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TC5613-6

C2
TC5613-6 VERSION C2

QTZ80(TC5613-6)
QTZ80 (TC5613-6) Tower Crane

Operating Instructions

Changsha Zoomlion Heavy Industry Science and Technology Development Co.Ltd

CUSTOMERS:

Thanks for your purchase and being one of the users of Zoomlion Tower Crane!

Go through the instructions for correct operation and maintenance, and always keep at
hand for consultation.

Pay attention to the sentences marked with Warning, Notice or Precautions in


this publication, which involves safety of construction.

Zoomlion has been devoting every effort to the perfect of her products. Therefore
they are changed without notice. If you have any questions, please don't hesitate to contact
Zoomlion for further consultation.

Manufacturer's No.

Shipped Date


Contents

Preface................................................................. 0-10-10

Part I Erection of Tower Crane

Erection................................................ 1.1-11.1-49

Dismantling........................................... 1.2-11.2-6

Part II Operation and Maintenance



Safety Operation of the Tower Crane..................................

2.1-12.1-6


Operation of Mechanisms & Electrical Equipment................

2.2-12.2-8


Safety Protection Device....................................................

2.3-12.3-9


Maintenance....................................................................

Appendix .......................................................................

Editor

Proofreader

2.4-12.4-8

Fu liang
Liu yi

Ratifier Yingxiong Fu

TC5613-6

0-1

Preface

TC5613-6 , JG/T5037-93

Model TC5613-6 tower crane is designed and manufactured by Changsha Zoomlion


Heavy Industry Science and Technology Development Co., Ltd. according to the Chinese
standard of JG/T5037-93 Classification of Tower Crane.
TC5613-6
The TC5613-6 tower crane is a self-climbing multi-purpose machine with a horizontal
jib, a trolleying mechanism and an upper slewing mechanism. Its characteristics are:
1. 56m 220m
The performance parameters and technical indicator of the crane are at a leading level in
China. The Maximum working radius is 56m and the maximum hoisting height is 220m.
2. ,
40.5m 220m
The crane has different working modes such as: outrigger stationary, undercarriage
stationary, mobile and inside climbing, so that it is applied in different construction
projects. The hoisting height of outrigger stationary is 40.5m and the hoist height of the
crane anchored to the building is 220m.
3.
High working speed and good regulated speed performance make the machine working
smoothly.
4. 34

The main electric elements are used world-renowned products, which service life is 3-4
times longer than China-made counterparts with less failure, simple maintenance and
reliable working.
5. 8
8 sets of safety devices ensure the tower crane work reliably, and the safety devices are
mechanical or integrated mechanical-electrical products.
6.

The design of the crane is based on the actual situations in China and on the safe-reliable
operation principles. Greatly absorb and adopt the well-established and reliable advanced
technology to enhance its overall technical level at the same time in the world.
Well-established advanced technology adopted as following:
1)

TC5613-6

0-2

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

2) TE
Electrics manufactured with the technology from TE, France.
3)

Weight limier, height limiter, radius limiter, slewing limiter, slewing brake, traction
brake and similar safety guards are China-made based on the imported technology.
4) ()
Carriage rope break-proof device (carriage slip-proof) and axle break-proof device;
5) Rope pay-off system for hoisting mechanism;
6) Traction rope-tensioning system;
7)

Large-radius hoisting jib suspended by double rigid tie rods, featuring good jib rigidity,
light jib weight, small jib cross-section, small wind resistance and nice-looking
appearance and several jib lengths, it is satisfied different construction needs.
8)

Out-hung operator cabin, featuring excellent field of view, spacious interior and
satisfactory working environment, and advanced inter-active control console, the
operator handles the mechanisms easy and services simply.
7. Design in complete conformity or superior to the
relevant national standards.

The crane is suitable for use in such large-sized construction projects as high-rise or
super high-rise buildings, bridge and water conservancy projects, large-span industrial
buildings, large gymnasiums, and high chimneys and silos constructed with slip form.

TC5613-6

0-3

8. Technical parameters of the tower crane


8.1 . ( 8-1)
Technical performance parameters for the whole machine (Table 8-1)
Table 8-1

Mechanism Group

Hoisting
Slewing
Trolleying

M5
M4
M3

kNm
Rated hoisting moment
m
Max hoisting height

m
Working Radius
t
Max hoisting capacity
Fall
m/min
Speed
t

800
Fall
Stationary
2
40.5
4
40.5
Maximum
Minimum

Anchored
220
110
56
2.5

6
2

80

40

8.88

40

20

4.44

1.5

Max. Load

kW
Power

Trolleying

Slewing

g
n
i
t
s
i
o
H

Jacking
(Erecting) mechanism
Total power kW

Counterweight

Operation Temperature

24/24/5.4
Speed m/min
Power kW
Speed r/min
Power kW
Working
Pressure MPa

50/25
3.3/2.2
0 0.8
4.02
25 ( Recommended Value)

0.56( Recommended
Value)
7.5 ( Recommended Value)
Power kW
35.3( Excluding Erecting Mechanism)
38
44
50
56
9.85
11.25
13.5
15.3
Speed m/min

2040

8.2 Technical parameters of the four mechanisms

TC5613-6

0-4

8.2.1 QS680D ( 8-2-1) Technical parameters of hoisting mechanism


QS680D(Table 8-2-1)
Table 8-2-1

Maximum traction of the rope


Specifications
Wire rope

Maximum linear speed


Wire

Rope Drum
Rope capacity
Model

Power
Motor
Speed
Model

Brake
Braking moment
Reducer ratio

17500

357-13-1770 or 6T29Fi+IWR-13-1770
or K439S-FC
m/min

160

450 (6)(layers6)

kW
r/min

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

N.m

630
16.75

8.2.2 BE33E ( 8-2-2)


Technical parameters of trolleying mechanism BE33C (Table 8-2-2)
Table 8-2-2

Maximum traction of the rope



Specifications

Maximum linear speed


Wire rope
44mJib

50mJib
Length
56mJib
Wire

Rope Drum
Drum Speed
Model

Power
Motor
Speed


Reducer
Ratio

5640
619-7.7-1550--
619-7.7-1550-- right-twist

m/min

m
r/min

kW
r/min

50/25

Wire rope

88
100
112

Wire
rope

33.49/16.74
YDEJ132S-4/8-B5
3.3/2.2
1440/720
43

8.2.3 HPW40B.100 ( 8-2-3)


Technical parameters of slewing mechanism HPW40B.100 (Table 8-2-3)

56
62
68

TC5613-6

Model

Power

Speed

Model

Ratio
Reducer

Output rotation moment

Modulus

Number of teeth
Gear parameter at

output end
Position-changing factor
Slewing speed
Slewing ring support

0-5

YTW112M-4B5
kW
4.0
r/min
01440
XX5-100.195CA-12/16
195

Motor

Nm

10000

m
Z

12
16

+0.5

r/min

00.6
011.45.1250
Table 8-2-3

8.2.4 ( 8-2-4)
Technical parameters of jacking mechanism (Table 8-2-4)
Table 8-2-4

Motor

Hydraulic
pump

Jacking
cylinder

Power
Speed
Flow

Working pressure
/
Cylinder /rod diameter

Maximum jacking force



Jacking speed

kW
r/min
l/min

7.5
1440
10.6

MPa

25

mm

160/110

50

m/min

0.56

8.3 Radius and Load Capacity


8.3.1 38m 38m Jibs Radius and Load Capacity

Radius (m)

Hoistin
g
weight
(t)

2
fall
4

18

19

20

2
fall
4
fall

23

25

27

4.26

3.85

3.51

3.00
6.00

5.67

5.32

5.01

33

35

38

2.81

2.61

2.35

2.75

2.55

2.29

fall

Radius (m)

Hoistin
g
weight
(t)

2.5 17.11

29

31
3.0

3.22

2.97

TC5613-6

0-6

8.3.2 44m 44m Jibs Radius and Load Capacity

Radius (m)

Hoistin
g
weight
(t)

2
fall
4

Radius (m)

Hoistin
g
weight
(t)

2
fall
4

2.5 17.1

18

19

20

23

25

27

4.26

3.85

3.51

3.00
6.00

5.67

5.32

5.01

33

35

38

41

44

2.81

2.61

2.35

2.14

1.95

2.75

2.55

2.29

2.08

1.89

fall

fall

29

31
3.0

3.22

2.97

TC5613-6

8.3.3

0-7

50m 50m Jibs Radius and Load Capacity


Radius (m)

2.5 16.8

17

20

23

26

29

30

Hoistin
g
weight
(t)

2
fall
4

Radius (m)

31

Hoistin
g
weight
(t)

2
fall
4

8.3.4

56m 56m Jibs Radius and Load Capacity

5.92

4.90

4.16

3.59

3.14

3.00

33

35

38

41

44

47

50

2.96

2.74

2.55

2.30

2.08

1.90

1.74

1.6

2.90

2.68

2.49

2.24

2.02

1.84

1.68

1.54

fall

2.5 16.25

2
fall
4

17

20

23

26

29

30

31

2.95

2.84

3.02 2.89

2.78

3. 00
6.00

5.70

4.71

4.00

3.45

fall

Radius (m)

Hoistin
g
weight
(t)

6.00

fall

Radius (m)

Hoistin
g
weight
(t)

3.00

2
fall
4
fall

32

35

38

41

44

47

50

53

56

2.73

2.44

2.20

1.99

1.82

1.66

1.53 1.41

1.30

2.67

2.38

2.14

1.93

1.76

1.60

1.47 1.35

1.24

TC5613-6

8.4 Overall dimensions of the crane


8.4.1 Overall dimensions of the stationary crane

TC5613-6

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

0-8

TC5613-6

0-9

2 TC5613-6
Fig.2 Overall dimensions of TC5613-6 Stationary Tower Crane with Foundation Undercarriage

TC5613-6

0-10

8.4.2 Overall dimensions of the crane anchored to the building

TC5613-6

Fig.3 Dimensions of Stationary Crane with Foundation Anchor

TC5613-6

1.1-1

Part I Installation of Tower Crane

Chapter I Erecting
1.1 Foreword

The user should go through the chapter in detail for proper and prompt erection of the
tower crane.
1.2 Cautions of erecting tower
1.2.1 14m/s;
The maximum wind speed atop should be less than 14m/s during crane erecting.
1.2.2 ;
Strictly follow the procedures of crane erecting.
1.2.3 1-1
Select a proper mobile crane and slings in accordance with items shown in Table 1-1.
1-1
Table 1-1 Component weight and height

No.

Designation

H(m) H(m)

Embedded
Undercarriage
H(m)
Weight anchor
stationary Traveling

(kg)

Driving Bogie 2850

1.2

Driven Bogie

2650

1.2

Total Beam

1300

0.9

1.7

Semi-Beam

2600

0.9

1.7

4115

0.9

1.7

1900

6.9

7.7

5
6

Tie Rod of Bottom Frame


1 2
Base Section &

Tower Strut

4255

5.4

6.2

Ballast (1)

43500

1.8

Ballast (2)

83400

3.2

4.0

10
11

EQ
Base Tower Section EQ
EQ7
Tower section EQ

1020

3.7

855

6.5

3300

15.3

18.5

19.3

3200

10.8

14.0

14.8

500

12.6

15.8

16.6

2400

20.0

23.2

24.0

4500

13.7

16.9

17.7

12
13
14

Climbing Frame

15

Slewing Assembly
Operator Cab

16

Tower Head

17

Counter Jib assembly

TC5613-6

18
19a
19b
19c
19d

20a

First
Block Counterweight
38
38m Jib assembly
44
44m Jib assembly
50
50m Jib assembly
56
56m Jib assembly
38

1.1-2

2250

16.7

19.9

20.7

5050

13.9

17.1

17.9

5450

13.9

17.1

17.9

5850

13.9

17.1

17.9

6250

13.9

17.1

17.9

16.7

19.9

20.7

16.7

19.9

20.7

16.7

19.9

20.7

22250
Counterweight of 38 m +1800+
1300
Jib
44

20b

20c

Counterweight of 44 m 42250
Jib
50
Counterweight of 50 m 52250
Jib
56

52250
16.7
19.9
20.7
Counterweight of 56 m
1800
Jib
20a 20b 20c
Note20a, 20b, 20c are the remaining counterweights after mounting a counterweight.
20d

1.2.4 ,
,;
The dismountable pins, connecting bolts and nuts for the slewing rings and tower sections of
the tower crane are special-made, which shall not be replaced freely.
1.2.5 ;
Stairs, platform and protecting fence should be installed for safe operation.
1.2.6 ()
, 2.250t ,;
The quantity of counterweight blocks shall be provided in accordance with the jib length
(refer to relevant chapter). Jib must be installed after placing one 2.25t counter-weight on
the counter-jib. It is prohibited to place two pieces or more counter-weight on the
counter-jib before installing jib.
1.2.7 ,,;
After jib installation, it is prohibited to hoist any load before placing specified
counter-weight on the counter-jib.
1.2.8 ,
1.5m, 1.2-1 ;
At the erection position of the tower crane, it must be no less than 1.5m distance between
the widest slewing part of the crane and around buildings, and the safe distance between any

TC5613-6

1.1-3

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

1.2.9 ;
Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be
provided before hand.
1.2.10 ( 1.2-1);
Reference size for tower crane erecting site is shown as Fig. 1.2-1.
1.2.11 ,,,
; Drive the trolley to the balance position
before jacking. Slew the jib to the right front of the in-let beam and thenlock the
slewing of tower crane by slewing brake.
1.2.12
It is prohibited to slewing the jib, move the trolley or make the hoist hook up and down
movement during jacking operation.
1.3 General layout of tower crane
1.3.1 ( 1.3-1) Assembly relation of main components for
stationary crane (Fig.1.3-1)

TC5613-6

1.1-4

1.3-1
Fig.1.3-1 Assembly relation of main components

1. Foundation
2. Tower Section (a-Section EQ, b-Mast Section EQ,)
3. Climbing frame
4. Slewing ring support
5. Slewing ring
6. Upper support
7. Operator cab
8. Tower head
9. Counter-jib
10. Jib (a=38m, b=44m, c=50m, d=56m)
11. Counter-weight (a=9.85t, b=11.25t, c=13.5t, d=15.3t)
12. Base frame (or undercarriage)
13. Foundation With Undercarriage
40.5m, 40.5m,

The TC 5613-6 tower crane, with embedded anchors or with an


undercarriage, independent hoisting height is 40.5m. 2-fall or 4-fall wire ropes may be used
for hoisting purpose. The tower sections are integral construction of square shaped steel
tube structure. The base section of tower body or the undercarriage is connected to the
foundation.

