TH QY8 EP FH OPERATOR’S MANUAL FOR CRANE QY8 LTRS BEA A RA SUNWARD INTELLIGENT EQUIPMENT CO., LTD$ sunwaro QY8 CRANE CONTENTS 1 ATTENTION. ee 2. BASIC STRUCTURE AND WORK PRINCIPLE... 2.1 IIB SYSTEM AND ITS EXPANSION. 2.2 WINDLASS SYSTEM. 2.3 SLEWING SYSTEM 24 AMPLITUDE MECHANISM. 2.$ HYDRAULIC SYSTEM. rnsencnoe 7 2.5.1 ADJUSTMENT OF HYDRAULIC PUMP. 2.6 SAFETY MEASURES. 3. CRANE OPERATION, 3.1 PREPARATION BEFORE START-UP. on : = 3.2 SAFETY RULE, : so o : o 10 4, MAINTENANCE AND REPAIR wr. : sn 10 5, PARAMETERS .croner et ee : 13 APPENDIX FIGURE 1 HYDRAULIC SYSTEM, wl APPENDIX FIGURE 2 ELECTRIC SYSTEM... 16$ sunwaro QY 8 CRANE 2. BASIC STRUCTURE AND WORK PRINCIPLE QY 8 crane is installed in ZYJ hydraulic static pile driver as a pile lifting device, which is just an auxiliary device. The crane’s structure is similar to the superstructure of general hydraulic truck crane and it is mainly composed of jib system, windlass system, slewing, and hydraulic control systems. 1- Lifting hook 2-Jib 3- Amplitude cylinder 4- Crane cabin 5+ Crane support 6- Windlass Figure 2-1 Crane structure 2.1 JIB SYSTEM AND ITS EXPANSION 1+ Fixed jib 2- Telescopic jib | ib structureSsunwano Jib system includes main jib, flexing jib, two parallel connected derticking cylinder, and driving system of expansion jib, etc. When extending ot retracting jib, place the jib horizontally and pull out, two shafts that fix expansion jib, then pull the operating handle of multidirectional valve to operate the jib expansion motor, so that the expansion jib expands relatively to fixed jib, Note: When extending or retracting jib, the angle between Jib and horizon should be less than 10° . There are ‘two adjustable jib lengths. After the jib length is adjusted, fix the extendable jib on fixed jib with shaft pin and lock bott. 2.2 WINDLASS SYSTEM Windlass system is composed of hydraulic motor, reducer, windlass drum mechanism of brake, windlass wire and pulley block. 2.3 SLEWING SYSTEM Slewing system includes a hydraulic motor, reducer, small gear, and slewing support. The slewing support is fixed on the machine seat, Hydraulic motor drives small gear via reducer, the small gear turns around the large gear ring on slewing support, | making the crane slew. QY8 CRANE Figure 2-4 Windlass structure Fig — ee 2-5 Slewing mechanism$F sunwano QY8 CRANE 2.4 AMPLITUDE MECHANISM Itis used to change the jib angle. The amplitude of QY8 crane is realized by the extension and retraction of cylinder, so that the horizontal distance between the hook center and slewing center, i.e. the amplitude, changes. 2.5 HYDRAULIC SYSTEM. See figure 2-6 for hydraulic system ( schematic diagram for hydraulic system is as figure2-8). A hydraulic pump( installed in the side part of main machine) supplies pressure oil; the system pressure is determined by overflow valve of multidirectional valve, the pressure is set as 16Mpa, Figure 2-6 Hydraulic system 1. Windlass mechanism 2- Slewing mechanism 3- Multiunit valve 4- Crane cabin 5- Pressure meter 6- Expansion motor 7- Balance valve Manual multidirectional valve includes 4 manual control valves, achieving derricking, windlassing, slewing, jib extending & retracting, and speed control. Pull multidirectional valve handle and treadle the pedal to achieve smooth derricking, slewing, and windlassing, 2.5.1 Adjustment of hydraulic pump Refer to figure 5, adjust the pressure of hydraulic pump as per follows: © Place ali the handles in the crane cabin on neutral position, the hydraulic system unloads (pull any multidirectional valve handle, the machine will be on loading position), ® Screw off plug of pump variable head, adjust the limitation screw, adjusting s adjusting screw of overflow valve Fas loose as possible. © Start oil pump, the variable head scale pointer should point at the full scale (10) position and the pump supplies oil at full flux. © Push the control handle of amplitude cylinder (see figure 3-1) to “fall jib” position till a eeve,$ sunwnse the cylinder retracts to the end (Before you push the handle, take care to watch whether the movement of jib affects other parts). Screw down adjustment screw of overflow valve FI gradually till oil pressure is increased to 13Mpa and serew loose