STT2OO

TOWER CRANE

II. OPERATION & SERVGE MANUAL

2410P164
Fushun Yongmao Construetion
[l,4ae

hinery flo,, tid,

STT2Oi)

]'OWER CIIANf, OPERATIONAND SERVICE NTANUAI,

Table of contents

TO\IIR

CF.T.\..E

ERECTION ]\IA\IJA,

l. Characteristic parameter
62 onr

l0r

!. r r.t I f-l

40 3 60i !r- --.1

;1q
R

=E

Fall

IV

1
55
50

R(c,"",) C(max) I t6 5l r0.00

3A.24 17.45

II ry
IT

5.00

l0 00
5.00

3t.66
)7.67 32.35

IV

II
4S

I0.00
5.00

lo.oo I lc _s.oo ls. 00

,n l 4rql * 5.0q I s .00

0.00

,t)

T;
5.00 6.45

5.00

5 0U

1q!9L!!

IV

l t? 33.91
{
35.08 _r .9l

,0.u0
5.00
10.00
5.uU

lqli
l!l!
r!.oo

I r0
5. uo

40

J.oo I

II
35 30

ff.-

-I{

J5.00

l0l!
5.00
10.00 5.00

] I 5.r 1o-oo lro. too ls(

lq

io

5o

30 00

ro.oo

I lo. J.o0 i5

ERECTTON ['IANUAL TOWER CRANE

,i",
,ilsa

r11""

rogelafs

3n1

,Fg -t9

O -"*a* "*

t"

service

oui of service Reaction lorce

':;r'l

Freestanding height erghl) and base bllast

(withortr counterweight

parameters Mechanisms main characteristic

Motor
4I
(s5hP)

45L[v258
5.0

1090m

55

55t.Fv25

4.0
1.5

>1090m*
0

0 o

57 m/min

95N.r
57 m^nin

2x120N

5Rl-cv

0.7 rpm 0.?

lpt

2)ti20 N
4:x2'615

12.5

25 rn/min

TOWI.]R CRANI OPER{TIO]AND SERVICtr I\IANUAL

2. Safety rules

2.I The regulation of correct

usel

l) It

is forbidden to use the tower crane which has not passed the performance test;

2) Acco.ding to the technical regulation and method of use, the crane must be used in

its good condition. Pay more attention to the safety to prevent the

dangerous!

Eliminate all kinds ofmallunctions in time which may cause the safety accident;
3) Operate the tower crane in specified scope oltemperahre: (_20.C_+40.C);

4) Qremte

d1e

tower crane in specified limit of wind speed (the max. rvind speed for

opemting is 20m,/s, the max. wind speed out ofservice is 42mls);

5) Obserue the regulation in operation manual and regulation related to serr,.ice and
maintenance.
2.2 Safety measures
1) The

operator should read the operation rules before operating the to\\,er crane:

2) The operator should always remember every safety measure and recognize the
hazard, meanwhile the operation rules should be visible;

3)

It\

forbidden lor the operator to be rvith Iong hair, wearing robe or wearing

jeweiry;
4) Often read the rvaming board about safety and prevcnting from hazard; 5)

lf

the crane is in abnormal condition, stop oper.ation immediately and report it to

the interested personl

6)
5

It is forbidden

1o change

or add any pa s of the cranc, unless the tower

crane

manulacturer permitted;

.{.m

7) Service, lubricate and debug the tower crane according to the cyole specihed in
operation ll,]anual;
8) The crane operalor should know the position the method

0N
r0

ol fire pr-oofing equiprnenl,

a1]d grasp

t.6t5:l

of using it.

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

ications

l-r"r*nn*'"ctingandtheirqualif

person; operated by qualihed be musts crane the 1) The tower regulation about specific a be musl must be trained There operator crane 2) The and sewice person; maintenance erectol' ability of driver' thal they and make them know responsibility' shoutd clari their 3) Crane operatols safety; which act against the orders the all shor'cl refuse ls

rvhen the tolver crane jobsite on personnel must supelise 4) The experience<1
or learners oPerated bY trainees

I I
1

operated by equipment must be electric of debug and maintenance 5) The installing'

I
I

he ooetatd b'v professional be oper must '-"'t mechanism each for 6) 'the debug and mair.ltenance
operated by r--^ 'rl^ devices ^' '.o'ices must be hydraulic of and maintenance 7) '1he installing' debug
exPerienced Person'
2.zt

competent

electfician

person;

working stage The safety rules during

uP:

t) Every time before starting

a). Gl\

supervisor: ( audience lo thc order ofiobsite

b). S\\'itch on the Po\\'er suPPlY;

c). Remove the cushion block'

devices (rvind sPeed

r'elease

and other the rail clamping device

irxing

13nT/s):

on the tracl(; d). Check that tirele iq on obstacles e). Cancel the

jib weathervane condition;

,']]lL.'"f^1^.1i\.r]er,]cesandsafetydel'icesal,einnot.lralconditiofl

TOWf,R CRANE OPEIIA]]ON AND SERVICE IlIANIJAf,

2) In service
a). The driver should operate the crane in the cabin;

b). Test the motion ofeach mechanism with no load and low speed;

c).

It is forbidden to use any

safety;

operating mode which may threaten the tower crane

d). Before traveling, drive the

e).

jib to the center line ofthe track;

It is ibrbidden to

pass the load over the person when the crane is in service;

0. It requires someone to guide when the load is out ofthe sight ofthe driver; g). It is forbidden to sling overload out ofthe specified radius;
h). It is forbidden to sling heavy load when the load has not been hang

tirmly;

i). It is forbidden to canting pull the load;

j). It is lorbidden to sling the load which has fixed to the ground; k). It is lorbidden to stop normal motion by emergency stop bulton; it only can be used in exceptional case which may threaten the safety;
l), lt is lorbidden to use limiter and brake as an normal stop device; rn). It is forbidden to shoft-circuit, change and adjust the safety device, or obstruct its normal operation;

n) when the max. wind speed is less than 20,r/s, the road should be iower than rm2/t. Stop working ifthe wind speed reaches to 20mls;

o) Make sure that there is no obstacle enters into jib slewing area after the
crane traveling;

tower.

p) lfthe 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 ai.eleclric
wire;

F
AND Sf,RVICE MANUAL TOWERCRANE OPEI{ATTON

2.6 ln
3)

to leave any load on is forbidden it meanwhile limit point' a). Lift the hook below the
the hook;

After one daY's work:

l) wl
be

a). On

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

to
b). Dr
c). No

during the tower crane operation clearance fault and 2.5 Maintenance to the method each pa ofthe crane according check-up and 1) Debug, maintenance devices and replace some pafis and manual; operation in and cycle specified
according to the regulation;
adopt tower crane with powel'off' the maintenance and 2l If it needs to service lock the power starting of the crane' First' false prevent to necessary measures

d). Cu
e). Do

cu

2) Me
ele

thc

panel; hang warning plate on the Second' key' the off take and supply panel after during service and mintenance' devices safety some 3) If it needs to dismantle

a) The
m

th

this. il should be assembled and readjusted'

Iin

b),

r
dis col

c).

i1

ma

.I'O\YER

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

2,6 Instruction for special dangerous

l)

When operating tower crane near the air line, there should be enough distance between the tower crane and air line.

a). Once the tower cmne connected with the air line, the driver should stay in the cab,

to prevent from getting an electric shock;

b). Drive the crane out ofdangerous zone at once;
c).

Noti

the person around don,t close to the crane;

d). Cut oflthe power supply which comected with the air line;
e).

Don't leave the tower crane unless you can confi.that the erectric wire has been
cut

off

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

electrician or trainee which is supervised by a qualified clectrician accordins to
the electrical rules.

a) Thc tower crane must be cut

olf the electricity during mainlenance and repai

meanwhile set up a waming plate of ,,manned operation, prohibit switch on,, on

the obvious position of power supply panel, then earlh or sho circuit the power

line (afler this, do please clismantle the eaflhing ancl short circuit line):

b)

The electdcal equiprnent

of tower crane should be

checked periodically.

If

discover some hidden clanger, such as connection loosen, elcctr.ical wire earlhing,
component

breakage, etc, it must be eliminated in time:

ou1

c)

Ifit [rust carry

li'e-\yire work,

tl.rere should [.e someone to r]ronitor. so that the

rnain powel supply can be cut

olI.in emergency situation.

TOWER CRANEOPERATION

AND SERVTCE MANUAL

2.?

IlYtlraulic

sYstem

"r. every kind of conduct check b). Periodicallv so' eliminate t if mlfunction' oil leak and extemal check up the
damage and frre); leak maY oause

O.,r,n" *'*sional

systeul! can operate the hydraulic person or experienced

tt'i.t"tl'-,lj-

::::ffi:;

regulations before relevant the to according component pressure the Release c).
pressure the high and low conect not Do pipe line correctly d). tnstall the hydraulic of the flexible pipe qual and length joint Meanrvhile' the interfaces in reverse

rePairing'

should meet the requiretnent:

oil box' and quality in the quantity oil the Hold e).

TOWTR CR,{NE OPERATION AND

Sf,

RYICE I\IANUAL

3. Operation

OPERATION TOWER CRANE

MANUAL AND SERVICE

Important

notice:
be made debug must

;;ra

it is service when into put be only tower rane can The the tower crane' the issuance of license' authorities with

installation - . t . -, ]La the i-"rqllation upon finishing

of and erection

l*-*U o' lo*l safety

i::::"#:iver

bv authoritative who has trained person qualiried must be e

the exam' units and passed specified or board of labor It is important the crane correctly' maintenance and opelate' service time and The driver must loss of working avoiding availability, improving device failure, for reducing

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

reducers' of all electric motors'

drums'

is more' construcdon What steel iniegral ropes' even the brakes and wire
personnel loss' and result in accident cause serious mechanical 3.2 OPeration highlights

it

may

lt is finishing equipment panel control 1) The or stopping' slowly when starting operated be must 2) The control lever to eet over shlft forbidden is it one' by 3) Change shift one ,-when stoppi"g to*" operation sequential 4) It is forbidden to disobey devl '^"' when actuating gradua tum to zero position 5) The control lever should stopped' mechanism completely the until Operate making reverse movement has a failure' unsoundn device safety the crane which 6) lt is forbidden to operate the safety,devices to pick off or sealed forbidden is it or inaccurate' fuilhenore

when operating must be careful

it'

uttbt

^t'^ **edtal"''.

TOWf,R CRANf, OPEMTIONAND Sf,RVICf, MANI'Af,

forbidden to operate the crane with failure.

8) The driver is entitled to refuse the command which against the safty rules.

9) The driver must master the moment curve, the max. load, the min. load (at the jib
end) and the load under hook in random radius. 3.3 Operation instruction 3.3.1 Starting

a) Check the tower crane before everyday stading according to the instruction
regulation. Ifthere is any problem, repo it and it is not allowed to start anv more.
b) Switch on the main power supply and press down the start button.

c) Test the working condition of all mechanisms with no load and low speed, check
the

limit devices of

al1

mechanisms.

d) Check that whether 3.3.2

a)

all safety devices are integrated and acting reliable.

Operating the hoisting winch

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
Stop forward movement when

oftrolley with low

speed.

* -

moving to the position of moment limiter.

Confirm rhe radius of rrolley stopping posirion.

&umate the weight radius.

of load according to moment characteristic diagram (table) and

)$

c) Use the

min. lifting speed before the wire rope tightened up.

\^

It

d)

u"" qrc lnln. '- -" loucr.in. .no,l

h^n t^,,,-"-., r^^r

SERVICE MANUAL OPERATION AND TOI{ER CRANE

ground) or be over load raking off rhe

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

of

load selecte low speed Heavy load of weight selected as per the g) The speed u'as (GV)' selecte high speed load light and (PV) limiter' operating the stroke
h) Stop moving before
on ground' i) Don't Put the hook

medium sPeed'

load' winding when placing rope avoid to j) Loosen the wire rope slowly

slewing mechanism 3.3.3 Operating the to the shift to be reached' speed according slewing the a) Select allowed' as long as the angle speed max' the b) Every time use

c)

If

;;;;"

its speed' suddenlv changes mechanism the slewing operation mu$ be deceleradon and t-ing So acceleration

t rn"l "":::l:-

,,.done

and It should decelerate firs brake' slewing jib by the d) It is forbidden to siop slewing speed' can brake in minor brake the that so release the control lever' jib in which can keep condition' windy in only be used e) The slewing brake can

graduallY.

then

its

position.

When s'lewing the

movement

iib, it

is recommended to operate

the

lifting or

lo1{ering

distofling of at the same time' to avoid

the

it wire roPe and

it

work' convenieni for the rope swivel to

,
,-

limiter stad to work'

TO\YER CRANE OPERAT'ION AND SERVICE MANUA,

3.3.4 Operating the trolleying winch

a) The trolley speed is selected by the distance

ofthe trolley.

b) It must accelerate or decelerate gradually to avoid swing when suddenly changing the shift oftrolley 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

oftraveling.

b) In order to ensure the tower crane safety, when it travels in the track, the trolley
must be at the

jib foot; if operating in the track

curve, beside keep the trolley in the

jib foot, it must travel with low

speed. Meanwhile

it is forbidden to keep the jib

facing toward the inside ofcurve track.

c) Belore
rst
ne

traveling to the end ofthe track, the tower crane operation must be stopped.

d) There are two brakes in the traveling

motot one of them used fbr buffering and

6-g

decelerating, the other used

for stopping the cmne movement which via

seconds time delay after powering

off and automatically baked. After the control

still run a few meters, so this operation should

lever return to zero, the crane can

be done in advance.
e)

Attention during crane traveling:

Wam people to leave the dangerous areas by hailer;
Observe

*
ng is

that ifthere are sorre obstacles on the track:

It is forbidden

to make the cable pileup or pull too tight.

wh"n tow.,
".ane

traveling, the jib *rust be in the centerline ofthe track.

OPERaT"'" TO\NER CRANE

nn'

"'*uttu

ttnnu*
l

during ourru I*u,,ont ].4 precautions

the is: _20C-+40C, -2( -- crane ^-^-tower temperature of environmental The \Yorking rvorking gratte is A4'

operation vr--

irtl
and

rnut.

t*'ting ''nrl

antl speed is 20m/s

of tt
adju

time before 3.4.1 Each

l, ,*. **

^-- i-.erfect in pelfec condition' and switches are cables tn"t tne power supply' the condition' restrict normal in are pin split each pin' f'oft and that sure b) Make
effect)' (release the weather-vane fieely sleu'ing are fixed hrmly' and base ballasts blocks the counter-weight c) Make sure that wire ropes and trolleying hoisting the Check ' d) , slerving 1^...i-artng' and reducer condition ofhoisting lubricating the e1 Check
the Power 0 Switch on

operation

jib

3.4.:

a)L

b)r
t
(
(

if brake and limiter' mechanism' each no load and check with g) Test all mechanisms
necessary, readusted

suPPlY'

No

anemoscoPe must an 50m, beyond of towel crane is height rvorking h) If rhe alarm' c) audible and visual sent can it 20m/s' speed exceeds installed ll the wind d) must stop $'orking' then the tower crane 3.4.2 During operation
a) Never

it'

be

Iifl

pern.ritted radius' load beyond the

plate

dilcction' blrever pull load in an oblique

instruction whether the extinguisher' that check cabin' c) When entering into the
and warning Plate are in Place

condition' haiiet' is in perfect d) Chcck that \\'hether the .-t. .,.,hich fixed on the ground'

TOWER CRANf, OP]RATION AND Sf,RVICE MAN

IA

I,

J:-i

Special notice:

If

hear some abnoflnal noise, stop operating the tower crane

immediately, and inform to the site supervisor;

if the wind

speed reaches to 20mls,

and sent audible and visual alarm, it must stop working;

ifthe load is out ofe sight

of the driver, there must be someone as a guide; never cancel any safety device or
adjust at random witout authorization. 3.4.3 Each time after operation
a)

Lift the hook to the top end

b) Drive the trolley to the

jib foot, staf

the weather-vane and brake device, to make

the

jib

slewing freely (weather-vane effect).

If

power

off

manual operate this

device. For traveling

devices.

spe of tower crane, anchor the crane by 4 rail clamping

' lNote: The weather-vane effect,

that is to say, above the upper slewing of the tower

area automdtically. Thus the

crane ca.n slew freely,

it can reduce the windward

,.
I

crane driver must start the weather-vane effect after he is off duty.

