Driving a crane truck is not easy, but quite interesting. Anyone who at least once saw a professional driver competition was probably delighted with how a professional closes a matchbox with a hook without crushing it. Each driver has his own experience, and he does not tell uninitiated people about them.
However, knowledge of the basics of working as a crane driver is interesting and useful even for an employer of equipment for loading and unloading or construction work.
In construction, they are usually used for laying the foundation. Loading and unloading operations are carried out either manually or using equipment. The first method is called manual, the second is mechanized. The latter is obligatory for loads weighing more than 50 kg, as well as for lifting loads to a height exceeding 2 m.
If the crane is used at a construction site, then before starting work, the truck crane driver must read the project of construction and installation work. If loading and unloading operations are coming, then inspect the site where they will be carried out. If there is a power line near the work site (less than 30 m), the driver will need a permit to get started.
It is allowed to use only a truck crane with a resource that has not yet been developed. It is technically prohibited to operate decommissioned cranes.
Before starting work, the driver inspects the machine that has not yet been started, checking its technical condition. Then the operator starts the crane to idlingto make sure the mechanisms are working properly.
The place where the work takes place must be well lit. If the working area is in heavy fog or it is snowing, which does not allow the crane operator to clearly distinguish between the load and the gestures of the slinger, work is stopped until the weather conditions change. The crane operator does the same in the event of a thunderstorm or strong wind.
AT winter time work on the truck crane can be performed only at a subzero temperature permissible by the vehicle registration certificate. There is also a limitation on air humidity at taps. Usually, if the air temperature is above 25 ° C, its humidity should not exceed 80%.
If the work is accompanied by more rigid climatic conditions (for example, tropical or Far North), you will need a special model of the truck crane.
The truck crane must be serviced by at least two people: the driver and the slinger. Some firms believe that one person can do it all. But this must not be allowed, since the driver must not leave the control panel. Only being in the cockpit can he control the situation.
The functions of the slinger include securing loads for lifting. For this, he uses a special device - slings. Each slinger undergoes professional training, no one will take a person "from the street" to fasten heavy dangerous goods... On the contrary, the more experienced the slinger, the better. Indeed, when securing other "non-format" loads, sometimes you have to apply engineering thought!
One slinger can handle a load weighing 5-10 tons. If the load weighs 40-50 tons, then it is physically impossible to sling it to one person. In some cases, the efforts of three or more slingers may be required, for example, if the work is impeded by severe climatic conditions or the load weighs up to 100 tons. The fixed load must necessarily take a stable position. If there is no information about the weight of the cargo, then they strap and move it, only having determined the actual weight.
Lifting, lowering, carrying load, braking are performed smoothly, without jerking. The lifted and moving load must be at least half a meter higher than objects that meet in its path.
There is a widespread stereotype that accidents inevitably occur at a construction site. However, there is a risk in any technical work - for example, in shipbuilding, car repairs and even during installation. electrical wiring residential building. Therefore, any work requires compliance with safety measures.
Moscow Masters 2015. Truck crane operator
Video: Rental of special equipment and cargo transportation services without intermediaries!
Driving a crane truck is hard but interesting work. Those who have at least once seen the competitions of professional skill of drivers, probably admired how professionals close a matchbox with a hook without crushing it. Each driver has his own experience, which he is unlikely to tell to uninitiated people. But the basics of working on a truck crane are useful and interesting to know even for those who simply hire equipment for loading and unloading or building a house.
During construction, truck cranes are usually used for "zero cycle" works, that is, when laying the foundation. Loading and unloading operations can be carried out either manually or using machinery. The first way is called - manual, the second - mechanized. The latter is mandatory for loads weighing over 50 kg, as well as when lifting loads to a height of more than 2 m.
Before starting work, a truck crane driver reads a project of construction and installation works, if the crane is used in construction, or inspects the site where loading and unloading will take place. If there is a power line closer than 30 meters from the working site, the driver must obtain a work permit for the crane.
A truck crane is allowed for use, the resource of which has not yet been developed. The operation of decommissioned cranes is technically prohibited.
Before starting work, the driver inspects the crane that has not yet been started, checks the technical condition of the mechanisms, readiness for work. Then the operator checks the serviceability of the mechanisms at idle speed.
The area where the work is taking place must be well lit. If there is heavy fog, snowfall within the working area, and the crane operator does not distinguish between the load and the signals of the slinger, work stops until the weather conditions improve. The crane operator does the same during a thunderstorm or in strong winds.
In winter, the truck crane can only work at the permissible subzero temperature specified in its data sheet. For example, the KS-45717 truck crane can be used at temperatures from +40 to -40 degrees Celsius. Cranes also have humidity restrictions environment... Typically, at temperatures above 25 Celsius, humidity should be no more than 80%.
For work in more severe climatic conditions, for example, in the tropics or in the Far North, special models of truck cranes are produced.
The truck crane must be serviced by a team of at least 2 people - a driver and a slinger. Some firms assume that one person can be both. But technically, this is unacceptable, since the crane operator must be in the cab all the time, at the control panel. From there, he controls the situation.
A slinger is a person who secures loads for lifting. There are special devices for this - slings. All slingers are trained by profession, no one will take a person "from the street" to fix tons of bricks and metal. On the contrary, the more experience the slinger has, the better. Indeed, when securing various loads, sometimes you have to solve very tricky engineering problems!
A load weighing 5-10 tons can be secured by one slinger. It is physically unrealistic to sling a load weighing 40-50 tons alone. In some cases (cargo weighing 80-100 tons, special climatic conditions, etc.), three slingers and even more may be needed. The load is secured only in a stable position, not in any way suspended or at an angle. If the weight of the load is unknown, it will only be lifted and moved after determining the actual weight.
Lifting, lowering, transferring the load, braking are performed smoothly, without jerking. During movement, the load must rise above the objects encountered on the way by at least half a meter.
Don't believe the stereotype “Construction is a place where accidents happen all the time”. Any risk technical work - shipbuilding, car repairs and even wiring in a residential building. Therefore, they all require compliance with safety measures. What can not be done when the truck crane is working, we talk in detail in the corresponding article. And if you do not make gross mistakes, working with a truck crane will be just a technical process. Quite challenging - and just as exciting.