the pump adjustment sleeve 4ill the variable head scale pointer of pump starts to swing. Then lock the adjustment sleeve, Continue to screw down the adjustment bolt of overflow valve till the oil pressure increases to 16Mpa, Serew down the limitation screw rod of pump gradually till the variable head pointer points at 8.0 position, then lock with locknut and screw in plug. Place the control handle of amplitude cylinder on neutral position. The adjustment of hydraulic pump is finished now. Then the pump’s flow and pressure vary automatically according to the curves of | quasi-constant power characterist QY8 CRANE Figure 2-7 Hydraulic variable adjustment mechanism Figure 2-8 Curves of quasi-constant power characteristicsF sunwneo QY 8 CRANE 2.6 SAFETY MEASURES 1, Jib overload protection Adjust the adjustment screw on derticking hydraulic cylinder equalizer valve (if screw clockwise, the pressure lower; screw widdershins, the pressure higher). The oil pressure which its the jib lifting should not exceed 16Mpa to prevent the jib overload. If the jib falls when idlass loads, which means the jib lifting angle is too small, it should be done to lift the jib and then begin to windlass. (see figure 2-6) 2. Hook ition protection, When hook reaches upper limit, the hydraulic system unloads and windlass stops to tise. Its working theory is as follows: When the hook reaches upper limit, hook assembly props up the hammer which is wrapped by wire rope, control switch connected with hammer switches on the electromagnetic valve, then the right position is switched on, overflow valve off-load, the winch lifting stops; pull the winch control handle to falling position, the process switch on control handle switches off the electromagnetic valve, the electromagnetic valve gets back to left position, the hydraulic system works normally, achieving falling hook, and the hook disengages from upper limit € see figure 2-7) 3. Torque limitation protection for the jib ‘The instruments will display different lengths, appropriate inclination angles, lifting ‘weight and other parameters at real-time. It can also tell the torque limitation weight with the lifted object in the current position. When the torque limitation weight is reached, it will give prewamning and warning to alarm operators. A power switch is installed in the right of instrument panel. After electricity failure, you have to repeat once the movement of switch-on and switeh-off to electrify. It starts to work normally when buzzer is sounding. Note: The instrument for torque limitation is optional, if customer needs to buy it, the requirement should be made clear in the purchase contract. aoS sunwano QY 8 CRANE Figure 2-9 Hook limitation protection 1- Connection box 2- Heavy hammerS sunwaro QY8 CRANE When operate rotation, derricking, windlass and expansion handles, it should be coordinated with the movement of stroking mechanism of hydraulic pump foot pedal so that to make the beginning and stopping movement of the above operations smooth without impact. Before the amplitude of crane starts to change, put the corresponding amplitude handle in appropriate position, then gradually operate the pedal valve to make the amplitude movement suitable for working situation. When windlass lifting hook reaches the upper limit, stop the windlass, and operate windlass handle of multiunit valve to unhiteh the hook until lifting hook leaves the upper limit heavy hammer Figure 3-3 Crane in wQY 8 CRANE 3.2 SAFETY RULE 1) Before each shift, operator should do normal inspection; When find any abnormal, operator should solve the failure then operate: Crane technical function in normal workings @AII safety device, safeguard could work normally or not; © Hydraulic parts such as ine. valve. oil pump ete. work function and its leaking status; @Lifting hook. hook nut and locking devie« © Brake function and related parts abrasion status; @Steel wire abrasion and its tail end mounting status; @Steel wire and accessary for binding. hanging: 2) If have one of following problem, operator should not operate: ® Overload or object weight unclear, such as suspending weight or pull unclear embedded ‘object, and pull or hang slantways ete.; @ Structure or parts