TOWER CRANE L Instruction Manual

Transcription

1 TOWER CRANE L Instruction Manual Zoomlion Heavy Industry Science &Technology Co.,Ltd Add:ON.667,Lugu Road,ChangSha,HuNan,P.R.CHINA Tel: Fax:

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3 TOWER CRANE L Data: Editor Approver: Revision:

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5 CUSTOMERS: Thanks for your purchase and being one of the users of Zoomlion Tower Crane! Go through the instrutions for correct operation and maintenance, and always keep at hand for consultation. Pay attention to the sentences marked with Warning, Notice or Precautions in this publication, which involves safety of constrution. Ignore the instrutions could result in accidents and injuries! Only through rigorous training and achieved qualified personnel to operate the tower crane Must strictly implement the relevant instrutions, the relevant regulations and directives (such as prevention of emergencies, etc.) Zoomlion has been devoting every effort to the perfect of her products. Therefore they are changed without notice. If you have any questions, please don't hesitate to contact Zoomlion for further consultation. i

6 contents 1 Security signs Main Parameters Overall Dimensions of The Tower Crane The Parked Position of Jib on Non-service Conditions Radius and Load Capacity Technical Performance Parameters for The Whole Machine Technical Parameters of The Mechanisms Transport Notice during Transport Transport Unit Preparation Weight and Erection Dimensions of Main Components Foundation Load on Foundation Of Crane With Outrigger The Foundation For Crane With Outrigger Install the Embedded Anchors Earthing Counter Ballast Counter Ballast Configuration of Different Jib Manufacture Counter Ballast Erection and Dismantling Cautions Security Signs of Tower Crane Components Weight and Height General Layout of Tower Crane Assembly Relation of Main Components for Stationary Crane with Embedded outrigger Tower Erection Steps of Tower Erection Install Mast Sections I

7 5.5.3 Install Climbing Frame Install the Slewing Ring Assembly Install the Slewing Tower Mast Install Operator Cab Install Counter Jib Assembly Install Hoisting Mechanism Install Luffing Mechanism Install A-frame Assembly Install Two Counter Ballast of 2.75t Install Jib Assembly Install Luffing Suspension Install Counter Ballast Wind Hoisting Wirerope, Install Hook Power on and Trial Operation Jacking Work of Crane with Outrigger Internal Jacking of Tower Crane Description of Internal Climbing Device Climbing of Internal Climbing Tower Crane Dismantling of crane Basic formality of dismantling tower Dismantle the tower body Dismantle counter ballast Dismantle hook The dismantling of luffing tie bar Dismantle safety rope Dismantle jib The Dismantling of counter ballast of 2.75T Dismantle travel machine Dismantle hosting mechanism Dismantle counter-jib assembly Dismantle operator cab Dismantle slewing tower II

8 Dismantle slewing support assembly Remove climbing frame Remove tower sections Attentions after dismantling tower crane Mechanism hoisting mechanism Summarize Technical parameters of Hoisting mechanism Motor Brake slewing mechanisms Luffing mechanism summarize performance parameters of luffing mechanism motor break SBD80-D safety brake Climbing Jack Summarize Erection and operation of the hydraulic system Operation Operation guide Pre-check before operation Attention for operation Safety Operation Adjusting working Checking part and coponents before adjusting working Introduction of safety device Experiment Electrical Control System Maintenance and Service maintenance III

9 9.1.1 Daily maintenance Week maintenance Mmonth maintenance Ordinary troubles, troubleshooting and solution Assebmlly Buffer s Maintenance and Service Buffer s structure Buffer s Maintenance and Service Wire rope steel rope basic knowledge Wire rope list Hoist rope length The trolley rope length Installing the wire ropeadhere Discard criteria of wire rope Maintenance of wire rope IV

10 1 Security signs WARNING: Live parts! Electrical installation, connection work and maintenance must be done only by authorized, properly qualified personnel. No standing under the radius No ascending Danger of rolling Danger of falling down! Wear and use a safety harness! Emergent stop Very hot, do not touch! Danger of crushing! 1

11 Insert pins while climbing the crane! Keep watch WARNING: Suspended loads! Wear safety helmet! Check ropes Lubricate! Adjust the height limiter! Check metal structures! Check brakes! Adjust brakes 2

12 Keep safety devices workable! Maximum load on maintenance cage Always close the hatches! Forbid to stand! Tie safety belt 3

13 2 Main Parameters 2.1 Overall Dimensions of The Tower Crane 4

14 2.2 The Parked Position of Jib on Non-service Conditions The parked position of jib must be controlled strictly so that the slewing mechanism of the tower crane can slew free on non-service conditions. Fig L the parked position of jib on non-service conditions Notice: (1)It is required that setting a windshield to increasing the frontal area of jib to insure that the jib can slew free on non-service conditions when the length of the jib is 30-45m. (2)Windshield is made by customers. Windshield and jib are better fastened by U bolts (including one U M12 bolts, two flat washer, two spring washer and two M12 nuts.) Every chord rods of the windshield must be drilled. Customers can also use other methods to fasten them based on practical conditions. But the windshield must be fastness and the jib is not damaged (3)The windshield should be closed to the jib tip as shown in Fig The bolt-holes of 5

15 windshield must be drilled when the windshield is fixed with the jib to make sure that the windshield can be assembled easily. 1 windshield 2 U bolt 3 backer plate 4 M12 nuts 5 spring washer 6 flat washer Fig the fastening of windshield on 30m jib of tower crane number name specification quantity material 1 windshield t Q235B 2 U bolt M12 6 Q235B 3 backer plate T5 6 Q235B 4 nut M washer washer HV 12 6

16 Fig, working drawing of U bolts and backer plate 7

17 2.3 Radius and Load Capacity 60m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 6.24 ~ m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 5.80 ~ m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 2-fall working radius (m) 2-fall hoisting capacity (t) 5.35 ~ ~ m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 2-fall working radius (m) 2-fall hoisting capacity (t) 4.55 ~ ~

18 40m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 2-fall working radius (m) 2-fall hoisting capacity (t) 4.48 ~ ~ m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 2-fall working radius (m) 2-fall hoisting capacity (t) 4.34 ~ ~ m Jib s Radius and Load Capacity 1-fall working radius (m) 1-fall hoisting capacity (t) 2-fall working radius (m) 2-fall hoisting capacity (t) 3.58 ~ ~ Note: above radius and Load Capacity are based on 53.4m free-standing height. When the working height of the tower crane has to be exceeded to 53.4m, the hoisting capacity in above tables must be reduced. Computational method: the hoisting capacity of calculated height= the hoisting capacity in tables- the weight of rope per meter (calculated height- 53.4) fall. (Unit: Height: m; Weight: t) 9

19 2.4 Technical Performance Parameters for The Whole Machine Group classification A4 Hoisting M4 Mechanism classification Slewing Luffing M5 M4 Travelling M3 Ratinghoistingmoment (kn.m) Max hoisting moment (kn.m) 3200 Outrigger Stationary 53.4 Max working height (m) Anchored Internal climbing 500 (1fall) 500 (1fall) Working radius(m) Min radius 3.3 Max radius 60.0 Max hoisting capacity 20(jib length 55m/60m, 10t) Fall 1 2 Hoisting mechanism Weight/(t) Speed(m/min) 0~100 0~80 0~40 0~50 0~40 0~20 Rope capacity (m) 75 Power (kw) 710 Luffing mechanis m Slewing mechanism Counter ballast Max luffing 2.2 time(min) Power(kW) 45 Speed (r/min) 0~0.7 Power (kw) 2 145N.m (RCV) Slewing ring QWA Max radius (m) Weight Design wind speed at the top of tower crane(m/s) 安装状态 Erection condition 14 工作状态 In service 20 10

20 Out of service condition EN14439 C25 Allowable temperature in service ( ) Power -20~+40 ~380V/50Hz Model Unit QPL20100A Max traction of the rope N Technical Parameters of The Mechanisms 起升机构Hoisting Mechanism Wire rope Drum Motor Specification DIEPAB Maximum linear speed m/min 100 Maximum Drum speed r/min 29.3 Rope capacity m 710 Model YZPFM315S-8 Power kw 75 Speed r/min 735 Ratio of Reduction Gears Model 单位 BPL450 Maximum traction of the rope N Luffing Mechanism Braking Moment N.m 1800 变幅机构6 29Fi+1WR 或 Specification Wire Rope 6 31WS+1WR Maximum linear speed m/min 54.7 Rpm rating r/min 20.7 Drum Speed Twist Layers Layer 3 Rope capacity m 190 Motor Model YZPFM280S2-8 Power kw 45 11

21 Speed r/min 735 Ratio of Reduction Gears Braking moment N. m 1250 Model HVV145B1.130A 1 Mechanism Ⅰ Luffing Motor Model YTLEJ132L-145-4B1 Power N m 145 Speed r/min Luffing Mechanism Mechanism Ⅱ Luffing Rreduction Model Unit HVV145B2.130A 1 Model YTLEJ132L-145-4B2 Motor Power N m 145 Speed r/min Model XX CLC-14/12 Gear Ratio i 195 Gear parameter at output end Modulus mm 14 Number of teethz 12 Profile shift coefficient +0.5 Overall Gear Ratio Slewing Speed r/min 0.53 Motor Power kw 7.5 Speed r/min 1440 Internal climbing Mechanism Hydraulic pump Double Jacking Cylinder Flow l/min 14.5 工作压力 Working pressure MPa 31.5 Cylinder /rod diameter mm 200/140 Journey mm 2000 Maximum jacking force t 98.9 Jacking Speed m/min 0.45 ism Mechan Jacking Motor Power kw 7.5 Speed r/min

22 Hydraulic pump Flow l/min 14.5 Working pressure MPa 31.5 Cylinder /rod diameter mm 200/140 Jacking Cylinder Journey mm 2000 Maximum jacking force t 98.9 Jacking Speed m/min 0.46 Slewing Ring Diameter mm

23 3 Transport 3.1 Notice during Transport The components of tower crane are dismantled into several modules to simplify packing and handling for different means of transportation. (1) All components must be safe-reliable in the transportaton process (2) Lighter components must be on the top of the heavier ones. (3) Every components must be separated from other metals by wood or other packing to avoid damaging of the painted surfaces (4) It is prohibited to directly put components on ground. (5) It is not allowed to transport components by unsuitable transportation, such as bulldozer and lift-ladder. (6) Make sure that all components are loaded and auxiliary devices are safe-reliable. (7) Check all the bandings of components. (8) Check all the bandings of transportation. (9) While running in public streets, observe the applicable rules. (10) Pay attention to the space,while passing underground passage, bridge and tunnels (11) Temperature during transport:-25~55. 14

24 3.2 Transport Unit No. Name Dimensions L(m) B(m) H(m) Weight Quantity 1 JibⅠ JibⅡ Jib Ⅳ Jib Ⅴ Jib Ⅵ Jib Ⅶ Jib Ⅷ Frontal-up strut and top-end pulley assembly Frontal-down strut (A-frame) Buffer (A-frame) Diagonal strut (A-frame)

25 No. Name Dimensions L(m) B(m) H(m) Weight Quantity 9 Back strut (A-frame) Slewing tower body Operating platform Climbing frame Introduction platform Jack beam Inner Base tower section Inner Tower section Luffing mechanism

26 No. Name Dimensions L(m) B(m) H(m) Weight Quantity 19 Hoisting mechanism Luffing pulley assembly Counter jib Lower strut of counter jib

27 4 Preparation 4.1 Weight and Erection Dimensions of Main Components Name Dimensions L mm W mm H mm Weigh t(t) quanti ty Embedded Anchor Base section 234c Tower section Climbing ladder Slewing tower mast Counter jib

28 Name Dimensions L mm W mm H mm Weigh t(t) quanti ty Luffing mechanism Hoisting mechanism A-frame Jib Jib tie plate Jib tie bar Φ Jib tie bar Φ Luffing pulley assembly Hoisting beam Punp station

29 4.2 Foundation Check the load capacity of subgrade before casting foundation. Design foundation according the erection height. Anchors on foundation must conform to the next characteristics: (1) The anchors must be symmetrical to the centerline of foundation to be a 2m 2m square. (2) The installed anchor must meet the demand of next figure. (3) It is allowed that the anchors are used one time. (4) Earthing correctly Load on Foundation Of Crane With Outrigger Fig load on foundation 20

30 (1) 60m jib Number of sections height (m) Table load on foundation for 60m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

31 (2) 55m jib Number of sections height (m) Table load on foundation for 55m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

32 (3) 50m jib Number of sections height (m) Table load on foundation for 50m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

33 (4) 45 m jib Number of sections height (m) Table load on foundation for 45m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

34 (5) 40 m jib Number of sections height (m) Table load on foundation for 40m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

35 (6) 35 m jib Number of sections height (m) Table load on foundation for 35m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

36 (7) 30 m jib Number of sections height (m) Table load on foundation for 30m jib operation status Moment Horizontal force Vertical force Torsion M(kN m) H(kN) V(kN) T(kN m) In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s In service Out of service Front wind-o.o.s

37 4.2.2 The Foundation For Crane With Outrigger The ground foundation is the precondition to ensure safe operation of the crane. It is made of reinforced concrete as shown in Fig Basic requirements as follows: (1) The ground under the foundation should be solid. The concrete strength grade must be no less than C35. The foundation load-bearing capacity must be no less than 0.2Mpa. (2) The dimension of concrete foundation is L mm L mm. And ti s height is 2000mm 28

38 Fig L ground foundation 29

39 4.2.3 Install the Embedded Anchors Fasten 4 anchors and the base section together by 8 pivots( φ 60 ); knock the pivots down until its shoulder tightly contact with the surface of chord rod. Place anti-rotation sleeves on pivots before inserting tiny pins and spring pins (Fig.1.2-4, Detail A) Notice: Notice: (1) According to the construction convenience and the progress of binding rebar, hoist the whole piece of anchors assembled with the base section into rebar net. The two areas with climbing lug of tower section must be perpendicular to building. Be sure that the number of re-bars around anchors must not be reduced and re-bars must not be cut off. The climbing ladder fit to the hatch (the hatch is on my right side when stand on slewing support facing to direct of jib erection) according to the certain direction for the section climbing system let-in. Pour concrete after rebars binded. The concrete strength grade must be no less than C35. Hang plumb lines along the center of reinforced tower section to calibrate the perpendicularity of the centerline of reinforced tower section to horizontal plane. Ensure that the perpendicularity of the embedded base section centerline to horizontal plane is less than 1/1000 after foundation completed; The planeness of the section between four anchor and reinforced tower section is no more than 2mm. The rate of concrete filling around the embedded anchors must be over 95%. 30

40 Fig Install the embedded Anchors 31

41 Assemble the First Base section ( include platform, handrail, climbing ladder and hoop guard) In TW250-20, there is only one base tower section including nameplate, power box, platform, pivots and bolts. The assembly drawing is Fig The spare part needed are shown in table4.2-5 (notice: pivots are used to connect anchors). Fig install base tower section 32

42 Table4.2-5 reinforced tower section spare part list Number Code Designation Designation Unit Qty 1 Base section structure 1 2 Support t8 1 3 Short Ladder 1 4 Long Ladder 1 5 Platform 1 6 Platform Ⅰ 1 7 Flex girder 4 8 Splint t8 2 9 GB/T Washer HV 4 10 GB/T Bolt M GB/T Washer GB/T Nut M GB/T Bolt M GB/T Washer HV 6 15 GB/T Washer GB/T Nut M GB/T Bolt M GB/T Bolt M GB/T Washer HV 8 20 GB/T Washer GB/T Nut M Bolt Pin Roll 8 24 Pin Roll 8 25 Axle Sleeve 8 26 GB/T Bolt M GB/T Washer 6-200HV 4 28 GB/T Washer GB/T Nut M GB/T Bolt M GB/T Washer 8-200HV 4 32 GB/T Washer GB/T Washer M

43 Thus the base tower section is installed Earthing (1) Before operating tower crane, operator should consider protecting tower crane from lightning. Take measures as shown in Fig when needed. (2) Lightning is necessary or not according to the rules of the authorities concerned. foundation. Fig protective earthing Notice:earth line should not be connected to the rebars of building 4.3 Counter Ballast Counter Ballast Configuration of Different Jib (1)Summary Counter ballast consists of several reinforced concrete blocks. Different counter ballast should be used for jib with different length. (2)Counter ballast 34

44 ballast jib Counter Table4.3-1 Counter ballast PHZ4000A PHZ4000 PHZ2750 PHZ3000 PHZ2000 Gross weight(t) 60m jib m jib m jib m jib m jib m jib m jib Manufacture Counter Ballast (1)Summary Counter ballasts are manufactured by customers. Counter ballast shouldn t be damaged during transport, erection and in use. (2)Dimensions of Counter Ballast There are 5 counter ballasts, all of which are cast with reinforced concrete. For detailed specification, refer to Fig.4-6a, Fig.4-7a, Fig.4-8a, Fig.4-9a and Fig.4-10a.respectively, for reinforced bar layout, see Fig.4-6b, Fig.4-7b, Fig.4-8b, Fig.4-9b and Fig.4-10b, for dimensions of reinforced bar spare part refer to Fig.4-6c,Fig.4-7c, Fig.4-8c, Fig.4-9c and Fig.4-10c. for spare parts of counter ballast are listed in table4-7, table4-8, table4-9, table4-10 and table4-11. It is advised to weigh every counter ballast block manufactured and engrave the weight permanently on the surface, with permitted weight tolerance of ±1%and concrete grade no less than C20 The dimensions can be changed according to the density (average density) of concrete for the tolerance. The density will change with the change of distribution of reinforced bar in counter ballast. 35

45 Notice: In this manual, the size of ballast for this crane is so designed that the concrete density is based on the theoretical value of 2400 kg/m 3 Customers can also design counter ballast by themselves. Make sure the width and thickness and dimensions of counter ballast is right to hange, you can adjust the length to appropriate value. Fig.4-6a Reinforced bar layout of PHZ2000 counter ballast 36

46 Fig.4-6b Reinforced bar spare part of PHZ2000 counter ballast Fig.4-6c Dimensions at the edge of reinforced bar spare part of PHZ2000 counter ballast 37

47 Fig.4-6d coaming box B Table4-7 Spare part list of PHZ2000 counter ballast No. Name Quantity Specification/ Material Remarks 1 steel reinforcementⅠ 10 Φ10/Ⅰgrade Fig.4-6b 2 steel reinforcementⅡ 12 Φ12/Ⅰgrade Fig.4-6b 3 steel reinforcemenⅢ 6 Φ10/Ⅰgrade Fig.4-6b 4 steel reinforcementⅣ 2 Φ /Ⅰgrade No drawing 5 Ⅴsteel reinforcementⅤ 16 Φ10/Ⅰgrade Fig.4-6b 6 round steel 4 Φ40-480/ Q235B 7 steel reinforcementⅥ 4 Φ10/Ⅰgrade Fig.4-6b 8 reinforced concrete 1 No drawing 9 angle steel a 4 L30 4/ Q235B Fig.4-6c 10 angle steel c 2 L / Q235B No drawing 11 angle steel 4 t4/ Q235B Fig.4-6c 12 angle steel f 4 L30 4/ Q235B Fig.4-6c 13 angle steel g 4 L30 4/ Q235B Fig.4-6c 14 angle steel h 4 L30 4 / Q235B Fig.4-6c 38

48 No. Name Quantity Specification/ Material Remarks 15 angle steel i 2 L / Q235B No drawing 16 B coaming box B 4 weldment Fig.4-6d Fig.4-7a Reinforced bar layout of PHZ3000 counter ballast Fig.4-7b Reinforced bar spare part of PHZ3000 counter ballast 39

49 Fig.4-7c Dimensions at the edge of reinforced bar spare part of PHZ3000 counter ballast Fig.4-7d coaming box B Table4-8 spare part list of PHZ1000 counter ballast 40

50 No. Name Quantity Specification/material Remarks 1 steel reinforcementⅠ 9 Φ10/Ⅰgrade Fig.4-7b 2 steel reinforcementⅡ 16 Φ10/Ⅰgrade Fig.4-7b 3 steel reinforcementⅢ 6 Φ10/Ⅰgrade Fig.4-7b 4 steel reinforcementⅣ 2 Φ /Ⅰgrade No drawing 5 steel reinforcementⅤ 16 Φ10/Ⅰgrade Fig.4-7b 6 Round steel 4 Φ40-600/ Q235B 7 steel reinforcementⅥ 2 Φ10/Ⅰgrade Fig.4-7b 8 steel reinforcementⅦ 2 Φ10/Ⅰgrade Fig.4-7b 9 steel reinforcementⅧ 1 Φ10/Ⅰgrade Fig.4-7b 10 concrete 1 No drawing 11 Angle steel a 4 L / Q235B No drawing 12 Angle steel b 4 L30 4/ Q235B Fig.4-7c, 4 piece, 2 symmetrical 13 Angle steel c 4 L / Q235B No drawing 14 Angle steel board A 2 t4/ Q235B Fig.4-7c 15 Angle steel e 2 L / Q235B No drawing 16 Angle steel f 4 L30 4/ Q235B Fig.4-7c 17 Angle steel g 2 L / Q235B No drawing 18 Angle steel h 2 L / Q235B No drawing 19 Angle steel i 4 L30 4/ Q235B 20 Angle steel j 4 L30 4/ Q235B Fig.4-7c, 4 piece, 2 symmetrical Fig.4-7c, 4 piece, 2 symmetrical 21 Angle steel k 2 L / Q235B No drawing 22 Angle steel l 2 L / Q235B No drawing 23 B Coaming box 4 weldment Fig.4-7d 41

51 Fig.4-8a reinforced bar layout of PHZ3000 counter ballast Fig.4-8b reinforced bar spare part of PHZ4000 counter ballast 42

52 Fig.4-8c dimensions at the edge of reinforced bar spare part of PHZ4000 counter ballast Table4-9 spare part list of PHZ4000 counter ballast NO. Name Quantity Specification/material Remarks 1 steel reinforcementⅠ 9 Φ10/Ⅰgrade Fig.4-8b 2 steel reinforcementⅡ 16 Φ10/Ⅰgrade Fig.4-8b 3 steel reinforcementⅢ 6 Φ10/Ⅰgrade Fig.4-8b 4 steel reinforcementⅣ 2 Φ /Ⅰgrade No drawing 5 steel reinforcementⅤ 16 Φ10/Ⅰgrade Fig.4-8b 6 round steel 4 Φ40-600/ Q235B 7 steel reinforcementⅥ 2 Φ10/Ⅰgrade Fig.4-8b 8 steel reinforcementⅦ 2 Φ10/Ⅰgrade Fig.4-8b 9 steel reinforcementⅧ 2 Φ10/Ⅰgrade Fig.4-8b 10 concrete 1 No drawing 11 angle steel a 4 L / Q235B No drawing 12 angle steel b 4 L30 4/ Q235B Fig.4-8c, 4 piece, 2 symmetrical 43

53 NO. Name Quantity Specification/material Remarks 13 angle steel c 4 L / Q235B No drawing 14 angle steel block B 2 t4/ Q235B Fig.4-8c 15 angle steel e 2 L / Q235B No drawing 16 angle steel f 4 L30 4/ Q235B Fig.4-8c 17 angle steel g 2 L / Q235B No drawing 18 angle steel h 2 L / Q235B No drawing 19 angle steel i 4 L30 4/ Q235B 20 angle steel j 4 L30 4/ Q235B Fig.4-8c, 4 piece, 2 symmetrical Fig.4-8c, 4 piece, 2 symmetrical 21 angle steel k 2 L / Q235B No drawing 22 angle steel l 2 L / Q235B No drawing 23 coaming box B 4 weldment Fig.4-8d Fig.4-9a reinforced bar layout of PHZ4000 counter ballast 44

54 Fig.4-9b reinforced bar spare part of PHZ4000 counter ballast Fig.4-9c dimensions at the edge of reinforced bar spare part of PHZ4000 counter ballast Table4-10 spare part list of PHZ4000A counter ballast No. Name Quantity Specification/Material Remarks 1 steel reinforcementⅠ 9 Φ10/Ⅰgrade Fig.4-9b 2 steel reinforcementⅡ 16 Φ10/Ⅰgrade Fig.4-9b 3 steel reinforcementⅢ 6 Φ10/Ⅰgrade Fig.4-9b 4 steel reinforcementⅣ 2 Φ /Ⅰgrade No drawing 45

55 No. Name Quantity Specification/Material Remarks 5 steel reinforcementⅤ 16 Φ10/Ⅰgrade Fig.4-9b 6 round steel 4 Φ40-600/ Q235B 7 steel reinforcementⅥ 2 Φ10/Ⅰgrade Fig.4-9b 8 steel reinforcementⅦ 2 9 steel reinforcementⅧ 2 Φ10/Ⅰgrade Fig.4-9b 10 Reinforced concrete 1 No drawing 11 angle steel a 4 L / Q235B No drawing 12 angle steel b 4 L30 4/ Q235B Fig.4-9c, 4 piece, 2 symmetrical 13 angle steel c 2 L / Q235B No drawing 14 angle steel block B 2 t4/ Q235B Fig.4-9c 15 angle steel e 2 L / Q235B No drawing 16 angle steel f 4 L30 4/ Q235B Fig.4-9c 17 angle steel g 2 L / Q235B No drawing 18 angle steel h 2 L / Q235B No drawing 19 angle steel i 4 L30 4/ Q235B 20 angle steel j 4 L30 4/ Q235B piece, 2 symmetrical Fig.4-9c, 4 piece, 2 symmetrical 21 angle steel k 2 L / Q235B No drawing 22 angle steel l 2 L / Q235B No drawing 23 angle steel m 2 L / Q235B No drawing 24 coaming box B 4 weldment Fig.4-7d 46

56 Fig.4-10a PHZ2750 counter ballast reinforced bar spare part of PHZ1000 counter ballast 47

57 Fig.4-10c dimensions at the edge of reinforced bar spare part of PHZ2750 counter ballast Fig.4-10d coaming box C Table4-11 spare part list of PHZ1000 counter ballast 48

58 No. Name Quantity Material Remarks 1 steel reinforcementⅠ 7 Φ10/Ⅰgrade Fig.4-10b 2 tube axle 1 Fig stationary plate 2 t8/ Q235A Fig.4-10b 4 steel reinforcementⅡ 16 Φ10/Ⅰgrade Fig.4-10b 5 steel reinforcementⅢ 5 Φ10/Ⅰgrade Fig.4-10b 6 steel reinforcementⅣ 12 Φ10/Ⅰgrade Fig.4-10b 7 round steel 4 Φ30-300/ Q235B 8 steel reinforcementⅤ 2 Φ10/Ⅰgrade Fig.4-10b 9 reinforced concrete 1 No drawing 10 angle steel Ⅰ 2 L30 4/ Q235B Fig.4-10c 11 angle steel Ⅱ 2 L / Q235B No drawing 12 angle steel Ⅲ 2 L30 4/ Q235B Fig.4-10c 13 angle steel Ⅳ 4 L / Q235B No drawing 14 angle steel Ⅴ 2 L30 4/ Q235B Fig.4-10c 15 angle steel Ⅵ 4 L / Q235B No drawing 16 coaming box C 4 weldment Fig.4-10d 49

59 Fig.4-11 tube axle 50

60 5 Erection and Dismantling 5.1 Cautions (1) The maximum wind speed atop (the highest crane point) should be less than 12m/s during crane erecting. (2) Strictly follow the procedures of tower crane erecting. (3) Properly select the hook point. Select the hoisting equipment with proper length and reliable quality to suit the components to be hoisted. (4) The dismountabel pins, connecting bolts and nuts for the slewing rings and mast sections of the tower crane are specially-made componets, which shall not be replace freely (5) Safty measures, such as ladders platform and grad rails should be installed for safe operation. (6) After jib installation, it is prohibited to hoist any load before placing specified counter-weight on the counter-jib. (7) At the erection position of the tower crane, it must be no less than 1.5m distance between the widest slewing part of the crane and around buildings, and the safe distance between any parts of the crane and overhead power lines shall comply with the stipulations as shown in the next table. Voltage(kV) Safe distance (m) <1 1~15 20~40 60~ Vertically Horizontally (8) Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be provided before hand. (9) Drive the trolley to the balance position before jacking. Slew the jib to the right front of the in-let beam and then lock the slewing of tower crane by slewing brake. (10) No slewing of the jib and no up and down movements of the hoist hook during jacking operation. No operating luffing mechanism and changing the position of jib. (11) Do not slew tower crane before having screwed slewing support and tower mast together by 8 pivots. (12) There must be aspecially-assigned person to command erection and dismantling. 51

61 (13) Erection and dismantling must be under the command of commander. (14) Commander should keep detailed record of erection and dismantling including weather and other environmental factors. 52

62 5.2 Security Signs of Tower Crane Security signs of L tower crane are shown in Fig.5.2-1a and Fig.5.2-1B. The meanings of each sign are shown in 1 Security signs. Fig.5.2-1a Security signs of L250-20tower crane 53

63 part sectioned view Fig.5.2-1b Security signs of L tower crane 54

64 5.3 Components Weight and Height 1 No. Name Weight (kg) Base section outrigger h(m) Internal climbing h(m) 2 Internal base section Internal section Standard section Climbing frame Turntable,slewing support and slewing ring 7 Slewing mas operator cab counter jib assembly A-frame assembly st and 2nd counter ballast 2750/ a 60m jib b 55m jib c 50m jib d 45m jib e 40m jib f 35m jib g 30m jib a 13b 13c 13d 13e Counter ballast for 60m jib Counter ballast for 55m jib Counter ballast for 50m jib Counter ballast for 45m jib Counter ballast for 40m jib A A A A A

65 13f 13g Counter ballast for 35m jib Counter ballast for 30m jib A A

66 5.4 General Layout of Tower Crane Assembly Relation of Main Components for Stationary Crane with Embedded outrigger As is shown in Fig.5.4-1, the free-standing height( to jib foot) of L250-20tower crane with Embedded outrigger is 53.4m, while the max radius is 60m, and the max hoisting capacity is 20t. 2-fall or 4-fall ropes may be used for hoisting purpose. Internal climbing base tower section and internal climbing tower sections are integrated structures. The tower sections(reinforced tower section) are slice structures and the climbing frame is integrated structure. The lower base section( or internal climbing base section) is connected to the foundation. The upper tower section is connected to the turntable through slewing support and slewing ring. The operator cab is set at the left front side of the turntable with the jib in front and counter-jib behind. The hoisting winch is in front of the counter-jib. Luffing mechanism is behind the counter-jib. Luffing mechanism drive the luffing jib The The climbing frames under the slewing support surround the tower mast. To meet construction needs, the jacking mechanism can jack the upper structure of the upper tower body to bring in tower sections of slice structure for increasing the height of tower crane 57

67 1- foundation 2-base section 3- Standard section 4- Internal climbing device 5- climbing frame6- slewing support 7- slewing ring 8- turntable 9- operator cab 10- slewing tower mast 11- counter jib 12-counter ballast 13-luffing mechanism 14-hoisting winch 15-A-frame 16-jib tie bar 17 hoisting steel wire 18-jib 19- hook Fig erection drawing of L crane with outrigger 58

68 5.5 Tower Erection Steps of Tow er Erection The main steps of the erection of the tower crane with outrigger as follows: (1)Install the embedded outriggers and tower sections; (2)Install the climbing frame; (3)Install the slewing ring assembly; (4)Install the slewing tower mast; (5)Install the operator cab; (6)Install the counter jib assembly( Also, you can firstly install counter jib, then luffing mechanism and hoisting winch); (7)Install the A-frame assembly; (8)Install the two counter ballasts of 2.75t; (9)Install the jib assembly; (10)Install the security ropes; (11)Install the jib tie bars; (12)Install the other counter ballasts. Special warnings: As the embedded outriggers are critical to the verticality of tower crane and the tower body connections, So before erection, inspections the verticality and the horizontality of the outriggers are mandatory. Any vertical or horizontal deviations will cause difficulties of tower crane erection, even operation accidents. After the erection of the embedded outriggers, the flatness must less than the related rule of this instruction book and must ensure the vertical requirements of the tower mast. 59

69 5.5.2 Install Mast Sections The Description of Structure There are two kinds of mast sections in L tower crane with outrigger: base tower section and reinforced tower section. There are three kinds of mast sections in L internal climbing tower crane: internal climbing base section, internal climbing tower section and reinforced tower section. (1)Base section: It is integrated structurecio consisted of angle irons, with switch box on it.and it is connected to embedded outriggers, referring to Fig

70 L Fig the base section of L luffing jib tower crane (2)Reinforced tower section: It is slice structure with 4 slices. Each slice is connected by 4 hinged bolts of M36 with hexagon head, referring to Fig

71 Fig the reinforced tower section of L (3)Internal climbing base section: It is integrated structure with internal climbing elastic beam as shown in Fig

72 Fig the internal climbing base section of L

73 (4)Internal climbing tower section: It is integrated structure as shown in Fig Fig the internal climbing tower section of L The assembling of reinforced tower sections The reinforced tower section of L is composed of 4 slices. Each slice is connected by 4 hinged bolts of M36 with hexagon head The pre-tensioning torsion moment of the bolts is 1640Nm. 64

74 Each bolt should be provided with one flat washer, one spring washer and one block nut which should be screwed down. Fig is the assembling drawing. The necessary spare parts are listed in Table Fig the assembling drawing of reinforced tower section of L

75 Table5.5-1 spare part list of reinforced tower section of L No Code Designation spec number material Remark 1 tower section slice A 1 2 climbing ladder and hoop guard 3 GB/T bolt M 级 grade Zn.D 4 GB/T nut M 级 grade Zn.D 5 GB/T washer Mn 6 GB/T Big flat washer Hv Zn.D 7 GB/T pin Q215 8 pivots 2 40Cr 9 diagonal 1 10 tower section slice D 1 11 BZJH1-11 spring pin 16 65Mn 12 BZJH1-10 pivots BZJH1-8 pivots 8 35CrMo 14 BZJH1-9 pin bushing 8 15 tower section slice C 1 16 BZJH1-4 hinged bolt 级 grade 17 GB/T nut M 级 grade Zn.D 18 GB/T washer Mn 19 GB/T washer Hv Zn.D 20 GB/T bolt M 级 grade Zn.D 21 GB/T nut M 级 grade Zn.D 22 GB/T washer Mn 23 GB/T 圈 washer HV Zn.D 24 tower section slice B 25 platform L

