CONTENTS

1. GENERAL PRINCIPLE ON OPERATING REGULATIONS

1.1 RULES OF START

1.2 RULES OF WORKING STATE

4
5

1.3 RULES OF SHUTDOWN

1.4 REGULAR CHECK

6
7

2. ELECTRIC SUPPLY

2.1 SOURCE OF POWER

2.2 STATIONARY TOWER CRANE
2.3 THE POWER SUPPLY OF THE RAIL-MOUNTED TRAVELLING CRANE
2.4 EARTH CONNECTION
2.4.1 EARTHING OF THE TRACK

8
8
9
10
11

3. ELECTRIC PRINCIPLE

12

4. HOISTING MECHANISM

13

4.1 PRINCIPLE OF 70RCS MECHANISM

4.2 CHANGING THE HOIST ROPE REEVING
4.2.1 2-FALL TO 4-FALL
4.2.2 4-FALL TO 2-FALL
4.3 ELECTROMAGNETIC BRAKE
4.3.1 WORKING PRINCIPLE
4.3.2 ADJUSTMENT
4.3.3 MANUAL RELEASE
4.3.4 MAINTENANCE
4.4 LIMITER
4.4.1 WORKING PRINCIPLE
4.4.2 ADJUSTMENT

13
14
14
15
16
16
17
17
17
17
17
18

5. SLEWING MECHANISM

20

5.1 OMD MECHANISM WORKING PRINCIPLE

5.2 RCV MECHANISM WORKING PRINCIPLE
5.3 WEATHERVANING DEVICE
5.3.1 AUTOMATIC WEATHERVANING EFFECT
5.3.2 HANDY WEATHERCOCK EFFECT
5.4 SLEWING BRAKE

20
21
22
22
23
24

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5.4.1 WORKING PRINCIPLE

5.4.2 ADJUSTMENT
5.5 Slewing limiter
5.5.1 WORKING PRINCIPLE
5.5.2 ADJUSTMENTS
5.6 PERIODICAL INSPECTION

24
24
27
27
27
28

6. TROLLEYING MECHANISM

29

6.1 4T3V4 MECHANISM WORKING PRINCIPLE

6.2 ADJUSTING THE ELECTROMAGNETIC BRAKE
6.2.1 ADJUSTMENT OF THE STATIONARY BRAKING TORQUE
6.2.2 REPLACEMENT OF THE FRICTION MATERIAL
6.3 LIMITER
6.3.1 WORKING PRINCIPLE
6.3.2 ADJUSTMENTS

29
30
30
31
31
32
32

7.SAFETY DEVICE

33

7.1 SUMMARY
7.2 SECURITY PARAMETER
7.3 MOMENT LIMITER
7.3.1WORKING PRINCIPLE
7.3.2 ADJUSTMENT
7.4 LOAD LIMITER
7.4.1WORKING PRINCIPLE
7.4.2 ADJUSTMENT

33
34
35
35
36
37
37
38

8. TRAVELLING MECHANISM

40

8.1 WORKING PRINCIPLE

8.2 TRAVELING BRAKE
8.2.1 WORKING PRINCIPLE
8.2.2 ADJUSTMENT
8.3 TRAVEL AND OVERRUN LIMIT SWITCHES
8.3.1 WORKING PRINCIPLE
8.3.2 ADJUSTMENTS

40
41
41
41
42
42
43

9. LUBRICATION

44

9.1 SYMBOL
9.2 REGULAR LUBRICATION
9.3 SKETCH OF LUBRICATED PARTS

44
44
45

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9.4 LUBRICATION OF STEEL ROPES

9.5 LUBRICATION OF HOOK
9.6 LUBRICATION OF SLEWING MECHANISM
9.7 LUBRICATION OF HOISTING MECHANISM
9.8 LUBRICATION AND MAINTENANCE OF THE ROPE CORRECTOR AND FLEETING PULLEY
9.9 LUBRICATION OF THE CABLE WINDER
9.10 LUBRICATION OF TRAVELING MECHANISM

46
47
47
48
49
49
50

10. HYDRAULIC GROUP

51

10.1 PUMP STATION

10.1.1 WORKING PRINCIPLE
10.1.2 MAINTENANCE
10.1.3 SYSTEM PRINCIPLE FIGURE
10.2 RAM
10.2.1 WORKING PRINCIPLE
10.2.2 MAINTENANCE AND GREASING

51
51
52
53
55
56
57

11. CABLE WINDER

59

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1. General principle on operating regulations

The problem of safety device for each mechanism will be referred in after sections. At first,
the general principle on operational regulations of start, operation, stop and regular check has been
collected into the table below, please conform strictly to it.

1.1 Rules of Start

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The tower crane

with the crossed
base must lock the
safe chain.

Get the key of

power switch.

Make sure that

the cables are in
good condition.

Check and fasten

the bolts

Clean up the trash of

the track

Check the ballast

(linked quantity)

Switch off the

weathercock

Loosen
clamp

the

track

Open up the fuse

box

Switch on the
power of tower
crane

1.2 Rules of working state

NOTE:
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Check the
emergency
shutdown (shut off
the main power)

Check the fire

extinguisher at
first, and
understand the
operating rules.

Test various motion

without load

Check the
loudspeaker

Dont hoist any

object outside the
trolleying radius

Run jack-up arm

parallel with track
during travel

Dont hoist loads

aslant

Dont hoist heavy

linked with the
ground or other
objects

Shut down and check while unusual noise is heard

5

Someone shall command on site when the object can not be seen clearly.
The safety device is not allowed to change at will.
Stop the operation when the wind speed 72km/h

1.3 Rules of shutdown

Hoist the cliver to

the top position

Travel to the safety

section (avoid strong
wind)

Switch on the
weathercock when
the dolly moving to
the boom point.

Press the emergency

shutdown
button,
and cut off the
power.