have shortage or damage which will affect safe work. Such as brake, safeguard failure, hook nut locking device damage, steel wire abrasion reach to reject standards @ Binding. hanging unstable or unbalanced which maybe cause sliding, no cushion between heavy load edge angle and steel wire etc.; @® There have person or floating object in hanging objects © Work side is dark and could not see ground. hanging object status and command signal ete, clearly; 3) Operator should abide following requests during operation: @ Inhandling, never pass through above person, no person under boom; @ Don’t check and maintain during crane working; ‘When hanging load is near or reach to rated loading capacity, it should operate at low level and short distance trial-handling, then handling stably; 4) Do following routine inspection. Routine inspection cycle could be according to crane work frequency, but never exceed one year: Metal assembly paris distortion, crack , corrosion, and connection status of welded seam, 10SUNWARD QY8 CRANE rivet . bolts @ Main parts abrasion. crack and distortion status; © Indicator device reliability and pre @Power system and controller etc. 4, MAINTENANCE AND REPAIR Proper routine maintenance is extremely important to operator's personal safety, machine's normal running and service lifetime. Please carry out routine maintenance to every machine parts. (see figure 4-2) Check often whether there are loose joint bolts in rotary support, hydraulic rotary mechanism and so on. Tighten loose bolts appropriately. (see figure 4-1) Table 4-1 Tightening torque for standard fasteners ( grade 8.8 ) 7 4 aaead Me |M8 |M10 |MiI2 |Mi6 {mis |M20 | M24 | M30 dimensions Moment of/19 2a 4s 78 [190 [260 [370 640 | 1300 torque(N'M) 7 | Table 4-2 Instructions on lubrication point Parts “T Number | Greasing | interval] Parts | Number ] Greasing | Interval name | of style name | of style greasing greasing point point i in Radius Wire 1 | Spreading | 7days | Saclus 2 a rope shaft gun Upper 1 wi | ji Giesso eee (oy ; wire lays | wire 4 Spreading | Everyday aa wheel wheel Pulley Grease ; ib Grease block 1 gun | 795 | wheel 4 ot 60days Slewing Grease | Slewing . say support | __1 run | 30days | Slee 1 _| spreading | 7aaysS sunwano QY 8 CRANE PARAMETERS ‘TABLE 5-1 MAIN TECHNICAL DATA Items Parameters ‘Max. radius-change moment 40 tf Max. lift weight au Max. lifting speed (4 wires) | 9 m/min Max. slewing speed 3 rhmin Rated pressure for lifting 16 Mpa Lifting flow rate(at full flow) | 90 Limin Lifting power 22KW Rated electric current AA ‘Hydraulic pump model installed } 63¥CY14-18 in the side part of main machine) Electric motor model Cinstalled | Y180L-4 in the side part of | main machine) TABLE 5-24 LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT Lifting angle Long jib Short jib OC) [Lining weight (0 [Stewing radius (m)| Lifting weight (| Stewing radius (m) o 195 140 233 2S 20 237 132 2.80 17 30 261 Ra 3.07 108 40 2.93 107 3a 9.58 30 3.40 9.00 3.96 8053 © 421 7.00 4.86 625 6 486 592 559 528 70 584 479 6.6 428 % 747 3.62 8.00 324 76 793 339 8.00 3.02 7 8.00 3.15 8.00 2.82 78 5.00 291 8.00 2.60 784 8.00 2.82 8.00 251$ sunwne QY 8 CRANE TABLE 5-28 QY8 (LENGTHEN JIB) LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT Lifting angle Long Short jib C) Lifting weight (t) | Slewing radius (m)| Lifting weight (0) | Slewing radius (m) 0 18 15.0 LR 133 20 178 1a 2.10 127 30 197 13.0 232 17 40 2.23 15 261 103 30 2.62 9.64 3.04 8.68 60 3.28 7.50 3.78 6.75 3.82 634 437 571 70 462 5.13 527 402 75 5.96 3.88 6.76 3.45 76 634 36 718 327 7 6.78 337 7.66 3.04 78 729 32 8.00 281 Attention: Operate lifting job according to the above table strictly.oS sunwaro QY8 CRANE APPENDIX FIGURE 1 HYDRAULIC SYSTEM Fi exponsion, ( aii his 1. Electrolyte swivel joint 2- Manual multiunit change valve 3- Pedal valve 4- Hydraulic cylinder 5- Balance valve 6- Expansion motor 7- Solenoid valveSsunwnso QY 8 CRANE, APPENDIX FIGURE 2 ELECTRIC SYSTEM. ACeatv an \ (@Jelectric collection ring grt ILS lose igterng SOL electric fan ev | |_f} tet _initation solendid valve ori _ @ | ry rus, © Us Uy ua 220/36/28 B28 7 ie tus | ie | ; xual fe 1a a ! 1 | t me | 225, tule rug hea PE {ue outs tigtening ] torque linitator