Tc6016a-8 Instruction Manual

Changsha Zoomlion Heavy Industry
Science and Technology Development Co. Ltd.
INSTRUCTION
HANDBOOK
PRODUCT TYPE: TOWER CRANE
PRODUCT MODEL: QTZ125（TC6016A-8）
SERIAL NUMBER:
User Manual Form

Issue Date: Prepared by: Approved by:
No:
Ex:
Page:1 / 123
TABLE OF CONTENTS
1- Product Description..............................................................................3
2- Foundations, Counter-weight and Center Ballast ..............................12
3- Installing .............................................................................................27
4- Adjusting ............................................................................................66
5- Operation ...........................................................................................80
6- Maintenance Instructions ...................................................................96
7- Electronic .........................................................................................110
APPENDIX
A.1 Crane log .......................................................................................111
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Introduction
Notice:
﹣Intended use
Operation voltage ～400V(±5%) 50Hz
Operation Temperature(℃) －20～＋40
Operation above sea level height (m) ≤1000
Operation humidity 30~95%
Deposited Temperature (℃) -25~70
Transportation Temperature (℃) -25~55
﹣Prohibited (Improper) use
Can't be used under the explosive circumstance，including the thunderous weather；
Can't be used under the lower visibility，including the situation that the wind speed is
higher than regulation capacity.
This manual is intended to help you operate the crane safely and to make full use of
all its permitted facilities and methods of working. The manual also provides
information on the operating principle of major assemblies and systems, and can be
consulted if spare parts have to be ordered.
Please ensure that only trained and qualified personnel are employed on this crane.
The operating instructions and all relevant legal requirements and similar directives
(for example accident prevention regulations) must be complied with.
Disregarding these instructions may cause accident or injury.
Special attention must be paid to the safety devices installed on the crane. They must
be regularly checked to ensure that they are in good working order. The crane must
not be operated if they have failed or become unreliable. Always remember: Safety
first!
If you receive any further information on the crane from us, for instance
technical information circulars, always note the contents carefully and insert
the information in the relevant section of the manual without delay
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1- Product Description
△Product type and model, type designation
■ Product type: Tower Crane
■ Product model: QTZ125 (TC6016A-8)
■ Type designation:
TC 60 16 A - 8
Max hoisting capacity (8t)
Remodel
The rising weight of the longest end of the jib is 1.6t
Maximal Jib (60m)
Tower crane
△Technical Specification Table

●Technical performance parameters for the whole machine
Hoisting M4
Mechanism Group Slewing M5
Trolleying M4
Rated hoisting moment (kNm) 1250
Working Radius（m） Maximum 60 Minimum 2.5
Outrigger Undercarriage
Anchored
Max hoisting height（m） Stationary Stationary
60 61 220
Max hoisting capacity（t） 8
Model QE8100D2
Fall α=2 α=4
hoisting
Weight/Speed
2/100 4/50 4/50 8/25
t/(m/min)
Min stable lowering
≤5
speed at 2 fall（m/min）
Power (kW) 37
Speed (m/min) 0~55
Trolleying
Power (kW) 5.5
Speed (r/min) 0~0.7
Slewing
Power (kW) 5.5×2
Speed (m/min) 0.56
Jacking(Erecting) Power (kW) 7.5
mechanism Working Pressure 31.5
（MPa）
Max Working
30 35 40 45 50 55 60
Radius（m）
Counterweight
Counter-weight
7.65 9.6 11.55 13.2 14.85 16.8 18.75
（t）
Total power （kW） 53.5＋2×5.5 （Excluding Erecting Mechanism)
Operation Temperature（℃） -20~+40
Noise in service (dB) 97
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●Technical parameters of the four mechanisms
▼Technical parameters of hoisting mechanism QE8100D2
Model QE8100D2
Maximum traction force N 27190
Wire Specification 35x7-14-1770
-rope Maximum linear speed m/min 200
Max drum Speed r/min 91.64
Drum
hoisting
Rope capacity m 610 (6 Layers)

Model YZRDW250L-4/8
Motor Power kW 37/37
Speed r/min 1425/725
Reduction-gear model J781C-20.34
Model YWZ3 -315/90-16
Brake
Braking Moment N.m 1250
▼Technical parameters of trolleying mechanism BP55B
Item Units parameters
Mechanism type BP40B
Maximum traction force N 5670
Specification 6x19-7.7-1550- right-twist
30m jib 68 44
Maximum 35m jib 78 49
traction of
the wire 40m jib 88 54
rope Wire
Length 45m jib m 98 Wire ropeⅡ 59
ropeⅠ
50m jib 100 64
55m jib 118 69
60m jib 128 74
Drum Speed r/min 0~ 40.9
Model YEJ112M-4B5
Motor Power kW 4.0
Speed r/min 1430
Ratio of Reduction Gears 43
Braking moment N. m 80
▼Technical parameters of slewing mechanism
Model YTW132S-4B5
Motor Power kW 5.5
Speed r/min 0~1440
Model XX5—130.195CLA-12/16
Slewing mechanism
Reduction Gear Ratio 195

Gears Output rotation moment N.m 13000
Output rotation speed r/min 0~7.1748
Gear Modulus m 12
parameter Number of teeth z 16
at output
Profile shift coefficient x +0.5
end
Overall Gear Ratio 1596.56
Slewing Speed 0~0.8
Model of Mechanism HPW55B.130
Page:5 / 123
▼Technical parameters of jacking mechanism
Power kW 7.5
Motor
Speed r/min 970
mechanism
Hydraulic Flow L/min 11.25

Jacking
pump Working pressure Mpa 31.5

Cylinder /rod diameter mm 160/110
Jacking
Maximum jacking force t 63
Cylinder
Jacking Speed m/min 0.58
Radius and Load Capacity

﹡30m Jib
Radius (m) 2.5 ～18.03 19 20 21 22 23 24 25 26 27
Hoisting 2 fall 4.00
weight (t) 4 fall 8.00 7.53 7.09 6.69 6.34 6.01 5.71 5.44 5.19 4.96
Radius (m) 28 29 30
weight (t) 4 fall 4.74 4.55 4.36
﹡35m Jib
Radius (m) 2.5 ～18 19 20 21 22 23 24 25 26 27
weight (t) 4 fall 8.00 7.51 7.08 6.68 6.33 6.00 5.70 5.43 5.18 4.95
Radius (m) 28 30 32.78 34 35

Hoisting 2 fall 4.00 3.82 3.69
weight (t) 4 fall 4.74 4.35 3.90 3.72 3.59
﹡40m Jib
Radius (m) 2.5 ～18 19 20 21 22 23 24 25 26 28
weight (t) 4 fall 8.00 7.51 7.07 6.68 6.32 6.00 5.70 5.43 5.18 4.73
Radius (m) 30 32.7 34 36 38 40
Hoisting 2 fall 4.00 4.07 3.66 3.3 3.09
weight (t) 4 fall 4.35 3.90 3.72 3.46 3.23 3.02
﹡45m Jib
Radius (m) 2.5 ～18 19 20 21 22 23 24 26 28 30
weight (t) 4 fall 8.00 7.51 7.07 6.68 6.32 6.00 5.70 5.18 4.73 4.35
Radius (m) 32.75 34 36 38 40 42 44 45

Hoisting 2 fall 4.00 3.82 3.56 3.33 3.12 2.93 2.76 2.68
weight (t) 4 fall 3.90 3.72 3.46 3.23 3.02 2.83 2.66 2.58
Page:6 / 123
50m Jib
Radius (m) 2.5 ～17.82 19 20 21 22 24 26 28 30 32.44
weight (t) 4 fall 8.00 7.43 6.99 6.60 6.25 5.64 5.12 4.68 4.30 3.90
Radius (m) 34 36 38 40 42 44 46 48 50
Hoisting 2 fall 3.78 3.52 3.29 3.08 2.89 2.73 2.57 2.43 2.30
weight (t) 4 fall 3.68 3.42 3.19 2.98 2.79 2.63 2.47 2.33 2.20
55m Jib
Radius (m) 2.5 ～17.47 18 19 20 21 22 24 26 28 30
weight (t) 4 fall 8.00 7.73 7.26 6.83 6.45 6.10 5.50 5.00 4.56 4.19
Radius (m) 31.78 34 36 38 40 42 44 46 48 50 52

Hoisting 2 fall 4.00 3.68 3.43 3.20 3.00 2.82 2.65 2.50 2.36 2.24 2.12
weight (t) 4 fall 3.90 3.58 3.33 3.10 2.90 2.72 2.55 2.40 2.26 2.14 2.02
Radius (m) 54 55
Hoisting 2 fall 2.01 1.96
weight (t) 4 fall 1.91 1.86
60m Jib
Radius (m) 2.5 ～16.6 17 18 19 20 21 22 24 26 28
weight (t) 4 fall 8.00 7.78 7.28 6.83 6.43 6.07 5.74 5.17 4.69 4.28
Radius (m) 30.16 32 34 36 38 40 42 44 46 48 50

Hoisting 2 fall 4.0 3.72 3.45 3.21 3.00 2.80 2.63 2.47 2.33 2.20 2.08
weight (t) 4 fall 3.90 3.62 3.35 3.11 2.90 2.70 2.53 2.37 2.23 2.10 1.98
Radius (m) 52 54 56 58 60
Hoisting 2 fall 1.97 1.87 1.77 1.68 1.60
weight (t) 4 fall 1.87 1.77 1.67 1.58 1.50
This curve is according to the data 60m which would be the highest altitude.When the altitude
is higher than 60m, diversified ranges of the rises will decrease graduly along with the
additions of the altiude.
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△Crane transport
The crane components have been constructed to be broken into modules to simplify
packing and handling for different means of transport(railway carriages, containers,
trucks etc.).
1、All components must be well secured tothe means of transportation.
2、Light modules must be placed on the top Of heavy ones.
3、To prevent damages to the paintedsurfaces,
place padded or woodenseparating material
between the elements.
4、Make sure the crane components are not in
direct contact with the ground during the
unloading phases to prevent impurities
(sand, earth etc.) from entering the mounting
holes.
5、Do not use unsuitable means of transport to move the crane parts, such as bulldo-
-zers or lift trucks.
A detailed description of the weights and dimensions of the ZOOMLION crane com-
-ponents is given in the following pages.
a、Before transporting crane, allways make sure all auxiliary equipment is safety stow-
-ed away.
b、Inspection of all loose parts fasteners.
c、Check transportation tie-downs.
d、While using public streets, observe the applicable rules.e、While passing under-
-passes, bridges,tunnels be mindful of ample clearances.
Packing list
No. Designation Weight (kg) Figure dimension（L×B×H）
1 Jib Section Ⅰ 1218 10000×1486×1300
Jib Section Ⅱ 1110 10000×1486×1300
Jib Section Ⅲ 501 5000×1486×1300
Jib Section Ⅳ 800 5000×1486×1300
Page:11 / 123
Jib Section Ⅴ 772 10000×1486×1300
Jib Section Ⅵ 396 5000×1486×1300
Jib Section Ⅶ 670 10000×1486×1300
Jib Section Ⅷ 140 600×1486×1300
2 Counter-jib sectionⅠ 880 1500×6000×600
3 Jib con-rod 465 280×180×8320
4 Counter-jib con-rod 145 260×160×3250
5 Counter-jib sectionⅡ 1305 7502×1600×650
6 hydraulic pump 400 450×650×950
7 Operator Cab 600 1250×1950×2100
8 Trolley 400 1750×2300×900
9 Lifting hook 282 1600×930×380
10 Upper & below support 5300 2760×2760×2550
11 Tower head 1700 1600×1700×7200
12 Main control cabinet 400 1700×520×1900
13 NO.1 box 430 1000×1000×1000
14 NO.2 box 800 1000×1000×1000
﹣Intended use
Operation voltage ～400V(±5%) 50Hz
Operation Temperature(℃) －20～＋40
Operation above sea level height (m) ≤1000
Operation humidity 30~95%
Deposited Temperature (℃) -25~70
Transportation Temperature (℃) -25~55
﹣Prohibited (Improper) use

Can't be used under the explosive circumstance，including the thunderous weather；
Can't be used under the lower visibility，including the situation that the wind speed is
higher than regulation capacity.
△Lightning Protection
Before setting into operation the operator has to consider the necessity of lightning
protection measures and/or earthing measures concerning electrostatic charge and, if
necessary, he has to carry out the appropriate earthing measure!
Whether or not the crane has to be provided with a lightning protection depends on
the regulations and specifications of the appropriate supervising authority, on the
rules for prevention of accidents of the employer's liability insurance association, on
Page:12 / 123
the recommendations of the property insurance companies etc., and on the request of
the building owner.
Notes: Not connected with the steel reinforcement of the building foundation.
●The rails must be earthed at both

ends. If the rail track is more than
20 m long, additional earthing points
should be installed every 20 meters.
If there are no other earthing devices
available one earthing rod which
must be driven at least 1.5 m into the
ground will suffice for each point.
Bolt M10 with Earthing rod which
●If there is steel rod or mat reinforcement inspring
the foundation
washer must be driven at
of the building, there must be placed a
connection link between the reinforcement and one rail. Climbing cranes must be
connected twice.
●Equipment, machines, metal pipes within 20m of the rails of the tower crane track
must be linked to the rails.
●Rail joints assembled by steel fishplates do not need to be bridged for lightning
protection.
●In order to protect the electrical equipment of the components, we recommend
installing over voltage arresters at the mains supply connection.
Page:13 / 123
2- Foundations, Counter-weight and Center Ballast

2.1 Foundation
2.1.1 Loads on Foundation with embedded
anchors（shown as Figure 2-1）
table 2.1
Load
Horizontal Vertical Bending Torque
Force Force moment Mn(kN.
Con-
Fh(kN) Fv(kN) M(kN.m) m)
-ditions
In service 31.05 740.6 3085 385
Out of
116.9 680.3 3830 0.0
service
Note: Fh, Fv and bending moment M in Table 2.1 refer Figure 2-1 Loads on Foundation
with embedded anchors
to the load at max bending moment of foundation. Torque
Mn refers to the load at max torsion moment of foundation.
2.1.2 Foundation for stationary with embedded anchor (shown asFigure.
2-2)
The ground foundation is the precondition to ensure safe operation of the stationary tower
crane. This foundation must closely comply with the regulations for different geological
conditions. Reinforced concrete foundations must be adopted. Basic requirements as
follows:
2.1.2.1 The soil below foundation must be tamped solid. The concrete strength grade
must not be lower than C35. The earth endurance must not be smaller than the
specifications as shown in table 2.2 and figuer2-2
2.1.2.2 The depth of concrete foundation must be no less than 1400mm
2.1.2.3 The upper plane of the four embedded anchors should be within the same level plane,
the planeness tolerance is less than 1/1000.
Table 2.2
Reinforcing steel Reinforcing steel
Earth
bar of upper layer bar of lower layer Concrete Vertical
endurance Weight T
L(mm) Lengthwise and Lengthwise and M3 reinforcing
Mpa
crosswise: crosswise: steel bar
Each side Each side
6500 32-φ25 32-φ25 0.16 59.15 142 256-φ12
7000 32-φ25 32-φ25 0.124 68.6 164.6 256-φ12
Page:14 / 123
figure 2-2 foundation with embedded anchored
2.1.3 Install the Embedded Anchor

