L250 20 Manual PDF

TOWER CRANE
L250-20
Instruction Manual
Zoomlion Heavy Industry Science &Technology Co.,Ltd
Add:ON.667,Lugu Road ,ChangSha ,HuNan,P.R.CHINA 410205

Tel: 400-8877748 Fax: 0713-88788451
TOWER CRANE
L250-20
Data:
Editor
Approver:
Revision:
CUSTOMERS:
Thanks for your purchase and being one of the users of Zoomlion Tower Crane!
Go through the instrutions for correct operation and maintenance, and always
keep at hand for consultation.
Pay attention to the sentences marked with “Warning, Notice or Precautions ”
in this publication, which involves safety of constrution.
Ignore the instrutions could result in accidents and injuries!
Only through rigorous training and achieved qualified personnel to operate the
tower crane。
Must strictly implement the relevant instrutions, the relevant regulations and
directives (such as prevention of emergencies, etc.)
Zoomlion has been devoting every effort to the perfect of her products.
Therefore they are changed without notice. If you have any questions, please
don't hesitate to contact Zoomlion for further consultation.
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L250-20
contents
1 Security signs ....................................................................................................................................1
2 Main Parameters ................................................................................................................................4
2.1 Overall Dimensions of The Tower Crane ...................................................................................4
2.2 The Parked Position of Jib on Non-service Conditions..............................................................5
2.3 Radius and Load Capacity ..........................................................................................................8
2.4 Technical Performance Parameters for The Whole Machine ...................................................10
2.5 Technical Parameters of The Mechanisms ............................................................................... 11
3 Transport..........................................................................................................................................14
3.1 Notice during Transport ............................................................................................................14
3.2 Transport Unit ...........................................................................................................................15
4 Preparation ......................................................................................................................................18
4.1 Weight and Erection Dimensions of Main Components ..........................................................18
4.2 Foundation ................................................................................................................................20
4.2.1 Load on Foundation Of Crane With Outrigger ..................................................................20
4.2.2 The Foundation For Crane With Outrigger........................................................................28
4.2.3 Install the Embedded Anchors ...........................................................................................30
4.2.4 Earthing..............................................................................................................................34
4.3 Counter Ballast .........................................................................................................................34
4.3.1 Counter Ballast Configuration of Different Jib .................................................................34
4.3.2 Manufacture Counter Ballast .............................................................................................35
5 Erection and Dismantling ................................................................................................................51
5.1 Cautions ....................................................................................................................................51
5.2 Security Signs of Tower Crane .................................................................................................53
5.3 Components Weight and Height ...............................................................................................55
5.4 General Layout of Tower Crane ...............................................................................................57
5.4.1 Assembly Relation of Main Components for Stationary Crane with Embedded outrigger
....................................................................................................................................................57
5.5 Tower Erection .........................................................................................................................59
5.5.1 Steps of Tower Erection .....................................................................................................59
5.5.2 Install Mast Sections ..........................................................................................................60
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5.5.3 Install Climbing Frame ......................................................................................................68

5.5.4 Install the Slewing Ring Assembly ....................................................................................71
5.5.5 Install the Slewing Tower Mast .........................................................................................78
5.5.6 Install Operator Cab ...........................................................................................................80
5.5.7 Install Counter Jib Assembly .............................................................................................81
5.5.8 Install Hoisting Mechanism ...............................................................................................85
5.5.9 Install Luffing Mechanism ................................................................................................86
5.5.10 Install A-frame Assembly ................................................................................................87
5.5.11 Install Two Counter Ballast of 2.75t ................................................................................96
5.5.12 Install Jib Assembly .........................................................................................................98
5.5.13 Install Luffing Suspension ...............................................................................................98
5.5.14 Install Counter Ballast ...................................................................................................101
5.5.15 Wind Hoisting Wirerope, Install Hook ..........................................................................103
5.5.16 Power on and Trial Operation ........................................................................................105
5.5.17 Jacking Work of Crane with Outrigger ..........................................................................105
5.6 Internal Jacking of Tower Crane ............................................................................................ 118
5.6.1 Description of Internal Climbing Device ........................................................................ 118
5.6.2 Climbing of Internal Climbing Tower Crane ...................................................................124
5.7 Dismantling of crane ..............................................................................................................132
5.7.2 Basic formality of dismantling tower ..............................................................................132
5.7.3 Dismantle the tower body ................................................................................................135
5.7.4 Dismantle counter ballast. ...............................................................................................137
5.7.5 Dismantle hook ................................................................................................................138
5.7.6 The dismantling of luffing tie bar ....................................................................................138
5.7.7 Dismantle safety rope ......................................................................................................138
5.7.8 Dismantle jib....................................................................................................................139
5.7.9 The Dismantling of counter ballast of 2.75T ...................................................................139
5.7.11 Dismantle travel machine ..............................................................................................139
5.7.12 Dismantle hosting mechanism .......................................................................................139
5.7.13 Dismantle counter-jib assembly.....................................................................................139
5.7.14 Dismantle operator cab ..................................................................................................140
5.7.15 Dismantle slewing tower ...............................................................................................140
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5.7.16 Dismantle slewing support assembly.............................................................................140

5.7.17 Remove climbing frame ................................................................................................140
5.7.18 Remove tower sections ..................................................................................................140
5.7.19 Attentions after dismantling tower crane .......................................................................140
6 Mechanism ....................................................................................................................................141
6.1 hoisting mechanism ................................................................................................................141
6.1.1 Summarize .......................................................................................................................141
6.1.2 Technical parameters of Hoisting mechanism .................................................................142
6.1.3 Motor ...............................................................................................................................142
6.1.4 Brake ................................................................................................................................144
6.2 slewing mechanisms ...............................................................................................................156
6.3 Luffing mechanism .................................................................................................................157
6.3.1 summarize ........................................................................................................................157
6.3.2 performance parameters of luffing mechanism ...............................................................159
6.3.3 motor ................................................................................................................................159
6.3.4 break ................................................................................................................................161
6.3.5 SBD80-D safety brake .....................................................................................................174
6.4 Climbing Jack .........................................................................................................................185
6.4.1 Summarize .......................................................................................................................185
6.4.2 Erection and operation of the hydraulic system ...........................................................187
7 Operation .......................................................................................................................................189
7.1 Operation guide ......................................................................................................................189
7.1.1 Pre-check before operation ..............................................................................................189
7.1.2 Attention for operation ....................................................................................................190
7.1.3 Safety Operation ..............................................................................................................191
7.2 Adjusting working ..................................................................................................................192
7.2.1 Checking part and coponents before adjusting working..................................................192
7.2.2 Introduction of safety device ...........................................................................................192
7.2.3 Experiment .......................................................................................................................210
8 Electrical Control System..............................................................................................................213
9 Maintenance and Service ..............................................................................................................213
9.1 maintenance ............................................................................................................................213
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9.1.1 Daily maintenance ...........................................................................................................213

9.1.2 Week maintenance ...........................................................................................................214
9.1.3 Mmonth maintenance ......................................................................................................214
9.2 Ordinary troubles, troubleshooting and solution ....................................................................214
9.3 Assebmlly ...............................................................................................................................218
9.4 Buffer’s Maintenance and Service .........................................................................................220
9.4.1 Buffer’s structure .............................................................................................................220
9.4.2 Buffer’s Maintenance and Service ...................................................................................220
10 Wire rope ..................................................................................................................................221
10.1 steel rope basic knowledge ...................................................................................................221
10.2 Wire rope list ........................................................................................................................225
10.2.1 Hoist rope length............................................................................................................225
10.2.2 The trolley rope length...................................................................................................226
10.3 Installing the wire ropeadhere ..............................................................................................226
10.4 Discard criteria of wire rope .................................................................................................226
10.5 Maintenance of wire rope .....................................................................................................231
IV
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1 Security signs
WARNING: Live parts!

Electrical installation, connection work
and maintenance must be done only by
No standing under the radius
authorized, properly qualified personnel.
No ascending
Danger of rolling
Danger of falling down!

Wear and use a safety harness! Emergent stop
Very hot, do not touch! Danger of crushing!
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Insert pins while climbing the crane! Keep watch
WARNING: Suspended loads! Check ropes

Wear safety helmet!
Adjust the height limiter!

Lubricate!
Check metal structures! Check brakes!
Adjust brakes
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Keep safety devices workable!
Maximum load on maintenance cage

Always close the hatches!
Tie safety belt

Forbid to stand!
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2 Main Parameters
2.1 Overall Dimensions of The Tower Crane
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2.2 The Parked Position of Jib on Non-service Conditions
The parked position of jib must be controlled strictly so that the slewing mechanism of the
tower crane can slew free on non-service conditions.
Fig. 2.2-1 L250-20 the parked position of jib on non-service conditions

Notice：
（1）It is required that setting a windshield to increasing the frontal area of jib to insure that the
jib can slew free on non-service conditions when the length of the jib is 30-45m.
（2）Windshield is made by customers. Windshield and jib are better fastened by U bolts
(including one U M12 bolts, two flat washer, two spring washer and two M12 nuts.) Every chord
rods of the windshield must be drilled. Customers can also use other methods to fasten them based
on practical conditions. But the windshield must be fastness and the jib is not damaged。
（3）The windshield should be closed to the jib tip as shown in Fig. 2.2-2. The bolt-holes of
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windshield must be drilled when the windshield is fixed with the jib to make sure that the
windshield can be assembled easily.
1—windshield 2—U bolt 3—backer plate 4—M12 nuts 5—spring washer 6—flat washer
Fig.2.2-2 the fastening of windshield on 30m jib of tower crane
number name specification quantity material
1 windshield t2-2400×1500 1 Q235B
2 U bolt M12 6 Q235B
3 backer plate T5 6 Q235B
4 nut M12-8 12
5 washer 12 12
6 washer 12-200HV 12
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Fig, 2.2-3 working drawing of U bolts and backer plate
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2.3 Radius and Load Capacity
60m Jib’s Radius and Load Capacity

1-fall working radius
6.24 ～ 25.9 30 35 40 45 50 55 60
（m）
1-fall hoisting capacity
10.00 8.29 6.72 5.52 4.57 3.81 3.20 2.71
（t）

5.80 ～ 27.2 30 35 40 45 50 55
（m）
10.00 8.81 7.14 5.87 4.88 4.09 3.47
（t）

5.35 ～ 28.0 30 35 40 45 50
（m）
10.00 9.18 7.49 6.21 5.22 4.45
（t）
5.08 ～ 13.9 15 20 25 30 35 40 45 50
（m）
20.00 19.08 14.10 10.91 8.72 7.11 5.89 4.97 4.32
（t）

4.55 ～ 28.7 30 35 40 45
（m）
10.00 9.49 7.79 6.55 5.60
（t）
4.46 ～ 14.1 15 20 25 30 35 40 45
（m）
20.00 19.33 14.43 11.32 9.20 7.53 6.29 5.40
（t）
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4.48 ～ 28.9 30 35 40
（m）
10.00 9.60 8.01 6.85
（t）
4.21 ～ 14.6 15 20 25 30 35 40
（m）
20.00 19.85 14.81 11.63 9.45 7.89 6.78
（t）

4.34 ～ 28.8 30 35
（m）
10.00 9.58 8.15
（t）
4.07 ～ 15.20 15 20 25 30 35
（m）
20.00 20.00 15.15 11.86 9.63 8.10
（t）

3.58 ～ 29.3 30
（m）
10.00 9.75
（t）
3.30 ～ 16 15 20 25 30
（m）
20.00 20.00 15.46 11.88 9.55
（t）
Note: above radius and Load Capacity are based on 53.4m free-standing height. When the working
height of the tower crane has to be exceeded to 53.4m, the hoisting capacity in above tables must be
reduced. Computational method: the hoisting capacity of calculated height= the hoisting capacity in
tables- the weight of rope per meter× (calculated height- 53.4) ×fall. (Unit: Height: m; Weight: t)
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2.4 Technical Performance Parameters for The Whole Machine
Group classification A4
Hoisting M4
Slewing M5
Mechanism classification
Luffing M4
Travelling M3
Ratinghoistingmoment （kN.m）
Max hoisting moment （kN.m） 3200

Outrigger Stationary 53.4
Max working height (m) Anchored 500 (1fall)
Internal climbing 500 (1fall)
Min radius ≤3.3
Working radius（m）
Max radius 60.0
Max hoisting capacity 20(jib length 55m/60m, 10t)
Fall 1 2
Weight/(t) 2.5 5 10 5 10 20
Hoisting
Speed（m/min） 0～100 0～80 0～40 0～50 0～40 0～20
mechanism
Rope capacity (m) 75
Power (kW) 710
Luffing Max luffing 2.2

mechanis time(min)
m Power(kW) 45
Speed （r/min） 0～0.7

Slewing
Power （kW） 2×145N.m (RCV)
mechanism
Slewing ring QWA1800.50
Counter Max radius （m） 60 55 50 45 40 35 30

ballast Weight 25.5 23.5 23.5 22.5 21.5 19.5 17.5
Design wind speed at the top of 安装状态 Erection condition 14

tower crane（m/s）工作状态 In service 20
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Out of service condition EN14439 C25
Allowable temperature in
-20～+40
service （℃）
Power ～380V/50Hz
2.5 Technical Parameters of The Mechanisms
Model Unit QPL20100A
Max traction of the rope N 108000
Specification DIEPAB55-24-1960
Wire rope
Maximum linear speed m/min 100
Hoisting Mechanism
起升机构
Maximum Drum speed r/min 29.3

Drum
Rope capacity m 710
Model YZPFM315S-8
Motor Power kW 75
Speed r/min 735
Ratio of Reduction Gears 62.929
Braking Moment N.m 1800
Model 单位 BPL450
Maximum traction of the rope N 100000
6×29Fi+1WR-20-1770 或
Specification
6×31WS+1WR-20-1770
Luffing Mechanism
变幅机构
Wire Rope
Maximum linear speed m/min 54.7
Rpm rating r/min 20.7
Drum Speed Twist Layers Layer 3
Rope capacity m 190
Model YZPFM280S2-8
Motor
Power kW 45
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Speed r/min 735
Ratio of Reduction Gears 35.461
Braking moment N. m 1250
Model HVV145B1.130A×1
Mechanism Ⅰ
Luffing Model YTLEJ132L-145-4B1
Motor Power N·m 145
Speed r/min 10-1250
Model Unit HVV145B2.130A×1

Mechanism Ⅱ
YTLEJ132L-145-4B2
Luffing
Model
Luffing Mechanism
Motor Power N·m 145
Speed r/min 10-1250
Model XX5-130.195CLC-14/12
Rreduction
Gear Ratio i 195
Modulus mm 14
Gear parameter
Number of teethz 12
at output end
Profile shift coefficient +0.5
Overall Gear Ratio 2356.25
Slewing Speed r/min 0.53
Power kW 7.5
Motor
Speed r/min 1440
Internal climbing Mechanism
Flow l/min 14.5

Hydraulic
pump MPa
工作压力 Working pressure 31.5
Cylinder /rod diameter mm 200/140

Journey mm 2000
Double Jacking Maximum jacking force t 98.9
Cylinder
Jacking Speed m/min
0.45
Mechan
Jacking
Power kW 7.5
ism
Motor
Speed r/min 1440
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Flow l/min 14.5

Hydraulic
pump Working pressure MPa 31.5
Cylinder /rod diameter mm 200/140
Jacking Journey mm 2000

Cylinder Maximum jacking force t 98.9
Jacking Speed m/min 0.46
Slewing Ring Diameter mm 1800
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3 Transport
3.1 Notice during Transport
The components of tower crane are dismantled into several modules to simplify packing and
handling for different means of transportation.
(1) All components must be safe-reliable in the transportaton process
(2) Lighter components must be on the top of the heavier ones.
(3) Every components must be separated from other metals by wood or other packing to avoid
damaging of the painted surfaces
(4) It is prohibited to directly put components on ground.
(5) It is not allowed to transport components by unsuitable transportation, such as bulldozer
and lift-ladder.
(6) Make sure that all components are loaded and auxiliary devices are safe-reliable.
(7) Check all the bandings of components.
(8) Check all the bandings of transportation.
(9) While running in public streets, observe the applicable rules.
(10) Pay attention to the space ,while passing underground passage, bridge and tunnels
(11) Temperature during transport:-25~55℃.
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3.2 Transport Unit
No. Name Dimensions L(m) B(m) H(m) Weight Quantity
1 JibⅠ 10.645 1.76 1.56 2.33 1
2 10.23 1.76 1.56 1.27 1

JibⅡ
3 Jib Ⅳ 10.23 1.76 1.56 1.13 1
4 Jib Ⅴ 10.23 1.76 1.56 1.04 1
5 5.22 1.76 1.56 0.59 1

Jib Ⅵ
6 Jib Ⅶ 5.22 1.76 1.56 0.61 1
7 Jib Ⅷ 10.85 1.76 1.56 1.71 1
Frontal-up
strut and
5 top-end 1.979 0.754 2.45 0.736 1
pulley
assembly
Frontal-down
6 strut 11.5 1.945 0.5 2.125 1
(A-frame)
Buffer
7 3.605 1.890 0.316 0.410 1
(A-frame)
Diagonal
8 strut 5.755 0.155 0.240 0.220 2
(A-frame)
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Back strut
9 11.015 1.805 0.366 0.905 1
(A-frame)
Slewing
11 1.995 1.8 2.04 1.2 1
tower body
Operating
12 4.424 2.222 2.20 0.80 1
platform
Climbing
13 9.71 2.764 3.1 4.937 1
frame
Introduction
14 2.6 2.55 0.38 401.6 1
platform
15 Jack beam 2.09 0.24 1.35 0.531 1
Inner Base
16 4.015 2.343 2.283 5.058 1
tower section
Inner
17 Tower 4.015 2.343 2.283 2.976 12
section
Luffing
18 2.632 1.685 1.52 3.03 1
mechanism
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Hoisting
19 3.796 1.772 2.37 7.216 1
mechanism
Luffing
20 1.14 0.61 0.575 0.12 1
pulley
assembly
21 Counter jib 8.12 1.98 0.86 3.873 1
Lower strut
22 4.20 1.83 0.275 0.657 1
of counter jib
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4 Preparation
4.1 Weight and Erection Dimensions of Main Components
L W H Weigh quanti
Name Dimensions
mm mm mm t（t） ty
Embedded
500 500 2215 406 4
Anchor
Base section 234c3 2283 4015 5057 1
Tower section 2343 2298 4015 2976 11
Climbing ladder 4330 593 971 6545 1
Slewing tower
1.8 1.9 2.04 1.319 1
mast
Counter jib 8200 4000 4000 5.75 1
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L W H Weigh quanti
Name Dimensions
mm mm mm t（t） ty
Luffing
2632 1685 1520 3.03 1
mechanism
Hoisting
3.796 1.772 2.37 7.12 1
mechanism
A-frame 7655 3255 11850 5106 1
Jib 61510 1730 1589 8830 1
Jib tie plate 1400 160 185 45 1
Jib tie bar Φ45×5000 －－－ 0.11 7
Jib tie bar Φ45×2500 －－－ 0.061 1
Luffing pulley
1140 610 575 120 1
assembly
Hoisting beam 2090 240 1350 531 1
Punp station 450 660 1010 0.264 1
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4.2 Foundation
Check the load capacity of subgrade before casting foundation. Design foundation
according the erection height.
Anchors on foundation must conform to the next characteristics:
(1) The anchors must be symmetrical to the centerline of foundation to be a 2m×2m square.
(2) The installed anchor must meet the demand of next figure.
(3) It is allowed that the anchors are used one time.
(4) Earthing correctly.
4.2.1 Load on Foundation Of Crane With Outrigger
Fig.4.2-1 load on foundation
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(1) 60m jib

Table.4.2-1 load on foundation for 60m jib
Horizontal Vertical
Number of Moment Torsion
height (m) operation status force force
sections
M(kN·m) H(kN) V(kN) T(kN·m)
In service 3010.1 21.4 968.0 615
6 27.15 Out of service 2048.6 102.8 897.5 0
Front wind-O.O.S -3216.6 -71.9 897.5 0
In service 3120.7 23.0 996.0 615
7 30.90 Out of service 2480.8 109.2 925.5 0
Front wind-O.O.S -3521.3 -76.3 925.5 0
In service 3243.2 24.6 1024.0 615
8 34.65 Out of service 2950.3 115.8 953.5 0
Front wind-O.O.S -3850.3 -80.8 953.5 0
In service 3378.6 26.1 1052.0 615
9 38.40 Out of service 3459.9 122.6 981.5 0
Front wind-O.O.S -4205.3 -85.3 981.5 0
In service 3527.6 27.7 1080.0 615
10 42.15 Out of service 4012.7 129.6 1009.5 0
Front wind-O.O.S -4588.0 -89.8 1009.5 0
In service 3691.6 29.3 1108.0 615
11 45.90 Out of service 4612.4 136.7 1037.5 0
Front wind-O.O.S -5000.3 -94.2 1037.5 0
In service 3871.9 30.9 1136.0 615
12 49.65 Out of service 5263.1 143.9 1065.5 0
Front wind-O.O.S -5444.8 -98.7 1065.5 0
In service 4070.0 32.4 1164.0 615
13 53.40 Out of service 5969.5 151.3 1093.5 0
Front wind-O.O.S -5924.2 -103.2 1093.5 0
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(2) 55m jib

Horizontal Vertical
sections
In service 3114.0 21.7 950.5 615
6 27.15 Out of service 1912.6 100.5 872.0 0
Front wind-O.O.S -3054.8 -70.4 872.0 0
In service 3226.0 23.3 978.5 615
7 30.90 Out of service 2334.5 106.9 900.0 0
Front wind-O.O.S -3351.7 -74.9 900.0 0
In service 3350.1 24.9 1006.5 615
8 34.65 Out of service 2793.2 113.5 928.0 0
Front wind-O.O.S -3672.4 -79.3 928.0 0
In service 3487.0 26.4 1034.5 615
9 38.40 Out of service 3291.2 120.3 956.0 0
Front wind-O.O.S -4018.4 -83.8 956.0 0
In service 3637.8 28.0 1062.5 615
10 42.15 Out of service 3831.8 127.3 984.0 0
Front wind-O.O.S -4391.2 -88.3 984.0 0
In service 3803.5 29.6 1090.5 615
11 45.90 Out of service 4418.3 134.4 1012.0 0
Front wind-O.O.S -4792.9 -92.7 1012.0 0
In service 3985.5 31.2 1118.5 615
12 49.65 Out of service 5054.5 141.7 1040.0 0
Front wind-O.O.S -5225.6 -97.2 1040.0 0
In service 4185.5 32.7 1146.5 615
13 53.40 Out of service 5745.2 149.1 1068.0 0
Front wind-O.O.S -5692.1 -101.7 1068.0 0
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(3) 50m jib

Horizontal Vertical
sections
In service 3212.6 21.5 946.7 615
6 27.15 Out of service 1788.0 98.1 858.2 0
Front wind-O.O.S -2825.9 -68.8 858.2 0
In service 3324.7 23.1 974.7 615
7 30.90 Out of service 2199.5 104.5 886.2 0
Front wind-O.O.S -3114.5 -73.3 886.2 0
In service 3448.9 24.7 1002.7 615
8 34.65 Out of service 2647.4 111.1 914.2 0
Front wind-O.O.S -3426.5 -77.7 914.2 0
In service 3586.1 26.2 1030.7 615
9 38.40 Out of service 3134.2 117.9 942.2 0
Front wind-O.O.S -3763.1 -82.2 942.2 0
In service 3737.3 27.8 1058.7 615
10 42.15 Out of service 3662.8 124.8 970.2 0
Front wind-O.O.S -4125.9 -86.7 970.2 0
In service 3903.6 29.4 1086.7 615
11 45.90 Out of service 4236.7 132.0 998.2 0
Front wind-O.O.S -4516.7 -91.2 998.2 0
In service 4086.4 31.0 1114.7 615
12 49.65 Out of service 4859.6 139.2 1026.2 0
Front wind-O.O.S -4937.6 -95.6 1026.2 0
In service 4287.4 32.5 1142.7 615
13 53.40 Out of service 5535.9 146.6 1054.2 0
Front wind-O.O.S -5391.2 -100.1 1054.2 0
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(4) 45 m jib
Horizontal Vertical
sections
In service 3131.1 21.2 952.8 615
6 27.15 Out of service 1387.1 95.8 851.6 0
Front wind-O.O.S -2975.9 -67.3 851.6 0
In service 3241.5 22.8 980.8 615
7 30.90 Out of service 1787.0 102.3 879.6 0
Front wind-O.O.S -3260.0 -71.8 879.6 0
In service 3364.1 24.4 1008.8 615
8 34.65 Out of service 2222.5 108.9 907.6 0
Front wind-O.O.S -3567.6 -76.3 907.6 0
In service 3499.5 26.0 1036.8 615
9 38.40 Out of service 2696.0 115.7 935.6 0
Front wind-O.O.S -3900.0 -80.8 935.6 0
In service 3648.7 27.5 1064.8 615
10 42.15 Out of service 3210.5 122.6 963.6 0
Front wind-O.O.S -4258.7 -85.2 963.6 0
In service 3812.9 29.1 1092.8 615
11 45.90 Out of service 3769.2 129.7 991.6 0
Front wind-O.O.S -4645.4 -89.7 991.6 0
In service 3993.5 30.7 1120.8 615
12 49.65 Out of service 4375.6 137.0 1019.6 0
Front wind-O.O.S -5062.3 -94.2 1019.6 0
In service 4192.0 32.3 1148.8 615
13 53.40 Out of service 5034.0 144.4 1047.6 0
Front wind-O.O.S -5511.9 -98.7 1047.6 0
24
L250-20
(5) 40 m jib
Horizontal Vertical
sections
In service 3196.0 21.0 952.5 615
6 27.15 Out of service 1178.1 93.0 835.1 0
Front wind-O.O.S -2858.2 -65.5 835.1 0
In service 3306.1 22.6 980.5 615
7 30.90 Out of service 1565.3 99.4 863.1 0
Front wind-O.O.S -3133.9 -69.9 863.1 0
In service 3428.3 24.1 1008.5 615
8 34.65 Out of service 1987.5 106.0 891.1 0
Front wind-O.O.S -3432.6 -74.4 891.1 0
In service 3563.5 25.7 1036.5 615
9 38.40 Out of service 2447.2 112.8 919.1 0
Front wind-O.O.S -3755.6 -78.9 919.1 0
In service 3712.7 27.3 1064.5 615
10 42.15 Out of service 2947.1 119.7 947.1 0
Front wind-O.O.S -4104.4 -83.4 947.1 0
In service 3877.0 28.9 1092.5 615
11 45.90 Out of service 3490.2 126.9 975.1 0
Front wind-O.O.S -4480.6 -87.8 975.1 0
In service 4057.8 30.4 1120.5 615
12 49.65 Out of service 4080.1 134.1 1003.1 0
Front wind-O.O.S -4886.3 -92.3 1003.1 0
In service 4256.6 32.0 1148.5 615
13 53.40 Out of service 4720.6 141.5 1031.1 0
Front wind-O.O.S -5323.8 -96.8 1031.1 0
25
L250-20
(6) 35 m jib
Horizontal Vertical
sections
In service 3144.5 20.6 940.6 615
6 27.15 Out of service 989.0 89.9 808.4 0
Front wind-O.O.S -2764.3 -63.5 808.4 0
In service 3252.4 22.2 968.6 615
7 30.90 Out of service 1363.0 96.3 836.4 0
Front wind-O.O.S -3031.0 -68.0 836.4 0
In service 3372.3 23.8 996.6 615
8 34.65 Out of service 1771.5 102.9 864.4 0
Front wind-O.O.S -3320.4 -72.4 864.4 0
In service 3505.0 25.4 1024.6 615
9 38.40 Out of service 2216.7 109.7 892.4 0
Front wind-O.O.S -3633.5 -76.9 892.4 0
In service 3651.4 26.9 1052.6 615
10 42.15 Out of service 2701.4 116.7 920.4 0
Front wind-O.O.S -3971.8 -81.4 920.4 0
In service 3812.5 28.5 1080.6 615
11 45.90 Out of service 3228.3 123.8 948.4 0
Front wind-O.O.S -4336.7 -85.8 948.4 0
In service 3989.8 30.1 1108.6 615
12 49.65 Out of service 3800.7 131.1 976.4 0
Front wind-O.O.S -4730.3 -90.3 976.4 0
In service 4184.8 31.7 1136.6 615
13 53.40 Out of service 4422.5 138.5 1004.4 0
Front wind-O.O.S -5154.7 -94.8 1004.4 0
26
L250-20
(7) 30 m jib
Horizontal Vertical
sections
In service 3017.6 20.3 930.4 615
6 27.15 Out of service 836.7 86.4 781.9 0
Front wind-O.O.S -2613.4 -61.2 781.9 0
In service 3122.7 21.9 958.4 615
7 30.90 Out of service 1196.2 92.8 809.9 0
Front wind-O.O.S -2869.7 -65.7 809.9 0
In service 3239.6 23.4 986.4 615
8 34.65 Out of service 1589.6 99.4 837.9 0
Front wind-O.O.S -3148.1 -70.1 837.9 0
In service 3368.9 25.0 1014.4 615
9 38.40 Out of service 2019.2 106.2 865.9 0
Front wind-O.O.S -3449.8 -74.6 865.9 0
In service 3511.5 26.6 1042.4 615
10 42.15 Out of service 2487.5 113.2 893.9 0
Front wind-O.O.S -3775.8 -79.1 893.9 0
In service 3668.5 28.2 1070.4 615
11 45.90 Out of service 2997.1 120.3 921.9 0
Front wind-O.O.S -4127.8 -83.6 921.9 0
In service 3841.1 29.7 1098.4 615
12 49.65 Out of service 3551.2 127.6 949.9 0
Front wind-O.O.S -4507.4 -88.0 949.9 0
In service 4030.9 31.3 1126.4 615
13 53.40 Out of service 4153.3 135.0 977.9 0
Front wind-O.O.S -4916.7 -92.5 977.9 0
27
L250-20
4.2.2 The Foundation For Crane With Outrigger
The ground foundation is the precondition to ensure safe operation of the crane. It is made of
reinforced concrete as shown in Fig.4.2-2. Basic requirements as follows:
(1) The ground under the foundation should be solid. The concrete strength grade must be no
less than C35. The foundation load-bearing capacity must be no less than 0.2Mpa.
(2) The dimension of concrete foundation is L mm×L mm. And ti’s height is 2000mm
28
L250-20
Fig.4.2-2 L250-20 ground foundation
29
L250-20
4.2.3 Install the Embedded Anchors
Fasten 4 anchors and the base section together by 8 pivots( φ 60 ); knock the pivots down until
its shoulder tightly contact with the surface of chord rod. Place anti-rotation sleeves on pivots
before inserting tiny pins and spring pins (Fig.1.2-4, Detail A)
(1) According to the construction convenience and the progress of binding rebar, hoist the
whole piece of anchors assembled with the base section into rebar net.
Notice:
 The two areas with climbing lug of tower section must be perpendicular to building.
 Be sure that the number of re-bars around anchors must not be reduced and re-bars
must not be cut off.
The climbing ladder fit to the hatch (the hatch is on my right side when stand on
slewing support facing to direct of jib erection) according to the certain direction for the
section climbing system let-in.
 Pour concrete after rebars binded.
Notice:
 The concrete strength grade must be no less than C35.
 Hang plumb lines along the center of reinforced tower section to calibrate the
perpendicularity of the centerline of reinforced tower section to horizontal plane.
 Ensure that the perpendicularity of the embedded base section centerline to
horizontal plane is less than 1/1000 after foundation completed; The planeness of the
section between four anchor and reinforced tower section is no more than 2mm.
 The rate of concrete filling around the embedded anchors must be over 95%.
30
L250-20
Fig.4.2-3 Install the embedded Anchors
31
L250-20
4.2.3.1 Assemble the First Base section ( include platform, handrail, climbing
ladder and hoop guard)

In TW250-20, there is only one base tower section including nameplate, power box, platform,
pivots and bolts. The assembly drawing is Fig.4.2-4. The spare part needed are shown in table4.2-5
(notice: pivots are used to connect anchors).
Fig.4.2-4 install base tower section
32
L250-20
Table4.2-5 reinforced tower section spare part list
Number Code Designation Designation Unit Qty
1 Base section structure 1

2 Support t8 1
3 Short Ladder 1
4 Long Ladder 1
5 Platform 1
6 Platform Ⅰ 1
7 Flex girder 4
8 Splint t8 2
9 GB/T97.1-2002 Washer 12-200HV 4
10 GB/T5783-2000 Bolt M12×60-8.8 4
11 GB/T93-1987 Washer 12 6
12 GB/T6170-2000 Nut M12-8 6
13 GB/T5783-2000 Bolt M16×90-8.8 2
14 GB/T97.1-2002 Washer 16-200HV 6
15 GB/T93-1987 Washer 16 6
16 GB/T6170-2000 Nut M16-8 6
17 GB/T5783-2000 Bolt M16×70-8.8 4
18 GB/T5783-2000 Bolt M10×35-8.8 8
19 GB/T96.1-2002 Washer 10-200HV 8
20 GB/T93-1987 Washer 10 8
21 GB/T6170-2000 Nut M10-8 8
22 Bolt 16
23 Pin Roll 8
24 Pin Roll 8
25 Axle Sleeve 8
26 GB/T5783-2000 Bolt M6×16-8.8 4
27 GB/T97.1-2002 Washer 6-200HV 4
28 GB/T93-1987 Washer 6 4
29 GB/T6170-2000 Nut M6-8 4
30 GB/T5783-2000 Bolt M8×30-8.8 4
31 GB/T97.1-2002 Washer 8-200HV 4
32 GB/T93-1987 Washer 8 4
33 GB/T6170-2000 Washer M8-8 4
33
L250-20
Thus the base tower section is installed.
4.2.4 Earthing
(1) Before operating tower crane, operator should consider protecting tower crane from lightning.
Take measures as shown in Fig.4.2-5 when needed.
(2) Lightning is necessary or not according to the rules of the authorities concerned.
Fig.4.2-5 protective earthing

Notice:earth line should not be connected to the rebars of building
foundation.
4.3 Counter Ballast
4.3.1 Counter Ballast Configuration of Different Jib
（1）Summary
Counter ballast consists of several reinforced concrete blocks. Different counter ballast should
be used for jib with different length.
（2）Counter ballast
34
L250-20
Table4.3-1 Counter ballast
Gross
Counter
PHZ4000A PHZ4000 PHZ2750 PHZ3000 PHZ2000 weight（t）
ballast
jib
60m jib 1 2 2 2 1 25.5
55m jib 1 2 2 2 0 23.5
50m jib 1 2 2 2 0 23.5
45m jib 1 2 2 1 1 22.5
40m jib 1 1 2 2 1 21.5
35m jib 1 2 2 0 1 19.5
30m jib 1 2 2 0 0 17.5
4.3.2 Manufacture Counter Ballast
（1）Summary
Counter ballasts are manufactured by customers.
Counter ballast shouldn’t be damaged during transport, erection and in use.
（2）Dimensions of Counter Ballast
There are 5 counter ballasts, all of which are cast with reinforced concrete. For detailed
specification, refer to Fig.4-6a, Fig.4-7a ， Fig.4-8a, Fig.4-9a and Fig.4-10a.respectively, for
reinforced bar layout, see Fig.4-6b, Fig.4-7b, Fig.4-8b, Fig.4-9b and Fig.4-10b, for dimensions of
reinforced bar spare part refer to Fig.4-6c，Fig.4-7c, Fig.4-8c, Fig.4-9c and Fig.4-10c. for spare
parts of counter ballast are listed in table4-7, table4-8, table4-9, table4-10 and table4-11.
It is advised to weigh every counter ballast block manufactured and engrave the weight
permanently on the surface, with permitted weight tolerance of ±1％and concrete grade no less than
C20
The dimensions can be changed according to the density (average density) of concrete for the
tolerance. The density will change with the change of distribution of reinforced bar in counter
ballast.
35
L250-20
Notice:
In this manual, the size of ballast for this crane is so designed that the concrete density is
based on the theoretical value of 2400 kg/m3
Customers can also design counter ballast by themselves. Make sure the width and
thickness and dimensions of counter ballast is right to hange , you can adjust the length to
appropriate value.
Fig.4-6a Reinforced bar layout of PHZ2000 counter ballast
36
L250-20
Fig.4-6b Reinforced bar spare part of PHZ2000 counter ballast
Fig.4-6c Dimensions at the edge of reinforced bar spare part of PHZ2000 counter ballast
37
L250-20
Fig.4-6d coaming box B

Table4-7 Spare part list of PHZ2000 counter ballast
No. Name Quantity Specification/ Material Remarks
1 steel reinforcementⅠ 10 Φ10/Ⅰgrade Fig.4-6b
2 steel reinforcementⅡ 12 Φ12/Ⅰgrade Fig.4-6b
3 steel reinforcemenⅢ 6 Φ10/Ⅰgrade Fig.4-6b
4 steel reinforcementⅣ 2 Φ10-1562/Ⅰgrade No drawing
5 Ⅴsteel reinforcementⅤ 16 Φ10/Ⅰgrade Fig.4-6b
6 round steel 4 Φ40-480/ Q235B
7 steel reinforcementⅥ 4 Φ10/Ⅰgrade Fig.4-6b
8 reinforced concrete 1 No drawing
9 angle steel a 4 L30×4/ Q235B Fig.4-6c
10 angle steel c 2 L30×4-1562/ Q235B No drawing
11 angle steel 4 t4/ Q235B Fig.4-6c
12 angle steel f 4 L30×4/ Q235B Fig.4-6c
13 angle steel g 4 L30×4/ Q235B Fig.4-6c
14 angle steel h 4 L30×4 / Q235B Fig.4-6c
38
L250-20
No. Name Quantity Specification/ Material Remarks
15 angle steel i 2 L30×4-1300/ Q235B No drawing
16 B coaming box B 4 weldment Fig.4-6d
Fig.4-7a Reinforced bar layout of PHZ3000 counter ballast
Fig.4-7b Reinforced bar spare part of PHZ3000 counter ballast
39
L250-20
Fig.4-7c Dimensions at the edge of reinforced bar spare part of PHZ3000 counter ballast
Fig.4-7d coaming box B

Table4-8 spare part list of PHZ1000 counter ballast
40
L250-20
No. Name Quantity Specification/material Remarks
3 steel reinforcementⅢ 6 Φ10/Ⅰgrade Fig.4-7b
5 steel reinforcementⅤ 16 Φ10/Ⅰgrade Fig.4-7b
6 Round steel 4 Φ40-600/ Q235B
8 steel reinforcementⅦ 2 Φ10/Ⅰgrade Fig.4-7b
9 steel reinforcementⅧ 1 Φ10/Ⅰgrade Fig.4-7b
10 concrete 1 No drawing
11 Angle steel a 4 L30×4-111/ Q235B No drawing

Fig.4-7c, 4 piece,
12 Angle steel b 4 L30×4/ Q235B
2 symmetrical
13 Angle steel c 4 L30×4-1298/ Q235B No drawing
14 Angle steel board A 2 t4/ Q235B Fig.4-7c
15 Angle steel e 2 L30×4-198/ Q235B No drawing
16 Angle steel f 4 L30×4/ Q235B Fig.4-7c
17 Angle steel g 2 L30×4-857/ Q235B No drawing
18 Angle steel h 2 L30×4-648/ Q235B No drawing