76 Install Mast Sections (1)Install Base Section First, hoist the assembled base section with platform and climbing ladder(or internal climbing base section with platform and climbing ladder for internal climbing tower crane). Then, connect the base section to embedded outriggers by 8 tailor-made pivots ( notice: the pinhole on anti-rotation bushing must match the pinhole on pivots). Finally, knock them to ensure that the axle shoulder tightly contacts the chord rod surface, and insert tiny pins and spring pins into the anti-rotation bushing and the pinhole on pivots. Inspect the verticality of base section by theodolite or plumb line, the verticality deviations of 4 sides of main chord rod could not be greater than 1.5/1000. Fig installing the internal climbing base section of L (2)Install internal climbing tower section(internal climbing tower crane). Hoist an internal climbing tower section(the platform of the section can be assembled in advance). Connect it to the installed base section by 8 pivots referring the installation of internal climbing base section. (3)Install reinforced tower section( tower crane with outrigger) As is shown in Fig.5.5-7, install the assembled reinforced tower section on the installed base section( the direction of mast lugs and platform ladder must be consistent with the direction of the installed reinforced tower section). 1 Connect reinforced tower section to base section by 8 pivots of Φ60. Knock them to ensure that axle shoulder tightly contacts chord rod surface. Put anti-rotation NO.2 sleeves on pivots before inserting NO.3 tiny pins and NO.4 spring pins (Notice: The spindle hole on spindle and the anti-rotation hole on the plate of node point must be coaxial so that the anti-rotation spindle can be 67

77 inserted. Fig.5.5-7, Detail drawing A); 2 Combine climbing ladders into one unit by NO.5 pivot (Notice: Keep clean all connection holes and connecting pins, no dirt allowable. Fig.1.3-7, Detail B); 3 Inspect the verticality by theodolite or plumb line. the verticality deviations of 4 sides of main chord rod could not be greater than 1.5/1000. Special Notice: The hinged bolts with hexagon head for the connection of tower sections of slice structure and the pivots for the connection of tower sections are tailor-made products. No replacement of them optionally by users Install Climbing Frame The Description of Structure Fig installing the reinforced tower section Climbing frame consists of the structure, platform, climbing ladders, hydraulic climbing system and indraught device. Jacking of tower crane is done mainly by this assembly. The jacking 68

78 cylinder is installed on the beam behind climbing frame (Namely, the side of pre-assembled counter-jib), The hydraulic pumping plant is placed on the platform on the side of hydraulic cylinder, The climbing frame has 16 rollers on the inner side, these rollers are supported on the outer side of the main chord rod of tower crane, acting as guidance and bearing, as is shown in Fig To facilitate erection of the climbing system and the satisfaction of safety needs, anti-drop devices are provided on jacking plates. Platforms and protection fences are provided on the upper, middle and lower portions of climbing frames, some platforms are also provided on the indraught beam. During jacking operation, operators stand on the platforms, operating the hydraulic system, to bring in tower sections and insert connection pivots. Fig The climbing frame of L

79 Hoist and Install Climbing Frame (1) Put the climbing frame on the outer side of the tower section gently. Notice: The jacking cylinder and the mast lug on tower section should be on the same side. (2) Place the supporting latches of climbing frame on the 4th pair of mast lug from down to up, then adjust the clearance between 16 climbing guide rollers and tower section (the clearance is 2~3mm) (3) Fix the jacking cylinder and hoist the hydraulic pumping plant to one corner of the platform, connect oil tubes, and check the hydraulic system for normal operation.in case of oil pump burning out, the sence of rotation of the motor s fan blades must be in the same as arrow indication on its casing. Having any errors, motor must be rewired. (4) Retract the oil cylinder, hang the supporting plate in the mast lugs of reinforced tower section nearing the push rods, and insert safety pins. 70

80 L Fig Installing climbing frame Install the Slewing Ring Assembly Assemble Components 1 Slewing Support The slewing support is an integral box structure. Its bottom is connec ted to transient beam by 8 pivots. Its top is connected to the inner ring of slewing support by 44 high-strength bolts of M27 (grade 10.9), Fig

81 Fig assembling slewing suppor and slewing ring The necessary spare parts for assembling are listed in Table Table the necessary spare parts for the assembling of slewing suppor and slewing ring 序号名称规格数量 Number Name specification Quantity 1 slewing suppor 1 2 slewing ring QWA bolt M nut M washer spindle Ⅰ 8 7 spindle Ⅱ BZJH spring pin BZJH (2)Slewing Ring 72

82 1bolt pair The high-strength bolts used on the slewing ring must reach grade 10.9 of GB/T Use flat washers which are hardening and tempering. Spring washers could not be used. The preload torque is 1100KN m 2Installation Before installing, clean the erecting datum plane of slewing ring and the erecting plane of yoke., and wipe off wet fouling, burr, paint and other foreign impurity. Fig Slewing Ring--- Check the flatness of support surface by clearance gauge after installing the slewing ring. Check the gear meshing condition before screwing down the high-strength bolts to make sure that the backlash at the three points where the gear runout is biggest (the teeth painted green) meet the demand. Screw down the high-strength bolts in the direction of 180 symmetrically and continuously. Make sure the preload moments are equal in screw bolts at the last time. 3lubrication, cleaning and maintenance Add grease into slewing ring regularly. Shorten the period of greasing in special working conditions such as in tropic, big humidity, too much dust, big range of temperature. Add enough new grease before and after tower crane out of working over a long period. 73

83 Fig the sequence of screwing down bolts Check the preload moment of bolts when slewing ring has worked for 100 hours.then check once more every 500 hours working time, ensuring there is preload moment Do not sluice slewing ring directly by water for fear that water get in. Check that the seal function well regularly. Replace the damaged seal in time. (3)Turntable,Platform The turntable is plate-shell structure. The flanges are welded on its both sides for the installation of slewing mechanism. The platforms and handrails are on the left and right side of turntable. On the front, there is a support for the installation of slewing limiter. The left platform is fastened by 6 spindles. Operator cab is connected to support of left platform by 3 spindles. The bottom of turntable is connected to the outer ring of slewing ring by 44 high-strength bolts of M27 (grade 10.9). The top of turntable is connected to slewing tower mast by 4 spindles (Φ80). 74

84 Fig assembling turntable and platform Table main spare parts Number Name Specification Quantity 1 Left platform 1 2 Handrail Ⅰ LGA

85 Number Name Specification Quantity 3 Handrail Ⅱ LGA Handrail Ⅲ LG Handrail Ⅳ LG Slewing mechanism 2 7 Right platform 1 8 Upper Support 1 9 Below Support 1 10 Handrail Ⅴ LGC Middle platform 1 12 Handrail Ⅵ LGB Handrail Ⅶ LG Handrail Ⅷ LGA Climbing ladder of turntable 1 16 Handrail plywood 7 Fig slewing ring assembly (the weight is 7800kg) 76

86 L Hoist and Install the Slewing Ring Assembly Inspect high-strength bolts of M27 (88 pieces, grade 10.9) connecting the slewing rings, slewing ring support, and upper support to make sure that their preload torsion moment are up to 1100kN m. Align 4 main chord rods of the slewing support to 4 main chord rod connections of mast section. Let them down slowly to keep main chord rod holes of the ring support in line with the corresponding holes of mast section connections. Remember to keep the position of passing holes of the slewing support in conformity to the position of mast climbing ladder on the tower section. During connecting the slewing support to the sleeve frame, their marks on four corners must correspond to one another. Connect 8 tailor-made spindles (Φ60 263/376) to tower section, knock the spindles into the holes, insert tiny pins and spring pins after installing anti-rotation sleeves Operate the climbing system to extrude the hydraulic cylinder to the second pair of mast lugs from down to up. Jack the climbing frame to contact the connecting ear-plate of the ring support. Connect the climbing frame to the ring support with 4 pieces of Φ60 spindles. Fig, hoisting and installing the slewing ring assembly 77

87 5.5.5 Install the Slewing Tower Mast The Description of Structure Slewing tower mast is integrated frame structure. Its top is connected to counter jib.,its bottom is connected to the turntable (Fig.5.4-1). Fig L slewing tower mast Table main spare parts of slewing tower mast Number Name Specification Quantity 1 slewing tower mast 1 2 pin XZ / A pivots A XZ / B pivots B XZ /

88 L Φ8 45 pin 24 Install the Slewing Tower Mast Hoist the slewing tower mast. Connect the slewing tower mast to the turntable with 4 pivots(φ63). Insert tiny pivots and pins into pivots (Fig ). Notice: please dismantle the handrail of turntable near counter jib for more easily installing the slewing tower mast. Fig installing the slewing tower mast 79

89 5.5.6 Install Operator Cab The Description of Structure The cab is thin plate structure, on the front of the upper support right side platform. There are large big glass windows on the four sides of the cab, the upper window in front can be opened to obtain a wide field of view. The cab is nice-looking and comfortable, equipping with inter-active control console (Fig ). Fig the operator cab L Hoist and Install the Operator Cab Notice: ensure that the electric equipment in the cab is mounted completely before hoisting. Hoist the cab to the left- front of the turntable platform. Align it with the position of ear-plate holes, then connect them with three pivots and put them in cotter pins (Alternatively assemble the cab and slewing ring assembly on the ground, then hoist the whole piece once for all). 80

90 5.5.7 Install Counter Jib Assembly The Description of Structure Fig hoisting and installing operator cab Counter-jib structure is welded structure consistsing of two main chord bars, vertical bar and diagonal. The main chord bars are welded of steel plate to an H structure. The platforms and handrails are set on the two sides of counter jib assembly. The front of counter jib is connected to slewing tower mast by two pivots. The other end of counter jib is supported by a tower strut. One end of the tower strut is connected to counter jib and the other end is connected to turntable. Hosting mechanism, luffing mechanism, hydraulic pumping plant, electric control box, resistance box, A-frame assembly, jib assembly and counter ballasts are all assembled on the counter jib. Undercarriage of hoisting mechanism and luffing mechanism ate connected to counter jib by 4 M24 bolts separately. The hydraulic pumping plant is connected to counter jib by 4 M10 bolts. The electric control box is connected to counter jib by 6 M12 bolts. The resistance box is connected to counter jib by 4 M12 bolts. The A-frame assembly is connected to counter jib by 4Φ40 81

91 pivots.φ60 pivots. The jib assembly is connected to counter jib by 2 Φ80 pins. The counter ballasts are assembled at the end of counter jib and fastened by bars and frames. Table spare parts for the counter jib assembly of L Name Quantity Weight Specification Remarks Counter jib structure Pivot 2 Φ /385 Strut Pivot 4 11 Φ80-215/305 Derrick Platform Pivot Φ30-70/105 Cotter pins 40 Handrail Handrail plywood Hoisting mechanism Luffing mechanism Hydraulic pump station include 2 Φ20 pivots, 4 cotter pins (6.3) include 2 Φ20 pivots, 4 cotter pins (5) From the afterbody to see the end On the counter jib,nearside flat roof width900, starboard flat roof width pair,1 M12 65 bolt, 1 M12 nut, 1 12 flat washer, 1 spring washer Φ40 pivots Φ40 pivots 个 M M bolts L

92 Fig the counter jib assembly of L

93 Assemble Counter Jib Place counter jib on two steel benches whose height are 1m. Connect the counter jib strut, which is hoisted to an appropriate position by forklift or crane, to the counter jib by 2 Φ80 pins, insert cotter pins and open it enough. Hang the gourd on the counter jib, put down the chain, hang the counter jib strut on the hook of gourd by ropes, take back the chain to hoist the counter jib strut. Assemble the platform, handrail, electric control box, resistance box by forklift or crane. Notice: hoisting mechanism and luffing mechanism can be installed one by one after counter jib installed in order to lighten the weight to hoist, during installing, hoisting mechanism should be installed firstly, and then install luffing mechanism (The weight of counter jib assembly with hoisting mechanism and luffing mechanism is 15899kg. The weight of counter jib assembly without hoisting mechanism and luffing mechanism is 5748kg.) Fig the assembling of counter jib assembly of L Hoist and Install Counter-jib Assembly Hoist counter jib assembly. Connect counter jib to slewing tower mast by 2 Φ100 pivots. Insert cotter pins and open it enough Discharge the chain, turn strut unde counter jib, adjust the chain, and align the pin holes of under strut to the holes of turntable, insert the two Φ80 pivots, insert Φ20 lock pins and cotter pins, ensure the cotter pins opened enough. Place the ladder of the two platforms of turntable towards counter jib at an appropriate position. Insert bolts and screw down. 84

94 L Fig Installing counter jib assembly Install Hoisting Mechanism Hoist the hoisting mechanism to the place in alignment with the 4 ear-base on the front of counter jib (Fig , the installing of hoist mechanism refers to Fig ), then fasten the hoisting mechanism by 4 connection bolts. 85

95 5.5.9 Install Luffing Mechanism Fig Installing hoisting mechanism Hoist the luffing mechanism to the place in alignment with the 4 ear-base on the back of count jib (Fig , the installing of luffing mechanism refers to Fig ), then fasten the luffing mechanism by 4 connection bolts. 86

96 Install A-frame Assembly The Description of Structure Fig Installing luffing mechanism A-frame is inclined cone. Its top is connented to the counter jib by luffing rope and jib tie bar. Back Stay Bar is connected to counter jib by 2 pins of Φ60,Frontal Stay Bar is connected to counter jib by 2 pins of Φ75. The main structure of A-frame consists of front-up tie rod, front-down tie rod, back tie rod, inclined tie rod and buffer. The front-up tie rod, front-down tie rod and back tie rod of A-frame are all integrated structures. The front-up tie rod and the front-down tie rod are connected each other by 8 M24 high-strength bolts ( grade 10.9, torque 900 ) after placing by two locating pins. The two inclined tie rod are connected to back tie rod and frontal-down tie rod by pins. Luffing pulley assembly and working platform are installed on the top of A-frame, spring buffer is installed on the middle of frontal-down tie rod (Fig ). 87

97 Fig A-frame assembly 88

98 Table spare parts of A-frame assembly No. Name Qty. Weight Specification Remarks 1 Frongtal-up strut Back strut Load moment limiter 4 Faceplate Incline strut Frongtal-down strut LXB2 Set on back strut Platform beam Climbing ladder handrail A set on lower ladder 10 Handrail B set on lower ladder 11 Buffer set on lower ladder for connection of back strut and down t 12 Buffer strut For fastening buffer 13 Top platform Pulley assembly Pivot Pivot Pivot Railing nip LGJB 19 Pivot Pivot Pivot Pivot 4 件 Pivot 1 件 Pivot 2 件 Bolts 8 套 M L Including 4 M16 40 bolts, 4 spring hers, 4 nuts, 2 incline washers ncluding 10 M16 40 bolts, 10 spring washer, 10 nuts Including rails as 1 L=3070;2 L=440; 820;1L=530;1 movable handrail; Set on frontal-down strut, including 4 M12 65 bolts, 4 spring washers, 4 nuts, For connecting back strut and counter every set including pin For connecting back strut and frontal-up strut,every set including pin For connecting top platform and frontal-up strut,every set including pin For connecting one railing and another, every set include 2 boards, 1 M12 65 bolt, 1 spring washer, 1 nut. For connecting one railing and another, ry set include 2 boards, 1 M12 65 bolt, 1 ng washer, 1 nut. For connecting incline strut and back strut,every set including pin For connecting Buffer and frontal-down strut,every set including pin For connecting buffer and buffer strut, every set including pin For fastening luffing rope, including pin For fastening security rope including 1 1 pin Connecting frontal-up strut and tal-down strut,every set including1 bolt, 89

99 No. Name Qty. Weight Specification Remarks 26 Safety Rop 1 套 27 Locating pin 2 件 件 Shaft-end damper Anemometer seat Obstacle lamp holder 4 件 件 件 0.66 asher, 1 spring washer, 1 nut. Set on handrails,including 2 connecting plate,1tightwire,6 Line-nip 8KTH, 4 M16 50 bolts, 4spring washer,4 nuts For locating frontal-up strut and frontal-down strut Set on frontal-up strut,including 4 Nylon and pin For fastening pulley spindle, including 2 M20 45 bolts, 2 spring washer,2 nuts Set on top of A-frame,Including 2 M8 25 bolts, 2spring washer Set on top of A-frame,Including 2 M8 25 bolts, 2spring washer,2 nuts 32 Pulley 1 件 Set on frontal-down strut Rope-hold Rod A Rope-hold Rod B 1 件 件 baffle 2 件 Shaft-end damper B 4 件 shaft sleeve A 8 件 shaft sleeve B 1 件 Pulley Assembly 5 件 Shaft 1 件 Little platform 1 件 Climbing ladder C 1 件 For hoisting pulley, Including pin For luffing pulley, Including pin Set on top of A-frame, every set including 2 M16 65 bolts, 2spring washer,2 nuts For fastening pulley spindle, including 2 M16 40 bolts, 2spring washer Set on pulley assembly on top of A-frame Set on pulley assembly on top of A-frame Set on top of A-frame, every set including2 bearing, 2 elastic damping ring Set on pulley assembly on top of A-frame,including 2 M8 1 oil cup Including 2 rail L=440, 4 M12 40bolts, 4 spring washer,4 nuts Set on frontal-down strut,every set including 4 M12 40 bolts, 4 spring washer,4 nuts 43 Nylon spindle 4 1 Set on frontal-up strut 44 Wheel Every set including pin 45 Shield ring For fastening nylon spindle 46 Seat of Camera Set on frontal-up strut 90

100 Assemble Components (1) Assemble front strut Notice: Ensure that the spare parts of the font-top strut and the front-down strut are all assembled completely before assembling front strut. Place 4 steel benches (Height: 1m) on flat ground. Put the front-down strut on the steel benches rightly. Put the front-up strut on the benches. Move the front-up strut to make the two connection flanges attached and the connection holes aligned. Assemble the front-up strut and front-down strut by 2 locating pins and 4 bolts (M24 120, grade 10.9). Special notice: the front-down strut welded two tie bars should be installed on the side as showm in Fig Fig assemble front strut of L A-frame (2) Aassemble diagonal strut Hoist one diagonal strut, connect the diagonal strut and front strut by one XZ01C-50 90/130 pivot, insert the cotter and open it enough, lay the diagonal strut on the front strut, as is showm in Fig Assemble the other diagonal strut in the same way. Fig assemble diagonal strut of L A-frame (3)Assemble back strut Put the back strut on the front strut and connect them by 2 XZ01D /140 pivots, insert cotter pin and open it enough. Then put the back strut on the support frame, fasten back strut to 91

101 front strut, as is shown in Fig Fig assemble back strut of L A-frame (4) Assemble Handrail, Spring Buffer, Climbing Ladder and Handhold Turn over the assembled front strut and back strut and place them on the steel benches. Move the top platform under the back strut, hoist the top platform, connect it to the back strut by 4 XZ01A-20 55/75 pivots, insert cotter pins and open them enough. install the platform beam by 4 M16 40 bolts. Connect the spring buffer to the front strut by XZ01C-40 70/105 pivot, insert cotter pins and open them enough, fasten the support rod of spring buffer by XZ01A-25 55/80 spindles (Notice: check that the buff latches i function well), refer to Fig connect the 2 climbing ladders to the front strut by 12 bolts (M16 40), fasten handhold A and B on the climbing ladders. Fig assemble platform and rail, spring buffer of L A-frame 92

102 Fig assemble climbing ladder and rail of L A-frame (5) Connect the incline strut and the back strut Loosen the rope using to tie the front strut and the back, hoist the front strut slowly and take the support frame away. Erect f the front strut and the back slowly to separate them. Rotate the incline strut, connect the two incline struts to the back strut by 2 XZ01C /225 pivots, insert cotter pins and open them enough. Connect the ttop platform beam by 4 M16 40 bolts. (Fig ) 93

103 Fig connect incline strut and back strut 94

104 L Istall A-frame Assembly Hoist the A-frame assembly, connect its back strut to counter jib by 2 XZ01C /225 pivots and its front strut to counter jib by 2 φ75 pivots, insert cotter pins and open them enough, refer to Fig Fig install A-frame assembly 95

105 Install Two Counter Ballast of 2.75t There are two 2.75t counter ballast of the four kinds of counter ballast of L Fig L counter ballast (2.75T) Notice: Pack crane at an appropriate place to avoid collision of the jib of the crane and the platform of A-frame when hoisting and installing the two 2.75t counter ballast. 96

106 Fig hoist and install counter ballast 97

107 Install Jib Assembly Install Luffing Suspension Install luffing pulley assembly Hoist luffing pulley assembly and lay it on the ear board of pulley frame of A-frame, insert bolts and screw them down, as is shown in Fig Fig install luffing pulley assembly Wind Luffing rope Switch on the power of luffing mechanism, start luffing mechanism, release luffing rope slowly, wind the rope as Fig Fasten the end of rope on pulley frame of A-frame by wedge, as is shown in Fig

108 Fig wind luffing wirerope Install Luffing Suspension Switch on the power of hoisting mechanism, start hoisting mechanism, release hoisting rope slowly. Wind rope across the pulley assembly of A-frame, and wind wirerope across the first pulley of jib in the opposite direction. Pull hoisting rope to the location of luffing pulley assembly by truck crane, connect the end of luffing rope to luffing pulley assembly by buckle and rope, as is shown in Fig Loosen the rope of truck crane after connecting the end of hoisting rope to luffing pulley assembly, screw out M16 bolts, remove baffle to loosen luffing pulley assembly, as is shown in Fig Release the rope of luffing mechanism, draw back the rope of hoisting mechanism, and pull luffing pulley assembly to the platform of jib tie bar, remove pulling rope. Connect luffing pulley assembly to tie board by a Φ45 pivot. Insert cotter pin and open it enough. Notice: keep the speed of rope of luffing mechanism and hoisting mechanism in harmony. 99

109 Fig connect hoisting wirerope to luffing pulley assembly Fig release the connection of luffing pulley assembly and A-frame 100

110 Install Counter Ballast The weight of counter-weight varies in proportional to the jib lengths (as is shown in Tablet 4.3-1). Install ballast according to the length of jib. Configuration and position of counter ballast for jib with different lengths refer to Fig Fig the drawing A of configuration and installation of L counter ballast 101

111 Fig the drawing B of configuration and installation of L250-20counter ballast 102

112 Fig the drawing B of configuration and installation of L counter ballast Wind Hoisting Wirerope, Install Hook Start hoisting mechanism to release hoisting rope. As is shown in Fig Fig , pull the hoisting rope to wind the first pulley on the jib as well as pulleys on jib head. Turn jib to make the installation of hook convenient. Continue releasing hoisting rope to ground and prepare to install hook. Use 1 pin of Φ60 to connect the heavy lantern ring at the end of the hoisting rope with the hook and then insert the split pin with opened enough (see Fig a). and now it is 1-fall condition. The way of installing 2-fall condition is different to 1-fall condition (see Fig b). 103

113 Wind the hoisting rope around the pulley of the hook and pull it to the anti-twist device. Use 1 pin of Φ80 to connect hoisting rope with anti-twist device and insert the split pin with opened enough. Fig wind hoisting wirerope Fig a Install Hook (1-Fall) 104

114 Fig b Install hook (2-fall) Power on and Trial Operation After the installation of the whole crane according to the above steps,check the verticality of tower body at non-load and wind speed less than 3m/s conditions, the verticality tolerance of free tower mast (the tower mast above the toppest anchor point) is 4/1000, the verticality tolerance of tower mast below the toppest anchor point is 2/1000. Switch on power of all electric circuits according to the electric circuit diagram and start all mechanisms for test run, check whether each mechanism work properly, at the same time, check ropes at different locations working normal and for any friction with structure member, remove all abnormal cases. Notice:Adjust safety device and make sure its function normal before using the tower crane Jacking Work of Crane with Outrigger Preparation for Jacking (1)Fill the oil tank with hydraulic oil according to the requirements of hydraulic pumping 105

115 plant. Ensure that the electric motor correctly connected, the fan turned to the right and the operating lever of hand control valve working smoothly without any clogging. (2)Put in order each mast section and apply the grease into its connection boltholes, Line up the tower sections under jib before jacking, thus the jacking time can be minimized. (3)Loosen the power cable until the length is slightly in excess of the total jacking height, then fix the cable. (4)Slew the jib to the front of the climbing frame and the counter-jib at the rear of climbing frame (jacking cylinder is just below the counter-jib). (5)Put 8 pivots on the middle platform of climbing ladder. (6)remove the locating pivot of platform hoisting machine, turn the drum of platform hoisting machine, turn over indraught platform, drop it until it is on the same level of indraught beam, insert the locating pivot, connect incline tie bar to ear board by Φ20 pivot, insert cotter pin and open it enough. On normall working condition, to avoid the interference between jib structure and hook at an large angle, therefore, dismantle the spindle that connects outer inclined tie bar and the ear ban of indraught platform according to the reversed sequence, turn indraught platform up 60 by rotating hoisting drum, then insert the locating pin of hoisting drum. L Notices of Jacking Operation: (1)Keep the tower crane in balance before jacking operation. (2)Jacking operation is prohibited when the speed of wind at the highest top exceeds 14m/s. (3)Forbid hoisting when jacking mechanism is jacking (up or down). (4)Forbid luffing when jacking mechanism is jacking. (5)The direction of jib and the direction of bringing in tower section should be same, when braking jib by the brake of slewing mechanism, jib must stop at the balance angle. (6)Forbid slewing and luffing before the spindle of bringing tower section is not connected to the installed tower section and slewing support by pivot. (7)If some tower sections should be continuously installed, the next tower section can only be hoisted after all the pivots of tower sections (include the 8 pivot of slewing support) are assembled. (8)The must lug of tower section should be aligned to the installed must lug of tower section before. (9)Forbid slewing, luffing and hoisting before the slewing support is connected to tower 106

116 mast by 8 Φ60 pivot. (10)Stop hoisting immediately if the hydraulic jacking mechanism is in trouble, draw back oil-hydraulic cylinder to lay slewing support on the top of tower mast, and connect slewing support to tower mast by 8 Φ60 pivots, then remedy of the trouble of hydraulic system. (11)After jacking is over, all the connections between tower sections and the connection between tower section and slewing support are 8 Φ60 pivots Keep the tower crane in balance before jacking operation (1)Before keeping the tower crane in balance, hoist one tower section ( its platform with handrail and climbing ladder is assembled) to inlet platform. Then balance the jib according to Table (the position of jib in table is approximation. Adjust it according to the practical situation). Dismantle the pivot between slewing support and tower section. Notice: the weight of the tower section (platform, handrail and climbing ladder are installed to the tower section) is 2800Kg.Users should increase the weight if the hoisting weight is heavier than 2800Kg. 107

117 Fig L hoisting balance Table jib angle and hoisting weight for different jib (for reference) max radius 60m 55m 50 m 45m 40m 35m 30m jib angle α hoisting weight (2)Push the operating handle of hydraulic jacking mechanism to hoisting direction. Jack climbing frame to the place where the leg of slewing support separates from main chord. (3)Check whether the leg that connects slewing support to tower section and the main chord are at a same vertical line, and observe whether the clearances between 16 guiding wheels of climbing frame and main chord are same, check whether the tower crane is in balance through these two measures, if the tower crane is not in balance, adjust the luffing angle of jib until the tower crane is in balance, making the barycentre of the top of tower crane located in the vertical plane of 108

118 hoisting beam. (4)Record the angle between jib and level. (Notice: the angle will be changed with differentlength of jib. (5)Descend climbing frame. Insert the pivots between slewing support and tower section Jacking Work Both 1-fall and 2-fall can be used in jacking work. (Special notice: jib angle should be less than 86 in progress of letting in tower section) 109

119 hook. Fig jacking work 1 (1)Hoist one tower section to the top of in-let car. Lay tower section on in-let car. Remove (2)Place the jib to a appropriate position according to the length of jib (refer to Table ). 110

120 Put down hook (Fig ). Tower crane is inbalance. (3)Use brake of slewing mechanism to brake the upper structure. No slewing allowed. Dismantle the 8 Φ60 pivots between tower mast and slewing support. (4)Start hydraulic jack system, extrude the piston of the cylinder place the pins of both ends of the jack beam into the cradle of the climbing lugs on tower section nearest to the beam (Notice: It should be checked by a specially-designed watchdog), jack the climbing frame and the upper part until it reaches the height of 10~50mm., check if there are any strange sounds, deformation, any self-retreat of piston rod etc, after confirmation, go on to erect. (5)Start hydraulic jack system until it reachs the height of 1/3 tower section and supporting latche 4 is at the top of must flag d. Stop jack and then retreat the piston to drop supporting latche on must flag d. (6)Confirm that the two support latches press the top of climbing lugs and bear the weight of climbing frame and the upper part without any strange sound and deformation. Remove security pin. Retreat the piston completely. Raise Hanging plate. Hang it on the nearest groove b of must flag. Insert security pins, Fig (7)Erect must flag d to the height of a little higher than must flag e, Fig (8)Stop jack and retreat piston to drop support latche to must flag e, Fig (9)Confirm that the two support latches press the top of climbing lugs and bear the weight of climbing frame and the upper part without any strange sound and deformation. Remove security pin. Retreat the piston completely. Raise Hanging plate 1. Hang it on the nearest groove c of must flag. Insert security pins, Fig There is a space of 2/3 tower section. (10)Stretch out oil-hydraulic cylinder to erect the upper part of tower crane to a height of a little more than 1/3 the tower section so that the space is fit for a tower section, Fig (11)Conduct tower section to the top of tower mast. Retreat piston slowly to let the bottom of in-let car attach the tower section. Retreat the piston completely. Align the pin hole of slewing support and tower section. Insert temporary pivot 7, Fig (12)Stretch our oil-hydraulic cylinder until in-let car separate from tower section. Push out in-let car. Retreat piston. Align the pin hole of two tower sections. Insert 8 Φ60 pivots. Knock them to axle shoulder tightly contacting chord rod surface. Install anti-rotate sleeve. Insert tiny pivot and spring pin. (13)Remove the temporary pivot 7. Retreat piston to align the pin hole of slewing support and tower section. Insert 8 Φ60 pivots without shoulder. Insert tiny pivots and spring pins. Insert anti-rotate sleeve tiny pivot and spring pin at the other end. 111

121 (14)The installation of one tower section is over. Install more tower section as the same steps above. For the last installed tower section: One end is connected to tower mast. the other end is connected to slewing support. Fig jacking work 2 112

122 Fig jacking work 3 113

123 Fig jacking work Anchorage of tower When the working height of the tower crane has to be exceeded to its stand-alone height, the tower body shall be anchored. The anchoring devices consist of 4 sets of mast-tie-frames and 4 inner ties. The 4 tie-frames are fastened into anchoring frames by 24 sets of M20 bolts (strength rating 8.8), nuts and washers (bolt pre-tensioned moment 640Nm). Anchoring frames are articulated with 4 tie-rods on 4 top points. The 4 brace rods shall be kept at the same horizontal level. Adjusting bolts can be used to push inner tie rods tightly against the 4 chord rods on the tower body (shown as ). 114

124 1- Conneting bolt 2-Frame 3- Inner strut 4- Inner strutadjusting bolt 5- Anchoring Fig L schematic diagram of anchorage (1) Anchorage frame be setted according to Fig Actual make and design distance is difference. Building anchorage link support and attended mode according practicality something to determine. Must contact to manufacturer. (2)Put on the tie frame on the tower section, push the 4 inner tie rods to the 4 chords on the tower, connect one end of anchored tie rod to the tie frame with pins, and the other end to the buildin (3)4 sets of anchoring tie rods on each frame shall be kept at the same horizontal plane. If they are interfered with some positions of the tower section during mounting of anchoring frames and inner tie rods, the height of frames will properly be raised or lowered. the height of frames and connecting basis not exceeding 200 meter 115

125 (4)The walkway for personnel passage from the building to tower crane can be placed on the anchoring tie rod, however no stockpiling of heavy objects on it 1-bolt connection 2-frame beam 3-internal strut 4-internal strut adjusting bolt 5-longer strut 6-shorter strut 7-adjusting bolt 8-connection base Fig anchorage for L tower mast (5)Load on anchoring points Before tower crane erection, customers or installation organizations are required to make necessary estimates of the load-bearing capability at building anchoring points (for the of connection foundation-fixing spots), as well as the construction period of the reinforced concrete structure affecting the anchoring point strength and similar factors., it gives the anchoring forces imposed at the anchoring points of the building (i.e. connection to the anchored foundation) at working and non-working conditions when the tower crane has its anchoring strut rods layout and location as shown in Fig The building s anchoring point shall not have its load-bearing capability smaller than the values shown in the table. The pre-embedded piece is embedded as Fig

126 Fig layout of anchorage strut Fig layout of anchorage foundation Notice: Load values at anchoring points vary to a great extent with the relative positions of the tower crane to the building, tie rod layout and size, height of the tower body suspension section over body. If the tower crane is anchored at the position different from Fig , including different arrangement of tie rods or different dimensions, please contact our company for further consultation, avoiding major accident. (6)During the mount of anchoring device, use the theodolite to check the axis of tower body for verticality. Its deviation shall not be greater than 4/1000 of the total tower crane height. This deviation can be achieved by adjusting the length of tie rod. (7)The connection of tie rods to tie frames, foundation and tie frames to the tower body and 117

127 inner tie rod shall be reliable. The inner tie rods shall reliably be pressed against the main chord rod of the tower body and also be clamped tightly to the web rod of the tower body. All connection bolts shall be fastened. Adjusting bolts, when properly adjusted, shall be tightened by nut. Cotter pins shall be opened as specified. After operation they shall be frequently checked for looseness. Timely adjustments shall be made just in case Notice: No matter how many anchoring is conducted, only the topmost anchoring tie frame can install the inner tie rod. Namely after each new attachment, the inner tie rod has to be removed into the newly-anchored frame 5.6 Internal Jacking of Tower Crane L Compare to other style tower crane, internal climbing tower crane can rise up with the height increase of building by its internal climbing device and internal climbing tower mast. Change tower crane from anchored condition to internal climbing condition before internal climb. Thus to say, drop climbing ladder to ground and dismantle it after sections are all assembled; Assemble internal climbing device when the building reach a certain height Description of Internal Climbing Device Internal climbing device consists of up internal climbing frame, middle internal climbing frame, dowm internal climbing frame, internal climbing base section, internal climbing tower section, internal climbing frame beam, internal strut, latch device and hydraulic jacking system. Internal climbing tower mast consists of 11 tower sections BZJHQ7, 1 internal climbing base section. The up, middle and down internal climbing frames are fasten on internal climbing frame beam when the whole tower is climbing. Tower crane climbs up by the hydraulic jacking mechanism on internal climbing frame. The up, middle and down internal climbing frames should be assembled before climbing. Oil-hydraulic cylinder and latch device is on middle internal climbing frame in the progress of climbing. There are always 2 internal climbing frame assembled on internal climbing frame beam. The telescopic beam of internal climbing section is on down internal climbing frame beam. They support the weight of whole tower crane. The load on up internal climbing frame is horizontal. The loads on down internal climbing frame are both horizontal and vertical. 118