The installation of the embedded anchors is very
important, please install them as following:
2.1.3.1Fasten 4 anchors and the base section to-
-gether with 16 high-tensile bolts
2.1.3.2 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 climbing lug on the
base section is placed perpendicularly to the buil-
figure 2-3 the embedded
anchors
Page:15 / 123
-ding in order to conveniently installing and dismantling the whole tower crane.
2.1.3.3 Be sure that the number of rebars around anchors must not be reduce or cut off.
2.1.3.4 If it is difficult to pass through the anchor,the main reinforcing rod can be turned
aside.
2.1.3.5 Gently hoist the whole piece of anchors assembled with the base section so that
it is in a vertical position before placing concrete. Hang plumb lines along the ce-
-nterline in 2 directions of the base section to ensure that the perpendicularity of
the embedded base section centerline and horizontal plane is less than1.5/1000.
2.1.3.6 Concrete filling rate around the embedded anchors must be over 95%.
2.1.3.7 Installation diagram is shown as Fig.2-3.
NOTICE:It is allowed that the anchors are used one time,and it is forbidden to dig
them out and use again.
2.2 Undercarriage stationary

2.2.1 Load on the foundercarriage( Fig 2-4)
table 2.3
Load
Horizontal Vertical Bending Torque
Force Force moment Mn(kN.
Con-
Fh(kN) Fv(kN) M(kN.m) m)
-ditions
In service 31.05 1547 3085 385
Out of
116.9 1367.3 3830 0.0
service
2.2.2 Foundation for Undercarriage(Fig 2-5)

The ground foundation is the precondition to ensure safe
Fig2-4 Load schematic
operation of the crane. This foundation must closely comply diagram on the founder
carriage
with the regulations for different geological conditions.It is built
of 4-blocks as base ballast, made of reinforced concrete. Basic requirements as follows:
⑴ The concrete strength grade shall be no less than C35.The soil below foundations shall be
tamped solid. The earth-bearing load shall be no less than 0.15MPa.
⑵ The depth of concrete foundation shall be more than 1000mm.
⑶ The contact surface between concrete foundation and frame girder shall be calibrated for
horizontality. Its planeness deviation shall be within 1/750.
⑷ Dig a pit (1200mm × 1200mm × 800mm) with water drains in the middle part of 4-block
foundation for the installing the frame gird
Page:16 / 123
⑸ The relative positions of 4-group foundation bolts shall be accurate to ensure proper
installation.
Figure2-5 foundation of underunder stationary
Page:17 / 123
2.3 The load on the foundation, track & foundation
2.3.1 The load on the foundation (shown as Fig. 2-6)
The load on the foundation is the maximum load when the
included angle of the jib and track is 450. TC6015A tower cran-
-es are equipped with undercarriage with 6m track gaugeIn the
table 2.3, there is the Max load onthe track of TC6015A Tower Crane.
Fig.2-6
Table 2.3 the load on the track
In service Out of service
track
model F1(kN) Max F1(kN) Min F1(kN) Max F1(kN) Min
foundation
pressure pressure pressure pressure
6MGCA
TC6015A 750.4 23.15 793.3 -109.7
6mGCB
In this table, F1 ---- the acting force of single dolly (with two traveling wheels) on the
track and foundation,
6mGCA,6mGCB,— the track foundation drawing No.
Notice: Each dolly may bear F1 because of rotation of tower crane.
2.3.2 Track & Foundation
The users can build track foundation according to track foundation drawing supplied
by us, or design it themselves by relative standards according to the load supplied by
us.
2.4 Counterweight
2.4.1 Counter-weight specifications
The counter-weight has three specifications; All are cast with reinforced concrete.(For
specific dimensions,refer to Fig.2-7).
1.65t counterweight
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1.95t counterweight
3t counterweight
figure 2-7 counterweight
Page:19 / 123
2.4.2 Basic requirements for counter-weight are as following:
a) Weigh the counter-weight pouting with reinforced concrete. Permitted weight
deviation is 2%, concrete grade no less than C18.
b) Counterweight should be equipped according to the length change of jib (Table
2.4)
c) To be consistent with the precision 2%, it is allowable to change the length
dimension of the couterweight 3590 to change the weight
table 2.4
30m jib 35m jib 40m jib 45m jib
2×3.0t 2×3.0t 2×3.0t 2×3.0t
Counter
Counter 1×1.95t Counter 2×1.95t Counter 2×1.95t
weight
weight 1×1.65t 1×1.65t weight 1×1.65t weight 2×1.65t
total 7.65t total 9.6t total 11.55t total 13.2t
50m jib 55m jib 60m jip
2×3.0t 2×3.0t 2×3.0t
weight 3×1.65t weight 3×1.65t weight 3×1.65t
total 14.85t total 16.8t total 18.75t
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2.5 Base ballast

The base ballast is made up of several reinforced concrete blocks which are
placed symmetrically on the chassis.
Fig2-8 Ballast (1)
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Fig2-9 Ballast (2)
These blocks must be positionned on the chassis as shown in the figures and the
corresponding table.
The reinforcing of the concrete blocks,except the one shown in the figure,is left
up to the customer who has slso the responsability for the ballast preparation .No
supply from us.
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Fig2-10 assemble diagram
Attention:
1. The protrusion of the block(1) must be symmetrically layed on the cross beam.
2. The block(2) must be symmetrically layed on the block(1) according to the
assembly diagram.
3. During installing, the hole centre line of upper block must be located the perron
center line of the below block.
4. Counterweight should be assembled along track direction.
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3- Installing
Chapter I Erecting
3.1 Introduction
Users are required to go through this section to ensure proper and smooth
erection of the tower crane. Before hoisting, select the proper truck crane to assembly
the Tower Crane.
3.2 Cautions
3.2.1The wind speed atop (the highest crane point) should be no greater
than 12m/s during crane erection.
3.2.2. Strictly follow the erection procedures of tower crane.
3.2.3.Properly select of hook point. Select the hoisting equipment with proper
length and reliable quality to suit the components to be hoisted (refer to Table 3.2)
3.2.4. Dismountable pins, nuts and bolts for connecting tower sections are
specially prefabricated parts. Customers are not allowed to replace them freely.
3.2.5. Stairs, platform and protecting fence should be installed for safe operation.
3.2.6. Be sure of the proper length of counter-jib and number of counter-weights
according to the length of jib (refer to relevant sections). Before Jib is installed, must
place one piece of counter-weights 3t on the counter-jib.
It is prohibited to place more counter-weights on the counter-jib before
installing jib.
3.2.7. After jib installating, it is prohibited to hoist any load before placing specified
counter-weight on the counter-jib.
3.2.8. It is necessary to keep the direction of every tower section in accordance,
otherwise it cannot add or reduce tower sections.
3.2.9. 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 Table 3.1
Table 3.1
voltage KV
<1 1~15 20~40 60~110 200
safe distance m
vertical distance 1.5 3.0 4.0 5.0 6.0
horizontal distance 1.0 1.5 2.0 4.0 6.0
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3.2.10.Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary
tools should be provided before hand.
3.2.11Reference size for tower crane erection site is shown as Fig3-1
3.2.12. 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.
3.2.13. No slewing of the jib and no up and down movements of the hoist hook
during jacking operation.
3.2.14 Weight specifications of crane parts and component(shown up Table3.2)
Table 3.2 Component weight and height
No. Embedded Undercarriage Traveling
Designation Weight(kg)
anchor H(m) stationary H(m) H(m)
1 Driving Bogie 870+820 / / 1.2
2 Driven Bogie 2X680 / / 1.2
3 Total Beam 1750 / 0.9 1.6
4 Semi-Beam 2X810 / 0.9 1.6
5 Tie rod 4X115 / 0.9 1.6
Base Section
6 3480 / 6.9 7.6
Ⅰ&Ⅱ
7 Tower Strut 4X350 / 5.4 6.1
8 Ballast (1) 4X3900 / 1 1.7
9 Ballast (2) 12X4500 / 4.1 4.8
Base Tower
10 1343 3.7 / /
Section MQQ
Tower section
11 1353 6.5 / /
MQQ
Tower section
12 2×1245 12.1 12.5 13.2
MQ
13 Climbing Frame 4250 18.1 18.5 19.2
Slewing
14 4400 14.2 14.6 15.3
Assembly
15 Operator Cab 500 16.0 16.4 17.1
16 Slewing tower body 1100 16.4 16.8 17.5
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17 Tower Head 1856 23.4 23.8 24.5
Counter Jib
18 6214 16.5 16.9 17.6
assembly
19 1st counterweight 3000 19.5 19.9 20.6
20a 30m Jib assembly 5338 16.7 17.1 17.8
20b 35m Jib assembly 5839 16.7 17.1 17.8
20c 40m Jib assembly 6235 16.7 17.1 17.8
20d 45m Jib assembly 6639 16.7 17.1 17.8
20e 50m Jib assembly 7035 16.7 17.1 17.8
20f 55m Jib assembly 7308 16.7 17.1 17.8
20g 60m Jib assembly 7704 16.7 17.1 17.8
Counterweight of
21a 1×3000+1650 19.5 19.9 20.6
30m Jib
Counterweight of 1×3000+1950
21b 19.5 19.9 20.6
35m Jib +1650
Counterweight of 1×3000+2×19
21c 19.5 19.9 20.6
40m Jib 50+1650
21d 19.5 19.9 20.6
45m Jib 50+2×1650
21e 19.5 19.9 20.6
50m Jib 50+3×1650
21f 19.5 19.9 20.6
55m Jib 50+3×1650
21g 19.5 19.9 20.6
60m Jib 50+3×1650
Note：21a、b、c、d、e、f、g are the remaining counterweights after mounting a counterweight.
3.3 General layout of tower crane

3.3.1Assembly relation of main components for stationary crane
(Fig3-2)
Fig3-2
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The TC6015A tower crane, with embedded anchors or with an undercarriage, in-
-dependent hoisting height is 60m. 2-fall or 4-fall wire ropes may be used for hoisting
purpose. The tower sections are integral construction of square shaped steel tube str-
-ucture. The base section of tower body or the undercarriage is connected to the foun-
-dation. Mast sections are connected to slewing ring support and slewing tower body
throught the upper support and slewing ring. The operator cab is set at the side of the
upper support with the jib in front and counter-jib behind. The hoisting mechanism is
located at the rear of the counter-jib and the slewing mechanism is symmetrically loc-
-ated on both sides of the upper support. The trolley is pulled by trolleying mechanism
to make to-and-fro movements along the jib. The jib and counter-jib are connected to
the tower head by the rigid tie rods.
The lower end of the slewing ring support is the climbing frame, which surrounds
the tower body. To meet construction needs, jacking mechanism can jack the upper
structure of the tower body to let in mast sections for increasing tower crane height.
3.3.2 Anchored State(show as Fig3-3、Fig3-4)
The maximum hoisting height can reach 60m when crane is stationary with
embedded anchors. If the hoisting height must be over 60m, it must be fastened with
tie-in onto the building and mast tie frame. The maximum hoisting height can reach
220m when the crane is fastened with tie-in onto the building. 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 tower crane anchored-to-building has the same structural layout
as stationary type, only with the exception of tower
section M added to the tower body for higher
hoisting. To enhance tower crane stability and
tower body rigidity, several anchors are provided
along the whole height of the tower body. If the
maximum hoisting height is 220m, the crane must
be equipped with 7anchors. Standard attachment,
the tower body center has to be kept 5m away
from the building. In case of the actual distance of
the project not in compliance with this requirement,
just contact our company for further information.
Fig3-3
Items 3.3.2.1 and 3.3.2.2 give consideration to
Page:27 / 123
project construction requirements and the stress of the tower body and anchored
frames. They specify the distance bet-
-ween anchored frame and foundation plane, distance between anchored frames and
suspension height limit
Fig3-3above anchored frame. Item 3.3.2.3 and3.3.2.4 (Fig3-3、Fig3-4) can
satisfy both ordinary construction needs and facilitate prefabrication of anchored
frames most economically for lower operation cost of the tower crane.
3.3.2.1 With one anchored attachment (Shown as Fig3-3)
(1)Tower height h1 below 1st anchored-frame attachment to the foundation (include
base section height in case of stationary crane with foundation anchor, and height of
upper base section and lower base section in case of stationary crane with base
frame.)
30(m)≤h1≤45(m)
Number of mast section below 1st attachment
10.7≤n1≤16.1
(2) The height of tower above the anchored-frame ho.
h0≤39(m)
Number of mast section above anchored-frame:
n0≤13.9
3.3.2.2 With two anchored frames or more Fig3-4
(1)Distance between each anchored-frame h2:
16.8(m)≤h2≤25.2(m)
numbers of mast section between two anchored-frame n2:
6≤n2≤9
(2) The height h0of tower above the highest anchor point is:
When hook height h is less than100m，h0 is the same shown in 3.3.2.1(2).
When hook height h is ＞100m
namely:n0≤12.9
3.3.2.3Most economic anchored-frame layout for the stationary crane with

embedded anchors
After 1st anchoring operation, the tower height above the anchored frame is less
than 39.32m; the maximum working height reaches 85.2m, from down to up, 1 base
Page:28 / 123
tower section MQQ, 1 tower section MQQ, 4 tower sections MQ and 24 tower
sections M
After 2nd anchoring operation, the tower height above the anchored frame is less
sections M
After 3rd anchoring operation, the tower height above the anchored frame is less
than 36.52m; the maximum working height reaches 130m, from down to up, 1 base
sections M
After 4th anchoring operation, the tower height above the anchored frame is less
sections M
sections M
sections M
After 7th anchoring operation, the tower height above the anchored frame is less than
36.52m; the maximum working height reaches 220m, from down to up, 1 base tower section
MQQ, 1 tower section MQQ, 4 tower sections MQ and 72 tower sections M
3.3.2.4Most economic anchored-frame layout for the stationary crane with
undercarriage
After 1st anchoring operation, tower height above the anchored frame is less than
39.32m; maximum working height reaches 85.2m, from down to up, 1 undercarriage,
4 tower sections MQ and 24 tower sections M
After 2nd anchoring operation, tower height above the anchored frame is less than
4 tower sections MQ and 32 tower sections M
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After 3rd anchoring operation, tower height above the anchored frame is less than
36.52m; maximum working height reaches130m, from down to up, 1 undercarriage, 4
tower sections MQ and 40 tower sections M .
After 4th anchoring operation, tower height above the anchored frame is less than
4 tower sections MQ and 48 tower sections M .
4 tower sections MQ and 56tower sections M
4 tower sections MQ and 64tower sections M
36.52m; maximum working height reaches 220m, from down to up, 1 undercarriage, 4
tower sections MQ and 72 tower sections M
3.4 Counterweight should be equipped according to the length

change of jib Table 3.3
table 3.3
30mjib 35mjib 40mjib 45mjib
2×3.0t 2×3.0t 2×3.0t 2×3.0t
Counter
weight
weight 1×1.65t 1×1.65t weight 1×1.65t weight 2×1.65t
total 7.65t total 9.6t total 11.55t total 13.2t
50mjib 55mjib 60mjib
2×3.0t 2×3.0t 2×3.0t
weight 3×1.65t weight 3×1.65t weight 3×1.65t
Total 14.85t Total 16.8t Total 18.75t
Page:30 / 123
3.5 Erecting
After installing the embedded anchors, The erection of tower crane shall be
conducted only after the concrete strength of foundation reaches the designed value
of 70%.
After installing the embedded anchors and the base section MQQ, the
installation sequence of the tower crane is as following
Fig.3-5 installing tower crane

with the embedded anchors
3.5.1Erecting Tower Section MQQ and 2 Tower Sections MQ

