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STT113 TOWER CRANE OPERATION AND SERVICE MANUAL

Chapter III Operation

I. General rules

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II. Operation highlight

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III. Operation instruction

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IV. Precautions during operation

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1. Each time before operation ·············································· 3B-7

2. During operation ·························································· 3B-7

3. Each time after operation ················································ 3B-8

4. Periodical inspection item ··············································· 3B-9

V. Operation

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1. Control panel layout and operating method ··························· 3B-14

2. Precautions during operation ············································ 3B-17

3. Operating method for weather vane effect ···························· 3B-18

Summary of Contents for STT113

Page 1: ...STT113 TOWER CRANE II OPERATION SERVICE MANUAL Fushun Yongmao Construction Machinery Co Ltd 2007R32 ...

Page 2: ...nd schematic diagram 4B 1 Chapter V Hoisting winch 5B 1 Chapter VI Slewing mechanism 6B 1 Chapter VII Trolley winch 7B 1 Attached Electric diagram Chapter VIII Safety device 8B 1 Chapter IX Hydraulic system 9B 1 Chapter X Fitting and inspection rules of wire rope for hoisting machinery 10B 1 Chapter XI Slewing ring 11B 1 Chapter XII Tower crane maintenance 12B 1 ...

Page 3: ...27 38 3 00 3 00 3 00 2 68 2 22 2 03 1 87 1 73 1 60 42 5 Ⅳ Ⅳ Ⅳ Ⅳ 15 53 6 00 4 47 3 43 2 74 2 26 2 07 1 90 1 75 Ⅱ Ⅱ Ⅱ Ⅱ 28 25 3 00 3 00 3 00 2 79 2 31 2 11 1 95 1 80 40 0 Ⅳ Ⅳ Ⅳ Ⅳ 15 24 6 00 4 37 3 35 2 68 2 20 2 01 1 85 Ⅱ Ⅱ Ⅱ Ⅱ 27 72 3 00 3 00 3 00 2 73 2 25 2 06 1 90 37 5 Ⅳ Ⅳ Ⅳ Ⅳ 15 72 6 00 4 53 3 48 2 79 2 29 2 10 Ⅱ Ⅱ Ⅱ Ⅱ 28 62 3 00 3 00 3 00 2 83 2 34 2 15 35 0 Ⅳ Ⅳ Ⅳ Ⅳ 15 75 6 00 4 54 3 49 2 79 2...

Page 4: ...6 5 4 3 2 1 H m 40 26 37 26 34 26 31 26 28 26 25 26 22 26 19 26 6 0 m 9 m 0 1 5 m 1 2x1 2m L 1 3 G 3 0 3 0 m L 1 3 G 2 0 8 14 76 11 76 12 L 4 3 G 2 0 7 5 m 44 76 41 76 38 76 11 L43A1 1 6x1 6m H m 1 2 3 4 5 6 7 8 9 10 35 76 32 76 29 76 26 76 23 76 20 76 17 76 6 0 m L 1 3 G 2 0 YZ43X 41 16 38 16 35 16 32 16 29 16 26 16 23 16 20 16 1 0 0 5 m 1 2x1 2m 3 m 4 5x4 5m H m 8 7 6 5 4 3 2 1 L13A1 F1 L43A1 1 ...

Page 5: ...STT113 TOWER CRANE OPERATION AND SERVICE MANUAL 2B 1 Chapter II Safe Rules of Tower Crane I manual of safe rules 2B 2 ...

Page 6: ... operation manual and regulation related to service and maintenance 2 Safety measures 1 The operator should read the operation rules before operating the tower crane 2 The operator should always remember every safety measure and recognize the hazard meanwhile the operation rules should be visible 3 It s forbidden for the operator to be with long hair wearing robe or wearing jewelry 4 Often read th...

Page 7: ...erated by trainees or learners 5 The installing debug and maintenance of electric equipment must be operated by competent electrician 6 The debug and maintenance for each mechanism must be operated by professional 7 The installing debug and maintenance of hydraulic device must be operated by experienced professional 4 The safety rules during working stage 1 Every time before starting up a Give aud...

Page 8: ...he load has not been hang firmly i It is forbidden to canting pull the load j It is forbidden to sling the load which has fixed to the ground k It is forbidden to stop normal motion by emergency stop button it only can be used in exceptional case which may threaten the safety l It is forbidden to use limiter and brake as an normal stop device m It is forbidden to short circuit change and adjust th...

Page 9: ...er outage adopt necessary measures to prevent false starting of the crane First lock the power supply panel and take off the key Second hang warning plate on the panel 3 If it needs to dismantle some safety devices during service and maintenance after this it should be assembled and readjusted 6 Instruction for special dangerous 1 When operating tower crane near the air line there should be enough...

Page 10: ...liminated in time c If it must carry out live wire work there should be someone to monitor so that the main power supply can be cut off in emergency situation 7 Hydraulic system a Only the professional or experienced person can operate the hydraulic system b Periodic check every kind of conduct pipe flexible pipe and joint so that check up the oil leak and external malfunction if so eliminate that...

Page 11: ...ion instruction 3B 4 IV Precautions during operation 3B 7 1 Each time before operation 3B 7 2 During operation 3B 7 3 Each time after operation 3B 8 4 Periodical inspection item 3B 9 V Operation 3B 14 1 Control panel layout and operating method 3B 14 2 Precautions during operation 3B 17 3 Operating method for weather vane effect 3B 18 ...

Page 12: ... the qualified professional who has trained by authoritative board of labor or specified units and passed the exam The driver must operate service and maintain the crane correctly It is important for reducing failure improving device availability avoiding loss of working time and prolonging service life of equipment Incorrect operating will result in damage of all electric motor reducer drum brake...

