Zoomlion Tower Crane Instrcution W450 25HC 138EN A01 220726

[En]
W450-25HC Tower Crane

Instruction Manual
W450-25HC-138EN-A01
W450-25HC-138EN-A01
Manufacturer:
Zoomlion Heavy Industry Science & Technology Co., LTD
No.658, Zoomlion Lugu Industrial Park
CN-410205 Changsha, Hunan
P.R. China
Contact us:
Home page: en.zoomlion.com
Email：tc_customercare@zoomlion.com
熊洁文 2022-07-26
W450-25HC-138EN-A01 INTRODUCTION
INTRODUCTION
This document has been issued for the crane as defined at the time of ordering. Please read
carefully the instructions therein before any crane operation.
Make sure that one complete copy of this document is always present at the location provided
for on the crane, especially in case of crane rental or resale.
The safety signals, rating plates and instruction plates as well as this document are integrated
part of the crane. In case of loss or damage of this instruction material you have order a new one
from the manufacturer indicating the serial number and the crane type.
IMPORTANT: In case of a technical crane modification, please make sure that this instruction
material will be updated.
The present document is only usable in complete original version or in complete reproduction.
ZOOMLION denies all responsibility concerning the consequences of using a partial reproduction
or an adaptation of the present document.
This document consists of 7 parts. The “safety instructions” part must compulsorily be read and
under-stood by every operator. The other parts give specific instructions to the concerned
operators for doing their tasks.
Part name Part intended for:
1 DOCUMENTS The crane operator
2 SAFETY INSTRUCTION Everybody
3 TECHNICAL DATA OF CRANE AND SITE Everybody
4 ERECTION/ADJUSTMENT/DISMANTLING The fitter
5 OPERATION AND CONTROL The crane driver
6 MAINTENANCE AND INSPECTION The maintenance technician
7 SPARE PARTS Everybody
1
INTRODUCTION W450-25HC-138EN-A01
Development of the technical instructions
ZOOMLION reserves the right, without prior notice, to improve the content and the form of this
document. For each technical modification ordered or carried out after delivery, an updating
will be supplied. On receipt of these new chapters, please insert them at the indicated space.
Warnings
The safety rules and the important observations which you must compulsorily observe are
marked in the various parts of this documents by the following symbols:
Signaling of an important risk of body injuries and even mortal danger, if

the described instructions are not observed.
Indicates the risk of equipment damage if the described instructions are

not observed.
Important information
Note
2
W450-25HC-138EN-A01 TOWER CRANE VOCABULARYS
TOWER CRANE VOCABULARYS
Composition Diagram of the Tower Crane
(1) Foundation (2) Outrigger

(3) Base tower section (4) Tower section
(5) Climbing equipment (6) Climbing mechanism
(7) Climbing hydraulic cylinder (8) Pump station
(9) Transition section (10) Erection platform
(11) Mounting device (12) Cabin
(13) Slewing mechanism (14) Slewing support
(15) Slewing ring (16) Turntable
(17) Counter ballast (18) Derrick
(19) Hoisting mechanism (20) Counter jib
(21) Jib (22) Trolley mechanism
(23) Trolley (24) Hook
3
GRAPHIC SYMBOLS W450-25HC-138EN-A01
GRAPHIC SYMBOLS
SYMBOLS SUBJECT
FORBIDDEN
STOPPING THE MOVEMENT
COMPULSORY SAFETY HARNESS
AUTHORIZED
PARALLEL
LEVEL
LISTEN
WEATHERVANING
4
W450-25HC-138EN-A01 GRAPHIC SYMBOLS
SYMBOLS SUBJECT
SLEWING
SLEWING TO LEFT
SLEWING TO RIGHT
HOISTING
HOISTING
LOWERING
TROLLEYING
TROLLEY OUT
TROLLEY IN
5
GRAPHIC SYMBOLS W450-25HC-138EN-A01
SYMBOLS SUBJECT
TRAVELLING FORWARD
TRAVELLING BACKWARD
CREEP SPEED
LOW SOEED
HIGH SPEED
SM (2-fall rope reeving, used in 2-fall)
DM (4-fall rope reeving, used in 4-fall)
TIGHTEN-LOCK-PRESS
LOOSEN-UNLOCK
6
W450-25HC-138EN-A01 METRIC SYSTEM AND IMPERIAL SYSTEM
METRIC SYSTEM AND IMPERIAL SYSTEM
1. CORRESPONDENCES
1. 1. GEOMETRIC UNITS
Metric system Imperial system
Values
Unit Symbol Unit Symbol
Lengths − distances
inch in 1 m = 39,3700787 in
foot ft 1 m = 3,2808399 ft
meter m
yard yd 1 m = 1,0936133 yd
mile mi 1 m = 0,0006214 mi
Area or surface
cubic inch in2 1 m2 = 1 550,0031 in2
square meter m2 cubic foot ft2 1 m2 = 10,7639104 ft2
cubic yard yd2 1 m2 = 1,195990 yd2
Volume
cubic inch cu in / in3 1 m3 = 61 023,7438368 in3
cubic meter m3 cubic foot cu ft / ft3 1 m3 = 35,3146666 ft3
cubic yard cu yd / yd3 1 m3 = 1,3079506 yd3
Flat angle
radian 1 r = 2 π rad
revolution r
degree 1 r = 360 °
radian 1 ° = 0,0174533 rad
degree ° minute 1 ° = 60’
second 1 ° = 3600”
7
METRIC SYSTEM AND IMPERIAL SYSTEM W450-25HC-138EN-A01
1. 2. MECHANICAL UNITS
Values
Flow rate
mile per hour mph 1 m/s = 2,2369 mph
meter per second m/s foot per second ft/s 1 m/s = 3,28084 ft/s
inch per second in/s 1 m/s = 39,3701 in/s
Radian frequency
radian per second rad/s radian per second rad/s 1 rad/s = 1 rad/s
revolution per
r.p.m. revolution per minute rpm 1 tr/min = 1 rpm
minute
Acceleration
meter per square
m/s2 foot per square second ft/s2 1 m/s2 = 3,2808399 ft/s2
second
Force
kilogram force kgf 1 daN = 1,0197162 kgf
Newton N
pound force lbf 1 daN = 2,248 lbf
Moment of force
1 N·m = 0,7375621
Newton meter N·m force pound foot lb−ft
lb−ft
Energy, work, quantity of heat
Joule J Watt−second Ws 1 J = 1 Ws
Power
Joule per second J/s 1 W = 1 J/s
kg−force meter per kgf, 1 W = 6,1182973
Watt W
minute m/min kgf.m/min
horsepower (metric) hp 1 W = 0,00135962 hp
Pressure, stress
1 Pa = 0,000145038
pound per square inch psi
psi
bar bar 1 Pa = 0,00001 bar
Pascal Pa kg−force per square 1 Pa = 0,1019716
kgf/m2
meter kgf/m2
Newton per square
N/cm2 1 Pa = 0,0001 N/cm2
centimeter
8
1. 3. MASS UNITS
Values
Mass
pound lb 1 kg = 2,2046226 lb
kilogram kg
ton (short) ton 1 kg = 0,0011023 ton
Mass per unit length
pound per inch lb/in 1 kg/m = 0,055997 lb/in
kilogram per meter kg/m pound per foot lb/ft 1 kg/m = 0,6719689 lb/ft
pound per yard lb/yd 1 kg/m = 2,015905 lb/yd
Surface mass
pound per square 1 kg/m2 = 0,2048161
lb/ft2
foot lb/ft2
kilogram per pound per square 1 kg/m2 = 0,0014223

square meter kg/m3 lb/in2
inch lb/in2
pound per square 1 kg/m2 = 1,8433451
lb/in2
yard lb/yd2
Density
pound lb 1 kg = 2,2046226 lb
kilogram kg
ton (short) ton 1 kg = 0,0011023 ton
Mass per unit length
kilogram per meter kg/m pound per inch lb/in 1 kg/m = 0,055997 lb/in
9
METRIC SYSTEM AND IMPERIAL SYSTEM W450-25HC-138EN-A01
1. 4. UNITS OF TIME
Values
Time (duration)
second s second s
minute min minute min 1 min = 60 s
hour h hour h 1 h = 60 min = 3600 s
day j day d 1 d = 24 h = 1440 min
Frequency
Hertz Hz Hertz Hz 1 Hz = 1 s−1
1. 5. EECTRIC UNITS
Values
Strength
Ampere A Ampere A
Voltage
Volt V Volt V
Power
Volt−Ampere VA Volt−Ampere VA
kiloVolt−Ampere kVA kiloVolt−Ampere kVA
Watt W Watt W
Electric resistance
Ohm Ω Ohm Ω
Quantity of electricity, load
Coulomb C
Coulomb C
Ampere·hour Ah 1 Ah = 3600 C
Capacity
Farad F Farad F
10
1. 6. THERMAL UNITS
Values
Temperature
Kelvin K °K = (°F + 459,7)/1,8
kelvin K Celsius C °C = 5/9 * (°F − 32)
Fahrenheit F °F = (9/5 * °C) + 32
1. 7. ACOUSTIC UNITS
Values
Sound pressure and acoustic power
decibel dB(A) decibel dB(A) 1dB=0.1B
2. EQUALITY BETWEEN FREQUENTLY USED UNITS

2. 1. LENGTHS−DISTANCES
1 centimeter (cm) = 10 millimeters (mm) = 0,3937008 inch (in)
1 decimeter (dm) = 10 centimeters (cm) = 3,937008 inches (in)
1 meter (m) = 10 dm = 100 cm = 1,0936133 yards (yd)
1 kilometer (km) = 1 000 meters (m) = 0,6213712 mile (mi)
Imperial system Metric system
1 inch (in) = 2,54 cm
1 foot (ft) = 12 inches (in) = 30,48 cm
1 yard (yd) = 3 feet (ft) = 36 inches (in) = 0,9144 m
1 mile (mi) = 1 760 yards (yd) = 1,609344 km
11
CONTENTS W450-25HC-138EN-A01
CONTENTS
INTRODUCTION ................................................................................................................... 1
TOWER CRANE VOCABULARYS ....................................................................................... 3
GRAPHIC SYMBOLS............................................................................................................ 4
METRIC SYSTEM AND IMPERIAL SYSTEM ....................................................................... 7
CONTENTS ......................................................................................................................... 12
1 DOCUMENTS.......................................................................................................................... 18
1.1 Sound pressure ............................................................................................................. 18
1.2 Commissioning report ................................................................................................... 19
2 SAFETY INSTRUCTION ......................................................................................................... 20
2.1 Foreword ....................................................................................................................... 20
2.2 Safety instructions ......................................................................................................... 21
General conditions of use ................................................................................... 21
Safety signaling ................................................................................................... 34
Safety controls .................................................................................................... 37
2.3 Storm wind speed-out of service ................................................................................... 38
General Notes ..................................................................................................... 38
Speed table ......................................................................................................... 38
3 TECHNICAL DATA OF CRANE AND SITE ............................................................................. 39
3.1 Foreword ....................................................................................................................... 39
3.2 Technical characteristics ............................................................................................... 39
Load curves......................................................................................................... 40
Characteristics of the mechanisms ..................................................................... 45
3.3 Mast composition .......................................................................................................... 49
General notes...................................................................................................... 49
Mast composition ................................................................................................ 50
3.4 Dimensions and weight ................................................................................................. 51
Slewing crane parts ............................................................................................ 51
Mast .................................................................................................................... 57
3.5 Auxiliary lifting equipment .............................................................................................. 59
3.6 Data sheet ..................................................................................................................... 61
Hoisting rope ....................................................................................................... 61
Trolley rope ......................................................................................................... 62
Data sheet of hook .............................................................................................. 63
3.7 Counter-jib ballast ......................................................................................................... 64
General notes...................................................................................................... 64
Configuration ....................................................................................................... 64
Fabrication .......................................................................................................... 64
12
W450-25HC-138EN-A01 CONTENTS
3.8 Foundation .................................................................................................................... 72

Calculation of stationary foundation ................................................................... 72
Foundation drawing of the tower crane .............................................................. 73
Loads on foundation of crane ............................................................................. 78
3.9 Power supply ................................................................................................................ 89
Definition ............................................................................................................. 89
Current supply .................................................................................................... 90
4 ERECTION/ADJUSTMENT/DISMANTLING........................................................................... 94
4.1 Foreword ....................................................................................................................... 94
4.2 Note on safety regarding erection ................................................................................. 95
Erection instructions ........................................................................................... 95
Fitting the split pins ............................................................................................. 96
Fitting the high-strength bolt ............................................................................... 97
The diagram of erection ...................................................................................... 98
4.3 Installing the tower section ......................................................................................... 102
Base tower section (X25G1816RaA) ............................................................... 102
Tower section (X25G1816) ............................................................................... 103
4.4 Installing the climbing system ..................................................................................... 104
Climbing equipment .......................................................................................... 104
Installing the climbing system ........................................................................... 105
4.5 Installing the transition section and mounting system ................................................ 106
Assembling the mounting device to transition section ...................................... 106
Assembling erection platform ........................................................................... 106
Installing transition section mounting device and erection platform ................. 108
4.6 Installing the slewing assembly .................................................................................. 109
Description ........................................................................................................ 109
Installing slewing assembly ............................................................................... 111
4.7 Mounting the counter-jib ..............................................................................................112
Description .........................................................................................................112
Installing the counter-jib .....................................................................................113
Installing one 3.9t counter weight ......................................................................115
4.8 Installing the jib assembly ............................................................................................116
Assembling the jib ..............................................................................................116
Installing the jib Ⅰ, Ⅱ assembly .......................................................................118
Hoisting the assembly of rest jib sections .........................................................119
Installing the assembly of rest jib sections ....................................................... 120
Installing the wind-sail plates ............................................................................ 121
4.9 Installing the counter-ballast ....................................................................................... 123
4.10 Installing the electrical control system ...................................................................... 124
4.11 Circling the ropes ...................................................................................................... 125
13
Circling the trolley ropes .................................................................................. 125

Circling the hoisting rope ................................................................................. 125
Power connection and test run ........................................................................ 127
4.12 Fall-changing system ................................................................................................ 128
Description ...................................................................................................... 128
Method for 2-fall to 4-fall conversion ............................................................... 129
Method for 4-fall to 2-fall conversion ............................................................... 130
4.13 Climbing operation .................................................................................................... 131
General Notices of Climbing Operation .......................................................... 131
Pre-climbing preparation ................................................................................. 132
Installing the tower section on the mounting device ....................................... 132
Keep the tower crane in balance before climbing ........................................... 133
Climbing operation .......................................................................................... 135
4.14 Tower anchored onto the building ............................................................................. 140
Description ...................................................................................................... 140
Arrangement of the attachment frame ............................................................ 143
4.15 Safety devices ........................................................................................................... 145
Foreword ......................................................................................................... 145
Table adjustments of safety devices ............................................................... 146
Load moment limiter ....................................................................................... 147
Load limit switch .............................................................................................. 162
Multifunction limiter ......................................................................................... 166
4.16 Tower crane tests ...................................................................................................... 177
Function test without load ............................................................................... 177
Load tests........................................................................................................ 177
4.17 Dismantling ................................................................................................................ 181
General notes.................................................................................................. 181
Dismantling sequences ................................................................................... 182
Dismantling ..................................................................................................... 182
5 OPERATION AND CONTROL............................................................................................... 185
5.1 Foreword ..................................................................................................................... 185
5.2 Attention for operation ................................................................................................. 185
5.3 Specific safety instructions .......................................................................................... 186
5.4 Instruction of control unit ............................................................................................. 187
Console ............................................................................................................. 187
Driving box ........................................................................................................ 191
Main control cabinet .......................................................................................... 193
Electric resistance box ...................................................................................... 195
Video monitoring system (optional)................................................................... 195
5.5 Frequency converter self-learning............................................................................... 196
14
HuiChuan frequency converter ......................................................................... 196

ABB frequency converter .................................................................................. 197
5.6 Operation .................................................................................................................... 200
5.7 Putting into service...................................................................................................... 201
Checks to be carried out before operation ....................................................... 201
Checks to be carried out after erection ............................................................ 204
Operating instructions ....................................................................................... 204
6 MAINTENANCE AND INSPECTION .....................................................................................211
6.1 Lubrication ...................................................................................................................211
Lubricants table ................................................................................................ 212
Lubrication for bearing ...................................................................................... 213
6.2 Safety notes ................................................................................................................ 213
Requirement on personnel ............................................................................... 213
Safety measures ............................................................................................... 214
Protective equipment for personnel .................................................................. 214
6.3 Required maintenance and inspections...................................................................... 214
6.4 Hoisting mechanism.................................................................................................... 217
Overview ........................................................................................................... 217
Adjustment and maintenance of the brake ....................................................... 218
Maintenance of the motor ................................................................................. 226
Maintenance of the reducer .............................................................................. 227
Coupling............................................................................................................ 229
6.5 Method of Rope Arrangement Problem of Hoisting Mechanism................................. 230
6.6 Trolley mechanism ...................................................................................................... 232
Overview ........................................................................................................... 232
Limiter of trolley mechanism ............................................................................. 233
Trolley brake ..................................................................................................... 234
Maintenance for motor ...................................................................................... 238
Oil adding of the reducer .................................................................................. 239
6.7 Slewing mechanism .................................................................................................... 239
Overview ........................................................................................................... 239
Slewing brake ................................................................................................... 240
Maintenance for slewing ring ............................................................................ 248
6.8 Maintenance climbing mechanism.............................................................................. 249
Working principle .............................................................................................. 249
Erection, operation, and maintenance of the hydraulic pressure system......... 251
6.9 Rope............................................................................................................................ 254
Basic Knowledge of Rope ................................................................................ 254
Rope List........................................................................................................... 260
The length of the rope....................................................................................... 261
15
Installation of the Rope ..................................................................................... 263

Discard Criteria of Rope .................................................................................... 264
Maintenance of Rope ........................................................................................ 270
6.10 Maintenance of pulley assembly ............................................................................... 271
Examination of pulley assembly...................................................................... 271
Pulley scrap..................................................................................................... 271
6.11 The high strength bolts .............................................................................................. 273
Basic knowledge of the high strength bolt....................................................... 273
Checking the bolts and bolt connection sets ................................................... 273
Lubricating the high strength bolt assembly .................................................... 273
Recycling the high strength bolt ...................................................................... 274
6.12 Steel structure ........................................................................................................... 275
Foreword ......................................................................................................... 275
Description ...................................................................................................... 275
Description ...................................................................................................... 276
Maintenance.................................................................................................... 276
6.13 Pins and holes of the tower section .......................................................................... 280
6.14 Hook .......................................................................................................................... 282
Check the locking of the hook ......................................................................... 282
Opening Degree of the Hook .......................................................................... 282
Wear ................................................................................................................ 283
Corrosion......................................................................................................... 283
Check hook anti-tripping device ...................................................................... 283
Oil hook bearing .............................................................................................. 283
6.15 Trolley ........................................................................................................................ 284
Routine inspection of trolley rollers ................................................................. 284
Routine inspection of side rollers of trolley ..................................................... 284
6.16 Maintenance of electronic control system ................................................................. 285
Electrical equipment inspection ...................................................................... 285
Maintenance for safety device ........................................................................ 288
6.17 Spare parts list .......................................................................................................... 289
Spare parts list of mechanism......................................................................... 289
Spare parts list of electrical control system .................................................... 290
Spare parts list of structure ............................................................................. 291
6.18 Appendix troubles and troubleshooting ..................................................................... 292
7 SPARE PARTS ...................................................................................................................... 303
7.1 Foreword ..................................................................................................................... 303
7.2 Examples of an “ASSEMBLY” parts list ...................................................................... 304
Jib ...................................................................................................................... 306
Trolley ................................................................................................................ 328
16
Hook ................................................................................................................. 334

Counter Jib ....................................................................................................... 338
Derrick .............................................................................................................. 346
Turntable ........................................................................................................... 348
Slewing Support................................................................................................ 350
Hoisting Mechanism ......................................................................................... 352
Trolley Mechanism ............................................................................................ 355
Slewing Mechanism ........................................................................................ 358
Climbing Equipment ........................................................................................ 362
Climbing Mechanism ...................................................................................... 365
Transition Section ........................................................................................... 366
Mounting Device ............................................................................................. 368
Erection Platform ............................................................................................ 370
Mast (Incline ladder) ....................................................................................... 372
Outrigger ......................................................................................................... 377
17
DOCUMENTS W450-25HC-138EN-A01
1 DOCUMENTS
1.1 Sound pressure
The sound pressure (LpA) is measured at the level of the crane driver’s ears by means of a
microphone under the most unfavorable conditions: noisy winch, short counter-jib.
Cranes with cabs:

Air conditioning at maximum level, windows closed, hoisting mechanism at low speed,
hoisting/lowering with maximum load.
Air conditioning at maximum level, windows closed, hoisting mechanism at high speed,
hoisting/lowering without load.
The highest value is taken for determining the sound pressure at the control unit.
Cranes with radio control:

The sound pressure level is given for a control unit which is at least 15 m away from the hoisting
mechanism.
Sound pressure level measured in the cab or on the ground:

Crane with winch in the
LpA (dBA) Crane with winch in the jib
counter - jib
Not soundproof cab V140C Sound pressure level = 79 Sound pressure level = 72
or V140S dB(A) dB(A)
Sound pressure level = 76 Sound pressure level = 70
Sound proof cab V140SX
dB(A) dB(A)
Sound pressure level lower
Control from the ground
than 70 dB(A)
18
W450-25HC-138EN-A01 DOCUMENTS
1.2 Commissioning report
19
SAFETY INSTRUCTION W450-25HC-138EN-A01
2 SAFETY INSTRUCTION
2.1 Foreword
The Safety Instructions describe the measures to be observed in order to reduce the risk of
personal or material accidents when operating a crane. They are of utmost importance and must
be consulted, comprehended, and applied by all parties intervening on the crane. A version
translated into the language understood by the person consulting those instructions shall be
supplied by the crane manager, if necessary.
Safety instructions figuring in the present chapter and based on the current state of knowledge
at the time of their establishment are to be considered as simple guide−lines for the reader:
ZOOMLION cannot anticipate in an exhaustive manner all the dangerous situations that may
arise. Consequently, safety operation of the crane is a responsibility incumbent to yourselves.
Local regulations that are valid at moment of crane utilization may stipulate adherence to
instructions that are more stringent than the present instructions, in which case those local
regulations shall prevail.
The crane is a hoisting device destined for handling suspended loads on a protected operational
site. It shall consequently be used exclusively for that purpose (cf. general utilization conditions
chapter).
The crane has been designed in compliance with EC directives concerning safety, and to be used
by professionals that are physically apt and qualified for the operation, assembly, piloting, and
maintenance of this type of equipment (identified in the present manual as “competent persons”).
These persons must know the technical data (part 3 of this document) so as not to exceed the
utilization limits described in this manual.
The illustrations of this part are general and do not correspond to your crane.
20
W450-25HC-138EN-A01 SAFETY INSTRUCTION
2.2 Safety instructions

General conditions of use
The purpose of these general conditions is to explain the conditions indicated in part 3 of this
“TECHNICAL DATA OF CRANE AND SITE” manual. In the event of unforeseen conditions,
please contact us.
Certain critically important information on crane driving is represented in illustrated form in part
4”ERECTION/ADJUSTMENT/DISMANTLING” of the present manual.
Climatic and geographical conditions

A. Wind
Out of service, the crane operating conditions, i.e.: free standing height, ballast, reaction, and pressure
under slab are determined by the storm reference wind speed measured at the crane installation site.
The storm wind speeds are described in the chapter “Storm wind speed − out of service”.
a) Specific conditions
Some conditions or configurations require prior study on your part to determine the storm
reference wind speed to be accounted for at the crane installation site. Please contact us when
in possession of such data.
These conditions are:
◼ absence of map
◼ national or local regulations
◼ altitude higher than that indicated on your map if that is specified
◼ bottom of hollow, narrow valley, hill top
◼ isolated hill or mountain
◼ cliff top
crane installed on a building
◼ constructions: refer to the examples below
21
b) Table for determination of crane operating conditions
c) Assembly, dismantling, change of configuration

Assembly, dismantling, change of configuration operations are possible only if the maximum wind
speed (gust) measured at top of crane (cathead or strut) is lower than 50 km/h (warning: mean
wind speed of approximately 35 km/h can exceed 50 km/h in gusts).
d) Crane in service
Use of the crane is possible only if the maximum wind speed (gust) measured at top of crane
(cat head or strut) is lower than 72 km/h (warning: mean wind speed of approximately 50 km/h
can exceed 72 km/h in gusts).
e) Surface exposed to the wind of the load handled

The surface exposed to the wind of the loads handled is considered as being less than or equal
to 1 𝑚2 /t. If this value exceeded, the “in service” wind speed must be limited to a value lower
than 72 km/h. The value to be taken into accounting is given in the table “Maximum admissible
wind speed for a load surface higher than 1 sq. m/t” (see part 3 “TECHNICAL DATA OF CRANE
AND SITE”).
For surface areas greater than those provided in the table, please consult us.
22
B. Ambient air temperature measured under cover
This corresponds to the temperature measured within a non−closed shelter,

protected from wind and rainfall, located 2 m above ground and within a max.
100 m radius.
Except for specific provisions defined by contract (E.g.: country specifications), the range of
temperatures for crane use is as follows:
◼ Crane in service: −20°C to +40°C:
In case of temperatures out of the above range, cease any work with the
crane (risk of malfunctioning or destruction of the components by
abnormal overheating).
◼ Crane out of service: −25°C to +55°C:
In the case of planned temperatures out of the above range, it is

preferable to dismantle the crane. In every case, apply the instructions
concerning the extended standstill of the crane in the maintenance part.
C. Humidity / rainfall
The maximum rate of humidity for crane use (in service and out of service) is of 95% without
condensation, excepting specific contractual provisions.
The maximum rate of humidity for a stored crane (dismantled) is of 95%.
D. Frost, ice, or snow

Frost, ice, or snow increase the weight of the structure and its surface exposed to wind. Those
conditions may generate damage to moving parts. They can also cause personnel to fall when
accessing the drivers stand.
It is strongly recommended to avoid using a crane when the latter is

covered with frost, ice, or snow.
E. Lightning
Lightning can generate current circulation in the crane framework and lead to a risk of
electrocuting any person in direct or indirect contact with the crane. E.g.: on part of the steel
structure, on a ladder, on ground when touching the crane or load.
Lightning may interfere with the operating of radio controls.
23
In the event of risk of storm, cease work and set crane to idle mode. Do
not access the crane during a storm.
In the case where the driver does not have time to leave the crane (sudden
storm), he should never attempt to leave the crane during the storm. The driver
runs less risk if he stays in the driving cab if he avoids touching any controls.
F. Sand storms
After a sand storm, sand may have penetrated internal electrical and mechanical elements and
plugged orifices.
Before restarting the crane, completely clean the electrical and

mechanical elements and remove moving parts if necessary.
G. Flooding / tidal waves

The above conditions are not accounted for, excepting specific contractual provisions.
In the case of flooding or tidal waves crane stability is reduced, thus cease any work with the
crane.
H. Earthquake
The crane is not designed to be seismic−resistant whatever the magnitude of the earthquake,
excepting specific contractual provisions.
I. Special installations
The crane is not designed to be installed on moving foundations such as off−shore platform,
barge, floating bin, etc. excepting specific contractual provisions.
J. Crane supports
Crane supports shall be designed to withstand the forces indicated in the crane technical data
and implemented in strict compliance with the tolerances provided.
Conditions relative to crane design

A. Appropriateness of crane to the operating site
Appropriateness of the crane to the operating site is incumbent to the user.
B. Crane power supply

The crane has been designed to work with a power supply the values and tolerances of which
must be strictly adhered to (cf. power supply chapter in part 3 “TECHNICAL DATA OF CRANE
AND SITE”).
24
Non−adherence to the values indicated can lead to malfunctioning of the

crane.
C. Driver control stand

According to options, the crane is driven from the cab or the control station on the ground. Driving
can be radio−controlled or remotely controlled.
Safety devices (force, movement, speed limiters) prohibit use of the crane out of its normal
operating conditions.
D. Safety devices
Safety devices (force, movement, speed limiters) prohibit use of the crane out of its normal
operating conditions.
Never modify safety device settings, nor hinder their functioning or

neutralize them.
E. Load indicator
The load indicator shall not be employed as a measurement tool.
F. Protective elements
Protective elements or devices prohibit access to dangerous areas. They must never be
suppressed.
Never start up a crane before all the protective elements (e.g.: housings,
life−lines, handrails, trap−doors etc...) are set in place.
G. Nominal crane life duration

The nominal crane life duration corresponds to the minimum life duration accounted for when
calculating the crane fatigue factor.
Except for specific contractual provisions, that nominal life duration is in conformity with the
classification FEM 1.001 version 3.
It is evaluated separately and differently for the complete crane and its individual mechanisms.
H. Nominal steel structure life duration

This is expressed in hoisting cycles (1 hoisting cycle = hoisting of a load, slewing and/or trolleying
of that load, lowering for laying down).
The classification group for single tower cranes is A3.
25
I. Nominal mechanism life duration

This is expressed in operating hours of the given mechanism.
The classification group for mechanisms depends on the type of crane and the given movement.
The classification group determines a nominal life duration according to mechanism
load−supporting state.
The different values above are provided in part 3 of the “TECHNICAL DATA OF CRANE AND
SITE” manual.
J. Mechanism working factor

The mechanism working factor is expressed by the percentage of: mechanism usage time /
mechanism usage time + rest time) measured over 20 cycles per hour.
The working factor indicated for mechanisms in part 6 of the “MAINTENANCE AND INSPECTION”
must in no case be exceeded.
K. Weathervane
The crane shall be able to weathervane through 360°. If that is not possible, please consult us.
L. Customer advertising plates

The dimensions of these plates shall not exceed planned dimensions.
Installation of advertising plates in areas other than those specifically provided is prohibited
without the written authorization of the manufacturer.
Attachment of plates is entirely incumbent to the customer.
M. Fire extinguisher
The supply and implementation of a fire extinguisher in the cab is incumbent to the user.
N. Modifications of the crane / welding

Without written agreement of the manufacturer, it is prohibited:
➢ to modify crane construction (E.g.: addition or renovation d of elements, blow−torch work,
welding, etc...),
➢ to adapt non−authorized accessories,
➢ to modify crane settings (E.g.: modification of pressures, tares, adjustment values, etc...),
➢ to perform welding operations on the crane.
Welding work under the load is prohibited if the load is not secured by
electrically insulated slings.
26
O. Adaptation of equipment / Replacement of parts

Any adaptation of equipment not supplied or recommended by the manufacturer and any
replacement by parts which are not genuine spare parts or parts authorized by the manufacturer
will be carried out under the entire responsibility of the user.
The user also has the responsibility for the consequences of these adaptations and replacements.
P. Surveillance of the crane / verifications

To ensure the crane is monitored, is kept in good working order, and is used safely, it shall be
submitted to the verifications (frequent, periodical, and extended) described in part 6,
“MAINTENANCE AND INSPECTION”.
If they are stricter, the verifications and directives related to local regulations shall take priority
over the instructions in this manual.
Update the crane’s maintenance records according to the instructions supplied in the manual.
Q. Scrapping
Eliminate all used products such as oil, grease, batteries in conformity with the regulations
prevailing at the site where the crane is used.
Crane installation conditions

A. Distance between crane and fixed obstacle
Adhere to the minimum regulatory distance between the pointing mobile part of the crane and
fixed obstacles. In the absence of regulations, that distance shall be of at least 0.5 m on ground
and 2 m for above ground elements.
B. Distance between crane and overhead electric line

Adhere to the safety distances imposed by the regulations at the operating site, concerning
hoisting devices with suspended loads, between crane elements and overhead electric lines. In
the absence of regulations, that distance shall be of at least 3 meters for voltages less than or
equal to 50000 V, with the addition of 1cm per additional 1000 V above 50000 V.
C. Distance between 2 cranes

If several cranes are close to each other, the minimum safety distance between any individual
part of a crane or its load must be greater than 2 m in relation to any individual part or load of
another crane.
D. Safety distance at track extremities

Adhere to the safety distances imposed by the regulations at the operating site concerning
hoisting devices with suspended loads, for track extremities.
In the absence of regulations, provide for a track length exceeding the end position planned for
the crane by 6m, in order to account for the stopping distance and the safety distances for
installation of end dampers.
27
E. Aircraft limiting lights

Use of the crane in areas close to airports or aerodromes, in the aircraft taking off or landing
cone, dictates the necessity of daytime and/or nighttime limiting light installations.
Apply the regulations prevailing at the operating site.
Handling conditions
A. Handling equipment
The crane is destined for load handling with use of its hook.
The use of any hoisting equipment generating dynamic effects such as, for example,
electromagnets, clutches, hammers, gathering buckets is prohibited.
B. Load handling
◼ Never hoist an incorrectly secured load.

◼ Never drag a load in oblique direction. The load must always be
hoisted in line with the trolley.
◼ Never hoist a load adhering to the ground or other elements.
◼ Never increase the weight of a load when suspended on the hook.
◼ Never swing the load to rest it out of the admissible range.
◼ Never leave the driving stand with a load suspended on the hook.
C. Handling with 2 cranes

The use of 2 cranes to hoist one and the same load is prohibited.
D. Hoisting of persons
The crane is not designed for hoisting persons. Such usage, which may be authorized by national
regulations concerning suspended−load hoisting devices, is the entire responsibility of the user.
E. Ballasting derricks
Ballasting derricks are reserved for the handling of ballast blocks and accessories provided for
in the present manual. Any other utilization is prohibited.
F. Maintenance derricks
Their use is strictly reserved for loads lower than those indicated on the derrick.
28
General safety instructions

The present general safety instructions concern all intervening parties. According to
circumstances, they address managers or operational staff: each person must participate
in their application.
Operate the crane in strict adherence to the general conditions of use.
Instruction relative to users

Adhere to local regulations concerning suspended−load hoisting devices for matters covering
the protection of personnel and the prevention of accidents.
A. Instructions concerning the managers of persons intervening on the crane

◼ Confide the execution of work on the crane to competent persons:
➢ having the minimum age required by the legislation of the country in which the crane is used
➢ for which the medical aptitude has been attested to (view, hearing, reflexes, agility, aptitude
for work at heights, etc...)
➢ who, through their training by the manufacturer or the latter’s correspondent and their
experience, perfectly master the operations to be performed and have full knowledge of the
danger associated to those operations (e.g.: electric risks, hydraulic risks, etc)
◼ Prohibit crane access to any person not satisfying the above criteria.
◼ Define the responsibilities of each participant in crane operation, for example:
➢ transfer driving control to the intervention manager (assembly, dismantling, testing,
maintenance, modification, etc...)
➢ designate the persons responsible for managing apprenticeship personnel
➢ designate a maneuver manager for any handling presenting specific characteristics.
◼ Ensure that the safety instructions are well known and assimilated by personnel intervening
on the crane and regularly verify application of the same.
◼ Impose on personnel intervening on the crane:
➢ appropriate appearance (e.g.: hair attached, appropriate clothing, etc...)
➢ the wearing of protective equipment: V safety helmet and footwear always V gloves for
manual interventions
➢ V safety harness for interventions above ground (≥ 3 m above ground)
➢ the use of protective devices according to the nature of work to be performed
➢ the specific recommendations of the present manual.
◼ Impose on the crane driver at shift end to carry out the putting out of service procedure of
the crane.
◼ For crane assembly−dismantling and maintenance operations, provide appropriate access
devices (ladders, catwalks, stairways, etc...) conforming to local regulations.
◼ Provide the persons responsible for maintenance with the tooling adapted to the values to
be measured or that tooling recommended by the manufacturer.
29
◼ Inform the crane driver of the risks specific to the site where the crane is operated and to the
work to be performed (e.g.: handling of large−dimension loads, prohibited overflying zone,
etc.)
◼ Radio−controlled crane driving may generate specific risks in the case of incorrect utilization.
Define the rules to avoid all risks of accidents.
B. Instructions concerning the managers of persons intervening on the site

◼ Inform the personnel working on the site where the crane is operated of the direct or indirect
risks generated by the latter (e.g.: site effects, load swinging due to wind, etc...).
◼ Inform the personnel working on the site where the crane is operated of the signification of
audio signals (see chapter on signals and safety controls).
◼ The use of appropriate signaling, prohibit personnel working on the site where the crane is
operated from working or walking under a suspended load.
◼ Check that the crane slewing area (crane slewing from the bottom) is delimited by a protecting
device and that the access to this area is forbidden.
◼ Confide load slinging and maneuver guiding to persons who perfectly master the operations
to be performed due to their training and their experience, and who fully appreciate the
dangers associated to those operations.
Instructions relative to operating conditions

A. Regulations relative to suspended-load hoisting devices
◼ Adhere to local regulations concerning suspended−load hoisting devices for matters
covering:
➢ roadway traffic
➢ fire−fighting equipment
➢ protection of the environment
➢ radio−control transmission−reception frequencies
➢ periodical verifications.
The dangers linked to the utilization and configuration of the machine

must be taken into accounting by the security services and rescue
services during the analysis carried out by the inspection authorities.
B. Climatic circumstances
◼ Establish a procedure relative to the behavior to be adopted in the case of particularly
climatic circumstances (E.g.: reduced−function operation, evacuation of the area).
That procedure may be supported by a system of climatic condition forecasting
implemented by the local meteorological department.
30
C. Access to crane / driving stand

◼ Access the driving stand via the access path provided, with the crane stopped.
◼ Access the driving stand with an elevated cab or personnel elevator only when the
crane is stopped and in adherence to the maximum authorized carrying capacity.
◼ Keep the access paths and control station perfectly clean. In particularly, remove all
waste, traces of grease or oil, spare parts, tools, etc. Store tools, accessories, and
parts in the positions provided for that purpose.
◼ Access the crane with hands unhindered by any object, facing the crane and always
maintaining contact at 3 points with its elements: ladders, railing, stairs, catwalks,
handrails, etc... (e.g.: 2 feet and 1 hand, 2 hands and 1 foot).
D. Malfunctioning
◼ In the case of malfunctioning, stop the crane until the risk has been assessed by a competent
person.
◼ Immediately correct any malfunctioning liable to compromise safety.
◼ Enter all malfunctions in the crane’s maintenance records.
E. Electric lines
◼ Define the procedure to be applied in the case of accidental contact between crane
and electric lines under voltage (direct contact or start of an electric arc).
◼ Examples:
➢ Do not leave the crane
➢ Do not touch the metallic structure
➢ Warn all persons outside that they must avoid approaching or touching the crane
➢ Withdraw the crane from the danger zone
➢ Have the electric line powered off then leave the crane.
F. Conditions for visibility

◼ Adapt the communication means to the visibility conditions at the site where the crane is
operated, for example use transceivers or video systems.
◼ In the case of low light, do not use the crane without an appropriate artificial lighting.
Instructions relative to specific danger

A. Installation
◼ Make sure that the electrical system is complete and undamaged
◼ Make sure that the electrical system has no condensation and humidity.
◼ The lifting lugs are recommended to be used during removals.
◼ The cabinet is recommended to be installed in predesigned position, and the number of
fasten needs to meet the designer’s needs.
◼ Fasten the screws with required torque (see details on APPENDIX), using recommended
plane pad or spring washer.
31
B. Wiring
◼ Confirm the power is off and no residual voltage.
◼ Wiring should be conducted by professional.
◼ Do not wiring when wearing loose clothes or jewelry,
◼ Avoid the damage of wires.
◼ Wiring with required wiring diagram,
◼ Wiring with required wires.
C. Test run
◼ Confirm the validity of the cabinet’s installation; turn on the power after closing the cabinet’s
door. DO NOT open the cabinet’s door when operating.
◼ Confirm the tower and mechanisms operate in allowable range.
D. Maintenance and Checking

◼ High-voltage exists in the high-voltage terminal, please DO NOT touch them.
◼ Turn off the cabinet’s door when operating. Close the related breakers and confirm no
residual voltage when disassembling the elements.
◼ DO NOT maintenance, check or replace the element unless an appointed specialist. Take
off the metal jewelry (watch, rings) before operating, using insulated tools when operating.
◼ Apply extra braking methods when checking any brake.
◼ DO NOT wiring or remove wires when the power is on.
◼ DO NOT Maintenance or checking when the weather is bad.
◼ Maintenance and checking are recommended to carry on in 20 minutes after power-off, the
residual voltage or high temperature exists in some elements.
◼ DO NOT reform the electrical system.
E. Additional
◼ DO NOT operate other mechanism when jacking.
◼ DO NOT operate when the safety device is not installed or debugged.
◼ The operator should pass through professional training.
Safety instructions relative to the preparation of each operating

phase
A. Transport
◼ Provide for access to the site where the crane is operated, suited to crane transport
conditions and, if necessary, the transport of auxiliary equipment used for
assembly−dismantling (ground resistance, climatic conditions, access ramp, maneuvering
zone, etc.).
◼ Install signaling equipment before any transport by road.
32
B. Preparation of the site

◼ Ensure that the site where the crane is used meets all crane characteristics and utilization
conditions.
a) Crane installation area
◼ Before installing the crane, study the constraints related to its operating site, such as:
➢ local regulations concerning work above public buildings or other, above roads, railroads,
fluvial canals, etc...
➢ proximity to other cranes, to an airport, to electric lines, to a transmitter of electromagnetic
waves, etc...
➢ configuration of the terrain, resistance of ground, excavations, slope, underground structure,
etc.
➢ storage zones for elements used in crane assembly or dismantling, positioning of handling
equipment, in order to determine the optimal crane position, in compliance with
assembly−dismantling and operating conditions.
b) Power supply
◼ Ensure that the power supply conforms to crane data and possesses the mandatory
protections.
C. Assembly-dismantling part
a) Preparation of assembly−dismantling
◼ Establish a document, for the attention of the personnel at the crane operating site, that
details the risks of assembly, dismantling or change of configuration operations and the
appropriate protective measures.
◼ Before any assembly, dismantling, change of configuration (e.g.: raising on supports,
passage to raised jib) of the crane, ensure with the relevant authorities that wind speeds will
not exceed the maximum authorized speed (refer to utilization conditions) throughout the
entire operation.
◼ Stake out the safety areas (zones for storage, handling, assembly, ...) when assembling,
dismantling, or testing the crane, with the use of signaling prohibiting access to
non−authorized personnel.
b) Assembly − dismantling − change of configuration
◼ Do not use the crane during assembly, dismantling or change of configuration operations.
◼ For any assembly or dismantling operations not covered by the normal procedures (example:
constraints related to the crane operating site, malfunctioning during assembling or
dismantling), please consult us.
D. Maintenance part
a) Preparation for maintenance
◼ Stake out a safety area in the case of crane malfunctioning or during maintenance
interventions, with the use of signaling prohibiting access to non−authorized personnel.
33
◼ Inhibit re−start of the crane on stoppage for intervention and signal that inhibition of re−start
by a warning attached to the main switch.
b) Maintenance
◼ Do not use the crane during maintenance operations.
◼ For any non−standard maintenance operation, please consult us.
Safety signaling
Explanation
Safety and health−hazard signaling corresponds to determined object, activity or
situation−related signals providing an indication or provision relative to safety or health matters.
That signaling is materialized, according to circumstances, by a panel, a color, an audio or
luminous signal.
Safety signaling can be broken down into 5 categories, each identified by a color code.
◼ Prohibition (red)
◼ Warning (yellow or orange−hue yellow)
◼ Mandatory (blue)
◼ Rescue and first−aid (green)
◼ Fire−fighting material or equipment (red)
Terminology
◼ Panel: signal providing a given indication via the combining of a geometrical shape and
certain colors with a symbol or a pictogram.
➢ Prohibition panel: prohibits behavior liable to generate running of a risk or provoking danger.
➢ Warning panel: warns of a risk or of danger.
➢ Mandatory panel: prescribes a given behavior to be adopted.
➢ Rescue and first−aid panel: provides indications relative to emergency exits or to rescue
and first−aid resources available.
➢ Fire−fighting panel: provides indications relative to the location of fire−fighting resources and
evacuation in the case of fire.
◼ Additional panel: panel used conjointly with another panel and providing complementary
indications.
◼ Symbol or pictogram: image describing a situation or prescribing a given behavior to be
adopted, and which is employed on a panel or a luminous surface.
➢ Luminous signal: signal emitted by a device composed of transparent or translucent material,
internally or back−lighted, in a way it stands out itself as a luminous surface.
➢ Audio signal: a coded audible signal emitted and broadcast by an ad hoc device, without the
use of a human or synthesized voice.
34
Signaling panels
A. Warning panels
Panels Signification Explanations
Do not intervene before

Electrical danger having powered off the
installation
Do not generate sparks or

flames nor smoke
Inflammable matter cigarettes at proximity to
inflammable products such
as paint, oil, glue, etc...
Do not enter within the

Danger of crushing radius of the slewing crane
part
Wait 10 minutes after

Danger of condenser having powered off the
discharge installation before
intervening
Carefully read the

Dangerous operation instructions in the manual
before any operations
Danger related to Read carefully the

free rotation of the instructions for start-up
jib and close of the crane
35
Do not separate the mast

Danger related to
from the Pin before having
climbing with
attached the cage to the
external cage
Pin and vice versa
Danger related to Periodically tighten (refer

transport of the to manual) the wheel nuts
crane on axles on the transport axles
Danger of crushing
Observe the weathervane
when setting into
procedure
weathervane position
B. Prohibiting panels
Panels Signification Explanations
An authorized person is
considering to be a
Access prohibited to
qualified person (see
unauthorized persons
general safety instructions
section)
Audio and luminous signals

A. Audio signals
The following dangers are signaled by automatic activation of an audio alarm:
◼ Crane start−up: short tone
◼ Activation of MSWL (maximum safe working load) cut−out or moment cut−out: continuous
tone
◼ Crane traveling mode: continuous dual tone during the complete duration of movement.
◼ Specific danger is signaled by voluntary action on the audio alarm in accordance with code
defined by local regulations or by the crane manager, such as for example: moving of loads
above persons, specific situations.
◼ Acquire knowledge of the tones and duration corresponding to each signal.
36
B. Luminous signals
According to the instructions or regulations on crane utilization site, luminous signals may be
used to indicate specific danger:
◼ Operating wind speed pre−alarm (adjustable): flashing orange light
◼ Pre−alarm limit: 90% of MSWL or MSWL moment:
➢ GMA: flashing orange light
➢ GME: orange light in control station
◼ Working area limiter not operating or neutralized: flashing red light
C. Associated audio and luminous signals

According to the instructions or regulations on crane utilization site, audio signals associated to
luminous signals may be used to indicate specific danger:
◼ Maximum operating wind speed (adjustable): 2−tone signal with flashing orange and red
lights
◼ (GMA) Pre−alarm limit: 95% of MSWL or MSWL moment: continuous−tone signal with
flashing orange light
◼ (GMA) Activation of the MSWL limiter or MSWL moment limiter: continuous signal plus
2−tone signal with flashing orange and red lights
D. Location of safety signaling:

Positioning on the crane and references of luminous or audio panels and devices are provided
in the section 7 < SPARE PARTS >.
Safety controls
The control console and the maintenance areas at winch proximity (in the case where the control
console is not portable) are equipped with a mechanically−lockable red emergency stop button.
The storm wind reference speeds are determined according to the FEM 1.004 / Edition 07/2000
standard.
Pressing one of those buttons generates immediate interruption of all

movements.
The emergency stop button must be used only in the case of danger and
not for interrupting movements.
37
2.3 Storm wind speed-out of service

General Notes
The storm wind reference speeds are determined according to the FEM 1.004 / Edition 07/2000
standard.
Speed table
Wind speed Dynamic pressure
Height 0−20 m above the ground 130 km/h (36 m/s) 800N/𝑚2
Height 20−100 m above the ground 150 km/h (42 m/s) 1100 N/𝑚2
Height higher than 100 m above the ground 165 km/h (46 m/s) 1300 N/𝑚2
38
W450-25HC-138EN-A01 TECHNICAL DATA OF CRANE AND SITE
3 TECHNICAL DATA OF CRANE AND SITE

