Linden Comansa 21 LC 290 18T - Manufacturer Manual
Linden Comansa 21 LC 290 18T - Manufacturer Manual
Linden Comansa 21 LC 290 18T - Manufacturer Manual
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
The purpose of this Instructions Manual is to provide the user with useful information regarding crane
handling, transportation, erection, operation, maintenance, disassembling and repairing. This information not
only will allow the user to operate the crane with the maximum safety but also, bearing in mind all its capacities,
obtain a better performance.
To make information retrieval easier, the Instructions Manual is divided into chapters as described in the
following sheets. Prior to crane operation read carefully those parts related to your duty and do not hesitate to
request any clarification or additional information if you should not understand the existing information or if it
should not be sufficient.
Crane operation is restricted to qualified personnel having received proper specialised training and
specific crane information. Apart from the operating instructions, applicable regulations must be taken
into account, specifically those related to safety precautions such as personal protection and hazard
prevention rules.
Prior to crane operation, the owner or user must make sure that any person involved in crane main-
tenance or operation is conversant with the safety and operating instructions regarding his duty,
described in this Manual, as well as with applicable standards and regulations.
Crane safety devices must be closely monitored. Check regularly their correct operation and, in case
of any failure or malfunction, prohibit crane operation.
Subsequent to receiving this manual data concerning the crane can be sent in the form of Technical
Information or Maintenance Reports. It is important that these documents are taken into account and added to
this Manual.
This manual has been issued for a specific crane model and serial number. If based on the modular
design of the crane range, crane model and set-up is changed to other model not contemplated in this manual,
complementary instructions for the new set-up must be applied for.
The Instructions Manual is an important part of the crane and it must be always attached
to the crane in good condition and updated.
Illustrations on this manual do not necessarily correspond with actual product set-up.
1. COMANSA stands warranty for its products against any material and manufacturing defects. This
warranty covers use and service in normal conditions for one year as from the date of delivery
of the product to the customer, or for 1800 hours of operation of the equipment, whichever is
shorter.
2. This warranty does not cover normal wear and tear of consumable elements, steel cables and
electrical wiring.
3. This warranty does not cover equipment maintenance and adjustment work.
4. COMANSA provides no warranty for malfunction or damage to motors, brake coils, electronic
electricity supplies. With the crane at rest and when it is operating with its motors at full load
or full speed the power supply at the base of the crane must be between 95 and 105% of the
5. The general warranty does not cover defects arising in products as a result of:
- Use of equipment by persons not legally authorised and/or not trained for such use.
other than that indicated in the COMANSA instruction manual and in regulation ITC.MIE.
AEM2; the points made in standard EN 60204-32 concerning the area around the insta-
- Overloads.
- Modifications to the equipment made without the consent of COMANSA or made with its
- When defects covered by the warranty are reported in writing within 30 calendar days
- When the faulty parts are shipped to COMANSA properly packaged and insured within
the period indicated by COMANSA. Shipping costs are payable always by the cus-
- When the customer, at the request of COMANSA, allows access of personnel answera-
ble to the latter so that they may inspect allegedly faulty equipment or materials on-site
and take possession of such parts as they may require for analysis by COMANSA or by
third parties.
7. COMANSA is responsible for supplying parts after defects have been detected, and may at
its own discretion repair faulty parts or equipment under warranty or replace them by new
parts. In the latter case the faulty parts or equipment shall become the property of COMAN-
SA.
8. In no case shall COMANSA be held liable under this warranty for damage that arises as a
direct or indirect consequence of defects covered by the warranty, even though the customer
may incur loss of profit due to the interruption or cessation of its activities or those of third
parties working for or with it. The liability of COMANSA shall be limited to the supply of parts
9. COMANSA’s product warranty extends only to its own customers. COMANSA shall therefore
not be bound to provide warranty cover to third parties, even if they are users of its products
10. Should any of the limitations laid down in this warranty be declared null and void under appli-
cable legislation, so that the warranty is therefore applicable, the warranty period shall be
These operating instructions comprise eight chapters. Chapters contain the following subjects.
1 GENERAL
This chapter gives information on the composition and use of the operating instructions, as well as general and
safety symbols there referred to.
Contents of the “Introduction” document at the beginning of this chapter are of great importance and must
strictly be respected.
2 TECHNICAL SPECIFICATIONS
This chapter contains technical information on the crane, i.e. technical data sheet, load diagrams, weight and
dimensions, construction features and guidance on overall crane design.
3 ERECTION / DISMANTLING
This chapter contains documents on crane erection, from jib assembling, including assembly design dimensions,
through the erection of different crane parts, to the calibration and checking of crane limiters and safety devices
for commissioning. Also, crane dismantling instructions are included, as well as guidance on the transportation
of different crane parts.
4 ELECTRICAL INSTALLATION
This chapter contains additional electrical information, complementary to information given in chapters EREC-
TION / DISMANTLING, CRANE OPERATION AND MAINTENANCE, which enable a correct crane electrical
installation and give ample knowledge on crane electrical system.
5 CRANE OPERATION
This chapter contains necessary information for a correct crane operation.
6 MAINTENANCE
This chapter informs on checks and adjustments to be performed periodically after crane erection.
7 SPARE PARTS
Different machine parts arranged into various construction groups are listed in this chapter. This information
helps to a better understanding of mechanical parts and thus to an easier identification of spare parts. Also,
precise information on how to place purchase orders for the required spare parts is given.
8 OTHER INFORMATION
Other crane information whether manufacturer or owner’s information could be incorporated into this chapter.
13
9 10 11 1 12
1 COMANSA LOGO
2 CHAPTER NAME
3 DOCUMENT TITTLE
Regarding chapter SPARE PARTS, sections 2 and 3 are available in several languages.
4 DOCUMENT CODE
LINDEN COMANSA internal code, for document filing purposes.
5,6 IDENTIFICATION DATA
Data regarding crane type, section, part or other data, intended to ease document retrieval and filing.
7 DIVISION LINES
Border lines of different document areas, such as heading, contents and footer.
8 CONTENTS
Texts, drawings and tables regarding instruction of applicable service instruction sheets.
For spare parts sheets, detail drawings and parts lists in several languages.
9 SHEET NUMBER OF TOTAL NUMBER OF SHEETS
Sheet number and number of sheets in document.
10 REVISION
Letter stating document revision; revisions start by letter A.
11 DATE
Document drawing up date.
12 APPROVAL
Document “O.K.” only in the Spanish version.
13 SHEET CODE
Gives sheet position in service instructions.
x / yyy / zzz
x Chapter.
yyy Chapter group (first three digits of DOCUMENT CODE)
zzz Sheet
0 CONTENTS
1 GENERAL DEFINITIONS
2 CRANE DEFINITIONS BASED ON FEATURES
3 PROCESS DEFINITIONS
4 PARAMETER DEFINITIONS
5 COMPONENT DEFINITIONS
1 GENERAL DEFINITIONS
- Crane
Discontinuous operation device used to hoist and distribute loads suspended from a hook over an
area.
- Slewing tower crane
Top slewing tower crane with slewing support on tower top end and with lower support connected to the
crane foot.
- Removable tower crane for worksites
Temporary slewing tower crane, used in construction sites, designed to cope with frequent erection and
dismantling operations, as well as transfers between different locations.
3 PROCESS DEFINITIONS
- CONDITION OF SERVICE
-Operational
Crane working under given operating conditions (crane setup, load reach, etc.) or ready to move
the loads for which it has been designed.
-Out of service
Unloaded crane left in stable position, in conditions specified by the manufacturer, without perfor-
ming any work, and ready to get into operation when circumstances so require and allow.
- Crane erection
The actual process of erecting the crane in the worksite, to perform as required. It includes preliminary
works such as foundations, track construction works, etc.
- Installed crane
Crane erected in the worksite, subject to design loads for crane out of service, but without the requirement
of being ready for operation.
- Commissioning
Set of crane checks and operations needed for making the crane operational.
4 PARAMETER DEFINITIONS
- Reach or radius
Horizontal distance measured between crane slewing axis and the vertical centerline of the hook without
load, when the crane is erected on horizontal ground.
- Lifting range
Vertical distance between upper and lower hook positions for the actual work.
- Lift
Vertical distance between hook rest level and upper hook position for the actual work.
- Lowering depth
Vertical distance between hook rest level and lowest position.
- Travelling speed
Speed of crane translation movement on the track for the type of work involved.
- Slewing speed
Angular speed of the slewing part of the crane for the type of work involved.
- Trolley speed
Speed of trolley translation movement for the type of work involved.
- Hoisting speed
Speed of the vertical movement of the load for the type of work involved.
- Positioning speed
Minimum load speed in erection or suspension processes, for the type of work involved.
- Tip load
Maximum load that can be hoisted at maximum reach.
- Maximum load
Maximum load that can be lifted according to crane manufacturer data.
- Support frame
Structural assembly supporting the slewing part or the fixed part of the crane tower.
- Ballast
Mass attached to the support frame for crane stability.
- Tower
Vertical structure of crane which supports the slewing part and allows for the required lift to be met.
- Slewing section
Structure including the slewing track and the slewing mechanism and comprising the elements
for the transition between the fixed and the moving part of the crane.
- Operator’s cabin
Cabin destined to normal control of the crane that houses the controls and the crane operator.
- Jib
Structural component of the crane, supporting the trolley and the hook, ensuring this way the required
reach and lift. One section includes the trolley winch.
- Counterjib
Structure able to support the crane counterweight, that can include the hoisting mechanism.
- Counterweight
Mass fixed to the counterjib, that helps compensate load actions.
- Trolley
Structure destined to the translation of suspended loads.
- Hook
Device for suspending the load.
- Erection cage
Structure placed on the tower upper part, that allows for hoisting the crane slewing part.
- Bracing frame
Structure, arranged on the tower, for transmitting loads derived from a tower extension.
- Travelling mechanism
Mechanism for crane translation on track.
- Slewing mechanism
Mechanism for turning the slewing part of the crane in a horizontal plane.
- Trolley winch
Mechanism for the translation of loads along the jib.
- Hoisting winch
Mechanism for hoisting and lowering loads.
- Limiter
Device for stopping or limiting crane movements or functions.
- Indicator
Device for furnishing the crane operator with necessary information for a perfect crane operation within
the operating parameter table.
6b 6 4 5c 5a 5
4d 5b
4e 7 8
6a
4a
4b
4c
4f
9
3
1.- Support frame, cross frame.
1a.- Support assembly.
3a 10 1b.- Structure assembly with translation mechanism
1c.- Base ballast
2.- Foundation anchor, foundation
2a.- Anchoring foot, Anchoring section.
3.- Tower.
3a.- Tower section.
4.- Slewing part.
1c 2a 4a.- Lower slewing track support.
4b.- Slewing track.
1 4c.- Upper slewing track support
4d.- Cat head.
4e.- Cabin.
4f.- Slewing mechanism.
5.- Jib
1a 2 5a.- Jib section.
1b 5b.- Jib end, moveable tip.
5c.- Trolley winch.
6.- Counterjib
6a.- Counterweights
6b.- Hoisting winch.
7.- Trolley.
8.- Hook.
9.- Erection cage.
10.- Bracing frame.
Symbol Meaning
Earthing.
The part involved must be connected to ground in accordance with specified instruc-
tions.
Voltage hazard.
Electric shock hazard.
Travelling.
Translation mechanism.
Hoisting.
Hoisting winch.
Trolley translation.
Trolley winch.
Slewing.
Slewing mechanism.
length m metre
mm millimetre
masa kg kilogramme
t ton
time s second
min minute
h hour
force N Newton
kN kilonewton
volume l litre
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
1,6 m 2,2 m
2,0 m
4,5 m
5,2 m
0,4 m
> 3,5 m
SM21-K2/S25
SM21-K2/S35
J2-10 = - 0,6 m
> 2,6 m
J4.1
BM215A FM215 AM282B AM272A AM262A AM250A AM240 AM230 AM220 AM244
LC 2100
H
= H - 0,4 m)
AM282B AM272A AM262A AM250A AM240 AM244
(
AM282B AM272A AM262A AM250A AM240
R m
2700 74
8000 40
7000 44
5300 50
4600 54
4000 60
3700 64
3000 70
kg
kg
2970
8800
7700
5830
5060
4400
4070
3300
4,5 m 6,0 m
CL XA XR XA XR ES EN 14439
(C/25)
DS.1308.09 02/13 Reserva de modificaciones. Subject to modifications. Modifications reservées. Konstruktionsänderungen vorbehalten.
Il Fabbricante si riserva la facoltà di apportare modifiche. Возможны изменения.
DIAGRAMA DE CARGAS
Load chart / Diagramme de charges / Lastdiagramm / Diagramma di carico / Диаграмма распределения нагрузки
R (m)
14,3 15 20 25,8 25,9 30 34 40 44 50 54 60 64 70 74,0 m
74
18000 17005 12165 9000 9000 7660 6660 5545 4980 4300 3930 3475 3220 2890 2700 kg
14,6 15 20 26,4 26,7 30 34 40 44 50 54 60 64 70,0 m
70
18000 17460 12500 9000 9000 7920 6890 5745 5155 4455 4075 3605 3340 3000 kg
15,7 20 25 28,4 29,1 34 40 44 50 54 60 64,0 m
64
18000 13585 10470 9000 9000 7580 6325 5685 4920 4505 3990 3700 kg
15,6 20 25 28,2 29,1 34 40 44 50 54 60,0 m
60
18000 13480 10390 9000 9000 7585 6335 5695 4930 4515 4000 kg
15,7 20 25 28,5 29,6 34 40 44 50 54,0 m
54
18000 13610 10500 9000 9000 7725 6450 5800 5020 4600 kg
16,3 20 25 29,7 31,0 34 40 44 50,0 m
50
18000 14255 11005 9000 9000 8140 6800 6115 5300 kg
18,2 20 25 30 33,1 35,0 40 44,0 m
44
18000 16115 12480 10100 9000 9000 7775 7000 kg (t)
18,5 20 25 30 33,8 35,9 40,0 m 18
40 =
18000 16490 12275 10345 9000 9000 8000 kg - 0,5
t
9
(m)
18000 14640 11300 9900 9000 9000 7330 6920 6230 5400 4940 4380 4070 kg
16,7 20 25 28 30,3 31,6 38 40 44 50 54 60,0 m
60
18000 14630 11290 9890 9000 9000 7350 6950 6250 5410 4960 4400 kg
16,9 20 25 28 30,6 32,2 38 40 44 50 54,0 m
54
18000 14800 11440 10010 9000 9000 7490 7080 6370 5520 5060 kg
17,6 20 25 28 31,9 33,8 38 40 44 50,0 m
50
18000 15530 12010 10520 9000 9000 7910 7470 6720 5830 kg
19,6 25 28 30 35,8 38,2 40 44,0 m
44 (t)
18000 13660 11990 11060 9000 9000 8550 7700 kg +10%
20,0 25 28 30 36,5 39,2 40,0 m 18
40 =
- 0,5
18000 14000 12290 11350 9000 9000 8800 kg t
9
(m)
MECANISMOS
Mechanisms / Mécanismes / Antriebe / Meccanismi / Механизмы
9
50 kW 790 m
9
65 kW * 790 m
9
110 kW *
6 6 6
3 3 3
1,7
1,1 0,7 t
t t
100
150
200
60
100
140
m/min
90
150
210
m/min m/min
38
224
30
150
54
228
18 18 18
12 12 12
6 6 6
3,4
2,2 1,3 t
t t
50
75
100
30
50
70
m/min
45
75
105
m/min m/min
19
112
15
75
27
114
DS.1308.09 02/13 Reserva de modificaciones. Subject to modifications. Modifications reservées. Konstruktionsänderungen vorbehalten.
Il Fabbricante si riserva la facoltà di apportare modifiche. Возможны изменения.
21LC290/18 t
MECANISMOS
Mechanisms / Mécanismes / Antriebe / Meccanismi / Механизмы
EFU6L-65-45 EFU4L-110-45
1280 m
9
65 kW * 1280 m
9
110 kW *
6 6
Para mecanismos de alta capacidad de cable consultar cargas. /
3 For mechanisms with high drum capacity, request loads. / Pour des 3
mécanismes avec une grande capacité de câble il faut consulter. 1,7
0,7 t
t / Für Hubmechanismen mit hoher Kabelkapazität, Lastdiagramm
100
150
200
m/min
90
150
210
m/min anfragen. / Gru con tamburo ad alta capacità di avvolgimento
38
224
54
228
fune, consultare il diagramma di carico. / Проконсультируйтесь о
нагрузках при механизмах с большей вместимостью кабля.
18 18
12 12
6 6
3,4
1,3 t
t
50
75
100
m/min
45
75
105
m/min
19
112
27
114
CFU-7.5
7,5 kW
GFU-7.5
3x 7,5 kW
TRA-7.5
2x 75 Nm
* TRA-7.5VC
2x 75 Nm
0 20 m/min 0 20 m/min
0 94 m/min 0 0,7 rpm
3XR72 5XR72 5XR72
LC 2100
EFU6-65-45 180 kVA
*
400 V
EFU6L-65-45 CFU-7.5 (3x) GFU-7.5 (2x) TRA-7.5 3ph 180 kVA
EFU4-110-45 50 Hz 250 kVA
EFU4L-110-45 250 kVA
64,9 m nº Ref. h
63,1 m 1 S25 2,0 5,5
H h (m)
C/25
H
C/25
1
1 (m)
1
1
42,6 m 1
1
H 1
C/25
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1 En servicio / In operation / 3XR72...... 105 t
1 En service / In Betrieb / In
1,6 m 1 1,9 m 1 servizio / При работе 5XR72...... 107 t
1
Z máx.
Fuera de servicio / Out
Z Z PS5 of service / Hors service 3XR72........ 74 t
4,5 6,0 m
m / Ausser Betrieb / Fuori
3XA72 5XA72 servizio / В стационарном 5XR72...... 132 t
3XR72 5XR72 ES72 состоянии
Otras zonas de viento o alturas superiores consultar / Other wind zones or additional hook heights on request / Autres zones de vent ou des hauteurs supplémentaires sur demande /
Andere Windzonen oder weitere Hakenhöhen auf Anfrage / Per zone con velocità del vento particolari o altezze superiori consultare il fabbricante / При других ветренных зонах о при
бóльшой высоте проконсультируйтесь с нами
DS.1308.09 02/13 Reserva de modificaciones. Subject to modifications. Modifications reservées. Konstruktionsänderungen vorbehalten.
Il Fabbricante si riserva la facoltà di apportare modifiche. Возможны изменения.
21LC290/18 t
GRÚA ARRIOSTRADA GRÚA TREPADORA
Braced crane / Grue à entretoisement / Abgespannter Kran / Internal climbing crane / Grue avec cage de télescopage intérieure / Kran
Gru ancorata / Наращиваемый кран mit klettern im Gebäude / Gru in rampante in cavedio / Монтажная клеть
98,9 m
96,8 m
H C/25
H
C/25
6
85,8 m 6
82,4 m 6
80,3 m H C/25 6
H C/25 6
74,8 m H C/25 6 6
LC 2100
6 6
69,3 m H C/25 6 6 6
6 6
65,6 m H C/25 6 6 6 6
H C/25 6 7
6 6 6 6 7
6 6 9
6 6 6 6 9
6 6 10
6 6 6 6 10
6 6 10
6 6 6 6 10
6 6 11
6 6 6 7 11
6 6 11
6 6 6 9 11
6 6 12
6 6 6 10 12
6 6 13
6 6 6 10 13
6 7 13
6 6 7 10 13
6 8 13
6 7 8 10 13
6 9 13
6 8 9 11 13
1,9 m 6 2,2 m 10 2,2 m 13
6 8 10 11 13
Load diagrams shown on following pages are valid for cranes with height under hook of about 100 m.
Above this height it should take into consideration the weight of the additional hoisting cable, reducing
the load capacity of the crane according to the attached tables.
Reduction of loads
from 100 from 200 from 300 from 400 from 500 from 600
to 200 m to 300 m to 400 m to 500 m to 600 m to 700 m
The reduction of loads depends on the number of reevings and on the weight of the added hoisting ca-
ble. For medium heights under hook, the weight “P” of the added hoisting cable must be reduced from
suspended “Q” load on the crane.
Q Q
Rope Weight per
diameter meter of cable
(mm) (kg)
21LC/12 t
18 1,5 h >100 m
21LC/18 t
21LC/24 t
21LC/36 t 22 2,2
21LC/48 t
Q+P
(t)
+10%
Single trolley (2 falls)
(m)
(t)
+10%
Motor
9 Make............................... LEROY SOMMER
Power ................................................ 50 kW
6 Brake
Type..............................................FCPL60H
3 Model........................................ FCPL60-2H
1,1 Drum
t Drum capacity................... 790 m in 3 layers
60
100
140
m/min
30
150
Máx. h.u.h. SC................................... 395 m
Máx. h.u.h. DC................................... 197 m
Operating voltage
18 Voltage............................400 V, 3 ph, 50 Hz
12
6
2,2
t
30
50
70
m/min
15
75
Motor
Make............................................. BESOZZI
Power .................................................... 7,5 kW
(t) Brake
18 Type............................................... BFK 458
Model........................................ BFK 458.16
Operating voltage
9 Voltage............................400 V, 3 ph, 50 Hz
0 47 94 (m/min)
Motor
Make............................................. BESOZZI
Power ..............................................7,5 kgm
-1 Brake
min 0 0,7 Type........................................................ GR
Model................................................... GR 7
Operating voltage
Voltage............................400 V, 3 ph, 50 Hz
Motor
Make............................................. BESOZZI
Power ........................................2 x 7,5 kgm
Brake
m/min 0 20 Type........................................................ MS
Model............................................... 110 MS
Operating voltage
0 20 (m/min) Voltage.....................................400 V 50 Hz
Motor
Make............................................. BESOZZI
Power ........................................4 x 7,5 kgm
Brake
m/min 0 20 Type........................................................... S
Model.................................................. 100 S
Operating voltage
0 20 (m/min) Voltage............................400 V, 3 ph, 50 Hz
Motor
Make............................................. BESOZZI
Power ........................................4 x 7,5 kgm
Brake
m/min 0 20 Type........................................................... S
Model.................................................. 100 S
Operating voltage
0 20 (m/min) Voltage............................400 V, 3 ph, 50 Hz
Motor
(t) Make.................................. LEROY SOMER
1,5 Power ............................................... 2,2 kW
I Brake
Type......................................................FCO
SR 8 m/min Model.............................................FCO-100
1,5 t
Drum
0 8 Drum capacity................... 160 m in 8 layers
(m/min) Máx. h.u.h. .......................................... 80 m
Operating voltage
Voltage............................400 V, 3 ph, 50 Hz
Motor
Make..................................................... ABB
Power ................................................ 20 CV
Operating voltage
Voltage............................400 V, 3 ph, 50 Hz
Pump
Make..............................................PARKER
Model.....................................PAF-20RK-3C
PS3 FOOT
1,55
0,40
0,40
4 x 120 kg
PS4 FOOT
1,98
0,40
0,40
4 x 190 kg
PS5 FOOT
1,98
0,40
0,40
4 x 220 kg
Сomplete 6000 kg
Transport 5100 kg
4 x 150 kg 4 x 60 kg 4 x 90 kg 1 x 75 kg
1 x 40 kg 4 x 60 kg 4 x 9 kg 1 x 14 kg
Сomplete 10200 kg
Transport 5100 kg
2 x 90 kg 4 x 60 kg 1 x 75 kg
1 x 40 kg 1 x 9 kg 1 x 14 kg
UNDERCARRIAGE
Complete
Transport
ARM PLATFORM
PLATFORM LADDER
UNDERCARRIAGE
Transport
ARM PLATFORM
PLATFORM LADDER
2630 kg
1,82 0,20
4 x 575 kg 50 kg 132 kg
3,14 0,70
0,47
1,05
1,05
0,23
0,66 5,80
1,44
1,82
35 kg 35 kg 2 x 18 kg 2 x 20 kg
2930 kg
1,82 0,20
4 x 650 kg 50 kg 132 kg
3,14 0,70
0,47
1,05
1,05
0,23
0,66 5,80
1,44
1,82
35 kg 35 kg 2 x 18 kg 2 x 20 kg
2930 kg
1,82 0,20
4 x 650 kg 50 kg 132 kg
3,14 0,70
0,47
1,05
1,05
0,23
0,66 5,80
1,44
1,82
35 kg 35 kg 2 x 18 kg 2 x 20 kg
3370 kg
1,82 0,20
4 x 760 kg 50 kg 132 kg
3,14 0,70
0,47
1,05
1,05
0,23
0,66 5,80
1,44
1,82
35 kg 35 kg 2 x 18 kg 2 x 20 kg
3370 kg
1,82 0,20
4 x 760 kg 50 kg 132 kg
3,14 0,70
0,47
1,05
1,05
0,23
0,66 5,80
1,44
1,82
35 kg 35 kg 2 x 18 kg 2 x 20 kg
CM215 + SM21-K2/S25
7,10
12500 kg
CM215
2,50
5,40
1,57
3800 kg
LADDER
2,10
0,48
0,10
11 kg
SM21-K2/S25
2,40
1,90
2,46 2,35
LADDER
2,20
0,48
0,09
3800 kg
PLATFORM + CABIN
2,30
4,20 1,80
1300 kg
0,25
0,95
0,25
0,36
2,18
2,30
0,17
0,70 0,70
145 kg 2 x 30 kg 4 kg 4 kg
2,06 1,11
1,94
1,20
1,20
0,14
0,81
14 kg 9 kg 9 kg
3,85
10,45 1,40 7140 kg
3,70
10,40 1,40 5500 kg
3,70
10,35 1,40
4850 kg
10,35 1,40
4230 kg
2,50
10,35 1,40
3830 kg
2,45
10,30 1,40
4300 kg
2,45
10,30 1,40
3700 kg
10,30 1,40
3300 kg
10,30 1,40
3600 kg
2,45
10,30 1,40
3000 kg
2,45
10,30 1,40 2600 kg
2,40
10,25 1,40
2700 kg
10,25 1,40
2310 kg
4,20 1,40
400 kg
1,80
10,25 1,40
1850 kg
1,75
10,25 1,40
1450 kg
1,75
10,10 1,40
1050 kg
10,20 1,40
700 kg
0,85
95 kg
STRUT INDICATOR
1,40
0,70
1,65
0,75
1,50
15 kg 214 kg
0,35
0,80
0,60
0,90
220 mm 210 mm 220 mm 210 mm
11 kg 12 kg 5 kg
1,40
1,05
1,15
1,95
0,60
250 kg 290 kg
1,65
1,30
1,30
0,60
1,15
120 kg 2,00 540 kg
25 kg 25 kg
FM218
3,70
4,40
1,40
1880 kg
FM215
2,50
8,40
1,75
3270 kg
BM215A
- Including hoisting machinery and
electrical equipment.
- Excluding hoisting rope and
auxiliary-jib.
EFU4-37-30 10000 kg
EFU5-50-30 11000 kg
EFU6-65-30 11500 kg
EFU5-50-45 11000 kg
EFU6-65-45 12000 kg
EFU4-110-45 12000 kg
EFU6-65-60 12500 kg
EFU4-110-60 12500 kg
Weights excluding hoisting rope.
EFU4L-110-60 13500 kg
FRAME
2,60
2,20 11,55
6200 kg
5,14
5,20
1,10
1275 mm x 4
0,75
4 x 165 kg 4 x 30 kg
0,85 0,55
1,10
1,10
739 mm 440 mm
2 x 8 kg 4 x 7 kg
MA02 FRAME
950 kg
2 x 250 kg 2 x 155 kg 4 x 35 kg
CAGE
TRANSPORT
13
9,
2,52
2,32
10800 kg
FRAME
13
9,
2,52
2,32
4950 kg
SUPPORT SCALE
0,26 1,87
1,10
0,17
0,10
1,45
475 kg 2 x 73 kg
SCALE SCALE
5,31 2,25
0,14
0,14
0,10
0,10
2 x 260 kg 2 x 115 kg
0,28 1,60
1,40
1,82
1,60
0,50
950 kg 230 kg
BLOCK HANDLE
1,00
0,46
0,93
2,56 0,10
0,50
540 kg 46 kg
SUPPORT SUPPORT
0,25
0,38 0,21
0,60
0,51
0,22
35 kg 28 kg
SUPPORT SUPPORT
0,44
0,72
2,48 0,40
2,48 0,48
190 kg 177 kg
FRAME FRAME
2,48
0,52
2,48 2,48
2,48
2,48
290 kg 320 kg
PLATFORM PLATFORM
2,79 0,29
0,48
0,84
0,63 2,66
68 kg 2 x 72 kg
PLATFORM PLATFORM
0,84
79 kg 74 kg
PLATFORM PLATFORM
1,04
72 kg 79 kg
PLATFORM PLATFORM
0,65
0,65
2 x 33 kg 2 x 33 kg
PLATFORM PLATFORM
0,68
0,68
1,18 0,83 1,18 0,83
50 kg 50 kg
2,28
0,88
1,10
2,75 1,29 1120 mm 1120 mm
134 kg 4 x 14 kg
3,84 1,78
1,10
1,10
2 x 23 kg 4 x 12 kg
1,10
1,10
5 x 8 kg 2 x 7 kg 2 x 8 kg
LADDER
0,48
7,00
53 kg
1,98
1,48
0,48
1,10
0,81
2,70
1794 mm
11 kg 19 kg 18 kg
3,60 0,71
1,63
0,75
0,55 0,85
47 kg 375 kg
3XA72; 3XR72
L
74 70 64 60 54 50 44 40
Block A: 5400 kg H
Block B: 2700 kg
12 x A 12 x A 14 x A
42,6 12 x A 14 x A 14 x A 18 x A 18 x A
1000 2xB 2xB 2xB
A
450
0 12 x A 12 x A 14 x A
500 37,1 12 x A 12 x A 14 x A 18 x A 18 x A
2xB 2xB 2xB
12 x A 12 x A 14 x A
31,6 12 x A 12 x A 14 x A 18 x A 18 x A
B 2xB 2xB 2xB
250
12 x A 12 x A 14 x A
26,1 12 x A 12 x A 14 x A 18 x A 18 x A
2xB 2xB 2xB
12 x A 12 x A 14 x A
20,6 12 x A 12 x A 14 x A 18 x A 18 x A
2xB 2xB 2xB
5XA72; 5XR72
L
74 70 64 60 54 50 44 40
H
64,9 14 x A 14 x A 14 x A 14 x A 14 x A 14 x A 16 x A 16 x A
Block A: 6750 kg
59,4 10 x A 10 x A 12 x A 12 x A 12 x A 12 x A 14 x A 14 x A
1500
A
0 53,9 8xA 8xA 10 x A 10 x A 10 x A 10 x A 12 x A 12 x A
625
300
3201-10352
Block : 5400 kg
A
Mark the slab weight in an
indeleble way
500
15
45º
2100 1200
3500 +1 500
1000
500
4500
90
60
0
r3
80
Ø
190
22
+0
130 -2
1- Tube Ø 139x5 (S235JR) L=500 1 p.
2- Lifting point Ø 20 (S355JO) 1 p.
3- ROUNDBAR Ø 20 (S235JR) L=350 1 p.
4420
920
1 2 4
900 440
3 4
250
250
Block : 2700 kg
A
Mark the slab weight in an
indeleble way
250
15
45º
2100 1200
3500 +1 500
1000
500
4500
90
60
0
r3
80
Ø
190
22
+0
130 -2
4420
920
1 2 4
900 190
3 4
250
250
3201-10354
Block : 6750 kg
300
45º
2500 1875
2800 1725
1500
750
4510 +1 870
6250
WEIGHT
BLOCK
(kg)
A 4000
B 2000
C 1000
21LC290/12 t
Jib lenght (m)
74 m 70 m 64 m 60 m 54 m 50 m 44 m 40 m
5xA
5xA 5xA 4xA 3xA 3xA
EFU3-37-30 1xB 5xA 4xA
1xB 1XC 1xC 1xB 1xC
1xC
4xA 2xA
4xA 4xA 4xA 3xA 3xA
EFU5-50-30 2xB 3xA 1xB
2xB 1xB 1xC 1xB 1xB
1xC 1xC
4xA 4xA 4xA 2xA
4xA 3xA 3xA
EFU6-65-30 2xB 2xB 1xB 3xA 1xB
1xB 1xB 1xB
1xC 1xC 1xC 1xC
21LC290/18 t
Jib lenght (m)
74 m 70 m 64 m 60 m 54 m 50 m 44 m 40 m
4xA
4xA 4xA 4xA 3xA 3xA 2xA
EFU5-50-45 2xB 3xA
2xB 1XB 1xC 1xB 1xB 1xB
1xC
4xA 4xA 4xA 2xA
4xA 3xA 3xA
EFU6-65-45 2xB 2xB 1xB 3xA 1xB
1xB 1xB 1xB
1xC 1xC 1xC 1xC
4xA 4xA 2xA
4xA 4XA 3XA 3XA 2xA
EFU4-110-45 2xB 2xB 1xB
1xB 1xB 1xB 1xB 1xB
1xC 1xC 1xC
3207-10194
Block: 4000 kg
A B C
1- Round bar Ø50 (S275JR) L=800 1 p. 1- Round bar Ø80 (S275JR) L=750 1 p. 1- Round bar Ø50 (S275JR) L=375 2 p.
2- Round bar Ø25 (S275JR) L=15 2 p.
3207-10195
Block: 2000 kg
A B C
1- Round bar Ø50 (S275JR) L=800 1 p. 1- Round bar Ø80 (S275JR) L=750 1 p. 1- Round bar Ø50 (S275JR) L=375 2 p.
2- Round bar Ø25 (S275JR) L=15 2 p.
3207-10196
Block: 1000 kg
A B C
1- Round bar Ø50 (S275JR) L=800 1 p. 1- Round bar Ø80 (S275JR) L=750 1 p. 1- Round bar Ø50 (S275JR) L=375 2 p.
2- Round bar Ø25 (S275JR) L=15 2 p.
CRANE’S DESIGNATION:
TOWER CRANES
SAFETY STANDARDS:
Machinery Directive 2006/42/EC
Electro magnetic compatibility Directive 2004/108/EC
Noise emission Directive 2000/14/EC modified by 2005/88/EC
Low voltage Directive 2006/95/CE
Cranes – Safety – Tower cranes EN14439
CALCULATION STANDARDS:
DIN 15018-1
DIN 15018-2
DIN 15019-1
FEM 1.001
FEM 1.005
EN 14439 Annex A
CLASSIFICATION GROUPS:
WIND CONDITIONS:
In service: 72 km/h (45 mph)
Out of service: C – region, 25 years recurrence interval (*)
(*) If more severe wind conditions are expected, please, contact to Linden Comansa for the best
solution
STEEL STANDARDS:
EN 10025
EN 10083-1
- DECLARATION OF CONFORMITY
We hereby certify that:
TOWER CRANE
TYPE: XXXX
EN 14439
21LC
Guaranteed sound Measured sound
Hoisting mechanism power level power level
Lwa Lwam
EFU3-37-__ 97 dB 91,7 dB
EFU5-50-__ 98 dB 97,5 dB
EFU6-65-__ 98 dB 97,5 dB
EFU4-110-__ 98 dB 97,5 dB
EFU4L-110-__ 98 dB 97,5 dB
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
Several points must be taken into account before selecting the crane site:
- Requirements inherent to the construction work
- Crane characteristics
- National and local regulations applicable in the site location
1 Minimum clear space for personnel passage between most outreaching crane parts and any obstacle
must be A=0,60 m width by B= 2,50 m height (Fig. 1)
In case this condition cannot be met, access of personnel to this hazardous area shall be prohibited.
Fig. 1
2 No part of the crane or the suspended loads should ever be allowed to come into contact with power
lines.
If they are high voltage lines the crane should never overhang them for any reason, although it may pass
underneath them. There should always be a safety space of 3.3 m + U/100 with a minimum of 5 metres
measured from its horizontal projection between these lines and any element of the crane or load (U
being the line voltage in kV) (Fig.2).
Fig. 2
3 If two cranes are close together, their location must be established such that there is a minimum
distance of D= 2 m between jib and mast parts subject to collide.
The minimum vertical distance between the lowest point (hook at the top position, or overhead
counterweight) of the highest crane and the highest point, subject to collide, of the other crane shall be
E= 3 m.
Fig. 3
4 For travelling cranes, an appropriate system must be provided to prevent cranes from getting closer
than any of the distances mentioned in the previous paragraph.
5 In case of cranes working on top of others, adequate measures must be taken to prevent the hoisting
cable or the load from colliding with any part of the lower crane.
6 If the crane is located near a slope, minimum safety distances must be kept for protection against
slips.
If keeping safety distances should not be possible, the slope must be reinforced to withstand the loads
transmitted by the crane. (Fig. 4)
F F
Fig. 4
7 The site must allow for safe erection and dismantling operations.
8 All crane conditions both initial and with later tower extensions and possible stays must be taken into
account.
1 Excavate.
Prepare 4 levelling blocks for the fixing angles. (Fig. 1)
Levelling Blocks
Fig. 1
4 Before erecting crane, ensure that concrete is duly cured to prevent possibility of movement.
5 Connect to ground the anchor base. See instructions in chapter "ELECTRICAL INSTALLATION"
Fig. 2
SET-UP
ES72 ES73 ES43 ES63 ES6A3 ES83
CRANE
21 LC 290 EPS52 -- -- -- --
21 LC 750 -- -- -- -- -- EPD63
FIXING ANGLES
PS5 PD3-2 PD4-2 PD5 PD6
MAST SECTIONS
S25 EPS52 -- -- -- --
S35 EPS53 -- -- -- --
TD33A
-- EPD3-23 -- -- --
D33
TD34
-- -- EPD4-23 -- --
D34
D35 -- -- -- EPD53 --
TD36B
-- -- -- -- EPD66
D36
ATTENTION:
Check the anchoring feet position in
1794±0,5 relation to the X and Y axes.
1680
2000
600 AxA Q
1 3 4 5
2
( m) (t)
5,0x5,0 120
5,5x5,5 145
6,0x6,0 173
6,5x6,5 203
A 7,0x7,0 235
7,5x7,5 270
8,0x8,0 307
GRATING
1 250 x 250
A
GRATING
2 150 x 150
CONCRETE RESISTANCE.................HA-30/F/20/IIa
MIN. CONCRETE DENSITY...............2400 kg/m³
MIN. STEEL RESISTANCE.................B 500 S
ALL MEASUREMENS ARE IN MILLIMETRES WEIGHT OF FOUNDATIONS.............Q t
PS5
450
ALL MEASUREMENS ARE IN MILLIMETRES
L L
L
40
40
40
40
50º
1 2 5
3 4
1 2 3 4 5
AxA Material Material Material
(m) Material Material
L L Quantity Quantity Quantity
Quantity Quantity
Length Length Length
5,0x5,0 4900 4900
Round Ø 10 (B 500 S)
Round Ø 20 (B 500 S)
Round Ø 20 (B 500 S)
Mesh 150 x 150
Mesh 250 x 250
L=1900 (mm)
L=2000 (mm)
L=1230 (mm)
16 Units
Anchor base must be electrically connected to ground, see instruction "ELECTRIC WIRING AND
GROUNDING" in chapter ELECTRICAL INSTALLATION of this manual.
Ax
G
Ø Diameter (mm)
L Length (mm)
Q Quantity
1 2
ø L Q ø L Q AxG
DESIGNATION CODE Reference
SC
ES72 DC
Mt -Torsional moment. (kNm)
Mt
Mv -Overturning moment. (kNm)
P -Weight of crane (kN)
Mv Fh -Horizontal reaction (kN)
Fh P Q -Mass of foundation concrete (kN)
e -Excentricity (m)
h
Q σt -Pressure on ground (kN/m²)
ea
AxA σt -Permissible ground pressure (kN/m²)
adm
L -Max. hook radius
SC -SIMPLE TROLLEY (2 reenvíos)
e= Mv + Fh x h < A DC -DOUBLE TROLLEY (4 reenvíos)
P+Q 3 H -Hook height
σt = 2(P + Q)
< σtadm A -Foundation dimensions
3xAxa
Mv 3812 3887 4085 4039 4097 4148 4427 4416 6056 6106 6135 6135 6069 6205 6344 6379
63,1
Fh 59 58 57 57 56 56 55 55 120 120 119 118 117 117 116 115
11 x S25
P 1054 1044 1035 1018 991 995 968 965 1027 1014 998 978 945 942 898 885
Mv 3486 3562 3753 3712 3772 3823 4093 4081 5367 5421 5454 5457 5396 5534 5679 5716
57,6
Fh 56 56 55 54 53 53 53 53 111 110 109 109 108 107 106 106
10 x S25
P 1021 1011 1002 985 958 962 934 931 994 981 965 945 912 908 864 851
Mv 3196 3271 3458 3420 3482 3532 3795 3783 4731 4787 4825 4830 4775 4915 5066 5106
52,1
Fh 53 53 52 52 51 51 50 50 101 101 100 99 98 98 97 96
9 x S25
P 988 978 969 951 924 928 901 898 961 948 932 911 878 875 831 818
Mv 2938 3013 3195 3161 3224 3274 3530 3517 4152 4210 4253 4260 4211 4354 4511 4552
46,6
Fh 51 50 49 49 48 48 47 47 92 91 90 90 89 89 88 87
8 x S25
P 955 945 935 918 891 895 868 865 928 915 898 878 845 842 798 785
Mv 2711 2786 2964 2932 2996 3045 3295 3282 3620 3680 3728 3737 3693 3838 4001 4045
41,1
Fh 48 48 47 46 46 45 45 45 82 82 81 81 80 79 78 78
7 x S25
P 921 911 902 885 858 862 835 832 894 881 865 845 812 809 765 752
Mv 2512 2586 2761 2731 2796 2845 3090 3076 3143 3205 3259 3270 3232 3379 3548 3593
35,6
Fh 45 45 44 44 43 43 42 42 73 73 72 71 70 70 69 69
6 x S25
P 888 878 869 852 824 828 801 798 861 848 832 812 778 776 731 718
Mv 2339 2413 2585 2557 2623 2672 2911 2897 2712 2777 2836 2849 2816 2966 3140 3188
30,1
Fh 43 42 41 41 40 40 39 39 64 63 62 62 61 60 59 59
5 x S25
P 855 845 836 818 791 795 768 765 828 815 799 778 745 742 698 685
Mv
Fh
P
A x A x h (m)
A x A x h -Foundation dimensions
D1 5,0 x 5,0 x 2,0 H -Hook height
D2 5,5 x 5,5 x 2,0 SR -Single reeving (2 reevings)
D3 6,0 x 6,0 x 2,0 DR -Double reeving (4 reevings)
D4 6,5 x 6,5 x 2,0
D5 7,0 x 7,0 x 2,0
D6 7,5 x 7,5 x 2,0 PRESSURE UNDER FOUNDATION IN
D7 8,0 x 8,0 x 2,0 kg/cm²
H D1 D2 D3 D4 D5 D6 D7
The cross shaped undercarriage consists of one beam and two arms that open having the form of an X.
They are fixed by rods and bolh. To the cross shaped undercarriage are screwed anchorage feet the differnt
types of masts.
To each end of the X is fitted a stabilising base, (fig. 1) a rail travelling. (fig. 2).
These bases must be supported on four concrete platforms or on a single continuous base, and must be big
enough to take the whole undercarriage suitably.
Foundation size is given by the characteristics of the ground and the pressure per corner (see sheets on
“BALLAST & REACTIONS”) in following pages.
In case of rail travelling, it is mounted on the travelling. In order to realise the rail travelling, see documents
"Installation of the crane and of the travelling" and "TRACK ERECTION" in following pages.
The soil must be firm and resistend, and must be adequate to withstand the loads transmitted to the
base.
The crane site must be big enough to allow erection manoeuvres, and any obstacles such as buildings
or power lines nearby should be taken into account
Base must be electrically connected to ground, see instruction "ELECTRIC WIRING AND GROUNDING"
in chapter ELECTRICAL INSTALLATION of this manual.
Fig. 1 Fig. 2
L=3,2 m
L=3,8 m L x L depending on the base
L=4,5 m
SUPPORT
PYRAMID
(Optional)
A x A x h (m)
CONCRETE RESISTANCE.................HA-30/F/20/IIa
MIN. CONCRETE DENSITY...............2400 kg/m³
Millimetre dimension all MIN. STEEL RESISTANCE.................B 500 S
PYRAMID
A x A x h (m)
0 CONTENTS
1 GENERAL
2 TRACK ERECTION
3 TRACK INSTALLATION
4 TRACK TOLERANCES
5 TRACK END
1 GENERAL
When selecting the crane site, recommendations given in “SITE, WARNINGS” document at the beginning of
this chapter, must be taken into account.
As a general rule, standard UNE 58101-2:2011, must be complied with, notwithstanding other applicable regu-
lations or standards required in the crane site location.
2 TRACK ERECTION
The user must make sure (through certified documentation on soil characteristics or geotechnical surveys) that
the soil where the crane is erected, as well as the foundations are adequate to correctly withstand the maximum
loads specified by the manufacturer.
Track rails and other track elements shall be designed and installed in such a manner as to guaranteeing an
effective transmission of the maximum loads specified by the manufacturer without permanent deflections.
RAIL
RAIL
L B e A H D
kg/m
Prefab track
3 TRACK INSTALLATION
Track rails must be electrically connected to ground see instruction "ELECTRIC WIRING AND GROUNDING"
in chapter ELECTRICAL INSTALLATION of this manual.
L (m)
B-B
B B
A (mm)
RAIL
4 TRACK TOLERANCES
Longitudinal levelling.
Rolling surface of the same rail shall be levelled to a maximum of 1/1000 of the track width “L”.
Transversal levelling
Difference in height between track rails shall not be more than 1/1000 of track width “L”.
10,0 30,0
Track condition
If used rails are employed, the flat worn surface of the head shall be fairly centered on the rail plane of
symmetry.
IF DURING OPERATION ANY OF THESE TRACK TOLERANCES ARE EXCEEDED IN MORE THAN
20% NECESSARY ACTION MUST BE TAKEN.
In case of bends, in slopes, or under special circumstances, the user must comply with the instructions and
applicable specifications given by the manufacturer for the specific case.
5 TRACK ENDS.
Track ends will be provided with:
- End of travel limiter actuator (limiter ramp) for the crane to stop at a minimum distance of 0,5 m from the
track stops.
- Bumpers placed at least 1 m before the end of the track.
TRACK STOP
LIMITER RAMP
TRACK END
Necessary data for material acquisition and erection shall be given by the manufacturer for each type of
crane.
H G
3XA72 SC 9000 kg
3XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
4,5 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
4,5 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
7 x S25
6 x S25
5 x S25
4 x S25
3 x S25
L
(m)
3XA72 SC 9000 kg
3XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
4,5 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
4,5 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
7 x S25
6 x S25
5 x S25
4 x S25
3 x S25
L
(m)
3XA72 SC 9000 kg
3XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
4,5 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
4,5 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
7 x S25
6 x S25
5 x S25
4 x S25
3 x S25
L
(m)
3XA72 SC 9000 kg
3XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
4,5 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
4,5 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
7 x S25
6 x S25
5 x S25
4 x S25
3 x S25
L
(m)
3XA72 SUPPORT
A x A x h (m)
A x A x h -Foundation dimensions. (m)
D1 1.0 x 1.0 x 0.5
H -Hook height. (m)
D2 1.2 x 1.2 x 0.5
D3 1.4 x 1.4 x 0.5 SC -Single trolley. (2 falls)
D4 1.6 x 1.6 x 0.5 DC -Double trolley.(4 falls) PIRAMIDE
D5 1.8 x 1.8 x 0.5 σ S -Presure under foundation. (kg/cm²) (optional)
D6 2.0 x 2.0 x 0.5 σ P -Presure under support cones. (kg/cm²)
σS
H σA σP D1 D2 D3 D4 D5 D6
42,6 65,8 16,5 10,7 7,4 5,5 4,2 3,4 2,8
37,1 61,7 15,4 10,0 7,0 5,2 4,0 3,2 2,6
31,6 58,1 14,5 9,4 6,6 4,9 3,8 3,0 2,4
SC
26,1 55,2 13,8 9,0 6,3 4,6 3,6 2,8 2,3
DC
20,6 53,4 13,3 8,7 6,1 4,5 3,5 2,8 2,3
5XA72 SC 9000 kg
5XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
6,0 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
6,0 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
10 x S25
11 x S25
TOWER
9 x S25
8 x S25
7 x S25
6 x S25
5 x S25
L
(m)
5XA72 SC 9000 kg
5XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
6,0 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
6,0 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
10 x S25
11 x S25
TOWER
9 x S25
8 x S25
7 x S25
6 x S25
5 x S25
L
(m)
5XA72 SC 9000 kg
5XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
6,0 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
6,0 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
10 x S25
11 x S25
TOWER
9 x S25
8 x S25
7 x S25
6 x S25
5 x S25
L
(m)
5XA72 SC 9000 kg
5XR72 DC 18000 kg
S...............In service
I FS.............Out of service
A B L...............Hook radius (m)
H...............Height under hook (m)
G...............Base ballast (t)
6,0 m SC............Simgle trolley (4 falls)
DC............Double trolley (8 falls)
C D Z...............Max. FS pressure (kN)
X...............Max. S pressure (kN)
6,0 m
V...............Horizontal force FS (kN)
W..............Horizontal force S (kN)
10 x S25
11 x S25
TOWER
9 x S25
8 x S25
7 x S25
6 x S25
5 x S25
L
(m)
5XA72
A x A x h (m)
A x A x h -Foundation dimensions. (m)
D1 1,6 x 1,6 x 0,6 H -Hook height. (m)
D2 1,8 x 1,8 x 0,6 SC -Single trolley. (2 falls)
D3 2,0 x 2,0 x 0,6 PIRAMIDE
PIRAMIDE
DC -Double trolley.(6 falls)
D4 2,2 x 2,2 x 0,6 σ S -Presure under foundation. (kg/cm²)
D5 2,4 x 2,4 x 0,6 σ P -Presure under support cones. (kg/cm²)
D6 2,6 x 2,6 x 0,6
σS
H σP D1 D2 D3 D4 D5 D6
64,9 10,9 5,3 4,2 3,4 2,9 2,4 2,1
59,4 8,9 4,3 3,5 2,8 2,4 2,0 1,7
53,9 7,6 3,7 3,0 2,4 2,0 1,7 1,5
SC
48,4 7,1 3,5 2,8 2,3 1,9 1,6 1,4
DC
42,9 6,6 3,3 2,6 2,1 1,8 1,5 1,3
37,4 6,2 3,1 2,5 2,0 1,7 1,4 1,3
31,9 5,8 2,9 2,3 1,9 1,6 1,4 1,2
5,8 m
X 4,5 m
Base Composition
Ballast (t) blocks
118,8 22xA
113,4 20xA + 2xB
108,0 20xA
Bloque A: 5400 kg
102,6 18xA + 2xB
Bloque B: 2700 kg
97,2 18xA
1000
91,8 16xA + 2xB
A
4500 86,4 16xA
500
81,0 14xA + 2xB
75,6 14xA
B
70,2 12xA + 2xB
250
64,8 12xA
59,4 10xA + 2xB
54,0 10xA
48,6 8xA + 2xB
43,2 8xA
37,8 6xA + 2xB
32,4 6xA
3201-10352
Block : 5400 kg
A
Mark the slab weight in an
indeleble way
500
15
45º
2100 1200
3500 +1 500
1000
500
4500
90
60
0
r3
80
Ø
190
22
+0
130 -2
1- Tube Ø 139x5 (S235JR) L=500 1 p.
2- Lifting point Ø 20 (S355JO) 1 p.
3- ROUNDBAR Ø 20 (S235JR) L=350 1 p.
4420
920
1 2 4
900 440
3 4
250
250
Block : 2700 kg
A
Mark the slab weight in an
indeleble way
250
15
45º
2100 1200
3500 +1 500
1000
500
4500
90
60
0
r3
80
Ø
190
22
+0
130 -2
4420
920
1 2 4
900 190
3 4
250
250
7,6 m
Bloque A: 6750 kg
1500
A
0
625
300
X6m
Base Composition
Ballast (t) blocks
148,5 22 x A
135,0 20 x A
121,5 18 x A
108,0 16 x A
94,5 14 x A
81,0 12 x A
67,5 10 x A
54,0 8xA
40,5 6xA
27,0 4xA
3201-10354
Block : 6750 kg
300
45º
2500 1875
2800 1725
1500
750
4510 +1 870
6250
1 Erections and dismantling operations shall be carried out by qualified personnel complying with
applicable regulations related to their function and the location where said operations are being
carried out.
2 The user must make sure that erection setup complies with applicable Regulations and Standards.
This is to say:
- Crane position must keep safety distances to other cranes or buildings.
- Foundations, supports and tracks erected in accordance with the loads transmitted by the
crane setup and required alignment and levelling tolerances.
- Power supply and earth connections in accordance with current regulations and crane
electrical data.
- Accessibility and provision of enough space to carry out erection activities in a safe
manner.
3 Keep operation sequences, safety warnings and instructions given in this manual.
5 If a mobile crane is used for erection make sure it is adequate for handling the heaviest part
taking into account its dimensions and the position of the mobile crane on site.
6 Hoisting accessories used for erection must be duly approved for the loads to be handled. Load
slinging and part handling must be done with care (see document “tackle and slings” in chapter
Crane Operation of this manual)
WARNING
WRONG ! RIGHT
0 CONTENTS
1 DESCRIPTION
2 FREESTANDING BASE ASSEMBLY SEQUENCE
3 TRAVELLING BASE ASSEMBLY SEQUENCE.
4 POSITIONING THE BASE BALLAST
1 DESCRIPTION
- The base consists of a girder and two articulated arms that open to form an "X".
The arms are secured to the girder using threaded rods.
- The base has four different surfaces prepared for bolting different anchors according to the different types
of towers that may be used.
Fig. 1 Fig. 2
Posición pies Posición pies
Fig. 3
para torre 1,2 m para torre 1,6 m
Posición pies
Ver documento Ver documento
para torre 2,0 m
MTJ060.0003 MTJ060.0051
Do not remove the transport attachments until the base is supported to avoid accidents due to
the arms opening.
During handling of the base, survey the arms closely to avoid possible accidents due to
sudden opening.
Fig. 4
- Open the arms simultaneously and place the rods (A) to lock the arms in place. (Fig. 5)
B C
A E
Fig. 5 Fig. 6
- Fit the four horizontal tubing bars Ø "C" and fix them at both ends. (Fig. 6)
- Fit the chosen support system and secure it to the base bolts. (Fig. 7)
Fig. 7
- Using the mobile crane, lift the assembly and remove the auxiliaries supports, position the base on the
support platforms (Fig. 6) and level it using the screws (F) (Fig. 8).
Leveling is done with respect to A base machined surfaces or with respect to the uprights of
the foot support B surfaces.
F F
B A
minimum
175 mm
65 mm
maxi-
mum
Fig. 8
- Place the crane base on the ground. See instructions in the section "ELECTRICAL INSTALLATION".
Do not remove the transport attachments until the base is supported to avoid accidents due to
the arms opening.
During handling of the base, survey the arms closely to avoid possible accidents due to
sudden opening.
- Suspend the base using the mobile crane and support it using auxiliary supports. (Fig. 9)
Open the arms simultaneously and place the rods (A) to lock the arms in place. (Fig. 9)
Fit the platform (B). (Fig. 10)
Position the mobile mechanisms, the motors (M) must be located on the long arm of the base and
inside the rails, and secure them to the base. (Fig. 10)
M
Trasvelling B
A
Fig. 8 Fig. 9
- Support the wheels on the rails and secure them using the anchor flanges (G). (Fig. 11)
- Fit the two tube Ø "C" bars, securing them only on one end. (Fig. 11)
- Fit the horizontal IPE "D" bars, bolting them on both ends. (Fig. 11)
- Fit the platform "E" and the stairs "F". (Fig. 11)
- Pace the crane base on the ground. See the instructions in the section "ELECTRICAL INSTALLATION"
C
G
F
E
Fig. 11
Fig. 12
- The ballast blocks cross over one another starting from a height allowing access to the tower.
BASE BASE
- FREESTANDING - MOBILE
Fig. 13
0 CONTENTS
1 DESCRIPTION
2 FREESTANDING BASE ASSEMBLY SEQUENCE
3 TRAVELLING BASE ASSEMBLY SEQUENCE.
4 POSITIONING THE BASE BALLAST
1 DESCRIPTION
- The base consists of a girder and two articulated arms that open to form an "X". The arms are secured
to the girder using threaded rods.
- The base has four different surfaces prepared for bolting different anchors according to the different types
of towers that may be used.
Fig. 1 Fig. 2
Anchor and access positions Anchor and access positions
for tower 1.6 m for tower 2.0 m
Fig. 3 Fig. 4
Anchor and access positions Anchor and access positions
for tower 2.5 m for tower 2.15 m
Fig. 5
- Remove the transport attachments, using the mobile crane, open the articulated arms and secure
them using the rods "A" (Fig. 6).
Be careful during manipulation with cross base arms opening to avoid any accident.
Fig. 6
- Level the base using the bolts of the support screw jacks. (Fig. 7)
Leveling is done with respect to A base machined surfaces or with respect to the uprights of
the foot support B surfaces.
250 mm
máximo
B A
mínimo
90 mm
Fig. 7
Fig. 8 Fig. 9
- Suspend the base using the mobile crane, remove the transport attachments, open the articulated
arms and secure them using the rods "A" (Fig. 10).
Once the base is fitted, secure it to the beams, always fitting the complete diagonal "E" to the
motorised mobile units (Fig. 11).
During handling of the base, survey the arms closely to avoid possible accidents due to sudden opening.
Fig. 10 Fig. 11
Fig. 12
Fig. 13
Fig. 14
DURING ALL THE ERECTION PROCESS, WATCH ALL THE POSSIBLE MOVEMENTS OF THE
LOADS TO AVOID ACCIDENTS.
0 CONTENT
1 ERECTION SECUENCE
2 POSSIBLE SECTION COMBINATIONS
3 GENERAL DIMENSIONS
1 ERECTION SECUENCE
- Put a panel on some balanced supports and assembly another one by pins, forming a right angle with
the first one (Fig. 1).
Fig. 1
- Following the instructions of fig. 2, turn one of the "L" for its later erection.
1º- To proceed to the section preparation putting it in a way which forms a triangle on the floor.