Fig.4-7c, 4 piece,
19 Angle steel i 4 L30×4/ Q235B
2 symmetrical
Fig.4-7c, 4 piece,
20 Angle steel j 4 L30×4/ Q235B
2 symmetrical
21 Angle steel k 2 L30×4-411/ Q235B No drawing
22 Angle steel l 2 L30×4-1094/ Q235B No drawing
23 B Coaming box 4 weldment Fig.4-7d
41
L250-20
Fig.4-8a reinforced bar layout of PHZ3000 counter ballast
Fig.4-8b reinforced bar spare part of PHZ4000 counter ballast
42
L250-20
Fig.4-8c dimensions at the edge of reinforced bar spare part of PHZ4000 counter ballast
NO. Name Quantity Specification/material Remarks
8 steel reinforcementⅦ 2 Φ10/Ⅰgrade Fig.4-8b
10 concrete 1 No drawing
11 angle steel a 4 L30×4-111/ Q235B No drawing

Fig.4-8c, 4 piece,
12 angle steel b 4 L30×4/ Q235B
2 symmetrical
43
L250-20
NO. Name Quantity Specification/material Remarks
14 angle steel block B 2 t4/ Q235B Fig.4-8c
15 angle steel e 2 L30×4-288/ Q235B No drawing
17 angle steel g 2 L30×4-857/ Q235B No drawing
18 angle steel h 2 L30×4-648/ Q235B No drawing

Fig.4-8c, 4 piece,
19 angle steel i 4 L30×4/ Q235B
2 symmetrical
Fig.4-8c, 4 piece,
20 angle steel j 4 L30×4/ Q235B
2 symmetrical
21 angle steel k 2 L30×4-411/ Q235B No drawing
22 angle steel l 2 L30×4-1094/ Q235B No drawing
23 coaming box B 4 weldment Fig.4-8d
Fig.4-9a reinforced bar layout of PHZ4000 counter ballast
44
L250-20
Fig.4-9b reinforced bar spare part of PHZ4000 counter ballast
Table4-10 spare part list of PHZ4000A counter ballast
No. Name Quantity Specification/Material Remarks
45
L250-20
No. Name Quantity Specification/Material Remarks
8 steel reinforcementⅦ 2
10 Reinforced concrete 1 No drawing
11 angle steel a 4 L30×4-111/ Q235B No drawing
Fig.4-9c, 4 piece,
12 angle steel b 4 L30×4/ Q235B
2 symmetrical
14 angle steel block B 2 t4/ Q235B Fig.4-9c
15 angle steel e 2 L30×4-288/ Q235B No drawing
17 angle steel g 2 L30×4-857/ Q235B No drawing
18 angle steel h 2 L30×4-373/ Q235B No drawing
piece, 2
19 angle steel i 4 L30×4/ Q235B
symmetrical
Fig.4-9c, 4 piece,
20 angle steel j 4 L30×4/ Q235B
2 symmetrical
21 angle steel k 2 L30×4-411/ Q235B No drawing
22 angle steel l 2 L30×4-1094/ Q235B No drawing
23 angle steel m 2 L30×4-1848/ Q235B No drawing
24 coaming box B 4 weldment Fig.4-7d
46
L250-20
Fig.4-10a PHZ2750 counter ballast
reinforced bar spare part of PHZ1000 counter ballast
47
L250-20
Fig.4-10d coaming box C

48
L250-20
No. Name Quantity Material Remarks
2 tube axle 1 Fig.4-11
3 stationary plate 2 t8/ Q235A Fig.4-10b
6 steel reinforcementⅣ 12 Φ10/Ⅰgrade Fig.4-10b
9 reinforced concrete 1 No drawing
10 angle steel Ⅰ 2 L30×4/ Q235B Fig.4-10c
11 angle steel Ⅱ 2 L30×4-532/ Q235B No drawing
12 angle steel Ⅲ 2 L30×4/ Q235B Fig.4-10c

angle steel Ⅳ 4 L30×4-1285/
13 No drawing
Q235B
14 angle steel Ⅴ 2 L30×4/ Q235B Fig.4-10c
15 angle steel Ⅵ 4 L30×4-518/ Q235B No drawing
16 coaming box C 4 weldment Fig.4-10d
49
L250-20
Fig.4-11 tube axle
50
L250-20
5 Erection and Dismantling
5.1 Cautions
(1) The maximum wind speed atop (the highest crane point) should be less than 12m/s during
crane erecting.
(2) Strictly follow the procedures of tower crane erecting.
(3) Properly select the hook point. Select the hoisting equipment with proper length and reliable
quality to suit the components to be hoisted .
(4) The dismountabel pins, connecting bolts and nuts for the slewing rings and mast sections of the
tower crane are specially-made componets, which shall not be replace freely
(5) Safty measures, such as ladders platform and grad rails should be installed for safe operation.
(6) After jib installation, it is prohibited to hoist any load before placing specified counter-weight
on the counter-jib.
(7) At the erection position of the tower crane, it must be no less than 1.5m distance between the
widest slewing part of the crane and around buildings, and the safe distance between any parts
of the crane and overhead power lines shall comply with the stipulations as shown in the next
table .
Voltage(kV)
Safe distance
＜1 1~15 20~40 60~110 200
(m)
Vertically 1.5 3.0 4.0 5.0 6.0

Horizontally 1.0 1.5 2.0 4.0 6.0
(8) Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be
provided before hand.
(9) Drive the trolley to the balance position before jacking. Slew the jib to the right front of the
in-let beam and then lock the slewing of tower crane by slewing brake.
(10) No slewing of the jib and no up and down movements of the hoist hook during jacking
operation. No operating luffing mechanism and changing the position of jib.
(11) Do not slew tower crane before having screwed slewing support and tower mast together by 8
pivots.
(12) There must be aspecially-assigned person to command erection and dismantling.
51
L250-20
(13) Erection and dismantling must be under the command of commander.
(14) Commander should keep detailed record of erection and dismantling including weather and
other environmental factors.
52
L250-20
5.2 Security Signs of Tower Crane
Security signs of L250-20 tower crane are shown in Fig.5.2-1a and Fig.5.2-1B. The meanings
of each sign are shown in “1 Security signs”.
Fig.5.2-1a Security signs of L250-20tower crane
53
L250-20
part sectioned view
Fig.5.2-1b Security signs of L250-20 tower crane
54
L250-20
5.3 Components Weight and Height
Internal
Weight outrigger
No. Name climbing
(kg) h(m)
h(m)
1
Base section 2533 4.01
2 Internal base section 4015 3.75
3 Internal section 2976 3.75
4 Standard section 2440 12.37
5 Climbing frame 8397 22.07 22.07

Turntable,slewing
6 support and slewing 7800 15.1 15.1
ring
7 Slewing mas 1319 16.9 16.9
8 operator cab 1.5 17.1 17.1
9 counter jib assembly 5747 20.4 20.4
10 A-frame assembly 6142 29.7 29.7

1st and 2nd counter
11 2750/2750 29.6 29.6
ballast
12a 60m jib 8814 19 19
12b 55m jib 8222 19 19
12c 50m jib 7809 19 19
12d 45m jib 7040 19 19
12e 40m jib 6507 19 19
12f 35m jib 5915 19 19
12g 30m jib 5306 19 19

2000×1+3000×2+
Counter ballast for
13a 4000×2+4000A× 29.6 29.6
60m jib
2+2750×2
3000×2+4000×2+
Counter ballast for
13b 4000A×1+2750× 29.6 29.6
55m jib
2
3000×2+4000×2+
Counter ballast for
13c 4000A×1+2750× 29.6 29.6
50m jib
2
2000×1+3000×1+
Counter ballast for
13d 4000×2+4000A× 29.6 29.6
45m jib
1+2750×2
2000×1+3000×2+
Counter ballast for
13e 4000×1+4000A× 29.6 29.6
40m jib
1+2750×2
55
L250-20
2000×1+4000×2+
Counter ballast for
13f 4000A×1+2750× 29.6 29.6
35m jib
2
Counter ballast for 4000×2+4000A×
13g 29.6 29.6
30m jib 1+2750×2
56
L250-20
5.4 General Layout of Tower Crane
5.4.1 Assembly Relation of Main Components for Stationary Crane with

Embedded outrigger
As is shown in Fig.5.4-1, the free-standing height( to jib foot) of L250-20tower crane with
Embedded outrigger is 53.4m, while the max radius is 60m, and the max hoisting capacity is 20t.
2-fall or 4-fall ropes may be used for hoisting purpose. Internal climbing base tower section
and internal climbing tower sections are integrated structures. The tower sections(reinforced tower
section) are slice structures and the climbing frame is integrated structure. The lower base
section( or internal climbing base section) is connected to the foundation. The upper tower section
is connected to the turntable through slewing support and slewing ring. The operator cab is set at the
left front side of the turntable with the jib in front and counter-jib behind. The hoisting winch is in
front of the counter-jib. Luffing mechanism is behind the counter-jib. Luffing mechanism drive the
luffing jib-------- The The climbing frames under the slewing support surround the tower mast. To
meet construction needs, the jacking mechanism can jack the upper structure of the upper tower
body to bring in tower sections of slice structure for increasing the height of tower crane
57
L250-20
1- foundation 2-base section 3- Standard section 4- Internal climbing device

5- climbing frame6- slewing support 7- slewing ring 8- turntable 9- operator cab 10-
slewing tower mast 11- counter jib 12-counter ballast 13-luffing mechanism
14-hoisting winch 15-A-frame 16-jib tie bar 17 hoisting steel wire 18-jib 19- hook
Fig.5.4-1 erection drawing of L250-20 crane with outrigger
58
L250-20
5.5 Tower Erection
5.5.1 Steps of Tower Erection
The main steps of the erection of the tower crane with outrigger as follows:
（1）Install the embedded outriggers and tower sections;
（2）Install the climbing frame;
（3）Install the slewing ring assembly;
（4）Install the slewing tower mast;
（5）Install the operator cab;
（6）Install the counter jib assembly( Also, you can firstly install counter jib, then luffing
mechanism and hoisting winch);
（7）Install the A-frame assembly;
（8）Install the two counter ballasts of 2.75t;
（9）Install the jib assembly;
（10）Install the security ropes;
（11）Install the jib tie bars;
（12）Install the other counter ballasts.
Special warnings:
 As the embedded outriggers are critical to the verticality of tower crane and the tower
body connections, So before erection, inspections the verticality and the horizontality of
the outriggers are mandatory. Any vertical or horizontal deviations will cause difficulties
of tower crane erection, even operation accidents.
 After the erection of the embedded outriggers, the flatness must less than the related rule
of this instruction book and must ensure the vertical requirements of the tower mast.
59
L250-20
5.5.2 Install Mast Sections
5.5.2.1 The Description of Structure
There are two kinds of mast sections in L250-20 tower crane with outrigger: base tower
section and reinforced tower section.
There are three kinds of mast sections in L250-20 internal climbing tower crane: internal
climbing base section, internal climbing tower section and reinforced tower section.
（1）Base section: It is integrated structurecio consisted of angle irons, with switch box on
it .And it is connected to embedded outriggers, referring to Fig.5.5-1.
60
L250-20
Fig.5.5-1 the base section of L250-20 luffing jib tower crane

（2）Reinforced tower section: It is slice structure with 4 slices. Each slice is connected by 4
hinged bolts of M36 with hexagon head, referring to Fig.5.5-1.
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L250-20
Fig.5.5-2 the reinforced tower section of L250-20

（3）Internal climbing base section: It is integrated structure with internal climbing elastic
beam as shown in Fig.5.5-3.
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L250-20
Fig.5.5-3 the internal climbing base section of L250-20
63
L250-20
（4）Internal climbing tower section: It is integrated structure as shown in Fig.5.5-4.
Fig.5.5-4 the internal climbing tower section of L250-20

5.5.2.2 The assembling of reinforced tower sections
The reinforced tower section of L250-20 is composed of 4 slices. Each slice is connected by 4
hinged bolts of M36 with hexagon head The pre-tensioning torsion moment of the bolts is 1640Nm.
64
L250-20
Each bolt should be provided with one flat washer, one spring washer and one block nut which
should be screwed down . Fig.5.5-5 is the assembling drawing. The necessary spare parts are listed
in Table5.5-1.
Fig.5.5-5 the assembling drawing of reinforced tower section of L250-20
65
L250-20
Table5.5-1 spare part list of reinforced tower section of L250-20
No Code Designation spec number material Remark
1 tower section slice A 1

climbing ladder and hoop
2 1
guard
3 GB/T5783-2000 bolt M16×50 4 8.8 级 grade Zn.D
4 GB/T6170-2000 nut M16 4 8 级 grade Zn.D
5 GB/T93-1987 washer 16 4 65Mn
6 GB/T97.1-2002 Big flat washer 16 8 200Hv Zn.D
7 GB/T91-2000 pin 6.3×50 4 Q215
8 pivots 2 40Cr
9 diagonal 1
10 tower section slice D 1
11 BZJH1-11 spring pin 16 65Mn
12 BZJH1-10 pivots 8 45
13 BZJH1-8 pivots 8 35CrMo
14 BZJH1-9 pin bushing 8
15 tower section slice C 1
16 BZJH1-4 hinged bolt 16 8.8 级 grade
18 GB/T93-1987 washer 36 16 65Mn
19 GB/T97.1-2002 washer 36 16 200Hv Zn.D
20 GB/T5783-2000 bolt M10×35 4 8.8 级 grade Zn.D
22 GB/T93-1987 washer 10 4 65Mn
23 GB/T96.1-2002 圈 washer 10 8 200HV Zn.D
24 1
tower section slice B
25 platform 1
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L250-20
5.5.2.3 Install Mast Sections
（1）Install Base Section

First, hoist the assembled base section with platform and climbing ladder(or internal climbing
base section with platform and climbing ladder for internal climbing tower crane). Then, connect
the base section to embedded outriggers by 8 tailor-made pivots ( notice: the pinhole on
anti-rotation bushing must match the pinhole on pivots). Finally, knock them to ensure that the axle
shoulder tightly contacts the chord rod surface, and insert tiny pins and spring pins into the
anti-rotation bushing and the pinhole on pivots.
Inspect the verticality of base section by theodolite or plumb line, the verticality deviations of
4 sides of main chord rod could not be greater than 1.5/1000.
Fig.505-6 installing the internal climbing base section of L250-20

（2）Install internal climbing tower section(internal climbing tower crane).
Hoist an internal climbing tower section(the platform of the section can be assembled in
advance) . Connect it to the installed base section by 8 pivots referring the installation of internal
climbing base section.
（3）Install reinforced tower section( tower crane with outrigger)
As is shown in Fig.5.5-7, install the assembled reinforced tower section on the installed base
section( the direction of mast lugs and platform ladder must be consistent with the direction of the
installed reinforced tower section).
① Connect reinforced tower section to base section by 8 pivots of Φ60. Knock them to ensure
that axle shoulder tightly contacts chord rod surface. Put anti-rotation NO.2 sleeves on pivots before
inserting NO.3 tiny pins and NO.4 spring pins (Notice: The spindle hole on spindle and the
anti-rotation hole on the plate of node point must be coaxial so that the anti-rotation spindle can be
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L250-20
inserted. Fig.5.5-7, Detail drawing A);
② Combine climbing ladders into one unit by NO.5 pivot (Notice: Keep clean all
connection holes and connecting pins, no dirt allowable. Fig.1.3-7, Detail B);
③ Inspect the verticality by theodolite or plumb line. the verticality deviations of 4 sides
of main chord rod could not be greater than 1.5/1000.
Special Notice: The hinged bolts with hexagon head for the connection of tower sections
of slice structure and the pivots for the connection of tower sections are tailor-made products.
No replacement of them optionally by users.
Fig.5.5-7 installing the reinforced tower section
5.5.3 Install Climbing Frame
Climbing frame consists of the structure, platform, climbing ladders, hydraulic climbing
system and indraught device. Jacking of tower crane is done mainly by this assembly. The jacking
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L250-20
cylinder is installed on the beam behind climbing frame (Namely, the side of pre-assembled
counter-jib), The hydraulic pumping plant is placed on the platform on the side of hydraulic
cylinder, The climbing frame has 16 rollers on the inner side, these rollers are supported on the
outer side of the main chord rod of tower crane, acting as guidance and bearing, as is shown in
Fig.5.5-8.
To facilitate erection of the climbing system and the satisfaction of safety needs, anti-drop
devices are provided on jacking plates. Platforms and protection fences are provided on the upper,
middle and lower portions of climbing frames, some platforms are also provided on the indraught
beam. During jacking operation, operators stand on the platforms, operating the hydraulic system,
to bring in tower sections and insert connection pivots.
Fig.5.5-8 The climbing frame of L250-20
69
L250-20
5.5.3.2 Hoist and Install Climbing Frame
(1) Put the climbing frame on the outer side of the tower section gently. Notice: The jacking
cylinder and the mast lug on tower section should be on the same side.
(2) Place the supporting latches of climbing frame on the 4th pair of mast lug from down to up,
then adjust the clearance between 16 climbing guide rollers and tower section (the clearance is
2~3mm)
(3) Fix the jacking cylinder and hoist the hydraulic pumping plant to one corner of the
platform, connect oil tubes, and check the hydraulic system for normal operation.In case of oil
pump burning out, the sence of rotation of the motor’s fan blades must be in the same as arrow
indication on its casing. Having any errors, motor must be rewired.
(4) Retract the oil cylinder, hang the supporting plate in the mast lugs of reinforced tower
section nearing the push rods, and insert safety pins.
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L250-20
Fig.5.5-9 Installing climbing frame
5.5.4 Install the Slewing Ring Assembly
5.5.4.1 Assemble Components
（1）Slewing Support
The slewing support is an integral box structure. Its bottom is connec ted to transient beam by
8 pivots. Its top is connected to the inner ring of slewing support by 44 high-strength bolts of M27
(grade 10.9), Fig.5.5-10.
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L250-20
Fig.5.5-10 assembling slewing suppor and slewing ring

The necessary spare parts for assembling are listed in Table.5.5-2
Table.5.5-2 the necessary spare parts for the assembling of slewing suppor and slewing ring
序号名称规格数量
Number Name specification Quantity
1 slewing suppor 1
2 slewing ring QWA1800.50 1
3 bolt M27×240-10.9 44
4 nut M27 88
5 washer 27 44
6 spindle Ⅰ 8
7 spindle Ⅱ BZJH1-10 16
8 spring pin BZJH1-11 32
（2）Slewing Ring
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L250-20
①bolt pair
 The high-strength bolts used on the slewing ring must reach grade 10.9 of
GB/T3098.1-2000.
 Use flat washers which are hardening and tempering. Spring washers could not be used.
 The preload torque is 1100KN·m
②Installation
 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.
Fig.5.5-11 Slewing Ring---

 Check the flatness of support surface by clearance gauge after installing the slewing ring.
 Check the gear meshing condition before screwing down the high-strength bolts to make
sure that the backlash at the three points where the gear runout is biggest (the teeth painted
green) meet the demand.
 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.
③lubrication, cleaning and maintenance
 Add grease into slewing ring regularly. Shorten the period of greasing in special working
conditions such as in tropic, big humidity, too much dust, big range of temperature. Add
enough new grease before and after tower crane out of working over a long period.
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L250-20
Fig.5.5-12 the sequence of screwing down bolts

 Check the preload moment of bolts when slewing ring has worked for 100 hours .Then
check once more every 500 hours working time, ensuring there is preload moment
 Do not sluice slewing ring directly by water for fear that water get in.
Check that the seal function well regularly. Replace the damaged seal in time.
（3）Turntable，Platform
The turntable is plate-shell structure. The flanges are welded on its both sides for the
installation of slewing mechanism. The platforms and handrails are on the left and right side of
turnTable. On the front, there is a support for the installation of slewing limiter. The left platform is
fastened by 6 spindles. Operator cab is connected to support of left platform by 3 spindles. The
bottom of turntable is connected to the outer ring of slewing ring by 44 high-strength bolts of M27
(grade 10.9). The top of turntable is connected to slewing tower mast by 4 spindles (Φ80).
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L250-20
Fig.5.5-13 assembling turntable and platform

Table.5.5-3 main spare parts
Number Name Specification Quantity
1 Left platform 1
2 Handrail Ⅰ LGA580 1
75
L250-20
3 Handrail Ⅱ LGA370 1
4 Handrail Ⅲ LG1920 1
5 Handrail Ⅳ LG760 1
6 Slewing mechanism 2
7 Right platform 1
8 Upper Support 1
9 Below Support 1
10 Handrail Ⅴ LGC1300 1
11 Middle platform 1
12 Handrail Ⅵ LGB2000 1
13 Handrail Ⅶ LG2200 1
14 Handrail Ⅷ LGA430 1
15 Climbing ladder of turntable 1
16 Handrail plywood 7
Fig.5.5-14 slewing ring assembly (the weight is 7800kg)
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L250-20
5.5.4.2 Hoist and Install the Slewing Ring Assembly
Inspect high-strength bolts of M27 (88 pieces, grade 10.9) connecting the slewing rings,
slewing ring support, and upper support to make sure that their preload torsion moment are up to
1100kN·m.
Align 4 main chord rods of the slewing support to 4 main chord rod connections of mast
section. Let them down slowly to keep main chord rod holes of the ring support in line with the
corresponding holes of mast section connections. Remember to keep the position of passing holes
of the slewing support in conformity to the position of mast climbing ladder on the tower section.
During connecting the slewing support to the sleeve frame, their marks on four corners must
correspond to one another.
Connect 8 tailor-made spindles (Φ60×263/376) to tower section, knock the spindles into the
holes, insert tiny pins and spring pins after installing anti-rotation sleeves
Operate the climbing system to extrude the hydraulic cylinder to the second pair of mast lugs
from down to up. Jack the climbing frame to contact the connecting ear-plate of the ring support.
Connect the climbing frame to the ring support with 4 pieces of Φ60 spindles.
Fig, 5.5-15 hoisting and installing the slewing ring assembly
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L250-20
5.5.5 Install the Slewing Tower Mast
Slewing tower mast is integrated frame structure. Its top is connected to counter jib.,its bottom
is connected to the turntable (Fig.5.4-1).
Fig.5.5-16 L250-20 slewing tower mast

Table.5.5-4 main spare parts of slewing tower mast
1 slewing tower mast 1
2 pin XZ-20-113/135- 12
3 A pivots A XZ-100-298/360 2
4 B pivots B XZ-80-298/370 4
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L250-20
5 pin Φ8×45 24
5.5.5.2 Install the Slewing Tower Mast
Hoist the slewing tower mast. Connect the slewing tower mast to the turntable with 4
pivots(Φ63). Insert tiny pivots and pins into pivots (Fig.5.5-17). Notice: please dismantle the
handrail of turntable near counter jib for more easily installing the slewing tower mast.
Fig.5.5-17 installing the slewing tower mast
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L250-20
5.5.6 Install Operator Cab
The cab is thin plate structure, on the front of the upper support right side platform. There are
large big glass windows on the four sides of the cab, the upper window in front can be opened to
obtain a wide field of view. The cab is nice-looking and comfortable, equipping with inter-active
control console (Fig.5.5-18).
Fig.5.5-18 the operator cab L250-20

5.5.6.2 Hoist and Install the Operator Cab
Notice: ensure that the electric equipment in the cab is mounted completely before
hoisting.
Hoist the cab to the left- front of the turntable platform. Align it with the position of ear-plate
holes, then connect them with three pivots and put them in cotter pins (Alternatively assemble the
cab and slewing ring assembly on the ground, then hoist the whole piece once for all).
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L250-20
Fig.5.5-19 hoisting and installing operator cab
5.5.7 Install Counter Jib Assembly
Counter-jib structure is welded structure consistsing of two main chord bars, vertical bar and
diagonal. The main chord bars are welded of steel plate to an “H” structure.
The platforms and handrails are set on the two sides of counter jib assembly. The front of
counter jib is connected to slewing tower mast by two pivots. The other end of counter jib is
supported by a tower strut. One end of the tower strut is connected to counter jib and the other end
is connected to turntable.
Hosting mechanism, luffing mechanism, hydraulic pumping plant, electric control box,
resistance box, A-frame assembly, jib assembly and counter ballasts are all assembled on the
counter jib. Undercarriage of hoisting mechanism and luffing mechanism ate connected to counter
jib by 4 M24 bolts separately. The hydraulic pumping plant is connected to counter jib by 4 M10
bolts. The electric control box is connected to counter jib by 6 M12 bolts. The resistance box is
connected to counter jib by 4 M12 bolts. The A-frame assembly is connected to counter jib by 4Φ40
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L250-20
pivots.Φ60 pivots. The jib assembly is connected to counter jib by 2 Φ80 pins. The counter ballasts
are assembled at the end of counter jib and fastened by bars and frames.
Table.5.5-5 spare parts for the counter jib assembly of L250-20
Name Quantity Weight Specification Remarks
Counter jib
1 3873.5
structure
include 2 Φ20 pivots, 4 cotter
Pivot 2 Φ100-325/385
pins (6.3)
Strut 1 657.68
include 2 Φ20 pivots, 4 cotter
Pivot 4 11 Φ80-215/305
pins (5)
Derrick 1 269.22
From the afterbody to see the end
On the counter jib,nearside flat
Platform 4 506.27
roof width900, starboard flat roof
width1060
Pivot 20 10.4 Φ30-70/105
Cotter pins 40
Handrail 8 196.94
pair，1 M12×65
Handrail
plywood
12 4.44 bolt ， 1 M12 nut, 1 12 flat
washer, 1 spring washer
Hoisting
mechanism
1 7.216 4 Φ40 pivots
Luffing
mechanism
1 1990 4 Φ40 pivots
Hydraulic pump 4个M10×40-8.8
1 170
station 4 M24×40-8.8 bolts
82
L250-20
Fig.5.5-20 the counter jib assembly of L250-20
83
L250-20
5.5.7.2 Assemble Counter Jib
Place counter jib on two steel benches whose height are 1m. Connect the counter jib strut,
which is hoisted to an appropriate position by forklift or crane, to the counter jib by 2 Φ80 pins,
insert cotter pins and open it enough. Hang the gourd on the counter jib, put down the chain, hang
the counter jib strut on the hook of gourd by ropes, take back the chain to hoist the counter jib strut.
Assemble the platform, handrail, electric control box, resistance box by forklift or crane.
Notice: hoisting mechanism and luffing mechanism can be installed one by one after
counter jib installed in order to lighten the weight to hoist, during installing, hoisting
mechanism should be installed firstly, and then install luffing mechanism (The weight of
counter jib assembly with hoisting mechanism and luffing mechanism is 15899kg. The weight
of counter jib assembly without hoisting mechanism and luffing mechanism is 5748kg.)
Fig.5.5-21 the assembling of counter jib assembly of L250-20

5.5.7.3 Hoist and Install Counter-jib Assembly
Hoist counter jib assembly. Connect counter jib to slewing tower mast by 2 Φ100 pivots. Insert
cotter pins and open it enough Discharge the chain, turn strut unde counter jib, adjust the chain, and
align the pin holes of under strut to the holes of turntable, insert the two Φ80 pivots, insert Φ20 lock
pins and cotter pins, ensure the cotter pins opened enough. Place the ladder of the two platforms of
turntable towards counter jib at an appropriate position. Insert bolts and screw down.
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L250-20
Fig.5.5.22 Installing counter jib assembly
5.5.8 Install Hoisting Mechanism

Hoist the hoisting mechanism to the place in alignment with the 4 ear-base on the front of
counter jib (Fig.5.5-23, the installing of hoist mechanism refers to Fig.5.5-20), then fasten the
hoisting mechanism by 4 connection bolts.
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L250-20
Fig.5.5-23 Installing hoisting mechanism
5.5.9 Install Luffing Mechanism

Hoist the luffing mechanism to the place in alignment with the 4 ear-base on the back of count
jib (Fig.5.5-23, the installing of luffing mechanism refers to Fig.5.5-20), then fasten the luffing
mechanism by 4 connection bolts.
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L250-20
Fig.5.5-24 Installing luffing mechanism
5.5.10 Install A-frame Assembly
A-frame is inclined cone. Its top is connented to the counter jib by luffing rope and jib tie bar.
Back Stay Bar is connected to counter jib by 2 pins of Φ60，Frontal Stay Bar is connected to
counter jib by 2 pins of Φ75. The main structure of A-frame consists of front-up tie rod, front-down
tie rod, back tie rod, inclined tie rod and buffer. The front-up tie rod, front-down tie rod and back tie
rod of A-frame are all integrated structures. The front-up tie rod and the front-down tie rod are
connected each other by 8 M24 high-strength bolts ( grade 10.9, torque 900 ) after placing by
two locating pins. The two inclined tie rod are connected to back tie rod and frontal-down tie rod by
pins. Luffing pulley assembly and working platform are installed on the top of A-frame, spring
buffer is installed on the middle of frontal-down tie rod (Fig.5.5-35).
87
L250-20
Fig 5.5-25 A-frame assembly
88
L250-20
Table.5.5-6 spare parts of A-frame assembly
No. Name Qty. Weight Specification Remarks
Frongtal-up
1 1 736
strut
2 Back strut 1 920
Load moment
3 1 16.92 LXB2 Set on back strut
limiter
4 Faceplate 1 1.35
for connection of back strut and down
5 Incline strut 2 219.74
t
Frongtal-down
6 1 1993.87
strut
Including 4 M16×40 bolts, 4 spring
7 Platform beam 2 4.85
hers, 4 nuts , 2 incline washers
ncluding 10 M16×40 bolts, 10 spring
8 Climbing ladder 2 36.58
washer, 10 nuts
9 handrail A 1 19.04 set on lower ladder
10 Handrail B 1 21.6 set on lower ladder
11 Buffer 1 409.72 set on lower ladder
12 Buffer strut 2 18.21 For fastening buffer

Including rails as 1 L=3070；2 L=440；
13 Top platform 1 141
820；1L=530；1 movable handrail;
Set on frontal-down strut, including 4
14 Pulley assembly 1 17.48
M12×65 bolts, 4 spring washers, 4 nuts ,
For connecting back strut and counter
15 Pivot 2 5.22 60×185
every set including 1 10×90 pin
For connecting back strut and frontal-up
16 Pivot 2 3 60×100
strut，every set including 1 5×40 pin
For connecting top platform and
17 Pivot 4 0.5 20×55 frontal-up strut，every set including 1
6.3×63 pin
For connecting one railing and another，
18 Railing nip 14 0.37 LGJB every set include 2 boards, 1 M12×65
bolt, 1 spring washer, 1 nut.
For connecting one railing and another，
19 Pivot 2 1.77 50×90 ry set include 2 boards, 1 M12×65 bolt, 1
ng washer, 1 nut.
For connecting incline strut and back
20 Pivot 2 3.24 50×185
For connecting Buffer and frontal-down
21 Pivot 2 1.14 40×70
For connecting buffer and buffer strut，
22 Pivot 4件 0.4 25×55
every set including 1 6.3×63 pin
For fastening luffing rope, including 1
23 Pivot 1件 0.98 38×150
8×71 pin
For fastening security rope including 1
24 Pivot 2件 1.2 40×90
1 pin
M24×120 Connecting frontal-up strut and
25 Bolts 8套
-10.9 tal-down strut，every set including1 bolt,
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L250-20
No. Name Qty. Weight Specification Remarks

asher, 1 spring washer, 1 nut.
Set on handrails ,Including 2 connecting

26 Safety Rop 1套 plate,1tightwire,6 Line-nip 8KTH , 4
M16×50 bolts, 4spring washer,4 nuts
For
27 Locating pin 2件 0.3 locating frontal-up strut and
frontal-down strut
Set on frontal-up strut ,Including 4 Nylon
28 1件 6.12
and 2 8×71 pin
Shaft-end For fastening pulley spindle , including
29 4件 1.9
damper 2 M20×45 bolts, 2 spring washer,2 nuts
Anemometer 。Set on top of A-frame,Including 2
30 1件 0.76
seat M8×25 bolts, 2spring washer
Obstacle lamp Set on top of A-frame,Including 2
31 1件 0.66
holder M8×25 bolts, 2spring washer,2 nuts
32 Pulley 1件 59.68 Set on frontal-down strut
Rope-hold Rod For hoisting pulley， Including 2 8×71
33 1件 2.12
A pin
Rope-hold Rod For luffing pulley， Including 2 8×71
34 1件 1.45
B pin
Set on top of A-frame, every set
35 baffle 2件 1.4 including 2 M16×65 bolts, 2spring
washer,2 nuts
Shaft-end For fastening pulley spindle , including
36 4件 0.3
damper B 2 M16×40 bolts, 2spring washer
Set on pulley assembly on top of
37 shaft sleeve A 8件 0.35
A-frame
38 shaft sleeve B 1件 0.6
A-frame
Set on top of A-frame, every set
Pulley
39 5件 5.12 including2 bearing, 2 elastic damping
Assembly
ring
40 Shaft 1件 14.2
A-frame，including 2 M8×1 oil cup
Including 2 rail L=440 ， 4
41 Little platform 1件 19.05
M12×40bolts, 4 spring washer,4 nuts
Set on frontal-down strut ， every set
Climbing ladder
42 1件 13.11 including 4 M12×40 bolts, 4 spring
C
washer,4 nuts
43 Nylon spindle 4 1 Set on frontal-up strut
44 Wheel 4 0.4 Every set including 2 4×35 pin
45 Shield ring 8 0.04 For fastening nylon spindle
46 Seat of Camera 1 4.5 Set on frontal-up strut
90
L250-20
5.5.10.2 Assemble Components
（1） Assemble front strut

Notice: Ensure that the spare parts of the font-top strut and the front-down strut are all
assembled completely before assembling front strut.
Place 4 steel benches (Height: 1m) on flat ground. Put the front-down strut on the steel
benches rightly. Put the front-up strut on the benches. Move the front-up strut to make the
two connection flanges attached and the connection holes aligned. Assemble the front-up strut
and front-down strut by 2 locating pins and 4 bolts (M24×120, grade 10.9). Special notice: the
front-down strut welded two tie bars should be installed on the side as showm in Fig.5.5-26.
Fig5.5-26 assemble front strut of L250-20 A-frame

（2） Aassemble diagonal strut
Hoist one diagonal strut, connect the diagonal strut and front strut by one XZ01C-50×90/130
pivot, insert the cotter and open it enough, lay the diagonal strut on the front strut, as is showm in
Fig.5.5-27. Assemble the other diagonal strut in the same way.
Fig.5.5-27 assemble diagonal strut of L250-20 A-frame

（3）Assemble back strut
Put the back strut on the front strut and connect them by 2 XZ01D-60×100/140 pivots, insert
cotter pin and open it enough. Then put the back strut on the support frame, fasten back strut to
91
L250-20
front strut, as is shown in Fig.5.5-28
Fig.5.5-28 assemble back strut of L250-20 A-frame

（4） Assemble Handrail, Spring Buffer, Climbing Ladder and Handhold
Turn over the assembled front strut and back strut and place them on the steel benches. Move
the top platform under the back strut, hoist the top platform, connect it to the back strut by 4
XZ01A-20×55/75 pivots, insert cotter pins and open them enough. install the platform beam by 4
M16×40 bolts. Connect the spring buffer to the front strut by XZ01C-40×70/105 pivot, insert cotter
pins and open them enough, fasten the support rod of spring buffer by XZ01A-25×55/80
spindles (Notice: check that the buff latches i function well), refer to Fig.5.5-29. connect the 2
climbing ladders to the front strut by 12 bolts (M16×40), fasten handhold A and B on the climbing
ladders.
Fig.5.5-29 assemble platform and rail, spring buffer of L250-20 A-frame
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L250-20
Fig.5.5-30 assemble climbing ladder and rail of L250-20 A-frame

（5） Connect the incline strut and the back strut
Loosen the rope using to tie the front strut and the back, hoist the front strut slowly and take
the support frame away. Erect f the front strut and the back slowly to separate them. Rotate the
incline strut, connect the two incline struts to the back strut by 2 XZ01C-50×185/225 pivots, insert
cotter pins and open them enough. Connect the ttop platform beam by 4 M16×40 bolts.
(Fig.5.5-31)
93
L250-20
Fig.5.5-31 connect incline strut and back strut
94
L250-20
5.5.10.3 Istall A-frame Assembly
Hoist the A-frame assembly, connect its back strut to counter jib by 2 XZ01C-60×185/225
pivots and its front strut to counter jib by 2 φ75 pivots, insert cotter pins and open them enough,
refer to Fig.5.5-32.
Fig.5.5-32 install A-frame assembly
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L250-20
5.5.11 Install Two Counter Ballast of 2.75t

There are two 2.75t counter ballast of the four kinds of counter ballast of L250-20.
Fig.5.5-33 L250-20 counter ballast (2.75T)

Notice: Pack crane at an appropriate place to avoid collision of the jib of the crane and
the platform of A-frame when hoisting and installing the two 2.75t counter ballast.
96
L250-20
Fig.5.5-34 hoist and install counter ballast
97
L250-20
5.5.12 Install Jib Assembly
5.5.13 Install Luffing Suspension
5.5.13.1 Install luffing pulley assembly
Hoist luffing pulley assembly and lay it on the ear board of pulley frame of A-frame, insert
bolts and screw them down, as is shown in Fig.5.5-49.
Fig.5.5-49 install luffing pulley assembly

5.5.13.2 Wind Luffing rope
Switch on the power of luffing mechanism, start luffing mechanism, release luffing rope
slowly, wind the rope as Fig5.5-50. Fasten the end of rope on pulley frame of A-frame by wedge, as
is shown in Fig5.5-50..
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Fig5.5-10 wind luffing wirerope

5.5.13.3 Install Luffing Suspension
Switch on the power of hoisting mechanism, start hoisting mechanism, release hoisting rope
slowly. Wind rope across the pulley assembly of A-frame, and wind wirerope across the first pulley
of jib in the opposite direction. Pull hoisting rope to the location of luffing pulley assembly by truck
crane, connect the end of luffing rope to luffing pulley assembly by buckle and rope, as is shown in
Fig.5.5-51. Loosen the rope of truck crane after connecting the end of hoisting rope to luffing pulley
assembly, screw out M16 bolts, remove baffle to loosen luffing pulley assembly, as is shown in
Fig.5.5-52. Release the rope of luffing mechanism, draw back the rope of hoisting mechanism, and
pull luffing pulley assembly to the platform of jib tie bar, remove pulling rope. Connect luffing
pulley assembly to tie board by a Φ45 pivot. Insert cotter pin and open it enough.
Notice: keep the speed of rope of luffing mechanism and hoisting mechanism in harmony.
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Fig.5.5-51 connect hoisting wirerope to luffing pulley assembly
Fig.5.5-52 release the connection of luffing pulley assembly and A-frame
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5.5.14 Install Counter Ballast

The weight of counter-weight varies in proportional to the jib lengths (as is shown in Tablet
4.3-1). Install ballast according to the length of jib. Configuration and position of counter ballast for
jib with different lengths refer to Fig.5.5-53.
Fig.5.5-53 the drawing A of configuration and installation of L250-20 counter ballast
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Fig.5.5-53 the drawing B of configuration and installation of L250-20counter ballast
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Fig.5.5-53 the drawing B of configuration and installation of L250-20 counter ballast
5.5.15 Wind Hoisting Wirerope, Install Hook

Start hoisting mechanism to release hoisting rope. As is shown in Fig Fig.5.5-55., pull the
hoisting rope to wind the first pulley on the jib as well as pulleys on jib head. Turn jib to make the
installation of hook convenient. Continue releasing hoisting rope to ground and prepare to install
hook. Use 1 pin of Φ60 to connect the heavy lantern ring at the end of the hoisting rope with the
hook and then insert the split pin with opened enough (see Fig. 5.5-55a). and now it is 1-fall
condition. The way of installing 2-fall condition is different to 1-fall condition (see Fig. 5.5-55b).
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Wind the hoisting rope around the pulley of the hook and pull it to the anti-twist device. Use 1 pin
of Φ80 to connect hoisting rope with anti-twist device and insert the split pin with opened enough.
Fig.5.5-55 wind hoisting wirerope
Fig. 5.5-55a Install Hook (1-Fall)
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Fig. 5.5-55b Install hook (2-fall)
5.5.16 Power on and Trial Operation

After the installation of the whole crane according to the above steps，check the verticality of
tower body at non-load and wind speed less than 3m/s conditions, the verticality tolerance of free
tower mast (the tower mast above the toppest anchor point) is 4/1000, the verticality tolerance of
tower mast below the toppest anchor point is 2/1000. Switch on power of all electric circuits
according to the electric circuit diagram and start all mechanisms for test run, check whether each
mechanism work properly, at the same time, check ropes at different locations working normal and
for any friction with structure member, remove all abnormal cases.
Notice：Adjust safety device and make sure its function normal before using the tower crane.
5.5.17 Jacking Work of Crane with Outrigger
5.5.17.1 Preparation for Jacking
（1）Fill the oil tank with hydraulic oil according to the requirements of hydraulic pumping
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plant. Ensure that the electric motor correctly connected, the fan turned to the right and the
operating lever of hand control valve working smoothly without any clogging.
（2）Put in order each mast section and apply the grease into its connection boltholes, Line up
the tower sections under jib before jacking, thus the jacking time can be minimized.
（3）Loosen the power cable until the length is slightly in excess of the total jacking height,
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 below the counter-jib).
（5）Put 8 pivots on the middle platform of climbing ladder.
（6）remove the locating pivot of platform hoisting machine, turn the drum of platform
hoisting machine, turn over indraught platform, drop it until it is on the same level of indraught
beam, insert the locating pivot, connect incline tie bar to ear board by Φ20 pivot, insert cotter pin
and open it enough.
On normall working condition, to avoid the interference between jib structure and hook at an
large angle, therefore, dismantle the spindle that connects outer inclined tie bar and the ear ban of
indraught platform according to the reversed sequence, turn indraught platform up 60°by rotating
hoisting drum, then insert the locating pin of hoisting drum.
5.5.17.2 Notices of Jacking Operation:
（1）Keep the tower crane in balance before jacking operation.