3.1 Foreword
The crane and site data group the assembly of technical information and characteristics
together which are necessary to mount and use the crane in full safety and especially to:
◼ Prepare the operating site (for ex: mains supply, access),
◼ Calculate and carry out the crane ground supports,
◼ Carry out the ballast of the crane,
◼ Choose the handling equipment which is necessary to carry out the loading and unloading
of the crane.
Certain data given in this part correspond to the maximum characteristics of the
crane type. For an appropriate use, take into accounting the crane configuration
must as defined at the time of order.
3.2 Technical characteristics
Fig. 3-1 W450-25HC tower crane sub-area
39
TECHNICAL DATA OF CRANE AND SITE W450-25HC-138EN-A01
Load curves
The following load curves are specific to the WA350-20T in 2/4-fall. The tables are separated for
different jib length.
Load curves for 80m jib

Radius(m) 4.3～14.9 15.0 17.5 20.0 22.5 25 27.5 28.1 30.0 32.5
2-fall(t) 12.5 11.6 10.5
4-fall(t) 25.00 24.8 20.6 17.5 15.1 13.2 11.7 11.4 10.5 9.4
Radius(m) 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5
2-fall(t) 9.6 8.9 8.2 7.6 7.1 6.6 6.2 5.9 5.5 5.2
4-fall(t) 8.6 7.8 7.1 6.5 6.0 5.6 5.1 4.8 4.4 4.1
Radius(m) 60.0 62.5 65.0 67.5 70.0 72.5 75.0 77.5 80

2-fall(t) 4.9 4.7 4.4 4.2 4.0 3.8 3.6 3.5 3.3
4-fall(t) 3.8 3.6 3.3 3.1 2.9 2.7 2.5 2.4 2.2
Load curves for 77.5m jib

Radius(m) 4.3～15.8 17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0
2-fall(t) 12.5 11.4 10.4 9.6 8.9 8.3 7.7
4-fall(t) 25.0 22.2 18.9 16.3 14.4 12.8 11.4 10.3 9.3 8.5 7.8 7.2 6.6
Radius(m) 47.5 50 52.5 55.0 57.5 60.0 62.5 65.0 67.5 70.0 72.5 75.0 77.5
2-fall(t) 7.2 6.8 6.4 6.0 5.7 5.4 5.1 4.8 4.6 4.4 4.2 4.0 3.8
4-fall(t) 6.1 5.7 5.3 4.9 4.6 4.3 4.0 3.7 3.5 3.3 3.1 2.9 2.7

Radius(m) 4.3～16.7 17.5 20 22.5 25 27.5 30 31.7 32.5 35 37.5 40 42.5
2-fall(t) 12.5 12.1 11.1 10.3 9.5 8.8
4-fall(t) 25 23.6 20.1 17.5 15.3 13.6 12.2 11.4 11.0 10.0 9.2 8.4 7.7
Radius(m) 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75
2-fall(t) 8.3 7.7 7.3 6.8 6.4 6.1 5.8 5.5 5.2 5.0 4.7 4.5 4.3
4-fall(t) 7.2 6.6 6.2 5.7 5.3 5.0 4.7 4.4 4.1 3.9 3.6 3.4 3.2
40

Radius(m) 4.3～17.5 20 22.5 25 27.5 30 32.5 33.2 35 37.5 40 42.5
2-fall(t) 12.5 11.8 10.8 10.1 9.4
4-fall(t) 25 21.3 18.5 16.2 14.4 13.0 11.7 11.4 10.7 9.8 9.0 8.3
Radius(m) 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5

2-fall(t) 8.7 8.2 7.7 7.2 6.8 6.5 6.1 5.8 5.5 5.3 5.0 4.8
4-fall(t) 7.6 7.1 6.6 6.1 5.7 5.4 5.0 4.7 4.4 4.2 3.9 3.7

Radius(m) 4.3～18.6 20 22.5 25 27.5 30 32.5 35.5 37.5 40 42.5
2-fall(t) 12.5 11.7 10.9 10.1
4-fall(t) 25 23.0 20.0 17.6 15.7 14.1 12.8 11.3 10.6 9.8 9.0
Radius(m) 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70

2-fall(t) 9.5 8.9 8.4 7.9 7.4 7.0 6.7 6.4 6.0 5.8 5.5
4-fall(t) 8.4 7.8 7.3 6.8 6.3 6.0 5.6 5.3 5.0 4.7 4.4

Radius(m) 4.3～18.7 20 22.5 25 27.5 30 32.5 35.7 37.5 40 42.5
2-fall(t) 12.5 11.8 11 10.2
4-fall(t) 25 23.1 20.1 17.7 15.8 14.2 12.8 11.4 10.7 9.9 9.1
Radius(m) 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5

2-fall(t) 9.5 8.9 8.4 7.9 7.5 7.1 6.7 6.4 6.1 5.8
4-fall(t) 8.4 7.8 7.3 6.8 6.4 6.0 5.6 5.3 5.0 4.7

Radius(m) 4.3～19.2 20 22.5 25 27.5 30 32.5 35 36.7 37.5 40
2-fall(t) 12.5 12.2 11.3
4-fall(t) 25 23.9 20.8 18.3 16.3 14.7 13.3 12.1 11.4 11.1 10.2
Radius(m) 42.5 45 47.5 50 52.5 55 57.5 60 62.5 65

2-fall(t) 10.5 9.8 9.2 8.7 8.2 7.7 7.3 7.0 6.6 6.3
4-fall(t) 9.4 8.8 8.1 7.6 7.1 6.6 6.2 5.9 5.5 5.2
41

Radius(m) 4.3～19.6 20 22.5 25 27.5 30 32.5 35 37.5 40
2-fall(t) 12.5 11.6
4-fall(t) 25 24.5 21.3 18.8 16.7 15.1 13.6 12.4 11.4 10.5
Radius(m) 42.5 45 47.5 50 52.5 55 57.5 60 62.5

2-fall(t) 10.8 10.1 9.5 8.9 8.4 8.0 7.5 7.2 6.8
4-fall(t) 9.7 9.0 8.4 7.8 7.3 6.9 6.4 6.1 5.7

Radius(m) 4.3～19.7 20 22.5 25 27.5 30 32.5 35 37.7
2-fall(t) 12.5
4-fall(t) 25 24.6 21.4 18.9 16.8 15.2 13.7 12.5 11.4
Radius(m) 40 42.5 45 47.5 50 52.5 55 57.5 60

2-fall(t) 11.7 10.9 10.2 9.5 9.0 8.5 8.0 7.6 7.2
4-fall(t) 10.6 9.8 9.1 8.4 7.9 7.4 6.9 6.5 6.1

Radius(m) 4.3～19.8 20 22.5 25 27.5 30 32.5 35 37.8
2-fall(t) 12.5
4-fall(t) 25 24.7 21.5 18.9 16.9 15.2 13.8 12.6 11.4
Radius(m) 40 42.5 45 47.5 50 52.5 55 57.5

2-fall(t) 11.7 10.9 10.2 9.6 9.0 8.5 8.0 7.6
4-fall(t) 10.6 9.8 9.1 8.5 7.9 7.4 6.9 6.5

Radius(m) 4.3～19.9 20 22.5 25 27.5 30 32.5 35 37.5
2-fall(t) 12.5
4-fall(t) 25 24.9 21.7 19.1 17.0 15.3 13.9 12.7 11.6
Radius(m) 38.1 40 42.5 45 47.5 50 52.5 55

2-fall(t) 12.5 11.8 11.0 10.3 9.7 9.1 8.6 8.1
4-fall(t) 11.4 10.7 9.9 9.2 8.6 8.0 7.5 7.0
42

Radius(m) 4.3～20 22.5 25 27.5 30 32.5 35
2-fall(t) 12.5
4-fall(t) 25 25.0 21.7 19.2 17.1 15.4 14.0 12.7
Radius(m) 37.5 38.2 40 42.5 45 47.5 50 52.5

2-fall(t) 12.5 11.8 11.0 10.3 9.7 9.1 8.6
4-fall(t) 11.7 11.4 10.8 9.9 9.2 8.6 8.0 7.5

Radius(m) 4.3～20.1 22.5 25 27.5 30 32.5 35
2-fall(t) 12.5
4-fall(t) 25 21.9 19.3 17.3 15.5 14.1 12.8
Radius(m) 37.5 38.5 40 42.5 45 47.5 50

2-fall(t) 12.5 12.0 11.1 10.4 9.8 9.2
4-fall(t) 11.8 11.4 10.9 10.0 9.3 8.7 8.1

Radius(m) 4.3～20.2 22.5 25 27.5 30 32.5 35
2-fall(t) 12.5
4-fall(t) 25 22.0 19.4 17.3 15.6 14.1 12.9
Radius(m) 37.5 38.6 40 42.5 45 47.5

2-fall(t) 12.5 12.0 11.2 10.4 9.8
4-fall(t) 11.8 11.4 10.9 10.1 9.3 8.7

Radius(m) 4.3～20.3 22.5 25 27.5 30 32.5 35 37.5 38.7 40 42.5 45
2-fall(t) 12.5 12.0 11.2 10.5
4-fall(t) 25 22.1 19.5 17.4 15.7 14.2 13.0 11.9 11.4 10.9 10.1 9.4

Radius(m) 4.3～20.4 22.5 25 27.5 30 32.5 35 37.5 39.0 40 42.5
2-fall(t) 12.5 12.1 11.3
4-fall(t) 25 22.2 19.6 17.5 15.8 14.3 13.0 12.0 11.4 11.0 10.2
43

Radius(m) 4.3～20.5 22.5 25 27.5 30 32.5 35 37.5 39.2 40
2-fall(t) 12.5 12.2
4-fall(t) 25 22.4 19.7 17.6 15.9 14.4 13.1 12.0 11.4 11.1

Radius(m) 4.3～20.6 22.5 25 27.5 30 32.5 35 37.5
2-fall(t) 12.5
4-fall(t) 25 22.5 19.8 17.7 15.9 14.5 13.2 12.1

Radius(m) 4.3～20.6 22.5 25 27.5 30 32.5 35
2-fall(t) 12.5
4-fall(t) 25 22.5 19.9 17.7 15.9 14.5 13.2

Radius(m) 4.3～20.6 22.5 25 27.5 30 32.5
2-fall(t) 12.5
4-fall(t) 25 22.5 19.9 17.8 16.0 14.5

Radius(m) 4.0～20.6 22.5 25 27.5 30
2-fall(t) 12.5
4-fall(t) 25 22.6 19.9 17.8 16.0
44
Characteristics of the mechanisms

Tower crane working grade A4
Hoisting mechanism M4
Mechanisms working grade Slewing mechanism M5
Trolleying mechanism M4
Rated hoisting moment (kN·m) 4000
Maximum hoisting moment (kN·m) 5150
Embedded outrigger With attachments

Maximum tower height(m)
60.0 396.3
Max. 80
Working radius(m)
Min. 4.3
80/77.5/75/72.5/70/67.5/65/62.5/60/57.5/55/
Jib length (m)
52.5/50/47.5/45/42.5/40/37.5/35/32.5/30
Maximum load(t) 25
Hoisting falls 2 4
Gears Ⅲ Ⅳ Ⅴ Ⅲ Ⅳ Ⅴ
Hoisting mechanism Maximum load(t) 12.5 6.25 3 25 12.5 6

H75FL63-1040 Speed(m/min) 30 60 80 15 30 40
Rope capacity(m) 1040m (7 layers)
Power(kW) 75
Trolley mechanism Speed(m/min) 0~100

T110FC85-b Power(kW) 11
Slewing mechanism Speed(r/min) 0～0.72

S75CA-130.146LB14/13A
S75CN-130.146LB14/13A Power(kW) 7.5×3
Working pressure
31.5
(MPa)
Pump station
BZ-15-31.5 Speed(m/min) 0.46
Power(kW) 15
Total power (kW) 108.5(Without climbing mechanism)
Power supply ~380V (±10%) / 50Hz
45
Jib length(m) 80 77.5 75 72.5 70 67.5 65 62.5 60 57.5 -
Counter ballast Counter jib length(m) 24
Weight(t) 26.4 26.4 25.4 25.4 26.4 25.4 25.4 24.5 23.4 22.5 -
Jib length(m) 55 52.5 50 47.5 45 42.5 40 37.5 35 32.5 30
Counter ballast Counter jib length(m) 24.0 20.0
Weight(t) 21.5 21.5 20.6 19.5 25.4 22.5 21.5 20.6 19.5 16.7 16.7
Climbing 14
In service 20
Maximum permitted wind speed (m/s) 0~20 36
Out of service 20~100 42
100~ 46
Working temperature(℃) -20～+40
Working altitude(m) ＜1000
Relative humidity ≤90%
Transporting temperature(℃) -25～+55
46
Hoisting mechanism
Type H75FL63-1040
Maximum traction /N 70000
Specification 35W×k7-20-1870
Rope
Maximum line speed m/min 150
Maximum rotating speed r/min 47.6

Drum
Maximum capacity /m 1040m (7 Layers)
Type YZPFM280M-6
Motor Power /kW 75
Rotating speed r/min 977
Type MB3H100H50BT
Reducer
Reduction ratio 51.28
Type YWZ5-400/125-2000-HL
Brake
Brake moment /N·m 2000
Slewing mechanism
S75CA-130.146LB14/13A
Type
S75CN-130.146LB14/13A
Host speed r/min 0～0.72
YTRVF132M2-4F1/B/BM1
Type
YTRVF132M2-4F2/B/BM1
Motor
Power /kW 7.5×3
Type XX5-130.146CLD-14/13
Reduction ratio 146

Reducer
Teeth number z 13
Pinion
Module-m 14
47
Trolley mechanism
Type T110FC85-b
Maximum traction /N 21000
Trolley travelling range /m 0~80
Specification 6×29Fi+IWR-11-1770-sZ
Rope Reference weight/kg·m-1 0.506
Maximum line speed m/min 0~100(70HZ)
Type YEJ132M-4
Motor Power /kW 7.5
Rotating speed r/min 1460(50Hz)
Type XX3-60.58
Reducer
Reduction ratio 58
Type DDZ-220-24
Brake
Braking moment N·m 220
Climbing mechanism
Pump Flux /l·min 23.3

station Working stress /MPa 31.5
Power /kW 15
Motor
Cylinder diameter /mm 250

Climbing Rod diameter /mm 160
hydraulic
cylinder Maximum jacking force /t 154
Jacking speed /m·min-1 0.46
48
3.3 Mast composition

General notes
Free standing cranes
The mast compositions are given for free standing heights IN SERVICE and OUT OF SERVICE
and for the static and rail−mounted versions indicated in the data sheet.
The assembling order is that given in paragraph for reasons of strength. The given mast
composition presents the optimum crane tower as concerns its composition. It is forbidden to
use mast section of low strength. But it is possible to fit mast sections of higher strength. These
documents deal with the optimum composition of the crane tower which is not allowed to be
lower. But it is possible to fit stronger sections.
Unusual cases
The very high cranes may be subjected to a downgrading of the load.
The standard mast composition for hook heights (HUH) higher than 100 m
are defined with wind gusts up to 165km/h. It is on the user’s responsibility
to make sure that this limiting value is not exceeded for very high cranes
(hook height over 200m, for ex.). Otherwise, please contact us
compulsorily.
Reducing the free-standing height due to the telescopic cage

If, for reasons of later increase in height, the telescopic cage is to be left at the top of the masts,
it is necessary to reduce the free-standing height” IN SERVICE” and” OUT OF SERVICE” by
removing X mast sections. Please consult us COMPULSORILY.
With rigid anchorages to the building

The mast compositions and the reactions on the anchorages are given in the chapter specific to
this operation.
With climbing inside the building

The mast compositions and the stresses applied on the frames are given in the chapter specific
to this operation.
With anchorage by guy ropes

Please consult us compulsorily.
49
Mast composition
65.7m free-standing height (Outrigger stationary tower crane)
Base Tower Section Tower Section

H.U.H(m)
X25G1816RaA X25G1816
8.7 1 1
14.4 1 2
20.1 1 3
25.8 1 4
31.5 1 5
37.2 1 6
42.9 1 7
48.6 1 8
54.3 1 9
60.0 1 10
65.7 1 11
50
3.4 Dimensions and weight

Slewing crane parts
Overview
51
Dimensions and weight of the parts

The weights of the winches or of assemblies comprising winches are indicated without ropes.
Rope weight:
R L B H G Q
e Sketch / Designation m m m kg e
f f
Ⅰ 9.8 1.3 2.52 6129 1
Front counter-jib
Ⅰ 4.2 1.6 1.7 1336 1
Middle counter-jib
Ⅰ 11.9 3.2 2.2 4637 1
Rear counter-jib
Ⅰ 3.0 2.31 1.3 4634 1
Hoisting mechanism
Ⅱ 2.1 1.8 2.3 800 1
Cabin
Ⅲ 2.44 2.44 0.98 3553 1
Turntable structure
Ⅲ 2.55 2.55 1.01 4013 1
Slewing support
52
0.42 0.42 1.51 356 2

Ⅲ
0.42 0.42 1.36 345 1

Slewing mechanism
Ⅳ 1.60 0.92 0.81 732 1
Trolley mechanism
Ⅳ 10.4 1.7 2.5 5724 1
Jib section Ⅰ
Ⅳ 5.4 1.5 2.5 2345 1
Jib section Ⅱ
Ⅳ 10.3 1.5 2.5 3487 1
Jib section Ⅲ
Ⅳ 10.3 1.5 2.5 2785 1
Jib section Ⅳ
Ⅳ 10.3 1.5 2.2 2163 1
Jib section Ⅴ
Ⅳ 5.2 1.5 1.92 893 1
Jib section Ⅵ
Ⅳ 2.6 1.5 1.9 423 1
Jib section Ⅶ
Ⅳ 10.3 1.5 1.9 1337 1
Jib section Ⅷ
53
Ⅳ 2.7 1.5 1.9 273 1
Jib section Ⅸ
Ⅳ 5.2 1.5 1.9 518 1
Jib section Ⅹ
Ⅳ 10.2 1.5 1.9 699 1
Jib section Ⅺ
Ⅳ 1.0 1.8 2.5 160 1
Jib section Ⅻ
Ⅴ 1.9 0.56 2.4 893 1
Hook
Ⅵ 2.2 1.75 1.2 506 1
Main trolley
Ⅵ 2.1 1.75 1.2 479 1
Auxiliary trolley
⭐Tolerance on the weight: ±5%.
54
Equipped jib weight

The weight indicated in the next table correspond to jibs equipped with：
◼ Trolley mechanism with rope
◼ Wind-sail plate (depending on the jib length)
◼ Guard rope
Jib length (m) Weight (kg)
80 21739
77.5 21460
75 21208
72.5 20929
70 21014
67.5 20735
65 20484
62.5 20205
60 19776
57.5 19299
55 18870
52.5 18843
50 18837
47.5 17937
45 17508
42.5 16033
40 15604
37.5 15127
35 14698
32.5 12770
30 12341
55
Compositions of the jib sections
① Jib section Ⅰ(000280905BT001000) ② Jib section Ⅱ(000280905BT002000)
③ Jib section Ⅲ(000280905BT003000) ④ Jib section Ⅳ(000280905BT004000)
⑤ Jib section Ⅴ(000280905BT005000) ⑥ Jib section Ⅵ(000280905BT006000)
⑦ Jib section Ⅶ(000280905BT007000) ⑧ Jib section Ⅷ(000280905BT008000)
⑨ Jib section Ⅸ(000280905BT009000) ⑩ Jib section Ⅹ(000280905BT010000)

⑪ Jib section Ⅺ(000280905BT011000) ⑫ Jib section Ⅻ(000280905BT012000)
56
Mast
Overview
Dimensions and weight of the mast sections

R L B H G Q
e Code Sketch / Designation m m m kg e
f f
X25G1816
Ⅰ 4.1 3.3 3.3 3595 1
Rg
Transition Tower Section
W600-
Ⅰ 11.6 4.96 4.63 9731 1
32U.11D
Climbing Equipment
W600-
Ⅰ 3.48 3.84 1.45 450 1
32U.20B
Erection Platform Part
57
W600-
Ⅰ 8.19 1.40 1.97 1579 1
32U.19
Mounting Device
W450-
Ⅰ 2.4 0.5 1.8 871 1
25HC.12
Climbing Mechanism
Ⅱ X25G1816 5.97 2.52 2.61 3980 10
Tower Section
X25G1816
Ⅱ 5.97 2.52 2.61 4463 1
RaA
Base Tower Section
WA350-
Ⅱ 1.93 0.50 0.50 406 4
20HA.15
Outrigger
58
3.5 Auxiliary lifting equipment

Before the tower crane climbing up by itself, it needs to be erected to the initial height by auxiliary
lifting equipment which is generally auto-crane. The hoisting height H and weight m (see the
figure below) should be considered when choosing the autocrine. The heights and weights of the
main parts to be hoisted can be saw in the table below.
Fig. 3-2 Important parameters of choosing auxiliary lifting equipment
Table 3-1 Hoisting heights and weights of the main parts

Height
No. Designation Weight (t)
H(m)
1 Base tower section X25G1816RaA 4.51 7.6
2 Tower section X23G1614 2x4.1 13.3/19.0
3 Climbing system 10.8 30.0
4 Transition section (With mounting device) 5.7 22.8
5 Slewing assembly (with cabin, slewing mechanism) 12.5 25.7
6 Front counter jib (with tie barⅠ) 6.3 26.5
Rear part Middle +rear counter jib
13.1
7 of counter (With hoisting mechanism and derrick) 26.5
jib Only rear counter jib 11.3
8 The first counter ballast 3.9 29.0
JibⅠ, Ⅱ sections
9 10.0 26.5
(with trolley and trolley mechanism)
80m 12.8
77.5m 12.4
75m 12.2
The rest
72.5m 12.0
10 jib 26.5
70m 11.9
sections
67.5m 11.8
65m 11.7
62.5m 11.5
59
Height
No. Designation Weight (t)
H(m)
60m 11.0
57.5m 10.6
55m 10.1
52.5m 9.9
50m 9.5
47.5m 9.0
45m 8.6
42.5m 7.2
40m 6.7
37.5m 6.3
35m 5.8
32.5m 6.2
30m 5.8
The rest
Jib length 3.9t 3.0t 2.0t counter
ballasts
80m 5 1 0 22.5
77.5m 5 1 0 22.5
75m 5 0 1 21.5
72.5m 5 0 1 21.5
70m 5 1 0 22.5
67.5m 5 0 1 21.5
65m 5 0 1 21.5
62.5m 4 1 1 20.6
The rest
60m 5 0 0 19.5
11 counter 29.0
57.5m 4 1 0 18.6
ballasts
55m 4 0 1 17.6
52.5m 4 0 1 17.6
50m 3 1 1 16.7
47.5m 4 0 0 15.6
45m 5 0 1 21.5
42.5m 4 1 0 18.6
40m 4 0 1 17.6
37.5m 3 1 1 16.7
35m 4 0 0 15.6
32.5m 2 1 1 12.6
30m 2 1 1 12.6
60
3.6 Data sheet

Hoisting rope
DATA SHEET – HOISTING ROPE

Rope identification 1090101128 (GS-k34-20-1960)
Maximum load 70kN
Minimum breaking load 368kN
Construction GS-k34
Number of external wires 7
Core： Steel core
Rope diameter 20
Strength of wire 1960Mpa
Diameter of external wires /
Stranding:
sZ(Right-hand regular lay) sZ
zZ(Right-hand langs lay)
Twist coefficient /
Weight per meter 1.97
61
Trolley rope
DATA SHEET – TROLLEY ROPE

Rope identification 1090100943 (6x29Fi+IWR-12-1770-sZ)
Maximum load 21kN
Minimum breaking load 90.7kN
Construction 6×29
Number of external wires 6
Core： Steel core
Rope diameter 12
Strength of wire 1770Mpa
Diameter of external wires /
Stranding:
sZ(Right-hand regular lay) sZ
zZ(Right-hand langs lay)
Twist coefficient \
Weight per meter 0.602
Hoisting rope is configured as rotary resistance rope. In addition, the following

requirements must be met: (D is the theoretical diameter of the rope)
◼ The minimum breaking tension of the Hoisting rope is not less than 368kN, and the trolley
rope minimum breaking tension of the variable amplitude rope is not less 90.7KN;
◼ For the Hoisting rope and the trolley rope, the diameter of any section is between 1.02d
and 1.04d. The noncircular error is within 0.03d.
◼ Anti-torsion performance of Hoisting rope is not more than 360°.
◼ The lateral pressure stability of the Hoisting rope is not more than 0.01d.
◼ The diameter shrinkage of the Hoisting rope is not more than 0.01d.
62
Data sheet of hook
Hook identification 000209609A1104000

Length (L) 970 mm
Nominal diameter (D) 140 mm
Weight 167kg
Greasing yes
Passage with hook safety path (Pal) 193 mm
Dimension (h) 134 mm
Dimension (e) 160 mm
63
3.7 Counter-jib ballast

General notes
The counter−jib ballast comprises several reinforced concrete blocks. Their combination allows
the different weights to be obtained, which are proper to each jib length used. There are three
types: The PHZ3900, PHZ3000M, PHZ2000H blocks, weight 3900 kg, 3000 kg and 2000 kg;
they are directly placed on the counter−jib.
Configuration
Jib-length (m) PHZ3900 PHZ3000M PHZ2000H Total weight (t)
80 6 1 0 26.4
77.5 6 1 0 26.4
75 6 0 1 25.4
72.5 6 0 1 25.4
70 6 1 0 26.4
67.5 6 0 1 25.4
65 6 0 1 25.4
62.5 5 1 1 24.5
60 6 0 0 23.4
57.5 5 1 0 22.5
55 5 0 1 21.5
52.5 5 0 1 21.5
50 4 1 1 20.6
47.5 5 0 0 19.5
45 6 0 1 25.4
42.5 5 1 0 22.5
40 5 0 1 21.5
37.5 4 1 1 20.6
35 5 0 0 19.5
32.5 3 1 1 16.7
30 3 1 1 16.7
Fabrication
The ballast blocks must be carried out according to the following drawings. It is recommended to
observe the outer dimensions of the blocks and the functional dimensions, especially the position
of the suspension holes, the position of the raising device and its dimensions.
The reinforcement of the blocks including the raising device will be determined and carried out
by the crane user to avoid the crumbling and dislocation of the blocks when handling and during
crane work.
64
Weight tolerance
All the counter weights are cast with reinforced concrete. For detailed specification, refer to the
following figures. Respectively, for spare parts layout, see the following tables.
◼ It is advised to use steel mould to cast the concrete counter weight to assure
the dimension of it and the flatness of every surface.
◼ It is advised to weigh every counter weight manufactured and engrave the
weight permanently on the surface, with permitted weight tolerance of ±1％
and concrete grade is no less than C20 (recommended C25). It must be
pounded firmly and the curing time should be more than 14 days.
◼ The dimensions can be changed according to the density (average density)
of reinforced concrete for the tolerance. The density will change with the
change of distribution of reinforced bar in counter weight.
◼ In this manual, the outline size of counter weight for this tower crane is
designed according to the concrete design density which is based on the
theoretical value of 2400 kg/m3.
◼ Customers can also design counter weight themselves. Make sure the
width, thickness and dimensions of counter weight is right to hang, you can
adjust the length to appropriate value.
Steel
Es: Longitudinal modulus of elasticity of steel: 200000 N/mm2 i.e. 200000MPa
Type 1: Reinforcement with high adherence obtained by hot−rolling of natural high−carbon steel.
Quality: Fe E 40 i.e. fe=400MPa
If the above rules are not applicable, refer to the rules applied in the user
country.
65
Preparing the block PHZ3900
◼ WEIGHT = 3900 kg ± 2% − Average density of reinforced concrete: C20

◼ Dimensions in cm-General tolerance: ±1cm except
Fig. 3-3 Counter weight PHZ3900
66
Table 3-2 Spare part list of PHZ3900
No. Designation Specification Qty Material Remarks
1 Lug t16 1 Q235B

2 Rebar Ф30-960 1 Q235B
3 Rebar Ф14 8 HPB300
6 Angle Steel L40×4 4 Q235B
7 Angle Steel L40×4-980 4 Q235B
9 Fixed Plate t8 4 Q235B
11 Concrete t16 1 C20
67
Preparing the block PHZ3000M

◼ Dimensions in cm-General tolerance: ±1cm except
Fig. 3-4 Counter weight PHZ3000M
68
Table 3-3 Spare part list of PHZ3000M
1 Lug t16 1 Q235B

2 Rebar Ф30-960 1 Q235B
69
Preparing the block PHZ2000H

◼ Dimensions in cm-General tolerance: ±1cm except.
Fig. 3-5 Counter weight PHZ2000H
70
Table 3-4 Spare part list of PHZ2000H
1 Lug t16 1 Q235B

2 Rebar Ф30-960 1 Q235B
71
3.8 Foundation
Calculation of stationary foundation

◼ Calculate of eccentricity
Fig. 3-6 Load of foundation

As the figure above, the stability condition of tower crane as the following:
M+H∗h L
𝑒= ≤
V+G 3
In the formula:
e-eccentricity, that is the distance between the resultant ground reaction and the base center,
m;
G—the gravity of the concrete foundation, kN.
72
◼ Calculation of earth bearing pressure

Earth endurance should not exceed the maximum permissible stress of the ground!
Earth endurance checking formula:
2 ∗ (V + G)
σB = ≤ σBp
3∗L∗c
L
c= −e
2
In the formula:
σB —Calculation the com pressive stress on the ground, MPa;
σBp —Allowable compressive stress on the ground, MPa: It shall be determined by the
situation officed investigation and foundation treatment.
Foundation drawing of the tower crane

The ground foundation is the precondition to ensure safe operation of the crane. It is made of
reinforced concrete as shown in figure below. Basic requirements are shown as follows:
◼ Excavate a trench to hard formation until the ground bearing pressure accords with the value
in the following table, and make the bottom level. And then backfill and tamp 100mm gravel
stratum. After making 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.
◼ The depth of the concrete cover of the main reinforcement is 40mm. Fix the embedded
anchors on the locating reinforcement bar and make sure that the verticality of the
embedded anchors centerlines and horizontal plane is less than 1.5/1000. Concrete filling
rate around the embedded anchors must be over 95%.
◼ The concrete strength grade shall be no less than C35. The curing duration of concrete is
more than 15 days.
◼ If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside, but
must not be reduced or cut off.
◼ No.6 which must drive 1.5m into the ground. Not connected with the steel reinforcement of
the building foundations.
◼ The No.10 is insulated copper cable with at least 16mm.
◼ This foundation is supposed to be applied for W450-25HC tower crane with the standard
free-standing height of 65.7m and for W450-25HC tower crane which is attached to the
building and in accordance with the requirement in the user's manual. The load on the
foundation can be found in the user's manual. The load-bearing capacity of the foundation,
the dimension L of the foundation and the layout of the reinforcement are all designed in
accordance with the standard FEM. The foundation can be produced under instruction of
the following table, the adjustment according to the actual situation is also allowed:
73
Main Main Ground Concrete Weigh Qty

a
L reinforcement reinforcement resistanc volume t of
(mm)
A B e (MPa) (m3) (t) No.5
Lengthwise Lengthwise
7000 and crosswise: and crosswise: 6920 0.23 78.4 188.2 324
35×Ф25 35×Ф25
7500 and crosswise: and crosswise: 7420 0.18 90.0 216 361
38×Ф25 38×Ф25
8000 and crosswise: and crosswise: 7920 0.16 102.4 246 400
40×Ф25 40×Ф25
If the modified bearing capacity of foundation is less than 0.1 MPa, the
pile foundation must be adopted. The pile foundation can also be
adopted, when the block foundation cannot be produced as above due
to the size limitation or other inevitable reasons.
74
75
Fig. 3-7 The foundation for embedded outrigger tower crane
76
Table 3-5 Spare part list of embedded outrigger crane foundation
No. Description Specification Qty Material Remarks
1 Main reinforcement A Ф25 70 HRB400
2 Main reinforcement B Ф25 70 HRB400
3 Locating reinforcement bar Ф25-4400 8 HRB400

4 Reinforcement bar Ф12-1720 324 HPB300
5 Concrete 1 C35
6 Earthing rod 1 Weldment
7 Bolt M12×40-8.8 1
8 Washer 12 1 65Mn
9 Nut M12-8 1
10 Earthing cable 1
11 Locating reinforcement bar Ф25-2230 8 HRB400
77
Loads on foundation of crane
If the tower crane erected to the maximum free-standing height 62.0m, set
down the climbing equipment on the foundation of the crane, or decrease
the height for at least one tower section.
T Torque M Bending moment H Horizontal force V Vertical force
Table 3-6 Loads on foundation for 80m jib

Number of Tower height Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 3987.2 37.4 1530.1 1144.7
1+3 25.8
Out of service -1980.5 108.7 1273.2 0.0
In service 4251.2 40.3 1585.0 1144.7
1+4 31.5
Out of service -1997.2 121.5 1328.1 0.0
In service 4546.1 43.2 1639.8 1144.7
1+5 37.2
Out of service -2018.5 134.2 1383.0 0.0
In service 4874.8 46.1 1694.7 1144.7
1+6 42.9
Out of service 2172.7 147.0 1437.9 0.0
In service 5240.9 49.0 1749.6 1144.7
1+7 48.6
Out of service 3086.2 159.8 1492.7 0.0
In service 5648.7 51.9 1804.5 1144.7
1+8 54.3
Out of service 4096.2 172.6 1547.6 0.0
In service 6103.7 54.8 1859.4 1144.7
1+9 60.0
Out of service 5210.9 185.3 1602.5 0.0
In service 6612.9 57.7 1914.2 1144.7
1+10 65.7
Out of service 6440.4 198.1 1657.4 0.0
78
Table 3-7 Loads on foundation for 77.5m jib

In service 4283.9 37.6 1519.2 1114.5
1+3 25.8
Out of service -1965.9 108.7 1262.0 0.0
In service 4551.4 40.5 1574.0 1114.5
1+4 31.5
Out of service -1982.3 121.5 1316.9 0.0
In service 4850.6 43.4 1628.9 1114.5
1+5 37.2
Out of service -2003.2 134.2 1371.7 0.0
In service 5184.4 46.3 1683.8 1114.5
1+6 42.9
Out of service 2187.3 147.0 1426.6 0.0
In service 5556.4 49.2 1738.7 1114.5
1+7 48.6
Out of service 3100.6 159.8 1481.5 0.0
In service 5971.2 52.1 1793.6 1114.5
1+8 54.3
Out of service 4110.2 172.6 1536.4 0.0
In service 6434.2 55.0 1848.4 1114.5
1+9 60.0
Out of service 5224.3 185.3 1591.3 0.0
In service 6952.7 57.9 1903.3 1114.5
1+10 65.7
Out of service 6452.8 198.1 1646.1 0.0

In service 4383.7 37.6 1515.7 1083.6
1+3 25.8
Out of service -2126.3 108.7 1258.6 0.0
In service 4652.3 40.5 1570.6 1083.6
1+4 31.5
Out of service -2144.0 121.5 1313.5 0.0
In service 4952.9 43.4 1625.4 1083.6
1+5 37.2
Out of service -2166.5 134.2 1368.3 0.0
In service 5288.4 46.3 1680.3 1083.6
1+6 42.9
Out of service -2194.4 147.0 1423.2 0.0
In service 5662.3 49.2 1735.2 1083.6
1+7 48.6
Out of service 2932.2 159.8 1478.1 0.0
In service 6079.3 52.1 1790.1 1083.6
1+8 54.3
Out of service 3938.7 172.6 1533.0 0.0
In service 6545.0 55.0 1845.0 1083.6
1+9 60.0
Out of service 5048.8 185.3 1587.9 0.0
In service 7066.5 57.9 1899.8 1083.6
1+10 65.7
Out of service 6272.6 198.1 1642.7 0.0
79

In service 4436.5 37.6 1513.2 1052.1
1+3 25.8
Out of service -2306.2 108.7 1256.2 0.0
In service 4705.7 40.5 1568.0 1052.1
1+4 31.5
Out of service -2325.4 121.5 1311.1 0.0
In service 5007.0 43.4 1622.9 1052.1
1+5 37.2
Out of service -2349.8 134.2 1365.9 0.0
In service 5343.2 46.3 1677.8 1052.1
1+6 42.9
Out of service -2380.0 147.0 1420.8 0.0
In service 5718.1 49.2 1732.7 1052.1
1+7 48.6
Out of service 2743.5 159.8 1475.7 0.0
In service 6136.2 52.1 1787.6 1052.1
1+8 54.3
Out of service 3746.4 172.6 1530.6 0.0
In service 6603.2 55.0 1842.4 1052.1
1+9 60.0
Out of service 4852.3 185.3 1585.5 0.0
In service 7126.1 57.9 1897.3 1052.1
1+10 65.7
Out of service 6071.0 198.1 1640.3 0.0

In service 4606.0 37.7 1523.0 1057.3
1+3 25.8
Out of service -2521.7 108.7 1266.5 0.0
In service 4877.6 40.6 1577.9 1057.3
1+4 31.5
Out of service -2542.8 121.5 1321.3 0.0
In service 5181.8 43.5 1632.7 1057.3
1+5 37.2
Out of service -2569.7 134.2 1376.2 0.0
In service 5521.8 46.4 1687.6 1057.3
1+6 42.9
Out of service -2603.0 147.0 1431.1 0.0
In service 5901.1 49.3 1742.5 1057.3
1+7 48.6
Out of service 2518.4 159.8 1486.0 0.0
In service 6324.6 52.2 1797.4 1057.3
1+8 54.3
Out of service 3517.7 172.6 1540.9 0.0
In service 6797.9 55.1 1852.3 1057.3
1+9 60.0
Out of service 4619.5 185.3 1595.7 0.0
In service 7328.6 58.0 1907.1 1057.3
1+10 65.7
Out of service 5833.6 198.1 1650.6 0.0
80

In service 4673.4 37.7 1511.1 1009.0
1+3 25.8
Out of service -2462.1 108.7 1254.3 0.0
In service 4945.5 40.6 1566.0 1009.0
1+4 31.5
Out of service -2482.6 121.5 1309.1 0.0
In service 5250.4 43.5 1620.9 1009.0
1+5 37.2
Out of service -2508.6 134.2 1364.0 0.0
In service 5590.9 46.4 1675.8 1009.0
1+6 42.9
Out of service -2540.7 147.0 1418.9 0.0
In service 5970.9 49.3 1730.7 1009.0
1+7 48.6
Out of service 2580.0 159.8 1473.8 0.0
In service 6395.0 52.2 1785.5 1009.0
1+8 54.3
Out of service 3579.9 172.6 1528.7 0.0
In service 6869.0 55.1 1840.4 1009.0
1+9 60.0
Out of service 4682.1 185.3 1583.5 0.0
In service 7400.2 58.1 1895.3 1009.0
1+10 65.7
Out of service 5896.5 198.1 1638.4 0.0

In service 4848.6 37.8 1500.2 971.5
1+3 25.8
Out of service -2425.9 108.7 1243.0 0.0
In service 5122.6 40.7 1555.1 971.5
1+4 31.5
Out of service -2445.8 121.5 1297.9 0.0
In service 5429.7 43.6 1610.0 971.5
1+5 37.2
Out of service -2471.2 134.2 1352.8 0.0
In service 5772.9 46.5 1664.9 971.5
1+6 42.9
Out of service -2502.5 147.0 1407.6 0.0
In service 6156.0 49.4 1719.7 971.5
1+7 48.6
Out of service 2617.3 159.8 1462.5 0.0
In service 6583.6 52.3 1774.6 971.5
1+8 54.3
Out of service 3617.2 172.6 1517.4 0.0
In service 7061.6 55.2 1829.5 971.5
1+9 60.0
Out of service 4719.4 185.3 1572.3 0.0
In service 7597.3 58.1 1884.4 971.5
1+10 65.7
Out of service 5933.4 198.1 1627.2 0.0
81

In service 4804.2 37.8 1497.7 934.7
1+3 25.8
Out of service -2588.7 108.7 1240.6 0.0
In service 5077.6 40.7 1552.6 934.7
1+4 31.5
Out of service -2609.9 121.5 1295.5 0.0
In service 5383.8 43.6 1607.4 934.7
1+5 37.2
Out of service -2636.9 134.2 1350.4 0.0
In service 5726.0 46.5 1662.3 934.7
1+6 42.9
Out of service -2670.3 147.0 1405.2 0.0
In service 6107.8 49.4 1717.2 934.7
1+7 48.6
Out of service -2710.7 159.8 1460.1 0.0
In service 6534.0 52.3 1772.1 934.7
1+8 54.3
Out of service 3443.5 172.6 1515.0 0.0
In service 7010.2 55.2 1827.0 934.7
1+9 60.0
Out of service 4541.9 185.3 1569.9 0.0
In service 7543.9 58.1 1881.8 934.7
1+10 65.7
Out of service 5751.3 198.1 1624.8 0.0

In service 4810.4 37.8 1483.1 881.9
1+3 25.8
Out of service -2587.7 108.7 1225.7 0.0
In service 5083.4 40.7 1538.0 881.9
1+4 31.5
Out of service -2608.7 121.5 1280.5 0.0
In service 5389.1 43.6 1592.8 881.9
1+5 37.2
Out of service -2635.3 134.2 1335.4 0.0
In service 5730.5 46.5 1647.7 881.9
1+6 42.9
Out of service -2668.2 147.0 1390.3 0.0
In service 6111.4 49.4 1702.6 881.9
1+7 48.6
Out of service -2708.1 159.8 1445.2 0.0
In service 6536.2 52.3 1757.5 881.9
1+8 54.3
Out of service 3443.0 172.6 1500.1 0.0
In service 7010.7 55.2 1812.4 881.9
1+9 60.0
Out of service 4540.3 185.3 1554.9 0.0
In service 7542.2 58.1 1867.2 881.9
1+10 65.7
Out of service 5748.2 198.1 1609.8 0.0
82

In service 4688.3 37.8 1469.1 825.4
1+3 25.8
Out of service -2690.7 108.7 1211.5 0.0
In service 4959.2 40.7 1523.9 825.4
1+4 31.5
Out of service -2712.2 121.5 1266.3 0.0
In service 5262.4 43.6 1578.8 825.4
1+5 37.2
Out of service -2739.6 134.2 1321.2 0.0
In service 5600.7 46.5 1633.7 825.4
1+6 42.9
Out of service -2773.3 147.0 1376.1 0.0
In service 5977.8 49.4 1688.6 825.4
1+7 48.6
Out of service -2814.3 159.8 1431.0 0.0
In service 6398.0 52.3 1743.5 825.4
1+8 54.3
Out of service 3331.9 172.6 1485.9 0.0
In service 6867.1 55.2 1798.3 825.4
1+9 60.0
Out of service 4426.0 185.3 1540.7 0.0
In service 7391.8 58.1 1853.2 825.4
1+10 65.7
Out of service 5629.7 198.1 1595.6 0.0

In service 4897.2 37.9 1447.0 802.6
1+3 25.8
Out of service -2497.6 108.7 1188.7 0.0
In service 5170.2 40.8 1501.9 802.6
1+4 31.5
Out of service -2517.2 121.5 1243.6 0.0
In service 5475.6 43.7 1556.8 802.6
1+5 37.2
Out of service -2542.0 134.2 1298.4 0.0
In service 5816.5 46.6 1611.6 802.6
1+6 42.9
Out of service -2572.7 147.0 1353.3 0.0
In service 6196.5 49.5 1666.5 802.6
1+7 48.6
Out of service 2538.9 159.8 1408.2 0.0
In service 6619.9 52.4 1721.4 802.6
1+8 54.3
Out of service 3535.0 172.6 1463.1 0.0
In service 7092.4 55.3 1776.3 802.6
1+9 60.0
Out of service 4631.5 185.3 1518.0 0.0
In service 7620.9 58.2 1831.2 802.6
1+10 65.7
Out of service 5837.5 198.1 1572.8 0.0
83

In service 4891.0 37.9 1447.0 747.3
1+3 25.8
Out of service -2522.0 108.7 1188.7 0.0
In service 5163.8 40.8 1501.9 747.3
1+4 31.5
Out of service -2541.7 121.5 1243.5 0.0
In service 5469.2 43.7 1556.7 747.3
1+5 37.2
Out of service -2566.8 134.2 1298.4 0.0
In service 5810.0 46.6 1611.6 747.3
1+6 42.9
Out of service -2597.8 147.0 1353.3 0.0
In service 6189.8 49.5 1666.5 747.3
1+7 48.6
Out of service -2635.4 159.8 1408.2 0.0
In service 6613.0 52.4 1721.4 747.3
1+8 54.3
Out of service 3509.0 172.6 1463.1 0.0
In service 7085.3 55.3 1776.3 747.3
1+9 60.0
Out of service 4605.1 185.3 1517.9 0.0
In service 7613.6 58.2 1831.1 747.3
1+10 65.7
Out of service 5810.5 198.1 1572.8 0.0

In service 4696.6 37.8 1442.6 704.9
1+3 25.8
Out of service -2748.1 108.7 1184.5 0.0
In service 4966.8 40.7 1497.5 704.9
1+4 31.5
Out of service -2769.6 121.5 1239.4 0.0
In service 5269.0 43.6 1552.4 704.9
1+5 37.2
Out of service -2796.8 134.2 1294.3 0.0
In service 5605.9 46.5 1607.2 704.9
1+6 42.9
Out of service -2830.4 147.0 1349.1 0.0
In service 5981.1 49.4 1662.1 704.9
1+7 48.6
Out of service -2871.2 159.8 1404.0 0.0
In service 6399.0 52.3 1717.0 704.9
1+8 54.3
Out of service 3268.3 172.6 1458.9 0.0
In service 6864.9 55.2 1771.9 704.9
1+9 60.0
Out of service 4359.3 185.3 1513.8 0.0
In service 7385.6 58.1 1826.8 704.9
1+10 65.7
Out of service 5558.7 198.1 1568.7 0.0
84

In service 4857.6 37.9 1418.3 653.3
1+3 25.8
Out of service -2563.5 108.7 1159.5 0.0
In service 5129.1 40.8 1473.2 653.3
1+4 31.5
Out of service -2582.9 121.5 1214.4 0.0
In service 5432.6 43.7 1528.1 653.3
1+5 37.2
Out of service -2607.8 134.2 1269.3 0.0
In service 5771.1 46.6 1583.0 653.3
1+6 42.9
Out of service -2638.4 147.0 1324.2 0.0
In service 6148.0 49.5 1637.9 653.3
1+7 48.6
Out of service -2675.5 159.8 1379.0 0.0
In service 6567.5 52.4 1692.7 653.3
1+8 54.3
Out of service 3462.0 172.6 1433.9 0.0
In service 7035.1 55.3 1747.6 653.3
1+9 60.0
Out of service 4555.0 185.3 1488.8 0.0
In service 7557.4 58.2 1802.5 653.3
1+10 65.7
Out of service 5756.2 198.1 1543.7 0.0

In service 4865.3 37.9 1453.7 635.6
1+3 25.8
Out of service -2566.9 108.7 1197.2 0.0
In service 5138.2 40.8 1508.6 635.6
1+4 31.5
Out of service -2587.1 121.5 1252.1 0.0
In service 5443.7 43.7 1563.5 635.6
1+5 37.2
Out of service -2612.9 134.2 1306.9 0.0
In service 5784.6 46.6 1618.3 635.6
1+6 42.9
Out of service -2644.7 147.0 1361.8 0.0
In service 6164.6 49.5 1673.2 635.6
1+7 48.6
Out of service -2683.2 159.8 1416.7 0.0
In service 6588.1 52.4 1728.1 635.6
1+8 54.3
Out of service 3462.2 172.6 1471.6 0.0
In service 7060.7 55.3 1783.0 635.6
1+9 60.0
Out of service 4557.9 185.3 1526.5 0.0
In service 7589.4 58.2 1837.9 635.6
1+10 65.7
Out of service 5763.2 198.1 1581.3 0.0
85

In service 4680.6 37.8 1420.6 548.3
1+3 25.8
Out of service -2733.8 108.7 1163.8 0.0
In service 4950.1 40.7 1475.5 548.3
1+4 31.5
Out of service -2754.7 121.5 1218.7 0.0
In service 5251.3 43.6 1530.4 548.3
1+5 37.2
Out of service -2781.3 134.2 1273.6 0.0
In service 5586.9 46.5 1585.3 548.3
1+6 42.9
Out of service -2814.1 147.0 1328.5 0.0
In service 5960.3 49.4 1640.2 548.3
1+7 48.6
Out of service -2853.9 159.8 1383.4 0.0
In service 6375.9 52.3 1695.0 548.3
1+8 54.3
Out of service 3281.7 172.6 1438.2 0.0
In service 6838.8 55.2 1749.9 548.3
1+9 60.0
Out of service 4371.5 185.3 1493.1 0.0
In service 7355.6 58.1 1804.8 548.3
1+10 65.7
Out of service 5569.0 198.1 1548.0 0.0

In service 4700.9 37.8 1407.0 513.7
1+3 25.8
Out of service -2727.5 108.7 1149.9 0.0
In service 4970.2 40.8 1461.8 513.7
1+4 31.5
Out of service -2748.1 121.5 1204.8 0.0
In service 5271.1 43.7 1516.7 513.7
1+5 37.2
Out of service -2774.2 134.2 1259.6 0.0
In service 5606.3 46.6 1571.6 513.7
1+6 42.9
Out of service -2806.5 147.0 1314.5 0.0
In service 5979.1 49.5 1626.5 513.7
1+7 48.6
Out of service -2845.7 159.8 1369.4 0.0
In service 6393.8 52.4 1681.4 513.7
1+8 54.3
Out of service 3287.0 172.6 1424.3 0.0
In service 6855.6 55.3 1736.2 513.7
1+9 60.0
Out of service 4376.0 185.3 1479.2 0.0
In service 7370.9 58.2 1791.1 513.7
1+10 65.7
Out of service 5572.3 198.1 1534.0 0.0
86

In service 4649.6 37.8 1392.9 476.6
1+3 25.8
Out of service -2781.0 108.7 1135.7 0.0
In service 4917.8 40.7 1447.8 476.6
1+4 31.5
Out of service -2801.7 121.5 1190.6 0.0
In service 5217.3 43.6 1502.7 476.6
1+5 37.2
Out of service -2828.0 134.2 1245.4 0.0
In service 5550.7 46.5 1557.6 476.6
1+6 42.9
Out of service -2860.5 147.0 1300.3 0.0
In service 5921.4 49.4 1612.5 476.6
1+7 48.6
Out of service -2899.9 159.8 1355.2 0.0
In service 6333.5 52.3 1667.3 476.6
1+8 54.3
Out of service 3229.0 172.6 1410.1 0.0
In service 6792.1 55.2 1722.2 476.6
1+9 60.0
Out of service 4315.9 185.3 1465.0 0.0
In service 7303.4 58.1 1777.1 476.6
1+10 65.7
Out of service 5509.4 198.1 1519.8 0.0

In service 4685.6 37.9 1378.3 459.0
1+3 25.8
Out of service -2730.6 108.7 1120.7 0.0
In service 4953.8 40.8 1433.2 459.0
1+4 31.5
Out of service -2750.6 121.5 1175.6 0.0
In service 5253.2 43.7 1488.1 459.0
1+5 37.2
Out of service -2776.0 134.2 1230.5 0.0
In service 5586.4 46.6 1543.0 459.0
1+6 42.9
Out of service -2807.5 147.0 1285.4 0.0
In service 5956.8 49.5 1597.9 459.0
1+7 48.6
Out of service -2845.6 159.8 1340.3 0.0
In service 6368.3 52.4 1652.7 459.0
1+8 54.3
Out of service 3281.1 172.6 1395.1 0.0
In service 6826.1 55.3 1707.6 459.0
1+9 60.0
Out of service 4368.0 185.3 1450.0 0.0
In service 7336.3 58.2 1762.5 459.0
1+10 65.7
Out of service 5561.1 198.1 1504.9 0.0
87

In service 4668.7 37.9 1331.6 407.4
1+3 25.8
Out of service -2706.5 108.7 1073.7 0.0
In service 4935.3 40.8 1386.5 407.4
1+4 31.5
Out of service -2725.4 121.5 1128.5 0.0
In service 5232.4 43.7 1441.4 407.4
1+5 37.2
Out of service -2749.4 134.2 1183.4 0.0
In service 5562.6 46.6 1496.3 407.4
1+6 42.9
Out of service -2779.1 147.0 1238.3 0.0
In service 5929.1 49.5 1551.2 407.4
1+7 48.6
Out of service -2815.1 159.8 1293.2 0.0
In service 6335.7 52.4 1606.0 407.4
1+8 54.3
Out of service 3302.2 172.6 1348.1 0.0
In service 6787.2 55.3 1660.9 407.4
1+9 60.0
Out of service 4386.4 185.3 1402.9 0.0
In service 7289.5 58.2 1715.8 407.4
1+10 65.7
Out of service 5575.2 198.1 1457.8 0.0

In service 4722.2 37.9 1317.0 376.4
1+3 25.8
Out of service -2640.0 108.7 1058.7 0.0
In service 4988.9 40.8 1371.9 376.4
1+4 31.5
Out of service -2658.1 121.5 1113.6 0.0
In service 5286.1 43.7 1426.8 376.4
1+5 37.2
Out of service -2681.2 134.2 1168.5 0.0
In service 5616.4 46.6 1481.7 376.4
1+6 42.9
Out of service -2709.7 147.0 1223.3 0.0
In service 5982.9 49.5 1536.5 376.4
1+7 48.6
Out of service -2744.3 159.8 1278.2 0.0
In service 6389.4 52.4 1591.4 376.4
1+8 54.3
Out of service 3371.0 172.6 1333.1 0.0
In service 6840.6 55.3 1646.3 376.4
1+9 60.0
Out of service 4455.4 185.3 1388.0 0.0
In service 7342.3 58.2 1701.2 376.4
1+10 65.7
Out of service 5644.1 198.1 1442.9 0.0
88
3.9 Power supply

Definition
Nominal power
This is the sum of the nominal powers (operating powers consumed simultaneously by the three
movements) of:
◼ hoisting mechanism
◼ trolley mechanism
◼ slewing mechanism
Starting power
This is the sum of the powers consumed temporarily by these same three movements under the
following conditions:
◼ starting power of the mechanism with the highest current consumption (in general: the hoisting
mechanism)
◼ nominal power of the two other mechanisms
Nominal current intensity
Results from the nominal power
Starting current intensity

Results from the starting power.
Nominal Nominal
Mechanism Frequency Type of mechanism
power in kW intensity at A
Hoisting
50Hz H75FL63-1040 75 135
mechanism
Slewing 50Hz S75CA-130.146LB14/13A 7.5*2 34.6

mechanism 50Hz S75CN-130.146LB14/13A 7.5 17.3
Trolley
50Hz T110FC85-b 11 20
mechanism
89
Current supply
Characteristic of the site power supply
The electrical installations on cranes are subjected to very strict

regulations in order to ensure the good working order of the equipment
and the protection of the personnel. They must be in accordance with the
Standards in force in the respective countries. Below, an example of a
corresponding general scheme.
The protection of power grid should include:

A distributing box after the voltage-meter, which has built-in automatic breakers and leakage
protection device, which is adjustable, to turn off the circuit.
The distributing box, included in tower crane electrical system should configure multistage switch.
The switch can be locked at off-location, in order to maintenance or dealing with accident.
Grounding
Installing grounding wire should accord with current standards, which requires:
➢ Metal parts’ grounding;
➢ Track’s grounding.
All the grounding parts should be connected, the connection of the grounding circuit should be
checking in period.
The grounding wire is yellow-green, which connects the “grounding” terminal of metal parts to
grounding plugs or grid. The method of grounding sees also in relative introductions of
mechanism parts, the grounding resistance should not more than 4 Ohms.
◼ It’s forbidden to replace the grounding wires with neutral wires.