3.5.1.1Structure description
There are four kinds of tower sections for stationary crane. Embedded anchor:The
crane with embedded anchors have 13 tower sections M, 3 tower sections MQ, one
tower section MQQ, one base tower section MQQ(figure3-6): base tower section
MQQ is connected with the embedded anchors (the upper and lower end faces of
each main chord have 4 bolt joints, and it has 2 supports for installing the nameplate
and the power switch).Above the base tower section, there is a tower section MQQ
(the upper end face has 3 bolt joints, and the lower end face has 4 bolt joints). Upon it,
there are 3 tower sections MQ (the upper and lower end faces of each main chord
have 3 bolt joints),the rest are 15 tower sections(the upper and lower end faces of
each main chord have 2 bolt joints) .There are a ladder and a platform in each tower
section.
Page:31 / 123
figure 3-6a base tower section MQQ Figure3-6b tower section MQQ
Figure3-6c tower sections MQ
3.5.1.2Erect one tower section MQQ and two tower sections MQ（Fig7）
a. Hoist the tower section MQQ onto the base tower section MQQ and screw
them together with 16 pieces high-tensile bolts (strength rating 10.9). Then hoist 2
tower sections MQ onto the tower section MQQ and screw them together with 12
pieces high-tensile bolts (strength rating 10.9). Be sure that the climbing lugs on each
section are placed on the same plane under counter-jib in order to conveniently
installing and dismantling the whole tower crane. At this time there are 1 base tower
section MQQ, 1 tower sectionMQQ and 2 tower sections MQ on the foundation, shown
as Fig3-7. If the crane with a undercarriage, hoist 2 tower sections MQ onto the
undercarriage and screw them together with 12 pieces high-tensile bolts.
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b.Tighten all M36 high-tensile bolts with
torque up to 2400N·m，and each bolt should
be equipped with two washers(one is put under
the head of the bolt, another is put under the
nuts, and the face with chamfer is faced to the
head
or the nuts, shown as Fig.3-7) and two nuts. The
loose-proof nut(the upper nut)should be fastened
with torque equal to or a little more than2400N·m.
c. 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.
Figure3-7 installing MQQ+2MQ
3.5.2 Hoist Climbing Frame
3.5.2.1 Structure description(shown as Fig3-8)

Consists of climbing frame structure, platform,
climbing stairs, hydraulic jack system and let-in de-
-vice for mast section. Jacking of the tower crane is
done mainly by this component. The jacking cylinder
(or called climbing jack) is installed on the beam at
the rear side of climbing frame (i.e. one side of pre-
-assembled counter-jib). The hydraulic pump station
is placed on the platform on the side of hydraulic
cylinder. Climbing frame have 16 rollers, which are
adjustable, on the inner side. These rollers are sup-
-ported on the outer side of the main chord rod of
the tower crane, acting as guide and bearing.For
the purpose of safety jack, platforms are provided
at the top of and in the middle of the climbing frame, Figure3-8 climbingframe 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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3.5.2.2 Hoist Climbing Frame
After pre-assembling the climbing
frame(shown as Fig 3-9), hoist the frame.
It should be noted that jacking cylinder
is fixed at the same side of the climbing
lugs on section.
a.Pull the climbing frame on the outer
side of the mast section gently.
b.Place supporting latches of climbing
frame on the 2thlug pair from down to up.
Adjust the clearance between16 climbing
guide rollers and tower sections MQ (cle-
-arance is 2~3mm).
c.Fix the jacking cylinder and hoist the
hydraulic pump station to one corner of
theplatform,connect oil tubes, and check
the hydraulic system for normal operation.
Be sure of the rotation of fan blades of the Figure3-9 hoisting climbing frame
oil pump motor in the same direction as
arrow indication on its casing. This will help
avoid oil pump burn-down.In case of any
errors, motors shall be rewired.
3.5.3 Install the assembly of slewing

ring
3.5.3.1 Structure description
The assembly of slewing ring consists of
the slewing ring support,slewing ring, upper
support and slewing mechanism. Shown as
Fig3-10.
The slewing ring support is an integrated box
structure. The lower portion of the ringsupport is
connected to the tower section by high-strength
bolts,and connected to the climbing frame by pins. Fig3-10
Its upper portion is connected to the outer ring of the slew-
Page:34 / 123
-ing ring by high-strength bolts. The upper support is a form of plate-shell structure.
The flanges are welded on its both sides for the installation of slewing mechanism. On
the four sides of the upper support is provided with an operating platform. On the front
of the right side of working platform is welded with a support lug for connection of the
operator cab. On the rear is provided a support for the installation of slewing limiter
and a support plate for mounting electrical whistle is provided in front. The upper sur-
-pport is connected to the slewing tower by 4 pins(φ63 ) on the upper face .
3.5.3.2 Hoist and install the assembly of slewing rings
Use 80 pieces of M24 high-strength bolts (strength rating 8.8) connect the slewing
ring support, the slewing ring and the upper support together. The pre-tensioned
torsion moment of the bolts is up to 640N·m. the checking nut （the upper nut）should
be fastened with torque equal to or a little more
than 640N·m.
Hoist the assembly of slewingrings shown
as Fig3-11. Hang the hookin the four pin-holes
of the upper slewing surpport main chord rods.
Let them down slowly to keep main chord bolt
joints of the ring support in line with the corres
ponding holes of tower section connections.It is
very important to keep the position of passing
holes of the slewing ring support in conformity
to the position of tower section’s climbing stairs
on the tower body. In connecting the slewing ring
support to the climbing frame,their marks on four
corners must correspond to one another.
b.Screw them together with 8 pieces
M36 high-tensile bolts（strength rating 10.9）, Figure3-11installing
and equipping each bolt with a washer and two nuts. Tightening all the bolts with
torque up to 2400N·m， the checking nut （the upper nut）should be fastened with
torque equal to or a little more than 2400N·m.
c. After installing operator cab, slewing tower body, tower head and assembly of
counter-jib, operate the jacking system to extrude the hydraulic cylinder to the second
pair of climbing lug from up to down. Jack the climbing frame to contact the connecting
Page:35 / 123
ear-plate of the ring support. Connect the climbing frame to the ring support with 4
pieces of pins.
3.5.4 Install the slewing tower body
3.5.4.1 Slewing tower assembly description
The slewing tower assembly consists of the slewing tower body and hoisting
weight limiter (Fig3-12). The slewing tower body is an integrated frame structure. Its
upper end surface has the ear-plates for mounting the jib and counter-jib respectively.
These plates are connected to the tower head by 4 pins. The hoisting weight limiter is
provided on the beam of the slewing tower to control the maximum hoisting weight at
different rapidity.
Figure3- 12 the slewing tower assembly
3.5.4.2 Hoist and install the slewing tower body（Shown as Fig3-13, place the）
hoisting wires at the four main chords,and then tighten the hoisting wires.
Page:36 / 123
a.Hoist the slewing tower body(Pay
attention to the direction of the ear-plates
for mounting jib and counter-jib). Keep the
ear-plates close to the side of the hook w-
-eight limiter and the jib on the upper tower
body support in the same direction.
b.Connect the slewing tower body and
the upper support together with 4 pins.
3.5.5 Installation of Tower Head
3.5.5.1 Structure Description(Fig3-14)
The tower head is a quadrangular cone-
-shaped structure. On its top, there is provided
with the tie plate frame and jib tie plate, which
are connected respectively to the counter-jib
Figure3- 13 installing the slewing tower body
and the jib through pins. The upper portion of
the tower head is provided with a working plat-
-form. The platform is bolted to the tower head.
The upper portion of the tower head is provided
with guide pulleys for hoisting wire rope and pu-
-lleys for mounting the jib tie rods. The lower
portion of the main rear chord of the tower head
is provided with a moment limiter, and ladders
with protection rings. The tower head has 4 ear-
-plates on its lower end, which are connected to
the slewing tower body through 4 pins.
3.5.5.2 Hoist and Install the Tower Head(Fig3-15)

a.Before hoisting, assemble the platform,
rails, ladders and moment limiter on the ground.
On each side at the back of the tower head,
mount one counter-jib tie rod for the convenient
figure 3-14 tower head
installation of the counter-jib.
b. Hoist the tower head onto the slewing tower body. Pay attention to align the
vertical side of the tower head to the jib direction of the upper support.
Page:37 / 123
c.Connect the tower head to the slewing tower body by 4 pieces of pins. Put
through and open up cotter pins
figure 3-15 installing tower head
3.5.6 Installation of counter-jib assembly

3.5.6.1 Structure Description(figure3-16)
The counter-jib has 2 sections, which are connected by pins. The counter-jib is
provided with railings, walkway and working platform. One end of the counter-jib is
connected to the slewing tower body by two pins and another end connected to the
tower head by two rigidly-combined tie rods. Its tail section is equipped with the
counter-weight and hoisting mechanism. The resistance box and the electric control
box are arranged at the root. The hoisting mechanism and its own base frame are
fixed on the counter-jib by six bolts. The weight of counter-weight varies with the jib
length, referred to table 3.3.
figure 3-16 counter-jib
Page:38 / 123
3.5.6.2 Hoist and Install Counter-jib Assembly

a.Assemble the counter-jib corresponding to the jib length on the ground. Install
the hoisting mechanism, lifting pole, electric control box, electric resistance box and
counter-jib tie rod(figure3-18) on the counter-jib and make sure of their solid
connection(figure3-17). 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.
b.Shown as Fig3-17, hoist the counter-weight (Four mounting ears are equipped
on it.)
c.Connect the front end of counter-jib to the slewing tower body with pins.
d.Shown as 3-19 for the counter-jib pull rods schematic diagram, lift up the
counter-jib slowly to a proper position for smooth connection of the counter-jib pull
rods to those on the tower head. Connect the pull rods by pins, insert and open up
cotter pins.
e.Lay down the counter-jib slowly. Hoist one pieces of 3t counter-weight at the
furthest position of the counter-jib, shown as Fig3-20.
Figure3- 17 installing counter-jib
Page:39 / 123
figure 3-18 counter-jib pull rods
Figure3- 19 installing Counter-jib pull rods
Page:40 / 123
figure 3-20 Hoisting and intall a 3.0t counter weight
Page:41 / 123
3.5.7 Install operator cab
3.5.7.1 Structure description (shown as
Fig3-21)
The cab is a sheet structure, offset at
the front on the upper support right side pl-
-atform. There are large big glass windows
on the four sides of the cab.The upper win-
-dow in front can be opened to obtain a wide
field of view.The cab is nice-looking and co-
-mfortable,equipped with inter-active control
console.
3.5.7.2 Hoist and install the operator cab
a.After the electric equipment in the cab
Figure 3-21 operator cab
is mounted, Hoist the cab to the front near
right platform of the upper support (Fig3-22). figure 3-21
Align it with the hole-position of ear-plate
and connect them with three pins and put
in cotter pins
b.Alternatively assemble on the ground
the cab and slewing ring assembly and hoist
the whole piece once for all).
3.5.8 Install jib assembly
The jib assembly consists of the jib,jib pull
rods, trolley, and trolleying mechanism.The
Figure3-22 installing operator
pull rods are placed on the rod-fixing frame on
the upper chord rod of the jib.
3.5.8.1Structure description (shown as
Fig5-23)
The upper and lower chord rods on the jib figure 3-22
are square tubes welded with two pieces of angle steel. The whole jib is a varied cross-
-section triangle spatial structure, consisting of eight sections. Section-to-section is
connected by pins for the purpose of convenient installing and dismantling. In order to
improve hoisting performance and reduce jib weight, the second and fifth jib is structured
of a double hook lugs and varied cross-section spatial truss. In the second section, the
Page:42 / 123
traveling mechanism is provided. The trolley moves along the jib lower chord as its track.
It is pulled by the traveling mechanism to move to and fro along the jib. On one side of the
trolley, a maintenance cage is provided for tower crane installation and maintenance.
Dislocation and free assembling are forbidden.
figure 3-23
The jib may be assembled with various jib lengths of60m、55m、50m、45m、40m、
35m、and30m to suit different construction requirements. Dismantling the 6th section, the
jib length is 55m, and dismantling the 7 jib length is 50m, dismantling 6th and 7th sections,
the jib length is 45m , dismantling 4th and 7th sections, the jib length is 40m , dismantling
4th ,6th and 7th sections, the jib length is 35m , dismantling 3th,4th ,6th and 7th sections,
the jib length is 30m. shown as Fig3-24.
figure 3-24 jib structure
Page:43 / 123
3.5.8.2 Hoist and install jib assembly
a.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 chords.
b.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 Fig3-25.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 6~8 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.
figure 3-25 trolleying wire rope layout
c. After assembling jib pull rods shown as Fig3-26, connect it to the jib hook lugs on the
upper chord of jib with pins, insert cotter pins, then place jib pull rods on the bracket of
upper chord on the jib
Page:44 / 123
figure 3-26 jib pull rods
d.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.
e. Hang up ropes as shown in Fig.3-23. Try the ropes for balance. In case of improper
balance, move the rope to proper hanging position. Lift the jib assembly to the mount
height. Use the axis-positioning frame and pins to connect the root section of jib to the
slewing tower body and then fasten the connection. Attention: Record the jib lifting point
for reference during tower crane dismantling.
figure 3-27 weightcenter of jib
Page:45 / 123
Notices:
1.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 below table.
55m jib 50m jib
L(m) 19.8 18
G(kg) 8100 7700
2. When hoisting, 8m＜L＜20m.
3.The assembled jib should be supported on the ground by at least 5 supports during
winding wire rope.
4.Hang up ropes shown as Fig3-27. Try the ropes for balance. In case of improper
balance, move properly the rope-hanging 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 Fig3-28. Attention: record the
jib lifting point for reference during tower dismantling.
figure 3-28 installing jib
5. Reeve the hoisting wire rope according

to Fig3-29，start 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 Fig3-30, Fig3-31. insert split pin, let off
wire rope of hoisting winch and lay down jib
slowly.
Figure 3-29 hoisting wire rope layout
6.Keep the tie rod tensioned. At this time,
Page:46 / 123
the jib is raised about 1/70. Loosen the hoisting rope on the pulley block.
Figure3-30 tower head structure at jib pull

dj i t
Figure3-31pull rod structure at tower head joint(↓)
3.5.9 Assemble counter-weight

