Zoomlion Tower Crane QTZ125(TC6016A-8) Instruction Manual - PDF DOWNLOAD

Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

INSTRUCTION HANDBOOK PRODUCT TYPE:

TOWER CRANE

PRODUCT MODEL:

QTZ125（TC6016A-8）

SERIAL NUMBER: User Manual Form No:

Issue Date:

Prepared by:

Approved by:

Ex:

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TABLE OF CONTENTS 1- Product Description..............................................................................3 2- Foundations, Counter-weight and Center Ballast ..............................12 3- Installing .............................................................................................27 4- Adjusting ............................................................................................66 5- Operation ...........................................................................................80 6- Maintenance Instructions ...................................................................96 7- Electronic .........................................................................................110 APPENDIX A.1 Crane log .......................................................................................111

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Introduction Notice: ﹣Intended use Operation voltage Operation Temperature(℃) Operation above sea level height (m) Operation humidity Deposited Temperature (℃) Transportation Temperature (℃)

～400V(±5%) 50Hz －20～＋40 ≤1000 30~95% -25~70 -25~55

﹣Prohibited (Improper) use Can't be used under the explosive circumstance，including the thunderous weather； Can't be used under the lower visibility，including the situation that the wind speed is higher than regulation capacity.

This manual is intended to help you operate the crane safely and to make full use of all its permitted facilities and methods of working. The manual also provides information on the operating principle of major assemblies and systems, and can be consulted if spare parts have to be ordered.

Please ensure that only trained and qualified personnel are employed on this crane.

The operating instructions and all relevant legal requirements and similar directives (for example accident prevention regulations) must be complied with.

Disregarding these instructions may cause accident or injury.

Special attention must be paid to the safety devices installed on the crane. They must be regularly checked to ensure that they are in good working order. The crane must not be operated if they have failed or become unreliable. Always remember: Safety first!

If you receive any further information on the crane from us, for instance technical information circulars, always note the contents carefully and insert the information in the relevant section of the manual without delay

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1- Product Description △Product type and model, type designation ■ Product type: Tower Crane ■ Product model: QTZ125 (TC6016A-8) ■ Type designation:

TC 60 16 A - 8 Max hoisting capacity (8t) Remodel The rising weight of the longest end of the jib is 1.6t Maximal Jib (60m) Tower crane

△Technical Specification Table ●Technical performance parameters for the whole machine Mechanism Group Rated hoisting moment (kNm) Working Radius（m） Max hoisting height（m）

Hoisting Slewing Trolleying

M4 M5 M4

1250 Maximum 60 Minimum 2.5 Outrigger Undercarriage Anchored Stationary Stationary 60 61 220 8 QE8100D2 α=2 α=4

hoisting

Max hoisting capacity（t） Model Fall Weight/Speed 2/100 4/50 4/50 8/25 t/(m/min) Min stable lowering ≤5 speed at 2 fall（m/min） 37 Power (kW) 0~55 Speed (m/min) Trolleying 5.5 Power (kW) Speed (r/min) 0~0.7 Slewing 5.5×2 Power (kW) 0.56 Speed (m/min) 7.5 (kW) Jacking(Erecting) Power mechanism 31.5 Working Pressure （MPa） Max Working 30 35 40 45 50 55 60 Radius（m） Counterweight Counter-weight 7.65 9.6 11.55 13.2 14.85 16.8 18.75 （t） Total power （kW） 53.5＋2×5.5 （Excluding Erecting Mechanism) -20~+40 Operation Temperature（℃） Noise in service (dB) 97

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●Technical parameters of the four mechanisms ▼Technical parameters of hoisting mechanism QE8100D2 Model

QE8100D2

Maximum traction force Wire -rope

N

27190

Specification

35x7-14-1770

hoisting

Maximum linear speed

m/min

200

Max drum Speed

r/min

91.64

Rope capacity

m

610 (6 Layers) YZRDW250L-4/8

Power

kW

Speed

r/min

37/37 1425/725

Drum

Model Motor

Reduction-gear model

J781C-20.34

Model

Brake

YWZ3 -315/90-16

Braking Moment

N.m

1250

▼Technical parameters of trolleying mechanism Item Mechanism type Maximum traction force Specification 30m jib Maximum traction of the wire rope

Length

35m

jib

40m 45m

jib jib

50m

jib

55m 60m

Units

parameters BP40B 5670 6x19-7.7-1550- right-twist 68

N

Wire ropeⅠ

m

BP55B

78

49

88 98

54 59

Wire ropeⅡ

100

64

jib

118

69

jib

128 0~ 40.9 YEJ112M-4B5 4.0 1430 43 80

74

Drum Speed Model Motor Power Speed Ratio of Reduction Gears Braking moment

r/min kW r/min N. m

▼Technical parameters of slewing mechanism Motor Slewing mechanism

Reduction Gears

44

Model Power Speed Model Gear Ratio Output rotation moment Output rotation speed Modulus m Number of teeth z

Gear parameter at output Profile shift coefficient x end Overall Gear Ratio Slewing Speed Model of Mechanism

kW r/min

N.m r/min

YTW132S-4B5 5.5 0~1440 XX5—130.195CLA-12/16 195 13000 0~7.1748 12 16 +0.5 1596.56 0~0.8 HPW55B.130

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▼Technical parameters of jacking mechanism Jacking mechanism

Motor Hydraulic pump Jacking Cylinder

Power Speed Flow Working pressure Cylinder /rod diameter Maximum jacking force Jacking Speed

kW r/min L/min Mpa mm t m/min

7.5 970 11.25 31.5 160/110 63 0.58

Radius and Load Capacity ﹡30m Jib Radius (m)

2.5 ～18.03

19

20

21

22

8.00

4 fall

Radius (m)

28

4 fall

7.53 29

25

26

27

7.09

6.69

6.34

6.01

5.71

5.44

5.19

4.96

20

21

22

23

24

25

26

27

6.33

6.00

5.70

5.43

5.18

4.95

22

23

24

25

26

28

6.00

5.70

5.43

5.18

4.73

23

24

26

28

30

5.18

4.73

4.35

30

4.00

2 fall

Hoisting weight (t)

24

4.00

2 fall

Hoisting weight (t)

23

4.74

4.55

4.36

2.5 ～18

19

﹡35m Jib Radius (m) Hoisting weight (t)

4.00

2 fall 4 fall

Radius (m) Hoisting weight (t)

8.00 28

30

2 fall 4 fall

7.51

7.08

6.68

32.78

34

35

3.82

3.69

4.00 4.35

3.90

3.72

3.59

2.5 ～18

19

20

21

4.74

﹡40m Jib Radius (m) Hoisting weight (t)

2 fall 4 fall

Radius (m) Hoisting weight (t)

2 fall 4 fall

4.00 8.00

7.51

7.07

6.68

6.32

34

36

38

40

4.07

3.66

3.3

3.09

3.90

3.72

3.46

3.23

3.02

2.5 ～18

19

20

21

22

30

32.7

4.00 4.35

﹡45m Jib Radius (m) Hoisting weight (t)

2 fall 4 fall

Radius (m) Hoisting weight (t)

4.00 8.00

7.51

7.07

6.68

6.32

6.00

5.70

32.75

34

36

38

40

42

44

45

2 fall

4.00

3.82

3.56

3.33

3.12

2.93

2.76

2.68

4 fall

3.90

3.72

3.46

3.23

3.02

2.83

2.66

2.58

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50m Jib Radius (m) Hoisting weight (t)

19

20

21

22

2 fall

24

26

28

30

32.44

4.30

3.90

4.00

4 fall

Radius (m) Hoisting weight (t)

2.5 ～17.82 8.00

7.43

6.99

6.60

6.25

5.64

5.12

4.68

34

36

38

40

42

44

46

48

50

2 fall

3.78

3.52

3.29

3.08

2.89

2.73

2.57

2.43

2.30

4 fall

3.68

3.42

3.19

2.98

2.79

2.63

2.47

2.33

2.20

2.5 ～17.47

18

19

20

21

22

24

26

28

30

55m Jib Radius (m) Hoisting weight (t)

2 fall 4 fall

Radius (m) Hoisting weight (t)

8.00

7.73

7.26

6.83

6.45

6.10

5.50

5.00

4.56

4.19

31.78

34

36

38

40

42

44

46

48

50

52

2 fall

4.00

3.68

3.43

3.20

3.00

2.82

2.65

2.50

2.36

2.24

2.12

4 fall

3.90

3.58

3.33

3.10

2.90

2.72

2.55

2.40

2.26

2.14

2.02

54

55

2 fall

2.01

1.96

4 fall

1.91

1.86

17

18

20

21

22

24

26

28

Radius (m) Hoisting weight (t)

4.00

60m Jib Radius (m) Hoisting weight (t)

4.00

4 fall

8.00

7.78

7.28

6.83

6.43

6.07

5.74

5.17

4.69

4.28

30.16

32

34

36

38

40

42

44

46

48

50

2 fall

4.0

3.72

3.45

3.21

3.00

2.80

2.63

2.47

2.33

2.20

2.08

4 fall

3.90

3.62

3.35

3.11

2.90

2.70

2.53

2.37

2.23

2.10

1.98

52

54

56

58

60

2 fall

1.97

1.87

1.77

1.68

1.60

4 fall

1.87

1.77

1.67

1.58

1.50

Radius (m) Hoisting weight (t)

19

2 fall

Radius (m) Hoisting weight (t)

2.5 ～16.6

This curve is according to the data 60m which would be the highest altitude.When the altitude is higher than 60m, diversified ranges of the rises will decrease graduly along with the additions of the altiude.

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△Crane transport The crane components have been constructed to be broken into modules to simplify packing and handling for different means of transport(railway carriages, containers, trucks etc.).

1、All components must be well secured tothe means of transportation.

2、Light modules must be placed on the top Of heavy ones.

3、To prevent damages to the paintedsurfaces, place padded or woodenseparating material between the elements.

4、Make sure the crane components are not in direct contact with the ground during the unloading phases to prevent impurities (sand, earth etc.) from entering the mounting holes.

5、Do not use unsuitable means of transport to move the crane parts, such as bulldo-zers or lift trucks.

A

detailed description of the weights and dimensions of the ZOOMLION crane com-ponents is given in the following pages.

a、Before transporting crane, allways make sure all auxiliary equipment is safety stow-ed away. b、Inspection of all loose parts fasteners. c、Check transportation tie-downs. d、While using public streets, observe the applicable rules.e、While passing under-passes, bridges,tunnels be mindful of ample clearances.

Packing list No. 1

Designation

Weight (kg)

Jib Section Ⅰ Jib Section Ⅱ Jib Section Ⅲ Jib Section Ⅳ

1218 1110 501 800

Figure dimension（L×B×H）

10000×1486×1300 10000×1486×1300 5000×1486×1300 5000×1486×1300

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Jib Section Ⅴ Jib Section Ⅵ Jib Section Ⅶ Jib Section Ⅷ 2 3 4 5 6 7 8 9 10 11 12 13 14

Counter-jib sectionⅠ Jib con-rod Counter-jib con-rod Counter-jib sectionⅡ hydraulic pump Operator Cab Trolley Lifting hook Upper & below support Tower head Main control cabinet NO.1 box NO.2 box

772 396 670 140

10000×1486×1300 5000×1486×1300 10000×1486×1300

880 465 145 1305 400 600 400 282 5300 1700

1500×6000×600 280×180×8320 260×160×3250 7502×1600×650 450×650×950 1250×1950×2100 1750×2300×900 1600×930×380 2760×2760×2550 1600×1700×7200 1700×520×1900 1000×1000×1000 1000×1000×1000

400 430 800

600×1486×1300

﹣Intended use Operation voltage Operation Temperature(℃) Operation above sea level height (m) Operation humidity Deposited Temperature (℃) Transportation Temperature (℃)

～400V(±5%) 50Hz －20～＋40 ≤1000 30~95% -25~70 -25~55

﹣Prohibited (Improper) use Can't be used under the explosive circumstance，including the thunderous weather； Can't be used under the lower visibility，including the situation that the wind speed is higher than regulation capacity.

△Lightning Protection Before setting into operation the operator has to consider the necessity of lightning protection measures and/or earthing measures concerning electrostatic charge and, if necessary, he has to carry out the appropriate earthing measure!

Whether or not the crane has to be provided with a lightning protection depends on the regulations and specifications of the appropriate supervising authority, on the rules for prevention of accidents of the employer's liability insurance association, on

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the recommendations of the property insurance companies etc., and on the request of the building owner.

Notes: Not connected with the steel reinforcement of the building foundation. ●The rails must be earthed at both ends. If the rail track is more than 20 m long, additional earthing points should be installed every 20 meters.

If there are no other earthing devices available one earthing rod which must be driven at least 1.5 m into the ground will suffice for each point.

Bolt M10 with ●If there is steel rod or mat reinforcement inspring the foundation washer

Earthing rod which must be driven at

of the building, there must be placed a connection link between the reinforcement and one rail. Climbing cranes must be connected twice. ●Equipment, machines, metal pipes within 20m of the rails of the tower crane track must be linked to the rails. ●Rail joints assembled by steel fishplates do not need to be bridged for lightning protection. ●In order to protect the electrical equipment of the components, we recommend installing over voltage arresters at the mains supply connection.

