TCT80(TGT5810)

Tower Crane

ll ,5x1.5 Gross-section, lnner Gage, Max'

Lifting Capacity: 6T)
enrrfacturing License: TS241 0639-201 6

Operating I nstructions

Guangxi Construction Engineering Group Machinery

Manufacturing Co., Ltd.
 yOu for choosi ng Our products I

the operating lnstructions carefully before you use the

lnrt '.l,rrrdards are referred to in design of the crane:

I rll/ I ' r( ).11 -2008 Tower Crane
lrlt/ I tlt 11-2008 Design Rules for Crane
I rll', I ,l.l 2006 Safety Code for Tower Crane
 Gontents
I ll^l'll t r;t NERAL ...............'.6

I )riEWoRD
( ......"...."..'. 6
l't rtFoRMANcr TnsLr ..............-.....7
()IIANTITY, SPECIFICATION AND WEIGHT OF TOWER CRANE PARTS QUANTITY,
I,I'ECIFICATION ANDWEIGHT OF TOWER CRANE PARTS ,..".....,11

Ii ;, INTRODUCTION OF TOWER CRANE STRUCTURE.........,...... ..,.,.. 12

I BtitEF cnnNE................
INTROOUCTTOru Or ......12
' Mt rAlltc StRucruRE:........... '-'.. 12

I{ :] PREPARATION BEFORE ERECTION .......... 18

I SlrE PREpAMTIoN................ ".... 18

' SKETcH or Ftxtno MrrNoo oF THE Ftnsr SrcrloN..........,.. ....'..........'. 1B

.J SrercH or BrnRtnc CRpRcttv on CorucREIE FouruoRt1oN.........,... .......'..'..........'.20

,1 CoTCNTTE SEAT OF FOUNDATION SECTION FIXED BY EMBEDDED BOLT, LAYING OF
CONCRETE FOUNDATION, FABRICATION OF EMBEDDED BOLTS AND PRESSURE PLATE, ETC
21

t rf wElcHr
CourureR ..-.--....21

t (i GRouruorruc ..................... 30

r t rAl 'IER 4 ERECTION OF TOWER CRANE .................32

1 i3r<trr lrutRootrciioN ........... ....'." ..i -

2 PRocEDUREnruo Steps or ERecrtou or TowrR CneNe....... ...-..........32

IIAI]TER V JACKING AND ANCHORING OF TOWER CRANE 4B

5.1 lrutRooucttoN.............. .............-.48

5.2 INSTRLLRTTON, JACK|NGnruOAtrtCt-tORtruO REOUTREMENTS ......................53
5,3 PREPARATToNS BEFORE Usr............ ................ 64

r IIAPTER 6 DISMOUNTING OF TOWER CRANE .....'.... 66

r TIAPTER 7 OPERATION OF TOWER CRANE ............... 68

7.1 OpenRttoN REoumrtoNs ................ .............. 68

7.2 Towen Cnnrur OpERRrtoru. ......... 68

7 .3 OprnnrroN CoNrnol or VnRtous AcrtoNs ...................... 69

7.4 SRrrrv PnEcnurtorus................ .................... 70

(;HAPTER B ELECTRICAL CONTROL SYSTEM (FULL VARIABLE FREQUENCY CONTROL)

74

8.1

8,2
8.3
8.4
 ur, Pnrcnurtorus.................
:;Ar ETy """""""" " 76

ll ti INVERTER Mq1NrcNnNlcE ................ """""""""77

ltl NcIIVATION OF LEAKAGE CIRCUIT BREAKER .".,.78
lr ll t IECTRICALSCHEMATIC DIAGRAM '"., ' ...",.".' BO

ltotsTlNc WINCH ....'.'."..""""' 90

I]R|EF TNTRODUCTIoN oF HolsrlNc W1NCH........ "" """ 90

WoRKING PntnctpLr """"""" ""' 91
HYDRAULIC PUSH-ROD BRAKE ,,,....92

tsRIEF INTRODUCTIONAND MAINTENANCE OF MAIN PARTS . ".''".,.'' 96

INsTALLATIoN AND ADJUSTMENT oF THE HoIsTING WINCH """"""" "" 103
,r rr SEnvtcr nNo MRINTTNANCE oF HolsrlNc wlNCH. .............. 04 1

I rl/\l'll li 10 SLEWING MECHANISM ...'........... """"""" 106

to I lNTRoDUCTroN...."......... ...""""" 106
t\t') DRrvE DIAGRAM FoRSLEWING MECHANIsM.......'.'..'... """" 106
ro :t woRKrNG pRrNcrpLE... ' ' """""" 106
t04 SLEWrNGLIMIrER....... ' "106
I1 5 PERIODIC INSPECTION OF SLEWING GEAR RING FASTENING 8O1T.",...."...,........""...,107
l0 0 MntnrErunNcE oF SLEWING MECHANISM.'..'.'..'.."" """"" ' '108
r I li\l 'I tR 11 TROLLEY MECHANISM """ ' 109
11 'r lNrRooucrtoN..... ........ "" """ 1i'19
11.2 WORxtt'tC PRtNctplr ".""' 109
11 3 TRoLLEYTRAVELINGLIMITER....... "' ' """"'109
11.4 MAtNTENANCEANDSERVICEOFTROLLEYTRAVELINGMECHANISM............"..'.....'..'..110
r rlAl)TER 12 SAFETY DEV|CE..... """" """ 111
12.1 GrNEnnl """"""" " 1'11
12.2 ToRoue LlMlrER """112
12.3 AolusrurNT oF MoMENT LlMlrER..'. """""""'1'13
12.4 INTEGRATEDSAFETYCONTROLSYSTEMOFTOWERCMNE ''.......'.,'.,...''.113
12.5 All-orort LrrlxRor CoNSoLE lNsrRurtoN AND UsAGr lnsrRuctloN ............ .......127
r IIAPTER 13 HYDRAULIC JACKING SYSTEM """" " ' 135
13.1 Hyonnultc Svsruv PRttictplEAND CoMPoslrloN .'..,....' 135
13.2 SAFETY VALVE Ao.1ustH,1eruT................ ...""" 137
13.3 CouHillOru FnulrCnusrANnLystsANDTRoUBLESHoOTlNG ..................138
(TIIAPTER 14 LUBRICATION .. 139

14.1 LueRtcnrtoN PARTS oF THE TowER CRnrur " ' 139

14.2 LuentcRrtNc OtL Ltsr...... ............140

CI-IAPTER 15 OPERATION AND MAINTENANCE OF TOWER CRANE ......,"......142

 tlr 1 .""
OprRRttott oF TowER CRANE.. """""""" 142

]lt 2 TowER cRANE oPERlTloN. "'."" 142

lir 3 MAINTENANCE oF TowER CRANE """ """"" '143

MI\IIJ II_NANCE MANUAL -'"'"" 145

I I II SALES SERVICE SCOPE AND WARRANTY PERIOD '"""' 158

^I
 Chapter 1 General
It I oreword
self-erecttng crane
tr llru10 flattop tower crane is a top-slewing' level-luffing- and
rlr,.'trIl)GdandmanufacturedindependentlybyGuangxiConstructionEngineertng
and industrial
(,rou[) Machinery Manufacturing co., Ltd' according to the national
,,l,rrrrlards and in reference to corresponding international standards
to satisfy the
,l:rrr;rnd at home and abroad. The maximr-rm
jib length of the Grane is SBm' the
rrr;rximum lifting capacity is 6 T and the rated
lifting moment is B00KN'm lt has the
cranes:
lolkrwing features cornpared with ordinary tower
for the capacity of lifting
l) The flat-top tower crane greatly lowers requirement
lt is featured with small unit mass and
equipment when dismounting tower crane.
lowmountingheightduetocancellationoftowercap.ltsmaximummounting
grade of capped tower crane' For
height is 10m leJs than that of the same
mountingjibsectionsofanordinarytowercrane'jibrootsandtierodsshallbe
first connected on ground and then be lifted wholly.
lt requires the lifting
equipmentwithalargeliftingcapacityandheight.lnaddition,afterthejibsand
the lius irratt be raised a lot to connect tie
rods'
pin shafts uru
"onn".ted,
Accidentsareeasytooccuratthistime.However,flat.toptowerCranecanbe
installedanddismountedsimply'quicklyandsafely'
in the site with special height
2) This tower crane is very suitable for construction
requirement'Thisisbecausetheflattoptowercranedoesnothaveatower
the utility rate of
greatly and
head, the effective height of its hook is increased
used in air port reconstruction and
space is improved. Foi example, it can be
construction in tunnels, plants and
expansion, construction near air port' and
+Dwer crane with head ir usually incompetent for
un.liijr l-lv ltne s The traditional
such construction'
with special radius
3) lt is also especially suitable for such construction sites jib sections, tower
requirement. The flattop tower crane has
specially connected
jib can be drsmounted and assembled section by
head and tie rods. Thus its
section simply and safely. ti tnere is a need
to change the iib length durtng
construction (extension or shortening), there
is no need to dismount the whole
jib
of fully varrable
4) All drive rnechanisms of the tower crane adopts solutiontrolley mechantsrn
rnechanism and
frequency, in which hoisting winch, slewing
control, therefore' the mechanisms are
are of variable frequency stepless speed
stablewhenstartingandstoppingandsuffersnoshock,leadingtoasafeand
induced by impact of starttng
reliable operation. Such solution ieduces shakes
extent and guarantees positioning for
and stopping on the crane to the maximum
as short as possible' The drive part for
ascending und dur""nding within the time
adopts general parts and standard
such mechanisms of the tower crane mostly
Parts for rePair and rePlacement'
our products, . some
Note: Since we keep improving and optimizing prior notice' lf there is
performances and parameters r"y-u" changed without
weight of components' external
conflict between the data of real object, "u"h ""
. dimensions and the data in the lnstructions,
the data of real object shall be
deemed to be the standard'
lt Performance Table
l) Lifting characteristics table
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Tower crane sketch

000!?.c x 000!

10
Ful,,r lniurce of power supply equipment
I I Mr rlor pow€r: whole motor 32KW (embedded type)

,rr \/,rltirge of power supply: 380V, tolerance t10%

rr I ro(luency of power supply: 50Hz
lJrrnrrtity, specification and weight of tower Grane parts quantity,
rpocification and weight of tower crane parts
{l ,,r r:fr:rence only. lncase of conflictwith real object, the data of real objectshall
be
, t,r,n r rr l to be the standard.)

Overall dimension
Narne

The first section of the 1 830x1 830x1 0450

embedded bolt fixed
Connecting pieces for 1 60x 1 60x350
inq tower
{ 1692x1692x5300
,l Hvdraulic mechanism 2368x1150
lnner and outer connecting 285x235x690

Slewinq assembl 1 91 6x1 856x2700

'1366x1366x10950
Self-elevating Platform 2996,2996x2360 | st s
3075x935x350
Counter jib (including 2595x11990x1490 2941
1 379
9BOxB50x
11 Hoistinq winch 1

1), Tie roi of couintei 795ix1 BC * 7^ 253

IJ Electric system 2100x600x1600 300
14 2290x1740x1 330
'15 5B9B0x 1 900x91 0
lo Travelinq mechanism 1'1 5Bx 1060

17 Travelinq trol 1 560x1 500x650

1B 840x236x 1 265

11
 clrapter 2 lntroduction of Tower crane structure
llrlol lntroduction of Crane
llr, lrwer crane is comprised of metallic structure, mechanical drive mechanism,
lryr11.111;,,' jacking mechanism, electrical control system as well as safety
protection
Of the whole Crane.
,,, lrrrlrrrtcnt, etc. Please referto the sChematiC diagram

Mul:rllic Structure:
11,,rr:-,ists of sorne main structural members such as base, tower, jib and counter-jib
twrllr ;rnchoring section in case of anchoring).

12
 lrolt fixed tyPe

1. First section
2. Embedded positioning frame (can be removed when erecting the tower)
3. Embedded bolts (embedded bolt fixed type)
The tower includes the first section, standard section, rnner cage, upper and
lower
slewing support frames, and tower roof section, etc
bolts at the
1) The first section is 10.15m tall, connected with the embedded anchorhigh-strength
bottom and with the standard section by means of the finished

13
_1

hinged bolts of class8.B on the top.

')) The standard section is 5m tall, comprised of four leaves connected by M24xGB
finished high-strength bolts. The tower tie rod is connected by bolts. Main angle
steels of the leaf type trusses are welded with lug-plate and foot-plate inside
respectively. The latter is used for bearing jacking leg and the former is used for
installing tie rod of the tower to improve twist resistance of tower structure and
Installing climbing ladder.

il
l\ M24 x 68

I
I' tFinirh"d bolt

M24 x 68
(:-
l-

(i-
l= t.
rr)
f
I 1
i

H-
a

1. One leaf of standard section

2. Ladder lug-plate
Standard Section
r) The inner cage is inserted into the first section or standard section. The inner
cage with jacking oil cylinder piston is supported on the foot-plate of the first
section or standard section by the lower cross-beam's movable foot, and the
upper cross-beam drives parts above the tower crane's inner cage to ascend or
descend to make the tower crane jacked to the desired lifting height.
The inner cage is connected with the lower slewing support frame. When the
tower crane is working, connect the inner and outer tower connecting pieces with
the standard section.

14
 I

_l
-l
F
B
I

,L
2

Jacking bean
Leg
Climbing ladder
Guide block
Oil cylinder
Oiltank
Cross beam
Leg
Cage Section
4) Slewing support assembly consists of upper slewing support frame, slewing
support, lower slewing support frame, cab and slewing mechanism, etc.
The lower slewing support frame is the transitional component connected with
the slewing support on the top and inner cage at the bottom. lt is equipped with a

15
 ln additron' it is
circular track for hanging the standard section during installation'
platform during tower crane self
equipped with two;ius tor hanging self-elevating
elevating.
device at
The upper slewing support frame is connected with the slewing support
the bottom, jib in the front and counter-jib in the back, with the operating
room
right side'
hung on the left side and slewing mechanism installed on the

[&r[ 4+fr+ HffiqEiI,4 K

121
L, J\'I M24 x 190 ( I0 94 ) LeOlI-l

1. Cab
2. Upper slewing support frame, slewing support
3. Slewing rnechanism
4. Slewing suPPort
5. Circular track
6. Lower slewing suPPort frame
Hoisting jib and counter-jib
jib could be determined
1) The jib is made up of secttons up to eight. Length of the
jib has a triangle
on the basis of practical construction requirement. The
cross-section while the lower chord rod of the jib has a square cross-section. The
traveling trolley moves with the lower jib chord rod as its track.
2) The counter-jib is a structure made of angle steel and H-shaped steel by

16
w( )lding.

I
--;
I

/1

4an

-3or

2.ao -
F 3.528
G 1.506
H 2.5
1.8

th A B C
5Bm 59.5m 12.726m 9.736m
56rn 57.7m 12.726m 9,736m
50m 51.5m 12.726m 9.736m
45m 46.5m 12.726m 9.736m
40m 41.5m 12.726m 9.736m
30m 31.5m 12.726m 9.736m

4'7
 Ghapter 3 Preparation before Erection
It Site Preparation
Before erecting tower crane, the first thing to do is to understand the site layout and
soil texture, remove surrounding obstacles and map the range of installation site.
prepare the lifting machine, sleepers, wooden wedges, iron wires, cord fasteners and
other common installation tools based on a lifting height of 16m with corresponding
tifting weight of 6t and on the maximum lifting height of 22m with corresponding lifting
weight of 1.21. ln addition, installation personnel shall be assigned, including 1
'1
commander, 4-6 lifting workers and erectors, 2 electricians and tower crane driver'

\
\
Max. 56.7m

L__
Assembly lensth of iib L1 L2
30m 31.7 44.4
40m 41.7 54.4
trn /
45rt 1(). i
50m 51.7 --d4T------1
70.4
56m 57.7
58m 59.7 72.4

Sketch of Fixing Method of the First Section

I - The firs1 section fixed bY
I n' Sru,"n of fixing method of first
embedded bolts

Positioning
frame or plale
Embedded bolt
(L=900)

18
 A section (tower crane fixed by
embedded bolts)
B: Positioned by positioning frame
C: Positioned by positioning plate
Technical requirements:
1. The embedded bolt M36, 16 in
total in quantity, shall be made
of 40 Cr material and subject
O to T235 heat treatment. The
O
-l nut M36 shall be made of 35
I

material. lts embedding

method shall be determined by
the construction contractor
based on bearing condition.
2. The bolts shall be embedded
in such a way that symmetry of
I \\r1
\'\-/ /
pitch center is ensured. They
can be positioned with the aid
\ ,/
-,'
of positioning frame (refer to
Fig. B) or positioned by
determining position of the
bolts according to positioning
plate (refer to Fig. C) before
embedding The
perpendicularity of the
embecrded bolts shall also be
ensured when they are fixed.
The positioning frame or plate
can be removeo when the
tower crane is erected.
Warning: When embedding
anchor bolts, they shall be
bound by stee! wires and steel
bars. Never fix the bolts by
means of spot welding.
B NOTE: THIS FIGURE IS USED

19
 FOR TOWER CRANE FIXED BY
Positioning
EMBEDDED BOLT. DIMENSION
OF CENTER LINE SHOWN IN
THE FIGURE IS NOT OVERALL
DIMENSON OF THE TOWER
BODY.

lr Sketch of Bearing Capacity of Concrete Foundation

Horizontal force applied to the foundation, KN

Py
Vertical force applied to the foundation, KN
Pz
L. -- UveriJrl :ilq L:u., ' aPPtrct-
Mx iil y foundation]KN m
Torque applied to the foundation, KN
Mz

r\
Bearinq capacity of foundation
Load Condition Px Py Pz Mx My Mz
condition 29 29 530 -989 -989 -335
Non-worki condition 53 53 470 -1170 -1170 1

Sketch of Bearing Capacity of Qoncrete Foundation

Ilefore erection of fixed or anchorirrg type tower crane, the user and erection
r;ontractor shall calculate and determine strength of concrete foundatiorr to be erected
;rnd construction method in advance.
Ihe tower crane is fixed on the foundation and the lifting height reaches 40r,'r. When
tlrc anchoring device is not used, the load value generated for the foundatron is the

20
nrirximum, see the table above for specific values'

Concrete seat of foundation section fixed by embedded bolt, laying of

concrete foundation, fabrication of embedded bolts and pressure
plate, etc.

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o 5" EE6 6
I

-r.l-
i1!
1-l o

ll
€

It-
r-r*
o
I
p
ti o

r :]*i''-- I

, 6
i

>c;
---E
=l
=ti-
I
I
€Y

i_i
I
- ---l-

il
I

rI ::'*
I
-
*\,,

ti I
t* ,r.
I
Bb

,l
I
l

l,.r ;lrnical requirements:

I Concrete grade: C35, specific gravity: 2300K9/m3'
., Anchor bolt(M36) shall be bound by steel wires and steel bars when they are
embedded. Never fix them by. means of spot welding.
(lounter weight
ln:,tructions
I trr , r;eunter weight consists of four types of concrete blocks (A, B, C and D), which are
,.1r1)iped to obtain various weights consistent with the jib length. These concrete
trt,r.kS are hung at the tail of the counter-jib piece by piece. Users are responsible for
t,rt11(;itting the concrete block counter weight. The combination and specific structure

21
,rxl dimension of the concrete counter-weight blocks are given as below'
trr order to obtain the desired weight of each piece of counter weight (tolerance t25kg),
r trrnension H can be changed (see the table below). lt is required to weigh the weight of

r,;rr;h concrete block and mark it on the side of each block.

Note: for various jib combinations, after installation of counter-jib completed,

irrstall a counter-weight D (z2aikg) first, and then install the hoisting.jib'
(l ounter wei ght combination

58m 56m

1
I I

DIA
lr

I
D D Il D D D D

I 3000Ks I 3 000Ke 1 2000Kg

40m 30m

l
I I l l I I l
I) D D C D l) D D ll l)

I 0500Kg titi0ttKs 6i'run;.

lioilsting jib length

(m) 5B 56 50 45 40 30i
A 3 3 2 1 1 0
( .0urnter B 0 0 1 0 0 0
wr:iight C 0 0 0 1 0 0
D 3 3 J 3 3 ?
.^<
1 3000 1 3000 1 2000 1 0500 BBOO 6730
ll,t rorlinq shaft 12 12 12 10 B 6.

22
l (.orurter weight design (for reference only)
Counter-weight A

280

11 =l
fl lr_l il tt A
7
10 trt- -rfl
-l-l
9

rffi ]kg
I

[il
I

til
Lill =l

t-j- H -t
!

rNl- L- L-I
!tl
ti l\ llt

4t)
l
lr-l-
\l ,,,1r,,1
I

Part 3 Part'l

E 41
=H

Round steel 912

Round bar steel 912
Round steel 912
Round tube 951 x4
 Material Lenqth Overall length
4 Angle steel 150x5 2860 11440
6 Angle steel 250x5 250 2000
935 1 870
2 Anqle steel 150x5
, Anqle steel 250x5 280 560
4 Angle steel 150x5 300 1200
327 1 308
4 Angle steel 250x5

( loncrete grade: C35, if the concrete proportion is more than 2300k9/m3, reduce
I I rc concrete length appropriately'

M;rrk the actual weight on the front and back, two sides and top with paint or by
other methods.
Angle steel and steel bar are welded together with E4303 welding rod and then
1,our the concrete. lf there is a large difference between theoretical weight and
;rctual weight, the actual weight shall prevail' The round steel used can be
rr:placed by the same-grade deformed steel.

24
 Counter-weight B

5
l'
\ 280

I
t-
=lE
LA
--T- r
t,f_l ta
Ut
A I I 6

l0
tr_
-rlL--
-|-r-
I'll
-t- --r
-II_-I
V $rl
l- ml
L
I lr

t- T 1--t
I

--1
r B

t- -1- -++ t- -.1

_-+-l tA
45 L,,
+F-+-+
1 1,,,1,,,1
,,, +->FF-+l 11
9 35 350

Part 3

=m=H
Part'1

Par1.4

r 4 30

Overall
S/N Qtv. Material Length lenqth
Round steel 912 1122 4360
1 2
Round steel 930 915 915
2, 1
23BB 14328
L 6 Round steel <P12
3560 1 7800
L 5 Round steel <P12
Round steel 912 1220 2440
5 2
Anqle steel 250x5 1 530 6120
7 4
250 2000
q 8 Angle steel 250x5
935 1 870
I 2 Angle steel 150x5
560
10 2 Angle steel 250x5 280
i 4 Angle steel 250x5 300 1200

25
fir,tr,
| ,,rn(:rotegrade: c35,if theconcreteproportionismorethan2300kg/m3,reduce
tl r, concrete length appropriately.

M,rrk the actual weight on the front and back, two sides
and top with paint or by
d
,
'llrlr methOdS.
rod and then
t /\rrrllc steel and Steel bar are welded together with E4303 welding
weight and
l,rrrrr th€ concrete. lf there is a large difference between theoretical
,rr ttr;rl weight, the actual weight shall prevail. The
round steel used can be
r,'plrrced by the same-grade deformed steel'

26
 Counter-weight C

t2 2

2 80

11
,-
taL t, a
: -r-

W,7
/1
rll
I

Ij-t]lt I
t_
10

9= tt -T
- JI _T
-t
I
I

L tr lkg
I

L- I

N
I

t\
-T
L_r __I
45
| ,, ,r!, ,. 3
,,-i
',,j
I

Part 3

=m=H
Part 1

S/N Qtv. Material Overall

Length
lenqth
1 2 Round steel 912 1122 4360
2 1 Round steel 930 915 915
3 o Round steel rp12 23BB 21492
4 5 Round steel 912 5112 25560
tr
2 Round steel 912 1220 2440
6 1 Round tube 951 x4 935 935

27
 Overall
Material Length lensth
h/N Qtv'
2306 9224
4 Angle steel /50x5
250 2000
B Anqle steel 250x5
935 1 870
ll 2 Angle steel 150x5
280 560
2 Angle steel 150x5
300 1200
4 Angle steel 250x5
327 1 308
4 Angle steel 150x5

m3' reduce
(:oncrete grade: C35, if the concrete proportion is more than 2300kg/
llrc concrete length appropriately'
Mirrk the actual weight on the front and back, two
sides and top with paint or by
other methods.
AnglesteelandsteelbarareweldedtogetherwithE4303weldingrodandthenand
theoretical weight
pour the concrete. lf there is a large difference between
The round steel used can be
;lctual weight, the actual weight shall prevail.
rcplaced by the same-grade deformed steel'

28
 Counterweight D

Part 3

844

Qty, Material Lenqth Overall length

S/N
2 Round steel 912 1122 4360
1

Round steel rP30 915 915

2 1

29
I

li/N Material Lenqth Overall length

t 11 Round steel q12 2388 26268
,l 5 Round steel 912 6650 33250
t, 2 Round steel 912 2000 4000
lr 1 Round tube tPS1x4 935 935
4 Angle steel 150x5 3075 12300
It q Anqle steel 250x5 250 2000
935 1 870
rl
? Anqle steel 250x5
ll) 2 Anqle steel 150x5 280 560
ll 4 Anqle steel 250x5 300 1200
l.' 4 Angle steel l50E 327 1 308

I ( lrrclete grade: C35, if the concrete proportion is more than 2300k9/m3' reduce
llrc concrete length appropriately'
Mrrrk the actual weight on the front and back, two sides and top with
paint or by
.'
olher methods.
r Arrgle steel and steel bar are welded together with E4303 welding rod and then
weight and
lrrur the concrete. lf there is a large difference between theoretical
,rr;tual weight, the actual weight shall prevail' The round steel used can be
rr:placed by the same-grade deformed steel,
l,rorrnding
I l,,tl llrc tower crane grounding wire shall not be replaced by fuse wire or switch and

;rre three types of grounding methods:

llre grounding body is the normal grounding stud, or q33x4.5mm steel prpe with
rlre tength of 1.5m, or L70x70 angle steel with the length of 1.5m.

Ihe grounding plate is made of steel other ductile metal Plate, with an
or ol
;rrea of 1m2, al1.5m depth in verlical m the surface. (See Fig. B)
from

E
Ihe copper conductor with the section of 21mm2 or iron conductor with the
30
 length determined
sectionof50mm2isburiedintothetrunking'withtheburial
according to the ground resistance condition'
(See Fig' C)

e
U
of the grounding body
Note: among the above 3 grounding methods, the section
;;;;";;Jpp", "onducior shal be >25mm'. tf theand soil conductivitv is poor,
L-.. .-.^.^,1-^ ha
then watering shall be
sodium chloride (salt) can be buried into the soil
-lrall

carried out.

31
 Chapter 4 Erection of Tower Crane
Brief lntroduction
Thetowercranecanbejackedbymeansofinnercageorself-liftingsection.adding
l.*inrv introduces the tower crane erection
based on users, needs. This chaptur.
pro."r, which is completed by mobile truck crane'
(1)lnstallthefirstsection,innercageandjackingoilcylinder'self-elevatingplatform,
tJwer siewing support frame' slewing
inner and outer tower connecting ;;;t proper order'
siewing support frame in
support, slewing mechantsm unO 'i-p"'
and counter-jib rod'
(2) lnstall counter-jib, hoisting winch
(3) lnstall part of the counter weights'
jib'
(4) lnstall the remaining sections of the crane
(5) lnstall remaining counterweights'
(6) wind the lifting wire rope and luffing wire rope'
(7)lnstallallauxiliarydevicesofthetowercrane(includingthecabandelectrical
cabinet, etc')
(B)CheckinstallationconditionsofeachpartofthetowerCraneandpreparefor
commissioning'
Tower Crane
i) Procedure and Steps of Erection of
type tower crane
4.'.I Erection of embedded bolt fixed
the verticality of the
anchor bolts directly and adjust
connect the first section with the
lower,sfirstsectionwithappropriatemethod.Then,loosenl6boltsforconnectingthe
concrete foundation
wett-art!t:stinq iron bo]ts^at the
crnbetjce,l secticn, and llcjd the trghten the 16 bolts'
;rnd base to make the verticality
of the iirst section <1/1000 Then'

1' .', I nstall self-elevating Platform

per the figure below and
on top of the first section as
lnstall the self-elevating platform section
steel, Jn'tn* lateral web member. Then, connect the standard
put four angle
withthefirstsectio-noyHaza,oafinishedhigh-strengthhingedbolts.

32
1. Long platform
) Short platform
J. Leg
lnstall the oil cylinder's jacking beam in the first section to
make the movable feet on
both ends of the beam placed on the bottom most foot_plate.
lnstall inner cage
After all parts of the inner cage assembled, lift them into the first
section, and then
Connect the piston lug ring with the hinging point of
the oil cylinder jacking beam by pin
shaft, and then fix the connecting pieces for erecting the
tower and the first section with
lrolts.

