tc5613-6 - operation manual

8/18/2019 TC5613-6 - Operation Manual

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TC5613-6 C2

TC5613-6 VERSION C2

QTZ80 (TC5613-6) Tower Crane

Operating Instructions

Changsha Zoomlion Heavy Industry Science and Technology Development Co.Ltd


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Go through the instructions 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 construction.

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.

Shipped Date


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Contents

Preface................................................................. 0-10-10

Part I Erection of Tower Crane

Erection................................................ 1.1-11.1-49

Dismantling........................................... 1.2-11.2-6

Part II Operation and Maintenance

Safety Operation of the Tower Crane.................................. 2.1-12.1-6

Operation of Mechanisms & Electrical Equipment................ 2.2-12.2-8

Safety Protection Device.................................................... 2.3-12.3-9

Maintenance.................................................................... 2.4-12.4-8

Appendix ....................................................................... 1

Editor

Fu liang

Proofreader Liu yi

Ratifier

Yingxiong Fu


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Preface

Model TC5613-6 tower crane is designed and manufactured by Changsha Zoomlion

Heavy Industry Science and Technology Development Co., Ltd. according to the Chinese

standard of JG/T5037-93 “Classification of Tower Crane”.

The TC5613-6 tower crane is a self-climbing multi-purpose machine with a horizontal

jib, a trolleying mechanism and an upper slewing mechanism. Its characteristics are:

The performance parameters and technical indicator of the crane are at a leading level in

China. The Maximum working radius is 56m and the maximum hoisting height is 220m.

The crane has different working modes such as: outrigger stationary, undercarriage

stationary, mobile and inside climbing, so that it is applied in different construction

projects. The hoisting height of outrigger stationary is 40.5m and the hoist height of the

crane anchored to the building is 220m.

High working speed and good regulated speed performance make the machine working

smoothly.

The main electric elements are used world-renowned products, which service life is 3-4

times longer than China-made counterparts with less failure, simple maintenance and

reliable working.

8 sets of safety devices ensure the tower crane work reliably, and the safety devices are

mechanical or integrated mechanical-electrical products.

The design of the crane is based on the actual situations in China and on the safe-reliable

operation principles. Greatly absorb and adopt the well-established and reliable advanced

technology to enhance its overall technical level at the same time in the world.

Well-established advanced technology adopted as following:


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Importing frequency transformer and realizing stepless speed regulated and frequency

altering make starting and braking smoothly without impact, running safety and reliable.

Electrics manufactured with the technology from TE, France.

Weight limier, height limiter, radius limiter, slewing limiter, slewing brake, traction

brake and similar safety guards are China-made based on the imported technology.

Carriage rope break-proof device (carriage slip-proof) and axle break-proof device;

Rope pay-off system for hoisting mechanism;

Traction rope-tensioning system;

Large-radius hoisting jib suspended by double rigid tie rods, featuring good jib rigidity,

light jib weight, small jib cross-section, small wind resistance and nice-looking

appearance and several jib lengths, it is satisfied different construction needs.

Out-hung operator cabin, featuring excellent field of view, spacious interior and

satisfactory working environment, and advanced inter-active control console, the

operator handles the mechanisms easy and services simply.

Design in complete conformity or superior to the

relevant national standards.

The crane is suitable for use in such large-sized construction projects as high-rise or

super high-rise buildings, bridge and water conservancy projects, large-span industrial buildings, large gymnasiums, and high chimneys and silos constructed with slip form.


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Technical parameters of the tower crane

Technical performance parameters for the whole machine (Table 8-1)

Table 8-1

Hoisting

Slewing Mechanism Group

Trolleying

kNm

Rated hoisting moment

Fall Stationary Anchored

Max hoisting height

Maximum

Working Radius Minimum

t

Max hoisting capacity

Fall

m/min

Speed

Max. Load

kW

Power

Speed m/min Trolleying Power kW

Speed r/min

Slewing Power kW

Working

Pressure MPa Recommended Value

Speed m/min Recommended

Value

Jacking

(Erecting) mechanism

Power kW Recommended Value

Total power kW Excluding Erecting Mechanism

Counterweight

Operation Temperature

Technical parameters of the four mechanisms


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Technical parameters of hoisting mechanism

QS680D(Table 8-2-1)

Table 8-2-1

Maximum traction of the rope N

Specifications

Wire rope

Maximum linear speed m/min 160

Wire

Rope Drum

Rope capacity m (6)(layers6)

Model YZTD225L2-4/8/32

Power kW 24/24/5.4

Motor Speed r/min 1440/720/160

Model YWZ3-315/45-16

Brake

Braking moment N.m 630

Reducer ratio 16.75

Technical parameters of trolleying mechanism (Table 8-2-2) Table 8-2-2

Maximum traction of the rope

Specifications

619-7.7-1550--

619-7.7-1550-- right-twist

Maximum linear speed

44mJib 88 56

50mJib 100 62

Wire rope

Length 56mJib

m

Wire rope112

Wire

rope 68

WireRope Drum

Drum Speed

Model YDEJ132S-4/8-B5

Power kW 3.3/2.2

Motor Speed r/min 1440/720

Reducer

Ratio43

Technical parameters of slewing mechanism (Table 8-2-3)


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Table 8-2-3

Technical parameters of jacking mechanism (Table 8-2-4) Table 8-2-4

Hydraulic

pump

Working pressure

Cylinder /rod diameter

Maximum jacking force

Jacking

cylinder

Jacking speed

Radius and Load Capacity

m Jib’s Radius and Load Capacity

Radius (m) 2fall

Hoistin

gweight

(t)

4

fall

Radius (m)

2

fall

Hoistin

gweight(t)

4fall

Model YTW112M-4B5

Power kW 4.0

Motor Speed r/min 1440

Model

Ratio 195

Reducer

Output rotation moment N·m 10000

Modulus m 12

Number of teeth Z 16

Gear parameter at

output end

Position-changing factor X +0.5

Slewing speed r/min

Slewing ring support 011.45.1250


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44m Jib’s Radius and Load Capacity

Radius (m)

2

fall

Hoisting

weight(t)

4

fall

Radius (m) 2

fall

Hoisting

weight(t)

4

fall


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Radius (m)

2fall

Hoistin

gweight

(t)

4

fall

Radius (m)

2

fall

Hoistingweight

(t)

4

fall


Radius (m)

2fall

Hoistin

gweight

(t)

4

fall

Radius (m)

2fall

Hoistin

g

weight

(t)

4

fall


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Overall dimensions of the crane

Overall dimensions of the stationary crane

Fig.1 Overall dimensions of the stationary TC5613-6 tower crane


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Fig.2 Overall dimensions of TC5613-6 Stationary Tower Crane with Foundation Undercarriage


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Overall dimensions of the crane anchored to the building

Fig.3 Dimensions of Stationary Crane with Foundation Anchor


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Part I Installation of Tower Crane

Chapter I Erecting

Foreword

The user should go through the chapter in detail for proper and prompt erection of the

tower crane.