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2- Foundations, Counter-weight and Center Ballast 2.1

Foundation

2.1.1

Loads on Foundation with embedded anchors（shown as Figure 2-1） table 2.1 Load

Con-ditions

Horizontal Vertical Force Force Fh(kN) Fv(kN)

Bending moment M(kN.m)

Torque Mn(kN. m)

In service

31.05

740.6

3085

385

Out of service

116.9

680.3

3830

0.0

Note: Fh, Fv and bending moment M in Table 2.1 refer

Figure 2-1 Loads on Foundation with embedded anchors

to the load at max bending moment of foundation. Torque Mn refers to the load at max torsion moment of foundation.

2.1.2 Foundation for stationary with embedded anchor (shown asFigure.

2-2) The ground foundation is the precondition to ensure safe operation of the stationary tower crane. This foundation must closely comply with the regulations for different geological conditions. Reinforced concrete foundations must be adopted. Basic requirements as follows: 2.1.2.1 The soil below foundation must be tamped solid. The concrete strength grade must not be lower than C35. The earth endurance must not be smaller than the specifications as shown in table 2.2 and figuer2-2 2.1.2.2 The depth of concrete foundation must be no less than 1400mm 2.1.2.3 The upper plane of the four embedded anchors should be within the same level plane, the planeness tolerance is less than 1/1000.

Table 2.2 Reinforcing steel bar of upper layer L(mm) Lengthwise and crosswise: Each side 6500 32-φ25 7000

32-φ25

Reinforcing steel bar of lower layer Lengthwise and crosswise: Each side 32-φ25 32-φ25

Earth endurance Mpa

Vertical Concrete Weight T reinforcing M3 steel bar

0.16

59.15

142

256-φ12

0.124

68.6

164.6

256-φ12

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figure 2-2 foundation with embedded anchored

2.1.3 Install the Embedded Anchor The installation of the embedded anchors is very important, please install them as following: 2.1.3.1Fasten 4 anchors and the base section to-gether with 16 high-tensile bolts 2.1.3.2 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. Be sure that the climbing lug on the base section is placed perpendicularly to the builfigure 2-3 the embedded anchors Page:15 / 123

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-ding in order to conveniently installing and dismantling the whole tower crane.

2.1.3.3

Be sure that the number of rebars around anchors must not be reduce or cut off.

2.1.3.4

If it is difficult to pass through the anchor,the main reinforcing rod can be turned aside.

2.1.3.5

Gently hoist the whole piece of anchors assembled with the base section so that it is in a vertical position before placing concrete. Hang plumb lines along the ce-nterline in 2 directions of the base section to ensure that the perpendicularity of the embedded base section centerline and horizontal plane is less than1.5/1000.

2.1.3.6

Concrete filling rate around the embedded anchors must be over 95%.

2.1.3.7 Installation diagram is shown as Fig.2-3.

NOTICE:It is allowed that the anchors are used one time,and it is forbidden to dig them out and use again.

2.2

Undercarriage stationary

2.2.1

Load on the foundercarriage( Fig 2-4) table 2.3 Load

Con-ditions

Horizontal Vertical Force Force Fh(kN) Fv(kN)

Bending moment M(kN.m)

Torque Mn(kN. m)

In service

31.05

1547

3085

385

Out of service

116.9

1367.3

3830

0.0

2.2.2

Foundation for Undercarriage(Fig 2-5)

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

Fig2-4 Load schematic diagram on the founder carriage

of 4-blocks as base ballast, made of reinforced concrete. Basic requirements as follows: ⑴ The concrete strength grade shall be no less than C35.The soil below foundations shall be tamped solid. The earth-bearing load shall be no less than 0.15MPa. ⑵ The depth of concrete foundation shall be more than 1000mm. ⑶ The contact surface between concrete foundation and frame girder shall be calibrated for horizontality. Its planeness deviation shall be within 1/750. ⑷ Dig a pit (1200mm × 1200mm × 800mm) with water drains in the middle part of 4-block foundation for the installing the frame gird

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⑸ The relative positions of 4-group foundation bolts shall be accurate to ensure proper installation.

Figure2-5

foundation of underunder stationary

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2.3

The load on the foundation, track & foundation

2.3.1

The load on the foundation (shown as Fig. 2-6)

The load on the foundation is the maximum load when the included angle of the jib and track is 450. TC6015A tower cran-es are equipped with undercarriage with 6m track gaugeIn the table 2.3, there is the Max load onthe track of TC6015A Tower Crane.

Fig.2-6 Table 2.3 model

track foundation

TC6015A

6MGCA 6mGCB

the load on the track In service F1(kN) Min F1(kN) Max pressure pressure 750.4

23.15

Out of service F1(kN) Max F1(kN) Min pressure pressure 793.3

-109.7

In this table, F1 ---- the acting force of single dolly (with two traveling wheels) on the track and foundation, 6mGCA,6mGCB,— the track foundation drawing No. Notice:

Each dolly may bear F1 because of rotation of tower crane.

2.3.2

Track & Foundation

The users can build track foundation according to track foundation drawing supplied by us, or design it themselves by relative standards according to the load supplied by us.

2.4

Counterweight

2.4.1 Counter-weight specifications The counter-weight has three specifications; All are cast with reinforced concrete.(For specific dimensions,refer to Fig.2-7).

1.65t counterweight

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1.95t counterweight

3t

counterweight

figure 2-7 counterweight

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2.4.2 Basic requirements for counter-weight are as following: a) Weigh the counter-weight pouting with reinforced concrete. Permitted weight deviation is 2%, concrete grade no less than C18. b) Counterweight should be equipped according to the length change of jib (Table 2.4) c) To be consistent with the precision 2%, it is allowable to change the length dimension of the couterweight 3590 to change the weight

table 2.4 30m jib 2×3.0t Counter weight

Counter weight

1×1.65t total 7.65t 50m jib 2×3.0t 2×1.95t 3×1.65t total 14.85t

40m jib

35m jib Counter weight

2×3.0t 1×1.95t 1×1.65t total 9.6t 55m jib 2×3.0t

Counter weight

3×1.95t 3×1.65t 16.8t total

Counter weight

Counter weight

2×3.0t 2×1.95t 1×1.65t total 11.55t 60m jip 2×3.0t

45m jib Counter weight

2×3.0t 2×1.95t 2×1.65t total 13.2t

4×1.95t 3×1.65t 18.75t total

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2.5 Base ballast The base ballast is made up of several reinforced concrete blocks which are placed symmetrically on the chassis.

Fig2-8

Ballast (1)

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Fig2-9 Ballast (2) These blocks must be positionned on the chassis as shown in the figures and the corresponding table.

The reinforcing of the concrete blocks,except the one shown in the figure,is left up to the customer who has slso the responsability for the ballast preparation .No supply from us.

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Fig2-10 assemble diagram

Attention: 1. The protrusion of the block(1) must be symmetrically layed on the cross beam.

2. The block(2) must be symmetrically layed on the block(1) according to the assembly diagram.

3. During installing, the hole centre line of upper block must be located

the perron

center line of the below block.

4. Counterweight should be assembled along track direction.

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3- Installing Chapter I Erecting 3.1 Introduction Users are required to go through this section to ensure proper and smooth erection of the tower crane. Before hoisting, select the proper truck crane to assembly the Tower Crane.

3.2 Cautions 3.2.1The wind speed atop (the highest crane point) should be no greater than 12m/s during crane erection.

3.2.2. Strictly follow the erection procedures of tower crane.

3.2.3.Properly select of hook point. Select the hoisting equipment with proper length and reliable quality to suit the components to be hoisted (refer to Table 3.2) 3.2.4. Dismountable pins, nuts and bolts for connecting tower sections are specially prefabricated parts. Customers are not allowed to replace them freely.

3.2.5. Stairs, platform and protecting fence should be installed for safe operation.

3.2.6. Be sure of the proper length of counter-jib and number of counter-weights according to the length of jib (refer to relevant sections). Before Jib is installed, must place one piece of counter-weights 3t on the counter-jib.

It is prohibited to place more counter-weights on the counter-jib before installing jib.

3.2.7. After jib installating, it is prohibited to hoist any load before placing specified counter-weight on the counter-jib.

3.2.8. It is necessary to keep the direction of every tower section in accordance, otherwise it cannot add or reduce tower sections.

3.2.9. 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 parts of the crane and overhead power lines shall comply with the stipulations as shown in Table 3.1 Table 3.1 voltage KV <1

1~15

20~40

60~110

200

safe distance m vertical distance

1.5

3.0

4.0

5.0

6.0

horizontal distance

1.0

1.5

2.0

4.0

6.0

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3.2.10.Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be provided before hand.

3.2.11Reference size for tower crane erection site is shown as Fig3-1

3.2.12. Drive the trolley to the balance position before jacking. Slew the jib to the right front of the in-let beam and then lock the slewing of tower crane by slewing brake.

3.2.13. No slewing of the jib and no up and down movements of the hoist hook during jacking operation.

3.2.14 Weight specifications of crane parts and component(shown up Table3.2) Table 3.2 Component weight and height No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

870+820 2X680 1750 2X810 4X115

Embedded anchor H(m) / / / / /

Undercarriage stationary H(m) / / 0.9 0.9 0.9

Traveling H(m) 1.2 1.2 1.6 1.6 1.6

3480

/

6.9

7.6

4X350 4X3900 12X4500

/ / /

5.4 1 4.1

6.1 1.7 4.8

1343

3.7

/

/

1353

6.5

/

/

2×1245

12.1

12.5

13.2

4250

18.1

18.5

19.2

4400

14.2

14.6

15.3

500 1100

16.0 16.4

16.4 16.8

17.1 17.5

Designation

Weight(kg)

Driving Bogie Driven Bogie Total Beam Semi-Beam Tie rod Base Section Ⅰ&Ⅱ Tower Strut Ballast (1) Ballast (2) Base Tower Section MQQ Tower section MQQ Tower section MQ Climbing Frame Slewing Assembly Operator Cab Slewing tower body

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17 18 19 20a 20b 20c 20d 20e 20f 20g 21a 21b 21c 21d 21e 21f 21g

Tower Head Counter Jib assembly 1st counterweight 30m Jib assembly 35m Jib assembly 40m Jib assembly 45m Jib assembly 50m Jib assembly 55m Jib assembly 60m Jib assembly Counterweight of 30m Jib Counterweight of 35m Jib Counterweight of 40m Jib Counterweight of 45m Jib Counterweight of 50m Jib Counterweight of 55m Jib Counterweight of 60m Jib

1856

23.4

23.8

24.5

6214

16.5

16.9

17.6

3000 5338 5839 6235 6639 7035 7308 7704

19.5 16.7 16.7 16.7 16.7 16.7 16.7 16.7

19.9 17.1 17.1 17.1 17.1 17.1 17.1 17.1

20.6 17.8 17.8 17.8 17.8 17.8 17.8 17.8

1×3000+1650

19.5

19.9

20.6

19.5

19.9

20.6

19.5

19.9

20.6

19.5

19.9

20.6

19.5

19.9

20.6

19.5

19.9

20.6

19.5

19.9

20.6

1×3000+1950 +1650 1×3000+2×19 50+1650 1×3000+2×19 50+2×1650 1×3000+2×19 50+3×1650 1×3000+3×19 50+3×1650 1×3000+4×19 50+3×1650

Note：21a、b、c、d、e、f、g are the remaining counterweights after mounting a counterweight.

3.3 General layout of tower crane

3.3.1Assembly relation of main components for stationary crane (Fig3-2)

Fig3-2

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The TC6015A tower crane, with embedded anchors or with an undercarriage, in-dependent hoisting height is 60m. 2-fall or 4-fall wire ropes may be used for hoisting purpose. The tower sections are integral construction of square shaped steel tube str-ucture. The base section of tower body or the undercarriage is connected to the foun-dation. Mast sections are connected to slewing ring support and slewing tower body throught the upper support and slewing ring. The operator cab is set at the side of the upper support with the jib in front and counter-jib behind. The hoisting mechanism is located at the rear of the counter-jib and the slewing mechanism is symmetrically loc-ated on both sides of the upper support. The trolley is pulled by trolleying mechanism to make to-and-fro movements along the jib. The jib and counter-jib are connected to the tower head by the rigid tie rods.

The lower end of the slewing ring support is the climbing frame, which surrounds the tower body. To meet construction needs, jacking mechanism can jack the upper structure of the tower body to let in mast sections for increasing tower crane height.

3.3.2 Anchored State(show as Fig3-3、Fig3-4) The maximum hoisting height can reach 60m when crane is stationary with embedded anchors. If the hoisting height must be over 60m, it must be fastened with tie-in onto the building and mast tie frame. The maximum hoisting height can reach 220m when the crane is fastened with tie-in onto the building. 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 tower crane anchored-to-building has the same structural layout as stationary type, only with the exception of tower section M added to the tower body for higher hoisting. To enhance tower crane stability and tower body rigidity, several anchors are provided along the whole height of the tower body. If the maximum hoisting height is 220m, the crane must be equipped with 7anchors. Standard attachment, the tower body center has to be kept 5m away from the building. In case of the actual distance of the project not in compliance with this requirement, just contact our company for further information.

Items 3.3.2.1 and 3.3.2.2 give consideration to

Fig3-3

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project construction requirements and the stress of the tower body and anchored frames. They specify the distance bet-ween anchored frame and foundation plane, distance between anchored frames and suspension height limit Fig3-3above anchored frame. Item 3.3.2.3 and3.3.2.4 (Fig3-3、Fig3-4) can satisfy both ordinary construction needs and facilitate prefabrication of anchored frames most economically for lower operation cost of the tower crane.

