 During all mechanisms operations it was forbidden to u
108. the trolley moment limiter SDMO 1 Measure the distance and mark the valid radius L pn for max load W and the radius L L L 10 on the ground 2 Lift the max load suspending in the air and drive the hook to the marked radius L Adjust device C 3 Drive the trolley to the jib foot then trolley out with rated speed Before reaches to the marked L the trolley motion should be cut off otherwise readjust it 3 Adjusting the moment limiter RDMO which decelerate before reaching to the max trolley radius I I I SE I A DS T E when trolley out Tr high speed R i speed Lift the load X at the jib center then trolley out with T rated speed and adjust device D so that the trolley can running with low speed instead of rated speed as soon as reaches to the radius D D 0 8Dmax Note a The load X W and radius L are selected according to the jib length and falls See table 10 6 3 and 10 6 4 b Adjusting the devices A C and D Unscrew the nuts and bolts until the bolts touches the contact of moment switch but will not cause circuit break 10B 10 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 6 Load limiter MSWL 10 6 1 Purpose The structure and hoisting winch of the tower crane are calculated and designed in accordance with max
109. too tight f When tower crane traveling the jib must be in the centerline of the track 3B 5 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 4 Precautions during operation The working environmental temperature of tower crane is 20 C 40 C the max working wind speed is 20m s and working grade is A4 3 4 1 Each time before operation a Make sure that the power supply cables and switches are in perfect condition b Make sure that each pin bolt and split pin are in normal condition restrict the jib slewing freely release the weather vane effect c Make sure that the counter weight blocks and base ballasts are fixed firmly d Check the hoisting and trolleying wire ropes e Check the lubricating condition of hoisting reducer and slewing ring f Switch on the power supply g Test all mechanisms with no load and check each mechanism brake and limiter if necessary readjusted it h If the working height of tower crane is beyond 50m an anemoscope must be installed If the wind speed exceeds 20m s it can sent audible and visual alarm then the tower crane must stop working 3 4 2 During operation a Never lift load beyond the permitted radius b Never pull load in an oblique direction c When entering into the cabin check that whether the extinguisher instruction plate and warning plate are in place d Check that whether the hailer is in perfect condition e Never lift load or other components w
110. tor of crane must neither include a fuse nor the core of a switch or a cable There are three types of earthing A The earth substance is made of normal earth stake either use q33x4 5mm length 1 5m tube or L70x70 length 1 5m angle B The earth plate is made of steel plate or other stretched metal plate with an area of 1m It was vertically buried 1 5m depth from the ground surface C The copper conductor with cross section more than 28 2 mm or iron conductors with cross section more than 50 mm is buried in the wire casing The buried depth is to be determined by the earth resistance In above earthing methods the copper conductor section coming from the earth substance should be more than 25mm If the soil conduction is poor buried sodium chloride salt in the soil and pour some water For traveling type of tower crane each section of rails must be electrical connected and the two rails must be electrical connected The earth resistance is less than 442 4B 4 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 4 3 Power supply capacity and supply voltage requirement The requirement power voltage of ST series tower crane is in accordance with CE138 and China National Standard 50HZ 60HZ 380V 5 This power voltage refers to the terminal voltage of Panel A during operating the tower crane If the real power voltage is lower than this value
111. ture 6 closed rotor disc hexagonal 4 drive the brake disc 3 to break away from brake state the motor start to work When the motor power off owing to the brake effect of electromagnetic field released the armature via the effect of the main and small spring to increase the pressure to the brake disc gradually make the brake moment increase gradually to make the brake smoothly 8 5 2 Maintenance and service Maintenance if found any abnormal condition such as great vibration overheat burned taste strange noise it must be stopped immediately It shouldn t be used until it is in normal working condition If the brake moment is not enough check that whether there was oil strain in the brake clean it if necessary if not should screw up the adjusting sleeve 9 to increase the working pressure The brake disc is easy worn parts when the distance between brake disc 3 and armature is near 0 5mm it must replace the brake disc 3 Rear cover Lever Slotted nut Spring pin Double threaded screw J i a P PE POSU MEM mE amp The manual release lever mounted at the end of motor When trolley winch suddenly power off and brake occurs failure cut off the power supply pull out gradually by lever 10 and make the brake released Service it must carry out scheduled maintenance every three months and overhaul once a year it only can be putting into service after