Crane control
Technically competent crane control ensures high performance and trouble-free operation. Excellent mastery of the levers and other crane controls is one of the basic requirements for an operator. Underestimation of this issue, recklessness while working on a crane or, conversely, the manifestation of lethargy, sluggishness in management can easily lead to serious consequences and even accidents.
Crane control consists of the following elements: correct use of levers and other crane controls in accordance with the operations performed; maintenance of the control system in excellent condition; adjustment of the control system and especially clutches and brakes.
The location of the levers and other controls on the crane, the combination of on and off of individual levers when performing a particular operation depends on design features crane; usually these data are indicated in the passport of the crane and in the instructions for its operation.
When operating a crane using lever systems, two possible options should be kept in mind:
1) if the engine driving the crane's power mechanisms has one direction of rotation (for example, a non-reversible steam engine), then each position of the lever will correspond to a well-defined operation performed by the crane;
2) if the engine is reversible and capable of changing the direction of its rotation, then there will be no such correspondence (for example, with the same position of the lever, the crane can rotate both to the right and to the left, depending on the direction of movement of the engine). Therefore, if, with a non-reversible engine, it is possible to quite accurately establish the order of switching on the control levers and their positions, then with a reversible engine, the most rational combination of the positions of the levers can only be recommended.
A non-reversible steam engine is installed on the PK-TSUMZ-15 steam valve, which allows you to accurately indicate the position of one or another lever or pedal when performing certain operations by the crane. Table B 25 shows data on the positions of the crane control levers PK-TSUMZ-15.
Skillful crane control allows you to combine operations, that is, to perform several operations simultaneously. In this case, the position of the levers corresponds to their positions when performing each operation separately. It should be borne in mind that the simultaneous execution of a number of operations is either completely impossible, or adversely affects the crane mechanisms. For example, for some cranes, it is not allowed to change the boom reach with a load on weight, and even more so at the same time to perform any other operations, since in this case difficult conditions operation of the boom lifting mechanism, on the one hand, and on the other, it is easy to exceed the maximum permissible reach for the raised load, which will disturb the stability of the crane.
It is also necessary to avoid, even on a horizontal section of the track, the simultaneous movement of the crane and its rotation if there is a load on the hook close to the maximum permissible for a given outreach. how general rule, it should be recommended to turn off all mechanisms that are not needed when performing a particular operation; braking means in these mechanisms are desirably activated.
In fig. 186 shows levers and pedals for controlling the PK-6 crane. This crane has a reversible steam engine as an engine, as a result of which recommendations on the order of switching on and off the control levers are given in the most general form.
Direction of rotation crankshaft steam engine is changed by the rocker control lever, and the middle position of this lever corresponds to the middle position of the rockers, at which the machine does not work.
The extreme positions of the rocker arm correspond to two opposite directions of rotation of the crankshaft.
Figure: 186. Levers and pedals for crane control PK-b:
1 - lever for engaging the load clutch; 2 - lever for engaging the clutch of the grab; 3 - lever for engaging the clutch of the main shaft; 4 - lever for turning clutch engagement; 5 - lever for engaging the travel clutch; b - lever for switching on the boom lifting clutch; 7 - turn brake pedal; 8 - movement brake pedal; 9 - load brake pedal
Table 25 
The position of the rocker lever "From itself" corresponds to forward motion steam engine, rotation of the crankshaft clockwise, and the lever position "Towards you" corresponds reverse steam engine.
The start and stop of the steam engine, as well as the regulation of the rotation speed of its crankshaft, are carried out by the steam regulator lever. The “Pull” position of the regulator lever corresponds to the closed position of the regulator, and the “Push” position corresponds to the opening of the regulator and steam access to the steam engine cylinders. In this case, the further the lever is deflected from itself, the more the regulator will be opened and the higher the number of revolutions of the crankshaft of the machine.
All crane lift mechanisms are operated by six levers and three foot pedals.
To perform certain operations with a PC crane. -6 it is recommended next order transfer of levers and parts from one position to another.
Lifting the load. To lift the load it is necessary to put the rocker lever in the "From yourself" position, and the levers of the load clutch and grab - to the "Towards" position.
Set the remaining levers to the positions at which the corresponding clutches will be disengaged. Disengage the gear of the grab drum.
The load is lifted by opening the regulator, while simultaneously pressing the load brake pedal. Lifting of the load stops when the regulator is closed and the load brake pedal is released. Both of these operations are performed at the same time.
The release of the load can be performed either on the brake When the load is up to 2 tons, or with a counter pair when the load is over 2 tons. In the first case, the load brake pedal is gently pressed, as a result of which the load is lowered by its own weight; In this case, the load clutch lever must be set to the "Push" position. In the second case, the regulator is slightly opened and the load, lowering under its own weight, is restrained by the steam engine; the position of the levers should be the same as when lifting the load.
Boom lift. To raise the boom, the boom clutch lever must be set forward (away from the boiler). The levers of the rocker and the main shaft can be in any, but the same position: if one is in the "From itself" position, then the other lever must also be in the "From itself" position.
To lower the boom, it is necessary to change the position of the rocker arm or the main shaft lever so that both of them occupy opposite positions: if one is "Toward", then the other must be in the "Toward" position.
To move the crane it is necessary to set the boom clutch lever to the "Back" position (towards the boiler), while the position of the main shaft lever can be any. The position of the rocker lever for forward and backward movement should be checked with test runs and memorized.
The various positions of this lever depend on the position of the lower frame of the crane and will be constant until the crane makes a turn on the turntable.
Turning the crane. To turn the crane to the right, the rotation lever and the rocker lever must be set to the same position: either both "Towards you", or both "Towards you". To turn to the left, these levers should be directed in different directions, if one is "Toward yourself", then the other is "From yourself".
When working with a grab, the following operations are possible: lifting the grab, opening the jaws, lowering the open grab, picking up the load, secondary lifting, turns, movement.
To perform these operations, use the rocker levers, grapple and load clutches, load brake pedal and adjuster lever. All other levers must be in positions corresponding to the disengaged clutches and the brakes.
