Zoomlion QTZ80 (TC5613-6) Tower Crane Operating Instructions Manual EN_ZH - PDF DOWNLOAD

TC5613-6 C2 版 TC5613-6 VERSION C2

QTZ80(TC5613-6)塔式起重机 QTZ80 (TC5613-6) Tower Crane

使用说明书 Operating Instructions

Changsha Zoomlion Heavy Industry Science and Technology Development Co.Ltd

致用户

CUSTOMERS:

感谢您选购和使用本公司的塔式起重机！ Thanks for your purchase and being one of the users of Zoomlion Tower Crane!

为了使您正确使用与维护该设备，操作前敬请仔细阅读本使 用说明书，并妥善保管，以备查询。 Go through the instructions for correct operation and maintenance, and always keep at hand for consultation.

本使用说明书中标有“注意：”的语句，涉及到施工的安全， 敬请注意。 Pay attention to the sentences marked with “Warning, Notice or Precautions ” in this publication, which involves safety of construction.

本公司致力于产品的不断完善，产品的某些局部结构或个别 参数更改时，恕不另行通知。如有疑问，请与本公司联系。 Zoomlion has been devoting every effort to the perfect of her products. Therefore they are changed without notice. If you have any questions, please don't hesitate to contact Zoomlion for further consultation.

出厂编号： Manufacturer's No.

出厂日期： Shipped Date

目 录 Contents

概

述 Preface................................................................. 0-1～0-10

第一篇 塔机的安装 Part I Erection of Tower Crane 第一章

立塔 Erection................................................ 1.1-1～1.1-49

第二章

拆塔 Dismantling........................................... 1.2-1～1.2-6

第二篇 塔机的使用与维护 Part II Operation and Maintenance 第一章 塔机安全操作规程 Safety Operation of the Tower Crane.................................. 2.1-1～2.1-6

第二章 机构及电气操作 Operation of Mechanisms & Electrical Equipment................ 2.2-1～2.2-8

第三章 安全保护装置 Safety Protection Device.................................................... 2.3-1～2.3-9

第四章 保养与维修 Maintenance.................................................................... 2.4-1～2.4-8

附录一 Appendix ....................................................................... 1

编制

Editor：符

校对 Proofreader：刘 审核

亮 Fu liang 毅 Liu yi

Ratifier：付英雄 Yingxiong Fu

TC5613-6塔式起重机

概

概

述

述

0-1

Preface

TC5613-6 塔式起重机,是长沙中联重工科技发展股份有限公司按 JG/T5037-93《塔 式起重机分类》设计的。 Model TC5613-6 tower crane is designed and manufactured by Changsha Zoomlion Heavy Industry Science and Technology Development Co., Ltd. according to the Chinese standard of JG/T5037-93 “Classification of Tower Crane”.

TC5613-6 塔机为水平起重臂、小车变幅、上回转自升多用途塔机。该机的特色有： The TC5613-6 tower crane is a self-climbing multi-purpose machine with a horizontal jib, a trolleying mechanism and an upper slewing mechanism. Its characteristics are: 1. 性能参数及技术指标国内领先，最大工作幅度 56m，最大起升高度 220m。 The performance parameters and technical indicator of the crane are at a leading level in China. The Maximum working radius is 56m and the maximum hoisting height is 220m.

2. 该机有地下浇基础固定式，底架固定独立式,轨道行走式，内爬式等工作方式，适 用各种不同的施工对象。独立式的起升高度为 40.5m，附着式的起升高度可达 220m。 The crane has different working modes such as: outrigger stationary, undercarriage stationary, mobile and inside climbing, so that it is applied in different construction projects. The hoisting height of outrigger stationary is 40.5m and the hoist height of the crane anchored to the building is 220m.

3. 工作速度高，调速性能好，工作平稳可靠。 High working speed and good regulated speed performance make the machine working smoothly.

4. 电气控制系统主要电器元件选用国际名牌，寿命比国产元件长 3～4 倍，故障少， 维修简单，工作可靠。 The main electric elements are used world-renowned products, which service life is 3-4 times longer than China-made counterparts with less failure, simple maintenance and reliable working.

5. 配置各种安全装置 8 种，且为机械式或机电一体化产品，能确保塔机工作可靠。 8 sets of safety devices ensure the tower crane work reliably, and the safety devices are mechanical or integrated mechanical-electrical products.

6. 设计在坚持切实符合国情，确保安全可靠原则的同时，尽可能地吸收采用了国内外 成熟可靠的先进技术，来提高整机的技术水平，采用的成熟可靠的先进技术有： The design of the crane is based on the actual situations in China and on the safe-reliable operation principles. Greatly absorb and adopt the well-established and reliable advanced technology to enhance its overall technical level at the same time in the world.

Well-established advanced technology adopted as following: 1) 回转机构选用进口变频器，实现变频无级调速，起、制动平稳，无冲击，安 全可靠。

TC5613-6塔式起重机

概

述

0-2

Importing frequency transformer and realizing stepless speed regulated and frequency altering make starting and braking smoothly without impact, running safety and reliable.

2) 专业电器厂引进法国 TE 公司技术生产的电器元件； Electrics manufactured with the technology from TE, France.

3) 引进国外先进技术并国产化了的重量限制器、力矩限制器、高度限位器、幅 度限位器、回转限位器、回转、牵引机构的制动器等安全装置。 Weight limier, height limiter, radius limiter, slewing limiter, slewing brake, traction brake and similar safety guards are China-made based on the imported technology.

4) 小车防断绳装置(防溜车)和防断轴装置； Carriage rope break-proof device (carriage slip-proof) and axle break-proof device; 5) 起升机构排绳系统；Rope pay-off system for hoisting mechanism; 6) 牵引绳张紧系统；Traction rope-tensioning system; 7) 刚性双拉杆悬挂大幅度起重臂，起重臂刚度好，自重轻，断面小，风阻小， 外形美观，长度有几种变化，满足不同施工需要； Large-radius hoisting jib suspended by double rigid tie rods, featuring good jib rigidity, light jib weight, small jib cross-section, small wind resistance and nice-looking appearance and several jib lengths, it is satisfied different construction needs.

8) 司机室独立外置，视野好，内部空间大，给操作者创造良好的工作环境； 司机用先进的联动台操纵各机构动作，操作容易，维修简单。 Out-hung operator cabin, featuring excellent field of view, spacious interior and satisfactory working environment, and advanced inter-active control console, the operator handles the mechanisms easy and services simply.

7. 设计完全符合或优于有关国家标准。Design in complete conformity or superior to the relevant national standards. 适用于高层或超高层民用建筑、桥梁水利工程、大跨度工业厂房、大型体育场以 及采用滑模法施工的高大烟囱及筒仓等大型建筑工程中。 The crane is suitable for use in such large-sized construction projects as high-rise or super high-rise buildings, bridge and water conservancy projects, large-span industrial buildings, large gymnasiums, and high chimneys and silos constructed with slip form.

TC5613-6塔式起重机

概

述

0-3

8. 起重机的各项参数。Technical parameters of the tower crane 8.1 起重机整体技术参数. (表 8-1) Technical performance parameters for the whole machine (Table 8-1) Table 8-1 机构工作级别 Mechanism Group

起 升 机 构 Hoisting 回 转 机 构 Slewing 牵 引 机 构 Trolleying

M5 M4 M3

额定起重力矩 kNm Rated hoisting moment 起升高度 m Max hoisting height

起升机构

工作幅度 m Working Radius 最大起重量 t Max hoisting capacity 倍率 Fall 速度 m/min Speed 起重量 t

800 倍率 Fall 固定式 Stationary α＝2 40.5 α＝4 40.5 最大工作幅度 Maximum 最小工作幅度 Minimum

附 着 式 Anchored 220 110 56 2.5

6 α＝2

α＝4

80

40

8.88

40

20

4.44

1.5

3

3

3

6

6

Max. Load

功率 kW Power 牵引机构 Trolleying 回转机构 Slewing

g n i t s i o H

顶升机构 Jacking (Erecting) mechanism 总功率 Total power kW 平衡重 Counterweight 工 作 温 度 ℃ Operation Temperature

24/24/5.4 速度 Speed m/min 功率 Power kW 速度 Speed r/min 功率 Power kW 工作压力 Working Pressure MPa

50/25 3.3/2.2 0 ～0.8 4.0×2 25 (推荐值 Recommended Value)

0.56( 推 荐 值 Recommended Value) 7.5 (推荐值 Recommended Value) 功率 Power kW 35.3(不包括顶升机构 Excluding Erecting Mechanism) 38 44 50 56 9.85 11.25 13.5 15.3 速度 Speed m/min

－20～＋40

8.2 起重机四大机构各项参数 Technical parameters of the four mechanisms

TC5613-6塔式起重机

概

述

0-4

8.2.1 QS680D 起升机构各项参数(表 8-2-1) Technical parameters of hoisting mechanism QS680D(Table 8-2-1) Table 8-2-1

最大牵引力 Maximum traction of the rope 规 格 钢丝绳 Specifications Wire rope 最大线速度 Maximum linear speed 卷 筒 Wire 容 绳 量 Rope Drum Rope capacity 型 号 Model 电 机 功 率 Power Motor 转 速 Speed 型 号 Model 制动器 制动力矩 Brake Braking moment 减速机速比 Reducer ratio

17500

N

35×7-13-1770 or 6T29Fi+IWR-13-1770 or K4×39S-FC m/min

160

m

450 (缠绕层数≤6)(layers≤6)

kW r/min

YZTD225L2-4/8/32 24/24/5.4 1440/720/160 YWZ3-315/45-16

N.m

630 16.75

8.2.2 BE33E 牵引机构各项参数(表 8-2-2) Technical parameters of trolleying mechanism BE33C (Table 8-2-2) Table 8-2-2

最大牵引力 Maximum traction of the rope 规 格 Specifications 最大线速度 钢丝绳 Maximum linear speed Wire rope 44mJib 长度 50mJib Length 56mJib 卷 筒 Wire 转 速 Rope Drum Drum Speed 型 号 Model 电动机 功 率 Power Motor 转 速 Speed 减速机 速 比 Reducer Ratio

N

5640 6×19-7.7-1550-Ⅱ-右交 6×19-7.7-1550-Ⅱ- right-twist

m/min

m

50/25 钢丝绳Ⅰ Wire rope

88 100 112

钢丝绳Ⅱ Wire rope

r/min

33.49/16.74

kW r/min

YDEJ132S-4/8-B5 3.3/2.2 1440/720 43

8.2.3 HPW40B.100 回转机构各项参数(表 8-2-3) Technical parameters of slewing mechanism HPW40B.100 (Table 8-2-3)

56 62 68

TC5613-6塔式起重机

概

述

型 号 Model 功 率 Power 转 速 Speed 型 号 Model 减速机 传 动 比 Ratio Reducer 输出转矩 Output rotation moment 模 数 Modulus 输出端齿轮参数 齿 数 Number of teeth Gear parameter at 变位系数 output end Position-changing factor 主 机 转 速 Slewing speed 回 转 支 承 Slewing ring support

0-5

YTW112M-4B5 kW 4.0 r/min 0～1440 XX5-100.195CA-12/16 195

电动机 Motor

N·m

10000

m Z

12 16

X

+0.5

r/min

0～0.6 011.45.1250 Table 8-2-3

8.2.4 顶升机构各项参数(表 8-2-4) Technical parameters of jacking mechanism (Table 8-2-4) Table 8-2-4

电动机 Motor 液压泵站 Hydraulic pump 顶升油缸 Jacking cylinder

功 率 Power 转 速 Speed 流 量 Flow 工 作 压 力 Working pressure 缸/杆直径 Cylinder /rod diameter 最大顶升力 Maximum jacking force 顶 升 速 度 Jacking speed

kW r/min l/min

7.5 1440 10.6

MPa

25

mm

160/110

t

50

m/min

0.56

8.3 起重特性表及起重特性曲线 Radius and Load Capacity 8.3.1 38m 臂起重特性表及起重特性曲线 38m Jib’s Radius and Load Capacity 幅度

Radius (m)

起重量 Hoistin g weight (t) 幅度

两倍率 2 fall 四倍率 4

18

19

20

两倍率 2 fall 四倍率 4 fall

23

25

27

4.26

3.85

3.51

3.00 6.00

5.67

5.32

5.01

33

35

38

2.81

2.61

2.35

2.75

2.55

2.29

fall

Radius (m)

起重量 Hoistin g weight (t)

2.5 ～17.11

29

31 3.0

3.22

2.97

TC5613-6塔式起重机

概

述

0-6

8.3.2 44m 起重特性表及起重特性曲线 44m Jib’s Radius and Load Capacity 幅度

Radius (m)

起重量 Hoistin g weight (t)

两倍率 2 fall 四倍率 4

幅度

Radius (m)

起重量 Hoistin g weight (t)

两倍率 2 fall 四倍率 4

2.5 ～17.1

18

19

20

23

25

27

4.26

3.85

3.51

3.00 6.00

5.67

5.32

5.01

33

35

38

41

44

2.81

2.61

2.35

2.14

1.95

2.75

2.55

2.29

2.08

1.89

fall

fall

29

31 3.0

3.22

2.97

TC5613-6塔式起重机

8.3.3 幅度

概

述

0-7

50m 起重特性表及起重特性曲线 50m Jib’s Radius and Load Capacity Radius (m)

2.5 ～16.8

17

20

23

26

29

30

起重量 Hoistin g weight (t)

两倍率 2 fall 四倍率 4

幅度

Radius (m)

31

起重量 Hoistin g weight (t)

两倍率 2 fall 四倍率 4

8.3.4

56m 起重特性表及起重特性曲线 56m Jib’s Radius and Load Capacity

幅度

幅度

5.92

4.90

4.16

3.59

3.14

3.00

33

35

38

41

44

47

50

2.96

2.74

2.55

2.30

2.08

1.90

1.74

1.6

2.90

2.68

2.49

2.24

2.02

1.84

1.68

1.54

fall

2.5 ～16.25

两倍率 2 fall 四倍率 4

17

20

23

26

29

3. 00 6.00

30

31

2.95

2.84

5.70

4.71

4.00

3.45

3.02 2.89

2.78

fall

Radius (m)

起重量 Hoistin g weight (t)

6.00

fall

Radius (m)

起重量 Hoistin g weight (t)

3.00

两倍率 2 fall 四倍率 4 fall

32

35

38

41

44

47

50

53

56

2.73

2.44

2.20

1.99

1.82

1.66

1.53 1.41

1.30

2.67

2.38

2.14

1.93

1.76

1.60

1.47 1.35

1.24

TC5613-6塔式起重机

概

述

8.4 整机外形尺寸 Overall dimensions of the crane 8.4.1 基础固定整机外形尺寸 Overall dimensions of the stationary crane

图1

TC5613-6 塔式起重机支腿固定独立式外形尺寸

Fig.1 Overall dimensions of the stationary TC5613-6 tower crane

0-8

TC5613-6塔式起重机

概

述

0-9

图 2 TC5613-6 塔式起重机底架固定独立式外形尺寸 Fig.2 Overall dimensions of TC5613-6 Stationary Tower Crane with Foundation Undercarriage

TC5613-6塔式起重机

概

述

0-10

8.4.2 附着式整机外形尺寸 Overall dimensions of the crane anchored to the building

图3

TC5613-6 塔式起重机支腿固定附着式外形尺寸 及附着架最经济配置示意图

Fig.3 Dimensions of Stationary Crane with Foundation Anchor

TC5613-6塔式起重机

立

塔

1.1-1

第一篇 塔机的安装 Part I Installation of Tower Crane 第一章

立塔

Chapter I Erecting 1.1 引言 Foreword 用户应熟读本章说明，以便正确迅速架设塔机。 The user should go through the chapter in detail for proper and prompt erection of the tower crane.

1.2 立塔的注意事项 Cautions of erecting tower 1.2.1 塔机安装工作时，塔机最高处风速不大于 14m/s; The maximum wind speed atop should be less than 14m/s during crane erecting.

1.2.2 必须遵循立塔程序; Strictly follow the procedures of crane erecting.

1.2.3 达到可顶升加节的位置前，需根据（表 1-1）选用一台合适的汽车吊。 Select a proper mobile crane and slings in accordance with items shown in Table 1-1. 表 1-1 吊装单元重量及高度 Table 1-1 Component weight and height 序号

名称

No.

Designation

支腿式 H(m) 底架式 H(m) 行走式 Embedded Undercarriage H(m) Weight anchor stationary Traveling

重量(kg)

1

主动台车 Driving Bogie 2×850

1.2

2

被动台车 Driven Bogie

2×650

1.2

3

整梁 Total Beam

1300

0.9

1.7

4

半梁 Semi-Beam

2×600

0.9

1.7

4×115

0.9

1.7

1900

6.9

7.7

5 6

底架拉杆 Tie Rod of Bottom Frame 基节 1＋基节 2 Base Section Ⅰ&Ⅱ

7

撑杆 Tower Strut

4×255

5.4

6.2

8

压重（一）Ballast (1)

4×3500

1

1.8

9

压重（二）Ballast (2)

8×3400

3.2

4.0

10 11

固定基节 EQ Base Tower Section EQ 标准节 EQ7 Tower section EQ

1020

3.7

855

6.5

3300

15.3

18.5

19.3

3200

10.8

14.0

14.8

500

12.6

15.8

16.6

2400

20.0

23.2

24.0

4500

13.7

16.9

17.7

12 13 14

爬升架 Climbing Frame 回转总成

15

Slewing Assembly 司机室 Operator Cab

16

塔顶 Tower Head

17

平衡臂总成 Counter Jib assembly

TC5613-6塔式起重机

立

18 19a 19b 19c 19d

20a

第一块平衡重 First

塔

1.1-2

2250

16.7

19.9

20.7

5050

13.9

17.1

17.9

5450

13.9

17.1

17.9

5850

13.9

17.1

17.9

6250

13.9

17.1

17.9

2×2250 Counterweight of 38 m +1800+ 1300 Jib

16.7

19.9

20.7

16.7

19.9

20.7

16.7

19.9

20.7

Block Counterweight 38 米起重臂总成 38m Jib assembly 44 米起重臂总成 44m Jib assembly 50 米起重臂总成 50m Jib assembly 56 米起重臂总成 56m Jib assembly 38 米起重臂平衡重

44 米起重臂平衡重 20b

20c

Counterweight of 44 m 4×2250 Jib 50 米起重臂平衡重 Counterweight of 50 m 5×2250 Jib 56 米起重臂平衡重

5×2250 16.7 19.9 20.7 Counterweight of 56 m ＋1800 Jib ※注：20a 20b 20c 是安装一块平衡重后剩下的平衡重 Note：20a, 20b, 20c are the remaining counterweights after mounting a counterweight.

20d

1.2.4 塔机各部件所有可拆的销轴,塔身、回转支承的连接螺栓、螺母均是专用特制零 件,用户不得随意代换; The dismountable pins, connecting bolts and nuts for the slewing rings and tower sections of the tower crane are special-made, which shall not be replaced freely.

1.2.5 必须安装并使用保护和安全措施，如扶梯、平台、护栏等; Stairs, platform and protecting fence should be installed for safe operation.

1.2.6 必须根据起重臂臂长，正确确定平衡重块数量(见有关章节)，在安装起重臂之 前,必须先在平衡臂上安装一块重量 2.250t 的平衡重,注意严禁超过此数量; The quantity of counterweight blocks shall be provided in accordance with the jib length (refer to relevant chapter). Jib must be installed after placing one 2.25t counter-weight on the counter-jib. It is prohibited to place two pieces or more counter-weight on the counter-jib before installing jib.

1.2.7 装好起重臂后,平衡臂上未装够规定的平衡重前,严禁起重臂吊载; After jib installation, it is prohibited to hoist any load before placing specified counter-weight on the counter-jib.

1.2.8 塔机在施工现场的安装位置,应确保其最大旋转部分与周围建筑物之间的距离 不小于 1.5m,塔机任何部位与架空输电线的安全距离应符合表 1.2-1 的规定; At the erection position of the tower crane, it must be no less than 1.5m distance between the widest slewing part of the crane and around buildings, and the safe distance between any

TC5613-6塔式起重机

立

塔

1.1-3

parts of the crane and overhead power lines shall comply with the stipulations as shown in Table 1.2-1.

1.2.9 准备辅助吊装设备、枕木、索具、绳扣等常用工具; Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be provided before hand.

1.2.10 塔机安装场地的参考尺寸(见图 1.2-1); Reference size for tower crane erecting site is shown as Fig. 1.2-1.

1.2.11 顶升前,应将小车开到规定的顶升平衡位置,起重臂转到引进横梁的正前方,然 后用回转制动器将塔机的回转锁紧; Drive the trolley to the balance position before jacking. Slew the jib to the right front of the in-let beam and thenlock the slewing of tower crane by slewing brake.

1.2.12 顶升过程中，严禁旋转起重臂或开动小车以及使吊钩起升或放下。 It is prohibited to slewing the jib, move the trolley or make the hoist hook up and down movement during jacking operation.

1.3 塔机的总体布置 General layout of tower crane 1.3.1 独立式主要组件装配关系(见图 1.3-1) Assembly relation of main components for stationary crane (Fig.1.3-1)

TC5613-6塔式起重机

立

塔

1.1-4

图 1.3-1 主要组件装配关系 Fig.1.3-1 Assembly relation of main components

1. Foundation 2. Tower Section (a-Section EQ, b-Mast Section EQ,) 3. Climbing frame 4. Slewing ring support 5. Slewing ring 6. Upper support 7. Operator cab 8. Tower head 9. Counter-jib 10. Jib (a=38m, b=44m, c=50m, d=56m) 11. Counter-weight (a=9.85t, b=11.25t, c=13.5t, d=15.3t) 12. Base frame (or undercarriage) 13. Foundation With Undercarriage 支腿固定独立式塔机起升高度 40.5m, 底架固定独立式塔机起升高度也是 40.5m, 可采用二倍率或四倍率钢丝绳起吊重物，塔身标准节为方钢管结构，塔身（或底架） 下部与基础相连。The TC 5613-6 tower crane, with embedded anchors or with an undercarriage, independent hoisting height is 40.5m. 2-fall or 4-fall wire ropes may be used for hoisting purpose. The tower sections are integral construction of square shaped steel tube structure. The base section of tower body or the undercarriage is connected to the foundation. 在下支座下端是爬升套架，环绕在塔身四周，顶升机构可顶起塔身上部结构和爬 升套架,引进标准节,升高塔机的高度。 The lower end of the slewing ring support is the climbing frame, which surrounds the tower body. According to the construction needs, jacking mechanism can jack the upper structure of the tower body to let in mast sections for increasing tower crane height.

TC5613-6塔式起重机

立

塔

1.1-5

1.3.2 附着式(参见图 3、图 4) Anchored State (shown as Fig.3 and Fig.4) 本塔机支腿固定独立式的最大起升高度为 40.5m.若起升高度要超过 40.5m，必须 增加塔身节并用附着装置加固塔身。至少增加 8 层附着装置后最大起升高度可达 220m。 在工作高度≤110m 时，可采用二倍率或四倍率起升，当工作高度>110m 时，只能采用 二倍率起升。附着时，要求塔身中心距建筑物 3.5m，如实际工程有变化请与本公司联 系设计非标附着装置。 The maximum hook height can reach 40.5m when crane is stationary with embedded anchors and 220m when anchored if it is fastened with tie-in onto the building and mast tie frame. When the height is ≤110m, hoisting can be done with 2-fall or 4-fall, but if the height is >110m, only 2-fall can do the job. The required distance between slewing center of tower and the building is 3.5 meters. As for unusual conditions, please contact Zoomlion for further consultation 1.3.2.1 和 1.3.2.2 考虑到施工要求与塔身、附着架的受力规定了附着架与基础 平面距离、附着架之间距离以及附着架以上悬高的极限值。1.3.2.3 和 1.3.2.4 既能 满足一般的施工要求，又能最经济的配制附着架，降低塔机的使用成本。 1.3.3.2.1 and 1.3.3.2.2 give consideration to project construction requirements and force-applied situations of the tower body and anchored frames. They specify the distance between anchored frame and foundation plane, distance between anchored frames and suspension height limit above anchored frame. Item 1.3.3.2.3 and 1.3.3.2.3 can satisfy both ordinary construction needs and facilitate prefabrication of anchored frames most economically to lower the cost of the tower crane.

1.3.2.1 第一道附着(见图 1.3-2) With one anchored attachment (Shown as Fig.1.3-2) (1)附着架以下的塔身高度 h（支腿固定式含基节 1 高度、底架固定式含基础节Ⅰ基础节Ⅱ高度）The h1 is the distance from first anchor point to the foundation surface.

18(m) ≤ h1 ≤31(m) 即第一道附着架以下的塔身节 数 n1 为： The quantity of tower sections in h1 is: 6.4 ≤n1≤ 11.1 (2) 附着架以上塔身悬高 h0： The height of tower above the anchor point is h0：

h0≤36.55(m) 即附着架以上塔身节数: The quantity of tower sections in h0 is:

n0≤12.5

图 1.3-2 Fig.1.3-2

1.3.2.2 第二道或第二道以上附着 With two anchored frames or more

TC5613-6塔式起重机

立

塔

1.1-6

(1) 两道附着架之间的距离 h2： (2) The distance h2 between two anchor points: 15(m) ≤ h2 ≤25.2(m) 即两道附着架之间的塔身节数 n2 为：The quantity of tower sections between 2 anchor points is： 5.4≤n2≤9.3 (2) 附着架以上塔身节的高度 h0： The height h0of tower above the highest anchor point is： 工作高度 h≤100m 时，与 1.3.2.1(2)中的一致.