◼ The grounding wires should be conducted, and isolated from any
breaker.
90
Power source cable

The power source cable includes 3 phase conductors, 1 neutral conductor, and 1 grounding
conductor which is yellow-green. The grounding line should be fixed on the reserved terminal.
Accident could be caused by any source line’s damage, so it’s recommended to dispose the
source lines in appropriate way to ensure that no damage on insulation of the lines.
The requirement of tower crane’s source

A. Power
The power of the source is determined by capacity of all mechanism, speed controlling manner
and working condition (With load or without load start-up).
B. Characteristic of supply voltage
◼ According to our technical specification, the supply voltage at the crane switch must be:
50 Hz in Europe
maximum voltage without load: 400 V + 6% (i.e. between 400 V and 420 V)
minimum voltage with load: 400 V - 10% (i.e. between 360 V and 400 V)
◼ The minimum voltage depends on:
the voltage supplied by the supply source with load,
the voltage drops in the supply cable,
the cable cross- section (the thicker the cable is, the lower the voltage drop will be),
the type of the cable (aluminum or copper),
the cable length between the supply source and the crane switch,
the current surge when starting the crane.
Choosing a cable cross-section
As a first approach, a cable cross- section is accepted if the current density which is passing
through is lower than 4 amperes per 𝑚𝑚2 .
Example: Current intensity of the crane 50 amperes:
50
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑐𝑎𝑏𝑙𝑒 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 = = 12.5𝑚𝑚2
4
◼ Take the cable cross- section (in the “Cable cross- section” column of the table below) which
is equal or slightly bigger, i.e. 3 x 16 mm2 + N (neutral)+T (earth)
91
Copper Cables
Voltage drop per kilometer per ampere, V/(km·A)
No. Cable cross- section
(cos Ф= 0,8)
1 3 x 6 mm2+ N+T 6.00
2
2 3 x 10 mm + N+T 3.50
3 3 x 16 mm2+ N+T 2.20
4 3 x 25 mm2+ N+T 1.50
5 3 x 35 mm2+ N+T 1.10
6 3 x 50 mm2+ N+T 0.77
2
7 3 x 70 mm + N+T 0.57
8 3 x 95 mm2+ N+T 0.46
9 3 x 120 mm2+ N+T 0.38
10 3 x 150 mm2+ N+T 0.32
11 3 x 185 mm2+ N+T 0.28
2
12 3 x 240 mm + N+T 0.23
C. Determining the coefficient of the voltage drop

◼ Take the coefficient of the voltage drop in the table above depending on the cable cross-
section calculated before.
Calculation of the maximum supply cable length for a known cable cross-section
Data:
➢ Supply source: 50 Hz
420 V with the crane without load
390 V with the crane with load
➢ Crane: Value of the permissible minimum voltage 360 V with load.
The voltage drop must not exceed 390 V - 360 V = 30 V in the cable of length L.
The formula will be:
𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑑𝑟𝑜𝑝

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑒𝑛𝑔𝑡ℎ =
𝑐𝑜𝑒𝑓𝑓.× 𝐼𝑑
with:
30 V: permissible voltage drop,
Voltage drop: depending on the cable cross- section,
Id: starting current intensity.
92
Example:
2
1. For a cable of 3 x 16 mm + N (neutral)+T (earth), the coefficient is of 2,2
2. With a starting current intensity of 190A

it is obtained:
30 30
= = 0,072 𝑘𝑚, 𝑖. 𝑒. 72 𝑚
2.2 × 190 418
0. In order to obtain a more considerable length, a bigger cable cross- section must be taken
(with a lower coefficient).
Example:
2
- For a cable of 3 x 35 mm + N (neutral)+T (earth), the coefficient is of 1,1
- With the same starting current intensity of 190 A

it is obtained:
30 30
= = 0,144 𝑘𝑚, 𝑖. 𝑒. 144 𝑚
1.1 × 190 209
Connecting the motors

Before connecting the crane, check the connection in the terminal boxes; carry out the same
operation when replacing a motor.
A. Identification of the motors

On the rating plate are indicated the supply voltage, the frequency of this voltage followed by the
sign for star or delta connection depending on the connection to be carried out for this voltage,
or there are two voltages indicated of which the lowest one corresponds to delta connection.
Furthermore, in order to call the servicemen’s attention to the motor 400 V in delta connection, a
plate is riveted on the motor stator.
B. Checking the direction of rotation of the motors

Having connected the crane to the mains, operate a” Lowering” pulse on the control unit or with
the jib retaining winch for GTMR and HDT cranes which are equipped with a LVF hoist winch;
check that the rope slackens.
◼ If yes, the direction of rotation is correct
◼ If not, interchange two wires in the plug or in the circuit breaker of the mains supply.
93
ERECTION/ADJUSTMENT/DISMANTLING W450-25HC-138EN-A01
4 ERECTION/ADJUSTMENT/DISMANTLING
4.1 Foreword
This part comprises the instructions allowing the fitter in charge with the crane installation on the site
to:
◼ erect the crane,

◼ carry out the adjustments,
◼ dismantle the crane.
According to the method applicable to the configuration(s) defined on the order.
The erection and dismantling operations of the crane must be ABSOLUTELY CARRIED OUT in
the indicated order.
This part does not comprise instructions concerning special operations.
These last operations can only be carried out by the constructor or his representative.
This part cannot be separated from the whole document: it can only be used after reading the
SAFETY INSTRUCTION (part 2 of this document) and TECHNICAL DATA OF CRANE AND SITE
(part 3 of this document).
94
W450-25HC-138EN-A01 ERECTION/ADJUSTMENT/DISMANTLING
4.2 Note on safety regarding erection

The operating mode defined below allows fast and safe assembling of the crane up to its climbing
or working position (complete erection by means of a mobile crane).
The erection operations need an auxiliary lifting equipment of which the characteristics must be
adapted to the parts to be handled.
AUXILIARY LIFTING EQUIPMENT
The optimization of the operating time of the mobile crane needs a good preparation and a good
coordination between the various erection and assembling sequences, the fitter teams, the
access possibilities, and the assembling area.
This document aims to familiarize yourself with the whole erection operations of which each one
is detailed in the specific files.
Erection instructions
◼ These instructions concern:
➢ The erection of the crane
➢ The increase in height of the crane
➢ The dismantling of the crane
◼ All the handling operations must be carried out according to the instructions of this manual.
and especially:
➢ Ensure the correct supports of the loads
➢ Do not work with overload
➢ Use slings in perfect condition and dimensioned for the weight of the elements to be handled.
➢ Observe the slinging points
The erection operations can only be carried out with the wind speed below 50 km/h.
The erection operations must be carried out in the order indicated in this manual.
During the preparing steps compulsorily fit the safety equipment such as ladders, platforms, grab
rails, guard ropes, etc. in order to use them during the erection.
Any hoisting operation is absolutely forbidden if the counter−jib ballast is

not placed.
COMPOSITION OF THE COUNTER−JIB BALLAST
95
FITTING THE COUNTER−JIB BALLAST BLOCKS
➢ For cranes on chassis and cross−shaped base, the ballast placed must correspond to the
hook height to be reached. In case of partial ballasting, the partial ballast must correspond
to the erection height of the crane, but must never be lower than the indicated minimum
value.
CHASSIS − BALLAST AND REACTIONS

CROSS−SHAPED BASE − BALLAST AND REACTIONS
➢ For cranes with special operating conditions, observe the given instructions.
SPECIAL CHARACTERISTICS
➢ For any particularly problem concerning the assembly organization or any other matter, do
not hesitate to ask for the technical assistance of the constructor.
For each crane, there are variable elements according to the models, versions,
options. The sketches used on the following pages represent the crane in one of
its possible configurations. When these sketches explain only a function, they
have a grey outline.
Before assembling the sections, carry out a visual check of the steel
structure parts, welds and assembling parts. Elements which show
deformations, corrosion and cracked welds must be returned to the
workshop for repairing.
Fitting the split pins

In order to ensure their pin locking function correctly, this split pin type must be fitted by opening
both split pin legs and not only the longest one (Detail B).
It is not compulsory to fold down the legs against the pin; It is sufficient to fold down each leg
according to an angle a, depending on the split pin diameter (detail C and table below). This
limited opening makes the split pin removal easier when dismantling the crane pins.
Nevertheless, it is necessary to check that the legs are not running the risk of abutting against
obstacles, what may lead to their deformation, and even their deterioration in case of shaft rotation.
In order to avoid this disadvantage, it may be necessary to fold the legs completely (Detail D).
96
Only use new split pins or split pins in good working order.
Fitting the high-strength bolt
The preload of the high-strength bolt must be aligned with the data in the
following Table 4-1
Table 4-1 Preload of high-strength bolt

Yield
Strength of Preload F1 kN
Performance point
extension
race Rel
Rm N/mm2 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39
N/mm2
8.8 ≥800 ≥640 70 86 110 135 158 205 250 310 366 437
10.9 ≥1000 ≥900 99 120 155 190 223 290 354 437 515 615
12.9 ≥1200 ≥1080 119 145 185 229 267 347 424 525 618 738
Calculate the effective area of

157 192 245 303 353 459 561 494 817 976
the bolt
Note:
The preload value in the table is calculated as 0.7 Rel, in which Rel take the minimum value
in each gear.
97
The diagram of erection

◼ Installing the base tower section to the outrigger foundation
◼ Installing two tower sections to the base tower section
◼ Installing the climbing equipment assembly (including climbing mechanism, climbing

hydraulic cylinder, pump station, etc.)
◼ Installing the transition section assembly (including mounting device and erection platfrom)
98
◼ Installing the slewing assembly (include turntable, slewing ring, slewing support, slewing
mechanisms, cabin, electrical control cabinet and electric resistance cabinet)
◼ Installing the front counter jib
◼ Installing the middle and rear counter jib (including hoisting mechanism and derrick)
99
◼ Installing a 3.9t counter ballast
◼ Installing the jib section Ⅰ and Ⅱ (including trolleys and trolley mechanism)
◼ Installing the rest jib sections
100
◼ Installing the remainder counter ballasts, electrical control system, the Hoisting rope and
hook
◼ The installation orders based on produces standard packing and delivery

status to make the optimal efficiency installation principle
◼ The installing of each unit assembly all based on the actual requirement. In
accordance with reasonable order to install in turns after dismantling. If you
have any questions, please consult our service staff.
101
4.3 Installing the tower section

Base tower section (X25G1816RaA)
The base tower section can be assembled by Ф40 pins. It connects to the outriggers by the Ф60
pin holes of the bottom, and connects to the tower sections by the Ф60 pin holes of the top. (See
the Fig. 4-1).
Fig. 4-1 Base tower section L69G20B
102
Tower section (X25G1816)

The tower section can be assembled by Ф40 pins. It connects to the base tower section or
another tower section by the Ф60 pin holes of the bottom, and connects to another tower section
or transition section by the Ф60 pin holes of the top. (See the Fig. 4-2).
Fig. 4-2 L68A1A
◼ The hinged bolts of the tower and connected pins of the tower
section are all special parts, users shall not replace them.
◼ The hexagon head of bolts should be toward outside!
◼ Pieces of the tower section are inner joint when being assembled.
103
4.4 Installing the climbing system

Climbing equipment
The climbing system consists of the structure, platform, ladders, cylinder, climbing beam, pump
station and so on, shown in Fig. 4-3. The installation of platform and rail see “SPARE PARTS
“chapters.
Fig. 4-3 Climbing system

(1) Upper platform (2) Climbing equipment structure
(3) Middle platform (4) Lower platform
(5) Ladder (6) Climbing hanging plate
(7) Climbing hydraulic cylinder (8) Climbing beam
(9) Pump station (10) Roller assembly 1
(11) Roller assembly 2
104
Installing the climbing system

After completing the climbing system assembly, as shown in Fig. 4-4, fixed the hoist on the
climbing equipment. The wire rope of hoist is packed up. Strictly make sure that the place of
Climbing hydraulic cylinder is in sync with the tower section.
The climbing equipment is installing outside the tower section.
The latch of climbing structure is place on the top of base section. Then the distance is adjusted
between the guide wheel and the tower section (the distance is 2~3mm).
Installing the climbing hydraulic cylinder, the pump station is hoisted on the lower platform. The
oil pipe is installed. Check in the pump station. Make sure that the motor fan is aligned with the
direction of the label.
Fig. 4-4 Installing the climbing system
◼ Make sure that the cylinder and the climbing lugs of sections should
be on the same side.
◼ The rollers are adjustable. Keep the gap between the rollers and
main chords of the tower sections at 2~3mm; Place the step-
changing hanging plate on the sixth step of the tower section. Then
fixing them by the pin.
105
4.5 Installing the transition section and mounting system

Assembling the mounting device to transition section
Install the mounting device to the transition section by two sets of Ф40×230 pins and 8×63 split
pins, as shown in Fig. 4-5.
Fig. 4-5 Installing the transition tower section
Assembling erection platform

In the process of tower crane erection and dismantling, in order to install the pin expediently, the
crane is equipped with an erection platform. The mounting platform is connected with the
transition joint by a latch.
1) The installation platform is composed of platform, bracket and railing, etc. It is connected
with the transition joint through latches. Assemble another piece of mounting platform, and
the required parts are the following table;
2) Assemble another piece of mounting platform in the same way;
3) Install the above assembled platform onto the import system, as shown in Fig. 4-6.
106
Fig. 4-6 Assembling the erection platform
Table 4-2 Name of parts required for assembly and erection platform
No. Designation Specification Qty
1 Railing 2
2 Railing 4
3 Railing 4
4 Railing 4
5 Support 2
6 Platform 2
7 Split pin 8×71 28
8 Pin 20×35 8
9 Spring pin 5×36 8
10 Railing splint t5 24
11 Bolt M12×70-8.8 12
12 Washer 12-200HV 24
13 Washer 12 12
14 Nut M12-8 12
107
Installing transition section mounting device and erection

platform
1) Hoisting the transition section mounting device and erection platform above the mast;
2) As shown in Fig. 5.4-14, the four main chords of the transition tower section are placed on
the tower section, then aligning their pin-holes. They are connected by 8 pins of Ф60-240,
then inserting the split pins and spring pins.
Fig. 4-7 Installing the transition section mounting device and erection platform
Make sure the stretch part of the single rail beam is on the opposite side
of the climbing lugs of sections.
108
4.6 Installing the slewing assembly

Description
The slewing assembly consists of turntable, slewing ring, slewing ring support, slewing
mechanisms, cabin and electrical control device, shown in Fig. 4-8. Turntable to slewing ring and
slewing ring support to slewing ring are all connected by 60 sets of M30×270 high-strength bolts.
Fig. 4-8 Slewing assembly

(1) Electrical control cabinet (2) Slewing mechanisms
(3) Cabin (4) Turntable
(5) Slewing ring (6) Slewing support
109
CAUTIONS:
◼ Bolt pair for slewing ring
➢ The high-strength bolts and the preload torque see the chapter 4.2.3.
➢ Use flat washers which need hardening and tempering. Spring washers could not be used.
◼ Installation of bolt pair for slewing ring
➢ Before installing, clean the erecting datum plane of slewing ring and the erecting plane of
yoke, and wipe off wet fouling, burr, paint, and other foreign impurity.
➢ During installing, the sign “S” and the hole with steel ball blocking should be placed less
under load area or no-load area (That is, the slewing ring near the installation place).
Fig. 4-9 Soft belt of the slewing ring
➢ Screw down the high-strength bolts in the direction of 180° symmetrically and continuously.
Make sure the preload moments are equal in screw bolts at the last time.
Fig. 4-10 The sequence of screwing down bolts
◼ Lubrication and maintenance
➢ Add grease into slewing ring regularly. Shorten the period of greasing in special working
condition such as in tropic, big humidity, too much dust and big range of temperature
changing. Add enough new grease before and after tower crane out of working over a long
period.
➢ Check the preload moment of bolts when slewing ring is in service for 100 hours. Then check
it once more after every 500 hours working time, ensuring there is enough preload.
➢ Do not sluice slewing ring by water for fear that water get in.
110
Installing slewing assembly

Align 4 main chords of the slewing ring support to 4 main chords connecting sleeve of transition
section. Let them down slowly to keep slewing support contact with the transition section, as
shown in figure below. Connect it to the transition section by 8 sets of Ф60×250 pins, then insert
small cotter pins of Ф20×160and spring pins.
Fig. 4-11 Installing slewing assembly
111
4.7 Mounting the counter-jib

Description
The counter jib comprises front-counter jib, middle-counter jib, rear-counter jib and counter-jib
strut, as shown in Fig. 4-12. The upper chords of counter-jib are connected by pins. The below
chords of counter-jib are connected by pin shaft positioning bolt. The front-counter jib is
connected with turntable by 4 Pins of Ф90.
There is a platform on the right part of front-counter jib to easy access. It is easy to install pins
that the top of front-counter jib has a little platform. There are two platform at the both sides of
the rear-counter jib. It is easy to install the counter jib tie bar, hoisting mechanism and counter
weights. The derrick which placed at tail of the rear-counter jib is used to repairing the hoisting
mechanism. Use the counter jib tie bar Ⅰand Ⅱ when the counter jib is short, use the counter
jib tie bar Ⅰ,Ⅱand Ⅲ when the counter jib is long.
Fig. 4-12 Counter-jib assembly

(1) Rear counter jib (2) Derrick
(3) Hoisting mechanism (4) Counter jib tie bar Ⅰ
(5) Counter jib tie bar Ⅲ (6) Middle counter jib
(7) Counter jib tie bar Ⅱ (8) Front counter jib
◼ When the jib is 45m,42.5m,40m,37.5m,35m,32.5m,30m, the middle-

counter jib needn’t to install, the counter jib is short. Otherwise,
install the middle counter jib, the counter jib is long.
◼ The hoisting wire rope support sheave is placed at the front-counter
jib.
112
Installing the counter-jib

(1) Installing the front counter jib
Hoist the front counter jib near to the turntable, align the connecting lug of turntable, slow down
to the installing position, use 4 pins of Ф90×330 to connect them, then install 25×140 split pins
and Ф6.3 spring pins.
Fig. 4-13 Installing the front-counter jib
(2) Assembling the middle or rear counter jib

Assembling the platforms, railings, hoisting mechanism and derrick to the counter jib before
installing.
Fig. 4-14 Assembled the middle or rear counter jib
113
(3) Installing the middle or rear counter jib

Hoisting the middle or rear counter jib near to the installed front counter jib, use 2 pins of Ф80×220
and Ф13×140 split pins to connect them (the holes of pins should be parallel with the counter jib),
then fix the counter jib tie bars by pins of Ф80×170 and Ф13×140 split pins.
Fig. 4-15 Installing the middle and rear counter jib
Fig. 4-16 Installing the rear counter jib
114
Installing one 3.9t counter weight
Fig. 4-17 Installing one 3.9t counter weight
◼ The counter weight is placed by hoisting mechanism, positioned at the

middle of left and right, the distance between the two sides of counter jib
and the side chords is uniform.
◼ The pins of counter weight must beyond the support plate of the counter
weight.
115
4.8 Installing the jib assembly

Assembling the jib
The jib assembly consists of the jib structure, trolley mechanism and trolley.
When assembling the jib, it should obey the sequence mark on each section, the
misplacement as well as the free assembly are not allowed. Due to the work specification,
the jib can have different length, such as 80m, 77.5m, 75m, 72.5m, 70m, 67.5m, 65m, 62.5m,
60m, 55m, 50m, 45m, 40m, 35m, and 30m.
◼ Different jib length and relation of jib order serial number and jib structure identifier
see chapter 3.4.1.4 Compositions of the .
CAUTION:
➢ To avoid of the hoisting and trolley pulleys touching the ground when being transported and
stored, the state of the pulleys should be like the Fig. 4-18.
Fig. 4-18 State of the hoisting and trolley pulleys in transportation
➢ When installing the hoisting and trolley pulleys of the Jib Ⅰ, adjust them to the after-installed
state. Otherwise, the hoisting and trolley ropes will wear the incline diagonal or the rope-
block rod as the Fig. 4-19.
Fig. 4-19 State of the hoisting and trolley pulleys after installed
116
◼ Several brackets with a length of about 1.2m are prepared near the tower crane the length
of jib above 50m shall not be less than 4, and that below 50m shall not be less than 3). Each
jib is connecting with the upper chord by a Pin, and two Pins are connecting with the bottom
chord. Assemble jib sections except jib Ⅰ, as show in Fig. 4-20.
Fig. 4-20 Assembling jib
The assembling sequence must be strictly according to the sign on each

jib section, assembling in wrong sequence or assembling optionally are
not allowed.
The trolley mechanism motor is on the opposite side of the driver’s cab.
◼ The jib pin dimensions
Table 4-3 Pins used to connect the upper chord of each adjacent jib
Connected position Pin specification Latch or split pin specification
Jib① & Counter-jib XZ04E-140×420/525 25×190
Jib① & Jib② XZ04E-120×370/455A 13×160
Jib② & Jib③ XZ04E-120×370/455A 13×160
Jib③ & Jib④ XZ04D-100×290/370A 13×140
Jib④ & Jib⑤ XZ04E-100×260/340 13×140
Jib⑤ & Jib⑥ XZ04D-70×170/230 13×110
Jib⑥ & Jib⑦ XZ04D-70×160/220 13×110
Jib⑦ & Jib⑧ XZ04D-70×160/220 13×110
Jib⑧ & Jib⑨ XZ04D-70×170/230 13×140
Jib⑨ & Jib⑩ XZ04D-70×170/230 13×110
Jib⑩ & Jib⑪ XZ04D-70×130/190 13×110
Jib⑪ & Jib⑫ XZ04D-70×130/190 13×110
117
Table 4-4 Pins used to connect the bottom chord of each adjacent jib
Connected position Pin specification Latch or split pin specification
Jib① & Counter-jib XZ04E-100×280/375 25×155
Jib① & Jib② Ф90×220/280 Ф16×130/160
Jib② & Jib③ Ф90×220/280 Ф16×130/160
Jib③ & Jib④ Ф80×201/255 Ф16×110/140
Jib④ & Jib⑤ Ф80×180/230 Ф16×110/140
Jib⑤ & Jib⑥ Ф60×160/205 Ф16×90/120
Jib⑥ & Jib⑦ Ф60×160/205 Ф16×90/120
Jib⑦ & Jib⑧ Ф60×143/190 Ф16×90/120
Jib⑧ & Jib⑨ Ф60×143/190 Ф16×90/120
Jib⑨ & Jib⑩ Ф60×121/170 Ф16×90/120
Jib⑩ & Jib⑪ Ф60×121/170 Ф16×90/120
Jib⑪ & Jib⑫ Ф60×121/170 Ф16×90/120
Installing the jib Ⅰ, Ⅱ assembly

(1) The jib Ⅰ, Ⅱ assembly including jib Ⅰ, Ⅱ, trolley mechanism and trolleys. Install the
trolley mechanism to the jib Ⅰ.
(2) Install the trolley to the jib Ⅰ and fix it to the root of jib Ⅰ by pins.
(3) Install the assembly to the counter jib by pins.
(4) When the jib length is 32.5m or 30m, there is no jib Ⅱ, install the jib Ⅰ assembly directly.
Fig. 4-21 Installing the jib Ⅰ, Ⅱ assembly
118
Hoisting the assembly of rest jib sections

(1) Operating the slewing mechanism and make it running or use the crank of slewing
mechanism to rotate the upper structure of tower crane to the position where the jib can be
conveniently installed.
(2) According to the center of gravity of the jib assembly of each jib length to hang the rope, as
shown in Fig. 4-22 and Table 4-5.Try to test the sling point whether balanced, otherwise the
position of the hanging rope can be moved appropriately. The distance between the two
sling points is 12m≤d≤20m.
Fig. 4-22 Hoisting the assembly of rest jib sections
Table 4-5 Reference gravity positions of the rest jib sections for different lengths
Jib length/m 80 77.5 75 72.5 70 67.5 65 62.5 60 57.5 55
L/m 24.2 23.3 22.6 21.8 21.9 21.1 20.5 19.7 18.7 17.7 16.7
G/t 12.7 12.4 12.2 11.9 12.0 11.8 11.7 11.5 11.0 10.6 10.1
Jib length/m 52.5 50 47.5 45 42.5 40 37.5 35 32.5 30
L/m 16.5 15.6 14.6 13.7 12.0 11.0 10.0 9.1 10.0 9.1
G/t 9.9 9.5 9.0 8.6 7.2 6.7 6.3 5.8 6.2 5.8
(3) Refer to the figure and table below to hoist single jib section if you need.
Fig. 4-23 Hoisting single jib section
Table 4-6 Reference gravity positions of single jib section

Jib section Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ Ⅵ Ⅶ Ⅷ Ⅸ Ⅹ Ⅺ Ⅻ
L/m 5.12 2.5 5 5 4.82 2.5 1.25 5 1.25 2.5 5 0.1
G/t 7.65 2.35 3.45 2.79 2.14 0.9 0.43 1.32 0.28 0.52 0.7 0.16
119
CAUTIONS:
◼ The above data are for reference and can be adjusted according to the actual situation on
site.
◼ Record the place of hoisting point for the dismantling use.
◼ Hoisting jib by rope, as shown in Fig. 4-24 Notice about hoisting jib, the methods of A, B, D
are right, while the methods of C is wrong.
◼ Forbid pulling aslant when hoisting jib assembly, as shown in Fig. 4-24 Notice about hoisting
jib.
◼ In order to reduce the volume and weight of the jib assembly, or reduce degree of difficulty
in the installation of air jib assembly and can be installed the counter jib after the completion
of any link first installed jib Ⅰ section , but this may need to be done in the air luffing rope
an tension.
Fig. 4-24 Notice about hoisting jib
Installing the assembly of rest jib sections

Lift the jib assembly to mounting height, as shown in Fig. 4-25. Connect the jib with tower head
by one Ф140×420/525 pin and two Ф100×280/375 pins.
Fig. 4-25 Installing the jib assembly
120
Installing the wind-sail plates

To ensure the tower crane slew with the wind freely and correctly when out of service, install the
wind-sail plates to jib according to the following plan:
1) When the jib length is 37.5m or 35m, install one wind-sail plate; when the jib length is 35.2m
or 30m, install two wind-sail plate.
2) The wind-sail plates are made by user yourselves. It is advised to use U-bolt sets to connect
the wind-sail plates and the jib (each set of bolts contains a U bolt of M16, two flat washers,
two spring washers, and two M16 bolts). At every position touching the web members of the
jib, it is needed to make a hole to connect. The users can adapt other connecting ways
according to the actual situation, but it must be ensured that the wind-sail plates are fixed
hard and the jib doesn’t be damaged;
3) The installing of the wind-sail plates as the figure below shows, the installing hole of the U-
bolts should be drilled at the scene to ensure the veracity.
Fig. 4-26 Installing of the wind-sail plates

(1) Wind-sail plate (2) U-bolt of M16 (3) Subplate
121
4) The drawings of the wind-sail plates are shown as the figure below. Place the wind-sail
plates to the jib, then drill the installing holes of U-bolts at the scene. The wind-sail plates
should connect to each incline web members of the jib, and the installing holes should be
drilled on the up and bottom square tube of the wind-sail plates.
Fig. 4-27 Drawing of the wind-sail plate
Table 4-7 Spare parts list of the wind-sail plate

No. Designation Specification Qty. Material
1 Square tube A □40×20×2.5-1200 2 Q235A
2 Square tube B □40×20×2.5-4866 2 Q235A
3 Round steel A Ф16-1120 3 Q235A
4 Round steel B Ф16-1220 4 Q235A
5 Plate t2-1200×5000 1 Q235A
6 Seal plate t3-20×40 4 Q235A
5) The drawings of the U-bolt and subplate see the figure below:
12.5
12.5
20
12.5
40
t6 Q235B
Fig. 4-28 Drawings of the U-bolt and subplate
122
4.9 Installing the counter-ballast

The counter-ballast block according to chapter 4.11. And the other counter-ballast, as shown in
Table 4-8 Installing the counter-ballast.
Table 4-8 Installing the counter-ballast
(Counter jib side← Jib side) 7 counter-ballasts
Jib length Installed counter ballast (t)
The other counter-ballast (t)
80m 3.0 3.9 3.9 3.9 3.9 3.9 3.9
77.5m 3.0 3.9 3.9 3.9 3.9 3.9 3.9
75m 2.0 3.9 3.9 3.9 3.9 3.9 3.9
72.5m 2.0 3.9 3.9 3.9 3.9 3.9 3.9
70m 3.0 3.9 3.9 3.9 3.9 3.9 3.9
67.5m 2.0 3.9 3.9 3.9 3.9 3.9 3.9
65m 2.0 3.9 3.9 3.9 3.9 3.9 3.9
62.5m 2.0 3.0 3.9 3.9 3.9 3.9 3.9
60m / 3.9 3.9 3.9 3.9 3.9 3.9
57.5m / 3.0 3.9 3.9 3.9 3.9 3.9
55m / 2.0 3.9 3.9 3.9 3.9 3.9
52.5m / 2.0 3.9 3.9 3.9 3.9 3.9
50m / 2.0 3.0 3.9 3.9 3.9 3.9
47.5m / / 3.9 3.9 3.9 3.9 3.9
45m 2.0 3.9 3.9 3.9 3.9 3.9 3.9
42.5m / 3.0 3.9 3.9 3.9 3.9 3.9
40m / 2.0 3.9 3.9 3.9 3.9 3.9
37.5m / 2.0 3.0 3.9 3.9 3.9 3.9
35m / / 3.9 3.9 3.9 3.9 3.9
32.5m / / 2.0 3.0 3.9 3.9 3.9
30m / / 2.0 3.0 3.9 3.9 3.9
123
Take the jib length is 30m for example, the installation of the other counter weights is shown as
following picture. First three pieces of 3.9t counter weight are installed near the jib side, then
3.0t counter weight is installed, and finally 2.0t counter weight is installed.
Users have to choose a proper plate to cover the remaining empty after
installing all the counter-weight.
After install all the counter weight, please check carefully and make sure
that all the counter weight are fixed stable.
4.10 Installing the electrical control system

After installing jib assembly, cabin, mechanism, and safe control devices could be debugged by
wiring. Except overload limiter, trolley mechanism and other safe control devices, other electrical
control system can be wiring and install on the counter jib.
The installation position of warning lights and anemometer, located in Fig. 4-29
Fig. 4-29 Warning light and anemometer

(1) Warning light (2) Camera (3) Anemometer
124
4.11 Circling the ropes
Circling the trolley ropes

Put the long and short trolley ropes cross the middle pulley, jib root pulley and jib end pulley, then
connect to the trolley.
Fig. 4-30 Trolley wire rope layout plan

(1) c Root jib pulley (2) Trolley mechanism drum
(3) Trolley (4) Jib’s rope wheel
(5) Tip pulley (6) Short ropes
(7) Long ropes
◼ When change the double trolleys to single trolley, take out the trolley
rope in the safe room of the auxiliary trolley.
◼ The short and long ropes of trolley mechanism must have three
circles of safety rope on the drum under any circumstances, and a
circle of isolation rope should be left on the drum.
◼ When changing the length of jib, the excess rope is tied and fixed to
the trolley.
Circling the hoisting rope

a) Fix the hook to the support (height 1.5m) on the ground as the figure below Put out the
Hoisting rope from the drum of hoisting mechanism, cross the roller of counter jib, pulley of
load limiter, then go back to the jib root pulley and get into the trolley and hook.
125
Fig. 4-31 Circling of the hoisting rope at 4-fall
Fig. 4-32 Circling of the hoisting rope at 2-fall

(1) c Drum (2) Roller
(3) Load limiter (4) Jib root pulley
(5) Trolley (6) Hook
(7) Anti-twist device
b) Fix the hoisting rope to the wedge connector, then fix to the trolley, as shown in Fig. 4-33
Fig. 4-33 The drawing of rope fixing

(1) Wire (2) Wedge (3) Hoisting rope
126
c) Slowly start the hoisting mechanism. Hoist the hook to a height of 1 meter above the ground,
and make sure that the hoisting rope has been fixed firmly.
d) Start the luffing mechanism to open the trolley and hook to the hoisting tip jib.
e) Fix the wedge at the tip jib anti-twisting device. Slowly lower the trolley to the support below
the tip jib. And dismantle the rope clamp that fixed the hoisting the trolley, and loosen the
hoisting rope.
◼ When hoisting ropes are non-rotating ones, the anti-twist device

shall lock tightly the locking screws 3 and 5 (see Fig. 4-34) while the
tower crane is in service.
◼ When Hoisting ropes are anti-rotation ones, the anti-twist device
shall unlock the locking screws when the crane is in service.
◼ When using new ropes, the hook will rotate at no-load operation.
Currently, unlock the anti-twist device.
◼ After long time using of tower crane, the wire ropes will be extended
and slightly twisted, in this case, unlock the anti-twist device
temporarily, and lock the device again when ropes have been
tensioned.
◼ Once rope has their strands loosened, the anti-twist device will
accelerate rope deterioration, so should change the deteriorated
ropes timely.
Fig. 4-34 Anti-twist device

(1) c Hoisting rope (2) Wedge
(3) Lock screws① (4) Anti-twist device structure
(5) Lock screws②
Power connection and test run

Switch on power to all electrical circuits according to the electric circuit diagram and start all
mechanisms for test run. Check mechanism for proper operations. At the same time, check wire
ropes at different locations for normal working and for any interference with structure member.
Remove all abnormal cases.
127
4.12 Fall-changing system

Description
The fall-change system consists of 4 parts, i.e. the main trolley, the auxiliary trolley and main
hook, auxiliary hook, the setting on the jib as Fig. 4-35. Rope winding on the main trolley, the
auxiliary trolley and main hook, auxiliary hook are as Fig. 4-36. The connection-disconnection of
the main trolley and the auxiliary trolley enable conversion of 2-fall and 4-fall (referred to
hereinafter as fall-change).
Fig. 4-35 The schema of the fall-changing system

(1) c Auxiliary Trolley (2) Auxiliary Hook
(3) Main Trolley (4) Main Hook
The fall-change is converted at the jib root section under the conditions of no-load, slow speed
and no swing. No matter how it is required to convert 2-fall to 4-fall or to convert 4-fall to 2-fall,
the by-pass switch must at first be turned to the by-pass status to disable the height limiter. After
conversion completion, the bypass switch must be restored to its original status. At the 2 fall
working conditions, the auxiliary trolley is fixed at jib root, the auxiliary hook with automatic
connection device contacts tightly the auxiliary trolley.
When main trolley and auxiliary trolley, main hook and auxiliary hook are connected together,
main hook and auxiliary hook like two traveling pulleys, so the trolley work at 4-fall; When main
trolley and auxiliary trolley, main hook and auxiliary hook are separated, auxiliary trolley is fixed
at jib root connected auxiliary hook, auxiliary trolley and auxiliary hook like one immobile pulley,
so the trolley work at 2-fall.
128
Method for 2-fall to 4-fall conversion
Fig. 4-36 2-fall to 4-fall conversion

(1) c Main Trolley (2) Auxiliary Trolley
(3) Auxiliary Hook (4) Pin A
(5) Pin B (6) Pin C
(7) Connecting base A (8) Connecting base B
Fig. 4-37 Hook

(1) c Plate (2) Main hook
(3) Auxiliary Hook (4) Pin A
(5) Pin B
129
1) Before fall-change, auxiliary hook is fixed at auxiliary trolley by shafts b, auxiliary trolley is
fixed at jib root by shafts a, and then auxiliary trolley is stopped (Fig. 4-36).
2) Operate slowly the trolley to move back, when the main trolley impacts the auxiliary trolley.
Connect the main trolley and auxiliary trolley with shafts c. Pull back the hoisting rope,
uninstalling the shafts b, disport the auxiliary hook and auxiliary trolley; uninstalling the
shafts a, disport the jib and trolley (Fig. 4-36).
3) Operate the hoisting mechanism, place down main hook and auxiliary hook on the ground,
insert pin a and pin b, connect main hook and auxiliary hook together (Fig. 4-37), then realize
the conversion 2-fall to 4-fall.
Method for 4-fall to 2-fall conversion

1) Lower the hook to the ground, dismantle the pin 1 pin 2, separate the auxiliary hook and
main hook.
2) Start the hoisting mechanism slowly, raise the auxiliary hook, at the same time, and operate
the trolley to the jib root. Raise the auxiliary hook continuously, when contact the auxiliary
trolley, stop hoisting, then insert shaft a and shaft b, dismantle the shaft c.
3) Drive the trolley mechanism, and let the main trolley to slowly move out. Then realize the
conversion 4-fall to 2-fall.
Please adjust the safety device before starting to use the tower crane.
130
4.13 Climbing operation

General Notices of Climbing Operation
1) Keep the crane rotation part in balance before climbing.
2) It is prohibited to operate the jacking system when the wind speed at the highest spot
exceeding 14m/s.
3) Make sure that the climbing system works normally before climbing.
4) It is prohibited to hoist load (up or down) while the jacking system is in operation or after
jacking.
5) It is prohibited to move the trolley while the jacking system is in operation or after jacking.
6) Keep the jib in the same direction as the in-let tower section during jacking operation. Stop
the jib with the slewing mechanism brake and be sure of the trolley stopping at the jack-
balanced position.
7) If several tower sections are to be added in succession, then after each section is added,
the next tower section is hoisted by the mast itself. The mast connected to transition must
contain 4 Ф60 pins (each main chord rods use one). Only in this case can each main chord
rods connected transition use 1 Ф60 pin, shoulder-free pins be permitted for use. Allow to
balance hoisting within trim range, but the slewing operation is prohibited.
8) Keep the climbing lugs on the newly added tower section in alignment with those on the
existed section.
9) It is prohibited to slew, change work-radius and hoist load without connection of the slewing
ring support to the tower body by Ф60 pins, except the seventh permit.
10) If the jacking hydraulic system has become abnormal in the course of jacking, stop
immediately the climbing operation then retract the oil cylinder and lower the slewing ring
support onto the top of tower body and use 8 Ф60 pins to connect the transition to the tower
body, and then removing troubles from the hydraulic system.
11) When the height has reached the demanded work height (not exceeded the independent
height), slewing the jib at different angles, check all the connections of the tower crane,
including the embedded bolts (if one main chord is below the counter jib, then fasten all the
nuts).
12) After finish climbing, all the connection of tower sections uses 8 Ф60 pins, the top tower
section connected transition by 8 Ф60 pins
Please strictly operate the tower crane according to the operation

instructions for the climbing process is most likely to have grave
accidents.
131
Pre-climbing preparation
1) Dismantling the binding hung beam rope, connected the pump station and circuit. Fill the oil
tank with hydraulic oil according to the requirements of hydraulic pump station. Make sure
of the electric motor circuit correctly connected and the fan rotates clockwise and the
operating lever of hand control valve working smoothly without any clogging.
2) Clean each tower mast. Set up each tower section with correct order and grease its
connection pinholes. Place in row the tower sections to be jacked just under the jib before
jacking. This will enable no slewing mechanism in the whole process of jacking operation
for adding sections, thus minimize the jacking time.
3) Release the power cable slightly in excess of the total jacking height, and then fix the cable.
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 front and rear sides of counter-jib). Use the slewing brake
to control the jib.
5) On the platform of the climbing frame, prepare 8 Ф105 pins.
6) Remove the movable brace rod.
Installing the tower section on the mounting device

Before balance the climbing, hoist none or one or two tower sections on the mounting device
according to the Table 4-10 and Table 4-11. The specific processes are:
1) Combine the tower section to be hoisted and the hoisting frame by hoisting shackle and
rope as the figure below.
Fig. 4-38 Combine the tower section to be hoisted and the hoisting frame
(1) Hoisting frame (2) Hoisting shackle (3) Rope (4) Mounting hook
2) Get to the upper platform of the climbing equipment and turn the rocker on the rear of the
mounting device, make the mounting trolley move to the far end.
3) Hang the mounting hook to the hoisting hook, then hook the hoisting frame and tower section
to the mounting hook and hoist them. Hang the hoisting frame on the mounting trolley slowly,
132
then secede the mounting hook.