（2）Jacking operation is prohibited when the speed of wind at the highest top exceeds 14m/s.
（3）Forbid hoisting when jacking mechanism is jacking (up or down).
（4）Forbid luffing when jacking mechanism is jacking.
（5）The direction of jib and the direction of bringing in tower section should be same, when
braking jib by the brake of slewing mechanism, jib must stop at the balance angle.
（6）Forbid slewing and luffing before the spindle of bringing tower section is not connected
to the installed tower section and slewing support by pivot.
（7）If some tower sections should be continuously installed, the next tower section can only
be hoisted after all the pivots of tower sections (include the 8 pivot of slewing support) are
assembled.
（8）The must lug of tower section should be aligned to the installed must lug of tower section
before.
（9）Forbid slewing, luffing and hoisting before the slewing support is connected to tower
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mast by 8 Φ60 pivot.
（10）Stop hoisting immediately if the hydraulic jacking mechanism is in trouble, draw back
oil-hydraulic cylinder to lay slewing support on the top of tower mast, and connect slewing support
to tower mast by 8 Φ60 pivots, then remedy of the trouble of hydraulic system.
（11）After jacking is over, all the connections between tower sections and the connection
between tower section and slewing support are 8 Φ60 pivots.
5.5.17.3 Keep the tower crane in balance before jacking operation
（1）Before keeping the tower crane in balance, hoist one tower section ( its platform with
handrail and climbing ladder is assembled) to inlet platform. Then balance the jib according to
Table5.5-13 (the position of jib in table is approximation. Adjust it according to the practical
situation). Dismantle the pivot between slewing support and tower section.
Notice: the weight of the tower section (platform, handrail and climbing ladder are
installed to the tower section) is 2800Kg.Users should increase the weight if the hoisting
weight is heavier than 2800Kg.
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Fig.5.5-58 L250-20 hoisting balance

Table.5.5-13 jib angle and hoisting weight for different jib (for reference)
max radius
60m 55m 50 m 45m 40m 35m 30m
jib angle α
hoisting weight
（2）Push the operating handle of hydraulic jacking mechanism to “hoisting direction”. Jack
climbing frame to the place where the leg of slewing support separates from main chord.
（3）Check whether the leg that connects slewing support to tower section and the main chord
are at a same vertical line, and observe whether the clearances between 16 guiding wheels of
climbing frame and main chord are same, check whether the tower crane is in balance through these
two measures, if the tower crane is not in balance, adjust the luffing angle of jib until the tower
crane is in balance, making the barycentre of the top of tower crane located in the vertical plane of
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hoisting beam.
（4）Record the angle between jib and level. (Notice: the angle will be changed with
differentLength of jib.
（5）Descend climbing frame. Insert the pivots between slewing support and tower section.
5.5.17.4 Jacking Work
Both 1-fall and 2-fall can be used in jacking work. (Special notice: jib angle should be less
than 86°in progress of letting in tower section)
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Fig.5.5-59 jacking work 1

（1）Hoist one tower section to the top of in-let car. Lay tower section on in-let car. Remove
hook.
（2）Place the jib to a appropriate position according to the length of jib (refer to Table.5.5-13).
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Put down hook (Fig.5.5-38). Tower crane is inbalance.
（3）Use brake of slewing mechanism to brake the upper structure. No slewing allowed.
Dismantle the 8 Φ60 pivots between tower mast and slewing support.
（4）Start hydraulic jack system, extrude the piston of the cylinder place the pins of both ends
of the jack beam into the cradle of the climbing lugs on tower section nearest to the beam (Notice: It
should be checked by a specially-designed watchdog), jack the climbing frame and the upper part
until it reaches the height of 10～50mm., check if there are any strange sounds, deformation, any
self-retreat of piston rod etc, after confirmation, go on to erect.
（5）Start hydraulic jack system until it reachs the height of 1/3 tower section and supporting
latche 4 is at the top of must flag d. Stop jack and then retreat the piston to drop supporting latche
on must flag d.
（6）Confirm that the two support latches press the top of climbing lugs and bear the weight of
climbing frame and the upper part without any strange sound and deformation. Remove security pin.
Retreat the piston completely. Raise Hanging plate. Hang it on the nearest groove b of must flag.
Insert security pins, Fig.5.5-60.
（7）Erect must flag d to the height of a little higher than must flag e, Fig.5.5-60.
（8）Stop jack and retreat piston to drop support latche to must flag e, Fig.5.5-60.
（9）Confirm that the two support latches press the top of climbing lugs and bear the weight of
climbing frame and the upper part without any strange sound and deformation. Remove security pin.
Retreat the piston completely. Raise Hanging plate 1. Hang it on the nearest groove c of must flag.
Insert security pins, Fig.5.5-60. There is a space of 2/3 tower section.
（10）Stretch out oil-hydraulic cylinder to erect the upper part of tower crane to a height of a
little more than 1/3 the tower section so that the space is fit for a tower section, Fig.5.5-61.
（11）Conduct tower section to the top of tower mast. Retreat piston slowly to let the bottom of
in-let car attach the tower section. Retreat the piston completely. Align the pin hole of slewing
support and tower section. Insert temporary pivot 7, Fig.5.5-62.
（12）Stretch our oil-hydraulic cylinder until in-let car separate from tower section. Push out
in-let car. Retreat piston. Align the pin hole of two tower sections. Insert 8 Φ60 pivots. Knock them
to axle shoulder tightly contacting chord rod surface. Install anti-rotate sleeve. Insert tiny pivot and
spring pin.
（13）Remove the temporary pivot 7. Retreat piston to align the pin hole of slewing support
and tower section. Insert 8 Φ60 pivots without shoulder. Insert tiny pivots and spring pins. Insert
anti-rotate sleeve tiny pivot and spring pin at the other end.
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（14）The installation of one tower section is over. Install more tower section as the same steps
above.
For the last installed tower section: One end is connected to tower mast. the other end is
connected to slewing support.
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5.5.18 Anchorage of tower
When the working height of the tower crane has to be exceeded to its stand-alone height, the
tower body shall be anchored. The anchoring devices consist of 4 sets of mast-tie-frames and 4
inner ties. The 4 tie-frames are fastened into anchoring frames by 24 sets of M20 bolts (strength
rating 8.8), nuts and washers (bolt pre-tensioned moment 640Nm). Anchoring frames are articulated
with 4 tie-rods on 4 top points. The 4 brace rods shall be kept at the same horizontal level.
Adjusting bolts can be used to push inner tie rods tightly against the 4 chord rods on the tower body
(shown as 5.5-63).
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1- Conneting bolt 2-Frame 3- Inner strut 4- Inner strutAdjusting bolt 5- Anchoring

Fig. 5.5-63 L250-20 schematic diagram of anchorage
（1） Anchorage frame be setted according to Fig5.5.64 . Actual make and design distance is
difference. Building anchorage link support and attended mode according practicality something to determine.
Must contact to manufacturer.
（2）Put on the tie frame on the tower section, push the 4 inner tie rods to the 4 chords on the
tower, connect one end of anchored tie rod to the tie frame with pins, and the other end to the
buildin
（3）4 sets of anchoring tie rods on each frame shall be kept at the same horizontal plane. If
they are interfered with some positions of the tower section during mounting of anchoring frames
and inner tie rods, the height of frames will properly be raised or lowered. the height of frames and
connecting basis not exceeding 200 meter
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（4）The walkway for personnel passage from the building to tower crane can be placed on the
anchoring tie rod, however no stockpiling of heavy objects on it
1-bolt connection 2-frame beam 3-internal strut 4-internal strut adjusting bolt
5-longer strut 6-shorter strut 7-adjusting bolt 8-connection base
Fig.5.5-64 anchorage for L250-20 tower mast
（5）Load on anchoring points
Before tower crane erection, customers or installation organizations are required to make
necessary estimates of the load-bearing capability at building anchoring points (for the of
connection foundation-fixing spots), as well as the construction period of the reinforced concrete
structure affecting the anchoring point strength and similar factors., it gives the anchoring forces
imposed at the anchoring points of the building (i.e. connection to the anchored foundation) at
working and non-working conditions when the tower crane has its anchoring strut rods layout and
location as shown in Fig. 5.5-65. The building’s anchoring point shall not have its load-bearing
capability smaller than the values shown in the table. The pre-embedded piece is embedded as Fig.
5.5-66.
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Fig.5.5-65 layout of anchorage strut
Fig.5.5-66 layout of anchorage foundation

Notice: Load values at anchoring points vary to a great extent with the relative positions of
the tower crane to the building, tie rod layout and size, height of the tower body suspension
section over body. If the tower crane is anchored at the position different from Fig. 1.9-1,
including different arrangement of tie rods or different dimensions, please contact our
company for further consultation, avoiding major accident.
（6）During the mount of anchoring device, use the theodolite to check the axis of tower body
for verticality. Its deviation shall not be greater than 4/1000 of the total tower crane height. This
deviation can be achieved by adjusting the length of tie rod.
（7）The connection of tie rods to tie frames, foundation and tie frames to the tower body and
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inner tie rod shall be reliable. The inner tie rods shall reliably be pressed against the main chord rod
of the tower body and also be clamped tightly to the web rod of the tower body. All connection bolts
shall be fastened. Adjusting bolts, when properly adjusted, shall be tightened by nut. Cotter pins
shall be opened as specified. After operation they shall be frequently checked for looseness. Timely
adjustments shall be made just in case
Notice: No matter how many anchoring is conducted, only the topmost anchoring tie frame
can install the inner tie rod. Namely after each new attachment, the inner tie rod has to be
removed into the newly-anchored frame
5.6 Internal Jacking of Tower Crane
Compare to other style tower crane, internal climbing tower crane can rise up with the height
increase of building by its internal climbing device and internal climbing tower mast. Change tower
crane from anchored condition to internal climbing condition before internal climb. Thus to say,
drop climbing ladder to ground and dismantle it after sections are all assembled; Assemble internal
climbing device when the building reach a certain height.
5.6.1 Description of Internal Climbing Device
Internal climbing device consists of up internal climbing frame, middle internal climbing
frame, dowm internal climbing frame, internal climbing base section, internal climbing tower
section, internal climbing frame beam, internal strut, latch device and hydraulic jacking system.
Internal climbing tower mast consists of 11 tower sections BZJHQ7, 1 internal climbing base
section. The up, middle and down internal climbing frames are fasten on internal climbing frame
beam when the whole tower is climbing. Tower crane climbs up by the hydraulic jacking
mechanism on internal climbing frame.
The up, middle and down internal climbing frames should be assembled before climbing.
Oil-hydraulic cylinder and latch device is on middle internal climbing frame in the progress of
climbing.
There are always 2 internal climbing frame assembled on internal climbing frame beam. The
telescopic beam of internal climbing section is on down internal climbing frame beam. They
support the weight of whole tower crane. The load on up internal climbing frame is horizontal. The
loads on down internal climbing frame are both horizontal and vertical.
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Fig.5.6-1 drawing of internal climbing device
5.6.1.1 Internal Climbing Frame
The up, middle and down internal climbing frames are the same structure, Fig.5.6-2. Each
internal climbing frame include 2 internal climbing frame made of 4 angle steel connected by 16
M24×80 high-strength bolts (pre-tensioned moment is 650 N.m). On the internal climbing frame
guide wheel device, support block device and latch device ear board are provided. Guide wheel
device guide tower with the help of main chord. Support block device prop on main chord to
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transmit the horizontal load of tower crane to the wall of elevator shaft. Latch device ear board is
used to fasten latch device. After limbing one time, the down internal climbing frame separate from
internal tower mast. Dismantle it to assemble on the top of internal climbing device. So it become
up internal climbing frame. The three internal climbing frame are used in turn like this.
Fig.5.6-2 internal climbing frame

Latch device and jacking mechanism connected on internal climbing frame accomplish latchs
changing and jacking. The oil-hydraulic cylinder turn outwards supported by baffle when it is not
jacking, Fig.5.6-3.
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图 5.6-3 顶升油缸侧置
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5.6.1.2 Internal Climbing Frame Beam
Telescopic beam is wielded from steel pate belonging to internal climbing section set on box
beam of internal climbing section. Pull telescope beam into box beam of internal climbing section
when crane is jacking. Stretch telescope beam to lie on internal climbing frame to bear the weight of
whole crane, Fig.5.6-4 when crane work normally.
Notice: when tower crane is in internal climbing, wrap the part of telescope beam
stretched out with plastic. Clear dregs in load-bearing beam regularly for telescope beam
easily stretching out next time.
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Fig.5.6-4 telescope beam
5.6.1.3 Load-bearing Beam of Internal Climbing Frame
Load-bearing beam is made by users (Load-bearing beam should be designed according to the
dimensions of elevator shaft). Calculate the intensity and rigidity of load-bearing beam to make sure
it meets the demands. The size of load-bearing beam (L) should bigger than the size of elevator
shaft.
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Fig.5.6-5 load-bearing beam
5.6.2 Climbing of Internal Climbing Tower Crane

Internal climbing tower crane is always set in elevator shaft. Remain a group of hole every
15~18m in the construction of elevator shaft. The dimensions of holes are shown in Fig.5.5-6.
The reinforced concrete foundation is out of work after the fisrt time climbing. So the loads of
tower crane are borne by building. Design the positions of hole before construct the elevator shaft.
Strengthen the hole and wall nearby
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图 5.6-6 电梯井预留孔位置及大小
Fig.5.6-6 the dimensions of hole
5.6.2.1 Installation for the first climbing
There may be no down fram used the first climbing. Middle frame become down frame and up
frame become middle frame after climbing. There may be no up frame when tower crane is in
service. Assemble up frame just before climbingwork.
（1）Install load-bearing beam of internal climbing frame
Install load-bearing beam of internal climbing frame as shown in Fig.5.6-8. The load-bearing
beam must be fastened securely. The method for fastening is designed by users according to work
condition.
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Fig.5.6-8 Install load-bearing beam of internal climbing frame

（2）Install up internal climbing frame
Install up internal climbing frame at th hole 30~36m away from foundation. Place the two half
internal climbing frame around tower mast. Before install internal climbing frame, turn jib to the
direction perpendicular to the ligature of two jacking oil-hydraulic cylinder. Brake slewing
mechanism. Balance tower crane.
（3）Install middle internal climbing frame
Place the two half internal climbing frame around tower mast 15~18m below up internal
climbing frame. Connect them with angle steel by M24×80 bolts. Fasten them on the load-bearing
beam by 32 M24×110 bolts (each including 1 bolt, 1 spring washer, 2 nuts).
Notice: no down internal climbing frame the first climbing.
（4）Install hydraulic jacking system
Hoist and install internal climbing system and latch device to middle internal climbing frame.
Assemble the 2 oil-hydraulic cylinder to middle internal climbing frame. Hydraulic hydraulic
jacking system is set on platform of building. Connect pipeline of hydraulic system. (Fig.5.6-9)
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5.6.2.2 Climbing
（1） Check before climbing

Check if hydraulic system is set rightly. Check if all the pivots are installed. Check if all the
cotter pins are opened up. Check if all the shaft-end dampers function well. Check if all the
pre-tensioned moments of high-strength bolts meet the demands. Test the hydraulic system when
everything is OK. Adjust the sping of hanging plate to make the angle between hanging plate and
the centerline of oil-hydraulic cylinder 10~15°.
Hang hanging plate on the lug of internal climbing section, Fig.5.6-10.
（2） Blance the tower before climbing
Tower crane must be balanced before climbing. Turn jib to a appropriate position (Fig.5.6-2) to
balance the tower crane. Notice: the positions in the table are approximation. You may need to
adjust them according practical condition.
Table.5.6-2 jib angle and hoisting weight to balance for different jibs (for reference)
Jib radius
60m 55m 50m 45m 40m 35m 30m
Jib angleα
Hoisting weight
（Kg）
（3）first climbing
① Loosen the pivot between internal climbing base section and anchors. Start hydraulic
jacking system to separate internal climbing base section from anchors. Hydraulic system pressure
rising show that oil-hydraulic cylinder begin to bear the weight of tower crane. Notice: the
pressure of hydraulic system should be not bigger than 31.5Mpa.
② Check everything is OK. Jack tower to the height 20mm away from anchors. Check if the
distance between the down surface of main chord and foundation is consistent. If not, turn jib at
lowest derricking speed to make it consistent. Stay here in ten minutes. Start hydraulic system to
jack if everything is Ok. There must be a specially-assigned person to observe the working
conditions of guide wheel and chord.
③ Keep on jacking until the must lug of internal climbing section is higher than the top
surface of support board of latch device. Turn latch device to let it block in must lug of internal
climbing. Retreat piston to drop upper tower crane on latch device.
④ Keep on retreating piston. If the pressure declines, the latch device begins to bear the
weight of tower crane. Stop hydraulic system for 10 minutes when jacking beam is 10mm away
from down surface of must lug. If everything is OK, start hydraulic system. Lower the height of
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jacking beam. Make the beam out to support on baffle until piston is retreated back entirely. Repeat
the above steps for second climbing.
Fig.5.6-09 Fig.5.6-10
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Fig.5.6-11 climbing condition

⑤ Tower crane rises up 1.25m after one jacking. After several jacking，internal climbing base
section will be a little higher than internal climbing frame. Now stop jacking and draw out
telescopic beams to lie on internal climbing frame. Operate hydraulic system to load the weight of
whole tower crane on the two telescopic beams. Jack the 8 support block to main chord. Remove
hoisting weight. Screw dowm bolts of support block. Until now the first climbing is over. Tower
crane can work.
⑥ Assemble 4 internal struts on the near top of up internal climbing frame. Force internal
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struts jacking on the 4 main chords by adjust the bolts, Fig.5.6-12.
Fig.5.6-12 install internal strut

（4）Climb several times
Tower carne should climb again when the building is constructed to a certain height. Transfer
down internal climbing frame to the hole beyond up internal climbing frame (guide wheel is
2~3mm away from main chord). If jacking mechanism is on down internal climbing frame, it
should be transferred to middle internal climbing frame (balance tower crane before install up
internal climbing frame).
① check before climbing
Check if hydraulic system is set rightly. Check if all the pivots are installed. Check if all the
cotter pins are opened up. Check if all the shaft-end dampers function well. Check if all the
pre-tensioned moments of high-strength bolts meet the demands. Test the hydraulic system when
everything is OK.
② Dimanche 4 internal struts.
③ Do balance tower crane before climbing. Refer to the part of “Blance the tower before
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climbing”.
④ Start hydraulic system. Press down jacking bottom. Let jacking beam in. Stretch out piston
a little. Hang hanging plate on must lug of internal climbing section. Stretch piston rod out. Make
sure hanging plate is hanging on must lug. Keep on jacking. Draw back telescopic beam into box
beam structure when telescopic beam bear no load.
Notice: do draw back telescopic beam into box beam structure. Otherwise, telescopic
beam will hit internal climbing frame.
⑤ Stop jacking until internal climbing base section is a little higher than internal climbing
frame. Turn latch device to let it block in must lug of internal climbing. Retreat piston to drop upper
tower crane on latch device.
⑥ Keep on retreating piston. If the pressure declines, the latch device begins to bear the
weight of tower crane. Then stretch out piston and repeat above operations for another jacking.
⑦ Tower crane rises up 1.25m after one jacking. After several jacking，internal climbing base
section will be a little higher than internal climbing frame. Now stop jacking and draw out
telescopic beams to lie on internal climbing frame. Operate hydraulic system to load the weight of
whole tower crane on the two telescopic beams. Jack the 8 support block to main chord. Remove
hoisting weight. Screw dowm bolts of support block. Until now the first climbing is over. Tower
crane can work.
⑧ Assemble 4 internal struts on the near top of up internal climbing frame. Force internal
struts jacking on the 4 main chords by adjust the bolts, Fig.5.6-12.
Notice:
① The down surface of internal climbing base sections should not be out of down
surface of middle internal climbing frame. Otherwise, the tower crane may fall down.
② Forbid tower crane climbing if wind speed is bigger than 14m/s.
③ The load-bearing beam of internal climbing frame laid on hole in elevator shaft
should be fastened firmly.
④ Make sure the interspace between idler wheel and tower section is about 3mm.
⑤ The up surface of concrete structure where load-bearing beam assembled must be
level. Make sure the 4 installing surface of internal climbing frame is in the same plane. The
planeness tolerance is 1/1000.
⑥ Adjust the internal climbing frame before climbing to let the up surface of support
board of latch device is on the same height (height error is within 4mm).
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5.7 Dismantling of crane
5.7.1 Precautions for the dismantling of tower crane

Dismantling of inner climbing crane is different to other cranes in that its mainly dismantling
depends on the cranes on house, before the main building body fulfilled, the installing position of
the crane on house should be considered according to dismantling convenience and carring capacity.
(1) Dismantling inner climb crane by cranes on house should strictly adhere to the operation
instruction of cranes on house.
（2）Before dismanting and carrying tower crane, as the climbing mechanism have not used for a
long time, users should maintain it and try operate it.
（3）Before dismanting and carrying out the tower crane, as the jacking mechanism have not used
for a long time, users should maintain it and try operate it.
（4）Check limiters, slewing mechanism brakes and so on for reliability during test-run.
（5）f tower crane mast sections have been dismantled, it is prohibited to use the slewing
mechanism, luffing mechanism and hosting mechanism before the slewing ring support has not
been connected to the tower body by 8Φ60 high-tensile bolts
（6）Often check the main stressed parts of the jacking mechanism, as the dismantling of tower
crane is a heavy and continuous work for the jacking mechanism
（7）While the jacking mechanism is working, all operating workers are required to focus on
observing whether the relative positions of moving parts are normal (e.g. the relative position
between rollers and main chord rods, the relative position between climbing frame and tower body.).
When climbing frame is rising between climbing frame, if tower body dclines, the jacking opreation
must be stopped and descend it, then reset.
（8）When dismantling tower crane, the wind speed is less than 14m/s at the highest point.
Take care of the stockpile location of workpiece as the building has been constructed and working
site space is limited during the tower crane dismantling, no carelessness at the time, otherwise
personal safety accidents will likely occur
5.7.2 Basic formality of dismantling tower
Special caution:
The dismantling of tower crane is a highly technical work, especially the dismantling of the
internal climbing device, tower sections, counter ballast, counter-jib and jib. Any slight neglect will
cause machine damage, personal injury even death. Therefore, users are required to strictly follow
the instructions-specified rules to dismantle these components. Tower operators must have been
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trained and obtained certificates.
Special notice：
Pay great attention to the two climbing latches during install or dismantle tower sections,
inspect if the latches are still in proper condition.
Rotate the tower crane to the dismantling area where there are no obstacles influencing the
dismantling operation. Its steps are opposite to the erecting steps. You should follow the Instructions
specified rules in all cases strictly.
5.7.2.1 The dismantling of crane with anchors
Basic programs of dismantling crane with anchors shown as Fig. 5.7-1

Lower down the tower sections (dismantle anchored devices if necssary)
（2）Dismantle counter ballast from counter-jib
(Keep only two 2.75t counter ballast on counter-jib)
（3）Dismantle hook
（4）Dismantleluffing tie bar
（5）Dismantle safe rope
（6）Dismantle jib assembly
（7）Dismantle the odd 2 counter ballast
（8）Dismantle A-frame assembly
（9）Dismantle counter-jib assembly；
（10） Dismantle the operator cab (or dismantle it together with the slewing assembly)
（11）Dismantle slewing mast assembly
（12）；Dismantle slewing support assembly
（13）；Dismantle the climbing frame
（14）Dismantle the tower sections。
Attention: The dismantled crane should be checked by technical persons and trained maintenance
persons. Check main stressed structural members for metal fatigue, weld fissure, structural
deformation, etc, check tower crane parts for damage or collision injury. After checking, repair the
defects found and defects potential, then complete the task of rust removing and painting.
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Fig. 5.7-1 the ordering of dismantling of L250-20

5.7.2.2 The Disassembly of internal climbing tower crane
Basic procedure and process of the dismantling of internal climbing tower crane are as
follows:
（1）Hoist anfd installed the tower crane onto the top of building by the crane on house.
（2）Reduce the height: Make full use of the internal climbing system to do it. And ensure that
two internal climbing frames are fixed in the remained hole of elevator.
（3）The disassembly of counter ballast: turn the counter jib to the working area of house crane,
disassemble counter ballast by house crane (remain two pieces of 2.75t bob-weight);
（4）The disassembly of jib assembly: turn the crane by 180° to make the jib close to the house
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crane, firstly make use of the house crane to hoist jib assembly onto the top of house and
disassemble it, then hoist the disassembled jib onto the ground.
（5）The disassembly of counter-jib: hoist the remained counter ballast onto the ground, then
hoist the counter-jib assembly onto the top of house and disassemble it, lastly hoist the
disassembled counter-jib onto the ground.
the house top to disassembly
（6）Hoist the top of tower, slewing tower body, slewing assembly, tower section, internal
climbing device onto the ground in turn by house crane.
（7） The disassembly of house crane：Disassemble the house crane completely, trainsport all
the parts onto the ground by construction elevator.
5.7.3 Dismantle the tower body
Fig. 5.7-2 dismantle the tower body 1
（1）Slewing the jib to the direction for the bringing in section (namely, the opening side of
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climbing frame), make slewing brake at the braking status and the tower crane at a balanced jacking
status, turn the jib to the balanced position (namely, in conformity to the balanced position of the jib
when additional sections are jacked during tower crane erection)
（2）Remove the connecting pin of the toppest tower secting 1 and tower secting 4, as is
shown in the left drawing of Fig. 5.7-2.
（3）Extend the jacking cylinder 3 to place the pin bolts onto the slot of the 6th lug counting
from up down, insert safety pins, jack the superstructure until the bottom of the trolley is moved to
30~50mm away from the top of the section 4 , as is shown in the left drawing of Fig. 5.7-2.
（4）Lead the trolley into the climbing frame. Retract the jacking cylinder until the bottom of
the trolley contacts the connection of top section 4, as is shown in the right drawing of Fig. 5.7-2.
5.7-3 dismantles the tower body 2

（5）Continue retracting the jacking cylinder until the mast section (1) is led down onto the
trolley. At this time, the indraught beam has descended a certain distance. Remove the pins that
connect the mast section (1) to the slewing ring support.
（6）Extrude the jacking cylinder until rollers of the trolley contact the indraught beam, at this
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time, the top connection surface of the mast section (1) is about 45~50mm away from the bottom
surface of support chord rod of the slewing ring. Move out the trolley, as is shown in the left
drawing of Fig. 5.7-3.
（7）Retract the jacking cylinder to make the lug-changing rod (2) fall on the lug (e)
（8）Ensure that the two supporting rods both are pressed on the slot of the lug (e) and bear the
weight of climbing frame and the parts above them. After that, pull out safety pins, hang the jacking
cylinder onto the slot of the lug (b). Insert safety pins.
（9）Slightly extend the jacking cylinder and pull the lug-changing rod (2) outwards to avoid
its falling from being interfered. Retract the jacking cylinder to make the rod (2) fall on the lug (d)
（10）Be sure that the two lug-changing rods both are pressed on the slot of the lug (d) and
bearing the weight of climbing frame and the parts above them. Pull out safety pins, hang the
jacking cylinder (3) onto the slot of the lug (a), then insert safety pins
（11）Slightly extend the jacking cylinder and pull the rod (2) outwards to prevent its falling
from being interfered. Retract the jacking cylinder to align connection pinholes of slewing ring
support chord to those of mast section (4). Insert 8 φ60 shoulder-free pins, knock them into holes,
insert tiny pins and spring pin at one end of the pins and put on anti-rotation sleeve at another end
before inserting tiny pins and spring pin.
（12）After connecting the slewing support to tower section, hoist the mast section down onto
the ground. If several mast sections are to be dismantled in succession, keep the tower body main
chord rod connected to the slewing ring support by 4φ60 shoulder-free pins after completion of
each section dismantling and before hoisting the next section. Only in this case can 4φ60 pins be
used
Notice: During the climbing frames lowering, it is necessary to dispatch special persons to
attend hanging plates, lug-changing rods and guide rollers, observing whether the climbing
frames are being clogged by obstacles so as to ensure their smoothly falling
Repeat the above opreations to dismantle the tower sections in sequence.
If the tower is to be further dismantled after the tower body has been dismantled to the
installation height, it is necessary to dismantle at first the counter ballast from the counter-jib.
5.7.4 Dismantle counter ballast.
Dismantle the counter ballast by auxiliary crane.

Dismantle the counter ballastt one by one in the sequence oppositing to counter ballast
mounting. Keep only two pieces of 2.75t counter ballast.
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5.7.5 Dismantle hook
In 1 fall condition, lie the hook on the ground, then remove the pivot used in the connection
between hoisting rope and hook, finally retrieve the hoisting rope. In the 2 fall working condition,
lower the hook to the ground, then make use of chain block or assistant device to lift the wire rope
with link anti-twist device of jib, unsnatch the link pin for rope and anti-twist device of jib. At last,
lower the ropes slowly to the ground, and the disassembling of hook is completed.
5.7.6 The dismantling of luffing tie bar
（1）Slowly revolve jib at angle of 10° to make the weight onto safety rope, and continue
operating luffing mechanism until luffing tie bar onto jib, then stop the operation. Dismantle the
spindle that connects luffing pulley assembly to frame. Fix lifting rope on first support and drill
through the block support underside to wind on the contrary. Use the rope and buckle to connect the
histing rope end and pulley block in the same. Right now travel mechanism roll the rope and life
mechanism slowly discharge rope will make pulley block to block support be fix on A frame
move(notice: adjusting of two mechanism ).
（2）Hoist luffing pulley assembly by truck crane, put it on the head of A-frame with board of
block frame and be warded off in board. Twist the bolt and tighten.
（3）Switch on hoisting mechanism to roll rope in coiling block and check the rope in all
length.
（4）Disassemble the rope from wedge connector of upside block be fixed on A-frame wedge
connector, Switch on luffing mechanism to roll rope in coiling block. Put block hang on the hook in
rope, dismantle M20 bolt, loosen block and lower block to ground.
5.7.7 Dismantle safety rope
（1）Hoist the jib by the truck crane round hinge joint go to above angle 20(notice: the
position of hoisting point is same as jib, refer to Fig5.5-45, Table5.5-11), at this time,
safety rope has no force applied.
After winding luffing rope round the top pulley of A-frame, connect the luffing rope to the end
of safety rope, dismantle link-pin of safety rope and A-frame.
Switch on luffing mechanism to release the safty rope, put the satefy rope on the above plate of
jib. Release another one in the same way.
Switch on luffing mechanism to draw back luffing rope into luffing drum, and check rope in
the whole length.
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5.7.8 Dismantle jib
Notice: Before dismantling, check whether component-to-component is still connected by

power cable
Make use of assistant truck crane to remove the pins connecting root of jib b with counter-jib,
lower the jib and lay it down on the sleeper-cushioned support.
5.7.9 The Dismantling of counter ballast of 2.75T
Make use of assistant crane to dismantle the remained two pieces of 2.75t counter ballast.
Notice: before disassembling, please check whether there is cable that link adjoining
discreteness.
Disassemble the link pin that links A-frame assembly root to the counter-jib by assistant truck
crane, lower the A-frame assembly onto the ground.
5.7.11 Dismantle travel machine
Dismantle luffing mechanism by assistant truck crane
5.7.12 Dismantle hosting mechanism
Dismantling hosting mechanism by assistant truck crane.
5.7.13 Dismantle counter-jib assembly
Hoist the counter-jib through 4 hook lugs on the counter-jib to make the jib pull rod at a
loosened status. Remove connecting pins of pull rod by chain block and then dismantle the
connections between counter-jib and slewing tower body. Put counter-jib in distance from the
ground above 1.5 meter. Lower the counter-jib down onto the ground.
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5.7.14 Dismantle operator cab
5.7.15 Dismantle slewing tower
5.7.16 Dismantle slewing support assembly
Support the lug changing rods of climbing frames on the tower body, then dismantle the
connection of the slewing ring support with the climbing frame and tower body, lower the slewing
assembly.
5.7.17 Remove climbing frame
Slowly hoist the climbing frames along the main chord rod of tower sections, then place them
down onto the ground
5.7.18 Remove tower sections
Remove the remained three tower sections, keep on hoisting the top tower section and pull out
the pins between the hoisted tower section and the next section. Hoist the tower section down onto
the ground. Repeat these operations until there are only the foundation anchors or base frame
remained.
5.7.19 Attentions after dismantling tower crane
（1）The dismantled crane needs to be checked and maintained by technical personnel and
trained maintenance personnel
（2）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
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6 Mechanism
6.1 hoisting mechanism
6.1.1 Summarize
The hoisting mechanism of the tower crane is QPL1690A, and the motor is YZPBF280M-8.
The transmission system of the hoisting mechanism is shown as in Fig. 6-1-1, the hoisting drum is
provided with the hook height limiter, When objects have been hoisted to the highest position, the
hoisting winch will stop automatically.
1－motor 2－coupler 4－Reduction 5－Undercarriage

6－Drum 7－Altitude limiter
Fig. 6-1-1 hoisting mechanism
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6.1.2 Technical parameters of Hoisting mechanism
Technical parameters of Hoisting mechanism speed

Technical parameters of hoisting mechanism speed
setting enactment （HZ）frequency average rate of rope（m/min）
Ⅰsetting 8 12
Ⅱ setting 25 36.5
Ⅲ setting 50 73
Ⅲ setting 100 146
Ⅴsetting 125 180
6.1.3 Motor
6.1.3.1 Summarize
YZPBF series frequence control three phase asynchronism motor be used in metallurgy and
crane. The motor is adopted assistant design and thought over the power of frequency conversion to
the motor bring the effect. The motor and some different frequency control device of all the other
country may be matched to composing AC frequency control system。 Interchangeability of The
motor is very strongly. The fixing size of the motor and the YZR2 series three phase asynchronism
motor is consistent to the smae machine. The motor is possess strong ability of over over
loading and machine intensity, especially adapt to equipment of short time and no continue to
start-up , frequently start-up and brake , positive and negative change, over load and distinct
libration and impact. Therefore the motor is the fit to frequence control system of crane and
metallurgy assistant
Motor rating pressure is 380V, frequency conversion range 1～100Hz , 1～50Hz is constant
torque timing . 50～100Hz is constant power timing . DOS shell of the motor safety grade is IP54,
and according to the using to make the IP55, insulated grade is F, and according to the using to
make the H.
6.1.3.2 Model explain
Y Z PB (F) 132 M 2 - 6
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Poles of motors
Asynchronous motor
for crane Code of core length
Frequency conversion Code of frame length

Forced – fan cooling Height of center
6.1.3.3 Type of motor cooling
YZPB series motor have coling ability, the basic character of service is S3～40%, YZPBF
series is adopt fan of autocephaly power to bring cooling wind to the motor. Benchmark character
of service is S1.
6.1.3.4 Structure and installation of motor
Structure and installing type of the motor are M1001、IM1003、IM1002、IM1004、IM3001、