Page 13: ...e making reverse movement Operate until the mechanism completely stopped f It is forbidden to operate the crane which safety device has a failure unsoundness or inaccurate furthermore it is forbidden to pick off or sealed the safety device g Discovery the stoppages should stop and check immediately forbid to be continue Once discover some failure it must be stopped and checked immediately It is fo...

Page 14: ...ty of the brake 2 Operating the hoisting winch a Confirm the lifting load radius according to the moment curve or table b Estimate the weight of lifting load Lift the load 1m high slowly in small radius Move the load forward slowly by changing radius of trolley with low speed Stop forward movement when moving to the position of moment limiter Confirm the radius of trolley stopping Estimate the wei...

Page 15: ...ation should be done gradually d It is forbidden to stop the jib by slewing brake It should decelerate first and then release the control lever so that the brake can brake in minor slewing speed e The slewing brake can only be used in windy condition it can keep jib in its position f When slewing the jib it is recommended to operate the lifting movement and lowering movement at the same time to av...

Page 16: ... the end of the track the tower crane operation must be stopped d There are two brakes in the traveling motor one of them used for buffering and decelerating the other used for stopping the crane movement which via 6 8 seconds time delay after powering off automatically braked After the control lever return to zero the crane can still run a few meters so this operation should be done advanced e At...

Page 17: ...e and limiter if necessary readjusted it h If the working height of tower crane is beyond 50m an anemoscope must be installed If the wind speed exceeds 20m s it can sent audible and visual alarm then the tower crane must stop working 2 During operation a Never lift load beyond the permitted radius b Never pull load in an oblique direction c When entering into the cabin check that whether the extin...

Page 18: ...wer off manual operate this device For traveling type tower crane anchor the crane by 4 rail clamping devices NOTE The weather vane effect that is to say above the upper slewing can slew freely it can reduce the windward area automatically Thus the crane driver must start the weather vane after he is off duty c Turn off the main power supply switch and take the measures against rain d Depress the ...

Page 19: ... conductor Check the earth resistance of tower crane Check the insulation resistance of electric equipment Check the motion of relay in each circuit which can protect the tower crane safety Check the insulation resistance of motor Check the contact condition of switch contact in circuit Check that whether the connecting terminal in each electrical panel and resistance box including the inner bindi...

Page 20: ...ction on standard mast jib counter jib and fixing plate on base plate including pin split pin and bolt Detect the crack of section steel and check the weld joint Mechanical parts Adjust and check the brake with max load Hoisting winch Slewing mechanism Trolleying winch Traveling mechanism Check the worn out of the wearing plate Hoisting winch Slewing mechanism Trolleying winch Traveling mechanism ...

Page 21: ...k pin and clamping plate Adjust the tensile force of trolley wire rope Check the wire rope and joint Check that whether the swing pulley is in perfect condition check that whether the prevent twist hook at fixing point of hook end is in perfect condition Check the automatic locking device in 2 4 fall or double trolley locking device ...

Page 22: ... Safety device Inspection item Cycle Before everyday work After changing fall after each erection A month Load limiter Moment limiter Hoisting limiter Slewing limiter Trolleying limiter Traveling limiter Prevent rope broken device Prevent pin broken device ...

Page 23: ...the prevent twist device of wire rope for jib end Slewing mechanism slewing ring external gear ring Trolleying winch bearing of drum trolley guide pulley wire rope The tensioner or tension spring of the wire rope hook assembly Traveling mechanism gear ring on driving bogie wheel roller support of driven bogie and motor ball gear ring for track curve device Cable drum bearing of drum Safety device ...

Page 24: ...a control lever in the center of the joystick see fig 3 2 1 layout of control panel and fig 3 2 2 schematic diagram of lever operating 4 Parallel connection button 5 Slewing brake button 2 Power off emergency stop button 3 Power light RG Slewing to the left RD Slewing to the right DAR Trolley in LH Hoisting LD Lowering 1 Power supply and hailer button DAV Trolley out TAR Traveling backwards TAV Tr...

Page 25: ...oystick the trolleying and slewing are operating at the same time The control lever can switch in various directions The trolley moves ahead DVA as push the lever ahead in reverse DAR the jib slew to the left RG as push the lever towards left RD In reverse The lever can be pushed at random towards left or right without limit of shift The bigger the turning angle of the lever is the faster the spee...

Page 26: ...cal control panel A is released The break button cannot reset turn back automatically If required turn it to the right until it springs up by itself Press the button to cut off current when the crane is out of service or to meet the emergent requirement such as the contactor attaching mechanism is out of control or other emergency requiring current break As shown on the panel the lever can be push...

Page 27: ...itch from shift 1 to shift 2 then shift 3 and in the slewing operation the control of the lever is required to be handled harmoniously 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 of weather vane whenever this shift s operation is finished 4 During the o...

Page 28: ... the side of electrical control panel HF inside the operators cabin the indicator lamp of weather vane lights up 2 Cut off the current of right panel by means of the break button O At this time the slewing brake is unlocked in released state At last cut off the main power supply of the crane 3 Unlock the slewing brake manually in release state see chapter 6 slewing mechanism ...

Page 29: ... distribution and two class protection The following system diagram for your reference 380V 50HZ TN S 子子子子 TN S TN S or TT orTT or TT Note Both the branch electrical control panel and branch switch box are equipped with air switches and leakage protector The operating parameter of leakage protector in branch switch box is 270mA 0 1S The user can select the installation method of TN S or TT acco...

Page 30: ... vertically inearthed 1 5m depth from the ground surface C Copper conductor with cross section more than 28 mm2 or iron conductor with cross section more than 50 mm2 is inearthed in the wire casing The inearthed depth is to be determined by earth resistance In above earthing modes the copper conductor section coming from the earth substance should be more than 25mm2 If the soil conduction is poor ...