4) Turn the rocker on the rear of the mounting device, make the mounting trolley and climbing
equipment move to the position of almost 3.0m from the tower center along the mounting
device.
Keep the tower crane in balance before climbing

Before keeping the tower crane in balance, hoisting device of the tower section and mounting
device must connect through 4 sets shackle, and then hoist the hoisting device and mounting
device of special hook, and put on the mounting beam of transition section (Show in Fig. 4-39).
Move the trolley to the reference balance position, show in Table 4-9. Hoist one tower section or
other weights (The trolley position in table is an approximate value, which must be adjusted
according to the actual situation in climbing), and then dismantling the pins between the transition
section and tower section.
Fig. 4-39 Keep the crane in balance
133
Table 4-10 Reference balance position of different lengths of jib (4-fall)

Jib length Weight G Radius L Jib length Weight G Radius L
(m) (t) (m) (m) (t) (m)
80m 46.3 52.5m 4.00 22.8
77.5m 0 58.1 50m 4.00 23.4
75m 56.4 47.5m 4.00 23.3
72.5m 4.00 16.3 45m 4.00 21.9
70m 4.00 18.6 42.5m 4.00 22.7
67.5m 4.00 18.4 40m 4.00 22.9
65m 4.00 20.7 37.5m 4.00 23.5
62.5m 4.00 20.6 35m 4.00×2 23.1
60m 4.00 20.9 32.5m 4.00×2 23.2
57.5m 4.00 22.0 30m 4.00×2 25.2
55m 4.00 22.4
Table 4-11 Reference balance position of different lengths of jib (2-fall)

Jib length Weight G Radius L Jib length Weight G Radius L
(m) (t) (m) (m) (t) (m)
80m 12.3 52.5m 4.00 25.5
77.5m 4.00 15.6 50m 4.00 26.2
75m 15.2 47.5m 4.00 26.2
72.5m 4.00 18.3 45m 4.00 24.6
70m 4.00 20.9 42.5m 4.00 25.5
67.5m 4.00 20.6 40m 4.00 25.7
65m 4.00 23.2 37.5m 4.00×2 26.3
62.5m 4.00 23.2 35m 4.00×2 25.9
60m 4.00 23.5 32.5m 4.00×2 26.0
57.5m 4.00 24.7 30m 4.00×2 28.3
55m 4.00 25.2
134
CAUTIONS:
◼ These values are based on approximate figures only, which must be adjusted according to
the actual situation in climbing.
◼ Make the top structure of the tower crane at the slewing-braking state by active the brake of
the slewing mechanism. Slewing movement is not allowed.
◼ Pushing the operation handle of the hydraulic climbing system to “Climbing direction”,
extract the oil cylinder to jack the hang plate into groove near the tower section’ climbing lug,
insert the safety pin, continue to extract the oil cylinder to jack the climbing frame to a
position where the transition section is just disengaged from the main chord rod of the tower
body.
◼ Check the support leg and tower body main chord rod connect the transition section and
tower sections to make sure that they are in the same vertical line. Check 16 guide rollers
and tower body main chord rod to make sure that they have the same clearance. This serves
to determine whether the tower crane is in balance. If not, adjust the balance position of the
trolley until balance is achieved to drop the center of gravity of the upper tower crane onto
the position of climbing cylinder beams.
◼ Record the balance position of trolley. Note: This value varies with the jib length.
◼ Operate the operation handle of the hydraulic system to fall the climbing equipment. Connect
the Pins between the transition tower section and tower section.
Climbing operation
135
Fig. 4-40 Climbing process Ⅰ
1) Use the brake on the slewing mechanism to hold the tower superstructure at a slewing
braking status, thus ensuring no slewing movements;
2) As the step ① in Fig. 4-40, dismantle 8 pins of Ф60 which connecting the tower head and
the transition section, save them on the platform;
3) As the step ② in Fig. 4-40, turn the step changing control handle up to make the step
changing plate incline to outside so to avoid intervening steps when climbing. Lock the
handle when the plate moves to appropriate position to prevent it rotating, as the step ③ in
Fig. 4-40;
4) Start the hydraulic climbing system, extend the climbing oil cylinder to set the climbing beam
to the channels of step A, then insert the safety pins, As the step ④⑤ in Fig. 4-40;
In the process, there must be someone professional to observe if the

climbing cross beam is set in the channels and insert the safety pins!
5) Ensure the climbing cross beam is set in the channels and the safety pins are inserted in.
As the step ⑥ in Fig. 4-40, keep climbing until the climbing equipment and the upper parts
is lifted for 10~50mm;
Keep the state for nearly 20 minutes, check if there are any abnormal
sounds, shifting, transformation in the force bearing parts of the climbing
equipment, climbing cross beam for example; check if there is abnormal
phenomenon such as automatic shrinking on the piston rod of the oil
cylinder. Only when the check results are OK, the climbing processes can
continue to be executed.
6) Keep climbing after checking the parts are OK; jack up the climbing equipment to make it a
little higher than the step C of the tower section, then stop climbing;
7) As the step ⑦⑧ in Fig. 4-40, shrink the oil cylinder slowly, turn the step changing control
handle down to make the step changing plates incline inward to be vertical and place in the
channels of step C, as the step ⑨⑩ in Fig. 4-40.
136
Fig. 4-41 Climbing process Ⅱ

8) Ensure the four step changing plates are pressing the step channels and standing the weight
of the climbing equipment and the upper parts, and make sure there is no abnormal
phenomenon such as transformation, abnormal sounds. Confirming OK, as the step ①②
in Fig. 4-41, pull the safety pins from the climbing cross beam, shrink all the pistons of the
oil cylinder, then the beam rises, place in the closest channels of step B and insert the
safety pins, as the step ③ in Fig. 4-41.
9) As the step ④⑤ in Fig. 4-41, turn the step changing control handle up to make the step
changing plate incline to outside so to avoid intervening steps when climbing. Lock the
handle when the plate moves to appropriate position;
10) As the step ⑥ in Fig. 4-41, extend the oil cylinder again, jack the climbing equipment up,
make the step changing plates a little higher than the step D. As the step ⑦⑧ in Fig. 4-41,
shrink the oil cylinder slowly, turn the step changing control handle down to make the step
changing plates incline inward to be vertical and place in the channels of step D, as the step
⑨⑩ in Fig. 4-41;
137
11) Ensure the four step changing plates are pressing the step channels and standing the weight
of the climbing equipment and the upper parts, and make sure there is no abnormal
phenomenon such as transformation, abnormal sounds. Confirming OK, pull the safety pins
from the climbing cross beam, shrink all the pistons of the oil cylinder, then the beam rises,
place in the closest channels of step C and insert the safety pins;
12) Operate as the prosses (10) ~ (12) until the climbing cross beam set on the step E of the
tower section and insert the safety pins, when the oil cylinder extends completely at the
time, there is a space bigger than one tower section above the mast, see the figure below:
Fig. 4-42 Climbing process Ⅲ

13) As the step ① in Fig. 4-42, start the mounting device, mount the tower section on the
mounting cross beam of the slewing support to the right above the mast. As the step ② in
Fig. 4-42shrink the oil cylinder slowly, make the connectors of the mounting tower section
and the uppermost tower section of the mast touch each other. Then shrink the oil cylinder,
align the pin holes of the mounting section and the uppermost section;
138
14) As the step ③ in Fig. 4-42, connect the mounting section and uppermost section by 8 pins
of Ф60 hard. Knock the pins in the holes, notice to align the installing hole direction on the
end of the pins to the hole direction of the tower section, insert the split pins the spring pins
after the inserting;
15) As the step ④ in Fig. 4-42, remove the connecting between the hoisting lugs of the tower
section and the tie bar, start the mounting device, pull out the lifting frame along the mounting
cross beam, as the step ⑤ in Fig. 4-42;
16) As the step ⑥ in Fig. 4-42, keep shrinking the oil cylinder, align the connecting pin holes of
the mounting tower section and the transition section, knock in 8 pins of Ф60, notice to align
the installing hole direction on the end of the pins to the hole direction of the transition section,
insert the split pins the spring pins after the inserting, as the step ⑦ in Fig. 4-42;
17) Until here the climbing processed of one tower section is done, if it is needed to climb more
tower section, follow and repeat the processes above.
18) The last tower section should be: Fixed to the mast at the bottom, fixed to the
transition section on the top.
139
4.14 Tower anchored onto the building

When the working height of the tower crane is required to exceed its free-standing height, the
tower body shall be anchored.
Description
The attachment is consisting of two frame beams and four room diagonals. The frame beams
can be fixed to be an attachment frame by 12 sets of M30 bolts, nuts, washers (preload 1400N•m).
There are four attachments strut rods connect to the joint points on the vertexes of the frame.
And there are connecting lugs on the end of the four strut rods for connecting to the foundation
supports on the building. The four strut rods should keep on the same horizon level, as shown in
Fig. 4-43.
Fig. 4-43 The attachment frame
Installing the attachment frame

1) Arrange the attachment according to Fig. 4-44. completely. If the actual distance is different
with the design distance, please contact us for nonstandard design. The way of connecting
the foundation supports and the building can be adjusted according to the actual situation.
2) Fist, cover the mast by the attachment frame, then use the four room diagonals to support
the four main chords and connect to the diagonals of the mast; connect one end of the
attachment rods to the frame by pins, connect the other end of the attachment rods to the
foundation support of the building.
140
Fig. 4-44 Arrangement of the attachment

3) The four attachment rods should keep on the same horizon level. But when installing the
attachment frame and room diagonals, if the parts interfere with the tower section, the height
of the frame can be adjusted. The height difference of the frame and foundation support
can’t be over 1/1000, the maximum value can’t be over 200mm.
4) It is allowed to set passage plate for people from the building to the crane, but it is prohibited
to place heavy things.
5) Load on the attaching point:
Before installing the crane, the users should estimate the load-standing power of the building
attaching point and the factors which influence the strength of the attaching point, such as the
constructing date of the concrete and rebar structure. The table below shows the maximum load
on the building attaching point when the attachment rods are set as the Fig. 4-45. The load-
standing power of the building attaching point can’t be less than the value in the table.
Fig. 4-45 Loads on the attachment points
141
Table 4-12 Loads on the attachment points

F1(kN.) F2(kN) F3(kN) F4(kN)
± 347 ± 412 ± 347 ± 412
Fig. 4-46 Drawing of the embedded attachment foundation
The load value can change sharply because of the relative position of the
crane and building, the arranging style and size of the brace rods, or the
height above the uppermost attachment frame. So, when attaching, if the
position of the attachment or the arranging style of the brace rods are
different from Fig. 4-45, please contact us for advice. Do not use the values
in Table 4-12 blindly.
6) When installing the attachment frame, use the theodolite to check the verticality of the axis
of the verticality of the axis of the tower mast. The vertical degree of the tower axis above
the highest attachment point is 4/1000, When the deviation of the vertical degree of the
tower axis does not meet requirements and the deviation is constant, the user can adjust
the length of attachment rod to meet the requirements.
7) All the connecting between the mast, the room diagonals, the attachment frame, the
attachment rods, the foundation support and the building must be stable. The bolts must be
fastened well, the adjust bolts must be fastened well after adjusting, the split pin must open
according to the standard. Check if the fasteners are loose or not frequently, if yes, adjust
them in time.
◼ No matter how many the attachments are, the highest and second
high attachment must install the room diagonals to the mast.
◼ Hang the attachment frame to the tower section by the rope to avoid
the frame falling down.
142
Arrangement of the attachment frame

1) The max hoisting height is 65.7m, use attachment to fix the crane if bigger height needed.
2) The maximum hoisting height for the 2-fall attached crane is 396.3m; if the crane is 4-fall
attached crane, the maximum height is 260m;
3) The structure arrangement of attached crane is the same with the free-standing crane. The
attached crane only increases the hoisting height and adds unitary type tower sections
needed. For increasing the stability and rigidity of the crane, there are several attachments
set on the whole mast;
4) When adding the attachments, the distance between the center of the mast and the building
should be 5.5m, if the actual distance is not, please contact us for advice. The following
arrangement plans of have considered the construction requirements, the force bearing of
the mast and attachment frame, the distance between the attachment frame and the plane
of the foundation, the distance between the attachments, and the maximum height above
the uppermost attachment. Section 4.9.3.2 can content the general construction
requirements and make a most economical attachment plan.
Anchored technical requirements for 51m free standing height

The tower crane anchored technical requirements as show in the following table. The height of
first anchored frames h1, the height of each two Anchored frame Δh and the height of tower
above the anchored-frame have given range, and the range of height change into corresponding
number of tower sections, that worth noting, when the working height is over 100m, the allowable
maximum height of tower above the anchored-frame can be reduce appropriately. Drawing of
attachment and important dimension refer to Fig. 4-47.
Fig. 4-47 Drawing of anchored tower crane
143
Table 4-13 Technical requirements of attachment

Below the first Height h1 /m 26.0≤h1 ≤43.1
anchored frames Quantity of tower sections n1 4 ≤ n1 ≤ 7
Height Δh /m 22.8 ≤ Δh1 ≤ 28.5
Each two anchored Maximum working
Quantity of tower
frames height H≤400m 4 ≤ Δn ≤ 5
sectionsΔn
Hˊ/m Hˊ≤ 42.75
Above maximum Maximum working
Quantity of tower
anchored frames height H≤400m n≤ 7
sections n
In this table “Hˊ” is refer to the distance of the highest anchored frame to the
bearing face of hook, “the height of tower above the anchored-frame L” is refer
to the distance of the highest anchored frame to the highest tower section of its
upper end plane.
Most economic anchored-frame layout for the stationary crane
with embedded anchors
Table 4-14 Parameter of most economic anchored-frame layout

Qty of Highest The height of Height of tower Qty of Qty of
anchored- working top attachment above the anchored- base tower
frame height H/m H/m frame Hˊ/m section section
1 H1=94.2 h1=54.15 ≤42.75 15
2 H2=122.7 h2=79.95 ≤42.75 20
3 H3=151.2 h3=108.45 ≤42.75 25
4 H4=179.7 h4=136.95 ≤42.75 30
5 H5=208.2 h5=165.45 ≤42.75 35
6 H6=236.7 h6=193.95 ≤42.75 40
1
7 H7=265.2 h7=222.45 ≤42.75 45
8 H8=293.7 h8=250.95 ≤42.75 50
9 H9=322.2 h9=279.45 ≤42.75 55
10 H10=350.7 h10=307.95 ≤42.75 60
11 H10=379.2 h10=336.45 ≤42.75 65
12 H10=396.3 h10=353.55 ≤42.75 68
144
4.15 Safety devices

Foreword
This description concerns the safety devices which have an action on the signaling and on the
crane motions. It contains the adjustment and maintenance instructions which are common for
all device types. The safety devices are not working devices. They only act exceptionally in order
to avoid the consequences of an incorrect maneuver or a driving error.
The safety devices are divided into families:
◼ Moment cutouts acting on the movements “Hoisting”, “Trolley out” “Jib Up and Down” (for
luffing jib cranes). They are often linked to other devices and act in the following order:
➢ Speed limiter (according to the version): decelerates the movement before the action of the
moment cutout
➢ Signaling of 90% of the max. moment
➢ Moment cutout: stops the movement when the max. crane capacity is reached
➢ Emergency moment cutout (according to the version): stops the crane in case of
malfunctioning of the moment cutout
◼ Load limiters acting on the hoisting movement and the Jib Up movement (Luffing jib crane).
These limiters are often linked to other devices and act in the following order:
➢ Adaptation of the hoisting speed depending on the load
➢ Signaling of 90% of the maximum load
➢ Load limiter: stops the “Hoisting” movement
➢ Emergency load limiter (according to the version): stops the crane in case of malfunctioning
of the MSWL cutout.
◼ Limit switches which limit the various crane movements: Hoisting/Lowering, JIB luffing,
slewing, trolleying, and traveling. These limit switches are often linked to other devices and
act in the following order:
➢ Speed limiter (according to the version): decelerates the movement before the action of the
limit switch
➢ Limit switch: stops the movement
➢ Emergency limit switch (according to the version): stops the movement in case of
malfunctioning of the limit switch
◼ Overspeed limiters (according to the version): stops the movement concerned in case of
runaway of the motor.
The functioning of the limit switches must be checked by the crane driver
at each work start with crane without load.
In case of releasing the emergency limit switches for moment, load or

speed, a maintenance technician must be called in order to check the
adjustments of the safety devices before putting again the crane into
services
145
Synopsis
(1) Hoisting limiter (2) Slewing limiter

(3) Trolley limiter (4) Mechanical load limiter
(5) Mechanical load moment limiter
Table adjustments of safety devices

check before the commissioning and texting
In order to check the correctness of erection work and ensure safe operation, a series of test
operation and comprehensive inspection of all parts of the tower are conducted.
◼ Check the connection between components.
◼ Check the installation of support platform and handrail.
◼ Check whether the wire rope is properly wound or not, and whether they are in interference
or friction.
◼ Check the cable traffic condition.
◼ Check the fixed condition of the counter weight.
◼ Check the platform and prevent the sundries from falling when the tower crane runs.
◼ Check the lubrication.
Adjusting the safety device
◼ Check the tower crane by operating all parts to ensure the assembly
is correct and can be used safely. According to section 1 of this
chapter.
◼ The adjustment and inspection of the safety devices are operated in
the 4-fall status.
Means "High Speed" Means "Middle Speed" Means "Low Speed"
146
Load moment limiter

A. Function
The rated load limit moment is constant. It is prohibited to exceed the rated load moment during
crane operation. The load moment limit switch is to prevent the cranes’ working moment from
exceeding rated load moment.
B. Working principle
The load moment limit switch consists of plates which can be moved via deformation and several
limit switches. The plate is fitted with several adjustable screws, which correspond to the trolley
moment respectively.
According to the clearance between adjustable screw and limit switch, the switch acts within the
safety control circuits subjected to load moment.
Fig. 4-48 Adjusting of load moment limiter
◼ The adjustment of Load moment limiter shall be at the fee standing height
of crane, which mark in the chapter 3 "TECHNICAL DATA OF CRANE AND
SITE”. If the tower crane over fee standing height or super height, the load
value shall reduce the weight of over height rope and additive hook.
◼ After adjustment, the anti-loose nut shall be lock.
147
C. Adjustment
a) Constant load for variable radius
◼ Adjustment of 80% hoisting moment alarm
Adjustment method: The maximum lifting weight 25t (4-fall) or 12.5t (2-fall) at the minimum
range,1m from the ground, trolley out toward at the normal rate, it should be able to trolley out
toward at low speed when reaching the 0.8 Rmax ~0.85Rmax.
Rmax represents the maximum working range for maximum weight. (After the same)
Fig. 4-49 Adjustment of trolley moment limiter

Adjust moment limit switch
Feedback signal of moment limiter
Adjusting bolts position D
Jib Load Start Feedback Yellow Red No No
Trolleying
length Fall Weight Position position light early light hoisting trolleying
slow down
R(m) W(t) R0(m) R1(m) warning alarm upwards forwards
4 25 10 11.9～12.7 ● / / / /
80
2 12.5 15 22.5～23.9 ● / / / /
4 25 10 12.9～13.5 ● / / / /
77.5
2 12.5 15 24.0～25.5 ● / / / /
4 25 10 13.4～14.2 ● / / / /
75
2 12.5 20 25.4～26.9 ● / / / /
4 25 10 14.0～14.8 ● / / / /
72.5
2 12.5 20 26.6～28.2 ● / / / /
4 25 10 14.9～15.8 ● / / / /
70
2 12.5 20 28.4～30.2 ● / / / /
4 25 10 15.0～15.9 ● / / / /
67.5
2 12.5 20 28.6～30.4 ● / / / /
4 25 10 15.4～16.3 ● / / / /
65
2 12.5 20 29.4～30.1 ● / / / /
4 25 10 15.7～16.7 ● / / / /
62.5
2 12.5 20 30.0～31.9 ● / / / /
4 25 10 15.8～16.8 ● / / / /
60
2 12.5 20 30.2～32.1 ● / / / /
57.5 4 25 10 15.8～16.8 ● / / / /
148
2 12.5 20 30.2～32.1 ● / / / /
4 25 10 15.9～16.9 ● / / / /
55
2 12.5 20 30.5～32.4 ● / / / /
52.5 4 25 10 16.0～17.0 ● / / / /
50 4 25 10 16.1～17.1 ● / / / /
47.5 4 25 10 16.1～17.1 ● / / / /
45 4 25 10 16.2～17.2 ● / / / /
42.5 4 25 10 16.3～17.3 ● / / / /
40 4 25 10 16.4～17.4 ● / / / /
37.5 4 25 10 16.4～17.5 ● / / / /
35 4 25 10 16.5～17.5 ● / / / /
32.5 4 25 10 16.5～17.5 ● / / / /
30 4 25 10 16.5～17.5 ● / / / /
◼ Adjustment of 90% hoisting moment alarm
toward at low speed when reaching the 0.9 Rmax ~0.95Rmax.
Fig. 4-50 Adjustment of moment limiter early warning

Adjusting bolts position C
Jib Load Start Feedback Trolleying Yellow No No
Red light
length Fall Weight Position position slow light early hoisting trolleying
alarm
R(m) W(t) R0(m) R1(m) down warning upwards forwards
4 25 10 13.4～14.1 / ● / / /
80
2 12.5 15 25.3～26.7 / ● / / /
4 25 10 14.3～15.0 / ● / / /
77.5
2 12.5 15 27.0～28.5 / ● / / /
4 25 10 15.0～15.9 / ● / / /
75
2 12.5 15 28.5～30.1 / ● / / /
72.5 4 25 10 15.7～16.6 / ● / / /
149
2 12.5 15 29.9～31.6 / ● / / /
4 25 10 16.8～17.7 / ● / / /
70
2 12.5 15 32.0～33.8 / ● / / /
4 25 10 16.9～17.8 / ● / / /
67.5
2 12.5 15 32.1～33.9 / ● / / /
4 25 10 17.3～18.3 / ● / / /
65
2 12.5 15 33.0～34.9 / ● / / /
4 25 10 17.7～18.7 / ● / / /
62.5
2 12.5 15 33.8～35.6 / ● / / /
4 25 10 17.8～18.8 / ● / / /
60
2 12.5 15 33.9～35.8 / ● / / /
4 25 10 17.8～18.8 / ● / / /
57.5
2 12.5 15 34.0～35.9 / ● / / /
4 25 10 17.9～18.9 / ● / / /
55
2 12.5 15 34.3～36.2 / ● / / /
52.5 4 25 10 18.0～19.0 / ● / / /
50 4 25 10 18.1～19.1 / ● / / /
47.5 4 25 10 18.2～19.2 / ● / / /
45 4 25 10 18.2～19.2 / ● / / /
42.5 4 25 10 18.3～19.4 / ● / / /
40 4 25 10 18.4～19.5 / ● / / /
37.5 4 25 10 18.5～19.5 / ● / / /
35 4 25 10 18.5～19.5 / ● / / /
32.5 4 25 10 18.5～19.5 / ● / / /
30 4 25 10 18.5～19.5 / ● / / /
◼ Adjustment of over hoisting moment alarm
toward at low speed when reaching the 1.05 Rmax ~1.10Rmax, the red light on the console should
work and the horn should blow at this time, and the hoisting up and trolleying out are cut off.
Fig. 4-51 Adjustment for alarm
150

Adjusting bolts position C
Jib Load Start Feedback Trolleying Yellow Red No No
length Fall Weight Position position slow light early light hoisting trolleying
R(m) W(t) R0(m) R1(m) down warning alarm upwards forwards
4 25 10 15.6～16.4 / / ● ● ●
80
2 12.5 20 29.5～30.9 / / ● ● ●
4 25 10 16.6～17.4 / / ● ● ●
77.5
2 12.5 20 31.5～33.0 / / ● ● ●
4 25 10 17.5～18.4 / / ● ● ●
75
2 12.5 20 33.3～34.9 / / ● ● ●
4 25 10 18.3～19.2 / / ● ● ●
72.5
2 12.5 20 34.9～36.5 / / ● ● ●
4 25 10 19.6～20.5 / / ● ● ●
70
2 12.5 20 37.3～39.1 / / ● ● ●
4 25 10 19.7～20.6 / / ● ● ●
67.5
2 12.5 20 37.5～39.3 / / ● ● ●
4 25 10 20.2～21.2 / / ● ● ●
65
2 12.5 20 38.5～40.4 / / ● ● ●
4 25 10 20.6～21.6 / / ● ● ●
62.5
2 12.5 20 39.4～41.3 / / ● ● ●
4 25 10 20.7～21.7 / / ● ● ●
60
2 12.5 20 39.6～41.5 / / ● ● ●
4 25 10 20.8～21.7 / / ● ● ●
57.5
2 12.5 20 39.7～41.5 / / ● ● ●
4 25 10 20.9～21.9 / / ● ● ●
55
2 12.5 20 40.0～41.9 / / ● ● ●
52.5 4 25 10 21.0～22.0 / / ● ● ●
50 4 25 10 21.1～22.1 / / ● ● ●
47.5 4 25 10 21.2～22.2 / / ● ● ●
45 4 25 10 21.3～22.3 / / ● ● ●
42.5 4 25 10 21.4～22.4 / / ● ● ●
40 4 25 10 21.5～22.5 / / ● ● ●
37.5 4 25 10 21.6～22.6 / / ● ● ●
35 4 25 10 21.6～22.6 / / ● ● ●
32.5 4 25 10 21.6～22.6 / / ● ● ●
30 4 25 10 21.6～22.6 / / ● ● ●
151
b) Adjustment constant radius for variable load
◼ Nominal load moment limiter adjustment
Hoist the rated weight load at the maximum trolley position with normal speed, the hoisting should
be normal and the load moment limiter should not work.
Fig. 4-52 100% load moment limiter adjustment

Adjusting bolts position -
Jib Load Feedback Trolleying Yellow Red No No
length Fall Weight position slow light early light hoisting trolleying
R(m) W(t) R1 (m) down warning alarm upwards forwards
4 2.20 / / ● / ●
80 80
2 3.30 / / ● / ●
4 2.70 / / ● / ●
77.5 77.5
2 3.80 / / ● / ●
4 3.20 / / ● / ●
75 75
2 4.30 / / ● / ●
4 3.70 / / ● / ●
72.5 72.5
2 4.80 / / ● / ●
4 4.40 / / ● / ●
70 70
2 5.50 / / ● / ●
4 4.70 / / ● / ●
67.5 67.5
2 5.80 / / ● / ●
4 5.20 / / ● / ●
65 65
2 6.30 / / ● / ●
4 5.70 / / ● / ●
62.5 62.5
2 6.80 / / ● / ●
4 6.10 / / ● / ●
60 60
2 7.20 / / ● / ●
4 6.50 / / ● / ●
57.5 57.5
2 7.60 / / ● / ●
55 4 7.00 55 / / ● / ●
152
2 8.10 / / ● / ●
52.5 4 7.50 52.5 / / ● / ●
50 4 8.10 50 / / ● / ●
47.5 4 8.70 47.5 / / ● / ●
45 4 9.40 45 / / ● / ●
42.5 4 10.20 42.5 / / ● / ●
40 4 11.10 40 / / ● / ●
37.5 4 12.10 37.5 / / ● / ●
35 4 13.20 35 / / ● / ●
32.5 4 14.5 32.5 / / ● / ●
30 4 16.0 30 / / ● / ●
◼ Adjustment for alarm
Hoist the rated weight load at the maximum trolley position with normal speed, the hoisting should
be normal and the load moment limiter should not work. Fall down the load to the ground, add
the load weight to 105~110% of the rated load, then hoist the load with minimum speed, the load
moment limiter should work and send warning signal, the load can’t be hoisted.
Fig. 4-53 Overload adjustment for alarm

Adjusting bolts position B
Yellow
Jib Load Add Feedback Red No No
Trolleying light
length Fall Weight weight position light hoisting trolleying
slow down early
R(m) W(t) T(kg) R1 (m) alarm upwards forwards
warning
4 2.20 110~220 / / ● / ●
80 80
2 3.30 165~330 / / ● / ●
4 2.70 135~270 / / ● / ●
77.5 77.5
2 3.80 190~380 / / ● / ●
4 3.20 160~320 / / ● / ●
75 75
2 4.30 215~430 / / ● / ●
153
4 3.70 185~370 / / ● / ●
72.5 72.5
2 4.80 240~480 / / ● / ●
4 4.40 220~440 / / ● / ●
70 70
2 5.50 275~550 / / ● / ●
4 4.70 235~470 / / ● / ●
67.5 67.5
2 5.80 290~580 / / ● / ●
4 5.20 260~520 / / ● / ●
65 65
2 6.30 315~630 / / ● / ●
4 5.70 285~570 / / ● / ●
62.5 62.5
2 6.80 340~680 / / ● / ●
4 6.10 305~610 / / ● / ●
60 60
2 7.20 360~720 / / ● / ●
4 6.50 325~650 / / ● / ●
57.5 57.5
2 7.60 380~760 / / ● / ●
4 7.00 350~700 / / ● / ●
55 55
2 8.10 405~810 / / ● / ●
52.5 4 7.50 375~750 52.5 / / ● / ●
50 4 8.10 405~810 50 / / ● / ●
47.5 4 8.70 435~870 47.5 / / ● / ●
45 4 9.40 470~940 45 / / ● / ●
42.5 4 10.20 510~1020 42.5 / / ● / ●
40 4 11.10 555~1110 40 / / ● / ●
37.5 4 12.10 605~1210 37.5 / / ● / ●
35 4 13.20 660~1320 35 / / ● / ●
32.5 4 14.5 725~1450 32.5 / / ● / ●
30 4 16.0 800~1600 30 / / ● / ●
154
c) Check
◼ Constant load for variable radius——Check for deceleration early-warning

Trolleying
slow down
4 12.5 15 20.9～22.2 ● / / / /
80
2 10.0 30 27.2～28.9 ● / / / /
4 12.5 15 22.3～23.7 ● / / / /
77.5
2 10.0 30 29.0～30.8 ● / / / /
4 12.5 20 23.6～25.1 ● / / / /
75
2 10.0 25 30.7～32.6 ● / / / /
4 12.5 20 24.7～26.3 ● / / / /
72.5
2 10.0 25 32.1～34.2 ● / / / /
4 12.5 20 26.4～28.1 ● / / / /
70
2 10.0 25 34.4～36.6 ● / / / /
4 12.5 20 26.6～28.2 ● / / / /
67.5
2 10.0 25 34.6～36.7 ● / / / /
4 12.5 20 27.3～29.0 ● / / / /
65
2 10.0 25 35.5～37.8 ● / / / /
4 12.5 20 27.9～29.6 ● / / / /
62.5
2 10.0 25 36.3～38.6 ● / / / /
4 12.5 20 28.0～29.8 ● / / / /
60
2 10.0 25 36.5～38.8 ● / / / /
4 12.5 20 28.1～29.8 ● / / / /
57.5
2 10.0 25 36.6～38.9 ● / / / /
4 12.5 20 28.3～30.1 ● / / / /
55
2 10.0 25 36.9～39.2 ● / / / /
52.5 4 12.5 20 28.4～30.2 ● / / / /
50 4 12.5 20 28.6～30.4 ● / / / /
47.5 4 12.5 15 28.7～30.5 ● / / / /
45 4 12.5 15 28.8～30.6 ● / / / /
42.5 4 17.5 15 22.0～23.4 ● / / / /
40 4 17.5 15 22.1～23.5 ● / / / /
37.5 4 17.5 15 22.2～23.6 ● / / / /
35 4 17.5 15 22.2～23.6 ● / / / /
32.5 4 17.5 15 22.2～23.6 ● / / / /
30 4 17.5 15 22.2～23.6 ● / / / /
155
◼ Constant load for variable radius——Check for early-warning

Trolleying
slow down
4 12.5 15 23.5～24.9 / ● / / /
80
2 10.0 30 30.6～32.3 / ● / / /
4 12.5 15 25.1～26.5 / ● / / /
77.5
2 10.0 30 32.6～34.4 / ● / / /
4 12.5 20 26.5～28.0 / ● / / /
75
2 10.0 25 34.5～36.4 / ● / / /
4 12.5 20 27.8～29.3 / ● / / /
72.5
2 10.0 25 36.2～38.2 / ● / / /
4 12.5 20 29.7～31.4 / ● / / /
70
2 10.0 25 38.7～40.9 / ● / / /
4 12.5 20 29.9～31.6 / ● / / /
67.5
2 10.0 25 38.9～41.1 / ● / / /
4 12.5 20 30.7～32.4 / ● / / /
65
2 10.0 25 40.0～42.2 / ● / / /
4 12.5 20 31.4～33.1 / ● / / /
62.5
2 10.0 25 40.9～43.1 / ● / / /
4 12.5 20 31.6～33.3 / ● / / /
60
2 10.0 25 41.1～43.4 / ● / / /
4 12.5 20 31.6～33.4 / ● / / /
57.5
2 10.0 25 41.2～43.4 / ● / / /
4 12.5 20 31.9～33.6 / ● / / /
55
2 10.0 25 41.5～43.8 / ● / / /
52.5 4 12.5 20 32.0～33.7 / ● / / /
50 4 12.5 20 32.2～34.0 / ● / / /
47.5 4 12.5 15 32.3～34.1 / ● / / /
45 4 12.5 15 32.4～34.2 / ● / / /
42.5 4 17.5 15 24.8～26.1 / ● / / /
40 4 17.5 15 24.9～26.3 / ● / / /
37.5 4 17.5 15 25.0～26.4 / ● / / /
35 4 17.5 15 25.0～26.4 / ● / / /
32.5 4 17.5 15 25.0～26.4 / ● / / /
30 4 17.5 15 25.0～26.4 / ● / / /
156
◼ Constant load for variable radius——Check for alarm

Trolleying
slow down
4 12.5 15 27.5～28.8 / / ● ● ●
80
2 10.0 30 35.7～37.4 / / ● ● ●
4 12.5 15 29.3～30.7 / / ● ● ●
77.5
2 10.0 30 38.1～39.9 / / ● ● ●
4 12.5 20 31.0～32.4 / / ● ● ●
75
2 10.0 25 40.2～42.2 / / ● ● ●
4 12.5 20 32.4～34.0 / / ● ● ●
72.5
2 10.0 25 44.2～44.2 / / ● ● ●
4 12.5 20 34.7～36.4 / / ● ● ●
70
2 10.0 25 45.2～47.3 / / ● ● ●
4 12.5 20 34.9～36.5 / / ● ● ●
67.5
2 10.0 25 45.4～47.6 / / ● ● ●
4 12.5 20 35.8～37.5 / / ● ● ●
65
2 10.0 25 46.6～48.9 / / ● ● ●
4 12.5 20 36.6～38.4 / / ● ● ●
62.5
2 10.0 25 47.7～49.9 / / ● ● ●
4 12.5 20 36.8～38.6 / / ● ● ●
60
2 10.0 25 47.9～50.2 / / ● ● ●
4 12.5 20 36.9～38.6 / / ● ● ●
57.5
2 10.0 25 48.0～50.3 / / ● ● ●
4 12.5 20 37.2～38.9 / / ● ● ●
55
2 10.0 25 48.4～50.7 / / ● ● ●
52.5 4 12.5 20 37.3～39.1 / / ● ● ●
50 4 12.5 20 37.6～39.4 / / ● ● ●
47.5 4 12.5 15 37.6～39.4 / / ● ● ●
45 4 12.5 15 37.8～39.6 / / ● ● ●
42.5 4 17.5 15 28.9～30.3 / / ● ● ●
40 4 17.5 15 29～30.4 / / ● ● ●
37.5 4 17.5 15 29.1～30.5 / / ● ● ●
35 4 17.5 15 29.2～30.6 / / ● ● ●
32.5 4 17.5 15 29.2～30.6 / / ● ● ●
30 4 17.5 15 29.2～30.6 / / ● ● ●
157
◼ Constant radius for variable load——Check for rated load moment

Jib Load Feedback Trolleying Yellow Red No No
length Fall Weight position slow light early light hoisting trolleying
R(m) W(t) R1 (m) down warning alarm upwards forwards
4 12.5 26.2 / / ● / ●
80
2 10.0 34.0 / / ● / ●
4 12.5 27.9 / / ● / ●
77.5
2 10.0 36.3 / / ● / ●
4 12.5 29.5 / / ● / ●
75
2 10.0 38.3 / / ● / ●
4 12.5 30.9 / / ● / ●
72.5
2 10.0 40.2 / / ● / ●
4 12.5 33.0 / / ● / ●
70
2 10.0 43.0 / / ● / ●
4 12.5 33.2 / / ● / ●
67.5
2 10.0 43.2 / / ● / ●
4 12.5 34.1 / / ● / ●
65
2 10.0 44.4 / / ● / ●
4 12.5 34.9 / / ● / ●
62.5
2 10.0 45.4 / / ● / ●
4 12.5 35.1 / / ● / ●
60
2 10.0 45.7 / / ● / ●
4 12.5 35.1 / / ● / ●
57.5
2 10.0 45.7 / / ● / ●
4 12.5 35.4 / / ● / ●
55
2 10.0 46.1 / / ● / ●
52.5 4 12.5 35.5 / / ● / ●
50 4 12.5 35.8 / / ● / ●
47.5 4 12.5 35.9 / / ● / ●
45 4 12.5 36.0 / / ● / ●
42.5 4 12.5 27.5 / / ● / ●
40 4 12.5 27.7 / / ● / ●
37.5 4 12.5 27.8 / / ● / ●
35 4 12.5 27.8 / / ● / ●
32.5 4 12.5 27.8 / / ● / ●
30 4 12.5 27.9 / / ● / ●
158
◼ Constant radius for variable load——Check for alarm

Adjusting bolts position B
Yellow
Jib Load Red No No
Feedbac Trolleyin light
lengt Fal Weigh Add weight light hoisting trolleyin
k position g slow early
h l t T(kg) alar upward g
R1 (m) down warnin
R(m) W(t) m s forwards
g
625~125
4 12.5 / / ● / ●
0 26.2
80
500~100 34.0
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 27.9
77.5
500~100 36.3
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 29.5
75
500~100 38.3
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 30.9
72.5
500~100 40.2
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 33.0
70
500~100 43.0
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 33.2
67.5
500~100 43.2
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 34.1
65
500~100 44.4
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 34.9
62.5
500~100 45.4
2 10.0 / / ● / ●
0
159
625~125
4 12.5 / / ● / ●
0 35.1
60
500~100 45.7
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 35.1
57.5
500~100 45.7
2 10.0 / / ● / ●
0
625~125
4 12.5 / / ● / ●
0 35.4
55
500~100 46.1
2 10.0 / / ● / ●
0
625~125
52.5 4 12.5 35.5 / / ● / ●
0
625~125
50 4 12.5 35.8 / / ● / ●
0
625~125
47.5 4 12.5 35.9 / / ● / ●
0
625~125
45 4 12.5 36.0 / / ● / ●
0
625~125
42.5 4 12.5 27.5 / / ● / ●
0
625~125
40 4 12.5 27.7 / / ● / ●
0
625~125
37.5 4 12.5 27.8 / / ● / ●
0
625~125
35 4 12.5 27.8 / / ● / ●
0
625~125
32.5 4 12.5 27.8 / / ● / ●
0
625~125
30 4 12.5 27.8 / / ● / ●
0
160
D. Adjustment of displacement sensor

Empty hook, the trolley drive to jib end, the hook hoist up to the highest, adjust moment limiter
displacement sensor RHM screw and let it in the safety monitoring system “information query”
→ “sampling value query” → “value of moment limiter displacement sensor is 300~400”.
E. Seal
After adjusting and checking moment limiter, close the rain cover of moment limiter, and then
wear it with steel wire through the hole of the rain cover and add lead seal.
Adjustment of displacement sensor

Empty hook, the trolley drive to jib end, the hook hoists up to the highest, adjust moment limiter
displacement sensor RHM screw and let it in the safety monitoring system “information query”
→ “sampling value query” → “value of moment limiter displacement sensor is 300~400”.
Seal
After adjusting and checking moment limiter, close the rain cover of moment limiter, and then
wear it with steel wire through the hole of the rain cover and add lead seal.
161
Load limit switch

A. Function
It is prohibited to exceed the maximum load capacity of tower crane during operation. Load limit
switches are used to prevent the tower crane from exceeding the maximum load capacity.
B. Working principle
The load moment limit switch is a dynamometric ring consisting of metal strips, adjustable screws,
several limits switch etc. Each screw corresponds to one limit switch. During HOIST operation,
certain force running over the Hoisting rope is applied to the dynamometric ring, and will cause
the metal strips to deflect. This deflection of metal strips allows the adjustable screws to contact
and act on the limit switch, which would alert the crane operator in case of any overload situation
via acoustic and optical signals.
This system allows the contactors to act on the safety circuit depending on the loads to be
controlled, when appropriately adjusting the gap between adjustable screw and limit switch.
Fig. 4-54 Adjusting load limit switch
The load limit switch has been pre-calibrated at the factory and needs to be
checked on site. If the deviation is too large, please adjust it according to the
following adjustment steps.
162
C. Adjusting
a) Adjusting for High-speed hoisting
Fig. 4-55 High-speed hoisting for rated load
Fig. 4-56 High-speed hoisting for 25% rated load
Adjust load limit switch Feedback signal of load limiter

Adjusting bolts position D Yellow Red
Speed Load weight Adding Feedback light early light Downshift
Fall
gear W(kg) load T(kg) position R1(m) warning alarm
4 6000 0 10 / / /
Ⅴ
2 3000 0 10 / / /
4 6000 300 10 / ● ●
Ⅴ
2 3000 150 10 / ● ●
163

Adjusting bolts position C Yellow Red
Speed Load weight Adding Feedback light early light Downshift
Fall
gear W(kg) load T(kg) position R1(m) warning alarm
4 12500 0 10 / / /
Ⅴ
2 6250 0 10 / / /
4 12500 625 10 / ● ●
Ⅴ
2 6250 310 10 / ● ●
b) Adjusting for Intermediate-speed hoisting

◼ 90% rated load adjustment for early-warning (only for CE)

Adjusting bolts position B Yellow
Red light
Speed Load weight Feedback light early Downshift
Fall alarm
gear W(kg) Position R1(m) warning
4 22500 10 ● / /
Ⅲ
2 11250 10 ● / /
◼ 100% rated load adjustment for alarm
Fig. 4-58 Intermediate-speed hoisting for 100% rated load
164
Fig. 4-60 Overload hoisting for 100% rated load

Adjusting bolts position B Yellow
Red light
Speed Load weight Feedback light early Downshift
Fall alarm
gear W(kg) Position R1(m) warning
4 25000 0 / / /
Ⅲ
2 12500 0 / / /
4 25000 1250 / ● ●
Ⅲ
2 12500 625 / ● ●
c) Check
Adjust the switch in high-speed and intermediate -speed, and each adjustment method should
be repeated three times. And the value of the weight must be equal in the three times (Don't
adjusting the bolt).
D. Seal
After adjusting and checking load limit switch, close the rain cover, and tightening the bolts, and
then wear it with steel wire and add lead seal.
E. Electronic sensor
Electronic sensor can be measure load weight and show on the display at the cabin. The sensor
mounting at the inner of load limit switch, the adjust methods refer to <ETI Operation Manual>.
165
Multifunction limiter
Multifunction limiter include: Hoisting limiter, Trolley limiter and Slewing limiter which significant
safe devices of crane to achieve mechanisms control and extremity limit function.
The hoisting mechanism, trolley mechanism and slewing mechanism all configure electronic
sensor which real-time monitoring of mechanism location, the control system converts the
position signals into electronic signals.
This crane can achieve double control of electronic sensor and mechanical sensor. The
mechanical limiter only uses in emergency mode which must be adjusted in accordance with the
requirements before use.
Table 4-15 Instruction of main mechanisms mechanical limiter
No. Hoisting limiter Trolley limiter Slewing limiter
1 Upward hoist stop Outward trolley stop Leftwards slewing stop
Upward hoist
2 Outward trolley decelerate Leftwards slewing decelerate
decelerate
3 Downward hoist stop Inward trolley stop Rightwards slewing stop
Downward hoist
4 Inward trolley decelerate Leftwards slewing decelerate
decelerate
◼ After the height of tower mast reach preset height, the adjustment must be
non-load. Before adjusting, use finger presses the contact of the KW jogging
switch to ensure the jogging switch correct about the hoisting or descend.
◼ It shall adjust hoisting limiter, when change the height and fall of crane.
◼ Tighten the M5 nut
◼ After adjusting, loose the M5 nut, otherwise the memory will disorder.
◼ After adjusting, mount the upper cover, otherwise the limiter may be flooded.
◼ After replace the steel rope or change hook assembly fall, the
extremity position of hook will change, you must readjust hoisting
limiter, otherwise the hook hit the jib may occur, steel rope cut off,
result in crane destruction and human death.
◼ Hook at the lowest position, three loops of steel rope shall be kept on
the drum.
166
◼ Function
The purpose of limiter is to avoid the fault operation may appear.
Hoisting limiter make the hook pulley block slow down and stop ascending motion when it is a
safety distance from the trolley. When descending, prevent the wire rope from loosening
completely and wrapping around the drum in the opposite direction.
Trolley limiter makes the trolley slow down and stop automatically before reaching the jib root
or the top head block.
Slewing limiter is used in tower crane without collector rings. Prevent cable winding and
damage. Maximum 3 turns allowed.
◼ Working principle
The limit device fixed on the bracket can be directly driven by the drum shaft, or through the
pinion meshing in the gear ring to drive the device within the deceleration mechanism, drive a
number of convex block rotation, the convex block control circuit breaker(micro-switch) action to
cut off the corresponding mechanism movement.
In addition to the mechanical travel switch, the limit device is also equipped with an encoder. As
shown in the following picture.
Fig. 4-61 The limiter
167
Hoisting height limit switch and trolley limit switch and slewing limit switch of the tower crane as
follows：
Fig. 4-62 Limiter inside view

◼ Adjusting procedure
1) Remove the upper cover, loose the M5 nut.
2) Operate the controlled mechanism to an appointed position (non-load) according to the need,
and here the micro-switch KW for controlling the motion of the mechanism must be switched
instantaneously (i.e. adjust the corresponding adjusting shaft(Z) until the memory cam (T)
presses the contact of the KW jogging switch.).
3) Tighten the M5 nut (the nut must be tightened tightly, otherwise the memory will disorder.).
4) The mechanism must run under non-load again and again to validate if the control of the
memory position is correct or not (if incorrect, make the above-mentioned adjustment again).
5) If the position is correct, make sure again that the M5 nut is tightened tightly. Then, mount
the upper cover.
6) After the mechanism runs normally, must check often if the memory control position changes
or not, in order to correct it in time.
168
Hoisting limiter
◼ Adjustment of Hoisting limiter
1) When the trolley and hook come to the deceleration position of L1 (7m for 2-fall, 4m for 4-
fall), adjust the (3Z) axle to make the long cam (3T) press the microswitch (3WK), then the
hook hoist upward slowly.
Fig. 4-63 Adjustment for hoisting deceleration
169
2) When the trolley and hook come to the stop position of L2 (1.5m), adjust the (4Z) axle to
make the long cam (4T) press the microswitch (4WK), screw the nut M5 down, then the
hook stop hoisting upward.
Fig. 4-64 Adjustment for hoisting limit
Execute the adjusting when it’s no-load, use finger to press the
microswitch (3WK, 4WK) to confirm if it’s correct.
After changed the rope or the hook fall, the limit position of the hook will
change. Readjust the Hoisting limiter, otherwise it may cause the hook
rush to the jib and break the rope even crash the crane!
170
Trolley limiter
4.15.5.2.1 Adjusting of trolleying out and decelerating
1) Loose the nut M5;
2) Drive the trolley to the position with a distance L1=5m away from the jib tip buffer. Adjust the
axle (3Z) to make the long cam (3T) press the microswitch (3WK), so the trolley can only
trolley out at low speed;
3) Screw the nut M5 down.
Fig. 4-65 Adjusting of trolleying out and decelerating
171
4.15.5.2.2 Adjusting of trolleying out to the limit position

2) Drive the trolley to the position with a distance L=500mm away from the jib tip buffer. Adjust
the axle (4Z) to make the long cam (4T) press the microswitch (4WK), so the trolley will stop
trolleying out;
Fig. 4-66 Adjusting of trolleying out to the limit position
172
4.15.5.2.3 Adjusting of trolleying in and decelerating

2) Drive the trolley to the position with a distance L=5m away from the jib root buffer. Adjust the
axle (1Z) to make the long cam (1T) press the microswitch (1WK), so the trolley can only
trolley in at low speed;
Fig. 4-67 Adjusting of trolleying in and decelerating
173
4.15.5.2.4 Adjusting of trolleying in to the limit position

5) Drive the trolley to the position with a distance L=500mm away from the jib root buffer. Adjust
the axle (2Z) to make the long cam (2T) press the microswitch (2WK), so the trolley will stop
trolleying in;
Fig. 4-68 Adjusting of trolleying in to the limit position
◼ Execute the adjusting when it’s no-load;

◼ Every time before using the crane after transferred to a new
construction site, the end cap at the bottom of the limiter must be
struck to drain the condensate water inside;
◼ If the crane have been working for a long time at a construction site,
the operation above must be executed too.
174
Slewing limiter
4.15.5.3.1 Adjusting of slewing anticlockwise
1) Adjust the slewing limiter only when the cable is at free state.
2) Slewing anticlockwise for 540°(1.5 rounds), adjust the axle (4Z) to make the cam (4T) act
to achieve transient changing by the micro-switch (4WK). Screw down M5 nuts.
Fig. 4-69 Adjusting of slewing anticlockwise
175
4.15.5.3.2 Adjusting of slewing clockwise

After the slewing anticlockwise adjusting finished, slew clockwise for 1080°(3 rounds); adjust
the axle (2Z) to make the cam (2T) move to achieve transient changing by the micro-switch
(2WK). Screw down M5 nuts.
Fig. 4-70 Adjusting of slewing clockwise
176
4.16 Tower crane tests

To confirm the tower crane's readiness, an acceptance test shall be performed. The test shall
include at least the following items:
◼ Nameplate of the tower crane and the grades;
◼ Tests of drive mechanism, limiter and indicator;
◼ Safety devices;
◼ In compliance with the load tests 4.16.1 and 4.16.2.
Function test without load

All functions (such as brakes, control systems and limiters etc.) shall be tested for reliability
throughout the whole range of admissible movements up to the maximum operating speed (such
as hoisting, trolley and slewing).
Load tests
Nominal load tests
The load at the maximum amplitude is 25%,50%,75%,100% separately to the nominal load, the
tests should comply with the acquirements in 4.16.1, all the tests should be reliable.
Static tests with load 125% of the rated capacity

After the success of the no-load test and the nominal load test, proceed the static overload tests.
The load tests result for different jib lengths show as Table 4-16.
The test shall be done at 4 falls.
The test load shall have 100~200 mm from the floor for a period of at least 10 min.
The static test shall be considered successful if no ruptures, permanent deformations, or
damages affecting the function or safety of the crane are visible and no connections have
loosened or become damaged.
Table 4-16 Static tests with load 125% of the rated capacity
Item
Fall RangeⅠ(m) LoadⅠ(t) RangeⅡ(m) LoadⅡ(t)
Jib length(m)
4 14.9 31.25 2.75
80 80
2 28.1 15.625 4.13
4 15.8 31.25 3.38
77.5 77.5
2 30.0 15.625 4.75
4 16.7 31.25 4.00
75 75
2 31.7 15.625 5.38
4 17.5 31.25 4.63
72.5 72.5
2 33.2 15.625 6.00
177
4 18.6 31.25 5.50

70 70
2 35.5 15.625 6.88
4 18.7 31.25 5.88
67.5 67.5
2 35.7 15.625 7.25
4 19.2 31.25 6.50
65 65
2 36.7 15.625 7.88
4 19.6 31.25 7.13
62.5 62.5
2 37.5 15.625 8.50
4 19.7 31.25 7.63
60 60
2 37.7 15.625 9.00
4 19.8 31.25 8.13
57.5 57.5
2 37.8 15.625 9.50
4 19.9 31.25 8.75
55 55
2 38.1 15.625 10.13
4 20.0 31.25 9.38
52.5 52.5
2 38.2 15.625 10.75
4 20.1 31.25 10.13
50 50
2 38.5 15.625 11.50
4 20.2 31.25 10.88
47.5 47.5
2 38.6 15.625 12.25
4 20.3 31.25 11.75
45 45
2 38.7 15.625 12.25
4 20.4 31.25 12.75
42.5 42.5
2 39.0 15.625 14.13
4 20.5 31.25 13.88
40 40
2 39.2 15.625 15.25
4 20.6 31.25 37.5 15.13
37.5
2 37.5 15.625 / /
4 20.6 31.25 35 16.50
35
2 35.0 15.625 / /
4 20.6 31.25 32.5 18.13
32.5
2 32.5 15.625 / /
4 20.6 31.25 30 20.00
30
2 30 15.625 / /
178
◼ It is forbidden to trolley and slew at the static overload test.