Cautions of erecting tower

The maximum wind speed atop should be less than 14m/s during crane erecting.

Strictly follow the procedures of crane erecting.

Select a proper mobile crane and slings in accordance with items shown in Table 1-1.

1-1 Table 1-1 Component weight and height

No.

Designation

(kg)

Weight

Traveling

Driving Bogie

Driven Bogie

Total Beam Semi-Beam

Tie Rod of Bottom Frame

Base Section &

Tower Strut

Ballast (1)

Ballast (2)

EQBase Tower Section EQ

EQ7

Tower section EQ

Climbing Frame

Slewing Assembly

Operator Cab

Tower Head

Counter Jib assembly


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First

Block Counterweight

38m Jib assembly

44m Jib assembly

50m Jib assembly

56m Jib assembly

Counterweight of 38 m

Jib

Counterweight of 44 mJib


Jib


Jib

20a 20b 20c

Note20a, 20b, 20c are the remaining counterweights after mounting a counterweight.

The dismountable pins, connecting bolts and nuts for the slewing rings and tower sections of

the tower crane are special-made, which shall not be replaced freely.

Stairs, platform and protecting fence should be installed for safe operation.

The quantity of counterweight blocks shall be provided in accordance with the jib length

(refer to relevant chapter). Jib must be installed after placing one 2.25t counter-weight on

the counter-jib. It is prohibited to place two pieces or more counter-weight on the

counter-jib before installing jib.

After jib installation, it is prohibited to hoist any load before placing specified

counter-weight on the counter-jib.

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


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parts of the crane and overhead power lines shall comply with the stipulations as shown in

Table 1.2-1.

Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be

provided before hand.

Reference size for tower crane erecting site is shown as Fig. 1.2-1.

Drive the trolley to the balance position

before jacking. Slew the jib to the right front of the in-let beam and thenlock the

slewing of tower crane by slewing brake.

It is prohibited to slewing the jib, move the trolley or make the hoist hook up and down

movement during jacking operation.

General layout of tower crane

Assembly relation of main components for

stationary crane (Fig.1.3-1)


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Fig.1.3-1 Assembly relation of main components

1. Foundation

2. Tower Section (a-Section EQ, b-Mast Section EQ,)

3. Climbing frame

4. Slewing ring support

5. Slewing ring

6. Upper support

7. Operator cab

8. Tower head

9. Counter-jib

10. Jib (a=38m, b=44m, c=50m, d=56m)

11. Counter-weight (a=9.85t, b=11.25t, c=13.5t, d=15.3t)

12. Base frame (or undercarriage)

13. Foundation With Undercarriage

The TC 5613-6 tower crane, with embedded anchors or with an

undercarriage, independent hoisting height is 40.5m. 2-fall or 4-fall wire ropes may be used

for hoisting purpose. The tower sections are integral construction of square shaped steel

tube structure. The base section of tower body or the undercarriage is connected to the

foundation.

The lower end of the slewing ring support is the climbing frame, which surrounds the

tower body. According to the construction needs, jacking mechanism can jack the upper

structure of the tower body to let in mast sections for increasing tower crane height.


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Anchored State (shown as Fig.3 and Fig.4)

The maximum hook height can reach 40.5m when crane is stationary with embedded

anchors and 220m when anchored if it is fastened with tie-in onto the building and mast tie

frame. When the height is 110m, hoisting can be done with 2-fall or 4-fall, but if the

height is >110m, only 2-fall can do the job. The required distance between slewing center of

tower and the building is 3.5 meters. As for unusual conditions, please contact Zoomlion for

further consultation

1.3.3.2.1 and 1.3.3.2.2 give consideration to project construction requirements and

force-applied situations of the tower body and anchored frames. They specify the distance

between anchored frame and foundation plane, distance between anchored frames and

suspension height limit above anchored frame. Item 1.3.3.2.3 and 1.3.3.2.3 can satisfy both

ordinary construction needs and facilitate prefabrication of anchored frames most

economically to lower the cost of the tower crane.

With one anchored attachment (Shown as Fig.1.3-2)

The

h1 is the distance from first anchor point to the

foundation surface.

The quantity of tower sections in h1 is:

The height of tower above the anchor point is h0

The quantity of tower sections in h0 is:

Fig.1.3-2

anchored frames or more


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The distance h2 between two anchor points:

The quantity of

tower sections between 2 anchor points is

The height h0of tower above the highest anchor point is

When hook height h is less than100mh0 is the same shown in

1.3.2.1(2).

When hook height h is 100mnamely:n011.5

Fig1.3-3

The least number of anchored frames for the tower crane with embedded anchors (shown as

Fig.3)

With 1 anchored frame, h036.55m, h 68.5m, there are 24 tower sections totally.

With 2 anchored frames, h0m, h 93.7m, there are 33 tower sections totally.

With 3 anchored frames, h0m, h m, there are 41 tower sections

totally.




With 7 anchored frames, h0m, h 202.9m, there are 72 tower sections totally


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With 8 anchored frames, h0m, h 220m, there are 78 tower sections totally

The least number of anchored frames for the tower crane with undercarriage (shown as

Fig.4)

With 1 anchored frame, h036.86m, h 68.8m, there are 22 tower sections totally.

With 2 anchored frames, h035.06m, h 94m, there are 31 tower sections totally.

With 3 anchored frames, h034.26m, h 119.2m, there are 40 tower sections totally.

With 4 anchored frames, h030.66 m, h 141.6m, there are 48 tower sections totally.



With 7 anchored frames, h0m, h 202.9m, there are 70 tower sections totally

With 8 anchored frames, h0m, h 220m, there are 76 tower sections totally

Foundation & Counterweight

Loads on Foundation with embedded anchorsshown

as Table1-3Fig.1.4-1

Fig.1.4-1 Load schematic diagram on the foundation

Fv(kN) Fh(kN) M(kN.m) T(kN.m)

In operation

Out of operation


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Foundation with embedded anchors

Reinforced concrete foundations must be adopted. Basic requirements for the

foundation with embedded anchors as following:

1.4.2.1

The concrete strength grade must not be lower than C35. The ground base must

hard ground and the earth endurance must not be less than the specifications as shown in the

table 1-4

Table1-4 1-4

L

Reinforcing steel bar

of upper layer

Reinforcing steel bar

of lower layer

Earth

endurance

Concrete

Weight

Vertical

reinforcing

steel bar

5300

24-

Lengthwise and

crosswise

Lengthwise and

crosswise

5500

Lengthwise and

crosswise

Lengthwise and

crosswise

The depth of the concrete foundation should be more than 1000mm

Adjust the level of the anchors upper surface to ensure that the planeness tolerance is 1/500.

Embedded Anchors Foundation ouring cncrete diagram of embedded anchors


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Install the embedded Anchors

The installation of the embedded anchors is very important, please install them as

following:

Fasten 4 anchors and the base section together with 12 high-tensile bolts (strength rating

10.9).