Page 31: ...ermined by the lowest power supply KVA for each type of tower crane The requirement power voltage of ST series tower crane is in accordance with CE138 and China National Standard 50HZ 380V 5 60HZ 440V 5 This power voltage refers to the terminal voltage of Panel L during operating the tower crane If the real power voltage is lower than terminal voltage the capacity of transformer and the distance s...

Page 32: ...actor relay coil graphic symbols which marked coordinate numbers at both sides It shows the quantity of main switch and auxiliary switch which the contactor relay used and the coordinate positions on the drawing The number on the upper right quarter shows the position of auxiliary switch contact With transverse line above the number is NC switch contact and without this line is NO switch contact A...

Page 33: ...igh speed SLChGV Limit switch for high speed proving ring SLChPV Limit switch for max load proving ring SLMO Lifting moment switch SLH Hook limit switch for highest position SLD Hook limit switch for lowest position TSLA LA panel control transformer Red Redx Rectifier silicon diode TSFUP primary breaker for control transformer RedFU Rectify protective breaker TSFU1 Secondary breaker for control tr...

Page 34: ...coil RXDAr decelerating travel switch for trolley backwards SDAV Controlling travel switch for trolley forwards RXDAV decelerating travel switch for trolley forwards SDAr Controlling travel switch for trolley backwards RDMO Moment switch for trolley decelerating SM Parallel connection limit switch for trolley SDMO Moment switch for trolley stop DMV Power supply contactor for trolley low speed XDAV...

Page 35: ...for weather vane effect XRGi1 Relay for weather vane effect RFa Contactor for controlling slewing brake XRGi2 Relay for weather vane effect T Terminal strip RD Power supply contactor for right slewing RG Power supply contactor for left slewing RRC Silicon controlled rectifier BSR Thermostat RFS Slewing brake RRa Eddy current brake for slewing GiFa Weather vane magnet coil HveM Motor for slewing bl...

Page 36: ...h for breaking off Asynchronous motor for squirrel cage type Interlock switch Transformer Time closing when releasing operating parts Brake DC exciting coil Time closing when attracting operating parts Eddy current brake coil Time lag trip when attracting operating parts Coil for contactor and relay Time lag trip when releasing operating parts Contactor relay releasing the coil of time delay switc...

Page 37: ...d list of installing cable for tower crane see fig 4 1 1 The consumer can intall the cable according to this electrical schematic diagram non traveling type of tower crane Fig 4 1 1a A A AL LM AL LM AL F AL H AL SDMO RDMO SLMO H R R RM 2 R RM 1 GTM R F R RM HF F DM SLCH DM ...

Page 38: ...ERVICE MANUAL 4B10 The consumer can intall the cable according to this electrical schematic diagram traveling type of tower crane Fig 4 1 1b A A AL LM AL LM AL F AL H AL SDMO RDMO SLMO H R R RM 2 R RM 1 GTM R F R RM HF F DM SLCH DM E TM ...

Page 39: ...STT113 TOWER CRANE OPERATION AND SERVICE MANUAL 5B 1 Chapter five Hoisting winch 24PQC15 Symbol instructions P Q C Single rope pull Mechanism code Motor power KW ...

Page 40: ... be about to the end Keep the rated speed of motor in normal hoisting condition Select hoist speed according to the load Raise a heavy load at low speed and raise a light load at high speed Stop movement before the safety stop acting NOTICE It is forbidden to put the hook on the ground Loosen the steel rope slowly while placing a load Note Reeving the rope must make tact namely work three minutes ...

Page 41: ...STT113 TOWER CRANE OPERATION AND SERVICE MANUAL 5B 3 Ⅰ Ⅰ Ⅰ Ⅰcomposing of hoist winch 1 limiter 2 drum 3 reducer 4 undercarriage 5 motor 6 disc brake 7 cool motor Fig 5 1 1 ...

Page 42: ...ve the multilayer five layers rope smoothly and tidily The drum passes the bearing of bearing block 2 Drum The reducer is making up of the spiral bevel gear pair and primary planet gear pair the box of reducer linked with the frame 3 Motor The three speed motor is TSYDE180L 2 4 16 The output of motor is 24 24 5 5KW There is a disk electromagnetic brake on the tail section of motor the motor is mak...

Page 43: ...Ⅱ Ⅱ Ⅱ Characteristic parameter working level M5 using grade T4 load condition L2 motor type YSYDE180L 2 4 16 motor speed min 2800 1400 300 raising speed and load m min 80 40 8 5 t 1 5 3 3 m min 40 20 4 2 t 3 6 6 rope diameter 12mm rope capacity of drum 400m ...

Page 44: ...n the electric control make the time which the brake affected lag 0 5 1s in order to prevent braking intensively to damage brake The intermediate speed shift PV and high speed shift GV of hoisting winch is work shift The low speed PV used to start up and low location generally it is not allow work long time Adjusting brake of three speed hoisting motor see Fig 5 Ⅳ Ⅳ Ⅳ Ⅳ 1 2 I Adjusting brake momen...

Page 45: ...ange the friction disk as following 1 Takeoff cover cap 40 2 screw off the nut 45 3 Takeoff electromagnet 47 4 screw off nut 39 37 5 Takeoff sprig 35 6 Takeoff gag bit 59 7 Takeoff brake holder block 33 8 when it is fitting cleanup the raffle and dust of each parts surface Ⅳ Ⅳ Ⅳ Ⅳ declutch method of machinery In good running the adjustment cover 55 of the brake end should in loosening condition no...

Page 46: ...gag bit 33 Brake holder block 34 Fixing cover of brake 35 Compression spring 37 Spring adjusting nut 39 45 Eectromagnet adjusting nut 40 Cover cap 46 Bolt 52 Manual adjustable lever 53 Check plate 54 Shaft pin 55 Adjustment cover 59 Gag bit 61 Bolt bar 47 electromagnet Fig 5 1 2 ...