◼ It is forbidden to adjust the brake at the static overload test.
◼ It is allowed to adjust load moment limiter and load limiter at the static
overload test.
Dynamic tests with load 110% of the rated capacity
The load tests result for different jib lengths show as Table 4-17.
The test shall be done at 4-fall when the jib length is 52.5~30m, at 2-fall or 4-fall when the jib
length is 80~55m.
The tests shall include the repeated starting and stop of each movement throughout the whole
sequence of the movement.
The static test shall be considered successful if no ruptures, permanent deformations or damages
affecting the function or safety of the crane are visible and no connections have loosened or
become damaged.
Table 4-17 Static tests with 110% of the rated capacity
Item
Fall RangeⅠ(m) LoadⅠ(t) RangeⅡ(m) LoadⅡ(t)
Jib length(m)
4 14.9 27.5 2.42
80 80
2 28.1 13.75 3.63
4 15.8 27.5 2.97
77.5 77.5
2 30.0 13.75 4.18
4 16.7 27.5 3.52
75 75
2 31.7 13.75 4.73
4 17.5 27.5 4.07
72.5 72.5
2 33.2 13.75 5.28
4 18.6 27.5 4.84
70 70
2 35.5 13.75 6.05
4 18.7 27.5 6.36
67.5 67.5
2 35.7 13.75 5.17
4 19.2 27.5 5.72
65 65
2 36.7 13.75 6.93
4 19.6 27.5 6.27
62.5 62.5
2 37.5 13.75 7.48
4 19.7 27.5 6.71
60 60
2 37.7 13.75 7.92
4 19.8 27.5 7.15
57.5 57.5
2 37.8 13.75 8.36
4 19.9 27.5 7.81
55 55
2 38.1 13.75 8.91
4 20.0 27.5 8.25
52.5 52.5
2 38.2 13.75 9.46
179
4 20.1 27.5 8.91

50 50
2 38.5 13.75 10.12
4 20.2 27.5 9.57
47.5 47.5
2 38.6 13.75 10.78
4 20.3 27.5 10.34
45 45
2 38.7 13.75 11.55
4 20.4 27.5 11.22
42.5 42.5
2 39.0 13.75 12.43
4 20.5 27.5 12.21
40 40
2 39.2 13.75 13.42
4 20.6 27.5 37.5 13.31
37.5
2 37.5 13.75 / /
4 20.6 27.5 35 14.52
35
2 35.0 13.75 / /
4 20.6 27.5 32.5 15.95
32.5
2 32.5 13.75 / /
4 20.6 27.5 30 17.6
30
2 30.0 13.75 / /
Operation of overload test circuit

If 110% and 125% overload weight test is needed at the construction site, the following steps
should be followed for circuit operation:
1) When the tower crane is not operation, pull out the XP16 at the lower part of the driving kit
in the driver’s cab, connect the spare 100% load unlimiting test pug to XS16, and then
temporarily the mechanical limit of 105% load.
2) Rotate the mode section key switch to “Mechanical” mode, when the electronic load limit is
not involved in the control, then the overload hoisting test can be performed.
3) After the completion of test, open the mode selection key and rotate it to the
“electromechanical” mode on the interface of “load weight calibration”. Remove the “100%
weight unlimiting test plug” and connect the weight limiter plug, the system will resume
normal operation.
◼ This operation must be carried out by professional testers.

◼ The operation shall be carried out in strict accordance with the test
process, and illegal driving and taking the plane during the test are
prohibited.
◼ Once test is completed, remove the “100% weight unrestricted test
plug”.
◼ This “100% load unrestricted test plug” is guaranteed to be used for
temporary overload test on construction site, and must not be
removed
180
4.17 Dismantling
General notes
1) Due to the climbing mechanism out of service for a long time, conduct maintenance and
test-run for the climbing mechanism before moving the tower crane out of the construction
site.
2) Before dismantling of tower crane, maintenance and test-run of the climbing mechanism is
necessary.
3) Check limiters, slewing mechanism brakes and similar for reliability during test-run.
4) It is prohibited to use the slewing mechanism, trolley 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 eight pins.
5) Check frequently the main stressed parts of the climbing mechanism, as the tower crane
dismantling is a heavy duty and successive work for the climbing mechanism.
6) While the climbing mechanism is working, all operating personnel are required to focus their
attention on observing the relative positions of moving parts for normal condition (e.g.
between guide rollers and main chord rods, between Telescopic cage and crane tower.). In
case of any deviation during the telescopic cage is being lifted, stop and lower climbing
immediately.
7) Carry out dismantling when the wind speed is lower than 14m/s atop the tower crane. Take
care of the stockpile location of dismantled parts because the working site is limited for tower
crane dismantling after the buildings have been constructed. Any slight carelessness might
cause serious accident.
◼ Users are required to strictly follow the Instructions-specified rules to

dismantle tower crane. Operators shall have been trained and with
certificates. Any slight neglect will cause machine damage, personal
injury or death.
◼ Pay great attention to the two moving mast lugs during inlet or
dismantle of additional mast sections. Inspect if the lugs are still in
proper level condition.
◼ Pay great attention to the two climbing latches during inlet or
dismantle of tower section. Inspect if the latches are still in proper
level condition. Slewing 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. Its steps are in
opposition to the steps of tower crane erection. Strictly follow the
instructions specified rules in all cases.
181
Dismantling sequences
1) Dismantle tower sections;
2) Dismantle the warning light, camera and anemograph;
3) Removing the hoisting rope;
4) Removing the cables of electric control system;
5) Dismantle the counter ballasts but keep a 3.9t counter ballast which near the jib most.
6) Dismantle the jib sections but jib Ⅰ,Ⅱ;
7) Dismantle the jib Ⅰ,Ⅱ (including the trolley and trolley mechanism);
8) Dismantle the last counter ballast;
9) Dismantle the rear part of counter jib (only rear section or middle section and rear section);
10) Dismantle the front counter jib;
11) Dismantle slewing assembly;
12) Dismantle the transition section, mounting device and the erection platform.
13) Dismantle climbing equipment;
14) Dismantle the rest tower sections and base tower section.
Dismantling
Dismantling the tower section
Remove the tower sections in turn, see chapter 4.3.
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 climbing
status, and the trolley staying at the balance position (i.e. in conformity to the balanced
position of the trolley when additional sections are jacked during tower crane erection).
2) Remove connecting pin between the upper tower section and transition section
3) Start hydraulic jack system, extrude the piston of the cylinder and place the hitch plates on
climbing lug (b) of tower section nearest to the beam, insert safe pins. Extend the piston
slowly to jack the climbing frame and the superstructure, connect inlet wheels on the top
tower section by 4 M20×80 bolts. Jack the superstructure until the bottom of the trolley is
moved to 20~50mm away from the top of the section. Push the top section out of tower
along the beam onto the inlet frame. (Shown as Fig. 4-71 (a))
4) Retreat oil cylinder to the place supporting latches onto the slot of lug (c), bear the weight
of upper parts confidently. (Shown as Fig. Fig. 4-71 (b))
5) Remove the safe pins and extend the piston to place hitch plates of jack beam in climbing
lug (a), insert safe pin. (Shown as Fig. Fig. 4-71 (c))
6) Put the climbing beam to the step lug at lower position and erect the climbing frame until the
latches can be turn at 90°again, retract oil cylinder to let the next section contact the slewing
ring support.
7) Connect slewing ring support to tower section with 8 Ф55 pins, hook the tower section on
the inlet platform to the ground.
8) Repeat the above actions to dismantle the tower sections in sequence.
9) Dismantle the crane to the safe height.
182
After the tower section is pushed to the mounting beam, the climbing
frame falls down. When the climbing claw and the tower section
connected with pins, the climbing claw must be turned over artificially, at
the same time, a special person is assigned to watch the climbing beam
and the guide wheel. There should not be any obstruction when the
climbing frame descends so that the climbing frame can slide smoothly.
Process Ⅰ Process Ⅱ Process Ⅲ Process Ⅳ

Fig. 4-71 Dismantling tower sections
Dismantling the hoisting rope

Removing hoisting rope follow the opposite steps of reeving hoisting rope.
Dismantling the hoisting rope

Unfasten the cables which influence the crane parts dismantling and draw them in.
Dismantling the counter ballasts

Dismantle the counter ballasts piece by piece in reverse order of installing sequence the counter
ballast. Only leave the 3.9t counter ballast block which near the jib most.
Dismantling the jib assembly

1) Before dismantling, check the jib assembly to see if component-to-component is still
connected by power cable.
2) Arrange hoisting rope at hook points as shown in Fig. 4-22 and Table 4-5 (reference the
record point when the jib was lifting).
183
3) Dismantle the connection pin and bolts of jib and counter-jib sectionⅠ.
4) Lower the jib and lay it down on the sleeper-cushioned support.
Dismantling the remainder counter ballast block

Remove the last counter ballast block by means of an auxiliary mobile crane.
Dismantling the counter jib

1) Sling the rear section of counter jib (rear section or middle section and rear section), sling
the counter jib tie rod to push the frame, remove the pin group connecting the rear section
and front section of counter jib
2) Take the locating pin of rear section and front section as fulcrum, slowly lift the rear section
to allow the tie rod in a relaxed state, fall on the support frame, remove connecting pin
between the tie rod and the front section’ tie rod.
3) Sling the rear section, and place it at an appropriate position on the ground.
4) Sling the front section, remove connecting pin between the front section and the turntable,
put the front section to an appropriate position on the ground.
Dismantling the slewing assembly

1) Sling the slewing assembly and remove the connecting pin between the lower support and
transition section.
2) Sling the slewing assembly place it at an appropriate position on the ground.
Dismantling the transition section and mounting device

1) The climbing frame is supported on the tower body through the telescopic oil cylinder;
2) Sling the transition section, remove the connecting pin between the transition section,
climbing frame and tower section.
3) Sling the transition section and place it at an appropriate position on the ground.
Dismantling the climbing equipment and rest tower section

1) Dismantle the cage in the sequence opposite to installing it.
2) Dismantle the rest sections in the sequence opposite to installing it.
◼ The dismantled crane needs to be checked and maintained by

technical personnel and trained maintenance personnel.
◼ Check main stressed structural members for metal fatigue; weld
fissure, structural deformation, etc. Check tower crane parts for
damage or collision injury.
◼ After completion of checks, repair the defects found and defects
potential. Carry out rust removing and painting.
184
W450-25HC-138EN-A01 OPERATION AND CONTROL
5 OPERATION AND CONTROL

5.1 Foreword
This part comprises the instructions allowing the crane driver to:
◼ Operators must be aged over 18.
◼ Operators should have healthy body and mind.
◼ The tower operator must have been trained, be familiar with the tower cranes and qualified.
◼ No drinking or taking psychotropic drugs before operating the tower crane.
◼ Operators must comply with the regulations of the country where the tower crane is.
◼ Operators must make record of the tower crane usage, maintenance, and shift handover.
This part cannot be separated from the whole document: it can only be used after reading the
SAFETY INSTRUCTION (part 2 of this document), the TECHNICAL DATA OF CRANE AND SITE
(part 3 of this document) and the load table.
The crane driver must not operate the crane if he does not meet all the
conditions relating to his profession stated in this part.
5.2 Attention for operation

◼ Operate the crane only all the safety devices are in good condition.
◼ Adjust the limiters according to the instruction handbook strictly.
◼ Sufficient lighting shall be provided to the working area for night working.
◼ Keep all platforms, ladders, rails, and handrails from dirt.
◼ No unauthorized persons are allowed climb the crane!
◼ People who have been approved can climb up or down the tower crane after the tower
operators stopping the crane!
◼ Test run before working, work after confirming the tower crane is in good condition.
◼ Whistle before action every time.
◼ Don’t lay the hook onto the ground in order to avoid disordering the ropes.
◼ Operators should give some relevant warning signals on occasion.
◼ Stop working immediately once some defects harming tower crane operation safety are
found.
◼ The tower crane driver should observer the state of the tower crane in the cabin during the
climbing and descending process, when the tower crane is abnormal, the driver should
handle the problem in time.
◼ When the tower crane rises and falls, no one is allowed stand under the tower crane without
permission
185
OPERATION AND CONTROL W450-25HC-138EN-A01
5.3 Specific safety instructions

When the crane is in service, all the control panel doors must be locked.
The crane driver must position the jib in the direction of the wind before
any weathervane operation.
At each operation in the slewing area of the slewing crane part, the crane
driver must be extremely vigilant (crushing hazard).
It is compulsory to put the control unit out of service as soon as the crane
driver lays it down or no longer controls the crane.
186
5.4 Instruction of control unit

Console
Fig. 5-1 The compose of console
No. Button Name Function
Cut down the power of the electrical

“EMERGENCY STOP” system when emergency happens, and
1
Button (Red) stop the tower working in usual. It’s self-
locked, turn around it can be released.
“Start /Horn” Button Electrical control system start button, and

2
(Green) the horn’s button
“Over 50% Weight When the load over 50% rated, the alarm
3 rated” alarm lamp lamp lighting, the buzzer will beep. (See
(Yellow) also in Num.7)
187
“Over 100% weight When the load over 100% rated, the
4 rated” alarm lamp alarm lamp lighting, the buzzer will beep.
(Red) (See also in Num.7)
“Over 90% moment When the moment over 90% rated, the
(Yellow) (See also in Num.7)
“Over 100% moment When the moment over 100% rated, the
(Red) (See also in Num.7)
⚫ Start-up: 4 beeps
⚫ Lack of GPS signal: beep 4s during
15s;
⚫ Over 100% moment: beep 4 times
per 0.5s;
⚫ Moment alarm: beep 2 times per
0.5s;
⚫ Over 100% load: beep 3 times per
7 Buzzer 0.5s;
⚫ Load alarm: beep 1 times per 0.5s;
⚫ Gear change: beep 1 times when
changing 0.5s;
⚫ Weather Vane release: beep 1
times when releasing;
⚫ Fault in PLC: Keep beeping;
(See also in “System indication and
alarm signal”)
Optional for traveling mechanism.

Traveling forward
8 Operate the handles to the left, the tower
direction
crane moves forward
188
Optional for traveling mechanism.

Traveling Backward
9 Operate the handles to the right, the
direction
tower crane moves backward
Hoisting upward Operate the right handle backwards, the

10
direction hook moves upward.
Hoisting downward Operate the right handle forwards, the

11
direction hook moves downward.
Low speed button Low speed switch of hoisting when

12 (Red, Optional for low- pushing, switch to zero-position to
speed function) release low speed.
See also in “System indication and alarm

13 Bypass button
signal”)
Weather vane release Weather vane release button, see also in

button (Optional for “Slewing brake and weather vane
NC brake) release”
14
Brake switch (Optional

Slewing release/Brake switch
for NO brake)
Start-up indicator
15 The light turns on after power-on.
(Green)
189
Weather vane release The light turns on after weather vane is

16
indicator (Blue) released.
Trolley backward Operate the left handle backward, the

17
direction trolley moves inward.
Trolley forward Operate the left handle forward, the

18
direction trolley moves forward.
Slewing Operate the left handle to left, the tower

19
left direction slew to left.
Slewing Operate the left handle right, the tower

20
right direction slew to right.
21 Reserved button Reserved function
190
Driving box
Driving box mounting in the cabin which a part of core control system. Programmable controller,
intermediate relay of safety device and other components are installed in the box.
Main switch and function as re show in following table:
Table 5-1 Driving box switch

No Code Function Remark
Electric whistle
1 QF1
power switch
Voltmeter
2 QF2 protection
switch
Safety loop
Disconnection of this circuit breaker will disable tower
3 QF3 protection
operation.
switch
Used for cutting-out protection of various lights, fans, and air
Power leakage
conditioning equipment in the cab. When the lighting circuit
4 QFE protection
breaker is closed (turn the small handle of the circuit breaker
switch in cab
upward), the lighting circuit is powered (single-phase 220V).)
2 working modes: electromechanical mode, mechanical mode.
When the electronic safety device is not calibrated or fails, the
Mode option
5 SPM mechanical mode can be opened. At this time, only the
switch
mechanical safety device plays a role, and hoisting, slewing
and trolley are all limited to 4 gear.
If the switch in the above table is air switch, the switch handle can be turned
upward to become “on” state. If the switch in the above table is electromagnetic
protection circuit breaker, the switch handle can be rotated clockwise until the
handle is in the vertical state to become “on” state.
191
The code number and function description of the door panel of driving box are show in following
table:
Table 5-2 Door panel component of driving box
No Graphic Code Function Note
Power supply The normal value of wiring voltage of

1 PV
indicator the power supply：380V±10%
The brake fails when the indicator is

Hoist brake
2 HA on, then the crane runs in zero-speed
indicator
hovering mode.
Do not start the crane when the power

Power
undervoltage indicator is on, otherwise
3 HU undervoltage
the related electrical damage may be
indicator
caused.
Climbing
4 SPP
operate button
192
Main control cabinet

Main control cabinet install on the slewing platform which main component of control system.
The parts are all in the cabinet: the main power switch, hoisting controller, slewing controller,
trolley controller, calorifier and cooling fan, etc.
Main switch and function as re show in following table:
Table 5-3 switches of main control cabinet
No Code Function Remark
1 QFH Hoisting mechanism controller switch
2 QFHB Hoisting brake switch
3 QFHC Hoisting motor cooling fan switch
4 QFS Slewing mechanism controller switch
5 QFV Trolley mechanism controller switch
6 QFP Hoisting mechanism main power switch
main control cabinet heat, cooling Some crane, this switch in the driving
7 QFFE
powered circuit protection switch bx, subject to actual layout.
voltage transformer and power monitor
8 QF4
switch
9 QF6 Controller, control circuit power switch
10 QF8 Slewing, trolley brake power switch
The code number and function description of the door panel of main control cabinet are show in
following table:
Table 5-4 Door panel component of main control cabinet
No Graphic Code Function Note
Turn the handle clockwise. The handle

Main power
marks of the finger when ON, the main
of electrical
power switch is closed; Rotate
1 QF control
counterclockwise, when the handle
system
indicator points to OFF, the main power
switch
will be cat off.
Only the QF handle points to OFF, the door of the main control cabinet can be
opened. Similarly, only the QF handle points to OFF, the door of the main control
cabinet is allowed be closed. Do not open and close the door of the main control
cabinet with violence to avoid damage related parts.
193
Heating dehumidification and cooling of main control cabinet:
◼ Heater：After power on, automatically detect the temperature and humidity, when the
temperature is ≤0℃ or humidity ≥80%, start heating.
◼ Cooling fan：After power on, automatically detect the temperature, when the temperature
is≥40℃, the fan in the cabinet to exhaust air.
◼ If the heater or cooling fan is operating under the set conditions, the cooling
fan and heater are not working, please check the components for damage.
◼ The working power supply of heater and cooling fan is U1, N; That is, when
the power supply of the knife switch box is turn on, it will start to work if the
working conditions of the heater and the cooling fan are met.
Component of outer cabinet:
On the upper part of the right panel of main control cabinet, an emergency stop button is installed,
as shown in the picture. Its function is the same as the emergency stop switch of the right linkage
platform in the cab’s room, and it is used to cut off the power supply and control power of the
crane in an emergency.
Do not use the emergency stop button to stop the crane in non-emergency circumstances.
Otherwise, it will have a great impact on the tower structure, even cause more serious safety
accidents.
This button is self-locking. After pressing it, it can only be released by rotation. Please make sure
that the emergency stop button is released before starting the tower crane
Fig. 5-2 Emergency stop button of main control cabinet
◼ Take the emergency stop button immediately, in the emergency.

◼ Because of the anti-slip hook function is enabled, the hoisting mechanism
enters the hover state. Do not press the emergency stop button.
◼ When the driver leaves the cab due to business after work or repairs and
checks the tower crane, he or she shall take the emergency stop button
when the tower crane is in the stop state.
194
Electric resistance box

Electric resistance box is a release component of the tower crane control system which main
function is release downward hoisting movement and the surplus energy produced in each
mechanism braking process. Please strictly follow the precaution, improper
Fig. 5-3 Electric resistance box
◼ Before the tower crane operation, please ensure its wiring is correct and
reliable, otherwise it may cause equipment damage;
◼ If cables need to be laid around the mounting bracket of the resistance box,
ensure cables and the shell of the resistance box is kept to 115cm;
◼ The resistance box is a heating part, please ensure that it is well ventilated
and shall not be covered;
◼ Do not pile up debris near the resistance box, otherwise it will lead to the
risk of fire.
The resistance box surface is high temperature, do not touch, otherwise

there is a risk of scalding.
Video monitoring system (optional)

The tower crane is equipped with three cameras to monitor the condition of the drum, hook, and
cab respectively. At the same time, it is displayed in real time on the display screen of video
monitoring system installed in front of the cab, and stored in the video recorder, which can be
looked back immediately.
The VCR can store up to three cameras simultaneously recording about 46 hours of video
information (32G memory card), and when the recording time is exceeded, the earliest video
information will be automatically overwritten.
195
5.5 Frequency converter self-learning
HuiChuan frequency converter

The tower crane is driven by full frequency conversion. When the crane is started for the first
time, after trial operation and calibration setting, and before normal operation, the frequency
converter of hoisting, slewing and trolley shall be studied and operated, so that the frequency
converter can obtain the internal mechanism and make the operation more stable and efficient.
Fig. 5-4 Frequency converter operation panel

◼ Self-learning methods of frequency converter
1) After the motor connected and powered on normally, first set the command source bF.04 of
the frequency converter to 0 (command and control of the operation panel); Input motor type
plate parameters (A0.01-A0.05).
2) Set function code b0.04 to 3 (static tuning) and press “Enter” to confirm. At this time, the
panel will display RUNE. Then press “RUN” on the panel and the frequency converter will
drive the motor to start running.
3) Set the frequency converter command source bF.04 to 1 (terminal control).
4) To further improve the performance of slewing mechanism, it is recommended to continue
online tuning of the slewing frequency converter after the completion of static tuning. The
steps are as follows:
5) Set the source bF.04 to 4 (online tuning), and then press “Enter” to confirm;
196
6) After confirming that there is enough room and safe operation, operate the slewing handle
to the 4th gear. At this time, the tower crane jib will rotate the 4th gear speed (frequency
converter display above 35Hz). The frequency converter will successively display:
UloC→LoC→Good, which indicates that the spectrum tuning is over and normal use can be
started.
Note: UloC: Start tuning online
LoC: Enter online tuning
Good: Online tuning ends
ABB frequency converter
Fig. 5-5 ABB frequency converter operation panel
197
Operation panel introduction

5.5.2.1.1 Screen
The screen will show the following icons in most views:
1) Control position and relevant icons (the control ways):
◼ No text: The frequency converter is local-controlled, but it controlled by other device. The
icons on the top windows show the permitted operation.
◼ Local: The frequency converter is local-controlled, which means controlled by the control
panel.
◼ Remote: The frequency converter is remote-controlled, which means controlled by the I/O
or the CAN at scene.
2) State icons: indicate the state of the frequency converter or motor. The directions of the
arrows show slewing clockwise or anticlockwise.
Table 5-5 Definitions of the arrows on the screen
No. State icon Flash State of the frequency converter
1 - Stop
2 - Stop, start forbidden
3 Blink Stop, send start order but forbidden
4 Blink Fault
5 Blink Working, with certain value, but value is 0
6 Rotate Working, without certain value
7 Rotate Working, with certain value
For the frequency converter without rotation, the number 1 and 0 indicate the
frequency converter working or not.
5.5.2.1.2 Left soft key

Using for quit or cancel generally. The soft key on the left bottom of the screen will show its
function in specific occasions.
5.5.2.1.3 Right soft key

Using for select, accept or confirm generally. The soft key on the right bottom of the screen will
show its function in specific occasions.
198
5.5.2.1.4 LED state

Using for indicating fault or warning.
Table 5-6 Definitions of the LEDs on the screen
No. LED state Definition
1 Green keeps on The frequency converter is working normally.
Data is transporting between PC tools and the frequency

2 Green blinks fast
converter by USB of the control disk.
3 Green blinks slowly There is active warning in the frequency converter.
4 Red keeps on There is active fault in the frequency converter.
5 Blue blinks fast Data is transporting by Bluetooth connector of the disk.
6 Blue blinks slowly Bluetooth connector is on (can be found and ready for pairing).
5.5.2.1.5 Help
Open the “Help” page.
5.5.2.1.6 Direction key

The up and down direction keys are using for highlighting the selections of the menu and
selection list, rolling the word page up and down, and adjusting values (set time, input password
or change parameter value, etc.).
The left and right direction keys are using for moving the cursor left and right when editing the
parameters and moving forward or backward in the helper. In different menus, the functions of
left and right direction keys are the same with the left and right soft keys.
5.5.2.1.7 Stop
In the local control, the stop key is using for stopping the frequency converter.
5.5.2.1.8 Start
In the local control, the start key is using for starting the frequency converter.
5.5.2.1.9 Local / Remote

Using for transitioning between local control and remote control.
5.5.2.1.10 USB connector terminal

Using for connection of control panel and PC.
199
Self-learning methods of ABB frequency converter

1) Push the “Loc/Rem” key (rectangle) on the middle-bottom of the control panel, so it changes
to local control mode.
2) Set the parameter of [99.13 recognize start request] to: Static.
3) Push the “Start” key (pentagon) on the right bottom of the control panel, so it starts self-
learning.
4) When self-learning is done, push the “Loc/Rem” key, so it changes to remote control mode.
5.6 Operation
Installation of electrical control system:
The installation of the electrical control system should be carried out under good weather
conditions (such as no rain, show, fog), otherwise it may damage the electrical control system or
cause personal injury.
Before the installation of the electrical control system, a preliminary inspection shall be carried
out on all components of the electrical control system to observe whether there is damage or
loss of part in the control cabinet, and whether there is damage, carbonization and loosening of
wires and cables. And please release the damaged equipment.
Before the electrical control system is not connected, separate insulation tests can be carried out
on the motor, resistor, cable, and other parts to judge whether there is a fault, but insulation test
cannot be carried out after the connection of the electrical control system.
The wire connection and the body installation of all components in the control cabinet should be
firm and reliable, and no loosening phenomenon should occur,
The display screen of the auxiliary safety monitoring system should be fixed firmly and the
communication cable connection should be reliable.
Please connect the cables between the control cabinets as well as between the control cabinets
and other external wiring diagram. please note that the connection of each cable should avoid
interference with moving part, and leave a margin for the moving part to move. If the cable slot,
please put the cable in the slot.
After the connection, please make sure that the connection is correct, the connection is firm and
reliable, and there is no short circuit.
◼ Tower suspension cable, cable mesh should be used, and a cable mesh set
every 20m;
◼ When the power cable needs to be lengthened, the middle wire box should
be used, and direct connection is not allowed.
◼ In cable wiring, the power cable and the control cable should be separated
from each other to avoid close parallel wiring.
200
5.7 Putting into service

Checks to be carried out before operation
The execution of the crane erection and the safety require a certain number of operations or
checks to be carried out according to the following description:
Synopsis
Before starting work, every founded anomaly must be transmitted to the

site foreman
201
On the ground
◼ Check the presence and the position of the stops.
◼ Check that the track is freed and horizontal.
◼ Check the correct grounding at the 4 track ends
◼ Check the passage and the fixing of the supply cable.
◼ Take the key and the instructions from the site foreman.
◼ Turn the switch of the site control panel to ON
◼ Check that the wind speed does not exceed 72km/h
◼ Unlock the rail clamps
◼ Check the position and the fixing of the ballast.
On the crane tower

◼ Use the permissible accesses
◼ Check the presence and the state of the connections
◼ Check that no article hinders the access platforms
On the slewing crane part

◼ Check the position and the fixing of the ballast.
◼ From the permissible accesses, check the correct winding, the state, and the tensioning of
the ropes.
◼ Clean and grease the fleeting pulley (according to the model)
On the control unit

◼ Check the presence of the powder-type fire extinguisher
◼ Press successively upon the ON button (the horn is activated), then on the emergency stop
button (movement stop)
◼ Reset the stop button
◼ Press upon the ON button and check the functioning of all the movements by means of the
control switches
◼ Check the dead man position of the control switches
◼ Check the functioning of the displays.
◼ Check the control of the slewing brake
◼ By the means of the test button, test the functioning of the sound signal and the signal lamps
(flashing lamps) located outside the cab and on the display block (configuration according
to model and option)
◼ Check the functioning of the lighting and the windscreen wipers
◼ Check without load the functioning of the limit switches
◼ Check the state of the hook safety catch
202
All the operations for putting into service of the crane serve to ensure its working under correct
driving and safety conditions.
Overall, all these operations can be split up into several groups:
➢ Checking and carrying out of mounting operations in order to avoid any hindrance as regards
the good working order of the crane or safety.
➢ Carrying out the adjustments of the various safety devices and the working conditions of the
crane.
For carrying out any adjustment or maintenance operation and in order to reach the control unit,
use the devices provided on the crane.
203
Checks to be carried out after erection

The execution of the crane erection and the safety require a certain number of operations or
checks to be carried out according to the following description:
Lower part
Concerned crane parts Operations to be carried out
➢ Check the fitting of the ladders and back loops, replace
Access
damaged parts.
➢ Check the fitting and locking of the mast connecting pins

Crane tower
➢ Check that the indicating plates are present and legible.
Slewing crane part

Concerned crane parts Operations to be carried out
➢ Check the fixing of the cab support and the access platforms
➢ Make sure that the driving instructions are properly affixed in
Cab the cab
➢ Check the fitting of the counter−jib catwalks and grab
➢ Check the fitting of the guard ropes of jib
➢ Check the correct installation of the electric supply cable
Jib and counter jib
➢ Check the correct reeving of the hoist and travelling ropes
Operating instructions
Requirement to the operators
◼ The crane operator is over 18 years of age.
◼ The crane operator is reliable, and is physically and mentally adept.
◼ The crane operator has been instructed in operation of the crane and is familiar with all risks
of accident.
◼ The crane operator has provided proof of qualification to the employer regarding operation
of the crane.
◼ The employer has designated the crane operator for operation of the crane is writing.
◼ The crane operator must have read and fully understand the instruction manual, in
particularly the chapters concerning notes on safety, as well as operation and control.
◼ The crane operator must have read and fully understood the local guidelines valid for
accident-prevention.
◼ The crane operator is familiar with the location and operation of fire extinguishers and has
been instructed in the onsite possibilities for fire detection and firefighting.
204
Protective equipment
The following must be worn:
◼ Safety helmet
◼ Safety boots
◼ Safety harness (e.g. for trolley travelling in the event of power failure)
Crane operation
It is strictly forbidden to lift a load the weight of which exceeds the crane
capacity. Consult the technical data for handling of loads when their
surface/lifted load ratio exceeds 𝟏𝐦𝟐 /𝐭.
◼ It is forbidden to lift an incorrectly slung load.
◼ It is forbidden to generate load swinging, to lift a load adhering to the ground and to lift a
load in oblique direction.
205
◼ It is forbidden to slew a load over the staff and roads.
◼ It is forbidden to handle a load in a space lower than 2 m from the ground.
◼ It is forbidden to erect a crane without observing the prescribed distances.
206
◼ It is forbidden to handle a load which is not visible without somebody’s help.
◼ It is forbidden to lift a load by means of several cranes.
◼ It is forbidden to lift persons.
207
◼ It is forbidden to use the crane as a pulling device for a load even a rolling one.
◼ It is forbidden to fill a grab (or other container) if this one is hooked to the crane, and to stack
big objects which could be unstable and fall to the ground.
208
◼ It is forbidden to lay down the pulley block and to let it on the ground, with slackened ropes.
◼ It is forbidden to let a load hooked on the hook during the night or in a rest period.
◼ It is forbidden to work in non-lift areas.
209
◼ The crane must compulsorily be out of service when the wind speed reaches or exceeds 72
km/h. Apply the procedure for the shift end.
◼ During the normal crane operation, do not stop the movements with the stop button.
◼ It is forbidden to work until the limit switches, so stop a little bit before.
It is forbidden to modify or to neutralize the moment cutouts, the load

limiters, the limit switches, and the interference control system.
Instructions to stop working
It is strictly forbidden to hinder the slewing of the jib, as for example, by

hooking the pulley block on a fixed point. The crane must compulsorily
be in weathervaning position.
◼ Position the jib in wind direction, lower the load to the ground, raise the hook without load
and move the trolley to the jib foot.
210
W450-25HC-138EN-A01 MAINTENANCE AND INSPECTION
6 MAINTENANCE AND INSPECTION

This chapter has been compiled for maintenance personnel who have been designated by the
contracting company to keep the crane in nominal operating condition. The maintenance
personnel will obtain an overview of all essential maintenance and inspection tasks stipulated in
the maintenance and inspection chart.
Especially:
◼ check the good working order of the crane components.
◼ carry out the periodically checking.
◼ carry out the adjustments.
◼ identify and repair the malfunctioning or failures.
◼ carry out the greasing.
All maintenance and inspection deadlines can be planned meticulously using the interval
specifications.
This part does not comprise instructions in order to carry out:
◼ repairs requiring a specific tool or which must be carried out in the workshop.
◼ important operations like overhauling, repairing.
6.1 Lubrication
The lubrication table recommends the type of lubricant to be used and the different lubrication
points. Lubricate thoroughly and regularly, since lubrication carried out according to our
instructions helps to prevent failures and premature wear.
◼ Any repair and maintenance work must only be carried out after the
crane has been out of service;
◼ Clean grease nipples and oil drain plugs before lubricating work;
◼ Only the correct use of suitable high-quality lubricants as
recommended by a specialist supplier will ensure maximum
performance and avoid faults and their consequences;
◼ Only use high quality brand-name lubricants.
211
MAINTENANCE AND INSPECTION W450-25HC-138EN-A01
Lubricants table
Table 6-1 Requirements of lubricants for ZOOMLION tower crane are shown as follows
Parts Lubricating
No. Specification of lubricants Oil
Description location
Cleans
Hoisting rope Graphite Calcium-based grease
1 Wire rope Spray
Trolley rope ZG-SSY1405-65
grease
Gearbox of
hoisting Industrial closed gear oil L-CKD 150
mechanism
1,Environmental temperature -20℃~140℃,

Gearbox of According
000# redactor general lithium-based grease
trolley to the label
2,Environmental temperature --40℃~-20℃,
2 Gearbox mechanism
7412# semi-fluid gear lubricating grease on the
gear box
1,Environmental temperature -20℃~140℃,
Gearbox of
000# general lithium-based grease;
slewing
2,Environmental temperature -50℃~-20℃,
mechanism
7023B# low temperature grease.
Drum bearing /
Rolling
3 Slewing ring Calcium-based grease
bearing /
bearing
1, Raceway,2# extreme pressure lithium
Raceway, base grease
4 Slewing ring /
Tooth surface 2, Tooth surface, Graphite Calcium-
based grease ZG-S
Winter with Calcium-based grease ZG-
2;
5 Pulley All pulley /
Summer with Calcium-based grease
ZG-5.
Anti-twist molybdic disulfide Calcium-based
6 Bearing /
device grease ZG-1
1,Environmental temperature exceed-
10℃, Calcium-based grease;
7 Rope wheel Pulley shaft /
2,Environmental temperature under-
10℃, grease thin oil
Hydraulic
8 Oil tank Hydraulic oil for anti-wear L-HM 46 /
pump station
9 Hook Bearing Grease oil /
Electro-
10 Brake DB-25 /
hydraulic thrust
212
Lubrication for bearing

The function of lubrication
There should be sufficient lubrication during the working hours of the bearings to achieve
effective and reliable movement. The function of bearing lubrication is as follow:
◼ Avoid or lessen direct metal contact among rolling element, raceway, and cage of a bearing
to reduce wear.
◼ Oil membrane formed on the friction surface can enlarge the bearing area of the parts and
lessen the contact stress to achieve the benefits of prolonging rolling contact fatigue life.
◼ Lubricant has a certain effect of antirust and anticorrosion.
◼ Grease can improve sealing performance and prevent the invasion of outer pollution.
◼ Lubrication has a certain effect of damping and noise-reducing.
Grease
The general used grease in the bearings of tower cranes is Calcium-based grease.1. Filling
amount of grease.
The filling amount of grease varies with the structure of bearing, space, operation speed and the
different kinds of grease. The filling amount of grease is consisting of two parts, one filled in the
inside of bearings, the other filled in the bearing seats.
The filling amount of grease could be decided by the ratio of allowed limiting rotational speed to
practical working speed. The factor shows in Table 6-2:
Table 6-2 The factor shows in table
Speed radio(limit/n=A) Filling amount
Grease accounts for 1/3 of the free space of the interior
A≤1.25
of the bearing
Grease accounts for 1/3 to 2/3 of the free space of the
1.25＜A≤5
interior of the bearing
Grease accounts for above 2/3 of the free space of the
A＞5
interior of the bearing
6.2 Safety notes

Requirement on personnel
The maintenance personnel must be designated by the operating company. Maintenance of the
crane requires specialist knowledge of crane technology. The operating company is responsible
for all damage caused as a direct result of improper maintenance.
213
Safety measures
◼ Switch off the crane and secure against incorrect or unauthorized restart.
◼ If there is any danger of falling objects: Cordon off the danger area or secure the area with
warning signs.
Protective equipment for personnel

The following must be worn:
◼ Safety helmet
◼ Protective gloves
◼ Safety boots
◼ Safety harness when working above head height
◼ High-visibility clothing
6.3 Required maintenance and inspections
Fig. 6-1 Parts required for maintenance

1. Hoisting mechanism 2. Trolley mechanism
3. Slewing mechanism 4. Slewing ring
5. Climbing equipment 6. Hook
214
The designated personnel must carry out the maintenance and inspection tasks according to
task guidelines as follows:
Maintenance/inspection
Task to be performed
intervals
Slewing ring③: Grease the ball track and gear teeth
Check the wire ropes and rope end fittings
Check the hook⑥
Climbing equipment ④ : Grease the Pins and guide section
rollers
Check when starting up Check the twist compensator during every erection
the crane and before every Grease all Pins during every erection
erection.
Check each framework part and connective part
Check each electric control implement and security implement
Check the quality and quantity of the oil in the reducer of
hoisting mechanism
Check the quality and quantity of the oil in the climbing
mechanism
Slewing mechanism ② brake
Trolley mechanism ⑤ brake
Daily check Hoisting mechanism ① brake
Travelling mechanism brake
Rope release implement
Slewing ring③—Grease the gear teeth, see Fig. 6-1
Check the electric control implement, cable and electric wire
Weekly maintenance
Check the security implement (load moment limiter, load limiter,
trolling limiter, slewing limiter, hoisting limiter)
Grease the wire ropes
Grease the rope pulleys
Grease the winch drum bearing
Fill with hydraulic oil in the climbing pump station
Inspect the high-tensile bolt connections 1 month after erection
Monthly maintenance
Travel gear: Grease the wheel bearings and the inside face of
the flanges
Hoisting gear①: Fill the gearbox with Oil
Check the stability of the vital framework, important weld and
connection parts (bolts and pins)
215
Maintenance/inspection
Task to be performed
intervals
Grease all lubricating nipples
Check the twist compensator
Half-yearly maintenance
Motor bearing: change oil after 1500 operation hours, once a
year at least
Inspect the high-tensile bolt connections and grease the bolt
Check the hook⑥
Yearly maintenance
Check freedom of the movement of the hinged joint of front
window of the cabin and lubricate it regularly
Oil change in the reduction of slewing mechanism②
Oil change in the reduction of hoist mechanism①
Oil change in the reduction of trolley mechanism⑤
After 2000 operation
Oil change in the brake of hoisting mechanism ①
hours
Oil change in the trolley travel gearbox
Oil change in climbing mechanism ④ after 2400 operation
hours
216
6.4 Hoisting mechanism

Overview
The structure of the hoisting mechanism is shown in the figure below. There are five gears in the
process of hoisting or falling. The first and second gears are transition gears which can be used
for slowly locating operation.
Fig. 6-2 Hoisting mechanism

(1) Motor (2) Brake
(3) Coupling (4) Reducer
(5) Drum (6) Hoisting limiter
(7) Bearing seat
217
Adjustment and maintenance of the brake

The type and relevant parameter of the hoisting mechanism brake are shown in the table
below.
Table 6-3 Relevant parameter of Brake
Rated braking moment Suggested braking moment
Part name Type
(Nm) (Nm)
YWZ5-400/125-
Brake 2000 1250—1300
2000-HL
Make sure drum not rotation unexpected leads to accidents before any
debugging for brake.
Adjusting the brake
Fig. 6-3 Hoisting mechanism brake

(1) Pull pin (2) Compensation cover
(3) Locknut 2 (4) Locknut 1
(5) Braking tie bar (6) Compensation device
(7) Fastening screw (8) Back-off adjusting nut
(9) Dish washer (near Spacer bush 2) (10) Dish washer (near Braking jib)
(11) Spacer bush 1 (12) Locknut 1
(13) Locknut 2 (14) Dish washer
(15) Spacer bush 2
218
CAUTION: It is prohibited to press the two locknuts together completely

when screwing the Locknut 1. Each of the locknut can be compressed
for at most 0.5mm, which means the maximum compression is 1mm.
The adjustment of the brake mainly includes the adjustments of: the braking moment, the shoe
clearance (compensation for travel of the pusher hb) and the shoe clearance balancing.
6.4.2.1.1 Adjustment of the braking moment

As the following figure shows, when using the wrench to screw the nut clockwise, the spring
shorten and the braking moment increases; when screwing anticlockwise, the moment
decreases.
Moment
adjusting nut
Fig. 6-4 Adjustment of the braking moment
Don’t overstep the range on the moment scutcheon when adjusting the
braking moment, otherwise the brake may work unmorally.
219
6.4.2.1.2 Adjustment of the shoe clearance

1) Open the brake by electrifying or manual release device (If it’s not opening enough, open
wider by adjusting the braking tie bar or back-off adjusting nut);
2) Screw the back-off adjusting nut clockwise for 3~5 circles, then close the brake;
3) Measure the compensation for travel of the pusher hb as the following figure, then repeat the
step 2) until the hb correspond with the rated value in the following table.
4) Screw the locknut 1 on the brake tie bar tightly after the adjustment (caution that It is
prohibited to press the two locknuts together completely when screwing the Locknut 1. Each
of the locknut can be compressed for at most 0.5mm, which means the maximum
compression is 1mm.)
Table 6-4 The compensation for travel of the pusher hb
Part name Type Rated hb (mm) Minimum hb(Nm)
Brake YWZ5-400/125-2000-HL 20±2 5
Fig. 6-5 Adjustment of the shoe clearance
6.4.2.1.3 Adjustment of the shoe clearance balancing

As the following figure shows, open the brake, observe the gap between the braking gasket and
the braking wheel. If the gaps of two sides are not equal, screw out the locking nut of the wider
gap side, and screw the adjusting bolt clockwise and keep observing, stop screwing when the
gaps are equal. Finally screw in the locking nut. This device is an automatic balance device, once
be adjusted well, it’s no need to adjust again in the working process. If it appears badly
unbalanced shoe clearance in the working process (appearance of the braking gasket on the
one side floating over the braking wheel when the brake is releasing), it may because the locking
nut of the shoe clearance balancing device is loose. To deal with it, just close the brake and screw
in the locking nut tightly.
220
Fig. 6-6 Adjustment of the shoe clearance balancing

(1) Locking nut (2) Locking nut
(3) Braking wheel (4) Balance lever
(5) Distance
Keep the balance levers almost horizontal. Keep the distance (5)
between the bottom of the middle of the balance levers and the bottom
plate not less than 8mm, and keep the distance between the top of the
balance levers and the braking wheel not less than 5mm.
221
Replacing the braking gasket

1) Open the brake to the widest position;
2) Unscrew the bolts of the pressing plate on the top of the gasket, take down the pressing
plate and the adjusting washer;
3) Hold the gasket and push to the side of the brake wheel, pull out the gasket to be replaced
along the edge of the braking wheel;
4) Infer to the following figure, insert a new braking gasket to the right position, assemble the
(5) (4) (3) (2) successively and screw the (1) tightly;
5) After inserting the braking gasket, check the brake and ensure it’s alright, then make the
brake run statically for 20~30 times, which means the main motor is power-off, the brake
runs for each 5s with 40% braking loads, operate the brake in this working condition
intermittently for 25~30 times. Observe if there is any unusual situation, if yes, find out the
reason and deal with the problem until the brake is normal;
6) Adjust the braking moment to 50% rated value, take a dynamical pilot run for 15~20
circulations with 30%~50% braking loads. Observe the braking length is almost the same or
not, if yes, stop the pilot run.
Keep the new braking gasket fitting to the braking shoe clearance well,
the gap on the fitting surface can’t be over 0.5mm, and the top of the
gasket should higher than the top of the shoe clearance for 1.2~2.0mm,
so that the gasket can be pressed tightly and be reliable. Besides, the
thickness of the gaskets of the pressing plates and baffles of two sides
can’t be over half of the original thickness of the gasket but not less than
the 1/3 (with the thickness of steel back plate).
222
Fig. 6-7 Adjustment of the shoe clearance balancing