Fasten
clamp

Switch off the main

power and lock it

the

track

Dismantle the plug

of on-site main
switchboard and
prevent it from rain

Hand over the keys to the on-site director and report the situation

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1.4 Regular check

Check the
Non-planeness of
track by meansof
chassis crossbeam

Check the ballast

Check the
Non-planeness of
track by means of
chassis crossbeam

Check the
counterweight

Check the terminal

of rack and
grounding

Check the safety

device

Check the brake

Check the
abrasion of steel
wire rope

Check the electric

equipment

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2. Electric Supply
2.1 Source of power
The source of power adopts three-phase and five-wire power supply system over 90 KVA with 50
HZ 380V or 60HZ 440V, and the distance from power transformer to the cables we provide is S.
When S 100m, the cable section is 3x35mm2+2x10mm2
When 100m S 200m, the cable section is 3x50mm2+2x16mm2

2.2 Stationary tower crane

Elcetric supply diagram of stationary tower crane

1. Mains supply

5. Multi-polar electric panel

2. Site switch

6. Supply cable

3. Autotransformer

7. Isolating switch

4. Site supply cable

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2.3 The power supply of the rail-mounted travelling crane

Power supply diagram of track-type tower crane

6. Fixed point of the supply cable
1. Mains supply
7. Flexible crane supply cable
2. Site switch
8. Cable winder
3. Autotransformer
9. Isolating switch
4. Site supply cable
5. Multi-polar electric panel
The electric supply of a rail-mounted travelling crane is normally taken from the middle point of
track so as to reduced to a minimum the cable length(z=Lv/2) to be wound onto the cable winder.

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Lv: Track length in m

L: total length of cable(L=L1+L2) in m
Z: capacity of cable winder in m

2.4 Earth connection

All the grounding device or the connected wired fixed by bolt must prepare jointing fixed point or
supply cable fixed point. The earth connection has three ways, of which one is available.
The resistance of the earth connection must be very weak. The earth connections must be buried
into humid places. In case of bad ground conductivity, it is necessary to dig chloride of sodium into
a ditch and to water it.(fig 2-4)

the earth connection is carried out

either by regular earth spikes or 33*45
mm tubes of 1.5 m length.

Bury 1 m2 sheet or expanded

metal vertically under the ground.

By a copper or iron conductor buried at

a shallow depth over a long length which
depends on the ground resistance.

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2.4.1 Earthing of the track

The rails must be linked electrically in order to short-circuit the electrical resistance due to the rail
joints.

Technical requirement:
Either by ground cables or copper braidings with a
minimum section of 28 mm2, bolted or soldered onto
the rails.
Or by iron conductors with a minimum section of 50
mm2,welded onto the rails.

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3. Electric Principle
SEE fig 1-26

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4. Hoisting mechanism
4.1 Principle of 70RCS mechanism

1. a hoist drum
2. a bevel reduction gear

3. two motors

4. an electrical control panel

5. a hoist limit switch
6. a resistance box

70RCS Hoisting mechanism is made up of two slip-ring motors with brakes self-excitation
generation. The intrinsic characteristic of the two motors connect to the input pole of the
speed-reducer are the same ,but the gear on the shaft of the upper motor has 19 teeth, the lower
motor has 38 ones .So the upper motor called low-speed motor(PV),and the lower one called
high-speed motor(GV).
The hoist winch allows 5 hoisting and 5 lowering speeds. The first 3 speeds are obtained by using
one motor as driving motor, the other motor as brake motor. Changing the amount of the
resistances can make up the first 3 different speeds. The 4th speed is nominal speed of the PV
motor, the 5th speed is the nominal speed of the GV motor.

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4.2 Changing the hoist rope reeving

4.2.1

2-fall to 4-fall

The top pulley block (1) next to the trolley, double-plate closed, under part pulley block(2) is
two falls traveling block. Manipulate hoisting, press the eliminate limit press untilthe
double-plate of the pulley block was opened, the incline on the double-plate should be guide, put
shaft (4) into the hole (5) of double-plate, the check plate in the two side of the shaft could
provided the double-plate opened. Manipulatelowering, working with 4 falls.

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4.2.2 Changing from 4-fall to 2-fall

Connecting with the top pulley block (1) and under pulley block (2) to manipulatehoisting, press
the eliminate limit press until the top pulley block close on the trolley. The shaft (4) located in the
top of the hole (5), opened the double-plate (3).Manipulate trolley to the inside, press the
eliminate limit press until the trolley get to the stop (6) of the jib root, opened the double-plate(3).
Control lowering until the hoisting limiter switch restoration and then make the trolley to the
outside, working with the 2 falls.

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4.3 Electromagnetic brake

4.3.1 Working Principle

The Electromagnetic brake gets into work when the power is cut, the wheelbrace (1) which is
drived by the motor rotated in the middle of two fixed plates. One is fixed on the shell. The other is
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fixed on the three brackets that the plate can slip on it.
Braking: the electric magnet (5) without electric supply, the spring (6) push the plate(3) back .
So the braking wheelbrace is pressed to the plate(2) and the braking ring, the braking ring is
apart of the plate(3)see fig4-5.
Brake release: the electric magnet(5) with electric supply, the plate(3) and the spring are
tightened completely, then loose the braking wheelbrace(1), so it can resume rotating freely.
See fig4-7.

4.3.2 Adjustment
Clearance adjustment: By adjusting the nut (7) and (8) to change the clearance <E>, make sure
that the clearance is 0.6mm.
Braking moment adjustment: The braking moment is 1.5 times than the max load , screw the
three nuts(9) to adjust the flex, check out the length of the three springs are the same.

4.3.3 Manual release

There is a manual released lever within the motor, use this lever to lift the plate (3), then the
wheelbrace is realeased.

4.3.4 Maintenance
Maintain per 200 hours or per month
Checkout the abrasion of the braking screw, change it before it out of work.
Be careful to keep the brake clean.

4.4 Limiter
It is used to prevent potential operation faults.
.Stop the hoisting motion when the cliver pulley block is close to dolly of arm frame.
.Prevent the complete loose of steel wire rope and wind the rope around the drum in the opposite
direction during lifting down.

4.4.1 Working principle

A limit switch with reduction gear driven either directly by the drum shaft or through a pinion
meshing a toothed ring rigidly fitted to the drum, registers the number of drum revolutions and so
the wound up rope length. This reduction gear drives cams(1) which operate the circuit-breakers
(2), thus cutting off the corresponding motion.