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

TC5613-6

1.1-5

1.3.2 ( 3 4) Anchored State (shown as Fig.3 and Fig.4)


40.5m. 40.5m
8 220m
110m >110m
3.5m

The maximum hook height can reach 40.5m when crane is stationary with embedded
anchors and 220m when anchored if it is fastened with tie-in onto the building and mast tie
frame. When the height is 110m, hoisting can be done with 2-fall or 4-fall, but if the
height is >110m, only 2-fall can do the job. The required distance between slewing center of
tower and the building is 3.5 meters. As for unusual conditions, please contact Zoomlion for
further consultation
1.3.2.1 1.3.2.2
1.3.2.3 1.3.2.4

1.3.3.2.1 and 1.3.3.2.2 give consideration to project construction requirements and


force-applied situations of the tower body and anchored frames. They specify the distance
between anchored frame and foundation plane, distance between anchored frames and
suspension height limit above anchored frame. Item 1.3.3.2.3 and 1.3.3.2.3 can satisfy both
ordinary construction needs and facilitate prefabrication of anchored frames most
economically to lower the cost of the tower crane.
1.3.2.1 ( 1.3-2) With one anchored attachment (Shown as Fig.1.3-2)
(1) h
1
The
h1 is the distance from first anchor point to the
foundation surface.
18(m) h1 31(m)
n1
The quantity of tower sections in h1 is:
6.4 n1 11.1
(2) h0
The height of tower above the anchor point is h0

h036.55(m)
:
The quantity of tower sections in h0 is:

n012.5

1.3-2
Fig.1.3-2

1.3.2.2
With two anchored frames or more

TC5613-6

1.1-6

(1) h2
(2) The distance h2 between two anchor points:
15(m) h2 25.2(m)

n2

The quantity of

tower sections between 2 anchor points is


5.4n29.3
(2) h0
The height h0of tower above the highest anchor point is
h100m 1.3.2.1(2).
When hook height h is less than100mh0 is the same shown in
1.3.2.1(2).
h100m , :
When hook height h is 100mnamely:

n 11.5
0

1.3-3
Fig1.3-3

1.3.2.3 ( 3 )
The least number of anchored frames for the tower crane with embedded anchors (shown as
Fig.3)
36.55m68.5m
24
With 1 anchored frame, h036.55m, h 68.5m, there are 24 tower sections totally.
36.55m93.7m
33
With 2 anchored frames, h036.55m, h 93.7m, there are 33 tower sections totally.
33.75m116.1m
41
With 3 anchored frames, h033.75m, h 116.1m, there are 41 tower sections
totally.
33.75m141.3m
50
With 4 anchored frames, h033.75m, h 141.3m, there are 50 tower sections totally.
30.95m163.7m
58 .
With 5 anchored frames, h030.95m, h 163.7m, there are 58 tower sections totally.
28.15m183.3m
65 .
With 6 anchored frames, h028.15m, h 183.3m, there are 65 tower sections totally.
28.15m202.9m
72 .
With 7 anchored frames, h028.15m, h 202.9m, there are 72 tower sections totally

TC5613-6

1.1-7

25.35m220m
78 .
With 8 anchored frames, h025.35m, h 220m, there are 78 tower sections totally
1.3.2.4 ( 4)
The least number of anchored frames for the tower crane with undercarriage (shown as
Fig.4)
35.86m68.8m
22
With 1 anchored frame, h036.86m, h 68.8m, there are 22 tower sections totally.
35.06m94.0m
31
With 2 anchored frames, h035.06m, h 94m, there are 31 tower sections totally.
34.26m1192m
40
With 3 anchored frames, h034.26m, h 119.2m, there are 40 tower sections totally.
30.66m141.6m
48
With 4 anchored frames, h030.66 m, h 141.6m, there are 48 tower sections totally.
30.95m163.7m
56 .
With 5 anchored frames, h030.95m, h 163.7m, there are 56 tower sections totally.
28.15m183.3m
63 .
With 6 anchored frames, h028.15m, h 183.3m, there are 63 tower sections totally.
28.15m202.9m
70 .
With 7 anchored frames, h028.15m, h 202.9m, there are 70 tower sections totally
25.35m220m
76 .
With 8 anchored frames, h025.35m, h 220m, there are 76 tower sections totally
1.4
Foundation & Counterweight
1-3 1.4-1
Loads on Foundation with embedded anchorsshown
as Table1-3Fig.1.4-1
1-3
Fv(kN) Fh(kN)

In operation

Out of operation

M(kN.m)

T(kN.m)

548.7

18.5

1693

300

487.5

74.7

1766

0
1.4-1
Fig.1.4-1 Load schematic diagram on the foundation

TC5613-6

1.1-8

1.4.2 ( 1.4-2)
Foundation with embedded anchors

Reinforced concrete foundations must be adopted. Basic requirements for the


foundation with embedded anchors as following:
1.4.2.1 C35.,1-4
The concrete strength grade must not be lower than C35. The ground base must be
hard ground and the earth endurance must not be less than the specifications as shown in the
table 1-4
Table1-4 1-4
L

5300

5500

Reinforcing steel bar


of upper layer


Reinforcing steel bar
of lower layer

24-25
Lengthwise and
crosswise
24-25
Lengthwise and
crosswise

24-25
Lengthwise and
crosswise
24-25
Lengthwise and
crosswise

Mpa

M
Concrete

T
Weight

0.14

25

60

144

0.12

30.25

72.6

144

Earth
endurance

Vertical
reinforcing
steel bar

1.4.2.2 1000mm
The depth of the concrete foundation should be more than 1000mm
1.4.2.3 1/500
Adjust the level of the anchors upper surface to ensure that the planeness tolerance is 1/500.

1.4-2
Embedded Anchors Foundation

1.4-3
Pouring cncrete diagram of embedded anchors

TC5613-6

1.1-9

1.4.3 Install the embedded Anchors

The installation of the embedded anchors is very important, please install them as
following:
1.4.3.1 4 EQ 12 10.9 ;
Fasten 4 anchors and the base section together with 12 high-tensile bolts (strength rating
10.9).
1.4.3.2 ,
EQ ;
According to the construction convenience and the progress of binding rebar, hoist the
whole piece of anchors assembled with the base section into rebar net.
1.4.3.3 ;
Be sure that the number of re-bars around anchors must not be reduced or cut off.
1.4.3.4 ,;
If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside.
1.4.3.5 EQ
EQ EQ
1.5/1000;
Gently hoist the whole piece of anchors assembled with the base section EQ so that it is in a
vertical position before placing concrete. Hang plumb lines along the centerline in 2
directions of the base section EQ to ensure that the perpendicularity of the embedded base
section centerline and horizontal plane is less than 1.5/1000.
1.4.3.6 95;
Concrete filling rate around the embedded anchors must be over 95%.
1.4.3.7 1.4-3
Installation diagram is shown as Fig.1.4-3.
Foundation Anchor bears the greatest pressure and pull, which should be equipped by the
factory, otherwise the contractor is responsible for the damage caused by incorrectly
prepared foundation anchor or by neglecting the foundation site conditions.
Notes:
1
The embedded anchors bear all loads of the crane, so they should be purchased
from our company. Otherwise if the users supply the embedded anchors, you are
responsible for the damage caused by anchors.
2
It is allowed that the anchors are used one time, and it is forbidden to dig them
out and use again.
1.4.4

( 1.4-4)

Foundation with embedded bolts

Reinforced concrete foundations must be adopted. Basic requirements for the

TC5613-6

1.1-10

foundation with embedded bolts as following:


1 1-4 100mm
100mm

Dig the foundation to the hard earth (Bearing load should reach the value shown as
Table 1-4), make it level, and then backfill 100mm gravel, after slip-formwork or laying
bricks for the side walls, pour concrete into pre-made reinforced rod net. The concrete block
surface should be 100mm higher than neighboring ground for the drainage of storm water,
then removal the formwork and backfill the neighboring ground with gravels.
2 >95% 56mm
Concrete filling rate under pallet should be more than 95%. The upper plane of the four
pallets should be within the same level plane and the pallet are allowed to be inserted into
concrete for 5-6mm.

1.4-4
Fig 1.4-4 Foundation with embedded bolts

TC5613-6

1.1-11

16

2mm
The relative position of the 4 sets of embedded bolts must be correct, and the length
tolerance of the diagonal line should be no more than 2mm after assembling, ensuring the
mounting of the base tower section.
4 90%
1/750
1.5/1000
It is allowed to insert pads but no more than 2 pads into the intervals of the base tower
section and the packings. The area of pad should be more than 90% area of the pallet to
ensure that the planeness tolerance is less than 1/750 after installing the base tower section,
and vertical tolerance of central line with level plane is within 1.5/1000.
5
The embedded bolts should be connected with the reinforcement of lower layer
L 13 1-4
The bearing load, dimensions L and arrangement of reinforcing rods are shown as
Table 1-3 and Table1-4.
Notes:

When screwing the embedded bolts, it is prohibitten to knock the wrench with a
sledgehammer.

It is allowed that the embedded bolts are used one time, and it is forbidden to dig
them out and use again. Because the embedded bolts are important parts which bear
the great mass of loads of the crane, we suggest that the bolts should be purchased
from our company. Users fabricate the bolts yourselves, the bolts must conform to the
requirements of drawing. But you are responsible for any damage caused by bolts, if
the bolts are supplied by yourselves.
1.4.5
Foundation for Undercarriage

The ground foundation is the precondition to ensure safe operation of the crane. This
foundation must closely comply with the regulations for different geological conditions. It is
built of 4-blocks as base ballast, made of reinforced concrete. Basic requirements as
follows:
1) c35 1.4-5
15
The concrete strength grade shall be no less than C35. The ground under the foundation

TC5613-6

1.1-12

should be solid with the bearing load value specified in the Table 1.4-5. The curing
duration of concrete is more than 15 days.
2) 800mm
The depth of concrete should be more than 800mm.
3) 1/750
The contact level plane between concrete foundation and frame beam should be
calibrated. The level tolerance of four pallets is 1/750.
4) 1300mm1300mm 800mm
Dig a pit (1300mm 1300mm 400mm) with water drains in the middle part of
4-block foundation for the installing the frame girder.
 5)
The relative positions of 4-group embedded bolts shall be accurate to ensure proper
installation.


6)

1.5/1000
Hang plumb lines along the centerline in 2 directions of the base section to ensure that
the perpendicularity of the embedded base section centerline and horizontal plane is less
than 1.5/1000.
7) 95%
Concrete filling rate around the four pallets should be over 95.

TC5613-6

1.1-13

1.4-5
Fig.1.4-5 Foundation for Undercarriage

1.4.6

lightning protection

Notes: Not connected with the steel reinforcement of the building foundation.

1.4.7 Counterweight
1.4-6

The counter-weight has two specifications; both are cast with reinforced concrete. For
specific dimensions, refer to Fig. 1.4-6. Basic requirements are as following:
1.4.6.1 2 C18;
Weigh the counter-weight cast with reinforced concrete. Permitted weight deviation is 2%,
concrete grade no less than C18.
1.4.6.2 1-5
Counterweight should be equipped according to the length change of jib (shown as Table
1-5).
1.4.6.3 3090 2%
Length change is allowed to change the weight of counterweight, but the weight accuracy of
2% should be secured.

TC5613-6

A(mm)
(t)Weight

220
1.8

280
2.25

1.4-6a 2.25t1.8t
Fig. 1.4-6a

2.25t1.8t Counterweight

1.1-14

TC5613-6

1.4-6b
Fig. 1.4-6b

1.1-15

1.3t
1.3t Counterweight

(Table) 1-5

56 (56m Jib)
62.25t1

1.8t
Counterweight
15.3t
44 (44m Jib)

Counterweight

50 (50m Jib)

Counterweight

62.25t

13.5t
38 (38m Jib)
32.25t
52.25t

1.8t+1.3t
Counterweight
11.25t

9.85t

1.5 Erecting
70%
1.5-1
The erection of tower crane shall be conducted only after the concrete strength of
foundation reaches the designed value of 70%.
Erecting sequence shall be conducted in according to Fig. 1.5-1

TC5613-6

1.1-16

1) Tower section 2) Climbing frame 3) Slewing ring


assembly
4) Tower head assembly 5) Counter-jib assembly
6) Counter-jib con-rod 7) 2.250t A block of 2.250t
counterweight
8) operator cab 9) Jib assembly
10)
Jib con-rod 11) () Equip the remaining counterweights
1.5-1
Fig. 1.5-1Installation sequence of stationary crane with embedded anchors

1.5.1 Tower Section Erecting


1.5.1.1
Structure description
40.5
14
EQ,13
EQ7

There are, totally, 14 tower


sections when the hook height is
40.5m, including one base tower
section EQ, 13 tower sections EQ7.
There are a ladder and a platform
in each tower section.
1.5.1-1 EQ7
Fig1.5.1-1 Tower Section EQ7

1.5.1-1 EQ7 3
There are three bolt joints on the upper and lower ends of each chord of tower section
EQ7,
EQ EQ EQ
EQ 3 EQ 3

Base tower section EQ is divided into the section connected with pre-buried
foundation anchor, which is respectively equipped with three bolt joints on upper and lower

TC5613-6

1.1-17

end of chord, and the section connected the foundation with fang bolts, which is equipped
with three bolt joints at upper end of chord, and a flange at lower end.
,
Be sure that the climbing lugs on the base section are placed perpendicularly to
the building in order to conveniently installing and dismantling the whole tower crane.
1.5.1.2

Erect two tower sections

1.5.1-2

Fig.1.5.1-2 Erect tower section

1) 1.5.1-2 EQ7;
Hoist a tower section EQ7 (shown as Fig. 1.5.1-2), it is forbidden to hoist on the horizontal
bar. on base tower section EQ7 and screw them together with 12 pieces high-tensile bolts
strength rating 10.9
2) 1 EQ7 EQ , 12 10.9

;
Hoist a tower section EQ7 onto the base tower section EQ and screw it together with 12
pieces high-tensile boltsstrength rating 10.9
3) EQ7 12 10.9 ;
EQ EQ7
Hoist a tower section EQ7 onto the tower section EQ and screw it together with 12 pieces
high-tensile boltsstrength rating 10.9. There are a base tower section EQ, two
the foundation.

tower sectin EQ7

on

4) 1400Nm

TC5613-6

1.1-18

, 1400Nm;
Tighten all high-tensile bolts with torque up to 1400Nmand each bolt should be equipped
with a washer and two nuts. The loose-proof nut the upper nutshould be fastened
with torque equal to or a little more than 1400Nm
5) , 1.5/1000.
Check the verticality with a theodolitem or a plumb line. The verticality around the main
chord should be within the tolerance of 1.5/1000.
1.5.2 Hoist Climbing Frame

1.5.2-1
Fig 1.5.2-1 Climbing frame

1.5.2.1 ( 1.5.2-1) Structure description(shown as Fig1.5.2-1)

Climbing frame consists of climbing frame structure, platform, climbing stairs,


hydraulic jack system and let-in device for tower section. Its function is jacking and
lowering the tower crane.
()
16 ,
.
Climbing jack is mounted on the beam of rear side of climbing frame (e.g. at the side
of pre-assembled counter jib shown as Fig. 1.5.2-1). Hydraulic pump station is placed on the
platform at one side of jack. 16 wheels are equipped inside of climbing frame. The wheels
support the outside of chord of tower during jack.