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.

Be sure that the number of re-bars around anchors must not be reduced or cut off.

If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside.

EQ

EQ EQ

Gently hoist the whole piece of anchors assembled with the base section EQ so that it is in a

vertical position before placing concrete. Hang plumb lines along the centerline in 2

directions of the base section EQ to ensure that the perpendicularity of the embedded base

section centerline and horizontal plane is less than 1.5/1000.

Concrete filling rate around the embedded anchors must be over 95%.

Installation diagram is shown as Fig.1.4-3.

Foundation Anchor bears the greatest pressure and pull, which should be equipped by the

factory, otherwise the contractor is responsible for the damage caused by incorrectly

prepared foundation anchor or by neglecting the foundation site conditions.

The embedded anchors bear all loads of the crane, so they should be purchased

from our company. Otherwise if the users supply the embedded anchors, you are

responsible for the damage caused by anchors.

It is allowed that the anchors are used one time, and it is forbidden to dig them

out and use again.

(

1.4-4)

Foundation with embedded bolts

Reinforced concrete foundations must be adopted. Basic requirements for the


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foundation with embedded bolts as following:

Dig the foundation to the hard earth (Bearing load should reach the value shown as

Table 1-4), make it level, and then backfill 100mm gravel, after slip-formwork or laying

bricks for the side walls, pour concrete into pre-made reinforced rod net. The concrete block

surface should be 100mm higher than neighboring ground for the drainage of storm water,

then removal the formwork and backfill the neighboring ground with gravels.

Concrete filling rate under pallet should be more than 95%. The upper plane of the four

pallets should be within the same level plane and the pallet are allowed to be inserted into

concrete for 5-6mm.

Fig 1.4-4 Foundation with embedded bolts


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The relative position of the 4 sets of embedded bolts must be correct, and the length

tolerance of the diagonal line should be no more than 2mm after assembling, ensuring the

mounting of the base tower section.

It is allowed to insert pads but no more than 2 pads into the intervals of the base tower

section and the packings. The area of pad should be more than 90% area of the pallet to

ensure that the planeness tolerance is less than 1/750 after installing the base tower section,

and vertical tolerance of central line with level plane is within 1.5/1000.

The embedded bolts should be connected with the reinforcement of lower layer

The bearing load, dimensions L and arrangement of reinforcing rods are shown as

Table 1-3 and Table1-4.

When screwing the embedded bolts, it is prohibitten to knock the wrench with a

sledgehammer.

It is allowed that the embedded bolts are used one time, and it is forbidden to dig

them out and use again. Because the embedded bolts are important parts which bear

the great mass of loads of the crane, we suggest that the bolts should be purchased

from our company. Users fabricate the bolts yourselves, the bolts must conform to the

requirements of drawing. But you are responsible for any damage caused by bolts, if

the bolts are supplied by yourselves.

Foundation for Undercarriage

The ground foundation is the precondition to ensure safe operation of the crane. This

foundation must closely comply with the regulations for different geological conditions. It is

built of 4-blocks as base ballast, made of reinforced concrete. Basic requirements as

follows:

The concrete strength grade shall be no less than C35. The ground under the foundation


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should be solid with the bearing load value specified in the Table 1.4-5. The curing

duration of concrete is more than 15 days

The depth of concrete should be more than 800mm.

The contact level plane between concrete foundation and frame beam should be

calibrated. The level tolerance of four pallets is 1/750.

Dig a pit (1300mm × 1300mm × 400mm) with water drains in the middle part of

4-block foundation for the installing the frame girder.

The relative positions of 4-group embedded bolts shall be accurate to ensure proper

installation.

Hang plumb lines along the centerline in 2 directions of the base section to ensure that

the perpendicularity of the embedded base section centerline and horizontal plane is less

than 1.5/1000.

Concrete filling rate around the four pallets should be over 95.


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Fig.1.4-5 Foundation for Undercarriage

lightning protection

Notes: Not connected with the steel reinforcement of the building foundation.

Counterweight

The counter-weight has two specifications; both are cast with reinforced concrete. For

specific dimensions, refer to Fig. 1.4-6. Basic requirements are as following:

Weigh the counter-weight cast with reinforced concrete. Permitted weight deviation is 2%,

concrete grade no less than C18.

Counterweight should be equipped according to the length change of jib (shown as Table

1-5).

Length change is allowed to change the weight of counterweight, but the weight accuracy of

2% should be secured.


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Fig. Counterweight


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Fig. Counterweight

(Table) 1-5

×

×

Counterweight

Counterweight

××

Counterweight

Counterweight

Erecting

The erection of tower crane shall be conducted only after the concrete strength of

foundation reaches the designed value of 70%.

Erecting sequence shall be conducted in according to Fig. 1.5-1


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1) Tower section 2) Climbing frame 3) Slewing ring

assembly 4) Tower head assembly 5) Counter-jib assembly

6) Counter-jib con-rod 7) 2.250t A block of 2.250t

counterweight 8) operator cab 9) Jib assembly 10)

Jib con-rod 11) () Equip the remaining counterweights

Fig. 1.5-1Installation sequence of stationary crane with embedded anchors

Tower Section Erecting

Structure description

13 EQ7

There are, totally, 14 tower

sections when the hook height is

40.5m, including one base tower

section EQ, 13 tower sections EQ7.

There are a ladder and a platform

in each tower section.

1.5.1-1 EQ7

Fig1.5.1-1 Tower Section EQ7

EQ7 3

There are three bolt joints on the upper and lower ends of each chord of tower section

EQ7,

EQ EQ EQ

EQ 3 EQ 3

Base tower section EQ is divided into the section connected with pre-buried

foundation anchor, which is respectively equipped with three bolt joints on upper and lower


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end of chord, and the section connected the foundation with fang bolts, which is equipped

with three bolt joints at upper end of chord, and a flange at lower end.

,

Be sure that the climbing lugs on the base section are placed perpendicularly to

the building in order to conveniently installing and dismantling the whole tower crane.

Erect two tower sections

1.5.1-2

Fig.1.5.1-2 Erect tower section

EQ7

Hoist a tower section EQ7 (shown as Fig. 1.5.1-2), it is forbidden to hoist on the horizontal

bar. on base tower section EQ7 and screw them together with 12 pieces high-tensile bolts

strength rating 10.9

2) EQ

Hoist a tower section EQ7 onto the base tower section EQ and screw it together with 12

pieces high-tensile boltsstrength rating 10.9

EQ EQ7

Hoist a tower section EQ7 onto the tower section EQ and screw it together with 12 pieces

high-tensile boltsstrength rating 10.9. There are a base tower section EQ, two tower sectin EQ7 onthe foundation.

·


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Tighten all high-tensile bolts with torque up to 1400N·mand each bolt should be equipped

with a washer and two nuts. The loose-proof nut the upper nutshould be fastened

with torque equal to or a little more than 1400N

m

Check the verticality with a theodolitem or a plumb line. The verticality around the main

chord should be within the tolerance of 1.5/1000.