The positions of the levers when performing operations with the grab are given in table. 26.
Table 26 
When performing the operation "Seize the load", it is necessary not to allow the supporting ropes to sag. To do this, as soon as the grapple jaws close, turn on the grab clutch by moving the lever to the "Towards" position.
If there is a jam and the grab does not open under its own weight, then it can be opened using a steam engine. To do this, the load clutch lever must be placed in the "Toward" position, the link lever must also be moved to the "Toward" position and smoothly open the steam regulator.
As you can see from the table. 26, grapple operations can be performed with one rocker arm position and only two levers and one pedal movement, allowing all operations to be performed quickly one after the other, ensuring high productivity.
When working with a grab, just like with a hook, you have to turn and move the crane. Depending on whether it is necessary to turn or move the crane, the corresponding additional levers are connected, while most often the operations of lowering or lifting the grab are combined with turning the crane.
In fig. 187 shows the pneumatic control circuit power mechanisms crane KDV-15p.
All crane mechanisms are controlled from one operating panel by eight levers of the pneumatic system and two foot pedals that duplicate the pneumatic control of the brakes of the right and left drums. The presence of redundant drum brake control systems allows them to be controlled both by hand levers and by pedals, which is often more convenient, especially when working with a grab, when it is very important to have a gradual depressing and disengaging of the brakes.
Compressed air from the compressor installed on the engine, through an intermediate sump and oil-moisture separator, enters the receiver and, through the spools activated by the levers on the control panel, enters the desired pneumatic cylinder, activating one or another mechanism.
The vertical position of the levers on the control panel corresponds to the neutral (non-engaged) position of the clutches and the braked state of the brakes. Table 27 shows the positions of the levers and pedals when performing basic crane operations both when working with a hook and when working with a grab for handling bulk cargo.
Observing technical condition the pneumatic control system and keeping it in proper working order are very important.
Pneumatic control along with clearly positive sides (ease of control, speed of response) has a number of easily vulnerable spots, faults in which disrupt the operation of the entire system.
The following basic requirements are imposed on the pneumatic system: it must not pass air through rubber sealing rings and oil seals, from main pipes, in cylinders, spools and rotating joints; entering the line and cylinders compressed air must not be wet and must not contain oil, as the moisture in the air in winter condenses and freezes in the pipelines.
The presence of oil has a detrimental effect on rubber seals, it erodes them relatively quickly and reduces their durability. In order to prevent contamination and humidification of clean and dry air, it is necessary to carefully monitor the condition of the oil-moisture separator, drain condensate more often through drain valves, periodically flush and clean the oil-moisture separator from contamination. Good cooling air in the outdoor receiver protects the line from moisture condensation in it and largely protects it from freezing in winter.
Figure: 187. Pneumatic control of the KDV-15p crane:
1-lever to control the boom lifting mechanism; 2 - lever for controlling the clutches of the travel mechanism; 3 - left drum brake control lever; 4 - control lever of the left drum clutch; 5 - right drum clutch control lever; 6 - right drum brake control lever; 7 - lever for controlling the slewing mechanism clutches; 8 - swing brake control lever; 9 - control cylinder of the right drum clutch; 10 - control cylinder of the left drum clutch; 11- oil-moisture separator; 12 - sump; 13 - receiver; 14 - compressor; 15 - rotation clutch control cylinder; 16 - boom lift clutch control cylinder; 17 - control cylinder of the travel mechanism clutch; 18 and 19 - brake pedals; 20 - control panel; 21 - steering brake control cylinder; 22 - cylinders for controlling brakes of the right and left drums
Table 27 
In fig. 188 shows a control panel for a diesel-electric crane KDE-151.
The control of this crane is electric by means of a series of controllers, command controllers, contactors, relays, buttons and switches. Monitoring and control over the operation of the engine and all electrical equipment are carried out by instruments located also on the control panel. The engine is controlled by a button, when pressed, the starter is turned on to crank the engine when started by the handle that controls the diesel fuel supply. To perform individual operations with a crane, it is necessary to turn it on and observe the following procedure for turning on the controls.
Self-propelled crane movement. The crane travel mechanism is activated by a handle. Moving it "Towards itself" or "From itself", it acts on the controller and, through the corresponding contactor, turns on the electric motors of the movement mechanisms, while the movement of the crane forward or backward is oriented according to the location of the crane running frame, that is, with one position of the handle, boom forward, and the cab forward, depending on the position of the upper rotary part relative to the chassis.
The handle has five positions (positions) on each side of the neutral position. It is necessary to move from one position to another gradually as the crane accelerates, reaching maximum speed in the 5th position. At the same time, a long delay at intermediate positions can cause excessive overheating of the starting resistors. The movement of the crane is stopped by moving the handle to the middle, neutral position without delay at intermediate positions, while the brake of the mechanism remains open and you must press the pedal to brake.
Boom lance change. To change the reach of the boom by changing its tilt, the control panel has a button station with three buttons corresponding to the movement of the boom: "Up", "Down" and "Stop". By pressing the "Up" button, the mechanism is turned on to lift the boom, while the lift is automatically stopped when the boom reaches the upper limit position due to the triggering of the limit switch. For the lower position of the boom, there is no limiter on the crane, so when you press the "Down" button, you must monitor the amount of rope on the drum and stop lowering when 1.5-2 rope turns remain on the drum.
Turning the crane. The swing mechanism is activated by the handle, while the "Toward" handle transfer provides the crane to turn to the right, and the "Move" transfer - the left turn. The handle has five positions for each side. In the last, 5th position, the swing speed is the highest - 2.6 rpm. The swing mechanism has a centrifugal friction clutch, which ensures smooth operation of the mechanism. The handles should be turned on gradually from position to position, to avoid overheating of the ballasts again, it should not be delayed for a long time in intermediate positions. Braking of the mechanism is carried out automatically simultaneously with turning off the electric motor, while pressing the button you can leave the mechanism unbraked until the button is released.