When hook height h is less than100m，h0 is the same shown in 1.3.2.1(2). 工作高度 h＞100m 时，需少加一节, 即: When hook height h is ＞100m，namely:

n ≤11.5 0

图 1.3-3 Fig1.3-3

1.3.2.3 支腿固定附着式附着架数量最少的附着方式(图 3 ) The least number of anchored frames for the tower crane with embedded anchors (shown as Fig.3) 第一次附着后，附着架以上塔身悬出段≤36.55m，塔机最大工作高度≤68.5m，使 用 24 个塔身标准节。 With 1 anchored frame, h0≤36.55m, h ≤68.5m, there are 24 tower sections totally. 第二次附着后， 附着架以上塔身悬出段≤36.55m，塔机最大工作高度≤93.7m， 使用 33 个塔身标准节。 With 2 anchored frames, h0≤36.55m, h ≤93.7m, there are 33 tower sections totally. 第三次附着后， 附着架以上塔身悬出段≤33.75m，塔机最大工作高度≤116.1m， 使用 41 个塔身标准节。 With 3 anchored frames, h0≤33.75m, h ≤116.1m, there are 41 tower sections totally. 第四次附着后， 附着架以上塔身悬出段≤33.75m，塔机最大工作高度≤141.3m， 使用 50 个塔身标准节。 With 4 anchored frames, h0≤33.75m, h ≤141.3m, there are 50 tower sections totally. 第五次附着后， 附着架以上塔身悬出段≤30.95m，塔机最大工作高度≤163.7m， 使用 58 个塔身标准节.

With 5 anchored frames, h0≤30.95m, h ≤163.7m, there are 58 tower sections totally. 第六次附着后， 附着架以上塔身悬出段≤28.15m，塔机最大工作高度≤183.3m， 使用 65 个塔身标准节.

With 6 anchored frames, h0≤28.15m, h ≤183.3m, there are 65 tower sections totally. 第七次附着后， 附着架以上塔身悬出段≤28.15m，塔机最大工作高度≤202.9m， 使用 72 个塔身标准节.

With 7 anchored frames, h0≤28.15m, h ≤202.9m, there are 72 tower sections totally

TC5613-6塔式起重机

立

塔

1.1-7

第八次附着后， 附着架以上塔身悬出段≤25.35m，塔机最大工作高度≤220m，使 用 78 个塔身标准节.

With 8 anchored frames, h0≤25.35m, h ≤220m, there are 78 tower sections totally。 1.3.2.4 底架固定附着式附着架数量最少的附着方式(图 4) The least number of anchored frames for the tower crane with undercarriage (shown as Fig.4) 第一次附着后，附着架以上塔身悬出段≤35.86m，塔机最大工作高度≤68.8m，使 用 22 个塔身标准节。 With 1 anchored frame, h0≤36.86m, h ≤68.8m, there are 22 tower sections totally. 第二次附着后， 附着架以上塔身悬出段≤35.06m，塔机最大工作高度≤94.0m， 使用 31 个塔身标准节。 With 2 anchored frames, h0≤35.06m, h ≤94m, there are 31 tower sections totally. 第三次附着后， 附着架以上塔身悬出段≤34.26m，塔机最大工作高度≤119。2m， 使用 40 个塔身标准节。 With 3 anchored frames, h0≤34.26m, h ≤119.2m, there are 40 tower sections totally. 第四次附着后， 附着架以上塔身悬出段≤30.66m，塔机最大工作高度≤141.6m， 使用 48 个塔身标准节。 With 4 anchored frames, h0≤30.66 m, h ≤141.6m, there are 48 tower sections totally. 第五次附着后， 附着架以上塔身悬出段≤30.95m，塔机最大工作高度≤163.7m， 使用 56 个塔身标准节.

With 5 anchored frames, h0≤30.95m, h ≤163.7m, there are 56 tower sections totally. 第六次附着后， 附着架以上塔身悬出段≤28.15m，塔机最大工作高度≤183.3m， 使用 63 个塔身标准节.

With 6 anchored frames, h0≤28.15m, h ≤183.3m, there are 63 tower sections totally. 第七次附着后， 附着架以上塔身悬出段≤28.15m，塔机最大工作高度≤202.9m， 使用 70 个塔身标准节.

With 7 anchored frames, h0≤28.15m, h ≤202.9m, there are 70 tower sections totally 第八次附着后， 附着架以上塔身悬出段≤25.35m，塔机最大工作高度≤220m，使 用 76 个塔身标准节.

With 8 anchored frames, h0≤25.35m, h ≤220m, there are 76 tower sections totally 1.4 固定基础及平衡重 Foundation & Counterweight 支腿固定式基础载荷（表 1-3、图 1.4-1） Loads on Foundation with embedded anchors（shown as Table1-3、Fig.1.4-1） 表 1-3 Fv(kN) Fh(kN) 工况 In operation 非工况 Out of operation

M(kN.m)

T(kN.m)

548.7

18.5

1693

300

487.5

74.7

1766

0 图 1.4-1 固定基础载荷示意图 Fig.1.4-1 Load schematic diagram on the foundation

TC5613-6塔式起重机

立

塔

1.1-8

1.4.2 预埋支腿固定基础(图 1.4-2) Foundation with embedded anchors 采用整体钢筋混凝土基础，对基础的基本要求如下： Reinforced concrete foundations must be adopted. Basic requirements for the foundation with embedded anchors as following: 1.4.2.1 混凝土强度等级C35.基础土质要求坚固牢实,且承压力不小于表1-4的规定； The concrete strength grade must not be lower than C35. The ground base must be hard ground and the earth endurance must not be less than the specifications as shown in the table 1-4 Table1-4 表 1-4 L

5300

5500

上层筋 Reinforcing steel bar of upper layer

下 层 筋 Reinforcing steel bar of lower layer

纵横向各 24-φ25 Lengthwise and crosswise 纵横向各 24-φ25 Lengthwise and crosswise

纵横向各 24-φ25 Lengthwise and crosswise 纵横向各 24-φ25 Lengthwise and crosswise

地耐力 Mpa

3

架立筋

混凝土 M Concrete

重量 T Weight

0.14

25

60

144

0.12

30.25

72.6

144

Earth endurance

Vertical reinforcing steel bar

1.4.2.2 混凝土基础的深度应大于1000mm； The depth of the concrete foundation should be more than 1000mm； 1.4.2.3 固定支腿上表面应校水平，平面度误差为1/500。 Adjust the level of the anchors upper surface to ensure that the planeness tolerance is 1/500.

图 1.4-2 预埋支腿固定基础 Embedded Anchors Foundation

图 1.4-3 固定支腿的浇注示意图 Pouring cncrete diagram of embedded anchors

TC5613-6塔式起重机

立

塔

1.1-9

1.4.3 固定支腿的安装 Install the embedded Anchors 固定支腿的安装十分重要，请参考以下程序施工： The installation of the embedded anchors is very important, please install them as following: 1.4.3.1 将 4 只固定支腿与预埋支腿固定基节 EQ 用 12 件 10.9 级高强螺栓装配在一起; Fasten 4 anchors and the base section together with 12 high-tensile bolts (strength rating 10.9).

1.4.3.2 为了便于施工,当钢筋捆扎到一定程度时，将装配好的固定支腿和预埋支腿固 定基节 EQ 整体吊入钢筋网内; According to the construction convenience and the progress of binding rebar, hoist the whole piece of anchors assembled with the base section into rebar net.

1.4.3.3 固定支腿周围的钢筋数量不得减少和切断; Be sure that the number of re-bars around anchors must not be reduced or cut off.

1.4.3.4 主筋通过支腿有困难时,允许主筋避让; If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside.

1.4.3.5 吊起装配好的固定支腿和预埋支腿固定基节 EQ 整体，浇注砼。在预埋支腿 固定基节 EQ 的两个方向中心线上挂铅垂线，保证预埋后预埋支腿固定基节 EQ 中心 线与水平面的垂直度≤1.5/1000; Gently hoist the whole piece of anchors assembled with the base section EQ so that it is in a vertical position before placing concrete. Hang plumb lines along the centerline in 2 directions of the base section EQ to ensure that the perpendicularity of the embedded base section centerline and horizontal plane is less than 1.5/1000.

1.4.3.6 固定支腿周围混凝土充填率必须达到 95％以上; Concrete filling rate around the embedded anchors must be over 95%.

1.4.3.7 安装示意图见图 1.4-3。 Installation diagram is shown as Fig.1.4-3.

Foundation Anchor bears the greatest pressure and pull, which should be equipped by the factory, otherwise the contractor is responsible for the damage caused by incorrectly prepared foundation anchor or by neglecting the foundation site conditions. 注意：Notes: 1 固定支腿受力最大，应由生产厂配套，否则一切责任自负； The embedded anchors bear all loads of the crane, so they should be purchased from our company. Otherwise if the users supply the embedded anchors, you are responsible for the damage caused by anchors.

2 固定支腿只能使用一次，不许从基础中挖出来重新使用。 It is allowed that the anchors are used one time, and it is forbidden to dig them out and use again.

1.4.4

预埋螺栓固定基础(图 1.4-4)

Foundation with embedded bolts

采用整体钢筋混凝土基础，对基础的基本要求如下： Reinforced concrete foundations must be adopted. Basic requirements for the

TC5613-6塔式起重机

立

塔

1.1-10

foundation with embedded bolts as following: 1 基础开挖至老土（基础承载力必须达到表 1-4 中要求）找平，回填 100mm 左右卵 石夯实，周边配模或砌砖后再行编筋浇注混凝土，基础周围地面低于混凝土表面 100mm 以上以利排水，周边配模，拆模以后回填卵石。 Dig the foundation to the hard earth (Bearing load should reach the value shown as Table 1-4), make it level, and then backfill 100mm gravel, after slip-formwork or laying bricks for the side walls, pour concrete into pre-made reinforced rod net. The concrete block surface should be 100mm higher than neighboring ground for the drainage of storm water, then removal the formwork and backfill the neighboring ground with gravels.

2 垫板下砼填充率>95%，四垫板上平面保证水平，垫板允许嵌入砼内 5～6mm。 Concrete filling rate under pallet should be more than 95%. The upper plane of the four pallets should be within the same level plane and the pallet are allowed to be inserted into concrete for 5-6mm.

图 1.4-4 预埋螺栓固定基础 Fig 1.4-4 Foundation with embedded bolts

TC5613-6塔式起重机

3

立

塔

1.1-11

四组地脚螺栓（16 根）相对位置必须准确，组装后必须保证地脚螺栓孔的对角

线误差不大于 2mm，确保固定基节的安装。 The relative position of the 4 sets of embedded bolts must be correct, and the length tolerance of the diagonal line should be no more than 2mm after assembling, ensuring the mounting of the base tower section.

4 允许在固定基节与垫板之间加垫片，垫片面积必须大于垫板面积的 90%，且每个 支腿下面最多只能加两块垫片，确保固定基节的安装后的水平度小于 1/750，其中心 线与水平面垂直度误差为 1.5/1000 。 It is allowed to insert pads but no more than 2 pads into the intervals of the base tower section and the packings. The area of pad should be more than 90% area of the pallet to ensure that the planeness tolerance is less than 1/750 after installing the base tower section, and vertical tolerance of central line with level plane is within 1.5/1000.

5 螺栓需与基础底筋相连。 The embedded bolts should be connected with the reinforcement of lower layer 基础的承载力、尺寸 L 及钢筋布置参见表 1－3、表 1-4 的要求。 The bearing load, dimensions L and arrangement of reinforcing rods are shown as Table 1-3 and Table1-4. 注意：Notes: 拧紧地脚螺栓时，不许用大锤敲打扳手。 When screwing the embedded bolts, it is prohibitten to knock the wrench with a sledgehammer. 地脚螺栓只能使用一次，不许挖出来重新使用。因地脚螺栓为重要受力件，我们 建议用户到塔机制造商处购买。用户制作地脚螺栓时，一定要符合图纸要求，由用户 自制的地脚螺栓所引发的一切事故，我公司概不负责。 It is allowed that the embedded bolts are used one time, and it is forbidden to dig them out and use again. Because the embedded bolts are important parts which bear the great mass of loads of the crane, we suggest that the bolts should be purchased from our company. Users fabricate the bolts yourselves, the bolts must conform to the requirements of drawing. But you are responsible for any damage caused by bolts, if the bolts are supplied by yourselves.

1.4.5 底架固定式的基础 Foundation for Undercarriage 底架固定式塔机的地基基础是保证塔机安全使用的必要条件，该基础采用四块整 体钢筋混凝土基础，对基础的基本要求如下： The ground foundation is the precondition to ensure safe operation of the crane. This foundation must closely comply with the regulations for different geological conditions. It is built of 4-blocks as base ballast, made of reinforced concrete. Basic requirements as follows: 1) 混凝土强度等级 c35。基础下土质应坚固牢实，承压力不小于图 1.4-5 规定混 凝土养护期大于 15 天。 The concrete strength grade shall be no less than C35. The ground under the foundation

TC5613-6塔式起重机

立

塔

1.1-12

should be solid with the bearing load value specified in the Table 1.4-5. The curing duration of concrete is more than 15 days.

2) 混凝土基础的深度应大于 800mm。 The depth of concrete should be more than 800mm.

3) 凝土基础与底梁接触表面应校水平， 四块垫板平面度误差为 1/750。 The contact level plane between concrete foundation and frame beam should be calibrated. The level tolerance of four pallets is 1/750.

4) 四个块基础中心连线的中间挖 1300mm×1300mm 深 800mm 的坑，便于底梁安装。 Dig a pit (1300mm × 1300mm × 400mm) with water drains in the middle part of 4-block foundation for the installing the frame girder.

5) 四块垫板相对位置必须准确，以保证底架的地脚螺栓安装。 The relative positions of 4-group embedded bolts shall be accurate to ensure proper installation.

6) 在底架基础节两个方向的中心线上挂铅垂线，保证安装后底架基础节中心线与

水平面的垂直度≤1.5/1000。 Hang plumb lines along the centerline in 2 directions of the base section to ensure that the perpendicularity of the embedded base section centerline and horizontal plane is less than 1.5/1000.

7) 四块垫板周围混凝土充填率必须达 95%以上。 Concrete filling rate around the four pallets should be over 95％.

TC5613-6塔式起重机

立

塔

1.1-13

图 1.4-5 底架固定式地基基础 Fig.1.4-5 Foundation for Undercarriage

1.4.6

防雷保护

lightning protection

注意：不要与建筑物基础的金属加固件连接。 Notes: Not connected with the steel reinforcement of the building foundation.

1.4.7 平衡重 Counterweight 平衡重共有三种规格，均采用钢筋混凝土浇注成形，具体外形尺寸参见图 1.4-6。 对平衡重的基本要求如下： The counter-weight has two specifications; both are cast with reinforced concrete. For specific dimensions, refer to Fig. 1.4-6. Basic requirements are as following: 1.4.6.1 用混凝土浇注成形后称重，重量允差 2％，砼标号不低于 C18; Weigh the counter-weight cast with reinforced concrete. Permitted weight deviation is 2%, concrete grade no less than C18.

1.4.6.2 平衡重的配置随起重臂长度的改变而变化。见表 1-5 中的值。 Counterweight should be equipped according to the length change of jib (shown as Table 1-5).

1.4.6.3 允许通过改变平衡重长度尺寸 3090 来改变其重量，满足 2%的重量精度要求。 Length change is allowed to change the weight of counterweight, but the weight accuracy of 2% should be secured.

TC5613-6塔式起重机

立

A(mm) 重量(t)Weight

220 1.8

塔

280 2.25

图 1.4-6a 2.25t、1.8t 平衡重 Fig. 1.4-6a

2.25t、1.8t Counterweight

1.1-14

TC5613-6塔式起重机

立

塔

图 1.4-6b

1.3t 平衡重外形尺寸

Fig. 1.4-6b

1.3t Counterweight

1.1-15

表(Table) 1-5

56 米臂长(56m Jib) 6×2.25t＋1× 平衡重 1.8t Counterweight 共计 15.3t 44 米臂长(44m Jib) 平衡重 Counterweight

50 米臂长(50m Jib) 平衡重 Counterweight

6×2.25t

共计 13.5t 38 米臂长(38m Jib) 3×2.25t＋ 5×2.25t 平衡重 1.8t+1.3t Counterweight 共计 11.25t 共计 9.85t

1.5 塔机组装 Erecting 塔机组装必须在固定基础的混凝土强度达到设计值的 70%以上后才能进行 塔机组装顺序按图 1.5-1 进行： The erection of tower crane shall be conducted only after the concrete strength of foundation reaches the designed value of 70%.

Erecting sequence shall be conducted in according to Fig. 1.5-1

TC5613-6塔式起重机

立

塔

1.1-16

1) 安装塔身节 Tower section 2) 吊装爬升架 Climbing frame 3) 安装回转支承总成 Slewing ring assembly 4) 安装塔帽总成 Tower head assembly 5) 安装平衡臂总成 Counter-jib assembly 6) 安装平衡臂拉杆 Counter-jib con-rod 7) 吊装一块 2.250t 重的平衡重 A block of 2.250t counterweight 8) 安装司机室 operator cab 9) 安装起重臂总成 Jib assembly 10) 安装起重 臂拉杆 Jib con-rod 11) 配装平衡重(余下的配重) Equip the remaining counterweights 图 1.5-1 支腿固定式塔机安装顺序示意图 Fig. 1.5-1Installation sequence of stationary crane with embedded anchors

1.5.1 安装塔身节 Tower Section Erecting 1.5.1.1 结构简述 Structure description 塔机在起升高度为 40.5 米 的独立状态下共有 14 节塔身节： 包括一节固定基节 EQ,13 节标准 节 EQ7，塔身节内有供人上下的 爬梯，并有供人休息的平台。 There are, totally, 14 tower sections when the hook height is 40.5m, including one base tower section EQ, 13 tower sections EQ7.

There are a ladder and a platform in each tower section. 图 1.5.1-1 标准节 EQ7 Fig1.5.1-1 Tower Section EQ7

图 1.5.1-1 为标准节 EQ7 示意图，其主弦杆上下端各有 3 个连接套。 There are three bolt joints on the upper and lower ends of each chord of tower section EQ7, 固定基节 EQ 又分预埋支腿固定基节 EQ 和预埋螺栓固定基节 EQ，预埋支腿固定 基节 EQ 主弦杆上下端各有 3 个连接套；预埋螺栓固定基节 EQ 主弦杆上端有 3 个连 接套，下端为法兰盘。 Base tower section EQ is divided into the section connected with pre-buried foundation anchor, which is respectively equipped with three bolt joints on upper and lower

TC5613-6塔式起重机

立

塔

1.1-17

end of chord, and the section connected the foundation with fang bolts, which is equipped with three bolt joints at upper end of chord, and a flange at lower end. 基础节上有踏步的一面应与建筑物垂直, 以便于塔机的安装和拆卸。 Be sure that the climbing lugs on the base section are placed perpendicularly to the building in order to conveniently installing and dismantling the whole tower crane.

1.5.1.2

吊装二个塔身节 Erect two tower sections

图 1.5.1-2

吊装标准节

Fig.1.5.1-2 Erect tower section

1) 如图 1.5.1-2 所示，吊起一节标准节 EQ7。注意严禁吊在水平斜腹杆上; Hoist a tower section EQ7 (shown as Fig. 1.5.1-2), it is forbidden to hoist on the horizontal bar. on base tower section EQ7 and screw them together with 12 pieces high-tensile bolts （strength rating 10.9） 2) 将 1 节标准节 EQ7 吊装到埋好在固定基础上的固定基节 EQ 上, 用 12 件 10.9 级高

强度螺栓连接牢; Hoist a tower section EQ7 onto the base tower section EQ and screw it together with 12 pieces high-tensile bolts（strength rating 10.9） 3) 再吊装一节标准节 EQ7，用 12 件 10.9 级高强度螺栓连接牢;此时基础上已有一节 固定基节 EQ、两节标准节 EQ7， Hoist a tower section EQ7 onto the tower section EQ and screw it together with 12 pieces high-tensile bolts（strength rating 10.9）. There are a base tower section EQ, two the foundation.

tower sectin EQ7

on

4) 所有高强度螺栓的预紧扭矩应达到 1400N·m，每根高强度螺栓均应装配二个垫圈

TC5613-6塔式起重机

立

塔

1.1-18

和二个螺母,并拧紧防松。双螺母中防松螺母预紧扭矩应稍大于或等于 1400N·m; Tighten all high-tensile bolts with torque up to 1400N·m，and each bolt should be equipped with a washer and two nuts. The loose-proof nut （the upper nut）should be fastened with torque equal to or a little more than 1400N·m 5) 用经纬仪或吊线法检查垂直度,主弦杆四侧面垂直度误差应不大于 1.5/1000.

Check the verticality with a theodolitem or a plumb line. The verticality around the main chord should be within the tolerance of 1.5/1000.

1.5.2 吊装爬升架 Hoist Climbing Frame

图 1.5.2-1 爬升架总成 Fig 1.5.2-1 Climbing frame

1.5.2.1 结构简述(见图 1.5.2-1) Structure description(shown as Fig1.5.2-1) 爬升架主要由套架结构、平台、爬梯及液压顶升系统、塔身节引进装置等组成， 塔机的顶升安装主要靠此部件完成。 Climbing frame consists of climbing frame structure, platform, climbing stairs, hydraulic jack system and let-in device for tower section. Its function is jacking and lowering the tower crane. 顶升油缸安装在爬升架后侧的横梁上(即预装平衡臂的一侧)，液压泵站放在液压 缸一侧的平台上，爬升架内侧有 16 个滚轮，顶升时滚轮支于塔身主弦杆外侧,起导向 作用.

Climbing jack is mounted on the beam of rear side of climbing frame (e.g. at the side of pre-assembled counter jib shown as Fig. 1.5.2-1). Hydraulic pump station is placed on the platform at one side of jack. 16 wheels are equipped inside of climbing frame. The wheels support the outside of chord of tower during jack. 爬升架中部及上部位置均设有平台。顶升时，工作人员站在平台上，操纵液压系 统，引入标准节，固定塔身螺栓，实现顶升.

For the purpose of safety jack, platforms are provided at the top of and in the middle of the climbing frame, including platform on the inlet beam. The worker standing on the platform during jack can control hydraulic system, inlet tower section and fasten the bolts.

TC5613-6塔式起重机

1.5.2.2 吊装 Hoisting 1) 架组装完毕后(如图 1.5.2-2 所示)，将吊具挂 在爬升架上，拉紧钢丝绳 吊起。切记安装顶升油缸 的位置必须与塔身踏步 同侧。 After pre-assembling the climbing frame (shown as 1.5.2-2), hoist the frame.

It should be noted that climbing jack is mounted at the same side of the climbing lugs on section.

2) 架缓慢套装在二个塔 身节外侧。 Enclose the climbing frame on the outer side of the mast section slowly

立

塔

1.1-19

图 1.5.2-2 吊装爬升架 Fig.1.5.2-2 Hoisting Climbing Frame

3) 架上的活动爬爪放在塔身节的第二节(从下往上数)上部的踏步上。 Place the frame over two tower sections and lower it until the pawl is supported by the upper climbing lugs of the second tower section (count down up).

4) 安装顶顶升油缸, 将液压泵站吊装到平台一角,接油管,检查液压系统的运转情 况。 Fix the jacking cylinder and hoist the hydraulic pump station to one corner of the platform, connect oil tubes, and check the hydraulic system for normal operation.

1.5.3 安装回转总成 Install the Assembly of Slewing Ring 1.5.3.1 结构简述 Structure description 回转总成包括下支座、回转支承、上支座、回转机构共四部分.见图 1.5.3-1.

The assembly of slewing ring consists of the slewing ring support, slewing ring, upper support and slewing mechanism. Shown as Fig 1.5.3-1 下支座下部分别与塔身节和爬升架相连，上部与回转支承通过高强度螺栓连接。 The lower portion of the ring support is connected to the tower section and the climbing frame. It is connected to the outer ring of the slewing ring by high-strength bolt at the upper. 上支座一侧有安装回转机构的法兰盘及平台，另一侧工作平台有司机室连接的支 耳，前方设有安装回转限位器的支座。用φ55 的销轴将上支座与塔帽连成一个整体。 There are flange and platform on one side for the installation of slewing mechanism.

On the other side of working platform is welded with a support lug for connection of the operator cab. There is a support for the installation of slewing limiter on the forepart.

TC5613-6塔式起重机

立

塔

1.1-20

图 1.5.3-1 回转总成 Fig.1.5.3-1 Slewing Assembly

1.5.3.2 吊装回转总成 Hoist and install the assembly of slewing rings 1) 检查回转支承上 8.8 级 M24 的高强螺栓的预紧力矩是否达 640N·m，且防松螺 母的预紧力矩稍大于或等于 640N·m。 Check if the torque of M24 high-tensile bolts （strength rating 8.8）reaches up to 640N.m, and the torque of loose-proof nuts（the upper nut）should be a little more than or equal to 640N·m.