33
Bolt F,l7i (J$-'1fi
Hexagon bolt
Bj60 z8-0$
Put the bolt head inside
during installation

Bort f'|14 x JS-78

Hexagon bolt
[1b0 7$-08
Put the bolt head inside
during installation

i&IIiHfiI
lnstall simple connecting pieces for erecting tower
tower with four angle steels of the
connect four simple connecting pieces for erecting
the bolts'
first section by tower's high-strength bolts, and tighten
lnstall slewing assemblY
(1) Structure introduction and weight
mechanism ('1)' slewing
Slewing assernbly components consist of: slewing
platform(2),upperslewingsupportframe(3)'slewingsupport(4)'circulartrack
(5), and lower slewing support frame (7)
supporl components can
The table below gives the weight of main parts, slewing
bedisassembledduringhandlingandtransportationprocess.

Connector S/N Sp""if"rtt"; of high-strength bolt

torque
ocAJr M24,190 (10.9 grade)
/r 1 900N. m

\
ln

Qtv. Name Weiqht (Ks)

S/N
Cab 300
1 1

2 1 Upper ilewing support frame '

1475
I UUV
J 2 Slewing mechanism
4 1 Slewing support -
| I
527
a rc
5 1 Lower slewing support tranle- --
Total 339 /

35
(2) Lift slewing suPPort assemblY
slewing support
As shown in Fig. A, installtwo Bm rig slings at 4-fall on the upper
pin hole for proper
frame (4) and put the end of the sling with ring through the
fixing, and tie a pull rope on the transrtional section'
washers
connect the transitional section (5) by 24 M24x7B bolts, nuts and spring
(1, 2 and 3), and then remove the rig sling'

Assemble crane jib and counter-jib

(1) Combination of crane jib and counter-jib
The crane jib shall be combined based on the desired jib length. The following
pages detail the length of the crane jib and counter-jib, types, dimensions and
quantities of various pin shafts and tie rod length, etc'

36
 55m jib combination

50m jib combination

45m jib combination

40m jib combination

30m jib combination

(2) Counter-jlbassemblY
a. lnstall the railings (1) on the counter-jib (2) by M'10x35 bolts in proper
order, as shown in Fig' A.
b. connect the main winch (4) with the counter-jib (2) by 930x95 pin shaft (3).
Note that the lifting drum of the hoisting winch shall face inward towards
the tower, as shown in Fig. A.
c. connect the tie rods (6) of the counter jib by <p60x2'13 pin shafts (5), as
shown in Fig. A.
After all assembled, lift the whole counter-jib onto the upper slewing support
frame, and connect it with the upper slewing support frame by <960x213 pin
shafts (5), as shown in Fig. B.

37
n
t1
(3) Crane jib connection

080x316 080x332 b70x272 o65x2i6 o50x20B 040x180

5Bm

/ I
oB0x332 M20 x 400 M20x 100 M20 x 170

080x316 080x332 b70x272 065x276 050x208 040x180

56m

080x332 M20x400 M20x 100 M20x 170

oB0x316 080x332 b70x272 065x276 050x208 040x180

50m

/ 1

oB0x332
M20x400 M20x 100
M20 x 170

o 80 x lli6 d,80x332 b70x272 065X276 0b0X208

llll_l
/ffiffr
45m

oB0x332 M20 x 400 M20x100 M20x170

080x316 080x332 b70x272 065x276

JIIIL
IrI 2I 3I
/*--T-) |
080x332
4_-]-

MZOX100 M20x170
1

-M20x400
oB0x3i6 o 80x332 b70x272

1
, 3
"'p^'6-
/
oB0x332 M20x400 M20x1i0

20
 The table below gives the specification and dimension of all connecting pieces in
case of 5Bm jib length. Please pay attention to them during installation.
When the jib length is 5Bm:
Dimension: q (M) ,1-
Crane jib connecting pieces
Connection Dimension Qtv
Name
position
Hiqh-strenqth bolt M20x 100 10
Lower chord rod of Hiqh-strenqth bolt M20x400 4
the jib Hiqh-strenoth bolt M20x170 2
Nut M20 44
Pin shaft 080x332 ?
Cotter pin 10x110 6
Pin shaft <p80x316 1

Plug pin rp20x336 1

Cotter pin 5x40 1

Cotter pin 12x100 1

Upper chord rod of Pin shaft rp70x272 1

the jib Cotter pin 12x100 2

Pin shaft (D65x276 1

Cotter pin 12x100 2

Pin shaft <p50x208 1

Cotter pin 6x60 2

Pin shaft <p40x 180 2
Cotter pin 6x60 4

(4) Crane jib travel sign

?a l0 40 50 56

56m

50m

45m

20 l0 40

#4om
20 l0

lgtt lrrstalltraction trolley and pulley block

(1) Steel wire rope fall change method
2-fallto 4-fall conversion and 4-fallto 2-fall conversion method
The pulley (1) of variable rope clings to the traction trolley (3). The lower pulley
block (2) is in 2-fall state. ln case of 2-fall to 4-fall conversion, press "lifting"
button to operate descending to descend the lower pulley block (2) onto the
 to lower the pulley (1) of vartable
ground, and keep on operating descending the pin shaft
its own ,,iuignt, and then connect
rope on the ground under action of
(a)with the lower pulley block (2) manually,
thln operate a.scending to complete
press "lifting" button to operate
conversion. ln case of 4-fall to 2-fall conversion,
descending.Whentnetowerpulleyblock(2)islowered.ontotheground'takeout
p'1f"V block (2) and the pulley (1) of
the pin shaft (4) connecting the lower
rope, then operate ascending until
the pulley (1)of variable rope clings
variable
to the traction trolleY (3)'

lnstall traction trolleY

Whileassemblingthecranejibontheground,installthetractiontrolley.lnthe
person standing on the counter-jib
instructions below, We aSSUme that one
jib head (see the figure below)
observes in the direction of the crane
G:meansthelefthandsideofthatperson,D:meanstherighthandsideofthat
person.
of three parts:
Traction trolley and pulley block consist
41
 a) Traction trolleY device
b) Pulley block assemblY and hook
c) Suspension cage for trolley inspection
jib' pay attention to placing the
when installing the traction trolley on the crane
steel wire rope accessories in front of and behind
the trolley on the left side (G)'
the trolley by two pin shafts
and install the suspension cage on the right side of
accidents during tower
(1), and then fix them with cotter pins. ln order to avoid
before carrying out
crane installation, fix the trolley onto the jib by iron wire
various tasks on the crane jib or trolley'

is
r!o
rl

;D

(3)Windingmethodoftractiontrolley'sreartractionsteelwirerope
stop-adjusting screw'
Move the trolley to the jib root to make it cling to the
roll, with the length
Unwind the troliey's rear traction rope (2) from the rope
below)' Put the tail
determined nased on the crane jib length (refer to the table
(3), fix one end on the drum
end of the steel wire rope (QB) through the pulley
flangeplatebytheropepressingplate(4),atthesametime,windthesteelwire
on the tensioning
rcpe on the drum, fix the other side (5) of the steel wire rope
plate bolts firmly, and wind it
reel of the traction trolley, and fix it with the pressing
tensioned'
with the tensioner reel untilthe luffing steelwire rope is

42
 45m 50m 56m 5Bm
Jib 30m 40m
100 110 115
1 70 BO 90
70 75 77
2 50 60 65

(4)Windingmethodoftractiontrolley'sfronttractionsteelwirerope

Unwindthetrolley,sfronttractionrope(1)fromtheroperoll,withthelength
on this page) Put the
determined based on the crane
jib length irefer to the table
pultey (7) and (3) respectively' Four
tail end of the steel wire rope throug[ tre
the drum (winding method of the steel
circles of steelwire rope shall be kept on
wireropeisfrornthebottomtotop),itstailend(6)isfixedonthetravelingtrolley
traction trolley, fasten
clips, loosen the
sling, and tightened with 3 steel wire rope
tensioning conditions and then
the steel wire rofe, check the steel wire rope's
tension the steel wire roPe again'
Note:lfitisrequiredthattheropeclampshouldbeusedforfixingand
connection,theremustbeatleast3clamps'And,incaseofsteelwirerope
diameterD>l0mm,theremustbeatleast4clamps'Theclampspacing
The rope head shall be not
must not be less than 6 times of rope diameter.
and bundled with
less than 140 mm from the iast rope clamp'
sliding saddle is placed on the
small-diameter steel wire. The rope clamp
during operation. The U-bolt is
side that the steelwire rope is under force
fastenedontheendofthesteelwirerope.Theropeclampsmustnotbe
alternativelysetup'Theropeclampsmustbetightenedbeforeandafterthe
force is aPPlied-
l*,, lrrstall counter-jib and hoisting jib
hoisting winch on the counter-jib'
( l) counter-jib installation preparation lnstall
by M12x25 bolts'
lnstall handrails, and fix them on the counter-jib
lnstall tie rods and connect them by pin shafts'
the tie rod position'
Use one barwood on the counter-jib to keep
Tiearope(1)ontheheadofthecounter-jibtoguideinstallationofcounter-jibon
the ground'

43
 EE
,#
I

(2) Lifting and installation of counter-jib

Tie the sling at the hanging point specially set on the counter-jib (two 7m sling at
the jib root, one '11m sling at jib tail, with diameter of O21.5), and then lift the
counter-jib slightly away from the ground, and check its stability.
Tie the sling on the specially set suspension point on the counter-jib (two 7m
slings at jib root, and one 11m sling at jib end, with the diameter of Q21.5). Lift
the counter-jib slightly away from the ground to check its stability. Lift the
counter-jib and connect it with the T-shaped section, and put on the pin shafts
and add cotter pins for fixing. ln order to facilitate tie rod connection, the
counter-jib shall have certain inclination. Use the pin shaft to connect the tie rod
and then level the counter-jib slowly, tension the tie rod and loosen the slings,
and then the installation is completed.
(:l) Hoisting jib installation preparation
Tie a rope on the hoisting jib head, to facilitate guiding on the g:round. After
assembling the jib on the ground, wind the unwound derricking rope along the
derricking tug rim, and tie the both ends on the jib root. Wtnd the steel wire rope
(see relevant cha pters).
Hoisting jib installation preparation

(4) lnstall slings on hoisting jib

Mark dimensions on the jib (see the sketch below) which is equivalent to the
theoretical distance from the center of gravity to jib root. Suspension point is only
theoretical. When necessary, try to lift the jib to 1Ocm height and observe the
balance status and then adjust the suspension point position.
Note: check the sling position which shall be in front of the node of the
upper chord rod on the jib (a) or behind the node (b). lt is absolutely
 Itrl

prohibited to place the point between the diagonal web member (c). At the
suspension Point.
of
For the jib with a combined length of SBm, use two Bm slings with a diameter
jibs with other combined
Q25 for bundling up and then lifting, and for the rest of
length, the slings can be shortened appropriately'

(5) Hoisting jib installation

. Lift the jib from the ground to check its stability and lateral horizontality.
* The jib can be lifted up directly by one mobile crane to the pin connected
position of the upper slewing support frame, and connect the upper slewing
support frarne with the support frame by pin shafts (see the figure below)'

I r rstall counter-weight
tJr:fore lifting the counter-weight, check the total weight and dimension of
the
r:ounter-weight, which shall conform to relevant requirements' Before lifting the
,;ounteruueight, check the gross weight and dimension and specification of the
, 0unterweight which shall comply with relevant requirements. ln case of
no check on
llrc ground, it will be dangerous to install the counterweights on the counter-jib'
or it
t)rrring lifting process, avoid that the counter-weight is jacked up by the counter-jib,
,,, u"ry dangerous. Place the counterweights in installation order
properly, and lift the
, ounterweight (1) by the auto crane to the horizontal position of the countenrueight
:,upport (2), and place it between the cross-beam of the counter-jib (as shown in Fig'
n), put the pin shaft (3) through the pin holes on both sides of the countenveight, drop
rt.wn the counterurreight to make the pin shaft fall into the groove of the upper
, ross-beam (4) (see Fig. B). During lifting process, prevent the countenrveight
from
1;rr:king up the counter-jib, or it will be very dangerous'
t ttlrer counterweights are installed in the same manner'
piece of
trr:;tallation sequence of counterweights: after the counter-jib installed, install 1
, ,rrrrrterweight D. Afterthe jib installed, make up the rest of countenrueights and install
tlr)rn as shown in Page 14.
N.te: before making up the rest of counterweights, it is prohibited to wind steel
45
r
E
E
E
E
E

E
E
wire rope and carry out other operation.

t
i
E

Wind lifting wire roPe

(1) lntroduction
The steel wire rope is generally wound on the drum to facilitate transportation
in

case of tower crane relocated installation. The steel wire rope is normally wound
on the drum to facilitate transportation of tower crane in case of installation at
different place. ln case of following reasons, remove the steel wire rope: when
removing the tower crane, the steel wire rope wear is found, and the length
cannot meet the lifting requirements on the new site. See the instructions on this
page for the steel wire rope selection, and see the instructions on the next page
for winding method.
(2) Winding method of lifting wire rope
putthe steet wire rope through the lifting weight limiter pulley (1)and pulley (2)
jib
on pulley yoke at the root continuously to lead it to the traction trolley at the
wire
root for 4-rope winding as shown in the figure below. ln order to avoid steel
rope friction, the pulley block can be supported vertically on the ground and put
the tail part of steel wire rope into the wedge sleeve (3) of the steel wire rope'
Move the traction trolley to the jib head, connect the steel wire rope wedge
 sleeve with the steel wire rope air bleeder (5) by pin shaft (4), and then lock them
joint.
with cotter pin, finally, check the rotation conditions of the steelwire rope

e-\_4
5

ll r.' r )heck that all installations are completed and connections are tight, connect the power

It t' t )arry out commissioning.

ll r'r tf everything goes smoothly during commissioning, start jacking and section-adding.
 Chapter V Jacking and Anchoring of Tower Crane
Introduction
(1) During jacking, assign 2 commanders (1 for the floor, and 1 for the self-elevating
platform), 5 erectors (1 for the ground, and 4 for the self-elevating platform), 2
tower crane drivers ('1 at the hydraulic system platform, and 1 at the operating
room) and 2 electricians (1 for coordinating hydraulic operation, and 1 at the
ground).
During jacking, 2 commanders ('1 on the ground and the other on the
self-elevating platform), 5 erectors (1 on the ground and 4 on the self-elevating
platform), 2 tower crane drivers (1 on the hydraulic system platform and the other
in the operating room) and 1 electrician.
()-) Turn the jib to the side requiring introduction of the standard section, and do not
allow it to turn back to or perform other lifting operations.
(:r) Put down the hook and remove the hook member, and install the special small
hook for jacking and section-adding on the hook pulley block frame plate.
(4) The personnel on ground assemble the plate-like standard section into U shape
first.
(1,) The commander on the self-elevating platform commands the driver to drive the
traveling trolley to the place about L(m) from the tower centerline, and lift the
jacking counterweight (refer to the tower crane jacking counterweight state
diagram), to adjust the front and back torques of the tower crane to be balanced,
and then commands the erectors to remove all bolts on the inner and outer tower
connecting pieces and hook the self-elevating system's steel wire rope on the
inner anc{ outer tower" connecting preces. The ccnti.rre',der cc,tlrnai-lds lhu
operating room to switch off power supply and switch the power supply to the
hydraulic jacking system. ln order to prevent damage of the hydraulic system
elements, loosen the system's overflow valve first, and then start the switch, and
increase the pressure slowly until that the inner cage and the weight above it are
jacked up slightly. Take down the inner and outer tower connecting pieces, start
the elevating system to lift the inner and outer tower connecting pieces to the top,
and then operate the hydraulic system to jack the part above the inner cage to
the position where it can be put into the standard section.
lmportant note: during operation process, be sure not to allow the guide
block on the inner cage separate from the main angle steel of the standard
section. Or, severe tower collapse accident will be caused!
Tower Crane Jacking Balance State

(theoretical distance for reference only, subject to actual balancing, note:

load P =1588k9 (1588k9 equivalent to the weight of one standard section)

48
 Counterweight G Distance L from the rotary
Jib lenght (m) Load P (ks)
(ko) center (m)
5B 1 3000 1 588 24.5
56 1 3000 1 588 24.5
55 1 3000 1 588 24.5
50 1 2000 1 5BB 24.5
45 1 0500 1 5BB 22
40 BBOO 1 588 19
30 6730 1 5BB 22
(6) Start the jacking winch to place the jacking counterweight to the ground, use the
special jacking hook to lift one piece of truss of the standard section, and use the
small hook under the lower slewing support frame's circular track to hook it,
loosen the hoisting steel wire rope, unfasten the special jacking hook and turn
the truss to the counter-jib side.
 One side of
counter-jib

v,, Guide

Pull to one side of

counter-jib

One side of jib

(7) Lift the U shape standard section, use the hook under the circular track to hook it,
loosen the hoisting steel wire rope, unfasten the special jacking hook, traveling
trolley drives back to about 33.5 m, lift up the counterweight to adjust the front
and back torques of the tower to be balanced. Cover the periphery of the inner
cage with the U shape standard section, connect it with the truss in position in
advance, switch off the power supply in the operating room, start the hydraulic
system, lower the oil cylinder, to make the standard section truss inserted into
the outer tower connecting plate, apply punch and tighten bolts. lf the clearance
between the inner cage and the periphery of the outer tower (the first section or
 standard section), and the standard section cannot be inserted into, stop the
hydraulic systern, start the traction trolley to move back and forth to adjust the
clearance to be uniform.

One side of
counter-jib

Finished
bolt

ffiI
rfrf
M24X 6B

d,

lre rod s
lug-plate

(rl) After all bolts on the standard section tightened, remove the small hook
suspended under the U shape track for hooking the standard section. Be sure to
check and confirm that the small hook has been removed. After this step
performed, the power supply can be switched to the jacking winch. Start
the hydraulic system, and continue jacking operation in the ascending
order of the jacking winch, and carry out installation of the second
standard section in above steps.

51
(oY
i
tB
.=[
{' g)
cDc
'Ec
(Ja)
rc(J
-0"o
 1
oE
.E
@ c
#o
: ry=(n
-.c
(]o
!
& co-
Esr
1c
=
d gr:
-.Y
(J(JO
rc
--l oiJ
oJ
-o

(10) lnstall one tie rod for each standard section to hang the climbing ladder of
the

last section.
sections
(9) According to the tower height required for construction, if the standard
inner and outer
determined to be installed cannot be fully installed, install the
tower connecting pieces and place the self-elevating
platform legs to the working
position before getting off work'
(10) After the standard sections determined to be installed fully installed, fix the inner
all movable legs
and outer tower connecting pieces, tighten all bolts, ensure that
of the self-elevating platform are at working position,
pack up the steel wire rope
circular track
for hoisting the self-elevating platform and the small hook under the
to wind the rope onto the tower web member for fixing'
the ground'
(11 ) Start the hoisting winch and unload the jacking countenveight onto
\12) After the tower crane installed, the sidewise verticality between the tower axis
lead and bearing surface is 4/1000'

ll lnstallation, Jacking and Anchoring Requirements

l) Tower crane installation shall be carried out by the installation
shall
organization
report the
obtaining corresponding qualification. such organization

tr'l
 installation scheme to the competent authority according to local government
requirements and implement it after approval. The installation and operation
personnel shall obtain the special equipment operation certificate recognized by
the state.
2) The installation and operation personnel shall be familiar with this instructions
and relevant tower crane technical documents, and installation, jacking and
operation procedures, and then can carry out work.
3) The tower crane shall be installed when the wind force is less than level 6 (s
13.8m/s), and jacking shall be carried out when the wind force is less than
(s7.9m/s).
4) To installthe towercrane's concrete foundation, the soil bearing capacity shall be
not less than 200KNim2.
l,) During jacking process, only lift those required for tower crane installation and do
not carry out other lifting work.
(;) When the lifting height of the traveling tower crane is more than 42.5m, and of
the tower crane fixed by embedded bolts more than 40m, anchoring section shall
be installed between the tower and building. Position of each anchoring point is
as shown in the figure below.
II Anchoring sketch

lnstructions on setting up anchoring

points
1. Before installing the anchoring
section, users and installation
organtzattort sitart cslcUrqr
and determine the strength of
the building anchoring points in
advance.
2. When the tower height
is >40m, install the first
Tower cranes anchoring point position anchoring section at the place
s30m, and after that install one
anchoring section in every
spacing <20m, and ensure that
the distance between the
highest anchoring section to
the jib hinging point (i.e. jib
section height)s30m.
c. When installing the second
and more anchoring sections,
establish practical anchoring
scheme based on the site
construction conditions or
construction personnel
allocation conditions. Three
schemes are given below for
reference only. Users shall
I follow the provisions of article
I wt-,rt<
2 above.
I *"*
54
\

Non-working 147 tto

(1) Before installing the second
11 13
condition and more anchoring sections,
carry out aPProPriate jacking
Px (KN) Pv (KN) Mn (KN.m)
and section-adding, and
Load
-35.28 45.62 380 control the jib section height
s30m, tighten bolts and fix the
tower, and then set uP and
install anchoring sections in
the spacing S20m, and go on
jacking and section-adding'
This scheme can minimize the
anchoring times and number
of anchoring devices.
Therefore, we recommend this
scheme to ordinary users, but
jacking and section-adding
shall be carried out in two
phases.
(2) After installing the anchoring
device at the Place S30m for
the first time, if the tower
height cannot meet the
construction requirements,
carry out aPProPriate jacking
and section-adding, and install
an anchoring section every
15m. Aftei" the fourth anchoring
section installed, remove the
second one for standbY
application, and then go on
installing the fifth anchoring
section. After the sixth
anchoring section installed,
remove the fourth one, but
keep the first, third, fifth and
sixth ones. ln short, the
principle of removing
excessive anchoring sections
is to ensure that the sPacing
between the uPPer most two
anchoring sections shall s20m,
and the sPacing between the
middle adjacent anchoring
sections <30m. The first
anchoring section shall not be
removed. The advantage of
this scheme lies in that jacking
and section-adding each time
can be comPleted in one-off
manner as Per the requirement
of maximum jig section S30m,
but the times and quantitY of
 anchoring sections are added
when it is inaPProPriate to
remove anchoring sections'
(3) The first anchoring device is
set uP at the Place S16m, and
those coming uP next are set
uP and installed in the sPacing
s16m. The advantage of this
scheme is the same as that of
scheme (2), the disadvantage
is adding anchoring times and
quantitY.

Anchoring installation instructlons

section is installed'
(1) on the cross web member of the tower where the anchoring into a derrick section'
use moso bamboo or scaffolding steel pipes to bundle
beam column of the
Embed anchor bolts and connecting steel plates on the
floors of same altitude.
(2) Use the tower crane hoisting hook to lift two half-beams onto the derrick section
and assemble them into a frame to frame the tower'
(3) section by pin shafts'
lnstall tie rod (l) and (ll) and connect them with anchoring
tie rod (l) and (ll) onto
tlse the theodolite to measure the tower verticality, and weld the
the connecting steel plate respectively'
tower's verticality error shall be controlled to be within 4/1000'
hased ort
anchoring scheme prgvidecl in the lns:r'tlctions is calculated
N<lte: the
is
the ,.anchoring installation sketch" below. lf actual installation dimension
please consult with our
large different frorn that provided in the instructions,
cteiign department ordesign institute with relevant
qualification'
 Anchoring Sketch
Note: the anciroring frame is supplied as per the cr:ntract, and tie rod will be made bv
the user, or the user can also authorize us to process the tie rod.

57
 flTt*-5

Txtf
\-
\-

Technical requirements
(-\ 1. The quenching and
tempering hardness is
H8241-286.
2. Material is 40Cr.

\
(-\
G

EmbeCded bolt

All materials are

Q3458

Embedded parts of double-lug connecting plate

 All materials are
Q345B

t----------1-t
I

--'---i----'-'
I

r-----+------]

Embedded parts of single-lug connecting plate

 Left adjusting
nut
Adjusting
screw

\r:v
Right
\ adjusting nrn

Steel channel
c16

Short connecting

Tie rod I (channel steel length can be adjusted based on actual conditions)

60
\
I (:lt il(lllr:,lll(l
nul
Adjusting screw

Right
adjusting nut

Steel channel
C16 splicing

Long
connecling
lug plate

Tie rod ll(channelsteel length can be adjusted based on actual conditions)

61
 o solS ?

t2,5

Lug plate

0. Left adjusting nut

.s-
\l I

t\
:\
i0t a
-S

Adjusting screw (rnaterial 45)

Y
"1 +
-b
x rt
--Dl
L
---f

1l
Locknut (material 45)
Note: locknuts consist of 3 left screw teeth and 3 right screw teeth, a total
of 6 pieces
 @
{) Right adjusting nut

I
Material Q3458
i

- ---t---- l

----!----r
,l

i
I

10. Short connecting lug Plate

63
 lt '"7

Material Q3458
I

'- -- -'t'-'-'- -'

I

I
I

Itl
i

11. Long connecting lug Plate

Preparations before Use
lntroduction
are for ensuring that the tower crane can
Before put into operation, all measures taken il
operate normally under safe conditions' I

l-hese measures can be divided into three types:

aCheckandcarryoutappropriateoperationstoavoidoccurrenceofsafety l

accidents;
b Make the tower crane meet site requirements: ii

t; Commission all safetY devices'

of the tower crane shall be used
Ltll

ln order to carry out commissioning, various devices

lor maintenance and operation control'
Itr lnspection work after tower erection
of the tower
lnordertocheckcorrectnessoftowererection,ensuresafeoperation
work as follows'
crane, carry out series of test run and inspection
Parts to be Wort< to Ue carried out
nd concrete foundation
are fixed firmly and anchoring accessories under
base section non-wort<ing Check that the cables are
"onditions'
smooth to Prevent cq!19 lamgge'
s and rePlace
Passage
he standard section's
Tower pins. C-heck that the cables are hooked on
"on*.ting
the cable hook bY the steel wire

64
Parts to be in Work to be carried out
Check that the cab is fastened at the working position.
Cab Check that the nameplate is fixed in the cab. Check that
the repair platform is installed in place.
Ensure that the passage staircases of the tower section
Passage
and transitional section are installed in place.
Check the installation conditions of all connecting pin
shafts of the T shaped section and hoisting jib and
counter-jib. Wind cables to put them into use. Check the
installation conditions of the counter-jib rail and passage.
)ounter-jib and hoisting
jib Ensure that the hoisting wire rope is wound correctly.
Check the fixing conditions of counter-jib counterweight.
Check that the passage on the counter-jib is free of
debris to avoid falling down to hurt people during tower
crane operation.
Check lubricant level and lubrlcation points as per the
Lubrication
operation instruction.