Figure: 188. Crane control panel KDE-151:
1-emergency switch; 2- control handle for crane rotation; 3 - control button for the motor-generator group; 4 - handle for controlling the cargo drum (right); 5 - button to control the line contactor; b - diesel fuel supply control handle; 7-button boom lift control station; 8- diesel starter start button; 9 - switch "transformer - accumulator"; 10 - handle for controlling the cargo drum (left); 11 - handle for controlling the movement of the crane; 12, 14, 16 - switches for lighting and heating; 13, 15, 17 - generator devices; 18, 20, 21, 22, 23 - diesel devices; 19. 24, 26 - switches for searchlights and signal lights; 25 - sound signal button; 27 - protection unit; 28 - cargo electromagnet control button; 29- right cargo drum release pedal; 30 - button for releasing the swing mechanism; 31- did not give a movement brake
Lifting and lowering the load. A feature of this crane is that it can lift the load with either of the two cargo drums or both at the same time, in the latter case, the lifting speed is twice as high.
The load lifting mechanism is controlled by the handle for the right drum and the handle for the left drum of the load. When these handles are moved to the "Towards" position, the mechanism is activated to lift the load, and by moving "Towards" the rotation of the drums ensures the release of the load.
Both handles for each side have three positions, with the 3rd position corresponding to highest speed lifting.
When lifting a load, it is necessary to monitor the winding of the rope on the drums, avoiding excessive winding on one of the drums by unwinding from the other, for which lifting should be done alternately with each drum.
When lowering a load, especially loads over 10 tons, the engagement of the levers should be moved to the last position as quickly as possible, since the lowering speeds can be increased at intermediate positions.
When stopping the load on weight, the handle should also be placed in the middle position, without lingering at intermediate positions. In addition, weights over 10 tons are recommended to be lowered alternately on two drums, preventing the development of high speed sinking. Forced lowering of the load from a low height can be performed by pressing the pedal when the load is lowered on the right drum without activating the mechanism.
Management when working with a grab. When working with a grab, the position of the handles and their switching sequence are as follows:
1. To lift a closed grab, it is necessary to move the handles 4 and 10 to "Towards you".
2. To open the grab by weight, you must put the handle 10 in the "From yourself" position, and all other handles must be in the neutral position.
3. To lower the open grab, you need to put both handles 4 to 10 in the "From yourself" position.
4. The load is picked up by the grab when the handle 10 is moved to the "Toward" position and the pedal is pressed, which provides the support rope undercutting for better penetration of the grab into the bulk load.
The combination of these operations with the operations of turning or moving the crane is achieved additional control handles.
In emergency cases in the event of abnormal operation of any mechanism, it is necessary to use an emergency switch, when turned off, all power circuits are de-energized, after which all levers should be put in neutral positions. Then you need to calmly understand the condition of the crane and, by turning on the button, take the crane out of the dangerous position.
The main requirement for lever control systems is the absence of backlash of the levers caused by increased slack-backlash in their joints.
To reduce backlash, it is necessary to systematically monitor the wear of the working surfaces in the hinge joints, to lubricate the working surfaces in a timely manner and well, avoiding their contamination.
It is not recommended to allow setting instead of rollers in the hinges of any other parts. Worn rollers must be replaced with new ones in time. The developed holes can be corrected with a sweep with a diameter of 1-2 mm larger than the holes themselves with the replacement of rollers or skillfully welded with electric welding followed by sweeping.
Each roller must be securely fastened with a check, pin or cotter pin; the fastening of the rollers by welding is in no case allowed.
Of great importance to normal work the levers have a state of locking devices. Latches and pawls of latches must act freely, without distortions and slack. The tabs of the latches, as well as the slots into which they fit, must have the correct shape. Poor fixation of the position of the levers can lead to spontaneous shutdown or activation of the lever and cause serious consequences. It is recommended that the surfaces of all hinges and latches be hardened.
Lever control systems are usually controlled by turnbuckles, mainly turnbuckles. Turnbuckles regulate the lengths of the rods in the system, after which they are secured using locknuts or other means, but so that they do not weaken in operation.
When electrical control crane, the excellent maintenance of the controls depends on the correct handling.
For trouble-free operation of electrical equipment, it is necessary to prevent its contamination and the ingress of oil and foreign objects into it. All equipment, depending on the installation scheme, must be protected either by separate protective covers or be in closed cabinets.
The fixed contacts must be tightly clamped and reinforced immediately if they are loose. In case of burning, moving contacts should be promptly cleaned, refilled or replaced with new ones. In no case should you allow the contacts to be closed by foreign objects, the setting of various kinds of jumpers or the disconnection of faulty equipment from the system. If malfunctions are identified in one or another equipment, it must be repaired with the participation of an electrician.
Adjustment of crane control systems is mainly reduced to adjusting the clutches and brakes.
The cam clutch control system must be adjusted so that the middle position of the lever or engagement handle corresponds to the middle position of the clutch, if it is two-sided. When the lever or handle is moved to the extreme position, the clutch must move until it is fully engaged.
The control systems for friction clutches and brakes must be so adjusted by the turnbuckles in the levers or by the position of the pistons-plungers in the working cylinders (when hydraulic system), so that when the lever or control handle is turned on, a reliable tightening is achieved (adhesion of the friction surfaces), and when moving to turn off, a complete departure of the friction surfaces from each other is ensured. Depending on the design features of the friction clutches and brakes, the amount of retreat of the engaging surfaces is different, but on average it fluctuates within 1-2.5 mm. If at least partial contact of the friction surfaces occurs when the lever is off, this will cause friction and, as a result, overheating and wear of the clutch. Excessive heating of the clutches can be the result of insufficient force of pressing the friction surfaces against each other, as a result of which they can slip. In such cases, first check the clutch adjustment and then the entire control system.
Disk friction clutch crane PK-TSUMZ-15 (see Fig. 94) is adjusted as follows.
The fist is put in working position, equalize the uniformity of pressing the two-armed levers on it, for which the nuts are tightened or released. Having loosened the tie bolt and turning the adjusting nut, tighten it to failure, after which the fist is placed in the middle position, and the nut is additionally tightened by turning it by 50-70 °. Having installed the adjusting nut in this way, fix its position with a tightening bolt.
