Zoomlion Tower Crane Instrcution Manual-WA7025-12E-220309

[En]
WA7025-12E Tower Crane

Instruction Manual
WA7025-12E-138EN-A04
Manufacturer:
Zoomlion Heavy Industry Science & Technology Co., LTD
No.658, Zoomlion Lugu Industrial Park
CN-410205 Changsha, Hunan
P.R. China
Contact us:
Home page: en.zoomlion.com
Email：tc_customercare@zoomlion.com
2
WA7025-12E INTRODUCTION
INTRODUCTION
This document has been issued for the crane as defined at the time of ordering. Please read
carefully the instructions therein before any crane operation.
Make sure that one complete copy of this document is always present at the location provided
for on the crane, especially in case of crane rental or resale.
The safety signals, rating plates and instruction plates as well as this document are integrated
part of the crane. In case of loss or damage of this instruction material you have order a new
one from the manufacturer indicating the serial number and the crane type.
IMPORTANT: In case of a technical crane modification, please make sure that this instruction
material will be updated.
The present document is only usable in complete original version or in complete reproduction.
ZOOMLION denies all responsibility concerning the consequences of using a partial
reproduction or an adaptation of the present document.
This document consists of 7 parts. The “safety instructions” part must compulsorily be read and
under-stood by every operator. The other parts give specific instructions to the concerned
operators for doing their tasks.
Part name Part intended for:
1 DOCUMENTS The crane operator
2 SAFETY INSTRUCTION Everybody
3 TECHNICAL DATA OF CRANE AND SITE Everybody
4 ERECTION/ADJUSTMENT/DISMANTLING The fitter
5 OPERATION AND CONTROL The crane driver
6 MAINTENANCE AND INSPECTION The maintenance technician
7 SPARE PARTS Everybody
3
INTRODUCTION WA7025-12E
Development of the technical instructions
ZOOMLION reserves the right, without prior notice, to improve the content and the form of
this document. For each technical modification ordered or carried out after delivery, an
updating will be supplied. On receipt of these new chapters, please insert them at the
indicated space.
Warnings
The safety rules and the important observations which you must compulsorily observe are
marked in the various parts of this documents by the following symbols:
Signaling of an important risk of body injuries and even mortal danger, if

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

not observed.
Important information
Note
4
WA7025-12E TOWER CRANE VOCABULARYS
TOWER CRANE VOCABULARYS
Composition Diagram of the Tower Crane
5
GRAPHIC SYMBOLS WA7025-12E
GRAPHIC SYMBOLS
SYMBOLS SUBJECT
FORBIDDEN
STOPPING THE MOVEMENT
COMPULSORY SAFETY HARNESS
AUTHORIZED
PARALLEL
LEVEL
LISTEN
WEATHERVANING
6
WA7025-12E GRAPHIC SYMBOLS
SYMBOLS SUBJECT
SLEWING
SLEWING TOLEFT
SLEWING TO RIGHT
HOISTING
HOISTING
LOWERING
TROLLEYING
TROLLEY OUT
TROLLEY IN
7
GRAPHIC SYMBOLS WA7025-12E
SYMBOLS SUBJECT
TRAVELLING FORWARD
TRAVELLING BACKWARD
CREEP SPEED
LOW SOEED
HIGH SPEED
SM (2-fall rope reeving, used in 2-fall)
DM (4-fall rope reeving, used in 4-fall)
TIGHTEN-LOCK-PRESS
LOOSEN-UNLOCK
8
WA7025-12E METRIC SYSTEM AND IMPERIAL SYSTEM
METRIC SYSTEM AND IMPERIAL SYSTEM
1. CORRESPONDENCES
1. 1. GEOMETRIC UNITS
Metric system Imperial system
Values
Unit Symbol Unit Symbol
Lengths − distances
inch in 1 m = 39,3700787 in
foot ft 1 m = 3,2808399 ft
meter m
yard yd 1 m = 1,0936133 yd
mile mi 1 m = 0,0006214 mi
Area or surface
cubic inch in2 1 m2 = 1 550,0031 in2
square meter m2 cubic foot ft2 1 m2 = 10,7639104 ft2
cubic yard yd2 1 m2 = 1,195990 yd2
Volume
cubic inch cu in / in3 1 m3 = 61 023,7438368 in3
cubic meter m3 cubic foot cu ft / ft3 1 m3 = 35,3146666 ft3
cubic yard cu yd / yd3 1 m3 = 1,3079506 yd3
Flat angle
radian 1 tr = 2 P rad
revolution r
degree 1 tr = 360 °
radian 1 ° = 0,0174533 rad
degree ° minute 1 ° = 60’
second 1 ° = 3600”
9
METRIC SYSTEM AND IMPERIAL SYSTEM WA7025-12E
1. 2. MECHANICAL UNITS
Values
Flow rate
mile per hour mph 1 m/s = 2,2369 mph
meter per second m/s foot per second ft/s 1 m/s = 3,28084 ft/s
inch per second in/s 1 m/s = 39,3701 in/s
Radian frequency
radian per second rad/s radian per second rad/s 1 rad/s = 1 rad/s
revolution per
r.p.m. revolution per minute rpm 1 tr/min = 1 rpm
minute
Acceleration
meter per square 1 m/s2 = 3,2808399
m/s2 foot per square second ft/s2
second ft/s2
Force
kilogram force kgf 1 daN = 1,0197162 kgf
newton N
pound force lbf 1 daN = 2,248 lbf
Moment of force
1 N.m = 0,7375621
newton meter N. m force pound foot lb−ft
lb−ft
Energy, work, quantity of heat
joule J Watt−second Ws 1 J = 1 Ws
Power
Joule per second J/s 1 W = 1 J/s
kg−force meter per kgf, 1 W = 6,1182973
watt W
minute m/min kgf.m/min
horsepower (metric) hp 1 W = 0,00135962 hp
Pressure, stress
1 Pa = 0,000145038
pound per square inch psi
psi
bar bar 1 Pa = 0,00001 bar
pascal Pa kg−force per square 1 Pa = 0,1019716
kgf/m2
meter kgf/m2
Newton per square
N/cm2 1 Pa = 0,0001 N/cm2
centimeter
10
1. 3. MASS UNITS
Values
Mass
pound lb 1 kg = 2,2046226 lb
kilogram kg
ton (short) ton 1 kg = 0,0011023 ton
Mass per unit length
pound per inch lb/in 1 kg/m = 0,055997 lb/in
kilogram per meter kg/m pound per foot lb/ft 1 kg/m = 0,6719689 lb/ft
pound per yard lb/yd 1 kg/m = 2,015905 lb/yd
Surface mass
pound per square 1 kg/m2 = 0,2048161
lb/ft2
foot lb/ft2
kilogram per pound per square 1 kg/m2 = 0,0014223
square kg/m3 lb/in2
meter inch lb/in2
pound per square 1 kg/m2 = 1,8433451
lb/in2
yard lb/yd2
Density
pound lb 1 kg = 2,2046226 lb
kilogram kg
ton (short) ton 1 kg = 0,0011023 ton
Mass per unit length
kilogram per meter kg/m pound per inch lb/in 1 kg/m = 0,055997 lb/in
11
METRIC SYSTEM AND IMPERIAL SYSTEM WA7025-12E
1. 4. UNITS OF TIME
Values
Time (duration)
second s second s
minute min minute min 1 min = 60 s
hour h hour h 1 h = 60 min = 3600 s
day j day d 1 d = 24 h = 1440 min
Frequency
hertz Hz Hertz Hz 1 Hz = 1 s−1
1. 5. EECTRIC UNITS
Values
Strength
ampere A Ampere Symbol
Voltage
volt V Volt V
Power
volt−ampere VA Volt−Ampere VA
kilovolt−ampere kVA Kilovolt−Ampere kVA
watt W Watt W
Electric resistance
ohm Ω Ohm Ω
Quantity of electricity, load
Coulomb C
coulomb C
Ampere.hour Ah 1 Ah = 3600 C
Capacity
farad F Farad F
12
1. 6. THERMAL UNITS
Values
Temperature
Kelvin K °K = (°F + 459,7)/1,8
kelvin K Celsius C °C = 5/9 * (°F − 32)
Fahrenheit F °F = (9/5 * °C) + 32
1. 7. ACOUSTIC UNITS
Values
Sound pressure and acoustic power
decibel dB(A) Decibel dB(A)
2. EQUALITY BETWEEN FREQUENTLY USED UNITS

2. 1. LENGTHS − DISTANCES
1 centimeter (cm) = 10 millimeters (mm) = 0,3937008 inch (in)
1 decimeter (dm) = 10 centimeters (cm) = 3,937008 inches (in)
1 meter (m) = 10 dm = 100 cm = 1,0936133 yards (yd)
1 kilometer (km) = 1 000 meters (m) = 0,6213712 mile (mi)
Imperial system Metric system
1 inch (in) = 2,54 cm
1 foot (ft) = 12 inches (in) = 30,48 cm
1 yard (yd) = 3 feet (ft) = 36 inches (in) = 0,9144 m
1 mile (mi) = 1 760 yards (yd) = 1,609344 km
13
CONTENTS WA7025-12E
CONTENTS
INTRODUCTION ................................................................................................................ 3
TOWER CRANE VOCABULARYS .................................................................................... 5
GRAPHIC SYMBOLS ......................................................................................................... 6
METRIC SYSTEM AND IMPERIAL SYSTEM .................................................................... 9
CONTENTS ...................................................................................................................... 14
1 DOCUMENTS....................................................................................................................... 20
1.1 Sound pressure .......................................................................................................... 20
1.2 Commissioning report ................................................................................................ 21
2 SAFETY INSTRUCTION ...................................................................................................... 22
2.1 Foreword .................................................................................................................... 22
2.2 Safety instructions ...................................................................................................... 23
2.2.1 General conditions of use ................................................................................ 23
2.2.2 General safety instructions .............................................................................. 31
2.2.3 Safety signaling ................................................................................................ 36
2.2.4 Safety controls ................................................................................................. 39
2.3 Storm wind speed-out of service ................................................................................ 40
2.3.1 General Notes .................................................................................................. 40
2.3.2 Speed table ...................................................................................................... 40
3 TECHNICAL DATA OF CRANE AND SITE .......................................................................... 41
3.1 Foreword .................................................................................................................... 41
3.2 Technical characteristics ............................................................................................ 41
3.2.1 Load curves ...................................................................................................... 42
3.2.2 Characteristics of the mechanisms .................................................................. 47
3.3 Dimensions and weight .............................................................................................. 49
3.3.1 Slewing crane part ........................................................................................... 49
3.3.2 Mast.................................................................................................................. 57
3.3.3 Crane base ....................................................................................................... 60
3.4 Mast composition ....................................................................................................... 62
3.4.1 General notes................................................................................................... 62
3.4.2 Mast composition ............................................................................................. 63
3.4.3 Loads on foundation of crane .......................................................................... 65
3.4.4 Corner pressure for the chassis crane with climbing equipment ..................... 83
3.5 Auxiliary lifting equipment ......................................................................................... 101
3.5.1 General notes................................................................................................. 101
3.5.2 Hook height .................................................................................................... 101
3.6 Identification ............................................................................................................. 103
3.6.1 General notes................................................................................................. 103
14
WA7025-12E CONTENTS
3.6.2 Identification the counter-jib ........................................................................... 103

3.6.3 Identification of the jib sections ...................................................................... 104
3.6.4 Jib composition .............................................................................................. 106
3.7 Data sheet ................................................................................................................ 107
3.7.1 Hoist rope ....................................................................................................... 107
3.7.2 Trolley rope .................................................................................................... 108
3.7.3 Data sheet of hook ......................................................................................... 109
3.8 Counter-jib ballast .....................................................................................................110
3.8.1 General notes.................................................................................................. 110
3.8.2 Configuration ................................................................................................... 110
3.8.3 Fabrication ...................................................................................................... 110
3.9 Central ballast ..........................................................................................................118
3.9.1 Configuration................................................................................................. 118
3.9.2 Making ............................................................................................................ 119
3.10 Foundation.............................................................................................................. 129
3.10.1 Embedded Outrigger .................................................................................... 129
3.10.2 Foundation for chassis ................................................................................. 134
3.10.3 Foundation for the travelling crane .............................................................. 134
3.11 Power supply .......................................................................................................... 139
3.11.1 Definition....................................................................................................... 139
3.11.2 Current supply .............................................................................................. 140
4 ERECTION/ADJUSTMENT/DISMANTLING ...................................................................... 144
4.1 Foreword .................................................................................................................. 144
4.2 Note on safety regarding erection ............................................................................ 145
4.2.1 Erection instructions ....................................................................................... 145
4.2.2 Fitting the split pins ........................................................................................ 146
4.2.3 Fitting the high-strength bolt .......................................................................... 147
4.2.4 The diagram of erection ................................................................................. 148
4.3 Installing the tower section and climbing frame assembly ....................................... 150
4.3.1 Tower section ................................................................................................. 150
4.3.2 Climbing system ............................................................................................. 155
4.3.3 Installing ......................................................................................................... 157
4.4 Installing the slewing assembly ................................................................................ 160
4.4.1 Description ..................................................................................................... 160
4.4.2 Installing slewing assembly ............................................................................ 162
4.5 Mounting the counter-jib ........................................................................................... 162
4.5.1 Description ..................................................................................................... 162
4.5.2 Assemble the front-counter jib ....................................................................... 163
4.5.3 Assemble the counter-jib ................................................................................ 163
4.5.4 Assemble the rear-counter jib ........................................................................ 164
15
CONTENTS WA7025-12E
4.5.5 Sling the rear-counter jib ................................................................................ 164

4.5.6 Installing the one 3.0 t counter weight ........................................................... 165
4.6 Installing the jib assembly ........................................................................................ 166
4.6.1 Assemble jib ................................................................................................... 166
4.6.2 Installing jib .................................................................................................... 168
4.7 Installing the counter-ballast..................................................................................... 170
4.8 Installing the electrical control system ...................................................................... 171
4.9 Circling the hoist rope............................................................................................... 172
4.9.1 Power connection and test run ...................................................................... 173
4.10 Fall-changing system ............................................................................................. 174
4.11 Climbing operation .................................................................................................. 175
4.11.1 Pre-jacking preparation ................................................................................ 175
4.11.2 General Notices of Climbing Operation........................................................ 175
4.11.3 Keep the tower crane in balance before climbing ........................................ 176
4.11.4 Climbing operation ....................................................................................... 177
4.11.5 Rung ladder (old style) and Inclined ladder add tower section .................... 179
4.12 Chassis stationary tower crane .............................................................................. 180
4.12.1 Installing the crossed-beamed of chassis stationary ................................... 180
4.12.2 Installing the base tower section and incline tie rod .................................... 182
4.13 Travelling tower crane ............................................................................................ 184
4.13.1 Erection of travelling mechanism ................................................................. 184
4.13.2 Erection of travelling chassis ....................................................................... 184
4.13.3 Erection of cable drum bracket and cable drum .......................................... 184
4.13.4 The remaining operations ............................................................................ 184
4.14 Safety devices ........................................................................................................ 185
4.14.1 Foreword ...................................................................................................... 185
4.14.2 Table adjustments of safety devices ............................................................ 186
4.14.3 Load moment limiter..................................................................................... 187
4.14.4 Load limit switch ........................................................................................... 192
4.14.5 Travel limiter ................................................................................................. 195
4.15 Tower crane tests ................................................................................................... 202
4.15.1 Function test without load ............................................................................ 202
4.15.2 Load tests ..................................................................................................... 202
4.16 Tower anchored onto the building .......................................................................... 206
4.16.1 Description ................................................................................................... 206
4.16.2 Layout of the anchored devices ................................................................... 209
4.16.3 Range of the anchored devices ................................................................... 212
4.16.4 Matters need attention ................................................................................. 213
4.16.5 Three Stay bar anchored device .................................................................. 214
4.16.6 Scheme of tower anchored onto building .................................................... 215
16
WA7025-12E CONTENTS
4.17 Dismantling ............................................................................................................. 218

4.17.1 General notes............................................................................................... 218
4.17.2 Preparations before dismantling .................................................................. 218
4.17.3 Dismantling sequences ................................................................................ 219
4.17.4 Dismantling .................................................................................................. 220
5 OPERATION AND CONTROL ............................................................................................ 222
5.1 Foreword .................................................................................................................. 222
5.2 Attention for operation .............................................................................................. 222
5.3 Specific safety instructions ....................................................................................... 223
5.4 Instruction of control unit .......................................................................................... 224
5.4.1 Console .......................................................................................................... 224
5.4.2 Driving box ..................................................................................................... 228
5.4.3 Main control cabinet ....................................................................................... 230
5.4.4 Electric resistance box ................................................................................... 232
5.4.5 Video monitoring system (optional) ................................................................ 232
5.5 Frequency converter self-learning ............................................................................ 233
5.6 Operation .................................................................................................................. 234
5.7 Putting into service ................................................................................................... 235
5.7.1 Checks to be carried out before operation ..................................................... 235
5.7.2 Checks to be carried out after erection .......................................................... 238
5.7.3 Operating instructions .................................................................................... 238
6 MAINTENANCE AND INSPECTION .................................................................................. 245
6.1 Lubrication ................................................................................................................ 245
6.1.1 Lubricants table .............................................................................................. 246
6.1.2 Lubrication for bearing ................................................................................... 247
6.2 Safety notes.............................................................................................................. 247
6.2.1 Requirement on personnel ............................................................................. 247
6.2.2 Safety measures ............................................................................................ 247
6.2.3 Protective equipment for personnel ............................................................... 248
6.3 Required maintenance and inspections ................................................................... 248
6.4 Hoisting mechanism ................................................................................................. 251
6.4.1 Overview ........................................................................................................ 251
6.4.2 Adjustment and maintenance of the brake..................................................... 251
6.4.3 Maintenance of the motor .............................................................................. 260
6.4.4 Maintenance of the reducer ........................................................................... 261
6.4.5 Coupling ......................................................................................................... 263
6.5 Method of Rope Arrangement Problem of Hoisting Mechanism .............................. 264
6.6 Trolley mechanism ................................................................................................... 266
6.6.1 Overview ........................................................................................................ 266
6.6.2 Limiter of trolley mechanism .......................................................................... 267
17
CONTENTS WA7025-12E
6.6.3 Trolley brake ................................................................................................... 268

6.6.4 Maintenance for motor ................................................................................... 272
6.6.5 Oil adding of the reducer ................................................................................ 273
6.7 Slewing mechanism ................................................................................................. 273
6.7.1 Overview ........................................................................................................ 273
6.7.2 Slewing brake................................................................................................. 273
6.7.3 Maintenance for slewing ring ......................................................................... 281
6.8 Maintenance climbing mechanism ........................................................................... 282
6.8.1 Working principle ............................................................................................ 282
6.8.2 Erection, operation, and maintenance of the hydraulic pressure system ...... 284
6.9 Rope ......................................................................................................................... 287
6.9.1 Basic Knowledge of Rope .............................................................................. 287
6.9.2 Rope List ........................................................................................................ 293
6.9.3 The length of the rope .................................................................................... 294
6.9.4 Installation of the Rope .................................................................................. 296
6.9.5 Discard Criteria of Rope ................................................................................. 297
6.9.6 Maintenance of Rope ..................................................................................... 302
6.10 Maintenance of pulley assembly ............................................................................ 303
6.10.1 Examination of pulley assembly ................................................................... 303
6.10.2 Pulley scrap.................................................................................................. 303
6.11 The high strength bolts ........................................................................................... 305
6.11.1 Basic knowledge of the high strength bolt.................................................... 305
6.11.2 Checking the bolts and bolt connection sets ................................................ 305
6.11.3 Lubricating the high strength bolt assembly ................................................. 305
6.11.4 Recycling the high strength bolt ................................................................... 306
6.12 Steel structure ........................................................................................................ 307
6.12.1 Foreword ...................................................................................................... 307
6.12.2 Description ................................................................................................... 307
6.12.3 Description ................................................................................................... 308
6.12.4 Maintenance................................................................................................. 308
6.13 Pins and holes of the tower section ....................................................................... 312
6.14 Hook....................................................................................................................... 314
6.14.1 Check the locking of the hook .................................................................. 314
6.14.2 Opening Degree of the Hook .................................................................... 314
6.14.3 Wear............................................................................................................. 315
6.14.4 Corrosion .................................................................................................... 315
6.14.5 Check hook anti-tripping device .............................................................. 315
6.14.6 Oil hook bearing ......................................................................................... 315
6.15 Trolley ..................................................................................................................... 316
6.15.1 Routine inspection of trolley rollers .............................................................. 316
18
WA7025-12E CONTENTS
6.15.2 Routine inspection of side rollers of trolley .................................................. 316

6.16 Maintenance of electrical control system ............................................................... 317
6.16.1 Electrical equipment inspection ................................................................... 317
6.16.2 Maintenance for safety device ..................................................................... 320
6.17 Spare parts list ....................................................................................................... 321
6.17.1 Spare parts list of mechanism ...................................................................... 321
6.17.2 Spare parts list of electrical control system ................................................. 323
6.17.3 Spare parts list of structure .......................................................................... 324
6.18 Appendix troubles and troubleshooting .................................................................. 325
7 SPARE PARTS ................................................................................................................... 336
7.1 Foreword .................................................................................................................. 336
7.2 Examples of an “ASSEMBLY” parts list.................................................................... 337
7.2.1 Jib ................................................................................................................... 340
7.2.2 Counter Jib ..................................................................................................... 358
7.2.3 Derrick ............................................................................................................ 362
7.2.4 Turntable ........................................................................................................ 364
7.2.5 Slewing Support ............................................................................................. 366
7.2.6 Trolley ............................................................................................................. 367
7.2.7 Hook ............................................................................................................... 371
7.2.8 Climbing Equipment ....................................................................................... 376
7.2.9 Slewing Mechanism ....................................................................................... 382
7.2.10 Trolley Mechanism ....................................................................................... 386
7.2.11 Hoisting Mechanism ..................................................................................... 389
7.2.12 Transition Tower Section .............................................................................. 393
7.2.13 Erection Platform.......................................................................................... 395
7.2.14 Mounting Device .......................................................................................... 397
7.2.15 Mast (Rung ladder) ...................................................................................... 400
7.2.16 Mast (Incline ladder)..................................................................................... 412
7.2.17 Powered Wheel Bogie.................................................................................. 420
7.2.18 Idler Wheel Bogie ......................................................................................... 423
7.2.19 Cable Drum .................................................................................................. 425
7.2.20 Slewing Limiter ............................................................................................. 427
19
DOCUMENTS WA7025-12E
1 DOCUMENTS
1.1 Sound pressure
The sound pressure (LpA) is measured at the level of the crane driver’s ears by means of a
microphone under the most unfavorable conditions: noisy winch, short counter - jib.
Cranes with cabs:

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

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

Crane with winch in the
LpA (dBA) Crane with winch in the jib
counter - jib
Not soundproof cab V140C Sound pressure level = 79 Sound pressure level = 72
or V140S dB(A) dB(A)
Sound pressure level = 76 Sound pressure level = 70
Sound proof cab V140SX
dB(A) dB(A)
Sound pressure level lower
Control from the ground
than 70 dB(A)
20
WA7025-12E DOCUMENTS
1.2 Commissioning report
21
SAFETY INSTRUCTION WA7025-12E
2 SAFETY INSTRUCTION
2.1 Foreword
The Safety Instructions describe the measures to be observed in order to reduce the risk of
personal or material accidents when operating a crane. They are of utmost importance and
must be consulted, comprehended, and applied by all parties intervening on the crane. A
version translated into the language understood by the person consulting those instructions
shall be supplied by the crane manager, if necessary.
Safety instructions figuring in the present chapter and based on the current state of knowledge
at the time of their establishment are to be considered as simple guide−lines for the reader:
ZOOMLION cannot anticipate in an exhaustive manner all the dangerous situations that may
arise. Consequently, safety operation of the crane is a responsibility incumbent to yourselves.
Local regulations that are valid at moment of crane utilization may stipulate adherence to
instructions that are more stringent than the present instructions, in which case those local
regulations shall prevail.
The crane is a hoisting device destined for handling suspended loads on a protected operational
site. It shall consequently be used exclusively for that purpose (cf. general utilization conditions
chapter).
The crane has been designed in compliance with EC directives concerning safety, and to be
used by professionals that are physically apt and qualified for the operation, assembly, piloting,
and maintenance of this type of equipment (identified in the present manual as “competent
persons”).
These persons must know the technical data (part 3 of this document) so as not to exceed the
utilization limits described in this manual.
The illustrations of this part are general and do not correspond to your crane.
22
WA7025-12E SAFETY INSTRUCTION
2.2 Safety instructions

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

A. Wind
Out of service, the crane operating conditions, i.e.: free standing height, ballast, reaction, and
pressure under slab are determined by the storm reference wind speed measured at the crane
installation site.
The storm wind speeds are described in the chapter “Storm wind speed − out of service”.
a) Specific conditions
Some conditions or configurations require prior study on your part to determine the storm
reference wind speed to be accounted for at the crane installation site. Please contact us when
in possession of such data.
These conditions are:
◼ absence of map
◼ national or local regulations
◼ altitude higher than that indicated on your map if that is specified
◼ bottom of hollow, narrow valley, hill top
◼ isolated hill or mountain
◼ cliff top
crane installed on a building
◼ constructions: refer to the examples below
23
b) Table for determination of crane operating conditions
c) Assembly, dismantling, change of configuration

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

The surface exposed to the wind of the loads handled is considered as being less than or equal
to 1 𝑚2 /t. If this value exceeded, the “in service” wind speed must be limited to a value lower
than 72 km/h. The value to be taken into accounting is given in the table “Maximum admissible
wind speed for a load surface higher than 1 sq. m/t” (see part 3 “TECHNICAL DATA OF CRANE
AND SITE”).
For surface areas greater than those provided in the table, please consult us.
24
B. Ambient air temperature measured under cover
This corresponds to the temperature measured within a non−closed shelter,

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

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

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

covered with frost, ice, or snow.
E. Lightning
Lightning can generate current circulation in the crane framework and lead to a risk of
electrocuting any person in direct or indirect contact with the crane. E.g.: on part of the steel
structure, on a ladder, on ground when touching the crane or load.
Lightning may interfere with the operating of radio controls.
25
In the event of risk of storm, cease work and set crane to idle mode. Do
not access the crane during a storm.
In the case where the driver does not have time to leave the crane (sudden
storm), he should never attempt to leave the crane during the storm. The driver
runs less risk if he stays in the driving cab if he avoids touching any controls.
F. Sand storms
After a sand storm, sand may have penetrated internal electrical and mechanical elements and
plugged orifices.
Before restarting the crane, completely clean the electrical and

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

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

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

The crane has been designed to work with a power supply the values and tolerances of which
must be strictly adhered to (cf. power supply chapter in part 3 “TECHNICAL DATA OF CRANE
AND SITE”).
26
Non−adherence to the values indicated can lead to malfunctioning of the

crane.
C. Driver control stand

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

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

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

This is expressed in hoisting cycles (1 hoisting cycle = hoisting of a load, slewing and/or
trolleying of that load, lowering for laying down).
The classification group for single tower cranes is A3.
27
I. Nominal mechanism life duration

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

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

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

Without written agreement of the manufacturer, it is prohibited:
➢ to modify crane construction (E.g.: addition or renovation d of elements, blow−torch work,
welding, etc...),
➢ to adapt non−authorized accessories,
➢ to modify crane settings (E.g.: modification of pressures, tares, adjustment values, etc...),
➢ to perform welding operations on the crane.
Welding work under the load is prohibited if the load is not secured by
electrically insulated slings.
28
O. Adaptation of equipment / Replacement of parts

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

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

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

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

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

Adhere to the safety distances imposed by the regulations at the operating site concerning
hoisting devices with suspended loads, for track extremities.
In the absence of regulations, provide for a track length exceeding the end position planned for
29
the crane by 6m, in order to account for the stopping distance and the safety distances for
installation of end dampers.
E. Aircraft limiting lights

Use of the crane in areas close to airports or aerodromes, in the aircraft taking off or landing
cone, dictates the necessity of daytime and/or nighttime limiting light installations.
Apply the regulations prevailing at the operating site.
2.2.1.4 Handling conditions

A. Handling equipment
The crane is destined for load handling with use of its hook.
The use of any hoisting equipment generating dynamic effects such as, for example,
electromagnets, clutches, hammers, gathering buckets is prohibited.
B. Load handling
◼ Never hoist an incorrectly secured load.

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

The use of 2 cranes to hoist one and the same load is prohibited.
D. Hoisting of persons
The crane is not designed for hoisting persons. Such usage, which may be authorized by
national regulations concerning suspended−load hoisting devices, is the entire responsibility of
the user.
E. Ballasting derricks
Ballasting derricks are reserved for the handling of ballast blocks and accessories provided for
in the present manual. Any other utilization is prohibited.
F. Maintenance derricks
Their use is strictly reserved for loads lower than those indicated on the derrick.
30
2.2.2 General safety instructions

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

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

◼ Confide the execution of work on the crane to competent persons:
➢ having the minimum age required by the legislation of the country in which the crane is
used
➢ for which the medical aptitude has been attested to (view, hearing, reflexes, agility, aptitude
for work at heights, etc...)
➢ who, through their training by the manufacturer or the latter’s correspondent and their
experience, perfectly master the operations to be performed and have full knowledge of
the danger associated to those operations (e.g.: electric risks, hydraulic risks, etc)
Prohibit crane access to any person not satisfying the above criteria.
◼ Define the responsibilities of each participant in crane operation, for example:
➢ transfer driving control to the intervention manager (assembly, dismantling, testing,
maintenance, modification, etc...)
➢ designate the persons responsible for managing apprenticeship personnel
➢ designate a maneuver manager for any handling presenting specific characteristics.
◼ Ensure that the safety instructions are well known and assimilated by personnel intervening
on the crane and regularly verify application of the same.
◼ Impose on personnel intervening on the crane:
➢ appropriate appearance (e.g.: hair attached, appropriate clothing, etc...)
➢ the wearing of protective equipment: V safety helmet and footwear always V gloves for
manual interventions
➢ V safety harness for interventions above ground (≥ 3 m above ground)
➢ the use of protective devices according to the nature of work to be performed
➢ the specific recommendations of the present manual.
◼ Impose on the crane driver at shift end to carry out the putting out of service procedure of
the crane.
◼ For crane assembly−dismantling and maintenance operations, provide appropriate access
devices (ladders, catwalks, stairways, etc...) conforming to local regulations.
◼ Provide the persons responsible for maintenance with the tooling adapted to the values to
be measured or that tooling recommended by the manufacturer.
31
◼ Inform the crane driver of the risks specific to the site where the crane is operated and to
the work to be performed (e.g.: handling of large−dimension loads, prohibited overflying
zone, etc.)
◼ Radio−controlled crane driving may generate specific risks in the case of incorrect utilization.
Define the rules to avoid all risks of accidents.
B. Instructions concerning the managers of persons intervening on the site

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

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

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

◼ Access the driving stand via the access path provided, with the crane stopped.
32
◼ Access the driving stand with an elevated cab or personnel elevator only when the
crane is stopped and in adherence to the maximum authorized carrying capacity.
◼ Keep the access paths and control station perfectly clean. In particularly, remove all
waste, traces of grease or oil, spare parts, tools, etc. Store tools, accessories, and
parts in the positions provided for that purpose.
◼ Access the crane with hands unhindered by any object, facing the crane and always
maintaining contact at 3 points with its elements: ladders, railing, stairs, catwalks,
handrails, etc... (e.g.: 2 feet and 1 hand, 2 hands and 1 foot).
D. Malfunctioning
◼ In the case of malfunctioning, stop the crane until the risk has been assessed by a
competent person.
◼ Immediately correct any malfunctioning liable to compromise safety.
◼ Enter all malfunctions in the crane’s maintenance records.
E. Electric lines
◼ Define the procedure to be applied in the case of accidental contact between crane
and electric lines under voltage (direct contact or start of an electric arc).
◼ Examples:
➢ Do not leave the crane
➢ Do not touch the metallic structure
➢ Warn all persons outside that they must avoid approaching or touching the crane
➢ Withdraw the crane from the danger zone
➢ Have the electric line powered off then leave the crane.
F. Conditions for visibility

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

A. Installation
◼ Make sure that the electrical system is complete and undamaged
◼ Make sure that the electrical system has no condensation and humidity.
◼ The lifting lugs are recommended to be used during removals.
◼ The cabinet is recommended to be installed in predesigned position, and the number of
fasten needs to meet the designer’s needs.
◼ Fasten the screws with required torque (see details on APPENDIX), using recommended
plane pad or spring washer.
33
B. Wiring
◼ Confirm the power is off and no residual voltage.
◼ Wiring should be conducted by professional.
◼ Do not wiring when wearing loosing clothes or jewelry,
◼ Avoid the damage of wires.
◼ Wiring with required wiring diagram,
◼ Wiring with required wires.
C. Test run
◼ Confirm the validity of the cabinet’s installation; turn on the power after closing the cabinet’s
door. DO NOT open the cabinet’s door when operating.
◼ Confirm the tower and mechanisms operate in allowable range.
D. Maintenance and Checking

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

phase
A. Transport
◼ Provide for access to the site where the crane is operated, suited to crane transport
conditions and, if necessary, the transport of auxiliary equipment used for
assembly−dismantling (ground resistance, climatic conditions, access ramp, maneuvering
zone, etc.).
◼ Install signaling equipment before any transport by road.
34
B. Preparation of the site

◼ Ensure that the site where the crane is used meets all crane characteristics and utilization
conditions.
a) Crane installation area
◼ Before installing the crane, study the constraints related to its operating site, such as:
➢ local regulations concerning work above public buildings or other, above roads, railroads,
fluvial canals, etc...
➢ proximity to other cranes, to an airport, to electric lines, to a transmitter of electromagnetic
waves, etc...
➢ configuration of the terrain, resistance of ground, excavations, slope, underground structure,
etc.
➢ storage zones for elements used in crane assembly or dismantling, positioning of handling
equipment, in order to determine the optimal crane position, in compliance with
assembly−dismantling and operating conditions.
b) Power supply
◼ Ensure that the power supply conforms to crane data and possesses the mandatory
protections.
C. Assembly-dismantling part
a) Preparation of assembly−dismantling
◼ Establish a document, for the attention of the personnel at the crane operating site, that
details the risks of assembly, dismantling or change of configuration operations and the
appropriate protective measures.
◼ Before any assembly, dismantling, change of configuration (e.g.: raising on supports,
passage to raised jib) of the crane, ensure with the relevant authorities that wind speeds
will not exceed the maximum authorized speed (refer to utilization conditions) throughout
the entire operation.
◼ Stake out the safety areas (zones for storage, handling, assembly, ...) when assembling,
dismantling, or testing the crane, with the use of signaling prohibiting access to
non−authorized personnel.
b) Assembly − dismantling − change of configuration
◼ Do not use the crane during assembly, dismantling or change of configuration operations.
◼ For any assembly or dismantling operations not covered by the normal procedures
(example: constraints related to the crane operating site, malfunctioning during assembling
or dismantling), please consult us.
D. Maintenance part
a) Preparation for maintenance
◼ Stake out a safety area in the case of crane malfunctioning or during maintenance
interventions, with the use of signaling prohibiting access to non−authorized personnel.
35
◼ Inhibit re−start of the crane on stoppage for intervention and signal that inhibition of re−start
by a warning attached to the main switch.
b) Maintenance
◼ Do not use the crane during maintenance operations.
◼ For any non−standard maintenance operation, please consult us.
2.2.3 Safety signaling

2.2.3.1 Explanation
Safety and health−hazard signaling corresponds to determined object, activity or
situation−related signals providing an indication or provision relative to safety or health matters.
That signaling is materialized, according to circumstances, by a panel, a color, an audio or
luminous signal.
Safety signaling can be broken down into 5 categories, each identified by a color code.
◼ Prohibition (red)
◼ Warning (yellow or orange−hue yellow)
◼ Mandatory (blue)
◼ Rescue and first−aid (green)
◼ Fire−fighting material or equipment (red)
2.2.3.2 Terminology
◼ Panel: signal providing a given indication via the combining of a geometrical shape and
certain colors with a symbol or a pictogram.
➢ Prohibition panel: prohibits behavior liable to generate running of a risk or provoking danger.
➢ Warning panel: warns of a risk or of danger.
➢ Mandatory panel: prescribes a given behavior to be adopted.
➢ Rescue and first−aid panel: provides indications relative to emergency exits or to rescue
and first−aid resources available.
➢ Fire−fighting panel: provides indications relative to the location of fire−fighting resources
and evacuation in the case of fire.
◼ Additional panel: panel used conjointly with another panel and providing complementary
indications.
◼ Symbol or pictogram: image describing a situation or prescribing a given behavior to be
adopted, and which is employed on a panel or a luminous surface.
➢ Luminous signal: signal emitted by a device composed of transparent or translucent
material, internally or back−lighted, in a way it stands out itself as a luminous surface.
➢ Audio signal: a coded audible signal emitted and broadcast by an ad hoc device, without
the use of a human or synthesized voice.
2.2.3.3 Signaling panels
36
A. Warning panels
Panels Signification Explanations
Do not intervene before

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

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

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

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

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

free rotation of the instructions for start-up
jib and close of the crane
37
Do not separate the mast

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

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

A. Audio signals
The following dangers are signaled by automatic activation of an audio alarm:
◼ Crane start−up: short tone
◼ Activation of MSWL (maximum safe working load) cut−out or moment cut−out: continuous
tone
◼ Crane traveling mode: continuous dual tone during the complete duration of movement.
◼ Specific danger is signaled by voluntary action on the audio alarm in accordance with code
defined by local regulations or by the crane manager, such as for example: moving of loads
above persons, specific situations.
◼ Acquire knowledge of the tones and duration corresponding to each signal.
38
B. Luminous signals
According to the instructions or regulations on crane utilization site, luminous signals may be
used to indicate specific danger:
◼ Operating wind speed pre−alarm (adjustable): flashing orange light
◼ Pre−alarm limit: 90% of MSWL or MSWL moment:
➢ GMA: flashing orange light
➢ GME: orange light in control station
◼ Working area limiter not operating or neutralized: flashing red light
C. Associated audio and luminous signals

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

Positioning on the crane and references of luminous or audio panels and devices are provided
in the section 7 « SPARE PARTS».
2.2.4 Safety controls

The control console and the maintenance areas at winch proximity (in the case where the
control console is not portable) are equipped with a mechanically−lockable red emergency stop
button.
The storm wind reference speeds are determined according to the FEM 1.004 / Edition 07/2000
standard.
Pressing one of those buttons generates immediate interruption of all

movements.
The emergency stop button must be used only in the case of danger and
not for interrupting movements.
39
2.3 Storm wind speed-out of service

2.3.1 General Notes
The storm wind reference speeds are determined according to the FEM 1.004 / Edition 07/2000
standard.
2.3.2 Speed table

Wind speed Dynamic pressure
Height 0−20 m above the ground 130 km/h (36 m/s) 800N/𝑚2
Height 20−100 m above the ground 150 km/h (42 m/s) 1100 N/𝑚2
Height higher than 100 m above the ground 165 km/h (46 m/s) 1300 N/𝑚2
40
3 TECHNICAL DATA OF CRANE AND SITE

3.1 Foreword
The crane and site data group the assembly of technical information and characteristics
together which are necessary to mount and use the crane in full safety and especially to:
◼ Prepare the operating site (for ex: mains supply, access),
◼ Calculate and carry out the crane ground supports,
◼ Carry out the ballast of the crane,
◼ Choose the handling equipment which is necessary to carry out the loading and unloading
of the crane.
Certain data given in this part correspond to the maximum characteristics of the
crane type. For an appropriate use, take into accounting the crane configuration
must as defined at the time of order.
3.2 Technical characteristics
Fig. 3-1 WA7025-12E tower crane sub-area
41
WA7025-12E TECHNICAL DATA OF CRANE AND SITE
3.2.1 Load curves

The following load curves are specific to the WA7025-12E in 2/4-fall separately.
3.2.1.1 2-fall load capacity

10~35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5 70.0
6.00 5.67 5.24 4.86 4.52 4.22 3.95 3.71 3.49 3.29 3.10 2.93 2.78 2.63 2.50
10~35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5
6.00 5.97 5.52 5.12 4.77 4.46 4.18 3.92 3.69 3.48 3.29 3.11 2.95 2.80
10~ 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0
6.00 5.77 5.35 4.99 4.66 4.37 4.11 3.87 3.65 3.45 3.27 3.10
10~ 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5
6.00 5.97 5.55 5.17 4.84 4.54 4.27 4.02 3.79 3.59 3.40
10~40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0
6.00 5.71 5.32 4.98 4.67 4.39 4.14 3.91 3.70
10~40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5
6.00 5.83 5.44 5.09 4.77 4.49 4.23 4.00
42
10~42.5 45.0 47.5 50.0 52.5 55.0
6.00 5.64 5.28 4.96 4.66 4.40
10~42.5 45.0 47.5 50.0 52.5
6.00 5.80 5.43 5.10 4.80
10~42.5 45.0 47.5 50.0
6.00 5.91 5.54 5.20
10~45 47.5
6.00 5.70
10~45
6.00
43
3.2.1.2 4-fall load capacity

10~17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5 70.0
12.00 11.78 10.27 9.07 8.10 7.30 6.62 6.05 5.55 5.12 4.74 4.41 4.11 3.84 3.59 3.37 3.17 2.99 2.82 2.66 2.52 2.39
10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5
12.00 10.78 9.53 8.52 7.68 6.98 6.38 5.86 5.41 5.01 4.66 4.34 4.06 3.81 3.58 3.37 3.18 3.00 2.84 2.69
10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0
12.00 11.23 9.93 8.88 8.01 7.28 6.66 6.12 5.65 5.24 4.88 4.55 4.26 3.99 3.76 3.54 3.34 3.15 2.99
10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5
12.00 11.61 10.27 9.19 8.29 7.54 6.90 6.34 5.86 5.43 5.06 4.72 4.42 4.15 3.90 3.68 3.47 3.29
10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0
12.00 11.91 10.54 9.44 8.52 7.75 7.09 6.52 6.03 5.59 5.21 4.87 4.56 4.28 4.03 3.80 3.59
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5
12.00 10.76 9.63 8.69 7.91 7.24 6.66 6.16 5.72 5.32 4.97 4.66 4.38 4.12 3.89
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0
12.00 11.13 9.97 9.00 8.19 7.50 6.91 6.39 5.93 5.53 5.17 4.84 4.55 4.29
44
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5
12.00 11.42 10.23 9.24 8.41 7.71 7.10 6.57 6.10 5.69 5.32 4.99 4.69
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0
12.00 11.63 10.42 9.41 8.57 7.85 7.23 6.69 6.22 5.80 5.42 5.09
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5
12.00 11.95 10.70 9.68 8.81 8.08 7.44 6.89 6.40 5.97 5.59
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0
12.00 11.97 10.73 9.70 8.83 8.10 7.46 6.91 6.42 5.99
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5
12.00 11.92 10.68 9.65 8.79 8.06 7.42 6.87 6.39
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0
12.00 11.78 10.55 9.54 8.69 7.96 7.33 6.79
10~22.5 25.0 27.5 30.0 32.5 35.0 37.5
12.00 11.71 10.49 9.48 8.63 7.91 7.29
45
10~22.5 25.0 27.5 30.0 32.5 35.0
12.00 11.53 10.33 9.34 8.50 7.79
10~22.5 25.0 27.5 30.0 32.5
12.00 11.39 10.20 9.21 8.39
10~22.5 25.0 27.5 30.0
12.00 11.23 10.06 9.09
46
3.2.2 Characteristics of the mechanisms

3.2.2.1 Hoisting mechanism
Type H45FP30-600P
Maximum traction /N 35000
Specification 35X7-16-1870
Rope Reference weight/kg·m-1 1.18
Maximum line speed m/min 190
Rope roll layers 6/7

Drum
Maximum capacity /m 605(6 layers)/725(7 layers)
Type YZPFM250M2-6
Motor
Power /kW 45
Type DF720-30-C
Reducer
Reduction ratio 30.41
YA65X142(18)
Coupling Type LX9-
YA55X112(16)
Type YWZ5-315/80-1000
Brake
Baking moment [N·m] 1000
3.2.2.2 Slewing mechanism
S75CA-130LB12/14A
Type
S75CN-130LB12/14A
YTRVF132M2-4F1/B/BM1
Type
Motor YTRVF132M2-4F2/B/BM1
Power /kW 7.5×2
Type XX5-130.195LB-12/14
Reduction ratio 195

Reducer
Teeth [z] 12
Pinion
Module [m] 10
47
TECHNICAL DATA OF CRANE AND SITE WA7025-12E
3.2.2.3 Trolley mechanism

Type BP55B
Maximum traction /N 12100
Trolley travelling range /m 75
Specification 6x19-9.3-1700-Ⅱ-Right
Rope Reference weight/kg·m-1 0.305
Maximum line speed m/min 75
Type YEJ132S-4B5
Motor
Power /kW 5.5
Type XL5.5-6-43
Reducer
Reduction ratio 43
48
3.3 Dimensions and weight

3.3.1 Slewing crane part
3.3.1.1 Overview
49
3.3.1.2 Dimensions and weight of the parts

The weights of the winches or of assemblies comprising winches are indicated without ropes.
Rope weight:
R L B H G Q
e Sketch / Designation m m m kg e
f f
Ⅰ 11.0 1.27 2.49 3756 1
Counter jib front section
Ⅰ 8.08 1.45 0.56 2800 1
Counter jib back section
Ⅰ 5.19 0.29 0.28 126 2
Strut
Ⅰ 2.03 0.40 2.44 260 1
Derrick
Ⅰ 1.54 2.03 1.13 2860 1
Hoisting mechanism
⭐Tolerance on the weight: ±5%.
50
R L B H G Q
f f
Ⅲ 2.08 1.30 2.16 480 1
Cab
Ⅲ 2.00 2.40 2.26 4600 1
Slewing unit
Ⅲ 0.42 0.42 1.30 0.35 2
Slewing mechanism
Ⅳ 10.32 1.15 2.55 3210 1
Jib section Ⅰ
Ⅳ 1.20 0.73 0.59 0.48 1
Trolley
Ⅳ 10.27 1.15 2.41 2470 1
Jib section Ⅱ
Ⅳ 10.23 1.15 2.38 1790 1
Jib section Ⅲ
51
R L B H G Q
f f
Ⅳ 10.20 1.15 2.35 1410 1
Jib section Ⅳ
Ⅳ 2.69 1.15 1.87 360 1
Jib section Ⅴ
Ⅳ 10.17 1.15 1.87 1020 1
Jib section Ⅵ
Ⅳ 5.16 1.15 1.85 400 1
Jib section Ⅶ
Ⅳ 2.66 1.15 1.83 201 1
Jib section Ⅷ
Ⅳ 10.15 1.15 1.83 580 1
Jib section Ⅸ
Ⅳ 0.87 1.15 2.06 110 1
Jib tip
52
R L B H G Q
f f
Ⅵ 2.13 1.86 1.04 410 1
Trolley
Ⅴ 1.07 0.36 1.81 420 1
Hook
⭐Tolerance on the weight: ±5%
53
3.3.1.3 Equipped jib weight

The weight indicated in the next table correspond to jibs equipped with：
◼ Trolley mechanism with rope
◼ Wind-sail plate (depending on the jib length)
◼ Guard rope
Jib length Weight (kg)
(m) Without Trolley
70 11535
67.5 11334
65 11134
62.5 10930
60 10960
57.5 10760
55 10560
52.5 10360
50 9998
47.5 9750
45 9550
42.5 9340
40 8980
37.5 7960
35 7600
32.5 7560
30 7200
54
3.3.1.4 Dimensions of the slewing crane part
55
3.3.1.5 Cross section of the jib sections
56
3.3.2 Mast
3.3.2.1 Overview
3.3.2.2 Dimensions and weight of the mast sections