128 Internal Climbing Frame Fig drawing of internal climbing device The up, middle and down internal climbing frames are the same structure, Fig Each internal climbing frame include 2 internal climbing frame made of 4 angle steel connected by 16 M24 80 high-strength bolts (pre-tensioned moment is 650 N.m). On the internal climbing frame guide wheel device, support block device and latch device ear board are provided. Guide wheel device guide tower with the help of main chord. Support block device prop on main chord to 119

129 transmit the horizontal load of tower crane to the wall of elevator shaft. Latch device ear board is used to fasten latch device. After limbing one time, the down internal climbing frame separate from internal tower mast. Dismantle it to assemble on the top of internal climbing device. So it become up internal climbing frame. The three internal climbing frame are used in turn like this. Fig internal climbing frame Latch device and jacking mechanism connected on internal climbing frame accomplish latchs changing and jacking. The oil-hydraulic cylinder turn outwards supported by baffle when it is not jacking, Fig

130 图 顶升油缸侧置 121

131 Internal Climbing Frame Beam Telescopic beam is wielded from steel pate belonging to internal climbing section set on box beam of internal climbing section. Pull telescope beam into box beam of internal climbing section when crane is jacking. Stretch telescope beam to lie on internal climbing frame to bear the weight of whole crane, Fig when crane work normally. Notice: when tower crane is in internal climbing, wrap the part of telescope beam stretched out with plastic. Clear dregs in load-bearing beam regularly for telescope beam easily stretching out next time. 122

132 Fig telescope beam Load-bearing Beam of Internal Climbing Frame Load-bearing beam is made by users (Load-bearing beam should be designed according to the dimensions of elevator shaft). Calculate the intensity and rigidity of load-bearing beam to make sure it meets the demands. The size of load-bearing beam (L) should bigger than the size of elevator shaft. 123

133 Fig load-bearing beam Climbing of Internal Climbing Tower Crane Internal climbing tower crane is always set in elevator shaft. Remain a group of hole every 15~18m in the construction of elevator shaft. The dimensions of holes are shown in Fig The reinforced concrete foundation is out of work after the fisrt time climbing. So the loads of tower crane are borne by building. Design the positions of hole before construct the elevator shaft. Strengthen the hole and wall nearby 124

134 图 电梯井预留孔位置及大小 Fig the dimensions of hole Installation for the first climbing There may be no down fram used the first climbing. Middle frame become down frame and up frame become middle frame after climbing. There may be no up frame when tower crane is in service. Assemble up frame just before climbingwork. (1)Install load-bearing beam of internal climbing frame Install load-bearing beam of internal climbing frame as shown in Fig The load-bearing beam must be fastened securely. The method for fastening is designed by users according to work condition. 125

135 Fig Install load-bearing beam of internal climbing frame (2)Install up internal climbing frame Install up internal climbing frame at th hole 30~36m away from foundation. Place the two half internal climbing frame around tower mast. Before install internal climbing frame, turn jib to the direction perpendicular to the ligature of two jacking oil-hydraulic cylinder. Brake slewing mechanism. Balance tower crane. (3)Install middle internal climbing frame Place the two half internal climbing frame around tower mast 15~18m below up internal climbing frame. Connect them with angle steel by M24 80 bolts. Fasten them on the load-bearing beam by 32 M bolts (each including 1 bolt, 1 spring washer, 2 nuts). Notice: no down internal climbing frame the first climbing. (4)Install hydraulic jacking system Hoist and install internal climbing system and latch device to middle internal climbing frame. Assemble the 2 oil-hydraulic cylinder to middle internal climbing frame. Hydraulic hydraulic jacking system is set on platform of building. Connect pipeline of hydraulic system. (Fig.5.6-9) 126

136 Climbing (1) Check before climbing Check if hydraulic system is set rightly. Check if all the pivots are installed. Check if all the cotter pins are opened up. Check if all the shaft-end dampers function well. Check if all the pre-tensioned moments of high-strength bolts meet the demands. Test the hydraulic system when everything is OK. Adjust the sping of hanging plate to make the angle between hanging plate and the centerline of oil-hydraulic cylinder 10~15. Hang hanging plate on the lug of internal climbing section, Fig (2) Blance the tower before climbing Tower crane must be balanced before climbing. Turn jib to a appropriate position (Fig.5.6-2) to balance the tower crane. Notice: the positions in the table are approximation. You may need to adjust them according practical condition. Jib angleα Table jib angle and hoisting weight to balance for different jibs (for reference) Jib radius 60m 55m 50m 45m 40m 35m 30m Hoisting weight (Kg) (3)first climbing 1 Loosen the pivot between internal climbing base section and anchors. Start hydraulic jacking system to separate internal climbing base section from anchors. Hydraulic system pressure rising show that oil-hydraulic cylinder begin to bear the weight of tower crane. Notice: the pressure of hydraulic system should be not bigger than 31.5Mpa. 2 Check everything is OK. Jack tower to the height 20mm away from anchors. Check if the distance between the down surface of main chord and foundation is consistent. If not, turn jib at lowest derricking speed to make it consistent. Stay here in ten minutes. Start hydraulic system to jack if everything is Ok. There must be a specially-assigned person to observe the working conditions of guide wheel and chord. 3 Keep on jacking until the must lug of internal climbing section is higher than the top surface of support board of latch device. Turn latch device to let it block in must lug of internal climbing. Retreat piston to drop upper tower crane on latch device. 4 Keep on retreating piston. If the pressure declines, the latch device begins to bear the weight of tower crane. Stop hydraulic system for 10 minutes when jacking beam is 10mm away from down surface of must lug. If everything is OK, start hydraulic system. Lower the height of 127

137 jacking beam. Make the beam out to support on baffle until piston is retreated back entirely. Repeat the above steps for second climbing. L Fig Fig

138 Fig climbing condition 5 Tower crane rises up 1.25m after one jacking. After several jacking,internal climbing base section will be a little higher than internal climbing frame. Now stop jacking and draw out telescopic beams to lie on internal climbing frame. Operate hydraulic system to load the weight of whole tower crane on the two telescopic beams. Jack the 8 support block to main chord. Remove hoisting weight. Screw dowm bolts of support block. Until now the first climbing is over. Tower crane can work. 6 Assemble 4 internal struts on the near top of up internal climbing frame. Force internal 129

139 struts jacking on the 4 main chords by adjust the bolts, Fig Fig install internal strut (4)Climb several times Tower carne should climb again when the building is constructed to a certain height. Transfer down internal climbing frame to the hole beyond up internal climbing frame (guide wheel is 2~3mm away from main chord). If jacking mechanism is on down internal climbing frame, it should be transferred to middle internal climbing frame (balance tower crane before install up internal climbing frame). 1 check before climbing Check if hydraulic system is set rightly. Check if all the pivots are installed. Check if all the cotter pins are opened up. Check if all the shaft-end dampers function well. Check if all the pre-tensioned moments of high-strength bolts meet the demands. Test the hydraulic system when everything is OK. 2 Dimanche 4 internal struts. 3 Do balance tower crane before climbing. Refer to the part of Blance the tower before 130

140 climbing. 4 Start hydraulic system. Press down jacking bottom. Let jacking beam in. Stretch out piston a little. Hang hanging plate on must lug of internal climbing section. Stretch piston rod out. Make sure hanging plate is hanging on must lug. Keep on jacking. Draw back telescopic beam into box beam structure when telescopic beam bear no load. Notice: do draw back telescopic beam into box beam structure. Otherwise, telescopic beam will hit internal climbing frame. 5 Stop jacking until internal climbing base section is a little higher than internal climbing frame. Turn latch device to let it block in must lug of internal climbing. Retreat piston to drop upper tower crane on latch device. 6 Keep on retreating piston. If the pressure declines, the latch device begins to bear the weight of tower crane. Then stretch out piston and repeat above operations for another jacking. 7 Tower crane rises up 1.25m after one jacking. After several jacking,internal climbing base section will be a little higher than internal climbing frame. Now stop jacking and draw out telescopic beams to lie on internal climbing frame. Operate hydraulic system to load the weight of whole tower crane on the two telescopic beams. Jack the 8 support block to main chord. Remove hoisting weight. Screw dowm bolts of support block. Until now the first climbing is over. Tower crane can work. 8 Assemble 4 internal struts on the near top of up internal climbing frame. Force internal struts jacking on the 4 main chords by adjust the bolts, Fig Notice: 1 The down surface of internal climbing base sections should not be out of down surface of middle internal climbing frame. Otherwise, the tower crane may fall down. 2 Forbid tower crane climbing if wind speed is bigger than 14m/s. 3 The load-bearing beam of internal climbing frame laid on hole in elevator shaft should be fastened firmly. 4 Make sure the interspace between idler wheel and tower section is about 3mm. 5 The up surface of concrete structure where load-bearing beam assembled must be level. Make sure the 4 installing surface of internal climbing frame is in the same plane. The planeness tolerance is 1/ Adjust the internal climbing frame before climbing to let the up surface of support board of latch device is on the same height (height error is within 4mm). L

141 5.7 Dismantling of crane Precautions for the dismantling of tower crane Dismantling of inner climbing crane is different to other cranes in that its mainly dismantling depends on the cranes on house, before the main building body fulfilled, the installing position of the crane on house should be considered according to dismantling convenience and carring capacity. (1) Dismantling inner climb crane by cranes on house should strictly adhere to the operation instruction of cranes on house. (2)Before dismanting and carrying tower crane, as the climbing mechanism have not used for a long time, users should maintain it and try operate it. (3)Before dismanting and carrying out the tower crane, as the jacking mechanism have not used for a long time, users should maintain it and try operate it. (4)Check limiters, slewing mechanism brakes and so on for reliability during test-run. (5)f tower crane mast sections have been dismantled, it is prohibited to use the slewing mechanism, luffing mechanism and hosting mechanism before the slewing ring support has not been connected to the tower body by 8Φ60 high-tensile bolts (6)Often check the main stressed parts of the jacking mechanism, as the dismantling of tower crane is a heavy and continuous work for the jacking mechanism (7)While the jacking mechanism is working, all operating workers are required to focus on observing whether the relative positions of moving parts are normal (e.g. the relative position between rollers and main chord rods, the relative position between climbing frame and tower body.). When climbing frame is rising between climbing frame, if tower body dclines, the jacking opreation must be stopped and descend it, then reset. (8)When dismantling tower crane, the wind speed is less than 14m/s at the highest point. Take care of the stockpile location of workpiece as the building has been constructed and working site space is limited during the tower crane dismantling, no carelessness at the time, otherwise personal safety accidents will likely occur Basic formality of dismantling tower Special caution: The dismantling of tower crane is a highly technical work, especially the dismantling of the internal climbing device, tower sections, counter ballast, counter-jib and jib. Any slight neglect will cause machine damage, personal injury even death. Therefore, users are required to strictly follow the instructions-specified rules to dismantle these components. Tower operators must have been 132

142 trained and obtained certificates. Special notice: Pay great attention to the two climbing latches during install or dismantle tower sections, inspect if the latches are still in proper condition. Rotate the tower crane to the dismantling area where there are no obstacles influencing the dismantling operation. Its steps are opposite to the erecting steps. You should follow the Instructions specified rules in all cases strictly The dismantling of crane with anchors Basic programs of dismantling crane with anchors shown as Fig Lower down the tower sections (dismantle anchored devices if necssary) (2)Dismantle counter ballast from counter-jib (Keep only two 2.75t counter ballast on counter-jib) (3)Dismantle hook (4)Dismantleluffing tie bar (5)Dismantle safe rope (6)Dismantle jib assembly (7)Dismantle the odd 2 counter ballast (8)Dismantle A-frame assembly (9)Dismantle counter-jib assembly; (10) Dismantle the operator cab (or dismantle it together with the slewing assembly) (11)Dismantle slewing mast assembly (12); Dismantle slewing support assembly (13); Dismantle the climbing frame (14)Dismantle the tower sections Attention: The dismantled crane should be checked by technical persons and trained maintenance persons. Check main stressed structural members for metal fatigue, weld fissure, structural deformation, etc, check tower crane parts for damage or collision injury. After checking, repair the defects found and defects potential, then complete the task of rust removing and painting. 133

143 Fig the ordering of dismantling of L The Disassembly of internal climbing tower crane follows: Basic procedure and process of the dismantling of internal climbing tower crane are as (1)Hoist anfd installed the tower crane onto the top of building by the crane on house. (2)Reduce the height: Make full use of the internal climbing system to do it. And ensure that two internal climbing frames are fixed in the remained hole of elevator. (3)The disassembly of counter ballast: turn the counter jib to the working area of house crane, disassemble counter ballast by house crane (remain two pieces of 2.75t bob-weight); (4)The disassembly of jib assembly: turn the crane by 180 to make the jib close to the house 134

144 crane, firstly make use of the house crane to hoist jib assembly onto the top of house and disassemble it, then hoist the disassembled jib onto the ground. (5)The disassembly of counter-jib: hoist the remained counter ballast onto the ground, then hoist the counter-jib assembly onto the top of house and disassemble it, lastly hoist the disassembled counter-jib onto the ground. the house top to disassembly (6)Hoist the top of tower, slewing tower body, slewing assembly, tower section, internal climbing device onto the ground in turn by house crane. (7) The disassembly of house crane:disassemble the house crane completely, trainsport all the parts onto the ground by construction elevator Dismantle the tower body L Fig dismantle the tower body 1 (1)Slewing the jib to the direction for the bringing in section (namely, the opening side of 135

145 climbing frame), make slewing brake at the braking status and the tower crane at a balanced jacking status, turn the jib to the balanced position (namely, in conformity to the balanced position of the jib when additional sections are jacked during tower crane erection) (2)Remove the connecting pin of the toppest tower secting 1 and tower secting 4, as is shown in the left drawing of Fig (3)Extend the jacking cylinder 3 to place the pin bolts onto the slot of the 6th lug counting from up down, insert safety pins, jack the superstructure until the bottom of the trolley is moved to 30~50mm away from the top of the section 4, as is shown in the left drawing of Fig (4)Lead the trolley into the climbing frame. Retract the jacking cylinder until the bottom of the trolley contacts the connection of top section 4, as is shown in the right drawing of Fig dismantles the tower body 2 (5)Continue retracting the jacking cylinder until the mast section (1) is led down onto the trolley. At this time, the indraught beam has descended a certain distance. Remove the pins that connect the mast section (1) to the slewing ring support. (6)Extrude the jacking cylinder until rollers of the trolley contact the indraught beam, at this 136

146 time, the top connection surface of the mast section (1) is about 45~50mm away from the bottom surface of support chord rod of the slewing ring. Move out the trolley, as is shown in the left drawing of Fig (7)Retract the jacking cylinder to make the lug-changing rod (2) fall on the lug (e) (8)Ensure that the two supporting rods both are pressed on the slot of the lug (e) and bear the weight of climbing frame and the parts above them. After that, pull out safety pins, hang the jacking cylinder onto the slot of the lug (b). Insert safety pins. (9)Slightly extend the jacking cylinder and pull the lug-changing rod (2) outwards to avoid its falling from being interfered. Retract the jacking cylinder to make the rod (2) fall on the lug (d) (10)Be sure that the two lug-changing rods both are pressed on the slot of the lug (d) and bearing the weight of climbing frame and the parts above them. Pull out safety pins, hang the jacking cylinder (3) onto the slot of the lug (a), then insert safety pins (11)Slightly extend the jacking cylinder and pull the rod (2) outwards to prevent its falling from being interfered. Retract the jacking cylinder to align connection pinholes of slewing ring support chord to those of mast section (4). Insert 8 φ60 shoulder-free pins, knock them into holes, insert tiny pins and spring pin at one end of the pins and put on anti-rotation sleeve at another end before inserting tiny pins and spring pin. (12)After connecting the slewing support to tower section, hoist the mast section down onto the ground. If several mast sections are to be dismantled in succession, keep the tower body main chord rod connected to the slewing ring support by 4φ60 shoulder-free pins after completion of each section dismantling and before hoisting the next section. Only in this case can 4φ60 pins be used Notice: During the climbing frames lowering, it is necessary to dispatch special persons to attend hanging plates, lug-changing rods and guide rollers, observing whether the climbing frames are being clogged by obstacles so as to ensure their smoothly falling Repeat the above opreations to dismantle the tower sections in sequence. If the tower is to be further dismantled after the tower body has been dismantled to the installation height, it is necessary to dismantle at first the counter ballast from the counter-jib Dismantle counter ballast. Dismantle the counter ballast by auxiliary crane. Dismantle the counter ballastt one by one in the sequence oppositing to counter ballast mounting. Keep only two pieces of 2.75t counter ballast. 137

147 5.7.5 Dismantle hook In 1 fall condition, lie the hook on the ground, then remove the pivot used in the connection between hoisting rope and hook, finally retrieve the hoisting rope. In the 2 fall working condition, lower the hook to the ground, then make use of chain block or assistant device to lift the wire rope with link anti-twist device of jib, unsnatch the link pin for rope and anti-twist device of jib. At last, lower the ropes slowly to the ground, and the disassembling of hook is completed The dismantling of luffing tie bar (1)Slowly revolve jib at angle of 10 to make the weight onto safety rope, and continue operating luffing mechanism until luffing tie bar onto jib, then stop the operation. Dismantle the spindle that connects luffing pulley assembly to frame. Fix lifting rope on first support and drill through the block support underside to wind on the contrary. Use the rope and buckle to connect the histing rope end and pulley block in the same. Right now travel mechanism roll the rope and life mechanism slowly discharge rope will make pulley block to block support be fix on A frame move(notice: adjusting of two mechanism ). (2)Hoist luffing pulley assembly by truck crane, put it on the head of A-frame with board of block frame and be warded off in board. Twist the bolt and tighten. length. (3)Switch on hoisting mechanism to roll rope in coiling block and check the rope in all (4)Disassemble the rope from wedge connector of upside block be fixed on A-frame wedge connector, Switch on luffing mechanism to roll rope in coiling block. Put block hang on the hook in rope, dismantle M20 bolt, loosen block and lower block to ground Dismantle safety rope (1)Hoist the jib by the truck crane round hinge joint go to above angle 20(notice: the position of hoisting point is same as jib, refer to Fig5.5-45, Table5.5-11), at this time, safety rope has no force applied. After winding luffing rope round the top pulley of A-frame, connect the luffing rope to the end of safety rope, dismantle link-pin of safety rope and A-frame. Switch on luffing mechanism to release the safty rope, put the satefy rope on the above plate of jib. Release another one in the same way. Switch on luffing mechanism to draw back luffing rope into luffing drum, and check rope in the whole length. 138

148 5.7.8 Dismantle jib Notice: Before dismantling, check whether component-to-component is still connected by power cable Make use of assistant truck crane to remove the pins connecting root of jib b with counter-jib, lower the jib and lay it down on the sleeper-cushioned support The Dismantling of counter ballast of 2.75T Make use of assistant crane to dismantle the remained two pieces of 2.75t counter ballast. Notice: before disassembling, please check whether there is cable that link adjoining discreteness. Disassemble the link pin that links A-frame assembly root to the counter-jib by assistant truck crane, lower the A-frame assembly onto the ground Dismantle travel machine Dismantle luffing mechanism by assistant truck crane Dismantle hosting mechanism Dismantling hosting mechanism by assistant truck crane Dismantle counter-jib assembly Hoist the counter-jib through 4 hook lugs on the counter-jib to make the jib pull rod at a loosened status. Remove connecting pins of pull rod by chain block and then dismantle the connections between counter-jib and slewing tower body. Put counter-jib in distance from the ground above 1.5 meter. Lower the counter-jib down onto the ground. 139

149 Dismantle operator cab Dismantle slewing tower Dismantle slewing support assembly Support the lug changing rods of climbing frames on the tower body, then dismantle the connection of the slewing ring support with the climbing frame and tower body, lower the slewing assembly Remove climbing frame Slowly hoist the climbing frames along the main chord rod of tower sections, then place them down onto the ground Remove tower sections Remove the remained three tower sections, keep on hoisting the top tower section and pull out the pins between the hoisted tower section and the next section. Hoist the tower section down onto the ground. Repeat these operations until there are only the foundation anchors or base frame remained Attentions after dismantling tower crane (1)The dismantled crane needs to be checked and maintained by technical personnel and trained maintenance personnel (2)Check main stressed structural members for metal fatigue, weld fissure, structural deformation, etc. Check tower crane parts for damage or collision injury. After completion of checks, repair the defects found and defects potential. Carry out rust removing and painting 140

150 6 Mechanism 6.1 hoisting mechanism Summarize The hoisting mechanism of the tower crane is QPL1690A, and the motor is YZPBF280M-8. The transmission system of the hoisting mechanism is shown as in Fig , the hoisting drum is provided with the hook height limiter, When objects have been hoisted to the highest position, the hoisting winch will stop automatically. 1-motor 2-coupler 4-Reduction 5-Undercarriage 6-Drum 7-Altitude limiter Fig hoisting mechanism 141

151 6.1.2 Technical parameters of Hoisting mechanism Technical parameters of Hoisting mechanism speed Technical parameters of hoisting mechanism speed setting enactment (HZ)frequency average rate of rope(m/min) Ⅰsetting 8 12 Ⅱ setting Ⅲ setting Ⅲ setting Ⅴsetting Motor Summarize YZPBF series frequence control three phase asynchronism motor be used in metallurgy and crane. The motor is adopted assistant design and thought over the power of frequency conversion to the motor bring the effect. The motor and some different frequency control device of all the other country may be matched to composing AC frequency control system Interchangeability of The motor is very strongly. The fixing size of the motor and the YZR2 series three phase asynchronism motor is consistent to the smae machine. The motor is possess strong ability of over over loading and machine intensity, especially adapt to equipment of short time and no continue to start-up, frequently start-up and brake, positive and negative change, over load and distinct libration and impact. Therefore the motor is the fit to frequence control system of crane and metallurgy assistant Motor rating pressure is 380V, frequency conversion range 1~100Hz, 1~50Hz is constant torque timing. 50~100Hz is constant power timing. DOS shell of the motor safety grade is IP54, and according to the using to make the IP55, insulated grade is F, and according to the using to make the H Model explain Y Z PB (F) 132 M

152 Poles of motors Asynchronous motor for crane Code of core length Frequency conversion Forced fan cooling Height of center Code of frame length Type of motor cooling YZPB series motor have coling ability, the basic character of service is S3~40%, YZPBF series is adopt fan of autocephaly power to bring cooling wind to the motor. Benchmark character of service is S Structure and installation of motor Structure and installing type of the motor are M1001 IM1003 IM1002 IM1004 IM3001 IM3003 IM3011 IM3013, and manufactured acrroding to the Table According to requirement of users, the motor can be equipped with sensors of different resolution rate(photoelectricity coder, motor with device of measure speed, excessive speed switch) electromagnetism brake, gear reducer etc accessories etc. 表 Table 结构及安装尺寸代号 Construction And Mounting Type Symbol IM1001 IM1003 IM1002 IM1004 IM3001 IM3003 IM3011 机座号 Frame No. 100~ ~ ~ ~ ~ ~ ~

153 IM ~ Brake Summarize YWZ5 brake of electric power and hydraulic pressure (The below is called brake) be used in different rise, strap conveyance, haven and metallurgy machine for retardment and apply the brake. The structure of the brake refers to Fig 6-1-2, the principle: when the power of machine turned off and the brake stop to work, then the drive of brake as turn off power, stopping drive. Then the spering of brake bring on a force to the both side of brake tile on the jib of brake, and to cause stated pressure to the surface on brake as a moment of brake to prevent move. When the machine power turn on the brake and drive start to work and drive bring on a enough force to push the handspike to compel the spring be decreased. The jib of brake splay to two outside.cause the move sides of brake tile leave the brake wheel, then the pressure and moment as clear away. The brake with automatic tile and retroversion. According to the requirement of user, adding the automatic repairment device of gasket abrasion make the retroversion, moment to keep invariableness and leave out different adjusting in process. Basic no adjusting and maintenance. The brake have been added the different limiter according to the make use of requirement. According to the PLC to control to carry out alarm dictate of trouble and limitation of gasket abrasion be found. The function is requirement to modernization crane of conveyance and highly effect machinesm. The brake is increased release device in hand and safety switch according to requirement. It is very convenience and safety to use. The brake is production of antisepsis, all fasteners and pin rolls are stainless steel, and the other components smeared the antisepsis paint may be used in the condition of salt atmosphere and acid atmosphere. The production is YTD or Ed series dirve, and possession advanced technic, reliable quality and longevity by no means appear oil be leaked. The gasket of brake usually is material of half metal of no contain the harmful material as the asbestos. the brake is noiseless, non-pollution green production. According to the requirement to provide the gasket of brake with steel and rubber, asbestos, brass wires etc. 144

154 fixing and testing of brake Fig schematic diagram of brake machine The brake should be installed rightly, otherwise the brake can not work normally. So users are required to inatalled according to the manual and process strictly. (1)The checking before installing 1 The Check of brake whether the components of brake are completely. Whether the operating of brake is quick. 145

155 Whether there are oil dirt, paint and impurity on surface of brake gasket. Checking the model of the brake before fixing.( pressure of power frequency and model of drive ) whether accord the spec. Notice: if above requirements can meet, you can not install until they are solved. 2 The checking of brake wheel Ensure that there is not rust, grease, smooth problems, dirt on the surface of brake, the brake wheel of previously bring on crack or severe bug are forbidden to use. while the brake around axes to circumgyrate, the radial offset : diameter of wheel less than 250; the offset less than0.1 Diameter of wheel more than 250 and less than 500; the offset less than 0.12; diameter of wheel more than 500 and less than 800; the offset less than Surface roughness of brake is 3.2, the surface too coarseness and lubricity cause the brake capability difference. 3 The construction of fixing pedestal and checking for brake Fixing pedestal of brake fexness is firm and smooth. Fixing pole locality dimension is correct. If the brake and fixing pedestal be fixed in the same. After the brake be go to and fix, Then fixup the brake and pedestal. if the brake no pole on fixing pedestal be made; then the brake be went to and fixed, drilling the hole in the same. the relatively tolerance(refer to figc6-1-3) no more than table (refer to figc6-1-4)of base level of brake support and the hole or wheel of brake. 146

156 图 Wheel of brake (mm) (mm)high of center K(mm) i (mm) (mm) Center offset (mm) Depth of paralleli sm remarke S e a ± ± ( ) ± (340 ± ) 425( ) 475(470 ±2 ± ) (2)The installing of brake ±1.5 ± ±0.5 ±2.5 ±3 0.8 ±0.8 ±3.5 ±5 1.0 YW YWB 147

157 Hoisting and installing brake refer to Fig It is forbidden to make use of the brake pole. Before the brake be installed, firstly ensure the maintenance and adjusting of brake at that side. If the back distance of equalization bolt not at the side,then they be demounted and fixed at the side.(refer to fig 6-1-3). 2 Put the back distance of equalization bolt and lock nut (ferer to fig 6-1-3), nut of on the screw all back to fit place. Make the lever no leash. 3 Open the brake to the opportune place.(refer to fig 6-1-4), for the basic model should be anticlock wise screw the bar(refer to fig 6-1-4); for the brake of automatic repair should be anticlock wise screw the back adjusting nut.(notic: loosen the lock bolt,release expiation cover in the needing must to pull out pin ); for the brake with manual device should be opend in the one. (If the distance lack must more open the distance by screw the bar of brake or back adjusting nut.) If the brake is fixed between the motor and reducer, one end of brake bar should be screwed out, make it opend (refer to Fig 6-1-5). 148

158 4 Move the brake opened to the fixing place, and hitch the wheel of brake, then make bay nut hole to aim at the hole of bolt be fixed on the foundation support. 5 Clock wise to screw the brake bar or backing nut (refer to Fig 6-1-4), put expiation journey hb of drive (refer Fig 6-1-4) adjust to the rating in Table 图 推动器补偿行程示意图 Fig expiation journey of drive 表 Table

159 brake spec YW(B) YWZ5 (E)-160/22 YW(B) YWZ5 (E)-200/22 YW(B) YWZ5 (E)-200/30 YW(B) YWZ5 (E)-250/22 YW(B) YWZ5 (E)-250/30 YW(B) YWZ5 (E)-250/50 YW(B) YWZ5 (E)-315/30 YW(B) YWZ5 (E)-315/50 YW(B) YWZ5 (E)-315/80 YW(B) YWZ5 (E)-400/50 YW(B) YWZ5 (E)-400/80 h b (mm) expiation journey Rating value Least value 25±2 5 30±2 5 25±2 5 30±2 6 28±2 6 brake spec YW(B) YWZ5 (E)-400/125 YW(B) YWZ5 (E)-500/80 YW(B) YWZ5 (E)-500/125 YW(B) YWZ5 (E)-500/200 YW(B) YWZ5 (E)-630/125 YW(B) YWZ5 (E)-630/200 YW(B) YWZ5 (E)-630/300 YW(B) YWZ5 (E)-710/200 YW(B) YWZ5 (E)-710/300 YW(B) YWZ5 (E)-800/300 h b (mm) expiation journey Rate value Least value 28±2 6 75±2 (18±2) Notice: The dimension in bracket is expiation journey for brake of automatic repair 6 Open the junction box, according to prescript correct connect the power wire of drive and earth line (refer to fig 6-3-7) the wire be over, the cover the casing screw the bolt. 6 Notice: Junction box of drive levels of protection is more than IP55, cable incomed by the filling to guide. The enter pipe of cable is M27 1.5, usually connection cable is 4 1.5mm and the 150

160 max specification of cable is 4 2.5mm2, the junction box be seted the bolt M5 of connect ground. The user according the using status to decide the thing.the drive have six wiring terminal with M5, to connect Y or.the user according to the draw to connect the power line and earth line. For the connection of drive motor, usually the connection is fulfilled before leave the company. The user change the connection is forbided unless the user fined the method no accord the using. The false method bring on the motor burn out, then our company is not quality duty. The drive connection wire and clamp is fastness, or else the loose cable brings on the wire take off. result in the power no tranquilization ect. Even the motor is burned out. 7 Power on 20~30 time during stop and start to switch. Then the brake automatically adjust to the middle,lastly observe the brake in power-off if the fixing place is correct. 8 Ensure the fixing location is correct, according to adjusting nut 1of the side to draw back equalization lever at level position.(notice: equalization lever and brake whee distance is more than 3mm, equalization lever and fixing pedestal distance is more than 12mm ) then the connection bolt of the other side be screwed to thread rod. And separate lock the nut 1, 2. 9 Screw foundation anchor and nut of connection pry (Notice: Donnot screw too tighte).the installing is over. (3)The adjusting of brake The adjusting of brake includes adjusting of brake monmengt, adjusting of wering plate and adjust of equalization with autocompensation installation of brake, when the early adjust of aready wearing plate,so the every work will needing to adjust, as if any out of way on working it will need not to adjust. 1 When the spanner clockwise rotation monmengt adjust nut3,so the brake spring working length will be shorten and brake moment will be add, theother way round will reduction. As required adjust of monment, in other place the limiter has rule. Consumer can according to the fact of 50 percent rated value change a suitable moment,from leave factory brake moment has already adjust. 151

161 图 6-8 Notice: while the brake be adjusted. (refer tofig6-1-8)please accord to prescriptive moment value on the moment scutcheon. or else the brake will appear abnormal phenomena. Tile of distance reducing Tile of distance reducing and h journey of drive is direct ratio linearity, and that the h(journey of drive) = H (rating journey value of drive ) hb(compensation value of drive).(for 1250N upwards drive be set the designation staff guage,fig the journey of drive value must be designaed inside the green line. If the value is inside the red line the journey of drive should be adjusted to compensation. For the brake with device of automatic compensation,the tile of distance reducing has already been set and adjusted beforeing leaving factory, therefore the customer need not to adjust the device is working in the normal. But the gasket of brake is changed new one or fixed need to adjusting. adjusting of wearing plate Brake has brake equalization device, seethe fig6-1-5, at working it not to adjust,if it has bed disproportionate phenomenon,may be equable devices nut loose,at this time turn up the brake and screw down the lock nut (note : equalization lever should approach locate near horizontal.) usag and maintenance brake (1)usage of brake 1 Before usage, the brake must be inspected as the below instruction: if the brake be fixed is correct and accord the claim. check if accord claim to model,pressure, frequency and connection,fill oil. 152

162 check if accord claim to testing check if accord claim to length of the brake spring If the brake washer and the brake plate are clean and without grease. 2 The brake is normal to after checking, then take off the motor, the brake in static circumgyrate above time according to 40% power to continu to work with cycle in five second. Continue to operation times to brake. Observe if the brake is abnormal. Please refer to second section prescribe to eliminate mistake. Then anew try to nomal. Adjusting the moment value to 50% to brake(refer to fig 6-1-8), the moment in 30%~50% refer to 2 and try to function 10~15 time ( in dynamic) to observe the brake for stabilization.only the brake is tranquilization to status that stopping. After the brake is normal work, put the moment value adjust to be prescribed.then the brake should be using in due form. (2)Brake maintenance 1 the brake must be inspected once every 1~3days (as per the practical situation),the inspected items are as follows: Check if the working stroke of (the pad cancelling) the driving unit works normally. Check if the autocompensation installation is wearing, if the compensation socket and the set screw are loose. Check if there is any change of the working length of the brake spring. if the touching board of the limit switch is loose and if the position is correct. if there is any oil soil on the surface of brake pulley and washer. the worn situation of the brake washer,if the effective abrasion thickness is less than 3mm, readjustment and running aer required for every time In emergency stop, Some stains with colors may occur on the brake wheel,if there is a serious crak,it is necessary to replace the brake wheel. 2 the inspection during usage in operation process, user must inspect the following items in time if there is any abnormal increase of the brake time and brake distance during operation. if over speed situation on the brake wheel happens during the usage of the mechanism. Check if the action of limiter switch is correct and normal. Check if there is lasting high temperature (more than 350 ) on the brake wheel and the brake washer or smoking. Ifany abnormity is found, stop the machine to inspect, find out 153