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

TC5613-6

1.5.2.2 Hoisting
1) (
1.5.2-2 )

After pre-assembling the


climbing frame (shown as
1.5.2-2), hoist the frame.
It should be noted that
climbing jack is mounted
at the same side of the
climbing lugs on section.
2)

Enclose the climbing


frame on the outer side of
the mast section slowly

1.1-19

1.5.2-2
Fig.1.5.2-2 Hoisting Climbing Frame

3) ()
Place the frame over two tower sections and lower it until the pawl is supported by the
upper climbing lugs of the second tower section (count down up).
4) , ,,

Fix the jacking cylinder and hoist the hydraulic pump station to one corner of the
platform, connect oil tubes, and check the hydraulic system for normal operation.
1.5.3
Install the Assembly of Slewing Ring
1.5.3.1 Structure description
. 1.5.3-1.
The assembly of slewing ring consists of the slewing ring support, slewing ring, upper
support and slewing mechanism. Shown as Fig 1.5.3-1

The lower portion of the ring support is connected to the tower section and the
climbing frame. It is connected to the outer ring of the slewing ring by high-strength bolt at
the upper.

55
There are flange and platform on one side for the installation of slewing mechanism.
On the other side of working platform is welded with a support lug for connection of the
operator cab. There is a support for the installation of slewing limiter on the forepart.

TC5613-6

1.1-20

1.5.3-1
Fig.1.5.3-1 Slewing Assembly

1.5.3.2 Hoist and install the assembly of slewing rings


1) 8.8 M24 640Nm
640Nm
Check if the torque of M24 high-tensile bolts strength rating 8.8reaches up to
640N.m, and the torque of loose-proof nutsthe upper nutshould be a little more than
or equal to 640Nm.

TC5613-6

1.1-21

1.5.3-2
Fig. 1.5.3-2hoist the assembly of slewing rings

2) 1.5.3-2 55
Shown as Fig. 1.5.3-2hoist the assembly of slewing ring by hooking the four
connecting ears (shoe) at the slewing ring platform.
3) EQ7 ,,
,
Put the assembly of slewing ring support on the top of tower. Four-corner marks on slewing
ring support and climbing frame should be aligned during the connection of them.
4 8 10.9 M30 E (
), 1400Nm
1400Nm
Screw them together with 8 pieces high-tensile boltsstrength rating 10.9, and equipping each
bolt with a washer and two nuts. Tightening all the bolts with torque up to 1800Nmthe
loose-proof nut the upper nutshould be fastened with torque equal to or a little
more than 1800Nm.
5) ,, 4
.
Operation of jack system: Jack the climbing frame until it is high enough to be pined
to the slewing ring support with four pins.

TC5613-6

1.1-22

1.5.4
Install Twer Head
1.5.4.1 ( 1.5.4-1)
Structure description (shown as
Fig.1.5.4-1)

The tower head is a pyramid structure.


At the top there are a support for
counter-jib con-rod, a support for jib
con-rod, a working platform for installing
1.5.4-1 (Tower Head Assembly)
con-rods, and a wire rope pulley and a
pulley block for installing jib con-rods.
Moment limiter and ladder with
handrails to the top of tower head are
equipped at the lower side of chord at
the rear of tower head.

.
The lower sector of tower head is is an
integral frame structure. Lugs are
welded at the middle of tower head for
connecting jib and counter-jib with
pins.
1.5.4.2 Hoist and Install
the Tower Head
1)

(
);
1.5.4-2
Fig.1.5.4-2 Hoist and Install the tower head
Before hoisting, assemble the platform,
rails, ladders and moment limiter on the ground. On each side at the back of the tower head,
mount one counter-jib con-rod for conveniently installing the counter-jib.
2) 1.5.4-2
( 1.5.3-1,
1.5.4-1)

TC5613-6

1.1-23

Shown as Fig. 1.5.4-2hoist the tower head onto the upper support. It should be noted that
the vertical side be faced to the direction of jib. (Shown as Fig.1.5.3-1, 1.5.4-1)
3) 4 55
Connect the tower head to the upper support with four pieces of 55 pins.

1.5.5 Install Counter-jib


1.5.5.1 ( 1.5.5-1) Structure description(shown as Fig.1.5.5-1)

1.5.5-1
Fig.1.5.5-1 Counter-jib assembly

The counter-jib is welded structure of channel steel and angle steel. There are banisters,
passage and operating platform on it. The counter-jib consists of two sections. The front end
is connected to the tower head with two pins, and the other end to upper of the tower head
with two stiff con-rods.

Its tail section is equipped with the counter-weight, hoisting mechanism. The resistance box
and the electric control cabinet are arranged at the root of the front section. The hoist
mechanism and its own base frame are fixed on the counter-jib by four bolts.

1.5.5.2
Hoist counter-jib assembly
1)
,
;

TC5613-6

Assemble the two sections of the


counter-jib with banisters, passage
and operating platform on the
ground. And fix the hoisting
mechanism, the electric control
cabinet, the resistance box and
counter-jib con-robs onto the
counter-jib. Connect the slewing
mechanism to the temporary
power supply, and slew the portion
above
slewing ring to a position for
convenient
mount
of
the
counter-jib.
2) 1.5.5-2
( 4
);
Shown as Fig. 1.5.5-2hoist the
counter-jib (Four mounting ears
are equipped on the counter-jib).
1.5.5-2
Fig.1.5.5-2 Hoist counter-jib assembly

1.5.5-3
Fig.1.5.5-3 Counter-jib con-rods assembly

3) ;
Connect the front end of counter-jib to the tower head with pins.

1.1-24

TC5613-6

1.1-25

4) 1.5.5-3

;(
1.5.5-4)
Shown as 1.5.5-3 for the counter-jib
con-rod schematic diagram, lift up the
counter-jib slowly to a proper position
for smooth connection of the counter-jib
con-rod to those on the tower head.
Connect the con-rods by pins, insert and
open up cotter pins. (Shown as
Fig.1.5.5-4)
5)
2.25t
( 1.5.5-5
)
Lay down the counter-jib slowly. Lift a
piece of 2.25T counter-weight at the
furthest position of the counter-jib,
shown as Fig.1.5.5-5.
1.5.5-4
Fig.1.5.5-4 Install counter-jib con-rod

Special Notice:
1.;
Be sure of mounting the baffle of the
counter-weight pins against the
counter-weight.
2.
.
Be sure of mounting the end face of the
counter-weight pin exceeding
the triangle plate.

1.5.5-5
Fig.1.5.5-5 Hoisting one piece of 2.25T counter-weight

TC5613-6

1.1-26

1.5.6
1.5.6.1 ( 1.5.6-1)
Structure description (shown as Fig.1.5.6-1)

The cab is a sheet structure, offset at the front


on the upper support right side platform. There
are large big glass windows on the four sides of
the cab. The upper window in front can be
opened to obtain a wide field of view. The cab
is nice-looking and comfortable, equipped with
inter-active control console.

1.5.6-1
Fig.1.5.6-1 Operator cab

1.5.6.2 collocation of control console ( 1.5.6-2)

1.5.6-2

Fig.1.5.6-2

No.

ico

designation

functions explanation

/
star/ringbutton

Electronic control system start-control-button


Ring-button.

TC5613-6

emergency stopbutton

100%

exceed 100% of working


momentalarm-light

90%

exceed 90% of working


momentalarm-light

100%

exceed 100% of working


loadalarm-light

50%

exceed 50% of working


loadalarm-light

operating indication of the


hook raising

operating indication of the


hook falling

operating indication
running ahead

of

10

operating indication
running back

of

1.1-27

In abnormal conditions,urgently cut off power of


control system. At the same time,the button can
be used in normal-stop. The button is anto-lock
only when be pressed down,the machine can run.
100%

When load-moment exceeds100% of working


moment ,the alarm-light is on.
90%

When load-moment exceeds 90% of working


moment ,the alarm-light is on.
100%

When load exceeds 100% of working load ,the


alarm-light is on.
50%
When load exceeds 50% of working load ,the
alarm-light is on.

When the handle of right collocation of control


console is at this direction, the hook is running
up.

When the handle of right collocation of control


console is at this direction, the hook is running
down.

When the handle of collocation of control


console is at this direction, the trolley is running
ahead.

When the handle of collocation of control


console is at this direction, the trolley is running
back.

TC5613-6

11

12

13

/
slewing/brakingbutton

bypass-button

start-indicator light

14

operating indication of
turning left

15

operating indication of
turning right

16

operating indication of
trolley-radius-changing
outside

17

operating indication of
trolley-radius-changing
inside

When the button is turn left ,the slewing brake is


off,jib can slew;when the button is turn right, the
slewing brake is on, jib cant slew.

When changing fall or running trollry inside,


pressing down the button, control-system is out
of the control of position-limiter, hoisting or
trolley-radius-changing can run continuesly.

When the electronic control system is start or run


state, the button is on.

When the handle of left collocation of control


console is at this direction, the slewing is turning
left.

When the handle of left collocation of control


console is at this direction, the slewing is turning
right.

When the handle of left collocation of control


console
is
at
this
direction,
the
trolley-radius-changing is running outside

When the handle of left collocation of control


console
is
at
this
direction,
the
trolley-radius-changing is running inside

80
The nosie in operator cab is below 80db when the tower crane in working.

1.5.6.2
Hoist and install the operator cab

1.1-28

TC5613-6

1.1-29

( 1.5.6-2
)
:
Mount the electric equipment in the cab and then hoist the cab to the front near right
platform of the upper support (Fig.1.5.6-2). Align it with the hole-position of ear-plate and
connect them with three pins and insert cotter pins.
Alternatively assemble on the ground the cab and slewing ring assembly and hoist the
whole piece once for all.

1.5.6-2
Fig.1.5.6-2 Hoist operator cab

1.5.7 Install jib assembly


1.5.7.1 ( 1.5.7-1) Structure description (shown as Fig.1.5.7-1)

The whole jib is a varied cross-section triangle spatial structure, consisting of ten
sections. Section-to-section is connected by pins for the purpose of convenient installing and
dismantling. The root of the first jib section is connected to the tower head by pins. The
second and seventh sections are provided with two hook lugs, through which jib con-rods
are connected to the tower head. The trolley mechanism is mounted in the 2nd section;
maintenance cage is set at the side of trolley for tower crane installation and maintenance.

56m40m44m 38m 50m


44m ;38m 1.5.7-2

TC5613-6

1.1-30

1.5.7-1
Fig 1.5.7-1 Jib structure

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

1.5.7-2
Fig.1.5.7-2 Jib assembly

1.5.7.2 Hoist and install jib assembly


1) ( 0.6m) 1.5.7-2 1.5.7-5

Assemble the jib on the flat sleepers (or supports) near the tower crane. No matter how
many the jib length is, the trolley must at first be mounted on the guide rail on the jib lower
chord.
2) ,
.

TC5613-6

1.1-31

Mount the maintenance cage to the trolley and move the trolley as close to the
minimum radius point of jib root (foot) as possible.
3)

( 1.5.7-3) 3
69
,
.
Mount the traveling mechanism at the jib root section, let two wire ropes from the wire
drum and let one of them pass over the guide pulley at the jib root, and then fix it at the back
of the trolley. Let the other rope pass over the guide pulley at the middle of jib and head
portions and then fix it at the front of the trolley, as shown in Fig. 1.5.7-3. At the rear of the
trolley is provided with three rope clips. And rope clip compression plates must be on the
side of ropes with force applied. The rope clip interval is 6~9 times of the wire rope
diameter. At the front end of the trolley is provided with tensioning devices. If the traction
rope has become loosened, adjust tensioning devices to tension the rope. The jib root section
is provided with another set of rope tensioning devices. Any loosened rope during its
operation can be tensioned by this tensioning set.

1.5.7-3
Fig. 1.5.7-3 Trolley Wire Rope Layout Plan

4) 1.5.7-4

After assembling jib con-rods shown as Fig.1.5.7-4, connect it to the jib hook lugs
on the upper chord of jib with pins, insert cotter pins, then place jib con-rods on the
bracket of upper chord on the jib.
5)

Check and perfect the circuit connection on the jib. Switch on the temporary power
supply of the slewing mechanism to slew the tower crane superstructure to a position for
convenient installation of the jib.
6) 1.5.7-5 (
) 1.5.7-6

TC5613-6

1.1-32

1.5.7-4
Fig. 1.5.7-4 Jib pull rod Diagram

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

1.5.7-5
Fig.1.5.7-5 position of hoisting the jib

L(m)
G(kg)

56
56m Jib
19.8
6250

50
50m Jib
18.3
5850

44
44m Jib
16.2
5450

38
38m Jib
14.2
5050

Notices:
1

TC5613-6

1.1-33

As for the position of center of gravity during jibs installation with different
lengths (incl. long and short tie rods, traveling mechanism, anti-drop device, and
trolley at the minimum radius), refer to the Table below.
2 8 l20
When hoisting, 8mL20m.
3 ,
, 5 ,,
.
The assembled jib should be supported on the ground by at least 5 supports
during winding wire rope.