Brakes, both band and shoe, are usually adjusted by changing the amount of strips or pads moving away from the friction surfaces when the brake is released. The amount of waste should not be particularly large and most often is 1.5-2 mm. In closed-type brakes, in addition to the retreat of the pads or bands, the tightening force is also adjusted by tightening the brake operating spring or increasing the counterweight arm by moving it along the lever.
The clutches and brakes should be adjusted so that during work with a change in the size of the load being lifted, intermediate adjustments are not required, that is, so that the clutches and brakes work equally well both when lifting small loads and when lifting heavy loads.
TO Category: - Organization of railway cranes
1.Description of XCMG QY25k5 Truck Crane Computer
If you need spare parts for Chinese mobile cranes, go here
Torque limiter series NS4900
Using a variety of signal sensors, the limiter can
control the control of various functions of the crane, and also provides
load data to the crane driver. Changes in crane operation
reflected directly in numerical values.
The limiter provides the crane driver with such information,
as the length and angle of the lifting jib, height, operating amplitude, nominal and
If the control of the crane is outside the permissible range,
torque limiter НС4900 will warn the crane driver about it.
At the same time, the warning light will light up and the work of those parts will stop
crane that could damage the control of the system.
2. Warning
In the case when in the operation of the crane may occur
malfunctions that can lead to loss of life or equipment breakdown,
the limiter sends a special warning signal for use
auxiliary device.
but this device cannot replace a balanced
driver's decision. Driver experience and competent machine control in accordance with
operating rules are essential conditions for safe
use of equipment.
The driver is responsible for driving safety. He must
carefully read and understand all points in this manual.
Attention!
If the limiter works correctly, no errors are allowed in the control, thenthe information on the indicator will be as useful as possible for the driver, in order to prevent accidents with fatalities and damage to equipment, when installing the limiter, you need to carefully check whether everything is in order.
3. Description of the system
NS4900 series torque limiter can be installed on
most cranes. It is necessary to calculate the moment of force and calculate the weight
load to avoid overloading and to prevent dangerous handling.
The HC4900 system is able to calculate the length, the angle of the crane boom,
maximum lifting height, operating amplitude of the crane, nominal lifting weight and
other data. The limiter by measuring these nodes is able to calculate
the value of the moment of force. When control goes beyond safe,
a warning signal appears on the LCD screen, at the same time
the control device sends the appropriate command, informing the driver that
you need to suspend work.
Functions, features and instructions for use are described below.
operation of the NS4900 series torque limiter .
4. Structuresystem we
1. Main mechanism - central controller.
2. Box of connecting wires CAN (local area network of controllers)
3. Indicator with color liquid crystal image
4. Oil pressure switch
5. Length / angle sensor
6. Height limit switch and weight
5.Instruction to control the crane truck computer
After normal adjustment, the force limiter can work automatically, therefore the crane driver must operate guided by knowledge of the limiter system, only the field of correct adjustment can be started.
6. Functions and control method of XCMG QY25k5 truck crane computer
6.1 Pointers
1. Height limit indicator
2. Warning indicator
3. Overload indicator
A. Barcode
B. Scope of work
C. Diameter reading area (shows steel wire rope data)
D. Boom length display area
E. Range of indication of the maximum lift height for a given
position of the tap
F. Angle display area for primary lifting boom
G. Range of indications of the working amplitude of the crane
H. Display area for actual load weight
I. Range of indications of rated lifting capacity
J. Level display area
K. Weight range
L. Wind speed display area
M. Time display area
N. Function button
O. Button for setting operating parameters
P. Cable Extension Adjustment Button
Q. Fault diagnosis button
R. Mute button
S. Outrigger status indication area (1/2% extended halfway, 1: fully extended).
Note: The two rows of numeric buttons represent the corresponding given numbers.
6.2 Method of control of the mobile crane computer
6.2.1 Language selection (Chinese / English)
The 4900 limiter system uses the IC4600 monitor and provides readings in both English and Chinese. When you turn on the system by default, the readings are displayed in Chinese, if you want to set the English language, follow the instructions: Press the "functions" button of the main menu shown in Fig. 1 (in the figure designation N) and go to the "functions" menu, shown in fig. 2.
Figure: 2 Function menu
Click the button shown in Figure 2 to change the Chinese language to English. To switch of English language press this button again, please note that after changing the language to English, the set language may not be saved for a long time. After the next connection to the power supply, you must re-install the desired language. After changing the language, the panel looks like this:
Figure: 3. Menu of functions of the computer of the truck crane after turning on the English language
6.2.2 Switching the measuring system
In order to meet export requirements, the monitor may display metric or inch units. The default is metric units. If you need to switch the system of measures in inches, follow the instructions: Press the main menu button.
To switch metric system press this button again.
Figure: 4 Function menu after switching on the measuring system in inches
6.2.3 Setting the operating parameters of the xcmg mobile crane computer
Setting the operating parameters is the setting of the limiter parameters according to the actual operating environment of the crane. When the crane is operating, it is necessary that the indicator readings coincide with the real working environment. Before starting work according to the crane model and working environment, find the job number, the readings should be adjusted to the actual situation.
Important to remember:Correctthe setting of operating parameters is an important factor that ensures faithfulsystem and crane operation. The system and the crane can be controlled only a highly qualified specialist. Do not work on a crane if the setting of parameters does not correspond to the real ones. Way correct installation working parameters:
When you need to adjust the limiter readings, click on the button in the main menu, and go to the menu "setting operating parameters" (Fig. 5)
Fig. 5 Operating parameters setting menu
In this menu, by operating the digital and functional
with the buttons, you can match the operating value displayed by the indicator and the actual control state. For example, setting the operating mode 1: first press the button, and in the column "new code" will display "o", press the button "1", and in the column "new code" will display "1". Press the button to confirm the set parameter and return to the main menu. If you need to set the operating mode 21: first press the button, while in the column "new code" will display "o", then press the number buttons "2" and "1" while in the column "new code" will display "21". Press the button to confirm the set parameter and return to the main menu. Press the button to cancel the set parameter. For specific parameter codes see paragraph 6.2.8
6.2.4 Setting the multiplicity of cable increase
The setting of the magnification is the information that is necessary in order for the limiter to set the magnification of the steel cable. The driver must adjust the actual and displayed cable gain before starting the ascent. Displayed and actual values \u200b\u200bare equal if:
The panel displays 1 - 16
Increasing the steel rope 1 - 16
Press the button in the main menu and go to the menu "setting the multiplicity of cable increase" (Fig. 6).