Fix slings through panel lattice window.
2º- Hang the "L" with cables of the same leng and taking as mooring points the corner beams, as it
indicates in figure 2.
3º- Finish the erection of the section assembly the two "L" by pins.
1 2
MOORING
MOORING
POINTS
POINTS
Fig. 2
DETAILS A
FIXING THE PROTECTION
Fig. 3
EFORE JOINING TWO TOWER SECTIONS MAKE SURE THE CONTACT SURFACES OF THE
B
UPRIGHTS AND THE HOUSING HOLES FOR THE PINS ARE CLEAN AND FREE OF PAINT
RESIDUE.
BEFORE JOINING TWO TOWER SECTIONS APPLYING GREASE TO THE HOUSING HOLES OF
THE PINS AND THE CONTACT SURFACES OF THE UPRIGHTS IS RECOMMENDED.
S22
S22
S23
TS24
TS24
TS24
S24
TS25
S25
3 GENERAL DIMENSIONS
1 2 3 4 5
Ø L Q Ø L Q Ø L Q Ø L Q Ø L Q
S22 55 160 8 16 120 4 20 35 2 20 70 2 20 70 24
"S" "TS"
DETAILS MAST
SECTIONS
ASSEMBLY
H A1 A2 LxG D1 D2
0 CONTENTS
1 SM21-K2/S25 PREPARATION
2 PREPARING THE APEX
3 ASSEMBLY OF APEX AND CROWN SUPPORT
4 ASSEMBLING THE CAB PLATFORM
1 SM21-K2/S25 PREPARATION
- The SM21-K2/S25 comprises the lower tower peak, crown and upper tower peak, rotating mechanisms
and rotation limiter.
Optionally, it may include a rotating collector instead of a rotation limiter.
Optionally, it may include an area limiter
The SM21-K2/S25 assembly arrives from the factory:
- With the lower platform mounted on the lower tower peak.
- With the slewing mechanisms and electrical connections ready to use.
- If the area limiter option is included, it comes assembled and with its electrical connections ready
to use.
- If the collection option is included, it comes disassembled.
Option
Rotating mechanisms Rotating collector
Rotation limiter
Upper
tower peak Option
Area limiter
Crown
Lower
tower peak
Fig. 1
4
D
Fig. 2
- Make sure that platform "D" accessing the lower tower peak is in position.
TESTS
- To test the screws or change the rotating mechanism, see the "Tightening the screws of the rotating
mechanism" document in the "MAINTENANCE" chapter.
- To test the crown screws, see the "Tightening the crown screws" document in the "MAINTENANCE"
chapter.
- To lubricate the crown, see the "Lubricating instructions (rotating crown)" document in the "MAINTENANCE"
chapter.
- To lubricate the rotating mechanism, see the "Lubricating instructions (rotating mechanism)" document
in the "MAINTENANCE" chapter.
- To lubricate the hoisting mechanism see the "Lubricating instructions (hoisting mechanism)" document
in the "MAINTENANCE" chapter.
- The apex arrives from the factory with the platforms installed.
- Check that the support frame of cab "A" is in position and secured with its pins (Fig. 3).
Ø25
120
Fig. 3
Jib
M52
Ø75
36
3
Fig. 4
- Use the truck crane to raise the assembly and attach it to the last tower section. See Fig. 4
Join the lower tower peak to the last tower section.
- Once assembled, place into position the access ladder of the last tower section to the tower peak.
- Once assembled, make the connections indicated in the "ELECTRICAL ASSEMBLY" document in the
"ELECTRICAL INSTALLATION" chapter.
Although the cab platform with the cab can be assembled on the ground, this unbalances the assembly
so it is better to assemble it off the ground, after attaching the lower tower peak to the last tower section.
The platform assembly arrives with the cab and cabinet mounted and wired to each other.
Fig. 5
- Suspend using the truck crane and secure to the upper tower peak with its pins (Fig. 6).
Fig. 6
- Place the enclosure railings "A" between the apex and cab platform (Fig. 7).
C A
Fig. 7
2 1 1 2
FM215 C AM282A
M
5 4 3
2 3 4 5
1
5
Pin
1 Ø=125 L=285
Cotter Pin
2 a=170 b=70 c=6
Bolt
Nut
4 Ø=M24 DIN985
Washer
2 1
3 3
1 3215P1005 2 3205-10142
PSI6x70x170 PSI6x70x170
093124300260088
3301P198.03
ARP25D6916
0985243008
Pin
3205P1005 ø 125 L=220
Cotter pin
PSI6*70*170 d= 6 b= 70 a= 170
Bolt
093124300260088 M= 24 L= 260 DIN0931
Washer
ARP25D6916 ø 25 DIN6916
3301P198.03 D= 45 d= 25 L= 20
Nut
0985243008 M=24 DIN0985
0 CONTENTS
1 PREPARING FM215
2 SUSPENDING SECTION FM215
3 PREPARING BM215A
1 PREPARING FM215
The first counter-jib section is attached to the cat-head.
- It arrives from the factory with footwalk "A" assembled (Fig. 1).
- Check that the counter-jib attachment pin "1" is in position.
- Prepare the counter-jib attachment screws "2" and secure them to the structure to prevent it from
falling when the section is hoisted for assembly.
Fig. 1 A
- The counter-jib sections can either be raised individually, always respecting the assembly sequence.
- The section must be raised at an angle to facilitate their assembly; firstly secure them to their upper part
and then lower them to screw them to their lower part.
- The position of the suspended sections for assembly must be at an angle of approximately 5º, see fig.
2.
Use slings of approximately 5 metres in length and sufficiently resistant for the load.
The truck crane must have slings with a minimum length of 3 m, prepared for the assembly load.
When choosing the slings, see the "Slings and tackles" section in the "CRANE USE" chapter.
aprox. 5º
Fig. 2
4 PREPARING BM215A
- Last counter-jib section.
- It arrives from the factory with the platforms installed and the hoisting mechanism with the hoist cable
wound around the drum.
Fig. 3
Ø25
1
90
Ø15
2
110
3
Fig. 4
SLINGS
- The section comes with welded suspension lugs.
- The position of the slings is shown in Fig. 6.
4 slings prepared for suspending the assembly are supplied with the section (Fig. 5).
Sling 3 includes a tightener for adjusting its length and for suspending the assembly completely balanced.
The truck crane must provide slings with a minimum length of 3 m, prepared for the assembly load.
Tiro 6,5 t
L = 5,3 m
Tiro 6,5 t
L = 2,9 m
Tiro 10,5 t
Tiro 10,5 t
L = 5,2 m
Fig. 5
M
m
in
.3
.3
n
Mi
m
Max. Max.
60º 60º
Fig. 6
0 CONTENTS
1 1st JIB SECTION
2 JIB PASSAGEWAYS
3 TROLLEY MECHANISM
4 JIB SHEAVES
5 JIB END
6 DISTANCE SIGNS
7 AUXILIARY CABLE REEVING
- The automatic tensioning system “D” and maximum load limiter “E” are already in position when the unit
leaves the factory.
"CASE I" -FITTING THE 1º JIB SECTION WITHOUT EITHER TROLLEY OR HOOK
- Support the 1º jib section on trestles (there may be two jib sections of the same height). Fasten the 1º
jib section to the trestle at "A" to prevent it tipping over. (Fig. 2).
Fig. 2
- Put the jib foot pulley support into position, with the start of the 1º jib section stopped up against cross
tie "B".
Use the appropriate flanges for fixing, depending on the jib section. (Fig. 3), the jib section AM299 doesn´t
need clamps.
Fig. 3
- Fix the reeving change ramp catch in position using screws “C”. (Fig. 4).
Fig. 4
- Hang the rear hook support by bolting it to the jib foot pulley support at holes “D”. Turn the support about
pin “D” and bolt together at holes “E”. (Fig. 5).
Fig. 5
"CASE II" -FITTING THE 1º JIB SECTION WITH BACK TROLLEY AND HOOK-
- Support the 1º jib section on trestles (there may be two jib sections of the same height). Fasten the 1º
jib section to the trestle at "A" to prevent it tipping over. (Fig. 6)
Fig. 6
- To realise the union of trolleys and back hooks and auxiliary cable sending back according to is indicated
in point 7 of this instruction.
- Assembly the back trolley and hook on the jib, to take them until the support and to hold them to avoid
that they move.
Place the protections of hook « PG» in its position and to fix it with circlip, to determine the protections
by means of the connecting rod « B» screwing it. (Fig 7).
Fig. 7
- Put the jib foot pulley support into position, with the start of the 1st jib section stopped up against cross
tie “B”. Use the appropriate flanges for fixing, depending on the jib section. (Fig. 8).
Fig. 8
- Fix the reeving change ramp catch in position using screws “C”. (Fig. 9).
Fig. 9
- Hang the rear hook support by bolting it to the jib foot pulley support at holes “D”. Turn the support about
pin “D” and bolt together at holes “E”. (Fig. 10).
Fig. 10
- Take the trolley and rear hook to the start of the jib. Hang the trolley by its front wheels and swing it on
the rear ones so it can be positioned with the hook housed in the support and the trolley supported on
the back wheels.
The trolley engagement catch “GE” must be lifted and resting on the catch ramp “RG”.
Fix the trolley and hook assembly to the hook support. (Fig. 11).
Fig. 11
2 JIB PASSAGEWAYS
- All jib sections have passageways to gain access to the end of the jib. Check that they are correctly fitted.
(Fig. 12).
Fig. 12
- Passage through the automatic tensioning system zone means moving on the outside of the jib. This
involves removing protection chain “A” and fastening the safety harness to fixing bar “B” before moving
outside. (Fig. 13).
Fig. 13
- Make sure protection chains “A” are in position after passing through the automatic tensioning
system.
3 TROLLEY MECHANISM
- The trolley mechanism sits on the jib and is fixed
using screws “A”.
Fig. 14
4 JIB SHEAVES
- For different jib lengths and depending on crane
model, sheaves are fitted to the jib for reeving the
trolley cable. (Fig. 15).
Fig. 15
5 JIB END
- Jib end module JE211, which is common to all the
LC2100 family, incorporates sheaves for reeving
the trolley cables and the hoisting cable rotating
point.
6 DISTANCE SIGNS
- The unit may be fitted with signs showing the distance
to the jib axis.
Fig. 17
7 DISTANCE SIGNS
- It is advisable to carry out a preliminary reeving with an auxiliary cable to make reeving the hoisting cable
easier.
Fig. 18
The trolley and hook must be fixed to the supports during these operations to prevent them falling.
- The front trolley and hook have fixings for fitting to the jib.
Fig. 19
- Hang the hook and fix it by shifting the fixing pin from position “2” to position “1”.
The trolley and hook must be fixed to the supports during these operations to prevent them falling.
Rev: A
1 2 3 3 7 10 13 6
10/02
AM282B AM272A AM262A AM250A AM240 AM230 AM220 AM244 JE211
15 16 16 17 17 17 17 17
8 11 14
17 17 17
4 6
12
JE211 AM244 JE211
17 17 17
ASSEMBLY / DISMANTLING
9 7
AM244 JE211
17 17
Vº Bº
5 6
AM244 JE211
17 17
-
21LC290
060 0292 IB
3 / 060 / 79
ASSEMBLY / DISMANTLING 060 0292 IB
-
JIB SECTIONS; PIN IDENTIFICATION 21LC290
3205P1001 3205P1693
1 PSI6x70x170 2 PSI6x70x170 3 3205P994
PSI6x70x170
10250160.14
4 3205P949
5 6 10250060.14
3205P994 PSA5x60
PSA5x60 3205P947 PSI4x25x85
PSI4x25x85 PSI6x70x170
3205P996
7 8 9
10250160.14 3205P946
3205P996 3205P950 PSI5x40x105
PSI5x40x105 PSA5x60
PSI4x25x85
10250120.14
10 11 12 3205P998
3205P998 3205P951
PSA5x60 3205P945
PSI5x40x105 PSI5x40x105
PSI4x25x85
13 14 10250120.14 15
3205P999 3205P1006
3205P1711 PSA5x60
PSI5x40x105 PSI4x25x85
093124300140088
3301P198.03
ARP25D6916
0985243008
16 17
093124300100088 093120250090088
ARP25D6916 ARP21D6916
0985243008 0985202508
Pin
3205P1001 ø 111 L=200
3205P994 ø 81 L=170
3205P996 ø 71 L=157
3205P998 ø 56 L=117
3205P999 ø 46 L=97
Pin
10250160.14 ø 25 L=160
10250120.14 ø 25 L=120
10250060.14 ø 25 L=60
Bushing
3205P947 D= 100 d= 82 L= 16
3205P950 D= 100 d= 26 L= 54
3205P945 D= 82 d= 57 L= 25
3205P1711 D= 82 d= 47 L= 40
3205P949 D= 82 d= 26 L= 55
3205P951 D= 57 d= 26 L= 34
3205P1006 D= 47 d= 26 L= 26
Cotter pin
PSI6*70*170 d= 6 b= 70 a= 170
PSI5*40*105 d= 5 b= 40 a= 105
PSI4*25*85 d= 4 b= 25 a= 85
PSA5*60 d= 5 a= 60
Bolt
093124300140088 M= 24 L= 140 DIN0931
093120250090088 M= 20 L= 90 DIN0931
Washer
ARP21D6916 ø 21 DIN6916
ARP25D6916 ø 25 DIN6916
3301P198.03 D= 45 d= 25 L= 20
Nut
0985202508 M=20 DIN0985
Pin Bolt
1 Ø=10 L=100 4 d=M16 L= 50 DIN931
DURING THE ERECTION AND DISMANTLING IS NECESSARY TO USE SAFETY HARNESS IN ORDER
TO AVOID ACCIDENTS.
ENSURE THAT THE TOTAL BALLAST FOR THE TRAVELLING OR FIXEND BASE (IF APPLICABLE)
IS IN PLACE BEFORE STARTING THE ERECTION OF JIB AND COUNTERJIB.
THE ASSEMBLY SEQUENCES EXPLAINED HERE BELOW SHOULD BE CARRIED OUT AVOIDING
LONG INTERUPTIONS.
3 2 1 4 5 6 7 9 10 11
BM215 FM215 AM282B AM272A AM262A AM250A AM240 AM230 AM220 AM244 74 m
Assembly counterweight JE211
8 4 blocks (16000 kg)
3 2 1 4 5 6 7 9 10
3 2 1 4 5 6 7 9 10
3 2 1 4 5 6 7 9
3 2 1 4 5 6 7 8
3 2 1 4 5 6 7
3 2 1 4 5 6 7
3 2 1 4 5 6
HOOK AND TROLLEY MUST ALWAYS BE MOUNTED ON THE HOME SECTION OF AM282B.
THE LAST STEP WILL BE TO POSITION THE AERIAL COUNTERWEIGHT IN ITS PLACE AT THE
BM215.
THE ERECTING ORDER OF STRUCTURAL ELEMENTS MUST BE FOLLOWED EXACTLY AS
DESCRIBED.
COUNTERWEIGHT BLOCKS SHOULD ALWAYS BE FITTED STARTING FROM THE REAR OF THE
COUNTERJIB AND WORKING TOWARDS THE TOWER.
SSEMBLY COUNTERWEIGHT BLOCKS IN THE RIGHT ORDER. SEE QUANTITY & POSITION IN
A
"MOUNTING COUNTERWEIGHT BLOCK POSITION".
THE SEQUENCE FOR DISMANTLING IS INVERSE TO ERECTION.
DURING ASSEMBLY / DISMANTLING OPERATIONS THE SLEWING MOVEMENT TO BE USED ONLY
IN FIRST SLEWING SPEED.
THE WIND SPEED DURING THE ERECTION PROCESS SHOULD BE LOW ENOUGH AS TO ALLOW
THE SAFE HANDLING OF THE CRANE ELEMENTES, I.E. APPOX. LESS THAN 25 km/h.
BLOCK WEIGHT(kg)
A 4000
B 2000
C 1000
A A A A
74 B B C 21000
• • • • • • •
A A A A
70 B B 20000
• • • • • •
A A A A
64 B 18000
• • • • •
A A A A
60 C 17000
• • • • •
A A A
54 B 14000
• • • •
A A A
50 B 14000
• • • •
A A A
44 • • • 12000
A A
40 B 10000
• • •
0 CONTENS
1 AERIAL COUNTERWEIGHT
2 ERECTION
1 AERIAL COUNTERWEIGHT
- The overhead counterweight is made up of 4000 kg (Fig. 1), 2000 kg (Fig. 2) and 1000 kg (Fig. 3)
blocks.
- The number of blocks and their position on the counterjib are defined in the following sheets entitled
“COUNTERWEIGHT ERECTION. BLOCK POSITION”, and depend on the hoisting mechanism and jib
length.
2 ERECTION
Safety harness must be used during erection operations..
A1 A1
Fig. 4
- The blocks are positioned on the counterjib and rock on round part “B” until coming to a stop up against
the bottom stop “C”.
- Keep a check on block position to see that they are fitted correctly.
B
D
RIGHT WRONG
Fig. 5
- To move the platform " P" to a comfortable position to facilitate the positioning of the blocks and enlistment
and it uncouples of the same
Fig. 6
3207-10194
Block: 4000 kg
A B C
1- Round bar Ø50 (S275JR) L=800 1 p. 1- Round bar Ø80 (S275JR) L=750 1 p. 1- Round bar Ø50 (S275JR) L=375 2 p.
2- Round bar Ø25 (S275JR) L=15 2 p.
3207-10195
Block: 2000 kg
A B C
1- Round bar Ø50 (S275JR) L=800 1 p. 1- Round bar Ø80 (S275JR) L=750 1 p. 1- Round bar Ø50 (S275JR) L=375 2 p.
2- Round bar Ø25 (S275JR) L=15 2 p.
3207-10196
Block: 1000 kg
A B C
1- Round bar Ø50 (S275JR) L=800 1 p. 1- Round bar Ø80 (S275JR) L=750 1 p. 1- Round bar Ø50 (S275JR) L=375 2 p.
2- Round bar Ø25 (S275JR) L=15 2 p.
LENGTH (m)
L = (H + 2) x n + R + LFM + 40
(FM215 = 8 m)
Maximun capacity of the winch depending on mechanism. (see technical data sheet).
CHARACTERISTICS
Rope diameter 18 mm
Rope grade 1960 N/mm²
Wire rope core Steel core
Weight * 147 kg/100 m
35 (W) x 7 Minimun m breaking force * 229,0 kN
Type Non-rotating cable
Type of lay Lang (zZ)
Protection Galvanised
Lubrication With grease
(According to EN 12385) (*) It may change subject to the manufacturer of the cable.
For use and maintenance of ropes see "INSTRUCTIONS FOR WIRE ROPES" in chapter 6 (Maintenance)
of this manual.
CHARACTERISTICS
Rope diameter 8 mm
Rope grade 1960 N/mm²
Wire rope core Steel core
Weight * 25,6 kg/100 m
Minimun m breaking force * 44,7 kN
6 x 19M Type No Non-rotating cable
Type of lay Right regular lay (sZ)
Protection Galvanised
Lubrication With grease
(According to
EN 12385) (*) It may change subject to the manufacturer of the cable.
For use and maintenance of ropes see "INSTRUCTIONS FOR WIRE ROPES" in chapter 6 (Maintenance)
of this manual.
CHARACTERISTICS
Rope diameter 5 mm
Rope grade 1770 N/mm²
Wire rope core Fiber core
Weight * 9,1 kg/100 m
6 x 19 Minimun m breaking force* 13,6 kN
Type No Non-rotating cable
Type of lay Right regular lay (sZ)
Protection Galvanised
(According to EN Lubrication With grease
12385)
(*) It may change subject to the manufacturer of the cable.
For use and maintenance of ropes see "INSTRUCTIONS FOR WIRE ROPES" in chapter 6 (Maintenance)
of this manual.
SAFETY CABLE
CHARACTERISTICS
Rope diameter 10 mm
Rope grade 1770 N/mm²
Wire rope core Fiber core
Weight * 35,0 kg/100 m
6 x 19 Minimun m breaking force* 54,4 kN
Type No Non-rotating cable
Type of lay Right regular lay (sZ)
Protection Galvanised
(According to EN Lubrication Without grease
12385)
(*) It may change subject to the manufacturer of the cable.
For use and maintenance of ropes see "INSTRUCTIONS FOR WIRE ROPES" in chapter 6 (Maintenance)
of this manual.
LENGTH (m)
L = (H +4) x 2
CHARACTERISTICS
Rope diameter 8 mm
Rope grade 1960 N/mm²
Wire rope core Steel core
Weight 26,2 kg/100 m (*)
Minimun m breaking force 44,7 kN (*)
Type Non-rotating cable
6 x 36
Type of lay Right regular lay (sZ)
Protection Galvanised
Lubrication With grease
(According to EN 12385)
(*) It may change subject to the manufacturer of the cable
For use and maintenance of ropes see "INSTRUCTIONS FOR WIRE ROPES" in chapter 6 (Maintenance)
of this manual.
The number and disposition of the pulleys depend on the length of the jib and counterjib.
FOR RIGGING OPERATIONS WEARING SAFETY HARNESS IS COMPLULSORY
0 CONTENTS
1 CABLE REEVING
2 RECOMMENDED SEQUENCE OF ASSEMBLY
3 TURNBUCKLE OPERATION
4 TROLLEY CABLE FAIL URESAFETY DEVICE
5 RECOMMENDED SEQUENCE OF DISMANTLING
1 CABLE REEVING
Poleas de pluma
Mecanismo de carro
Tambor
Final de pluma
Tensor
Carro delantero
Poleas
Carro trasero
pie de pluma
- The crane leaves the factory with the trolley cables clamped and fully or partially wound on the drum.
- Fit the front trolley at the start of the second jib section.
C B
Fig. 1
- Take the tip of the cable and pass it through the trolley reeving sheaves, then fix the end to the front
trolley using the cable terminal at point “B” (Fig. 1). See the document entitled “Trolley cable reeving” for
sheave position.
- Fasten the trolley to the jib cross member.
Operate the trolley mechanism, moving the trolley forward to take up the slack in the cable without putting
it under too much tension.
IN OPERATION IDLE
Fig. 2
- Fit the moving tensioner sheaves to a fixed point (A) to prepare for reeving.
- Bring the leaving pawels(G) in working position to hold the trolley cable whinch, removing pin (D)
- Reeve the ratchet cable.
Tighten the rope with the open-end ratchet wrench (L), place the wrench between the ratchet drum axle
and the flange teeth, turn the ratchet drum. Repeat the operation until the rope is taut but not too tight
(Fig 2).
- Unwind the rear trolley cable, pass it through the trolley reeving sheaves and fix it to the end of the trolley
at point “C” (Fig. 1). See the document entitled “Trolley cable reeving” for sheave position.
- Release the moving sheave and fit the protections preventing the cable coming off the sheave.
The trolley cable rear reeving will be slack.
- Repeat the rope-tightening operation with the open-end ratchet wrench (L) until the ratchet cable reeving
moving sheave is suspended in the air.
- Release the trolley from the jib cross member.
Initial tensioning of the trolley cable will be done by hoisting a load after cable rigging during crane start
up.
After tensioning, pawl (G) must be brought to rest position and blocked by pin (D) (Fig. 2).
The retaining bolt (R) of the rope-break safety device should be removed from the trolley once the
tightening has been completed to activate the system. See Point 4.
3 TURNBUCKLE OPERATION
The trolley rope turnbuckle is an system which provides tension to the trolley rope through the hoisting rope
when the crane lifts a load.
The system consists of two adjustable springs which are adjusted at the factory and should not be readjusted
without good reason.
Trolley cable tensioning by load hoisting must only be done if necessary, as a general rule during crane start
up and maintenance operations.
After tensioning, pawl (G) must be brought to rest position and blocked by pin (D) (Fig. 4).
Leaving pawls (G) in working position can result into trolley cable over-tensioning, which may lead to
cable failure
Fig. 3
Its adjustment has an influence on the final tension of the trolley rope but it should not be adjusted to
that end.
L1 = 251 mm
65 mm
Fig. 4
If L1 is increased, the trolley rope tension increases.
Tambor ø140
Tambor ø193
Fig. 5
- The trolley has a built-in safety system to block the trolley in case the rope breaks.
- The system leaves the factory prepared and retained in this position by the bolt (R).
- It comprises a series of rods and a spring connected to the trolley ropes, kept in this working position by
the tension of these parts.
ASSEMBLY
Fig. 6
- The bolt should be removed (R) and placed in its housing in order to activate the system, once the reeving
and tightening of the ropes has been carried out.
- If the rope breaks, the spring will close displacing the stop (T), which collides with the latticing of the jib,
causing the trolley to stop.
If the rope-break safety device has operated, the trolley and jib structure should be checked and the
necessary elements repaired or replaced before the crane is restarted.
The tension on the trolley rope should be released before it can be safely dismantled.
- Block the trolley rope-break safety device by reinstalling the retaining bolt (R) in the rod.
- Use the open-end ratchet wrench (L), applying tension to the rope to remove the ratchet drum retaining
pawls (H).
Turn the wrench in the reverse direction, releasing rope from the ratchet drum.
Reinstall the pawls retaining the ratchet drum.
Repeat the operation until the rope is slack.
- Set the hoisting blocks at point (A) and release the cable from the trolley terminals.
Rewind the rope on the trolley mechanism drum for transport.
Fig. 7
For advice on handling cables, see the relevant specifications in the chapter "MAINTENANCE" of the
document entitled "Steel cables".
The crane leaves the factory with the hoisting cable wound on the drum.
Fig. 1
- By moving the trolley, take the end of the hoisting cable to the tip of the jib and fix cable terminal "6" at
the end of the jib at the rotatating point. (Fig. 2).
- Free the hoisting cable from the trolley.
Fig. 2
- Tension the hoisting cable and release the front trolley and hook fixing by shifting the bolt joining them
from position "1" to position "2". (Fig. 3).
- Release the joint connecting the rear trolley and rear hook.
Free the screwed joint between the trolley and hook, then shift the drawbolts joining them from position
"1" to position "2". (Fig. 3).
- Move several trolley and hoisting movements to check for correct cable positioning and rotary movement
of the terminal.
Fig. 3
Fig. 4
A safety harness must be worn during fitting and dismantling work involving hoisting cable reeving.
auxiliary trolley
trolley
hoisting
0 CONTENTS
1 GENERAL DESCRIPTION
2 ASSEMBLY ON JIB
3 REEVING EXECUTION
ALL WORK ON UPPER STRUCTURE OF CRANE TO BE CARRIED OUT USING SAFETY HARNESS
AND WITH PERSONNEL EXCLUSION AREA UNDER CRANE DURING WORK.
1 GENERAL DESCRIPTION
- The assembly of the system can be carried out at the same time that the erection of the complete crane
is carried out or after the crane has been erected and in operation.
«CAD»
«D»
«T»
«CD»
«CAT»
Auxiliari trolley
«PE»
Trolley
Hoisting
«CT»
Fig. 1
2 ASEEMBLY ON JIB
- Incorporate anticatenary trolleys during crane erection.
- Mount on jib and secure to front trolley during jib erection.
Tornillos Tornillos
«CD»
«CAT» «CAD»
Fig. 2
- To facilitate assembly and incorporation to the crane, the trolleys are formed of two parts, which are
connected by means of bolts (Fig. 2)
3 REEVING EXECUTION
3.1 reeving toward the jib end
- Situate the "CT" housed in the rear hook support and the "CD" to approximately 20 m (65.61 ft.)from the
centre of the tower.
- Situate the "CAT" against the "CT" and the "CAD" in the centre of the jib. (Fig. 3)
«CAT»
«CT»
«CD» «CAD»
Fig. 3
- Prepare the anticatenary trolley rope by passing (Fig. 1) it through the sheaves of the inside of the jib
see document "INSTALLATION AND ERECTION" (Auxiliary trolley cables reeving).
- Pass the anticatenary rope end through the end sheaves of the jib and take this to the "D" turnbuckle in
the "CAD" (Fig. 4)
«D»
«CAD»
Fig. 4
GUIDE ROLLERS
«CAT»
Fig. 5
«T»
«CAD»
«D»
Fig. 6
- Secure the pushing pads on the anticatenary rope, in the vicinity of the jib foot. (Fig. 7 )
«PE»
«CT»
Fig. 7
Once the reeving has been carried out, conduct several forward and reverse manoeuvres to check the correct
operation of the system.
0 CONTENTS
REEVING CHANGES MUST ALWAYS BE CARRIED OUT FROM A POSITION THAT ALLOWS THE
PERSON MAKING THE CHANGE TO SEE WHAT IS HAPPENING AND THEREBY PREVENT ANY
FAULT OR MALFUNCTION THAT COULD LEAD TO A HAZARDOUS SITUATION.
THE REEVING CHANGE OPERATION MUST BE CARRIED OUT WITH NO LOAD, SLING OR OTHER
LOAD SUSPENSION TACKLE ON THE HOOK.
ALL CRANE LIMITS MUST BE PROPERLY ADJUSTED. THIS OPERATION INVOLVES THE HOOK UP
AND CARRIAGE BACK TRAVEL LIMITS AS WELL AS THE LOAD LIMITER. SEE THE DOCUMENTS
“HOISTING LIMITER”, “CARRIAGE LIMITER” AND “LOAD LIMITER” IN THE “USE AND MAINTENAN-
CE” CHAPTER.
Fig. 2
- Take the front trolley and hook closer to the start of the jib without going beyond the hook up and trolley
back limits.
- Use the crane control to cancel the trolley back limit, and take the front trolley towards the start of the jib
until it reaches a stop against the rear trolley, operating the front trolley position limiter (LPCD) to enable
the change to continue.
ONCE THE “TROLLEY BACK” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE HOOK UP
MOVEMENT IS LOCKED UNTIL THE FRONT TROLLEY POSITION LIMITER COMES INTO OPERATION.
Fig. 3
- Use the crane control to cancel the hook up limit, and take the front hook up at slow speed until it is
housed in the rear hook and stops up against it.
ONCE THE “HOOK UP” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE TROLLEY
FORWARD MOVEMENT IS LOCKED UNTIL THE FIRST LOAD LIMITER COMES INTO OPERATION.
(LC4).
Fig. 4
- Continue the upward movement, and the hook assembly and rear trolley swings on the rear wheel, the
front hook is housed in the front trolley, and protection “PG” swings, hiding the front hook anchor and
securing the two hooks.
- As the upward movement continues, the hoisting cable comes under tension and the first load limiter
(LC4) comes into operation, thereby stopping the movement.
Fig. 5
- Move the trolley and hook assembly forward until it leaves the rear hook support.
Fig. 6
- Continue the trolley forward movement until the trolley back limit zone has been exceeded.
- Use the crane hook down control, and the rear trolley will swing so that its front wheels rest on the track
profile.
- The hitching catch (GE) will couple the two trolleys.
- Taking the trolley forward, the crane is ready to work with both trollies and both hooks hitched together.
(DOUBLE REEVING).
- Loads must be suspended from the rear hook anchor.
REMOVING THE FRONT HOOK ANCHOR PROTECTION TO HANG LOADS DURING DOUBLE-
REEVING WORKING IS PROHIBITED.
FAILURE TO OBSERVE THIS RESTRICTION MAY LEAD TO ACCIDENT.
Once the operation connected with cancelling the safety system has been completed, the crane must
be stopped and subsequently restarted.
REEVING CHANGES MUST ALWAYS BE CARRIED OUT FROM A POSITION THAT ALLOWS THE
PERSON MAKING THE CHANGE TO SEE WHAT IS HAPPENING AND THEREBY PREVENT ANY
FAULT OR MALFUNCTION THAT COULD LEAD TO A HAZARDOUS SITUATION.
THE REEVING CHANGE OPERATION MUST BE CARRIED OUT WITH NO LOAD, SLING OR OTHER
LOAD SUSPENSION TACKLE ON THE HOOK.
ALL CRANE LIMITS MUST BE PROPERLY ADJUSTED. THIS OPERATION INVOLVES THE HOOK UP
AND CARRIAGE BACK TRAVEL LIMITS AS WELL AS THE LOAD LIMITER. SEE THE DOCUMENTS
“HOISTING LIMITER”, “CARRIAGE LIMITER” AND “LOAD LIMITER” IN THE “USE AND MAINTENANCE”
CHAPTER.
Fig. 8
- The crane is working with two trollies and the two hooks joined. (DOUBLE REEVING).
Fig. 9
- Use the crane control to cancel the hook up limit, and at slow hoisting speed draw the hooks closer to
the trollies until the rear hook makes contact with the rear trolley.
ONCE THE “HOOK UP” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE TROLLEY
FORWARD MOVEMENT IS LOCKED UNTIL THE FIRST LOAD LIMITER COMES INTO OPERATION.
(LC4).
Fig. 10
- Continue the upward movement, and the rear trolley swings on the rear wheel and the front hook is
housed in the front trolley.
- The hoisting cable comes under tension and the first load limiter (LC4) comes into operation, thereby
stopping the movement.
Fig. 11
- Use the crane control to cancel the trolley back limit, and take the trollies towards the start of the jib.
- The trolley coupling catch (GE) enters the ramp (RG).
Fig. 12
- Continue taking the trolley back until the reeving change position limiters (LPCT) and (LPCD) come into
operation.
ONCE THE “TROLLEY BACK” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, HOOK MO-
VEMENT IS LOCKED UNTIL THE LOAD POSITION LIMITERS COME INTO OPERATION.
Fig. 13
- Operate slow speed down movement and the rear trolley swings on the rear wheel until the rear hook is
housed in the rear hook support. (SG).
- The front hook anchor protection (PG) swings and frees the front and rear hook coupling.
THE TROLLEY CANNOT BE MOVED WHILE THE FRONT HOOK IS OVER THE HOOK UP LIMIT.
Fig. 14
- Continue the downward movement until the front hook is below the “hook up” hoisting limit.
Fig. 15
- Taking the trolley forward, the crane is ready to work with a single trolley and hook (the front ones).
(SINGLE REEVING).
Fig. 16
The ID cancelling switch for the reeving change safety system may only be used by service personnel
who are fully aware of the effect of cancelling the safety system.
All operations carried out with the safety system cancelled must be especially well supervised to avoid
creating a hazardous situation.
Once the operation connected with cancelling the safety system has been completed, the crane must
be stopped and subsequently restarted.
If a crane should be left with single trolley (discarding the possibility of a 2nd trolley for double reeving), apart
from removing the trolley (see ASSEMBLY/DISASSEMBLY) the following operations must be done:
a) Physically remove jib mounted trolley position limiters ( LPCT and LPCD ).
b) Switch off the power connection of the limiters (removing plugs in electrical cabinet or disconnecting-
terminals in junction boxes, as applicable).
c) Place jumpers in tower top electrical cabinet
43-44 AID contactor.
53-54 AID contactor .
14 ABCT contactor and 14 ALCT contactor.
13-14 ALCDE contactor.
d) Check SR trolley operation against end stops with trolley backwards.
If the 2nd trolley should be replaced in order that double reeving is available, proceed in reverse order (points
a, b and c) and check the correct operation of changing from single to double reeve trolley and viceversa.
(see points 1 and 2 in this instruction).
After erection is completed, having obtained permits for crane operation, the instructions described in
this section must be complied with prior to commissioning.
Following these instructions will guarantee the safety of crane operation.
9.- For cranes equipped with single hook/double reeving, check correct operation of the re-reeving
system.
See instruction “REEVING CHANGE / TROLLEY CHANGE” in this chapter.
13.- Check that all maintenance operations set down for every crane after erection have been carried out
14.- Make sure that all requirements for crane power supply and electrical installation are complied with.
See chapter Electrical Installation in this Manual.
15.- Carry out all instructions set forth for crane commissioning other than the above stated points.
See chapter Operation in this Manual.
3 5 6 4
7
2
1 TRAVELLING LIMITER
2 ROTATION LIMITER OR SLIP-RING UNIT
3 LIFTING LIMITER
4 TROLLEY LIMITER
5 MOMENT LIMITER
6 LOAD LIMITER
7 REEVING CHANGE / TROLLEY CHANGE LIMITERS
8 CAGE MOMENTUM LIMITER
NOTE: See instructions about the adjusment of limiters on the following pages.
THE CRANE SHOULD NOT BE USED UNTIL THIS LIMITER HAS BEEN APPROPRIATELY ADJUSTED
AND FULLY COMPLIES WITH THE PURPOSE FOR WHICH IT HAS BEEN INSTALLED
0 CONTENTS
1 LOCATION
2 OVERVIEW
3 TRAVELLING MOVEMENT LIMITS
4 CHECKING
1 LOCATION
Normally the limiter is located in one of the driving trolleys or by default in the head girder.
2 OVERVIEW
The Travelling movement limiter stops the movement in both directions.
On the two track ends, mechanical stops and a limiter activating rail must be provided, so that the limiter is ac-
tivated and the crane stopped before impacting against the mechanical stops.In order for the limiter to operate
properly, it is important that the 25
mm height coordinate be respected.
The limiter actuating arm height can be adjusted.
25 mm
Actuating arm
Actuating rail Actuating rail
Neutral position
4 CHECKING
Make sure the hook is free and is not loaded.
Make sure the limiter is not physically damaged and that the activating arm returns to the neutral position of
the limiter when it moves towards the sides manually.
Move the crane to the Travelling movement limiting positions and make sure that the movement is stopped at
the positions described in Section 3.
During these operations the crane operator should be ready to stop the movement suddenly if required.
If the system does not work as previously explained, the cause should be found and corrected.
THE CRANE MUST NOT BE USED UNTIL THIS LIMITER IS CORRECTLY ADJUSTED AND MEETS
ALL THE REQUIREMENTS FOR WHICH IT IS INSTALLED
0 CONTENTS
1 LOCATION
2 GENERAL DESCRIPTION
3 MOVEMENT LIMITS
4 CHECKING
5 ADJUSTMENT
1 LOCATION
On the slewing ring, which transmits the slewing movement to the limiter via a cog wheel.
This is a turns-counter type limiter.
2 GENERAL DESCRIPTION
The limiter has two limiting positions: one for each slewing direction.
3 MOVEMENT LIMITS
The slewing limiter is normally used to prevent the crane rotating more times than permitted
The crane should not turn more than two complete rotations in each slewing direction, counting as from a
position in which the electric cables passing through the slewing ring are not twisted.
This is stipulated to prevent damage to electric cables as a result of twisting.
Note: The crane is delivered from factory with the slewing limiter already prepared for carrying out one and a
half turn in each sense of the slewing.
Nevertheless, it is necessary to verify its correct functioning during the assembly.
The slew limiter on this machine is factory set to two turns in each slewing direction.
4 CHECKING
Ensure that the hook is free and not under load.
Slew the crane to the limit positions and check that the limiter stops slewing there.
If slewing continues beyond the limit position or stops early, adjust the limiter as per point 5 below.
5 ADJUSTMENT
Release the
assembly 5.1 Remove the protective cover from the limiter.
5.2 Ensure that the hook is free and the crane can slew freely through 360
degrees (complete rotation).
5.3 Slew the crane clockwise to the limit position.
5.4 Unscrew the adjuster cam locking screw.
5.5 Adjust the cam for the clockwise slewing limiter contact block (1).
5.6 Slew the crane anti-clockwise to the limit position.
5.7 Adjust the cam for the anti-clockwise slewing limiter contact block (2).
5.8 Tighten the cam locking screw and fit the cover on the limiter
Adjust the 5.9 Check limiter operation as indicated in point 4 above.
cams
Right Wrong
THE CRANE MUST NOT BE USED UNTIL THIS LIMITER IS CORRECTLY ADJUSTED AND MEETS
ALL THE REQUIREMENTS FOR WHICH IT IS INSTALLED.
0 CONTENTS
1 LOCATION
2 GENERAL DESCRIPTION
3 HOOK MOVEMENT LIMITS
4 CHECKING
5 ADJUSTMENT
1 LOCATION
This rev-counter type limiter is located on the hoisting winch.
2 GENERAL DESCRIPTION
The limiter is activated by the hoisting drum.
The drum and the limiter are mechanically linked, usually by direct coupling but sometimes by pinions or chains.
The job of the limiter is to stop the hook movement before it exceeds the working limits set for it.
For instance when the hook is moving up this means before the hook block hits the trolley.
The limiter also includes the device for preventing fast hoisting speeds when the hook is close to the point
where its movement is limited.
4 CHECKING
Ensure that the hook is free and under no load. Move the hook to the upper and lower limits of its travel and
check that the limiter stops it at the required positions. Check also that rapid hoisting speed is not permitted
close to the limit points. While making these checks the crane operator should be ready to stop hook movement
suddenly if necessary.
If the hoisting winch continues to work beyond the set working limits the limiter must be adjusted as per section
5 of this chapter.
5 ADJUSTMENT
IF THE HOOK MUST BE LIMITED ON ITS DOWNWARD TRAVEL FOR REASONS OTHER THAN THE
MAINTAINING OF THE MINIMUM NUMBER OF TURNS ON THE DRUM THIS SYSTEM MUST BE
ADJUSTED AFTER EACH OPERATION TO CHANGE THE NUMBER OF HOOK REEVINGS.
Upward travel limitation does not need to be adjusted after changing hook reevings.
IF THE CRANE IS TO WORK WITH BOTH 2 AND 4 REEVINGS, THE UPPER AND LOWER
HOOK LIMIT SHOULD BE DONE WITH DOUBLE REEVING.
When limiting high spped, take into account the travel required
to slow down from top speed (on cranes with hoisting speed
range selection, select top spped to adjust and check the high
speed limiter)
THE CRANE MUST NOT BE USED UNTIL THIS LIMITER IS CORRECTLY ADJUSTED AND MEETS
ALL THE REQUIREMENTS FOR WHICH IT IS INSTALLED
0 CONTENTS
1 LOCATION
2 GENERAL DESCRIPTION
3 MOVEMENT LIMITS
4 CHECKING
5 ADJUSTMENT
1 LOCATION
This rev-counter type limiter is located on the trolley winch.
2 GENERAL DESCRIPTION
The limiter is activated by the trolley rope drum. The drum and the limiter are mechanically linked, usually by
direct coupling but sometimes by chains.
The job of the limiter is to stop the trolley’s movement before it hits the mechanical stops at the end of the jib.
3 MOVEMENT LIMITS
The purpose of the limiter is to stop the trolley winch before the trolley reaches the stop.
The limiter triggering point is a function of the type of braking, inertia, etc.
Trolley must stop at a minimum distance of 0,3 m from the stop, when the maximum travelling speed is used.
Top speed must be limited earlier, and the trolley must be in low gear when approximately 5 m from the
mechanical stops.
4 CHECKING
Check working whenever the trolley rope is tensioned, and ensure that the hook is free and under no load.
Move the trolley in low gear to the forward and backward limits of its travel and check that the limiter stops it at
the required positions before the stops are reached.
Check also that rapid trolley speed is not permitted close to the limit points. While making these checks the
crane operator should be ready to stop trolley movement suddenly if necessary.
If the trolley winch continues to work beyond the set working limits the limiter must be adjusted as per section
5 of this chapter.
5 ADJUSTMENT
The limiter must also be adjusted whenever the trolley rope is changed.
The limiter has four independent contact blocks:
- blocks 2 and 4 are used to limit hook travel towards the tower and tip respectively;
- blocks 1 and 3 are used to limit top speed. Block 1 is for trolley backward movement and block 3
for forward movement.
THE CRANE MUST NOT BE USED UNTIL THE SYSTEM HAS BEEN PROPERLY ADJUSTED AND
UNTIL IT FULLY MEETS THE REQUIREMENTS FOR WHICH IT HAS BEEN INSTALLED
0 CONTENTS
1 GENERAL DESCRIPTION
2 MOMENTUM LIMITING SYSTEM
3 SYSTEM LIMITING (OPTIONAL)
1 GENERAL DESCRIPTION
The momentum limiter is a double spring system associated with a set of position limiter switches.
It is located at the top of the crane.
The crane is subjected to load-momentum stress which is transferred through the top's structure, causing the
compression of the structural tubes to which the limiting system's springs are connected.
LM LIMITERS OPERATING
LMPWL WITH THE CORRECT LOAD
LM2
INDICATORS
OPTION
LIMITERS TRIGGERED
DUE TO EXCESS LOAD
Fig. 1
LM
LMPWL
LM2
INDICATORS
OPTION
LIMITERS OPE-
RATING WITH
THE CORRECT
LOAD
LIMITERS TRIGGERED
DUE TO EXCESS LOAD
Fig. 2
The value of the loads is obtained from the crane's technical data sheet, depending on the number of
reeving lines and the length of the crane's jib.
The test loads must be manufactured according to national and local standards.
The test will be performed with the trolley in the maximum span position.
Ensure that the system operates correctly by lifting the corresponding loads.
No
Upwards hoisting
Yes Yes (for 5-10 seconds, No
Trolley forward
then both)
2.4 Settings
The adjustment will be made with the trolley in the maximum span position.
The operation of the span limiter must be checked before adjusting the momentum limiting system.
In cranes with SR/DR hook, the test should be performed preferably with double reeving (DR).
The momentum limiters should be adjusted in the following order to prevent the pressure exerted by the
position switches on the spring from affecting the operation of the maximum load limiter:
1 LM2 approaching maximum momentum limiter.
2 LMPWL Powerlift limiter.
3 Maximum momentum limiter.
1.- With the trolley in the maximum span position, lift test load A.
2.- Adjust the actuator screw (1) which acts on the LM2 limiter so that the amber pilot light comes on in
the cab and the crane's horn sounds intermittently.
3.- Block the actuator screw (1) with the nut (2). Fig.1
4.- Deposit the load on the ground.
5.- Check the adjustment by following the instructions in section 2.3.
1. With the trolley in the maximum span position, gently lift the test load "A+B" until it is raised from the
ground.
2. With the load raised and the crane at rest, adjust the actuator screw (1), which acts on the LMPWL limiter
until it is activated (fig. 1), as indicated in the system's checklist.
3. Block the actuator screw (1) with the nut (2) (fig. 1).
4. Deposit the load on the ground.
5. Check the adjustment by following the instructions in section 2.3.
To make the adjustment easier, it is recommended that you press the IAPWL button inside the electrical
cabinet.
Each time the stop button is activated during the operation, the IAPWL button must be pressed again.
1. With the trolley in the maximum span position, gently lift the test load "A+C" until it is raised from the
ground.
2. With the load raised and the crane at rest, adjust the actuator screw (1), which acts on the LM limiter
until it is activated (fig. 1), as indicated in the system's checklist.
3. Block the actuator screw (1) with the nut (2) (fig. 1).
4. Deposit the load on the ground.
5. Check the adjustment by following the instructions in section 2.3.
If you only have a test load equal to "A+C" (110% of the maximum jib-end load) you can adjust the
approaching maximum momentum limiter with said load.
To do this, position load "A+C" at a distance of "D":
(%M)
D= x Maximum span
110
For example:
Maximum span = 40 m
Jib-end load = "A+C" = 1.5 t
Approaching 90% of maximum momentum limiter.
90
D (90% M) = x 40 = 32.7 m
110
This system could be explicitly contraindicated by applicable standards in the country or region where
the crane is being used.
THE CRANE SHOULD NOT BE USED UNTIL THIS SYSTEM IS PROPERLY ADJUSTED AND MEET THE
FUNCTION FOR WHICH THE SYSTEM HAS BEEN DESIGNED
0 CONTENT
1 GENERAL DESCRIPTION
2 TEST LOADS
3 CHECKING THE SYSTEM
4 ADJUSTMENT
1 GENERAL DESCRIPTION
The load limiting system is situated on the jib, above the trolley-rope.
The pull force applied on the load suspended from the hook is transmitted through a reeving of the hoist rope
on an articulated arm, which compresses the spring of the limiter, and governs the movements of adjustment
bushes with respect to position limiters. Refer to figure below.
There exist 4 limiters:
Adjustment bushes
Position
limiters
LC Maximum load allowed for the crane depending on the number of falls. In case of being
activated, the hook's and trolley's mevements of hoisting are disabled. The red warning
lamp in the cabin will be switched on and the horn of the crane will sound continuosly.
LC2, LC3 and LC4 Intermediate load levels for the control of the control of the maximum allowed hoisting
speeds depending on the load under hook.
2 TRIAL LOADS
The following loads should therefore be available on site:
Load A: This is the maximum permitted load for the crane configuration in use,
depending the number of reevings on the hook.
Principal load 9000 kg for SR and 18000 kg for DR.
Load B: This is the maximum load test overload.
10% of load A, 900 kg for SR and 1800 kg for DR.
Load C: (LC2) Intermediate load to regulate the frequency converter.
6000 kg for SR and 12000 kg for DR.
Load D: (LC3) Intermediate load to regulate the frequency converter.
4000 kg for SR and 8000 kg for DR.
Load E: (LC4) Intermediate load to regulate the frequency converter.
Surchage 2000 kg for SR and 4000 kg for DR.
3 SYSTEM CHECK
3.1 Maximum load limit
The check will be carried out with the trolley in the rear trolley position and the lifting speed in position 1.
The system should allow to lift the A load but not A+B loads together.
Otherwise, proceed with adjustment according to Section 4.1.
1 A LC
2 C LC2
3 D LC3
4 E LC4
For this, once the position of the commutator is selected, check that it is possible to lift the load related to the
maximum speed and that an excess weight of 10% impedes the ascent and descent movements and the SCEM
pilot in the control cabin illuminates.
Otherwise, proceed with the adjustment according to Section 4.2.
NOTE. If during the normal operation of the crane, it is observed that the load limiter impedes lifting
operations with a lighter load than that allowed or, if on the contrary, operations are allowed with greater
loads, then the adjustment of the load limit should be carried out, as is indicated in Section 4 of this
chapter. An incorrect adjustment of the intermediate load levels of the frequency converter regulation
may cause the load racing safety system not to operate correctly.
4 ADJUSTMENT
4.1 Maximum load limit adjustment
Lift A load with the trolley in the rear position and the lifting speed commutator in position 1.
Adjust the LC limiter with the associated bushing.
Check the adjustment according to Point 3.1.
Block the adjusting bushing shift.
THE CLIMBING SECTION MUST NOT BE USED UNTIL THIS SYSTEM HAS BEEN ADJUSTED
PROPERLY AND UNTIL IT FULLY MEETS THE REQUIREMENTS FOR WHICH IT HAS BEEN
INSTALLED.
0 CONTENTS
1 IMPORTANT NOTES
2 DESCRIPTION OF THE SYSTEM
3 DESCRIPTION OF THE ELECTRICAL EQUIPMENT
4 CONNECTING THE ELECTRICAL EQUIPMENT
5 INITIAL CHECK AND VERIFICATION OF OPERATION
6 EQUIPMENT OPERATION
1 IMPORTANT NOTES
The telescoping operation should be performed exclusively by previously-trained personnel (erector and
crane operator).
During the telescoping procedures, you should always know where the equilibrium point is and avoid
manoeuvres that may tend to shift the crane away from that position.
The control system provided in the AJ control cabinet allows the operator who is next to the control unit
to act upon the crane movements, thus communication and coordination between this operator and the
crane operator must be guaranteed at all times.
This system only works after the support of the rotating part of the cage structure has been fully transferred.
The system does not detect an imbalance prior to transfer and, therefore, does not prevent the extension
of the cylinder.
Before performing the balancing and telescoping procedures, you must check the proper functioning of
the system, as described in these instructions.
This is a safety system and the limiters should not engage except when necessary.
Limiters should not be used under any circumstances as a reference for telescoping.
The balancing and telescoping operation should always be performed from the control cab or with a
remote control cable. It should never be performed through radio control.
2 DESCRIPTION OF THE SYSTEM
The cage momentum limiter is a double spring system connected to a series of position limit switches.
It is located in the crane's climbing section (fig. 1).
2 1
Fig. 1
The climbing section is subjected to a load-moment solicitation that is transferred through the structure causing
a deformation of the structural tubes to which the limiting system's springs are attached.
The deformation of the structural tubes, increased by the springs, causes a displacement of the actuators
located at their end.
The position of actuators 1 can be regulated by screws 2. The actuators activate or deactivate the electromechanical
limiters 3 depending on their position
The electrical telescoping equipment includes a limiting system that blocks movements that may tend to increa-
se imbalance after one of the permissible momentum limits (forward or rear) has been reached. The limiters
engage only after the support of the part that will telescope to the cage structure has been fully transferred.
LJMP
LJMN
LJMN
LJMP
LJMP
Fig. 2
When either of the micros - LJMP or LJMN - engage, the electromechanical control system blocks those
movements that tend to increase the state of forward or rear momentum, respectively.
Before starting the hydraulic control unit using button I on the electronic motor protection relay, you must make
the following connections:
- Connect coupling EJ from the control cabinet AJ to coupling EJ of the LJMP and LJMN limiters.
- Connect coupling E92 from the control cabinet AJ to coupling E92 located inside the cab's electrical
cabinet.
- Connect coupling E8 from the control unit's electronic motor protection relay to coupling E8 in the
counter jib's electrical cabinet (luffing-jib crane) or the top cabinet (tower crane).
Once the connections are made, all the crane's cylinder extension movements remain locked until the system
is started up using button PMJ in AJ (see operation of electrical equipment).
E8
E92
EJ LJMP
LJMN
AJ
Fig. 3
See the "CLIMBING SECTION ASSEMBLY, balanced loads" document for its installation.
efore beginning telescoping, electrical equipment checks should be carried out as described below, as
B
well as the rest of the mechanical checks specified in the instructions.
Every time the cage's electrical equipment is to be used for telescoping, the functional checks and verifications
of the electrical equipment listed below should be performed beforehand:
,- Check that the position of the LJMP and LJMN micros in the spring is correct.
- Check that the manual bypass valve of the electrovalve is closed (the lever is perpendicular to the pipe)
and it is padlocked into position.
- Activate the TEST button located on the front of the AJ control cabinet.
Check that:
- The LAMP and LAMN lights are on.
- The LAOD light is off.
- All the crane's movements are locked.
- Extending the cylinder is not permitted
- Retracting the cylinder is permitted.
- Simultaneously press the IOD button located inside the AJ control cabinet and the TEST button. Check
that:
- The LAMP, LAMN and LAOD lights are on.
- All the crane's movements are permitted.
- Extending and retracting the cylinder is permitted
- Manually press each of the micros.
Check that:
- The LAMP and LAMN lights light up alternatively according to the micro being pressed.
- The system works by preventing movement as shown in the table in the "Operation of electrical
equipment" section.
6 EQUIPMENT OPERATION
6.1 Start-up
very time the cage is to be used for telescoping, the checks specified in the "Initial checks and verification
E
of operation" section must be performed.
The PMJ start-up button activates the limitation system so that the crane and cylinder extension movements
are authorised in accordance with the position of the LJMP and LJMN micros. To activate the compressor motor
of the control unit, push button I on the electronic motor protection relay. Once the compressor is running, you
may use the distribution lever to extend or retract the cylinder.
The PPJ push-button allows you to lock all the crane's movements and the cylinder extension movement from
the AJ control cabinet. When pressed, the movements are stopped after a pause controlled by the frequency
inverters. The brakes are applied after the deceleration. To fully stop the control unit's compressor motor, press
button 0 on the electronic motor protection relay.
To reset the limitation system after having pushed the PPJ push-button, you must reset the push-button and
press the PMJ start-up button again.
The electrical equipment allows or blocks the crane's movements or the extension of the cylinder according to
the status of the micros, according to the following table:
Upon reaching the forward momentum limit, the amber LAMP light on the front of the AJ control cabinet will
light up.
Upon reaching the rear momentum limit, the amber LAMN light on the front of the AJ control cabinet will light up.
The system suppression function should only be activated when necessary and may lead to dangerous
situations. If for some reason it is necessary to use it, you should restore the system to its normal operation
as soon as possible.
The IOD button located inside the AJ control cab suppresses the performance of the cage's limitation system
if held down. When released, the system will return to normal functionality.
While the button is pressed, a red LAOD light on the front of the AJ control cabinet will light up and the slewing
and trolley movements will operate at reduced speeds.
When the ICL switch located on the front of the AJ control cabinet is activated, the crane will work with the trolley
or counterweight at reduced speed
7 ADJUSTMENT
The crane must be balanced.
Failure to carry out this balancing operation could result in serious accidents.
See the "CLIMBING SECTION ASSEMBLY, balanced loads" document for its installation.
7.1 Initial limiter position
Before beginning the telescoping operation, centre actuators 1 in relation to the limiters.
approx. 105 mm
Fig. 4
2 1
Fig. 5
2 1
Fig. 6
1000 - - - 37 30 28 17 13
2000 - 33 21 17 15 13 - -
3000 25 22 14 - - - - -
4000 19 16 - - - - - -
The ID switch for overriding the reeving changing safety system should only be used by those personnel
who are fully aware of the possible consequences of overriding said safety system.
All operations carried out whilst the safety system is out of action must be carefully supervised in order
to avoid any hazardous situations.
Once the operation requiring the safety system to be overridden has been completed, the crane should
be stopped and reset.
IF YOU OBSERVE ANY IRREGULARITY WHILE CARRYING OUT ANY OPERATION DURING THE
CANCEL OF THE SECURITY SYSTEM, ADVISE IMMEDIATELY SERVICE DEPARTMENT FOR
ANALYSIS.
Fig. 3
0 CONTENTS
1 IMPORTANT NOTES
2 COMPONENT IDENTIFICATION
3 CAGE TRANSPORT
4 ASSEMBLING/DISASSEMBLING THE CRATE
5 PREPARING THE CAGE
6 ACCESS PLACEMENT
1 IMPORTANT NOTES
DURING ASSEMBLY OPERATIONS WIND SPEED MUST NOT BE SO HIGH AS TO PREVENT SAFE
HANDLING OF THE CRANE'S ELEMENTS. (NO HIGHER THAN 25 km/h).
USE SUITABLE SLINGS FOR THE LOADS HANDLED DURING LOADING, UNLOADING AND ASSEMBLY
OF THE CAGE.
MONITOR THE MOVEMENTS OF THE PARTS TO PREVENT ACCIDENTS DURING THE LOADING,
UNLOADING AND ASSEMBLY OF THE CAGE.
AKE AVAILABLE SUFFICIENT SPACE ON THE SITE, WITH A FLAT AND LEVELLED SURFACE, FOR
M
LOADING, UNLOADING AND ASSEMBLY OF THE CAGE.
EAD THESE INSTRUCTIONS CAREFULLY BEFORE STARTING THE LOADING, UNLOADING AND
R
ASSEMBLY OF THE CAGE.