R L B H G Q
e Designation / Sketch m m m kg e
f f
WA7527-
Ⅰ 7.20 2.54 2.78 4431 1
20D(Abroad).11
Climbing frame
Ⅰ 2.90 0.40 1.93 920 1
Jacking mechanism
57
R L B H G Q
f f
Ⅰ 1.00 0.72 0.45 240 1
Pump station
L68A4
Ⅱ 2.10 2.10 3.27 1610 17
(Rung ladder)
Tower section
L68B7
(Rung ladder,
only for chassis
Ⅱ 2.10 2.10 3.27 1930 1
stationary and
travelling tower
crane)
Tower section
L68A1A
Ⅱ 2.10 2.10 3.27 1708 17
(Rung ladder)
Tower section
L68B2A
(Rung ladder,
only for chassis
Ⅱ 2.10 2.10 3.27 2081 1
stationary and
travelling tower
crane)
Tower section
58
R L B H G Q
f f
L68G23
(Only for
Ⅱ outrigger 7.77 2.10 2.10 4200 1
stationary tower
crane) Bast mast section
Ⅱ 2.61 2.52 2.26 1630 1
Transition tower section

59
3.3.3 Crane base

3.3.3.1 Overview
60
3.3.3.2 Dimensions and Weights

R L B H G Q
f f
I 1.19 0.55 0.55 0.23 4
Outrigger stationary
I 8.94 0.90 1.38 2190 1
Long cross
I 4.33 0.42 1.27 1060 2
Short cross beam
Ⅰ 5.19 0.29 0.28 420 4
Strut
I 0.85 2.20 2.20 750 1
Cable
61
3.4 Mast composition

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

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

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

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

Please consult us compulsorily.
62
3.4.2 Mast composition

3.4.2.1 Rung ladder crane
◼ Outrigger stationary tower crane
H.U.H
L68G23 L68A4 L68A2
(m)
28.65 1 6 1
31.65 1 7 1
34.65 1 8 1
37.65 1 9 1
40.65 1 10 1
43.65 1 11 1
46.65 1 12 1
49.65 1 13 1
52.65 1 14 1
55.65 1 15 1
58.65 1 16 1
61.65 1 17 1
◼ Stationary/chassis tower crane

H.U.H
L68B7 L68A4 L68A2
(m)
24.15 1 6 1
27.15 1 7 1
30.15 1 8 1
33.15 1 9 1
36.15 1 10 1
39.15 1 11 1
42.15 1 12 1
45.15 1 13 1
48.15 1 14 1
51.15 1 15 1
54.15 1 16 1
57.15 1 17 1
63
3.4.2.2 Incline ladder crane

◼ Outrigger stationary tower crane
H.U.H
L68G21A L68A1A L68A2
(m)
28.65 1 6 1
31.65 1 7 1
34.65 1 8 1
37.65 1 9 1
40.65 1 10 1
43.65 1 11 1
46.65 1 12 1
49.65 1 13 1
52.65 1 14 1
55.65 1 15 1
58.65 1 16 1
61.65 1 17 1
◼ Stationary/chassis tower crane

H.U.H
L68B7 L68A1A L68A2
(m)
24.15 1 6 1
27.15 1 7 1
30.15 1 8 1
33.15 1 9 1
36.15 1 10 1
39.15 1 11 1
42.15 1 12 1
45.15 1 13 1
48.15 1 14 1
51.15 1 15 1
54.15 1 16 1
57.15 1 17 1
When assembling tower section, please strictly follow the operation instruction.
Tower section L68A1A, L68A1 (outdated), L68B7 and L68B2A use inner
assemble method.
64
3.4.3 Loads on foundation of crane
T Torque M Bending moment H Horizontal force V Vertical force
In the following configuration, there is no climbing equipment. If the crane

is erected with climbing equipment, lower it to the bottom after erection
and the vertical force adds 40kN.
65
3.4.3.1 Loads on foundation for 70m jib

Table 3-1 Loads on foundation for 70m jib
Tower height M H V T
Number of sections Operation status
(m) (kN·m) (kN) (kN) (kN·m)
In service 2534.3 25.1 903.6 723.9
1+6 27.0
Out of service -1194.7 99.0 716.1 0.0
In service 2640.1 26.6 919.2 723.9
1+7 30.0
Out of service -1204.0 105.5 731.8 0.0
In service 2758.0 28.1 934.9 723.9
1+8 33.0
Out of service 1311.4 112.0 747.5 0.0
In service 2886.6 29.6 950.6 723.9
1+9 36.0
Out of service 1673.1 118.5 763.1 0.0
In service 3026.8 31.1 966.3 723.9
1+10 39.0
Out of service 2060.8 125.0 778.8 0.0
In service 3179.5 32.5 982.0 723.9
1+11 42.0
Out of service 2476.1 131.6 794.5 0.0
In service 3345.8 34.0 997.6 723.9
1+12 45.0
Out of service 2920.7 138.1 810.2 0.0
In service 3527.0 35.5 1013.3 723.9
1+13 48.0
Out of service 3396.5 144.6 825.9 0.0
In service 3724.8 37.0 1029.0 723.9
1+14 51.0
Out of service 3905.9 151.1 841.5 0.0
In service 3940.7 38.5 1044.7 723.9
1+15 54.0
Out of service 4451.4 157.6 857.2 0.0
In service 4177.2 40.0 1060.4 723.9
1+16 57.0
Out of service 5036.2 164.2 872.9 0.0
In service 4436.6 41.4 1076.0 723.9
1+17 60.0
Out of service 5663.9 170.7 888.6 0.0
66
3.4.3.2 Loads on foundation for 67.5m jib

Table 3-2 Loads on foundation for 67.5m jib
In service 2515.5 25.1 901.4 681.5
1+6 27.0
Out of service -1333.3 99.0 714.1 0.0
In service 2621.0 26.6 917.1 681.5
1+7 30.0
Out of service -1343.6 105.5 729.8 0.0
In service 2738.5 28.1 932.7 681.5
1+8 33.0
Out of service -1355.4 112.0 745.5 0.0
In service 2866.6 29.6 948.4 681.5
1+9 36.0
Out of service 1529.4 118.5 761.2 0.0
In service 3006.3 31.0 964.1 681.5
1+10 39.0
Out of service 1915.2 125.0 776.9 0.0
In service 3158.4 32.5 979.8 681.5
1+11 42.0
Out of service 2328.3 131.6 792.5 0.0
In service 3324.1 34.0 995.5 681.5
1+12 45.0
Out of service 2770.4 138.1 808.2 0.0
In service 3504.6 35.5 1011.1 681.5
1+13 48.0
Out of service 3243.4 144.6 823.9 0.0
In service 3701.4 37.0 1026.8 681.5
1+14 51.0
Out of service 3749.6 151.1 839.6 0.0
In service 3916.4 38.5 1042.5 681.5
1+15 54.0
Out of service 4291.6 157.6 855.3 0.0
In service 4151.7 39.9 1058.2 681.5
1+16 57.0
Out of service 4872.4 164.2 870.9 0.0
In service 4409.9 41.4 1073.9 681.5
1+17 60.0
Out of service 5495.6 170.7 886.6 0.0
67

In service 2696.2 25.2 897.7 628.8
1+6 27.0
Out of service -1250.7 99.0 710.8 0.0
In service 2803.9 26.7 913.4 628.8
1+7 30.0
Out of service -1260.3 105.5 726.4 0.0
In service 2923.9 28.2 929.0 628.8
1+8 33.0
Out of service 1253.7 112.0 742.1 0.0
In service 3054.9 29.7 944.7 628.8
1+9 36.0
Out of service 1614.5 118.5 757.8 0.0
In service 3197.8 31.1 960.4 628.8
1+10 39.0
Out of service 2001.3 125.0 773.5 0.0
In service 3353.5 32.6 976.1 628.8
1+11 42.0
Out of service 2415.5 131.6 789.2 0.0
In service 3523.2 34.1 991.8 628.8
1+12 45.0
Out of service 2858.8 138.1 804.8 0.0
In service 3708.2 35.6 1007.4 628.8
1+13 48.0
Out of service 3333.1 144.6 820.5 0.0
In service 3910.0 37.1 1023.1 628.8
1+14 51.0
Out of service 3840.6 151.1 836.2 0.0
In service 4130.5 38.6 1038.8 628.8
1+15 54.0
Out of service 4384.1 157.6 851.9 0.0
In service 4371.8 40.0 1054.5 628.8
1+16 57.0
Out of service 4966.5 164.2 867.6 0.0
In service 4636.7 41.5 1070.2 628.8
1+17 60.0
Out of service 5591.3 170.7 883.2 0.0
68

In service 2725.4 25.2 882.6 585.3
1+6 27.0
Out of service -1301.4 99.0 697.0 0.0
In service 2832.9 26.7 898.2 585.3
1+7 30.0
Out of service -1311.2 105.5 712.7 0.0
In service 2952.6 28.2 913.9 585.3
1+8 33.0
Out of service -1322.4 112.0 728.4 0.0
In service 3083.3 29.7 929.6 585.3
1+9 36.0
Out of service 1560.6 118.5 744.1 0.0
In service 3225.7 31.2 945.3 585.3
1+10 39.0
Out of service 1946.3 125.0 759.7 0.0
In service 3380.8 32.6 961.0 585.3
1+11 42.0
Out of service 2359.0 131.6 775.4 0.0
In service 3549.7 34.1 976.6 585.3
1+12 45.0
Out of service 2800.5 138.1 791.1 0.0
In service 3733.8 35.6 992.3 585.3
1+13 48.0
Out of service 3272.7 144.6 806.8 0.0
In service 3934.4 37.1 1008.0 585.3
1+14 51.0
Out of service 3777.7 151.1 822.5 0.0
In service 4153.5 38.6 1023.7 585.3
1+15 54.0
Out of service 4318.0 157.6 838.1 0.0
In service 4393.1 40.0 1039.4 585.3
1+16 57.0
Out of service 4896.6 164.2 853.8 0.0
In service 4655.8 41.5 1055.0 585.3
1+17 60.0
Out of service 5516.9 170.7 869.5 0.0
69

In service 2818.7 25.3 890.4 615.5
1+6 27.0
Out of service -1288.4 99.0 704.2 0.0
In service 2927.6 26.8 906.1 615.5
1+7 30.0
Out of service -1298.2 105.5 719.8 0.0
In service 3049.1 28.2 921.8 615.5
1+8 33.0
Out of service -1309.5 112.0 735.5 0.0
In service 3181.8 29.7 937.5 615.5
1+9 36.0
Out of service 1574.8 118.5 751.2 0.0
In service 3326.5 31.2 953.1 615.5
1+10 39.0
Out of service 1960.9 125.0 766.9 0.0
In service 3484.2 32.7 968.8 615.5
1+11 42.0
Out of service 2374.2 131.6 782.6 0.0
In service 3656.1 34.2 984.5 615.5
1+12 45.0
Out of service 2816.4 138.1 798.2 0.0
In service 3843.4 35.6 1000.2 615.5
1+13 48.0
Out of service 3289.4 144.6 813.9 0.0
In service 4047.9 37.1 1015.9 615.5
1+14 51.0
Out of service 3795.4 151.1 829.6 0.0
In service 4271.3 38.6 1031.5 615.5
1+15 54.0
Out of service 4337.1 157.6 845.3 0.0
In service 4515.8 40.1 1047.2 615.5
1+16 57.0
Out of service 4917.3 164.2 861.0 0.0
In service 4784.1 41.6 1062.9 615.5
1+17 60.0
Out of service 5539.5 170.7 876.6 0.0
70

In service 2734.9 25.2 880.7 571.1
1+6 27.0
Out of service -1419.7 99.0 695.3 0.0
In service 2842.4 26.7 896.4 571.1
1+7 30.0
Out of service -1430.4 105.5 711.0 0.0
In service 2962.2 28.2 912.0 571.1
1+8 33.0
Out of service -1442.6 112.0 726.7 0.0
In service 3092.9 29.7 927.7 571.1
1+9 36.0
Out of service 1438.1 118.5 742.3 0.0
In service 3235.3 31.2 943.4 571.1
1+10 39.0
Out of service 1822.1 125.0 758.0 0.0
In service 3390.5 32.6 959.1 571.1
1+11 42.0
Out of service 2233.1 131.6 773.7 0.0
In service 3559.4 34.1 974.8 571.1
1+12 45.0
Out of service 2672.5 138.1 789.4 0.0
In service 3743.5 35.6 990.4 571.1
1+13 48.0
Out of service 3142.4 144.6 805.1 0.0
In service 3944.1 37.1 1006.1 571.1
1+14 51.0
Out of service 3644.8 151.1 820.7 0.0
In service 4163.2 38.6 1021.8 571.1
1+15 54.0
Out of service 4182.2 157.6 836.4 0.0
In service 4402.8 40.0 1037.5 571.1
1+16 57.0
Out of service 4757.5 164.2 852.1 0.0
In service 4665.4 41.5 1053.2 571.1
1+17 60.0
Out of service 5374.1 170.7 867.8 0.0
71

In service 2712.8 25.2 878.5 524.1
1+6 27.0
Out of service -1538.1 99.0 693.3 0.0
In service 2819.9 26.7 894.2 524.1
1+7 30.0
Out of service -1549.6 105.5 709.0 0.0
In service 2939.2 28.2 909.9 524.1
1+8 33.0
Out of service -1562.8 112.0 724.7 0.0
In service 3069.4 29.7 925.6 524.1
1+9 36.0
Out of service -1577.7 118.5 740.4 0.0
In service 3211.3 31.1 941.2 524.1
1+10 39.0
Out of service 1698.0 125.0 756.1 0.0
In service 3365.8 32.6 956.9 524.1
1+11 42.0
Out of service 2107.1 131.6 771.7 0.0
In service 3534.0 34.1 972.6 524.1
1+12 45.0
Out of service 2544.5 138.1 787.4 0.0
In service 3717.2 35.6 988.3 524.1
1+13 48.0
Out of service 3012.1 144.6 803.1 0.0
In service 3916.9 37.1 1004.0 524.1
1+14 51.0
Out of service 3511.8 151.1 818.8 0.0
In service 4134.9 38.6 1019.6 524.1
1+15 54.0
Out of service 4046.3 157.6 834.5 0.0
In service 4373.3 40.0 1035.3 524.1
1+16 57.0
Out of service 4618.3 164.2 850.1 0.0
In service 4634.5 41.5 1051.0 524.1
1+17 60.0
Out of service 5231.2 170.7 865.8 0.0
72

In service 2807.5 25.3 867.7 481.0
1+6 27.0
Out of service -1511.2 99.0 683.5 0.0
In service 2915.3 26.7 883.4 481.0
1+7 30.0
Out of service -1522.4 105.5 699.2 0.0
In service 3035.5 28.2 899.1 481.0
1+8 33.0
Out of service -1535.1 112.0 714.9 0.0
In service 3166.6 29.7 914.8 481.0
1+9 36.0
Out of service -1549.5 118.5 730.6 0.0
In service 3309.6 31.2 930.5 481.0
1+10 39.0
Out of service 1724.9 125.0 746.3 0.0
In service 3465.2 32.7 946.1 481.0
1+11 42.0
Out of service 2134.0 131.6 761.9 0.0
In service 3634.6 34.2 961.8 481.0
1+12 45.0
Out of service 2571.3 138.1 777.6 0.0
In service 3819.0 35.6 977.5 481.0
1+13 48.0
Out of service 3038.5 144.6 793.3 0.0
In service 4020.0 37.1 993.2 481.0
1+14 51.0
Out of service 3537.8 151.1 809.0 0.0
In service 4239.4 38.6 1008.9 481.0
1+15 54.0
Out of service 4071.6 157.6 824.7 0.0
In service 4479.1 40.1 1024.5 481.0
1+16 57.0
Out of service 4642.7 164.2 840.3 0.0
In service 4741.7 41.6 1040.2 481.0
1+17 60.0
Out of service 5254.3 170.7 856.0 0.0
73

In service 2760.4 25.2 866.0 446.7
1+6 27.0
Out of service -1600.7 99.0 682.0 0.0
In service 2867.7 26.7 881.7 446.7
1+7 30.0
Out of service -1612.5 105.5 697.7 0.0
In service 2987.1 28.2 897.4 446.7
1+8 33.0
Out of service -1626.0 112.0 713.3 0.0
In service 3117.4 29.7 913.1 446.7
1+9 36.0
Out of service -1641.2 118.5 729.0 0.0
In service 3259.3 31.2 928.8 446.7
1+10 39.0
Out of service 1631.1 125.0 744.7 0.0
In service 3413.8 32.7 944.4 446.7
1+11 42.0
Out of service 2038.9 131.6 760.4 0.0
In service 3582.0 34.1 960.1 446.7
1+12 45.0
Out of service 2474.6 138.1 776.1 0.0
In service 3765.1 35.6 975.8 446.7
1+13 48.0
Out of service 2940.1 144.6 791.7 0.0
In service 3964.5 37.1 991.5 446.7
1+14 51.0
Out of service 3437.5 151.1 807.4 0.0
In service 4182.1 38.6 1007.2 446.7
1+15 54.0
Out of service 3969.1 157.6 823.1 0.0
In service 4419.8 40.1 1022.8 446.7
1+16 57.0
Out of service 4537.7 164.2 838.8 0.0
In service 4680.2 41.5 1038.5 446.7
1+17 60.0
Out of service 5146.5 170.7 854.5 0.0
74

In service 2892.4 25.3 842.8 476.5
1+6 27.0
Out of service -1537.8 99.0 660.9 0.0
In service 3000.3 26.8 858.5 476.5
1+7 30.0
Out of service -1548.7 105.5 676.5 0.0
In service 3120.5 28.3 874.2 476.5
1+8 33.0
Out of service -1561.2 112.0 692.2 0.0
In service 3251.5 29.8 889.8 476.5
1+9 36.0
Out of service -1575.3 118.5 707.9 0.0
In service 3394.3 31.2 905.5 476.5
1+10 39.0
Out of service 1694.5 125.0 723.6 0.0
In service 3549.6 32.7 921.2 476.5
1+11 42.0
Out of service 2102.2 131.6 739.3 0.0
In service 3718.5 34.2 936.9 476.5
1+12 45.0
Out of service 2537.7 138.1 754.9 0.0
In service 3902.2 35.7 952.6 476.5
1+13 48.0
Out of service 3002.8 144.6 770.6 0.0
In service 4102.3 37.2 968.2 476.5
1+14 51.0
Out of service 3499.3 151.1 786.3 0.0
In service 4320.3 38.7 983.9 476.5
1+15 54.0
Out of service 4029.6 157.6 802.0 0.0
In service 4558.3 40.1 999.6 476.5
1+16 57.0
Out of service 4596.3 164.2 817.7 0.0
In service 4818.6 41.6 1015.3 476.5
1+17 60.0
Out of service 5202.5 170.7 833.3 0.0
75

In service 2795.2 25.3 846.8 431.5
1+6 27.0
Out of service -1636.2 99.0 664.5 0.0
In service 2902.2 26.8 862.5 431.5
1+7 30.0
Out of service -1647.9 105.5 680.2 0.0
In service 3021.2 28.2 878.2 431.5
1+8 33.0
Out of service -1661.2 112.0 695.9 0.0
In service 3150.9 29.7 893.9 431.5
1+9 36.0
Out of service -1676.4 118.5 711.6 0.0
In service 3292.2 31.2 909.6 431.5
1+10 39.0
Out of service -1693.4 125.0 727.3 0.0
In service 3445.9 32.7 925.2 431.5
1+11 42.0
Out of service 1998.6 131.6 742.9 0.0
In service 3613.0 34.2 940.9 431.5
1+12 45.0
Out of service 2432.8 138.1 758.6 0.0
In service 3794.8 35.6 956.6 431.5
1+13 48.0
Out of service 2896.4 144.6 774.3 0.0
In service 3992.7 37.1 972.3 431.5
1+14 51.0
Out of service 3391.4 151.1 790.0 0.0
In service 4208.4 38.6 988.0 431.5
1+15 54.0
Out of service 3920.1 157.6 805.7 0.0
In service 4443.8 40.1 1003.6 431.5
1+16 57.0
Out of service 4485.0 164.2 821.3 0.0
In service 4701.3 41.6 1019.3 431.5
1+17 60.0
Out of service 5089.4 170.7 837.0 0.0
76

In service 2757.7 25.3 833.1 391.1
1+6 27.0
Out of service -1646.0 99.0 652.0 0.0
In service 2863.7 26.7 848.8 391.1
1+7 30.0
Out of service -1657.5 105.5 667.7 0.0
In service 2981.6 28.2 864.4 391.1
1+8 33.0
Out of service -1670.6 112.0 683.4 0.0
In service 3109.9 29.7 880.1 391.1
1+9 36.0
Out of service -1685.5 118.5 699.1 0.0
In service 3249.6 31.2 895.8 391.1
1+10 39.0
Out of service -1702.2 125.0 714.8 0.0
In service 3401.5 32.7 911.5 391.1
1+11 42.0
Out of service 1986.4 131.6 730.4 0.0
In service 3566.5 34.1 927.2 391.1
1+12 45.0
Out of service 2419.8 138.1 746.1 0.0
In service 3745.8 35.6 942.8 391.1
1+13 48.0
Out of service 2882.3 144.6 761.8 0.0
In service 3940.9 37.1 958.5 391.1
1+14 51.0
Out of service 3375.9 151.1 777.5 0.0
In service 4153.3 38.6 974.2 391.1
1+15 54.0
Out of service 3902.8 157.6 793.2 0.0
In service 4384.9 40.1 989.9 391.1
1+16 57.0
Out of service 4465.6 164.2 808.8 0.0
In service 4638.0 41.6 1005.6 391.1
1+17 60.0
Out of service 5067.3 170.7 824.5 0.0
77

In service 2762.2 25.3 815.2 350.9
1+6 27.0
Out of service -1581.3 99.0 635.8 0.0
In service 2867.6 26.8 830.9 350.9
1+7 30.0
Out of service -1592.0 105.5 651.5 0.0
In service 2984.7 28.2 846.6 350.9
1+8 33.0
Out of service -1604.3 112.0 667.1 0.0
In service 3112.1 29.7 862.2 350.9
1+9 36.0
Out of service -1618.1 118.5 682.8 0.0
In service 3250.7 31.2 877.9 350.9
1+10 39.0
Out of service 1646.1 125.0 698.5 0.0
In service 3401.3 32.7 893.6 350.9
1+11 42.0
Out of service 2052.3 131.6 714.2 0.0
In service 3564.8 34.2 909.3 350.9
1+12 45.0
Out of service 2485.7 138.1 729.9 0.0
In service 3742.3 35.6 925.0 350.9
1+13 48.0
Out of service 2948.1 144.6 745.5 0.0
In service 3935.2 37.1 940.6 350.9
1+14 51.0
Out of service 3441.4 151.1 761.2 0.0
In service 4145.0 38.6 956.3 350.9
1+15 54.0
Out of service 3967.6 157.6 776.9 0.0
In service 4373.6 40.1 972.0 350.9
1+16 57.0
Out of service 4529.4 164.2 792.6 0.0
In service 4623.0 41.6 987.7 350.9
1+17 60.0
Out of service 5129.5 170.7 808.3 0.0
78

In service 2761.9 25.3 777.2 308.7
1+6 27.0
Out of service -1516.8 99.0 601.2 0.0
In service 2865.9 26.8 792.9 308.7
1+7 30.0
Out of service -1526.5 105.5 616.9 0.0
In service 2981.2 28.3 808.5 308.7
1+8 33.0
Out of service -1537.5 112.0 632.6 0.0
In service 3106.6 29.7 824.2 308.7
1+9 36.0
Out of service -1550.0 118.5 648.2 0.0
In service 3242.7 31.2 839.9 308.7
1+10 39.0
Out of service 1709.1 125.0 663.9 0.0
In service 3390.3 32.7 855.6 308.7
1+11 42.0
Out of service 2114.7 131.6 679.6 0.0
In service 3550.4 34.2 871.3 308.7
1+12 45.0
Out of service 2547.1 138.1 695.3 0.0
In service 3723.8 35.7 886.9 308.7
1+13 48.0
Out of service 3008.0 144.6 711.0 0.0
In service 3911.9 37.2 902.6 308.7
1+14 51.0
Out of service 3499.0 151.1 726.6 0.0
In service 4116.1 38.6 918.3 308.7
1+15 54.0
Out of service 4022.3 157.6 742.3 0.0
In service 4338.0 40.1 934.0 308.7
1+16 57.0
Out of service 4580.0 164.2 758.0 0.0
In service 4579.5 41.6 949.7 308.7
1+17 60.0
Out of service 5174.9 170.7 773.7 0.0
79

In service 2650.3 25.2 767.9 275.8
1+6 27.0
Out of service -1565.2 99.0 592.8 0.0
In service 2752.9 26.7 783.6 275.8
1+7 30.0
Out of service -1575.0 105.5 608.5 0.0
In service 2866.3 28.2 799.3 275.8
1+8 33.0
Out of service -1586.2 112.0 624.1 0.0
In service 2989.6 29.7 814.9 275.8
1+9 36.0
Out of service -1598.9 118.5 639.8 0.0
In service 3123.3 31.2 830.6 275.8
1+10 39.0
Out of service 1657.9 125.0 655.5 0.0
In service 3268.2 32.7 846.3 275.8
1+11 42.0
Out of service 2062.4 131.6 671.2 0.0
In service 3425.1 34.1 862.0 275.8
1+12 45.0
Out of service 2493.7 138.1 686.9 0.0
In service 3595.1 35.6 877.7 275.8
1+13 48.0
Out of service 2953.3 144.6 702.5 0.0
In service 3779.4 37.1 893.3 275.8
1+14 51.0
Out of service 3442.7 151.1 718.2 0.0
In service 3979.1 38.6 909.0 275.8
1+15 54.0
Out of service 3964.0 157.6 733.9 0.0
In service 4196.0 40.1 924.7 275.8
1+16 57.0
Out of service 4519.4 164.2 749.6 0.0
In service 4431.8 41.5 940.4 275.8
1+17 60.0
Out of service 5111.6 170.7 765.3 0.0
80

In service 2585.8 25.2 767.5 235.6
1+6 27.0
Out of service -1586.3 99.0 592.4 0.0
In service 2687.6 26.7 783.1 235.6
1+7 30.0
Out of service -1596.2 105.5 608.1 0.0
In service 2800.3 28.2 798.8 235.6
1+8 33.0
Out of service -1607.5 112.0 623.7 0.0
In service 2922.6 29.7 814.5 235.6
1+9 36.0
Out of service -1620.4 118.5 639.4 0.0
In service 3055.2 31.1 830.2 235.6
1+10 39.0
Out of service 1636.0 125.0 655.1 0.0
In service 3198.9 32.6 845.9 235.6
1+11 42.0
Out of service 2040.3 131.6 670.8 0.0
In service 3354.5 34.1 861.5 235.6
1+12 45.0
Out of service 2471.3 138.1 686.5 0.0
In service 3523.1 35.6 877.2 235.6
1+13 48.0
Out of service 2930.4 144.6 702.1 0.0
In service 3705.6 37.1 892.9 235.6
1+14 51.0
Out of service 3419.5 151.1 717.8 0.0
In service 3903.6 38.6 908.6 235.6
1+15 54.0
Out of service 3940.3 157.6 733.5 0.0
In service 4118.4 40.0 924.3 235.6
1+16 57.0
Out of service 4495.3 164.2 749.2 0.0
In service 4352.0 41.5 939.9 235.6
1+17 60.0
Out of service 5086.9 170.7 764.9 0.0
81

In service 2600.7 25.2 750.6 206.7
1+6 27.0
Out of service -1511.0 99.0 577.1 0.0
In service 2702.2 26.7 766.3 206.7
1+7 30.0
Out of service -1520.2 105.5 592.8 0.0
In service 2814.3 28.2 782.0 206.7
1+8 33.0
Out of service -1530.7 112.0 608.4 0.0
In service 2935.9 29.7 797.7 206.7
1+9 36.0
Out of service -1542.5 118.5 624.1 0.0
In service 3067.8 31.2 813.4 206.7
1+10 39.0
Out of service 1712.3 125.0 639.8 0.0
In service 3210.6 32.6 829.0 206.7
1+11 42.0
Out of service 2116.9 131.6 655.5 0.0
In service 3365.1 34.1 844.7 206.7
1+12 45.0
Out of service 2548.1 138.1 671.2 0.0
In service 3532.3 35.6 860.4 206.7
1+13 48.0
Out of service 3007.2 144.6 686.8 0.0
In service 3713.2 37.1 876.1 206.7
1+14 51.0
Out of service 3496.1 151.1 702.5 0.0
In service 3909.3 38.6 891.8 206.7
1+15 54.0
Out of service 4016.5 157.6 718.2 0.0
In service 4121.8 40.1 907.4 206.7
1+16 57.0
Out of service 4570.6 164.2 733.9 0.0
In service 4352.7 41.5 923.1 206.7
1+17 60.0
Out of service 5161.0 170.7 749.6 0.0
82
3.4.4 Corner pressure for the chassis crane with climbing

equipment
➢ Case 1：
➢ Case 2：
In Table.3.31~3.60 negative numbers indicate tension and positive numbers