163 the reason,usage is allowed after trouble clearing. 3 touch-up painting: during transportation process,storage,erection and operation, there maybe damage to painting.re-painting if it is found, otherwise, the anticorrosion property will reduce.the following parts are forbidden to be contaminated when the touch-up painting is disposing to the brake and other relative parts: all the points of the hinge joint Firction surface of the brake wheel and the brake washer. the surface of the auto compensation device and the push rod of the driving rod The sueface of the bearing. 4Lubrication: allthe hinge points of the brake aer adopted with self-lubricating composite bearings; extra lubrication is not required during usage. 5 replacemengt of the brake washer: if the brake is used for a period of time,the brake washer will become thinner due to friction,when the effective adrasion thickness (grinding material thickness) is less than 3mm, the washer must be replaced.pay more attention when carrying out the replacemengt. The following is the instruction of the replacement: open the brake to the max.angle position.according to3 screw the pressboard bolts on the washer diwn,then get out the pressboard and adjust the washer.(fig 6-1-9) old the washer and breake it off to one side of the brake whaal,get the replaced then insert the new brake washer (notice the correct position) Mount the baffle and the pressboard in turn; fasten the bolys,note that the brake washer and the brake pad should be joint well, and the clearances of all the joint section will not be longer than 0.5mm,the upper part of which should be higher than the top of the brake pad,the superelevation of it (c) must be accordance with the drawings and the table6-3-4 below, so the brake washer could be jammed,and fixed well.in addition, the pressboards on the two sides,as well as the brake washer on the gland of the baffle,their thickness could not exceed the 1/2 of the original thickness of the brake (including the thickness of the steel back), while could not be less than the 1/3(including the thickness of the steel back). 154

164 图 Fig 表 Tab le specification of wheel diameter on the brake C ~ ~ ~ ~ Notice: After fixing washer of brake, please check, test run refer to the requirements in table (1). 6.Themaintennance of the driving unit: the brake adopts YTD or Ed series. the driving unit is filled with hydraulic grease before leaving the factory. It belongs to free-maintenance product, if the user would like to refill or exchange the hydraulic grease, please carry out the operation as per the instructions in the operation manual. 155

165 6.2 slewing mechanisms There are 2 sets of slewing mechanisms symmetrically arranged on both sides of up seat. With A suit of HVV145B1.130AThey are driven by 2 sets of 7.5KW motors, which model is YTW132M-4B5. They drive the pinions through planet gear reducer, hence making the jib and counter-jib slew to the left or the right. The motors are provided with disc brakes at their tails, which are kept at constant open status. The slewing brakes are used at windy conditions. They can hold the tower crane in the specified direction and location while hoisting or jacking operation is going on. It is forbidden to stop by brake. Stopping the crane in off duty through electromotiona or hand movement to open the brake of turn vane.making the jib follow the wind turn to tail wind direction. The slewing mechanisms makes use of grease to lubricate (000 grease), when maintaining or leakaging causes the oil level decline, renewthe grease in time ensuring that the grease arrives at plug screw. 1. motor 2. reductor 3. slewing gear 4. slewing support 5. small gear 6. slewing limitter fig sketch map of slewing mechanisms drive 156

166 6.3 Luffing mechanism summarize The the luffing mechanism of this tower crane is BPL370, the most luffing force is 40t, the motor of frequency conversion is YZPB(F)250M2-8, rating load lowest decline speed is not greater than 10 m/min. Luffing mechanism is similar to the hoist mechanism in luffing tower crane, the constitution of thedrive system of luffing mechanism refers to Fig 6-1. When luffing, the motor drives the drum through the planetary reducer and connectors to link. The distance of crown block and travling block through the wire rope is turn by drum to adjusting. The trolleying pole drives the jib up and down turn for trolleying Drum end of trolleying mechanism be fixed the journey limit device. While luffing move to the limit position, it will stop automatically. 1-motor 2-brake 3-coupler 4-reducer 5-roll 157

167 6-multifunctional stopper 7-safe brake 8-undercarriage Fig trolleying mechanism 158

168 6.3.2 performance parameters of luffing mechanism Table performance parameters of trolleying mechanism motor summarize YZP series three phase asynchronism motor be used in metallurgy and crane. It be used different crane machine and the other similar production. And the power of motor is frequency control device. The motor and all over the world different frequency control device assort to compose frequency control system. The motor change speed area very wide, strong ability of over loading, stably and reliable function, high efficiency. Therefore the motor is the same with device 159

169 for short time, no continue to start-up,brake,over load and libration and impact condition of using It can work normally in case of altitude not exceeding 1000m. The F level is suit in the condition of temperature in-20 ~40, the Hlevel is suit to the air temperature in-20 ~ basic forms Mark Preesure:380V basic frequency:50hz,1-50hz timing of constant torque,50-100hz timing of constant power level of protection:ip54 insulation grade :F 或 H fashion of cooling: coling fan(ic416) Basic job :S3-40% fashion of fixing:b3(112~400) B5(112~250) V1(112~315) B35(132~315) connection fashion ofstator : (stator winding of motor is Y connection under 132 ) ;( stator winding of motor is connection under 160 ) Notice: according to the using requiremengt to set the switch with temperature inductor to protect hyperthermia, dampproof device. Brake of electromagnetism, encoder and switch of hypervelocity etc, for the requirement to provide the motor that the basic frequency under 50Hz type of coling fan Mark Preesure:380V basic frequency:50hz Basic job:s1 at axes flow power of fan: 230W ( Power of coling fan independent be used, forbid to use the power of frequency conversion ) The correct using mothods of motor. The prepareing before fixing. (1)Check whether the motor exist damp evidence (2)Must be careful clear dirt and coat on the surface and side of assemblage (3)Check if motor nameplate data is accord to requirement. 160

170 (4)Must be careful check if the motor is distortion and damnification, and fastener is loose and break off. Putting the motor adjusting in status of release. The motor be turned by hand, the turn must be agility, no blocking,and no rubbing etc abnormal status. Recovering the status of brake after checking. (6) The motor be kept more than two years. Must be checking grease of axletree, if the grease turn induration, the news will be change the spec in the same The storage and transit of motor (1)If motors need leave in storage, they must be properly taken care of. The motors that have been opend for checking, they must be taken care of anew. (2)Motor must be kept in bursary of cleanliness, desiccation, no acid and alkali or other causticity gas. And change of rapid ambience and temperature be avoid. (3)Motor too high accumulate in storage will cause less airiness and shatter the bottom casing of motor. (4)Motor must be avoid incline to place or roll in storage and transit break summarize YWZ5 arrester of electric power and hydraulic pressure (brake) can be widely used in different hoisting, strap conveyance, haven and metallurgy machine of retardment and apply the brake. Structure of The brake as follow Fig 6-3-2, The principle: when the machine power turn off the brake stop to work. Then the drive of brake as turn off power, stopping drive. Then the spering of brake bring on a force to the both side of brake tile on the jib of brake, and to cause stated pressure to the surface on brake as a moment of brake to prevent move. When the machine power turn on the brake and drive start to work and drive bring on a enough force to push the handspike to compel the spring be decreased. The jib of brake splay to two outside.cause the move side of brake tile leave the brake wheel, then the pressure and moment as clear away. There are tile and retroversion with automatism in the brake. According to the using 161

171 requirement to add the automatic repairmen abrasion gaske cause the retroversion, moment to keep invariableness and no adjusting in process. The brake have been added the different limiter for the using. According to the PLC to control, and conk out and limit of gasket abrasion once appear to alarm and show the signal. The function is requirement to modernization crane of conveyance and highly effect machinesm. The brake adds to release device in hand and safety switch according to requirement. Convenience and safety in using. The brake can provide with antisepsis productions, all fasteners and pin roll are stainless steel, and the other components are smeared the antisepsis oil paint. The production is YTD or Ed series dirve, and possession advance technology, reliable quality and longevity by no means appear leakage oil. The gasket of brake usually is material of half metal that no contains the injurant as the asbestos. the brake is noiseless, non-pollution green production. According to the using requirement to provide the gasket of brake with steel and rabber, asbestos, brass wires etc. 162

172 Fig schematic diagram of brake mechanism 163

173 The installing and testing of brake Brake should be installed rightly, otherwise the nomal work of brake will be influenced, so the installing is required to strictly according to the manual and process. (1)The checking before fixing 1:The checking of brake check if the components of brake are complete; Check if the operation of the brake is agility. Check whether there is oil dirt that influences friction force on the surface of gasket of brake. Check whether the model of the brake before fixing. (Including pressure of power, frequency and model of drive) correspond to the requirements. Notice: If above qualifications can not meet the requirement, So you must solve them, then begin to install. 2The checking of brake wheel The surface of brake cann t be stained with rust, grease dirt, smooth problem, forbid using brake wheel of previously bring on crack or severe bug. While the brake gyrating around axes, the radial offsets: diameter of wheel less than 250, the offset less than0.1, diameter of wheel is more than 250 and less than 500, the offset is less than 0.12, diameter of wheel is more than 500 and less than 800, the offset is less than Notice: The surface roughness of brake is 3.2, the surface excessively coarseness or lubricity of brake will cause the brake capability difference. 3The Construction of installing pedestal and the check for brake The fixing pedestal of brake fexness should be firm and smooth, fixing pole locality dimension should be correct. If the brake and fixing pedestal are fixed at the same time, you should fixup the brake and pedestal after the brake locating and preparatorily installing. If the poles on fixing pedestal have not machininged, you should drill the hole after the brake located rightly, Notice: the relatively tolerance of base level of brake support and the hole or wheel of 164

174 brake (refer to Figc6-3-2)can not exceed the requirements in Table table 6-2 Wheel of brake (mm) h1(mm) high of center K(mm) i (mm) (mm) Center offset (mm) Depth of paralleli sm remarke S e a ± ± ( ) ± (340 ± ) (420 ) (470 ) ±2 450 ± ±1.5 ± ±0.5 ±2.5 ±3 0.8 ±0.8 ±3.5 ±5 1.0 YW YWB 165

175 (2)The installing of brake Hoisting brake should refer to Fig6-3-2, it is forbid to make use of the brake pole to hoist. 1Before the brake installed, firstly ensure the maintenance and adjusting of brake at that side. If the back distance of equalization bolts is not at the side, then they be demounted and fixed at the side. 2 Put the back distance of equalization bolt and lock nut, nut of on the screw all back to fit place. Make the lever no leash. 3Open the brake to the opportune place (refer to Fig 6-3-4), the basic model should be anticlock wise screw the bar (refer to Fig 6-3-4); for the brake of automatic repair should be anticlock wise screw the back adjusting nut. (Notice: loosen the lock bolt, release expiation cover in the needing must to pull out pin); for the brake with manual device should be opend in the one. (if the distance lack must more open the distance by screw the bar of brake or back adjusting nut ). If the brake is fixed between the motor and reducer, one end of brake bar should be screwed out, make it open (refer to Fig 6-3-5). 图

176 4Move the opend brake to the installing location, and hitch the wheel of brake, then align the hole of foundation anchor to the hole of bolt the foundation support, screw the foundation anchors loose, at last,install the brake anew. 5Screw the brake bar or backing nut clockwise (refer to Fig 6-3-4), adjust expiation journey hb of impulse (refer to Fig6-3-6 ) to the value in Table 6-3-6, then screw the check nut of brake bar tightly. Fig expiation journey of impulse 表 6-3 brake spec Hb(mm) expiation journey brake spec Hb(mm) expiation journey 167

177 Rate value Least value Rate value Least value YW(B) YWZ5(E)-160/22 YW(B) YWZ5 ( E ) -400/125 YW(B) YWZ5(E)-200/22 YW(B) YWZ5(E)-500/80 YW(B) YWZ5(E)-200/30 YW(B) YWZ5 ( E ) 25± /125 28±2 6 YW(B) YWZ5(E)-250/22 YW(B) YWZ5 ( E ) -500/200 YW(B) YWZ5(E)-250/30 YW(B) YWZ5 ( E ) -630/125 YW(B) YWZ5(E)-250/50 30±2 5 YW(B) YWZ5 ( E ) -630/200 YW(B) YWZ5(E)-315/30 YW(B) YWZ5(E)-315/50 25±2 5 YW(B) YWZ5 ( E ) -630/300 YW(B) YWZ5 ( E ) 75±2 (18±2) 6-710/200 YW(B) YWZ5(E)-315/80 30±2 6 YW(B) YWZ5 ( E ) -710/300 YW(B) YWZ5(E)-400/50 YW(B) YWZ5(E)-400/80 28±2 6 YW(B) YWZ5 ( E ) -800/300 Notice: The dimensions in bracket are expiation journey for brake of automatic repair 6 Open the junction box, connect the power wire of drive and earth line correctly according to prescript (refer to Fig 6-3-7), after connecting wire, cover the connecting box and screw the bolt tightly. Notice: The protectiing level of conneting box in impulse equipment is above IP55, cable incomed by the filling equipment. The size of incoming cable is M27 1.5, Connection cable usually is 4 1.5mm 2 and the max specification of cable is 4 2.5mm 2.The junction box set the ground device both inside and outside with M5 bolt. The user could equip under the necessity of oneself. The drive 168

178 have six terminal connector with M5, which include two type about Y and. So user could connect the power line and earth line according to the schematic diagram. The connection of drive motor has finished before leave the factory. The user couldn t change the connection unless the method isn t meet the requirement of user. The incorrect wiring probably conduce the motor burnout, which is not duty of our company. The impulse s connection wire must be fastness and electric cable also must be fastness by the filling equipment, otherwise the loose of cable lead to the interface break off and the power no tranquilization etc, even the motor burned out. 7 Power on 20~30 times during stop and start to switch, make the brake automatically adjust to the middle,lastly observe the brake in power-off whether the fixing place is correct. 8 Ensure the installing location correctly, according to adjusting nut 1 of the side to draw back equalization lever at level position(reference6-3-3). (Notice: equalization lever and brake wheel distance is more than 3mm,equalization lever and fixing pedestal distance is more than 12mm ), then the connection bolt of the other side be screwed to thread rod. And lock the nut 1, 2 separately. Then screw the other in the same way. 9 Screw the bay bolt and nut of connection pry (notice: not tighter), the fixing be over. (3)adjusting of brake Adjusting of brake include adjusting of brake monmengt, adjusting of wering plate and adjusting of equalization with autocompensation installation of brake, when the early adjust of aready wearing plate,so the every work will needing to adjust, it will need not to adjust if any out of way on working. 1 The brake monment adjust: the brake monment has already adjust since leave factory brake moment. As required adjust of monment, User could according to the fact of 50 percent rated value to change a suitable moment. Adjust method: when the spanner clockwise rotation monmengt adjust nut, the brake spring working length will be shorten and brake moment will be add, the other way round will reduction(reference6-3-8). 169

179 图 Notice: Please don t exceed prescriptive moment value of the moment scutcheon while adjusted the brake moment. Otherwise the brake will appear abnormal phenomena. 2 Adjustment of distance reducing: The reducing distance of tile and journey of drive is direct ratio linearity, h(journey of drive) = H (rating journey value of drive ) hb(compensation value of drive). (The inpulse upwards 1250N have indication guage, refer to Fig The journey of drive value must be inside the green line. The compensation journey of drive should be adjusted if the value is inside the red line. The distance reducing of tile has already been set about the brake with device of automatic compensation have been adjusted beforeing leaving factory, so the user need not to adjust the device in normal, which except changing a new one and fixed situation. The menthod of adjusting refer to Fig The adjusting of wearing plate All of brake has distance reducing automatism equalization device(refer to Fig6-3-3), it does not need to adjust in working situation(this is proprietary technology of our company), it appear disproportionate phenomenon when the equable devices nut is loose, it is need turn up the brake and screw down the lock nut right now (note : equalization lever should locate near horizontal) usag and maintenance brake (1) usage of brake 1 Before usage, the brake must be inspected as the below instruction: The brake fixed correctly accord the claim or not;. 170

180 Check if the model, pressure, frequency and connection, fill oil of impule meet the requirement. Check if brake testing meet the requirement. Check if the length of the brake spring meet the requirement. Check if brake washer and the brake plate are clean and without grease. 2 After Checking the brake is normal. The brake run time in static circumgyrate in condition of motor power-off, the power continu rate is 40% and cycle time is five second. Continue to operation time, Observe the brake is normal or not. Please eliminate mistake refer to second section prescribe if the brake is unnormal, then try again until nomal. 3Adjusting the brake moment value to 50% of specified value (refer to fig 6-3-5). refer to 2 to run 10~15 time ( in dynamic) in the 30%~50% of brake moment, then observe the brake for stabilization. It could stop if the brake is tranquilization. 4If brake is normal work, put the moment adjust to prescribed value.then the brake could be used. (2)the maintenance of brake 1the brake must be inspected once every 1-3days (as per the practical situation), the primary coverage items are as follow: Check if the working stroke of (the pad cancelling) the driving is works normally. Check if the autocompensation installation is wearing. The compensating socket and the set screw are loose. Check if there is any change of the working length of the brake spring. Check if there is any loose in touchingboard of the limit switch and the position is correct. Check if there is any oil soil on the surface of brake pully and brake wheel. If this is worn situation in the brake washer and the effective abrasion thickness is less than 3mm, it should change and adjusting and running for every time. Some stains with colors may occur on the brake wheel in emergency stop, it is necessary to replace the brake wheel if there is a serious crack. 2The inspection during usage User must check the following items in time for operation process: There is abnormal increase of the brake time and brake distance during operation or not. 171

181 Check if over speed situation on the brake wheel happens during the usage of the mechanism. Check if the action of limiter switch is correct and normal. Check if there is lasting high temperature (more than 350 ) or smoking on the brake wheel and the brake washer. Stop the machine if any abnormity is found, then find out the reason. Running again after trouble clearing. 3Add painting: During storage and erection operation and transportation process, the painting maybe damage in some palce, re-painting if it found, otherwise, the anticorrosion property will reduce.to contaminate the following parts are forbidden when the touch-up painting is disposing to the brake and other relative parts: All of the points of the hinge joint Firction surface of the brake wheel and the brake washer. The surface of the auto compensation device and the push rod of the driving rod. The sueface of the bearing. 4 Lubrication: all of the hinge points of the brake are adopted with self-lubricating composite bearings; extra lubrication is not required during usage. 5Replacemengt of the brake washer:the brake washer will become thinner due to friction if the brake is used for a period of time. When the effective adrasion thickness (grinding material thickness) is less than 3mm, the washer must be replaced. Pay more attention when carrying out the replacemengt. The instruction of the replacement are as following : Open the brake to the max angle position according to Screw the pressboard bolts on the washer diwn,then get out the pressboard and adjust the washer.(fig 6-8) Hold the washer and pull it to the brake wheel side, the get the washer to replace according to circumference direction. then insert the new brake washer (notice the correct position) Mount the baffle and the pressboard in turn, fasten the bolys. Note: the brake washer should joint well with the brake pad, and the clearances of the joint section should not longer than 0.5mm, the upper part of which should be higher than the top of the brake pad, the superelevation of it (c) must be accordance with the drawings and the table 6-3-4, 172

182 so the brake washer could be jammed and fixed well. In addition, the thickness of the pressboards on two sides and the brake washer on gland of the baffle could not exceed the 1/2 of the original thickness of the brake (including the thickness of the steel back), it also could not less than the 1/3 of the original thickness (including the thickness of the steel back). 173

183 表 Specification of wheel diameter on the brake C ~ ~ ~ ~ After mounting the new brake washer, please check and try to run according to 1. 6The maintennance of the driving unit: the brake adopt YTD or Ed series. the driving unit is filled with hydraulic grease before leaving the factory. It belongs to free-maintenance product. If the user would like to refill or exchange the hydraulic grease, please carry out the operation according to the instructions SBD80-D safety brake Summarize which mainly be used in the emergent safety brake for big-sized or medium-sized crane with low speed axes of main rising mechanism, it also could be used to brake for big-sized or medium-sized windlass and drive mechanism of inclined aerotransport, as well as cable car and crane with rope. The dish spring is used in this brake and the hydraulic station drive could be released, so the configuration is compact and it simple to be maintained. The production and the friction material are not contain asbestos to personal health. In conclusion, the brake is a advanced and high-performance product. The configuration of brake is in fig , the operation principle are as follow :when the pressure oil in the hydraulic pump station enters into the brake cylinder under the control of the magnet valve, the hydraulic oil compress the spring further to push the piston rod driving the brake arm to the both sides, so the brake monment is eliminated; when the magnet value reset with 174

184 power off, the hydraulic oil back-flow to the hydraulic pump station under the force of the spring, meanwhile, the spring force is applied to the forced brake plate through brake arm,finally the defined brake moment is established. 1. eyebolt 2. lock screw 3. brake screw (support bar) 4. support bar for limit swiych 5. plugging 6. rate plate 7. hydraulic cylinder(with spring) 8. frame 9. brake arm 10. backing lock nut 11. backing adjusting screw 12. accompanied device 13. brake washer 14. brake arm 15. limit switch fig moment specification (mm) Back distance of tile (kn)pressure of clamp (kn)friction force (MPa) Release pressure SBD80-D-Ⅱ /10 fig is schematic diagram of hydraulic pressure,fig is schematic diagram of electricity control, the user could design the schematic diagram according to personal requirement. 175

185 Fig Schematic diagram of hydraulic pressure fixing and adjusting Fig Principium and connection with electricity equipment Brake should be correct fixed, otherwise, it will short of the capability of design, so the user should fix and test according to the method of handbook. please contact the market department if need help. 176

186 (1)before preparative of fixing Check if the brake with the scutcheon and request accord before fix. Check if components of brake is complete (Check if connecting pipe and options is complete if fix with hydraulic pressure ) Check if rustiness and block is active dot. Check if brake gasket face is not dirt and cover impurity affect the capability. Ensure the brake plate is not rustiness, oil dirt, electricity welding and out-of-flatness. Forbid to use brake which is crack and severity disfigurement. It should be ensure correct If founded abnormity. (2)Fixing Please follow the fig to life and install the brake. Forbid to use the oil-hydraulic cylinder and plunger pole to life The bracket should be fixed before install the brake, the bracket should have enough intension and rigidity. The form and dimension reference the fig It connect to pedestal with bolt. The specification and amount and capability must meet the requirement of table Fig Connecting of Brake and B racket Specification of brake Specification NO. Capability Screw moment of bolt SBD80-D01 M Nm Please reference the follow process to fix brake: Before install the brake, the hydraulic stage should be fixed in place, pipe line and control circuitry should be disposed. Use the bolt to connect the brake and bracket. Open the brake arm and ensure the distance of brake gasket greater than brake check thickness above 3mm. Putting the support plank of being fixed and brake of being opend placidly move to fixing place (fig 6-13). Please notice the oil mouth of brake is in the side of hydraulic pressure pipeline(the brake be fixed with twin, pipeline disposal is symmetry ). Make sure the brake close with brake disk in the correct place. Then Check if the place of brake is correct. 177

187 Notice: Ensure both side of gasket and brake is parallel (fig ), use the pad to adjust the side of connecting on plank and brake if not. Connect hydraulic pressure pipeline with oil-hydraulic cylinder oil mouth of brake, entering oil mouth of brake oil-hydraulic cylinder is internal thread M18X1.5. Fix cable of the journey switch according to host computer PLC claim (signal indication). Connection must be fastness and make sure screw clamp of cable is fastness Table Dimension od install Type of brake A B C D E H d SBD80-D

188 (3)adjusting It must be adjust at first fixing and change new attrition gasket. Please according to follow step to adjust at first time. 1Adjusting of tile backing distance and clamping force: brake Tile back distance will directly influence clampping force of brake, so it must be adjusted prescriptive value before use. Tile back distance and X value and clamping force have bijection nexus. Check if dimension X of the brake in close status accord table Please adjust as follow mothod if status is not correct : Firsly open the brake ( it is two mothod to open the brake in anytime ) ;Operate the hydraulic pressure station to bring pressure oil so that open the brake. Operate manual the hydraulic pump to open the brake, The X value decreased if adjust the nut with eddy method (fig ). Contrarily clamp pressure increased if X value increased. Then cloes the brake to observe X value after adjust, once more adjust the brake until accord to the value, then screw down the nut. specification Table6-3-8 (mm) every tile back distance (mm) X distance SBD80-D Notice: Stick direction lable for measure part and measure value near fluid cylinder ( fig ), please reference during the adjusting. 图 fig Brake model Friction X(mm) SBD80-D01 57KN Self-motion device of pull springthe is setted in two brake tile of brake (fig ). 179

189 Loosing the nut before fixe the brake (part 10) to make the spring(part 12) is in loosen; Screw the bolt(part 10) in situation of the brake is clamped status after the brake be firm fixed It is not to adjust under normal status, the place of spring is loose if the place is abnormality, So it should be re-fix or change the spring and adjust according to above-mentioned mothed. 3 Adjusting of back distance equal: brake should be adjusting in original fixing or gasket of brake appear abrasion. Firstly release the brake to normal, then observing the clearance of brake tile and brake tray is consistent or not. It should be adjusting the clearance to the same if not. The method of adjusting are as follow: firstly looseing the lock nut of back distance equal device in both sides(part 10), then screw the bolt of major distance until both sides back distance basic is equal, (Notice: it should exist some space between the adjusting bolt and wall of base in the other side, it must back the nut bolt if it is not space ), then adjust the nut bolt of small side until the distance between pedestal is 0.2~0.5mm, lastly screw lock nut to both side. 图 Adjusting of release limit switch: Each brake take with journey switch of brake release signal. Adjust the travel switch after all of adjusting complete. Methods are as follow: make sure the brake is closed, measure distance between the head of switch to inductor using calipers, it should above 3mm. otherwise, loose the lock nut on switch support(no disassembly), then move the switch front or back until accord with the claim(fig6-15), then release and close brake for many time, lock nut until the switch signal tranquilization. 180

190 Using and maintenance (1)Using Check content are as follow before using of brake: Check if the install of brake is correct and tally with the claim. Check if all of adjusting arrive at technical requirement. Check if the brake gasket and facies of brake tray is clean. Check if paint is complete, otherwise it should be re-paint. The follow part could not be polluted In repairing process: 1. All of articulate dot of brake; 2. The brake gasket and facies of brake tray 3. Facies of axes It could be use if normal. (2)Maintenance 1 Check the brake every 7 to10 days, the content are as follow: Check if spring of dish is cataclasm or not and fluid cylinder leak to dish spring or not from fluid cylinder of brake espial window. The new part must be changed or maintain the old one while dish spring is cataclasm or oil reveal. (Develop method of fluid cylinder of brake is optimum design, so the life of theory for work is above 500 thousand ). Disassembly fluid cylinder of brake are as follow: firstly open the brake, loose the adjusting nut (at least loose 10mm). Disassembly the lock nut, Then close the brake (remove the force of spring), remove pipeline of fluid cylinder and end of fluid cylinder link pin(fig 6-10), at last fluid cylinder could be complete remove. The new fluid cylinder fixed in reverse order, then adjust the new one according to section, it could be used after adjust. Notice: 1. Inner structure of fluid cylinder is different to other one, and it containing expert link technic, so don t disassemble by youself. contact to us will prevent hurting person from dish reed come out. 2. We advice chang the failure of fluid cylinder with whole, which should back to our company to maintain. Check if journey switch poll of touch is loose and action is correct. X dimension become longer because of attrition of gasket, which make clamp force decrease. So it should adjust to prescribe value. 181

191 2 Lubricate: articulate dot of brake is used the Lubricate bearing, no Lubricate in process of use. 3 Change of gasket: new attrition gasket shold be change while attrition gasket thickness less than 3mm,. Process are as follows: Open the brake most locality. loosen the fixing screws of gasket. Firstly hold the gasket and pull into the side of brake disk, which make the gasket disengage from join key, then draw the old gasket out along circumference. Check if surface of gasket is clean and distortion, it should change the new gasket if the surface occur oil is dirt accord with provision New gasket should be cutted in fixing place along circumference, put key of gasket into the place of conection, at the same time, screw down connect bolt. After install new gasket please adjusting again according to Warning: because of the brake gasket is weight, please caution it hurt person if falling down, please make sure brake be opened status and prevent close frequent trouble analyse and eliminate. (1)To arrester give off electricity signal of No acting 1 Cause checking and remove of trouble. Circuitry or control trouble cause electricity valve of drive Hydraulic pressure lead to stop to power. So checking the circuitry or control to exclude trouble. Control electricity valve turn off will lead magnetic valve stop acting. Use multimeter to measure winding turn off or not. It must change the new if the Loop turn off. Flooding valve press too low to enactment cause arrester not opened. Observe the value of pressure gage for hydraulic pressure station and arrester mark out value whether consistent; the value should be adjust pressure value to high if low to the demand need. Checking the motor with multimeter if Motor burned out, the motor should be change the new correspond spec model if motor be damaged (according to detail of instruction book ). 182

192 If hydraulic fluid is disagree with local entironment and temperature lead the oil could not inhale to oil pump, the hydraulic fluid should be changed to correspond spec In such case( the temperature is 0~+30, recommend to use L-HM46 或 DTE25. the temperature is -20~+25, recommend to use L-HM46 或 DTE25.) 2trouble preventive measure Keeping Control loop element for protecting motor is right, loop of electromagneticvalve could not over the setting pressure. Preventing the loop burned out instantaneous, keep the hydraulic fluid is clean, Don't random adjusting each part of Hydraulic pressure station during the work time (2) Distance of two side is not equality.and one side may adhibit on brake disk. 1cause checking and remove of trouble. The center of brake deflection to one side when arrester is installed with serious deflexion. adjusting the gasket between fixing support and ransition board. Adjust if incorrect adjusting according to former means. 2preventive measure Correct fix and adjust. (3) Journey switch action trouble. 1 cause checking and remove of trouble.. Adjust limit switch roller and ejector pin for location refer to d if distance adjust improper. Hydraulic fluid is not fit because of season. Brake is opened up to ordain place as a entirety result from weather chill and viscosity increase. Hydraulic fluid should be replaced in time and opportune adjust the press for Hydraulic pressure station system in such case. 2 Preventive measure Correct adjusting in install, Check if the mandril is loose. Hydraulic fluid should fit the work environment in local Quick-wear part listing mode title spec/fig number gasketremark SBD80-D0 break gasket SBD Made by 183

193 1 oneself Induction switch Bi5-M18-AZ3X 1 Truck Dust proof AF2 80/2 1 AOKANG U -ring AU1 8090/1 1 AOKANG Guide strip BS50704 L=260 1 AOKANG site envelop AS AOKANG Guide strip BS50704 L=465 1 AOKANG U -ring AU AOKANG o -ring 158X1.5 1 GB o -ring 40X3.5 1 GB site envelop AS AOKANG 184

194 6.4 Climbing Jack Summarize (1)Structure introduce The hydraulic system consists of pump station, climbing jack, high-pressure hose and special oil. It could jack or lower the upper parts of the climbing frame, and stop for tower section remove at any position, it shown as Fig This hydraulic installation is compact, efficient, reliable and easy to maintain Fig Hydraulic connection for hydraulic system 185

195 nominal voltage MPa MPa Rated Pressure Table6-4-1Main Parameters of pump station Flux L/min Power kw Hose JB Oil tank capacity L Oil Requirement A-10Ⅱ 100 ESSO AW46 Cylinder Diameter (mm) Table Main Parameters of Climbing Jack Diameter of Rod (mm) Distance of Travel (mm) Installation Distance (mm) (m/min) Jack speed (m/min) Max. Jack force (t) mm 140mm 2000mm 2663mm Jack cylinder 2.Balance valve 3.Manual control valve 4.Pressure gauge 5.High pressure overflow valve 6. Motor 7.Level meter 8. Bent axis pump 9. oil filter 10.fine oil filter 11.Air filter Fig Schematic diagram of climbing Jack ydraulic System (The fig is only to reference, Please read the operation instructions of hydraulic system if you need the detail of configuration ) 186

196 6.4.2 Erection and operation of the hydraulic system Oil cleaning Screw open air filter II, Fill into the oil tank up to the upper limit mark with 10μ of hydraulic oil filtered by hand-held oil filter. Then start the oil pump motor (look down at the motor blades to make sure the rotation direction is same as the marked at the motor tail). Pay attention to the fact that the pump may be rotated either left or right. Wrong wiring will cause the system is not work and pump burn-down. (1)Check if the connect of high-pressure hose openings is clean. Connect the ports A.B of the hydraulic pump station with the hydraulic cylinders through high-pressure hose, then Screw down the connectors. (2)Air exhausting of the system 1Air exhausting from hydraulic pressure: firstly unscrew the handle of overflow valve 5, then unscrew the high-pressure of hose-to-port A connector. Move the handle of hand-operated valve 3 into up position. Start the motor to drive the air out of Port A until the pump noise has become normal and no foam formation from oil liquid. 2 Make the cylinder into no-load status. In order to exhaust the air from cylinder into oil tank through oil hose completely, pushing the operating handle to drive upper cylinder or piston rod move up and down at full strokes for several times, Notice:pull back the handle immediately to its middle position when the piston rod has moved to its extreme position, then keep this position for several minutes until air bubbles in oil tank have disappeared, and then carry out another action System operation Before system operation, check if the oil cylinder is well connected to the crane frame, including the relevant portions of the tower crane meet relevant technical requirements or not. (1)Maximum working pressure setting: Adjusting of max work pressure: Unscrew the locking nuts in front of the control handle of high-pressure overflow valve 5, Start motor 6. Move the operating handle to upper position and extend the cylinder piston rod to its extreme position. pressure gauge readings will rise at this time. Keep on screwing down the handle of the overflow valve until the readings on pressure gauge is 187

197 31.5 Mpa. Then screw down the locking nut in front of the regulating handle of the high-pressure overflow valve (The overflow valve shall not be adjusted by unauthorized or untrained person). Operate the handle in a reverse direction to retract the piston rod. Finally move the handle back to its middle position. (2)Start motor 6 and move operating handle to its up position. The cylinder piston rod is extrude to hang the hanging plate which is connected to the piston rod into the lugs slot of the tower mast section. Carry out the jacking operation for new section adding (or tower section disintegrate) Maintenance and precautions of hydraulic system The hydraulic system is an uper high-pressure or high-pressure equipment. The whole process of oil filling to adjustment should be accomplished strictly according to the operating instructions (1)Hydraulic oil for the system The hydraulic system should use the anti-friction hydraulic oil AW46 by ESSO, USA Filling oil for hydraulic system Fully fill the tank with oil for the first time, Extrude the cylinder rod after start-up, then retract the cylinder rod, at this time, fill the tank with make-up oil up to the tank upper limit mark. hydraulic system is a high-pressure hydraulic system with strict requirements of highly cleaned oil, which should be filtered for 4~6 hours by hand hold filter. The oil cleanness should reach 7~8 degree (NAS1638) before run the system. The oil should be completely changed after the system work for 2,400hr and add part of clean oil after working for 200h. Shut the system when it is out of service because of the poor condition of ventilation. 188

