SLT160 (L5523-12) Service Manual

SLT160(L5523-12) Service Manual (NO.
1)
SLT160(L5523-12)
Luffing Jib Tower Crane
Service Manual
中国·三一塔式起重机械有限公司
SANY Tower Cranes Co.,Ltd
SLT160(L5523-12) Service Manual (NO.1)
SANY Tower Cranes Co.,Ltd

1.2 Overview
SLT260(L5523-12) is a self-raising tower crane
developed based on GB/T5031 "Tower Crane",
GB/T3811 "Crane Design Specifications", GB/T13752
"Tower Crane Design Specifications" and related laws,
regulations. The advantages are as followed:
1.The working modes of SLT260(L5523-12) tower crane
include: support reinforced based, bottom reinforced
based, adhesion, traveling and climbing. The Rated
hoisting moment is 1600kN•m, the Max. working radius
is 55m, the Max.hoisting weight at the maximum radius is
2.30t and the Max.adhesion height is 230m.
2.It is equipped with complete safety device and anti-
disassembly device of the highest level of protection.
3.The hoisting mechanism adopts three-speed motor with
unique technique of zero speed in place, which enables
the gentle movement of tower crane during speed
changeover, and light swaying, low brake noise when
brake stops.
4. The electrical system adopts SYMC special for SANY
tower crane, whose protection performance has surpassed
all the other products in this field.
5.It adopts SYCD high definition display, which can be
used to display actual working parameters. Also this
display possesses the function of GPS remote control,
interaction and storage.
6.The side-set cab can provide you broad view; the
control levers enable convenient operation, and the pedal
can increase the comfort of operation.
Based on its excellent performance, the tower crane by
SANY can be applied in large construction projects like
high-rise or super high-rise buildings for civil use, water
conservancy project,large-span industrial plant and tall
chimney&silo constructed with slip form.
Jib length Height

Item Unit Parameter

Rated hoisting torque kN.m 1600
Max.rated hoisting capacity t 12
ax.rated hoisting radius under overall jib
m 20.9
length
Rated load capacity at Max.radius t 2.14(α=3)/2.3(α=2)
Working radius m 55/5.8
Independent hoisting height m 52.58/94.08
Name Speed Power/KW
Hoisting speed 0~96 m/min 55
Luffing speed T≤2.5min 30
Slewing speed 0~0.7r/min 18.5
Parts of
α=2 α=3
Lifting line
Performance Range 25 33.43 55 25 33.43 55
（55m） Load
6 6 2.3 9 5.84 2.14
capacity(t)
Parts of
α=2 α=3 α=4
line
Lifting
Performance Range 20.9 25.8 34.25 55 20.9 25.8 34.25 55 20.9 25.8 34.25 55
（50m） Load
6 6 6 3.1 9 9 5.9 3.03 12 8.88 5.78 2.94
capacity(t)
Max.load
Radius 23 25 28 30 33 35 38 40 43 45 48 50 53 55
capacity
5.55-32.38m 5.8 5.2 4.5 4.1 3.6 3.3 2.9 2.7 2.4
6 2.3
55 6t 2 7 8 7 5 5 5 3 4
m 5.55-24.57m 8.7 7.3 6.6 5.6 5.1 4.4 4.0 3.5 3.2 2.8 2.6 2.3 2.2
9
9t 8 9 4 8 4 5 5 3 3 5 2 4 1
5.12-33.81m 5.6 4.9 4.5 3.7 3.3
6 4 3.1
6t 8 5 5 1 1
50 5.12-25.54m 7.8 7.0 6.1 5.5 4.8 4.4 3.2 3.0
9 3.9 3.6
m 9t 6 9 1 5 4 2 1 1
5.12-20.61m 10. 9.1 7.7 6.9 5.9 5.4 4.7 4.3 3.7 3.4 3.1 2.9
12t 3 5 3 6 8 3 1 1 8 9 1 2
4.68-34.53m 5.8 5.1 4.7 4.2
6 4
6t 8 7 8 7
45 4.68-25.86m 8.0 7.2 6.3 5.7 5.0 4.6 4.1 3.9
9
m 9t 4 7 1 6 7 8 7 1
4.68-20.77m 10. 9.3 7.9 7.1 6.1 5.6 4.9 4.5 4.0 3.8
12t 44 1 1 4 8 5 6 7 8 3
4.25-35.17m 5.3
6 5
6t 7
40 4.25-26.11m 8.1 7.4 6.4 5.9 5.2 4.9
9
m 9t 8 1 7 4 6 1
4.25-20.88m 10. 9.4 8.0 6.3 5.8 5.1 4.8
7.3
12t 56 1 5 6 3 7 2
3.81-35m 6t 6
35 3.81-26.48m 8.3 6.6 6.1
9 7.6
m 9t 5 8 9
3.81-21.08m 10. 8.2 6.5
9.6 7.5 6.1
12t 71 3 9
3.38-30m 6t 6
30 3.38-26.79m 8.4 7.7
9
m 9t 9 8
3.38-21.27m 10. 9.7 8.4 7.6
12t 85 4 1 9
Jib length State Fv（KN） Fh（KN） M（KN.m） T（KN.m）