Hoist Climbing Frame

Fig 1.5.2-1 Climbing frame

Structure description(shown as Fig1.5.2-1)

Climbing frame consists of climbing frame structure, platform, climbing stairs,

hydraulic jack system and let-in device for tower section. Its function is jacking and

lowering the tower crane.

Climbing jack is mounted on the beam of rear side of climbing frame (e.g. at the side

of pre-assembled counter jib shown as Fig. 1.5.2-1). Hydraulic pump station is placed on the

platform at one side of jack. 16 wheels are equipped inside of climbing frame. The wheels

support the outside of chord of tower during jack.

For the purpose of safety jack, platforms are provided at the top of and in the middle ofthe climbing frame, including platform on the inlet beam. The worker standing on the

platform during jack can control hydraulic system, inlet tower section and fasten the bolts.


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Hoisting

After pre-assembling the

climbing frame (shown as

1.5.2-2), hoist the frame.

It should be noted that

climbing jack is mounted

at the same side of the

climbing lugs on section.

Enclose the climbing

frame on the outer side of

the mast section slowly

Fig.1.5.2-2 Hoisting Climbing Frame

Place the frame over two tower sections and lower it until the pawl is supported by the

upper climbing lugs of the second tower section (count down up).

,

Fix the jacking cylinder and hoist the hydraulic pump station to one corner of the

platform, connect oil tubes, and check the hydraulic system for normal operation.

Install the Assembly of Slewing Ring

Structure description

The assembly of slewing ring consists of the slewing ring support, slewing ring, upper

support and slewing mechanism. Shown as Fig 1.5.3-1

The lower portion of the ring support is connected to the tower section and the

climbing frame. It is connected to the outer ring of the slewing ring by high-strength bolt at

the upper.

There are flange and platform on one side for the installation of slewing mechanism. On the other side of working platform is welded with a support lug for connection of the

operator cab. There is a support for the installation of slewing limiter on the forepart.


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Fig.1.5.3-1 Slewing Assembly

Hoist and install the assembly of slewing rings

·

·

Check if the torque of M24 high-tensile bolts strength rating 8.8reaches up to

640N.m, and the torque of loose-proof nutsthe upper nutshould be a little more than

or equal to 640N·m.


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Fig. 1.5.3-2hoist the assembly of slewing rings

Shown as Fig. 1.5.3-2hoist the assembly of slewing ring by hooking the four

connecting ears (shoe) at the slewing ring platform.

Put the assembly of slewing ring support on the top of tower. Four-corner marks on slewing

ring support and climbing frame should be aligned during the connection of them.

·

·

Screw them together with 8 pieces high-tensile boltsstrength rating 10.9, and equipping each

bolt with a washer and two nuts. Tightening all the bolts with torque up to 1800N·mthe

loose-proof nut

the upper nut

should be fastened with torque equal to or a little

more than 1800N

m.

Operation of jack system: Jack the climbing frame until it is high enough to be pined

to the slewing ring support with four pins.


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Shown as Fig. 1.5.4-2hoist the tower head onto the upper support. It should be noted that

the vertical side be faced to the direction of jib. (Shown as Fig.1.5.3-1, 1.5.4-1)

Connect the tower head to the upper support with four pieces of 55 pins.

Install Counter-jib

Structure description(shown as Fig.1.5.5-1)

Fig.1.5.5-1 Counter-jib assembly

The counter-jib is welded structure of channel steel and angle steel. There are banisters,

passage and operating platform on it. The counter-jib consists of two sections. The front end

is connected to the tower head with two pins, and the other end to upper of the tower head

with two stiff con-rods.

Its tail section is equipped with the counter-weight, hoisting mechanism. The resistance box

and the electric control cabinet are arranged at the root of the front section. The hoist

mechanism and its own base frame are fixed on the counter-jib by four bolts.

Hoist counter-jib assembly


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Assemble the two sections of the

counter-jib with banisters, passage

and operating platform on the

ground. And fix the hoisting

mechanism, the electric control

cabinet, the resistance box andcounter-jib con-robs onto the

counter-jib. Connect the slewing

mechanism to the temporary

power supply, and slew the portion

above

slewing ring to a position for

convenient mount of the

counter-jib.

Shown as Fig. 1.5.5-2hoist the

counter-jib (Four mounting ears

are equipped on the counter-jib).

Fig.1.5.5-2 Hoist counter-jib assembly

Fig.1.5.5-3 Counter-jib con-rods assembly

Connect the front end of counter-jib to the tower head with pins.


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Shown as 1.5.5-3 for the counter-jib

con-rod schematic diagram, lift up the

counter-jib slowly to a proper position

for smooth connection of the counter-jib

con-rod to those on the tower head.

Connect the con-rods by pins, insert and

open up cotter pins. (Shown as

Fig.1.5.5-4)

Lay down the counter-jib slowly. Lift a

piece of 2.25T counter-weight at the

furthest position of the counter-jib,

shown as Fig.1.5.5-5.

Fig.1.5.5-4 Install counter-jib con-rod

Special Notice:

Be sure of mounting the baffle of the

counter-weight pins against the

counter-weight.

Be sure of mounting the end face of the

counter-weight pin exceeding

the triangle plate.

Fig.1.5.5-5 Hoisting one piece of 2.25T counter-weight


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Structure description (shown as Fig.1.5.6-1)

The cab is a sheet structure, offset at the front

on 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, equipped with

inter-active control console.

1.5.6-1

Fig.1.5.6-1 Operator cab

collocation of control console

1.5.6-2

No.

ico

designation

functions explanation

1

star/ring button

Electronic control system start-control-button

Ring-button.


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2

emergency stop button

In abnormal conditions,urgently cut off power of

control system. At the same time,the button can

be used in normal-stop. The button is anto-lock

only when be pressed down,the machine can run.

3

exceed 100% of working

momentalarm-light

When load-moment exceeds100% of working

moment ,the alarm-light is on.

4


momentalarm-light

When load-moment exceeds 90% of workingmoment ,the alarm-light is on.

5


load alarm-light

When load exceeds 100% of working load ,the

alarm-light is on.

6


load alarm-light

When load exceeds 50% of working load ,the

alarm-light is on.

7

operating indication of the

hook raising

When the handle of right collocation of control

console is at this direction, the hook is running

up.

8

operating indication of the

hook falling

When the handle of right collocation of control

console is at this direction, the hook is running

down.

9

operating indication of

running ahead

When the handle of collocation of control

console is at this direction, the trolley is running

ahead.

10


running back

When the handle of collocation of control

console is at this direction, the trolley is running

back.


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11

slewing/braking button

When the button is turn left ,the slewing brake is

off,jib can slew;when the button is turn right, the

slewing brake is on, jib can´t slew.

12

bypass-button

When changing fall or running trollry inside,

pressing down the button, control-system is out

of the control of position-limiter, hoisting or

trolley-radius-changing can run continuesly.