TC5613-6塔式起重机

立

塔

1.1-21

图 1.5.3-2 吊回转总成 Fig. 1.5.3-2，hoist the assembly of slewing rings

2) 如图 1.5.3-2 所示，将吊具挂在上支座φ55 的销轴上，将回转总成吊起。 Shown as Fig. 1.5.3-2，hoist the assembly of slewing ring by hooking the four connecting ears (shoe) at the slewing ring platform.

3) 下支座的八个连接套对准标准节 EQ7 四根主弦杆的八个连接套,缓慢落下,将回 转总成放在塔身顶部。下支座与爬升架连接时,应对好四角的标记。 Put the assembly of slewing ring support on the top of tower. Four-corner marks on slewing ring support and climbing frame should be aligned during the connection of them.

4）用 8 件 10.9 级的 M30 高强度螺栓将下支座与标准节 E 连接牢固(每个螺栓用双 螺母拧紧防松), 螺栓的预紧力矩应达 1400N·m，双螺母中防松螺母的预紧力矩稍大 于或等于 1400N·m。 Screw them together with 8 pieces high-tensile bolts（strength rating 10.9）, and equipping each bolt with a washer and two nuts. Tightening all the bolts with torque up to 1800N·m，the loose-proof nut （the upper nut）should be fastened with torque equal to or a little more than 1800N·m.

5) 操作顶升系统,将爬升架顶升至与下支座连接耳板接触,用 4 根销轴将爬升架与 下支座连接牢固.

Operation of jack system: Jack the climbing frame until it is high enough to be pined to the slewing ring support with four pins.

TC5613-6塔式起重机

立

塔

1.1-22

1.5.4 安装塔帽 Install Twer Head 1.5.4.1 结构简述(见图 1.5.4-1) Structure description (shown as Fig.1.5.4-1) 塔帽上部为四棱锥形结构，顶部有平 衡臂拉板架和起重臂拉板并设有工作 平台，以便于安装各拉杆；塔帽上部 设有起重钢丝绳导向滑轮和安装起重 臂拉杆用的滑轮，塔帽后侧主弦下部 设有力矩限制器并设有带护圈的扶梯 通往塔帽顶部。 The tower head is a pyramid structure.

At the top there are a support for counter-jib con-rod, a support for jib con-rod, a working platform for installing 图 1.5.4-1 塔帽总成 (Tower Head Assembly) con-rods, and a wire rope pulley and a pulley block for installing jib con-rods.

Moment limiter and ladder with handrails to the top of tower head are equipped at the lower side of chord at the rear of tower head. 塔帽下部为整体框架结构，中间部 位焊有用于安装起重臂和平衡臂的 耳板。通过销轴与起重臂、平衡臂相 连.

The lower sector of tower head is is an integral frame structure. Lugs are welded at the middle of tower head for connecting jib and counter-jib with pins.

1.5.4.2 吊装塔帽 Hoist and Install the Tower Head 1) 吊装前在地面上先把塔帽上的平 台、栏杆、扶梯及力矩限制器装好 (为使安装平衡臂方便，可在塔帽的后侧 左右两边各装上一根平衡臂拉杆); 图 1.5.4-2 吊装塔帽总成 Fig.1.5.4-2 Hoist and Install the tower head Before hoisting, assemble the platform, rails, ladders and moment limiter on the ground. On each side at the back of the tower head, mount one counter-jib con-rod for conveniently installing the counter-jib.

2) 如图 1.5.4-2 所示，将塔帽吊到上支座上，应注意将塔帽垂直的一侧应对准上支 座的起重臂方向。(参见图 1.5.3-1, 1.5.4-1)

TC5613-6塔式起重机

立

塔

1.1-23

Shown as Fig. 1.5.4-2，hoist the tower head onto the upper support. It should be noted that the vertical side be faced to the direction of jib. (Shown as Fig.1.5.3-1, 1.5.4-1) 3) 用 4 件φ55 销轴将塔帽与上支座紧固。 Connect the tower head to the upper support with four pieces of φ55 pins.

1.5.5 安装平衡臂总成 Install Counter-jib 1.5.5.1 结构简述(见图 1.5.5-1) Structure description(shown as Fig.1.5.5-1)

图 1.5.5-1 平衡臂总成 Fig.1.5.5-1 Counter-jib assembly

平衡臂是槽钢及角钢组焊成的结构，平衡臂上设有栏杆、走道和工作平台，平衡 臂的前端用两根销轴与塔帽连接，另一端则用两根组合刚性拉杆同塔帽连接。 The counter-jib is welded structure of channel steel and angle steel. There are banisters, passage and operating platform on it. The counter-jib consists of two sections. The front end is connected to the tower head with two pins, and the other end to upper of the tower head with two stiff con-rods. 尾部装有平衡重、起升机构，电阻箱、电气控制箱布置在靠近塔帽的一节臂节上。 起升机构本身有其独立的底架，用四组螺栓固定在平衡臂上。 Its tail section is equipped with the counter-weight, hoisting mechanism. The resistance box and the electric control cabinet are arranged at the root of the front section. The hoist mechanism and its own base frame are fixed on the counter-jib by four bolts.

1.5.5.2 吊装平衡臂总成 Hoist counter-jib assembly 1) 在地面组装好两节平衡臂，将起升机构、电控箱、电阻箱、平衡臂拉杆装在平衡臂 上并固接好。回转机构接临时电源,将回转支承以上部分回转到便于安装平衡臂的方 位;

TC5613-6塔式起重机

立

塔

Assemble the two sections of the counter-jib with banisters, passage and operating platform on the ground. And fix the hoisting mechanism, the electric control cabinet, the resistance box and counter-jib con-robs onto the counter-jib. Connect the slewing mechanism to the temporary power supply, and slew the portion above slewing ring to a position for convenient mount of the counter-jib.

2) 如图 1.5.5-2 所示，吊起平衡 臂(平衡臂上设有 4 个安装吊 耳); Shown as Fig. 1.5.5-2，hoist the counter-jib (Four mounting ears are equipped on the counter-jib). 图 1.5.5-2 吊平衡臂总成 Fig.1.5.5-2 Hoist counter-jib assembly

图 1.5.5-3 平衡臂拉杆总成 Fig.1.5.5-3 Counter-jib con-rods assembly

3) 用销轴将平衡臂前端与塔帽固定联接好; Connect the front end of counter-jib to the tower head with pins.

1.1-24

TC5613-6塔式起重机

立

塔

1.1-25

4) 按平衡臂拉杆示意图 1.5.5-3 所示， 将平衡臂逐渐抬高，便于平衡臂拉杆与 塔帽上平衡臂拉杆相连，用销轴连接， 并 穿 好 充 分 张 开 开 口 销 ;( 如 图 1.5.5-4) Shown as 1.5.5-3 for the counter-jib con-rod schematic diagram, lift up the counter-jib slowly to a proper position for smooth connection of the counter-jib con-rod to those on the tower head.

Connect the con-rods by pins, insert and open up cotter pins. (Shown as Fig.1.5.5-4) 5) 缓慢地将平衡臂放下，再吊装一块 2.25t 重的平衡重安装在平衡臂最靠近 起升机构的安装位置上(如图 1.5.5-5 所示)。 Lay down the counter-jib slowly. Lift a piece of 2.25T counter-weight at the furthest position of the counter-jib, shown as Fig.1.5.5-5. 图 1.5.5-4 安装平衡臂拉杆 Fig.1.5.5-4 Install counter-jib con-rod

特别注意:

Special Notice: 1.安装销的挡块必须紧靠平衡重块; Be sure of mounting the baffle of the counter-weight pins against the counter-weight.

2.安装销必须超过平衡臂上安装平衡重 的三角挡块.

Be sure of mounting the end face of the counter-weight pin exceeding the triangle plate.

图 1.5.5-5 安装一块平衡重 Fig.1.5.5-5 Hoisting one piece of 2.25T counter-weight

TC5613-6塔式起重机

立

塔

1.1-26

1.5.6 安装司机室 1.5.6.1 结构简述(见图 1.5.6-1) Structure description (shown as Fig.1.5.6-1) 司机室为薄板结构，侧置于上支座右侧 平台的前端，四周均有大面积的玻璃窗，前 上窗可以开启，视野开阔。司机室内壁用保 丽板装饰，美观舒适，内设有联动操纵台。 The cab is a sheet structure, offset at the front on the upper support right side platform. There are large big glass windows on the four sides of the cab. The upper window in front can be opened to obtain a wide field of view. The cab is nice-looking and comfortable, equipped with inter-active control console. 图 1.5.6-1 司机室 Fig.1.5.6-1 Operator cab

1.5.6.2 联动台面板布置 collocation of control console (见图 1.5.6-2)

图 1.5.6-2

Fig.1.5.6-2

序号

图标

名 称

功 能 说 明

No.

ico

designation

functions explanation

1

“启动/电笛”按钮 “star/ring”button

电控系统启动控制按钮。 此按钮同时也是电笛控制按钮。 Electronic control system start-control-button Ring-button.

TC5613-6塔式起重机

立

2

“紧急停止”按钮 “emergency stop”button

3

“超 100%额定力矩” 报警灯 “exceed 100% of working moment”alarm-light

4

“超 90%额定力矩” 报警灯 “exceed 90% of working moment”alarm-light

5

“超 100%额定起重量”报 警灯 “exceed 100% of working load”alarm-light

6

“超 50%额定起重量” 报警灯 “exceed 50% of working load”alarm-light 吊钩上升操作方向指示

7

operating indication of the hook raising

吊钩下降操作方向指示 8

operating indication of the hook falling

向前行走操作方向指示 9

operating indication running ahead

of

向后行走操作方向指示 10

operating indication running back

of

塔

1.1-27

当出现异常的情况时，紧急切断控制系统电源 的操作按钮，同时也可在正常停止工作时使 用。该按钮为自锁式，按下后，需旋转才能释 放。 In abnormal conditions,urgently cut off power of control system. At the same time,the button can be used in normal-stop. The button is anto-lock only when be pressed down,the machine can run. 当负载力矩超过额定力矩的 100%时，该报警灯 亮。 When load-moment exceeds100% of working moment ,the alarm-light is on. 当负载力矩超过额定力矩的 90%时，该报警灯 亮。 When load-moment exceeds 90% of working moment ,the alarm-light is on. 当吊重超过额定起重量的 100%时，该报警灯 亮。 When load exceeds 100% of working load ,the alarm-light is on. 当吊重超过额定起重量的 50%时，该报警灯亮。 When load exceeds 50% of working load ,the alarm-light is on. 当右联动台手柄向此方向操作，吊钩向上运 行。 When the handle of right collocation of control console is at this direction, the hook is running up. 当右联动台手柄向此方向操作，吊钩向下运 行。 When the handle of right collocation of control console is at this direction, the hook is running down. 当右联动台手柄向此方向操作，行走台车向前 运行。 When the handle of collocation of control console is at this direction, the trolley is running ahead. 当右联动台手柄向此方向操作，行走台车向后 运行。 When the handle of collocation of control console is at this direction, the trolley is running back.

TC5613-6塔式起重机

11

12

13

立

“回转/制动”控制旋钮 “slewing/braking”button

“旁路”按钮 bypass-button

“启动”指示灯 start-indicator light

向左旋转操作方向指示 14

operating indication of turning left

向右旋转操作方向指示 15

operating indication of turning right

向外变幅操作方向指示 16

operating indication of trolley-radius-changing outside 向内变幅操作方向指示

17

operating indication of trolley-radius-changing inside

塔

当该旋钮向左旋转，回转制动器释放，吊臂可 以旋转；当该旋钮向右旋转，回转制动器投入 工作，吊臂不可旋转。 When the button is turn left ,the slewing brake is off,jib can slew;when the button is turn right, the slewing brake is on, jib can´t slew. 当更换倍率或进一步内收小车时，按下此按 钮，可使控制系统不受限位信号限制，继续驱 动起升或变幅机构运行。 When changing fall or running trollry inside, pressing down the button, control-system is out of the control of position-limiter, hoisting or trolley-radius-changing can run continuesly. 当电控系统处于启动、运行状态时，该指示灯 亮。 When the electronic control system is start or run state, the button is on. 当左联动台手柄向此方向操作，回转机构向左 旋转。 When the handle of left collocation of control console is at this direction, the slewing is turning left. 当左联动台手柄向此方向操作，回转机构向右 旋转。 When the handle of left collocation of control console is at this direction, the slewing is turning right. 当左联动台手柄向此方向操作，变幅机构向外 运行。 When the handle of left collocation of control console is at this direction, the trolley-radius-changing is running outside 当左联动台手柄向此方向操作，变幅机构向内 运行。 When the handle of left collocation of control console is at this direction, the trolley-radius-changing is running inside

塔机工作时，司机室噪音不超过 80 分贝。 The nosie in operator cab is below 80db when the tower crane in working.

1.5.6.2 吊装司机室 Hoist and install the operator cab

1.1-28

TC5613-6塔式起重机

立

塔

1.1-29

司机室内的电气设备安装齐全后，吊到上支座靠右平台的前端(如图 1.5.6-2 所 示)，对准耳板孔的位置后用三根销轴联接。 注: 司机室也可在地面先与回转总成组装好后，整体一次性吊装。 Mount the electric equipment in the cab and then hoist the cab to the front near right platform of the upper support (Fig.1.5.6-2). Align it with the hole-position of ear-plate and connect them with three pins and insert cotter pins.

Alternatively assemble on the ground the cab and slewing ring assembly and hoist the whole piece once for all.

图 1.5.6-2 吊装司机室 Fig.1.5.6-2 Hoist operator cab

1.5.7 安装起重臂总成 Install jib assembly 1.5.7.1 结构简述(见图 1.5.7-1) Structure description (shown as Fig.1.5.7-1) 起重臂为三角形变截面的空间桁架结构，共分为十节。节与节之间用销轴连接， 拆装方便。第一节根部与塔帽用销轴连接，在第二节、第七节上设有两个吊点，通过 这两点用起重臂拉杆与塔帽连接；第二节中装有牵引机构，载重小车在牵引机构的牵 引下，沿起重臂下弦杆前后运行。载重小车一侧设有检修吊篮，便于塔机的安装与维 修。 The whole jib is a varied cross-section triangle spatial structure, consisting of ten sections. Section-to-section is connected by pins for the purpose of convenient installing and dismantling. The root of the first jib section is connected to the tower head by pins. The second and seventh sections are provided with two hook lugs, through which jib con-rods are connected to the tower head. The trolley mechanism is mounted in the 2nd section; maintenance cage is set at the side of trolley for tower crane installation and maintenance. 起重臂组装时，必须严格按照每节臂上的序号标记组装，不允许错位或随意组装。 根据施工要求可以将起重臂组装成 56m、40m、44m 及 38m 臂长。50m 臂拆下第九节； 44m 臂则拆下第九、五节;38m 臂则拆下第九、五、八节。如图 1.5.7-2 所示。

TC5613-6塔式起重机

立

塔

1.1-30

图 1.5.7-1 起重臂结构 Fig 1.5.7-1 Jib structure

Jib sections should be assembled strictly according to the series number marked on each section, and the jib may be assembled with various jib lengths of 56m, 50m and 44m according to the construction requirements. Dismantling the 9th section, the jib length is 50m, and dismantling 5th and 9th sections, the jib length is 44m, and dismantling 5th and 8th and 9th sections, the jib length is 38m, shown as Fig. 1.5.7-2.

图 1.5.7-2 起重臂的组装 Fig.1.5.7-2 Jib assembly

1.5.7.2 吊装起重臂总成 Hoist and install jib assembly 1) 在塔机附近平整的枕木(或支架，高约 0.6m)上按图 1.5.7-2 及图 1.5.7-5 的 要求，拼装好起重臂。注意无论组装多长的起重臂，均应先将载重小车套在起重臂下 弦杆的导轨上。 Assemble the jib on the flat sleepers (or supports) near the tower crane. No matter how many the jib length is, the trolley must at first be mounted on the guide rail on the jib lower chord.

2) 将维修吊篮紧固在载重小车上,并使载重小车尽量靠近起重臂根部最小幅度 处.

TC5613-6塔式起重机

立

塔

1.1-31

Mount the maintenance cage to the trolley and move the trolley as close to the minimum radius point of jib root (foot) as possible.

3) 安装好起重臂根部处的牵引机构，卷筒绕出两根钢丝绳，其中一根短绳通过臂 根导向滑轮固定于载重小车后部，另一根长绳通过起重臂中间及头部导向滑轮，固定 于载重小车前部(图 1.5.7-3)。在载重小车后部有 3 个绳卡，绳卡压板应在钢丝绳受 力一边，绳卡间距为钢丝绳直径的 6～9 倍。如果长钢丝绳松弛，调整载重小车的前端 的张紧装置即可张紧。在使用过程中出现短钢丝绳松驰时,可调整起重臂根部的另一套 牵引钢丝绳张紧装置将其张紧.

Mount the traveling mechanism at the jib root section, let two wire ropes from the wire drum and let one of them pass over the guide pulley at the jib root, and then fix it at the back of the trolley. Let the other rope pass over the guide pulley at the middle of jib and head portions and then fix it at the front of the trolley, as shown in Fig. 1.5.7-3. At the rear of the trolley is provided with three rope clips. And rope clip compression plates must be on the side of ropes with force applied. The rope clip interval is 6~9 times of the wire rope diameter. At the front end of the trolley is provided with tensioning devices. If the traction rope has become loosened, adjust tensioning devices to tension the rope. The jib root section is provided with another set of rope tensioning devices. Any loosened rope during its operation can be tensioned by this tensioning set.

图 1.5.7-3 牵引钢丝绳绕绳示意图 Fig. 1.5.7-3 Trolley Wire Rope Layout Plan

4)将起重臂拉杆按图 1.5.7-4 所示拼装好后与起重臂上的吊点用销轴连接，穿好 开口销，放在起重臂上弦杆的定位托架内。 After assembling jib con-rods shown as Fig.1.5.7-4, connect it to the jib hook lugs on the upper chord of jib with pins, insert cotter pins, then place jib con-rods on the bracket of upper chord on the jib.

5)检查起重臂上的电路走线是否完善。使用回转机构的临时电源将塔机上部结构 回转到便于安装起重臂的方位。 Check and perfect the circuit connection on the jib. Switch on the temporary power supply of the slewing mechanism to slew the tower crane superstructure to a position for convenient installation of the jib.

6)按图 1.5.7-5 挂绳，试吊是否平衡，否则可适当移动载重小车的位置 (记录下 吊点位置便于拆塔时用) ，起吊起重臂总成至安装高度。如图 1.5.7-6 所示用销轴将 塔帽与起重臂根部连接固定。

TC5613-6塔式起重机

立

塔

1.1-32

图 1.5.7-4 起重臂拉杆组成示意图 Fig. 1.5.7-4 Jib pull rod Diagram

Hang up ropes shown as Fig. 1.5.7-5. Try the ropes for balance. In case of improper balance, move properly the trolley position. Lift the jib assembly to the mount height. Use the axle-positioning frame and pins to connect the slewing tower body to the root section of jib and then fasten the connection shown as Fig. 1.5.7-6. Attention: record the jib lifting point for reference during tower dismantling.

图 1.5.7-5 起重臂吊点 Fig.1.5.7-5 position of hoisting the jib

L(m) G(kg)

56 米臂长 56m Jib 19.8 6250

50 米臂长 50m Jib 18.3 5850

44 米臂长 44m Jib 16.2 5450

38 米臂长 38m Jib 14.2 5050

注 Notices: 1 起重臂安装时的参考重心位置含长短拉杆、牵引机构、载重小车、且载重小车 位置在最根部时；

TC5613-6塔式起重机

立

塔

1.1-33

As for the position of center of gravity during jibs installation with different lengths (incl. long and short tie rods, traveling mechanism, anti-drop device, and trolley at the minimum radius), refer to the Table below.

2 吊装时 8 米＜l＜20 米； When hoisting, 8m＜L＜20m.

3 组装好的起重臂用支架支承在地面时,严禁为了穿绕小车牵引钢丝绳的方便仅 支承两端,全长内支架不应 少于 5 个,且每个支架均应垫好受力,为了穿绕方便允许 分别支承在两边主弦杆下.

The assembled jib should be supported on the ground by at least 5 supports during winding wire rope.

图 1.5.7-6 吊装起重臂 Fig. 1.5.7-6 Install jib assembly

7) 接通起升机构的电源，放出起升钢 丝绳按图 1.5.7-7 缠绕好钢丝绳，用汽车 吊逐渐抬高起重臂的同时开动起升机构向 上，直至起重臂拉杆靠近塔顶拉板，按图 1.5.7-8 及图 1.5.7-9 将起重臂长短拉杆 分别与塔顶拉板Ⅰ、Ⅱ用销轴连接，并穿 好开口销。松驰起升机构钢丝绳把起重臂 缓慢放下。 图 1.5.7-7 安装起重臂拉杆时起升钢丝绳绕法 Fig.1.5.7-7 Hoisting rope layout for installing jib con-rods

TC5613-6塔式起重机

立

塔

1.1-34

Reeve the hoisting wire rope according to Fig. 1.5.7-7，start hoisting winch while lifting the jib slowly with a mobile crane till jib-tie reaches hauling plate, then fasten short and long jib-ties to the Plate I and II at the cat head with pins shown as Fig. 1.5.7-8 and Fig. 1.5.7-9, insert split pin, let off wire rope of hoisting winch and lay down jib slowly.

图 1.5.7-8 与起重臂拉杆连接处塔帽结构 图 1.5.7-9 塔帽与起重臂拉杆连接处结构 Fig. 1.5.7-8 Tower head structure at the joint of jib con-rod Fig. 1.5.7-9 Joint structure

8) 使拉杆处于拉紧状态，最后松脱滑轮组上的起升钢丝绳。 After connecting jib con-rods to tower head, dismantle the hoisting rope.

1.5.8 配装平衡重 Assemble counter-weight 平衡重的重量随起重臂长度的改变 而 改变。见表 1-5 中的值。 The weight of counter-weight varies in proportional to the jib length (Table 1-5). 根据所使用的起重臂长度，按图 1.5.8-1 要求吊装平衡重。 The counter-weight is hoisted according to the jib length used. 起重臂四种臂长工况下平衡重的配 置及安装位置严格按要求安装。 The counter-weight configuration and mounting position are strictly acted on the requirements of four jib-length conditions. 特别注意:

Special Notice: 1.安装销的挡块必须紧靠平衡重块;

图 1.5.8-1

Be sure of mounting the baffle of the counter-weight

Fig.1.5.5-5 Hoisting counter-weight

pins against the counter-weight.

吊装平衡重

TC5613-6塔式起重机

立

塔

1.1-35

2.安装销必须超过平衡臂上安装平衡重的三角挡块.

Be sure of mounting the end face of the counter-weight pin exceeding the triangle plate.

1.6 绕绳系统 Rope-winding system of hoist mechanism 1.6.1 穿绕钢丝绳 吊装完毕后，进行起升钢 丝绳的穿绕。如图 1.6-1 所示， 起升钢丝绳由起升机构卷筒放 出，经机构上排绳滑轮，绕过 塔帽导向滑轮向下进入塔顶上 起重量限制器滑轮，向前再绕 到载重小车和吊钩滑轮组，最 后将绳头通过绳夹，用销轴固 定在起重臂头部的防扭装置 上。 图 1.6-1 起升钢丝绳绕绳示意图 Fig.1.6-1 Hoisting rope layout

After installation, wind hoisting ropes. As shown in Fig.1.6-1, the hoisting rope is released from the wire rope drum, passing through the rope discharging pulley, going through the guide pulley on tower head, going down into the pulley of overload limiter in the tower head, runing further to the trolley and hook pulley block. It is finally fixed on the anti-torsion device at the jib tip by rope clips.

1.6.2 接电源及试运转 Power on and Trial operation 当整机按前面的步骤安装完毕后，在无风状态下，检查塔身轴心线对支承面的垂直 度，允差为 4/1000；再按电路图的要求接通所有电路的电源，试开动各机构进行运转， 检查各机构运转是否正确(详见有关章节)，同时检查各处钢丝绳是否处于正常工作状 态，是否与结构件有摩擦，所有不正常情况均应予以排除。如果安装完毕就要使用塔 机工作，则必须按第三章的要求调整好安全装置。 After the installation of the whole crane according to the above steps, check the verticality of tower body axis at no wind conditions. The verticality tolerance is 4/1000.

Switch on power to all electric circuits according to the electric circuit diagram and start all mechanisms for test run. Check mechanism for proper operations (details, refer to relevant instructions). At the same time, check wire ropes at different locations for normal working and for any friction with structure member. Remove all abnormal cases. If the tower crane needs to be put into service immediately after the installation, the safety device must be adjusted as specified in section3.

TC5613-6塔式起重机

立

塔

1.1-36

1.7 换倍率器的使用(见图 1.7-1) Fall-change system 换倍率装置是一个带有活动滑轮的挂体，当其与吊钩连成一体时,起升钢丝绳系统 为 4 倍率,当挂体与吊钩脱离并顶在载重小车底面时,起升钢丝绳系统则变为 2 倍率。 Fall-change-device is a hanging block with movable pulley, when the hanging block is integrated with hook; the hoisting wire rope system is 4-fall. It is changed into 2-fall when hanging block is separated from hook and abuts on the bottom of trolley.