(1) Bolt (2) Spring washer
(3) Pressing plate (4) Baffle
(5) Adjusting washer
Maintenance of the brake

1) Inspect the brake for every 1~3 days (according to the actual situations), the things to be
inspected are:
◼ The shoe clearance is normal or not;
◼ The static length of the spring is changed or not;
◼ The touch plate of the limit switch is loose or not, the position of the limit switch is correct
or not;
◼ The surface of the brake or braking gasket are contaminated by oil or not;
◼ The wear of the braking gasket (If the thickness of the gasket is less than 3mm, the
gasket must be changed, then adjust and run the brake for adaptation.);
◼ The crack on the brake wheel, change the wheel if there is any deep crack.
223
2) In the working process, the following situations must be inspected if occurred:

◼ The braking time or distance increases abnormally;
◼ The braking wheel is overspeed;
◼ The movement of the limit switch is abnormal;
◼ The braking wheel or gasket is keeping hot or smoking. If occurred, stop the crane, and
find out the cause, solve it then the crane can be used again;
3) Paint mending: The paint on the brake can be damaged in the transporting, saving, installing,
or working processes. The paint damage must be touched up in time, otherwise the
antiseptic performance of the surface will reduce. The following parts are prohibited to be
contaminated in the paint touch-up process:
◼ Every hinge joint;
◼ The rubbing surface of the braking wheel and gasket;
◼ The surface of the automatic compensating device and the push rod of the pusher;
◼ The surface of the shafts.
4) Lubrication: Every hinge joint of the brake is self-lubricating composite bearing which is no
need to add lubricating oil;
5) Replacing the braking gasket: The braking gasket will wear out and be thinner after working
for some time. When the thickness of the gasket is less than 3mm, the gasket should be
replaced. Caution that the gasket is heavy when replacing. Please inspect, adapt, and take
a pilot run after the replacing;
6) Maintaining the brake: The brake has been filled with hydraulic oil when leave factory. The
pusher is a maintenance-free product (As the following figure). After working for a long time,
the hydraulic oil will be muddy and must be replaced. Generally, the hydraulic oil should be
replaced for every 1~2 years according to the actual situations. Replace the hydraulic oil
refer to the processes below:
◼ Remove the brake pusher and deliver it to the repairing workbench;
◼ Screw out the oil inlet plug and remove all the hydraulic oil inside;
◼ Fill the pusher with new hydraulic oil to the marked oil level.
(The types of the hydraulic oil according to the following table or Type plate on the product.)
Table 6-5 The types of the hydraulic oil
Surrounding Temperature Type Standard
DB-25 GB2536
-25℃~+50℃ DTE-21(Mobil) ISO VG15
HL-10 DIN51524
＜-25℃ YH-10 GB2512
224
Fig. 6-8 Parts of the braking pusher

(1) Head of pusher rod (2) Oil level mark
(3) Oil inlet plug (4) Piston rod
(5) Piston (6) Sealing element of motor
(7) Bearing (8) Support
(9) Shell of motor (10) Motor
(11) Middle flange (12) Impeller
(13) Oil guiding plate (14) Cylinder sleeve
(15) Cylinder (16) Sealing element of rod
(17) Spring pin (18) Limit switch
(19) Line-in hole
Ensure the hydraulic oil has cool down to the surrounding temperature
before observing or replacing, otherwise once the oil inlet plug opened,
the heated oil may splash out!
Ensure there is no any impurity in the added oil (filter it if necessary). To

exhaust the air in the cylinder and ensure enough filling, pull and push
the pusher rod slowly for several times when filling the oil.
If the brake work as S3, 60% brokenly, the pusher must be heavy
repaired or the brake be replaced.
225
Maintenance of the motor

Storing the motor
The motor should be stored in the dry and ventilated place and be covered by rain cloth. Keep
the motor clean, avoid any water, oil, dust, or corrosive gas get into the motor, and clean the dust
inside or outside the motor regularly.
For the motor stored over one year, clean the impurity inside and dry, apply a coat of clean anti-
rust oil to the bearing, all the fasteners (except the earthing bolts) and fitting surfaces.
The cover plate, junction box cover and unused outlet should be covered well, for avoiding things
as water, dust, oil, or emulsion get into the motor, and caution the mouse destroying the coil.
Maintenance before use the motor again

1) Observe the motor and transmission after starting, if any abnormal situation occurs, stop the
motor immediately, find out the cause and solve it, then the motor can restart;
2) The increase heat of the working motor is prohibited to exceed the permission value. Using
the temperature gauge to measure the heat increase of the iron core or shell, generally the
increase can’t exceed 60℃, the increase of bearing can’t exceed 95℃, always monitor the
heat increase of the parts in the working;
3) Notice the smell, vibration, and noise of the motor. The winding will scorch with smell
because overheat. Some problems, especially the mechanism problem, will show as
vibration or noise, so the motor should be stopped immediately when the abnormal smell,
vibration, and noise occur;
4) Check if the bearing is overheating or oil-leaking constantly, and pay attention to supplement
or replace grease regularly. The grease is generally made of No,2 lithium grease. Use the
same grease as possible, the grease in the bearing room should not exceed 70%;
5) Keep the motor clean, no water, oil and impurities can fall into the motor. The air inlet and
outlet must always be unobstructed;
6) If the motor leaves unused for a long time, mind to deal with the exposed parts of the motor
by dustproof and waterproof treatment. When use again, take a mechanism check before
installing, check if the assembly is complete, if the fasteners are loose. The dust or impurities
inside should be cleaned if there are, use dry compressed air to clean if necessary. Must
use 500V megohmmeter to measure the insulation resistance between the stator winding
and the shell. If it’s lower than 0.5 MΩ, the motor must be dried, charging in low-voltage
electric is a suggested way. The temperature of the winding is not allowed to exceed 125℃.
To avoid the motor rusting, when assembling after the excreting and checking, all the
fasteners (except the earthing bolts) and fitting surfaces should be applied with a coat of
clean anti-rust oil. All the fasteners should be attached with spring washer to avoid loose.
After the assembling, rotate the rotor by hands, the rotor should roll flexibly and have no
friction.
226
Avoid to crash, knock the brake and rotary encoder in the tail of the
motor. Check if the brake and rotary encoder are assembled completely
and installed right, and if the fasteners are loose.
Maintenance of the reducer

Period of the maintenance
Users should maintain the reducer regularly according to the items in the following table:
Table 6-6 The period of the reducer maintenance
Check items Period Remarks
Check the oil temperature Everyday
Check the abnormal noise of the
Everyday
reducer
Check the height of oil level Per month
Check the oil leaking of the reducer Per month
Clean the vent cover Every three months
After working four-hundred hours, once
Check the water contain in oil
a year at least
Replacing oil after starting the reducer
After working four-hundred hours
for the first time
Every eighteen months or five-
Oil replacing afterwards
thousand working hours
Clean the filter Every three months
Clean the vent cover Every three months
If the motor leaves unused for a long time, mind to deal with the exposed
parts of the motor by dustproof and waterproof treatment. When use
again, take a mechanism check before installing, check if the assembly
is complete, if the fasteners are loose. The dust or impurities inside
should be cleaned if there are, use dry compressed air to clean if
necessary.
227
Oil adding of the reducer

The spare parts of the reducer are as following figure:
Fig. 6-9 Parts of the Hoisting reducer

(1) Oil inlet (2) Shell
(3) Dipstick (4) Oil outlet plug
The oil adding steps are:

1) Open the part (1), remove the part (4), clear the waste oil inside, install the part (4) back;
2) Add gear oil conforms to the Table 6-1 into the reducer;
3) Observe by the dipstick, add oil until the level comes to half of the dipstick;
4) Install the part (1) back.
Ensure the gear oil has cool down to the surrounding temperature before
adding or replacing oil, otherwise the operator can be scalded.
228
Coupling
◼ Allowable motor axle deviation inspection
➢ Check the motor axle deviation of coupling from the inlet shaft of the reducer. Axial
deviation≤4mm, radial deviation≤1.5mm, angle deviation≤1° and radial run-out of braking
wheel≤0.7mm. If the value goes beyond, please adjust it into the prescribed limit or contact
after-sales service of our company;
➢ Check the coupling elastomers and half-coupling, if damages or cracks are found, please
stop operate or contact after-sales service of our company to check and change it.
If the value goes beyond, please adjust it into the prescribed limit or
contact after-sales service of our company.
◼ Coupling elastomers and half-coupling inspection
If damages or cracks are found on coupling elastomers and half-coupling,

please stop operating or contact after-sales service of ZOOMLION for
replacement.
229
6.5 Method of Rope Arrangement Problem of Hoisting

Mechanism
Rope of tower crane hoisting mechanism is multilayer coiling. The drum is lebus drum which is
fit for multilayer rope coiling. The characteristic is most of the rope race is straight line rope race.
The under-layer rope arrangement has obvious guide effect to the upper rope arrangement. It is
not easy to lead to rope climbing and rope disordering phenomena and is helpful to arranging
multilayer rope coiling orderly. Rope arrangement of hoisting mechanism is shown in
Fold line rope race
Straight line rope race
Rope
stretching
direction
Fig. 6-10 Drum structure
Table 6-7 Rope arrangement problem summary of hoisting mechanism
Rope arrangement problem summary
Problems description Reason analysis Handling Method
Check the lubrication condition, if dry

lubricating grease is found, wipe it off and
paint new lubricating grease. If the
Bad lubrication of A-frame guide
environment temperature is too low and
pulley leads to clamped pulley
Bad rope viscidity of lubricating grease is too high,
cannot guide well.
arrangement and add thin grease to the pulley (Check before
rope jumping of drum starting the machine and paint thin grease
if necessary).
Hoisting mechanism is installed Check whether the bracket is installed

aslant aslant, if yes, adjust it.
230
Center lines of hoisting Adjust mechanism installation seat to let

mechanism drum and counter jib the center lines of hoisting mechanism
are not aligned drum and counter jib be aligned.
Bracket of hoisting mechanism Check the flatness of the bracket. If it is not

is not installed flatly flat, adjust it.
Check if the first layer rope is arranged

Upper layer rope is pressed
tightly, if not, arrange it tightly with some
under the lower layer rope of the
load (2% of the minimum broken tension of
drum
the rope or 10% of rated hoisting load)
CAUTIONS:
◼ The lubricating condition has some effects to the rope arrangement. Check the lubricating
condition of the rope. If dry lubricating grease is found, wipe it off and paint new lubricating
grease.
◼ If rope disordering occurs, arrange the first layer rope tightly and well with some load (2% of
the minimum broken tension of the rope or 10% of rated hoisting load)
◼ When the tower crane is at the height and below free-standing height, the 6×29 non-rotate
hoisting rope can be used; The height of the tower crane greater than free-standing height,
the 35W×7 rotate rope suggest to be used.
◼ Disorderly rope during the service is related to diameter and pre-tightening force of the rope.
The rope was pre-tensioned when leave factory. The first layer rope must keep-in, lined up
and as much load as possible (2% of minimum breaking load rope or 10% of rated load).
◼ In order to reduce the probability of mutual extrusion and random rope caused by more
layers around the rope, according to the construction progress, use cycle, final height, fall
change, life expectancy and other comprehensive conditions, consider the configuration of
multiple rope of different lengths, to ensure that the first layer of the drum rope has pre-
tightening force. By using short rope in the early stage, the service life of rope can be
effectively extended and the service cost of rope can be reduced.
◼ When the height of the tower crane is low, the length of the rope is suggested to use adopt
4-fall, and the pre-tightening force of the whole length can be satisfied through the load, to
prevent the phenomenon of rope sinking and chaos caused by the partial rope not being
preloaded.
◼ After the maximum length of rope is released, the rope on the drum should be retained for
at least 3 laps.
◼ The lubrication of the rope also has a certain influence on the arrangement of the rope. The
rope should be checked regularly. If the rope is found to have dry grease, it should be
removed manually and then smeared with new grease, see Table 6-1.
231
6.6 Trolley mechanism

Overview
The structure of the trolley mechanism is shown in the figure below.
Fig. 6-11 Structure of the trolley mechanism

(1) Motor (2) Travel limiter
(3) Reducer (4) Drum
232
Limiter of trolley mechanism

Function
The function of the limiter of trolley mechanism is to avoid potential wrong operation and keep
the hoisting jib moving within allowable operating angle range.
Working principle
The limiter with a reduction gear is directly driven by the reel shaft and the limiter records the reel
revolutions and the wire rope length. The cam ① driven by the reduction gear on the limiter acts
on the switch ② so as to complete the connection or disconnection action. See Fig. 6-12.
Fig. 6-12 Limiter of trolley mechanism
The plug at the lower part of the limiter must be removed to drain the
condensate in the limiter each time the tower crane is transferred to a new
construction site and before it is used.
If the tower crane has been used for a long time at a construction site, the
above operations shall also be performed regularly.
233
Trolley brake
2 3 4 5 6
7
Fig. 6-13 Trolley brake
(1) Brake disk (2) Hollow bolt
(3) Armature iron (4) Mounting screw
(5) Magnetic yoke assembly (6) Spring
(7) Fixture wire
The apply and release of brake
Fig. 6-14a Apply the electromagnetic brake Fig. 6-14 b Release the electromagnetic brake
Fig. 6-14 Apply and release of brake
234
Adjust the air gap of the trolley travel gear brake

Ensure the main motor and brake are power-off!
The normal working air gap of the brake is 0.6mm, maximum gap is 1.2mm. If check out the
brake is not working or the air gap over the maximum gap value the brake need to adjust.
1) See Fig. 6-15 loosen the retaining bolts ① and remove the fan cover ②;
2) See Fig. 6-15 loosen the installing screw ③ and then adjust the hollow nut ④ to the proper
position.
1 4
3
2
Fig. 6-15
3) See Fig. 6-16, install the fan cover ② and tighten the retaining bolts ①.
Fig. 6-16
If the air gap is not appropriate, repeat the step 2 and adjust it to 0.6 mm, it
should be consistent in all directions.
235
Maintenance
◼ Maintain once for every 450 hours or three months.
◼ Adjust the air gap: the standard air gap value E=0.6mm for the electromagnetic brake of
three-phase asynchronous motor. See Fig. 6-17.
I
Examine air gap
检查气隙 4:1
δ
Fig. 6-17 Adjust the air gap
Ensure that there are no sundries (for example: concrete, sand, or grease)
in the electromagnetism brake.
When the minimum value of the brake disk is reached, replace it as follows:
1) See Fig. 6-18, loosen the retaining bolts ① and remove the fan cover ②;
2) See Fig. 6-18 loosen the fixing screws ⑤, and remove the brake ⑥.
3) See Fig. 6-19, Remove the retaining ring⑦, pull out of the brake disk and the splinted sleeve
⑧
4) See Fig. 6-19, install new brake disk and splinted sleeve ⑧and fit the retaining ring ⑦;
5) See Fig. 6-20, install the brake ⑥ and the mounting bolts ⑤(adjust the air gap according
3.3.2 )
6) See Fig. 6-20, install the fan cover ② and tighten the retaining bolts ①.
236
1 6 5
2
Fig. 6-18 Maintenance process 1 and 2.
8 8
7 7
Fig. 6-19 Maintenance process 3 and 4
1
6 5 2
Fig. 6-20 Maintenance process 5 and 6
237
Maintenance for motor

The storage of motor
◼ The motor should be stored in dry and ventilative places and covered by waterproof cloth.
Keep the motor clean, and no droplet, greasy dirt, dust or erosion gas could be get into it.
Clean the inside and outside of the motor regularly.
◼ As for motors that have been stored for more than one year, clean the inside of it and dry
the inner water. Daub clean antirust oil on the bearings, all the matching surfaces and
fasteners with thread( except for grounded bolt).
◼ The covers, covers of connecting box and unused outlets on the end cover should be
covered soundly to avoid water, dust, oil or grease getting into the motor. Watch out for
mouse.
Maintenance for motor before reusing
◼ As for motors that have been stored for more than one year, check whether there is rust in
bearings and the location of bearings. If rust exist, exchange bearings immediately. Clean
and refuel the bearings before restarting to avoid damages or noise caused by dried grease.
◼ Check whether the assemble is integrated, or whether the fasteners are tight. If there are
dust or foreign materials inside, please clean up and use dry compressed air when
necessary.
◼ If the mechanism is left unused for a long time, the exposed parts of the motor should be
kept dust-free and dry. When it is to use again, perform mechanical check before installation.
Check whether the assemble is integrated, or whether the fasteners are tight. If there are
dust or foreign materials inside, please clean up and use dry compressed air when
necessary. Measuring the insulation resistance between stator winding and shell with 500V
Megohmmeter before using. When the figure is less than 0.5 megohm, the motor should be
withered and the drying treatment could be performed by bubbling low pressure air into the
winding ( the temperature should not be more than 125℃). To avoid motor rusty, it is
recommended to daub anticorrosive oil on the matching surface and fasteners with thread
(except for grounding bolts) during installing. Also, all the fasteners should be with spring
washer to avoid automatic relaxation. After installation, turn the rotor manually and it could
rotate freely with no friction.
◼ After installation, check whether the brake could close firmly or release. After energizing,
the rotor of the motor could be rotated elastically by hand.
◼ When install gear or coupling, clear the rust on the shaft first. Heavy strike should be
forbidden to avoid damages to the bearings
◼ The connection box is equipped with grounding bolts which should be grounded reliably
after installation.
◼ The method of connection of motor should be exactly the same with the requirements
offered in this technical file, or abnormal operation or even overburn will occur.
◼ After installation of motor, it should run 30~40 minutes without load. If the condition is well,
then add load and watch out for the stability of power. When deviation between the voltage
of power( the frequency is rated) and rated voltage is no more than ± 5%; or positive
deviation occurs both for voltage and frequency and the sum total of them is no more than
238
6%; or negative deviation occurs both for voltage and frequency or one is positive and the
other is negative, and the total sum of them of absolute value is no more than 5%, the motor
is allowed to operate in rated condition.
Oil adding of the reducer

The reducer is filled by “0# general lubricating oil for reducer” when left the factory.
Pay attention to the following things when adding or replacing oil:
◼ Add oil to the reducer in time when the oil level fell;
◼ Add in the same type lubricating oil, don’t use different oil.
6.7 Slewing mechanism

Overview
W450-25HC tower crane has two slewing mechanisms arranged on both sides of the upper
support. The specific parameters are as follows:
◼ Cover the working junction box

and the unused outlets to prevent
foreign matters from entering the
motor;
◼ Carry out regular maintenance
for the motor;
Oil change
◼ Lubricating oil grade: 000#
lubricating grease for reducer;
◼ Add the lubricating grease in
time during overhaul or when the
oil level drop s due to leakage;
◼ Add the lubricating grease of
specified grade as required.
Different grades of lubricating
grease shall not be mixed;
◼ Ensure that the lubricating
grease level reaches the position
of the oil level plug;
Fig. 6-21 S75CA-130.146LB14/12A
239
Fig. 6-22 Arrangement of slewing mechanism and slewing ring
Slewing brake
Working principle
The slewing brake is an electromagnetic brake, which will be applied once the power supply is
cut off. See Fig. 6-23
Fig. 6-23a Brake released Fig. 6-23b Brake applied

Fig. 6-23 Working state of brake
240
Clearance adjustment and maintenance (1)

For conventional brake structure as shown in Fig. 6-24, brake friction plate (13) after long-term
use of friction losses, armature (10) and field core (9) increase the air gap δ, brake spring (16)
length increases, reduce the braking moment, because the air gap δ may increase at the same
time, the armature (10) have difficult in actuation, serious will not be able to actuation, result the
motor in braking state, and then the motor burnout. Therebefore, it is necessary to check the air
gap δ value frequently. When the static braking moment is less than the stipulate value or greater
than 1.2mm, the δ should be adjusted in time. And if the friction plate (13) is worn to close to its
steel mail, the friction plate (13) should be replaced in time.
1 2 3 4
17
5
16
6
7
15
8
9
δ
10
11
13
12
13
14
Fig. 6-24 Brake structure

(1) Cover (2) Adjust nut
(3) Release rod (4) Release handle
(5) Armature (6) Push handle
(7) Electromagnet (8) Locating screw
(9) Field core (10) Armature
(11) Friction disk (12) Braking plate
(13) Friction piece (14) Motor engine base with cover
(15) Spring chamber (16) Braking spring
(17) Release screw
241
◼ Regular inspection
Regular inspection once a month, do not remove any parts, the braking opening, braking
should be metal impact sound; When the motor is running, the brake should have no abnormal
sound (friction, metal impact) and vibration.
◼ Regular adjust
Once every 3 months, remove the weathercock cover. Flat mouth screwdriver loosens the
positioning screw and counterclockwise moving armature pull cylindrical gear, let the armature
against field core, to promote the positioning screw, make its end stick close with armature ends,
at the same time with a flat mouth screwdriver clockwise slowly moving armature pull cylindrical
gear, when the end of the armature fifth hole through the end of the positioning screw, insert and
tighten the set screw on moving (the clearance values δ: 0. 75-~1.0m). When the brake is opened
and braking, the action should be sensitive and there should be obvious metal impact. When the
motor is running, the brake has no abnormal sound (rubbing sound, metal impact sound) and
action.
◼ Regular dismantling and check
Once every 6 months, remove the whole lower vane brake and check the friction plate (13).
When its thickness is less than 3m, the friction plate must be replaced. Install the whole windward
marker brake, and adjust the clearance δ value according to the regular debugging requirements.
◼ Replace Steps of brake friction disk
1) Put the tower crane in the safe state, ensure will not happen any accident when
Dismantling motor operation, otherwise the following operations were prohibit！
2) Cut off all power;
3) Dismantling electrical weather vane;
4) Unscrew locating screw (8);
5) Unscrew the spring chamber (15), take out the brake spring (16), unscrew the mounting
screw of the exciting iron core (9), carefully remove the exciting iron core (pay attention to
protecting the exciting iron core lead), remove the friction disc (11) and brake disc (12),
and check the friction disk mounted on the cover frame (14) and the friction disk
respectively. The friction plate on (11) if the friction plate is seriously worn, it should be
replaced immediately (13), remove the worn friction plate (13) and install a new;
6) Remove the worn friction plate and install a new one;
7) Reinstall the removed parts in the reverse order, and adjust the brake gap δ according to
the second (regular debugging), and adjust the electric weathercock according to the fifth
(adjustment steps of the electric weathercock).
◼ Adjustment steps of electric weathervane
1) Disconnect all power supplies, and adjust the brake gap δ according to the second
(regular debugging);
2) Put the motor under braking state (weathercock release lever (3) can move downwards
freely);
3) Hold down the weathercock release handle (4), and slightly loosen the adjusting nut (2) in a
counterclockwise direction, so that the weathercock armature (5) emerges about 1mm
below the weathercock release lever (3);
242
4) Release the electric weathercock by sounding to see if the action is normal. If the
weathercock armature (5) is blocked from free movement under the weathercock release
lever (3), the adjusting nut (2) should be loosened again at this time, if the weathercock
armature (5) If the weathercock release lever (3) cannot be supported, the adjusting nut
(2) should be properly tightened;
5) Manual and electric release several times, and then close the weathercock cover after the
action is normal.
◼ Check whether the weathercock is working properly, and readjust if

necessary. When the gap value is greater than 1.2mm, the gap value should
be adjusted in time, and the recommended gap value is about 0.8mm;
◼ When the thickness of the friction plate is less than 3mm, the friction plate
should be replaced in time;
◼ The adjusted electromagnetic brake and electric wind indicator should be
checked if the manual release function, electric release function and braking
function are normal, and they can be put into use after being normal.
◼ The electromagnet of the electric weathercock cannot be energized for a
long time, otherwise it will burn the electric weathercock electromagnet.
◼ When the motor is working normally. The electric release action of the
electric weathercock cannot be used, otherwise it will cause the motor brake
to work abnormally, which will affect the safety of the tower crane in severe
cases.
243
Clearance adjustment and maintenance (2)

Lay out of new designed slewing motor as shown the following Fig. 6-25.
Fig. 6-25 The structure of the YTRVF series variable frequency motor with vane brake
Table 6-8 Spare parts of YTRVF series motor
No. Designation Qty No. Designation Qty
1 Front-cover 1 7 Electric weather vane 1
2 Bearing 2 8 Brake 1
3 Connecting box 1 9 Fan blade 1
4 Stator 1 10 Coder 1
5 Rotator 1 11 Cover 1
6 Back -cover 1
244
Adjustment of the weather vane braking ： Divide into weather vane adjustment and brake
adjustment. The structure of the weather vane brake as show in the following picture:
Fig. 6-26 The structure of the weather vane brake
Table 6-9 Spare parts of weather vane brake
No. Designation Qty No. Designation Qty
1 Long pin 2 10 Spring 4
2 Bottom plate of loose brake 1 11 Static core assembly 1
3 Clip-on 2 12 Moving plate 1
4 Reset spring 2 13 Friction assembly 1
5 Waterproof block 1 14 Screw sleeve 3
6 Loose brake rod 1 15 Microswitch 2
7 Shield 1 16 Spline hub 1
8 Basal plate 1 17 Dual disc 1
9 Brake type plate 1
1) Adjustment steps of electromagnetic brake
After long-term use and wear of the brake friction plate, the gap between the armature and the
excitation magnet core increases, the length of the brake spring increases, and the braking
torque is reduced. At the same time, due to the enlarged gap, it is difficult for the armature to pull
in. In severe cases, it cannot be pulled in, causing the motor to be in a braking state, and even
the motor is burned out. When the static braking torque is less than the specified value or the
245
gap is greater than 1.5mm, it should be adjusted in time. When the thickness of one side of the
integral friction disc is less than 1.5mm, it should be replaced in time.
2) Adjustment of electric weathervane
Both the brake and the contact plate are energized and closed, and the lower end surface of the
release brake bottom plate and the end surface of the contact plate (figure number 1) have a
clearance of 0.3m. The gap between the contact plate and the micro switch (Figure No. 2) is
0.5m to prevent damage to the micro switch contact caused by long-term overvoltage.
Fig. 6-27 Electromagnetic iron assembly

3) Adjustment steps of electromagnetic brake gap
As show in the Fig. 6-28, the adjustment steps of electromagnetic brake gap can be divided into:
adjust the gap between static core and moving plate; adjust the gap between bottom plate of
loose brake and contact plate.
Fig. 6-28 Adjust electromagnetic brake gap

(1) Release brake bottom plate (2) Gap 2
(3) Contact plate (4) Nut
(5) Screw 1 (6) Static core
(7) Gap 1 (8) Moving plate
(9) Adjusting bolt (10) Screw 2
246
◼ Adjust the gap between the static core and the moving plate
➢ Put the tower crane in a safe state to ensure that the motor is operated on the premise that
no safety accident occurs during disassembly. Otherwise, the following operations are
prohibited;
➢ Disconnect all power supplies;
➢ Insert the 0.7mm feeler gauge into gap 1, tighten the screw 1. When the feeler gauge is
clamped, stop screwing the screw 1;
➢ Turn the adjusting bolt to the left, stop turning the adjusting bolt when the feeler gauge can
be easily taken out, and then tighten the screw 1 completely;
➢ When the feeler gauge is pulled out, there is a sense of blockage and the gap meets the
requirements. If the gap is too large, loosen the screw and adjust the bolt. Fine-tune to the
right, and then fully tighten the screw 1. On the contrary, if the gap is too small, fine-tune the
adjusting bolt to the right;
➢ Repeat the above steps to adjust the front of the remaining 2 screws.
◼ Adjust the gap between the brake release bottom plate and the contact plate
After power on, the contact plate is attracted and the contact plate is in a vertical state. The gap
between the upper surface of the contact plate and the lower surface of the loose gate is
0.3~0.5mm. When adjusting the gap, first screw down the nut on the screw 2. When the gap is
too large, screw the screw 2 upwards, and when the gap is too small, screw the screw 2
downwards until the gap meets the requirements, and then tighten the nut.
4) Replacement of the integral friction disc
◼ The overall friction disc should be replaced by a professionally trained person, otherwise it
is easy to cause other damage;
◼ Put the tower crane in a safe state to ensure that the motor is disassembled without any
safety accidents. One step operation, otherwise, the next operation is prohibited;
◼ Disconnect all power;
◼ Remove the wind vane and brake connecting wire;
◼ Remove the parts at the rear end of the integral friction disc one by one (the entire
weathercock brake);
◼ Replace with a new integral friction disc of the same specification;
◼ Install the disassembled parts one by one, and adjust the brake according to the same
clearance adjustment procedure of the electromagnetic brake.
After adjusting the brake and electric wind indicator, check whether their braking,
manual release and electric release functions are normal. After everything is
normal, the motor can be put into use.
247
Maintenance for slewing ring

◼ The rolling groove of the slewing ring has been filled with 2# extreme pressure lithium base
grease when leaves the factory. Add the grease once every 100 hours of operation, Addition
of lithium base grease, should make the slewing mechanism rotated slowly, while rotation,
while the oil, the grease filling evenly, until the seal a grease extrusion, said the old fat has
been replaced by. Special working environment, such as rain, humidity, dust, temperature
variation and continuous operation, it should shorten the lubrication cycle;
◼ After long time idle, enough new grease must be added to slewing ring;
◼ Exposure of tooth surface and tooth surface, often should clean the rubbish, and coated
with grease corresponding;
◼ Slewing bearing the first 100 hours of operation, should check the retightening force of bolt.
After examining every 500 hours of operation time, must keep enough preload force;
◼ The use of the process, if found, the impact of noise, power increases suddenly, should
immediately stop check, troubleshooting, remove check when necessary;
◼ Never use water directly scour slewing bearing the use of the process, to water entering the
race;
◼ To prevent the hard foreign body close to or into the meshing area;
◼ Always check the seal intact, if it is found that the sealing strip damaged should be replaced
promptly, if found off should be timely reset.
248
6.8 Maintenance climbing mechanism

Working principle
The climbing hydraulic system consists of pump station, climbing cylinder and high-pressure
hose. It can jack or lower the upper parts of the telescopic cage, and stop at any position for
mounting or dismounting tower mast sand tower sections. Refer to the figure below:
Fig. 6-29 Schematic diagram of tubes connecting of the Hydraulic system

(1) Balance valve (2) Climbing cylinder
(3) Motor (4) Terminal box
(5) Air switch (6) Pressure gage
(7) Control handle (8) Liquid level meter
(9) Pump station
249
Fig. 6-30 Schematic diagram of hydraulic system

(1) Pump station (2) Balance valve
(3) Manual control valve (4) Pressure gauge
(5) High pressure overflow valve (6) Motor
(7) Level meter (8) Level meter
(9) Oil filter (10) Fine oil filter
(11) Air filter (12) Tube
250
Erection, operation, and maintenance of the hydraulic
pressure system
Erection, operation of the hydraulic pressure system
◼ Oil cleaning
Screw open oil suction screen 11, fill 10μ hydraulic oil filtered by hand-held oil filter into the oil
tank up to the upper limit mark. After that, start the oil pump motor (look down at the motor blades
to see if the rotation direction is the same as that marked at the motor tail)
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.
◼ Connect high-pressure hose openings for clean status

Connect ports A.B of the hydraulic pump station to the hydraulic cylinders through high-pressure
hose. Screw down the connectors.
◼ Air exhausting of the system
Unscrew the handle of overflow valve, and then the high-pressure hose-to-port A connector.
Move the handle of hand-operated valve 3 to its up position. Start the motor to drive the air out
of Port A until the pump noise has become normal and no foam formation from oil liquid. Make
the cylinder into no-load status. Push the operating handle to let upper cylinder or piston rod
move up and down at full strokes for several times to completely exhaust the air from cylinder
into oil tank through oil hose.
When the piston rod has moved to its extreme position, pull back the handle
immediately to its middle position and keep this position for several minutes until
air bubbles in oil tank have disappeared, and then carry out another action.
◼ 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:
1) Maximum working pressure setting: Unscrew the locking nuts, in front of the control handle,
of overflow valve 5 at non-climbing operation status. Start motor 6. Move the operating
handle to upper position and extend the cylinder piston rod to its extreme position. At this
time, pressure gauge 4 readings rise. Keep on screwing down the handle of the overflow
valve until the readings on pressure gauge 4 have become stable at 31.5 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.
2) 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 climbing operation for new section adding (or tower section
dismantling).
251
Maintenance and precautions for hydraulic system

The hydraulic system is super high-pressure or high-pressure equipment. The whole process
from oil filling to adjustment shall be accomplished strictly according to the stipulations in its
operating instructions.
◼ Hydraulic oil for the system
➢ Anti-wear hydraulic oil L-HM 46 shall be used in the hydraulic system according to the
regulations. Mixture other hydraulic oils or fill directly without filtering the oil are prohibit.
When oil foaming or emulsification, should be timely cleaning mailbox replacement of new
oil;
➢ Filling oil: Fully fill the tank with oil for the first time. After start-up, extrude the cylinder rod,
and then retract the cylinder rod. At this time, fill the tank with make-up oil up to the tank
upper limit mark;
➢ At this time it is a high-pressure hydraulic system with strict requirements of highly cleaned
oil, which should be filtered for 4~6 hours by hand-hold filter. The oil cleanness should reach
7~8 levels (NAS1638) before starting the system;
➢ The oil should be completely changed after the system working for 2400h and add part of
clean oil after working for 1 month;
◼ Shut the system when it is out of service because of the poor condition of ventilation;
◼ To avoid damage the components, the pump station should be protected well by rainproof
shield when raining;
◼ Be careful when lifting and transporting. No charge and discharge rudely. Don’t put it in
environment that can corrode metal and rubber.
252
Common troubles and troubleshooting

Table 6-10 The common troubles and methods of troubleshooting
No. Trouble Reason Troubleshooting
Motor rotates in wrong
Commutate the motor line
direction
Oil relief valve get stuck by Dismantle main valve and
impurity in unclean oil clean it
Pump station outputs no
Hose had ruptured and Dismantle the hose, weld
pressure / Pressure can't
1 spill oil the crack or replace it
be adjusted to rated value /
Hose joint is loose Tighten the joint
Pressure is not stable
Seal of joint is broken Replace the broken seal
Coarse oil filter is blocked Clean it
Pump is broken for
Replace the pump
overloading
Joint at line terminal and Check the line, connect it
circuit breaker has according to the
loosened schematic circuit diagram
Motor don't revolve after
2 Circuit breaker
power source is connected Check the contact and
automatically tripped or
breaker, repair or replace
burned because of
it
overloading or short circuit
◼ Never let the cylinder’s balance valve and the pipeline be crashed, check
that if the clamping screw of the balance valve is loose when change place
and set up the tower, to avoid the danger!
◼ The O-ring between the balance valve and cylinder should be change once
two year!
◼ Don’t adjust the pressure of the pump station when the cylinder on the work,
only in the condition that the piston rod of the cylinder retract or extend!
◼ When the piston rod retracts completely, the pressure lever of the oil tank
should reach the max lever position!
◼ To avoid safety accident, the climbing pumping station should not be used
when natural wind over fourth lever!
◼ When power off and the pump out of work, adjust the balance valve
clockwise to make the piston rod retract.
◼ If the pump station out of work for a long time, it must run for more than 30-
minutes before use.
253
6.9 Rope
Basic Knowledge of Rope
1) The structure of rope
Wire rope is a spiral structure, which made up of a certain number of a layer or layers of wire
strands, see the figure below.
2) The lay of rope as the following figure
Fig. 6-31 The structure of Rope Fig. 6-32 The twist of Rope
3) Measuring the Diameter of Rope

Measure the diameter of the rope through correct method, see the figure below.
Fig. 6-33 Measuring the diameter of the rope
254
4) Discharge and Storage

To avoid the contingency, be careful when discharging the ropes. The reel should not go down.
It is not allowable to insert the rope by metal hook or lifter fork, see the figure below.
Fig. 6-34 Discharging the ropes
255
Ropes should be stored in the cool and dry warehouse and cannot be in contact with the ground.
Ropes must not be stored in the location which is easy to be affected by chemistry fog, steam,
or other corrosives. Check the stored ropes regularly, and if necessary, bind the ropes up. If
outdoors storage cannot be avoided, cover the ropes to avoid the damp corroding the ropes, see
the figure below.
Thoroughly clean the discharged from the crane. Bind every rope up before storing them. The
ropes whose lengths exceed 30m should be stored on the reel.
Fig. 6-35 The storage of the rope
256
5) Uniting the Rope

When uniting the rope, put the rope on specified bracket or reeve a steel tube through rope reel
hole, hoist the two ends after being put rope sleeves and rotate the rope reel slowly, refer to the
figure below.
Fig. 6-36 Untiring rope from rope sheaf
257
258
Fig. 6-37 Uniting rope from rope reel

6) Rope clamp
◼ Arrangement of the rope clamps
The rope clamp must be buckled on the working rope line in such a way as is shown as the
following figure. Buckle the U-shape rope clamp on the end of the rope.
Fig. 6-38 Correct method to arrange the rope clamps
◼ Number of rope clamps

For the situation according with the requirement of this standard, the minimum number of rope
clamps needed by every connecting section is as indicated in the next table.
Table 6-11 The minimum number of rope clamps needed

Nominal dimension of rope clamp mm
≤19 >19~32 >32~38 >38~44 >44~60
(nominal diameter of rope d)
The minimum number of the rope
3 4 5 6 7
clamp(suit)
259
◼ Interval between two rope clamps

As the figure below, the distance A between two rope clamps is about 6~7 times of the rope
diameter.
Fig. 6-39 Interval between two rope clamps
◼ The fastening method of rope clamps

Considering every rope clamp can be forced reasonably when you fasten and fix the clamps,
the farthest clamp should not be fastened and fixed firstly. The rope clamp abutting the rope
ring (the first rope clamp) should be as close to the rope ring as possible, and the rope clamp
shall be correctly tightened without damaging the outside layer of wires.
Rope List
Ropes for W450-25HC are shown as the table below:
Table 6-12 Ropes for W450-25HC
Nominal Minimum
Diameter length braking Fixing
Designation Specification Remark
(mm) mass force method
kg/100m (kN)
The
diameters
of the
selected
GS-k34-20- Pressing
Hoisting rope Ф20 197 368 ropes must
1960 plate
meet the
requireme
nt listed in
the table
The
minimum
breaking
force of the
6×29Fi+IWR-
Trolley rope Ф12 60.2 85.6 Cappel rope shall
12-1770-sZ
not be less
than the
value listed
in the table
260
The length of the rope

The length of the selected rope must meet the use requirement of this tower crane. There must
be three rounds of rope on the terminal location of the drum at least. According to the use
condition, if it is needed to cut a section of rope from the long rope, the two ends need special
handling or adopt proper method to avoid the rope loosing during cutting off the rope, see the
figure below.
Fig. 6-40 Preparation for cutting off the rope (L≥2d)
261
Calculating the Length of the Hoisting Rope

Total length required for hoisting rope
L＝L0+f×H
L0——The sum of the rope lengths of the hook on the max hoisting height, m; see the table
below.
f——Falls used;
H——Hoisting height, m.
Fig. 6-41 Calculating the Length of the Hoisting Rope
Table 6-13 The length of hoisting rope for different length jibs
Jib(m) 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55
L0(m) 90 92.5 95 97.5 100 102.5 105 107.5 110 112.5 115
Jib(m) 57.5 60 62.5 65 67.5 70 72.5 75 77.5 80
L0(m) 117.5 120 122.5 125 127.5 130 132.5 135 137.5 140
The Length of the Trolley Rope

The length of trolley rope is fixed as the jib changing, see the table below.
Table 6-14 The length of trolley rope for different length jibs
Jib lengths (m) 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55
RopeⅠLengths (m) 60 65 70 75 80 85 90 95 100 105 110
RopeⅡLengths (m) 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75
Jib lengths (m) 57.5 60 62.5 65 67.5 70 72.5 75 77.5 80
RopeⅠLengths (m) 115 120 125 130 135 140 145 150 155 160
RopeⅡLengths (m) 77.5 80 82.5 85 87.5 90 92.5 95 97.5 100
262
Installation of the Rope

The rope should not be disturbed during installation, when uncoiling the wire rope from a reel or
coil, every precaution shall be taken to avoid the Tweaked or tightened kink, bends etc. of the
rope.
During installation, the rope shall always bend in the same direction: i.e., pay out from the top of
the reel to the top of the drum, or from the bottom of the reel to the bottom of the drum, see the
figure below.
Care shall be taken to ensure that termination anchorages are made and secured in accordance
with the instructions in the crane manual.
If the rope rubs against any part of the crane during installation, then the points of contact shall
be suitably protected.
Fig. 6-42 The rope winding

Replacing steel rope of Tower crane should be carried out in accordance with the relevant
chapters in the tower crane operation manual to correctly wear around, and make wire rope bend
in the same direction as far as possible, otherwise will seriously affect the life of wire rope.
Wire rope should be installed at pre-tightening condition.
Before put into use wire rope on hoisting machinery, the user should ensure that all related to the
wire rope work device is installed in place and working properly.
In order to make the steel wire rope stable in place, about 10% of the rated load shall be used to
rope wheel system running operation for several times, in order to make wire rope can be
accurate and stable in the system, more joint drum steel wire rope, the rope internal release, it is
advantageous to the rope neatly, and effectively prevent the wire rope to disturb.
263
Discard Criteria of Rope

1) Nature and number of broken wires
The table below take these factors into account when considered in conjunction with the factors
given in (2) to (19). So, it can be applied to all structure’s ropes.
Table 6-15 The number of visible broken wires that meet or exceed the scrap standard in single
strand wire rope and parallel twist compacted wire rope used on steel pulley
The number of visible broken wire rope Concerned with fatigue
when lifting machinery must be scrapped
Section of multi-
A section of wire rope working on a steel
layer wire rope
Kinds Number of loads pulley and mill or single layer wound on a
wound on the
of bearing wires of reel (Random distribution of wire breaks)
drum
wires the outer layer of
Working classification M1~M4 or unknown Off Working
RCN the rope n
classification classification
Interaction of twist Concurrent twist Interaction of twist
Length arranges Length arrange
e e e e
>6d >30d >6d >30d >6de >30de
01 n≤50 2 4 1 2 4 8
02 51≤n≤75 3 6 2 3 6 12
03 76≤n≤100 4 8 2 4 8 16
04 101≤n≤120 5 10 2 5 10 20
05 121≤n≤140 6 11 3 6 12 22
06 141≤n≤160 6 13 3 6 12 26
07 161≤n≤180 7 14 4 7 14 28
08 181≤n≤200 8 16 4 8 16 32
09 201≤n≤220 9 18 4 9 18 36
10 221≤n≤240 10 19 5 10 20 38
11 241≤n≤260 10 21 5 10 20 42
12 261≤n≤280 11 22 6 11 22 44
13 281≤n≤300 12 24 6 12 24 48
n>300 0.04n 0.08n 0.02n 0.04n 0.08n 0.16n
Note 1: Silu type wires ropes with outer strands and 519 wires per share (e.g 6×1 silu type)
are listed in two rows in the table. The top row represents the number of normally placed
outer strands carrying wires.
Note 2: The above values in the multilayer wound reel section may also be applied to other
sections of the wire rope working on pulleys made of synthetic materials or having synthetic
wheel lining. However, it is not applicable to wire ropes which are specially made of synthetic
materials or which are operated on a single winding pulley consisting of a composite wheel
lining.
264
a Filled steel wire in standard is not regarded as load-bearing steel wire, so it is not included
in the n value.
b A broken wire will have two broken ends (count by one wire)
c These values apply to sections that are damaged by interference between the jump zone
and the overlap layer duo to the effect of the entanglement angle (and not only those section
where the pulley is working and where the wire rope is not wound around the drum).
d Two times of the number of broken wires listed above can be used for mechanisms whose
working class is known to be M5~M8. See GB/T24811.1-2009.
e Nominal diameter of the wire rope.
Table 6-16 Number of visible broken wires of non-rotating wire rope that meet or exceed the
scrap standard
The number of visible broken wire rope Concerned with
fatigue when lifting machinery must be scrapped
Kinds Number of loads A section of wire rope working on a
Section of multi-layer
of bearing wires of steel pulley and mill or single layer
wire rope wound on
wires the outer layer wound on a reel (Random
the drum
RCN of the rope n distribution of wire breaks)
Length arranges Length arranges
>6de >30de >6de >30de
21 4 n ≤100 2 4 2 4
3n or 4 n ≤100 2 4 4 8
at least 11 outer
layers
23-1 76≤n≤100 2 4 4 8
23-2 101≤n≤120 2 4 5 10
23-3 121≤n≤140 2 4 6 11
24 141≤n≤160 3 6 6 13
25 161≤n≤180 4 7 7 14
26 181≤n≤200 4 8 8 16
27 201≤n≤220 4 9 9 18
28 221≤n≤240 5 10 10 19
29 241≤n≤260 5 10 10 21
30 261≤n≤280 6 11 11 22
31 281≤n≤300 6 12 12 24
n>300 6 12 12 24
Only use ropes which correspond with the specifications in the ZOOMLION rope
list.
265
2) Broken wires at the termination

Broken wires at, or adjacent to, the termination, even if few, are indicative of high stresses at this
position and can be caused by incorrect fitting of the termination. The cause of this deterioration
shall be investigated and, where possible, the termination shall be remade, shortening the rope
if sufficient length remains for further use, otherwise the rope shall be discarded.
3) Localized grouping of broken wires

Where broken wires are very close together, constituting a localized grouping of such breaks, the
rope shall be discarded. If the grouping of such breaks occurs in a length less than 6d or is
concentrated in any one strand, it may be necessary to discard the rope even if the number of
wire breaks is smaller than the maximum number shown in the table above.
4) Increase rate of the broken wires

In applications where the predominant cause of rope deterioration is fatigue, broken wires will
appear after a certain period of usage, and the number of breaks will progressively increase over
time. When the time interval becomes shorter and shorter, it is recommended to conduct careful
periodic examination and recording of the number of broken wires, with a view to establishing
the rate of increase in the number of broken wires. This law may be used to confirm a future date
for discarding rope.
5) Fracture of strands
If a complete strand fracture occurs, the rope shall be immediately discarded.
6) Reduction of rope diameter resulting from core deterioration

Reduction of rope diameter results from deterioration of a fiber core or fracture of a steel core. If
rope diameters notable reduces, the rope shall be immediately discarded.
Low values of deterioration might not be so apparent from normal examination, particularly if the
rope stresses are well balanced throughout the individual strands. However, the condition can
result in a high loss of rope strength, so any suggestion of such internal deterioration shall be
verified by internal examination procedures, If such deterioration is confirmed, the rope shall be
discarded.
7) External abrasion
Abrasion of the crown wires of outer strands in the rope results from rubbing contact, under
pressure, with the grooves in the sheaves and drums. The condition is particularly evident on
moving ropes at points of sheave contact when the load is being accelerated or decelerated, and
is revealed by flat surfaces on the outer wires.
Wear is promoted by lack of lubrication, or incorrect lubrication, and by the presence of dust and
grit. Wear reduces the strength of ropes by reducing the cross-sectional area of the steel strands.
If, due to external wear, the actual rope diameter has decreased by 7% or more of the nominal
rope diameter, the rope shall be discarded even if no wire breaks are visible.
8) Elasticity decreases
266
Under certain circumstances usually associated with the working environment, a rope can
sustain a distinct decrease in elasticity and is thus unsafe for further use. Decreased elasticity is
difficult to detect. If the examiner has any doubt, advice shall be obtained from a specialist
in wire ropes.
While no wire breaks may be visible, the wire rope will be noticeably stiffer to handle and will
certainly have a reduction in diameter greater than that related purely to wear of individual wires.
This condition can lead to abrupt failure under dynamic loading and is sufficient justification for
immediate discard.
9) External and internal corrosion

◼ Corrosion of the outer wires can often be detected visually. When the pits appear on the
wires and the wires are quite loose, the rope should be discarded.
◼ If there is any indication of internal corrosion, the rope should be carried out internal
examination as indicated by governors. The ropes with serious internal corrosion are
sufficient to be discarded immediately.
10) Waviness distortion

As the figure below, when the waviness distortion occurs, when the rope length is no more than
25d, d1>4d/3, the rope shall be discarded. In the formula d is the nominal diameter of the rope
and d1 is the diameter corresponding to the envelope of the distorted rope.
Fig. 6-43 Waviness distortion
11) Basket or lantern deformation

Basket or lantern deformation is a result of a difference in length between the rope core and the
outer layer of strands. Ropes with a basket or lantern deformation shall be immediately discarded
as the figure below.
Fig. 6-44 Basket or lantern deformation
267
12) Strand protrusion