Tum off the main power supply switch and take the measures against rain.
ss

down the emergency stop button, and cut offthe power supply.

li

ii:

OPERATION TOWER CRANE

MANUAL AND SERVICE

3.,

3.4.4 Periotlical insPection

3.4.4.l Electricity
lnspection item

I r
After each efection
\
I

voltage crane supply oftower value Check the rax

sr.""r tt ut *h"thffi

:ffi i[T

.*l.--'------'-.'--**.*"*-:""11'::lrt::X:'":,::'*'*o
tower crane resistance of earth the Check of electric equipment resismnce Check the insulation

resistance of insulation the Check

otor

Check the contact

coffi

in of switch contact

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

'ff ::t'Xffi
condition.
been tightened uP

I illiltJfi

TOWER CIIANE OPERATION:1ND SI]RYICE ]!TA'UAL

3.-1.1..:. achinery
Inspection item Mast vefticality and levelness
:1

ViV

Visual inspection ofgear ring bolt Metal

structure

Tighten up of slewing gear ring bolt

inspection rhe fishplare connecron on counrerjib and fixing plare on ',Tlllo-T3^r, ,1,9: base plate, iir"t'uoing piri.iptit
_ -Vi,sual

pil;;?ffii:

Detect the crack ofsection steel and check the weld joint

Adjust and check the brake with max. load

Mechanical parls

Check the worn out wearing plate

of

Check the oil level reducer

of

Hoisting winch Slewing mechanism Trolleying winch Traveling mechanism Hoistins winch Slewing mechanism Trolleying winch Traveling mechanism Hoisting winch Slewing mechanism Trolleying winch fraveling mechanisrr
Cable drun.r Ilydraulic push rod

Check the hook, hook pin and clamping plate

Adjust the tensile force oftrolley wire rope

Check the wire rope and
Othes

+l
-

joint

Check that whether the swing pulley is in periect

condition

chcck that whether the prcr enr ru isl hook at frxing point othoo[ p.ri..i JYrii,t',

"rIr'i,

'lccr( lhe autornalic locking der ice in 2,4 lall or doublc lrolley loc[ing device

iv
],,

I
I

SERVICE MANUAL OPERAIION AND TOWER CRAN 3

devices 3.4.4 3 SafetY

tAfter each
erection

Inspection item

Load limiter Moment limiter

Hoisting limiter
Slewing limiter TrolleYing limiter Traveling limiter
devices Prevent roPe broken devices Prevent shaft broken

.I'OWI]R

C&{NT OPI,]RA]'IO\ AND Sf,RVICI IIIANUAf

3.4.4.4 Lubrication Cycle

Inspeclion item

After each
erection

One month

guide pulley ofhoisting wire rope

bearing or axle box ofhoisting drum

Hoisting winch

lubricate the grooved clutch gear

t all thrust bearing ofprevent

twist

_-!qri""

lor hoisting hook

hoisting wire rope

the prevent twisr device of wire rope for iib end Slewing imechanism
I I

slewing ring extemal gear ring

bearing of drum

trolley guide pulley

L

lTroJleying

I
I
l

winch

wlre rope
The tensioner or tension spring ofthe wire rope

hook assem b1y

gear ring on driving bogie wheel Traveling
mechanism

rollel support ofdriven bogie and

nrotor

ball eear ring lor track curr c device

I

fsc--l---.devi.,

Cable drum

bearing ofdrum

Hre";i-i I prvot L joint

pin. spring. inion. prevenr rope broken device cabin cloor, tumed-door

Track

_i
J

whecl rirr.r side olthe bogie

IOWER

CRANE' OPERATION

NTANUAL AND SERVICE

3'5 OPeration

;a;';*-'
There are
also catled

*"el

method lavout and opertins

unO

panel lefi control

the seat (they are of side both panel on

'igl't "ont'ot
(See Figure

fthe ioystick. in the cente u' "'- -' lever t here is a control
catrin

ioYstick)

oflever operating)

side for hoisting Co-nirol console tor siewing sioe Controt consote

Riqht

_:i..
I

ILD

Let

DAv

_-^,

RG-,

r l,i , _o
i
ot
I

'.- il.
iLH

ivgr)

lo)

tsHl

XRFS

,o*"*,,

RG :
DAR LH

Slewing

leltrvards

RD
TAV

Slewing right\ards

DAV : TAR :
,.

Trolley out Trarelling ba':ku ( Travelling t)Pe)

ard\

TrolleY in

Tra{elling fo(wards
( Traveling tYPe )

Hoisting Locking Posilio11

.x
I

I,D

: Lo$e

ng
\1r^'iinP Dosition
l

i
-..

lr

',

TOWER CRANE OPERATIONAND SRVCE ]TIANUAL

ON THE LEFT CONTROL PANEL:

1). Parallel connection button

SII. Graphical symbol

ryith functions as

follorvs:
The button is used in the special case such as telescoping, changing iall, and so on. when move the trolley to the jib foot or raise the hook to limited position, the limited switch cut

ofl

Press the button SH so as to continue moving the trolley to the

jib root

of the crane tower or making the hoist hook to a highest position until finishing the
aforementioned job.

2)

Slewin lrake lockin

functions as follows:

In the windy working circumstance and the speed of the wind is under 20mls, it,s
necessary to hoist a load bake, which made

in fixed point. As the button

w.as pressed, apply the slewing

jib fixed in place well

and truly. But the plgmise is to stop the iib

Th"
control lever can switch

in various directions as shown in

Fig.2_3_1. The trolley

moves ahead DVA as push the lever ahead,

in reverse, DAR . There are three shifts

respectively

for moving forwards and backwads the jib slew to the left RG as push
left RD. In reverse. The lever can be pushed at random towards left

the lever towards

or dght without

limit of shift. The bigger the turning angle of the lever. is, the faster

e speed of slewing
contolled
diection Thee

will

be. The lever can also pushed

in oblique direction (to

be

in the form of x) which drive both the trolleying and slewing operate in 2

at the same

tire.

__

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

SERVICE MANUAL TOWER CRANE OPERATONAND

-* "r*rls"t*

rn"*-l"""

result in which is likely to run mechanisms and

(zero) be started if the lever is not in neutral cannot supply power accidents. The pin up with shown in figure and press locking as lever the of hold position. Take was strictly forbidden to pin' it Iocking pressing Before lever' push the

hnger, then

parts was destroyed' push the lever lest have the function panel and the right control panel control left the both on The levers

of auto-reset (returning zero)'

IS EQUIPPED WITH: THE RIGHT CONTROL PANEL VOI button') symbol ; warning light horn (also button supply Power

and
to

button O' To begin with' tum the emergency break button (emergency button)

therighttillitwassprungout.ThenpresstheporversupplyStartbutton.Thepower electrical control panel A was stafied (main contactor P of

supply of the towet crane

Startwork)whilethehomhootingandwaminglrghtshining.Whenpressthebreak (main contactor P of O' the power supply is hrmed off

button (the emergency button)
(1um The break button cannot reset released)' is A panel control electrical
back)

automatically.Ifrequired,turnittotherightuntilitspringsupbyitself'PIeSSthe is out of service or to meet the emergent button to cut off current when the crane or other attaching mechanism is out of control
requirement such as the contactor
eurergency requiring current break'

accordance As shown on the panel, the lever can be pushed in

* '"

instead 0l

*X",

Push the lever forward that is the lever can not be pushed in oblique direction'

to lower the hook. travelling cond lwhen the lever is nushed to the left or to the right (TAV TAR)' the

TOWf,R CRANN OPER,{TIONAND SERVICE ]!IANUA,

rin
ero)

olthe crane is effected. But for the anchorage or climbing crane, there
ofcontrol lever installed. And no control circuit is set on the panel.
(2) . Precautions during the operation

is no such kind

,'/ith

nto

l)

Obserue the safety operation regulations strictly during the operation. The
operation which might influence the safety of the crane is absolutely forbidden.

ltlon

For example, raise 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 colligared

firmly; raise
and
.on to a load in

oblique direction or operating after drinking; and so on.

2) During all mechanisms operation,

it was forbidden to use lower shift for a long

time (not exceed 10 seconds according to the regulation), the shifts should be inueased or reduced gradually, the time between two shifts should not less than

)ower mel A
break

1-1.5 seconds. During lifting operation switch tleqrently between shift 4 ad

shift 5 is not permitl.ed lest the parl

will

be destroyed.

It is impodant thal nufture

shift
1

rrP
back)

good operating habit. When move the trolley, do your best to switch from

to shift 2 then shift 3 and in the slewing operation the contlol of the lever is
required to be handled harmoniously.

lss
I

In any case:

It

is absolutely forbidden to operate in reverse direction (make

return) suddenly or to press brake button forcibly during the running of the jib.
3) Set the tower crane in the state
finished. 4) Duing

rcad

of weather vane whenever tl.ris shift,s operation is

rhe operation, provicled that the crane falls into the trouble, please call on

service

man

o[ the rnender in 1io Tt ic f^rhi1. i^

/r1r^rqi rhe crap r.,irh

Sf,RVICE MANUAL OPEBATION AND CBANE TO1{EB

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

;:::":::J;J;''"'-*
hoist speed limiter SLCIIPY

their initial anl truly during well which is adjusted a'Iiustments' their moalify

RDMO' sDMo' tro,ev re'lrucer to absolute forbidden is it limiter SLCIIGV)'

overroad

calibration' installation and with relevant regulaiions accordance in operation your crane during Lubricate 5) CRANE)' Pav special
(SEE CIIAPTER

RULES OF TIIE

wom state lubdcation and the to afiendon

' '"U 'o"'"t

INSTALLATION' I1B, CODE FOR

FOR CRANE) STEEL WIRE ROPE

(SEE CIIAPTER ofthe steel wire ropes DISCARD OF AND EXAMINATION

weather vane (3). OPeration of

(unlock the slewing

brake)

rq_rs which situate in the

the indicator lamp

t)wt,"ntt,'"ctaneisoutofsewice,plessthebuftonfolls!2s,w cabin)' (inside the operators IIF panel control

side of electrical

lights of weather vane

up'

,,

;:,;'l,: l::;-;;;

last' cut off the main At state)' unlocked (in released slewing brake is
suPPlY of the crane'

,*", 'v

break bufton means of the

o ^

,r+tt iqtime,th time' the this At

power

(in brake manually slewing the Unlock 3)

mechanism) '

slewin9 (see chapter 7B release state)

TOWf,R CRANE OPERATION AND SDRVICE MANUAL

4. Power supply and schematic diagram

4.1 Power

supply.. supply

........._...............48-z

4.1.1 Power

........................48_z

,l

I
F

4. 2 Lightning protection and earthing Earthing.......................................4B_4

4. 3 Power supply capacity and supply voltage requirement ...................48_6

4. 4 How to see electrical schematic diagrams......................................... 48_6

4. 5 Electrical schematic diagram symbol................................................48-7

l.:,4. 6

Electrical schematic diagram figure ................................................48-10

ERVICE NTANUAL .TO\YER CRANI] OPER'TIIONAND

4.1 Po\ler suPPlY 4.1.1

standard according to the national crane tower of equipment Install the eleclrical in design and the relevant regulations

Pott"t tupPlY

series to\\'er orane meet requitement ST the use on iobsite and supply power of management regulation manufacture. the four-wire system or TT three-phase five-wire three-phase requiretrents of TN-S construction must meet the national supply porver jobsite The s.vstem power supply "third class distribution supply use requirement po\\'er the requirements'
department

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

Jib site

1\-S
or TT or TT

Branch sitcl't

TN.S

k^\

3U0V

50t{Z

main electdcal

ho\

pael

Note:

wi switch box are equipped branch and panel control 1) Both the branch electrical

box: {3OmA protector in branch switch leakage of 2) The operaLing parameter to the of TN-S or TT according method installation 3) The user can select the
regulations' supply network acltninistralive by user' cable) should be prepared (i[cluding box A beiore 4) All the devices

air swiiches and leakage ptoteciors'

local

TOWER CRANE OPf,RTIONAND SERYICE MANUAL

Connection mode ofpower supply entering into A box3

Ll

L2 L3 PEN

Ll

L2 L3

PE

TN-S

TT

tower crane must be earthed properl no matter which mode of power

ERVICE MANUAL OPER{'TION AND CRANE TOWER

]Q;-gn'ni'eP'otectionandearthins

;"..:"'",::-:":,::::::ilIiJ.::.,'..*iX',:lXil-: be taken into

protection shall 'n,*n". oqoipping
personnel' .o*oon"nts and

the crane

or surge suppressor

" "t:-:'";;n necessar) measures "tt*Y:*.:l:.;""

earth conductt Attentiotr: The a cable' of a switch or of eafihing: are three tyPes
There

:t":,1:-1*

with lightning rotl condition he above special or take aiming at protection' recommended to the actual conilition'
according

.rr,

""t,n"t

the core t"clude a fuse nor

A. The earth

substance

is made of normal

eat1h stake'

(length: 1 5m) tube 5mm <P33x4 either use

(length 1 5m) angle

or

L70x70

r'1
11i ili ,:.]1
,i

is made-of,ree"i'ilr":.1T;,lt:::t: B. The earrh ptare an area ol Im ' metat Plate \\ith the ground surlace' l.5m depth from

c.

rhe coPPer conductor conductors " rurrnr or iron casmg' buried in the wire
mm2 is

il:lX'::::H
l:,:"i;.;r;"d

:::::

l[:';
ro
be

deprh is

resistance' ,.1^t..mined by the ealth

TOWf,R CRANE oPERATIoNAA,D sERvicE bIANUAL

In

above earthing methods, the copper conductor

,""0o,

substance should be more than 25mm2.

chloride (salt) in the soil and pour some water. For traveling type oftower crale, each section of rails must be electrical cormected, and the two rails must be electrical connected. The earth esistance is less than 4.

ffthe soil conduction is poor, buried sodium

"o-rr[--il

TOWERCRANE

SERVTCE MANUAL OPERATION AND

fhe requirement rhe

cEr38

Yurlo- -,ard; power voltage

JJ;;" ,"*rinal ,"-;"-"r';"""=' ',

conductol'

standard: and china National : operatins the tower crane. during A voltage of Panel

'

tl

voltase power voltage ,r,, This ::::'":)"1."1.r" t':"1 s0fl7,l60*T,,3g0v+5%.

^-::;"

If the real

t:^",:i;:

and adjust< should be insPected

::::" :; :::':H:
sTT200(100

:i::::til;

Power suPPlY caPaci

1.4

the e'lectrical needs to look up often it and sen'ice' In the process of installing to -- ' "" comPlete tn" purPur" ine n"*ot" *ttn wlth diagram schematic ;chematic r-.^+ lttr svmbols and graphic

flow to

see

electrical schematic

diagrams

theiM::::#lS

o,'n., ",o

i"",,,u,"lv.

,': .":i"1';:;:::;.

"JHt ,,o
o-,-,

symbols in coordinate

diagram' sc schematic elecfical ^,-:, every "lectrical are under coordinate numbers Horizontal 4-1-2. symbols' which (relay) coil BraPhic line t"ld"t "*O""**tor there is a ve(ical t:: at uuLrr ar numbers on th marked narked coordinate rpositions used *u tn" ""-:t:t:::on contactor (relav) the which of auxiliarJ auxiliary switch

drawing which ,'*'*':.-. ""H::::,1.'n'"*o*

,ev-; *"*' ;; ;;;

t"""Y:t"l:H:::"I

(contact)' ad drawing.Thenumberontheuppel.Iightquafielshowsthepos switch NC is tn" number

switch (contact)'wttn

t'u"tu"t""

wiout this line is No

:-1;::"l". :::

;)::l::J:".:'J #;

.*t"":;;;

'l'-t"

"*"

;;"w markl t"-:".tt:::t:

t-,-,o".' t*lt"'t line shows the position oi J;;;;';t"n working condition, look ror t'"

(relay) was contactor a (contact) When 0r (contact) or con:a:lor switches

;;;;;-er

quarler
'1ef'i

ve'llca 'f -" ir

*uo
,1.5

"**"

o"a*tloNAND
'ERVICE

ilrANUaL

rth

Electrical schematic diagram symbol (see Table 4.5-t )

Descriplon
Start Button

ge

Smbol r vol

ymbol

:al
rce

Dcscriptior
Emergency stop
. -...-.....-

rly

HCX0L lero
Sh
H,I

I Poe 6.uo].
Su.irch

button

ttir,

_Uo;.,,

CXORD

Zero swilch {Lefl panel)

Hon
SD

Limir Srrircn rp:rallel Hoisr.l ferminal Srrjp (HF

j

Paallel Relay (Trolley Hoist) Teminal stdp (L panei)

Tempeaturc conloller

I,

xl
Red,

cal

Redx
P

Relav --______.__ Rectifier {silicon Diode,

rrolectlon

Di

Mains Srvitch

;
i I SFI'P

._----__
XP
RedFU

Contacto ( a)oor

;;;-i
Lraini

] Transformer (A panel)

**+.""--c"*"r
I

fOrmer

Contactor (Door)

I rr&r,Lrqteake(CaxtDlrrNf_*r

Circuit-beake

XBa

Cicuit-breake
lransformer) Lanlem

(C*,..