图 1.7-1 换倍率装置 Fig.1.7-1 Fall-change Device

1.7.1 当需要用 2 倍率工作时，操纵起升机构，使吊钩向下运动并着地，拔出挂体销 轴，然后开动起升机构，收紧钢丝绳，使挂体上升至与载重小车接触。注意：起升机 构的排绳情况不得有乱绳情况出现。这样起升钢丝绳系统就转换成 2 倍率。 When need the 2-fall condition, start hoisting mechanism and move the hook downward till touching the ground, pull pin of the hanging block out, and then start hoisting mechanism, wind wire rope and lift the hanging block untill it touches trolley. At this time the hoisting rope is changed into 2-fall.

Notice: The wire rope should be regular on the drum of the hoisting mechanism.

1.7.2 若要再将起升钢丝绳系统转换 4 倍率，则又操纵起升机构，放下吊钩至地面， 并使挂体落回到吊钩的挂体槽内。插上销轴和开口销，并充分张开开口销。这样起升 钢丝绳系统就自动转换为 4 倍率。 If you need to change the hoisting rope into the 4-fall condition, start hoisting mechanism, lay down hook untill it touches ground, let the hook block fall down into cradle, insert pin and split pin. At this time the hoisting rope is changed into 4-fall.

TC5613-6塔式起重机

立

塔

1.1-37

1.8 顶升加节 Jacking operation for adding sections

引进滚轮的使用方法 The usage method of the inlet roll 1、将引进滚轮的销轴插入标准节的连接套中，如上图中的 1 所示。 Insert the pin of the inlet roll into the bolthole of the tower section. The step is shown as the 1st of the upper drawing.

2、将引进滚轮旋转 900，使之托住标准节的水平腹杆，如上图中的 2 所示。 Rotate the inlet roll through 900 and then it supports the level bar of the tower section.

The step is shown as the 2nd of the upper drawing.

3、将四个引进滚轮按上述步骤都安装好后，将标准节吊装到引进平台上，引进滚 轮的滚轮对准引进平台的引进梁，这样四个引进滚轮将标准节抬起来了，如上图中的 3 所示。 According to the step 1 and the step 2, install the four inlet rolls into the boltholes, and then hoist the tower section onto the inlet platform, put the rolls on the beams (each side 2

TC5613-6塔式起重机

立

塔

1.1-38

rolls) of the platform. So the four inlet rolls support the tower section (shown as the 3rd of the upper drawing).

1.8.1 顶升前的准备 Pre-jacking preparations 1.8.1.1 按液压泵站要求给其油箱加油; Fill the oil tank with hydraulic oil according to the requirements of hydraulic pump station.

1.8.1.2 清理好各个塔身节，在塔身节连接套内涂上黄油，将待顶升加高用的标准节 EQ7 在顶升位置时的起重臂下排成一排，这样能使塔机在整个顶升加节过程中不用回 转机构，能使顶升加节过程所用时间最短; Put in order each mast section and apply the grease into its connection boltholes. Line up the tower sections EQ7 under jib before jacking. This will enable no use of the slewing mechanism in the whole process of jacking operation for adding sections, thus minimizing the jacking time.

1.8.1.3 放松电缆长度略大于总的顶升高度，并紧固好电缆; Loosen the power cable length slightly in excess of the total jacking height, and then fix the cable.

1.8.1.4 将起重臂旋转至爬升架前方，平衡臂处于爬升架的后方(顶升油缸正好位于 平衡臂下方); Slew the jib to the front of the climbing frame and the counter-jib at the rear of climbing frame (jacking cylinder is just under the counter-jib).

1.8.1.5 在引进平台上准备好引进滚轮，爬升架平台上准备好塔身高强度螺栓。 Preparation should be made on the platform to inlet wheels and high-tensile bolts for tower sections on the climbing frame.

1.8.2 顶升前塔机的配平(见图 1.8-1) jacking operation (Fig.1.8-1)

Keep the tower crane in balance before

图 1.8-1 顶升前的平衡 Fig.1.8-1 Keep the tower crane in balance

TC5613-6塔式起重机

立

塔

1.1-39

1.8.2.1 塔机配平前，必须先将载重小车运行到图 1.8-1 所示的配平参考位置，并吊 起一节标准节 EQ7 或其它重物(表中载重小车的位置是个近似值，顶升时还必须根据实 际情况的需要调整)。然后拆除下支座四个支腿与标准节 EQ7 的连接螺栓; Before keeping the tower crane in balance, hoist one tower section EQ7 onto the introduction platform and then move the trolley to the reference balance position shown as Fig. 1.8-1. Hoist one mast section or other weights (The trolley position in table is an approximate value, which must be adjusted according to the actual situation in jacking).

Then remove all the bolts connecting outriggers of the slewing ring support to tower section EQ7.

1.8.2.2 将液压顶升系统操纵杆推至“顶升”方向， 使爬升架顶升至下支座支腿刚刚 脱离塔身的主弦杆的位置； Push the operation handle of the hydraulic jacking system to <<Jacking direction>> to jack the climbing frame to a position where the legs of slewing ring support are just disengaged from the main chord rod of the tower body.

1.8.2.3 通过检验下支座支腿与塔身主弦杆是否在一条垂直线上,并观察爬升架 16 个 导轮与塔身主弦杆间隙是否基本相同来检查塔机是否平衡。略微调整载重小车的配平 位置，直至平衡。使得塔机上部重心落在顶升油缸梁的位置上; Check if the outrigger of slewing ring support is on the same vertical line with the chord of the tower section. Check 16 guide rollers on the climbing frame and tower body main chord rod to make sure that they have the same clearance. This serves to determine whether or not the tower crane is in balance. If not, adjust the balance position of the trolley until balance is achieved so as to drop the center of gravity of the upper tower crane onto the position of jacking cylinder beams.

1.8.2.4 记录下载重小车的配平位置。但要注意该位置随起重臂长度不同而改变； Record the balance position of the trolley for the convenience of dismantling. This mark position varies with different jib lengths.

1.8.2.5 操纵液压系统使爬升架下降，连接好下支座和塔身节间的连接螺栓。 Operate the hydraulic system to lower down the sleeve frame. Connect the slewing ring support to tower sections with bolts.

1.8.3 顶升作业(见图 1.8-2 所示) Jacking operation (shown as Fig. 1.8-2) 1.8.3.1 将一节标准节 EQ7 吊至顶升爬升架引进横梁的正上方，在标准节 EQ7 下端装 上四只引进滚轮，缓慢落下吊钩，使装在标准节 EQ7 上的引进滚轮比较合适地落在引 进横梁上，然后摘下吊钩; Hoist a tower section EQ7 to the top of inlet platform of climbing frame, install four inlet rolls at the lower end of tower section EQ7, lower the hook slowly so that the inlet wheels are seated onto the inlet beam properly, Then remove the hook.

1.8.3.2 再吊一节标准节 EQ7，将载重小车开至顶升平衡位置; Hoist another tower section EQ7 and drive the trolley to the position for balance.

1.8.3.3 使用回转机构上的回转制动器，将塔机上部机构处于制动状态; Use the brake on the slewing mechanism to hold the tower superstructure at a slewing braking status, thus ensuring no slewing movements.

1.8.3.4 卸下塔身顶部与下支座连接的 8 个高强度螺栓。

TC5613-6塔式起重机

立

塔

1.1-40

Remove the eight bolts connecting tower section to slewing ring support.

1.8.3.5 开动液压顶升系统，使油缸活塞杆伸出，将顶升横梁两端的销轴放入距顶升 横梁最近的塔身节踏步的圆弧槽内并顶紧(要设专人负责观察顶升横梁两端销轴都必 须放在踏步圆弧槽内)，确认无误后继续顶升，将爬升架及其以上部分顶起 10～50mm 时停止，检查顶升横梁等爬升架传力部件是否有异响、变形，油缸活塞杆是否有自动 回缩等异常现象，确认正常后， 继续顶升；顶起略超过半个塔身 节高度并使爬升架上的活动爬 爪滑过一对踏步并自动复位后， 停止顶升，并回缩油缸，使活动 爬爪搁在顶升横梁所顶踏步的 上一对踏步上。确认两个活动爬 爪全部准确地压在踏步顶端并 承受住爬升架及其以上部分的 重量，且无局部变形、异响等异 常情况后，将油缸活塞全部缩 回，提起顶升横梁，重新使顶升 横梁顶在爬爪所搁的踏步的圆弧 图 1.8-2 顶升过程 Fig1.8-2 Operation of Climbing 槽内，再次伸出油缸，将塔机上部结构再顶起略超过半个塔身节高度，此时塔身上方 恰好有能装入一个塔身节的空间，将爬升架引进平台上的标准节 EQ7 拉进至塔身正上 方，稍微缩回油缸，将新引进的标准节 EQ7 落在塔身顶部并对正，卸下引进滚轮，用 12 件 M30 的高强度螺栓(每根高强螺栓必须有两个螺母)将上、下标准节 EQ7 连接牢靠 (预紧力矩 1400kN·m)。 Start hydraulic jack system; extrude the piston of the cylinder place the pins of both ends of the jack beam into the cradle of the climbing lugs on tower section nearest to the beam (It should be checked by a specially- designed watchdog). Erect the climbing frame and the upper part until it reaches the height of 10～50mm. Check if there are any strange sounds, deformation, any self-retreat of piston rod etc, after confirmation, go on to erect until it reaches the height of half the tower section, the support latches on the climbing frame pass through a pair of climbing lugs and resets automatically, then retreat the jack to let the support latches stay at the upper climbing lugs, confirm that the two support latches press the top of climbing lugs and bear the weight of climbing frame and the upper part without any strange sound and deformation, retreat the piston completely, lift jack beam so as to support the cradle of climbing lugs. Erect the upper part of tower crane to a height of a little more than half the tower section so that the space is fit for a tower section, drag the tower section EQ7 on the inlet platform of climbing frame into upper part of tower, retreat the jack slightly so that the new tower section EQ7 alight at the top of tower and conduct proper alignment, remove the inlet wheels, fasten the upper and lower sections with 12 pieces of M30 bolts with torque of 1400kN·m, each bolt must be equipped with two nuts. 再次缩回油缸，将下支座落在新的塔身顶部上，并对正，用 8 件 M30 高强螺栓将 下支座与塔身连接牢靠(每根高强螺栓必须有两个螺母)，即完成一节标准节 EQ7 的加 节工作。若连续加几节标准节 EQ7，则可按照以上步骤重复几次即可。为使下支座顺

TC5613-6塔式起重机

立

塔

1.1-41

利地落在塔身顶部并对准连接螺栓孔,在缩回油缸之前，可在下支座四角的螺栓孔内从 上往下插入四根(每角一根)导向杆,然后再缩回油缸，将下支座落下。 Retreat the jack once more to let the lower of slewing ring support alight at the top of new mast and conduct proper alignment, then fasten ring support to tower section with eight pieces of M30 high-tensile bolts, each bolt must be equipped with two nuts. Then a tower section is mounted. If several sections are to be mounted, just repeat procedures mentioned above，As for proper alignment of slewing ring support with connecting bolt holes, insert four guiding rods into four bolt holes at the corners of slewing ring support before retreat the jack.

1.8.4 顶升过程的注意事项： General Notices of Jacking Operation 1.8.4.1 塔机最高处风速大于 14m/s 时，不得进行顶升作业; Jacking operation is prohibited when the wind speed at the highest top exceeding 14m/s.

1.8.4.2 顶升过程中必须保证起重臂与引入标准节 EQ7 方向一致， 并利用回转机构制 动器将起重臂制动住，载重小车必须停在顶升配平位置; Keep the jib in the same direction as the in-let mast section during jacking operation. Stop the jib with the slewing mechanism brake be sure of the trolley stopping at the jack-balanced position.

1.8.4.3 若要连续加高几节标准节 EQ7， 则每加完一节后，用塔机自身起吊下一节标 准节 EQ7 前，塔身各主弦杆和下支座必须有 8 个 M30 的螺栓连接，唯有在这种情况下， 允许这 8 根螺栓每根只用一个螺母; If several tower sections are to be mounted, after mounting a section, all the chords of the section must be fastened with 8 M30 bolts before hooking another section.

1.8.4.4 所加标准节 EQ7 上的踏步，必须与已有塔身节对正; Keep the climbing lugs on the newly added tower section in alignment with those on the existed sections.

1.8.4.5 在下支座与塔身没有用 M30 螺栓连接好之前，严禁起重臂回转、载重小车变 幅和吊装作业; It is prohibited to slew, change work-radius and hoist load without connection of the slewing ring support to the tower body by 8 M30 bolts.

1.8.4.6 在顶升过程中，若液压顶升系统出现异常，应立即停止顶升，收回油缸，将 下支座落在塔身顶部，并用 8 件 M30 高强度螺栓将下支座与塔身连接牢靠后，再排除 液压系统的故障; If the jacking hydraulic system has become abnormal in the course of jacking, stop immediately the jacking operation, retract the oil cylinder, lower the slewing ring support onto the top of tower body and use 8 M30 bolts to connect the slewing ring support to the tower body before removing troubles from the hydraulic system.

1.8.4.7 塔机加节达到所需工作高度(但不超过独立高度)后，应旋转起重臂至不同的 角度，检查塔身各接头处、基础支脚处螺栓的拧紧问题(哪一根主弦杆位于平衡臂正下 方时就把这根弦杆从下到上的所有螺母拧紧 ，上述连接处均为双螺母防松)。 When tower section reaches the desired working height, turn the jib to different directions, check if all the joints of the tower section, bolts for foundation are fastened sufficiently with two nuts.

TC5613-6塔式起重机

1.9 塔机的附着 Tower anchored onto the building 1.9.1 当塔机的工作高度超过其独立 高度时，须进行塔身附着; When the working height of the tower crane has to be exceeded to its stand-alone height, the tower body shall be anchored.

1.9.2 附着装置由四套框梁、四套内 撑杆和三根附着撑杆组成，四套框梁 由 24 套 M20 高强度（8.8 级）螺栓、 螺母、垫圈紧固成附着框架（预紧力 矩为 370N.m）。附着框架上的两个顶 点处有三根附着撑杆与之铰接，三根 撑杆的端部有连接套与建筑物附着处 的连接基座铰接。三根撑杆应保持同 在一水平面内，通过调节螺栓可以推 动内撑杆顶紧塔身四根主弦 (参见图 1.9-1);

立

塔

1.1-42

图 1.9-1 附着架示意图 Fig. 1.9-1 Schematic Diagram of Tie Frame

The anchoring devices consist of 4 sets of mast-tie-frames and 4 inner ties. The 4 tie-frames are fastened into anchoring frames by 24 sets of M20 bolts (strength rating 8.8), nuts and washers (bolt pre-tensioned moment 370Nm). Anchoring frames are articulated with 3 tie-rods on 3 top points. The 3 brace rods shall be kept at the same horizontal level.

Adjusting bolts can be used to push inner tie rods tightly against the 4 chord rods on the tower body (shown as 1.9-1).

1.9.3 附着点的载荷 Load on anchoring points 表 1.9-1 给出了塔机在图 1.9-1 所示的附着撑杆布置形式和位置条件下建筑物附 着点(即连接基座固定处) 的载荷值。用户需根据此载荷值的大小、附着点在建筑物结 构上的具体位置、安装附着装置的附着点处建筑物局部的承载能力等因素，确定连接 基座与建筑物的连接固定方式和局部结构处理方式。 Table 1.9-1 shows the arrangement of tie rod and the load value of anchored points on the building under certain position condition of tower crane in Fig. 1.9-1. The customers should decide how to tie their cranes to the building and conduct necessary partial modifications according to the load value, specific tie locations, local load capacity on the building etc. 注意：附着点的载荷值与塔机和建筑物的相对位置、附着撑杆的布置形式与尺寸、 附着框架以上塔身悬出段长度值的变化而大幅度改变。因此，塔机附着时，如塔机位 置、附着撑杆布置形式及尺寸与图 1.9-1 所示的不同时，请向本公司咨询。切不可盲 目套用表 1.9-1 中的数值自行制作处理，以免产生重大安全事故。 Notice: Load values at anchoring points vary to a great extent with the relative positions of the tower crane to the building, tie rod layout and size, height of the tower

TC5613-6塔式起重机

立

塔

1.1-43

body suspension section over body. If the tower crane is anchored at the position different from Fig. 1.9-1, including different arrangement of tie rods or different dimensions, please contact our company for further consultation, avoiding major accident.

表 1.9-1 F1(kN)

±142

F2(kN)

±222

F3(kN)

±109

F4(kN)

±222

图 1.9-2 附着点载荷 Fig. 1.9-2 Load on the anchored point

1.9.4 先将附着框架套在塔身上，并通过四根内撑杆将塔身的四根主弦杆顶紧；通过 销轴将附着撑杆的一端与附着框架连接，另一端与固定在建筑物上的连接基座连接; Put on the tie frame on the tower section, push the 4 inner tie rods to the 4 chords on the tower, connect one end of anchored tie rod to the tie frame with pins, and the other end to the building.

1.9.4.1 每道附着架的三根附着撑杆应尽量处于同一水平面上。但在安装附着框架和 内撑杆时，若与标准节 E 的某些部位干涉，可适当升高或降低内撑杆的安装高度; 3 sets of anchoring tie rods on each frame shall be kept at the same horizontal plane. If they are interfered with some positions of the tower section E during mounting of anchoring frames and inner tie rods, the height of frames will properly be raised or lowered.

1.9.4.2 附着撑杆上允许搭设供人从建筑物通向塔机的跳板，但严格禁止堆放重物; The walkway for personnel passage from the building to tower crane can be placed on the anchoring tie rod, however no stockpiling of heavy objects on it.

1.9.5 安装附着装置时，应当用经纬仪检查塔身轴线的垂直度，其偏差不得大于塔身 全高的 4/1000，允许用调节附着撑杆的长度来达到; During the mount of anchoring device, use the theodolite to check the axis of tower body for verticality. Its deviation shall not be greater than 4/1000 of the total tower crane height. This deviation can be achieved by adjusting the length of tie rod.

1.9.6 附着撑杆与附着框架，连接基座，以及附着框架与塔身、内撑杆的连接必须可 靠。内撑杆应可靠地将塔身主弦杆顶紧，各连接螺栓应紧固好。各调节螺栓调整好后， 应将螺母可靠地拧紧。开口销应按规定充分张开，运行后应经常检查有否发生松动， 并及时进行调整。 The connection of tie rods to tie frames, foundation and tie frames to the tower body and inner tie rod shall be reliable. The inner tie rods shall reliably be pressed against the main chord rod of the tower body and also be clamped tightly to the web rod of the tower body.

All connection bolts shall be fastened. Adjusting bolts, when properly adjusted, shall be

TC5613-6塔式起重机

立

塔

1.1-44

tightened by nut. Cotter pins shall be opened as specified. After operation they shall be frequently checked for looseness. Timely adjustments shall be made just in case. 注意：不论附着几次，只在最上面的一个附着框架内安装内撑杆，即新附着一次 内撑杆就要移到最新附着的框架内。 Notice: No matter how many anchoring is conducted, only the topmost anchoring tie frame can install the inner tie rod. Namely after each new attachment, the inner tie rod has to be removed into the newly-anchored frame 1.10 投入使用前的工作 Preparations before operation 塔机投入使用前的工作，是为了保证塔机能正确操纵，并在安全条件下运行。这 些工作主要是：对塔机部件的检查及调试各安全装置。 The pre-operation preparations of the tower crane aim are ensuring its correct control and smooth operation at safe conditions. Main preparations are to check tower crane components and to test-run safety devices.

1.10.1 部件检查 Parts and Components Checking 为了检查架设的正确性和保证安全运转,应对塔机各部件进行系列试运转和检查.

In order to ensuring the correct erection of tower crane and its safe operation, a series of test-runs and overall checks of tower crane components shall be conducted.

1.10.1.1 各部件之间的紧固联接状况检查； Check component-to-component connections.

1.10.1.2 检查支承平台及栏杆的安装情况； Check the installation of supporting platform and fences.

1.10.1.3 检查钢丝绳穿绕是否正确，不能与塔机机构和结构件相磨擦； Check wire ropes for correct winding, avoiding interference and friction with other parts.

1.10.1.4 检查电缆通行状况； Check power cables for smooth and proper routing.

1.10.1.5 检查平衡臂配重的固 定状况； Check if the counter-weights on the counter-jib are properly fixed.

1.10.1.6 检查平台上有无杂物， 防止塔机运转时杂物下坠伤人； Clear the lumber on platforms in order to prevent them from falling and avoid injuring persons during tower crane operation. 图 1.10-1 整机安全保护装置的安装位置 Fig.1.10-1The mounting positions of whole crane safety devices

1.10.1.7 检查各润滑面和润滑点。 Check lubrication surfaces and points.

1.10.2 安全装置调试 Test-run for the safety device

TC5613-6塔式起重机

立

塔

1.1-45

塔机安全装置主要包括：行程限位器和载荷限制器。 -Safety devices for the tower crane mainly include the travel limiter and load limiter. 行程限位器有：起升高度限位器、回转限位器、幅度限位器。 The travel limiter includes the hoisting height limiter, slewing limiter and working radius limiter. 载荷限制器有：起重力矩限制器、起重量限制器。此外还包括风速仪。调试方法 见第二篇第三章。整机安全保护装置的安装位置如图 1.10-1 所示。 The load limiter includes the hoisting moment limiter and hoisting weight limiter, otherwise anemometer. Debugging is shown in the Chapter 3 of the Part 2. The mounting positions of whole crane safety guards are shown in Fig.1.10-1.

1.10.3 立塔后检查项目(见表 1.10-2) Items-checking after tower erection (Table 1.10-2) 表 1.10-2

检查项目 Item

检

查 内 Contents

table1.10-2

容

1.检查地脚螺栓的紧固情况 Check if the foot bolts are fastened

基 础 Foundation

2.检查输电线距塔机最大旋转部分的安全距离并检查电缆通过情况，以防 损坏； Check safety distance between the surrounding power lines and tower crane.

Check power cable for smooth routing to avoid damage.

塔身 Tower 检查塔身节连接螺栓的紧固情况 section Check the bolt connection of tower sections

爬升架 Climbing frame

上、下支座

1.检查与下支座的连接情况 Check its connection to slewing ring support 2.检查各滚轮、活动爬爪、销轴连接各部件的转动或摆动是否灵活 Check if the guide wheels, latches, pin-bolt-connected parts move smoothly 3.检查走道，栏杆的紧固情况 Check if the walkway and fence are fastened 1.检查与回转支承连接的螺栓紧固情况 Check if the bolts connecting slewing ring is properly fixed.

2.检查电缆的通行状况 Check power cable for smooth passage 3.检查平台、栏杆的紧固情况 Check if the platform and fence are fastened

司机室 Upper support, slewing ring 4.检查与司机室的连接情况 Check the connection for operator cab support and 5.司机室内严禁存放润滑油、油棉纱及其它易燃物品. No storage of operator cab lubrication oils, oil cotton yarns and combustible materials in the cab.

1. 检查起重臂、栏杆、平衡臂拉杆的安装情况 塔 帽 Tower head

2. Check tie rods of jib and counter-jib tie rods for proper installation.

3. 检查扶梯、平台、护栏的安装情况 4. Check ladders, platforms and protection rails.

TC5613-6塔式起重机

立

塔

1.1-46

3.保证起升钢丝绳穿绕正确 Secure that the hoisting rope is properly wired and arranged

起重臂 Jib

1.检查各处连接销轴、垫圈、开口销安装的正确性 Check connection pins, washers and cotter pins for correct mounting.

2.检查载重小车安装运行情况，载人吊篮的紧固情况 Check if the trolley is properly installed and operates smoothly, check maintenance cage for fixing.

3.检查起升、变幅钢丝绳的缠绕及紧固情况 Check hoisting and radius-changing ropes for winding and fixing

平衡臂 Counter-jib

1.检查平衡臂的固定情况 Check counter-jib for fixing 2.检查平衡臂栏杆及走道的安装情况，保证走道无杂物 Check protection rails of the counter-jib and walkway. Ensure no foreign substances on the walkway

吊 具 Hook

1.检查换倍率装置，吊钩的防脱绳装置是否安全、可靠 Check rope off-proof devices of the hook and fall-changing device for safety and reliability 2.检查吊钩有无影响使用的缺陷 Check hoist hook group for defects influencing operation 3.检查起升、变幅钢丝绳的规格、型号应符合要求 Check specifications and models of hoist ropes and radius-changing ropes for compliance with requirements.

4.检查钢丝绳的磨损情况及绳端固定情况 Check wire ropes for wear.

机 构 Mechanism

1.检查各机构的安装、运行情况 Check mechanism for installation and operation 2.各机构的制动器间隙调整合适 Check mechanism brakes for correct clearance adjustment 3.检查牵引机构，当载重小车分别运行到最小和最大幅度处，卷筒上钢丝 绳至少应有 3 圈安全圈 When trolley has moved to its minimum and maximum trolley radius-changing locations respectively, make sure if steel ropes on wire drum have over 3 lays for safety.