1.5.7-6
Fig. 1.5.7-6 Install jib assembly

7)
1.5.7-7

1.5.7-8 1.5.7-9

1.5.7-7
Fig.1.5.7-7 Hoisting rope layout for installing jib con-rods

TC5613-6

1.1-34

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

1.5.7-8
1.5.7-9
Fig. 1.5.7-8 Tower head structure at the joint of jib con-rod
Fig. 1.5.7-9
Joint structure

8)
After connecting jib con-rods to tower head, dismantle the hoisting rope.

1.5.8
Assemble counter-weight

1-5
The weight of counter-weight varies in
proportional to the jib length (Table 1-5).

1.5.8-1
The counter-weight is hoisted
according to the jib length used.

The counter-weight configuration and


mounting position are strictly acted on the
requirements of four jib-length conditions.
:

Special Notice:
1.;
Be sure of mounting the baffle of the counter-weight
pins against the counter-weight.

1.5.8-1

Fig.1.5.5-5 Hoisting counter-weight

TC5613-6

1.1-35

2..
Be sure of mounting the end face of the counter-weight pin exceeding the triangle plate.

1.6
Rope-winding system of hoist
mechanism
1.6.1

1.6-1

1.6-1
Fig.1.6-1 Hoisting rope layout

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

4/1000
()

After the installation of the whole crane according to the above steps, check the
verticality of tower body axis at no wind conditions. The verticality tolerance is 4/1000.
Switch on power to all electric circuits according to the electric circuit diagram and start all
mechanisms for test run. Check mechanism for proper operations (details, refer to relevant
instructions). At the same time, check wire ropes at different locations for normal working
and for any friction with structure member. Remove all abnormal cases. If the tower crane
needs to be put into service immediately after the installation, the safety device must be
adjusted as specified in section3.

TC5613-6

1.1-36

1.7 ( 1.7-1) Fall-change system


,
4 ,, 2
Fall-change-device is a hanging block with movable pulley, when the hanging block is
integrated with hook; the hoisting wire rope system is 4-fall. It is changed into 2-fall when
hanging block is separated from hook and abuts on the bottom of trolley.

1.7-1
Fig.1.7-1 Fall-change Device

1.7.1 2

2
When need the 2-fall condition, start hoisting mechanism and move the hook
downward till touching the ground, pull pin of the hanging block out, and then start hoisting
mechanism, wind wire rope and lift the hanging block untill it touches trolley. At this time
the hoisting rope is changed into 2-fall.
Notice: The wire rope should be regular on the drum of the hoisting mechanism.
1.7.2 4

4
If you need to change the hoisting rope into the 4-fall condition, start hoisting
mechanism, lay down hook untill it touches ground, let the hook block fall down into cradle,
insert pin and split pin. At this time the hoisting rope is changed into 4-fall.

TC5613-6

1.1-37

1.8 Jacking operation for adding sections

The usage method of the inlet roll


1 1
Insert the pin of the inlet roll into the bolthole of the tower section. The step is shown
as the 1st of the upper drawing.
2 900 2
Rotate the inlet roll through 900 and then it supports the level bar of the tower section.
The step is shown as the 2nd of the upper drawing.
3

3
According to the step 1 and the step 2, install the four inlet rolls into the boltholes, and
then hoist the tower section onto the inlet platform, put the rolls on the beams (each side 2

TC5613-6

1.1-38

rolls) of the platform. So the four inlet rolls support the tower section (shown as the 3rd of
the upper drawing).
1.8.1 Pre-jacking preparations
1.8.1.1 ;
Fill the oil tank with hydraulic oil according to the requirements of hydraulic pump station.
1.8.1.2
EQ7
;
Put in order each mast section and apply the grease into its connection boltholes. Line up the
tower sections EQ7 under jib before jacking. This will enable no use of the slewing
mechanism in the whole process of jacking operation for adding sections, thus minimizing
the jacking time.
1.8.1.3 ;
Loosen the power cable length slightly in excess of the total jacking height, and then fix the
cable.
1.8.1.4 (
);
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).
1.8.1.5
Preparation should be made on the platform to inlet wheels and high-tensile bolts for tower
sections on the climbing frame.
1.8.2 ( 1.8-1)
jacking operation (Fig.1.8-1)

Keep the tower crane in balance before

1.8-1
Fig.1.8-1 Keep the tower crane in balance

TC5613-6

1.1-39

1.8.2.1 1.8-1
EQ7 (
) EQ7 ;
Before keeping the tower crane in balance, hoist one tower section EQ7 onto the
introduction platform and then move the trolley to the reference balance position shown as
Fig. 1.8-1. Hoist one mast section or other weights (The trolley position in table is an
approximate value, which must be adjusted according to the actual situation in jacking).
Then remove all the bolts connecting outriggers of the slewing ring support to tower section
EQ7.
1.8.2.2

Push the operation handle of the hydraulic jacking system to <<Jacking direction>> to jack
the climbing frame to a position where the legs of slewing ring support are just disengaged
from the main chord rod of the tower body.
1.8.2.3 , 16

;
Check if the outrigger of slewing ring support is on the same vertical line with the chord of
the tower section. Check 16 guide rollers on the climbing frame and tower body main chord
rod to make sure that they have the same clearance. This serves to determine whether or not
the tower crane is in balance. If not, adjust the balance position of the trolley until balance is
achieved so as to drop the center of gravity of the upper tower crane onto the position of
jacking cylinder beams.
1.8.2.4
Record the balance position of the trolley for the convenience of dismantling. This mark
position varies with different jib lengths.
1.8.2.5
Operate the hydraulic system to lower down the sleeve frame. Connect the slewing ring
support to tower sections with bolts.
1.8.3 ( 1.8-2 ) Jacking operation (shown as Fig. 1.8-2)
1.8.3.1 EQ7 EQ7
EQ7
;
Hoist a tower section EQ7 to the top of inlet platform of climbing frame, install four inlet
rolls at the lower end of tower section EQ7, lower the hook slowly so that the inlet wheels
are seated onto the inlet beam properly, Then remove the hook.
1.8.3.2 EQ7;
Hoist another tower section EQ7 and drive the trolley to the position for balance.
1.8.3.3 ;
Use the brake on the slewing mechanism to hold the tower superstructure at a slewing
braking status, thus ensuring no slewing movements.
1.8.3.4 8

TC5613-6

1.1-40

Remove the eight bolts connecting tower section to slewing ring support.
1.8.3.5
(
) 1050mm

1.8-2 Fig1.8-2 Operation of Climbing

EQ7
EQ7
12 M30 () EQ7
( 1400kNm)
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 1050mm. Check if there are any strange
sounds, deformation, any self-retreat of piston rod etc, after confirmation, go on to erect
until it reaches the height of half the tower section, the support latches on the climbing
frame pass through a pair of climbing lugs and resets automatically, then retreat the jack to
let the support latches stay at the upper climbing lugs, confirm that the two support latches
press the top of climbing lugs and bear the weight of climbing frame and the upper part
without any strange sound and deformation, retreat the piston completely, lift jack beam so
as to support the cradle of climbing lugs. Erect the upper part of tower crane to a height of a
little more than half the tower section so that the space is fit for a tower section, drag the
tower section EQ7 on the inlet platform of climbing frame into upper part of tower, retreat
the jack slightly so that the new tower section EQ7 alight at the top of tower and conduct
proper alignment, remove the inlet wheels, fasten the upper and lower sections with 12
pieces of M30 bolts with torque of 1400kNm, each bolt must be equipped with two nuts.
8 M30
() EQ7
EQ7

TC5613-6

1.1-41

,
(),
Retreat the jack once more to let the lower of slewing ring support alight at the top of
new mast and conduct proper alignment, then fasten ring support to tower section with eight
pieces of M30 high-tensile bolts, each bolt must be equipped with two nuts. Then a tower
section is mounted. If several sections are to be mounted, just repeat procedures mentioned
aboveAs for proper alignment of slewing ring support with connecting bolt holes, insert
four guiding rods into four bolt holes at the corners of slewing ring support before retreat
the jack.
1.8.4
General Notices of Jacking Operation
1.8.4.1 14m/s ;
Jacking operation is prohibited when the wind speed at the highest top exceeding 14m/s.
1.8.4.2 EQ7
;
Keep the jib in the same direction as the in-let mast section during jacking operation. Stop
the jib with the slewing mechanism brake be sure of the trolley stopping at the
jack-balanced position.
1.8.4.3 EQ7
EQ7 8 M30
8 ;
If several tower sections are to be mounted, after mounting a section, all the chords of the
section must be fastened with 8 M30 bolts before hooking another section.
1.8.4.4 EQ7 ;
Keep the climbing lugs on the newly added tower section in alignment with those on the
existed sections.
1.8.4.5 M30
;
It is prohibited to slew, change work-radius and hoist load without connection of the
slewing ring support to the tower body by 8 M30 bolts.
1.8.4.6
8 M30
;
If the jacking hydraulic system has become abnormal in the course of jacking, stop
immediately the jacking operation, retract the oil cylinder, lower the slewing ring support
onto the top of tower body and use 8 M30 bolts to connect the slewing ring support to the
tower body before removing troubles from the hydraulic system.
1.8.4.7 ()
(
)
When tower section reaches the desired working height, turn the jib to different directions,
check if all the joints of the tower section, bolts for foundation are fastened sufficiently with
two nuts.

TC5613-6

1.9
Tower anchored onto the building
1.9.1
;
When the working height of the tower
crane has to be exceeded to its
stand-alone height, the tower body shall
be anchored.
1.9.2

24 M20 8.8

370N.m

(
1.9-1);

1.1-42

1.9-1
Fig. 1.9-1 Schematic Diagram of Tie Frame

The anchoring devices consist of 4 sets of mast-tie-frames and 4 inner ties. The 4 tie-frames
are fastened into anchoring frames by 24 sets of M20 bolts (strength rating 8.8), nuts and
washers (bolt pre-tensioned moment 370Nm). Anchoring frames are articulated with 3
tie-rods on 3 top points. The 3 brace rods shall be kept at the same horizontal level.
Adjusting bolts can be used to push inner tie rods tightly against the 4 chord rods on the
tower body (shown as 1.9-1).
1.9.3 Load on anchoring points
1.9-1 1.9-1
()

Table 1.9-1 shows the arrangement of tie rod and the load value of anchored points on
the building under certain position condition of tower crane in Fig. 1.9-1. The customers
should decide how to tie their cranes to the building and conduct necessary partial
modifications according to the load value, specific tie locations, local load capacity on the
building etc.

1.9-1
1.9-1
Notice: Load values at anchoring points vary to a great extent with the relative
positions of the tower crane to the building, tie rod layout and size, height of the tower

TC5613-6

1.1-43

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

1.9-1
F1(kN)

142

F2(kN)

222

F3(kN)

109

F4(kN)

222

1.9-2
Fig. 1.9-2 Load on the anchored point

1.9.4
;
Put on the tie frame on the tower section, push the 4 inner tie rods to the 4 chords on the
tower, connect one end of anchored tie rod to the tie frame with pins, and the other end to
the building.
1.9.4.1
E ;
3 sets of anchoring tie rods on each frame shall be kept at the same horizontal plane. If they
are interfered with some positions of the tower section E during mounting of anchoring
frames and inner tie rods, the height of frames will properly be raised or lowered.
1.9.4.2 ;
The walkway for personnel passage from the building to tower crane can be placed on the
anchoring tie rod, however no stockpiling of heavy objects on it.
1.9.5
4/1000;
During the mount of anchoring device, use the theodolite to check the axis of tower body for
verticality. Its deviation shall not be greater than 4/1000 of the total tower crane height. This
deviation can be achieved by adjusting the length of tie rod.
1.9.6

The connection of tie rods to tie frames, foundation and tie frames to the tower body and
inner tie rod shall be reliable. The inner tie rods shall reliably be pressed against the main
chord rod of the tower body and also be clamped tightly to the web rod of the tower body.
All connection bolts shall be fastened. Adjusting bolts, when properly adjusted, shall be

TC5613-6

1.1-44

tightened by nut. Cotter pins shall be opened as specified. After operation they shall be
frequently checked for looseness. Timely adjustments shall be made just in case.

Notice: No matter how many anchoring is conducted, only the topmost anchoring
tie frame can install the inner tie rod. Namely after each new attachment, the inner tie
rod has to be removed into the newly-anchored frame
1.10
Preparations before operation

The pre-operation preparations of the tower crane aim are ensuring its correct control
and smooth operation at safe conditions. Main preparations are to check tower crane
components and to test-run safety devices.
1.10.1 Parts and Components Checking
,.
In order to ensuring the correct erection of tower crane and its safe operation, a series
of test-runs and overall checks of tower crane components shall be conducted.
1.10.1.1
Check component-to-component connections.
1.10.1.2
Check the installation of supporting platform and fences.
1.10.1.3
Check wire ropes for correct
winding, avoiding interference and
friction with other parts.
1.10.1.4
Check power cables for smooth
and proper routing.
1.10.1.5

Check if the counter-weights on


the counter-jib are properly fixed.
1.10.1.6

Clear the lumber on platforms in


order to prevent them from falling
and avoid injuring persons during
tower crane operation.
1.10-1
Fig.1.10-1The mounting positions of whole crane safety devices

1.10.1.7
Check lubrication surfaces and points.
1.10.2 Test-run for the safety device

TC5613-6

1.1-45

-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
radius limiter.

1.10-1
The load limiter includes the hoisting moment limiter and hoisting weight limiter,
otherwise anemometer. Debugging is shown in the Chapter 3 of the Part 2. The mounting
positions of whole crane safety guards are shown in Fig.1.10-1.
1.10.3 ( 1.10-2)
Items-checking after tower erection (Table 1.10-2)
1.10-2

Item

Contents

table1.10-2

1.
Check if the foot bolts are fastened


Foundation

2.

Check safety distance between the surrounding power lines and tower crane.
Check power cable for smooth routing to avoid damage.