Page 47: ...o code designation and oil capacity 18 distillate hyperbolic gear oil Rope Array in order and have no breakage broken rope extruding and distortion end fixity is fastness Jointing element Anchor screw is not loosening and not missing parts linking the pin end to fixing and prevent fall off Limiter The hook limit position correctly Every lubricate parts In the good lubrication condition see the cha...

Page 48: ...c gear lubricant to the oil level according to the demand The crane should check the oiliness and oil level position after operated each 200h and filling up the oil to the oil level operated the 2400h should emptying the oil cleaning up and renewal the clean oil Pouring orifice Oil level position Reservoir sweep opening ...

Page 49: ...ther sensitivity before operate the crane every day 4 If the motor found unusual noise in operation should stop and check immediately When the vibrate and noise increase obviously should check the bearing of motor if the play more than 0 1mm should replacing the new bearing and keep the grease in bearing simultaneously 5 There is grease fitting on the each outside of the bearing block for barrel a...

Page 50: ...lewing mechanism and its working principle 6B 2 III Working principle of controller RTC 6B 4 IV Operating and fault clearance of slewing mechanism RTC 6B 5 V Slewing brake 6B 8 1 Manual brake release 6B 9 2 Electric starting of weather vane device 6B 11 3 Service and maintenance of slewing brake 6B 12 VI Wiring chart of R box 6B 13 ...

Page 51: ... system The speed is adjusted via adjusting supply voltage of the stator for moment motor the eddy current brake and the eddy current The slewing driving system is composed of moment motor and planetary reduction gear The moment motor is with eddy current brake and weather vane brake Weather vane brake can be brake and released automatically or manually Electromagnetic brake is released when power...

Page 52: ...d so as to form potential field and then current that is bow wave is obtained Because of the action of the magnetic field of bow wave and the magnetic field of Electromagnet to one another produce brake moment that is directly proportional to excited current and rotate speed of the armature Regulating excited current and voltage of motor carry out stepless speed regulation of the motor 1 moment mo...

Page 53: ...eddy current brake to adjust the exciting voltage of eddy current After the second circuit magnify by amplifier according the voltage polar to decide position and negative turning of motor The third circuit striking the six crystal brake tubes by the triphase triggering and make the motor gain the linear change voltage then make rotate speed stepless change idiographic circuit as follows IC IC IC ...

Page 54: ...RTC mechanism in normal range if the slewing is in abnormal condition cut off the power first and then inspect from the following aspects 1 The crane can but running in single direction after stopping a period of time another direction can running after running a period of time only running in single direction again If in such condition stop the crane immediately and cut off the power to check tha...

Page 55: ...w check the AC voltage 48V which entering into the thyristor module If there is no voltage cut off the supply and check the connecting line in this part check again whether the thyristor module is damaged The inspection methods are as follows 1 The resistance between gate electrode G and cathode K should be 7 100Ω 2 The resistance between the anode A and cathode K is infinitely great If there is n...

Page 56: ...end point should have plus minus constant voltage if there isn t voltage input the controller have problem When above check normal need check RD or A1 end of RG contactor should have 48V voltage under the operate handle condition and farther check the controller have 48V voltage above check normal please replacing the slewing controller 7 Slewing controller and crystal break tube both burn and tur...

Page 57: ... Release the pressure on the push button 2 No clearance is allowed between the button and the brake release lever 1 Otherwise the operation must be carried out again Readjust if the clearance still remains e When the weather vane effect has accomplished the slewing mechanism should be allowed to rotate freely 2 Release the weather vane device a Raise the brake lever 1 i e act A b Under the action ...

Page 58: ...ple Note E is the clearance of brake which value must be kept between 0 8 1 2mm Adjust it if necessary 2 Electric starting of weather vane device Description It is an electromagnetic brake which is braked when switched off It has independent power supply Working principle 2 Brake released 2 Brake released ...

Page 59: ...nd maintenance should be carried out under the following conditions a Insufficient braking moment which is caused by worn brake disc b The indicator is out of work 2 Scheduled maintenance a Every 200 hours or every one month once b Check the clearance and brake moment as well as the worn condition of the brake disc replace it if necessary c Check that whether there is some foreign substance in the...

Page 60: ...1 7 9 HVeM HVeM 8 1 9 11 16 H R 1 4 3 1 2 4 7 5 6 6 5 RRa 19 22 47 48 49 46 9 11 14 LFa 11 12 15 16 G1Fa 13 14 15 16 F RM RM VI Wiring chart of R box see fig 6 5 1 Terminal strip for the connecting box of slewing center R box Fig 6 5 1 Terminal Terminal ...

Page 61: ...ANUAL 7B 1 Chapter VII Trolley winch I Explanation of symbols 7B 7B 7B 7B 2 2 2 2 II Composition of trolley winch and its working principle 7B 7B 7B 7B 3 3 3 3 III Trolley brake 7B 5 1 Working principle of trolley brake 7B 5 2 Maintenance 7B 6 ...

Page 62: ...tion of symbols D T C Description The trolley speed should be selected in accordance with the trolley distance It is necessary to acceleration or deceleration gradually Locked rotor torque Eddy current speed regulation Variable voltage speed control Trolley winch ...

Page 63: ... voltage drop 230 260V The second speed PV can be obtained by resultant of field excitation of bow wave brake and running of motor under rated voltage 380V When the motor run under rated voltage 380V and bow wave is without field excitation the third speed PV is obtained When the trolley mechanism begins running the winding of electromagnetic brake remains current fed so that gag bit is attracted ...

Page 64: ... release brake 12 Nut M8 which locked the hand wheel in service 13 Screw M8 which simultaneous running with brake disc 14 Spring pipe which used to adjust the spring pressure of the brake 15 Pin for locking screw of the brake disc which inserted in the third and forth hole of brake disc 16 Protective cover 17 Spline housing coupling piece which connect the motor and transmission shaft 18 Bearing 8...