3.3.2.1 With one anchored attachment (Shown as Fig3-3) (1)Tower height h1 below 1st anchored-frame attachment to the foundation (include base section height in case of stationary crane with foundation anchor, and height of upper base section and lower base section in case of stationary crane with base frame.)

30(m)≤h1≤45(m) Number of mast section below 1st attachment 10.7≤n1≤16.1 (2) The height of tower above the anchored-frame ho. h0≤39(m) Number of mast section above anchored-frame: n0≤13.9 3.3.2.2 With two anchored frames or more (1)Distance between each anchored-frame h2:

Fig3-4

16.8(m)≤h2≤25.2(m) numbers of mast section between two anchored-frame n2: 6≤n2≤9 (2) The height h0of tower above the highest anchor point is: When hook height h is less than100m，h0 is the same shown in 3.3.2.1(2).

When hook height h is ＞100m namely:n0≤12.9 3.3.2.3Most economic anchored-frame layout for the stationary crane with embedded anchors After 1st anchoring operation, the tower height above the anchored frame is less than 39.32m; the maximum working height reaches 85.2m, from down to up, 1 base

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tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 24 tower sections M After 2nd anchoring operation, the tower height above the anchored frame is less than 36.52m; the maximum working height reaches 107.6m, from down to up, 1 base tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 32 tower sections M After 3rd anchoring operation, the tower height above the anchored frame is less than 36.52m; the maximum working height reaches 130m, from down to up, 1 base tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 40 tower sections M After 4th anchoring operation, the tower height above the anchored frame is less than 36.52m; the maximum working height reaches 152.4m, from down to up, 1 base tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 48 tower sections M After 5th anchoring operation, the tower height above the anchored frame is less than 36.52m; the maximum working height reaches 174.8m, from down to up, 1 base tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 56 tower sections M After 6th anchoring operation, the tower height above the anchored frame is less than 36.52m; the maximum working height reaches 197.2m, from down to up, 1 base tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 64 tower sections M After 7th anchoring operation, the tower height above the anchored frame is less than 36.52m; the maximum working height reaches 220m, from down to up, 1 base tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 72 tower sections M 3.3.2.4Most economic anchored-frame layout for the stationary crane with undercarriage After 1st anchoring operation, tower height above the anchored frame is less than 39.32m; maximum working height reaches 85.2m, from down to up, 1 undercarriage, 4 tower sections MQ and 24 tower sections M After 2nd anchoring operation, tower height above the anchored frame is less than 36.52m; maximum working height reaches 107.6m, from down to up, 1 undercarriage, 4 tower sections MQ and 32 tower sections M

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After 3rd anchoring operation, tower height above the anchored frame is less than 36.52m; maximum working height reaches130m, from down to up, 1 undercarriage, 4 tower sections MQ and 40 tower sections M .

After 4th anchoring operation, tower height above the anchored frame is less than 36.52m; maximum working height reaches 152.4m, from down to up, 1 undercarriage, 4 tower sections MQ and 48 tower sections M .

After 5th anchoring operation, tower height above the anchored frame is less than 36.52m; maximum working height reaches 174.8m, from down to up, 1 undercarriage, 4 tower sections MQ and 56tower sections M After 6th anchoring operation, tower height above the anchored frame is less than 36.52m; maximum working height reaches 197.2m, from down to up, 1 undercarriage, 4 tower sections MQ and 64tower sections M After 7th anchoring operation, tower height above the anchored frame is less than 36.52m; maximum working height reaches 220m, from down to up, 1 undercarriage, 4 tower sections MQ and 72 tower sections M

3.4 Counterweight should be equipped according to the length change of jib Table 3.3 table 3.3 30mjib 2×3.0t Counter weight

Counter weight

1×1.65t total 7.65t 50mjib 2×3.0t

35mjib Counter weight

Counter 2×1.95t weight 3×1.65t Total 14.85t

2×3.0t 1×1.95t 1×1.65t total 9.6t 55mjib 2×3.0t

40mjib

2×3.0t Counter 2×1.95t weight 1×1.65t total 11.55t 60mjib 2×3.0t Counter 3×1.95t 4×1.95t weight 3×1.65t 3×1.65t Total 16.8t Total 18.75t

45mjib Counter weight

2×3.0t 2×1.95t 2×1.65t total 13.2t

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3.5 Erecting After installing the embedded anchors, The erection of tower crane shall be conducted only after the concrete strength of foundation reaches the designed value of 70%.

After installing the embedded anchors and the base section MQQ, the installation sequence of the tower crane is as following

Fig.3-5 installing tower crane with the embedded anchors

3.5.1Erecting Tower Section MQQ and 2 Tower Sections MQ 3.5.1.1Structure description There are four kinds of tower sections for stationary crane. Embedded anchor:The crane with embedded anchors have 13 tower sections M, 3 tower sections MQ, one tower section MQQ, one base tower section MQQ(figure3-6): base tower section MQQ is connected with the embedded anchors (the upper and lower end faces of each main chord have 4 bolt joints, and it has 2 supports for installing the nameplate and the power switch).Above the base tower section, there is a tower section MQQ (the upper end face has 3 bolt joints, and the lower end face has 4 bolt joints). Upon it, there are 3 tower sections MQ (the upper and lower end faces of each main chord have 3 bolt joints),the rest are 15 tower sections(the upper and lower end faces of each main chord have 2 bolt joints) .There are a ladder and a platform in each tower section.

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figure 3-6a

base tower section MQQ

Figure3-6b tower section MQQ

Figure3-6c tower sections MQ

3.5.1.2Erect one tower section MQQ and two tower sections MQ（Fig7） a. Hoist the tower section MQQ onto the base tower section MQQ and screw them together with 16 pieces high-tensile bolts (strength rating 10.9). Then hoist 2 tower sections MQ onto the tower section MQQ and screw them together with 12 pieces high-tensile bolts (strength rating 10.9). Be sure that the climbing lugs on each section are placed on the same plane under counter-jib in order to conveniently installing and dismantling the whole tower crane. At this time there are 1 base tower section MQQ, 1 tower sectionMQQ and 2 tower sections MQ on the foundation, shown as Fig3-7. If the crane with a undercarriage, hoist 2 tower sections MQ onto the undercarriage and screw them together with 12 pieces high-tensile bolts.

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b.Tighten all M36 high-tensile bolts with torque up to 2400N·m，and each bolt should be equipped with two washers(one is put under the head of the bolt, another is put under the nuts, and the face with chamfer is faced to the head or the nuts, shown as Fig.3-7) and two nuts. The loose-proof nut(the upper nut)should be fastened with torque equal to or a little more than2400N·m. c. 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.

Figure3-7

installing MQQ+2MQ

3.5.2 Hoist Climbing Frame 3.5.2.1 Structure description(shown as Fig3-8) Consists of climbing frame structure, platform, climbing stairs, hydraulic jack system and let-in de-vice for mast section. Jacking of the tower crane is done mainly by this component. The jacking cylinder (or called climbing jack) is installed on the beam at the rear side of climbing frame (i.e. one side of pre-assembled counter-jib). The hydraulic pump station is placed on the platform on the side of hydraulic cylinder. Climbing frame have 16 rollers, which are adjustable, on the inner side. These rollers are sup-ported on the outer side of the main chord rod of the tower crane, acting as guide and bearing.For the purpose of safety jack, platforms are provided at the top of and in the middle of the climbing frame,

Figure3-8 climbingframe 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.

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3.5.2.2 Hoist Climbing Frame After pre-assembling the climbing frame(shown as Fig 3-9), hoist the frame.

It should be noted that jacking cylinder is fixed at the same side of the climbing lugs on section. a.Pull the climbing frame on the outer side of the mast section gently. b.Place supporting latches of climbing frame on the 2thlug pair from down to up.

Adjust the clearance between16 climbing guide rollers and tower sections MQ (cle-arance is 2~3mm). c.Fix the jacking cylinder and hoist the hydraulic pump station to one corner of theplatform,connect oil tubes, and check the hydraulic system for normal operation.

Be sure of the rotation of fan blades of the

Figure3-9

hoisting climbing frame

oil pump motor in the same direction as arrow indication on its casing. This will help avoid oil pump burn-down.In case of any errors, motors shall be rewired.

3.5.3 Install the assembly of slewing ring 3.5.3.1 Structure description The assembly of slewing ring consists of the slewing ring support,slewing ring, upper support and slewing

mechanism. Shown as

Fig3-10.

The slewing ring support is an integrated box structure. The lower portion of the ringsupport is connected to the tower section by high-strength bolts,and connected to the climbing frame by pins.

Fig3-10

Its upper portion is connected to the outer ring of the slew-

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-ing ring by high-strength bolts. The upper support is a form of plate-shell structure.

The flanges are welded on its both sides for the installation of slewing mechanism. On the four sides of the upper support is provided with an operating platform. On the front of the right side of working platform is welded with a support lug for connection of the operator cab. On the rear is provided a support for the installation of slewing limiter and a support plate for mounting electrical whistle is provided in front. The upper sur-pport is connected to the slewing tower by 4 pins(φ63 ) on the upper face .

3.5.3.2 Hoist and install the assembly of slewing rings Use 80 pieces of M24 high-strength bolts (strength rating 8.8) connect the slewing ring support, the slewing ring and the upper support together. The pre-tensioned torsion moment of the bolts is up to 640N·m. the checking nut （the upper nut）should be fastened with torque equal to or a little more than 640N·m.

Hoist the assembly of slewingrings shown as Fig3-11. Hang the hookin the four pin-holes of the upper slewing surpport main chord rods.

Let them down slowly to keep main chord bolt joints of the ring support in line with the corres ponding holes of tower section connections.It is very important to keep the position of passing holes of the slewing ring support in conformity to the position of tower section’s climbing stairs on the tower body. In connecting the slewing ring support to the climbing frame,their marks on four corners must correspond to one another. b.Screw them together with 8 pieces M36 high-tensile bolts（strength rating 10.9）,

Figure3-11installing

and equipping each bolt with a washer and two nuts. Tightening all the bolts with torque up to 2400N·m， the checking nut （the upper nut）should be fastened with torque equal to or a little more than 2400N·m. c. After installing operator cab, slewing tower body, tower head and assembly of counter-jib, operate the jacking system to extrude the hydraulic cylinder to the second pair of climbing lug from up to down. Jack the climbing frame to contact the connecting

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ear-plate of the ring support. Connect the climbing frame to the ring support with 4 pieces of pins.

3.5.4 Install the slewing tower body 3.5.4.1 Slewing tower assembly description The slewing tower assembly consists of the slewing tower body and hoisting weight limiter (Fig3-12). The slewing tower body is an integrated frame structure. Its upper end surface has the ear-plates for mounting the jib and counter-jib respectively.

These plates are connected to the tower head by 4 pins. The hoisting weight limiter is provided on the beam of the slewing tower to control the maximum hoisting weight at different rapidity.

Figure3- 12 the slewing tower assembly

3.5.4.2 Hoist and install the slewing tower body（Shown as Fig3-13, place the） hoisting wires at the four main chords,and then tighten the hoisting wires.

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a.Hoist the slewing tower body(Pay attention to the direction of the ear-plates for mounting jib and counter-jib). Keep the ear-plates close to the side of the hook w-eight limiter and the jib on the upper tower body support in the same direction. b.Connect the slewing tower body and the upper support together with 4 pins.

3.5.5 Installation of Tower Head 3.5.5.1 Structure Description(Fig3-14) The tower head is a quadrangular cone-shaped structure. On its top, there is provided with the tie plate frame and jib tie plate, which are connected respectively to the counter-jib and the jib through pins. The upper portion of

Figure3- 13 installing the slewing tower body

the tower head is provided with a working plat-form. The platform is bolted to the tower head.

The upper portion of the tower head is provided with guide pulleys for hoisting wire rope and pu-lleys for mounting the jib tie rods. The lower portion of the main rear chord of the tower head is provided with a moment limiter, and ladders with protection rings. The tower head has 4 ear-plates on its lower end, which are connected to the slewing tower body through 4 pins.

3.5.5.2 Hoist and Install the Tower Head(Fig3-15) a.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 tie rod for the convenient

figure 3-14 tower head

installation of the counter-jib. b. Hoist the tower head onto the slewing tower body. Pay attention to align the vertical side of the tower head to the jib direction of the upper support.

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c.Connect the tower head to the slewing tower body by 4 pieces of pins. Put through and open up cotter pins

figure 3-15 installing tower head

3.5.6 Installation of counter-jib assembly 3.5.6.1 Structure Description(figure3-16) The counter-jib has 2 sections, which are connected by pins. The counter-jib is provided with railings, walkway and working platform. One end of the counter-jib is connected to the slewing tower body by two pins and another end connected to the tower head by two rigidly-combined tie rods. Its tail section is equipped with the counter-weight and hoisting mechanism. The resistance box and the electric control box are arranged at the root. The hoisting mechanism and its own base frame are fixed on the counter-jib by six bolts. The weight of counter-weight varies with the jib length, referred to table 3.3.

figure 3-16 counter-jib Page:38 / 123

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3.5.6.2 Hoist and Install Counter-jib Assembly a.Assemble the counter-jib corresponding to the jib length on the ground. Install the hoisting mechanism, lifting pole, electric control box, electric resistance box and counter-jib tie rod(figure3-18) on the counter-jib and make sure of their solid connection(figure3-17). 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. b.Shown as Fig3-17, hoist the counter-weight (Four mounting ears are equipped on it.) c.Connect the front end of counter-jib to the slewing tower body with pins. d.Shown as 3-19 for the counter-jib pull rods schematic diagram, lift up the counter-jib slowly to a proper position for smooth connection of the counter-jib pull rods to those on the tower head. Connect the pull rods by pins, insert and open up cotter pins. e.Lay down the counter-jib slowly. Hoist one pieces of 3t counter-weight at the furthest position of the counter-jib, shown as Fig3-20.