indicate pressure.
Since tower crane can rotate in 360°, every support point has the
possibility to endure any load in the table above
83
3.4.4.1 Reaction force for 70m jib with climbing equipment
Table 3-18 Reaction force for 70m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 164.2 580.7 580.7 164.2 372.4 670.2 372.4 74.6
7 27.5
Out of service 424.1 227.0 227.0 424.1 325.6 186.2 325.6 464.9
In service 160.2 592.5 592.5 160.2 376.3 686.2 376.3 66.5
8 30.5
Out of service 428.6 230.3 230.3 428.6 329.5 189.2 329.5 469.7
In service 177.4 627.2 627.2 177.4 402.3 725.4 402.3 79.2
9 33.5
Out of service 455.3 255.6 255.6 455.3 355.4 214.2 355.4 496.7
In service 171.9 640.6 640.6 171.9 406.2 743.7 406.2 68.7
10 36.5
Out of service 460.1 258.7 258.7 460.1 359.4 217.0 359.4 501.8
In service 187.6 676.8 676.8 187.6 432.2 785.3 432.2 79.1
11 39.5
Out of service 230.5 540.1 540.1 230.5 385.3 635.9 385.3 134.8
In service 180.4 691.8 691.8 180.4 436.1 806.2 436.1 66.0
12 42.5
Out of service 204.1 574.5 574.5 204.1 389.3 688.2 389.3 90.3
In service 194.4 729.8 729.8 194.4 462.1 850.5 462.1 73.6
13 45.5
Out of service 197.7 632.8 632.8 197.7 415.2 765.9 415.2 64.6
In service 207.4 768.7 768.7 207.4 488.1 896.4 488.1 79.7
14 48.5
Out of service 189.3 693.1 693.1 189.3 441.2 846.9 441.2 35.5
In service 241.4 830.8 830.8 241.4 536.1 965.9 536.1 106.3
15 51.5
Out of service 200.8 777.7 777.7 200.8 489.2 953.5 489.2 24.9
In service 230.1 849.9 849.9 230.1 540 993.1 540 86.9
16 54.5
Out of service 165.8 820.4 820.4 165.8 459.5 1053.7 459.5 0
In service 217.5 870.3 870.3 217.5 543.9 1022.3 543.9 65.6
17 57.5
Out of service 128.4 865.7 865.7 128.4 400.7 1186.9 400.7 0
In service 203.6 892.1 892.1 203.6 547.8 1053.6 547.8 42.1
18 60.5
Out of service 88.3 913.6 913.6 88.3 337.4 1329.0 337.4 0
84
3.4.4.2 Reaction force for 67.5m jib with climbing equipment
Table 3-19 Reaction force for 67.5m jib with climbing equipment
Operation
of height
sections (m)
In service 165.2 578.6 578.6 165.2 371.9 667.5 371.9 76.3
7 27.5
Out of service 435.1 215.1 215.1 435.1 325.1 169.5 325.1 480.6
In service 161.2 590.4 590.4 161.2 375.8 683.4 375.8 68.2
8 30.5
Out of service 439.7 218.3 218.3 439.7 329.0 172.5 329.0 485.5
In service 178.5 625.1 625.1 178.5 401.8 722.6 401.8 81.0
9 33.5
Out of service 466.4 243.5 243.5 466.4 355.0 197.3 355.0 512.6
In service 173.0 638.4 638.4 173.0 405.7 740.9 405.7 70.5
10 36.5
Out of service 471.3 246.5 246.5 471.3 358.9 200 358.9 517.8
In service 188.7 674.6 674.6 188.7 431.7 782.5 431.7 80.9
11 39.5
Out of service 498.2 271.4 271.4 498.2 384.8 618.5 384.8 151.2
In service 181.6 689.6 689.6 181.6 435.6 803.3 435.6 67.9
12 42.5
Out of service 215.7 561.9 561.9 215.7 388.8 670.6 388.8 106.9
In service 195.6 727.5 727.5 195.6 461.6 847.5 461.6 75.6
13 45.5
Out of service 209.5 620 620 209.5 414.7 748.0 414.7 81.5
In service 208.6 766.4 766.4 208.6 487.5 893.3 487.5 81.7
14 48.5
Out of service 201.3 680.1 680.1 201.3 440.7 828.7 440.7 52.7
In service 242.7 828.4 828.4 242.7 535.5 962.7 535.5 108.3
15 51.5
Out of service 213.0 764.5 764.5 213.0 488.7 935.1 488.7 42.4
In service 231.5 847.5 847.5 231.5 539.5 989.8 539.5 89.1
16 54.5
Out of service 178.3 807.0 807.0 178.3 476.8 1017.0 476.8 0
In service 219.0 867.8 867.8 219.0 543.4 1018.9 543.4 67.9
17 57.5
Out of service 141.2 852.0 852.0 141.2 418.4 1149.5 418.4 0
In service 205.1 889.5 889.5 205.1 547.3 1050.1 547.3 44.5
18 60.5
Out of service 101.4 899.6 899.6 101.4 355.6 1290.7 355.6 0
85
Operation
of height
sections (m)
In service 149.3 592.6 592.6 149.3 371.0 687.7 371.0 54.2
7 27.5
Out of service 427.4 221.0 221.0 427.4 324.2 178.3 324.2 470.1
In service 145.2 604.5 604.5 145.2 374.9 703.8 374.9 46.0
8 30.5
Out of service 432.0 224.3 224.3 432.0 328.1 181.3 328.1 475.0
In service 162.3 639.4 639.4 162.3 400.8 743.2 400.8 58.5
9 33.5
Out of service 458.7 249.6 249.6 458.7 354.1 206.2 354.1 502.0
In service 156.6 652.9 652.9 156.6 404.8 761.8 404.8 47.7
10 36.5
Out of service 463.4 252.6 252.6 463.4 358.0 209.0 358.0 507.1
In service 172.1 689.4 689.4 172.1 430.7 803.7 430.7 57.7
11 39.5
Out of service 490.4 277.6 277.6 490.4 384.0 627.6 384.0 140.4
In service 164.7 704.6 704.6 164.7 434.7 824.9 434.7 44.4
12 42.5
Out of service 207.7 568.2 568.2 207.7 387.9 679.9 387.9 95.9
In service 178.4 742.8 742.8 178.4 460.6 869.6 460.6 51.7
13 45.5
Out of service 201.4 626.4 626.4 201.4 413.9 757.4 413.9 70.4
In service 191.2 782.0 782.0 191.2 486.6 915.8 486.6 57.4
14 48.5
Out of service 193.1 686.6 686.6 193.1 439.9 838.3 439.9 41.5
In service 224.8 844.4 844.4 224.8 534.6 985.7 534.6 83.5
15 51.5
Out of service 204.7 771.1 771.1 204.7 487.9 944.8 487.9 31.0
In service 213.2 863.8 863.8 213.2 538.5 1013.4 538.5 63.7
16 54.5
Out of service 169.9 813.7 813.7 169.9 464.4 1038.4 464.4 0
In service 200.3 884.6 884.6 200.3 542.5 1043.0 542.5 41.9
17 57.5
Out of service 132.6 858.8 858.8 132.6 405.9 1171.2 405.9 0
In service 186.0 906.8 906.8 186.0 546.4 1074.9 546.4 17.9
18 60.5
Out of service 92.7 906.6 906.6 92.7 342.9 1312.8 342.9 0
86
Operation
of height
sections (m)
In service 143.1 591.3 591.3 143.1 367.2 687.4 367.2 47.0
7 27.5
Out of service 428.2 213.4 213.4 428.2 320.8 168.9 320.8 472.7
In service 139.0 603.2 603.2 139.0 371.1 703.4 371.1 38.7
8 30.5
Out of service 432.7 216.7 216.7 432.7 324.7 171.9 324.7 477.5
In service 156.1 638.0 638.0 156.1 397.1 742.9 397.1 51.2
9 33.5
Out of service 459.5 241.9 241.9 459.5 350.7 196.8 350.7 504.5
In service 150.4 651.6 651.6 150.4 401.0 761.4 401.0 40.5
10 36.5
Out of service 464.3 244.9 244.9 464.3 354.6 199.5 354.6 509.7
In service 166.0 688.0 688.0 166.0 427.0 803.3 427.0 50.6
11 39.5
Out of service 491.2 269.9 269.9 491.2 380.6 617.9 380.6 143.3
In service 158.6 703.2 703.2 158.6 430.9 824.4 430.9 37.3
12 42.5
Out of service 208.8 560.2 560.2 208.8 384.5 670 384.5 99.0
In service 172.4 741.3 741.3 172.4 456.8 869.0 456.8 44.6
13 45.5
Out of service 202.6 618.3 618.3 202.6 410.5 747.3 410.5 73.6
In service 185.1 780.5 780.5 185.1 482.8 915.2 482.8 50.4
14 48.5
Out of service 194.4 678.4 678.4 194.4 436.4 828.0 436.4 44.8
In service 218.9 842.8 842.8 218.9 530.8 985.0 530.8 76.6
15 51.5
Out of service 206.2 762.7 762.7 206.2 484.4 934.3 484.4 34.6
In service 207.3 862.2 862.2 207.3 534.8 1012.6 534.8 56.9
16 54.5
Out of service 171.6 805.2 805.2 171.6 464.9 1023.7 464.9 0
In service 194.5 882.8 882.8 194.5 538.7 1042.1 538.7 35.3
17 57.5
Out of service 134.5 850 850 134.5 406.7 1155.8 406.7 0
In service 180.3 904.9 904.9 180.3 542.6 1073.7 542.6 11.4
18 60.5
Out of service 94.9 897.5 897.5 94.9 344.1 1296.6 344.1 0
87
Operation
of height
sections (m)
In service 137.4 600.9 600.9 137.4 369.1 700.2 369.1 38.1
7 27.5
Out of service 428.9 216.3 216.3 428.9 322.6 172.2 322.6 472.9
In service 133.2 612.9 612.9 133.2 373.1 716.4 373.1 29.7
8 30.5
Out of service 433.4 219.5 219.5 433.4 326.5 175.2 326.5 477.8
In service 150.2 647.9 647.9 150.2 399.0 756.0 399.0 42.0
9 33.5
Out of service 460.2 244.8 244.8 460.2 352.5 200.1 352.5 504.8
In service 144.3 661.6 661.6 144.3 402.9 774.8 402.9 31.1
10 36.5
Out of service 465.0 247.8 247.8 465.0 356.4 202.8 356.4 509.9
In service 159.7 698.1 698.1 159.7 428.9 816.9 428.9 41.0
11 39.5
Out of service 491.9 272.8 272.8 491.9 382.4 621.3 382.4 143.4
In service 152.2 713.5 713.5 152.2 432.8 838.3 432.8 27.4
12 42.5
Out of service 209.4 563.2 563.2 209.4 386.3 673.5 386.3 99.1
In service 165.7 751.9 751.9 165.7 458.8 883.2 458.8 34.5
13 45.5
Out of service 203.2 621.3 621.3 203.2 412.2 750.9 412.2 73.6
In service 178.3 791.3 791.3 178.3 484.8 929.6 484.8 39.9
14 48.5
Out of service 194.9 681.5 681.5 194.9 438.2 831.6 438.2 44.8
In service 211.8 853.8 853.8 211.8 532.8 999.8 532.8 65.8
15 51.5
Out of service 206.6 765.8 765.8 206.6 486.2 938.0 486.2 34.5
In service 199.9 873.5 873.5 199.9 536.7 1027.8 536.7 45.6
16 54.5
Out of service 171.9 808.4 808.4 171.9 466.4 1027.8 466.4 0
In service 186.8 894.5 894.5 186.8 540.6 1057.8 540.6 23.5
17 57.5
Out of service 134.8 853.3 853.3 134.8 408.0 1160.2 408.0 0
In service 172.2 916.9 916.9 0 544.6 1089.9 544.6 0
18 60.5
Out of service 95.0 901.0 901.0 95.0 345.3 1301.3 345.3 0
88
Operation
of height
sections (m)
In service 141.8 591.6 591.6 141.8 366.7 688.0 366.7 45.4
7 27.5
Out of service 437.5 203.2 203.2 437.5 320.4 154.7 320.4 486.1
In service 137.7 603.5 603.5 137.7 370.6 704.1 370.6 37.2
8 30.5
Out of service 442.1 206.4 206.4 442.1 324.3 157.6 324.3 491.0
In service 154.8 638.4 638.4 154.8 396.6 743.5 396.6 49.7
9 33.5
Out of service 468.9 231.6 231.6 468.9 350.3 182.4 350.3 518.1
In service 149.1 651.9 651.9 149.1 400.5 762.1 400.5 38.9
10 36.5
Out of service 473.8 234.6 234.6 473.8 354.2 185.0 354.2 523.3
In service 164.7 688.3 688.3 164.7 426.5 804.0 426.5 49.0
11 39.5
Out of service 500.8 259.5 259.5 500.8 380.1 209.5 380.1 550.8
In service 157.3 703.5 703.5 157.3 430.4 825.1 430.4 35.7
12 42.5
Out of service 505.9 262.2 262.2 505.9 384.1 655.0 384.1 113.2
In service 171.1 741.7 741.7 171.1 456.4 869.7 456.4 43.0
13 45.5
Out of service 212.7 607.4 607.4 212.7 410 732.1 410 88.0
In service 183.8 780.8 780.8 183.8 482.3 915.9 482.3 48.8
14 48.5
Out of service 204.6 667.4 667.4 204.6 436.0 812.5 436.0 59.5
In service 217.6 843.1 843.1 217.6 530.4 985.7 530.4 75.0
15 51.5
Out of service 216.6 751.5 751.5 216.6 484.0 918.5 484.0 49.5
In service 206.1 862.5 862.5 206.1 534.3 1013.3 534.3 55.3
16 54.5
Out of service 182.2 793.7 793.7 182.2 479.6 992.5 479.6 0
In service 193.2 883.2 883.2 193.2 538.2 1042.8 538.2 33.6
17 57.5
Out of service 145.4 838.4 838.4 145.4 421.7 1124.0 421.7 0
In service 179.0 905.2 905.2 179.0 542.1 1074.4 542.1 9.8
18 60.5
Out of service 105.9 885.6 885.6 105.9 359.5 1264.0 359.5 0
89
Operation
of height
sections (m)
In service 143.1 589.2 589.2 143.1 366.2 684.9 366.2 47.4
7 27.5
Out of service 446.8 192.9 192.9 446.8 319.9 140.4 319.9 499.4
In service 139.0 601.1 601.1 139.0 370.1 700.9 370.1 39.2
8 30.5
Out of service 451.5 196.1 196.1 451.5 323.8 143.2 323.8 504.4
In service 156.2 635.9 635.9 156.2 396.1 740.3 396.1 51.8
9 33.5
Out of service 478.3 221.2 221.2 478.3 349.8 167.9 349.8 531.6
In service 150.5 649.4 649.4 150.5 400 758.9 400 41.1
10 36.5
Out of service 483.3 224.1 224.1 483.3 353.7 170.4 353.7 536.9
In service 166.1 685.8 685.8 166.1 425.9 800.7 425.9 51.2
11 39.5
Out of service 510.4 248.9 248.9 510.4 379.7 194.8 379.7 564.5
In service 158.8 701.0 701.0 158.8 429.9 821.7 429.9 38.0
12 42.5
Out of service 515.6 251.5 251.5 515.6 383.6 196.9 383.6 570.3
In service 172.6 739.1 739.1 172.6 455.8 866.3 455.8 45.4
13 45.5
Out of service 222.6 596.5 596.5 222.6 409.5 716.8 409.5 102.3
In service 185.4 778.2 778.2 185.4 481.8 912.3 481.8 51.3
14 48.5
Out of service 214.8 656.2 656.2 214.8 435.5 797.0 435.5 74.0
In service 219.2 840.4 840.4 219.2 529.8 982.1 529.8 77.6
15 51.5
Out of service 226.9 740.2 740.2 226.9 483.5 902.8 483.5 64.3
In service 207.8 859.7 859.7 207.8 533.7 1009.5 533.7 58.0
16 54.5
Out of service 192.7 782.2 782.2 192.7 487.5 968.1 487.5 6.8
In service 195.0 880.3 880.3 195.0 537.7 1038.9 537.7 36.4
17 57.5
Out of service 156.1 826.6 826.6 156.1 436.7 1092.1 436.7 0
In service 180.9 902.3 902.3 180.9 541.6 1070.5 541.6 12.7
18 60.5
Out of service 117.0 873.6 873.6 117.0 374.8 1231.5 374.8 0
90
Operation
of height
sections (m)
In service 132.6 594.4 594.4 132.6 363.5 693.3 363.5 33.7
7 27.5
Out of service 442.2 192.7 192.7 442.2 317.4 141.0 317.4 493.8
In service 128.4 606.3 606.3 128.4 367.4 709.4 367.4 25.4
8 30.5
Out of service 446.8 195.9 195.9 446.8 321.3 143.9 321.3 498.8
In service 145.5 641.2 641.2 145.5 393.4 748.9 393.4 37.8
9 33.5
Out of service 473.6 221.0 221.0 473.6 347.3 168.7 347.3 526.0
In service 139.8 654.8 654.8 139.8 397.3 767.5 397.3 27.0
10 36.5
Out of service 478.5 223.9 223.9 478.5 351.2 171.2 351.2 531.3
In service 155.3 691.2 691.2 155.3 423.2 809.4 423.2 37.1
11 39.5
Out of service 505.6 248.8 248.8 505.6 377.2 195.6 377.2 558.8
In service 147.9 706.5 706.5 147.9 427.2 830.6 427.2 23.7
12 42.5
Out of service 510.8 251.5 251.5 510.8 381.1 640.6 381.1 121.6
In service 161.6 744.7 744.7 161.6 453.1 875.3 453.1 31.0
13 45.5
Out of service 217.9 596.3 596.3 217.9 407.1 717.5 407.1 96.7
In service 174.3 783.9 783.9 174.3 479.1 921.5 479.1 36.7
14 48.5
Out of service 210.1 656.0 656.0 210.1 433.1 797.7 433.1 68.4
In service 208.0 846.2 846.2 208.0 527.1 991.4 527.1 62.9
15 51.5
Out of service 222.2 739.9 739.9 222.2 481.1 903.4 481.1 58.7
In service 196.5 865.6 865.6 196.5 531.0 1019.0 531.0 43.1
16 54.5
Out of service 188.0 782.0 782.0 188.0 485.0 968.7 485.0 1.3
In service 183.6 886.3 886.3 183.6 535.0 1048.6 535.0 21.4
17 57.5
Out of service 151.5 826.4 826.4 151.5 428.8 1098.2 428.8 0
In service 169.4 908.4 908.4 0 538.9 1080.2 538.9 0
18 60.5
Out of service 112.4 873.3 873.3 112.4 367.0 1237.3 367.0 0
91
Operation
of height
sections (m)
In service 136.0 590.1 590.1 136.0 363.0 687.4 363.0 38.7
7 27.5
Out of service 449.2 184.9 184.9 449.2 317.0 130.2 317.0 503.9
In service 131.9 602.0 602.0 131.9 367.0 703.5 367.0 30.5
8 30.5
Out of service 453.9 188.0 188.0 453.9 321.0 133.0 321.0 508.9
In service 149.1 636.8 636.8 149.1 392.9 742.9 392.9 43.0
9 33.5
Out of service 480.7 213.1 213.1 480.7 346.9 157.7 346.9 536.2
In service 143.4 650.3 650.3 143.4 396.9 761.4 396.9 32.3
10 36.5
Out of service 485.7 216.0 216.0 485.7 350.8 160.2 350.8 541.5
In service 159.0 686.7 686.7 159.0 422.8 803.2 422.8 42.4
11 39.5
Out of service 512.8 240.8 240.8 512.8 376.8 184.5 376.8 569.2
In service 151.6 701.9 701.9 151.6 426.7 824.3 426.7 29.2
12 42.5
Out of service 518.1 243.4 243.4 518.1 380.7 186.5 380.7 574.9
In service 165.4 740 740 165.4 452.7 868.8 452.7 36.6
13 45.5
Out of service 545.5 267.9 267.9 545.5 406.7 705.9 406.7 107.5
In service 178.3 779.1 779.1 178.3 478.7 914.9 478.7 42.5
14 48.5
Out of service 217.7 647.6 647.6 217.7 432.7 786.0 432.7 79.4
In service 212.1 841.3 841.3 212.1 526.7 984.6 526.7 68.8
15 51.5
Out of service 230 731.4 731.4 230 480.7 891.5 480.7 69.9
In service 200.6 860.6 860.6 200.6 530.6 1012.1 530.6 49.2
16 54.5
Out of service 196.0 773.3 773.3 196.0 484.6 956.6 484.6 12.6
In service 187.9 881.2 881.2 187.9 534.5 1041.4 534.5 27.7
17 57.5
Out of service 159.6 817.5 817.5 159.6 440 1074.1 440 0
In service 173.8 903.1 903.1 173.8 538.5 1072.9 538.5 4.0
18 60.5
Out of service 120.7 864.2 864.2 120.7 378.5 1212.7 378.5 0
92
Operation
of height
sections (m)
In service 119.2 595.2 595.2 119.2 357.2 697.1 357.2 17.4
7 27.5
Out of service 438.7 184.8 184.8 438.7 311.8 132.2 311.8 491.3
In service 115.1 607.2 607.2 115.1 361.2 713.2 361.2 9.1
8 30.5
Out of service 443.4 188.0 188.0 443.4 315.7 135.1 315.7 496.3
In service 132.2 642.1 642.1 132.2 387.1 752.7 387.1 21.5
9 33.5
Out of service 470.2 213.1 213.1 470.2 341.6 159.9 341.6 523.4
In service 126.4 655.7 655.7 126.4 391.0 771.3 391.0 10.8
10 36.5
Out of service 475.0 216.1 216.1 475.0 345.6 162.4 345.6 528.7
In service 141.9 692.1 692.1 141.9 417.0 813.2 417.0 20.8
11 39.5
Out of service 502.1 241.0 241.0 502.1 371.5 186.9 371.5 556.2
In service 134.5 707.3 707.3 134.5 420.9 834.4 420.9 7.4
12 42.5
Out of service 507.2 243.7 243.7 507.2 375.5 189.1 375.5 561.8
In service 148.3 745.5 745.5 148.3 446.9 879.1 446.9 14.7
13 45.5
Out of service 214.8 588.0 588.0 214.8 401.4 708.1 401.4 94.7
In service 161.0 784.7 784.7 161.0 472.9 925.2 472.9 20.5
14 48.5
Out of service 207.1 647.7 647.7 207.1 427.4 788.1 427.4 66.6
In service 194.8 847.0 847.0 194.8 520.9 995.1 520.9 46.7
15 51.5
Out of service 219.4 731.4 731.4 219.4 475.4 893.6 475.4 57.2
In service 183.3 866.4 866.4 183.3 524.8 1022.6 524.8 27.1
16 54.5
Out of service 185.4 773.2 773.2 185.4 479.3 958.6 479.3 0
In service 170.5 887.0 887.0 170.5 528.7 1052.0 528.7 5.5
17 57.5
Out of service 149.1 817.4 817.4 149.1 422.3 1088.5 422.3 0
In service 156.3 909.0 909.0 0 532.7 1083.5 532.7 0
18 60.5
Out of service 110.3 864.1 864.1 110.3 361.0 1226.7 361.0 0
93
Operation
of height
sections (m)
In service 128.3 588.2 588.2 128.3 358.2 686.7 358.2 29.8
7 27.5
Out of service 447.8 177.6 177.6 447.8 312.7 121.6 312.7 503.7
In service 124.2 600.1 600.1 124.2 362.2 702.8 362.2 21.6
8 30.5
Out of service 452.5 180.7 180.7 452.5 316.6 124.5 316.6 508.7
In service 141.4 634.9 634.9 141.4 388.1 742.1 388.1 34.1
9 33.5
Out of service 479.3 205.8 205.8 479.3 342.6 149.2 342.6 536.0
In service 135.7 648.4 648.4 135.7 392.1 760.6 392.1 23.5
10 36.5
Out of service 484.3 208.7 208.7 484.3 346.5 151.6 346.5 541.3
In service 151.3 684.7 684.7 151.3 418.0 802.4 418.0 33.7
11 39.5
Out of service 511.4 233.5 233.5 511.4 372.5 175.9 372.5 569.0
In service 144.1 699.8 699.8 144.1 421.9 823.4 421.9 20.5
12 42.5
Out of service 516.6 236.1 236.1 516.6 376.4 178.0 376.4 574.7
In service 157.9 737.9 737.9 157.9 447.9 867.9 447.9 28.0
13 45.5
Out of service 544.1 260.6 260.6 544.1 402.3 696.9 402.3 107.8
In service 170.8 776.9 776.9 170.8 473.9 913.8 473.9 34.0
14 48.5
Out of service 216.8 639.8 639.8 216.8 428.3 776.7 428.3 79.9
In service 204.7 839.1 839.1 204.7 521.9 983.4 521.9 60.4
15 51.5
Out of service 229.2 723.5 723.5 229.2 476.3 882.0 476.3 70.6
In service 193.4 858.3 858.3 193.4 525.8 1010.7 525.8 41.0
16 54.5
Out of service 195.3 765.2 765.2 195.3 480.3 946.9 480.3 13.6
In service 180.8 878.7 878.7 180.8 529.7 1039.9 529.7 19.6
17 57.5
Out of service 159.1 809.2 809.2 159.1 437.0 1062.8 437.0 0
In service 166.9 900.5 900.5 0 533.7 1071.1 533.7 0
18 60.5
Out of service 120.5 855.7 855.7 120.5 375.9 1200.6 375.9 0
94
Operation
of height
sections (m)
In service 127.9 581.7 581.7 127.9 354.8 679.0 354.8 30.6
7 27.5
Out of service 445.5 173.6 173.6 445.5 309.5 117.3 309.5 501.8
In service 123.9 593.6 593.6 123.9 358.7 694.9 358.7 22.5
8 30.5
Out of service 450.1 176.8 176.8 450.1 313.5 120.2 313.5 506.8
In service 141.1 628.3 628.3 141.1 384.7 734.2 384.7 35.2
9 33.5
Out of service 477.0 201.9 201.9 477.0 339.4 144.9 339.4 534.0
In service 135.6 641.7 641.7 135.6 388.6 752.5 388.6 24.7
10 36.5
Out of service 481.9 204.8 204.8 481.9 343.4 147.4 343.4 539.3
In service 151.3 677.9 677.9 151.3 414.6 794.1 414.6 35.0
11 39.5
Out of service 509.0 229.6 229.6 509.0 369.3 171.7 369.3 566.9
In service 144.1 692.9 692.9 144.1 418.5 815.0 418.5 22.0
12 42.5
Out of service 514.3 232.2 232.2 514.3 373.2 173.8 373.2 572.7
In service 158.2 730.8 730.8 158.2 444.5 859.2 444.5 29.7
13 45.5
Out of service 541.7 256.8 256.8 541.7 399.2 692.3 399.2 106.1
In service 171.2 769.7 769.7 171.2 470.4 905.0 470.4 35.9
14 48.5
Out of service 214.7 635.7 635.7 214.7 425.2 772.1 425.2 78.3
In service 205.3 831.6 831.6 205.3 518.5 974.3 518.5 62.6
15 51.5
Out of service 227.2 719.2 719.2 227.2 473.2 877.3 473.2 69.1
In service 194.2 850.6 850.6 194.2 522.4 1001.3 522.4 43.5
16 54.5
Out of service 193.4 760.8 760.8 193.4 477.1 941.9 477.1 12.3
In service 181.8 870.8 870.8 181.8 526.3 1030.1 526.3 22.5
17 57.5
Out of service 157.3 804.8 804.8 157.3 432.7 1058.8 432.7 0
In service 168.2 892.3 892.3 0 530.2 1060.9 530.2 0
18 60.5
Out of service 118.8 851.1 851.1 118.8 371.9 1196.1 371.9 0
95
Operation
of height
sections (m)
In service 123.0 577.7 577.7 123.0 350.3 675.1 350.3 25.6
7 27.5
Out of service 436.1 174.9 174.9 436.1 305.5 120.8 305.5 490.2
In service 119.0 589.5 589.5 119.0 354.3 691.0 354.3 17.5
8 30.5
Out of service 440.7 178.1 178.1 440.7 309.4 123.7 309.4 495.1
In service 136.3 624.1 624.1 136.3 380.2 730.2 380.2 30.3
9 33.5
Out of service 467.5 203.2 203.2 467.5 335.4 148.5 335.4 522.3
In service 130.8 637.5 637.5 130.8 384.1 748.5 384.1 19.8
10 36.5
Out of service 472.4 206.2 206.2 472.4 339.3 151.1 339.3 527.5
In service 146.6 673.6 673.6 146.6 410.1 790 410.1 30.3
11 39.5
Out of service 499.4 231.1 231.1 499.4 365.3 175.5 365.3 555.0
In service 139.6 688.5 688.5 139.6 414.0 810.7 414.0 17.4
12 42.5
Out of service 504.5 233.8 233.8 504.5 369.2 177.7 369.2 560.6
In service 153.7 726.3 726.3 153.7 440 854.8 440 25.2
13 45.5
Out of service 531.9 258.4 258.4 531.9 395.1 696.0 395.1 94.3
In service 166.8 765.1 765.1 166.8 466.0 900.3 466.0 31.6
14 48.5
Out of service 205.1 637.1 637.1 205.1 421.1 775.8 421.1 66.5
In service 201.0 826.9 826.9 201.0 514.0 969.5 514.0 58.5
15 51.5
Out of service 217.6 720.7 720.7 217.6 469.1 881.0 469.1 57.3
In service 190.1 845.8 845.8 190.1 517.9 996.2 517.9 39.6
16 54.5
Out of service 183.8 762.3 762.3 183.8 473.1 945.6 473.1 0.5
In service 177.9 865.8 865.8 177.9 521.8 1024.8 521.8 18.9
17 57.5
Out of service 147.8 806.2 806.2 147.8 416.9 1074.1 416.9 0
In service 164.5 887.0 887.0 0 525.8 1055.3 525.8 0
18 60.5
Out of service 109.3 852.5 852.5 109.3 356.2 1211.3 356.2 0
96
Operation
of height
sections (m)
In service 113.4 568.3 568.3 113.4 340.8 665.7 340.8 15.9
7 27.5
Out of service 422.2 171.5 171.5 422.2 296.8 119.5 296.8 474.1
In service 109.5 580 580 109.5 344.7 681.5 344.7 8.0
8 30.5
Out of service 426.8 174.8 174.8 426.8 300.8 122.6 300.8 478.9
In service 126.9 614.5 614.5 126.9 370.7 720.5 370.7 20.9
9 33.5
Out of service 453.5 200 200 453.5 326.7 147.5 326.7 506.0
In service 121.6 627.7 627.7 121.6 374.6 738.6 374.6 10.7
10 36.5
Out of service 458.2 203.1 203.1 458.2 330.6 150.2 330.6 511.1
In service 137.5 663.7 663.7 137.5 400.6 779.9 400.6 21.4
11 39.5
Out of service 485.2 228.1 228.1 485.2 356.6 174.8 356.6 538.4
In service 130.7 678.4 678.4 130.7 404.5 800.3 404.5 8.8
12 42.5
Out of service 490.2 230.9 230.9 490.2 360.5 618.2 360.5 102.8
In service 145.0 716.0 716.0 145.0 430.5 844.1 430.5 16.9
13 45.5
Out of service 198.7 574.3 574.3 198.7 386.5 694.7 386.5 78.3
In service 158.4 754.5 754.5 158.4 456.5 889.3 456.5 23.7
14 48.5
Out of service 191.2 633.7 633.7 191.2 412.5 774.4 412.5 50.5
In service 192.9 816.0 816.0 192.9 504.5 958.0 504.5 51.0
15 51.5
Out of service 203.8 717.2 717.2 203.8 460.5 879.4 460.5 41.6
In service 182.3 834.5 834.5 182.3 508.4 984.2 508.4 32.6
16 54.5
Out of service 170.2 758.7 758.7 170.2 449.4 958.8 449.4 0
In service 170.6 854.1 854.1 170.6 512.3 1012.2 512.3 12.5
17 57.5
Out of service 134.3 802.4 802.4 134.3 393.1 1087.2 393.1 0
In service 157.6 874.9 874.9 0 516.2 1042.0 516.2 0
18 60.5
Out of service 96.1 848.4 848.4 96.1 332.8 1223.5 332.8 0
97
Operation
of height
sections (m)
In service 120.3 556.8 556.8 120.3 338.5 650.4 338.5 26.6
7 27.5
Out of service 424.1 165.4 165.4 424.1 294.7 111.8 294.7 477.7
In service 116.5 568.4 568.4 116.5 342.4 666.0 342.4 18.8
8 30.5
Out of service 428.7 168.6 168.6 428.7 298.6 114.8 298.6 482.5
In service 134.0 602.8 602.8 134.0 368.4 704.9 368.4 31.9
9 33.5
Out of service 455.4 193.8 193.8 455.4 324.6 139.7 324.6 509.6
In service 128.8 615.8 615.8 128.8 372.3 722.7 372.3 21.9
10 36.5
Out of service 460.2 196.9 196.9 460.2 328.5 142.4 328.5 514.7
In service 145.0 651.6 651.6 145.0 398.3 763.8 398.3 32.8
11 39.5
Out of service 487.1 221.9 221.9 487.1 354.5 167.0 354.5 542.1
In service 138.3 666.2 666.2 138.3 402.2 783.9 402.2 20.5
12 42.5
Out of service 492.1 224.7 224.7 492.1 358.4 169.3 358.4 547.5
In service 152.8 703.5 703.5 152.8 428.2 827.4 428.2 29.0
13 45.5
Out of service 201.0 567.8 567.8 201.0 384.4 686.5 384.4 82.3
In service 166.5 741.8 741.8 166.5 454.1 872.2 454.1 36.1
14 48.5
Out of service 193.5 627.2 627.2 193.5 410.4 766.0 410.4 54.7
In service 201.3 803.1 803.1 201.3 502.2 940.6 502.2 63.8
15 51.5
Out of service 206.2 710.6 710.6 206.2 458.4 870.9 458.4 45.9
In service 191.0 821.2 821.2 191.0 506.1 966.4 506.1 45.8
16 54.5
Out of service 172.7 751.9 751.9 172.7 451.8 945.6 451.8 0
In service 179.5 840.5 840.5 179.5 510 993.9 510 26.2
17 57.5
Out of service 137.0 795.5 795.5 137.0 395.7 1073.6 395.7 0
In service 166.9 860.9 860.9 166.9 513.9 1023.2 513.9 4.7
18 60.5
Out of service 98.9 841.4 841.4 98.9 335.6 1209.4 335.6 0
98
Operation
of height
sections (m)
In service 125.5 551.3 551.3 125.5 338.4 642.8 338.4 34.0
7 27.5
Out of service 425.7 163.5 163.5 425.7 294.6 109.2 294.6 480.1
In service 121.8 562.9 562.9 121.8 342.3 658.3 342.3 26.3
8 30.5
Out of service 430.3 166.8 166.8 430.3 298.5 112.2 298.5 484.9
In service 139.4 597.2 597.2 139.4 368.3 697.1 368.3 39.5
9 33.5
Out of service 457.1 192.0 192.0 457.1 324.5 137.1 324.5 512.0
In service 134.2 610.2 610.2 134.2 372.2 714.8 372.2 29.6
10 36.5
Out of service 461.8 195.0 195.0 461.8 328.4 139.8 328.4 517.1
In service 150.4 645.9 645.9 150.4 398.2 755.7 398.2 40.6
11 39.5
Out of service 488.8 220 220 488.8 354.4 164.3 354.4 544.5
In service 143.8 660.4 660.4 143.8 402.1 775.8 402.1 28.4
12 42.5
Out of service 493.8 222.8 222.8 493.8 358.3 166.7 358.3 550
In service 158.5 697.7 697.7 158.5 428.1 819.1 428.1 37.0
13 45.5
Out of service 521.1 247.5 247.5 521.1 384.3 683.8 384.3 84.8
In service 172.3 735.8 735.8 172.3 454.0 863.8 454.0 44.3
14 48.5
Out of service 195.3 625.2 625.2 195.3 410.3 763.3 410.3 57.2
In service 207.2 797.0 797.0 207.2 502.1 932.0 502.1 72.1
15 51.5
Out of service 208.0 708.6 708.6 208.0 458.3 868.1 458.3 48.5
In service 197.0 815.0 815.0 197.0 506.0 957.6 506.0 54.4
16 54.5
Out of service 174.5 749.9 749.9 174.5 454.3 940.2 454.3 0
In service 185.7 834.1 834.1 185.7 509.9 984.9 509.9 34.9
17 57.5
Out of service 138.8 793.4 793.4 138.8 398.2 1068.0 398.2 0
In service 173.2 854.4 854.4 173.2 513.8 1014.0 513.8 13.7
18 60.5
Out of service 100.8 839.3 839.3 100.8 338.2 1203.7 338.2 0
99
Operation
of height
sections (m)
In service 120 548.4 548.4 120 334.2 640.4 334.2 28.0
7 27.5
Out of service 415.7 165.9 165.9 415.7 290.8 114.1 290.8 467.5
In service 116.3 559.9 559.9 116.3 338.1 655.9 338.1 20.3
8 30.5
Out of service 420.3 169.2 169.2 420.3 294.7 117.2 294.7 472.3
In service 133.9 594.2 594.2 133.9 364.1 694.6 364.1 33.6
9 33.5
Out of service 446.9 194.5 194.5 446.9 320.7 142.2 320.7 499.2
In service 128.8 607.2 607.2 128.8 368.0 712.3 368.0 23.7
10 36.5
Out of service 451.7 197.6 197.6 451.7 324.6 144.9 324.6 504.3
In service 145.1 642.9 642.9 145.1 394.0 753.1 394.0 34.8
11 39.5
Out of service 478.5 222.6 222.6 478.5 350.6 169.6 350.6 531.5
In service 138.6 657.2 657.2 138.6 397.9 773.1 397.9 22.7
12 42.5
Out of service 483.5 225.5 225.5 483.5 354.5 612.6 354.5 96.4
In service 153.3 694.5 694.5 153.3 423.9 816.3 423.9 31.4
13 45.5
Out of service 192.5 568.5 568.5 192.5 380.5 689.0 380.5 71.9
In service 167.1 732.5 732.5 167.1 449.8 860.9 449.8 38.8
14 48.5
Out of service 185.0 627.9 627.9 185.0 406.4 768.5 406.4 44.4
In service 202.1 793.6 793.6 202.1 497.9 928.9 497.9 66.8
15 51.5
Out of service 197.7 711.2 711.2 197.7 454.5 873.3 454.5 35.6
In service 192.1 811.5 811.5 192.1 501.8 954.4 501.8 49.2
16 54.5
Out of service 164.2 752.5 752.5 164.2 437.6 958.3 437.6 0
In service 180.9 830.5 830.5 180.9 505.7 981.5 505.7 29.9
17 57.5
Out of service 128.6 796.0 796.0 128.6 381.6 1086.0 381.6 0
In service 168.6 850.6 850.6 168.6 509.6 1010.3 509.6 8.9
18 60.5
Out of service 90.6 841.9 841.9 90.6 321.7 1221.5 321.7 0
100
3.5 Auxiliary lifting equipment

3.5.1 General notes
The minimum characteristics of the auxiliary lifting equipment are determined by:
◼ The hoisting height of the jib
◼ The weight of the jib
◼ A minimum radius of 10 m from the slewing axis of the auxiliary of the auxiliary lifting
equipment.
3.5.2 Hook height

The hook height of height of the auxiliary lifting equipment (H1) is equal to the hook height (H2)
of the crane to be erected plus X m depending on the packages.
The H2 height is given with respect to the ground support level of the crane.
If the auxiliary lifting equipment does not work at the same level as the
erection area of the crane, or due to special site conditions, adjust the
height and the radius to determine correctly the characteristics of the
auxiliary lifting equipment.
H1 must not be obtained in the upper limit switch position of the auxiliary lifting equipment.
101
3.5.2.1 Erection by means of a mobile crane

The crane is completely erected to its free-standing height by means of the mobile of the mobile
crane.
3.5.2.2 Erection by telescoping

A. Mounting of the telescopic cage using the auxiliary lifting equipment
The crane is erected by means of the auxiliary lifting equipment at low height. Then the
telescopic cage is fitted onto the mast from above before mounting the slewing crane part. The
free-standing height is reached by telescoping of 3.0m mast sections with lugs.
B. Fitting the telescopic cage by means of the crane

The crane is erected by means of the auxiliary lifting at low height.
Add at least one additional mast section by means of the auxiliary lifting
equipment so that the telescopic cage can be fitted by means of the
crane.
Then the telescopic cage is fitted into the mast from the side by means of the crane. The free-
standing height is reached by telescoping 3.0m mast sections with lugs. Adjust the
characteristic of the mobile crane height accordingly.
102
3.6 Identification
3.6.1 General notes
The assembly of the jibs and counter−jibs depends on good visual identification of the main
components.
The following paragraphs give details about the lengths of the counter−jibs with respect
to the jibs as well as the position and the fitting of the wind−sail plates.
Pay particularly attention to the pins of which the various types are made of
high−strength steel. They must be compulsorily used in the position provided for
this purpose.
Before assembling the sections, carry out a visual check of the bars and
welds. Sections which show deformations or having the bars distorted or
the welds cracked, must be returned to the workshop for repairing.
3.6.2 Identification the counter-jib
2 4 5
3
6 7
8 9
Fig. 3-2 Counter-jib

(1) Counter-ballast (2) Derrick
(3) Hoist gear (4) Hoist rope
(5) Counter-jib tie rod (6) Rear jib-section
(7) Front jib-section (8) Platform
(9) Handrail
103
3.6.3 Identification of the jib sections
1 2 3 4 5 6 7 8 9 10
11
16
12
13
14
15
Fig. 3-3 Jib assembly

(1) Jib Ⅰ(jib foot) (2) Jib Ⅱ
(3) Jib Ⅲ (4) Jib Ⅳ
(5) Jib Ⅴ (6) Jib Ⅵ
(7) Jib Ⅶ (8) Jib Ⅷ
(9) Jib Ⅸ (10) Jib end
(11) Pulley assembly (12) Trolley travel gear
(13) Trolley (14) Hook assembly
(15) Trolley travel rope (16) Catwalk
104
3.6.3.1 Jib Ⅰ
1
4 5 6
7 8
Fig. 3-4 Jib Ⅰ

(1) Upper chord (2) Support bar
(3) Left bottom chord (4) Anti-collision block
(5) Right bottom chord (6) Incline diagonal
(7) Walkway (8) Horizontal diagonal
3.6.3.2 Jib tip
Fig. 3-5 Jib tip

(1) Warning light seat (2) Anti-twist device
105
3.6.4 Jib composition
① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨⑩
No. ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩
Code
000261705AT001000
000261705AT002000
000261705AT003000
000261705AT004000
000261705AT005000
000261705AT006000
000261705AT007000
000261705AT008000
000261705AT009000
000281705AT001000
Length
70m ● ● ● ● ● ● ● ● ● ●
67.5m ● ● ● ● ● ● ● ○ ● ●
65m ● ● ● ● ● ● ○ ● ● ●
62.5m ● ● ● ● ● ● ○ ○ ● ●
60m ● ● ● ● ● ● ● ● ○ ●
57.5m ● ● ● ● ● ● ● ○ ○ ●
55m ● ● ● ● ● ● ○ ● ○ ●
52.5m ● ● ● ● ● ● ○ ○ ○ ●
50 m ● ● ● ● ○ ● ○ ○ ○ ●
47.5 m ● ● ● ● ● ○ ● ○ ○ ●
45m ● ● ● ● ● ○ ○ ● ○ ●
42.5 m ● ● ● ● ● ○ ○ ○ ○ ●
40 m ● ● ● ● ○ ○ ○ ○ ○ ●
37.5 m ● ● ○ ● ● ○ ● ○ ○ ●
35m ● ● ○ ● ○ ○ ● ○ ○ ●
32.5 m ● ● ○ ● ● ○ ○ ○ ○ ●
30 m ● ● ○ ● ○ ○ ○ ○ ○ ●
Part length 10m 10m 10m 10m 2.5m 10m 5m 2.5m 10m /
106
3.7 Data sheet

3.7.1 Hoist rope
DATA SHEET – HOIST ROPE

Rope identification 1090101164 (35×7-16-1870)
Maximum Load 35kN
Minimum breaking load 172kN
Construction 35Wx7
Number of external wires 7
Core： Steel core
Rope diameter 16mm
Strength of wire 1870MPa
Diameter of external wires /
Stranding:
sZ(Right-hand regular lay) sZ
zZ(Right-hand langs lay)
Twist coefficient /
Weight per meter 1.18
107
3.7.2 Trolley rope
DATA SHEET – TROLLEY ROPE

Rope identification 1090100080 (6×19-9.3-1700-Ⅱ-Right)
Maximum load 12.1kN
Minimum breaking load 46.495kN
Construction 6×19
Number of external wires 6
Core： Steel core
Rope diameter 9.3
Strength of wire 1700MPa
Diameter of external wires /
Stranding:
sZ(Right-hand regular lay) sZ
zZ(Right-hand langs lay)
Twist coefficient \
Weight per meter 0.3045
Hoist rope is configured as rotary resistance rope. Hoist rope and trolley rope
must comply with relevant provisions of GB/T20118. In addition, the following
requirements must be met: (D is the theoretical diameter of the rope)
◼ The minimum breaking tension of the hoist rope is not less than 132kN, and the trolley
rope minimum breaking tension of the variable amplitude rope is not less 46.495KN;
◼ For the hoist rope and the trolley rope, the diameter of any section is between 1.02d and
1.04d. The noncircular error is within 0.03d.
◼ Anti-torsion performance of hoist rope is not more than 360°.
◼ The lateral pressure stability of the hoist rope and trolley rope is not more than 0.01d.
◼ The diameter shrinkage of the hoist rope and trolley rope is not more than 0.01d.
108
3.7.3 Data sheet of hook
Hook identification 000209605A2102200

Model number 8
Class P
Length (L) 734 mm
Nominal diameter (D) 110 mm
Weight 72kg
Greasing yes
Passage with hook safety path (Pal) 85mm
Dimension h 100 mm
Dimension e 100 mm
109
3.8 Counter-jib ballast

3.8.1 General notes
The counter−jib ballast comprises several reinforced concrete blocks. Their combination allows
the different weights to be obtained, which are proper to each jib length used. There are three
types: The PHZ3000N, PHZ2500L, PHZ1300G blocks, weight 3000 kg, 2500 kg and 1300 kg;
they are directly placed on the counter−jib.
3.8.2 Configuration
Jib-length PHZ3000N PHZ2500L PHZ1300G Total weight(t)
70 m 7 1 0 23.5
67.5 m 7 1 0 23.5
65 m 7 0 1 22.3
62.5 m 6 1 1 21.8
60 m 6 1 1 21.8
57.5 m 6 1 1 21.8
55 m 6 1 1 21.8
52.5 m 7 0 0 21.0
50 m 6 1 0 20.5
47.5 m 6 0 1 19.3
45 m 6 0 1 19.3
42.5 m 5 1 1 18.8
40 m 5 1 0 17.5
37.5 m 5 0 0 15.0
35 m 4 1 0 14.5
32.5 m 4 1 0 14.5
30 m 4 0 1 13.3
3.8.3 Fabrication
The ballast blocks must be carried out according to the following drawings. It is recommended
to observe the outer dimensions of the blocks and the functional dimensions, especially the
position of the suspension holes, the position of the raising device and its dimensions.
The reinforcement of the blocks including the raising device will be determined and carried out
by the crane user to avoid the crumbling and dislocation of the blocks when handling and during
crane work.
110
3.8.3.1 Weight tolerance

All the counter weights are cast with reinforced concrete. For detailed specification, refer to Fig.
3-6, Fig. 3-7, Fig. 3-8. Respectively, for spare parts layout, see Table 3-35, Table 3-36, and
Table 3-37.
◼ It is advised to use steel mould to cast the concrete counter weight to assure
the dimension of it and the flatness of every surface.
◼ It is advised to weigh every counter weight manufactured and engrave the
weight permanently on the surface, with permitted weight tolerance of ±1％
and concrete grade is no less than C20 (recommended C25). It must be
pounded firmly and the curing time should be more than 14 days.
◼ The dimensions can be changed according to the density (average density)
of reinforced concrete for the tolerance. The density will change with the
change of distribution of reinforced bar in counter weight.
◼ In this manual, the outline size of counter weight for this tower crane is
designed according to the concrete design density which is based on the
theoretical value of 2400 kg/m3.
◼ Customers can also design counter weight themselves. Make sure the
width, thickness and dimensions of counter weight is right to hang, you can
adjust the length to appropriate value.
3.8.3.2 Steel
Es: Longitudinal modulus of elasticity of steel: 200000 N/mm2 i.e. 200000MPa
Type 1: Reinforcement with high adherence obtained by hot−rolling of natural high−carbon steel.
Quality: Fe E 40 i.e. fe=400MPa
If the above rules are not applicable, refer to the rules applied in the user
country.
111
3.8.3.3 Preparing the block PHZ3000N
◼ WEIGHT = 3000 kg ± 2% − Average density of reinforced concrete: C20

◼ Dimensions in cm-General tolerance: ±1cm except
112
Fig. 3-6 Counter weight PHZ3000N
Table 3-35 Spare part list of PHZ3000N
No. Designation Specification Qty Material Remarks
1 Angle Steel L40×4-940 4 Q235B

3 Fixed Plate t8 4 Q235B
4 Rebar Φ14 6 HPB300
7 Ear Board t16 1 Q235B
8 Round Steel Φ30-950 1 Q345B
9 Angle Steel L40×4 4 Q235B
11 Concrete 1
113
3.8.3.4 Preparing the block PHZ2500L

◼ Dimensions in cm-General tolerance: ±1cm except
114
Fig. 3-7 Counter weight PHZ2500L
Table 3-36 Spare part list of PHZ2500L

11 Concrete 1
115
3.8.3.5 Preparing the block PHZ1300G

◼ Dimensions in cm-General tolerance: ±1cm except.
116
Fig. 3-8 Counter weight PHZ1300G
Table 3-37 Spare part list of PHZ1300G

11 Concrete 1
117
3.9 Central ballast

Chassis stationary and travelling tower crane need configure central ballast.
3.9.1 Configuration
The tower crane has two types of central ballast: YZ3900(3.9t) and YZ4500(4.5t).
Table 3-38 Central ballast configuration for different height
Number of sections Working height /m

Weight/t YZ3900 Qty YZ4500 Qty
(Exclude chassis) Chassis Travelling
1+3 18.5 19.5 15.6 4 0
1+4 21.5 22.5 15.6 4 0
1+5 24.5 25.5 15.6 4 0
1+6 27.5 28.5 15.6 4 0
1+7 30.5 31.5 15.6 4 0
1+8 33.5 34.5 15.6 4 0
1+9 36.5 37.5 24.6 4 2
1+10 39.5 40.5 42.6 4 6
1+11 42.5 43.5 51.6 4 8
1+12 45.5 46.5 69.6 4 12
1+13 48.5 49.5 87.6 4 16
1+14 51.5 52.5 105.6 4 20
1+15 54.5 55.5 105.6 4 20
1+16 57.5 58.5 105.6 4 20
1+17 60.5 61.5 105.6 4 20
118
3.9.2 Making
All the central ballasts are cast with reinforced concrete. For detailed specification, refer to Fig.
3-9 and Fig. 3-10, the spare parts see Table 3-39 and Table 3-40.
In this Operation Manual, the central ballasts detailed specification shall be design according
to theoretical value 2400kg/m3. In the production process, the density is different from this, so
the dimension of the pressure thickness direction can be adjusted accordingly to maintain the
same weight.
It is advised to weigh every central ballasts manufactured and engrave the weight permanently
on the surface, with permitted weight tolerance of ±2％and concrete grade is no less than C25.
It must be pounded firmly and the curing time should be more than 14 days.
3.9.2.1 Center Ballast YZ4500

◼ The perron, which supports the whole weight of the centre ballast, must be made
smoothing.
◼ The No.2,5,9,12,15,18,21,24 are below reinforements, they have the same diameter Φ16.
The No.1,4,8,11,14,17,20,23 are upper reinforements, they have the same diameter Φ12.
Don't mistake using.
◼ The concrete strength is C30. Stamped concrete, the curing period of the counter-weight
must not be less than 14 days after pouring.
◼ The positions of the locating perron(140x140x50) and the locating hole (180x180x50) must
be correct.
119
120
121
122
Fig. 3-9 Center Ballast YZ4500
123
Table 3-39 Spare parts of Center Ballast YZ4500

No. Designation Specification Qty Material
1 Reinforcement Φ12-3500 1 HPB235
2 Below reinforcement Φ16-3550 1 HPB235
3 Hooped reinforcement (1) Φ6-3100 2 HPB235
6 Additional reinforcement Φ6-3520 2 HPB235
12 Below reinforcement Φ20-2150 2 Q235B
13 Hooped reinforcement (4) 1 C30
124
3.9.2.2 Center Ballast YZ3900

◼ The perron, which width and depth is 380×20mm, supports the whole weight of the ballast,
and must be made smoothing.
◼ The concrete strength is C30. Stamped concrete, the curing period of the Ballast must not
be less than 14 days after pouring.
◼ The positions of the locating perron(140×140×50) and the locating hole(180×180×50) must
be correct.
125
126
Fig. 3-10 Center Ballast YZ3900
127
Table 3-40 Spare parts of Center Ballast YZ3900

No. Designation Specification Qty Material
1 Concrete 1 C30
2 Additional reinforcement (1) Φ16-1100 2 HPB235
4 Upper reinforcement (1) Φ12-5916 7 HPB235
5 Below reinforcement (1) Φ18-6120 7 HPB235
6 Hooped reinforcement Φ6-2820 24 HPB235
8 Below reinforcement (2) Φ18-300 2 HPB235
12 Lifting ear Φ20-1950 2 Q235B
128
3.10 Foundation
3.10.1 Embedded Outrigger
3.10.1.1 Calculation of stationary foundation
◼ Calculate of eccentricity
Fig. 3-11 Load of foundation

As Fig. 3-11, the stability condition of tower crane as the following:
M+H∗h L
𝑒= ≤
V+G 3
In the formula:
e-eccentricity, that is the distance between the resultant ground reaction and the base
center, m;
G—the gravity of the concrete foundation, kN.
129
◼ Calculation of earth bearing pressure

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

The ground foundation is the precondition to ensure safe operation of the crane. It is made of
reinforced concrete as shown in Fig. 3-12. Basic requirements are shown as follows:
◼ Excavate a trench to hard formation until the ground bearing pressure accords with the
value in the following table, and make the bottom level. And then backfill and tamp 100mm
gravel stratum. After making formwork or laying bricks for the side walls, pour concrete into
pre-made reinforced rod net. The concrete block surface should be 100mm higher than
neighboring ground for the drainage of storm water, then removal the formwork and backfill
the neighboring ground with gravels.
◼ The depth of the concrete cover of the main reinforcement is 40mm. Fix the embedded
anchors on the locating reinforcement bar and make sure that the verticality of the
embedded anchors centerlines and horizontal plane is less than 1.5/1000. Concrete filling
rate around the embedded anchors must be over 95%.
◼ The concrete strength grade shall be no less than C35. The curing duration of concrete is
more than 15 days.
◼ If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside, but
must not be reduced or cut off.
◼ NO.6 which must drive 1.5m into the ground. Not connected with the steel reinforcement
of the building foundations.
◼ The NO.10 is insulated copper cable with at least 16mm.
◼ This foundation is supposed to be applied for WA7025-12E tower crane with the standard
free-standing height of 60m and for WA7025-12E tower crane which is attached to the
building and in accordance with the requirement in the user's manual. The load on the
foundation can be found in the user's manual. The load-bearing capacity of the foundation,
the dimension L of the foundation and the layout of the reinforcement are all designed in
accordance with the standard FEM. The foundation can be produced under instruction of
the following table, the adjustment according to the actual situation is also allowed:
130
Main Main Ground Concrete Qty.

a Weight
L reinforcement reinforcement resistance volume of
(mm) (t)
A B (MPa) (m3) No.5
Lengthwise Lengthwise
7000 and crosswise: and crosswise: 6920 0.20 78.4 188.2 324
35×Ф25 35×Ф25
7500 and crosswise: and crosswise: 7420 0.16 90 216 361
35×Ф25 38×Ф25
8000 and crosswise: and crosswise: 7920 0.13 102.4 246 400
40×Ф25 40×Ф25
If the modified bearing capacity of foundation is less than 0.1 MPa, the
pile foundation must be adopted. The pile foundation can also be
adopted, when the block foundation cannot be produced as above due
to the size limitation or other inevitable reasons.
131
132
Fig. 3-12 The foundation for embedded outrigger tower crane
Table 3-41 Spare part list of embedded outrigger crane foundation
No. Description Specification Qty Material Remarks
1 Main Reinforcement A Φ25 70 HRB400
2 Main Reinforcement B Φ25 70 HRB400
3 Reinforcement Bar Φ12-1720 324 HPB300

4 Locating Reinforcement Bar Φ25-3050 8 HRB400
5 Concrete 1 C35
6 Earthing Rod 1 Weldment
7 Bolt M12×40-8.8 1
8 Washer 12 1 65Mn
9 Nut M12-8 1
10 Earthing Cable 1
133
3.10.2 Foundation for chassis

Be left vacant for the time being.
3.10.3 Foundation for the travelling crane

◼ The ground foundation must be tamped solid, its bearing pressure must be larger than
0.2MPa;
◼ During working, users should check the track on time: The distance error of 2 tracks is less
than ±5mm; Track height error in the same section is less than 5mm; The longitudinal error
of the track height is less than 1/1000, The total height error is less than 10mm.
◼ The joints of two tracks should be staggered upon 1500mm.
◼ The buffer stop must be set at the end of the track according to the specific situation of
building site, the buffer for the travel limit switch must be set on the site shown in the
drawing, travel limit test should be done in advance to ensure its safety in the process of
working.
◼ The rails must be earthed at both ends. If the rail track is more than 20m long, additional
earthing points should be installed every 20 meters. If there are no other earthing devices
available one earthing rod which must be driven at least 1.5m into the ground will suffice
for each point. The earth resistance must be less than 4Ω.
◼ There must be placed a connection link between two rails.
◼ The account in the specification sheet is counted base on the track which is 100m.
◼ The degree of finish of the machining face is .The degree of finish of the machining
hole is .
◼ The length of cable is the distance which from the fixed point to the further track end plus
15m.
◼ Setting 4 anchoring boards outside of the rail track. The boards are used for fixing the
crane when the wind speed is higher;
◼ Manufacturing and locating method of the board are shown in the drawing to the drawing,
the
◼ location of the equipment based on the practical situation; the user can also take some
other
◼ effective and safe methods to anchor;
◼ The main reinforcements on the drawing are twisted steel (HRB335), the hoop
reinforcements are twisted steel (HPB235).
134
135
136
Fig. 3-13 The foundation for travelling crane
137
Table 3-42 Spare part list of travelling crane foundation

No. Description Specification Qty Material
1 Rail 50kg/m 16 U71Mn
2 Press plate 804 Q235B
3 Fishplate 28 B7
4 Base plate t20-240×340 368 Q235B
5 Bolt M24×160-8.8 84
6 Nut M24-10 168
7 Washer 24-200HV 168
8 Bumper Φ20 4 Q235B
9 Base plate t10-260×350 4 Q235B
10 Slip bumper 4 Weldment
11 Stop bumper 4 Weldment
12 Embedded bolt M20-8.8 804
13 Nut M20-8 1608
14 Washer 20-200HV 804
15 Channel steel [16a-6340 17 Weldment
16 Plate t20 804 Q235B
17 Ear plate t24 4 Q235B
18 Plate A t20-50×130 16 Q235B
19 Plate B t20-130×130 4 Q235B
138
3.11 Power supply

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

Results from the starting power.
Nominal Nominal
Mechanism Frequency Type of mechanism
power in kW intensity at A
Hoisting
50Hz H45FP30-600P 45 82
mechanism
Trolley
50Hz BP55B 5.5 11.6
mechanism
Slewing S75CA-130LB12/14A
50Hz 2*7.5 34.6
mechanism S75CN-130LB12/14A
139
3.11.2 Current supply

3.11.2.1 Characteristic of the site power supply
The electrical installations on cranes are subjected to very strict

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

A distributing box after the voltage-meter, which has built-in automatic breakers and leakage
protection device, which is adjustable, to turn off the circuit.
The distributing box, included in tower crane electrical system should configure multistage
switch. The switch can be locked at off-location, in order to maintenance or dealing with
accident.
3.11.2.2 Grounding
Installing grounding wire should accord with current standards, which requires:
➢ Metal parts’ grounding;
➢ Track’s grounding.
All the grounding parts should be connected, the connection of the grounding circuit should be
checking in period.
The grounding wire is yellow-green, which connects the “grounding” terminal of metal parts to
grounding plugs or grid. The method of grounding sees also in relative introductions of
mechanism parts, the grounding resistance should not more than 4 ohms.
◼ It’s forbidden to replace the grounding wires with neutral wires.
◼ The grounding wires should be conducted, and isolated from any
breaker.
140
3.11.2.3 Power source cable

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

A. Power
The power of the source is determined by capacity of all mechanism, speed controlling manner
and working condition (With load or without load start-up).
B. Characteristic of supply voltage
◼ According to our technical specification, the supply voltage at the crane switch must be:
50 Hz in Europe
maximum voltage without load: 400 V + 6% (i.e. between 400 V and 420 V)
minimum voltage with load: 400 V - 10% (i.e. between 360 V and 400 V)
◼ The minimum voltage depends on:
the voltage supplied by the supply source with load,
the voltage drops in the supply cable,
the cable cross- section (the thicker the cable is, the lower the voltage drop will be),
the type of the cable (aluminum or copper),
the cable length between the supply source and the crane switch,
the current surge when starting the crane.
Choosing a cable cross-section
As a first approach, a cable cross- section is accepted if the current density which is passing
through is lower than 4 amperes per 𝑚𝑚2 .
Example: Current intensity of the crane 50 amperes:
50
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑐𝑎𝑏𝑙𝑒 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 = = 12.5𝑚𝑚2
4
◼ Take the cable cross- section (in the “Cable cross- section” column of the table below) which
is equal or slightly bigger, i.e. 3 x 16 mm2 + N (neutral)+T (earth)
141
Copper Cables
voltage drop per kilometer per ampere, V/(km·A)
No. Cable cross- section
(cos ϕ = 0,8)
1 3 x 6 mm2+ N+T 6.00
2 3 x 10 mm2+ N+T 3.50
3 3 x 16 mm2+ N+T 2.20
4 3 x 25 mm2+ N+T 1.50
5 3 x 35 mm2+ N+T 1.10
6 3 x 50 mm2+ N+T 0.77
7 3 x 70 mm2+ N+T 0.57
8 3 x 95 mm2+ N+T 0.46
9 3 x 120 mm2+ N+T 0.38
10 3 x 150 mm2+ N+T 0.32
11 3 x 185 mm2+ N+T 0.28
12 3 x 240 mm2+ N+T 0.23
C. Determining the coefficient of the voltage drop

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

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑒𝑛𝑔𝑡ℎ =
𝑐𝑜𝑒𝑓𝑓.× 𝐼𝑑
with:
30 V: permissible voltage drop,
Voltage drop: depending on the cable cross- section,
Id: starting current intensity.
142
Example:
2
1. For a cable of 3 x 16 mm + N (neutral)+T (earth), the coefficient is of 2,2
2. With a starting current intensity of 190A

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

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

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

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

Having connected the crane to the mains, operate a” Lowering” pulse on the control unit or with
the jib retaining winch for GTMR and HDT cranes which are equipped with a LVF hoist winch;
check that the rope slackens.
◼ If yes, the direction of rotation is correct
◼ If not, interchange two wires in the plug or in the circuit breaker of the mains supply.
143
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E
4 ERECTION/ADJUSTMENT/DISMANTLING
4.1 Foreword
This part comprises the instructions allowing the fitter in charge with the crane installation on the site
to:
◼ erect the crane,

◼ carry out the adjustments,
◼ dismantle the crane.
According to the method applicable to the configuration(s) defined on the order.
The erection and dismantling operations of the crane must be ABSOLUTELY CARRIED OUT
in the indicated order.
This part does not comprise instructions concerning special operations.
These last operations can only be carried out by the constructor or his representative.
This part cannot be separated from the whole document: it can only be used after reading the
SAFETY INSTRUCTION (part 2 of this document) and TECHNICAL DATA OF CRANE AND
SITE (part 3 of this document).
144
WA7025-12E ERECTION/ADJUSTMENT/DISMANTLING
4.2 Note on safety regarding erection

The operating mode defined below allows fast and safe assembling of the crane up to its
telescoping or working position (complete erection by means of a mobile crane).
The erection operations need an auxiliary lifting equipment of which the characteristics must be
adapted to the parts to be handled.
AUXILIARY LIFTING EQUIPMENT
The optimization of the operating time of the mobile crane needs a good preparation and a
good coordination between the various erection and assembling sequences, the fitter teams,
the access possibilities, and the assembling area.
This document aims to familiarize yourself with the whole erection operations of which each
one is detailed in the specific files.
4.2.1 Erection instructions

◼ These instructions concern:
➢ The erection of the crane
➢ The increase in height of the crane
➢ The dismantling of the crane
◼ All the handling operations must be carried out according to the instructions of this manual.
and especially:
➢ Ensure the correct supports of the loads
➢ Do not work with overload
➢ Use slings in perfect condition and dimensioned for the weight of the elements to be
handled.
➢ Observe the slinging points
The erection operations can only be carried out with the wind speed below 50 km/h.
The erection operations must be carried out in the order indicated in this manual.
During the preparing steps compulsorily fit the safety equipment such as ladders, platforms,
grab rails, guard ropes, etc. in order to use them during the erection.
Any hoisting operation is absolutely forbidden if the counter−jib ballast is

not placed.
COMPOSITION OF THE COUNTER−JIB BALLAST
145
FITTING THE COUNTER−JIB BALLAST BLOCKS
➢ For cranes on chassis and cross−shaped base, the ballast placed must correspond to the
hook height to be reached. In case of partial ballasting, the partial ballast must correspond
to the erection height of the crane, but must never be lower than the indicated minimum
value.
CHASSIS − BALLAST AND REACTIONS

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

In order to ensure their pin locking function correctly, this split pin type must be fitted by opening
both split pin legs and not only the longest one (Detail B).
It is not compulsory to fold down the legs against the pin; It is sufficient to fold down each leg
according to an angle a, depending on the split pin diameter (detail C and table below). This
limited opening makes the split pin removal easier when dismantling the crane pins.
Nevertheless, it is necessary to check that the legs are not running the risk of abutting against
obstacles, what may lead to their deformation, and even their deterioration in case of shaft rotation.
In order to avoid this disadvantage, it may be necessary to fold the legs completely (Detail D).
146
Only use new split pins or split pins in good working order.
4.2.3 Fitting the high-strength bolt

The preload of the high-strength bolt according to the GBT 13752 / Edition 09 / 2017 standard.
The preload of the high-strength bolt must be aligned with the data in the
following Table 4-1
Table 4-1 Preload of high-strength bolt

Yield
Strength of Preload F1kN
Performance point
extension
race Rel
Rm N/mm2 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39
N/mm2
8.8 ≥800 ≥640 70 86 110 135 158 205 250 310 366 437
10.9 ≥1000 ≥900 99 120 155 190 223 290 354 437 515 615
12.9 ≥1200 ≥1080 119 145 185 229 267 347 424 525 618 738
Calculate the effective area of the

157 192 245 303 353 459 561 494 817 976
bolt
Note: the preload value in the table is calculated as 0.7 Rel, in which Rel take the minimum value in each
gear.
147
4.2.4 The diagram of erection