IM3003、IM3011、IM3013, and manufactured acrroding to the Table 6-1-3.
According to requirement of users, the motor can be equipped with sensors of different
resolution rate(photoelectricity coder , motor with device of measure speed , excessive speed switch)
electromagnetism brake, gear reducer etc accessories etc.
表 6-1-3 Table 6-1-3
结构及安装尺寸代号机座号
Construction And Mounting Type Symbol Frame No.
IM1001 100～160
IM1003 180～400
IM1002 100～160
IM1004 180～400
IM3001 100～160
IM3003 180～315
IM3011 100～160
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IM3013 180～315
6.1.4 Brake
6.1.4.1 Summarize
YWZ5 brake of electric power and hydraulic pressure (The below is called brake) be used in
different rise, strap conveyance, haven and metallurgy machine for retardment and apply the brake.
The structure of the brake refers to Fig 6-1-2, the principle: when the power of machine turned
off and the brake stop to work, then the drive of brake as turn off power, stopping drive. Then the
spering of brake bring on a force to the both side of brake tile on the jib of brake, and to cause
stated pressure to the surface on brake as a moment of brake to prevent move. When the machine
power turn on the brake and drive start to work and drive bring on a enough force to push the
handspike to compel the spring be decreased. The jib of brake splay to two outside.cause the move
sides of brake tile leave the brake wheel, then the pressure and moment as clear away.
The brake with automatic tile and retroversion. According to the requirement of user, adding
the automatic repairment device of gasket abrasion make the retroversion, moment to keep
invariableness and leave out different adjusting in process. Basic no adjusting and maintenance.
The brake have been added the different limiter according to the make use of requirement.
According to the PLC to control to carry out alarm dictate of trouble and limitation of gasket
abrasion be found. The function is requirement to modernization crane of conveyance and highly
effect machinesm. The brake is increased release device in hand and safety switch according to
requirement. It is very convenience and safety to use.
The brake is production of antisepsis, all fasteners and pin rolls are stainless steel, and the
other components smeared the antisepsis paint may be used in the condition of salt atmosphere and
acid atmosphere.
The production is YTD or Ed series dirve, and possession advanced technic, reliable quality
and longevity by no means appear oil be leaked. The gasket of brake usually is material of half
metal of no contain the harmful material as the asbestos. the brake is noiseless, non-pollution
“ green production ”. According to the requirement to provide the gasket of brake with steel and
rubber, asbestos, brass wires etc.
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Fig 6-1-2 schematic diagram of brake machine
6.1.4.2 fixing and testing of brake
The brake should be installed rightly, otherwise the brake can not work normally. So users are
required to inatalled according to the manual and process strictly.
（1）The checking before installing
① The Check of brake
 whether the components of brake are completely.
 Whether the operating of brake is quick.
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 Whether there are oil dirt, paint and impurity on surface of brake gasket.
 Checking the model of the brake before fixing.( pressure of power 、frequency and
model of drive ) whether accord the spec.
Notice: if above requirements can meet, you can not install until they are solved.
② The checking of brake wheel
 Ensure that there is not rust, grease, smooth problems, dirt on the surface of brake, the
brake wheel of previously bring on crack or severe bug are forbidden to use.
 while the brake around axes to circumgyrate, the radial offset : diameter of wheel less than
250; the offset less than0.1
 Diameter of wheel more than 250 and less than 500; the offset less than 0.12; diameter of
wheel more than 500 and less than 800; the offset less than 0.15.
Surface roughness of brake is 3.2, the surface too coarseness and lubricity cause the brake
capability difference.
③ The construction of fixing pedestal and checking for brake
 Fixing pedestal of brake fexness is firm and smooth. Fixing pole locality dimension is
correct.
 If the brake and fixing pedestal be fixed in the same. After the brake be go to and fix, Then
fixup the brake and pedestal.
 if the brake no pole on fixing pedestal be made; then the brake be went to and fixed,
drilling the hole in the same.
the relatively tolerance(refer to figc6-1-3) no more than table (refer to figc6-1-4)of base level
of brake support and the hole or wheel of brake .
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图 6-1-3
（mm）
(mm) Depth
Wheel of （mm）high of of
K(mm) i (mm) Center remarke
brake center
offset paralleli
（mm） sm
S≤ e≤ a
160 132 130
±1 55
200 160 145 ±1.5 ±1.5 0.5
±0.5
250 190 180 65
225(230 ±0.5
315 220 80
)
±1.5 YW、
400 280 270 100 ±2.5 ±3 0.8
YWB
335(340 ±0.8
500 325 130
)
425(420
630 400 170
)
475(470 ±2 ±1.5 ±0.8 ±3.5 ±5 1.0
710 450 190
)
800 530 520 210
（2）The installing of brake
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Hoisting and installing brake refer to Fig.6-1-2.It is forbidden to make use of the brake pole.
Before the brake be installed, firstly ensure the maintenance and adjusting of brake at that side.
If the back distance of equalization bolt not at the side,then they be demounted and fixed at the
side.(refer to fig 6-1-3).
② Put the back distance of equalization bolt and lock nut (ferer to fig 6-1-3), nut of on the
screw all back to fit place. Make the lever no leash.
③ Open the brake to the opportune place.(refer to fig 6-1-4), for the basic model should be
anticlock wise screw the bar(refer to fig 6-1-4); for the brake of automatic repair should be
anticlock wise screw the back adjusting nut.(notic: loosen the lock bolt ,release expiation cover in
the needing must to pull out pin ); for the brake with manual device should be opend in the one. (If
the distance lack must more open the distance by screw the bar of brake or back adjusting nut.)
If the brake is fixed between the motor and reducer, one end of brake bar should be screwed
out, make it opend (refer to Fig 6-1-5).
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④ Move the brake opened to the fixing place, and hitch the wheel of brake, then make bay nut
hole to aim at the hole of bolt be fixed on the foundation support.
⑤ Clock wise to screw the brake bar or backing nut (refer to Fig 6-1-4), put expiation
journey hb of drive (refer Fig 6-1-4) adjust to the rating in Table 6-3-6.
图 6-1-6 推动器补偿行程示意图 Fig 6-1-6 expiation journey of drive

表 6-1-5 Table 6-1-5
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hb hb
（mm）（mm）
expiation expiation
brake spec brake spec
journey journey
Rating Least Rate Least
value value value value
YW(B)160-220 YWZ5 YW(B)400-1250 YWZ5
（E）-160/22 （E）-400/125
YW(B)200-220 YWZ5 YW(B)500-800 YWZ5
（E）-200/22 （E）-500/80
28±2 6
YW(B)200-300 YWZ5 YW(B)500-1250 YWZ5
25±2 5
（E）-200/30 （E）-500/125
YW(B)250-220 YWZ5 YW(B)500-2000 YWZ5
（E）-250/22 （E）-500/200
YW(B)250-300 YWZ5 YW(B)630-1250 YWZ5
（E）-250/30 （E）-630/125
YW(B)250-500 YWZ5 YW(B)630-2000 YWZ5
30±2 5
（E）-250/50 （E）-630/200
YW(B)315-300 YWZ5 YW(B)630-3000 YWZ5
25±2 5
（E）-315/30 （E）-630/300 75±2
6
YW(B)315-500 YWZ5 YW(B)710-2000 YWZ5 (18±2)
（E）-315/50 （E）-710/200
30±2 6
YW(B)315-800 YWZ5 YW(B)710-3000 YWZ5
（E）-315/80 （E）-710/300
YW(B)400-500 YWZ5 YW(B)800-3000 YWZ5
（E）-400/50 （E）-800/300
28±2 6
YW(B)400-800 YWZ5
（E）-400/80
Notice: The dimension in bracket is expiation journey for brake of automatic repair
⑥ Open the junction box, according to prescript correct connect the power wire of drive and
earth line (refer to fig 6-3-7) the wire be over, the cover the casing screw the bolt.
Notice: Junction box of drive levels of protection is more than IP55, cable incomed by the
filling to guide. The enter pipe of cable is M27×1.5, usually connection cable is 4×1.5mm and the
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max specification of cable is 4×2.5mm2, the junction box be seted the bolt M5 of connect ground.
The user according the using status to decide the thing.the drive have six wiring terminal with M5,
to connect Y or △ .the user according to the draw to connect the power line and earth line. For the
connection of drive motor, usually the connection is fulfilled before leave the company. The user
change the connection is forbided unless the user fined the method no accord the using. The false
method bring on the motor burn out, then our company is not quality duty. The drive connection
wire and clamp is fastness, or else the loose cable brings on the wire take off. result in the power no
tranquilization ect. Even the motor is burned out.
⑦ Power on 20~30 time during stop and start to switch. Then the brake automatically adjust
to the middle，lastly observe the brake in power-off if the fixing place is correct.
⑧ Ensure the fixing location is correct, according to adjusting nut 1of the side to draw back
equalization lever at level position.(Notice: equalization lever and brake whee distance is more than
3mm, equalization lever and fixing pedestal distance is more than 12mm ) then the connection
bolt of the other side be screwed to thread rod. And separate lock the nut 1, 2.
⑨ Screw foundation anchor and nut of connection pry (Notice: Donnot screw too tighte) .The
installing is over.
（3）The adjusting of brake
The adjusting of brake includes adjusting of brake monmengt, adjusting of wering plate and
adjust of equalization with autocompensation installation of brake, when the early adjust of aready
wearing plate,so the every work will needing to adjust, as if any out of way on working it will need
not to adjust.
① 。When the spanner clockwise rotation monmengt adjust nut3,so the brake spring working
length will be shorten and brake moment will be add, theother way round will reduction.
As required adjust of monment, in other place the limiter has rule. Consumer can according
to the fact of 50 percent rated value change a suitable moment,from leave factory brake
moment has already adjust.
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图 6-8
。Notice: while the brake be adjusted. （refer tofig6-1-8）Please accord to prescriptive moment
value on the moment scutcheon. or else the brake will appear abnormal phenomena.
 Tile of distance reducing
Tile of distance reducing and h journey of drive is direct ratio linearity , and that the h(journey of
drive) = H (rating journey value of drive ) –hb(compensation value of drive) .(for 1250N upwards
drive be set the designation staff guage ,fig 6-1-8.the journey of drive value must be designaed
inside the green line. If the value is inside the red line the journey of drive should be adjusted to
compensation. For the brake with device of automatic compensation ,the tile of distance reducing
has already been set and adjusted beforeing leaving factory , therefore the customer need not to
adjust the device is working in the normal. But the gasket of brake is changed new one or fixed
need to adjusting.
 adjusting of wearing plate
Brake has brake equalization device, seethe fig6-1-5, at working it not to adjust,if it has bed
disproportionate phenomenon,may be equable devices nut loose,at this time turn up the brake and
screw down the lock nut (note : equalization lever should approach locate near horizontal.)
6.1.4.3 usag and maintenance brake
（1）usage of brake
① Before usage, the brake must be inspected as the below instruction:
 if the brake be fixed is correct and accord the claim.
 check if accord claim to model ,pressure , frequency and connection,fill oil.
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 check if accord claim to testing

 check if accord claim to length of the brake spring
 If the brake washer and the brake plate are clean and without grease.
② The brake is normal to after checking, then take off the motor, the brake in static
circumgyrate above 25-30 time according to 40% power to continu to work with cycle in five
second. Continue to operation 25-30 times to brake. Observe if the brake is abnormal. Please refer
to second section prescribe to eliminate mistake. Then anew try to nomal.
Adjusting the moment value to 50% to brake(refer to fig 6-1-8), the moment in 30%~50%
refer to ② and try to function 10~15 time ( in dynamic) to observe the brake for stabilization.only
the brake is tranquilization to status that stopping.
After the brake is normal work, put the moment value adjust to be prescribed .then the
brake should be using in due form.
（2）Brake maintenance
① the brake must be inspected once every 1~3days (as per the practical situation) ,the
inspected items are as follows:
 Check if the working stroke of (the pad cancelling) the driving unit works normally.
 Check if the autocompensation installation is wearing , if the compensation socket and the
set screw are loose.
 Check if there is any change of the working length of the brake spring.
 if the touching board of the limit switch is loose and if the position is correct.
 if there is any oil soil on the surface of brake pulley and washer.
 the worn situation of the brake washer ,if the effective abrasion thickness is less than 3mm,
readjustment and running aer required for every time
 In emergency stop , Some stains with colors may occur on the brake wheel,if there is a
serious crak,it is necessary to replace the brake wheel.
② the inspection during usage
in operation process, user must inspect the following items in time
 if there is any abnormal increase of the brake time and brake distance during operation.
 if over speed situation on the brake wheel happens during the usage of the mechanism.
 Check if the action of limiter switch is correct and normal.
 Check if there is lasting high temperature (more than 350℃) on the brake wheel and the
brake washer or smoking. Ifany abnormity is found, stop the machine to inspect, find out
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the reason,usage is allowed after trouble clearing.

③ touch-up painting: during transportation process,storage,erection and operation, there
maybe damage to painting .re-painting if it is found, otherwise, the anticorrosion property will
reduce.the following parts are forbidden to be contaminated when the touch-up painting is
disposing to the brake and other relative parts:
 all the points of the hinge joint
 Firction surface of the brake wheel and the brake washer.
 the surface of the auto compensation device and the push rod of the driving rod
 。The sueface of the bearing.
④Lubrication: allthe hinge points of the brake aer adopted with self-lubricating composite
bearings; extra lubrication is not required during usage.
⑤ replacemengt of the brake washer: if the brake is used for a period of time ,the brake
washer will become thinner due to friction,when the effective adrasion thickness (grinding material
thickness) is less than 3mm, the washer must be replaced.pay more attention when carrying out the
replacemengt. The following is the instruction of the replacement:
 open the brake to the max .angle position.according to③
 screw the pressboard bolts on the washer diwn ,then get out the pressboard and adjust the
washer.(fig 6-1-9)
 old the washer and breake it off to one side of the brake whaal ,get the replaced
 then insert the new brake washer (notice the correct position)
 Mount the baffle and the pressboard in turn; fasten the bolys ,note that the brake washer
and the brake pad should be joint well, and the clearances of all the joint section will not
be longer than 0.5mm,the upper part of which should be higher than the top of the brake
pad,the superelevation of it (c) must be accordance with the drawings 6-3-8 and the
table6-3-4 below, so the brake washer could be jammed ,and fixed well.in addition, the
pressboards on the two sides,as well as the brake washer on the gland of the baffle,their
thickness could not exceed the 1/2 of the original thickness of the brake (including the
thickness of the steel back) , while could not be less than the 1/3(including the thickness of
the steel back).
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图 6-1-9
Fig. 6-1-9
表 6-1-6 Table 6-1-6

specification of wheel diameter on the brake C
160
200 0.8~1.2
250
315 1~1.5
400
1.2~2.0
500
630
710 1.5~2.0
800
Notice: After fixing washer of brake, please check, test run refer to the requirements in table
(1).
⑥．Themaintennance of the driving unit: the brake adopts YTD or Ed series. the driving unit is
filled with hydraulic grease before leaving the factory. It belongs to free-maintenance product, if the
user would like to refill or exchange the hydraulic grease, please carry out the operation as per the
instructions in the operation manual.
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6.2 slewing mechanisms
There are 2 sets of slewing mechanisms symmetrically arranged on both sides of up seat. With
A suit of HVV145B1.130AThey are driven by 2 sets of 7.5KW motors, which model is
YTW132M-4B5. They drive the pinions through planet gear reducer, hence making the jib and
counter-jib slew to the left or the right. The motors are provided with disc brakes at their tails,
which are kept at constant open status. The slewing brakes are used at windy conditions. They can
hold the tower crane in the specified direction and location while hoisting or jacking operation is
going on. It is forbidden to stop by brake.
Stopping the crane in off duty through electromotiona or hand movement to open the brake of
turn vane .making the jib follow the wind turn to tail wind direction.
The slewing mechanisms makes use of grease to lubricate (000 grease), when maintaining or
leakaging causes the oil level decline, renewthe grease in time ensuring that the grease arrives at
plug screw .
1. motor 2. reductor 3. slewing gear 4. slewing support

5. small gear 6. slewing limitter
fig 6-2-2 sketch map of slewing mechanisms drive
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6.3 Luffing mechanism
6.3.1 summarize
The the luffing mechanism of this tower crane is BPL370, the most luffing force is 40t, the
motor of frequency conversion is YZPB(F)250M2-8 , rating load lowest decline speed is not greater
than 10 m/min.
Luffing mechanism is similar to the hoist mechanism in luffing tower crane, the constitution
of thedrive system of luffing mechanism refers to Fig 6-1. When luffing, the motor drives the drum
through the planetary reducer and connectors to link. The distance of crown block and travling
block through the wire rope is turn by drum to adjusting. The trolleying pole drives the jib up and
down turn for trolleying。Drum end of trolleying mechanism be fixed the journey limit device.
While luffing move to the limit position, it will stop automatically.
1－motor 2－brake 3－coupler 4－reducer 5－roll
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6－multifunctional stopper 7－safe brake 8－undercarriage
Fig 6-3-1 trolleying mechanism
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6.3.2 performance parameters of luffing mechanism
Table 6-3-1 performance parameters of trolleying mechanism
6.3.3 motor
6.3.3.1 summarize
YZP series three phase asynchronism motor be used in metallurgy and crane. It be used
different crane machine and the other similar production. And the power of motor is frequency
control device. The motor and all over the world different frequency control device assort to
compose frequency control system. The motor change speed area very wide, strong ability of over
loading, stably and reliable function, high efficiency. Therefore the motor is the same with device
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for short time, no continue to start-up ,brake ,over load and libration and impact.
6.3.3.2 condition of using
It can work normally in case of altitude not exceeding 1000m. The F level is suit in the
condition of temperature in-20℃~40℃ , the Hlevel is suit to the air temperature in-20℃~60℃.
6.3.3.3 basic forms
Mark Preesure：380V
basic frequency：50Hz，1-50Hz
timing of constant torque ，50-100Hz timing of constant power
level of protection：IP54 insulation grade ：F 或 H
fashion of cooling： coling fan（IC416）
Basic job ：S3-40%
fashion of fixing：B3（112~400）、B5（112~250）、V1（112~315）、B35（132~315）
connection fashion ofstator ： (stator winding of motor is Y connection under 132 ) ;( stator
winding of motor is △ connection under 160 )
Notice: according to the using requiremengt to set the switch with temperature inductor to
protect hyperthermia , dampproof device. Brake of electromagnetism, encoder and switch of
hypervelocity etc , for the requirement to provide the motor that the basic frequency under 50Hz .
6.3.3.4 type of coling fan
Mark Preesure：380V basic frequency：50Hz

Basic job：S1
at axes flow power of fan: 230W ( Power of coling fan independent be used , forbid to use
the power of frequency conversion )
6.3.3.5 The correct using mothods of motor.
The prepareing before fixing.

（1）Check whether the motor exist damp evidence
（2）Must be careful clear dirt and coat on the surface and side of assemblage
（3）Check if motor nameplate data is accord to requirement.
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（4）Must be careful check if the motor is distortion and damnification , and fastener is loose
and break off.
Putting the motor adjusting in status of release. The motor be turned by hand, the turn must be
agility, no blocking ,and no rubbing etc abnormal status. Recovering the status of brake after
checking.
（6） The motor be kept more than two years. Must be checking grease of axletree, if the
grease turn induration, the news will be change the spec in the same.
6.3.3.6 The storage and transit of motor
（1）If motors need leave in storage, they must be properly taken care of. The motors that have
been opend for checking, they must be taken care of anew.
（2）Motor must be kept in bursary of cleanliness, desiccation, no acid and alkali or other
causticity gas. And change of rapid ambience and temperature be avoid.
（3）Motor too high accumulate in storage will cause less airiness and shatter the bottom
casing of motor.
（4）Motor must be avoid incline to place or roll in storage and transit.
6.3.4 break
6.3.4.1 summarize
YWZ5 arrester of electric power and hydraulic pressure (brake) can be widely used in different
hoisting, strap conveyance, haven and metallurgy machine of retardment and apply the brake.
Structure of The brake as follow Fig 6-3-2,
The principle: when the machine power turn off the brake stop to work. Then the drive of
brake as turn off power, stopping drive. Then the spering of brake bring on a force to the both side
of brake tile on the jib of brake, and to cause stated pressure to the surface on brake as a moment of
brake to prevent move. When the machine power turn on the brake and drive start to work and drive
bring on a enough force to push the handspike to compel the spring be decreased. The jib of brake
splay to two outside.cause the move side of brake tile leave the brake wheel , then the pressure and
moment as clear away.
There are tile and retroversion with automatism in the brake. According to the using
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requirement to add the automatic repairmen abrasion gaske cause the retroversion, moment to keep
invariableness and no adjusting in process. The brake have been added the different limiter for the
using. According to the PLC to control, and conk out and limit of gasket abrasion once appear to
alarm and show the signal. The function is requirement to modernization crane of conveyance and
highly effect machinesm. The brake adds to release device in hand and safety switch according to
requirement. Convenience and safety in using.
The brake can provide with antisepsis productions, all fasteners and pin roll are stainless steel,
and the other components are smeared the antisepsis oil paint.
The production is YTD or Ed series dirve, and possession advance technology, reliable quality
and longevity by no means appear leakage oil. The gasket of brake usually is material of half metal
that no contains the injurant as the asbestos. the brake is noiseless, non-pollution “ green
production ”. According to the using requirement to provide the gasket of brake with steel and
rabber, asbestos, brass wires etc.
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Fig 6-3-2 schematic diagram of brake mechanism
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6.3.4.2 The installing and testing of brake
Brake should be installed rightly, otherwise the nomal work of brake will be influenced, so the
installing is required to strictly according to the manual and process.
（1）The checking before fixing
①：The checking of brake
 check if the components of brake are complete;
 Check if the operation of the brake is agility.
 Check whether there is oil dirt that influences friction force on the surface of gasket of
brake.
 Check whether the model of the brake before fixing. (Including pressure of power,
frequency and model of drive) correspond to the requirements.
Notice: If above qualifications can not meet the requirement, So you must solve them,
then begin to install.
②The checking of brake wheel
 The surface of brake cann’t be stained with rust, grease dirt, smooth problem, forbid using
brake wheel of previously bring on crack or severe bug.
 While the brake gyrating around axes, the radial offsets: diameter of wheel less than 250,
the offset less than0.1, diameter of wheel is more than 250 and less than 500, the offset is
less than 0.12, diameter of wheel is more than 500 and less than 800, the offset is less than
0.15.
Notice: The surface roughness of brake is 3.2, the surface excessively coarseness or
lubricity of brake will cause the brake capability difference.
③The Construction of installing pedestal and the check for brake
 The fixing pedestal of brake fexness should be firm and smooth, fixing pole locality
dimension should be correct.
 If the brake and fixing pedestal are fixed at the same time, you should fixup the brake and
pedestal after the brake locating and preparatorily installing.
 If the poles on fixing pedestal have not machininged, you should drill the hole after the
brake located rightly,
Notice: the relatively tolerance of base level of brake support and the hole or wheel of
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brake (refer to Figc6-3-2)can not exceed the requirements in Table 6-3-2.
table 6-2
（mm）
(mm) Depth
Wheel of h1（mm）
K(mm) i (mm) Center of remarke
brake high of center
offset paralleli
（mm） sm
S≤ e≤ a
160 132 130
±1 55
200 160 145 ±1.5 ±1.5 0.5
±0.5
250 190 180 65
±0.5
225(230
315 220 80
)
±1.5 YW 、
400 280 270 100 ±2.5 ±3 0.8 YWB
335(340 ±0.8
500 325 130
)
425(420
630 400 170
)
475(470 ±2 ±1.5 ±0.8 ±3.5 ±5 1.0
710 450 190
)
800 530 520 210
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（2）The installing of brake

Hoisting brake should refer to Fig6-3-2, it is forbid to make use of the brake pole to hoist.
①Before the brake installed, firstly ensure the maintenance and adjusting of brake at that side.
If the back distance of equalization bolts is not at the side, then they be demounted and fixed at the
side.
②。Put the back distance of equalization bolt and lock nut, nut of on the screw all back to fit
place. Make the lever no leash.
③Open the brake to the opportune place (refer to Fig 6-3-4), the basic model should be
anticlock wise screw the bar (refer to Fig 6-3-4); for the brake of automatic repair should be
anticlock wise screw the back adjusting nut. (Notice: loosen the lock bolt, release expiation cover in
the needing must to pull out pin); for the brake with manual device should be opend in the one. (if
the distance lack must more open the distance by screw the bar of brake or back adjusting nut ) .
If the brake is fixed between the motor and reducer, one end of brake bar should be screwed
out, make it open (refer to Fig 6-3-5).
图 6-3-4
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④Move the opend brake to the installing location, and hitch the wheel of brake, then align the
hole of foundation anchor to the hole of bolt the foundation support, screw the foundation anchors
loose, at last,install the brake anew.
⑤Screw the brake bar or backing nut clockwise (refer to Fig 6-3-4), adjust expiation journey
hb of impulse (refer to Fig6-3-6 ) to the value in Table 6-3-6, then screw the check nut of brake
bar tightly.
Fig 6-3-6 expiation journey of impulse
表 6-3
Hb(mm) Hb(mm)
brake spec expiation brake spec expiation
journey journey
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Rate Least Rate Least

value value value value
YW(B)160-220 YWZ5（E）-160/22 YW(B)400-1250 YWZ5 （ E ）
-400/125
YW(B)200-220 YWZ5（E）-200/22 YW(B)500-800 YWZ5（E）-500/80
YW(B)200-300 YWZ5（E）-200/30 YW(B)500-1250 YWZ5 （ E ） 28±2 6
25±2 5 -500/125
YW(B)250-220 YWZ5（E）-250/22 YW(B)500-2000 YWZ5 （ E ）
-500/200
YW(B)250-300 YWZ5（E）-250/30 YW(B)630-1250 YWZ5 （ E ）
-630/125
YW(B)250-500 YWZ5（E）-250/50 YW(B)630-2000 YWZ5 （ E ）

30±2 5
-630/200
YW(B)315-300 YWZ5（E）-315/30 YW(B)630-3000 YWZ5 （ E ）

25±2 5
-630/300 75±2
6
YW(B)315-500 YWZ5（E）-315/50 YW(B)710-2000 YWZ5 （ E ） (18±2)
-710/200
30±2 6
YW(B)315-800 YWZ5（E）-315/80 YW(B)710-3000 YWZ5 （ E ）
-710/300
YW(B)400-500 YWZ5（E）-400/50 YW(B)800-3000 YWZ5 （ E ）
28±2 6 -800/300
YW(B)400-800 YWZ5（E）-400/80
Notice: The dimensions in bracket are expiation journey for brake of automatic repair
⑥ Open the junction box, connect the power wire of drive and earth line correctly according
to prescript (refer to Fig 6-3-7), after connecting wire, cover the connecting box and screw the bolt
tightly.
Notice: The protectiing level of conneting box in impulse equipment is above IP55, cable incomed
by the filling equipment. The size of incoming cable is M27×1.5 , Connection cable usually is
4×1.5mm2 and the max specification of cable is 4×2.5mm2 .The junction box set the ground device
both inside and outside with M5 bolt. The user could equip under the necessity of oneself. The drive
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have six terminal connector with M5, which include two type about Y and △. So user could connect
the power line and earth line according to the schematic diagram . The connection of drive motor
has finished before leave the factory. The user couldn’t change the connection unless the method
isn’t meet the requirement of user. The incorrect wiring probably conduce the motor burnout, which
is not duty of our company. The impulse’s connection wire must be fastness and electric cable
also must be fastness by the filling equipment , otherwise the loose of cable lead to the interface
break off and the power no tranquilization etc, even the motor burned out.
⑦ Power on 20~30 times during stop and start to switch, make the brake automatically adjust
to the middle，lastly observe the brake in power-off whether the fixing place is correct.
⑧ Ensure the installing location correctly, according to adjusting nut 1 of the side to draw
back equalization lever at level position(reference6-3-3). (Notice: equalization lever and brake
wheel distance is more than 3mm ,equalization lever and fixing pedestal distance is more than
12mm ), then the connection bolt of the other side be screwed to thread rod. And lock the nut 1, 2
separately. Then screw the other in the same way.
⑨ Screw the bay bolt and nut of connection pry (notice: not tighter), the fixing be over.
（3）adjusting of brake
Adjusting of brake include adjusting of brake monmengt, adjusting of wering plate and
adjusting of equalization with autocompensation installation of brake, when the early adjust of
aready wearing plate,so the every work will needing to adjust, it will need not to adjust if any out of
way on working.
① The brake monment adjust: the brake monment has already adjust since leave factory brake
moment. As required adjust of monment, User could according to the fact of 50 percent rated value
to change a suitable moment. Adjust method: when the spanner clockwise rotation monmengt adjust
nut, the brake spring working length will be shorten and brake moment will be add, the other way
round will reduction(reference6-3-8).
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图 6-3-8
Notice: Please don’t exceed prescriptive moment value of the moment scutcheon while
adjusted the brake moment. Otherwise the brake will appear abnormal phenomena.
② Adjustment of distance reducing:
The reducing distance of tile and journey of drive is direct ratio linearity, h(journey of drive)
= H (rating journey value of drive ) –hb(compensation value of drive). (The inpulse upwards 1250N
have indication guage, refer to Fig 6-3-5. The journey of drive value must be inside the green line.
The compensation journey of drive should be adjusted if the value is inside the red line. The
distance reducing of tile has already been set about the brake with device of automatic
compensation have been adjusted beforeing leaving factory, so the user need not to adjust the device
in normal, which except changing a new one and fixed situation. The menthod of adjusting refer to
Fig 6-3-1.
③The adjusting of wearing plate
All of brake has distance reducing automatism equalization device(refer to Fig6-3-3), it does
not need to adjust in working situation(This is proprietary technology of our company), it appear
disproportionate phenomenon when the equable devices nut is loose, it is need turn up the brake and
screw down the lock nut right now (note : equalization lever should locate near horizontal).
6.3.4.3 usag and maintenance brake
（1） usage of brake

① Before usage, the brake must be inspected as the below instruction:
 The brake fixed correctly accord the claim or not;.
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 Check if the model, pressure, frequency and connection , fill oil of impule meet the
requirement .
 Check if brake testing meet the requirement.
 Check if the length of the brake spring meet the requirement.
 Check if brake washer and the brake plate are clean and without grease.
② After Checking the brake is normal. The brake run 25-30 time in static circumgyrate in
condition of motor power-off, the power continu rate is 40% and cycle time is five second.
Continue to operation 25-30 time, Observe the brake is normal or not. Please eliminate mistake
refer to second section prescribe if the brake is unnormal, then try again until nomal.
③Adjusting the brake moment value to 50% of specified value (refer to fig 6-3-5). refer to ②
to run 10~15 time ( in dynamic) in the 30%~50% of brake moment, then observe the brake for
stabilization. It could stop if the brake is tranquilization.
④If brake is normal work , put the moment adjust to prescribed value.then the brake could be
used.
（2）the maintenance of brake
①the brake must be inspected once every 1-3days (as per the practical situation), the primary
coverage items are as follow:
 Check if the working stroke of (the pad cancelling) the driving is works normally.
 Check if the autocompensation installation is wearing. The compensating socket and the
set screw are loose.
 Check if there is any change of the working length of the brake spring.
 Check if there is any loose in touchingboard of the limit switch and the position is correct.
 Check if there is any oil soil on the surface of brake pully and brake wheel.
 If this is worn situation in the brake washer and the effective abrasion thickness is less
than 3mm, it should change and adjusting and running for every time.
 Some stains with colors may occur on the brake wheel in emergency stop, it is necessary
to replace the brake wheel if there is a serious crack.
②The inspection during usage
User must check the following items in time for operation process:
 There is abnormal increase of the brake time and brake distance during operation or not.
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 Check if over speed situation on the brake wheel happens during the usage of the
mechanism.
 Check if the action of limiter switch is correct and normal.
 Check if there is lasting high temperature (more than 350℃) or smoking on the brake
wheel and the brake washer. Stop the machine if any abnormity is found, then find out the
reason. Running again after trouble clearing.
③Add painting: During storage and erection operation and transportation process, the painting
maybe damage in some palce, re-painting if it found, otherwise, the anticorrosion property will
reduce.To contaminate the following parts are forbidden when the touch-up painting is disposing to
the brake and other relative parts:
 All of the points of the hinge joint
 Firction surface of the brake wheel and the brake washer.
 The surface of the auto compensation device and the push rod of the driving rod.
 The sueface of the bearing.
④ Lubrication: all of the hinge points of the brake are adopted with self-lubricating composite
bearings; extra lubrication is not required during usage.
⑤Replacemengt of the brake washer:The brake washer will become thinner due to friction if
the brake is used for a period of time. When the effective adrasion thickness (grinding material
thickness) is less than 3mm, the washer must be replaced. Pay more attention when carrying out the
replacemengt. The instruction of the replacement are as following :
 Open the brake to the max angle position according to 6.3.4.2.2.3
 Screw the pressboard bolts on the washer diwn ,then get out the pressboard and adjust the
washer.(fig 6-8)
 Hold the washer and pull it to the brake wheel side, the get the washer to replace
according to circumference direction .
 then insert the new brake washer (notice the correct position)
 Mount the baffle and the pressboard in turn, fasten the bolys. Note: the brake washer
should joint well with the brake pad, and the clearances of the joint section should not
longer than 0.5mm, the upper part of which should be higher than the top of the brake pad,
the superelevation of it (c) must be accordance with the drawings 6-3-8 and the table 6-3-4,
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so the brake washer could be jammed and fixed well. In addition, the thickness of the
pressboards on two sides and the brake washer on gland of the baffle could not exceed the
1/2 of the original thickness of the brake (including the thickness of the steel back), it also
could not less than the 1/3 of the original thickness (including the thickness of the steel
back).
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表 6-3-4
Specification of wheel diameter on the brake C
160
200 0.8~1.2
250
315 1~1.5
400
1.2~2.0
500
630
710 1.5~2.0
800
After mounting the new brake washer, please check and try to run according to ①.
⑥The maintennance of the driving unit: the brake adopt YTD or Ed series. the driving unit is
filled with hydraulic grease before leaving the factory. It belongs to free-maintenance product. If the
user would like to refill or exchange the hydraulic grease, please carry out the operation according
to the instructions.
6.3.5 SBD80-D safety brake
6.3.5.1 Summarize
which mainly be used in the emergent safety brake for big-sized or medium-sized crane with
low speed axes of main rising mechanism, it also could be used to brake for big-sized or
medium-sized windlass and drive mechanism of inclined aerotransport, as well as cable car and
crane with rope. The dish spring is used in this brake and the hydraulic station drive could be
released, so the configuration is compact and it simple to be maintained. The production and the
friction material are not contain asbestos to personal health. In conclusion, the brake is a advanced
and high-performance product.
The configuration of brake is in fig 6-3-10, the operation principle are as follow :when the
pressure oil in the hydraulic pump station enters into the brake cylinder under the control of the
magnet valve, the hydraulic oil compress the spring further to push the piston rod driving the
brake arm to the both sides, so the brake monment is eliminated; when the magnet value reset with
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power off, the hydraulic oil back-flow to the hydraulic pump station under the force of the spring,
meanwhile, the spring force is applied to the forced brake plate through brake arm,finally the
defined brake moment is established.
1. eyebolt 2. lock screw 3. brake screw (support bar)

4. support bar for limit swiych 5. plugging 6. rate plate
7. hydraulic cylinder(with spring) 8. frame 9. brake arm
10. backing lock nut 11. backing adjusting screw
12. accompanied device 13. brake washer 14. brake arm 15. limit switch
fig 6-3-10 moment
（mm）（MPa）
（kN）pressure （kN）friction
specification Back distance of Release
of clamp force
tile pressure
SBD80-D-Ⅱ 1.5 80 57 8/10
fig 6-3-11 is schematic diagram of hydraulic pressure ，fig 6-3-12 is schematic diagram of
electricity control, the user could design the schematic diagram according to personal requirement .
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Fig 6-3-11 Schematic diagram of hydraulic pressure
Fig 6-3-12 Principium and connection with electricity equipment
6.3.5.2 fixing and adjusting
Brake should be correct fixed, otherwise, it will short of the capability of design, so the user should
fix and test according to the method of handbook. please contact the market department if need
help.
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（1）before preparative of fixing
 Check if the brake with the scutcheon and request accord before fix.
 Check if components of brake is complete (Check if connecting pipe and options is
complete if fix with hydraulic pressure )
 Check if rustiness and block is active dot.
 Check if brake gasket face is not dirt and cover impurity affect the capability.
 Ensure the brake plate is not rustiness, oil dirt, electricity welding and out-of-flatness.
Forbid to use brake which is crack and severity disfigurement.
。
It should be ensure correct If founded abnormity.
（2）Fixing
Please follow the fig 6-3-9 to life and install the brake. Forbid to use the oil-hydraulic
cylinder and plunger pole to life。
The bracket should be fixed before install the brake, the bracket should have enough
intension and rigidity. The form and dimension reference the fig 6-3-13. It connect to pedestal with
bolt.
The specification and amount and capability must meet the requirement of table 6-3-6
Fig 6-3-6
Connecting of Brake and B racket
Specification of brake Specification NO. Capability Screw moment
of bolt
SBD80-D01 M30 4 ≥8.8 1000Nm
Please reference the follow process to fix brake:

 Before install the brake, the hydraulic stage should be fixed in place, pipe line and control
circuitry should be disposed.
 Use the bolt to connect the brake and bracket .
 Open the brake arm and ensure the distance of brake gasket greater than brake check
thickness above 3mm.
 Putting the support plank of being fixed and brake of being opend placidly move to fixing
place (fig 6-13). Please notice the oil mouth of brake is in the side of hydraulic pressure
pipeline(the brake be fixed with twin, pipeline disposal is symmetry ). Make sure the
brake close with brake disk in the correct place. Then Check if the place of brake is
correct.
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Notice: Ensure both side of gasket and brake is parallel (fig6-3-13 ), use the pad to adjust
the side of connecting on plank and brake if not.
Connect hydraulic pressure pipeline with oil-hydraulic cylinder oil mouth of brake,
entering oil mouth of brake oil-hydraulic cylinder is internal thread M18X1.5.
 Fix cable of the journey switch according to host computer PLC claim (signal indication).
Connection must be fastness and make sure screw clamp of cable is fastness。
Table 6-3-7 Dimension od install

Type of brake A B C D E H d
SBD80-D01 150 240 16.5 800-1800 45 320.5 32
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（3）adjusting
。It must be adjust at first fixing and change new attrition gasket. Please according to follow
step to adjust at first time.
①Adjusting of tile backing distance and clamping force: brake Tile back distance will directly
influence clampping force of brake, so it must be adjusted prescriptive value before use. Tile back
distance and X value and clamping force have bijection nexus. Check if dimension X of the brake in
close status accord table 6-3-8. Please adjust as follow mothod if status is not correct :
Firsly open the brake ( it is two mothod to open the brake in anytime )
 ；Operate the hydraulic pressure station to bring pressure oil so that open the brake.
 Operate manual the hydraulic pump to open the brake, The X value decreased if adjust the
nut with eddy method (fig 6-3-15). Contrarily clamp pressure increased if X value
increased. Then cloes the brake to observe X value after adjust, once more adjust the brake
until accord to the value, then screw down the nut.
Table6-3-8
（mm）（mm）
specification
every tile back distance X distance
SBD80-D01 1.5 160-0.5
Notice: Stick direction lable for measure part and measure value near fluid cylinder ( fig
6-3-14 ), please reference during the adjusting.
图 6-3-14 fig 6-3-14

Brake model Friction X（mm）
SBD80-D01 57KN 16-0.5
② Self-motion device of pull springthe is setted in two brake tile of brake (fig 6-3-15).
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Loosing the nut before fixe the brake (part 10) to make the spring(part 12) is in loosen; Screw the
bolt(part 10) in situation of the brake is clamped status after the brake be firm fixed。It is not to
adjust under normal status , the place of spring is loose if the place is abnormality, So it should be
re-fix or change the spring and adjust according to above-mentioned mothed.
③ Adjusting of back distance equal: brake should be adjusting in original fixing or gasket of
brake appear abrasion. Firstly release the brake to normal， then observing the clearance of brake
tile and brake tray is consistent or not. It should be adjusting the clearance to the same if not. The
method of adjusting are as follow: firstly looseing the lock nut of back distance equal device in both
sides(part 10), then screw the bolt of major distance until both sides back distance basic is equal,
(Notice: it should exist some space between the adjusting bolt and wall of base in the other side, it
must back the nut bolt if it is not space ), then adjust the nut bolt of small side until the distance
between pedestal is 0.2~0.5mm, lastly screw lock nut to both side.
图 6-3-15
④Adjusting of release limit switch: Each brake take with journey switch of brake release
signal. Adjust the travel switch after all of adjusting complete. Methods are as follow: make sure
the brake is closed, measure distance between the head of switch to inductor using calipers, it
should above 3mm. otherwise, loose the lock nut on switch support(no disassembly), then move the
switch front or back until accord with the claim(fig6-15), then release and close brake for many
time, lock nut until the switch signal tranquilization.
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6.3.5.3 Using and maintenance