65
 Chapter 6 Dismounting of Tower Grane
lower crane shall be dismounted according
to procedure that is reverse to it erectton
;rnd jacking, i.e. the cornponent or part that
is installed last shall be dismounted first'
during tower dismounting is slightly
Ihe lowering action of the hydraulic jacking winch
tlifferent(refertolower|ngpositionofthejackingwinchonpage4T)'
t'reparation before dismounting
permits
l.irstly, personnel disrnounting and erecting
the tower crane must obtain work
facility' Workers should be
,f special equipments, be familiar with peiormance of the
;rssignedappropriatelytotheworks'secondly,thesiteshouldbecleanedupand
llrckingcounterweightrequiredbydismountingofthetowercraneshouldalsobe
checked for normal operation The tower
prepared. Finally, all rnechanisms must be
t;rane shoulO noi Ue dismounted unless all
check results are OK'

t)ismounting tower standard section

pressure slowly until the upper weight of
fhen, start the switch, and then increase the
take down the connector of rnner and
the inner cage can be jacked up slightly, and
small hook for lifting standard
.uter tower. First, lift the counterweiiht by the special
section to make the front and baclitorque
of the tower crane balanced' hang the
of inner and outer tower connecting
self-elevating platforrn, and then remove all bolts
l.riecesandcommandtheoperatingroomtoswitchthepowersupplytothejacking
system elements' loosen the overflow
winch. ln orderto prevent damageLf frydrautic
zeio. Then, start the switch and then
valve of the hydraulic system and sei it to
above the inner cage is iacked up slightly'
,rcrease the pressure slowly until the weight
pieces' Then' lower the inner
irnd take down the inner and outer tower connecting
r:age until four snnall hooks nn the upper
slewing supoort frame hook the luq of the
hydraulic system lowering process' rerrlove
all connecttng
standard section (during
plate of the upper most standard section)'
Irolts of the rear single plate and U-snapeo
standard section and the section below
Remove all connecting bolts of the upper most
jacking to make the main angle steel of the upper
rt, and confirm that it is ok, operate
connecting plate of the standard section
rnost standard section separated fiom tnl
below it.
steel of the last standard section
lmportant note: it is ok that the main angle
piate of the standard section below it'
separates slighily from the connecting
anditisabsolutelyprohibitedtoallowtheguideblockoftheinnercageto
Push out the U-shaped plate and
exceed the main angle steel of the next
section'
then take the same method to lift the
lift it to the ground by the special hook and
singleplatestandardsectiontotheground.Repeataboveoperationsuntilall
standard sections are removed'
I 4 Drsmounting part of the counterweights
pieces
After standard sections removed, connect
the inner and outer tower connecting
part of the counterweights'
with the first section first and then remove
Er, Dismounting hoisting 1ib

t tr Dismounting all counterweights

Ft Dismounting counter-jib
Ell Dismounting oPerating room
Dismounting slewing support assembly
Dismounting inner cage
Dismounting self-elevating platform
Dismounting the first section
Dismounting base

b/
 _ttlt

Chapter 7 OPeration of Tower Crane

Operation Regulations
1)Theoperatorsoperatingthetowercranemustbetrained,arefamiliarwiththe
rules of its operation and maintenance'
construction uni p"rrori..,ance and with
Thetowercraneshallbeattendedbyexclusivelydesignatedperson.No
climbing on the tower crane without authorization'
2)Thecraneworksatambienttemperaturerangingfrom-20to40"C,withwind
velocitY not greater than 20 m/s'
3) Don,thandleorremovetheproperlyadjustedsafeguardsonthetowerCrane.
4) Duringoperationatnight,theconstructionsitemustbewelllightened'
by exclusively designated
5) The tower crane operation must be commanded performed with
to the driver must be
persons on the ground and floor. The liaison
pre-definedsignals,handsignals,orbannerwavingsrgnals.Usewalkietalkies
as practical as Possible.
6) Ensurethatthetowercraneoperatingvoltageshouldbewithin3BOVtl0%.
repairing'
7) Don't lift the load during maintenance and
B) Thecabshallbeequippedwithfireextinguishermeetingrequirementsoffire
by the user')
fighting. (Fire extinguisher shall be provided
Tower Crane OPeration
1)TheoperatorswitchesonthetowerCranefromgroundandthenentersintothe
that the indicator light of
examining
control room' By switching on the air breaker,
powersupplyistiton'andswitchingonfromtheelectricalcontrolcabinet.the
oPeration is standbY'
2)Thedrivercanonlyoperateuponthecommandingsignalsfromthegroundor
people must carefully listen'
and the
floor. Befor" op"ruiion, the bell must sound
performance and lifting characteristics for
3) strictly follow the tower crane technical
' opuruiion' Don't overload and roughly
handle it'

4)Lifttheloadverticallyonly.Don'tusethetowercraneforpullingthepileandthe
like.
only after they stop'
5) During operation, reverse the motors
tower crane, immediately stop and switch
6) ln case of abnorrnalities found from the
off. Don't use it until successful troubleshooting'
7)Uponcompletionofoperation,raisethehook.Allowthatthetrolleystopsat
jib. off before leaving' ln case of
switch
location by 25 rn approximately from the
held with rail clamp so that the tower
a traveling tower .run", the rail shall be
is stopped'
crane is fixed properly when the crane
B) Beforedailyoperation,checkandtightenthepreciseboltsandpinsonthe
criticalpartssuchastower,jib,slewingring'jibrod'andcounter-jibrodetc'
no loose or drop'
Perform operation only after confirming
pulley, and the
e) perform routine rnaintenance as specified for the speed reducer'
otherdrivingcornponents.lncaseofoilleakageetc.,immediatelyaskthe
maintainer for repairing and remedies.
carefully check the nylon pin on the
work every day'
coupting of the hoisting winch before starting
Before formally put into service, check
the reliability of the safety devices one by
10)
safety device'
one. Don't use any malfunctional or defective
68
11) Carefully check the steel wire rope clamp for safety. lf it is required that the rope
clamp should be used for fixing and connection, there must be at least 3 clamps.
And, in case of steel wire rope diameter D>10 mm, there must be at least 4
clamps. The clamp spacing must not be less than 6 times of rope diameter. The
rope head shall be not less than 140 mm from the last rope clamp, and bundled
with small-diameter steel wire. The rope clamp sliding saddle is placed on the
side that the steel wire rope is under force during operation. The U-bolt is
fastened on the end of the steel wire rope. The rope clamps must not be
alternatively setup. The rope clamps must be tightened before and after the force
is applied.
12) During driving operation process, the driver shall stay in his post to make the
load of the tower crane be within visible range throughout the working cycle.
13) Before the towercrane put into operation, the towercrane aftererected shall be
subject to commissioning for various safety devices. See the operation
instruction for commissioning method. lt is a basic requirement for the driver to
estimate the load weight and travel, that is to say, the driver can estimate the
load size accurately as much as possibly. Remember that the load shall also
include the weight of the suspension cage or grab bucket or other slings (mark
weight on the slings). ln order to estimate the working radius accurately, insert
the travel sings from 20m of the jib and every 5m or 10m after that.
Operation Control of Various Actions
Ihe machine hastwo control boxes, i.e. box 1 and2, inside the operating room.
I he left control box 1 consists of the following parts:
Oontrol rod @, voltmeter @, voltage switch @, current indicator @, operating room
r;ciling lamp switch, project lamp switch (11 ) and fault Iamp switch ('12).
the right control box 2 consists of the following parts:
Oontrol rod @, start button @, stop button (13)and bell button @.
Fig. A: the control rod @ on the left side operates and controls the heavy load to move
track and forth along the crane jib.
I'ig. B:the control rod @onthe leftside operates and controls rotation of the crane jib.
Fig. C: the control rod @ on the right side operates and controls the heavy load to
:rscend and descend.
t:ig. D: the control rod tJ on the right side operates and controls the tower crane to
travel.

69
 BT
,,on,EI F-;l '"0
[T;ll= E
,,., ll".l, I L:-l

"Htf--l

ff,-ffi ffi M'ffi,8x

Safety Precautions
The applicable temperature of the tower crane
is -20'C-40'C'

1. Before installing the tower

crane, check that the
installation site allows the
tower crane to rotate freelY
under load conditions.

70
The tower crane shall be
installed on the smooth
ground. lf one side subsides,
ensure that no ground
subsidence and collaPse take
place; there shall be no Pit and
hole on the track end surface.

It is not allowed to change and

adjust the safetY devices
arbitrarily.

Check actions of all limit

switches for accuracy and
reliability frequerrtlY.

Do not tilt the lifting load.

Do not use the slewing

mechanism and traveling
trolley to push and Pull.
 7. Never lift the heavY load buried
underground and kePt under
other articles or fastened,
since the additional force will
cause very dangerous
consequencelll

V
B. Do not lift heavY load at the
EET]
EEtrI v place where the driver's view is
Etrtr
trIEtr
V
V blocked.
t]t]tr
trntr
V
V
trrEtl v

9. Pay attention to the wind

velocitY. When the maximum
wind velocitY closes to 20 m/S
(equivalent to level B wind),
stop working. Wnen the towc'
crane stoPs working, follow
provisions of article 10, 11 and
12 of this chaPter.

10. When the tower crane stoPs

working, do not hang heavY
load.

11. When the tower crane stoPs

working, move the trolleY to
the middle of the crane jib, and
loosen the rotary braking
device to make the jib rotate
freely, while lifting the hook to
be near traveling trolleY.
 :
12. When the tower crane stoPs
(\ working, be sure to switch off

fl the power supply.

il
_//

4 13. Maintain the tower crane

elaborately, and check worn
parts carefully (such as brake,
pulley, steelwire rope, etc.)

N 14. During tower

maintenance and
unloading
crane
loading and
operations,
operators shall wear overalls

N and safety helmet and fasten

\i the safety belt complying with

safety requirements.

73
()lrapter 8 Electrical Control System (Full Variable Frequency
Control)
Overview
TCTSB10 hoisting winch, slewing mechanism and traveling mechanism adopt the
variable frequency speed control system composed by Shenzhen lnovance frequency
converter.The hoisting control is by closed loop control, with the advantages of high
reliability, good speed control performance, stable working performance, high
efficiency, strong load-bearing ability, high electricity saving performance and others.
The tower crane is applied with three-phase four-wire AC 3B0V 50HZ power supply; in
addition to the 24V voltage needed by the slewing and luffing DC brake, whose power
is supplied by control transformer of the tower crane, 4BV voltage shall be provided for
all coils, and standard voltage for others.
Control of the entire tower crane is centralized in the electrical control cabinet, so as to
facilitate installation and repalr. The control cabinet is installed in the cab and located
at the rear part of the cab.

Electrical operations of tower crane

(l) Checking and power supply: before starting up the tower crane, it is required
to check the power supply condition at the site, whether grounding is favorable,
and whether cable suffers from breakage and electric leakage; close the switch
to supply power after the inspection is completed. Close the master switch (air
switch) and supply power to lighting circuit in the operating room; when power
indicator light is lit on, it means power has been connected; then close the
control knife switches QF, QF1 and QF2, to energize the control circuit and wait
for operation.
Note: in case of failure found, stop and repair immediately, and do not
carry out tower crane operation before failure or potential safety hazard
eliminated.
(2) Hoisting winch: driven by 1M1 (YZP200L2-6, 22KW) three-phase
asynchronous motor used for metallurgy and lifting; in conjunction with an
inverter, it is able to achieve both ascending and descending speeds in 5 gears
respectively. lt is equipped with rotation encoder, in closed loop control.
(3) Slewing mechanism: driven by 2M1 motor (Y7A{132S-6 , 3KW AC
asynchronous motor); it is able to achieve speed in 4 gears by using the
operating handle controlled inverter, The DC brake Y1 is also set for the slewing
mechanism. When there is wind load, it may use the SA rotary switch to control
the DC brake to lock the slewing device'
(4) Trolley traveling mechanism: driven by an AC asynchronous motor (YEJ112M,
4KW); the gear command is sent from the operating room's linkage console; the
control inverter controls the forward and backward movement of luffing motor in
3 gears. The trolley is provided with forward and backward deceleration limiters
FWDEC and BWDEC; when the trolley passes by forward and backward
deceleration lirniters FWDEC and BWDEC, the trolley will decelerate; when the
trolley passes by the moment limiter LSQ4 (80% moment limit), the trolley will
also decelerate; when the trolley reaches the foruvard or backward end, the
forward limit switch FWL or backward limit switch BWL will be actuated to cut off
the power for forward or backward motor; when hoisting weight on the hook
exceeds tower crane lifting moment (see lifting performance table), the moment

74
 limit switch LSQg will be actuated to stop fonryard movement of the trolley, at
which time the trolley can only move backward to the root of the tower; the trolley
traveling mechanism is mounted with a normally closed brake; when operating
handle is in zero position, the brake will close; when operating handle is in gears,
the brake will open. For details, see the electrical schematic diagrams.
(5) Hydraulic jacking mechanism: its power supply is connected behind the
master switch (interlocked with main contactor KM), so as to facilitate installation
and use; it is driven by YM hydraulic motor (Y2-1325-4-5.5, 5.5KW); the jacking
mechanism is provided with a dedicated electrical control cabinet installed in
inner cage of the tower.
Safety devices
(1) Zero protection: To avoid dangerous action of tower crane after energization
due to manual-reset master controller, etc., that are not in zero position, the zero
protection device is specially provided to ensure that master AC contactor KM
can be powered only when all controllers are in zero position. All operating
mechanisms are provided with a zero protection device; therefore, the power
supply can be connected and various mechanisms of tower crane can start
working only after masterAC contactor KM is closed.
(2) Automatic air switch: lnstalled at the place where the power source comes in,
with tripping current set at 150A; it is the overload protection device of main
power supply.
(3) Motor Protection: Provided by the protection function of the inverter itself.
(4) Short circuit protection: A small circuit breaker is provided in the lighting
control circuit for short circuit protection.
(5) Signalling and lighting devices: power indicator HL is provided on the console on
the left side inside the operation room. Red solar obstruction lights are provided
on boom, balance arm end and tower head section frame. ELr overhead lights
are provided inside the operation room.
(6) Limit protection:
1) Hook's ascending deceleration limit: Ascending deceleration limit switch
GSQ2 and over-height limit switch share one multi-function limiter;
DXZ{ype travel switch (with certain gear ratio) is driven by the hoisting
winch; when the hook rises to a predetermined height, the ascending
deceleration limit switch GSQ2 will deactivate the gears ll, lll, lV and V, and
the motor will be under operation in low speed gear (Gear l).
2) Hook's over'height limit: over-height limit switch GSQ1 is mounted
beside the lifting drum; DXZ{ype travel switch (with certain gear ratio) is
driven by the hoisting winch; when the hook rises to a predetermined limit
height, the over-height limit switch GSQ will cut off the power for ascending
motion of lifting motor.
3) Left and right rotation limit of slewing device: The 2SQ1-2 series
D)G-type travel switches are mounted beside the slewing gear ring; the
slewing angles of both switches are not more than 360" respectively, so as
to avoid cable twisting.
4) Forward and backward deceleration limit of traveling trolley: the
FWDEC and BWDEC and trolley fonarard and backward deceleration limit
switches share one multi-function limiter; it is directly driven by trolley
mechanism (with certain speed ratio); when trolley is driven to the

75
I

predetermined end point, the travel switch cam will depress the switch
contact, to achieve the purpose of motor deceleration'
5) Travel lirnit of traveling trolley: The FWL and BWL series DXZtype
travel switches are directly driven by trolley mechanism (with certain speed
ratio); when trolley is driven to the predetermined end point, the travel
switch cam will depress the switch contact, to achieve the purpose of
cutting off the power supply.
6) Moment protection: the lifting moment limiter of the tower crane is the
lever-type moment limiter; its actuator is JLXKr-411 travel switch, whose
contact is connected in series in the ascending circuit of the hoisting winch
and in the forward circuit of traveling trolley; once the moment exceeds the
given value, the alarm signal will be sent and the power will be cut off.
Sound and light signals: the tower crane is provided with electric bell and
7)
whistle as the sound signals. The bell is used as startup signal; after
pressing down the SB1 button, the bell HA1 will send out sound to attract
operating personnel's attention. The whistle HA2 is used as overload alarm
signal. HL3 is the fault signal indicator; when inverter is faulty, HL3 will be
lit on; after pressing fault reset button SA2, HL3 will be turned off and
inverter fault code will be cleared.
Note: HL2 is the hoisting brake wear audible and visual alarm. When alarm is
given, it indicates that the hoisting winch inverter detects that the hoisting brake
may have high degree of wear or brake clearance is not adjusted properly, put
the operation handle downward to cancel the audible and visual alarm. Then, it
rs required to put the heavy load at safe area, and then check, adjust or replace
the brake.
Motor
L.
I he motors for mechanisms of the tower crane are as shown in the following table:
Mechanisrn
Hoistinq winch YZP2OOL2-6
'inq mechanism YZ|U1325-6
Trol mechanism YZJ112M-4V1
inq mechanism
Total installed capacity of
32KW (embedded and weight tYPe)
entire tower crane
Safety Precautions
( I ) ln the three-phase four-wire power grid, the tower can not be used as neutral line;
the neutralconnection and ground connection must be separated. Two rails shall
be provided with multiple grounding; the grounding resistance must not be
greater than 4 ohms.
(;,) Within 5 to 1O m outside the working range of the tower crane jib, poles for HV
and LV electric wires shall not be allowed (5 m for LV electric wire pole, and 10 m
for HV electric wire Pole).
( r) Before installation, insulation resistance to ground of various components shall
be firstly measured through megger; motor insulation resistance shall not be less
than 1 megohrn, and the insulation resistance of wires electrical cabinet
conductor shall not be less than 1 megohm.
(,1) Lock the doors and windows. Turn on the slewing brake, to make the tower
crane can swing with wind.
lnverter Maintenance
Due to influence by changes in working environment of inverter, such as temperature,
humidity, smoke, dust, etc., and by other factors such as aging of its internal
components, the inverter may be subject to various faults. Therefore, daily checks and
regular maintenance rnust be carried out in the process of storage and use of the
inverter.
o After transportation and before use, the inverter must be checked to confirm
whether its components are intact and whether the screws are tightened.
o During normal use of the inverter, dirt shall be cleaned away regularly and
screws shall be checked for tightness.
r ln case inverterwill not be used for a long time, it is recommended thatthe
tower crane shall be powered on for appropriately one hour every three
months during storage, so as to prevent failure of electronic devices.
o lt shall be avoided to use the inverter in damp environment or in the environment
with much metallic dust. ln case it is needed to use it in such environment, it
must be placed in the electrical cabinet or on-site protection cell provided with
protective measures.
Routine maintenance
During normal operation of inverter, make sure the following items:
o Whether the motor has abnormal sound and vibration;
o Whether inverter and motor have abnormal heating;
o Whether ambient temperature is too high;
c Whether tlre value on ioad current meter is normal as usual;
o Whether inverter's cooling fan is under normal operation.
Regular inspection
Depending on the use condition, the customer shall carry out regular inspections to the
inverter, so as to eliminate failures and potential safety hazards. During the inspection,
be sure to cut off the power; inspection is allowed only after power indicator llght
"CHARGE" of the rnain circuit is off. The inspection contents are as shown in Table
B-1.
Table B-1 Contents of regular inspection

Screws of main
circuit terminals and Tighten them with a
Whether screws are loose; screwdriver.
control circuit
terminals
Radiatinq fins Blow them out with the
Whether there are dirt and foreign dry compressed air
Printed circuit board matters; under the pressure of
(PcB)
Whether there are abnormal
sound and vibration;
Cooling fan Replace the cooling fan.
Whether the cumulative running
time is up to 20,000 hours;
 T"

Whether there is dust
Power components accumulated;
Whether there are discoloration,
E lectrolytic caPacito r abnormal smell and bu!!l!ry'-
Counteraeasures for
Abhoiirialitias
Blow them out with the
dry compressed air
under the Pressure of
4-6kslcm2.
Replace the electrolYttc
caoacitor.

Maintenance and replacement of components

ln order to achieve long-term normal operation of the inverter, the internal electronic
Components of the inverter must be subject to regular maintenance and replacement
of the
according to their service life. The service life of internal electronic components
inverter is different depending on working environment and conditions- The
replacement period of the inverter given in Table B-2 is provided only for reference
by
USCTS.

Table 8-2 Replacement Period of lnverter Components

fan
Electrolvtic capacitor
Printed circuit board
is
The working conditions on which replacement period of the inverter components
Irased are:
ir) Ambient temperature: annual average 30"C'
b) Load factor: below B0% or less.
()) Operation time: 12'hours or less per day.
Warranty of inverter
ln case of the following situations happened to the inverter, the Company will
provide
llre warranty service:
ir) Scope of warranty: the inverter proper;
li) During normal use, the Company is responsible for warranty service in case the
inverter is faulted or damaged within one year, and will charge a reasonable sum
of repair cost if such fault or damage occurs after one year;
A cerlain amount of repair cost will also be charged in case of the following
') situations happened within one year:
o lnverter darnage due to failure to use it in accordance with instructions in
the oPerating manual;
o lnverter darnage due to flood disaster, fire disaster, abnormal voltage, etc';
o lnverter darnage due to incorrect wiring, etc';
o lnverter darnage due to rebuilding by the user;
(l) Relevant service fees will be calculated based on the actual cost' ln case an
agreement is signed, the agreement shall prevail'
Activation of leakage circuit breaker
l)uring operation of the inverter, the leakage circuit breaker is activated'
l,or the reason that the inverter output is high-frequency PWM signal, it produces
lrigh-frequency leakage current and it is required to select a special-purpose inverter
t,,ikage circuit breaker with current sensitivity above 30mA. ln case of an ordinary
78
leakage circuit breaker, it is required to select one with the current sensitivity more than
200mA and the activation time more than 0'1s.
Electrical schematic diagram
starter, see Page 69;
For electrical schematic diagram of power supply and
Page 70;
For electrical schematic diagram of hoisting winch' see
Forelectricalschematicdiagramofslewingmechanism,seePageTl;
see Page 72;
For electrical schematic diagram of trolley mechanism,
system, see Page 73;
For electrical schematic diagram of signal and lighting
jacking system, see Page 74;
For electrical schematic diagram of hydraulic
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For electrical schematic diagram of hydraulic

86
 TCT5810 Electrical Component List
Designation Remark
Description Model Quantity
No.
lnverter of hoisting
BPl cs700-4T30G 1
winch
lnverter of slewing cs700-4T4.0
BP2 1
rnechanism G
lnverter of trolley cs700-4T4.0
BP3 1
mechanism G
JBK3-4OOA,
T Transformer 1
3BOV/4BV
JBK3-5OOA,
2T Transformer 1
380V/15V127V
Miniature circuit DZ47-63, D25,
QM2, QM3 2
breaker 3P
1KM1 , 3KA2 Contactor GSCl -1201 2
1KA2,1KA4 Contactor JZC3-22d 2
1KAS,1KA6 Contactor JZC3-31d 2
Miniature circuit DZ47-63, D10,
QF1, 2QF1 2
breaker 2P
Miniature circuit DZ47-63, D10,
QFz,2QF2 2
breaker 1P
3KA1, MY2N-J,
Relay 3
1KAl,2KA1 24VDC
cGMl-100D/3
QM1 Circuit breaker 1
300
KM Contactor GSCl-8011 1

c,q\/1-225|' !3
QF Main circuit breaker 1
300
DZ47LE-40,
QFO Circuit breaker 1
c25,2P
2R1, 3R1 Aluminum resistor 500w,500 2
1R1 Hoistinq resitor 1

Tower crane safety

1
rnonitorinq svstem
Discharge circuit
1
board
LRV-2 Eddv current controller 1

External Circuit Specifications of Electrical Diagram for lnverter

1. QF is main power supply circuit breaker in the cab.
2. QM1 is inverter power supply circuit breaker of hoisting winch.
3. QM2 is power supply circuit breaker of inverter of slewing mechanism.
4. QM3 is power supply circuit breaker of inverter of trolley mechanism.
5. QF1 and QF2 are power supply circuit breaker of contactor control circuit.
0. 2QF1 and 7QFZ are power supply circuit breakers of slewing and traveling
brake.
T is power supply transformer of contactor control circuit (380V is transformed to
48v).
IJ 2T is power supply transformer of slewing, traveling brake (27V).
I 1OKM is a main starting contactor; KM1 is hoisting brake control contactor (When
the gear is shifted up and after the inverter reaches ZHz,the inverter is engaged;

97
 and when the gear is shifted down and after the inverter reaches BHz, the
inverter is disengaged); 1KA1 is miniature intermediate relay of inverter of
hoisting winch (the coil DC voltage is 24V, and controlled by FDT function of the
inverter; the relay is engaged when the gear is shifted up and after the inverter
reaches 2Hz, and disengaged when the gear is shifted down and after the
inverter reaches 8Hz); 1KA2 is fault output relay of the hoisting inverter (after the
relay is engaged after startup, and disengaged when the inverter is failed); 1KA3
is hoisting brake ear alarm relay;ZKA1 is slewing eddy current control relay
(there is eddy current when it is null, and no eddy current exists when the gear is
shifted during slewing); 3KA1 is miniature intermediate relay of inverter of trolley
mechanism fault output (it is disengaged after startup, and engaged to control
brake for power-off when the inverter is failed); 3KA2 is control brake relay of
inverter of trolley mechanism (it is controlled by FDT function of inverter, and
engaged after the traveling inverter reaches o.1Hz during gear up, and
dislngaged when the inverter of trolley mechanism is returned to 0'1Hz during
gear down).
10. 2Q2 is slewing and traveling brake silicon stack'
11. 1R1 is hoisting braking resistor (stainless steel resistor); 2R1 is slewing braking
resistor (aluminurn resistor); 3R1 is traveling braking resistor (aluminum resistor).
These resistors are slightly heated, unlike those speed regulating resistors which
are heated highlY.
12. FSQ2 is the liftingweight limiter (QTZ5013D is located at jib root, TCTSB'10 is
'deactivated when it is
provided in the hoisting dynamometric ring, and is
'1.5{on hoisting
adjusted to 4 ropes for 3{on hoisting capacity and 2 ropes for
capacity); FSQ1 is the hoisting over-weight limiter; LSQ1 is the hoisting moment
limiter; GSQl is the hoisting over-height limiter; GSQ2 is the hoistinE
deceleration lirniter (GSa2 uses the long projected point, and GSQl uses the
shorl projected point in the over-height limiter, the GSQl is firstly adjusted in
place during adjustment, and then the GSQ2 is adjusted by such means that it is
projected over GSQ1 slightly. This is because 3 seconds is required for
decelerating and stopping the inverter when returning from the Sth gear to zero
position, so it is required to carry out deceleration in advance to avoid reaching
maximum limit position.); 2SQ1 and 2SQ2 are slewing limiters; LSQ3 is the
traveling moment limiter; FWL is the forward traveling limiter, and BWL is the
backward traveling limiter; FWDEC, and BWDEC are fonarard and backward
traveling deceleration limiters (This is because 3 seconds is required for
decelerating and stopping the inverter when returning from the 3'd gear to zero
position, so it is required to carry out deceleration in advance to prevent the
traveling trolley from being over the maximum limit position; the adjustment
method is the same as that of hoisting deceleration limiter); LSQ4 is the traveling
moment fonruard deceleration limiter (This is because 3 seconds is required for
decelerating and stopping the inverter when returning from the 3'd gear to zero
position, so it is required to carry out deceleration in advance to prevent the
traveling trolley from being over the maximum limit position, resulting in
over-torque; during adjustment, it is activated at the same time of torque alarm or
earlier than the alarm); LSQ2 is the moment alarm limiter; FSQ3 is the
over-weight alarm limiter.
1.)
t.). 2y2 is the slewing braking discharge diode, and 3V is the traveling braking
discharge diode.
14. 2R3 and 3R2 are discharge resistors.

88
15. FN1 and FN2 are exhaust fans in the electrical cabinet.
16. SAO is stop button on the right linkage console, SA1 is start button on the right
linkage console, SA2 is (frequency convert)fault reset button on the right linkage
console, and 2S7 is slewing cam zero position point in the left linkage console.
17 1M1 is the hoisting motor (YZP200L-6 22Kw, squirrel-cage hoisting motor with
forced draft fan; remember to properly adjust the rotation directron of the fan),
and YM is the hydraulic hoisting push-rod motor; 2M1 is the slewing motor
(YZM32-6 3.7KW, squirrel-case eddy current hoisting motor); 3Mt is the
traveling motor (YEJ112-4 4KW, ordinary squirrel-cage motor with DC brake
and forced draft fan; remember to properly adjust the rotation direction of the
fan).
18. ln case that the tower crane is failed, it is possible to use the following method to
judge whether the fault is resulted from external circuit or inverter: first remove
the external limiter cable from the terminal, and then connect corresponding
shorting stub: 11#shorted to 1'19#; 11# shorted lo 141#;203# shortedto 213#;
205# shorted to 215#; 303# shorted to 315#; 305# shorted to 307#; 101# shorted
to 307#; thus to restore to the workshop trialrun condition to observe if running
conditions meet set requirments and all contactors are activated as per drawings.
lf it is activated right, it is required to inspect wire connection of external limiter. lf
it is not activated right, it is required to reset parameters of the inverter or inspect
wire connection of the linkage console.
 Ghapter 9 Hoisting Winch
Brief introduction of hoisting winch
22JLD15F hoisting winch (shown as following figure) consists of motor, electric
hydraulic block brake, speed reducer, grooveless drum, frame and hoisting height
limiter.