4.检查各钢丝绳绳头的压紧有无松动 Check if the ends of steel ropes are loosened or improper compressed.

安全装置 Safety device

1.检查各安全保护装置是否按本说明书的要求调整合格 Check safety device for proper adjustment as specified in the Instructions 2.检查塔机上所有扶梯、栏杆、休息平台的安装紧固情况 Check all ladders, protection rails and rest platforms for properly fastened.

润 滑 Lubrication

根据使用说明书检查润滑情况 Check lubrication conditions according to the operation instructions.

TC5613-6塔式起重机

立

塔

1.1-47

1.10.4 塔机组装好后，先对机构及其制动器、安全保护装置进行调整合适后（见有关 章节）应依次进行下列试验(每转移一个工地都必须进行) Conduct the following tests after the erection of tower crane (The following test must be done every time when the tower crane shifts to a new construction site) 1.10.4.1 空载试验 No-load test 各机构应分别进行数次全程范围内的运行，然后再做三次组合动作运行，运行过 程不得发生任何异常现象，各机构制动器、操作系统、控制系统、联锁装置及各限位 器应动作，准确可靠，否则应及时排除故障。 Conduct operation tests of each mechanism several times. After that, conduct combined operation tests three times. No abnormal incidents occur from all mechanisms during these tests. Brakes, operation systems, control systems, interlocking devices and limiters shall all act accurately and reliably. In case of any trouble occurrence, remove it immediately.

1.10.4.2 负荷试验 On-load test 在最大幅度处分别吊对应额定起重量的 25％,50％,75％,100％,按 1.10.4.1 条要 求进行试验。运行过程中不得发生任何异常现象，各机构制动器、力矩限制器、起重 量限制器应动作准确、可靠，否则应及时排除故障。 Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the rated hoist load at the maximum working radius for tests. No incidents happen during these tests.

Brakes, operation systems, control systems, interlocking devices and limiters shall all act accurately and reliably.

1.10.5 底架固定式塔机按图 1.10-2 安装顺序进行组装：Stationary tower crane with undercarriage installed according to the procedures shown as Fig. 1.10-2 1)

安装底架总成；Installation of Undercarriage Assembly

2)

其它安装顺序与支腿固定式塔机安装顺序相同。

Other assembling procedures are the same as tower crane with embedded anchors.

图 1.10-2 底架固定式塔机安装顺序示意图 Fig.1.10-2 Installation sequence of stationary tower crane with undercarriage

TC5613-6塔式起重机

立

塔

1.1-48

1.10.5.1 安装底架 Undercarriage installation 1.

底 架 的 组 装

Assembly

of

undercarriage 1) 拼装十字梁(见图 1.10-3)，并置 于基础上，用地脚螺栓和槽钢将其固定； Support cross beam assembly (shown as Fig.1.10-3)，fasten it to the foundation with embedded bolts and channel steel.

2) 安装基础节 1 及 2(见图 1.10-4)； Installation of Undercarriage tower section1 and 2( shown as Fig.1.10-4)；

图 1 .10-3 底架组装 Fig.1.10-3 Assembly of Undercarriage

3) 安装斜撑杆；(见图 1.10-4) Install the tower strut

图 1.10-4 底架基础节及斜撑杆的组装 Fig.1.10-4 Assembly of base tower section and strut

2. 安装压重 1、2； (见图 1.10-5) Mount the Base Ballast 1,2. The total weigh is 41.5 t (shown as Fig.1.10-5)

TC5613-6塔式起重机

4 块(blocks) 3.5t ,

立

塔

1.1-49

压重总重(Total weight):

41.2 t

8 块(blocks) 3.4t 图 1.10-5 压重安装

Fig. 1.10-5 Centre Ballast Assembly

TC5613-6塔式起重机

拆

塔

1.2-1

第二章 拆 塔 Chapter Ⅱ Dismantling 2.1 拆卸注意事项： Precautions for tower crane dismantle 2.1.1 塔机拆塔之前，顶升机构由于长期停止使用，应对各机构特别是顶升机构进行 保养和试运转; Conduct maintenance and test-run for the jacking mechanism before moving the tower crane out of the construction site.

2.1.2 在试运转过程中，应有目的地对限位器，回转机构的制动器等进行可靠性检查; Check limiters, slewing mechanism brakes and similar devices for reliability during test-run.

2.1.3 在塔机标准节 EQ7 已拆出，但下支座与塔身还没有用 M30 高强螺栓连接好之前， 严禁使用回转机构、牵引机构和起升机构; It is prohibited to use the slewing mechanism, trolleying mechanism and hosting mechanism before the tower crane mast sections have been dismantled and the slewing ring support has not been connected to the tower body by 8 M30 high-tensile bolts.

2.1.4 塔机拆卸对顶升机构来说是重载连续作业，所以应对顶升机构的主要受力件经 常检查; Check frequently the main stressed parts of the jacking mechanism, as the tower crane dismantling is a heavy and continuous work for the jacking mechanism.

2.1.5 顶升机构工作时，所有操作人员应集中精力观察各相对运动件的相对位置是否 正常(如滚轮与主弦杆之间，爬升架与塔身之间)，是否有阻碍爬升架运动(特别是下降 运动时)的物件; While the jacking mechanism is working, all operating personnel are required to focus their attention on observing the relative positions of moving parts for being normal (e.g. between rollers and main chord rods, between climbing frame and tower body.).

2.1.6 拆卸时最高处风速应低于 14m/s。由于拆卸塔机时，建筑物已建完，工作场地 受限制，应注意工作程序和吊装堆放位置，不可马虎大意，否则容易发生人身安全事 故.

Carry out dismantling when the wind speed is lower than 14m/s at the highest point. Take care of the stockpile location of dismantled parts because the building has been constructed and working site space is limited during tower crane dismantling. No carelessness in this operation, otherwise personal safety accidents will be likely.

2.2 拆塔的具体程序 Procedures of Tower dismantling 特别提醒：塔机拆卸是一项技术性很强的工作，尤其是塔身节、平衡重、平衡臂、 起重臂等部件的拆卸，稍有疏忽，便会导致机毁人亡。因此用户在拆除这些部件时需 严格按照本说明书的规定，严禁违反操作程序。上塔操作人员，必须是经过培训并拿 到证书的人员。 Special caution: tower dismantling is a highly technical work, especially the dismantling of the mast sections of tower body, counter-weight, counter-jib and jib.

Any slight neglect will cause machine damage, personal injury or death. End-users are

TC5613-6塔式起重机

拆

塔

1.2-2

therefore required to strictly follow the Instructions-specified rules to dismantle these components. Tower operators shall have been trained and with certificates. 请特别注意：两个爬爪因一定时间内不用产生锈蚀或运输碰撞等原因，很可能不 能自动恢复到水平状态，故引进标准节 EQ7 或拆除标准节 EQ7 时，对爬爪应特别注意!

Notice：Pay great attention to the two climbing latches during inlet or dismantle of tower section EQ7. Inspect if the latches are still in proper level condition. 将塔机旋转至拆卸区域，保证该 区域无影响拆卸作业的任何障碍。 如图 2.2-1 所示的顺序,进行塔机拆 卸。其步骤与立塔组装的步骤相反。 拆塔具体程序如下： Move the tower crane to the dismantling area where there shall be no obstacles influencing the operation.

Carry out tower crane dismantling according to the sequence as shown in Fig.2.2-1. Its steps are in opposition to the steps of tower crane erection.

Strictly follow the Instructions specified rules in all cases.

1. 降塔身标准节 EQ7(如有附着 装置，相应地拆卸)； Lower down the tower sections (dismantle anchored devices if any).

2. 拆 下 平 衡 臂 配 重 ( 留 一 块 2.25t 的配重)； 图 2.2-1 塔式起重机的拆卸 Fig.2.2-1 Dismantle of the tower crane

Dismantle counter-weights from counter-jib. (Keep one piece of 2.25t counter-weight).

3. 起重臂的拆卸； Dismantle the jib.

4. 拆卸一块 2.25t 的配重； Dismantle the last counter-weight.

5. 平衡臂的拆卸； Dismantle the counter-jib.

6. 拆卸司机室；(亦可待至与回转总成一起拆卸) Dismantle the operator cab (or dismantle it together with the slewing assembly).

7. 拆卸塔帽； Dismantle the tower head.

8. 拆卸回转总成； Dismantle the slewing ring assembly.

9. 拆卸爬升架及塔身节。 Dismantle the climbing frame and the remanent tower sections.

TC5613-6塔式起重机

拆

塔

1.2-3

1.2.1 拆卸塔身(参见图 2.2.1-1) Dismantle the tower sections(shown as Fig. 2.2.1-1)

图 2.2.1-1 拆卸塔身

2.2.1.1 将起重臂回转到引进方向(爬升架中有开口的一侧)，使回转制动器处于制动 状态，载重小车停在配平位置(与立塔顶升加节时载重小车的配平位置一致); Slewing the jib to the direction for the let-in section (i.e. the opening side of climbing frame) and place the slewing brake at a braking status, make the tower crane at a balanced jacking status, and the trolley staying at the balanced position (i.e. in conformity to the balanced position of the trolley when additional sections are jacked during tower crane erection) 2.2.1.2 拆掉最上面塔身标准节 EQ7 的上、下连接螺栓，并在该节下部连接套装上引 进滚轮; Remove the upper and lower bolts connecting of the top tower section EQ7, connect inlet wheels on the below section.

2.2.1.3 伸长顶升油缸，将顶升横梁顶在从上往下数第四个踏步的圆弧槽内，将上部 结构顶起;当最上一节标准节 EQ7(即标准节 1)离开标准节 2 顶面 2～5cm 左右,即停止顶 升; Extend the jacking cylinder to place the pin bolts onto the slot of the 4th lug counting from up down. Insert safety pins, jack the superstructure until the bottom of the trolley is moved to 20~50mm away from the top of the section.

2.2.1.4 将最上一节标准节沿引进梁推出;

TC5613-6塔式起重机

拆

塔

1.2-4

Push the top section out of tower along the beam onto the inlet frame.

2.2.1.5 扳开活动爬爪，回缩油缸，让活动爬爪躲过距它最近的一对踏步后，复位放 平，继续下降至活动爬爪支承在下一对踏步上并支承住上部结构后，再回缩油缸; Rotate the latches 900, retreat oil cylinder to avoid the last pair of step lugs, then reset the latches at level, go on to lower until the latches reaches the next climbing lugs and bear the weight of upper parts confidently, retreat the cylinder again.

2.2.1.6 将顶升横梁顶在下一对踏步上，稍微顶升至爬爪翻转时能躲过原来支撑的踏 步后停止，拨开爬爪，继续回缩油缸，至下一标准节与下支座相接触时为止; Put the climbing beam to the step lug at lower position and erect the climbing frame until the latches can be turn at 900 again, retract oil cylinder to let the next section（section 2 in fig 2.2.1-1）contact the slewing ring support.

2.2.1.7 下支座与塔身标准节之间用螺栓连接好后，用小车吊钩将标准节吊至地面 。 Connect slewing ring support to tower section with bolts, hook the tower section on the inlet platform to the ground. 注意：爬升架的下落过程中，当爬升架上的活动爬爪通过塔身标准节主弦杆踏步 和标准节连接螺栓时,须用人工翻转活动爬爪，同时派专人看管顶升横梁和导向轮,观 察爬升架下降时有无被障碍物卡住的现象。以便爬升架能顺利地下降。 Attention: In the course of lowering climbing frame, it is necessary to dispatch special persons to turn the latches when it passes through the climbing lugs and the bolts of the tower section, and another persons to observe the jacking beam and the guide rollers. There should be not any barriers to interrupt the climbing frame for smooth lowering.

2.2.1.8 重复上述动作，将塔身标准节依次拆下。 Repeat the above actions to dismantle the tower sections in sequence. 塔身拆卸至安装高度后，若要继续拆塔，必须先拆卸平衡臂上的平衡重。 If the tower has to be further dismantled after the tower body has been dismantled to the safety height, it is necessary to dismantle at first the counter-weight from the counter-jib.

2.2.2 拆卸平衡臂配重 Dismantle counter-weight from counter-jib 2.2.2.1 将载重小车固定在起重臂根部，借助辅助吊车拆卸配重; Fix the trolley at the jib root and use the auxiliary crane to dismantle the counter-weight.

2.2.2.2 按装配重的相反顺序，将各块配重依次卸下。仅留下一块 2.250t 的配重块。 Dismantle the counter-weight piece by piece in the sequence opposite to counter-weight mounting. Keep only one 2.25t counter-weight piece on counter-jib.

2.2.3 起重臂的拆卸 Dismantle jib 2.2.3.1 放下吊钩至地面，拆除起重钢丝绳与起重臂前端上的防扭装置的连接，开动 起升机构，回收全部钢丝绳; Lower the hook to the ground, remove the connection of anti-twist device with hoisting wire, and then start the hoist mechanism to wind back the wire rope.

2.2.3.2 根据安装时的吊点位置挂绳; Arrange hoist ropes according Fig.1.5.7-5 shown hook points.

TC5613-6塔式起重机

拆

塔

1.2-5

2.2.3.3 轻轻提起起重臂，慢慢起动起升机构，使起重臂拉杆靠近塔顶拉杆；拆去起 重臂拉杆与塔顶拉板的连接销，放下拉杆至起重臂上固定；拆去钢丝绳，拆掉起重臂 与塔帽的连接销; Hoist the jib lightly and fix the ropes onto pins on the tower head. Start up the hoist mechanism slowly to make the head of con-rod close to the tower head. Remove the pins connecting con-rod frame with the tower head, lower con-rods onto the jib and fix them.

Remove wire ropes, remove pins connecting jib with slewing tower body.

2.2.3.4 放下起重臂，并搁在垫有枕木的支座上。 Lower the jib and lay it down on the sleeper-cushioned support.

2.2.4 平衡臂的拆卸 Dismantle counter-jib 将配重块全部吊下，然后通过平衡臂上的四个安装吊耳吊起平衡臂，使平衡臂拉 杆处于放松状态，拆下拉杆连接销轴。然后拆掉平衡臂与塔帽的连接销，将平衡臂平 稳放至地面上。 Hoist down the last counter-weight. Hoist the counter-jib through 4 hook lugs on the counter-jib to make the jib tie rod at a loosened status. Remove connecting pins of tie rod and then dismantle the connections between counter-jib and slewing tower body. Hook the counter-jib down onto the ground.

2.2.5 拆卸司机室 Dismantle operator cab 2.2.6 拆卸塔帽 Dismantle tower head 拆卸前，检查与相邻的组件之间是否还有电缆连接。 Before dismantling, check the tower head to see if component-to-component is still connected by power cable.

2.2.7 拆卸回转总成 Dismantle slewing assembly 拆掉下支座与塔身的连接螺栓,伸长顶升油缸，将顶升横梁顶在踏步的圆弧槽内并 稍稍顶紧,拆掉下支座与爬升架的连接销轴, 回缩顶升油缸,将爬升架的爬爪支承在塔 身上，再用吊索将回转总成吊起卸下。 Support the lug changing rods of climbing frames on the tower body and then dismantle the connection of the slewing ring support with the climbing frame and tower body. Hoist the slewing assembly for dismantling.

2.2.8 拆走爬升架及塔身标准节 Dismantle the climbing frame and tower sections 2.2.8.1 吊起爬升架，缓缓地沿标准节主弦杆吊出，放至地面。 Slowly hoist the climbing frames out along the mast section main chord rod and place them down onto the ground.

2.2.8.2 依次吊下各节标准节。 Hook down the tower sections one by one.

2.2.9 拆走底架总成 Dismantle of the Undercarriage Assembly 拆卸方法与底架安装方法相反.

TC5613-6塔式起重机

拆

塔

1.2-6

Dismantle the undercarriage assembly in reversed way of installation.

2.3 塔机拆散后的注意事项 Attention after tower crane dismantling 2.3.1 塔机拆散后由工程技术人员和专业维修人员进行检查。 The dismantled crane needs to be checked and maintained by technical personnel and trained maintenance personnel.

2.3.2 对主要受力的结构件应检查金属疲劳，焊缝裂纹，结构变形等情况，检查塔机 各零部件是否有损坏或碰伤等。 Check main stressed structural members for metal fatigue; weld fissure, structural deformation, etc. Check tower crane parts for damage or collision injury.

2.3.3 检查完毕后，对缺陷、隐患进行修复后，再进行防锈、刷漆处理。 After completion of checks, repair the defects found and defects potential. Carry out rust removing and painting.

TC5613-6塔式起重机

塔机安全操纵规程

2.1-1

第二篇 塔机的使用与维护 PartⅡ Operation and Maintenance 第一章 塔机安全操纵规程 ChapterⅠ Safety Operation 1.1 司机与起重工 Crane operator and hoist man 1.1.1 必须严格执行 ZBJ80012-89《塔式起重机操作使用规程》的有关规定,司机与起 重工必须是按劳动人事部门有关规定进行考核并取得合格证者; The trained crane operators and hoist men are required to strictly follow the regulations as specified in The Operating Instructions for Tower Crane.

1.1.2 司机必须了解所操作塔机的工作原理，熟悉该塔机的构造及安全装置的功用及 其调整方法，掌握该起重机各项性能的操作方法以及该起重机的维修保养技术; Operators are required to understand the working principles of the tower crane and to familiarize themselves with its structure and functions and adjustment methods for safety guards. They are also required to master the operating methods for different performances as well as the maintenance technique.

1.1.3 严格按本说明书提供的起重特性表操作，严禁超载运行; Operate the crane strictly according to the hoist characteristics provided in the Instructions.

No over-load operating.

1.1.4 起升机构、回转机构、牵引机构的操作动作要柔和，由低速到高速逐步转换， 不得将操作手柄从静止(或低速)猛地向中速或高速位置推进; Operate gently the hoist mechanism, slewing mechanism and traveling mechanism. Carry out low speed-to-high speed conversion progressively. No violent pushing of the operation handles from the static position (or low-speed) to the intermediate speed or high-speed position.

1.1.5 不准斜拉斜吊物品，不准抽吊交错挤压物品，不准起吊埋在土里或冻粘在地上 的物品; It is prohibited to pull, or hoist objects in an inclined way, or hoist the staggered or squeezed objects and or hoist the objects buried in soil or frozen on ground.

1.1.6 有物品悬挂在空中时，司机与起重工不得离开工作岗位; Operators and hoist men are not permitted to leave their working posts while objects are being hung in the air.

1.1.7 指挥的信号、手势、旗号应符合 GB5082-85 规定; Commanding signals, hand gestures and flag signs shall conform to the specifications.

1.1.8 司机必须认真做好起重机的使用、维修、 保养和交接班的记录工作; Operators are required to carefully operate and maintain the crane, as well as to keep work shift-changing records.

1.1.9 严禁司机疲劳、酒后上塔操作。 It is prohibited that the operator is drunk, ill or tired on working.

TC5613-6塔式起重机

塔机安全操纵规程

2.1-2

1.2 机械部分及其它 Mechanical part and others 1.2.1 起重机的工作环境温度为-20℃～+40℃，最高处工作风力应小于 20m/s; Working environment temperature for the crane is in the range of -20℃~+40℃, wind speed at the highest working point should be smaller than 20m/s.

1.2.2 所有安全保护装置，必须随时保养，严禁任意搬动和拆卸，严禁超负荷使用; All the tower safety guards shall be maintained constantly. No moving and dismantling of them freely. No over-load operation.

1.2.3 夜间作业，施工现场必须备有充分的照明设施; The construction site shall be provided with adequate lighting facilities for night operation.

1.2.4 塔机经过大修或转移重新安装前注意事项： After the tower crane has been overhauled and transferred to a new site and before re-erection, observe the following: 1.2.4.1 严格认真检查各联接处各铰接头，销轴有无裂纹、锈蚀、损伤; Check the articulations for pins cracks, rusting corrosion and damage.

1.2.4.2 检查拉杆、钢丝绳、滑轮、吊钩及换倍率器等重要零件是否符合使用条件; Check the rigid tie rods, wire ropes, pulleys, hoist hooks, fall-changing devices, etc. for conformity to operating conditions.

1.2.4.3 检查金属结构件变形，焊缝等情况应符合使用条件; Check the metal structure members for deformations and weld fissures to make sure of their conformity to operating conditions.

1.2.4.4 对起升、顶升、回转、变幅应进行试运转至正常; Conduct trial operation for the mechanism of hoisting, jacking, slewing, trolley-radius-changing until they have become normal.

1.2.5 停机修理或维护保养时，必须切断总电源，不许带电作业; Switch off the main power supply when the crane operation is to be stopped for repair or maintenance. No operation with power on.

1.2.6 地面、楼台、施工面要设专人指挥塔机作业，与司机联络，必须规定严格的信 号或手势，旗号等，最好采用步话机联络; Dispatch special persons at the ground, platform and construction work face to direct crane operations and contact the operator. Signals hand gestures, flag signs, etc. are absolutely necessary. Better to carry out communications by walkie-talkie.

1.2.7 应保证塔机的使用电压在 380V±10%的范围时，否则塔机的电气设施容易损坏; Assure the working voltage of the tower crane at 380V±10% range, otherwise crane electrics will be damaged easily.

1.2.8 在遇大雷雨，暴雨，浓雾或塔机最高处风速超过 20m/s 时一律停止起重作业; Stop all hoisting operations in case of thunderstorm, heavy rain, thick mist or the top wind speed of the crane is higher than 20m/s.

1.2.9 多台塔机同时进入一个施工现场时，塔机的平面布置要合理，相互之间不得在 空间交错和发生干涉; Provide a proper crane layout plan without spatial interception and interference from another when several cranes have to work at the same construction site.

TC5613-6塔式起重机

塔机安全操纵规程

2.1-3

1.2.10 司机在接通地面电源，登上塔机进入司机室内应全面检查按钮操作手柄等是否 处于非工作状态，确认无误后方可启动总按钮; When the operator has switched on power and entered the cab, he should make overall checks of push buttons, operation handles for non-service conditions. He is not permitted to press the master push-button until OK confirmed.

1.2.11 司机必须严格按照本塔机技术性能表和起重特性曲线图的规定作业，不得超载 或强行作业; The operator must operate the crane strictly according to its technical characteristic diagrams and hoisting characteristic curves. No over-load operation or forced operation.

1.2.12 操作时避免起重吊钩着地，以免引起卷筒钢丝绳排列不齐而遭损坏，如果吊钩 必须着地，则吊钩着地后再次起升时，必须注意监视卷筒钢丝绳排列情况，必要时须 重新将钢丝绳排列整齐; During crane working, avoid the hoisting hook touching the ground, causing rope on the wire drum in an irregular order. If the hook has to be on the ground, pay attention to drum rope arrangement when it rises again. Make a regular rope arrangement if necessary.

1.2.13 紧固在载重小车侧面的吊篮是供维修使用的，当需要维修起重臂上的某一零件 时，维修人员可站在吊栏内随载重小车一起执行维修任务，吊篮的额定承载重量为 100 公斤，当起吊重物时，吊栏内严禁站人，在每次立塔施工中，地面安装起重臂时，要 仔细检查吊篮与载重小车的连接是否完善可靠; The cage fixed on the side of the trolley is for maintenance. When maintenance of some part of the jib is necessary, the maintenance person can stand in the cage and do the maintenance work along with the trolley. The load capacity of the cage is 100kg. No person standing in the cage when heavy objects are being hoisted. During the assembling of the jib on the ground and tower erection, cage-to-hoist trolley must be checked for proper connections and reliability.

1.2.14 各机构需要反向运行时，必须待电机正转停止后，再启动反转，反之也一样; When mechanisms are required to operate in a reverse direction, it is necessary to wait for the motor to stop its clockwise rotation before counter clockwise rotation start.

1.2.15 发现塔机有异常现象时，应停机切断电源，待查清并排除故障后再使用; If the tower crane is found abnormal, stop the crane and switch off the power supply. Do not operate the crane again until the troubles have been identified and removed.

1.2.16 塔机在每班作业完毕后，必须将起重臂转到与建筑物平行的方向，吊钩升高至 超过周围最高障碍物的高度，载重小车应在最小幅度处，回转制动器处于松开状态， 切断总电源方可离去; After crane operation completion at each shift, lift the hoist hook higher than the height of the highest surrounding obstacle, retract the trolley at the smallest radius and keep the slewing brake at an open status. The operator cannot leave his post until the power supply has been switched off.

1.2.17 每班工作前，司机必须对塔身、起重臂、回转支承、起重臂刚性拉杆，平衡臂 拉杆、卷筒联接螺栓，刹车制动器及换倍率器等主要关键部位的销轴，螺栓等进行日 常检查、紧固，确定无松动或脱离现象才允许开车作业; Before work start at each shift, the operator is required to carry out routine checks of the pins of such key components as the tower body, jib, slewing support, rigid jib tie rod,

TC5613-6塔式起重机

塔机安全操纵规程

2.1-4

counter-jib tie rod, brake and fall-changing device, also of the tower body connection axles.

Fasten the checked parts to make sure of no looseness or disengagement before operation start.

1.2.18 司机对减速器、滑轮、轴承座及换倍率器等处要按规定日常保养加油，如发现 有漏油现象，要及时处理; The operator is required to carry out routine maintenance and oiling of the speed reducer, pulley, bearing seat and anti-drop device. If oil leakage is found, remove the defect immediately.