Working 909.40 44.07 4524.70 327.53
55m Non-
786.30 154.40 5820.67 0.00
working
Working 946.47 45.60 4602.24 296.50
50m Non-
795.65 159.40 5875.08 0.00
working
Working 945.25 43.97 4411.33 266.54
45m Non-
789.80 156.39 5254.35 0.00
working
Working 954.42 43.98 4352.85 236.29
40m Non-
799.15 161.35 5317.20 0.00
working
Working 948.28 42.27 4127.72 210.82
35m Non-
793.42 158.89 4882.96 0
working
Working 957.30 42.08 4077.73 194.94
30m Non-
802.66 163.87 5018.11 0.00
working
4 Installation
4.1 Preparation before installation
4.1.1 Preparation at work site
1 Check the installation area for

tower crane.
Make sure there is enough
space for the installation, the tower
crane can slewing freely with no
interference with surroundings.

2. Power supply preparation
Refer to safety symbol and
chapter 3 “Technical Specification”
for the requirements for the power
supply.
3. Lighting protection
Before operation, check the
lighting protection and grounding.
Commonly there are 3 grounding

Fig. 4-1
modes:
1) Normal ground stud made, 1.5m
φ33× 4.5 steel pipe, or 1.5m L70 ×70
angle steel (see Fig. 4-1).
2) 1m2 ground plate made of steel
plate or other extensible metal plate,

Fig. 4-2
bury it into the ground 1.5m (see
Fig. 4-2).
3) Bury the section ≥ 28mm2 copper
conductor or ≥ 50mm2 iron
conductor into the groove 1.5m away
from the ground. The buried length
depends on the ground resistance

Fig. 4-3
(see Fig. 4-3).
1 The connection between the ground object and the tower crane
basic mast or base should adopt section≥ 25 mm² copper cable or ≥
100mm² anti-rust metal strip. The metal strip can be directly welded
onto the tower, and the cable can be connected through the screws.
2 The final ground resistance has something to do with the ground
object, the contact area with soil and the conductivity of the soil. Once
the ground resistance is less than 4Ω, it can be resolved by increasing
the conductivity of soil through ground object increase or salt.