198 7 Operation 7.1 Operation guide Pre-check before operation Checking item Foundation Tower body climbing frame slewing support turntable operator cab A-frame Crane arm Counter jib Checking content Check fastness of foundation bolts Check safety margin between the surrounding power lines and tower crane Check power cables for smooth routing to avoid damage. Check the tightness of tower sections bolts. Check the tightness of platform, handrail and ladder Check the connection for slewing support. Check if the guide wheels, latches, pin-bolt-connected parts move smoothly Check the tightness of walkway,railing Check the tightness of bolts connecting to slewing ring Check if the guide dolly move smoothly Check power cables for smooth passage Check the tightness of platform, handrail Check the tightness of slewing support and turntable connecting to tower body Check the connection for operator cab Check the connection for inner circuit No storage of lubrication oils, oil cotton yarns and combustiblematerials in the cab Check connection pins, washers and split pins for correct mounting Check the tightness of staircase, platform, handrail Check if luffing rope fix right and tightness of its upside Check the tightness of spring buffer Check connection pins, washers and split pins for correct mounting Check the tightness of platform, ladder channels cage for fixing Check hoisting and trolleying ropes for winding and fixing. Check the tightness chang of breadth tie bar fixing Check the ropes for winding and fixing Check if the anti-twist device move smoothly Check connection pins, shaft baffle and split pins for correct Check walkway andcounter jib railing for fixing.assure walkway 189

199 Checking item Checking content no sundries Check the tightness of electrical control cabinet and resistance cabinet on counter jib Attention for operation Person must be trained in operation, familiar with crane and qualified operator (1) Operate the crane only if all of safe device in good condition (2) Adjust limit switch referencing to instruction manual (3) No unauthorized persons are allowed to board the crane! (4) Do not land the hook blockcausing rope on the wire drum in an irregular orde (5) No over-loading even if overload device is adjusted! (6) Crane lamp is necessary to operate cranes at night. (7) Keep all platforms, ladders and handrails from dirt. (8) Loading persons is forbidden! (9) Avoid any operation that might be a risk to the stability of the crane! For example: 吊拉固定的物体 Loading a fixed object. 吊装后添加重物 Increasing the load after lifting it. 斜拉吊重 Loading at an angle. 吊重作单摆运动 Loading pendulously 超过额定起重量 Loading beyond the rated lifting capacity (1) Stop all hoisting operations in case of thunderstorm, heavy rain, thick mist or the top wind speed of the crane is higher than 20m/s 190

200 (2) Do not make any changes or modification without permission of themanufacturer! (3) The operator must be able to observe the working area and the load! Safety Operation (1)The trained crane operators and hoist men are required to strictly follow the regulations as specified in <The Operating Instructions for Tower Crane>. (2)Operators are required to understand the working principles of the tower crane and to familiarize themselves with its structure and functions and adjustment methods for safety guards. They are also required to master the operating methods for different performances as well as the maintenance technique. (3)Operate the crane strictly according to the hoist characteristics provided in the Instructions. No over-load operating. (4) Operate gently the hoist mechanism, slewing mechanism and traveling mechanism. Carry out low-speed to high-speed conversion progressively. No violent pushing of the operation handles from the static position (or low-speed) to the intermediate speed or high-speed position. (5)It is prohibited to pull or hoist objects in an inclined way or hoist the staggered or squeezed objects or hoist the objects buried in soil or frozen on ground. (6)Operators and hoist men could not permitted to leave their working posts while objects are being hung in the air. (7)Commanding signals, hand gestures and flag signs should conform to the specifications. (8)Operators are required to carefully operate and maintain the crane, as well as to keep work shift-changing records. (9)It is prohibited that the operator is drunk, ill or tired on working 191

201 7.2 Adjusting working Checking part and coponents before adjusting working In order to ensuring the correct erection of tower crane and its safe operation, a series of test-runs and overall checks of tower crane components should be conducted. Check component-to-component connections; Check the installation of supporting platform and fences; Check wire ropes for correct winding, avoiding interference and friction with other parts; Check power cables for smooth and proper routing; Check if the counter-weights on the counter-arm are properly fixed; Clear the lumber on platforms in order to prevent them falling and avoid injuring persons during tower crane operation. Check applying of lubrication oil or grease in it Introduction of safety device The safety guards of tower crane consist mainly of travelling limiter and load limiter. The travelling limiters include hoisting limiter, slewing limiter, derricking limiter and anti-back-tipping device. The load limiters include the hoist moment limiter and load limiter. The anemometer is also included. The installation positions of safety devices are shown in Figure Serial number Designation 1 load moment limiter 2 Luffing mechanism (clamshell brake, brake, derricking limiter) 3 anti-back-tipping device 4 hoisting mechanism (brake, hoisting limiter) 5 electronic angle display 6 Mechanical angle indicating device 7 slewing mechanism (brake,slewing limiter) 8 load limiter 192

202 9 anemometer Multiple-purpose limiter Hook height limiter of this tower crane is DXZ-4/7, luff limiter is DXZ-4/7 and slewing limiter is DXZ-4/3. (1)Adjustment procedures 1 Dismantle the upper cover, check and screw down 2-M3 55 screws. 2 Unscrew M5 nuts 3 Drive the mechanism under control to an designed position (without load ) of requirements. At this time, the micro-switch should make transient change-over corresponding to the action of this mechanism i.e. adjust the corresponding axle (z) to make the memory gear (T) to press down the micro-switch (WK) contact. 193

203 occur) 4 Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will 5 Make the mechanism operate under no-load condition again and again several times to check memorized positions for accuracy (repeat the above adjustments in case of deviations) 6Make sure that the position is specified. Screw down M5 nuts and re-cover the casing 7 After the mechanism working normally, check the position of the memory control position for deviations. Correct the deviations if any. (2)Adjustment for hook height limiter 1Adjustment(adjusting procedures according to item 1) 2 Adjust at no-load conditions. Press down micro-switches (IWK, 2WK,3WK) by finger to check the rising micro-switch or lowering micro-switch for correct action. 3 Height limiter slow down and interruption of power: In twice fall speed, ensure distance 194

204 between the hook and rope fixing is more than fifteen meter, then adjust axle (1Z) to make cam (1T) act to press down micro-switch (1WK) which make the speed of hoist mechanism change into low. In condition of five meter between the hook and rope fixing, aadjust axle (2Z) to make cam (2T) act to press down micro-switch (2WK) to stop power of raising motor in movement. Loosen the nut M5. 4 Customers could adjust the lower limit by 3WK to avoid operation errors and make the hoisting hook stop lowering movement before the hook touching the ground (no less than 3-round steel ropes on the wire drum). The adjustment method is the same as?? (4) Adjustment for slewing limiter 1 Adjust the slewing limiter while the crane arm is in erection position (power cable at free status). 2 Adjust in condition of no-load. Press down the micro-switch (WK) by finger to check the switch for correct left and right control. 3 Slew to the left for 540 (1.5 rounds). Follow the Item to adjust the axle (4Z) to make the cam (4T) move to achieve transient changing by the micro-switch (4WK). Screw down M5 nuts. 4 Rotate 1080 right (3 rounds). Follow item to adjust the axle (12) to make the cam (1T) move to achieve transient changing by the micro-switch (1WK). Screw down M5 nuts. 5 Check if the left and right slewing is correct. (5)Adjustment Method for radius 1 Put crane arm Slew to 20, Adjust the axle (2Z) to enable the cam (1T) act on the micro-switch (2WK) for the speed instantaneous shift from 5 to 1. (in order to aovid slowdown be interfere before brake. adjust the cam (3T)and cam (2T)to superpose each other) Screw down the nut M5, Put crane arm proceed rislewing for 15. Adjust the axle (1Z) to enable the cam (1T) act on themicro-switch (1WK) for the motor stopping instantaneous. Screw down the nut M5. 2Inward travel and the most angle of extreme position limiting. The adjustment method is the same as idem. Carry out speed reduction adjustment and position limiting angle at the 82 and 84.5 (3Z-3T-3WK,4Z-4T-4WK ). 3 验正和修正 Check and correct 195

205 electron angle and machine angle display Electron angle display and machine angle display are fixed on crane arm end, make a signal transfer to parameter display sensor. So that operation could know position of the arm at any monment. Notice: Adjustment of electron angle and machine angle display should in condition of no load. (1)One fall with no-load 1 Instance of the angle 15 for work Put electron angle and machine angle display at 15 in follow situation according to the difference of arm length. The crane arm length is 60 m and the distance between hook to tower center is m The crane arm length is 55 m and the distance between hook to tower center is m The crane arm length is 50 m and the distance between hook to tower center is 50.14m The crane arm length is 45 m and the distance between hook to tower center is m The crane arm length is 40 m and the distance between hook to tower center is m The crane arm length is 35m and the distance between hook to tower center is m The crane arm length is 30m and the distance between hook to tower center is m 2 Instance of the angle 60 for work Put electron angle and machine angle display at 60 in follow situation according to the difference of arm length. The crane arm length is 60 m and the distance between hook to tower center is m The crane arm length is 55 m and the distance between hook to tower center is m The crane arm length is 50 m and the distance between hook to tower center is 26.46m The crane arm length is 45 m and the distance between hook to tower center is m The crane arm length is 40 m and the distance between hook to tower center is m The crane arm length is 35m and the distance between hook to tower center is m The crane arm length is 30m and the distance between hook to tower center is m 3 Instance of the angle 85 for work Put electron angle and machine angle display at 85 in follow situation according to the 196

206 difference of arm length. The crane arm length is 60 m and the distance between hook to tower center is 6.24m The crane arm length is 55 m and the distance between hook to tower center is 5.80 m The crane arm length is 50 m and the distance between hook to tower center is 5.35m The crane arm length is 45 m and the distance between hook to tower center is 4.55m The crane arm length is 40 m and the distance between hook to tower center is 4.48 m The crane arm length is 35m and the distance between hook to tower center is 4.34 m The crane arm length is 30m and the distance between hook to tower center is 3.58 m (2)Two fall with no-load 1 Instance of the angle 15 for work Put electron angle and machine angle display at 15 in follow situation according to the difference of arm length. The crane arm length is 50 m and the distance between hook to tower center is 49.69m The crane arm length is 45 m and the distance between hook to tower center is m The crane arm length is 40 m and the distance between hook to tower center is 40.03m The crane arm length is 35m and the distance between hook to tower center is m The crane arm length is 30m and the distance between hook to tower center is 30.01m 4 Instance of the angle 60 for work Put electron angle and machine angle display at 60 in follow situation according to the difference of arm length. The crane arm length is 50 m and the distance between hook to tower center is 26.09m The crane arm length is 45 m and the distance between hook to tower center is m The crane arm length is 40 m and the distance between hook to tower center is m The crane arm length is 35m and the distance between hook to tower center is 16.5 m The crane arm length is 30m and the distance between hook to tower center is m 5 Instance of the angle 85 for work Put electron angle and machine angle display at 85 in follow situation according to the difference of arm length. The crane arm length is 50 m and the distance between hook to tower center is 5.08 m The crane arm length is 45 m and the distance between hook to tower center is 4.46 m 197

207 The crane arm length is 40 m and the distance between hook to tower center is 4.21 m The crane arm length is 35m and the distance between hook to tower center is 4.07 m The crane arm length is 30m and the distance between hook to tower center is 3.30 m Upper and lower limit Journey switch of crane arm Journey switch have both protect function on counter-arm. Which make sure motor power-off if the arm at most angle 86 or least angle 15. The motor of travel mechanism stop with hydraulic brake and the travel roll brake with hydraulic clamp, but motor of travel mechanism could move in reverse. The adjusting steps are as follows: (1)Adjust length of leader for lower limit Journey switch start-up while the arm angle arrive at 15, then locking up lower limit Journey switch leader. (2)Adjust length of leader for upper limit Journey switch start-up while the arm angle arrive at 86, then locking upper limit Journey switch leader. Upper and lower limit Journey switch of crane arm 198

208 Device for prevent crane arm to back rebound Device prevent arm to back rebound be fixed on A frame. The mandril support will contact with mandril while angle of the arm arrive at 83. Spring have sufficient thrust to prevent mandril to compress and backwaed when the angle at max value. 1. spring bushing 2. amortize spring 3. guide set 4. mandril Fig7-2 Device for prevent arm to back rebound Hoisting sensor The hoisting weight is measure with pressur sensor. The data will be display in cab. This sensor axes is block axes on root of arm (Fig 7-3). 199

209 Fig 7-3 The installation position of pressure sensor (1) High speed adjustment 1One multiple a. Hoist the weight of 2500kg, the hook up and down at low speed and high speed and middle speed each time. It should not be block at above-mentioned speed. Put weight data in display apparatu to 2500kg; b. Add another 50kg to the load and adjust the parameter. Lift the load at high speed to10m if it could, then down the load onto the ground. c. Repeat all the actions mentioned in the step b until high speed could not be lift. The weight must between kg kg, which close to 2500kg to be great. d. Got the weight data should be equal when repeat actions c twice in three time. 2Two multiple a.. Hoist the weight of 5000kg, the hook up and down at low speed and high speed and middle speed each time. It should not be block at above-mentioned speed. Put weight data in display apparatu to 5000kg. b. Add another 50kg to the load and adjust the parameter. Lift the load at high speed to 10m if it could, then down the load onto the ground. c. Repeat all the actions mentioned in the step b until high speed could not be lift. The weight 200

210 must between kg which close to 5000kg to be great. dgot the weight data should be equal when repeat actions c twice in three time. (2) Adjusting of middle speed 1One multiple a. Hoist the weight of 5000kg, the hook up and down at low speed and middle speed each time. It should not be block at above-mentioned speed. Apparatu display weight data should above kg, error less than 4%. b. Add another 50kg to the load and adjust the parameter. Lift the load at middle speed to 10m if it could, then down the load onto the ground. c. Repeat all the actions mentioned in the step b until middle speed could not be lift. The weight must between kg, which close to 5000kg to be great. d. Got the weight data should be equal when repeat actions c twice in three time. 2 Two multiple a. Hoist the weight of 10000kg, the hook up and down at low speed and middle speed each time. It should not be block at above-mentioned speed. Apparatu display weight data should above 10000kg, error less than 4%. b. Add another 50kg to the load and adjust the parameter. Lift the load at middle speed to 10m if it could, then down the load onto the ground. c. Repeat all the actions mentioned in the step b until middle speed could not be lift. The weight must between10000kg-10320kg, which close to 10000kg to be great. d. Got the weight data should be equal when repeat actions c twice in three time. (3)Adjusting of low speed 1 One multiple a. Hoist the weight of 10000kg, the hook up and down at low speed one time. It should not be block at above-mentioned speed. Apparatu display weight data should above kg, error less than 4%. b. Add another 100kg to the load and adjust the parameter. Lift the load at low speed to 10m if it could, then down the load onto the ground. 201

211 c. Repeat all the actions mentioned in the step b until low speed could not be lift. The weight must between kg, which close to 10000kg to be great. d. Got the weight data should be equal when repeat actions c twice in three time. 2 Two multiple a. Hoist the weight of 20000kg, the hook up and down at low speed one time. It should not be block at above-mentioned speed. Apparatu display weight data should above kg, error less than 4%. b. Add another 100kg to the load and adjust the parameter. Lift the load at low speed to 10m if it could, then down the load onto the ground. c. Repeat all the actions mentioned in the step b until low speed could not be lift. The weight must between kg, which close to 20000kg to be great. d. Got the weight data should be equal when repeat actions c twice in three time. Notice:It should adjust again when switch1 2fall Moment limiter (1)Moment limiter of electron Moment limiter of electron is from the data of transition of angle transducer and hosit transducer. 202

212 (2)mechanism Moment limiter 1-Fixed block 2-Elastic plate 3-Limit switch 4-Adjusting screw 5-Luck nut The tower crane is provided with a mechanical type-moment limiter for protection purpose. Hositing and outward act switch to secondly speed when the moment has reached 80% of its rated value. The pre-warning light in the operator cab is on when the moment has reached 90% of its rated value. When the moment has reached 100%~110% of its rated value, power of hoisting up and the trolley out wards-travel are off and over-load alarm at the same time The moment limiter consists of two-spring plates 2, three travel switches 3 and adjusting bolt 4. They are fixed on the chord rod on the tower crane rear side through mounting block1. If the tower head has deformed during crane operation, the distance between two spring plates will become narrower, thus activating the adjusting bolt for adjusting bolt contacts and travel switch. 203

213 Corresponding moment will give warnings and cut off the power for the crane up and trolley outward-travel, thus playing the role in moment limiting protection (3)Adjustment of mechanism Moment limiter 1 Adjustment of constant load and variable radius of trolley travel A. Adjustment of 80% of rating hoists moment speed-down When the arm length is 60m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of20.22~23.22m. When the arm length is 55m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of 21.26~22.26m. When the arm length is 50m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of that bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of 21.9~22.9m. When the arm length is 45m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of 22.46~23.46m. When the arm length is 40m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of Bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of 22.62~23.62m. When the arm length is 35m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of Bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of 22.54~23.54m. When the arm length is 30m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust 80% of bolt in Fig 7-4, which to enable the hook outward move from high speed to low speed when the hook moves to the range of 22.94~23.94m. B. Adjustment of 90% of rating hoists moment early waring to When the arm length is 60m, weight of hoists 10t and the hook moves outwards from 20m point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 22.81m~23.81m When the arm length is 55m, weight of hoists 10t and the hook moves outwards from 20m 204

214 point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 23.98m~24.98m When the arm length is 50m, weight of hoists 10t and the hook moves outwards from 20m point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 24.7m~25.7m When the arm length is 45m, weight of hoists 10t and the hook moves outwards from 20m point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 25.33m~26.33m When the arm length is 40m, weight of hoists 10t and the hook moves outwards from 20m point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 25.51m~26.51m When the arm length is 35m, weight of hoists 10t and the hook moves outwards from 20m point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 25.42m~26.42m When the arm length is 30m, weight of hoists 10t, and the hook moves outwards from 20m point at a slow speed. Adjust 90% of Bolt in Fig 7-4, which to enable the warning light power on in the operator cab when the trolley moves to the range of 25.87m~26.87m C. 100% of rating hoists moment alarm to adjustment When the arm length is 60m, weight of hoists 10t, and the hook moves outwards from 20m point at a slow speed Adjust constant load and variable radius of bolt in Fig 7-4, which to enable the hook move the range of 25.9m~28.49m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. When the arm length is 55m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust the constant load and variable radius of Bolt in Fig 7-4, which to enable hook move the range of 27.2m~29.92m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. When the arm length is 50m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust the constant load and variable radius of Bolt in Fig 7-4, which to enable hook move the range of 28m~30.8m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. When the arm length is 45m, weight of hoists 10t and moves outwards from 20m point at a 205

215 slow speed. Adjust the constant load and variable radius of Bolt in Fig 7-4, which to enable hook move the range of 28.7m~31.57 m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. When the arm length is 40m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust constant load and variable radius of Bolt in Fig 7-4, which to enable hook move the range of 28.9m~31.79m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. When the arm length is 35m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust constant load and variable radius of Bolt in Fig 7-4, which to enable hook move the range of 28.8 m~31.68 m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. When the arm length is 30m, weight of hoists 10t and moves outwards from 20m point at a slow speed. Adjust constant load and variable radius of Bolt in Fig 7-4, which to enable hook move the range of 29.3m~32.23m, meanwhile, upward hoisting and outward travelingis power off and give an over-load warning sound. 2 Adjustment of constant load and variable radius of trolley travel for Moment Limiter. When the arm length is 60m, loading 2.71t at 60m point with a normal hoisting speed, then add load 271kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is forbidden upward hoisting and give an over-load warning sound at the same time When the arm length is 55m, loading 3.47t at 55m point with a normal hoisting speed, then add load 347kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is forbidden upward hoisting and give an over-load warning sound at the same time When the arm length is 50m, loading 4.45 t at 50m point with a normal hoisting speed, then add load 445kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is forbidden upward hoisting and give an over-load warning sound at the same time. When the arm length is 45m, loading 5.6 t at 45m point with a normal hoisting speed, then add load 560kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is forbidden upward hoisting and give an over-load warning sound at the same time. When the arm length is 40m, loading 6.85 t at 40m point with a normal hoisting speed. Add load 685kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is 206

216 forbidden upward hoisting and give an over-load warning sound at the same time. When the arm length is 35m, loading 8.15t at 35m point with a normal hoisting speed. Add load 815kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is forbidden upward hoisting and give an over-load warning sound at the same time. When the arm length is 30m, loading 9.75t at 30m point with a normal hoisting speed. Add load 975kg at formerly load. Adjust constant load and variable radius of Bolt in Fig 7-4, It is forbidden upward hoisting and give an over-load warning sound at the same time. Test the step for 3 times and keep the function stability (4) Adjustment of mechanism Moment limiter Conduct calibration to the moment limiter for 3 times each other 1 Adjustment of mechanism Moment limiter for constant load and variable radius of trolley traveling A.Adjustment of 80% of rating hoists moment speed-down When the arm length is 60m, loading 8t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of 24.38m~25.38m. When the arm length is 55m, loading 8t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of 25.24m~26.24m When the arm length is 50m, loading 8t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of 26.47m~27.47m. When the arm length is 45m, loading 8t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of m~28.26 m. When the arm length is 40m, loading 8t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of m~28.42 m. When the arm length is 35m, loading 9t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of 25.06m~26.06m. 207

217 When the arm length is 30m, loading 9.5t, trolley travels outwards from 20m point at a slow speed. It is allow upward hoisting and outward traveling with speed down when travelling to the range of 23.97m~24.97m. B.Checking of 90% of rating hoists moment alarm. When the arm length is 60m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of27.5 m~28.5 m. When the arm length is 55m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of 28.45m~29.45m. When the arm length is 50m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~30.83m. When the arm length is 45m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of 30.73m~31.73m. When the arm length is 40m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~31.91m. When the arm length is 35m, loading 9t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~29.26m. When the arm length is 40m, loading 9.5t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~m C. Checking of 100% of rating hoists moment alarm. When the arm length is 60m, loading 8t, trolley travels outwards from 28m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~31.61m. When the arm length is 55m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling 208

218 outward in the range of 31.67m~32.67m. When the arm length is 50m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~34.21m. When the arm length is 45m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of 34.2m~35.2m. When the arm length is 40m, loading 8t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of 34.4 m~35.4m. When the arm length is 35m, loading 9t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~32.45m. When the arm length is 40m, loading 9.5t, trolley travels outwards from 25m point at a slow speed, the mechanisms give an over-load warning sound when hoisting upward and traveling outward in the range of m~m Adjustment of mechanism Moment limiter for constant load and variable radius of trolley traveling. When the arm length is 60m, loading 8t at 31.13m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly hosit at 8.8t, the moment limiter should act and not to be hoist. When the arm length is 55m, loading 8t at 32.17m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly hosit at 8.8t, the moment limiter should act and not to be hoist. When the arm length is 50m, loading 8t at 33.71m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly hosit at 8.8t, the moment limiter should act and not to be hoist. When the arm length is 45m, loading 8t at 34.7m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly 209

219 hosit at 8.8t, the moment limiter should act and not to be hoist. When the arm length is 40m, loading 8t at 34.9 m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly hosit at 8.8t, the moment limiter should act and not to be hoist. When the arm length is 40m, loading 9t at m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly hosit at 9.9t, the moment limiter should act and not to be hoist. When the arm length is 40m, loading 9.5t at m point with a normal hoisting speed, the moment limiter should not act and upward hoisting is permission. Put down the load and slowly hosit at 10.45t, the moment limiter should act and not to be hoist. (5) Leadclose of Moment limiter After Moment limiter adjusting and checking; put rain-proof cover on the Moment limiter, the rope should pull on hole of rain-proof cover to close Experiment (1)No-load test The upward speed decrease to one step when upward hoisting reach 82 ; traveling outward is allow and inward is forbid when angle of traveling is Press the bypass button will continue to inward with one step speed in such case. Traveling inward is forbid when angle of traveling is 86. Outward speed will switch to one step speed automatic when angle of traveling is 17.5 ; traveling inward is allow and outward is forbid when angle of traveling is Press the bypass button will continue to outward with one step speed in such case. Traveling outward is forbid when angle of traveling is 15. The gyre rate will automatic under three step when big arm angle less than 20 or more than 60. Brakes, operation systems, control systems, interlocking devices and limiters should act accurately and reliably. No abnormal incidents occur on mechanisms during these tests. (2)on-Load test Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the rated hoist load for tests according to (1). No abnormal incidents happen during these tests. Brakes, operation 210

220 systems, control systems, interlocking devices and limiters should act accurately and reliably (3)Static state test of 25% Over-load (two fall,one fall when the arm length is 60m/55m). Conduct the static test at over-load after no-load tests and on-load tests. Test loads based for different arm lengths are shown in Table 7-1. Table 7-1. Item Hook weight length of arm length of arm Ⅰ RadiusⅡ Hook weightⅡ 61.51m 25.87m(66 ) 12.5 t 60.03m(15 ) 3.45t 56.39m 27.31(62 ) 12.5 t 55.08m(15 ) 4.31t 51.39m 13.82m(75 ) 25 t m(15 ) 5.56t 46.27m 13.9 m(73 ) 25 t 44.81m(15 ) 6.95t 41.27m 14.64m(70 ) 25 t 40.03m(15 ) 8.59t 36.15m 15.2m(66 ) 25 t 35.08m(15 ) 10.14t m 15.96m(60 ) 25 t 30.13m(15 ) 12.00t Hoist the 1.25 multiplying of rated weight at radius I and radius II from the ground for 100~200mm height at the lowest safe speed. Stay for 10min. Check metal structures and welds for any cracks, permanent deformations and loosened connections after unloading. Attention: It is prohibited to move the trolley and revolve during the static tests of over-load. Dynamic test at 10% of over-load(2 fall, 1fall when arm lengt is 60m/55m). In full-range to hoist corresponding weight in tab 7-2, mechanism should tests for 3 times in full-range action. Each start-up should steady stopping. The mechanism should act smoothly and the brake should reliably. There is no abnormal incidents in mechanisms and structures, the parts should not loosen and damage table 7-2,. Item Length of armⅠ Hook Length of armⅡ Hook 211

221 weightⅠ weightⅠ Length of arm 61.51m 25.87m(66 ~86 ) 11t 60.03m(15 ~86 ) 3.04t 56.39m 27.31(62 ~86 ) 11t 55.08m(15 ~86 ) 3.80t 51.39m 13.82m(75 ~86 ) 22t m(15 ~86 ) 4.90t 46.27m 13.9 m(73 ~86 ) 22t 44.81m(15 ~86 ) 6.12t 41.27m 14.64m(70 ~86 ) 22t 40.03m(15 ~86 ) 7.56t 36.15m 15.2m(66 ~86 ) 22t 35.08m(15 ~86 ) 8.92t m 15.96m(60 ~86 ) 22t 30.13m(15 ~86 ) 10.56t 212

222 塔式起重机操作手册 安全标识技术参数运输准备立塔和拆塔内爬操作与安全电气控制系统

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224 Tower Crane Instruction Manual 8 Electrical Control System 1 Electrical System Electrical System Schematic Electrical System Components Electrical Control System Electrical Crane Erection Operation of Electrical System Steps of Operating Electrical System Preparation Operation of Each Mechanism System Prompt and Alarm Signal Electrical Control Unit Slewing Eddy Current Debug System Inverter Appendix Instruction for the Tower Crane Monitoring System Instruction for LCD Color Monitor Electrical Drawings...46 Electrical equipment Electrical equipment 8-1

225 Tower Crane Instruction Manual Electrical equipment 8-2 Electrical equipment

226 Tower Crane Instruction Manual Electrical System 1 Electrical System 1.1 Electrical System Schematic Hydraulic Pump Station Hoisting Hydraulic Pliers Detection Trolley Hydraulic Pliers Detection Trolley Over-speed Detection Hoisting Over-speed Detection Angle Sensor Weight Sensor Wind Speed Sensor Height Sensor Moment Limiter Hoisting Mechanism Trolley Mechanism Slewing Mechanism Parameter Monitor Vedio Monitor Left Console Electrical Room Right Console Isolating Switch Power Supply Electrical equipment Electrical equipment 8-3

227 Tower Crane Instruction Manual 1.2 Electrical System Components No. Symbol Description Position 1 QS Isolating switch Basic section 2 PP2 Pump station Telescopic cage 3 HH Horn Under the cabin 4 EY Glass screen wiper Operation Cabin 5 MH Hoisting motor Counter jib 6 HINV HINV Electrical room 7 MHB Hoisting brake motor Counter jib 8 MHC Cooling motor for hoisting Counter jib 9 PGH Encoder for hoisting Counter jib 10 YZB Hydraulic Pressure Pumping Station Counter jib 11 UVR Trolley Over-speed protector Electrical room 12 UHR Hoisting Over-speed Protector Electrical room 13 SHUC,SHU,SHDC,SHD Hoisting limit switch Counter jib 14 MS1,MS2 Slewing motor Slewing support 15 SINV Slewing Inverter Electrical room 16 MSC1,MSC2 Cooling motor for slewing Slewing support 17 SECC Eddy Current Controller Electrical room 18 YSB Slewing brake Slewing support 19 YBSE1,YBSE2 The Eddy Current Brake of Slewing Slewing support 20 YSFB Weather vane Slewing support 21 MV Trolley motor Jib 22 VINV Trolley Inverter Electrical Room 23 YVB Trolley brake Jib 24 PGV Trolley Encoder Counter jib 25 SVBW,SVBC,SVFW,SVFC Trolley limit switch Jib 26 SVA1,SVA2 Trolley Limit Switch Base of the Jib 27 SSL,SSR Slewing limit switch Slewing support 28 SM1,SM2,SM3,SM4 Moment limit switch Jib 29 TC,TE,TS Transformer Electrical Room 30 DCM1,DCM2 Commutate Electrical Room 31 HB1 Impediment Lamp Top of the Tower 32 HB2 Impediment Lamp Counter jib 33 HB3 Impediment Lamp Jib Electrical equipment 8-4 Electrical equipment

228 Tower Crane Instruction Manual 1.3 Electrical Control System DANGER accident! Forbit the person who don't get the authorization to modify the circuit, otherwise it may cause an CAUTION (1) Ensure that the cable diameter is not lower than the permissible value! (2) Electrical installation and connection work must be done only by properly qualified, licensed person! Power Supply Site junction box (Provided by the costumer) Rail-mounted crane: The power supply is connected from the site junction box to a motor driven cable drum on the undercarriage Stationary crane: The power supply is connected from the site junction box to switch box Electrical room The electrical room is the control center of the electrical system, it contains the following equipment: (1) Main switch and main contactor (crane power switch) (2) Control circuit transformer for the control voltage (3) Control systems for hoisting gear, slewing gear and trolley gear (4) Adjustable system for the eddy current of slewing (5) The door switch, lighting and air condition of the electrical room Operation Cabin (1) Left console slewing gear and trolley gear slewing brake button weather vane release indicator light bypass button (2) Right console Hoisting gear and travel gear Start button Emergency stop Alarm lamp and buzzer (3) Power supply for cabin(230vac) Electrical equipment Electrical equipment 8-5

229 Tower Crane Instruction Manual Power supply for air condition, lighting and socket of the operation cabin (4) Windscreen Wiper (24VDC) (5) Electrical room Emergency stop Key switch Hoisting mechanism, Slewing mechanism and Trolley mechanism (1) Hoisting mechanism hoisting motor hoisting brake cooling motor for hoisting hoisting limit switch hoisting encoder hoisting over-speed protector (2) Slewing mechanism Slewing motor The eddy current of slewing Cooling motor for slewing Slewing brake (number is decided by the configuration of motor ) Weather vane(number is decided by the configuration of motor ) Weather vane release contacts(number is decided by the configuration of motor ) (3) Trolley mechanism Trolley motor Cooling motor for trolley Trolley brake Trolley limit switch Trolley encoder Trolley over-speed protector Safety Limit Switch (1) Moment limit switch (2) Load Sensor (3) Angle Sensor Electrical equipment 8-6 Electrical equipment

230 Tower Crane Instruction Manual 2 Electrical Crane Erection (1) Connect the power supply cable to isolating switch -QS in the switch box operation-erection, (keep the isolating switch is cut off) (2) Connect the main cable from the switch box to electrical room keep the main switch is turn off The power cord contains three phase-lines a zero line (N) which is black and a protection line (GND) which is green yellow. Any damage to the power cord may lead to serious accidents, so you should select durable line as the power cord, and take appropriate measures to protect power cord from any damage. (3) Connect the electrical room (4) connect the hoisting mechanism The power supply cable (L201) connect with the hoisting motor from the terminal of the hoisting inverter The cable (L203,L202) connect with the electrical room from brake motor (MHB) and the cooling motor MHC The cable (L211, L212) connect with the electrical room from the hydraulic pressure pumping station Connect the hoisting encoder to the inverter Please connect the hoisting encoder follow the drawing, PGB is the PG extended card (accessory of inverter), PGH is the hoisting encoder (5) connect the slewing mechanism (6) connect the trolley mechanism (7) connect the climbing mechanism (8) Ground wire Electrical equipment Electrical equipment 8-7

231 Tower Crane Instruction Manual CAUTION Ground wire is yellow-green wire for protection, it will connect all parts of the "ground" terminal and "ground" plug. Don t use the neutral wire in place of ground wire. The protection wire must be independent of any circuit device. Electrical equipment 8-8 Electrical equipment

232 Tower Crane Instruction Manual 3 Operation of Electrical System Examination before working: You should exam all kinds of switches, buttons (the emergency stop button especially), the operate handles, arresters, mechanical limit devices, protective buttons and so on. Make sure that they can work in normal; Checking whether mechanical limit devices are adjusted (Details is in the instruction of the tower crane) or not. Check when the limit device is connected, whether the electric control system has the corresponding function of protection or not. Once the tower crane has a fault, you should stop it at once. The tower crane shouldn t be put into work before it is examed and repaired. 3.1 Steps of Operating Electrical System (1) Preparation: Including the operation of isolate switch, auto air-break switch, start button and emergency stop button. (2) Operation of each mechanism: Including the operation of hoisting and lower, slewing and trolley. (3) Other operation: Including the operation of climbing. 3.2 Preparation Operation of Isolate Switch Isolate switch (-QS) is installed in switch box which locates in foot of tower crane, and play the role of isolating power supply. The isolate switch is closed once put ON the handle. And when you put OFF the handle, it is cut down while the tower lost power. Cut down the isolate switch(-qs) after driver was off duty Operation of the Equipment in Cabin (1) lighting of cabin (2) Control the temperature, keeping the temperature is comfortable, you can use the air condition to adjust Auto Air-break Switch Only under the condition that all preparation work is ready, the driver on his duty and need operating, the air-break switch (-QF) can be closed. Before the switch is turn on, check the lamp(-hu) if Over &Under voltage signal is normal. Air-break switch(-qf) is installed in electrical room. The handle is outside the cabinet in order to operate. When you push up the handle, the switch is closed. Pull down the handle, the switch(-qf) is cut down. The auto air-break switch(-qf) controls power supply of all mechanisms in tower crane except the lighting for cabin and electrical room. CAUTION Electrical equipment The air-break switch must be cut immediately under the conditions as follows: There are something emergency when electric control system is failure (such as the contact of Electrical equipment 8-9