Figure3- 17 installing

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figure 3-18 counter-jib pull rods

Figure3- 19 installing Counter-jib pull rods

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figure 3-20 Hoisting and intall a 3.0t counter weight

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3.5.7 Install operator cab 3.5.7.1 Structure description (shown as Fig3-21) The cab is a sheet structure, offset at the front on the upper support right side pl-atform. There are large big glass windows on the four sides of the cab.The upper win-dow in front can be opened to obtain a wide field of view.The cab is nice-looking and co-mfortable,equipped with inter-active control console.

3.5.7.2 Hoist and install the operator cab a.After the electric equipment in the cab is mounted, Hoist the cab to the front near right platform of the upper support (Fig3-22).

Figure 3-21 operator cab figure 3-21

Align it with the hole-position of ear-plate and connect them with three pins and put in cotter pins b.Alternatively assemble on the ground the cab and slewing ring assembly and hoist the whole piece once for all).

3.5.8 Install jib assembly The jib assembly consists of the jib,jib pull rods, trolley, and trolleying mechanism.The pull rods are placed on the rod-fixing frame on

Figure3-22 installing operator

the upper chord rod of the jib.

3.5.8.1Structure description (shown as Fig5-23) The upper and lower chord rods on the jib

figure 3-22

are square tubes welded with two pieces of angle steel. The whole jib is a varied cross-section triangle spatial structure, consisting of eight sections. Section-to-section is connected by pins for the purpose of convenient installing and dismantling. In order to improve hoisting performance and reduce jib weight, the second and fifth jib is structured of a double hook lugs and varied cross-section spatial truss. In the second section, the

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traveling mechanism is provided. The trolley moves along the jib lower chord as its track.

It is pulled by the traveling mechanism to move to and fro along the jib. On one side of the trolley, a maintenance cage is provided for tower crane installation and maintenance.

Dislocation and free assembling are forbidden.

figure 3-23

The jib may be assembled with various jib lengths of60m、55m、50m、45m、40m、 35m、and30m to suit different construction requirements. Dismantling the 6th section, the jib length is 55m, and dismantling the 7 jib length is 50m, dismantling 6th and 7th sections, the jib length is 45m , dismantling 4th and 7th sections, the jib length is 40m , dismantling 4th ,6th and 7th sections, the jib length is 35m , dismantling 3th,4th ,6th and 7th sections, the jib length is 30m. shown as Fig3-24.

figure 3-24 jib structure

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3.5.8.2 Hoist and install jib assembly a.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 chords. b.Mount the maintenance cage to the trolley and move the trolley as close to the minimum radius point of jib root (foot) as possible. 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 Fig3-25.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 6~8 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.

figure 3-25 trolleying wire rope layout c. After assembling jib pull rods shown as Fig3-26, connect it to the jib hook lugs on the upper chord of jib with pins, insert cotter pins, then place jib pull rods on the bracket of upper chord on the jib

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figure 3-26 jib pull rods

d.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. e. Hang up ropes as shown in Fig.3-23. Try the ropes for balance. In case of improper balance, move the rope to proper hanging position. Lift the jib assembly to the mount height. Use the axis-positioning frame and pins to connect the root section of jib to the slewing tower body and then fasten the connection. Attention: Record the jib lifting point for reference during tower crane dismantling.

figure 3-27 weightcenter of jib

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Notices: 1.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 below table.

55m jib

50m jib

L(m)

19.8

18

G(kg)

8100

7700

2. When hoisting, 8m＜L＜20m.

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

4.Hang up ropes shown as Fig3-27. Try the ropes for balance. In case of improper balance, move properly the rope-hanging 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 Fig3-28. Attention: record the jib lifting point for reference during tower dismantling.

figure 3-28 installing jib

5. Reeve the hoisting wire rope according to Fig3-29，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 Fig3-30, Fig3-31. insert split pin, let off wire rope of hoisting winch and lay down jib slowly.

6.Keep the tie rod tensioned. At this time,

Figure 3-29 hoisting wire rope layout

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the jib is raised about 1/70. Loosen the hoisting rope on the pulley block.

Figure3-30 dj i t

tower head structure at jib pull

Figure3-31pull rod structure at tower head joint(↓)

3.5.9 Assemble counter-weight The weight of counter-weight varies in proportional to the jib length. The counter-weight is hoisted according to the jib length used shown as Fig3-32. The counter-weight configuration and mounting position are strictly acted on the requirements of seven jib-length conditions.

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figure 3-32 installing counter-weight

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3.6 Rope-winding system of hoisting mechanism After installation,wind hoistingropes.

As shown in Fig3-33, the hoisting rope is released from the wire rope drum, 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

Figure 3-33 hoisting wire rope layout

3.7 Power on and Trial operation

Figure3- 33 hoisting wire rope layout

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 Chapter 4st-adjusting

3.8 Fall-change system The automatic fall-change system consists of 3 parts, i.e. the trolley, upper pulley block and lower pulley block (incl. hoisting hook). They mount on the jib (Fig3-34),rope winding on the trolley and upper-lower pulley blocks (Fig3-35) and the connection-disconnection of the upper pulley block to lower pulley block enable conversion of 2-fall and 4-fall (referred to hereinafter as fall-change).

figure 3-34 schematic diagram of the installation of trolley on jib

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The fall-change is converted at the jib root section under the conditions of no-load, slow speed and no swing. No matter how it is required to convert 2 fall to 4-fall or to convert 4-fall to 2-fall, the by-pass switch must at first be turned to the by-pass status to disable the height limiter.

After conversion completion, the by-pass switch must be restored to its original status. At the 2 fall working conditions, the upper pulley block (1) with automatic connections contacts tightly the trolley. The upper pulley block is connected automatically to the lowerpulley block

figure 3-35 schematic diagram of trolley hoisting

through 2 connection plates (2). The plates have waistshaped long holes (3) for connection and locking through pins (4)on the lower pulley block.

The upper pulley block is disconnected from the lower pulley block through the unlocking device (5). This device is fixed on the upper portion of the trolley by spring (6).

When the trolley moves to the jib root, a wedge piece(9) under the jib acts on the co-nnection plate (2) through this device so as to open the plate (2), thus the upper pulley block is disconnected from the lower pulley block.

3.8.1 Method for 2-fall to 4-fall conversion(Fig3-36) 3.8.1.1 Before conversion, the upper pulleyblock (1) has tightly contacted the trolley andthe connection plate (2) is at a close state.

3.8.1.2 Move the trolley to a position near the jib root wedge and stop there (Attention: at this time, the unlocking device(5) is unable tocontact the wedge (9)).Lift slowly the lower pulley block at no-load and no swing conditions.

When the connection(2) contacts the pins (4) tail on the lower pulley block, the connection plate will rotate with the pins (7) as the center,thus being pushed open.

When the long waist-shapedhole (3) on the connection plate is against the pins (4) on the lower pulley block, the connection plate will be closed. At this time the lower pulley block must stop rising, thus combining automatically the upper pulley block and lower pulley block into one unit.

3.8.1.3 While the hoisting hook is going down, the pulley block is at a working state of 4-fall. Lower the pulley block down to the ground, put the safety pins (8) into the upper hole of the lower pulley blockto lock connection plate, thus the processof 4-fall is conve-rsion completed.

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figure 3-36 diagram of2-fall to 4-fall conversion

figure 3-37 diagram of4-fall to 2-fall

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3.8.2 Method for 4-fall to 2- fall conversion figure 3-37 3.8.2.1Lower the hoist hook onto the ground and place the safety pin (8) into the lower hole on the pulley block. Release the locking connection plate (2). (Fig3-37a).

3.8.2.2 Lift the hoisting hook to İts maximum working height. Move the trolley to the jib root and stop it at a spot where the unlocking device (5) is 100~200mm away from the wedge(9). Continue to lift the hoisting hook slowly to make the pulley block tightly con-tact the trolley, and the upper pul- -ley block-lower pulley block contact each other before stop. At this location, the pin (4) on the lower pulley block is at the upper portion of the long hole (3) on the connection plate (2), thus no more locking the connection plate. Move the trolley slowly along the wedge(9) in the jib root direction. (Fig.37b).

3.8.2.3 With the inward movement of the trolley, the unlocking device moves downwards to act on the connection plate (2) and make the plate (2) rotate with the pin (7) as its cen-ter until the plate has been opened fully before stop (Fig3-37c).(Attention: Never let the unlocking device on the trolley move into the wedge, otherwise the trolley will be unable to change its working radius) 3.8.2.4 Lower the hook and move the trolley forwards. The upper pulley block contacts tightly the trolley due to wire rope tensile forces. The lower pulley block moves with the hook, thus completing 4-fall to 2-fall conversion (Fig3-37d).

3.9 Jacking operation for adding sections 3.9.1 Pre-jacking preparations 3.9.1.1 Fill the oil tank with hydraulic oil according to the requirements of hydraulic pump station. Be sure of the electric motor correctly connected, the fan turned to the right and the operating lever of hand control valve working smoothly without any clogg-ing.

3.9.1.2 Put in order each mast section MQ and apply the grease into its connection boltholes. Line up the tower sections MQ 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.

3.9.1.3 Loosen the power cable length slightly in excess of the total jacking height, and then fix the cable.

3.9.1.4 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).

3.9.1.5 Preparation should be made on the platform to inlet wheels and high-tensile bolts for tower sections on the climbing frame.

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3.9.2 Keep the tower crane in balance before jacking operation 3.9.2.1 Before keeping the tower crane in balance, hoist one tower section MQ onto the introduction platform and then move the trolley to the reference balance position shown as Fig3-38. 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 se-ction.

3.9.2.2 Push the operation handle of the hydraulic jacking system to <<Jacking direc-tion>> 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.

3.9.2.3 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 deter-mine whether or not the tower crane is in balance. If not, adjust until balance is achiev-ed so as to drop the center of gravity of the upper tower crane onto the position of jacking cylinder beams.

Figure3-38 keep the tower crane

3.9.2.4 Record the balance position of the trolley for the convenience of dismantling.

This mark position varies with different jib lengths.

3.9.2.5 Operate the hydraulic system to lower down the sleeve frame. Connect the slewing ring support to tower sections MQ with bolts.

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3.9.3 Jacking operation (shown as Fig3-39) 3.9.3.1 Hoist another mast section and drive the trolley to the position for balance, shown as Fig3-38.

3.9.3.2 Use the brake on the slewing mechanism to hold the tower superstructure at a slewing braking status, thus ensuring no slewing movements.

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

3.9.3.4 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 f rame 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 on the inlet platform of climbing frame into upper part of tower, retreat the jack slightly so that the new tower section alight at the top of tower and conduct proper alignment, remove the inlet wheels, fasten the upper and lower sections with eight pieces of M36 bolts with torque of 2400kN·m, each bolt must be equipped with two nuts.

Figure3-39 operation in

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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 M36 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.

3.9.4 General Notices of Jacking Operation: 3.9.4.1 Jacking operation is prohibited when the wind speed at the high-est top exceeding 12m/s.

3.9.4.2 Keep the jib in the same direction as the in-let tower section during jacki-ng operation. Stop the jib with the slewing mechanism brake be sure of the trolley stopping at the jack-balanced position.

3.9.4.3 If several tower sections are to be mounted, after mounting a section, all the chords of the section must be fastened with 8 pieces of M36 bolts before hooking another section. Only at this time, it is permitted to use one nut of each bolt.

3.9.4.4 Keep the climbing lugs on the newly added tower section in alignment wi-th those on the existed sections.

3.9.4.5 It is prohibited to slew, change work-radius and hoist load without conne-ction of the slewing ring support to the tower body by 8 pieces of M36 bolts.

3.9.4.6 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 M36 bolts to connect the slewing ring support to the tower body before removing troubles from the hydraulic system.

3.9.4.7 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.

3.10 Tower anchored onto the building 3.10.1 When the working height of the tower crane has to be exceeded to its standalone height, the tower body shall be anchored.

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3.10.2 The anchoring devicesconsist of 4 sets of mast-tie-framesand 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 4 strut-rods on 4 top points. The 4 strut 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 Fig3-40).

1. connection pedestal

2. short brace

3. long brace

4. anchoring frames

5. connection bolts 6. inner tie rods

7. adjusting screw

8. adjusting bolt figure 3-40 anchoring device

3.10.3 Load on anchoring points table 3.5 Before tower crane erection, customers or installation organizations are required to make necessary estimates of the load-bearing capability at building anchoring poi-nts (for the of connection foundation-fixing spots), as well as the construction period of the reinforced concrete structure affecting the anchoring point strength and similar factors. In the table 3.5, it gives the anchoring forces imposed at the anchoring points of the building ,at working and non-working conditions when the tower crane has its anchoring strut rods layout and location as shown in Figure3-41. The building’s anch-oring point shall not have its load-bearing capability smaller than the values shown in the table.

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table 3.5

F1(kN.)