◼ Chassis
➢ Installing the bogies
➢ Fit the chassis and place the ballast.
◼ Outrigger stationary foundation and one base mast section
◼ The climbing frame assembly (include tower section, climbing frame, mounting device and
transition section)
◼ The slewing assembly (include turntable, slewing ring, slewing support, slewing
mechanisms, cabin, electrical control cabinet and electric resistance cabinet)
◼ The counter-jib assembly (include hoisting mechanism and tie bar).
148
◼ The first 3t counter ballast
◼ Jib assembly (include trolley and trolley mechanism)
◼ The remainder counter ballast, electrical control system, the hoist rope and climbing
operation
◼ The installation orders based on produces standard packing and delivery

status to make the optimal efficiency installation principle
◼ The installing of each unit assembly all based on the actual requirement. In
accordance with reasonable order to install in turns after dismantling. If you
have any questions, please consult our service staff.
149
4.3 Installing the tower section and climbing frame
assembly
4.3.1 Tower section
4.3.1.1 Tower section (Rung ladder)
◼ Base tower section
There are four groups of vertical pin shaft connection holes at the top and below surfaces of
the base tower section, the top pin hole is Φ55, the below pin hole is Φ65. (shown as Fig. 4-1)
Fig. 4-1 Embedded bolts base tower section L68G23
All the tower section is unitary which connected and assembled with special
bolts.
150
◼ Tower section
Tower section L68A4 is a piece structure, each piece is assembled by dedicated bolts, the top
and he below pin hole is Φ55; Tower section L68A4 ((shown as Fig. 4-2) can also be substituted
for L68B6.
Fig. 4-2 L68A4
Tower section L68B7 is a piece structure, each piece is assembled by bolts, the top pin hole is
Φ55, the below pin hole is Φ65. (shown as Fig. 4-3)
Fig. 4-3 L68B7
151
Every Tower Section is equipped with channels, flat roof and ladders for human’s resting and
pass. The channels have D、A two types (as shown in Fig. 4-4).The installation of Tower Section
and channel has been done on the ground and they must be used relatively. All elbow ladders
should be installed on the side leaf of jacking pedestal. According to the height of tower body,
the bottom tower section must install Channel A, the remaining channels A and channels D
alternate installation in turn.
Fig. 4-4 Passageway H and Passageway J
152
4.3.1.2 Tower section (Incline ladder)

◼ Base tower section
There are four groups of vertical pin shaft connection holes at the top and below surfaces of
the base tower section L68G21A, the top pin hole is Φ55, the below pin hole is Φ60. (shown as
Fig. 4-5).
Fig. 4-5 Base tower section L68G21A
153
◼ Tower section
Tower section L68A1A is a piece structure, each piece is assembled by bolts, the top and below
pin hole are Φ55 (see Fig. 4-6); Tower section L68A1A can also be substituted for L68B1A
(seeFig. 4-7).
Fig. 4-6 L68A1A
Fig. 4-7 L68B1A
Tower section L68B2A (use for chassis stationary) is a piece structure, each piece assembles
by special bolts, the top pin hole is Φ55, and below pin hole is Φ65. (see Fig. 4-8)
Fig. 4-8 L68B2A
154
4.3.2 Climbing system

4.3.2.1 Climbing frame
The climbing system consists of the structure, platform, ladders, cylinder, climbing beam, pump
station and so on, shown in Fig. 4-9. The installation of platform and rail see “SPARE PARTS
“chapters.
Fig. 4-9 Climbing system

(1) Upper platform (2) Climbing frame structure
(3) Middle-level platform (4) Cylinder, pump station
(5) Climbing beam
4.3.2.2 Transition tower section

According to the picture, mounting the platform、short ladder and ladder Ⅱ, assemble the
transition tower section
Fig. 4-10 Transition tower section assembly
155
4.3.2.3 Mounting device
Fig. 4-11 Assemble mounting device

(1) Transition tower section (2) Mounting device
(3) Platform
4.3.2.4 Assembling the Climbing unit
Fig. 4-12 Installation scheme 1 of Climbing unit

(1) Transition tower section (2) Climbing frame
(3) Base tower section (4) Cylinder, pump station
(5) Climbing beam
156
Fig. 4-13 Installation scheme 2 of Climbing unit

(1) Platform (2) Transition tower section
(3) Mounting device (4) Climbing frame
(5) Base tower section (6) Cylinder, pump station
(7) Climbing beam
4.3.3 Installing
1) Assembly two tower sections;
2) Installing Transition tower section:
➢ Sling the transition tower section on the tower section, align the opening direction of the
platform in the transition tower section to the tower section, then descend slowly. It
connected with climbing frame;
3) Installing climbing frame (Include climbing beam and cylinder):
➢ Assembly climbing frame (The tower mast and climbing unit assembly had been
assembled as our company require, users only need to install the accessories such as
platforms and rails);
➢ Climbing frame slowly mounting at the outside of tower mast, the location of cylinder must
align the tower mast (same side);
➢ Climbing frame contact with transition section through 4 sets Φ50 pins;
➢ Put the hang plate on the upper latch of the tower section.
157
Fig. 4-14 Installing the Climbing unit

(1) Outrigger stationary foundation (2) Outrigger
(3) Climbing unit
In order to ascend and descend the tower crane successfully, please

ensure that the tower has a step plane perpendicular to the building.
158
The base tower section and the climbing lug must be aligned.
Sling the Climbing unit, fixed it on the outrigger with 8 sets Φ65-203 pins as shown in Fig. 4-15.
Check the mast verticality through theodolite or lifting line method. The verticality error of four
side of main chord rod shall be not more than 1.5/1000.
Fig. 4-16 Pin connection
◼ The roller is adjustable. When the crane is working, adjust the gap
between the climbing frame guide wheel and the main chord of the
tower section to the widest state; when the crane is heightening,
adjust the gap to 1~3mm.
◼ Installing the climbing hydraulic cylinder, the pump station is hoisted
on the lower platform. The oil pipe is installed. To avoid cylinder
burning-out, please check in the pump station. Make sure that the
motor fan is aligned with the direction of the label. If there is any
error, you should reconnect the motor cable;
◼ Make sure that the cylinder and the mast latch should be on the
same side. The mounting platform is opposite to the mast latch of
the tower.
◼ Put the climbing claws on the lugs of tower section
◼ The large free-standing height of M tower mast shall be lowered the
climbing frame to the ground or reduce the use of off-working.
159
4.4 Installing the slewing assembly

4.4.1 Description
The main parts of slewing assembly had assembled following our company require, users only
install the Platform and rail, etc.
The slewing assembly consists of turntable, slewing ring, slewing support, slewing mechanisms,
cabin, and electrical control cabinet, as shown in Fig. 4-17. The selection of high-strength bolt
for turntable and slewing ring, slewing support, and slewing ring refer to chapter 4.3.
Fig. 4-17 Slewing assembly

(1) Electrical control cabinet (2) Resistance cabinet
(3) Turntable (4) Slewing ring
(5) Slewing support (6) Slewing mechanisms
(7) Cabin
160
CAUTIONS:
◼ Bolt pair for slewing ring
➢ The high-strength bolts and the preload torque see the chapter 4.2.3.
➢ Use flat washers which need hardening and tempering. Spring washers could not be
used.
◼ Installation of bolt pair for slewing ring
➢ Before installing, clean the erecting datum plane of slewing ring and the erecting plane of
yoke, and wipe off wet fouling, burr, paint, and other foreign impurity.
➢ During installing, the sign “S” and the hole with steel ball blocking should be placed less
under load area or no-load area (That is, the slewing ring near the installation place).
Fig. 4-18 Soft belt of the slewing ring
➢ Screw down the high-strength bolts in the direction of 180° symmetrically and continuously.
Make sure the preload moments are equal in screw bolts at the last time.
Fig. 4-19 The sequence of screwing down bolts
◼ Lubrication and maintenance
➢ Add grease into slewing ring regularly. Shorten the period of greasing in special working
condition such as in tropic, big humidity, too much dust and big range of temperature
changing. Add enough new grease before and after tower crane out of working over a long
period.
➢ Check the preload moment of bolts when slewing ring is in service for 100 hours. Then
check it once more after every 500 hours working time, ensuring there is enough preload.
➢ Do not sluice slewing ring by water for fear that water get in.
161
4.4.2 Installing slewing assembly

Align 4 main chords of the slewing ring support to 4 main chords connecting sleeve of transition
section. Let them down slowly to keep slewing support contact with the transition section, as
shown in figure below. Connect it to the transition section by 8 sets Ф55 pins.
Fig. 4-20 Installing slewing assembly
4.5 Mounting the counter-jib

4.5.1 Description
Counter-jib consists of front-counter jib, rear-counter jib, hoisting mechanism, derrick and
counter-jib strut (the short strut fixed on the front-counter jib, installing with counter jib
section).The front-counter jib connected with turntable by 4 sets Ф70 pins, as shown in Fig.
4-21.
Fig. 4-21 Counter-jib assembly
162
4.5.2 Assemble the front-counter jib

Before sling front-counter jib, each short strut connect to front-counter jib by 1 sets Ф50×90/130
pin, the installation as following picture.
Fig. 4-22 The front-counter jib
4.5.3 Assemble the counter-jib

The front-counter jib connect to turntable by 4 sets Ф70×335 pins, pay attention to washer
between the bottom chord rod of counter jib and split pin to avoid the pin scrape bottom chord
rod while the tower crane in service.
Fig. 4-23 Assemble the counter-jib
163
4.5.4 Assemble the rear-counter jib

Before sling the rear-counter jib, in addition to install the platform、rail、derrick and hoisting
mechanism, and also necessary to install the counter-jib strut, as the following picture. The
mechanism can be sling together or separately.
The main parts of counter-jib (including the strut and hoisting mechanism) assembly had
assembled following our company require, users only install the Platform and rail, etc.
Fig. 4-24 Assemble the rear-counter jib
4.5.5 Sling the rear-counter jib

Before sling, slewing the upper of the tower crane to convenient install the counter jib
section Ⅱ position, and then sling rear-counter jib by the 4 ear-plate on jib, as show in the
following picture.
Fig. 4-25 Sling the rear-counter jib

Use 2 sets Ф55×100/150 pin connect bottom chord of counter jib section Ⅱ to bottom chord
of counter jib section Ⅰ through pin holes tie-in, and then sling the jib section slowly to make
it turn around lower chord pin, fixed the long and short strut by Ф50×90/130 pin, as show in the
following picture.
164
Fig. 4-26 Sling the rear-counter jib

Finally, put the rear-counter jib down slowly, and then finish the installation.
4.5.6 Installing the one 3.0 t counter weight
Fig. 4-27 Installing one 3.0t counter weight

◼ The counter weight is placed by hoisting mechanism, positioned at the
middle of left and right, the distance between the two sides of counter jib
and the side chords is uniform.
◼ The pins of counter weight must beyond the support plate of the counter
weight.
165
4.6 Installing the jib assembly

4.6.1 Assemble jib
The jib assembly consists of the jib structure, trolley mechanism and trolley.
1) When assembling the jib, it should obey the sequence mark on each section, the
misplacement as well as the free assembly are not allowed. Due to the work
specification, the jib can have different length, such as70m, 67.5 m, 65m, 62.5m, 60m,
57.5m, 55m, 52.5m、50m、47.5m、45m、42.5m、40m、37.5m、35m、32.5m and 30m
◼ Different jib length and relation of jib order serial number and jib structure identifier
see chapter 3.6.4 Dimensions of the slewing crane part.
◼ Several brackets with a length of about 1.2m are prepared near the tower crane the length
of jib above 50m shall not be less than 4, and that below 50m shall not be less than 3).
Each jib is connecting with the upper chord by a pivot, and two pivots are connecting with
the bottom chord. Assemble jib sections except jib Ⅰ, as show in Fig. 4-28.
Fig. 4-28 Assembling jib
The assembling sequence must be strictly according to the sign on each

jib section, assembling in wrong sequence or assembling optionally are
not allowed.
The trolley mechanism motor is on the opposite side of the driver’s cab.
◼ The jib pin dimensions
166
Table 4-2 A pivot is used to connect the upper and bottom chord of each adjacent jib
Upper chord pin Bottom chord pin
Position
D [mm] L0 [mm] L [mm] D [mm] L0 [mm] L [mm]
Jib① & Jib② Ф100 290 370 Ф80 201 255
Jib② & Jib③ Ф80 270 335 Ф70 177 220
Jib③ & Jib④ Ф80 240 305 Ф70 160 205
Jib④ & Jib⑤ Φ60 200 260
Jib⑤ & Jib⑥ Φ60 190 250 Ф60 143 190
Jib⑥ & Jib⑦ Φ60 170 230
Jib⑦& Jib⑧
Jib⑧& Jib⑨ Φ60 130 190 Ф60 121 170
Jib⑨& Jib⑩
2) Trolley mechanism from the side before loading jib section Ⅱ, as shown in Fig. 4-29.
Fig. 4-29 Installing auxiliary mechanism
3) Jib sectionⅠ installation connected to jib assembly section, and then remove the auxiliary
mechanism to the jib sectionⅠroots and fixed, as shown in Fig. 4-30 Installing jib section
Ⅰ.
Fig. 4-30 Installing jib section Ⅰ

No matter how long the jib is assembled, the auxiliary mechanism should
be fixed on the guide rail of the bottom chord of the jib to prevent sliding.
The two lug ropes (the short and long ropes) are connecting with auxiliary
mechanism through the root pulley and tip pulley respectively, and then
the length of the rope is tensioned respectively.
167
Fig. 4-31 Trolley wire rope layout plan

(1) c Root jib pulley (2) Trolley mechanism drum
(3) Trolley (4) Jib’s rope wheel
(5) Tip pulley (6) Short ropes
(7) Long ropes
◼ The short and long ropes of luffing mechanism must have three
circles of safety rope on the drum under any circumstances, and a
circle of isolation rope should be left on the drum.
◼ When changing the length of jib, the excess rope is tied and fixed to
the trolley.
4.6.2 Installing jib

1) Operating the slewing mechanism and make it running or use the crank of slewing
mechanism to rotate the upper structure of tower crane to the position where the jib can
be conveniently installed.
2) According to the center of gravity of the jib assembly of each jib length to hang the rope,
as shown in Fig. 4-32 and Table 4-3.Try to test the sling point whether balanced, otherwise
the position of the hanging rope can be moved appropriately. The distance between the
two sling points is 8m≤d≤20m.
Fig. 4-32 Reference center of gravity of jib

Table 4-3 Reference center of gravity of jib with different lengths
Jib length/m 70 67.5 65 62.5 60 57.5 55 52.5 50
L/m 23.9 23.3 22.6 22.0 21.9 21.4 20.9 20.3 19.4
G/t 12.7 12.4 12.3 12.0 12.1 11.9 11.7 11.5 11.1
Jib length/m 47.5 45 42.5 40 37.5 35 32.5 30 /
L/m 18.6 17.2 17.7 16.7 14.9 14.1 14.0 13.1 /
G/t 10.8 11.2 10.4 10.1 9.1 8.7 8.7 8.3 /
168
◼ The above data are for reference and can be adjusted according to
the actual situation on site.
◼ Record the place of hoisting point for the dismantling use.
◼ Hoisting jib by rope, as shown in Fig. 4-33 Notice about hoisting jib,
the methods of A, B, D are right, while the methods of C is wrong.
◼ Forbid pulling aslant when hoisting jib assembly, as shown in Fig.
4-33 Notice about hoisting jib.
◼ In order to reduce the volume and weight of the jib assembly, or
reduce degree of difficulty in the installation of air jib assembly and
can be installed the counter jib after the completion of any link first
installed jib Ⅰ section , but this may need to be done in the air
luffing rope an tension.
Fig. 4-33 Notice about hoisting jib
3) Lift the jib assembly to mounting height, as shown in Fig. 4-34. Connected the jib with
tower mast by one Ф110×330/435 pin and two 90×250/320 pins
Fig. 4-34 Installing the jib assembly
169
4.7 Installing the counter-ballast

The counter-ballast block according to chapter 4.11. And the other counter-ballast, as shown in
Table 4-4 Installing the counter-ballast.
Table 4-4 Installing the counter-ballast
(rear→front) 8 counter-ballast
Jib length
Installed counter The other counter-ballast
70m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t
67.5m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t
65m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 1.3t
62.5m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t 1.3t
60m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t 1.3t
57.5m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t 1.3t
55m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t 1.3t
52.5m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t /
50m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t /
47.5m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 1.3t /
45m 3.0t 3.0t 3.0t 3.0t 3.0t 3.0t 1.3t /
42.5m 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t 1.3t /
40m 3.0t 3.0t 3.0t 3.0t 3.0t 2.5t / /
37.5m 3.0t 3.0t 3.0t 3.0t 3.0t / / /
35m 3.0t 3.0t 3.0t 3.0t 2.5t / / /
32.5m 3.0t 3.0t 3.0t 3.0t 2.5t / / /
30m 3.0t 3.0t 3.0t 3.0t 1.3t / / /
After install all the counter-ballast, please check carefully and make sure
that all the cotter weight are fixed stable and properly supported on the
counter-jib, to avoid falling of the counter-ballast due to the shaking of the
tower crane during work, which may cause heavy loss of personnel and
property.
170
4.8 Installing the electrical control system

After installing jib assembly, cabin, mechanism, and safe control devices could be debugged
by wiring. Except overload limiter, trolley mechanism and other safe control devices, other
electrical control system can be wiring and install on the counter jib.
The installation position of warning lights and anemometer, located in Fig. 4-35
Fig. 4-35 Warning light and anemometer

(1) c Warning light (2) Anemometer
171
4.9 Circling the hoist rope

◼ Moving the trolley to the jib root. It is placed below the trolley that the support is made by
customer self. The hook is fixed vertically.
◼ As shown in Fig. 4-36, the hoisting ropes are released from the wire rope drum, passing
through the rope discharging mechanism to go over the guide pulley on Jib I down into the
pulley of hook weight limiter in the slewing tower. It runs further to the trolley and hook
pulley block.
Fig. 4-36 The drawing of wind hoisting rope

(1) c Drum (2) Over load limiter
(3) Root pulley (4) Trolley
(5) Hook (6) Anti-twist device
◼ Use two clips to fix the hoisting rope to the proper position on the trolley, leaving a margin
of not less than 1.2m.
◼ Remove the wedge from the anti-twist device of the jib tip, tie the end of the hoisting rope
with soft rope, as shown in Fig. 4-37, and then make it rewind and secure with the fixing
rope clamp.
Fig. 4-37 The drawing of rope fixing

(1) c Wire (2) Hoisting rope
(3) Wedge
172
◼ Slowly start the hoisting mechanism. Hoist the hook to a height of 1 meter above the
ground, and make sure that the hoisting rope has been fixed firmly.
◼ Start the luffing mechanism to open the trolley and hook to the hoisting tip jib.
◼ Fix the wedge at the tip jib anti-twisting device. Slowly lower the trolley to the support below
the tip jib. And dismantle the rope clamp that fixed the hoisting the trolley, and loosen the
hoisting rope.
◼ When hoisting ropes are non-rotating ones, the anti-twist device

shall lock tightly the locking screws 3 and 5 (see Fig. 4-38) while the
tower crane is in service.
◼ When hoist ropes are anti-rotation ones, the anti-twist device shall
unlock the locking screws when the crane is in service.
◼ When using new ropes, the hook will rotate at no-load operation.
Currently, unlock the anti-twist device.
◼ After long time using of tower crane, the wire ropes will be extended
and slightly twisted, in this case, unlock the anti-twist device
temporarily, and lock the device again when ropes have been
tensioned.
◼ Once rope has their strands loosened, the anti-twist device will
accelerate rope deterioration, so should change the deteriorated
ropes timely.
Fig. 4-38 Anti-twist device

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

Switch on power to all electrical circuits according to the electric circuit diagram and start all
mechanisms for test run. Check mechanism for proper operations. At the same time, check wire
ropes at different locations for normal working and for any interference with structure member.
Remove all abnormal cases.
173
4.10 Fall-changing system

The fall-changing system is a pendulum system that consists a pulley assembly, when the
device is connected to the hook, the whole system is 4-fall, when the device is off from the hook
and stay at the below surface of trolley, the whole system is 2-fall. As shown in Fig. 4-39.
Fig. 4-39 The schema of the fall-changing system

(1) c Trolley (2) Upper pulley assembly
(3) Lower pulley assembly
The fall-change is converted at the jib root section under the conditions of no-load, slow speed
and no swing. No matter how it is required to convert 2-fall to 4-fall or to convert 4-fall to 2-fall,
the by-pass switch must at first be turned to the by-pass status to disable the height limiter.
After conversion completion, the by-pass switch must be restored to its original status.
When needing the 2-fall, manipulate the climbing system, the hook moves towards the ground,
pull out the pivot, start the climbing system again, let the pendulum system arise for it contacts
the trolley. When needing the 4-fall, let the hook move towards the ground, put the pivot back.
If the hoisting rope is converted to 4-fall, the hoisting rope mechanism is manipulated again,
the hook is lowered to ground, and the hanging body falls back the groove of the hook. Insert
the pin and split pin, and the split pin fully open. Debugging Referring to the chapter 6
Advise for Fall- changing about the height of tower crane over free-standing height: to avoid 4-
fall change to 2-fall occur collide the top and the top hung body of hook do not fall on the ground,
we advise consumer change fall on the floor or platform of climbing frame.
Please adjust the safety device before starting to use the tower crane.
174
4.11 Climbing operation

4.11.1 Pre-jacking preparation
◼ Fill the oil tank with hydraulic oil according to the requirements of hydraulic pump station.
Make sure of the electric motor circuit correctly connected and the fan rotates clockwise
and the operating lever of hand control valve working smoothly without any clogging.
◼ Set up each tower section with correct order and grease its connection pinholes. Place in
row the tower sections to be jacked just under the jib before jacking. This will enable no
slewing mechanism in the whole process of jacking operation for adding sections, thus
minimize the jacking time.
◼ Release the power cable slightly in excess of the total jacking height, and then fix the cable.
◼ Before jack-up, please random distribution of 4 core cable (one side is four phase plugs,
other is four loose thread (include 1 ground PE)) to the jacking pumping station terminal
blocks, and then insert the plug into the master four phase of tank wall socket. At the time,
switch the jacking operation switch of drive box cup cabinet door to ON status. Right now,
slewing the trolley limiter to first gear. At the time, you can through the operation of the
hydraulic pump station to handle the jacking operation.
◼ Slew the jib to the front of the climbing frame and the counter-jib at the rear of climbing
frame (jacking cylinder is just under the counter-jib).
◼ On the platform of the climbing frame, prepare the pins tower mast pins.
4.11.2 General Notices of Climbing Operation

◼ Keep the crane rotation part in balance.
◼ It is prohibited to operate the jacking system when the wind speed at the highest spot
exceeding 14m/s.
◼ Make sure that the climbing system works normally before climbing.
◼ It is prohibited to hoist load (up or down) while the jacking system is in operation or after
jacking.
◼ Adjust the roller gab at 1~3mm before climbing operation, then adjust the gap at maximum
after climbing finish
◼ It is prohibited to move the trolley while the jacking system is in operation or after jacking.
◼ Keep the jib in the same direction as the in-let tower section during jacking operation. Stop
the jib with the slewing mechanism brake and be sure of the trolley stopping at the jack-
balanced position.
◼ If several tower sections are to be added in succession, the main chord rods and slewing
ring support of the lower body must be connected by 8 Φ55 pins without shoulder after
adding one section and before hoisting the next section. Only in this case can 8 Φ55
shoulder-free pins be permitted for use.
◼ Keep the climbing lugs on the newly added tower section in alignment with those on the
existed section.
◼ It is prohibited to slew, change work-radius and hoist load without connection of the slewing
175
ring support to the tower body by 8 Φ55 shoulder-free pins.

◼ When the height has reached the demanded work height (not exceeded the independent
height), slewing the jib at different angles, check all the connections of the tower crane,
including the embedded bolts (if one main chord is below the counter jib, then fasten all
the nuts, the above-mentioned connection is all double nut to prevent loosening).
Please strictly operate the tower crane according to the operation

instructions for the climbing process is most likely to have grave
accidents.
4.11.3 Keep the tower crane in balance before climbing

Before keeping the tower crane in balance, hoisting device of the tower section and mounting
device must connect through 4 sets shackle, and then hoist the hoisting device and mounting
device of special hook, and put on the mounting beam of transition section (Show in Fig. 4-40).
Move the trolley to the reference balance position, show in Table 4-5. Hoist one tower section
or other weights (The trolley position in table is an approximate value, which must be adjusted
according to the actual situation in jacking), and then dismantling the pins between the transition
section and tower section.
Fig. 4-40 Keep the crane in balance

(1) c Platform (2) Tower section
Table 4-6 Reference balance position of different lengths of jib

Jib length Weight G Radius L Jib length Weight G Radius L
(m) (t) (m) (m) (t) (m)
70 1.61 22.8 47.5 1.61 37.7
67.5 1.61 27.9 45 1.61 41.2
65 1.61 25.7 42.5 1.61×2 26.0
62.5 1.61 22.3 40 1.61×2 24.9
60 1.61 27.4 37.5 1.61×2 24.4
57.5 1.61 40.0 35 1.61×2 25.7
55 1.61 36.4 32.5 1.61×2 26.2
52.5 1.61 35.8 30 1.61×2 24.8
50 1.61 39.7 / / /
176
CAUTIONS:
◼ These values are based on approximate figures only, which must be adjusted according
to the actual situation in jacking.
The balance weight above is according to the weight of tower section L68A4/L68A1
without passageways, when the tower sections are L68A1A/ L68B1A/ L68B1, the
balance position must change accordingly.
◼ Make the top structure of the tower crane at the slewing-braking state by active the brake
of the slewing mechanism. Slewing movement is not allowed.
◼ Pushing the operation handle of the hydraulic jacking system to “Jacking direction”, extract
the oil cylinder to jack the hang plate into groove near the tower section’ climbing lug, insert
the safety pin, continue to extract the oil cylinder to jack the climbing frame to a position
where the transition section is just disengaged from the main chord rod of the tower body.
◼ Check the support leg and tower body main chord rod connect the transition section and
tower sections to make sure that they are in the same vertical line. Check 8 guide rollers
and tower body main chord rod to make sure that they have the same clearance. This
serves to determine whether the tower crane is in balance. If not, adjust the balance
position of the trolley until balance is achieved to drop the center of gravity of the upper
tower crane onto the position of jacking cylinder beams.
◼ Record the balance position of trolley. Note: This value varies with the jib length.
◼ Operate the operation handle of the hydraulic system to fall the climbing equipment.
Connect the pivots between the transition tower section and tower section.
4.11.4 Climbing operation

1) First, hoist the climbing device, and install it to the mounting beam. Then hoist a tower
section, move the trolley to balance position according to the Table 4-6.
2) Use the brake on the slewing mechanism to hold the tower superstructure at a slewing
braking status, thus ensuring no slewing movements. Dismantle 4 group pins connecting
the tower head to the transition section.
3) Start up the hydraulic system to extrude the oil cylinder, lift the hanging plate into the slots
of the group of lugs of one tower section at the shortest distance (Check the jacking beam
whether in the round groove). Insert safety pins, ensuring without error, jack the climbing
frame and the parts above it for 10~50 mm and then stop. Check the hanging beam and
climbing frame and similar power transmission parts for abnormal noise and deformation.
Check the oil cylinder for automatic retraction and similar abnormal incidents. In case of
OK confirmed, continue to jack (see Fig. 4-41).
A special person is required to be at the lower platform and observe

whether the hanging plate is hung in the lug slots and inserting-pulling
safety pins.
177
Fig. 4-41 Climbing process

(1) c Jacking rod (2) Jacking cylinder
(3) Jacking hang plate (4) Jacking beam
4) Jack the climbing frames for about the height of a little more than 1/2 tower section and
position the climbing frame until jacking rod is above the climbing lug, automatic reset.
Stop jacking and retract the oil cylinder to let the rod down onto the lug of jacking beam.
5) Confirm that the two Jacking rod lay on the top of climbing lugs and bear the weights of
climbing frame and the upper part without any strange sound and deformation, retract the
oil cylinder completely, hoist jacking beam, put the hang plate into jacking beam circle
groove again, insert safe pins.
6) Extrude the oil cylinder again to jack the upper structure of the tower crane for about the
height of a little more than 1/2 tower section, thus there is a space for a tower mast, retract
the oil cylinder slightly, align the new introduced tower section on the upper tower head,
use 4 pins to connect each long fish-plate pin holes, and then each short fish-plate pin
holes connect ed by 4 pins, install the locking pin to connect firmly the upper and below
tower sections.
7) Remove the safe pins of jacking plate, retract the oil cylinder again to put the transition
section fall on the new tower mast, line up. Use 8 pins to connect firmly the transition
section and the tower mast. At this time, one tower section has been added. If several
sections are to be added in succession, repeat the steps above. To ensure the transition
section fall on the tower mast successfully, before retracting, you can insert two guide rods
(each opposite angle have one rod) into pin holes of transition angles, and then retract oil
cylinder, the transition section falling.
8) At this time, one tower section has been added. If several sections are to be added in
succession, repeat the steps above.
9) The last tower section must be fixed between the tower body and the transition section.
178
4.11.5 Rung ladder (old style) and Inclined ladder add tower section
2.0m Rung ladder (old style) and Inclined ladder can be used interchangeably, oblique section
at the top of the distillation section rung ladder tower section mast be installation anti-dropping
device, the device can also easily mount at the bottom of the tower section (that is, platform
side), the installation method as shown in Fig. 4-42. It can easily pass and turned over specially,
and can effectively prevent people falling from the rung ladder.
It has a slight impact on the passage and can effectively avoid the risk of missing the step
because the anti-dropping device. The optional part of anti-dropping device can be purchased
according to the user’s demand. It is suggested that the tower section of rung ladder be installed
centrally, and user only need to purchase.
Fig. 4-42 Anti-dropping device
Table 4-7 Spare part of anti-dropping device

No. Code Designation Specification Qty Material Remake
Anti-dropping device 2.0m
1 1 Weldment
structure mast
M12×100-
2 GB/T5783-2000 Bolt 2
8.8
3 GB/T93-1987 Washer 12 2 65Mn
4 GB/T6170-2000 Nut M12-8 2
5 GB/T97.1-2002 Washer 12-200HV 4
179
4.12 Chassis stationary tower crane

Installing the chassis assembly, assemble it according to Fig. 4-43.
Fig. 4-43 Chassis stationary tower crane
4.12.1 Installing the crossed-beamed of chassis stationary

◼ Put the long cross beam on the foundation and fixed with bolts, as shown in Fig. 4-44.
Fig. 4-44 Installing the long cross beam
180
◼ As shown in Fig. 4-45, place one end of the short cross beam on the foundation and fixed
with embedded bolts, which connect the other end with the long cross beam with 2 pins
Φ60×430. Install another short cross beam in the same way.
Fig. 4-45 Installing the short cross beam
◼ As shown in Fig. 4-46, the tie rod connected to long and short cross beam respectively by
2 Φ30×105 pins. Install another 3 tie rods as the same way.
Fig. 4-46 Installing the tie rod
181
4.12.2 Installing the base tower section and incline tie rod
As shown in Fig. 4-47, put the base tower section on the crosse beam and connect them by
Φ65 pins. Use 2 Φ70×200 pins to connect the incline tie rod to the base tower section and the
crosse beam. Install another 3 incline tie rods as the same way.
Fig. 4-47 Installing the base tower section
◼ The left and right numbers of central ballast keep accordance, placed
symmetrically (refer to Table 3-38 to configure the central ballast).
◼ The central ballast of 3.9t concrete protruding part to be press on the
crossed beam, about uniform.
◼ Used raise platform, positioning, and center of the platform and hole shall
be centered.
182
◼ Ensure that the perpendicularity of the base section is not more

than 1.5/1000 after completing pouring foundation.
◼ During the assembly, each pin with cooperate face shall scribble
lubricating grease
◼ Split pin must extend fully, bolts tighten
◼ Install the central ballast as the figure below, install the
nameplate to the base tower section by 4 M6×16 bolts.
183
4.13 Travelling tower crane

4.13.1 Erection of travelling mechanism
Travelling mechanism consists of 2 powered wheel bogie, 2 idler wheel bogie and cable device,
etc. Attention of installation:
◼ The 2 powered wheel bogie and 2 idler wheel bogie are arranged diagonally (track clamps
facing outwards), as shown in Fig. 4-48.
◼ The travelling motor should be on the inside of the gauge
◼ The central ballast must be mounted along the track direction;
◼ The safe distance between the travelling bogie and the building outside the track shall not
be less than 450mm;
◼ The cable drum is equipped with M-type power drum, which is installed on the travelling
chassis.
Fig. 4-48 Arranged the travelling bogie

(1) Rail (2) Building
(3) Idler wheel bogie (4) Power wheel bogie
(5) Rail distance (6) Chassis
(7) Central ballast (8) Power wheel bogie
(9) Idler wheel bogie (10) Rail
4.13.2 Erection of travelling chassis

Erection of travelling chassis refer to chapter 4.12 about installing the undercarriage stationary
4.13.3 Erection of cable drum bracket and cable drum

The cable drum of our company is equipped with M-type power drum, which on the travelling
chassis is arranged centre of the two tracks.
4.13.4 The remaining operations

Please refer to <General Tower Crane Operation Manual of Travelling crane>
184
4.14 Safety devices

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

speed, a maintenance technician must be called in order to check the
adjustments of the safety devices before putting again the crane into
services
185
Synopsis
(1) Hoisting height limiter (2) Slewing limiter

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

4.14.2.1 check before the commissioning and texting
In order to check the correctness of erection work and ensure safe operation, a series of test
operation and comprehensive inspection of all parts of the tower are conducted.
◼ Check the connection between components.
◼ Check the installation of support platform and handrail.
◼ Check whether the wire rope is properly wound or not, and whether they are in interference
or friction.
◼ Check the cable traffic condition.
◼ Check the fixed condition of the counter weight.
◼ Check the platform and prevent the sundries from falling when the tower crane runs.
◼ Check the lubrication.
4.14.2.2 Adjusting the safety device
◼ Check the tower crane by operating all parts to ensure the assembly
is correct and can be used safely. According to section 1 of this
chapter.
◼ The adjustment and inspection of the safety devices are operated in
the 4-fall status.
186
4.14.3 Load moment limiter

A. Function
The rated load limit moment is constant. It is prohibited to exceed the rated load moment during
crane operation. The load moment limit switch is to prevent the cranes’ working moment from
exceeding rated load moment.
B. Working principle
The load moment limit switch consists of plates which can be moved via deformation and
several limit switches. The plate is fitted with several adjustable screws, which correspond to
the trolley moment respectively.
According to the clearance between adjustable screw and limit switch, the switch acts within
the safety control circuits subjected to load moment.
Fig. 4-49 Adjusting of load moment limiter
◼ The adjustment of Load moment limiter shall be at the fee standing height
of crane, which mark in the chapter 3 "TECHNICAL DATA OF CRANE AND
SITE”. If the tower crane over fee standing height or super height, the load
value shall reduce the weight of over height rope and additive hook.
◼ After adjustment, the anti-loose nut shall be lock.
187
C. Adjustment
Hoist the maximum rated lifting weight W to 1m above the ground at a small trolley, and change
trolley out toward at a normal speed. When it reaches Ld, the adjusting load moment limiter
SMA2 is triggered, and the trolley will automatically change outward to low speed.
Fig. 4-50 Adjustment of trolley moment limiter
D. Adjustment for early warning

If the trolley continue to outward at a low speed and reaches Lw,, the adjusting load moment
limiter SMA1 is triggered, 90% moment yellow lights up and alarm.
Fig. 4-51 Adjustment of moment limiter early warning
188
E. Constant load for variable radius

When the trolley reaches L~L’, the adjusting load moment limiter SMA2 is triggered, 100%
moment red lights up and alarm, the out toward and hoist actions are restricted.
Fig. 4-52 Adjustment of moment limiter constant load for variable radius
F. Adjustment constant radius for variable load

The normal permit maximum load at the jib end is X, without any moment limiter being triggered
and normal hoisting. When the load to Y, the adjusting moment limiter SMA2 is triggered. At
this time, the hoisting power should be cut off, the 100% moment red lights up and alarm, the
out toward and hoist actions are restricted.
Fig. 4-53 Adjustment of constant radius moment limiter for variable load
189
4.14.3.1 Table of moment limiter Adjustment
Table 4-8 Adjust parameter of moment limiter (2-fall)

Lf X Y W Ld Lw L L’
/m /kg /kg /kg /m /m /m /m
70 2500 2750 5000 32.71 36.79 40.88 44.97
67.5 2800 3080 5000 34.25 38.53 42.81 47.09
65 3100 3410 5000 35.58 40.03 44.48 48.93
62.5 3400 3740 5000 36.72 41.31 45.89 50.48
60 3700 4070 5000 37.65 42.35 47.06 51.76
57.5 4000 4400 5000 38.37 43.17 47.97 52.76
55 4400 4840 5000 39.63 44.58 49.53 54.49
52.5 4800 5280 5000 40.61 45.69 50.76 /
50 5000 5500 5000 40.00 45.00 50.00 /
47.5 5000 5500 5000 38.00 42.75 47.50 /
45 5000 5500 5000 36.00 40.50 45.00 /
42.5 5000 5500 5000 34.00 38.25 42.50 /
40 5000 5500 5000 32.00 36.00 40.00 /
37.5 5000 5500 5000 30.00 33.75 37.50 /
35 5000 5500 5000 28.00 31.50 35.00 /
32.5 5000 5500 5000 26.00 29.25 32.50 /
190
Table 4-9 Adjust parameter of moment limiter (4-fall)

Lf X Y W Ld Lw L L’
/m /kg /kg /kg /m /m /m /m
70 2408 2648 10000 17.99 20.24 22.49 24.74
67.5 2708 2978 10000 18.82 21.17 23.53 25.88
65 3008 3308 10000 19.54 21.98 24.42 26.87
62.5 3308 3638 10000 20.15 22.67 25.18 27.70
60 3608 3968 10000 20.65 23.23 25.81 28.39
57.5 3908 4298 10000 21.04 23.67 26.30 28.93
55 4308 4738 10000 21.71 24.43 27.14 29.85
52.5 4708 5178 10000 22.24 25.02 27.80 30.58
50 5108 5618 10000 22.62 25.45 28.28 31.11
47.5 5608 6168 10000 23.20 26.10 29.00 31.90
45 6008 6608 10000 23.27 26.18 29.09 32.00
42.5 6408 7048 10000 23.20 26.10 29.00 31.90
40 6808 7488 10000 22.98 25.85 28.73 31.60
37.5 7308 8038 10000 22.88 25.74 28.60 31.46
35 7808 8588 10000 22.60 25.43 28.25 31.08
32.5 8408 9248 10000 22.37 25.17 27.96 30.76
30 9108 10018 10000 22.13 24.89 27.66 /
4.14.3.2 Adjustment of displacement sensor

Empty hook, the trolley drive to jib end, the hook hoist up to the highest, adjust moment limiter
displacement sensor RHM screw and let it in the safety monitoring system “information query”
→ “sampling value query” → “value of moment limiter displacement sensor is 300~400”.
4.14.3.3 Seal
After adjusting and checking moment limiter, close the rain cover of moment limiter, and then
wear it with steel wire through the hole of the rain cover and add lead seal.
191
4.14.4 Load limit switch

A. Function
It is prohibited to exceed the maximum load capacity of tower crane during operation. Load limit
switches are used to prevent the tower crane from exceeding the maximum load capacity.
B. Working principle
The load moment limit switch is a dynamometric ring consisting of metal strips, adjustable
screws, several limits switch etc. Each screw corresponds to one limit switch. During HOIST
operation, certain force running over the hoist rope is applied to the dynamometric ring, and will
cause the metal strips to deflect. This deflection of metal strips allows the adjustable screws to
contact and act on the limit switch, which would alert the crane operator in case of any overload
situation via acoustic and optical signals.
This system allows the contactors to act on the safety circuit depending on the loads to be
controlled, when appropriately adjusting the gap between adjustable screw and limit switch.
Fig. 4-54 Adjusting load limit switch
The load limit switch has been pre-calibrated at the factory and needs to be
checked on site. If the deviation is too large, please adjust it according to the
following adjustment steps.
192
4.14.4.1 Adjusting
1) Adjusting for High-speed hoisting
Hoisting load A at the minimum radius, the hoist speed can be reach at high speed, add 10%
weight, and then adjust load limit switch K2 is triggered. At this time, the high-speed hoisting
radius is restricted, “50% rated load” yellow lights up, the height of hoisting is restricted at low
speed.
Fig. 4-55 High-speed hoisting for 50% rated load
2) Adjusting for maximum hoisting load

Hoisting load B at the minimum radius, the hoist speed can be reach at low speed, add 10%
weight, and then adjust load limit switch K1 is triggered. Currently, “100% load” red lights up
and alarm, the upward hoist actions are restricted.
Fig. 4-56 Adjusting for maximum hoisting load
193
4.14.4.2 Adjust parameter table of load limit switch
Table 4-10 Adjust parameter table of load limit switch

Falls A A+10% B B+10%
2/4 /kg /kg /kg /kg
2500 2750 5000 5500
5000 5500 10000 11000
4.14.4.3 Seal
After adjusting and checking load limit switch, close the rain cover, and tightening the bolts, and
then wear it with steel wire and add lead seal.
4.14.4.4 Electronic sensor

Electronic sensor can be measure load weight and show on the display at the cabin. The sensor
mounting at the inner of load limit switch, the adjust methods refer to <ETI Operation Manual>.
194
4.14.5 Travel limiter

Travel limiter include: Hoisting limiter, Trolley limiter and Slewing limiter which significant safe
devices of crane to achieve mechanisms control and extremity limit function.
The hoisting mechanism, trolley mechanism and slewing mechanism all configure electronic
sensor which real-time monitoring of mechanism location, the control system converts the
position signals into electronic signals.
This crane can achieve double control of electronic sensor and mechanical sensor. The
mechanical limiter only uses in emergency mode which must be adjusted in accordance with
the requirements before use.
Table 4-11 Instruction of main mechanisms mechanical limiter

No. Hoisting limiter Trolley limiter Slewing limiter
1 Upward hoist stop Outward trolley stop Leftwards slewing stop
Upward hoist
2 Outward trolley decelerate Leftwards slewing decelerate
decelerate
3 Downward hoist stop Inward trolley stop Rightwards slewing stop
Downward hoist
4 Inward trolley decelerate Leftwards slewing decelerate
decelerate
◼ After the height of tower mast reach preset height, the adjustment must be
non-load. Before adjusting, use finger presses the contact of the KW jogging
switch to ensure the jogging switch correct about the hoisting or descend.
◼ It shall adjust hoisting limiter, when change the height and fall of crane.
◼ Tighten the M5 nut
◼ After adjusting, loose the M5 nut, otherwise the memory will disorder.
◼ After adjusting, mount the upper cover, otherwise the limiter may be flooded.
◼ After replace the steel rope or change hook assembly fall, the
extremity position of hook will change, you must readjust hoisting
limiter, otherwise the hook hit the jib may occur, steel rope cut off,
result in crane destruction and human death.
◼ Hook at the lowest position, three loops of steel rope shall be kept on
the drum.
195
4.14.5.1 Hoisting limiter

Function
The hoist limit switches ensure:
◼ to slow down and to stop the “Hoisting” motion as soon as the pulley block comes near the
trolley.
◼ to forbid the complete unwinding of the rope and its winding up in reverse direction during
the “Lowering” movement.
Working principle
The device comprises a reduction gear meshing the hoisting mechanism drum. This device
drives cams (T) which control the circuit breakers (WK). Each circuit breaker causes the
interruption or the deceleration of the concerned movement.
196
Adjusting procedure
The adjustment is carried out without load and with 4-fall rope reeving.
Carry out the adjustments of the various limit switches by observing the following order:
I. Adjusting the upper hoist limit switch (4WK)

◼ Position the pulley block at the distance of H1(1m) from the trolley
Adjust the limit switch as follows:

◼ Remove the upper cover. Check and tighten two M3×55 bolts.
◼ Loose the M5 nut.
◼ Adjust the cam (4T) by the means of turning the corresponding shaft (4Z) until the micro-
switch (4WK) depressed.
◼ Retighten the M5 nut.
Check the correct functioning of the limit switch by operating a “Hoisting” movement at slow
speed until the movement is stopped at the distance indicated above.
II. Adjusting the limit switch “Decelerating-Hoisting” (3WK)

◼ Position the pulley block at the distance of H2(4m) from the trolley.

switch (3WK) is depressed.
Check the correct functioning of the limit switch by operating a “Hoisting” movement at high
speed until the movement is decelerated at the distance indicated above.
197
III. Adjusting the lower limit switch (1WK)

Position the pulley block at the distance of about H1(1m) from the ground. Make sure that at
least 3 rope turns remain on the drum

switch (1WK) is depressed.
Check the correct functioning of the limit switch by operating a “Lowering” movement at high
speed until the movement is decelerated at the distance indicated above.
In case of rope reeving change, the limit switch does not operate at the
same distance from the ground.
198
4.14.5.2 Trolley limiter

The trolley limit switches ensure to slow down and to stop the trolley movement before reaching
the jib foot and jib nose buffers.
Working principle
The device comprises reduction gear meshing with the trolley mechanism drum. This device
drives cams which control the circuit breakers. Each circuit breaker causes the interruption or
the deceleration of the concerned movement.
Adjustment procedure
The adjustment is carried out without load and with 4-fall rope reeving.
Carry out the adjustments of the various limit switches by observing the following order:
I. Adjusting the “decelerate speed -Trolley out” limit switch

◼ Position the trolley at L1(0.2m) from the jib end buffer.

◼ Loose the M5 locking screw.
◼ Adjust the axle (4Z) until which act on the memory cam (4T) to press down the micro-
switch (4WK).
◼ Retighten the M5 locking screw.
Check the correct functioning of the limit switch by operating a “Trolley out” movement at low
speed until the motion is stopped.
199
II. Adjusting the “Stop-Trolley out” limit switch

◼ Position the trolley at L2(2m) from the jib end buffer.
◼ Loose the M5 locking

switch (3WK).
◼ Retighten the locking crew
Checking the correct functioning of the limit switch by operating a “Trolley out” movement at
high speed until deceleration of the motion.
III. Adjusting the “decelerate speed -Trolley in” limit switch

◼ Position the trolley at a L1(0.2m) distance from the jib foot buffer.

◼ Loose the locking screw M5.
switch (1WK).
◼ Retighten the locking screw M5.
Check the correct functioning of the limit switch by operating a “Trolley in” movement at low
speed until the motion is stopped.
IV. Adjusting the “stop-Trolley in” limit switch

◼ Position the trolley at distance L2 from the jib foot stop.