13

start-indicator light

When the electronic control system is start or run

state, the button is on.

14


turning left

When the handle of left collocation of control

console is at this direction, the slewing is turning

left.

15


turning right


console is at this direction, the slewing is turning

right.

16


trolley-radius-changing

outside


console is at this direction, the

trolley-radius-changing is running outside

17


trolley-radius-changing

inside


console is at this direction, the

trolley-radius-changing is running inside

80

The nosie in operator cab is below 80db when the tower crane in working.

Hoist and install the operator cab


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Mount the electric equipment in the cab and then hoist the cab to the front near right

platform of the upper support (Fig.1.5.6-2). Align it with the hole-position of ear-plate and

connect them with three pins and insert cotter pins.

Alternatively assemble on the ground the cab and slewing ring assembly and hoist the

whole piece once for all.

Fig.1.5.6-2 Hoist operator cab

Install jib assembly

Structure description (shown as Fig.1.5.7-1)

The whole jib is a varied cross-section triangle spatial structure, consisting of ten

sections. Section-to-section is connected by pins for the purpose of convenient installing and

dismantling. The root of the first jib section is connected to the tower head by pins. The

second and seventh sections are provided with two hook lugs, through which jib con-rods

are connected to the tower head. The trolley mechanism is mounted in the 2nd section;

maintenance cage is set at the side of trolley for tower crane installation and maintenance.


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Fig 1.5.7-1 Jib structure

Jib sections should be assembled strictly according to the series number marked on each

section, and the jib may be assembled with various jib lengths of 56m, 50m and 44m

according to the construction requirements. Dismantling the 9th section, the jib length is

50m, and dismantling 5th and 9th sections, the jib length is 44m, and dismantling 5th and

8th and 9th sections, the jib length is 38m, shown as Fig. 1.5.7-2.

Fig.1.5.7-2 Jib assembly

Hoist and install jib assembly

Assemble the jib on the flat sleepers (or supports) near the tower crane. No matter how

many the jib length is, the trolley must at first be mounted on the guide rail on the jib lower

chord.


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Mount the maintenance cage to the trolley and move the trolley as close to the

minimum radius point of jib root (foot) as possible.

Mount the traveling mechanism at the jib root section, let two wire ropes from the wire

drum and let one of them pass over the guide pulley at the jib root, and then fix it at the back

of the trolley. Let the other rope pass over the guide pulley at the middle of jib and head

portions and then fix it at the front of the trolley, as shown in Fig. 1.5.7-3. At the rear of the

trolley is provided with three rope clips. And rope clip compression plates must be on the

side of ropes with force applied. The rope clip interval is 6~9 times of the wire rope

diameter. At the front end of the trolley is provided with tensioning devices. If the traction

rope has become loosened, adjust tensioning devices to tension the rope. The jib root section

is provided with another set of rope tensioning devices. Any loosened rope during its

operation can be tensioned by this tensioning set.

Fig. 1.5.7-3 Trolley Wire Rope Layout Plan

After assembling jib con-rods shown as Fig.1.5.7-4, connect it to the jib hook lugson the upper chord of jib with pins, insert cotter pins, then place jib con-rods on the

bracket of upper chord on the jib.

Check and perfect the circuit connection on the jib. Switch on the temporary power

supply of the slewing mechanism to slew the tower crane superstructure to a position for

convenient installation of the jib.


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Fig. 1.5.7-4 Jib pull rod Diagram

Hang up ropes shown as Fig. 1.5.7-5. Try the ropes for balance. In case of improper

balance, move properly the trolley position. Lift the jib assembly to the mount height. Use

the axle-positioning frame and pins to connect the slewing tower body to the root section of

jib and then fasten the connection shown as Fig. 1.5.7-6. Attention: record the jib lifting

point for reference during tower dismantling.

1.5.7-5

Fig.1.5.7-5 position of hoisting the jib

56

56m Jib

50

50m Jib

44

44m Jib

38

38m Jib


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As for the position of center of gravity during jibs installation with different

lengths (incl. long and short tie rods, traveling mechanism, anti-drop device, and

trolley at the minimum radius), refer to the Table below.

2

8

l

20

When hoisting, 8m

L

20m.

The assembled jib should be supported on the ground by at least 5 supports

during winding wire rope.

Fig. 1.5.7-6 Install jib assembly

Fig.1.5.7-7 Hoisting rope layout for installing jib con-rods


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Reeve the hoisting wire rope according to Fig. 1.5.7-7start hoisting winch while

lifting the jib slowly with a mobile crane till jib-tie reaches hauling plate, then fasten short

and long jib-ties to the Plate I and II at the cat head with pins shown as Fig. 1.5.7-8 and Fig.

1.5.7-9, insert split pin, let off wire rope of hoisting winch and lay down jib slowly.

Fig. 1.5.7-8 Tower head structure at the joint of jib con-rod Fig. 1.5.7-9 Joint structure

After connecting jib con-rods to tower head, dismantle the hoisting rope.

Assemble counter-weight

The weight of counter-weight varies in

proportional to the jib length (Table 1-5).

The counter-weight is hoisted

according to the jib length used.

The counter-weight configuration and

mounting position are strictly acted on the

requirements of four jib-length conditions.

Special Notice:

Be sure of mounting the baffle of the counter-weight Fig.1.5.5-5 Hoisting counter-weight

pins against the counter-weight.


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Be sure of mounting the end face of the counter-weight pin exceeding the triangle plate.

Rope-winding system of hoist

mechanism

Fig.1.6-1 Hoisting rope layout

After installation, wind hoisting ropes. As shown in Fig.1.6-1, the hoisting rope is

released from the wire rope drum, passing through the rope discharging pulley, going

through the guide pulley on tower head, going down into the pulley of overload limiter in

the tower head, runing further to the trolley and hook pulley block. It is finally fixed on the

anti-torsion device at the jib tip by rope clips.

Power on and Trial operation

After the installation of the whole crane according to the above steps, check the

verticality of tower body axis at no wind conditions. The verticality tolerance is 4/1000.

Switch on power to all electric circuits according to the electric circuit diagram and start all

mechanisms for test run. Check mechanism for proper operations (details, refer to relevant

instructions). At the same time, check wire ropes at different locations for normal working

and for any friction with structure member. Remove all abnormal cases. If the tower craneneeds to be put into service immediately after the installation, the safety device must be

adjusted as specified in section3.


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Before keeping the tower crane in balance, hoist one tower section EQ7 onto the

introduction platform and then move the trolley to the reference balance position shown as

Fig. 1.8-1. Hoist one mast section or other weights (The trolley position in table is an

approximate value, which must be adjusted according to the actual situation in jacking).

Then remove all the bolts connecting outriggers of the slewing ring support to tower section

EQ7.

Push the operation handle of the hydraulic jacking system to to jack

the climbing frame to a position where the legs of slewing ring support are just disengaged

from the main chord rod of the tower body.

