Terex CBR 40H-4 Operating Instructions - Installation Maintenance Download Page 1

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Self-Erecting

Tower Crane

CBR 40H

–

REV.000-1

O p e r a t i n g I n s t r u c t i o n s - I n s t a l l a t i o n

M a i n t e n a n c e

Summary of Contents for CBR 40H-4

Page 1: ...Self Erecting Tower Crane CBR 40H 4 REV 000 1 Operating Instructions Installation Maintenance...

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Page 3: ...he safety of persons at risk and cause mortal accidents CAUTION When failure to observe or incorrect observation of the prescribed instructions can cause damage to the machine NOTICE This is used to d...

Page 4: ...STANDARD 1 06 1 3 3 RANGE OF CONTEMPLATED SET UPS 1 06 1 3 4 OPERATING ENVIRONMENT 1 10 1 3 5 PERMITTED MOVEMENTS AND THEIR SIMULTANEITY 1 10 1 3 6 POSSIBILITY OF INTERFERENCE WITH OTHER EQUIPMENT 1 1...

Page 5: ...ATION 2 01 2 1 1 ERECTION CLEARANCES 2 01 2 1 2 SUPPORTING BASE 2 01 2 1 3 ELECTRICAL CONNECTION 2 02 2 1 4 PROTECTION FROM ELECTRIC DISCHARGE 2 03 2 1 5 GROUNDING SYSTEM 2 03 2 1 6 COUNTERWEIGHT BALL...

Page 6: ...G THE SAFETY DEVICES ON THE CRANE 3 14 3 2 2 STATIC MOMENT LIMITER 3 15 3 2 3 DYNAMIC MOMENT LIMITER 3 16 3 2 4 HIGH SPEED LIMITER 3 17 3 2 5 MAXIMUM LOAD LIMITER 3 18 3 2 6 UP LIMIT SWITCH 3 19 3 2 7...

Page 7: ...4 06 4 2 INSTRUCTIONS FOR ROUTINE REPAIRS 4 07 4 2 1 GENERAL TROUBLE OF AN ELECTRICAL NATURE 4 07 4 2 2 ELECTRICAL TROUBLE WITH HOISTING 4 08 4 2 3 ELECTRICAL TROUBLE WITH TROLLEY TRAVERSING 4 09 4 2...

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Page 9: ...Self Erecting Tower Crane CBR 40H 4 REV 000 1 MAIN CHARACTERISTICS 1...

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Page 11: ...net E mail info comedil com Internet home page http www terexcranes com IMPORTER RESELLER 1 1 2 TYPE OF MACHINE TOWER CRANE equipment with discontinuous operation for professional use intended to hois...

Page 12: ...the request of the authorities and to be handed over to the new owner if the crane is sold 1 1 4 NOISE EMISSION MARKING The crane bears the marking for noise emission in the environment in conformity...

Page 13: ...TIFICATION PLATE The data plate shown below is on the door of the electric box It bears the crane s specifications as well as its identification data The data plate is an integral part of the machine...

Page 14: ...ve specific knowledge of this model Comedil disclaims all responsibility deriving from using fitters who do not belong to its After Sales Service organization Use of the crane is anyhow subordinate to...

Page 15: ...to consider proposals to improve the manual If the crane is sold the user is invited to notify Comedil of the address of the new owner in order to facilitate sending any supplements to this manual 1 2...

Page 16: ...rs and the ground and any anchorages are not considered as belonging to the crane and therefore are not mentioned in the manual 1 3 2 CLASSIFICATION ACCORDING TO THE CALCULATION STANDARD calculation s...

Page 17: ...1 MAIN CHARACTERISTICS CBR 40H page 1 07 rev 40H_1i_07 25 6 m 1000 kg 38 8 m 1000 kg 39 5 m 32 2 m 29 1 m WARNING When the jib is raised by 10 and 15 it is permissible to use the 2 part line only...