◼ Loose the locking screw M5.
switch (2WK).
◼ Retighten the locking screw M5.
Check the correct functioning of the limit switch by operating a “Trolley in” movement at high
speed until the motion is decelerated.
200
4.14.5.3 Slewing limiter

The slewing limiters are designed for cranes which are not equipped with collector. It is the
purpose of the slewing limiters to prevent the torsion and damaging of the electric cables.
Working principle
The device comprises a reduction gear meshing with the slewing ring. During the slewing
motions the limiters record the number of revolutions carried out by the slewing crane part. This
device drives the cams which control the circuit breakers.
Each circuit breaker causes the interruption of the concerned movement.
Adjustment procedure
The adjustment is carried out without load.
I. Adjusting the limiter “Slewing to left”

◼ Put the jib in Erection position so that the electric cables are not twisted (position after the
mounting of the slewing crane part).
◼ Carry out 1.5 revolutions in the “slewing to right” direction.
201
II. Adjusting the limiter “Slewing to right”

◼ Loose locking screw M5
switch (4WK).
◼ Drive the slewing part to the left by 1/4 resolution.
switch (3WK)
◼ Retighten locking screw M5
4.15 Tower crane tests

To confirm the tower crane's readiness, an acceptance test shall be performed. The test shall
include at least the following items:
◼ Nameplate of the tower crane and the grades;
◼ Tests of drive mechanism, limiter and indicator;
◼ Safety devices;
◼ In compliance with the load tests 4.15.1 and 4.15.2.
4.15.1 Function test without load

All functions (such as brakes, control systems and limiters etc.) shall be tested for reliability
throughout the whole range of admissible movements up to the maximum operating speed
(such as hoisting, trolley and slewing).
4.15.2 Load tests

4.15.2.1 Nominal load tests
The load at the maximum amplitude is 25%,50%,75%,100% separately to the nominal load, the
tests should comply with the acquirements in 4.15.1, all the tests should be reliable.
202
4.15.2.2 Static tests with load 125% of the rated capacity

After the success of the no-load test and the nominal load test, proceed the static overload
tests. The load tests result for different jib lengths show as Table 4-12.
The test shall be done at 4 falls.
The test load shall have a distance of 100~200 mm from the floor for a period of time of at least
10 min.
The static test shall be considered successful if no ruptures, permanent deformations, or
damages affecting the function or safety of the crane are visible and no connections have
loosened or become damaged.
Table 4-12 Static tests with load 125% of the rated capacity
Item
RangeⅠ(m) LoadⅠ(t) RangeⅡ(m) LoadⅡ(t)
Jib length(m)
70 19.69 15 70 2.98
67.5 20.53 15 67.5 3.36
65 21.25 15 65 3.73
62.5 21.86 15 62.5 4.11
60 22.36 15 60 4.48
57.5 22.75 15 57.5 4.86
55 23.42 15 55 5.36
52.5 23.95 15 52.5 5.86
50 24.33 15 50 6.36
47.5 24.90 15 47.5 6.98
45 24.95 15 45 7.48
42.5 24.85 15 42.5 7.98
40 24.60 15 40 8.48
37.5 24.47 15 37.5 9.11
35 24.16 15 35 9.73
32.5 23.89 15 32.5 10.48
30 23.61 15 30 11.36
◼ It is forbidden to trolley and slew at the static overload test.

◼ It is forbidden to adjust the brake at the static overload test.
◼ It is allowed to adjust load moment limiter and load limiter at the
static overload test.
203
4.15.2.3 Dynamic tests with load 110% of the rated capacity

The load tests result for different jib lengths show as Table 4-13.
The test shall be done at 4-fall.
The tests shall include the repeated starting and stop of each movement throughout the whole
sequence of the movement.
The static test shall be considered successful if no ruptures, permanent deformations, or
damages affecting the function or safety of the crane are visible and no connections have
loosened or become damaged.
Table 4-13 Static tests with 110% of the rated capacity

Item
RangeⅠ(m) LoadⅠ(t) RangeⅡ(m) LoadⅡ(t)
Jib length(m)
70 19.69 13.2 70 2.62
67.5 20.53 13.2 67.5 2.95
65 21.25 13.2 65 3.28
62.5 21.86 13.2 62.5 3.61
60 22.36 13.2 60 3.94
57.5 22.75 13.2 57.5 4.27
55 23.42 13.2 55 4.71
52.5 23.95 13.2 52.5 5.15
50 24.33 13.2 50 5.59
47.5 24.90 13.2 47.5 6.14
45 24.95 13.2 45 6.58
42.5 24.85 13.2 42.5 7.02
40 24.60 13.2 40 7.46
37.5 24.47 13.2 37.5 8.01
35 24.16 13.2 35 8.56
32.5 23.89 13.2 32.5 9.22
30 23.61 13.2 30 9.99
204
4.15.2.4 Operation of overload test circuit

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

◼ The operation shall be carried out in strict accordance with the test
process, and illegal driving and taking the plane during the test are
prohibited.
◼ Once test is completed, remove the “100% weight unrestricted test
plug”.
◼ This “100% load unrestricted test plug” is guaranteed to be used for
temporary overload test on construction site, and must not be
removed
205
4.16 Tower anchored onto the building
When the working height of the tower crane is required to exceed its free-standing height, the
tower body shall be anchored.
4.16.1 Description
The 2.0m fish plate tower mast recommend adopt retractable attachment frame YWB-FZJ2000
(000209911A2600000) is mainly consist of attachment frame, inner support column, strut rods
(including strut rods double-headed screw, connecting sleeve, pin, split pin and nut.), the
Foundation support constitute, as shown in Fig. 4-57.
Fig. 4-57 The retractable attachment frame YWB-FZJ2000
Table 4-14 Spare parts of retractable attachment frame YWB-FZJ2000

No Code Designation Order No. Qty
1 Attachment frame 000209911A0610000 FZK2000-YWB 1
2 Long strut rods 000209911A2701000 2
3 Short strut rods 000209911A2702000 2
4 Foundation support 000209911A0211650 FZJZ-S300/H160/260/Φ60 2
206
4.16.1.1 Attachment frame

Positioning dimensions of connecting pin holes on attachment frame as show in Fig. 4-58.
Fig. 4-58 Attachment frame

4.16.1.2 Attachment rods
The 2.0m tower mast retractable attachment frame including two long and short strut rods of
each. The length of the long rod is between 4960~860mm while the length of the short rod is
between 4200~7040mm, as shown in Fig. 4-59.
Fig. 4-59 Layout of the strut rods
Table 4-15 Spare parts of long strut rods

No Order No. Code Designation Qty
1 000209911A2701100 Strut rodsⅠ 1
2 000209910A1122601 XZ01C-60×270/305 Pin 2
3 1040500186 GB/T91-2000 Pivot 6
4 000209911A2701200 Strut rods Ⅱ 1
5 1040202429 GB/T6172.1-2000 Nut 1
6 000209911A0211900 FZLG-M80 Double-headed screw 1
7 1040202430 GB/T6172.1-2000 Nut 1
8 000209911A0211850 FZJT-M80-350Φ60 Threaded connector 1
9 000209910A4122401 XZ04C-60×240/300 Pin 1
10 000209911A1101001 Washer 2
207
Table 4-16 Spare parts of short strut rods

No Order No. Code Designation Qty
1 000209911A2702100 Strut rodsⅠ 1
2 000209910A1122601 XZ01C-60×270/305 Pin 2
3 1040500186 GB/T91-2000 Pivot 6
4 000209911A2702200 Strut rods Ⅱ 1
5 1040202429 GB/T6172.1-2000 Nut 1
6 000209911A0211900 FZLG-M80 Double-headed screw 1
7 1040202430 GB/T6172.1-2000 Nut 1
8 000209911A0211850 FZJT-M80-350Φ60 Threaded connector 1
9 000209910A4122401 XZ04C-60×240/300 Pin 1
10 000209911A1101001 Washer 2
4.16.1.3 Foundation support

The pin bore position on the base seat and the base plate are as follows.
Fig. 4-60 The pin bore and the base plate
The connection between the mast-pull-frames and the building:

a) The construction organization shall design the connection between the foundation support
and building according to the support force provided in the attachment arrangement from
and carry out the corresponding calculation (including the calculation of the connection
strength and the bearing capacity of the building).
b) If used the embedded ways, it is recommendable to use the embedded plate (prepared by
customers), the material is Q355B and the thickness is no less than 25mm, length and
width not less than 600×500mm.
c) The welding between foundation support and the embedded plate are recommend to use
E5016 welding rod, height of weldment is 24mm, 9 of Φ33 hole plug welding.
d) If used the bolts to connect, position size of the embedded bolts according to bottom
foundation support from the Fig. 4-60 to assign, M30 bolt must be more than 8.8.
208
4.16.2 Layout of the anchored devices

4.16.2.1 Layout form 1
As shown in the Fig. 4-61 is the layout form 1.
Fig. 4-61 layout form 1

(1) Strut rods A (2) Strut rods B
(3) Strut rods C (4) Strut rods D
The length of the Strut rods is L1, L2, L3, L4 respectively, the angle between the rod A, D and
the building is α, β respectively, the distance between the center of the tower crane and the two
sides of the building is L5 and L6, the distance between the center of the tower crane and the
center of the base seat is L7 and L8. When using this form, the layout configuration must meet
the following conditions:
a) α, β must meet: 35°≤α≤67°, 35°≤β≤67°;
b) L1, L2, L3, L4 must meet: two rods are 4960~8600mm, the others are 4200~7040mm.
The maximum reaction from the anchored points to the building is given below:
Fx1/kN Fy1/kN Fx2/kN Fy2/kN

±525 ±456 ±525 ±456
209
Some examples when L5=L6 for the form 1:
L5=L6/mm L7/mm L8/mm
3000 5500≤L7≤6800 5500≤L7≤6800

3500 5300≤L7≤7500 5300≤L7≤7500
4000 5000≤L7≤8000 5000≤L7≤8000
4500 4600≤L7≤7800 4600≤L7≤7800
5000 4100≤L7≤7600 4100≤L7≤7600
5500 4100≤L7≤7200 4100≤L7≤7200
6000 4300≤L7≤6600 4300≤L7≤6600
6500 4500≤L7≤5900 4500≤L7≤5900
7000 4700≤L7≤4900 4700≤L7≤4900

Fig. 4-62 layout form 2

When using this form, the layout configuration must meet the following conditions:
a) α, β must meet: 35°≤α≤78°,35°≤β≤78°;
210
±512 ±645 ±524 ±640
Some examples when L5=L6 for the form 2:

3000 5500≤L7≤6800 4600≤L7≤6700
3500 5300≤L7≤7500 3900≤L7≤6900
4000 5000≤L7≤8000 2700≤L7≤6500
4500 4600≤L7≤7800 2500≤L7≤6000
5000 4100≤L7≤7600 2700≤L7≤5400
5500 3300≤L7≤7200 2800≤L7≤5100
6000 2900≤L7≤6600 2900≤L7≤4700
6500 3000≤L7≤5900 3000≤L7≤4300
7000 3100≤L7≤4900 3100≤L7≤3800

Fig. 4-63 Layout form 3

211
When using this form, the layout configuration must meet the following conditions:
a) α, β must meet: 40°≤α≤70°,42°≤β≤85°;
±465 ±664 ±438 ±750
Some examples when L5=L6 for the form 3

5000 4000≤L7≤7600 3900≤L8≤4700
5500 3700≤L7≤7200 3200≤L8≤5300
6000 3900≤L7≤6600 1700≤L8≤5800
6500 4000≤L7≤5900 1500≤L8≤6300
7000 4300≤L7≤4900 1600≤L8≤5800
4.16.3 Range of the anchored devices

Range of 2.0m tower section anchored devices as show in Fig. 4-64:
Fig. 4-64 Attachable locations on the tower section
212
4.16.4 Matters need attention

a) When installing the attachment frame, use the theodolite to check the verticality of the axis
of the verticality of the axis of the tower mast. The vertical degree of the tower axis above
the highest attachment point is 4/1000, and the vertical degree of the tower axis below the
highest attachment point is 2/1000. When the deviation of the vertical degree of the tower
axis does not meet requirements and the deviation is constant, the user can adjust the
length of attachment rod to meet the requirements.
b) When installing the attachment frame, the flat surface of the frame beam should be kept
consistent with the horizontal position as far as possible, and it should be hung on the
tower section with slings such as steel rope to prevent falling.
c) The gap of attachments and height of tower above the anchored-frame should meet the
operation manual of tower crane. The top two anchored-frames must be installed with inner
strut rods. It is suggested that each attachment should be installed with inner strut rods.
d) When there is interference in the position of the attachment frame of the inner strut rods
installation, it can adjust up and down appropriately, and the distance between the
installation position and the attachment frame is within 200mm of the tower section
diagonal, the inner strut rods may not be installed.
e) The Maximum allowable axial load of the single strut rod: in service is 500 kN, out of service
is 550kN.
f) In this manual, the length of the strut rods refers to the distance from the pin hole of
attachment frame to foundation support. When installing the attachment, the levelness of
strut rods shall not exceed 1/100 of the strut rods.
g) When the gap between pin holes and pin more than 1mm, the telescopic strut is prohibited
to used.
h) If none of them is satisfied, please contact our company, the force calculation can be
provided according to the actual situation.
213
4.16.5 Three Stay bar anchored device

4.16.5.1 Layout of the three strut rods anchored devices
Layout of the three strut rods anchored devices as show in Fig. 4-65
Fig. 4-65 Anchoring form
User can choose the appropriate attachment points according to the actual requirements of
construction, and the attachment height, gap of attachment and height of tower above the
anchored-frame should meet the requirements of this manual.
4.16.5.2 The level reaction of attachment points
F: Level reaction of attachment points; T:Torque; α:Angle of F and X axis

Fig. 4-66 Drawing of anchoring form
Table 4-17 level reaction of attachment points

Load
level reaction /kN Torque/kN.m
service
In service 190 715.8
Out of service 410 0
214
◼ User can calculate strut rod force and foundation support force according to the
attachment point level reaction force
◼ Our company telescopic attachment is the same tower mast in the largest load model to
calculate the foundation support force, as the most unfavorable state, different types of
crane with the same tower mast reaction force consistent.
◼ Angle α change from 0 to 360°

◼ Torque T direction is arbitrary, which may be clockwise or counterclockwise
(where the out of service is 0), in the table 715.8kN·m is the maximum
torque value of the tower crane torque
Please consult our company for out of service level reaction against
typhoon
4.16.6 Scheme of tower anchored onto building

The maximum hoisting height can reach 60m, if the hoisting height must be over 60m, it must
be fastened with tie-in onto the building and mast tie frame the maximum hoisting height can
reach 300m. When the height is less than 150m m, 2-fall and 4-fall are all satisfaction for the
hoisting. When the height is more than132.5m, just 2-fall is allowed.
The tower crane anchored-to-building has the same structural layout as stationary type, only
for higher hoisting height. To enhance tower crane stability and tower body rigidity, several
anchors are provided along the whole height of the tower body, the crane must be equipped
with several anchors. In case of the actual distance of the project not in compliance with this
requirement, just contact our company for further information.
4.16.6.1 Anchored technical requirements for 51m free standing height

The tower crane anchored technical requirements as show in the following table. The height of
first anchored frames h1, the height of each two Anchored frame Δh and the height of tower
above the anchored-frame have given range, and the range of height change into
corresponding number of tower sections, that worth noting, when the working height is over
100m, the allowable maximum height of tower above the anchored-frame can be reduce
appropriately. Drawing of attachment and important dimension refer to Fig. 4-67.
215
Fig. 4-67 Drawing of anchored tower crane
Table 4-18 Technical requirements of attachment

Height h1 /m 33.9≤h1 ≤48.9
Below the first 8.8≤n1 ≤ 13.8
anchored frames Quantity of tower sections n1 (Including base
tower section)
Each two anchored Height Δh /m 27≤Δh1≤36
frames Quantity of tower sectionsΔn 9≤Δn≤12
Hˊ/m Hˊ≤ 47
Maximum working
Quantity of tower
height H≤100m n ≤15.7
Above maximum sections n
attachment Hˊ /m Hˊ≤44
Maximum working
Quantity of tower
height H>100m n ≤ 14.7
sections n
In this table “Hˊ” is refer to the distance of the highest anchored frame to the
bearing face of hook, “the height of tower above the anchored-frame L” is refer
to the distance of the highest anchored frame to the highest tower section of its
upper end plane.
216
4.16.6.2 Most economic anchored-frame layout for the stationary crane

with embedded anchors
Table 4-19 Parameter of most economic anchored-frame layout

Qty of Highest The height of Height of tower Qty of Qty of
anchored- working top attachment above the anchored- base tower
frame height H/m H/m frame Hˊ/m section section
1 H1=96 h1=49 ≤47 29
2 H2=132 h2=85 ≤47 41
3 H3=168 h3=121 ≤47 53
4 H4=201 h4=157 ≤44 1 64
5 H5=234 h5=190 ≤44 75
6 H6=267 H6=223 ≤44 86
7 H7=300 H7=256 ≤44 97
217
4.17 Dismantling
4.17.1 General notes
All the instructions specific to the erection and the telescoping apply also to the dismantling and
the telescoping down operations.
The final dismantling phase is carried out by means of an auxiliary lifting equipment. For this,
make sure that the capacity of the auxiliary lifting equipment is sufficient.
AUXILIARY LIFTING EQUIPMENT
Depending on the site conditions, dismantling can be carried out partially by means of the
hoisting mechanism (unballasting); this requires that the electrical installations remain
untouched.
◼ For telescoping down and dismantling, the wind speed is

limited to 50 km/h. It is forbidden to pass under a hanging load.
◼ It is forbidden to transport the staff hanging from the load.
◼ During the dismantling operations it is compulsory to use the safety
harness.
4.17.2 Preparations before dismantling

Make sure that no obstacle will interfere during the dismantling operations.
For cranes with travelling gear:
◼ Bring the crane to the dismantling area.
◼ Fold down the rail clamps of the bogies and tighten them onto the rails.
The dismantling operations are the erection operations in reverse order. Specific
dismantling procedures are indicated in the chapters of the concerned crane
parts.
TELESCOPING / General instructions
218
4.17.3 Dismantling sequences

◼ Dismantle mast sections.
◼ Removing the hoisting rope.
◼ Dismantle counter weights remain from counter-jib, only keep a counter ballast block.
◼ Dismantle the jib.
◼ Dismantle the last counter ballast block.
◼ Dismantle the counter-jib (include hoisting mechanism).
◼ Dismantle tower head and slewing assembly.
◼ Dismantle the transition section, climbing frame and the mounting system.
◼ Dismantle the rest tower sections and base tower section.
CAUTIONS:
◼ Due to the telescoping mechanism out of service for a long time, conduct maintenance
and test-run for the telescoping mechanism before moving the tower crane out of the
construction site.
◼ Before dismantling of tower crane, maintenance and test-run of the jacking mechanism is
necessary.
◼ Check limiters, slewing mechanism brakes and similar for reliability during test-run.
◼ It is prohibited to use the slewing mechanism, trolley and hosting mechanism before the
tower crane mast sections have been dismantled and the slewing ring support has not
been connected to the tower body by eight pins.
◼ Check frequently the main stressed parts of the telescoping mechanism, as the tower
crane dismantling is a heavy duty and successive work for the telescoping mechanism.
◼ While the jacking mechanism is working, all operating personnel are required to focus their
attention on observing the relative positions of moving parts for normal condition (e.g.
between guide rollers and main chord rods, between Telescopic cage and crane tower.).
In case of any deviation during the telescopic cage is being lifted, stop and lower
telescoping immediately.
◼ Carry out dismantling when the wind speed is lower than 14m/s atop the tower crane. Take
care of the stockpile location of dismantled parts because the working site is limited for
tower crane dismantling after the buildings have been constructed. Any slight carelessness
might cause serious accident.
219
◼ Users are required to strictly follow the Instructions-specified rules to

dismantle tower crane. Operators shall have been trained and with
certificates. Any slight neglect will cause machine damage, personal
injury, or death.
◼ Pay great attention to the two moving mast lugs during inlet or
dismantle of additional mast sections. Inspect if the lugs are still in
proper level condition.
◼ Pay great attention to the two climbing latches during inlet or
dismantle of tower section. Inspect if the latches are still in proper
level condition. Slewing the tower crane to the dismantling area where
there shall be no obstacles influencing the operation. Carry out tower
crane dismantling according to the sequence. Its steps are in
opposition to the steps of tower crane erection. Strictly follow the
instructions specified rules in all cases.
4.17.4 Dismantling
4.17.4.1 Dismantling the tower section
Remove the tower sections in turn, see chapter 4.3.
When the climbing frame is climbing down, a dedicated person must be assigned
to take charge of the hanger plate, step change jacking lever and guide rollers,
and to check if the climbing frame is seized by obstructions, ensuring the
climbing frame climbs down successfully.
4.17.4.2 Dismantling the hook and the hoisting wire rope

◼ Lower the hook to the ground, remove the connection between the hoist wire rope and the
anti-twisting device on the jib, start the hoist mechanism and recover all the wire ropes.
4.17.4.3 Dismantling the electrical control wire

◼ Disconnect the circuit of the electronic system that affects the lifting of the tower
components and gather it at one end.
4.17.4.4 Dismantling the part counter weights

◼ Dismantle the counter-weight piece by piece in reverse order of installing sequence the
counter ballast. Only leave a 2.8t counter ballast block.
4.17.4.5 Dismantling the jib assembly

◼ Before dismantling, check the jib assembly to see if component-to-component is still
connected by power cable.
◼ Arrange hoisting rope at hook points. (reference the record point when the jib was lifting);
◼ Dismantle the connection pin and bolts of jib and counter-jib.
◼ Lower the jib and lay it down on the sleeper-cushioned support.
220
4.17.4.6 Dismantling the last one counter weight

◼ Remove the last one counter ballast block, and lift it in the proper position on the ground.
4.17.4.7 Dismantling the hoisting mechanism

◼ Sling the hoisting mechanism, remove the connecting pin shaft between the hoisting
mechanism and the counter-jib, and sling it in an appropriate position on the ground.
4.17.4.8 Dismantling the counter jib

◼ Sling the counter-jib and the bracket of the counter-jib tie bar and fix it with the pivot.
◼ Take the upper chord of the counter-jib and fixed pin of the tower head as the fulcrum,
slowly lift the counter-jib, and rotate around the fulcrum, so that tie bar is in a relaxed state,
the tie bar falls on the support frame, and remove the connecting pin shaft between the
long tie bar and the short tie bar.
◼ Hook the counter-jib down onto the ground.
4.17.4.9 Dismantling tower head and the slewing assembly

◼ Sling slewing assembly (contain the tower head), dismantling the connecting pin shaft
between the slewing support and the transition section, and sling it in an appropriate
position on the ground.
4.17.4.10 Dismantling the transition section, climbing equipment and the

tower section
◼ Sling the climbing frame, slowly hoist it out along the main chord of the tower section to
the ground.
◼ Dismantling the tower section and the mast section in turn. Chassis fixed tower crane to
remove.
◼ The dismantled crane needs to be checked and maintained by

technical personnel and trained maintenance personnel.
◼ Check main stressed structural members for metal fatigue; weld
fissure, structural deformation, etc. Check tower crane parts for
damage or collision injury.
◼ After completion of checks, repair the defects found and defects
potential. Carry out rust removing and painting.
221
OPERATION AND CONTROL WA7025-12E
5 OPERATION AND CONTROL

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

◼ Operate the crane only all the safety devices are in good condition.
◼ Adjust the limiters according to the instruction handbook strictly.
◼ Sufficient lighting shall be provided to the working area for night working.
◼ Keep all platforms, ladders, rails, and handrails from dirt.
◼ No unauthorized persons are allowed climb the crane!
◼ People who have been approved can climb up or down the tower crane after the tower
operators stopping the crane!
◼ Test run before working, work after confirming the tower crane is in good condition.
◼ Whistle before action every time.
◼ Don’t lay the hook onto the ground in order to avoid disordering the ropes.
◼ Operators should give some relevant warning signals on occasion.
◼ Stop working immediately once some defects harming tower crane operation safety are
found.
◼ The tower crane driver should observer the state of the tower crane in the cabin during the
jacking and descending process, when the tower crane is abnormal, the driver should
handle the problem in time.
◼ When the tower crane rises and falls, no one is allowed stand under the tower crane
without permission
222
WA7025-12E OPERATION AND CONTROL
5.3 Specific safety instructions

When the crane is in service, all the control panel doors must be locked.
The crane driver must position the jib in the direction of the wind before
any weathervane operation.
At each operation in the slewing area of the slewing crane part, the crane
driver must be extremely vigilant (crushing hazard).
It is compulsory to put the control unit out of service as soon as the crane
driver lays it down or no longer controls the crane.
223
5.4 Instruction of control unit

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

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

2
(Green) and the horn’s button
“Over 50% Weight When the load over 50% rated, the
3 rated” alarm lamp alarm lamp lighting, the buzzer will
(Yellow) beep. (See also in Num.7)
224
“Over 100% weight When the load over 100% rated, the
(Red) beep. (See also in Num.7)
“Over 90% moment When the moment over 90% rated, the
(Yellow) beep. (See also in Num.7)
“Over 100% moment When the moment over 100% rated, the
(Red) beep. (See also in Num.7)
⚫ Start-up: 4 beeps
⚫ Lack of GPS signal: beep 4s
during 15s;
⚫ Over 100% moment: beep 4 times
per 0.5s;
⚫ Moment alarm: beep 2 times per
0.5s;
⚫ Over 100% load: beep 3 times per
0.5s;
7 Buzzer
⚫ Load alarm: beep 1 times per
0.5s;
⚫ Gear change: beep 1 times when
changing 0.5s;
⚫ Weather Vane release: beep 1
times when releasing;
⚫ Fault in PLC: Keep beeping;
(See also in “System indication
and alarm signal”)
Optional for traveling mechanism.

Traveling forward
8 Operate the handles to the left, the
direction
tower crane moves forward
225
Optional for traveling mechanism.

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

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

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

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

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

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

Slewing release/Brake switch
for NO brake)
Start-up indicator
15 The light turns on after power-on.
(Green)
226
Weather vane release The light turns on after weather vane is

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

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

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

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

20
right direction slew to right.
21 Reserved button Reserved function
227
5.4.2 Driving box

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

No Code Function Remark
Electric whistle
1 QF1
power switch
Voltmeter
2 QF2 protection
switch
Safety loop
Disconnection of this circuit breaker will disable tower
3 QF3 protection
operation.
switch
Used for cutting-out protection of various lights, fans, and air
Power leakage
conditioning equipment in the cab. When the lighting circuit
4 QFE protection
breaker is closed (turn the small handle of the circuit breaker
switch in cab
upward), the lighting circuit is powered (single-phase 220V).)
2 working modes: electromechanical mode, mechanical
mode.
Mode option When the electronic safety device is not calibrated or fails,
5 SPM
switch the mechanical mode can be opened. At this time, only the
mechanical safety device plays a role, and hoisting, slewing
and trolley are all limited to 4 gear.
If the switch in the above table is air switch, the switch handle can be turned
upward to become “on” state. If the switch in the above table is electromagnetic
protection circuit breaker, the switch handle can be rotated clockwise until the
handle is in the vertical state to become “on” state.
228
The code number and function description of the door panel of driving box are show in following
table:
Table 5-2 Door panel component of driving box
No Graphic Code Function Note
Power supply The normal value of wiring voltage of

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

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

Power
power undervoltage indicator is on,
3 HU undervoltage
otherwise the related electrical
indicator
damage may be caused.
Jacking operate
4 SPP
button
229
5.4.3 Main control cabinet

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

Main power
marks of the finger when ON, the main
of electrical
power switch is closed; Rotate
1 QF control
counterclockwise, when the handle
system
indicator points to OFF, the main power
switch
will be cat off.
Only the QF handle points to OFF, the door of the main control cabinet can be
opened. Similarly, only the QF handle points to OFF, the door of the main control
cabinet is allowed be closed. Do not open and close the door of the main control
cabinet with violence to avoid damage related parts.
230
Heating dehumidification and cooling of main control cabinet:
◼ Heater：After power on, automatically detect the temperature and humidity, when the
temperature is ≤0℃ or humidity ≥80%, start heating.
◼ Cooling fan：After power on, automatically detect the temperature, when the temperature
is≥40℃, the fan in the cabinet to exhaust air.
◼ If the heater or cooling fan is operating under the set conditions, the cooling
fan and heater are not working, please check the components for damage.
◼ The working power supply of heater and cooling fan is U1, N; That is, when
the power supply of the knife switch box is turn on, it will start to work if the
working conditions of the heater and the cooling fan are met.
Component of outer cabinet:
On the upper part of the right panel of main control cabinet, an emergency stop button is
installed, as shown in the picture. Its function is the same as the emergency stop switch of the
right linkage platform in the cab’s room, and it is used to cut off the power supply and control
power of the crane in an emergency.
Do not use the emergency stop button to stop the crane in non-emergency circumstances.
Otherwise, it will have a great impact on the tower structure, even cause more serious safety
accidents.
This button is self-locking. After pressing it, it can only be released by rotation. Please make
sure that the emergency stop button is released before starting the tower crane
Fig. 5-2 Emergency stop button of main control cabinet
◼ Take the emergency stop button immediately, in the emergency.

◼ Because of the anti-slip hook function is enabled, the hoisting mechanism
enters the hover state. Do not press the emergency stop button.
◼ When the driver leaves the cab due to business after work or repairs and
checks the tower crane, he or she shall take the emergency stop button
when the tower crane is in the stop state.
231
5.4.4 Electric resistance box

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

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

The tower crane is equipped with three cameras to monitor the condition of the drum, hook,
and cab respectively. At the same time, it is displayed in real time on the display screen of video
monitoring system installed in front of the cab, and stored in the video recorder, which can be
looked back immediately.
The VCR can store up to three cameras simultaneously recording about 46 hours of video
information (32G memory card), and when the recording time is exceeded, the earliest video
information will be automatically overwritten.
232
5.5 Frequency converter self-learning

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

◼ Self-learning methods of frequency converter
➢ After the motor connected and powered on normally, first set the command source bF.04
of the frequency converter to 0 (command and control of the operation panel); Input motor
type plate parameters (A0.01-A0.05).
➢ Set function code b0.04 to 3 (static tuning) and press “Enter” to confirm. At this time, the
panel will display RUNE. Then press “RUN” on the panel and the frequency converter will
drive the motor to start running.
➢ Set the frequency converter command source bF.04 to 1 (terminal control).
➢ To further improve the performance of slewing mechanism, it is recommended to continue
online tuning of the slewing frequency converter after the completion of static tuning. The
steps are as follows:
➢ Set the source bF.04 to 4 (online tuning), and then press “Enter” to confirm;
➢ After confirming that there is enough room and safe operation, operate the slewing handle
to the 4th gear. At this time, the tower crane jib will rotate the 4th gear speed (frequency
233
converter display above 35Hz). The frequency converter will successively display:
UloC→LoC→Good, which indicates that the spectrum tuning is over and normal use can
be started.
Note: UloC: Start tuning online
LoC: Enter online tuning
Good: Online tuning ends
5.6 Operation
Installation of electrical control system:
The installation of the electrical control system should be carried out under good weather
conditions (such as no rain, show, fog), otherwise it may damage the electrical control system
or cause personal injury.
Before the installation of the electrical control system, a preliminary inspection shall be carried
out on all components of the electrical control system to observe whether there is damage or
loss of part in the control cabinet, and whether there is damage, carbonization and loosening
of wires and cables. And please release the damaged equipment.
Before the electrical control system is not connected, separate insulation tests can be carried
out on the motor, resistor, cable, and other parts to judge whether there is a fault, but insulation
test cannot be carried out after the connection of the electrical control system.
The wire connection and the body installation of all components in the control cabinet should
be firm and reliable, and no loosening phenomenon should occur,
The display screen of the auxiliary safety monitoring system should be fixed firmly and the
communication cable connection should be reliable.
Please connect the cables between the control cabinets as well as between the control cabinets
and other external wiring diagram. please note that the connection of each cable should avoid
interference with moving part, and leave a margin for the moving part to move. If the cable slot,
please put the cable in the slot.
After the connection, please make sure that the connection is correct, the connection is firm
and reliable, and there is no short circuit.
◼ Tower suspension cable, cable mesh should be used, and a cable mesh set
every 20m;
◼ When the power cable needs to be lengthened, the middle wire box should
be used, and direct connection is not allowed.
◼ In cable wiring, the power cable and the control cable should be separated
from each other to avoid close parallel wiring.
234
5.7 Putting into service

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

site foreman
235
5.7.1.2 On the ground

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

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

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

◼ Check the presence of the powder-type fire extinguisher
◼ Press successively upon the ON button (the horn is activated), then on the emergency
stop button (movement stop)
◼ Reset the stop button
◼ Press upon the ON button and check the functioning of all the movements by means of
the control switches
◼ Check the dead man position of the control switches
◼ Check the functioning of the displays.
◼ Check the control of the slewing brake
◼ By the means of the test button, test the functioning of the sound signal and the signal
lamps (flashing lamps) located outside the cab and on the display block (configuration
according to model and option)
◼ Check the functioning of the lighting and the windscreen wipers
◼ Check without load the functioning of the limit switches
◼ Check the state of the hook safety catch
236
All the operations for putting into service of the crane serve to ensure its working under correct
driving and safety conditions.
Overall, all these operations can be split up into several groups:
➢ Checking and carrying out of mounting operations in order to avoid any hindrance as
regards the good working order of the crane or safety.
➢ Carrying out the adjustments of the various safety devices and the working conditions of the
crane.
For carrying out any adjustment or maintenance operation and in order to reach the control unit,
use the devices provided on the crane.
237
5.7.2 Checks to be carried out after erection

The execution of the crane erection and the safety require a certain number of operations or
checks to be carried out according to the following description:
5.7.2.1 Lower part

Concerned crane parts Operations to be carried out
➢ Check the fitting of the ladders and back loops, replace
Access
damaged parts.
➢ Check the fitting and locking of the mast connecting pins

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

Concerned crane parts Operations to be carried out
➢ Check the fixing of the cab support and the access platforms
➢ Make sure that the driving instructions are properly affixed in
Cab the cab
➢ Check the fitting of the counter−jib catwalks and grab
➢ Check the fitting of the guard ropes of jib
➢ Check the correct installation of the electric supply cable
Jib and counter jib
➢ Check the correct reeving of the hoist and travelling ropes
5.7.3 Operating instructions

5.7.3.1 Requirement to the operators
◼ The crane operator is over 18 years of age.
◼ The crane operator is reliable, and is physically and mentally adept.
◼ The crane operator has been instructed in operation of the crane and is familiar with all
risks of accident.
◼ The crane operator has provided proof of qualification to the employer regarding operation
of the crane.
◼ The employer has designated the crane operator for operation of the crane is writing.
◼ The crane operator must have read and fully understand the instruction manual, in
particularly the chapters concerning notes on safety, as well as operation and control.
◼ The crane operator must have read and fully understood the local guidelines valid for
accident-prevention.
◼ The crane operator is familiar with the location and operation of fire extinguishers and has
been instructed in the onsite possibilities for fire detection and firefighting.
238
5.7.3.2 Protective equipment

The following must be worn:
◼ Safety helmet
◼ Safety boots
◼ Safety harness (e.g. for trolley travelling in the event of power failure)
5.7.3.3 Crane operation
It is strictly forbidden to lift a load the weight of which exceeds the crane
capacity. Consult the technical data for handling of loads when their
surface/lifted load ratio exceeds 𝟏𝐦𝟐 /𝐭.
◼ It is forbidden to lift an incorrectly slung load.
◼ It is forbidden to generate load swinging, to lift a load adhering to the ground and to lift a
load in oblique direction.
239
◼ It is forbidden to slew a load over the staff and roads.
◼ It is forbidden to handle a load in a space lower than 2 m from the ground.
◼ It is forbidden to erect a crane without observing the prescribed distances.
240
◼ It is forbidden to handle a load which is not visible without somebody’s help.
◼ It is forbidden to lift a load by means of several cranes.
◼ It is forbidden to lift persons.
241
◼ It is forbidden to use the crane as a pulling device for a load even a rolling one.
◼ It is forbidden to fill a grab (or other container) if this one is hooked to the crane, and to
stack big objects which could be unstable and fall to the ground.
242
◼ It is forbidden to lay down the pulley block and to let it on the ground, with slackened ropes.
◼ It is forbidden to let a load hooked on the hook during the night or in a rest period.
◼ It is forbidden to work in non-lift areas.
243
◼ The crane must compulsorily be out of service when the wind speed reaches or exceeds
72 km/h. Apply the procedure for the shift end.
◼ During the normal crane operation, do not stop the movements with the stop button.
◼ It is forbidden to work until the limit switches, so stop a little bit before.
It is forbidden to modify or to neutralize the moment cutouts, the load

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

hooking the pulley block on a fixed point. The crane must compulsorily
be in weathervaning position.
◼ Position the jib in wind direction, lower the load to the ground, raise the hook without load
and move the trolley to the jib foot.
244
WA7025-12E MAINTENANCE AND INSPECTION
6 MAINTENANCE AND INSPECTION

This chapter has been compiled for maintenance personnel who have been designated by the
contracting company to keep the crane in nominal operating condition. The maintenance
personnel will obtain an overview of all essential maintenance and inspection tasks stipulated
in the maintenance and inspection chart.
Especially:
◼ check the good working order of the crane components.
◼ carry out the periodically checking.
◼ carry out the adjustments.
◼ identify and repair the malfunctioning or failures.
◼ carry out the greasing.
All maintenance and inspection deadlines can be planned meticulously using the interval
specifications.
This part does not comprise instructions in order to carry out:
◼ repairs requiring a specific tool or which must be carried out in the workshop.
◼ important operations like overhauling, repairing.
6.1 Lubrication
The lubrication table recommends the type of lubricant to be used and the different lubrication
points. Lubricate thoroughly and regularly, since lubrication carried out according to our
instructions helps to prevent failures and premature wear.
◼ Any repair and maintenance work must only be carried out after the
crane has been out of service;
◼ Clean grease nipples and oil drain plugs before lubricating work;
◼ Only the correct use of suitable high-quality lubricants as
recommended by a specialist supplier will ensure maximum
performance and avoid faults and their consequences;
◼ Only use high quality brand-name lubricants.
245
MAINTENANCE AND INSPECTION WA7025-12E
6.1.1 Lubricants table

Table 6-1 Requirements of lubricants for ZOOMLION tower crane are shown as follows
Parts Lubricating
No. Specification of lubricants Oil
Description location
Hoisting Cleans
Graphite Calcium-based grease ZG-
1 Wire rope rope Spray
SSY1405-65
Trolley rope grease
Gearbox of
hoisting Industrial closed gear oil L-CKD 150
mechanism
1,Environmental temperature -20℃~140℃,

Gearbox of According
000# redactor general lithium-based grease
trolley to the
2,Environmental temperature --40℃~-20℃,
2 Gearbox mechanism label on
7412# semi-fluid gear lubricating grease
the gear
box
1,Environmental temperature -20℃~140℃,
Gearbox of
000# general lithium-based grease;
slewing
2,Environmental temperature -50℃~-20℃,
mechanism
7023B# low temperature grease.
Drum
/
Rolling bearing
3 Calcium-based grease
bearing Slewing
/
ring bearing
1, Raceway,2# extreme pressure lithium
Raceway,
Slewing base grease
4 Tooth /
ring 2, Tooth surface, Graphite Calcium-based
surface
grease ZG-S
Winter with Calcium-based grease ZG-2;
5 Pulley All pulley /
Summer with Calcium-based grease ZG-5.
Anti-twist molybdic disulfide Calcium-based grease
6 Bearing /
device ZG-1
1,Environmental temperature exceed-10℃,
Rope Calcium-based grease;
7 Pulley shaft /
wheel 2,Environmental temperature under-10℃,
grease thin oil
Hydraulic
8 pump Oil tank Hydraulic oil for anti-wear L-HM 46 /
station
9 Hook Bearing Grease oil /
Electro-
10 hydraulic Brake DB-25 /
thrust
246
6.1.2 Lubrication for bearing

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

6.2.1 Requirement on personnel
The maintenance personnel must be designated by the operating company. Maintenance of
the crane requires specialist knowledge of crane technology. The operating company is
responsible for all damage caused as a direct result of improper maintenance.
6.2.2 Safety measures

◼ Switch off the crane and secure against incorrect or unauthorized restart.
◼ If there is any danger of falling objects: Cordon off the danger area or secure the area with
warning signs.
247
6.2.3 Protective equipment for personnel

The following must be worn:
◼ Safety helmet
◼ Protective gloves
◼ Safety boots
◼ Safety harness when working above head height
◼ High-visibility clothing
6.3 Required maintenance and inspections
1. Hoisting mechanism 2. Slewing mechanism

3. Slewing ring 4. Telescoping equipment
5. Trolley mechanism 6. Hook
Fig. 6-1 Parts required for maintenance
248
The designated personnel must carry out the maintenance and inspection tasks according to
task guidelines as follows:
Maintenance/inspection
Task to be performed
intervals
Slewing ring③: Grease the ball track and gear teeth
Check the wire ropes and rope end fittings
Check the hook⑥
Telescoping equipment ④ : Grease the pivots and guide
section rollers
Check when starting up Check the twist compensator during every erection
the crane and before Grease all pivots during every erection
every erection.
Check each framework part and connective part
Check each electric control implement and security implement
Check the quality and quantity of the oil in the reducer of
hoisting mechanism
Check the quality and quantity of the oil in the climbing
mechanism
Slewing mechanism ② brake
Trolley mechanism ⑤ brake
Daily check Hoisting mechanism ① brake
Travelling mechanism brake
Rope release implement
Slewing ring③—Grease the gear teeth, see Fig. 6-1
Check the electric control implement, cable and electric wire
Weekly maintenance
Check the security implement (load moment limiter, load
limiter, trolling limiter, slewing limiter, hoisting limiter)
Grease the wire ropes
Grease the rope pulleys
Grease the winch drum bearing
Fill with hydraulic oil in the jacking pump station
Inspect the high-tensile bolt connections 1 month after
Monthly maintenance
erection
Travel gear: Grease the wheel bearings and the inside face of
the flanges
Hoisting gear①: Fill the gearbox with Oil
Check the stability of the vital framework, important weld and
249
Maintenance/inspection
Task to be performed
intervals
connection parts (bolts and pins)
Grease all lubricating nipples
Check the twist compensator
Half-yearly maintenance
Motor bearing: change oil after 1500 operation hours, once a
year at least
Inspect the high-tensile bolt connections and grease the bolt
Check the hook⑥
Yearly maintenance
Check freedom of the movement of the hinged joint of front
window of the cabin and lubricate it regularly
Oil change in the reduction of slewing mechanism②
Oil change in the reduction of hoist mechanism①
Oil change in the reduction of trolley mechanism⑤
After 2000 operation
Oil change in the brake of hoisting mechanism ①
hours
Oil change in the trolley travel gearbox
Oil change in climbing mechanism④ after 2400 operation
hours
250
6.4 Hoisting mechanism

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

(1) Motor (2) Coupling
(3) Reducer (4) Brake
(5) Tooth flange (6) Drum
(7) Hoisting limiter
6.4.2 Adjustment and maintenance of the brake

The type and relevant parameter of the hoisting mechanism brake are shown in the table
below.
Table 6-3 Relevant parameter of Brake
Rated braking moment Suggested braking moment
Part name Type
(Nm) (Nm)
Brake YWZ5-315/80-1000-HL 1000 750
Make sure drum not rotation unexpected leads to accidents before any
debugging for brake.
251
6.4.2.1 Adjusting the brake
Fig. 6-3 Hoisting mechanism brake

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

when screwing the Locknut 1. Each of the locknut can be compressed
for at most 0.5mm, which means the maximum compression is 1mm.
The adjustment of the brake mainly includes the adjustments of: the braking moment, the shoe
clearance (compensation for travel of the pusher hb) and the shoe clearance balancing.
252
6.4.2.1.1 Adjustment of the braking moment
As the following figure shows, when using the wrench to screw the nut clockwise, the spring
shorten and the braking moment increases; when screwing anticlockwise, the moment
decreases.
Moment
adjusting nut
Fig. 6-4 Adjustment of the braking moment
Don’t overstep the range on the moment scutcheon when adjusting the
braking moment, otherwise the brake may work unmorally.
253
6.4.2.1.2 Adjustment of the shoe clearance
1) Open the brake by electrifying or manual release device (If it’s not opening enough, open
wider by adjusting the braking tie bar or back-off adjusting nut);
2) Screw the back-off adjusting nut clockwise for 3~5 circles, then close the brake;
3) Measure the compensation for travel of the pusher hb as the following figure, then repeat
the step 2) until the hb correspond with the rated value in the following table.
4) Screw the locknut 1 on the brake tie bar tightly after the adjustment (caution that It is
prohibited to press the two locknuts together completely when screwing the Locknut 1.
Each of the locknut can be compressed for at most 0.5mm, which means the maximum
compression is 1mm.)
Table 6-4 The compensation for travel of the pusher hb
Part name Type Rated hb (mm) Minimum hb(Nm)
Brake YWZ5-315/80-1000-HL 18±2 5
Fig. 6-5 Adjustment of the shoe clearance
6.4.2.1.3 Adjustment of the shoe clearance balancing
As the following figure shows, open the brake, observe the gap between the braking gasket
and the braking wheel. If the gaps of two sides are not equal, screw out the locking nut of the
wider gap side, and screw the adjusting bolt clockwise and keep observing, stop screwing when
the gaps are equal. Finally screw in the locking nut. This device is an automatic balance device,
once be adjusted well, it’s no need to adjust again in the working process. If it appears badly
unbalanced shoe clearance in the working process (appearance of the braking gasket on the
one side floating over the braking wheel when the brake is releasing), it may because the
locking nut of the shoe clearance balancing device is loose. To deal with it, just close the brake
and screw in the locking nut tightly.
254
Fig. 6-6 Adjustment of the shoe clearance balancing

(1) Locking nut (2) Locking nut
(3) Braking wheel (4) Balance lever
(5) Distance
Keep the balance levers almost horizontal. Keep the distance (5)
between the bottom of the middle of the balance levers and the bottom
plate not less than 8mm, and keep the distance between the top of the
balance levers and the braking wheel not less than 5mm.
255
6.4.2.2 Replacing the braking gasket

1) Open the brake to the widest position;
2) Unscrew the bolts of the pressing plate on the top of the gasket, take down the pressing
plate and the adjusting washer;
3) Hold the gasket and push to the side of the brake wheel, pull out the gasket to be replaced
along the edge of the braking wheel;
4) Infer to the following figure, insert a new braking gasket to the right position, assemble the
(5) (4) (3) (2) successively and screw the (1) tightly;
5) After inserting the braking gasket, check the brake and ensure it’s alright, then make the
brake run statically for 20~30 times, which means the main motor is power-off, the brake
runs for each 5s with 40% braking loads, operate the brake in this working condition
intermittently for 25~30 times. Observe if there is any unusual situation, if yes, find out the
reason and deal with the problem until the brake is normal;
6) Adjust the braking moment to 50% rated value, take a dynamical pilot run for 15~20
circulations with 30%~50% braking loads. Observe the braking length is almost the same
or not, if yes, stop the pilot run.
Keep the new braking gasket fitting to the braking shoe clearance well,
the gap on the fitting surface can’t be over 0.5mm, and the top of the
gasket should higher than the top of the shoe clearance for 1.2~2.0mm,
so that the gasket can be pressed tightly and be reliable. Besides, the
thickness of the gaskets of the pressing plates and baffles of two sides
can’t be over half of the original thickness of the gasket but not less than
the 1/3 (with the thickness of steel back plate).
256
Fig. 6-7 Adjustment of the shoe clearance balancing

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

1) Inspect the brake for every 1~3 days (according to the actual situations), the things to be
inspected are:
◼ The shoe clearance is normal or not;
◼ The static length of the spring is changed or not;
◼ The touch plate of the limit switch is loose or not, the position of the limit switch is
correct or not;
◼ The surface of the brake or braking gasket are contaminated by oil or not;
◼ The wear of the braking gasket (If the thickness of the gasket is less than 3mm, the
gasket must be changed, then adjust and run the brake for adaptation.);
◼ The crack on the brake wheel, change the wheel if there is any deep crack.
257
2) In the working process, the following situations must be inspected if occurred:

◼ The braking time or distance increases abnormally;
◼ The braking wheel is overspeed;
◼ The movement of the limit switch is abnormal;
◼ The braking wheel or gasket is keeping hot or smoking. If occurred, stop the crane,
and find out the cause, solve it then the crane can be used again;
3) Paint mending: The paint on the brake can be damaged in the transporting, saving,
installing, or working processes. The paint damage must be touched up in time, otherwise
the antiseptic performance of the surface will reduce. The following parts are prohibited to
be contaminated in the paint touch-up process:
◼ Every hinge joint;
◼ The rubbing surface of the braking wheel and gasket;
◼ The surface of the automatic compensating device and the push rod of the pusher;
◼ The surface of the shafts.
4) Lubrication: Every hinge joint of the brake is self-lubricating composite bearing which is no
need to add lubricating oil;
5) Replacing the braking gasket: The braking gasket will wear out and be thinner after working
for some time. When the thickness of the gasket is less than 3mm, the gasket should be
replaced. Caution that the gasket is heavy when replacing. Please inspect, adapt, and take
a pilot run after the replacing;
6) Maintaining the brake: The brake has been filled with hydraulic oil when leave factory. The
pusher is a maintenance-free product (As the following figure). After working for a long
time, the hydraulic oil will be muddy and must be replaced. Generally, the hydraulic oil
should be replaced for every 1~2 years according to the actual situations. Replace the
hydraulic oil refer to the processes below:
◼ Remove the brake pusher and deliver it to the repairing workbench;
◼ Screw out the oil inlet plug and remove all the hydraulic oil inside;
◼ Fill the pusher with new hydraulic oil to the marked oil level.
(The types of the hydraulic oil according to the following table or nameplate on the product.)
Table 6-5 The types of the hydraulic oil
Surrounding Temperature Type Standard
DB-25 GB2536
-25℃～+50℃ DTE-21(Mobil) ISO VG15
HL-10 DIN51524
＜-25℃ YH-10 GB2512
258
Fig. 6-8 Parts of the braking pusher