±135

F2(kN)

±182

F3(kN)

±135

F4(kN)

±182

figure 3-41 load at anchoring

Attention： Load values at anchoring points vary to a great extent with the relative positions of the tower crane to the building, the struts layout and size, the height of the tower body suspension sections over the anchored frame. If the tower crane anchoring position, anchoring strut layout and size are not in compliance with what is shown in Fig3-41during tower crane attachment, just contact our company for advice. Never apply mechanically this issue by using the values in Table 3.5 in order to avoid serious accidents.

3.10.4 Pull anchoring tie frames onto the tower body, use 4 inner tie rods to press them against 4 main chord rods of the tower body and connect them to its web rods.

Use pins to connect one end of the tie rod to the attaching frame and another end to the connection pedestal fixed to the building.

3.10.4.1

4 sets of anchoring tie rod on each frame shall be kept at the same

horizontal plane. If they are interfered with some positions of the tower body during mounting of anchoring frames and inner tie rods, the height of frames will properly be raised or lowered. The permitted height difference of anchoring frames to foundation connection shall not be greater than 200mm.

3.10.4.2The 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.

3.10.5 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 5/1000 of the total tower crane height. This deviation can be achieved by adjusting the length of the strut rods.

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3.10.6 The connection of strut rods to tie frames, foundation and tie frames to the tower body and inner strut rods shall be reliable. The inner strut 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 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.

Attention: No matter how many anchoring is conducted, only the topmost anchoring tie frame can accommodate the inner strut rod. i.e. after each new attachment, the inner strut rods have to be removed into the newly-anchored frame.

3.11 Preparations before operation The pre-operation preparations of the tower crane aim at ensuring its correct co- -ntrol and smooth operation at safe conditions. Main preparations are to check tower crane components and to test-run safety devices.figure3-42.

1. Hoisting mechanism (arresters、height limit) 3. Weight limit

2. Moment limit

4. Trolly mechanism (arresters、radius limit)

5. Slewing mechanism (arresters、slewing limit) Figure3-42 the mounting positions of safety devices

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3.11.1 Checking Parts and Components 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.

3.11.1.1 Check component-to-component connections.

3.11.1.2 Check the installation of Supporting platform and fences 3.11.1.3 Check wire ropes for correct winding, avoiding interference and friction with other parts.

3.11.1.4 Check power cables for smooth and proper routing.

3.11.1.5 Check if the counter-weights on the counter-jib are properly fixed.

3.11.1.6 Clear the lumber on platforms in order to prevent them from falling and avoid injuring persons during tower crane operation.

3.11.1.7 Check lubrication surfaces and points.

3.11.2 Test-run for the safety device Safety devices for the tower crane mainly include the travel limiter and load limiter.

The travel limiter includes the hoisting height limiter, slewing limiter and working radi-us limiter. The load limiter includes the hoisting moment limiter and hoisting weight limiter. The anemometer is also included. The test-run method is referred to the secti-on 3 of the Part II.

3.11.3 Items-checking after tower erection table 3.6 Item

Foundation

Tower section Climbing frame

Upper support, slewing ring support and operator cab

Contents 1.Check if the foot bolts are fastened 2.Check safety distance between the surrounding power lines and tower crane.

3.Check power cable for smooth routing to avoid damage.

4.Check the resistance,less than 4 Ω Check the bolt connection of tower sections 1. Check its connection to slewing ring support 2. Check if the guide wheels, latches, pin-bolt-connected parts move smoothly 3.Check if the walkway and fence are fastened 1. Check if the bolts connecting slewing ring is properly fixed.

2. Check power cable for smooth passage 3. Check if the platform and fence are fastened 4. Check the connection for operator cab 5. No storage of lubrication oils, oil cotton yarns and combustible materials in the cab.

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd. 1. Check tie rods of jib and counter-jib tie rods for proper installation.

2. Check ladders, platforms and protection rails.

Tower head 3. Secure that the hoisting rope is properly wired and arranged

Jib

Counter-jib

Hook

Mechanism

Safety device Lubrication

1.Check connection pins, washers and cotter pins for correct mounting.

2.Check if the trolley is properly installed and operates smoothly, check maintenance cage for fixing.

3.Check hoisting and radius-changing ropes for winding and fixing 1.Check counter-jib for fixing 2.Check protection rails of the counter-jib and walkway. Ensure no foreign substances on the walkway 1.Check rope off-proof devices of the hook and fall-changing device for safety and reliability 2.Check hoist hook group for defects influencing operation 3.Check specifications and models of hoist ropes and radius-changing ropes for compliance with requirements.

4.Check wire ropes for wear.

1. Check mechanism for installation and operation 2. Check mechanism brakes for correct clearance adjustment 3. 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.Check if the ends of steel ropes are loosened or improper compressed.

1. Check safety device for proper adjustment as specified in the Instructions 2.Check all ladders, protection rails and rest platforms for properly fastened.

Check lubrication conditions according to the operation instructions.

3.11.4 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).

3.11.4.1 No-load test 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.

3.11.4.2 Load test Before load test, the brake of the hoisting mechanism must be adjusted at hoisting 1.1 times rated load.

Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the rated hoist load at the maximum working radius for tests.

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3.11.4.3 Static test at 25% over-load Conduct the static test at over-load after no-load tests and on-load tests have been completed as specified.

Test loads based on different jib lengths are shown in Table below. İtem Jib

60m 55m 50m 45m 40m 35m

RadiusⅠ(m)

Hook weightⅠ(t)

RadiusⅡ(m)

Hook weightⅡ(t)

13.25 14.19 14.76 14.76 14.77 14.77

12.5 12.5 12.5 12.5 12.5 12.5

60 55 50 45 40 35

1.71 2.21 2.71 3.15 3.7 4.41

30m 14.79 12.5 30 5.37 Hoist the weight at radius I and radius II from the ground for 100~200 mm height at the lowest safe speed. Put additional successive weighs onto the hoist hook up to 1.25 times the first weight. Stay on for 10 minute. Carry out unloading and check metal structures and welds for any cracks, permanent deformations and loosened connections.

Attention: No trolley radius-changing and slewing during over-load static tests 3.11.4.4 Dynamic test at over-load Hoist 1.51t weight at maximum radius (1.95t for 55m jib, 2.39t for 50m jib, 2.77t for 45m jib, 3.26t for 40m jib, 3.88t for 35m jib, 4.73t for 30m jib) to make each mechanism conduct corresponding full-range action tests for 3 times. The mechanism shall act smoothly and the brake shall act reliably. There shall be no abnormal incidents from mechanisms and structures, neither loosened parts and damages.

3.12 Stationary tower crane with undercarriage installed according to the procedures shown as Fig3-43.

1) Install the undercarriage assembly 2)Other assembling procedures are the same as tower crane with embedded anchors

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1.Undercarriage

2.Base section 3.Climbing frame

4.Slewing assembly

5. Tower head

6. Counter-jb

8. Counter-weight

9. Cab

7. Counter-jb rods

10. Slewing tower body

11. Jib rods

12. Jib

figure 3-43 installing sequence of stationary tower crane with undercarriage

3.12.1 Install the Undercrriage Assemble the undercarriage 1).Assemble the crossbeam assembly (shown as Fig3-44); fasten it to the foundation with embedded bolts and channel steel.

figure 3-44 assemble undercarriage

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2).Installa the base tower section1 and 2 (shown as Fig3-45); 3).Install the struts(shown as Fig3-45);

Figure 3-45 assemble the base section and struts

4). Assemble the Center Ballast (shown as Fig3-46)

Figure3- 46 assemble the center

4 pieces of3.9t Center Ballast，12 pieces of4.5t Center Ballas，total weight69.6t

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Chapter Ⅱ Dismantling 3.13 Precautions for tower crane dismantle 3.13.1 Conduct maintenance and test-run for the jacking mechanism before moving the tower crane out of the construction site.

3.13.2 Check limiters, slewing mechanism brakes and similar devices for reliability during test-run.

3.13.3 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 M36 high-tensile bolts.

3.13.4 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.

3.13.5

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.).

3.13.6 Carry off dismantling when the wind speed is lower than 12m/s at the high-est 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.

Fig3-47a dismantle tower crane with embedded anchors

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Figure 3-47b dismantle tower crane with undercarriage

3.14 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 therefore required to strictly follow the Instructions-specified rules to dismantle these components. Tower operators shall have been trained and with certificates.

Notice：Pay great attention to the two climbing latches during inlet or dismantle of tower section. Inspect if the latches are still in proper level condition.Mov 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 Fig3-47 Its steps are in opposition to the steps of tower crane erection.Strictly follow the instructions specified rules in all cases.

The concrete sequence of the dismantling as following: 1) Lower down the tower sections (dismantle anchored devices if any).

2) Dismantle counter-weights from counter-jib. (Keep one piece of 3t counterweight)

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3) Dismantle the jib.

4)Dismantle the last counter-weights. Dismantle the counter-jib.

5) Dismantle the operator cab (or dismantle it together with the slewing assembly) 6) Dismantle the tower head.

7) Dismantle the slewing tower body.

8) Dismantle the slewing ring assembly.

9)Dismantle the climbing frame and the remanent tower sections.

10)Dismantle the the center ballast and undercarriage (if the crane has a undercarriage)

3.14.1 dismantle the tower sections 3.14.1.1 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

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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) 3.14.1.2 Remove the upper and lower bolts connecting of the top tower section, connect inlet wheels on the below section. 3.14.1.3 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.

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

3.14.1.5Rotate 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.

3.14.1.6 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 contact the slewing ring support.

3.14.1.7Connect slewing ring support to tower section with bolts, hook the tower section on the inlet platform to the ground.

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.

Repeat the above actions to dismantle the tower sections in sequence.

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.

3.14.2 Dismantle the counter-weight from the counter-jib Fix the trolley at the jib root and use the auxiliary crane to dismantle the counter-weight.

Dismantle the counter-weight piece by piece in the sequence opposite to counter-weight mounting. Keep one piece of 3 t counter-weight

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3.14.3 Dismantle the jib 3.14.3.1 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, and check the hoisting rope carefully.

3.14.3.2 Arrange hoisting rope at hook points.

3.14.3.3 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 pull rod close to the tower head.

Remove the pins connecting pull rod frame with the tower head, lower pull rods onto the jib and fix them. Remove wire ropes, remove pins connecting jib with slewing tower body.

3.14.3.4 Lower the jib and lay it down on the sleeper-cushioned support.

3.14.4 dismantle counter-jib Hoist down the last counter-weights. 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.

3.14.5 Dismantle the operator cab 3.14.6 Dismantle the tower head Before dismantling, check the tower head to see if component-to-component is still connected by power cable.

3.14.7 Dismantle the slewing tower body 3.14.8 Dismantle the slewing assembly 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.

3.14.9 Dismantle the climbing frame and tower sections 3.14.9.1 Slowly hoist the climbing frame out along the mast section main chord rod and place them down onto the ground.

3.14.9.2 Hoist down the tower sections one by one.

3.14.10 Dismantle the undercarriage Dismantling the center ballast and undercarriage is opposite to the installing them.

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3.15 Attention after dismantling tower crane 3.15.1The dismantled crane needs to be checked and maintained by technical personnel and trained maintenance personnel.

3.15.2 Check main stressed structural members for metal fatigue; weld fissure, structural deformation, etc. Check tower crane parts for damage or collision injury.

3.15.3 After completion of checks, repair the defects found and defects potential.

Carry out rust removing and painting.

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4- Adjusting 4.1 Pre-check

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 400V±5% Operate the hoisting handle to watch the hoisting operation. When pulling the handle inwards, the hoisting hook shall move upwards. When pushing the ha-ndle outwards, the hook shall move downwards. If not so, adjust the phase sequence of power supply of the hoisting motor to meet the above requireme-nts.

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 pu-shing 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 pu-shing 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.

4.2 Power-on test run 4.2.1 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 400V±5% (The gro-und power net shall supply adequate capacity to protect normal motor start and operation).

4.2.2 Release the height limiter and radius limiter. Arrange the wire ropes of the trolley to match mechanical erection.

4.2.3 Operate the hoisting handle to watch the hoisting operation. When pulling the handle inwards, the hoisting hook shall move upwards. When pushing the han-dle outwards, the hook shall move downwards. If not so, adjust the phase sequ-ence of power supply of the hoisting motor to meet the above requirement.

4.2.4 After completion of hoisting test-run, operate the slewing handle and trolleyradius-changing handle respectively. When pushing the handle to the left, the jib

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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 trav-el 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 me-et the above requirements. (Two slewing mechanisms shall separately be test-run to ensure slewing directions in conformity).

4.2.5 Notice for proper operation 4.2.5.1 After power supply to the operator cab (before pneumatic switch on), power for the blocking light and lighting in operator cab can be supplied through switc-hes on the control panel. The sockets are also available for fan plugs.

4.2.5.2 Press start-button, and all operating handles shall return to zero, so as to power on the master contactor.

4.2.5.3. 2 slewing mechanisms, with the technology of frequency altering and stepless speed regulated, start smoothly and slew fast.

4.2.5.4. 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.

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

4.2.5.6.Frequency converter is available for the operation of radius-changing mecha-nism. Proper speed is selected to suit different work conditions.

4.2.5.7.Before jacking, check the rotation direction of pump station motor in confor-mity to your requirements. If not, adjust the rotation to the correct direction. It is pro- -hibited to slew, hoist and change working radius during jacking. This aims at accident prevention and no breaking of the power cable due to twisting.

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 replace-ments should be conducted according to the instructions for the electrical system.

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4.3.Adjusting Hydraulic System The Motor must rotated at right direction.