（1）Using
Check content are as follow before using of brake:
 Check if the install of brake is correct and tally with the claim.
 Check if all of adjusting arrive at technical requirement.
 Check if the brake gasket and facies of brake tray is clean.
 Check if paint is complete, otherwise it should be re-paint. The follow part could not be
polluted In repairing process:
1. All of articulate dot of brake;
2. The brake gasket and facies of brake tray
3. Facies of axes
It could be use if normal.
（2）Maintenance
① Check the brake every 7 to10 days, the content are as follow:
 Check if spring of dish is cataclasm or not and fluid cylinder leak to dish spring or not
from fluid cylinder of brake espial window. The new part must be changed or maintain the
old one while dish spring is cataclasm or oil reveal. (Develop method of fluid cylinder of
brake is optimum design, so the life of theory for work is above 500 thousand ).
 Disassembly fluid cylinder of brake are as follow: firstly open the brake, loose the
adjusting nut (at least loose 10mm). Disassembly the lock nut, Then close the brake
(remove the force of spring), remove pipeline of fluid cylinder and end of fluid cylinder
link pin(fig 6-10), at last fluid cylinder could be complete remove. The new fluid cylinder
fixed in reverse order, then adjust the new one according to 6.3.5 section, it could be used
after adjust.
 Notice: 1. Inner structure of fluid cylinder is different to other one, and it containing
expert link technic, so don’t disassemble by youself. contact to us will prevent hurting
person from dish reed come out. 2. We advice chang the failure of fluid cylinder with
whole , which should back to our company to maintain .
 Check if journey switch poll of touch is loose and action is correct.
 X dimension become longer because of attrition of gasket, which make clamp force
decrease. So it should adjust to prescribe value.
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② Lubricate: articulate dot of brake is used the Lubricate bearing , no Lubricate in process of
use.
③ Change of gasket: new attrition gasket shold be change while attrition gasket thickness
less than 3mm,. Process are as follows:
 Open the brake most locality.
 loosen the fixing screws of gasket.
 Firstly hold the gasket and pull into the side of brake disk, which make the gasket
disengage from join key, then draw the old gasket out along circumference.
 Check if surface of gasket is clean and distortion, it should change the new gasket if the
surface occur oil is dirt accord with provision。
 New gasket should be cutted in fixing place along circumference, put key of gasket into
the place of conection, at the same time, screw down connect bolt.
 After install new gasket please adjusting again according to 6.3.5.
Warning: because of the brake gasket is weight, please caution it hurt person if
falling down, please make sure brake be opened status and prevent close.
6.3.5.4. frequent trouble analyse and eliminate.
（1）To arrester give off electricity signal of No acting

① Cause、checking and remove of trouble .
 Circuitry or control trouble cause electricity valve of drive Hydraulic pressure lead to stop
to power. So checking the circuitry or control to exclude trouble.
 Control electricity valve turn off will lead magnetic valve stop acting. Use multimeter to
measure winding turn off or not. It must change the new if the Loop turn off.
 Flooding valve press too low to enactment cause arrester not opened. Observe the value of
pressure gage for hydraulic pressure station and arrester mark out value whether consistent;
the value should be adjust pressure value to high if low to the demand need.
 Checking the motor with multimeter if Motor burned out, the motor should be change the
new correspond spec model if motor be damaged (according to detail of instruction
book ).
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 If hydraulic fluid is disagree with local entironment and temperature lead the oil could not
inhale to oil pump, the hydraulic fluid should be changed to correspond spec In such
case( the temperature is 0~+30℃, recommend to use L-HM46 或 DTE25. the temperature
is -20~+25℃ , recommend to use L-HM46 或 DTE25.)
②trouble preventive measure
Keeping Control loop element for protecting motor is right, loop of electromagneticvalve
could not over the setting pressure. Preventing the loop burned out instantaneous, keep the
hydraulic fluid is clean, Don't random adjusting each part of Hydraulic pressure station during the
work time
（2） Distance of two side is not equality.and one side may adhibit on brake disk.
①cause、checking and remove of trouble.
 The center of brake deflection to one side when arrester is installed with serious deflexion.
adjusting the gasket between fixing support and ransition board.
 Adjust if incorrect adjusting according to former means.
②preventive measure
Correct fix and adjust.
（3） Journey switch action trouble.
① cause、checking and remove of trouble..
 Adjust limit switch roller and ejector pin for location refer to 6.3.5.2.d if distance adjust
improper.
 Hydraulic fluid is not fit because of season. Brake is opened up to ordain place as a
entirety result from weather chill and viscosity increase. Hydraulic fluid should be
replaced in time and opportune adjust the press for Hydraulic pressure station system in
such case.
② Preventive measure
 Correct adjusting in install, Check if the mandril is loose. Hydraulic fluid should fit the
work environment in local.
6.3.5.5. Quick-wear part listing
mode title spec/fig number gasketremark

SBD80-D0 break gasket SBD0180.4 2 Made by
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1 oneself
Induction
Bi5-M18-AZ3X 1 Truck
switch
Dust proof AF2 80/2 1 AOKANG
U -ring AU1 8090/1 1 AOKANG
Guide strip BS50704 L=260 1 AOKANG
site envelop AS1300800 1 AOKANG
Guide strip BS50704 L=465 1 AOKANG
U -ring AU3 145160 1 AOKANG
o -ring 158X1.5 1 GB3452.1
o -ring 40X3.5 1 GB3452.1
site envelop AS1301450 1 AOKANG
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6.4 Climbing Jack
6.4.1 Summarize
（1）Structure introduce
The hydraulic system consists of pump station, climbing jack, high-pressure hose and special
oil. It could jack or lower the upper parts of the climbing frame, and stop for tower section remove
at any position, it shown as Fig. 6-4-2
This hydraulic installation is compact, efficient, reliable and easy to maintain
Fig. 6-4-2 Hydraulic connection for hydraulic system
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Table6-4-1Main Parameters of pump station
nominal Power Hose Oil tank Oil

Flux
voltage kW JB1885-77 capacity L Requirement
L/min
MPa
1.5 14.5 7.5 A-10Ⅱ 100 ESSO AW46
Table 6-4-2 Main Parameters of Climbing Jack

MPa Cylinder Diameter Distance Installation (m/min)
Max. Jack
Rated Diameter of Rod of Travel Distance Jack speed
force (t)
Pressure (mm) (mm) (mm) (mm) (m/min)
31.5 200mm 140mm 2000mm 2663mm 0.46 98.9
1.Jack cylinder 2.Balance valve 3.Manual control valve 4.Pressure gauge

5.High pressure overflow valve 6. Motor 7.Level meter 8. Bent axis pump
9. oil filter 10.fine oil filter 11.Air filter
Fig. 6-4-3 Schematic diagram of climbing Jack ydraulic System
(The fig is only to reference, Please read the operation instructions of hydraulic system if you need
the detail of configuration )
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6.4.2 Erection and operation of the hydraulic system
6.4.2.1 Oil cleaning
Screw open air filter II, Fill into the oil tank up to the upper limit mark with 10μ of hydraulic
oil filtered by hand-held oil filter. Then start the oil pump motor (look down at the motor blades to
make sure the rotation direction is same as the marked at the motor tail). Pay attention to the fact
that the pump may be rotated either left or right. Wrong wiring will cause the system is not work
and pump burn-down.
（1）Check if the connect of high-pressure hose openings is clean. Connect the ports A.B of
the hydraulic pump station with the hydraulic cylinders through high-pressure hose, then Screw
down the connectors.
（2）Air exhausting of the system
①Air exhausting from hydraulic pressure: firstly unscrew the handle of overflow valve 5, then
unscrew the high-pressure of hose-to-port A connector. Move the handle of hand-operated valve 3
into 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.
②。Make the cylinder into no-load status. In order to exhaust the air from cylinder into oil tank
through oil hose completely, pushing the operating handle to drive upper cylinder or piston rod
move up and down at full strokes for several times,
Notice:pull back the handle immediately to its middle position when the piston rod has
moved to its extreme position, then keep this position for several minutes until air bubbles in
oil tank have disappeared, and then carry out another action
6.4.2.2 System operation
Before system operation, check if the oil cylinder is well connected to the crane frame,
including the relevant portions of the tower crane meet relevant technical requirements or not.
（1）Maximum working pressure setting:
Adjusting of max work pressure: Unscrew the locking nuts in front of the control handle of
high-pressure overflow valve 5, Start motor 6. Move the operating handle to upper position and
extend the cylinder piston rod to its extreme position. pressure gauge readings will rise at this time.
Keep on screwing down the handle of the overflow valve until the readings on pressure gauge is
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31.5 Mpa. Then 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 6 and move operating handle to its up position. The cylinder piston rod is
extrude to hang the hanging plate which is connected to the piston rod into the lugs slot of the tower
mast section. Carry out the jacking operation for new section adding (or tower section disintegrate).
6.4.2.3 Maintenance and precautions of hydraulic system

The hydraulic system is an uper high-pressure or high-pressure equipment. The whole
process of oil filling to adjustment should be accomplished strictly according to the operating
instructions
（1）Hydraulic oil for the system
The hydraulic system should use the anti-friction hydraulic oil AW46 by ESSO, USA
Filling oil for hydraulic system
 Fully fill the tank with oil for the first time, Extrude the cylinder rod after start-up, then
retract the cylinder rod, at this time, fill the tank with make-up oil up to the tank upper
limit mark.
hydraulic system 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
degree (NAS1638) before run the system.
 The oil should be completely changed after the system work for 2,400hr and add part of
clean oil after working for 200h.
 Shut the system when it is out of service because of the poor condition of ventilation.
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7 Operation
7.1 Operation guide
7.1.1 Pre-check before operation
Checking item Checking content

Check fastness of foundation bolts
Check safety margin between the surrounding power lines and
Foundation
tower crane
Check power cables for smooth routing to avoid damage.
Check the tightness of tower sections’ bolts.
Tower body
Check the tightness of platform , handrail and ladder
Check the connection for slewing support.
Check if the guide wheels, latches, pin-bolt-connected parts move
climbing frame
smoothly
Check the tightness of walkway,railing
Check the tightness of bolts connecting to slewing ring
Check if the guide dolly move smoothly
slewing support Check power cables for smooth passage
turntable Check the tightness of platform , handrail
Check the tightness of slewing support and turntable connecting to
tower body
Check the connection for operator cab
operator cab Check the connection for inner circuit

No storage of lubrication oils, oil cotton yarns and
combustiblematerials in the cab
Check connection pins, washers and split pins for correct mounting
Check the tightness of staircase, platform , handrail
A-frame
Check if luffing rope fix right and tightness of its upside
Check the tightness of spring buffer
Check connection pins, washers and split pins for correct mounting
Check the tightness of platform , ladder channels cage for fixing
Check hoisting and trolleying ropes for winding and fixing.
Crane arm
Check the tightness chang of breadth tie bar fixing
Check the ropes for winding and fixing
Check if the anti-twist device move smoothly
Check connection pins, shaft baffle and split pins for correct
Counter jib
Check walkway andCounter jib railing for fixing .assure walkway
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Checking item Checking content

no sundries
Check the tightness of electrical control cabinet and resistance
cabinet on counter jib
7.1.2 Attention for operation
Person must be trained in operation, familiar with crane and qualified operator
（1） Operate the crane only if all of safe device in good condition
（2） Adjust limit switch referencing to instruction manual
（3） No unauthorized persons are allowed to board the crane!
（4） Do not land the hook blockcausing rope on the wire drum in an irregular orde。
（5） No over-loading even if overload device is adjusted!
（6） Crane lamp is necessary to operate cranes at night.
（7） Keep all platforms, ladders and handrails from dirt.
（8） Loading persons is forbidden!
（9） Avoid any operation that might be a risk to the stability of the crane! For example:
吊拉固定的物体吊装后添加重物斜拉吊重 Loading

Loading a fixed Increasing the at an angle.
object. load after lifting it.
吊重作单摆运动超过额定起重量
Loading Loading beyond
pendulously the rated lifting
capacity
（1） Stop all hoisting operations in case of thunderstorm, heavy rain, thick mist or the top
wind speed of the crane is higher than 20m/s
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（2） Do not make any changes or modification without permission of themanufacturer!

（3） The operator must be able to observe the working area and the load!
7.1.3 Safety Operation
（1）The trained crane operators and hoist men are required to strictly follow the regulations as
specified in <The Operating Instructions for Tower Crane>.
（2）Operators are required to understand the working principles of the tower crane and to
familiarize themselves with its structure and functions and adjustment methods for safety guards.
They are also required to master the operating methods for different performances as well as the
maintenance technique.
（ 3 ） Operate the crane strictly according to the hoist characteristics provided in the
Instructions. No over-load operating.
（4） Operate gently the hoist mechanism, slewing mechanism and traveling mechanism.
Carry out low-speed to high-speed conversion progressively. No violent pushing of the operation
handles from the static position (or low-speed) to the intermediate speed or high-speed position.
（5）It is prohibited to pull or hoist objects in an inclined way or hoist the staggered or
squeezed objects or hoist the objects buried in soil or frozen on ground.
（6）Operators and hoist men could not permitted to leave their working posts while objects
are being hung in the air.
（7）Commanding signals, hand gestures and flag signs should conform to the specifications.
（8）Operators are required to carefully operate and maintain the crane, as well as to keep
work shift-changing records.
（9）It is prohibited that the operator is drunk, ill or tired on working
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7.2 Adjusting working
7.2.1 Checking part and coponents before adjusting working
In order to ensuring the correct erection of tower crane and its safe operation, a series of
test-runs and overall checks of tower crane components should be conducted.
 Check component-to-component connections;
 Check the installation of supporting platform and fences;
 Check wire ropes for correct winding, avoiding interference and friction with other parts;
 Check power cables for smooth and proper routing;
 Check if the counter-weights on the counter-arm are properly fixed;
 Clear the lumber on platforms in order to prevent them falling and avoid injuring persons
during tower crane operation.
 Check applying of lubrication oil or grease in it.
7.2.2 Introduction of safety device
The safety guards of tower crane consist mainly of travelling limiter and load limiter. The
travelling limiters include hoisting limiter, slewing limiter, derricking limiter and anti-back-tipping
device. The load limiters include the hoist moment limiter and load limiter. The anemometer is also
included.
The installation positions of safety devices are shown in Figure 7.2-1.
Serial number Designation
1 load moment limiter
2 Luffing mechanism (clamshell brake, brake, derricking limiter)
3 anti-back-tipping device
4 hoisting mechanism (brake, hoisting limiter)
5 electronic angle display
6 Mechanical angle indicating device
7 slewing mechanism (brake,slewing limiter)
8 load limiter
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9 anemometer
7.2.2.1 Multiple-purpose limiter
Hook height limiter of this tower crane is DXZ-4/7, luff limiter is DXZ-4/7 and slewing
limiter is DXZ-4/3.
（1）Adjustment procedures
① Dismantle the upper cover, check and screw down 2-M3×55 screws.
② Unscrew M5 nuts
③ Drive the mechanism under control to an designed position (without load ) of requirements.
At this time, the micro-switch should make transient change-over corresponding to the action of this
mechanism i.e. adjust the corresponding axle (z) to make the memory gear (T) to press down the
micro-switch (WK) contact.
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④ Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will
occur)
⑤ Make the mechanism operate under no-load condition again and again several times to
check memorized positions for accuracy (repeat the above adjustments in case of deviations)
⑥Make sure that the position is specified. Screw down M5 nuts and re-cover the casing
⑦ After the mechanism working normally, check the position of the memory control position
for deviations. Correct the deviations if any.
（2）Adjustment for hook height limiter
①Adjustment(adjusting procedures according to item 1)
② Adjust at no-load conditions. Press down micro-switches (IWK, 2WK,3WK) by finger to
check the rising micro-switch or lowering micro-switch for correct action.
③ Height limiter slow down and interruption of power: In twice fall speed, ensure distance
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between the hook and rope fixing is more than fifteen meter, then adjust axle (1Z) to make cam
(1T) act to press down micro-switch (1WK) which make the speed of hoist mechanism change into
low. In condition of five meter between the hook and rope fixing, aAdjust axle (2Z) to make
cam (2T) act to press down micro-switch (2WK) to stop power of raising motor in movement.
Loosen the nut M5.
④ Customers could adjust the lower limit by 3WK to avoid operation errors and make the hoisting
hook stop lowering movement before the hook touching the ground (no less than 3-round steel
ropes on the wire drum). The adjustment method is the same as ??
（4） Adjustment for slewing limiter
① Adjust the slewing limiter while the crane arm is in erection position (power cable at free
status).
② Adjust in condition of no-load. Press down the micro-switch (WK) by finger to check the
switch for correct left and right control.
③ Slew to the left for 540°(1.5 rounds). Follow the Item 2.3.1.1 to adjust the axle (4Z) to make the
cam (4T) move to achieve transient changing by the micro-switch (4WK). Screw down M5 nuts.
④ Rotate 1080° right (3 rounds). Follow item 2.3.1.1 to adjust the axle (12) to make the cam (1T)
move to achieve transient changing by the micro-switch (1WK). Screw down M5 nuts.
⑤ Check if the left and right slewing is correct.

（5）Adjustment Method for radius
① Put crane arm Slew to 20°, Adjust the axle (2Z) to enable the cam (1T) act on the
micro-switch (2WK) for the speed instantaneous shift from 5 to 1. (in order to aovid slowdown be
interfere before brake. adjust the cam (3T)and cam (2T)to superpose each other) Screw down the
nut M5, Put crane arm proceed rislewing for 15°. Adjust the axle (1Z) to enable the cam (1T) act on
themicro-switch (1WK) for the motor stopping instantaneous. Screw down the nut M5.
②Inward travel and the most angle of extreme position limiting.

The adjustment method is the same as idem. Carry out speed reduction adjustment and position
limiting angle at the 82° and 84.5° (3Z-3T-3WK，4Z-4T-4WK ).
③ 验正和修正。Check and correct
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7.2.2.2 electron angle and machine angle display
Electron angle display and machine angle display are fixed on crane arm end, make a signal
transfer to parameter display sensor. So that operation could know position of the arm at any
monment.
Notice: Adjustment of electron angle and machine angle display should in condition of no load.
（1）One fall with no-load
① Instance of the angle 15° for work

Put electron angle and machine angle display at 15° in follow situation according to the
difference of arm length.
 The crane arm length is 60 m and the distance between hook to tower center is 60.03 m
 The crane arm length is 50 m and the distance between hook to tower center is 50.14m
 The crane arm length is 35m and the distance between hook to tower center is 35.53 m
② Instance of the angle 60° for work
③ Instance of the angle 85° for work
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（2）Two fall with no-load
 ① Instance of the angle 15° for work
 The crane arm length is 30m and the distance between hook to tower center is 30.01m
④ Instance of the angle 60° for work
⑤ Instance of the angle 85° for work
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7.2.2.3 Upper and lower limit Journey switch of crane arm
Journey switch have both protect function on counter-arm. Which make sure motor power-off
if the arm at most angle 86° or least angle 15°. The motor of travel mechanism stop with hydraulic
brake and the travel roll brake with hydraulic clamp , but motor of travel mechanism could move in
reverse. The adjusting steps are as follows: （1）Adjust length of leader for lower limit Journey
switch start-up while the arm angle arrive at 15°, then locking up lower limit Journey switch leader.
（2）Adjust length of leader for upper limit Journey switch start-up while the arm angle arrive
at 86°, then locking upper limit Journey switch leader.
Upper and lower limit Journey switch of crane arm
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7.2.2.4 Device for prevent crane arm to back rebound
Device prevent arm to back rebound be fixed on A frame. The mandril support will contact
with mandril while angle of the arm arrive at 83°. Spring have sufficient thrust to prevent mandril to
compress and backwaed when the angle at max value.
1. spring bushing 2. amortize spring 3. guide set 4. mandril

Fig7-2 Device for prevent arm to back rebound
7.2.2.5 Hoisting sensor
The hoisting weight is measure with pressur sensor. The data will be display in cab. This
sensor axes is block axes on root of arm (Fig 7-3).
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Fig 7-3 The installation position of pressure sensor

（1） High speed adjustment
①One multiple
a. Hoist the weight of 2500kg, the hook up and down at low speed and high speed and
middle speed each time. It should not be block at above-mentioned speed. Put weight data in
display apparatu to 2500kg;
b. Add another 50kg to the load and adjust the parameter. Lift the load at high speed to10m if it
could, then down the load onto the ground.
c. Repeat all the actions mentioned in the step b until high speed could not be lift. The weight
must between 2500-2550kg kg, which close to 2500kg to be great.
d. Got the weight data should be equal when repeat actions c twice in three time.
②Two multiple
a.. Hoist the weight of 5000kg, the hook up and down at low speed and high speed and
middle speed each time. It should not be block at above-mentioned speed. Put weight data in
display apparatu to 5000kg.
b. Add another 50kg to the load and adjust the parameter. Lift the load at high speed to 10m if
it could, then down the load onto the ground.
c. Repeat all the actions mentioned in the step b until high speed could not be lift. The weight
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must between 5000-5160kg which close to 5000kg to be great.

dGot the weight data should be equal when repeat actions c twice in three time.
（2） Adjusting of middle speed
①One multiple
a. Hoist the weight of 5000kg, the hook up and down at low speed and middle speed each time.
It should not be block at above-mentioned speed. Apparatu display weight data should above5 5000
kg, error less than 4%.
b. Add another 50kg to the load and adjust the parameter. Lift the load at middle speed to 10m
if it could, then down the load onto the ground.
c. Repeat all the actions mentioned in the step b until middle speed could not be lift. The
weight must between 5000-5160 kg, which close to 5000kg to be great.
② Two multiple
a. Hoist the weight of 10000kg, the hook up and down at low speed and middle speed each
time. It should not be block at above-mentioned speed. Apparatu display weight data should above
10000kg , error less than 4%.
b. Add another 50kg to the load and adjust the parameter. Lift the load at middle speed to 10m
if it could, then down the load onto the ground.
c. Repeat all the actions mentioned in the step b until middle speed could not be lift. The
weight must between10000kg－10320kg, which close to 10000kg to be great.
（3）Adjusting of low speed
① One multiple
a. Hoist the weight of 10000kg, the hook up and down at low speed one time. It should not be
block at above-mentioned speed. Apparatu display weight data should above 10000 kg, error less
than 4%.
b. Add another 100kg to the load and adjust the parameter. Lift the load at low speed to 10m if
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c. Repeat all the actions mentioned in the step b until low speed could not be lift. The weight
must between 10000∽10200 kg, which close to 10000kg to be great.
② Two multiple
a. Hoist the weight of 20000kg, the hook up and down at low speed one time. It should not be
block at above-mentioned speed. Apparatu display weight data should above 20000 kg, error less
than 4%.
b. Add another 100kg to the load and adjust the parameter. Lift the load at low speed to 10m if
c.。Repeat all the actions mentioned in the step b until low speed could not be lift. The weight
must between20000∽20400kg, which close to 20000kg to be great.
Notice:It should adjust again when switch1、2fall.
7.2.2.6 Moment limiter
（1）Moment limiter of electron
Moment limiter of electron is from the data of transition of angle transducer and hosit
transducer.
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（2）mechanism Moment limiter
1－Fixed block 2－Elastic plate 3－Limit switch 4－Adjusting screw

5－Luck nut
The tower crane is provided with a mechanical type-moment limiter for protection purpose.
Hositing and outward act switch to secondly speed when the moment has reached 80% of its rated
value. The pre-warning light in the operator cab is on when the moment has reached 90% of its
rated value. When the moment has reached 100%~110% of its rated value, power of hoisting up and
the trolley out wards-travel are off and over-load alarm at the same time
The moment limiter consists of two-spring plates 2, three travel switches 3 and adjusting bolt 4.
They are fixed on the chord rod on the tower crane rear side through mounting block1. If the tower
head has deformed during crane operation, the distance between two spring plates will become
narrower, thus activating the adjusting bolt for adjusting bolt contacts and travel switch.
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Corresponding moment will give warnings and cut off the power for the crane up and trolley
outward-travel, thus playing the role in moment limiting protection
（3）Adjustment of mechanism Moment limiter
① Adjustment of constant load and variable radius of trolley travel
A. Adjustment of 80% of rating hoists moment speed-down
When the arm length is 60m, weight of hoists 10t and moves outwards from 20m point at a
slow speed. Adjust 80% of bolt in Fig 7-4, which to enable the hook outward move from high speed
to low speed when the hook moves to the range of20.22～23.22m.
to low speed when the hook moves to the range of 21.26～22.26m.
slow speed. Adjust 80% of that bolt in Fig 7-4, which to enable the hook outward move from high
speed to low speed when the hook moves to the range of 21.9～22.9m.
slow speed. Adjust 80% of Bolt in Fig 7-4, which to enable the hook outward move from high
slow speed. Adjust 80% of Bolt in Fig 7-4, which to enable the hook outward move from high
B. Adjustment of 90% of rating hoists moment early waring to
When the arm length is 60m, weight of hoists 10t and the hook moves outwards from 20m
point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in
the operator cab when the trolley moves to the range of 22.81m～23.81m
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When the arm length is 30m, weight of hoists 10t, and the hook moves outwards from 20m
C. 100% of rating hoists moment alarm to adjustment
When the arm length is 60m, weight of hoists 10t, and the hook moves outwards from 20m
point at a slow speed Adjust constant load and variable radius of bolt in Fig 7-4, which to enable the
hook move the range of 25.9m～28.49m, meanwhile, upward hoisting and outward travelingis
power off and give an over-load warning sound.
slow speed. Adjust the constant load and variable radius of Bolt in Fig 7-4, which to enable hook
move the range of 27.2m～29.92m , meanwhile, upward hoisting and outward travelingis power off
and give an over-load warning sound.
move the range of 28m～30.8m, meanwhile, upward hoisting and outward travelingis power off
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move the range of 28.7m～31.57 m, meanwhile, upward hoisting and outward travelingis power off
slow speed. Adjust constant load and variable radius of Bolt in Fig 7-4, which to enable hook move
the range of 28.9m～31.79m , meanwhile, upward hoisting and outward travelingis power off and
give an over-load warning sound.
the range of 28.8 m～31.68 m , meanwhile, upward hoisting and outward travelingis power off and
the range of 29.3m～32.23m, meanwhile, upward hoisting and outward travelingis power off and
② Adjustment of constant load and variable radius of trolley travel for Moment Limiter.
When the arm length is 60m, loading 2.71t at 60m point with a normal hoisting speed, then
add load 271kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is
forbidden upward hoisting and give an over-load warning sound at the same time
When the arm length is 55m, loading 3.47t at 55m point with a normal hoisting speed, then
forbidden upward hoisting and give an over-load warning sound at the same time
When the arm length is 50m, loading 4.45 t at 50m point with a normal hoisting speed, then
forbidden upward hoisting and give an over-load warning sound at the same time.
When the arm length is 45m, loading 5.6 t at 45m point with a normal hoisting speed, then add
load 560kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is
When the arm length is 40m, loading 6.85 t at 40m point with a normal hoisting speed. Add
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When the arm length is 35m, loading 8.15t at 35m point with a normal hoisting speed. Add
When the arm length is 30m, loading 9.75t at 30m point with a normal hoisting speed. Add
Test the step for 3 times and keep the function stability
(4) Adjustment of mechanism Moment limiter
Conduct calibration to the moment limiter for 3 times each other
① Adjustment of mechanism Moment limiter for constant load and variable radius of
trolley traveling
A．Adjustment of 80% of rating hoists moment speed-down
When the arm length is 60m, loading 8t, trolley travels outwards from 20m point at a slow
speed. It is allow upward hoisting and outward traveling with speed down when travelling to the
range of 24.38m～25.38m .
range of 25.24m～26.24m
range of 26.47m～27.47m.
range of 27.26 m～28.26 m.
range of 27.42 m～28.42 m.
range of 25.06m～26.06m.
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When the arm length is 30m, loading 9.5t, trolley travels outwards from 20m point at a slow
range of 23.97m～24.97m.
B．Checking of 90% of rating hoists moment alarm .
speed, the mechanisms give an over-load warning sound when hoisting upward and traveling
outward in the range of27.5 m～28.5 m.
outward in the range of 28.45m～29.45m.
outward in the range of 29.83 m～30.83m.
outward in the range of 27.03 m～m.28.03
C． Checking of 100% of rating hoists moment alarm .
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outward in the range of 30.09 m～m.31.09
② Adjustment of mechanism Moment limiter for constant load and variable radius of
trolley traveling.
When the arm length is 60m, loading 8t at 31.13m point with a normal hoisting speed, the
moment limiter should not act and upward hoisting is permission. Put down the load and slowly
hosit at 8.8t, the moment limiter should act and not to be hoist.
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When the arm length is 40m, loading 8t at 34.9 m point with a normal hoisting speed, the
When the arm length is 40m, loading 9t at 31.95 m point with a normal hoisting speed, the
When the arm length is 40m, loading 9.5t at 30.59 m point with a normal hoisting speed, the
（5） Leadclose of Moment limiter
After Moment limiter adjusting and checking; put rain-proof cover on the Moment limiter, the
rope should pull on hole of rain-proof cover to close.
7.2.3 Experiment
（1）No-load test
The upward speed decrease to one step when upward hoisting reach 82°; traveling outward is
allow and inward is forbid when angle of traveling is 84.5°. Press the bypass button will continue to
inward with one step speed in such case. Traveling inward is forbid when angle of traveling is 86°.
Outward speed will switch to one step speed automatic when angle of traveling is 17.5°; traveling
inward is allow and outward is forbid when angle of traveling is 15.5°. Press the bypass button will
continue to outward with one step speed in such case. Traveling outward is forbid when angle of
traveling is 15°.
The gyre rate will automatic under three step when big arm angle less than 20°or more than
60°.
Brakes, operation systems, control systems, interlocking devices and limiters should act
accurately and reliably. No abnormal incidents occur on mechanisms during these tests.
（2）on-Load test
Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the rated hoist
load for tests according to (1). No abnormal incidents happen during these tests. Brakes, operation
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systems, control systems, interlocking devices and limiters should act accurately and reliably
（3）Static state test of 25% Over-load （two fall ,one fall when the arm length is 60m/55m）.
Conduct the static test at over-load after no-load tests and on-load tests. Test loads based for
different arm lengths are shown in Table 7-1.
Table 7-1.
Item Hook weight Hook
length of arm RadiusⅡ
length of arm Ⅰ weightⅡ
61.51m 25.87m(66°) 12.5 t 60.03m(15°) 3.45t
56.39m 27.31(62°) 12.5 t 55.08m(15°) 4.31t
51.39m 13.82m(75°) 25 t 49.69 m(15°) 5.56t
46.27m 13.9 m(73°) 25 t 44.81m(15°) 6.95t
41.27m 14.64m(70°) 25 t 40.03m(15°) 8.59t
36.15m 15.2m(66°) 25 t 35.08m(15°) 10.14t
31.15 m 15.96m(60°) 25 t 30.13m(15°) 12.00t
Hoist the 1.25 multiplying of rated weight at radius I and radius II from the ground for
100~200mm height at the lowest safe speed. Stay for 10min. Check metal structures and welds for
any cracks, permanent deformations and loosened connections after unloading.
Attention: It is prohibited to move the trolley and revolve during the static tests of over-load.
Dynamic test at 10% of over-load(2 fall , 1fall when arm lengt is 60m/55m).
In full-range to hoist corresponding weight in tab 7-2 , mechanism should tests for 3 times in
full-range action. Each start-up should steady stopping. The mechanism should act smoothly and
the brake should reliably. There is no abnormal incidents in mechanisms and structures, the parts
should not loosen and damage
table 7-2 ,.
Item Length of armⅠ Hook Length of armⅡ Hook
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weightⅠ weightⅠ
Length
of arm
61.51m 25.87m(66°～86°) 11t 60.03m(15°～86°) 3.04t
56.39m 27.31(62°～86°) 11t 55.08m(15°～86°) 3.80t
51.39m 13.82m(75°～86°) 22t 49.69 m(15°～86°) 4.90t
46.27m 13.9 m(73°～86°) 22t 44.81m(15°～86°) 6.12t
41.27m 14.64m(70°～86°) 22t 40.03m(15°～86°) 7.56t
36.15m 15.2m(66°～86°) 22t 35.08m(15°～86°) 8.92t
31.15 m 15.96m(60°～86°) 22t 30.13m(15°～86°) 10.56t
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塔式起重机操作手册
安全标识
技术参数
运输
准备
立塔和拆塔
内爬
操作与安全
电气控制系统
Tower Crane Instruction Manual
Electrical Control System

1 Electrical System ................................................................................................................................3
1.1 Electrical System Schematic ......................................................................................................3
1.2 Electrical System Components ..................................................................................................4
1.3 Electrical Control System ..........................................................................................................5
2 Electrical Crane Erection.....................................................................................................................7
3 Operation of Electrical System............................................................................................................9
3.1 Steps of Operating Electrical System.........................................................................................9
3.2 Preparation .................................................................................................................................9
3.3 Operation of Each Mechanism .................................................................................................10
4 System Prompt and Alarm Signal ......................................................................................................14
5 Electrical Control Unit .......................................................................................................................17
5.1 Slewing Eddy Current Debug System......................................................................................17
5.2 Inverter .....................................................................................................................................20
6 Appendix ...........................................................................................................................................31
6.1 Instruction for the Tower Crane Monitoring System ...............................................................31
6.2 Instruction for LCD Color Monitor..........................................................................................44
6.3 Electrical Drawings ..................................................................................................................46
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Electrical equipment 8-1

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8-2 Electrical equipment

Electrical System
1 Electrical System
1.1 Electrical System Schematic
Left Console
Right Console
Parameter Monitor
Hydraulic Pump Station Vedio Monitor

Hoisting Hydraulic Pliers Detection
Electrical Room
Trolley Hydraulic Pliers Detection
Trolley Over-speed Detection
Hoisting Over-speed Detection
Angle Sensor
Isolating Switch
Power Supply
Weight Sensor
Wind Speed Sensor
Height Sensor
Moment Limiter
Hoisting Mechanism
Slewing Mechanism
Trolley Mechanism
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1.2 Electrical System Components

No. Symbol Description Position
1 QS Isolating switch Basic section
2 PP2 Pump station Telescopic cage
3 HH Horn Under the cabin
4 EY Glass screen wiper Operation Cabin
5 MH Hoisting motor Counter jib
6 HINV HINV Electrical room
7 MHB Hoisting brake motor Counter jib
8 MHC Cooling motor for hoisting Counter jib
9 PGH Encoder for hoisting Counter jib
10 YZB Hydraulic Pressure Pumping Station Counter jib
11 UVR Trolley Over-speed protector Electrical room

12 UHR Hoisting Over-speed Protector Electrical room
13 SHUC,SHU,SHDC,SHD Hoisting limit switch Counter jib
14 MS1,MS2 Slewing motor Slewing support
15 SINV Slewing Inverter Electrical room
16 MSC1,MSC2 Cooling motor for slewing Slewing support
17 SECC Eddy Current Controller Electrical room
18 YSB Slewing brake Slewing support
19 YBSE1,YBSE2 The Eddy Current Brake of Slewing Slewing support
20 YSFB Weather vane Slewing support

21 MV Trolley motor Jib
22 VINV Trolley Inverter Electrical Room
23 YVB Trolley brake Jib
24 PGV Trolley Encoder Counter jib
25 SVBW,SVBC,SVFW,SVFC Trolley limit switch Jib
26 SVA1,SVA2 Trolley Limit Switch Base of the Jib
27 SSL,SSR Slewing limit switch Slewing support
28 SM1,SM2,SM3,SM4 Moment limit switch Jib
29 TC,TE,TS Transformer Electrical Room
30 DCM1,DCM2 Commutate Electrical Room
31 HB1 Impediment Lamp Top of the Tower
32 HB2 Impediment Lamp Counter jib
33 HB3 Impediment Lamp Jib
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1.3 Electrical Control System
DANGER
Forbit the person who don't get the authorization to modify the circuit, otherwise it may cause an
accident!
CAUTION
(1) Ensure that the cable diameter is not lower than the permissible value!
(2) Electrical installation and connection work must be done only by properly qualified, licensed person!
1.3.1 Power Supply

Site junction box (Provided by the costumer)
•• Rail-mounted crane: The power supply is connected from the site junction box to a motor driven
cable drum on the undercarriage
•• Stationary crane: The power supply is connected from the site junction box to switch box
1.3.2 Electrical room

The electrical room is the control center of the electrical system, it contains the following equipment:
(1) Main switch and main contactor (crane power switch)
(2) Control circuit transformer for the control voltage
(3) Control systems for hoisting gear, slewing gear and trolley gear
(4) Adjustable system for the eddy current of slewing
(5) The door switch, lighting and air condition of the electrical room
1.3.3 Operation Cabin

(1) Left console
•• slewing gear and trolley gear
•• slewing brake button
•• weather vane release indicator light
•• bypass button
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Electrical
(2) Right console

•• Hoisting gear and travel gear
•• Start button
•• Emergency stop
•• Alarm lamp and buzzer
(3) Power supply for cabin(230VAC)

•• Power supply for air condition, lighting and socket of the operation cabin
(4) Windscreen Wiper (24VDC)
(5) Electrical room
•• Emergency stop
•• Key switch
1.3.4 Hoisting mechanism, Slewing mechanism and Trolley mechanism

(1) Hoisting mechanism
•• hoisting motor
•• hoisting brake
•• cooling motor for hoisting
•• hoisting limit switch
•• hoisting encoder
•• hoisting over-speed protector
(2) Slewing mechanism
•• Slewing motor
•• The eddy current of slewing
•• Cooling motor for slewing
•• Slewing brake (number is decided by the configuration of motor )
•• Weather vane(number is decided by the configuration of motor )
•• Weather vane release contacts(number is decided by the configuration of motor )
(3) Trolley mechanism
•• Trolley motor
•• Cooling motor for trolley
•• Trolley brake
•• Trolley limit switch
•• Trolley encoder
•• Trolley over-speed protector
1.3.5 Safety Limit Switch

(1) Moment limit switch
(2) Load Sensor
(3) Angle Sensor
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2 Electrical Crane Erection

(1) Connect the power supply cable to isolating switch -QS in the switch box operation-erection, (keep
the isolating switch is cut off)
(2) Connect the main cable from the switch box to electrical room keep the main switch is turn off
The power cord contains three phase-lines a zero line (N) which is black and a protection line (GND)
which is green yellow. Any damage to the power cord may lead to serious accidents, so you should select
durable line as the power cord, and take appropriate measures to protect power cord from any damage.
(3) Connect the electrical room
(4) connect the hoisting mechanism
•• The power supply cable (L201) connect with the hoisting motor from the terminal of the hoisting
inverter
•• The cable (L203,L202) connect with the electrical room from brake motor (MHB) and the cooling
motor MHC
•• The cable (L211, L212) connect with the electrical room from the hydraulic pressure pumping
station
•• Connect the hoisting encoder to the inverter
•• Please connect the hoisting encoder follow the drawing, PGB is the PG extended card (accessory of
inverter), PGH is the hoisting encoder
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Electrical
(5) connect the slewing mechanism

(6) connect the trolley mechanism
(7) connect the climbing mechanism
(8) Ground wire

CAUTION
•• Ground wire is yellow-green wire for protection, it will connect all parts of the "ground" terminal
and "ground" plug.
•• Don’t use the neutral wire in place of ground wire. The protection wire must be independent of any
circuit device.
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3 Operation of Electrical System

Examination before working:
You should exam all kinds of switches, buttons (the emergency stop button especially), the operate
handles, arresters, mechanical limit devices, protective buttons and so on. Make sure that they can work
in normal; Checking whether mechanical limit devices are adjusted (Details is in the instruction of the
tower crane) or not. Check when the limit device is connected, whether the electric control system has the
corresponding function of protection or not. Once the tower crane has a fault, you should stop it at once. The
tower crane shouldn’t be put into work before it is examed and repaired.
3.1 Steps of Operating Electrical System

(1) Preparation: Including the operation of isolate switch, auto air-break switch, start button and
emergency stop button.
(2) Operation of each mechanism: Including the operation of hoisting and lower, slewing and trolley.
(3) Other operation: Including the operation of climbing.
3.2 Preparation
3.2.1 Operation of Isolate Switch

Isolate switch (-QS) is installed in switch box which locates in foot of tower crane, and play the role of
isolating power supply. The isolate switch is closed once put “ON” the handle. And when you put “OFF” the
handle, it is cut down while the tower lost power. Cut down the isolate switch(-QS) after driver was off duty.
3.2.2 Operation of the Equipment in Cabin

(1) lighting of cabin
(2) Control the temperature, keeping the temperature is comfortable, you can use the air condition to
adjust
3.2.3 Auto Air-break Switch

Only under the condition that all preparation work is ready, the driver on his duty and need operating,
the air-break switch (-QF) can be closed. Before the switch is turn on, check the lamp(-HU) if ‘Over &Under
voltage’ signal is normal. Air-break switch(-QF) is installed in electrical room. The handle is outside the
cabinet in order to operate. When you push up the handle, the switch is closed. Pull down the handle, the
switch(-QF) is cut down. The auto air-break switch(-QF) controls power supply of all mechanisms in tower
crane except the lighting for cabin and electrical room.
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Electrical
CAUTION
The air-break switch must be cut immediately under the conditions as follows:
•• There are something emergency when electric control system is failure (such as the contact of

contactor burn and stick together, the emergency stop button of control console was failure)
•• Driver is off duty or leave cab
3.2.4 Start Button and Emergency Stop Button

Start Button (-SST) (green) locates on the panel of right console (D). It is a dual function button, namely
Start and Warning horn. Operator can control the warning horn of all times once the air-break switch(-QF) is
closed. In addition, only after the air-break switch(-QF) is closed, the system can start after press down the
button.
When system starts up, driver will hear sound like “di” made by buzzer (-HBZ) the sound will last two
seconds. At the same time four alarm lamps will twinkle four times, then the buzzer stops and four alarm
lamps go out, the green startup indicator lamp locates on the right console will light. If there is no such
feedback after pressing down start button, it means failure to start and the handle on console doesn’t work.
Emergency stop button (-SEM) also locates on the panel of right console (D) , it is a red self-locking
mushroom-head button. Contrary to the start button, the function of emergency stop button is stop the relay(0-
KM) of the main circuit and the relays(-KMC1,-KMC2)of the control circuit. Emergency stop button is not
controlled by other control loop. It controls the main circuit with safety relay (-KMSC1). So it has protective
function.
CAUTION
When there are something emergent and couldn’t stop according to normal program or control handle
is out of control, operator must press emergency stop button immediately! If there are nothing emergent,
operator can’t use emergency stop button to stop the tower crane, or it will make huge impact.
3.3 Operation of Each Mechanism

After electric control system starts successfully, operator can operate each mechanism. Operator can use
two operate handles and all kinds of buttons which locate on the control console. Before using operate handle,
operator need release zero-position self-locking. After these have been done, the handle can be pushed and
pulled freely. When operator pushes handle, the buzzer will make a short sound like “di” each time shift gear.
At the same time, Operator should notice signals of the electric control system. Generally, the electric control
system will make corresponding feedback when the alarm signals occur.
3.3.1 Hoisting and Lower Operation

The hoisting and lower operation is controlled by the control handle located on the right console (D).
When operator pull inward the control handle, tower crane hoisting, on the contrary, When operator push
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Electrical
outward the control handle, tower crane lower. Hoisting and lower are each divided into five gears, and each
gear corresponds a speed.