112. uency converter has already been set and adjusted before leaving factory The code of frequency converter can ensure the system runs in correct stable and safe conditions The digital actuator is provided for repairing checking and setting of parameters Therefore the customer needn t to open the electric control panel during the system is working in normal condition If it is in abnormal condition check the display state of digital actuator and write down the failure code to judge and clear the fault 7B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 7 4 3 The malfunction monitoring and maintenance of the frequency converter Display Explanation Causes Solution 1 loss of phase in power Low voltage of main circuit supply UVI Standard 380V 2 momentary power failure A n e ong dso and 10 6 3 voltage unstable INA 4 bad contact 1 power voltage too high Adjust the input voltage OV High voltage of main circuit datos Set the deceleration time a check the brake resistor circuit 1 output side earthed short 2 t OC Current is 200 of the rated 2 od with too short Find out the reason and current Accelerationior resolve it deceleration time Output side earthed current i GF is55007 ofthe riced current Output side earthed Resolve it nr ST PANE BUDDLyMS Adjust the power ON OFF UV2 The voltage of control Replace the frequency power supply is too low convert
113. ved clutch gear V V Hoisting winch ball thrust bearing of prevent twist V V device for hoisting hook hoisting wire rope V V the prevent twist device of wire rope V V for jib end Slewing slewing ring V espais external gear ring V V bearing of drum V trolley guide pulley V pol eymg wire rope V winch The tensioner or tension spring of the V wire rope hook assembly V gear ring on driving bogie wheel V Traveling roller support of driven bogie and V mechanism motor ball gear ring for track curve device V Cable drum bearing of drum V Safety pin spring pinion prevent rope V devices broken device Hinge of cabin door turned door V pivot joint Track wheel rim side of the bogie V 3B 11 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 3 5 Operation 3 5 1 Control panel layout and operating method There are left control panel and right control panel on both side of the seat they are also called joystick There is a control lever in the center of the joystick See Figure of lever operating Cabin slewing side joystick hoisting side joystick left DAY dcn right Va 2 Xe K ES RG f Lf 3b 2 CG TGV TAR TAY TGV a L2 Y E ES x y DAR y LH VOI XRFS LI GVI Wi vat Neg OR Ni power lights slewing brake button hoisting power indicator hoisting hight speed indicator IN O LES HEEN 0 U SH back up Nec NL Nb SL de energize emergency st
114. wering even caused the mast swinging Reason The adjustment of throttle valve for oil return circuit is unsuitable Troubleshooting Adjust the throttle valve according to the operation manual until it reaches to the optimum condition If the opening position of throttle valve didn t align with the screw thread it can not be adjusted 2 The joint sleeve damaged Reason The manufacturing process of sleeve wasn t ensured Troubleshooting Replace the joint or weld i e weld the nut and direct connection completely At this time the joint can t adjust the direction of oil pipe 3 The cylinder continually falling down Reason Two chambers of the cylinder have residual gas left not well sealed or the hydraulic oil wasn t clear Troubleshooting Eliminate the gas of the cylinder ensure the seal of control piston and check valve often check the oil cleanliness and ensure the oil box well sealed the control valve of hydraulic pump must be accurately adjusted The high and low pressure interface of hydraulic telescoping system cannot be overturned it is forbidden to adjust the throttle valve with load it must be careful to adjust the high pressure throttle valve 9B 8 en version 2 0 TOWER CRANE OPERATION AND SERVICE MANUAL 10 Safety devices TOT Erik OC COU aco ouo o eiui lebten iu de beth denter tci aud 10B 2 10 2 Hoisting limit switch lille delie 10B 3 II A A A A 10B 3 10 2 2 Working Principle cette etre Hl bea ieget 10

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