2 COMPONENT IDENTIFICATION
The names used in this figure will be used throughout the entire document.
4 5 6 18
19
21
7
11
1
17 2
12 3
22
20
14
16 8
13 15
10
9
1/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 146
ASSEMBLY / DISMANTLING 110 0077 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
3 CAGE TRANSPORT
Use suitable slings for the loads handled during loading and unloading of the cage.
Monitor the movements of the parts to prevent accidents during the loading and unloading of the cage.
ake available sufficient space on the site, with a flat and levelled surface, for loading and unloading of
M
the cage.
Fig. 2
2/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 147
ASSEMBLY / DISMANTLING 110 0077 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
Monitor the movement of the parts to prevent accidents during the assembly or disassembly
of the crate.
ake available sufficient space on the site, with a flat and levelled surface, for assembly and disassembly
M
of the crate.
- Remove the transport attachments (A) from the structure (Fig 2).
5 4 20 19
6 6 18 6
17 13 14 16 11
12 12 10
Fig. 3
3/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 148
ASSEMBLY / DISMANTLING 110 0077 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
22
22
Fig. 4
4/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 149
ASSEMBLY / DISMANTLING 110 0077 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
Z
D
B
C
Fig. 5
5/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 150
ASSEMBLY / DISMANTLING 110 0077 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
- Check that the following are assembled: the climbing guide rollers (1), the pins for hanging the cage during
assembly (2), the cage lock pins (3) and the return pulleys for the mast section suspension cable (4).
- Make the mast section suspension cable return.
- Reposition the transport attachments (A) to turn over the entire assembly.
A
4
3
4
2
Fig. 6
6 ACCESS PLACEMENT
MONITOR THE MOVEMENT OF THE PARTS (ABRUPT AND SUDDEN KNOCKS) WHICH CAN CAU-
SE ACCIDENTS.
- With the transport attachments positioned hook the lug assembly (Y). Gently rotate the assembly on
support blocks (A), support it on auxiliary workhorses (B).
- Position the upper rear platform (C) and side walkways (D) on the "U" structure, assemble the handrails
on the platforms.
Position the tilting platform (E), rotated on its anchors and fixed to the side walkway (D).
- Position the ladder (F) offset on its platform anchors and fasten it to the structure.
E
F Y
A
C
D
B D
Fig. 7
6/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 151
ASSEMBLY / DISMANTLING 110 0077 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
- Raise the suspended lug assembly (Y), turning it on its supports until it is in the vertical position.
- Remove the transport attachments.
MONITOR THE MOVEMENT OF THE PARTS (ABRUPT AND SUDDEN KNOCKS) WHICH CAN CAUSE
ACCIDENTS.
- Position the lower rear platform (C) and side walkways (D) on the "U" structure, assemble the handrails
on the platforms.
Position the tilting platform (E), rotated on its anchors and fixed to the side walkway (D).
- Position the access ladder (F) in its position between the lower and upper platforms and position the
guard (G).
- Position the balconies (H) on the square brackets.
- Prepare the balcony for the hydraulic unit (J) on the slider (K) and fasten it to the structure. Position the
access ladder (L) on the platform (C), offset from its position.
When the assembly is raised the hydraulic system platform will glide along the slider (K) to its working
position, the ladder (L) should then be repositioned for correct access.
F
G
L
E
K
J
H
J
Fig. 8
7/7 Ver: A 12/25 Construcciones Metálicas COMANSA S.A. Approval 3 / 110 / 152
ASSEMBLY / DISMANTLING 110 0078 IB
J2-10
ASSEMBLY OF THE CLIMBING SECTION (CAGE) -
0 CONTENTS
1 IMPORTANT NOTES
2 COMPONENT IDENTIFICATION
3 ASSEMBLY OF CAGE SUPPORT BEAMS AND SECTION ASSEMBLY RAIL
4 ASSEMBLY OF THE CLIMBING SECTION
5 CAGE ASSEMBLY
1 IMPORTANT NOTES
DURING ASSEMBLY OPERATIONS WIND SPEED MUST NOT BE SO HIGH AS TO PREVENT SAFE
HANDLING OF THE CRANE'S ELEMENTS. (NO HIGHER THAN 25 km/h).
USE SUITABLE SLINGS FOR THE LOADS HANDLED DURING LOADING, UNLOADING AND ASSEMBLY
OF THE CAGE.
MONITOR THE MOVEMENTS OF THE PARTS TO PREVENT ACCIDENTS DURING THE LOADING,
UNLOADING AND ASSEMBLY OF THE CAGE.
AKE AVAILABLE SUFFICIENT SPACE ON THE SITE, WITH A FLAT AND LEVELLED SURFACE, FOR
M
LOADING, UNLOADING AND ASSEMBLY OF THE CAGE.
EAD THESE INSTRUCTIONS CAREFULLY BEFORE STARTING THE LOADING, UNLOADING AND
R
ASSEMBLY OF THE CAGE.
2 COMPONENT IDENTIFICATION
The names used in this figure will be used throughout the entire document.
4 5 6 18
19
21
7
11
1
17 2
12 3
22
20
14
16 8
13 15
10
9
- Prepare the assembly pole (17) fixing the 540 kg counterweight block in its position.
Fig. 2
- Using the assembly pole (17) suspend the rear cage joist hanger (4) and connect it to the cage support
lugs on section S23J or TS24J or the lower crown holder depending on the crane model.
When positioning the cage joist hangers, take into account the direction in which the mast sections are
assembled.
Fig. 3
Fix the section hoist trolley (18) to the rail to prevent movement during assembly.
- Attach the front cage joist hanger (5) over the rear rail.
- Connect the assembly pole (17) to the assembly lugs on the rear rail "6R".
Suspend the lug set (Z), the assembly will be practically balanced when raised.
Prepare a second sling fixed to the lug (Y) for lowering the pole.
- Insert the assembly into the mast, fix the rear rail to the rear joist and screw the front joist to the cage
support lugs on the mast section.
When assembling the rails, control their movement to prevent accidents due to entrapment inside the
mast section.
- Change the suspension sling on the pole of lug (Y) before removing the connecting pins (R) from the
rear rail, the pole will be balanced when lowered.
6R
6P
6D
R
18
Z
Y
Fig. 4
16 17
12A
14
13
A
12B
12C 11 B
Fig. 5
5 CAGE ASSEMBLY
MONITOR THE MOVEMENT OF THE PARTS (ABRUPT AND SUDDEN KNOCKS) WHICH CAN CAUSE
ACCIDENTS.
- Suspend the cage from the indicated lugs via two slings, the entire assembly rotates on the supports (A).
- On suspending the assembly, the support platform for the hydraulic control unit will glide along its slider
to its working position; reposition the platform access ladder for correct access.
Exercise extreme caution this operation.
Handle the loads at reduced speeds to prevent abrupt movements as far as possible.
Leave a space free from obstacles for moving the load.
A
Fig. 6
- Hang the cage from the lugs on the rear cage joist hanger. Lower the truck crane, the cage rotates on
the pins moving closer to the mast.
With the help of a block and tackle, tilt the cage until it is in the vertical position.
- Remove the rods connecting the open square brackets (A) and close, position the corresponding con-
necting pins.
- Remove the platform connections, lower them into their position.
Fig. 7
- On tilting the cage, the cage's rear connecting lugs align with the lugs on the rear cage joist hanger; insert
the connecting pins in (A).
Connect the front part of the cage to the front cage hanger using the rod (B).
Using a block and tackle, tilt the cage to facilitate inserting the pins.
- Remove the block and tackle once the cage is closed.
- Remove the pins (C) suspending the cage from the rear cage joist hanger.
- Position the support (D) to support the mast section lifting bar on the lower platform.
- Connect the mast section suspension return to the mast section hoist bar (10) and the mast section
hanger (11).
- Using the crane hook, tense the mast section suspension cable until the rods (E) can be removed and
place the mast section hanger in its working position hanging from the climbing tabs on the mast section.
A
B
11
10
11
Fig. 8
12
13 B
B
C
A A
14
B
B B
A A
Fig. 9
0 CONTENTS
1 IMPORTANT NOTES
2 POSITIONING THE SECTION ON THE HANGER RAIL
3 BALANCING
4 TELESCOPING
5 INSERTING THE MAST SECTION
6 RECOVERING THE CLIMBING MAST SECTIONS
7 REPEATING OPERATIONS
8 FINAL OPERATIONS
1 IMPORTANT NOTES
DURING TELESCOPING WIND SPEED MUST NOT BE SO HIGH AS TO PREVENT SAFE HANDLING
OF THE CRANE'S ELEMENTS. (NO HIGHER THAN 25 km/h).
FOR LIMITED TOWER HEIGHTS, THE CLIMBING SECTION MUST BE LOWERED FOR EACH JIB
CONFIGURATION.
HE MAST SECTIONS TO BE LIFTED MUST BE ASSEMBLED AND PLACED AT THE FOOT OF THE
T
CRANE BEFORE STARTING TELESCOPING.
THE CRANE MUST BE BALANCED, USING THE HANGER SPECIFICALLY EQUIPPED FOR THIS
PURPOSE, BEFORE STARTING TELESCOPING OPERATIONS.
Prepare the section for suspension, fix the hanger eye strops to the section (19), the eye strops must be identical
in the length to keep the section level.
19
1300 mm
Fig. 1
Using the hoist hook (20) position the mast section on the section assembly trolley (18), on the section assembly
rail (6).
20
18
20
Fig. 2
Once the section is in position, unhook and remove the hoist hook (20).
3 BALANCING
THE CRANE MUST BE BALANCED, USING THE HANGER SPECIFICALLY EQUIPPED FOR THIS
PURPOSE, BEFORE STARTING TELESCOPING OPERATIONS.
During telescoping operations, the balance of the crane can vary due to the position of the section on the
assembly trolley or the effects of the wind on the crane. The balance point of the crane is obtained by moving
the trolley and the hook.
Fig. 3
4 TELESCOPING
IT IS ESSENTIAL THAT THE CRANE IS BALANCED.
FAILURE TO CARRY OUT THE BALANCING OPERATION COULD RESULT IN SERIOUS ACCIDENTS.
MAKE SURE THE MAST SECTIONS ARE IN CONTACT WITH THE THICK METAL PLATE OF THE
MAST SECTION HANGER BEFORE STARTING TELESCOPING OPERATIONS.
If the mast sections need repositioning, actuate on the hydraulic cylinder with the lower climbing catch hooks
(A) positioned on the mobile climbing crossbeam (14) and the upper climbing catch hooks (C) removed from
the fixed climbing crossbeam, gently retract the cylinder, the climbing mast sections (12) will rise; place them
against the thick metal plate of the mast sections hanger and gently return the cylinder to its initial position.
Before starting crane telescoping operations, the connecting pins should be removed from the last section of
the mast on the cage support section.
To facilitate this operation it may be necessary to actuate on the hydraulic cylinder, with the lower climbing catch
hooks (A) positioned on the mobile climbing crossbeam (14) and the upper climbing catch hooks (C) removed
from the fixed climbing crossbeam; gently remove the cylinder to align the section splice holes and eliminate
the pressure on the pins.
12
Mast
sections
position
A
14
14
Fig. 4
Once the connecting pins have been removed from the final section of the cage support section, the
crane should not be turned.
If the trolley and hook need to be moved to achieve better balancing this must be done very slowly.
With the lower catch hooks (A) positioned on the mobile crossbeam (14), continue to withdraw the cylinder
until the holes on the fixed crossbeam (13) and those on the mast sections (12) are aligned; position the upper
catch hooks (C).
Gently retract the cylinder until the cage is supported on the upper catch hooks (C) and the lower catch hooks
can be removed (A); continue to retract the cylinder, so that the fixed crossbeam (13) rises; align the holes of
the fixed crossbeam and those of the mast sections, position the lower catch hooks.
Gently withdraw the cylinder until it is supported on the lower catch hooks and remove the upper ones, continue
to withdraw the cylinder until the holes on the fixed crossbeam and mast sections are aligned, ...
Repeat the operations until finishing the mast sections.
When the last section is reached, monitor the extraction of the cylinder so that it does not reach the mechanical
limit (T) between the mast sections hanger (11) and the plate supporting the fixed crossbeam (J).
12
13
A
14
11
T
Fig. 5
The distance between the lower part of the hanging section and the upper part of the lugs on the mast section
will be approximately 80 mm (Fig. 6).
80 mm
Fig. 6
Use the auxiliary return cable located on the section assembly rail to facilitate this operation.
Auxiliary return
Fig. 7
Reverse the telescoping process in the previous point until the new mast section is inserted, at its lower part,
into the crane mast and they can be pinned using the working pins (A).
Remove the section suspension eye strops and pull the assembly trolley (18) out to the end of the rail (6).
Continue to lower the climbing section until the upper part of the new section is inserted in the cage support
section and the assembly pins (B), which have a smaller diameter and a head, can be positioned. Four assembly
pins are used, one per corner.
ONCE THE NEW MAST SECTION IS CONNECTED TO THE CAGE SUPPORT SECTION VIA THE
ASSEMBLY PINS, THE MAXIMUM ROTATION ALLOWED FOR THE CRANE IS 10º IN EACH DIRECTION
AND AT THE FIRST ROTATION SPEED ONLY
Fig. 8
o move the climbing mast sections assembly, the mast sections must be repositioned; they must be
T
against the thin steel plate on the mast sections hanger.
Connect the auxiliary hook (20) to the mast sections hoist bar (10) and using the crane's main hook, tense the
cable connecting the hoist bar to the mast sections hanger (11), check that the cable runs correctly through
the return pulleys (Fig. 9).
With the lower climbing catch hooks (A) positioned, close the cylinder so that the mast sections rise, at the
same time, raise the mast sections hanger using the crane's main hook, remove it from its housing in the mast
section and move it so that the mast sections are against the thin steel plate of the hanger, remove the cylinder
so that the mast sections are supported on the hanger and remove the lower climbing catch hooks (A) (Fig. 9).
Pull the hoist bar and raise the assembly until the mast sections can be repositioned in the climbing tabs of
the upper section.
During mast section hoisting, ensure that there are no snags between the mast section structure and
the cage or the mast section.
To reposition the mast sections, actuate on the hydraulic cylinder with the lower climbing catch hooks (A) posi-
tioned on the mobile climbing crossbeam (14) and the upper climbing catch hooks (C) removed from the fixed
climbing crossbeam; gently retract the cylinder, the climbing mast sections (12) will rise, place them against the
thick metal plate of the mast sections hanger and gently withdraw the cylinder to its initial position.
MAKE SURE THE MAST SECTIONS ARE IN CONTACT WITH THE THICK METAL PLATE ON THE
MAST SECTIONS HANGER BEFORE CONTINUING TELESCOPING OPERATIONS.
10
20
11
Mast sections
position
Fig. 9
7 REPEATING OPERATIONS
Repeat the operations in sections 2 to 6 until the final height of the crane is reached.
8 FINAL OPERATIONS
Insert working pins in the connection between the final mast section and the cage support section.
Remove the section climbing cage, follow the assembly process in reverse.
Inspect and check that the mast accesses are correctly positioned.
Fig. 10
Level union
mast section
65
140
253
Ø62
2000
2490
2
Ø5
2000
2490
RIGID TIE-FRAME
Frame
C Stringer Stringer
A B
Knee- Knee-
Stringer brace Cable brace Stringer Cable
Turnbuckle Turnbuckle
A A B A B
MANUFACTURERS
SUPPLIES ONLY ITEMS:
A Inner tie-frame
B Outer tie-frame
C Tie-pin
2490
Frame
Cable
A
Turnbuckle
Concrete block
Concrete block
Turnbuckle
Cable
Frame
0 CONTENTS
1 DESCRIPTION
2 OUTER FRAME ASSEMBLY
3 INNER FRAME ASSEMBLY
1 DESCRIPTION
6 1 2
10 11
13 12
Prepare the crossbeams and arms on the floor, placing the outer frame adjustment elements in position.
Hang a crossbeam "1" from its tabs and raise it to the desired height.
Move the crossbeam near the tower and attach it to the tower section's tabs.Keep it tethered to the tower with
an auxiliary fastening system.
FIG. 3
Attach arms "13" to the tabs of the tower's sections and fasten them to crossbeam "1" with screws "2" (fig. 4)
forming a "U".
Finally, mount the crossbeam with remaining joining elements 2, 3, 4 and 5. (See Fig.4)
Fig. 4
Fix the pre-assembled frame to the section with the use of the adjustment elements of each sector. (See Fig.2)
3 INNER FRAME ASSEMBLY
Place the supports "9" of the inner frame on the handrails of the tower's section and fix it to them.
Fig. 5
Adjust screw "A" to align the height of support "B" with shaft "C" of the outer frame.
C A
Fig. 6
Place the inner frame "10" supporting the arms on the supports "9" and adjust it to the inside of the struts with
the use of the shafts "11" of each arm. (See Fig.7)
Fig. 7
If a crane needs to be erected at a height greater than its free-standing height (H), it must be braced via a frame
which embraces the tower section.
Bracing is fitted at the join between standard sections.
Depending on the final height under hook, several tie-frames may be necessay.
H Free-standing height.
frame.
A 3XA72 5XA72
42,6 64,9
H
(7xS25) (11xS25)
81,1 97,9
(14xS25) (17xS25)
H1
h 52,0 (9xS25) h 46,5 (8xS25)
h0 29,1 (5xS25) h0 51,4 (9xS25)
108,6 130,9
(19xS25) (23xS25)
If a crane needs to be erected at a height greater than its free-standing height (H), it must be braced via a frame
which embraces the tower section.
Bracing is fitted at the join between standard sections.
Depending on the final height under hook, several tie-frames may be necessay.
H Free-standing height.
frame.
A ES72
63,1
H
(11xS25)
96,1
(17xS25)
H1
h 46,5 (8xS25)
h0 49,6 (9xS25)
129,1
(23xS25)
H2 h 46,5 (8xS25)
h1 33,0 (6xS25)
h0 49,6 (9xS25)
1.- If crane height is greater than self-stable height, with stays, tower sections will be removed by means
of the climbing cage until reaching a height such that the mobile crane may be used (see documents
regarding CLIMBING SECTION ERECTION).
Remove the cage.
Social awareness of the need for Sustainable Growth requires the construction field to enable recycling for
equipment and materials that have reached the end of their useful lives.
The most outstanding advantage to this recycling effort is the concurrent solution of problems originating in
elimination of some sub-products of waste as well as obtaining new raw material, which reduces the quantity
of newly extracted natural resources.
Waste from maintenance operations, before being disposed of, must be classified according to type:
At the end of the crane's useful life its raw materials should be recycled rather than thrown away.
The apparatus, accessories, fluids and packaging should be sent to sites set aside for ecological reutilization.
Waste from electronics and electronic devices should be stored at places set aside for selective recovery.
Disposal and scrapping of the crane should be performed according to the provisions of current legislation
in the country where the work is performed.
Proper disposal of waste generated in the scrapping of the crane contributes to the conservation of resources
and the prevention of possible environmental problems.
The owner may scrap the crane by separating all materials according to their type:
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
he electrical connection must guarantee a rated voltage of 400 V with fluctuations of less than +5%
T
and a wave frequency of 50 Hz with fluctuations of less than +1%.
0 CONTENTS
1 Regulations
2 Site switchboard
3 Power supply cable
4 Equipment electrical data
5 Earthing (power supply)
6 Earthing of crane structure
7 Leakage currents
1 Regulations
The following regulations have been complied with
- IEC 60364-4-41, Protection against electric shocks
- IEC 364-4-47, Application of protective measures for safety
- IEC 60364-5-54, Earthing arrangements and protective conductors
- IEC 60364-6, Low-voltage electrical installations. Verification.
Also, other regulations and standards might be applicable and must be complied with as a function of the
crane site.
2. Site switchboard
Electrical supply to the crane must be taken from the site switchboard (standards IEC 60436-4; EN 60439-4)
This switchboard must be provided with a protective enclosure adequate for the actual environment. IP44
minimum protection made of insulating material is recommended.
The electrical supply cable from site switchboard to the crane shall be provided with short-circuit and thermal
circuit breakers. This protection can be accomplished by:
- Line protection fuses, characteristic curve gL.
Fuses must be selected in accordance with the cross section of the cable to be protected (See manufacturer’s
specific tables with data of cables used). Design cable current shall never be higher than fuse rated
current.
- Line protection thermal magnetic circuit breaker, tripping curves B and C, or above (curves D or K or
motor overload protection)
Breaker current may not be higher than maximum line working current.
A differential circuit breaker must also be provided for protection against indirect contacts. This protection
and the earthing of the electrical supply line must comply with national standards and regulations applicable
at the site.
Cranes with frequency converters could exhibit fault currents continuously tripping protection differential
circuit breakers. If this should be the case, differential circuit breakers immune to this kind of fault currents
shall be used.
Some crane electric devices like inverters include filters to bring voltage supply quality to a sufficient level. These
filters are passive components which “clean” the supply voltage by blocking high frequency current harmonics
and diverting them to earth. Under some circumstances, these leakage currents can make the RCD (residual
current device) to trip. If such is the case, immunized RCD devices must be used instead.
2 / 4
POWER SUPPLY GENERATOR
POWER ELECTRICAL SUPPLY
3 x 400 V 50 Hz (4)
Model
Hoist Trolley Slewing Travel Current (1) Current (2) Fuse (3) Cable (5) Length (6) Length (7)
kVA
Rev: A
kW kW kW kW Total (A) Crest (A) (A) Type Total (m) minimun
13/21
50 152 248 200 160 50 135 40
21LC290/12 t
7,5 3 x 7,5 2 x 3,7
21LC290/18 t
65 176 291 250 180 70 160 60
other elements of the electrical supply :
21LC400/12 t 2 x 3,7
21LC400/18 t
50 165 264 200 170 50 130 40
7,5 4 x 7,5
21LC550/12 t
65 188 307 250 195 70 150 60
21LC550/18 t
21LC550/24 t 4 x 3,7
110 251 424 315 260 95 140 80
Vº Bº
21LC660/24 t
21LC660/36 t 65 197 318 250 205 70 140 60
21LC660/48 t
13 4 x 7,5 4 x 3,7
21LC750/24 t
Below please find a table with electrical data for the installation to assist in selecting the cable and
-
21LC750/48 t
020 0022 IB
4 / 020 / 5
ELECTRICAL INSTALLATION 020 0022 IB
21LC
ELECTRIC WIRING AND GROUNDING -
NOTES:
1. Total current is the sum of all motor rated currents with a simultaneity coefficient of 0.8
2. Peak current is the sum of hoist motor maximum current (at speed change) and the rated currents
of the rest of the motors.
3. Line protection fuse gL or magnetic thermal circuit breaker (see par. 2 – site switchboard)
4. The generator must be able to start with hoist motor maximum current (at speed change). and with
the breaking power related to lowering of maximum load at maximum speed.
5. Electrical supply cable may not be smaller than size stated in table.
6. This length is the maximum allowable for the cable stated. The length is the sum of the electrical
supply to the crane foot plus the length of cable installed in the tower.
This cable has been designed for 4% voltage drop at rated current.
If the total length of the electrical supply cable plus the tower cable should be above the stated
value, a cable with more cross section shall be installed. Cable cross section selection must also
take into account the voltage drop through tower cable (cross section of this cable is table stated
cross section) and table stated currents.
7. Electrical supply cable length plus tower cable length must always be above this value.
8. The power values indicate the rated mechanical power of each mechanism working separately.
The electrical power required to supply them is somewhat higher.
S < 16 S
16 < S < 35 16
S > 35 S/2
Earthing must be done by a qualified engineer, and must be adequate for the selected differential protection
against indirect contacts and must be done according to the set of standards and laws applicable on the
place where the crane is erected. Its effectiveness must be checked as indicated on IEC 60364-6.
The earthing of the current supply must be connected before connecting the voltage and must be disconnect
after disconnecting the voltage.
6. Earthing of the structure
Prior to crane start up, the contractor must check the need for earthing of the crane structure as well as
protection measures against lightning (applicable regulations for accident hazard prevention – insurance
company’s or owner’s requirements – etc.)
Earthing the structure is recommended as a precaution measure against electrostatic discharge, although
this will not guarantee full protection against lightning.
If the crane should need full protection against lightning, it shall comply with jobsite local regulations in force.
If this should be the case, installing lightning arrestors at the power supply connection is recommended for the
protection of crane electrical equipment.
- Minimum earthing lead cross section shall be 35 mm2 for copper conductors, or 30 mm x 3,5 mm
galvanised strip.
- Earth electrodes must be driven to a minimum depth of 2m
- Leads shall be connected through M10 bolts with lock nuts and washers
- Earth resistance above 20 ohms is not recommended
- Crane structure earthing surface must be ground for a better electric contact
- For cranes on track: Rail ends must be earthed through earth electrodes. Rails longer than 20 m must
have an earth connection every 20 m. Rail sections must be electrically linked and all rail ends must have
a direct earth connection.
7 Leakage currents
Some of the units of the crane have electrical filters, which are necessary for reducing the level of electric
interference conducted to and from the unit. Due to their operating principle, the filters can generate leakage
currents greater than 30mA that, nevertheless, do not imply a risk to people. These leakage currents can
make the differential switches that protect the crane trip.
As indicated in the section "Switching panel", if nuisance differential protection trips occur, you must use a
differential that is immune to this type of default currents. When selecting the differential, you must choose a
differential suitable for the installation and take into account the nominal current of the crane indicated in the
table in the "Electrical data for installation" section.
The following table shows the typical and maximum leakage currents for the different crane models:
Note: the values in the table are orientative. Factors such as the phase unbalance, the length of the
supply and the load of the motors can make the leakage level significantly higher or lower than the typical
leakage level.
0 CONTENTS
1 BLOCK DIAGRAM
2 TOWER FOOT BOX AND TOWER CABLE
3 SWITCHGEAR CABINET
4 TOP ASSEMBLY / SLEWING PART
5 CRANE CONTROL
6 LIMIT SWITCHES AND LIMITERS
1 BLOCK DIAGRAM
MP
LTA, LTT
MRT1, FMT1, MTR2, FMT2,
MTR3, FMT3, MTR4, FMT4
Fig. 1
The tower cable to be connected to the cabinet by a quick connect plug comes from this box. (included
in the power supply of the T22 crane, in case required).
The cabinet is equipped with an isolator located in the door which disconnects the electric power supply from
the power and movement control circuits.
The corresponding key should be used to open the cabinet doors and this can only be carried out if the door
isolator is not in the disconnected position «0».
The cage cabinet AJ is located next to the hydraulic unit and contains the cage operation equipment and tools.
The crane is provided with two emergency stop buttons (mushroom type) situated close to the hoisting winch
and trolley winch, for use in case necessary during crane maintenance operations.
The electric cabinet are provided with one 230 V - 1 A outlet, for the computer connection.
Electrical storms can cause disturbances in the power grid that may damage some of the crane's electronic
equipment. Some of this equipment remains connected to the network after the remote's stop button is
pressed. When a storm is predicted, it is recommended to disconnect the crane from the CJA inlet box,
thus disconnecting all the equipment and reducing the risk of damage.
The electric power supply connections of the items that do not come factory wired, are done using fast connector
plugs.
Optional items, such as assembly equipment or an auxiliary jib, are also connected to the cabinet of the cabin
platform using fast connector plugs.
5 CRANE CONTROL
The crane is controlled from the cabin using a fast connector plug connected to the cabinet of the cabin platform.
The controls always have automatic reset and locking against conflicting movements.
- Moment limiters
The system incorporates 3 position limiters situated in the cathead of the crane. The maximum moment limiter
is used to prevent the crane from being overloaded by the load moment (See load–range diagram). It cuts off
the elevation movements of the hook and trolley to the jib point. In addition, it indicates the limit condition by
illuminating a red light and sounding the claxon continuously.
The 90% moment limiter disables the fast speed of the trolley. In addition, it indicates the approach to maximum
moment by illuminating an amber light and intermittently sounding the claxon.
LMPWL limiter is associated with the POWERLIF system.
- Load limiters.
There are four position limiters situated in the first jib section which are used to prevent the crane from being
overloaded. One of these is activated when the maximum load is exceeded and disconnects the hoisting mo-
vement of the hook and trolley movement to the jib point. In addition, the limit condition is indicated with the
illumination of a red light and the horn sounding continuously. The other three limit switches are used to limit
the maximum lifting load according to the speed range selected in the cab.
Good condition and proper operation and calibration of limiters and limit switches are a must for guaranteeing
a safe crane operation.
For more details on limiters and limit switches, see inspection and calibrating instructions in chapter “ASSEMBLY
/ DISMANTLING” of this manual, and “CHECKS PRIOR TO START UP”.
Note: A switch with a key (IACM) located in the cabinet of the cabin platform allows for the maximum load and
momentum limiters to be disabled, for supervision tasks. (fig. 3)
Fig. 3
Ensure that the load and momentum limiters are not disabled by the IACM switch while the crane is
operating.
0 CONTENTS
1 FACTORY MADE CONNECTIONS.
2 ELECTRIC ASSEMBLY SEQUENCE
- Apex.
Includes:
- The LM, LM2 and LMPWL momentum limitation system with CJLM intermediate limiters box,
connected to the electrical service box by means of the EL connector.
- Counter-jib unit.
Includes:
- Hoisting mechanism and end stop.
- ME lifting motor.
- Travel limitation system.
- RE Dissipation resistor.
- E2P Power connector.
- E2E Motor encoder connector.
- E2S Speed sensor connector.
- E2R Dissipation resistor connector.
- E2C Connector for the rest of the lifting components (brake, ventilation, probes and travel
limitation).
- CJE Distribution box.
The travel limitation system has a built-in lift position detector for the in-cab indication system.
- Auxiliary jib (optional), with its control system.
- Cab.
Includes:
- E5 connector for cab power.
- E9 connector for crane manoeuvring.
- E933 connector for the IMDL46 cab recorder (optional). The cables to subsequently connect the
CQ load pin to the lift and trolley end stops, slewing sensor (optional) and momentum capture
system come out of the IMDL46 central indication unit.
- Climbing section.
Includes:
- Hydraulic group to control box connections via connectors E8/1 and E8/2 (optional).
- Anemometer unit connected to trolley/slewing unit service box terminals X1-IO, X1-I1G and X1-G.
- Travel unit connected to trolley/slewing unit service box terminals X1-L41, L42, L43, 34, 35, 36, 37, 38,
I0, I11 and GND (optional).
All connectors are marked with their names and codes in order to facilitate correct connections.
All the electrical components built into each of the above structural components are factory-wired together;
during the assembly/disassembly sequence it is necessary to connect/disconnect these elements using
the built-in quick connectors.
Cab connectors:
E5 cab power
E9 cab control (exterior)
E933 IMDL46 Signal recording connector
E110 110 V 10 A auxiliary
E230 230 V 10 A auxiliary
E91 cab control (interior)
E92 zone limitation system
E93 recorder (indication system)
E991 trolley sensor (indication system)
E992 lift sensor (indication system)
E993 momentum sensor (indication system)
E994 load sensor (indication system)
E995 slewing sensor (indication system)
- Install service box CJA by means of its support at the base of the crane. The service box comes connected
to the service cable; to install it, pull from the inside of the cable roll using the hanger fastened to it.
- If the crane is equipped with auxiliary transformer T22 (optional for destination with 60 Hz supply) connect
the transformer input to the service entrance available at the connection point; voltage range can be
selected from 480 V to 520 V in order to ensure 460 V 60 Hz supply for crane operation.
- Bring electrical supply to the tower, placing the intermediate hangers a maximum of 40 metres apart.
Once the rotating part is in place, fasten the service cables to it using the upper support.
- Once the cab platform is in place on top of the rotating part, connect the slewing connectors E41, E42,
E43, E44 and E4E.
- Once the first counter-jib section and the first jib section are in place, you may connect junction box CJLM
(momentum limiters, load and reeving change) using the EL connector. Before making this connection
you must connect the CJL load limiters box to the CJLM box using the E33 connector.
Attach the electrical service cables from the service box to the support using the pin located on the vertical
of the rotating part.
- Connect the connectors from electrical service box E to the ones that come out of the apex service box
(follow the matching colours and markings on the cable).
The service cable should be connected by qualified personnel, according to the instructions in this manual
for "ELECTRICAL SERVICE AND GROUNDING".
During assembly, it is prohibited to make any of the crane's active phase connections without having first
connected the grounding cable. Likewise, during disassembly, it is obligatory to keep the grounding cable
connected until all active phases have been disconnected. This must be taken into consideration provided
the connection/disconnection operation is not carried out by means of a connector which connects all
phases simultaneously, for example if unipolar tower hoses are being used.
- At this time, once the electrical power is on and controls E9, E5 and E933 are connected, the slewing
unit may be rotated to facilitate assembly of the jib and counter-jib.
To carry out this operation without the E1S trolley connector and the E2S lift connector being connected,
you must connect the aerial connectors from the right side of the service box to the corresponding E1S
and E2S service box cables.
- Once the slewing unit jib is assembled, connect trolley connectors E2P and E2S to the service box.
- Once the counter-jib is assembled, connect all the lift connectors E2P, E2S, E2R, E2E and E2C to the
electrical service box.
- To interconnect the cab indication system, remove the cables that go to the load and moment systems
(in the first jib section), to the trolley and lift end stops and to the rotation sensor (optional) from the inside
of the cab. These cables must be pulled through the opening in the upper part of the cab's external
connections area.
- For travelling cranes, make the connection from the apex service box to the travel service box at the
base, for both power and manoeuvring, routing the cables in the same place as the main electrical service
cable. Install the travel end stop in its work position and connect the travel motor cables.
- If the crane is equipped with radio control, install the amber-green lamp that is supplied with the crane
following the "USING THE CRANE" instructions in this manual.
- If the crane is equipped with an anemometer, install the signal unit where it is visible to people in the
vicinity of the crane.
To facilitate and enable lifting, trolley and slewing movements in the crane assembly/disassembly stage
only, there is a ID key-operated selector switch inside the lift service box.
0 CONTENTS
1 START UP SYSTEM
2 PHASE PROTECTION RELAY
3 START STOP SAFETY RELAY
1 START UP SYSTEM
For start up press the start up button located in the crane control panel
This operation can only be done if:
The two latter pushbuttons are provided in case they are needed during crane erection and maintenance
operations
- A permissive start up signal is given by the safety relay as a function of a number of external
conditions.
See start stop safety relay in this chapter.
In case the permissive signal is present, pressing the start pushbutton entails the connection of the main
switch in electrical cabinet (power and control), the crane being ready for operation.
OPERATION DESCRIPTION
TROUBLE SHOOTING
OPERATION DESCRIPTION
- 24 V a.c. supply....................A1, A2
- Stop circuit A........................S11, S12
- Stop circuit B........................S21, S22
Connections - Start......................................S12, S39
- Relay K1 output....................13, 14
- Relay K2 output....................23, 24
- Bridge between....................13, 23
TROUBLE SHOOTING
0 CONTENTS
1 DESCRIPTION OF SYSTEM
2 BCR30 CONTROL CARD
3 BPR POWER BLOCK
4 OPERATING TABLES
There are three speeds in either direction. The most suitable values for stator supply and decelerator voltages
are selected to achieve this. The special concept of the motors allows a really reduced first speed without the
need for high braking values, thereby avoiding excessive heating.
The control signals from the crane operator´s control are received in the BCR30 control card, which governs
both the power stages of the motors, control gear and BPR power blocks, as well the decelerators and elec-
tromechanical parking brakes.
- gradual shift between speeds, producing a high degree of smoothness during acceleration
- protection against a sharp reversal in operating direction from the control
- adjustment of first speed value
- adjustment of second speed value
- movement braking via supply to decelerator and subsequent actuation of electromechanical parking
brake
- adjustment of movement braking torque value
- protection against supply phase fault
Movement is blocked by electromechanical brakes located in the motors. These brakes are actuated once mo-
vement has been stopped by the motor decelerator braking. In case of need, there is a pushbutton to actuate
the brakes.
While transfer movement is taking place an alarm siren at the foot of the crane sounds intermittently to warn
anyone in the vicinity.
Inside the rotational motion cabinet there is a key switch that can lock rotational movement from the base of
the crane. It should only be activated once rotational movement has stopped. After activating the key switch
and before proceeding to work in the rotational area, you must check that rotational movement is impossible in
both directions. The use of the key switch locks the crane's movement but it also keeps the cabinet elements
powered (refer to the electric diagram).
In some cranes, the travel system incorporates a mechanical lock system in the wheel housing. This system
includes positioning switches which prevent travel if any of the latches are in the lock position or any position
other than idle in the unlock position. If the travel mechanism needs to be activated when the latches are not in
the idle in unlock position (for example, if the latches have become jammed), there is a switch with a key inside
the travel unit which cancels any limitations to the travel movement when activated.
- Supply for decelerator braking, depending on the speed selected by the operator.
- Control of the BPR power changer for supply of the motor stator.
- Intelligent anti-reverse protection, distinguishing the speed point from when reverse starts.
The BCR30 card can control one or several "BPR" power blocks, depending on the number of motors involved
in a movement.
- Thermal limitation.
If the temperature of the electronic circuit exceeds a certain safety level, then the maximum voltage which
may be supplied for decelerator braking is reduced to 10 Vdc.
- Incorrect control.
If the card receives commands to operate in both directions, no output will be produced, and the slewing
system will remain at rest.
- The card incorporates a green indicator Led:
On (steady) = normal operation.
Flashing = operation with thermal limitation.
Off = failure of supply to card.
2.3 Regulation.
The system includes the facility to set four parameters, each with its own potentiometer located in the "BCR30"
control card.
CARD BCR30
P1 P2 P3 P4
P1 P2 P3 P4
5 5 5 5
1 9 1 9 1 9 1 9
st
1 Speed 2nd Speed Stop Brake time
P4 "Brake time" controls the time for each actuation of the electromechanical brake.
"MAX" means greater time.
Electromechanical brake actuation time between 2 and 20 sec.
The potentiometers P1, P2, P3, P4 are adjusted at the COMANSA factory to the theoretically
ideal average values for the crane in question.
Should adjustment be considered necessary, this should be carried out with full knowledge of the
procedure and its consequences. Do not hesitate to consult with the factory.
This system incorporates a pushbutton in the operator's control to brake movement. The button cancels
the delay in the actuation of the electromechanical brake, and may be used, for example, to lock crane
travelling once it has already been stopped by dynamic braking, and there is a strong wind prevailing.
- In the first speeds, it provides the motor with a reduced supply voltage, while in fast speed it supplies the
motor with the rated mains voltage.
+ Red led:
- Off = normal operation.
- On (steady) = phase fault in supply input.
- Flashing = thermal limitation.
3.3 Regulation.
R S T U V W
Red Green
1 2
Initial Voltage
Block input Earth Output to Ramp Commutation
motor terminal
POT1
Controls the value of stator supply voltage in the first speeds, and therefore the torque applied by the
motors at these speeds.
Less voltage (less motor torque).
More voltage (more motor torque).
POT2 Changes the value of the voltage ramp in the step between the reduced value of the first speeds and
the rated mains voltage corresponding to fast spped.
Output voltage
V2
V1
Time
T1 T2
T1 = Time to establish first speeds voltage (fixed and very short value).
The potentiometers POT1 and POT2 are adjusted at the COMANSA factory to the theoretically ideal
average values for the crane in question.
Should adjustment be considered necessary, this should be carried out with full knowledge of the pro-
cedure and its consequences. Do not hesitate to consult with the factory.
POT1 This should be set to obtain a good first speed for the working conditions on site.
It is inadvisable to exceed 300 V with 400 V 50 Hz mains, or 360 V with 480 V 60 Hz mains, becau-
se:
- A greater deceleration is needed to have a small 1st speed.
- Motor consumption, and therefore heating, is greater at low speeds.
- Slewing starting torques are greater, so that the demands on mechanisms, and crane structurE
are greater.
Power block output voltage values should be similar, to avoid motors working out of balance.
4 OPERATING TABLES
X = Working
Contactor status
Control position -- = Rest
TAD TAT FT RT
Rest -- -- -- --
Travelling forwards 1 X -- X X
Travelling forwards 2 X -- X X
Travelling forwards 3 X -- X X
Travelling back 1 -- X X X
Travelling back 2 -- X X X
Travelling back 2 -- X X X
( 2) When the joy-stick passes zero, movement is braked by the motor decelerator during the time set in card BCR30.
After this time has elapsed, supply to the decelerators is cut off (contactor RG = OFF) and the electromechanicar
brake is actuated (FG = OFF)
NO = Contact open
BCR30 Card terminals BPR Terminals (1)
NC = Contact closed
Control position
1-2 1-3 1-4 1-5 1-6 2-7 1-8 1-9 1-10 11-12 13-14 15-16 (1) R-S-T U-V-W
Rest 48 Va -- -- -- -- -- -- -- -- NO 48 Va (3) -- --
Travelling
48 Va 48 Va -- -- -- -- 48 Va -- 48 Va NO 48 Va 6-9 Vdc 400 Vac 250-310 Va
forwards 1
Travelling
48 Va 48 Va -- 48 Va -- -- 48 Va -- 48 Va NO 48 Va 0,5-2 Vdc 400 Vac 250-310 Va
forwards 2
Travelling
48 Va 48 Va -- 48 Va 48 Va -- 48 Va -- 48 Va NC 48 Va -- 400 Vac 400 Vac
forwards 3
During braking
(2) on passing 48 Va -- -- -- -- -- -- -- 48 Va NO 48 Va 6-9 Vdc -- --
zero
Travelling back
48 Va -- 48 Va -- -- -- -- 48 Va 48 Va NO 48 Va 6-9 Vdc 400 Vac 250-310 Va
1
Travelling back
48 Va -- 48 Va 48 Va -- -- -- 48 Va 48 Va NO 48 Va 0,5-2 Vdc 400 Vac 250-310 Va
2
Travelling back
48 Va -- 48 Va 48 Va 48 Va -- -- 48 Va 48 Va NC 48 Va -- 400 Vac 400 Vac
2
On pressing
travelling brake
48 Va -- -- -- -- 48 Va -- -- -- NO 48 Va (3) --
with control at
0 (4)
( 1) Voltage values for the decelerator and motor may be adjusted via card BCR30 and block BPR respectively
( 2) When the joy-stick passes zero, movement is braked by the motor decelerator during the time set in card BCR30.
After this time has elapsed, supply to the decelerators is cut off and the electromechanicar brake is actuated
( 3) If the decelerator circuit is not under load, the voltage reading on the direct current side (terminals 15-16) in not signi-
ficant.
( 4) The travelling brake pushbutton cancels timing of the electromechanical brake actuation when the joy-stick is a rest.
0 CONTENTS
1 OPERATION DESCRIPTION
2 TROUBLESHOOTING
3 BRAKING RESISTANCES
1 OPERATION DESCRIPTION
The high-performance systems allow high-speed movement of loads. The crane operator should be
aware that the space needed to decelerate loads increases with increasing speed
The crane operator must always choose a suitable speed for the work conditions and other factors such
as visibility, obstacles, proximity of people, proximity to moving objects, reaction time, etc.
If the variator is replaced, before connecting it ensure that the motor and the braking resistances are not
diverted to earth. Failure to do so may cause damage to the variator.
The test must be carried out using an insulation tester.
The crane operator should be shown how to correctly use the slewing movement that could be different
from other types of tower cranes, as well as how to properly adjust the PAG and PDG potentiometers
to facilitate proper handling according to the construction site circumstances (see recommendations in
points 2, 3 and 4)
Working with fewer slewing motors than the crane is equipped with in normal operating mode may cause
damage to system components (crown, gearbox or pinion). The correct operation of the motors must be
checked regularly and rescue mode should be used when working with fewer motors than the crane is
equipped with.
The slewing movement is powered by a frequency converter in order to avoid sudden jumps in speed and to
guarantee smooth operation, according to the order given by the crane operator using the controls.
The frequency inverter feeds 2, 3 or 4 asynchronous motors depending on the crane model. One of the motors
has a built-in encoder which closes the variator control loop. Every motor has its own built-in shut-off tempera-
ture sensor, a brake and a remote weathervaning mechanism. During braking, the frequency inverter absorbs
the energy of the movement and dissipates it into a braking resistor.
The control has 3 speed settings, graduated from a minimum speed to the maximum permissible speed. Mo-
vement is smooth for both acceleration and deceleration.
When the jib reaches the end stop, the movement gradually and smoothly decelerates until it comes to a full stop.
There are three speeds in each direction. There are 2 speeds for keypad-run mechanisms, with the medium
speed being a step below the maximum speed.
The control signals from the crane operator controls are received by the variator, which executes a series of
control algorithms developed specifically for this application in order to ensure that:
- Changes of speed are gradual, producing smooth acceleration and deceleration movements.
- Sudden changes in running direction from the control are prevented.
- In normal operations, when the control is released, the variator gradually stops in a controlled way before
the mechanical brake is applied.
Retention of movement is achieved through electromechanical brakes located in the motors that are applied
once movement has stopped or when the crane operator presses a button on the control (PCFG).
Weathervane protection can be controlled remotely from the crane operator's control, and manually in the event
of a power failure.
The slewing system has a switch inside the service box that lets users work in rescue mode. Work can continue
when certain malfunctions occur, because rescue mode allows jib rotation with reduced performance. Temporary
unavailability of the crane is thereby avoided.
The potentiometer is marked from 0 to 10. If it is on 0, the jib output will be smoother. If it is on 10, it will be
more forceful.
1.2 Adjusting the braking ramp to adapt it to the configuration of the assembled crane
Warning note: Note that the variation of the braking ramp will affect the time and angle travelled during braking.
To adjust it, take precautions to check that there are no obstacles in the angle swept by the jib. Otherwise, the
ramp reduction could cause a collision.
The frequency inverter's built-in control algorithm allows you to adapt the crane's braking features based on the
length of the assembled jib or user preferences. A potentiometer located inside the electrical service box (PDG)
can increase or decrease the reactivity of the crane during braking, in order to fine-tune the system response
based on the particular working conditions and operator preference.
The potentiometer is marked from 0 to 10. If it is on 0, the braking will be smoother. If it is on 10, it will be more
forceful.
2 TROUBLESHOOTING
If a variator is replaced, before connecting it ensure that the motor and the brake resistors are not are
not diverted to earth.
Failure to do so may cause damage to the variator.
4 3 2 1
ESC ENT
When the console is connected, the converter's status is indicated through the RUN, WARN and FAULT indi-
cations on the display.
The following shows the correspondence between the indicator status and the converter operation status.
LED screens
LED H1 green LED H2 red Status
On Power connected, self-testing in progress
on off
Equipment active and ready
flashing
On Equipment error. Consult parameter 310 for
off flashing information about the error.
off power off or power supply fault.
off Equipment ready, not activated (FUF + STR or STL).
flashing Equipment ready but OFF.
flashing
Consult parameter 269 for further information about the lock
CTRL
FUF:
The variator is not operational and will not react to control orders. Check the X210.3 connection
for variator operation.
F…
F 0700 Indicates the error code triggered by the variator. The variator can only be activated by pressing
the RESET in the electrical cabinet or pressing the start/stop pushbutton or turning off the variator
power. When the error is reset, the screen shows a numeric value once more (see the table of
trigger codes). Outside of the console error screen, it is possible to read the actual error status of
the variator by reading the contents of parameter 259.
When voltage is supplied to the converter, the screen shows parameter 241 which is the actual real frequency of
the motor (estimated in open-loop and measured by the encoder in closed-loop configuration). Other parameters
may be displayed on the screen by navigating through the menu structure.
The display interface has 3 menus: CTRL, PARA and VAL. The following diagram shows the layout of menus
and the content of each menu.
MAIN MENU
- ADJUSTABLE PARAMETERS
- OPERATION CHANGES
To navigate through the menus, use the buttons on the console with the following functions:
- Up ( ) and down( ) buttons: these are used to navigate through the menu structure and to
change the value of settings and parameters.
- ENT Key:
This is used to access the content of menus and the content of parameters and values of each
menu as well as to confirm changes to a parameter value.
- ESC Key:
This is used to return to the main menu or a submenu or to cancel a change made to a parameter
that has not yet been confirmed.
As well as the basic information, described in the sections above, the variator includes functions that will help
the equipment operator or technical support to solve problems when an error occurs:
1) Converter status at latest error: If a converter fault occurs, the variator records the values of currents,
voltages, frequencies etc. in parameters 330 to 360. It is recommended that errors are checked when
they occur, especially when the reason for the fault is unknown.
2) List of the latest 16 errors: each one of the parameters from 310 to 325 record a description of the error
and the operation time at which it occurred (hours-minutes from the first use of the variator).
3) Error sum: this records the total number of errors that have occurred during the life of the variator
(parameter 362 of the VAL menu).
If autotuning is necessary, request instructions from the manufacturer for the operation.
When the variator has been triggered, we recommend noting the fault code that appears on the screen and to
find its causes.
Each time an error occurs, the following messages will be displayed on the KP 100 control unit with the mo-
ving code and text and red background. The error displayed is deleted by pressing the start/enter button. The
error status may be checked by reading the parameter 259 in the VAL menu (if there is no error then F0000 is
displayed for this parameter).
7 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
F0000 NO ERROR There is no error No error occurred. - -
Convertor overloaded for more than - Overload of lifting weight. - Testing of mechanical variables:
13/22
60 s. - Mechanical overload, motor load, possible obstruction, etc.
This appears when the output strain.
current exceeds the machine - Motor lock, stiff.
F0100 IXT Overload
safety values for a specific period.
Examples: 150% for more than 60
seconds.
130% for more than 30 seconds.
Convertor overloaded at low output - Overload of lifting weight. - Testing of mechanical variables:
frequency. Check operation and - Mechanical overload, motor load, possible obstruction, etc.
F0000 IXT DC DC overload
motor. Similar to IXT but for low strain.
power supply frequencies (<5Hz) - Motor lock, stiff.
Converter overloaded for 60s. -Overload of lifting weight. -Testing of mechanical variables:
-Mechanical overloads, motor load, possible obstruction, etc.
F0000 LONG TERM IXT Lengthy load
strain.
ELECTRICAL INSTALLATION
- Stiffness
Convertor overloaded for 1s -Overload of lifting weight. -Testing of mechanical variables:
load strain.
- Stiffness
HEAT SINK Over This appears when the heatsink -Excessive air temperature. -Check cooling electrical cabinet.
Approval
F0000 OVER temperature on temperature exceeds 80°C or 90°C. -Converter cooling not operating or -Check converter cooling.
TEMPERATURE the heatsink obstructed.
-
GFU
070 0007 IB
4 / 070 / 32
ERROR MESSAGES
8 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
This appears when the heatsink -Internal sensor of the converter -Check electrical cabinet heating.
Heatsink
temperature sensor is faulty or the faulty. -Change equipment.
F0000 HEAT SINK temperature
machine is too cold (see the range of -Excessively low-temperature.
sensor
13/22
acceptable working temperatures).
This appears when the variator -Excessive air temperature. -Check cooling electrical cabinet.
OVER Over temperature
F0000 internal temperature exceeds 70°C. -Converter cooling not operating or -Check converter cooling.
TEMPERATURE of the variator
obstructed.
This appears when the variator -Excessively low-temperature. -Check electrical cabinet heating.
UNDER Variator low
F0000 internal temperature drops below
TEMPERATURE temperature
0°C.
This appears when the motor -Temperature motor too high (PTC -Check the connection to the PTC
temperature probe (PTC) switches > 3 kOhm). probe.
Motor Motor tempera- or when its value is higher than 3000 -PTC terminals of the motor not -Measure the PTC resistance.
F0400
TEMPERATURE ture Ohms. connected to X464.1/2 on the -Check operation of the air
variator. circulation.
-PTC probe cable ruptured.
Activation of the A motor protection switch has been - Motor connection or phase fault. - Check motor
MOTORPROTEC-
F0000 motor protection activated
TIVE SWITCH
switch
ELECTRICAL INSTALLATION
The converter has not detected one -A converter output phase is off. -Check the motor and its cabling
Approval
CURRENT current
the converter rated value). on the motor shaft. -If the fault occurs again without a
-Transistors short-circuiting. load, replace the converter.
-
GFU
070 0007 IB
4 / 070 / 33
ERROR MESSAGES
9 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
This appears when a short circuit -Short circuit or earth/ground fault -Check motor cabling for possible
UCE- or earth/ground fault occurs on the in the motor or its power cables. diversion.
F0000 UCE Control
CONTROL output. -Transistors short-circuiting. -If the fault occurs again without a
13/22
load, replace the converter.
The converter detects a sudden -Instantaneous motor overload. - Testing of mechanical variables:
DYN. PHASE-CU-
Limitation of pha- current surge -Short-circuit on one motor phase. load, possible obstruction, etc.
F0000 RRENT LIMITA-
TION se current -Check the motor and its cabling
from the variator terminals
This appears when a short circuit -Short circuit or earth/ground fault -Check motor cabling for possible
DC LINK over-
or earth/ground fault occurs on the in the motor or its power cables. diversion.
F0000 OVER current on the DC
CURRENT output. -Transistors short-circuiting. -If the fault occurs again without a
connection
load, replace the converter.
CURRENT - Motor mechanical or electrical - Check motor.
Current controller Prolonged overload of the current
F0000 LIMIT CONTRO- limit controller. fault.
LLER limit
EARTH FAULT over- This appears when the sum of cable -Current leakage. -Check motor cabling for possible
F0000 OVER current leakage currents is incorrect. diversion.
CURRENT to earth
Motor phase current very high. -Instantaneous motor overload. - Testing of mechanical variables:
ELECTRICAL INSTALLATION
Approval
from the variator terminals
-
GFU
070 0007 IB
4 / 070 / 34
ERROR MESSAGES
10 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
F0600 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETEC-TION: 0H detection power board
DETECTED
13/22
F0601 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETECTION: FH detection power board
DETECTED
F0602 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETECTION: detection power board
TOLERANCE
ERROR
F0603 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETECTION: detection power board
MEASUREMENT
ERROR
F0604 Unknown Power Unknown power Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
Unit unit power board
F0605 Power Unit De- Power unit de- Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
tection: Error tection power board
ELECTRICAL INSTALLATION
This appears when the voltage on -Power voltage too high. -Verification of the mains voltage.
the intermediate DC circuit exceeds -Voltage spikes or problems on the -Verification of the dynamic braking
Approval
UNDER the intermediate DC circuit is lower -Fault on a power supply phase. on all phases.
F0000 Low voltage
VOLTAGE than permitted (350 Vdc). Voltage on -Voltage drop due to cable losses. -Verification of cabling.
the DC bus too low.
This appears when there is a -Power supply unstable or too low. -Verification of the mains voltage
F0000 POWER FAILURE Power failure converter power supply fault. on all phases.
-
-Verification of cabling.
GFU
070 0007 IB
4 / 070 / 35
ERROR MESSAGES
11 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
PHASE FAILURE Power supply Variator power supply phase fault -There is no voltage on one of the -Check the variator power supply.
F0703 LINE phase failure variator power supply phases. -Check the variator chooses.
OVERVOLTAGE DC bus voltage -The voltage value of parameter p.680 -Excess power supply voltage -Check power supply voltage.
13/22
F0704 UDC LIMITATION limit has been exceeded. -Check value of parameter p.680
This appears when the voltage of the -Power voltage too high. -Verification of the mains voltage.
OVER Braking circuit intermediate DC circuit is higher than -Use of the crane without -Ensure that the crane connection
F0000
VOLTAGE BC overvoltage the dynamic braking circuit activation connection transformer suitable. guarantees a suitable voltage.
voltage.
Motor Chopper This appears when the voltage of the -Power voltage too high. -Verification of the mains voltage.
OVER
F0000 circuit overvol- intermediate DC circuit is higher than -Use of the crane without connec- -Ensure that the crane connection
VOLTAGE MC
tage the Motor chopper circuit activation tion transformer suitable. guarantees a suitable voltage.
voltage.
Appears when the +/-15 Vdc voltage -Converter fault. -Replace converter.
15V VOLTAGE 15V – voltage too
F0000 is too low on the controller board. -Control terminals cabling. -Check the cabling to the control
TOO LOW low
terminals.
Appears when the 24 Vdc voltage is -Converter fault. -Replace converter.
24V VOLTAGE 24V – voltage too
F0000 too low on the controller board. -Control terminals cabling. -Check the cabling to the control
TOO LOW low
terminals.
ELECTRICAL INSTALLATION
Power Interface Power Interface Internal fault on the power interface -Variator internal fault -Check for the unusual source of
Elec. Voltage unit voltage board -Excessive electrical noise. excessive electrical noise in the
-Replace variator.
24 V. -Replace converter.
24V VOLTAGE Appears when the 24 Vdc voltage is -Converter fault.
F0000 voltage too -Check the cabling to the control
TOO SMALL too high on the controller board. -Control terminals cabling.
Approval
high terminals.
Bootstrap Pre- Precharge initial Fault in the initial condenser precharge -Variator internal fault -Replace variator.
F0000
charge process system.
-
GFU
070 0007 IB
4 / 070 / 36
ERROR MESSAGES
12 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
PRE- This appears when the preload -Turn off the power supply, wait
F0000 LOAD CON- Preload contactor contactor has triggered or is not -Load circuit overheated. five minutes and turn on the power
TACTOR activated. supply once more.
13/22
Brake Chopper Brake circuit Fault in the braking transistor. -Internal variator fault caused by a -Carefully check the braking resis-
F0000 fault in the braking transistor. tance for a short-circuit and correct it.
-Replace variator.
This appears when the variator -Converter fault. -Check the settings of the load
FRE-
detects that the upper Frequency -Load limiting system incorrectly limiting system.
F0000 QUEN- Frequency limit
CY LIMIT Switch-Off Limit has been reached, set or faulty. -Check variator operation.
parameter 417.
F1101 Frequency Limit DC bus frequency Speed limit reached due to brake -Problem in the brake circuit. -Carefully check the braking resis-
UDC Limitation limitation problem. -Overload of the brake circuit. tance to see if it is in open circuit
configuration.
- Testing of mechanical variables:
load, possible obstruction, etc.
F1110 Speed Limit Speed limit Speed limit reached. -Encoder broken. - Testing of mechanical variables:
-Electromagnetic noise from load, possible obstruction, etc.
encoder. -Check correct operation of the
-Encoder bad connection. encoder.
ELECTRICAL INSTALLATION
or earth/ground fault occurs on the in the motor or its power cables. diversion.