Strand protrusion usually happens with basket or lantern deformation. It shows the rope
misbalanced. Rope with strand protrusion shall be immediately discarded as the figure below.
Fig. 6-45 Strand protrusion
13) Wire protrusion

In wire protrusion, certain wires or groups of wires rise, on the side of the rope opposite to the
sheave groove, in the form of loops. Rope with wire protrusion shall be immediately discarded
as the figure below.
Fig. 6-46 Wire protrusion
14) Local increase of diameter of the rope

A local increase in rope diameter can occur and might affect a relatively long length of the rope.
This condition usually relates to a deformation of the core (in particular environments, a fiber core
can swell up owing to the effect of moisture) and consequently creates imbalance in the outer
strands, which become incorrectly oriented. If the local actual rope diameter increases seriously,
the rope shall be immediately discarded as the figure below.
Fig. 6-47 Local increase of diameter of the rope
268
15) Flattened portions

Flattened portions of rope results from machine accidences as the figure below. If flattened
portions of rope is serious, the rope shall be discarded immediately.
Fig. 6-48 Flattened portions
16) Kinks or tightened loops

A kink or tightened loop is a deformation created by a loop in the rope which has been tightened
without allowing for rotation about its axis. Imbalance of lay length occurs, which will cause
excessive wear, and in severe cases the rope will be so distorted that it will have only a small
proportion of its strength remaining. As the figure below showing, rope with serious kinks
tightened loop shall be immediately discarded.
Fig. 6-49 Tweaked or tightened kink
17) Bends
Bends are angular deformations of the rope caused by external influence. Rope with a severe
bend should be immediately discarded as the figure below.
Fig. 6-50 Bends

18) Local decrease of diameter of the rope
A local decrease in rope diameter usually relates to a fracture of the core. As the figure below
showing, local decrease of diameter of the rope shall be immediately discarded.
Fig. 6-51 Local decrease of diameter of the rope
269
19) Damage due to heat or electric arcing

Ropes that have been subjected to exceptional thermal effects, externally recognized by the
colors produced in the rope, shall be immediately discarded.
Maintenance of Rope
Maintenance of the rope should be relative to the crane usage environment and involved rope
type. Paint lubricating grease and lubricating oil when installing the rope. The rope shall be
cleaned where necessary, and the rope being reused in regular time interval, especially before
the section of rope passing round the pulley shows signs of dryness or corrosion should be kept
in good lubricating condition.
The rope lubricating oil (grease) should be Graphite calcium base grease ZG-SSY1405-65, it
has strong penetration. A shorter working life of rope will result from lack of maintenance.
If wire rope grease on the surface dry, it should be cleaned in time, and apply new accord with
the prescribed grease.
Wire rope surface should avoid applying too much grease. Surface blotted out too much grease
may produce the following question
1) Aggravated deterioration of the rope rupture
2) Environmental pollution
3) Easy adhesion of the dust or other substances, make the wire rope from corrosion
270
6.10 Maintenance of pulley assembly

Examination of pulley assembly
Hoist pulley, trolley pulley, trolley and hook pulley are non-lubricating bearings. The pulley shaft
has no oil nozzles and does not need to be lubricating,
◼ Daily inspection of bearings:
➢ whether there is oil leakage
➢ Shaft end seals
➢ Elastic ring
➢ Operation noise and resistance
➢ Bearing clearance.
◼ Table of pulley parameters, Table 6-17
Table 6-17 Pulley parameters

Diameter Rope groove Rope groove
Designation Specification
(mm) depth (h) radius (R)
Hoist pulley HL-500-430-80-9.6 500 35 9.6
Trolley pulley HL-295-1 295 22.5 6
Pulley scrap
The main forms of pulley damage are worn and extrusion of the pulley groove caused by the
steel rope. Generally, the surface condition of the pulley groove (Fig. 6-52 and Fig 6-51), wear
depth and arc radius are the basis for judging whether the pulley is normal or not.
◼ Surface condition of rope groove

The surface of the pulley groove should be worn evenly and smoothly. When there is obvious
indentation, the pulley should be replaced.
271
Fig. 6-52 Example pulley indentation Fig. 6-53 Depth detection of rope groove
◼ Depth of rope groove

Due to wear, the h value of rope groove depth increases gradually. For the hoist pulley, the pulley
should be replaced when the value increases by 30%d over the theoretical value. For the trolley
pulley, the pulley should be replaced when the h value increases by 30%d over the theoretical
value.
◼ Rope groove radius

➢ Due to wear, the radius R of the rope groove will change. when the value of R exceeds
0.525d~0.6d, the pulley should be replaced.
➢ The rope groove radius detection method as shown in Fig. 6-54
➢ The radius of the pulley grooves is detected by the pulley gauge or radius gauge (R gauge).
From the beginning of the large diameter measuring tool to the arc of the measuring tool
basically coincides with the arc of the normal section of the pulley groove.
Fig. 6-54 Examples of radius detection of pulley groove arc
◼ When the pulley is found to have flange, crack and other phenomena, the pulley should also
be replaced.
272
6.11 The high strength bolts

Basic knowledge of the high strength bolt
◼ There are many high strength bolts, they are used to connect the components and pass
load.
◼ All the high strength bolts which are used to connect the components of the tower crane are
vital for the tower crane and must be installed, maintained, and checked seriously.
◼ Check the high strength bolts occasionally, to assure the fastness and reliability of the
connections. Looseness of the bolt may lead damage and even the stale connection of
single component.
◼ If users choose the bolts by themselves, please ensure the strength grade of the nut can
match the bolt.
For example：
8.8 grade bolt -> 8 grade nut;
10.9 grade bolt -> 10 grade nut
12.9 grade bolt -> 12 grade nut
Checking the bolts and bolt connection sets

Clean and check all the bolt connecting components before the installation. The checking
contents include bolts, nuts, thread, the transition part between the bolt head and the screw and
so on.
Using the damaged bolts and nuts is strictly prohibited! Don’t use the
bolts whose screws are rusty and the bolts or the nuts whose threads are
rusty!
Lubricating the high strength bolt assembly

Use molybdenum disulfide to lubricate all the bolt assemblies before installing them. Good
lubrication can supply uniform friction and standard preload for the bolt.
As is shown in Fig. 6 53 please lubricate the threads of the bolts and nuts
and the contact surfaces. If the preload is exerted on the bolt head, the
contact surfaces of the bolt head need to be lubricated as well.
273
Fig. 6-55 Lubricate the contact surface
Recycling the high strength bolt

All the bolt assemblies which were exerted preload rightly can be recycled when erecting the
tower crane again. However, all the bolt assemblies recycled must have been checked and are
not damaged.
274
6.12 Steel structure

Foreword
This description contains the maintenance instructions for the steel structure elements of the
crane.
Description
Fig. 6-56 Steel structure of the crane

(1) Fixing angles (2) Crane tower
(3) Telescopic cage (4) Counter-jib
(5) Jib
275
Description
The structure defines all the metallic parts constituting the crane steel structure.
◼ Cleanness / cleaning
General condition / appearance
◼ Paint / corrosion
◼ Ballast
◼ Derrick/ mast/ crane tower/ jib / counter−jib
◼ pins / screw bolts
Steel structure ◼ Ladders / platforms / grab rails / catwalks / guard
ropes
◼ Lifting cab guiding system
◼ Greasing
Maintenance
General condition / appearance
Check the general crane aspect: cleanness (concrete, mud, and sand splashes, etc...).
Cleanness and general correct appearance of the crane avoid risks and
operating problems.
Cleanness / cleaning
The cleaning must be carried out with fresh water without detergent. Using a high−pressure
apparatus is possible if the following instructions are observed:
Never apply the squirt directly on hinges, cables, safety devices and
electrical equipment: control panel interior, cables, connectors, terminal
strips, etc..
The control panel inside must be freed from dust by means of compressed air. Remove dust from
the electrical equipment and the safety devices with a dry cloth.
After each cleaning all the required parts must be lubricated and
greased.
276
Paint / corrosion
Carry out a visual check of the following points:
◼ In case of a drain line due to an invisible corrosion, carry out a regular check,
◼ In case of corrosion on a painted part, clean and grind the area, then apply a layer of rust
preventing agent and paint,
◼ In case of wear of the surface treatment, clean and grind the area, then apply a layer of rust
preventing agent and paint.
Steel structure
Carry out a visual check of the ballast concerning the following points:
◼ In case of cracks, fretting, too considerable wear, carry out a weighing in order to make sure
that the ballast weight is still within the tolerance.
Tolerance of the ballast weight: 0 to + 4% (base) / −2 to +2% (counter-jib).
◼ In case of corrosion on the metallic ballast, clean and grind the area, then apply a layer of
rust preventing agent and paint,
◼ In case of a drain line due to invisible corrosion carry out a regular check,
◼ In case of wear of the slinging loops or their fixings to the ballast blocks including the risk of
a break, replace the ballast.
Derrick / mast / crane tower / jib / counter−jib

Carry out a visual check on the whole crane steel structure (deformations, cracks, damages, ...).
The crane steel structure is an essential part. As soon as an anomaly is

detected: cracks, crackled paint, deformation, anomalous noise,
compulsorily stop the crane operation and contact a ZOOMLION expert.
277
Deformations:
◼ Deformation of the steel structure
◼ Deformation of a bracing
◼ Pressure, sinking
◼ Friction
278
Pins / screw bolts

Carry out a visual check on all assembling points of the parts constituting the crane.
Assembling by fish joints, pins and screw bolts is of highest importance.

As soon as an anomaly is detected, stop the crane operating and solve
the problem.
◼ Pins
◼ Screw bolts.
Ladders / platforms / grab rails / catwalks / guard ropes

Carry out a careful visual check of all welding on the whole crane.
All the accesses must compulsorily be present, correctly fastened, and

free.
279
6.13 Pins and holes of the tower section

After assembling the tower section, please check the pins and holes as follow the steps.
◼ Before hoisting the tower section, please make certain that the surface of pin-hole and pin
is cleaned. It can use the polisher to clear the pin-hole, but grinding wheel is prohibited which
enlarges the pin-hole. After cleaning, the pin-hole should have mental luster.
Step 1: Before
hoisting, please
make sure that the
surface of pin-hole
and hinge pin are
clean.
◼ When installing the tower section, please check the pin-hole again and make sure there are
no sundries, if there are any sundries please clear it.
Step 2: When
installing, please
check the pin-
hole again.
280
◼ After cleaning the surface of pin-hole and pin, uniformly daubing the AG1 rusting preventive
grease on the inner surface of the pin-hole and outer surface of hinge pin. Then installing
the hinge pin. Strictly prohibit mixing the difference kinds of grease. Strictly prohibit mixing
the new AG1 with old AG1.
Step 3: Apply grease

to the pin-hole and
hinge pin, then
install the hinge pin.
◼ After dismantling, the hinge pins must be placed in the clean and waterproof box which
should be placed indoors. If the pin-hole of tower section is rusting or the grease
consolidation, firstly cleaning the pin-hole, then daubing the AG1 rusting preventive grease.
It must have adapting cushion between the tower section and ground.
Step 4: Attention
after dismantling.
◼ Check if the rabbet of the tower section main chord can shake, if it can shake, the shake
value cannot exceed 0.7mm, if it exceeds, please contact our company’s after-sales staff to
handle it before it can be used.
281
6.14 Hook
Check the locking of the hook
◼ All the fasteners of pulley pin and connecting pin are normal;
◼ The press plate on the hook nut is installed in place, without deformation, and the bolts on
the press plate are firmly fixed; The tower crane needs to be checked before use. If the fixing
bolt is loose or damaged, please tighten or replace the bolt in time.
Opening Degree of the Hook
Inspect the deformations at least once a month.
◼ The initial value of hook opening degree a0 = 112 0+6 mm . (According to the measuring value
before the first time use of the hook)
◼ If the opening degree has been more than 110% of the initial value a0, replace the hook.
◼ Check the torsion deformation of the hook. When the torsion angle of the hook body exceeds
10°, replace the hook.
◼ The handle of the hook should not be plastic deformation, otherwise it should be replaced
282
Wear
The initial value： h0 = 132
The wear on hook may not be greater than 5% of the height “H”. It is not permitted to carry out
welding work on hook to repair the wear.
Check hook wear at least once a month.
◼ Surface cracks
➢ If there are obvious distortions of the hook, do the surface cracks check to
the hook using appropriate method or change the hook.
➢ Damages and surface cracks can be removed, but no gap can be left. The
hook dimension after being removed the cracks and damages should not
exceed the permissible tolerance.
➢ If the installed hook cannot be checked, dismantle it and check it.
➢ Before making checks, ensure that the surfaces are put into a condition
permitting the definite identification of surface cracks!
Corrosion
◼ The diameter d1 of hook handle cannot be corroded to be less than 95%, if the diameter is
less than 95%, change the hook.
◼ The threads on the hook cannot be corroded.
Hook defects are not allowed to be repaired by welding.
Check hook anti-tripping device

◼ Hook anti-tripping device, under normal use, anti-rope device and hook can form a closed
cavity. If the anti-tripping device and hook cannot form a closed cavity, the anti-tripping
device shall be corrected. If it cannot be corrected, shall be replaced.
◼ If the anti-tripping device or the connecting pin between the anti-tripping device and the hook
is deformed, which affects the normal use, please replace the pin.
The anti-tripping device should be check before the tower crane is used.
Oil hook bearing

Thrust ball bearing are used on the hook assembly, which are provided with lubricating oil holes
and need to be lubricated regularly.
283
6.15 Trolley
Routine inspection of trolley rollers
◼ Check roller bearings;
◼ The roller rotates normally;
◼ There is no damage or deformation of roller;
◼ Roller wear;
◼ The nut and lock washer of the roller shaft are not loose;
◼ All the rollers of the trolley are in contact with the jib;
◼ In the process of running the trolly, he roller, the roller cover and the belly rod of the jib do
not interfere
Routine inspection of side rollers of trolley

◼ Check the side roller bearings;
◼ The roller rotates normally;
◼ There is no damage or deformation of roller;
◼ Check the wear of side rollers (see Table 6-18 Side roller specification table); Replace the
side roller when the wear of the side roller reaches 5% of the diameter
Table 6-18 Side roller specification table

No. Order No. Specification
1 000209705A0001400 Ф80-30
2 000209710A0600001 Ф120-50
3 000209716A0010019 Ф140-50
4 000209705A0001200 Ф150-50
◼ There is no damage to the split pin or clamp plate used for the limit of the side roller shaft,
and it is firmly fixed
284
6.16 Maintenance of electronic control system

The electronic control system should be frequently maintained and maintained to eliminate faults,
eliminate safety hazards, ensure the normal operation of the whole crane, and extend the service
life of the equipment. Maintenance work should be carried out by professionals with relevant
qualifications.
Electrical equipment inspection

Table 6-19 Checklist of electrical equipment
Inspection cycle Inspection item
Electrical Equipment:
Whether the door of the electric control cabinet
closes
The air switch in the cabinet
Circuit breaker
Display
Electric whistle
Sensor
Over load display
Daily operate before inspection Moment percentage display
Trolley position display
Hoisting height display
Wind speed display
Weathercock brake release
Indicator light/indicator device：
Voltmeter
Overvoltage indicator light
Cab light
Beacon light
Main power
Main power switch box
Phase sequence
Service voltage
Length and shuck of main cable
Check each erection and inspection Every position for reliable earthing
cycle (suggest cycle is 2-3 weeks) Cable:
Meet a criterion
Shuck of main cable in perfect condition, good
insulation Plugins in correct location, good contact
and reliable
Cable stress relief.
285
Electrical device:
Air switch
Circuit breaker
Electric relay, contactor
Display
Sensor
Over load and moment alarm normal
Brake, weathercock brake
External equipment connector good contact and
reliable
Indicator light/indicator device：
Voltmeter
Overvoltage indicator light
Cab light
Beacon light
Electrical control cabinet
Temperature switch and humidity switch set values
correctly
Power voltage control set values correctly
◼ The inspection of electrical equipment must be carried out under no-load conditions:
➢ The hook moves up and down slowly;
➢ Trolley slowly moves outwards and inwards;
➢ The tower crane slowly rotates to the left and right;
➢ All control parts run correctly and smoothly,
➢ The position of the trolley and the height of the hook on the display screen are displayed
accurately and continuously.
➢ The wind speed display value on the display is correct and reasonable
➢ The mechanism starts quickly and smoothly,
➢ Increase and decrease gears, continued, no gears, skipping, and the operating handle can
automatically return to the zero position,
➢ When running in no-load, there is no obvious special noise or vibration
◼ Check of component setting value

Temperature sensor and humidity sensor in the main control cabinet, voltage monitoring relay,
as shown in the figure
286
Fig. 6-57 Temperature switch and humidity switch in the main control cabinet
Fig. 6-58 Check set value of main control cabinet monitor electric relay
Table 6-20 Check detailed list for safety device
Code Definition Setting value
Coating fan temperature +40℃
ST
Heater working temperature 0℃
SRH Heating humidity RH +80%
Overvoltage protection value(>U) 420V
Undervoltage protection value(>U) 340V
Delay time 2S
KAU1
Operating mode Reset delay + no phase sequence

monitoring
287
Maintenance for safety device

Every limiter and sensor require to calibrate and recalibrate definite value during every erection.
Table 6-21 Check detailed list for safety device
Location of limiter:
Maximum trolley position for trolley (jib length);
Minimum trolley position for trolley;
Daily operate before check Upper stop position for hook;
Hook stop position at bottom according require;
Load capacity/moment limiter: over load alarm for load limiter,
load moment;
Location of limiter:
Maximum trolley position for trolley (jib length);
Minimum trolley position for trolley;
Upper stop position for hook;
Bottom stop position for hook;
Load capacity:
Check each erection and
inspection cycle (suggest Check the accuracy of the load capacity display (Sling the
cycle is 2-3 weeks) known load);

Check the accuracy of mechanism load limiter is triggered
Check the accuracy of mechanism moment limiter is triggered
(constant load for variable radius, constant radius for variable
load);
Check the percentage accuracy of mechanism moment limiter
display (Take the mechanism moment limiter for refer);
Every mechanism requires to recheck and recalibrate when
change hoisting rope, trolley, hoisting mechanism, trolley
mechanism, load sensor and other relevant safety parts.
Out of inspection cycle
Recalibrate if the jib change length
Recalibrate after climbing operation
288
6.17 Spare parts list

The spare parts can be selected with price increase. Those adding “*” in the serial number
column are wearing parts.
Spare parts list of mechanism

Spare parts list of hoisting mechanism
Table 6-22 Hoisting mechanism H75FL50-880
No. Order No. Designation Code Install position Qty
1 1039905115 Brake YWZ5-315/80-ⅡA 1
MLL8-I-315-
2 000209944A0000680 Coupling YA75×142(20)/ Hoisting 1
JA50×112(14) mechanism
3* 000209101E1003002 Elastomer MT8-b H75FL63-1040 1
4* 1090100091 Rope 35×7-18-1870 (000209195A70
5 1021500637 Limiter DXZ1:360B0×20 00000) 1
ETF100-
6 1020202010 Encoder 1
H(Nr:851223/0.8)
Spare parts list of trolley mechanism

Table 6-23 Trolley mechanism BP75A
1 1031700142 Brake DLTZ3-80 1
2 000209324A1004000 Coupling GR28-65-1 Trolley 1
Nylon gear mechanism
3* 000209301E0003002 GR28 1
ring T110FC85-b
6×29Fi+IWR-11- (000209370A40
4* 1090100470 Rope
1770 00000)
5 1021500642 Limiter DXZ1:188B0×22 1
Spare parts list of slewing mechanism

Table 6-24 Slewing mechanism
1 1021500640 Limiter DXZ1:46B0×21 Slewing mechanism 1
2 1029805619 Brake DDZ-175/DFB S75CA-130.146LB14/13A 1
(000209289A8700000)
ECK58B
3 1020202072 Encoder /S75CN-130.146LB14/13A 1
(Nr:851249/10)
(000209289A8800000)
289
Spare parts list of electrical control system

Table 6-25 Spare parts list of electrical control system
No. Order No Designation Code Qty
1 1020104287 Programable controller AFPX0L60MR-ZLN 1
2 1020103894 Extension module AFPX0E40RD 1
Electric measuring and monitoring
3 1020303383 CM-PVS.41 1
relay
4 1022001015 Phase sequence monitor CM-PFE 1
5 1021901007 Transformer ST10 1
6 1022400099 Converter CS710-4T75GB-ZL-QS 1
7 1020005345 Converter CS710-4T37GB-ZL-HZ 1
8 1020005426 Converter CS710-4T11GB-ZL 1
9 1020005439 Expansion card MD38PGMD 1
DILM9-10C
10 1020304846 Contactor 2
(220V 50/60Hz)
11 1020303114 Electric relay AHN22324 5
12 1020304036 Electric relay seat AHNA21 5
13 1020903401 Switch power CP-PX-24/14.6 1
14 1020903398 Switch power CP-PX-24/4.5 1
15 1020602104 Breaker BKN 1P C4A 1
16 1020604531 Breaker BKN 1P C10A 1
290
Spare parts list of structure

Table 6-26 Spare parts list of structure
No. Designation Order No. Code Install position Qty
Trolley, Hook,
1 Pulley 000209906A0040018 HL-500-430-80-9.6 8
JibⅠ
HL-500-430-80-
2 Pulley 000209906A0040039 Jib 1
130-9.6
3 Carrier wheel 000209721B0120010 Trolley 2
4 Carrier wheel 000209721F0101008 Trolley 5
5 Roller 000209705A0001200 FXC08B-12 Trolley 8
6 Side roller 000209705A0001400 FXC08B-14 Trolley 8
Cylinder roller
7 1050202248 NJ312E-2RS Trolley, Hook 14
bearing
Deep groove
8 1050201944 6206-2RS Trolley 10
ball bearing
Deep groove
9 1050201565 6004-2RS1 Trolley 24
ball bearing
10 Bearing 1050100008 6210-2RS Trolley 16
11 Retaining ring 1040300284 42 Trolley 16
12 Retaining ring 1040300281 130 Trolley, Hook 14
13 Retaining ring 1040300279 90 Trolley 16
Thrust ball
14 1050200507 51315 Hook 1
bearing
15 Oil cup 45° 1080000010 M6×1 Hook 1
16 Pulley 000210105AT001310 HL-295-1 JibⅠ, JibⅩ 2
214-178-B41-80-
17 Pulley 000209906A0017000 JibⅣ, JibⅦ 2
R6
18 Retaining ring 1040300281 130 JibⅠ, Pulley 4
JibⅠ, JibⅣ, Jib
19 Retaining ring 1040300322 80 Ⅶ, JibⅩ, 8
Pulley
20 Bearing 1050202084 6312-2RS JibⅠ 4
JibⅠ, JibⅣ, Jib
21 Bearing 1050201563 6208-2RS1 Ⅶ, JibⅩ, 8
Pulley
Anti-twist
22 Bearing 1050200429 51308 1
device
Anti-twist
23 Oil cup 1080000206 M10×1 1
device
291
6.18 Appendix troubles and troubleshooting
No. Troubl Troubleshooting Solution

a. Check the oil surface,
adjust the height if
The temperature of the a. Excessive lubrication oil necessary.
1 reduction gearbox is too b. Oil is old-fashioned b. Figure out the time of
high. c. Oil is grievously polluted last oil change, change
oil if necessary.
c. Change the type of oil.
a. Excessive or deficient
a. Properly replace
grease.
The temperature of the grease
b. Poor grease quality.
2 reduction gearbox b. Re-adjust the bearing
c. Improper axial clearance
bearings is too high. clearance
of the bearings or bearings
c. Replace bearings
is already damaged.
a. Leakage from the input
and output shaft end of the
reduction gearbox.
a. Replace sealing rings.
Oil leakage from b. The strainer of the air
3 b. Clean the strainer.
reduction gearbox cleaner is blocked.
c. Reseal.
c. The sealing rings of end
covers or the matching
surface is sabotaged.
a. The rotary direction of a. Check the line of the
the motor is wrong. motor.
b. The escape valve is b. Remove the main
blocked by unclean oil. valve and clean it with
c. Tube leakage. kerosene.
No output from the pump d. Pipe connections c. Remove the pipe and
station/ cannot be become flexible. weld the broken part or
4 adjusted to rated e. The sealing parts of the exchange it.
pressure/ the pressure is pipe connections are d. Screw the pipe
not steady. broken. connection.
f. Coarse strainer is e. Exchange the seal
blocked. washer.
g. The pump station is f. Clean the strainer.
damaged by long-time g. Exchange the pump
over load. station.
292
a. Check the line and

rewire the circuit by
a. Terminals and breakers
Climbing mechanism electrical schematic
be loosed.
motor diagram
5 b. The breaker tripped or
does not rotate when b. Repair or replace the
burned by overload or
power on breaker by checking the
short circuit
contacts and
electromagnetic trip;
a. Worn oil pump, declined
efficiency a. Repair or replace the
b. Oil in the tank is damaged parts
insufficient or oil filter b. Fill adequate oil or
clogged clean oil filter
Climbing speed is too
6 c. Hand-operated valve c. Exchange the hand-
slow
rod and valve hole operated valve or the
severely worn worn parts.
d. Oil cylinder piston seal d. Reseal the oil cylinder
is damaged and internal oil piston.
leakage.
a. Severe internal leakage a. Repair or replace the
from oil pump worn parts
b. Overflow valve pressure b. Adjust pressure as
Climbing force is not
set too low required
7 adequate or unable to
c. Hand-operated valve c. Clean hydraulic
jack
core excessively worn valve.
d. Overflow valve clogged d. Exchange overflow
down valve.
Noise and vibration occur
8 during climbing operation Oil filter clogged Clean oil filter
at increasing pressure
Motor rotation and oil
Climbing system is not Change motor rotation
9 pump rotation both in
working direction
wrong directions
a. Air not completely
exhausted from oil cylinder a. Exhaust air as
Creeping and quivering
piston required.
during climbing operation
10 b. Trouble with guide b. Adjust guide pulleys
mechanism
Trouble with guide a. Exhaust air as
Adjust guide pulleys
mechanism required.
293
a. There are troubles with

balance valve of the
Climbing drop when a. Remove trouble
11 cylinder head.
loaded b. Replaces sealing parts
b. Piston sealing of oil
cylinder is damaged
a. Operating handle not
a. Operating handle back
back to zero
to zero
b. Fuse burned
12 Start button fault b. Replace fuse
c. Poor contact of stop
c. Repair or replace the
button
button
and start button
a. Breaker pull due to a. The hoisting brake
over current must be opened
13 Tripping while hoisting
b. Transformer capacity b. Replace the
too small transformer
a. Check the wiring
diagram
a. Wrong connection of the
b. Replace with a larger
Control circuit.
fuse
b. Fuse blown.
c. Measuring the grid
c. Voltage of the motor’s
voltage
too low
Hoisting mechanism d. Check the circuit of the
14 d. Wrong connection for
cannot start Wire wound resistors.
wire wound resistors
e. Check the voltage of
e. Hoisting brake closed
the Brake to find if the
f. Excessive load for motor
Wire wound is opened
or transmission machinery
circuit.
fault
f. Check if the motor is
overload.
294
a. Check the uniformity of

the clearance between
a. Friction between stator
stator and rotor.
and rotor.
b. Check the
b. The shaft of the motor
concentricity. If it is too
and the shaft of the gear
large, adjust it.
box is not concentric.
c. Check the
c. Bearings are in oil
Noise and vibration occur circumstance of the
15 deficiency or broken.
to trolley mechanism bearings. If they are
d. Gear box is in oil
broken, exchange them.
deficiency.
If they lack oil, refuel the
e. Gear friction. corresponding oil.
f. There are abnormal d. Refuel the stated oil.
noises during two-phase
e. Exchange the gear.
performance.
f. Cut off the power and
fix it.
a. The bearings are a. Exchange the
The temperature of the broken. bearings.
16 bearings in trolley b. The grease is b. Clean the bearings
mechanism is too high. deteriorative or of bad and exchange the
quality or too few. grease.
a. The power line or the
a. Check the connection.
ground connection is
The trolley b. Make sure that
wrongly connected.
17 mechanism is grounding condition is
b. Defective grounding.
Charged. well.
c. The line of the motor is
d. Figure out and adjust.
broken and grounding.
a. The brake torque is too
The brake of the trolley a. Exchange the brake
low.
18 mechanism is out of spring
b. The clearance of the
service. b. Adjust the clearance.
brake plate increases.
a. Dismantle it to check
whether the weathercock
a. Weathercock brake is brake is open and clear
not open the troubles.
Impotence or inability of b. Coupler is lack of oil b. Refuel provided type of
19
the slewing mechanism c. The motor is broken oil.
d. The wind is strong and c. Change the motor
operates against the wind. d. Operates when the
wind is weak or following
wind.
295
a. Measure the current of

a. Overload. the stator. If it is over
b. Continuous load or rated figure, reduce load.
irregular working. b. Operate under order.
c. The two phases are far c. Measure the three-
away. phase current and clear
d. The voltage is too low or troubles.
too high. d. Check the input
e. Motor winding is earthed voltage and clear
or cutting-out troubles.
The motor of the trolley
f. The clearance between e. Figure out reasons and
20 mechanism is smoking or
friction plates is wrong clear troubles.
of high temperature.
g. The time of braking and f. Adjust the clearance
releasing is wrong. based on regulation.
h. The air gallery of the g. Check the voltage of
motor is blocked, so the the brake and the
temperature rises. movement time of delay
i. The brake is opened time chopper, then clear
unthoroughly or is closed troubles.
so that the motor is h. Unblock the air gallery
unmoved and emit heat. i. Adjust the brake under
regulation.
a. Power off. a. Power on.
b. Switch off. b. Switch on
c. Emergency stop button c. Reset the emergency
on. stop button by clock
The tower crane act d. Air plugs of the linkage wising it
21 without any reaction when loosed. d. Reinstall the air plugs
press the start button e. Zero switches (SZR, e. Reset the zero switch
SZL) do not reset or be or replace with a new one
damaged. f. Repair the main
f. Main contactor cannot contactor or replace with
pull. a new one
The circuit breakers trip The rate current of the Replace with a larger
22
frequently switch is too small switch
296
a. Check the lubricating

circumstance of sheave.
If any dry and hard
situation exist, clear it
and daub new grease. If
a. Invalidation in
the environment
lubrication of sheave,
temperature is too low,
which result in sluggish
diluted oil should be
movement and bad
daubed on (check daily).
guiding function
b. Check if declination
b. Declination in
happens, adjust it.
Invalidation of rope mechanism installation
23 c. Adjust the mechanism
releasing or rope jumping c. The center line of drum
seat
is not coordinate to the
d. Check the level degree
center line of counter jib
of under frame, if uneven
d. Uneven in mechanism
situation exists, adjust it
under frame
e. Check if the first layer
e. Upper rope pushing into
is tightened, if not, tighten
under rope
up the first layer with
certain load when
releasing. (2% of the
breaking force or 10% of
the rated load)
a. Check the sequence of
a. Phase sequence error
the power supply. Check
b. Power phase loss (open
the phase sequence
The tower crane cannot circuit or the fuse burned)
between U2, V2, W2
24 start properly when press c. Poor quality of the
b. Replace fuse
the start button phase sequence relay
c. Replace a new phase
d. Setting with a wrong
sequence relay.
parameter
d. Reset the parameters
a. Reset the phase
a. The phase sequence sequence relay or
relay is unstable or with a replace with a new one
Tower crane become
wrong parameter. b. Improve if the power is
instable after starting and
25 b. Unstable power supply shortage. Otherwise,
the contactors trip
c. The loosing of the air increase the conductor
frequently
plug causing the poor cross-section or cut the
contact of the start circuit wire
c. Reinstall the air plugs
297
a, Replace the switch

a. Poor quality of the b.
26 The leakage switch trips leakage switch 1)Inspect the motor
electric circuit fault 2)Check the electric
circuit
a. YASKAWA Inverter：
set the carrier frequency
parameter C6~02=1
The leakage switch trips The frequency of the
27 b. MEGMEET Inverter:
when slewing inverter is too high
transfer a smaller carrier
frequency parameter
value of P12.02
There were
The hook of tower crane Electromagnetic Please use Nylon sling
28
with power transmission tower in the with Standard
vicinity
Hoisting has no high The contactor of the
29 Check it!
speed for winding motor resistor box loosed
a. Replace the PGO or
the PG card
a. Rotary encoder fault
b. Checks the voltage
(PGO)
setting on the braking
b. Overvoltage (OV)
unit whether it is installed
Troubleshooting of the c. Resistor box fever in
correctly
30 altivao Inverter for serious condition
c. Replace the brake unit
hoisting d. Motor jitter or the
d. Rewire the rotary
inverter displayed OL2
encoder
e. Trolley brake fault (SE2,
e. The contactor of the
SE3, SE4)
trolley loosed, adjust the
braking torque
a. Wrong wiring or
damage of the rotary
Troubleshooting of the a. Load does not follow encoder
31 Schneider Inverter for b. Motor short circuit b. Rewire the rotary
slewing c. Motor jitter encoder
c. Rewire the rotary
encoder
298
a. Check the contacts of

a. The command of the
the Cooperative console;
Cooperative console is
check the input of the
Lighting has no high incorrect
32 PLC
speed b.50% Weight limit
b. Check the contactor of
c. The loosing of KHH let
the limiter
the KHB remain open
c. Replace the KHH
a. Replace the phase
a. Phase sequence losing
sequence relay
b. Bad electrical
Shaking or murmur while b. Check the electrical
33 connection
lifting connection of the eddy
c. Wrong closing of the
current
contactor
c. Replace the contactors
The circuit breaker pulls Check the cable, replace
34 Slewing brake damage
when the rotational stops the brake
a. Slewing limit
b. Bad electrical a. Check the circuit of
connection slewing limit
c. Inverter fault b. Check the circuit
d. Contactor fault c. Repair the Inverter
e. The rotor of the motor d. repair the contactor
After working a while, the
be damaged e. Repair the motor
35 tower crane cannot turn
f. Resistor box be f. Repair or replace the
right/left
damaged resistor box
g. Wrong connection of the g. Rewire the electrical
rotor circuit
h. RCV stops running h. Repair the RCV
i. Wiring confusion when i. Rewire the circuit
installing two motors
Slowing time is short Bad
electrical connection for
Overvoltage (OV)
resistance Overvoltage
for power supply
Troubleshooting of
Voltage under the value
36 Yaskawa Inverter for Undervoltage (UVI)
of L2-05
slewing
Wind is too strong
Motor over torque (OL1) outside Eddy current
voltage is too high
Electric Current warnings Motor or circuit grounded
299
Check the contacts (NC)

of the contactor and
Contactor cannot pull
Contactor judge whether to replace
37
troubleshooting it
The Motor murmurs and Contactor’s main contact
cannot run normally loses phase, replace it.
a. Reset the eddy current
a. Eddy current voltage is voltage
too high b. Adjust the location of
Slewing has not high
38 b. HVV’s voltage is too low terminals for the reactor
speed
c. Wrong setting of the c. Adjust the frequency of
Inverter the Inverter; set L3-04=0,
E1-03=5;
a. Set C2-01, C2-02, C2-
a. Wrong setting of the 03, C2-04>2.0
Slewing jitter and Inverter b. Remove the line of X4,
39
murmurs b. Reversing contactor of X5, X6, find a small line
the RCV interval rebounds and connect the RCV to
Cooperative console
Rotary battery loses
No braking when power off
power
a. KSB cannot pick
40 Slewing cannot brake
No braking even normal b. Electromagnetic brake
operation fault
c. Rectifier fault
a. Adjust the trolley limit
and check the circuit
a. Trolley limited or open
b. Replace the air plugs if
circuit
line barrier
b. Incorrect command from
c. Repair or replace the
41 Trolley stops running Cooperative console
PLC
c. PLC fault
d. Repair or replace the
d. Relay fault
relay
e. Trolley breaker tripped
e. Please close the
breaker
a. Reduce the lifting
a. Torque limited
weight
Trolley has not high b. Trolley limited
42 b. Normal work
speed c. Cooperative console
c. Check the Cooperative
fault
console
300
a. KVOW, KVIW, KVL, a. Replace the contactor

Trolley jitter and lost KVJ fault b. Change the voltage
43
control b. Inverter motor lost control to current control,
control tuning the motor
The display does not Environment temperature Adjust the switch on the
44
flash clearly is too cool or too hot main cabinet
The system does not Disconnection of power Check power supply
45
work supply circuit
Power switch of the main
Display does not flash
46 machine cabinet Turn on the powers witch
after being started up
disconnected
Disconnection of
47 The display rolls over Check grounding circuit
grounding system
Certain weight value Weight calibration is not Perform weight
48
displayed with empty load made calibration
Significant shift of actual Poor grounding or broken

49 Check grounding circuit
weight grounding cable
The displayed value No zero line for power Immediately shut down
50 automatically gets bigger supply to the equipment or main machine and check
without operation over-voltage power supply circuit
The travel switch gets
Error of length display Check installation of the
51 loose due to impact of the
increases switch
trolley
Check the junction box,
The data of height is no Disconnection of the
52 cable and plugs of the
change transmission circuit
main machine
Check the junction box,
The data diminish Disconnection of the
53 cable and plugs of the
automatically. transmission circuit
main machine
Check assembly of the
The transmission shaft of
transmission link.
The data larger the hoisting height slewing
54 Replace the damaged
automatically. limit switch gets loose or
parts with new slewing
damaged
limit switch
301
a. Limiter does not a. Rewire the limiter

properly connect to the circuit
circuit b.
b. Cooperative console 1)Rewire the circuit
bad connected to the PLC 2)Repair or replace the
1)Wire loose PLC
55 No hoisting (with PLC)
2)PLC’s input point 3)Repair or replace the
damaged cooperative console
3)Contact of Cooperative c. Repair or replace the
console damaged relay
c. Relay fault d. Repair or replace the
d. Inverter fault Inverter
a. Quality or wrong
settings of KAE
a. Reset the KAE;
b. Bad connection from
Otherwise, replace it
X22/X24 to PLC
b. Rewire the circuit
c. Eddy current module
Hoisting has not low c. Replace the eddy
56 fault
speed current module
d. The main contact of
d. Replace the KHE
KHE be damaged
e. Please close the
e. Breaker of the eddy
breaker
current module be opened
or tripped
302
W450-25HC-138EN-A01 SPARE PARTS
7 SPARE PARTS
7.1 Foreword
This part groups the whole information together allowing you to:
➢ identify the spare parts (designation and code)
➢ identify the recommended parts for the preventive maintenance
➢ locate the position of a part in an assembly
➢ identify the “ready for mounting” sets.
The “Using the operating instructions” chapter indicates you the optimum method to search and
to use the information given in this part.
When ordering the spare parts, it is necessary to indicate:

➢ the crane types
➢ the serial crane numbers
➢ the reference, the designation, and the number of the required parts.
The constructor, with the constant desire of improving his products, reserves the right to replace
an ordered part by an adaptable part of equivalent characteristics.
Using parts which are not genuine spare parts or not recommended by the
manufacturer can lead to risks for equipment and staff.
In this case the manufacturer disclaims all responsibility.
Using the operating instructions

There are two types of parts lists:
H a parts list” Assembly” (for ex. hoist mechanism, slewing mechanism),
H a parts list” Subassembly” (for ex. squirrel cage motor, hoist mechanism shaft).
303
SPARE PARTS W450-25HC-138EN-A01
7.2 Examples of an “ASSEMBLY” parts list
Fig. 7-1 Spare parts list of the W450-25HC Tower Crane
Dear Users:
If you need maintenance or fittings for your equipment, please check the order
number and the designations of the parts you need in the spare parts manual at
first, and inform the local after-sales department of ZOOMLION.
304
Table 7-1 Spare parts list of the W450-25HC Tower Crane

No. Designation Order No. Code Notes Qty
1 Foundation 000280999CT030000 W450-25HC-ZGJA 1
2 Outrigger 000281815AT000000 WA350-20HA.15 4
Base tower Incline
3 000209023A2500000 X25G1816RaA 1
section ladder
Incline
4 Tower section 000209023A1200000 X25G1816 10
ladder
Climbing
5 000212011ET000000 W600-32U.11D Double “U” 1
equipment
Climbing
6 000280912AT000000 W450-25HC.12 1
mechanism
Climbing hydraulic YG250/160-
7 000200929A0100000 1
cylinder 2220/1650-31.5
8 Pump station 000209501A6900000 BZ-15-31.5 1
9 Transition section 000209023A2100000 X25G1816Rg Unitary type 1
10 Mounting device 000212019AT000000 W600-32U.19 1
11 Erection platform 000212020CT000000 W600-32U.20B 1
12 Cabin 1130000843 CM7 1
S75CA-
000209289A8700000 2
Slewing 130.146LB14/13A
13
mechanism S75CN-
000209289A8800000 1
130.146LB14/13A
14 Turntable 000280909AT000000 W450-25U.09 1
15 Slewing ring 1031500344 011.60.2240.1.00.42 1
16 Slewing support 000280910BT000000 W450-25HC.10 1
17 Counter ballast 000280999AT010000 W450-25-PHZ 1
18 Derrick 000209914B0006000 TCBG1500.1A Optional 1
Hoisting
19 000209195A7000000 H75FL63-1040 1
mechanism
20 Counter jib 000280901AT000000 W450-25U.01 1
21 Jib 000280905BT000000 W450-25U.05A 1
Trolley
22 000209370A4000000 T110FC85-b 1
mechanism
23 Trolley 000209710A0600000 XC32D 1
24 Hook 000209609A1100000 DG25E 1
305
Jib
Fig. 7-2 000280905BT000000
306
Table 7-2 Spare part list of Jib (W450-25U.05A)

No. Order No. Code Designation Specification Qty
1 000280905BT001000 Jib Ⅰ 1
2 000280905BT002000 Jib Ⅱ 1
3 000280905BT003000 Jib Ⅲ 1
4 000280905BT004000 Jib Ⅳ 1
5 000280905BT005000 Jib Ⅴ 1
6 000280905BT006000 Jib Ⅵ 1
7 000280905BT007000 Jib Ⅶ 1
8 000280905BT008000 Jib Ⅷ 1
9 000280905BT009000 Jib Ⅸ 1
10 000280905BT010000 Jib Ⅹ 1
11 000280905BT011000 Jib Ⅺ 1
12 000280905BT012000 Jib Ⅻ 1
13 000209910A0161601 XZ03B-16×160/175 Pin 16×160 4
14 1040500228 GB/T91-2000 Split pin 4×32 8
15 000261005AT005200 Pin tray 4
16 1040000216 GB/T5783-2000 Bolt M12×70-8.8 4
17 1040200096 GB/T6170-2000 Nut M12-8 4
307
JibⅠ
Fig. 7-3 000280905BT001000
308
Table 7-3 Spare part list of JibⅠ

1 000280905BT001100 Jib Ⅰ Structure 1
Overload limit
2 000280905AT001200 1
switch
3 000209910A4243701 XZ04E-120×370/455A Pin 120×370 1
4 1040500750 GB/T91-2000 Split pin 13×160 2
6×19-7.7-
5 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
6 1090100358 GB/T5976-1986 Rope clamp 8KTH 6
7 000280905AT002001 Pin 90×220/280 2
8 000231805AT001002 Pin Ф16×130/160 2
9 000209938A0000060 TX-4-16/20 Spring Cotter 2
10 000231805AT001010 Platform 2
11 1040000656 GB/T5783-2000 Bolt M24×90-8.8 4
12 1040200102 GB/T6170-2000 Nut M24-8 8
13 1040300212 GB/T96.1-2002 Washer 24-200HV 8
14 000280905AT001050 Maintenance platform 1
15 000209913B0007000 LGA700A Railing 3
16 1040002440 GB/T5783-2000 Bolt M12×45-8.8 16
17 1040200096 GB/T6170-2000 Nut M12-8 18
18 1040301044 GB/T97.1-2000 Washer 12 36
19 1040300054 GB/T93-1987 Washer 12 18
20 000280905AT001020 Platform 1
21 000280905AT001030 Platform 1
22 000261005AT001500 Hoisting Pulley 1
23 000280905AT001300 Trolley pulley 1
24 000280905BT001040 Platform 1
25 000209910A3041901 XZ03B-20×190/210 Pin 20×190 1
26 1040500253 GB/T91-2000 Split pin 5×32 4
27 000209910A1081801 XZ01C-40×180/205 Pin 40×180 2
28 1040500217 GB/T91-2000 Split pin 8×63 11
29 000209910A3041101 XZ03B-20×110/130 Pin 20×110 1
30 000209910A1081001 XZ01C-40×100/125 Pin 40×100 1
31 1040000216 GB/T5783-2000 Bolt M12×70-8.8 2
32 000209910A1040701 XZ01A-20×70/90 Pin 2
33 1040500216 GB/T91-2000 Split pin 6.3×50 4
34 000209910A1081601 XZ01C-40×160/185 Pin 40x160 1
35 000209910A1050501 XZ01B-25×50/70 Pin 25×50 2
36 000209913A6000000 LGJB2 Railing splint t6 4
309
JibⅡ
Fig. 7-4 000280905BT002000
Table 7-4 Spare part list of JibⅡ

1 000280905BT002100 Jib Ⅱ Structure 1
6×19-7.7-1550-
2 1090100352 GB/T8918-1996 Rope 1
Ⅱ-sZ
XZ04E-
4 000209910A4243701 Pin 120×370 1
120×370/455A
5 1040500750 GB/T91-2000 Split pin 13×160 2
6 000231805AT001002 Pin Ф16×130/160 2
7 000209938A0000060 TX-4-16/20 Spring pin 2
8 000280905AT002001 Pin 90×220/280 2
310
JibⅢ
Fig. 7-5 000280905BT003000
Table 7-5 Spare part list of Jib Ⅲ

1 000280905BT003100 Jib Ⅲ Structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
XZ04D-
4 000209910A4202903 Pin 100×290 1
100×290/370A
5 1040500646 GB/T91-2000 Split pin 13×140 2
6 000231705AT003002 Pin Ф16×110/140 2
7 000209938A0000060 TX-4-16/20 Spring pin 2
8 000231805AT002001 Pin 80×201/255 2
311
JibⅣ
Fig. 7-6 000280905BT004000
Table 7-6 Spare part list of JibⅣ

1 000280905BT004100 JibⅣ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
4 000209910A4202601 XZ04E-100×260/340 Pin 1
5 1040500646 GB/T91-2000 Split pin 13×140 2
6 000231705AT003002 Pin Ф16×110/140 2
7 1040500097 GB/T91-2000 Split pin 4×30 2
8 000231805AT003001 Pin 80×180/230 2
312
JibⅤ
Fig. 7-7 000280905BT005000
313
Table 7-7 Spare part list of JibⅤ

1 000280905BT005100 Jib Ⅴ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
4 000209910A4141701 XZ04D-70×170/230 Pin 70×170 1
5 1040500965 GB/T91-2000 Split pin 13×110 2
6 000209906A0017000 214-178-B41-80-R6 Pulley 1
7 1040300322 GB/T893.2-1986 Retainer 80 2
Deep groove
8 1050201563 GB/T276-2004 6208-2RS1 2
ball bearing
9 000212005AT007001 Pin 40×72 1
10 000210105A0010002 Shaft sleeve 2
11 000210105A0010001 Shaft end baffle t6 1
12 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
13 1040300067 GB/T93-1987 Washer 10 2
14 000270405BT007002 Pin Ф16×90/120 2
15 000209938A0000060 TX-4-16/20 Spring pin 2
16 000270405AT001001 Pin 60×160/205 2
314
JibⅥ
Fig. 7-8 000280905BT006000
315
Table 7-8 Spare part list of JibⅥ

1 000280905BT006100 JibⅥ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
4 000209910A4141701 XZ04D-70×160/220 Pin 70×170 1
5 1040500965 GB/T91-2000 Split pin 13×110 2
6 000270405BT007002 Pin Ф16×90/120 2
7 1040500097 GB/T91-2000 Spring pin 4×30 2
8 000270405AT001001 Pin 60×160/205 2
316
JibⅦ
Fig. 7-9 000280905BT007000
317
Table 7-9 Spare part list of JibⅦ