233 Tower Crane Instruction Manual contactor burn and stick together, the emergency stop button of control console was failure) Driver is off duty or leave cab Start Button and Emergency Stop Button Start Button (-SST) (green) locates on the panel of right console (D). It is a dual function button, namely Start and Warning horn. Operator can control the warning horn of all times once the air-break switch(-qf) is closed. In addition, only after the air-break switch(-qf) is closed, the system can start after press down the button. When system starts up, driver will hear sound like di made by buzzer (-HBZ) the sound will last two seconds. At the same time four alarm lamps will twinkle four times, then the buzzer stops and four alarm lamps go out, the green startup indicator lamp locates on the right console will light. If there is no such feedback after pressing down start button, it means failure to start and the handle on console doesn t work. Emergency stop button (-SEM) also locates on the panel of right console (D), it is a red self-locking mushroom-head button. Contrary to the start button, the function of emergency stop button is stop the relay(0- KM) of the main circuit and the relays(-kmc1,-kmc2)of the control circuit. Emergency stop button is not controlled by other control loop. It controls the main circuit with safety relay (-KMSC1). So it has protective function. CAUTION When there are something emergent and couldn t stop according to normal program or control handle is out of control, operator must press emergency stop button immediately! If there are nothing emergent, operator can t use emergency stop button to stop the tower crane, or it will make huge impact. 3.3 Operation of Each Mechanism After electric control system starts successfully, operator can operate each mechanism. Operator can use two operate handles and all kinds of buttons which locate on the control console. Before using operate handle, operator need release zero-position self-locking. After these have been done, the handle can be pushed and pulled freely. When operator pushes handle, the buzzer will make a short sound like di each time shift gear. At the same time, Operator should notice signals of the electric control system. Generally, the electric control system will make corresponding feedback when the alarm signals occur Hoisting and Lower Operation Electrical equipment The hoisting and lower operation is controlled by the control handle located on the right console (D). When operator pull inward the control handle, tower crane hoisting, on the contrary, When operator push outward the control handle, tower crane lower. Hoisting and lower are each divided into five gears, and each gear corresponds a speed Electrical equipment

234 Tower Crane Instruction Manual CAUTION The gear must be shifted step by step Hoisting action table Gear LI1 LI2 LI5 LI4 LI3 KHB Frequency 1 Gear 8Hz 2 Gear 25 Hz 3 Gear 50 Hz 4 Gear 100 Hz 5 Gear 125 Hz Lower action table Gear LI1 LI2 LI5 LI4 LI3 KHB Frequency 1 Gear 8Hz 2 Gear 25 Hz 3 Gear 50 Hz 4 Gear 100 Hz 5 Gear 125 Hz Remark: LI1 LI2 LI3 LI4 LI5:multi-step speed input points of Inverter Slewing operation Slewing is controlled by the handle located on the left console (C). Pull leftward the handle if you want the trolley turn left and pull rightward the handle if you want the trolley turn right. The handle is divided into five gears each in right and left, and each gear corresponds to a speed. (1) The operation of slewing brake Slewing is running, the brake is energized to open immediately slewing is stop, delay 15 seconds, the slewing brake is brake automatically. In the after slewing stop 15 seconds delay, when the wind or the need for human brake, etc., you can press down the "weather vane release button" on left console, the slewing brake is work immediately. CAUTION The point should be noticed when slewing and braking operation: There is very big inertia force because the tower jib is very long, so the slewing operation must be steady Don t use the brake switch before the tower jib hasn t stopped steadily Electrical equipment Electrical equipment 8-11

235 Tower Crane Instruction Manual NOTICE "weather vane release button " (with lamp) (-SSB)is a slewing brake can be used for both emergency brake, also be used to achieve the weather vane electric brake release. After the operator is off duty, to prevent dangerous high winds occur down the tower, tower crane needs to be in free rotation state. Slewing weather vane electric release: Description: weather vane brakes and slewing brakes with standard use, you can achieve the release of electromagnetic and electric brake manual release function, after the weather vane release, the slewing brake is opened even the tower crane without power, so the tower crane can slewing freely. Conditions: slewing stopped, and the slewing brake is braking. Operation: Press the "weather vane release button " and "bypass button" for about 4 seconds, weather vane is automatically released. Logic: press down the "weather vane release button " and "bypass button" at the same time, first, the slewing brake is open, second, the weather vane is work after 1 second, third, the slewing brake is closed after another 1 second, then, release the "weather vane release button " and "bypass button." If the weather vane does not release successfully one time, please repeat! Do not hold the "wind release button marked" and "Bypass button" for long time! CAUTION Electrical equipment Pay Attention When Operation the Slewing and the Braker:h Please release the weather vane when the wind speed exceed level 6. The gear must be shifted step by step. Left action table Gear LI1 LI2 LI5 LI4 LI3 KSB Frequency 1 Gear 8Hz 2 Gear 15 Hz 3 Gear 25 Hz 4 Gear 35 Hz 5 Gear 50 Hz Right action table Gear LI1 LI2 LI5 LI4 LI3 KSB Frequency 1 Gear 8Hz 2 Gear 15 Hz 3 Gear 25 Hz 4 Gear 35 Hz 5 Gear 50 Hz Remark: LI1 LI2 LI3 LI4 LI5:multi-step speed input points of Inverter Notice: The twinkle of Y0 (Y0-COM0) stands for the eddy current, that is to say, the quicker Y0 twinkles, the higher the eddy current is Electrical equipment

236 Tower Crane Instruction Manual Trolley operation Trolley is controlled by the handle located on the left console. Pushing outward the handle vertically if operator wants to trolley out, on the contrary, pulling inward the handle vertically if operator wants to trolley in. Trolley out and trolley in are divided into five gears. No matter from low speed to high speed or from high speed to low speed, the gear must be shifted step by step. CAUTION The gear must be shifted step by step Trolley out action table Gear LI1 LI2 LI5 LI4 LI3 KVB Frequency 1 Gear 8Hz 2 Gear 15 Hz 3 Gear 25 Hz 4 Gear 35 Hz 5 Gear 50 Hz Trolley in action table Gear LI1 LI2 LI5 LI4 LI3 KVB Frequency 1 Gear 8Hz 2 Gear 15 Hz 3 Gear 25 Hz 4 Gear 35 Hz 5 Gear 50 Hz Remark: LI1 LI2 LI3 LI4 LI5:multi-step speed input points of Inverter Other operations Climbing operation Each tower crane equip has a four-core cable (one head is three-phase plug (with PE wire) the other head is separate wire). In first way, before climbing please connect the four separate wire with the jacking pump station (PP2), then insert the three-phase plug into the four-core socket(-xsp) that located in the electrical room. After doing these, driver can start jacking up by operating the handle that located on the hydraulic pump station. Electrical equipment Electrical equipment 8-13

237 Tower Crane Instruction Manual 4 System Prompt and Alarm Signal Electrical equipment Driver should be familiar with all kinds of alarm signal listed as follows when he is operating electrical control system. (1) Over moment signal When hoist moment exceeds 105% the maximum, the electrical control system will response as follows: The red alarm lamp (-HML) will twinkle The buzzer will continuously make alarm sound like di-di-di-di The red alarm lamp of the three-color alarm lamp will light Main hook was forbad hoisting motion, lowering motion only work in 1 gear Trolley was forbad moving outward Horn will continuously make alarm sound Resolve: Drive the trolley inward (2) Over moment signal When hoist moment exceeds 100% the maximum, the electrical control system will response as follows: The red alarm lamp (-HML) will twinkle The buzzer will continuously make alarm sound like di-di-di-di The red alarm lamp of the three-color alarm lamp will light Main hook hoisting motion only work in 1 gear, lowering motion only work in 1 gear Trolley was forbad moving outward Horn will make alarm sound (3) Overload signal When hoisting weight exceeds the maximum, the electrical control system will response as follows: The red alarm lamp (-HLL) will twinkle The buzzer will continuously make alarm sound, just like di-di-di Main hook was forbad rising motion, lowering motion only work in 1 gear Trolley was forbad moving inward and inward motion only work in 1 gear Horn will continuously make alarm sound Lowering and reduce load (4) Moment early-warning signal When hoist moment exceeds 90% of the maximum, the electric control system will response as follows: The yellow alarm lamp (-HMA)will twinkle The buzzer will continuously make alarm sound like di-di The yellow alarm lamp of the three-color alarm lamp will light The main hook s hoisting and lowering motion are limited to working within 2 gear Trolley can only be driven outward in 2 gear, if it moves outward in high speed originally, it will decelerate. When hoist moment exceeds 80% of the maximum, the electric control system will response as follows: The yellow alarm lamp (-HMA)will twinkle The main hook s hoisting and lowering motion are limited to working within 3 gear 8-14 Electrical equipment

238 Tower Crane Instruction Manual Trolley can only be driven outward in 3gear (5) Shift speed with overload signal When hoisting weight exceeds 50% of the maximum, the electrical control system will response as follows: The yellow alarm lamp (-HLC)will twinkle The main hook s hoisting and lowering motion are limited to working within 3 gear The buzzer will continuously make alarm sound like di-di When hoisting weight exceeds 25% of the maximum, the electrical control system will response as follows: The main hook s hoisting and lowering motion are limited to working within 4 gear (6) Hoisting height limit signal When the hook reaches to the maximum high the electrical control system will response as follows: The hoisting movement of hook is prohibited when key switch (SHJ) is in ON position, then press the bypass button (SSJ) The lowering movement can work slowly in 1 gear. (7) Hoisting height limit approach deceleration signal When the distance between hook and height limit switch is only several meters, the electric control system will response as follows: Hoisting can only be driven in 1 gear, if it running in high speed originally, it will decelerate to 1 gear. (8) Lowering height limit signal When the hook reaches to the maximum lowering, the electrical control system will response as follows: The lowering movement of hook is prohibited Lowering height limit approach deceleration signal When the distance between hook and the maximum lowering is only several meters, the electrical control system will response as follows: Hook can only be driven hoist down in low speed (1 gear), if it be driven hoist down in high speed originally, it will decelerate to 1 gear. (9) Trolley out stop signal: When the angle of the jib reaches to 15, the electric control system will response as follows: The trolley is prohibited to move outward. If the trolley is moving outward, it will stop suddenly. (10) Trolley out limit signal: When the angle of the jib reaches to 15.5, the electric control system will response as follows: The trolley is prohibited to move outward. If the trolley is moving outward, it will stop suddenly. (11) Trolley out limit signal: When the angle of the jib reaches to 20, the electric control system will response as follows: There is only 1 gear when the trolley moves outward. If the trolley is moving outward with high speed, it will decelerate to the lowest speed(1 gear) suddenly. (12) Trolley in stop signal: Electrical equipment Electrical equipment 8-15

239 Tower Crane Instruction Manual NOTICE When the angle of the jib reaches to 86, the electric control system will response as follows: The trolley is prohibited to move inward. If the trolley is moving inward, it will stop suddenly. (13) Trolley in limit signal: When the angle of the jib reaches to 84.5, the electric control system will response as follows: The trolley is prohibited to move inward. If the trolley is moving inward, it will stop suddenly. when key switch (SHJ) is in ON position, then press the bypass button (-SSJ) The trolley inward movement can work slowly in 1 gear. (14) Trolley in deceleration signal: When the angle of the jib reaches to 84.5, the electric control system will response as follows: There is only 1 gear when the trolley moving inward. If the trolley is moving inward with high speed, it will decelerate to the lowest speed(1 gear) suddenly. (15) Slewing deceleration signal: When the angle of the jib is smaller than 25 or bigger than 75, the electric control system will response as follows: The slewing motion is limited to working within 4 gear (16) Slewing left limit signal: When the number of rotation carried out by the crane while slewing leftward have exceeded one and a half, the electrical control system will response as follows: The jib is prohibited to slewing leftward. If it s slewing leftward, the slewing mechanism will be cut power supply suddenly. (17) Slewing right limit signal: NOTICE Electrical equipment When the number of rotation carried out by the crane while slewing rightward have exceeded one and a half, the electric control system will response as follows: The jib is prohibited to slewing rightward. If it s slewing rightward, the slewing mechanism will be cut power supply suddenly. (18) Over or under voltage protection signal: The lamp (-HU) in left console (-C) is for Over or under voltage signal When the voltage of power supply is greater than 105% of the rating voltage or less than 95% of the rating voltage, The lamp (-HU yellow) will be light. If the over or under voltage signals appear continually, please cut the power supply, Don t start up and work lest the electric motors and electric appliance will be damaged. Please check the power supply loop and obviate malfunction Electrical equipment

240 Tower Crane Instruction Manual 5 Electrical Control Unit 5.1 Slewing Eddy Current Debug System Illuminate for Debugging the Slewing Eddy Current Controller This Controller is only suit for the tower crane which contains slewing eddy current controller controlled by PLC. The eddy current controller controls the voltage by the output signal of the PLC. The controller have been debugged when leave the factory, but you should regulate the output of the eddy current controller when the following problem happening. The slewing is hard to start up, and the start up time is long. The tower crane shake strongly when stopping the slew. The motor of slew become very hot after working a few minutes Control Principle The eddy current controller contains two parts: PLC and SECC.The Y0 of PLC output different signal according to different gear.the SECC receives the signal of PLC and outputs different voltage, which means different eddy current Debug When the tower crane leaves the factory, the eddy current have been debugged and divided into five gears: 14V, 10V, 6V, 2V, 0V, or four gears: 14V, 8V, 4V, 0V, The voltage is the DC voltage between 607and 608, or 609 and 610, which are the outputs of the SECC. The voltage determines the moment of the eddy current brake. That is to say, the higher the voltage is, the stronger the moment of the eddy current brake is. However, because of that the performance of the eddy current brake isn t consistent, the voltage of the eddy current maybe need to be adjust. The method is as follows: When use default vaule, the voltage of the eddy current is adjusted though the touched monitor.pay attention: the eddy current should be set from gear 0 to gear 4, gear by gear. The maximum value of eddy current is 24V,and the corresponding control numerical is When use Potentiometer to adjust the eddy current: Two Potentiometer Description: "Potentiometer 0" and "potentiometer 1" are adjustable analog potentiometer, and its corresponding value range: 0 ~ 255. When the anti-clockwise (that is, to figure the direction of small arrow) to the smallest screw, corresponding to the smallest value is 0 (as shown in Figure 2 of the A-point); When the clockwise (that is, to figure the direction of big arrow) screw to the largest and corresponds to the maximum value of 255 (as shown in Figure 2 of the D-point). Electrical equipment Electrical equipment 8-17

241 Tower Crane Instruction Manual Fig.1 PLC left Department potentiometer (p0, p1), programming port Electrical equipment Fig.2 Schematic diagram of analog potentiometer value The open-loop / closed-loop slew control conversion settings: Closed-loop control: Set up internal procedures for when the "potentiometer 1" the value of less than 50, procedures for the closed-loop control operation, that is, as shown in Figure 2 the interval A-B, Only in the tower crane equipped with slew encoder feedback slew-motor. Can use closed-loop control operation, otherwise only modulation to run open-loop. Open-loop control: Set up internal procedures for when the "potentiometer 1" value greater than 50, the procedures for open-loop control operation, that is, as shown in Figure 2 the interval B-C. Adjustment method is as follows: First: the "potentiometer 1" anti-clockwise (that is, to figure the direction of small arrow) to the smallest screw (as shown in Figure 2 of the A-point); Second: then slowly clockwise to the direction of the arrow big screw, when screwed into its corresponding value can be greater than 50 (as shown in Figure 2 of the B point), at the same time hear the words, just like di, that has been twisted to the point of greater than 50. Open-loop eddy current testing Identify at the open-loop operation of eddy current debugging state (Figure 2 "C-D"): Set up internal procedures for when the "potentiometer 1" when the value is greater than 230 (as shown in Figure 2 of the C points), procedures for the open-loop eddy current debug state. As follows: The "potentiometer 1" slowly clockwise to the direction of the arrow big screw, when screwed to the C point, the buzzer will "drop" the voice said that it has entered the open Debugging vortex ring state, when in this state, for debugging prompt staff, buzzer every 2 second "drop" ring out; Cut off the air-switch for slew inverter, tower crane static eddy current testing; 8-18 Electrical equipment

242 Tower Crane Instruction Manual Which file needs to adjust slew eddy current, will handle play where slew files; For example: Test slew (1 gear) eddy current First: cut off the air-switch of the slew Inverter; Second: the "potentiometer 1" to "open-loop eddy current debugging state" (Figure 2 "C-D "), will hear the buzzer at the same time every two seconds, "di", express has been transferred to this interval; Third: operate handle of the console to slew 1 gear (turn left or turn right); Fourth: adjust "potentiometer 0", can change the "potentiometer 0" value, that can change the eddy current output value, and then use a multimeter measuring the eddy current output value; Fifth: adjusting to a required output of the eddy current value, press the "bypass" button to save the parameters into the PLC program; Sixth: eddy current parameter values debugging completed, must transferred back the "potentiometer 1" to "open-loop eddy current running zone" (Figure 2 "B-C "). Restore the Open loop eddy current parameter value to the factory: First: cut off the air-switch of the slew converter; Second: Using two small short cables, connect the PLC input of left / right slew at the same time. Third: put on slew braking; Fourth: In the third step, after 5 seconds press the "bypass", at the same time to hear buzzer "di", it means that the eddy current parameter has been restored factory (not heard the words "di", Description not yet recovered successfully, you can repeat several times). NOTICE In the debugging process, we should make corresponding adjustment according to analyze the specific circumstances: Firstly, Combined with the observation of the current value, which comes from the digital actuator of the general inverter. In each step of operation, the current value should not be greater than two times of the rated current of the motor. Secondly, when the rotation is difficult to start, or the start time is long, if there is no machinery fault, you should adjust the size of eddy current though the page "rotary parameter settings" in the monitor screen. Thirdly, after a period of working time, if you find the rotary motor overheating, it may be caused by the high voltage of eddy current, adjusting the voltage until satisfied. (1) From low-gear to high-gear, the voltage can be adjusted to following empirical value: For the product of five gears:14v, 10V, 6V, 2V, 0V For the product of four gears:14v, 10V, 6V, 2V, 0V (2) In the regulation of eddy current voltage, disconnect rotary breaker QFS first, and connect the rotary breaker QFS after adjustment. Electrical equipment Electrical equipment 8-19

243 Tower Crane Instruction Manual 5.2 Inverter The operation of inverterdisplay of Inverter Low-power inverter feature an integrated display terminal with a 7-segment 4-digit display. The graphic display terminal described on the previous pages can also be connected to these drives as an option. Function of the display: Electrical equipment 8-20 Electrical equipment

244 Tower Crane Instruction Manual e.g:accessing menu parameters Menu Parameter Value or assignment Graphic display terminal Electrical equipment Electrical equipment 8-21

245 Tower Crane Instruction Manual CAUTION UNINTENDED EQUIPMENT OPERATION Before turning on and configuring the inverter, check that the PWR(POWER REMOVAL)input is deactivated(at state 0) in order to prevent unintended operation. Before turning on the inverter, or when exiting the configuration menus, check that the inputs assigned to the run command are deactivated (at state 0) since they can cause the motor to start immediately. TERMINALS Power terminals Terminals 3 R/L1,S/L2,T/L3(1) PO PO.1, PO.2 PA/+ PC/- PA PB U/T1,V/T2,W/T3 RO,SO,TO BU+,BU- X20,X92,X3 Function Protective ground connection terminals Power section line supply DC choke connection DC choke connection DC bus+ polarity and DC choke connection DC bus- polarity Output to braking resistor Output to braking resistor Output to the motor Separate fan supply when inverter is only powered by the DC bus + and polarities to be connected to the braking unit Braking unit control cable connection Control terminals Terminals Function Electrical characteristics R1A Common point C/O contact R1B (R1C) of programmable relay R1 Minimum switching capacity:3ma for 24V(DC) R1C Maximum switching capacity on resistive load: 5Afor 250V(AC) or 30V(DC) R2A R2C N/O contact of R2 program mable relay Maximum switching current on inductive load (cosφ=0.4l/r=7ms):2a for 250V(AC)or 30V(DC) Electrical equipment V (DC) power supply for 1to10KΩ reference +10V (DC) (10.5V±0.5V) 10mA, max. potentiometer 8-22 Electrical equipment

246 Tower Crane Instruction Manual Terminals Function Electrical characteristics AI1+, AI1- Differential analog input AI1-10V to +10v(DC)(max. safe voltage24v) COM Analog (I/O) common 0V AI2 Depending on software Configuration: Analog voltage or current input Analog input 0 to+10v(dc) (max. safe voltage 24V),impedance 30 KΩ or Analog input X-Y ma, X and Y can be programmed from 0 to 20mA impedance 250Ω P24 +24V(DC)(min.19V,max.30V) Input for external +24V(DC) control section power Power 30 watts supply Analog input 0 to+10v(dc) min. load voltage impedance 50 KΩ AO1 Depending on software Configuration: Analog voltage or current output or logic output or Analog input X-Y ma, X and Y can be programmed from 0 to 20mA max. load voltage impedance 500Ω or logic output 0to 10V or 0to 20mA 0V Logic input common and 0V of P24power supply 0V LI1to LI5 Programmable logic inputs +24V(DC)(max. 30V) impedance 3.5 KΩ SW2=LI: Same characteristics as logic inputs LI1to L15 LI6 Depending on the position of the SW2 switch: LI or PTC SW2=PTC: Trip threshold 3 KΩ,reset threshold 1.8 KΩ Short-circuit detection threshold<50ω SW1 switch in Source or Sink Int position: +24V Power supply (DC) Internal +24V(DC)power supply 200mA, max SW1 switch in Sink Ext position: Electrical equipment Input for external +24V(DC)power supply for the logic inputs Electrical equipment 8-23

247 Tower Crane Instruction Manual Terminals Function Electrical characteristics Power Removal safety 24V(DC)(max.30V) PWR Function input Impedance 1.5 KΩ Auto tuning Code (tun) Leave factory setting: (NO) (no) tun no YES done (NO) (no): Auto-tuning not performed. (YES) (YES): Auto-tuning is performed as soon as possible, then the parameter automatically change to(done) (done) (DONE)(dOnE):Use of the values given the time auto-tuning was performed. Asynchronous motor: (Rated motor volt) (UnS), (Rated motor freq) (FrS), (Rated motor current)(ncr) (Nom motor speed) (nsp), (Rated motor power)(npr) If at least one of these parameters is modified after auto-tuning has been performed,(auto-tuning)(tun) returns to(no)(no)and must be performed again. Auto-tuning is only performed if no stop command has been activated, If a freewheel stop or fast stop function has been assigned to a logic input. This input must be set to 1(active at 0) Auto-tuning takes priority over any run or prefluxing commands, which will be taken into account after the auto-tuning sequence If auto-tuning fails, the inverter display (NO)(nO) and depending on the configuration of (AutoTunFltCont) (tnl),may switch to [AUTO-TUNING](tnF) fault mode. Auto-tuning may last for 1to2 seconds, Do not interrupt the process, Wait for the display to change to (Done)(dOnE) or (NO)(nO). CAUTION (1) It is essential that all the motor parameters are correctly, configured before starting auto-tuning (2) If Auto-tuning fails, the drive displays[no](no) (3) During auto-tuning the motor operates at rated current Normal display with no fault present Code Signification Code Signification Electrical equipment 43.0 Display of the parameter selected in the SUP menu (default selection: motor frequency) nlp No line power(no line power on L1, L2, L3) ACC Acceleration nst Freewheel stop CLI Current limiting Obr Auto-adapted deceleration CtL Controlled stop on input phase loss PrA Power Removal function active (inverter locked) dcb DC injection braking in progress rdy Inverter ready dec Deceleration SOC Controlled output cut in progress FLU Motor fluxing in progress tun Auto-tuning in progress FSt Fast stop USA Undervoltage alarm 8-24 Electrical equipment

248 Tower Crane Instruction Manual Faults-Causes-Remedies (1) Inverter does not start, and no fault displays. If the display does not light up, check the power supply to the Inverter. The assignment of the Fast stop or Freewheel stop functions will prevent the Inverter from starting if the corresponding logic inputs are not powered up. The ATV71 then displays [Freewheel] (nst) in freewheel stop and [fast stop] (Fst) in fast stop. This is normal since these functions are active at zero so that the Inverter will be stopped safely if there is a wire break. Make sure that the run command input or inputs are activated in accordance with the selected control mode. (2) Fault which cannot be reset automatically The cause of the fault must be removed before resetting by turning off and then back on. Fault Name Probable cause Remedy AI2F [AI2 input] Non-conforming signal on analog Check the wiring of analog input AI2 input AI2 and the value of the signal. Anf [Load slipping] The encoder speed feedback does not 1.Check the motor, gain and stability match the reference parameters. 2.Add a braking resistor. 3.Check the size of the motor/inverter/ load. 4.Check the encoder s mechanical coupling and its wiring. brf [MECHANICAL BRAKE FLT] The brake feedback contact does not 1.Check the feedback circuit and the match the brake logic control brake logic control circuit. 2.Check the mechanical state of the brake. CrFI [PRECHARGE FAULT] Charging relay control fault or 1.Check the intermal connections. charging resistor damaged 2.Inspect/repair the Inverter. ECF [ENCODER COUPLING] Break in encoder s mechanical Check in encoder s mechanical coupling coupling. Electrical equipment Electrical equipment 8-25

249 Tower Crane Instruction Manual Fault Name Probable cause Remedy EEF1 EEF2 [CONTROL EEPROM FLT] Internal memory fault 1.Check the environment(electromagnetic compatibility) 2.Turn off, reset, return to factory settings. 3.Inspect/repair the Inverter. EnF [ENCODER FAULT] Encoder feedback fault 1.Check [Number of pulses](pgi)and [encoder type](ens). 2.Check that the encoder s mechanical and electrical operation, its power supply and connections are all correct. 3.Check and, if necessary, reverse the direction of rotation of the motor or the encoder signals. FCFI [OUTPUT CONT.CLOSEL] The output contactor remains closed 1.Check the contactor and its wiring. although the opening conditions have 2.Check the feedback circuit. been met ILF [INTERNALLINK FAULT] Communication fault between option card and Inverter 1.Check the environment (electromagnetic compatibility). InF1 [RATING ERROR] The power card is different from the card stored InF2 [INCOMPATIBLE PB] The power card is incompatible with the control card InF3 [INT.SERIAL LINK FLT] Communication fault between the internal cards 2.Check the connections. 3.Replace the option card. 4.Inspect/repair the Inverter. Check the power card s catalog number. Check the power card s part number and compatibility. 1.Check the internal connections. 2.Inspect/repair the Inverter. InF4 [INTERNAL FLT-Mfg AREA] Internal data inconsistent Recalibrate the Inverter Electrical equipment InF6 [INTERNAL FLT-OPTION] The option installed in the Inverter is not recognized InF7 [INTERN. FLT-HARD.INT] Initialization of the Inverter is incomplete InF8 [INT.FLT-CONTROL SUP.] The control section power supply is incorrect Check the reference and compatibility of the option. Turn off and reset. Check the control section power supply 8-26 Electrical equipment

250 Tower Crane Instruction Manual Fault Name Probable cause Remedy InF9 [INTERN.FLT-I MEASURE] Incorrect current measurements 1.Replace the current sensors or the power card. 2.Inspect/repair the Inverter. InFA [INTERNAL-MAINS CIRCUIT] Input stage not operating correctly Inspect/repair the Inverter. InFb [INTERN.FLT-TH.SENSOR] Fault on the electronic time measurement component 1.Replace the temperature sensor 2.Inspect/repair the Inverter. InFC [INTERN.FLT-TIME MEAS.] Internal microprocessor fault Inspect/repair the Inverter. InFE [CPU FAULT] Internal microprocessor fault Turn off and reset. Inspect/repair the Inverter. PrF [POWER REMOVAL FAULT] Fault with the Inverter s Power removal safety function Inspect/repair the Inverter. OCF [OVERXURRENT] 1.Parameters in the [SETTINGS](Set-) 1.Check the parameters. and(drc-)menus are not correct 2.Inertia or load too high 2.Check the size of the motor/inverter/ load 3.Mechanical locking 3.Check the state of the mechanism PrF [POWER REMOVAL FAULT] Fault with the Inverter s Power Inspect/repair the Inverter. removal safety function SCF1 [MOTOR SHORT CIRCUIT] 1.Short-circuit or grounding at the 1.Check the cables connecting the Inverter output Inverter to the motor, and the motor insulation 2.Significant earth leakage current at SCF2 [IMPEDANT SH. CIRCUIT the Inverter output if several motors 2.Reduce the switching frequency are connected in parallel 3.Connect chokes in series with the motor SCF3 [GROUND SH. CIRCUIT] SOF [OVERSPEED] Instability or driving load too high 1.Check the motor, gain and stability parameters. 2.Add a braking resistor. 3.Check the size of the motor/inverter/ load SPF [SPEED FEEDBACK LOSS] Encoder feedback signal missing 1.Check the wiring between the encoder and the Inverter. 2.Check the encoder. tnf [AUTO-TUNING FAULT] 1.Motor not connected to the Inverter 1.Check that the motor is present during auto-tuning. 2.Special motor or motor whose power is not suitable for the Inverter 2.If an output contactor is being used close it during auto-tuning. Electrical equipment 3.Check that the motor/inverter are compatible. (3) Faults that can be reset with the automatic restart function, after the cause has disappeared. Electrical equipment 8-27

251 Tower Crane Instruction Manual Fault Name Probable cause Remedy APF [APPLICATION FAULT] Controller Inside card fault Please refer to the card documentation. blf [BRAKE CONTROL FAULT] 1.Brake release current not reached 2.Brake control parameters 1.Check the Inverter/motor connection 2.Check the motor windings 3.Apply the recommended settings not set when brake logic control is assigned CnF [NETWORK FAULT] Communication fault on communication card 1.Check the environment(electromagnetic compatibility) 2.Check the wiring. 3.Check the time-out 4.Replace the option card 5. Inspect/repair the Inverter. COF [CANopen FAULT] I n t e r r u p t i o n i n 1.Check the communication bus c o m m u n i c a t i o n o n t h e 2.Check the time-out CANopen bus 3.Refer to the relevant product documentation EPF1 [EXTERNAL FAULT L1/ Fault triggered by an external Check the device which caused the fault, and reset. Bit] device, depending on user EPF2 [EXTERNAL FAULT NET.] Fault triggered by an external Check the device which caused the fault, and reset. device, depending on user FCF2 [OUTPUT CONT.OPENED] The output contactor remains 1.Check the contactor and its wiring open although the closing 2.Check the feedback circuit conditions have been met LCF [LINE CONTACT.FAULT] The Inverter is not powering 1.Check the contactor and its wiring up although the contactor is 2.Check the time-out controlled 3.Check the line/contactor/inverter connection LFF2 LFF3 LFF4 [Al2 4-20Ma loss] [Al2 4-20Ma loss] [Al2 4-20Ma loss] Loss of the 4-20mA reference Check the connection on the analog inputs on analog input Al1,Al2,Al3 oral4 Electrical equipment ObF [OVERBRAKING] B r a k i n g t o o s u d d e n o r 1.Increase the deceleration time. driving load 2.Add a braking resistor if necessary. 3.Activate the [Dec ramp adapt.](bra)function, if it is compatible with the application 8-28 Electrical equipment

252 Tower Crane Instruction Manual Fault Name Probable cause Remedy OHF [INVERTER OVERHEAT] Inverter temperature too high Check the motor load, the Inverter ventilation and the ambient temperature. Wait for the Inverter to cool down before restarting. OLF [MOTOR OVERLOAD] Triggered by excessive motor Check the setting of the motor thermal protection, current check the motor load. Wait for the Inverter to cool down before restarting. OPF1 [1MOTOR PHASE LOSS] Loss of one phase at Inverter Check the connections from the Inverter to the motor. output OPF2 [3MOTOR PHASE LOSS] 1.Motor not connected or 1.Check the connections from the Inverter to the motor motor power too low 2.Output contactor open 2.Test on a low power motor or without a motor: In factory settings mode, motor output phase loss detection [Output Phase Loss](OPL)=[No](nO) 3.Instantaneous instability in the motor current 3.Check and optimize the [Rated motor volt](uns) and[rated mot. current](ncr)parameters and perform an [Auto tuning](tun)operation OSF [MAINS 1.Line voltage too high Check the line voltage OVERVOLTAGE] 2.Disturbed mains supply OtF1 [PTC 1 OVERHEAT] Overheating of the PTC1 1.Check the motor load and motor size probes detected 2.Check the motor ventilation 3.Wait for the motor to cool before restarting 4.Check the type and state of the PTC probes OtF2 [PTC 2 OVERHEAT] Overheating of the PTC2 probes detected OtFL [PTC=L16 overheat] Overheating of the PTC probes detected on input Ll6 PtF1 [PTC1 FAILURE] PTC1 probes open or shortcircuited Check the PTC probes and the wiring between them and the motor/inverter PtF2 [PTC2 FAILURE] PTC2 probes open or shortcircuited PtFL [L16=PTC FAILURE] PTC probes on input Ll6 open or short-circuited SCF4 [IGBT SHORT CIRCUIT] Power component fault Inspect/repair the Inverter SCF5 [LOAD SHORT CIRCUIT] Short-circuit at Inverter 1.Check the cables connecting the Inverter to the output motor and the motor insulation 2.Inspect/repair the Inverter SLF1 [MODBUS COM,] I n t e r r u p t i o n i n 1.Check the communication bus c o m m u n i c a t i o n o n t h e 2.Check the time-out Modbus bus 3.Refer to the relevant product documentation Electrical equipment Electrical equipment 8-29