Tower
section
Check the bolt connection of tower sections

Climbing
frame

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

Upper
support,
slewing ring
4. Check the connection for operator cab
support and
5.. No storage of
operator cab
lubrication oils, oil cotton yarns and combustible materials in the cab.
1.

Tower head

2. Check tie rods of jib and counter-jib tie rods for proper installation.
3.
4. Check ladders, platforms and protection rails.

TC5613-6

1.1-46

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

Jib

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

Counter-jib

1.
Check counter-jib for fixing
2.
Check protection rails of the counter-jib and walkway. Ensure no foreign
substances on the walkway


Hook

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.


Mechanism

Safety
device

Lubrication

1.
Check mechanism for installation and operation
2.
Check mechanism brakes for correct clearance adjustment
3.
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.

TC5613-6

1.1-47

1.10.4
() 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)
1.10.4.1 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.
1.10.4.2 On-load test
25,50,75,100, 1.10.4.1

Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the rated hoist
load at the maximum working radius for tests. No incidents happen during these tests.
Brakes, operation systems, control systems, interlocking devices and limiters shall all act
accurately and reliably.
1.10.5 1.10-2 Stationary tower crane with
undercarriage installed according to the procedures shown as Fig. 1.10-2
1)

Installation of Undercarriage Assembly

2)

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

1.10-2
Fig.1.10-2 Installation sequence of stationary tower crane with undercarriage

TC5613-6

1.1-48

1.10.5.1
Undercarriage installation
1.

Assembly

of

undercarriage
1) ( 1.10-3)

Support cross beam assembly (shown


as Fig.1.10-3)fasten it to the foundation
with embedded bolts and channel steel.
2) 1 2( 1.10-4)
Installation of Undercarriage tower
section1 and 2( shown as Fig.1.10-4)

1 .10-3
Fig.1.10-3 Assembly of Undercarriage

3) ( 1.10-4)
Install the tower strut

1.10-4
Fig.1.10-4 Assembly of base tower section and strut

2. 12 ( 1.10-5) Mount the Base Ballast 1,2. The total weigh is 41.5
t (shown as Fig.1.10-5)

TC5613-6

4 (blocks) 3.5t ,

8 (blocks) 3.4t

(Total weight):

1.10-5

Fig. 1.10-5 Centre Ballast Assembly

1.1-49

41.2 t

TC5613-6

1.2-1


Chapter Dismantling
2.1
Precautions for tower crane dismantle
2.1.1
;
Conduct maintenance and test-run for the jacking mechanism before moving the tower
crane out of the construction site.
2.1.2 ;
Check limiters, slewing mechanism brakes and similar devices for reliability during test-run.
2.1.3 EQ7 M30
;
It is prohibited to use the slewing mechanism, trolleying mechanism and hosting mechanism
before the tower crane mast sections have been dismantled and the slewing ring support has
not been connected to the tower body by 8 M30 high-tensile bolts.
2.1.4
;
Check frequently the main stressed parts of the jacking mechanism, as the tower crane
dismantling is a heavy and continuous work for the jacking mechanism.
2.1.5
()(
);
While the jacking mechanism is working, all operating personnel are required to focus their
attention on observing the relative positions of moving parts for being normal (e.g. between
rollers and main chord rods, between climbing frame and tower body.).
2.1.6 14m/s

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

Special caution: tower dismantling is a highly technical work, especially the


dismantling of the mast sections of tower body, counter-weight, counter-jib and jib.
Any slight neglect will cause machine damage, personal injury or death. End-users are

TC5613-6

1.2-2

therefore required to strictly follow the Instructions-specified rules to dismantle these


components. Tower operators shall have been trained and with certificates.

EQ7 EQ7 !
NoticePay great attention to the two climbing latches during inlet or dismantle of
tower section EQ7. Inspect if the latches are still in proper level condition.

2.2-1 ,

Move the tower crane to the


dismantling area where there shall be
no obstacles influencing the operation.
Carry out tower crane dismantling
according to the sequence as shown in
Fig.2.2-1. Its steps are in opposition to
the steps of tower crane erection.
Strictly follow the Instructions
specified rules in all cases.
1. EQ7(
)
Lower down the tower sections
(dismantle anchored devices if any).
2. (
2.25t )
2.2-1

Fig.2.2-1 Dismantle of the tower crane

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


3.
Dismantle the jib.
4. 2.25t
Dismantle the last counter-weight.
5.
Dismantle the counter-jib.
6. ()
Dismantle the operator cab (or dismantle it together with the slewing assembly).
7.
Dismantle the tower head.
8.
Dismantle the slewing ring assembly.
9.
Dismantle the climbing frame and the remanent tower sections.

TC5613-6

1.2-3

1.2.1 ( 2.2.1-1) Dismantle the tower sections(shown as Fig. 2.2.1-1)

2.2.1-1

2.2.1.1 ()
();
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 crane at a balanced jacking
status, and the trolley staying at the balanced position (i.e. in conformity to the balanced
position of the trolley when additional sections are jacked during tower crane erection)
2.2.1.2 EQ7
;
Remove the upper and lower bolts connecting of the top tower section EQ7, connect inlet
wheels on the below section.
2.2.1.3
; EQ7( 1) 2 25cm ,
;
Extend the jacking cylinder to place the pin bolts onto the slot of the 4th lug counting from
up down. Insert safety pins, jack the superstructure until the bottom of the trolley is moved
to 20~50mm away from the top of the section.
2.2.1.4 ;

TC5613-6

1.2-4

Push the top section out of tower along the beam onto the inlet frame.
2.2.1.5
;
Rotate the latches 900, retreat oil cylinder to avoid the last pair of step lugs, then reset the
latches at level, go on to lower until the latches reaches the next climbing lugs and bear the
weight of upper parts confidently, retreat the cylinder again.
2.2.1.6
;
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 sectionsection 2 in fig
2.2.1-1contact the slewing ring support.
2.2.1.7
Connect 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.
2.2.1.8
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.
2.2.2
Dismantle counter-weight from counter-jib
2.2.2.1 ;
Fix the trolley at the jib root and use the auxiliary crane to dismantle the counter-weight.
2.2.2.2 2.250t
Dismantle the counter-weight piece by piece in the sequence opposite to counter-weight
mounting. Keep only one 2.25t counter-weight piece on counter-jib.
2.2.3
Dismantle jib
2.2.3.1
;
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.
2.2.3.2 ;
Arrange hoist ropes according Fig.1.5.7-5 shown hook points.

TC5613-6

1.2-5

2.2.3.3

;
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 con-rod close to the tower head. Remove the pins
connecting con-rod frame with the tower head, lower con-rods onto the jib and fix them.
Remove wire ropes, remove pins connecting jib with slewing tower body.
2.2.3.4
Lower the jib and lay it down on the sleeper-cushioned support.
2.2.4
Dismantle counter-jib

Hoist down the last counter-weight. Hoist the counter-jib through 4 hook lugs on the
counter-jib to make the jib tie rod at a loosened status. Remove connecting pins of tie rod
and then dismantle the connections between counter-jib and slewing tower body. Hook the
counter-jib down onto the ground.
2.2.5
Dismantle operator cab
2.2.6 Dismantle tower head

Before dismantling, check the tower head to see if component-to-component is still


connected by power cable.
2.2.7
Dismantle 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.
2.2.8
Dismantle the climbing frame and tower sections
2.2.8.1
Slowly hoist the climbing frames out along the mast section main chord rod and place them
down onto the ground.
2.2.8.2
Hook down the tower sections one by one.
2.2.9
Dismantle of the Undercarriage Assembly
.

TC5613-6

1.2-6

Dismantle the undercarriage assembly in reversed way of installation.


2.3
Attention after tower crane dismantling
2.3.1
The dismantled crane needs to be checked and maintained by technical personnel and
trained maintenance personnel.
2.3.2

Check main stressed structural members for metal fatigue; weld fissure, structural
deformation, etc. Check tower crane parts for damage or collision injury.
2.3.3
After completion of checks, repair the defects found and defects potential. Carry out rust
removing and painting.

TC5613-6

2.1-1

Part Operation and Maintenance



Chapter Safety Operation
1.1
Crane operator and hoist man
1.1.1 ZBJ80012-89,
;
The trained crane operators and hoist men are required to strictly follow the regulations as
specified in The Operating Instructions for Tower Crane.
1.1.2
;
Operators are required to understand the working principles of the tower crane and to
familiarize themselves with its structure and functions and adjustment methods for safety
guards. They are also required to master the operating methods for different performances
as well as the maintenance technique.
1.1.3 ;
Operate the crane strictly according to the hoist characteristics provided in the Instructions.
No over-load operating.
1.1.4
();
Operate gently the hoist mechanism, slewing mechanism and traveling mechanism. Carry
out low speed-to-high speed conversion progressively. No violent pushing of the operation
handles from the static position (or low-speed) to the intermediate speed or high-speed
position.
1.1.5
;
It is prohibited to pull, or hoist objects in an inclined way, or hoist the staggered or squeezed
objects and or hoist the objects buried in soil or frozen on ground.
1.1.6 ;
Operators and hoist men are not permitted to leave their working posts while objects are
being hung in the air.
1.1.7 GB5082-85 ;
Commanding signals, hand gestures and flag signs shall conform to the specifications.
1.1.8 ;
Operators are required to carefully operate and maintain the crane, as well as to keep work
shift-changing records.
1.1.9
It is prohibited that the operator is drunk, ill or tired on working.

TC5613-6

2.1-2

1.2
Mechanical part and others
1.2.1 -20+40 20m/s;
Working environment temperature for the crane is in the range of -20~+40, wind speed
at the highest working point should be smaller than 20m/s.
1.2.2 ;
All the tower safety guards shall be maintained constantly. No moving and dismantling of
them freely. No over-load operation.
1.2.3 ;
The construction site shall be provided with adequate lighting facilities for night operation.
1.2.4
After the tower crane has been overhauled and transferred to a new site and before
re-erection, observe the following:
1.2.4.1 ;
Check the articulations for pins cracks, rusting corrosion and damage.
1.2.4.2 ;
Check the rigid tie rods, wire ropes, pulleys, hoist hooks, fall-changing devices, etc. for
conformity to operating conditions.
1.2.4.3 ;
Check the metal structure members for deformations and weld fissures to make sure of their
conformity to operating conditions.
1.2.4.4 ;
Conduct trial operation for the mechanism of hoisting, jacking, slewing,
trolley-radius-changing until they have become normal.
1.2.5 ;
Switch off the main power supply when the crane operation is to be stopped for repair or
maintenance. No operation with power on.
1.2.6
;
Dispatch special persons at the ground, platform and construction work face to direct crane
operations and contact the operator. Signals hand gestures, flag signs, etc. are absolutely
necessary. Better to carry out communications by walkie-talkie.
1.2.7 380V10%;
Assure the working voltage of the tower crane at 380V10% range, otherwise crane
electrics will be damaged easily.
1.2.8 20m/s ;
Stop all hoisting operations in case of thunderstorm, heavy rain, thick mist or the top wind
speed of the crane is higher than 20m/s.
1.2.9
;
Provide a proper crane layout plan without spatial interception and interference from
another when several cranes have to work at the same construction site.

TC5613-6

2.1-3

1.2.10
;
When the operator has switched on power and entered the cab, he should make overall
checks of push buttons, operation handles for non-service conditions. He is not permitted to
press the master push-button until OK confirmed.
1.2.11
;
The operator must operate the crane strictly according to its technical characteristic
diagrams and hoisting characteristic curves. No over-load operation or forced operation.
1.2.12

;
During crane working, avoid the hoisting hook touching the ground, causing rope on the
wire drum in an irregular order. If the hook has to be on the ground, pay attention to drum
rope arrangement when it rises again. Make a regular rope arrangement if necessary.
1.2.13
100

;
The cage fixed on the side of the trolley is for maintenance. When maintenance of some part
of the jib is necessary, the maintenance person can stand in the cage and do the maintenance
work along with the trolley. The load capacity of the cage is 100kg. No person standing in
the cage when heavy objects are being hoisted. During the assembling of the jib on the
ground and tower erection, cage-to-hoist trolley must be checked for proper connections and
reliability.
1.2.14 ;
When mechanisms are required to operate in a reverse direction, it is necessary to wait for
the motor to stop its clockwise rotation before counter clockwise rotation start.
1.2.15 ;
If the tower crane is found abnormal, stop the crane and switch off the power supply. Do not
operate the crane again until the troubles have been identified and removed.
1.2.16

;
After crane operation completion at each shift, lift the hoist hook higher than the height of
the highest surrounding obstacle, retract the trolley at the smallest radius and keep the
slewing brake at an open status. The operator cannot leave his post until the power supply
has been switched off.
1.2.17

;
Before work start at each shift, the operator is required to carry out routine checks of the
pins of such key components as the tower body, jib, slewing support, rigid jib tie rod,

TC5613-6

2.1-4

counter-jib tie rod, brake and fall-changing device, also of the tower body connection axles.
Fasten the checked parts to make sure of no looseness or disengagement before operation
start.
1.2.18
;
The operator is required to carry out routine maintenance and oiling of the speed reducer,
pulley, bearing seat and anti-drop device. If oil leakage is found, remove the defect
immediately.
1.2.19
;
Before normal operation, the operator is required to carry out item-by-item checks of
various safety guards for reliability. No forced operation when they have any failures.
1.2.20
1.2-1 4 6t
The operator is required to keep a clear mind that the maximum hoist weight is limited
at different speeds when operating the hoist mechanism. Refer to table1.2-1
1.2-1

Speed

Fall
4 Fall
2 Fall

Table 1.2-1

Low speed


Medium Speed

High speed

6t
3t

6t
3t

3t
1.5t

1.2.21

When checking high-strength bolts every month, it is necessary to check the bolt joints
and the nearby material. It is especially necessary to check them of the three tower
sections on the foundation if the tower crane is not anchored to the building. Otherwise
it is especially necessary to check them of the tower sections nearby the anchored point.
It is necessary to check the tower head, especially the connecting plates and the nearby
material.
1.2.22

It is necessary to check the connecting plates and the nearby material every three
monthes.
1.2.23

When adding or lowering down the tower sections every time, it is necessary to check
the climbing lugs and the beam of the Climbing Mechanism.