4.1.2 Installation personnel preparation
1 The construction unit has the installation license.
2 The installation personnel should understand the operation manual
be familiar with and can correctly use the protective equipment.
3 Make sure all components are in right place and in good state with
no defect.
4 The installation personnel should know the location of hoisting
points for all the components.
5 The installation supervisor should possess rich experience and skill.
6 Before assembly, make sure the weather will not affect the stability
of tower crane and its components; it is forbidden to conduct assembly if
danger may be caused by the bad weather.
Instructions for erection:
1 Wind speed at top does not exceed 12m/s.
2 Well know the erection procedure
3 Each connection is special, no authorized replacement is allowed.
4 Do correctly install all the safety devices.
5 Well know the installation order and weight of the counterweight.
6 It is forbidden to conduct hoisting when it is not completely
assembled.
4.1.3 Foundation (fixing angles +basic Mast)
A qualified solid base is the precondition for the safety operation of
tower crane SYT250 requires a complete reinforced concrete base
The dimension of foundation and construction mode is specified by SANY
The foundation is designed based on
different earth bearing capacities The
technical requirement goes like following
(1) The soil below the concrete
must be solid Select foundation based
on the soil texture see Table 4-1 .

Table 4-1 Foundation for different earth bearing capacity
3
Earth bearing L/m Top main Lower main Erection Concrete/m
capacity/MP m reinforcement reinforcement reinforcement
a
≥0.21 7000 Longitudinal Longitudinal 400-φ12 78.4
&horizontal42-φ25 &horizontal42-φ25
(2) Backfill the foundation with

100mm pebble bed, compact it and
then braid the reinforcement.
(3) The top lower rebar and the
erection reinforcement are made of
the
rebar of Grade 2. The rebar on each
layer is composed of 2 cross beddings
(see Fig 4 6) . For the convenience of
Construction, tighten the rebar with φ8
rebar of Grade I when it is tied up to a
certain extent.
(4) During installation, fix the four

fixing angles onto the mounted mold or
the basic mast before put them into
the cage of rebars, then introduce an
adjustable block below the angles.
Strictly assure the size 150mm (See
Fig.4-7, 4-8).
(5) After arranging the rebars and

fixing angles, pour the concrete in,
meanwhile, level the angles to ensure
the
upper surface evenness tolerance of
the
four fixing angles no more than 1/1000
(2mm) of an standard cross section’s.
(6) Near the fixing angles, never cut
the rebars nor reduce their number
given.
(7) The concrete filling rate around
the fixing angles must exceed 95%, and
the concrete grade should not less
than
C35, the maintenance period is at least
15 days.
(8) The depth of foundation is no
less than 1.6m.
(9) For the convenience of drainage,
the concrete surface should be 100mm
higher than the surrounding ground.
(10) For attached installation, it is
required that the distance between the
tower slewing center and the mounting
hole edge on the anchorage embedded
bracket is 5m.
(11) The fixing angles are provided
by SANY and the others (like rebars,
concrerte ) are prepared by the
customers themselves.
The four fixing angles are provided

by SANY. SANY will bear no
responsibility for any accident caused
by not adopting genuine parts.
.
.
When connecting the fixing angles

with the mounted mode or basic mast,
please keep the joint face and the pin
clean. There should be no dirty.
.
4.2 Installation of tower crane
4.2.1 Instruction for the installation of
tower crane
1. Make sure the links and locking
Components (like pins, bolt shafts,
shaft end retaining plates and bulldog
grips) are complete and securely
connected.
2. Tighten the high strength bolts
with specified pretightening force and
torque. Coat all the bolt components
with lubricating oil to decrease friction.
The lubricating locations cover all the
flats of thread and the contact
surface
of pretightening force applied
componets (see Fig.4-12).
3. Make sure the pins are securely
connected and tightened The following
conditions are not allowed:
a) No split pin is installed;
b) The ends of split pins are not bent
separately as specified;
c) Replace the large split pins with
small ones;
d) Substitute the split pins with steel
wire.
4. Check the wear of pin holes if
the wear does affect the tightening
and connection of pin, it is a must to
remedy it before installation.
5. Before hoisting, make sure the
components on the counter-jib and jib
are securely tightened and the hoisted
components are in balanced status.
.
6.During assembling make sure

the number, weight, location of the
counterweight and the assembling
procedure of the jib can meet the
requirements specified in this manual.
It is forbidden to adopt damaged

bolts and nuts or the ones with rusted
screw rod and flat of thread.
7. Select appropriate crane based

on the weight and hoisting data
specified in Table 4-2. Well prepare the
hoisting equipments like sleeper,
bracket, rigging and cable loops.
The minimum hoisting height in the

table refers to the hoisting height
required by each components in
erection.
In erection, only 1 basic mast
section and 1 standard mast section
are hoisted, the other mast sections
are added by telescoping.
4.2.2 Installation order
4.2.3 Basic mast installation