1.2.19 司机在正式作业之前，必须逐项检查各安全装置的可靠性，绝不允许在安全装 置不可靠失灵的情况下勉强作业; Before normal operation, the operator is required to carry out item-by-item checks of various safety guards for reliability. No forced operation when they have any failures.

1.2.20 司机操作起升机构时，对于不同档位速度，有最大起重量的限制，具体参照表 1.2-1。如用 4 倍率以高速提升 6t 物时，高速无法动作，其将自动切换到中速档位上。 The operator is required to keep a clear mind that the maximum hoist weight is limited at different speeds when operating the hoist mechanism. Refer to table1.2-1 表 1.2-1

速

度 Speed

倍

率 Fall 4 倍率 Fall 2 倍率 Fall

Table 1.2-1

低 速 Low speed

中 速 Medium Speed

高 速 High speed

6t 3t

6t 3t

3t 1.5t

1.2.21 每月检查高强度螺栓时，须对安装高强度螺栓的连接套及附近的母材进行检 查，未安装附着架塔机特别需对基础以上的三节塔身节进行检查，安装了附着架的塔 机特别需对最上一道附着架附近的上两节下一节塔身节进行检查。每月须对塔顶进行 检查，特别需对其连接耳板及附近的母材进行检查。 When checking high-strength bolts every month, it is necessary to check the bolt joints and the nearby material. It is especially necessary to check them of the three tower sections on the foundation if the tower crane is not anchored to the building. Otherwise it is especially necessary to check them of the tower sections nearby the anchored point.

It is necessary to check the tower head, especially the connecting plates and the nearby material.

1.2.22 每三个月须对起重臂上弦杆的连接耳板及附近的母材和下弦杆的接头及附近 的母材进行检查。 It is necessary to check the connecting plates and the nearby material every three monthes.

1.2.23 每次顶升加节或降塔减节时，须对塔身节的踏步及液压顶升系统的顶升横梁进 行检查。 When adding or lowering down the tower sections every time, it is necessary to check the climbing lugs and the beam of the Climbing Mechanism.

TC5613-6塔式起重机

塔机安全操纵规程

2.1-5

1.3 高强度螺栓的使用和检查 Routine check of high-strength bolt 1.3.1 高强度螺栓安装前的准备 Preparations of high- strength bolt before tower erecting 塔身和回转总成的高强度连接螺栓使用前必须检查，检查时须用煤油等清洗剂对 螺栓、螺母和垫圈清洗干净。破损和任何可疑的破损（包括螺杆和螺纹部分锈蚀）都 不能使用。 It is necessary to check these high-strength bolts of connecting tower sections and slewing assembly before using. And it is necessary to clean the bolts, nuts and washers with kerosene oil. It is prohibited to use damaged bolts (including rust bolts). 每次安装前螺栓、螺母和垫圈必须用 MoS2 润滑脂涂裹，特别是结合面，以达到均 衡摩擦。 Before using, it is necessary to coat the MoS2 grease on contact surfacs of the bolts, nuts and washers to equilibrium friction.

1.3.2 高强度螺栓的拧紧 Tighten the high-strength bolts 高强度螺栓的双螺母须达到预紧力矩，其中防松螺母矩应稍大于预紧力矩。 The tighten torque on the nuts must reach the specified torque and the torque of loose-proof nuts（the upper nut）should be a little more than or equal the specified torque.

1.3.3 安装后的检查 Check after installing 塔机立塔后应按下列规定对螺栓进行检查，先一周二次，再一周一次，两周一次 然后一月一;每年内拆下 2～3 组螺栓检查其变形、腐蚀等情况。 Check all bolts 2 times in a week, then one time in a week, then one time in two weeks, and then one time in a month after erecting the tower crane. Dismantle 2-3 bolt groups each year and check them for deformation, corrosion, rust, etc.

1.3.4 重复使用 Repeat usage 中联公司的高强度螺栓均可以多次使用，但必须达到 1.3.1 和 1.3.2 的要求。 The high-strength bolts can be used many times, but agreed with the requirements of the above item 1.3.1 and the item 1.3.2.

1.4 钢丝绳的检查 Routine check of wire rope 1.4.1 起重机械中的钢丝绳是易损件。缺乏维护是钢丝绳寿命短的主要原因之一.

The wire ropes used in hoisting machinery are easily-worn parts. Lack of proper maintenance is one of the causes for their short service life.

1.4.2 对钢丝绳应进行适时地清洗并涂以润滑油或润滑脂。 Carry out timely cleaning of wire ropes and applying of lubrication oil or grease to them.

1.4.3 每个工作日都要尽可能对钢丝绳的任何可见部位进行观察，以便发现损坏与变 形情况。特别应留心钢丝绳在机械上的固定部位，发现有任何明显变化时，应予报告 并由主管人员按照《起重机械用钢丝绳检验和报废实用规范》（GB5972-86）中第 2.4.2

TC5613-6塔式起重机

塔机安全操纵规程

2.1-6

款进行检验。 Watch over their visible parts as much as possible on each workday so as to find any damages and deformations. Particularly care about the fixed ropes on machinery. When finding any apparent changes, report to the person in charge. And such person shall carry out checks according to item 2.4.2 in The Practical Regulations for Checking and Rejecting of the Hoisting Machinery-Used Wire Ropes. 每日工作前和塔机工作时司机和地面工作人员应注意载重小车和吊钩的钢丝绳是 否有跳绳现象，发现跳绳现象应立即停止工作，穿好钢丝绳再工作。 Watch over the wire rope on trolley and hook as much as possible on each workday so as to find that rope is out of the pulley or not. If the rope is out of the pulley, stop working and wind the rope again.

1.4.4 保证每周至少检验一次。 Chek the wire ropes one time every week.

TC5613-6塔式起重机

机构及电气操作

第二章 Chapter

2.2-1

机构及电气操作

Ⅱ Mechanical and Electrical operation

2.1 电气安装与使用 Electrical mounting and operation 2.1.1 电气安装 Electrical mounting 2.1.1.1 电气安装应在塔机安装完毕后(塔机处于安装高度时)进行，参看原理图，外 部接线图及控制箱接线图，连接各控制及动力电缆、制动器电缆，及安全装置，接地 装置，障碍灯等; Electrical erection shall be conducted after completion of tower crane erection at low-level in reference to the electrical principle diagram, external wiring diagram and wiring diagram in control cabinet, connection of controls to the power cable, braking cable, safety devices, earthing devices, aerial lights and anemometer.

2.1.1.2 送电之前对电气系统进行如下检查，符合下列要求后方可通电: Check the following items before power on. Only in conformity to the following requirements, power can be switched on.

1)所有线路联接必须正确无误，须固定的电线电缆应有可靠的固定，防止塔机在 运行时损伤电缆; Be sure that of all wire lines are correctly connected. Fix reliably the electrical lines and cables to be well fixed to avoid their damage during tower crane operation.

2)在通电之前应对电气进行绝缘检查，主回路控制回路对地绝缘电阻不应小于 0.5 兆欧，塔身对地的接地电阻应不大于 4 欧; Before power on, check the electrical lines and cables for insulation. Be sure of the earth insulation resistance of main control circuits no smaller than 0.5m Ω(Ohm). and the earth resistance of the tower body no greater than 4Ω(Ohm).

3)主电缆(地面连司机室电缆)在进入司机室前应穿入电缆保护圈后再进入司机 室，并留适当长度，保证塔机在左右一圈半的旋转时不致损坏电缆，且保证爬升 时不损伤电缆; Put cable protection rings onto the main cables (ground-to-operator cab cable) before its entering the cab. Reserve the cable for adequate length to make sure that the tower crane will not damage the cable when the crane is slew one round and a half right and left and when it is being jacked.

4)将司机室所有操作机构置在安全位置，主开关放在断电位置，最后连接好地面 电源电缆。 Place all cab controls at safe positions. Place the main switch at the power-off position. Finally connect the power cables on the ground.

2.1.2 通电调试 Power-on test run 2.1.2.1 将地面电源开关合上，送电到司机室，检查三相电源应三相平衡，且电压应 为 380V±10％(地面电网应能提供足够的容量，以保护电机正常启动和运转); Switch on the power switch on the ground to supply power to the operator cab. Check 3-phase power supply for balance. Check voltage for 380V±10% (The ground power net shall supply adequate capacity to protect normal motor start and operation).

TC5613-6塔式起重机

机构及电气操作

2.2-2

2.1.2.2 松开高度限位器，幅度限位器，配合机械安装，穿好起升，载重小车的牵引 钢丝绳; Release the height limiter and radius limiter. Arrange the wire ropes of the trolley to match mechanical erection.

2.1.2.3 起升机构的调试:先操作起升手柄，观察起升运转情况，当起升手柄向内拉时， 吊钩应向上运动，向外推时，吊钩应向下运动，否则应调整接至起升电机的电源的相 序，以符合以上要求; Test-run (debugging) of hoisting mechanis: Operate the hoisting handle to watch the hoisting operation. When pulling the handle inwards, the hoisting hook shall move upwards. When pushing the handle outwards, the hook shall move downwards. If not so, adjust the phase sequence of power supply of the hoisting motor to meet the above requirements.

2.1.2.4 起升调试完毕后，分别操作回转和变幅手柄，回转手柄向左推时，起重臂应 向左转；手柄向右推时，起重臂应向右转；变幅手柄向内拉时，载重小车向内走；手 柄向外推时，载重小车应向外走；否则应调整接至各电机电源线的相序，以符合以上 要求。 After completion of hoisting test-run, operate the slewing handle and trolley-radius-changing handle respectively. When pushing the handle to the left, the jib shall slew to the left. When pushing the handle to the right, the jib shall slew to the right.

When pulling the radius-changing handle inwards, the trolley shall travel inwards. When pushing the handle outwards, the trolley shall travel outwards. If not so, adjust the phase sequence of power supply of respective motor to meet the above requirements.

2.1.3 使用注意事项 Notice for proper operation 2.1.3.1 电送到司机室后(空气开关合上之前)障碍灯和司机室照明可通过操作台上的 开关送电，插座上也有电，可供插风扇之用; After power supply to the operator cab (before pneumatic switch on), power for the aerial light and lighting in operator cab can be supplied through switches on the control panel. The sockets are also available for fan plugs.

2.1.3.2 按启动按扭时，各操作手柄必须归零位，总接触器才可得电自保; Press start-button, and all operating handles shall return to zero, so as to power on the master contactor.

2.1.3.3 为防止回转打反车和紧急刹车扭伤塔机，在电气上设置延时装置。在起重臂 向右(向左)转后,不能马上以额定速度向左(向右)转，须有几秒的间隔。回转手柄归零 后，不能马上刹车，须有几秒的延时才能刹住车; To prevent reversed slewing or emergency stop from any damage to the tower crane, electrics are provided with time-delayed devices. When the jib slews to the right (or left), it cannot immediately slew to the left (or right) at a rated speed. Several-second delay is necessary. After the slewing handle returned to zero, immediate braking cannot be done due to several seconds delay.

2.1.3.4 即使有上述延时装置,仍严禁回转机构打反车制动和紧急刹车.以防电气损 伤;

TC5613-6塔式起重机

机构及电气操作

2.2-3

No braking and emergency stop at revered slewing though the crane is equipped with above-mentioned time-delay device.

2.1.3.5 顶升之前要检查泵站电机转向是否与要求一致，否则应将转向调整正确方可 进行顶升，顶升时严禁回转、变幅和起升，以防止发生安全事故和绞断电缆; Before jacking, check the rotation direction of pump station motor in conformity to your requirements. If not, adjust the rotation to the correct direction. It is prohibited to slew, hoist and change working radius during jacking. This aims at accident prevention and no breaking of the power cable due to twisting.

2.1.3.6 控制箱内延时继电器，过流继电器已调好，不要随便调整，如果更换元件则 应按电气系统说明书调整正确。 No free adjustment of the time-delayed relay and over-current relay in the control cabinet, they have been adjusted in the factory as specified. Any component replacements should be conducted according to the instructions for the electrical system.

2.2 塔机各机构 Working mechanisms of tower crane 起重机的工作机构包括：起升机构、回转机构、小车牵引机构及顶升机构，分别 简介如下： The working mechanisms of the tower crane consist of the hoisting mechanism, slewing mechanism, trolley traveling mechanism and jacking mechanism.

2.2.1 起升机构 Hoisting mechanism 起升机构型号为 QS680C,该电机型号为 YZTD225L2-4/8/32 型三速电机.起升机构 有三种速度来实现轻载高速,重载低速.起升机构传动系统示意图见 2.2-1.在卷筒轴 的未端装有起升高度限位器,当吊运物品达最高位置时,起升机构能自动停车.

The model of hoist mechanism for the tower crane is QS680C, motor is YZTD225L2-4/8/32 three-speed motor, with the function of high-speed light-load hoisting and low-speed heavy-load hoisting. The transmission system for the hoist mechanism is shown as Fig.2.2-1. The wire drum is provided with the hook height limiter. When objects have been hoisted to the highest position, the hoisting winch will stop automatically.

2.2.2 回转机构(传动系统示意图参见图 2.2-2) Slewing mechanism (For the schematic diagram of transmission system, refer to Fig.2.2-2) 回转机构布置在回转支承一侧，由 2 台 YTW112M-4B5，4.0kW 电动机驱动，经行 星齿轮减速机带动小齿轮，从而带动塔机上部的起重臂、平衡臂等左、右回转，在电 机尾部带有盘式制动器，盘式制动器处于常开状态. 回转制动器用于有风状态下，将 工作或顶升时的塔机定位在规定的方位，严禁用制动器停车。 There is 1 set of slewing mechanisms arranged on one sides of slewing ring. It is driven by 2 set 4.0KW motors model YTW112M-4B5. It drive the pinions through the planetary reducer, hence making the jib and counter-jib slew to the left and right. The motors are provided with disc brakes at their tails, which are kept at constant open status. The slewing brakes are used at windy conditions. They can hold the tower crane in the specified direction and location while hoisting or jacking operation is going on. It is forbidden to stop the slewing mechanism by brake. 回转减速机为脂润滑（000 号减速器润滑脂），在检修或油位因渗漏而下降时，

TC5613-6塔式起重机

机构及电气操作

2.2-4

应及时补充润滑脂，保证润滑脂液面达到油位螺塞的位置（减速机上部堵塞）。 The reducer of the slewing mechanism is lubricated with grease(000# grease), When maintained or the level of oil dropped, supplements grease in time to guarantee the level of grease arrive at the bolt of oil.

图 2.2-1 起升机构传动系统图 Fig. 2.2-1 Transmission System of Hoisting Mechanism

图 2.2-2 回转机构传动系统图 Fig. 2.2-2 Transmission System of Slewing Mechanism

2.2.3 小车牵引机构(传动系统示意图参见图 2.2-3) 小车牵引机构是小车变幅的驱动装置，由一台双速电机(YDEJ132S-4/8-B5,带电 磁盘式制动器)驱动,经由行星减速机带动卷筒，通过钢丝绳(6×19-7.7-1550-右交)， 使载重小车在起重臂轨道上往返变幅运动。牵引绳有两根,它们的一端分别固定在牵 引卷筒的两端，经缠绕后分别向起重臂的前后引出，经起重臂臂根和起重臂臂端导向 滑轮后，两根绳的另一端都固定在载重小车上。变幅时靠这两根绳一收一放来保证载 重小车正常工作。载重小车运行到最小和最大幅度时，卷筒上两根钢丝绳的圈数均不 得小于 3 圈。 The trolleying mechanism is for radius changing on the trolley. When doing radius changing, the two-speed motor (model: YDEJ132S-4/8-B5 with magnetic disk brake) drives the drum through the planetary reducer, thus making the trolley travel to-and-fro along the jib. Travel traction is done by 2 wire ropes (6×19-7.7-1550-right twisted). One end of the two wire ropes are fixed at both ends of the wire drum, wound on the drum and led separately to the front and rear of the jib. They pass over the guide pulleys at the jib root and jib tip. Another end of the wire rope are fixed on the trolley. In the course of radius changing, one rope retracts and the other rope extrudes for the normal operation of trolley. When the trolley travels to its minimum or maximum radius, the number of turns of both ropes on the wire drum shall not be less than 3. 小车牵引机构制动器的调整(示意图参见图 2.2-4) The adjustment of trolley brake device: (shown as Fig. 2.2-4) 制动器的磨擦材质，经长期使用后，将受到磨损，引起电磁铁与衔铁间的气隙增 大，使吸合力减少，严重时不能吸合。 After long time service, the clearance between electromagnet and armature shall be

TC5613-6塔式起重机

机构及电气操作

2.2-5

increased due to the abrasion, and the suction is decreased. 调整方法：打开制动器罩(件 1)，旋动支承螺栓，然后再旋动相应的内六角螺钉， 即可以调整衔铁与线圈行程。合理的气隙应在 0.5～1mm 之间。 Adjustment: Open the cover of brake device, turn the support bolts, and then the relevant inner hexagonal screws, the travel distance between armature and winding is adjusted. The desired clearance should be within 0.5～1mm.

图 2.2-3 牵引机构传动系统图 Fig. 2.2-3 Transmission System of Trolley Driving Mechanism

图 2.2-4 小车牵引制动器示意图 Fig. 2.2-4

Trolley Brake Device

2.2.4 顶升机构(图 2.2-5) Climbing Jack (shown as Fig. 2.2-5)

图 2.2-5 顶升系统液压接管示意图 Fig.2.2-5 Hydraulic Connection

图 2.2-6 液压系统原理图 Fig. 2.2-6 Schematic diagram of hydraulic System

该顶升液压系统由泵站、顶升油缸，高压软管及专用液压油组成，它可顶升和下

TC5613-6塔式起重机

机构及电气操作

2.2-6

降塔机爬升架以上部分，并可使其停留在任何位置，以便塔身标准节的装拆。 The hydraulic system consists of pump station, climbing jack, high-pressure hose and special oil. It can jack or lower the upper parts of the climbing frame, and stop at any position for mounting or dismounting tower section/masts. 该液压装置结构紧凑，效率高，使用维修方便，安全可靠。 It is compact, efficient, reliable and easy to maintain.

2.2.4.1 顶升液压系统的主要参数(液压系统原理参见图 2.2-6)(详见顶升液压系统使 用说明书) Main parameters (System principle is shown as Fig. 2.2-6) (Please refer to the operation instructions of hydraulic system) 液压泵站主要技术参数表 Main Parameters of pump station 表 2-1 工作压力 流 量 电机功率 配高压胶管 油箱容积(L) 用 油 Oil Pressure Flow Power Hose Oil tank Requirement (MPa) (L/min) (kW) (JB1885-77) capacity 美国 ESSO 公司的抗磨 液压油 AW46 A-10Ⅱ USA ESSO anti-wearing 25 10.6 7.5 100 Hydraulic oil AW46 顶升油缸主要技术参数表 Main Parameters of Climbing Jack 表 2-2 额定压力 缸 径 杆 径 行 程 安装距 顶升速度 最大顶升力 Rated Cylinder Diameter Distance of Installation Jack speed Max. Jack Diameter of Rod Travel Pressure Distance (m/min) force (t) (Mpa) (mm) (mm) (mm) (mm) 25 160 110 1600 2070 0.56 50 2.2.4.2 液压系统的安装及使用 1) 油液的清洁处理 Oil cleaning 首先旋开空气滤清器 11，加入过滤精度为 10μ的手提滤油机过滤的液压油至油箱 上油标上限为止，方可启动油泵电机(俯看电动机风叶旋向是否与泵座上所标方向一 致)。 Screw open air filter II, fill 10μ hydraulic oil filtered by hand-held oil filter into the oil tank up to the upper limit mark. After that, start the oil pump motor (look down at the motor blades to see if the rotation direction is the same as that marked at the motor tail). 注意：泵的旋向有左右之分，如接错，该系统不能工作。 Pay attention to the fact that the pump may be rotated either left or right. Wrong wiring will cause no system working and pump burn-down.

2) 系统管路连接 Connect high-pressure hose openings for clean status. 首先检查高压胶管口清洁与否，然后将液压站的 A、B 口与油缸两腔油口通过高压 胶管连接并拧紧接头。 Connect ports A.B of the hydraulic pump station to the hydraulic cylinders through

TC5613-6塔式起重机

机构及电气操作

2.2-7

high-pressure hose. Screw down the connectors.

3) 系统的排气 Air exhausting of the system 启动电机，拧松油缸上 A 口（或 B 口）高压胶管接头，移动手动换向阀 3 的手柄（以 下简称操作手柄）于上升（或下降）位置，使液压油进入管内，将空气从 A 口（或 B 口）溢出，直至油液从接头处流出且无气泡时为止，然后拧紧高压胶管接头。油缸空 载时推动操作手柄，让油缸活塞杆全行程上下运动几次，将油缸内的空气通过油管挤 入油箱而排尽。 Unscrew the handle of overflow valve, and then the high-pressure hose-to-port A connector. Move the handle of hand-operated valve to its up position. Start the motor to drive the air out of Port A until the pump noise has become normal and no foam formation from oil liquid. Make the cylinder into no-load status. Push the operating handle to let upper cylinder or piston rod move up and down at full strokes for several times to completely exhaust the air from cylinder into oil tank through oil hose. 操作时应注意：当活塞杆运动到上(或下)极限位置后，应立即扳回操作手柄，使 之处于中间位置，并停留几分钟，待挤入油箱液压油内的气泡消失后，再进行下一个 动作。 Notice: When the piston rod has moved to its extreme position, pull back the handle immediately to its middle position and keep this position for several minutes until air bubbles in oil tank have disappeared, and then carry out another action.

4) 系统的使用 System operation 操作前检查油缸与机架联接是否正确、可靠、检查塔机有关部分是否达到有关技 术要求后再进行如下操作。 Before system operation, check if the oil cylinder is well connected to the crane frame, including the check of relevant portions of the tower crane for meeting relevant technical requirements. a.系统最大工作压力的调定：拧松高压溢流阀 5 的调节螺杆和锁紧螺母，启动电 机 6，移动操作手柄于上升位置，让油缸活塞杆伸长至极限位置，此时压力表 4 的读 数上升，不断拧紧溢流阀调节螺杆，直至使压力表 4 的读数稳定在 25MPa 为止。然后 拧紧高压溢流阀调节螺杆上的锁紧螺母（不允许未经培训合格人员擅自调动溢流阀）， 反向操作手柄收回活塞杆，最后使操作手柄回复中位。 Maximum working pressure setting: Unscrew the locking nuts, in front of the control handle, of high-pressure overflow valve 5 at non-jacking operation status. Start motor. Move the operating handle to upper position and extend the cylinder piston rod to its extreme position. At this time, pressure gauge readings rise. Keep on screwing down the handle of the overflow valve until the readings on pressure gauge have become stable at 28 Mpa. Screw down the locking nut in front of the regulating handle of the high-pressure overflow valve (The overflow valve shall not be adjusted by unauthorized or untrained person). Operate the handle in a reverse direction to retract the piston rod. Finally move the handle back to its middle position. b.上升（下降）操作: 启动电机 6，将操作手柄移至上升位置,油缸活塞杆伸出， 将连接在活塞杆上的顶升横梁两端销轴放置在合适的塔身节踏步圆弧槽内（详见第一

TC5613-6塔式起重机

机构及电气操作

2.2-8

章 1.8.3 和第二章 2.2.1），进行顶升加节（或拆卸塔身）工作。 Move up (or down) operation: Start motor, and move operating handle to its up position. Extrude the cylinder piston rod to hang the hanging plate connected to the piston rod into the lugs slot of the tower mast section. Carry out the jacking operation for new section adding (or tower section dismantling).

2.2.4.3 液压系统的维护，保养及注意事项： Maintenance and precautions of hydraulic system 该液压系统属于高压液压装置，从加油到调整全过程都应严格按使用说明书中规 定进行。 The hydraulic system is super high-pressure or high-pressure equipment. The whole process from oil filling to adjustment shall be accomplished strictly according to the stipulations in its operating instructions.

1) 液压系统的用油 Hydraulic oil for the system: a. 该液压系统应按规定使用美国 ESSO 抗磨液压油 AW46，不允许混合使用其它液 压油，不允许未经过滤直接加注液压油，当发现油液发泡、乳化时，应及时清 洗油箱、更换新油。 The hydraulic system shall use the anti-friction hydraulic oil AW46 by ESSO, USA, which can't be mixed with other oils. Unfiltered oil can't be filled directly. When foam is found in the oil and oil is emulsified, the oil tank should be cleaned immediately and fill new oil. b. 液压系统的加油: 第一次加油应装满油箱，开机后伸出油缸活塞杆，再缩回活 塞杆，这时向油箱内补油至油位达到油箱油标上限为止。 Oil filling: Fully fill the tank with oil for the first time. After start-up, extrude the cylinder rod, and then retract the cylinder rod. At this time, fill the tank with make-up oil up to the tank upper limit mark. c. 此液压系统属于高压液压系统，各方面都要求较严，所以对油液清洁度有明确 要求，必须用手提过滤机循环过滤 4～6 小时，清洁度指标达到 7～8 级 (NAS1638)，方可开机使用。 At this time it is a high-pressure hydraulic system with strict requirements of highly cleaned oil, which should be filtered for 4~6 hours by hand –hold filter. The oil cleanness should reach 7～8 ,NAS1638 before starting the system. d. 液压系统开始工作 2400 小时后，应完全换油。工作 200 小时后，应加添部分 清洁油液。 The oil should be completely changed after the system work for 2,400hr and add part of clean oil after working for 200hr.