Figure: 6 Menu for setting the zoom ratio
The method of adjusting the cable magnification ratio is similar to setting the operating parameters.
6.2.5 Information on failures in the safety system
Press the main menu button and go to the fault information menu. This menu provides information on faults (description). This information will help you with maintenance and troubleshooting.
Figure: 7. Menu with codes and information about faults
Press the "up" and "down" button to identify the DTC. Press the button to return to the main menu.
6.2.6 Setting time and date
To set the time, press number 1 in the function menu (Fig. 2) and go to the “time setting” menu.
Figure: 8 Time setting menu
To set the time, follow the instructions: By pressing the function buttons select the object to be changed and use the number buttons to enter the data. For example, you need to set the date to 1.05.08 and the time to 18:30. Using the buttons
"Up" and "down" move the green point to the "year" position and press the number buttons "0" and "8". Press the down button to set the month, press the number buttons "0" and "5". Press the down button to set the number, press the number buttons "0" and "1". Press the down button to set the hour, press the number buttons "1" and "8". Press the down button to set the minutes, press the number buttons "3" and "0". Press the button to confirm the set parameters. After installation, the menu looks like this:
Figure: 9. Time setting menu
Note: after setting the time, the seconds countdown starts from "0"
6.2.7 Checking CAN status
To check the CAN status, press button 2 in the function settings menu. In this menu the operator can check the operation of the main CAN wire. If the wire is faulty, the cause of the fault is displayed. In this case, a green square - the work of the part is normal, yellow - the part is ready for work, red - a part malfunction.
Figure: 10. CAN Status Check Menu Press the button to return to the main menu.
6.2.8 Checking the operating parameters
Press number button 3 in the main menu to enter the "check operating parameters" menu. Use the up and down buttons to scroll through the operating parameter codes. Press the button to return to the main menu.
Fig. 11 Menu for checking operating parameter codes
6.2 Setting the lower and upper limit of the angle of the truck crane xcmg
The torque limiter system can limit the operating angle of the lifting arm, this will help the driver to maintain safe and moderate driving in the presence of obstacles (structures, bridges, high voltage lines).
Attention! The boom angle limiting system of this system has a warning function and controls all dangerous actions. When you turn on the limiter again the limit value must be set again.
6.3.1 Setting the upper limit of the angle.
According to the situation, increase the boom amplitude to the maximum safe position. Click on the button in the main menu, on the left side of the upper limit of the boom angle value will appear. This sets the upper limit of the boom angle to the current angle position. When the limit value is increased, the indicator lights up and at the same time a warning signal sounds to remind the driver to operate the crane more safely.
Attention: the set angle of the upper limit cannot be reduced to the already setangle of the lower limit.
6.3.2 Setting the lower angle limit
Decrease the boom amplitude to the minimum safe position as appropriate for the situation. Click on the button in the main menu, the lower limit of the boom angle appears on the left side of the arrow. The limiter then sets the lower boom angle limit as the current angle position. When the limit value is reduced, the indicator lights up and at the same time a warning signal sounds, reminding the driver to operate the crane more safely.
Note: the set lower angle limit cannot be increased up to the already set upper angle limit.
Example: The setting of the upper limit angle of 75º and the lower limit of 60º is shown below.
Fig. 12 Menu bar after setting upper and lower angle limits
6.3.3 Removing an angle limit
Press the numeric button "0" in the upper and lower angle limit setting menu, thus you will cancel the set angle limit.
The horn of the HC4900 system emits a warning signal in the following situations:
Exceeding the maximum rated load moment
Boom hook approached maximum height
Exceeding the working area of \u200b\u200bthe crane
Restraint system problems
Management errors
Click on the button on the main panel, so you can cancel the warning
sound signal 20S.
6.5 Description of the indicators of the xacmg car floor computer
6.5.1 Height limit indicator
When the weight of the height limit switch and lifting equipment is touched, the
the red indicator of the limit switch and an audible signal (buzzer) sounds, this means that the limit height is close. It is necessary to stop lifting, extending the boom, changing the amplitude. To prevent injury to people and damage to the crane, check the height limit switch systems before starting work.
Checking method:
Raise the height limiter by hand, the indicator should light up and a beep appears.
Raise the lifting equipment slowly or change the amplitude, extend the boom to extend the height limit switch weight, the indicator should light up and a beep sounds. Boom lift, amplitude change, boom extension should stop.
If the buzzer and indicator did not work, the crane did not stop working, this indicates a system malfunction or a crane malfunction, it is necessary to eliminate the malfunction and only then start work.
6.5.2 Warning indicator.
When the actual bearing torque reaches 90% -100% of the rated bearing torque, the yellow indicator is lit on the screen, it means that the overload condition is near, the operator should be careful.
6.5.3 Overload indicator
When the actual bearing torque reaches 100% of the rated bearing torque, the red indicator lights up on the screen and a beep sounds Also, this indicator is on when the overload indicator is malfunctioning. In this case, it is necessary to stop lifting, extending the boom, changing the amplitude.
7. Functions of the xcmg truck crane limiter
7.1 Warning
If one of the following situations occurs, the HC4900 system beeps and the indicator lights up:
Overloading the crane
The lifting mechanism of the crane is raised to the maximum height
Limiter system malfunction
When coordinated with the crane's electrical system, when a signal is given in the event of a hazardous situation, one of the following operations is prohibited:
Decrease boom amplitude
Boom extension
Boom lifting In this case, the system allows safe operations, i.e .:
Boom amplitude increase
Arrow retraction
Arrow descent.
Attention
If the setting to automatically stop the limiter operations
is in working position, the automatic stop signal is received
constantly. Only the functions "not the ability to perform hazardous work",
“Performing only safe operations” is associated with the crane's electrical system,
including "safe direction measuring switch",
"Safety solenoid valve". The moment limiter itself does not accept
a decision on the hazard or safety of the line of work.