Hoist the basic mast with an
appropriate crane and lower it slowly
until it comes to rest onto the
fishplates of the 4 fixing angles,
pin-connect it by
means of 8 φ65 shafts, 4 φ15 pins and 4
split pins (see Fig. 4-15).
Take care the following things when
fitting the pins:
1. Ensure no burr and wear on the
fishplate and its sides.
2. Lubricate the pins and inner holes
with grease.
3. Drive the shaft in until it completely
in.
The direction of the mast section

introduction is decided by the direction
of the lug on the basic/standard mast
during telescoping (see Fig. 4-16). Take
the telescoping and disassembly into
account when laying the basic mast.
4.2.4 Mast section assembly installation

The standard mast section adopts chip
structure, and comprises 4 panels which
differ from each, ladder and platform.
Installation procedure:
1.Fit each panel by means of M27 hexagon
higed bolt (950 N·m pretightening torque),
and fit the cross beam using M20 bolt (370
N·m pretightening torque)(see Fig.4-17).
Carry out fitting strictly according to

the diagrams, and notice the distinctions
between the 4 panels: panelⅠand panelⅡ
include lugs, whereas, panel Ⅲ don t
have. Moreover, there is a mounting plate

of platform on the web member in the
middle of the panelⅠand panel Ⅲ.
The cross beam connecting the panelⅠand
panelⅡincludes a mounting plate
that distinguishes it from the other 3

beams.
1.For the safety operation of tower,
crane, it is a must to tighten the
high-strength bolts with the
pretightening torque specified in this
manual.
2. Fix the upper end of the ladder onto

the mounting plate of the cross beam, and
fit the split pin (see Fig. 4-18)
3. Fit the platform assembly onto the

mounting plate of the middle web member
using M12 bolt components. And thus,
complete the assembly of the mast section
(see Fig. 4-19)
One platform should be installed every 10m

height or 3 standards.
The ladder can be fastened by meas of iron

wire to avoid shaking.
4. Lift the assembled standard mast,

lower it slowly and rest it onto the basic
mast fish plates, connect them using 8 φ55
pin shafts, 4 φ 15 position pins, and 4
split pins. Meanwhile, secure the lower
end of the ladder to the mounting plate on
basic mast (see Fig. 4-20).
5. Check verticality with theodolite
or plumbing method. The verticality
difference of the 4 sides on main chord
should less than 1.5/1000.
Keep the lugs on each mast section in
the same direction as well as the channels.

4.2.5 Telescoping cage installation

The telescoping cage is mainly composed of
steel structure, platform and hydraulic
telescoping device (see Fig. 4-18)
Inside the telescoping cage, there are 16
rollers, during telescoping, they stand
outside the main chord functioning to
guide. For safety, there equips respectively
a working platform in the upper, the middle
and the lower part of the telescoping cage
is hinged to the hydraulic cylinder,
functioning to support the telescoping load
from cylinder . There exist 2 swing claw
operated by a lever in the middle part of
telescoping cage, they can support the
weight from the upper structure if laid
upon the upper face of the lug during the
process of cylinder retracting and mast
section introducing.
It is a must to protect the telescoping
pump and cylinder during installation.