Page 65: ...ed which drives the friction disc 5 compress the spring 2 and make the brake disc entering into releasing state The brake is ready for next brake when the current is cut off Clearance adjustment Remove the protective cover 9 and screw 8 Move the disc by screw until it lean against the cover of the latch Move the disc again and locked it in the 3rd At this time the clearance is 0 8 to 1 2mm Brake m...

Page 66: ...or every one month once b Check the clearance and brake moment as well as the worn condition of the brake disc replace it if necessary c Don t replace the brake until it worn out completely d Check that whether there is some foreign substance in the brake such as cement sand grease etc ...

Page 67: ...n procedure diagram for relay and contactor of trolley winch XDGV XDAr XDGV XDPV XDPV XDAV PD DAV SD DFa DAr DMV DGV DPV1 DMV1 DPV 0 档 RXDAr SDAv SDM0 RDMr RXDAv SDAr SD DPv 1 S 1 S DPv Attracting when power on Keep former attracting state Release when power down ...

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Page 72: ...Control relay Lfa AC contactor XLPV Control relay LH AC contactor LD AC contactor P AC contactor DI Auto circuit breaker LMV AC contactor LPV AC contactor LGV AC contactor Auxiliary relay L Terminal strip Button LFU Circuit breaker RedFu1 Circuit breaker RedFu Circuit breaker A HF Socket XBa Circuit breaker Auxiliary relay Auxiliary relay Auxiliary relay Auxiliary relay Auxiliary relay ...

Page 73: ... circuit breaker 1 TSFUP TSFU1 RedFU1 RedFU LFU XBa Circuit breaker 6 Red Rectifying diode 2 XJ 3 Phase contactor 1 P LH LD LMV LPV LGV LFa AC contactor 7 CXL XP XL SH XLPV Control relay 5 Connecting XLPV LPV LD LH LGV LMV Auxiliary relay 6 L Terminal strip 44 Au Button 1 A HF Socket 1 ...

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Page 78: ...act PD trolley motor contactor XRi1 Weather vane contactor XRi2 Weather vane relay RFa Slewing braking contactor SD Hoist relay DGV Trolley relay high speed DFa Trolley braking relay DRV Control relay RedFU1 Circuit breaker TSFU1 Circuit breaker RD Right slewing contactor F Terminal strip Auxiliary contact Auxiliary contact Auxiliary contact Auxiliary contact Auxiliary contact GtDi Circuit breaker...

Page 79: ...breaker 8 DAV DAR DPV DMV1 RD RG DMV RFS PD XRi1 AC contactor 10 SD DGV DPV1 DFA XRi2 XRa1 XRa2 XRD XRG DRV Control relay 10 RFS DAV DAr DFa XRi1 DPV RD RG XRa1 XRa2 Auxiliary contact 10 RCV Slewing controller 1 MTC Silicon controlled rectifier 4 H F Terminal strip 107 VGi Weather vane Light 1 XRi Weather vane Button 1 HF L HF R HF D HF LK HF DRK HF M0 Socket 6 ...

Page 80: ...dscreen Wipe Skt 插座 Socket XCF 风扇开关 Control Fan CF 风扇 Fan XDC 直流电源开关 Control DC Power Supply DCZ 直流电源 DC Power Supply L N V COM EC AC 220v Skt XDC CF A H CADi CATS 0v F K 50 A B 51 B T 53 T XEg XEg D A T E SIGN DESIGN DATE DOC NO DRAWING MARK WEIGHT SCALE Page of Y O N G M A O IND NUMBER 100 101 100 101 102 103 104 105 106 107 108 109 220v 2007 07 09 CAB D333C WIRING DIAGRAM OF THE CAB ...

Page 81: ...MHR MDR HOIST RADIUS LOAD CELL MONITOR SLCL LMM MONITOR 48V 060629 D A T E SIGN DESIGN DATE DOC NO DRAWING MARK WEIGHT SCALE Page of Y O N G M A O IND NUMBER DISPLAY WIRING DIAGRAM LOAD D333A ...

Page 82: ...ciple 8B 5 3 Adjustment 8B 6 IV Trolley limiter 8B 7 1 Purpose 8B 7 2 Working principle 8B 7 3 Adjustment 8B 8 V Moment limiter 8B 9 1 Purpose 8B 9 2 Working principle 8B 10 3 Adjustment 8B 11 VI Load Limiter 8B 13 1 Purpose 8B 13 2 Working principle 8B 13 3 Adjustment 8B 13 VII Anemoscope 8B 16 1 Purpose 8B 16 2 Main technical characteristic 8B 16 3 Structure instruction and its working principle...

Page 83: ...random The limit switch for each mechanism is to limit the motion range of them The safety devices are important objects of supervision for the driver and maintenance personnel Note If the top of tower crane exceeds 30m it is necessary to install red obstacle indicator lights on the top of strut jib nose and counter jib nose which remain current feed even the tower crane stopped If the joint heigh...

Page 84: ...principle The limit switch equipped with a reduction gear and located on the chassis of drum is driven either directly by the drum shaft or through a pinion meshing a toothed ring It drives several cams that control the circuit breakers so as to cut off the corresponding motion Note Each time when transferring to a new site and before putting the tower crane into service it is ESSENTIAL to unscrew...

Page 85: ...d pulley block Turn cam 4 by means of corresponding adjusting screw and check hoist control until it depresses the corresponding contact D so as to stop hoisting See Fig 8 2 2 2 Adjusting hoist limit switch for moving down SLD This is carried out with 2 fall or 4 fall Turn cam 1 by means of corresponding adjusting screw so that it depresses the corresponding contact A Here the hook stops before re...