TC5613-6

2.1-5

1.3
Routine check of high-strength bolt
1.3.1
Preparations of high- strength bolt before tower erecting

It is necessary to check these high-strength bolts of connecting tower sections and


slewing assembly before using. And it is necessary to clean the bolts, nuts and washers with
kerosene oil. It is prohibited to use damaged bolts (including rust bolts).
MoS2

Before using, it is necessary to coat the MoS2 grease on contact surfacs of the bolts,
nuts and washers to equilibrium friction.
1.3.2 Tighten the high-strength bolts

The tighten torque on the nuts must reach the specified torque and the torque of loose-proof
nutsthe upper nutshould be a little more than or equal the specified torque.
1.3.3
Check after installing

; 23
Check all bolts 2 times in a week, then one time in a week, then one time in two weeks,
and then one time in a month after erecting the tower crane. Dismantle 2-3 bolt groups each
year and check them for deformation, corrosion, rust, etc.
1.3.4
Repeat usage
1.3.1 1.3.2
The high-strength bolts can be used many times, but agreed with the requirements of
the above item 1.3.1 and the item 1.3.2.
1.4
Routine check of wire rope
1.4.1 .
The wire ropes used in hoisting machinery are easily-worn parts. Lack of proper
maintenance is one of the causes for their short service life.
1.4.2
Carry out timely cleaning of wire ropes and applying of lubrication oil or grease to them.
1.4.3

GB5972-86 2.4.2

TC5613-6

2.1-6

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.

Watch over the wire rope on trolley and hook as much as possible on each
workday so as to find that rope is out of the pulley or not. If the rope is out of the
pulley, stop working and wind the rope again.
1.4.4
Chek the wire ropes one time every week.

TC5613-6

Chapter

2.2-1

Mechanical and Electrical operation

2.1
Electrical mounting and operation
2.1.1 Electrical mounting
2.1.1.1 ()

;
Electrical erection shall be conducted after completion of tower crane erection at low-level
in reference to the electrical principle diagram, external wiring diagram and wiring diagram
in control cabinet, connection of controls to the power cable, braking cable, safety devices,
earthing devices, aerial lights and anemometer.
2.1.1.2 :
Check the following items before power on. Only in conformity to the following
requirements, power can be switched on.
1)
;
Be sure that of all wire lines are correctly connected. Fix reliably the electrical lines
and cables to be well fixed to avoid their damage during tower crane operation.
2)
0.5 4 ;
Before power on, check the electrical lines and cables for insulation. Be sure of the
earth insulation resistance of main control circuits no smaller than 0.5m (Ohm). and
the earth resistance of the tower body no greater than 4(Ohm).
3)()

;
Put cable protection rings onto the main cables (ground-to-operator cab cable) before
its entering the cab. Reserve the cable for adequate length to make sure that the tower
crane will not damage the cable when the crane is slew one round and a half right and
left and when it is being jacked.
4)

Place all cab controls at safe positions. Place the main switch at the power-off position. Finally
connect the power cables on the ground.

2.1.2 Power-on test run


2.1.2.1
380V10();
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 380V10% (The ground power net
shall supply adequate capacity to protect normal motor start and operation).

TC5613-6

2.2-2

2.1.2.2
;
Release the height limiter and radius limiter. Arrange the wire ropes of the trolley to match
mechanical erection.
2.1.2.3 :

;
Test-run (debugging) of hoisting mechanis:
Operate the hoisting handle to watch the hoisting operation. When pulling the handle
inwards, the hoisting hook shall move upwards. When pushing the handle outwards, the
hook shall move downwards. If not so, adjust the phase sequence of power supply of the
hoisting motor to meet the above requirements.
2.1.2.4

After completion of hoisting test-run, operate the slewing handle and


trolley-radius-changing handle respectively. When pushing the handle to the left, the jib
shall slew to the left. When pushing the handle to the right, the jib shall slew to the right.
When pulling the radius-changing handle inwards, the trolley shall travel inwards. When
pushing the handle outwards, the trolley shall travel outwards. If not so, adjust the phase
sequence of power supply of respective motor to meet the above requirements.
2.1.3 Notice for proper operation
2.1.3.1 ()
;
After power supply to the operator cab (before pneumatic switch on), power for the aerial
light and lighting in operator cab can be supplied through switches on the control panel. The
sockets are also available for fan plugs.
2.1.3.2 ;
Press start-button, and all operating handles shall return to zero, so as to power on the
master contactor.
2.1.3.3
(),()
;
To prevent reversed slewing or emergency stop from any damage to the tower crane,
electrics are provided with time-delayed devices. When the jib slews to the right (or left), it
cannot immediately slew to the left (or right) at a rated speed. Several-second delay is
necessary. After the slewing handle returned to zero, immediate braking cannot be done due
to several seconds delay.
2.1.3.4 ,.
;

TC5613-6

2.2-3

No braking and emergency stop at revered slewing though the crane is equipped with
above-mentioned time-delay device.
2.1.3.5
;
Before jacking, check the rotation direction of pump station motor in conformity to your
requirements. If not, adjust the rotation to the correct direction. It is prohibited to slew, hoist
and change working radius during jacking. This aims at accident prevention and no breaking
of the power cable due to twisting.
2.1.3.6

No free adjustment of the time-delayed relay and over-current relay in the control cabinet,
they have been adjusted in the factory as specified. Any component replacements should be
conducted according to the instructions for the electrical system.
2.2 Working mechanisms of tower crane

The working mechanisms of the tower crane consist of the hoisting mechanism,
slewing mechanism, trolley traveling mechanism and jacking mechanism.
2.2.1 Hoisting mechanism
QS680C, YZTD225L2-4/8/32 .
,. 2.2-1.
,,.
The model of hoist mechanism for the tower crane is QS680C, motor is
YZTD225L2-4/8/32 three-speed motor, with the function of high-speed light-load hoisting
and low-speed heavy-load hoisting. The transmission system for the hoist mechanism is
shown as Fig.2.2-1. The wire drum is provided with the hook height limiter. When objects
have been hoisted to the highest position, the hoisting winch will stop automatically.
2.2.2 ( 2.2-2) Slewing mechanism (For the schematic
diagram of transmission system, refer to Fig.2.2-2)
2 YTW112M-4B54.0kW

There is 1 set of slewing mechanisms arranged on one sides of slewing ring. It is driven
by 2 set 4.0KW motors model YTW112M-4B5. It drive the pinions through the planetary
reducer, hence making the jib and counter-jib slew to the left and right. The motors are
provided with disc brakes at their tails, which are kept at constant open status. The slewing
brakes are used at windy conditions. They can hold the tower crane in the specified
direction and location while hoisting or jacking operation is going on. It is forbidden to stop
the slewing mechanism by brake.
000

TC5613-6

2.2-4

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.

2.2-1
Fig. 2.2-1 Transmission System of Hoisting Mechanism

2.2-2
Fig. 2.2-2 Transmission System of Slewing Mechanism

2.2.3 ( 2.2-3)
(YDEJ132S-4/8-B5,
),(619-7.7-1550-)
,

3
The trolleying mechanism is for radius changing on the trolley. When doing radius
changing, the two-speed motor (model: YDEJ132S-4/8-B5 with magnetic disk brake)
drives the drum through the planetary reducer, thus making the trolley travel to-and-fro
along the jib. Travel traction is done by 2 wire ropes (619-7.7-1550-right twisted). One
end of the two wire ropes are fixed at both ends of the wire drum, wound on the drum and
led separately to the front and rear of the jib. They pass over the guide pulleys at the jib
root and jib tip. Another end of the wire rope are fixed on the trolley. In the course of
radius changing, one rope retracts and the other rope extrudes for the normal operation of
trolley. When the trolley travels to its minimum or maximum radius, the number of turns of
both ropes on the wire drum shall not be less than 3.
( 2.2-4)
The adjustment of trolley brake device: (shown as Fig. 2.2-4)

After long time service, the clearance between electromagnet and armature shall be

TC5613-6

2.2-5

increased due to the abrasion, and the suction is decreased.


( 1)
0.51mm
Adjustment: Open the cover of brake device, turn the support bolts, and then the
relevant inner hexagonal screws, the travel distance between armature and winding is
adjusted. The desired clearance should be within 0.51mm.

2.2-3
Fig. 2.2-3 Transmission System of Trolley Driving Mechanism

2.2-4
Fig. 2.2-4

Trolley Brake Device

2.2.4 ( 2.2-5) Climbing Jack (shown as Fig. 2.2-5)

2.2-5
Fig.2.2-5 Hydraulic Connection

2.2-6
Fig. 2.2-6 Schematic diagram of hydraulic System

TC5613-6

2.2-6

The hydraulic system consists of pump station, climbing jack, high-pressure hose and
special oil. It can jack or lower the upper parts of the climbing frame, and stop at any
position for mounting or dismounting tower section/masts.

It is compact, efficient, reliable and easy to maintain.


2.2.4.1 ( 2.2-6)(
)
Main parameters (System principle is shown as Fig. 2.2-6) (Please refer to the
operation instructions of hydraulic system)

Main Parameters of pump station


2-1


(L)

Oil
Pressure
Flow
Power
Hose
Oil tank
Requirement
(MPa)
(L/min)
(kW)
(JB1885-77)
capacity
ESSO
AW46
A-10
USA ESSO anti-wearing
25
10.6
7.5
100
Hydraulic oil AW46

Main Parameters of Climbing Jack


2-2


Rated
Cylinder Diameter
Distance of Installation
Jack speed
Max. Jack
Diameter
of Rod
Travel
Pressure
Distance
(m/min)
force (t)
(Mpa)
(mm)
(mm)
(mm)
(mm)
25
160
110
1600
2070
0.56
50
2.2.4.2
1) Oil cleaning
11 10
(
)
Screw open air filter II, fill 10 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).

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.
AB

Connect ports A.B of the hydraulic pump station to the hydraulic cylinders through

TC5613-6

2.2-7

high-pressure hose. Screw down the connectors.


3) Air exhausting of the system
A B 3
A B

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.
()

Notice: When the piston rod has moved to its extreme position, pull back the
handle immediately to its middle position and keep this position for several minutes
until air bubbles in oil tank have disappeared, and then carry out another action.
4) 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.
a. 5
6 4
4 25MPa

Maximum working pressure setting:


Unscrew the locking nuts, in front of the control handle, of high-pressure overflow
valve 5 at non-jacking operation status. Start motor. Move the operating handle to upper
position and extend the cylinder piston rod to its extreme position. At this time, pressure
gauge readings rise. Keep on screwing down the handle of the overflow valve until the
readings on pressure gauge have become stable at 28 Mpa. Screw down the locking nut in
front of the regulating handle of the high-pressure overflow valve (The overflow valve shall
not be adjusted by unauthorized or untrained person). Operate the handle in a reverse
direction to retract the piston rod. Finally move the handle back to its middle position.
b.: 6,

TC5613-6

2.2-8

1.8.3 2.2.1
Move up (or down) operation:
Start motor, and move operating handle to its up position. Extrude the cylinder piston
rod to hang the hanging plate connected to the piston rod into the lugs slot of the tower mast
section. Carry out the jacking operation for new section adding (or tower section
dismantling).
2.2.4.3
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.
1) Hydraulic oil for the system:
a. ESSO AW46

The hydraulic system shall use the anti-friction hydraulic oil AW46 by ESSO, USA,
which can't be mixed with other oils. Unfiltered oil can't be filled directly. When foam
is found in the oil and oil is emulsified, the oil tank should be cleaned immediately and
fill new oil.
b. :

Oil filling: Fully fill the tank with oil for the first time. After start-up, extrude the
cylinder rod, and then retract the cylinder rod. At this time, fill the tank with make-up
oil up to the tank upper limit mark.
c.
46 78
(NAS1638)
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 78 ,NAS1638 before starting the system.
d. 2400 200

The oil should be completely changed after the system work for 2,400hr and add part
of clean oil after working for 200hr.
2)
Shut the system when it is out of service because of the poor condition of ventilation.

TC5613-6

2.3-1

Chapter

Safety Guards

The safety guards of tower crane consist mainly of the travel limiter and load limiter.
The former consists of the hook height limiter, slewing limiter and trolley travel limiter. The
load limiter consists of the hoist moment limiter and overload limiter. The anemometer is
also included.
3.1
Multiple-purpose limiter

DXZ-4/7
DXZ-4/F(i=600) DXZ-4/3
( 3.1-1)
3 kinds of limiters: DXZ-4/7
hooking height limiter, DXZ-4/F
(i=600) trolley travel limiter, and
DXZ-4/3 slewing limiter.
3.1.1 Adjustment
procedures

3.1.1.1
2 M355 ;
Dismantle the upper cover, check
and screw down 2-M355
screws.
3.1.1.2 M5 ; Unscrew
M5 nuts
3.1-1

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

3.1.1.3 (),
:(Z)(T)(WK);
Drive the mechanism under control to an designed position (without load ) to meet the
requirements. At this time, the micro-switch should make transient change-over
corresponding to the action of this mechanism i.e. adjust the corresponding axle (z) to make
the memory gear (T) press down the micro-switch (WK) contact.
3.1.1.4 M5 ();
Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will

TC5613-6

2.3-2

occur).
3.1.1.5 ();
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)
3.1.1.6 M5 ;
Make sure that the position is as specified. Screw down M5 nuts and re-cover the casing.
3.1.1.7
After the mechanism working normally, check at certain interval the memory
control position for deviations. Correct the deviations if any.
3.1.2 ( 3.1.1 )
Adjustment for hook height limiter (adjusting procedures according to item 2.3.1.1)
3.1.2.1 (2WK3WK4WK))
;
Adjust at no-load conditions. Press down micro-switches (2WK3WK4WK) by finger to
check the rising micro-switch or lowering micro-switch for correct action.
3.1.2.2 5 (3Z)
(3T)(3WK)
1 (4Z)(4T)(4WK)
M5 ;
Adjust axle(3Z) to make cam (3T) act and press down micro-switch (3WK) for changingthe
hook rising decelerate. This is done when the minimum distance from trolley to hook is
smaller than 1m in hoisting to its extreme limit. Adjust axle(4Z) to make cam (4T) act and
press down micro-switch (4WK) for changingthe hook stop rising. This is done when the
minimum distance from trolley to hook is smaller than 1m in hoisting to its extreme limit.
Screw down M5 nuts.
3.1.2.3 2WK (
3 ),, 3.1.1 (2Z-2T-2WK)
Customers can adjust the lower limit by 2WK so as to avoid operation errors and make the
hoisting hook stop lowering movement before the hook touching the ground (no less than
3-round steel ropes on the wire drum). The adjustment method is the same as item 2.3.1
2Z-2T-2WK

Especially Note: After changing wire rope, it is necessary to adjust the height
limiter again. Otherwise the hook may crash the trolley and the wire rope breaks,
which will lead to the crane destroying and people death.