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Note: Each time when starting a new site and before putting into service it is essential to remove
the plug located at the lowest part of the limit switch in order to eliminate the condensation water.
This plug is to be re-placed for crane transport.

4.4.2 Adjustment
Adjustment must be carried out without load. Carry out the adjustment by controlling the rise and
fall, and operate the contact (6) or (10) by hands in order to determine the contact which can
control the motion. (See figure 4-6)
1 Adjust the hoist up hoisting speed reducer(SLH-1):
Control hoisting in 2 fall for(SM-DM) version ,raising the pulley block until the distance between
the jib trolley and the pulley block is 5 m only . Turn the corresponding cam(3), check the
hoisting control ,until it depresses the corresponding contact(4).
(2)Adjust the hoist up hoisting limit switch (SLH):
Control hoisting in 2 fall for(SM-DM) version ,raising the pulley block until the distance between
the jib trolley and the pulley block is 1 m only. Turn the corresponding cam(5) , check the
hoisting control ,until it depresses the corresponding contact(6).
(3)Adjust the hoist down of the hoisting speed reducer (SLD-1):
It is carried out in 4 fall for SM-DM version trolleys. until the distance between the pulley block
And the ground is 5 m, Turn the corresponding cam(7), check the hoist down, until it depresses the
corresponding contact(8).

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(4)Adjust the hoist down of the hoisting limit switch(SLD):

It is carried out in 4 fall for SM-DM version trolleys. Turn the corresponding cam(9), check the
hoist down, until it depresses the corresponding contact(10).
This limit switch can be adjusted in such a way that the hook stops before reaching the ground or
that only 3 rope winding s remain wound on the drum.

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5. Slewing Mechanism
5.1 OMD mechanism working principle

1. a squirrel-cage Motor

5. one or two brakes

2. an electrodynamic brake assembly

6. a tachometer dynamo

3. a planetary reduction gear

7. a slewing limiter

4. the drive pinion

Motor (1) employs belt (2) to drive the free-rotating inductor (3) on the electrical coupler. After
power on, the inductor will generate the magnetic field which can drive bell housing (4). The bell
housing (4) is firmly mounted on the reducer (5) and transfers the motion to the small driving gear
(6) joggled with the slewing gear ring. Move the control lever backwards and supply power to the
immovable inductor on the electromagnetic brake (8) to move the housing (4) into the magnetic
field slowly.
The interaction between the two magnetic fields generated by the two inductors on the bell housing
(4) ensures the stability of speed. The electronic device checks the slip ratio of electrical coupler
and electromagnetic brake according to the speed specified by the central controller. (fig 5-2 ,5-3)

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5.2 RCV mechanism working principle

1) a squirrel-cage Motor
2) a planetary reduction gear
3) the drive pinion
4) a slewing limiter

The CSCT controller adopt three-phase AC regulate voltage timing traveling control device.
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the whole system of the CSCT are composed of controller electric control box the crane
control platform with relay moment motor and reducer. when the joystick is on operation, it
drive the potentiometer, and output an analogy signal to the CSCT controller. it control the
trigger transmit angle of the three-phase AC voltage. Output different voltage by trigger the
transistor module. A pair of line-voltage of the three-phase output voltage feed back to the
controller form the closed loop control. Fig 5-5

Vortex voltage output

Rotate forward contactor
Rotate backward contactor
AC voltage output

Voltage feedback

5.3 Weathervaning Device

The constitute of weathervaning device(fig5-8,5-10): Fastness the brake lining support(5)to the
yoke(4) with 3 double-ended spanner or snuggle bolt adapt to the brakes shape. The release rod (6)
connect a joy stick with jointing, so that it could control the handy weathervaning. The release
rod is out work under the springs effect. The adjusting platte(7)must wedge in the flute of the
Electromagnet (8). The adjust paneled is fixed on the release rod(13) ,the panel (12) joints a
joy-stick(14), and two joy-sticks protected by tubes (15),(16).

5.3.1 Automatic Weathervaning Effect

Driving: Magnetic release by simple impulse on the button(1).
Working Principle:
Release the protection (P) by pressing on the OFF button on the control unit.
Completely depress the weathervaning button, the yoke (2) and the electromagnet (3) are supplied
with 20V DC. The yoke (2) attracts the mobile armature (4) and the brake lining support (5) which
drives the release rod (6); the adjusting platte (7) by means of nut(8), the same movement under
the effect of the spring blade(9). The electromagnet (3) attracts the trigger (10) which pushes down
the miniature switch(11), the weathervaning pilot light goes on.
After the brakes magnetic yoke is power off, it is required there is still current in the
Electromagnet (3). The duration of pressing Weathercock Effect Button must be longer than the
delay time (0.5 sec.) of XRGIT, only in this way the yoke (2) can be power off automatically. The
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Movable Armature (4), Brake Lining Bearer (5) and Releasing Lever (6) then receive the pressure
from the spring (12). Once stopping on the Trigger Plate (10), the Adjusting Plate will restrict the
motion of the Brake Lining Bearer by right of the nut (8). Upon releasing the button, the
electromagnetic iron will be power off immediately, however, the Trigger Plate (10) will be still at
the position of being attracted due to the pressure of the Control Lever (13).
Upon the completion of above operation, the indicator lamp beside the electric control button
should be still on, indicating that the tower crane is under the Wethervaning Effect.
Upon cutting off the circuit breaker or turning off the breaker switch, the indicator lamp will be off.
When the tower crane is in operation, the brake will restore automatically.
Note:
If the wethervaning device should not operate(lack of current), weathervaning can be obtained see
following page.

5.3.2 Handy weathercock effect

Drive : Lift the Unlock Handle (2), and move it in A direction. Move the lever (1) from Position
D to Position B, the Trigger Plate (3) is below the Adjusting Plate (4), a click can be heard. Release
the brakes Releasing Lever and move it in C direction, and place it on the Trigger Plate (3) and
then lock the Trigger Plate. Relieve the pressure on the lever (1), the lever (1) and brakes
Releasing Lever should not have more clearance, otherwise, make adjustment according to the
following method.
Remove :
Lift the brakes Releasing Lever (2) and move it in A direction. Move the lever (1) from Position B
to Position D. Release the brakes Releasing Lever (2) and move it in C direction. The brake must
be released. Check if the bell housing has stopped rotating.
Note: The brakes Releasing Lever must be at the position of releasing the brake.