Figure 9-1 Scher-natic Diagrann of 22J\"D15F Hoist;ng \A/inch

1) YZP series variable frequency and speed three-phase asynchronous motor,
which boasts wide speed regulation range, strong overload capacity, high
efficiency, stable stepless speed regulation and starting and braking
performance, and other benefits.
2) The brake device shall be provided with electric hydraulic block brake, which is
freatured as safe and reliable performance, stable braking and high frequency of
action, ensuring easy adjustment of braking torque as well as convenient
replacement and rnaintenance of the device.
3) The speed reducer is a rectangular axis speed reducer.
4) The hoisting drum is composed of grooveless drum, spline housing end plate
and bearing pedestal. The drum is supported on the bearing pedestal of the
frame through the drum shaft. The speed reducer drives the drum to rotate
through spline shaft and spline housing end plate.
5) The frame is applied with profiled steel welding structure with perfect overall
rigidity, thus to have less deformation under workload and enhance working
stability of the mechanism.
6) The hoisting height limiter is installed on the bearing pedestal through bracket.
The mechanism has been equipped with type DXZ4IB multi-function travel
limiter.
I

Figure 9-2 Outline of 22JLD15F Hoisting Winch

Working PrinciPle
of input power
The mechanism changes hoisting speed by changing the frequency
frequency is equal to or
supply of the motor thrlugh a inverter; when the power supply
tess than rated frequen.y (gaHz), the hoisting winch can
hoist rated hoisting capacity;
(3BHZ), the hoisting
when the power supplyir"qr"n"y is more than rated frequency
r:apacity hoisted by the hoisting winch is decreased as
the speed is increased'
of inverter
lnstruction for speed regulation of the hoisting winch by use
The electric rnotor is operated in quadrant 1 ,2,3 and 4.
when the motor is operated in
resistor by braking
rjeceleration status, the electric energy is released to the braking
unit. Operating condition of the motor requires frequent
operations of the brake' The
system is designed to guarantee accurate adjustment of
logic control' so as to ensure
brake is energized and
that the inverter has enough output current before the motor
released, and the hook cannot be glided after the brake is
released; meanwhile' it is
reaches 150% of rated
required that the motor is started at zero speed and its torque
it to hoist the heavy
value after ensuring that the brake is released, so aS to enable
object successfully; rn" design meets design requirements for
individual safety
devices of the hoisting winch, improving safety and reliability
of the system; the

ol
l maximum operating speed of the motor can be controlled based on different hoisting
capacity, si gnificantly i rn provi ng o perati ng efficiency.
The control circuit is also provided with zero protector, motor protector and lifting
weight limiter, moment limiter, height limit protector and other devices to prevent
occurrence of accidents.
Working principle of electric circuit (See electrical diagram for details):
Close the air switch QF and circuit breaker QF1 and QF2 switches, set the operating
handle at zero position, and press the start button SA1, so that the current passes by
the stop button SAO--+start button SA1---zero contact ISO ofoperating
handle--3S0---+phase sequence relay JX and AC contactor coil KM to constitute a
circuit for energization, achieving preparation of ascending or descending control
circuit.
The opening of hoisting brake is delayed and advance closing of the hoisting brake is
made through unique FDT function of the inverter in the hoisting circuit, ensuring
that
the hoisting motor has enough moment when the brake is open or closed; so, the hook
is not glided, ensuring that the mechanism is operated safely. Meanwhile, a fault
protection of the inverter is also added in the hoisting brake circuit. When the invefter
is failed, it is required to ensure that the hoisting brake is activated reliably.
When the hook is hoisted to originally set height limit, GSQI contact is activated (the
contact is open), the inverter stops output, and the motor stops operation, preventing
the hook from being beyond the limit; when hoisting capacity of the hook exceeds
maximum hoisting capacity or hoisting torque, the limit switch FSQ1 and LSQ1 contact
are activated (the contact is open), the inverter stops output, the mechanism stops
moving upward to protect steel structure of the whole machine for use within safety
rangu. At this mcrnieni, the rnotoi'Ganilot be ascen0co, tlut can l-re cjescendud'

ll Hydraulic push-rod brake

ltt Brief introduction of structure and actuation

I
I

ir

Figure 9-3 Block brake

Brake bracket:
1. Baseplate
-'t

2. Equalizing brake lever

3. Eccentric pin
4. Brake shoe adjusting bolt
5. Brake shoe assembly
6. Brake arm
7. Travel adjusting screw
B. Lever
9, Spring gear
Thruster: 1 0. Electro-hydraulic thruster
Hydraulic block brake (Figure 9-3) is comprised of brake bracket and matching yTl
type electro-hydraulic thruster.
The electro-hydraulic thruster (Figure 9-4) is comprised of special drive motor
and the
body (centrifugal pump), and the ratter is made up of cover, cylinder, piston, push-rod,
impeller and rotation shaft.
The special drive motor refers to a totally enclosed two-pole three-phase
asynchronous micromotor. The motor casing is cast in aluminum alloy. protruding
end
of main shaft of the motor is hollow (excluding JO2 motor) for ascending or descending
of rotation shaft of the thruster. E grade insulating materials are applied on the
motor.
ln steady thermal state, insulation resistance of its windings on the casing
will not be
less than 1.0 MQ. lf the motor is operated at place with elevation of 1000m
and with
temperature of cooling medium 40"C above zero, maximum temperature rise
of the
stator winding shall not exceed 75'C (resistance method), and rolling temperature
shall not exceed gS"C (thermometer method). Rated power of ti;e motor
is 750W,
rated frequency is 50Hz while rated voltage is 3B0V (Y-connection).
Motors of 60Hz or
different voltage or damp and tropical type can be equipped upon request
by the user.
Drive motor and body of the electro-hydraulic thruster are coupled with
a cover
between. Piston with two push rods is provided inside the body, while an impeller
connected firmly with rotation shaft is provided inside the piston, and the rotation
shaft
is supported by a holding plate equipped with rolling bearing. The holding plate
is
supported on the piston and secured with screws (excluding yT1-320). TnL
Uooy is
lointed with cross-bearn at top via push-rod; connecting rod is installed on the
cross-beam, which is jointed with lever of the brake bracket with pin shafts;
the body is
lointed with baseplate of the brake bracket with pin shafts at bottom.
 4
3

Figure 9-4 Electro-hydraulic Thruster

Drive motor:
'1. Electric motor Body
2. Vent plug
3. Rotation shaft
4. Oil level plug
5. Cylinder cap
6. Oil filling plug
7. Protecting pipe
B. Connecting rod
9. Cross-beam
10. Cylinder body
11. Push-rod
12. lmpeller
13, Piston
When energized, the motor drives rotation shaft and impeller on the rotation shaft to
rotate, imposing pressure inside the oil circuit. The pressure drives oil from
upper part
of the piston to lower part, thus hydraulic oil on upper and lower parts of the piston
resulting in differential pressure, which forces the piston as well as push rod
and
cross-beam secured to it to ascend rapidly. When the piston ascends to the
top,
pressure at lower part of the piston is constant, and this will open the
brake shoe
(releasing brake) by compression spring based on leverage. When deenergized,
the
impeller stops rotating, and the piston descends rapidly under effect of loid spring
force and the gravity of itself, forcing oil to flow to upper part of the piston again.
Ri tnis
 time, the brake shoe is closed (contracting brake) based on leverage for braking.
Irr Procedure on operation of brake
Note: This adjustment procedure is only for reference. For actual adjustment,
see accompanying operating instruction of the brake.
(1) lnspection priorto installation
1) lnspect whether individual parts of brake are complete;
2) lnspect whether the brake is activated flexibly, and each flexible hinging
point is rusted and jammed;
3) Prior to installation of brake, the brake drum must be cleaned by use of
petroleum solvent. Any oil stains and corrosion protection measures
significantly reduces friction coefficient;
4) Cleanliness of mounting surface and brake drum is very important;
5) Brake lining should not be contaminated by oil stains, and the oil stains will
si g nificantly red uce the frictio n coefficient;

6) Clean hydraulic oil without any dirt and mechanical impurities has to be
filled in the hydraulic thruster before operation.
(2) lnspection of brake drum
1) The brake drum should not be rusted, cracked, oil stained, and should be
free from out-of-flatness and other defects. It is prohibited to use brake disc
that has been cracked or has other major defects;
2) When the brake drum rotates around the shaft, its co-axial deviation of
braking face from the axis should not exceed 0.15;
3) The brake drum surface roughness is 3.2; if the surface is too smooth, or
too rough, it will result in difference in braking performance.
(3) lnstallation of brake
1) First, check whether mounting seat of the brake is stable and flat, and
position and dimension of the mounting hole is correct. lf mounting seat of
the brake is mounted together with the brake, the mounting seat should be
fixed (welded) securely after the brake is positioned correctively during
preliminary i nstallation
;

2) Screw ouMard the adjusting rod as far as possible to maximize clearance

between brake arms, so that the drstance between brake linings is 3mm
larger than brake drum, facilitating installation of the brake;
3) Move the brake into mounting position, and screw nuts onto 4 bolts of the
brake loosely;
4) The thruster is connected to the power supply;
5) After being energized, the brake is activated for several times, so that the
brake is automatically aligned during activation; and then, observe whether
the brake is mounted at right position after being de-energized;
6) After it is rnounted at right position, it is power off to observe whether the
returning distance of brake lining is kept about 1mm; if it is mounted at
wrong position, it is possible to change its position by adjusting position of
the adjusting rod;
7) After everything is normal, the foundation anchors are tightened securely,
and the installation is completed.
(4) Adjustment of brake
1) Adjustment of brake return distance: As shown in figure (9-3), release
spring force to minimum level, adjust travel adjusting screw (7) so that the
brake is in closed state. Rotate continually and push-rod of the brake will
rise slowly so as to make compensation travel H1 reach specified value
(usually, it is approximately 20mm), and the adjustment of operating travel
is finished.
2) Adjustment of braking moment: Tighten spring adjusting screw in the
spring gear (9) so that the spring is compressed to the corresponding scale
or dimension (a brake moment scale is provided on the spring tube) as
indicated in the name plate, thus necessary brake moment is obtained.
3) Turn right and left clearance adjusting screws to limited positions, and
loosen thern one turn. Tighten screws.
4) lnspection: Pull the rotating arm in a direct manner (using force of about
30Kg). At this time, clearance between the brake pad and brake drum shall
be 0.7-1.5. lf the clearance is too wide, tighten the travel adjusting screw
and pull the rotating arm; if the clearance is too narrow, loosen the travel
adjusting screw and pull down the rotating arm. Tighten the travel adjusting
screw.
(5) Maintenance of brake
1) The brake lining should be broken in before use of the brake, othenrvise the
braking torque will not meet design requirements.
2) Heavy objects shall be lifted up before working every day to inspect
whether the bi"ake is effective, or adju:,tnient has to be made.
3) Nut securing the brake shoe (see figure 4-1) shall be loosened
appropriately, and a state in which the brake shoe cannot be moved freely
is preferred.
4) After the brake is operated for a while, the lining will be worn, and return
distance of the brake is increased, so it is required that the return distances
are kept consistent by adjusting position of the adjusting rod in time.
5) Observe wear conditions of the brake lining; when thickness of the friction
material only remains 3mm, it is required to change the brake lining.
I ist of oil recommended to use in various ambient temperature: Table 9-1
Temp. of surrounding
Applicable oil recommended
media
+45oC-+20oC No. 20 machine oil (Freezing point -15'C) G8443-64
+lQ"Q-9"6 No. 10 transformer oil (Freezing point -10'C)
sYB1351-62
ooc-15.c No. 25 transformer oil (Freezing point -25"C)
sYB1351-62
_15.C_30"C lnstrument oil (Freezino point -60'C) GB4B7-62
Lower than-30"C Mixture of alcohol and glycerol
Brief introduction and maintenance of main parts
lnverter
With the operation panel, functional parameters, working condition and operation of
( )5700 can be modified, monitored and controlled (startup & shutdown) respectively.

liee the following Figure for the profile and functional area of the operation panel.
 il

Forward/reverse
Command source rotation indicator
On: forward rotation
On: terminallcontrol
Off: reverse rotation
Off: kevboard control
Flicker: communication
control

Tuning/fault indicator
Run indicator
iuN LocAlIREMor
1t

Display field
unit indicator

|tz A

@
Shift key
Shortcut keY
@ Progressive
decrease key

Shutdown/reset keY
@
Functional reserve

Panel
Fig.2-1: Schematic Diagram of Operation
Table 2-1: List of Keyboard Function

Enter the first-level menu or quit to the

previous
menu (not save parameter settings)

ffienus one bY one' and

.ontim parameter settings (save parameter

Progressive increase of data or parameters

Progressive decrease of data or parameters

rrent' busbar
;"[rg;, etc.) can be circularly selected on
shutdtwn and operation display screens;
Modifier bit of a parameter can be selected
when modifYing su9!-Pqqrn9l9!
keyboard
It is used for startup and shutdown under
running mode.
this keY is
pressei down in running condition; f:.:t,:3t]-:,i
I;;il ;-i;i; k"v i; piessed down under raurt
I
DescriPtion Functloll
Kev
Functional reserve
@
l
(NonJunction)

Functional Functional reserye

@ reserve

DisplaY Field
and funr;tttttt
kinds of monitoring data' alarm code
s-bit LED display screen on which all
parameters can be disPlaYed, e'g'

Parameter Parameter
Serial nurnber of the S/N
currentlY connected moto

rtUH LSCAUREM( { FED]REY

F ig.2-2 -F uncti o n Pa ra mete r

Fault code
Fault Fault level
indication

Fig.2-3:Alarm Code

Function lndicator

98
 o

TUNE/TC

Name of lndicators Meaning of lndicators

When this indicator is on, it means that the frequency
RUN converter is running; when it is off, it means the frequency
conveder is stopped.
On: panel startup/shutdown control mode;
LOCAL/REMOT Off: terminal startup/shutdown control mode;
F licker: communication sta rtu p/shutdown control mode
Forward/reverse rotation indicator: if on, it means it is
FWD/REV
under forward reverse condition.
Tuning indicator: if on, it means it is under tuning operation
TUNEffC
go-[qjgq!.-

Unit lndicator Unit

HzAV Hz: frequency unit
o-RPM-o-Y._o
Ilz A A: current unit
o-RPM-a*o/ro
HzAV V:voltage unit
o-RPM-o-%-a
HzAV RMP: rotating speed unit
o-RPM-a-%-o
Access to and Modification of Function Codes
See Fig.4-2 for the operation flow.
 Functional When there is flicker digit, press
Stop/operation
parameter code A/VD to modify

Last parameter
50.00 Enter/Esc
parameter setting
-ffi._.
rFHtnter.
l
I

@-
tsc: d0 not save
-@'*u'
parameters {
Parameter coo(
value o oo
Fig.2-4: Operation Flow of Different Screens
E.g. change the pararneter setting of b1 .02 from 10.00H2 to 15.00H2

Fig.2-5: Example of Parameter Editing Operation

lf there isn't any flicker bit of a parameter shown on the parameter setting screen, it
means such parameter can't be modified, and possible causes are listed below.
1) This parameter is an unmodifiable parameter, e.g. monitoring parameter, run
record parameter, etc.
2) This parameter is unmodifiable in running status, and can only be modified in
shutdown condition.
Troubleshooting
S/N Phenomenon Possible Cause Solutions
a Power voltage is zero or too
low;
a The switching power supply
on the frequency converter
drive board fails; a lnspect the power source;
a The rectifier bridge is a lnspect the busbar voltage;
No display after
damaged; a Pull out and re-plug the
I power on
a Buffer resistance of 8-core and 28-core drop-out
frequency converter is lines;
damaged; a Contact the manufacturer for
t Control panel and keyboard help.
fail;
a Wire connecting the control
board to the drive
board/kevboard is broken.
a Bad contact of the wire
connecting the drive board to

"CrAnE""CrAnE"
control board; a Pull out and re-plug the
a Relative parts on the control 8-core and 28-core drop-out
is shown board is damaged; lines;
2
continuously for a
a long{ime
The motor and motor line is a Contact the manufacturer for
short-circuit to ground; help.
a Failure of Hall components;
a Power qrid voltaqe too low.

3
"Er123" alarm a The motor or output line is a Measure the insulation of
after power on short-circuit to ground; motor and output line with a
 a Damage of the frequencY megameter;
converter a Contact the manufacturer for

Normal
condition is
displayed after
power on, but a Damage or locked rotor of a Replace the fan
"CrAnE" is fan; a Eliminate anY external
displayed and a Short-circuit of PeriPheral short-circuit fault.
shutdown control terminal connection
occurs
immediatelY

a The carrier frequencY is set

Fault Er114
too high; 'O Reduce carrier frequency;
(overheat of
t Damage of the fan or block of a Replace the fan and clean
the air duct; off the air duct;
modules) is
reported
a Damage of intemal Parts of a Contact the manufacturer for
the frequencY converter helP.
frequently
(thermocouPle or

a Motor and motor line; a Recheck the connection

a lncorrect frequencY converter
The motor fails parameters are set (motor
to rotate after parameters)
the running of
the frequencY
a Bad contact ofthe
connection between the drive
converter
board and control board
a Failure of the drive board
a lncorrect parameters are set;
a Incorrect external signals;
Dl terminal
failure
) Loosing of OP and +24V
jump wire;
a Control board failure.
between the frequencY
converter and the motor;
a Replace the motor or
eliminate anY mechanical
fault;
a Check and reset the motor
Check and reset relative
para'rreters of bll group:
Reconnect external signal
lines;
Recheck OP and +24V jumP
wire
Contact the manufacturer for

Motor speed a Encoder error; a Replace the coding disc and

can't be a Wrong wiring or bad wire recheck the wiring;
increased under contact of the encoder; a Replace the PG card;
closed looP a PG card error; a Contact the manufacturer for
vector control a Drive board failure.
a Reset motor Parameters or
Overcurrent and a lncorrect motor Parameter implement motor tuning;
overvoltage settings: a Set aPProPriate acceleration
failure is a lnappropriateacceleration and deceleration time,
reported and deceleration time; a Contact the manufacturer for
frequently a Load fluctuation
a Check whether the contactor
cable is loose;
a Check whether the contactor
is failed;
Er117 is
reported after
a The soft startuP contactor is a Check the 24V Power suPPlY
not engaged. of the contactor for anY
power on
failure;
a Contact the manufacturer for

a Relative parts on the control a RePlace the control board.

board are damaged.
 Lines
Fault Codes lndicating Faults on External
Fault
Code fail ure
1. I nsta;taneotls Power
2. The inPut end voltage of the 1. Reset failure;
frequencY converter is not 2. Adjust the voltage to
within the sPecified range of normal range;
Undervoltage the specification; J. Seek technical suPPort
fault J. Abnormal busbar voltage; i Seek technical suPPort
4. Abnormal rectifler bridge E Seek technical suPPort
and buffer resistance, b. Seek technical suPPort
5. Abnormal drive board;
6. Abnormal control board'
t lWnetner the load is too 1. Reduce the load and
large or whether the motor check motor and
rotor is blocked; mechanical conditions'
Overload of 2. The selected model of ?. Select frequencY converter
frequencY frequencY converter is with larger Power level;
converter relativelY small; 3. Refer to 25#
3. There is one default outPut Troubleshooting'

L WheGr aPProPriate motor CorrectlY set this

bE'01 parameter;
Protection Parameter
is set; Reduce the load and
2. Whether the load is too inspect the motor and
Overload of large or the motor rotor is mechanical condition'
motor blocked; Select a frequencY
3. The selected frequencY converter with larger
converter model is relativelY power level.

1. Check and eliminate anY

pcwer suPPlY; pIODler I lS existtr,g tn
Abnormal drive board; peripheral circuits;
Abnormal lightning 2. Seek technical suPPorl
protection board J. Seek technical suPPort
Abnormal main control 4. Seek technical suPPort
1. eorrectlly set the encoder
l Mismatch of encoder type aciording to actual
model; conditions;
Encoder error 2. Encoder connection error; 2. Eliminate anY line failure;
3. Encoder damaged; Replace the encoder;
4. PG card abnormal' 4. lace the PG card.

Replace the cable or motor

Short-circuit of motor to ground
1. Elrminate any PeriPheral
llAbnormal lead wire
fault;
connecting the frequencY
2. Check whether the
converter to the motor;
three-Phase winding of the
Default outPut 2. Unbalancethree-Phase
motor is normal and
phase outPut during motor
oPeration;
eliminate anY fault;
3. Seek technical suPPort
3. Drive board abnormal,
4. Seek technical
4. Module abnormal.
f- Checl$hether the motor
Parameter settings are
correct;

FrequencY The given frequencY direction 2. Check whether it is

overload;
direction and the feedback frequencY
abnormal direction are oPPosite. 3. Check whether the band
brake is disengaged;
4. Adjust the settings of

ffiing response enor of T:trect< whether the motor

oiven frequencY and motor
ie ed back f requ qlqylllgP-l
 ll r '
l

Fault
Code Z. - Check whether it is
overload,
3. Adjust the settings of
bC.03 and bC.!4
f .-- neOGe the load and
1. Whether it is overload or check motor and
whether motor rotor is mechanical conditions;
Wave limiting blocked; 2. Select ftequencY converter
failure ?. The selected frequencY with larger Power level;
converter model is small; 3. Refer to 25#
3. One default outPut Phase'
T Cnecx the circuit
connection of the brake;
2. Check the functional
Brake release See the oPerating instruction of selection of the control
failure parameter b6.08 ' board brake release
feedback inPut Point

1.---66eck1he brake circuit

connection;
2. Check the function
Band brake See the oPerating instruction of selection of the control
failure parameter b6.08 for detail' board brake feedback
inPut Point (inPut function

1. Check the PeriPheral

The frequencY converter detects
the forward and reverse runnlng
directions simultaneouslY
Running command or given
The control rod is freoueniy signal input is detected
not returned to after Power-on of the frequencY
zero converter.
circuit of the forward and
reverse running command'
?. ProPerlY increase the
terminal fi ltering duration'
1. --The normrllY oPen inPrrt
Point signal shall be
ensured of being
ineffective in the Power-on
process.
2. ilunning command shall
be inPut when the
initialization of the sYstem

Dl input function 7: effective

winch
lnstallation and adjustment of the hoisting
tower crane counter-lib,,1llt:',rO;:^:?J[r'i:
The user fixes the mechanism onto the lf 2-M16 bolts
:hfflJli,Li'ftl"rtion dimension requirements durins installation'
havebeenprovidedunoerthemotor,trrevsnarrbefixedandweldedonthecounter-jib
to adjust stabilitY of the rnotor'
wire rope to
Prior to installation, it is required to fix one end of the hoisting steel
externalwallofthesideplateofthedrumbyuseofwedgeSleeveandwireWedge.
approximate 1/10 single rope rated
tighfly tv ,r" of
Then, the steelwire rope is pulled steelwire
tt.]u 0t.,* is rotated to enable the
pulling force. When the motor is energized,
ropetowindonthedrumlayerbylayer.TheSafetycoefficientofthesteelwirerope
cannot be less than 5'
frame,
position of rope limiter installed on the
Prior to use, it is necessary to adjust its rope stopping
of the steel wire rope' and ensuring
enabling it not to hinder retraction
effect.
 I 'I

winch
Service and Maintenance of Hoisting
Lubrication, service and maintenance for automobiles to
it is required to fill GL-S heavy-duty gear oil
Prior to installation,
specified oil level (about 1BL)'
Thebearingpedestalhasbeenfullyfiltedwith#3extremepressurelithiumbase
ih" g'"ute should be inspected every
grease at aft end otlr'" oiu' ouring oetJJry'
filled through
titfrium.6St: n^t:ite can be
200 operating hours; #3 extreme pressure
the bearing pedestal as required'
grease nipple at external side of
lubricating oils (greases) in
a mixed mannerl
It is prohibited to use different

ltisrequiredtofrequentlyinspecttighteningconditionsoffastenersatindividualparts;
in time'
be fastened
in case of looseness, they should
lubricating oil level of
ltisrequiredtofrequentlyinspeclwhetherthereisoilleakage;ifany,itisrequiredto
eliminatuinu tlarage in time. it is important to inspect
repair and oil level'
and maintain corrective
the speed reducer, u"Jtil irnricating oil intime,
of parts in case of
ltisrequiredtofrequentlYinsPectwearconditionofsplinejoiningdrumshaftand
speed reducer; tn"il"tff should be shut down for replacement
eccentric wear or heavY wear'
lncaseofabnormalsoundandheatproducedduringinspection,theyshouldbe
etiminateO by shutting down
the motor'

hecontentsandperiodsofmandatorymaintenancearedescribedasfollows:
flimesof Periodor Contents
qg alLng Ji
m-e
tueuG le!g" -l__o-
i.
r'ili rubnc@
\ onu month or 250 sPecified oil level'
of
First time I hourt 2. iheck or adjust the braking torque
r-.,,Ararrlin nrrsh rod bfake'
l. iffireducerto
oil level'
sPecified
brake lining
4 months or 1500 ?. Check wear condition of the
Second time ;;i;; hYdraulic Push rod brake'and
hours on tts
change braking lining based
UUI
ilo.t,,nor
rvvvvYr' and
'
1. Empty useo oll lfl rllE DPsvu
J"in tne cavity, and refill lubricating oil
fullY' ,brake
--,-^ r:".

lining
2. Check wear condition of the
brake'.and
;;ih; hYdraulic Push based on trs
rod
Subsequent 6 months or 2500
hours change braking lining
time interval condition.
between
3. Check wear condition of spline
drum and sPeed reducer connecting

l0 7 Lubricating oil
ln?1 Lubricating oil of sPeed reducer
(G813895-1992)
(1) GL-5 heavy duty gear oilfor automobiles
Theoiltakesmineraloilorsyntheticoilasbasicoil,andextremepressureagent,
used. lt is recommended to
antioxidant,rustinhibitor,andantiwearagentandetc.B0W/90orB5W/90with use
viscosity rc.sl)+;;rr"'at 100"c ,uv"o"
8OW/90 in northern area'
 Trt

\-,
(2\lftheuserdesirestouselubricatingoilproduceony^tteforeignoilcompattttls'
the rubricat,"s ;i .i,Jo
ne ot TrXi:'
y'':{:Xrtfi""ffi3,m"""Ji?:i?:
21 05D Military
Specification: Lubric

(3)oilfillingcapacity:Filltheoiluntiltneoitindicatorpositionisfullyimmersed..
without oil being filled,
(4)ltismustconfirmedthatthe.lubricatingoilisfilled..::.p"'requirementspriorto
tr.u ,ulnin""l. u="0
that
use, and it is piohibited
grease
grease
Bearing pedestal
Pedestal ot'* has been filled with #3
, r-, ^{ +h6 rlrrrm
prior to product delivery', tn" T::::,t"i?:El-:UX;
Prior gg+).
cxtreme pressure
""",]lnl'ouj-"
lithium ;;;;;
D?sB gteao" (be
t:' zgzg-r
. - -^^r^nic,
replenishment of srease:
should be met durins
;t:ffiIili";;'""t be #3;
grease (NLGI) should
Viscosity grade of the
theperformanceindexofoilproductsshouldcomplywithGBT323.lg94.
measures
Fault causes and
the
Faults GspeA6a change
TG=teelw'rre roPe is
the
m"p?faaaanse
Tangling of ffirumis
steelwire
ropes ffit
the steelwire roPe are
ot
Contact the manufacturer

E;Aame bearing
matlng
the the
Mating surfaces of cover, clean
sealed ]ulu"", and re-aPPIY
U"unng"P"Oestal is
Oil leakage PoorlY' seQ!fl!-
Cha re the oil seaL

ffsG@?1eg
\**
\E reducer

105
 ChaPter 10 Slewing Mechanism

1 ; :]*T loti n s o i

;;i;'1il'
carri e d
t'ii'
jilz
by,
:'1u.ux"i,'l:-llxr::Tff [r[[:i ;; lil:: il;'*
slewins reducer (3)'
pinion (4) and
, rrrrent variable-spJ
(5)'
l,rtl slewing gear ring
mechanism
Drive diagram for slewing

1. EddY current motor

2. Brake
3. JH07 slewing reducer
4. Pinion
5. Big slewing gear ring

l03 Working principle -^ ^ ^,,\^t 6^+r inion

jib and
,o ,r',o"]i'ulirtne roftrns tower' hoisting
TheslewingmechanismisdrivenbyYAN1325-6,3KWmotor,andtheslewingp
reducer, the reason
is driven via JH07 srewing rignt ai ,""ii"n to"ed of 0'56r/min' For
iutt anO braking ' the
counter-.iib to ne stew-eO i;';i;; ;'ble slewing startup and
,ui"iiv
that the speed ,=
uddy current is power off
Jsl'Jutt"ithe slewin[ mechanism
uraxe is
norma,y-op"n ",""i,JI,;;,i; accurately'
*ut tn" n"iJi"g ;inch positioned
and shut down, *nni'"ri "
lll 4 Slewing limiter
1) without current co*ector,
whose purpose is
for a tower crane
H:t""" "" is used

106
 to winding of cable'
prevent it frorn being damaged due
to
)) "e
ffJ::'J* ;':;' *n"" with pe d
l: 11 "::':.: r : ffi il':i;:
s e ""?:':F' il' Xn' ffi i':''
*"-l:*-"',lJ;::;**: ffi::?'#1xi"!'{ii1};',
bv the pinion ili
tower crane ls
.ffi 'nT[!
I

ie"o'O"O after the

d riv e s *'i z'; i.
u .utn
J
",n
" ", slewtng
i

:"'""##*il J ?; ;;"*"gn:'f
[g), that corresponding
'o
motion'
3) Adiustment
. :^ carried nofl_load condition.
nr rt in nc
Manipulate <<Left slewing>>
boss
is ^^,.iarr out to determine which
The adiustment contact
uno
or <<Right slewing>>' 13*uriffi;il
is separateo tiorn
iott"sponding motion'
limiter (2SO2)
a Adjustment of right slewing position
to the lnamlry Tiji:?;t"I:i':t::Ji::i::
Prace the rotatins iib

::irli"",I'"1*lr:*,iTl"'itrlii^'fiJ6:;;;;;*i'lsac'lua'lon
contact (5) is pressed'
until the corresponding
(2SO1)
slewing limiter
b Adiustrnent of left
Rotatethejiboneandhalfturnsinclockwisedirection,andadjusttheboss
(7) is pressed'
tol u'itiiii" contact
Note:Theadjustmentmentionedabovemustbeinspectedeverydaybeforethe
,t*". crane is put into service' it is required to remove
the
^rano
Everytimethetowercraneisre.locatedtoanewpl.u""]itisrequiredtoren
pug,.'1y::*:{ili}.,,'Jx*l**}*#lif;'}::t:"{?Tffi :'"#il:'x?ii:
Put into servlce
tower crane'

g 52 Figure 52

fastening bolt
inspection of slewing gear ring
10.5 Periodic
again as needed'
tunricat'rng giuu'"
l.Attimeofslewingsupportdelivery,3#calciumbasegrease':^9,^"nu'u''yfilled.
When used, custo*"r, "rnI'il'uppltpi'""
2.Undergeneralworkingcondition,checktheboltpretighteningforceafer
107
 operatingforl00hrafterinstallation,andafterthat,checkonceevery500hrof
be kept. Every 7 years or after
operation. sumcienifr"tignt"ning force'Jatl
iroort<ing for 14000hr, replace the bolts'
installed, fill
general working condition, after'the ball type slewing support
J. Under 50hr of operation
the grease on"u ;00;; of-operation, and fill once every
"r.[
forrollertypeslewingsupport.Afterthat,checkonoeevery400hrofoperation, record' When
appropri;f"-b leep gooO fuOri"rting state, and keep
and fill as at least
places witn a ft1 of O'uri and high numiOity, ensure lubrication
used at A"toiu and after long-time stop
of
once a week according to specific "onOitiont. fill the roller path
machines, update the grease.
nt time.oituuiicating each time,
th;'J;i;g s"upport slowly, to make it filled
grease. wneniooing, rotate
with fu*
sufficientlY and uniformlY'
operatethetowercrane,andensurethebolttobeinspectedisfreefromtensile
load and counterweight'
force under influence of the
pre-tightening torque
torque wrench or torque multiplier wrench to inspect
Use a
table if necessary'
p*in"',orque values specified in following torque of
". time: During inspection, pre-tightening
Replace the bolt from time to listed in the
bolts may exceed maxi,rium or minimum value
one or several
followingtable,sotheseboltsmustbereplacedunderthiscircumstance'
Replacetheboltsonaregularbasis:Theboltsusedintheslewinggearring
years'
t every seven
I
assemnty must be replaced
Re-tighteningofthebolts:Theboltsmustbetightenedtoratedtorquevalue
the bolts are
after the tower crane is operatedlor seveial weeks where
again
replacedorslewinggearringis,e-assembled(normallybyuseofnewbolts).
the thread and nut
required to apoly grease on
when tightening the tofts, it is bolts.syrnmetricaiiy for sr"reral
wrench to tignten'the
end face, and use a torque for the last tirne'
uno ,uiln tightening the bolts
times in circumferentiat oirection, conform to
pre_tightening ,o,Or"'li"""i O"ii
,.oufJ n" ,ipro"irltely equal, and
specified value in the table'
Grade a.a gotts
ffito.o eoI
inq-Torque (N.m

lll (i Maintenance of slewing mechanism

oTheslewingreducershouldbefilledwith#3calciumbasegrease,andthe
year;
grease should be replaced every
-
oTheslewingsupportshouldbefilledwith#3calciumbasegrease'andthe
hours'
operating
gr"u.e snoutO be filled every 100

Thebigslewinggearringsurfacecanbeappliedwith#3calciumbaselubricatingoil.