Page 86: ...lled the slewing limiter the max slewing circle is 3 2 Working principle The limiter is with reduction gear which driven by a pinion the pinion engaged directly with the slewing ring When the crane slewing this reduction gear drives cams 4 and 6 rotating which controlled the circuit breaker sensitive switch thus cutting off the slewing motion in suitable position via adjustment See Fig 8 3 1 Fig 8...

Page 87: ... then adjust cam 4 and check up its motion until it depresses the corresponding contact 5 b Adjusting the left slewing limiter SRG Make three cycles slewing in the reverse direction Then adjust the cam 6 until it depresses the contact 7 Note The above mentioned adjustments should be checked everyday before the tower crane putting into service Each time when transferring the tower crane to a new si...

Page 88: ... the trolley and jib nose or jib foot 2 Working principle The trolley limiter is with a reduction gear which is engaged with the gear ring on the drum via a pinion This reduction gear drives cams 3 6 7 and 9 rotating which controlled the circuit breaker sensitive switch 4 5 8 and 10 thus cutting off the corresponding motion See Fig 8 4 1 Fig 8 4 1 10 8 4 5 9 7 3 6 1 2 ...

Page 89: ...lley to a distance about 20cm from the jib nose buffer Turn cam 6 until it depresses the contact 5 Don t adjust the cam 3 3 Adjusting trolley in and decelerate safety device RDAr and the trolley in limiter SDAr as above described drive the trolley to the jib foot Turn the cam 7 for decelerating until it depresses the contact 8 and then adjust the limit cam 9 until it depresses the contact 10 Note ...

Page 90: ...ION AND SERVICE MANUAL 8B 9 V Moment limiter Fig 8 5 1 The adjustment for device A C and D Loosen the nut 1 and turn the bolt 2 until it touches the contact 3 and pressing the switch contact After accurate adjustment lock nut 1 ...

Page 91: ...The moment limiter which is located on the cat head consists of a pair of elastic plate three micro inching limit switches as well as installation support adjustable screw housing and so on When hoisting a load the elastic plate begins distorting the distance between two amplifier bars reduced due to the action of load moment If the load exceeds the stated limit the adjustable screw on one elastic...

Page 92: ...5 3 D 2 C A 4 1 3 Adjustment 1 Elastic plate 2 Limit switch 3 Adjusting bolts 4 Moment housing 5 Support for installation Fig 8 5 2 SLMO A fixed radius variable load SDMO C fixed load variable radius RDMO D variable radius deceleration Light load Over load ...

Page 93: ... the air and drive the hook to the marked radius L Adjust device C 3 Drive the trolley to the jib foot then trolley out with rated speed Before reaching the marked L the trolley motion should be cut off otherwise readjust it 3 Adjusting the moment limiter RDMO which decelerate before reaching the max trolley radius when trolley out Lift the load X at the jib center then trolley out with rated spee...

Page 94: ...limiter which connects with the pulley As the load change the load limiter begins distorting so as the steel plate on which inching switches 2 5 and adjustable screw 1 6 is fitted also distort accordingly principle is the same as the moment limiter According to the requirement of the load by proper adjustment the inching switch 2 5 is depressed as to control the circuit properly 3 Adjustment Fig 8...

Page 95: ... add 10 to the load Lift it with low speed then try to lift it with high speed At this moment it shouldn t obtain the high speed the fifth gear otherwise readjusted Adjusting the max load limiter SLCHPV 1 Lift load X with low speed 2 Adjusting bolt 3 until the bolt head touches the sensitive switch 4 3 Lower the load and add 10 to the load Lift it with low speed If the load can be lifted readjuste...

Page 96: ...000 26 22 28 84 38 45 0 1600 1760 3000 27 38 30 12 36 42 5 1800 1980 3000 28 25 31 08 34 40 0 1900 2090 3000 27 72 30 49 32 37 5 2150 2365 3000 28 62 31 48 30 35 0 2350 2585 3000 28 67 31 54 28 30 0 3000 3300 3000 30 30 24 Table 8 6 4 4 fall DM Hoisting moment limiter SLMO Trolley moment limiter SDMO L m X 10N Y 10N W 10N L m L m D m 52 5 950 1045 6000 12 76 14 04 42 50 0 1250 1375 6000 14 43 15 8...

Page 97: ... the current is magnified and fed into the display to show the wind speed A dedicated circuit board processes the signal which then powers 201 LEDs The alarm sounds when the wind speed reaches the limit 3 2 Instructions for use Before applying electricity connect the sensor with the display using the included power cable Screw tightly When electricity is applied you can instantly read the wind spe...

Page 98: ...s case a specialist can open the box and adjust the corresponding potentiometer Each potentiometer has the following purposes W1 13m s limit alarm setup W2 20m s limit alarm setup W3 LED bar full capacity adjustment W4 wide angled needle display full capacity adjustment W5 test signal magnitude adjustment Signal display wind sensor ON OFF 20 13 nine eight seven six five four three two one wind spe...

Page 99: ...RVICE MANUAL 9B 1 Chapter IX Hydraulic system I Composition of hydraulic pump station 9B 2 II Basic technical parameter 9B 3 III Working principle 9B 4 IV Operating and maintenance 9B 6 V The common failure reason and its clearance 9B 8 ...

Page 100: ...rsing valve pressure limiting valve and pressure gauge Pump station outline drawing throttle valve air bleed hole Outline drawing for telescoping cylinder 1 Motor 2 Electromagnetic starter 3 Combination reversing valve 4 Name plate 5 Oil box 6 Temperature gauge for liquid lever 7 Oil outlet 8 Lifting point 9 Hydraulic air cleaner 10 High pressure hydraulic fluid connection 11 Low pressure hydrauli...