Page 18: ...5 19 2 23 0 24 5 27 6 34 7 40 m raised 10 2 part line only 2000 1850 1600 1200 1000 kg 22 7 24 2 27 3 34 3 39 5 m raised 15 2 part line only 1000 kg constant Jib folded radius 27 5 m 2 4 part line 40...

Page 19: ...kW micro 6 2000 2 part line slow 23 2000 8 8 fast 46 1000 HOISTING micro 3 4000 4 part line slow 11 5 4000 8 8 fast 23 2000 TROLLEY TRAVERSING 16 46 4000 2000 3 SLEWING 0 3 0 9 rpm 1 1 6 daNm ERECTION...

Page 20: ...n is not permissible if there are any of the following conditions interference of the revolving part with any fixed or movable obstacle that may be in the crane s range of action interference between...

Page 21: ...advisable to use the signals illustrated here It is recommended to precede the start of operations with an audible warning LANDING balancing and tensioning of ties LIFTING upward movement of the hand...

Page 22: ...rol knob is on the outside of the electric box In case of danger the main switch can also be used as an emergency stop WARNING To cut off the electric power supply to the crane completely you need to...

Page 23: ...shbutton panel and the other on the electric box The emergency stop applies the mechanical brakes immediately considerably reducing the time for stopping the movements CAUTION Since shorter stopping t...

Page 24: ...e the payload that can be hoisted Hoisting accessories are not permissible when they permit immediately releasing the load are able to cause dynamic overstresses and accidental overloading limit the f...

Page 25: ...hoisting for loads greater than the permissible ones Do not hoist loads secured to the ground uprooting Do not hoist loads potentially anchored trees poles dismantling items made of to the ground by...

Page 26: ...axis of the centre of gravity when there may etc be tipping over or wild swinging of the load Do not swing a hanging load to deposit Do not make any up or down movements it outside the crane s range...

Page 27: ...the opposite or passageways preceding manoeuvre have not ended Do not make any manoeuvres with the load in a Do not affix on the equipment any banners signs position where it is not visible or any oth...

Page 28: ...l Do not leave the hook constrained to a weight resting or stuck on the ground when the crane is out of service Do not use the limit switches as manoeuvring elements to systematically stop the load in...

Page 29: ...r section 5 Lower vertical tie rod 6 Tower struts 7 Tower cylinder 8 Upper tower section 9 Ballast arm 10 Ballast arm tie rod 11 Vertical tie rod 12 Erection strut 13 Upper vertical tie rod 14 Jib str...

Page 30: ...sections and round drawn elements The jib is supported by a system of tie rods and struts fastened to the slewing platform All these structures are protected by hot galvanization 1 4 3 LOAD HANDLING D...

Page 31: ...1 MAIN CHARACTERISTICS CBR 40H page 1 21 rev 40H_1i_21 1 4 4 1 Rope diagram 1 4 4 1 Rope diagram TROLLEY ROPE HOISTING ROPE 2 PART LINE 4 PART LINE Hoisting rope drum Rope socket Trolley rope drum...

Page 32: ...W with twin disc with two braking surfaces reduction gear with orthogonal axes and cylindrical gears in cast iron casing with hollow shaft and flange at motor input and output shaft for drum reduction...

Page 33: ...diameter 300 mm length 390 mm 1 1 4 5 3 Slewing The slewing unit is flanged onto the revolving slewing platform and comprises motor 1 three phase asynchronous self braking 4 poles 6 daNm with disc br...

Page 34: ...l indicator 3 control valves with 3 positions with solenoid valves pressure relief valve set to approximately 300 bar pressure gauge hydraulic pipes 5 16 type SAE 100 R7 The tower cylinder located on...

Page 35: ...1 MAIN CHARACTERISTICS CBR 40H page 1 25 rev 40H_1i_25 1 4 6 1 HYDRAULIC DIAGRAM CYLINDER TOWER CYLINDER JIB TAIL SECTION CYLINDER JIB END SECTION...