The weight of counter-weight varies in proportional to the jib length. The counter-
-weight is hoisted according to the jib length used shown as Fig3-32. The counter-
-weight configuration and mounting position are strictly acted on the requirements of
seven jib-length conditions.
Page:47 / 123
figure 3-32 installing counter-weight
Page:48 / 123
3.6 Rope-winding system of hoisting mechanism
After installation,wind hoistingropes.
As shown in Fig3-33, the hoisting rope is
released from the wire rope drum, 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 Figure 3-33 hoisting wire rope layout
3.7 Power on and Trial operation Figure3- 33 hoisting wire rope layout
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 crane needs to be put into service immediately after the installation, the
safety device must be adjusted as specified in Chapter 4st-adjusting
3.8 Fall-change system
The automatic fall-change system consists of 3 parts, i.e. the trolley, upper pulley
block and lower pulley block (incl. hoisting hook). They mount on the jib (Fig3-34),rope
winding on the trolley and upper-lower pulley blocks (Fig3-35) and the connection-
-disconnection of the upper pulley block to lower pulley block enable conversion of 2-fall
and 4-fall (referred to hereinafter as fall-change).
figure 3-34 schematic diagram of the installation of trolley on jib
Page:49 / 123
The fall-change is converted at the jib root section under
the conditions of no-load, slow speed and no swing. No
matter how it is required to convert 2 fall to 4-fall or to
convert 4-fall to 2-fall, the by-pass switch must at first be
turned to the by-pass status to disable the height limiter.
After conversion completion, the by-pass switch must
be restored to its original status. At the 2 fall working
conditions, the upper pulley block (1) with automatic
connections contacts tightly the trolley. The upper pulley
figure 3-35 schematic
block is connected automatically to the lowerpulley block diagram of trolley hoisting
through 2 connection plates (2). The plates have waist-
shaped long holes (3) for connection and locking through pins (4)on the lower pulley
block.
The upper pulley block is disconnected from the lower pulley block through the
unlocking device (5). This device is fixed on the upper portion of the trolley by spring (6).
When the trolley moves to the jib root, a wedge piece(9) under the jib acts on the co-
-nnection plate (2) through this device so as to open the plate (2), thus the upper pulley
block is disconnected from the lower pulley block.
3.8.1 Method for 2-fall to 4-fall conversion(Fig3-36)

3.8.1.1 Before conversion, the upper pulleyblock (1) has tightly contacted the trolley
andthe connection plate (2) is at a close state.
3.8.1.2 Move the trolley to a position near the jib root wedge and stop there (Attention:
at this time, the unlocking device(5) is unable tocontact the wedge (9)).Lift slowly the
lower pulley block at no-load and no swing conditions.
When the connection(2) contacts the pins (4) tail on the lower pulley block, the
connection plate will rotate with the pins (7) as the center,thus being pushed open.
When the long waist-shapedhole (3) on the connection plate is against the pins (4) on
the lower pulley block, the connection plate will be closed. At this time the lower pulley
block must stop rising, thus combining automatically the upper pulley block and lower
pulley block into one unit.
3.8.1.3 While the hoisting hook is going down, the pulley block is at a working state of
4-fall. Lower the pulley block down to the ground, put the safety pins (8) into the upper
hole of the lower pulley blockto lock connection plate, thus the processof 4-fall is conve-
-rsion completed.
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figure 3-36 diagram of2-fall to 4-fall conversion
figure 3-37 diagram of4-fall to 2-fall
Page:51 / 123
3.8.2 Method for 4-fall to 2- fall conversion figure 3-37
3.8.2.1Lower the hoist hook onto the ground and place the safety pin (8) into the lower
hole on the pulley block. Release the locking connection plate (2). (Fig3-37a).
3.8.2.2 Lift the hoisting hook to İts maximum working height. Move the trolley to the jib
root and stop it at a spot where the unlocking device (5) is 100~200mm away from the
wedge(9). Continue to lift the hoisting hook slowly to make the pulley block tightly con-
-tact the trolley, and the upper pul- -ley block-lower pulley block contact each other
before stop. At this location, the pin (4) on the lower pulley block is at the upper portion
of the long hole (3) on the connection plate (2), thus no more locking the connection
plate. Move the trolley slowly along the wedge(9) in the jib root direction. (Fig.37b).
3.8.2.3 With the inward movement of the trolley, the unlocking device moves downwards
to act on the connection plate (2) and make the plate (2) rotate with the pin (7) as its cen-
-ter until the plate has been opened fully before stop (Fig3-37c).(Attention: Never let the
unlocking device on the trolley move into the wedge, otherwise the trolley will be unable
to change its working radius)
3.8.2.4 Lower the hook and move the trolley forwards. The upper pulley block contacts
tightly the trolley due to wire rope tensile forces. The lower pulley block moves with the
hook, thus completing 4-fall to 2-fall conversion (Fig3-37d).
3.9 Jacking operation for adding sections

3.9.1 Pre-jacking preparations
3.9.1.1 Fill the oil tank with hydraulic oil according to the requirements of hydraulic
pump station. Be sure of the electric motor correctly connected, the fan turned to the
right and the operating lever of hand control valve working smoothly without any clogg-
-ing.
3.9.1.2 Put in order each mast section MQ and apply the grease into its connection
boltholes. Line up the tower sections MQ under jib before jacking. This will enable no
use of the slewing mechanism in the whole process of jacking operation for adding
sections, thus minimizing the jacking time.
3.9.1.3 Loosen the power cable length slightly in excess of the total jacking height,
and then fix the cable.
3.9.1.4 Slew the jib to the front of the climbing frame and the counter-jib at the rear
of climbing frame (jacking cylinder is just under the counter-jib).
3.9.1.5 Preparation should be made on the platform to inlet wheels and high-tensile
bolts for tower sections on the climbing frame.
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3.9.2 Keep the tower crane in balance before jacking operation
3.9.2.1 Before keeping the tower crane in balance, hoist one tower section MQ onto the
introduction platform and then move the trolley to the reference balance position shown
as Fig3-38. 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 se-
-ction.
3.9.2.2 Push the operation handle of the hydraulic jacking system to <<Jacking direc-
-tion>> 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.
3.9.2.3 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 deter-
-mine whether or not the tower crane is in balance. If not, adjust until balance is achiev-
-ed so as to drop the center of gravity of the upper tower crane onto the position of
jacking cylinder beams.
Figure3-38 keep the tower crane
3.9.2.4 Record the balance position of the trolley for the convenience of dismantling.
This mark position varies with different jib lengths.
3.9.2.5 Operate the hydraulic system to lower down the sleeve frame. Connect the
slewing ring support to tower sections MQ with bolts.
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3.9.3 Jacking operation (shown as Fig3-39)
3.9.3.1 Hoist another mast section and drive the trolley to the position for balance, shown
as Fig3-38.
3.9.3.2 Use the brake on the slewing mechanism to hold the tower superstructure at a
slewing braking status, thus ensuring no slewing movements.
3.9.3.3 Remove the eight bolts connecting tower section to slewing ring support.
3.9.3.4 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 (It should be checked by a specially- designed watchdog). Erect 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 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 f rame
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 on the inlet platform of climbing
frame into upper part of tower, retreat the jack slightly so that the new tower section
alight at the top of tower and conduct proper alignment, remove the inlet wheels, fasten
the upper and lower sections with eight pieces of M36 bolts with torque of 2400kN·m,
each bolt must be equipped with two nuts.
Figure3-39 operation in
Page:54 / 123
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 M36 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 above，As 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.
3.9.4 General Notices of Jacking Operation:

3.9.4.1 Jacking operation is prohibited when the wind speed at the high-
-est top exceeding 12m/s.
3.9.4.2 Keep the jib in the same direction as the in-let tower section during jacki-
-ng operation. Stop the jib with the slewing mechanism brake be sure of the trolley
stopping at the jack-balanced position.
3.9.4.3 If several tower sections are to be mounted, after mounting a section, all
the chords of the section must be fastened with 8 pieces of M36 bolts before hooking
another section. Only at this time, it is permitted to use one nut of each bolt.
3.9.4.4 Keep the climbing lugs on the newly added tower section in alignment wi-
-th those on the existed sections.
3.9.4.5 It is prohibited to slew, change work-radius and hoist load without conne-
-ction of the slewing ring support to the tower body by 8 pieces of M36 bolts.
3.9.4.6 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 M36 bolts to connect the
slewing ring support to the tower body before removing troubles from the hydraulic
system.
3.9.4.7 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.
3.10 Tower anchored onto the

building
3.10.1 When the working height of the tower crane has to be exceeded to its stand-
alone height, the tower body shall be anchored.
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3.10.2 The anchoring devicesconsist of 4 sets of mast-tie-framesand 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 4 strut-rods on 4 top points. The 4 strut 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 Fig3-40).
1. connection pedestal 2. short brace 3. long brace

4. anchoring frames 5. connection bolts 6. inner tie rods
7. adjusting screw 8. adjusting bolt
figure 3-40 anchoring device
3.10.3 Load on anchoring points table 3.5

Before tower crane erection, customers or installation organizations are required
to make necessary estimates of the load-bearing capability at building anchoring poi-
-nts (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. In the table 3.5, it gives the anchoring forces imposed at the anchoring points
of the building ,at working and non-working conditions when the tower crane has its
anchoring strut rods layout and location as shown in Figure3-41. The building’s anch-
-oring point shall not have its load-bearing capability smaller than the values shown in
the table.
Page:56 / 123
table 3.5
±135
F1(kN.)
F2(kN) ±182
F3(kN) ±135
F4(kN) ±182
figure 3-41 load at anchoring
Attention：
Load values at anchoring points vary to a great extent with the relative
positions of the tower crane to the building, the struts layout and size, the
height of the tower body suspension sections over the anchored frame. If the tower
crane anchoring position, anchoring strut layout and size are not in compliance with
what is shown in Fig3-41during tower crane attachment, just contact our company for
advice. Never apply mechanically this issue by using the values in Table 3.5 in order
to avoid serious accidents.
3.10.4 Pull anchoring tie frames onto the tower body, use 4 inner tie rods to press
them against 4 main chord rods of the tower body and connect them to its web rods.
Use pins to connect one end of the tie rod to the attaching frame and another end to
the connection pedestal fixed to the building.
3.10.4.1 4 sets of anchoring tie rod on each frame shall be kept at the same
horizontal plane. If they are interfered with some positions of the tower body during
mounting of anchoring frames and inner tie rods, the height of frames will properly be
raised or lowered. The permitted height difference of anchoring frames to foundation
connection shall not be greater than 200mm.
3.10.4.2The 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.
3.10.5 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 5/1000 of the total
tower crane height. This deviation can be achieved by adjusting the length of the strut
rods.
Page:57 / 123
3.10.6 The connection of strut rods to tie frames, foundation and tie frames to the
tower body and inner strut rods shall be reliable. The inner strut 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.
Attention:
No matter how many anchoring is conducted, only the topmost
anchoring tie frame can accommodate the inner strut rod. i.e. after
each new attachment, the inner strut rods have to be removed into
the newly-anchored frame.
3.11 Preparations before operation
The pre-operation preparations of the tower crane aim at ensuring its correct co- -ntrol
and smooth operation at safe conditions. Main preparations are to check tower crane
components and to test-run safety devices.figure3-42.
1. Hoisting mechanism (arresters、height limit) 2. Moment limit

3. Weight limit 4. Trolly mechanism (arresters、radius limit)
5. Slewing mechanism (arresters、slewing limit)
Figure3-42 the mounting positions of safety devices
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3.11.1 Checking Parts and Components
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.
3.11.1.1 Check component-to-component connections.
3.11.1.2 Check the installation of Supporting platform and fences
3.11.1.3 Check wire ropes for correct winding, avoiding interference and friction with
other parts.
3.11.1.4 Check power cables for smooth and proper routing.
3.11.1.5 Check if the counter-weights on the counter-jib are properly fixed.
3.11.1.6 Clear the lumber on platforms in order to prevent them from falling and
avoid injuring persons during tower crane operation.
3.11.1.7 Check lubrication surfaces and points.
3.11.2 Test-run for the safety device
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 radi-
-us limiter. The load limiter includes the hoisting moment limiter and hoisting weight
limiter. The anemometer is also included. The test-run method is referred to the secti-
-on 3 of the Part II.
3.11.3 Items-checking after tower erection table 3.6
Item Contents
1.Check if the foot bolts are fastened
2.Check safety distance between the surrounding power lines and tower
Foundation crane.
3.Check power cable for smooth routing to avoid damage.
4.Check the resistance,less than 4 Ω
Tower section Check the bolt connection of tower sections
1. Check its connection to slewing ring support
2. Check if the guide wheels, latches, pin-bolt-connected parts move
Climbing frame
smoothly
3.Check if the walkway and fence are fastened
1. Check if the bolts connecting slewing ring is properly fixed.
2. Check power cable for smooth passage
Upper support,
3. Check if the platform and fence are fastened
slewing ring support
4. Check the connection for operator cab
and operator cab
5. No storage of lubrication oils, oil cotton yarns and combustible materials in
the cab.
Page:59 / 123
1. Check tie rods of jib and counter-jib tie rods for proper installation.
Tower head 2. Check ladders, platforms and protection rails.
3. Secure that the hoisting rope is properly wired and arranged
1.Check connection pins, washers and cotter pins for correct mounting.
2.Check if the trolley is properly installed and operates smoothly, check
Jib
maintenance cage for fixing.
3.Check hoisting and radius-changing ropes for winding and fixing
1.Check counter-jib for fixing
Counter-jib 2.Check protection rails of the counter-jib and walkway. Ensure no foreign
substances on the walkway
1.Check rope off-proof devices of the hook and fall-changing device for
safety and reliability
2.Check hoist hook group for defects influencing operation
Hook
3.Check specifications and models of hoist ropes and radius-changing ropes
for compliance with requirements.
4.Check wire ropes for wear.
1. Check mechanism for installation and operation
2. Check mechanism brakes for correct clearance adjustment
3. When trolley has moved to its minimum and maximum trolley
Mechanism
radius-changing locations respectively, make sure if steel ropes on wire drum
have over 3 lays for safety.
4.Check if the ends of steel ropes are loosened or improper compressed.
1. Check safety device for proper adjustment as specified in the Instructions
Safety device
2.Check all ladders, protection rails and rest platforms for properly fastened.
Lubrication Check lubrication conditions according to the operation instructions.
3.11.4 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).
3.11.4.1 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.
3.11.4.2 Load test
Before load test, the brake of the hoisting mechanism must be adjusted at
hoisting 1.1 times rated load.
Hoist the loads corresponding respectively to 25%, 50%, 75% and 100% of the
rated hoist load at the maximum working radius for tests.
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3.11.4.3 Static test at 25% over-load
Conduct the static test at over-load after no-load tests and on-load tests have
been completed as specified.
Test loads based on different jib lengths are shown in Table below.
İtem
RadiusⅠ(m) Hook weightⅠ(t) RadiusⅡ(m) Hook weightⅡ(t)
Jib
60m 13.25 12.5 60 1.71
55m 14.19 12.5 55 2.21
50m 14.76 12.5 50 2.71
45m 14.76 12.5 45 3.15
40m 14.77 12.5 40 3.7
35m 14.77 12.5 35 4.41
30m 14.79 12.5 30 5.37
Hoist the weight at radius I and radius II from the ground for 100~200 mm
height at the lowest safe speed. Put additional successive weighs onto the hoist hook
up to 1.25 times the first weight. Stay on for 10 minute. Carry out unloading and check
metal structures and welds for any cracks, permanent deformations and loosened
connections.
Attention: No trolley radius-changing and slewing during

over-load static tests
3.11.4.4 Dynamic test at over-load

Hoist 1.51t weight at maximum radius (1.95t for 55m jib, 2.39t for 50m jib, 2.77t
for 45m jib, 3.26t for 40m jib, 3.88t for 35m jib, 4.73t for 30m jib) to make each
mechanism conduct corresponding full-range action tests for 3 times. The mechanism
shall act smoothly and the brake shall act reliably. There shall be no abnormal
incidents from mechanisms and structures, neither loosened parts and damages.
3.12 Stationary tower crane with undercarriage installed according to

the procedures shown as Fig3-43.
1) Install the undercarriage assembly
2)Other assembling procedures are the same as tower crane with embedded
anchors
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1.Undercarriage 2.Base section 3.Climbing frame 4.Slewing assembly