1 Inside Box

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5.4 Slewing Brake

The brake lining support(1) gets close to the shell for the springs in use. The mobile armature(3)
is fixed on the brake lining support(1), so it can attract the yoke(4). Thus
freeing the bell.(fig
5-10)

5.4.1 Working principle

(1).Brake release:
Yoke(4) is put under voltage and attracts the mobile armature(3) and the brake lining support(1),
thus freeing the bell.
Brake:
(2).As soon as the supply of yoke(4) is cut by means of XRFS or 0 push-button of the control
unit, the mobile armature(3) and the brake lining support (1) are freed; later is pushed against the
bell by spring(2). The bell is braked. .(fig 5-10)

5.4.2 Adjustment
(1) Adjustment of Air-gap (E)
A. Loosen the screw (1);
B. Completely loosen the screws of the Movable Frame (2) and then make adjustment on the
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notch outside the screws until it is clung on the yoke iron (3);
C. Re-fix the frame with the screw (1) in the third hold; adjust the clearance to appro. 0.6mm
(E).
(2) Adjustment of Braking Torque:
Have been pre-adjusted before delivery.
(3) Adjustment of Weathercock Device:
The clearance of brake has been adjusted appropriately; remove the plug screw (4); loosen the
nut (5) (with 13 Socket Spanner) until the Releasing Lever (6) can be moved from left to
right and from the top down optionally with a wet finger.
From this time on, there are two conditions for adjustment:
The brake is power on;
The brake is power off.
When power on:
A. Connect the brakes yoke iron (3) with the power so that pulse is generated in the slewing
control combination switch on the right side or left side;
B. Screw down the nut (5) until the Adjusting Plate (7) contacts the Trigger (8);
C. When the Trigger (8) contacts the Adjusting Plate (7), keep it immovable;
D. Slightly loosen the nut (5) until the Trigger (8) returns to the original position under the
action of the Return Spring (9);
E. Make sure that the Trigger (8) can be turned flexibly without any restriction when it
contacts the Adjusting Plate, otherwise slightly loosen the nut (5).
After the completion of the adjustment of Weathercock Device, it is necessary to check the outer
shell (10) and make sure it can rotate flexibly, then re-place the plug screw (4).
When power off:
A. Follow the operation instruction described in the Power Adjustment Column;
B. Re-screw down the nut (5) by 1/3 round (1.5mm pitch), thus the Weathercock can be
ensured;
C. Make sure that the outer shell (10) can rotate flexibly;
D. Re-place the plug screw (4).
Important:
This adjustment must be carried out:
After repair of the brake (parts replaced or air-gap adjusted).
When brake linings are worn out, which can be detected by insufficient brake release and by
the release lever having no play in the braked position.
When the signal light does not work. .(fig 5-9)

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Figure 5-8

Figure 5-9

Figure 5-10

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5.5 Slewing limiter

It is provided for machines without collector, the purpose of the slewing limter is to prevent the
electric cables from getting twisted and damaged.(fig 5-11)

5.5.1 Working principle

A limit switch with reduction gear driven by a pinion(1) meshing directly the teeth of the slewing
ring, registers the number of rotations carried out by the crane whilst slewing. This reduction gear
drives cams(2) which operate the circuit-breakers(3),thus cutting off the corresponding movement.

5.5.2 Adjustments
They are carried out WITHOUT LOAD. Control left slewing or right slewing and act manually
onto the break keys (A) in order to determine which one cuts the controlled motion. Adjusting the
right hand slewing limiter(SRD), slew the jib so that the electric cables are not twisted (jib position
after erecting the crane), carry out 1 1/2 turn to the right, then adjust the cam(4) checking this
movement until it depresses the corresponding contact(5). Adjusting the left hand slewing limiter
(SRG), carry out 3 turns in the reverse direction .adjust the cam (6) until it depresses the contact
(7).
Note: the adjustments must be checked everyday before putting into service.
Every time when the tower crane moved to a new place, must pull out the plug at the end of the
limiter before put to use, drain the water of condensation in it, and must stopper the plug before the
crane move to another workplace.

NOTE:
Install a limit switch on the E flat plate of the slewing mechanism,the mechanism
will stop working when the E flat plate is open.
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5.6 Periodical inspection

Compulsory periodical inspection of the bolt tightening for the slewing ring assembly.
Frequency of inspections: at each crane dismantling and at least once a year.
Method of inspection: should the machine be in service, make sure that the bolts to be checked are
not exposed to the tensile strength due to load or counter-weights. Using a torque-wrench (and if
required, a torque multiplier would be in use), check the tightening torque of the bolts corresponds
to the value as listed in the table 5-1.
When checking, the bolts must not be tightened.
Necessary replacement: during an inspection, it may happen that the values of the tightening
torque of one or more bolts beyond the minimum and maximum as shown in the table, in this case,
it is necessary to replace several even all the bolts.
Systematic replacement: The screws and bolts used for the slewing ring assembly must be replaced
every 7 years.
Retightening of the bolts: Whenever bolts have been replaced or the slewing ring reassembled
(always use new bolts), retighten the bolts to the nominal torque once the parts in contact have
settled after some working weeks.
For further details about the method of inspection, the bolt fixing, retightening and the replacement
conditions, please consult our local agent.

BOLT CLASS 10.9

BOLT CLASS 8.8

Tightening torque
in mkg

Tightening torque
in mkg

BOLT
(IN MM)

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Max

Nom

Min

Max

Nom

Min

20

55

46

40

40

35

30

22

71

65

58

24

95

85

70

70

64

50

27

144

124

110

100

93

75

33

248

220

190

200

181

160

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6. Trolleying Mechanism
6.1 4T3V4 mechanism working principle

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Outer support plate

Rod
Drum and reduction gear
Pinion
Inner support plate
Limit switch
Eddy brake, excitation voltage DC 20 V
Motor
Brake, excitation voltage DC 20 V
Nut
Hand wheel
Nut M8, which lock the hand wheel in
service

13.
14.
15.
16.
17.
18.
19.
20.