253 Tower Crane Instruction Manual Fault Name Probable cause Remedy SLF2 [POWERSUITE COM,] Fault communicating with 1.Check the PowerSuite connecting cable PowerSuite 2.Check the time-out SLF3 [HMI COM.] Fault communicating with 1.Check the terminal connection the graphic display terminal 2.Check the time-out SrF [TORQUE TIME OUT FLT] The time-out of the torque 1.Check the function s settings. control function is attained 2.Check the state of the mechanism SSF [TORQUE/I LIMIT FLT] Switch to torque limitation 1.Check if there are any mechanical problems 2.Check the limitation parameters tjf [IGBT OVERHEAT] Inverter overheated 1.Check the size of the load/motor/inverter 2.Decrease the switching frequency 3.Wait for the motor to cool before restarting Faults that can be reset as soon as their causes disappear Fault Name Probable cause Remedy CFF [INCORRECT CONFIG.] The current configuration is Check the card inconsistent(error due to a change of card) CF1 [INVALID CONFIG.] Invalid configuration. The configuration loaded in the Inverter via the serial link is inconsistent 1.Check the configuration loaded previously. 2.Load a compatible configuration PHF [INPUT PHASE LOSS] Inverter incorrectly supplied or a fuse blown 1.Check the power connection and the fuses 2.Reset 3.Use a three-phase line supply USF [UNDERVOLTAGE] 1.Line supply too low 2.Transient voltage dip 3.Damaged pre-change resistor 4.Disable the fault by setting 1.Check the voltage and the voltage parameter 2.Replace the pre-charge resistor. 3.Inspect/repair the Inverter Electrical equipment If the inverter is not turned on for a long period, the performance of its electrolytic capacitors will be reduced. If it is stopped for a prolonged period, turn the inverter on every two years for at least 5 hours to restore the performance of the capacitors, then check its operation Electrical equipment

254 Tower Crane Instruction Manual 6 Appendix 6.1 Instruction for the Tower Crane Monitoring System Main Interface Start Screen As long as the main air switch of the tower crane is closed, the monitor will be electrified and start up. The first screen after the start is shown in the following screen. Fig Start Screen In the boot screen will show the name of tower crane, manufacturers and other basic information, as well as the version of the program, equipment number, date, running time and other information. Click on the screen, or wait 5 seconds, the screen will automatically switch to the main screen. Main Screen( Monitor Screen) Electrical equipment Fig Main Screen Electrical equipment 8-31

255 Tower Crane Instruction Manual On the main screen will show all the basic state of tower crane. On the main screen,there is a diagram of the tower crane structure, as well as the angle of the tower crane jib, rotary amplitude, height of rotary inverted. On the left and right side of the main screen is vertical progress bars showing the moment and weight of the tower crane. At the bottom of the screen is the schematic diagram of moment curve, and with a flashing point shows the current state of tower crane. The above is the system date and time. The middle is the numerical display of the moment, weight, ratio, maximum hoisting weight, arm length and wind speed. If there are faults, the fault information will be displayed in lantern way in the middle of the screen. You can use " " button to display the menu, specific methods of using the menu please refer to the corresponding menu sections of the paper. The function that this key in other window is also menu displaying. In the video monitor screen, it displays the video taken by the arm tip camera. At the same time, in its lower part also provides the control button on the camera, such as menu, zoom in, zoom out,enlarging focus, focus. Full screen button can enter the video window. In the above of the video monitor screen, displays the moment and weight of the tower crane with a horizontal progress bar as well as numerical. On the right there is numerical value that shows the jib angle, radius of slewing, hoisting magnification, the maximum hoisting capacity, the current wind speed etc.. Main Menu Electrical equipment Fig Main menu On the right-hand corner of the window there is a " " button, click it to close the current window. Part of the pop-up window also has this button, and the function is the same. Click the "Login" button to enter the login window, and then you can use the name and password to login the system and can modify some parameters of the tower crane. Click the "Language" button to enter the language selection window, and then you can chang the the display language of the screen. Click the "Information" button to enter the information window, the window will display the relevant information of the electrical control system. Click the "Close" button to close the current menu or to return to the main menu. In the main menu, there are "Monitor Screen", "Video Monitor Screen", "Mechanism Status", "Tower Crane Set", "Input and Output", "Alarm Information" etc Electrical equipment

256 Tower Crane Instruction Manual Click the "Monitor Screen", "Video Monitor Screen" button to enter the main screen and video monitor screen. Click the "Mechanism Status", "Tower Crane Set", "Input and Output", "Alarm Information" button to enter the corresponding submenu. Mechanism Status Menu Via this menu, you can enter the corresponding mechanism status screen or mechanism detection screen. Detailed description of the relevant screen is refer to the section "Mechanism Status and Detection Screen". Fig Mechanism Status Menu Tower Crane Set Menu Fig Tower crane set menu Via this menu, you can enter the screen for setting the tower crane parameters and related sensor. IO Status Menu (Input and Output) Electrical equipment Electrical equipment 8-33

257 Tower Crane Instruction Manual Fig IO status menu Via this menu, you can enter the screen for viewing the input and output point of the PLC.Detailed description of the relevant screen is refer to the section " Input and Output of the PLC". Alarm Information Menu Fig Alarm information menu Via this menu, you can enter the screen for viewing current alarm and alarm history, specify the relevant screen, please refer to the "alarm" in the description section. Detailed description of the relevant screen is refer to the section " Alarm Screen". Login Window Electrical equipment Fig Login window Input user name and password, and click the button, then you can login the system and 8-34 Electrical equipment

258 Tower Crane Instruction Manual set the tower crane. The default user name is "User", and the password is "zoomlion ". Language Choosing Menu Fig Language choosing menu Via this menu, you can choose the display language of the screen. Information Window Fig Information window On the information window, it will show the name of tower crane, manufacturers and other basic information, as well as the program version of the electrical control system, equipment number, date, running time and other information Mechanism Status and Detection Screen Start-up and mechanism detection Electrical equipment Electrical equipment 8-35

259 Tower Crane Instruction Manual Fig Start-up detection Fig Hoisting system detection Electrical equipment Fig Slewing system detection 8-36 Electrical equipment

260 Tower Crane Instruction Manual Fig Trolley system detection This screen is displayed by the way of steps. Expounds how to check and eliminate the fault of the system step by step. General fault can be checked out according to the steps Tower Crane Parameters and Sensor Setting You will only be allowed to view the parameters if you don t login. If you want to set the parameters or the sensor, you will be required to login CAUTION Please set the parameters following the steps, otherwise it may lead to the electronic security system work abnormally, and due to equipment failure, loss of property, personal danger. Tower Crane Parameters Setting Electrical equipment Fig Tower crane parameters setting Via this screen, you can set the arm length and the magnification of the hook.relevant parameters in the Electrical equipment 8-37

261 Tower Crane Instruction Manual control system will automatically adjust. Please select the arm length and magnification of the hook correctly according to the configuration of the tower. The parameters in this screen are the basis of other parameters, if the parameters are set error, it will cause the other parameter be set error. Weight Sensor Correction Fig Weight sensor correction The weight sensor is a sensor that converts weight to electrical signal. The weight sensor of this tower crane is mounted on a pulley shaft on the jib. The sensor has a couple of electrical signal channels. When the two electrical signal are difference, the screen will display a alam. This screen provides two kinds of correction model: One kind is double correction mode. This mode can completely correct the weight signal, but standard weights is needed. Another kind is single correction mode. This correction mode is more convenient, do not need additional accessory, but only for fine-tuning. If the weight display quite different, you must use the double correction mode. Weight sensor correction can be completed in accordance with the steps on the screen. CAUTION Electrical equipment The magnification is used in weight correction, please ensure the magnification settings are right before correcting the weight sensor, otherwise it will result in great weight error, and effecting the work of electronic security system. Angle Sensor Correction 8-38 Electrical equipment

262 Tower Crane Instruction Manual Fig Angle sensor correction The angle sensor is a kind of sensor that convert angle into electric signal, the angle sensor is mounted on the jib. Before the angle sensor leaving the factory, it has been corrected to the horizontal plane. However, because of the installation problem, angle sensor and the jib is not parallel, so the angle sensor need to be corrected. Single correction mode, only need to know the true jib angle, The angle sensor correction can be completed in accordance with the steps on the screen. The current angle can be calculated through the rang length of the jib, but the calculation may have error. The angle sensor may have a reverse installation, so sensor orientation may need to modified. The angle sensor need to be corrected again after direction changed CAUTION The arm length and the magnification are used in angle correction, please ensure the arm length and the magnification settings are right before correcting the angle sensor, otherwise it will result in great angle error, and effecting the work of electronic security system. Wind Speed Sensor Correction Electrical equipment Electrical equipment 8-39

263 Tower Crane Instruction Manual Fig Wind speed sensor correction The wind speed sensor is a kind of sensor that convert wind speed into electric signal, the wind speed sensor is mounted on the top of the tower crane. Wind speed sensor has been corrected before leaving the factory, it can be used directly. if the error of the sensor is large,it can be corrected. In single correction mode,only need to know the current true wind speed, prompt correction can be completed in accordance with the steps on the screen. Tower Crane Limiter Setting Fig Tower crane limiter setting Electrical equipment All limit switches and electronic limit system setting are shown on this screen. It is convenient to adjust the limits when setup the tower crane. In accordance with the limiter s function, it is divided into six forms to display. These six forms respectively are trolley mechanism limiter, hoisting mechanism limiter, slewing mechanism limiter, weight limiter, moment limiter, as well as the electronic limiter control settings. Trolley mechanism limiter is one of the most important luffing tower crane limiter, so two sets of limiter are provided in this control system. One set of limit device is mechanical contactor, installed on the mechanism; The other is a electronic limiter, achieved through the angle sensor. In trolley limiter table, the 8-40 Electrical equipment

264 Tower Crane Instruction Manual first column is the movement should be limit, the second column is the signal feedback by mechanical limiter, the third column is the electronic limiter signal, the fourth column is limit angle value for electronic limiter. The fourth column angle can be set, when the angle signal returned by the angle sensor reaches the set point, the corresponding electronic limiter will generate a limit signal. Hoisting limiter only have mechanical limiting device, installed in the mechanism. The first column of the table is movement should be limit, the second column is the signal feedback by mechanical limiter. The stop signal of the slewing limiter is mechanical limiter, and the deceleration signal is electronic limiter. When the jib angle is smaller then 25 or bigger then 75, the speed limit signal will be generated, and the max slewing speed is only gear 4. Weight limiter only have electronic limiter, The first column of the table is the control range, the second column is the electronic limiter signal, the third column is the weight value for the electronic limiter, the value is calculated automatically according to the magnification. Moment limiter is one of the most important limiting device of tower crane, so two sets of limiter are provided in the control system. One set of limiter is mechanical limit device, installed in the A frame; the other is the electronic limiter, achieved through the angle and the weight sensor. In the moment limiter table, the first column is control range, the second column is feedback from mechanical limiter, the third column is the electronic limiter signal, the fourth is the weight value for corresponding electronic limiter. When the magnitude changed, the weight value in the fourth column will be calculated automatically according to torque curve and be displayed. The electronic limiter control setting is a set of functions for the electronic limiter. The first column of the table is the name of the corresponding electronic limiter, the second column is the status, whether the electronic limiter can not start because of failures, the third column shows whether the electronic limiter is disable, the button in the fourth column is to enable or disable the corresponding electronic limiter. CAUTION If you disable electronic limiter, all corresponding electronic limit signal will automatically expire, please pay attention to operate the tower crane and prevent accidents. The weight limiter only have electronic limiter, if the electronic weight limiter is disabled, in order to ensure safety, the highest speed of hoisting mechanism will be only gear 3. Under normal working condition, please regulate the turning down time of hoisting hydraulic pliers and luffing hydraulic pliers as 1200 seconds Electrical equipment Electrical equipment 8-41

265 Tower Crane Instruction Manual Input and Output Status of PLC Fig Output status of PLC Fig Input status of PLC (1) Electrical equipment 8-42 Electrical equipment

266 Tower Crane Instruction Manual Fig Input status of PLC (2) Each input and output status and function definitions of PLC are displayed on the screens Alarm Screen When faults arise, the screen will pop up the alarm screen, display the current alarm. The history alarm information can be reviewed in History Alarm Screen. Fig Alarm screen Electrical equipment Electrical equipment 8-43

267 Tower Crane Instruction Manual Fig History Alarm Screen 6.2 Instruction for LCD Color Monitor The LCD Color Monitor is used to monitor the state of the hook. LCD Color Monitor - + MENU CAM MODE POWER Electrical equipment Fig Interface of the LCD Color Monitor Instruction for the buttons of the LCD color monitor: POWER: Power switch CAM: Cam video selection(av1/av2) MODE: Mode video selection(av1/av2) MENU: Menu - : Decrease button + : Increase button The focus of the camera on the A frame can t be adjusted. The focus of the camera on the tip of the jib can be adjusted as follow: 1. Press the Video Adjust button 8-44 Electrical equipment

268 Tower Crane Instruction Manual Fig Main Menu 2. Enter into the screen as follow, there are some buttons for operating the camera on the tip of the jib, such as Menu, Zoom In, Zoom Out, Focus, Expansion of focus. Fig Video Adjust Screen In the above of the video monitor screen, displays the moment and weight of the tower crane with a horizontal progress bar as well as numerical. On the right there is numerical value that shows the jib angle, radius of slewing, hoisting magnification, the maximum hoisting capacity, the current wind speed etc.. If there are faults, the fault information will be displayed in lantern way in the lower of the screen. Electrical equipment Electrical equipment 8-45

269 Tower Crane Instruction Manual 6.3 Electrical Drawings No. Size Drawing Symble Version Num. Drawing Name Remark 1 A A a 1 Menu of the Drawing 2 A A a 1 Circuit Diagram(Main-1) 3 A A a 1 Circuit Diagram(Main-2) 4 A A a 1 Circuit Diagram(Hoist-1) 5 A A a 1 Circuit Diagram(Hoist-2) 6 A A a 1 Circuit Diagram(Hoist-3) 7 A A a 1 Circuit Diagram(Slewing-1) 8 A A a 1 Circuit Diagram(Slewing-2) 9 A A a 1 Circuit Diagram(Slewing-3) 10 A A a 1 Circuit Diagram(Trolley-1) 11 A A a 1 Circuit Diagram(Trolley-2) 12 A A a 1 Circuit Diagram(Trolley-3) 13 A A a 1 Circuit Diagram(Trolley-4) 14 A A a 1 Circuit Diagram(PLC Control) 15 A A a 1 Circuit Diagram(Sensor) 16 A A a 1 Circuit Diagram(Cammera) 17 A A a 1 Circuit Diagram(Consoles) 18 A A a 1 Wiring Diagram(1) 19 A A a 1 Wiring Diagram(2) 20 A A a 1 Wiring Diagram(3) 21 A A a 1 Wiring Diagram(4) 22 A A a 1 Wiring Diagram(5) 23 A A a 1 Wiring Diagram(6) 24 A A a 1 Components Dispose(1) 25 A A a 1 Components Dispose(2) 26 A A a 1 Components Dispose(3) 27 A A a 1 Cable List 28 A A a 1 Component List(1) 29 A A a 1 Component List(2) 30 A4 31 A4 Electrical equipment 8-46 Electrical equipment

270 Tower Crane Instruction Manual 1 Pump For Hydraulic Jack Over-undervoltage And Phase Protection Lamp For Main Power 5 6 Main Power Isolate Switch Voltage Meter Main Switch Pump For Hydraulic Jack Power For Cab 3P+N+PE AC 380V PE N L1-1 L1-2 L1-3 3*95+2*35 mm 2 -QS U1 V1 W1 /.C1 I> I> I> UP1 VP1WP1 -QFP1 ME32C 4mm 2 1.5mm 2 U2 V2 W2 -QF -QF10 320A 1A 1.5mm 2 1.5mm 2 I> I> I> UP2 VP2WP2 -QFP2 ME22C 4mm 2 PE N U2 V2 W2 /.B5,/2.B2 /.D1 /.C4,/3.A1,/6.A1,/9.A1 /.D4,/2.B1,/3.A1,/6.A1,/8.B1,/9.A1 /2.C1,/3.A1,/6.A1,/8.B1,/9.A1 1 N1 PE /.C2 /.D2 /.A5 4mm /2.D5 /2.D5 /.C6 /.D6 /.D3 A B -XSP1 -XPP1 V1 W1 -PP1 V 4 11KW -PV -KAU -KAP 28 -HM W2 -PP2 -XSP2 -XPP2 7.5KW 1 L N1 N1 AC220V -Cab PE PE MX1 -SLC MX2 EY6 74 -EY 71 EY7 EF5 102 FAN U1 /.A2 N 4mm 2 -QFES 32A 5 1 -SST:2 KAML /13.D3 -KAU /.B HH -HU -EF1 6 -QF101 3A T> Blue-STC1 U2 V2 -QFY 3A C IN2 AC 380V -QFTS 6A TS AC 22V 71 IN1 IN2 AC.Input V1+ OUT1 AC 22V -QF1 10A 75 IN1 SW1 -DCM QF2 1.5 mm 2 10A V2+ OUT2 V2- V1- IN- IN- SW2 4 /.C3 /2.D6 /.A5 N1 /.B /.A5 /.A /6.C5,/6.C6 -EY 1.5 mm VDC /6.C5,/6.C6 71 D Electrical Leakage Protecing Device For Cab ZOOMLION HEAVY INDUSTRY & SCIENCE Horn Over-undervoltage Indicate Fan Protection Transformer Transformer Commutate Protection Commutate Commutate Protection Power For Wiper Circuit Diagram(Main-1) DWG No A02101 Version -a 1 Electrical equipment Electrical equipment 8-47

271 Tower Crane Instruction Manual Electrical equipment 1 Protection Transformer Transformer Circuit Protection Contactor For Start Contactor Start Indicate DC24V/12V For Control Zero Position Switch Start Button V2 -QFTC -TC 10A /1.A5 10 AC 380V W2 /1.A AC 230V mm 2 -QFA 10A L N PE MP L2 N2 PE L1 N1 PE -QF3 10A -KMC1 -KMC2 /.C6 /.C KMC1 -KMC2 -KMH -KMS -KMV -HP 41 /.C6 /.C6 /4.A5,/5.D4,/8.D5,/11.D2,/12.A1,/14.C1 83 IN1 SW1 IN1 IN2 IN2 AC.Input OUT1 V1+ -DCM1 IN- IN- V1- V2- OUT2 V2+ SW2 84 -KAMH -KAMS -KAMV /13.D4 /13.D4 /13.D /3.A2 /3.A2 /3.A2 /6.A2 /6.A2 /6.A2 85 /9.A2 /9.A2 /9.A /4.A5,/5.A4,/8.A5,/11.A5,/12.A1 /.C6,/4.A5,/14.C1 AC AC DC -BU1 (DRP ) DC -BU2 (S-15-12) -QF4 -SZL 10A /.C4 -KMC /.D6 -SZR 42 /.C5,/8.D6,/13.D2 794 /.C6 /.A4 -KMC1 -SST:1 /.D5,/4.C1,/4.B3,/5.D1,/7.D1,/10.D2,/11.D /.D5,/4.C1,/12.C3,/13.D1,/13.D4 30 A1 S33 S KMC1 -KMC2 24VDC -KMSC + 220VAC A2 S11 S12 S21 S /.C6 /.C SEM SED -KMC1 -KMC2 /.D4 /.B /.A3 /.A3 91 -SLC -KAP /.B3 /.B /.C4 /.C4 /.D5,/4.D1,/4.D3,/8.A6,/10.D2,/12.D3,/13.D1,/13.C A -QF5 1A -QF /.14.B2,/14.C3,/14.C5,/14.C6,/15.D VDC For Sensor /14.B2,/14.C4,/14.C5,/15.D1 /15.B2,/15.A6 12VDC /15.B2,/15.C6 A B C D ZOOMLION HEAVY INDUSTRY & SCIENCE Commutate Protection Commutate DC24V Power Supply Circuit Diagram(Main-2) Emergence,Door Switch Control Circuit Contactor DWG No A02102 Version -a Electrical equipment

272 Tower Crane Instruction Manual Protection For Hoist Contactor For Hoist Protection For Cooling Motor Protecing Device For Brake Converter For Hoisting Resistance A AC 380V U2 /1.A5 V2 /1.A5 W2 /1.B5 200A -QFH 50 mm 2 W20 V20 U20 -KMH /2.B3 170A 213 /5.B5 W21 V21 U /5.C5 -QFHC 4-6.3A 25KW*3=75KW -RHB1 -RHB2 -RHB3 1.5mm 2 1.5mm 2 L1 L2 L3 -LH 6*16 mm U V W 2 U21 V21 W U21 V21 W21 /5.C5 U24 V24 W R S T PB PA+ 216 /5.C5 -HINV -HINV-EX I> I> I> -QFHB I> I> I> U V W +VS 0VS A A- B B A PE B 99 /8.B4 276 /5.A3 -KHC /5.D5 U22 V22 UHC VHC W22 WHC /8.B4 275 /5.A3 -KHB /5.D5 U23 UHB 1 1 V23 VHB 2 2 W23 WHB 3 3 UH VH WH 棕白绿 -PGH 黄 C -MHC 3 -MHB 3 -MH YHB D Cooling Motor For Hoisting Brake For Hoisting Hoisting Motor Encoder ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Hoist-1) DWG No A02103 Version -a 3 Electrical equipment Electrical equipment 8-49

273 Tower Crane Instruction Manual Electrical equipment Input Of The Hoist Converter 1#Proximity Switch Of Hydraulic Clamp 2#Proximity Switch Of Hydraulic Clamp Proximity Switch Of Lifting Reel A -SQ1 -SQ /2.B4 /2.B4 -SQH BN BK BU 290 0V -KAH1 -KAH2 -KAH3 -KAH4 -KAH5 /5.D1 /5.D1 /5.D2 /5.D2 /5.D LI1 LI2 LI3 LI4 295 LI5 90 /2.C4 Brown Blue 1 1 BN BU Black 2 2 BK BN BU Brown Blue Black BK Brown Black Blue -UHR PE PE B -HINV R1A R1C R2A R2C C /5.B2 /8.B /2.C4 91 /2.D4 -KAHG1 /5.B4 -KAHG2 -KAHR1 -KAHR2 /5.B4 /5.B3 /5.B6 91 /2.D4 -KAHB /5.B5 D Alarm Signal For The Hoist Converter Brake Signal For The Hoist Converter Speed Moniter For Hoisting ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Hoist-2) DWG No A02104 Version -a Electrical equipment

274 Tower Crane Instruction Manual 1 Up Limit Up Control Down Limit Down Control Alarm Signal For Brake Signal For Signal Of Over Speed Signal Of Hoist Converter Hoist Converter Cooling Motor Hydraulic Clamp A 99 /8.B4 -SHU -SHUC -SHD -SHDC -HINV -KHB -KHC R1C R1A -KAHR1 -KAHG1 -KAHG2 /3.C4 /3.C2 /4.C6 /4.C4 /4.C5 -SHJ 40 /2.A4 -KAHB /4.D2 -KAHC /.D PLC1 X X10 X X X X X X X X X43 -KA21 /.D KAHEV -KAHR2 /.D3 /4.C B Y2 Y Y4 283 Y5 Y6 Y22 Y Y21 -KAHR1 -QFHC /4.C6 /3.B QFHB /3.B YZB 161 C 90 /2.C4 -KAH1 -KAH2 -KAH3 -KAH4 -KAHC -KAH5 -KA21 -KAHEV /4.B1 /4.B2 /4.B2 /4.B2 /4.B3 /.B5 /.B5 /.B6 /3.C4 /3.C4 /11.B5 41 /2.B4 -KHB /3.C4 -KHC /3.C3 /3.C3 /3.C3 D Relay For Relay For Relay For Hoist Relay For Contactor For Contactor For Hoisting Brake Cooling Motor Hydraulic Clamp Hoisting Brake Cooling Motor Control Cabinet Of Hydraulic Clamp ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Hoist-3) DWG No A02105 Version -a 5 Electrical equipment Electrical equipment 8-51

275 Tower Crane Instruction Manual Electrical equipment 1 Protection For Slew Contactor For Slew Protection For Cooling Motor Converter For Slewing Resistance A U2 /1.A5 V2 /1.A5 W2 /1.B5 -QFS 63A mm 2 U30 V30 W KMS 50A 99 /8.B4 378 /7.B3 -QFSC A -KSC /8.D6 /2.B4 U32 I> V32 I> I> W32 VSC VSC USC WSC USC WSC mm 2 U31 V31 W /8.D3 U -LS 1 1 V US VS WS L1 L2 L3 U V W U33 V33 W T R S PA+ PB W SINV FRS1 -FRS2 /7.A /7.B3 US1 VS1 WS1 US2 VS2 WS KW -RSB mm /8.D /1.C6 /1.D6 /1.C6 /1.D6 -KSFB -KSB /8.D5 -YSFB /8.D /1.C5 /1.C5 -YSB 71 B C 3 -MSC1 3 -MSC2 -YBSE1 3 -MS1 -MS /8.D3 /8.D YBSE2 785 /8.C6 -SSK 91 /2.D4 D ZOOMLION HEAVY INDUSTRY & SCIENCE Cooling Motor For Slewing Eddy Slewing Motor Wind Vane Brake For Slewing Inching Switch Of The Wind Vane Circuit Diagram(Slew-1) DWG No A02106 Version -a Electrical equipment

276 Tower Crane Instruction Manual 1 Left Limit Right Limit Alarm Signal For Slewing Converter Brake Signal For Slewing Converter Signal Of Cooling Motor Input Of The Slewing Converter A 99 /8.B4 -SSL -SSR SINV R1C R1A X13 X14 X R2C R2A X33 -KSB -QFSC /8.D5 /6.B2 377 X X31 -FRS1 /6.C FRS2 /6.C4 379 X35 0V -KAS1 -KAS2 -KAS3 -KAS4 -KAS5 /.D1 /.D1 /.D2 /.D2 /.D LI1 LI2 LI3 -SINV LI4 LI5 395 B -PLC1 R1A R1C R2A R2C Y7 Y10 Y11 Y12 Y Y27 Y Y C 90 /2.C4 -KAS1 -KAS2 -KAS3 -KAS4 -KAS5 -KASB -KASFB -KASC /.B5 /.B5 /.B5 /.B5 /.B6 /8.B5 /8.B5 /8.B6 D ZOOMLION HEAVY INDUSTRY & SCIENCE Relay For Slew Relay For Relay For Relay For Slewing Brake Wind Vane Cooling Motor Circuit Diagram(Slew-2) DWG No A02107 Version -a 7 Electrical equipment Electrical equipment 8-53

277 Tower Crane Instruction Manual Electrical equipment 1 Transformer Protection Transformer A +24V -PLC1 COM 40 /2.A /2.D4 V2 /1.A5 380VAC -QF8 10A -TE -QF A VAC 399 Y0 394 COM0 99 /3.C2,/3.C3,/5.A1,/7.A1,9.C2,/9.C3,/13.A1 -KASB -KASFB -KASC /7.D3 /7.D3 /7.D SSK B VDC W2 /1.B Power Power Supply + - C Control Control -SECC H1 H2 H3 OUT1 OUT /6.C3 /6.D3 /6.C4 /6.D4 OUT /2.B4 -KSB -KSFB -KSC /6.C5 /7.B3 92 /2.C4 + -HF /6.C5 /6.C2 /6.C2 /6.C2 D ZOOMLION HEAVY INDUSTRY & SCIENCE Eddy current device Circuit Diagram(Slew-3) Contactor For Contactor For Contactor For Slewing Brake Wind Vane Cooling Motor Indicate Of The Wind Vane DWG No A02108 Version -a Electrical equipment

278 Tower Crane Instruction Manual Protection For Trolley Contactor For Trolley Protection For Cooling Motor Protection For Brake Converter For Trolley Resistance A AC 380V U2 /1.A5 V2 /1.A5 W2 /1.B5 -QFHVG 16A -QFV 125A 25 mm 2 U40 V40 W40 -KMV 115A 415 /11.B6 416 /11.C6 -QFVC A U41 V41 I> I> W41 I> 1.5 mm mm /11.C6 414 /11.C6 -QFVB A U42 V42 W42 I> I> I> -LV L1 L2 L3 U V W U46 V46 W46 R -VINV S T U V W 15KW*3=45KW PB 400 -RVB1 -RVB2 -RVB3 -VINV-EX +VS 0VS A PA+ 401 A- B 6*10 mm 2 B- PE B -KHVG 12A 99 U43 V43 W43 /8.B4 U44 V44 W44 -KVC 2 -KVB /11.D6 /11.D UVG VVG WVG /11.B3 UVC VVC WVC /11.B4 UVB UHG 1 VHG 2 WHG /8.B4 U45 V45 VVB W45 WVB 3 3 棕白 VV UV WV 绿黄 C -PGV -MHVG 3 -MVC MVB 3 -MV YVB D Motor For Hydraulic Clamp Cooling Motor Brake For Trolley Trolley Motor Encoder ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Trolley-1) DWG No A02109 Version -a 9 Electrical equipment Electrical equipment 8-55

279 Tower Crane Instruction Manual Electrical equipment 1 ZOOMLION HEAVY INDUSTRY & SCIENCE Input Of The Trolley Converter A -KAV1 -KAV2 -KAV3 -KAV4 -KAV5 /11.D1 /11.D1 /11.D2 /11.D2 /11.D2 B V LI1 LI2 LI3 LI4 LI5 -VINV R1A R1C R2A R2C C /2.C4 91 /2.D4 -KAVB /11.B6 D Alarm Signal For Trolley Converter Relay For Trolley Brake Circuit Diagram(Trolley-2) DWG No A02110 Version -a Electrical equipment

280 Tower Crane Instruction Manual 1 Forward Backward Limit Limit Backward Limit Backward Control Forward Limit Forward Control Alarm Signal For Trolley Converter Signal Of Cooling Motor Brake Signal For Trolley Converter Over Speed Signal Of Hydraulic Clamp A 99 /8.B4 40 /2.A4 -SVA1 -SVA2 -SVBW -SVBC -SVFW -SVFC VINV R1C R1A 476 -KVC -KVB /.D6 /.D6 /12.D KAVR1 -KAVGX 479 /12.D KAHEV -KAVEV -KAVB -KAVC /5.D3 /.D3 /10.D5 /.D B X15 X16 X17 X20 X21 X22 -PLC1 X36 X37 X40 X41 X KA31 /.D3 412 Y14 Y15 Y16 Y17 Y20 Y Y25 Y KAVR1 /12.D5 -QFVC /9.B C -QFVB /9.B /2.C4 -KAV1 -KAV2 -KAV3 -KAV4 -KAV5 -KAVEV -KA31 -KAVC /10.B3 /10.B3 /10.B4 /10.B4 /10.B5 /.B5 /.B6 /.B6 41 /2.B4 -KHVG -KVB -KVC /9.C1 /9.C1 /9.C1 /9.C4 /9.C4 /9.C4 /9.C3 /9.C3 /9.C3 D ZOOMLION HEAVY INDUSTRY & SCIENCE Relay For Trolley Relay For Relay For Relay For Trolley Brake Cooling Motor Hydraulic Clamp Circuit Diagram(Trolley-3) Contactor For Hydraulic Clamp Contactor For Contactor For Trolley Brake Cooling Motor DWG No A02111 Version -a 11 Electrical equipment Electrical equipment 8-57

281 Tower Crane Instruction Manual Electrical equipment 1 Power For Hydraulic Clamp Proximity Switch Of Hydraulic Clamp Proximity Switch Of Trolley Reel A 40 /2.A4 BN 41 /2.B4 -SQV BK BU -QF402 4A KAVEV KAVR2 90 /2.C4 Brown Bule BN BU BK Black SQ3 12 Brown Black Bule UVR PE PE B C -YZB /2.D4 -KAVGX -KAVR1 /11.B4 /11.B4 /11.C6 -KAVR2 /.C2 D Control Cabinet Of Hydraulic Clamp Relay For Proximity Switch Speed Moniter For Trolley ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Trolley-4) DWG No A02112 Version -a Electrical equipment

282 Tower Crane Instruction Manual Contactor 105% For Start Moment 1 100% Moment 90% Moment Moment Slewing 80% Break/ Bypass Console-gear swtich for Hoist Console-gear swtich for Slew Console-gear swtich for Trolley A 99 /8.B4 -KMC KMC2 -SM1 -SM2 -SM3 -SM4 SSF SSJ 5 向 4 3 上 2 -SH 向 2 3 下 向 4 3 左 2 -SS 向 2 3 右 向 4 3 外 2 -SV 向 2 3 内 4 5 B X2 X3 X4 X5 X6 X44 X45 X46 X47 X0 X1 X2 X3 X4 X5 X6 X7 X10 X11 X12 X13 X14 X15 X16 X17 -PLC1 -PLC2 91 /2.D COM2 /2.C4 /2.D4 COM3 COM4 -KAML -KAMA -KAMA COM5 COM6 Y32 Y S3 红色 800 -S2 黄色 -S1 绿色 92 /2.C Y Y35 Y36 Y37 Y40 Y41 Y RBZ 90 /2.C HML -KAML -HMA -KAMA -HLL -HLA -HBZ -KAMH -KAMS -KAMV -KA90 -KA91 -KA92 -KA93 -KA94 /.C2 /.D1 /2.A3 /2.A4 /2.A4 /15.B5 /15.B5 /15.C5 /15.B5 /15.C5 /1.C2 /.D KA Y43 Y44 Y45 Y KA91 -KA KA C D ZOOMLION HEAVY INDUSTRY & SCIENCE Three-color Lamp For Alam Red Lamp For Moment Yellow Lamp For Moment Red Lamp For Weight Yellow Lamp For Weight Buzzer Relay For Main Contactor Circuit Diagram(PLC Control) Relay For Camera DWG No A02113 Version -a 13 Electrical equipment Electrical equipment 8-59

283 Tower Crane Instruction Manual 63 /2.A PLC3 10K -R PE PE PE PE PE PE Red White Black Red Green Blue + O - 1 Electrical equipment 1 PLC Analog Input Model PLC CAN Model A -PLC4 V1+ I1+ VI1- FG V2+ I2+ VI2- FG V3+ I3+ VI3- FG V4+ I4+ VI4- FG RES+ RES- CANH CANL GND B 64 Red White O PE PE Black CANH CANL V++ Red GND Blue CANH Yellow CANL Green PE PE C -AG1 -AG2 -FS -JD RPH -HG D Load Sensor Anemometer Hoisting Sensor Angle Sensor Circuit Diagram(Sensor) DWG No A02114 Version -a V+ 24V+ 24V+ -PLC2 64 /2.A /2.A4 /2.B4 -PLC1 L N 24V+ 24V- ZOOMLION HEAVY INDUSTRY & SCIENCE 8-60 Electrical equipment