5. Tower head 6. Counter-jb 7. Counter-jb rods 8. Counter-weight
9. Cab 10. Slewing tower body 11. Jib rods 12. Jib
figure 3-43 installing sequence of stationary tower crane with undercarriage
3.12.1 Install the Undercrriage

Assemble the undercarriage
1).Assemble the crossbeam assembly (shown as Fig3-44); fasten it to the
foundation with embedded bolts and channel steel.
figure 3-44 assemble undercarriage
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2).Installa the base tower section1 and 2 (shown as Fig3-45);
3).Install the struts(shown as Fig3-45);
Figure 3-45 assemble the base section and struts
4). Assemble the Center Ballast (shown as Fig3-46)
Figure3- 46 assemble the center
4 pieces of3.9t Center Ballast，12 pieces of4.5t Center Ballas，total weight69.6t
Page:63 / 123
Chapter Ⅱ Dismantling
3.13 Precautions for tower crane dismantle
3.13.1 Conduct maintenance and test-run for the jacking mechanism
before moving the tower crane out of the construction site.
3.13.2 Check limiters, slewing mechanism brakes and similar devices for reliability
during test-run.
3.13.3 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 M36 high-
-tensile bolts.
3.13.4 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.
3.13.5 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.).
3.13.6 Carry off dismantling when the wind speed is lower than 12m/s at the high-
-est point. Take care of the stockpile location of dismantled parts because the building
has been constructed and working site space is limited during tower crane dismantling.
No carelessness in this operation, otherwise personal safety accidents will be likely.
Fig3-47a dismantle tower crane

with embedded anchors
Page:64 / 123
Figure 3-47b dismantle tower

crane with undercarriage
3.14 Special caution:

tower dismantling is a highly technical work, especially the dismantling
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 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. Inspect if the latches are still in proper level
condition.Mov the tower crane to the dismantling area where there shall
be no obstacles influencing the operation. Carry out tower crane
dismantling
according to the sequence as shown in Fig3-47 Its steps are in opposition to the steps
of tower crane erection.Strictly follow the instructions specified rules in all cases.
The concrete sequence of the dismantling as following:
1) Lower down the tower sections (dismantle anchored devices if any).
2) Dismantle counter-weights from counter-jib. (Keep one piece of 3t counter-
weight)
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3) Dismantle the jib.
4)Dismantle the last counter-weights. Dismantle the counter-jib.
5) Dismantle the operator cab (or dismantle it together with the slewing
assembly)
6) Dismantle the tower head.
7) Dismantle the slewing tower body.
8) Dismantle the slewing ring assembly.
9)Dismantle the climbing frame and the remanent tower sections.
10)Dismantle the the center ballast and undercarriage (if the crane has a
undercarriage)
3.14.1 dismantle the tower sections
3.14.1.1 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
Figure 3-48
Page:66 / 123
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)
3.14.1.2 Remove the upper and lower bolts connecting of the top tower section,
connect inlet wheels on the below section. 3.14.1.3 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 moved to 20~50mm away
from the top of the section.
3.14.1.4 Push the top section out of tower along the beam onto the inlet frame.
3.14.1.5Rotate the latches 900, retreat oil cylinder to avoid the last pair of step
lugs, then reset the latches at level, go on to lower until the latches reaches the next
climbing lugs and bear the weight of upper parts confidently, retreat the cylinder
again.
3.14.1.6 Put the climbing beam to the step lug at lower position and erect the
climbing frame until the latches can be turn at 900 again, retract oil cylinder to let the
next section contact the slewing ring support.
3.14.1.7Connect slewing ring support to tower section with bolts, hook the tower
section on the inlet platform to the ground.
Attention:
In the course of lowering climbing frame, it is necessary to dispatch
special persons to turn the latches when it passes through the climbing
lugs and the bolts of the tower section, and another persons to observe the jacking
beam and the guide rollers. There should be not any barriers to interrupt the climbing
frame for smooth lowering.
Repeat the above actions to dismantle the tower sections in sequence.
If the tower has to be further dismantled after the tower body has been dismantled to
the safety height, it is necessary to dismantle at first the counter-weight from the
counter-jib.
3.14.2 Dismantle the counter-weight from the counter-jib
Fix the trolley at the jib root and use the auxiliary crane to dismantle the
counter-weight.
Dismantle the counter-weight piece by piece in the sequence opposite to
counter-weight mounting. Keep one piece of 3 t counter-weight
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3.14.3 Dismantle the jib
3.14.3.1 Lower the hook to the ground, remove the connection of anti-twist device
with hoisting wire, and then start the hoist mechanism to wind back the wire rope, and
check the hoisting rope carefully.
3.14.3.2 Arrange hoisting rope at hook points.
3.14.3.3 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 pull rod close to the tower head.
Remove the pins connecting pull rod frame with the tower head, lower pull rods onto
the jib and fix them. Remove wire ropes, remove pins connecting jib with slewing
tower body.
3.14.3.4 Lower the jib and lay it down on the sleeper-cushioned support.
3.14.4 dismantle counter-jib
Hoist down the last counter-weights. 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.
3.14.5 Dismantle the operator cab
3.14.6 Dismantle the tower head
Before dismantling, check the tower head to see if component-to-component is
still connected by power cable.
3.14.7 Dismantle the slewing tower body
3.14.8 Dismantle the 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.
3.14.9 Dismantle the climbing frame and tower sections
3.14.9.1 Slowly hoist the climbing frame out along the mast section main chord
rod and place them down onto the ground.
3.14.9.2 Hoist down the tower sections one by one.
3.14.10 Dismantle the undercarriage
Dismantling the center ballast and undercarriage is opposite to the installing them.
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3.15 Attention after dismantling tower crane

3.15.1The dismantled crane needs to be checked and maintained by
technical personnel and trained maintenance personnel.
3.15.2 Check main stressed structural members for metal fatigue; weld fissure,
structural deformation, etc. Check tower crane parts for damage or collision injury.
3.15.3 After completion of checks, repair the defects found and defects potential.
Carry out rust removing and painting.
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4- Adjusting
4.1 Pre-check
Switch on the power switch on the ground to supply power to the operator cab.
Check 3-phase power supply for balance. Check voltage for 400V±5%
Operate the hoisting handle to watch the hoisting operation. When pulling the
handle inwards, the hoisting hook shall move upwards. When pushing the ha-
-ndle outwards, the hook shall move downwards. If not so, adjust the phase
sequence of power supply of the hoisting motor to meet the above requireme-
-nts.
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 pu-
-shing 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 pu-
-shing 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.
4.2 Power-on test run

4.2.1 Switch on the power switch on the ground to supply power to the operator cab.
Check 3-phase power supply for balance. Check voltage for 400V±5% (The gro-
-und power net shall supply adequate capacity to protect normal motor start and
operation).
4.2.2 Release the height limiter and radius limiter. Arrange the wire ropes of the trolley
to match mechanical erection.
4.2.3 Operate the hoisting handle to watch the hoisting operation. When pulling the
handle inwards, the hoisting hook shall move upwards. When pushing the han-
-dle outwards, the hook shall move downwards. If not so, adjust the phase sequ-
-ence of power supply of the hoisting motor to meet the above requirement.
4.2.4 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
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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 trav-
-el 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 me-
-et the above requirements. (Two slewing mechanisms shall separately be test-
-run to ensure slewing directions in conformity).
4.2.5 Notice for proper operation
4.2.5.1 After power supply to the operator cab (before pneumatic switch on), power
for the blocking light and lighting in operator cab can be supplied through switc-
-hes on the control panel. The sockets are also available for fan plugs.
4.2.5.2 Press start-button, and all operating handles shall return to zero, so as to
power on the master contactor.
4.2.5.3. 2 slewing mechanisms, with the technology of frequency altering and
stepless speed regulated, start smoothly and slew fast.
4.2.5.4. To prevent reversed slewing or emergency stop from any damage to the
tower crane, electrics are provided with time-delayed devices. When the jib sle-
ws 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.
4.2.5.5. No braking and emergency stop at revered slewing though the crane is equ-
-ipped with above-mentioned time-delay device.
4.2.5.6.Frequency converter is available for the operation of radius-changing mecha-

-nism. Proper speed is selected to suit different work conditions.
4.2.5.7.Before jacking, check the rotation direction of pump station motor in confor-
-mity to your requirements. If not, adjust the rotation to the correct direction. It is
pro- -hibited 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 replace-
-ments should be conducted according to the instructions for the electrical system.
Page:71 / 123
4.3.Adjusting Hydraulic System
The Motor must rotated at right direction.

4.3.1 Hydraulic System
Fig4.3.1a Fig4.3.1b
a. Main parameters (System principle is shown as Fig4.3.1b) (Please refer to the

operation instructions of hydraulic system)
Main Parameters of pump station
Pressure Flow Power Hose Oil tank Oil Requirement
(MPa) (L/min) (kW) (JB1885-77) capacity（L） USA ESSO anti-wearing
7.5 A-10Ⅱ 100 Hydraulic oil AW46
31.5 11.25
Main Parameters of Climbing Jack
Rated Cylinder Diameter Distance of Installation
of Rod Distance Jack speed Max. Jack
Pressure Diameter Travel
(m/min) force (t)
(Mpa) (mm) (mm) (mm) (mm)
31.5 160 110 1600 2070 0.56 63
b.Erection and operation of the hydraulic system
1) Oil cleaning
Screw open air filter II, fill 10µ hydraulic oil filtered by hand-held oil filter into
the oil tank up to the upper limit mark. After that, start the oil pump motor (look
down at the motor blades to see if the rotation direction is the same as that
marked at the motor tail)
Page:72 / 123
Pay attention to the fact that the pump may be rotated either left or
right. Wrong wiring will cause no system working and pump
burn-down.
2) Connect high-pressure hose openings for clean status.
Connect ports A.B of the hydraulic pump station to the hydraulic cylinders
through high-pressure hose. Screw down the connectors.
3) Air exhausting of the system
Unscrew the handle of overflow valve, and then the high-pressure
hose-to-port A connector. Move the handle of hand-operated valve to its up
position. Start the motor to drive the air out of Port A until the pump noise has
become normal and no foam formation from oil liquid. Make the cylinder into
no-load status. Push the operating handle to let upper cylinder or piston rod
move up and down at full strokes for several times to completely exhaust the
air from cylinder into oil tank through oil hose
When the piston rod has moved to its extreme position, pull back
the handle immediately to its middle position and keep this
position for several minutes until air bubbles in oil tank have
disappeared, and then carry out another action.
4) System operation
Before system operation, check if the oil cylinder is well connected to the
crane frame, including the check of relevant portions of the tower crane for
meeting relevant technical requirements.
Maximum working pressure setting:
Unscrew the locking nuts, in front of the control handle, of high-pressure overflow
valve 5 at non-jacking operation status. Start motor. Move the operating handle to
upper position and extend the cylinder piston rod to its extreme position. At this time,
pressure gauge readings rise. Keep on screwing down the handle of the overflow va-
-lve until the readings on pressure gauge have become stable at 31.5 Mpa. Screw do-
-wn the locking nut in front of the regulating handle of the high-pressure overflow valv-
-e (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.
Page:73 / 123
Start motor, and move operating handle to its up position. Extrude the cylinder
piston rod to hang the hanging plate connected to the piston rod into the lugs slot of
the tower mast section. Carry out the jacking operation for new section adding (or
tower section dismantling).
c.Maintenance and precautions of hydraulic system
The hydraulic system is super high-pressure or high-pressure equipment. The
whole process from oil filling to adjustment shall be accomplished strictly according to
the stipulations in its operating instructions.
Hydraulic oil for the system
The hydraulic system shall use the anti-friction hydraulic oil AW46 by ESSO,USA,
which can't be mixed with other oils. Unfiltered oil can't be filled directly. When
foam is found in the oil and oil is emulsified, the oil tank should be cleaned imme-
-diately and fill new oil.
Filling oil: Fully fill the tank with oil for the first time. After start-up, extrude the
cylinder rod, and then retract the cylinder rod. At this time, fill the tank with
make-up oil up to the tank upper limit mark
At this time it is a high-pressure hydraulic system with strict requirements of
highly cleaned oil, which should be filtered for 4~6 hours by hand –hold filter. The
oil cleanness should reach 7～8 grade,NAS1638 before starting the system.
The oil should be completely changed after the system work for 2,400hr and add
part of clean oil after working for 200hr
4.3.2 setting maximum working pressure
(1). Unscrew the locking nuts of high-pressure overflow valve in front of the control
handle at non-jacking operation status.
(2). Start motor. Move the operating handle to upper position and extend the
cylinder piston rod to its extreme position.
(3). Keep on screwing down the handle of the overflow valve until the readings on
pressure gauge have become stable at 31.5 Mpa.
The overflow valve can not be adjusted by untrained person
Page:74 / 123
4.4 Adjusting travel limiter

There are 3 kinds of limits in Tower Crane TC6517C-10E: DXZ-4/7 hooking
height limit, DXZ-4/F (i=600) trolley travel limit, and DXZ-2/3 slewing limit.
①（WK）Micro-switch ②（T）Memory cam ③Inputting Axis

Fig. 4.4.1 Hoisting height and trolleying limit
The corresponding relations of the adjusting axis(Z)、cam(T) and micro-switch is

shown as follows:
1Z→1T→1WK 2Z→2T→2WK 3Z→3T→3WK 4Z→4T→4WK
①（WK）Micro－switch ②（T）Memory cam ③Inputting Axis