108
 \\

Mechanism
GhaPter 11 TrolleY
ntroduction
lntroduction the load-bearing
trolley' and I motor
' -:-a ;;'fi* :?:ti[",r1i
ic a n...,wer unit of
is a Rower 111t11'lli''fi via
;.""-,*
rhe trollev travelins '":h?lltTlt"T":-:::,ives
lJ::ll?Y.'"chanism
+xw is aoon111tff iiH#itr the drum
J?.:'i[",,1i
,Hll'lfiI:1';)d!.{{:l**i:::H:;:;liiill{fu;::[i;J,T;'r"ffi
r;"r;;;t?,
YEJ11Zlvt-+! +r\YY H:Iil6]; load-bearing [
trottev to
u",,", '" be t
1- r
j-onto
--.^ the load-bearing
+!.6 ,nacr-bea.ns
#;'-oiu"u,, thus to:"3:nt::^':l?-il"
l-ena'fe the putt rope are trxe , ^., r-,6arino trolley is
inq trosey rs

ffi il,f ifxlJH":"d:i:',!.:]1;i:,']:':];,",n;?:["Ji::*:',::"::'51':

il;;n; steer
Steer wire
wtrs
through'respectivet '"buring
i,:;:: ::,.il:,"Jo"J'on '':1.,1"-
:,8",,f travel, normal operarlorr
road-beartng
'"",oium
of the drum is
provided
provt with a
ffi;
trolley, respectiv-ely^rl*
steetwire iloJl5n"
^{ +ha creer*,ru
.t",nl ,op". On" end
"no
tluaranteed bY retrac
iravel limit switch'
Working PrinciPle

1. Motor
2. Worm reducer
3. Drum
4. Travel
"T;Jr: of Troltey Travelins
Mechanism
of Drive system

limiter
r1.3 TrolleY traveling
1) usage the trolley to stop
.. ,:-i+^r nan nr€Veflt misoperation, enabling
pr3J;ii*ltio
limiter or jib root'
The trollev traveling "?"
the bumP
it touches
motion before
2) Working PrinciPle
is provided,in the
trollev travelins jlrth:'&||:li"xtt"$:::
A speed reducer
,n" g,:T
:["J,tl,i,i.ll"l,IffX;:ii" .pTi reducer
the sear n"n'il;;J;,lo (2) to stop
recorded,nun to tnJ microswitch
be known Ur".O-on are applied
bosses (1) whict
drives several I;
motion'
co"esPonding
is
3) Adjustment and safety device: The trolley
. --r +.a,arinn so€€d reduction
traveling sP
Adjust the outward
109
 rl

end' and
5m aWay from rubber block at the iib
place where it is contact (4)'
travelred to the *"Jto""o"lJ
untir it presses ''"tot*itch to
the boss (3) is turnei lower boss should be aligned
the upper and
adiustment'
Key point: During t;duction before braking'
prevent interruptron ;";;
until it
L"o the bosl (5) is turnedalloweo
Adiusttheoutwardtravelinglimiter:TtretrolleYistravelledlotheplacewhereitis
the
20bmm away from
,,iL,i'".k at iin
""1
iui. nt this moment'
it is not
oresses "ontl""t
"orr"roonJ,:ffi;;;ircn
ioadiusttheboss(3)' , ^!:^^ -^r{ .afetv device and inward

i3[T"I"-i5rti:El:[3;:i::J:i[:iTi[iq:j:;'?i""*nere'l.1
il ;; ;v'," i'Tl):J;# $:i[T
33 fi H rJ'W:: i: tffi
;

,nt,r n piu""t microsvitch :"^1t1":^t?l':ffiil;;"ss (9)

(g) is turned
,n"'i'*ni;;;";"
until
J:
it presses Iti
it is 0.2m u*uy tro,l.,"i..,"l,i',*,. r"0
the
put into service, it is required to check
crrne is
m::;"il::i"r
:J"-,ff];:ffi :,,1#!,=::r*":,:"-i,T:,iii,"?il-::t"Ji"'l:j:Ji'
tt" must be removed
to
prrs ut ro:;l"r"o'n "t
is put into li*,*linl
crane ']T]:t
drainaccum,r,tuo-*,t",'o,iingu,".o|nJ*nofthetowercrane,theplugmust
ll
be installed'
I

10

Lfi

rt1

mechanism
and seryice of trolley traveling
il4 Maintenance
1)Thespeedreduceroftrotleyl3chanismshouldbefilledwithZL'3lithiumbase
regu arv based

I trJ[ili*ffi*t;;ll'r
on operating i'"qu"n"v
of the
ill]r1"J'i ,= nspec'ied
o"n"'*i*in t"*i"" riiu'*u' The adjustment

3)
3, l* : i: :i[:,!"-y,.*^" J:ffi.:": :l i,H"lil' li',il ii,.i,ii.-ll
prope
$i#
.v bv
rope'is not
Hl":i*ii""mgx*nlJ:r:xf iJill'!i"il"o""'uo''"'ted
rt tne steetwire
open g:?r
use of uu+
",i.lo 'roJi*i5ti)iz-asl
used ror,,".n o*il.,lt**r:',,;;'i:S
wire roPe' tt ts
.x{y" i*l; ::X;:':J::}'H:::
r"Pfuting the steel
-12-1870'
*iir' ceiro ?-7435x7

110
I
GhaPter 12 SafetY Device
travellins
include.hoist:-n-T'nnt limiters''loa9 T'*"nt limiters'
f,;[T:r'ces mainlv as following figure:
,rJring limiters. rr," *o"rnting position is shown
rroiley rimiters ano
' Weight limiter
',c.gLr lmirer Yotat ^.f-

SlNing limiter ,Traveling limiter

and lifting
trolley traveling limiter
Thesafetydeviceisanon-operatingdevice,whichisspecificallvusedtoprevent
into *"
nu oiuiied
mis-operation, and "un "'*n"ties:
weight limiter'
as follows:
be adjusted in the order
Lifting weight limiter shall
lifting weight limiter
speed timiter--Maximum
Moment limiter--High
1) Traveling limiter
A' Hoisting limiter
B. Slewing limiter
C' TrolleY traveling limiter

2) Lifting weight limiter

D. Moment limiter
limiter
limiter and high sPeed
E. Maximum lifting weight
limiter
List for Adjustment of Moment
-Xa1g7o(kg) X-10% (ks) W(ko) L1(ml L2(m)
Lf(m) Y/Irn\ 14.13 16.17
900 6000
1 UUU 1100 15.U6 16.59
5B 990 6000
11 00 121\) 15.6 17.16
56 T5G 6000
1450 1595 16.08 17.69
50 lc/c 6000
1750 1925 16.11 17 72
45 845
40 2050 2255 1
16.16 17.78
2655 6000
30 2950 3245
Lifting Weight L imiter
;r,"rAdjustment of Maximum

111
--! l

v(KgI---- z(kg)
w(ks) X(kq) 5400
//t n\ AAOo
v \^v, 6000
3000 3300

Torque Limiter
Application 'num load torque' During
};:X or the torque
rhe tower crane is carcurated '::o'11s.
maxtmutlffffilo
exceeding
;"ff[:;ffi|..,}il*e
,oo'Jrt,"", do not allow anOir"aueting rated
p,"u"ni overload'
load' to pret
timiter is to check tnt'i"itti"g
ltt2 Working Principle ..,i, in.roAse the elastic deformation
;";r r'dother
::ff;"H ;U',:;:,'::::3 ru3!i:':iiii'"i:i:
to achieve the purpose'lt'ouu'-torque
limitation
"no
'irsser 'ihe
control

microswitch,
functions' rr^mrwerd€d
Adiustrng
$t9(

A_A Lead sealrng

hole

Lead *aling
hole

e
Moment limiter

112
I 1'"\

I limiter
Adiustment of moment
moment limiter
ROiustment of hoisting to be traveled- to
Enable the trolley
ffi; n"ro, und hoi"t the spe-cif'red
two to?u: ll
i;;i iat rated sPeed bY
device
ffi;'Ji iin r"ngth (adjusting
A)

hoist a load
Lower the load' and
io- Y=x+Xx1o% at
lowest
il;i
II:il ; ::: :l,yo"
hoisting motion snc
#111;,J
;;;;i'" it should be adjusted

again.

moment limiter il
lt'.t.2 Adiustment of traveling and rrla'k ihe
Measure the distance'
effective travel
(L1) and travel
the sround when
ii=L.irx1o%.on load (W)'
hoisting the maxtmum
load
Hoist the maximum P"
and *o1l"':1u
.r.o""olo in the air)'
travel (L1)
hook to the "tf""iiu"
device B)'
(Ad.iusting
* Return the trolley
to the .iib root' and
outward at' rated
change the travel
I

should be stopped
speed;tne tra'eiing"
I

before reacning tne be adjusted

mark (12);
'
otherwise, is should
it
again'

amons individuar iib

12.3.3
:'''11il :lffi:'[]iff
J,
':d:,i''n" T3.1ry:*':i'"'
u"r",,"n ,.iLv i. 'yt:lf;t';1y.::1ffi"i;rflr;
combination. r", when
fiom high' speed operation
"*u*pr;,
low speed
";;il;
j:inii'r'ffi :'"?H,i.'r:::i'.i'"n".
l,)
"\.4
,,rj:i"ii*.:*,li**i-:"*
in case of reaching
safety control system of tower Grane
12.4 lntegrated
113
 t"\

Working PrinciPle
same time'
ltsworkingprincipleisasfollows:weightofloadhoistedbythetowercraneisappliotl
steel wirc .p";';;th" [TTffiH]""""",T:""1J:
io rhe pin sensor throush
relays and
tir""norJ u'f'"t' lrrus to J..iuu t"iut"d
:,;i,,#;il}:i"*[11""::I{{i?::;::]iT;Hi,.Ix1;;;.bvab.vesens'rs
*'in'pi"-""t
11;";;;i "l1lil,|;il,ilt,:i:Xff :::
wi* be compared i
acnieve weisht, ?u"1
resoectivery pre-warnrng
traveling) control'
*tigtti and moment 90%
a nd'u': n"'f
nI nuoi"u'J' *" *nt 50% l]ll;
d eceleratio
"o -ll
ForversionwithJiuheHoistingWinch,thesystemcanprovideweight6tandmoment Ind moment 90%
hoistilng uno,i'J"liing; ani weigni 5t, 4t and 3t
"ont|.o'' '*relnnt
100% alarm tin"r'Jing u"o o"J"r";;", control,
pre-warning tin"r,oi.]g,t,uu"r,ng
control.
lnstallation of Pin sensor
ano outgoing rope of
Wheninstalling,pleasebesurethatthecenterlineoJ]::'y"oanglesbetweenlateral
two steet*li" ropu,
(in"oming
arrow on the pin J;;;r;;J ',ope
in the following figure:
u'u O"]"utfy the same' as shown
the pulley)

of
Direction under stress

fl

Tower Crane
Pin Roll of TCT5512
lnstallation Drawing of

114
l lnstallation of Pulling
tt:" ="*

above' il'#':i::T llil?;i$i ""

As shown
* Jil; * li''',,1115":::':fl IT lT;e
;t u'i' :i:l
i"
-H"fi
me nt se ns r o
o
" ""'
oo

"
I' k'ih n c

:'#il' HTi;1ii
mo
"
Tt i:T*: =""s:*
side screw rods' as
shown :ffiy
above'
moment'"n=o' on the gl th" tower crane (or at on
the
sensor assembly
2. lnsta* the above moment rod is tightened
po=itilnJ. one side screw nut at least' The
original ,""n-J""i
moment with one
the fixed enas ot the tower.
side
"r"ri]l"l'-""it*t,
is ,"=Lit"O'"iin" ii*". ends but not tightened'
shown
screw ,oO o,rit,"
other
kept under
;itfto't forces applied' As i

a,owing tnem io be "X;"'til I

in the figure:
it
ffi;*" il installed on each end
I

of Moment Sensor
lnstallation Drawing

withcomp,*".'1"''ll'"';iii{lt':'"nff "Ti;#;,:"r::i:1''#ill;
I;'ff :I'J:["i:"['t"lil*gii::',Hl*'ti::i=iiil]ilit
3.

oisptaved bv ul9:i':il"",r]',t '0"'*lr""o' After the nut is

ir**iitir':";:;ri*.!i*xuf
il'"';;;"i is nut iT,*ii::"ff$:ffi;il:irl;
I ;lil"" J iil ;the
:;J;;it,;ing i":i9ll":,"Llll'"Ji""ok. ; momentnt va e sharrI ransee
varue
mome I u sha I ra n s

;,;Xf: i' lff "H:';J,',el,i:T

115
1

following figure:
from 550 to 580' As shown in the
ffi ,;;; ;,;;"' jis ?^tlTj:
c ra n e h as b een
p":11 t:.
:t
tt
i" 3T;,:t :l
::ffi'il''u'iii'ilin"'""n=or roosened' incapabre
" or
HH"tT:ff -- 1^ re-aoiust
-^ ^.tirre{ +ha rockins nut bv
the loekino bV
1,"'"".il,,1it ;::i:::, i".,,i,'n.'";:;;!"*1o
slo to s8o.lna, it should be re'calibrated'

fOfusting Switch of
Tower Crane's
Number of RoPes

iiEcatron of Tower
Crane's Number of
RoPes

Parameters DisPlaY on LCD

lnstallation of wind velocity sensor

ThewindvelocitySensormount(optional)isweldedonjletowerCranejiborthecab
is bolted *ld'd
roof. rhe wind velocitv sensor *Tt-*,Ii:iJ:t:i:'-:;'J;:::X'"
in the ro,owins risure:
;"""1J?:y#':ffi:'il:ffi;#; il; s;";;i:1".'no*n

of Wind Velocity Sensor

Figure 7 Example for lnstallation

4. lnstallation of LCD
MounttheLCDatpositiontofacilitatetheobservationbythetowercranedriver, driver'
not affect sight of the tower crane
based on the prin"ipi" ir,rt it does
lnstallation of main unit
Themainunitisjustdirectlyinstalledontheguiderailinsidetheelectrical
wiring is
disturbance ,our""r. The electrical
cabinet and away fiom strong
7:
installed as shown in Figure
(Thedisturbancesourcesmainlyincludeinverter,walkie-talkie,high.power
contactor, etc.)

116
 EE %nwhite
EoEffi
Black White Green Reo
Black
s$ld
J L Moment Sensor J L wJign-t s"n'o'

0[0
weisht Moment 1?11:n Reset
51s1uj
#ilXii""
"I"ffi,[.

o ;mffiffi* {i ld
Nanning Ketuo Automatic Equipment
Co" Ltd t-

90% 1oo7o- ..,^,10^?,"*^- f DisPlaY ;

tf,,r#ilntft"'"""nl[*".!|{""].!*:'oil

Drawing (ordinary Hoisting winch)

Figure Ba Erectricar rnstailation
Terminalsarrangementofordinaryhoistingwinch:
(1)TheTerminalsl2-l5ontheupperrowareforihepinrollsensul...j\ttheti,i"'eof
installation,thecablesofthepinrollSensorareconnectedtotheTerminals
be noted that the
1z-lsaccording to the color on tnJ main panel. tt sh-ould
i" s.hielded one which shall
cable with btaik thermat snrinkale ""rALi, !.h? with the black cable'
is paralteled
be connected to Terminal ts, rnii"-, it
(2)TheTerminalsB-llontheupperrowareforthemomentSensor'Atthetimeof
installation,thecablesofthemomentSensorareconnectedtotheTerminals
B-llaccordingtothecoloronthe*uinp,n"t.And,thesilvershieldedcablewill
be removed or not connected'
(3)TheTerminals5-Tontheupperrowareforthewindvelocitysensor.Atthetime
ofinstallation,thecablesofthewindvelocitysensorareConnectedtothe
main panel'
$ Terminals S-i accorOing to the color on the

(4)TheTerminals3and4ontheUpperrowareforthe4sv(Ac)operationalpower
supplyinput,whichshouldneapptieowithvoltageasindicated'Thevoltage
voltage.of operational power supply
rli"
input range. trom 4gv -2t%-*toii
canbecustomizedaccordingtomanufacture/srequirements).
(5)TheTerminalsland2ontheupperrowarefortheelectricbetlswitch(No
contact).Whenthetoadormomentreachesuptog0%o,theinternalcontact
is closed.
(6)TheTerminalsl3-l5onthelowerrowarefortheLCD,connectedwithblue'
in turn'
left to right
brown, and yellow wire from
(7)TheTerminalsl-l2onthelowerrowareforthecontrolrelays.TheTerminalsll
(connected to the hoisting control);
the
and 12 are for moment, weight
nv-ioi"Z'

117
-l Y'T

go"i ito the trotley travelins speed limit);

Terminalsgandl0formomentbyl00%(forcontrolofluffingvariablelength);
the Terminats 7 ana i'f;;;;;",.lig
uv
6 are respectively
i"rr"i"rf. unOZ'uniierminats 5 and
the Terminals 1 and Z,
under the condition of
for speed limit of *"'nit ;;*" i'io-83%' contacts
but tfl" Jot*toi terminals are NC
energization ";;";;";fuading,
with-caPacitY of 250V/3
A'

Black
Black White Green il-"0 R"O Green White
IJ a"o Blue White J \ weight sensor
Shield
a
I Etectric'1 L I wino velocity I L Moment Sensor
bell Sensor
BU
Weight Moment
[\
{9frins n"it
Calibration Calibration Status
Calibraction lnstruction
SkiP
the Calibraction and OK Moment
1. Simultaneously press
E Units
DigiUTens' i"[T*5"fl \1ll'",1'i.'"""ilf "?J'o.3l'in"*"'nn'
starts
Calibra
tion
Sensor Wiring
Zone

calibration
Dioit middle is on, the momenl
3. When green light in tne
starts
tr Tenths'
DigiUUnits
Dioil
calibration
4. When Yellow light in the
alarm threshold setting
m,iddle is on, the wind
stans
velocity OK

Equipment Co" Ltd

Nanning Ketuo Automatic
'100% DisPlaY 1
90%
travelins
100%
f
Blue Brown Yellow
4{on s-ton 'l ft"udins 1 f lweishllom 1
f , ,
.9-

Winch)
Drawing (Jiuhe Hoisting
Figure Bb Electrical lnstallation
hoisting winch:
for special main unit of Jiuhe
Terminals arrangement
(1)TheTermina|s12-15ontheupperrowareforthepinrollsensor.Atthetimeof to the Terminals
of the pin.roll sensor are connected
the cables be noted that the
on tnJ *rin prn"r. ft shoutd
installation,
12-15r""orolng-lJ'in" "oro, i",r,alnis the shietded one which shatt
cabte witn oiaix ih.rmat
to Terminal
"n1rli"
ts, tnast i;,"i'lt'p"i"n"ted
with the htack cable'
be
connected
(2\TheTerminalsB-llontheupperrowareforthemomentSensor.Atthetimeof
installation,thecablesofthemomentSensorareconnectedtotheTerminals cable will
pun"r And, the silver shielded
to the color on tne mlin
B-11 according
be removed or not connected'
(3)TheTerminals5-TontheupPe|rowareforthewindvelocitysensor'Atthetirne
ofinstallation'thecablesofthewindvelocitysensoraieconnectedtothe
on the main panel'
Terminals S-i accorOing to the color

(4)TheTerminals3and4ontheupperrowareforthe4sv(Ac)operationalpower
power supply
uon,ge of operational
.supptyinput'-wnichshourld.U"-uppfi"Owithvoltageasindicated'Thevoltage
-20%-+10f,;"'tli.
input range"'tr"*Jgv
can be customized)'
(4)TheTerminalsland2are,formomentbyg0%andweightpre.warningelectric
bell'

118
-l
(5) TheTerminalsl3-lsonthelowerrowarefortheLCD,connectedwithblue,
right in turn'
left to
brown, and yellow wire from
(6)
*'" n"''ting controri in" rlt"als'9 and 10 forfor105%
TheTerminalsllandl|onthelowerrowarefor6tonload^and105%moment
90%
control (connected 7 and B
,ne Terminals
moment control (t" '"
l;;;;";riunrJr"ngtn "i^it"rl' Terminals 5 and 6 for
S-ton
contror (to trorey travering 1 and2tor
moment "p."iri.itJ;'iheirmit;the'rerminals
4i;';#i
speed rimit;the r;;;i; C ano +ior
b-ut not overloading'
the
condition
3-ton speed limit; ,nJuiil".l" "i'"nogirutionv/3 A' Electric bell contact
contacts *ith
controt terminals
"r;'NC ";p;;iiv"t'iiso
is NO.
panel
t/ 45 DescriPtion of main

f,r,jl"" "T,",#;l:n [ffi n"="t

q
r
Units' 1.
Units
Simultaneouslv press the
;rJil,ffi;;;;ier
Calibractionand OK
into tne calibration sratus
is on' the weight
o
EI
o
^'rchhrrtlonsto"ni"tintothecalibrationtt?t'?-^ ..,^,^.,
Digitrrens' ). wnen gr"Jn"'igni'"ri"ir" r"tt calibrati
Dioit calibration starts. moment
rho moment on
in the middle is on' the

6
3. when n'""X
Tenths' calibration starts "nnt
DioiUUnits' a. wnen yettoiiiight
"'';;;;'*
in the middle is on' the
alarm ti'reshold 3etting
starls'
velocitv
.,in.t velocity
wind
OK
o
Automatic Equipment Co''
Ltd
Nanning Ketuo

e0% f 1007o_ ^1??,"1^-

Ifd;ilrtf ",""',"rt[ffi '''o''1..,1

(Ordinary Hoisting Winch)

Figure 1a Panelsketch

119
I

) l(, l? lY IY;JY; rH; I

#r "" o UPPer
Terminal

I ;;',
Block
serscr _
;n 0 E\=-
lr1- ---"^m'"Yf#5li^1"'$#Reset-
llJ-ffii,:iri.ni:fr"ir*:":":: -::,
Oiglfi"nt' i:"iv";;; green light at the ler
Dioit calibration tt"f
rs urr' rrrv "- J
tion
the moment

t in the middle is on,

llgrr(
3 When green ,tnn,
Tenths' calibration ttu'llion' the middle is on' the wind velocity
Disiuunits'
in
AV

i#il,l.iXi,'r'un,"g'lon'
N'nningK;iuoou'o*'ticEquipmentCo''Ltd
100% ? DisPlaY 1
90%
travelins 6-ton Slue Brown Yellow
s'ton @dine 1f 1
+-ton lrf 1 ,
3{on l f , ,

Hoisting Winch)
1b Main Panel Sketch (Only for Jiuhe
Figure
one is the units' digit
1'TheleftDlPswitchis{orweightcalibrationandwindvelocitythresholdsetting.
tne 'ooli
During r"r=ergnt calibration' ="'n'l'"?'"* digit
lio
(0. ,),';;;;
''il" ;rnd velocitv threshold
on" i.,tr.*'tJnin.' is the units'digit
tr.ot ano-iil"',o*", one is,h"i;d;giitiojuno til'.i,"' one
setting. Tr..,u,pp"t.
(1 0)

z on the upper PT :" :::: ::;,':ffi

weisht'ca'lltftil:""''"#;;;i
ifi.,i;:ll ::i
,Iff ,':i*#:l-i"i:: ffi f
tne inorcaior lisht of tne status this machine
of

["JxH."'"t.*;*:,:r-::lf .[i!lllT: '';""'"rn":r1:""'mainv

woixins status]'*"[nilalibration';;;"";i
calibration' and wind
incluoe toi
velocity calibration' r^- Dacor skin catibration' and oK
in turn from
-
are for Reset' Skip'
3' The right four pushbuttons
the toP'
for operation of main unit
12.4.6- Description
1' Self'check status
pin roll' moment, and wind
Afterthernainunitisenergized'itl:"'t:::"^:tintoself-checkslatustocheck
including ,un,J|-. for
i, no,.,i
s*ffi
,
whether the system
*"1'l' r: ]rril# [Hil;iHx
," o"iiv"- l1:# [lli
x""p inu relav contact "P-":"-1'^'1:::":""i'H;' ; il; svstem is abnormal'
the

[:,:i}"ilJi:['T*[ffi,*"^1*1ryil:;:J'"lTi'i'?':'ii':io3sanden'ler
intotf,eworkingstatus.il;'"''';;anJauOiOtJufu*tindicateasfollowing:
(1)lfthegreenindicatortightofy"]91..,",.'brationflickersandthebuzzer
thl pushbutton is faulty'
beeps for three ti;;'
120
 beeps
nickers
rrg:tr:I,:::t$,:3';:5u" '"0:n"
tf the red indicator
(2)
three tirnes' the
ptn lotr svt ''"'. '-.', :'-er
and the buzzer beeps
for -;,^^ *i.kers
frickers
""'::"
(3) rf the green,.r,T1"*r*:l,g::::[ rrv'. t"j[:
for three times'
the momet tt rsr ,' -'.- fli^kors the buzzer beeps
flickers and the
light of threshold ?fttinO velocitv sensor
lf the red indicator se"n'o' o' the wind
(4)
for three tirnes'
*";"'l' ;;;';J vetocity

is faultY'

working status complete the self-check within

2.
the svstem may
L^.., ^^ rhp ., *t:?Tl:1il"
beeping
main unit is switched on' the *"lni^n sstatus after
working
After the enter into
5s as a maximal' ";il;i;;atrcarrv
once'
Undernormaloperation,therearethreeworkingstatusesincludingNormal,
tight is tit on
the sre:t indicator version rs
'-;#,::'i:;'::::i:"0'.o??!::1,and )"ni a the open-circuft
tilni
The internat"ortltiti"li't "'iua
indicator
circuit oPened)' interval"anl'!" yellow
or::''ong
buzzerbeeps
Pre'warning: The tnJ'ii'nn't bett is closed'
tisht fticke"' ne:;;;;; '"iv
version ts
ii or the open-circuft
Ararm:Thebuzzerbeepsbriefry.andtheredindicato-rtightflickers'The
t "i'v
internat controt'i!.,ii',i-"i.*i
'"iriuit
closed)' . wind velocity exceeding
:-r^ +h6 ar2rm status include:(1)
;I';";i;i"J"ffi
H;:::';ff ilIil:luJ[efu "ffi ,'::;,?"nTfi :'.;r
t

H,H "Hi::'i : i[1[

q;U; llt i ;','ffi i [;1, mot
rated weisht;(3)
[ ;]] lg "
;ffiu
threshold;(21'"#i"t!'in'nrooY"
moment threshotd'
into tne ore-war1.19
rhe conditions enterins momenl; i,lXtl'r[.i]',X:,ll",T:::ii':"-n"
weight less than
90o/o
than 90% 'ut"j'*ligni'(2) ,,u,ut include:(1)

tlt*;rlx'-:"#:?;::"'il'Tt;vo*;;"ithreshord
rerav olll" 1?'1l"iil:J?ffill,tiltff:
or the svstem:rhe
workins process
jtf;;i;r'iiF'nc"uno'ln".q]'"n
lJffi "11=j[#ixh1a;1:lli' t j"
n d ic r r,t
ato r
r,', Jn",-
i g
" " ""
wvil
T
t*l:'ll :t,i ; 3;#: *it ;:ml,T.:Y'J'$"[ i{ the
rn"-u"iirelay is closed
i

