T2850-120V Tower Crane

Instruction Manual

T2850-120V-138Y-A02

T2850-120V-138Y-A02
1 Working condition

China Mainland 380V±10％~50Hz

India 400V±10％~50Hz
Malaysia 415V±10％~50Hz
Working Voltage (V)
Philippine 440V±10％~60Hz
Thailand 380V±10％~50Hz
Vietnam 380V±10％~50Hz
Allowable Temperature in Service (℃) -20~+40℃
Altitude(m) ≤1000

2 Use forbidden condition

(1) It cannot be used in the thunder and explosive condition;

(2) It cannot be used when the visibility is low and the wind speed is more than the
allowable value.

3 Main content

This handbook is supplied to help you know how to operate and use the tower crane
safely; moreover, it introduces the working principles of main components and systems
and includes the necessary accessory list.
This handbook includes the following sections:
(1) Safety Instructions
(2) Technical parameters
(3) Transportation
(4) Prerequisite
(5) Erection and Dismantling
(6) Internal Climbing(NOT standard)
(7) Operation and Safety
(8) Electrical Control System
(9) Maintenance
(10) Spare Part List
Only having passed rigorous training and achieved relevant qualifications, the
personnel can operate the tower crane. The relevant instructions, regulations and

T2850-120V-138Y-A02
directives (such as prevention of emergencies, etc.) must be implemented strictly.

Ignoring the instructions could result in accidents and

injuries!
Pay special attention to all the safety devices of the tower crane. Check the safety
devices to keep them are being in the good working condition. Don’t operate or use the
tower crane when it is in trouble or cannot be used reliably.

Safety First!
If any relevant data such as technical letters about the tower crane are received,
please insert them into the relevant sections in time.

Strictly follow this handbook during the tower crane erection, operation, maintenance
and other operations.

T2850-120V-138Y-A02
 ①
Safety Instructions

Contents

1 Safety instructions ....................................................................................................... 1

2 Danger grades classification ....................................................................................... 5

T2850-120V-138Y-A02
 Safety Instructions

1 Safety instructions

WARNING: Live parts!

Electrical installation, connection
work and maintenance must be done
only by authorized, properly qualified Don’t stand under the working radius.
personnel.

Prohibit climbing! Danger of rolling!

Danger of falling down!

Wear and use a safety harness! Emergent stop

Safety Instructions T2850-120V-138Y-A 02 1-1

 Carefully read this handbook before The tower crane need to be able to slew
handling the machine! freely when it is out of service

Danger of crushing!
Very hot, do not touch!

Insert pins while the crane climbing! Keep watching!

WARNING: floating loads! Check ropes

Wear safety helmet!

1-2 T2850-120V-138Y-A02 Safety Instructions

 Adjust the height limiter!
Lubricate!

Check metal structures! Check brakes for clearance!

Keep safety devices workable! Adjust the brakes

Caution! High strength connection bolt of M30

Safety Instructions T2850-120V-138Y-A 02 1-3

 Maximum load on maintenance cage Always close the hatches!

Prohibit standing! Tie safety belt!

1-4 T2850-120V-138Y-A02 Safety Instructions

2 Danger grades classification

DANGER means to be on guard against severe danger. If the danger cannot be

avoided, it will lead to death, serious injury or destructive damage of the equipment.

WARNING means to be on guard against moderate danger. If the danger cannot be

avoided, it will lead to death, serious injury or severe damage of the equipment.

CAUTION means to be on guard against mild danger. If the danger cannot be

avoided, it will lead to slight wound, moderate injury or damage of the machine or spare
parts.

NOTICE means the safety instruction sign. If it is ignored, property loss will occurs.