Check if the outrigger of slewing ring support is on the same vertical line with the chord of

the tower section. Check 16 guide rollers on the climbing frame and tower body main chord

rod to make sure that they have the same clearance. This serves to determine whether or not

the tower crane is in balance. If not, adjust the balance position of the trolley until balance is

achieved so as to drop the center of gravity of the upper tower crane onto the position of

jacking cylinder beams.

Record the balance position of the trolley for the convenience of dismantling. This mark

position varies with different jib lengths.

Operate the hydraulic system to lower down the sleeve frame. Connect the slewing ring

support to tower sections with bolts. Jacking operation (shown as Fig. 1.8-2)

Hoist a tower section EQ7 to the top of inlet platform of climbing frame, install four inlet

rolls at the lower end of tower section EQ7, lower the hook slowly so that the inlet wheels

are seated onto the inlet beam properly, Then remove the hook.

Hoist another tower section EQ7 and drive the trolley to the position for balance.

Use the brake on the slewing mechanism to hold the tower superstructure at a slewing

braking status, thus ensuring no slewing movements.


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Remove the eight bolts connecting tower section to slewing ring support.

Fig1.8-2 Operation of Climbing

·

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 (It should be checked by a specially- designed watchdog). Erect the climbing frame

and the upper part until it reaches the height of 1050mm. Check if there are any strange

sounds, deformation, any self-retreat of piston rod etc, after confirmation, go on to erect

until it reaches the height of half the tower section, the support latches on the climbing

frame pass through a pair of climbing lugs and resets automatically, then retreat the jack to

let the support latches stay at the upper climbing lugs, 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, retreat the piston completely, lift jack beam so

as to support the cradle of climbing lugs. Erect the upper part of tower crane to a height of a

little more than half the tower section so that the space is fit for a tower section, drag the

tower section EQ7 on the inlet platform of climbing frame into upper part of tower, retreat

the jack slightly so that the new tower section EQ7 alight at the top of tower and conduct

proper alignment, remove the inlet wheels, fasten the upper and lower sections with 12

pieces of M30 bolts with torque of 1400kN·m, each bolt must be equipped with two nuts.


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Retreat the jack once more to let the lower of slewing ring support alight at the top of

new mast and conduct proper alignment, then fasten ring support to tower section with eight

pieces of M30 high-tensile bolts, each bolt must be equipped with two nuts. Then a tower

section is mounted. If several sections are to be mounted, just repeat procedures mentioned

aboveAs for proper alignment of slewing ring support with connecting bolt holes, insert

four guiding rods into four bolt holes at the corners of slewing ring support before retreat

the jack.

General Notices of Jacking Operation

Jacking operation is prohibited when the wind speed at the highest top exceeding 14m/s.

Keep the jib in the same direction as the in-let mast section during jacking operation. Stop

the jib with the slewing mechanism brake be sure of the trolley stopping at the

jack-balanced position.

If several tower sections are to be mounted, after mounting a section, all the chords of the

section must be fastened with 8 M30 bolts before hooking another section.

Keep the climbing lugs on the newly added tower section in alignment with those on the

existed sections.

It is prohibited to slew, change work-radius and hoist load without connection of the

slewing ring support to the tower body by 8 M30 bolts.

If the jacking hydraulic system has become abnormal in the course of jacking, stop

immediately the jacking operation, retract the oil cylinder, lower the slewing ring support

onto the top of tower body and use 8 M30 bolts to connect the slewing ring support to the

tower body before removing troubles from the hydraulic system.

When tower section reaches the desired working height, turn the jib to different directions,check if all the joints of the tower section, bolts for foundation are fastened sufficiently with

two nuts.


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Tower anchored onto the building

When the working height of the tower

crane has to be exceeded to its

stand-alone height, the tower body shall

be anchored.

Fig. 1.9-1 Schematic Diagram of Tie Frame

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 370Nm). Anchoring frames are articulated with 3tie-rods on 3 top points. The 3 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 1.9-1).

Load on anchoring points

Table 1.9-1 shows the arrangement of tie rod and the load value of anchored points on

the building under certain position condition of tower crane in Fig. 1.9-1. The customers

should decide how to tie their cranes to the building and conduct necessary partial

modifications according to the load value, specific tie locations, local load capacity on the

building etc.

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


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body suspension section over body. If the tower crane is anchored at the position

different from Fig. 1.9-1, including different arrangement of tie rods or different

dimensions, please contact our company for further consultation, avoiding major

accident.

±

±

±

±

Fig. 1.9-2 Load on the anchored point

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 building.

E

3 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 E during mounting of anchoring

frames and inner tie rods, the height of frames will properly be raised or lowered.

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.

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.

The connection of tie rods to tie frames, foundation and tie frames to the tower body and

inner tie rod shall be reliable. The inner tie rods shall reliably be pressed against the mainchord 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


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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

Preparations before operation

The pre-operation preparations of the tower crane aim are ensuring its correct control

and smooth operation at safe conditions. Main preparations are to check tower crane

components and to test-run safety devices.

Parts and Components Checking

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 shall 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 onthe counter-jib are properly fixed.

Clear the lumber on platforms in

order to prevent them from falling

and avoid injuring persons during

tower crane operation.

Fig.1.10-1The mounting positions of whole crane safety devices

Check lubrication surfaces and points.

Test-run for the safety device


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-Safety devices for the tower crane mainly include the travel limiter and load limiter.

The travel limiter includes the hoisting height limiter, slewing limiter and working

radius limiter.

The load limiter includes the hoisting moment limiter and hoisting weight limiter,

otherwise anemometer. Debugging is shown in the Chapter 3 of the Part 2. The mounting

positions of whole crane safety guards are shown in Fig.1.10-1.

Items-checking after tower erection (Table 1.10-2)

1.10-2 table1.10-2

Item

Contents

Foundation

Check if the foot bolts are fastened

Check safety distance between the surrounding power lines and tower crane.

Check power cable for smooth routing to avoid damage.

Tower

section

Check the bolt connection of tower sections

Climbing

frame

Check its connection to slewing ring support

Check if the guide wheels, latches, pin-bolt-connected parts move smoothly

Check if the walkway and fence are fastened

Upper

support,

slewing ring

support and

operator cab

Check if the bolts connecting slewing ring is properly fixed.

Check power cable for smooth passage

Check if the platform and fence are fastened

Check the connection for operator cab

No storage of

lubrication oils, oil cotton yarns and combustible materials in the cab.

Tower head

Check tie rods of jib and counter-jib tie rods for proper installation.

Check ladders, platforms and protection rails.


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Secure that the hoisting rope is properly wired and arranged

Jib

Check connection pins, washers and cotter pins for correct mounting.

Check if the trolley is properly installed and operates smoothly, check

maintenance cage for fixing.

Check hoisting and radius-changing ropes for winding and fixing

Counter-jib

Check counter-jib for fixing

Check protection rails of the counter-jib and walkway. Ensure no foreign

substances on the walkway

Hook

Check rope off-proof devices of the hook and fall-changing device for safety

and reliability

Check hoist hook group for defects influencing operation

Check specifications and models of hoist ropes and radius-changing ropes for

compliance with requirements.