50%. The trolleY

,n,. 6"0"i'.,"-"[*o l"^':
'ir".r,nr"
n iffi;'"]
greater
moment",*.ll,ii',.il;;iy::*i,f"T:,il'";*:*:lf Jg,J",'.i'"-,,..iS':
retav is
and variabr.-ninin ,r66v" "?"":.:.'tj::I#ffi'
io'tr'" J";;; oxrorr-controt
ini
the etectric bett
'oi
recrosed o "i,'!'J"'fi'lJii'i;;"i;;;
relaYs is -i'n
'"i""11"^
other
revet
-"o"r*tis
'nu the same as it' programs are as
.. ..,:^^h
hoisting winch' the
ooerating
op
with Jiuhe
For the
""ton
following: :^ ^,aarotthan 3 tons. Then, the
,-a
buzzer

ont";'n;;
The3-tonrerayisopened,l_T:-*"'nntissreatertn';.',;,;;;;tosedif,theweisht
indicator light flickers tnan 4 tons;
beeps on"t''lio'inl'g'""n
';greater
lr;:"T'T['[""il::',J'iin""*"ign'issrea'ier
i::i::J:ii,3j3T,l'Tiliiff
121
 traveling speed limit relay is
than 5 tons; reclosed if less than 5 tons. The trolley
opened if the rnoment is greater than 90%; reclosed
if less than 90%' The
is greater than 90%; opened if
electric bell relay is closed if the moment or weight
traveling relay are
less than g0%. The 6ton weight relay and 100% trolley
openediftheweightisgreaterthan6tonsorthemomentisgreaterthanl00%;
both closed if less than 100%;
3. Status of calibration
pressed for 2 to 3 seconds and
The Calibrate and oK buttons are simultaneously
calibration is lit on' showing
then released. The left green indicator light of weight
that the system is under the calibration status
when the
(1) After the green indicator light of weight calibration is litonontheandhook' press
tower crane is under the condition that there is no load
theoKkey.Thiscranerecordstheweightoftheno-loadhookandthe
zero-moment value. Then, it will automatically be
transferred to the weight
calibrationstatus(theyellowindicatorlightofweightcalibrationisliton).
the weight
(2) under condition of weight calibration, the indicator light of
interval, as a result' the
calibration flickers and the buzzer beeps at long
systemprornptstheoperatorthatitisnotallowedtobeweightcalibration
applied on the single
because of too low weight for calibration if the force
rope is less than 0.2 tons; the indicator light of the weight calibration is
applied on the single
stably lit on and the buzzer stops beeping if the force
ropeisgreaterthan0.2tons.Aftertheweightisstablehung'presstheoK
enter into the weight
key. The machine will record the current weight and
adjustmentstatus(theredindicatorlightoftheweightcalibrationisliton),
light of weight
(3) Under the weight adjustment status (the red indicator
digit (0'1) of the left
calibration is lit on), the units' di.qit (1 .0) and the tenths'
DIP switch is adjusted so that the values are identical
with the rorces
the oK key ls
applied on the single rope of the steel wire rope' Finally,
pressedtofinishthecalibrationprocess.Forexample,iftheweightisl,6
the load applied on a
tons and the tower crane is under the 4-rope status,
DIP switch (units'digit)
single rope is 1.614=O.4tons. Adjust the left upper
by0andlowerDlPswitch(tenths'digit)by4,indicatingby0'4tons.lfthe
on a single rope
tower crane is provided with 2 ropes, the the load applied
(units' digit) by 0 and
is 1.6/2=0.8 tons. Adjust the left upper DIP switch
tower DtP switch (tenihs' digit) by B, indicating by 0.8
tons' lt is suggested
applied
that the weight calibration should be performed if the forces
Thus, the calibration accuracy
on a single iope is greater than 1 ton.
may be increased for the tower crane. ln order to save
the calibration
weight
time, it is suggested that, before the weight calibration, the
heavier tnan i ton should be properly prepared in advance. The

no.loadhookandweightcalibrationmaybeseparatelyperformed.lf
press the Skip
one or all calibrations will not be performed, you may
keytoskipthisprocess.However,itisthebestpracticethatthe
no-loadhookcalibrationshouldbeenperformedbeforeweight
calibration'
(4) Moment calibration: After the weight calibration is
finished, the system will
be automatically transferred to the moment calibration status' Now' the
central green indicator light of momenvwind velocity
is lit on of flickers' lf
the
the green indicator light flickers and the buzzer beeps intermittently'
operatorispromptedthatthemomentduetotheloadistoolow,theoK

122
 t'

keyisnotactive'Now''theweight*uV?3liftedandthetravelingtrolleyis
press
c""ntrJi|,-u* inoi",tor lioht stops flickering,
movedbytheamptituoe-cl"L'p""ol"gtoil''itload'Waitfor5s
"trtu
approximitely after
tne indicator light
the oK key to finish
the *""'*' calibration' tf
""nttal
ataim threshold may
be done'
become red,the setting ";|il;';jJ"t.city
is 1 0
tn* i'ino velocity threshold
(5)AdjusttheupperleftDllswitchbyl(tens,digit)andthelower,DlPby0
,snowing
jigit), that ;ffi ;ii ,"no 1t
(unitli
alarm'
;i;; othe' values e'g' 12 m/s for
mls.}inatty,presstheoKffi'tofrnisntni"p."",..Alternatively,thewind
velocity alarm thresnold
is

lfoneorallcalibrationswillnotbeperformed,youmaypresstheSkipkey
to skiP this Process'
measurins pu'ev
^'| -r:1i:o:^"''ihe forcesapplied on the pin
;,""";|;:il1,i:.[:::'::fi e ;F:':::" .,"u'u'"
witn t'at of tne.nolrinut
tot""
direction identical
shall have a cot.,u"ttv
the load and the
i*p;$i;'to
roll. otherwise, it is reduced'
toaO-carryingcapacity is
a single rope
the force applied on
2'Thesystemdetectstheforceappliedon'a.si1o]eropeofthesteelwirerope.
operat'o, J'i"ii"''"'late
tne
During catifration, crane'
the ropes on the tower
'""o'o'ni'io;;;;'*tJof tishtenins nut)
+zo' inoi"teo witn
3.Withmomentsensorproperlyinstatledand-underno.loadstatus,thedisplay
,.ungl;ls l,."[
shall show the moment ^Joi"
is normally opened.
;;;";tact Jt the interialllr,v
4,Forthesystem,theinternal.,"Lyi,designed*]:l,capacityof250V(3A).When
the system is deenergiz"d,

tl4.8 Technical data: (suh;ject to

+'r^':e 'ialrre indicated
-2'o/r-.+10% or 4BV -20%-+1iJ%
Vortage input: 220V
main unit)
on thl label of the
exceeding 6W
Power inPut: Not
rope), optional
of road rimit: 0 to 25.5 tons (singre
Range rope)
0'2 to 9'9 tons (single
Range of weight calibration:
Less than 5%
Load error of measurement:
-40-+85'C
OPerating temPerature:

123
I
Electrical Gircuit Diagram
Weight
Yellow Brown Blue Moment Travel l-ravel

30o/, 25o/o .t050h

gOp/o
105.o/o

MCU
Signal microProcessor
DC12V DC5V

White Red AC48V/220v

arlcr wnrite 8,u.n tto Bllck Wnite Green Red Blue

of System
Circuit Diagram of Main Unit

t2 4.10 Troubleshooting
Fmachine is @electronic
"oe kePt awaY from sPark'
How is the crane devices, which shall
high-frequencY Jisturbance,
inverter, high-Power
installed?
contactor, etc'
are Provided under
uti,t^
the plasti c stri p-shape J
pf
"o'"' Use ln ln"r'1fl:::::
a rlat-ended
Are there i:; ':XH oi","nJ""'n 'nit' l-'-tl'
pushbutton on this screwd rive r to g htly re T.ou.u lh " ?
I i
: :"::l^*::",t;
to
machine? iff,ilftrv ,"potj"' rheir functions are referred
c)' with
How can I determine noJold hook, the o'uzier beeps J:t-:T.,"-i,^:I:." flickers'
whether the main ;;;;;"J the indicator light sYnchronouslv
lt shows that
unit normallY Hi""ivliir" gii"n-inoi"utoi tisni is.l'rt on'
oPerates? inu'nuin@ g to the
instructions or to wirinilnstructions ?"^il"l::"],,:i
How is the main unit iil:";"#';*: [;;;i; ;; noted that the main unit
a maximum capacity of
connected? internal relay is Oesig;eO with the control
250 VAC 3A. NevJr-Jirectly connect
switch to the 380 V' triggering
are so
WhY is the unintentionally, all tne pusfrUuttons pressed!::l1T:
for 2 s
pushbutton not ili1".'Ji)ffi'oJr"i,"u''fter thev are
active? and then release4' tl:
Why is the moment
(1 ) rhe momenl..u*?111i*:T,"":"^:, H
unit. The moment sensor should
be
main
not active? ;;;;""1;;
124
 Solutions
Frroblems

';-:3tti"t#'@
tio* +so to azo'

Whv does the

Calibraie Pushbutton
tne
fail to enter into
r
calibration status

WhY does the

when
buzzer beeP
the OK keY ts
oressed during
calibration of no-loao
hook?

WhY does the ,B

buzzer beeP wnen giql];q$f ;ffi "*ri;;
the moment ^
threshold is setting'l
'i+
".r,,*=,,, *.[i H
t'oll"Y'=T!'u"m
truruling
iiii
WhY does the
buzzer beeP wnen
the wind velocttY ^
threshold is setttng
t
t*r*+*t[t$s$ary
DIP swtrut"- ""'---nnr' a,g', (',.0).
tens'dgrt.lJllD en9]l
-uowAiaetermine
whether the Yellow
rig;it"in)t,"1 ;Yt;;t;i"n
discrettzattuil or Y'--
v'I Product'
plate
4r r

ffiH':$?:JI"l.in",.n=
Tl3
of the svslem,
:::1.;;".enis the tenths' disit'
How is the
calibration load
t*#'[:'L"'ff : i":9 :f i?]Jr;,1]]'='r;',"'X;
adjusted?
\
H:: iH:llir:i,*:i[*it
0' tt
ruS' :', : ::"'::
toweione nY
i"*i"li:
How is the wind,
velocitY threshoto
r:rs 6i}{jll n:"j "a*t ::nt,[:.",
switc}'$
set? flY,i;J3[?1,'['f,'),fr"i'o;;io]p --

It seems that this

machine is not
accurate' *r. *'q9-!Y-!9qyg
 @tidu')ght catioraiiln' no
__^,^^,
D urins we i
"T1r.:tt::i;'H'':
machine is
?"Y''in [?:l'li,J';';'o;; .t15^
force applied on a sinsle
rope
ft;;;;;r the
fitting";Jio be calibrated
is 2'4
Given that the
tons, the olP switJnlnuri-n" -sel !v.f-al4=o'6
i'ltz=l'2 tons for 2
uv
tons for 4 ropes
'^i
roDes.
The load of calibratio.n
is too,low;llt t:Y:::t;ol
gi",t"' than 2 4-tons ror
Iil: liSTid":';;;;;
['[0"I,'n.*i". trl t z t?,i?r?l? Illf;i
ing l; the l
in ir.,;
pi"ir"'itiJsutted from: I

factory. The above

of sensor' For correct
(1) lncorrect "onn"tiion left corner of the' *?:i
\

connection, on iri"lo*"r 4, ft:* left are

\

unit, the r""nin"'iJ i to

i
+ shielded ,
I

respectively !l1ck
;ilk ilIttui
(in "onnJtiuo'to-ineshrinkase conduit)' l
on t'" pin roll sensor
laver
I #;;i;
'h"
";J;;;""t"J
white, green, pin roll cable or
I

i tzl Damased prn "' ;ll' ;;; lhecxing whether theis

The rnachine can I
i
damased sensor cable
normallY oPerate if I oin roll is a"'il"gld' if. the
1

disconnect the pin roll

I

the Pin roll sensor ts i visuatry unOam"i"A'"*ii'

not connected' Once 1 from the t"in use a multimeter to i

:l the pin roll'

it is connected' I -"a=rr" tnJ"tJ;'t;;"h"ll
'#til"*- t"ns" from 700
i

alarm imrnediatelY I
|
Horrnallv, the
the red and black
sends and the relaY I to 850 ohms-["t*""n
!

between the white and

is oPened' as a i cable; from i6oit 705
]

gr""n c"utel]'itt" resistance

is infinite
result +"he main untt i
I uetnveen ttre-strietOeO layer anu the other
can not oPerate'
\ :ilT;" r;;; il;;-iotowgl orrms between the
metallic part'
tf't"
i shieldedditt;;;;;arn
taylr
"nO unit uv.welding sparks'
rst Stronslv
' walkie-talki"''fi;til etc' Solution: Theinpina
I'
1

1 roll ""n"o' "'i*rotja layer (installed

1 utocx il''""i"i shrinkage . conduit)'
is
lef i'e'
I "o..ent"o"if'tlJi"itrritiil.l from
I oaralr"r"o'iiiilti'"-ui""t,""bt""l e norrnal'
Tne main unit
rveth at th e'"'i''5^i
t:::" tlf.i,:]l "Jd'fr'J
*
normal. The Pin roll
obse be pararrer with the
resistance is also
f-'""S;,l$lff"iI#;;;i 'nouto erther identical or
pin rolli*iti'oi'""tion
arrow on the tl5"'
normal. But, the angle not more than
opposite), with a o"uiuiion aporoximately
weight calibration f"rtgu i.e,.
lf the deviation ung,""i""ioo the pin roll
cannot be Passed'
e0", the force is i*;tibi;Ii:"ti'"1?:d the pin roll
The buzzer and Turn
load capacity is red"u'c'ei''soiultn'
calibration light (left)
s0'and !!g!Jgi!
When thtdisPlaY is
setting, the load tower, moDlre ,,,""iffi"oipin
Solution: The ,.off.
disPlaY data is
(instauJn a utocr'
esPeciallY instable' 3ff?:'',Tl33l'?ilui ''ili
is comm'ented to the
with Percentage ihermal shrinkage ionauiil' with the black
fluctuating bY more Terminal 1 from b;'"i;';;ialleled
than 10o/o, and alarm of the Pin roll'
""U1" connected. lt
Tne-mai1ttgl

126
I ""rmaly "P"rate
the moment sensor
is not connected'
After the mornent
sensor is connected'
the main unit sends
if

alarm and the relaY

** *;3#H53#i,t ."o'""o n' 'n"
panel of the main unit'
The moment tun'or cable
disconnected or the
is damaged or
moment sensor ls
;,a-#ffi;o, "rt""xing whether
undamageO, Oiscoln""t
tf't"
the-pin roll is
cable is visually
damaged, if the ""ti=ot pin roll from the
to -measure the
main unit, use a muttim"t"t Normally'
roll' the
resistance of tne pin
is oPened, as a
result, the tower ranseJttt 1:?^i",1U: ?*'l:
crane cannot
resistance -"'i;;;lack
reslsralr'E stratt
cable; from 350 to
between the re'
cables'
oPerate' and green
353 between ttre wtrite
(3) The mome"t lcd) of^the moment
sensor is too
';';'6
;il; ;;too low Re-adjust the
nut so that the moment
adjusting anO tign'tening re.perform the
And,
is controlled byi;6 i""azo.
moment cq!rbglgn'

characteristics:
All-digital linkage console
l.Thehardwarestructureadoptsredundancydesigntoensurehighreliab'ilit;'6t
control instruction transmission
2'lntheinstructiondataframestructure,addredundancycheckalgorithmwhich
ability for data error
has the error correction life' small
operating i' adopted' with long service
3. Non-contact type l:l:'
drive labor intensity
operating torce'and ieducing
4,Thehandleisofunlockkeydesign,safeandreliable,avoidingmisoperation
circuit
contror circuit is of contact-free
5. ;i:"1# crane movement gea.r.position
life and high reliability
design, witn fong service :r:^^ ^rrcor rlrrrino S(

6.Adoptself-adaptionstepmode,toavoidneutralpositionoffsetduringServtce
Process effectivelY in the figure below'
linkage console,s operation part is as shown
The tower crane

127
 Console Operation Panel
Fig. 1 Tower Crane All-digital Linkage
l. All-digital Linkage Gonsole Design
1. Linkage Gonsole Hardware Design

I Block Diagram
Fig. 2 Digital Linkage Console Schematic
installed
circuit adopts in-built design mode'
t The linkage console data acquisition
inthelinkageconsolehandlecontrolpanelbox.Thelinkageconsoledata
cabinet, connected with the data
receiver is installed in-tn" power distribution
acquisition circuit via the bus type cable'
Functionofeachpartofall.digitallinkageconsoleschematicblockdiagramisas
follows.
value sensor: operation handle
Main function of user instruction, switching
instructions, such as slewing, hoisting,
converts the user,s tower Crane operation
traveling,electricbellandfaultresettingandothersfrommechanicalactioninto
electric signal'
128
 Y''l"

via internal Mcu '

i*o uuiiJi"i''i=*"'on fata
Mainfunctionofdataacquisition3r]dl:"".singcircuit'":lu"ntheoperation
;r;il;;;r", and transmit
instruction acquired
ffi
lccorOing ;'#;il;me structure'
and pack tne instruc'til
tnr",ign serial bus'
and
, r^^^.ri^^ circuit: the data receiving
nircuit: tn?
data receiving and.decoding In" ,";,;uctioi oata
Main function of
t ^3"try, l:*.L
l:n:r,x:l'1,ttdecision output #th:i i;: Ti:l#: instruction
of data
Function "'t",:',:"';;'f"or*on"ts of the
ff 1T"fi ;''tr'"""*""ution
H':l.;XU;iT::':l;""TXJ"i:,';::t'5-ff
instruction ' amoro€ocv stop circuit and corresponding
of
r -+_
meclalil
Function independent
the "*-"1^Y"",)
emergencv ;., imptementation
linKage
linkage
i*prlr"nting parts: i"ilure of the digital
ruilure
independent tro*'ii" "i""troni",ll"-? "".J "t
"ut"Jot
stop operation'
console, for emergency

l*1'::Ulil:ilT:*i:ffi:".*]*t*,,,trl'=1f,,["iH"""r:',:::J:
,.,5}:k'.J;"[l#f e'
: i fJl'l"l i;; ; " "
w

l;:; J,i[n ;:tt,':l

:
; b

Power on
Self-check

."u:".

Calibration
Working
status
status

Diagram
Linkage Console Status Conversion
Fig' 3 Digital

s e rf - c h e ck statu
s : at ti m e of th
e nr'u g
r i
".'*r': rm;l
operatr:3
; i ll'i'
"lli
#t#:jj
the svstem and do not arrow
#tul';;;i, io check ir
is found.' se #; i;;;diateiv'
to protect
;;;i. ;;andte abnormalitv
working status' Prevent mrso ieration,
the linkage console'" ""*il"to
safety'
il ;;ir"; and equipment -r^^ *-rar normal, the tinkage
thcv are I;
that they
working status: if
the serf-check indicates * instructions
into' iiu"*orkins
status,ril'::::"?I;*""fi'1";;; after data
console enters
lever and contro'
t*lt:?J.ir"*'",Jricat
cabinet via the
i.*""o"rrting
sT',il'+i:'ff^+;il':ri""xnguno
::1l;lff ::x1::[:fl*y:r""tffi
i"",0,"n,":T'i"ll"*J;:#".":#*[;I.:"nr,!'^:-ff ffi ill.l,?[lil'iliitl
a.r.::;;':"*, I tat t.:;;
status Imanually
between the rnain
collecto-r
and switch 13i"11"p to backup st?tUS
Jutomatica,,r,"#'*to"n
.",*"il"'illg "ut" il;
the backup *orr.in!"*t-riu-. H ;osition -1f:,JifH?"I"-Xi[::
necessary,"
j l*il J[. :i" :Hl'l;i;;; r s a s'l n c

ffi ffi h1 ; *tk "'W

: .;i:
129
 T
I

judgmentbasisofwhetherthelinkageconsoleisnormal.Theunlockkeyisset
ontheupperp"n"ltneoperationp*"ihandletopreventmisoperationofthe
operating lever' I of time, if the neutral

and record the

;g::;::l:"fl:':t?J^lqF"?:G5'.,l'"":iit3''::"li#;';nscabra"n
,,*"n.I*ror" *irt,-ca]cuiate each gear position
life of the linkage
process, ,n" rn tni* way, long service in the
calibration ,u.r,izu,omatically. is introduced in details
console o"'uJ'u;' il" "uriu'uiiJn''"linoo
"un
instruction Part'
l

oPerating
receiver and their
l;' rish'i conso:"i' ou" and data
ii";llllJ:::::lJ:::::""'i:.?'Ji ffit ;;;
others. The core iutt uno right consoles
connecting caute anJ
receiver.
receiver.
consoles is as shown in the figure below:
left and right
1. The panel of the ,
i

/clO
,, rrr,llcatof

Hoisting gear
Position
indicator
ita,rrli' /€l'O
t,,.,rlron
l,rrilOf

r,.rr, ltttg,
iB.?rrrllqear
r il r(licalof
I

I r,rvoling,
',1'.wing
,,,,rlrol handl€ *-l ::
lndeoenOenl
l
I

em"roencv ston
) \

Console Panel Diagram

Fig' 4 Left and Right
on the reft consore' tnev.are,11l^Y;,li^*:,f:J:ff:['",:,',*';t?:"""'1il:ffij!
(caubration/skip)' startup
ilJffii"J,llli"tlii.xiJ;::4 91",:t*' ""'i'"""tons
U;j;"ffi ::"1';{f"gff :I:fl "#l:iTsXliltp:H:,1::'"=il:
of the left console'
a
i",."m of the left console'
upper right angle.,n","", iiur." i.,t",r,*T.'""".i"
-rigfrt buzzet'
side, they are in order:
Thehoistinghandteisontheleftsideo{therightconsole,h-oistinggearposition
indicator is on the
Jil;l"i orn .on ru"rri inoi"utor a1o. power indicator' the
tt.'"
inoicator,
hoisting uru*, uonlll-rtity the ro*""igilt u;;;l;
emersencv r,op t*it"n
is on
oi'n" left and right consoles
ry]:""lX"i:Iff
are cc ffflfH:
and repair, all inte#et
plugs.
with shieldins'
t Jin-"' tn'o'sn the cable
Theoperatingleverandswitchareinstalledontheleftandrightconsoles ln
respectivelv' Thev "'"n the,serial bus cable'
";;"";;;i"J
and connectto the ;**;;i;abinet
Orir't"""i'"' 'liu
snatt be installed
at the
order to avoid interflr"""",
**
t"tt uno''igni"Jon"=ores

ffi; r*rvJtt" strong electricity interference'

130
 I'

: il ;? iltH f::"J # il:

:'1, :; lI."', ff "ilHi
ote e st ro n s
: th :
N
-:' : :T:
shall not be b9unc. -.-,

ffi
6-to t"tuY 25ovl3A

TYPe DRC-A
linkage console
crane dual redundancy digital
Tower

TEvetsq

"."":,.,"F. **o.",, """:i'

*o,srns -- I ()\/ l-;'
,fl**p** -*-, -

=,=r=rxlal6l6im
@arz

---ru r't 18 le
5lel9l9l9l9lYtYtYt---'='=-..'
t 2 3 4 5l *"":'L:'
Fis 5 Linkage
Fig'
consore
Linkase Consote ::::::'::ff
^=";-'.'' (terminar '1' 2)'
-'^"t^^ nower (terminal I

r,?Y :l jilj::: : : ::, ?i3,T Ji""

r he
)j ;i*;i;51,t; *:l;;,ru
up pe
f
;',:H%:["[qli,H':;li jlrr:]i"?#::T#""'"-lfti:J;$:;tlt:
delay brake or'iptrt of the *1^*""t;:*ro'"r,
contacts'
ihe maximum capacitycurrent exceeds r
wttnr'tw"
switch
ooen O1.'iiOU, or the
control voltage. 11["""ail;rJuy o, co ntactor.
;i;;ivia thl'.."':::il:,'T:i,
?"","" the hoistins 'illl?Jr:l::,[ :ffi:fl
lm:llqii:iffi :ll,;li1*"rj"".*nfq::*Hi:h:;?,:1r
:",m,I',1*;l**'il#itTft :^x5;,r;iirlut[::r::;t:.'tr
1
all sear Positions.,"h only sear '?.:t_1t'::,:: operation is
disconnected,
is allowed ror descendins; ontv il;;
:o-:"11:'tl1%':;;ration
traveling'
:l;;"olrr front and rear r .t aia *re working power of the whole
It is requirea to note that terminal]; 3rilTffi[]"'
'r",':&:i::i#i
;n",u*:;T:il::ffi
hoistins inu",,",.,'l"llli"rii
t"l";';il;
*" il{:ul:^#'r,r::,Hffi
,r
?1u
voltase positive
gear 1 control'tu'il';;t
re"spectivelv'
i"rl"
and descerrdins pil.t a
terminat 2,3 are;;';iil are hoisting gear 2-5 contro
the lowero* oti"'"*]n'ioi control power' 'n:rl
corresponotrln
Eo* fiinu"'t"' 24v
* i n a r e s * "',0:"HYr",'"T:::t if":["j:
l[] : t[:'i1ll,. "'
r h e owe.o* o,,"'
i

slewing left turn unoi';'l;';on,?oi,"t.inals' Terminall5' 16 itrtr

the
10, 11 are
s"?l p'::T:.';:r":I'H;;i"i;'*in'r
17 1B.art..
ilttr
'
12-14are the '**i"g sear 1 control' tritvt:lttttl
the travelinn tJ*"tiJJ
o
backw-ard
control terminals' and terrY;;;'"ig
tho
''
Z'
traveling n""uj"t'i'" "
131
 -'t**irug*****ffi
outPut terminal'
inverter 24V

outPut abil
strictlY Prohibited!
(2) iHHil*dffiJ*i'
*:*L"#'"1*"ffi*e*ffi
console linkage console'
that o{ traditional
lll. use of All'digitat'uinx"g" ;t same as

Y:f ;i,n',':*Xi$?ff;"[:":[:'n1T':i]''"measthato{-'lli***;T:}.*
,,l''rn"oneralin;"t;:::"'J"'H:l-*:hli$:1"r::ffiJ"'::{.tiiffi
Ir
requiring lar!
lii

a
$ffimu*guumffi
a.
out'
oPerating
Durins. ,:1
I

appl;:::*f;:irffi'JJ;*""I*i"a ,,staruoK' "raurt

;:'':,d;,1",,ili'-"fr
resetting/c
c'
[$:"J:ilt****il,]i,i,if;ffi ,*i
left side
right cons
Positions
au'""'"' -
gear 0 state -,-^ Galibration: While
;; u' t?ear -^^Ain..., oear.