LMO
SLD

ru9ue switch(lor\er ;".:: _r9sI9!-)

;r*---;---r-

xl, >a
f
I

!91!ion)
Position)

Hook Limjt "h

xi

,Flefre"

_--.----

n*r -U.it -l*rc,r,"J

-

SLChGV SLChPV Lfa

Liitswircfi GIeh Fo o\.el&dtil@

L S\df.. M*
---_:-limite)

i""d f"-doad

odrery Checking elay Rejay (dow"\

..-

C(ltunfo.lloifokrhke
dmorff ,ssor

LPV
l
Relay (up)

'=-

StpplyCrllccforhvE

LPVl

r*

-=--

--''a.Y

llnd shifr
shir

Electic Cotactor for lo* rolor

*.d _rrr

LRaGV
l,Ra2

Lontactor(for
sralo-I)

high

speerl motor,s

Relay (Jrd

Resistrncc

i!+.-l ----=' \ 'ur snrft)

Rebv

r.

r4.)
rrake)

con

tor (eri",s,

.",-rr.r
I

LRa

lcsislance coDtaclor (enelgy consutne

AND SERVICE TTANUAL 'TOWER CRANE OPER-$ION

SYbol

Description
Relay (4th shift)

Symbol
LRaPV

DecriPtion
stalor Co rtactor for Iow sPeed motor's

xL41

xL5
LD LH
SH

lRelay

(5th shift)

I,GV

El""t

i"

"ontu"to.

for high

sPeed

Supply Cotactor (do*fl) Supply Contactor (uP)

LGVl
T,1

I*t*o,
stator

fo, high sPeed motor's

Resistance contactol for first section

Hoist Relay (Parallel)

t,2
L3

esistance Contactol

for

second

resistance CXL2 - Relay for short-circuited

section Resistance Contactor for third

CXL3
LFs Rf1, Rf)

Relay for short-circited resistance

TSL

Control tansformer

lHoistine brake
Resistance

LMGV
I,MPV
R1-R23
F

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

--

lesistance (pressre sellsitive) Control tansformer

resistance of electric moto

lTiming
esistance for brake motor

TSl
TS3

1--F6
JTiming TS2

Autotansfomer
AnemoscoPe looP

JControl transforme

FADi

Protectio switch
Switch Reductio Trolley backward

\_I

SDAV

lfrolley forward switch

I(olley backward switch

RXDAI

SDAr
SM

switch RXDAV lReduction trotlcy forward

Irolley limit Switch

Supply mntactor for Iow speed trolley

RDMO
SDMO

Reduction switch for fixed dius

DMV

Switch for fixed load vadable

radius

DMVl
DFa

Supply contactor It.ollev

for low

sPeed

Y'
XDAr

Panel sNitch for trolle}r torwar"

Contactor for trclley brake

I*

ro. r,o,,"r

oud*'o

DAV

Suf'ply contaclor

for

Itolle)

XDp\

Panel s$'itch fot

niddle Ered

rol{

TOWER CRANE OPERATIONAND Sf,RVICE MANUAL

Sl mbol

Description
SLrpply

Description trolley
Panel switch fo high speed

DAr

contactor for

back*ard

rolley

DpV
DGV
DRa

Suppl Conacror lor middle peed elr\ ror ]ltsh

speed trolley

Relay for middle speed trolley

Contactor for trolley blower

Brake for troile,borv rvave

Trolley brake

DM
DDi

JrolleJ moror

DveM

Motor for trolley blower Motor fo telescoping

Button for weather vane effect

1'rolley circuit beaker fo main .Gt clrcuit

Relay for rveather vane Relay for weather

vane

RFa

Contactor for

slerg

brake

RD

Supply contactor for dghl siewing

Tcminal stip
Supply contactor for left slewing Temperature controi Brake lor slerving bow wave

Silicon conlolled rectifi er

Slewing brake
Elecbo-magnetic loop for ueadr vate

Signal light of rveather vane Button for sleq, baking Switch for ieft slcwing Switch for right slewing

Motor for slewing blower

RM

] Slerving motor Slewing potentiometer Main circuit brcaker.for slewing

OPER'{IION OWER CRANE

NNDSERVTCE

NTNNAL

iliagram figure schematic 4.6 Electrical

(See table 4'6-1)

Table 4.6-1
DescriPtion

Figure

I
l

DescriPtion
(HF Panel) Termrnal striP
(L Panel) Terminal striP (R Box) Terminal striP (HF Panel) Terminal striP (D Box) Terminal striP

V1 \
i

ElectricHorn
switch Ovedoad Auto-break

ring

off button (Emergenc'v

bulion

swit"]!------

Push-button s\\itch

switch) Por ,er switch(Stroke

,r*ri-"**""u,ornosuitchL
cage Thlee Phase squinel motor asynchronous

Push-button switch

Linkage switch

rotor Three Phases rvind

Resistaoce

asynchrglq1llgq liansfo ner

winding Brake DC excitation
rryindinB Bow uave brake

contact DelaY action N/C

contact Delay action N/O
contact DelaY action N/O

TOWER CR]{Ntr OPERATION AND SERVICE MNLIAI,

Description Coil for relay contactor

Coil ofa slowreJeasing relay

Delay action N/C contact

Coil ofa slow operating relay

Anemoscope

Thermo-sensitive resistance

Potentiometer

Main contacts of conactor

3 phase Autotransformer

RectiSing diode Thyristor(silicon controlled

Crossing junction

Crossing without electrical

Pressure-sensitive resistance

AND SERYICE MANUAL TOWER CBANE OPEBATION

4,7

diagram' to this electrical schematic according cable the can install The consumer

Wiring tliagram of cable

\ \\

:!

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

,i
,1

TOWER CII{NE OPER{TTONAND SERVICE MANUA,

,. "
L o^

Rruo
1D

!rl

l2i

i'L

qiilii
ltltk

lrr

fig.4.7-2

Wiring diagram of walk cable

.TOWER CRANE OPE'RATION

TTANUAL AND SERVICE

/1

Notice:
ani"d

rr,3rrtailu gutt

is 5mm' keep diameter the cable, can protect the wire rope whi<)h

the usage as follow' the same heieht' the cable net to with "'' ;;,:::' ""t" '"ith it " hang 4 7-2' rope as figure \1';e ofthe on one end fi gure every 10m as Hoid a clamp for ring a to make use the clamp slewing' on lor'r'er (ftgure by nylon belt the steel book ring the on to ground lio* cables the 't"'ulng making wtre 4.7-3. Fix ail the wire ropes' on distribution of cabie unifornl rveight the from damage 4.7-4). Make cables' the eight of ' "'"'.t^:*::-t.::.*oo undertaking need secunng rope the wire ropes 100m' exceeds When the height

tension because of in
lOOm' to

the weight distributed

uniformly
.

"u.tl

"ntore

,a1'

't)el

Frg,. 4.7 -3

F\g.

4.1

-2

-..-

/1

1 \

.I'OWER

CR{NE OPERA'I'IONAND SERVICE ,IANUA ,

ep
conftol element

Control procedure charts for power supply A box

eiectrify order
explanation

to
.lr9
50Hz/60H2 3B0V

i lre
'ire
rge

Di
airbeaker

tA

48V-control voltage

I
SAHzt\AHz 4Bv

ing
CXORK,CXOL

I
starting

CXORD-let inrerlock desk zero p..irion CXOL- righr inrerlock desk zcro posirion AU-.en icing butron

l
I

Bsl--arise motor t"-p"rotur" prot."t

reiay
XJ-phase protect
]

rela,

\P-Joor
P-rioor

conracror

relay

I I

XP-P
iriphasc power

suppty

brcak

clolvn

TOWER CRANE OPERATIONAND

SIRYICf, MANUAI,

5. Traveling
The composition of bogie traveling system The bogie traveling system is c, of four bogies (with traveling audible uno ur.ru,"rotoosed mo
erectric contror panei. Each educe *,hich

or*r,

'.**1'n' b"*:]'1 consists of a driving

u':

,,*n,, ;:Tr]"t]-J,i1li;i '*- wheel driven

and a a dual-speed squirei wheei, a
case motor,

and each motor is

"ra"r"ol'e

"qripp"-a

;;

:#rt :*"

ffiililJ,:ini]i,Jl':'
o'T":"*
1"1 external

Ycw3 x 50+2 x r6mm2 which is hea,y rubber

or beiow,

5.r

u, [aKe more mechanical force, the Iongtime allowaho *uo'" .,,^-,_,_:-_''-'' working temperature of the cable shall not exceed 65 c), ,,w,, type tnt featues such as weather "u0," resistance and oil esistance, which is suitable a. ,nut and the site contacting National Standard oil stain, Chinese ,"",,r".,0oos accodance with the requirements "0j_ Intemationar Erectro;;,;; specified in -urrmission IEC215(t 980). -* wortng

**" ., ,.",",,,*Tffi:l:'r:ilj::;,:::;i:,r750v rL

princ;;

The speed adjusrmenr stan and soft

ard auxiJiary brake. TAv is a

sop pol..hang:irg conrrol. and

of bogie trareljg jspi5 lbu

sets

of dual-speed motor, solt

with seyice brake
t(

each motor. equipped

**;;-1";;,'"::':":::'
coaols
the

contactor to control mov ing loruard: TAr i5 a colaelor Dackward; Tp,, ;"

^^

r*,,r'.,, '"'r uaKc: I windin" -- , ^_l]'_' unu ind ing of cable drum. p*::.",,o '"!4utrons:

contror nrst shift rGv,. ; l"'""# " are aveling audible and visual aiarm cievice; RE controls lhe sen ice brake and lneanr.r hile ,,I

-,]-,"j',i

""",,rl

fu,,,":::";::,;[,,,,jr

due to adopting soft stop, when the cranc stop traveling, confinue sliding it witt f( a certain dstance, normally the sliding tlistance is 2.2m _ rrr when the crane direcfly stops af the secord shift, be s.re to a"".1* elerate in advance when the crane comes close to fh^ -^., _

.tOWER CRANE OPERATTON AND SERVCE NIANUAL

5.2 llogie brake bv hard brake' They take effect one and brake soft both st"" brake includes stop the RE conffols the auxiliary brake When brake' set.rice the .",r,r",' it flrst' then stable deceleration' after that friction soft a provides it O"*",

;;. ;:

"r.'a , *",,*

make the bogie bands brake and 5.3 Cabte drum

fully stopped'

of chassis' and parallel with the 'fhe cable dmn.r is installed on the horizontal bracing
rail.

u'orting principle of cable drum slip ring' bracket' drurr 'fhe cable drum is composed of moment motor' reducer'
5.3.1 Features and

and

roller box.

the the po\Yer supply direction" stad up to\\'ards moYing crane Whcn the tower to drum via rotor disc and moment the transfers 'l rotor moment motor. he moment when the tower cable is involved in the disc; the rotate' slou'l.v drum flange, then the the r'ia dra$ing ol the cable to conquer supply' pou'er the against crane moving cable auto exit' u,hich pulling the disc rotate, and the reducer, the in moment friction

TOWER CRANE OPERA,IION AND SERVICE IVIANUAI,

5.3.2 Wiring of cable drum

'y le

it

The outer porver supply cabie pass through the roller box (see Fig. l), as per the direction of arrorv in Fig. 1A to induct the drum inne ring, via the inner hole of the reducer output sha1 to get into the slip ring, connect with thee real line connecting plates ol the slip ring inner ring and a zero line comecting plate; the service motor cable via the cable elborv into the slip ring, and corutect it to the conductor.clip on curent conducting plate ol the slip ring outer ring. The marked curent conducting plate connect with zero line, the othe three cuffent conducting plates connect with the eal line. (See l A, the p vieu,.)

the
and

the

{it.
Slip rig

Dun

Cabl.

OPEBATION TOWER CRANO

ANT'

SERV::::

. f:

P
Current conducting Plate

view
culfent conducting
Plate

Plate Real line connecting

TOWf,R CRANT] OPERATIONAND ERYICE ITTANUAL

5.3.3 Debug

olthe cable drum

Before the cabre drum putting into service, screw out the rocking pans on the shelr reducer (See Fig. 1A. for its position in reducer). Check that whether the groove adjusting nut of reducer and the installing hole

of
of

of locking parts are aligned. If

not,

manual rotate the disc until the groove is aligned with the hole, then insert the locking pafis into the hole (see Fig. 2) and rotate the disc. The person stands outside the drum,

if rotate the disk clockwise, the adjusting nut under the limit of locking pafis moves
towards the spring and increase the output torque by force. In reverse, rotate the disk

anticlockwise rvill reduce the output torque. Adjust fhe output epeatedly, until the
cable can extend
sides

wind successfully and avoid overheat of motor. This optimum position can
scre.w the locking parts which

e life ol reducer. pull out the locking parts,

with threaded into the hole ofeducer. see Fig. 3.

Installing direction of locking part:

In debug
Sockel

Out ofdebug
l-ocking part
Socket Reducer housing

fuducrhousing
Adjusring

Locking part

nut

Adjusling nut

Fig.

SERVICE MANUAL OPER{IION AND TOWER CRANE

i-r""*ao*"'ngoPeratingcabledrum slip dng; ' '^c^" ^'"nins the housing of

a.SwitchoffthepowersupplybeforeoperunguleuwuDn,".-.-r working the nut groove in into parts locking the {orbidden to insefi b. It is strictly
hole' the center of inspection above be should level of the reducer c. The grease
condition;

Service antl maintenance

month' time' after the hrst first the for pulting into service a. When the reducer
must be replaced' grease in the reducer

the

center ol is lower than the it when month' of reducer every two b. Check the oil level

ring every two month slip in parts condition of electrical c. Check the tightening is reliable' connection of cable ioint the and well contact Make sure that they normal the cable drum fo check time' of a period puning into serr'ice

grease' insPection hole' add

d. After

..... ^,,, -he screlv ue' grease' the When replacing reducer each year' in grease the e. Replace the screw orrt meanwhile oil' the dirty to the boftom to drain close plug hexagonal oil draining the dify after plug screw up the hexagonal locking parts, and then parts' screw up the locking then and grease' clean add the

r.rinding and

unwinding

motor and reducer f. Keep the surface of slip ring,

clean

g.

ll

.-c^,manc6 pet'"'operatrng the already influenced the part wom a lot and had

replace it in time.

,].OWER

CRNIJ OPERATIONAND ERVICE ]\tANUAL

6. Hoisting winch

( r -- RCS r__

Explanation of symbols

Single linc puli Double motors adjusting mechanism

\,Iotot potiel in Krv

Description
Tension the steel rvire rope at minimum raising speed.
To lorver a load at minimum

lorering

speed.

At beginning or the end ofhoist. use t.riddle speed.

In normal hoist opcration, the motots u.ork at rated speed
Select hoist speed according to the
raise a

ioad: Raise

a hearry load at low speed, and

light load at high speed.

Stop movement befol.e the

limit s\,itch colnes on

NOTICE: I
tho

It is fbrbidden to put the hook on the ground. Loosen the steel rope

slowly while placing a load.

Pay attention to the recve

f
v

tho

ofthe rvire rooe.