F0000 EARTH FAULT Earth fault
output circuit. -Transistors short-circuiting. -If the fault occurs again without a
load, replace the converter.
IDC This appears when the variator -A converter output phase is off. -Check the motor and its cabling.
Approval
Compensation
F0000 COM- supplies power to an irregular load. -Motor cable rupture.
PENSATION of IDC system
MIN. CURRENT Very low control The reference current cannot be - Motor connection or phase - Check motor
F0000 reached after opening the brake. problem
CONTROL current
-
GFU
070 0007 IB
4 / 070 / 37
ERROR MESSAGES
13 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
A n a l o g Va l u e Analogue input va- The potentiometer input value is in- -Internal fault on the variator analo-
F0000 -Replace variator.
MFI1A missing lue fault adequate. gue input circuit.
MFI1 : Overcu- Overcurrent on Overcurrent on the potentiometer -Potentiometer ohmic value to low. -Check potentiometer resistance.
13/22
rrent the analogue in- input. -Short-circuit on the potentiometer -Check potentiometer cabling.
F0000 put input. -Replace variator.
-Internal fault on the variator analo-
gue input circuit.
ENCO- This appears when encoder -Encoder broken. -Check encoder connections.
No encoder
F0000 DER: NO ENCO- monitoring detects a fault in the -Encoder connection incorrect. -Replace encoder.
DER SIGNAL signal
encoder signal. -Encoder cable cut.
ENCO- This appears when encoder -Encoder broken. -Check encoder connections.
Fault on one
F0000 DER: ONE CHAN- monitoring detects the absence of -Encoder connection incorrect. -Replace encoder.
NEL FAULT encoder channel
one of the encoder signal channels. -Encoder cable cut.
ENCO- This appears when the encoder -Encoder broken. -Check encoder connections.
DER: Encoder: wrong monitoring detects an incorrect -Encoder connection incorrect. -Replace encoder.
F0000
WRONG DIREC- direction operation direction of rotation.
TION
F1434 Encoder: Low Di- N u m b e r o f The variator detects that the number of -The encoder connected is unsui- -Check correct operation of the
ELECTRICAL INSTALLATION
vision Marks encoder divisions encoder pulses is lower than expected. table. encoder.
insufficient -Encoder broken. -Check the number of pulses per
F1435 Encoder: Low Di- N u m b e r o f The variator detects that the number -The encoder connected is unsui- -Check correct operation of the
vision Marks encoder divisions of encoder pulses is higher than ex- table. encoder.
excessive pected. -Encoder broken. -Check the number of pulses per
Approval
encoder cycle.
Encoder 1: Divi- Encoder division Encoder division marks fault -The variator detects a fault in the -The encoder connected is unsui-
F0000 sion Marks Fault marks fault encoder division marks. table.
-Encoder broken.
-
GFU
070 0007 IB
4 / 070 / 38
ERROR MESSAGES
14 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
F2300 Unknown CM Unidentified CM Fault on a variator optional board -Electromagnetic noise. -Check for the unusual source of
board -Variator internal fault excessive electrical noise in the
installation and the surroundings.
13/22
-Replace variator.
Unknown EM Unidentified EM Fault on a variator optional board -Electromagnetic noise. -Check for the unusual source of
board -Variator internal fault excessive electrical noise in the
F0000
installation and the surroundings.
-Replace variator.
F0AXX - - Fault in the variator EEPROM. -Sporadic fault in reading memory. -Turn the variator off and on again.
-Program incorrectly stored in me- -Load suitable program.
mory. -Replace variator.
-Memory faulty. -Check for the unusual source of
-Electromagnetic noise. excessive electrical noise in the
installation and the surroundings.
F0BXX - - Control board fault -Electromagnetic noise. -Check for the unusual source of
-Variator internal fault excessive electrical noise in the
installation and the surroundings.
-Replace variator.
ELECTRICAL INSTALLATION
F0CXX - - Control board fault -Electromagnetic noise. -Check for the unusual source of
-Variator internal fault excessive electrical noise in the
-Replace variator.
SFXXX - - Internal fault during autotuning. -Fault during the motor parameters -Repeat autotuning.
identification process. -Check motor parameters.
Approval
SAXXX - - Internal fault during autotuning. -Fault during the motor parameters -Repeat autotuning.
identification process. -Check motor parameters.
-
GFU
070 0007 IB
4 / 070 / 39
ELECTRICAL INSTALLATION 070 0007 IB
GFU
SLEWING SYSTEM - ELECTRIC SECTION -
Apart from the previous error messages, there are additional error messages that are not listed here. If
you receive an error message not mentioned in the above list, please contact the COMANSA technical
support area.
Note: The most useful parameters for the user have been highlighted using italics and bold lettering.
VAL menu (variables that may be monitored) VAL menu (variables that may be monitored)
VAL menu (variables that may be monitored) VAL menu (variables that may be monitored)
VAL menu (variables that may be monitored) PARA menu (parameter configurations)
nº Abbrev. Name/meaning Unit
nº Abbrev. Name/meaning Unit
Name of program ins- 33 cha-
29 NAME
Analogue output 2 upon talled racters
347 EOUT1 mA
last error
30 CONF Configuration Selection
Analogue output 3 upon
348 EOUT1 mA Selec-
last error 33 LANG Language
tion
Frequency output repeti- 123:
349 EFO Hz
tion upon last error Rearm
Command line for ori-
4444:
34 PROG ginal settings reset or
Status of digital inputs Original
350 EIND error reset.
upon last error set-
tings.
Status of digital outputs 39 TVENT Air cooling on temp. °C
351 EOUTD
upon last error Selec-
237 PHCLR Reset memory
tion
h:m:s.
352 ETIME Time since last error Motor data
ms
370 MUR Rated voltage V
Heatsink temperature
353 ETC °C
371 MIR Rated current A
upon last error
Internal temperature 372 MNR Rated speed -1/min
354 ETI °C
upon last error 373 MPP Nº of pole pairs
Controller status at latest
355 EC text 374 MCOPR Rated j cosine
error:
Warning status upon last 375 MFR Rated frequency Hz
356 EW text
error 376 MPR Rated power kW
Internal value 1 upon last
357 EI1 400 FT Switching frequency kHz
error
Internal value 2 upon last Error and warning compartment
358 EI1
error 405 WIXTD Lim. warning IxT DC %
Extended value 1 upon 406 WIXT Lim. warning IxT %
359 EF1
last error
407 WTC Limit warning Tc °C
Extended value 2 upon
360 EF1 408 WTI Limit warning Ti °C
last error
Checksum upon last 409 CTMSG Controller status Selection
361 CHSUM
error Communication interface
0 ... Time watchdog RS232/
362 ESUM Number of errors 413 WDOG s
32767 RS485
Error and warning compartment
PARA menu (parameter configurations) 415 DCCMX DC compensation limit V
545 C1OFF Lower comparator off % 680 UDLIM Reference DC bus limitation V
736 SCSUT Torque upper limit source Selection 803 BRT4 Brake open delay time 4 s
737 SCSLT Torque lower limit source Selection 804 BRT11 Brake close delay time 1 s
805 BRT12 Brake close delay time 2 s
Speed control switching
738 SCSWP Hz
limit 806 BRT13 Brake close delay time 3 s
739 SCULP Upper power limit kW 807 BRT14 Brake close delay time 4 s
3 BRAKING RESISTORS
Both the braking resistors and their enclosures may reach very high temperatures.
Before beginning inspection or maintenance ensure that it is at a temperature that will not cause damage.
Even if the variator is not dissipating energy in the braking resistors, this does not guarantee that they
are electrically disconnected.
Before beginning any maintenance operation on the braking resistors, turn off the variator and wait 5
minutes until the direct-current bus is discharged. Otherwise, you may be subjected to an electrical dis-
charge.
During deceleration of variator movement, the inertia is dissipated by heating a battery of electrical resistors
that are designed to consume high quantities of energy without any damage.
The condition of this battery must be verified so that the system operates correctly, given that the variator be-
haviour is quite sensitive to variations in resistance value. Given the need to dissipate heat, the resistor bank
is not sealed and is therefore exposed to small particles.
In salty or dusty environments, the resistor bank must be checked regularly and, if necessary, it must be cleaned
using air and brushes to avoid situations that may affect its electrical resistance value.
0 CONTENTS
1 OPERATION DESCRIPTION
2 TROUBLESHOOTING
3 OVERSPEED CONTROL SYSTEM
4 BRAKING RESISTANCES
5 EFFI+ SYSTEM
1 OPERATION DESCRIPTION
Because of the sensitivity of the crane operator control, it is recommended that lifting and lowering
operations are carried out in the positioning mode.
The high-performance systems allow high-speed movement of loads. The crane operator should take
into account the space required to slow down the loads after acceleration
The crane operator must always choose a suitable speed for the work conditions and other factors such
as visibility, obstacles, proximity of people, proximity to moving objects, reaction time, etc.
The winch is powered by a frequency converter in order to avoid sudden jumps in speed and to guarantee a
smooth operation, according to the order given by the crane operator using the controls.
The control includes a potentiometer, which can be used to select any speed ranging from 0 to the maximum
permitted speed of the specific hook status and the range of speeds selected by the crane operator. (see load/
speed diagrams).
When the hook is approaching the end of its range, the maximum lifting speed is reduced automatically (high-
speed pre-limitation).
load
LIFTING/LOWERING
speed
At the beginning of movement, the brake is only released if the converter has ensured that the motor has
sufficient torque.
The brakes are applied at zero speed to avoid shuddering due to brake activation.
At the end of the movement, the converter reduces the mechanism speed until it is practically zero then orders
application of the brakes.
Because this is a retention brake system and not a working brake system, the brake wear and maintenance
is kept to a minimum.
Despite the above, emergency stops triggered by the crane operator using the control or due to triggering
of the frequency converter protection both cause the brake to be activated with a moving load, so it must be
again highlighted that the brakes must be serviced soon after to ensure that they operate properly (see brake
adjustment instructions).
The positioning mode provides gentle and precise operation for load positioning.
When the crane operator chooses this mode of operation, the range of speed according to the movement of
the crane operator control is noticeably reduced and the brake is not applied when passing the zero point. It
also provides high sensitivity at low speeds, small lowering/lifting movements for positioning, eliminating all
shudders and sudden stops.
The positioning mode may be selected by the crane operator, even while the mechanism is moving, for example,
when the load is approaching the stopping point and then used to gently and precisely lower the load.
The retention brakes are activated when the crane operator changes to normal operation and the controller is
at point zero.
The range of lifting speeds is selected by the crane operator using the four-position switch located in the crane
operator cabin. (see the section "Crane operator control").
If a range of speeds is selected and the hook load is higher than allowed for this range, then the lifting movement
is blocked (both lifting and lowering) and the overload management (SCEM) indicator in the cab indicates this
situation.
The crane is fitted with a safety system that protects against uncontrolled load movements in case the
frequency converter malfunctions. An inductive sensor on the lifting motor shaft sends a speed signal to a
programmable computer (AEQ) located in the lifting cabinet, so if the speed is higher than the suitable speed
for the hook load, lifting is stopped.
So that the safety system operates correctly, the load limitation system must be correctly set.
2 TROUBLESHOOTING
If a variator is replaced, before connecting it ensure that the motor and the brake resistors are not short-
circuited to ground.
Failure to do so may cause damage to the variator.
X210.4 Lifting.
X210.5 Lowering.
X210.6 High-speed limitation (bit 1).
X210.7 High-speed limitation (bit 2).
X210.8 Speed range selection (bit 1).
X210.9 Speed range selection (bit 2).
X210.10 Reset.
X210.12 Speed signal reached. (90 rpm)
X210.13 Brake control
X211.1 10 V.
X211.2
0 V.
X211.4
X211.3 Speed reference.
X460.1
Internal auxiliary braking relay.
X460.2
X464.1
Turning on the motor thermal probe.
X464.2
4 3 2 1
ESC ENT
When the console is connected, the converter's status is indicated through the RUN, WARN and FAULT indi-
cations on the display.
The following shows the correspondence between the indicator status and the converter operation status.
LED screens
LED H1 green LED H2 red Status
On Power connected, self-testing in progress
On off
Equipment active and ready
flashing
On Equipment error. Consult parameter 310 for
off flashing information about the error.
off power off or powersupply fault.
off Equipment ready, not activated (FUF + STR or STL).
flashing Equipment ready but off Check parameter
flashing
269 for further information about the lock
FUF: The variator is not operational and will not react to control orders. Check the X210.3 con-
nection for variator operation.
241
A numerical value: The converter is operating normally. By default, the value of parameter 241 is
displayed, which is the frequency monitor of motor rotation (estimate for open-loop or measured
by the encoder if closed-loop).
F… indicates the error code triggered by the variator. The variator can only be activated by pressing
F 0700 the RESET in the electrical cabinet or pressing the start/stop pushbutton or turning off the variator
power. When the error is reset, the screen shows a numeric value once more (see the table of
trigger codes). Outside of the console error screen, it is possible to read the actual error status of
the variator by reading the contents of parameter 259.
MAIN MENU
- ADJUSTABLE SETTINGS/PARAMETERS
- OPERATION CHANGES
1) Converter status at latest error: If a converter fault occurs, the variator records the values of currents,
voltages, frequencies etc. in parameters 330 to 360. It is recommended that errors are checked when
they occur, especially when the reason for the fault is unknown.
2) List of the latest 16 errors: each one of the parameters from 310 to 325 record a description of the error
and the operation time at which it occurred (hours-minutes from the first use of the variator).
3) Error sum: this records the total number of errors that have occurred during the life of the variator
(parameter 362 of the VAL menu).
If autotuning is necessary, request instructions from the manufacturer for the operation.
6 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
F0000 NO ERROR There is no error No error occurred. - -
Convertor overloaded for more than - Overload of lifting weight. - Testing of mechanical variables:
12/43
60 s. - Mechanical overload, motor load, possible obstruction, etc.
This appears when the output strain.
current exceeds the machine - Motor lock, stiff.
F0000 IXT Overload
safety values for a specific period.
Examples: 150% for more than 60
seconds.
130% for more than 30 seconds.
Convertor overloaded at low output - Overload of lifting weight. - Testing of mechanical variables:
frequency. Check operation and - Mechanical overload, motor load, possible obstruction, etc.
F0000 IXT DC DC overload
motor. Similar to IXT but for low strain.
powersupply frequencies (<5Hz) - Motor lock, stiff.
Converter overloaded for 60s. -Overload of lifting weight. -Testing of mechanical variables:
-Mechanical overloads, motor load, possible obstruction, etc.
F0000 LONG TERM IXT Lengthy load
strain.
ELECTRICAL INSTALLATION
- Stiffness
Convertor overloaded for 1s -Overload of lifting weight. -Testing of mechanical variables:
load strain.
- Stiffness
HEAT SINK Over This appears when the heatsink -Excessive air temperature. -Check cooling electrical cabinet.
F0000 OVER temperature on temperature exceeds 80°C or 90°C. -Converter cooling not operating or -Check converter cooling.
TEMPERATURE the heatsink obstructed.
Approval
-
EFU
080 0009 IB
4 / 080 / 52
ERROR MESSAGES
7 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
This appears when the heatsink -Internal sensor of the converter -Check electrical cabinet heating.
Heatsink
temperature sensor is faulty or the faulty. -Change equipment.
F0000 HEAT SINK temperature
machine is too cold (see the range of -Excessively low-temperature.
sensor
12/43
acceptable working temperatures).
This appears when the variator -Excessive air temperature. -Check cooling electrical cabinet.
OVER Over temperature
F0000 internal temperature exceeds 70°C. -Converter cooling not operating or -Check converter cooling.
TEMPERATURE of the variator
obstructed.
This appears when the variator -Excessively low-temperature. -Check electrical cabinet heating.
UNDER Variator low
F0000 internal temperature drops below
TEMPERATURE temperature
0°C.
This appears when the motor -Temperature motor too high (PTC -Check the connection to the PTC
temperature probe (PTC) switches > 3 kOhm). probe.
MOTOR Motor tempera- or when its value is higher than 3000 -PTC terminals of the motor not -Measure the PTC resistance.
F0400
TEMPERATURE ture Ohms. connected to X464.1/2 on the -Check operation of the air
variator. circulation.
-PTC probe cable ruptured.
Activation of the A motor protection switch has been - Motor connection or phase fault. - Check motor
MOTORPROTEC-
F0000 motor protection activated
TIVE SWITCH
switch
ELECTRICAL INSTALLATION
The converter has not detected one -A converter output phase is off. -Check the motor and cabling from
Approval
-Transistors short-circuiting. replace the converter.
-
EFU
080 0009 IB
4 / 080 / 53
ERROR MESSAGES
8 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
This appears when a short circuit -Short circuit or earth/ground fault -Check motor cabling for possible
UCE- or earth/ground fault occurs on the in the motor or its power cables. diversion.
F0000 UCE Control
CONTROL output. -Transistors short-circuiting. -If the fault reoccurs without a load,
12/43
replace the converter.
The converter detects a sudden -Instantaneous motor overload. - Testing of mechanical variables:
DYN. PHASE-CU-
Limitation of pha- current surge -Short-circuit on one motor phase. load, possible destruction, etc.
F0000 RRENT LIMITA-
TION se current -Check the motor and its cabling
from the variator terminals
This appears when a short circuit -Short circuit or earth/ground fault -Check motor cabling for possible
DC LINK over-
or earth/ground fault occurs on the in the motor or its power cables. diversion.
F0000 OVER current on the DC
CURRENT output. -Transistors short-circuiting. -If the fault occurs again without a
connection
load, replace the converter.
CURRENT - Motor mechanical or electrical - Check motor.
Current controller Prolonged overload of the current
F0000 LIMIT CONTRO- limit controller. fault.
LLER limit
EARTH FAULT over- This appears when the sum of cable -Current leakage. -Check motor cabling for possible
F0000 OVER current leakage currents is incorrect. diversion.
CURRENT to earth
Motor phase current very high. -Instantaneous motor overload. - Testing of mechanical variables:
ELECTRICAL INSTALLATION
Approval
-
EFU
080 0009 IB
4 / 080 / 54
ERROR MESSAGES
9 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
F0600 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETEC-TION: 0H detection power board
DETECTED
12/43
F0601 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETECTION: FH detection power board
DETECTED
F0602 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETECTION: detection power board
TOLERANCE
ERROR
F0603 POWER UNIT Power unit Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
DETECTION: detection power board
MEASUREMENT
ERROR
F0604 Unknown Power Unknown power Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
Unit unit power board
F0605 Power Unit De- Power unit de- Internal fault in the detection of the -Variator internal fault -Please contact COMANSA.
tection: Error tection power board
ELECTRICAL INSTALLATION
This appears when the voltage on -Power voltage too high. -Verification of the mains voltage.
the intermediate DC circuit exceeds -Voltage spikes or problems on the -Verification of the dynamic braking
Approval
the DC bus too low.
This appears when there is a -Power supply unstable or too low. -Verification of the mains voltage
F0000 POWER FAILURE Power failure converter powersupply fault. on all phases.
-
-Verification of cabling.
EFU
080 0009 IB
4 / 080 / 55
ERROR MESSAGES
10 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
PHASE FAILURE Power supply Variator powersupply phase fault -There is no voltage on one of the -Check the variator powersupply.
F0703 LINE phase failure variator powersupply phases. -Check the variator chooses.
OVERVOLTAGE DC bus voltage -The voltage value of parameter p.680 -Excess power supply voltage -Check power supply voltage.
12/43
F0704 UDC LIMITATION limit has been exceeded. -Check value of parameter p.680
This appears when the voltage of the -Power voltage too high. -Verification of the mains voltage.
OVER Braking circuit intermediate DC circuit is higher than -Use of the crane without -Ensure that the crane connection
F0000
VOLTAGE BC overvoltage the dynamic braking circuit activation connection transformer suitable. guarantees a suitable voltage.
voltage.
Motor Chopper This appears when the voltage of the -Power voltage too high. -Verification of the mains voltage.
OVER
F0000 circuit overvol- intermediate DC circuit is higher than -Use of the crane without connec- -Ensure that the crane connection
VOLTAGE MC
tage the Motor chopper circuit activation tion transformer suitable. guarantees a suitable voltage.
voltage.
Appears when the +/-15 Vdc voltage -Converter fault. -Replace converter.
15V VOLTAGE 15V – voltage too
F0000 is too low on the controller board. -Control terminals cabling. -Check the cabling to the control
TOO LOW low
terminals.
Appears when the 24 Vdc voltage is -Converter fault. -Replace converter.
24V VOLTAGE 24V – voltage too
F0000 too low on the controller board. -Control terminals cabling. -Check the cabling to the control
TOO LOW low
terminals.
ELECTRICAL INSTALLATION
Power Interface Power Interface Internal fault on the power interface -Variator internal fault -Check for the unusual source of
Elec. Voltage unit voltage board -Excessive electrical noise. excessive electrical noise in the
-Replace variator.
24 V. -Replace converter.
24V VOLTAGE Appears when the 24 Vdc voltage is -Converter fault.
F0000 voltage too -Check the cabling to the control
TOO SMALL too high on the controller board. -Control terminals cabling.
high terminals.
Approval
Bootstrap Pre- Precharge initial Fault in the initial condenser precharge -Variator internal fault -Replace variator.
F0000
charge process system.
-
EFU
080 0009 IB
4 / 080 / 56
ERROR MESSAGES
11 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
PRE- This appears when the preload -Turn off the power supply, wait
F0000 LOAD CON- Preload contactor contactor has triggered or is not -Load circuit overheated. five minutes and turn on the power
TACTOR activated. supply once more.
12/43
Brake Chopper Brake circuit Brake transistor fault. -Internal variator fault caused by a -Carefully check the braking resis-
F0000 fault in the braking transistor. tance for a short-circuit and correct it.
-Replace variator.
This appears when the -Converter fault. -Check the settings of the load
FRE-
variator detects that the upper -Load limiting system incorrectly limiting system.
F0000 QUEN- Frequency limit
CY LIMIT Frequency Switch-Off Limit has been set or faulty. -Check variator operation.
reached, parameter 417.
F1101 Frequency Limit DC bus frequen- Speed limit reached due to brake -Problem in the brake circuit. -Carefully check the braking resis-
UDC Limitation cy limitation problem. -Overload of the brake circuit. tance to see if it is in open circuit
configuration.
- Testing of mechanical variables:
load, possible destruction, etc.
F1110 Speed Limit Speed limit Speed limit reached. -Encoder broken. - Testing of mechanical variables:
-Electromagnetic noise from load, possible destruction, etc.
encoder. -Check correct operation of the
-Encoder bad connection. encoder.
ELECTRICAL INSTALLATION
or earth/ground fault occurs on the in the motor or its power cables. diversion.
F0000 EARTH FAULT Earth fault
output circuit. -Transistors short-circuiting. -If the fault reoccurs without a load,
replace the converter.
IDC -A converter output phase is off. -Check the motor and its cabling.
Compensation This appears when the variator
F0000 COM- supplies power to an irregular load. -Motor cable rupture.
Approval
PENSATION of IDC system
MIN. CURRENT Very low control The reference current cannot be - Motor connection or phase - Check motor
F0000 reached after opening the brake. problem
CONTROL current
-
EFU
080 0009 IB
4 / 080 / 57
ERROR MESSAGES
12 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
A n a l o g Va l u e Analogue input va- The potentiometer input value is in- -Internal fault on the variator analo-
F0000 -Replace variator.
MFI1A missing lue fault adequate. gue input circuit.
MFI1 : Overcu- Overcurrent on Overcurrent on the potentiometer -Potentiometer ohmic value to low. -Check potentiometer resistance.
12/43
rrent the analogue in- input. -Short-circuit on the potentiometer -Check potentiometer cabling.
F0000 put input. -Replace variator.
-Internal fault on the variator analo-
gue input circuit.
ENCO- This appears when encoder -Encoder broken. -Check encoder connections.
No encoder
F0000 DER: NO ENCO- monitoring detects a fault in the -Encoder connection incorrect. -Replace encoder.
DER SIGNAL signal
encoder signal. -Encoder cable cut.
ENCO- This appears when encoder -Encoder broken. -Check encoder connections.
Fault on one
F0000 DER: ONE CHAN- monitoring detects the absence of -Encoder connection incorrect. -Replace encoder.
NEL FAULT encoder channel
one of the encoder signal channels. -Encoder cable cut.
ENCO- This appears when the encoder -Encoder broken. -Check encoder connections.
DER: Encoder: wrong monitoring detects an incorrect -Encoder connection incorrect. -Replace encoder.
F0000
WRONG DIREC- direction operation direction of rotation.
TION
F1434 Encoder: Low Di- N u m b e r o f The variator detects that the number of -The encoder connected is unsui- -Check correct operation of the
ELECTRICAL INSTALLATION
vision Marks encoder divisions encoder pulses is lower than expected. table. encoder.
insufficient -Encoder broken. -Check the number of pulses per
F1435 Encoder: Low Di- N u m b e r o f The variator detects that the number -The encoder connected is unsui- -Check correct operation of the
vision Marks encoder divisions of encoder pulses is higher than ex- table. encoder.
excessive pected. -Encoder broken. -Check the number of pulses per
encoder cycle.
Approval
Encoder 1: Divi- Encoder division Encoder division marks fault -The variator detects a fault in the -The encoder connected is unsui-
F0000 sion Marks Fault marks fault encoder division marks. table.
-Encoder broken.
-
EFU
080 0009 IB
4 / 080 / 58
ERROR MESSAGES
13 / 21
KP 100 SCREEN PROBLEM SOLUTION
Rev: A
F2300 Unknown CM Unidentified CM Fault on a variator optional board -Electromagnetic noise. -Check for the unusual source of
board -Variator internal fault excessive electrical noise in the
installation and the surroundings.
12/43
-Replace variator.
Unknown EM Unidentified EM Fault on a variator optional board -Electromagnetic noise. -Check for the unusual source of
board -Variator internal fault excessive electrical noise in the
F0000
installation and the surroundings.
-Replace variator.
F0AXX - - Fault in the variator EEPROM. -Sporadic fault in reading memory. -Turn the variator off and on again.
-Program incorrectly stored in me- -Load suitable program.
mory. -Replace variator.
-Memory faulty. -Check for the unusual source of
-Electromagnetic noise. excessive electrical noise in the
installation and the surroundings.
F0BXX - - Control board fault -Electromagnetic noise. -Check for the unusual source of
-Variator internal fault excessive electrical noise in the
installation and the surroundings.
-Replace variator.
ELECTRICAL INSTALLATION
F0CXX - - Control board fault -Electromagnetic noise. -Check for the unusual source of
-Variator internal fault excessive electrical noise in the
-Replace variator.
SFXXX - - Internal fault during autotuning. -Fault during the motor parameters -Repeat autotuning.
identification process. -Check motor parameters.
SAXXX - - Internal fault during autotuning. -Fault during the motor parameters -Repeat autotuning.
Approval
identification process. -Check motor parameters.
-
EFU
080 0009 IB
4 / 080 / 59
ELECTRICAL INSTALLATION 080 0009 IB
EFU
LIFTING SYSTEM - ELECTRICAL SECTION -
Apart from the previous error messages, there are additional error messages that are not listed here. If
you receive an error message not mentioned in the above list, please contact the COMANSA technical
support area.
Note: The most useful parameters for the user have been highlighted using italics and bold lettering.
VAL menu (variables that may be monitored) VAL menu (variables that may be monitored)
VAL menu (variables that may be monitored) VAL menu (variables that may be monitored)
VAL menu (variables that may be monitored) PARA menu (parameter configurations)
nº Abbrev. Name/meaning Unit
nº Abbrev. Name/meaning Unit
Name of program 33 cha-
29 NAME
Analogue output 2 upon installed racters
347 EOUT1 mA
last error
30 CONF Configuration Selection
Analogue output 3 upon
348 EOUT1 mA Selec-
last error 33 LANG Language
tion
Frequency output 123:
349 EFO Hz
repetition upon last error Rearm
Command line for
4444:
34 PROG original settings reset
Status of digital inputs Original
350 EIND or error reset.
upon last error set-
tings.
Status of digital outputs 39 TVENT Air cooling on temp. °C
351 EOUTD
upon last error Selec-
237 PHCLR Reset memory
tion
h:m:s.
352 ETIME Time since last error Motor data
ms
370 MUR Rated voltage V
Heatsink temperature
353 ETC °C
371 MIR Rated current A
upon last error
Internal temperature 372 MNR Rated speed -1/min
354 ETI °C
upon last error 373 MPP Nº of pole pairs
Controller status at latest
355 EC text 374 MCOPR Rated j cosine
error:
Warning status upon last 375 MFR Rated frequency Hz
356 EW text
error 376 MPR Rated power kW
Internal value 1 upon last
357 EI1 400 FT Switching frequency kHz
error
Internal value 2 upon last Error and warning compartment
358 EI1
error 405 WIXTD Lim. warning IxT DC %
Extended value 1 upon 406 WIXT Lim. warning IxT %
359 EF1
last error
407 WTC Limit warning Tc °C
Extended value 2 upon
360 EF1 408 WTI Limit warning Ti °C
last error
Checksum upon last 409 CTMSG Controller status Selection
361 CHSUM
error Communication interface
0 ... Time watchdog RS232/
362 ESUM Number of errors 413 WDOG s
32767 RS485
Error and warning compartment
PARA menu (parameter configurations) 415 DCCMX DC compensation limit V
545 C1OFF Lower comparator off % 680 UDLIM Reference DC bus limitation V
736 SCSUT Torque upper limit source Selection 803 BRT4 Brake open delay time 4 s
737 SCSLT Torque lower limit source Selection 804 BRT11 Brake close delay time 1 s
805 BRT12 Brake close delay time 2 s
Speed control switching
738 SCSWP Hz
limit 806 BRT13 Brake close delay time 3 s
739 SCULP Upper power limit kW 807 BRT14 Brake close delay time 4 s
LED panel
The following table indicates the software status according to the status of the LEDs:
4 BRAKING RESISTORS
Both the braking resistors and their enclosures may reach very high temperatures.
Before beginning inspection or maintenance ensure that it is at a temperature that will not cause damage.
Even if the variator is not dissipating energy in the braking resistors, this does not guarantee that they
are electrically disconnected.
Before beginning any maintenance operation on the braking resistors, turn off the variator and wait five
minutes until the direct-current bus is discharged. Otherwise, you may be subjected to an electrical dis-
charge.
During deceleration of variator movement, the inertia is dissipated by heating a battery of electrical resistors
that are designed to consume high quantities of energy without any damage.
The condition of this battery must be verified so that the system operates correctly, given that the variator be-
haviour is quite sensitive to variations in resistance value. Given the need to dissipate heat, the resistor bank
is not sealed and is therefore exposed to small particles.
In salty or dusty environments, the resistor bank must be checked regularly and, if necessary, it must be cleaned
using air and brushes to avoid situations that may affect its electrical resistance value.
5 EFFI+ System
The Effi+ system lets users increase the maximum speed of the lifting system in order to achieve significant
increases in the crane's productivity.
On occasion it may be advisable to deactivate the system to prevent it from reaching high speeds, for example,
when working with a low under-hook height. For this purpose, there is a switch inside the cabinet that lets users
cancel the job in high-speed areas.
0 CONTENTS
1 OPERATING DESCRIPTION
2 TROUBLESHOOTING
3 BRAKING RESISTANCES
1 OPERATING DESCRIPTION
The crane operator must match the speed to the working conditions and to factors such as visibility,
obstacles, proximity of people, proximity to other moving objects, reaction time, etc. at all times.
The movement of the winch is secured by the frequency converter in such a way that it occurs gradually,
without any abrupt changes in speed, in accordance with the command given by the crane operator through the
controls. The controls include a potentiometer, which allows the operator to select any speed from a minimum
up to the maximum permitted speed. The maximum permitted speed depends on the location of the trolley, the
load that is being handled and the speed range selected by the crane operator (see load / speed diagram).
If the trolley comes close to the limit switch or the crane is loaded with a moment of more than 90% of the
permitted maximum, the maximum speed is automatically reduced (quick speed pre-limiting).
load
(1) Mechanism in quick speed pre-limiting position due to proximity to limit switch or because the crane
is loaded with a moment of more than 90% of the maximum permitted.
(2) Speed in reduced speed range, via cabin switch ( ) or due to load limit.
(3) Speed in maximum speed range, via cabin switch ( ) without load limit.
2 TROUBLESHOOTING
If a variator is replaced, before connecting it check that the braking resistors have no earth leakage.
Failure to check this point could result in irreparable damage to the variator.
4 3 2 1
ESC ENT
When the console is connected, the state of the converter is indicated via the messages RUN, WARN and
FAULT in the display.
Below we show how the state of the LEDs or the display messages correspond to the operating status of the
converter.
FUF: The variator is not enabled and will not respond to the commands given via the controls.
Check the X210.3 connection for enabling the variator.
241 A numeric value: The converter is operating as normal. By default, the value of parameter 241 is
shown, which monitors the turn frequency of the motor (which will be estimated if it is open-loop
or measured by the encoder if it is closed-loop).
F… Indicates the error code that has tripped the variator (See table of trip codes). The variator
will not be able to be started until either the RESET button, in the electrical cabinet, or the start/
F 0700
stop mushroom-head button has been pressed, or the power supply to the variator has been
disconnected. When the error has been reset, the screen goes back to displaying a numerical
value. If you leave the console error screen, it is possible to see the current error status of the
variator by reading the contents of parameter 259.
MAIN MENU
- CONFIGURABLE PARAMETERS
- OPERATING MODIFICATION
The functions carried out through the menus shown in the viewer are as follows:
1) VAL menu: Allows for the viewing of values that give information on the state or the operating mode
of the motor and the variator. Specialist personnel can find in this menu relevant information about
the operation of the application.
2) PARA menu: Allows for the viewing and modification of parameters that alter the behaviour of the
application. No adjustments should be made without previously consulting the COMANSA SAT
department.
3) CTRL menu: Dedicated to the variator's setup process and to the direct operation of the motor.
It should not be used without previously consulting the technical service of COMANSA.
To move through the menus use the console keys, which work as follows:
- Up ( ) and down( ) keys : used to navigate through the menu structure and to modify the
value of values and parameters.
- ENT key: used to access the menus and the parameters and values in each menu, as well as to
confirm a change made to the value of a parameter.
- ESC key: used to go back to the main menu or to a submenu or to cancel a modification made to
a parameter that is yet to be confirmed.
2.2.4 Investigating errors: the state of the variator when an error occurs, error log
The variator allows you to consult on the console display information which is very useful for solving any errors
that may occur during operation.
In addition to the basic information, which has been explained in previous sections, the variator includes two
features that help the user of the device or the technical service team to solve problems when an error occurs:
3) Sum of errors:
Gives a total sum of all the errors that have occurred during the lifetime of the variator (parameter 362
of the VAL menu).
The following error messages are shown on the display whenever an error has occurred. The error can be removed
from the screen by pressing the start/enter key. It is also possible to check the state of the error by reading the
contents of parameter 259 of the VAL submenu (If no error is present, this parameter will show F0000).
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTION
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTION
Appears when the value of the motor's -Temperature of motor -Check PTC probe
heat probe (PTC) changes or has a value too high (PTC > 3 connection.
that exceeds 3000 Ohms. kOhm) -Measure PTC
-PTC terminals of the resistance.
F0400 motor not connected -Check that the forced
to X464.1/2 on the cooling is working
variator. properly.
-PTC Probe cable
broken.
The converter fails to detect one of the -Disconnection of a -Check the motor and
phases of the motor phase of the converter its wiring from the
output. variator terminals.
F0403
-Motor cables cut.
-Motor phase in open
circuit.
Appears when the output current -Short-circuit or earth -Check motor's wiring
momentarily exceeds the predetermined fault in the motor or its and for any possible
value (around 200% of the nominal value supply line. leakage.
of the converter). -Excessive momentary -Check the hoist load.
F0500
demand on the motor -If the fault is recurring,
axle. even without load,
-Short-circuited replace the converter.
transistors.
The converter detects a sudden -Momentary overload -Check the mechanical
overcurrent. in the motor. variables: load,
-Short-circuit in one possible blockage, etc.
F0502
of the phases of the -Check the motor and
motor. its wiring from the
variator terminals.
Appears when a short-circuit or earth fault -Short-circuit or earth -Check motor's wiring
occurs in the output. fault in the motor or its and for any possible
supply line. leakage.
F0503
-Short-circuited -If the fault is recurring,
transistors. even without load,
replace the converter.
Appears when a short-circuit or earth fault -Short-circuit or earth -Check motor's wiring
occurs in the output. fault in the motor or its and for any possible
supply line. leakage.
F0504
-Short-circuited -If the fault is recurring,
transistors. even without load,
replace the converter.
Appears when the sum of the line -Current leakage -Check motor's wiring
F0505 currents is incorrect. and for any possible
leakage.
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTIO7N
Current phase of motor very high. -Momentary overload -Check the mechanical
in the motor. variables: load, possible
-Short-circuit in one blockage, etc.
F0506
of the phases of the -Check the motor and
motor. its wiring from the
variator terminals.
Fault in current monitoring -Momentary overload -Check the mechanical
in the motor. variables: load, possible
-Short-circuit in one blockage, etc.
F0507 of the phases of the
motor. -Check the motor and
its wiring from the
variator terminals.
Internal fault detecting the power card -Internal variator fault -Contact COMANSA.
F0600
Internal fault detecting the power card -Internal variator fault -Contact COMANSA.
F0601
Internal fault detecting the power card -Internal variator fault -Contact COMANSA.
F0602
Internal fault detecting the power card -Internal variator fault -Contact COMANSA.
F0603
Internal fault detecting the power card -Internal variator fault -Contact COMANSA.
F0604
Internal fault detecting the power card -Internal variator fault -Contact COMANSA.
F0605
Appears when the voltage of the -Supply voltage too -Check the network
intermediate DC circuit exceeds the high. voltage.
maximum permitted limit (780 Vdc). -Voltage spikes or -Check the dynamic
disturbances on the braking resistors.
F0700 supply line.
-Fault in the braking
transistor.
-Fault in the braking
resistor.
Appears when the voltage of the -Unsteady or excessively -Check the network
intermediate DC circuit falls below the low supply voltage. voltage in all the phases.
F0701 minimum permitted limit (350 Vdc). DC bus -Fault in a supply phase. -Check the wiring.
voltage too low. -Voltage drop caused by
dip in the cables.
Appears when there is a fault in the -Unsteady or excessively -Check the network
F0702 converter power supply. low supply voltage. voltage in all the phases.
-Check the wiring.
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTION
-Fault in a supply phase of the variator. -One of the supply -Check the variator
phases of the variator power supply.
F0703
has no power. -Check the fuses of the
variator.
Appears when the voltage of the -Supply voltage too -Check the network
intermediate DC circuit is incorrect high. voltage.
-Crane being used -Check that the
F0704
without a correctly crane's connection can
connected transformer. guarantee the correct
voltage.
Appears when the voltage of the -Supply voltage too -Check the network
intermediate DC circuit is higher than the high. voltage.
activation voltage of the dynamic braking -Crane being used -Check that the
F0705
circuit. without a correctly crane's connection can
connected transformer. guarantee the correct
voltage.
Appears when the voltage of the -Supply voltage too -Check the network
intermediate DC circuit is higher than the high. voltage.
activation voltage of the Motor chopper -Crane being used -Check that the
F0706
circuit. without a correctly crane's connection can
connected transformer. guarantee the correct
voltage.
Appears when the 24 Vdc electronics -Defective converter. -Replace the converter.
F0801 voltage is too low in the controller card. -Wiring of the control -Check the wiring of
terminals. the control terminals.
Internal fault in the power interface card -Internal variator fault. -Check for a source of
-Excessive electrical any unusual excessive
noise. electrical noise in
F0803
the installation or its
surroundings.
-Replace variator.
Appears when the electronics voltage is -Defective converter. -Replace the converter.
F0804
too high. -Wiring of the control -Check the wiring of
terminals. the control terminals.
Fault in the bootstrap precharge system of -Internal variator fault -Replace variator.
F0810
the condensers.
Appears when the preload contactor has -Load circuit overheated. -Disconnect the power
F0900 failed or has not been activated. supply, wait five minutes
and reconnect it.
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTION
Fault in the braking transistor. -Internal fault in the -Carefully check the
variator caused by a braking resistor for a
F1000 defect in the braking possible short-circuit and
transistor. correct it.
-Replace variator.
Appears when the variator detects that -Badly configured or -Check the calibration of
the Frequency Switch-Off Limit, parameter defective load limit the load limit system.
F1100
417, has been exceeded. system. -Check that the variator
-Defective converter. is working properly.
Speed limit reached due to problem with -Problem in braking -Carefully check the
braking. circuit. braking resistor to see if
-Overloaded braking it was in open circuit.
F1101
circuit. -Check the mechanical
variables: load, possible
blockage, etc.
Speed limit reached. -Faulty encoder. -Check the mechanical
-Electromagnetic noise variables: load, possible
in the encoder. blockage, etc.
F1110 -Badly connected -Check that the encoder
encoder. is working correctly.
-Excessive speed for the
load level.
Appears when a short-circuit or earth fault -Short-circuit or earth -Check motor's wiring
occurs in the output circuit. fault in the motor or its and for any possible
supply line. leakage.
F1300
-Short-circuited -If the fault is recurring,
transistors. even without load,
replace the converter.
Appears when the variator supplies an -Disconnection of a -Check the motor and its
irregular load. phase of the converter wiring.
F1310 output.
-Motor cables cut.
Appears when the variator detects an -Badly connected motor -Check the motor
irregular signal in the MFIA1 multifunction potentiometer. potentiometer
F1401 input (potentiometer controls). -Faulty motor connections.
potentiometer. -Repair or replace motor
potentiometer.
Appears when the variator detects an -Badly connected motor -Check the motor
overcurrent in the MFIA1 multifunction potentiometer. potentiometer
F1407 input (potentiometer controls). -Faulty motor connections.
potentiometer. -Repair or replace motor
potentiometer.
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTION
The variator fails to detect a signal from the -Faulty encoder. -Check that the encoder
encoder. -Electromagnetic noise is working correctly.
in the encoder. -Check the encoder's
connection and wiring.
-Check for a source of
F1430 any unusual excessive
electrical noise in
the installation or its
surroundings.
-Check the conduction of
the encoder cable.
Appears when the encoder control detects -Faulty encoder. -Check the encoder
that one of the encoder's signal channels is -Incorrect encoder connections.
F1431
absent. connection. -Replace the encoder.
-Cut encoder cable.
Appears when the encoder control detects -Faulty encoder. -Check the encoder
F1432 an incorrect turn direction. -Incorrect encoder connections.
connection. -Replace the encoder.
The variator detects a lower number of -The connected encoder -Check that the encoder
encoder pulses than expected. is not suitable. is working correctly.
F1434 -Faulty encoder. -Check the number of
pulses per turn of the
encoder.
The variator detects a higher number of -The connected encoder -Check that the encoder
encoder pulses than expected. is not suitable. is working correctly.
F1435 -Faulty encoder. -Check the number of
pulses per turn of the
encoder.
Fault in the encoder divisions. -The variator detects -The connected
F1436 a fault in the encoder encoder is not suitable.
marks. -Faulty encoder.
Fault in an optional card of the variator. -Electromagnetic noise. -Check for a source of
-Internal variator fault. any unusual excessive
electrical noise in
F2300
the installation or its
surroundings.
-Replace variator.
Fault in an optional card of the variator. -Electromagnetic noise. -Check for a source of
-Internal variator fault. any unusual excessive
electrical noise in
F2301
the installation or its
surroundings.
-Replace variator.
ERROR MESSAGES
CONSOLE
SOLUTION TO PROBLEM
DISPLAY
SCREEN EXPLANATION CAUSE SOLUTION
Fault in the EEPROM memory of the -Temporary fault reading -Switch off the variator
variator. from memory. and then switch it on
-Program badly stored in again.
memory. -Load correct program.
-Defective memory. -Replace variator.
F0AXX
-Electromagnetic noise. -Check for a source of
any unusual excessive
electrical noise in
the installation or its
surroundings.
Fault in the control card. -Electromagnetic noise. -Check for a source of
-Internal variator fault. any unusual excessive
electrical noise in
F0BXX
the installation or its
surroundings.
-Replace variator.
Fault in the control card. -Electromagnetic noise. -Check for a source of
-Internal variator fault. any unusual excessive
electrical noise in
F0CXX
the installation or its
surroundings.
-Replace variator.
Internal fault during autotuning. -Fault in the motor -Repeat autotuning.
SFXXX parameter identification -Check motor
process. parameters.
Internal fault during autotuning. -Fault in the motor -Repeat autotuning.
SAXXX parameter identification -Check motor
process. parameters.
Apart from the previous error messages, there exist additional error messages that are not listed here.
If an error message not listed here is received, contact the technical service of Comansa.
Note: Those parameters that may be of most use to the user have been emphasized in either italics or
bold.
F0000
Time since activation at h:m:s.
320 ERR11 00000:00; Error11 352 ETIME
F9999 time of last error ms
F0000 Radiator temperature at
321 ERR12 00000:00; Error12 353 ETC °C
F9999 time of last error
F0000 Internal temperature at
322 ERR13 00000:00; Error13 354 ETI °C
F9999 time of last error
F0000
323 ERR14 00000:00; Error14 F9999 Controller status at time
355 EC text
of last error
F0000 Warning status at time of
324 ERR15 00000:00; Error15 356 EW text
F9999 last error
F0000 Internal value 1 at time of
325 ERR16 00000:00; Error16 357 EI1
F9999
last error
DC bus voltage at time of
330 EUDC V Internal value 2 at time of
last error 358 EI2
last error
Output voltage at time of
331 EURMS V Long value 1 at time of
last error 359 EF1
last error
Stator frequency at time
332 EFS Hz Long value 2 at time of
of last error 360 EF2
last error
Frequency of encoder 1
333 EEC1 Hz Checksum at time of last
at time of last error 361 CHSUM
error
Frequency of encoder 2
334 EEC2 Hz 0 ...
at time of last error 362 ESUM No. of Errors
32767
Ia phase current at time
335 EIA A No. of auto-recognised 0 ...
of last error 363
Errors 32767
Ib phase current at time
336 EIB A
of last error
755 MC LL Lower Imr reference limit A 805 BRT12 Brake closing delay 2 s
806 BRT13 Brake closing delay 3 s
756 MCLCD Deviation control limit % 807 BRT14 Brake closing delay 4 s
Torque controller
3 BRAKING RESISTANCES
Both the braking resistances as well as their enclosures may reach very high temperatures.
Before beginning inspection or maintenance ensure that it is at a temperature that will not cause damage.
Even if the variator is not dissipating energy in the braking resistances, this does not guarantee that they
are electrically disconnected.
Before beginning any maintenance operation on the braking resistances, turn off the variator and wait
five minutes until the direct-current bus is discharged. Otherwise, you may be subjected to an electrical
discharge.
During deceleration of variator movement, the inertia is dissipated by heating a bank of electrical resistances
that are designed to consume high quantities of energy without any damage.
The condition of this battery must be verified so that the system operates correctly, given that the variator
behaviour is quite sensitive to variations in resistance value. Given the need to dissipate heat, the resistance
battery is not sealed and is therefore exposed to small particles.
In salty or dusty environments, the resistance battery must be checked regularly and, if necessary it must be
cleaned using air and brushes to avoid situations that may vary its electrical resistance value.
0 CONTENTS
REEVING CHANGES MUST ALWAYS BE CARRIED OUT FROM A POSITION THAT ALLOWS THE
PERSON MAKING THE CHANGE TO SEE WHAT IS HAPPENING AND THEREBY PREVENT ANY
FAULT OR MALFUNCTION THAT COULD LEAD TO A HAZARDOUS SITUATION.
THE REEVING CHANGE OPERATION MUST BE CARRIED OUT WITH NO LOAD, SLING OR OTHER
LOAD SUSPENSION TACKLE ON THE HOOK.
ALL CRANE LIMITS MUST BE PROPERLY ADJUSTED. THIS OPERATION INVOLVES THE HOOK UP
AND CARRIAGE BACK TRAVEL LIMITS AS WELL AS THE LOAD LIMITER. SEE THE DOCUMENTS
“HOISTING LIMITER”, “CARRIAGE LIMITER” AND “LOAD LIMITER” IN THE “USE AND MAINTENAN-
CE” CHAPTER.
Fig. 2
- Take the front trolley and hook closer to the start of the jib without going beyond the hook up and trolley
back limits.
- Use the crane control to cancel the trolley back limit, and take the front trolley towards the start of the jib
until it reaches a stop against the rear trolley, operating the front trolley position limiter (LPCD) to enable
the change to continue.
ONCE THE “TROLLEY BACK” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE HOOK
UP MOVEMENT IS LOCKED UNTIL THE FRONT TROLLEY POSITION LIMITER COMES INTO
OPERATION.
Fig. 3
- Use the crane control to cancel the hook up limit, and take the front hook up at slow speed until it is
housed in the rear hook and stops up against it.
ONCE THE “HOOK UP” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE TROLLEY
FORWARD MOVEMENT IS LOCKED UNTIL THE FIRST LOAD LIMITER COMES INTO OPERATION.
(LC4).
Fig. 4
- Continue the upward movement, and the hook assembly and rear trolley swings on the rear wheel, the
front hook is housed in the front trolley, and protection “PG” swings, hiding the front hook anchor and
securing the two hooks.
- As the upward movement continues, the hoisting cable comes under tension and the first load limiter
(LC4) comes into operation, thereby stopping the movement.
Fig. 5
- Move the trolley and hook assembly forward until it leaves the rear hook support.
Fig. 6
- Continue the trolley forward movement until the trolley back limit zone has been exceeded.
- Use the crane hook down control, and the rear trolley will swing so that its front wheels rest on the track
profile.
- The hitching catch (GE) will couple the two trolleys.
- Taking the trolley forward, the crane is ready to work with both trollies and both hooks hitched together.
(DOUBLE REEVING).
- Loads must be suspended from the rear hook anchor.
REMOVING THE FRONT HOOK ANCHOR PROTECTION TO HANG LOADS DURING DOUBLE-
REEVING WORKING IS PROHIBITED.
FAILURE TO OBSERVE THIS RESTRICTION MAY LEAD TO ACCIDENT.
Once the operation connected with cancelling the safety system has been completed, the crane must
be stopped and subsequently restarted.
REEVING CHANGES MUST ALWAYS BE CARRIED OUT FROM A POSITION THAT ALLOWS THE
PERSON MAKING THE CHANGE TO SEE WHAT IS HAPPENING AND THEREBY PREVENT ANY
FAULT OR MALFUNCTION THAT COULD LEAD TO A HAZARDOUS SITUATION.
THE REEVING CHANGE OPERATION MUST BE CARRIED OUT WITH NO LOAD, SLING OR OTHER
LOAD SUSPENSION TACKLE ON THE HOOK.
ALL CRANE LIMITS MUST BE PROPERLY ADJUSTED. THIS OPERATION INVOLVES THE HOOK UP
AND CARRIAGE BACK TRAVEL LIMITS AS WELL AS THE LOAD LIMITER. SEE THE DOCUMENTS
“HOISTING LIMITER”, “CARRIAGE LIMITER” AND “LOAD LIMITER” IN THE “USE AND MAINTENANCE”
CHAPTER.
Fig. 8
- The crane is working with two trollies and the two hooks joined. (DOUBLE REEVING).
Fig. 9
- Use the crane control to cancel the hook up limit, and at slow hoisting speed draw the hooks closer to
the trollies until the rear hook makes contact with the rear trolley.
ONCE THE “HOOK UP” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE TROLLEY
FORWARD MOVEMENT IS LOCKED UNTIL THE FIRST LOAD LIMITER COMES INTO OPERATION.
(LC4).
Fig. 10
- Continue the upward movement, and the rear trolley swings on the rear wheel and the front hook is
housed in the front trolley.
- The hoisting cable comes under tension and the first load limiter (LC4) comes into operation, thereby
stopping the movement.
Fig. 11
- Use the crane control to cancel the trolley back limit, and take the trollies towards the start of the jib.
- The trolley coupling catch (GE) enters the ramp (RG).
Fig. 12
- Continue taking the trolley back until the reeving change position limiters (LPCT) and (LPCD) come into
operation.
ONCE THE “TROLLEY BACK” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, HOOK MO-
VEMENT IS LOCKED UNTIL THE LOAD POSITION LIMITERS COME INTO OPERATION.
Fig. 13
- Operate slow speed down movement and the rear trolley swings on the rear wheel until the rear hook is
housed in the rear hook support. (SG).
- The front hook anchor protection (PG) swings and frees the front and rear hook coupling.
THE TROLLEY CANNOT BE MOVED WHILE THE FRONT HOOK IS OVER THE HOOK UP LIMIT.
Fig. 14
- Continue the downward movement until the front hook is below the “hook up” hoisting limit.
Fig. 15
- Taking the trolley forward, the crane is ready to work with a single trolley and hook (the front ones).
(SINGLE REEVING).
Fig. 16
The ID cancelling switch for the reeving change safety system may only be used by service personnel
who are fully aware of the effect of cancelling the safety system.
All operations carried out with the safety system cancelled must be especially well supervised to avoid
creating a hazardous situation.
Once the operation connected with cancelling the safety system has been completed, the crane must
be stopped and subsequently restarted.
If a crane should be left with single trolley (discarding the possibility of a 2nd trolley for double reeving), apart
from removing the trolley (see ASSEMBLY/DISASSEMBLY) the following operations must be done:
a) Physically remove jib mounted trolley position limiters ( LPCT and LPCD ).
b) Switch off the power connection of the limiters (removing plugs in electrical cabinet or disconnecting-
terminals in junction boxes, as applicable).
c) Place jumpers in tower top electrical cabinet
43-44 AID contactor.
53-54 AID contactor .
14 ABCT contactor and 14 ALCT contactor.
13-14 ALCDE contactor.
d) Check SR trolley operation against end stops with trolley backwards.
If the 2nd trolley should be replaced in order that double reeving is available, proceed in reverse order (points
a, b and c) and check the correct operation of changing from single to double reeve trolley and viceversa.
(see points 1 and 2 in this instruction).
0 CONTENTS
1 DESCRIPTION
2 OPERATION
3 MANUAL OPERATION
4 WIRING
5 ADJUSTMENT
6 CHECKING OPERATION
1 DESCRIPTION
The crane is prepared for weather vaning by releasing the brake on the slewing motor(s), leaving the upper
crane free to move with the wind. The brakes are released remotely via the release units on the brake cover
of each slewing motor.
A control box in the operator’s cabin (or at the base of the crane when there is no cabin) governs the release
units.
In case of a power cut-off or malfunction in the release system, weather vaning can be done manually.
2 OPERATION
Weathervaning sequence (Fig. 1)
1 Opening the motor brake causes the manual lever (1) to move upwards
2 The electromagnet (5) attracts the moving armature (2) and positions it below the manual lever
(1).
3 When the brake drops the manual lever (1) rests against the moving armature (2), preventing the
brake from closing and weathervaning the crane.
Activating weathervaning
1 The crane must be in operation.
2 Press the weathervaning button on
the crane control panel and wait 5-10
seconds. If the crane siren is still
blowing after that time, the crane is
weathervaned.
3 Press Stop to cut the siren.
4 Press Start. The siren should continue
to blow when the Start button is
released.
5 Press stop to cut the siren.
Deactivating weathervaning.
1 Engage the slewing control with the
crane in operation.
Some cranes have a lamp on the weathervaning button to indicate that weathervaning is engaged.
el dispositivo de veleta está activado.
3 MANUAL OPERATION
If there is a malfunction or power cut-off the slewing motor brakes can be
released manually.
1- Lift the lever, overcoming the resistance of the brake springs, and
keep it lifted.
2- Press and hold down the button.
3- Release the lever.
4- Release the button.
This procedure should be repeated with each release unit.
Repeat the process on each release unit
Fig. 2
2
4 WIRING
3 1-2 48V (50/60 Hz) electro-magnet power
4 3-4 Electro-magnet operating indicator micro-switch.
.
Fig. 3
5 ADJUSTMENT
To regulate the unblocking weather vanning, proceed as follows:
1- Manually lift the unblocking lever (1).
2- Push the button (3) until the mobile armature (2) comes inside
under the lever (1).
3- Unscrew the nut (4) in such a way that the distance "a" between
armature (2) and lowr part of the lever (1) when this is lifted at
its highest be approximatively 0.5 mm.
4- Check electrical operation: the armature (2) should enter freely
when the weathervaning button is pressed on the crane controls,
and should release when slewing movement is commanded. If
it does not, slacken the self-locking nut (4) 1/12 of a turn (half a
facet) and try again.
IMPORTANTE: The brake gap should not be less than 1 mm if weathervaning is to be regulated
correctly.
6 CHECKING OPERATION
Weathervaning must be used in windy conditions: if the jib points in the direction of the wind then the weathervaning
system is working correctly.
To check weathervaning when it not windy, proceed as follows:
1- Ensure that the crane can turn freely with no obstacles in its path.
2- With the trolley back and the hook raised and under no load, engage first gear and slew slowly.
3- Still in first gear, press the weathervaning button (the crane siren will sound).
4- Still slewing in first gear and with the weathervaning button engaged, press the stop control and check
that the jib continues to turn freely under its own inertia.
5- If it does not do so, readjust the brake gap (which should be 1 mm) and adjust the weathervaning
system..
0 CONTENTS
1 SYSTEM OVERVIEW
2 OPERATION CHECK
3 ALARM AND TEST PROGRAMMING
4 RS 485 WIND-SPEED OUTPUT
5 HEATING SYSTEM FOR THE WIND-SPEED SENSOR
1 SYSTEM OVERVIEW
The basic configuration has a wind-speed sensor (1), which is connected to the control and signalling unit
(2).
The system operates as follows:
- The control and signalling unit is electrically powered from the crane electric cabinet.
- The orange luminous beacon is activated when the wind-speed exceeds 50 km/h.
- The red luminous beacon and warning siren are activated when the wind-speed exceeds 70
km/h..
1 Wind-speed sensor
2 Control and signalling unit
4 Fastening magnets
5 Orange and red beacons
6 Siren
7 Line fastening to the structure
8 Cabin display
Fig. 1
2 OPERATION CHECK
2.1 Indication and control unit
- Check the operation of the beacons and siren as follows:
- Check the crane is powered.
- The switches at the bottom of the crane and the general switch on the electrical cabinet are
in the ON position.