2) 该系统散热条件较差，不工作时，请及时关机，以免温升过高影响使用。 Shut the system when it is out of service because of the poor condition of ventilation.

TC5613-6塔式起重机

安全保护装置

2.3-1

第三章

安全保护装置

Chapter

Ⅲ Safety Guards

塔机安全保护装置主要包括：行程限位器和载荷限制器. 行程限位器有：起升高度限位器，回转限位器和幅度限位器； 载荷限制器有：起重力矩限制器，起重量限制器，此外还包括风速仪。 The safety guards of tower crane consist mainly of the travel limiter and load limiter.

The former consists of the hook height limiter, slewing limiter and trolley travel limiter. The load limiter consists of the hoist moment limiter and overload limiter. The anemometer is also included.

3.1 多功能限位器 Multiple-purpose limiter 本塔机的起升高度、变幅、 回转限位器分别为 DXZ-4/7， DXZ-4/F(i=600) DXZ-4/3，三个 多功能限位器。(图 3.1-1) 3 kinds of limiters: DXZ-4/7 hooking height limiter, DXZ-4/F (i=600) trolley travel limiter, and DXZ-4/3 slewing limiter.

3.1.1 调 整 程 序 Adjustment procedures 检查并拧紧 3.1.1.1 拆开上罩壳， 2 个 M3×55 螺钉; Dismantle the upper cover, check and screw down 2-M3×55 screws.

3.1.1.2 松开 M5 螺母; Unscrew M5 nuts 图 3.1-1

起升高度，回转，变幅限位器

Fig.3.1-1 Limiters for hoisting height, slewing, and trolleying

3.1.1.3 根据需要将被控机构开至指定位置(空载),这时控制该机构动作时对应的微动 开关瞬时切换。即:调整对应的调整轴(Z)使记忆凸轮(T)压下微动开关(WK)触点; Drive the mechanism under control to an designed position (without load ) to meet the requirements. At this time, the micro-switch should make transient change-over corresponding to the action of this mechanism i.e. adjust the corresponding axle (z) to make the memory gear (T) press down the micro-switch (WK) contact.

3.1.1.4 拧紧 M5 螺母(螺母一定要拧紧，否则将产生记忆紊乱); Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will

TC5613-6塔式起重机

安全保护装置

2.3-2

occur).

3.1.1.5 机构反复空载运行数次，验证记忆位置是否准确(有误时重复上述调整); Make the mechanism operate under no-load condition again and again several times to check memorized positions for accuracy (repeat the above adjustments in case of deviations) 3.1.1.6 确认位置符合要求，紧固 M5 螺母，装上罩壳; Make sure that the position is as specified. Screw down M5 nuts and re-cover the casing.

3.1.1.7 机构正常工作后，应经常核对记忆控制位置是否变动，以便及时修正。 After the mechanism working normally, check at certain interval the memory control position for deviations. Correct the deviations if any.

3.1.2 起升高度限位器的调整方法(调整程度按 3.1.1 条) Adjustment for hook height limiter (adjusting procedures according to item 2.3.1.1) 3.1.2.1 调整在空载下进行，用手指分别压下微动开关(2WK、3WK、4WK))，确认限制提 升或下降的微动开关是否正确; Adjust at no-load conditions. Press down micro-switches (2WK、3WK、4WK) by finger to check the rising micro-switch or lowering micro-switch for correct action.

3.1.2.2 调整提升限位时，当载重小车与吊钩滑轮的最小距离小于 5 米时，调动(3Z) 轴，使凸轮(3T)动作并压下微动开关(3WK)换接，使吊钩减速提升；当载重小车与吊钩 滑轮的最小距离小于 1 米时，调动(4Z)轴，使凸轮(4T)动作并压下微动开关(4WK)换接， 使吊钩停止提升；拧紧 M5 螺母; Adjust axle(3Z) to make cam (3T) act and press down micro-switch (3WK) for changing，the hook rising decelerate. This is done when the minimum distance from trolley to hook is smaller than 1m in hoisting to its extreme limit. Adjust axle(4Z) to make cam (4T) act and press down micro-switch (4WK) for changing，the hook stop rising. This is done when the minimum distance from trolley to hook is smaller than 1m in hoisting to its extreme limit.

Screw down M5 nuts.

3.1.2.3 用户根据需要可通过 2WK 以防止操作失误，使下降时吊钩在接触地面前(确保 卷筒上不少 3 圈钢丝绳时),能终止下降运动,其调整方法同 3.1.1 条(2Z-2T-2WK)。 Customers can adjust the lower limit by 2WK so as to avoid operation errors and make the hoisting hook stop lowering movement before the hook touching the ground (no less than 3-round steel ropes on the wire drum). The adjustment method is the same as item 2.3.1 （2Z-2T-2WK） 特别注意：在更换钢绳后一定要重新调整高度限位器，否则可能导致吊钩冲顶， 钢丝绳张断，造成机毁人亡严重后果。 Especially Note: After changing wire rope, it is necessary to adjust the height limiter again. Otherwise the hook may crash the trolley and the wire rope breaks, which will lead to the crane destroying and people death.

TC5613-6塔式起重机

安全保护装置

2.3-3

3.1.3 回转限位器调整方法(调整程序同 3.1.1) Adjustment for slewing limiter (the same procedures as item 2.3.1.1) 3.1.3.1 在电缆处于自由状态时调整回转限位器; Adjust the slewing limiter while the jib is at erection position (power cable at free status).

3.1.3.2 调整在空载下进行，用手指逐个压下微动开关(WK)确认控制左右方向的微动开 关(WK)是否正确; Adjust under no-load condition. Press down the micro-switch (WK) by finger to check the switch for correct left and right control.

3.1.3.3 向左回转 540°(1.5 圈)按 3.1.1 条程序,调动调整轴(4Z)使凸轮(4T)动作至 使微动开关(4WK)瞬时换接，然后拧紧 M5 螺母; Slew to the left for 540°(1.5 rounds). Follow the Item 2.3.1.1 to adjust the axle (4Z) to make the cam (4T) move to achieve transient changing by the micro-switch (4WK). Screw down M5 nuts.

3.1.3.4 向右回转 1080°(3 圈)按 3.1.1 条程序，调动调整轴(1Z)，使凸轮(1T)动作 至微动开关(1WK)瞬时换接，并拧紧 M5 螺母; Rotate 1080° right (3 rounds). Follow item 2.3.1.1 to adjust the axle (12) to make the cam (1T) move to achieve transient changing by the micro-switch (1WK). Screw down M5 nuts.

3.1.3.5 验证左右回转动作。 Check if the left and right slewing is correct.

3.1.4 幅度限位器的调整方法(调整程序同 3.1.1 条) Adjustment Method for radius (trolley travel) limiter (the same procedures as item 2.3.1.1).

3.1.4.1 向外变幅及减速和起重臂臂尖极限限位: 将载重小车开到距起重臂臂尖缓冲 器 1.5m 处，调整轴(2Z)使记忆凸轮(2T)转至将微动开关(2WK)动作换接。(调整时应同 时使凸轮(3T)与(2T)重叠，以避免在制动前发生减速干扰)，并拧紧 M5 螺母，再将载 重小车开至起重臂臂尖缓冲器 220mm 处，按程序调整轴(1Z)使(1T)转至将微动开关(1WK) 动作，拧紧 M5 螺母; Outward travel at lower speed and extreme position limiting at the jib tip: Drive the trolley at the position of 1.5m away from the jib tip buffer. Adjust the axle (2Z) to turn the memory cam (2T) to enable the micro-switch (2WK) for action. (Enable simultaneous overlap of the cam (3T) to the cam (2T) to avoid speed reduction interference before braking). Screw down M5 nuts. Drive the trolley to the position of 220mm away from the jib tip. Follow the procedures to adjust the axle (1Z) to rotate (1T) to make the micro-switch (1WK) act. Screw down M5 nuts.

3.1.4.2 向内变幅及减速和起重臂臂根限位:调整方法同“3.1.4.1”,分别距起重臂臂 根缓冲器 1.5m 和 200mm 处进行（3Z-3T-3WK，4Z-4T-4WK）减速和起重臂臂根限位和调 整。 Inward travel and extreme position limiting at the jib tip: The adjustment method is the same as item 3.1.4.1 Carry out speed reduction adjustment and position limiting at the jib root

TC5613-6塔式起重机

安全保护装置

2.3-4

( 32-3T-3WK, 42-4T-4WK ) at 1.5m and 200mm away from the jib root buffer respectively.

3.1.4.3 验正和修正。 Check and correct 3.2 力矩限制器(图 3.2-1) Moment limiter(Fig. 3.2-1) 本机装有机械式力矩限制器保护装置，当力矩达到额定值的 90％时，司机室内的 预报警灯亮,当超过 100％但小于 110％的额定值时,起升向上断电，小车向外变幅断电， 同时发出超载报警声。 The tower crane is provided with a mechanical type-moment limiter for protection purpose. When the moment has reached 90%of its rated value, the pre-warning light in the operator cab is on. When the moment has reached 100%~110% of its rated value, hoisting up and the trolley outwards-travel are stopped due to power off and over-load alarm at the same time. 力矩限制器由两条弹簧板 2， 三处行程开关 3 及调整螺杆 4 等组 成，通过安装块 1 固接在塔顶中部 后侧的弦杆上，塔机工作时，塔顶 发生变形，两条弹簧板之间的距离 缩小，带动调整螺杆移动，调整螺 杆触及行程开关，相应力矩能够报 警和切断塔机起升向上和载重小车 向外变幅的电路，起到限制力矩的 保护作用。 图 3.2-1

力矩限制器示意图

Fig.3.2-1 Schematic diagram of the moment limiter

The moment limiter consists of two-spring plates 2, three travel switches 3 and adjusting bolt 4. They are fixed on the chord rod on the tower crane rear side through mounting block1. If the tower head has deformed during crane operation, the distance between two spring plates will become narrower, thus activating the adjusting bolt for adjusting bolt contacts and travel switch. Corresponding moment will give warnings and cut off the power for the crane up and trolley outward-travel, thus playing the role in moment limiting protection.

3.2.1 力矩限制器的调整 (钢丝绳四倍率) Adjustment of Moment Limiter (wire rope at 4-fall) 3.2.1.1 定码变幅调整 Adjustment of constant load and variable radius of trolley travel:

TC5613-6塔式起重机

安全保护装置

2.3-5

56m 起重臂长吊重 2.67t(50m 臂长吊重 2.78t,44m、38m 臂长吊重 2.85t),载重小 车以慢速由 20m 幅度开始向外变幅，调整图 3.2-1 中的一根螺杆 4，使幅度在 28.8m 左右时，司机室内预报警灯亮；调整图 3.2-1 中的定码变幅那根那根螺杆 4，使幅度在 32～33.6m 时，起升向上、变幅向外断电，同时发出超载报警声。 When the jib length is 56m, trolley hoists 2.67t(the jib length is 50m, trolley hoists 2.78t loads. the jib length is 44m and 38m , trolley hoists 2.85t) and moves outwards from 20m point at a slow speed. Adjust one Bolt 4, to enable the warning light power on in the operator cab when the trolley moves to the range of about28.8m. And adjust another bolt 4 to enable the mechanisms power off and give over-load warning sound at the same time when the trolley moves to the range of 32m～33.6m. It is forbidden upward hoisting or outward traveling.

3.2.1.2 定幅变码调整 Adjustment of constant radius of trolley travel and variable hook load 在幅度 23m 时,56m 起重臂吊重 4.0t(50m 臂吊重 4.16t,44m、38m 臂吊重 4.25t)， 允许起升。再加载 200kg，调整图 3.2-1 中的定幅变码那根螺杆 4，使起升不能向上， 同时发出超载报警声。 When the jib length is 56m, at 23m point, the loading 4t (the jib length is 50m, loading 4.16t, the jib length is 44m and 38m, the loading 4.25t), upward hoisting is permission.

Adding 200Kg to the load, adjust the third bolt 4, to enable the mechanisms power off and give over-load warning sound at the same time. It is forbidden upward hoisting or outward traveling. 上述动作要求重复三次，保持功能稳定。 Test the step 3 times to keep the function stability.

3.2.2 力矩限制器的校核 (钢丝绳四倍率) Checking moment limiter (at 4-fall). 按定码变幅和定幅变码方式分别进行校核,各重复三次.

Conduct calibration to the moment limiter 3 times each according to Item3.2.1.1 and item 3.2.1.2.

3.2.2.1 定码变幅校核 Checking of constant load and variable radius of trolley traveling 1) 小幅度校核:吊重 6t，载重小车以慢速由 8m 幅度开始向外变幅，幅度在 16.2～17.1m (50m 臂长在 16.8～17.6m，44m 臂长及 38m 臂长在 17.1～18m)时，起升向上、变幅向 外断电，同时发出超载报警声; Checking at small radius: When the jib length is 56m, loading 6t, trolley travels outwards from 8m point at a slow speed. When travelling to the range of 16.2～17.1m (the jib length is 50m, the range of 16.8～17.6m, the jib length is 44m and 38m, the range of 17.1～18m), the mechanisms power off and give over-load warning sound at the same time.

It is forbidden upward hoisting or outward traveling.

2) 2) 大幅度校核: 56m 臂长吊重 1.5t(50m 臂长吊重 2.0t，44m 臂长吊重 2.5t, 38m 臂长吊重 3.0t)，载重小车以慢速向外变幅，使幅度在 49.2～51.7m(50m 臂在 41.35～

TC5613-6塔式起重机

安全保护装置

2.3-6

43.4m，44m 臂在 35.5～37.3m, 38m 臂在 30.68～32.2m)时，起升向上及变幅向外断电， 同时发出超载报警声(小值较为理想)。 Checking at large radius: When the jib length is 56m, loading 1.5t, trolley travels outwards from 40m point at a slow speed. When travelling to the range of 49.2～51.7m, the mechanisms power off and give over-load warning sound at the same time. It is forbidden upward hoisting or outward traveling. When the jib length is 50m, loading 2.0t, trolley travels outwards from 30m point at a slow speed. When travelling to the range of 41.35～ 43.4m, the mechanisms power off and give over-load warning sound at the same time. It is forbidden upward hoisting or outward traveling. When the jib length is 44m, loading 2.50t, trolley travels outwards from 30m point at a slow speed. When travelling to the range of 35.5～37.3m, the mechanisms power off and give over-load warning sound at the same time.

It is forbidden upward hoisting or outward traveling. When the jib length is 38m, loading 3.0t, trolley travels outwards from 30m point at a slow speed. When travelling to the range of 30.68～32.2m m, the mechanisms power off and give over-load warning sound at the same time. It is forbidden upward hoisting or outward traveling.

3.2.2.2 定幅变码校核 Checking of constant radius and variable load 1) 最大幅度校核: 在最大工作幅度处以正常工作速度起升额定起重量(56m 臂长吊重 1.24t，50m 臂长吊重 1.54t，44m 臂长吊重 1.89t, 38m 臂长吊重 2.29t)，力矩限制器 不应动作,允许起升。放下重物,然后以慢速起升 1.3t(56m 臂长)(50m 臂长吊重 1.62t， 44m 臂长吊重 1.98t, 38m 臂长吊重 2.4t),力矩限制器应动作,不能起升。 Checking of maximum radius: When the jib length is 56m, loading 1.24t at 56m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading 1.3t load at 56m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the jib length is 50m, loading 1.54t at 50m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading 1.62t load at 50m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the jib length is 44m, loading 1.89t at 44m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading 1.98t load at 44m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the jib length is 38m, loading 2.29t at 38m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading 2.4t load at 38m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling.

2) 小幅度校核: 56m 臂(50m，44m 臂，38m 臂)塔机在 20m 幅度处以正常工作速度起升 额定起重量 4.71t(50m 臂吊重 4.9t，44m 臂及 38m 臂吊重 5.02t)，力矩限制器不应动

TC5613-6塔式起重机

安全保护装置

2.3-7

作,允许起升。放下重物,然后以慢速起升 4.95t(50m 臂吊重 5.15t，44m 臂及 38m 臂吊 重 5.27t),力矩限制器应动作，不能起升。 Checking of small radius: When the jib length is 56m, loading 4.71t at 20m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission.

When loading 4.95t load at 20m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the jib length is 50m, loading 4.9t at 20m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading 5.15t load at 20m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the jib length is 44m and 38m, loading 5.02t at 20m point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading5.27t load at 20m point, the moment limiter works normally and the mechanisms power off. It is forbidden upward hoisting or outward traveling.

3.3

起重量限制器 (见图 3.3-1) Hoisting weight limiter (Refer to Fig.3.3-1) 起重量限制器调整(结构调整方法见外购件 MSWL-360B 起重量限制器说明书，此塔 机只使用其四个微动开关中的二个)。调整时吊钩采用四倍率滑轮组。 As for the structural adjustment of hoisting weight limiter, please refer to the operation instructions for hoisting weight limiter MSWL-360B. This crane uses only two of the four micro-switches, and the hook uses 4-fall pulley block during adjusting.

3.3.1 高速档调整 3.3.1.1 吊 2950Kg，吊钩以低、高三档速度各升降一次，不允许任何一档产生不能升 降现象; Hoist 2950Kg with the hook to travel up and down at low speed and high speed one time each. There should be no block at above-mentioned speed.

3.3.1.2 再加吊重 100kg，以高档起升，若能起升，调整螺钉 1，直至高档不能起升为 止。再下降至地面。 Add another 100kg to the 2950kg load, lift the load at high speed, if the hoisting-weight limiter does not act, and the hoisting mechanism can run at high speed, at the same time, adjust Screw 1 on the hoist weight limiter until the hoisting mechanism cannot run at high speed. Then lower the load onto the ground.

3.3.1.3 重复 1）、2）项全部动作，当载荷为 3000Kg 时，高速档可以运行，当载荷在 3000～3100kg 之间时高档不能运行。接近小值较为理想。

TC5613-6塔式起重机

安全保护装置

2.3-8

Repeat all actions mentioned in the Items 1), 2), lifting 4 tons load, and the hoisting mechanism can run at high speed. Lifting the load about 3000 ～ 3100kg, the hoisting mechanism cannot run at high speed, at this time, the load gains ground on 3000Kg that is ideal.

3.3.2 低速档调整：(幅度不能大于 12 米) Low speed adjustment (Traveling radius is less than 12m) 3.3.2.1 吊重 5900kg，以低、中档速度升降 一次，不允许产生不能升降现象; Hoist the weight of 5900kg. The hoisted weight travels up and down at low speed one time each. Do not permit no hoisting.

3.3.2.2 再加吊重 200kg，以低、中档速度起升，若能起升，调整螺钉 1，直至低、中 档不能起升为止。再下降至地面。 Add another 200kg to the 5900kg load, lift the load at high speed, if the hoisting-weight limiter does not act, and the hoisting mechanism can run at low speed, at the same time, adjust Screw 1 on the hoist weight limiter until the hoisting mechanism cannot run at low speed. Then lower the load onto the ground.

3.3.2.3 重复上述两项全部动作，当载荷为 6000Kg 时，低、中速档可以运行，当载荷 在 6000～6200kg 之间时低、中速档不能运行。接近小值较为理想。 Repeat all actions mentioned in the Items 1), 2), lifting 6 tons load, and the hoisting mechanism can run at low speed. Lifting the load about 6000～6400kg, the hoisting mechanism cannot run at low speed, at this time, the load gains ground on 6000Kg that is ideal.

3.4 防扭装置的使用(见图 3.4-1) Operation of anti-twist device (Refer to Fig. 3.4-1) 3.4.1 起升绳为不旋转（防扭）钢丝绳时，塔机在工作状态本防扭装置应将锁紧螺钉锁 紧。 Hoisting ropes are non-rotating (anti-twist) ones. The anti-twist device shall lock tightly the locking bolts while the tower crane is at service.

3.4.2 起升绳为普通钢丝绳时，塔机在工作状态本防扭装置应将锁紧螺钉打开。 If hoisting ropes are of ordinary type, the anti-twist device shall unlock the locking bolts while the tower crane is at working.

3.4.3 新换钢丝绳后，空载运行时吊钩旋转，此时应打开防扭装置，钢丝绳将自由旋转 到与吊钩一致。若防扭装置处于锁紧状态，长时间空载运行将使钢丝绳在全长范围内 产生扭转，直至吊钩不再转动。

TC5613-6塔式起重机

安全保护装置

2.3-9

After changing for new wire ropes, the hoisting hook will rotate at no-load operation. At this time, unlock the anti-twist device, wire ropes will freely rotate till it is identical with the hoisting hook If the anti-twist device is at locked status, no-load operation for a long period, it will cause steel ropes twisted along the whole length until the hook no longer rotates.

3.4.5 塔机在长时间使用后，钢丝绳伸长 并产生轻微扭转，此时应暂时打开防扭装 置，待钢丝绳张紧后再次锁紧。 When the tower crane has been used for a long period of time, steel ropes will be made longer and slightly twisted. At this time, unlock the anti-twist device for the time being until ropes have been tensioned, then lock the device once again.

3.4.6 一旦钢丝绳散股，防扭装置将会加速钢丝绳的破坏，所以应及时更换钢丝绳。Once steel ropes have their strands loosened, the anti-twist device will accelerate rope deterioration. Therefore change the deteriorated ropes timely as required.

TC5613-6塔式起重机

保养与维修

第四章 Chapter

2.4-1

保养与维修

Ⅳ Service and Maintenance

为确保安全经济地使用塔机，延长其使用寿命，必须做好塔机的保养与维修及润 滑工作。 To ensure safe and economic operation of the tower crane for a longer service life, it must be properly maintained and lubricated.

4.1

塔机的保养

Tower crane maintenance 4.1.1 检查各减速器的油量，及时加油。 Check speed reducers for oil quantity. Fill oil in time.

4.1.2 检查各部位钢丝绳有无散股、断丝、磨损等现象，超过有关规定必须及时更换。 Check wire ropes at different positions for looseness, breakage or being worn-out. Change defective ropes as required as per relevant stipulations.

4.1.3 检查制动器的效能、间隙，必须保证可靠的灵敏度。 Check brakes for performance and clearance to ensure reliable sensitivity.

4.1.4 检查各安全装置的灵敏可靠性。 Check safety guards for reliable sensitivity.

4.1.5 检查各螺栓连接处，尤其塔身标准节连接螺栓，当每使用一段时间后，必须重 新进行紧固。 Check bolt connections. Re-tighten the bolts once again when they have been used for a certain period of time.

4.1.6 检查各钢丝绳头压板、卡子等是否松动，应及时紧固。 Check steel rope head clampers and clips for loose status. Tighten them if loosened.

4.1.7 钢丝绳、卷筒、滑轮、吊钩等的报废,应严格执行 GB5144-94 和 GB5972-86 规定.

Reject steel ropes, drums, pulleys and hoisting hooks strictly according to the relevant stipulations.

4.1.8 检查各金属构件的杆件,腹杆及焊缝有无裂纹,特别应注意油漆剥落的地方和 部位,尤以油漆呈 45°的斜条纹剥离最危险，必须迅速查明原因并及时处理。 Check the rods, web rods and welds of metal structure members for fractures and fissures.

Pay special attention to the positions where the paints are peeled. The most dangerous is that the paint is striped (in 45° oblique strings. Trace the cause immediately and dress the issue in time.

4.1.9 塔身各处(包括基础节与底架的连接)的连接螺栓螺母，各处连接直径大于Φ20 的销轴等均为专用特制件，任何情况下，绝对不准代用，而塔身安装时每一个螺栓必 须用双螺母拧紧。 Inspect the connecting bolts and nuts of tower sections, including the connection of Undercarriage tower section and undercarriage. The parts with the diameter of connecting pin bolts of more than Φ20 are specially-made, no substitutes shall be replaced under any conditions. Each bolt shall be tightened with two nuts for the installation of tower sections.

4.1.10 塔身标准节螺栓性能等级为 10.9 级，螺母性能等级为 10 级(双螺母防松)，螺

TC5613-6塔式起重机

保养与维修

2.4-2

栓头部顶面和螺母头部顶面必须有性能等级标志，否则一律不准使用。 The strength rating of high-tensile bolts for connecting tower sections are 10.9, and nuts are 10, which should marked on the head of bolts and nuts, The bolts and nuts without grade marked on the head are prohibited to use.

4.1.11 整机及金属机构每使用一个工程后，应进行除锈和喷刷油漆一次。 Conduct rust removing and painting of the whole tower crane and its metal mechanisms after completion of their each use in a project.

4.1.12 起升钢丝绳经过一段时间使用磨损拉长后，需重新按规定调整高度限位器。 The hoisting height limiter should be adjusted again after the rope serves for a period of time.

4.1.13 观察各电器触头是否氧化或烧损，若有接触不良应修复或更换。 Check if the electrics connectors are oxidized or burned-down. Repair or replace any poor connectors.

4.1.14 各限位开关和按钮不得失灵，零件若有生锈或损坏应及时更换。 No function failures of limit switches and push buttons. Replace rusted or damaged parts in time.