OPETi{TION TOWER CRANE

MANI]AL AND ERVICD

lI,....-...--.-,,*o**'*winch:(see6-1-1)

l. Limit switch
5. Two motors

2. IJrum

Rcductiorr gear

4. Chassis

box 6. Resistance Fig.6.1-1

of hoist vinch 6.1. ComPosing

drum, height limiiator' motot' of chassis' reduceL' I composing winch The hoist control Panel electr'tc and repair device' examines oneself lisriter support' save
and resistance box'

6.2.

equip with _J^. ihe end end the asytlchronous motor' 'lhis lnotot is wound rotor triphase
crect, omasnetic

working

principle

th

brake or power

;;";

;"'""*"

11,

]1,,::,t::li5:

TO\YER CRANS OPI]M],TONAND SERYICE MANUAL

through drive the reducer.

operating by rating rotate D|,lsu alone. speed arone, lr it rorm form two different speed on the drum

LMPV motor tandem connection stailing resistor electuomotion opel.ate, the motor LMGV stator under the early excitation condition, its rotors generate electricity and feedback to self_excitation supply porver and consume power brake of stator
operation. Through transf-er the resisance value of
and resistance value

The electric control rcises and descends five gears respectively. .lhe speed increase by degrees frol the first gears to five gears. Raise fiist three gears the rotor of

LMpV rotor tandem connection

seconcl.

F of LMGV feedback loop so compose raise the first,

third gears different speed. The contactor

LpV and LpVl make LMpV fix rotor into

tandem connection resistance value F into

electromotion operate condition. the contol rotor tandem connection tlte R numeical value by the contactor L I, L2, L3, rhe contactor LRa2 and LpVl make GV thow into action supply power condition. The contactor LRa2 and LRa

contol consume power br.ake loop. In the fourth gears, LMpV make electromotion operation alone,
connection

LMpV rotor

tandem

two segments resistor

buffer

it come into e fburlh gears, (affect shift

and L3

then truncate the

espectively,
sPeed

resist, cr one by one at 1s interval by L2

pV
Increase

LM'V

come into the stable elecuornotion operation after 2s. the drum

ng hook speed reach speed

LPYLPVf,IZ,I-

to the fifth

gears,

tir.st,

I t

lu codition.
t still

t"U .,o"" the LGVI and

LMcv

cut off the electricity and make motor divorce circuit, then
make motor LMGV enter electromoton opcrate

"* '"ect

motor.s rotor also tandem connection two segments resistol

"hifi bulle| tlrc, tnlrcate te rc.i.tor.ne hv nn- a, r" ;,.,^....-r

fANUAL OPI'RATION AND SERVICE TOWER CRANE

<the resPectivelY' LMGV cotne

and L3

after 2s' stable electronotion operation

particular Need specific indicate in GV speed reach and hook speed the drum speed load; depend on the size ol lifting gears fifth the into \\'hether come

":";.'.r:.,

2'5t(2'5t+2'5x107o) and than more should two scale lactor rvhen Laise the rope forbid than 5t (5t+5xl0o/o) all more should factor four scale when raise the rope due damage the motor LMGV only not otherwise, speed. occur the fifth gears proofread accident' Therefore' must other generate also to over loading but limit the high speed) capaci hoisting that (the switch and verifv the SLchGV link) and debug exactly' (dynamonmeter brake in hoisting capacity uP self-excitation genemte nrake LMPV motor gear the Descendent rst three moreover the motol' condition' 11'6(ig btake pou'er electricity and consume and the electromotion in the second in.rpedance bunch LMGV operating undel'rotor perch heavy by motor speed slowest the gain geal and third gcar. Descend one Molor LMGV

performance independently LMPV genemte elcctriclty

electromotion operale, the LMpv

loop bunch into supply po*,er and feedback

one

of segment and two segmenls

second the sPeed of first -eear' resistance in turn' so

in tun gear and third gear improve

tl.re motor LMPV Descend four geat's and

electromotion gears the motor LN4GV ltve Descend alone' electromotion operate

opelate alone.

TOWER CRANE OPf,RATIONAND SERVICE MANUAL

6.3.

Wiring diagram of hoist eler ric control panel L (L panet (see 6-1_3) )

L panel terminal strip of hoist 43- 40

I
l

Ri-3
R

11-

13
2

Fl-F6

R21-

Fig. 6.1-3

Mu st check and fastening al the binding screw and terminal strip wire splice inside the resistance . box when put in service new
,

cran and after worked a month.

Sf,'RVICE MANUAL OPERATION AND TOWER CRANE

ffi

"ff""t

or the iliotle in brake

t,
1

'{ LH (LD) LFa co

,

1). When relay

CXLT and contactor

time: closed at the same

cycle' and or Ac negative half cycle harf positive AC electric potential whatever a" to "b"' flow ftom always coil brake the circuit in the was cut out' the LFa contactor the If 2).

on the brake when contactor crosed,

.0a,, erectric potential higher than

"b'

AC power supply' brake coil cut out the value to the curent from maximum changes of zero at that time' this
induced cuent all/alt produced self the electric e.m.f. in the brake coil'

potential

rb'

ra'' higher than

the

induced current
through the diode.

Oo'' u to

r(b"

brake closed 0'5 This induced current used to kept the

TOWER CRA'E OPf,RATION AI{D Sf,RVICE ]UANUAI,

Switching Sequence for Hoisting Mechanism (Moving Downj

ln service

o:

Out ofsevice

motor conditio

1f,)'

'-' a

.?.

'
o

JC

a':

.J

:t 4 .i'

j t oo
...

-.,]

j
j

.o:l
o.

..,]

,+ --r .-.r (,)

i
-:-i(J

-j

. : _i Qd.rx

o J o J
h
,
9l

..
J
U

,9

'F
P
E

:E I

e*
E'E

PE *:

E
--,4

2
.i

iil

E
l

!i 2 6 qp

I
;
z
a

z'e
2-

:
.- q

Q;

t p

!+l
6yp
3 -F t8, ; ;

;.=
Z E ?:

l
I I

'7 Z- i

7
2'

7 =

= --

6E

i,

l.-l i
lL ': jl l

- ll1

.- --tI*

ir ir
/!' -i
i

i*rtl
]

trl-)l

1,

,\',

li,llil ()t

-...1

t-

eL
i. .! =
>

> dj
.:J

> ^j
,o+

T,.><
l
-l .
^

_q
E

'j':*,

3<
,^.

tu Ets

b I

1E

E
.eU.)

hE i{p
E'2F

a2

i,

EE

2l

(,

o
3 o
1
d

+E

4,

1',4

;
?,8

, a
E

"E

=a

:2 =z

.EiiP EBB

9r 2

,.,

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

7. Slewing mechanism (RTC)

7.1 Explanation of

symbols................ princip1e...............

-.-.-.........-......--..78-2

7.2 Composition of slewing mechanism and its working principle..........7B-2 7.3

7.4

RIC controller

.........................7B-4

RIC slewing mechanism operating and troubleshooting...................7B-5

.........................78-7 ........................78-7
.... ...:............7B-8

7.5

Slewingbrake. 7.5.1 Manual brak release.................. 7.5.2 Electric starhrp ofweathervane.....

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

A!!D SERVICEMANUAL OPT]RATION OWER CRAN'

?.1 ExPlanation

of sYmbols

t j1

Explanation:

required Accelerate displacement ^rrdance with the in accoroa""" speed by iorce via slewing choose the slerving ,- "-^tt e iib iib by the stop gradually Don't slewing speed the The slewing or decelerate movement slewing then stop the ti"t' than decelerate "l speed is less brake, it must wind the when t; position;" to it must '"'hoisting brake is only used the same time' at out *,a* are carried n",.,-* and slewing 13m/s. If the
rope from disLoning' pre\ enl the u ire

TOWER CRANE OPf,RATION AND SERVICE MANUAL

7,2 Composition of slewing mechanism and its

working principle

The slewing mechanism is composed of torque motor and planetary reduction gear (see Fig.7.2-1). adopts electronic variable voltage control system. Through adjusting the torque motor stator power voltage, the eddy_cunent brake

It

and

driving system is composed of torque motor, which adopts two sets of eddy-current brakes and
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
,

eddy-current, the speed can be adjusted. The slewing

one set of

{ways released. During operation, ifnecessary adopt the slewing brake to protect the irane against action of wind, under the condition of wind speed is ress than l3m/s

slewing movement stops completery.

At the end of

each shift, make the

magnetic brake work automatically or manually so that the tower crane into the state ofweathervane effect.

ieddy-cu[ent brake armature

of the motor

rotates

with

the

shaft. the

of the eddy-current brake produces magnetic field in the air gap 61 the armature when the excited coil was supplied with .lhe
direct current.
: incises the magnetic field so as to form potential field and the current (that

went) is obtained. Because of the mutual action of magnetic field of

and electromagnet, produce brake moment that is directly proporlional

curent and rotate speed of the armature. Through the frequency control
-current

braking, it can

fulfill

the stepless speed regulation perfectly.

SERVICE IIIANUAL TOWER CRAN OPERATIONAND

i1

and troubleshooting mechanism operating slelving RTC 7.4 oPerating RTC 7.4.1 Notice for controller adopts special slewing mechanism slewing the loop' 7.4.1.i In the control o*o** or down un speed that ensure which (electronic block)' due to stop and reversion suddenly emergency liom crane the and s'hich prevent block)' slewing conffoller (electronic the that inpofiant very is mispla,r'. Thus it block and alr parts of erectronic of supply power conrroi panel, potentiometer, and reliable' connection ale cor-rect in regular' Refore the failure mechanism slerving the and service 7.4.1.2 Maintenance destroy Otherwise' it may serious ii operate continue to is eiiminated, it is forbidden l even result in serious accidents structures' and pafis the transmission RTC maintenance methotl of and diagnosis 7.4.2 Malfunction in normarri irthe srewing doesn't work

s1bl1.:::::'n*'*

ln::i:'l::^

ll"LT]:l:::"ffi;';
condition,
aspects:

it

followingl first and then check the t'pply po'u"t the off cut should

l'',,*' *"'"'

7,4.2.|

oPelate Thetower. clane can only

t''nnil.'g' uft"' time, another direction can cut offtht stop immediately and ot"u''"d' to"ndnton this by single direction again ll and between control panel conr.recting lines two power supply to check that wl]ethel There isa well is grip earthing and centre tap clectric contl'ol panel, potentiometer

a period o| in single direction, aftef Stop it can only operatt a period time running'

bloch didn't connect well' relay contact ot slerving control or onct direction; other the than fast .7.4.2.2 Theslewing speed in or.re direction is on towards rotate mechanism the slewing closed the slewing air breaker RDi' at]rhetheff imnrediately and c}rgck .,0,,, th" off cut ,'*", Should It direction, *'i,"*rr, ofut tuvh lt addition' I, ci'cuit il open potentiometer open wire ot

Measuletheresistanceofcentletaparrdslidingendbymultimeter|n,|r' position readjusl the zero should it othelwise !) , should be \vithin 0.-50
potentiometer.

:.--

;^n.'lino In this condition' it

should Pos

TOWf,R CRANE OPERATIONAND SERVICE MA^-UAL

oller
'king, te to ock),
,

on and check the motor three phase of voltage whethe loss of phase; thrce phase voltage rvhether balance. In normal condition, the degree ofunbalance for three phase voltage shouldn,t be more than 3%. Namely, the voltage of three phase output line
can't exceed

l5V Ifthe declination

is too high, please replace the slewing controller

ts of.
ilure
)stuoy

7.4.2.1 The sleu,ing system staft up fast and stop slowly. Check the exciting voltage of RRa eddy-cunent, it should about 20V direct current in stop state. If the voltage is too low, check that rvhether the altemaring voltage (4gV) ofthyristor module is too iow, if it has no voltage, cut offthe porver supply and check the connecting line ofthis part; check that whether the thyristor modure damaged again, the inspection method is as

follows:

1)

The resistance between gate G and negative pole sh ouid be 7-100 O.

sm
ormal cwing

2) The resistance

infinitely great between the positive

pole A and negative pole K.

iod

of

Ifall above have no problem, please replace the slewing controller. 7.4.2.5 After tIe control handle back to zeo, there is a contactor (RD or RG) still power on. It should power off and check the zero position of potentiometer pull
the insertion

out

pert off tlc

.el

piece belween controller and mother boad of thyristor Measure the esistance between potentiometer earthing end and sliding end by multimeter, if the resistance is infinitely great, replace the potentiometer.
4'2.6 The clockwise and anticlockrvise contactor (RD or RG) no athacting. Fit.st, check that whether the cormection wire roosen or broken; next check that whether the
?

re ls

I
Js

r^.. )lltc

*a

of potentiometer Rp has

hel

problem of controller. When all the above check is in condition, check that whether the contacror RD or A1 end of RG have 48V , ]llal volho" ,._ . ,h. operate handle condition and farther check the controller have 4gV ,olr:-' ") lut, rr all the above check is in normal condition, please replace the slerving

've no voltage output. it.s the

di rect voltage (when the handle operate), ut crdrsrr if ll

''

rne slewing controller and thyristor both bur out and blackening. Check the lar first, then checi( that *h"th", th" por"", supply voltage is too high. lf all the I ch.^r. - "' ls ln normal condirion. please clrech the sleu ing conLrollcr.

sERvlcE oPERATIoN AND To\{ER CRANE

M:)1

brake 7.5 Slewing

release (See ot*" ,ar'***t the we*:**: 7.s. r. l srart l-"],;.r

al.

Eig 7 5-1)

Lift

brake release I the manual

A. (l ), i.e. movement

;, ;:.;;;,"-." ,,) ""* ":::;";::;:."'.t:" brake rek -' '"t"^"" th" mut'ai pin the clip
"''

-,"st

then the on the clip(3),

'sm oan rotate fteely mechant the siewing accomplished and effect d). The weathervane device tt'" weather vane n"t"u'" Z.S.t.Z i'e movement A' (t)' lever brake release a). Lift the manual (4)' spring foroe the under out O' "t"oted Jr. be standstill' ll' o"'"""" *"

,1"* t.',

*"

(3)' t"cked by the cltn

*"c**

*"'*"]*-*]|".

effect accontl'"""-d). The weathervane

*"*'n"nould ll)'tn" -

TOWER CRANE OPRAT'IONAND SERVICE MANUAI,

7.5.1 .3 Working principJe

1. bake cgaged

2. brake released

eely.

Note: "E,, is the clearance of brake, which value must be kept between 0.8necessary adj ust it. l.2nim.
7.5,2 Electric staftup

if

ofweather yaxe

l:r::*.,it cut oft t has its

L brake engaged

is an electromagneric brake, which is engaged as soon as rhe cur.ent own and independent power supply.
2. brake eleased

TOWERCRANE

OPERATTON

IIANUAT' AND SETVICE

^^^';"" of slewing brakc ' >EL"''anu '7 .5 .) M aintenance

Note: it
ctc.)

grease' as cement' sand' (such braf(es in the foreign bodles any have mustn't

7.5.3.1 Unscheduled

maintenance

conditions: the following under out should be caied The maintenance ofbrake pad damage and by worn which is caused moment braking
a). lnsufflcient

is out ofwork' b). fhe indicator light maintenance 7.5.3.2 Scheduled or each month' hou 200 every slerving br ake of te a). Maintenance the conrlition wear as the torque as well brake and b). Check the clearance
pad, teplace them
sand, .^.,^L as o".ement, ce (such the brahes loreign boclies in no are thee that c). Check

brak

ifnecessary

greasl

TOWER CRANE OFERAIION AND SERVICE MANUAI,

7.6 R box wiring diagram

t IF t
23
25

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

47.48,49,46

r
progressive
grease Iubricating system

I . Intoduction ofprogressive

(pRG) grease lubricating system

do differential
mainry depends

Progressive grease lubricating system consists of lubrication pump, progressive oil distributoq pipeline accessories and control unit. When system supplies oir, a series ofpistons ofprogressive oir distribufor would

reciprocating motion

successively escapes at the ind

in a

certain order The oil

distributor. The scope ofgrease used for system is NLGI 000-2#, working pressure is l -300Mpa, dispiacer

",,n. r,",", l"lill ::t:

il:: ::"r,:::::::.T:

is

r50r. 1-200 rubricutrng

distributor can be connected to three stages at most-

#:':::';:':il'::rT::::.::;

The motion
through the

The system can be equipped with oil indicator rod and blockage alarm so as to monitor the oil supply situation of each outlet. In case that the system is blocked or a certain outlet cannot supply oil, the indicator rod will stop motion, and the alarm will emit the waming signal immediately.

controller.

of indicator rod alrso can calry out timing and counting

According to the structure, progressive oil distributor can be divided into two types, integration type and sli By choosing different structure and different ''o" slice composition,"t"
carry out periodica,
Features;

*o,rr-",.,,"i]

can

"j,;:,ffi:,*apprication

1. 2'

Accurate oiling capacity; Regionalization performance: operation and monitoring on individual region;

. 4 5.

inspeotion ; SimPle malfixrction point easily; Testing the malfrmction oil distributor easily' replace and Repa

Lubrication PumP

1. ComPosition:

1.