Check wire ropes for wear.

Mechanism

Check mechanism for installation and operation

Check mechanism brakes for correct clearance adjustment

When trolley has moved to its minimum and maximum trolley

radius-changing locations respectively, make sure if steel ropes on wire drum

have over 3 lays for safety.

Check if the ends of steel ropes are loosened or improper compressed.

Safety

device

Check safety device for proper adjustment as specified in the Instructions

Check all ladders, protection rails and rest platforms for properly fastened.

Lubrication

Check lubrication conditions according to the operation instructions.


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Conduct the following tests

after the erection of tower crane (The following test must be done every time when the

tower crane shifts to a new construction site)

No-load test

Conduct operation tests of each mechanism several times. After that, conduct

combined operation tests three times. No abnormal incidents occur from all mechanisms

during these tests. Brakes, operation systems, control systems, interlocking devices and

limiters shall all act accurately and reliably. In case of any trouble occurrence, remove it

immediately.

On-load test

Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the rated hoist

load at the maximum working radius for tests. No incidents happen during these tests.

Brakes, operation systems, control systems, interlocking devices and limiters shall all act

accurately and reliably.

Stationary tower crane with

undercarriage installed according to the procedures shown as Fig. 1.10-2

Installation of Undercarriage Assembly

Other assembling procedures are the same as tower crane with embedded anchors.

Fig.1.10-2 Installation sequence of stationary tower crane with undercarriage


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Undercarriage installation

Assembly of

undercarriage

Support cross beam assembly (shown

as Fig.1.10-3)fasten it to the foundation

with embedded bolts and channel steel.

Installation of Undercarriage tower

section1 and 2( shown as Fig.1.10-4)

Fig.1.10-3 Assembly of Undercarriage

Install the tower strut

Fig.1.10-4 Assembly of base tower section and strut

Mount the Base Ballast 1,2. The total weigh is 41.5t (shown as Fig.1.10-5)


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Chapter Dismantling

Precautions for tower crane dismantle

Conduct maintenance and test-run for the jacking mechanism before moving the tower

crane out of the construction site.

Check limiters, slewing mechanism brakes and similar devices for reliability during test-run.

It is prohibited to use the slewing mechanism, trolleying mechanism and hosting mechanism

before the tower crane mast sections have been dismantled and the slewing ring support has

not been connected to the tower body by 8 M30 high-tensile bolts.

Check frequently the main stressed parts of the jacking mechanism, as the tower crane

dismantling is a heavy and continuous work for the jacking mechanism.

While the jacking mechanism is working, all operating personnel are required to focus their

attention on observing the relative positions of moving parts for being normal (e.g. between

rollers and main chord rods, between climbing frame and tower body.).

Carry out dismantling when the wind speed is lower than 14m/s at the highest point. Take

care of the stockpile location of dismantled parts because the building has been constructedand working site space is limited during tower crane dismantling. No carelessness in this

operation, otherwise personal safety accidents will be likely.

Procedures of Tower dismantling

Special caution: tower dismantling is a highly technical work, especially thedismantling of the mast sections of tower body, counter-weight, counter-jib and jib.

Any slight neglect will cause machine damage, personal injury or death. End-users are


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therefore required to strictly follow the Instructions-specified rules to dismantle these

components. Tower operators shall have been trained and with certificates.

Notice

Pay great attention to the two climbing latches during inlet or dismantle of

tower section EQ7. Inspect if the latches are still in proper level condition.

Move the tower crane to the

dismantling area where there shall beno obstacles influencing the operation.

Carry out tower crane dismantling

according to the sequence as shown in

Fig.2.2-1. Its steps are in opposition to

the steps of tower crane erection.

Strictly follow the Instructions

specified rules in all cases.

Lower down the tower sections

(dismantle anchored devices if any).

Fig.2.2-1 Dismantle of the tower crane

Dismantle counter-weights from counter-jib. (Keep one piece of 2.25t counter-weight).

Dismantle the jib.

Dismantle the last counter-weight.

Dismantle the counter-jib.

Dismantle the operator cab (or dismantle it together with the slewing assembly).

Dismantle the tower head.

Dismantle the slewing ring assembly.

Dismantle the climbing frame and the remanent tower sections.


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Dismantle the tower sections(shown as Fig. 2.2.1-1)

Slewing the jib to the direction for the let-in section (i.e. the opening side of climbing frame)

and place the slewing brake at a braking status, make the tower crane at a balanced jacking

status, and the trolley staying at the balanced position (i.e. in conformity to the balanced

position of the trolley when additional sections are jacked during tower crane erection)

;

Remove the upper and lower bolts connecting of the top tower section EQ7, connect inlet

wheels on the below section.

;,

Extend the jacking cylinder to place the pin bolts onto the slot of the 4th lug counting from

up down. Insert safety pins, jack the superstructure until the bottom of the trolley is movedto 20~50mm away from the top of the section.


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Hoist the jib lightly and fix the ropes onto pins on the tower head. Start up the hoist

mechanism slowly to make the head of con-rod close to the tower head. Remove the pins

connecting con-rod frame with the tower head, lower con-rods onto the jib and fix them.

Remove wire ropes, remove pins connecting jib with slewing tower body.

Lower the jib and lay it down on the sleeper-cushioned support.

Dismantle counter-jib

Hoist down the last counter-weight. Hoist the counter-jib through 4 hook lugs on the

counter-jib to make the jib tie rod at a loosened status. Remove connecting pins of tie rod

and then dismantle the connections between counter-jib and slewing tower body. Hook the

counter-jib down onto the ground.

Dismantle operator cab

Dismantle tower head

Before dismantling, check the tower head to see if component-to-component is still

connected by power cable.

Dismantle slewing assembly

,

Support the lug changing rods of climbing frames on the tower body and then

dismantle the connection of the slewing ring support with the climbing frame and tower body. Hoist the slewing assembly for dismantling.

Dismantle the climbing frame and tower sections

Slowly hoist the climbing frames out along the mast section main chord rod and place them

down onto the ground.

Hook down the tower sections one by one.

Dismantle of the Undercarriage Assembly


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Dismantle the undercarriage assembly in reversed way of installation.

Attention after tower crane dismantling

The dismantled crane needs to be checked and maintained by technical personnel and

trained maintenance personnel.

Check main stressed structural members for metal fatigue; weld fissure, structural

deformation, etc. Check tower crane parts for damage or collision injury.

After completion of checks, repair the defects found and defects potential. Carry out rust

removing and painting.


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Chapter

Safety Operation

Crane operator and hoist man

The trained crane operators and hoist men are required to strictly follow the regulations as

specified in The Operating Instructions for Tower Crane.

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.

Operate the crane strictly according to the hoist characteristics provided in the Instructions.

No over-load operating.

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.