- Press the stop button in the crane control and then press the start button (radiocontrol,
telecontrol or seat).
- This procedure allows to detect a problem in:
- Orange or red beacons.
- Siren.
- Unit power supply.
The device checks the proper operation of the red and orange beacons and of the siren by switching the
beacons and the siren (each beacon should blink twice and the siren must horn once).
- If one or several elements do not operate, this is because there is a problem in the electric supply
or in the elements themselves.
During this test, physically cover the siren to prevent being deafened by the noise this produces.
- Double check that the control and signal code units are properly fixed by the magnets and check
that the unit is appropriately secured to the crane structure with the fastening line (7) which is
supplied.
- Check that the unit is visible from the crane operator’s control position.
Necessary material:
- Cabin wind velocity display.
Instructions:
A. Connect the cabin wind velocity displayto the control unit (See Point 4).
B. Move the wind velocity detector cups either through the action of the wind or by turning them by
hand.
C. Check that there is a velocity reading on the cabin wind velocity display.
Necessary materials:
- Cabin wind velocity display.
- One complete portable anemometer with built-in display.
Instructions:
A. Connect the cabin wind velocity display to the control unit (See Point 4).
B. Install the portable anemometer pickup near the crane pickup and under the same wind reception
conditions.
C. Compare the wind velocity readings on the two displays (the check will be much more effective if
the auxiliary anemometer is calibrated).
Fig. 2
The device can be configured in different ways, by changing a set of 4 mini-switches 4 placed inside it. The
different functions that can be activated or deactivated are: autotest function, configuration in which the device
must be reinitialized after the 70km/h alarm is activated, cancel the acoustic warning when working close to
low noise areas like hospitals, residentials...
To access to the connections or configuration, loose the screws that fix the small bottom cover.
ON (1) Autotest ON
DIP1
OFF Autotest OFF.
After the wind-speed goes above 70 km/h , the ALARM remains activated , even if the
ON speed goes to 0 km/h (The alarm will be deactivated only after the unit supply is switched
DIP3 off for more thatn 15 seconds).
OFF (1) The ALARM is deactivated immediately after the speed goes below 70 km/h.
The DIP4 configuration is exclusively to be changed by an authorised person. Its proper position is ON.
Otherwise, the device indicates a "SENSOR FAILURE"
Before changing the position of the switches, ensure that it complies with the required standard for the
installation and that the new alarm method (sound and visual) is understood by the crane operators.
3.3 Alarms.
The device includes the following alarm modes:
- At 50 km/h only amber light, and at 70 km/h only red light.
- At 50 km/h only amber light, and at 70 km/h red light + siren.
The default factory setting is "at 50 km/h only amber light, and at 70 km/h red light + siren".
Fig. 3
In case there is any abnormal behaviour signal at the sensor, a cable that has been cut or an improper connection,
the system beacons intermittently blink until the problem is solved.
4 RS 485 WIND-SPEED OUTPUT
The control and signalling unit (Fig. 4) is equipped with an RS 485 output that allows a fast connection to the
indicator system in the cabin. Refer to the crane wiring schematic for more details.
Fig. 4
This heater system is supplied from a point which is placed before the general crane contactor G (see wiring
schematic) . If the general switch of the crane (IG) is ON and the crane bottom switch is ON, the heating system
will be operative, regardless the stop control is pressed or not. This allows the system to melt the frost even
when the crane controls are switched off.
0 CONTENTS
1 IMPORTANT NOTES
3 SYSTEM INSTALLATION.
3.1 General description and location of the system on the crane (complete system).
3.2 System basic technical specifications.
3.3 Description of the devices.
1 IMPORTANT NOTES
INDICATORS SHALL NEVER REPLACE A SCALE AND SHOULD NEVER BE USED AS A SUBSTITUTE
FOR THE CRANE LOAD AND MOMENT LIMITERS.
DATA DISPLAYED ARE SIMPLY INDICATIONS AND CANNOT REPLACE THE PERSONAL SUPERVISION
OF THE OPERATOR AND HIS OWN IMPRESION OF THE SIZE OF THE LOAD BEING HANDLED.
ANY CHANGE ON THE CRANE CONFIGURATION MAY RESULT IN A BAD OPERATION OF THE INDI-
CATION, DATA LOGGING OR FORBIDDEN ZONES SYSTEM. AFTER ANY CRANE CONFIGURATION
CHANGE, IT IS NECESSARY TO READJUST THE SYSTEM AND CHECK THAT THE UNIT IS FULLY
OPERATIVE AND PROPERLYWORKING.
THE FORBIDDEN ZONES SYSTEM ALONE SHOULD NOT BE USED TO AVOID TO DRIVE THE
CRANE ABOVE PIPE INSTALLATIONS THAT MIGHT CONTAIN FLAMMABLE LIQUIDS OR GASES.
THE FORBIDDEN ZONES SYSTEM SHALL NOT BE USED TO AVOID TO DRIVE THE CRANE ABOVE
ELECTRIC CABLES. ON SUCH SITUATIONS, IT IS NECESSARY TO MAKE A SAFETY ASSESSMENT
AND TAKE ADDITIONAL MEASURES (I.E. MOUNTING THE CRANE SO THAT THERE IS NO POSSI-
BILITY OF INTERFERENCE WITH THE CABLE) THAT LEAD TO A PROPER RISK REDUCTION.
Before beginning to use the system, it is compulsory to properly train the operator. Furthermore, the
maintainer of the crane or whoever performs any adjustment or change on it, must carefully read
this manual until he understands the working principle and the procedures for its adjustment.
The indication screens on this document may suffer some change as a result of any improvement of the
system software.
DLZ341 may optionally include the following special functions (on demand):
- Extended indication (the system can be supplied with additional information like slewing position
or travelling position).
- Forbidden zones system (prevents the hook from entering the areas defined by the user. If the
system is equipped with forbidden zones, it must include the slewing sensor and the travelling
sensor, if needed, to properly perform the forbidden zone function).
The addition of new functions to a crane with the system basic configuration is possible through addition of
an upgrade kit (contact factory for more details). The kit is made up of an informatic software upgrade and of
additional hardware (slewing and travelling sensors, electrical cabinet IM45 interface...).
Additional functions are always based on the basic system configuration. It is not possible to install an optional
function without previously installing the basic system.
COMANSA does not supply anticollision system (a system which avoids the risk of collision between
working cranes), however, a dedicated plug which gives access to the proper electrical points where the
connections of such a system must be done is supplied.
Screen messages use pictograms recommended by FEM1003 standard which list the symbols to be
used on tower crane indications, so that an effective and error-free communication is achieved.
The indication function offers an instantaneous and intuitive sight that shows the load state of the crane and
the crane position. The data are represented in numerical format and also as a progress bar, allowing a faster
and easier understanding.
Further information on the indication function may be found in point 5 of this document.
The data logger function supplies information referred to the crane operation (number of working hours of each
winch, number of overloads, information on the last movements, alarms…).
Further information on the data logger function may be found in point 6 of this document.
The forbidden zones function allows the user to define a number of zones where the hook will be prevented
from entering. Once the system is properly adjusted, the crane stores the zones information in memory and
operates in an intelligent way, automatically preventing the hook from entering into the forbidden areas.
Further information on the forbidden zones function may be found in point 7 of this document.
The installation and setting up of the DLZ341 system must be performed by qualified people, specially
trained and with a good understanding of this document.
There is no element within the DLZ341 system that needs any maintance by the crane operator.
Any change in the crane configuration may demand a readjustment on the DLZ341 system (see 4.9).
The commissioning of the unit should be done at the same time as the commissioning of the crane.
The UCDL46 indicator screen shows a question mark in the indication numerical field of a sensor if the asso-
ciated sensor is bad adjusted or is not properly sending the signal. It will also be represented by an error code
in the left zone of the screen (see annex 4) .
3 SYSTEM INSTALLATION.
3.1 General description and location of the system on the crane (complete system).
The complete system (indicators, data logger and forbidden zones) comprises the following devices :
6, 4 5, 8
9
1, 2, 3, 11
UCDL46 IMDL46
Central Unit Sensor interface
2 3
5
8
1
9 Option
10 Option
Opción 11
Fig. 1
The forbidden zones system (option) includes the devices of the above list and also the following:
9 Slewing position sensor BROR45C.
10 Travelling position sensor (if the crane is allowed to move on a railtrack).
11 IM45 relays interface unit for the intelligent movement stop.
Picture.1 is a sketch and the real position of the devices on the crane may change depending on crane
models.
UDCL46 screen is the only interface between the system and the crane operator.
It can also be used to program and adjust the unit and to diagnose the system state.
The IMDL46 terminal box supplies and links every subsystem (sensors, IM45, UCDL...), and acts as a sensor
signals and electrical cabinet signals hub.
Communication flow between each element and the central unit (which lies inside the UCDL46) always goes
through the IMDL46 unit and is done by means of a CAN bus network protocol (Control Area Network).
The CANANA units are electronic modules which convert the trolley, hoisting and moment analog signals into
digital signals, that can be transmitted and understood through the CAN network.
The load cell contains an amplifier that transforms the strain gauge mVolts signal into Volts. The Volts signal is
later converted into a digital signal within the IMDL46 unit.
The anemometer signal is sent to the IMDL46 unit and is transformed to a special digital format different than
the CAN format.
The travelling sensor also sends the information to the IMDL46 in CAN bus digital format.
The following table shows the elements description, their location and the configuration option that includes
them.
(1) The power source supplies a 24Vdc stabilized voltage to the system.
(2) UCDL46 integrates its own heating and cooling system. UCDL46 CPU can work from -20 ºC up to 60ºC,
however, the screen does not begin to work before the display is heated above -5 ºC. When the internal
temperature of the units approaches to the maximum operation temperature, the fan starts so as to keep
the temperature below the maximum switch off temperature.
Display
Fixing bracket
2
4 5
Fig. 2
When UCDL46 internal temperature goes below -10ºC or above +60ºC, the screen is switched off and the
power supply green LED blinks. The functions of the system keep working but the screen is automatically
switched off to avoid damages.
The UCDL46 unit is mounted inside the cabin on a fixing bracket that permits several rotations and movements.
It allows the crane operator to set an optimal position from an ergonomic point of view.
To adjust the display position and orientation, loose both swivels, set the unit to the desired position and tighten
them again (Fig.2).
4 8
9
3 7
2 6
1 5
11 12 13 14
Fig. 3
The sensor signals ar connected to the IMDL46 front through CAN M12 plugs as indicated in the following
table.
REFERENCE FUNCTION
1 Load cell signal
2 Not used
3 Not used
4 Not used
6 Hoisting signal
7 Moment signal
Digital signals coming or going into the crane electrical cabinet go through the multipole fast plug (9) connected
at the bottom of the IMDL46. This plug carries the signals needed for the data logger function.
The green fast terminal connectors on both sides of the IMDL46 connect devices which are permanently insi-
de the cabin and, therefore, do not need to be connected or disconnected every time the crane is erected or
dismantled (power source, IMDL46 to UCDL46 connection...). They are also used to connect some optional
devices (anemometer, travelling…)
The following table describes the functions of the various devices which are connected to the IMDL46 through
green fast connectors:
SIMBOLO FUNCIÓN
11 RS485 connection for the anemometer speed sensor signal.
Not used.
12 SHUNT KEY
Further information on the connection of each device and on the electrical cabinet signals to the IMDL46,
is available in the electrical wiring diagram.
3.4.3 IM45 system to seat-radiocontrol interface (forbidden zones option)
IM45 is fixed to the cab electrical cabinet by means of 4 magnets on its back.
IM45 system-seat-ra-
diocontrol interface- IM45 to IMDL46 CAN
giro connector
Fig. 4
IM45 consists of a relays interface that deccelerate and stops the crane movements when the crane approaches
to any of the forbidden zones (see 7).
The relays contained in IM45 can stop the signals going from the seatcontrol or radiocontrol to the electrical
cabinet.
The following sketch shows the concept which allows the system to control the crane movements.
The cabin is wired (Fig.5) in such a way that allows the IM45 to selectively stop the crane movements . Further
information on the connection of each device and on the electrical cabinet signals to the IM45, is available in
the electrical wiring diagram.
Fig. 5
If the system does not include the forbidden zones function, a bypass plug replaces the IM45. This bypass plug
re-establishes the path between IM45 and the electrical cabinet, thus allowing the normal work of the crane.
IMPORTANT NOTE: the removal of the bypass plug stops the crane immediately as when pressing the emer-
gency stop button. Do not remove the plug when moving the crane. A bad connection of the IM45 or of the
bypass plug leads to the stop or prevention of some or every movement.
The trolley and hoisting sensors CANANAs are screwed inside the hoisting and trolley limiter.
The moment sensor CANANA is placed close to the moment inductive sensor and is fixed to the crane structure
by means of a magnet. Moment CANANA must be vertically placed and must be close to the inductive sensor
to prevent water from entering.
IIt is necessary to identify the CANANAs on the CAN network, so that the IMDL46 knows which sensor co-
rresponds to each signal. To do so, every CANANA has got a switch set named SW2 that must be adjusted
as per picture. 6.
Fig. 6
CAN M12 plugs are plastic injected to achieve a good sealing when properly connected.
M 12plug
Brown
Blue
White
Black
Gray
Fig. 7
The trolley and hoisting analog signals come from a potentiometer of resistance between 0 and 10 kOhms (1,
in picture 8). The potentiometer axle is connected through a gearbox to the rotating axle of the mechanism
(trolley or hoisting). The analog signal is then translated to a digital signal comprehensible by the CAN network
through a CANANA unit (2 in Fig. 8). (See 3.3.4).
The following picture identifies the potentiometer and the CANANA position within the limitter.The potentiometer
adjustment is independent of the limit switches adjustment.
CONNECTOR CANM12
1 2
POTENTIOMETER CANANA
Fig. 8
The connection between the potentiometer and the CANANA is shown in the following picture.
0V Blue
SIGNAL White J3
1
+V Red
Fig. 9
The digital signal generated by the CANANA is sent to IMDL46 unit through a CAN cable. This cable is con-
nected to the limiter through a female CAN M12 connector.
The connection between the CANANA and the CAN M12 female plug is shown in Fig. 10.
Brown
1
Blue J1
oV
2 1
Connector +V White
CANM12 3
CAN+ Black
4
CAN- Gray
5
Fig. 10
It is necessary to set up each CANANA so that the IMDL46 can identify to which sensor corresponds each
signal received. To do so, the SW2 switches of the CANANA must be set up as shown in 3.3.4.
Fig. 11
1.- Loose two of the three screws (2) from the coupling of the pontentiometer. In case that you have a bad
access to the screws (2) loose the complete assembly with the screws (1) and mount the same com-
plete assembly in such a way that the accessibility is good to the two screws (2).Loose the two screws
(2)
2.- Move the wheel (3) until you have reached the required value.
3.- Tighten again the two screws (2) in such a way, that the axle of the potentiometer remains in the middle
of the coupling (see picture below).
Fig. 12
The moment is indirectly estimated by measuring the movement of the moment leaf spring. The movement of
the leaf spring increases as the moment exerted by the load on the crane increases. The movement is measured
through the inductive sensor drawn in Fig. 13.
The inductive sensor generates an analog signal (4-20 mA) which is then translated to a digital signal through
a CANANA (see 3.3.4).
The CANANA digital signal is sent to the IMDL46.
The connection between the moment inductive sensor and the CANANA is shown in Fig.13.
Sensor
Red
White
Signal
Fig. 13
It is necessary to set up each CANANA so that the IMDL46 can identify to which sensor corresponds each
signal received. To do so, the SW2 switches of the CANANA must be set up as shown in 3.3.4.
Fig. 14
WHEN ADJUSTING THE MOMENT SENSOR IT IS NECESSARY TO CHECK THAT THERE IS NO POS-
SIBILITY OF GEOMETRICAL CONTACT BETWEEN THE INDUCTIVE SENSOR AND THE MOMENT
LEAF SPRING OF THE CRANE, UNDER ANY CIRCUMSTANCE.
To connect the load cell to the IMDL46, it is enough to connect the cable with the fast CANM12 connectors to
the load cell.
The signal is generated in the load cell by means of a gauge bridge. The signal conditioning is done through
an amplifier, inside the load cell.
The load cell translates the strain applied on it to a voltage signal which goes from 0 to 5 Vdc. This signal is
sent to the IMDL46.
Sensor
Brown
24 Vdc supply
White
Measurement 0Vdc
Blue
0 Vdc supply
Black
Measurement
0 Vdc to 5 Vdc
Fig. 15
The connection between the Slewing sensor and the IMDL46 is done through a CAN M12 cable.
The slewing angle is transmitted to the sensor through a pinion connected to the luffing ring.
The pinion transfers the slewing movement to an axle which is reduced through a gear inside the slewing sensor
box, and then it is transferred to an absolute encoder in a 1:1 ratio.
The absolute encoder signal is transformed into a CAN signal inside the slewing sensor box by means of an
electronic board.
The slewing sensors are different depending on the crane models as the gear ratio and the teeth number and
modulus depends on the slewing ring model.
1 Pinion
2 Slewing ring 1 2
3 CAN M12 connector
Fig. 16
REFERENCE EXPLANATION
D4 Power on LED.
U1 Microcontroller.
This function allows the correction of the deviation due to the slip on the track-wheel contact every time
the crane passes through this railtrack position.
When the railtrack is long, an additional reset sensor can be supplied so that the readjustment can be
done in two positions of the track.
1 2 3 4 5
Fig. 17
1 CAD40 electronic board is the processing unit for the signals received from the inductive sensors. It de-
termines the sense of the movement and the crane position on the track and transmits it to the IMDL46
through the a CAN cable (the length of the cable depends on the crane height)
2 Limit switch TER GF4C equipped with an incremental encoder to count the turns of the travelling whe-
el.
3 An inductive sensor for repositioning, to reset the error due to the slip in the contact between wheel and
track.
For long tracks, a second repositioning sensor may be necessary.
4 A bracket for the repositioning sensor and its screws and bolts. A second bracket is delivered when two
repositioning sensors are used.
5 A repositioning flag to weld along the track. A second repositioning flag is necessary when two reposi-
tioning sensors are used.
Some of the following steps imply an important crushing danger. DO NOT hesitate to lock the travelling
winch when necessary and to ensure a good and permanent communication with the crane driver.
- Encoder:
The encoder is mounted in a TER GF4C limiter. It generates spaced pulses when the wheel rotates.
TER GF4C limiter is fixed by means of a bracket and is connected to the wheel or gear axle depending
on the bogie type.
DISPLAY
FAST CONNECTOR
Fig. 18
SYMBOL FUNCTION
SIMBOLO FUNCIÓN
LED6 (green) «can bus» : ON if messages are correctly received over the CAN bus.
LED7 (red) «RS485» : ON if messages are correctly received over the RS485 link.
Wiring of CAD40
Brown
Yellow
Brown
Green
Brown
White
Black
Black
Blue
Blue
Repositioning sensors
Fig. 19
Fig. 20
Unit programming
Before any new programming, restore the default values. The CAD40 restarts, and you must type the secret
code again to be able to change settings.
The value is adjusted one digit at a time, starting from the most left digit. Press «S» to go to the next digit.
The last «S» validates the complete value.
To enter the values of inits 1 and 2, it is possible to directly take the value by simultaneously pressing «+» and
«S», starting with «+».
The complete programming menu is the following : (the chapter numbers are for guidance only in this
document)
1. Setting:
1.1 Secret code: (from 000 to FFF)
1.2 Language: (F / GB / D)
1.3 Sensor type: (travelling/trolley/hoisting)
1.4 Use of inits: (none/ 1 / 2 / double 1 (secure))
1.5 Init values:
1.5.1 Init 1 : (from 0 to 1023)
1.5.2 Init 2 : (from 0 to 1023)
2. Options:
2.1 Max acceptable reset on reinit:V (1 to50)
2.2 Pre-division factor: not used(de to 100)
3. Information:
3.1 Software information
3.2 Average offset
3.3 Last error
3.4 CAN bus status
4. Restore all default settings (confirmation is requested)
1.2 Language.
Menu for the language selection. Only the error messages are always in English.
After restoring the default values, the language is French.
Init 1
Use it to set the value of init 1.
If no init is used, this value is unnecessary. For 1, 2 or a double init, this value is taken into account.
It is possible to define the current value as the init value by simultaneously pressing «+» and «S», starting with
«+».
After restoring the default values, the CAD40 is defined as a travelling sensor and init 1 is set to 500.
Init 2
Use it to the value of init 2.
If using a single init , or if using double init is used, this value is unnecessary.
It is possible to define the current value as the init value by simultaneously pressing «+» and «S», starting with
«+».
After restoring the default values, init 2 is always 0.
2. Options
2.1 Max acceptable reset on re-init: 1 to 50.
Used to set the max slip beyond which a fault is generated.
At the level of the init marker, the software determines the correction to be applied to the value it has in memory
to reset the init value. If the difference is greater than this «max reset», an internal fault is generated. The red
LED comes on and an error message can be read.
After restoring the default values, the max reset is 15.
2.2 Pre-division factor: 1 to 100
This function is used reduce the number of flags. If «N» is the value of this factor, the CAD40 will increment by
1 every N flags only. This function is to be used only in special cases.
After restoring the default values, the pre-division factor is 1.
3 Information
3.1 Software information.
Software version and checksum.
The sensors have a LED on their back to check their status (detection or not). This status can also be checked
on LED 1 to 4 in the CAD40.
It is necessary to take the slack of the wheel on its axis into account. Depending on the travelling track this
slack can be very important and modify the distance flag/sensor you may have adjusted.It is then required to
check that both sensors detect all flags and only the flags all along the track to avoid any error in the counting
and then the positioning of the crane.
repositioning sensor
15 mm minimum
15 mm
counting sensor minimum
8 mm > 12 mm
8 mm > 12 mm
Fig. 21
To achieve it, while you travel the crane from one side to the other of the track, look at the LED 5 (SENS POSITIF)
in the CAD40. This one must be permanently ON (or OFF, depending on the direction of travelling). If the LED5
flashes even a short while during the crane travelling it means that one of the sensors didn’t detect a counting
flag (gap between flag and sensor to big), or detected the wheel (gap between flag and sensor to small).
If this is the case, readjust the sensor and then repeat the previous operation several times to ensure a good
counting all along the track.
While keeping the repositioning sensor(s) disconnected in the CAD40, move the crane till the repositioning
sensor is completely above the repositioning flag (Fig.21). Setting and for the corresponding sensor (I1 or I2)
enter the Init value. You can either read this value in the main screen (number of impulses) or learn it directly.
Re-plug the set sensor.
Repeat this step for the second repositioning sensor if necessary.
Fig. 22
The following table shows the pictograms in this page and their meaning.
2 Enter.
5 Escape.
6 Screen backlight control (in Page P1). In some other pages it is a help button.
14 Show the version information and software upgrading page Basic system
Basic system
15 Current reeving and manual reeving change.
Fig. 23
4 500.00 m Confirm the current digit value and pass to the next one.
5 000.00 m Exit the field.
P1 Main page
Indication function
Main page
P1 P4
Indication function
P42
digital outputs forcing page P43
P20 P44
The configuration export operation consists on saving to the USB key all the registered parameters of page
[P10] an also the current scaling of the sensors for the indication and also the registered parameters and zones
of forbidden zones option [P11] / [P41]. The configuration import consist on downloading the configuration file
contained on the USB key to the UCDL46.
Insert the USB key in the UCDL46 port (see 3.3.2), then follow the process visually described below, until rea-
ching the transfer confirmation screen. The process is the other way for exporting importing the data.
Use the button for exporting the configuration to a USB key or the button to import a confi-
guration from a USB key.
Levels
N0-N1-N2
Fig. 24
Press to confirm the transfer or to cancel. Once the transfer is done, indicates that it has
been succesfully performed and the USB key can be removed.
indicates that the transfer failed. Check that the key has been properly inserted and that the available
memory is enough to complete the operation and try again.
Note: it is not guaranteed that any USB will properly work with the UCDL46. It is recommended that you ask
the factory for a USB if the one supplied from factory is lost.
Levels
N0-N1-N2
Fig. 25
Press to restore the factory configuration or to cancel. indicates that restoration was successful
that the USB key can be removed.
Restoring the factory settings, completely erases the previous configuration, including the forbidden
zones configuration. Events data log are not deleted.
Levels
N0-N1-N2
Fig. 26
EXPLANATION
1 UCDL46 serial number.
2 Current activation code.
Current active functions.
Every function are preinstalled in the UCDL46 unit, however, only the chosen functions are active.(see
4.8.1)
3 A = Indication.
D = Data logger.
Z = Forbidden zones.
Fill in the active field; validate the field to register the code.
Once the process finishes, ndicates that it has been successfully performed and the new function is
active.
There is a different code for each UCDL46 unit and that means that this code can only be used with that
particular unit.
Once the activation process is finished, the UCDL46 CAN M12 plug must be removed and reconnected
to reinitialize the system.
To add the new function it can be necessary to use additional hardware and sensor (e.g., forbidden
zones).
The good operation of the system depends on the consistency between the parameters in the DLZ341 system
and the crane and environment actual situation.
It is compulsory to assess if a crane or enviromental change demand the readjustment of the DLZ341
system.
The following table shows a list some of the changes that demand a readjustment of the DLZ341 system.
CRANE/ENVIRONMENTAL
REQUIRED ACTION SEE
CHANGE
Daylight saving time DST change Date and time adjustment 5.2.1
Time zone change Date and time adjustment 5.2.1
International system/imperial
units change Configuration change 5.2.1
Anemometer alarm thresholds
Configuration change 5.2.8
Anemometer connection/
disconnection Configuration change 5.2.1
CRANE/ENVIRONMENTAL
REQUIRED ACTION SEE
CHANGE
Basic parameters change P10 5.2.1
Forbidden zones parameter change P41 7.2.1
Jib length Trolley sensor scaling 5.2.2
Hoisting sensor scaling 5.2.3
Slewing stop readjustment 7.2.5
THE INDICATION SCREENS SHOWN IN THIS DOCUMENT MAY SUFFER SOME CHANGE DUE TO
ANY SYSTEM SOFTWARE IMPROVEMENT.
1 2
3
7
10
8
4
9
Fig. 27
3 Trolley position.
With respect to the tower mast central axis.
4 Hoisting position.
Indicated with respect to a chosen ground level (0 meters).
This value can be positive or negative depending on wheter the hook can go below the chosen ground
level or not.
5 Reeving state.
Displays the current crane reeving state.
The system does not automatically detect the reeving number. To indicate the proper number of reevings,
press the reeving change button (see 4.2).
An incorrect number of reeving choice may lead to an incorrect hook height and load indication and thus
to a possible incorrect operation of the forbidden zones height limitation.
This indication is just a rough value and only pretends to be an aid to the crane operator. It is compulsory
that the crane operator knows and refers to the load chart diagrams of the crane and never lifts loads
above the crane capacity indicated on the chart.
7 Angle between current jib position and another reference position. The angle must be increased when
the crane turns clockwise (slewing sensor option).
8 Maximum permitted reach for the current load.
This value is attained through calculations based on the crane parameters of [P10] (ver punto 5.2.1) and
on the measured values .
This indication is just a rough value and only pretends to be an aid to the crane operator. It is compulsory
that the crane operator knows and refers to the load chart diagrams of the crane and never lifts loads
above the crane capacity indicated on the chart.
If there is a failure on any of the sensors or on its configuration, the screen shows this pictogram
and an error code (see Appendix 4).
The indication set up must be done in the order explained below. To configure the unit, the necessary
information must be available so that it can be correctly set during the configuration process (load chart
and technical sheets).
2
1
3
4
5
Levels
6 N0-N1-N2
7
Fig. 28
Forbidden zones activate and deactivate Available when Forbidden zones option
3
checkbutton. is installed.
Unit System choice buttons. - International system units.
4 - Imperial units.
Moment threshold warning sound activa-
5
tion/deactivation checkbutton.
Moment calculation method checkbuttons Both fields must be always filled in with the
and related fields. sum of the trolley and hook, in single reeving
If any of them is checked, the calculation is (1) and in double reeving (2), regardless the
done by multiplying the estimated load by method of calculation of the moment.
6
the trolley position. Otherwise, the signal
coming from the moment sensor is used.
Maximum permitted end jib load for the It depends on the number of jib sections.
7 current crane assembly.
Maximum load.
8
Maximum distance from the tower mast It depends on the number of jib sections.
9 axis to the end jib trolley position for the
current crane assembly.
Maximum heigth under hook from ground It changes when assemblying additional
10 level for the current crane assembly. tower mast sections.
(1) The calendar does not automatically change to Daylight Saving Time. It must be manually changed.
The UCDL46 comes from factory with basic adjustments which correspond to a crane assembled with
the maximum jib and counterjib length , with the self supporting heigth and with double reeving. The
moment alarm and the anemometer alarm are disconnected.
Levels
N0-N1-N2
Fig. 29
REFERENCE EXPLANATION
Trolley limiter potentiometer voltage indi- Move the trolley backward to the closest possible position to
1 cation . the tower mast and adjust the potentiometer to get a value
The trolley distance in meters or feet is close to 0.30 V.
indicated once the escaling is completed. Move the trolley forward to the closest possible position to the
jib end and check that the voltaje is not more than 4.85 V.
Move the trolley to the closest possible position to the jib end
P12-2(see annex 2) and measure the distance between the
3 Second position. Trolley forward capture. tower mast axis and the trolley centered vertical axis.
Type the distance measured on proper units in the field under
the voltage indication and confirm pressing .
Once the second position has been captured, the escale will be set. Do not forget to save the settings before
leaving [P12] by pressing .
If the jib lenght is modified, it is necessary to perform trolley scaling again . (see 4.9).
Levels
N0-N1-N2
Fig. 30
REFERENCE EXPLANATION
Hoist limiter potentiometer voltage indi- Move the hook to the closest possible position below the jib and
cation . adjust the potentiometer to get a value close to 0.30 V.
1 The hook height in meters or feet is indica- Lower the hook to the lowest position possible and check
ted once the escaling is completed. that the voltaje is not more than 4.85 V.
If the crane height is modified, it is necessary to perform hoisting scaling again . (see 4.9).
Levels
N0-N1-N2
Fig. 31
REFERENCE EXPLANATION
Access to page [P14] is possible if a moment sensor is used to measure the crane moment. If the moment is
not measured but calculated(see point 6 of table on 5.2.1), this page will not be available.
Move the empty hook to the upper position and the trolley
Moment sensor voltage indication
to the closest possible position to the tower mast and adjust
1 the potentiometer to get a value close to 0.30 V.
The moment in % is indicated once the
Lift the maximum jib end permitted load and check that the
escaling is completed.
voltaje is not more than 4.5 V.
Move the empty hook to the upper position and the trolley to
the closest possible position to the tower mast.
2 First position. No load moment capture.
Type "0"in the field in the field under the voltage indication
and confirm pressing .
Lift the maximum end jib permitted load or a load that makes
the 100% moment limiter to activate.
3 Second position. Maximum load moment
Type "100"in the field in the field under the voltage indication
capture.
and confirm pressing .
Once the second position has been captured, the escale will be set. Do not forget to save the settings before
leaving [P14] by pressing .
If the jib lenght is modified, it is necessary to perform moment scaling again. (see 4.9).
Levels
N0-N1-N2
Fig. 32
REFERENCE EXPLANATION
To get higher precision, the scaling should be done with the maximum permitted load for the reeving used.
Check that the reeving chosen in the screen when performing the setting up is the same as the one actually
bein used on the crane.
Once the second position has been captured, the escale will be set. Do not forget to save the settings before
leaving [P15] by pressing .
If the crane height is modified, it is necessary to perform load cell scaling again . (see 4.9).
Levels
N0-N1-N2
Fig. 33
REFERENCE EXPLANATION
Indication of pulses detected by the It is better to set the «zero» out of the track.
travelling sensor.
1 The travelling position in meters or feet is
indicated once the escaling is completed.
Once the second position has been captured, the escale will be set. Do not forget to save the settings before
leaving [P16] by pressing .
Levels
N0-N1-N2
Fig. 34
REFERENCE EXPLANATION
Once the second position has been captured, the escale will be set. Do not forget to save the settings before
leaving [P17] by pressing .
Levels
N0-N1-N2
Fig. 35
REFERENCE EXPLANATION
Wind speed prealarm and alarm configu- Prealarm speed field. When winds peed goes beyond this
1 ration. value, the unit will show this amber pictogram in page [P1]
together with an intermittent prealarm sound.
Levels
N0-N1-N2
Fig. 36
PICTOGRAM FUNCTION
THE INDICATION SCREENS SHOWN IN THIS DOCUMENT MAY SUFFER SOME CHANGE DUE TO
ANY SYSTEM SOFTWARE IMPROVEMENT.
Accumulated values
since the last reset
Fig. 37
6.1.1 Accumulated values since the last reset.
Zone 2 on page [P2] (Fig. 37) registers and displays the values accumulated since the last reset (see 6.2.1)
All the information listed below, except the total load, is calculated by processing the activation/deactivation
information coming from the digital inputs received by the IMDL46 (see 5.3).
PICTOGRAM EXPLANATION
A cycle begins when the lifted load goes beyond 5% of the crane maximum load specified in [P10] during
more than 5 seconds.
A cycle ends when the lifted load goes below al 5% of the crane maximum load specified in [P10] during
more than 5 seconds.
D
4 Nº 3
C 3 Nº 2
B Nº 1
2
A 1
Fig. 38
EXPLANATION
To choose the moment % ranges thresholds, follow the procedure shown in Fig.39.
Levels
N0-N1-N2
Fig. 39
EXPLANATION
Cycle number.
Reeving state.
Press to access the field , and use to go throught the cycle list.
Press to exit.
Fig. 41
1 Chronology of the events.
2 Event identification page (see Appendix 4).
3 Complementary info (see Appendix 4).
Press to access the field , and use to go throught the cycle list.
Press to exit.
Levels
N0-N1-N2
Fig. 42
Fig. 43
The pictogram indicates that the transfer has not been done.
Check that the USB key is properly inserted in the UCDL USB port and that there is free memory enough in
the USB key.
The data are exported in MS Excel format and it is necessary to have a license of the program to display the
information in a PC.
THE INDICATION SCREENS SHOWN IN THIS DOCUMENT MAY SUFFER SOME CHANGE DUE TO
ANY SYSTEM SOFTWARE IMPROVEMENT.
3
6
5
7
4
8
Fig. 44
1 Jib and counterjib drawing, scaled proportionally to the parameters in page [P11].
2 Trolley drawing, scaled proportionally to the parameters in page [P11].
3 Active forbidden zone drawing (red coloured line).
A zone can be activated or deactivated selectively.
4 Band indicating the current crane position coordinates.
5 Travelling track drawing (option).
6 Deactivated forbidden zone (green coloured line).
The deactivated zone is recorded, but the crane is allowed to enter inside.
7 Scaled grid.
8 Global forbidden zones activation or deactivation pressbutton.
PICTOGRAMA EXPLICACIÓN
1 Slewing angle referred to the "zero" set during the slewing sensor scaling.
2 Trolley position.
Height under hook referred to the ground level set on the hoist sensor
3
scaling
4 Travelling position referred to the "zero" set on the travelling sensor scaling.
Hook position referred to cartesian absolute axis. The intersection of x and y
axis is set on the mast center.
5
The arrows associated to each movement in [P1] will blink in red when the DLZ system stops the mo-
vement.
Every time the system stops a movement to avoid entering a forbidden zone, it warns the operator . This warning
is done by showing a pictogram, both in page [P4] and in page [P1].
The movement stop pictograms are listed in the following list.
PICTOGRAMA FUNCIÓN
3 Hoisting stop.
4 Lowering stop.
The forbidden zones set up must be done in the order explained below. To configure the unit, the neces-
sary information must be available so that it can be correctly set during the configuration process (load
chart and technical sheets).
3
5
4 Levels
N0-N1-N2
7
6
Fig. 45
do not change
9 Machine control mode
Levels
N0-N1-N2
Fig. 46
REFERENCE EXPLANATION
Trolley position and speed indicator
1
Levels
N0-N1-N2
Fig. 47
REFERENCE EXPLANATION
Hook position and speed indicator
1
Once the second value has been set, do not forget to save the settings before leaving [P13] by pressing .
Levels
N0-N1-N2
Fig. 48
REFERENCE EXPLANATION
Travelling position and speed indicator
1
Once the second value has been set, do not forget to save the settings before leaving [P16] by pressing
Levels
N0-N1-N2
Fig. 49
REFERENCE EXPLANATION
Slewing position and angular speed indi-
1
cator
Move the slewing at maximum speed and write down the
2 Maximum slewing speed. maximum speed reached shown in the indication 1 (Fig. 49).
Type the value in the field 2 (Fig. 49).
Maximum angle travelled by the jib before Estimate the maximum stop angle and type the value in
3 stopping from maximum speed to zero. field 3 (Fig. 49).
Once the second value has been set, do not forget to save the settings before leaving [P17] by pressing .
Levels
N0-N1-N2
Fig. 50
PICTOGRAM EXPLANATION
Select it and confirm by pressing to access the page to draw the zones.
5 - Rectangular shape [P42].
- Circular shape [P43]. (not to be used).
- Polygonal or point by point shape [P44].
Once the options have been set, do not forget to save the settings before leaving [P41] by pressing
.
4 Select it and confirm by pressing to access the drawing page and redefine
the zone drawing.
Once the options have been set, do not forget to save the settings before leaving [P41] by pressing
.
PICTOGRAM EXPLANATION
Choose the zone selection field. The field will be highlighted in blue.
1 3 Select the zone.
2 Select it to to delete the selected zone.
Once the zone has been deleted, do not forget to save the settings before leaving [P41] by pressing
.
This action will be automatically registered in the event log on page [P3].
PICTOGRAM EXPLANATION
Choose the zone selection field. The field will be highlighted in blue.
1 3
Select the zone.
Check the box to activate the zone or uncheck it to deactivate.
2 The deactivated zones will be green coloured on page [P4].
Once the activation or deactivation has been performed, do not forget to save the settings before
leaving [P41] by pressing .
This action will be automatically registered in the event log in page [P3].
PICTOGRAM EXPLANATION
Press it to completely override the zoning function.
1 This action may also be done on page [P4].
2 Press it to re-activate the forbidden zones function.
Fig. 51
If the hook height forbidden zones management is chosen, it is necessary to define a fourth point named Pz to
define the minimum hook height allowed in each zone.
PICTOGRAM EXPLANATION
It is important to take into account the safety distance (d) defined at page [P11] to set the points of the
rectangle.
The safety distance is automatically applied all around the defined zone perimeter by the software .
The drawings on the screen show the zone to which the hook access is prevented. However, the crane
movements are stopped (d)m before.
PICTOGRAM EXPLANATION
Place the hook at the first rectangle vertex
P1.
Register the point by pressing V.
1 1 The point coordinates are shown a few
seconds after registering the point and the
point number will change to P2.
Place the hook at the second rectangle
2 2 vertex P2.
Register the point by pressing V.
Place the hook at the third rectangle vertex
3 3 P3.
Register the point by pressing V.
If height management is selected, move the
4 hook to the desired limit Pz.
Register the point by pressing V.
Once the above process is finished, the zone definition is done. However, the zone will not be closed
and saved until the zone is saved pressing .
During the drawing of the zones, it is possible to modify any of the previously defined points. It is not possible
to do so after saving the points.
PICTOGRAMA EXPLANATION
1 To modify the points P1 or P2, first select the desired point in the selection
field.
2 Place the hook at the desired point and register it by pressing V.
To modify P3, enter the field and manually modify the depth value.
It is possible to invert the depth sense with respect to P1-P2 by using the
3
fields of _
Move the hook to the desired limit Pz and check its coordinate.
4 Enter Pz field and adjust manually to the desired value.
Once the options have been set, do not forget to save the settings before leaving [P42] by pressing
.
3
4
1
Geometric definition of the polygon.
2
5 6
Fig. 50
At each point, the system registers the slewing , the trolley and travelling (option) coordinates
.
If the hook height forbidden zones management is chosen, it is necessary to define a fourth point named Pz to
define the minimum hook height allowed in each zone.
PICTOGRAM EXPLANATION
Select it to indicate that the system will automatically close the polygon by
4 drawing a line between the first and the last point.
Select it always.
Hook lowest position allowed in the forbidden zone(point Pz).
5
Select it to define the zone outside the drawn polygon as forbidden and allow
6
the zone inside the polygon.
It is important to take into account the safety distance (d) defined at page [P11] to set the points of the
rectangle.
The safety distance is automatically applied all around the defined zone perimeter.
The screen drawing indicates the exact zone to which the hook access is prevented. However, the crane
movements are stopped (d)m before.
PICTOGRAM EXPLANATION
Place the hook at the first polygon vertex
P1.
Register the point by pressing V.
1
The point coordinates are shown a few
seconds after registering the point and the
point number will change to P2.
Place the hook at the second polygon
2 vertex P2.
Register the point by pressing V.
Once the above process is finished, the zone definition is done. However, the zone will not be closed
and saved until the zone is saved pressing .
During the drawing of the zones, it is possible to modify any of the previously defined points. It is not possible
to do so after saving the points.
PICTOGRAM EXPLANATION
1 To modify the points P1 to P21, first select the desired point in the selection
field.
2 Place the hook at the desired point and register the point by pressing V.
Before beginning to use the Forbidden zones option it is compulsory to check that DLZ341 forbidden zones
system is able to stop each of the crane movements through the proper relay output.
5 6
1
8
2
9
3
Levels
4 10 N0-N1-N2
11
7
12
13
Fig. 53
PICTOGRAM EXPLANATION
8 APPENDICES
Appendix 1 – Geometric parameters for forbidden zones configuration.
Fig. 54
Fig. 55
Appendix 3– Reading the event log from a PC using the USB key.
A USB key is supplied with the DLZ341 system. The USB stores the application DLZ341-GAT.xls that works
under MS Excel. This application allows to view and print the information registered by the Data logger. To do
so, it is necessary a personal computer and the program MS Excel.
1 Once the information has been transferred from UCDL46 into the USB key (see 6.3), plug it to PC USB
port.
The following screen appears after opening the USB folder.
Fig. 56
Fig. 57
To open the file, it is necessary that MS Excel is configured at a low safety level, so that it allows to run
Macros. If an error message appears on the screen when trying to oper the excel file, check the safety
level in the menu Tools/Macro/Safety settings, or in the MS Excel equivalent version menu. If the safety
level is too high, decrease it so that it does not interfere with the program.
Application use:
The report is made up of the data registered in the three sheets described below.
PICTOGRAM EXPLANATION
1 Previous page.
2 Print report.
3 Next page.
To navigate through the sheets use the buttons placed at the bottom of the sheet.
2
1
Fig. 58
REFERENCE EXPLANATION
2 Time and date of the UCDL to USB key event log down-
load
-Grue: Configuration program
3 Crane identification -Modèle: Model
-NS: Crane serial number
1 4
3 5
2 6
Fig. 59
REFERENCE EXPLANATION
2
Fig. 60
REFERENCE EXPLANATION
Being the cycle 1 the most recent
1 Cycle number
cycle.
3 Page 2 .
The page shows a bargraph which indicates the number of registered cycles classified in four ranges depending
on the moment exerted on the crane during the cycle.
Fig. 61
The ranges can be modified in page [P2] by changing the threshold values (see 6.1.2).
The cycles indicated by the bargraphs correspond to the ranges defined at [P2], though the side inscrip-
tions indicate the default ranges.
Fig. 62
These tables register details of the last 10 cycles in the 3rd and 4th ranges.
The information of this table is the same as that in the table «last cycles» of the 1st page of the report
(see 2 of this Appendix).
3 Page 3 description :
Page 3 shows the events log registered in the DLZ341 system database.
The event log records the last 2000 events since the last reset, ordered in a FIFO list (The list alway contains
2000 events. A new event is placed in position 1, the rest are moved to the next position, and the one in po-
sition 2000 is deleted)
Fig. 63
REFERENCE EXPLANATION
Event number. The left arrow allows to go through
1
the whole list of events.
2 Event time and date Hours and minutes.
1 Reeving state.
2 Reeving state.
3 Reeving state.
4 Reeving state
5 Reeving state
15 Hoisting stop.
16 Lowering start .
17 Lowering stop.
When the hoist mechanism is stopped at
18 Hoist stopped state start. the same position for more than 5 seconds.
The position is also registered.
When the hoist mechanism is stopped at
19 Load hung state start. the same position for more than 5 seconds.
The load value is also registered.
20 Moment limitation state start.
26 Weathervaning on.
27 Weathervaning off.
30 UCDL46 on.
31 UCDL46 off.
Luffing angle sensor badly scaled or sensor Only in luffing jib crane.
41 1
failure.
42 Trolley sensor badly scaled or sensor
2
failure
Load cell badly scaled or load cell
43 3
failure.
Moment sensor badly scaled or sensor
44 4 failure
Hoisting sensor badly scaled or sensor
45 5 failure
Anemmometer sensor badly scaled or
46 6 Option
sensor failure
Slewing sensor badly scaled or sensor
47 7 Forbidden zones option
failure
Travelling sensor badly scaled or sensor
48 8 Option
failure
49 9 System error
51 11 Memory corruption.
WARNINGS:
EACH PIECE OF DATA ENTERED AND THE CORRECT SYSTEM OPERATION MUST BE CHECKED
AFTER THE INSTALLATION.
The following tables provide orientative information that may help when parameterising the system of indicators
and prohibited areas.
SETTINGS P10
(INDICATION FUNCTION)
MODEL
SETTINGS P10
(INDICATION FUNCTION)
MODEL
The following table shows the settings that are filled in on page P11, (it is only necessary to enter this data if
the crane has the prohibited areas unit).
SETTINGS P11
(PROHIBITED AREAS ONLY)
MODEL
The connection of a system of areas other than the original supplied with the crane or an anti-collision
system is the responsibility of the crane installer.
In each case, the crane installer is responsible for carrying out a risk analysis and assessing if the
maximum safety level provided by the system chosen is sufficient for the work it must do.
Any change made to the crane as a consequence of the installation of a limitation system of this type
shall be the responsibility of the installer.
For any later service, any modification made in the electric wiring must be noted on the electrical diagrams
sent in the control panels and on he diagram in the crane manual.
Likewise, the changes must be written in any other modifications record system necessary for later
follow-up.
In the control panel inside the cab, there is a plug E92 that allows access to each of the control signals for all
the movements of the crane.
If no area limitation system is installed, you must connect the E92 plug to the E92 jumper socket. If you
disconnect the E92 plug from the E92 jumper socket, the crane will not receive any control signals and it will
not be possible to make any movement.
CONTROL SIGNALS
ACCESS PLUG E92
JUMPER SOCKET E92 (USED IF
THERE IS NO LIMITATION SYSTEM)
By acting on the E92 plug in a controlled way, it is possible to interrupt the movements of the crane
selectively.
The contacts and what to do to impede or allow the crane movements are shown below:
EFFECT ON MOVEMENT
MOVEMENT PINS
0 CONTENTS
1 ELECTRIC CABINET
2 ELECTRIC MOTORS
3 RESISTORS
4 ELECTRIC CABLES
5 LIMITERS
6 ELECTRIC COLLECTOR
7 ANEMOMETER
8 FORBIDDEN AREAS SYSTEM
9 CABIN
10 POWER SURGES PROTECTION SYSTEM
1 ELECTRIC CABINET
Regularly ensure the following conditions
- Water-tightness of the envelope against water entry and proper door sealing closure.
- Proper greasing of cabinet hinges.
- If ventilation and heating elements are fitted, that these operate properly.
- The cabinet door switch can easily be operated.
- There are no loose cable connections, either in connection terminal boards or in the terminals of the
electrical switchgear elements.
- The cabinet is clean and free from foreign objects inside.
- The contacts of the contactors are in proper condition. Only replace the contacts or the contactor, if any
contact is fully worn-out (virtually non-existent silver surface) or there are signs that it has been soldered.
Never file the contact surface.
- The labels in the outside of the cabinet are in good state and are legible.
- If the cabinet has an air inlet grid with filter.
- Check its condition regularly.
- Clean the filter to ensure air flow.
- The maintenance light points located inside the cabinet light up on when the switches are
pressed.
The frequency of reviews depends on the surrounding pollution. In case of extreme pollution, weekly
cleaning may be required.
When permanent obstructions are detected in the screen or breaks in it, it must be replaced.
If a variator is replaced, before connecting it ensure that the motor and the brake resistors are not short-
ciruited to grounding. Failure to do so may cause damage to the variator.
IN THE EVENT OF A SHORT-CIRCUIT, CONTROL CONTACT OF THE CONTACTORS THAT MAY
HAVE BEEN INVOLVED. CONTACTS MAY HAVE BECOME SOLDERED TOGETHER.
2 ELECTRIC MOTORS
Regularly ensure the following conditions:
- -Water-tightness against water entry is maintained.
- The compression glands are properly tightened (fully closed tightening nut) and the cables are properly
fitted to the compression glands (the compression gland acts on the outside covering of the cables and
these are not forced obliquely against the compression gland).
- The airing windows are free from obstructions.
- If forced ventilation is available, that it is working properly and is free from obstructions.
- Motor connections are properly tightened.
3 RESISTORS
Both brake resistors and the envelope where they are lodged can reach very high temperatures. Before
starting inspection or maintenance ensure that they are at a temperature that will not cause damage.
The fact that the variator is not dissipating energy to the braking resistors does not guarantee that they
are electrically insulated. Before beginning any maintenance operation on the brake resistors, turn off
the variator and wait five minutes until the direct-current bus is discharged. Otherwise, you may be suffer
an electrical discharge.
Regularly ensure the following conditions:
- Connections with screws, both on cable connection terminals and in the resistors' internal connections,
are properly tightened.
- The resistor tubes and components are not damaged.
In salty or dusty environments, frequently review the state of the resistor battery, and if necessary clean with
compressed air and brushing to prevent short-circuits that may vary the electric resistance value.
4 ELECTRIC CABLES
Regularly check:
- that the external covers of the cables are free of physical damages.
- that the cables are not subject to stretching or twisting efforts.
- that the cables are not forced at the receptor inlet sites (motors, derivation boxes, etc.).
5 LIMITERS
For a safe use of the crane, the limiters and end stops must be in good condition.
Regularly check:
- The actuators of position limiters act properly (actuation and return to rest position with no efforts or
seizing of the outside covering of the cables, that are free from physical damage.
- The envelopes and covers ensure limiter water-tightness.
- The compression glands are properly tightened (fully closed tightening nut) and the cables are properly
fitted to the compression glands (the compression gland acts on the outside cover of the cables and
these are not forced obliquely against the compression gland).
6 ELECTRIC COLLECTOR
Regularly check:
- Status of brushes and rings.
- Electric connections.
- Envelope water-tightness.
- The compression glands are properly tightened (fully closed tightening nut) and the cables are properly
fitted to the compression glands (the compression gland acts on the outside cover of the cables and
these are not forced obliquely against the compression gland).
7 ANEMOMETER
Regularly check anemometer and alarm operation:
- Operation of light beacons and siren (press TEST button).
- The anemometer pickup turns freely and is not affected by screening of the structure.
- The cable between the pickup and the control / signalling unit is not cut or unplugged.
- The signalling unit can be seen by the crane operator.
- The signalling unit is properly attached to the structure using the supplied chain.
For further details, see the "Anemometer - Indication / Wind speed alarm" instruction.
9 CABIN
Regularly check equipment operation, including the cabin:
9.1 Air conditioning.
- Remove the air filters, clean them with soap and warm water, dry them and reassemble.
- Check that the suction and ventilation ducts are not blocked.
ON ON ON ON
ON
ON
ON ON ON ON
NOMBRE DESCRIPCION
NAME DESCRIPTION
BAL1 BALIZA
BUOY
BAL2 BALIZA
BUOY
BAL3 BALIZA
BUOY
BO BOCINA
HOOTER
F1 FOCO 1 PLUMA
FLOOD LIGHT 1
F2 FOCO 2 PLUMA
FLOOD LIGHT 2
F3 FOCO 3 PLUMA
FLOOD LIGHT 3
G CONTACTOR GENERAL
MAIN CONTACTOR
IF INTERRUPTOR FOCOS
LAMP INTERRUPTOR SWITCH
IG INTERRUPTOR GENERAL
GENERAL INTERRUPTOR SWITCH
IL INTERRUPTOR LIMPIAPARABRISAS
WINDSCREEN-WIPER INTERRUPTOR SWITCH
MC MOTOR CARRO
TROLLEY MOTOR
ME MOTOR ELEVACION
HOISTING MOTOR
MP MOTOR PLUMIN
AUXILIARY JIB MOTOR
PL PILOTO LINEA
LINE PILOT
PM PULSADOR MARCHA
ON PUSH-BUTTON
PP PULSADOR PARO
OFF PUSH-BUTTON
NOMBRE DESCRIPCION
NAME DESCRIPTION
RC RESISTENCIA CARRO
TROLLEY RESISTOR
RE RESISTENCIA ELEVACION
HOIST RESISTOR
T3 TRANSFORMADOR SERVICIO
SERVICE TRANSFORMER
T4 TRASFORMADOR CABINA
CABIN TRANSFORMER
TF TRANSFORMADOR FOCOS
TRANSFORMER BULBS
NOMBRE DESCRIPCION
NAME DESCRIPTION
X9 BORNERO CABINA
CABIN TERMINAL-BOX
Cables bajo tensión después de pulsar la seta de parada y emergencia o desconectar el interruptor IG Naranja
Tensión de control 48Vac Rojo
Ttensión de control 400Vac Negro
La lista de notas a continuación no es exhaustiva y no sustituye la obligación de lectura del manual del fabricante:
-El mantenimiento eléctrico debe ser realizado exclusivamente por personal especialmente formado que haya
leído y tenga acceso al manual de la grúa.
-Se debe asegurar que el gruista recibe una copia de la instrucción“Utilización de Grúa” del manual.
-El funcionamiento de los equipos está garantizado en niveles de tensión de ±5% con respecto a la nominal.
-Los manuales de accesorios (radio MP3, aire acondicionado, etcétera) se envían en el interior de la cabina.
Bloqueo de movimientos
- Hay una seta de emergencia en el puesto de manejo de la grúa y en la proximidad de cada cabrestante que
interrumpe todos los movimientos cuando se pulsa.
-En grúas con traslación por vía, un interruptor en el interior del armariode traslación en la base de la grúa
permite bloquear el movimiento de la traslación.
Armario eléctrico:
-Cada armario eléctrico incluye resistencias de caldeo autoventiladas y ventiladores de extracción controlados por
dos termostatos independientes. Se deben ajustar para evitar condensación y acondicionar la temperatura interior.
-Hay un esquema eléctrico en cada armario eléctrico, en la cabina y en el manual del fabricante. Si el usuario o
propietario realiza modificaciones sobre los circuitos originales, debe actualizar los esquemas.
-En el interior del armario eléctrico se envía un conjunto de fusibles de repuesto.
-El interruptor general IG interrumpe la alimentación a todos los circuitos salvo el naranja. Consultar esquema.
Acometida
-Los filtros eléctricos garantizan los niveles de emisión y protección frente a interferencias electromagnéticas
conducidas según la normativa europea pero pueden provocar disparos intempestivos del diferencial. Una solución
es sustituir los interruptores diferenciales estándar por otros superinmunizados.
-En el manual se indican los datos necesarios para dimensionar la acometida.
Ajustes
-Para realizar el ajuste del sistema de indicadores y zonas prohibidas se debe consultar el manual.
-Para realizar el ajuste de limitadores se debe consultar el manual.
-Para realizar el ajuste de frenos se debe consultar el manual.
Live cables after pressing the emergency stop button or turning the master switch off Orange
Control voltage, 48V AC Red
Control voltage, 400V AC Black
The following list of notes is not exhaustive, and does not replace the user's obligation to read the manufacturer's
manual:
-Electrical maintenance is to be performed exclusively by specialized personnel that have received specific
training and that have read and can access the crane manual.
-Please ensure the crane operator receives a copy of the "Crane Operation" instructions of the manual.
-The operation of the equipment is guaranteed with voltage levels of ±5% in relation to the nominal voltage.
-The accessory manuals (MP3 radio, air-conditioning, etc.) are shipped inside the cabin.
Movement blocking:
- An emergency palm button is provided at the crane operator station and next to each winch. It stops all crane
movements when pressed.
-For rail-mounted cranes, a switch inside the traveling cabinet at the base of the crane can be used to block the
traveling movement.
Electrical enclosure:
-Every electrical cabinet has automatically ventilated heating elements and extractor fans controlled by two
independent thermostats.These must be adjusted to avoid condensation and to condition the internal temperature.
-A wiring diagram is provided on each electrical cabinet, in the cabin and in the manufacturer's manual. If the
user or the owner make any changes to the original circuits, they must update these diagrams.
-A set of spare fuses is shipped inside the electrical cabinet.
-The master switch MS cuts power to all circuits, except the orange colored ones. Please check the diagram.
Connection:
-Electrical filters guarantee the levels of emission and protection against conducted electromagnetic interference
according to European regulations, but may result in accidental tripping of the ground fault interrupter. One
solution consists of replacing standard ground fault interrupters for GFIs with over-current protection.
-The manual contains the information required for dimensioning the connection.
Adjustments:
-Please consult the manual before adjusting the system of indicators and danger zones.
-Please consult the manual before adjusting the limiters.
-Please consult the manual before adjusting the brakes.
- Die elektrische Wartung darf nur von eigens dafür ausgebildetem Personal durchgeführt werden, das das Bedienhandbuch des
Krans gelesen und Zugang dazu hat.
- Der Kranführer muss ein Exemplar des Kapitels "Bedienung des Krans" erhalten haben.
- Der Betrieb der Geräte ist bei einer Spannungsabweichung von ±5 % von der Nennspannung gewährleistet.
- Die Handbücher zum Zubehör (Radio, MP3, Klimaanlage usw.) liegen in der Führerkabine bei.
Arretierung:
- Ein Notausschalter befindet sich am Führerstand des Krans und in der Nähe jeder Seilwinde. Bei Betätigung werden alle
Bewegungen des Krans unterbrochen.
- Bei Schienenkranen befindet sich ein Schalter im Innern des Schienenschranks an der Kranbasis, mit dem man die
Bewegung auf den Schienen stoppen kann.