Motor grease pump

2. Size-changed

joint

block

3' Oil pipe rp8x1

pressure gauge

4. Oii PiPe

joint

femrle 5. Bipyramid
block
S.Greas e

6 Radial

7. Tee oil-distributing
10.

filter

9' Progressive distributor

Motor
system of grease lubricating Schematic 1 Fig'

2.

pump shown in:l:' grease manual joint of First connect the outlet u"' rill the erease lnto the inlet of electric"

Working PrinciPle

2 to

container

'' -::'-#.: ';;;;;'it t':,,*tl"-*^"i.lr *t of electr'""t r'""t" 0*'O'

when system

,'"""

pump

is 2L;

supplles

,r under

nrlantiFrcationallyandperiodicallytoeprogressiveoildistributo

certin orde and the oil successively escapes at the individual outlets. The oil capacity supplied mainly depends on the piston stroke and section area of progressive
distributor' For working piece of double outlets, be sure not to let any outlet be blocked so as not to affect nomal working, otherwise the distributor will be damaged.

differential reciprocating motion

the control of controller. A series of pistons in the distributor would do

in a

-!t
1.

-,.,

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

-;-,.

Fig .2 Manual greasc pump

Fig.3 Schematic of electrical grease lubrication

3.

Operation ofauto lubricating device

Refer to the drawing,

Low

avoiding the device to be damaged when thee is no oil in oil drum (as Fig.4), it is connected to the normal closed point ofoil drum switch (Note: no oil is the closed point, with oil is the open point).
Refer to the drawing, S switch with the function of avoiding the device to be damaged when mallinction occurs on distributor, it is connected to a

switch (oir lever switch) with the function of

hicroswitch

on the distributor (as lig.5), connected to the nomal opon point ofthis switch, viz. on the black and yellow line.

-Oil

level s\!"LrL

le indicator

trltl

ti

i-. tall

'

I
i

'

!ig.5: Disfibutor
Fig

4:

Oil dru'

in the when the oil capacitv :1' oil controlling limit switch
the

-::":'**,i1tl"llT"
"^t:'::,
s'r' :,;;;king -"
I

"j""1 ";
lubricatrng

lubricating 5)5tcrrr controllcr' the auto

and the buzzer

will alarm simulianeouslv'

at e

moment

lr*.*lo *"'
If

then restad the oPemtlon' tne grease' and

:" :t:-:::-"

the cycle switch order' in oil will supply in the system' there are any faults lf cycle supplY of c}cle completing one oil any motion time
such as leakage,

distributor each outlet on normally' rvorks system after the auto lubricating (S) will give ofl signal

",o,

.,

ou,,,o

o,*n,

making

to switch (S) delayed

tht

"on"oll"'

uoo lubricating syslem will the buzzer will give

*tl"'** "O"r

auto (5 mins)' the time alarm preset and controller' of control the

cut off the at the moment

to inspecl the auto lubricating system

"fi "*'t"'*"it"'"ously' lubricating pump'

4.

Mechanical performance parameter

Ml2x1.s

ij

ll
I

lil
l',
i

Ill
1

SM-AC ControLler
General

sN4-AC

is a multi-purpose

to control \r,hich can be used

gramming' thror'rgh simPle Pro
pos se sse s

:"":ffi::,:jtt:::["]::J'rl"";
t",

rhis controller

ensure rhe accurate

T:::T; ":.,ilil *'[T;::: oil *"'. ":;r';;ition

and anti-interference

almost all kinds

grade, excelient

o[ rouph indu'
antlvibration

protective due to its high performance'

board 2. Panel and keY

terminal Wiring of inner

St'1-AC

'

u R " A0 A1 3 4 rar 12 ^,
'

A2

l.Terminalt.:eo*.,inptltlphaSeline.nostrictrequllellt(1,.'.
etc )' solenoid valve or motor Load input (pump 2. Terminal 3,4: the switch is closed, (The input level signal 3. ltrminal 5,6: Low offalarrn)' corrtroller nill give :^ )

zero line)'

4.

switch (NO) pressure r'vith Terminal 7,8: collnect 3 or NC) at mode (No switch connect with cyclc

at rloo( "'

5. Terminal A0, A1, A2: Output terminal of fault alarm

connected with alamr or mainframe controller.

relay.

AO-Almeans Normal Close, A0_A2 means Normal Open, can be

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

Funct ion setting and program review.

Data store, reset and run.

R t

<: Re move cursor

Data setting

A. Switch on:
the power is switched on, the controller

will be work

and display

on the data stored before power off, follow the procedure below
data needed to be reset:
.

if

Data Setting

1. Press "S,, and

flashes-

"R"

simultaneously to enter setting mode, one

At the setting mode, press

.,-,,

and

.f

,,

to modisr the data.

TOWER CRANE OPf,RATIONAND Sf,RVICf, MANUAL

8.
8.

Ilottey winch (DTC)

I Explanation of syrnbols

Locked rotor torque Eddy-current speed regulation Variable voltage speeJcontot Trolley winch

speed should be selected

in accordance with the holley distance. It is

to acceleration or deceleration gradually.

TO\!ERCRANE

IIANUAL OPER'\TION AND ERVICE

bake (see 8.3. Trolley

fig' 7-3-1)

when switched brake' which is braked electromagnetic an is Descriptioni It

indePendent Poer
suPPlY'

off lt

has

principle oftrolley brake \\roing 8.3.1.

9

1. Exciting coil 4. Moving atmature 7. Brahe lining

2. SPling 5. Fliction disk 8. Screrv

3. Release nut 6. Brake disk

9. Protective cover

rig.8.3-l
switching off, the elecffomagnelic coil exciting the Braking: when
disappears, lhe
atraction
()

disc disc (5)' then the brake lriction the brake spring (2) pushes

at"armature ls the coil, exciting into thc Br.akc rcre.se: whcn curlent enter.ing

entets inlo hrakc

statc

,,",cLed

m'L" the b:":.:t (2)' spLing tlle (5)' co*.rptess "nd r rvhich drives the liicrion disc 1"" the fol next brake when rcady is brake fhe c.terirs. inlo rereasing statc.

TOWER CMNE OPEMTION A\TI SERVICE MANUAL

Clearance adjustment: Remove the protective cover (9) ana

_.._ (r)*r""" *

disc by screw, until it lean ag;nst the cove ofthe latch. Move the disc again, and locked it in the 3.d. At this time, the cleaace is 0.g to l.2mm

brake moment adjustment: It is already adjusted in the manufactuer. Manual brake release: Tighten the release nut (3). Do not forget to unscrew the nut
when restarting.
.3.2. Maintenance

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

it if necessary.

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

r
I

ro\vER

CRANE oPERAlloN

NIA AND st)Rvlct',

of relaY and contactor

trolle!

t\

a
,,,
iLo

o o
C

r.

t,='

iO

o ':-'-

?-

RD-, Ri51\!-,...

>Yl:; otl cll

oo
O t

o
I

xlli
:

.n.\'

... ::,i', r'i'.r,.i?-r j

:/,

-a u

oo - '

oo ,
\
r

t., I 't
'- -:r --

aa

' u-.r. o o -.r

rili' 7
.
--^" on Attracting when Power when Power down
Release

ioiO ^i-i iol io, i ioioi r i -,r-,.

til
1"", lts r
I

rl

^'

sute K""P form"r uttracting

l
:l

j_

____.ir,

..- =l =J*l
I
I

POWER TRAVELING PANEL ELECTRIC LAYOUT

14_XJ

Phase

sequence
Dotecor

I5.DI

ai

lo-xP

1I.RE

switch

26-Tfu1

Cable

drum
cotactor

" i-3,

-t-

f--

-t_-,\-:_
i-

| | ral =t .J. ______-i

t ----\-

9-. -6 I

?'?

: a*l = "

3i

:
-6g

'lr'
liil -L-:J
"i; H
I

.-lt
al
- EC

ali
< a

s 9a

--.1=l n

3=
.-A
E gB

ll

r
l= =
E Al9

llr
t--l

-a?-{

E=+\
f=
I

-l

.lJ:
EI

.J :/:_____j1--

lAEs=!
I

__

iFi I
I

l4

I,l

.. l[s
l

I / r-rr.rrrr r - ---x / e alel -l )' - ja

_\
I I Et I I pt l ?--l?t--'r<-<l
I

-,.3_

i',
rl
l

*t

| s s

:E

.-1?

iL-l>

'-:

-ta_ =r1l

Es

=l:]:

-la

furucalLrsr
TSFUp, psdF

Name Transformer

94

_l
2

Bcaker

XLIJ. XLD, xI_2. xr:. xrq. 'XL.l1. XL5. SH. CXL2. CXL3
CXL

Middle relav
Conn.ol relav

rcv, rpvl. r .l ciJo. lll. LR.

I

L1. L2,
LFa
onnect CXI l Connect XL2.
L

R"l. I Rap\
L:l
.

Lnir

AC contacto

Xii

CXL3

XL4.

Tirne de la relay

conneer

_!&

sH.

lRar. L:. r l
Connect

in"pv.-ini
LpV

fime

Aelay

rilav cover

CCtLPVI. LD,

LGV]. LH
BSL

iV,EH.
1

Auxiliary

BSL

Tonperutra" alay

Terminal strip

__l
4

,r---

--.-15

6t

)l

-7--l
rlf

,'

=lE=*

-------*q
ji

L--Q:;; i
- --

I'e,

=k_--

-l-

tc

o 6
I u-

!t-t; * *-a4alrt-=;irLJIl i j illl -i *-rv--\1-ry

l i

==R== it++q

l!

'

.,?

f_--+
...-^-sJ ,\-/\eJ
4l

I.{YOUT oF SLEWING/TRoLLEY
TS1

Transforme

TS2

Transfome

Red

Diode

Red2

Diode
RDM
Control relay

DAr

DMVl

DPV

DMV

DPV I

DCV
Control relay

DDi
Circuit-brea

tvc;
I

Control relay

l****,. Lisht
*o'

XRGjI

XRGi2
Control relay

I
I

Lrl
xnur
XRa2 Control relay

I
I

Rr"

SD

DFa

DRV
Control relay

SDM
Conrrol relay

RDi

Conroi relay

Cont.ol
relay

Circuitbrea
ker

Ar,iliury

Auxiliary

Au\iliary

Auxiliary

Au\ilialy

rsrunjrsrutlooi
MTC
Circuil-brealCircuit-brealCircu;t_rea

Silicon conto1led recifier

ker Ir.,

lr..
RD

AC contactor
XRT)

XRG

RedFU

RedFUl

FaDi

t:!
Conlrol
relay Control relay Circuit-brea Circuitbrea Circui!brea RC

[]

ke

ker

Auxilia4

I'/I,K

IIF,DRK
Socket

Socket

ELECTzuC PARTS L IST OF SLEWING/TROLLEY .-Symbol

TSl ra.)
Name Transforme

a3
1

rs3
Red. Red2

T;;=:Diode

I I
2 I
_l

----GD-.DDi fSFLTP .j"dFlrp-<

RDi

rslin-

Circuit-breaker

-l
2

-- ---** DAV. DAr.

Dpv.-Mttl
ACconractor

__

xRai

XRal. XRa2, XRG, XRD.

__tDM. RDM SD. DG. Dptl. DF"DRV

-*Yi------l
gon;ctE"lP

r-----l
Control relav Control relay

l I

2 9

.- tRGr, -.--.-_.--co',re.iD-. - -Conne.t

r,:;i- .'-il-

Time delay relay

lr lr

ll

uunnect

.-RG

XRa2, RFa. RD,

n,n" d.lrnr;lay
"CI/",

-Jgryectoav,
MTC

Ric=-

Da.-

Auxiliary

---r
___
__

4 2 I

;;;*"
Silicon controlled rectifier

-- R;d;t'--

l
I 25

T.

Terminal strip

-Ri

VGi

*1._rlryao ,,,roR[
-_.-.-rJr/D.E,R

ft:.I!l{.

FtF/Mo

@e,erlgr,. Brflnr

_q l

--

Socket Socket e^^r-^l

< o
-J , o l-, o =

6 I 6

CD OD

z, O
=

= C'

-, C) := -l .-J

{lt
HE

EI

ITE
-J <.) -J <t) CJ
LU

o < o
-t
<n

tl_. E

CE

6 -

o-J
cE

--

<

E, =

ra

o
-

> o

<\.1

<\

u:

3b.3iE

.3

(Y) CD

OD

:
.= .:

o
I

EE
E

rH i;iH:*! *d.3H
tk EfE
E

E*- ! = F. :*l<. i
6

e
,.t

CJ
r.-

g 2 o
o
=

5F5sEsEEelxEpsr

H,.9-.*gr

6r

U-E=
{il|
IiE

:F<9r =,

E--

TOWER CRANE OPEMTION AND StrRVICE MANUAL

9. .Hydraulic system

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

Sf,RVICE NIANUAL TOWER CRANI] OPERA]TIONAND

l" n*urrn

system

ol

of: lrydraulic purrp' ST series tower crane is con.tposed

joining hose and so on' cylinder' telescoping

of hydrautic pump station 9.1 Composition

It

nrainl-v nrakes

oil pump, combination reversal up of oil box' lter' motor'

vaive'

pressure

gauge' liniting valve and pressure

1.

Molor

2
3

6
:

2. Illectromagnetic siarter valve 3. Combination revelsal

4. Name Piate

9
10
11

5. Oil box for liquid 6. Temperature gauge 7. Oil outlct 8. Lifting Point 9. Hldraulic air cleanel

li

t13

connectroi 10. High Pressure lluid connecrol 11. Low Pressre fluid

12. Pressure relief valve 13. Pressure gauge

PLrrnp outline diagratn

:
I

cylinder Outline dlarvirg of Lclescoping

TOWER CRNE oPERATI0N AJ{D SERVICE MANUAL

9.2 Basic technical parameter

N46 antiwea hydraulic oil or 40 thickened oil Volume of oil box

Mofor power
SafetJ

ylye settirg pressure

working pressure for tetescopitg

Max. working pressure for lowering
BaLrnce valve pressur.e

Oil pump capacity

Cylinder inner diameler
Piston rcd diameter O 180 mm

Mx. telescoping force

Telescoping speed

Return speed
Cylitrder trvel
prcsure hoe
Pressure hose ssemblv

Adjustable in safe range

West Germany

stadad 4D-13-60

AND ERVICE MANUAL TOWER CRANE OPERATION

9.3 Working PrinciPle

makes the oil after motor starting up The oil pump coupling by pu[rp oil Drive the valve and cylinder via the filter' combination reversal telescoping to box oil from between the oil pump and hose assembly' The setting pressure

high pressure

combination reversal valve

is

valve 44MPa' the telescoping overflow

of

the

and the balance lowering overflow valve is 6 5Mpa combination valve is 40Mpa, the

valve is 2.5Mpa before leaving factory'

combindtion re{erir \ arle
high Pressure hose assembl)

pressure

gaugc l{'
P

'

reliefvalve

10\lP!

hl draulic air cleaner

e\tra high pressure val!'e

)

\
oilbox

relescoPig cYlinder

rnolor

Hydraulic principle of telescoping system

TOWER CRANE OPEMTIONAND SERVTCE IITANUAL

-es the

oil

lah

power supply
l

valve and

ump

and

SBh

SBz

e of
Le

the

balance

l\, M-a

Electrical principle of pump

The combination eversal

valve in the middle position H, the opening p and opening T are joined togetheq the hydraulic oil ofthe oil pump outputted went back to the oil box, the hydraulic system is in oft,load condition at this moment.
revesal valve is in the left position of figure (when lifting the lever of colnbination reversal valve), the hydraulic oil ofoil pump outputted come into the big chamber via the combination revers
Combination

rhe hydrauric rock.

open,r.