TC5613-6

2.3-3

3.1.3 ( 3.1.1)
Adjustment for slewing limiter (the same procedures as item 2.3.1.1)
3.1.3.1 ;
Adjust the slewing limiter while the jib is at erection position (power cable at free status).
3.1.3.2 (WK)
(WK);
Adjust under no-load condition. Press down the micro-switch (WK) by finger to check the
switch for correct left and right control.
3.1.3.3 540(1.5 ) 3.1.1 ,(4Z)(4T)
(4WK) M5 ;
Slew to the left for 540(1.5 rounds). Follow the Item 2.3.1.1 to adjust the axle (4Z) to make
the cam (4T) move to achieve transient changing by the micro-switch (4WK). Screw down
M5 nuts.
3.1.3.4 1080(3 ) 3.1.1 (1Z)(1T)
(1WK) M5 ;
Rotate 1080 right (3 rounds). Follow item 2.3.1.1 to adjust the axle (12) to make the cam
(1T) move to achieve transient changing by the micro-switch (1WK). Screw down M5 nuts.
3.1.3.5
Check if the left and right slewing is correct.
3.1.4 ( 3.1.1 )
Adjustment Method for radius (trolley travel) limiter (the same procedures as item
2.3.1.1).
3.1.4.1 :
1.5m (2Z)(2T)(2WK)(
(3T)(2T)) M5
220mm (1Z)(1T)(1WK)
M5 ;
Outward travel at lower speed and extreme position limiting at the jib tip:
Drive the trolley at the position of 1.5m away from the jib tip buffer. Adjust the axle
(2Z) to turn the memory cam (2T) to enable the micro-switch (2WK) for action. (Enable
simultaneous overlap of the cam (3T) to the cam (2T) to avoid speed reduction interference
before braking). Screw down M5 nuts. Drive the trolley to the position of 220mm away from
the jib tip. Follow the procedures to adjust the axle (1Z) to rotate (1T) to make the
micro-switch (1WK) act. Screw down M5 nuts.
3.1.4.2 :3.1.4.1,
1.5m 200mm 3Z-3T-3WK4Z-4T-4WK

Inward travel and extreme position limiting at the jib tip: The adjustment method is the same
as item 3.1.4.1 Carry out speed reduction adjustment and position limiting at the jib root

TC5613-6

2.3-4

( 32-3T-3WK, 42-4T-4WK ) at 1.5m and 200mm away from the jib root buffer respectively.
3.1.4.3
Check and correct
3.2 ( 3.2-1) Moment limiter(Fig. 3.2-1)
90
, 100 110,

The tower crane is provided with a mechanical type-moment limiter for protection
purpose. When the moment has reached 90%of its rated value, the pre-warning light in the
operator cab is on. When the moment has reached 100%~110% of its rated value, hoisting
up and the trolley outwards-travel
are stopped due to power off and
over-load alarm at the same time.
2
3 4
1

3.2-1

Fig.3.2-1 Schematic diagram of the moment limiter

The moment limiter consists of two-spring plates 2, three travel switches 3 and
adjusting bolt 4. They are fixed on the chord rod on the tower crane rear side through
mounting block1. If the tower head has deformed during crane operation, the distance
between two spring plates will become narrower, thus activating the adjusting bolt for
adjusting bolt contacts and travel switch. Corresponding moment will give warnings and cut
off the power for the crane up and trolley outward-travel, thus playing the role in moment
limiting protection.
3.2.1 ()
Adjustment of Moment Limiter (wire rope at 4-fall)
3.2.1.1
Adjustment of constant load and variable radius of trolley travel:

TC5613-6

2.3-5

56m 2.67t(50m 2.78t,44m38m 2.85t),


20m 3.2-1 4 28.8m
3.2-1 4
3233.6m
When the jib length is 56m, trolley hoists 2.67t(the jib length is 50m, trolley hoists
2.78t loads. the jib length is 44m and 38m , trolley hoists 2.85t) and moves outwards from
20m point at a slow speed. Adjust one Bolt 4, to enable the warning light power on in the
operator cab when the trolley moves to the range of about28.8m. And adjust another bolt 4 to
enable the mechanisms power off and give over-load warning sound at the same time when
the trolley moves to the range of 32m33.6m. It is forbidden upward hoisting or outward
traveling.
3.2.1.2
Adjustment of constant radius of trolley travel and variable hook load
23m ,56m 4.0t(50m 4.16t,44m38m 4.25t)
200kg 3.2-1 4

When the jib length is 56m, at 23m point, the loading 4t (the jib length is 50m, loading
4.16t, the jib length is 44m and 38m, the loading 4.25t), upward hoisting is permission.
Adding 200Kg to the load, adjust the third bolt 4, to enable the mechanisms power off and
give over-load warning sound at the same time. It is forbidden upward hoisting or outward
traveling.

Test the step 3 times to keep the function stability.


3.2.2 ()
Checking moment limiter (at 4-fall).
,.
Conduct calibration to the moment limiter 3 times each according to Item3.2.1.1 and
item 3.2.1.2.
3.2.2.1
Checking of constant load and variable radius of trolley traveling
1) : 6t 8m 16.217.1m
(50m 16.817.6m44m 38m 17.118m)
;
Checking at small radius: When the jib length is 56m, loading 6t, trolley travels
outwards from 8m point at a slow speed. When travelling to the range of 16.217.1m (the
jib length is 50m, the range of 16.817.6m, the jib length is 44m and 38m, the range of
17.118m), the mechanisms power off and give over-load warning sound at the same time.
It is forbidden upward hoisting or outward traveling.
2) 2) : 56m 1.5t(50m 2.0t44m 2.5t, 38m
3.0t) 49.251.7m(50m 41.35

TC5613-6

2.3-6

43.4m44m 35.537.3m, 38m 30.6832.2m)


()
Checking at large radius: When the jib length is 56m, loading 1.5t, trolley travels
outwards from 40m point at a slow speed. When travelling to the range of 49.251.7m, the
mechanisms power off and give over-load warning sound at the same time. It is forbidden
upward hoisting or outward traveling. When the jib length is 50m, loading 2.0t, trolley
travels outwards from 30m point at a slow speed. When travelling to the range of 41.35
43.4m, the mechanisms power off and give over-load warning sound at the same time. It is
forbidden upward hoisting or outward traveling. When the jib length is 44m, loading 2.50t,
trolley travels outwards from 30m point at a slow speed. When travelling to the range of
35.537.3m, the mechanisms power off and give over-load warning sound at the same time.
It is forbidden upward hoisting or outward traveling. When the jib length is 38m, loading
3.0t, trolley travels outwards from 30m point at a slow speed. When travelling to the range
of 30.6832.2m m, the mechanisms power off and give over-load warning sound at the
same time. It is forbidden upward hoisting or outward traveling.
3.2.2.2 Checking of constant radius and variable load
1) : (56m
1.24t50m 1.54t44m 1.89t, 38m 2.29t)
,, 1.3t(56m )(50m 1.62t
44m 1.98t, 38m 2.4t),,
Checking of maximum radius: When the jib length is 56m, loading 1.24t at 56m point
with a normal hoisting speed, the moment limiter shall not act and upward hoisting is
permission. When loading 1.3t load at 56m point, the moment limiter works normally and
the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the
jib length is 50m, loading 1.54t at 50m point with a normal hoisting speed, the moment
limiter shall not act and upward hoisting is permission. When loading 1.62t load at 50m
point, the moment limiter works normally and the mechanisms power off. It is forbidden
upward hoisting or outward traveling. When the jib length is 44m, loading 1.89t at 44m
point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is
permission. When loading 1.98t load at 44m point, the moment limiter works normally and
the mechanisms power off. It is forbidden upward hoisting or outward traveling. When the
jib length is 38m, loading 2.29t at 38m point with a normal hoisting speed, the moment
limiter shall not act and upward hoisting is permission. When loading 2.4t load at 38m point,
the moment limiter works normally and the mechanisms power off. It is forbidden upward
hoisting or outward traveling.
2) : 56m (50m44m 38m ) 20m
4.71t(50m 4.9t44m 38m 5.02t)

TC5613-6

2.3-7

,, 4.95t(50m 5.15t44m 38m


5.27t),
Checking of small radius: When the jib length is 56m, loading 4.71t at 20m point with a
normal hoisting speed, the moment limiter shall not act and upward hoisting is permission.
When loading 4.95t load at 20m point, the moment limiter works normally and the
mechanisms power off. It is forbidden upward hoisting or outward traveling. When the jib
length is 50m, loading 4.9t at 20m point with a normal hoisting speed, the moment limiter
shall not act and upward hoisting is permission. When loading 5.15t load at 20m point, the
moment limiter works normally and the mechanisms power off. It is forbidden upward
hoisting or outward traveling. When the jib length is 44m and 38m, loading 5.02t at 20m
point with a normal hoisting speed, the moment limiter shall not act and upward hoisting is
permission. When loading5.27t load at 20m point, the moment limiter works normally and
the mechanisms power off. It is forbidden upward hoisting or outward traveling.
3.3

( 3.3-1) Hoisting weight limiter (Refer to Fig.3.3-1)


( MSWL-360B
)
As for the structural adjustment of hoisting weight limiter, please refer to the operation
instructions for hoisting weight limiter MSWL-360B. This crane uses only two of the four
micro-switches, and the hook uses 4-fall pulley block during adjusting.
3.3.1
3.3.1.1 2950Kg
;
Hoist 2950Kg with the hook to travel up and down at low speed and high speed one
time each. There should be no block at above-mentioned speed.
3.3.1.2 100kg 1

Add another 100kg to the 2950kg load, lift the load at high speed, if the hoisting-weight
limiter does not act, and the hoisting mechanism can run at high speed, at the same time,
adjust Screw 1 on the hoist weight limiter until the hoisting mechanism cannot run at high
speed. Then lower the load onto the ground.
3.3.1.3 12 3000Kg
30003100kg

TC5613-6

2.3-8

Repeat all actions mentioned in the Items


1), 2), lifting 4 tons load, and the hoisting
mechanism can run at high speed. Lifting the
load about 3000 3100kg, the hoisting
mechanism cannot run at high speed, at this
time, the load gains ground on 3000Kg that is
ideal.
3.3.2 ( 12 )
Low speed adjustment (Traveling radius is less
than 12m)
3.3.2.1 5900kg
;
Hoist the weight of 5900kg. The hoisted
weight travels up and down at low speed one
time each. Do not permit no hoisting.
3.3.2.2 200kg 1

Add another 200kg to the 5900kg load, lift the load at high speed, if the hoisting-weight
limiter does not act, and the hoisting mechanism can run at low speed, at the same time,
adjust Screw 1 on the hoist weight limiter until the hoisting mechanism cannot run at low
speed. Then lower the load onto the ground.
3.3.2.3 6000Kg
60006200kg
Repeat all actions mentioned in the Items 1), 2), lifting 6 tons load, and the hoisting
mechanism can run at low speed. Lifting the load about 60006400kg, the hoisting
mechanism cannot run at low speed, at this time, the load gains ground on 6000Kg that is
ideal.
3.4 ( 3.4-1)
Operation of anti-twist device (Refer to Fig. 3.4-1)
3.4.1

Hoisting ropes are non-rotating (anti-twist) ones. The anti-twist device shall lock tightly the
locking bolts while the tower crane is at service.
3.4.2
If hoisting ropes are of ordinary type, the anti-twist device shall unlock the locking bolts
while the tower crane is at working.
3.4.3

TC5613-6

2.3-9

After changing for new wire ropes, the hoisting hook will rotate at no-load operation. At this
time, unlock the anti-twist device, wire ropes will freely rotate till it is identical with the
hoisting hook If the anti-twist device is at locked status, no-load operation for a long period,
it will cause steel ropes twisted along the
whole length until the hook no longer
rotates.
3.4.5

When the tower crane has been used for a


long period of time, steel ropes will be
made longer and slightly twisted. At this
time, unlock the anti-twist device for the
time being until ropes have been tensioned,
then lock the device once again.
3.4.6 Once
steel ropes have their strands loosened, the anti-twist device will accelerate rope
deterioration. Therefore change the deteriorated ropes timely as required.

TC5613-6

Chapter

2.4-1

Service and Maintenance

To ensure safe and economic operation of the tower crane for a longer service life, it must be
properly maintained and lubricated.
4.1

Tower crane maintenance


4.1.1
Check speed reducers for oil quantity. Fill oil in time.
4.1.2
Check wire ropes at different positions for looseness, breakage or being worn-out. Change
defective ropes as required as per relevant stipulations.
4.1.3
Check brakes for performance and clearance to ensure reliable sensitivity.
4.1.4
Check safety guards for reliable sensitivity.
4.1.5

Check bolt connections. Re-tighten the bolts once again when they have been used for a
certain period of time.
4.1.6
Check steel rope head clampers and clips for loose status. Tighten them if loosened.
4.1.7 , GB5144-94 GB5972-86 .
Reject steel ropes, drums, pulleys and hoisting hooks strictly according to the relevant
stipulations.
4.1.8 ,,
, 45
Check the rods, web rods and welds of metal structure members for fractures and fissures.
Pay special attention to the positions where the paints are peeled. The most dangerous is that
the paint is striped (in 45 oblique strings. Trace the cause immediately and dress the issue in
time.
4.1.9 ()20

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 20 are specially-made, no substitutes shall be replaced under any
conditions. Each bolt shall be tightened with two nuts for the installation of tower sections.
4.1.10 10.9 10 ()

TC5613-6

2.4-2

The strength rating of high-tensile bolts for connecting tower sections are 10.9, and nuts are 10,
which should marked on the head of bolts and nuts, The bolts and nuts without grade marked
on the head are prohibited to use.
4.1.11
Conduct rust removing and painting of the whole tower crane and its metal mechanisms after
completion of their each use in a project.
4.1.12
The hoisting height limiter should be adjusted again after the rope serves for a period of
time.
4.1.13
Check if the electrics connectors are oxidized or burned-down. Repair or replace any poor
connectors.
4.1.14
No function failures of limit switches and push buttons. Replace rusted or damaged parts in
time.
4.1.15 0.5M
Be sure that the insulation of electric switches to switch panels meet the relevant
requirements, with insulation resistance no less than 0.5M.
4.1.16 ,.
Check if the bolts connecting electric components are loosened: Check power cables and
other conducting wires for fractures. Remove the trouble if any.
4.2
Main troubles and troubleshooting
4.2.1
Ordinary troubles, troubleshooting and solution
4.2-1

No.