[{fiill*ikf:;,,'{'"
g#' iH*,,q:'*$.'p
:ili' ::ill
il
i:'
:::: fl:',
: ;,,h e,u rne d
::.". i,x,1, ;;: :'lT

tffi;sfiuu.guff*
once to indicat

$*ufi*##;g*ry
ihoi.ting gear 5"
zero gear
"u'-':^::^, ri.rr,t flickers
indicator ligt
to indicz

Finally, the
132
 tl

During this p.roccss' il 1rr.s*rttttl

I

confirmation'Press,.starUok,,key,andthebuzzergivesaltltlllstlttttrltrttt:t:
to indicate hoisting calibration."o*pi",ion. (loirl
*fault resetting/cilibration/skip,,, ;*'p the hoisting/desccndrrrll

calibration'
Gear Calibration:
2\ Left and Right Slewing
the linkage console will
entt:r
(1) After completing hoisting
llibration'
intothesiewingcalibrationJuto*uii"urly,andturnontheslewitlll
zeropositionindicatorlight"nil;Ltt"on'ore(sharedwithslewing
th" tr"*ing/traveling operating
lever'
gear 0)';i;'i"'y while releasing
press...iuJon,;,r."y,andtn",uu".,"iin"upJ,shortlyoncetoindicate
"slewing gear 0" calibration
completion'

(2)Then,accordingtotheturned-ondirectionofthegearposition lever to the

slewing/traveling o.perating
indicator light, push the
kev' to carry out
rishtrnosti;t;dout"risht.sl"e;;;.;"4'rcalibration'whilepushins
the operatins lever to
the .beeps,' shortly
gear '*;il;;t:;[t'13t311"k"
d Catibration, the buzzer
hoisting/deslending completion'
"right slewing g"ut 4" calibration
once to indicate
(3)Afterthat,pulltheslewing/travelingoperating'.levertotheleftmostto
;tt'ru3x *"'' to carry oYt
carryout.,leftslewingg"u,'o.,,."uri6,.,iion,while.pullingtheoperating
lever to the leftmost' ;';;;- the -buzzer
.,beeps,, shortly
hoisting/descending
g"u, o'"llilratlon,
indicate,,reft srewing
g"a, +" caribration completion'
once to
u long sound once
Finally,thezerogearindicatorlightfl]"kT-to"indicatewaitingfor
confirmation' Press
r"f' ani the buzzer
"starUok" 9]Y"t During thts process'
'"uli[iution completion.
left and right slewing
to indicate
I
ifpressing;i"rt'-*'trns/catinr;;i;;;itp"'skiptheleftandrightslewingl
gear calibration' crane'
Gear Calibratio-n: (for h?li19n'tal traveling tower
3) Luffing Jib
press't"i.,ft--'"=ettingtcatiUraiionlsXip"keytoskipthisgear
calibration)
(1)Aftercomptetingslewing.calibration,thelinkageconsolewillenter
intotheluffingjibcalibratiJnautomatically,andlurnontheluffingjib
zeropositionindicatortigrrtontherightconsole(sharedwithhoisting
gear0),whilerelea.,ingii"-hoisiing"/tuffingjibooeratinglever,press
..starUok,,key,andtnenuzz"erto""p",,snorttyoncetoindicate..luffing
jib gear 0" calibration completion'
leftmost to
hoisting/luffing iib operating' lever to the
push the
\2) Then'
.,raising
iio gear;i
while pushing the operating
_i,tuI.UoK,
- i"ur,[,,,ion,
carry out
;; key, to ",.|'y.
out
lever to the r"ttl.no,i,
hoisting/descendingg"u,o""uubration,thebuzzer..beeps,,shortly
oncetoindicate..raisinglugeaf4''calibrationcompletion.
the
,,bendinn ;; catlur-ation, while pulling
(3)Afterthat,pullthehoisting/luffingjiboperatinglevertotherightmost
to carry out ";!,j;*'n",#pt:'""- "starUok" key' the buzzer
operating lever to tnu"lgni';i
.beeps,,shorflyoncetoinii""t""bendingoverjibgear4"calibration
comPletion'
Finally,thezerogearindicatorlight(snar,e!',withhoisting)flickersto gives
prEtt "staruok' key' and the buzzer
for confirmao"..
indicate waiting this
to inoi"ui""rrmng jin cariuration tompletion' During
a long sound once

133
 skip the luffing jib gear
process, if pressing "fault resetting/calibration/skip",
calibration'
4\ Front and Back Traveling Gear Calibration:
(1)Aftercompletingorskippingluffingjibcalibration,thelinkageconsole
calibration automatically,
will enter into the front and oact< iraveting
andturnonthetravelingzeropositionindicatorlightontheleft
releasing the
console (JareO with slewing gear 0)' ,similarly',while
travelingoperatinglever'press""starUok"key'andthebuzzer"beeps"
gear 0" calibration completion'
shorily once to inJicate "traveling
gear position indicator light'
(2) Then, according to the prompt of the to the foremost to carry out
push the slewing/traveling operating lever
..forward gear 3,, calibration, while pushing the operating lever to the
.staruok" key, the buzzer "beeps" shortly once to
foremost] piess
indicate "forward gear 3" calibration completion'
jib lever to the
(3) After that, pull the slewing/traveling .oP!.rating
4" calibration, while pulling the
rearmost to carry out "backw-ard gear
operatinglevertotherearmost,press.,starVok,,key,thebuzzer
..beeps,,shortlyoncetoindicate.,backwardgear3',calibration
comPletion'
Finally,thezerogearindicatorlightflickerstoindicatewaitingfor
gives a long sound once
il the buzzer
confirmation. pressi,starUok" t<ey, ano
toindicatefrontandbacktravelingcalibrationcompletion,andreturnto
il
workingstatusautomatically.ouringthisprocess,ifpressing,,fault
resetting/calibration/skip",skipthefrontandbacktravelinggearcalibration'
and return to working status'
5) Other Precautions during Calibration:
(1)Undercalibrationstate,ifhearingcontinuousshortsoundofthe
buzzerforfivetimes,itindicatetnattnethereismistakeinthisstep
duringcalibration,whichmightbefailuretopushandpull
to the gear position
"o,,",p*dingoperatingleveroroperatingleverdamage'trytocarry
out such ste-p of calibration again according
this step, press "fault
lnoicator lighi prompt. lf failing to complete
resetting/cJlibration/skip" to s[ip this
step, after completing other
calibrations,contacttheafter-salesserviceengineer,the
after.servicenumberofNanningKetuoAutomationEquipmentCo.,
Ltd.
(2)lfyouarenotgoingtocalibratethisstep,press,.fault
linkage console to skip
resettingicalibration/skip'; to make the
digital
to the working status'
to the nlxt step or return
Generally,thedigitallinkageconsoleissubjecttogearposition
calibrationbeforeleavingthefactory.lncaseofnon.zeroposition
drifting(startingbyitselfafterpressingtheunlockkeyofthetower
Granehandle),thereisnoneedto""'ryoutgearpositioncalibration.

134
 Ghapter 13 Hydraulic
Jacking System
and Composition
Hydraulic System Principle
filter'
valve, w u-63x 1 00 suction
Hydraulicclimbing(jacking)mechanismconsistsofY2.l32S.4-5'5,5.5KWmotor'
cwB_F3 1 1 n"u''u.ijl
a;i.-Eoor-r/M,;;d;;*
-rr""r","t hydraulic cylinder and
others'
oue2 oiting filter, ffi; ""Jteo,.nm
Rt time-ot tower crane
self-elevating
The hydrauti" mecniilrl,
'I;
,", on the of the tower is adiusted to be
the front '"n"l"In"'
u"o ,"ur;rque
section-adding or climbing, plate's upper plane'
jacking fgg.'''Oryt' Jn tne'tower bearing
balanced, and then the
oJt juitting section-adding'
to jack up the tower;";.y

r-
I
13-gIrg-155
55gf{_

I
I
I
I
I
I
I

Outline Drawing
Hydraulic Hoisting Winch

135
13.1.1 HydraulicSchematicDiagram

1- Oil cYlinder
2- Remote controlted balance valve
3. Manual diverter valve
4. Overflow valve
5. Pressure gage
6' Motor
7. Oil PumP
B. Oilfilter
9. Oiltank
Winch Technical Parameters
13.1.2 Hydraulic Hoisting
o Rated Power: 5'51ryV
o Rated Pressure: 20MPa
o Rated flow: 101/MlN
of Hydraulic Hoisting Winch
13.1.3 Service and Maintenance
1)Motorwiringshallk-eep,themotorrotationdirectionconsistentwiththepump
n'
inverse co nnection ;
iit""tt'n' without
'ot'tio
2)operatethehydraulichandletocontrolascendinganddescendinEottheclil
cYlinder;

136
 3)Attimeoffirst-timeinstallation,adjustthehydraulicvalveoverflowvalveelement
p'"'"u'" ajdusted to I BMPa;
to make the valve working
4)Thehydraulicoilshallbekeptclean,L-HM46recommendedforwinterand
L-HM32 for winter accordance with the
oil' carry out,oiling or oil change ttn strict
5) For using hydraulic
t,bl;,,i0 the inside of the oil tank.
specificatio; .;;; tuurication "ru,n
if its
jacking
Before carrying out
;;;, use tne oil p|."..u|." gage to check
6)Aftertheoverflowvalvepressureadjusted,changeshallnotbemaderandomly.
normal'
",J
Pressure is
7)Checkifeachpipejointistightfrequently'oilleakageisnotallowed.
B)Checkiftheoilfilterisblockedfrequently,andcheckifthesafetyvalve
after used'
adjustmenivalue is changed
9)Fortheoilpumpandoilcylindercontrolvalve'examineandrepairifleakage
pump for the.first time '
and overhaur, when starting the oir
10) ll:or"""ral assembry inu"""ty' rotation direction is correct'
check if the inlet and outlet
"r"'.]"^""t"J
oilsuctionlineleaksairfirst,andthenstartandcarryouttrialoperationin
sPecified rotational sPeed'
use officially'
11)Attimeofstartupinwinter,startandstopformanytimesrepeatedly.Aftertheoil
rise and control ,"tion flexible, and then
temperature "ui*
time, increase
working pi",.,," ;";";; j,&ing or dismounting each
12)Theratedpressureol}h:.Py",GranehydraulicsystemislBMPa,andmaximurn
is 21 MPa.
thehydraulicsystempressuretoiatedp,"=.u*slowly,andthenlockthe
overfltlwvalve,andthencar|outjackingoPeration,lithesystemworking and t!:u totyer
or slightly the rated working pre-qsure'
pressure ,"urn", "*Lu"o, cannot-ltirri" jacked up' check
and
crane inner cage and its ,p;;;;;r"ture
analyzeir,..u,,".nttertrou[ie'i"".'"s'.....".i1rm.thereisnoblockage'andthen
o'in" result is inconceivable.
continuejacking.ltisnotallowedtocontinuelact.ingordismounlingwhenthe
the maximu* p|'","u,",
working [|.","u," exceeds
13)Aftereachjackingolgiyo.,ntingworkingdaycompleted,adjustthehydraulic
systempressureto0MPa,Wnetnerthepressur"n,n"isaccuratehasadirectTherefore' before
safety i""n,nn'rid d,rro'nting"op"eration'
impact on the ", Oirmo,]nting operation' vlrify the accuracy' lf the
error rs
each time of jacking anO allowed'
and actinglashly is not
more than t5%' replace'

It z SafetY Valve Adiustment

Lock nut

Drawing
SafetY Valve Adjustment
valve regulation method
Hydraulic station safety

137
l 1)

2)
3)

4)
Unscrew the safety valve
Loosen the lock nut;
Use Allen wrench to
decrease the Pressure;
Adjust to appropriate
protective cover;

turn the pressure regulating screw' turntng

pressure lnd,then
clockwise to

tighten the lock nut (safety

to be adjusted to 20MPa)
valve

opening pressure '= 'u"o""nded

properly'
5) lnstallthe protective cover
and Troubleshooting
13.3 Common Fault Cause Analysis
Failure

l--fhe hyaEulic cYlinder is

Vibration and mixed with air; Vent
and
noise during 2. Mechanical mechanism are Repair or rePlace
hoisting hydraulic cYlinder Parts

I-fiFEuiic control valve T- Repair or rePlace

Hydraulic does not work;
2. Check and rePlace
relevant seal
cylinder 2. lnternal or external leakage
3. Check and
descending of hYdraulic cYlinder;
after loaded 3. PiPelinsi11ernl-eU-!g
@outof 1. Check or rePlace
order, 2. Check and
2. Other mechanical eliminate
mechanisms interfere'
@stmentis 1. Adjust, rePair or
incorrect or out of order; rePlace
2. Low oil tank level; 2. oil
3. HYdraulic PumP abrasion; 3. RePair or rePlace
Hoisting slowlY i. M"anual diverter valve not in 4. RePair or rePlace
Place or oil leakage; 5. RePair or rePlace
5. internal or external leakage seal
of hydraulic cYlinder; 6. Eliminate
ffisumpoil;
It 2. lnverse rotation or low
1. oil
efficiencY of hYdraulic
pump; 2. RePair or rePlace
3. bu".fto* valve jammed and 3. RePair or rePlace
sPring fractured;
4. RePair or rePlace
Powerless
4. Manual diverter valve 5. RePair or rePlace
hoisting or
leakage or not in Place;
6. Check, clean or
failure to hoist rePlace
5. Oil PiPe damage or oil 7. RePair and
leakage;
eliminate
6. Filter blockage;
7. Other mechanismsiy9499d'
interference alq
T. lniernal-leakage of gear 1. Replace with new
pump pumP assemblY
lnsufficient
pressure
2. Adjust safetY valve valve 2. Replace with new
element, in case of pump assemblY

Oil deterioration or thinning

138
 Cfrect< the wiring
condition, or ask
professional motor
iepair for treatment

ChaPter 14 Lubrication
Crane
Lubrication Parts of the Tower

1. Cage lubrication
2. Slewing suPPort lubrication
3. Slewing mechanism lubrication
4. Hoisting winch lubrication
5. Steelwire roPe lubrication
6. Travelingmechanismlubrication
7. Hook lubrication
B. PulleY lubrication

139
Lubricating Oil List mahod and
ilbrfiiins
ffiod(make
g-sU when.wotking for 240hr'
GL-5T heavY load ""nj when
"ir'"'f r."Pf u"" oil 10-12L
Hoisting winch reducer vehicle gear oil tot-l!oo!fl--..-
working

TAGI'Ing mechanism No. MWA150 worm lmmersion oil method

and gear reducer
Dismount and aPPIY the oil (carry
Over-neight anO -out
No. MWA150 worm oiling as appropriate when
under-height limiter
and gear reducer w6rking for 240hr)
bearing worm gear
fficarryout *,h"n working
appropriate,
Hoisting winch drum "i,iln'rJ
gear couPler
@out.oilingas
" ''
when. working for
Hoisting, traveling upP.Ptia-te
drum bearing
ffi(carryoutwhen working
# HL-68 hYdraulic oil
,. uPploPl?l?
"ifing
#5?alcium base
ffijecttne
Dismount the reouce
Sewing reducer gear lubricant (carry out oiling
as
when working for
approPriatb
#3 calcium base
ffioutoilingas
" '''uppt'oPrirte
when.workiry fof
Slewing and traveling " I 6o' B#Hyd;odynamic ^
z+fflunJ L-ptace oil for 4'71 r"iietr
dtive oil (liquid)
hydriulic nnr,^l^. I
, . .i-^. '*a couPler
working for 1500hr) -
ffinceafter.ineri *'
#3 calcium base
grease
#liilir; t Sonr 1T-";3ld
" ''""' -"--
ApptY on the gear su n;"" 'niformlY
'
-"'io*ing
[,iu'r" ro oills-aPProo']'l?^Yf "n
and clear
for 56hr'
#3 calcium base
Slewing suPPort gear grease impurities dn"" -"'"ry I o -d?I^t-;*d
and Pinion #rl;;;;ilfor o.5L when workins
for 1500hr)
ffi(make
'
when workins'?r,1911^
r.lp
TrolleY traveling HL-68 hYdraulic oil "iiir
,*lr"'o'r""'oir gu when working for
mechanism reducer
--TrotteY traveling
ffitnod
(;;,t outtiling u:-1nfj:nut"
mechaniim drurn shaft w'hen working for 240hr
ffiandaddleY"l
1m'at<e uP
to the 9i9:.:?Y,"^:
HM-46 antiwear oil 7oL when working
Jacking mechanism
hydraulic oil l'r';;;;;l
hydraulic oil tank for 1500hrl-
ffieoil(carry
-out
as appropriate when
oiling
w6rkins f9!240h

140
 Iubricating ntethod and
charginq amount
DsmounGnd aPPIY the oil (carry
out oiling as aPProPriate when
Hook, sliding bearings

#3 calcium base ffitheoil for

(rePlace
1500hr
oil when working
@ountand (carry out oiling as.
Bearing of PulleY shaft #3 calcium base aPPIY
and PulleY, wheel, grease approPriate when. working for
roller and others
It'rs recornmended to
General moving Part of use the mechanical lnject bY oil can (make uP oil as
each hinge Point of oilwith higher uJptoptirt" when working for 56hr)
brake
@ject(makeuP
working for 240'hr'
olitor when
O.St-
electromagnetic and HL-32 hYdraulic oil and rePlace oil for 2L when working
hydraulic Push rod
brake
Gnfiut oilrng aa aPProPriate
Steelwire roPe w'hen working for 1200hr
Apply lubricant

@ct(makeuP
working for 240.hr'
Ordinary industrial oiiior 0.5L when
Traveling mechanisrn and replace oil for 2L when working
reducer gear oil #90
for 1500hr)
fravetrng mechanisrn
ffieoil (carry
when
out oiling as aPProPriate
reducer and trolleY for ?,-4!I'.r)-- - --
-vuo{llg
Note: the
when the transmission is static' and
1. Reducer oiling shall be carried out or the position indicated by the
charging amount shall r."u"f", tf,u scaleplate
access hole; the user.
oilfillin and ent shall be
2. Above vQMse

141
rt
of Tower Grane
Chapter 15 Operation and Maintenance
15.1 Operation of tower crane
1)Theoperatorsoperatingthetowercranemustbetrained,arefamiliarwiththe
and maintenance'
and with rules of its operation
construction and performance
by exclusively designated person'
No
The tower crane shall be uttuno"J
authorization'
climbing on the tower crane without
2)Thecraneworksatambienttemperaturerangingfrom-20to40.C,withwind
velocitY not greaterthan 20 m/s'
3)Don,thandleorrernovetheproperlyadjustedsafeguardsonthetowercrane.
4)Duringoperationatnight,theconstructionsitemustbewelllightened.
5)Thetowercraneoperationmustbecommandedbyexclusivelydesignated
must be performed with
persons on the sround and floor'.
i;;l'*' ::.I:,::""r
pre-definedsignals,handsignals,orbannerwavingsignals.Usewalkie-talkies
as Practical as Possible'
voltage should be 380t10%V'
6) Ensure that the tower crane operating
and repairing'
7) Don't lift the load during maintenance
B)Thecabshallbeequippedwithfireextinguishermeetingrequirementsoffire
be provided by the user')
fighting. tni'l e^tnng'ith"' shall

15.2 Tower Grane operation

1)Theoperatorswitchesonthetowercranefromgroundandthen.entersintothe
exJmining that the indicator
light of
air breaker,
control room. By switching on the
powersupplyisliton,andswitchingonfromtheelectricalcontro|cabinet,the
oPeration is standbY'
2)ThedriverCan"ofllyoperateuponthecommandingsignalsfromthegroundor
floor.Beforeoperation,thebellmustsoundandthapeoplemustcarefullylisten.for
performance and lifting characteristics
3) strictly follow the tower crane technical
handle it'
opu"lion' Don't overload and roughly
4)Lifttheloadverticallyonly.Don,tusethetowercraneforpullingthepileandthe
like'
5)SeelnstructionsforElectricalControlsystemandoperationfortheoperationof
each mechanisrn'
motors only after they stop'
6) During operation' reverse the
7)lncaseofabnormalitiesfoundfromthetowercrane,immediatelystopandswitch
troubleshooting'
otf. Oon't use it until successful
B)Uponcompletionofoperation,raisethehook.Allowthatthetrolleystopsat
the jib. Switch off before leaving'
ln case of
location by 25 rn uppror,nlriliv tro*
atravelingtowercrane'tneraitshallbeheldwithrailclampsothatthetower
i' fried properly when the crane is stopped'
"rrn"
9)Beforedailyoperation,checkandtightenthepreciseboltsandpinsonthe
criticalpartssuchastower,jib,slewingsupport,librod,andcounter-jibrodetc'
or drop'
P";;il;peration only after confirming no loose

10)Performroutinemaintenanceasspecifiedforthespeedreducer,pulley,andthe
otherdrivingcomponents.lncaseofoilleakageetc.,immediatelyaskthe
maintainerforrepatnngandremedies'Carefully-checkthenylonpinonthe

142
 day'
before starting work every
coupling of the hoisting winch
11)Beforeformallyputintoseryice,checkthereliabilityofthesafetydevicesoneby
one.Don.tuseanymalfunctionalordefectivesafetydevice.
12)Carefullycheckthesteelwireropeclampforsafety.lfitisrequiredthattherope
connection, there must be
at least 3 clamps'
ctamp s'nould be used to, tixlnglno at least 4
of steel wire |."i" oi,,"ter D>10 mm, there must be
And, in case diameter' The
clamp spacing'r1", be less than 6 times of rope
clamps. The "", mm from the last rope clamp' and bundled
head shall be not less inr"
r+o
rope
withsmall-diametersteetwire'Theropeclampslidingsaddleisplacedonthe
sidethatthesteel*i,.u,.op"isunderforceduringoperation.TheU-boltis
fastenedontheendofthesteelwirerope.Theiopeclampsmustnotbe after the force
setup. rn" |,opJ"Li.|ps must be tightened before and
atternatively
is aPPlied'

15.3 Maintenance of tower crane

Towercranemaintenanceworksshallbecarriedoutinthefollowingseveralaspects
crane maintenance
practically trrlo lnl".orounce with the unit's tower
"in]urtaneously
sYstem):
(1)Lubricatingofalldrivecomponents:thelubricationintervalsforvariousdrive
modescanbebasedonroutinemaintenancesystemforgeneralconstruction lubrication
machinery. For lubricating"Jl,
,nd lubricating methods at various
10;
Points, see ChaPter
(2)Forcommonfaultcausesandtroubleshooting,seeattachedTablel3-1;
(3)Forvarioustransmissionpartsandsealingmembersofhydraulicsystem'see
13-4;
attached Tables 13-2 and
(O).*-,o'rollerbearingsinthevariousmechanisrts'seeatter:heeiTahlcl3-5:
(Sj- Uaintenance of electrical systems;

a)Alwayscheckallcablesandwiresfordamage,andtimelywrapand
replace damaged Parts'
b)lffi ",1-,]',,""",x1ffi :iff 'ffi ::'il:"",:T::;J::,,:"':1";ru:
::*"T",:f
good.
c)Thecontrolboxshouldalwaysbekeptclean,anddustonelectrical
in time'
equipment should be removed
d)openingandclosingoflimitswitchcontactsforthesafetydevicemustbe
be polished in time'
reliable, and contacirecess must
e)Measuretheprotectionearthingresistancewithtelemetertwiceayearand
ensure it be less than 4 ohms'
(6) Other maintenance:
a)Forallopendrivegearsandothertransmissionparts,thesand,mortar,
other debris must be cleaned'
b)Electricalcontrolbox,linkageconsole'etc.mustbekeptclean,thusto
manner'
remove dust and dirt in a timely
c)Notecheckwhethersteelwireropesatvariouspartsaresubjecttobroken
exceeded' they
wires and roor" in case relevant regulations are
'i'*J;
must be rePlaced immediatelY'
d)Duringtransportationandinstallationprocess,youshouldtrytoprevent
143
 al

damageanddeformationduetocollisionofmetalstructure;ifdamagedor
deformed,installationanou"eareonlyallowedafterrepairandadjustment
elements'
as qualified, especially standard
e)lnadditiontoroutinemaintenance,metalstructuresmustberegular
maintenanceandrepair;conn"ctingboltsofallcomponentsmustbe
hours of use' Metal structures
retightened with wrench aftLr every-1,000
1 to 2 years'
shall be painted once for every other
precautions:
The operator and driver shail observe the foilowing
xWhentheloadapproachestheground,itshouldbenotedthatthesteelwirerope
mustnotbereleasedifthehooktackle-blockdropsontothegroundorontothe
otherobjects.Thesteelwireropeshallbekepttensionedtoavoidbendingor
disorderlyropeonthedrum."',rtinginflattenedorfracturedplieswhen
make the steel wire rope in
good
re-tensioning. lf that is a case, ,rr"oiut"rv
order.lncaseofbent,flattened,orfracturedsteelwireroperesultingfromthe
hooktackle-blockhitonthegroundduetoimproperoperation,evenifwithinthe
may arise from'
claim which
warranty period, we will accept no
XTheweightshalldropatthelowestspeedwhenitapproachesthegroundsothat
itmaydropontotheground'Afterthis,thesteelwireropeisreleasedalittlebit.
Aftertheweightisstable,contirrueto,oropatthelowestvelocitysothattherig
hook drop onto the ground' ln
slings are completely released.
Note: Donit let the
addition,payattentiontotimelystopduring.theweightisliftedbecausethe
mechanism'
not an operating
height limiter is a safety device'
Warning
l.Performcorrectcommissioningfortheliftingweightlimiterafterthetowercrane
isinstallecl.Athigh-speedgear,theloadtimitisbelow3tonsat4Xandbelowl.5
tonsat2X,,atlow.speedgear,theloadlimitisbelow6tonsat4Xandbeic';,J3
tons at 2X;
2,lncaseofhookglidingduringoperation,itisnotallowedthatthehandleis
movedtotheUPgear'Theemergencystopbuttononthelinkageconsolemust
occurrence of accidents'
be immediately prlssed to prevent
3.lfthetowercraneisusedwithimproperlycommissionedliftingweightlimiterafter
the following accidents may occur:
installation, when the load exceedt
if'" ii'it'
Theweightmaybeliftedfromtheground,allowingitbehungintheheight'
,uy J."r, during stopping or dropping' we will
However, serious hook gliding
bearnoresponsibilitiesforanydamageduetoloadexceedingthelimit.
4.Don,treverseslewingduringoperationoftheslewingmechanismofthetower
crane.
models:
This Warning is applicable to the following

QT25013D,QT25510,QT25512,QT75015,QT25513,QT25515,QT26015,TCT5512'
OA
TCT561 3, TCT6O1 2, TCTsB1

144
l
TCTso (TCT5810)
Tower Crane

Maintenance Manual

Group Machinery
Guangxi Construction Engineering
Manufacturing Go., Ltd

145
E
_T
I
I
, Gontents
E t47
MRINTTNANCE OF TOWER
CRNNT.......
i CHNPTEN 1 CODE TOR 149
MECHRNISIIII
OF MECHNNICRI DNIVE
CHAPTER 2 MNIUTTNNNCE 149
HYDMuLIc Jncxtt'tc SvsrEu
CHnpren 3 MRtNr-rNRNcE oF
4 MAINTENANCE oF MrrRlutc
Stnucrunr
CHnpren ..... 150
OF EICCTRICRU SYSTTU
CHNPTER 5 MAINTENANCE '151
oF SreelWIRE RopE """"'
CHRpTER 6 MRtuteNaNCE 152
T Rrcumn Cuecr or FRsteNtNc
Bolr or Genn Rttvt """"""
CHRpreR 153
CHnPTR B LuentcRrtox TnalE
SYSTEM A::
CHnptrn I CoMMoN Fnruune
or MecunutcRlTnnnsulssloN 154
TRoueLesFtoorlNG
CHnprrnl0CoMMoNCRusEsorEt-EcrRtcRlFRtluReRtloTRoueLESHooTlNG....''''...'..155

146
 of Tower Crane
Chapter 1 Code for Maintenance proper maintenance in
order to
and perform
operating.procedures life'
I'tilase observe the following and extend its service
orin";;;;;;;
i,'r)rove the operatinn';;;'';t
ror operation rhe crane

i ; 1",:i;^,="',:fi##ffi#H:::''"n""-'::''r:n'on
r ve rs
d ;
: J;i" i-:," :: 1f#"jTili5;tl{' m *" 1!': J,:,:f iffi :
The towe
Pu"onnut authoritY'
and are ram,iar wi'ih 'ihe
,? ;":tr*":":::l;!::l#i::T:"
nstruction and
mechanical co
p"'ut' ng
'':::i:^lrained
nc""u""J *Jtn- the
o perfo rma
aintena nce of the
m

tf'"it adlustment' Don't access

functions.ot tn" t'['V
devices
mechanisms, anO 'nJ tn" tower crane must
without,utnori.ution'
in" o""on''i*"ing
the tower and dismantling'
"run" Use safety,o"n l*."n it'
wear safety helmet' 'nstatlation
for operation. Don't overload
crane rifting characteristics
13 stricry totrow the tower
speeo to high speed'
and shift gear by ni"t tt"' i"i
|4Gentlyhandlethehoistingwinch,slewingmechanism,travelingtrolley,andtraction
mechanism
ground'
l.5Don.tlifttheloadinaninclinedway.Don,talternativelyextrudetheload'Don'tliftthe
soiro' adhered on the
object o'i'"oi" in" t not leave their

l.6Whentheloadishungintheheight'thedriverandcraneoperatormus'
posts' banner signal shall meet
the requirements
' hand
command signals'
'! -^r ^innalc ancl banner
signals' and
1.7 The
or
and shift handover/takeover
, - ffi*ilii*::'ml':'""i"'T::gmaintenance'
the crane'
l.gThedrivermustnotoperatethecraneundertheinfluenceofalcohol.
parts and others
of mechanical
2. Safety instructions

'rr,
2.lThecraneoperatesn::Tlllyatoperatingtemperaturerangingfrom-20.Cto40"C
must be maintained
properrv Don't
iI:UilU:':''="'llXT:"t:" loY,"l:Tu
them' Don't overload
them'
move and dismantle

2.3Duringworkingatnight'theconstructionsitemustbewelllightened'
joints' ;il' il;tt n9-' static-' dynamic-load
2,4Afterthecraneismgved.}oanothersiteor.afteritisoverhauled,strictlycheckthatno
tn" p*in iolls and rated
crack can be found
t,.orn liftins load is 125%
safety:5"''; ;;io'" r'tt'ngTnJiJ'l'1n"
rests and adjust the
weightforthestatictest,^o.io;,lrateoweigntforthedynamictest.
live parts' The crane
for repairor iiut,unun"" ut'"'.tiol il;t work on oround, floor, and
2.SCheckthattheelectricalsystemshallmeet^therequirements.Switchoffthemain
power supply uy u*"r,1I.I",;;;;;;; 9",Ih: hand
shall be
tower operation follow ihe signals'
""#,,"0"0 witn th";;;':lt'i"tty
construction level
to p"nr,t^'ititon
signals,bannersignals,ui".p,"tu,ublyusewatkie-talkiesforliaison.
2'6Ensurethatthetowercraneoperatingvoltageshallbe3B0tl0%.othenruise,theor
' the wind ve,ocitv at
the hishest point
,o, i**::;ffi:*i;::1J".::;",:hr
the tower crane exceeds i0 */t' never operate the crane'