Page 36: ...he hydraulic fluid level is greatest when the crane is dismantled In this condition the level must be visible through the level indicator plug on the reservoir Before doing any erection or dismantling...

Page 37: ...s two positions off on marked by the symbols O and I It is possible to block the knob in the off position with a padlock Opening and closing the door of the electrical equipment is only possible with...

Page 38: ...ckwise to be released Simply pressing the green START ALARM button enables all the movement controls and operates the audible warning Simply pressing the SLOW and RAPID buttons enables speeds II and I...

Page 39: ...erection blocks and 13 completion blocks The erection blocks are an integral part of the crane and remain in position during transport too The completion blocks are supplied and transported separately...

Page 40: ...1 MAIN CHARACTERISTICS CBR 40H page 1 30 rev 03_05 40H_1i_30 1 4 9 1 COMPLETION BLOCKS Weight of block kg 1550 30 Density 2450 kg m3...

Page 41: ...Self Erecting Tower Crane CBR 40H 4 REV 000 1 SITE PREPARATION TRANSPORTATION 2...

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Page 43: ...to erect and dismantle the crane is free from all obstructions 2 1 2 SUPPORTING BASE Before the crane reaches the site it is necessary to prepare four supports on a base square as shown in the figure...

Page 44: ...CAL CONNECTION The electrical connection must be made by accredited personnel and must be in conformity with current standards Ahead of the supply cable there must be a residual current device of clas...

Page 45: ...ROUNDING SYSTEM Installation of the crane on site must obligatorily include the system for grounding and protecting against atmospheric discharge in observance of the standards and laws in force in th...

Page 46: ...receive the eye of the crane s drawbar and made so as to prevent the pin from accidentally slipping out 2 1 8 TEST LOADS To check the setting and operation of the safety devices the user must have the...

Page 47: ...ome of the main signs to display beware of hanging loads no entry to be put up at the crane fencing entrance no transiting or standing in the range of action of the crane no manoeuvring when the machi...

Page 48: ...crane with the erection ballast block only This travelling must take place on solid firm ground at a maximum speed of 10 km h and with tyres inflated as directed in point 2 2 5 The maximum permissibl...

Page 49: ...red with the connecting pins 2 as shown in the detail of the figure 2 2 2 3 DETACHED PARTS The crane has no detached parts except for the ballast completion blocks see point 1 4 9 and the axles whose...

Page 50: ...nder the rear wheels The wedges must be suitable for a wheel of diameter approximately 84 cm 2 2 7 TOWING OPERATIONS NOT PERMITTED The following towing operations are definitely not permissible towing...

Page 51: ...e by using the specific hooks on the crane with slings suited to withstand a balanced load of 22 000 kg or by using the vehicle s runways In this case with the aid of two hydraulic jacks it is necessa...

Page 52: ...accessible from the ground it is obligatory to use a suitable platform or extending scaffolding Access to the lower parts of the structure is never permitted with the crane in operation WARNING Stand...

Page 53: ...Self Erecting Tower Crane CBR 40H 4 REV 000 1 ERECTION OPERATION DISMANTLING 3...

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Page 55: ...of entanglement CAUTION Meticulously follow the instructions in the sequence specified in this manual 3 1 1 ELECTRICAL CONNECTION Make sure that the prescriptions of point 2 1 have been observed and...

Page 56: ...turn the switch 1 onto the ERECTION position Close the door of the electric box and turn the main switch 2 onto I Press the green START ALARM button of the pushbutton panel 3 the sound of the horn war...

Page 57: ...ical equipment connection or on the motor sockets The erection movements are governed by hydraulic cylinders one for the tower and two for the jib supplied by the hydraulic power pack through control...

Page 58: ...the pins 2 Open the two front undercarriage arms 3 tower side arranging them as shown in the figure NOTICE To aid the operation of opening the supporting arms operate RIGHT and LEFT slewing Position f...

Page 59: ...platform Fit the split pins back on the pins and take the axle out of the range of action of the crane to aid this operation and prevent the axle tipping over support it with the drawbar made integra...