8. Maintenance and adjustment methodcomputer truck crane
If during maintenance or adjustment problems, contact the manufacturer.
1) Check the connection and integrity of all wires. If you find a faulty wire, replace it.
2) Check the connecting wire of the length sensor and height limit switch, and the wire insulation, if the insulation or wire is faulty, replace it in time.
3) Check the operation of the height limit switch.
4) Check the coil of wires.
5) Check that there is no leakage from the amplitude change oil cylinder pressure sensor and the connecting pipe.
8.2 Setting the length sensor of the mobile crane xcmg
If the displayed boom length is not correct, adjust as follows:
Retract the boom to the main one, check the pre-tension of the drum with the cable (the cable must be stretched), open the outer cover of the length and angle sensor, another name is a hanging box), slowly turn the axial shaft of the length potentiometer (when rotating clockwise - increase, counterclockwise - decrease ), rotate until the actual length matches the displayed length.
8.3 Adjusting the boom angle sensor
Angle sensor and boom length sensor are installed in the same housing. When checking, first retract the boom to the main one, the displayed length should correspond to the actual one.
When doing so, check that the boom angle and amplitude match. If the displayed value does not match the actual value, the angle sensor must be adjusted. To do this, loosen the three bolts (shown by arrows in the figure), gradually move the angle sensor body until the actual value of the angle and amplitude matches the values \u200b\u200bdisplayed on the screen. Then tighten the screws.
8.4 Length of sound signal
If, after turning on the engine, the indicators displayed on the screen are normal, there is no malfunction code, but the buzzer emits a long beep, it is necessary to check the serviceability of the length measurement wire, the operation of the height limit switch, the reliability of the connection of the height limiter and the boom junction box, the connection of the height limiter, and check the wires for a short circuit.
8.5 The cable to be measured is difficult to remove
If, when retracting the crane boom, it becomes difficult to retract the cable to be measured, this may be caused by too little pretensioning of the spring inside the box or by incorrect position of the cable in the box.
In this case, it is necessary to adjust the pre-tensioning force as follows:
1) Remove the boom, place the boom on the frame.
2) Remove the fixed end of the cable from the boom and slowly rotate the blade,
so that the cable returns to the groove, to its original place.
3) Pre-stretch the box (turn the wire and make sure
so that the measured wire and the box rotate together).
4) Pull out the wire, secure the end to the boom.
5) If after adjustment the readings have not changed, check the serviceability of the length sensor or adjust it.
Attention!
Be careful when adjusting.
Incorrect adjustment can lead to accident or damage.
After graduation
make sure the setting is correct again.
9. Malfunctions of the xcmg crane computer and how to fix them
If a malfunction occurs during the operation of the crane, a malfunction code will flash on the screen.
According to this code, the operator must find the cause of the problem and fix it.
Below is the decoding of the xcmg truck crane safety system trouble codes.
|
Malfunction |
Way |
||
|
Working |
Amplitude |
Reduce |
|
|
Working |
Amplitude |
Increase |
|
|
No |
Operating state not saved code selected The main boom is in the illegal area |
Turn |
|
|
Boom length is out of scope permissible length |
1. The main boom is too extended, or vice versa, not extended enough. For example, the maximum shoulder length has been exceeded 2. Adjusted the sensor length, e.g. cable lagged behind the disc wires 3. Problems with springs in the box of wires, e.g. broken wire |
1. Extend or retract the primary boom to the desired 2. Retract the boom and Check if the sensor is showing abnormal data. Set elevation 3. Change the kit Spring including moving wheel. Thereafter Adjust the sensor |
|
|
Primary Boom Length Sensor Voltage Below Limit |
1. Breakage of the length sensor |
1. Replace the sensor 2. In the DGA6.i.3 device simulate the correct value |
|
|
Oil pressure sensor voltage below limit |
1. Breakage of the length sensor 2.Not supported by PDB 3. Breakage of electrical parts |
1. Replace the sensor 2. In the DGA6.i.3 device simulate the correct value 3.Replace the sensor |
|
|
Voltage |
See |
See |
|
|
Primary Boom Angle Sensor Voltage Below Limit |
1. Broken angle sensor 2. Breakdown of electrical parts |
1. Replace the sensor 2. In the DGA6.i.3 device simulate the correct value |
|
|
Measurements |
See |
See |
|
|
Measurements |
See |
See |
|
|
Measurements |
See |
See |
|
|
Measurements |
See |
See |
|
|
Measurements |
See |
See |
|
|
Error |
System + UB not starting system + UB system did not detect equipment activation system System on / off contact error + UB |
System Turn on / off + UB again |
|
|
Error |
Breakage of the element responsible for the system program Broken Flash EPROM |
Install working software Replace the main unit |
|
|
Program |
Not |
Install |
|
|
Not |
Not |
Install |
|
|
Error |
Breaking |
Replace |
|
|
Error Measurements |
CRC memory signal error There is no battery charge (1kOhm,<2V) Breakdown of the main unit |
Raise LMI Replace main unit battery Replace main unit |
|
|
Error |
Broken Flash EPROM |
Replace main unit |
|
|
Error |
Invalid data stored in the digital data of the crane (load curve) Broken Flash EPROM |
Set valid data Replace main unit |
|
|
Error |
Not |
Install |
|
|
Error |
Invalid data stored in the digital data of the crane Broken Flash EPROM |
Replace main unit |
|
|
Error |
Invalid data stored in the digital data of the crane Broken Flash EPROM |
Restore or install valid data Replace main unit |
|
|
Error |
Broken or short circuit in the CAN bus wire between the main unit and Short circuit of CAN bus wire |
Check connection Replace main unit Replace CAN bus wire |
|
|
Error |
Broken wire between main unit and sensor Failure of the CAN bus output on the main unit Broken sensor |
Check connection Replace main unit Replace sensor |
|
|
Error |
Analog values \u200b\u200bof sensor element not supported |
Replace sensor |
|
|
Error |
See |
See |
|
|
Error |
Selected |
Select other operating parameters Check tap program |
|
|
Error |
Calculated |
Check tap program |
|
|
The code |
The code |
Please select |
|
|
No |
Broken monitor cable or broken monitor CAN system malfunction |
Replace monitor or cable |
|
|
Active |
Excess |
Reinstall the system Check connections |
|
|
A short |
Short circuit of wire A2B Short circuit of the connecting wire of the A2B switch |
Replace switch A2B |
|
|
Shutdown |
Switching off the A2B wire circuit Switching off the circuit of the connecting wire of the switch A2B |
Connect or replace switch A2B Connect or replace connecting wire |
|
|
Not |
Sensor error CAN bus delay Radiogram delay Invalid radio message ID |
Replace switch A2B Replace connecting wire Replace battery Set ID in DFG6.i.2 |
|
|
Error |
Deleting |
Again |
|
|
Active digital |
Excess |
Reinstall the system Check connections |
|
|
No |
Low |
Replace |
Before starting work, a crane operator authorized to operate a crane must:
- familiarize yourself with the entries in the logbook;
- make acceptance of the crane;
- make sure that all mechanisms, metal structures, assemblies and other parts of the crane are in good working order, as well as the crane track.