4.3.1 Hydraulic System

Fig4.3.1a

Fig4.3.1b

a. Main parameters (System principle is shown as Fig4.3.1b) (Please refer to the operation instructions of hydraulic system) Main Parameters of pump station Pressure (MPa)

Flow (L/min)

Power (kW)

Hose (JB1885-77)

Oil tank capacity（L）

31.5

11.25

7.5

A-10Ⅱ

100

Rated Pressure (Mpa)

Cylinder Diameter (mm)

Diameter of Rod (mm)

Oil Requirement USA ESSO anti-wearing Hydraulic oil AW46

Main Parameters of Climbing Jack Distance of Travel (mm)

31.5 160 110 1600 b.Erection and operation of the hydraulic system

Installation Distance

(mm) 2070

Jack speed (m/min)

Max. Jack force (t)

0.56

63

1) Oil cleaning 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)

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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) Connect high-pressure hose openings for clean status.

Connect ports A.B of the hydraulic pump station to the hydraulic cylinders through high-pressure hose. Screw down the connectors.

3) Air exhausting of the system 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 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) System operation 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.

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 va-lve until the readings on pressure gauge have become stable at 31.5 Mpa. Screw do-wn the locking nut in front of the regulating handle of the high-pressure overflow valv-e (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.

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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). c.Maintenance and precautions of hydraulic system 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.

Hydraulic oil for the system 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 imme-diately and fill new oil.

Filling oil: 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 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 grade,NAS1638 before starting the system.

The oil should be completely changed after the system work for 2,400hr and add part of clean oil after working for 200hr

4.3.2

setting maximum working pressure

(1). Unscrew the locking nuts of high-pressure overflow valve in front of the control handle at non-jacking operation status.

(2). Start motor. Move the operating handle to upper position and extend the cylinder piston rod to its extreme position.

(3). Keep on screwing down the handle of the overflow valve until the readings on pressure gauge have become stable at 31.5 Mpa.

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4.4 Adjusting travel limiter There are 3 kinds of limits in Tower Crane TC6517C-10E: DXZ-4/7 hooking height limit, DXZ-4/F (i=600) trolley travel limit, and DXZ-2/3 slewing limit.

①（WK）Micro-switch

②（T）Memory cam

③Inputting Axis

Fig. 4.4.1 Hoisting height and trolleying limit

The corresponding relations of the adjusting axis(Z)、cam(T) and micro-switch is shown as follows: 1Z→1T→1WK

2Z→2T→2WK

①（WK）Micro－switch

3Z→3T→3WK

4Z→4T→4WK

cam

③Inputting Axis

②（T）Memory

Fig. 4.4.2 Slewing limit

The corresponding relations of the adjusting axis(Z)、cam(T) and micro-switch is shown as follows: 1Z→1T→1WK

2Z→2T→2WK

4.4.1 Adjustment procedures 4.4.1.1 Dismantle the upper cover, check and screw down 2-M3×55 screws; 4.4.1.2 Unscrew M5 nuts;

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4.4.1.3Drive 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.

4.4.1.4 Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will occur).

4.4.1.5 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) 4.4.1.6 Make sure that the position is as specified. Screw down M5 nuts and re-cover the casing.

4.4.1.7 After the mechanism working normally, check at certain interval the memory control position for deviations. Correct the deviations if any.

NOTICE： For the 4-loop limits（DXZ-4/7、DXZ-4/F） that used in hoist and trolley, long cam is for the purpose of limiting the speed, short cam is for the purpose of limiting the radius;and the limit switch of Slewing limit must be connected to the long cam switch.

4.4.2

Adjustment for hook height limit (2-fall when adjusting)

4.4.2.1 Adjusting procedures according to 3.1.1 4.4.2.2 Adjust at no-load conditions. Press down micro-switches (1WK、2WK) by finger to check the rising micro-switch or lowering micro-switch for correct action.

4.4.2.3 Adjust axle (2Z) to make cam (2T) act and press down micro-switch (2WK) for decelerating the hook rising when the distance from trolley to hook is about 5m (10m for frequency conversion cotrol). Adjust axle(1Z) to make cam (1T) act and press down micro-switch (1WK) to stop the hook rising when the minimum distance from trolley to hook is not smaller than 1m (3.1m for frequency conversion control, the ultimate distance between trolley to hook must be not smaller than 1 m) . Screw down M5 nuts.

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4.4.2.4 Validate the limit position of hoisting Especially Notice: 1. After wire rope changed, the height limit shall be adjusted again.

Otherwise the hook may crash the trolley and the wire rope breaks, which may lead to the crane destroying and people death.

2. If the adjustment of height limit in 2-fall, the limit radius and speed will be doubled when the wire rope transformed from 2-fall to 4-fall. If the adjustment of height limit in 4-fall, there are no limit function in the condition of 2-fall.The users should pay great attention to it.

4.4.3 Adjustment for slewing limit (the same procedures as item 3.1.1) 4.4.3.1 Adjust the slewing limit while the jib is at erection position (power cable at free status).

4.4.3.2 Adjust under no-load condition. Press down the micro-switch (1WK, 2WK) by finger to check the switch for correct left and right control.

4.4.3.3 Slew to the left for 540°(1.5 rounds). Follow the Item 3.1.1 to adjust the axle (1Z) to make the cam (1T) move to achieve transient changing by the micro-switch (1WK). Screw down M5 nuts.

4.4.3.4 Rotate 1080° right (3 rounds). Follow item 3.1.1 to adjust the axle (2Z) to make the cam (2T) move to achieve transient changing by the micro-switch (2WK). Screw down M5 nuts.

4.4.3.5 Check if the left and right slewing is correct.

4.4.4 Adjustment method of radius (trolley travel) limit (the same procedures as item 3.1.1).

4.4.4.1 Outward travel at lower speed and extreme position limiting at the jib tip: Drive the trolley at the position of 1.5m (4.6m for frequency conversion cotrol) 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 (4T) 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 bumper.

Follow the procedures to adjust the axle (1Z) to rotate (1T) to make the micro-switch (1WK) act. Screw down M5 nuts.

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4.4.4.2 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 ( 3Z-3T-3WK, 4Z-4T-4WK ) at 1.5m (4.6m for frequency conversion cotrol) and 220mm away from the jib root buffer respectively.

4.4.4.3 Check and modify.

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4.5 Adjusting Moment limiter

Fig4-2

moment limiter

wire rope at 4-fall 4.5.1 Adjustment of constant load and variable radius of trolley

Trolley hoists 8t and moves outwards from 8m point at slow speed. Adjust the

90％ Adjusting screw（shown as Fig4-2）to enable the warning light power on in the operator cab when the trolley moves to the range of 14.1～14.9m when 60m jib.(the jib length is 55m, trolley moves to the range of 14.8～15.7m. The jib length is 50m,trolley moves to the range of 15.1～16.0m. The jib length is 45、40m、35m、 30m,trolley moves to the range of 15.3～16.2m). And adjust adjusting screwn of constant load and variable radius of trolley to enable the mechanisms power off and give over-load warning sound at the same time when the trolley moves to the range of 16.6m～17.4m, It is forbidden upward hoisting or outward traveling.(the jib length is 55m, trolley moves to the range of 17.4～18.3m. The jib length is 50m, trolley moves to the range of 17.8～18.7m. 45m,40m,35m, 30m,trolley moves to the range of 18.00～18.9m ).

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4.5.2Adjustment of constant radius of trolley and variable hook load When the jib length is 60m, the loading1.5t at 60m point (the jib length is 55m, loading 1.86t at 55m, the jib length is50m, the loading2.2t at 50m, the jib length is 45m, the loading 2.58t at 45m. the jib length is 40m, the loading3.02t at 40m, the jib length is 35m, the loading 3.59t at 35m. the jib length is 30m, the loading4.36t at 30m), upward hoisting is permission. Adding 75kg to the load (the jib length is 55m,93kg , the jib length is 50m, 110kg, the jib length is 45m, 129kg .the jib length is40m,151kg , the jib length is 35m, 180kg, the jib length is 30m, 218kg), adjust the Adjusting screw of constant radius of trolley and variable hook load to enable the mechanisms power off and give over-load warning sound at the same time. It is forbidden upward hoisting or outward traveling. Test the step 3 times to keep the function stability

4.5.3

Check moment limiter

4.5.3.1

Check of constant load and variable radius of trolley

When the jib length is 60m, loading4t, trolley travels outwards from 20m point at a slow speed. When travelling to the range of 29.56～31.04m (the jib length is 55m, the range of 31.15～32.71m, the jib length is 50m, the range of 31.79～ 33.38m,45m,40,35m ,the range of 32.10～33.71m, the jib length is 30m, the range of 32.60～33.88m,), the mechanisms power off and give over-load warning sound 4.5.3.2

Check of constant radius and variable load

When the jib length is 60m, loading 8t at 16.6m (the jib length is 55m, loading 8t at 17.47m, the jib length is 50m, loading 8t at 17.82m , the jib length is 45m, loading 8t at 18.0m, the jib length is 40m, loading 8t at 18.0m, the jib length is 35m, loading 8t at 18.0m, the jib length is30m, loading 8t at 18.03m)point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is permission. When loading 8.8t load, the moment limiter works normally and the mechanisms power off.

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4.6 Adjust weight limiter

1. The two microswitches connect in series with the four microswitches 2. wire rope at 4-fall Adjusting the situation of high speed Hoist the weight of 5000kg. The hoisted weight travels up and down at low、 middle、high speed one time each. Do not permit no hoisting.

Add another 300kg load, lift the load at high speed, at the same time adjusting the first screw if the hoisting mechanism can run, when the load is lifted about 10m ,the load is lowerd until the ground.

Repeat upper all movement befor thehoisting mechanism can’t operate at high speed.the weight of hoisting load between 5000 and 5300 is comparatively perfect. upper all movement is repeat another twice(don’t adjusting the first screw)the results should are same Adjusting the situation of lowe speed(radius is not the more long than 12m) Hoist the weight of 10000kg. The hoisted weight travels up and down at low、 middlespeed one time each. Do not permit no hoisting.

Add another 400kg load, lift the load at middle speed, at the same time adjusting the third screw if the hoisting mechanism can run, when the load is lifted about 10m ,the load is lowerd until the ground.

Repeat upper all movement befor thehoisting mechanism can’t operate at middle speed.the weight of hoisting load between 10000 and 10400 is compar-atively perfect. upper all movement is repeat another twice(don’t adjusting the thirdscrew), the results should are same

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4.7 Operation of anti-twist device (shown as Fig4-7) a.

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.

b.

If hoisting ropes are ordinary wire rope, the anti-twist device shall unlock the locking bolts while the tower crane is at working.

c.

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.

d.

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.

e.

Once steel ropes have their strands loosened, the anti-twist device will accelerate rope deterioration. Therefore change the deteriorated ropes timely as required.

Fig4-7

4.8 Working mechanisms of the tower crane The working mechanisms of the tower crane consist of the hoisting mechanism, slewing mechanism, trolley traveling mechanism and jacking mechanism.

4.8.1 hoist mechanism(shown as Fig4-8.1)

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The model of hoist mechanism for the tower crane is QE8100D2, motor model YZRDW250L-4/8, equipped with draft fan, with the function of high-speed light-load hoisting and low-speed heavy-load hoisting.

The minimum stable speed is smaller than 5m/min to ensure stable hoisting and braking of objects. The wire drum is provided with the hook height limiter. When objects have been hoisted to the highest position, the hoisting mechanism will stop automatically.

4.8.2 slewing mechanisms (Fig4.8.2)

Fig4-8.1

There are 2 sets of slewing mechanisms symmetrically arranged on both sides of slewing ring. They are driven by 2 sets of 95N.m motors model YTLEJ112L-4F1andYTLEJ112L-4F2BMZL. They drive the pinions through planet gear reducer, hence making the jib and counter-jib slew to the left or the right. The one motor is provided with disc brakes at tits tail,which is kept at constant close 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 by brake.

Fig 4.8.2 1. Motor 2. Brake 3. Reducer4.Slewing Pinion 5. Slewing ring 6. Slewing limiter 7. Pinion

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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.

4.8.3Trolleying mechanism(Fig4-8.3a) a. The trolleying mechanism is for radius changing by the trolley. When doing ra-dius changing, the frequency conversion motor (model: YEJ132S-4B5 with magnetic disk brake) drives the drum through the planetary reducer, thus making the trolley tra-vel to-and-fro along the jib. Travel traction is done by 2 wire ropes (6×19-9.3-1700-Ⅱ -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.

Fig 4.8.3a

1. Brake 2. Motor 3. Limiter 4. Reducer 5. Support 6. Drum

Fig 4-8.3b

b. The adjustment of trolley brake device(Fig4.8.3b) After long time service, the clearance between electromagnet and armature shall be increased due to the abrasion, and the suction is decreased

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4.9 installing anemoscope the monitor of the wind speed installed in the control-plate of the operator cab. the power lines of the anemoscope are connected to the 50、51 ports of the control-cabnet of the operator cab.

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5 –Operation Attention: Tower crane can be operated only by trained and qualified person!

5.1 Safety instr uctions

WARNING: Live parts!

Electrical installation, connection work and maintenance must be done only by authorized, properly qualified personnel.

No ascending

Danger of falling down!

Wear and use a safety harness!

No standing under the radius

Danger

of rolling

Emergency stop

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Read the manual before use!

Slew freely when out of service

Very hot, do not touch!