It is prohibited to pull, or hoist objects in an inclined way, or hoist the staggered or squeezed

objects and or hoist the objects buried in soil or frozen on ground.

Operators and hoist men are not permitted to leave their working posts while objects are

being hung in the air.

Commanding signals, hand gestures and flag signs shall conform to the specifications.

Operators are required to carefully operate and maintain the crane, as well as to keep work

shift-changing records.

It is prohibited that the operator is drunk, ill or tired on working.


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Mechanical part and others

Working environment temperature for the crane is in the range of -20~+40, wind speed

at the highest working point should be smaller than 20m/s.

All the tower safety guards shall be maintained constantly. No moving and dismantling of

them freely. No over-load operation.

The construction site shall be provided with adequate lighting facilities for night operation.

After the tower crane has been overhauled and transferred to a new site and before

re-erection, observe the following:

Check the articulations for pins cracks, rusting corrosion and damage.

Check the rigid tie rods, wire ropes, pulleys, hoist hooks, fall-changing devices, etc. for

conformity to operating conditions.

Check the metal structure members for deformations and weld fissures to make sure of their

conformity to operating conditions.

Conduct trial operation for the mechanism of hoisting, jacking, slewing,

trolley-radius-changing until they have become normal.

Switch off the main power supply when the crane operation is to be stopped for repair or

maintenance. No operation with power on.

Dispatch special persons at the ground, platform and construction work face to direct crane

operations and contact the operator. Signals hand gestures, flag signs, etc. are absolutelynecessary. Better to carry out communications by walkie-talkie.

Assure the working voltage of the tower crane at 380V±10% range, otherwise crane

electrics will be damaged easily.

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.

Provide a proper crane layout plan without spatial interception and interference from

another when several cranes have to work at the same construction site.


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When the operator has switched on power and entered the cab, he should make overall

checks of push buttons, operation handles for non-service conditions. He is not permitted to

press the master push-button until OK confirmed.

The operator must operate the crane strictly according to its technical characteristic

diagrams and hoisting characteristic curves. No over-load operation or forced operation.

During crane working, avoid the hoisting hook touching the ground, causing rope on the

wire drum in an irregular order. If the hook has to be on the ground, pay attention to drum

rope arrangement when it rises again. Make a regular rope arrangement if necessary.

The cage fixed on the side of the trolley is for maintenance. When maintenance of some part

of the jib is necessary, the maintenance person can stand in the cage and do the maintenance

work along with the trolley. The load capacity of the cage is 100kg. No person standing in

the cage when heavy objects are being hoisted. During the assembling of the jib on the

ground and tower erection, cage-to-hoist trolley must be checked for proper connections and

reliability.

When mechanisms are required to operate in a reverse direction, it is necessary to wait for

the motor to stop its clockwise rotation before counter clockwise rotation start.

If the tower crane is found abnormal, stop the crane and switch off the power supply. Do not

operate the crane again until the troubles have been identified and removed.

After crane operation completion at each shift, lift the hoist hook higher than the height of

the highest surrounding obstacle, retract the trolley at the smallest radius and keep the

slewing brake at an open status. The operator cannot leave his post until the power supply

has been switched off.

Before work start at each shift, the operator is required to carry out routine checks of the

pins of such key components as the tower body, jib, slewing support, rigid jib tie rod,


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Routine check of high-strength bolt

Preparations of high- strength bolt before tower erecting

It is necessary to check these high-strength bolts of connecting tower sections and

slewing assembly before using. And it is necessary to clean the bolts, nuts and washers with

kerosene oil. It is prohibited to use damaged bolts (including rust bolts).

Before using, it is necessary to coat the MoS2 grease on contact surfacs of the bolts,

nuts and washers to equilibrium friction.

Tighten the high-strength bolts

The tighten torque on the nuts must reach the specified torque and the torque of loose-proof

nutsthe upper nutshould be a little more than or equal the specified torque.

Check after installing

Check all bolts 2 times in a week, then one time in a week, then one time in two weeks,

and then one time in a month after erecting the tower crane. Dismantle 2-3 bolt groups each

year and check them for deformation, corrosion, rust, etc.

Repeat usage

The high-strength bolts can be used many times, but agreed with the requirements of

the above item 1.3.1 and the item 1.3.2.

Routine check of wire rope

The wire ropes used in hoisting machinery are easily-worn parts. Lack of proper

maintenance is one of the causes for their short service life.

Carry out timely cleaning of wire ropes and applying of lubrication oil or grease to them.


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Watch over their visible parts as much as possible on each workday so as to find any

damages and deformations. Particularly care about the fixed ropes on machinery. When

finding any apparent changes, report to the person in charge. And such person shall carry

out checks according to item 2.4.2 in The Practical Regulations for Checking and

Rejecting of the Hoisting Machinery-Used Wire Ropes.

Watch over the wire rope on trolley and hook as much as possible on each

workday so as to find that rope is out of the pulley or not. If the rope is out of the

pulley, stop working and wind the rope again.

Chek the wire ropes one time every week.


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Release the height limiter and radius limiter. Arrange the wire ropes of the trolley to match

mechanical erection.

Test-run (debugging) of hoisting mechanis:

Operate the hoisting handle to watch the hoisting operation. When pulling the handle

inwards, the hoisting hook shall move upwards. When pushing the handle outwards, the

hook shall move downwards. If not so, adjust the phase sequence of power supply of the

hoisting motor to meet the above requirements.

After completion of hoisting test-run, operate the slewing handle and

trolley-radius-changing handle respectively. When pushing the handle to the left, the jib

shall slew to the left. When pushing the handle to the right, the jib shall slew to the right.

When pulling the radius-changing handle inwards, the trolley shall travel inwards. When

pushing the handle outwards, the trolley shall travel outwards. If not so, adjust the phase

sequence of power supply of respective motor to meet the above requirements.

Notice for proper operation

After power supply to the operator cab (before pneumatic switch on), power for the aerial

light and lighting in operator cab can be supplied through switches on the control panel. The

sockets are also available for fan plugs.

Press start-button, and all operating handles shall return to zero, so as to power on the

master contactor.

To prevent reversed slewing or emergency stop from any damage to the tower crane,

electrics are provided with time-delayed devices. When the jib slews to the right (or left), it

cannot immediately slew to the left (or right) at a rated speed. Several-second delay is

necessary. After the slewing handle returned to zero, immediate braking cannot be done due

to several seconds delay.


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No braking and emergency stop at revered slewing though the crane is equipped with

above-mentioned time-delay device.

Before jacking, check the rotation direction of pump station motor in conformity to your

requirements. If not, adjust the rotation to the correct direction. It is prohibited to slew, hoist

and change working radius during jacking. This aims at accident prevention and no breaking

of the power cable due to twisting.

No free adjustment of the time-delayed relay and over-current relay in the control cabinet,

they have been adjusted in the factory as specified. Any component replacements should be

conducted according to the instructions for the electrical system.

Working mechanisms of tower crane

tc5613-6 - operation manual

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