During hoisting:
1. After the assembling of the telescoping
cage, hand the sling onto the frame and
hoist it with wire rope (see Fig. 4-19), the
telescoping cylinder must be fitted on the
same side with the lug.
2.Fit the telescoping cage outside the
tower mast with gentle motion.
3.Rest the claws onto the 2nd pair of lugs
on basic mast press down the control lever
to lock the claws.
4. Properly fit the telescoping cylinder,
hoist the hydraulic pump to a corner on the
platform, connect oil pipes and then check
the operation of hydraulic system (refer to
chapter 3.6 for the content of hydraulic
system).
4.2.6 Slewing assembly installation

Slewing assembly installation:
Connect the upper, lower support and
slewing bearing with 120 M27 high-strength
bolts of Grade 10.9. Tighten the bolts with
double nut, and the pretightening torque
for each bolt is 1100N·m.
Platform installation: hook the platform
onto the mounting pin shaft of the upper
support, lock it at the top using fixed pin
and split pin. Proceed in the same way to
fit the other two platforms. Then fix the
handrails, and secure the neighboring
handrail with pipe clip assembly. Finally, fit
the driver s cab onto the platform by
means of 3 φ16 pins.
Install the introducing guide rails correctly
and insert the pins and split pins as shown
in the following figure.
Hoisting procedure:
Hoist the slewing assembly through the 4
lifting lugs on the upper support, lower it
slowly until the connecting board of the
lower support rests on the fishplate of the
standard mast, and then connect them by
means of φ55 pin shaft components. The
channel on the lower support should be in
same direction as the one on the mast (see
Fig. 4-23)
After confirmation of the reliable

connection between the slewing assembly
and the mast, extend the hydraulic cylinder
to hook the support shoes at both sides of
the cross beam onto the lugs on basic
mast, and insert the safety pin. Raise the
control lever to release the claw, and lock it
with the securing ring.
Telescope the cage till it abuts against the
connecting plate on the lower support, fit it
using 4 φ55 pins and secure it with locking
pin (see Fig.4-24).
Withdraw the safety pin and retract the
hydraulic cylinder.
4.2.8 Counter-jib assembly installation

The counter-jib assembly is composed of
counter-jib, platforms, handrails, hoisting
mechanism, power cabinets, counter-block
Installation pole, and maintenance frame
(see Fig. 4-26).
Hoist the counter jib assembly:

Connect the slewing mechanism to a
temporary power supply and turn the parts
above the slewing bearing toward the
direction convenient to fit the counter-jib.
Connect the counter-jib to the slewing
mast with φ65 pins (see Fig.4-27).
4.2.9 A-type Frame assembly installation

The A-type Frame assembly is composed of
an A-type frame, pulley system, platforms,
handrails, ladder stands, and shock
eliminator,
(see Fig. 4-26).
Hoist A-type Frame assembly:

Hoist A-type Frame assembly slowly,
connect the joints to counter-jib assembly
and the slewing assembly with φ60 pins (see
Fig. 4-29).
4.2.10 Counter-blocks installation

Hoist one counter-block, move the
counter-block onto the counter-block
installation pole, then put down slowly, make
the rods through the holes (see Fig.4-31).
4.2.11 Jibs installation

Lift and tilt jib 1, move slowly to another jib,
then connected with the pin of the upper
chord (see Fig.4-32).
Lock the lower chord of both jibs with

shoulder pin shaft and split pin (see
Fig.4-33).
Connect the other jibs in the same way.

Hoist jibs assembly:

Hoist jibs assembly slowly at a suitable
position (see Fig. 4-33), connect jibs
assembly to slewing assembly with φ75 pins
(see Fig.4-34)
4.2.12 Wire rope winding

Rope clip installation:
Make the U-type bolt buckle (1) in the
non-working section (2) of the wire rope.
The clamp seat (3) is fastened on the
working section (4) of the wire rope (see
Fig.4-35)
Changing amplitude wire rope installation:

Wire rope is wound between the top of the
tower support frame (1) and the luffing
pulley block (2) (see Fig. 4-35).
Install the wedge sleeve (1) on the end of the

wire rope. Fix the wedge sleeve on the
torsion preventer (2) with pin shaft (3) and
cotter pin (4). Install rope clip (5) on the
non-working section of the wire rope (see
Fig. 4-36).
Hoisting wire rope installation:

Run the wire rope from the reel (1) through
the rope runner pulley (2). Lead the wire
rope to the top of the brace and through the
pulley (3). Run the wire rope down through
the pulley (4). Lead the wire rope up again
through the brace pulley (5). Insert the wire
rope into the guide wire bracket (6). Thread
the wire rope through the pulley (7) at the
end of the jib, then go through the hook
wheel pulley (8-10)
(see Fig. 4-36).
Install the wire rope in the torsion preventer

(2). Draw out torsion preventer (2), pin shaft
on wedge sleeve (1). Attach the wedge to the
wire rope (3), then fix wire rope clip (4) on the
non-working section of the wire rope. Fix
the wedge sleeve (1) to the torsion preventer
(2) with pin shaft (5) and cotter pin (6) (see
Fig. 4-38).
For our consistent improvement in technology,
specifications may change without notice.
If you are looking for our after-sales service, please

call our service hotline 4008 87 8318.
Address：Jinzhou development zone, Changsha, Hunan, China

Tel：(86)731-87873131
Fax：(86)731-84031999-196
Service Hotline：4008 87 8318
Complaint Phone：4008 87 9318
All rights reserved. Reproduction in whole or part without written permission is prohibited.

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SLT160(L5523-12) Service Manual (NO.

SANY Tower Cranes Co.,Ltd

Jib length Height

Item Unit Parameter

Jib length State Fv（KN） Fh（KN） M（KN.m） T（KN.m）

4.1.1 Preparation at work site

1 Check the installation area for

Make sure there is enough

space for the installation, the tower

crane can slewing freely with no

interference with surroundings.

2. Power supply preparation

Refer to safety symbol and

chapter 3 “Technical Specification”

for the requirements for the power

Before operation, check the

lighting protection and grounding.

Commonly there are 3 grounding

1) Normal ground stud made, 1.5m

φ33× 4.5 steel pipe, or 1.5m L70 ×70

angle steel (see Fig. 4-1).

2) 1m2 ground plate made of steel

plate or other extensible metal plate,

bury it into the ground 1.5m (see

3) Bury the section ≥ 28mm2 copper

conductor or ≥ 50mm2 iron

conductor into the groove 1.5m away

from the ground. The buried length

depends on the ground resistance

basic mast or base should adopt section≥ 25 mm² copper cable or ≥

2 The final ground resistance has something to do with the ground

the ground resistance is less than 4Ω, it can be resolved by increasing

the conductivity of soil through ground object increase or salt.

4.1.2 Installation personnel preparation

1 The construction unit has the installation license.

2 The installation personnel should understand the operation manual

be familiar with and can correctly use the protective equipment.

4 The installation personnel should know the location of hoisting

points for all the components.

5 The installation supervisor should possess rich experience and skill.

of tower crane and its components; it is forbidden to conduct assembly if

danger may be caused by the bad weather.

Instructions for erection:

1 Wind speed at top does not exceed 12m/s.

2 Well know the erection procedure

3 Each connection is special, no authorized replacement is allowed.

4 Do correctly install all the safety devices.

5 Well know the installation order and weight of the counterweight.

6 It is forbidden to conduct hoisting when it is not completely

4.1.3 Foundation (fixing angles +basic Mast)

A qualified solid base is the precondition for the safety operation of

tower crane SYT250 requires a complete reinforced concrete base

The dimension of foundation and construction mode is specified by SANY

The foundation is designed based on

different earth bearing capacities The

technical requirement goes like following

(1) The soil below the concrete

must be solid Select foundation based

on the soil texture see Table 4-1 .

Table 4-1 Foundation for different earth bearing capacity

(2) Backfill the foundation with

(4) During installation, fix the four