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

exhaust the air in the cylinder and ensure enough filling, pull and push
the pusher rod slowly for several times when filling the oil.
If the brake work as S3, 60% brokenly, the pusher must be heavy
repaired or the brake be replaced.
259
6.4.3 Maintenance of the motor

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

1) Observe the motor and transmission after starting, if any abnormal situation occurs, stop
the motor immediately, find out the cause and solve it, then the motor can restart;
2) The increase heat of the working motor is prohibited to exceed the permission value. Using
the temperature gauge to measure the heat increase of the iron core or shell, generally
the increase can’t exceed 60℃, the increase of bearing can’t exceed 95℃, always monitor
the heat increase of the parts in the working;
3) Notice the smell, vibration, and noise of the motor. The winding will scorch with smell
because overheat. Some problems, especially the mechanism problem, will show as
vibration or noise, so the motor should be stopped immediately when the abnormal smell,
vibration, and noise occur;
4) Check if the bearing is overheating or oil-leaking constantly, and pay attention to
supplement or replace grease regularly. The grease is generally made of No,2 lithium
grease. Use the same grease as possible, the grease in the bearing room should not
exceed 70%;
5) Keep the motor clean, no water, oil and impurities can fall into the motor. The air inlet and
outlet must always be unobstructed;
6) If the motor leaves unused for a long time, mind to deal with the exposed parts of the motor
by dustproof and waterproof treatment. When use again, take a mechanism check before
installing, check if the assembly is complete, if the fasteners are loose. The dust or
impurities inside should be cleaned if there are, use dry compressed air to clean if
necessary. Must use 500V megohmmeter to measure the insulation resistance between
the stator winding and the shell. If it’s lower than 0.5 MΩ, the motor must be dried, charging
in low-voltage electric is a suggested way. The temperature of the winding is not allowed
to exceed 125℃. To avoid the motor rusting, when assembling after the excreting and
checking, all the fasteners (except the earthing bolts) and fitting surfaces should be applied
with a coat of clean anti-rust oil. All the fasteners should be attached with spring washer to
avoid loose. After the assembling, rotate the rotor by hands, the rotor should roll flexibly
and have no friction.
260
Avoid to crash, knock the brake and rotary encoder in the tail of the
motor. Check if the brake and rotary encoder are assembled completely
and installed right, and if the fasteners are loose.
6.4.4 Maintenance of the reducer

6.4.4.1 Period of the maintenance
Users should maintain the reducer regularly according to the items in the following table:
Table 6-6 The period of the reducer maintenance
Check items Period Remarks
Check the oil temperature Everyday
Check the abnormal noise of the
Everyday
reducer
Check the height of oil level Per month
Check the oil leaking of the reducer Per month
Clean the vent cover Every three months
After working four-hundred hours,
Check the water contain in oil
once a year at least
Replacing oil after starting the reducer
After working four-hundred hours
for the first time
Every eighteen months or five-
Oil replacing afterwards
thousand working hours
Clean the filter Every three months
Clean the vent cover Every three months
If the motor leaves unused for a long time, mind to deal with the exposed
parts of the motor by dustproof and waterproof treatment. When use
again, take a mechanism check before installing, check if the assembly
is complete, if the fasteners are loose. The dust or impurities inside
should be cleaned if there are, use dry compressed air to clean if
necessary.
261
6.4.4.2 Oil adding of the reducer

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

(17) Oil inlet (18) Shell
(19) Dipstick (20) Oil outlet plug
The oil adding steps are:

1) Open the part (1), remove the part (4), clear the waste oil inside, install the part (4) back;
2) Add gear oil conforms to the Table 6-1 into the reducer;
3) Observe by the dipstick, add oil until the level comes to half of the dipstick;
4) Install the part (1) back.
Ensure the gear oil has cool down to the surrounding temperature before
adding or replacing oil, otherwise the operator can be scalded.
262
6.4.5 Coupling
◼ Allowable motor axle deviation inspection
➢ Check the motor axle deviation of coupling from the inlet shaft of the reducer. Axial
deviation≤4mm, radial deviation≤1.5mm, angle deviation≤1° and radial run-out of braking
wheel≤0.7mm. If the value goes beyond, please adjust it into the prescribed limit or contact
after-sales service of our company;
➢ Check the coupling elastomers and half-coupling, if damages or cracks are found, please
stop operate or contact after-sales service of our company to check and change it.
If the value goes beyond, please adjust it into the prescribed limit or
contact after-sales service of our company.
◼ Coupling elastomers and half-coupling inspection
If damages or cracks are found on coupling elastomers and half-coupling,

please stop operating or contact after-sales service of ZOOMLION for
replacement.
263
6.5 Method of Rope Arrangement Problem of Hoisting
Mechanism
Rope of tower crane hoisting mechanism is multilayer coiling. The drum is lebus drum which is
fit for multilayer rope coiling. The characteristic is most of the rope race is straight line rope race.
The under-layer rope arrangement has obvious guide effect to the upper rope arrangement. It
is not easy to lead to rope climbing and rope disordering phenomena and is helpful to arranging
multilayer rope coiling orderly. Rope arrangement of hoisting mechanism is shown in
Fold line rope race
Straight line rope race
Rope
stretching
direction
Fig. 6-10 Drum structure
Table 6-7 Rope arrangement problem summary of hoisting mechanism
Rope arrangement problem summary
Problems description Reason analysis Handling Method
Check the lubrication condition, if dry

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

aslant aslant, if yes, adjust it.
264
Center lines of hoisting Adjust mechanism installation seat to let

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

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

Upper layer rope is pressed
tightly, if not, arrange it tightly with some
under the lower layer rope of the
load (2% of the minimum broken tension of
drum
the rope or 10% of rated hoisting load)
CAUTIONS:
◼ The lubricating condition has some effects to the rope arrangement. Check the lubricating
condition of the rope. If dry lubricating grease is found, wipe it off and paint new lubricating
grease.
◼ If rope disordering occurs, arrange the first layer rope tightly and well with some load (2%
of the minimum broken tension of the rope or 10% of rated hoisting load)
◼ When the tower crane is at the height and below free-standing height, the 6*29 non-rotate
hoisting rope can be used; The height of the tower crane greater than free-standing height,
the 35W×7 rotate rope suggest to be used.
◼ Disorderly rope during the service is related to diameter and pre-tightening force of the
rope. The rope was pre-tensioned when leave factory. The first layer rope must keep-in,
lined up and as much load as possible (2% of minimum breaking load rope or 10% of rated
load).
◼ In order to reduce the probability of mutual extrusion and random rope caused by more
layers around the rope, according to the construction progress, use cycle, final height, fall
change, life expectancy and other comprehensive conditions, consider the configuration
of multiple rope of different lengths, to ensure that the first layer of the drum rope has pre-
tightening force. By using short rope in the early stage, the service life of rope can be
effectively extended and the service cost of rope can be reduced.
◼ When the height of the tower crane is low, the length of the rope is suggested to use adopt
4-fall, and the pre-tightening force of the whole length can be satisfied through the load, to
prevent the phenomenon of rope sinking and chaos caused by the partial rope not being
preloaded.
◼ After the maximum length of rope is released, the rope on the drum should be retained for
at least 3 laps.
◼ The lubrication of the rope also has a certain influence on the arrangement of the rope.
The rope should be checked regularly. If the rope is found to have dry grease, it should be
removed manually and then smeared with new grease, see Table 6-1.
265
6.6 Trolley mechanism

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

(1) Motor (2) Travel limiter
(3) Reducer (4) Drum
266
6.6.2 Limiter of trolley mechanism

6.6.2.1 Function
The function of the limiter of trolley mechanism is to avoid potential wrong operation and keep
the hoisting jib moving within allowable operating angle range.
6.6.2.2 Working principle

The limiter with a reduction gear is directly driven by the reel shaft and the limiter records the
reel revolutions and the wire rope length. The cam ① driven by the reduction gear on the
limiter acts on the switch ② so as to complete the connection or disconnection action. See Fig.
6-12.
Fig. 6-12 Limiter of trolley mechanism
The plug at the lower part of the limiter must be removed to drain the
condensate in the limiter each time the tower crane is transferred to a new
construction site and before it is used.
If the tower crane has been used for a long time at a construction site, the
above operations shall also be performed regularly.
267
6.6.3 Trolley brake

2 3 4 5 6
7
Fig. 6-13 Trolley brake
(1) Brake disk (2) Hollow bolt
(3) Armature iron (4) Mounting screw
(5) Magnetic yoke assembly (6) Spring
(7) Fixture wire
6.6.3.1 The apply and release of brake
Fig. 6-14a Apply the electromagnetic brake Fig. 6-14 b Release the electromagnetic brake
Fig. 6-14 Apply and release of brake
268
6.6.3.2 Adjust the air gap of the trolley travel gear brake
Ensure the main motor and brake are power-off!
The normal working air gap of the brake is 0.6mm, maximum gap is 1.2mm. If check out the
brake is not working or the air gap over the maximum gap value the brake need to adjust.
1) See Fig. 6-15 loosen the retaining bolts ① and remove the fan cover ②;
2) See Fig. 6-15 loosen the installing screw ③ and then adjust the hollow nut ④ to the
proper position.
1 4
3
2
Fig. 6-15
3) See Fig. 6-16, install the fan cover ② and tighten the retaining bolts ①.
Fig. 6-16
If the air gap is not appropriate, repeat the step 2 and adjust it to 0.6 mm, it
should be consistent in all directions.
269
6.6.3.3 Maintenance
◼ Maintain once for every 450 hours or three months.
◼ Adjust the air gap: the standard air gap value E=0.6mm for the electromagnetic brake of
three-phase asynchronous motor. See Fig. 6-17.
I
Examine air gap
检查气隙 4:1
δ
Fig. 6-17 Adjust the air gap
Ensure that there are no sundries (for example: concrete, sand, or grease)
in the electromagnetism brake.
When the minimum value of the brake disk is reached, replace it as follows:
1) See Fig. 6-18, loosen the retaining bolts ① and remove the fan cover ②;
2) See Fig. 6-18 loosen the fixing screws ⑤, and remove the brake ⑥.
3) See Fig. 6-19, Remove the retaining ring⑦, pull out of the brake disk and the splinted
sleeve⑧
4) See Fig. 6-19, install new brake disk and splinted sleeve ⑧and fit the retaining ring ⑦;
5) See Fig. 6-20, install the brake ⑥ and the mounting bolts ⑤(adjust the air gap according
3.3.2 )
6) See Fig. 6-20, install the fan cover ② and tighten the retaining bolts ①.
270
1 6 5
2
Fig. 6-18 Maintenance process 1 and 2.
8 8
7 7
Fig. 6-19 Maintenance process 3 and 4
1
6 5 2
Fig. 6-20 Maintenance process 5 and 6
271
6.6.4 Maintenance for motor

6.6.4.1 The storage of motor
◼ The motor should be stored in dry and ventilative places and covered by waterproof cloth.
Keep the motor clean, and no droplet, greasy dirt, dust or erosion gas could be get into it.
Clean the inside and outside of the motor regularly.
◼ As for motors that have been stored for more than one year, clean the inside of it and dry
the inner water. Daub clean antirust oil on the bearings, all the matching surfaces and
fasteners with thread( except for grounded bolt).
◼ The covers, covers of connecting box and unused outlets on the end cover should be
covered soundly to avoid water, dust, oil or grease getting into the motor. Watch out for
mouse.
6.6.4.2 Maintenance for motor before reusing
◼ As for motors that have been stored for more than one year, check whether there is rust in
bearings and the location of bearings. If rust exist, exchange bearings immediately. Clean
and refuel the bearings before restarting to avoid damages or noise caused by dried
grease.
◼ Check whether the assemble is integrated, or whether the fasteners are tight. If there are
dust or foreign materials inside, please clean up and use dry compressed air when
necessary.
◼ If the mechanism is left unused for a long time, the exposed parts of the motor should be
kept dust-free and dry. When it is to use again, perform mechanical check before
installation. Check whether the assemble is integrated, or whether the fasteners are tight.
If there are dust or foreign materials inside, please clean up and use dry compressed air
when necessary. Measuring the insulation resistance between stator winding and shell
with 500V Megohmmeter before using. When the figure is less than 0.5 megohm, the motor
should be withered and the drying treatment could be performed by bubbling low pressure
air into the winding ( the temperature should not be more than 125℃). To avoid motor rusty,
it is recommended to daub anticorrosive oil on the matching surface and fasteners with
thread( except for grounding bolts) during installing. Also, all the fasteners should be with
spring washer to avoid automatic relaxation. After installation, turn the rotor manually and
it could rotate freely with no friction.
◼ After installation, check whether the brake could close firmly or release. After energizing,
the rotor of the motor could be rotated elastically by hand.
◼ When install gear or coupling, clear the rust on the shaft first. Heavy strike should be
forbidden to avoid damages to the bearings
◼ The connection box is equipped with grounding bolts which should be grounded reliably
after installation.
◼ The method of connection of motor should be exactly the same with the requirements
offered in this technical file, or abnormal operation or even overburn will occur.
◼ After installation of motor, it should run 30~40 minutes without load. If the condition is well,
then add load and watch out for the stability of power. When deviation between the voltage
of power( the frequency is rated) and rated voltage is no more than ± 5%; or positive
272
deviation occurs both for voltage and frequency and the sum total of them is no more than
6%; or negative deviation occurs both for voltage and frequency or one is positive and the
other is negative, and the total sum of them of absolute value is no more than 5%, the
motor is allowed to operate in rated condition.
6.6.5 Oil adding of the reducer

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

6.7.1 Overview
There are two slewing mechanisms arranged on both sides of the upper support. The braking
method is normally closed braking with weathercock. The motor and reducer need maintenance
regularly.
6.7.2 Slewing brake

6.7.2.1 Working principle
The slewing brake is an electromagnetic brake, which will be applied once the power supply is
cut off. See Fig. 6-21
Fig. 6-21a Brake released Fig. 6-21b Brake applied

Fig. 6-21 Working state of brake
273
6.7.2.2 Clearance adjustment and maintenance (1)

For conventional brake structure as shown in Fig. 6-22, brake friction plate (13) after long-term
use of friction losses, armature (10) and field core (9) increase the air gap δ, brake spring (16)
length increases, reduce the braking moment, because the air gap δ may increase at the same
time, the armature (10) have difficult in actuation, serious will not be able to actuation, result
the motor in braking state, and then the motor burnout. Therebefore, it is necessary to check
the air gap δ value frequently. When the static braking moment is less than the stipulate value
or greater than 1.2mm, the δ should be adjusted in time. And if the friction plate (13) is worn to
close to its steel mail, the friction plate (13) should be replaced in time.
1 2 3 4
17
5
16
6
7
15
8
9
δ
10
11
13
12
13
14
Fig. 6-22 Brake structure

(1) Cover (2) Adjust nut
(3) Release rod (4) Release handle
(5) Armature (6) Push handle
(7) Electromagnet (8) Locating screw
(9) Field core (10) Armature
(11) Friction disk (12) Braking plate
(13) Friction piece (14) Motor engine base with cover
(15) Spring chamber (16) Braking spring
(17) Release screw
274
◼ Regular inspection
Regular inspection once a month, do not remove any parts, the braking opening, braking
should be metal impact sound; When the motor is running, the brake should have no
abnormal sound (friction, metal impact) and vibration.
◼ Regular adjust
Once every 3 months, remove the weathercock cover. Flat mouth screwdriver loosens the
positioning screw and counterclockwise moving armature pull cylindrical gear, let the armature
against field core, to promote the positioning screw, make its end stick close with armature ends,
at the same time with a flat mouth screwdriver clockwise slowly moving armature pull cylindrical
gear, when the end of the armature fifth hole through the end of the positioning screw, insert
and tighten the set screw on moving (the clearance values δ: 0. 75-~1.0m). When the brake is
opened and braking, the action should be sensitive and there should be obvious metal impact.
When the motor is running, the brake has no abnormal sound (rubbing sound, metal impact
sound) and action.
◼ Regular dismantling and check
Once every 6 months, remove the whole lower vane brake and check the friction plate (13).
When its thickness is less than 3m, the friction plate must be replaced. Install the whole
windward marker brake, and adjust the clearance δ value according to the regular debugging
requirements.
◼ Replace Steps of brake friction disk
1) Put the tower crane in the safe state, ensure will not happen any accident when
Dismantling motor operation, otherwise the following operations were prohibit！
2) Cut off all power;
3) Dismantling electrical weather vane;
4) Unscrew locating screw (8);
5) Unscrew the spring chamber (15), take out the brake spring (16), unscrew the mounting
screw of the exciting iron core (9), carefully remove the exciting iron core (pay attention
to protecting the exciting iron core lead), remove the friction disc (11) and brake disc (12),
and check the friction disk mounted on the cover frame (14) and the friction disk
respectively. The friction plate on (11) if the friction plate is seriously worn, it should be
replaced immediately (13), remove the worn friction plate (13) and install a new;
6) Remove the worn friction plate and install a new one;
7) Reinstall the removed parts in the reverse order, and adjust the brake gap δ according to
the second (regular debugging), and adjust the electric weathercock according to the fifth
(adjustment steps of the electric weathercock).
◼ Adjustment steps of electric weathervane
1) Disconnect all power supplies, and adjust the brake gap δ according to the second
(regular debugging);
2) Put the motor under braking state (weathercock release lever (3) can move downwards
freely);
275
3) Hold down the weathercock release handle (4), and slightly loosen the adjusting nut (2) in
a counterclockwise direction, so that the weathercock armature (5) emerges about 1mm
below the weathercock release lever (3);
4) Release the electric weathercock by sounding to see if the action is normal. If the
weathercock armature (5) is blocked from free movement under the weathercock release
lever (3), the adjusting nut (2) should be loosened again at this time, if the weathercock
armature (5) If the weathercock release lever (3) cannot be supported, the adjusting nut
(2) should be properly tightened;
5) Manual and electric release several times, and then close the weathercock cover after the
action is normal.
◼ Check whether the weathercock is working properly, and readjust if

necessary. When the gap value is greater than 1.2mm, the gap value should
be adjusted in time, and the recommended gap value is about 0.8mm;
◼ When the thickness of the friction plate is less than 3mm, the friction plate
should be replaced in time;
◼ The adjusted electromagnetic brake and electric wind indicator should be
checked if the manual release function, electric release function and braking
function are normal, and they can be put into use after being normal.
◼ The electromagnet of the electric weathercock cannot be energized for a
long time, otherwise it will burn the electric weathercock electromagnet.
◼ When the motor is working normally. The electric release action of the
electric weathercock cannot be used, otherwise it will cause the motor brake
to work abnormally, which will affect the safety of the tower crane in severe
cases.
276
6.7.2.3 Clearance adjustment and maintenance (2)

Lay out of new designed slewing motor as shown the following Fig. 6-23.
Fig. 6-23 The structure of the YTRVF series variable frequency motor with vane brake
Table 6-8 Spare parts of YTRVF series motor
No. Designation Qty. No. Designation Qty.
1 Front-cover 1 7 Electric weather vane 1
2 Bearing 2 8 Brake 1
3 Connecting box 1 9 Fan blade 1
4 Stator 1 10 Coder 1
5 Rotator 1 11 Cover 1
6 Back -cover 1
277
Adjustment of the weather vane braking：Divide into weather vane adjustment and brake
adjustment. The structure of the weather vane brake as show in the following picture:
Fig. 6-24 The structure of the weather vane brake
Table 6-9 Spare parts of weather vane brake
No. Designation Qty. No. Designation Qty.
1 Long pin 2 10 Spring 4
2 Bottom plate of loose brake 1 11 Static core assembly 1
3 Clip-on 2 12 Moving plate 1
4 Reset spring 2 13 Friction assembly 1
5 Waterproof block 1 14 Screw sleeve 3
6 Loose brake rod 1 15 Microswitch 2
7 Shield 1 16 Spline hub 1
8 Basal plate 1 17 Dual disc 1
9 Brake type plate 1
1) Adjustment steps of electromagnetic brake
After long-term use and wear of the brake friction plate, the gap between the armature and the
excitation magnet core increases, the length of the brake spring increases, and the braking
torque is reduced. At the same time, due to the enlarged gap, it is difficult for the armature to
pull in. In severe cases, it cannot be pulled in, causing the motor to be in a braking state, and
even the motor is burned out. When the static braking torque is less than the specified value or
278
the gap is greater than 1.5mm, it should be adjusted in time. When the thickness of one side of
the integral friction disc is less than 1.5mm, it should be replaced in time.
2) Adjustment of electric weathervane
Both the brake and the contact plate are energized and closed, and the lower end surface of
the release brake bottom plate and the end surface of the contact plate (figure number 1) have
a clearance of 0.3m. The gap between the contact plate and the micro switch (Figure No. 2) is
0.5m to prevent damage to the micro switch contact caused by long-term overvoltage.
Fig. 6-25 Electromagnetic iron assembly
3) Adjustment steps of electromagnetic brake gap
As show in the Fig. 6-26, the adjustment steps of electromagnetic brake gap can be divided
into: adjust the gap between static core and moving plate; adjust the gap between bottom plate
of loose brake and contact plate.
Fig. 6-26 Adjust electromagnetic brake gap

(1) Release brake bottom plate (2) Gap 2
(3) Contact plate (4) Nut
(5) Screw 1 (6) Static core
(7) Gap 1 (8) Moving plate
(9) Adjusting bolt (10) Screw 2
279
◼ Adjust the gap between the static core and the moving plate
➢ Put the tower crane in a safe state to ensure that the motor is operated on the premise
that no safety accident occurs during disassembly. Otherwise, the following operations are
prohibited;
➢ Disconnect all power supplies;
➢ Insert the 0.7mm feeler gauge into gap 1, tighten the screw 1. When the feeler gauge is
clamped, stop screwing the screw 1;
➢ Turn the adjusting bolt to the left, stop turning the adjusting bolt when the feeler gauge can
be easily taken out, and then tighten the screw 1 completely;
➢ When the feeler gauge is pulled out, there is a sense of blockage and the gap meets the
requirements. If the gap is too large, loosen the screw and adjust the bolt. Fine-tune to the
right, and then fully tighten the screw 1. On the contrary, if the gap is too small, fine-tune
the adjusting bolt to the right;
➢ Repeat the above steps to adjust the front of the remaining 2 screws.
◼ Adjust the gap between the brake release bottom plate and the contact plate
After power on, the contact plate is attracted and the contact plate is in a vertical state. The gap
between the upper surface of the contact plate and the lower surface of the loose gate is
0.3~0.5mm. When adjusting the gap, first screw down the nut on the screw 2. When the gap is
too large, screw the screw 2 upwards, and when the gap is too small, screw the screw 2
downwards until the gap meets the requirements, and then tighten the nut.
4) Replacement of the integral friction disc
◼ The overall friction disc should be replaced by a professionally trained person, otherwise
it is easy to cause other damage;
◼ Put the tower crane in a safe state to ensure that the motor is disassembled without any
safety accidents. One step operation, otherwise, the next operation is prohibited;
◼ Disconnect all power;
◼ Remove the wind vane and brake connecting wire;
◼ Remove the parts at the rear end of the integral friction disc one by one (the entire
weathercock brake);
◼ Replace with a new integral friction disc of the same specification;
◼ Install the disassembled parts one by one, and adjust the brake according to the same
clearance adjustment procedure of the electromagnetic brake.
After adjusting the brake and electric wind indicator, check whether their braking,
manual release and electric release functions are normal. After everything is
normal, the motor can be put into use.
280
6.7.3 Maintenance for slewing ring

◼ The rolling groove of the slewing ring has been filled with 2# extreme pressure lithium base
grease when leaves the factory. Add the grease once every 100 hours of operation,
Addition of lithium base grease, should make the slewing mechanism rotated slowly, while
rotation, while the oil, the grease filling evenly, until the seal a grease extrusion, said the
old fat has been replaced by. Special working environment, such as rain, humidity, dust,
temperature variation and continuous operation, it should shorten the lubrication cycle;
◼ After long time idle, enough new grease must be added to slewing ring;
◼ Exposure of tooth surface and tooth surface, often should clean the rubbish, and coated
with grease corresponding;
◼ Slewing bearing the first 100 hours of operation, should check the retightening force of bolt.
After examining every 500 hours of operation time, must keep enough preload force;
◼ The use of the process, if found, the impact of noise, power increases suddenly, should
immediately stop check, troubleshooting, remove check when necessary;
◼ Never use water directly scour slewing bearing the use of the process, to water entering
the race;
◼ To prevent the hard foreign body close to or into the meshing area;
◼ Always check the seal intact, if it is found that the sealing strip damaged should be replaced
promptly, if found off should be timely reset.
281
6.8 Maintenance climbing mechanism

6.8.1 Working principle
The climbing hydraulic system consists of pump station, climbing cylinder and high-pressure
hose. It can jack or lower the upper parts of the telescopic cage, and stop at any position for
mounting or dismounting tower mast sand tower sections. Refer to the figure below:
Fig. 6-27 Schematic diagram of tubes connecting of the Hydraulic system

(1) Balance valve (2) Climbing cylinder
(3) Motor (4) Terminal box
(5) Air switch (6) Pressure gage
(7) Control handle (8) Liquid level meter
(9) Pump station
282
Fig. 6-28 Schematic diagram of hydraulic system

(1) Pump station (2) Balance valve
(3) Manual control valve (4) Pressure gauge
(5) High pressure overflow valve (6) Motor
(7) Level meter (8) Level meter
(9) Oil filter (10) Fine oil filter
(11) Air filter (12) Tube
283
6.8.2 Erection, operation, and maintenance of the hydraulic

pressure system
6.8.2.1 Erection, operation of the hydraulic pressure system
◼ Oil cleaning
Screw open oil suction screen 11, fill 10μ hydraulic oil filtered by hand-held oil filter into the oil
tank up to the upper limit mark. After that, start the oil pump motor (look down at the motor
blades to see if the rotation direction is the same as that marked at the motor tail)
Pay attention to the fact that the pump may be rotated either left or right. Wrong
wiring will cause no system working and pump burn-down.
◼ Connect high-pressure hose openings for clean status

Connect ports A.B of the hydraulic pump station to the hydraulic cylinders through high-
pressure hose. Screw down the connectors.
◼ Air exhausting of the system
Unscrew the handle of overflow valve, and then the high-pressure hose-to-port A connector.
Move the handle of hand-operated valve 3 to its up position. Start the motor to drive the air out
of Port A until the pump noise has become normal and no foam formation from oil liquid. Make
the cylinder into no-load status. Push the operating handle to let upper cylinder or piston rod
move up and down at full strokes for several times to completely exhaust the air from cylinder
into oil tank through oil hose.
When the piston rod has moved to its extreme position, pull back the handle
immediately to its middle position and keep this position for several minutes until
air bubbles in oil tank have disappeared, and then carry out another action.
◼ System operation
Before system operation, check if the oil cylinder is well connected to the crane frame, including
the check of relevant portions of the tower crane for meeting relevant technical requirements:
1) Maximum working pressure setting: Unscrew the locking nuts, in front of the control handle,
of overflow valve 5 at non-jacking operation status. Start motor 6. Move the operating
handle to upper position and extend the cylinder piston rod to its extreme position. At this
time, pressure gauge 4 readings rise. Keep on screwing down the handle of the overflow
valve until the readings on pressure gauge 4 have become stable at 31.5 Mpa. Screw
down the locking nut in front of the regulating handle of the high-pressure overflow valve
(The overflow valve shall not be adjusted by unauthorized or untrained person). Operate
the handle in a reverse direction to retract the piston rod. Finally move the handle back to
its middle position.
2) Start motor, and move operating handle to its up position. Extrude the cylinder piston rod
to hang the hanging plate connected to the piston rod into the lugs slot of the tower mast
section. Carry out the jacking operation for new section adding (or tower section
dismantling).
284
6.8.2.2 Maintenance and precautions for hydraulic system

The hydraulic system is super high-pressure or high-pressure equipment. The whole process
from oil filling to adjustment shall be accomplished strictly according to the stipulations in its
operating instructions.
◼ Hydraulic oil for the system
➢ Anti-wear hydraulic oil L-HM 46 shall be used in the hydraulic system according to the
regulations. Mixture other hydraulic oils or fill directly without filtering the oil are prohibit.
When oil foaming or emulsification, should be timely cleaning mailbox replacement of new
oil;
➢ Filling oil: Fully fill the tank with oil for the first time. After start-up, extrude the cylinder rod,
and then retract the cylinder rod. At this time, fill the tank with make-up oil up to the tank
upper limit mark;
➢ At this time it is a high-pressure hydraulic system with strict requirements of highly cleaned
oil, which should be filtered for 4~6 hours by hand-hold filter. The oil cleanness should
reach 7~8 levels (NAS1638) before starting the system;
➢ The oil should be completely changed after the system working for 2400h and add part of
clean oil after working for 1 month;
◼ Shut the system when it is out of service because of the poor condition of ventilation;
◼ To avoid damage the components, the pump station should be protected well by rainproof
shield when raining;
◼ Be careful when lifting and transporting. No charge and discharge rudely. Don’t put it in
environment that can corrode metal and rubber.
285
6.8.2.3 Common troubles and troubleshooting

Table 6-10 The common troubles and methods of troubleshooting
No. Trouble Reason Troubleshooting
Motor rotates in wrong
Commutate the motor line
direction
Oil relief valve get stuck by Dismantle main valve and
impurity in unclean oil clean it
Pump station outputs no
Hose had ruptured and Dismantle the hose, weld
pressure / Pressure can't
1 spill oil the crack or replace it
be adjusted to rated value /
Hose joint is loose Tighten the joint
Pressure is not stable
Seal of joint is broken Replace the broken seal
Coarse oil filter is blocked Clean it
Pump is broken for
Replace the pump
overloading
Joint at line terminal and Check the line, connect it
circuit breaker has according to the
loosened schematic circuit diagram
Motor don't revolve after
2 Circuit breaker
power source is connected Check the contact and
automatically tripped or
breaker, repair or replace
burned because of
it
overloading or short circuit
◼ Never let the cylinder’s balance valve and the pipeline be crashed, check
that if the clamping screw of the balance valve is loose when change place
and set up the tower, to avoid the danger!
◼ The O-ring between the balance valve and cylinder should be change once
two year!
◼ Don’t adjust the pressure of the pump station when the cylinder on the work,
only in the condition that the piston rod of the cylinder retract or extend!
◼ When the piston rod retracts completely, the pressure lever of the oil tank
should reach the max lever position!
◼ To avoid safety accident, the jacking pumping station should not be used
when natural wind over fourth lever!
◼ When power off and the pump out of work, adjust the balance valve
clockwise to make the piston rod retract.
◼ If the pump station out of work for a long time, it must run for more than 30-
minutes before use.
286
6.9 Rope
6.9.1 Basic Knowledge of Rope
1) The structure of rope
Wire rope is a spiral structure, which made up of a certain number of a layer or layers of wire
strands, see the figure below.
2) The lay of rope as the following figure
Fig. 6-29 The structure of Rope Fig. 6-30 The twist of Rope
3) Measuring the Diameter of Rope

Measure the diameter of the rope through correct method, see the figure below.
Fig. 6-31 Measuring the diameter of the rope
287
4) Discharge and Storage

To avoid the contingency, be careful when discharging the ropes. The reel should not go down.
It is not allowable to insert the rope by metal hook or lifter fork, see the figure below.
Fig. 6-32 Discharging the ropes
288
Ropes should be stored in the cool and dry warehouse and cannot be in contact with the ground.
Ropes must not be stored in the location which is easy to be affected by chemistry fog, steam,
or other corrosives. Check the stored ropes regularly, and if necessary, bind the ropes up. If
outdoors storage cannot be avoided, cover the ropes to avoid the damp corroding the ropes,
see the figure below.
Thoroughly clean the discharged from the crane. Bind every rope up before storing them. The
ropes whose lengths exceed 30m should be stored on the reel.
Fig. 6-33 The storage of the rope
289
5) Uniting the Rope

When uniting the rope, put the rope on specified bracket or reeve a steel tube through rope
reel hole, hoist the two ends after being put rope sleeves and rotate the rope reel slowly, refer
to the figure below.
Fig. 6-34 Untiring rope from rope sheaf
290
291
Fig. 6-35 Uniting rope from rope reel

6) Rope clamp
◼ Arrangement of the rope clamps
The rope clamp must be buckled on the working rope line in such a way as is shown as the
following figure. Buckle the U-shape rope clamp on the end of the rope.
Fig. 6-36 Correct method to arrange the rope clamps
◼ Number of rope clamps

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

Nominal dimension of rope clamp mm
≤19 >19~32 >32~38 >38~44 >44~60
(nominal diameter of rope d)
The minimum number of the rope
3 4 5 6 7
clamp(suit)
292
◼ Interval between two rope clamps

As the figure below, the distance A between two rope clamps is about 6～7 times of the rope
diameter.
Fig. 6-37 Interval between two rope clamps
◼ The fastening method of rope clamps

Considering every rope clamp can be forced reasonably when you fasten and fix the clamps,
the farthest clamp should not be fastened and fixed firstly. The rope clamp abutting the rope
ring (the first rope clamp) should be as close to the rope ring as possible, and the rope clamp
shall be correctly tightened without damaging the outside layer of wires.
6.9.2 Rope List

Ropes for WA7025-12E are shown as the table below:
Table 6-12 Ropes for WA7025-12E
Nominal Minimum
Diameter length braking Fixing
Designation Specification Remark
(mm) mass force method
kg/100m (kN)
The diameters of the

selected ropes must
meet the
Hoisting requirement listed in
35×7-16-1870 Φ16 118 172 Wedges
rope the table
The minimum
breaking force of the
rope shall not be
less than the value
6×19-9.3-
Trolley rope Φ9.3 30.45 46.495 Sleeves listed in the table
1700-Ⅱ-Right
293
6.9.3 The length of the rope

The length of the selected rope must meet the use requirement of this tower crane. There must
be three rounds of rope on the terminal location of the drum at least. According to the use
condition, if it is needed to cut a section of rope from the long rope, the two ends need special
handling or adopt proper method to avoid the rope loosing during cutting off the rope, see the
figure below.
Fig. 6-38 Preparation for cutting off the rope (L≥2d)
294
6.9.3.1 Calculating the length of the hoisting rope

Total length required for hoisting rope
L＝L0+f×H
L0——The sum of the rope lengths of the hook on the max hoisting height, m; see the table
below.
f——Falls used;
H——Hoisting height, m.
Fig. 6-39 Calculating the length of the hoisting rope
295
6.9.4 Installation of the Rope

The rope should not be disturbed during installation, when uncoiling the wire rope from a reel
or coil, every precaution shall be taken to avoid the Tweaked or tightened kink, bends etc. of
the rope.
During installation, the rope shall always bend in the same direction: i.e., pay out from the top
of the reel to the top of the drum, or from the bottom of the reel to the bottom of the drum, see
the figure below.
Care shall be taken to ensure that termination anchorages are made and secured in accordance
with the instructions in the crane manual.
If the rope rubs against any part of the crane during installation, then the points of contact shall
be suitably protected.
Fig. 6-40 The rope winding

Replacing steel rope of Tower crane should be carried out in accordance with the relevant
chapters in the tower crane operation manual to correctly wear around, and make wire rope
bend in the same direction as far as possible, otherwise will seriously affect the life of wire rope.
Wire rope should be installed at pre-tightening condition.
Before put into use wire rope on hoisting machinery, the user should ensure that all related to
the wire rope work device is installed in place and working properly.
In order to make the steel wire rope stable in place, about 10% of the rated load shall be used
to rope wheel system running operation for several times, in order to make wire rope can be
accurate and stable in the system, more joint drum steel wire rope, the rope internal release, it
is advantageous to the rope neatly, and effectively prevent the wire rope to disturb.
296
6.9.5 Discard Criteria of Rope

1) Nature and number of broken wires
The table below take these factors into account when considered in conjunction with the factors
given in (2) to (19). So, it can be applied to all structure’s ropes.
Table 6-13 Allowable number of broken wires

The number of visible broken wire rope Concerned with fatigue when
Number of loads lifting machinery must be scrapped
bearing wires of Working classification M1, M2, Working classification M5, M6,
the outer layer M3, M4 M7, M8
of the rope ordinary lay Lang lay ordinary lay Lang lay
n Length range Length range
6d 30d 6d 30d 6d 30d 6d 30d
n≤50 2 4 1 2 4 8 4 8
51≤n≤75 3 6 2 3 6 12 6 12
76≤n≤100 4 8 2 4 8 16 8 16
101≤n≤120 5 10 2 5 10 20 10 20
121≤n≤140 6 11 3 6 12 22 12 22
141≤n≤160 6 13 3 6 12 26 12 26
161≤n≤180 7 14 4 7 14 28 14 28
181≤n≤200 8 16 4 8 16 32 16 32
201≤n≤220 9 18 4 9 18 36 18 36
221≤n≤240 10 19 5 10 20 38 20 38
241≤n≤260 10 21 5 10 10 42 10 21
261≤n≤280 11 22 6 11 20 42 20 42
281≤n≤300 12 24 6 12 22 44 22 44
n>300 0.04n 0.08n 0.02n 0.04n 0.08n 0.16n 0.08n 0.16n
NOTE
Filler rope cannot be regarded as bearing rope, so be deducted from check number. Layers
of strands wire rope only consider the visible outer strand, rope with steel core which is
regarded as an internal core strand rope would not be considered
d ——nominal diameter of rope, unit: mm
297
2) Broken wires at the termination

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

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

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

Reduction of rope diameter results from deterioration of a fiber core or fracture of a steel core.
If rope diameters notable reduces, the rope shall be immediately discarded.
Low values of deterioration might not be so apparent from normal examination, particularly if
the rope stresses are well balanced throughout the individual strands. However, the condition
can result in a high loss of rope strength, so any suggestion of such internal deterioration shall
be verified by internal examination procedures, If such deterioration is confirmed, the rope shall
be discarded.
7) External abrasion
Abrasion of the crown wires of outer strands in the rope results from rubbing contact, under
pressure, with the grooves in the sheaves and drums. The condition is particularly evident on
moving ropes at points of sheave contact when the load is being accelerated or decelerated,
and is revealed by flat surfaces on the outer wires.
Wear is promoted by lack of lubrication, or incorrect lubrication, and by the presence of dust
and grit. Wear reduces the strength of ropes by reducing the cross-sectional area of the steel
strands. If, due to external wear, the actual rope diameter has decreased by 7% or more of the
nominal rope diameter, the rope shall be discarded even if no wire breaks are visible.
298
8) Elasticity decreases
Under certain circumstances usually associated with the working environment, a rope can
sustain a distinct decrease in elasticity and is thus unsafe for further use. Decreased elasticity
is difficult to detect. If the examiner has any doubt, advice shall be obtained from a specialist
in wire ropes.
While no wire breaks may be visible, the wire rope will be noticeably stiffer to handle and will
certainly have a reduction in diameter greater than that related purely to wear of individual wires.
This condition can lead to abrupt failure under dynamic loading and is sufficient justification for
immediate discard.
9) External and internal corrosion

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

As the figure below, when the waviness distortion occurs, when the rope length is no more than
25d, d1>4d/3, the rope shall be discarded. In the formula d is the nominal diameter of the rope
and d1 is the diameter corresponding to the envelope of the distorted rope.
Fig. 6-41 Waviness distortion
11) Basket or lantern deformation

Basket or lantern deformation is a result of a difference in length between the rope core and
the outer layer of strands. Ropes with a basket or lantern deformation shall be immediately
discarded as the figure below.
Fig. 6-42 Basket or lantern deformation
299
12) Strand protrusion

Strand protrusion usually happens with basket or lantern deformation. It shows the rope
misbalanced. Rope with strand protrusion shall be immediately discarded as the figure below.
Fig. 6-43 Strand protrusion
13) Wire protrusion

In wire protrusion, certain wires or groups of wires rise, on the side of the rope opposite to the
sheave groove, in the form of loops. Rope with wire protrusion shall be immediately discarded
as the figure below.
Fig. 6-44 Wire protrusion
14) Local increase of diameter of the rope

A local increase in rope diameter can occur and might affect a relatively long length of the rope.
This condition usually relates to a deformation of the core (in particular environments, a fiber
core can swell up owing to the effect of moisture) and consequently creates imbalance in the
outer strands, which become incorrectly oriented. If the local actual rope diameter increases
seriously, the rope shall be immediately discarded as the figure below.
Fig. 6-45 Local increase of diameter of the rope
300
15) Flattened portions

Flattened portions of rope results from machine accidences as the figure below. If flattened
portions of rope is serious, the rope shall be discarded immediately.
Fig. 6-46 Flattened portions
16) Kinks or tightened loops

A kink or tightened loop is a deformation created by a loop in the rope which has been tightened
without allowing for rotation about its axis. Imbalance of lay length occurs, which will cause
excessive wear, and in severe cases the rope will be so distorted that it will have only a small
proportion of its strength remaining. As the figure below showing, rope with serious kinks
tightened loop shall be immediately discarded.
Fig. 6-47 Tweaked or tightened kink
17) Bends
Bends are angular deformations of the rope caused by external influence. Rope with a severe
bend should be immediately discarded as the figure below.
Fig. 6-48 Bends

18) Local decrease of diameter of the rope
A local decrease in rope diameter usually relates to a fracture of the core. As the figure below
showing, local decrease of diameter of the rope shall be immediately discarded.
Fig. 6-49 Local decrease of diameter of the rope
301
19) Damage due to heat or electric arcing

Ropes that have been subjected to exceptional thermal effects, externally recognized by the
colors produced in the rope, shall be immediately discarded.
6.9.6 Maintenance of Rope

Maintenance of the rope should be relative to the crane usage environment and involved rope
type. Paint lubricating grease and lubricating oil when installing the rope. The rope shall be
cleaned where necessary, and the rope being reused in regular time interval, especially before
the section of rope passing round the pulley shows signs of dryness or corrosion should be kept
in good lubricating condition.
The rope lubricating oil (grease) should be Graphite calcium base grease ZG-SSY1405-65, it
has strong penetration. A shorter working life of rope will result from lack of maintenance.
If wire rope grease on the surface dry, it should be cleaned in time, and apply new accord with
the prescribed grease.
Wire rope surface should avoid applying too much grease. Surface blotted out too much grease
may produce the following question
1) Aggravated deterioration of the rope rupture
2) Environmental pollution
3) Easy adhesion of the dust or other substances, make the wire rope from corrosion
302
6.10 Maintenance of pulley assembly

6.10.1 Examination of pulley assembly
Hoist pulley, trolley pulley, trolley and hook pulley are non-lubricating bearings. The pulley shaft
has no oil nozzles and does not need to be lubricating,
◼ Daily inspection of bearings:
➢ whether there is oil leakage
➢ Shaft end seals
➢ Elastic ring
➢ Operation noise and resistance
➢ Bearing clearance.
◼ Table of pulley parameters, Table 6-14
Table 6-14 pulley parameters

Diameter Rope groove Rope groove
Designation Specification
(mm) depth (h) radius (R)
Hoist pulley HL-450-380-80-130- R8.5 450 35 8.5
Trolley pulley 214-178-B41-80-R6 214 18 6
6.10.2 Pulley scrap

The main forms of pulley damage are worn and extrusion of the pulley groove caused by the
steel rope. Generally, the surface condition of the pulley groove (Fig. 6-50 and Fig 6-51), wear
depth and arc radius are the basis for judging whether the pulley is normal or not.
◼ Surface condition of rope groove

The surface of the pulley groove should be worn evenly and smoothly. When there is obvious
indentation, the pulley should be replaced.
303
Fig. 6-50 Example pulley indentation Fig. 6-51 Depth detection of rope groove
◼ Depth of rope groove

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

➢ Due to wear, the radius R of the rope groove will change. when the value of R exceeds
0.525d~0.6d, the pulley should be replaced.
➢ The rope groove radius detection method as shown in Fig. 6-52
➢ The radius of the pulley grooves is detected by the pulley gauge or radius gauge (R gauge).
From the beginning of the large diameter measuring tool to the arc of the measuring tool
basically coincides with the arc of the normal section of the pulley groove.
Fig. 6-52 Examples of radius detection of pulley groove arc
◼ When the pulley is found to have flange, crack and other phenomena, the pulley should
also be replaced.
304
6.11 The high strength bolts

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

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

Use molybdenum disulfide to lubricate all the bolt assemblies before installing them. Good
lubrication can supply uniform friction and standard preload for the bolt.
As is shown in Fig. 6 53 please lubricate the threads of the bolts and nuts
and the contact surfaces. If the preload is exerted on the bolt head, the
contact surfaces of the bolt head need to be lubricated as well.
305
Fig. 6-53 Lubricate the contact surface
6.11.4 Recycling the high strength bolt

All the bolt assemblies which were exerted preload rightly can be recycled when erecting the
tower crane again. However, all the bolt assemblies recycled must have been checked and are
not damaged.
306
6.12 Steel structure

6.12.1 Foreword
This description contains the maintenance instructions for the steel structure elements of the
crane.
6.12.2 Description
Fig. 6-54 Steel structure of the crane

(1) Fixing angles (2) Crane tower
(3) Telescopic cage (4) Counter-jib
(5) Jib
307
6.12.3 Description
The structure defines all the metallic parts constituting the crane steel structure.
◼ Cleanness / cleaning
General condition / appearance
◼ Paint / corrosion
◼ Ballast
◼ Derrick/ mast/ crane tower/ jib / counter−jib
◼ pins / screw bolts
Steel structure ◼ Ladders / platforms / grab rails / catwalks / guard
ropes
◼ Lifting cab guiding system
◼ Greasing
6.12.4 Maintenance
General condition / appearance
Check the general crane aspect: cleanness (concrete, mud, and sand splashes, etc...).
Cleanness and general correct appearance of the crane avoid risks and
operating problems.
Cleanness / cleaning
The cleaning must be carried out with fresh water without detergent. Using a high−pressure
apparatus is possible if the following instructions are observed:
Never apply the squirt directly on hinges, cables, safety devices and
electrical equipment: control panel interior, cables, connectors, terminal
strips, etc..
The control panel inside must be freed from dust by means of compressed air. Remove dust
from the electrical equipment and the safety devices with a dry cloth.
After each cleaning all the required parts must be lubricated and
greased.
308
Paint / corrosion
Carry out a visual check of the following points:
◼ In case of a drain line due to an invisible corrosion, carry out a regular check,
◼ In case of corrosion on a painted part, clean and grind the area, then apply a layer of rust
preventing agent and paint,
◼ In case of wear of the surface treatment, clean and grind the area, then apply a layer of
rust preventing agent and paint.
Steel structure
Carry out a visual check of the ballast concerning the following points:
◼ In case of cracks, fretting, too considerable wear, carry out a weighing in order to make
sure that the ballast weight is still within the tolerance.
Tolerance of the ballast weight: 0 to + 4% (base) / −2 to +2% (counter-jib).
◼ In case of corrosion on the metallic ballast, clean and grind the area, then apply a layer of
rust preventing agent and paint,
◼ In case of a drain line due to invisible corrosion carry out a regular check,
◼ In case of wear of the slinging loops or their fixings to the ballast blocks including the risk
of a break, replace the ballast.
Derrick / mast / crane tower / jib / counter−jib

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

detected: cracks, crackled paint, deformation, anomalous noise,
compulsorily stop the crane operation and contact a ZOOMLION expert.
309
Deformations:
◼ Deformation of the steel structure
◼ Deformation of a bracing
◼ Pressure, sinking
◼ Friction
310
Pins / screw bolts