Page 101: ... box 85L Motor power 4KW Max working pressure for telescoping 20MPa Oil pump capacity 8 4L mm Cylinder inner diameter Φ160mm Piston rod diameter Φ110mm Max telescoping force 40 2t Telescoping speed 0 42 m min Return speed Adjustable in safe range Hydraulic travel 1600mm High pressure hose West Germany standard 40 13 60 H type high pressure hose assembly 4m ...

Page 102: ...from oil box to telescoping cylinder pass through the filter combine change valve and high pressure glue pipe assembly Hydraulic principle for telescoping system P T 44MPa 40MPa 6 5MPa B H 25MPa Combination reversing valve High pressure hose assembly Pressure gauge Safety valve Hydraulic air cleaner Extra high pressure valve Telescoping cylinder Oil box Motor Filter ...

Page 103: ...k high pressure glue pipe assembly combine change valve B and T the telescoping cylinder start raise work The flow quantity of cylinder confirms the raise speed Combine change valve in the right position of dig when press the combine change valve s handle the output hydraulic oil of oil pump come into the small chamber pass through the combine change valve P and B the high pressure glue pipe assem...

Page 104: ...a before leave the factory have no need to adjust in service But you can adjust demand pressure depend on need adjustment of the down flooding valve is 6 5Mpa namely be observed the pressure when the cylinder overhanging completely and after it recovery completely Finished the above work can put into normal work 2 Although top up the oil at first time it reduce and from oil box to the cylinder whe...

Page 105: ...ycle to filled oils with its surface to have no rust and protect pump valve and cylinder 4 The hydraulic oils must be replacing in time when it have milkiness freezing and feculence phenomenon The cylinder will be cleared and checked some place whether have rusted when replaced the oils When occurred above phenomenon must be complete deal before refill oil and operate The important never adjusting...

Page 106: ...t ensured Eliminate method Replace the joint or weld i e weld the nut and direct connection hard At this time the joint can t adjust the direction of oil pipe 3 The cylinder continually falling down Reason Two chambers of the cylinder have residual gas left not well sealed or the hydraulic oil wasn t clear Eliminate method Eliminate the gas from the cylinder ensure the seal of control piston and o...

Page 107: ...Internal Checking on wire rope 10B 7 5 Inspecting places at the end of wire rope 10B 7 VI The discard as useless standard of rope 1 The quality and quantity of broken rope 10B 8 2 Rope end broken wire 10B 9 3 Broken wire part collection 10B 9 4 Broken wire increase rate 10B 9 5 Wire of rope breaking down 10B 9 6 Rope diameter decrease due to the core of rope break down 10B 9 7 Flexibility decrease...

Page 108: ...must ensure that the characteristics and the capability of new wire rope is not lower than the original one and the new wire rope is applicable to the groove of drum and pulleys Prevent wire rope from knotting twisting together and buckling or adhering sundries when drawing out the wire rope from scroll or wire rope roll Before using the wire rope of the crane the consumer should ensure that all k...

Page 109: ...grips The length of the wire rope s jut from the last bulldog grip is no less than 3cm the tightening moment of the screws of bulldog grip is 9 mdaN 4 Apply Hoisting up operation to enwind the rope on the drum for 4 10 circles At the same time tension the rope properly Fig 10 2 2 5 Check adjustment of the limit switch and readjust it if necessary Fig 10 2 1 Fig 10 2 2 ...

Page 110: ... the primary reasons of short life time especially when the tower crane works in a caustic environment or the wire rope can not be greased due to some reasons caused by the limitation of the operation Inspection Ⅳ Ⅳ Ⅳ Ⅳ 1 Daily observing It is recommended to observe all the visible parts of the wire rope every working day so as to discover any damage or distortion in time Pay special attention to ...

Page 111: ...on on the whole length of the wire rope should also be made a The places with rope running and two fixed ends of the rope b The rope sections reeling through the pulley block Pay special attention to all the places reeving through pulleys during the hoisting when the mechanism effect repeated operation c The rope sections located in the balancing pulley d The rope sections that can be worn due to ...

Page 112: ... Check for broken rope and for the erosions on the wire rope around its fixing points The same inspection should be made on the rope section near the balancing pulley c Check for distortion of rope d Check the diameter of the wire rope Check places around traveling block a Check carefully on the section passing through the traveling pulleys especially the section around the pulleys while hoisting ...

Page 113: ... and the bits in the rope by using a screwdriver so as to effect observation easily The items to be inspected are as follows A Internal lubrication B Degree of erosion C Steel wire impress due to extrusion and abrasion D Confirm if there are broken rope then restore it to its original state Then grease on the surface This method will not be adopted on the wire rope with multiple layers 5 Inspectin...

Page 114: ...e scrap in the hoisting machinery Table 10 6 1 n the number of out layer rope load rope construction working grade for mechanism M3 M8 alternate lay albert lay extent 6d 30d 6d 30d 101 120 6x19 7x19 6x 19 6w 19 34x7 10 19 5 10 221 240 6x37 19 38 10 19 Notice 1 The working grade of mechanism for tower crane is M4 2 The diameter of wire rope d_ 3 Should take out the stuff steel wire from the check n...

Page 115: ...rope even if broken wire number less than the list shown 4 Broken wire increase rate In some use occasion fatigue is an important reason result in the rope s damage but the broken wire start occurs after using period and its number increase in short time In this condition should check and write down the broken wire increase condition in order to adjudicate it increase rate This rule could confirm ...

Page 116: ... easy to bent and the diameter decrease will damage badly than wear out the rope purely which will result in the rope break down suddenly under move load effect so should discard as useless immediately 8 Outside and inside attrition a Inside attrition and press delve This phenomena caused by rubbing between every wire of rope and steel wire in particular when the rope often stand the bent again an...