CAUTION
The gear must be shifted step by step
Hoisting action table

Gear LI1 LI2 LI5 LI4 LI3 KHB Frequency
1 Gear ● ● ● 8Hz
2 Gear ● ● ● 25 Hz
3 Gear ● ● ● ● 50 Hz
4 Gear ● ● ● 100 Hz
5 Gear ● ● ● ● 125 Hz
Lower action table

Gear LI1 LI2 LI5 LI4 LI3 KHB Frequency
1 Gear ● ● ● 8Hz
2 Gear ● ● ● 25 Hz
3 Gear ● ● ● ● 50 Hz
4 Gear ● ● ● 100 Hz
5 Gear ● ● ● ● 125 Hz
Remark： LI1、LI2、LI3、LI4、LI5：multi-step speed input points of Inverter
3.3.2 Slewing operation

Slewing is controlled by the handle located on the left console (C). Pull leftward the handle if you want
the trolley turn left and pull rightward the handle if you want the trolley turn right. The handle is divided into
five gears each in right and left, and each gear corresponds to a speed.
(1) The operation of slewing brake
•• Slewing is running, the brake is energized to open immediately
•• slewing is stop, delay 15 seconds, the slewing brake is brake automatically.
In the after slewing stop 15 seconds delay, when the wind or the need for human brake, etc., you can
press down the "weather vane release button" on left console, the slewing brake is work immediately.
CAUTION
The point should be noticed when slewing and braking operation:

•• There is very big inertia force because the tower jib is very long, so the slewing operation must be
steady
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Electrical
•• Don’t use the brake switch before the tower jib hasn’t stopped steadily

NOTICE
"weather vane release button " (with lamp) (-SSB)is a slewing brake can be used for both emergency
brake, also be used to achieve the weather vane electric brake release.
After the operator is off duty, to prevent dangerous high winds occur down the tower, tower crane needs
to be in free rotation state.
•• Slewing weather vane electric release:
Description: weather vane brakes and slewing brakes with standard use, you can achieve the release of
electromagnetic and electric brake manual release function, after the weather vane release, the slewing brake
is opened even the tower crane without power, so the tower crane can slewing freely.
Conditions: slewing stopped, and the slewing brake is braking.
Operation: Press the "weather vane release button " and "bypass button" for about 4 seconds, weather
vane is automatically released.
Logic: press down the "weather vane release button " and "bypass button" at the same time, first, the
slewing brake is open, second, the weather vane is work after 1 second, third, the slewing brake is closed
after another 1 second, then, release the "weather vane release button " and "bypass button."
•• If the weather vane does not release successfully one time, please repeat!
•• Do not hold the "wind release button marked" and "Bypass button" for long time!
CAUTION
•• Pay Attention When Operation the Slewing and the Braker:h

Please release the weather vane when the wind speed exceed level 6 .
•• The gear must be shifted step by step.
Left action table
Gear LI1 LI2 LI5 LI4 LI3 KSB Frequency
1 Gear ● ● ● 8Hz
2 Gear ● ● ● 15 Hz
3 Gear ● ● ● ● 25 Hz
4 Gear ● ● ● 35 Hz
5 Gear ● ● ● ● 50 Hz
Right action table
Gear LI1 LI2 LI5 LI4 LI3 KSB Frequency
1 Gear ● ● ● 8Hz
2 Gear ● ● ● 15 Hz
3 Gear ● ● ● ● 25 Hz
4 Gear ● ● ● 35 Hz
equipment
5 Gear ● ● ● ●
Electrical
50 Hz
Notice: The twinkle of Y0 (Y0-COM0) stands for the eddy current, that is to say, the quicker Y0
twinkles, the higher the eddy current is.

3.3.3 Trolley operation

Trolley is controlled by the handle located on the left console. Pushing outward the handle vertically if
operator wants to trolley out, on the contrary, pulling inward the handle vertically if operator wants to trolley
in. Trolley out and trolley in are divided into five gears. No matter from low speed to high speed or from high
speed to low speed, the gear must be shifted step by step.
CAUTION
The gear must be shifted step by step

Trolley out action table
Gear LI1 LI2 LI5 LI4 LI3 KVB Frequency
1 Gear ● ● ● 8Hz
2 Gear ● ● ● 15 Hz
3 Gear ● ● ● ● 25 Hz
4 Gear ● ● ● 35 Hz
5 Gear ● ● ● ● 50 Hz
Trolley in action table

Gear LI1 LI2 LI5 LI4 LI3 KVB Frequency
1 Gear ● ● ● 8Hz
2 Gear ● ● ● 15 Hz
3 Gear ● ● ● ● 25 Hz
4 Gear ● ● ● 35 Hz
5 Gear ● ● ● ● 50 Hz
3.3.4 Other operations

•• Climbing operation
Each tower crane equip has a four-core cable (one head is three-phase plug (with PE wire) the other head
is separate wire). In first way, before climbing please connect the four separate wire with the jacking pump
station (PP2), then insert the three-phase plug into the four-core socket(-XSP) that located in the electrical
room. After doing these, driver can start jacking up by operating the handle that located on the hydraulic
pump station.
equipment
Electrical

4 System Prompt and Alarm Signal

Driver should be familiar with all kinds of alarm signal listed as follows when he is operating electrical
control system.
(1) Over moment signal
When hoist moment exceeds 105% the maximum, the electrical control system will response as follows:
•• The red alarm lamp (-HML) will twinkle
•• The buzzer will continuously make alarm sound like “di-di-di-di”
•• The red alarm lamp of the three-color alarm lamp will light
•• Main hook was forbad hoisting motion, lowering motion only work in 1 gear
•• Trolley was forbad moving outward
•• Horn will continuously make alarm sound
•• Resolve: Drive the trolley inward
(2) Over moment signal
When hoist moment exceeds 100% the maximum, the electrical control system will response as follows:
•• The red alarm lamp (-HML) will twinkle
•• The buzzer will continuously make alarm sound like “di-di-di-di”
•• The red alarm lamp of the three-color alarm lamp will light
•• Main hook hoisting motion only work in 1 gear, lowering motion only work in 1 gear
•• Trolley was forbad moving outward
•• Horn will make alarm sound
(3) Overload signal
When hoisting weight exceeds the maximum, the electrical control system will response as follows:
•• The red alarm lamp (-HLL) will twinkle
•• The buzzer will continuously make alarm sound, just like “di-di-di”
•• Main hook was forbad rising motion, lowering motion only work in 1 gear
•• Trolley was forbad moving inward and inward motion only work in 1 gear
•• Horn will continuously make alarm sound
•• Lowering and reduce load
(4) Moment early-warning signal
When hoist moment exceeds 90% of the maximum, the electric control system will response as follows:
•• The yellow alarm lamp (-HMA)will twinkle
•• The buzzer will continuously make alarm sound like “di-di”
•• The yellow alarm lamp of the three-color alarm lamp will light
•• The main hook’s hoisting and lowering motion are limited to working within 2 gear
equipment
Electrical
•• Trolley can only be driven outward in 2 gear, if it moves outward in high speed originally, it will
decelerate.
When hoist moment exceeds 80% of the maximum, the electric control system will response as follows:
•• The yellow alarm lamp (-HMA)will twinkle

•• Trolley can only be driven outward in 3gear

(5) Shift speed with overload signal
When hoisting weight exceeds 50% of the maximum, the electrical control system will response as
follows:
•• The yellow alarm lamp (-HLC)will twinkle
•• The buzzer will continuously make alarm sound like “di-di”
When hoisting weight exceeds 25% of the maximum, the electrical control system will response as
follows:
(6) Hoisting height limit signal
When the hook reaches to the maximum high the electrical control system will response as follows:
•• The hoisting movement of hook is prohibited
•• when “key switch”(SHJ) is in “ON” position , then press the “bypass” button (SSJ) The lowering
movement can work slowly in 1 gear.
(7) Hoisting height limit approach deceleration signal
When the distance between hook and height limit switch is only several meters, the electric control
system will response as follows:
•• Hoisting can only be driven in 1 gear, if it running in high speed originally, it will decelerate to 1
gear.
(8) Lowering height limit signal
When the hook reaches to the maximum lowering, the electrical control system will response as follows:
•• The lowering movement of hook is prohibited
•• Lowering height limit approach deceleration signal
When the distance between hook and the maximum lowering is only several meters, the electrical
control system will response as follows:
•• Hook can only be driven hoist down in low speed (1 gear), if it be driven hoist down in high speed
originally, it will decelerate to 1 gear.
(9) “Trolley out”stop signal:
When the angle of the jib reaches to 15°, the electric control system will response as follows:
•• The trolley is prohibited to move outward. If the trolley is moving outward, it will stop suddenly.
(10) “Trolley out” limit signal:
When the angle of the jib reaches to 15.5°, the electric control system will response as follows:
•• The trolley is prohibited to move outward. If the trolley is moving outward, it will stop suddenly.
equipment
Electrical
(11) “Trolley out” limit signal:

•• There is only 1 gear when the trolley moves outward. If the trolley is moving outward with high
speed, it will decelerate to the lowest speed(1 gear) suddenly.
(12) “Trolley in”stop signal:

NOTICE
•• The trolley is prohibited to move inward. If the trolley is moving inward, it will stop suddenly.
(13) “Trolley in” limit signal:
•• The trolley is prohibited to move inward. If the trolley is moving inward, it will stop suddenly.
•• when “key switch”(SHJ) is in “ON” position , then press the bypass button (-SSJ) The trolley
inward movement can work slowly in 1 gear.
(14) “Trolley in” deceleration signal:
•• There is only 1 gear when the trolley moving inward. If the trolley is moving inward with high
speed, it will decelerate to the lowest speed(1 gear) suddenly.
(15) Slewing deceleration signal:
When the angle of the jib is smaller than 25°or bigger than 75° , the electric control system will response
as follows:
•• The slewing motion is limited to working within 4 gear
(16) Slewing left limit signal:
When the number of rotation carried out by the crane while slewing leftward have exceeded one and a
half, the electrical control system will response as follows:
•• The jib is prohibited to slewing leftward. If it’s slewing leftward, the slewing mechanism will be cut
power supply suddenly.
(17) Slewing right limit signal:
NOTICE
When the number of rotation carried out by the crane while slewing rightward have exceeded one and a
half, the electric control system will response as follows:
•• The jib is prohibited to slewing rightward. If it’s slewing rightward, the slewing mechanism will be
cut power supply suddenly.
(18) Over or under voltage protection signal:
•• The lamp (-HU) in left console (-C) is for Over or under voltage signal
•• When the voltage of power supply is greater than 105% of the rating voltage or less than 95% of the
equipment
rating voltage, The lamp (-HU yellow) will be light.

Electrical
•• If the “over or under voltage” signals appear continually, please cut the power supply, Don’t start
up and work lest the electric motors and electric appliance will be damaged. Please check the power
supply loop and obviate malfunction.

5 Electrical Control Unit
5.1 Slewing Eddy Current Debug System
Illuminate for Debugging the Slewing Eddy Current Controller

This Controller is only suit for the tower crane which contains slewing eddy current controller controlled
by PLC.
The eddy current controller controls the voltage by the output signal of the PLC.
The controller have been debugged when leave the factory, but you should regulate the output of the
eddy current controller when the following problem happening.
•• The slewing is hard to start up, and the start up time is long.
•• The tower crane shake strongly when stopping the slew.
•• The motor of slew become very hot after working a few minutes.
5.1.1 Control Principle

The eddy current controller contains two parts: PLC and SECC .The Y0 of PLC output different signal
according to different gear.The SECC receives the signal of PLC and outputs different voltage, which
means different eddy current.
5.1.2 Debug
When the tower crane leaves the factory, the eddy current have been debugged and divided into five
gears: 14V, 10V, 6V, 2V, 0V, or four gears: 14V, 8V, 4V, 0V, The voltage is the DC voltage between 607and
608, or 609 and 610, which are the outputs of the SECC. The voltage determines the moment of the eddy
current brake. That is to say, the higher the voltage is, the stronger the moment of the eddy current brake is.
However, because of that the performance of the eddy current brake isn’t consistent, the voltage of the eddy
current maybe need to be adjust. The method is as follows:
When use default vaule, the voltage of the eddy current is adjusted though the touched monitor.Pay
attention: the eddy current should be set from gear 0 to gear 4, gear by gear. The maximum value of eddy
current is 24V ,and the corresponding control numerical is 2000.
When use Potentiometer to adjust the eddy current:
Two Potentiometer Description:
"Potentiometer 0" and "potentiometer 1" are adjustable analog potentiometer, and its corresponding
value range: 0 ~ 255.
•When the anti-clockwise (that is, to figure the direction of small arrow) to the smallest screw,
equipment
Electrical
corresponding to the smallest value is 0 (as shown in Figure 2 of the A-point);

•When the clockwise (that is , to figure the direction of big arrow) screw to the largest and corresponds
to the maximum value of 255 (as shown in Figure 2 of the D-point).

Fig.1 PLC left Department potentiometer (p0, p1), programming port
Fig.2 Schematic diagram of analog potentiometer value

● The open-loop / closed-loop slew control conversion settings:
• Closed-loop control: Set up internal procedures for when the "potentiometer 1" the value of less than
50, procedures for the closed-loop control operation, that is, as shown in Figure 2 the interval A-B, Only in
the tower crane equipped with slew encoder feedback slew-motor. Can use closed-loop control operation,
otherwise only modulation to run open-loop.
•Open-loop control: Set up internal procedures for when the "potentiometer 1" value greater than 50, the
procedures for open-loop control operation, that is, as shown in Figure 2 the interval B-C.
Adjustment method is as follows:
First: the "potentiometer 1" anti-clockwise (that is, to figure the direction of small arrow) to the smallest
screw (as shown in Figure 2 of the A-point);
Second: then slowly clockwise to the direction of the arrow big screw, when screwed into its
corresponding value can be greater than 50 (as shown in Figure 2 of the B point), at the same time hear the
words, just like “di” , that has been twisted to the point of greater than 50.
●Open-loop eddy current testing
•Identify at the open-loop operation of eddy current debugging state (Figure 2 "C-D"): Set up internal
procedures for when the "potentiometer 1" when the value is greater than 230 (as shown in Figure 2 of the
equipment
C points), procedures for the open-loop eddy current debug state. As follows: The "potentiometer 1" slowly
Electrical
clockwise to the direction of the arrow big screw, when screwed to the C point, the buzzer will "drop" the
voice said that it has entered the open Debugging vortex ring state, when in this state, for debugging prompt
staff, buzzer every 2 second "drop" ring out;
•Cut off the air-switch for slew inverter, tower crane static eddy current testing;

•Which file needs to adjust slew eddy current, will handle play where slew files;
•For example: Test slew (1 gear) eddy current
First: cut off the air-switch of the slew Inverter;
Second: the "potentiometer 1" to "open-loop eddy current debugging state" (Figure 2 "C-D "), will hear
the buzzer at the same time every two seconds, "di", express has been transferred to this interval;
Third: operate handle of the console to slew 1 gear (turn left or turn right);
Fourth: adjust "potentiometer 0", can change the "potentiometer 0" value, that can change the eddy
current output value, and then use a multimeter measuring the eddy current output value;
Fifth: adjusting to a required output of the eddy current value, press the "bypass" button to save the
parameters into the PLC program;
Sixth: eddy current parameter values debugging completed, must transferred back the "potentiometer 1"
to "open-loop eddy current running zone" (Figure 2 "B-C ").
● Restore the Open loop eddy current parameter value to the factory:
First: cut off the air-switch of the slew converter;
Second: Using two small short cables, connect the PLC input of left / right slew at the same time.
Third: put on slew braking;
Fourth: In the third step, after 5 seconds press the "bypass", at the same time to hear buzzer "di" , it
means that the eddy current parameter has been restored factory (not heard the words "di" , Description not
yet recovered successfully, you can repeat several times).
NOTICE
In the debugging process, we should make corresponding adjustment according to analyze the specific
circumstances: Firstly, Combined with the observation of the current value, which comes from the digital
actuator of the general inverter. In each step of operation, the current value should not be greater than two
times of the rated current of the motor. Secondly, when the rotation is difficult to start, or the start time
is long, if there is no machinery fault, you should adjust the size of eddy current though the page "rotary
parameter settings" in the monitor screen. Thirdly, after a period of working time, if you find the rotary motor
overheating, it may be caused by the high voltage of eddy current , adjusting the voltage until satisfied.
(1) From low-gear to high-gear, the voltage can be adjusted to following empirical value:
•• For the product of five gears:14V, 10V, 6V, 2V, 0V
•• For the product of four gears:14V, 10V, 6V, 2V, 0V
(2) In the regulation of eddy current voltage, disconnect rotary breaker QFS first, and connect the rotary
breaker QFS after adjustment.
equipment
Electrical

5.2 Inverter
5.2.1 The operation of inverterDisplay of Inverter
Low-power inverter feature an integrated display terminal with a 7-segment 4-digit display. The graphic
display terminal described on the previous pages can also be connected to these drives as an option.
Function of the display:
equipment
Electrical

e.g：Accessing menu parameters
Menu Parameter Value or assignment
•• Graphic display terminal
equipment
Electrical

CAUTION
UNINTENDED EQUIPMENT OPERATION

Before turning on and configuring the inverter, check that the PWR(POWER REMOVAL)input is
deactivated(at state 0) in order to prevent unintended operation.
Before turning on the inverter, or when exiting the configuration menus, check that the inputs assigned
to the run command are deactivated (at state 0) since they can cause the motor to start immediately.
•• TERMINALS
Power terminals
Terminals Function
3× Protective ground connection terminals
R/L1,S/L2,T/L3(1) Power section line supply

PO DC choke connection
PO.1, PO.2 DC choke connection
PA/+ DC bus+ polarity and DC choke connection
PC/- DC bus- polarity
PA Output to braking resistor
PB Output to braking resistor
U/T1,V/T2,W/T3 Output to the motor
RO,SO,TO Separate fan supply when inverter is only powered by the DC bus
BU+,BU- + and – polarities to be connected to the braking unit
X20,X92,X3 Braking unit control cable connection
Control terminals
Terminals Function Electrical characteristics

R1A
Common point C/O contact
R1B Minimum switching capacity:3mA for 24V(DC)
(R1C) of programmable relay R1
R1C Maximum switching capacity on resistive load:
5Afor 250V(AC) or 30V(DC)
Maximum switching current on inductive load

R2A N/O contact of R2 program
(cosφ=0.4L/R=7ms):2A for 250V(AC)or
R2C mable relay 30V(DC)
equipment
Electrical
+10V (DC) power supply for 1to10KΩ reference +10V (DC) (10.5V±0.5V) 10mA, max.
+10
potentiometer

AI1+ , AI1- Differential analog input AI1 -10V to +10v(DC)(max. safe voltage24V)
COM Analog (I/O) common 0V
Analog input 0 to+10V(DC)

Depending on software
(max. safe voltage 24V),impedance 30 KΩ
Configuration:
AI2 or
Analog voltage or current input
Analog input X-Y mA, X and Y can be
programmed from 0 to 20mA impedance 250Ω
+24V(DC)(min.19V,max.30V)
Input for external +24V(DC) control section power
P24 Power 30 watts
supply
Analog input 0 to+10V(DC) min. load voltage

impedance 50 KΩ
Depending on software or
Configuration: Analog input X-Y mA, X and Y can be

AO1
programmed from 0 to 20mA
Analog voltage or current output or logic output
max. load voltage impedance 500Ω
or
logic output 0to 10V or 0to 20mA
0V Logic input common and 0V of P24power supply 0V
+24V(DC)(max. 30V)
LI1to LI5 Programmable logic inputs
impedance 3.5 KΩ
SW2=LI:
Same characteristics as logic inputs LI1to L15
LI6 Depending on the position of the SW2 switch: LI or PTC SW2=PTC:
Trip threshold 3 KΩ,reset threshold 1.8 KΩ
Short-circuit detection threshold<50Ω

SW1 switch in Source or Sink Int position:
Internal +24V(DC)power supply

equipment
Electrical
200mA, max
+24V Power supply (DC)
SW1 switch in Sink Ext position:
Input for external +24V(DC)power supply for

the logic inputs


Power Removal safety 24V(DC)(max.30V)
PWR Function input Impedance 1.5 KΩ
•• Auto tuning
Code (tUn)
Leave factory setting: (NO) (nO)
nO (NO) (nO): Auto-tuning not performed.
(YES) (YES): Auto-tuning is performed as soon as possible, then the parameter
YES
tUn automatically change to(Done) (dOnE)
dOnE (DONE)(dOnE):Use of the values given the time auto-tuning was performed.
Asynchronous motor: (Rated motor volt) (UnS) , (Rated motor freq) (FrS), (Rated motor current)(nCr)
(Nom motor speed) (nSP) , (Rated motor power)(nPr)
If at least one of these parameters is modified after auto-tuning has been performed,(Auto-tuning)(tUn)
returns to(NO)(nO)and must be performed again.
Auto-tuning is only performed if no stop command has been activated, If a “freewheel stop” or “fast
stop” function has been assigned to a logic input. This input must be set to 1(active at 0)
Auto-tuning takes priority over any run or prefluxing commands, which will be taken into account after
the auto-tuning sequence
If auto-tuning fails, the inverter display (NO)(nO) and depending on the configuration of
(AutoTunFltCont) (tnL),may switch to [AUTO-TUNING](tnF) fault mode.
Auto-tuning may last for 1to2 seconds , Do not interrupt the process, Wait for the display to change to
“(Done)(dOnE)”or“(NO)(nO)”.
CAUTION
(1) It is essential that all the motor parameters are correctly, configured before starting auto-tuning
(2) If Auto-tuning fails, the drive displays[NO](nO)
(3) During auto-tuning the motor operates at rated current
•• Normal display with no fault present

Code Signification Code Signification
Display of the parameter selected in the SUP
43.0 nLP No line power(No line power on L1, L2, L3)
menu (default selection: motor frequency)
ACC Acceleration nSt Freewheel stop
equipment
CLI Current limiting Obr Auto-adapted deceleration

Electrical
Power Removal function active (inverter

CtL Controlled stop on input phase loss PrA
locked)
dcb DC injection braking in progress rdY Inverter ready
dEC Deceleration SOC Controlled output cut in progress
FLU Motor fluxing in progress tUn Auto-tuning in progress
FSt Fast stop USA Undervoltage alarm

•• Faults-Causes-Remedies
(1) Inverter does not start, and no fault displays.
If the display does not light up, check the power supply to the Inverter.
The assignment of the “Fast stop” or “Freewheel stop” functions will prevent the Inverter from
starting if the corresponding logic inputs are not powered up. The ATV71 then displays [Freewheel] (nSt) in
freewheel stop and [fast stop] (Fst) in fast stop. This is normal since these functions are active at zero so that
the Inverter will be stopped safely if there is a wire break.
Make sure that the run command input or inputs are activated in accordance with the selected control
mode .
(2) Fault which cannot be reset automatically
The cause of the fault must be removed before resetting by turning off and then back on.
Fault Name Probable cause Remedy

AI2F [AI2 input] Non-conforming signal on analog Check the wiring of analog input AI2
input AI2 and the value of the signal.
Anf [Load slipping] The encoder speed feedback does not 1.Check the motor, gain and stability
match the reference parameters.
2.Add a braking resistor.
3.Check the size of the motor/Inverter/

load.
4.Check the encoder’s mechanical

coupling and its wiring.
brF [MECHANICAL BRAKE FLT] The brake feedback contact does not 1.Check the feedback circuit and the
match the brake logic control brake logic control circuit.
2.Check the mechanical state of the

brake.
CrFI [PRECHARGE FAULT] C h a rg i n g r e l a y c o n t r o l f a u l t o r 1.Check the intermal connections.

charging resistor damaged
2.Inspect/repair the Inverter.
ECF [ENCODER COUPLING] B r e a k i n e n c o d e r ’s m e c h a n i c a l Check in encoder’s mechanical

coupling coupling.
equipment
Electrical


EEF1 [CONTROL EEPROM FLT] Internal memory fault 1.Check the
environment(electromagnetic
EEF2
compatibility)
2.Turn off, reset, return to factory

settings.
EnF [ENCODER FAULT] Encoder feedback fault 1.Check [Number of pulses](PGI)and

[encoder type](EnS).
2.Check that the encoder’s mechanical

and electrical operation, its power
supply and connections are all correct.
3.Check and, if necessary, reverse the

direction of rotation of the motor or
the encoder signals.
FCFI [OUTPUT CONT.CLOSEL] The output contactor remains closed 1.Check the contactor and its wiring.
although the opening conditions have
2.Check the feedback circuit.
been met
ILF [INTERNALLINK FAULT] Communication fault between option 1.Check the environment
card and Inverter (electromagnetic compatibility).
2.Check the connections.
3.Replace the option card.

InF1 [RATING ERROR] The power card is different Check the power card’s
from the card stored catalog number.
InF2 [INCOMPATIBLE PB] The power card is incompatible Check the power card’s part
with the control card number and compatibility.
InF3 [INT.SERIAL LINK FLT] Communication fault between 1.Check the internal connections.
the internal cards 2.Inspect/repair the Inverter.
InF4 [INTERNAL FLT-Mfg AREA] Internal data inconsistent Recalibrate the Inverter
InF6 [INTERNAL FLT-OPTION] The option installed in the Check the reference and
Inverter is not recognized compatibility of the option.
InF7 [INTERN. FLT-HARD.INT] Initialization of the Inverter is Turn off and reset.
equipment
Electrical
incomplete
InF8 [INT.FLT-CONTROL SUP.] The control section power Check the control section
supply is incorrect power supply


InF9 [INTERN.FLT-I MEASURE] Incorrect current measurements 1.Replace the current sensors or the
power card.
InFA [INTERNAL-MAINS CIRCUIT] Input stage not operating correctly Inspect/repair the Inverter.
InFb [INTERN.FLT-TH.SENSOR] Fault on the electronic time 1.Replace the temperature sensor
measurement component
InFC [INTERN.FLT-TIME MEAS.] Internal microprocessor fault Inspect/repair the Inverter.
InFE [CPU FAULT] Internal microprocessor fault Turn off and reset. Inspect/repair the
Inverter.
PrF [POWER REMOVAL FAULT] Fault with the Inverter’s“Power Inspect/repair the Inverter.
removal”safety function
OCF [OVERXURRENT] 1.Parameters in the [SETTINGS](Set-) 1.Check the parameters.

and(drC-)menus are not correct
2.Inertia or load too high load
3.Mechanical locking 3.Check the state of the mechanism
PrF [POWER REMOVAL FAULT] Fault with the Inverter ’s“Power Inspect/repair the Inverter.
removal”safety function
SCF1 [MOTOR SHORT CIRCUIT] 1.Short-circuit or grounding at the 1.Check the cables connecting the
Inverter output Inverter to the motor, and the motor
insulation
2.Significant earth leakage current at
SCF2 [IMPEDANT SH. CIRCUIT
the Inverter output if several motors 2.Reduce the switching frequency
are connected in parallel
3.Connect chokes in series with the
motor
SCF3 [GROUND SH. CIRCUIT]
SOF [OVERSPEED] Instability or driving load too high 1.Check the motor, gain and stability
parameters.
2.Add a braking resistor.

load
SPF [SPEED FEEDBACK LOSS] Encoder feedback signal missing 1.Check the wiring between the
encoder and the Inverter.
2.Check the encoder.

tnF [AUTO-TUNING FAULT] 1.Motor not connected to the Inverter 1.Check that the motor is present
equipment
Electrical
during auto-tuning.
2.Special motor or motor whose power
is not suitable for the Inverter 2.If an output contactor is being used
close it during auto-tuning.
3.Check that the motor/Inverter are

compatible.
(3) Faults that can be reset with the automatic restart function, after the cause has disappeared.


APF [APPLICATION FAULT] Controller Inside card fault Please refer to the card documentation.
bLF [BRAKE CONTROL 1.Brake release current not 1.Check the Inverter/motor connection
FAULT] reached
2.Check the motor windings
2.Brake control parameters
3.Apply the recommended settings
not set when brake logic
control is assigned
CnF [NETWORK FAULT] Communication fault on 1.Check the environment(electromagnetic
communication card compatibility)
2.Check the wiring.
3.Check the time-out
4.Replace the option card
5. Inspect/repair the Inverter.
COF [CANopen FAULT] I n t e r r u p t i o n i n 1.Check the communication bus

communication on the
CANopen bus
3.Refer to the relevant product documentation
EPF1 [EXTERNAL FAULT L1/ Fault triggered by an external Check the device which caused the fault, and reset.
Bit] device , depending on user
EPF2 [EXTERNAL FAULT NET.] Fault triggered by an external Check the device which caused the fault, and reset.
device , depending on user
FCF2 [OUTPUT CONT.OPENED] The output contactor remains 1.Check the contactor and its wiring
open although the closing
2.Check the feedback circuit
conditions have been met
LCF [LINE CONTACT.FAULT] The Inverter is not powering 1.Check the contactor and its wiring
up although the contactor is
controlled
3.Check the line/contactor/Inverter connection
LFF2 [Al2 4-20Ma loss] Loss of the 4-20mA reference Check the connection on the analog inputs
on analog input Al1,Al2,Al3
LFF3 [Al2 4-20Ma loss]
orAl4
LFF4 [Al2 4-20Ma loss]
ObF [OVERBRAKING] B r a k i n g t o o s u d d e n o r 1.Increase the deceleration time.

equipment
driving load
Electrical
2.Add a braking resistor if necessary.
3.Activate the [Dec ramp adapt.](brA)function, if it is

compatible with the application


OHF [INVERTER OVERHEAT] Inverter temperature too high Check the motor load, the Inverter ventilation and
the ambient temperature. Wait for the Inverter to cool
down before restarting.
OLF [MOTOR OVERLOAD] Triggered by excessive motor Check the setting of the motor thermal protection,
current check the motor load. Wait for the Inverter to cool
down before restarting.
OPF1 [1MOTOR PHASE LOSS] Loss of one phase at Inverter Check the connections from the Inverter to the motor.
output
OPF2 [3MOTOR PHASE LOSS] 1.Motor not connected or 1.Check the connections from the Inverter to the motor
motor power too low
2.Test on a low power motor or without a motor:
2.Output contactor open In factory settings mode, motor output phase loss
detection [Output Phase Loss](OPL)=[No](nO)
3.Instantaneous instability in
the motor current 3.Check and optimize the [Rated motor volt](UnS)
and[Rated mot. current](nCr)parameters and perform
an [Auto tuning](tUn)operation
OSF [MAINS 1.Line voltage too high Check the line voltage
OVERVOLTAGE] 2.Disturbed mains supply

OtF1 [PTC 1 OVERHEAT] Overheating of the PTC1 1.Check the motor load and motor size
probes detected
2.Check the motor ventilation
3.Wait for the motor to cool before restarting
4.Check the type and state of the PTC probes

OtF2 [PTC 2 OVERHEAT] Overheating of the PTC2
probes detected
OtFL [PTC=L16 overheat] Overheating of the PTC
probes detected on input Ll6
PtF1 [PTC1 FAILURE] PTC1 probes open or short- Check the PTC probes and the wiring between them
circuited and the motor/Inverter
PtF2 [PTC2 FAILURE] PTC2 probes open or short-

circuited
PtFL [L16=PTC FAILURE] PTC probes on input Ll6

open or short-circuited
SCF4 [IGBT SHORT CIRCUIT] Power component fault Inspect/repair the Inverter
SCF5 [LOAD SHORT CIRCUIT] Short-circuit at Inverter 1.Check the cables connecting the Inverter to the
equipment
Electrical
output motor and the motor insulation
2.Inspect/repair the Inverter
SLF1 [MODBUS COM,] I n t e r r u p t i o n i n 1.Check the communication bus

communication on the
Modbus bus
3.Refer to the relevant product documentation


SLF2 [POWERSUITE COM,] Fault communicating with 1.Check the PowerSuite connecting cable
PowerSuite
SLF3 [HMI COM.] Fault communicating with 1.Check the terminal connection
the graphic display terminal
SrF [TORQUE TIME OUT FLT] The time-out of the torque 1.Check the function’s settings.
control function is attained
2.Check the state of the mechanism
SSF [TORQUE/I LIMIT FLT] Switch to torque limitation 1.Check if there are any mechanical problems
2.Check the limitation parameters
tJF [IGBT OVERHEAT] Inverter overheated 1.Check the size of the load/motor/Inverter
2.Decrease the switching frequency
3.Wait for the motor to cool before restarting
Faults that can be reset as soon as their causes disappear

CFF [INCORRECT CONFIG.] The current configuration is Check the card
inconsistent(Error due to a
change of card)
CF1 [INVALID CONFIG.] Invalid configuration. The 1.Check the configuration
configuration loaded in the loaded previously.
Inverter via the serial link is
2.Load a compatible
inconsistent
configuration
PHF [INPUT PHASE LOSS] Inverter incorrectly supplied or 1.Check the power connection and the
a fuse blown fuses
2.Reset
3.Use a three-phase line supply
4.Disable the fault by setting

USF [UNDERVOLTAGE] 1.Line supply too low 1.Check the voltage and the voltage
parameter
2.Transient voltage dip
2.Replace the pre-charge resistor.
3.Damaged pre-change resistor
3.Inspect/repair the Inverter
If the inverter is not turned on for a long period, the performance of its electrolytic capacitors will be
equipment
Electrical
reduced.
If it is stopped for a prolonged period, turn the inverter on every two years for at least 5 hours to restore
the performance of the capacitors, then check its operation.

6 Appendix
6.1 Instruction for the Tower Crane Monitoring System
6.1.1 Main Interface

•• Start Screen
As long as the main air switch of the tower crane is closed, the monitor will be electrified and start up .
The first screen after the start is shown in the following screen.
Fig 6.6-1 Start Screen
In the boot screen will show the name of tower crane, manufacturers and other basic information, as well
as the version of the program, equipment number, date, running time and other information.
Click on the screen, or wait 5 seconds, the screen will automatically switch to the main screen.
•• Main Screen( Monitor Screen)
equipment
Electrical
Fig 6.6-2 Main Screen

On the main screen will show all the basic state of tower crane.
On the main screen ,there is a diagram of the tower crane structure, as well as the angle of the tower
crane jib, rotary amplitude, height of rotary inverted.
On the left and right side of the main screen is vertical progress bars showing the moment and weight of
the tower crane . At the bottom of the screen is the schematic diagram of moment curve, and with a flashing
point shows the current state of tower crane. The above is the system date and time. The middle is the
numerical display of the moment, weight, ratio, maximum hoisting weight, arm length and wind speed.
If there are faults, the fault information will be displayed in lantern way in the middle of the screen.
You can use " " button to display the menu, specific methods of using the menu please refer to
the corresponding menu sections of the paper. The function that this key in other window is also menu
displaying.
In the video monitor screen, it displays the video taken by the arm tip camera. At the same time, in its
lower part also provides the control button on the camera, such as menu, zoom in, zoom out,enlarging focus,
focus. Full screen button can enter the video window.
In the above of the video monitor screen, displays the moment and weight of the tower crane with a
horizontal progress bar as well as numerical . On the right there is numerical value that shows the jib angle,
radius of slewing, hoisting magnification, the maximum hoisting capacity, the current wind speed etc..
•• Main Menu
Fig 6.6-5 Main menu

On the right-hand corner of the window there is a " " button, click it to close the current window . Part
of the pop-up window also has this button, and the function is the same.
Click the "Login" button to enter the login window, and then you can use the name and password to
login the system and can modify some parameters of the tower crane.
Click the "Language" button to enter the language selection window, and then you can chang the the
display language of the screen.
equipment
Click the "Information" button to enter the information window, the window will display the relevant
Electrical
information of the electrical control system.