Fig. 4.4.2 Slewing limit
The corresponding relations of the adjusting axis(Z)、cam(T) and micro-switch is

shown as follows:
1Z→1T→1WK 2Z→2T→2WK
4.4.1 Adjustment procedures

4.4.1.1 Dismantle the upper cover, check and screw down 2-M3×55 screws;
4.4.1.2 Unscrew M5 nuts;
Page:75 / 123
4.4.1.3Drive the mechanism under control to an designed position (without load ) to
meet the 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) press down the micro-switch
(WK) contact.
4.4.1.4 Screw down M5 nuts (be sure of screwing them down, otherwise foul-up
memory will occur).
4.4.1.5 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)
4.4.1.6 Make sure that the position is as specified. Screw down M5 nuts and re-cover
the casing.
4.4.1.7 After the mechanism working normally, check at certain interval the memory
control position for deviations. Correct the deviations if any.
NOTICE：
For the 4-loop limits（DXZ-4/7、DXZ-4/F） that used in hoist and trolley, long
cam is for the purpose of limiting the speed, short cam is for the purpose of
limiting the radius;and the limit switch of Slewing limit must be connected to
the long cam switch.
4.4.2 Adjustment for hook height limit (2-fall when adjusting)

4.4.2.1 Adjusting procedures according to 3.1.1
4.4.2.2 Adjust at no-load conditions. Press down micro-switches (1WK、2WK) by
finger to check the rising micro-switch or lowering micro-switch for correct action.
4.4.2.3 Adjust axle (2Z) to make cam (2T) act and press down micro-switch (2WK) for
decelerating the hook rising when the distance from trolley to hook is about 5m (10m
for frequency conversion cotrol). Adjust axle(1Z) to make cam (1T) act and press
down micro-switch (1WK) to stop the hook rising when the minimum distance from
trolley to hook is not smaller than 1m (3.1m for frequency conversion control, the
ultimate distance between trolley to hook must be not smaller than 1 m) . Screw down
M5 nuts.
Page:76 / 123
4.4.2.4 Validate the limit position of hoisting
Especially Notice:
1. After wire rope changed, the height limit shall be adjusted again.
Otherwise the hook may crash the trolley and the wire rope breaks, which may
lead to the crane destroying and people death.
2. If the adjustment of height limit in 2-fall, the limit radius and speed will be
doubled when the wire rope transformed from 2-fall to 4-fall. If the adjustment of
height limit in 4-fall, there are no limit function in the condition of 2-fall.The
users should pay great attention to it.
4.4.3 Adjustment for slewing limit (the same procedures as item 3.1.1)
4.4.3.1 Adjust the slewing limit while the jib is at erection position (power cable at free
status).
4.4.3.2 Adjust under no-load condition. Press down the micro-switch (1WK, 2WK) by
finger to check the switch for correct left and right control.
4.4.3.3 Slew to the left for 540°(1.5 rounds). Follow the Item 3.1.1 to adjust the axle
(1Z) to make the cam (1T) move to achieve transient changing by the micro-switch
(1WK). Screw down M5 nuts.
4.4.3.4 Rotate 1080° right (3 rounds). Follow item 3.1.1 to adjust the axle (2Z) to make
the cam (2T) move to achieve transient changing by the micro-switch (2WK). Screw
down M5 nuts.
4.4.3.5 Check if the left and right slewing is correct.
4.4.4 Adjustment method of radius (trolley travel) limit (the same procedures as item
3.1.1).
4.4.4.1 Outward travel at lower speed and extreme position limiting at the jib tip:
Drive the trolley at the position of 1.5m (4.6m for frequency conversion cotrol)
away from the jib tip buffer. Adjust the axle (2Z) to turn the memory cam (2T) to
enable the micro-switch (2WK) for action. (Enable simultaneous overlap of the cam
(4T) to the cam (2T) to avoid speed reduction interference before braking). Screw
down M5 nuts. Drive the trolley to the position of 220mm away from the jib tip bumper.
Follow the procedures to adjust the axle (1Z) to rotate (1T) to make the micro-switch
(1WK) act. Screw down M5 nuts.
Page:77 / 123
4.4.4.2 Inward travel and extreme position limiting at the jib tip:
The adjustment method is the same as item 3.1.4.1 Carry out speed reduction
adjustment and position limiting at the jib root ( 3Z-3T-3WK, 4Z-4T-4WK ) at 1.5m
(4.6m for frequency conversion cotrol) and 220mm away from the jib root buffer
respectively.
4.4.4.3 Check and modify.
Page:78 / 123
4.5 Adjusting Moment limiter
Fig4-2 moment limiter
wire rope at 4-fall
4.5.1 Adjustment of constant load and variable radius of trolley

Trolley hoists 8t and moves outwards from 8m point at slow speed. Adjust the
90％ Adjusting screw（shown as Fig4-2）to enable the warning light power on in
the operator cab when the trolley moves to the range of 14.1～14.9m when 60m
jib.(the jib length is 55m, trolley moves to the range of 14.8～15.7m. The jib length
is 50m,trolley moves to the range of 15.1～16.0m. The jib length is 45、40m、35m、
30m,trolley moves to the range of 15.3～16.2m). And adjust adjusting screwn of
constant load and variable radius of trolley to enable the mechanisms power off
and give over-load warning sound at the same time when the trolley moves to the
range of 16.6m～17.4m, It is forbidden upward hoisting or outward traveling.(the
jib length is 55m, trolley moves to the range of 17.4～18.3m. The jib length is 50m,
trolley moves to the range of 17.8～18.7m. 45m,40m,35m, 30m,trolley moves to
the range of 18.00～18.9m ).
Page:79 / 123
4.5.2Adjustment of constant radius of trolley and variable hook load

When the jib length is 60m, the loading1.5t at 60m point (the jib length is 55m,
loading 1.86t at 55m, the jib length is50m, the loading2.2t at 50m, the jib length is
45m, the loading 2.58t at 45m. the jib length is 40m, the loading3.02t at 40m, the
jib length is 35m, the loading 3.59t at 35m. the jib length is 30m, the loading4.36t
at 30m), upward hoisting is permission. Adding 75kg to the load (the jib length is
55m,93kg , the jib length is 50m, 110kg, the jib length is 45m, 129kg .the jib length
is40m,151kg , the jib length is 35m, 180kg, the jib length is 30m, 218kg), adjust the
Adjusting screw of constant radius of trolley and variable hook load to enable the
mechanisms power off and give over-load warning sound at the same time. It is
forbidden upward hoisting or outward traveling. Test the step 3 times to keep the
function stability
4.5.3 Check moment limiter

4.5.3.1 Check of constant load and variable radius of trolley
When the jib length is 60m, loading4t, trolley travels outwards from 20m point
at a slow speed. When travelling to the range of 29.56～31.04m (the jib length is
55m, the range of 31.15～32.71m, the jib length is 50m, the range of 31.79～
33.38m,45m,40,35m ,the range of 32.10～33.71m, the jib length is 30m, the range
of 32.60～33.88m,), the mechanisms power off and give over-load warning sound
4.5.3.2 Check of constant radius and variable load
When the jib length is 60m, loading 8t at 16.6m (the jib length is 55m, loading
8t at 17.47m, the jib length is 50m, loading 8t at 17.82m , the jib length is 45m,
loading 8t at 18.0m, the jib length is 40m, loading 8t at 18.0m, the jib length is
35m, loading 8t at 18.0m, the jib length is30m, loading 8t at 18.03m)point with a
normal hoisting speed, the moment limiter shall not act and upward hoisting is
permission. When loading 8.8t load, the moment limiter works normally and the
mechanisms power off.
Page:80 / 123
4.6 Adjust weight limiter
1. The two microswitches connect in series with the four

microswitches
2. wire rope at 4-fall
Adjusting the situation of high speed

Hoist the weight of 5000kg. The hoisted weight travels up and down at low、
middle、high speed one time each. Do not permit no hoisting.
Add another 300kg load, lift the load at high speed, at the same time
adjusting the first screw if the hoisting mechanism can run, when the load is lifted
about 10m ,the load is lowerd until the ground.
Repeat upper all movement befor thehoisting mechanism can’t operate at
high speed.the weight of hoisting load between 5000 and 5300 is comparatively
perfect.
upper all movement is repeat another twice(don’t adjusting the first screw)the
results should are same
Adjusting the situation of lowe speed(radius is not the more long than 12m)
Hoist the weight of 10000kg. The hoisted weight travels up and down at low、
middlespeed one time each. Do not permit no hoisting.
Add another 400kg load, lift the load at middle speed, at the same time
adjusting the third screw if the hoisting mechanism can run, when the load is lifted
about 10m ,the load is lowerd until the ground.
Repeat upper all movement befor thehoisting mechanism can’t operate at
middle speed.the weight of hoisting load between 10000 and 10400 is compar-
-atively perfect.
upper all movement is repeat another twice(don’t adjusting the thirdscrew),
the results should are same
Page:81 / 123
4.7 Operation of anti-twist device (shown as Fig4-7)

a. Hoisting ropes are non-rotating (anti-twist) ones. The anti-twist device
shall lock tightly the locking bolts while the tower crane is at service.
b. If hoisting ropes are ordinary wire rope, the anti-twist device shall unlock
the locking bolts while the tower crane is at working.
c. After changing for new wire ropes, the hoisting hook will rotate at no-load
operation. At this time, unlock the anti-twist device, wire ropes will freely
rotate till it is identical with the hoisting hook .If the anti-twist device is at
locked status, no-load operation for a long period, it will cause steel ropes
twisted along the whole length until the hook no longer rotates.
d. When the tower crane has been used for a long period of time, steel ropes
will be made longer and slightly twisted. At this time, unlock the anti-twist
device for the time being until ropes have been tensioned, then lock the
device once again.
e. Once steel ropes have their strands loosened, the anti-twist device will
accelerate rope deterioration. Therefore change the deteriorated ropes
timely as required.
Fig4-7
4.8 Working mechanisms of the tower crane

The working mechanisms of the tower crane consist of the hoisting
mechanism, slewing mechanism, trolley traveling mechanism and jacking
mechanism.
4.8.1 hoist mechanism(shown as Fig4-8.1)
Page:82 / 123
The model of hoist mechanism for the tower crane is QE8100D2, motor model
YZRDW250L-4/8, equipped with draft fan,
with the function of high-speed light-load
hoisting and low-speed heavy-load hoisting.
The minimum stable speed is smaller than
5m/min to ensure stable hoisting and braking
of objects. The wire drum is provided with the
hook height limiter. When objects have been
hoisted to the highest position, the hoisting
mechanism will stop automatically.
4.8.2 slewing mechanisms (Fig4.8.2) Fig4-8.1
There are 2 sets of slewing mechanisms symmetrically arranged on both sides of

slewing ring. They are driven by 2 sets of 95N.m motors model
YTLEJ112L-4F1andYTLEJ112L-4F2BMZL. They drive the pinions through planet
gear reducer, hence making the jib and counter-jib slew to the left or the right. The
one motor is provided with disc brakes at tits tail,which is kept at constant close 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.
Fig 4.8.2
1. Motor 2. Brake 3. Reducer4.Slewing Pinion

5. Slewing ring 6. Slewing limiter 7. Pinion
Page:83 / 123
The reducer of the slewing mechanism is lubricated with grease(000# grease), When
maintained or the level of oil dropped, supplements grease in time to guarantee the level of
grease arrive at the bolt of oil.
4.8.3Trolleying mechanism(Fig4-8.3a)
a. The trolleying mechanism is for radius changing by the trolley. When doing ra-
-dius changing, the frequency conversion motor (model: YEJ132S-4B5 with magnetic
disk brake) drives the drum through the planetary reducer, thus making the trolley tra-
-vel to-and-fro along the jib. Travel traction is done by 2 wire ropes (6×19-9.3-1700-Ⅱ
-right twisted). One end of the two wire ropes are fixed at both ends of the wire drum,
wound on the drum and led separately to the front and rear of the jib. They pass over
the guide pulleys at the jib root and jib tip. Another end of the wire rope are fixed on
the trolley. In the course of radius changing, one rope retracts and the other rope
extrudes for the normal operation of trolley. When the trolley travels to its minimum or
maximum radius, the number of turns of both ropes on the wire drum shall not be less
than 3.
Fig 4.8.3a
1. Brake 2. Motor 3. Limiter

Fig 4-8.3b
4. Reducer 5. Support 6. Drum
b. The adjustment of trolley brake device(Fig4.8.3b)

After long time service, the clearance between electromagnet and armature shall be
increased due to the abrasion, and the suction is decreased
Page:84 / 123
4.9 installing anemoscope
the monitor of the wind speed

installed in the control-plate of the
operator cab.
the power lines of the anemoscope
are connected to the 50、51 ports of the
control-cabnet of the operator cab.
Page:85 / 123
5 –Operation
Attention: Tower crane can be operated only by
trained and qualified person!
5.1 Safety instr uctions
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! Emergency stop
Page:86 / 123
Read the manual before use! Slew freely when out of service
Very hot, do not touch! Danger of crushing!
Insert safety pins in climbing! Keep watch!
WARNING: Suspended loads!

Wear safety helmet! Check ropes
Page:87 / 123
Lubricate! Adjust the height limiter!
Check metal structures! Check brakes!
Keep safety devices workable! Adjust brakes
High-tensile strength bolt M36 High-tensile strength bolt M30

connections connections
Page:88 / 123
Maximum load on maintenance cage Always close the hatches!
5.2 Overall dimensions of the crane

5.2.1 Overall dimensions of the crane
Fig5-1 Overall dimensions of the stationary tower crane TC6016A
5.2.2 Overall dimensions of the crane anchored to the building
Page:89 / 123
Fig5-2 Overall dimensions for the stationary tower crane with chassis anchored to the building
Fig5-3 Overall dimensions for the stationary tower crane with stationary anchored to the building
Page:90 / 123
Anchored by Chassis stationary

embedded support Traveling
NO Order NO. Code Designation Qty Remark
1 0021001A0000 TC6015.01 Counter-jib 1
2 0021002A0000 TC6015.02 Counter-jib guy rods 1
3 0021003A0000 TC6015.03 Tower head 1
4 109060001001 LFM-4 Anemoscope 1
5 0029321B0000 BP55B Trolleying mechanism 1
6 0021004A0000 TC6015.04A Jib guy rods 1
7 0021005A0000 TC6015.05A Hoisting jib 1
8 0029605A0000 FDG08A Load hook 1
9 0029705C0000 FXC08C Trolley 1
10 0029115C0000 QP8100D2 Hoisting mechanism 1
11 0020308C0000 TC5613A.08C Slewing mast 1
Page:91 / 123
Continuation
NO Order NO. Code Designation Qty Remark
HVV95 1
12 Slewing mechanism
HVV95 1
13 0029502G0000 TC5023AG.12A Jacking equipment 1
14 0020411B0000 TC5023A.11B Climbing equipment 1
15 109050001002 TWL-10 Overload limit switch 1
16 S7 Operator’s cab 1
17 0020309C0000 TC5613A.09C Upper support 1
18 103160001003 011.45.1400 Nutation support 1
19 0020410B0000 TC5023A.10A Below support 1

The quantity depends on
20 0029007C0000 BZJM1 Tower section M1 15
the hoisting height .
For anchored by
21 0029008C0000 BZJMQ1 Tower section MQ1 4 embedded support
pillars.
Base tower section MQQ Only for anchored by
22 0029008C1000 BZJMQQ1 anchored by embedded support 1 embedded support
pillars pillars.
Base tower section MQQ Only for anchored by
23 0029008C2000 BZJMQQ2 anchored by embedded 1 embedded support
support pillars pillars.
Foundation with embedded Only for anchored by
24 0021015A0000 TC6015A.15A 1
support pillars embedded pillars.
Only for attached crane.
The quantity depends on
25 0020616A0000 TC6020A.16 Accrete-frame the hoisting height and
distance between two
adjacent anchor points.
For chassis stationary /
26 0020614A0000 TC6020A.14 Undercarriage 1
traveling.
Page:92 / 123
5.4 Safety instructions on the crane
For an explanation of the symbols, see "Safety instructions".
detail Ⅰ
Page:93 / 123
detailⅡ
View A
Page:94 / 123
5.5 Operating instructions

5.5.1 Pre-start checks
(1) (2) Check the
Check the wind speed!
environment temperature!
¾ Max. permissible wind speed in
The working temperature the crane
operation: 72 km/h (wind force 8). is in the range of -20 ~+40℃.
¾ Max. permissible wind speed in
(6) Make sure that all ballast and
erection or climbing: 50 km/h (wind
counter-weights are complete and
force 6). secure.
(4) Total freedom of movement in the (5) Check the condition of foundation.
travelling and stewing area
(3) Assure the working voltage

fluctuates ±5%.
(7) Check ropes: (8) Check the tightness of all bolts!