1 000280905BT007100 JibⅦ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Wire rope 1
1550-Ⅱ-sZ
3 1090100358 GB/T5976-1986 Rope Clip 8KTH 6
4 000209910A4141601 XZ04D-70×160/220 Pin 70×160 1
5 1040500965 GB/T91-2000 Split pin 13×110 2
6 000270405BT007002 Pin Ф16×90/120 2
7 1040500097 GB/T91-2000 Split pin 2
8 000270405AT002001 Pin 60×143/190 2
318
JibⅧ
Fig. 7-10 000280905BT008000
319
Table 7-10 Spare part list of JibⅧ

1 000280905BT008100 JibⅧ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
4 000209910A4141501 XZ04D-70×150/210 Pin 70×150 1
5 1040500646 GB/T91-2000 Split pin 13×140 2
6 000270405BT007002 Pin Ф16×90/120 2
7 000209938A0000060 TX-4-16/20 Spring pin 2
8 000270405AT002001 Pin 60×143/190 2
320
JibⅨ
Fig. 7-11 000280905BT009000
321
Table 7-11 Spare part list of JibⅨ

1 000280905BT009100 Jib Ⅸ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
3 1090100358 GB/T5976-1986 Rope Clamp 8KTH 6
4 000209910A4141701 XZ04D-70×170/230 Pin 70×170 1
5 1040500965 GB/T91-2000 Split pin 13×110 2
6 000270405BT007002 Pin Ф16×90/120 2
7 000209938A0000060 TX-4-16/20 Spring pin 2
8 000231805AT008001 Pin 60×121/170 2
322
JibⅩ
Fig. 7-12 000280905BT010000
Table 7-12 Spare parts list of JibⅩ

1 000280905BT010100 JibⅩ structure 1
6×19-7.7-
2 1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
4 000209910A4141301 XZ04D-70×130/190 Pin 70×130 1
5 1040500965 GB/T91-2000 Split pin 13×110 2
6 000209906A0017000 214-178-B41-80-R6 Pulley 1
7 000210105A0010002 Shaft Sleeve 2
8 000210105A0010001 Shaft-end baffle t6 1
9 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
10 1040300067 GB/T93-1987 Spring washer 10 2
11 000270405DT003001 Pin Ф40-68/100 1
Deep groove
12 1050201563 GB/T276-2004 6208-2RS1 2
ball bearing
13 1040300322 GB/T893.2-1986 Retainer 80 2
14 000270405BT007002 Pin Ф16×90/120 2
15 1040500097 GB/T91-2000 Split pin 4×30 2
16 000231805AT008001 Pin 60×121/170 2
323
Jib Ⅺ
Fig. 7-13 000280905BT011000
324
Table 7-13 Spare parts list of JibⅪ

1 000280905BT011100 Jib Ⅺ structure 1
2 6×19-7.7-
1090100352 GB/T8918-1996 Rope 1
1550-Ⅱ-sZ
3 1090100358 GB/T5976-1986 Rope Clamp 8KTH 6
4 000209910A4141301 XZ04D-70×130/190 Pin 70×130 1
5 1040500965 GB/T91-2000 Split pin 13×110 2
6 000270405BT007002 Pin Ф16×90/120 2
7 000209938A0000060 TX-4-16/20 Spring pin 2
8 000231805AT008001 Pin 60×121/170 2
325
Jib Ⅻ
Fig. 7-14 000280905BT012000
326
Table 7-14 Spare part list of JibⅫ

1 000280905BT012100 Jib Ⅻ structure 1
2 1040500215 GB/T91-2000 Split pin 5×63 1
3 000209910A0000515 XZ03A-12×80/95 Pin 12×80 2
4 1040500228 GB/T91-2000 Split pin 4×32 4
5 000210105A0010001 Shaft-end baffle t6 1
6 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
7 1040300067 GB/T93-1987 Washer 10 2
8 000212005AT007001 Pin 40×72 1
9 000210105A0010002 Shaft sleeve 2
Deep groove ball
10 1050201563 GB/T276-2004 6208-2RS1 2
Bearing
11 1040300322 GB/T893.2-1986 Retainer 80 2
240-190-B41-80-
12 000209906A0016000 Pulley 1
R8
13 000261005AT010500 20# Anti-twist device 1
14 000231705BT010010 Platform 1
15 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
16 1040200096 GB/T6170-2000 Nut M12-8 4
17 1040300041 GB/T97.1-2002 Washer 12-200HV 4
18 1040300054 GB/T93-1987 Washer 12 4
327
Trolley
Fig. 7-15 000209710A0600000

Components No.1 and No.2 are exploded in another drawings
Table 7-15 Spare parts list of Trolley (XC32D)

1 000209710A0601000 Auxiliary trolley 1

2 000209710A0602000 Main trolley 1
3 000209901A0600000 DL6 Maintenance cage 1
328
Auxiliary Trolley
Fig. 7-16 000209710A0601000

Table 7-16 Spare parts list of Auxiliary Trolley
1 000209710A0601002 Cover t4 4
2 1040001680 GB/T5783-2000 Bolt M10×30-8.8 12
3 1040300061 GB/T97.1-2002 Washer 10-200HV 20
4 1040300067 GB/T93-1987 Washer 10 12
5 1040200679 GB/T6170-2000 Nut M10-8 8
Auxiliary Trolley
6 000209710A0601100 1
Frame
7 000209709C0001700 XZ01C-35×60/90 Pin 35×60 2
8 000209720A0301001 Pin 3
9 000209709C0001400 Split pin 3
10 1090100353 JB/T8108.2-1999 Chain d4-L400 3
11 000209720A0410001 Block plate t10 2
12 000209709A0001004 Shaft sleeve 2
13 1050201620 GB/T288-2013 Bearing 21315CC 4
14 000209710A0301001 Spacer sleeve 2
329
15 000209710A0301002 Pulley shaft 2

16 000209709C0001730 Shaft sleeve 2
17 1080000007 JB/T7940.1-1995 Oil cup M10×1 2
18 000209710A0301003 Shaft sleeve 4
19 1040500355 GB/T91-2000 Split pin 6.3×56 8
20 000209709C0001720 Damper shaft Ф33.7×3.2 2
HL-600-525-108-
21 000209906A0040029 Pulley 2
160-12
22 1040300681 GB/T893.2-1986 Retainer 160 4
23 000209710A0301004 Metal seal ring 4
24 000209710A0600001 Side roll Ф120-50 4
25 1040300226 GB/T893.2-1986 Retainer 62 8
26 000209710A0601003 Shaft sleeve Ф30-8.8 8
27 000209710A0600002 Side roll shaft Ф30 4
Deep groove
28 1050201944 GB/T276-2013 6206-2RS 12
ball bearing
29 000209910A1061601 XZ01B-30×160/185 Pin 30×160 2
30 000209721F0101008 Roller 2
31 000209721F0101003 Shaft sleeve 4
32 1040500277 GB/T91-2000 Split pin 8×56 2
33 1040200763 GB/T812-1988 Nut M56×2 4
34 1040300679 GB/T858-1988 Washer 56 4
35 000209710A0600003 Roller shaft Ф60 4
Deep groove
36 1050201562 GB/T276-2004 6212-2RS1 8
ball bearing
37 1040300283 GB/T893.2-1986 Retainer 110 8
38 000209709A0003003 Roller 4
39 000209710A0301010 Safety gate 1
40 000209709A0001039 Shaft sleeve 4
41 000200211CF001300 XZ01A-25×105/130 Pin 25×105 2
42 000209721B0120010 Roller 2
Deep groove
43 1050201565 GB/T276-2004 6004-2RS1 4
ball bearing
44 000201116A0000002 XZ01A-20×140/160 Pin 20×140 2
45 000209705A0001100 FXC08B-11 Shaft sleeve 4
46 1040500263 GB/T91-2000 Split pin 5×56 2
47 000209704A1200001 Buffer 2
48 1040000101 GB/T5783-2000 Bolt M12×40-8.8 2
49 1040300054 GB/T93-1987 Washer 12 2
50 1040300041 GB/T97.1-2002 Washer 12-200HV 2
330
Main Trolley
Fig. 7-17 000209710A0602000
331
Table 7-17 Spare parts list of Main Trolley

1 000209710A0601002 Cover t4 4
2 1040001680 GB/T5783-2000 Bolt M10×30-8.8 12
3 1040300061 GB/T97.1-2002 Washer 10-200HV 20
4 1040300067 GB/T93-1987 Washer 10 12
5 1040200679 GB/T6170-2000 Nut M10-8 8
Main Trolley
6 000209710A0602100 1
Frame
7 000209720A0410001 Block plate t10 2
8 000209709A0001004 Shaft sleeve 2
9 1050201620 GB/T288-2013 Bearing 21315CC 4
10 000209710A0301001 Shaft sleeve 2
11 000209710A0301002 Pulley shaft 2
12 000209709C0001730 Shaft sleeve 2
13 1080000007 JB/T7940.1-1995 Oil cup M10×1 2
14 000209710A0301003 Shaft sleeve 4
15 1040500355 GB/T91-2000 Split pin 6.3×56 13
16 000209709C0001720 Damper shaft Ф33.7×3.2 2
HL-600-525-108-
17 000209906A0040029 Pulley 2
160-12
18 1040300681 GB/T893.2-1986 Retainer 160 4
19 000209710A0301004 Metal seal ring 4
20 000209710A0600001 Side roller Ф120-50 4
21 1040300226 GB/T893.2-1986 Retainer 62 8
22 000209710A0601003 Shaft sleeve Ф30-8.8 8
23 000209710A0600002 Side roller shaft Ф30 4
Deep groove
24 1050201944 GB/T276-2013 6206-2RS 12
ball bearing
25 000209910A1061601 XZ01B-30×160/185 Pin 30×160 2
26 000209721F0101008 Roller 2
27 000209721F0101003 Shaft sleeve 4
28 1040500277 GB/T91-2000 Split pin 8×56 2
29 1040200763 GB/T812-1988 Nut M56×2 4
30 1040300679 GB/T858-1988 Washer 56 4
31 000209710A0600003 Roller shaft Ф60 4
Deep groove
32 1050201562 GB/T276-2004 6212-2RS1 8
ball bearing
33 1040300283 GB/T893.2-1986 Retainer 110 8
34 000209709A0003003 Roller 4
35 000209709A0001039 Shaft sleeve 4
332
36 000209710A0301010 Safety gate 1

37 000200211CF001300 XZ01A-25×105/130 Pin 25×105 2
38 000209704A1200001 Buffer 4
39 1040000101 GB/T5783-2000 Bolt M12×40-8.8 6
40 1040300054 GB/T93-1987 Washer 12 6
41 1040300041 GB/T97.1-2002 Washer 12-200HV 6
42 000209910A1051651 XZ-25-165/185 Pin 2
43 1040300074 GB/T97.1-2002 Washer 30-200HV 1
44 000209938A0000030 TX-6-25/30 Spring pin 2
45 000209710A0302020 Tension pulley 1
46 000209708D0102002 Shaft sleeve 1
47 000209910A4061701 XZ03C-30×170/205 Pin 30×170 1
48 1090100708 GB/T5973-2006 Wedge 12 2
49 000209910A1050501 XZ01B-25×50/70 Pin 25×50 1
50 000209710A0302010 Safety gate 1
51 1090100213 GB/T5976-1986 Rope clamp 12 1
52 1090100709 GB/T5973-2006 Wedge cover 12 1
53 1040200096 GB/T6170-2000 Nut M12-8 4
54 000209708A0400100 Tension plate 1
333
Hook
Fig. 7-18 000209609A1100000

Components No.1 and No.2 are exploded in another drawing
Table 7-18 Spare parts list of Hook (DG25E)

1 000209609A1101000 Auxiliary hook 1
2 000209609A1102000 Main hook 1
3 000209609A0000003 XZ01A-18×50/70 Pin 18×50 2
4 1040500240 GB/T91-2000 Split pin 3.2×25 2
5 000209609A1103000 Bending plate 1
6 000209609A1104000 Hook assembly 1
7 000209910A1152401 XZ01D-75×240/280 Pin 75×240 3
8 1040500965 GB/T91-2000 Split pin 13×110 3
334
Auxiliary Hook
Fig. 7-19 000209609A1101000
335
Table7-19 Spare parts list of Auxiliary Hook

1 000209609A1101100 Auxiliary splint 1
HL-600-525-108-
2 000209906A0040029 Pulley 1
160-12
3 000209710A0301001 Spacer sleeve 1
4 1040300681 GB/T893.2-1986 Retainer 160 2
5 000209710A0301004 Metal seal ring 2
6 000209710A0301003 Shaft sleeve 2
Positioning
7 000209609A0901004 2
sleeve
8 1040000114 GB/T5783-2000 Bolt M10×25-8.8 2
9 1040300067 GB/T93-1987 Washer 10 2
10 000209609A0000106 Block plate t10 1
11 1080000007 JB/T7940.1-1995 Oil cup M10×1 1
12 000209609A0901005 Pulley shaft 1
13 1050201620 GB/T288-2013 Bearing 21315CC 2
14 000209609A0901001 Rope guard shaft Ф26.9×2.8 2
15 1040500216 GB/T91-2000 Split pin 6.3×50 4
336
Main Hook
Fig. 7-20 000209609A1102000
Table7-20 Spare parts list of Main Hook

1 000209609A1102100 Main splint 1
HL-600-525-108-
2 000209906A0040029 Pulley 2
160-12
3 000209710A0301001 Spacer sleeve 2
4 1040300681 GB/T893.2-1986 Retainer 160 4
5 000209710A0301004 Metal seal ring 4
6 000209710A0301003 Shaft sleeve 4
7 000209609A1102001 Positioning sleeve 4
8 1040000114 GB/T5783-2000 Bolt M10×25-8.8 4
9 1040300067 GB/T93-1987 Washer 10 4
10 000209609A0000106 Block plate t10 2
11 1080000007 JB/T7940.1-1995 Oil cup M10×1 2
12 1050201620 GB/T288-2013 Bearing 21315CC 4
13 000209609A0901005 Pulley shaft 2
14 000209609A0901001 Rope guard shaft Ф26.9×2.8 2
15 1040500216 GB/T91-2000 Split pin 6.3×50 4
337
Counter Jib
Fig. 7-21 000280901AT000000

Components No.1, No.2 and No.6 are exploded in other drawings
338
Table 7-21 Spare part list of Counter Jib (W450-25U.01)

1 000280901AT010000 Front counter jib 1
2 000280901AT020000 Middle counter jib 1
3 000280901AT001000 Counter jib tie barⅠ 2
4 000231801BT003000 Counter jib tie barⅢ 2
5 000231801BT002000 Counter jib tie barⅡ 2
6 000280901AT030000 Rear counter jib 1
7 1040500646 GB/T91-2000 Split pin 13×140 6
XZ01D-
8 000209910A1161701 Pin 80×170 6
80×170/210
339
Front Counter Jib
Fig. 7-22 000280901AT010000
340
Table 7-22 Spare parts list of Front Counter Jib

Front-Counter
1 000280901AT011000 1
Jib Structure
2 000280901AT010010 Platform t3 4
3 000280901AT010001 Skirting Board t6 4
4 000209910A4162101 XZ04D-80×210/275 Pin 80×210 2
5 000209910A4161901 XZ04D-80×190/255 Pin 80×190 2
6 1040500646 GB/T91-2000 Split Pin 13×140 8
Rope-Support
7 000280801AT000300 1
Sheave
8 000209910A4202801 XZ04E-100×280/375 Pin 100×280 2
9 000280901AT010004 Pin 25×155 2
10 1040302325 GB/T97.1-2000 Washer 24-200HV 14
11 1040500216 GB/T91-2000 Split pin 6.3×50 22
12 000209910A3051201 XZ03B-25×120/150A Pin 25×120 2
13 1040000101 GB/T5783-2000 Bolt M12×40-8.8 40
14 1040300054 GB/T93-1987 Washer 12 42
15 1040200096 GB/T6170-2000 Nut M12-8 26
16 1040300571 GB/T96-1985 Washer 12-200HV 64
17 000280901AT010005 Pin 4
18 000280901AT010006 Pin 25×140 4
19 000209910A4284201 XZ04E-140×420/525 Pin 140×420 1
20 000209910A3051901 XZ04B-25×190/220 Pin 25×190 2
21 000209910A3051101 XZ03B-25×110/140 Pin 25×110 4
22 000280901AT010020 Platform 1
23 1040002441 GB/T5783-2000 Bolt M12×50-8.8 2
24 1040301044 GB/T97.1-2000 Washer 4
341
Middle Counter Jib
Fig. 7-23 000280901AT020000
342
Table 7-23 Spare parts list of Middle Counter Jib

Middle-Counter
1 000280901AT021000 1
Jib Structure
2 000209913B0020000 LGB2000A Railing 4
3 000231801BT020001 Support Bar [10 2
4 000231701BT020010 Platform t3 2
5 000231701BT020020 Platform t3 1
6 000231801AT020002 Pin Ф20 4
7 1040500228 GB/T91-2000 Split pin 4×32 4
8 1040000216 GB/T5783-2000 Bolt M12×70-8.8 4
9 1040300054 GB/T93-1987 Spring washer 12 18
10 1040300041 GB/T97.1-2002 Washer 12-200HV 24
11 1040200096 GB/T6170-2000 Nut M12-8 6
13 1040500381 GB/T91-2000 Split pin 8×71 8
14 1040000101 GB/T5783-2000 Bolt M12×40-8.8 12
15 000209910A4122001 XZ04C-60×200/260 Pin 60×200 4
16 1040500186 GB/T91-2000 Split pin 10×90 8
17 000280901AT010020 Platform 1
18 1040002441 GB/T5783-2000 Bolt M12×50-8.8 2
343
Rear Counter Jib
Fig. 7-24 000280901AT030000
344
Table 7-24 Spare parts list of Rear Counter Jib

Rear-Counter
1 000280901AT031000 1
Jib Structure
2 000209913C0030000 LGB3000B Railing 2
3 000231801AT030001 Support rod [10 2
4 000280901AT030015 Passage t2 2
5 000280901AT030025 Passage t2 4
6 000209913C0007000 LGA700B Railing 2
7 000209913C0020000 LGB2000B Railing 2
8 000209913C0005800 LGA580B Railing 2
9 000280901AT032000 Platform 1
10 000209913F1055900 LGVI5590B VI railing 2
11 000271001BT030400 Platform 1
12 000209913C0015000 LGC1500B Railing 2
13 000231801AT032000 Platform 1
14 000270201BH003000 Platform B 1
15 000209913C0006300 LGA630B Railing 4
16 000209913C0008200 LGA820B Railing 1
17 1040000216 GB/T5783-2000 Bolt M12×70-8.8 17
18 1040300054 GB/T93-1987 Washer 12 41
19 1040300041 GB/T97.1-2002 Washer 12-200HV 36
20 1040200096 GB/T6170-2000 Nut M12-8 18
22 000208899A0002076 TX-6-24/35 Spring pin Ф6×117 52
Obstacle light
23 000209915A0001000 ZADZ 1
seat
24 1040500047 GB/T91-2000 Split pin 5×70 1
25 1040000696 JB/ZQ4321-1997 U-Bolt 33-Zn 2
26 1040300067 GB/T93-1987 Washer 10 4
27 1040300061 GB/T97.1-2002 Washer 10-200HV 4
28 1040200113 GB/T6170-2000 Nut M10-8 4
29 000200111T0000204 XZ01A-16×45/65 Pin 16×45 12
30 000209938A0000060 TX-4-16/20 Spring pin 12
31 000209910A3041501 XZ03B-20×150/170 Pin 20×150 4
32 000201213A0000003 Spring pin 8
33 000280901AT030002 Pin 40×100 4
34 1040000101 GB/T5783-2000 Bolt M12×40-8.8 24
35 000280801BT000002 SXTZ Camera seat L80×8 1
36 1040000091 GB/T5783-2000 Bolt M5×20-8.8 2
345
37 1040300060 GB/T93-1987 Washer 5 2

38 1040300048 GB/T97.1-2002 Washer 5-200HV 2
39 1040200107 GB/T6170-2000 Nut M5-8 2
40 1040300571 GB/T96-1985 Washer 12-200HV 24
41 000209913D0010000 LGA1000C Railing 2
Derrick
Fig. 7-25 000209914B0006000
346
Table 7-25 Spare parts list of Manual Derrick (TCBG1500.1A)

1 000209914B0006100 Support 1
XZ01C-
2 000209914A0006200 Pin A 30×180 1
30×180/210
3 1040500222 GB/T91-2000 Split pin 8×80 1
4 000209914A0007000 Rotational column 1
5 000209914A0006300 Pulley seat 1
6 000209914A0006400 Pulley A 1
7 000209914A0006500 Pin B 2
8 000209914A0006600 Bushing A 4
9 000209914A0006700 Pulley B 2
10 000209914A0006800 Shaft-end baffle A t6 2
11 1040000116 GB/T5783-2000 Bolt M10×20-8.8 6
12 1040300067 GB/T93-1987 Washer 10 16
13 1080000007 JB/T7940.1-1995 Oil cup M10×1 3
14 000209914A0006900 Block bar t6 2
15 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
16 1040300054 GB/T93-1987 Washer 12 4
17 1040300041 GB/T97.1-2002 Washer 12-200HV 4
18 1040200096 GB/T6170-2000 Nut M12-8 4
19 1040300678 GB/T853-1988 Washer 12 4
20 000209914A0008100 Pin C 1
21 000209914A0008200 Shaft-end baffle B t10 1
22 000209914A0008300 Bushing B 2
M30×110-
23 1040000758 GB/T5782-2000 Bolt 6
8.8
24 1040200197 GB/T6170-2000 Nut M30-8 12
25 1040300074 GB/T97.1-2002 Washer 30-200HV 12
347
Turntable
Fig. 7-26 000280909AT000000
348
Table 7-26 Spare parts list of Turntable (W450-25U.09)

1 000280909AT004000 Turntable structure 1
Electrical control
2 000280909AT003000 1
cabinet platform
3 000280909AT005000 Cabin platform 1
4 1040000145 GB/T5783-2000 Bolt M16×80-8.8 36
5 1040300052 GB/T97.1-2002 Washer 16-200HV 60
6 1040300065 GB/T93-1987 Washer 16 48
7 000261009AT000030 Backing plate t8 1
8 1040000122 GB/T5783-2000 Bolt M10×35-8.8 16
9 1040300764 GB/T96-1985 Washer 10-200HV 34
10 1040300067 GB/T93-1987 Washer 10 20
11 000242009AT000300 Step clap 1
12 1040000198 GB/T5783-2000 Bolt M16×50-8.8 12
13 1040200110 GB/T6170-2000 Nut M16-8 12
14 1040200113 GB/T6170-2000 Nut M10-8 18
XZ03B-
15 000209910A3040901 Pin 20×90 4
20×90/110
16 1040500063 GB/T91-2000 Split pin 5×36 8
17 000201109B0000390 Anti-collide device 1
18 000221601AT000010 Mounting base 1
JB/ZQ4321-
19 1040000696 U-Bolt 33-Zn 2
1997
Shield of slewing
20 000261009AT000040 3
limit switch A
21 1040002924 GB/T5782-2000 Bolt M30×270-10.9 60
22 1040301788 GB/T97.1-2002 Washer 30-300HV 120
23 1040201133 GB/T6170-2000 Nut M30-10 120
24 000280909AT000800 Trunking 2
25 000280909AT000600 Railing 1
26 000280909AT000700 Railing 1
27 000280909AT000400 Railing Ⅲ 2
29 1040000899 GB/T5782-2000 Bolt M12×70-8.8 3
30 1040300054 GB/T93-1987 Washer 12 3
31 1040200096 GB/T6170-2000 Nut M12-8 3
32 1040300756 GB/T97.1-2002 Washer 12-200HV 6
33 1040500222 GB/T91-2000 Split pin 8×80 8
349
Slewing Support
Fig. 7-27 000280910BT000000
350
Table 7-27 Spare part list of Slewing Support (W450-25HC.10)

Slewing support
1 000280910BT003000 1
structure
M30×270-
2 1040002924 GB/T5782-2000 Bolt 60
10.9
3 1040301788 GB/T97.1-2002 Washer 30-300HV 120
4 1040201133 GB/T6170-2000 Nut M30-10 120
5 000280910BT002000 Ladder 1
XZ08E-
6 000209910A8122501 Pin 60×250 8
60×250/345
XZ03A-
7 000209910A3041601 Pin 20×160 8
20×160/180
8 000201213A0000003 Spring pin 16
9 00000000000000002 - 1
10 1040000257 GB/T5782-2000 Bolt M16×50-8.8 4
11 1040300052 GB/T97.1-2002 Washer 16-200HV 4
12 1040300065 GB/T93-1987 Washer 16 4
13 1040200110 GB/T6170-2000 Nut M16-8 4
14 1040300041 GB/T97.1-2002 Washer 12-200HV 2
15 1040300054 GB/T93-1987 Washer 12 2
16 1040200096 GB/T6170-2000 Nut M12-8 2
351
Hoisting Mechanism
Fig. 7-28 000209195A7000000
352
Table 7-28 Spare parts list of Hoisting Mechanism (H75FL63-1040)

1 1020005202 YZPFM280M-6 Motor 75kW 1
2 1040000502 GB/T5782-2000 Bolt M20×100-8.8 4
3 1040300256 GB/T96.1-2002 Washer 20-200HV 8
4 1040300038 GB/T93-1987 Washer 20 10
5 1040200097 GB/T6170-2000 Nut M20-8 8
ETF100-H ETF100-H
6 1020202010 Encoder 1
(Nr:851223/0.8) (Nr:851223/0.8)
7 000209195A2700001 Baffle t12 1
8 1040000556 GB/T5783-2000 Bolt M20×55-8.8 1
9 1040300106 GB/T97.1-2002 Washer 20-200HV 10
10 000209195A3200100 Brake cover 1
11 1040000116 GB/T5783-2000 Bolt M10×20-8.8 3
12 1040300764 GB/T96-1985 Washer 10-200HV 3
13 1040302271 GB/T93-1987 Washer 10 27
MLL9-Ⅰ-400-
Braking wheel
14 000209944A0000730 YA75×142(20)/J 1
coupling
A60×142(18)
15 000209143A1000008 Retainer t10 1
16 1040000175 GB/T5783-2000 Bolt M20×50-8.8 1
YWZ5-400/125-
17 1031700163 Brake 1
2000-HL
18 1040000377 GB/T5783-2000 Bolt M20×80-8.8 4
MB3H100H50B
19 1030202545 Reducer 1
T
20 000209171A0200010 Adjusting pad A t1 0
21 000209171A0200011 Adjusting pad B t1.5 0
22 1040000766 GB/T5782-2000 Bolt M24×120-8.8 6
23 1040300050 GB/T97.1-2002 Washer 24-200HV 28
24 1040300049 GB/T93-1987 Washer 24 14
25 1040200102 GB/T6170-2000 Nut M24-8 14
26 1040600112 GB/T1096-2003 Bond 36×20×450 2
Self-aligning
27 1050201140 GB/T288-1994 23030 1
roller bearing
Bearing end
28 000209154A0000002 t21 1
cover AⅠ
29 000209154A0000003 Collar AⅠ 1
30 1040000122 GB/T5783-2000 Bolt M10×35-8.8 24
Bearing end
31 000209154A0000004 t21 1
cover AⅡ
353
32 000209154A0000005 Collar AⅡ 1
33 000209195A7001000 Bearing seat A 1
34 1040000564 GB/T5783-2000 Bolt M24×110-8.8 8
35 000209195A7002000 Chassis frame 1
36 000209195A7000001 Main shaft 1
37 000209195A7003000 Drum 1
38 000209195A7000002 Shaft sleeve 1
39 000209195A3200003 Collar BⅠ 1
Bearing end
40 000209195A3200004 t21 1
cover BⅠ
41 000209195A7004000 Bearing seat B 1
Self-aligning
42 1050200254 GB/T288-1994 22222C 1
roller bearing
Bearing end
43 000209195A3200009 t21 1
cover BⅡ
44 000209195A5700002 Oil seal 1
45 000209944A0200023 NLT-3 Nylon sleeve 1
46 1040500054 GB/T91-2000 Split pin 4×40 1
47 000209195A6500003 Dial pin 1
48 000209195A5700004 Pressing plate t8 1
49 1040000107 GB/T5783-2000 Bolt M6×20-8.8 2
50 1040300062 GB/T93-1987 Washer 6 2
51 1040000151 GB/T5783-2000 Bolt M5×12-8.8 4
52 1040300048 GB/T97.1-2002 Washer 5-200HV 4
53 1040300060 GB/T93-1987 Washer 5 4
54 000209944A0400030 XWZJ-01 Limiter support t5 1
55 1040000267 GB/T5783-2000 Bolt M8×20-8.8 4
56 1040300066 GB/T97.1-2002 Washer 8-200HV 4
57 1040300063 GB/T93-1987 Washer 8 4
JB/T7940.2-
58 1080000009 Oil cup 90° M10×1 2
1995
Rope-blocking
59 000209195A7005000 1
device
60 1040000198 GB/T5783-2000 Bolt M16×50-8.8 8
61 1040200110 GB/T6170-2000 Nut M16-8 8
62 1040300052 GB/T97.1-2002 Washer 16-200HV 16
63 1040300065 GB/T93-1987 Washer 16 8
H75FL63-1040-
64 000209195A7000009 Nameplate 1
MP
65 1040400058 GB/T827-1986 Rivet 2.5×8 4
354
Trolley Mechanism
Component No.20 is exploded in other drawing

Fig. 7-29 000209370A4000000
Table 7-29 Spare parts list of Trolley Mechanism (T110FC85-b)
1 1040000553 GB/T5783-2000 Bolt M24×65-8.8 4
2 1040200102 GB/T6170-2000 Nut M24-8 4
3 1040300050 GB/T97.1-2002 Washer 24-200HV 4
4 1040300049 GB/T93-1987 Spring Washer 24 4
5 000209331A0001100 Support Frame 1
Elastic cylindrical
6 1040500677 GB/T879.1-2000 12×50 2
pin
7 1040000177 GB/T5783-2000 Bolt M16×55-8.8 4
8 1040300065 GB/T93-1987 Spring Washer 16 8
9 000209331A0000002 End cover 1
10 000209331A0000200 Adapter sleeve 1
11 1040000132 GB/T5783-2000 Bolt M10×16-8.8 2
355
12 1040300067 GB/T93-1987 Washer 10 2

13 1040300211 GB/T96.1-2002 Washer 10-200HV 2
14 000209370A2000004 Rope block 2
15 000209370A3200300 Drum 1
16 1040000149 GB/T5783-2000 Bolt M12×50-8.8 24
17 1040300041 GB/T97.1-2002 Washer 12-200HV 32
18 1040300054 GB/T93-1987 Washer 12 32
19 1030201232 XX3-60.58 Reducer 1
20 000209331A0000400 Coupling 1
21 1040000101 GB/T5783-2000 Bolt M12×40-8.8 8
22 000209331A0000007 Flange A 1
23 000209331A0000008 Hatch I 1
Self-aligning ball
24 1050200566 GB/T281-1994 1322 1
bearing
25 1040100122 GB/T70.1-2000 Screw M8×25-8.8 12
26 1040300063 GB/T93-1987 Washer 8 16
27 000209331A0000009 Hatch II 1
28 000209331A0000010 Collar 125 1
29 000209331A0000500 Flange B 1
30 000209331A0000012 Washer 1
1020005138 YVFE-160M-
31 Motor 11kW 1
4B5(TJ)
32 00020000000000001 - - - -
33 000209331A0000013 Collar 110 1
34 1040001581 GB/T897-1988 Bolt M16×65-8.8 4
35 1040300052 GB/T97.1-2002 Washer 16-200HV 4
36 1040000151 GB/T5783-2000 Bolt M5×12-8.8 4
37 1040300060 GB/T93-1987 Washer 5 4
38 000209331A0000600 Limiter support 1
39 1040000267 GB/T5783-2000 Bolt M8×20-8.8 4
40 1040300066 GB/T97.1-2002 Washer 8-200HV 4
41 1040500054 GB/T91-2000 Split pin 4×40 1
42 000209331A0000015 Little gear 1
43 000209331A0000016 Fixing support 2
Elastic cylindrical
44 1040500631 GB/T879.1-2000 12×26 2
pin
45 1040200110 GB/T6170-2000 Nut M16-8 4
46 000209370A4000007 Nameplate 1
47 1040400058 GB/T827-1986 Rivet 2.5×8 4
356
Coupling
Fig. 7-30 000209331A0000400
Table 7-30 Spare parts list of Gear Coupling

1 000209331A0000402 Half coupling II 1
2 000209301E0003002 Nylon Gear 1
3 000209331A0000401 Half Coupling I 1
357
Slewing Mechanism
S75CA-130.146LB14/13A
Fig. 7-31 000209289A8700000
358
Table 7-31 Spare parts list of Slewing Mechanism (S75CA-130.146LB14/13A)

1 1020005445 YTRVF132M2-4F1/B/BM1 Motor 7.5kW 1
2 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
3 1040300054 GB/T93-1987 Washer 12 4
4 1040300041 GB/T97.1-2002 Washer 12-200HV 4
5 1030202388 XX5-130.146CLD-14/13 Reducer 1
6 000209289A8700100 Nameplate 1
7 1040400058 GB/T827-1986 Rivet 2.5×8 4
359
S75CN-130.146LB14/13A
Fig. 7-32 000209289A8800000
360
Table 7-32 Spare parts list of Slewing Mechanism (S75CN-130.146LB14/13A)

1 1020005446 YTRVF132M2-4F2/B/BM1 Motor 7.5kW 1
2 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
3 1040300054 GB/T93-1987 Washer 12 4
4 1040300041 GB/T97.1-2002 Washer 12-200HV 4
5 1030202388 XX5-130.146CLD-14/13 Reducer 1
6 000209289A8800100 Nameplate 1
7 1040400058 GB/T827-1986 Rivet 2.5×8 4
8 1020202072 ECK58B(Nr:851249/10) Encoder 1024PPR 1
361
Climbing Equipment
Fig. 7-33 000212011ET000000
362
Table 7-33 Spare parts list of Climbing Equipment (W600-32U.11D)

1 000209913C0006300 LGA630B Railing 13
2 000209913C0020000 LGB2000B Railing 10
3 000209913C0030000 LGB3000B Railing 3
4 000212011ET000100 Ladder 1
Climbing
5 000212011ET001000 equipment 1
structure
Step-
6 000212011BT000200 1
changing rod
8 1040000562 GB/T5783-2000 Bolt M12×65-8.8 26
9 1040300041 GB/T97.1-2002 Washer 12-200HV 26
10 1040200096 GB/T6170-2000 Nut M12-8 26
11 1040000095 GB/T5783-2000 Bolt M16×60-8.8 6
12 1040200110 GB/T6170-2000 Nut M16-8 12
13 1040300065 GB/T93-1987 Washer 16 12
14 1040300052 GB/T97.1-2002 Washer 16-200HV 16
15 000240811AT100003 Pin 16
16 1040500233 GB/T91-2000 Split pin 5×40 16
17 1040000681 GB/T5783-2000 Bolt M20×90-8.8 4
18 1040300038 GB/T93-1987 Washer 20 4
19 1040200097 GB/T6170-2000 Nut M20-8 4
20 1040300106 GB/T97.1-2002 Washer 20-200HV 8
21 000212011BT000300 Flexible strut 1
22 1040500381 GB/T91-2000 Split pin 8×71 59
Pressing
23 000200311A0000151 t5 16
plate
24 1040000132 GB/T5783-2000 Bolt M10×16-8.8 32
25 1040300067 GB/T93-1987 Washer 10 32
26 1040200276 GB/T6170-2000 Nut M36-8 16
27 000212011CT000010 Screw 16
28 1040000618 GB/T75-1985 Screw M8×12 32
29 000212011CT000020 Roller frame 16
30 000223011AL101002 Roller 16
31 000200911B0000180 Sleeve 16
32 000212011CT000030 Shaft 16
33 1080000005 JB/T7940.1-1995 Oil cup M6×1 16
34 000209910A1121501 XZ01C-60×150/185-T Pin 60×150 2
35 1040500222 GB/T91-2000 Split pin 8×80 2
363
36 000212011CT000400 PlatformⅠ 4
37 000212011CT000500 Platform Ⅱ 1
38 000212011ET000200 Platform Ⅲ 1
39 000212011CT000700 Platform Ⅳ 1
40 000209913D0005300 LGA530B Railing 2
41 000212011CT000800 Platform Ⅴ 1
42 1040000082 GB/T5783-2000 Bolt M16×40-8.8 4
43 1040300215 GB/T853-1988 Washer 16 4
364
Climbing Mechanism
Fig. 7-33 000280912AT000000
Table 7-33 Spare parts list of Climbing Mechanism (W450-25HC.12)

1 000280912AT000100 Climbing beam 1
2 000209910A1121801 XZ01C-60×180/215 Pin 60×180 2
3 1040500252 GB/T91-2000 Split pin 10×90 2
4 000209506A0000025 Pin 2
5 1040500247 GB/T91-2000 Split pin 13×125 2
6 000280912AT000200 Hanging plate 2
7 000209504A0000300 TC7030.12-3 Spring pin 2
365
Transition Section
Fig. 7-34 000209023A2100000
366
Table 7-34 Spare parts list of Transition Section (X25G1816Rg)

Transition
1 000209023A2110000 1
section structure
2 000209023A1902000 Ladder 1
3 000209023A2120000 Platform 1
Ladder and
4 000209023A2130000 1
guard ring
5 1040000198 GB/T5783-2000 Bolt M16×50-8.8 6
6 1040300052 GB/T97.1-2002 Washer 16-200HV 16
7 1040300065 GB/T93-1987 Washer 16 8
8 1040200110 GB/T6170-2000 Nut M16-8 8
9 000200710A0000004 Pin 4
10 000200710A0000005 Inserting pin 4
Connecting
11 000209036B0100002 t12 1
plate
M16×140-
12 1040000755 GB/T5783-2000 Bolt 2
8.8
13 000209009C1000700 Ladder blocker 1
14 1040500381 GB/T91-2000 Split pin 8×71 1
15 1040000108 GB/T5783-2000 Bolt M12×30-8.8 4
16 1040300041 GB/T97.1-2002 Washer 12-200HV 12
17 1040300054 GB/T93-1987 Washer 12 4
18 1040200096 GB/T6170-2000 Nut M12-8 6
19 000209910A1161701 XZ01D-80×170/210 Pin 80×170 4
20 000209910A3020901 XZ03B-10×90/105 Pin 10×90 4
21 1040500396 GB/T91-2000 Split pin 3.2×25 8
22 000209910A8122401 XZ08E-60×240/335 Pin 60×240 8
23 000209910A3041601 XZ03A-20×160/180 Pin 20×160 8
24 000201213A0000003 Spring pin 16
25 000209009A0402101 Connector 4
26 000209910A9122221 XZ09E-60×222/248 Pin 8
27 000209009B0401101 Support ring 60 8
28 1040302978 ГОСТ13940-86 Concentric ring 60 8
367
Mounting Device
Fig. 7-33 000212019AT000000
368
Table 7-33 Spare parts list of Mounting Device (W600-32U.19)

1 000271019BT010000 Mounting mechanism 1
2 000212019AT010000 Mounting beam 1
3 000212019AT030000 Platform 1
4 000209913C0030000 LGB3000B Railing 2
5 1040500381 GB/T91-2000 Split pin 8×71 8
6 000209913C0006300 LGA630B Railing 1
8 1040000216 GB/T5783-2000 Bolt M12×70-8.8 2
9 1040300041 GB/T97.1-2002 Washer 12-200HV 6
10 1040300054 GB/T93-1987 Washer 12 2
11 1040200096 GB/T6170-2000 Nut M12-8 6
12 000271019BT040000 Mounting hook 1
13 000271019BT050000 Pulley assembly 1
14 000271019BT060000 Mounting trolley 1
15 000271019BT070000 Lifting frame 1
Rope with connector
16 000212019AT040000 4
1.61
17 000213010AR002002 Hanging hook 2
6×19-7.7-
19 1090100352 GB/T8918-1996 Rope 2
1550-Ⅱ-sZ
XZ01C-
20 000209910A1082301 Pin 40×230 2
40×230/255
21 1040500217 GB/T91-2000 Split pin 8×63 2
22 1040000095 GB/T5783-2000 Bolt M16×60-8.8 8
23 1040300065 GB/T93-1987 Washer 16 8
24 1040300052 GB/T97.1-2002 Washer 16-200HV 16
25 1040200110 GB/T6170-2000 Nut M16-8 8
XZ01A-
26 000209910A0010054 Pin 20×35 4
20×35/55
27 1040500063 GB/T91-2000 Split pin 5×36 4
369
Erection Platform
Fig. 7-35 000212020CT000000
370
Table 7-35 Spare parts list of Erection Platform (W600-32U.20B)

1 000209913B0020000 LGB2000A Railing 2
2 000209913B0005800 LGA580A Railing 4
3 000209913B0005300 LGA530A Railing 4
4 000209913B0004300 LGA430A Railing 4
5 000212020CT001000 Support 2
6 000212020CT002000 Platform 2
7 1040500381 GB/T91-2000 Split pin 8×71 28
8 000209910A0010054 XZ01A-20×35/55 Pin 20×35 8
9 1040500063 GB/T91-2000 Split pin 5×36 8
11 1040000216 GB/T5783-2000 Bolt M12×70-8.8 12
12 1040300041 GB/T97.1-2002 Washer 12-200HV 24
13 1040300054 GB/T93-1987 Washer 12 12
14 1040200096 GB/T6170-2000 Nut M12-8 12
371
Mast (Incline ladder)

Tower Section (X25G1816)
372
Fig. 7-36 000209023A1200000
373
Table 7-36 Spare parts list of Tower Section (X25G1816)

Tower section
1 000209023A1201000 1
structure
2 000209023A1203000 Short Ladder 1
3 000209023A1204000 Platform 1
Long ladder
4 000209023A1205000 1
and guard ring
5 1040000169 GB/T5783-2000 Bolt M12×45-8.8 12
6 1040200096 GB/T6170-2000 Nut M12-8 18
7 1040300054 GB/T93-1987 Washer 12 18
8 1040300041 GB/T97.1-2002 Washer 12-200HV 22
9 1040002423 GB/T5783-2000 Bolt M16×90-8.8 2
10 1040300052 GB/T97.1-2002 Washer 16-200HV 6
11 1040300065 GB/T93-1987 Washer 16 6
12 1040200685 GB/T6170-2000 Nut M16-8 6
13 1040000095 GB/T5783-2000 Bolt M16×60-8.8 2
14 000209910A8122401 XZ08E-60×240/335 Pin 60×240 8
15 000209910A3041601 XZ03A-20×160/180 Pin 20×160 8
16 000201213A0000003 Spring pin 16
17 000209023A1200001 Railing Ф33.7×3.2 4
18 000209023A1200002 Ladder plate t8 1
19 1040000216 GB/T5783-2000 Bolt M12×70-8.8 4
20 000209023A1200003 Splint plate t8 2
21 000209023A1206000 Ladder blocker 1
Connecting
22 000209036B0100002 t12 1
plate
23 1040000755 GB/T5783-2000 Bolt M16×140-8.8 2
24 1040500381 GB/T91-2000 Split pin 8×71 1
374
Base Tower Section (X25G1816RaA)
Fig. 7-37 000209023A2500000
375
Table 7-37 Spare parts list of Base Tower Section (X25G1816RaA)

Base tower
1 000209023A2510000 section 1
structure
2 000209023A1203000 Short ladder 1
3 000209023A1204000 Platform 1
Long ladder
4 000209023A1403000 1
and guard ring
Nameplate
5 000209023A1401000 1
support
6 1040300041 GB/T97.1-2002 Washer 12-200HV 22
7 1040300054 GB/T93-1987 Washer 12 18
8 1040200096 GB/T6170-2000 Nut M12-8 18
9 1040000169 GB/T5783-2000 Bolt M12×45-8.8 12
10 1040002423 GB/T5783-2000 Bolt M16×90-8.8 2
11 1040300052 GB/T97.1-2002 Washer 16-200HV 6
12 1040300065 GB/T93-1987 Washer 16 6
13 1040200685 GB/T6170-2000 Nut M16-8 6
14 1040000095 GB/T5783-2000 Bolt M16×60-8.8 2
15 000209910A8132401 XZ08E-65×240/335 Pin 8
16 000209910A4041551 XZ03A-20×155/175 Pin 20×155 8
17 000201213A0000003 Spring pin 16
18 000209023A1200001 Railing Ф33.7×3.2 4
19 000209023A1200002 Ladder plate t8 1
20 1040000216 GB/T5783-2000 Bolt M12×70-8.8 4
21 000209023A1200003 Splint t8 2
Connecting
22 000209036B0100002 t12 1
plate
23 000209023A1206000 Ladder blocker 1
24 1040000755 GB/T5783-2000 Bolt M16×140-8.8 2
25 1040500381 GB/T91-2000 Split pin 8×71 1
376
Outrigger
Fig. 7-38 000281815AT000000
377
Table 7-38 Spare parts list of Outrigger (WA350-20HA.15)

1 000241815AT000001 Connector 1
2 000200715B0000101 Reinforced rib plate A t20 7
3 000200715B0000102 Middle plate 1
4 000281815AT000010 Chord 1
5 000200715A0000104 Bottom plate t25- 500×500 1
6 000241815AT000002 Seal plate t6-Ф75 4
7 000281815AT000001 Pin 2
8 000200715B0000103 Reinforced rib plate B t20 1
(THE END)
Thanks for your reading!
378

Zoomlion Tower Crane Instrcution W450 25HC 138EN A01 220726

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Zoomlion Tower Crane Instrcution W450 25HC 138EN A01 220726

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W450-25HC Tower Crane

Part name Part intended for:

1 DOCUMENTS The crane operator

2 SAFETY INSTRUCTION Everybody

3 TECHNICAL DATA OF CRANE AND SITE Everybody

4 ERECTION/ADJUSTMENT/DISMANTLING The fitter

5 OPERATION AND CONTROL The crane driver

6 MAINTENANCE AND INSPECTION The maintenance technician

7 SPARE PARTS Everybody

Development of the technical instructions

Signaling of an important risk of body injuries and even mortal danger, if

Indicates the risk of equipment damage if the described instructions are

TOWER CRANE VOCABULARYS

Composition Diagram of the Tower Crane

(1) Foundation (2) Outrigger

STOPPING THE MOVEMENT

COMPULSORY SAFETY HARNESS

SM (2-fall rope reeving, used in 2-fall)

DM (4-fall rope reeving, used in 4-fall)

METRIC SYSTEM AND IMPERIAL SYSTEM

kilogram per pound per square 1 kg/m2 = 0,0014223

2. EQUALITY BETWEEN FREQUENTLY USED UNITS

1 centimeter (cm) = 10 millimeters (mm) = 0,3937008 inch (in)

1 decimeter (dm) = 10 centimeters (cm) = 3,937008 inches (in)

1 meter (m) = 10 dm = 100 cm = 1,0936133 yards (yd)

1 kilometer (km) = 1 000 meters (m) = 0,6213712 mile (mi)

Imperial system Metric system

1 inch (in) = 2,54 cm

1 foot (ft) = 12 inches (in) = 30,48 cm

1 yard (yd) = 3 feet (ft) = 36 inches (in) = 0,9144 m

1 mile (mi) = 1 760 yards (yd) = 1,609344 km

3.8 Foundation .................................................................................................................... 72

Circling the trolley ropes .................................................................................. 125

HuiChuan frequency converter ......................................................................... 196

Installation of the Rope ..................................................................................... 263

Hook ................................................................................................................. 334

Cranes with cabs:

Cranes with radio control:

Sound pressure level measured in the cab or on the ground:

1.2 Commissioning report

2.2 Safety instructions

Climatic and geographical conditions

b) Table for determination of crane operating conditions

c) Assembly, dismantling, change of configuration

e) Surface exposed to the wind of the load handled

B. Ambient air temperature measured under cover

This corresponds to the temperature measured within a non−closed shelter,

◼ Crane out of service: −25°C to +55°C:

In the case of planned temperatures out of the above range, it is

D. Frost, ice, or snow

It is strongly recommended to avoid using a crane when the latter is

Before restarting the crane, completely clean the electrical and

G. Flooding / tidal waves

Conditions relative to crane design

B. Crane power supply

Non−adherence to the values indicated can lead to malfunctioning of the

C. Driver control stand

Never modify safety device settings, nor hinder their functioning or

G. Nominal crane life duration

H. Nominal steel structure life duration

I. Nominal mechanism life duration

J. Mechanism working factor