Click the "Close" button to close the current menu or to return to the main menu.
In the main menu, there are "Monitor Screen", "Video Monitor Screen", "Mechanism Status", "Tower
Crane Set", "Input and Output", "Alarm Information" etc.

Click the "Monitor Screen", "Video Monitor Screen" button to enter the main screen and video monitor
screen.
Click the "Mechanism Status", "Tower Crane Set", "Input and Output", "Alarm Information" button to
enter the corresponding submenu.
•• Mechanism Status Menu
Via this menu, you can enter the corresponding mechanism status screen or mechanism detection screen.
Detailed description of the relevant screen is refer to the section "Mechanism Status and Detection Screen" .
Fig 6.6-6 Mechanism Status Menu
•• Tower Crane Set Menu
Fig 6.6-7 Tower crane set menu

Via this menu, you can enter the screen for setting the tower crane parameters and related sensor .
•• IO Status Menu (Input and Output)
equipment
Electrical

Fig 6.6-8 IO status menu
Via this menu, you can enter the screen for viewing the input and output point of the PLC .Detailed
description of the relevant screen is refer to the section " Input and Output of the PLC" .
•• Alarm Information Menu
Fig 6.6.-9 Alarm information menu
Via this menu, you can enter the screen for viewing current alarm and alarm history , specify the relevant
screen, please refer to the "alarm" in the description section. Detailed description of the relevant screen is
refer to the section " Alarm Screen" .
•• Login Window
equipment
Electrical
Fig 6.6-10 Login window

Input user name and password, and click the button “ ”, then you can login the system and

set the tower crane. The default user name is "User", and the password is "zoomlion ".
•• Language Choosing Menu
Fig 6.6-11 Language choosing menu

Via this menu, you can choose the display language of the screen.
•• Information Window
Fig 6.6-12 Information window

On the information window, it will show the name of tower crane, manufacturers and other basic
information, as well as the program version of the electrical control system, equipment number, date, running
time and other information.
6.1.2 Mechanism Status and Detection Screen

•• Start-up and mechanism detection
equipment
Electrical

Fig 6.6-13 Start-up detection
Fig 6.6-14 Hoisting system detection

equipment
Electrical
Fig 6.6-15 Slewing system detection

Fig 6.6-16 Trolley system detection

This screen is displayed by the way of steps. Expounds how to check and eliminate the fault of the
system step by step. General fault can be checked out according to the steps.
6.1.3 Tower Crane Parameters and Sensor Setting

You will only be allowed to view the parameters if you don’t login. If you want to set the parameters or
the sensor, you will be required to login
CAUTION
Please set the parameters following the steps, otherwise it may lead to the electronic security system
work abnormally, and due to equipment failure, loss of property, personal danger.
•• Tower Crane Parameters Setting
equipment
Electrical
Fig 6.6-18 Tower crane parameters setting

Via this screen, you can set the arm length and the magnification of the hook.Relevant parameters in the

control system will automatically adjust. Please select the arm length and magnification of the hook correctly
according to the configuration of the tower.
The parameters in this screen are the basis of other parameters, if the parameters are set error, it will
cause the other parameter be set error.
•• Weight Sensor Correction
Fig 6.6-19 Weight sensor correction

The weight sensor is a sensor that converts weight to electrical signal. The weight sensor of this tower
crane is mounted on a pulley shaft on the jib. The sensor has a couple of electrical signal channels. When the
two electrical signal are difference, the screen will display a alam.
This screen provides two kinds of correction model:
One kind is double correction mode. This mode can completely correct the weight signal, but standard
weights is needed.
Another kind is single correction mode. This correction mode is more convenient, do not need additional
accessory, but only for fine-tuning. If the weight display quite different, you must use the double correction
mode.
Weight sensor correction can be completed in accordance with the steps on the screen .
CAUTION
The magnification is used in weight correction, please ensure the magnification settings are right
before correcting the weight sensor, otherwise it will result in great weight error , and effecting the work of
electronic security system.
equipment
Electrical
•• Angle Sensor Correction

Fig 6.6-20 Angle sensor correction

The angle sensor is a kind of sensor that convert angle into electric signal, the angle sensor is mounted
on the jib.
Before the angle sensor leaving the factory, it has been corrected to the horizontal plane. However,
because of the installation problem, angle sensor and the jib is not parallel, so the angle sensor need to be
corrected.
Single correction mode, only need to know the true jib angle, The angle sensor correction can be
completed in accordance with the steps on the screen. The current angle can be calculated through the rang
length of the jib, but the calculation may have error.
The angle sensor may have a reverse installation, so sensor orientation may need to modified. The angle
sensor need to be corrected again after direction changed
CAUTION
The arm length and the magnification are used in angle correction, please ensure the arm length and the
magnification settings are right before correcting the angle sensor, otherwise it will result in great angle error,
and effecting the work of electronic security system.
•• Wind Speed Sensor Correction

equipment
Electrical

Fig 6.6-21 Wind speed sensor correction

The wind speed sensor is a kind of sensor that convert wind speed into electric signal, the wind speed
sensor is mounted on the top of the tower crane.
Wind speed sensor has been corrected before leaving the factory, it can be used directly. if the error of
the sensor is large,it can be corrected .
In single correction mode,only need to know the current true wind speed, prompt correction can be
completed in accordance with the steps on the screen .
•• Tower Crane Limiter Setting
Fig 6.6-22 Tower crane limiter setting
All limit switches and electronic limit system setting are shown on this screen. It is convenient to adjust
the limits when setup the tower crane. In accordance with the limiter’s function, it is divided into six forms
equipment
Electrical
to display. These six forms respectively are trolley mechanism limiter, hoisting mechanism limiter, slewing
mechanism limiter, weight limiter, moment limiter, as well as the electronic limiter control settings.
Trolley mechanism limiter is one of the most important luffing tower crane limiter, so two sets of
limiter are provided in this control system. One set of limit device is mechanical contactor, installed on the
mechanism; The other is a electronic limiter, achieved through the angle sensor. In trolley limiter table, the

first column is the movement should be limit, the second column is the signal feedback by mechanical limiter,
the third column is the electronic limiter signal, the fourth column is limit angle value for electronic limiter.
The fourth column angle can be set, when the angle signal returned by the angle sensor reaches the set point,
the corresponding electronic limiter will generate a limit signal.
Hoisting limiter only have mechanical limiting device, installed in the mechanism. The first column of
the table is movement should be limit, the second column is the signal feedback by mechanical limiter.
The stop signal of the slewing limiter is mechanical limiter, and the deceleration signal is electronic
limiter. When the jib angle is smaller then 25 ° or bigger then 75 °, the speed limit signal will be generated,
and the max slewing speed is only gear 4.
Weight limiter only have electronic limiter, The first column of the table is the control range, the second
column is the electronic limiter signal, the third column is the weight value for the electronic limiter, the
value is calculated automatically according to the magnification.
Moment limiter is one of the most important limiting device of tower crane, so two sets of limiter are
provided in the control system. One set of limiter is mechanical limit device, installed in the A frame; the
other is the electronic limiter, achieved through the angle and the weight sensor. In the moment limiter table,
the first column is control range, the second column is feedback from mechanical limiter, the third column
is the electronic limiter signal, the fourth is the weight value for corresponding electronic limiter. When the
magnitude changed, the weight value in the fourth column will be calculated automatically according to
torque curve and be displayed.
The electronic limiter control setting is a set of functions for the electronic limiter. The first column of
the table is the name of the corresponding electronic limiter, the second column is the status, whether the
electronic limiter can not start because of failures, the third column shows whether the electronic limiter is
disable, the button in the fourth column is to enable or disable the corresponding electronic limiter.
CAUTION
If you disable electronic limiter, all corresponding electronic limit signal will automatically expire,
please pay attention to operate the tower crane and prevent accidents.
The weight limiter only have electronic limiter, if the electronic weight limiter is disabled, in order to
ensure safety, the highest speed of hoisting mechanism will be only gear 3.
Under normal working condition, please regulate the turning down time of hoisting hydraulic pliers and
luffing hydraulic pliers as 1200 seconds
equipment
Electrical

6.1.4 Input and Output Status of PLC
Fig 6.6-23 Output status of PLC
Fig 6.6-24 Input status of PLC (1)

equipment
Electrical

Fig 6.6-25 Input status of PLC (2)

Each input and output status and function definitions of PLC are displayed on the screens
6.1.5 Alarm Screen

When faults arise, the screen will pop up the alarm screen, display the current alarm. The history alarm
information can be reviewed in History Alarm Screen.
Fig 6.6-26 Alarm screen

equipment
Electrical

Fig 6.6-27 History Alarm Screen
6.2 Instruction for LCD Color Monitor

The LCD Color Monitor is used to monitor the state of the hook .
LCD Color Monitor
- + MENU CAM MODE POWER
Fig 8.6-28 Interface of the LCD Color Monitor

Instruction for the buttons of the LCD color monitor:
•• POWER: Power switch
•• CAM: Cam video selection(AV1/AV2)
•• MODE: Mode video selection(AV1/AV2)
•• MENU: Menu
•• - : Decrease button
+ : Increase button
equipment
Electrical
The focus of the camera on the A frame can’t be adjusted. The focus of the camera on the tip of the jib
can be adjusted as follow:
1. Press the “Video Adjust” button

Fig 8.6-29 Main Menu

2. Enter into the screen as follow, there are some buttons for operating the camera on the tip of the jib,
such as “Menu”, “Zoom In”, “Zoom Out”, “Focus”, “Expansion of focus”.
Fig 8.6-30 Video Adjust Screen
In the above of the video monitor screen, displays the moment and weight of the tower crane with a
horizontal progress bar as well as numerical . On the right there is numerical value that shows the jib angle,
radius of slewing, hoisting magnification, the maximum hoisting capacity, the current wind speed etc..
If there are faults, the fault information will be displayed in lantern way in the lower of the screen.
equipment
Electrical

6.3 Electrical Drawings

No. Size Drawing Symble Version Num. Drawing Name Remark
1 A4 00024072701A02000 -a 1 Menu of the Drawing
2 A4 00024072701A02101 -a 1 Circuit Diagram(Main-1)
3 A4 00024072701A02102 -a 1 Circuit Diagram(Main-2)
4 A4 00024072701A02103 -a 1 Circuit Diagram(Hoist-1)
7 A4 00024072701A02106 -a 1 Circuit Diagram(Slewing-1)
10 A4 00024072701A02109 -a 1 Circuit Diagram(Trolley-1)
14 A4 00024072701A02113 -a 1 Circuit Diagram(PLC Control)
15 A4 00024072701A02114 -a 1 Circuit Diagram(Sensor)
16 A4 00024072701A02115 -a 1 Circuit Diagram(Cammera)
17 A4 00024072701A02201 -a 1 Circuit Diagram(Consoles)
18 A4 00024072701A02202 -a 1 Wiring Diagram(1)
24 A4 00024072701A02301 -a 1 Components Dispose(1)
27 A4 00024072701A02401 -a 1 Cable List
28 A4 00024072701A02501 -a 1 Component List(1)
29 A4 00024072701A02502 -a 1 Component List(2)
30 A4
31 A4
equipment
Electrical

1 2 3 4 5 6
Pump For Over-undervoltage Lamp For
Main Power Isolate Switch Hydraulic Jack Voltage Meter Main Switch And Phase Protection Pump For Hydraulic Jack Power For Cab
Main Power
Electrical equipment
PE PE /.B5,/2.B2
N N /.D1
3P+N+PE U1 /.C1 U2
L1-1 U2 /.C4,/3.A1,/6.A1,/9.A1
AC 380V L1-2 V1 V2 V2 /.D4,/2.B1,/3.A1,/6.A1,/8.B1,/9.A1
L1-3 W1 W2 W2 /2.C1,/3.A1,/6.A1,/8.B1,/9.A1
3*95+2*35 mm2
-QS -QFP1 -QF -QF10 -QFP2
320A 1A ME22C
ME32C
1.5mm2 1 N1 PE 38 32 74 71 102
I> I> I> I> I> I>
1.5mm2 1.5mm2 /.C2 /.D2 /.A5
WP1 WP2 /2.D5 /2.D5 /.C6 /.D6 /.D3 B
UP1VP1 4mm2 UP2VP2 4mm2 2
4 mm
-XSP1 -XSP2 1 N1 PE 74 71 102
4
4
-XPP1 -XPP2 L N1 PE MX1 MX2 EY6 EY7 EF5
V1 W1 28 W2 AC220V -SLC -EY FAN
-PP1 V -KAU -KAP -PP2 7.5KW
11KW -PV /.C3 /2.D6 -HM
-Cab
-QFES -QF101 U2 -QFTS -QF1

U1 4 mm2 1 3A 10A 2
/.A2
32A /.A5 6A 14 -TS -QF2 1.5 mm
73 75 79 10A C
72
KAML 101 AC 22V /6.C5,/6.C6
-SST:2 371
OUT2
/13.D3
5 T>40℃ Blue-STC1
2 -KAU AC 380V -QFY
/.B3
71 3A
2
-DCM2
6 AC 22V 370 24VDC

102
AC.Input
V2 74
OUT1
1 /.A5 13 77
IN1 IN1 IN2 IN2 IN- IN-
SW1 V1+ V1- V2- V2+ SW2
N 76 -EY
N1 1
/.A5 /.B5
1.5 mm 2
-HH -HU -EF1 71
/6.C5,/6.C6
D
Horn Over-undervoltage Transformer

Electrical Leakage Protecing Device For Cab Indicate Fan Transformer Commutate Protection Commutate Commutate Protection Power For Wiper
Protection
8-47
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Main-1) DWG No. 00024072701A02101 Version -a 1
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
Transformer Transformer Zero Position Switch、
Circuit Protection Contactor For Start Contactor Start Indicate DC24V/12V For Control
8-48
Protection Start Button
A
42 /.C6,/4.A5,/14.C1 -QF5 /.14.B2,/14.C3,/14.C5,/14.C6,/15.D1
68 3A 64
AC
+ 24VDC For Sensor
-QFA -KMC1 -KMC2 40
10A - 63
/.C6 /.C6 /4.A5,/5.A4,/8.A5,/11.A5,/12.A1 DC
/14.B2,/14.C4,/14.C5,/15.D1
12 L L2 26 -KAMH -KAMS -KAMV
-QFTC -TC 15 N2 /13.D4 /13.D4 /13.D5 -BU1
V2 (DRP-120-24)
/1.A5
10A 10 AC 230V PE 210 310 410
N MP
L1
N1
-QF6 /15.B2,/15.A6
PE PE 1A
6 mm2 AC 67 62 B
+ 12VDC
- 61
AC 380V DC /15.B2,/15.C6
16 31 27 -BU2
-KMC1 -KMC2 -HP (S-15-12)
80 -KMH -KMS -KMV 41
/.C6 /.C6 /3.A2 /6.A2 /9.A2 /4.A5,/5.D4,/8.D5,/11.D2,/12.A1,/14.C1
/3.A2 /6.A2 /9.A2
W2 /3.A2 /6.A2 /9.A2
/1.A5 11
91 798
-QF4 -SZL
92 /.C4 796
10A 92 +
-KMC2 39
/.D6 -SZR 42
85 +
/.C5,/8.D6,/13.D2 /.C6
794 /.A4 C
-QF3 /.D5,/4.C1,/4.B3,/5.D1,/7.D1,/10.D2,/11.D1
-SST:1
OUT2
10A 83 /.D5,/4.C1,/12.C3,/13.D1,/13.D4
-KMC1 29 795
30 A1 S33 S39 13 23
90 -KMSC
24VDC 220VAC
-DCM1
-KMC1 -KMC2 +
A2 S11 S12 S21 S22 14 24
AC.Input
/.C6 /.C6
OUT1
81 790 791 35 36
IN1 IN1 IN2 IN2 IN- IN-

SW1 V1+ V1- V2- V2+ SW2
84 - -SEM 792 793
91 -KMC1 -KMC2 31
/.D4 -SED 38 /.B3
37 /.A3 /.A3
- -SLC -KAP /.B3 /.B3
91 32 33 /.C4 /.C4
/.D5,/4.D1,/4.D3,/8.A6,/10.D2,/12.D3,/13.D1,/13.C1
D
Commutate Protection Control Circuit

Commutate DC24V Power Supply Emergence,Door Switch Contactor
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Main-2) DWG No. 00024072701A02102 Version -a 2
1 2 3 4 5 6
Protection For Hoist Contactor For Hoist Protection For Cooling Motor Protecing Device For Brake Converter For Hoisting Resistance
U2 U20 U21
/1.A5 25KW*3=75KW
V20 V21
AC 380V V2
/1.A5 W20 W21
W2 -RHB1
/1.B5
-QFH 2 -KMH -RHB2
50 mm /2.B3
200A 170A 2 2
-RHB3
1.5 mm 1.5 mm
L1 L2 L3
-LH 6*16 mm 2
U V W
213 U21 V21 W21 212 U21 V21 W21 U24 V24
/5.B5
W24 200 201
/5.C5
B
R S T PB PA+
214 216
/5.C5 /5.C5 -HINV
-HINV-EX
-QFHC U V W +VS 0VS A A- B B- PE
4-6.3A I> I> I> -QFHB I> I> I>
1.6-2.5A
99 V22 99 V23
U22 W22 U23 W23
/8.B4 /8.B4
棕白绿黄
276 275
/5.A3 /5.A3
-KHC -KHB C
/5.D5 UHC VHC WHC VHB VH -PGH
1 2 3 /5.D5 UHB 1 2 WHB 3 UH WH
1 2 3 1 2 3
-MHC 3 4 -MHB 3 4 -MH 3

4 4
-YHB
D
Cooling Motor For Hoisting Brake For Hoisting Hoisting Motor Encoder
8-49
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Hoist-1) DWG No. 00024072701A02103 Version -a 3
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
Input Of The Hoist Converter 1#Proximity Switch Of Hydraulic Clamp 2#Proximity Switch Of Hydraulic Clamp Proximity Switch Of Lifting Reel
8-50
A
-SQH
40 41 BN
/2.B4 /2.B4
-SQ1 -SQ2
BK BU
BN BN Brown Black Blue

-KAH1 -KAH2 -KAH3 -KAH5 3 PE
-KAH4 263 1 264 2 265
/5.D1 /5.D1 /5.D2 /5.D2 /5.D2 1 2 3
BU BK BU BK PE
B
Brown Blue Black Brown Blue Black 19 20 3 4 5
290 291 292 293 294 295
1 2 3 1 2 3
1 2 3 1 2 3
261 262 -UHR
0V LI1 LI2 LI3 LI4 LI5 90
/2.C4 12 14 13 15
-HINV
R1A R1C R2A R2C
266 267
C
274 99 260
/5.B2 /8.B4
91
90 /2.D4 -KAHG1 -KAHG2 -KAHR1 -KAHR2
/5.B4 /5.B4 /5.B3 /5.B6
/2.C4
91
/2.D4 -KAHB
/5.B5
D
Alarm Signal For The Hoist Converter Brake Signal For The Hoist Converter Speed Moniter For Hoisting
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Hoist-2) DWG No. Version 4
00024072701A02104 -a
1 2 3 4 5 6
Signal Of
Up Limit Up Control Down Limit Down Control Alarm Signal For Brake Signal For Cooling Signal Of
Hoist Converter Hoist Converter Motor Over Speed Hydraulic Clamp
99
/8.B4
40
/2.A4
-SHU -SHUC -SHD -SHDC -HINV -KHB -KHC -KAHR1 -KAHG1 -KAHG2 -SHJ
/3.C4 /3.C2 /4.C6 /4.C4 /4.C5
R1C
R1A
-KAHB -KAHC
/4.D2 /.D3 168
215 213 B
270 271 272 273 274 275 276 277 278 279 290
-KAHEV -KAHR2
X7 X10 X11 X12 X23 X24 X25 X26 X27 X30 X43 /.D3 /4.C6
-KA21
/.D4
3 5
-PLC1 211 160 3 161 5
160 161
Y2 Y3 Y4 Y5 Y6 Y22 Y23 Y21
-KAHR1 -QFHC
280 281 282 283 284 285 286 287 /4.C6 /3.B2
212
-YZB C
-QFHB
/3.B4
214
216
90
/2.C4
41
-KAH2 -KAH3 -KAH4 -KAH5 -KA21 -KAHC -KAHEV /2.B4 -KHB -KHC
-KAH1 /3.C3
/4.B1 /4.B2 /4.B2 /4.B2 /4.B3 /.B5 /.B5 /.B6 /3.C4
/11.B5 /3.C4 /3.C3
/3.C4 /3.C3
D
Relay For Relay For Relay For Contactor For Contactor For
Relay For Hoist Hoisting Brake Cooling Motor Hydraulic Clamp Hoisting Brake Cooling Motor Control Cabinet Of Hydraulic Clamp
8-51
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Hoist-3) DWG No. 00024072701A02105 Version -a 5
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
Protection For Contactor For Slew Resistance
Slew Protection For Cooling Motor Converter For Slewing
8-52
A
15KW
U2 U30 U31
/1.A5 -RSB1
V30 V31
V2
/1.A5 W30 W31
W2 1.5 mm 2
/1.B5
10 mm 2 -KMS /2.B4 L1 L2 L3
50A
-QFS 99 -LS
U V W
63A /8.B4 6 mm 2
U33 V33 W33 300 301 B
378 R S T PA+ PB
/7.B3
I> I> I> -SINV
-QFSC
1.6-2.5A U V W
V32 US VS WS
U32 W32
72 71 72 71
-KSC /1.C6 /1.D6 /1.C6 /1.D6
/8.D6 99 388
-KSFB -KSB
-FRS1 -FRS2 /8.D5 /8.D5
/7.A3 -YSFB -YSB
388 1 2 379 /7.B3 371 370 C
VSC VSC 2 3 1 3 /1.C5 /1.C5
USC 1 2 WSC 3 USC 1 2 WSC 3 US1 1 VS1 WS1
2 3
US2 1 VS2 WS2 3
2
1 2 3 1 2 3 607 609
/8.D3 /8.D3
3 3 785
3 3 /8.C6
-MSC1 4 -MSC2 4 44
4 4 -MS1 44 -MS2 -SSK
608 610 91
/2.D4
/8.D3 /8.D3
-YBSE1 -YBSE2
D
Cooling Motor For Slewing Eddy Slewing Motor Wind Vane Brake For Slewing Inching Switch Of The Wind Vane
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Slew-1) DWG No. 00024072701A02106 Version -a 6
1 2 3 4 5 6
Alarm Signal For Brake Signal For Signal Of Input Of The Slewing Converter
Left Limit Right Limit Slewing Converter Slewing Converter Cooling Motor
99
/8.B4
-FRS1
/6.C3
R1C R2C
-KSB -QFSC 388
-SSL -SSR R1A R2A /8.D5 /6.B2
-SINV -FRS2
/6.C4 -KAS1 -KAS2 -KAS3 -KAS4 -KAS5
/.D1 /.D1 /.D2 /.D2 /.D3
390 391 392 393 394 395
373 374 375 376 377 378 379 B
0V LI1 LI2 LI3 LI4 LI5
X13 X14 X32 X33 X34 X31 X35
-SINV
-PLC1
R1A R1C R2A R2C
Y7 Y10 Y11 Y12 Y13 Y27 Y30 Y31

375 99 376 99
380 381 382 383 384 385 386 387
C
90
/2.C4
-KAS1 -KAS2 -KAS3 -KAS4 -KAS5 -KASB -KASFB -KASC

/.B5 /.B5 /.B5 /.B5 /.B6 /8.B5 /8.B5 /8.B6
D
Relay For Relay For Relay For

Relay For Slew
8-53
Slewing Brake Wind Vane Cooling Motor
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
Transformer Protection Transformer
8-54
A
+24V COM
40 91 -
/2.A4 /2.D4
-PLC1
Y0 COM0
-TE -KASB -KASFB -KASC
-QF8 -QF9 399 394 /7.D3 /7.D3 /7.D4
10A 600 10A
603 604 314 315 316 B
V2 99
/1.A5
/3.C2,/3.C3,/5.A1,/7.A1,9.C2,/9.C3,/13.A1
380VAC 22VAC -SSK
601 605 24VDC

W2
/1.B5
785
+ + - - + -
C
Power Power Supply Control Control
-SECC
H1 H2 H3 OUT1 OUT2 OUT3

1+ 1- 2+ 2- 2+ 2-
+
41 92
/2.C4
/2.B4 -KSB -KSFB -KSC
/6.C5 /6.C5 /6.C2
-HF
607 608 609 610 /7.B3
/6.C3 /6.D3 /6.C4 /6.D4 /6.C2
/6.C2 D
Contactor For Contactor For Contactor For Indicate Of

Eddy current device Slewing Brake Wind Vane Cooling Motor The Wind Vane
1 2 3 4 5 6
Protection For Converter For Trolley
Protection For Trolley Contactor For Trolley Cooling Motor Protection For Brake Resistance
U2 U40 15KW*3=45KW
/1.A5
V40
AC 380V V2
/1.A5 W40
W2 -RVB1
/1.B5
2 -RVB2
-QFV 25 mm -KMV
125A 115A 2 2 L1 L2 L3 -RVB3
1.5 mm 1.5 mm
-LV
U V W
U46 V46 W46 6*10 mm 2
415 U41 V41 W41 413 U42 V42 W42
/11.B6 /11.C6 400 401
B
R S T PB PA+
416 414
/11.C6 /11.C6 -VINV
-VINV-EX
-QFHVG U V W +VS 0VS A A- B B- PE
16A -QFVC I> I> I> -QFVB I> I> I>
1.6-2.5A 1.6-2.5A
99 99
U43 V43 W43 /8.B4 U44 V44 W44 /8.B4 U45 V45 W45
-KHVG -KVC -KVB 棕白绿黄

12A /11.D6 /11.D6
477 478
UVG VVG WVG /11.B3 /11.B4 C
UVC VVC WVC UVB VVB WVB VV -PGV
1 2 3 1 2 3 1 2 3 UV WV
1 2 3 1 2 3
UHG 1 VHG 2 WHG 3
-MHVG 3 -MVC 3 -MVB 3 4 -MV 3

4
4 4
-YVB D
Motor For Hydraulic Clamp Cooling Motor Brake For Trolley Trolley Motor Encoder
8-55
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Trolley-1) DWG No. 00024072701A02109 Version -a 9
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
Input Of The Trolley Converter
8-56
A
-KAV1 -KAV2 -KAV3 -KAV4 -KAV5

/11.D1 /11.D1 /11.D2 /11.D2 /11.D2
B
490 491 492 493 494 495
0V LI1 LI2 LI3 LI4 LI5
-VINV
R1A R1C R2A R2C
C
476 99 460
90
/2.C4
91
/2.D4 -KAVB
/11.B6
D
Alarm Signal For

Trolley Converter Relay For Trolley Brake
1 2 3 4 5 6
Forward Backward Forward Forward Alarm Signal For Signal Of Brake Signal For Over Speed Signal Of Hydraulic Clamp
Backward Limit Limit Backward Limit Control Limit Control Trolley Converter Cooling Motor Trolley Converter
99
/8.B4
40
/2.A4
-SVA1 -SVA2 -SVBW -SVBC -SVFW -SVFC -VINV -KVC -KVB -KAVR1 -KAVGX
/.D6 /.D6 /12.D5 /12.D4
R1C
R1A -KAHEV -KAVEV -KAVB -KAVC
/5.D3 /.D3 /10.D5 /.D3
470 471 472 473 474 475 476 477 478 479 480 B
411 415
X15 X16 X17 X20 X21 X22 X36 X37 X40 X41 X42
417 -KA31
/.D3
-PLC1 412
Y14 Y15 Y16 Y17 Y20 Y24 Y25 Y26

-KAVR1 -QFVC
481 482 483 484 485 486 487 488 /12.D5 /9.B3
413 416 C
-QFVB
/9.B3
414
90
/2.C4
41
-KAV2 -KAV3 -KAV4 -KAV5 -KAVEV -KA31 -KAVC /2.B4 -KHVG -KVB -KVC
-KAV1
/9.C1 /9.C4 /9.C3
/10.B3 /10.B3 /10.B4 /10.B4 /10.B5 /.B5 /.B6 /.B6 /9.C1 /9.C4 /9.C3
/9.C1 /9.C4 /9.C3
D
Relay For Relay For Relay For Contactor For Contactor For Contactor For
Relay For Trolley Trolley Brake Cooling Motor Hydraulic Clamp Hydraulic Clamp Trolley Brake Cooling Motor
8-57
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
Power For Proximity Switch Of Hydraulic Clamp Proximity Switch Of Trolley Reel
Hydraulic Clamp
8-58
A
40
/2.A4
BN
41
/2.B4
-SQV
BK BU
Brown Black Bule

BN PE B
463 1 464 2 465 3
169 1 2 3 PE
-SQ3
BU BK
-QF402 -KAVEV -KAVR2
19 20 3 4 5
4A Brown Bule Black
1 2 3
1 2 3 4 1 2 3
150 1 151 2 160 3 162 4 462 -UVR
90 12 14 13 15
150 151 160 162 /2.C4
C
-YZB 466 467
91
/2.D4
-KAVGX -KAVR1 -KAVR2
/11.B4 /11.B4 /.C2
/11.C6
D
Control Cabinet Of Hydraulic Clamp Relay For Proximity Switch Speed Moniter For Trolley
1 2 3 4 5 6
Contactor 105% 100% 90% 80% Break/ Bypass
Console-gear swtich for Hoist Console-gear swtich for Slew Console-gear swtich for Trolley
For Start Moment Moment Moment Moment Slewing
99 5 5 5
/8.B4
向 4 向 4 向 4
-KMC1 3 3 3
上 2 左 2 外 2
185 -SH 1 -SS 1 -SV 1
-KMC2 -SM1 -SM2 -SM3 -SM4 SSF SSJ 0 0 0
1 1 1
向 2 向 2 向 2
3 3 3
下 4 右 4 内 4 B
5 5 5
180 181 182 183 184 770 768 750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767
X2 X3 X4 X5 X6 X44 X45 X46 X47 X0 X1 X2 X3 X4 X5 X6 X7 X10 X11 X12 X13 X14 X15 X16 X17
-PLC2
-PLC1
COM2 COM3 COM4 COM5 COM6 Y32 Y33 Y34 Y35 Y36 Y37 Y40 Y41 Y42 Y43 Y44 Y45 Y46
C
91
/2.D4 780 781 782 783 784 970 971 972 950 951 952 953 958
-KA92 -KA91 -KA94 -KA93
-KAML -RBZ
802
4
4
90 954 955 956 957
+ /2.C4
-KAMA 801 -S3红色 -
3
3
+
-KAMA 800 -S2黄色 92
2
2
90
/2.C4
91 /2.C4
/2.D4
1
1
- -S1绿色
-HML -KAML -HMA -KAMA -HLL -HLA -HBZ -KAMH -KAMS -KAMV -KA90 -KA91 -KA92 -KA93 -KA94
/.C2 /.D1 /2.A3 /2.A4 /2.A4 /15.B5 /15.B5 /15.C5 /15.B5 /15.C5
/1.C2 /.D1 D
Yellow Lamp Red Lamp Yellow Lamp

Three-color Lamp For Alam Red Lamp For Moment For Moment For Weight For Weight Buzzer Relay For Main Contactor Relay For Camera
8-59
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(PLC Control) DWG No. 00024072701A02113 Version -a 13
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
PLC Analog Input Model PLC CAN Model
8-60
A
399
24V+ 24V+ 24V+
-PLC2
-PLC1 -PLC3 -PLC4
L N 24V+ 24V- V1+ I1+ VI1- FG V2+ I2+ VI2- FG V3+ I3+ VI3- FG V4+ I4+ VI4- FG RES+ RES- CANH CANL GND
981 982 983 984

B
63
/2.A6
42 41 64
/2.A4 /2.B4 /2.A6
2 1 3 4 PE
2 1 3 4 PE
10K -R1
64 981 64 982 64 983 64 63 CANH CANL
2 63 1 3 PE 2 3
63 1 PE 2 3
63 1 PE 2 3 1 PE
2 1 3 PE 2 3 1 PE 2 3 1 PE 2 3 1 PE
Red White Black Red White Black Red Green Blue 82 984 63 Red Blue Yellow Green C
+ O - + O - 1 3 2 V++ GND CANH CANL
-AG1 -AG2 -FS -JD

RPH
-HG
D
Load Sensor Anemometer Hoisting Sensor Angle Sensor

ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Sensor) DWG No. 00024072701A02114 Version -a 14
1 2 3 4 5 6
LCD Color Monitor Camera
2
2
62
/2.B6
-RC1 -KA90 -KA91 -KA93
/13.D5 /13.D5 /13.D6
2.7K-1/2W
-LCD2 -CCD
3
3
961
M
4
4
962 B
Z
5
963
5
12V
F
6
6
968
AVIN1 AV C
7
7
969 960
AVGND1 AVG
2.7K-1/2W
-RC2 -KA92 -KA94

12V /13.D6 /13.D6
1
1
VCC 62
/2.B6 GND
GND 61 61
/2.B6
/2.B6
C
-LCD1 -PLC1
64 24V+
/2.A6
63 24V- COM1 PORT0
/2.A6
D
Graphic Terminal PLC
8-61
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Cammera) DWG No. 00024072701A02115 Version -a 15
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
8-62
A
-SZL -SZR
796 798 794 796
QTC01D-F2 Console Layout
Slewing leftward -SS Slewing rightward -SH
Hoist Down
5 4 3 2 1 0 1 2 3 4 5 5 4 3 2 1 0 1 2 3 4 5
-SS/-SV -SH/-SD
756 750
757 751
758 752 -HMA -HLL
759 753 -HML -HLC
760 -HP -HF
754
761 755 -SSF -SSJ -SST -SEM B
99
-SV -SD
Trolley out Trolley in
5 4 3 2 1 1 2 3 4 5 Travelling foreward Travelling backward
0 2 1 0 1 2
762 702
763 704
764 706
765 708
766 40
767 92
-HML -HMA -HLL -HLC -HBZ 1 -SH,-SS,-SV,-SD Console-gear 4
99 780 781 782 783 2 -SZL,-SZR Zero Position 2 C
-RBZ
784 3 -HP Start Indicae 1
-SEM 4 -HF Wind Vane 1
-HP -HF 790 792 794 -SST:1
40 41 92 785 795 5 -SSF Break/Slewing 1
791 793 -SST:2
-SSF -SSJ 1 5 6 -SSJ Bypass 1
99 770 99 768 7 -HML 100% Moment 1
1 8 -HMA 90% Moment 1
5
-HLL 100% Load 1

704
790
792
796
708
791
40
702
99
750
751
752
753
754
755
92
780
782
784
99
781
783
759
793
795
756
757
758
760
761
762
763
764
765
766
767
768
770
92
785
796
798
40
41
10 -HLC 50% Load 1
11 -SST Start/Horn 1
12 -HBZ Buzzer 1 D
13 -SEM Emergence 1
14 -RBZ Resistance 1
ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Consoles) DWG No. 00024072701A02201 Version -a 16
1 2 3 4 5 6
Power Supply A
L0
U0
PE
V0
W0
-QFP1
ME32C
QS
U1
V1
PE
W1
VP1
UP1 WP1 -XSP1
PE -XPP1
L1-1 L1-2L1-3 N PE C
L1 L100
YC3*95+2*35 YZ3*4+1*2.5 A－ Isolate Switch Cabinet

B－ Electrical Cabinet
C－ Console(Left)
D－ Console(Right)
E -PP1
H－ Graphic Terminal D
G－ LCD Color Monitor
CCD- Camera Cabinet
8-63
ZOOMLION HEAVY INDUSTRY & SCIENCE Wiring Diagram（1） DWG No. 00024072701A02202 Version -a 17
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
8-64
Slewing Limiter
Moment Limiter Trolley Limiter Hoisting Sensor Slewing Eddy Current Horn 1#Load Sensor Camera 2#Load Sensor
Angle Sensor Anemometer
SM1 SM2 SM3 SM4 SVA1 SVA2 -HG -SSL -SSR -YBSE1 -YBSE2
181 182 183 184 607 609
470 471 82 RPH63 373 374
-HH -AG1 -JD -FS -CCD -AG2
99 99 99 984 99 608 610
L101 L103 L104 L106 L108 L109 L110 L112 L125
L102 L105 L107 L111
FTKYR 5*1 YZ2*1 YZ2*1 RVVP3*0.5 YZ3*1 YZ2*1.5 YZ2*1.5 YZ2*1 RVVP3*0.5 RVVP4*0.5 RVVP3*0.5 RVVP7*0.34 RVVP3*0.5
-XP3 -XP4 -XP5 -XP6 -XP7 -XP8 -XP9 -XP10 -XP11 -XP12 -XP13 -XP14 -XP34
-XS3 -XS4 -XS5 -XS6 -XS7 -XS8 -XS9 -XS10 -XS11 -XS12 -XS13 -XS14 -XS34
1
2
1
2
3
4
5
1
2
1
2
3
1
2
1
2
1
2
1
2
3
1
2
3
4
1
2
3
1
2
3
1
2
3
4
5
6
7
1
2
3
Black Red White Blue Red Yellow Green Blue Red Green Black Red White
99
82
99
99
99
64
64
64
64
62
63
63
63
63
63
N1
470
61
374
984
373
969
962
982
609
983
963
CANH
968
607
608
184
471
CANL
182
183
981
961
610
181
1 2 3 4 5 5 6 7 8 9 10 11 PE 12 13 14 15 16 17 18 19 20 21 22 23 PE 24 25 26 27 PE 28 29 30 PE 31 32 33 34 35 36 37 38 39 40 PE
ZDU 4 ZPE 4 ZPE 4 ZPE 4
HQ007-G1 HQ007-G2 HQ007-G3 HQ007-G4 HQ007-G5 HQ012-P8 HQ012-P8 HA04 HQ007-G6 HQ007-G7 HQ007-G8 HQ012-P9 HQ012-P15
B电气房 HQ012-P10 HQ012-P11 HQ007-G9 HQ007-G10 ZPE 4 HQ007-G11 HQ007-G12 HQ012-P14 HQ012-P12 R1,10K,1/4W
ZPE 4
HQ012-P13
51 52 53 54 55 56 57 58 59 60 61 PE 62 63 64 65 66 67 68 69 70 PE 71 72 73 74 75 76 77
45 46 47 48 49 50
41 42 43 44
82
64
464
90
90
463
465
90
99
91
91
462
91
262
474
264
472
473
475
263
265
261
99
272
273
270
271
71
71
91
785
370
371
91
802
800
801
1
2
3
4
5
1
2
3
4
5
1
2
3
1
2
3
1
2
3
4
5
6
1
2
3
1
2
3
1
2
3
1
2
3
4
-XP17 -XP18 -XS19 -XS31 -XS33
-XS17 -XS18 -XP19 -XP31 -XP33
-XP16 YZ3*1 RVVP3*1 YZ3*1 YZ3*1 RVVP3*1 -XS20
-XP32 -XP15 -XS16
-XS32 -XS15 L114 L115 L116 -XP20 L118
L120 L113 L117 L124 L121
YZ4*1 FTKYR 5*1 FTKYR 5*1 FTKYR 5*1 A－Isolate Switch Cabinet
BN BN BN BN BN B－ Electrical Cabinet
91 270 271 272 273 472 473 474 475 C－Console(Left)
S1 Green 71 370 71 371 D－Console(Right)
99 BU BK BU BK BU BK BU BK BU BK H－Graphic Terminal
S2 Yellow 99 G-LCD Color Monitor
S3 Red -SHUC -SHDC 90 91 462 463 465 464 90 91 261 90 91 262 263 265 264 -SVBW -SVFW CCD-Camera Cabinet
785 -SHU -SHD -SVBC -SVFC
Three-color Lamp -SQ3 -SQV -SQ1 -SQ2 -SQH
-YSB -YSFB -SSK
For Alam Hoisting Limiter Proximity Switch Proximity Switch Proximity Switch Proximity Switch Proximity Switch Trolley Limiter
1 2 3 4 5 6
A
Cooling Motor For Hoist Slewing Motor Cooling Motor For Slew Resistance For Hoisting
Hoisting Motor Hoist Brake
-MHC -MHB -MS1 -MS2 -MSC1 -MSC2 -RHB1 -RHB2 -RHB3