2.BlfmanytowercranessimultaneouslymoveintotheSameconstructionsite,theCrane
147
E
planeshallbereasonablyarranged'Nointerferencecanoccurforthespaceeach
other' the cab'
^"^^r" {'nm the oround' After entering into that the
/ {} ffi:,iJ-'':HI :l:'",f":',:l
Iffi :il::liill"ll""'ff,l1: pt"ition]pi"l. tf,"
wor*ins condition
button after conftrmation'
and

joystick tevet'L* at neutrat 'u't"r

.p""iur attentionlo the arrangement
/l0Duringoperation,don,thitthehookontothegroundtoavoiddamageduetodisorderly
of steel wire rope on tn" drum. e"y the ground if it is
arrangement
rope on tne drum ;"; ir," noo* i. rn"o again from the steel
of the steer wire tn" ground' lf neceisary' re-arrange
must nii'""t"
inevitable that the hook
maintenance rf
tro*ev is for repairins and
;[: :",:::;:: I;:l a part o,it'"-"runu jib, the mai-ntainer may stand on the cradle
*re sife of the crane
, 11
is designed with
it is necessary to repai,
trrX'*tn th" t|.un" tt"il;;' il" "'udt"
to perform inl maintenance ritting the rouo, person can be found from
when t;'crane-is "o check the connection
rated weight of 100 t<g.

ln each constructiori of irt" vertical to*u'' "u'"fully

the cradle.
crane trolley'
between the cradle and
,)12lfitisnecessarytoreverseamechanism,starttoreversethemechanismonlyafterthe
immediaterv stop and
switch orr
rrom the tower crane'
) 13 ;":::::::;:iJ:;:l ,1,1
iiuntil successful troubleshooting'
Don't use
,).l4Uponcompletionofelctshrft.thecranejibmustbeturnedtothedirectionparallelwith stop in
i. ,.u,""i'iJinu nlgn"tt p"i"i' ir'" crane trolley should
the building. The hook
reteaseO' The power
supply is
in"-riu*in! OraXe is
the middle point of luffing.
bolts and
check and ,shten the connectins
,2.15 ;:[r:* shift' tne driver must routinerv
tie rod' counter-jib' i:rake'
tower cap'
,"*", .run" jiul"rr"*]"g the hoisting
pin roils "'pport' tn"
and driving
"i*l
mechanism *", ",p""iurri tn" nvron-pinlt
":,!1T^.on
accuracy of each safety
winch.Thetowercranecan;;il;"usedaftercJnfirmingnolooseningordropping'
oplrut"o only the reliability ind
n"
The tower crane can only day'
befoie starting work every
device have been verified
of any
method and o* r,,i'"g'orr"tiiv cr'artl.
il;**"diate action in case
2.16Thedriverroutinelynerforry.sandlubricatesthe-speedreducerand.sheaves(referto
rubricating
For
commissioned or unreliable'
the safety devices are not
2.17 HffI] must not drive if
thecommissioningottf'esaie-g"tOt'seethelnstructionsforUse'

148
-r
Mechanism
2 Maintenance of Mechanical Drive of the
Chapter
checked and adjusted for the clearance
mechanism,stra*
be retiabilitv'
The brake of each i,*". time to"l]r"sJl frexiniritv.andfree of dirt'
brakins **"i'i.i be
braking puo uJin"
trom o.si;m' The u'[t'"" ia"e tnari
#'i;
with a
"r"rrun"l'rrnging

Til::ffi:r':'.ui,i1ilF:'fr
filled according to tnt
**r*,';in!1;ill"i::':i;,J"rca'iedand
.ng, plies
nfJrauticatty plies' knotting, and.loosening
weanffii.L"'ii;:i:,":1"", The
broken r1ire1, fracture limits'
r check the possible
t,;'::i:;,'ff ;:r": a n d'ih' s e
:ix' H*J,i
il lff:::iyll;:,.:" 5:i q:".I,: '?:
on^e (ir anv) rhe
rishten roosene!
k"Jlil:**::""#:t;"::n ":ry::* ;:l'"J'!:fiiil:
^ uorts s-iJt
tower
be
tnuitn'"
checked
pu"to
J*"iiiont"i-19;*l;m:X:'f
'"' is under pressL pin'
be checked
(Ensure provided with split
connecting pin roll mustbe'""""iy
llRegularly"r'""xnormal:p".:llonofmechanismandpossibleabnormalnoise.Take
of fault (if any)'
i*m"oiut" uJt]'n'iol"ri*inution
6 Atthetimeof insta,ration,.',*;Ht*:,Jru*;..lfl"H1?,t:if,l]li;illii'1
the
that the center line
of Ptnro "*"#;'ti"L-not than 70%' The less
the tarse g";, ot
the slewins':H;;'-;
0'3 mm'
be 0'2 mm to
meshing
"ffi;"';hould Jacking System
Chapter 3 Maintenance of Hydraulic
flushed'
*'* o* tJnii'riJi u" internallv
l.Hydraulicoitfillingand.changeshallbestrictlyperformedac.cordingtothe
of tire tuuri;rtion"i'XJ*'-n'i" Before JirL'"''r.g'
,uquir"me,.is varve arbitar*y'
of the overflowing
the adjuste^dpressure
2. Don,t change
Anv eakase s n.'i
:::ffiI,:r::",.,me
*#f;ffI:*::",ru:: value of
allowed'
is not crogged. check that the adjusting
check that the frrter
4. From time to time putting into service'
not changeJ after

" the safety valve is

5.Serviceimmediatelythecontrolvalveoftheoilpumpandoilcylinderincaseofany

6 leakage'

HI":.H?1"',#:"$il:J::i::
:i:i:!i{F:1ili#:::"""J$:?:}[:""?l"1xlllfl
O,Ou,,nl'lniif'en
sta't ,o t'Lf
O"i".* at specified revolution'
'un
no leakage of suction

7 y;ffiJ,[I,n1#"11,*,g"nl;U3 ;ifi.ili,il:"'i:":'m'?;"':::"1'''*i='
's 17 MPa and the
operatesfree. -- ^,^^d ih" nvo*'ri'
I For the hydrauric "r"-"I^:lJi:fiffi;:il1;:::#::$tJ::t'.TT'ung'
maximum oPerating Pre'ss
:'H";J?f"Tr:
ffi :r:;?ilr;:$i,m;*i;ilit*':l#t*1ff structures are not
int"'nu' t'u*" and its Yp?utafter conforming no
pressure O*tnJ'i"*!icrane
op"ruiing toiact<
i*r"o,ut"'f, tt'fl""n""l"J'rc""*ue ns p re ss u re
able to be jackeC,
i
"
*,,
"nl'N;;;' ":ll":#y+
the maximum Pr
r*j"", ::l[X ;:':l-;f::ff l5:"i
exceeds

149
E
pressure must be
jacking or. dismanaing is ended, the hydrau*c on the jackins or
*rrrr one working day
of guus" r'-as
r,trrsted to 0 MPa'
T.1";;;;;ciof tne #"t;; uJtore lact<ing and
'oilct'influence dismantling'
safety. rneretore, *,e
accwacl';';";i';ritieo
,rr*man,ing
;;;;-;eoing tsY"' Never work rashly'
fl'place that with
"" of Metallic Structure
Ghapter 4 Maintenance from being
structural members
effort to p*"-"ll-11" jib and its tie
I During transportation, luk"--"]^:ry inu to*"' stanOaid elements' crane
and
of damage
deformed and damag"d, "rpu"itf
its tie ,ooi'.{*I,.;;;
;"9 ;;;' in
"u'"
rod, counter.jib and it is correctly repaired'
must instatt""J unO u'"d
only
deformation, ifru "runu 'tt"i
,,Duringoperation,takeperiodicservicingandmaintenancetopreventfrombeing
rusted. bolts'
marnhers are nnot damaged'
^--r members
welds' and
check that the
t From time to time
deformed' and loosened'
one to two years'
,1 Paint the crane once
of Electrical System
Chapter 5 Maintenance
lFromtimetotimecheckthatallthewiresandcablesarenotdamaged.lmmediately
', ,;o;*'".,"ff::,:hiil:i*::i.y.:3];jmmediatervshutdowntotroubreshoot
shall be well lubricated'
them' rn""'"oiJ"u'ing'
3.Forthebrushes,thecontactsurfaceshallbe-keptclean'Thebrushpressureisso
contact area is not less
than 50%'
adjusted in" tne

4.Alwayskeepthecontrolboxesanddistributionboxesclean.Removethedust(ifany)
-'''secr rhe
must be reriabiv
traver switch
of the
; *:m::;::il:l!:i.;ontact
be removed by grinding'
contact t'ut"ishall
results on the tower
Re"orJ the inspection
6.Beforedailyoperationofthetowercrane'checkthatthesafetydevicesareworking
perform readjustmeniit n"""ttary'
reliably.
and
earthinn,:1''"un"e twice
a veat (in sprins
7 :**::':ffi^i::;::"tive
shall not be greater
than 4 ohms'
uutu*t'i]il;;il'iit
B. Maintenance lntervals
every 1'000 operating
8.1
and erectricar svstem
8,2 ::::fi ffi::T::i?il:Hchanicar
hours. 4,000 operating
mechanical and electrical system every
for the
8.3 Partial repair is rnade
hours. every 8'000 operating
for the mechanicar and electricar system
8.4 overhauling is made
hours'
follows'
I must be arranged as
Whenmaintainingandinstallingtheshiftlimitswitchofreducer,thefastandslowshift
ut
timit switche" rnu"il"
instatted
"o*"i'p"i'0""t'''

150
 Steel Wire Rope
Ghapter 6 Maintenance of we focus on its
is essential to safety' So'
the tower crane'.the :*^"l,yfi:Ii
Ar, ir critical part of
precautions in this chapter'
rrririntenance and operating twistins'
on the sround' avoidins
;:T:ffiffi::;" steelwire rope must be spread
.^+^ltaA intn fhc or
been instarred into the drum
:il: :ffi;, that the steer wire rope has
"n"*
sheave groove'
hours'
once every 120 operating
Grease the steelwire rope
Dailycheckallthevisiblepartsofthesteelwirerope,Fortheconnectionbetweenthe from
rope which is introduced
rope and ir,. rri" equipment, check from the
steelwire fixing device'
the rope end
the fixed end and check from
Don,tusethesteelwireropewithfracturedpliesorwithsand,cement'andespecially
screes'
action'
Duringinstallationanduse'th."'1""1-Y].teropeshallbewellprotected'Don'tfolditlf
is twisted, immediately stop
,ai.infine rtook and take corrective
the rope
roPe if:
I RePlace the steelwire

t1 Withinalengthequalto6timesofdiameterofthesteelwirerope,thenumberofthe
fractured wires exceeds:
rope;
i. 9% total of wires for ordinary-lay
lay rope'
ii. 9.5% total of wires for lang-
because' although
Thenumberoffracturedwiresshallbecalculatedfromthemostheavilywornsteel
to iJentity the fractured wires
difficult
wire rope. However, it is very protruding on the rope surface'
fractured, both ends are a oirlt*,th-out wires' Rub the
the wires are identification of frattured
Remove tn" grea;i
ir," ,op* surrace'for
hano so iiratthe bui;'
*,in a softwood. lf possible, bend the rope by
steel wire rop" Thus' the fiactured wires may
be
*ir" protril'"J'o*'
ends of tne tractureO
"re
to rope surface worn or corroded'
ff:::r: diarneter is reduced by 7%due
t') ^ominar
I '..\ Thedeformationswilloccurifthesteelwireropelosesitsnormalshape:
oWavy:Whenthewaveheightisgreaterthan4/3timesofropediameter'
@ Cage-shaPed (see figure 1);
iii. Plies extruded;
2);
iv. Steel wire rope extruded (see figure
v. Rope partially enlarged or reduced;
vi. Steelwire rope flattened;
vii' Folded (see figure 3);
viii. Twisted' (see figure 4)'

151
Y
Rim
of Fastening Bolt of Gear
Chapter 7 Regular Check
grease if needed'
Slewingsupportisnorrnallyfilledwith#3calciumbasegreaseinthefactory.
refill ii" .i"*,"g support *it, ,ppropriate
customers may
pretightening torque
,,,ffi ;;;J';i*", i"r"r,r',an ano check the bolt
Undergeneralworkingconditions,itisrequiredto.checktheboltpretighteningtorque
,)

for shatl be kept'

when operated
,tt"*urO$ in"orJn pietigntening torque
every 500 operatinJioro 14'000 operating hours'
Replace the bolt
7 y""' or
"'Jty
roller-type slewtng
ior 100 r,ourr"ftli inJartation and to fill the
Undergeneralworkingconditro-ns,itisrequiredtofilltheo.,ll,,,uslewingsupportwith
grease when it op"rr,lJ
grease
rorio nours. check and appropriately fill
support *itn gruur"l;lln
it opurutuo it. When
;;;,;; good lubrication, and record
afterwards t"
;;;,. -hu;ioiti, is required
every 400 operating nign at least one lubrication
used in areas *itn'*JJn-d;.;;; ;;;;;i;d to refill grease before
and after
conditions.
every week based .O"JO. 6e filled with grease for
shall
"" t",. a long tim"''ri"
'rnutt filling grease' to
the machinu i, ,nui'oJir" ,uppof
'aceway
oe stowty rotated when
the srewing
every rubrication, and
and uniformly filled'
make sure grease is fully
Method of check: -r-^i ^r..a, ho {ree from tension under
^Beforeoperatingtowercrane,theboltstobecheckedshallbefreefromtt
check the preload moment'
wrench mav be used to
- f":::ffi::ffitJ rnultiplierin the following table'
tne;;li';; speciiied
according to
:
il il iili i[: ffi :::":: ;li
JI#:"Ji" I"J'*:,T
Re p
rr,::
a ce
xi
exceeded the maxtn
r : lm ;;H ::ffI
bolts. gear rim must be entirely
botts: the borts for a cornporrent of srewing
Regurarry reprace the
replaced every 7 Years'
my.",::J:''l:[:":L'",JH:*'"T?[":1"fff [1fi,i:11
fll::ff:,l,iJ"lli;:thelcots
r\strlrrrrv""'v -' if the ootts ?rc luytawv"^L'^'t' i'r'ricatirio
#s,^','"d1::[:.ffi ;:"il,f *'fi ,;n:l["ffioil atthe
lr several weeks
',il;o{;rry*l1:i;f
:,",'l'JH:^i:l[:?:[J[':if ends ii[:ii:
::ffi |fl:["J[:,ff yffi
:,X,ff"'#::ffi'"]*Ji:::lililtneoirecton
*h*"*s:H:ll5ffi x'Hll#:T:il::"'.il""[T:*="'m*:fl ':',:;x;:
:l:",,.*::*::*'"""1"":; li#i:tr1::i:*:*l,1ijx::,::,ll;#:T"il'"iil:l'n'''n
JI"i"l* i" in";;1,", ,r"_":,'.:T-y''"
iljny:";;1,",""';J;:,:?,1"lT;lniJilxl GEde a.g gotts
GEoe to.g aoft

152
q
Chapter 8 Lubrication Table
Lubrication Point, Oil and Filling
rrrame-oi Lubrication
Location
Gearbox of hoisting winch
Worffind{ear reducer of
Worm gear oil MWA 150
Trollev mechanism
Beanng worm gear Pair of
Worm gear oil MWA 150
overhe limiter
for a drum
Cear;oupiing
of hoi winch
BArinfii-ho'rsiing and
drum shaft
Slewing reducer
Gear shaft bearing of
slewinq reducer
eoupllng Joint and bearing
of slewing reducer
Slewing and traveling
hydraulic couPling
Slewing suPPort
Bull gear and Pinion gear
of slewing suPPort
Reducer of trolleY
mechanism
Right end of drum of
trolley mechanism
Hydraulic oil tank of
jacking mechanism
Cable drum bearing
Hook and sliding bearings
Motor bearing for all Parts
ffinnfiianding wheel
shat, pulleY, idler PulleY
and contact roller
GeneEI nexiUte Position of
- grake of hYdraulic
Dressure, electromagnetic
OilType
ffifiII3-5Lofoil
Gear oil of heavY load every 24Oworking hours and rePlace
vehicle GL-57 d-lZtof oil every 1500 working
ffirlYfill
Calcium-base grease Ma"Glly appffpr"perly fill oil every
No.3
Calcium-base grease
No.3
Hydraulic oil HL-68
Calcium-base grease
No'3
Calcium-base grease
No.3
Hydraulic transmission
oil (fluid)6#, B#
Calcium-base grease
No.3
Calcium-base grease
No.3
Hydraulic oil HL-68
Calcium-base grease
No.3
Anti-wear hYdraulic oil
HM.46
Calcium-base grease
No.3
Calcium-oase grease
No.3
Calcium-base grease
No.3
Calcium-base grease
No.3
trrtacninery oil with larger
Hydraulic oil HL-32
153
ffindFillins
lmmerse oil
oil
240 working hours
1500 working houlq
FillE orl gun (properly fill oil every
240 working hours
ffil (proPerlYfill
240 working hours
Dismantle reducer and fill Iubricant
(properlY fill oil every 240 working
hours)
ffivfill oil every
240 working hours and replace.4'7L
Tili wiih diisfilrilGiiEfhe rirst 1 00
working hours and every 400 working
hours aftqry1r.ds)-,--
rvbiirv ipbrv on ine to"i ;ui'face
(properly fill oil every 56 working- ^
nours,'cteir foreign matters every 10
days, and rePlace 0.5L of oil every
1500 working hours)
ffiel (fill llofoil
every 30 working hours and rePlace
3L oioil every 1'500 working hours)
Lubricaie bY manual aPPlicatlon
(properly fill oil every 240 working
opfiffi'il hole;nd fill oil (fill oil to
the upper limit and replace 70l.of oil
1,500 working hours
ffiroPerlYfill oil
240 working hours
Dsmantfind aPPt (ProPerlY fill oil
ffiplaceoil
1,500 workllg-bggIl
@ntletoaPPlY 240 working
(properlY fill oil every
Fillwtth oil canGroperly fill oil every
56 working hours
(fill o.SLof
@ll hours and
oil every Z4O worfing
Y
@andFilling
Narnfif Lubrication
Location @oworking
;na hFEm-icPush rod
Suface grease of steel @oworking
Steelwire roPe
Lubricate bY aPPlication
eonnectrng bolt of the
tower ffiil
""l"ii""L.v workins-l9'*
(fillo.5L

General industrial gear

240 ii9-
Traveling mechanism rJpf r"" zt- tt oit every 1'500 working
reducer
oilNo.90
ffiedY.fill
240 workilg-lqulg
oil
fraveting mechanism

eomrnon Failure
fill
rope-aligning axle and Rust removal and regularlY
Steelwire roPe tubricating oil as sPecified'
disorder tait< of lubricating oilfor

hlcreastsprmg Pressure of
Too smallbrake moment
SuFace oii Pollution of Remove oil Pollution

Fxcessive brake Adjust toa ProPer brake

Hoisting
winch --- I -.
se b rake -s ho e
n c_-rea
Too short braking time clearance or Push rod travel
Excessive shocking Unbalanced clearance
under load Adjust to the balance
on both sides of brake
block
BTake-treats and ProperlY adjust the clearance

or too smatt Adjust to the Proper

rieGive
fxessivetY fill oil in the
PropeEleduce the filling

nOjust wneel levelness'

Deviation of wheel verticalitY or diagonal
installation
Chew the track
Traveling
owiation qf!99!19
Mechanism Ctean the rail
OiGnd water existed
nOiust tne wheel Pressure
Uneven wheel Pressure
ani parattel track of the jib

154
_.,-r

and Troubleshooting
10 Gommon Causes of Electrical Failure
ChaPter
1. Hoisting winch
Failure Cause
t,--The cort of totat
AC contactor KM
1. Check whether the
is broken or
coil of totalAC
burned out;
contactor KM is in
4BV voltage exists at 2. The handle of the good condition;
both ends of control combination
circuit L03 and 2' The control console
2. Put the operatrng
handle alzero
iotalAC contactor KM has not been
Position;
cannot close when reset (zero
oressing the start Position);
3. Exchange anY
two-Phase inPut
button SA1' 3. Phase sequence I Power;
of the
phase-sequence

eh6k wheinE-the wiring

The totalAC contactor
KM can start, but not
self-lock'
The circuit 1-11#for
self-locking ontact of
iotalAC contactor KM
is oPened or
damaged.
No frequencY
outPut from the
inverter causes
no close of 1KA1
(it closes al?Hz
of
t-oit"ft-fo.t ing contacl
is
iotuf nC contactor KM
successtut, and whether
ine contact is in good
Check whether the
circuit is oPened,
and whether the
inverter is damaged'
Check whether the ,

of o,-rtput inv.rter is dairiagec'

freouencY) and whether the
When ascending or The frequencY of inverter Parameter is
descending, KMI inverter rises too wrong'
(control the hoisting slowlY Press the reset
brake) Gannot close' The inverter button to reset the
reports failure' inverter.
causing 1KA2 RePlace Y1 contact
contact triPs off' witi"r VZ contact, and
The Y1 contact of reset relevant
the inverter is parameter'
d
1.
--[5sck rising
deceleration limiter
deceleration
GSQ2.
limiter is
damaged'
2. Check whether the
terminals of 101#
Fail to enter the toP 2. OPened between
and 131# are
gearwhen hook the circuit 101#
.
loosened'
ascends or descenos' and 131#'
3. Check whether the
3. lntermediate relaY
1KA4 coil is burned
1KA4 is

The fault reset

1. Check the fault reset
button is
button'
Pressing the fault damaged.
reset button cannot Serious failure of 2. Consult technicians
for advice'
I clear the failure' the inverter'
cannot clear the
I
-

Failure Cause
r'ir rhleshootino
No. Eoilr,ra Svntom
r^:1,

1. Poor brake torce ilneaotusttne I

of hYdraulic Push hYdraulic Push rod I

rod brake' brake.

SlipPing haPPens 2. Too heavY load 2. Lift the weight
when the hook is
3. Too low oPerating sPecified in the
6
I ascending or voltage'
g.
manual.
I d"t"ending. influencing the I Ensure normal
normaloPeration I oP"ruting voltage of
nf fhe inverter. I tne inverter.
The brake unfi ls 1. Cfrect< tfie brake
1. I

damaged. unit, and timelY

The hoisting braking replace if damaged'
resistor is seriouslY 2. Work under a
7
heavy load for a 2. ProperlY reduce the
heated.
lnnn time work intensitY.
tne
--I-rhe deceieration fa ils Does not adjust limiter
Readjust the rising
B I during th.e hook is deceleration deceleration limiter'
I nstng' GSQ2.
1. The weight limiter load has exceeded
FSQ2 striPs off' the limit.
2. The oPerating 2. Check whether the
voltage is oPerating voltage
The total contactor KM unstable, and the loses a Phase, or
strips off when it is JX contact of whether the voltage
working' Phase-sequence is too low.
relaY triPs out' 3. Check
I g. Phase-sequence Phase-sequence
! retaY is faultY. relav. -:-.:-t-
--:

2. Slewing Mechanism:
After the handle
returns to zero
oosition, the slewing
mechanism stoPs after
a long time.
The slewing
mechanism stoPs in a
too shorttime'
Failure Cause
t. ChecX the slewing
The eddY current eddY current'
fails to function. 2. Check whether the
The motor eddY eddY current coils of
current coils are slewing motor are
damaged.
ffitting of slewing
eddv current voltage
The slewing eddY includes 27V, 35V,40V,
and 45V. ProPerlY reduce
current voltage is too
high. the eddY current voltage
based on the Practical

t. fne eddY current

After inverter striPs off
due to a failure, the
slewing mechanism
stops in a longer time'
Check the eddY
circuit fails to
function. current circuit.
Consult technician
2. The EB contact of
for advice.
the inverter is

T.
- c#Atfre switch of
Wnen operating, the the switch of
slewing limiter slewing limiter 2SQ1
slewing mechanism or readjust it'
normallY rotates to the 2SQ1 functions
left direction, but fails (open circuit). 2. Check intermediate
I to the right direction' lntermediate

156
 Failure Gause
Failure

Tfr6lwitcn ot
l--
" Thtswtch of
siewing limiter 2SO2
slewing limiter functions (oPen
When oPerating, the 25Q2 functions
slewing mechanism (oPen circuit)'
circuit)'
normallY rotates tothe lntermediate relay
r Check intermediate
iior't oir-u"tion, but fails relaY 2KA3 and the
"to 2KA3 is not
the left direction'
zero
Th#ewing zero Point Check the slewing
The footbrake fails to 2S7 broken or Poor point.
function'

3. TrolleY mechanism:

t.--TGTWI- ano T--rineZotust tne

fonruard and
When oPerating, the BWL limit switch
backward limit
go been
trolleY can neither have not
ttrwaio nor backward' fine adjusted'
TG troGYEact<ward Adiust the limit switch
limiter BWL is in oPen 35Qz'
AaiustiFe-limit switch
Tne troGY forward lifting
The trotleY can go 3S'a', or reduce the
limiter FWL is in oPen

The trolleY stoPs

ffiotbrake disc is Adjust the brake
trolleY clearance.
working. The sliding
excessive.
"$i$1nce1q!9q Tne m,:ment
limiter LSQ4 was
activated alreadY'
The forward 1. Check the causes for
deceleration activation of LSQ4'
limiter FWDEC 2. Readiust the
Fail to enter the toP FWDEC limiter'
was activated
oear before and after alreadY. Readjust BWDEC
3.
ihe trolleY'
The backward limiter.
deceleration
limiter BWDEC
was activated
alre
f .--Tfre inverter en
contact is 1. Consult technicians
damaged' for advice'
2. The inverter striPs 2 Press the fault reset
The trolleY brake off due to a button to reset the
cannot be oPened' failure, causing inverter' lf not' find
3KA1 closed and the failure causes'
brake circuit
disconnected'

157
Electricalelementsinetectricalcabinet(includingjackingcontrolboxand Three months
resistor cabinet), weisht
imiter' I tJ[:"1['5:",'i:1':,i
:*:l"H
YTT,*'^l erectric berr'
indicator'
;fi;Hi,flll?lli"illf#t#i" ""0 "''i'
pulley' and steel*nu'q'
""rocitv
ligh1,
"utirr.ii"" r:artmechanism
Gear reduc", of noittig-'p''luy' t'"*ing "nd
cable' hoister' and slewer
All motors of tornninution-Jnt'olconsole'

ffi
Bearing and slewing suPPort

O,n"r" wearing Pads

not indicated
due
,utid from tne date of delivery' Any-damages
period of wrrruntyl[
L

The above details and be out of the warranty'

af a111uly or careles' op"*i[n shall
to user,s improper dismaniling of continLrous
td remove pronrcms for users- ln consic.eration
However, we wi, make
efforts
uncertain when you 'l'J
tn't manual and find material
,o, rnay feel
improvement to proJr"t.,
;#; the designer and technical
I'rrvrvwith orisinal T:::::]:
conflicts
J;;';' "on*"t
object vvr
uu,.,vr
Thank Yt
your cooperation'
department. "io,.

158
 +l' fl *[t&
rcr58 1 o +9:*'fa4l1nHl* and sp ecifi cati o ns
TCT 5 B 1 0M ain,.,u..i,J,i ^t*.i,I

NSme
Rod .
Ste;@4ry9* T3454
l*r i ?EfT35 x 12
Material

UpPer chord Q345H

The 1st iib Part
Lower chord 2Ai
L=10440mm
-F*
Oblique bar 20 1

The Znd iib Part

'
Web member

UpPuryhotd
Lower chord
Effi#
o 5+xs
o3aqE-
E5+se
20
0blique bar 20
L=10000mm .x<OY4
Web member o3458
ploax loBxB
UpPer chord 15+se
The 3ed iib Part
Lower chord egrrggnq- 20
Oblique bar
L=10000mm 20
Web member

UoPer chord
ffidta
- nnfinxE - -
Q3458
03458
l-J lzvz-vv'
Lovr,er chord
50x4
,

The I .th iib Part 20

Oblique bar
s
L=1 0000mm
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045x4 *- 20
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TfgoxSox6- Q3458
o3458
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The o4 Ux4
t=,5000mm I qr,r r0X4
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1 Lower chord
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membet t3458
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Lr---. rlrnrrl l.J ou

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Lower chord
LJ OU
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0blique bar 040x4
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Web member
s34x3
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Bth iib Part
UpPer chord
E saxs4x !- Q3458
Q3458
Lower chord n a0xEdxs
-=6000mm 2A
0blique ba t040x4 2a_
los+x3_-
lg:r"qr$ YZt,to* t"1o jJ Q3458
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bwerbodYl '5
x1 5m l-Qb]is!r! a"L* TsoxSoxs Q235B _
hp
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-+ lvrorrr vr'-
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t10 6zssn
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Pull rod x'1 6 o3458
cnnnter iib ro
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Web member
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Q2358
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Oblique bar
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