The crane operator is obliged to receive a key stamp for operating the overhead crane in accordance with the procedure established at the enterprise from the crane operator who hand over the shift (from the person responsible for issuing the key stamps). If at the time of acceptance the crane is under repair, then the key stamp is accepted after the completion of the repair from the person responsible for the repair.
The crane operator is obliged to observe safety measures when entering the crane cab. If the entrance to the crane cabin is arranged through a bridge, then at magnetic cranes the trolleys supplying the electromagnet should not be disconnected when the door is opened in the end railings and should be fenced or located in a place inaccessible for contact;
The crane operator should inspect the crane mechanisms, their mountings and brakes, as well as the undercarriage and anti-theft grips.
It is also necessary to check the presence and serviceability of the guards of the mechanisms and the presence of dielectric mats in the cab.
It is necessary to check the lubrication of the transmission, bearings and ropes, as well as the condition of the lubricating devices and oil seals, inspect the crane metal structures, welded, riveted and bolted joints in accessible places.
The condition of the ropes and their fastening on drums and in other places is checked. Particular attention is paid to the correct laying of the ropes in the streams of blocks and drums.
Inspection of the hook, its attachment in the cage, the locking device on it is carried out (the same applies to another replaceable load-gripping body - the non-hook).
The presence of locks, devices and safety devices on the crane, the serviceability of the lighting of the crane and the working area is checked;
A thorough inspection of the gantry crane tracks and dead-end stops is necessary, as well as an inspection of electric motors in accessible places, trolleys (or flexible current supply cable), pantographs, control panel, protective grounding.
Attention should be paid to the fact that between the gantry crane and the stacks of cargo and other structures along the entire length of the crane runway, there must be at least 700 mm wide passages.
Together with the slinger, the crane operator must check the serviceability of removable lifting devices and containers, their compliance with the weight and nature of the cargo, the presence of stamps or tags on them indicating the carrying capacity, test date and number.
Inspection of the crane is carried out only with inoperative mechanisms and the disconnected switch in the crane operator's cab.
Inspection of the current supply cable is carried out with the disconnected switch, supplying voltage to the crane.
If additional lighting is required, a portable lamp with a voltage not exceeding 12 V can be used.
After inspecting the crane to test it, the crane operator must turn on the switch and the contact lock of the protective panel.
Before starting the crane into operation, the crane operator is obliged to empty all the crane mechanisms and check the correctness of the operation:
- crane mechanisms and electrical equipment;
- brakes for lifting and travel mechanisms;
- locks, signaling device, devices and safety devices available on the crane;
- zero blocking of magnetic controllers;
- emergency switch and contact lock with a key stamp.
In the event that the crane operator has discovered malfunctions (malfunction) that impede safe operation, and if it is impossible to eliminate them on his own, the crane operator must, without starting work, make an entry in the logbook and notify the person responsible for the safe performance of the cranes, and an engineer and technical worker responsible for the maintenance of hoisting machines in good condition.
It is prohibited to start work if:
- there are cracks or deformations in the metal structure of the crane, bolted or riveted connections are loose;
- the clamps for fastening the ropes are damaged or missing or their bolts are loose;
- the load rope has a number of wire breaks or wear exceeding the norm established by the crane operating manual, as well as a broken strand or local damage;
- mechanisms for lifting load, moving a crane or trolley are defective;
- parts of brakes or crane mechanisms are damaged;
- the wear of the hook in the jaw exceeds 10% of the initial section height, the device that closes the jaw of the hook is faulty, the fastening of the hook in the cage is broken;
- faulty or missing locks, audible signal device, limit switches for lifting mechanisms, moving a crane or trolley;
- damaged rope blocks or pulley blocks;
- the load hook or blocks do not rotate;
- there are no fences for mechanisms or non-insulated live parts of electrical equipment, and grounding is missing or damaged;
- faulty crane tracks;
- damaged or missing anti-theft devices;
- the terms of technical examination, repair, maintenance and preventive inspection have expired.
It is forbidden for the crane operator to correct malfunctions of electrical equipment, connecting the crane to the power supply, replacing fuses, connecting heating devices on his own. In the event of such malfunctions, the crane operator must call an electrician.
In addition, the crane operator is obliged to check the presence of a certificate for the right to sling loads and a distinctive sign from the slinger who first starts working with him.
The crane operator does not have the right to start work if workers who do not have a slinger certificate are allocated for slinging goods.
The crane operator must ensure that there is sufficient illumination of the working platform in the area of \u200b\u200bthe crane.
A corresponding entry is made on the acceptance of the crane in the logbook. After receiving the assignment and work permit from the person responsible for the safe operation of the cranes, the crane operator can start working.
OOO Kranstaloffers to significantly reduce the likelihood of emergency situations in production. We will provide the most complete range of services for the maintenance of lifting equipment of domestic and foreign production.
Produced by our certified specialists:
- checking the condition of the crane runways (leveling the crane runways);
scheduled inspections of the technical condition of hoists;
scheduled inspections of crane girders (bridge cranes), metal structures, etc.
will ensure your peace of mind and the safety of your employees at the facility.