A -MH -PP2
200 201 200 201 200 201
L203 L213 L214 L206 L207
L1 L201 YZ4*1 (YZP)4*2.5 (YZP)4*2.5 YZ4*1 YZ4*1
L202
-XP22 -XP23 -XP24 -XP25 -XP26
YC3*95+2*35 (YCP)3*50+1*25 -XS21 YZ4*1 -XS24 BVR16 BVR16 L200
-XS22 -XS23 -XS25 -XS26
-XP21
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
VP2 B
UP2 WP2
WHC
VHC
UHC
UH VH WH 200 201 200 201 200 201
US2
USC
VSC
U1 V1 W1 N PE
WSC
VS2
WS2
WS1
US1
UHB
VSC
WHB
VS1
WSC
USC
VHB
TC2003 PE
78 79 80 PE 81 82 83 PE 84 85 86 PE PE 87 88 89 PE PE 90 91 92 PE 93 94 95 PE
ZDU 4 ZDU 6 ZDU 4 -HINV -XSP2/-XPP2
HQ012-P1 HQ012-P2 HSB006-F1 HSB006-F1 HQ012-P3 HQ012-P3
B
HQ012-P4 HQ012-P5 HQ012-P6 HQ012-P7 -VINV -HINV -VINV
ZDU 4 -SINV
TC1503 96 97 98 PE 99 100 101 PE 102 103 104 PE 105 106 107 108 109
B+
B-
PE
A+
A-
B+
B-
PE
A+
A-
+Vs
0Vs
+Vs
0Vs
WVB
WVG
WVC
VVB
VVG
VVC
UVB
UVG
UVC
162
150
160
151
161
UV VV WV 400 401 400 401 400 401 300 301
C
1
2
3
4
5
1
2
3
4
1
2
3
4
1
2
3
4
(YCP)3*25+1*10 -XP27 -XS28 -XS29 -XS30
-XP28 -XP29 -XP30
-XS27 BVR10 BVR10 BVR10 BVR10 L301 L302
L208 YZ4*1 YZ4*1 YZ4*1.5
L209 L210 L211 FTKYR 5*1 A－ Isolate Switch Cabinet
L212 -RVB1 -RVB2 -RVB3 -RSB1 B－ Electrical Cabinet
-MV 401 400 401 400 401 300 301 C－Console(Left)
-MVC -MVB -MVG 400 D－Console(Right)
-YZB H－Graphic Terminal
Trolley Motor G-LCD Color Monitor
Trolley Brake Resistance For Trolley Resistance For Slewing CCD-Camera Cabinet D
Cooling Motor For Trolley Motor For Hydraulic Clamp
-PGH -PGV
8-65
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
8-66
G A
H G
-Cab obligate
L119 L122
H
YZ3*0.75 YZ2*0.75 L123
YF-XL20(10m)
White
Red Shield
1
71
N1
86
89
PE
74
102
968
40
969
41
63
61
704
64
62
702
PE
708
COM0
B
110 111 PE 112 113 114 115 116 -PLC 117 118 PE 119 120 121 122 123 124 125 126 127 128
ZDU4
B ZDU4 ZDU4
166
163
167
172
151
152
158
161
168
169
160
164
165
150
153
154
155
170
171
173
174
156
159
162
157
148
147
149
146
145
144
137
129
130
133
135
138
139
140
141
142
143
131
132
134
136
1
5
40
99
704
92
792
796
708
791
790
753
702
750
751
752
754
755
780
782
784
41
781
783
99
40
793
795
761
758
757
759
760
763
764
765
766
767
768
770
92
785
796
756
762
798
C
RVV25*1 L204 RVV25*1 L205

A－ Isolate Switch Cabinet
C D C－ Console(Left)
D－ Console(Right)
D
H－ Graphic Terminal
G-LCD Color Monitor
CCD-Camera Cabinet
1 2 3 4 5 6
B
B
L123
B -PLC B
L122
L119 L112
61
62
Red Black
64
63
62
61
961
962
963
969
968
PE
Power Video1 Video2
C
F
Z
M
12V
GND
COM1
AV
24V+
24V-
960
G
H -RC1 -RC2 -CCD
A－ Isolate Switch Cabinet

C－ Console(Left)
D－ Console(Right)
D
H－ Graphic Terminal
G- LCD Color Monitor
CCD- Camera Cabinet
8-67
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
8-68
L
4 mm 2
2.5mm 2 2.5mm 2 2.5mm 2 2.5mm 2 2.5mm 2 A
Socket For Cab Air-condition Socket For Air-condition
Socket For Electrical Room

N1
Socket For Power Supply Socket For Electrical Room
PE
MX1 1.5 mm 2
1.5mm 2 1.5 mm 2 1.5mm 2 B
Switch Switch Switch

EF5
DL3 CL4
Lamp For Electrical Room Lamp For Cab Fan
MX2
EY6 1.5 mm 2
C
Switch
Wiper
EY7
D
1 2 3 4 5 6
B
-DCM1
-KMH
-QFH
-EF1
-QF
-KMV
-QFV
-DCM2
C
-PV
-HU
D
8-69
ZOOMLION HEAVY INDUSTRY & SCIENCE Components Dispose（1） DWG No. 00024072701A02301 Version -a 23
equipment
Electrical
Electrical
equipment
1 2 3 4 5 6
8-70
A
-LS
-SINV
-LV
B
-VINV
-VINV-EX
D
1 2 3 4 5 6
-QFES
-QFY
-BU2 -BU3
-UHR -QF5
-TE
-QF6
-KAU -KAP -MP

-UVR -QF101
-UPV
C32 C3 C3 C1 C3 2C6
-BU1
-KAV1 -QFTS
TC2003
-KAV2
-KAV3 -QF1
-TS
-KAV4 -QF2
-KAV5
2C10 C10 2C10

-KA31 -QFTC
ME10C ME07C
-KAVC
TC1503
ME22C ME07C
-KAVB -QFA
-KAVEV B
-KA90 -QF3
-KSL -KSR -KMSC -KMS

-KA91 -KAVR1
-TC
-KA92 -KAVR2 -QF4

-KA93 -KAVGX -QF8
-KSB -KSFB -KSC -QFP2 -QFSC -KMC1 -KMC2

-KA94 -KAH1 -QF9
C6 2C10 C10 2C10 C10 C1

-KASB -KAH2 -QF10
2C4
-QF402
-PLC1
-KASFB -KAH3
TC3004
-KASC -KAH4
3D50
-KAMH -KAH5 -QFS -QFHVG
3D10
-KAHR1 -KA21
-KAHR2 -KAHC
-SECC
-KAML -KAHB
-KASL
-PLC2
-KAMA
-QFHC -QFHB -KHC -KHB -STC -KVC -KVB -KHVG
-KALL -KASR
-FRS1 -FRS2
-QFVC -QFVB
-KAMV ME07C ME07C C
-KAMS
-PLC3 -PLC4
-PE
-LH
-HINV
D
-HINV-EX
8-71
equipment
Electrical
ZOOMLION HEAVY INDUSTRY & SCIENCE CABLE LISE Page 1 of 1

No. Symbol Code Type Toward Length(m) Remark
1 L1 1022303190 YC3*95+2*35 A-B \
2 L100 1022303101 YZ3×4+1×2.5 A-PP1 30
3 L101 1022303057 FTKYR 5×1 B-Moment Limiter 20
4 L102 1022303004 YZ2×1 B-Trolley Limiter 12
5 L103 1022303004 YZ2×1 B-Trolley Limiter 12
6 L104 1022304023 RVVP3×0.5 B-Hoisting Sensor 14
7 L105 1022303005 YZ3×1 B-Slewing Limiter 8
8 L106 1022303030 YZ2×1.5 B-Slewing Eddy Current 8
9 L107 1022303030 YZ2×1.5 B-Slewing Eddy Current 9
10 L108 1022303004 YZ2×1 B-Horn 5
11 L109 1022304023 RVVP3×0.5 B-Load Sensor 5
12 L110 1022304018 RVVP4×0.5 B-Angle Sensor 15
13 L111 1022304023 RVVP3×0.5 B-Anemometer 30
14 L112 1022304030 RVVP7×0.34 B-CCD 75
15 L113 1022303057 FTKYR 5×1 B-Slewing Brake 9
16 L114 1022303057 FTKYR 5×1 B-Hoisting Limiter 13
17 L115 1022303005 YZ3×1 B-Proximity Switch 17
18 L116 1022304003 RVVP3×1 B-Proximity Switch 18
20 L118 1022303057 FTKYR 5×1 B-Trolley Limiter 18
21 L119 1022303067 YZ3×0.75 B-G 8
22 L120 1022303018 YZ4×1 B-Three-color Lamp 8
23 L121 1022304003 RVVP3×1 B-Proximity Switch 18
25 L125 1022304023 RVVP3×0.5 B-Load Sensor 5
26 L200 1022303101 YZ3×4+1×2.5 B-PP2 25
27 L201 1020702451 (YCP)3*50+1*25 B-Hoisting Motor 19
28 L202 1022303018 YZ4×1 B-Cooling Motor For Hoist 18
29 L203 1022303018 YZ4×1 B-Hoist Brake 18
30 L204 1020700918 RVV25*1 B-C 5
31 L205 1020700918 RVV25*1 B-D 6
32 L206 1022303018 YZ4×1 B-Cooling Motor For Slew 8
33 L207 1022303018 YZ4×1 B-Cooling Motor For Slew 9
34 L208 1020702449 (YCP)3*25+1*16 B-Trolley Motor 17
35 L209 1022303018 YZ4×1 B-Cooling Motor For Trolley 16
36 L210 1022303018 YZ4×1 B-Trolley Brake 17
37 L211 1022303048 YZ4×1.5 B-Motor For Hydraulic Clamp 20
38 L212 1022303057 FTKYR 5×1 B-Control Of Hydraulic Clamp 20
39 L213 1029900539 (YZP)4×2.5 B-Slewing Motor 8
40 L214 1029900539 (YZP)4×2.5 B-Slewing Motor 9
41
42
43
44
45
equipment
Electrical
46
47
48
49
A:solate Switch Cabinet,B: Electrical Cabinet,C:Console(Left),D:Console(Right),S-LCD Color Monitor 1,H-LCD Color Monitor
2,X-Junction Box for Hoisting,Y-Junction Box for Trolley,Z-Junction Box for Slewing

ZOOMLION HEAVY INDUSTRY & SCIENCE COMPONENT LISE Page 1 of 1

No. Symbol Code Name Num. Site
1 \ 00024072701A01400 Cable Package with 1 \
Plugs
2 \ 00024072701A01500 Cable Package 1 \
3 \ 00024072701A01300 Main Cable Package 1 \
4 -LH 1020604028 Filter 1 Electrical Room
5 -LV 1020604128 Filter 1 Electrical Room
6 CCD 1029801219 Camera 1 Tip of the Jib
7 -DCM1/-DCM2 1020903025 Rectifier 2 Electrical Room
8 -FS 1021402136 Wind Speed Sensor 1 Top of the crane
9 -HH 1020403003 Horn 1 Under the
Electrical Room
10 -HINV 1020002039 Inverter 1 Electrical Room
11 -HINV/-VINV 1020099003 Expansion Card 2 Electrical Room
accessories
12 -HM 1020402166 Indicator Light 1 Isolate Switch
Box
13 -HU 1020402171 Indicator Light 1 Electrical Room
14 -JD 1021402600 Angle Sensor 1 Jib
15 -KA* 1020303114 Relay 41 Electrical Room
16 -KA* 1020304036 Base of Relay 41 Electrical Room
20 -KAP 1020303036 Three-Phase sequence 1 Electrical Room
Relay
21 -KHVG 1020301073 Contactor 1 Electrical Room
22 -KMC1/-KMC2/-KHB/- 1020301031 Contactor 9 Electrical Room
KHC/-KSC/-KSB/-
KSFB/-KVC/-KVB
23 -KMH 1020604390 Contactor 1 Electrical Room
24 -KMS 1020301070 Contactor 1 Electrical Room
25 -KMV 1020604267 Contactor 1 Electrical Room
26 -QFES 1021102481 Breaker 1 Electrical Room
27 -LCD1 1022002015 LCD Monitor 1 Cab
28 -PGH/-PGV 1021401014 Encoder(Φ45) 2 Motor
29 -SHJ 1020514007 Key switch 1 Electrical Room
30 -PLC1 1020101069 PLC 1 Electrical Room
31 -PLC2 1020103311 Expansion Modle for 1 Electrical Room
Input
32 -PLC3 1020103240 Analog Input Model 1 Electrical Room
33 -PLC4 1020201497 CAN Model 1 Electrical Room
34 -QF 1020601069 Breaker 1 Electrical Room
35 -QF1/-QFTC/-QF3/- 1020602148 Breaker 4 Electrical Room
QF8
36 -QFTS 1020602113 Breaker 1 Electrical Room
37 -QF12/-QFE2 1020602100 Breaker 2 Electrical Room
equipment
Electrical
38 -QF2/-QF4/-QF9/- 1020604329 Breaker 4 Electrical Room

QFA
39 -QF402 1020602146 Breaker 1 Electrical Room
40 -QFP2 1020602202 Breaker 1 Electrical Room
41 -QFP1 1020602231 Breaker 1 Electrical Room
42 -QFHVG 1020602175 Breaker 1 Electrical Room
43 -QFV 1020601029 Breaker 1 Electrical Room

ZOOMLION HEAVY INDUSTRY & SCIENCE COMPONENT LISE Page 1 of 1

No. Symbol Code Name Num. Site
44 -QFS 1020602259 Breaker 1 Electrical Room
45 -QFH 1020002039 Breaker 1 Electrical Room
46 -QFHB/-QFVC/- 1020602133 Breaker 4 Electrical Room
QFVB/-QFSC
47 -QFHC/-QFHB/- 1020602288 Auxiliary Contacts 5 Electrical Room
QFVC/-QFVB/-QFSC for Breakers
accessories
48 -QFHC 1020602150 Breaker 1 Electrical Room
49 -KAML/-KAMA 1020303438 Relay 2 Electrical Room
50 -KAML/-KAMA 1020303439 Base of Relay 2 Electrical Room
51 -KAU 1020303035 Over-Under Voltage 1 Electrical Room
Relay
52 -QS accessories 1020517047 Handle for QS 1 Electrical Room
53 -QF accessories 1020519284 Handle for QF 1 Electrical Room
54 -QS 1020511114 Isolate Switch 1 Electrical Room
55 -R1 1021102021 Resistance 1 Electrical Room
56 -RC1/-RC2 1021102029 Resistance 2 Camera Box
57 -RHB/-RVB/-RSV 1029904187 Brake Resistance 1 Electrical Room
58 -SECC 1020102034 Eddy Current 1 Electrical Room
Controller
59 -SED 1020502028 Emergency Stop 1 Electrical Room
60 -SED 1020509007 Base of Button 1 Electrical Room
61 -SINV 1020002042 Inverter 1 Electrical Room
62 -SLC 1021102483 Limiter Switch 1 Electrical Room
63 -SQ1 1020516014 Proximity Switch 1 Hydraulic Pressure
Pumping Station
64 -TC 1021901007 Transformer 1 Electrical Room
65 -TS/-TE 1021901005 Transformer 2 Electrical Room
66 -BU1 1020901018 Switch Power Supply 1 Electrical Room
67 -BU2 1020903139 Switch Power Supply 1 Electrical Room
68 -UVR/-UHR 1022001022 Over Speed Monitor 2 Electrical Room
69 -VINV 1020002035 Inverter 1 Electrical Room
70 -QTC01D 1020810529 Console 1 Electrical Room
71 -XS1/-XS2 1022200752 Soccket 1 Electrical Room
72 -XS1/-XS2 1029802064 Soccket 1 Electrical Room
accessories
73 -XSP1/-XSP2 1022200085 Soccket 2 Electrical Room
74 Communication 1022301065 Communication Cable 1 Electrical Room
Cable for LCD Monitor
75 Barrier Light 1020401052 Solar Light 3
76 -PV 1022101015 Voltage Meter 1 Cab
77 -AG 1021402510 Load Sensor 1 Electrical Room
78 -LCD2 1020400417 Video Monitor 1 Cab
79 -QF6/-QF10 1020602072 Breaker 2 Electrical Room
equipment
Electrical
80
81
82

L250-20
8 Electrical Control System
9 Maintenance and Service

To ensure safe and economic operation of the tower crane for a longer service life, it must be
properly maintained and lubricated.
9.1 maintenance
9.1.1 Daily maintenance
(1) Check speed reducers for oil quantity. Fill oil in time.
(2) Check wire ropes at different positions for looseness, breakage or being worn-out. Change
defective ropes as required as per relevant stipulations.
(3) Check brakes for performance and clearance to ensure reliable sensitivity.
(4) Check safety guards for reliable sensitivity.
(5) Check bolt connections. Re-tighten the bolts once again when they have been used for a certain
period of time.
(6) Check steel rope head clampers and clips for loose status. Tighten them if loosened.
(7) Reject steel ropes, drums, pulleys and hoisting hooks strictly according to the relevant
stipulations.
(8) Check the rods, web rods and welds of metal structure members for fractures and fissures. Pay
special attention to the positions where the paints are peeled. The striation of paint in 45°
oblique strings is most dangerous.Trace the cause immediately and dress the issue in time.
Inspect the connecting bolts and nuts of tower sections, including the connection of
Undercarriage tower section and undercarriage. The parts with the diameter of connecting pin
bolts of more than Φ20 are specially-made, no substitutes shall be replaced under any
conditions.
(9) Conduct rust removing and painting of the whole tower crane and its metal mechanisms after
completion of their each use in a project.
(10) Check if anti- doff of hook safety and credibility.
(11) Check if the electrics connectors are oxidized or burned-down. Repair or replace any poor
connectors
(12) No function failures of limit switches and push buttons. Replace rusted or damaged parts in
289
L250-20
time
(13) Be sure that the insulation of electric switches to switch panels meet the relevant requirements,
with insulation resistance no less than 0.5MΩ
(14) Check if the bolts connecting electric components are loosened: Check power cables and other
conducting wires for fractures. Remove the trouble if any
9.1.2 Week maintenance

(1) Check Trolley wire ropes at different positions for looseness, breakage or being worn-out.
Change defective ropes as required as per relevant stipulations。
(2) Check wearing statu to block assembly of Trolley. Arrive at reject relevant stipulations must
replace in time.
9.1.3 Mmonth maintenance

(1) Check the status of conncetion pin and nearby material
(2) Check the bottom three section for no attachment crane.
(3) Check the top three section for crane with attachment.
(4) Check the A frame、arm and turntable connection pin nearby with state of counter jib and
counter jib support
9.2 Ordinary troubles, troubleshooting and solution
Ordinary troubles, troubleshooting and solution table9-1

No. Trouble Troubleshooting Solution
Reducer temperature Lubrication oil deficient or Properly increase or
1
is too hot excessive decrease oil
Excessive or deficient grease
Properly replace grease
The temperature of
Grease quality very poor Re-adjust the clearance
2 the reducer bearings
Improper axial clearance of the of of bearings
is too high
bearings or bearings is already Replace bearings
damaged
Contacting surface of
Oil leakage from
connections is not tightened
3. speed reducer Replace sealing rings
enough, sealing rings at shaft
ends is worn and damaged
Jacking speed is too a.Worn oil pump, declined Repair or replace the
4
slow efficiency damaged parts
290
L250-20
b.Oil in the tank is insufficient or Fill adequate oil or clean

oil filter clogged oil filter
c.Hand-operated valve rod and
valve hole severely worn
d.Oil cylinder piston seal is
damaged and internal oil
leakage
a. Severe internal leakage from
oil pump Repair or replace the
Jacking force is not b. Overflow valve pressure set worn parts
5 adequate or unable too low Adjust pressure as
to jack c.Hand-operated valve core required
excessively worn Clean hydraulic valve
d. Overflow valve clogged down
Noise and vibration
occur during jacking
6 Oil filter clogged Clean oil filter
operation at
increasing pressure
Jacking system is Motor rotation and oil pump Change motor rotation
7
not working rotation both in wrong directions direction
a. Air not completely
Creeping and exhausted from oil cylinder
Exhaust air as required.
8 quivering during piston
Adjust guide pulleys
jacking operation b. Trouble with guid
emechanism
a. Trouble with balance valve of
Jacking drop when the cylinder head Remove trouble, replaces
9
loaded b. 坏 Piston sealing of oil sealing parts
cylinder is damaged
1. Operation handle not
1. Return handle to
returned to zero
zero.
Malfunction of 2. Fuse in the electric control
10 2. Replace fuse
Master push-button cabinet is burned down
3. Repair or replace the
3. Poor contact of the
button
start-button and stop-button
1. Over current from hoisting 1. Check hoisting
motor, actuating over-current brakes for open-up.
Power is stopped breaker. Check over-current
11 during hoisting 2. Capacity of the site stabilization value for
operation transformer is inadequate, or variation
power cable from 2. Replace transformer
transformer to tower crane or increase cable
has inadequate diameter diameter
Hoisting mechanism Control wiring in a wrong way 1. Check wiring
12
unable to start Fuse burned-down. diagram.
291
L250-20
Electric motor windings 2. Check fuse capacity,

short-circuited, grounded or change for larger one
circuit breaking if too small
1. Motor working voltage is too 3. Measure power grid
low voltage
2. Windings wiring in a wrong 4. Supply power to suit
way different speeds so as
3. Electromagnetic brake not to find out short
released circuit and circuit
4. Too heavy load or trouble breaking. Repair the
with the transmission findings
mechanism 5. Check brake voltage
and windings for
circuit breaking or
clogging
Trolleying
(1) Replace bearings
mechanism 1. Bearings burned down
13 (2) Add grease as
Bearings 2. Grease too much or too few
required
over-heated
1. Find out the cause,
1. Power line or earth line and remove the
Electrification with wired in a wrong way trouble.
14 the trolleying 2. Poor earth connection 2. Improve earth
mechanism 3. Motor wires scratched and connection
earthed 3. Find the cause, and
remove the trouble
Brake failure with 1. Brake spring broken,
1. Braking moment too small
15 the trolleying replace the spring
2. Increased friction clearance
mechanism 2.Excitation and
of friction pieces.
inadequate voltage
Slewing mechanism See if foreign matters are
16 Remove foreign matters
unable to start clogged in the gear..
1. Load excessive 1. Measure stator
2. Load continuing and work current, e.g. decrease
not as specified load if heavier than
2-phase operation rated value.
3. Power supply voltage too 2. Operate as required.
Trolleying
low or too high 3. Measure 3-phase
mechanism
17 5. Motor windings earthed or current to remove
motor over-heated
short circuited between turns, or troubles.
or smoke emission
between phases 4. Check input voltage
6. Incorrect clearance between for necessary
friction pieces correction
7. Braking time and releasing 5. Find out the cause to
time not correct repair
292
L250-20
8. Moter clogged, causing 6. Adjust clearance as

temperature rise. required
7.Check brake for
voltage and time-delay
for circuit breaker
action and remove the
trouble.
8.Keepsmoothventilation
293
L250-20
9.3 Assebmlly
Parts Lubricating Lubricating method

No Lubricating varity
Description location & duration
Grease the rope each
Graphite
Hoisting rope after overhaul or
1 Wire rope Calcium-based grease
Trolley rope medium
ZG-SSY1405-65 maintenance
Lubricate the reducer
Summer:
Gearbox of after it serves for 240
with N220 gear oil
hoisting hrs ， Change the oil
Winter: with N150
winch after working for
gear oil
1500hrs
Sulphur
Reducer Reducer of
2 molybdenum-2# or Replaceing lubricate
trolleying
ZL-2# lithium-based fat in repair
mechanism
grease
In repair and the oil
Gearbox of
fall,in time
slewing 000 reducer grease
makeup.assure the
mechanism
grease up to snail.
Rolling bearings Grease the bearings
in the reducer each after they work
Rolling ZL-3 lithium-based
3 Drum bearing for 160 hrs ， Clean
Bearing grease
them once after half a
Hook bearings year.
。 Change the grease
4 Motor bearing All the motors lithium-based grease after working for 1500
hrs.
Pulleys and
guiding pulley in
Change the grease
the hoisting winc Winter：ZG-2
5 Pulley Block after working for 240
A Frame Summer：ZG-5
hr
Hoisting hook
Sliding bearings
in the trolley Add grease after
Winter：ZG-2
Sliding traveling working for 160 hrs,
6
Bearings mechanism and Summer：ZG-2 and conduct cleaning
drum half a year
7 Articulated All the

Fill oil after working
points of brake articulated Machine oil
for 56 hrs
lever points
Two articulated All the Winter：ZG-2
Before dismantle or
8 points between articulated
installation
arm and tower points Summer：ZG-2
294
L250-20
section
thearticulated
points of
All Wnter：ZG-2 Before dismantle or
9 luffing
thearticulated Summer：ZG-5 installation
suspension and
points
jib
Hoist machine
Wnter：ZG-2 Before dismantle or
10 of Climibing sports part
Summer：ZG-5 installation
frame
All the
connectors of Grease once after a
11 Gear connector Calcium-based grease
mechanisms and season
gears
Add filtered grease

Pump station after working for
AW46
12 of hydraulic Oil tank 200hrs
American ESSO AW46
erection and change the
greaseafter working
for 2400 hrs.
Add grease after
working for 160 hrs,
13 A Frame Calcium-based grease
and conduct cleaning
half a year
ZL-2 lithium-based Fill oil after working
14 slewing ring
grease for 50 hrs
Add grease after
Device Of
working for 160 hrs,
15 Prevent wire thrust bearing lithium-based grease
and conduct cleaning
rope to wring
half a year
295
L250-20
9.4 Buffer’s Maintenance and Service
9.4.1 Buffer’s structure
Fig.9.4.1-1 Buffer’s
1- Telescopical par 2- Nut 3 Washer 4 Washer 5 Guiding bush 6 Spring 7 Bolt 8 Spring bush
9.4.2 Buffer’s Maintenance and Service

1.Please add grease to guide collar to make sure that the telescopic rod can stretch out and draw
back freely before assembling buffer. Please check that the telescopic rod head can contact the
buffer base on jib
2.Check the lubrication condition of guide collar, add grease every month and check that the
telescopic rod can stretch out and draw back freely.
296
L250-20
10 Wire rope
10.1 steel rope basic knowledge
(1) Structure of wire rope, wire rope is consist of several wire-steels.shown as fig 10-1.
(2) Direction of wire rope twist（fig 10-2）
fig 10-1.Structure of wire rope, fig10-2

(3) Measure the diameter of the wire rope
When measure the diameter of the wire rope, please note the correct methods(Fig.10-3).
(4) Unwinding the wire rope from the reel
When winding off, wire rope should be placed on a special bracket and can drill through the
wire rope using a steel tube, suspend it with both side wearing rope cover, let the wire rope rotate
slowly(Fig. 10-4).
297
L250-20
Measure the diameter of the wire rope Fig.10-3
Fig.10-4 Unwinding the wire rope from the reel

(5) wire rope clamp
① Arranging the rope clamp
The bulldog grip must be fitted in such a way that the stirrup rests on the dead ropeline
and its base plate on the working rope line, see Fig 10-5
298
L250-20
Fig 10-5 Fitting a bullog grip

②number of bulldog grips
The minimum number of bulldog grips recommended for every connecting section is as
indicated in the following table
number of bulldog grips
Nominal dimension ））Nominal dimension of The minimum
The minimum number of the
of rope clamp (mm) rope clamp (mm)
number of the
rope clamp(suit)
(nominal diameter d) rope clamp(suit) (nominal diameter d)
≤19 3 >38~44 6
>19~32 4 >44~60 7
>32~38 5
③ Bulldog grips interval
As shown in fig10-6, the distance A between two bulldog grips is about 6～7 times the length of
rope diameter.
299
L250-20
fig10-6 Bulldog grips interval

④ The fastening of bulldog grip
The load applied on the each bulldog grip shall be taken into account; the bulldog grip
farthest from the rope ring cannot be firstly fastened and fixed. The bulldog grip 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 externa wires.
(6) diameter of the wire rope and groove relation
The wire rope and groove Fitting relation fig10-7a. Large groove(fig10-7b) add core of wire
rope fatigue to break. Small groove(fig10-7c) add core of wire rope to severity wear and tear.
Groove radius R and diameter of the wire rope ratio 0.525-0.559.
（a）correct （b） error （c） error

fig10-7a wire rope and groove relation
300
L250-20
10.2 Wire rope list
table 10-2 Wire rope list

Designation Specification Diameter（mm） Quntity Note
Hoist rope DIEPA B55-24-1960 24 1
Trolley rope 6×29Fi+1WR-20-1770 20 1
10.2.1 Hoist rope length
Fig 10-8 total length required for hoist rope
301
L250-20
L＝L0+ f×7+f×H
其中 L0——Hoist rope length required for hook lift height 0 in m table10-3
f——Falls used
H——Hook height in m. 7m From hook to end of arm at 7 meter
Arm length(m) 60 55 45 40 35 30
For example: hoist rope require for crane with 60m arm lenght and 80m hook height at 4falls
operation
L＝95+4×7+4×80＝443m
10.2.2 The trolley rope length
No equivalent arm length to L250-20 crane. Length of trolley rope is fixedness at 190 m
10.3 Installing the wire ropeadhere
When unwiding rope from the reel we need some operations to prevent the wire rope Being
loop、kinks or tightened loops、bend or adhere to. Before use the wire rope, the user make sure
device be fixed and operated.
New wire rope style and spec the same as old one. If the wire rope be sliced in long one that all
end should be deal with. To prevent wire rope loose.
10.4 Discard criteria of wire rope
(1) Property and quantity of broken wires

Tables 10-5.and（2）～（19）items are considered in the same.It is the same with all wire.
(2) Broken wires at rope end
Broken wires at, or adjacent to, the rope end, even if few in number, 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 rope end shall beremade, 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 shownin Tables10-5.
302
L250-20
(4) Rate of increase of broken wires

In applications where the predominant cause of rope deterioration is fatigue, broken wires will
appear after a certain period of use, and the number of breaks will progressively increase over time.
In these cases, it is recommended that careful periodic examination and recording of the number of
broken wires be undertaken, with a view to establishing the rate of increase inthe number of breaks.
This premise may be used to propose a future date for rope discard.
In crane discard and of wire rope and fatigue relate to visible broken wires
Number of
mechanisms classification M1, M2, mechanisms classification M5, M6, M7 or M8
load
M3 or M4
bearingwires
each other twist the same twist 交互捻同向捻
in all
outerstrands length range length range
of the rope
6d 30d 6d 30d 6d 30d 6d 30d
n≤50 2 4 1 2 4 8 2 4
51≤n≤75 3 6 2 3 6 12 3 6
76≤n≤100 4 8 2 4 8 16 4 8
101≤n≤120 5 10 2 5 10 19 5 10
121≤n≤140 6 11 3 6 11 22 6 11
141≤n≤160 6 13 3 6 13 26 6 13
161≤n≤180 7 14 4 7 14 29 7 14
181≤n≤200 8 16 4 8 16 32 8 16
201≤n≤220 9 18 4 9 18 38 9 18
221≤n≤240 10 19 5 10 19 38 10 19
241≤n≤260 10 21 5 10 21 42 10 21
261≤n≤280 11 22 6 11 22 45 11 22
281≤n≤300 12 24 6 12 24 48 12 24
n>300 0.04n 0.08n 0.02n 0.04n 0.08n 0.16n 0.04n 0.08n
注：
(1) filler wires are not regarded as load-bearingwires and are not included in the value of n. In ropes
having a number of layers of strands, only the visible outer layer is considered in the value of n. In
ropes having a steel core, this is regarded as an internal strand and is not considered in the value of
n
(2) d is nominal rope diameter, unit :mm
(5) Fracture of strands

If a complete strand fracture occurs, the rope shall be immediately discarded
303
L250-20
(6) Reduction of rope diameter resulting from core deterioration

If the steel core ( in a number of layers of strands)be breaken cause rope diameter to decrease ,
wire rope must discard. Jerkwater be breaken , Especially stress of each strand is balance the usual
check no distinct.in the case of intensity of rope greatly debase.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 wear
External wear of rope due to press make rope and rope groove of block or roll to
rub. In such case crane load is speed-up and speed-down and rope and block contact very
evidence. The External rope wear to plane.
Wear make the rope section area decrease and that intension be decrease. 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 fall
Under certain circumstances usually associated with the working environment, a rope can
sustain a substantial decrease in elasticity and is thus unsafe for further use The person of check
find some question to rope That must consult expert of rope.
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. Wire slackness due to corrosion
attack/steel loss is justification for immediate rope discard
If there is any indication of internal corrosion, the rope should be subjected tointernal examination
as indicated. This shall be carried out by a competent person.Confirmation of severe internal
corrosion is justification for immediate rope discard.
(10) Waviness
In the case of waviness fig 10-9, the wire rope shall be discarded , under length of the rope less than
25d ,if d1>4d/3 that rope will be discarded.
load condition on a straight portion of rope
d is the nominal diameter of the rope
d1 is the diameter corresponding to the envelope of the deformed rope.
304
L250-20
Fig10-9 Waviness
(11) Basket or lantern deformation
Ropes with a basket or lantern deformation shall be immediately discarded, shown as Fig 10-10.
Fig 10-10 Basket or lantern deformation

(12) Core or strand protrusion/distortion
Rope with core or strand protrusion/distortion shall be immediately discarded,shown as Fig10-11.
Fig10-11 Core or strand protrusion/distortion

(13) Wire protrusion
Rope with wire protrusion shall be immediately discarded, shown as Fig10-12
Fig10-12 Wire protrusion

(14) Local increase in diameter of rope
Local increase in diameter of rope will affect quite long rope .the diameter of rope is increaseed
cause of rope core aberrance (under special environment, fibre core will be affected with damp) that
bring on no balance to External rope ,It will bring about location falseness .If this condition causes
the Local increase in diameter of rope the rope shall be immediately discarded, shown as Fig10-13 .
305
L250-20
Fig 10-13 Local increase in diameter of rope

(15) Kinks or tightened loops
Kinks or tightened loops is a distortion that rope be ring cause no move around the axes and
strain. In such case rope be fraied result from twist distance.So rope will be twist very severity that
a portion of rope small intensity be remained.
wire ropeKinks or tightened loops

(16) Local decrease in diameter of rope
Local decrease in diameter of rope relative to rupture of rope. Especially Check if
end of rope to distortion .In such cases the rope shall be discarded immediately shown as
Fig 10-14.
Fig 10-14 Local decrease in diameter of rope

(17) Flattened portions
Flattened portions of rope which pass through a sheave will quickly deteriorate, exhibiting
broken wires and may damage the sheave. In such cases the rope shall be discarded
immediately,.
fig10-15 the part rope be staved
(18) Bends
306
L250-20
Rope with a severe bend will suffer similarly to flattened portions of rope and should
be immediately discarded, shown as fig10-16
fig10-16 rope bend

(19) Mangle because of thermal effects or electric arc
Ropes that have been subjected to exceptional thermal effects, externally ecognized by the colors
produced in the rope, shall be immediately discarded.
10.5 Maintenance of wire rope
After the rope be used that lack of dressing of grease cause dust and chipping on surface ,
result from abrasion rope and block . In such case must often clean and dressing of grease. Before
put lube of calefaction and engine oil daub on surface rope, make a simple mean that steel wire
brush to clean filth on surface of rope.
it is recommended that careful periodic examination and recording of rope in the work.except
the cleanout and dressing of lube.Check abrasion, breake wire,rust of rope and abrasion of
hook,blockg roove。In case be found the question that shall be immediately discarded.
307

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TOWER CRANE

Zoomlion Heavy Industry Science &Technology Co.,Ltd

Add:ON.667,Lugu Road ,ChangSha ,HuNan,P.R.CHINA 410205

keep at hand for consultation.

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

in this publication, which involves safety of constrution.

Ignore the instrutions could result in accidents and injuries!

directives (such as prevention of emergencies, etc.)

don't hesitate to contact Zoomlion for further consultation.

5.5.3 Install Climbing Frame ......................................................................................................68

5.7.16 Dismantle slewing support assembly.............................................................................140

9.1.1 Daily maintenance ...........................................................................................................213

WARNING: Live parts!

Danger of falling down!

Very hot, do not touch! Danger of crushing!

Insert pins while climbing the crane! Keep watch

WARNING: Suspended loads! Check ropes

Adjust the height limiter!

Check metal structures! Check brakes!

Keep safety devices workable!

Maximum load on maintenance cage

Tie safety belt

2.2 The Parked Position of Jib on Non-service Conditions

Fig. 2.2-1 L250-20 the parked position of jib on non-service conditions

number name specification quantity material

1 windshield t2-2400×1500 1 Q235B

2 U bolt M12 6 Q235B

3 backer plate T5 6 Q235B

Fig, 2.2-3 working drawing of U bolts and backer plate

2.3 Radius and Load Capacity

60m Jib’s Radius and Load Capacity

55m Jib’s Radius and Load Capacity

50m Jib’s Radius and Load Capacity

45m Jib’s Radius and Load Capacity

35m Jib’s Radius and Load Capacity

30m Jib’s Radius and Load Capacity

2.4 Technical Performance Parameters for The Whole Machine

Max hoisting moment （kN.m） 3200

Luffing Max luffing 2.2

Speed （r/min） 0～0.7

Counter Max radius （m） 60 55 50 45 40 35 30

Design wind speed at the top of 安装状态 Erection condition 14

Out of service condition EN14439 C25

2.5 Technical Parameters of The Mechanisms

Model Unit QPL20100A

Max traction of the rope N 108000

Maximum Drum speed r/min 29.3

Maximum traction of the rope N 100000

Rpm rating r/min 20.7

Drum Speed Twist Layers Layer 3

Rope capacity m 190

Speed r/min 735

Ratio of Reduction Gears 35.461

Braking moment N. m 1250

Motor Power N·m 145

Speed r/min 10-1250

Model Unit HVV145B2.130A×1

Motor Power N·m 145

Speed r/min 10-1250

Overall Gear Ratio 2356.25

Slewing Speed r/min 0.53

Flow l/min 14.5

Cylinder /rod diameter mm 200/140

Jib tie bar Φ45×5000 －－－ 0.11 7

Jib tie bar Φ45×2500 －－－ 0.061 1