Screw M8
Spring sleeve
Screw 3rd hole and 4th hole
Fan cover
Spline sleeve
Bearing 80212
Transmission shaft
Normal speed ratio of the reducer r =
30.36
21. Bearing 60209
22. Body frame seal PD 115 x 140 x 14

23. Wedge of the trolley rope

The moment motor, which drives the mechanism 4T3V4, is equipped with an eddy brake and a
direct current disc brake.
The trolley has 3 trolley out speeds and 3 trolley in speeds, for these speeds are obtained by
successively putting under voltage the 3 windings and the eddy brake corresponding to the 3 motor
speeds.
The 1st notch MV is the eddy brakes max-excitation in combination with the motors step-down
control.
The 2nd notch PV is the eddy brakes mid-excitation in combination with the full staring motor.
The 3rd notch GV is in self-control of the full starting motor. No excitation from eddy.
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6.2 Adjusting the electromagnetic brake

(1) Shaft
(2) Flange cover
(3) Bearing
(4) Claw magnetic
(5) Field coil (I)
(6) Armature
(7) Body (I)
(8) Stator winding
(9) Stator core
(10) Rotor
(11) Body (II)

(12) Terminal box (I)

(13) Body (II)
(14) Inner fan
(15) Screw
(16) Fan
(17) Friction material
(18) Brake disc
(19) Friction disc
(20) Field core
(21) Screw
(22) Protection cover

(23) Nut
(24) Nut
(25) Spring box
(26) Release screw
(27) Release nut
(28) Brake spring
(29) Field coil (II)
(30) Armature
(31) Spline sleeve
(32) Terminal Box (II)

The friction screw of the electromagnetic brake would be abraded after a long time usage, and the
air-gap between the armature and the field core increased, the length of the brake spring increased
and the braking moment decreased, so the armature is not easy to be attracted, even un-attracted if
seriously, so that the motor will be stalled and then burn out. Therefore, the air-gap must be
checked daily. When the fixed braking torque is less than the rated value or the air-gap is more
than 1.2 mm, adjust them. Replace the friction material by a new one when the metal surface will
be worn.

6.2.1 Adjustment of the stationary braking torque

a. Cut off the electricity supply.
b. Release the nut (24) towards the left.

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c.
d.
e.
f.

Remove the protection cover.

Release the screw (21) towards the left using a screw driver.
Release the nut (23) (about 5 mm) towards the left using a spanner.
Tighten the spring box towards the right using a spanner and compress the braking spring until
the sstationary braking torque reach the rated value.
g. Tighten the nut (23) towards the right with a spanner.
h. By the tooth space on the armature circle, turn the armature towards the left with a screw
driver through the window of the field core (20) until the armature holds the field core. Insert
the screw (21) and hold it against the armature with the screw. Turn the armature towards the
right slowly. Find out the 1st hole that the screw (21) go through the armature, take it as the
starting mark, turn to the 5th hole continuously and then tighten the screw (21). Now, the
air-gap is about 0.65 mm (2 holes located on the armature and the excitation core, 12 holes
located on the circle equally). The thread pitch between the armature and the brake disc (I) is
1.5 mm.
i. Replace the protection cover and tighten the nut (24).

6.2.2 Replacement of the friction material

A.
B.
C.
D.
E.

First, operate as the step a ~ d in paragraph 6.2.1.

Remove the nut (23).
Remove the release nut (27).
Remove the spring box and the braking spring.
Remove the bolt connects the excitation core (20) and the bell (III). Remove the field
core (20) carefully (protect the lead-in-wire of the field coil), remove the friction disc (19)
and the brake disc (18).
F. Remove the friction material (17) from the bell (III) and replace it by a new one.
G. Remove the friction material (17) from the friction disc and replace it by a new one then
adhibit it.
H. Refix the brake disc (18), friction disc (19), excitation core (20), braking spring (28) and
spring box (25).
I. Adjust the dead braking torque and the air-gap as the step f ~ i in paragraph 6.2.1. Fit the
protection cover and tighten nut (24).

J. Tighten two release nuts (27) and lock them at the spring box (25) about 5 mm apart.
After adjusting the electromagnetic brake, check the manual released device and the armature
could be attracted or not when the power is supplied. If the adjustment is all right, then put the
motor into service.

6.3 Limiter
The purpose of the trolley limit switch is to avoid any possible driving error and to stop the trolley
motion before reaching the stops of the jib nose or foot.

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6.3.1 Working principle

A limit switch with reduction gear driven through a pinion meshing a toothed ring rigidly fitted to
the drum, registers the number of arum revolutions and so the unwound rope length. This reduction
gear drives cams(1) which operate the circuit-breakers(2), thus cutting off the corresponding
motion.

6.3.2 Adjustments
Adjusting the trolley out-slowing down safety device(RDAv)
Move the trolley to a distance of 1.50m form the jib nose rubber stops. Turn cam(3) until it
depresses the corresponding contact.
Important: Adjust so that the 2 cams are overlapping in order to avoid any interruption of slowing
down before the motion is cut off.
Adjusting the trolley out limit switch (SDAv)
Move the trolley to about 20cm from the jib nose rubber stops, Turn cam(5) until it depressed the
corresponding contact(6) without however modifying the adjustment of cam(3).
Adjusting the trolley in- slowing down safety device(RDAr)
Move the trolley to the jib foot and operate the slowing down cam(7) to depressed the contact(8).
Adjusting the trolley in limit switch(SDAr)
Proceed as described above turn cam(9) until it depressed the contact(10).
NOTE: the adjustments must be checked daily at each putting into service.