4.1.15 各电器开关，开关板等的绝缘必须良好，其绝缘电阻不应小于 0.5MΩ。 Be sure that the insulation of electric switches to switch panels meet the relevant requirements, with insulation resistance no less than 0.5MΩ.

4.1.16 检查各电器元件之紧固螺栓是否松动,电缆及其它导线有否破裂并及时排除.

Check if the bolts connecting electric components are loosened: Check power cables and other conducting wires for fractures. Remove the trouble if any.

4.2 主要故障及排除方法 Main troubles and troubleshooting 4.2.1 一般性故障及排除 Ordinary troubles, troubleshooting and solution 表 4.2-1 序号

故障现象

故障原因

No.

Trouble

Troubleshooting

减速器温度过高 1

Reducer temperature is too hot

润滑油缺少或过多 Lubrication oil deficient or excessive

解决方案 Solution 注意适量增减油量 Properly increase or decrease oil

主要是润滑脂过量或太少； __Excessive or deficient grease 润滑脂质量差； 减速器轴承温度过高 2

The temperature of the reducer bearings is too high

__Grease quality very poor 轴承轴向间隙不符合要求或轴承已 损坏 __Improper axial clearance of the bearings or bearings is already damaged

按规定更换润滑脂并适量 __Properly replace grease 重新调整轴承间隙 __Re-adjust the clearance of of bearings 更换轴承 ___Replace bearings

TC5613-6塔式起重机

保养与维修

减速器漏油 3.

Oil leakage from speed reducer

联接部位贴合面的密合性差,轴端密 封圈磨损环 Contacting surface of connections is not tightened enough, sealing rings at shaft ends is worn and damaged a. 油泵磨损、效率下降 Worn oil pump, declined efficiency b. 油箱油量不足或滤油器堵塞

顶升太慢 4

Jacking speed is too slow

Oil in the tank is insufficient or oil filter clogged c. 手动换向阀阀杆与阀孔磨损严 重。 Hand-operated valve rod and valve hole severely worn d. 油缸活塞密封有损伤出现内泄漏

2.4-3

更换密封圈 Replace sealing rings

修复或更换损坏件 __ Repair or replace the damaged parts 加足油量或清洗滤油器 __Fill adequate oil or clean oil filter

Oil cylinder piston seal is damaged and internal oil leakage a. 油泵严重内泄

顶升无力或不能顶升 5

Jacking force is not adequate or unable to jack

Severe internal leakage from oil pump b. 溢流阀调定压力过低 Overflow valve pressure set too low c. 手动换向阀阀芯过度磨损 Hand-operated valve core excessively worn d. 溢流阀卡死

1. 修复或更换磨损件 Repair or replace the worn parts 2. 按要求调节压力 Adjust pressure as required 3. 清洗液压阀 Clean hydraulic valve

Overflow valve clogged down 顶升升压时出现噪声 振 动 Noise and 6

7

8

滤油器堵塞

清洗滤油器

Oil filter clogged

Clean oil filter

电机转向与油泵转向不对

改变电机旋向

Jacking system is not working

Motor rotation and oil pump rotation both in wrong directions a. 缸头上的平衡阀出现故障

Change direction

顶升时发生颤动爬行

Air not completely exhausted from oil cylinder piston b. 油缸活塞密封损坏

vibration occur during jacking operation at increasing pressure 顶升系统不工作

Creeping and quivering during jacking operation

Trouble with guide mechanism a. 缸头上的平衡阀出现故障 顶升有负载后自降 9

Jacking loaded

drop

when

Trouble with balance valve of the cylinder head c. 油 缸 活 塞 密 封 损 坏 Piston sealing of oil cylinder is damaged

motor

rotation

按有关要求排气 __Exhaust air as required. 调整导向轮 __Adjust guide pulleys

排出故障,更换密封件 Remove trouble, sealing parts

replaces

TC5613-6塔式起重机

保养与维修

2.4-4

1. 操作手柄没归零

总起按钮失灵 10

Malfunction of Master push-button

Operation handle not returned to zero 2. 电控柜熔断器烧断 Fuse in the electric control cabinet is burned down 3. 启动按钮、停止按钮接触不良 Poor contact of the start-button and stop-button 1. 起升电机过流，过流断电器因过 流吸合

起升动作时跳闸 11

Power is stopped during hoisting operation

Over current from hoisting motor, actuating over-current breaker.

2. 工地变压器容量不够或变压器至 塔机动力电缆的线径不够 Capacity of the site transformer is inadequate, or power cable from transformer to tower crane has inadequate diameter 1. 控制接线错误

Fuse burned-down.

3. 电机绕组相同短路，接地及断路

起升机构不能起动 12

Hoisting mechanism unable to start

or

Motor working voltage is too low 5. 绕组接线错误 Windings wiring in a wrong way 6. 电磁制动器未松闸 Electromagnetic brake not released 7. 负载过大或传动机械有故障 Too heavy load or trouble with the transmission mechanism 1.机械磨擦

牵引机构有异常噪声 振动过大 13

Abnormal noise and vibration from trolleying mechanism

Return handle to zero.

2. 换熔断器 Replace fuse 3. 修或换按钮 Repair or replace the button 1. 检 查 起 升 刹 车 是 否 打 开，过流稳定值是否变 化 Check hoisting brakes for open-up. Check over-current stabilization value for variation 2. 更换变压器或加粗电缆 Replace transformer increase cable diameter 1. 核对接线图

or

Check wiring diagram.

2. 检 查 熔 丝 容 量 是 否 太 小,如小更换大的。

Control wiring in a wrong way 2. 熔丝烧断

Electric motor windings short-circuited, grounded circuit breaking 4. 电机电压过低

1. 将手柄归零

a.定转子相擦 b.电机和减速箱不同心 Mechanical wear, due to: a. Friction between stator-rotor b. Motor-speed reducer box not in concentricity

Check fuse capacity, change for larger one if too small 3. 测量电网电压 Measure power grid voltage 4. 按各种速度供电找出短 路、断路处予以修复 Supply power to suit different speeds so as to find out short circuit and circuit breaking.

Repair the findings 5. 检查制动器电压及绕组 是否有断路或卡住 Check brake voltage and windings for circuit breaking or clogging 1. 检查定转子间隙是否均 匀 Check rotor clearance for being uniform 2. 检查滑环是否磨损，并 更换 Check slip rings for wear.

Replace them if any

TC5613-6塔式起重机

保养与维修

2. 轴承严重缺油或损坏 Bearings without oil or damaged.

3. 齿轮箱内缺油 Gear box without oil 4. 齿轮磨损 Gear worn 5. 两相运行,有啸啸声

变幅机构轴承过热 14

Trolleying mechanism Bearings over-heated

15

Electrification with the trolleying mechanism

16

17

Brake failure with the trolleying mechanism

1. 轴承烧坏

Switch off power supply.

Check and repair 1. 更换轴承

Bearings burned down 2. 润滑脂过多或过少

Replace bearings 2. 按要求加润滑脂

Grease too much or too few

Add grease as required 1. 查出并纠正

Power line or earth line wired in a wrong way 2. 接地不良 Poor earth connection 3. 电机接线擦伤接地

1. 制动力矩过小 Braking moment too small 2. 摩擦片磨损间隙增大 Increased friction clearance of friction pieces.

回转机构无法启动

主要看有否异物卡在齿轮处

Slewing mechanism unable to start

See if foreign matters are clogged in the gear..

1. 负载过大 Load excessive 2. 负载持续及工作不符合规定

牵引机构电动机温升 过高或冒烟 18

Trolleying mechanism motor over-heated or smoke emission

Clean bearings and add fresh lubrication oil.

Replace bearings 4. 更换齿轮箱

2-phase operation with abnormal noise

Motor wires scratched and earthed

变幅机构制动器失灵

3. 清洗轴承加新润滑油， 更换轴承

Replace gearbox.

5. 切断电源检查并修复。

1. 电源线及接地线接错 变幅机构带电

2.4-5

Load continuing and work not as specified 3. 两相运行 2-phase operation 4. 电源电压过低或过高 Power supply voltage too low or too high 5. 电机绕组接地或匝间、相间短路 Motor windings earthed or short circuited between turns, or between phases

Find out the cause, and remove the trouble.

2. 接地要接触良好 Improve earth connection 3. 查出并纠正 Find the cause, and remove the trouble 1. 制动器弹簧断失效，须更 换 Brake spring broken, replace the spring 2. 励磁,电压不足 citation and inadequate voltage 清除异物 Remove foreign matters 1. 定子电流, 如大于额定 值要减小负载 Measure stator current, e.g. decrease load if heavier than rated value.

2. 按规定进行运行 Operate as required.

3. 测量三相电流, 排除故 障 Measure 3-phase current to remove troubles.

4. 检查输入电压并纠正 Check input voltage necessary correction

for

TC5613-6塔式起重机

保养与维修

2.4-6

6. 摩擦片间隙不对

5. 找出原因，并修复

Incorrect clearance between friction pieces 7. 动和释放时间不对

Find out the cause to repair 6. 按要求调节间隙

Braking time and releasing time not correct 8. 电机通阻塞，温度升高 Moter clogged, causing temperature rise.

Adjust clearance as required 7. 检查制动器电压及延迟 断电器动作时间，消除故 障 Check brake for voltage and time-delay for circuit breaker action and remove the trouble.

8. 保持通风道畅通 Keep smooth ventilation

4.2.2 与电气有关的故障及排除 The electrical failures and solutions 因电气元件接触不良或元件耗损，导致与之相应的动作失灵或不准确等故障。请 参看有关电控部件的说明书，查找原因，排除故障。 The electrical failures, which are caused by defect of contact or component wear-out, lead to wrong operation or out of operation. Please to refer to the electrical struction to find troublesshooting and solution.

4.2.3 序 号 No

1

各部润滑表 零部件名称 Parts Description

钢丝绳

润滑部位名称

润滑剂种类

Lubricating location

Lubricant specifications

起升钢丝绳

石墨钙基润滑脂

Hoisting rope 变幅钢丝绳

Graphite Calcium-based grease ZG-SSY1405-65

Trolley rope

Wire rope

起升机构变速箱

2

减速器 Reducer

Reducer of hoisting winch 回转机构减速器 Reducer of mechanism

slewing

夏季（高于 10℃）：N220 中 负荷工业齿轮油 Summer（over 10°C） with N220 gear oil 冬季（不高于 10℃）：N150 中负荷工业齿轮油 Winter（below 10°C） with N150 gear oil

润滑方法及周期 Lubricating method & duration 每工作一周涂润滑脂一 次，每大中修时煮油。 Grease the rope after working for a week, and boil the grease after overhaul or medium maintenance. 每工作 240 小时，适当 加油 1500 小时换油一 次 Lubricate the reducer after it serves for 240 hrs，Change the oil after working for 1500hrs.

TC5613-6塔式起重机

保养与维修

变幅机构减速器 Reducer of trolleying mechanism

回 转 机 构 减 速 器 the reducer of the slewing mechanism

3

二硫化钼-2 或 ZL-2 或锂基润 滑脂

在检修时，更换或补充 润滑脂。

Sulphur molybdenum-2# or ZL-2# When maintained, lithium-based grease supplements grease in time 在维修或油位下降时， 及时补充。保证润滑脂 液面达到油位螺塞（减 速机上部堵塞）的位置。 000 号 减 速 器 润 滑 脂 When maintained or the # 0000 grease level of oil dropped, supplements grease in time to guarantee the level of grease arrive at the bolt of oil.

减速器中各滚动轴承

钙基润滑脂 Calcium-based grease

滚动轴承

Rolling bearings in the reducer. 卷筒轴承

Rolling Bearing

Drum bearing 吊钩止推轴承 Hook bearings 回转支承装置

2.4-7

ZG-2

钙基润滑脂 Calcium-based grease

每工作 160 小时，适当 加油, 每半年清除一次 Grease the bearings each after they work for 160 hrs ， Clean them once after half a year.

Slewing ring

电动机轴承 4

5

Motor bearing

定、动滑轮 组 Pulley Block

滑动轴承 6

Sliding Bearings

制动器杠杆 系统铰点 7

Articulated points of brake lever

所有电动机 All the motors

起升机构定，动滑轮 各导向轮 Pulleys and guiding pulley in the hoisting winch 牵引机构滑动轴承 电缆卷筒滑动轴承 Sliding bearings in the trolley traveling mechanism and drum

各个铰点 All the points

articulated

冬季：钙基润滑脂 ZG-2 Winter：Calcium-based grease

每工作 1500 小时，换油 一次

ZG-2 夏季：钙基润滑脂 ZG-5 Summer ： Calcium-based

Change the grease after working for 1500 hrs.

grease ZG-5 冬天： Winter：ZG-2 夏天 Summer：ZG-5 冬天 Winter：ZG-2 夏天 Summer：ZG-5

机油 Machine oil

每工作 240 小时，换油 一次 Change the grease after working for 240 hrs. 每工作 160 小时，适当 加油，每半年清除一次 Add grease after working for 160 hrs, and conduct cleaning half a year 每工作 56 小时用油壶 加油一次 Fill oil after working for 56 hrs

TC5613-6塔式起重机

保养与维修

2.4-8

起重臂与塔 身二铰点

8

9

Two articulated points between jib and tower section

各个铰点

换倍率装置

各运动部位及导向槽

Fall-change Device

All the motion parts and guiding groove

齿轮联轴器 10

Gear connector

All the points

11

拆卸与安装前

Calcium-based grease ZG-2 (ZG-5)

Before dismantle installation

机油

每工作 160 小时用油壶 加油一次

Machine oil

各机构、齿轮联轴器 All the connectors of mechanisms and gears

液压顶升 泵站 Pump station of hydraulic erection

articulated

钙基润滑脂 ZG-2 (ZG-5)

油箱 Oil tank

钙基润滑脂 Calcium-based grease

美国 ESSO 公司 AW46 American ESSO AW46

or

Fill oil after working for 160 hrs 一季度注油一次 Grease season

once

after

a

工作 200 小时增添部分 清洁油，工作 2400 小时 后完全更换油 Add filtered grease after working for 200 hrs， and change the grease after working for 2400 hrs.

注：表中所提及的工作时间是指该零部件的实际累积工作时间

Note: The hours mentioned in the table means the accumulated working hours of the parts.

TC系列塔式起重机

附录

1

附录一 Appendix Ⅰ

顶升防脱装置 Anti-drop device of jacking system 根据国家标准的要求，中联塔机的顶升机构都设有防脱装置，塔机每次顶升加节 或降塔减节时都必须使用防脱装置。 According to the national standard requirements, Zoomlion tower cranes are equipped with anti-drop device of jacking system. During adding tower sections or lower tower sections, the device must be used. 防脱装置由两部分组成，一是顶升横梁上的插销，二是标准节踏步的防脱插销孔， 其使用方法如下： The anti-drop device consists of the thumb latches on the jacking beam and the anti-drop holes on the climbing lugs of tower sections. The usage method as following: 1.塔机开始顶升加节或降塔减节时，顶升横梁的销轴搁置在标准节的销轴孔内， 须将顶升横梁的防脱插销插入标准节的防脱销孔内，且固定在前槽内。 During adding tower sections or lower tower sections, put the thumb latches in the anti-drop holes and fix the in the fore groove.

2.在完成一个顶升步骤、顶升横梁要脱离标准节踏步时，须先将防脱销轴退出标 准节防脱销孔，固定在后槽内。（注意：防脱销轴未退出标准节防脱销孔，启动顶升 机构强行升横梁脱离标准节踏步会损坏防脱销轴） After finishing a jacking step, the thumb latches must have been moved away from the anti-drop holes befor puting the jacking beam away from the climbing lugs.

Otherwise the latches are damaged.

TC系列塔式起重机

附录

2

附录二 Appendix Ⅱ

安 全 指 示

safety indications 塔机开始顶升加节或降塔减节时，顶升横梁 的销轴搁置在标准节的销轴孔内，须将顶升 横梁的防脱插销插入标准节的防脱销孔内， 且固定在前槽内。 When adding or subtracting tower sections, placed the pin of climbing beam in the hole of tower sections and fixed the safe pin in the pin hole of tower sections.

注视 Watching

当心高空坠物砸头 Take care objects to fall

严禁站人 forbid to stand

TC系列塔式起重机

附录

3

附录三 Appendix Ⅲ

风速仪的安装

installing anemoscope

1. 风速杯安装在图示中位置 1 处； installs the anemoscope at the position of figure 1.

2.风速显示仪安装在司机室中的安装板上； the monitor of the wind speed installed in the control-plate of the operator cab.

3.风速仪的供电线连接到司机室内电控柜的 50、51 号接线端子上（AC230V）。 the power lines of the anemoscope are connected to the 50 、 51 ports of the control-cabnet of the operator cab.

Figure 1

塔机各部件润滑记录表 Table for Parts Lubrication 表 1 Table1 序号

零部件名称

润滑部位名称

润滑剂种类

润滑方法及周期

润滑人

润滑日期

No.

Parts Description

Lubricating location

Lubricant specifications

Lubricating method & duration

Lubricated by

Lubricating date

起升钢丝绳 1

钢丝绳

Hoisting rope

Wire rope

变幅钢丝绳 Trolley rope 起升机构变速箱 Reducer of

减速器 2

Reducer

每工作一周涂润滑脂一次，每大中修 石墨钙基润滑脂

时煮油。

Graphite Calcium-based grease

Grease the rope after working for a

ZG-SSY1405-65

week, and boil the grease after overhaul or medium maintenance.

夏季(高于 10℃)：N220 中负荷工业齿 轮油

hoisting winch

Summer(over 10°C) with N220 gear oil

每工作 240 小时，适当加油，1500

回转机构减速器

冬季(不高于 10℃)：N150 中负荷工业

小时换油一次。

齿轮油

Lubricate the reducer after it serves for

slewing mechanism

Winter(below 10°C) with N150 gear oil

240 hrs，change the oil after working

变幅机构减速器

二硫化钼-2 或 ZL-2 或锂基润滑脂

for 1500hrs.

Reducer of

Reducer of trolleying mechanism 减速器中各滚动轴承 Rolling bearings in the reducer.

Sulphur

molybdenum-2#

3

Drum bearing

Rolling Bearing

吊钩止推轴承

ZL-2#

lithium-based grease 钙基润滑脂 Calcium-based grease 每工作 160 小时，适当加油, 每半年

卷筒轴承 滚动轴承

or

ZG-2

清除一次 Grease the bearings each after they work for 160 hrs, clean them once after

Hook bearings

钙基润滑脂

回转支承装置

Calcium-based grease

Slewing ring

half a year.

续表 1 序号

零部件名称

润滑部位名称

润滑剂种类

润滑方法及周期

润滑人

No.

Parts Description

Lubricating location

Lubricant specifications

Lubricating method & duration

Lubricated by

冬季：钙基润滑脂 ZG-2 4

电动机轴承

所有电动机

Winter：Calcium-based grease ZG-2

Motor bearing

All the motors

夏季：钙基润滑脂 ZG-5 Summer：Calcium-based grease ZG-5

5

6

每工作 1500 小时，换油一次。 Change the grease after working for 1500 hrs.

起升机构定、动滑轮

冬天：ZG-2

定、动滑轮组

各导向轮

Winter：ZG-2

Pulley Block

Pulleys and guiding pulley in

夏天：ZG-5

the hoisting winch

Summer：ZG-5

牵引机构滑动轴承

冬天：ZG-2

每工作 160 小时，适当加油，每半年

滑动轴承

电缆卷筒滑动轴承

Winter：ZG-2

清除一次

Sliding Bearings

Sliding bearings in the trolley

夏天：ZG-5

Add grease after working for 160 hrs,

traveling mechanism and drum

Summer：ZG-5

and conduct cleaning half a year

钙基润滑脂 ZG-2 (ZG-5)

拆卸与安装前

Calcium-based grease ZG-2 (ZG-5)

Before dismantle or installation

机油

每工作 160 小时用油壶加油一次

Machine oil

Fill oil after working for 160 hrs

每工作 240 小时，加油一次 Add the grease after working for 240 hrs.

起重臂与塔身 二铰点 7

Two articulated points between jib

各个铰点 All the articulated points

and tower section

换倍率装置 8

Fall-change Device

各运动部位 及导向槽 All the motion parts and guiding groove

Continuation Table 1 润滑日期 Lubricating date

续表 1

Continuation Table 1

序号

零部件名称

润滑部位名称

润滑剂种类

润滑方法及周期

润滑人

润滑日期

No.

Parts Description

Lubricating location

Lubricant specifications

Lubricating method & duration

Lubricated by

Lubricating date

制动器杠杆系统 9

铰点

各个铰点

Articulated points

All the articulated points

机油

每工作 56 小时用油壶加油一次

Machine oil

Fill oil after working for 56 hrs

钙基润滑脂

一季度注油一次

Calcium-based grease

Grease once after a season

of brake lever

齿轮联轴器 10

Gear connector

各机构、齿轮联轴器 All the connectors of mechanisms and gears

工作 200 小时增添部分清洁油，工作 液压顶升泵站 11

Pump station of hydraulic erection

油箱 Oil tank

美国 ESSO 公司 AW46

2400 小时后完全更换油

American ESSO AW46

Add filtered grease after working for 200 hrs， and change the grease after working for 2400 hrs.

塔机部件检查记录表一 Table 1 for Parts check 表 2 Table 2 序号

零部件名称

检查周期

备注

检查人

检查日期

部件状况及处理方法

No.

Parts Description

Checking duration

Notes

Checked by

Checking date

Parts state and method to settle

塔身、起重臂、回转支承、起重 臂刚性拉杆、平衡臂拉杆、卷筒 联接螺栓、刹车制动器及换倍率 器等主要关键部位的销轴，螺栓 等 1

The pins and bolts of such key components as the tower body, jib, slewing support, rigid jib tie rod, counter-jib tie rod, brake and fall-changing device.

每班工作前

确定无松动或脱离

Before work start at

Make sure of no looseness or disengagement before

each shift

operation start.

塔机部件检查记录表二 Table 2 for Parts check 表 3 Table 3 序号

零部件名称

检查周期

备注

检查人

检查日期

部件状况及处理方法

No.

Parts Description

Checking duration

Notes

Checked by

Checking date

Parts state and method to settle

特别是基础以上的三节塔身节螺栓（未安装附着架 塔机）或最上一道附着架附近的上两节下一节塔身 节螺栓（安装附着架的塔机）以及塔顶和回转塔身

安装高强度螺栓的连接套及附 近的母材，塔顶和回转塔身 2

The high-strength bolt joints and the nearby material, the tower

连接耳板及其附近母材

每月

Especially the connecting plates and the nearby

Every month

material of the tower head and slewing mast, the bolts of three tower sections on the foundation if the tower

head and slewing mast.

crane is not anchored to the building, or the tower sections nearby the anchored point if it is anchored 起重臂上弦杆的连接耳板和下 3

弦杆的接头及其附近的母材

每三个月

The connecting plates and the

Every three months

nearby material 每次顶升加节或降

4

塔身节的踏步及液压顶升系统

塔减节

的顶升横梁

When

The climbing lugs and the beam

lowering down the

of the Climbing Mechanism

tower sections every

adding

or

time

续表 3

Continuation Table 3

序号

零部件名称

检查周期

备注

检查人

检查日期

部件状况及处理方法

No.

Parts Description

Checking duration

Notes

Checked by

Checking date

Parts state and method to settle

先一周二次，再一周 一次，两周一次，然 后一月一次 Check all bolts 2 高强度螺栓 5

High-strength bolts

times in a week, then

每年内拆下 2～3 组螺栓检查其变形、腐蚀等情况

one time in a week,

Dismantle 2-3 bolt groups each year and check them

then one time in two

for deformation, corrosion, rust, etc.

weeks, and then one time in a month after erecting

the

tower

crane.

1.每个工作日都要尽可能对钢丝绳的任何可见部位 进行观察，以便发现损坏与变形情况特别应留心钢 丝绳在机械上的固定部位。 Watch over their visible parts as much as possible on each workday so as to find any damages and 6

钢丝绳

至少每周

Wire rope

Every week

deformations. Particularly care about the fixed ropes on machinery.

2.每日工作前和塔机工作时司机和地面工作人员应 注意载重小车和吊钩的钢丝绳是否有跳绳现象，发 现跳绳现象应立即停止工作，穿好钢丝绳再工作。 Watch over the wire rope on trolley and hook as much as possible on each workday so as to find that rope is out of the pulley or not. If the rope is out of the pulley, stop working and wind the rope again.

长沙 中 联 重 工 科 技 发 展 股 份 有 限 公 司 CHANGSHA ZOOMLION HEAVY INDUSTRY SCIENCE & TECHNOLOGY DEVELOPMENT CO. LTD

湖 南 省 长 沙 市 银 盆 南 路 361 号（中联科技园） Headquarter Address：361 Yinpen（s）Road. Changsha,Hunan,China PC: 410013

FAX: +86-731-8928101

E-mail:

yxglb@zlzk.com

TEL：

+86-731－8928166

http://www.zoomlion.com / +86-731－8928163

全国服务监督专线：SPECIAL TEL:

800-878-6112

☆ We reserve the right to change specification without notice 2008 年简体中英文 C2 版