284 Tower Crane Instruction Manual LCD Color Monitor Camera A -LCD2 -CCD AVIN1 AVGND AV AVG M C Z F 960 -RC1 2.7K-1/2W K-1/2W -KA90 -KA91 /13.D5 /13.D KA93 /13.D6 12V 62 /2.B6 B VCC 62 /2.B6 GND 61 /2.B6 12V GND -RC2 -KA92 -KA94 /13.D6 /13.D /2.B6 C -LCD1 -PLC V+ /2.A V- COM1 PORT0 /2.A6 D Graphic Terminal PLC ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Cammera) DWG No A02115 Version -a 15 Electrical equipment Electrical equipment 8-61

285 Tower Crane Instruction Manual Electrical equipment SZL -SZR Slewing leftward -SS Slewing rightward SH Hoist Down SS/-SV -HP -SSF QTC01D-F2 Console Layout -HMA -HF -HML -SSJ -SST -SH/-SD -HLL -HLC -SEM A B Trolley out HP -SSF SV Trolley in SEM -HF SSJ SD Travelling foreward Travelling backward 2 -HML -HMA -HLL -HLC SST:1 -SST: HBZ 783 -RBZ SH,-SS,-SV,-SD -SZL,-SZR 4 2 C HLL 100% Load -HLC 50% Load SST -HBZ Start/Horn Buzzer -SEM Emergence -RBZ Resistance SSF Break/Slewing -SSJ -HML -HMA Console-gear Zero Position -HP Start Indicae 1 -HF Wind Vane Bypass 100% Moment 90% Moment D ZOOMLION HEAVY INDUSTRY & SCIENCE Circuit Diagram(Consoles) DWG No A02201 Version -a Electrical equipment

286 Tower Crane Instruction Manual 1 ZOOMLION HEAVY INDUSTRY & SCIENCE Power Supply A L0 B VP1 UP1 WP1 -XSP1 PE -XPP1 C U1 V1 W1 N PE U0 V0 W0 N PE -QFP1 ME32C QS L1-1 L1-2L1-3 N PE A L1 L100 YC3*95+2*35 E -PP1 YZ3*4+1*2.5 A- Isolate Switch Cabinet B- Electrical Cabinet C- Console(Left) D- Console(Right) H- Graphic Terminal G- LCD Color Monitor CCD- Camera Cabinet D Wiring Diagram(1) DWG No A02202 Version -a 17 Electrical equipment Electrical equipment 8-63

287 Tower Crane Instruction Manual Electrical equipment Slewing Limiter Slewing Eddy Current Horn 1#Load Sensor Angle Sensor Anemometer Camera 2#Load Sensor Hoisting Sensor Moment Limiter Trolley Limiter -AG2 SM1 SM2 SM3 SM4 SVA1 SVA2 -HG -SSL -SSR -YBSE1 -YBSE RPH CCD -FS -JD -AG1 -HH L125 RVVP3*0.5 L112 RVVP7*0.34 L110 L111 RVVP4*0.5 RVVP3*0.5 L109 RVVP3*0.5 L107 L108 YZ2*1.5 YZ2*1 L106 YZ2*1.5 -XP8 -XS8 L105 L104 RVVP3*0.5 L103 YZ2*1 L102 YZ2*1 -XP4 -XS4 L101 -XP34 -XS34 -XP14 -XS14 -XP13 -XS13 -XP12 -XS12 -XP11 -XS11 -XP10 -XS10 -XP9 -XS9 YZ3*1 -XP7 -XS7 -XP6 -XS6 -XP5 -XS5 FTKYR 5*1 -XP3 -XS Blue Red Yellow Green Blue Red Green Black Red White Black Red White CANL CANH N PE PE PE PE ZPE ZPE 4 PE ZPE 4 5 HQ012-P15 HQ012-P9 HQ007-G6 ZDU 4 HQ007-G7 HQ007-G8 HQ012-P8 HA04 HQ012-P8 HQ007-G4 HQ007-G5 HQ007-G3 HQ007-G1 HQ007-G2 R1,10K,1/4W HQ012-P12 HQ007-G11 HQ007-G10 HQ007-G9 HQ012-P11 HQ012-P ZPE 4 PE HQ012-P14 HQ007-G12 ZPE 4 PE B 电气房 HQ012-P XS33 -XS31 -XS19 -XP17 -XS XP33 -XP31 -XP19 -XP18 -XS18 -XS20 RVVP3*1 YZ3*1 YZ3*1 RVVP3*1 YZ3*1 L118 -XP16 -XS16 -XP20 L121 L124 L117 L116 L115 L114 -XP15 -XS15 -XP32 -XS32 FTKYR 5*1 L113 A-Isolate Switch Cabinet B- Electrical Cabinet C-Console(Left) D-Console(Right) H-Graphic Terminal G-LCD Color Monitor -SVFW CCD-Camera Cabinet -SVFC FTKYR 5*1 L120 YZ4*1 FTKYR 5* BN BN BN BN BN BK BU BU BK BK 99 -SVBW -SVBC BU BK BU BK BU -SHDC SQ3 -SQV -SQ S1 Green S2 Yellow S3 Red 265 -SQH SQ SHU -SHUC -SHD Hoisting Limiter Proximity Switch Proximity Switch Proximity Switch Proximity Switch Proximity Switch Trolley Limiter -YSB -YSFB -SSK Three-color Lamp For Alam ZOOMLION HEAVY INDUSTRY & SCIENCE Wiring Diagram(2) DWG No A02203 Version -a Electrical equipment

288 Tower Crane Instruction Manual A Resistance For Hoisting Slewing Motor Cooling Motor For Slew Cooling Motor For Hoist Hoist Brake Hoisting Motor -RHB2 -RHB3 -RHB1 -MS1 -MS2 -MSC1 -MSC2 -MHB -MHC -PP A MH L213 (YZP)4*2.5 L203 -XP23 -XS23 L201 L202 YZ4*1 -XP22 (YCP)3*50+1*25 -XS21 YZ4*1 -XS22 L1 BVR16 L207 YZ4*1 -XP26 -XS26 L206 YZ4*1 L214 (YZP)4*2.5 L200 BVR16 -XP25 -XS25 -XP24 -XS24 YC3*95+2*35 -XP21 B VP UP2 WP2 PE WSC VSC USC WSC VSC USC WS2 VS2 US2 WS1 VS1 US1 WHB VHB UHB WHC VHC UHC WH UH VH PE N W1 V1 U1 PE PE PE TC2003 -HINV HQ012-P PE PE PE PE 90 ZDU 6 ZDU 4 HSB006-F1 HSB006-F1 PE -XSP2/-XPP2 HQ012-P3 HQ012-P2 ZDU 4 HQ012-P1 B -VINV -HINV -SINV -VINV HQ012-P7 HQ012-P6 HQ012-P5 HQ012-P4 ZDU 4 +Vs 0Vs A+ A- B+ B- PE A+ A- B+ B- PE PE PE PE TC1503 0Vs +Vs WVG VVG UVG WVB VVB UVB WVC VVC UVC WV UV VV C XS30 -XP30 -XS29 -XP29 -XS28 -XP27 (YCP)3*25+1*10 L302 L301 BVR10 BVR10 BVR10 BVR10 FTKYR 5*1 L212 YZ4*1.5 L211 -XS27 -XP28 YZ4*1 YZ4*1 L209 L210 L208 -RSB1 -RVB3 -RVB2 -RVB MV -MVG -MVB -MVC -YZB D A- Isolate Switch Cabinet B- Electrical Cabinet C-Console(Left) D-Console(Right) H-Graphic Terminal G-LCD Color Monitor CCD-Camera Cabinet Trolley Motor Trolley Brake Resistance For Trolley Resistance For Slewing Motor For Hydraulic Clamp Cooling Motor For Trolley -PGV -PGH ZOOMLION HEAVY INDUSTRY & SCIENCE Wiring Diagram(3) DWG No A02204 Version -a 19 Electrical equipment Electrical equipment 8-65

289 Tower Crane Instruction Manual G A H G -Cab obligate Electrical equipment L122 YZ2*0.75 L119 H YZ3*0.75 L123 YF-XL20(10m) DWG No A02205 Version -a 20 Wiring Diagram(4) 1 Red White Shield ZOOMLION HEAVY INDUSTRY & SCIENCE B PE COM N1 PE PE C RVV25*1 L204 RVV25*1 L205 D C D B PLC PE ZDU4 ZDU4 ZDU A- Isolate Switch Cabinet B- Electrical Cabinet C- Console(Left) D- Console(Right) H- Graphic Terminal G-LCD Color Monitor CCD-Camera Cabinet 8-66 Electrical equipment

290 Tower Crane Instruction Manual 1 A- Isolate Switch Cabinet B- Electrical Cabinet C- Console(Left) D- Console(Right) H- Graphic Terminal G- LCD Color Monitor CCD- Camera Cabinet ZOOMLION HEAVY INDUSTRY & SCIENCE A B L123 -PLC B B AV G -RC1 -RC2 -CCD COM1 C D Wiring Diagram(5) DWG No A02206 Version -a 21 24V+ 24V PE V GND M Z F C B L119 B L122 L Red Black Power Video1 Video2 H Electrical equipment Electrical equipment 8-67

291 Tower Crane Instruction Manual Electrical equipment 1 ZOOMLION HEAVY INDUSTRY & SCIENCE L N1 PE mm mm mm mm mm mm 2 A Socket For Cab Air-condition Socket For Air-condition Socket For Electrical Room Socket For Power Supply Socket For Electrical Room 1.5 mm MX mm mm 2 1.5mm 2 B Switch Switch Switch EF5 DL3 CL4 Lamp For Electrical Room Lamp For Cab Fan MX2 EY6 1.5mm 2 C Switch EY7 Wiper D Wiring Diagram(6) DWG No A02207 Version -a Electrical equipment

292 Tower Crane Instruction Manual A B -EF1 -QF -QFH -KMH -QFV -KMV C -PV DWG No A02301 Version -a 23 Components Dispose(1) 1 ZOOMLION HEAVY INDUSTRY & SCIENCE -HU D -DCM1 -DCM2 Electrical equipment Electrical equipment 8-69

293 Tower Crane Instruction Manual A -LS -SINV B -LV Electrical equipment C DWG No A02302 Version -a 24 Components Dispose(2) 1 ZOOMLION HEAVY INDUSTRY & SCIENCE -VINV -VINV-EX D 8-70 Electrical equipment

294 Tower Crane Instruction Manual A -BU2 -KAU -BU3 B -TS -TC -SECC -QFHC -QFHB -KHC ME10C ME07C -QFES -QFY -UHR -QF5 -QF6 -UVR -QF101 -KAV1 -QFTS -KAV2 -KAV3 -QF1 -KAV4 -KAV5 -QF2 -KA31 -QFTC -KAVC -KAVB -QFA -KAVEV -KAVR1 -QF3 -KAVR2 -QF4 -KAVGX -QF8 -KAH1 -QF9 -KAH2 -QF10 -KAH3 -KAH4 -KAH5 -QFS -KA21 -KAP -TE -UPV -KSB -KSFB -KSC C32 C3 C3 C1 C3 2C6 -MP -KSL C6 2C10 C10 2C10 C10 C1 -KMSC -KMS -KHB -QFP2 -QFSC -KMC1 -KMC2 ME22C ME07C 2C10 C10 2C10 -KSR -STC -QF402 2C4 -PLC1 -KVC -QFHVG 3D50 3D10 -KVB -QFVC ME07C -KHVG -PLC2 -KASL -KASR C -QFVB ME07C -FRS1 -FRS2 -KAHC -KAHB -PLC3 -PLC4 -LH -HINV D -HINV-EX DWG No A02303 Version -a 25 Components Dispose(3) -BU1 -KA90 -KA91 -KA92 -KA93 -KA94 -KASB -KASFB -KASC -KAMH -KAHR1 -KAHR2 -KAML -KAMA -KALL -KAMV -KAMS 1 TC2003 TC1503 TC3004 -PE ZOOMLION HEAVY INDUSTRY & SCIENCE Electrical equipment Electrical equipment 8-71

295 Tower Crane Instruction Manual Electrical equipment ZOOMLION HEAVY INDUSTRY & SCIENCE CABLE LISE Page 1 of 1 No. Symbol Code Type Toward Length(m) Remark 1 L YC3*95+2*35 A-B \ 2 L YZ A-PP L FTKYR 5 1 B-Moment Limiter 20 4 L YZ2 1 B-Trolley Limiter 12 5 L YZ2 1 B-Trolley Limiter 12 6 L RVVP3 0.5 B-Hoisting Sensor 14 7 L YZ3 1 B-Slewing Limiter 8 8 L YZ2 1.5 B-Slewing Eddy Current 8 9 L YZ2 1.5 B-Slewing Eddy Current 9 10 L YZ2 1 B-Horn 5 11 L RVVP3 0.5 B-Load Sensor 5 12 L RVVP4 0.5 B-Angle Sensor L RVVP3 0.5 B-Anemometer L RVVP B-CCD L FTKYR 5 1 B-Slewing Brake 9 16 L FTKYR 5 1 B-Hoisting Limiter L YZ3 1 B-Proximity Switch L RVVP3 1 B-Proximity Switch L YZ3 1 B-Proximity Switch L FTKYR 5 1 B-Trolley Limiter L YZ B-G 8 22 L YZ4 1 B-Three-color Lamp 8 23 L RVVP3 1 B-Proximity Switch L YZ3 1 B-Proximity Switch L RVVP3 0.5 B-Load Sensor 5 26 L YZ B-PP L (YCP)3*50+1*25 B-Hoisting Motor L YZ4 1 B-Cooling Motor For Hoist L YZ4 1 B-Hoist Brake L RVV25*1 B-C 5 31 L RVV25*1 B-D 6 32 L YZ4 1 B-Cooling Motor For Slew 8 33 L YZ4 1 B-Cooling Motor For Slew 9 34 L (YCP)3*25+1*16 B-Trolley Motor L YZ4 1 B-Cooling Motor For Trolley L YZ4 1 B-Trolley Brake L YZ4 1.5 B-Motor For Hydraulic Clamp L FTKYR 5 1 B-Control Of Hydraulic Clamp L (YZP)4 2.5 B-Slewing Motor 8 40 L (YZP)4 2.5 B-Slewing Motor A:solate Switch Cabinet,B: Electrical Cabinet,C:Console(Left),D:Console(Right),S-LCD Color Monitor 1,H-LCD Color Monitor 2,X-Junction Box for Hoisting,Y-Junction Box for Trolley,Z-Junction Box for Slewing 8-72 Electrical equipment

296 Tower Crane Instruction Manual ZOOMLION HEAVY INDUSTRY & SCIENCE COMPONENT LISE Page 1 of 1 No. Symbol Code Name Num. Site 1 \ A01400 Cable Package with 1 \ Plugs 2 \ A01500 Cable Package 1 \ 3 \ A01300 Main Cable Package 1 \ 4 -LH Filter 1 Electrical Room 5 -LV Filter 1 Electrical Room 6 CCD Camera 1 Tip of the Jib 7 -DCM1/-DCM Rectifier 2 Electrical Room 8 -FS Wind Speed Sensor 1 Top of the crane 9 -HH Horn 1 Under the Electrical Room 10 -HINV Inverter 1 Electrical Room 11 -HINV/-VINV Expansion Card 2 Electrical Room accessories 12 -HM Indicator Light 1 Isolate Switch Box 13 -HU Indicator Light 1 Electrical Room 14 -JD Angle Sensor 1 Jib 15 -KA* Relay 41 Electrical Room 16 -KA* Base of Relay 41 Electrical Room 20 -KAP Three-Phase sequence 1 Electrical Room Relay 21 -KHVG Contactor 1 Electrical Room 22 -KMC1/-KMC2/-KHB/ Contactor 9 Electrical Room KHC/-KSC/-KSB/- KSFB/-KVC/-KVB 23 -KMH Contactor 1 Electrical Room 24 -KMS Contactor 1 Electrical Room 25 -KMV Contactor 1 Electrical Room 26 -QFES Breaker 1 Electrical Room 27 -LCD LCD Monitor 1 Cab 28 -PGH/-PGV Encoder(Φ45) 2 Motor 29 -SHJ Key switch 1 Electrical Room 30 -PLC PLC 1 Electrical Room 31 -PLC Expansion Modle for 1 Electrical Room Input 32 -PLC Analog Input Model 1 Electrical Room 33 -PLC CAN Model 1 Electrical Room 34 -QF Breaker 1 Electrical Room 35 -QF1/-QFTC/-QF3/ Breaker 4 Electrical Room QF8 36 -QFTS Breaker 1 Electrical Room 37 -QF12/-QFE Breaker 2 Electrical Room 38 -QF2/-QF4/-QF9/ Breaker 4 Electrical Room QFA 39 -QF Breaker 1 Electrical Room 40 -QFP Breaker 1 Electrical Room 41 -QFP Breaker 1 Electrical Room 42 -QFHVG Breaker 1 Electrical Room 43 -QFV Breaker 1 Electrical Room Electrical equipment Electrical equipment 8-73

297 Tower Crane Instruction Manual Electrical equipment ZOOMLION HEAVY INDUSTRY & SCIENCE COMPONENT LISE Page 1 of 1 No. Symbol Code Name Num. Site 44 -QFS Breaker 1 Electrical Room 45 -QFH Breaker 1 Electrical Room 46 -QFHB/-QFVC/ Breaker 4 Electrical Room QFVB/-QFSC 47 -QFHC/-QFHB/- QFVC/-QFVB/-QFSC Auxiliary Contacts for Breakers 5 Electrical Room accessories 48 -QFHC Breaker 1 Electrical Room 49 -KAML/-KAMA Relay 2 Electrical Room 50 -KAML/-KAMA Base of Relay 2 Electrical Room 51 -KAU Over-Under Voltage 1 Electrical Room Relay 52 -QS accessories Handle for QS 1 Electrical Room 53 -QF accessories Handle for QF 1 Electrical Room 54 -QS Isolate Switch 1 Electrical Room 55 -R Resistance 1 Electrical Room 56 -RC1/-RC Resistance 2 Camera Box 57 -RHB/-RVB/-RSV Brake Resistance 1 Electrical Room 58 -SECC Eddy Current 1 Electrical Room Controller 59 -SED Emergency Stop 1 Electrical Room 60 -SED Base of Button 1 Electrical Room 61 -SINV Inverter 1 Electrical Room 62 -SLC Limiter Switch 1 Electrical Room 63 -SQ Proximity Switch 1 Hydraulic Pressure Pumping Station 64 -TC Transformer 1 Electrical Room 65 -TS/-TE Transformer 2 Electrical Room 66 -BU Switch Power Supply 1 Electrical Room 67 -BU Switch Power Supply 1 Electrical Room 68 -UVR/-UHR Over Speed Monitor 2 Electrical Room 69 -VINV Inverter 1 Electrical Room 70 -QTC01D Console 1 Electrical Room 71 -XS1/-XS Soccket 1 Electrical Room 72 -XS1/-XS Soccket 1 Electrical Room accessories 73 -XSP1/-XSP Soccket 2 Electrical Room 74 Communication Communication Cable 1 Electrical Room Cable for LCD Monitor 75 Barrier Light Solar Light PV Voltage Meter 1 Cab 77 -AG Load Sensor 1 Electrical Room 78 -LCD Video Monitor 1 Cab 79 -QF6/-QF Breaker 2 Electrical Room Electrical equipment

298 8 Electrical Control System 9 Maintenance and Service To ensure safe and economic operation of the tower crane for a longer service life, it must be properly maintained and lubricated. 9.1 maintenance Daily maintenance (1) Check speed reducers for oil quantity. Fill oil in time. (2) Check wire ropes at different positions for looseness, breakage or being worn-out. Change defective ropes as required as per relevant stipulations. (3) Check brakes for performance and clearance to ensure reliable sensitivity. (4) Check safety guards for reliable sensitivity. (5) Check bolt connections. Re-tighten the bolts once again when they have been used for a certain period of time. (6) Check steel rope head clampers and clips for loose status. Tighten them if loosened. (7) Reject steel ropes, drums, pulleys and hoisting hooks strictly according to the relevant stipulations. (8) Check the rods, web rods and welds of metal structure members for fractures and fissures. Pay special attention to the positions where the paints are peeled. The striation of paint in 45 oblique strings is most dangerous.trace the cause immediately and dress the issue in time. Inspect the connecting bolts and nuts of tower sections, including the connection of Undercarriage tower section and undercarriage. The parts with the diameter of connecting pin bolts of more than Φ20 are specially-made, no substitutes shall be replaced under any conditions. (9) Conduct rust removing and painting of the whole tower crane and its metal mechanisms after completion of their each use in a project. (10) Check if anti- doff of hook safety and credibility. (11) Check if the electrics connectors are oxidized or burned-down. Repair or replace any poor connectors (12) No function failures of limit switches and push buttons. Replace rusted or damaged parts in 289

299 time (13) Be sure that the insulation of electric switches to switch panels meet the relevant requirements, with insulation resistance no less than 0.5MΩ (14) Check if the bolts connecting electric components are loosened: Check power cables and other conducting wires for fractures. Remove the trouble if any Week maintenance (1) Check Trolley wire ropes at different positions for looseness, breakage or being worn-out. Change defective ropes as required as per relevant stipulations (2) Check wearing statu to block assembly of Trolley. Arrive at reject relevant stipulations must replace in time Mmonth maintenance L (1) Check the status of conncetion pin and nearby material (2) Check the bottom three section for no attachment crane. (3) Check the top three section for crane with attachment. (4) Check the A frame arm and turntable connection pin nearby with state of counter jib and counter jib support 9.2 Ordinary troubles, troubleshooting and solution Ordinary troubles, troubleshooting and solution table9-1 No. Trouble Troubleshooting Solution Reducer temperature Lubrication oil deficient or Properly increase or 1 is too hot excessive decrease oil Excessive or deficient grease Properly replace grease The temperature of Re-adjust the clearance 2 the reducer bearings of of bearings is too high Replace bearings 3. 4 Oil leakage from speed reducer Jacking speed is too slow Grease quality very poor Improper axial clearance of the bearings or bearings is already damaged Contacting surface of connections is not tightened enough, sealing rings at shaft ends is worn and damaged a.wor n oil pump, declined efficiency Replace sealing rings Repair or replace the damaged parts 290

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

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

302 8. Moter clogged, causing temperature rise. 6. Adjust clearance as required 7.Check brake for voltage and time-delay for circuit breaker action and remove the trouble. 8.Keepsmoothventilation 293

303 9.3 Assebmlly No Parts Description 1 Wire rope 2 Reducer 3 Rolling Bearing Lubricating location Hoisting rope Trolley rope Gearbox hoisting winch Reducer trolleying mechanism Gearbox slewing mechanism of of of Rolling bearings in the reducer Drum bearing Hook bearings Lubricating varity Graphite Calcium-based grease ZG-SSY Summer: with N220 gear oil Winter: with N150 gear oil Sulphur molybdenum-2# or ZL-2# lithium-based grease 000 reducer grease ZL-3 grease lithium-based 4 Motor bearing All the motors lithium-based grease 5 Pulley Block Pulleys and guiding pulley in the hoisting winc A Frame Hoisting hook Winter:ZG-2 Summer:ZG-5 Lubricating method & duration Grease the rope each after overhaul or medium maintenance Lubricate the reducer after it serves for 240 hrs, Change the oil after working for 1500hrs Replaceing fat in repair lubricate In repair and the oil fall,in time makeup.assure the grease up to snail. Grease the bearings each after they work for 160 hrs, Clean them once after half a year. Change the grease after working for 1500 hrs. Change the grease after working for 240 hr 6 Sliding Bearings Sliding bearings in the trolley traveling mechanism and drum Winter:ZG-2 Summer:ZG-2 Add grease after working for 160 hrs, and conduct cleaning half a year 7 Articulated points of brake lever Two articulated 8 points between arm and tower All articulated points All articulated points the the Machine oil Winter:ZG-2 Summer:ZG-2 Fill oil after working for 56 hrs Before dismantle or installation 294

304 section 9 10 thearticulated points of luffing suspension and jib Hoist machine of Climibing frame 11 Gear connector All thearticulated points sports part All the connectors of mechanisms and gears Wnter:ZG-2 Summer:ZG-5 Wnter:ZG-2 Summer:ZG-5 Calcium-based grease Before dismantle or installation Before dismantle or installation Grease once after a season 12 Pump station of hydraulic erection Oil tank AW46 American ESSO AW46 13 A Frame Calcium-based grease 14 slewing ring 15 Device Of Prevent wire rope to wring thrust bearing ZL-2 grease lithium-based lithium-based grease Add filtered grease after working for 200hrs and change the greaseafter working for 2400 hrs. Add grease after working for 160 hrs, and conduct cleaning half a year Fill oil after working for 50 hrs Add grease after working for 160 hrs, and conduct cleaning half a year 295

305 9.4 Buffer s Maintenance and Service Buffer s structure Fig Buffer s 1- Telescopical par 2- Nut 3 Washer 4 Washer 5 Guiding bush 6 Spring 7 Bolt 8 Spring bush Buffer s Maintenance and Service 1.Please add grease to guide collar to make sure that the telescopic rod can stretch out and draw back freely before assembling buffer. Please check that the telescopic rod head can contact the buffer base on jib 2.Check the lubrication condition of guide collar, add grease every month and check that the telescopic rod can stretch out and draw back freely. 296

306 10 Wire rope 10.1 steel rope basic knowledge (1) Structure of wire rope, wire rope is consist of several wire-steels.shown as fig (2) Direction of wire rope twist(fig 10-2) fig 10-1.Structure of wire rope, (3) Measure the diameter of the wire rope fig10-2 When measure the diameter of the wire rope, please note the correct methods(fig.10-3). (4) Unwinding the wire rope from the reel When winding off, wire rope should be placed on a special bracket and can drill through the wire rope using a steel tube, suspend it with both side wearing rope cover, let the wire rope rotate slowly(fig. 10-4). 297

307 Measure the diameter of the wire rope Fig.10-3 (5) wire rope clamp Fig.10-4 Unwinding the wire rope from the reel 1 Arranging the rope clamp The bulldog grip must be fitted in such a way that the stirrup rests on the dead ropeline and its base plate on the working rope line, see Fig

308 Fig 10-5 Fitting a bullog grip 2number of bulldog grips The minimum number of bulldog grips recommended for every connecting section is as indicated in the following table number of bulldog grips Nominal dimension of rope clamp (mm) (nominal diameter d) ) The minimum number of the rope clamp(suit) )Nominal dimension of rope clamp (mm) (nominal diameter d) The minimum number of the rope clamp(suit) 19 3 >38~44 6 >19~32 4 >44~60 7 >32~ Bulldog grips interval As shown in fig10-6, the distance A between two bulldog grips is about 6~7 times the length of rope diameter. 299

309 fig10-6 Bulldog grips interval 4 The fastening of bulldog grip The load applied on the each bulldog grip shall be taken into account; the bulldog grip farthest from the rope ring cannot be firstly fastened and fixed. The bulldog grip abutting the rope ring (the first rope clamp) should be as close to the rope ring as possible, and the rope clamp shall be correctly tightened without damaging the externa wires. (6) diameter of the wire rope and groove relation The wire rope and groove Fitting relation fig10-7a. Large groove(fig10-7b) add core of wire rope fatigue to break. Small groove(fig10-7c) add core of wire rope to severity wear and tear. Groove radius R and diameter of the wire rope ratio (a)correct (b) error (c) error fig10-7a wire rope and groove relation 300

310 10.2 Wire rope list table 10-2 Wire rope list Designation Specification Diameter(mm) Quntity Note Hoist rope DIEPA B Trolley rope 6 29Fi+1WR Hoist rope length Fig 10-8 total length required for hoist rope 301

311 L=L0+ f 7+f H 其中 L 0 Hoist rope length required for hook lift height 0 in m table10-3 f Falls used H Hook height in m. 7m From hook to end of arm at 7 meter Arm length(m) For example: hoist rope require for crane with 60m arm lenght and 80m hook height at 4falls operation L= =443m The trolley rope length No equivalent arm length to L crane. Length of trolley rope is fixedness at 190 m 10.3 Installing the wire ropeadhere When unwiding rope from the reel we need some operations to prevent the wire rope Being loop kinks or tightened loops bend or adhere to. Before use the wire rope, the user make sure device be fixed and operated. New wire rope style and spec the same as old one. If the wire rope be sliced in long one that all end should be deal with. To prevent wire rope loose Discard criteria of wire rope (1) Property and quantity of broken wires Tables 10-5.and(2)~(19)items are considered in the same.it is the same with all wire. (2) Broken wires at rope end Broken wires at, or adjacent to, the rope end, even if few in number, are indicative of high stresses at this position and can be caused by incorrect fitting of the termination.the cause of this deterioration shall be investigated and, where possible, the rope end shall beremade, shortening the rope if sufficient length remains for further use, otherwise the rope shall be discarded. (3) Localized grouping of broken wires Where broken wires are very close together, constituting a localized grouping of such breaks, the rope shall be discarded. If the grouping of such breaks occurs in a length less than 6d or is concentrated in any one strand, it may be necessary to discard the rope even if the number of wire breaks is smaller than the maximum number shownin Tables

312 (4) Rate of increase of broken wires In applications where the predominant cause of rope deterioration is fatigue, broken wires will appear after a certain period of use, and the number of breaks will progressively increase over time. In these cases, it is recommended that careful periodic examination and recording of the number of broken wires be undertaken, with a view to establishing the rate of increase inthe number of breaks. This premise may be used to propose a future date for rope discard. Number of load bearingwires in all outerstrands of the rope In crane discard and of wire rope and fatigue relate to visible broken wires mechanisms classification M1, M2, M3 or M4 each other twist the same twist 交互捻同向捻 length range mechanisms classification M5, M6, M7 or M8 length range 6d 30d 6d 30d 6d 30d 6d 30d n n n n n n n n 注 : 201 n n n n n n> n 0.08n 0.02n 0.04n 0.08n 0.16n 0.04n 0.08n (1) filler wires are not regarded as load-bearingwires and are not included in the value of n. In ropes having a number of layers of strands, only the visible outer layer is considered in the value of n. In ropes having a steel core, this is regarded as an internal strand and is not considered in the value of n (2) d is nominal rope diameter, unit :mm (5) Fracture of strands If a complete strand fracture occurs, the rope shall be immediately discarded 303

313 (6) Reduction of rope diameter resulting from core deterioration If the steel core ( in a number of layers of strands)be breaken cause rope diameter to decrease, wire rope must discard. Jerkwater be breaken, Especially stress of each strand is balance the usual check no distinct.in the case of intensity of rope greatly debase.so any suggestion of such internal deterioration shall be verified by internal examination procedures. If such deterioration is confirmed, the rope shall be discarded. (7) External wear External wear of rope due to press make rope and rope groove of block or roll to rub. In such case crane load is speed-up and speed-down and rope and block contact very evidence. The External rope wear to plane. Wear make the rope section area decrease and that intension be decrease. The actual rope diameter has decreased by 7 % or more of the nominal rope diameter, the rope shall be discarded even if no wire breaks are visible (8) elasticity fall Under certain circumstances usually associated with the working environment, a rope can sustain a substantial decrease in elasticity and is thus unsafe for further use The person of check find some question to rope That must consult expert of rope. While no wire breaks may be visible, the wire rope will be noticeably stiffer to handle and will certainly have a reduction in diameter greater than that related purely to wear of individual wires. This condition can lead to abrupt failure under dynamic loading and is sufficient justification for immediate discard (9) External and internal corrosion Corrosion of the outer wires can often be detected visually. Wire slackness due to corrosion attack/steel loss is justification for immediate rope discard If there is any indication of internal corrosion, the rope should be subjected tointernal examination as indicated. This shall be carried out by a competent person.confirmation of severe internal corrosion is justification for immediate rope discard. (10) Waviness In the case of waviness fig 10-9, the wire rope shall be discarded, under length of the rope less than 25d,if d1>4d/3 that rope will be discarded. load condition on a straight portion of rope d is the nominal diameter of the rope d1 is the diameter corresponding to the envelope of the deformed rope. 304

314 (11) Basket or lantern deformation Fig10-9 Waviness Ropes with a basket or lantern deformation shall be immediately discarded, shown as Fig (12) Core or strand protrusion/distortion Fig Basket or lantern deformation Rope with core or strand protrusion/distortion shall be immediately discarded,shown as Fig (13) Wire protrusion Fig10-11 Core or strand protrusion/distortion Rope with wire protrusion shall be immediately discarded, shown as Fig10-12 (14) Local increase in diameter of rope Fig10-12 Wire protrusion Local increase in diameter of rope will affect quite long rope.the diameter of rope is increaseed cause of rope core aberrance (under special environment, fibre core will be affected with damp) that bring on no balance to External rope,it will bring about location falseness.if this condition causes the Local increase in diameter of rope the rope shall be immediately discarded, shown as Fig

315 Fig Local increase in diameter of rope (15) Kinks or tightened loops Kinks or tightened loops is a distortion that rope be ring cause no move around the axes and strain. In such case rope be fraied result from twist distance.so rope will be twist very severity that a portion of rope small intensity be remained. wire ropekinks or tightened loops (16) Local decrease in diameter of rope Local decrease in diameter of rope relative to rupture of rope. Especially Check if end of rope to distortion.in such cases the rope shall be discarded immediately shown as Fig (17) Flattened portions Fig Local decrease in diameter of rope Flattened portions of rope which pass through a sheave will quickly deteriorate, exhibiting broken wires and may damage the sheave. In such cases the rope shall be discarded immediately,. fig10-15 the part rope be staved (18) Bends 306

316 Rope with a severe bend will suffer similarly to flattened portions of rope and should be immediately discarded, shown as fig10-16 fig10-16 rope bend (19) Mangle because of thermal effects or electric arc Ropes that have been subjected to exceptional thermal effects, externally ecognized by the colors produced in the rope, shall be immediately discarded Maintenance of wire rope After the rope be used that lack of dressing of grease cause dust and chipping on surface, result from abrasion rope and block. In such case must often clean and dressing of grease. Before put lube of calefaction and engine oil daub on surface rope, make a simple mean that steel wire brush to clean filth on surface of rope. it is recommended that careful periodic examination and recording of rope in the work.except the cleanout and dressing of lube.check abrasion, breake wire,rust of rope and abrasion of hook,blockg roove In case be found the question that shall be immediately discarded. 307