Page 60: ...and the capacity signs are ready for the required set up The crane can also work with the jib raised by 10 or 15 and or folded back as indicated in point 1 3 3 Range of Set Ups The various set ups are...

Page 61: ...pe and the block assembly do not get entangled with anything Stop the operation when the pressure has risen to 120 bar WARNING Do not erect the towers if the wind speed is greater than 30 km h NOTICE...

Page 62: ...k fork lift truck etc with a capacity greater than the weight of each block Take the trolley to approximately 3 4 m from the tower and lower the block assembly until it can be connected with the ring...

Page 63: ...all the blocks unhook the ring 1 of the self ballasting rope 2 from the work hook Pull the other end of the rope until the ring rests on the idle pulley 3 Insert the rope through the pegs of the bloc...

Page 64: ...st point the jib reaches is approximately 40 m off the ground WARNING The operation of aligning and folding the jib cannot be performed if the wind exceeds 30 km h When carrying out this operation SLE...

Page 65: ...2 is fully extended After completing the operation stop when the pressure has risen to approximately 200 bar this ensures the cylinder has reached its limit stop NOTICE The crane can work with the jib...

Page 66: ...until cylinder 3 is fully extended After completing the operation stop when the pressure has risen to 200 bar this makes sure the cylinder has reached its limit stop Cylinder 3 After completing the o...

Page 67: ...ne with any one of the safety devices partially or totally inefficient can be a serious danger for people Each device is marked with an abbreviation permitting it to be easily identified The position...

Page 68: ...TIC MOMENT limiter U8 2 DYNAMIC MOMENT limiter U3 7 8 9 3 HIGH SPEED limiter U5 4 MAXIMUM LOAD limiter U4 5 UP limit switch U1 6 DOWN limit switch U2 7 NEAR limit switch U6 8 DISTANT limit switch U7 9...

Page 69: ...ee point 2 1 8 and proceeding as follows take the trolley to approximately 3 metres from the tower hook on a load of 2100 kg suitably slung and hoist it by approximately 20 cm off the ground take the...

Page 70: ...ter U3 must be checked by using the contemplated TEST LOADS see point 2 1 8 and proceeding as follows take the trolley to the end section of the jib hook on a load of 1100 kg suitably slung operate UP...

Page 71: ...he trolley to approximately 3 metres from the tower hook on a load of 1100 kg suitably slung operate UP at MICRO SPEED LOW SPEED and HIGH SPEED In this condition the HIGH SPEED movement must be blocke...

Page 72: ...es from the tower hook on a load of 2100 kg 4200 kg with 4 part line suitably slung operate UP at MICRO SPEED In this condition the MICRO SPEED UP movement must be blocked If it does not it is necessa...

Page 73: ...t switch U1 tripping It must stop before contact is made between the block assembly and trolley check that the position reached is the one required and that anyhow the minimum distance between the blo...

Page 74: ...mit switch U2 tripping check that the position reached is the one required and that anyhow the block assembly does not rest on the ground even with the trolley near the tower check that at least 3 tur...

Page 75: ...STANT movements before the trolley strikes the buffers The function of the pre slowdown contact is to shift down to first speed before stopping The crane is supplied with the limit switch already set...

Page 76: ...the movement must be stopped after making the second turn If it does not it is necessary to do the setting by carrying out the following operations turn the crane so that the cables are not twisted op...

Page 77: ...N The self locking nuts must be tightened with the same angular movement so that the springs are all equally preloaded make sure that the energized electromagnet 3 is able to effectively retrieve the...

Page 78: ...tromagnet 3 nearer or further away to reach the correct adjustment use a feeler gauge to check that the required value is constant all along the perimeter of the electromagnet carefully tighten the nu...

Page 79: ...the residual current device check that all the limiters and limit switches work properly check that the movements correspond to the indications of the control elements see point 1 4 8 check the brake...