Trouble

Troubleshooting

Reducer temperature is
too hot

Lubrication oil deficient or excessive

Solution

Properly increase or decrease


oil

__Excessive or deficient grease

The temperature of the


reducer bearings is too
high

__Grease quality very poor

__Improper axial clearance of the


bearings or bearings is already
damaged

__Properly replace grease

__Re-adjust the clearance of


of bearings

___Replace bearings

TC5613-6

3.

Oil leakage from speed


reducer

Contacting surface of connections is


not tightened enough, sealing rings at
shaft ends is worn and damaged
a.
Worn oil pump, declined efficiency
b.

Jacking speed is too


slow

Oil in the tank is insufficient or oil


filter clogged
c.

Hand-operated valve rod and valve


hole severely worn
d.

2.4-3

Replace sealing rings

__ Repair or replace the


damaged parts

__Fill adequate oil or clean


oil filter

Oil cylinder piston seal is damaged


and internal oil leakage
a.

Jacking force is not


adequate or unable to
jack

Severe internal leakage from oil pump


b.
Overflow valve pressure set too low
c.
Hand-operated valve core excessively
worn
d.

1.
Repair or replace the worn
parts
2.
Adjust pressure as required
3.
Clean hydraulic valve

Overflow valve clogged down


Noise
and
6

Oil filter clogged

Clean oil filter

Jacking system is not


working

Motor rotation and oil pump rotation


both in wrong directions
a.

Change
direction

Air not completely exhausted from oil


cylinder piston
b.

vibration occur during


jacking operation at
increasing pressure

Creeping and quivering


during jacking operation

Trouble with guide mechanism


a.

Jacking
loaded

drop

when

Trouble with balance valve of the


cylinder head
c. Piston
sealing of oil cylinder is damaged

motor

rotation

__Exhaust air as required.

__Adjust guide pulleys

,
Remove trouble,
sealing parts

replaces

TC5613-6

2.4-4

1.

10

Malfunction of Master
push-button

Operation handle not returned to zero


2.
Fuse in the electric control cabinet is
burned down
3.
Poor contact of the start-button and
stop-button
1.

11

Power is stopped during


hoisting operation

Over current from hoisting motor,


actuating over-current breaker.
2.

Capacity of the site transformer is


inadequate, or power cable from
transformer to tower crane has
inadequate diameter
1.

Fuse burned-down.
3.

12

Hoisting
mechanism
unable to start

or

Motor working voltage is too low


5.
Windings wiring in a wrong way
6.
Electromagnetic brake not released
7.
Too heavy load or trouble with the
transmission mechanism
1.

13

Abnormal noise and


vibration
from
trolleying mechanism

Return handle to zero.


2.
Replace fuse
3.
Repair or replace the button
1.

Check hoisting brakes for


open-up. Check over-current
stabilization
value
for
variation
2.
Replace
transformer
increase cable diameter
1.

or

Check wiring diagram.


2.
,

Control wiring in a wrong way


2.

Electric motor windings


short-circuited,
grounded
circuit breaking
4.

1.

a.
b.
Mechanical wear, due to:
a. Friction between stator-rotor
b. Motor-speed reducer box not
in concentricity

Check fuse capacity, change


for larger one if too small
3.
Measure power grid voltage
4.

Supply power to suit different


speeds so as to find out short
circuit and circuit breaking.
Repair the findings
5.

Check brake voltage and


windings for circuit breaking
or clogging
1.

Check rotor clearance for


being uniform
2.

Check slip rings for wear.


Replace them if any

TC5613-6

2.
Bearings without oil or damaged.
3.
Gear box without oil
4.
Gear worn
5. ,

14

Trolleying mechanism
Bearings over-heated

15

Electrification with the


trolleying mechanism

16

17

Brake failure with the


trolleying mechanism

1.

Switch off power supply.


Check and repair
1.

Bearings burned down


2.

Replace bearings
2.

Grease too much or too few

Add grease as required


1.

Power line or earth line wired in a


wrong way
2.
Poor earth connection
3.

1.
Braking moment too small
2.
Increased friction clearance of friction
pieces.

Slewing mechanism
unable to start

See if foreign matters are clogged in


the gear..
1.
Load excessive
2.

18

Trolleying mechanism
motor over-heated or
smoke emission

Clean bearings and add fresh


lubrication
oil.
Replace
bearings
4.

2-phase operation with abnormal noise

Motor wires scratched and earthed

3.

Replace gearbox.
5.

1.

2.4-5

Load continuing and work not as


specified
3.
2-phase operation
4.
Power supply voltage too low or too
high
5.
Motor windings earthed or short
circuited between turns, or between
phases

Find out the cause, and


remove the trouble.
2.

Improve earth connection


3.

Find the cause, and remove


the trouble
1.

Brake spring broken, replace


the spring
2. ,
citation and inadequate voltage

Remove foreign matters


1. ,

Measure stator current, e.g.


decrease load if heavier than
rated value.
2.
Operate as required.
3. ,

Measure 3-phase current to


remove troubles.
4.
Check input voltage
necessary correction

for

TC5613-6

2.4-6

6.

5.

Incorrect clearance between friction


pieces
7.

Find out the cause to repair


6.

Braking time and releasing time not


correct
8.
Moter clogged, causing temperature
rise.

Adjust clearance as required


7.

Check brake for voltage and


time-delay
for
circuit
breaker action and remove
the trouble.
8.
Keep smooth ventilation

4.2.2 The electrical failures and solutions

The electrical failures, which are caused by defect of contact or component wear-out,
lead to wrong operation or out of operation. Please to refer to the electrical struction to find
troublesshooting and solution.
4.2.3

No

Parts
Description

Lubricating location

Lubricant specifications

Hoisting rope

Graphite
Calcium-based
grease
ZG-SSY1405-65

Trolley rope

Wire rope

Reducer

Reducer of hoisting
winch

Reducer of
mechanism

slewing

10N220

Summerover 10C with


N220 gear oil
10N150

Winterbelow 10C with


N150 gear oil

Lubricating method &


duration

Grease the rope after


working for a week, and
boil the grease after
overhaul or medium
maintenance.
240
1500

Lubricate the reducer


after it serves for 240
hrsChange the oil after
working for 1500hrs.

TC5613-6

Reducer of trolleying
mechanism

the
reducer of the slewing
mechanism

Rolling
Bearing

-2 ZL-2

Sulphur molybdenum-2# or ZL-2# When


maintained,
lithium-based grease
supplements grease in time

000
When maintained or the
#
0000 grease
level of oil dropped,
supplements grease in
time to guarantee the
level of grease arrive at
the bolt of oil.

Rolling bearings in the


reducer.

Calcium-based grease
ZG-2

Drum bearing

Hook bearings

2.4-7

Calcium-based grease

160
,
Grease the bearings each
after they work for 160
hrs Clean them once
after half a year.

Slewing ring

Motor
bearing

Pulley
Block

Sliding
Bearings

Articulated
points of
brake lever

All the motors

Pulleys and guiding


pulley in the hoisting
winch

Sliding bearings in the


trolley
traveling
mechanism and drum

All the
points

articulated

ZG-2
WinterCalcium-based grease

1500

ZG-2
ZG-5
Summer Calcium-based

Change the grease after


working for 1500 hrs.

grease ZG-5

WinterZG-2

SummerZG-5

WinterZG-2

SummerZG-5

Machine oil

240

Change the grease after


working for 240 hrs.
160

Add
grease
after
working for 160 hrs, and
conduct cleaning half a
year
56

Fill oil after working for


56 hrs

TC5613-6

2.4-8

Two
articulated
points
between jib
and tower
section

Fall-change
Device

All the motion parts


and guiding groove

10

Gear
connector

All the
points

11

Calcium-based grease ZG-2


(ZG-5)

Before dismantle
installation

160

Machine oil

All the connectors of


mechanisms
and
gears

Pump
station of
hydraulic
erection

articulated

ZG-2 (ZG-5)

Oil tank

Calcium-based grease

ESSO AW46
American ESSO AW46

or

Fill oil after working for


160 hrs

Grease
season

once

after

200
2400

Add filtered grease after


working for 200 hrs
and change the grease
after working for 2400
hrs.

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

TC

Appendix

Anti-drop device of jacking system

According to the national standard requirements, Zoomlion tower cranes are


equipped with anti-drop device of jacking system. During adding tower sections or
lower tower sections, the device must be used.

The anti-drop device consists of the thumb latches on the jacking beam and the
anti-drop holes on the climbing lugs of tower sections. The usage method as following:
1.

During adding tower sections or lower tower sections, put the thumb latches in the
anti-drop holes and fix the in the fore groove.
2.

After finishing a jacking step, the thumb latches must have been moved away from
the anti-drop holes befor puting the jacking beam away from the climbing lugs.
Otherwise the latches are damaged.

TC

Appendix

safety indications

When adding or subtracting tower sections,


placed the pin of climbing beam in the hole of
tower sections and fixed the safe pin in the
pin hole of tower sections.

Watching

Take care objects to fall

forbid to stand

TC

Appendix

installing anemoscope

1. 1
installs the anemoscope at the position of
figure 1.
2.
the monitor of the wind speed installed in
the control-plate of the operator cab.
3.
5051 AC230V
the power lines of the anemoscope are
connected to the 50 51 ports of the
control-cabnet of the operator cab.

Figure 1


Table for Parts Lubrication
1 Table1

No.

Parts Description

Lubricating location

Lubricant specifications

Lubricating method & duration

Lubricated by

Lubricating date

Hoisting rope

Wire rope

Trolley rope

Reducer of
hoisting winch

Reducer

Reducer of
slewing mechanism

Reducer of trolleying
mechanism

Rolling bearings in the reducer.

Graphite Calcium-based grease

Grease the rope after working for a

ZG-SSY1405-65

week, and boil the grease after


overhaul or medium maintenance.

( 10)N220

Summer(over 10C) with N220 gear oil

240 1500

( 10)N150

Lubricate the reducer after it serves for

Winter(below 10C) with N150 gear oil

240 hrschange the oil after working

-2 ZL-2

for 1500hrs.

Sulphur

molybdenum-2#

Drum bearing

Rolling Bearing

ZL-2#

lithium-based grease

Calcium-based grease
160 ,

or

ZG-2

Grease the bearings each after they


work for 160 hrs, clean them once after

Hook bearings

Calcium-based grease

Slewing ring

half a year.

No.

Parts Description

Lubricating location

Lubricant specifications

Lubricating method & duration

Lubricated by

ZG-2
4

Motor bearing

All the motors

WinterCalcium-based grease ZG-2


ZG-5
SummerCalcium-based grease ZG-5

Pulley Block

Pulleys and guiding pulley in

ZG-2
WinterZG-2
ZG-5

1500
Change the grease after working for
1500 hrs.

240
Add the grease after working for 240
hrs.

the hoisting winch

SummerZG-5

ZG-2

160

WinterZG-2

Sliding Bearings

Sliding bearings in the trolley

ZG-5

Add grease after working for 160 hrs,

traveling mechanism and drum

SummerZG-5

and conduct cleaning half a year

ZG-2 (ZG-5)

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

Before dismantle or installation

160

Machine oil

Fill oil after working for 160 hrs

Two articulated
points between jib

All the articulated points

and tower section

Fall-change
Device

All the motion parts and


guiding groove

Continuation Table 1

Lubricating
date

Continuation Table 1

No.

Parts Description

Lubricating location

Lubricant specifications

Lubricating method & duration

Lubricated by

Lubricating date

Articulated points

All the articulated points

56

Machine oil

Fill oil after working for 56 hrs

Calcium-based grease

Grease once after a season

of brake lever

10

Gear connector

All the connectors of


mechanisms and gears

200

11

Pump station of
hydraulic erection

Oil tank

ESSO AW46

2400

American ESSO AW46

Add filtered grease after working for


200 hrs and change the grease after
working for 2400 hrs.


Table 1 for Parts check
2 Table 2

No.

Parts Description

Checking duration

Notes

Checked by

Checking date

Parts state and method to settle

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

Make sure of no looseness or disengagement before

each shift

operation start.


Table 2 for Parts check
3 Table 3

No.

Parts Description

Checking duration

Notes

Checked by

Checking date

Parts state and method to settle

The high-strength bolt joints and


the nearby material, the tower

Especially the connecting plates and the nearby

Every month

material of the tower head and slewing mast, the bolts


of three tower sections on the foundation if the tower

head and slewing mast.

crane is not anchored to the building, or the tower


sections nearby the anchored point if it is anchored

The connecting plates and the

Every three months

nearby material

When

The climbing lugs and the beam

lowering down the

of the Climbing Mechanism

tower sections every

adding

or

time

Continuation Table 3

No.

Parts Description

Checking duration

Notes

Checked by

Checking date

Parts state and method to settle

Check all bolts 2

High-strength bolts

times in a week, then

23

one time in a week,

Dismantle 2-3 bolt groups each year and check them

then one time in two

for deformation, corrosion, rust, etc.

weeks, and then one


time in a month after
erecting

the

tower

crane.

1.

Watch over their visible parts as much as possible on


each workday so as to find any damages and
6

Wire rope

Every week

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.


CHANGSHA ZOOMLION HEAVY INDUSTRY SCIENCE & TECHNOLOGY DEVELOPMENT CO. LTD

361
Headquarter Address361 YinpensRoad. Changsha,Hunan,China
PC: 410013

FAX: +86-731-8928101

E-mail:

yxglb@zlzk.com

TEL

+86-7318928166

http://www.zoomlion.com
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