Danger of crushing!

Insert safety pins in climbing!

Keep watch!

WARNING: Suspended loads!

Wear safety helmet!

Check ropes

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Lubricate!

Adjust the height limiter!

Check metal structures!

Check brakes!

Keep safety devices workable!

Adjust brakes

High-tensile strength bolt M36 connections

High-tensile strength bolt M30 connections

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Maximum load on maintenance cage

Always close the hatches!

5.2 Overall dimensions of the crane 5.2.1 Overall dimensions of the crane

Fig5-1 Overall dimensions of the stationary tower crane TC6016A

5.2.2 Overall dimensions of the crane anchored to the building

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Fig5-2 Overall dimensions for the stationary tower crane with chassis anchored to the building

Fig5-3 Overall dimensions for the stationary tower crane with stationary anchored to the building

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Anchored by embedded support

Chassis stationary

Code

Designation

Traveling

NO

Order NO.

Qty

1

0021001A0000

TC6015.01

Counter-jib

1

2

0021002A0000

TC6015.02

Counter-jib guy rods

1

3

0021003A0000

TC6015.03

Tower head

1

4

109060001001

LFM-4

Anemoscope

1

5

0029321B0000

BP55B

Trolleying mechanism

1

6

0021004A0000

TC6015.04A

Jib guy rods

1

7

0021005A0000

TC6015.05A

Hoisting jib

1

8

0029605A0000

FDG08A

Load hook

1

9

0029705C0000

FXC08C

Trolley

1

10

0029115C0000

QP8100D2

Hoisting mechanism

1

11

0020308C0000

TC5613A.08C

Slewing mast

1

Remark

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Continuation NO

Order NO.

Code HVV95

12

HVV95

Designation

Slewing mechanism

Qty 1 1

13

0029502G0000

TC5023AG.12A

Jacking equipment

1

14

0020411B0000

TC5023A.11B

Climbing equipment

1

15

109050001002

TWL-10

Overload limit switch

1

S7

Operator’s cab

1

16 17

0020309C0000

TC5613A.09C

Upper support

1

18

103160001003

011.45.1400

Nutation support

1

19

0020410B0000

TC5023A.10A

Below support

1

20

0029007C0000

BZJM1

Tower section M1

15

21

0029008C0000

BZJMQ1

Tower section MQ1

4

22

0029008C1000

BZJMQQ1

23

0029008C2000

BZJMQQ2

24

0021015A0000

TC6015A.15A

25

0020616A0000

TC6020A.16

Accrete-frame

26

0020614A0000

TC6020A.14

Undercarriage

Base tower section MQQ anchored by embedded support pillars Base tower section MQQ anchored by embedded support pillars Foundation with embedded support pillars

Remark

1 1 1

1

The quantity depends on the hoisting height .

For anchored by embedded support pillars.

Only for anchored by embedded support pillars.

Only for anchored by embedded support pillars.

Only for anchored by embedded pillars.

Only for attached crane.

The quantity depends on the hoisting height and distance between two adjacent anchor points.

For chassis stationary / traveling.

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5.4 Safety instructions on the crane For an explanation of the symbols, see "Safety instructions".

detail Ⅰ

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detailⅡ

View A

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5.5 Operating instructions 5.5.1 Pre-start checks (1)

(2) Check the wind speed!

¾ Max. permissible wind speed in operation: 72 km/h (wind force 8).

Check the environment temperature!

The working temperature the crane is in the range of -20 ~+40℃.

¾ Max. permissible wind speed in erection or climbing: 50 km/h (wind force 6).

(4) Total freedom of movement in the travelling and stewing area

(6) Make sure that all ballast and counter-weights are complete and secure.

(5) Check the condition of foundation.

(3) Assure the working voltage fluctuates ±5%.

(7) Check ropes: ¾ Make sure that all ropes are not damaged.

(8) Check the tightness of all bolts! e.g. bolts for ball slewing ring connection and sections connection etc.

(9) Make sure that venting valves of the hydraulic unit have been opened.

¾ Make sure that all ropes are properly fitted in the pulleys. ¾ Check that rope grooves are free of hardened grease.

(11) Make sure that ropes must be wound evenly onto their drums.

(13) If the crane is equipped with a lightning protection, ensure correct earthing!

(10) Check the height limiter!

Adjust the hoisting height limiter again after the rope serves for a period of time.

(12) Check the insulation of electric switches! Make sure that ¾ the earth insulation resistance of main control circuits is no smaller than 0.5 MΩ. ¾ the earth resistance of the tower body is no greater than 4Ω.

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(14) Make sure that all limit switches and push buttons are funtional.

(15) Rail track(only for travelling crane)

(16) Make sure that the safety instructions and warnings attached to the crane always complete and perfectly legible.

(17) Make sure that all open gear wheels have been lubricated well.

(18) Check safety devices to ensure them reliable.

5.5.2 User’s operations (1) The crane should be operated only by qualified persons who are complete familiar with the crane.

(2) Before starting up the crane, make sure that nobody can be endangered.

(3) Before beginning work, make yourself familiar with the circumstances of the site.

(4) Operate the crane only if all protective and safety devices are in place and fully functional.

(5) Do not bridge any safety devices (limit switch).

(6) No unauthorized persons are allowed to access the crane.

(7)When changing the jib length of the crane,reset the overload limits according to radius and load capacity.

(8) Do not land the hook block!

(9) No loads exceeding the lifting capacity regardless of an installed overload protection!

(11) Night operation do not permit bad visibility and darkness, and crane lamps or construction site lamps are essential.

Slack rope

(10) During start-up and shut-down procedures always watch the indicators according to the instruction manual.

(12) Secure tools and loose objects against falling.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

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(13) Avoid any operation that might endanger the tower crane!

For example: Pulling off fixed loads

Horizontal displacement of fixed loads

Adding the load after lifting it

Pendulous movements or swinging of the load

Exceeding the rated lifting capacity

Pulling loads at an oblique angle

(14) The carriage of persons with the load is forbidden.

(15) Whenever a load is suspended from the hook, the operator must remain at the controls.

(16) Maintain the safety distance:

(17) WARNING: Suspended loads!

Wear safety helmet!

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

(18)The operator must be able to observe the working area and the load!

(19) Hoisting down the load from a great hook height: The horn signals: Overload(the rope weight increases).

Do not hoist down!

Trolley in to the minimum radius and hoist down.

Over-load alarm

Pre-warn

(20) Maintain a safety distance from overhead electric lines. ¾ Do not leave the tower crane. ¾ Do not touch the steel construction of the tower crane. ¾ If practicable, drive the crane out of the hazard zone. ¾ Warn others against approaching and touching the crane. ¾ Arrange to have the power switched i off in the contacted/damaged line. ¾ Do not leave the tower crane until the contacted/damaged line has been safely de-energized.

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(21) Suddenly removing the load can damage the crane and therefore must not be attempted without the approval of the manufacturer!

(22) In heavy thunder-storm or thick fog days, or the wind speed at the top of the crane over 20m/s, the crane must be out of service.

(24) Do not make any changes, install or modify anything without permission from the manufacturer!

(25) No slewing of the jib and no up and down movements of the load hook in climbing!

5.5.3 Safety operating procedures of operator (2). The operators must read the instruction of the tower crane carefully. They must (1).

No unauthorized persons must allowedoperating to operate the crane. is forbidden be familiar with the constitution, thebe features, methods andItthe technique that the operators areThey drunk operate the crane. of maintaining the who crane. also must master the constitution of safety devices, its principle of running and means of debugging.

(3). Before attempting to lift a load, the operator must check the safety devices and limit switches one by one, and run the crane without loads. After confirming all devices without problem he can run the crane with loads. It is forbidden to operate the crane with loads when the safety devices don’t work.

(4). During operating: ¾ The operator must operate the crane according to the instruction of the crane and the regulations which are framed by the government or the trade. It is forbidden to overload, pull loads at an oblique angle, use the crane to drag loads which have stuck fast and lift the weight-unknown loads. ¾ Avoiding the load hook to drop on to the ground can prevent accidents caused by slack and no neatly hoisting rope. If the load hook must drop on to the ground, the operator should check the rope on the drum. It is necessary to wind it again until neatly. ¾ The operator must give warning whistle when necessary. ¾ The operation of

the mechanism must be smoothly, and the change of speed

from low to high must be step by step. Slewing movement of the crane can not be braked by applying reverse slewing and emergency braking.During hoisting or lowering, the shifting-gears cannot be used for a long time under load. The detail is mentioned in the instruction of the crane ¾ When a load is suspended, the operator and the signalman must not leave crane.

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¾ In big thunder-storm or thick fog days, or the wind speed at the top of the crane over 20m/s, the crane must be shut down. ¾ When the mechanism need to run on opposite, the motor must be stopped, then reversed. ¾ If any defects likely to affect operating safety are noted, the operator should stop work and shut down the power. After checking and resolving the problem, the crane can be used. ¾ When loading it is forbidden to carry persons in maintenance cage and convey persons.

(5). Set down the suspended load, raise the load hook as high as possible and run the trolley back to the minimum working radius. The operator must ensure that the control point is abandoned, the controls are returned to the zero or neutral positions and the power supply is switched off and locked, then he can leave.

(6). The operator should report the usage, maintenance and handing over carefully.

(7). The others are mentioned in the instruction of the crane or relative standards and regulations.

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6- Maintenance Instructions Mian Maintenance point

Switch off the main power supply when the crane operation is to be stopped for repair or maintenance. No operation with power on.

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To ensure safe and economic operation of the tower crane for a longer service life, it must be properly maintained and lubricated.

Summary of

required

maintenance

content Items-checking before work start at each shift every day： ¾ Check speed reducers for oil quantity. Fill oil in time. ¾ Check wire ropes at different positions for looseness, breakage or being worn-out. Change defective ropes as required as per relevant stipulations. ¾ Check brakes for performance and clearance to ensure reliable sensitivity. ¾ Check safety protecting devices for reliable sensitivity. ¾ Check bolt connections. Re-tighten the bolts once again when they have been used for a certain period of time. ¾ Check steel rope head clampers and clips for loose status. Tighten them if loosened. ¾ 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. ¾ The hoisting height limiter should be adjusted again after the rope serves for a period of time. ¾ No function failures of limit switches and push buttons. Replace rusted or damaged parts in time. ¾ Be sure that the insulation of electric switches to switch panels meet the relevant requirements, with insulation resistance no less than 0.5MΩ. ¾ Check if the bolts connecting electric components are loosened: Check power cables and other conducting wires for fractures. Remove the trouble if any.

Monthly maintenance： ¾ Check the high-strength bolt joints and the nearby material. ¾ Check them of the three tower sections on the foundation if the tower crane is not anchored to the building. ¾ Check them of the tower sections nearby the anchored point. ¾ Check the tower head, especially the connecting plates and the nearby material. quarterly maintenance： ¾ Check the connecting plates and the nearby material every three months. when starting up the crane and before every erection： ¾ Check the articulations for pins cracks, rusting corrosion and damage. ¾ Check the rigid tie rods, wire ropes, pulleys, hoist hooks, fall-changing devices, etc. for conformity to operating conditions. ¾ Check the metal structure members for deformations and weld fissures to make sure of their conformity to operating conditions. ¾ Conduct trial operation for the mechanism of hoisting, jacking, slewing, trolleyging until they have become normal.

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Notes: z

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

z

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.

z

Each bolt shall be tightened with two nuts for the installation of tower sections.

z

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.

z

Conduct rust removing and painting of the whole tower crane and its metal mechanisms after completion of their each use in a project.

Routine check of high-strength bolt content

Preparation

¾ 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). ¾ Before using, it is necessary to coat the MoS2 grease on contact surfacs of the bolts, nuts and washers to equilibrium friction.

¾ The tighten torque on the nuts must reach the specified torque Tightening and the torque of loose-proof nuts（the upper nut）should be a little more than or equal the specified torque. ¾ 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 Check erecting the tower crane. Dismantle 2-3 bolt groups each year and check them for deformation, corrosion, rust, etc. ¾ The high-strength bolts can be used many times, but agreed with Repeat usage the requirements of the above item 5.1 and the item 5.2.

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Routine check of wire rope ¾

¾ ¾ ¾

content 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 (GB5972-86).

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.

Carry out timely cleaning of wire ropes and applying of lubrication oil or grease to them.

Check the wire ropes one time every week.

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.

Maintenance and precautions of hydraulic system Work condition

¾ ¾

¾ Hydraulic oil

¾

¾

content Shut the system when it is out of service because of the poor condition of ventilation.

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.

Filling oil: 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.

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.

The oil should be completely changed after the system work for 2,400hr and add part of clean oil after working for 200hr.

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.

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Content

Maintenance of the JQC type cable drum

¾ Add lubricating oil to chain wheels, chains and lubricating point every 80 working hours, and check the tightness of each bolt at any time. ¾ Often check collector ring assembly, tighten connection bolts, treat head hot discoloration fittings, clean rust and power. If any electric corrosion, burning occurs on collector ring, polish with abrasive cloth. If 1/3 of the brush is worn, should exchange the brush.

Cut off the power before open cover！

Maintenance of the cable drum

¾ Measure insulation condition of cable drum every 400 working hours, insulating resistance should not be less than 5 MΩ.