Safety Instructions T2850-120V-138Y-A 02 1-5

 ②
Technical Parameters
Contents

1 Overall dimensions of mobile tower crane ................................................................... 1

2 Technical performance parameters for the tower crane............................................... 2
3 Technical parameters of the mechanisms ................................................................... 3
（1） Performance parameters of hoisting mechanism ......................................... 3
（2） Performance parameters of trolleying mechanism ....................................... 4
（3） Performance parameters of slewing mechanism .......................................... 4
（4） Performance parameters of climbing mechanism......................................... 4
（5） Performance parameters of travelling mechanism ....................................... 5
4 Hoisting performances................................................................................................. 6
（1） Hoisting performance of jib length 85m ........................................................ 6
（2） Hoisting performance of jib length 80m ........................................................ 7
（3） Hoisting performance of jib length 70m ........................................................ 7
（4） Hoisting performance of jib length 60m ........................................................ 8
（5） Hoisting performance of jib length 50m ........................................................ 8

Techniacl Parameters T2850-120V-138Y-A02 2-i

 Technical Parameters

1 Overall dimensions of mobile tower crane

Fig.2.1-1 Overall dimensions of the T2850-120V mobile tower crane

Jib Length
K(m) H1(m) H(m)
（To slewing centre）

85m 87.8 82.8 69.0

80m 82.8 82.8 69.0

70m 72.8 82.8 69.0

60m 62.8 82.8 69.0

50m 52.8 82.8 69.0

Techniacl Parameters T2850-120V-138Y-A02 2-1

2 Technical performance parameters for the tower crane

Hoisting mechanism M4
Mechanisms Slewing mechanism M5
working grade Trolley mechanism M4
Traveling mechanism M3

Tower crane working grade A4

Rated hoisting moment （kN·m） 28500

Maximum hoisting moment （kN·m） 29540
Maximum tower Outrigger Mobile Anchor
height (m) 67 69 267.5
Maximum working radius (m) 85/80/70/60/50
Working Radius
Minimum working radius (m) 5.0
Maximum hoisting capacity (t) 120
Model H132FL150-1230D
Hoisting mechanism

Fall α＝2 α＝4 α＝8

Hoisting
30 15 7.5 2 60 30 15 4 120 60 30 8
capacity(t)
speed(m/mi 2
20 40 68 100 10 20 34 50 5 10 17
n) 5
Min stable speed (m/min) ≤0.8
Power (kW) 132
Speed (m/min) 0~10 0~20 0~40
Trolley
Hoisting capacity (t) 0~120 0~60 0~30
mechanism
Power (kW) 18.5
Slewing Speed (r/min) 0~0.38
mechanism Power (kW) 4×18.5
Travelling Speed (r/min) 0~15
mechanism Power (kW) 6×11
Working pressure（MPa） 25
Climbing
Speed（m/min） 0.4
mechanism
Power (kW) 37

Power (kW) 224.5+6×11(No include climbing mechanism)

50 60 70 80 85
Counter-weight(t)
80.5 92 103.5 115 115
Work voltage ~380(±10% )V 50 Hz
Allowable wind Erection & Climbing ≤14

2-2 T2850-120V-138Y-A02 Techniacl Parameters

 speed at the top In service ≤20
of crane (m/s) 0~20m ≤36
Our of service 20~100m ≤42
100m~ ≤46
Allowable Temperature in service（℃） -20～+50
Height above sea level in service (m) ≤1000
Storage and transportation temperature (℃) -25～+55

3 Technical parameters of the mechanisms

（1） Performance parameters of hoisting mechanism

Item Unit parameters

Rated traction force per single rope N 17.4×104
Max hoisting capacity/falls t/f 120/8
Hoisting mechanism H132FL150-1230D

Model / 35W×K7-32-1870
Rope Rate diameter mm 32
Max linear speed m/min 200
Max drum speed r/min 37
Drum
Rope capacity m/r 1230/7(layers)
Model YZTPF400L2-8(25Hz)
Motor Power kW 132KW
Revolving speed r/min 366
Model / B3HH17-50-B
Reducer
Ratio of reduction gears / 49.935
YP31-Ed2000-710×30-ⅠA-
Model /
Brake WL.H
Braking moment N.m 7600

Techniacl Parameters T2850-120V-138Y-A02 2-3

（2） Performance parameters of trolleying mechanism

Item Unit parameters

Model / T185FC87
Maximum tractive force N 100000
Maximum radius (m) m 87
Trolleying mechanism