Schaltschrank:
- Jeder Schaltschrank enthält selbstkühlende Wärmeschutzschalter sowie Abluftventilatoren, die von zwei unabhängigen
Thermostaten gesteuert werden. Die Thermostate müssen entsprechend justiert werden, um Kondensation zu vermeiden und
um die Innentemperatur zu regeln.
- In jedem Schaltschrank, in der Führerkabine und im Handbuch des Herstellers befindet sich ein Schaltplan.Wenn der
Benutzer oder Eigentümer die Original-Schaltkreise verändert, müssen die Schaltpläne aktualisiert werden.
- Im Innenraum des Schaltschranks befindet sich ein Satz Ersatzsicherungen.
- Der Überspannungsschutz unterbricht die Spannungszufuhr für alle Stromkreise, mit Ausnahme des orangefarbenen. Siehe
Schaltplan.
Anschluss:
- Die elektrischen Filter gewährleisten in Übereinstimmung mit der europäischen Richtlinie eine Begrenzung der Emission von
elektromagnetischen Interferenzen sowie den entsprechenden Schutz davor. Es kann jedoch zu heftigem Auslösen des
Schutzschalters kommen. Eine Lösung liegt darin, konventionelle Schutzschalter durch Schutzschalter mit geringer
Empfindlichkeit zu ersetzen.
- Das Handbuch enthält die notwendigen Informationen, um einen entsprechenden Anschluss herzustellen.
Einstellungen:
- Einstellung der Kennlinien und der verbotenen Bereiche, siehe Handbuch.
- Einstellung der Überlastsicherung, siehe Handbuch.
- Einstellung der Bremsen, siehe Handbuch.
- La maintenance électrique doit être exclusivement réalisée par du personnel spécialement formé ayant lu le manuel de la grue
et pouvant y accéder pour toute consultation.
- Veiller à ce qu'une copie des instructions fournies dans la section « Utilisation de la grue » du manuel soit remise au grutier.
- Le fonctionnement des équipements est garanti à des niveaux de tension de ±5 % par rapport à la tension nominale.
- Les manuels relatifs aux accessoires (radio MP3, air conditionné, etc.) sont disponibles à l'intérieur de la cabine.
Armoire électrique :
- Chaque armoire électrique renferme des résistances chauffantes autoventilées ainsi que des ventilateurs d'aspiration
commandés par deux thermostats indépendants. Ces éléments doivent être réglés pour éviter toute condensation et réguler la
température intérieure.
- Un schéma électrique est disponible dans chaque armoire électrique, dans la cabine et dans le manuel du fabricant. En cas de
modifications apportées aux circuits d'origine par l'utilisateur ou le propriétaire, les schémas doivent être mis à jour.
- Un ensemble de fusibles de rechange est disponible à l'intérieur de l'armoire électrique.
- L'interrupteur général IG coupe l'alimentation de tous les circuits à l'exception des câbles de couleur orange. Se reporter au
schéma.
Raccordements électriques :
- Les filtres électriques garantissent les niveaux d'émission et de protection contre les interférences électromagnétiques
conduites conformément à la réglementation européenne. Ces derniers peuvent toutefois provoquer des déclenchements
intempestifs du disjoncteur différentiel. Pour remédier à ce problème, il est possible de remplacer les disjoncteurs différentiels
standard par des disjoncteurs super-immunisés.
- Les informations nécessaires au dimensionnement des raccordements électriques sont fournies dans le manuel.
Réglages :
- Consulter le manuel pour procéder au réglage du système d'indicateurs et des zones interdites.
- Consulter le manuel pour procéder au réglage des limiteurs.
- Consulter le manuel pour procéder au réglage des freins.
12 10
1, 3, 4 5, 6, 7, 8, 9
12
1 160 0394 ARMARIO ELÉCTRICO ARMOIRE ELECTRIQ. CONTROL CABINET SCHALTSCHKRAN 111
2 160 0395 CONJ. MANGUERAS ENSEMBLE CABLES CABLES SET SATZ KABEL 119
3 160 0178 RESISTENCIA RESISTANCE RESISTENCE WIDERSTAND 125
4 160 0189 RESISTENCIA RESISTANCE RESISTENCE WIDERSTAND 127
5 160 0327 CABINA MANDO CABINE COMMANDE CABIN STEUERUNG 121
6 160 0315 CONJ. INDICADORES INDICATEURS CABIN CABIN INDICATORS KABINENANZEIGE 111
7 160 0301 CONJ. INDICADORES INDICATEURS CABIN CABIN INDICATORS KABINENANZEIGE 111
8 160 0302 CONJ. INDICADORES INDICATEURS CABIN CABIN INDICATORS KABINENANZEIGE 111
9 160 0303 CONJ. INDICADORES INDICATEURS CABIN CABIN INDICATORS KABINENANZEIGE 111
10 160 0246 ANEMOMETRO ANEMOMETRE ANEMOMETER WINDMESSER 111
11 160 0292 TRASLACION TRANSLATION TRAVELLING FAHRWERK 111
12 160 0330 PLUMÍN POTENCE AUX. JIB BALLASTIERKRAN 145
2
3
4
5
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
This chapter contains useful information leading to a better crane performance under safety conditions.
Read this information thoroughly and bear in mind the recommendations and warnings given herein.
Crane operation is restricted to properly trained and qualified personnel, complying with the applicable regulations
and being conversant with the Safety Rules relative to his task. Being familiar with crane operation and operating
limits is crane operator responsibility.
Never operate the crane if the SAFETY SYSTEMS are not working or work incorrectly.
Be always alert toward anomalies in crane performance and immediately report them to the applicable
responsible person. The approach should be:
SAFETY FIRST
Later, additional information can be sent (i.e. technical maintenance bulletins) which must be read thoroughly
attaching it to the appropriate section.
Symbol Meaning
Voltage hazard.
Electric shock hazard.
Travelling.
Translation mechanism.
Hoisting.
Hoisting winch.
Trolley translation.
Trolley winch.
Slewing.
Slewing mechanism.
CRANES MUST INCLUDE ALL WARNING NOTICE BOARDS / SIGNS STATED IN THIS DOCU-
MENT..
Nº Significado Nº Significado
11 Information Label
PROGRAMA/FILE
1 Electric Hazard
12 Danger Warning
Secondary Registration
2
Numberplate
13 Danger Warning
3 Operation Regulations
21 LC ---
6 Nameplate
16 Load Diagram
19 Danger Warning
9 230 V Information Label
0 CONTENTS
1 GENERAL
2 SIGNS ON BASE
3 SIGNS ON TOWER
4 SIGNS ON SLEWING PART
5 SWINGING SIGNS
1 GENERAL
The posting of advertising signs on the crane increases the part exposed to the wind beyond the
amount considered in the calculations, which may cause problems in the stability of the crane.
Due to the interest in the posting of signs on the part of the owners, the possibilities have been
studied.
2 SIGNS ON BASE
If the crane is mounted on the base, the ballast area can be covered with advertising signs.
If the crane is embedded, an advertising sign of the same dimensions as the crane load sign can be
posted, both situated less than 20 meters high.
1m
3X_ nº of blocks x 0,5 m
5X_ nº of blocks x 0,3 m
2m 3X_ _ _= 4,5 m
5X_ _ _= 6,0 m
2m
Max. 20 m
Fig. 1
3 SIGNS ON TOWER
Whenever you wish to attach an advertising sign to the upper part of the tower, the self-stabilizing
height of the crane should be reduced.
The reduction of the self-stabilizing height is determined by the size of the sign and the tower version
to be mounted (See table).
21LC290
Reduction 1 section Reduction 2 section Reduction 3 section
Versión 3X_72 9,0 m Toda la torre Entire tower
Versión 5X_72 7,5 m 19,5 m Entire tower
Versión ES72 7,5 m 19,5 m Entire tower
The posting of signs in other areas or of signs larger than those indicated by the manufacturer may cause
accidents.
In case the crane will be mounted on cross base the calculations for the corresponding foundation and
base ballast concrete blocks should be made based on the reaction forces like if the crane was mounted
at its maximum self standing height.
In case the crane will be mounted on fixing angels the calculations for the foundation should be made
based on the reaction forces like if the crane was mounted at its maximum self standing height.
L máx.
del cartel.
Fig. 2
The posting of advertising signs on the slewing part of the crane is limited to the areas and sizes defined
in Fig. 3.
3,85 m
1 m
Cartel
Publicitario
Cartel
Publicitario
Fig. 3
5 SWINGING SIGNS
Swinging signs suspended from the counterjib structure that allow that structure to move freely can be
always be posted provided that they do not exceed the characteristics indicated in the following:
1m
4m
Fig. 4
1,6 m 2,2 m
2,0 m
4,5 m
5,2 m
0,4 m
> 3,5 m
SM21-K2/S25
SM21-K2/S35
J2-10 = - 0,6 m
> 2,6 m
J4.1
BM215A FM215 AM282B AM272A AM262A AM250A AM240 AM230 AM220 AM244
LC 2100
H
= H - 0,4 m)
AM282B AM272A AM262A AM250A AM240 AM244
(
AM282B AM272A AM262A AM250A AM240
R m
2700 74
8000 40
7000 44
5300 50
4600 54
4000 60
3700 64
3000 70
kg
kg
2970
8800
7700
5830
5060
4400
4070
3300
4,5 m 6,0 m
CL XA XR XA XR ES EN 14439
(C/25)
DS.1308.09 02/13 Reserva de modificaciones. Subject to modifications. Modifications reservées. Konstruktionsänderungen vorbehalten.
Il Fabbricante si riserva la facoltà di apportare modifiche. Возможны изменения.
DIAGRAMA DE CARGAS
Load chart / Diagramme de charges / Lastdiagramm / Diagramma di carico / Диаграмма распределения нагрузки
R (m)
14,3 15 20 25,8 25,9 30 34 40 44 50 54 60 64 70 74,0 m
74
18000 17005 12165 9000 9000 7660 6660 5545 4980 4300 3930 3475 3220 2890 2700 kg
14,6 15 20 26,4 26,7 30 34 40 44 50 54 60 64 70,0 m
70
18000 17460 12500 9000 9000 7920 6890 5745 5155 4455 4075 3605 3340 3000 kg
15,7 20 25 28,4 29,1 34 40 44 50 54 60 64,0 m
64
18000 13585 10470 9000 9000 7580 6325 5685 4920 4505 3990 3700 kg
15,6 20 25 28,2 29,1 34 40 44 50 54 60,0 m
60
18000 13480 10390 9000 9000 7585 6335 5695 4930 4515 4000 kg
15,7 20 25 28,5 29,6 34 40 44 50 54,0 m
54
18000 13610 10500 9000 9000 7725 6450 5800 5020 4600 kg
16,3 20 25 29,7 31,0 34 40 44 50,0 m
50
18000 14255 11005 9000 9000 8140 6800 6115 5300 kg
18,2 20 25 30 33,1 35,0 40 44,0 m
44
18000 16115 12480 10100 9000 9000 7775 7000 kg (t)
18,5 20 25 30 33,8 35,9 40,0 m 18
40 =
18000 16490 12275 10345 9000 9000 8000 kg - 0,5
t
9
(m)
18000 14640 11300 9900 9000 9000 7330 6920 6230 5400 4940 4380 4070 kg
16,7 20 25 28 30,3 31,6 38 40 44 50 54 60,0 m
60
18000 14630 11290 9890 9000 9000 7350 6950 6250 5410 4960 4400 kg
16,9 20 25 28 30,6 32,2 38 40 44 50 54,0 m
54
18000 14800 11440 10010 9000 9000 7490 7080 6370 5520 5060 kg
17,6 20 25 28 31,9 33,8 38 40 44 50,0 m
50
18000 15530 12010 10520 9000 9000 7910 7470 6720 5830 kg
19,6 25 28 30 35,8 38,2 40 44,0 m
44 (t)
18000 13660 11990 11060 9000 9000 8550 7700 kg +10%
20,0 25 28 30 36,5 39,2 40,0 m 18
40 =
- 0,5
18000 14000 12290 11350 9000 9000 8800 kg t
9
(m)
MECANISMOS
Mechanisms / Mécanismes / Antriebe / Meccanismi / Механизмы
9
50 kW 790 m
9
65 kW * 790 m
9
110 kW *
6 6 6
3 3 3
1,7
1,1 0,7 t
t t
100
150
200
60
100
140
m/min
90
150
210
m/min m/min
38
224
30
150
54
228
18 18 18
12 12 12
6 6 6
3,4
2,2 1,3 t
t t
50
75
100
30
50
70
m/min
45
75
105
m/min m/min
19
112
15
75
27
114
DS.1308.09 02/13 Reserva de modificaciones. Subject to modifications. Modifications reservées. Konstruktionsänderungen vorbehalten.
Il Fabbricante si riserva la facoltà di apportare modifiche. Возможны изменения.
21LC290/18 t
MECANISMOS
Mechanisms / Mécanismes / Antriebe / Meccanismi / Механизмы
EFU6L-65-45 EFU4L-110-45
1280 m
9
65 kW * 1280 m
9
110 kW *
6 6
Para mecanismos de alta capacidad de cable consultar cargas. /
3 For mechanisms with high drum capacity, request loads. / Pour des 3
mécanismes avec une grande capacité de câble il faut consulter. 1,7
0,7 t
t / Für Hubmechanismen mit hoher Kabelkapazität, Lastdiagramm
100
150
200
m/min
90
150
210
m/min anfragen. / Gru con tamburo ad alta capacità di avvolgimento
38
224
54
228
fune, consultare il diagramma di carico. / Проконсультируйтесь о
нагрузках при механизмах с большей вместимостью кабля.
18 18
12 12
6 6
3,4
1,3 t
t
50
75
100
m/min
45
75
105
m/min
19
112
27
114
CFU-7.5
7,5 kW
GFU-7.5
3x 7,5 kW
TRA-7.5
2x 75 Nm
* TRA-7.5VC
2x 75 Nm
0 20 m/min 0 20 m/min
0 94 m/min 0 0,7 rpm
3XR72 5XR72 5XR72
LC 2100
EFU6-65-45 180 kVA
*
400 V
EFU6L-65-45 CFU-7.5 (3x) GFU-7.5 (2x) TRA-7.5 3ph 180 kVA
EFU4-110-45 50 Hz 250 kVA
EFU4L-110-45 250 kVA
64,9 m nº Ref. h
63,1 m 1 S25 2,0 5,5
H h (m)
C/25
H
C/25
1
1 (m)
1
1
42,6 m 1
1
H 1
C/25
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1 En servicio / In operation / 3XR72...... 105 t
1 En service / In Betrieb / In
1,6 m 1 1,9 m 1 servizio / При работе 5XR72...... 107 t
1
Z máx.
Fuera de servicio / Out
Z Z PS5 of service / Hors service 3XR72........ 74 t
4,5 6,0 m
m / Ausser Betrieb / Fuori
3XA72 5XA72 servizio / В стационарном 5XR72...... 132 t
3XR72 5XR72 ES72 состоянии
Otras zonas de viento o alturas superiores consultar / Other wind zones or additional hook heights on request / Autres zones de vent ou des hauteurs supplémentaires sur demande /
Andere Windzonen oder weitere Hakenhöhen auf Anfrage / Per zone con velocità del vento particolari o altezze superiori consultare il fabbricante / При других ветренных зонах о при
бóльшой высоте проконсультируйтесь с нами
DS.1308.09 02/13 Reserva de modificaciones. Subject to modifications. Modifications reservées. Konstruktionsänderungen vorbehalten.
Il Fabbricante si riserva la facoltà di apportare modifiche. Возможны изменения.
21LC290/18 t
GRÚA ARRIOSTRADA GRÚA TREPADORA
Braced crane / Grue à entretoisement / Abgespannter Kran / Internal climbing crane / Grue avec cage de télescopage intérieure / Kran
Gru ancorata / Наращиваемый кран mit klettern im Gebäude / Gru in rampante in cavedio / Монтажная клеть
98,9 m
96,8 m
H C/25
H
C/25
6
85,8 m 6
82,4 m 6
80,3 m H C/25 6
H C/25 6
74,8 m H C/25 6 6
LC 2100
6 6
69,3 m H C/25 6 6 6
6 6
65,6 m H C/25 6 6 6 6
H C/25 6 7
6 6 6 6 7
6 6 9
6 6 6 6 9
6 6 10
6 6 6 6 10
6 6 10
6 6 6 6 10
6 6 11
6 6 6 7 11
6 6 11
6 6 6 9 11
6 6 12
6 6 6 10 12
6 6 13
6 6 6 10 13
6 7 13
6 6 7 10 13
6 8 13
6 7 8 10 13
6 9 13
6 8 9 11 13
1,9 m 6 2,2 m 10 2,2 m 13
6 8 10 11 13
Load diagrams shown on following pages are valid for cranes with height under hook of about 100 m.
Above this height it should take into consideration the weight of the additional hoisting cable, reducing
the load capacity of the crane according to the attached tables.
Reduction of loads
from 100 from 200 from 300 from 400 from 500 from 600
to 200 m to 300 m to 400 m to 500 m to 600 m to 700 m
The reduction of loads depends on the number of reevings and on the weight of the added hoisting ca-
ble. For medium heights under hook, the weight “P” of the added hoisting cable must be reduced from
suspended “Q” load on the crane.
Q Q
Rope Weight per
diameter meter of cable
(mm) (kg)
21LC/12 t
18 1,5 h >100 m
21LC/18 t
21LC/24 t
21LC/36 t 22 2,2
21LC/48 t
Q+P
(t)
+10%
Single trolley (2 falls)
(m)
(t)
+10%
Motor
9 Make............................... LEROY SOMMER
Power ................................................ 50 kW
6 Brake
Type..............................................FCPL60H
3 Model........................................ FCPL60-2H
1,1 Drum
t Drum capacity................... 790 m in 3 layers
60
100
140
m/min
30
150
Máx. h.u.h. SC................................... 395 m
Máx. h.u.h. DC................................... 197 m
Operating voltage
18 Voltage............................400 V, 3 ph, 50 Hz
12
6
2,2
t
30
50
70
m/min
15
75
Motor
Make............................................. BESOZZI
Power .................................................... 7,5 kW
(t) Brake
18 Type............................................... BFK 458
Model........................................ BFK 458.16
Operating voltage
9 Voltage............................400 V, 3 ph, 50 Hz
0 47 94 (m/min)
Motor
Make............................................. BESOZZI
Power ..............................................7,5 kgm
-1 Brake
min 0 0,7 Type........................................................ GR
Model................................................... GR 7
Operating voltage
Voltage............................400 V, 3 ph, 50 Hz
Motor
Make............................................. BESOZZI
Power ........................................2 x 7,5 kgm
Brake
m/min 0 20 Type........................................................ MS
Model............................................... 110 MS
Operating voltage
0 20 (m/min) Voltage.....................................400 V 50 Hz
Motor
Make............................................. BESOZZI
Power ........................................4 x 7,5 kgm
Brake
m/min 0 20 Type........................................................... S
Model.................................................. 100 S
Operating voltage
0 20 (m/min) Voltage............................400 V, 3 ph, 50 Hz
Motor
Make............................................. BESOZZI
Power ........................................4 x 7,5 kgm
Brake
m/min 0 20 Type........................................................... S
Model.................................................. 100 S
Operating voltage
0 20 (m/min) Voltage............................400 V, 3 ph, 50 Hz
Motor
(t) Make.................................. LEROY SOMER
1,5 Power ............................................... 2,2 kW
I Brake
Type......................................................FCO
SR 8 m/min
Model.............................................FCO-100
1,5 t
Drum
0 8 Drum capacity................... 160 m in 8 layers
(m/min) Máx. h.u.h. .......................................... 80 m
Operating voltage
Voltage............................400 V, 3 ph, 50 Hz
Motor
Make..................................................... ABB
Power ................................................ 20 CV
Operating voltage
Voltage............................400 V, 3 ph, 50 Hz
Pump
Make..............................................PARKER
Model.....................................PAF-20RK-3C
1. Only duly qualified personnel complying with current Regulations in force and familiar with Safety Rules
relative to his task is authorised to operate the crane.
2. Never work on safety devices in order to override or modify their calibration out of range. (Fig. 1)
4. Never operate the crane before all protections and safety devices are installed and in correct working
order.
5. If changes in crane setup are introduced (jib length, height, etc), make sure that load limiters and limit
switches are readjusted for the new setup. (Fig. 2)
Fig. 1 Fig. 2
As a last alternative to reach areas not accessible by other means the tower crane may be used to raise
and lower personnel to that area, provided the following criteria is met.
The device that will carry the personnel being transported shall be manufactured and approved for that
purpose, and all procedures related to the crane operation and the transportation of personnel shall be
in accordance with all Local, State and Government standards.
Fig. 3 Fig. 4
10. Do not rest the hook on he load or any other surface as lifting cables must never be loose.
11. If during a lifting operation the steel cables become loose, the operation must be interrupted until
the cause of loosening is found and check the proper winding of the cable and that it is not out of
pulleys or guides.
12. The emergency stop should not be used for stopping during normal operations.
In case of repeated emergency stops within a short period of time, the brakes should be checked imme-
diately by qualified personnel, since they may be adversely affected and lose their braking power and
load-retaining capabilities.
13. If the work is interrupted, never leave loads in suspension or the crane running.
15. The operator must have a perfect view of the working area and the load (Fig 8)
16 When lack of view is due to poor light, floodlights covering the full working area shall be used.
17. A signal man must direct the operation if lack of view is due to physical obstacles. (Fig 9)
18 Signals given by the signal man must be based on specific systems (national standards, if any, shall
be used) (Fig 10)
19. When the crane is operated from the cabin, visibility conditions must be maintained by window
cleaning avoiding any view limiting objects.
Keep the wipers in good condition.
Cleaning of cabin windows must be done by using exclusively thos e accessories enabling it with no
need for going outside passages or access platforms to the cabin.
21 The crane operator must be kept informed about the existing wind velocity.
Anemometers give this information and are very useful in windy areas.
22 As a general rule, work must cease if wind velocity makes handling loads difficult with hazard to
persons.
23 Make sure there are no hazards to persons prior to starting the crane (See checks prior to
commissioning)
24 Before work commencement, the operator must be familiar with condition existing at the site such as
main obstacles, traffic areas, interferences, etc.
25 Crane travelling, when required, must not be used in conjunction with any other movement and then,
the jib and counterjib must be placed in the direction of the track.
27 Make sure that safety signs and warnings are in good condition and in the right place.
28 Keep access and working platforms in good condition and free from tools or objects that can fall down.
Instructions in this section are given for complementary guidance; therefore they do not replace current
safety regulations in force, national and international laws, local regulations or of the insurance compa-
nies.
1 Carry out standard inspections and specific inspections prior to start up and after major crane modifica-
tions.
4 Crane documents (Instructions Manual, certificates, records, etc.) must be kept at the crane in an acces-
sible place.
5 All personnel involved with crane erection, dismantling, operation and maintenance must be conversant
with the instructions given in this Manual. Should the information contained in any paragraph be incom-
plete or confusing, applicable clarification shall be requested before carrying out any action.
6 The crane must be free from permanent deformations, fractures, cracks or other defects affecting its-
safety.
7 Foreign elements not being part of the crane are not allowed provided they have not been authorised by
the manufacturer.
8 Personnel appointed for crane operation (crane operators) must have appropriate qualifications and be
conversant with the instructions and specific features of the crane being operated.
9 Before beginning crane operation, the crane operator must proceed with all the checks mentioned in this
Manual for commissioning stage.
10 When crane work has been finalised, the operator shall follow the instructions for taking the crane out of
service. Thus:
11 The crane operator must know the wind conditions to be able to discontinue crane work if necessary.
For a direct knowledge of the real wind velocity, the provision of an anemometer at the site is advisa-
ble.
0 CONTENTS
1 POWER SUPPLY
2 CRANE TRACK
3 CLEARANCES
4 BASE BALLAST AND OVERHEAD COUNTERWEIGHTS
5 LIGHTNING ARRESTERS
6 BARE GEARS
7 STEEL CABLES AND PULLEYS
8 MAINTENANCE
1 POWER SUPPLY
Make sure that power supply source is adequate for the crane and that fluctuations are less than +-5%
of rated value. See chapter Electrical Installation.
2 CRANE TRACK
Check that rails are in good condition and correctly mounted and the track is free from foreign objects.
Check that rail ties are in good condition and that end of track bumpers are correctly placed.
3 CLEARANCE
Check that the crane can move free from obstacles keeping minimum safe clearances between the crane
or the load and possible obstacles (at least 0,5 m).In case electric lines are present, check that the safety
distance is in accordance with the line voltage.
5 LIGHTNING ARRESTERS
If lightning arresters are installed check that the structure earthing connection is properly made.
6 BARE GEARS
Check that bare gears are properly greased
8 MAINTENANCE
Check that all required maintenance operations have been carried out.
Crane siren will sound meaning that the crane is free slewing
5 Check the operation of crane siren by pressing the pushbutton on the crane controls
If any crane malfunction is detected, stop the crane (pressing the stop button) and call for service.
9 Operate the crane in accordance with instructions in document “CRANE CONTROL” in this chapter
0 CONTENTS
1 DESCRIPTION
2 OPERATION
1 DESCRIPTION
The PowerLift system improves the load diagram by 10% at reduced speeds.
With this system, the crane can move the nominal load shown in the diagram over greater distances.
This system will not allow the crane to have more than the maximum load capacity. What it does allow
for is a 10% increase in the nominal load range that appears in the load diagram, up to the maximum
load limit shown in the data sheet.
The PowerLift system is a momentum control and limiting method which, by automatically reducing the trolley
and elevation speed, gives the crane the potential of achieving up to 10% more load for jobs that require it.
Example: The 21LC400/18 t, with an 80 metre jib, can load 18,000 kg over a jib length of up to 16.6 metres.
Thanks to the PowerLift system, it can load those same 18,000 kg over a span of approximately up to 18 metres.
In addition, if this crane has a jib-end load of 3,000 kg, with the PowerLift system it can load 3,300 kg.
2 OPERATION
The PowerLift system is automatic and not at all difficult to use:
- When a load reaches its maximum standard range, the trolley and elevation movements are automatically
interrupted, activating the momentum limiting red pilot light situated in the operator's position inside the
cab.
- After a few seconds, in which the oscillation of the load is dampened, a blue pilot light comes on inside the
cab and trolley and elevation movements are authorised again, limiting the elevation speed to values of
between 20 and 30 metres per minute. The trolley can advance at a reduced speed a few more metres.
Having achieved this additional range, the crane limits movements once again and the momentum limiting
red pilot light comes on again in the cab.
To benefit from the advantages of this new system, the crane's installation engineer must adjust the crane's
capacity limiters differently to their previous settings.
The instructions and all the necessary information for achieving this are available in the crane's instruc-
tion manual.
0 CONTENTS
1 IMPORTANT NOTES
2 CONTROL PANEL
3 LEFT CONTROL
4 RIGHT CONTROL
1 IMPORTANT NOTES
Stop operating the crane and put it out of service if the following is observed while driving the crane:
- When there is a malfunction of any movement or movement retaining brakes
- Non-activation of the end stops at the movement limits.
- Loads greater than authorised can be lifted.
In case of repeated emergency stops in a short time, have the brakes immediately reviewed by qualified
staff, as they may be affected and braking and load retention performance may be lost.
In periods with freezing temperatures, ensure that the crane's mobile components (brakes, crown,
collector, etc.) are not locked up by ice formation. In these cases, the first operating manoeuvres should
be done with care
Crane operation should be stopped when the wind speed makes it dangerous for people to handle the
loads. See documents “Stopping work due to wind” and "Anemometer - Wind speed indicator / alarm"
in this chapter of the manual.
When the crane is switched off, the wind indicator / alarm system is not operational.
In case the crane is disconnected, it should be placed out-of-service (including wind protection).
When the crane is unsupervised, it should be out-of-service. Take into account that the radiocontrols
automatically disconnect the crane when it is not used for some time.
The crane driver must be aware of the loads they are handling and the crane's load capacity, which must
not be exceeded.
Load and momentum limiters should not be used as a working system, as these are safety elements that
should not usually be activated.
Movements must stop before reaching the movement limits. The end stops are safety elements, and
should not usually be used for stopping movement.
The use of several portable radiocontrols in the same working area can lead the crane operator not
knowing which machine they are controlling with the radiocontrol used, with the consequent risk.
If the crane operator detects this risk, they should warn others about it.
It is the operator's responsibility to have the means for ensuring that no confusion occurs, for instance,
by a radiocontrol marking and identification system so that the crane operator can distinguish without
error which radiocontrol controls which crane.
It is the operator's responsibility to have the means and establish the safety procedures so that when the
radiocontrols and/or telecontrols are not working or being used, they are removed from the work area to
prevent anyone from believing that their emergency stop device is active.
Moreover, the operator must set up safety procedures to ensure that a radiocontrol or telecontrol is NOT
used. It is recommended to keep them under lock and key.
If the crane is fitted with radiocontrol, it includes a factory-fitted electric light beacon, connected to the
top cabinet, this beacon has a magnetic fastening system and a steel cable with a safety spring hook to
fasten it and secure it to the crane's structure.
The crane operator must fit the beacon in a place where it is visible to all people working close to the
crane.
This beacon has different coloured lamps:
- Yellow lamp:
Fixed light warning when the crane has exceeded 90% of its momentum capacity.
- Green lamp:
Fixed light warning when the radio control receiver of the crane is on.
Both warnings are enabled when the power supply switches on the base of the crane and those of the
top cabinet are in the ON position, at the same time as the crane is in the ON state in the control.
2 CONTROL PANEL
2
9 24
12
16
15
14
18
13
8 4
11
23
7
5
6
17
10
3 LEFT CONTROL
Pushbuttons
6 Slewing brake pushbutton
Cancels the delay in the electromechanical brake application of the slewing motor.
Under normal conditions, once the joystick is brought to zero setting, the jib movement will be
brought to rest through the motor braking action in a progressive manner. The electromechanical
brake is a park brake and acts subsequently.
Under certain conditions with strong winds, the jib must be locked after the movement stops,
using this pushbutton.
During the reeving change operation and once the trolley backwards and hook up
limitations have been surpassed, depending on the position of the trolley and the
hook, some of the movements: backwards or forwards trolley and up or down hoisting
may be hindered as the reeving change manoeuvre was started and was not properly
performed.
13.1 Orientation
Movement acceleration and deceleration are accomplished by varying the current supplied to the
motor stator and motor idler so that a perfect performance against load swinging is obtained.
Movement braking is automatically done, during speed change or when the joystick is brought
to the zero position, through the current supplied to the idler.
SPEED
MOVEMENT MACHINERY SITUATION
POINT
3 Motor at top speed
2 motor at intermediate speed
<
LEFT SLEWING 1 Motor at micro-speed
0 Motor idle, brake locked
1 Motor at micro-speed
> 2 Motor at intermediate speed
RIGHT SLEWING
3 Motor at top speed
There is a bushbutton for overriding the delay of the electromechanical brake. For its use, see
section 1.1.1, point 6.
Top hoisting speed is automatically reduced when the trolley comes close to the end stop.
Movement acceleration and slowing down are gradual and never sudden.
The electromechanic brake locks the movement when the motor has fully stopped (frequency
converter control).
2 speed ranges are available, see trolley speed switch. (Right control nº 11)
POSITION SWITCH nº 11
VARIANCE
MOVEMENT LEVER
CONTROL
0 47 m/min 0 94 m/min
TROLLEY FORWARDS
0 47 m/min 0 94 m/min
TROLLEY BACKWARDS
When the crane is loaded with over 90% of momentum, the trolley speed is automatically
limited to a low value.
4 RIGHT CONTROL
Push-buttons
1 ON light pushbutton
Used to start the crane.
Pressing this pushbutton switches on the main contactor and the light inside it comes on.
When the crane is power supplied through the main contactor, the hoist and trolley frequency
converters go into a self-test checking for errors. This takes a few seconds.
Hoisting and trolley movements are not possible during this time.
2 Stop Pushbutton
The normal use of the stop push button is to disconnect the power supply to the crane when no
work is being done, or as an initial measure to switching off the main contactor prior to leaving
the work place at the end of the shift.
Also, it may be used as an emergency stop when crane work so requires.
On turning the power off, the frequency converters start the capacitors' disconnection
and discharge stage, which lasts about 10 seconds. If during this period, crane start is
pressed again, the converter may not start properly and it will stay in trigger status, not
allowing the related movement.
If this occurs, stop again, wait 10 seconds and start it again.
3 Alarm button
Pressing this pushbutton also continuously sounds the crane's alarm.
On the lower part (on the outside) of the left control there is a thermostat that allows the heating
to be adjusted.
Lower speed ranges can be selected, even with lighter loads, in order to obtain greater movement
precision.
Maximum speeds based on the selected speed range are:
The hoisting mechanism allows for very high speeds to be selected. (for instance,
156 m/min in single reeving, with the speed range switch set to position 4).
The path of the hook in slowing down movement before coming to a stop, must be taken
into account.
he speed range change can be made with a load on the hook, but the hoist idle.
T
The system is protected against using this switch with the hoist operating.
If during normal crane operation the load limiter hinders lifting a work load lower than the
allowed one or if on the other hand working with higher loads is allowed, technical service
should be called in to adjust the load limitation system.
Wrong selection of the speed range can cause the load to speed out of control if the
load limitation system is not properly adjusted and does therefore not protect against this
event.
14 Hoisting/travelling joystick
14.1 Hoisting
Hoisting movement is achieved through a frequency converter governed by the control panel
joystick.
The combiner includes a potentiometer which allows for selecting any speed, from zero to the
maximum allowed, depending on the load on the hook and the jib position.
The speed adjustment depending on the load function is automatically obtained by the
converter.
Movement acceleration and slowing down are gradual and never sudden.
The electromechanical brake locks movement when the motor is stopped (controlled by the
frequency converter that monitors motor speed at all times).
The positioning mode is obtained by pressing the control knob button of the lifting combiner
(see 15), allowing great precision at low lifting speeds. In addition, the electro mechanical brakes
are open while the pushbutton is pressed, avoiding sudden stops and starts that occur every
time the joystick passes by zero.
In the positioning mode the load is held securely thanks to the frequency converter.
Switching operating modes (normal to operating or vice versa) can be done with the hoist
operating, without any problem. If when working in normal mode the lever button is pressed, the
lifting motor speed range decreases automatically and on the contrary it increases on switching
from positioning to normal (release lever button).
The lever has automatic return to zero position. Therefore, when the lever is released, the lifting
movement stops and the electromechanical retention brake is applied.
If the hook is close to the end of path of the hoist, speed decreases automatically.
The hoisting mechanism allows for very high speeds to be selected. (for instance,
156 m/min in single reeving, with the speed range switch set to position 4).
The path of the hook in slowing down movement before coming to a stop, must be taken
into account.
14.2 Travelling
Movement acceleration and slowing down are obtained by changing the motor's power supply,
providing gradual movement.
Movement braking is automatically carried out by speed changing or bringing the joystick to
zero setting.
There is a bushbutton for overriding the delay of the electromechanical brake. See section
1.2.1-5
An acoustic alarm located at the base of the crane operates intermittently while travel movement
occurs. Its sound is different from the normal crane horn.
SPEED
MOVEMENT MACHINERY SITUATION
POINT
3 motor at top speed
2 motor at medium speed
TRAVELLING 1 motor at micro-speed
FORWARDS
0 motor idle, brake locked
1 motor at micro-speed
The knob of the lifting lever has a button that is pressed to select the positioning mode in the
lifting movement (See 14.1)
0 CONTENTS
1 IMPORTANT NOTES
2 INTRODUCTION TO THE SYSTEM.
2.1 System overview.
2.2 Basic configuration and optional functions.
2.3 System features and functions.
3 USE OF UCDL46 DISPLAY
3.1 Information on the screen and use of the keyboard.
3.2 Dynamic menu.
3.3 Editable fields.
4 USE OF THE INDICATION FUNCTION.
4.1 Introduction to the indication page [P1].
5 USE OF THE DATA LOGGER FUNCTION.
5.1 Permanent events indication page [P2].
5.2 Events log page [P3].
6 USE OF THE FORBIDDEN ZONES FUNCTION
6.1 Forbidden zones indication page [P4].
7 APPENDICES
– Event list and failure codes.
1 IMPORTANT NOTES
INDICATORS SHALL NEVER REPLACE A SCALE AND SHOULD NEVER BE USED AS A SUBSTITUTE
FOR THE CRANE LOAD AND MOMENT LIMITERS.
DATA DISPLAYED ARE SIMPLY INDICATIONS AND CANNOT REPLACE THE PERSONAL SUPERVISION
OF THE OPERATOR AND HIS OWN IMPRESION OF THE SIZE OF THE LOAD BEING HANDLED.
ANY CHANGE ON THE CRANE CONFIGURATION MAY RESULT IN A BAD OPERATION OF THE INDI-
CATION, DATA LOGGING OR FORBIDDEN ZONES SYSTEM. AFTER ANY CRANE CONFIGURATION
CHANGE, IT IS NECESSARY TO READJUST THE SYSTEM AND CHECK THAT THE UNIT IS FULLY
OPERATIVE AND PROPERLYWORKING.
THE FORBIDDEN ZONES SYSTEM ALONE SHOULD NOT BE USED TO AVOID TO DRIVE THE
CRANE ABOVE PIPE INSTALLATIONS THAT MIGHT CONTAIN FLAMMABLE LIQUIDS OR GASES.
THE FORBIDDEN ZONES SYSTEM SHALL NOT BE USED TO AVOID TO DRIVE THE CRANE ABOVE
ELECTRIC CABLES. ON SUCH SITUATIONS, IT IS NECESSARY TO MAKE A SAFETY ASSESSMENT
AND TAKE ADDITIONAL MEASURES (I.E. MOUNTING THE CRANE SO THAT THERE IS NO POSSI-
BILITY OF INTERFERENCE WITH THE CABLE) THAT LEAD TO A PROPER RISK REDUCTION.
Before beginning to use the system, it is compulsory to properly train the operator. Furthermore, the
maintainer of the crane or whoever performs any adjustment or change on it, must carefully read
this manual until he understands the working principle and the procedures for its adjustment.
The indication screens on this document may suffer some change as a result of any improvement of the
system software.
DLZ341 may optionally include the following special functions (on demand):
- Extended indication (the system can be supplied with additional information like slewing position
or travelling position).
- Forbidden zones system (prevents the hook from entering the areas defined by the user. If the
system is equipped with forbidden zones, it must include the slewing sensor and the travelling
sensor, if needed, to properly perform the forbidden zone function).
Screen messages use pictograms recommended by FEM1003 standard which list the symbols to be
used on tower crane indications, so that an effective and error-free communication is achieved.
The indication function offers an instantaneous and intuitive sight that shows the load state of the crane and
the crane position. The data are represented in numerical format and also as a progress bar, allowing a faster
and easier understanding.
Further information on the indication function may be found in point 4 of this document.
The data logger function supplies information referred to the crane operation (number of working hours of each
winch, number of overloads, information on the last movements, alarms…).
Further information on the data logger function may be found in point 5 of this document.
The forbidden zones function allows the user to define a number of zones where the hook will be prevented
from entering. Once the system is properly adjusted, the crane stores the zones information in memory and
operates in an intelligent way, automatically preventing the hook from entering into the forbidden areas.
Further information on the forbidden zones function may be found in point 6 of this document.
Display
Fixing bracket
2
4 5
DLZ341
Fig. 1
When UCDL46 internal temperature goes below -10ºC or above +60ºC, the screen is switched off and
the power supply green LED blinks. The functions of the system keep working but the screen is automa-
tically switched off to avoid damages.
The UCDL46 unit is mounted inside the cabin on a fixing bracket that permits several rotations and movements.
It allows the crane operator to set an optimal position from an ergonomic point of view.
To adjust the display position and orientation, loose both swivels, set the unit to the desired position and tighten
them again (Fig.1).
Fig. 2
The following table shows the pictograms in this page and their meaning.
SIDE BAND PICTOGRAMS
PICTOGRAM EXPLANATION CONFIGURATION
1 Wind speed. Basic system
2 Enter.
5 Escape.
6 Screen backlight control (in Page P1). In some other pages it is a help button.
14 Show the version information and software upgrading page Basic system
Basic system
15 Current reeving and manual reeving change.
4 500.00 m Confirm the current digit value and pass to the next one.
5 000.00 m Exit the field.
THE INDICATION SCREENS SHOWN IN THIS DOCUMENT MAY SUFFER SOME CHANGE DUE TO
ANY SYSTEM SOFTWARE IMPROVEMENT.
1 2
3
7
10
8
4
9
Fig. 3
3 Trolley position.
With respect to the tower mast central axis.
4 Hoisting position.
Indicated with respect to a chosen ground level (0 meters).
This value can be positive or negative depending on wheter the hook can go below the chosen ground
level or not.
5 Reeving state.
Displays the current crane reeving state.
The system does not automatically detect the reeving number. To indicate the proper number of reevings,
press the reeving change button 5.
An incorrect number of reeving choice may lead to an incorrect hook height and load indication and thus
to a possible incorrect operation of the forbidden zones height limitation.
This indication is just a rough value and only pretends to be an aid to the crane operator. It is compulsory
that the crane operator knows and refers to the load chart diagrams of the crane and never lifts loads
above the crane capacity indicated on the chart.
7 Angle between current jib position and another reference position. The angle must be increased when
the crane turns clockwise (slewing sensor option).
This indication is just a rough value and only pretends to be an aid to the crane operator. It is compulsory
that the crane operator knows and refers to the load chart diagrams of the crane and never lifts loads
above the crane capacity indicated on the chart.
If there is a failure on any of the sensors or on its configuration, the screen shows this pictogram
and an error code (see Appendix).
THE INDICATION SCREENS SHOWN IN THIS DOCUMENT MAY SUFFER SOME CHANGE DUE TO
ANY SYSTEM SOFTWARE IMPROVEMENT.
Accumulated values
since the last reset
Fig. 4
PICTOGRAM EXPLANATION
A cycle begins when the lifted load goes beyond 5% of the crane maximum load specified in [P10] during
more than 5 seconds.
A cycle ends when the lifted load goes below al 5% of the crane maximum load specified in [P10] during
more than 5 seconds.
D
4 Nº 3
C 3 Nº 2
B Nº 1
2
A 1
Fig. 5
EXPLANATION
A Number of cycles with moment % below N°1.
EXPLANATION
Cycle number.
Reeving state.
Press to access the field , and use to go throught the cycle list.
Press to exit.
Fig. 7
THE INDICATION SCREENS SHOWN IN THIS DOCUMENT MAY SUFFER SOME CHANGE DUE TO
ANY SYSTEM SOFTWARE IMPROVEMENT.
Fig. 8
PICTOGRAMA EXPLICACIÓN
1 Slewing angle referred to the "zero" set during the slewing sensor scaling.
2 Trolley position.
Height under hook referred to the ground level set on the hoist sensor
3
scaling
4 Travelling position referred to the "zero" set on the travelling sensor scaling.
Hook position referred to cartesian absolute axis. The intersection of x and y
axis is set on the mast center.
5
The arrows associated to each movement in [P1] will blink in red when the DLZ system stops the mo-
vement.
Every time the system stops a movement to avoid entering a forbidden zone, it warns the operator . This warning
is done by showing a pictogram, both in page [P4] and in page [P1].
The movement stop pictograms are listed in the following list.
PICTOGRAMA FUNCIÓN
3 Hoisting stop.
4 Lowering stop.
1 Reeving state.
2 Reeving state.
3 Reeving state.
4 Reeving state
5 Reeving state
15 Hoisting stop.
16 Lowering start .
17 Lowering stop.
When the hoist mechanism is stopped at
18 Hoist stopped state start. the same position for more than 5 seconds.
The position is also registered.
When the hoist mechanism is stopped at
19 Load hung state start. the same position for more than 5 seconds.
The load value is also registered.
20 Moment limitation state start.
26 Weathervaning on.
27 Weathervaning off.
30 UCDL46 on.
31 UCDL46 off.
Luffing angle sensor badly scaled or sensor Only in luffing jib crane.
41 1
failure.
42 Trolley sensor badly scaled or sensor
2
failure
Load cell badly scaled or load cell
43 3
failure.
Moment sensor badly scaled or sensor
44 4 failure
Hoisting sensor badly scaled or sensor
45 5 failure
Anemmometer sensor badly scaled or
46 6 Option
sensor failure
Slewing sensor badly scaled or sensor
47 7 Forbidden zones option
failure
Travelling sensor badly scaled or sensor
48 8 Option
failure
49 9 System error
51 11 Memory corruption.
0 CONTENTS
REEVING CHANGES MUST ALWAYS BE CARRIED OUT FROM A POSITION THAT ALLOWS THE
PERSON MAKING THE CHANGE TO SEE WHAT IS HAPPENING AND THEREBY PREVENT ANY
FAULT OR MALFUNCTION THAT COULD LEAD TO A HAZARDOUS SITUATION.
THE REEVING CHANGE OPERATION MUST BE CARRIED OUT WITH NO LOAD, SLING OR OTHER
LOAD SUSPENSION TACKLE ON THE HOOK.
ALL CRANE LIMITS MUST BE PROPERLY ADJUSTED. THIS OPERATION INVOLVES THE HOOK UP
AND CARRIAGE BACK TRAVEL LIMITS AS WELL AS THE LOAD LIMITER. SEE THE DOCUMENTS
“HOISTING LIMITER”, “CARRIAGE LIMITER” AND “LOAD LIMITER” IN THE “USE AND MAINTENAN-
CE” CHAPTER.
Fig. 2
- Take the front trolley and hook closer to the start of the jib without going beyond the hook up and trolley
back limits.
- Use the crane control to cancel the trolley back limit, and take the front trolley towards the start of the jib
until it reaches a stop against the rear trolley, operating the front trolley position limiter (LPCD) to enable
the change to continue.
ONCE THE “TROLLEY BACK” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE HOOK
UP MOVEMENT IS LOCKED UNTIL THE FRONT TROLLEY POSITION LIMITER COMES INTO
OPERATION.
Fig. 3
- Use the crane control to cancel the hook up limit, and take the front hook up at slow speed until it is
housed in the rear hook and stops up against it.
ONCE THE “HOOK UP” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE TROLLEY
FORWARD MOVEMENT IS LOCKED UNTIL THE FIRST LOAD LIMITER COMES INTO OPERATION.
(LC4).
Fig. 4
- Continue the upward movement, and the hook assembly and rear trolley swings on the rear wheel, the
front hook is housed in the front trolley, and protection “PG” swings, hiding the front hook anchor and
securing the two hooks.
- As the upward movement continues, the hoisting cable comes under tension and the first load limiter
(LC4) comes into operation, thereby stopping the movement.
Fig. 5
- Move the trolley and hook assembly forward until it leaves the rear hook support.
Fig. 6
- Continue the trolley forward movement until the trolley back limit zone has been exceeded.
- Use the crane hook down control, and the rear trolley will swing so that its front wheels rest on the track
profile.
- The hitching catch (GE) will couple the two trolleys.
- Taking the trolley forward, the crane is ready to work with both trollies and both hooks hitched together.
(DOUBLE REEVING).
- Loads must be suspended from the rear hook anchor.
REMOVING THE FRONT HOOK ANCHOR PROTECTION TO HANG LOADS DURING DOUBLE-
REEVING WORKING IS PROHIBITED.
FAILURE TO OBSERVE THIS RESTRICTION MAY LEAD TO ACCIDENT.
Once the operation connected with cancelling the safety system has been completed, the crane must
be stopped and subsequently restarted.
REEVING CHANGES MUST ALWAYS BE CARRIED OUT FROM A POSITION THAT ALLOWS THE
PERSON MAKING THE CHANGE TO SEE WHAT IS HAPPENING AND THEREBY PREVENT ANY
FAULT OR MALFUNCTION THAT COULD LEAD TO A HAZARDOUS SITUATION.
THE REEVING CHANGE OPERATION MUST BE CARRIED OUT WITH NO LOAD, SLING OR OTHER
LOAD SUSPENSION TACKLE ON THE HOOK.
ALL CRANE LIMITS MUST BE PROPERLY ADJUSTED. THIS OPERATION INVOLVES THE HOOK UP
AND CARRIAGE BACK TRAVEL LIMITS AS WELL AS THE LOAD LIMITER. SEE THE DOCUMENTS
“HOISTING LIMITER”, “CARRIAGE LIMITER” AND “LOAD LIMITER” IN THE “USE AND MAINTENANCE”
CHAPTER.
Fig. 8
- The crane is working with two trollies and the two hooks joined. (DOUBLE REEVING).
Fig. 9
- Use the crane control to cancel the hook up limit, and at slow hoisting speed draw the hooks closer to
the trollies until the rear hook makes contact with the rear trolley.
ONCE THE “HOOK UP” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, THE TROLLEY
FORWARD MOVEMENT IS LOCKED UNTIL THE FIRST LOAD LIMITER COMES INTO OPERATION.
(LC4).
Fig. 10
- Continue the upward movement, and the rear trolley swings on the rear wheel and the front hook is
housed in the front trolley.
- The hoisting cable comes under tension and the first load limiter (LC4) comes into operation, thereby
stopping the movement.
Fig. 11
- Use the crane control to cancel the trolley back limit, and take the trollies towards the start of the jib.
- The trolley coupling catch (GE) enters the ramp (RG).
Fig. 12
- Continue taking the trolley back until the reeving change position limiters (LPCT) and (LPCD) come into
operation.
ONCE THE “TROLLEY BACK” BUTTON HAS BEEN PRESSED TO EXCEED THE LIMIT, HOOK MO-
VEMENT IS LOCKED UNTIL THE LOAD POSITION LIMITERS COME INTO OPERATION.
Fig. 13
- Operate slow speed down movement and the rear trolley swings on the rear wheel until the rear hook is
housed in the rear hook support. (SG).
- The front hook anchor protection (PG) swings and frees the front and rear hook coupling.
THE TROLLEY CANNOT BE MOVED WHILE THE FRONT HOOK IS OVER THE HOOK UP LIMIT.
Fig. 14
- Continue the downward movement until the front hook is below the “hook up” hoisting limit.
Fig. 15
- Taking the trolley forward, the crane is ready to work with a single trolley and hook (the front ones).
(SINGLE REEVING).
Fig. 16
The ID cancelling switch for the reeving change safety system may only be used by service personnel
who are fully aware of the effect of cancelling the safety system.
All operations carried out with the safety system cancelled must be especially well supervised to avoid
creating a hazardous situation.
Once the operation connected with cancelling the safety system has been completed, the crane must
be stopped and subsequently restarted.
If a crane should be left with single trolley (discarding the possibility of a 2nd trolley for double reeving), apart
from removing the trolley (see ASSEMBLY/DISASSEMBLY) the following operations must be done:
a) Physically remove jib mounted trolley position limiters ( LPCT and LPCD ).
b) Switch off the power connection of the limiters (removing plugs in electrical cabinet or disconnecting-
terminals in junction boxes, as applicable).
c) Place jumpers in tower top electrical cabinet
43-44 AID contactor.
53-54 AID contactor .
14 ABCT contactor and 14 ALCT contactor.
13-14 ALCDE contactor.
d) Check SR trolley operation against end stops with trolley backwards.
If the 2nd trolley should be replaced in order that double reeving is available, proceed in reverse order (points
a, b and c) and check the correct operation of changing from single to double reeve trolley and viceversa.
(see points 1 and 2 in this instruction).
0 CONTENTS
1 TROLLEY AND HOOK POSITION
2 CLEARANCE
3 FREE SLEWING
4 CONTROL VOLTAGE DISCONNECTION
5 POWER SUPPLY DISCONNECTION
6 FASTEN THE CRANE TO THE TRACK (if crane on rails)
7 ACCESS TO CRANE CONTROLS
2 CLEARANCE
Make sure the crane can slew a complete turn with no obstructions.
3 FREE SLEWING
Set the crane free slewing by pressing the applicable pushbutton on the crane controls.
The siren will sound to indicate that the crane is free slewing.
By pressing the crane stop button, the siren will cease.
Press again the start button; the siren will indicate that free slewing has correctly been activated.
If compliance with any of the above instructions should not be possible, notify the maintenance personnel
to take corrective action before taking the crane out of service.
On line outage or electrical system malfunction, acting on devices installed on slewing motors can set
free slewing manually. See document “FREE SLEWING” in this chapter of the Manual.
0 CONTENTS
1 DESCRIPTION
2 OPERATION
3 MANUAL OPERATION
4 WIRING
5 ADJUSTMENT
6 CHECKING OPERATION
1 DESCRIPTION
The crane is prepared for weather vaning by releasing the brake on the slewing motor(s), leaving the upper
crane free to move with the wind. The brakes are released remotely via the release units on the brake cover
of each slewing motor.
A control box in the operator’s cabin (or at the base of the crane when there is no cabin) governs the release
units.
In case of a power cut-off or malfunction in the release system, weather vaning can be done manually.
2 OPERATION
Weathervaning sequence (Fig. 1)
1 Opening the motor brake causes the manual lever (1) to move upwards
2 The electromagnet (5) attracts the moving armature (2) and positions it below the manual lever
(1).
3 When the brake drops the manual lever (1) rests against the moving armature (2), preventing the
brake from closing and weathervaning the crane.
Activating weathervaning
1 The crane must be in operation.
2 Press the weathervaning button on
the crane control panel and wait 5-10
seconds. If the crane siren is still
blowing after that time, the crane is
weathervaned.
3 Press Stop to cut the siren.
4 Press Start. The siren should continue
to blow when the Start button is
released.
5 Press stop to cut the siren.
Deactivating weathervaning.
1 Engage the slewing control with the
crane in operation.
Some cranes have a lamp on the weathervaning button to indicate that weathervaning is engaged.
el dispositivo de veleta está activado.
3 MANUAL OPERATION
If there is a malfunction or power cut-off the slewing motor brakes can be
released manually.
1- Lift the lever, overcoming the resistance of the brake springs, and
keep it lifted.
2- Press and hold down the button.
3- Release the lever.
4- Release the button.
This procedure should be repeated with each release unit.
Repeat the process on each release unit
Fig. 2
2
4 WIRING
3 1-2 48V (50/60 Hz) electro-magnet power
4 3-4 Electro-magnet operating indicator micro-switch.
.
Fig. 3
5 ADJUSTMENT
To regulate the unblocking weather vanning, proceed as follows:
1- Manually lift the unblocking lever (1).
2- Push the button (3) until the mobile armature (2) comes inside
under the lever (1).
3- Unscrew the nut (4) in such a way that the distance "a" between
armature (2) and lowr part of the lever (1) when this is lifted at
its highest be approximatively 0.5 mm.
4- Check electrical operation: the armature (2) should enter freely
when the weathervaning button is pressed on the crane controls,
and should release when slewing movement is commanded. If
it does not, slacken the self-locking nut (4) 1/12 of a turn (half a
facet) and try again.
IMPORTANTE: The brake gap should not be less than 1 mm if weathervaning is to be regulated
correctly.
6 CHECKING OPERATION
Weathervaning must be used in windy conditions: if the jib points in the direction of the wind then the weathervaning
system is working correctly.
To check weathervaning when it not windy, proceed as follows:
1- Ensure that the crane can turn freely with no obstacles in its path.
2- With the trolley back and the hook raised and under no load, engage first gear and slew slowly.
3- Still in first gear, press the weathervaning button (the crane siren will sound).
4- Still slewing in first gear and with the weathervaning button engaged, press the stop control and check
that the jib continues to turn freely under its own inertia.
5- If it does not do so, readjust the brake gap (which should be 1 mm) and adjust the weathervaning
system..
0 CONTENTS
1 SYSTEM OVERVIEW
2 OPERATION CHECK
3 ALARM AND TEST PROGRAMMING
4 RS 485 WIND-SPEED OUTPUT
5 HEATING SYSTEM FOR THE WIND-SPEED SENSOR
1 SYSTEM OVERVIEW
The basic configuration has a wind-speed sensor (1), which is connected to the control and signalling unit
(2).
The system operates as follows:
- The control and signalling unit is electrically powered from the crane electric cabinet.
- The orange luminous beacon is activated when the wind-speed exceeds 50 km/h.
- The red luminous beacon and warning siren are activated when the wind-speed exceeds 70
km/h..
1 Wind-speed sensor
2 Control and signalling unit
4 Fastening magnets
5 Orange and red beacons
6 Siren
7 Line fastening to the structure
8 Cabin display
Fig. 1
2 OPERATION CHECK
2.1 Indication and control unit
- Check the operation of the beacons and siren as follows:
- Check the crane is powered.
- The switches at the bottom of the crane and the general switch on the electrical cabinet are
in the ON position.
- Press the stop button in the crane control and then press the start button (radiocontrol,
telecontrol or seat).
- This procedure allows to detect a problem in:
- Orange or red beacons.
- Siren.
- Unit power supply.
The device checks the proper operation of the red and orange beacons and of the siren by switching the
beacons and the siren (each beacon should blink twice and the siren must horn once).
- If one or several elements do not operate, this is because there is a problem in the electric supply
or in the elements themselves.
During this test, physically cover the siren to prevent being deafened by the noise this produces.
- Double check that the control and signal code units are properly fixed by the magnets and check
that the unit is appropriately secured to the crane structure with the fastening line (7) which is
supplied.
- Check that the unit is visible from the crane operator’s control position.
Necessary material:
- Cabin wind velocity display.
Instructions:
A. Connect the cabin wind velocity displayto the control unit (See Point 4).
B. Move the wind velocity detector cups either through the action of the wind or by turning them by
hand.
C. Check that there is a velocity reading on the cabin wind velocity display.
Necessary materials:
- Cabin wind velocity display.
- One complete portable anemometer with built-in display.
Instructions:
A. Connect the cabin wind velocity display to the control unit (See Point 4).
B. Install the portable anemometer pickup near the crane pickup and under the same wind reception
conditions.
C. Compare the wind velocity readings on the two displays (the check will be much more effective if
the auxiliary anemometer is calibrated).
Fig. 2
The device can be configured in different ways, by changing a set of 4 mini-switches 4 placed inside it. The
different functions that can be activated or deactivated are: autotest function, configuration in which the device
must be reinitialized after the 70km/h alarm is activated, cancel the acoustic warning when working close to
low noise areas like hospitals, residentials...
To access to the connections or configuration, loose the screws that fix the small bottom cover.
ON (1) Autotest ON
DIP1
OFF Autotest OFF.
After the wind-speed goes above 70 km/h , the ALARM remains activated , even if the
ON speed goes to 0 km/h (The alarm will be deactivated only after the unit supply is switched
DIP3 off for more thatn 15 seconds).