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

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

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

free.
311
6.13 Pins and holes of the tower section

After assembling the tower section, please check the pins and holes as follow the steps.
◼ Before hoisting the tower section, please make certain that the surface of pin-hole and pin
is cleaned. It can use the polisher to clear the pin-hole, but grinding wheel is prohibited
which enlarges the pin-hole. After cleaning, the pin-hole should have mental luster.
Step 1: Before
hoisting, please
make sure that the
surface of pin-hole
and hinge pin are
clean.
◼ When installing the tower section, please check the pin-hole again and make sure there
are no sundries, if there are any sundries please clear it.
Step 2: When
installing,
please check
the pin-hole
again.
312
◼ After cleaning the surface of pin-hole and pin, uniformly daubing the AG1 rusting
preventive grease on the inner surface of the pin-hole and outer surface of hinge pin. Then
installing the hinge pin. Strictly prohibit mixing the difference kinds of grease. Strictly
prohibit mixing the new AG1 with old AG1.
Step 3: Apply
grease to the pin-
hole and hinge pin,
then install the
hinge pin.
◼ After dismantling, the hinge pins must be placed in the clean and waterproof box which
should be placed indoors. If the pin-hole of tower section is rusting or the grease
consolidation, firstly cleaning the pin-hole, then daubing the AG1 rusting preventive grease.
It must have adapting cushion between the tower section and ground.
Step 4: Attention
after dismantling.
◼ Check if the rabbet of the tower section main chord can shake, if it can shake, the shake
value cannot exceed 0.7mm, if it exceeds, please contact our company’s after-sales staff
to handle it before it can be used.
313
6.14 Hook
6.14.1 Check the locking of the hook
◼ All the fasteners of pulley pin and connecting pin are normal;
◼ The press plate on the hook nut is installed in place, without deformation, and the bolts on
the press plate are firmly fixed; The tower crane needs to be checked before use. If the
fixing bolt is loose or damaged, please tighten or replace the bolt in time.
6.14.2 Opening Degree of the Hook
Inspect the deformations at least once a month.
◼ The initial value of hook opening degree a 0 = 85 +−32 mm . (According to the measuring
value before the first time use of the hook)

◼ If the opening degree has been more than 110% of the initial value A0, replace the hook.
◼ Check the torsion deformation of the hook. When the torsion angle of the hook body
exceeds 10°, replace the hook.
◼ The handle of the hook should not be plastic deformation, otherwise it should be replaced
314
6.14.3 Wear
The initial value： h0 = 100 +−52
The wear on hook may not be greater than 5% of the height “H”. It is not permitted to carry out
welding work on hook to repair the wear.
Check hook wear at least once a month.
◼ Surface cracks
➢ If there are obvious distortions of the hook, do the surface cracks check to
the hook using appropriate method or change the hook.
➢ Damages and surface cracks can be removed, but no gap can be left. The
hook dimension after being removed the cracks and damages should not
exceed the permissible tolerance.
➢ If the installed hook cannot be checked, dismantle it and check it.
➢ Before making checks, ensure that the surfaces are put into a condition
permitting the definite identification of surface cracks!
6.14.4 Corrosion
◼ The diameter d1 of hook handle cannot be corroded to be less than 95%, if the diameter
is less than 95%, change the hook.
◼ The threads on the hook cannot be corroded.
Hook defects are not allowed to be repaired by welding.
6.14.5 Check hook anti-tripping device

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

Thrust ball bearing are used on the hook assembly, which are provided with lubricating oil holes
and need to be lubricated regularly.
315
6.15 Trolley
6.15.1 Routine inspection of trolley rollers
◼ Check roller bearings;
◼ The roller rotates normally;
◼ There is no damage or deformation of roller;
◼ Roller wear;
◼ The nut and lock washer of the roller shaft are not loose;
◼ All the rollers of the trolley are in contact with the jib;
◼ In the process of running the trolly, he roller, the roller cover and the belly rod of the jib do
not interfere
6.15.2 Routine inspection of side rollers of trolley

◼ Check the side roller bearings;
◼ The roller rotates normally;
◼ There is no damage or deformation of roller;
◼ Check the wear of side rollers (see Table 6-15 Side roller specification table); Replace the
side roller when the wear of the side roller reaches 5% of the diameter
Table 6-15 Side roller specification table

No. Order No. Specification
1 000209705A0001400 Φ80-30
2 000209710A0600001 Φ120-50
3 000209716A0010019 Φ140-50
◼ There is no damage to the split pin or clamp plate used for the limit of the side roller shaft,
and it is firmly fixed
316
6.16 Maintenance of electrical control system

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

Table 6-16 Checklist of electrical equipment
Inspection cycle Inspection item

Electrical Equipment:
Whether the door of the electric control cabinet
closes
The air switch in the cabinet
Circuit breaker
Display
Electric whistle
Sensor
Over load display
Daily operate before inspection Moment percentage display
Trolley position display
Hoisting height display
Wind speed display
Weathercock brake release
Indicator light/indicator device：
Voltmeter
Overvoltage indicator light
Cab light
Beacon light
Main power
Main power switch box
Phase sequence
Service voltage
Length and shuck of main cable
Check each erection and inspection Every position for reliable earthing
cycle (suggest cycle is 2-3 weeks) Cable:
Meet a criterion
Shuck of main cable in perfect condition, good
insulation Plugins in correct location, good contact
and reliable
Cable stress relief.
317
Electrical device:
Air switch
Circuit breaker
Electric relay, contactor
Display
Sensor
Over load and moment alarm normal
Brake, weathercock brake
External equipment connector good contact and
reliable
Indicator light/indicator device：
Voltmeter
Overvoltage indicator light
Cab light
Beacon light
Electrical control cabinet
Temperature switch and humidity switch set values
correctly
Power voltage control set values correctly
◼ The inspection of electrical equipment must be carried out under no-load conditions:
➢ The hook moves up and down slowly;
➢ Trolley slowly moves outwards and inwards;
➢ The tower crane slowly rotates to the left and right;
➢ All control parts run correctly and smoothly,
➢ The position of the trolley and the height of the hook on the display screen are displayed
accurately and continuously.
➢ The wind speed display value on the display is correct and reasonable
➢ The mechanism starts quickly and smoothly,
➢ Increase and decrease gears, continued, no gears, skipping, and the operating handle can
automatically return to the zero position,
➢ When running in no-load, there is no obvious special noise or vibration
◼ Check of component setting value

Temperature sensor and humidity sensor in the main control cabinet, voltage monitoring relay,
as shown in the figure
318
Fig. 6-55 Temperature switch and humidity switch in the main control cabinet
Fig. 6-56 Check set value of main control cabinet monitor electric relay
Table 6-17 Check detailed list for safety device
Code Definition Setting value
Coating fan temperature +40℃
ST
Heater working temperature 0℃
SRH Heating humidity RH +80%
Overvoltage protection value(>U) 420V
Undervoltage protection value(>U) 340V
Delay time 2S
KAU1
Operating mode Reset delay + no phase sequence

monitoring
319
6.16.2 Maintenance for safety device

Every limiter and sensor require to calibrate and recalibrate definite value during every erection.
Table 6-18 Check detailed list for safety device
Location of limiter:
Maximum trolley position for trolley (jib length);
Minimum trolley position for trolley;
Daily operate before check Upper stop position for hook;
Hook stop position at bottom according require;
Load capacity/moment limiter: over load alarm for load limiter,
load moment;
Location of limiter:
Maximum trolley position for trolley (jib length);
Minimum trolley position for trolley;
Upper stop position for hook;
Bottom stop position for hook;
Load capacity:
Check each erection and
inspection cycle (suggest Check the accuracy of the load capacity display (Sling the
cycle is 2-3 weeks) known load);
Check the accuracy of mechanism load limiter is triggered
Check the accuracy of mechanism moment limiter is triggered
(constant load for variable radius, constant radius for variable
load);
Check the percentage accuracy of mechanism moment limiter
display (Take the mechanism moment limiter for refer);
Every mechanism requires to recheck and recalibrate when
change hoisting rope, trolley, hoisting mechanism, trolley
mechanism, load sensor and other relevant safety parts.
Out of inspection cycle
Recalibrate if the jib change length
Recalibrate after jacking operation
320
6.17 Spare parts list

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

Spare parts list of hoisting mechanism
Table 6-19 Hoisting mechanism H45FP30-600P

No. Order No. Designation Code Install position Qty
YWZ5-315/80-
1 1031700155 Brake 1
1000-HL
LX9- Hoisting
2 000209944A0000850 Coupling Y65×142(18)/Y55× mechanism 1
112(16) H45FP30-
3* 000209944A0000712 Elastomer GR75 600P 1
4* 1090101164 Rope 35×7-16-1870 (000209195A2
5 1020202083 Limiter DXZ1:360A0×20 900000) 1
ETF100-
6 1020202010 Encoder 1
H(Nr:851223/0.8)
Spare parts list of trolley mechanism
Table 6-20 Trolley mechanism

1 1031700142 Brake DLTZ3-80 1
2 000209321B0002000 Coupling GR28-65-1 1
Nylon gear Trolley mechanism
3* 000209301E0003002 GR28 1
ring BP55B
6×19-9.3-1700- (000209321B0000000)
4* 1090100080 Rope
Ⅱ-Right
5 1021500669 Limiter DXZ1:60A0×22 1
Spare parts list of slewing mechanism
Table 6-21 Slewing mechanism

1 1999900214 Limiter DXZ-4/3 Slewing mechanism 1
2 1029805619 Brake DDZ-40DFB/HZDZ-40 S75CA-130LB12/14A 1
(000209289A6700000)
3 1020202072 Encoder ECK58B(Nr:851249/10) S75CN-130LB12/14A 1
(000209289A6800000)
321
Spare parts list of travelling mechanism

Table 6-22 Travelling mechanism

Buffer
1 000209401A0000003 000209401A0000003
sleeve
2 1050200326 Bearing 22220C (1050200326)
Travelling
3 1030200210 TX25(1030200210)
reducer
Travelling
4 1020000154 Motor YTXZ112M2-2B-5.2KW mechanism
Bearing (Only use in
5 000209401A0000034 000209401A0000034
seatⅠ travelling
Bearing crane)
6 000209401A0000040 000209401A0000040
seat Ⅱ
Travelling
7 000209401D1000036 000209401D1000036
wheel
Travelling
8 1020500695 XCR-F17
switch
M822 cable M822 cable
drum drum (Only
9 1029901693 collect point K530 use in 1
ring inner travelling
core crane) M822
322
6.17.2 Spare parts list of electrical control system

Table 6-23 Spare parts list of electrical control system
No Order No Designation Code Qty
1 1020303114 Electric relay AHN22324 3
2 1020304036 Electric relay seat AHNA21 3
3 1029905217 Residual-current circuit breaker NDB1LG-32C20 1
4 1020903398 Switching power supply CP-PX-24/4.5 1
5 1020404546 Solar light W-001 1
6 1020004569 Axial flow fan M115BA2HSL 1
7 1022001015 Phase sequence monitor CM-PFE 1
8 1020303383 Electric measuring and monitoring relay CM-PVS.41 1
DILM95C
9 1020304845 Contactor 1
(220V50/60HZ)
DILM9-10C
10 1020304846 Contactor 2
(220V50/60HZ)
11 1020005439 Expansion cards MD38PGMD 1
12 1021000270 Heater WR200 1
323
6.17.3 Spare parts list of structure

Table 6-24 Spare parts list of structure
Install position Designation Order No. Code Qty
Trolley, Hook, HL-400-340-55-110-
Pulley 000209906A0040028 9
Jib section Ⅰ 7.5
Pulley (HL-400- 6212-2RS1
Bearing 1050201562 18
340-55-110-7.5) (GB/T276-2004)
Jib sectionⅠ,
Pulley 000209906A0017000 214-178-B41-80-R6 4
Ⅲ, Ⅴ, Jib end
Pulley(214-178- 6208-2RS1
Bearing 1050201563 8
B41-80-R6) (GB/T276-2004)
Trolley idler
Trolley 000209704A0100007 4
wheel
Trolley idler 6207-RS1
Bearing 1050201328 8
wheel (GB/T 276-1994)
Trolley side
Trolley 000209705A0001400 FXC08B-14 4
roller
Trolley side 6004-2RS1
Bearing 1050201565 8
roller (GB/T276-2004)
Pulley (HL-450-
Retaining ring
380-80-130- 1040300281 GB/T893.2-1986 9
130
R8.5)
Pulley(214-178- Retaining ring
1040300322 GB/T893.2-1986 4
B41-80-R6) 80
Trolley idler Retaining ring
1040300283 GB/T893.2-1986 8
wheel 110
Trolley side Retaining ring
GB/T893.2-1986 8
roller 42
Trolley Buffer block 000209708A0001063 4
Thrust ball
Hook 1050200505 GB/T301-1995 1
Bearing 51313
324
6.18 Appendix troubles and troubleshooting
No. Troubl Troubleshooting Solution

a. Check the oil surface,
adjust the height if
The temperature of the a. Excessive lubrication oil necessary.
1 reduction gearbox is too b. Oil is old-fashioned b. Figure out the time of
high. c. Oil is grievously polluted last oil change, change
oil if necessary.
c. Change the type of oil.
a. Excessive or deficient
a. Properly replace
grease.
The temperature of the grease
b. Poor grease quality.
2 reduction gearbox b. Re-adjust the bearing
c. Improper axial clearance
bearings is too high. clearance
of the bearings or bearings
c. Replace bearings
is already damaged.
a. Leakage from the input
and output shaft end of the
reduction gearbox.
a. Replace sealing rings.
Oil leakage from b. The strainer of the air
3 b. Clean the strainer.
reduction gearbox cleaner is blocked.
c. Reseal.
c. The sealing rings of end
covers or the matching
surface is sabotaged.
a. The rotary direction of a. Check the line of the
the motor is wrong. motor.
b. The escape valve is b. Remove the main
blocked by unclean oil. valve and clean it with
c. Tube leakage. kerosene.
No output from the pump d. Pipe connections c. Remove the pipe and
station/ cannot be become flexible. weld the broken part or
4 adjusted to rated e. The sealing parts of the exchange it.
pressure/ the pressure is pipe connections are d. Screw the pipe
not steady. broken. connection.
f. Coarse strainer is e. Exchange the seal
blocked. washer.
g. The pump station is f. Clean the strainer.
damaged by long-time g. Exchange the pump
over load. station.
325
a. Check the line and

rewire the circuit by
a. Terminals and breakers
Jacking mechanism electrical schematic
be loosed.
motor diagram
5 b. The breaker tripped or
does not rotate when b. Repair or replace the
burned by overload or
power on breaker by checking the
short circuit
contacts and
electromagnetic trip;
a. Worn oil pump, declined
efficiency a. Repair or replace the
b. Oil in the tank is damaged parts
insufficient or oil filter b. Fill adequate oil or
clogged clean oil filter
6 Jacking speed is too slow c. Hand-operated valve c. Exchange the hand-
rod and valve hole operated valve or the
severely worn worn parts.
d. Oil cylinder piston seal d. Reseal the oil cylinder
is damaged and internal oil piston.
leakage.
a. Severe internal leakage a. Repair or replace the
from oil pump worn parts
b. Overflow valve pressure b. Adjust pressure as
Jacking force is not
set too low required
7 adequate or unable to
c. Hand-operated valve c. Clean hydraulic
jack
core excessively worn valve.
d. Overflow valve clogged d. Exchange overflow
down valve.
Noise and vibration occur
8 during jacking operation Oil filter clogged Clean oil filter
at increasing pressure
Motor rotation and oil
Jacking system is not Change motor rotation
9 pump rotation both in
working direction
wrong directions
a. Air not completely
exhausted from oil cylinder a. Exhaust air as
Creeping and quivering
piston required.
during jacking operation
10 b. Trouble with guide b. Adjust guide pulleys
mechanism
Trouble with guide a. Exhaust air as
Adjust guide pulleys
mechanism required.
326
a. There are troubles with

balance valve of the
Jacking drop when a. Remove trouble
11 cylinder head.
loaded b. Replaces sealing parts
b. Piston sealing of oil
cylinder is damaged
a. Operating handle not
a. Operating handle back
back to zero
to zero
b. Fuse burned
12 Start button fault b. Replace fuse
c. Poor contact of stop
c. Repair or replace the
button
button
and start button
a. Breaker pull due to a. The hoisting brake
over current must be opened
13 Tripping while hoisting
b. Transformer capacity b. Replace the
too small transformer
a. Check the wiring
diagram
a. Wrong connection of the
b. Replace with a larger
Control circuit.
fuse
b. Fuse blown.
c. Measuring the grid
c. Voltage of the motor’s
voltage
too low
Hoisting mechanism d. Check the circuit of the
14 d. Wrong connection for
cannot start Wire wound resistors.
wire wound resistors
e. Check the voltage of
e. Hoisting brake closed
the Brake to find if the
f. Excessive load for motor
Wire wound is opened
or transmission machinery
circuit.
fault
f. Check if the motor is
overload.
327
a. Check the uniformity of

the clearance between
a. Friction between stator
stator and rotor.
and rotor.
b. Check the
b. The shaft of the motor
concentricity. If it is too
and the shaft of the gear
large, adjust it.
box is not concentric.
c. Check the
c. Bearings are in oil
Noise and vibration occur circumstance of the
15 deficiency or broken.
to trolley mechanism bearings. If they are
d. Gear box is in oil
broken, exchange them.
deficiency.
If they lack oil, refuel the
e. Gear friction. corresponding oil.
f. There are abnormal d. Refuel the stated oil.
noises during two-phase
e. Exchange the gear.
performance.
f. Cut off the power and
fix it.
a. The bearings are a. Exchange the
The temperature of the broken. bearings.
16 bearings in trolley b. The grease is b. Clean the bearings
mechanism is too high. deteriorative or of bad and exchange the
quality or too few. grease.
a. The power line or the
a. Check the connection.
ground connection is
The trolley b. Make sure that
wrongly connected.
17 mechanism is grounding condition is
b. Defective grounding.
Charged. well.
c. The line of the motor is
d. Figure out and adjust.
broken and grounding.
a. The brake torque is too
The brake of the trolley a. Exchange the brake
low.
18 mechanism is out of spring
b. The clearance of the
service. b. Adjust the clearance.
brake plate increases.
a. Dismantle it to check
whether the weathercock
a. Weathercock brake is brake is open and clear
not open the troubles.
Impotence or inability of b. Coupler is lack of oil b. Refuel provided type of
19
the slewing mechanism c. The motor is broken oil.
d. The wind is strong and c. Change the motor
operates against the wind. d. Operates when the
wind is weak or following
wind.
328
a. Measure the current of

a. Overload. the stator. If it is over
b. Continuous load or rated figure, reduce load.
irregular working. b. Operate under order.
c. The two phases are far c. Measure the three-
away. phase current and clear
d. The voltage is too low or troubles.
too high. d. Check the input
e. Motor winding is earthed voltage and clear
or cutting-out troubles.
The motor of the trolley
f. The clearance between e. Figure out reasons and
20 mechanism is smoking or
friction plates is wrong clear troubles.
of high temperature.
g. The time of braking and f. Adjust the clearance
releasing is wrong. based on regulation.
h. The air gallery of the g. Check the voltage of
motor is blocked, so the the brake and the
temperature rises. movement time of delay
i. The brake is opened time chopper, then clear
unthoroughly or is closed troubles.
so that the motor is h. Unblock the air gallery
unmoved and emit heat. i. Adjust the brake under
regulation.
a. Power off. a. Power on.
b. Switch off. b. Switch on
c. Emergency stop button c. Reset the emergency
on. stop button by clock
The tower crane act d. Air plugs of the linkage wising it
21 without any reaction when loosed. d. Reinstall the air plugs
press the start button e. Zero switches (SZR, e. Reset the zero switch
SZL) do not reset or be or replace with a new one
damaged. f. Repair the main
f. Main contactor cannot contactor or replace with
pull. a new one
The circuit breakers trip The rate current of the Replace with a larger
22
frequently switch is too small switch
329
a. Check the lubricating

circumstance of sheave.
If any dry and hard
situation exist, clear it
and daub new grease. If
a. Invalidation in
the environment
lubrication of sheave,
temperature is too low,
which result in sluggish
diluted oil should be
movement and bad
daubed on (check daily).
guiding function
b. Check if declination
b. Declination in
happens, adjust it.
Invalidation of rope mechanism installation
23 c. Adjust the mechanism
releasing or rope jumping c. The center line of drum
seat
is not coordinate to the
d. Check the level degree
center line of counter jib
of under frame, if uneven
d. Uneven in mechanism
situation exists, adjust it
under frame
e. Check if the first layer
e. Upper rope pushing into
is tightened, if not, tighten
under rope
up the first layer with
certain load when
releasing. (2% of the
breaking force or 10% of
the rated load)
a. Check the sequence of
a. Phase sequence error
the power supply. Check
b. Power phase loss (open
the phase sequence
The tower crane cannot circuit or the fuse burned)
between U2, V2, W2
24 start properly when press c. Poor quality of the
b. Replace fuse
the start button phase sequence relay
c. Replace a new phase
d. Setting with a wrong
sequence relay.
parameter
d. Reset the parameters
a. Reset the phase
a. The phase sequence sequence relay or
relay is unstable or with a replace with a new one
Tower crane become
wrong parameter. b. Improve if the power is
instable after starting and
25 b. Unstable power supply shortage , Otherwise,
the contactors trip
c. The loosing of the air increase the conductor
frequently
plug causing the poor cross-section or cut the
contact of the start circuit wire
c. Reinstall the air plugs
330
a, Replace the switch

a. Poor quality of the b.
26 The leakage switch trips leakage switch 1)Inspect the motor
electric circuit fault 2)Check the electric
circuit
a. YASKAWA Inverter：
set the carrier frequency
parameter C6~02=1
The leakage switch trips The frequency of the
27 b. MEGMEET Inverter:
when slewing inverter is too high
transfer a smaller carrier
frequency parameter
value of P12.02
There were
The hook of tower crane Electromagnetic Please use Nylon sling
28
with power transmission tower in the with Standard
vicinity
Hoisting has no high The contactor of the
29 Check it!
speed for winding motor resistor box loosed
a. Replace the PGO or
the PG card
a. Rotary encoder fault
b. Checks the voltage
(PGO)
setting on the braking
b. Overvoltage (OV)
unit whether it is installed
Troubleshooting of the c. Resistor box fever in
correctly
30 altivao Inverter for serious condition
c. Replace the brake unit
hoisting d. Motor jitter or the
d. Rewire the rotary
inverter displayed OL2
encoder
e. Trolley brake fault (SE2,
e. The contactor of the
SE3, SE4)
trolley loosed, adjust the
braking torque
a. Wrong wiring or
damage of the rotary
Troubleshooting of the a. Load does not follow encoder
31 Schneider Inverter for b. Motor short circuit b. Rewire the rotary
slewing c. Motor jitter encoder
c. Rewire the rotary
encoder
331
a. Check the contacts of

a. The command of the
the Cooperative console;
Cooperative console is
check the input of the
Lighting has no high incorrect
32 PLC
speed b.50% Weight limit
b. Check the contactor of
c. The loosing of KHH let
the limiter
the KHB remain open
c. Replace the KHH
a. Replace the phase
a. Phase sequence losing
sequence relay
b. Bad electrical
Shaking or murmur while b. Check the electrical
33 connection
lifting connection of the eddy
c. Wrong closing of the
current
contactor
c. Replace the contactors
The circuit breaker pulls Check the cable, replace
34 Slewing brake damage
when the rotational stops the brake
a. Slewing limit
b. Bad electrical a. Check the circuit of
connection slewing limit
c. Inverter fault b. Check the circuit
d. Contactor fault c. Repair the Inverter
e. The rotor of the motor d. repair the contactor
After working a while, the
be damaged e. Repair the motor
35 tower crane cannot turn
f. Resistor box be f. Repair or replace the
right/left
damaged resistor box
g. Wrong connection of the g. Rewire the electrical
rotor circuit
h. RCV stops running h. Repair the RCV
i. Wiring confusion when i. Rewire the circuit
installing two motors
Slowing time is short Bad
electrical connection for
Overvoltage (OV)
resistance Overvoltage
for power supply
Troubleshooting of
Voltage under the value
36 Yaskawa Inverter for Undervoltage (UVI)
of L2-05
slewing
Wind is too strong
Motor over torque (OL1) outside Eddy current
voltage is too high
Electric Current warnings Motor or circuit grounded
332
Check the contacts (NC)

of the contactor and
Contactor cannot pull
Contactor judge whether to replace
37
troubleshooting it
The Motor murmurs and Contactor’s main contact
cannot run normally loses phase, replace it.
a. Reset the eddy current
a. Eddy current voltage is voltage
too high b. Adjust the location of
Slewing has not high
38 b. HVV’s voltage is too low terminals for the reactor
speed
c. Wrong setting of the c. Adjust the frequency of
Inverter the Inverter; set L3-04=0,
E1-03=5;
a. Set C2-01, C2-02, C2-
a. Wrong setting of the 03, C2-04>2.0
Slewing jitter and Inverter b. Remove the line of X4,
39
murmurs b. Reversing contactor of X5, X6, find a small line
the RCV interval rebounds and connect the RCV to
Cooperative console
Rotary battery loses
No braking when power off
power
a. KSB cannot pick
40 Slewing cannot brake
No braking even normal b. Electromagnetic brake
operation fault
c. Rectifier fault
a. Adjust the trolley limit
and check the circuit
a. Trolley limited or open
b. Replace the air plugs if
circuit
line barrier
b. Incorrect command from
c. Repair or replace the
41 Trolley stops running Cooperative console
PLC
c. PLC fault
d. Repair or replace the
d. Relay fault
relay
e. Trolley breaker tripped
e. Please close the
breaker
a. Reduce the lifting
a. Torque limited
weight
Trolley has not high b. Trolley limited
42 b. Normal work
speed c. Cooperative console
c. Check the Cooperative
fault
console
333
a. KVOW, KVIW, KVL, a. Replace the contactor

Trolley jitter and lost KVJ fault b. Change the voltage
43
control b. Inverter motor lost control to current control,
control tuning the motor
The display does not Environment temperature Adjust the switch on the
44
flash clearly is too cool or too hot main cabinet
The system does not Disconnection of power Check power supply
45
work supply circuit
Power switch of the main
Display does not flash
46 machine cabinet Turn on the powers witch
after being started up
disconnected
Disconnection of
47 The display rolls over Check grounding circuit
grounding system
Certain weight value Weight calibration is not Perform weight
48
displayed with empty load made calibration
Significant shift of actual Poor grounding or broken
49 Check grounding circuit
weight grounding cable
The displayed value No zero line for power Immediately shut down
50 automatically gets bigger supply to the equipment or main machine and check
without operation over-voltage power supply circuit
The travel switch gets
Error of length display Check installation of the
51 loose due to impact of the
increases switch
trolley
Check the junction box,
The data of height is no Disconnection of the
52 cable and plugs of the
change transmission circuit
main machine
Check the junction box,
The data diminish Disconnection of the
53 cable and plugs of the
automatically. transmission circuit
main machine
Check assembly of the
The transmission shaft of
transmission link.
The data larger the hoisting height slewing
54 Replace the damaged
automatically. limit switch gets loose or
parts with new slewing
damaged
limit switch
334
a. Limiter does not a. Rewire the limiter

properly connect to the circuit
circuit b.
b. Cooperative console 1)Rewire the circuit
bad connected to the PLC 2)Repair or replace the
1)Wire loose PLC
55 No hoisting (with PLC)
2)PLC’s input point 3)Repair or replace the
damaged cooperative console
3)Contact of Cooperative c. Repair or replace the
console damaged relay
c. Relay fault d. Repair or replace the
d. Inverter fault Inverter
a. Quality or wrong
settings of KAE
a. Reset the KAE;
b. Bad connection from
Otherwise, replace it
X22/X24 to PLC
b. Rewire the circuit
c. Eddy current module
Hoisting has not low c. Replace the eddy
56 fault
speed current module
d. The main contact of
d. Replace the KHE
KHE be damaged
e. Please close the
e. Breaker of the eddy
breaker
current module be opened
or tripped
335
SPARE PARTS WA7025-12E
7 SPARE PARTS
7.1 Foreword
This part groups the whole information together allowing you to:
➢ identify the spare parts (designation and code)
➢ identify the recommended parts for the preventive maintenance
➢ locate the position of a part in an assembly
➢ identify the “ready for mounting” sets.
The “Using the operating instructions” chapter indicates you the optimum method to search and
to use the information given in this part.
When ordering the spare parts, it is necessary to indicate:

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

There are two types of parts lists:
H a parts list” Assembly” (for ex. hoist mechanism, slewing mechanism),
H a parts list” Subassembly” (for ex. squirrel cage motor, hoist mechanism shaft).
336
WA7025-12E SPARE PARTS
7.2 Examples of an “ASSEMBLY” parts list
Fig. 7-1 Spare parts list of the crane
337
Table 7-1 Spare parts list of the crane

No. Designation Order No. Code Notes Qty
1 Outrigger 000200615J0001000 TC6517C.15B 4/0
Base tower
2 000209012A2300000 L68G23 1/0
section
000209012A2600000 L68A4 Rung ladder 17
3 Tower section
000209012A3600000 L68A1A Incline ladder 17
4 Passageway J 000209014A1300000 L68TDJ Rung ladder 9
5 Passageway H 000209014A1200000 L68TDH Rung ladder 8/9
Climbing WA7527-
6 000261811CT000000 Double “U” 1
equipment 20D(Abroad).11
Climbing
7 000210612AT000000 TCT6527-16E.12 1
mechanism
Climbing
YG180/125-
8 hydraulic 000200429A0100000 1
2160/1640-31.5
cylinder
9 Pump station 000209501A8700000 BZ-11-31.5F 1
F02WA0A0181806-
1140220834 1
3000
10 Hose assembly
F02WA0A0181806-
1140220835 1
4000
Erection Unitary,
11 000270320BT000000 T6513-8E.20A 1
platform 90°connector
Mounting
12 000270319AT000000 T6513-8E.19 1
device
Transition tower
13 000209012B3800000 L68C3B Unitary 1
section
Slewing
14 000281710DT000000 WA7025-12E.10 1
support
15 Slewing ring 1031500447 QWA1600.50Z5 1
16 Turntable 000281709BT000000 W7025-12KA.09A 1
Slewing 000209289A6700000 S75CA-130LB12/14A
17 1
mechanism 000209289A6800000 S75CN-130LB12/14A
18 Slewing Limiter 000209905B0007000 HZXW.6A 1
WA7025-
19 Counter jib 000281701ET000000 1
12E(Abroad).01
Hoisting
20 000209195A2900000 H45FP30-600P 1
mechanism
21 Derrick 000209914B0006000 TCBG1500.1A Manual /
22 / / / / /
23 Cabin 1139804016 CM6-A 1
Trolley
24 000209321B0000000 BP55B 1
mechanism
338
WA7025-
25 Jib 000281705DT000000 1
12E(Abroad).05
26 Trolley 000209707K0100000 XC12N 1
27 Hook 000209607A1900000 DG12H 1
000200614D1000000 TC6517B-10E.14 Rung ladder
Stationary
28 WA7025- 1/0
chassis 000281714AT000000 Incline ladder
12E(Abroad).14
Tower section 000209012A2800000 L68B7 Rung ladder 1/0
29
(for chassis) 000209012A4000000 L68B2A Incline ladder 1/0
Powered wheel
30 000209401D1000000 ZA52-D 2/0
bogie
Idler wheel
31 000209402D1000000 B52-D 2/0
bogie
000200623A1000000 TC6517B-10E.23 Rung ladder
32 Mobile chassis WA7025- 1/0
000281723AT000000 Incline ladder
12E(Abroad).23
33 Cable Drum 000209940A0000010 M822 1/0
339
7.2.1 Jib
Fig. 7-2 000281705DT000000
340
Table 7-2 Spare parts list of Jib

No. Order No. Code Designation Specification Qty
1 000271705CT001000 JibⅠ 1
2 000271705AT002000 JibⅡ 1
3 000271705AT003000 JibⅢ 1
4 000271705AT004000 JibⅣ 1
5 000271705AT005000 JibⅤ 1
6 000261705AT006000 JibⅥ 1
7 000261705AT007000 JibⅦ 1
8 000261705AT008000 JibⅧ 1
9 000261705AT009000 JibⅨ 1
10 000281705AT001000 Jib end 1
11 000209910A0161601 XZ03B-16×160/175 Pin 16×160 2
12 1040500228 GB/T91-2000 Split pin 4×32 4
13 000261005AT005200 Pin tray 1
14 000292005AT007010 Pin tray 1
341
7.2.1.1 JibⅠ
Fig. 7-3 000271705CT001000

Components No.19 and 21 are exploded in other drawings
342
Table 7-3 Spare parts list of JibⅠ

1 000271705CT001100 Jib Ⅰ structure 1
XZ04D-
2 000209910A4202903 Pin 100×290 1
100×290/370A
3 1040500646 GB/T91-2000 Split pin 13×140 2
4 000231705AT003002 Pin Φ16×110/125 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT002001 Pin 80×201/255 2
7 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
8 1040200110 GB/T6170-2000 Nut M16-8 4
9 1040300065 GB/T93-1987 Washer 16 4
10 1040300052 GB/T97.1-2002 Washer 16-200HV 8
11 000261705AT001020 Platform 2
12 1040002440 GB/T5783-2016 Bolt M12×45-8.8 14
13 1040200096 GB/T6170-2000 Nut M12-8 14
14 1040300728 GB/T95-2002 Washer 12-200HV 28
15 1040300054 GB/T93-1987 Washer 12 14
16 000261705AT001030 Platform 1
17 000209910A1081701 XZ01C-40×170/195 Pin 40×170 2
18 1040500222 GB/T91-2000 Split pin 8×80 6
19 000251705BT001800 Hoisting pulley 1
20 000209910A1081001 XZ01C-40×100/125 Pin 40×100 1
21 000261605BT001400 Trolley pulley 1
22 1040500253 GB/T91-2000 Split pin 5×32 4
23 000250801AT010003 XZ03B-20×135/155 Pin 20×135 1
24 000209910A1081301 XZ01C-40×130/155 Pin 40×130 1
25 000203003AR000006 XZ01A-25×55/80 Pin 25×55 2
26 1040500216 GB/T91-2000 Split pin 6.3×50 2
Load limiter
27 000251705BT001900 1
bracket
28 000209910A3041801 XZ03B-20×180/200 Pin 20×180 1
29 000209910A1071501 XZ01C-35×150/175 Pin 35×150 2
30 000209912A0000013 Washer 2
31 000261705AT001040 Platform 1
Detachable
32 000222705AT001010 1
bumper block
Detachable
33 000222705AT001020 1
bumper block
343
7.2.1.1.1 Hoisting pulley
Fig. 7-4 000251705BT001800
344
Table 7-4 Spare parts list of Hoisting pulley

XZ03A-
1 000209910A4051421 Pin 25×145 1
25×145/175
2 1040500216 GB/T91-2000 Split pin 6.3×50 2
3 000209709A0001003 Plate t10 1
4 1040000090 GB/T5783-2000 Bolt M10×30-8.8 2
5 1040300067 GB/T93-1987 Washer 10 2
Hoisting pulley
6 000251705BT001810 1
bracket
HL-450-380-80-
7 000209906A0040035 Pulley 1
130-R8.5
8 1050202084 GB/T276-2013 Bearing 6312-2RS 2
9 000251705BT001801 Pin Φ60×134/176 1
10 000201105B0000402 Bushing 2
11 1040300281 GB/T893.2-1986 Retaining ring 130 2
345
7.2.1.1.2 Trolley pulley
Fig. 7-5 000261605BT001400
Table 7-5 Spare parts list of Trolley pulley

Trolley pulley
1 000270705AT001040 1
bracket
2 000261605BT001410 Pulley 1
3 000270405DT003001 Pin Φ40×68/100 1
4 000210105A0010002 Bushing 2
5 000210105A0010001 Shaft-end damper t6 1
6 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
7 1040300067 GB/T93-1987 Washer 10 2
XZ03A-
8 000209910A0000515 Pin 12×80 2
12×80/95
9 1040500228 GB/T91-2000 Split pin 4×32 4
346
7.2.1.2 JibⅡ
Fig. 7-6 000271705AT002000
Table 7-6 Spare parts list of JibⅡ

1 000271705AT002100 Jib Ⅱ structure 1
2 000209910A4162501 XZ04D-80×250/315 Pin 80×250 1
3 1040500646 GB/T91-2000 Split pin 13×140 2
4 000231705AT003002 Pin Φ16×110/125 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231705AT002001 Pin 70×177/220 2
347
7.2.1.3 JibⅢ
Fig. 7-7 000271705AT003000
Table 7-7 Spare parts list of JibⅢ

1 000271705AT003100 Jib Ⅲ structure 1
2 000209910A4162401 XZ04D-80×240/305 Pin 80×240 1
3 1040500646 GB/T91-2000 Split pin 13×140 2
4 000231705AT003002 Pin Φ16×110/125 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231705AT003001 Pin 70×160/205 2
348
7.2.1.4 JibⅣ
Fig. 7-8 000271705AT004000
Table 7-8 Spare parts list of JibⅣ

1 000271705AT004100 Jib Ⅳ structure 1
2 000209910A4122001 XZ04C-60×200/260 Pin 60×200 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin Φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000270405AT002001 Pin 60×143/190 2
7 000209906A0017000 214-178-B41-80-R6 Pulley 1
8 000210105A0010002 Bushing 2
Shaft-end
9 000210105A0010001 t6 1
damper
10 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
11 1040300067 GB/T93-1987 Washer 10 2
12 000270405DT003001 Pin Φ40×68/100 1
13 1050201563 GB/T276-2004 Bearing 6208-2RS1 2
349
7.2.1.5 JibⅤ
Fig. 7-9 000271705AT005000
Table 7-9 Spare parts list of JibⅤ

1 000271705AT005100 Jib Ⅴ structure 1
2 000209910A4121901 XZ04D-60×190/250 Pin 60×190 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin Φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000270405AT002001 Pin 60×143/190 2
350
7.2.1.6 JibⅥ
Fig. 7-10 000261705AT006000
Table 7-10 Spare parts list of JibⅥ

1 000261705AT006100 Jib Ⅵ structure 1
XZ04C-
2 000209910A4121701 Pin 60x170 1
60×170/230
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin Φ16×90/120 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000270405AT002001 Pin 60×143/190 2
214-178-B41-80-
7 000209906A0017000 Pulley 1
R6
8 000210105A0010002 Bushing 2
Shaft-end
9 000210105A0010001 t6 1
damper
10 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
11 1040300067 GB/T93-1987 Washer 10 2
12 000270405DT003001 Pin Φ40×68/100 1
13 1050201563 GB/T276-2004 Bearing 6208-2RS1 2
351
7.2.1.7 JibⅦ
Fig. 7-11 000261705AT007000
Table 7-11 Spare parts list of JibⅦ

1 000261705AT007100 Jib Ⅶ structure 1
2 000209910A4121301 XZ04C-60×130/190 Pin 60×130 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin Φ16×90/120 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT008001 Pin 60×121/170 2
352
7.2.1.8 JibⅧ
Fig. 7-12 000261705AT008000
Table 7-12 Spare parts list of JibⅧ

1 000261705AT008100 Jib Ⅷ structure 1
2 000209910A4121101 XZ04C-60×110/170 Pin Φ60 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin Φ16×90/120 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT008001 Pin 60×121/170 2
353
7.2.1.9 JibⅨ
Fig. 7-13 000261705AT009000
Table 7-13 Spare parts list of JibⅨ

1 000261705AT009100 Jib Ⅸ structure 1
2 000209910A4121101 XZ04C-60×110/170 Pin Φ60 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin Φ16×90/120 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT008001 Pin 60×121/170 2
354
7.2.1.10 Jib end
Fig. 7-14 000281705AT001000

Component No.13 is exploded in another drawing
Table 7-14 Spare parts list of Jib end

1 000261705AT010100 Jib Ⅷ structure 1
2 1040500215 GB/T91-2000 Split pin 5×63 1
3 000209910A0000515 XZ03A-12×80/95 Pin 12×80 2
4 1040500243 GB/T91-2000 Split pin 5×25 4
214-178-B41-80-
5 000209906A0017000 Pulley 1
R6
6 000210105A0010002 Bushing 2
7 000270405DT003001 Pin Φ40×68/100 1
8 1050201563 GB/T276-2004 Bearing 6208-2RS1 2
11 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
12 1040300067 GB/T93-1987 Washer 10 2
13 000209923A0002800 05FNXB(16#) Anti-twist device 1
14 000261705AT010001 Platform Tb4 1
15 000261705AT010002 Platform Tb4 1
16 1040500005 GB/T91-2000 Split pin 5×45 6
355
7.2.1.10.1 Anti-Twist Device
Fig. 7-15 000209923A0002800
356
Table 7-15 Spare parts list of Anti-Twist Device

1 1040000251 GB/T5783-2000 Bolt M12×60-8.8 2
2 1040200096 GB/T6170-2000 Nut M12-8 2
3 000209923A0002110 Support 1
4 1040200215 GB/T6178-1986 Nut M30-8 1
5 1040500224 GB/T91-2000 Split pin 6.3×63 3
6 000200914A0000011 XZ01C-30×140/170 Pin 30×140 1
7 000209923A0002101 Plate 1
8 1050200429 GB/T301-1995 Bearing 51308 1
9 000209923A0002301 Shaft 1
10 000209910A8340701 XZ-34-70/100 Pin Φ34-70/100 1
11 1040300090 GB/T97.1-2002 Washer 36-200HV 2
12 1090101250 GB/T5973-2006 Wedge sleeve 16-40.0kN 1
13 1090101249 GB/T5973-2006 Wedge 16-40kN 1
14 1040500003 GB/T91-2000 Split pin 2.5×30 1
15 1090100387 GB/T5976-1986 Rope clamp 16KTH 1
16 1080000206 JB/T7940.1-1995 Oil cup M10×1 1
357
7.2.2 Counter Jib
Fig. 7-16 000281701ET000000
358
359
Table 7-16 Spare parts list of Counter Jib

Front counter jib
1 000281701ET010000 1
structure
2 000251701AT000100 Tie bar B 2
3 000209913C0020000 LGB2000B Handrail 2
4 000209913F1055900 LGVI5590B Advertising shield 2
5 000251701AT000200 Tie bar A 2
6 000270501AT000060 Support rod 1
Rear counter jib
7 000281701AT020000 1
structure
8 000209913C0005800 LGA580B Handrail 4
9 000271201AT000025 Platform t2 4
10 000209913C0030000 LGB3000B Handrail 2
11 000271201AT000100 Platform 1
12 000209913C0008200 LGA820B Handrail 1
13 000270501AT000045 Platform t2 4
14 000270501AT000100 Platform 1
15 000270501AT000095 Platform t2 2
16 000270501AT000200 Platform 1
17 000281701AT000035 Platform t2 4
18 000281701AT000001 Plate t6 4
19 000270501AT000400 Platform 1
20 000270501AT000300 Platform 1
21 000271201AT000200 Platform 1
22 000209915A0001000 ZADZ Obstacle light seat 1
23 1040500047 GB/T91-2000 Split pin 5×70 1
24 1040000696 JB/ZQ4321-1997 U-Bolt 33-Zn 1
25 1040300067 GB/T93-1987 Washer 10 2
26 1040300061 GB/T97.1-2002 Washer 10-200HV 2
27 1040200113 GB/T6170-2000 Nut M10-8 2
28 1040000216 GB/T5783-2000 Bolt M12×70-8.8 8
29 1040300054 GB/T93-1987 Washer 12 130
30 1040300041 GB/T97.1-2002 Washer 12-200HV 20
31 1040200096 GB/T6170-2000 Nut M12-8 98
Handrail locking
32 000209913A6000000 LGJB2 t6 16
splint
33 000208899A0002076 TX-6-24/35 Spring pin Φ6×117 32
34 000209910A3041001 XZ03B-20×100/120 Pin 20×100 4
35 000200111T0000204 XZ01A-16×45/65 Pin 16×45 12
36 000209938A0000060 TX-4-16/20 Spring pin 12
37 1040500186 GB/T91-2000 Split pin 10×90 10
38 000209910A1101002 XZ01C-50×100/130 Pin 50×100 6
360
39 000209910A4111001 XZ04C-55×100/155 Pin 2

40 1040000101 GB/T5783-2000 Bolt M12×40-8.8 120
41 000251701BT000003 Pin 70×230 4
42 000209910A3041301 XZ03B-20×130/150 Pin 20×130 1
XZ04E-
43 000221101A0000002 Pin 110×330 1
110×330/435
44 1040500005 GB/T91-2000 Split pin 5×45 12
Rope-support
45 000271701CT007000 1
sheave
46 000261701AT000002 Pin 90×250 2
47 000251701BT000002 Pin 20×110 4
48 1040500216 GB/T91-2000 Split pin 6.3×50 6
49 1040300983 GB/T97.1-2002 Washer 20 14
50 000209910A3040901 XZ03B-20×90/110 Pin 20×90 4
51 000209910A3041601 XZ03A-20×160/180 Pin 20×160 1
52 000231701BT010002 Pin 20×140 2
53 000209910A3041101 XZ03B-20×110/130 Pin 20×110 2
54 1040300651 GB/T96-1985 Washer 12-140HV 208
55 1040002441 GB/T5783-2000 Bolt M12×50-8.8 2
56 000281701AT000010 Platform 1
57 000281701AT000020 Support rod 1
58 000201213A0000003 Spring pin 8
361
7.2.3 Derrick
Fig. 7-17 000209914B0006000
362
Table 7-17 Spare parts list of Derrick

1 000209914B0006100 Support 1
XZ01C-
2 000209914A0006200 Pin A 30×180 1
30×180/210
3 1040500222 GB/T91-2000 Split pin 8×80 1
4 000209914A0007000 Rotational column 1
5 000209914A0006300 Pulley seat 1
6 000209914A0006400 Pulley A 1
7 000209914A0006500 Pin B 2
8 000209914A0006600 Bushing A 4
9 000209914A0006700 Pulley B 2
Shaft-end damper
10 000209914A0006800 t6 2
A
11 1040000116 GB/T5783-2000 Bolt M10×20-8.8 6
12 1040300067 GB/T93-1987 Washer 10 16
13 1080000007 JB/T7940.1-1995 Oil cup M10×1 3
14 000209914A0006900 Block bar t6 2
15 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
16 1040300054 GB/T93-1987 Washer 12 4
17 1040300041 GB/T97.1-2002 Washer 12-200HV 4
18 1040200096 GB/T6170-2000 Nut M12-8 4
19 1040300678 GB/T853-1988 Washer 12 4
20 000209914A0008100 Pin C 1
Shaft-end damper
21 000209914A0008200 t10 1
B
22 000209914A0008300 Bushing B 2
M30×110-
23 1040000758 GB/T5782-2000 Bolt 6
8.8
24 1040200197 GB/T6170-2000 Nut M30-8 12
25 1040300074 GB/T97.1-2002 Washer 30-200HV 12
363
7.2.4 Turntable
Fig. 7-18 000281709BT000000
364
Table 7-18 Spare parts list of Turntable

1 000261709AT002000 Cabin platform 1
XZ03B-
2 000209910A3041301 Pin 20×130 2
20×130/150
3 000201213A0000003 Spring pin 4
4 000281709BT005000 Turntable structure 1
5 000200609C0000400 Protective shield 2
6 1040000122 GB/T5783-2000 Bolt M10×35-8.8 14
7 1040300764 GB/T96-1985 Washer 10-200HV 14
8 1040300067 GB/T93-1987 Washer 10 14
9 1040200113 GB/T6170-2000 Nut M10-8 12
10 1040201105 GB/T6170-2000 Nut M27-10 96
11 1040301787 GB/T97.1-2002 Washer 27-300HV 96
M27×230-
12 1040002952 GB/T5782-2000 Bolt 48
10.9
XZ01C-
13 000209910A1081001 Pin 40×100 4
40×100/125
14 1040500222 GB/T91-2000 Split pin 8×80 4
15 1040000095 GB/T5783-2000 Bolt M16×60-8.8 24
16 1040300065 GB/T93-1987 Washer 16 24
17 1040300052 GB/T97.1-2002 Washer 16-200HV 24
18 000281709BT003000 platform 1
19 000270509BT000200 Handrail 1
20 000209913C0006300 LGA630B Handrail 1
21 000209913C0008200 LGA820B Handrail 1
22 000209913C0020000 LGB2000B Handrail 1
23 000212409AT000400 Handrail 1
24 000281709BT000200 Handrail 2
25 000209913C0015000 LGC1500B Handrail 1
26 000209913C0005800 LGA580B Handrail 1
Limiter mounting
27 000280809AT004000 t8 1
plate
Handrail locking
28 000209913A6000000 LGJB2 t6 10
splint
29 1040000899 GB/T5782-2000 Bolt M12×70-8.8 5
30 1040300054 GB/T93-1987 Washer 12 5
31 1040300756 GB/T97.1-2002 Washer 12-200HV 10
32 1040200096 GB/T6170-2000 Nut M12-8 5
33 000208899A0002076 TX-6-24/35 Spring pin Φ6×117 18
365
7.2.5 Slewing Support
Fig. 7-19 000281710DT000000
Table 7-19 Spare parts list of Slewing Support