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7.Safety Device
7.1 Summary
Safety device is specially used to avoid the wrong operation. It includes a limiter and an overload
limiter.
The overload limiter adjusted order: a. Moment Limiter b. Max. Working Load and Speed Limiter

I. Limiter
A) Hoisting Limiter
B) Slewing Limiter
C) Trolleying Limiter
D) Traveling Limiter
II. Overload Limiter
E) Moment Limiter
F) Max. Working Load and Speed Limiter

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7.2 Security
parameter

Lf

HOISTING
MOMENT LIMITER
SLMO

2-FALL
SM

Lf

X(kg) Y(kg) Z(kg) W(kg)

+10% -10%

Lm

L m Dm
+10% 80%

50

2600

2860

2340

5000

28.2

31

45

2950

3245

2655

5000

28.2

31

40

3400

3740

3060

5000

28.2

31

32

35

3950

4345

3555

5000

28.2

31

28

30

4700

5170

4230

5000

28.2

31

24

2/4FALL
SM/DM

Lf

TROLLEYING MOMENT
LIMITER
SDMO

HOISTING
MOMENT LIMITER
SLMO

40
36

TROLLEYING MOMENT
LIMITER
SDMO

Lf m

X(kg)

Y(kg)

Z(kg)

W(kg)

Lm

Lm

Dm

50

2300

2530

2070

5000

26.8

29.4

40

45

2650

2915

2385

5000

26.8

29.4

36

40

3100

3410

2790

5000

26.8

29.4

32

35

3650

4015

3285

5000

26.8

29.4

28

30

4400

4840

2960

5000

26.8

29.4

24

Max. Working Load limiter

5500

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7.3 Moment Limiter

The tower crane is designed and calculated according to the constant max. load moment, so it is
forbidden to exceed the max. load moment during the use.

7.3.1Working Principle
The device has a pair of spring plates (1) which may bend to a certain extent under the action of
load moment. As there are several adjustable bolts on the spring plates, when the load is excessive,
the adjustable bolts will press down switch.

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7.3.2 Adjustment
(1)

Adjust the hoisting moment limiter SLMO

Drive the trolley to the head of jib, and then hoist the
specified load X at the rated speed of 4-rope at full
arm length (adjusting Device A).

Lift down the load, and then hoist the load Y=X+10%
at the min. speed of 4-rope. The hoisting motion should
be stopped, otherwise make readjustment.

(2) Adjust trolleying moment limiter SDMO

Measure the distance and mark the effective radius
(L) and the radius L1=L+10%L at max. load. Hoist
the max. load (hang in the air) and then move the
hook to the mark of effective radius (L) (adjusting
Device C).
Drive the trolley to the boom point and then apply
outward
trolleying
at
rated
speed.
The
trolleying motion should be stopped before reaching
the mark (L), otherwise make readjustment.

(3)

Adjust trolleying moment limiter RDMO

Hoist the load X at the middle position of boom and
then apply outward trolleying at rated speed and adjust
Device D so as to make the trolley to stop its motion at
rated speed at the radius D and automatically change to
travel at slow speed.

Note: Check SDMO Safety Device (it is not necessary to check SLMO) and stop the outward
trolleying motion.
For the different load value and jib length, see the initial part of this section.
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4)Adjustment method
Adjustment of Device A, C, D:
Screw the nut (1) and the bolt (2) to make the bolt to contact the switchs contact (3), but not cause
short circuit.

7.4 Load Limiter

The structure of the tower crane and its hoisting are all designed and calculated according to the
max. load, so the working load should not exceed the max. load. The Load Limiter is a safety
device used to protect against overload.

7.4.1Working Principle
The hoisting ropes running through the sheave transmit the stress to the dynamometer link which is
connected with the sheave in way of rigid connection so that the dynamometer link distorts along
with the change of load. On the metal bar mounted in the link there is a switch and adjustable bolt
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which may record the distortion. After appropriate adjustment, the switch may play the function of
safety circuit. What the safety circuit controls is the load.

Adjustment

7.4.2
Adjust Speed Limiter (SLCHGV)

To hoist the load at medium speed

(PV) first and then high speed. To
adjust the bolt (1) until its head
contacts the switch (2).

X
To lift down the load, add the load
by 10% and hoist the new load at
medium speed and then at high speed.
At this moment, there should not be
high speed hoisting action, otherwise
readjustment.

Adj
ust Speed Limiter (SLCHPV)
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To hoist the load at slow speed

(MV) first and then medium speed. To
adjust the bolt (3) until its head
contacts the switch (4).

X
To lift down the load, add the load
by 10% and hoist the new load at low
speed At this moment, there should not
be any hoisting action, otherwise make
readjustment.

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8. Travelling mechanism
8.1 working principle
The crane is fitted with a traveling mechanism which comprises:
4 motor bogies(1), each made up of:
1 squirrel cage motor(2) with a double acting brake, 1 reduction gear (3) directly meshing the
powered wheel, rail cramps for non-working condition, a limit switch(5) with its ramps(6).

Note : The limit switch ramps are in the clients charge.

Traveling forwards: Operate the control lever traveling forwards, the motor rotates and the brake
releases.
To stop: release the control lever, this cut the motor supply and the working brake comes on,
whilst the parking brake remains working, applying the parking brake in according to the
following :
Acting on the off button (cutting off the general crane supply)
Automatically closed by means of a time-delayed contact.
Caution: in the case of the emergency during traveling, depress the OFF button.
Traveling backwards: operate the control lever traveling backwards, the motor is being fed in the
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reverse direction and the brake releases.

To stop: see traveling forwards
Note : in the case of a 2-speed traveling mechanism with curve track, it is necessary to return to
low speed in order to travel round the curves.

8.2 Traveling brake

Its an electromagnetic brake which operates when the current is switched off, it has a separated
electric supply.

8.2.1 working principle

When the general supply is cut, the moving plate (1) and (2) are pushed by the springs generate the
max braking moment.

A)holding brake control by means of the on-off buttons:

When depressing the on button, (5) is fed without however attracting the plate(1),(otherwise
check the air gap adjustment). The traveling motion remains brake at a maximum.
When traveling , the coil(6) is fed and attracts the plate(2). Later compresses the spring(4) and (3)
through the spacer(7). The plate(1) is hard against the yoke(11),thus giving complete brake
release.
When stopping the traveling, the supply of the coil(6) is cut. Under the pressure of spring(4) the
plate(2) comes hard against the brake disc, thus provoking a progressive braking action.
When depressing the OFF button, the coil(5) is no more fed, spring(3) now reinforces the action
spring(4) to give maximum braking which is maintained until the next traveling motion.