OFF (1) The ALARM is deactivated immediately after the speed goes below 70 km/h.
The DIP4 configuration is exclusively to be changed by an authorised person. Its proper position is ON.
Otherwise, the device indicates a "SENSOR FAILURE"
Before changing the position of the switches, ensure that it complies with the required standard for the
installation and that the new alarm method (sound and visual) is understood by the crane operators.
3.3 Alarms.
The device includes the following alarm modes:
- At 50 km/h only amber light, and at 70 km/h only red light.
- At 50 km/h only amber light, and at 70 km/h red light + siren.
The default factory setting is "at 50 km/h only amber light, and at 70 km/h red light + siren".
Fig. 3
In case there is any abnormal behaviour signal at the sensor, a cable that has been cut or an improper connection,
the system beacons intermittently blink until the problem is solved.
4 RS 485 WIND-SPEED OUTPUT
The control and signalling unit (Fig. 4) is equipped with an RS 485 output that allows a fast connection to the
indicator system in the cabin. Refer to the crane wiring schematic for more details.
Fig. 4
This heater system is supplied from a point which is placed before the general crane contactor G (see wiring
schematic) . If the general switch of the crane (IG) is ON and the crane bottom switch is ON, the heating system
will be operative, regardless the stop control is pressed or not. This allows the system to melt the frost even
when the crane controls are switched off.
To carry out this operation, swing the clamps by loosening the mounting.
Once the clamps have been positioned embracing the rail, they should be mounted with the fittings.
Crane's operations should be interrupted whenever the wind velocity endangers the
handling o the load for the operating staff.
According to the calculation standard (DIN 15019-1), the crane has to be taken out of service when the wind
velocity Vo corresponding to the dynamic pressure limit qo, determined from a 10 seconds average, is excee-
ded.
qo < q - 30 t
qo = Vo ² / 1.6
t Vo
(min) m/s km/h
5 17 61
10 16 58
15 15 54
20 14 50
25 13 47
Example: If 15 minutes will be needed for the fullfilment of safety measures (Procedure for taking units out
of service), the crane's operations have to be interrupted when the wind velocity reaches 54 km/h.
registered within 10 seconds.
NOTE: Cranes working in areas where wind velocity is likely to be above design limit must be provided
with anemometers.
See "ANEMOMETER - WIND SPEED INDICATION / ALARM" instruction in this manual.
Work with the crane must stop when the wind speed makes manipulating loads hazardous for people.
In cranes that are going to work in areas where winds can reach service limits, the user must install an
anemometer. (ITC "MIE-AEM-2" 2003).
See instruction "ANEMOMETER" in this manual.
The maximum surface permitted for a load exposed to wind is obtained by the formula:
Permitted service wind speeds depending on the surface of the load (km/h)
Surface of
the load
(m2)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Load (t)
1 72 51 42 36 32 29 27 25 24 23 22 21 20 19 19 18 17 17 17 16
2 72 72 59 51 46 42 38 36 34 32 31 29 28 27 26 25 25 24 23 23
3 72 72 72 62 56 51 47 44 42 39 38 36 35 33 32 31 30 29 29 28
4 72 72 72 72 64 59 54 51 48 46 43 42 40 38 37 36 35 34 33 32
5 72 72 72 72 72 66 61 57 54 51 49 46 45 43 42 40 39 38 37 36
6 72 72 72 72 72 72 67 62 59 56 53 51 49 47 46 44 43 42 40 39
7 72 72 72 72 72 72 72 67 63 60 57 55 53 51 49 48 46 45 44 43
8 72 72 72 72 72 72 72 72 68 64 61 59 56 54 53 51 49 48 47 46
9 72 72 72 72 72 72 72 72 72 68 65 62 60 58 56 54 52 51 50 48
10 72 72 72 72 72 72 72 72 72 72 69 66 63 61 59 57 55 54 52 51
11 72 72 72 72 72 72 72 72 72 72 72 69 66 64 62 60 58 56 55 53
12 72 72 72 72 72 72 72 72 72 72 72 72 69 67 64 62 60 59 57 56
13 72 72 72 72 72 72 72 72 72 72 72 72 72 69 67 65 63 61 60 58
14 72 72 72 72 72 72 72 72 72 72 72 72 72 72 70 67 65 63 62 60
15 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 70 68 66 64 62
16 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 70 68 66 64
17 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 70 68 66
18 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 70 68
19 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 70
20 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72
Permitted service wind speeds depending on the surface of the load (km/h)
Surface of
the load
(m2)
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Load (t)
21 72 70 69 67 66 65 63 62 61 60 59 58 57 57 56 55 54 54 53 52
22 72 72 70 69 68 66 65 64 63 62 61 60 59 58 57 56 56 55 54 53
23 72 72 72 70 69 68 66 65 64 63 62 61 60 59 58 58 57 56 55 55
24 72 72 72 72 71 69 68 67 65 64 63 62 61 60 60 59 58 57 56 56
25 72 72 72 72 72 71 69 68 67 66 65 64 63 62 61 60 59 58 58 57
26 72 72 72 72 72 72 71 69 68 67 66 65 64 63 62 61 60 60 59 58
27 72 72 72 72 72 72 72 71 69 68 67 66 65 64 63 62 62 61 60 59
28 72 72 72 72 72 72 72 72 71 70 68 67 66 65 64 63 63 62 61 60
29 72 72 72 72 72 72 72 72 72 71 70 69 67 66 66 65 64 63 62 61
30 72 72 72 72 72 72 72 72 72 72 71 70 69 68 67 66 65 64 63 62
31 72 72 72 72 72 72 72 72 72 72 72 71 70 69 68 67 66 65 64 63
32 72 72 72 72 72 72 72 72 72 72 72 72 71 70 69 68 67 66 65 64
33 72 72 72 72 72 72 72 72 72 72 72 72 72 71 70 69 68 67 66 65
34 72 72 72 72 72 72 72 72 72 72 72 72 72 72 71 70 69 68 67 66
35 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 71 70 69 68 67
36 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 71 70 69 68
37 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 71 70 69
38 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 71 70
39 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 71
40 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72 72
Permitted service wind speeds depending on the surface of the load (km/h)
Surface of
the load
(m2)
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Load (t)
41 72 71 70 70 69 68 67 67 66 65 65 64 63 63 62 62 61 61 60 60
42 72 72 71 70 70 69 68 67 67 66 65 65 64 63 63 62 62 61 61 60
43 72 72 72 71 70 70 69 68 67 67 66 65 65 64 64 63 63 62 61 61
44 72 72 72 72 71 70 70 69 68 68 67 66 66 65 64 64 63 63 62 62
45 72 72 72 72 72 71 70 70 69 68 68 67 66 66 65 65 64 63 63 62
46 72 72 72 72 72 72 71 70 70 69 68 68 67 66 66 65 65 64 64 63
47 72 72 72 72 72 72 72 71 71 70 69 68 68 67 67 66 65 65 64 64
48 72 72 72 72 72 72 72 72 71 71 70 69 69 68 67 67 66 65 65 64
49 72 72 72 72 72 72 72 72 72 71 71 70 69 69 68 67 67 66 66 65
50 72 72 72 72 72 72 72 72 72 72 71 71 70 69 69 68 67 67 66 66
0 CONTENTS
1 GENERAL
2 DAILY INSPECTION
3 MONTHLY AND SEMIANNUAL INSPECTIONS
4 YEARLY INSPECTION
5 SPECIAL INSPECTIONS
6 SUMMARY
1 GENERAL
The purpose of the instructions below is to describe the operations required to keep the crane in safe condition.
It serves as a guidance for detecting defects, taking necessary action to overcome the situation.
Apart from these inspections, National or Local Regulations must also be complied with.
2 DAILY INSPECTIONS
Visual inspection without part removal and checking the operation of the various mechanisms.
These must be done by personnel involved with the crane, e.g. the crane operator.
The inspection is carried out prior to starting crane work and must include:
- Observation of apparent defects in crane supports, cables, structure, etc.
- Operation of drives, movements and brakes, with no load.
- Operation of limiters and indicators
3 MONTHLY AND SEMIANNUAL INSPECTIONS
Based on visual inspection, generally without part removal and checking the operation of the various mecha-
nisms
4 YEARLY INSPECTIONS
This inspection must be carried out every time the crane is erected or every year if the crane is still
operating at the site.
Yearly inspections are based on visual inspection, generally without part removal.
Prior to every erection some inspections can more easily be done with the parts on ground level and other
inspections with the crane erected.
Inspection includes:
- Monthly and semi-annual inspections
- Checking for presence of nameplates
- Checking for presence of instructions manual
- Checking reports of previous inspections
- Checking that installed components coincide with components stated in documents
- Checking equipment condition for damage prevention
- Check for leaks of oil or grease
- Check for any damage in couplings
- Check for abnormal noise during operation
- Check for abnormal equipment temperature in operation
- Check that connecting bolts are tightened and free from cracks and defects.
- Check that brakes are not worn out or damaged
- Check that the machine is in overall good condition, clean, without critical corrosion, etc.
- Check that the electrical installation is free from damage.
- Check that cables are free from wear or critical deformations.
- Check that hooks are free from deformations or cracks.
- Checking drive operation
- Load limiters
- Indicator operation
- Brake operation
- Overall inspection of the structure, welds condition, corrosion, deformations, etc.
- Inspection of crane support (foundations, track), check for any settlement
5 SPECIAL INSPECTIONS
The inspector must be provided with the previous inspection report and must be informed on the type of crane
work.
Special inspections may require part removal and non-destructive tests if deemed necessary as a function
of:
- Result of previous inspections
- Result of load and braking tests, etc.
- Result of visual inspections
6 SUMMARY
Overall condition
Daily, yearly
Motors and brakes
Slewing drive
Fastening
Monthly, semi-annual,
Greasing
yearly
Gear condition
Overall condition
Daily, yearly
Motors and brakes
Hoisting drive
Fastening Monthly, semi-annual,
Greasing yearly
Overall condition
Daily, yearly
Motors and brakes
Trolley drive
Fastening Monthly, semi-annual,
Greasing yearly
0 CONTENTS
1 GENERAL
2 PERSONNEL DUTIES
3 PRINCIPLES FOR ESTABLISHING A SIGNAL CHART
4 SIGNAL DEFINITION
Prior to performing any operation check that the load being moved is perfectly fastened and ready for
movement.
Make sure that neither persons nor materials that could be damaged are present in the load area.
Do not allow persons along the load path while operations are being carried out.
1 GENERAL
THIS INSTRUCTION IS BASED ON STANDARD UNE 58000
2 PERSONNEL DUTIES
2.2 SIGNALMAN
This person reports to the operations superintendent
He takes over as chief of the crane operator since the “take control” signal is made until the “Quit
control” signal is made.
The signalman is fully responsible for directing the crane operator since the load starts moving,
through load transfer, until the load arrives to its final position as well as securing the slings around
the load from the start to the end of the operation.
Communication with the crane operator will be through hand signals with the arm(s) and signals must
not be repeated except for slow approach movements or if the crane operator so demands.
The signalman must always be in the crane operator field of view, see the load at all times, remain
outside the load path and keep personnel out of the load path.
In case he cannot see both the crane operator and the load, the operations superintendent shall appoint
an assistant.
Signalman and crane operator must know each other and maintain their functions during the job, and
due to the relevance of this function, training courses and physical examinations are required (Standard
UNE58158)
New instructions must be requested for restarting (two short acoustic or light signals)
- “Take control” and “Quit control” signals determine the moment from which the crane operator
effectively depends on the signalman.
- Signals must be made:
- Using ample and vigorous movements perfectly differentiated.
- Using ample hand and finger movements recognised under any condition (lighting, distance)
- In two well differentiated planes
a) In a vertical plane, to the right or to the left of the signalman body
b) In a horizontal plane, above or below
To command a movement or a stop, the signalman must always move the arm or forearm with no repetition
nor keeping on the movement (once the “understood” signal has been received) except for approach or
joined movements.
4 SIGNAL DESCRIPTION
0 CONTENTS
Sling breakage almost always causes serious accidents, injuring personnel and damaging goods. Good
quality slings must therefore be used, constructed with the utmost care.
Accidents involving sling breakage are often caused not by technical faults but by human error.
The site foreman and the hooker on must therefore know how to choose slings suited to each manoeuvre and
how to use them according to safety rules.
Fig. 1
2 CHOOSING A SLING
Slings must be chosen on the basis of the following points:
- wood 0.8,
- stone & concrete 2.5,
- steel, iron and cast iron 8.
- The angle formed by the strands of a sling reduces its strength. For the sake of illustration we provide
coefficients below by which sling strength must be divided according to the angle between the strands
when the sling is in working position (Fig. 3 and 4).
Observations:
When a load is supported by a 4 strand sling the angle must be measured as indicated in figure 4, and
the sling strength calculated on the basis of total weights being supported by
- 2 strands if the load is rigid,
- and 3 strands if it is flexible.
For a 2 strand sling with a given strength (Pm), capacity decreases as the angle between the ends
increases (Fig.4).
3 USING SLINGS
When working with slings you need to know:
There are many reasons. Apart from wear, knots, welds in cables and the devices used in connections
must be taken into account.
- Knots reduce sling strength by 30-50%.
- Welds in final rings or eyelets, even if technically very well done, reduce strength by between 15 and
20%.
- Connections made with cable holders, even when they are used properly and in sufficient numbers,
reduce sling strength by around 20%.
Fig. 5 Fig. 6
4 CONNECTIONS
Hooks, rings and eyes are used to connect hoisting equipment to loads.
- Eyes
These are made of forged steel, and comprise U-bolt and a fitted shaft, which is usually screwed onto
one arm of the U-bolt (Fig. 7).
- Rings
These come in various shapes, though they are usually circular in cross section. As with eyes the load
they can support depends on their cross section, on their shape and on the steel from which they are
made (fig. 9). It is essential to check that they retain their shape over time.
Fig. 7 Fig. 8
5 HOOKS
Their shape enables loads to be attached rapidly.
- Description
There are many types of hook. The most widely used are beaked hooks (Fig.8),
which are connected by a hole or rod.
Fig. 9
- Hook construction
Unlike rings and eyes, hooks work by flexion, and are therefore designed and built to very severe stan-
dards.
You should therefore never attempt to build your own hoisting hooks.
- Using hooks
Never try to widen the shape of a hook so that it will take a larger cable. Likewise, never heat hooks
for any reason, as heating will change the properties of the steel.
In some cases mere swinging of the load may produce such forces.
Fig. 10
Fig. 11 Fig. 12
Semi-gantries are used for normal loads, and they prevent or reduce any bending stresses in loads at the level
of the points where they are supported.
Never exceed the loading capacity of these gantries, which should be indicated on them.
Fig. 13 Fig. 14
- Choose attachment points on the load to be hoisted which do not allow the sling to slip. Ensure that these
points are properly arranged around the centre of gravity of the load.
The load must be stably balanced, and a gantry should be used if necessary to balance the forces in the
slings, whose strands should form the smallest possible angles.
- Cables and ropes should not have rings or welds except at their ends.
- The ends of cables and ropes must be secured with ties to prevent fraying.
- Lifting equipment must be protected against fire. heat, corrosives (acids, solvents, cements, etc), moisture
and light in the case of synthetic fibre ropes.
0 CONTENTS
1 TERMINALS, ASYMMETRIC WEDGE SOCKET
2 WIRE ROPE CLAMP, U-BOLT CLAMPS
PIN
SOCKET BODY
WEDGE
Fig. 1
It is essential that the appropriate terminal is used, and that it is checked that the wedge and socket body are
those indicated for the cable. A large wedge or one with an incorrect angle will not enter the socket body suffi-
ciently to provide a secure fastening; a small wedge will enter too far causing an excess load over the socket
body of the terminal, damaging it.
The cables should be placed such that the active leg is over the straight part of the terminal.
The inactive leg should have the necessary length to allow a safety system to be attached.
Fig. 3
Distance X between the cable-fastening clamp and the terminal should be less than 75% of the length of the
wedge.
When it is necessary to re-install the terminal, should be located over a part of the cable which has not been
previously used for the same purpose.
After each assembly, check that the wedge and cable are correctly seated in the socket body of the terminal,
to prevent cable slip and stop the wedge from slipping out of the socket body of the terminal.
Antirotation cables tend to become deformed on being bent over the wedge; to prevent this, it is recommended
that the cable be lined, for example, with adhesive tape, during the mounting of the terminal. The lining should
be removed to the extent possible to permit inspection of the cable.
If any defect is found in the terminal as well as in the cable, replace it.
The cable-fastening clamps are formed of a fork threaded at its ends, a connector and two nuts.
Castings can be distinguished from forgings by the way in which they are manufactured.
FORK FORK
CONNECTOR CONNECTOR
CAST CABLE FORGED CABLE
FASTENER NUT FASTENER NUT
Fig. 4
Fig. 5
When a thimble is used in making the grommet, the first clamp should be located against the thimble.
The tightening torques indicated in the table are for greased threads.
The tightening of the clamps should be checked on application of the initial load.
8 30 / 60 4 6,0
10 30 / 60 4 9,0
12 36 / 72 4 20
14 42 / 84 4 33
16 48 / 96 4 49
18 48 / 96 4 68
The distance between clamps and the number of clamps are indicated in the table.
The tightening torques indicated in the cable are for clean, dry and ungreased threads.
The tightening of the clamps should be checked on application of the initial load.
8 133 3 40,7
10 165 3 61,0
12 178 3 88,0
14 305 3 129,0
16 305 3 129,0
18 460 4 176,0
- The connector is located over the active leg of the cable, at a distance from the end of the inactive l
eg equal to the width of the connector.
- The nuts are tightened uniformly and alternately up to the tightening torque.
- The second clamp is placed against the thimble and the nuts are tightened without locking them.
- The remaining clamps are installed distributed between the first two.
- The nuts of all the cable fasteners are tightened uniformly and alternately up to the tightening torque
indicated in the table.
Fig. 6
0 CONTENTS
1 GENERAL DEFINITIONS
2 CRANE DEFINITIONS BASED ON FEATURES
3 PROCESS DEFINITIONS
4 PARAMETER DEFINITIONS
5 COMPONENT DEFINITIONS
1 GENERAL DEFINITIONS
- Crane
Discontinuous operation device used to hoist and distribute loads suspended from a hook over an
area.
- Slewing tower crane
Top slewing tower crane with slewing support on tower top end and with lower support connected to the
crane foot.
- Removable tower crane for worksites
Temporary slewing tower crane, used in construction sites, designed to cope with frequent erection and
dismantling operations, as well as transfers between different locations.
3 PROCESS DEFINITIONS
- CONDITION OF SERVICE
-Operational
Crane working under given operating conditions (crane setup, load reach, etc.) or ready to move
the loads for which it has been designed.
-Out of service
Unloaded crane left in stable position, in conditions specified by the manufacturer, without perfor-
ming any work, and ready to get into operation when circumstances so require and allow.
- Crane erection
The actual process of erecting the crane in the worksite, to perform as required. It includes preliminary
works such as foundations, track construction works, etc.
- Installed crane
Crane erected in the worksite, subject to design loads for crane out of service, but without the requirement
of being ready for operation.
- Commissioning
Set of crane checks and operations needed for making the crane operational.
4 PARAMETER DEFINITIONS
- Reach or radius
Horizontal distance measured between crane slewing axis and the vertical centerline of the hook without
load, when the crane is erected on horizontal ground.
- Lifting range
Vertical distance between upper and lower hook positions for the actual work.
- Lift
Vertical distance between hook rest level and upper hook position for the actual work.
- Lowering depth
Vertical distance between hook rest level and lowest position.
- Travelling speed
Speed of crane translation movement on the track for the type of work involved.
- Slewing speed
Angular speed of the slewing part of the crane for the type of work involved.
- Trolley speed
Speed of trolley translation movement for the type of work involved.
- Hoisting speed
Speed of the vertical movement of the load for the type of work involved.
- Positioning speed
Minimum load speed in erection or suspension processes, for the type of work involved.
- Tip load
Maximum load that can be hoisted at maximum reach.
- Maximum load
Maximum load that can be lifted according to crane manufacturer data.
- Support frame
Structural assembly supporting the slewing part or the fixed part of the crane tower.
- Ballast
Mass attached to the support frame for crane stability.
- Tower
Vertical structure of crane which supports the slewing part and allows for the required lift to be met.
- Slewing section
Structure including the slewing track and the slewing mechanism and comprising the elements
for the transition between the fixed and the moving part of the crane.
- Operator’s cabin
Cabin destined to normal control of the crane that houses the controls and the crane operator.
- Jib
Structural component of the crane, supporting the trolley and the hook, ensuring this way the required
reach and lift. One section includes the trolley winch.
- Counterjib
Structure able to support the crane counterweight, that can include the hoisting mechanism.
- Counterweight
Mass fixed to the counterjib, that helps compensate load actions.
- Trolley
Structure destined to the translation of suspended loads.
- Hook
Device for suspending the load.
- Erection cage
Structure placed on the tower upper part, that allows for hoisting the crane slewing part.
- Bracing frame
Structure, arranged on the tower, for transmitting loads derived from a tower extension.
- Travelling mechanism
Mechanism for crane translation on track.
- Slewing mechanism
Mechanism for turning the slewing part of the crane in a horizontal plane.
- Trolley winch
Mechanism for the translation of loads along the jib.
- Hoisting winch
Mechanism for hoisting and lowering loads.
- Limiter
Device for stopping or limiting crane movements or functions.
- Indicator
Device for furnishing the crane operator with necessary information for a perfect crane operation within
the operating parameter table.
6b 6 4 5c 5a 5
4d 5b
4e 7 8
6a
4a
4b
4c
4f
9
3
1.- Support frame, cross frame.
1a.- Support assembly.
3a 10 1b.- Structure assembly with translation mechanism
1c.- Base ballast
2.- Foundation anchor, foundation
2a.- Anchoring foot, Anchoring section.
3.- Tower.
3a.- Tower section.
4.- Slewing part.
1c 2a 4a.- Lower slewing track support.
4b.- Slewing track.
1 4c.- Upper slewing track support
4d.- Cat head.
4e.- Cabin.
4f.- Slewing mechanism.
5.- Jib
1a 2 5a.- Jib section.
1b 5b.- Jib end, moveable tip.
5c.- Trolley winch.
6.- Counterjib
6a.- Counterweights
6b.- Hoisting winch.
7.- Trolley.
8.- Hook.
9.- Erection cage.
10.- Bracing frame.
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
This chapter contains information on crane periodical checks and calibrations after commissioning.
Qualified personnel must carry out these operations after reading and understanding the instructions
given in this manual.
National regulations call for controls and inspections that must be duly documented, but these controls
do not exempt the user from regular crane maintenance.
For all maintenance works the following points must be taken into account:
2 Always use a safety harness when working at heights over 2m and, as a general rule, use personal
protection equipment adequate for the job.
3 Take special precautions when working on crane moving parts. Use adequate garments without loose
ohanging parts that can be caught by moving parts (avoid clocks, rings, chains, etc.).
6 Make sure there is no voltage present prior to working with electrical components.
- Never work alone.
7 Make sure no relevant changes have taken place after the last inspection.
8 Immediately report to the responsible person any detected malfunction. Stop crane operation and take
necessary measures.
9 During draining operations, oil and other fluids must be collected into a suitable container.
10 Oil and grease must only be stored in places meant for lubricating materials. Remove any oil or grease
residues to avoid skidding.
WHEN WHAT
- Check cables, inspect general condition.
- Check pulleys, check for jams.
- Check the structure, inspect general condition.
Daily - Check supports, track clear of obstructions, rail condition.
Before start up - Check movement of all mechanisms.
- Check brake operation.
- Check limiters operation.
- Check indicators operation.
- Translation mechanism, grease teeth.
- Crown wheel and slewing mechanism, grease teeth.
- Check cables and pulleys.
Weekly
- Inspect reeving.
- Inspect winding on drum
- Check electrical installation, inspect general condition.
- Grease mechanisms.
- Check levels, fill up if necessary.
- Grease slewing crown wheel.
- Grease hydraulic group .
Monthly - Check levels, fill up if necessary.
- Check hook, distortions, safety catch condition, etc.
- Check connections.
- Appearance, corrosion, etc.
- Clearances, movements, etc
- Check brakes.
- Check operation.
- Adjustment
Every three months
- Inspection of hydraulic equipment
- Hose condition
- Leaks, etc.
- Inspection of electrical installation.
Every six months - See "ELECTRICAL MAINTENANCE" in chapter 4
- Inspection of crane anchorage, general condition.
- Check bolted connections.
- Check connections.
Yearly
- Check limiters, calibration.
Every new erection
- Check brakes, adjustment.
- General inspection of structure.
- Replace lubricant in:
- Hoist drive mechanism.
Every 2500 hour operation
- Trolley drive mechanism.
- Hydraulic group.
- Replace lubricant in :
Every 4000 hour operation - Translation mechanism.
- Slewing mechanism.
- Cables, terminals.
- Pulleys and hook.
Regular maintenance
- Crane control.
- Access.
0 CONTENTS
1 GENERAL
2 FREQUENCY
3 REGULAR MAINTENANCE
1 GENERAL
All crane member connections must be checked regularly and, if needed, corrective action shall be taken:
- Connections must be free from damage that might affect negatively their function and strength.
- Checking unions which use high strength screws with controlled tightening torque
- See specific documents for bolted connections with specified tightening torque.
- Unless otherwise stated, bolted connections shall be tightened to a torque level in accordance with
mechanical good practice.
- All bolts and screws must be adequately secured.
- All securing elements must be tight enough as to prevent loosening
2 FREQUENCY
This instruction service must be carried out after the first 100-hour operation and then every 500-hour
operation or every six months provided a lower compulsory frequency period has not been established.
3 REGULAR MAINTENANCE
During compulsory regular maintenance the following points shall be checked:
A Bolted connections
- Equipment anchorage to structure.
- Gear reducer, drum support and motor frame anchorage
- Auxiliary jib fixing. (optional)
- Electrical cabinet fixing
- Slewing crown wheel bolts
- Bolts for anchoring tower foot to base
C TOWER
- Bolts are continuously subject to loads and must be replaced by new ones if corrosion or wear
damage
exceeding 0,3 mm in depth are detected
- In any case they must be replaced after 6-year operation.
D ANCHORAGE FOOTING
- Make sure that anchorage footing does not move.
- This is done by lowering and lifting the test load, used for limiting crane operation, in both tower
diagonal directions.
E BASE
- Section anchorage to base
- Fastening of translation parts (driving mechanisms, shafts, wheels, rail fastening clamps, etc.)
- Fastening of supports (spindles, plates, pyramids)
Other connectingelements
- Connecting elements not mentioned in this or other sections must be checked with adequate
frequency, as a function of the conditions under which the crane is working.
0 CONTENTS
1 GENERAL
2 CONTINUOUS SERVICING
1 GENERAL
A visual inspection of the crane should be made to detect any deformation, cracks, breakage, corrosion or other
damage. If the damage is capable of affecting the fatigue strength of the crane, the crane must immediately be
taken out of use until the damage has been repaired or other instructions received.
2 CONTINUOUS SERVICING
When necessary:
- If there is some doubt as to whether the crane may have suffered damage during manoeuvres, for exam-
ple the load swinging against the section or the jib striking an obstacle as it is moving, then the relevant
zone of the crane must be inspected immediately and measures taken as appropriate.
- Make sure that welds on the crane are not cracked or corroded. Pay particular attention to the following
points:
- Welds on the tabs of the profiles forming part of tower sections, jib sections, cat head and counterjib.
- Welds on the diagonals of tower, jib and counterjib sections.
- Welds on the slewing part.
Check bolted joints. If d1 - d2 > 0.5 mm, the structure must be repaired or replaced.
Other observations:
- When repainting, all corrosion must be removed before applying the first coat.
0 CONTENTS
1 HANDLING AND STORAGE
1 HANDLING AND STORAGE
- Suitable slings must be used for handling the load of the concrete blocks to be moved and the blocks
should be hooked to the points designated for this purpose.
For sling selections, see the "SLINGS AND ACCESSORIES" section in the chapter "USING THE CRA-
NE".
Hook up points
Fig. 1
Position
Position separators
Separators separators
Position Position
separators separators
Fig. 2
- At least two operators are required when handling and storing ballast blocks.
- Protect the ballast blocks from being knocked during handling.
-Failure to follow these instructions may result in the ballast blocks developing fissures and damage
which may harm their appearance and integrity.
Only qualified, skill and trained personnel may carry out maintenance operations.
0 CONTENTS
1 GENERAL
2 SLEWING MECHANISM
3 SLEW RING
4 SLEW LIMITER
5 ANGLE LIMITER
6 STRUCTURE
1 GENERAL
The purpose of this instruction is defining the guidelines to carry out crane maintenance operations as indica-
ted in the «MAINTENANCE PLAN», (MAN 020 0001).
7
1
2
4
6 5 3
1 Slewing mechanism
2 Slewing mechanism fixing bolts
3 Slew ring
4 Ring fixing bolts
5 Slew limiter
6 Sector limiter
7 Structure
Fig. 1
2 SLEWING MECHANISM
Fig. 2
3 SLEW RING
Slew ring maintenance operations are:
1 Check for proper tightening of ring fixing bolts, see corresponding document, later in this chapter.
2 Check for proper track and teeth lubrication, see document "GREASING INSTRUCTIONS (Slew ring)",
(MAN 050 0001) later in this chapter.
Fig. 3
4 SLEW LIMITER
Monitor drive pinion condition, check for proper gear mesh.
Check for proper lubrication of the limiter shaft.
Check for proper limiter condition, see document «ELECTRICAL MAINTENANCE», (INE 120 0001) in chap-
ter «ELECTRICAL INSTALLATION».
LIMITADOR DE GIRO
1
LIMITADOR DE ZONAS
Fig. 4
5 ANGLE LIMITER
Monitor drive pinion condition, check for proper gear mesh.
Check for proper lubrication of the limiter shaft.
Check for proper limiter condition, see document «ELECTRICAL MAINTENANCE», (INE 120 0001) in chap-
ter «ELECTRICAL INSTALLATION».
6 STRUCTURE
See document «MAINTENANCE PLAN (structure)», in this chapter
Only qualified, skill and trained personnel may carry out maintenance operations.
0 CONTENTS
1 GENERAL
2 TROLLEY MECHANISM
3 TROLLEY ROPE
1 GENERAL
The purpose of this instruction is defining the guidelines to carry out crane maintenance operations as indi-
cated in the «MAINTENANCE PLAN», (MAN 020 0001).
1
4
1 Motor
2 Gear box
3 Limiter
4 Drum
5 Frame
Fig. 1
2 TROLLEY MECHANISM
2.1 Motor
2 Check the state of the motor brake; see document "BRAKE : "BFK 458" TYPE" (MAN 080 0009) later in
this chapter.
To find out the type of brake that is installed, see: "CHARACTERISTICS OF MECHANISMS" in the
chapter: "TECHNICAL SPECIFICATIONS" or "USING THE CRANE".
2.2 Gearbox
The maintenance operations to carry out on the gearbox are:
1 Check that the bolts attaching the box to the frame are tightened correctly.
2 Check the lubricant; see document "GREASING INSTRUCTIONS (Trolley mechanism)" (MAN 070 0004)
later in this chapter.
2.4 Structure
See document "MAINTENANCE PLAN (structure)", in this chapter.
3 TROLLEY CABLE
For the use and maintenance of cables, see the document "INSTRUCTIONS FOR STEEL CABLES" (MAN 120.0001)
in this chapter.
Only qualified, skill and trained personnel may carry out maintenance operations
0 CONTENTS
1 GENERAL
2 HOISTING MECHANISM
3 HOISTING ROPE
1 GENERAL
The purpose of this instruction is defining the guidelines to carry out crane maintenance operations as indi-
cated in the «MAINTENANCE PLAN», (MAN 020 0001).
3
1 Motor
2 Gear box
3 Resistance
4 Limiter
5 Guard
6 Drum
7 Frame
Fig. 1
2 HOISTING MECHANISM
2.1 Motor
Do not touch motor housings as they can be very hot.
2 Check for motor brake condition, see corresponding document later in this chapter.
In order to know the type of brake installed, see: «MECHANISMS DATA» in chapter: «TECHNICAL
SPECIFICATIONS» or «CRANE OPERATION».
2 Check for proper gear reducer lubricant, see corresponding document later in this chapter.
2.3 Resistance
Do not touch resistances as they can be very hot.
2.4 Limiter
Check for proper limiter condition, see document «ELECTRICAL MAINTENANCE», (INE 120 0001) in chap-
ter «ELECTRICAL INSTALLATION».
2.5 Structure
See document «MAINTENANCE PLAN (structure)», in this chapter.
3 HOISTING ROPE
For use and maintenance of ropes see "INSTRUCTIONS FOR WIRE ROPES" (MAN 120.0001) in this
chapter.
0 CONTENTS
1 GENERAL
2 HOOK
3 PULLEYS
4 WHEELS
4 HOIST CABLE
1 GENERAL
The purpose of these instructions is to provide a guide to carrying out the maintenance operations
indicated in the crane's "MAINTENANCE PLAN" (MAN 020 0009).
2 HOOK
2.1 Front hook
Check that the anchor support frame has not suffered any damage or deformation.
Check that the fastening elements are correctly secured.
Check the condition of the pulleys. (See point 3).
2.3 Anchor
Check the condition of the anchor.
- Check the anchor shaft and the fastening nut. Look for any signs of corrosion.
If the thread is worn down by more than 0.1 mm, replace the anchor.
- Check the movement of the anchor, grease the block housings and the axial bearing.
- Check that the anchor lock works correctly.
d maximum
a d h y
load
9t 71 Rd 50x6 85 130
y
12 t 80 Rd 56x6 95 145
a
18 t 100 Rd 72x8 118 180
Fig. 1
3 PULLEYS
Check that the pulley turns correctly.
Check that the pulley is not damaged. d
Check that the fastening pins of the pulleys are not de- R
formed and that they are correctly fastened.
Check that the locks preventing the release of the cable
are in place.
Check the wear of the groove.
- Clean of any grease residues.
- Measure the diameter at the bottom of the pulley
groove.
4 WHEELS
4.1 Crane travel wheels
Check their condition.
- Check that the wheel turns correctly.
- Check that the wheel is neither damaged nor deformed.
- Check the wear on the wheel. Look for any signs of corrosion.
- Check that the fastening pins of the wheels are not deformed and that they are correctly
fastened.
- Clean of any grease residues.
5 HOIST CABLE
For the use and maintenance of cables, see the document "INSTRUCTIONS FOR STEEL CABLES"
(MAN 120.0001) in this chapter.
LUBRICANTS
place type capacity
LUBRICANT CHANGES
initial maintenance
EQUIVALENCE OF GREASE
A GEARBOX
The gears are housed in the upper part of the gearbox.
On the top there are two caps: one for filling and another for checking the level.
The gearboxes must always be filled up to this level. Doing so guarantees that the gears and bearings are
correctly lubricated, assuming that a lubricant of suitable quality is used.
The bearings should not be greased independently, since they are lubricated by the splashing of lubricant given
off by the gears.
In accordance with the previously specified changes or depending on the current state of the lubricant (unsuitable
viscosity, oil oxidation, silica contamination, etc.) it may be necessary to change the lubricant.
To do so:
- Place a sufficiently large container underneath the discharge cap.
- Remove the discharge cap and let the oil flow out. To speed up the discharge operation, it is best to carry
it out when the oil is hot.
If the new oil is not of the same type as the old oil, carry out an internal wash using a light solvent.
- Bolt down the discharge cap after having replaced its seal.
- Pour in the new oil up to the correct level.
- Bolt down the filling caps after having replaced their seals.
The lubricants, solvents and detergents are toxic/harmful products. Handle them with care and use
suitable personal protective equipment.
Do not allow their fumes to disperse into the atmosphere and dispose of them in accordance with current
legal regulations.
QUALITY OF LUBRICANTS.
It is essential to use lubricants that have a high capacity for reducing the friction coefficient, a high heat and
oxidation stability, and high anti-corrosive and anti-rust power when working in humid conditions. They must
be resistant to the formation of foam, separate well from water, and have exceptional characteristics in terms
of resisting extreme pressure and wear.
The lubricants used must comply with the following specifications: DIN 51517/3, CLP-PAO ISO, U.S. Steel 224,
AGMA 250.04 and ISO/TR3498-CKC.
B HOOD.
The lower part of the gearbox is separated from the gears by a seal. This zone is filled with long-life grease
which need not normally be changed.
The lubricants, solvents and detergents are toxic/harmful products. Handle them with care and use
suitable personal protective equipment.
Do not allow their fumes to disperse into the atmosphere and dispose of them in accordance with current
legal regulations.
QUALITY OF LUBRICANTS.
Synthetic, semi-fluid greases will be used, enriched with anti-oxidant, anti-corrosion and extreme pressure
additives, "fort E. P.".
They have high oxidation stability and are resistant to both leaking and the formation of grooves.
They also have a wide margin of service temperatures and very low friction coefficients.
C GEAR TEETH.
The aim of greasing the teeth is to form a superficial film of lubricant that prevents direct contact with the
metal.
GREASING PERIODS.
Establish greasing periods depending on the service conditions.
Before and after any prolonged periods in which the crane is not in service it is essential to re-grease.
LUBRICANT EQUIVALENTS
If lubricants other than those given in the table are applied, the manufacturer or supplier of the lubricant
should be asked to provide confirmation that the selected lubricant is suitable for the planned application
and that its characteristics at least correspond to the requirements indicated in the table.
1-Nipple
LUBRICANTS
place type capacity
GREASE CHANGES
1
initial maintenance
In order to improve the covering of the contact surfaces and their durability, we recommend that greasing
should be done using a brush throughout the 360º of the rotation crown.
For tasks with small rotation sectors, increase the greasing frequency for those sectors to once a
week.
Lack of regular greasing may lead to noise during the rotation manoeuvre.
In case it is used another lubricant different from those specified on the table, the manufacturer or the
supplier should give a written confirmation that the chosen lubricant is also appropriated for that determined
use, and that its qualities comply at least with those indicated in the mentioned table. Special greases or
lubricants will be required in case the crane will be used at a very low temperatures ( <-20ºC ).
EQUIVALENCE OF GREASE
GEARBOX
Gearboxes should be filled up whenever the level of lubricant falls below that marked as "normal" on the level
indicator.
Doing so guarantees that the gears and bearings are correctly lubricated, assuming that a lubricant of suitable
quality is used.
When filling the gearbox, the level marked "normal" must not be exceeded.
The bearings should not be greased independently, since they are lubricated by the splashing of oil given off
by the gears.
1 Fill plug
2 Drain plug
3 Sight glass
LUBRICANT QUALITY
Two types of lubricants can be used depending on the gearbox operating conditions and environmental con-
ditions at the work site.
1 MINERAL OILS
They are appropriate for moderate loads, normal use of the mechanism and with no extreme tempera-
tures.
Lubricants with great ability to reduce the friction coefficient, high heat and corrosion stability, high co-
rrosion and oxidation resistance in the presence of moisture, foaming resistance, good water separation
ability, and high performance under extreme pressure and high wear resistance shall be used.
Lubricants must comply with DIN 51517 part 3, U.S. Steel 224, AGMA 250.04 and Cincinnati Milacron
P-35 and P-59 specifications.
2 SYNTHETIC OILS
They are appropriate for heavy loads, continuous operation and where extreme temperatures are ex-
pected.
Medium viscosity synthetic oil or grease containing antioxidant additives, corrosion resistant and good
performance under extreme pressure «fort E.P.», high
temperatures and very small friction coefficient shall be used.
LUBRICANT CHANGE
The lubricant of gearboxes using mineral oil must be changed periodically.
The lubricant of gearboxes using synthetic oil or grease does not need changing but the lubricant level or
quantity must be maintained.
The lubricant must be changed in accordance with the specified frequency or as a function of the lubricant
condition (adequate viscosity, oil oxidation, sand contamination, etc.).
For this purpose, all gears must be thoroughly cleaned with petrol. The purpose of said cleaning is to remove
the metallic wear particles that could result in more wear, substantial pitting and scratching on the gear teeth
surface. Also, said wear particles act as lubricant oxidation catalyst.
Make sure the oil selected is compatible with the mechanism oil, otherwise, carry out a thorough cleaning
prior to oil change.
If the lubricant used differs from the ones shown in the table, seek confirmation from the lubricant ma-
nufacturer or supplier that the lubricant selected is appropriate for the application and complies at least
with the quality requirements shown in the table.
For low temperature applications (<-20 ºC), special grease or lubricant is required.
The gearbox leaves the factory with the lubricant shown in the table below.
OIL CHANGE
Sight glass
FIRST CHANGE MANTENIMIENTO
Drain plug
150 hours 2500 hours
GEARBOX
Gearboxes should be filled up whenever the level of lubricant falls below that marked as "normal" on the level
indicator.
Doing so guarantees that the gears and bearings are correctly lubricated, assuming that a lubricant of suitable
quality is used.
When filling the gearbox, the level marked "normal" must not be exceeded.
The bearings should not be greased independently, since they are lubricated by the splashing of oil given off
by the gears.
1 Fill plug
2 Drain plug
3 Sight glass
LUBRICANT QUALITY
Two types of lubricants can be used depending on the gearbox operating conditions and environmental con-
ditions at the work site.
1 MINERAL OILS
They are appropriate for moderate loads, normal use of the mechanism and with no extreme tempera-
tures.
Lubricants with great ability to reduce the friction coefficient, high heat and corrosion stability, high co-
rrosion and oxidation resistance in the presence of moisture, foaming resistance, good water separation
ability, and high performance under extreme pressure and high wear resistance shall be used.
Lubricants must comply with DIN 51517 part 3, U.S. Steel 224, AGMA 250.04 and Cincinnati Milacron
P-35 and P-59 specifications.
2 SYNTHETIC OILS
They are appropriate for heavy loads, continuous operation and where extreme temperatures are ex-
pected.
Medium viscosity synthetic oil or grease containing antioxidant additives, corrosion resistant and good
performance under extreme pressure «fort E.P.», high
temperatures and very small friction coefficient shall be used.
LUBRICANT CHANGE
The lubricant of gearboxes using mineral oil must be changed periodically.
The lubricant of gearboxes using synthetic oil or grease does not need changing but the lubricant level or
quantity must be maintained.
The lubricant must be changed in accordance with the specified frequency or as a function of the lubricant
condition (adequate viscosity, oil oxidation, sand contamination, etc.).
For this purpose, all gears must be thoroughly cleaned with petrol. The purpose of said cleaning is to remove
the metallic wear particles that could result in more wear, substantial pitting and scratching on the gear teeth
surface. Also, said wear particles act as lubricant oxidation catalyst.
Make sure the oil selected is compatible with the mechanism oil, otherwise, carry out a thorough cleaning
prior to oil change.
If the lubricant used differs from the ones shown in the table, seek confirmation from the lubricant ma-
nufacturer or supplier that the lubricant selected is appropriate for the application and complies at least
with the quality requirements shown in the table.
For low temperature applications (<-20 ºC), special grease or lubricant is required.
The gearbox leaves the factory with the lubricant shown in the table below.
ORIGINAL OIL
Fill plug
TYPE: mineral oil QUANTITY
OIL CHANGE
Sight glass
FIRST CHANGE MAINTENANCE
Drain plug
150 h 2500 h
GEARBOX
Gearboxes must always be refilled with oil whenever the oil level is below the indicator «normal» level mark.
Said level ensures a correct gear and bearing lubrication, provided a lubricant of adequate quality is used.
During gearbox refill, the «normal» level mark must not be exceeded.
Bearings must not be lubricated separately, as they are splash lubricated by the gear motion.
1 Fill plug
2 Drain plug
3 Sight glass
LUBRICANT QUALITY
Two types of lubricants can be used depending on the gearbox operating conditions and environmental con-
ditions at the work site.
1 MINERAL OILS
They are appropriate for moderate loads, normal use of the mechanism and with no extreme tempera-
tures.
Lubricants with great ability to reduce the friction coefficient, high heat and corrosion stability, high co-
rrosion and oxidation resistance in the presence of moisture, foaming resistance, good water separation
ability, and high performance under extreme pressure and high wear resistance shall be used.
Lubricants must comply with DIN 51517 part 3, U.S. Steel 224, AGMA 250.04 and Cincinnati Milacron
P-35 and P-59 specifications.
2 SYNTHETIC OILS
They are appropriate for heavy loads, continuous operation and where extreme temperatures are ex-
pected.
Medium viscosity synthetic oil or grease containing antioxidant additives, corrosion resistant and good
performance under extreme pressure «fort E.P.», high
temperatures and very small friction coefficient shall be used.
LUBRICANT CHANGE
The lubricant of gearboxes using mineral oil must be changed periodically.
The lubricant of gearboxes using synthetic oil or grease does not need changing but the lubricant level or
quantity must be maintained.
The lubricant must be changed in accordance with the specified frequency or as a function of the lubricant
condition (adequate viscosity, oil oxidation, sand contamination, etc.).
For this purpose, all gears must be thoroughly cleaned with petrol. The purpose of said cleaning is to remove
the metallic wear particles that could result in more wear, substantial pitting and scratching on the gear teeth
surface. Also, said wear particles act as lubricant oxidation catalyst.
Make sure the oil selected is compatible with the mechanism oil, otherwise, carry out a thorough cleaning
prior to oil change.
If the lubricant used differs from the ones shown in the table, seek confirmation from the lubricant
manufacturer or supplier that the lubricant selected is appropriate for the application and complies at
least with the quality requirements shown in the table.
Special greases or lubricants will be required in case the crane will be used at a very low temperatures
(<-20ºC ).
The gearbox leaves the factory with the lubricant shown in the table below.
OIL CHANGE
Sight glass
FIRST CHANGE MAINTENANCE
The brake types are described according to the motor model or type installed at the crane in
the "TECHNICAL SPECIFICATIONS" section, in the Chapter entitled "MECHANISM SPECI-
FICATIONS".
The following pages contain, maintenance instructions for each brake model.
- When the crane is installed for the first time or when the motors
or brakes are new, the brakes should be checked after approximately
one working week and adjusted if necessary.
O CONTENTS
1 GENERAL DESCRIPTION
2 PERIODICAL SERVICE
3 BRAKING COUPLE ADJUSTMENT
4 AIR GAP CHECKING AND ADJUSTMENT
5 COIL REPLACEMENT
6 BRAKE DISC REPLACEMENT
IMPORTANT NOTE:
Some of the operations described below, for instance, replacing the magnet, will require to leave the
motor with the locking brake inoperative. In this case, make sure that the motor will not rotate, for
instance, preventing the hook to fall freely or the trolley to move. If this is not possible, suitably lock any
possible movement before proceeding to carry out the required maintenance operation. In any case,
these maintenance operations shall be performed with no load suspended from the hook.
On cranes that can be weathervaned remotely from the control panel, this system loses its adjustment
when the realese device is dismounted so the brake can be accessed. It must therefore be readjusted
when the device is re-mounted, as per points 3 and 4 of these instructions.
1 GENERAL DESCRIPTION
1 Brake protection
2 Column
3 Coil fixing nut
4 Air gap adjustment nut
5 Braking torque adjustment nut
6 Brake spring
7 Moving magnet
8 Brake disc
9 Coil
10 Manual releasing
2 PERIODICAL SERVICE
Every three months:
Verify for a correct air gap (“A” distance) between moving magnet (7) and brake coil (9). Adjust air gap if required:
refer to paragraph 4.
Important.
Make sure that all friction surfaces are free from grease.
The following contains the information to adjust the braking torqueof the trolley,slewing and traveling motor
brakes:
Before adjusting the spring, check its color and choose the appropiate valve from the table.
Important:
Make sure that braking force adjustment is made by actuating on the three nuts (5). Spring pressure must be
suitably balanced.
Do not actuate on nuts (3 and 4) when performing this adjustment operation.
minimum maximum
60 0,3 1,2
70 - 80 - 90 0,5 1,2
100 - 110 - 120 1,0 1,5
140 - 160 - 180 - FM158/1 1,0 1,5
Adjust air gap whenever dimension “A” exceeds the maximum allowable value.
Adjustment:
If dimension “A” exceeds the maximum allowable value:
4.1 Loosen the three nuts (4)
4.2 Tighten the three nuts (3), moving the coil toward the moving magnet.
4.3 Verify for a correct air gap and make sure that dimension “A” is within the allowable range and is
evenly distributed along the entire coil circumference.
4.4 Tighten the three nuts (4) to keep the coil locked.
5 COIL REPLACEMENT
The coil is covered with a solid resin, making up a compact block which must be totally replaced if required.
5.1 Disconnect coil supply wires from motor terminal box.
5.2 Remove manual brake releasing assembly, if any.
5.3 Remove brake protection cover.
5.4 Remove the three nuts (3) and then the coil.
5.5 Replace the coil by a new one.
5.6 Assemble the brake by following a reverse procedure, taking care to adjust the air gap as described
in paragraph 4.
The disc should be changed when the thickness of the brake lining
is inferior to the value indicated in the table.
Minimum Thickness
Brake type of Brake dining (K)
80 1
100 - 110 - 120 1,5
140 - 160 - FM158/1 1,7
TO LEARN WHICH STANDARD BRAKE IS INCLUDED SEE THE SECTION ON MOTOR CHARACTERISTICS
IN THE CHAPTER “TECHNICAL SPECIFICATIONS”
0 CONTENTS
1 GENERAL DESCRIPTION
2 CONTINUOUS SERVICE
3 GAP ADJUSTMENT
4 BRAKING TORQUE
5 DISASSEMBLY/ASSEMBLY
6 MANUAL RELEASE
IMPORTANT NOTE:
Some of the operations below (e.g. changing the electro-magnet) will lead to the motor being left without a
locking brake. In such cases, ensure that the motor cannot slip, causing for instance free fall of the hook on
hoisting motors or trolley displacement. Block any movements before carrying out the operation. In any event
these operations should always be performed with no load on the hook.
1 GENERAL DESCRIPTION
1 Brake cover
2 Armature
4 Nut
5 Lock nut
6 Brake spring
8 Gap adjustment screw
9 Fixed electro-magnet
10 Fixed brake ring
11 Brake disc
12 Brake endshield
13 Rotor shaft
An electro-magnetic brake is used to brake the movement of the electric motor. It is normally activated elec-
trically (open brake) when the manipulator controlling the movement to which the motor belongs is moved out
of the neutral position by the crane operator.
It is deactivated electrically (close brake) when the manipulator is returned to the neutral position. However on
some occasions brake action may be delayed for smoother braking.
When the fixed electro-magnet (9) is powered it opens the armature (2) which compresses the spring (6) and
frees the disc (11). The brake is then open.
When power is disconnected the armature (2) is free, and under pressure from the spring (6) it presses the
crown wheel (10) onto the disc (11).
The crown wheel (10) is prevented from spinning by the brake endshield (12).
2 CONTINUOUS SERVICE
Every 3 months: check that the brake works properly. If opening speed is too slow, adjust the gap.
3 GAP ADJUSTMENT
The gap must be adjusted as soon as release is observed not to
take place properly (brake opening too slowly or not at all). Unscrew
the positioning screw (8) and take it out of the holes in the armature
(2). Using a screwdriver on the slotted exterior, fully unscrew the
armature so that it rests on the electro-magnet (9). Screw up the
armature (2) again, resting on the screw (7) in the third hole.
4 BRAKING TORQUE
Braking torque is factory set and cannot be adjusted on site.
5 DISASSEMBLY/ASSEMBLY
5.1 Disassembly
Cut the power. Open the terminal box and identify the cables and their positions (motor and brake power, pro-
bes, etc.). Then disconnect the power cables.
Dismount the brake motor using suitable tools (extractors, plastic body maces, calibrated screwdrivers & wren-
ches, grips for circlips, etc.)
Remove the lock nut (5) and unscrew the nut (4).
Unscrew the three fixing screws on the electro-magnet and remove the magnet carefully so as not to damage
the power cables.
Remove the armature (2) and lined crown wheel (11) assembly, and unscrew the armature from the crown
wheel.
Clean the components.
Use only an air jet for electrical components (no solvents or wet products),
white spirit or a similar cleaner for mechanical parts,
and a scraper for connections.
If necessary degrease the brake disc(s) and lining(s).
Change the seals and check the condition of the bearings. Disconnect the rectifier bridge and check the stator
insulation (> 100 megohms).
Identify any faulty item so that a replacement can be ordered.
5.2 Assembly
Open bearings must be re-greased before assembly with grease suitable for their working conditions. Shafts
and bearing boxes should be lightly lubricated. The lips of seals should be lined with grease and re-fitted with
care (using the key slot protection bushes). Connections which must be leak-tight must be coated with a fine
layer of sealing paste.
Screw the armature (2) onto the lined crown wheel (11) with the flat side outwards. Remove the electro-magnet
positioning screw (8), and position the crown/armature assembly and the spring stop in the electro-magnet.
Fit the spring (6) and the nut (7) on the release bar, and screw the nut onto the electro-magnet a few turns.
Assemble on the brake endshield (12) and attach via the three screws and washers, tightening them alternately
until they are locked.
Adjust the gap and the braking torque (see sections 3 & 4).
Screw up the lock nut (5).
Re-connect the rectifier bridge and the probes if necessary, then the motor, ensuring that the cables are correctly
placed. Close the terminal box.
Check that the whole unit works properly and ensure, if necessary, that the release lever is properly fitted before
mounting the unit on the machine.
6 MANUAL RELEASE
To release the brake manually, turn the lock nut (5) clockwise. This operation should only be carried out when
really necessary, and should be left to competent personnel familiar with the effects of releasing or braking the
motor.
Unscrew the lock nut (5) again before returning to normal operation.
O CONTENTS
1 GENERAL DESCRIPTION
2 BRAKING TORQUE
3 ADJUSTING AND CHECKING THE AIR GAP
4 CHANGING FERODO LININGS
5 MICRO APERTURE BRAKE
6 MANUAL UNLOCKING
7 DOUBLE BRAKE
IMPORTANT NOTE:
Certain operations described below involve leaving the motor without the locking brake, such as changing
the electromagnet or adjusting the air gap. Under these circumstances, make sure this would not allow
the motor to slip, for example allowing the hook to fall freely in the case of the hoisting motor, or the trolley
to move. If this is possible, lock any possible movement before proceeding with the task in hand. In any
case, these operations should always be carried out with no load on the hook.
1 GENERAL DESCRIPTION
Fig. 1
The brake is of electromagnetic type using a brake disc with two braking surfaces. The brake is applied by
pressure springs in the absence of current, and released by electromagnetic force.
If the coil (1) is not supplied with energy, the cylindrical springs (19) push the moving armature (4) axially against
the brake disc (5). The disc is clamped between the moving armature (4) and the flange (7), so that the motor
shaft is locked via the pinion (8) which joins it to the brake disc (5).
When the coil (1) is supplied with energy, the moving armature (4) is attracted towards the coil body (1), over-
coming the spring (19) pressure and operating the microswitch (16) with the actuator bolt (17)
This frees the brake disc (5), the brake is open (off) and a status signal is sent.
2 BRAKING TORQUE
Brakes are supplied set to the rated torque.
Brakes cannot be adjusted or reset.
63 0,7 1,5
100 0,7 1,6
100/140 0,7 1,6
100/140 Doble (*) 0,7 1,6
160/210R 0,7 1,6
Remove the electromagnet body and moving armature fixing screws and fit the threaded plugs (35) in their
place.
NOTE: If the shim (3) had already been taken out, the brake disc (5) will have to be changed and a new shim
fitted.
When changing Ferodo linings, make sure the braking surfaces are free from grease or dry lubricants.
If necessary, degreasers such as trichloroethylene or tetra chloromethane may be used for cleaning.
Never use petrol.
This microswitch prevents the motor working against the brake, in case of a malfunction of the latter.
During the commencement of each lifting operation, it is verified that the microswitch has actuated after
a brief time period and the movement is stopped if this is not the case.
The system is protected against short circuit of the microswitch or in the signal cables, such that the
lifting movement will not operate in this case. Before the movement commences, the condition of the
microswitch is checked, which should be open (since the brake is not activated).
5.2 Maintenance
The microswitch does not require maintenance or adjustment during normal operation.
The microswitch does not require adjustment when a gap adjustment is carried out.
The microswitch should only be adjusted in case of malfunctioning, or if the location or regulation is
adjusted during maintenance operations (for example, coil replacement).
INSERT GAUGES
Fig. 2
1.- Remove plugs (35), remove electromagnet fixing screws (25) next to the plugs and put them in place to
disengage the brake. Once this is done, remove the encoder cover (8) and proceed to remove the brake
by undoing the screws (23).
2.- With the brake on a working surface, loosen the three electromagnet fixing screws (25), and introduce
0.2 mm thick feeler gauges in each air gap inspection hole, tighten screws (25) until these two gages
are trapped.
3.- Turn the brake to place the mobile armature (4) facing up. Place a multimeter between black and brown
cables of the micro. Loosen locknut (18) and adjust plunger stud (17) until the multimeter measures
electrical continuity and beeps, then tighten locknut (18) without moving the plunger stud (17).
4.- ALoosen electromagnet fixing screws (25), remove the 0.2 mm feeler gauges and introduce the 0.3 mm
gauges, tighten again screws (25) until these other two feeler gauges are trapped.
If NO electrical continuity is measured by the multimeter the micro is correctly set. If there is continuity
repeat the procedure of section 3.
5.- Loosen electromagnet fixing screws (25), and remove the feeler gauges, mount the brake into the motor
fixing it by screws (23), remove electromagnet fixing screws (25) and place them in their original position,
place plugs (35) in position and finally install the encode cover (8).
1.- Remove air gap inspection covers (22) and introduce 0.3 mm thick feeler gauges into each inspection
hole.
2.- Remove plugs (35), undo electromagnet fixing screws (25) next to the plugs and place them in position,
tighten the screws until the two feeler gauges are trapped.
3.- Place a multimeter between black and brown cables of the micro; no electrical continuity must be mea-
sured.
4.- Loosen electromagnet fixing screws (25), remove 0.3 mm feeler gauges and introduce the 0.2 mm gau-
ges, tighten again screws (25) until these other two feeler gauges are trapped.
If the multimeter measures electrical continuity, the micro is correctly adjusted; if no electrical continuity is
measured proceed to adjust the micro correctly in accordance with paragraph 5.2.1 Micro adjustment.
b.- The mobile armature (4) does not close properly against the electromagnet body (1) as a result of the
presence of foreign bodies between both.