¾ Make sure that all ropes are not e.g. bolts for ball slewing ring
damaged. connection and sections connection
etc.
(9) Make sure that venting valves of the

hydraulic unit have been opened.
¾ Make sure that all ropes are
properly fitted in the pulleys.
¾ Check that rope grooves are free of (10) Check the height limiter!
hardened grease. Adjust the hoisting height limiter
again after the rope serves for a
(11) Make sure that ropes must be period of time.
wound evenly onto their drums.
(12) Check the insulation of electric
switches! Make sure that
¾ the earth insulation resistance of
main control circuits is no smaller
than 0.5 MΩ.
(13) If the crane is equipped with a
lightning protection, ensure correct ¾ the earth resistance of the tower
earthing! body is no greater than 4Ω.
Page:95 / 123
(14) Make sure that all limit switches (15) Rail track(only for travelling crane)
and push buttons are funtional.
(16) Make sure that the safety

instructions and warnings attached
to the crane always complete and
perfectly legible.
(17) Make sure that all open gear (18) Check safety devices to ensure
wheels have been lubricated well. them reliable.
5.5.2 User’s operations
(1) The crane should be operated only (2) Before starting up the crane, make
by qualified persons who are sure that nobody can be
complete familiar with the crane. endangered.
(3) Before beginning work, make (4) Operate the crane only if all
yourself familiar with the protective and safety devices are in
circumstances of the site. place and fully functional.
(5) Do not bridge any safety devices (6) No unauthorized persons are
(limit switch). allowed to access the crane.
(7)When changing the jib length of the (8) Do not land the hook block!
crane,reset the overload limits
according to radius and load
capacity.
Slack rope
(10) During start-up and shut-down

procedures always watch the
(9) No loads exceeding the lifting
indicators according to the
capacity regardless of an installed
instruction manual.
overload protection!
(12) Secure tools and loose objects
(11) Night operation do not permit bad against falling.
visibility and darkness, and crane Keep all handles, steps, handrails,
lamps or construction site lamps platforms, landings and ladders
are essential. free from dirt, snow and ice.
Page:96 / 123
(13) Avoid any operation that might endanger the tower crane!
For example:
Pulling off fixed loads Horizontal displacement of Adding the load after lifting it
fixed loads
Pendulous movements Exceeding the rated lifting Pulling loads at an oblique

or swinging of the load capacity angle
(14) The carriage of persons with the (15) Whenever a load is suspended
load is forbidden. from the hook, the operator must
remain at the controls.
(16) Maintain the safety distance: (17) WARNING: Suspended loads!

Wear safety helmet!
Page:97 / 123
(18)The operator must be able to observe the working area and the load!
(19) Hoisting down the load from a great hook height:

The horn signals: Do not hoist down! Trolley in to the
Overload(the rope weight minimum radius and
increases). hoist down.
Over-load
alarm
Pre-warn
(20) Maintain a safety distance from overhead electric lines.

¾ Do not leave the tower crane.
¾ Do not touch the steel construction of
the tower crane.
¾ If practicable, drive the crane out of
the hazard zone.
¾ Warn others against approaching and
touching the crane.
¾ Arrange to have the power switched i
off in the contacted/damaged line.
¾ Do not leave the tower crane until the
contacted/damaged line has been safely
de-energized.
Page:98 / 123
(21) Suddenly removing the load can (22) In heavy thunder-storm or thick fog
damage the crane and therefore days, or the wind speed at the top
must not be attempted without the of the crane over 20m/s, the crane
approval of the manufacturer! must be out of service.
(24) Do not make any changes, install (25) No slewing of the jib and no up and
or modify anything without down movements of the load hook
permission from the manufacturer! in climbing!
5.5.3 Safety operating procedures of operator
(2). The operators must read the instruction of the tower crane carefully. They must
(1). No unauthorized
be familiar persons must
with the constitution, thebe allowedoperating
features, to operate the crane.
methods andItthe
is forbidden
technique
that the operators
of maintaining the who areThey
crane. drunk operate
also the crane.
must master the constitution of safety devices,
its principle of running and means of debugging.
(3). Before attempting to lift a load, the operator must check the safety devices and
limit switches one by one, and run the crane without loads. After confirming all
devices without problem he can run the crane with loads. It is forbidden to operate
the crane with loads when the safety devices don’t work.
(4). During operating:

¾ The operator must operate the crane according to the instruction of the crane
and the regulations which are framed by the government or the trade. It is
forbidden to overload, pull loads at an oblique angle, use the crane to drag loads
which have stuck fast and lift the weight-unknown loads.
¾ Avoiding the load hook to drop on to the ground can prevent accidents caused
by slack and no neatly hoisting rope. If the load hook must drop on to the
ground, the operator should check the rope on the drum. It is necessary to wind
it again until neatly.
¾ The operator must give warning whistle when necessary.
¾ The operation of the mechanism must be smoothly, and the change of speed
from low to high must be step by step. Slewing movement of the crane can not
be braked by applying reverse slewing and emergency braking.During hoisting
or lowering, the shifting-gears cannot be used for a long time under load. The
detail is mentioned in the instruction of the crane
¾ When a load is suspended, the operator and the signalman must not leave
crane.
Page:99 / 123
¾ In big thunder-storm or thick fog days, or the wind speed at the top of the crane
over 20m/s, the crane must be shut down.
¾ When the mechanism need to run on opposite, the motor must be stopped, then
reversed.
¾ If any defects likely to affect operating safety are noted, the operator should stop
work and shut down the power. After checking and resolving the problem, the
crane can be used.
¾ When loading it is forbidden to carry persons in maintenance cage and convey
persons.
(5). Set down the suspended load, raise the load hook as high as possible and run
the trolley back to the minimum working radius. The operator must ensure that the
control point is abandoned, the controls are returned to the zero or neutral positions
and the power supply is switched off and locked, then he can leave.
(6). The operator should report the usage, maintenance and handing over carefully.
(7). The others are mentioned in the instruction of the crane or relative standards
and regulations.
Page:100 / 123
6- Maintenance Instructions
Mian Maintenance point
Switch off the main power supply when the crane operation is to be
stopped for repair or maintenance. No operation with power on.
Page:101 / 123
To ensure safe and economic operation of the tower crane for a longer service
life, it must be properly maintained and lubricated.
content
Items-checking before work start at each shift every day：
¾ Check speed reducers for oil quantity. Fill oil in time.
¾ Check wire ropes at different positions for looseness, breakage or being
worn-out. Change defective ropes as required as per relevant stipulations.
¾ Check brakes for performance and clearance to ensure reliable sensitivity.
¾ Check safety protecting devices for reliable sensitivity.
¾ Check bolt connections. Re-tighten the bolts once again when they have been
used for a certain period of time.
¾ Check steel rope head clampers and clips for loose status. Tighten them if
loosened.
¾ 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.
maintenance
The most dangerous is that the paint is striped in 45° oblique strings.
Trace the cause immediately and dress the issue in time.
¾ The hoisting height limiter should be adjusted again after the rope serves for a
period of time.
¾ No function failures of limit switches and push buttons. Replace rusted or
required
damaged parts in time.

¾ Be sure that the insulation of electric switches to switch panels meet the
relevant requirements, with insulation resistance no less than 0.5MΩ.
¾ Check if the bolts connecting electric components are loosened: Check power
Summary of
cables and other conducting wires for fractures. Remove the trouble if any.
Monthly maintenance：
¾ Check the high-strength bolt joints and the nearby material.
¾ Check them of the three tower sections on the foundation if the tower crane is
not anchored to the building.
¾ Check them of the tower sections nearby the anchored point.
¾ Check the tower head, especially the connecting plates and the nearby
material.
quarterly maintenance：
¾ Check the connecting plates and the nearby material every three months.
when starting up the crane and before every erection：
¾ Check the articulations for pins cracks, rusting corrosion and damage.
¾ Check the rigid tie rods, wire ropes, pulleys, hoist hooks, fall-changing devices,
etc. for conformity to operating conditions.
¾ Check the metal structure members for deformations and weld fissures to
make sure of their conformity to operating conditions.
¾ Conduct trial operation for the mechanism of hoisting, jacking, slewing,
trolleyging until they have become normal.
Page:102 / 123
Notes:
z Reject steel ropes, drums, pulleys and hoisting hooks strictly according to the
relevant stipulations.
z 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.
z Each bolt shall be tightened with two nuts for the installation of tower sections.
z The strength rating of high-tensile bolts for connecting tower sections are 10.9,
and nuts are 10, which should marked on the head of bolts and nuts, The
bolts and nuts without grade marked on the head are prohibited to use.
z Conduct rust removing and painting of the whole tower crane and its metal
mechanisms after completion of their each use in a project.
Routine check of high-strength bolt
content
¾ 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
Preparation
damaged bolts (including rust bolts).
¾ Before using, it is necessary to coat the MoS2 grease on contact
surfacs of the bolts, nuts and washers to equilibrium friction.
¾ The tighten torque on the nuts must reach the specified torque
Tightening and the torque of loose-proof nuts（the upper nut）should be a
little more than or equal the specified torque.
¾ 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
Check
erecting the tower crane. Dismantle 2-3 bolt groups each year
and check them for deformation, corrosion, rust, etc.
¾ The high-strength bolts can be used many times, but agreed with
Repeat usage
the requirements of the above item 5.1 and the item 5.2.
Page:103 / 123
Routine check of wire rope
content
¾ 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 (GB5972-86).
¾ 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.
¾ Carry out timely cleaning of wire ropes and applying of lubrication oil or grease to
them.
¾ Check the wire ropes one time every week.
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.
Maintenance and precautions of hydraulic system

content
Work ¾ Shut the system when it is out of service because of the poor
condition condition of ventilation.
¾ The hydraulic system shall use the anti-friction hydraulic oil AW46 by
ESSO, USA, which can't be mixed with other oils. Unfiltered oil can't
be filled directly. When foam is found in the oil and oil is emulsified,
the oil tank should be cleaned immediately and fill new oil.
¾ Filling oil: Fully fill the tank with oil for the first time. After start-up,
extrude the cylinder rod, and then retract the cylinder rod. At this
Hydraulic time, fill the tank with make-up oil up to the tank upper limit mark.
oil ¾ At this time it is a high-pressure hydraulic system with strict
requirements of highly cleaned oil, which should be filtered for 4~6
hours by hand –hold filter. The oil cleanness should reach 7～
8 ,NAS1638 before starting the system.
¾ The oil should be completely changed after the system work for
2,400hr and add part of clean oil after working for 200hr.
The hydraulic system is super high-pressure or high-pressure equipment.

The whole process from oil filling to adjustment shall be accomplished strictly
according to the stipulations in its operating instructions.
Page:104 / 123
Content
¾ Add lubricating oil to chain wheels, chains and lubricating

point every 80 working hours, and check the tightness of
each bolt at any time.
¾ Often check collector ring assembly, tighten connection bolts,
treat head hot discoloration fittings, clean rust and power. If
Maintenance any electric corrosion, burning occurs on collector ring, polish
of the with abrasive cloth. If 1/3 of the brush is worn, should
JQC type exchange the brush.
cable drum
Cut off the power before open cover！
¾ Measure insulation condition of cable drum every 400
working hours, insulating resistance should not be less than
5 MΩ.
¾ Must exchange lubricating oil in reducer after the first

Maintenance of the cable drum
one-month operation.
¾ Check the oil level of reducer every two months, when it is
below center of sight hole, and then add HL-30 lubricating oil.
¾ Check the tightness of electric parts of collector ring every
two months, to ensure good contact and reliable connection
of cable fittings. At same time, measure insulation condition,
the insulating resistance should not be below 5 MΩ.
¾ Change lubricating oil in the reducer every year. Turn out the
hexagon plug screw at bottom to drain off dirt oil, and screw
out brake parts simultaneously. Screw on the hexagon plug
screw and add clean HL-30 lubricating oil, Screw on brake
parts after cleaning the dirt oil.
Maintenance
¾ Keep the surface of collector ring, motor, reducer cleaning.
of M type
¾ Exchange parts in time if the parts are worn greatly and affect
cable drum
performance.
z Cut off the power before open the collector ring.

z Prohibit inserting stop parts into nut indentation
during operation.
z Lubricating oil level in reducer should be above the
center position of the sight hole.
z When the crane moves toward the direction of
power, the motor of cable drum should be started
simultaneously with traveling mechanism, while the
traveling mechanism stops, the motor of the cable
drum should power off after 3 seconds. The motor
should not power on when the crane moves away
the power.
Bearing Wheel bearing model: GB288-87. Bearing 5320
model 4 wheel each dolly.
Page:105 / 123
Parts Lubrications
Parts Lubricating Lubricant Lubricating method
No Description location specifications & duration
Graphite Calcium-based Grease the rope each
Hoisting rope
1 Wire rope grease after overhaul or
Trolley rope
ZG-SSY1405-65 medium maintenance
Lubricate the reducer
Summer（over 10°C）
after it serves for 240
Reducer of with N220 gear oil
hrs，Change the oil
hoisting winch Winter（below 10°C）
after working for
with N150 gear oil
1500hrs.
When maintained or
the level of oil
Sulphur
Reducer of dropped,
molybdenum-2# or
Trolleying supplements grease
2 Reducer ZL-2# lithium-based
mechanism in time to guarantee
grease
the level of grease
arrive at the bolt of oil.
When maintained or
the level of oil
reducer of the dropped,
slewing #
000 grease supplements grease
mechanism in time to guarantee
the level of grease
arrive at the bolt of oil.
Rolling bearings Grease the bearings
Calcium-based grease
in the reducer each after they work
Rolling
3 Drum bearing ZG-2 for 160 hrs，Clean
Bearing
them once after half a
Hook bearings Calcium-based grease
year.
Winter：Calcium-based
grease ZG-2 Change the grease
Motor
4 All the motors Summer： after working for 1500
bearing
Calcium-based grease hrs.
ZG-5
Pulleys and Change the grease
Pulley Winter：ZG-2
5 guiding pulley in after working for 240
Block
the hoisting winch Summer：ZG-5 hrs.
Sliding bearings in Add grease after
Sliding the trolley traveling Winter：ZG-2 working for 160 hrs,
6
Bearings mechanism and Summer：ZG-5 and conduct cleaning
drum half a year
Articulated
All the articulated Fill oil after working
7 points of Machine oil
points for 56 hrs
brake lever
Page:106 / 123
Parts Lubricating Lubricant Lubricating method