B)holding brake control by means of the traveling control:

When traveling is operatered, the coils(5) and (6) simultaneously fed, the moving plates(1) and (2)
are attracted and are hard against the yokes. The springs(3) and (4) are compressed. The brake is
now released.
When stopping the traveling, the coil(6) is no more fed whilst the coil(5) remains fed by the cable
winder control. The progressive breaking is ensured by the spring(4) only. The spring(3) remains
compressed. After 5 to 7 seconds (time lag of the cable winder control) the supply of coil(5) is
suppressed. The brake moment becomes maximum as soon as the spring (3) is acting.

8.2.2 Adjustment
a) air gap coil(6):
remove screw(8). Unscrew the plate (2) completely acting on its outer notches until it is hard
against the yoke(12). Screw up the plate pushing on the screw(8); at the 3rd hole encountered,
block(8).
b) air gap (5):
remove screw(10) so that the plate can be reached. Remove screw(9). Unscrew the plate(1)
completely acting on its outer notches until it is hard against the yoke. Screw up the plate
pushing on the screw(9); at the 2nd hole encountered, block(9). Screw up the screw(10).
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NOTE: if the plate is attracted when depressing the ON button, increase the air gap(3rd and 4th
hole).
c) brake moment :
the brake moments are defined by the springs(3) and (4) ,spring box completely tightened.

8.3 Travel and overrun limit switches

The purpose off the travel limit switch is to compensate for potential driving errors. It allows the
crane traveling motion to be stopped before reaching the track stops. The purpose of the travel
overrun limit switch is to stop the crane in case of limit switch failure.

8.3.1 Working principle

The limit switch (1) and the overrun limit switch (2) consist of:
A box(3) comprising of a lever (4) equipped with a roller(5) fitted on the crane chassis or on a
boggie.
2 ramps (6)and (7) operating the limit switch lever(1) when the crane reaches the track extremities.
2 ramps (8) and (9) operating the overrun limit switch lever(2) in case of limit switch failure.
When the limit switch is operated, it only cuts off the traveling motion whereas the overrun limit
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switch cuts off the general supply to the crane.

After cutting off by the limit switch, operate reverse movement in order to leave the zone.
After cutting off by the overrun limit switch, it will be necessary to dismantle it to put the crane in
service again. Before re-fitting it, the crane driver will have to check the adjustment and good
working order of the limit switch.
NOTE: the overrun limit switch must cut off the traveling motion only in case of limit switch
failure.

8.3.2 Adjustments
Position the ramps(6)and (7)
requested:
The crane being at nominal
speed and taking into
account that it works under
wind, after slowing down
its sped over a distance L,
comes to rest 50 cm before
the stops (10).
The lever(4) of the limit
switch and of the overrun
limit
switch
whilst
controlling the motion cut
off, still has a minimum
clearance before reaching
the
mechanical
stop.
Position the ramps(8) and
(9) so that the overrun limit
switch cuts off the motion
immediately after the limit
switch.

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9. Lubrication
9.1 Symbol
M ---- Before use;
N ---- Oil level control;
V ---- Discharge oil;
R ---- Inject oil;
G ---- lubricating grease
----ZL45-2,2# Aviation Grease
----R MIL-L2105BSAE80
----MOS2,Complex calcium base grease MOS2 4#
--YH10SY1181-65 10# Aviation Hydraulic Grease(N46 unti-abraded hydraulic grease )

, In

winter: Lan chou40 1Hydraulic oil with uncoagulable liquid

--F

MIL-H5606B

CPF MIL-L 2105B SAE 80 (used in frigid zone)

CPC MIL-L 2105B SAE 90 (used in torrid zone)
----SAE 80W/90 (20# gear grease), In winter: SSSH 0385 992.
----(ZL45-2)Graisse-Fett-Grease-NLGI 0 Lithium.
Use Mobil shc626 lubrication oil to lubricate Hoisting Mechanism decelerator, Slewing
Mechanism decelerator In winter.

9.2 Regular Lubrication

a) Initial lubrication should be made after working for 200 hours;
b) Use oil gun to inject lubricating oil to the hinge without nozzle tip (such as door hinge, hinge,
link, lock and chain axis of safety device);
c) When checking oil leveler or discharging oil, in order to avoid the interfusion of impurity, it is
necessary to keep the parts nearby the oil plug clean (such as oil level control, inject oil and
discharge out);
d) The injection amount of lubricating oil is subject to the instructions, and must reach the lowest
scale of oil leveler.

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9.3 Sketch of Lubricated Parts

1
2
3

6
7
8
9
10

1 Lubrication of hoisting rope and trolleying

rope
2 Lubrication of hook
3 Lubrication of trolleying mechanism
4 Lubrication of slewing mechanism
5 Lubrication of slewing decelerator

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6 Lubrication of hoisting mechanism

7 Lubrication of climbing device
8 Lubrication of pedestal
9 Lubrication of traveling mechanism
10 Lubrication of cable winder

45

9.4 Lubrication of Steel Ropes

However, if the rope appears to be dry or tends

to oxidize, we recommend to oil moderately
using .
After a longer standstill, it is possible to protect
the rope by a spray with grease .

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9.5 Lubrication of Hook

9.6 Lubrication of Slewing Mechanism

Lubrication of slewing ring see the down figure

Explanation: life-time lubrication for the decelerator; check the abrasion of the brush (A) every
year or every 2400 hours, and when the brushs length is less than 15mm, it should be replaced;
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check the tension of V-belts.

9.7 Lubrication of Hoisting Mechanism

Check the reduction gear carefully before use, only filled more than 20# gear greases that it could
be used.
In order to prolong the using-life of the reduction gear, please lubricate according to the following
instruction.

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9.8 Lubrication and maintenance of the rope corrector and fleeting

pulley
Particularly take care in the lubricating the shaft, two possibilities:
1) Oil the shaft everyday with CPF type oil.
2) Every 50 hours grease the shaft by
means

of

,but

before

each

lubrication clean the shaft from the

worn grease.
Note : recommend the first solution
Adjusting the stops(1):
Carry out a first adjustment of the stop B, L

After the aforementioned adjustment, check

that the rope winds up correctly with and
without load and at low and high speed.