B and I the telescopins .ylinder start to telescope. The ''''"'"''"" cvl telescoping Gp.od.,'",,. ,,, tc rlow ^"* ol oilpurnp. \-

move downward; the hydraulio oil ofthe small chamber flow back to the oil box via the hydraulic rock, high pressu.e hose assembry and combination reversal valve
speed

0fcylinder

rr::;:::': :::"T" ::j,:j" ;,.:l

AND SERVIC[ !f dNUAI' TOWER CRANE OPERAIION

Cornbination

ffiposition ls tn rer ersal valve

the of hgure (when press down

oil of oil pump outputted come hydraulic the valve)' revesal lerer of combination the high pressure reversal valve P and B' combination the via chamber into the small time and hydraulic lock at the saure the Open lock and the hydraulic hose assembl-v small chamber the hydraulic oil of the upward; move of cyrinder make the pisto' and pressure hose assembly high lock' via the hydraulic flow back to the oil box start to lower' The lowet cylinder telescoping the T' revesal valve Fl and
combinatiou

throttle valve of cylinder' speed depends on the

9.4 OPerating and maintenance

main power supply 9.4.1 Coffect connect the

ol motor' Make the motor

rotate

up the clean and fill and filter air hyclraulic cover of anticlockwise OPen the telescoping system pipelinc hydraulic the Connect appointed hydraulic oil joinl: test run and and screw up the diagram system according to the hydraulic rraybe normal condition The cylinder in is pump h'vdrar'rlic chcck that whether the and bleed hole of cylinder air via screw ailbleed lelt the ioggirg at beginning' tuln tighten up more' jogging any didn'L it times' if spun some oil Operate it several (the overflow valve oftelescoping pressure check the thc ailblced screrv tightwarcl; necessao' it no needs to adrust. If factory, reaving betbre overflorv varve is 40Mpa
namely for lorvering is 6 5Mpa)' valve ovelllow the and it can be ad.iusted Afler completely retract and completely the pressure $'hen the cylindel cxtends rlrc ebor e
rr ot

obselve

k. it can hc l'trtt ing into serr ice'

t
TO\YER CRANI OPERATION AND SIiRVfCE ]UANUAL

n the
30me
SSUIC

9.4.2 Although the

oil box

--...................."........................................-

has

o" en filled up with oil, sore

cylinder when it

stft rp, .o it need to add some hydrauric oir

"r*;;;;;
until it eaches to the

e and rmber

and

lower

upper rimit of level gauge check the creanliness ofhydraulic oil every six month or after 2000 hours,running. According to the specific circumstances, it can be checked in advance. Ifthe oil is milkiness, freezing and dirt, it must be replaced. In orde to protect the seal ring of cylinder, wipe the dirry bodies on piston rod. The hydraulic pump should be covered weil with plastic materiai after work with the pulpose to protect the oil quality and prolong the selice

life.

9.4.3 Check that whether the oil is curdle

ifit

didn,t work for a long time. Operate the

rotate

hydraulic system every two or three months with no load, which will protect the pump, valve and cylinder.
9.4.4

,n

and

peline

and

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 ofthe rust first, then add the new oil.

maYbe

9.4.5 Check
periodically.

te and Jen up ve (th

essafy' rbsefve

the oil qualiry belore everyday work.

lr

musr be mainrenance

throttle valve with load. otherwise

it

may occur

"".,".tJe

$f

MANUAL OPERAIION AND SERVICE TOWER CRANE

9,5 Th" "ollnoo even heavilv when it lowering' shakes 1) The cvlinder retum circuit is unsuitable' of throttle valve for oil

fuilures and troubleshooting

caut::"::::*:*t"-

**l* ,* 'r*t'"ent

until it to the operation manual' according valve Adjust the thottle Troubleshooting: didn't posidon of throttle valve opening the If condition' reaches to the optimum
thread' it can not be adjusted' screw the with align
2) The

joint sleeve damaged

Reason:Themanufacturingprocessofsleevewasn,tensured. connection weld the nut and direct e i weld' joint or the Troubleshooting: Replace of oil pipe)' adjust the direction joint can't the time' completely' (At this falling down 3) The cylinder continually or the gas left; not well sealed; residual have of e cylinder Reason: Two chambers hydraulic oil wasn't clear'

of control

Piston
sealedl

Troubleshooting:Eliminatethegasofthecylinder;ensuretheseal well and ensure the oil box cleanliness oil the often check
and check valve;

thecontrolvalveofhydraulicpumpmustbeaccuratelyadjusted.
telescoping interface of hylraulic pressure low and The high
systerrt

valve rrith throttle the adjust is forbidtlen to cannot be overturned; it

load;itmustbecarefultoa.ljustthehighpressurethrottlevalve.

TOWER CRANE oPERATIoNAND sERvIcE MAIUA

10. Safety devices

to ensure the safety ofperson crane are important devices tower of The safe devices
and equiPment'

0. 1

Introduction

for the load limiter set a limit the ard limiter devices' the moment Among the safe breaking off' and the wire rope fiom overtuming to protect it against tower crane so as The purpose of each adjustments their are set' don't modi After the safety devices mechanism' the motion range of each timit to switch timit

O. If the top of tower craneexceeds30m,itisnecessarytofitredobstacleindicator stopped' even the tower crane feed current remain lights, which

O. If

the pivot joint height of

anemoscoPe,

jib foot exceeds 50m' it.is ""::::i"":: exceeds operation when wind speed stop to *u*i'g o,rt which ."rr-d

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

sPeed' max. limit of working

TOWER CIIANE OPERATION AND SERVICE ,ft{UAL

10.2 Hoisting

limit switch

10.2.1 Purpose

the
I off.

:ach

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 re'vr uuu,' qomes c< near the jib trorey (at l-2m

distance).

b). To prevent the wire rope from completely unwinding or winding up onto the drum in the everse diection when the pulley block is lowered.
I

0.2.2 Working principle

limit switch, which equipped with a reduction gear and located on the chassis of , is driven either directly by e drum shaft or the pinion
engaged a gear ring.

It

several cams to rotate which control the circuit breakers, so as to cut off the onding motion.

Each time when transferring the tower crane

to a new jobsite and before

it into service, it is essential to unscrew the plug located at the lowest pa of switch in order to drain away the condensing water. This plug must be
before the tower cane transportration.

rr
{

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

10.2 3 Adjustments

tl
I

height: reaches to the predetermined crane torver After the

lowering load Control the hoisting or no with out carried be Adjustmenis must the manually so as to detennine 4W and lW microswitch motion ard operate or falls (Note: If changing the height molion control the oll hich cuts micros'itch

of

1o\\'e1.

for hoisting the hoisting limit switch adjust ro necessary is it crane,

)

and

lo\\erirg.

f'.r,

i-

17 2Z

1Z

,2

4l
3W 2W
3T

4Z

2Z

2f
1T

"rrO
Adjusing spiudle Ivficroswitch

ng
he

lls
rd

Adjusfing p"o"...,

t_

4z-

| ::a ---:.-

=-

4Z
1W

I l) D i.u.r"rb,-ng the
z) r oo,.n nut r

housing t

3) Adjus ting the h";;,;;,::"

Lower rhe hook

]rl;" ;,:":t'*'"r
,.

check and screw up 2 scews F.

"ompreterv
irch ror rouerins (Sr D)

."_, ,;; r;;,

Iz
,spihdle

.r, ,r,r,. .rr",a

Adjusr rhe rimier ar rhe

uoo. before reaching ,o ,n" loou took

eaches

o"ot"r"n.

id ha. At o,
s

. *. o";;; - .. -' ;;;:"*' l.u.t , ,"u., . ,"r;, ,--, at the ";;;" lorvest posiion).

-2m distance. rt is rorbidden to make rhe ",u rre pu{pose to prevent the rope unwinding unwinriio rrom r.^* ., the ;.trte *'trdings should remain on the drum (when the hool<
I

"orr".oororr*l;"

fi"::;"

SERVTCE I1ANUAL OPERATION AND CRANE TOWER

distance or 4-fa'll' until the 2-fall with up the hook Hoist t:"]-::^:;.

"-

*;*"mit

(SLH) switch for hoisting

b":::::::"::::::r:

motion stopped' 4W and the hoisting contact the coresponding until it depresses disorder' make the memory will it otherrvise Scre up nut E' Check that times with no load several rvotk u'inch and Operare the hoisting it as the above process' adjust lfnot' position is right whether the memory housing' nut E' install the up screw right' If the position is conol' so as t' memory of position of l'inch' check the

oa*"p*u* o'

and rotate cam

conol' 4r" check the hoisting

5)

6)

7)

8)

Afte the operalion

time' correct it in the Proper

"6**"'

'"*'st

fails erection and changing each after s'itch the hoisting lirnit

ToWf,R CMNE OPERATIONAID SERVICE MANIAL

10.3 slewing

limit switch

10.3.1 Purpose:

This device is used on the tower crane which hasn,t have slip ring. Its function focus on avoiding cable twist and damage. It,s equipped with slewing limite, and allows the max slewing circle is three.
I

0.3.2 Working principle:

Limiter has reducing device with pinion driving. pinion joggle with slewing ring directly. When slewing, limiter reducing device bring protruding block slewing. And ing block controls breaker (iggle switch). So the slewing can be stopped by

Fig

10.3

-l

ANT' SERVICE J\IANtNTL TO\YER CRANtr OPERATTON

10.3'3 Adjustnents

ot' 1ift load. Control thc right slewing no with ou1 carried be Adjustments must to determine the and 4W manually so as 1W mict'oswitch slerving and opetate rr hich e uis olf >ler'r ing rnotion '

mi.r osr'iLcll

fi,
1Z

4Z

2Z 3Z

lL

41
3W 2W
3T

42

2l
1T

and lc, cam ant Comparir tiYe ta blc for atljusling sPind

idius ting spindle

I

Cm
l

micros*itch --1 Mlcros'r'itch -- ] I

tL
1,2 37,

t
I

1'l

2T 3T

| ,'l 1,'u-)

[.r:i

--l

TOWER CR-{NE OPf,lL{TIONAND SERVICE MANUAL

Adjusting process:

rift
the

i il:r)r,i
42

/ ,._

,'

-1 r,._,i 17

1)

2)

D isassembling the housing of limiter, check and screw up 2 screws o. Loosen nut E and make it loose completely.

3)Adjusting the right slewing limit switch 1br lou,ering ( SRD ) Slew the jib make the cable not twist, sle.right for. half rotation ,and then adjust spindle 1Z and rotate cam I T until press relevant microsq,itch to lw, stop slewinr . 4)Adjusting the deceleration limit su,itch tbr lifl slerving ( SRG )
Slew

right for half rotation, and adjust spindle 42 and rotate cam
to,lW,stop
slerr,,ing.

4.1_,

inspect

o1.

hoisting until press releyant microsrvitch

5) Screrv up

nut E, otherwise it rviil make the memory disorder

6) Operate

whether the memory

the slerving winch and rvork several times with no load. Check that
position is right. If.not, adjust it as the above process.

?)
8)

t,

If the position is right, screw up nut lr, install the housing. After the operation of winch, check the position of memory
,, ,n the proper time.

control, so as to

]Ql

Everyday adjust the crane all above before in service, when the ctane diYcrt to other lieltl must [re pultr out plug of limiter lower and drain away oholtg
condensation

rv"t"

agai.

water.

Beflore the crane cut to the plug must be plugging

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

f O,+

f.ott"Y limit switch

And make the trolley and mistake' operation liom can prevent

10.4.1 PurPose:

jib foot

Trolley liritel

distance to running' have a safet'

10.4.2 Working

which is joggles wifh the teeth ring it limiter; device in trolley Thete is a teducing slewing' the protruding block brings device b"v a pinion Reducing fixed on the drum relevant switch). so cut off the (iggre breaker contrors And the protrr-rding block movlng.

Principle:

.,i1,.. irll

I'OWI]R CRANE OI'I'IL4TION AND ERVICE MANUAI,

I0,1.3

Adjustments

foot

ch is
ving.
3vant

t
\
q!u-\,

iji

42.
4W
3W

1Z

2Z 32

.t
, , 2: 4Z

12

4r 3T
2r
1T

2W

Cornparative

table f<rr adjusting spindle, cam antl micro switch

Cam

Atljusting spindlc

3Z

AND SERYICE MANUAL TOWERCRANE OPERATION

Adiusting Proces

1Z

22 3Z
T

4W3W 2W

/ lrr) I \,.' *-/ /

3Z

/--..a -- 1'\ l-

3T

4z^.-1:Y--22

2r

-|f
limiter' check and screw up 2 screws F'

1) Disassembling the housing of

2) Loosen nut E and make it loose completely'

3) Adjusting the

toliey limit switch for out (RDAV)

arm of buffe adjust spindle 22 and The trolley is apart from 1 5m for the top
oontact 2W' rotate cam 2T so as to depress the corresponding 4) Adjusting the trolley

limit switch for out' (SDAV)

adjust spindle 12 and of buffer top the for 20cm about from ' The trolley is apart lw, stop trolley and stop contact coresponding the depless as to so rotate cam lT
adjust for cam 2T.
5) Adjusting the trolley

limit switch for entad' (RDAR)

to cam 3T so as

and rotate admit to the trolley for arm root, adjust spindle 32
depress the corresponding contact 3W' 6) Adjusting the trolley

limit switch stop for entad' (SDAR)

Admit to the trolley for arm root, adjust sPindle

depress the corresponding contact 4W, stop

4Z

4T so and rofale cam

a t0

trolley

TOWERCRAT OPEIL{I,ION AT{D SER\'ICE MANTJIAL

7) Scew up nut E, otherwise it will make the memory disorder8) Operate the trolley winch and work several mes with no load. Check that whether the memory position is right. Ifnot, adjust it as the above process.
9)

Ifthe position

is right, screw up nut E, install the housing.

10) After the operation

of winch, check the posion of memory control, so as to

correct it in the proper time.

Note

Everyday must be to adjust crane before in service.

AND SERVICE MANUAL TOWER CRANE OPERATION

10.5 Monent

limiter

l.

Fig 10.5-1

:::'jff:[,

then the contact (3)' touches it ,ntil (2) rotate the bolt

clos

the

exact adiustments' switch contact. Lock the nut (1) after

TO\yER CRA\-E OPERATIONAND SERVCE M^NUAL

10.5.1 Purpose

cranefr.omovertuming.ruauUi1topleventthetower
1

'Ihe tower crane is calculated and designed according to constant r load moment. It is forbidden to exceed the max. load moment. The -o_"rra ,rr.lll a device to inspect the hoisting and f"ll";i;g motion with rated ,oad.o ur,ottt"'is
0.5-2 Working principle

The moment limiter, rvhich is located on the main member at the counter-jib foot, is of a pair of elastic plate, three micro_inching limit switches as well as :r,"1:.:"d installation suppoft. adjustable screw, housing und ,o on. When hoisting with load, the elastic prate began distorting (the distance between the two p-l-ates became sma,er) due to the action of load moment. If the load exceeds rated value, the adjustable screw on one elastic plate depresses the switch contact which located on the other elastic plate so as to cut offthe control circuit and stop the mechanism motion. 10.5.3 Adjustments

:-:,

Specialsuggestion:

Confirm the rated load moment of tower crane beibre adjusting the moment limiter, then debug the relevant data. l
Lisht load
Overload

SLMO
SDMO
e fbe

(i'ixed radius, variable load)

C

(Fixed load, variable radius) (Variable radius, deceleration)

RDMO

t)

l. Elastic plate 4.Monrent housing

2.

Limit switch

3. Adjustable screw

5. Ins tallalion suppolt

Fig. 10.5-J

SERVICE TfANUAL TOWtrR CRANE OPERATIONAND

I0.6
Table 10 5-1
1.
1

0.6.

Adjusting the hoisting moment limiter SLMO

specied l)rive the trolley to the jib nose and lift the according to thejib load X vith rated speed in 2 falls

1).