Slewing support
1 000281710DT003000 1
structure
2 000281710DT002000 Ladder 1
M27×240-
3 1040003331 GB/T5782-2000 Bolt 48
10.9
4 1040201105 GB/T6170-2000 Nut M27-10 96
5 1040301787 GB/T97.1-2002 Washer 27-300HV 96
6 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
7 1040300065 GB/T93-1987 Washer 16 4
8 1040200110 GB/T6170-2000 Nut M16-8 4
9 1040300052 GB/T97.1-2002 Washer 16-200HV 4
10 1090100308 MZKW Hanging net 1
366
7.2.6 Trolley
Fig. 7-20 000209707K0100000
Table 7-20 Spare parts list of Trolley

NO. Order NO. Code Designation Dimension Qty
1 000209707K0101000 Trolley(Remove Maintenance Cage) 1
2 000209901A0600000 DL6 Maintenance Cage 1
367
7.2.6.1 Trolley without Maintenance Cage
Fig. 7-21 000209707K0101000
368
Table 7-21 Spare parts list of Trolley without Maintenance Cage

Trolley
1 000209707K0101100 1
structure
2 000209707K0101001 Rope rod Φ33.7×3.2 2
3 1040500216 GB/T91-2000 Split pin 6.3×50 12
4 000209707K0101002 Card support t8 4
5 1040002436 GB/T5783-2000 Bolt M12×25-8.8 8
6 1040300041 GB/T97.1-2002 Washer 12-200HV 14
7 1040300054 GB/T93-1987 Washer 12 12
8 000209707K0101003 Pulley shaft 2
9 000209707K0101004 Bushing 2
10 000209707K0101005 Bushing 2
HL-450-380-80-130-
11 000209906A0040035 Pulley 4
R8.5
13 1050202084 GB/T276-2013 Bearing 6312-2RS 8
14 000209707K0101006 Bushing 2
15 1050201562 GB/T276-2004 Bearing 6212-2RS1 8
17 000209709A0003003 Roller 4
18 000209707J0101004 Bushing 4
19 000209707K0101007 Roller shaft 4
20 1040200342 GB/T812-1988 Nut M52×1.5 4
21 1040300265 GB/T858-1988 Washer 52 4
22 000209710A0600001 Side roller Φ120-50 4
24 1050201944 GB/T276-2013 Bearing 6206-2RS 8
25 000209710A0600002 Side roller shaft Φ30 4
26 000209710A0601003 Bushing Φ30-8.8 8
27 000209707K0101010 Stretching plate 1
28 1040200096 GB/T6170-2000 Nut M12-8 6
29 000209707K0101020 Safety brake 2
30 000209719A0601008 Bushing 4
31 000209910A1050701 XZ01B-25×70/90 Pin 25×70 2
32 1090100081 GB/T5976-2006 Rope clamp 10KTH 1
33 000209719A0601006 Press plate t16 1
34 000209719A0601007 Bushing 2
35 000209910A1040601 XZ01B-20×60/80 Pin 20×60 1
36 1040500253 GB/T91-2000 Split pin 5×32 5
37 000209705D0000002 Bushing 1
38 1090100713 GB/T5973-2006 Wedge 10 2
369
Stretching
39 000209719A0601010 1
pulley
40 000209705D0000009 Bushing 1
41 000209910A4061341 XZ03C-30×135/170 Pin 30×135 1
42 1090100722 GB/T5973-2006 Wedge sleeve 10 1
43 000209910A0000113 XZ01A-20×45/65 Pin 20×45 1
44 000209707J0101006 Cover t4 4
45 000209708A0001063 Buffer block 4
46 1040000489 GB/T5783-2000 Bolt M10×50-8.8 4
47 1040300559 GB/T96-1985 Washer 10 4
48 1040200679 GB/T6170-2000 Nut M10-8 8
49 1040300061 GB/T97.1-2002 Washer 10-200HV 12
50 1040300067 GB/T93-1987 Washer 10 8
51 1040002435 GB/T5783-2000 Bolt M10×35-8.8 4
52 000209705A0000900 FXC08B-9 Glide wheel 3
53 1050201565 GB/T276-2004 Bearing 6004-2RS1 6
Glide wheel
54 000209707F0301003 Φ20 3
shaft
55 000209705A0001100 FXC08B-11 Bushing 6
56 1040002440 GB/T5783-2016 Bolt M12×45-8.8 2
370
7.2.7 Hook
Fig. 7-22 000209607A1900000

Component No.1 and No.2 are exploded in other drawings
Table 7-22 Spare parts list of Hook

1 000209606A1701000 Upper part of the hook 1
2 000209607A1902000 Lower part of the hook 1
371
7.2.7.1 Upper Part of the Hook
Fig. 7-23 000209606A1701000
Table 7-23 Spare parts list of Upper Part of the Hook

1 1040300067 GB/T93-1987 Washer 10 2
2 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
3 000209605A0000018 FDG08A.01-5 Plate 1
4 000209606A1401100 Pulley frame 1
HL-450-380-80-130-
5 000209906A0040035 Pulley 1
R8.5
6 000209606A1401001 Bushing 2
7 000209606A1702001 Pulley shaft 1
8 1050202084 GB/T276-2013 Bearing 6312-2RS 2
10 000209910A1121901 XZ01C-60×190/225 Pin 60×190 1
11 1040500260 GB/T91-2000 Split pin 10×80 1
372
7.2.7.2 Lower Part of the Hook
Fig. 7-24 000209607A1902000
373
Table 7-24 Spare parts list of Lower Part of the Hook

1 000209607A1902100 Pulley frame 1
HL-450-380-80-130-
2 000209906A0040035 Pulley 2
R8.5
4 1050202084 GB/T276-2013 Bearing 6312-2RS 4
5 000209605A0000018 FDG08A.01-5 Plate 3
6 1040300067 GB/T93-1987 Washer 10 6
7 1040000116 GB/T5783-2000 Bolt M10×20-8.8 4
8 000209606A1702001 Pulley shaft 2
9 000209606A1401001 Bushing 4
10 000209606A1402001 Pin 1
11 000209606A1702200 Load hook 1
374
7.2.7.3 Load Hook
Fig. 7-25 000209606A1702200
Table7-25 Spare parts list of Load Hook

1 000209606A1702210 Plate 1
2 000209606A1702202 Hook nut M56 1
3 1050201632 GB/T301-1995 Bearing 51312 1
4 1080000007 JB/T7940.1-1995 Oil cup M10×1 1
5 1999904306 FCM(TPTC) Oil cup cover Φ10 1
6 000209606A1702230 Hook Chuck 1
7 000209606A1702201 Hook 1
8 000209606A1702205 Pin 10X130 1
9 1040500243 GB/T91-2000 Split pin 5×25 1
10 1040000108 GB/T5783-2000 Bolt M12×30-8.8 2
11 1040300061 GB/T97.1-2002 Washer 10-200HV 3
12 1040300054 GB/T93-1987 Washer 12 2
13 000209606A1702203 Plate t10 1
375
7.2.8 Climbing Equipment
376
Fig. 7-26 000261811CT000000

Components No.1, 8, 15 are exploded in other drawings
377
Table 7-26 Spare parts list of Climbing Equipment (WA7527-20D(Abroad).11)

Climbing
1 000261811CT001000 equipment 1
structure
2 000209913D0005300 LGA530B Railing 18
3 000209913C0006300 LGA630B Railing 9
4 000209913C0020000 LGB2000B Railing 7
5 000261811AT030000 Ladder 1
6 000209910A1101301 XZ01C-50×130/160 Pin 50×130 2
7 1040500186 GB/T91-2000 Split pin 10×90 2
Climbing
8 000261811AT040000 operation 1
platform
9 000209913C0009500 LGA950B Railing 1
10 000209913C0015000 LGC1500B Railing 1
11 000261811AT050000 Platform A 1
12 000261811AT060000 Platform B 4
13 000261811AT070000 Platform C 1
14 000261811CT080000 Platform D 1
Jacket stop shoe
15 000200411D0000060 1
mechanism
16 000209910A1040801 XZ01B-20×80/100 Pin 20×80 2
17 1040500253 GB/T91-2000 Split pin 5×32 2
18 000209910A1141701 XZ01D-70×170/210 Pin 70×170 1
19 1040500965 GB/T91-2000 Split pin 13×110 1
Railing clamp
20 000209913A6000000 LGJB2 t6 68
plate
21 1040000170 GB/T5782-2000 Bolt M12×65-8.8 34
22 1040300041 GB/T97.1-2002 Washer 12-200HV 68
23 1040300054 GB/T93-1987 Washer 12 34
24 1040200096 GB/T6170-2000 Nut M12-8 34
25 000261811AT000001 Pin 18
26 1040500097 GB/T91-2000 Split pin 4×30 18
27 000208899A0002076 TX-6-24/35 Spring pin Φ6×117 72
28 1040006134 GB/T5783 Bolt M16×60-8.8 4
29 1040300052 GB/T97.1-2002 Washer 16-200HV 16
30 1040300215 GB/T853-1988 Washer 16 8
31 1040200110 GB/T6170-2000 Nut M16-8 8
32 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
33 000261811AT000002 Roller shaft 16
34 000261811AT090000 Roller assembly 16
35 000200411D0000052 Lock pin 16
378
36 1040500254 GB/T91-2000 Split pin 4×25 32

37 000261811AT000003 Hanging hook t10 2
7.2.8.1 Climbing equipment frame
Fig. 7-27 000261811CT001000
379
Table7-27 Spare parts list of Climbing equipment structure (000261811CT001000)

1 000261811CT001100 Rear U structure 1
2 000261811CT001200 Front U structure 1
Mobilizable
3 000261811AT020000 1
brace rod
4 1040002697 GB/T5783-2000 Bolt M16×100-10.9 32
5 1040300052 GB/T97.1-2002 Washer 16-200HV 64
6 1040200073 GB/T6170-2000 Nut M16-10 64
XZ01B-
7 000209910A1040801 Pin 20×80 2
20×80/100
8 1040500253 GB/T91-2000 Split pin 5×32 2
7.2.8.2 Climbing operation platform
Fig. 7-28 000261811AT040000
Table7-28 Spare parts list of Climbing operation platform

1 000261811AT040001 Expanded steel PF4×24×550×2570 1
2 000261811AT040100 Outrigger 2
3 000261811AT040002 Bent plate t4 2
4 000200111F0000430 Angle steel L50×4 3
5 000210111A0006005 Bent plate t4 2
6 000209913A4000002 Railing support Φ42×3-48 16
380
7.2.8.3 Jacket stop shoe mechanism
Fig. 7-29 000200411D0000060
Table7-29 Spare parts list of Climbing operation platform

1 000200911A0000081 Lock card 2
2 000200411D0000070 Jacket stop shoe 2
XZ01B-
3 000209910A0160501 Pivot 16×50 4
16×50/65
4 1040500228 GB/T91-2000 Split pin 4×32 4
Movable rod of stop
5 000200411D0000065 M16-8 1
shoe
6 1040500980 GB/T91-2000 Split pin 10×60 4
7 000200411D0000063 Connecting rod 1
381
7.2.9 Slewing Mechanism

7.2.9.1 S75CA-130LB12/14A Slewing Mechanism
Fig. 7-30 000209289A6700000
382
Table 7-30 Spare part list of S75CA-130LB12/14A Slewing Mechanism

YTRVF132M2-
1 1020005445 Motor 1
4F1/B/BM1
2 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
3 1040300054 GB/T93-1987 Spring washer 12 4
4 1040300041 GB/T97.1-2002 Washer 12-200HV 4
XX5-130.195LB-
5 1030202399 Reduction gear 1
12/14
6 000209289A6700100 Nameplate 1
7 1040400058 GB/T827-1986 Rivet 2.5×8 4
383
7.2.9.2 S75CN-130LB12/14A Slewing Mechanism
Fig. 7-31 000209289A6800000
384
Table 7-31 Spare part list of S75CN-130LB12/14A Slewing Mechanism

YTRVF132M2-
1 1020005446 Motor 1
4F2/B/BM1
2 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
Spring
3 1040300054 GB/T93-1987 12 4
washer
4 1040300041 GB/T97.1-2002 Washer 12-200HV 4
Reduction
5 1030202399 XX5-130.195LB-12/14 1
gear
6 000209289A6800100 Nameplate 1
7 1040400058 GB/T827-1986 Rivet 2.5×8 4
8 1020202072 ECK58B(Nr:851249/10) Encoder 1024PPR 1
385
7.2.10 Trolley Mechanism
Fig. 7-33 000209321B0000000

Component No.22 is exploded in other drawing
386
Table 7-33 Spare parts list of Trolley Mechanism (BP55B)

No. Order NO. Code Designation Dimension Qty
1 000209321B0000001 Angel steel L80×8 2
2 1040000177 GB/T5783-2000 Bolt M16×55-8.8 4
3 1040200110 GB/T6170-2000 Nut M16-8 12
4 1040300065 GB/T93-1987 Washer 16 12
5 1040300052 GB/T97.1-2002 Washer 16-200HV 12
6 1040500631 GB/T879.1-2000 Spring pin 12×26 2
7 000209321B0000004 End cover t5 1
8 1040000094 GB/T5783-2000 Bolt M12×35-8.8 18
9 1040300054 GB/T93-1987 Washer 12 26
Supporting plate
10 000209321B0001000 1
A
Connecting
11 000209321B0000003 1
sleeve
12 000209321B0000002 Stud bolt Φ20 4
13 1040000216 GB/T5783-2000 Bolt M12×70-8.8 8
14 1040200096 GB/T6170-2000 Nut M12-8 16
15 1040300041 GB/T97.1-2002 Washer 12-200HV 20
16 1040000098 GB/T5783-2000 Bolt M8×16-8.8 2
17 1040300210 GB/T96.1-2002 Washer 8-200HV 2
18 000209321B0000005 Rope clamp 2
19 000209321B0000006 Flange A t20 1
20 000209321B0000007 Drum 1
21 1030200185 XL5.5-6-43 Reducer 1
22 000209321B0002000 Gear coupling 1
23 000209301E0000010 Hatch A t22 1
24 000209301E0000011 Oil seal 110 1
25 1040100122 GB/T70.1-2000 Screw M8×25-8.8 8
26 1040300063 GB/T93-1987 Washer 8 12
27 000209321B0000008 Flange B 1
28 1050200151 GB/T281-1994 Bearing 1222 1
29 000209301E0000013 Oil seal 125 1
30 1040100087 GB/T70.1-2000 Screw M12×25-8.8 8
31 000209301E0000017 Redress washer t2 1 Set
32 000209301E0000018 XX2-12.44 Reducer t3 1
Supporting plate
32 000209321B0003000 1
B
33 000209301E0000016 Limiting pinion 1
34 1040500054 GB/T91-2000 Split pin 4×40 1
35 1040100087 GB/T70.1-2000 Screw M12×25-8.8 8
36 1040000118 GB/T5783-2000 Bolt M5×16-8.8 8
37 1040300060 GB/T93-1987 Washer 5 8
387
38 1040300048 GB/T97.1-2002 Washer 5-200HV 8

Limit switch
39 000209301E0000015 1
support
40 1040000267 GB/T5783-2000 Bolt M8×20-8.8 2
41 1040300066 GB/T97.1-2002 Washer 8-200HV 2
YEJ132S-4B5-
42 1020000005 Electric motor 1
5.5kW
43 000209321B0000009 Nameplate 1
7.2.10.1 Gear Coupling
Fig. 7-32 000209321B0002000
Table 7-32 Spare parts list of Gear Coupling

1 000209321B0002001 Half coupling A 1
2 000209301E0003002 Nylon gear 1
3 000209301E0003003 Half coupling B 1
388
7.2.11 Hoisting Mechanism
Fig. 7-33 000209195A2900000 (2-1)
Table 7-33 Spare parts list of Hoisting Mechanism (H45FP30-600P) (2-1)

1 1020005200 YZPFM250M2-6 Electromotor 45kW 1
M20×140-
2 1040000278 GB/T5782-2000 Bolt 4
8.8
3 1040300106 GB/T97.1-2002 Washer 20-200HV 7
4 1040300252 GB/T853-1988 Washer 20 4
5 1040300038 GB/T93-1987 Washer 20 11
6 1040200097 GB/T6170-2000 Nut M20-8 4
7 1020202010 ETF100-H(Nr:851223/0.8) Encoder 1
LM9-
8 000209944A0000850 Coupling 1
YA65×142(18)/YA55×112(16)
8.1 1040102120 GB/T77-2000 Screw M12×30 2
Semi-
8.2 000209944A0000851 1
coupling 1
8.3 000209944A0000712 Elastic body 1
389
Semi-
8.4 000209944A0000713 1
coupling 2
Coupling
9 000209195A2900100 1
cover
10 1040000267 GB/T5783-2000 Bolt M8×20-8.8 8
11 1040300066 GB/T97.1-2002 Washer 8-200HV 20
12 1040300063 GB/T93-1987 Washer 8 26
Reduction
13 1030202231 DF720 i=30.41 1
Gear
14 000209195A6501000 Brake cover 1
15 1040000116 GB/T5783-2000 Bolt M10×20-8.8 4
16 1040300061 GB/T97.1-2002 Washer 10-200HV 4
17 1040302271 GB/T93-1987 Washer 10 4
18 1031700155 YWZ5-315/80-1000-HL Brake 1
Braking
19 000209195A2900002 1
wheel
20 000209195A2900001 Plate 3
21 1040000175 GB/T5783-2000 Bolt M20×50-8.8 7
22 1040000177 GB/T5783-2000 Bolt M16×55-8.8 6
23 1040200110 GB/T6170-2000 Nut M16-8 6
24 1040300052 GB/T97.1-2002 Washer 16-200HV 8
25 1040300065 GB/T93-1987 Washer 16 8
26 1040200102 GB/T6170-2000 Nut M24-8 8
M24×100-
27 1040000281 GB/T5782-2000 Bolt 8
8.8
28 1040300050 GB/T97.1-2002 Washer 24-200HV 8
29 1040300263 GB/T853-1988 Washer 24 8
30 1040300049 GB/T93-1987 Washer 24 8
Redress
31 000209101E1000010 t1 0
washer A
Redress
32 000209101E1000011 t1.5 0
washer B
390
Fig. 7-34 000209195A2900000 (2-2)
391
Table 7-34 Spare parts list of Hoisting Mechanism (H45FP30-600P) (2-2)

34 1050200175 GB/T288-1994 Bearing 22216 C 1
35 000209112D1000005 Bushing 1
36 000209195A2902000 Drum 1
37 000209195A2900004 Shaft 1
38 1040600016 GB/T1096-2003 Bond 20×80 1
39 000209112D1000002 Gear connector 1
40 000209101E1000005 Pin 4
41 000209112D1000001 Retaining ring t3 1
42 1040000098 GB/T5783-2000 Bolt M8×16-8.8 6
43 1050000314 GB/T9163-2001 Bearing GE80ES 1
44 000209112D1000003 Plate t3 1
45 000209195A2908000 Underframe 1
46 000209195A6500003 Pin 1
47 000209195A6500002 Bearing cover t16 1
48 000209112D1000008 Spacing sleeve 1
49 000209195A2905000 Bearing seat 1
50 000209112D1000006 End coverⅠ 1
51 1040000288 GB/T5783-2000 Bolt M8×25-8.8 12
52 000209112D1000007 Oil seal Ⅰ 1
53 1040000286 GB/T5783-2000 Bolt M16×65-8.8 2
54 1080000007 JB/T7940.1-1995 Oil cup M10×1 1
55 000209195A5700002 Oil seal 1
56 000209944A0200023 NLT-3 Nylon sleeve 1
57 1040500054 GB/T91-2000 Pin 4×40 1
58 1040300048 GB/T97.1-2002 Washer 5-200HV 4
59 1040300060 GB/T93-1987 Washer 5 4
60 1040000151 GB/T5783-2000 Bolt M5×12-8.8 4
61 000209944A0400030 XWZJ-01 Limiter bracket t5 1
62 000209195A2900010 H45FP30-600P-MP Nameplate 1
63 1040400058 GB/T827-1986 Rivet 2.5×8 4
64 000209195A5700004 Plate t8 1
65 1040000107 GB/T5783-2000 Bolt M6×20-8.8 2
66 1040300062 GB/T93-1987 Spring Washer 6 2
67 000200610A0007004 XZ03C-30×90/125 Pin 30×90 4
392
68 1040500040 GB/T91-2000 Pin 6.3×50 8
7.2.12 Transition Tower Section
Fig. 7-35 000209012B3800000
393
Table 7-35 Spare parts list of Transition Tower Section (L68C3B)

Transition tower
1 000209012B3801000 1
section structure
2 000209012B3802000 Ladder 1
3 1040000095 GB/T5783-2000 Bolt M16×50-8.8 4
4 1040300052 GB/T97.1-2002 Washer 16-200HV 4
5 1040300065 GB/T93-1987 Washer 16 4
6 1040200110 GB/T6170-2000 Nut M16-8 4
7 000210610AR100001 Pin 8
8 000209012A0000003 Pin 4
9 000200610A0007401 XZ03A-20×65/85 Pin 20×65 8
10 1040500228 GB/T91-2000 Split pin 4×32 20
11 000209910A1101301 XZ01C-50×130/160 Pin 50×150 4
12 1040500252 GB/T91-2000 Split pin 10×90 4
13 000200610A0007002 Pin 4
14 1040000152 GB/T5783-2000 Bolt M10×40-8.8 4
15 1040200813 GB/T6170-2000 Nut M10-8 4
16 1040300211 GB/T96.1-2002 Washer 10-200HV 8
17 000209012A1703000 Platform 1
18 000231710BT000002 Pin 55×165 8
19 000209910A3041001 XZ03B-20×100/120 Pin 20×100 8
20 000201213A0000003 Spring pin 16
394
7.2.13 Erection Platform
Fig. 7-36 000270320BT000000
395
Table 7-36 Spare parts list of Erection Platform (T6513-8E.20A)

1 000209913B0020000 LGB2000A Handrail 2
2 000209913B0009500 LGA950A Handrail 2
3 000209913B0004300 LGA430A Handrail 4
4 000209913B0005300 LGA530A Handrail 4
5 000270320BT002000 Platform 2
Handrail locking
6 000209913A5000001 LGJB1 t5 20
splint
7 1040000216 GB/T5783-2000 Bolt M12×70-8.8 10
8 1040300041 GB/T97.1-2002 Washer 12-200HV 10
9 1040300054 GB/T93-1987 Washer 12 10
10 1040200096 GB/T6170-2000 Nut M12-8 10
11 1040500222 GB/T91-2000 Split pin 8×80 24
12 000240811AT100003 Pin 4
13 000201213A0000003 Spring pin 4
396
7.2.14 Mounting Device
Fig. 7-33 000270319AT000000

Component No.2 is exploded in other drawing
Table 7-33 Spare parts list of Mounting Device (T6513-8E.19)

No. Order NO. Code Designation Dimension Qty
1 000270319AT000100 Guide way 2
2 000200610A0007400 Lifting device 1
3 000209910A4060601 XZ03C-30×60/95 Pin 30×60 4
4 1040500222 GB/T91-2000 Split pin 8×80 8
397
7.2.14.1 Lifting Device
Fig. 7-37 000200610A0007400
398
Table 7-37 Spare parts list of Gear Coupling

1 000200610A0007410 Lifting beam 1
2 1040100950 GB/T6563-1986 Screw M6×14 4
3 000200610A0007201 Shaft 4
5 000200610A0007202 Roller 4
6 1050200499 GB/T276-1994 Bearing 6207-z 4
8 1040000102 GB/T5783-2000 Bolt M14×35-8.8 4
9 1040300068 GB/T93-1987 Washer 14 4
10 1040000089 GB/T5782-2000 Bolt M20×80-8.8 4
11 1040200097 GB/T6170-2000 Nut M20-8 4
12 1040300106 GB/T97.1-2002 Washer 20-200HV 4
13 000200610A0007420 Bring-in hook 4
14 000200610A0007401 XZ03A-20×65/85 Pin 20×65 4
15 1040500222 GB/T91-2000 Split pin 8×80 8
399
7.2.15 Base Tower Section (L68G23)
Fig. 7-38 000208890A0099000
400
Table 7-38 Spare parts list of Base Tower Section (L68G23)

Base tower section
1 000209012A2301000 1
structure
Ladder and guard
2 000209014A1301100 1
ring
4.5 m ladder and
3 000209012A2302000 1
guard ring
4 000209014A1200930 Ladder joint 4
5 1040000095 GB/T5783-2000 Bolt M16×60-8.8 24
6 1040300052 GB/T97.1-2002 Washer 16-200HV 24
7 1040300065 GB/T93-1987 Washer 16 24
8 1040200685 GB/T6170-2000 Nut M16-8 24
9 000200615F0000001 Pin 8
10 000209012A0000003 Pin 4
11 1040500228 GB/T91-2000 Split pin 4×32 4
12 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
13 1040200111 GB/T6170-2000 Nut M6-8 4
14 1040300062 GB/T93-1987 Washer 6 4
15 1040300051 GB/T97.1-2002 Washer 6-200HV 4
401
7.2.16 Mast (Rung ladder)

7.2.16.1 Tower Section
7.2.16.1.1 L68A4
Fig. 7-39 000209012A2600000
402
Table 7-39 Spare parts list of Tower Section (L68A4)

1 000209012A1001000 Tower section piece A 1
2 000209012A1002000 Tower section piece B 1
3 000209012A2601000 Tower section piece C 1
4 000209012A2602000 Tower section piece D 1
5 000209012A0000001 Bolt 20
6 000209012A0000002 Pin 8
7 000209012A0000003 Pin 4
8 1040500228 GB/T91-2000 Split pin 4×32 4
9 000209012A0000004 Nut 20
403
7.2.16.1.2 L68B7
Fig. 7-40 000209012A2800000
404
Table 7-40 Spare parts list of Tower Section (L68B7)

1 000209012A3001000 Tower section piece A 1
2 000209012A3002000 Tower section piece B 1
3 000209012A2801000 Tower section piece C 1
4 000209012A2802000 Tower section piece D 1
5 000209012A0000001 Bolt 20
6 000200615F0000001 Pin 8
7 000209012A0000003 Pin 4
8 1040500228 GB/T91-2000 Split pin 4×32 4
9 000209012A0000004 Nut 20
405
7.2.16.2 Passageway
7.2.16.2.1 L68TDJ
Fig. 7-41 000209014A1300000
Table 7-41 Spare parts list of Passageway (L68TDJ)

Ladder and
1 000209014A1301100 1
guard ring
2 000209014A1200930 Ladder joint 2
3 1040000095 GB/T5783-2000 Bolt M16×60-8.8 12
4 1040300052 GB/T97.1-2002 Washer 16-200HV 12
5 1040300065 GB/T93-1987 Washer 16 12
6 1040200685 GB/T6170-2000 Nut M16-8 12
406
7.2.16.2.2 L68TDH
Fig. 7-42 000209014A1200000
Table 7-42 Spare parts list of Passageway (L68TDH)

Ladder and guard
1 000209014A1200910 1
ring
2 000209012A0000610 Platform D 1
3 000209014A1200930 Ladder joint 2
4 1040000095 GB/T5783-2000 Bolt M16×60-8.8 12
5 1040300052 GB/T97.1-2002 Washer 16-200HV 12
6 1040300065 GB/T93-1987 Washer 16 12
7 1040200685 GB/T6170-2000 Nut M16-8 12
Platform fixing
8 000209012A0000690 4
plate
9 1040000152 GB/T5783-2000 Bolt M10×40-8.8 4
10 1040300067 GB/T93-1987 Washer 10 4
11 1040200813 GB/T6170-2000 Nut M10-8 4
407
7.2.16.3 Stationary Chassis
Fig. 7-43 000200614D1000000
408
Table 7-43 Spare parts list of Stationary Chassis (TC6517B-10E.14)

1 000200614D1007000 Whole beam 1
2 000200614D1002000 Rod 4
3 000200614D1003000 Strut 4
4 000200614D1008000 Half-beam 2
5 000200614D1009000 Base tower section 1
6 000200614D1006000 Short ladder 1
7 1040500252 GB/T91-2000 Split pin 10×90 8
5 m Ladder and
8 000200614C0000200 1
guard ring
9 000200614C0000010 Ladder support 1
10 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
11 1040200110 GB/T6170-2000 Nut M16-8 4
12 1040300065 GB/T93-1987 Washer 16 4
13 1040300052 GB/T97.1-2002 Washer 16-200HV 4
14 000200615F0000001 Pin 8
15 000209012A0000003 Pin 4
16 1040500228 GB/T91-2000 Split pin 4×32 4
17 000200614D1000001 XZ01C-60×385/425 Pin 4
18 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
19 1040500309 GB/T91-2000 Split pin 6.3×45 8
20 000200614C0000001 XZ01C-70×150/205 Pin 8
21 1040500250 GB/T91-2000 Split pin 12×100 8
22 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
23 1040200111 GB/T6170-2000 Nut M6-8 4
24 1040300062 GB/T93-1987 Washer 6 4
25 1040300051 GB/T97.1-2002 Washer 6-200HV 4
26 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
27 1040200744 GB/T6170-2000 Nut M8-8.8 4
28 1040300063 GB/T93-1987 Washer 8 4
29 1040300066 GB/T97.1-2002 Washer 8-200HV 4
30 1040000152 GB/T5783-2000 Bolt M10×40-8.8 2
31 1040200113 GB/T6170-2000 Nut M10-8 2
32 1040300067 GB/T93-1987 Washer 10 2
33 000200614C0000002 Pressing plate L100×10 2
34 000200614C0000020 Ladder handrail 1
Ladder fixing
35 000209012A0000602 8
plate
Ladder fixing
36 000209012A0000603 8
clamp
37 000209012A0000604 Wedge 8
38 1040000267 GB/T5783-2000 Bolt M8×20-8.8 8
409
7.2.16.4 Mobile Chassis
Fig. 7-44 000200623A1000000
410
Table7-44 Spare parts list of Mobile Chassis (TC6517B-10E.23)

1 000200623A1001000 Whole beam 1
2 000200614D1002000 Rod 4
3 000200614D1003000 Strut 4
4 000200623A1002000 Half-beam Ⅰ 1
Base tower
5 000200614D1009000 1
section
Bracket for
6 000200723C0003000 M822 rope 1
drum
7 000200614D1006000 Short ladder 1
8 1040500252 GB/T91-2000 Split pin 10×90 8
5 m ladder and
9 000200614C0000200 1
guard ring
10 1040000095 GB/T5783-2000 Bolt M16×60-8.8 12
11 1040200110 GB/T6170-2000 Nut M16-8 12
12 1040300065 GB/T93-1987 Washer 16 12
13 1040300052 GB/T97.1-2002 Washer 16-200HV 12
14 000200623A1003000 Half-beam 1
Ladder
15 000200614C0000010 1
support
16 000200615F0000001 Pin 16
17 000209012A0000003 Pin 8
18 1040500228 GB/T91-2000 Split pin 4×32 8
19 000200614D1000001 XZ01C-60×385/425 Pin 4
20 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
21 1040500309 GB/T91-2000 Split pin 6.3×45 8
22 000200614C0000001 XZ01C-70×150/205 Pin 8
23 1040500250 GB/T91-2000 Split pin 12×100 8
24 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
25 1040200111 GB/T6170-2000 Nut M6-8 4
26 1040300062 GB/T93-1987 Washer 6 4
27 1040300051 GB/T97.1-2002 Washer 6-200HV 4
28 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
29 1040200744 GB/T6170-2000 Nut M8-8.8 4
30 1040300063 GB/T93-1987 Washer 8 4
31 1040300066 GB/T97.1-2002 Washer 8-200HV 4
32 1040000152 GB/T5783-2000 Bolt M10×40-8.8 2
33 1040200113 GB/T6170-2000 Nut M10-8 2
34 1040300067 GB/T93-1987 Washer 10 2
35 000200614C0000002 Pressure plate L100×10 2
36 000200614C0000020 Handrail 1
411
Fixing plate for

37 000209012A0000602 8
ladder
Fixing hoop for
38 000209012A0000603 8
ladder
39 000209012A0000604 Wedge 8
40 1040000267 GB/T5783-2000 Bolt M8×20-8.8 8
41 1040300215 GB/T853-1988 Washer 16 8
7.2.17 Mast (Incline ladder)

7.2.17.1 Tower Section
7.2.17.1.1 L68A1A
Fig. 7-45 000209012A3600000
412
Table 7-45 Spare parts list of Tower Section (L68A1A)

Tower section
1 000209012A3601000 2
piece A
Tower section
2 000209012A3602000 1
piece B
Tower section
3 000209012A3603000 1
piece C
4 000209012A0000002 Pin 8
5 000209012A0000003 Pin 4
6 1040500228 GB/T91-2000 Split pin 4×32 4
7 000209012A0000004 Nut 20
8 000209012A0000001 Bolt 20
9 000209012A3608000 Long ladder 1
10 000209012A3607000 Platform 1
11 1040000169 GB/T5783-2000 Bolt M12×45-8.8 4
12 1040300054 GB/T93-1987 Washer 12 4
13 1040300041 GB/T97.1-2002 Washer 12-200HV 4
14 1040200096 GB/T6170-2000 Nut M12-8 4
15 1040000095 GB/T5783-2000 Bolt M16×60-8.8 2
16 1040300052 GB/T97.1-2002 Washer 16-200HV 2
17 1040300065 GB/T93-1987 Washer 16 2
18 1040200110 GB/T6170-2000 Nut M16-8 2
413
7.2.17.1.2 L68B2A
Fig. 7-46 000209012A4000000
414
Table 7-46 Spare parts list of Tower Section (L68B2A)

Tower section
1 000209012A4001000 2
piece A
Tower section
2 000209012A4002000 1
piece B
Tower section
3 000209012A4003000 1
piece C
4 000209012A0000001 Bolt 20
5 000200615F0000001 Pin 8
6 000209012A0000003 Pin 4
7 1040500228 GB/T91-2000 Split pin 4×32 4
8 000209012A0000004 Nut 20
9 000209012A3608000 Long ladder 1
10 000209012A3607000 Platform 1
11 1040000095 GB/T5783-2000 Bolt M16×60-8.8 2
12 1040300052 GB/T97.1-2002 Washer 16-200HV 2
13 1040300065 GB/T93-1987 Washer 16 2
14 1040200110 GB/T6170-2000 Nut M16-8 2
15 1040000169 GB/T5783-2000 Bolt M12×45-8.8 4
16 1040300054 GB/T93-1987 Washer 12 4
17 1040300041 GB/T97.1-2002 Washer 12-200HV 4
18 1040200096 GB/T6170-2000 Nut M12-8 4
415
7.2.17.2 Stationary Chassis
Fig. 7-47 000281714AT000000
416
Table 7-47 Spare parts list of Stationary Chassis (WA7025-12E(Abroad).14)

1 000281714AT001000 Whole beam 1
2 000200614D1002000 Rod 4
3 000281723AT003000 Strut 4
4 000200623A1003000 Half-beam 2
Base tower
5 000281723AT001000 1
section
6 000200614D1006000 Short ladder 1
7 1040500252 GB/T91-2000 Split pin 10×90 8
Ladder and
8 000281723AT002000 1
guard ring
9 1040000095 GB/T5783-2000 Bolt M16×60-8.8 16
10 1040200110 GB/T6170-2000 Nut M16-8 16
11 1040300065 GB/T93-1987 Washer 16 16
12 1040300052 GB/T97.1-2002 Washer 16-200HV 16
13 000200615F0000001 Pin 16
14 000209012A0000003 Pin 8
15 1040500228 GB/T91-2000 Split pin 4×32 8
16 000200614D1000001 XZ01C-60×385/425 Pin 4
17 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
18 1040500309 GB/T91-2000 Split pin 6.3×45 8
19 000200614C0000001 XZ01C-70×150/205 Pin 8
20 1040500250 GB/T91-2000 Split pin 12×100 8
21 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
22 1040200111 GB/T6170-2000 Nut M6-8 4
23 1040300062 GB/T93-1987 Washer 6 4
24 1040300051 GB/T97.1-2002 Washer 6-200HV 4
25 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
26 1040200744 GB/T6170-2000 Nut M8-8.8 4
27 1040300063 GB/T93-1987 Washer 8 4
28 1040300066 GB/T97.1-2002 Washer 8-200HV 4
417
7.2.17.3 Mobile Chassis
Fig. 7-48 000281723AT000000
418
Table7-48 Spare parts list of Mobile Chassis (WA7025-12E(Abroad).23)

1 000200623A1001000 Whole beam 1
2 000200614D1002000 Rod 4
3 000281723AT003000 Strut 4
4 000200623A1002000 Half-beam Ⅰ 1
Base tower
5 000281723AT001000 1
section
Bracket for M822
6 000200723C0003000 1
rope drum
7 000200614D1006000 Short ladder 1
8 1040500252 GB/T91-2000 Split pin 10×90 8
Ladder and
9 000281723AT002000 1
guard ring
10 1040000095 GB/T5783-2000 Bolt M16×60-8.8 24
11 1040200110 GB/T6170-2000 Nut M16-8 24
12 1040300065 GB/T93-1987 Washer 16 24
13 1040300052 GB/T97.1-2002 Washer 16-200HV 24
14 000200623A1003000 Half-beam 1
15 000200615F0000001 Pin 16
16 000209012A0000003 Pin 8
17 1040500228 GB/T91-2000 Split pin 4×32 8
18 000200614D1000001 XZ01C-60×385/425 Pin 4
19 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
20 1040500309 GB/T91-2000 Split pin 6.3×45 8
21 000200614C0000001 XZ01C-70×150/205 Pin 8
22 1040500250 GB/T91-2000 Split pin 12×100 8
23 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
24 1040200111 GB/T6170-2000 Nut M6-8 4
25 1040300062 GB/T93-1987 Washer 6 4
26 1040300051 GB/T97.1-2002 Washer 6-200HV 4
27 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
28 1040200744 GB/T6170-2000 Nut M8-8.8 4
29 1040300063 GB/T93-1987 Washer 8 4
30 1040300066 GB/T97.1-2002 Washer 8-200HV 4
31 1040300215 GB/T853-1988 Washer 16 8
419
7.2.18 Powered Wheel Bogie
Fig. 7-49 000209401D1000000
420
Table 7-49 Spare parts list of Powered Wheel Bogie (ZA52-D)

1 1080000206 JB/T7940.1-1995 Oil cup M101 6
2 1040500241 GB/T119.1-2000 Split pin B1660 2
3 000209401D1000012 Connecting plate t36 1
4 000209401A0000023 Plate 1
5 000209401A0000031 Shaft 1
6 000209401D0000004 Steel sleeve 2
7 000209401A0000040 Bearing seat 3
8 1050200176 GB/T288-1994 Bearing 22220 C 4
9 000209401D1000038 Dust cover 4
10 000209401D1000039 Oil seal 4
11 000209401D1000036 Travelling wheel 2
12 000209401D1000037 Shaft 1
13 1040600015 GB/T1096-2003 Bond 32110 2
14 1040300432 GB/T858-1988 Washer 90 1
15 1040200486 GB/T812-1988 Nut M902 1
16 000209401D1000056 Shaft 1
17 1040200574 GB/T6170-2000 Nut M5-8 4
18 1040300514 GB/T97.1-2002 Washer 5-200HV 4
19 1040300060 GB/T93-1987 Washer 5 6
20 1020500695 XCR-F17 Limit switch 1
21 1020400378 JD90A-L+02+R+024 Alarm light 1
22 1040100065 GB/T818-2000 Screw M516-4.8 2
23 000209401A0000061 Bracket 2
24 1040001592 GB/T5783-2000 Bolt M560-8.8 4
25 000209401A0000045 Rail clamp 1
26 000209401D1000100 Bogie frame 1
27 000209401A0000057 Bracket 2
28 1040000592 GB/T31.1-1988 Bolt M24240-8.8 1
29 1040500233 GB/T91-2000 Split pin 540 1
30 000209401A0000002 Hatch 2
31 000209401A0000003 Buffer block 2
32 000209401A0000034 Bearing seat 1
33 000209401A0000033 Oil seal 1
34 1040000069 GB/T5783-2000 Bolt M1225-8.8 8
35 1040300054 GB/T93-1987 Washer 12 8
36 1040300067 GB/T93-1987 Washer 10 26
37 1040000931 GB/T5783-2000 Bolt M1020-8.8 18
38 000209401D1000035 Bushing 2
39 000209401A0000001 Bushing 1
40 1080000009 JB/T7940.2-1995 Oil cup 90 M101 1
41 1020000154 YTXZ112M2-2B-5.2KW Electric motor 1
421
42 1040000110 GB/T5783-2000 Bolt M835-8.8 4

43 1040300063 GB/T93-1987 Washer 8 4
44 1040300066 GB/T97.1-2002 Washer 8-200HV 4
45 1040200192 GB/T6170-2000 Nut M8-8 4
46 000209401D1000400 Motor support 1
47 000209401D1000700 Motor cover 1
48 000209401A0000032 Hatch t8 1
49 1040000114 GB/T5783-2000 Bolt M1025-8.8 4
50 1030200210 TX25 Reducer 1
51 1040200326 GB/T6178-1986 Nut M24-8 1
52 1040000198 GB/T5783-2000 Bolt M1650-8.8 16
53 1040300065 GB/T93-1987 Washer 16 16
55 000209401D1000200 Bracket 1
56 000209401D0000013 Shaft 1
57 1040000553 GB/T5783-2000 Bolt M2465-8.8 4
58 1040300049 GB/T93-1987 Washer 24 4
422
7.2.19 Idler Wheel Bogie
Fig. 7-50 000209402D1000000
423
Table 7-50 Spare parts list of Idler Wheel Bogie (B52-D)

1 1040000488 GB/T5783-2000 Bolt M2470-8.8 4
2 1040300049 GB/T93-1987 Washer 24 4
3 1040500241 GB/T119.1-2000 Split pin B1660 2
4 1040500241 JB/T7940.1-1995 Oil cup M101 7
5 000209401D1000012 Connecting plate t36 1
6 000209401A0000023 Plate 1
7 000209401A0000031 Shaft 1
8 000209401D0000004 Steel sleeve 2
9 000209401A0000040 Bearing seat 4
10 1050200176 GB/T288-1994 Bearing 22220 C 4
11 000209401D1000038 Dust cover 4
12 000209401D1000039 Oil seal 4
13 000209401D1000036 Travelling wheel 2
14 1040600015 GB/T1096-2003 Bond 32110 2
15 1040300432 GB/T858-1988 Washer 90 1
16 1040200486 GB/T812-1988 Nut M902 1
17 000209401D1000056 Shaft 2
18 000209401A0000045 Rail clamp 1
19 1040300067 GB/T93-1987 Washer 10 16
20 1040000931 GB/T5783-2000 Bolt M1020-8.8 16
21 000209401D1000035 Bushing 2
22 000209401A0000061 Bracket 4
23 1040000069 GB/T5783-2000 Bolt M1225-8.8 8
24 1040300054 GB/T93-1987 Washer 12 8
25 000209402D1000100 Bogie frame 1
26 1040000198 GB/T5783-2000 Bolt M1650-8.8 16
27 1040300065 GB/T93-1987 Washer 16 16
29 000209401D1000200 Bracket 1
30 000209401D0000013 Shaft 1
424
7.2.20 Cable Drum
Fig. 7-51 000209940A0000010
Table 7-51 Spare parts list of Cable Drum (M822)

1 1020004122 YLJ112-16N.m-4KW Electric motor 1
2 1029901693 K530 Collector ring 1
3 1030200866 WC97.5-60 Reducer 1
4 1029903916 8YWD.180.008 Flange 1
5 1029903914 5YWD.223.004 Plate 2
6 1029903915 5YWD.089.003.1 Frame 1
7 1029903913 5YWD.269.003 Roller box 1
8 000209940A0000011 Bolt package 1
425
7.2.20.1 Bolt Package
Table 7-52 Spare parts list of Bolt Package (000209940A0000011)

1 1040003346 8YWD.932.012 Threaded rod M10260 12
2 1040200113 GB/T6170-2000 Nut M10-8 48
3 1040300061 GB/T97.1-2002 Washer 10-200HV 52
4 1040300067 GB/T93-1987 Washer 10 52
5 1040000095 GB/T5783-2000 Bolt M1660-8.8 7
6 1040200110 GB/T6170-2000 Nut M16-8 7
7 1040300052 GB/T97.1-2002 Washer 16-200HV 7
8 1040300065 GB/T93-1987 Washer 16 7
9 1040000167 GB/T5783-2000 Nut M1055-8.8 12
10 1040000122 GB/T5783-2000 Nut M1035-8.8 16
426
7.2.21 Slewing Limiter
Fig. 7-52 000209905A0022000
427
Table 7-53 Spare parts list of Slewing Limiter (HZXW.20)

1 1040101090 GB/T818-2000 Screw M5×20-8.8 4
2 1040300048 GB/T97.1-2002 Washer 5-200HV 4
3 1040300060 GB/T93-1987 Washer 5 4
4 1040001599 GB/T5782-2000 Bolt M4×30-8.8 3
5 1040200100 GB/T6170-2000 Nut M4-8 3
6 1040300044 GB/T93-1987 Washer 4 3
7 000209905A0021010 Shaft 1
8 000209905A0000013 HZXW.1-2 Bushing 2
9 000209905A0002001 HZXW.3-1 Gear 1
428
(THE END)
Thanks for your reading!

Zoomlion Tower Crane Instrcution Manual-WA7025-12E-220309

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Zoomlion Tower Crane Instrcution Manual-WA7025-12E-220309

Uploaded by

Copyright:

Available Formats

[En]

WA7025-12E Tower Crane

Part name Part intended for:

1 DOCUMENTS The crane operator

2 SAFETY INSTRUCTION Everybody

3 TECHNICAL DATA OF CRANE AND SITE Everybody

4 ERECTION/ADJUSTMENT/DISMANTLING The fitter

5 OPERATION AND CONTROL The crane driver

6 MAINTENANCE AND INSPECTION The maintenance technician

7 SPARE PARTS Everybody

Development of the technical instructions

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

Indicates the risk of equipment damage if the described instructions are

TOWER CRANE VOCABULARYS

Composition Diagram of the Tower Crane

STOPPING THE MOVEMENT

COMPULSORY SAFETY HARNESS

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

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

METRIC SYSTEM AND IMPERIAL SYSTEM

2. EQUALITY BETWEEN FREQUENTLY USED UNITS

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

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

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

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

Imperial system Metric system

1 inch (in) = 2,54 cm

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

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

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

3.6.2 Identification the counter-jib ........................................................................... 103

4.5.5 Sling the rear-counter jib ................................................................................ 164

4.17 Dismantling ............................................................................................................. 218

6.6.3 Trolley brake ................................................................................................... 268

6.15.2 Routine inspection of side rollers of trolley .................................................. 316

Cranes with cabs:

Cranes with radio control:

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

1.2 Commissioning report

2.2 Safety instructions

2.2.1.1 Climatic and geographical conditions

b) Table for determination of crane operating conditions

c) Assembly, dismantling, change of configuration

e) Surface exposed to the wind of the load handled

B. Ambient air temperature measured under cover

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

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

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

D. Frost, ice, or snow

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

Before restarting the crane, completely clean the electrical and

G. Flooding / tidal waves

2.2.1.2 Conditions relative to crane design

B. Crane power supply

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

C. Driver control stand

Never modify safety device settings, nor hinder their functioning or

G. Nominal crane life duration

H. Nominal steel structure life duration

I. Nominal mechanism life duration

J. Mechanism working factor

L. Customer advertising plates

N. Modifications of the crane / welding