No Description location specifications & duration
Two
articulated
points All the Calcium-based grease Before dismantle or
8
between jib articulated ZG-2 (ZG-5) installation
and tower points
section
All the motion
Fall-chang Fill oil after working
9 parts and guiding Machine oil
e Device for 160 hrs
groove
All the connectors
Gear Grease once after a
10 of mechanisms Calcium-based grease
connector season
and gears
Add filtered grease
Pump
after working for 200
station of
11 Oil tank American ESSO AW46 hrs， and change the
hydraulic
erection grease after working
for 2400 hrs.
The hours mentioned in the table means the accumulated working hours
of the parts.
Page:107 / 123
Ordinary troubles, trouble shooting and solution
No. Trouble Trouble shooting Solution

Reducer
Lubrication oil deficient or Properly increase or
1 temperature is too
excessive decrease oil
hot
_Excessive or deficient grease
The temperature of _Properly replace grease
_Grease quality very poor
the reducer _Re-adjust the clearance
2 _Improper axial clearance of
bearings is too of of bearings
the bearings or bearings is
high _Replace bearings
already damaged
Contacting surface of
Oil leakage from connections is not tightened
3.
speed reducer enough, sealing rings at shaft Replace sealing rings
ends is worn and damaged
_Worn oil pump, declined
efficiency
_Oil in the tank is insufficient or
_ Repair or replace the
oil filter clogged
Jacking speed is damaged parts
4 _Hand-operated valve rod and
too slow _Fill adequate oil or clean
valve hole severely worn
oil filter
_Oil cylinder piston seal is
damaged and internal oil
leakage
_Severe internal leakage from
oil pump
_Repair or replace the
Jacking force is not _Overflow valve pressure set
worn parts
5 adequate or too low
_Adjust pressure as
unable to jack _Hand-operated valve core
required
excessively worn
_Clean hydraulic valve
_Overflow valve clogged down
Noise and vibration
occur during
6 jacking operation Oil filter clogged
Clean oil filter
at increasing
pressure
Jacking system is Motor rotation and oil pump Change motor rotation
7
not working rotation both in wrong directions direction
Page:108 / 123

Creeping and _Air not completely exhausted
_Exhaust air as required.
8 quivering during from oil cylinder piston
_Adjust guide pulleys
jacking operation _Trouble with guide mechanism
_Trouble with balance valve of
Jacking drop when the cylinder head Remove trouble, replaces
9
loaded _Piston sealing of oil cylinder is sealing parts
damaged
_Operation handle not returned
Malfunction of to zero _Return handle to zero.
_Fuse in the electric control _Replace fuse
10 Master cabinet is burned down _Repair or replace the
push-button _Poor contact of the button
start-button and stop-button
_Over current from hoisting
_Check hoisting brakes for
motor, actuating over-current
open-up. Check
breaker.
Power is stopped over-current
_Capacity of the site
11 during hoisting stabilization value for
transformer is inadequate, or
operation variation
power cable from transformer
_Replace transformer or
to tower crane has
increase cable diameter
inadequate diameter
_Check wiring diagram.
_Control wiring in a wrong way
_Check fuse capacity,
_Fuse burned-down.
change for larger one if
_Electric motor windings
too small
short-circuited, grounded or
_Measure power grid
circuit breaking
Hoisting voltage
_Motor working voltage is too
12 mechanism unable _Supply power to suit
low
different speeds so as to
to start _Windings wiring in a wrong
find out short circuit and
way
circuit breaking. Repair
_Electromagnetic brake not
the findings
released
_Check brake voltage and
_Too heavy load or trouble with
windings for circuit
the transmission mechanism
breaking or clogging
Trolleying
mechanism _Bearings burned down _Replace bearings
13
Bearings _Grease too much or too few _Add grease as required
over-heated
Page:109 / 123

_Mechanical wear, due to:
_Check rotor clearance for
a. Friction between
being uniform
stator-rotor
_Check slip rings for wear.
Abnormal noise b. Motor-speed reducer box
Replace them if any
and vibration from not in concentricity
14 _Clean bearings and add
_Bearings without oil or
trolleying fresh lubrication oil.
damaged.
mechanism Replace bearings
_Gear box without oil
_Replace gearbox.
_Gear worn
_Switch off power supply.
_2-phase operation with
Check and repair
abnormal noise
_Power line or earth line wired _Find out the cause, and
Electrification with in a wrong way remove the trouble.
15 the trolleying _Poor earth connection _Improve earth connection
mechanism _Motor wires scratched and _Find the cause, and
earthed remove the trouble
Brake failure with _Brake spring broken,
16 _Braking moment too small
the trolleying replace the spring
_Increased friction clearance of
_Excitation and
mechanism friction pieces.
inadequate voltage
Slewing
17 See if foreign matters are
mechanism Remove foreign matters
clogged in the gear.
unable to start
_Measure stator current,
e.g. decrease load if
heavier than rated
_Load excessive
value.
_Load continuing and work not
_Operate as required.
as specified
_Measure 3-phase current
_2-phase operation
to remove troubles.
_Power supply voltage too low
_Check input voltage for
Trolleying or too high
necessary correction
mechanism _Motor windings earthed or
18 _Find out the cause to
short circuited between turns,
motor over-heated repair
or between phases
or smoke emission _Adjust clearance as
_Incorrect clearance between
required
friction pieces
_Braking time and releasing
_Check brake for voltage
time not correct
and time-delay for circuit
_Moter clogged, causing
breaker action and
temperature rise.
remove the trouble.
_Keep smooth ventilation
Page:110 / 123
Spare parts list
(The parts in the list are provided if users pay for them, the parts with "*" in the number
column are easily-worn parts.)
Transmission Mechanism
No. Code Designation Position Quantity
Friction lining of
1* φ315 2
brake
MLL8-I-φ315-ZA70×112
2 Shaft coupling 1
（18）/ZA60×112（18）
3 MT8B Quincunx elastic body 1
QE8100D2 According to
4* 14 Wire rope the max height
of hoisting
Roller wheel for wire
5* 1
rope
6 DXZ-4/7 Multifunction limiter 1
NL5-(YA38×145(10))/ Dentate spring
7 1
(YA35×105(10)) coupling
8* BP55-5 Pinion BP55 1
9 DXZ-4/F（i=660） Multifunction limiter 1
10 9.3 Wire rope 120+73(m)
11 DZJ-80 Magnet brake 1
HPW55
12 DXZ-4/3 Multifunction limiter 1
13 ZDA52-4 Wheel 8
14 GB/T288-1994 53520-Bearing 16
ZD52
Overstroke safety
15* LX10-21 4
device
Page:111 / 123
Trolley and Hook

HL-400 Pulley Hook assembly 8
1
FXC08B-12 Pulley Trolley and Tower head 4
2 FXC08B-14 Roll Trolley 4
3* GB/T276-1994 Side roll Trolley 16
6212-Z Used for HL-360 and HL-400
4 GB/T276-1994 8
Bearing pulley
6210-Z
5 GB/T276-1994 Used for trolley roll 8
Bearing
6004-Z
6 GB/T301-1995 Used for side roll 1
Bearing
8313 Used for the beam of hook
7 FDG08A.02.7-4 1
Bearing assembly
8 HL-400 Hook Hook assembly 8
Others
1 TC5613A.05-13 Buffer stopper Jib 4
Overstroke safety
2 D4MC-5000 Moment limiter 3
device
3 TWL10 Overload limit switch Slewing mast 1
Sealing for climbing
4 1600 Climbing mechanism 1
hydraulic cylinder
5 LSHF36 High-strength bolt Tower section 240
Page:112 / 123
7. Electronic
Shown as TC6016A INSTRUCTION HANDBOOK
Page:113 / 123
A.1 Crane log
商标（Brand）
________________
型号（Type）
________________
所有者（Ownership）
________________
Page:114 / 123
Records of the usage
Data Duration Max weight of Status of usage User

loadings
Page:115 / 123
塔机润滑记录表(Records of Lubrication)
N Parts Lubricating Lubricant specifications Lubricating method & Lubricated Lubricating

l ti Grease the d rope
ti after b d t
Hoisting rope Graphite Calcium-based
1 Wire rope working for a week, and
grease
Trolley rope boil the grease after
ZG-SSY1405-65
overhaul or medium
Reducer of Summer(over 10°C) with N220
gear oil
2 Reducer hoisting winch Lubricate the reducer after
Reducer of Winter(below 10°C) with N150 it serves for 240 hrs，

Reducer of Sulphur molybdenum-2# or ZL-2# change the oil after working
Rolling bearings Calcium-based grease Grease the bearings each

Rolling
3 after they work for 160 hrs,
Hook bearings
Bearing Calcium-based grease clean them once after half
Slewing ring
a year.
EXAMPLE: F_UM_ TC_6016A_00 Page:116 / 123

Winter：Calcium-based
Motor grease ZG-2 Change the grease after
4 All the motors
bearing Summer：Calcium-based working for 1500 hrs.
grease ZG-5
Pulleys and
Winter：ZG-2 Add the grease after
5 Pulley Block guiding pulley in
Summer：ZG-5 working for 240 hrs.
the hoisting winch
Sliding bearings in
the trolley Add grease after working
Sliding Winter：ZG-2
6 traveling for 160 hrs, and conduct
Bearings Summer：ZG-5
mechanism and cleaning half a year
drum
Two
articulated
points All the articulated Calcium-based grease
7 Before dismantle or
between jib points ZG-2 (ZG-5)
installation
and tower
section
All the motion
Fill oil after working for 160
8 Fall-change parts and guiding Machine oil
hrs
Device groove

Articulated
All the articulated Fill oil after working for 56
9 points of Machine oil
points hrs
brake lever
All the connectors of

Gear Grease once after a
10 mechanisms and Calcium-based grease
connector season
gears
Add filtered grease after

Pump
working for 200 hrs，
station of American ESSO AW46
11 Oil tank and change the grease
hydraulic
after working for 2400
erection
hrs.

Records of check
Checking Checked Checking Parts state and

No. Parts Description Notes
duration by date method to settle
The pins and bolts of

such key
components as the
Before work Make sure of no looseness or
tower body, jib,
1 start at each disengagement before operation
slewing support, rigid
shift start.
jib tie rod, counter-jib
tie rod, brake and
fall-changing device.

Especially the connecting plates

and the nearby material of the
The high-strength bolt
tower head and slewing mast, the
joints and the nearby
bolts of three tower sections on the
2 material, the tower
Every month foundation if the tower crane is not
head and slewing
anchored to the building, or the
mast.
tower sections nearby the
anchored point if it is anchored
When
adding or
The climbing lugs and lowering
3 the beam of the down the
Climbing Mechanism tower
sections
every time

Check all bolts 2

times in a week,
then one time in a
Dismantle 2-3 bolt groups each
High-strength week, then one time
4 year and check them for
bolts in two weeks, and
deformation, corrosion, rust, etc.
then one time in a
month after erecting
the tower crane.
1.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.
5 Wire rope Every week 2.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.

122
Records of servicing/maintenance/repair done on the crane
Checked
date Trouble Troubleshooting Solution
by

123
长沙中联重工科技发展股份有限公司
湖南省长沙市银盆南路 361 号（中联科技园）
Headquarter Address：361 Yinpen（s）Road. Changsha,Hunan,China
PC: 410013 FAX: +86-731-8928101
E-mail: yxglb@zlzk.com http://www.zoomlion.com

TEL： +86-731－88928166 / +86-731－88928163
全国服务监督专线：SPECIAL TEL: 800-878-6112
We reserve the right to change specification without notice

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Changsha Zoomlion Heavy Industry

Science and Technology Development Co. Ltd.

PRODUCT MODEL: QTZ125（TC6016A-8）

User Manual Form

△Technical Specification Table

Rope capacity m 610 (6 Layers)

Reduction Gear Ratio 195

Hydraulic Flow L/min 11.25

pump Working pressure Mpa 31.5

Radius and Load Capacity

Radius (m) 28 30 32.78 34 35

Radius (m) 32.75 34 36 38 40 42 44 45

Radius (m) 31.78 34 36 38 40 42 44 46 48 50 52

Radius (m) 30.16 32 34 36 38 40 42 44 46 48 50

﹣Prohibited (Improper) use

●The rails must be earthed at both

2- Foundations, Counter-weight and Center Ballast

figure 2-2 foundation with embedded anchored

2.1.3 Install the Embedded Anchor

2.2 Undercarriage stationary

2.2.2 Foundation for Undercarriage(Fig 2-5)

Figure2-5 foundation of underunder stationary

figure 2-7 counterweight

2.5 Base ballast

Fig2-8 Ballast (1)

Fig2-9 Ballast (2)

Fig2-10 assemble diagram

3.3 General layout of tower crane

3.3.2.3Most economic anchored-frame layout for the stationary crane with

3.4 Counterweight should be equipped according to the length

Fig.3-5 installing tower crane

3.5.1Erecting Tower Section MQQ and 2 Tower Sections MQ

Figure3-6c tower sections MQ

3.5.2 Hoist Climbing Frame

3.5.2.1 Structure description(shown as Fig3-8)

3.5.3 Install the assembly of slewing

Figure3- 12 the slewing tower assembly

3.5.5.2 Hoist and Install the Tower Head(Fig3-15)

figure 3-15 installing tower head

3.5.6 Installation of counter-jib assembly

figure 3-16 counter-jib

3.5.6.2 Hoist and Install Counter-jib Assembly

Figure3- 17 installing counter-jib

figure 3-18 counter-jib pull rods

Figure3- 19 installing Counter-jib pull rods

figure 3-20 Hoisting and intall a 3.0t counter weight

figure 3-24 jib structure

figure 3-25 trolleying wire rope layout

figure 3-26 jib pull rods

figure 3-27 weightcenter of jib

figure 3-28 installing jib

5. Reeve the hoisting wire rope according

Figure3-30 tower head structure at jib pull

Figure3-31pull rod structure at tower head joint(↓)

3.5.9 Assemble counter-weight

figure 3-32 installing counter-weight

figure 3-34 schematic diagram of the installation of trolley on jib

3.8.1 Method for 2-fall to 4-fall conversion(Fig3-36)

figure 3-36 diagram of2-fall to 4-fall conversion

figure 3-37 diagram of4-fall to 2-fall

3.9 Jacking operation for adding sections

Figure3-38 keep the tower crane

3.9.4 General Notices of Jacking Operation:

3.10 Tower anchored onto the

the monitor of the wind speed