Page 117: ...osion badly 10 Distortion The ropes lose the normal switch and produce the visible freak owing to mechanical damage or local fatigue in rope using which can result in rope inner distributor of stress asymmetry familiar there are undulation cage shape distortion appear in multilayer enwind rope steel wire force out rope diameter local accretion kinking rope diameter local minish part crushed and ki...

Page 118: ...anical drive when it worn out Don t allow the rope distort in any condition which can damage the rope safety and service life Process the eye survey inspection for overall length of rope each three month Replacing the rope in time if found following breaking down the rope diameter reduce by erosion and wear out If it is not breaking off Proceed distort crush fold knot or other damage Twist distort...

Page 119: ...efect caused by stress changing Increased diameter of a parallel winding wire rope results in distortion to the metal core due to sudden stress thus caused Corrosion and signs of wear are often noted on the external layer of the wire rope Example of serious bending of the wire rope Basket slacking nest of a multi strand wire rope twisting resistant type caused by forced rotation of the wire rope r...

Page 120: ...ue wrench and if required a torque multiplier check that the tightening torque of the bolts corresponds to the values as listed in the table 11 1 1 Occasional replacement It may happen that during an inspection one or several bolts show a tightening torque beyond the minimum and maximum torques as stated in the table In such a case it will be necessary to replace part of or all the bolts Systemati...

Page 121: ...Ф20 580 520 690 620 Ф22 780 700 930 840 Ф24 1000 900 1080 1200 Ф27 1500 1350 1800 1620 Ф30 2000 1800 2400 2160 The bolts remarked with are selected for connecting the slewing mechanism of the tower crane they must be checked weekly If the bolts become less tightened please re tighten with the torque value shown in table 11 1 1 Maintenance for slewing ring G Lubricate GC Lubricating oil G2 Lubricat...

Page 122: ...gh viscosity index special hydraulic oil 40 C 22mm2 S 100 C 5 6 mm2 S T X 01032 45 ISO6743 4 hydraulic oil HV type 40 C 68mm2 S E E 01032 26 ISO6743 4 hydraulic oil HV type 40 C 46mm2 S G2 E 01032 51 Li Ca extreme pressure grease NLGI2 grade S000 H 12032 52 carbowax lithium base grease NLGI000 grade special purpose G3 S 12032 38 lithium base grease NLGI3 grade ATD 46MR401 lubricating grease for in...

Page 123: ...sembling and disassembling 1 Check and adjust the brakes periodically according to the recommended cycles in the manual Each time before crane erection and dismounting all the mechanisms should be inspected properly 2 For fast erection and self erection tower crane it required the folded winch to installing and dismantling So it is necessary to check up each mechanism 3 Make sure that nothing may ...

Page 124: ... G G G C G h G 450 1900 900 h h M 50 G h G H E G G H G G G h 50 7 year 1900 900 450 h h h 10 M h motor with weather vane Maintenance schedule C checking G lubricating N oil level R fillup E replacing H refueling P air blasting V draining checking lifetime lubricating ...

Page 125: ...ance on trolley mechanism The following rules should be strictly observed to do any kind of maintenance on trolley The operator must tie the safety rope 1 When making maintenance on the brake the operator must ride on the motor and step on the mechanism pedal 2 1 2 ...

Page 126: ...ERATION AND SERVICE MANUAL 12B 5 2 Maintenance on hook The bearing on the traverse beam of the hook must be greased every 200 hours using calcium based grease G2 Li Ca extreme pressure grease NLGI2 grade M 150 hours 1 month ...

Page 127: ...STT113 TOWER CRANE OPERATION AND SERVICE MANUAL 12B 6 3 Maintenance on rope twist protector G Lubricating Ta Ca extreme pressure grease NLG12 grade G G 350 hours 3 months M ...

Page 128: ...ecommend to lubricate them very moderately using RCF grease and RC grease In case of a longer standstill it is possible to protect the rope by spraying P grease Detailed please see chapter X fixing and testing rules for rope 5 Maintenance for hydraulic pump station M when starting N oil level V draining R fillup G lubricating E oil HV465NF E 060200 R N N V Maximum Minimum Minimum 1 year 1800 hours...

Page 129: ...tiwear hydraulic oil Above N80 Antiwear hydraulic oil Original grade 30D 20 20 30 40 50 6 Rope guiding pulley Before using the rope guiding pulley grease at the oil fittings and supplement grease every 50 hours 2 AERO Grease ZL45 2 Before greasing please clean out the waste oil on the shaft 7 Greasing the slewing ring Before installing the slewing ring grease it fully Then supplement grease every ...

Page 130: ...e lithium base grease 1 2 BG7324 1994 gear carbon calcium base grease ZG S SH0369 1992 labyrinth seal for metal isolation block High temperature and wet 40 C 140 C raceway extreme pressure lithium base grease 1 2 GB7323 1994 MOS2 complex calcium lubricating grease 2 gear 4 high temperature grease 4 SY1511 65 80 C 180 C raceway MOS2 complex calcium lubricating grease 2 gear 4 high temperature greas...

Page 131: ...st time for oiling replace the oil every 2400 hours The lubricating oil is N100 gear oil and fill it to the scale between the oil scales 2 Lubricating for drum bearing Fill the lubricating oil in drum bearing before putting into service after this fill it every 500 hours and don t fill too much it may cause the falling off of seal ring Note Keep the air hole clean and smooth 1 oil scale 2 oil drai...

Page 132: ...STT113 TOWER CRANE OPERATION AND SERVICE MANUAL 12B 11 9 Manitenance for telescoping cage G2 M when starting G Lubricating 500h ...

Page 133: ... Add No 3 Yuanda Road Shuncheng District Fushun Liaoning P R China Tel 86 413 7648899 7649988 Fax 86 413 7649999 Postcode 113126 Website http www yongmao com cn E mail sun yongmao com cn Manufacture License of Special Equipment No TS2410592 2008 ...

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