6 MANUAL UNLOCKING
This operation is only allowed in cases of emergency, for example to lower a load on the hook in the
absence of electrical power, or during maintenance work, and may only be carried out by competent
personnel who are aware of the consequences of unlocking the brake.
This procedure must never be used as a normal method of working.
Use the manual lever (14) if the brake is fitted with one.
If not, unlock the brake using the screws (35) that fix the electromagnet body to the moving armature (see
section 3.2). This involves fitting them in place of the threaded plugs. Make sure to remove the screws (35) and
replace the threaded plugs before bringing the brake into use.
7 DOUBLE BRAKE
Fig. 3
The operation of the double brake is the same as that described in Point 1 of this chapter.
The internal brake disk (motor side) and the external brake disk (encoder side) operate at the same time.
Since both brakes (disks, springs, etc.) are almost the same, the points described 1, 2, 3, 4
and 5, for a brake, similarly apply for the double brake.
The dismantling of the internal brake is carried out by first dismantling the external brake.
0 CONTENTS
1 GENERAL DESCRIPTION
2 CONTINUOUS SERVICING
3 ADJUSTMENT OF BRAKING TORQUE
4 ADJUSTMENT OF AIR GAP
5 CHANGING BRAKE DISC
6 MANUAL UNLOCKING
IMPORTANT NOTE
Certain operations described below involve leaving the motor without the locking brake, changing the
electromagnet or brake disc, for example. In these cases, the mechanism must be appropriately immobilised
to make sure the motor cannot slip before proceeding. In any case, these operations should always be
carried out with no load on the hook.
1 GENERAL DESCRIPTION
The brake is of electromagnetic type using a brake disc with two braking surfaces. Spring pressure ensures
braking torque through friction. The brake is opened by supplying direct current to the brake coil.
During braking the rotor (2.0), which moves axially on the pinion (3.0), is pressed against the friction surface
by the moving electromagnet (1.2) by means of springs (1.4).
When the brake is applied there is an air gap SLü between the coil body (1.1) and the moving electromagnet
(1.2). When the brake is opened, direct current is supplied to the coil (1.1); the magnetic force generated attracts
the moving electromagnet (1.2) towards the coil body (1.1), overcoming the force of the springs. The braking
disc is freed and the motor rotor may turn freely.
2 CONTINUOUS SERVICING
Wear on the braking surface of the brake disc depends on operating conditions. There is a gradual reduction
in friction until brake adjustment becomes necessary.
It is recommended to check the air gap SLü a week after putting into service, and thereafter every three months.
Checking the brake lining thickness and brake operation is also recommended every three months.
1. Measure the air gap SLü between the moving electromagnet and the coil body using feeler gau-
ges.
2. Compare the measurement taken with the maximum permitted, depending on brake size (see
table).
3. If necessary, adjust the air gap to the recommended value.
Note the stops when turning the nut. Positions between stops are not permitted.
This regulation of the torque by means of adjustment nut is only possible in elevation the connected
motor brakes.
Unlocking
lever
6 MANUAL UNLOCKING
This operation may only be carried out, in case of need, by competent personnel aware ofthe
consequences of working on the brake unlocking mechanism.
To realese the brake, push the realese leaver towards the motor.
The unfreezing normal is only included in elevation the connected motor brakes.
TO LEARN MORE ABOUT THE TYPE OF BUILT-IN BRAKE, SEE CHAPTER "TECHNICAL SPECIFICATIONS"
--SECTION-- MOTOR CHARACTERISTICS
0 CONTENTS
1 GENERAL DESCRIPTION
2 INSTALLATION
3 POWER SUPPLY
4 ADJUSTING THE AIR GAP
5 REPLACING THE DISC
6 FITTING
7 CHARACTERISTICS
8 OPTIONAL
9 REPAIR GUIDE
IMPORTANT NOTE:
In the following instructions, there are certain operations, for example replacing the electromagnet or
the disc brake, or adjusting the screws for tightening the brake spring, which will involve leaving the
motor without a locking brake. In these cases, ensure that this does not mean that motor will slide
out of position, for example, by falling freely from the hook. If this risk is present, block any possible
movement before carrying out the operation. In any case, these operations must be always carried
out with no load under the hook.
1 GENERAL DESCRIPTION
8 8 Axle shaft
9 Yoke
11 Mobile electromagnet
12 Friction element
15 Disc
21 Washer
24 Nuts
28 Spring
31 Nuts
34 Columns
39 Rear cover
50 Joint sealing
73 Joint
Fig. 1
2 INSTALLATION
Follow the general start-up recommendations for the installation of brake coupled motors.
3 POWER SUPPLY
The FCPL60H brake is equipped with a DC coil and a CDF 7 power supply unit.
The technical data and information is available in the manual supplied with the card.
The air gap is the distance that separates the mobile electromagnet 11 from the yoke 9 when the coil is not
energised (Fig. 2).
It must be adjusted when abnormal unlocking occurs or when its value reaches 1.3 mm.
he intervals between checks and adjustments depends on the types of service, service factor, motor
T
position and its application.
Fig. 2
- Remove the rear cover 39 and disconnect the power supply cables of the brake.
In the case of the encoder option, disconnect it and unlock the coupling. Slide the encoder and pull it
fully away from the coupling.
- Insert two 150 mm M8 threaded rods fitted with washers and nuts in the holes of the yoke 9.
Once in position, tighten the nut until it is separated from the surface, constituting a single braking
block.
6 FITTING
- Place the brake block in the correct position by first adjusting the mobile electromagnet 11 to the column
34; next, place the nuts 31 and pass the lugs 9 through before completing the process.
- Gradually tighten the nuts 31 on the framework's surface 11 and make sure that it is not in contact with
the disc.
- Place the nuts 24 in position.
- Remove the threaded rods.
- Adjust the air gap (see point 3).
- If necessary, replace the seal on joint 50.
- Put the brake in the correct position before putting the cover back.
7 CHARACTERISTICS
8 OPTIONAL
8-1 Micro-contact (see Fig. 3)
The micro-contact is adjusted at the factory for different applications, depending on whether it will be used to
detect the wear on brakes or act as a brake activation pilot lamp.
In theory, the micro-contact does not have to be adjusted, except when the coil 9 is replaced.
Fig. 3
However, the adjustment might be necessary when the contact distance is incorrect.
To adjust the micro-contact, the distances must comply with the minimum value (see Fig. 3)
9 REPAIR GUIDE.
Fig. 4
TO LEARN MORE ABOUT BUILT-IN BRAKES SEE THE "MOTOR CHARACTERISTICS" SECTION OF THE
"TECHNICAL SPECIFICATIONS" CHAPTER
0 CONTENTS
1 GENERAL DESCRIPTION
2 CONTINUOUS SERVICE
3 BRAKE TORQUE ADJUSTMENT
4 TESTING AND ADJUSTING THE AIR GAP
5 REPLACING THE COIL
6 REPLACING THE BRAKE DISC
IMPORTANT NOTE:
In the following instructions there are certain operations, for example replacing the electromagnet,
which will leave the motor without a locking brake. In these situations, make sure that this will not
lead to the motor sliding, for example a free fall of the hook in the case of the lifting motor or due to
movement of the trolley in its case. If this risk is present, block any possible movement before carrying
out the operation. In any case, these operations must always be carried out with no load on the hook.
In cranes with remote wind protection operated from the crane control, when removing the release
to access the brake it becomes uncalibrated, which is why during assembly it must be recalibrated
according to points 3 and 4 of this instruction.
1 GENERAL DESCRIPTION
B A Attachment screw
B Washer
C C Coil
D Release lever
D (Optional)
E Torque spring
F Mobile electromagnet
E
G Lock nut
H Brake disc
F
I Pinion
G
The brake is electromagnetic with a double sided brake disc. The pressure of the springs (E) ensures the
braking torque through friction.
The brake is opened by applying alternating current to the brake coil.
When the coil is powered (C), the mobile electromagnet (F) is drawn towards the coil overcoming the force of
the springs (E).
The brake disc (H), which is coupled by the pinion (I) to the motor shaft, is freed to enable the rotation of
the motor rotor.
When the coil (C) has no power feed, the springs (E) push the mobile electromagnet (F) pressing
the disc (H) against the engine shield and blocking its rotation.
2 CONTINUOUS SERVICE
Braking disc surface wear depends on the operating conditions.
As the brake disc lining wears out, the air gap grows and the spring pressure drops. When the spring pressure
drops, braking torque likewise drops. The air gap must be readjusted when the maximum value indicated in
the table is exceeded. The disc must be changed when the thickness of the brake lining is less than the re-
commended minimum.
Manufactu- Number of
Movement Motor Brake Braking torque
rer springs
ROTATION 7.5 kgm BESOZZI GR7 4 54 Nm
Use of the brake causes wear of the braking disc surface (H); this increases the air gap.
It will be checked every three months that the value of the air gap is within the range indicated in the above
table, by using a set of gauges.
The air gap must be adjusted whenever its value exceeds the maximum allowed.
4.1 Verifications.
4.2 Adjustment.
When the air gap distance is greater than the maximum allowed:
This operation should be carried out when the crane is not in service and with no load on the hook.
If the adjustment is made at the end of a work session, make sure that the brake body is not overheated.
An air gap larger than the recommended value may cause excessive loss of braking torque.
1 Loosen the lock nuts (G) and the attachment screws (A).
2 Tighten the screws (A) until the nominal air gap is obtained (see table). Perform this operation alternately
(one screw and then the opposite with gauges). The lock nuts (G) must not prevent the tightening of the
screws (A); if necessary, loosen the screws a little more.
3 Keeping the screws (A) fixed, tighten the lock nuts (G) on the motor shield.
1 Disconnect the electrical power supply cables of the coil in the motor terminal box.
2 Remove the brake manual unlocking assembly, if one is fitted.
3 Remove the brake protection cover.
4 Loosen the 6 lock nuts (G) until they touch the mobile electromagnet (F).
5 Remove the whole of the mobile electromagnet (F) and fixed electromagnet (C) by loosening the atta-
chment screws (A).
6 Carefully separate the mobile electromagnet (F) from the fixed electromagnet (C) so that the springs
inside it do not fall.
7 Replace the coil, i.e. the fixed electromagnet (C), with a new one.
8 Refit the brake following the above steps in reverse order, making sure that the air gap is adjusted in
accordance with the specifications stated in section 4.
The disc must be replaced when the thickness of the brake pad is less than the value shown in the table.
0 CONTENTS
1 DESCRIPTION
2 OPERATION
3 MANUAL OPERATION
4 WIRING
5 ADJUSTMENT
6 CHECKING OPERATION
1 DESCRIPTION
The crane is prepared for weather vaning by releasing the brake on the slewing motor(s), leaving the upper
crane free to move with the wind. The brakes are released remotely via the release units on the brake cover
of each slewing motor.
A control box in the operator’s cabin (or at the base of the crane when there is no cabin) governs the release
units.
In case of a power cut-off or malfunction in the release system, weather vaning can be done manually.
2 OPERATION
Weathervaning sequence (Fig. 1)
1 Opening the motor brake causes the manual lever (1) to move upwards
2 The electromagnet (5) attracts the moving armature (2) and positions it below the manual lever
(1).
3 When the brake drops the manual lever (1) rests against the moving armature (2), preventing the
brake from closing and weathervaning the crane.
Activating weathervaning
1 The crane must be in operation.
2 Press the weathervaning button on
the crane control panel and wait 5-10
seconds. If the crane siren is still
blowing after that time, the crane is
weathervaned.
3 Press Stop to cut the siren.
4 Press Start. The siren should continue
to blow when the Start button is
released.
5 Press stop to cut the siren.
Deactivating weathervaning.
1 Engage the slewing control with the
crane in operation.
Some cranes have a lamp on the weathervaning button to indicate that weathervaning is engaged.
el dispositivo de veleta está activado.
3 MANUAL OPERATION
If there is a malfunction or power cut-off the slewing motor brakes can be
released manually.
1- Lift the lever, overcoming the resistance of the brake springs, and
keep it lifted.
2- Press and hold down the button.
3- Release the lever.
4- Release the button.
This procedure should be repeated with each release unit.
Repeat the process on each release unit
Fig. 2
2
4 WIRING
3 1-2 48V (50/60 Hz) electro-magnet power
4 3-4 Electro-magnet operating indicator micro-switch.
.
Fig. 3
5 ADJUSTMENT
To regulate the unblocking weather vanning, proceed as follows:
1- Manually lift the unblocking lever (1).
2- Push the button (3) until the mobile armature (2) comes inside
under the lever (1).
3- Unscrew the nut (4) in such a way that the distance "a" between
armature (2) and lowr part of the lever (1) when this is lifted at
its highest be approximatively 0.5 mm.
4- Check electrical operation: the armature (2) should enter freely
when the weathervaning button is pressed on the crane controls,
and should release when slewing movement is commanded. If
it does not, slacken the self-locking nut (4) 1/12 of a turn (half a
facet) and try again.
IMPORTANTE: The brake gap should not be less than 1 mm if weathervaning is to be regulated
correctly.
6 CHECKING OPERATION
Weathervaning must be used in windy conditions: if the jib points in the direction of the wind then the weathervaning
system is working correctly.
To check weathervaning when it not windy, proceed as follows:
1- Ensure that the crane can turn freely with no obstacles in its path.
2- With the trolley back and the hook raised and under no load, engage first gear and slew slowly.
3- Still in first gear, press the weathervaning button (the crane siren will sound).
4- Still slewing in first gear and with the weathervaning button engaged, press the stop control and check
that the jib continues to turn freely under its own inertia.
5- If it does not do so, readjust the brake gap (which should be 1 mm) and adjust the weathervaning
system..
0 CONTENTS
1 SYSTEM OVERVIEW
2 OPERATION CHECK
3 ALARM AND TEST PROGRAMMING
4 RS 485 WIND-SPEED OUTPUT
5 HEATING SYSTEM FOR THE WIND-SPEED SENSOR
1 SYSTEM OVERVIEW
The basic configuration has a wind-speed sensor (1), which is connected to the control and signalling unit
(2).
The system operates as follows:
- The control and signalling unit is electrically powered from the crane electric cabinet.
- The orange luminous beacon is activated when the wind-speed exceeds 50 km/h.
- The red luminous beacon and warning siren are activated when the wind-speed exceeds 70
km/h..
1 Wind-speed sensor
2 Control and signalling unit
4 Fastening magnets
5 Orange and red beacons
6 Siren
7 Line fastening to the structure
8 Cabin display
Fig. 1
2 OPERATION CHECK
2.1 Indication and control unit
- Check the operation of the beacons and siren as follows:
- Check the crane is powered.
- The switches at the bottom of the crane and the general switch on the electrical cabinet are
in the ON position.
- Press the stop button in the crane control and then press the start button (radiocontrol,
telecontrol or seat).
- This procedure allows to detect a problem in:
- Orange or red beacons.
- Siren.
- Unit power supply.
The device checks the proper operation of the red and orange beacons and of the siren by switching the
beacons and the siren (each beacon should blink twice and the siren must horn once).
- If one or several elements do not operate, this is because there is a problem in the electric supply
or in the elements themselves.
During this test, physically cover the siren to prevent being deafened by the noise this produces.
- Double check that the control and signal code units are properly fixed by the magnets and check
that the unit is appropriately secured to the crane structure with the fastening line (7) which is
supplied.
- Check that the unit is visible from the crane operator’s control position.
Necessary material:
- Cabin wind velocity display.
Instructions:
A. Connect the cabin wind velocity displayto the control unit (See Point 4).
B. Move the wind velocity detector cups either through the action of the wind or by turning them by
hand.
C. Check that there is a velocity reading on the cabin wind velocity display.
Necessary materials:
- Cabin wind velocity display.
- One complete portable anemometer with built-in display.
Instructions:
A. Connect the cabin wind velocity display to the control unit (See Point 4).
B. Install the portable anemometer pickup near the crane pickup and under the same wind reception
conditions.
C. Compare the wind velocity readings on the two displays (the check will be much more effective if
the auxiliary anemometer is calibrated).
Fig. 2
The device can be configured in different ways, by changing a set of 4 mini-switches 4 placed inside it. The
different functions that can be activated or deactivated are: autotest function, configuration in which the device
must be reinitialized after the 70km/h alarm is activated, cancel the acoustic warning when working close to
low noise areas like hospitals, residentials...
To access to the connections or configuration, loose the screws that fix the small bottom cover.
ON (1) Autotest ON
DIP1
OFF Autotest OFF.
After the wind-speed goes above 70 km/h , the ALARM remains activated , even if the
ON speed goes to 0 km/h (The alarm will be deactivated only after the unit supply is switched
DIP3 off for more thatn 15 seconds).
OFF (1) The ALARM is deactivated immediately after the speed goes below 70 km/h.
The DIP4 configuration is exclusively to be changed by an authorised person. Its proper position is ON.
Otherwise, the device indicates a "SENSOR FAILURE"
Before changing the position of the switches, ensure that it complies with the required standard for the
installation and that the new alarm method (sound and visual) is understood by the crane operators.
3.3 Alarms.
The device includes the following alarm modes:
- At 50 km/h only amber light, and at 70 km/h only red light.
- At 50 km/h only amber light, and at 70 km/h red light + siren.
The default factory setting is "at 50 km/h only amber light, and at 70 km/h red light + siren".
Fig. 3
In case there is any abnormal behaviour signal at the sensor, a cable that has been cut or an improper connection,
the system beacons intermittently blink until the problem is solved.
4 RS 485 WIND-SPEED OUTPUT
The control and signalling unit (Fig. 4) is equipped with an RS 485 output that allows a fast connection to the
indicator system in the cabin. Refer to the crane wiring schematic for more details.
Fig. 4
This heater system is supplied from a point which is placed before the general crane contactor G (see wiring
schematic) . If the general switch of the crane (IG) is ON and the crane bottom switch is ON, the heating system
will be operative, regardless the stop control is pressed or not. This allows the system to melt the frost even
when the crane controls are switched off.
IT IS MOST IMPORTANT TO TAKE GOOD CARE OF THE OIL IN AN OIL-HYDRAULIC SYSTEM, AS IT NOT
ONLY TRANSMITS POWER BUT ALSO LUBRICATES MOVING PARTS
0 CONTENTS
1 OIL CLEANING
2 FILTER CLEANING
3 OIL CHANGES
4 CHECKING FOR LEAKS
5 CLEANING RAM RODS
6 TROUBLESHOOTING
1 OIL CLEANING
Oil can deteriorate due to the combined action of high running temperatures, air, water and contaminant particles.
This can cause the system to run poorly, and may lead to pump cavitation, jerky movements, increased wear,
valve failures, etc.
Before assembly, always check the condition of the oil and change it if necessary.
2 FILTER CLEANING
To prevent oil from becoming contaminated hydraulic groups have return and air filters, which must be cleaned
or replaced as necessary.
The intake filter (item 4 on the hydraulic layout) must always be cleaned before oil is changed and when the
noise characteristic of pump cavitation is detected. Clean it as follows:
a) Remove the screws from the cover of the mini-hydraulic group and thoroughly clean the cover,
edges and screws with before fully unscrewing them with compressed air.
b) Remove the cover, unscrew the filters and remove them from the tank.
c) Submerge the filters in petroleum, trichloroethylene or a similar solvent. Clean the inside with
compressed air. Remove all traces of solvent before re-fitting.
d) Screw them back into their housings.
e) Fit the clean cover, changing the seals if necessary, and screw it down.
How often air filters (item 2 on the hydraulic layout) need to be checked will depend on the surrounding
environment.
3 OIL CHANGES
Before assembly always top up the oil in the tank to the maximum level, using oil of the same characteristics
as that used by the manufacturer.
Recommended oil types are listed in the lubrication instructions.
Change oil every 2500 hours or more often if it is seen to be deteriorated or contaminated.
Completely eliminate the old oil.
Ensure that the inside of the system is completely clean before filling it with new oil.
The cleaner a system is, the longer those parts subject to wear will last.
Do not attempt to clean the tank with cotton or similar materials: use white cloths free from dust and fluff, or
preferably foam-rubber sponges.
New oil should preferably be added through a portable pump unit with a filter to prevent dirty oil getting in.
To stop leaks their cause must be eliminated: tighten connectors, and change seals or elastomers as necessary.
The surfaces of the hydraulic circuit should be kept clean to prevent accidents and contamination and to enable
leaks to be detected.
Check that hoses are not cut, trapped or deteriorated. Defects of this type affect the properties of the hose and
therefore its safety coefficients. If defects are found, change the hose.
6 TROUBLESHOOTING
0 CONTENS
1 OPERATION INSTRUCTIONS
2 REGULATION OF THE MAXIMUN PRESSURE
3 REGULATION OF THE CYLINDER SPEED
1 OPERATION INSTRUCTIONS
Before making operational the hydraulic equipment, check the oil level and condition.
Also check the hoses, valves and bends.
HYDRAULIC SYSTEM
The tank must be topped up whenever its level drops below the “normal” mark on the level indicator.
This is the level required to ensure proper operation of the hydraulic system.
Do not top up to above the “normal” mark with the cylinder withdrawn.
1 Filter
2 Inspection plug
The used lubricants must fulfill the specifications DIN 51524 part 2 class HLP, Denison HF-0, HF-1 y HF-2, Cin-
cinnati Milacron P-68, P69 y P-70, AFNOR NFE 48603-HM, VIKERS I-286-S y M2950-S, y ISO 6743/4-HM.
CLEAN OIL
Oil may become dirty due to a combination of high working temperatures, air, water and contaminant parti-
cles.
All this leads the system to run poorly, with brusque movements, increased wear, valve failures, etc.
Before assembly, check the condition of the oil and change it if necessary.
To prevent oil from getting dirty an air filter is fitted. Check this at intervals, depending on the environment.
OIL CHANGES
Change the oil at the times indicated or when its viscosity or oxidation levels make this advisable.
Ensure that the inside of the system is completely clean before pouring in new oil. The cleaner the system, the
longer wear parts will last.
Do not try to clean the tank with cotton rags or similar: use white cloth free from dust and frayed threads, or
preferably a foam rubber sponge.
Add new oil with a portable pump unit fitted with a filter to prevent any dirt getting in at the same time.
To make sure that the chosen oil is compatible with which has the hydraulic system, on the contrary, to
come to a thorough cleaning before the change.
If lubricants other than those shown in the table are used, confirm with the manufacturer or supplier that
they are suitable for the intended use and meet the minimum requirements for those listed.
For applications at very low temperatures (<-20°C) special oils are required.
The hydraulic group leaves factory with the oil indicated in the table inferior.
INITIAL LUBRICANT
TYPE CAPACITY
REPSOL
125 litros
Filter LIBRA HIDRÁULICO HLP 46
Inspection
plug LUBRICANT CHANGES
INITIAL MAINTENANCE
2500 hours
EQUIVALENT LUBRICANT
Q=30 l/min
P=250 Bar
20 C.V.-1500 rpm
V-1;220/380V-50Hz
4,5,6,7,8
11,12
10
COMPONENTS LIST COMPONENTS LIST
Pos. Cant. Description Pos. Cant. Description
1 1 Oil tank c=125Lts. 12 1 Manometer
2 1 Filter 13 1 Key
3 1 Level 14 1 Plate
4 1 Pump 15 1 Electrovalve
5 1 Support 16 - Hose
6 1 Coupling 17 1 Cylinder
7 1 Motor 20 CV 18 1 Takes pressure
8 1 Antireturn 19 1 Antireturn
9 1 Filter 20 1 Valve
10 1 manual distributor with safety valve 21 1 Quick plug
11 1 Safety key 22 1 Quick plug
0 CONTENTS
1 GENERAL
2 CABLE HANDLING
3 STORAGE AND PRESERVATION
4 CABLE UNWINDING
5 INSTALLATION INSTRUCTIONS
6 LUBRICATION
7 INSPECTION
8 INSPECTION POINTS
9 CRITERIA FOR REPLACEMENT
10 CABLE LIFE
11 VERIFICATION OF AUXILIARY EQUIPMEN
1 GENERAL
Nonspinning cables are made up of several layers of strands twisted alternately in one or other direction. By
this way, the opposite torsion moments generated when suspending a load from the cable are balanced.
Because their construction, wire ropes are very delicate and should be only used if necessary. They must
be handled and installed with extreme care to prevent serious problems. Because of this, we recommend
to strictly follow the instructions given in UNE standard 58-111-91WIRE ROPES FOR HOISTING DEVICES,
EXAMINATION CRITERIA AND REPLACEMENT OF ROPES.
2 CABLE HANDLING
Forms of supply:
Cables may be supplied in rolls, X-reels or flanged reels as required by the user.
Roll
The most economic form of supply is in rolls, but cable unwinding is cumbersome and should be only used in
case of thin, short cables. (Fig. 1)
X-Reel
It prevents the cable becoming tangled, but their transport is more difficult. (Fig. 1)
Flanged reel
It prevents the cable becoming tangled and handling is very easy. It also prevents the cable touching the floor,
thus preventing being fouled. It also protects the cable during loading, unloading and transport operations.
(Fig. 1)
Fig. 1
4 CABLE UNWINDING
We are sure that the users know the procedures for installing and handling the cables and that they also know,
from their own experience, that if the required precautions are not taken a premature failure could occur.
However, we believe that it would be very useful to recall these precautions, especially because they are often
neglected, in spite that they are well known.
The figures below show the correct procedures, as well as the incorrect procedures, to be followed, or avoided,
when unwinding a cable. (Fig. 2)
If the procedure is not correct, the initial twisting of the cable proper is modified and its structure significantly
altered in some positions.
Sometimes, if unsuitably handled, the cable is subjected to an overtwisting effect which will make it difficult to
handle, causing kinks. Another times there is a risk of loosening and opening the strands because the twisting
effect of strands is partially lost, impairing also the balance of the cable.
Incorrect method.
Fig. 2
5 INSTALLATION INSTRUCTIONS
1.- When replacing a cable, use a new cable of the type specified by the manufacturer. If other type of cable
is used, make sure that the specifications given by the same manufacturer are strictly complied with.
2.- Cable ends shall be suitably bound in order to prevent cable strands being untwisted.
3.- Before installing a new cable verify that drum and sheave slots are of suitable size.
4.- Suitably unwind the cable according to the instructions given below.
5.- When being installed, prevent the cable being twisted about its axis, as otherwise the concentric strand
layers would become separated, facilitating the formation of kinks and swellings.
6.- When installing a cable on a crane, unwind the cable from the reel and at the same time wind it on the
crab drum while applying a slight tension on the cable between reel and crab drum. It is of paramount
importance that the cable will be unwound and wound in the same direction, that is, that the reel and
crab drum will rotate in the same direction.
7.- Before putting a cable recently installed into service, make sure that all auxiliary devices are correctly
mounted and ready for operation.
8.- Perform several operations with a load 10% the nominal load to allow the cable to stabilize.
9.- Avoid applying sudden stresses.
6 LUBRICATION
The lubrication of a cable is as important as the lubrication of a car engine. The lubricant will reduce wear and
will protect the cable against corrosion.
When a load is suspended from a cable, the internal wires move and rub against each other and the external
wires are subjected to wear when sliding on sheaves and drums. The lubricant will reduce wear of both internal
and external wires.
During the manufacture of a cable, the fiber core, wire and strands are suitably lubricated with an adequate hot
lubricant. When a cable is put into service, the pressure of strands against the core makes the lubricant to be
forced outward, thus being lost more or less quickly depending on the viscosity and movement of cable.
Because of this, all cables must be periodically lubricated during their working life.
If when a cable is being lubricated, the core does not receive the amount of grease required to compensate the
grease lost, the grease applied during the manufacturing process will continue being lost, becoming increasingly
dry and finally being decomposed. As a result, the strands will be without support, being excessively pressed
against each other, the pitch of strands will become longer and the cable will quickly deteriorate.
The cable should be lubricated during its working life with the same attention and extreme care as during its
manufacturing process.
For the lubrication of an installed cable to be efficient, the following points must be observed:
- Previously clean the cable. This cleaning operation may be carried out using either rushes or pressure
air. Use a solvent to easily remove old grease residues.
- Thoroughly lubricate the cable. The lubricant should be suitably applied. If the lubricant is simply applied as
a external coating on cable surface, without penetrating into the core, the cable would be improperly
lubricated.
- Use a suitable lubricant of the following characteristics:
a.- High viscosity
b.- Resistant to the working environment, neither generating corrosive products nor hardening
c.- To remain on the cable for a long time. Lubrication frequency will depend on the working
conditions.This frequency may be determined through inspections.
Daily inspections.
Whenever possible, daily examine all exposed parts of cables in order to verify for signals of deterioration or
deformations. Pay special attention to the points in which the cable is fastened to the device. Any sensible
change in the cable condition should be identified, followed by an examination by a qualified technician.
Regular Inspections.
In determining inspection intervals, take the following into account:
a.- Requirements of law.
b.- Type of apparatus & conditions of use.
c.- Group in which the apparatus is classified.
d.- Results of previous inspections.
e.- Time of use of cable.
Periodical special.
In any case, when an incident may be cause of wear of cable and/or fastening points, or in such cases as when
a cable is put into service after being reassembled, the cable should be newly inspected.
When a hoisting device has been out of service for a certain time, the cables should be inspected before putting
then newly into service.
8 INSPECTION POINTS
General
When a cable is examined on its entire length, the following points should be inspected with special care:
- Fastening points at the ends of both working cables and idle cables.
- Parts of cable wound on sheaves of sheave block and return sheaves. For devices performing operations,
parts of cable passing on the sheaves at the point from which the load is suspended.
Schematic diagram showing the possible defects to be considered when examining the different parts
of a cable
1.- Inspect the point at which the cable is fastened to the drum.
2.- Verify for any faulty winding causing deformations (cable
flattening) or wear, especially at the points in which cable direction
Polea
changes.
3.- Check for broken wires.
4.- Check for corrosion signals.
5.- Check for deformations caused by intermittent stresses.
Tambor
6.- Examine the part of the cable wound on a sheave to check for
broken wires or wear.
7.- Verify fastening points
- check for broken wires or corrosion
- inspect also the part of the cable incontact to or near
compensation sheaves
8.- Verify for any deformation
Polea
9.- Verify cable diameter
Carga
10.- Carefully inspect the part of the cable wound on the sheave block,
especially the point from which the load is suspended.
11.- Check for broken wires or surface wear.
Fig. 3 12.- Check for corrosion.
- Cable ends, excepting slings. Cables should be examined on those areas in which cable end fastenings
are located, as those areas are critical for wire breakage and corrosion. Thimbles on cable ends should
be examined for deformation or wear of both the thimble and the cable.
- Cable fastenings using clamping bushes should examined in a similar manner as for cable thimbles,
verifying for bush cracking and sliding.
- Moving unions of cable ends (cable hangers, cable pincers, etc.) should be examined for broken wires,
sliding of unions or loose clamping screws. This examination should verify that all requirements of
applicable standards and regulations are complied with.
- Cable end unions made by splicing shall be examined to verify for broken wires and sliding of joined
strands. For this, let the union exposed by removing any coating or textile tie.
- If broken wires are observed in a cable end, it should be possible to cut the cable in order to newly
fastening it. If any sliding or loosen screw is observed, proceed to tighten it. However, the remaining
cable length should be sufficient to allow the cable to be properly wound on the drum.
The following criteria can be used as a basis to determine the safety degree of a cable in service:
All the above criteria should be separately examined. However, the juxtaposition of certain alterations on certain
areas may be cause of a cumulative effect which should be kept in mind when deciding whether a cable is to
be replaced.
In any case, it should be determined whether the defects are caused by a faulty device and if so, to repair the
faulty device before installing a new cable.
Tabla - 1 -
Number of visible broken wires on
nonspinning cables working on steel sheaves
On a length 1) of On a length 1) of
6d 30d 6d 30d
2 4 4 8
1) d = cable diameter.
NOTE: If a cable is totally or in part working on synthetic sheaves or metallic sheaves with synthetic
slots, breakage of internal wires with no visible breakage or wear of external wires could occur.
e) Strand breakage
If a strand is broken, the cable must be replaced.
If because any of the above causes, cable diameter (mean value of two orthogonal measurements) is reduced
with respect to nominal diameter by 3% for nonspinning cables or 10% for other cables, the cable must be
removed even if there is no visible broken wire.
A small deterioration may not be detected through a normal examination, in particular if the stresses are evenly
distributed across the strands. However, this may be cause of a significant loss of strength, which should be
determined by means of external examination procedures. If this deterioration is confirmed, the cable must be
removed.
NOTE: The actual diameter of a new cable may be greater than nominal diameter. In this case, the allowable
wear under the same conditions will be also greater.
g) Loss of elasticity
In some cases, related to the work site, cable elasticity may be significantly reduced, involving a serious risk
when subjected to high stresses.
Loss of elasticity is very difficult to detect. In case of doubt, contact a specialized technician. This fault shows
in most case the following symptoms:
This cable condition may lead to a sudden breakage when subjected to dynamic loads and must be
replaced.
h) External wear
Wear of filler wires of external strands of a cable is caused by friction of cable against sheave and drum slots.
This effect is especially evident at the contact points of moving cables with sheaves during acceleration and
slowdown periods, and results in a variation of thickness of external wires.
Wear is promoted by an insufficient or improper lubrication as well as by the presence of dust. When, as a
result of wear, the external diameter of cable is reduced by 7% or more with respect to nominal diameter, the
cable must be removed even if there is no visible broken wire.
If you suspect of internal corrosion, the cable may be subjected to internal examination, performed by a
qualified technician.
If internal corrosion is confirmed, the cable must immediately removed.
j) Deformation
The apparent alteration of a cable structure is called deformation.
The different types of deformation are in general identified by a loosening of cable structure, at least in the
vicinity of deformed parts, resulting in a uneven distribution of stresses.
4d where d is the nominal cable diameter and d1 the diameter of deformed cable evolvent when
d1 >
3 not subjected to stresses, and provided the length of cable considered does not exceed 25d.
Fig. 4 - Curl-shaped deformation: cable longuitudinal axis takes the shape of a helix.
If the deformation exceeds the value given in a, the cable should be removed
Fig. 9- Worsening of the above defect by one degree will require the cable to be removed
Fig. 10- Local increase of diameter of a cable with a filler layer, caused by
the extrusion of a multi-strand wire core as a result of impacts.
Cable should be immediately removed.
Fig. 12- Local decrease of cable diameter, external strands tending to occupy core position.
Note that broken wires are present. Cable should be immediately removed.
Fig. 14- Flattening caused by a mechanical action applied on a certain lenght of a cable with several strand layers.
Note the flattening and elongation of pitch of external strands as well as
their loosening. Cable should be removed.
Fig. 15- Very serious kink. Note the expansion of textile fibre core.
Cable should be immediately removed.
Fig. 16- Cable put into service in spite of having a kink and which are now subjected to local wear as well as to typical
deformation.
10 CABLE LIFE
After the user has acquired sufficient practical experience, an estimation can be made about the life expectancy
of a cable. However, these estimations should be only used for stock management purposes and in no case
affect the frequency of inspections or be used to extend the life of a cable beyond specifications.
GENERAL
Screws, nuts and washers used for HV unions should comply with COMANSA standard NP11-01-03.
High strength screws with controlled tightening torque should be tightened using a torque wrench. The tightening
torque required is given in the section for assembling.
Torque wrenches should be periodically checked for proper operation.
Tightening torques should be within ±10% the value given in table (1).
Strength class according ISO 898 part 1 and 2 must be stamped on screw head, nut and washer as shown in
fig. 1, 2 and 3.
Strength class of screws, nuts and washers will be specified for each crane. Strength classes shown in the
figures are only for illustration purposes.
Seating surfaces and screw holes must be free from dirt, paint and other foreign particles.
HV washers should be located with the bevels outward, facing screw head or nut.
For the screws in the slewing ring, see specific section for the
slewing ring.
Atention!
10.9
10.9
10.9
Trademark
Trademark
Checking unions which use high strength screws with controlled tightening torque:
1.- Check unions every time the crane is disassembled or before assembling it again, but never later than 1
year after last check-out.
Screws tightened according to a controlled tightening torque and then dismantled may be reused in subsequent
assemblies provided that both screw head and thread are not damaged and free from rust.
DIN 6914 screws and related DIN 6915 nuts have a width across flats greater than DIN 931 screws and related
DIN 934 nuts (Refer to table II).
When selecting the nuts, verify that nut strength is the same as screw strength.
For instance: A nut 8 will require a screw 8.8
A nut 10 will require a screw 10.9
A nut 12 will require a screw 12.9
Washers used on unions with HV screws should be high strength washers of the same material as screws and
nuts used.
Avoid using:
Screws with rusty shank or thread as well as nuts with rusty thread and screws or nuts damaged or with da-
mage signals.
If a broken or elongated (loosened) screw is observed in a union, replace all screws in that union.
These checking and tightening operations can be done more easily with the crane
disassembled.
- The figures on the above chart are only applicable to the fixing elements which comply with
NP11-01-03 COMANSA standard.
- The torque ratings are obtained by means of torque wrench and must be accurate to ±10%.
- The torque ratings are intended for fixing elements free from lubricant, dust, dirt, paint or other
foreingn bodies. In case of any other conditions, different to the indicated, the torque should be
adjusted to these new conditions.
Cross bases consist of a cross-beam plug two arms which fold out to form a cross, secured by pinned, vertical panels.
Different anchor feet are bolted the cross-base for each type of mast section
4 M:33 10 D934 16
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection, WITHOUT
GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other foreign objects. For
any other condition than that descrubed above, the torque should should be adjusted accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their
torque to below the permitted tolerance, should be 10% less than that applied during the initial installation
of the ring, so as to avoid overtightening the bolts as a result of different conditions from those exisitng
at the time of initial installation.
Procedure for checking torque of cross-base anchor feet bolts on erected crane:
A. Visual Inspection:
A.1 Observe carefully the visual aspect of the bolts and nuts, insofar as to establish that they are all in place and have
no appreciable defects (noticeable loosening, damaged nuts or bolts, rust stains,...)
A.2 Check that the seating of the anchor feet on the cross-base is correct and that no play or movement is
apparent. This can be best controlled by slewing the crane, without load, and observing the seating on
the side of the ring facing the jib.
N.B. A visual inspection carried out in a professional manner can detect important defects
more efectively than a spot checking of the torque.
With the crane dismantled, on the ground, checking of slewing ring bolt torque can be carried
out much more simply and evenly, in sequence.
Cross bases consist of a cross-beam plug two arms which fold out to form a cross, secured by pinned, vertical panels.
Different anchor feet are bolted the cross-base for each type of mast section
4 M:36 10 D934 24
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection, WITHOUT
GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other foreign objects. For
any other condition than that descrubed above, the torque should should be adjusted accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their
torque to below the permitted tolerance, should be 10% less than that applied during the initial installation
of the ring, so as to avoid overtightening the bolts as a result of different conditions from those exisitng
at the time of initial installation.
Procedure for checking torque of cross-base anchor feet bolts on erected crane:
A. Visual Inspection:
A.1 Observe carefully the visual aspect of the bolts and nuts, insofar as to establish that they are all in place and have
no appreciable defects (noticeable loosening, damaged nuts or bolts, rust stains,...)
A.2 Check that the seating of the anchor feet on the cross-base is correct and that no play or movement is
apparent. This can be best controlled by slewing the crane, without load, and observing the seating on
the side of the ring facing the jib.
N.B. A visual inspection carried out in a professional manner can detect important defects
more efectively than a spot checking of the torque.
With the crane dismantled, on the ground, checking of slewing ring bolt torque can be carried
out much more simply and evenly, in sequence.
Different anchor feet are bolted the cross-base for each type of mast section
PMD4-3
3 M:36 10 D934 48
D34; TD34
ASSEMBLY TORQUE
(M) CHECHING TORQUE
(C)
(NIC\9603-01)
Bolt 1........... 2790 Nm Bolt 1........... 2510 Nm
PMD6
3 M:36 10 D934 48
D36; TD36A
ASSEMBLY TORQUE
(M) CHECHING TORQUE
(C)
(NIC\9603-01)
Bolt 1........... 2790 Nm Bolt 1........... 2510 Nm
Screw support
base supported
Description Nº Dimension Grade Norm Q
2 M:30 10 D934 32
D:65 d:31
4 3301P192.06 32
L:45
ASSEMBLY TORQUE
(M) CHECHING TORQUE
(C)
1, 2, 3, 4 (NIC\9603-01)
Bolt 1........... 1600 Nm Bolt 1........... 1440 Nm
Support mechanism
base translation
Description Nº Dimension Grade Norm Q
2 M:30 10 D934 32
D:65 d:31
4 3301P192.09 32
L:35
ASSEMBLY TORQUE
(M) CHECHING TORQUE
(C)
1, 2, 3, 4 (NIC\9603-01)
Bolt 1........... 1600 Nm Bolt 1........... 1440 Nm
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection,
WITHOUT GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other
foreign objects. For any other condition than that descrubed above, the torque should should be adjusted
accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their
torque to below the permitted tolerance, should be 10% less than that applied during the initial installation
of the ring, so as to avoid overtightening the bolts as a result of different conditions from those exisitng
at the time of initial installation.
N.B. A visual inspection carried out in a professional manner can detect important defects more
efectively than a spot checking of the torque.
With the crane dismantled, on the ground, checking of slewing ring bolt torque can be carried
out much more simply and evenly, in sequence.
3 M:36 10 D934 48
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection,
WITHOUT GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other
foreign objects. For any other condition than that descrubed above, the torque should should be adjusted
accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their
torque to below the permitted tolerance, should be 10% less than that applied during the initial installation
of the ring, so as to avoid overtightening the bolts as a result of different conditions from those exisitng
at the time of initial installation.
Procedure for checking torque of cross-base anchor feet bolts on erected crane:
N.B. A visual inspection carried out in a professional manner can detect important defects more
efectively than a spot checking of the torque.
With the crane dismantled, on the ground, checking of slewing ring bolt torque can be carried
out much more simply and evenly, in sequence.
2 M:30 10 D934 32
1, 2, 3, 4
ASSEMBLY TORQUE (M)
CHECHING TORQUE (C)
(NIC\9603-01)
Bolt 1........... 1600 Nm Bolt 1........... 1440 Nm
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection,
WITHOUT GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other
foreign objects. For any other condition than that descrubed above, the torque should should be adjusted
accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their
torque to below the permitted tolerance, should be 10% less than that applied during the initial installation
of the ring, so as to avoid overtightening the bolts as a result of different conditions from those exisitng
at the time of initial installation.
Procedure for checking torque of cross-base anchor feet bolts on erected crane:
N.B. A visual inspection carried out in a professional manner can detect important defects more
efectively than a spot checking of the torque.
With the crane dismantled, on the ground, checking of slewing ring bolt torque can be carried
out much more simply and evenly, in sequence.
3 d:M24 10 D934 72
ASSEMBLY TORQUE
CHECHING TORQUE
(M)
(C)
(NIC\9603-01)
Bolt 1....................800 Nm Bolt 1 720 Nm
Bolt 2..................1600 Nm Bolt 2 1440 Nm
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection, WITHOUT
GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other foreign objects. For
any other condition than that descrubed above, the torque should should be adjusted accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their torque to
below the permitted tolerance, should be 10% less than that applied during the initial installation of the ring, so as to
avoid overtightening the bolts as a result of different conditions from those exisitng at the time of initial installation.
A. Visual Inspection:
A.1. Observe carefully the visual aspect of the bolts and nuts, insofar as to establish that they are all in place and
have no appreciable defects (noticeable loosening, damaged nuts or bolts, rust stains,...)
A.2. Check that the seating of the slewing ring on the turntable is correct and that no play or movement is apparent.
This can be best controlled by slewing the crane, without load, and observing the seating on the side of the ring
facing the jib.
N.B. A visual inspection carried out in a professional manner can detect important defects
more efectively than a spot checking of the torque.
B.1. Suspend load from the hook and trolley out to the corresponding safe load radius.
B.2. Lock (brakes applied) slewing in a determined position.
B.3. Check the torque (as per (C) above) of the bolts on the Jib side of the ring (half the bolts).
B.4. Remove load from hook and trolley in to minimum radius.
B.5. Check the torque of remaining half of the bolts on the counter-jib side of the ring.
With the crane dismantled, on the ground, checking of slewing ring bolt torque can be carried
out much more simply and evenly, in sequence.
(M) The given torque corresponds to the specified type of bolt, DACROMET type 320A surface protection, WITHOUT
GREASE, and is applied to bearing surfaces and holes free from grease, dirt, paint and other foreign objects.
For any other condition than that descrubed above, the torque should should be adjusted accordingly.
(C) The Checking torque applied during inspections and maintenance, to detect if any bolts have lost their torque
to below the permitted tolerance, should be 10% less than that applied during the initial installation of the ring,
so as to avoid overtightening the bolts as a result of different conditions from those exisitng at the time of initial
installation.
N.B. A visual inspection carried out in a professional manner can detect important defects
more efectively than a spot checking of the torque.
2.1: Dismounting
- Use the threaded extractor bolt holes in the clamping ring of the mechanism. Tighten the pressure screws
successively until the mechanism is released.
2.2: Mounting
- Contact surfaces must be completely free from oil and grease. Use degreasers to clean them.
- Tighten the slewing mechanism fixing screws.
Social awareness of the need for Sustainable Growth requires the construction field to enable recycling for
equipment and materials that have reached the end of their useful lives.
The most outstanding advantage to this recycling effort is the concurrent solution of problems originating in
elimination of some sub-products of waste as well as obtaining new raw material, which reduces the quantity
of newly extracted natural resources.
Waste from maintenance operations, before being disposed of, must be classified according to type:
At the end of the crane's useful life its raw materials should be recycled rather than thrown away.
The apparatus, accessories, fluids and packaging should be sent to sites set aside for ecological
reutilization.
Waste from electronics and electronic devices should be stored at places set aside for selective recovery.
Disposal and scrapping of the crane should be performed according to the provisions of current legislation
in the country where the work is performed.
Proper disposal of waste generated in the scrapping of the crane contributes to the conservation of resources
and the prevention of possible environmental problems.
The owner may scrap the crane by separating all materials according to their type:
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60
DEPARTURE DATE............................................................... ( )
If you look at the drawing of any assembly, you will note that each part has a number which, as per the list
attached to the drawing, provides the necessary data to place an order.
Example:
In order to find the hook sheave, or pulley, the followings steps must be followed:
1º- In the GENERAL ASSEMBLY page you can find out that the HOOK is marked with the reference
030 0216
2º In the HOOK ASSEMBLY page you can see that the sheave is given number 2. Its corresponding
reference is POL18387DT4791.
3º Purchase Order.
PURCHASE ORDER
CRANE MODEL 21 LC ---
35 42
77 36 43
78 37 44 49
79 38 45 40
80 39 46 41
81 85 70 29 40 47 42
82 86 71 32 41 48 53 54
31 90 60
20 61
21 62
22 63
91 26 64
92 65
93
94
96 15
16
97
3
4
1 2
5 9 10
11
12
2 X X -
3 - - X
63
64
65
4,5
21, 22, 23
16
11, 15
10, 12, 13
17, 18, 19
2
6
9, 14 15 8
17, 18, 19
20, 18, 19
17, 18, 19
3
4
3
4
26
27
1
A A
29 28
30 29
31 30
B B
16 19 22
17 20 23 9
18 21 24 10
15
25 32
2
33
34
3 35
4
5
13
6 14
10
11
12
8 7
9
3, 4,5
6
1
2, 4, 5
16, 17, 18
21
22
20
22 7
6
23
22 24 19
25
22 1
26
27
11
12
8, 9, 10
2 3 4
34 X X X X
64 X
77 X
78 X X X
79 X
81 X X
82 X
83 X
84 X X
85 X
86 X
124 X
24
25 2
13
1 26 3 5
7, 8
22 19, 15, 20
6
14, 15, 16
17, 18
10, 11, 12 27
9 21
23
15
15 16
11
1
17 9
10
3
2 12, 13, 14
AM282B
5, 7, 8
AM282B
1er Tramo
6, 7, 8 4
AM262A AM250A
9 1
10 1
11 1
15 1
16 2
17 1
7 2 3 6 5 4
8, 9, 10
8, 9, 10
14, 16, 17
2
2
2
2
6
11
1
8 10
7
12, 13, 14
2
3, 4, 5
9 4 5 8 7 6
13
10, 11, 12
14, 15, 16
3
2
AM240 AM244
4 1 1
5 1 1
13 - 2
9 4 5
1
6, 7, 8
10, 11, 12
3
2
AM220 AM244
4 1 1
5 1 1
9 - 1
9 4 5
1
6, 7, 8
10, 11, 12
3
2
AM210 AM244
4 1 1
5 1 1
9 - 2
6 7
8
1 9, 10, 11
2, 3, 4, 5
6, 7
12, 13
9, 10, 11
2
17
18, 19
3, 4, 5
16
16
14, 15
11 12
13
19
9
20 14
21
11
26
10
8 2
12
3
4
7
5
6
17
23
24
25
11
21, 5
22
21, 5
20
27
10
4, 5
7, 8, 9
12
11
3
8
17
17
18, 19
14
13
24, 25, 26
47 6
46
24, 25, 26
48
51
15, 16
45
48
49
50
53
23
40, 43
41, 42
MTRCF5685-2
52
21, 5, 39
44
38
31
36, 37
33, 34
32
11,20,25
40,31
28,29
45
11,20,25
21
39
40
14,31
13,21,26
38
35
3
33
10
32
23,15
34
8
16,24,27
4
16,27
5
5
36
2
6
9,18
49
43,46
41
7
43,46
42
48
44
1
12,19,22
47
37
LISTA DE MATERIALES
Nº de
Descripción Cant. Código o Norma Material Observaciones
Orden
1 Anillo V-ring V-85A Lado A 1
2 Platillo exterior delantero 1 6.14.82-9 Fe. Fundido
3 Rodamiento lado A 1 Nº6317
4 Tapa delantera 1 7.52.03-1 Caldereria
5 Platillo interior 2 6.14.81-2 Fe. Fundido
6 Eje y rotor 1 EJEMT250M011 F-125
7 Carcasa y estator 1 7.52.20-1 Caldereria
8 Tapa Trasera 1 7.52.02-2 Caldereria
9 Retén lado B 1 120x160x12-BA
10 Casquillo interior lado B 1 85x112x32 F-114
11 Casquillo exterior lado B 1 85x120x32-R F-114
12 Piñon freno Stromag NFF-160 1 80x160x125
13 Freno Stromag 1 NFF-160
14 Encoder Kubler 1 A020H RS422
15 Tapa encoder 1 8.46.33 Fibra vidrio
16 Junta caja bornas 1 8.44.03-B EPDM60 sh.
17 Caja de bornas tornilleria y racores 1 8.44.03-24 Fe. Fundido
18 Placa de bornas con tornilleria 1 Nº 930
19 Junta tapa de bornas Ø4 1 8.44.03 EPDM60 sh.
20 Tapa de bornas y tornilleria 1 8.44.04 Fe. Fundido
21 Junta caja de bornas (encoder) 1 6.04.03-A1 EPDM60 sh.
22 Caja de bornas tornilleria y racores (enco.) 1 6.04.03 Aluminio
23 Regleta gris 10 agujeros 1
24 Junta tapa de bornas Ø2 (encoder) 1 6.04.03-B EPDM60 sh.
25 Tapa de bornas y tornilleria (encoder) 1 6.04.04 Aluminio
26 Junta ventilador 1 8.45.40A EPDM60 sh.
27 Visera laberinto caracol 1 Caldereria
28 Rejilla ventilador 1 Chapa
29 Caracol ventilador 1 200/1070 Caldereria
30 Rodete ventilador 1 200/1070 Caldereria
31 Brida ventilador 1 130.5x420x5 Caldereria
32 Tapa brida (ventilador) 1 6.01.23-5 Fe. Fundido
33 Carcasa y estator (ventilador) 1 6.01.20 Fe. Fundido
34 Rodamiento lado A (ventilador) 1 Nº6205-2RS
35 Eje y rotor (ventilador) 1 EJEKV092N001 F-114
36 Rodamiento lado B (ventilador) 1 Nº6304-2RS
37 Tapa trasera (ventilador) 1 6.01.01-1 Fe. Fundido
38 Rodete refrigerador (ventilador) 1 1,022.00 Plastico
39 Caperuza (ventilador) 1 6.01.05 Chapa
40 Junta caja de bornas (ventilador) 1 6.04.03-A1 EPDM60 sh.
41 Caja de bornas tornilleria y racores (vent.) 1 6.04.03 Aluminio
42 Placa de bornas con tornilleria (vent,) 1 Nº500
43 Tapa de bornas y tornilleria (ventilador) 1 6.04.04 Aluminio
21, 5
22
21, 5
20
27
10
4, 5
7, 8, 9
12
11
3
8
17
17
18, 19
14
13
24, 25, 26
47 6
46
24, 25, 26
48
51
15, 16
45
48
49
50
53
23
40, 43
41, 42
MTRCF5685-2
52
21, 5, 39
44
38
31
36, 37
33, 34
32
11,20,25
40,31
28,29
45
11,20,25
21
39
40
14,31
13,21,26
38
35
3
33
10
32
23,15
34
8
16,24,27
4
16,27
5
5
36
2
6
9,18
49
43,46
41
7
43,46
42
48
44
1
12,19,22
47
37
LISTA DE MATERIALES
Nº de
Descripción Cant. Código o Norma Material Observaciones
Orden
1 Anillo V-ring V-85A Lado A 1
2 Platillo exterior delantero 1 6.14.82-9 Fe. Fundido
3 Rodamiento lado A 1 Nº6317
4 Tapa delantera 1 7.52.03-1 Caldereria
5 Platillo interior 2 6.14.81-2 Fe. Fundido
6 Eje y rotor 1 EJEMT250M011 F-125
7 Carcasa y estator 1 7.52.20-1 Caldereria
8 Tapa Trasera 1 7.52.02-2 Caldereria
9 Retén lado B 1 120x160x12-BA
10 Casquillo interior lado B 1 85x112x32 F-114
11 Casquillo exterior lado B 1 85x120x32-R F-114
12 Piñon freno Stromag NFF-160 1 80x160x125
13 Freno Stromag 1 NFF-160
14 Encoder Kubler 1 A020H RS422
15 Tapa encoder 1 8.46.33 Fibra vidrio
16 Junta caja bornas 1 8.44.03-B EPDM60 sh.
17 Caja de bornas tornilleria y racores 1 8.44.03-24 Fe. Fundido
18 Placa de bornas con tornilleria 1 Nº 930
19 Junta tapa de bornas Ø4 1 8.44.03 EPDM60 sh.
20 Tapa de bornas y tornilleria 1 8.44.04 Fe. Fundido
21 Junta caja de bornas (encoder) 1 6.04.03-A1 EPDM60 sh.
22 Caja de bornas tornilleria y racores (enco.) 1 6.04.03 Aluminio
23 Regleta gris 10 agujeros 1
24 Junta tapa de bornas Ø2 (encoder) 1 6.04.03-B EPDM60 sh.
25 Tapa de bornas y tornilleria (encoder) 1 6.04.04 Aluminio
26 Junta ventilador 1 8.45.40A EPDM60 sh.
27 Visera laberinto caracol 1 Caldereria
28 Rejilla ventilador 1 Chapa
29 Caracol ventilador 1 200/1070 Caldereria
30 Rodete ventilador 1 200/1070 Caldereria
31 Brida ventilador 1 130.5x420x5 Caldereria
32 Tapa brida (ventilador) 1 6.01.23-5 Fe. Fundido
33 Carcasa y estator (ventilador) 1 6.01.20 Fe. Fundido
34 Rodamiento lado A (ventilador) 1 Nº6205-2RS
35 Eje y rotor (ventilador) 1 EJEKV092N001 F-114
36 Rodamiento lado B (ventilador) 1 Nº6304-2RS
37 Tapa trasera (ventilador) 1 6.01.01-1 Fe. Fundido
38 Rodete refrigerador (ventilador) 1 1,022.00 Plastico
39 Caperuza (ventilador) 1 6.01.05 Chapa
40 Junta caja de bornas (ventilador) 1 6.04.03-A1 EPDM60 sh.
41 Caja de bornas tornilleria y racores (vent.) 1 6.04.03 Aluminio
42 Placa de bornas con tornilleria (vent,) 1 Nº500
43 Tapa de bornas y tornilleria (ventilador) 1 6.04.04 Aluminio
40
39 14
41 31 33
35
34 33
36
2
38
4
16
24
45 27
15
23
3
9 1 12
18 13
10 21
21 8 11 55
6
20
22
25
23
42
49
52 7
17
20 37 53
22 54
25
28
29
30 56 26 37
19 46
44 48
49
23, 24 32
29
25, 26 16
14, 13, 12
39, 26 26
30
22 16 38
19, 20, 21
26, 34, 35
11
36, 43
40, 41, 42
33
16 28, 14
32
15 27
26, 34, 35
31
14, 13, 12
2
7
37
6
1
5
8, 9, 10 3, 4
9, 7, 8
3
10, 11 4 9, 7, 8
6, 7, 8
1 2
31
32
33
8
9
10 5
6
7
13
30
7
11
12 3
14
21
22
23
24
25
28
31 29
32
33
19
20
26
27
16
17
18
15
35 5
36 6
37
2 1 5
6
6
7
23 3
24
25 9
18
19
16 20
17 21
12
13 29
14 30
15
6
7
26
8
22
27
28
6
7
10
11
31
32
33
34
39
7 40
11
10 39
12 40
20
21
22
30 31
32
7
9
10 17
11 18
12 19
12
14 2
15
26
27
36 28
37 29
38
23
24
33 25
34
35
41 7
42 8
43
44 4
45 5
46 6
14
26
4
10 2 28 7
19
26 26 29 22
30 23
24
19
26 3
26
6
26
13
22
9 14 17 23
26 27 24
11
22 28
23 2 29
14
24 26 26
16 8
18 19 10 27 22
22 26 28 2 23
38 37 23 29 26 24
38 22 25
40 23 36
41 25 26 6
26
12
19 22
26 23
24
4
28
15 29
27 30
28
9 14 29
26
11
22
23 2 19
24 26 5 26
22
23
25
20
26
4,5,6,7,8
16
11,12
17 9
20
10
17
18
10
19
20
21
22
15 11 2
3
16 12
4
13
5
14
6
21LC290/18 t 16053 / 54 / 55 / 56
EFU5-50-45-00 / 57 / 58 / 59 / 60