Page 80: ...ices are supplied already programmed and preset Any adjustments must be made solely by personnel of the Comedil After Sales Organization 3 4 3 TAKING OUT OF SERVICE At the end of each work shift or wh...

Page 81: ...right position so as to help the rope run on the relative pulleys Take the block assembly 2 down to the ground and hook it onto the block assembly 1 with the pin 3 Set the up and down limit switches U...

Page 82: ...e trolley in the middle portion of the jib intermediate jib section and hoist the block assembly to 4 5 m from the jib Switch the cylinder selector located on the door of the electric box onto positio...

Page 83: ...in which it is not possible to fold the jib you must contact the Comedil After Sales Service Stop the operation when the pressure has risen to 200 bar Switch the cylinder selector onto position 1 Remo...

Page 84: ...xact the trolley while moving backwards and forwards during the transitory phase will enter its seat precisely without any interference CAUTION During the phase of folding back the towers check the ar...

Page 85: ...Self Erecting Tower Crane CBR 40H 4 REV 000 1 MAINTENANCE 4...

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Page 87: ...ear protective clothing eyewear gloves hard hat and any other suitable protective equipment Welding work can only be performed if expressly authorized in writing by Gru Comedil In these cases it is ne...

Page 88: ...gear check level change oil Brake check gap HOISTING check level Reduction gear change oil Brake check gap TROLLEY check level Reduction gear change oil Brake check gap ELECTRICAL SYSTEM check functio...

Page 89: ...e and grease Pulleys and bearings remove and grease Feet check stability and levelling of crane Bolts clean and grease HYDRAULIC SYSTEM check level Tank change filter change oil Cylinder overcenter ch...

Page 90: ...o greater than 3 mm measured axially between the outer ring and the inner ring 4 1 4 TROLLEY ROPE TENSIONER The tensioning and compensation of the trolley rope are governed by the tensioner in the upp...

Page 91: ...th equal to 6 or 30 times the diameter of the rope exceeds the limit shown in the chart ROPE 6 diameters 30 diameters Hoisting 5 strands 10 strands Trolley traversing 8 strands 16 strands 2 The total...

Page 92: ...ncovered gears hydraulic oil OSO46 AGIP oil BLASIA 220 AGIP grease GREASE MU EP2 AGIP grease GREASE MU EP2 AGIP grease spray URANUS NILS WARNING After changing the oils and greases must be recovered a...

Page 93: ...th the control but try releasing the disc by levering between the disc and the adjacent fixed parts of the brake An electromechanical brake does not work The electromagnet has burnt The gap is too wid...

Page 94: ...or in the line of the electric panel immediately downstream from the main switch of the panel The residual current device of the site panel systematically trips even with the crane s main disconnectin...

Page 95: ...the left The limit switch right movement is off its setting or there is a fault on its electric circuit The LEFT movement does not work The crane might have reached its left limit switch position tur...

Page 96: ...ficulty with the rotation of a pulley due to rubbing on the support or a bearing jamming remove the cause of the difficulty with rotation The rope might have some obstruction to its free movement chec...

Page 97: ...eriving from imperfect control over the trajectory of the load by the operator use solely expert and trained operators choose trajectories free from obstacles and far from areas occupied by persons th...

Page 98: ...ere are parts in motion during maintenance work cut off the electricity supply to the crane and padlock the switch of the electric box on position 0 during maintenance make sure that the lever of the...

Page 99: ...h the risk of electric shock when the operator touches the hook or the load connected to it When the crane works in these conditions the following standards must be observed the personnel must be info...

Page 100: ...aring no vertigo when working at heights no disorders due to drugs or alcohol b psychological aspect behaviour under stress mental balance sense of responsibility Training must moreover provide comple...

Page 101: ...ition is assigned to third parties it is necessary to use firms authorized for disposal of the above mentioned materials If you do the demolishing it is necessary to separate the materials by type and...

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Terex CBR 40H-4, Operating Instructions - Installation Maintenance

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