9.9 Lubrication of the cable winder

Lubricate according to the fig 9-7

1month 1year

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9.10 Lubrication of traveling mechanism

Lubricate according to the fig 9-8

Reduction gear are greased for life-time

fig 9-8
Lubrication of the hoist device and the pedestal:
Everytime lubricate the wheel before fixing mast, the slewing part also need to oil.
The rotating parts of the pedestal also need to lubricate.

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10. Hydraulic group

Hydraulic group is composed of pump station, oil reservoir and accessories.

10.1 Pump station

1 squirrel cage motor

2 oil reservoir
3 piston pump
4 pressure regulator

5 directional control valve

6 high pressure regulator
7 low pressure regulator
8 balancing valve

10.1.1 Working principle

Neutral position:
The oil flows to the directional control valve and returns to the reservoir.
Hoist up position:
The oil is sent in the HP circuit, the pressure is limited by the high pressure regulator. The oil from
the small chamber flows to the directional control valve and returns to the reservoir.
Lowing position:
The oil flows to the small chamber and returns to the reservoir. The balancing valve with
anti-return valve allows to hold the telescoping beam in position and prevents the ram rod from
being extended in the neutral position.
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10.1.2 Maintenance
Adjustment of the high pressure regulator(fig 10-2):
unscrew the knurled cap(1), then hold the control
lever to the hoist up position. Re-screw it until
telescoping is possible, then screw it again slightly so
as to adjust it to a somewhat higher value. If the
maximum pressures couldnt reached after having
screwed in the knurled cap(1) completely, un-screw
the cap(1) completely and screw the adjusting nut(2)
to the place of cap(1) before un-screwed, and restart
the adjustment procedure.
The high pressure regulator shouldnt adjust to the
maximum pressure frequently.
The low pressure regulator is calibrated at the
factory and mustnt be adjusted.

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10.1.3 System principle figure

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10.2 Ram

1) ram body

6) piston

2) ram piston

7) non-return valve(small flow)

3) piston rod

8) piston

4) ram bottom

9) throttle-valve

5) non-return valve(great flow)

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10.2.1 Working principle

Hoist up control

Telescoping up (extending the rod) Fig 1a:

When controlling the movement, the oil flows under high pressure to (A), forces back the
non-return valves (5) and (7) enters into the great ram chamber and pushes the piston. The oil in
the small ram chamber returns to the hydraulic group through the pipe(C) and the low pressure
circuit (B). The hoist speed depends on the pump flow. When the operation is stopped, the valves
(5) and (7) are closed under the pressure of the load which remains in position.

Lowing down the telescoping beam (telescoping down) Fig 2a:

The weight of the telescoping beam is driving, and the procedure is the same as for the telescoping
up. When the control is stopped, the oil cannot flow back to the reservoir through the low pressure
circuit, as the pressure produced by the weight of the telescoping beam is not greater than the
calibrated pressure of the balancing valve. Consequently, the load remains in its position.

Lowering down control

Telescoping down(de-telescoping) Fig 1b:

As soon as operated, the oil arrives under low pressure at (b) and (c). In (c), the low pressure is
added to the pressure produced by the load. In (b), it controls the piston(8), which opens the
valve(7); but it cannot open the valve(5) with the piston (6) (the force of the pressure on (6) is
smaller than the effort due to the pressure in the great ram chamber). So the oil of the great ram
chamber returns to the group through the throttle-valve(9), the valve(7) and the high pressure
circuit(a).
NOTE: We emphasize that it is dangerous to invert the high and low pressure hoses. As a matter of
fact, if the lowering down operation was controlled under high pressure, the piston(6) would force
open the valve(5), and the return flow would not be limited any longer. The lowering down
operation would take place at an uncontrolled high speed, with shocks and pump cavitation.

Raising telescoping beam (retracting the rod) Fig 2b:

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The weight of the telescoping beam is resisting. The procedure is the same as for telescoping down.
The raising speed depends on the pump flow.
a: fixed part
P: weight of the telescoping beam
b: moving part
R: resisting
P: weight of the slewing crane part
r: driving

10.2.2 Maintenance and greasing

Hydraulic connection:
Once check out that the connection of the hoses are clean or not, connect to outlets of the hydraulic
group with those of the ram, making sure that the high pressure and low pressure for ram group
coincide with the hydraulic group. Do not tighten too much the connection(8.5 mkg torque). It is
strictly forbidden and very dangerous to invert the high pressure and low pressure piping.

Bleeding the ram:

Must be carried out with the unloaded ram, the telescopic equipment resting on the mast lugs.

The way of bleed the circuit of air:

Unscrew the high pressure limiter of the group, once the piston is retracted, unscrew 1/4 turn the
bleed screw BP(V1) using a spanner, extend the piston as soon as possible, retighten the bleed
screw V1. Unscrew 1/4 turn the high pressure bleed screw(V2), retract the ram piston, retighten the
screw. Repeat the these operations until the oil flows with no air bubbles.

Throttle-valve adjustment:
Check first that the hydraulic oil in the ram has been cleared, take off the domed cap (a). Unscrew
the lock nut (b). Completely screw up the needle pin(5). Unscrew 1/4 turn (not more when starting
the telescoping) and block the lock nut. If it doesnt fit very well, adjust again by 1/4 turn
maximum at a time. Then lock the nut and refit the domed cap nut.

Never adjust the throttle-valve when the ram is operating under load:

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SERIOUS RISK OF ACCIDENT.

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11. Cable Winder

This cable winder is fixed and adjusted over in the factory, when the circuit power is connected ,
adjust the tension of the cable, proceed as follows:
a. Unscrew the plug(1),turn it around and introduce it into filling bole in order to block the
adjusting screw(2).
b. Turn the cable winder by hand to the right (A) (operater on the side of the cable winder ) so as to
increae the moment of the friction pulley and to the left(B) to decrease it(fig 11-1)
c. The moment is exact when the cable bears at standstill on the lower roller of the guide roller
box.
d. The friction pulley must never be blocked.
Note: neither to the right, risk of damage of the friction pulley.
nor to the left, risk to decentre the collector with respect to the brush-holders.

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PE

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