The s accol
l'uax.

overk
10.6.'.

legth (ad.just device

A)

of Y=X+X l0% wjth 2). Lowcr the load. then lift a load switch the lowest spee<1 in 2 falls The inching

Wher
produ

circuit' otherlvise SLMO will move artl cut olf the it should be readjusted'
2.

ring (
distor

6 and
load, contr(
i 0.6.:

the trolley momcnt limiter SDMO

^djusting the valid radius (L) 1). I{easure the dislance and mark 10% on lor max. load (W) and the radius L':L+L
the ground.
2). Lift

air) and drive the the max. load [suspending in thc (Adjust devicc C) hook to the markerl raditls (I-)

Confi
the re

t:.

trolley out with 3). Dd\e e trolle,\' to the jib lbot' then rated speed. Ilefore reaches 1() the markcd

(L)'

the

t
lrigh speed

tro11e] motion shouid be

outff, othe$ise

readjust it'

i
R
LorY

oojuuin=

,n"

trrorlent limiter I{DMO' lvhich

I I I

trolley radius deceleEte before reaching to thc max'

hcn trolleY out.

speec

Lili the

Load

at the

jib

center, theD trolley

ou1

witl
as

so that the trolley rated sp.ed and acliust clcvice D,

olrated speed can runni1tg rvith lorv speed instead

soon as rcachcs to the radius D-J)-O'8D-'411

Note:
(a) The loacl X,

I I

t'alls the j ib leng r and and raditts L are selectcd accorcling to

(Se

table I 0.6-3 and 10.6-4).

I I ;l
i{

Notet

(b) Adjusling the devices A,

and D:

until the bolts bolts and nuts the Unscrerv

l) Th
2) E,
a

r{
JJ

louches the contact ol momcnt switch, but

will flot

cause circuit break'

'I'OWER CR{NI] OPER TION AND SE]iVICf] ]IIANUAL

10.6 Load limiter MSWL I 0.6.1 Purpose

,l

The stuctue and hoisting winch of the tower cr.ane are calculated and designed in accordance u,ith maximum load. It is fobidden that the wol*ing load exceeds the max. load. The load limiter MSWL is a safeq, device to prevent the towel. crane fton.r
overload.
I

0.6.2 Wbrking principle

When passing though 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) ich coLnects with the pulley. As the load changes, the proving ring begins distoting, as well as the metal plate (10) which equipped with inching switches (2,4, 6 and 7) and adjustable screw (1, 3, 5 and g). According to the requirenent of the load, via proper adjustment, the inching switch (2, +,6 and 7) was depressed so as to control the circuit.
10.6.3 Adjustments

Special suggestion: Confirm the rated load of tower crane before adjusting the load limiter, then debug the relevant data.
itlt
the

.,..,

ich
ius

viih
lleY

las

Fig. 10.6-1
(See

l, 3, 5 and 8 - adjustable bolt

2, 4, 6 and,7
Notel

9. proving ring
10. metal plate

inching switch

boltj

It/ rre

to\ver cr.ane should be set 2 sensitive switches ard adjustable bolt.s. ''^(cpt normal inspection arrd rnaintenance lor the lord lilniter, afier.each erecriorr and changing falls, it must be readjusted according to characteristic parameters.

t'

l-

AND SDRYICE MANUAL TOWER CRANE OPT'RATION

Table 10.6-1

lodiu*,r*,n"

limiter ( sLcHGV )
'oeed

lirr,. l-.

(PV)' then r"^ V with low speed

sPeed hoist uP u'ith high

.Adjusting the max' load limiter

1.

( SLCHPV )

Lift the load X with low

sPeed'

o"tt l'""d t"'"h"t th .,** a-. *u *** [, to the load l: r,o*.rttl. r., * " r0o load can oe

- '-,

Llft it with tou speed lfthe

lilted, readlu>teo lr'

-:i''-=--'.ti

1"1
J'I

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

itl.
.h

Yl

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

Load table for max. working load limiter

(l2t):
Table t0. 6 2 Overload m-itel

Load limiter for high speed limiting

SLChPV&{V\

w
(10N)
2500 (10N)
2500

x
(10N)
5000

(10N)
s500

5000

5500

10000

11000
l

Adjusting load and radius table for the moment limiter (l2t):
SNI 2 ropes

(m)
ti0

Lf

Hoisting limiter SLMO

(10N)
2240
2600 3000

Table 10 Trolleying limiter

(10N)
o000
c001)

(10\)
2420
2i3ii0
3

SDM)

(m)

(m)
36.5 75

RDTIO

D m)
48

'I

2
70

1.1

55

3'7.t)7
31.07

41 10
36

50 45 40
35 30

300

4000

70

3500
430u

38r0
4730 5500 5500

5000 5000 5000 5000

31. 60

38.06
39.05
3',1.4

35.50 34.00 30.00

32 28 24

000
5000

3t.0u

Table 10.6-4
4ropes

DM

Hoisting Iimiter SLMO

(10N)
1700

_
(10N)
10000 10000

'frolleyilg Iimitcr

Lf
(m)

SDMO
L
(m) 17.04

Rr)uo

(10N)
1870

lf

(-)
18.744
19.97 6

L'

(n,
4B
.1,1

I lll

r!
L

60 55 50

,L

2t70
2570
3r 70
3.170

tB. i6
18. 15
18. 69

r0000
34fJ7

t9.965 20.559 20.999

20.19

40 36
32 23

45
l

10000 10000 10000 10000

40 35 30

,12i7
5

r9.09 r8.90
18. 77

467t) 5570

t37

6127

20.647

2,t

SERVICE MANUAL OPERAIION AND TOWER CRANE

10.7 AnemoscoPe

rn 7 I Technical sPecifications uoltage: 48VAc/50Hzl

,0.r.,.,. ro*t' *ind ,0.r.,.r. ttun'n*

10.7.1.3.
t

sPeed

5m/s:

Dial

gawge <+3oA\

tempelature: O.l.Z Op"'u'ing "nvironment -40 - +50'C;0 - 100%RH sensor: t,"ed , ,. *trr' ,4., 'Jor,rl,,r.r.r*, -2s +5oc; o - 7oYoRH

r*r"

The ---^^+-,1 rvirh three core cables' to the wind speed' Thewindspeedsensorandthedialgaugealeconneciedwiththf which ProPortionated t'" is magnified wind speed sensor outputs level Then the current *to

"tnciples i0 7.3.1 Wolking principles

.,

.,

**Ot,

use and instructions for

the pulse was

rearr"*"u
*ut'*"

and fed into the

"" to

the signal via exclusive limit value' *ltta tp"ed exceeds the *t

processes light beam gauge tED the sp""a' i}t" winO The alarm sounds 'no* up 201 raster lines'

;;" ;; *"":;"'*

""

"""'"';;;;

';s

cable screw .,,:+r. rhe included inclu the -^ with gauge the sensor and dial Before power on, connect

"n-tt.t" for 10.7.3.2 Instructions

use

;;;;, ;""

n"*", o',

the oP readings. Green rePresents danser zone red represents the

"'no*"

ffiin:;:X

T:lii',:: *i

;;il;;;;"" J;;t;;t;eed value to 20 when it working'

lo.l.4 Rdrr,ing und service wind 10.7.4.1 rhe circuit of the

au'* out both audible and visual value' it can reset automatically' limit the tO* ,, ,0"*

wind When the work to tft" relay contact began

set the lirnit hoisting it when to 13 limits' it set above the exceeds

il is . , -^^,{., o:"" h.en adiusred. alreadv anemoscope has l;;;; t',,,,'0"* U"'*":*t:r":; ln the event of sufficient 0"" Ot^' l' necessary to readjust it' preset t* "llo" 1";inaccurate or the "ttt conditions, the display can be anemosc( "0"" staff can open the
not

"**

this case, only a professional --- ^- r:-^

^

-,.2

TOWER CRANf, OPERATION AND SERVICE MNUAIT

The purpose ofeach potentiometer is as follows:

Wl - l3m/s limit alarm

set;

W2 - 20mls limit alarm setup; W3 - LED light beam gauge full range adjustment;
W4

wide angle gauge full range adjustrnent;

W5 - test signal amptude adjustrnent;

w21
.20

- 6

13

u
II

" v|t
-6
IX

fils

o
I

3.,n

oFFEoN 13r0

WS-2 anemoscope

three weather vane

Signal output socket

Wind speed sensor

SERVICE MANUAL fOWER CRANE OPERATIONAND

10.8 Height indicator

light

1.

should be crane top beyond 30m' tl.re tower crane tower of height the Fo light on crane top and two equipped with red obstruction
by power failure' porver supply should not be influenced

jib

ends' and ensure the

2.

FoI the height of tower crane

be equipped

jib foot pivot beyond 50m' the tower

speed beyond the

crane should
speed of

\\'ith anemoscope, when the wind

limit

rvorking, il should make a sound alarm'

3.

for each time' all the safety devices When modifu the crane working condition
should be reviewed and readjusted'

TOWER CRANE OPERATION AND SERVICE MANUAL

11. tr'ixing and testing rules

for wire rope

Incease rate of broken wire

rope.........

Rope strand

broken

..............._... 1lB_g

....................1lB_g

Rope diameter decreased due to the rope core broken.......................... 1lB,g and intemal

wear..

........ 1lB-9

.............. t equipment conditions for wire rope .

which caused by heat or arc

...... 1lB_9

......... l18_10

D(: Common wire rope defects

.I

SERVICE I\'IANUAL OPT]RATION AND OWER CIANE

11.1 ExPlanation

A1thoughitSStructureiScompactanditSappeaIanceiSSffong,thefatigueandwearof rope will dauraged rapidly' wire wear and fatigue The rvire roPe is unavoidable if the users personar and equipment) on (both in serious accidents rvhich mal, result
attentiori to do not pa special

'

The

l'ire

equipment,

hoist inspecdon. For the periodical by found rope condition can be of expendable. It should be kind a as taken be the ire rope should

it'

5)

and strength reduced' replaced once its intensity rope 11.2 FitLing the wire

one lf same as the original the be should of ner'v wire rope The type and sPecification capability of new wire the ancl that the characteristics not. the user must ensure the groove rope is applicable to wire nerv the and originat one are not lower than the twisting together'

rope
I

uire rope from knotting' the ?revent pulleys of tlruts and

buck1ingot.adheringsundries.BeloIeputtingthewireropeof1owelcraneint0 work of
rvith the kinds of devices involved all that ensure servicc. the users shoriid in place l(eep the wire rope to order ln 'orting condition ,ire r.ope are in nomal times' rated load several ofthe 100 with crare steaclil'. opetate the to\!er
1

(see any twist avoid and ground rvile rope on the clean 1) cornplctely unu'i.td the large utlwind it in completely' roPe unwind the wire 2-1). ll it is no1 possible to onto tho rope wire the cluling enrvinding danger avoid can it ay loops. Ir tlris

i.2.1 F-itting nel rvire t'oPe

rig'

dl um.

^f.,,i-a r^rle

TOltTh

CRAAts OPERATION AN SERVICE MANUAL

3) Enwind the wire rope onto the drum via a sling and fasten it with bulldog grips.

of
llv,
ers

The distance between the wire rope and the last bulldog grip should be not less
than 3cm (the tightening moment of the screw is gmdaN).

4) Hoisting up and enwind the wire rope onto the drum 4-10 circles tightly (See Fig.
)

-)\
limit stch
and readjust it

oist
be

5) Check the adjustuent of

if

necessary.

.::

Fig. 2-1

Fig,2-2

TOWER CRANE OPERAITONAND

SERVICE MANUAL

li: ,H|"J:::"r

the or hoisting machinery' purpose the on wire rope depends wire rope should used lf possible' the rope *i'" tf'" ut as well working environment o'l *O" rope which and curved bended the greased' especially :un be cleaned and be suitable to the grease should oil lubricating of the pultey tle type reeled through is one of the common rnaintenance of Lack wire rope tactory works in which used in the when the machinery life time of wire 'op"'' "tp""iully reasons reasons fot shorl be greased due to some not can rope wire or the corrosive environment of operation' caused by the limitation
1

1.4 InsPections

il::i:ffi:

ll."*"

da wire rope every working orthe parts ,isibre *,"

sPecial attention

damage so as to discover any on the tower crane'

:: the person m found''inform is if any obvious change which fixed fourth item listed below' the to according wire rope charge to inspect the by person in charge 11.4.2 Periodical inspection the inspection order to detemine in account into e iaken The lollowing items shoutd

o' di'to'tion in time Pay

:TT

;:::::j:HT:
tower crane";

r"1.'.,",''-

or "saretv rures GB5144-2006 as machinery' such

and it working b). Types oflT oisting machinery machinery; c). Working grade of hoisting defects before; d). The test results and the

environment;

-"' '1'1"*"u ?.::Til: ::: ."- :::. :.?:',::::'":;" into sel'vic putting the wire rope
week. After an accident or before thoroughly' dismounting, inspect the wire rope

a'i reas' 'ce agait zlter

TOWER CRANE OPERATIO]!AND SERVIC: IIANUAI,

1

1.5 Inspection places

1.5.I Gener.al inspecting places

Pay special attention to the following places although a thorough inspection on the rvhole length of the rvire rope should be made.
a.).

The places ofrope running and two fixed ends

ofwire rope.

,n

in
ils

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 lope sections rvhich located on the balancing pulley.
d). The rope sections rvhich may be wom due to extemal factos.

e). Internal inspection

ry, art

lor corosion and fatigue. The inspection results should be

recorded on the equipment inspection notebook.

5.2 Inspecting the drum (See Fig. 5_l)
a). Check the end places

in

ofthe wire rope on

the drum.

Iixed
pulley

b). Check for distorlion and wear which

ion

caused

by

unqualified enwinding,

n.u. . ,

point

especiafly

rof

r rhe uire rope groove

Movablc pulley

jumping an<l over.lapping places.

c). Check
d). Check

lor broken rvire rope.

lor corrosion ofthe rvire rtrpe.

e) Check lbr distortion which caused by

adding load sucldenly.
ceg rftr

V
Fig. 5-l

l.od

''

r'J lnspecring the fixed pullcy and iixed poinrs

aI Check for the broken and wear

L, -

olwire ropc u4rich reeving through pulleys.

"l' eheck lor brol<en and corrosion of wir.e r.ope on fixing points, as well as the wir.e
rope sections around the balancing pulleys.

MANUAL AND SERVICE OPERATION CRANE TOWER

--^'-*
o'r.

Ji""" r'""*.1"*i:Tt]::"i:l on tnt *^t-*o check carefully

a).
ar' --^-i^1lv the rope sections

.ntto

wire c* dir,oion of t"' tnt Ut"'"tttt ":,'J::

rope'

:t,,0;

*.

the movabre punevs' throush passing which pulleys wirh load.

n,.

c ).

Intemal damage rope' Intemal :::;;" and latigue or uire extemal be di"o' tred bY not ;; ,r--. ir the wire roPe is nearlY

of wire rope' Checl' for conosion inspecting oI wire 'oO1 rr.r'a I 1.5.4 lntemal is mainly carrsed

aJ*.t"'

o'"*"n ol'tht *i'e

wear' rope and surface

^,,---

,--. the .u. by

;;":;';"""
,i,"oi.,;

u'rotr-* "o*pt"t"tv'

-"*.U "t

is as int*"t":^:t.:,t inspection method of internal

;'*t

rhe th" i"t"*ul insPedion'

The person

in

charge

***'

foU"t:l

wire ropes firmly tishten the

lavers cramo so rhar rhe ourer

'I::rump. --. *itt,

:.1";;" ;;:;," o[tt

is untwisted When the wire roPe ale as follows: *spection items

,,,;]P..j;;;.

screw the suitabte dimensions. roPe core oIwire divorced from the the rope bv in chip und gr"u."

."**ol**

a). Intemal lubrication;

'n"

b). Conosion conditions;

"i

are d). confirrn if there wire rc the :::: for l';.;:;;li"ab1" i then grease (This method layers )

,,,".r" ,.**'*'1"':111I[::T:Ji:li:
t*l

il: :'ifi":#i,

wire rope 11.5.5 Inspecting the

sall wear' the rnd end fatigue ' rone from rhe lixing o"-' t*t" wire the iF dangerous very rr is a: roPe'ax'"i**"tn "".n", devices' 5qh xing nth"' on 'oF inspecrion should be *,dt t"t drrr check on ttt" if there is crackl crarnp and so on. check

end

*ttt't

':';;"

TOWER CRANE OPERATIONAND SERVICE MANIIAI,

I 1.6
1 1

The discard standard of wire rope

.6,1 The quality and quantity of broken wire rope

ys,

For rvire 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

rli
The wire no. of outer strands
the

Mechanism working grade M3

Mg

Altemate lay
Wre rope structure

Lang lay

Length range
6d 30d
19
6d, 5

toPe.