Maintenance of M type cable drum

¾ Must exchange lubricating oil in reducer after the first one-month operation. ¾ Check the oil level of reducer every two months, when it is below center of sight hole, and then add HL-30 lubricating oil. ¾ Check the tightness of electric parts of collector ring every two months, to ensure good contact and reliable connection of cable fittings. At same time, measure insulation condition, the insulating resistance should not be below 5 MΩ. ¾ Change lubricating oil in the reducer every year. Turn out the hexagon plug screw at bottom to drain off dirt oil, and screw out brake parts simultaneously. Screw on the hexagon plug screw and add clean HL-30 lubricating oil, Screw on brake parts after cleaning the dirt oil. ¾ Keep the surface of collector ring, motor, reducer cleaning. ¾ Exchange parts in time if the parts are worn greatly and affect performance.

Cut off the power before open the collector ring.

Prohibit inserting stop parts into nut indentation during operation. z Lubricating oil level in reducer should be above the center position of the sight hole. z When the crane moves toward the direction of power, the motor of cable drum should be started simultaneously with traveling mechanism, while the traveling mechanism stops, the motor of the cable drum should power off after 3 seconds. The motor should not power on when the crane moves away the power.

Wheel bearing model: GB288-87. Bearing 5320 4 wheel each dolly. z z

Bearing model

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Parts No 1

2

3

4

5

6

7

Lubrications Lubricant Lubricating method specifications & duration Graphite Calcium-based Grease the rope each Hoisting rope Wire rope grease after overhaul or Trolley rope ZG-SSY1405-65 medium maintenance Lubricate the reducer Summer（over 10°C） after it serves for 240 Reducer of with N220 gear oil hrs，Change the oil hoisting winch Winter（below 10°C） after working for with N150 gear oil 1500hrs.

When maintained or the level of oil Sulphur Reducer of dropped, molybdenum-2# or Trolleying supplements grease ZL-2# lithium-based Reducer mechanism in time to guarantee grease the level of grease arrive at the bolt of oil.

When maintained or the level of oil reducer of the dropped, # slewing supplements grease 000 grease mechanism in time to guarantee the level of grease arrive at the bolt of oil.

Rolling bearings Grease the bearings Calcium-based grease in the reducer each after they work Rolling Drum bearing ZG-2 for 160 hrs，Clean Bearing them once after half a Hook bearings Calcium-based grease year.

Winter：Calcium-based grease ZG-2 Change the grease Motor All the motors after working for 1500 Summer： bearing hrs.

Calcium-based grease ZG-5 Pulleys and Change the grease Winter：ZG-2 Pulley guiding pulley in after working for 240 Block the hoisting winch Summer：ZG-5 hrs.

Sliding bearings in Add grease after Sliding the trolley traveling Winter：ZG-2 working for 160 hrs, Bearings mechanism and and conduct cleaning Summer：ZG-5 drum half a year Articulated All the articulated Fill oil after working Machine oil points of points for 56 hrs brake lever Parts Description

Lubricating location

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No

8

9 10

11

Parts Description

Lubricating location

Two articulated All the points between jib articulated and tower points section All the motion Fall-chang parts and guiding e Device groove All the connectors Gear of mechanisms connector and gears Pump station of hydraulic erection

Oil tank

Lubricant specifications

Lubricating method & duration

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

Before dismantle or installation

Machine oil

Fill oil after working for 160 hrs

Calcium-based grease

Grease once after a season

American ESSO AW46

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

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

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Ordinary troubles, trouble shooting and solution No.

Trouble

1

Reducer temperature is too hot

2

3.

4

5

6

7

Trouble shooting Lubrication oil deficient or excessive

_Excessive or deficient grease The temperature of _Grease quality very poor the reducer _Improper axial clearance of bearings is too the bearings or bearings is high already damaged Contacting surface of Oil leakage from connections is not tightened speed reducer enough, sealing rings at shaft ends is worn and damaged _Worn oil pump, declined efficiency _Oil in the tank is insufficient or oil filter clogged Jacking speed is _Hand-operated valve rod and too slow valve hole severely worn _Oil cylinder piston seal is damaged and internal oil leakage _Severe internal leakage from oil pump Jacking force is not _Overflow valve pressure set adequate or too low unable to jack _Hand-operated valve core excessively worn _Overflow valve clogged down Noise and vibration occur during jacking operation Oil filter clogged at increasing pressure Jacking system is Motor rotation and oil pump not working rotation both in wrong directions

Solution Properly increase or decrease oil _Properly replace grease _Re-adjust the clearance of of bearings _Replace bearings

Replace sealing rings

_ Repair or replace the damaged parts _Fill adequate oil or clean oil filter

_Repair or replace the worn parts _Adjust pressure as required _Clean hydraulic valve

Clean oil filter Change motor rotation direction

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No.

Trouble

Trouble shooting

8

Creeping and quivering during jacking operation

9

Jacking drop when loaded

10

Malfunction of Master push-button

_Air not completely exhausted from oil cylinder piston _Trouble with guide mechanism _Trouble with balance valve of the cylinder head _Piston sealing of oil cylinder is damaged _Operation handle not returned to zero _Fuse in the electric control cabinet is burned down _Poor contact of the start-button and stop-button _Over current from hoisting motor, actuating over-current breaker. _Capacity of the site transformer is inadequate, or power cable from transformer to tower crane has inadequate diameter

11

Power is stopped during hoisting operation

Solution _Exhaust air as required. _Adjust guide pulleys Remove trouble, replaces sealing parts

_Return handle to zero. _Replace fuse _Repair or replace the button _Check hoisting brakes for open-up. Check over-current stabilization value for variation _Replace transformer or increase cable diameter

12

Hoisting mechanism unable to start

_Control wiring in a wrong way _Fuse burned-down. _Electric motor windings short-circuited, grounded or circuit breaking _Motor working voltage is too low _Windings wiring in a wrong way _Electromagnetic brake not released _Too heavy load or trouble with the transmission mechanism

_Check wiring diagram. _Check fuse capacity, change for larger one if too small _Measure power grid voltage _Supply power to suit different speeds so as to find out short circuit and circuit breaking. Repair the findings _Check brake voltage and windings for circuit breaking or clogging

13

Trolleying mechanism Bearings over-heated

_Bearings burned down _Grease too much or too few

_Replace bearings _Add grease as required

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No.

Trouble

14

Abnormal noise and vibration from trolleying mechanism

15

Electrification with the trolleying mechanism

16

17

18

Trouble shooting _Mechanical wear, due to: a.

Friction between stator-rotor b. Motor-speed reducer box not in concentricity _Bearings without oil or damaged. _Gear box without oil _Gear worn _2-phase operation with abnormal noise _Power line or earth line wired in a wrong way _Poor earth connection _Motor wires scratched and earthed

Solution _Check rotor clearance for being uniform _Check slip rings for wear.

Replace them if any _Clean bearings and add fresh lubrication oil.

Replace bearings _Replace gearbox. _Switch off power supply.

Check and repair _Find out the cause, and remove the trouble. _Improve earth connection _Find the cause, and remove the trouble _Brake spring broken, replace the spring _Excitation and inadequate voltage

Brake failure with the trolleying mechanism

_Braking moment too small _Increased friction clearance of friction pieces.

Slewing mechanism unable to start

See if foreign matters are clogged in the gear.

Trolleying mechanism motor over-heated or smoke emission

_Measure stator current, e.g. decrease load if heavier than rated _Load excessive value. _Load continuing and work not _Operate as required. as specified _Measure 3-phase current _2-phase operation to remove troubles. _Power supply voltage too low _Check input voltage for or too high necessary correction _Motor windings earthed or _Find out the cause to short circuited between turns, repair or between phases _Adjust clearance as _Incorrect clearance between required friction pieces _Braking time and releasing _Check brake for voltage time not correct and time-delay for circuit _Moter clogged, causing breaker action and temperature rise. remove the trouble. _Keep smooth ventilation

Remove foreign matters

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Spare parts list (The parts in the list are provided if users pay for them, the parts with "*" in the number column are easily-worn parts.)

No. 1* 2 3

Transmission Mechanism Code Designation Friction lining of φ315 brake MLL8-I-φ315-ZA70×112 Shaft coupling （18）/ZA60×112（18） MT8B Quincunx elastic body

Position

2 1 QE8100D2

4*

14

5* 6 7 8* 9 10 11 12 13 14 15*

DXZ-4/7 NL5-(YA38×145(10))/ (YA35×105(10)) BP55-5 DXZ-4/F（i=660） 9.3 DZJ-80 DXZ-4/3 ZDA52-4 GB/T288-1994 LX10-21

Wire rope Roller wheel for wire rope Multifunction limiter Dentate spring coupling Pinion Multifunction limiter Wire rope Magnet brake Multifunction limiter Wheel 53520-Bearing Overstroke safety device

Quantity

1 According to the max height of hoisting 1 1 1

BP55

HPW55

ZD52

1 1 120+73(m) 1 1 8 16 4

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

No.

2 3*

Code HL-400 FXC08B-12 FXC08B-14 GB/T276-1994

4

GB/T276-1994

5

GB/T276-1994

6

GB/T301-1995

7

FDG08A.02.7-4

8

HL-400

No. 1

Code TC5613A.05-13

2

D4MC-5000

3

TWL10

4

1600

5

LSHF36

1

Trolley and Hook Designation Position Pulley Hook assembly Pulley Trolley and Tower head Roll Trolley Side roll Trolley 6212-Z Used for HL-360 and HL-400 Bearing pulley 6210-Z Used for trolley roll Bearing 6004-Z Used for side roll Bearing 8313 Used for the beam of hook Bearing assembly Hook Hook assembly Others Position Designation Buffer stopper Overstroke safety device Overload limit switch Sealing for climbing hydraulic cylinder High-strength bolt

Quantity 8 4 4 16 8 8 1 1 8 Quantity

Jib

4

Moment limiter

3

Slewing mast

1

Climbing mechanism

1

Tower section

240

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

7.

Electronic

Shown

as

TC6016A

INSTRUCTION

HANDBOOK

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

A.1 Crane log 商

标 （Brand） ________________

型

号 （Type） ________________

所有者 （Ownership） ________________

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

Records of the usage Data

Duration

Max weight of

Status of usage

loadings

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User

Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

塔 机 润 滑 记 录 表(Records of Lubrication) N 1

2

3

Parts Wire rope

Reducer

Lubricating l ti Hoisting rope

Lubricant specifications

d rope ti after Grease the working for a week, and boil the grease after overhaul or medium

Trolley rope

Graphite Calcium-based grease ZG-SSY1405-65

Reducer of

Summer(over 10°C) with N220

hoisting winch

gear oil

Lubricate the reducer after

Reducer of Reducer of

Winter(below 10°C) with N150

it serves for 240 hrs，

Sulphur molybdenum-2# or ZL-2#

change the oil after working

Rolling bearings

Calcium-based grease

Grease the bearings each

Rolling Bearing

Lubricating method &

Hook bearings Slewing ring

EXAMPLE: F_UM_ TC_6016A_00

Lubricated

Lubricating

b

d t

after they work for 160 hrs, Calcium-based grease

clean them once after half a year.

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

4

Motor bearing

All the motors

Winter：Calcium-based grease ZG-2 Summer：Calcium-based grease ZG-5

5

Pulley Block

Pulleys and guiding pulley in the hoisting winch

Winter：ZG-2 Summer：ZG-5

Add the grease after working for 240 hrs.

6

Sliding Bearings

Sliding bearings in the trolley traveling mechanism and drum

Winter：ZG-2 Summer：ZG-5

Add grease after working for 160 hrs, and conduct cleaning half a year

7

Two articulated points between jib and tower section

All the articulated points

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

All the motion parts and guiding groove

Machine oil

8

Fall-change Device

EXAMPLE: F_UM_ TC_6016A_00

Change the grease after working for 1500 hrs.

Before dismantle or installation

Fill oil after working for 160 hrs

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

9

Articulated points of brake lever

All the articulated points

Machine oil

Fill oil after working for 56 hrs

10

Gear connector

All the connectors of mechanisms and gears

Calcium-based grease

Grease once after a season

11

Pump station of hydraulic erection

Oil tank

EXAMPLE: F_UM_ TC_6016A_00

American ESSO AW46

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

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

Records of check No.

Parts Description

Checking duration

Notes

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.

Before work start at each shift

Make sure of no looseness or disengagement before operation start.

EXAMPLE: F_UM_ TC_6016A_00

Checked by

Checking date

Parts state and method to settle

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

2

3

The high-strength bolt joints and the nearby material, the tower head and slewing mast.

The climbing lugs and the beam of the Climbing Mechanism

EXAMPLE: F_UM_ TC_6016A_00

Every month

Especially the connecting plates and the nearby material of the tower head and slewing mast, the bolts of three tower sections on the foundation if the tower crane is not anchored to the building, or the tower sections nearby the anchored point if it is anchored

When adding or lowering down the tower sections every time

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

4

5

High-strength bolts

Wire rope

EXAMPLE: F_UM_ TC_6016A_00

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.

Every week

1.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.

2.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.

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Records of servicing/maintenance/repair done on the crane date

Trouble

EXAMPLE: F_UM_ TC_6016A_00

Troubleshooting

Solution

Checked by

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Changsha Zoomlion Heavy Industry Science and Technology Development Co. Ltd.

长沙 中 联 重 工 科 技 发 展 股 份 有 限 公 司 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：

+86-731－88928166

http://www.zoomlion.com / +86-731－88928163

全国服务监督专线：SPECIAL TEL:

800-878-6112

We reserve the right to change specification without notice

EXAMPLE: F_UM_ TC_6016A_00

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