30d

pe by

101)) I Note:
1).

120

6x19,7x19,6x(19) 6w(19),34x7
6x37

l0 l9

t0
19

)-

10

I ste,
rultiple

The rvorking grade

oftower crane mechanism is M4.

2), d'represerts the diameter of wire rope,

'r' lhe lilling wires is not the load-bearing wires, so it must be take out from the

sare ( cabl'
re

hsPection number.
hould

en roP I u"-,

take out the stuff steel wire froln the check number because can,t make

sluff

dfur"

w,re as l.ud sreel wire. The multilayer wire rope only considered its visible
Iayer For the wire rope with steel core, consider it as the intemal strands.

trr^-, -'"

SERVCE MANUAL OPERATION AND TOWER CIANE

11.6 .2

gtok""

ti'"

on roPe end

end or around' it rope breaks at rope wire the When orrope end Find out the installation incorrect bv be caused it again if its length is allowable' fix and part broken Cut off the reason for damage

indi"*:tt"l:::

:::l',t:r:

:ffi;;;av

rvire Part focusing 11.6.3 Broken

within the length of wire focusing part wire be discard if the broken The rope should number is even if the broken wire sand one in or it concentated rope less than 6d
listed above' less than the table
of broken wire rope 11.6.4 Increase rate wire rope damage' The broken for reason is an important In some events, the fatigue time ln increases in a short number broken period of time and its occurs after using a rate in order to

the broken wire increasing down write and this condition, check
discard date' conltrm the wire rope

broken 11.6.5 RoPe strand

The rope should be discarded

broekn' ifthe whole wire rope

broken due to the rope core decreased diameter 11.6.6 Rope obviously due decreased diameter discarded when the rope The rvire rope should be for multilaYer inner wire rope strand (or break core steel to the fiber core damage and
structure).
1l .6.7 Elasticity

decfeased

related to the In some conditions (generally

. ,:-^-*anrl the flexibilitY working environme)'

-

of

to use any more safe noi it's wire rope shall decrease obviously'
accompany with follow conditions:
a). The roPe dianeter decreased;

Generally '

I'OWER CRANI] OPIiR{TION AND SERVICE MANUAI,

c). Lack of air gap between the wire rope and wire strand due to extrusion ofeach other. d). Thele 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 irnmediately.

6.8 Extemal and intemal wear
,1re

a). Internal rvear:

rls

'fhe internal \year was caused by friction between the wire rope and wire strand, in
pafiicular the wire rope bend frequently.
b). External wear

'rylle
e.

The wear for outer layers

of wire rope surface was caused by the wear of pulley and

In
t0

drum groove or the wear between ropes on the drums. The lack
incorrect lubrication, dust and sancl
discarded

of lubrication,

:r

will

enlarge the wear The wire rope should be

if

the outer layer wear

reaches 4 0o%

ol its

diameter.

If

the wire rope

diameter decreases 7Yo

should be discarded.
I

of its nominal

diameter., even there is no broken wire.

it also

1.b.9 l.xrernal and inremal

corosion:

due

a).

Extemal corrosion outer corrosion of wire rope can be observed by naked eye. The wire rope should

iilayer

The
be

discarded

ifthe surface

appears pit and the wire rope became slack.

b) lnteural corrosion

ilitY of
nerailY

Thewire

rope should be discardecl

ifthe internal corrosion is serious.

ll

6.l o

Distortion

l-' -qr . ratrguc.

''rc wire rope can generate the visible de{bmalion clue

to mechanical darnage

oi.

T)rey ar.e undulation, cage distortion (appeared in rnullilaycr wire r.ope)

Itt .*u.r,tin, t^.et i,-icr nlarni r.j-r,:--

M^NIJAL TOWER CRANE OPERATION AND SERVICE

discarded bending and so on' The wire rope should be

if it

appeared

the

APP

"ottupring, above conditions'

1

by heat or arc 1.6.11 Damage which caused

due to the heat factor' it should

Ifthe surface ofu'ire rope is in annealing condition

discarded,

be

Ifthe
follo

wire rope 11.7 Relevant equipment conditions for

in order to keep them in The drun.r and pulley should be checked periodically' be suitable for the nominal nomal condition. The radius of pulley groove should
diameter of wire roPe.

Notice in particular
after it damaged' o It is forbidden to use the wire rope on mechanical drives damage the safety and o It is lorbidden to make the wire rope distorling, which may
service life of wire roPe.

r Visually

three months' inspect the whole length ofthe wire rope every

e Replace the u'ire rope ifoccurs the following conditions:

- breaking down. - the wire rope diameter decreased due to corrosion or wear'

- distort, crushing, folding, knot or other damage' - twist distofiion. - ifthe wire rope drying or oxidation, using the RC oil to lubricate' o Dismantling the old wire roPe - lower down the pulley block on fixing suppott' - loosen the wire rope from its fixing end. - unu,ind the wire rope from the druur. of wire rvile rope ancl loosen the single bulldog

- dismantle the double bulldog

rope, but don't dismantle

o1'

it.

,-_

TOWf,R CRANf, OPf,MTION AI\iD SDRVICf, MANUAL

APPEIIDIX:
Common wire rope defects

Ifthe wire

rope damaged, it must be replaced immediately. The damage causes are as

ldividual wies bend up and prorrude from the straEds, the wire rope serious
damaged whicb caused by stess changiDg.

Iceased diametet ofa parallel enwinding wire rope tesults in distortion to e metal core due to abrupt change stess. Coosion and wea are often noted on the extemal layer ofthe wire tope.

Example
rope

of

serious bending

of

the \'re

Basket-slacking (birdcage) of multilayer wre rope (non rotadng T,e) &hich caused by forced enwinding of the wire rope llrough narow groove or large deflection
angle.

TOWER CR{Nf, OPIIRATION AND f,RVICE T1ANUAI,

12. Slewing

ring

Periodical inspection for fastening bolt of slewing ring (type eWA1390.5OZt) Frequency of inspection: After the initial 100 hours,running ofthe slewing ring, the pretension ofthe bolt should be inspected. After this, it should be inspected 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 bv
the tension force due to load or counter weights,

Using a torque wrench to check the tightening torque of the bolts coresponds to the
values as listed in Table

l2.l

-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

i the table. In such case, it

will

be necessary to replace part or all

ofthe bolts.

Systematic replacement: The screws and bolts used for the slewing ring assembly tlust be systematically replaced every seven years or 14000 hours.
.

&'ghtening

of the bolts: No matter it is after the replacement of the bolts

or. the

.lewing

ring is e-assembled by using new bolts, the tighr.ening ofthe bolts should be

ed out continuously and symmetrically Iore

in lg0o clir.ection. Then re-tighlen

them

tine to make

sure that all the bolts on the circle have the same pretension.

TOWER CRANE OPERATION AND ERVICE MANUAL

Table 12.1-

Bolt type 10.9 Bolt diameter

(run)
@20 @22 @24

Tightening moment (N.m )

t3

Max,
580 780 10000

Rated 520 700 900

l3

@27

41500
2000

41350
1800

t3.

(D30

The bolts remarked with

are selected for connecting the slewing mechanism ofthe

tower crane, they must be checked weekty.

retighten it with the torque value shown in table

If
1.

the bolts become loosen'

please

I
1

I 13.4

TOWf, R CRANE OPf, R{TION AND SERVICE MANUAL

13. Maintenance

I i
!

I
t

SERYICE I\'IANUAL fOWER CRANE OPERATIONAND

13.1 Every

kind of lubricating symbols

Table 1 3.1International standard or main characteristic

l
;
L

s mbols

T12032

16

grease 3 # industry lithium based

HL-20

20 # gear oil

7 # a\rcraft grease ZL45

N100 gear oil

MIL-L21osB sAE80-voIo3242

iised in tue countq' with cold weather

4# Compound calciurr base MOS2

winter' 32 # antiwear hydraulic oil in summer 46 # an'tiwear hydraulic oil in

MrL-I. 21058 sAE 90-J0103255 i'li" ,ir" ."r"ny with hot or comfo weather

TOWIR CII{NE OPERATION AND SXRVICf, ]TIANUAI,

13.2 General instruction

1-1

--]

M
N

Table 13.2- l When startig

Oil level

v
R
G
13.2.1 Running-in period

Fill up
Lubricating

Cary out the first draining ofoil in the reducer aler 450 working hours.
13.2.2 Using the grease gun Grease all the connecting pieces without grease nipples (such as door and trap door hinges, joystick, locks and hinges ofthe safety devices). 2) ln order to avoid any impurity getting into the oil when checking the oil level and draining, clean the parts which located around the plugs.

l)

3) The oil quantities shown in this manual are only for the user,s reference; essential that the oil reaches to the lower part ofthe oil level plug.
13.2.3 Checl<s to be

it

is

caried out belore assenbling and disassembling

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 last eection and self-erection tower crane, it required the folded winch to installing and disrnantling thejib. So it is necessary to checr<
3) Check the

1). Check and adjust the brakes

each mechanism.

ifnecessary.

condition of brake dirsc' each friction surface ancl the pins Adjust them

4) Make sure that nothing will influence the goocl worting order of tower. crane (perl'ect motor and brake supply circuit , fuses in place and in good working order,
flexible ofthe rod for manual brake release, remove the nut, ifnecessary ) Note: Ihe dr.um must be locked when can.ying out re above checks. carere\sness ofthis warning rnay cause serious resulrs-

Ary

NIANUAL .fOWT'RCRANE OPERATION AND SERYICE

Ir,

*rrnt""un""
draining

schedule

G: lubricating

N: oillcvel

checking

a:

.a:-,

6p :

..
L

r:lt

.: t)

;;. ,rr if

I i:r
:l

i 'i' rl I i- ,
1,,,

,l

r0
;
,e

I !.,
,:,,

,O

.M .: 450 h

900 h

t900h

t>: ia)

,..))

TOTVER CR]{NE OPERAiIONAND SERVICE MANUAL

1

3 .3 . 1

Maintenance on trolley winch

The following rules should be stictly observed to do any kind of maintenance on trolley winch:
The operator must fasten the safety rope.

When carri/ out maintenance the brake, the operator must ride on the motor.

13.3.2 Maintenance on hook The bearing on the traverse beam

ofthe hook must be greased every 200 hours using

,calcium based grease.

Oil sy mbol

350 h
3 month

AND SERVICE MANUAL TOWER CRANE OPERATION

.,

Mutn

"nu""e

on rope-twist protector

13.:

M:

-!9)

--li 'ptr

3.3.4 Greasing the wire roPes

they seem to be dry or tend when or monlhs 6 every The wire ropes must be greased lubrication' lubricate them using 10 # mechanical that recommended We to oxidize. should be grease (Detailed it rope' wire the of using no In case of long time information
please see

Be
hy,
ac(

l
lr

"fixing

rope")' and testing rules for wire

en

It(

TOWER CRANE OPI]RATION AND SERVICE I\I-ANUAL

13.3.5 Maintenance on hydraulic pump station

M: when

starting

N : oil

level

V: draining

R: fill up

I year (1800 hours)

o o o
,!:

Maximum

Minimum

tend

Minimum

don.

Because of different working environment temperature, the lubrication

oil used in the

iled

hydraulic purnp station should be different. The user should add proper hydraulic oil
according to the environment temperature.

Number ofhydraulic oil

eqviromenta lfempeature

-30,-20" C
D

-20--10"c
YC.N32

-10 -0"c
YB.N32

0-20'c 20-38.C
YB-N46

J8-80.C

I yB,N68

lyB-N8o abo\ e

New grade

N46D N32# N32 Low freezirng Low freezing lAbovc N80/ Antiwear Anti$cr Anti\ Anti\vear point poirt hyaulic oil lr-vrlufrc,ril hyJrrurli. oil I h)drauli. oiJ hydraulic oil r hydraulic oil

N4 | i

N8 crr

Original
Srad

30r)#

20#

20H

t,t l;

I,;

SERVICE NANUAL 'TOWER CRANE OPERATIONAND

'l
rope guiding pulley 13.3.6 Greasing the

pulley putting into service' Before the rope guiding

fill

up the grease Meanwhile add

I
i_ l'"

based grease) Before greasing clean out the (2 Iithium # hours 50 every grease

impuri' oil on the shaft'

13.3.7 Greasing the slewing ring

Before installing the slewing ring,

hours.

fill

50 up the grease' Meanwhile add grease every

In

case

be greased Each of long time no using of the slewing ring' it should

fully greased until time when greasing, the gear ring should be

it

bleed ftom the

while greasing which can make the grease sealing place. Tum the slewing ring slowly
evenly.
li
base
i

.fhe tooth surface should be cleaned every 10 days and lubricate with calcium
grease.

TOWER CRNE OPf,RATION AND SERVICE MANUAL

Tii. iubricaring grer."

add
Bea struclure

"-

:ted according to

th.

lollowingiffi
Lubricating grease

the

Woking conditions

50

rubber seal ring for piasic isolation biock

extreme

low temperature, normal temperature, -40"C +69'6

pressure

Iithium base
cabon calcium base

BG7324-J q94

lach
r the
'ease

sH0369_1992

1#,2#

GB712l-1991

40.c
labl,rinth seal for metal isoiation block

aceway

140"c High
lemperature and wet

MOS2 complex calcium lubricating

base

sYl511-65
MOS2 complex calcium lubricating

80"c
180"c

raceway

sY151l-65

nomal tempetature.
proofseawater colosion - 50"c

2# complex

aluminium
4#, complex

aluminium

sH0378-1992

SERYICE NTANUAL TOWER CRANE OPERATIONAND

hoisting winch 133.8 Gt"aring th" drain plug of reducer and 1) Unscrew the
and volatilizing' the plug after draining

1:

fill

diesel

oil for cleaning reducer' Tighten

2)

Fill

18-20

gear lubricant'

then tighten the

plug Keep the grease

standard oil level' Oil level: reaching to about 1/5 of dirty or nipple and around clean' Prevent

working hours Drain the oil after 200 every oil add and level 3) Check the oil refill with oil' 2400 hours, clean it and then
working
on the drum tail' was filled up support bearing the outside 4) The grease nipple which

the oil' foreign bodies getting into

with2#lithiumbasedgreasebeforeleavingfactory.Checkandfillupwiththis
200 hours' kind of grease after working

Ihten

rvel.

Scope of mainlenance

yor
Paint la,er fte

#f:lm
Insfructions uatty

ori'n".J.

o avoid corosion

up

,:;ffiT::H[

:is

Lubrication

system

ln. normat

'*ffi
;;;","""""

,fl*i*r."ffi**,',,,,:*lm
[ g:".',

Fasteners

injecrinp o ."!L!tron: ,rn,,ooG-Ur

t1{&3!

in" ii I r

# :irn'.t
pnerrnaric

Electic equiprent

Effi
Do ,or

,*;;;:":f l;,,;,J,4'"11^::_

,-it

=oeaIn,r rubber strip

rhe event

/.",,o\\,ng codiion"
"rrotld.slop usin-g .,r( - (lr.lver.s cah

*11

ofthJ

Strloe

1*;mm
lreglllsll. J
tIr I)raDulaclUrcr
o

d;;:' " i",ll[:

ururF;::*mfi_T*:,; ,r.io-.;-.,==-.
; J"?,]:T'

l',";' ,Y;B

Fushun Yongrnao Construction Mar;hinery Co',

Ltt-

Add
fel.
Fax.

^-, P'R China No.3Yuanda Road, Shrnlcheng Districi' FLrslrun' Liaoning'

l',t:..4'1

3-76

rtt99.

764998b

B6-413-764!999

Hot Iinr) Postco(le

i

86-80-8900088 36-400-6154555 86113-7648!89

11:.t126

Wuiisito E, ail
Mat

ww\/.yor'\gmao.com.cn

sun@yongmao.com.c
Licer-i:e

I i

riaciJre

of Special Equipmcnt

tio'

-[S2''l

10592

2012

r
1