Rope Specification / 6×29Fi+IWR-22-1870

Drum Linear speed m/min 0～40
Model / YZPFE225M2-6T
Motor Power/Frequency kW/Hz 18.5/25
Revolving speed r/min 469
Model / YMDZ540-24
Brake
Braking moment N.m 540
Model / XX5-500.135
Reducer
Ratio of reduction gears / 133.759

（3） Performance parameters of slewing mechanism

Item Unit parameters

Model HPW185F1.350A YTRVFW180L1-4F1（F2）-18.5KW
Slewing mechanism

Power/Frequency kW/Hz 18.5/50

Revolving speed r/min 1400
Braking moment N.m 80
Motor

Output rotation
N.m 35000
moment
Ratio of reduction
/ 275
gears

（4） Performance parameters of climbing mechanism

Item Unit parameters

Climbing mechanism

Power kW 37
Motor
Revolving speed r/min 1480
Flux l/min 66
Hydraulic pump station
Working pressure MPa 25
Cylinder/rod diameter mm 250/160
Climbing cylinder Rated climbing force t 154
Climbing speed m/min 0～0.34

2-4 T2850-120V-138Y-A02 Techniacl Parameters

（5） Performance parameters of travelling mechanism

Travelling speed m/min 15

Travelling mechanism

Diameter of travelling wheel mm Φ630

Model YVFSE3-160M-4

Motor Power kW 11

Braking moment N·m 50+110

Model KA/T97B-50-AG160
Reducer
Ratio of reduction gears 49.16

Techniacl Parameters T2850-120V-138Y-A02 2-5

4 Hoisting performances

（1） Hoisting performance of jib length 85m

Radius（m） 5 18 20 22.3 25 28 30 32 35
2-fall (t) 30.00
4-fall (t) 60.00
8-fall (t) 120.00 104.93 91.53 84.16 77.75 69.57

Radius（m） 40 43.06 45 48 50 52 55 58 60
2-fall (t) 30.00
4-fall (t) 60.00 57.00 52.87 50.40 48.12 45.03 42.26 40.57
8-fall (t) 58.77 53.45 50.45 46.32 43.85 41.57 38.48 35.71 34.02

Radius（m） 62 65 68 70 72 75 78.12 80 85
2-fall (t) 30.00 29.13 27.00
4-fall (t) 38.99 36.82 34.84 33.61 32.46 30.84 29.29 28.42 26.29
8-fall (t) 32.44 30.27 28.28 27.06 25.90 24.29 22.74 21.87 19.74

2-6 T2850-120V-138Y-A02 Techniacl Parameters

 Techniacl Parameters

（2） Hoisting performance of jib length 80m

Radius（m） 5 20 24.62 25 28 30 33 35
2-fall (t) 30.00
4-fall (t) 60.00
8-fall (t) 120.00 117.84 102.98 94.81 84.49 78.64

Radius（m） 40 45 47.59 48 50 52 55 58 60
2-fall (t) 30.00
4-fall (t) 60.00 59.40 56.66 54.14 50.70 47.64 45.77
8-fall (t) 66.66 57.44 53.45 52.85 50.11 47.59 44.15 41.09 39.21

Radius（m） 61 63 65 68 70 72 75 78 80
2-fall (t) 30
4-fall (t) 44.88 43.19 41.60 39.41 38.05 36.77 34.98 33.32 32.29
8-fall (t) 38.33 36.64 35.05 32.85 31.50 30.22 28.42 26.77 25.74

（3） Hoisting performance of jib length 70m

Radius（m） 5 20 24.62 25 28 30 33 35
2-fall (t) 30.00
4-fall (t) 60.00
8-fall (t) 120.00 117.84 102.98 94.81 84.49 78.64

Radius（m） 40 45 47.59 48 50 52 55 58 60
2-fall (t) 30.00
4-fall (t) 60.00 59.40 56.66 54.14 50.70 47.64 45.77
8-fall (t) 66.66 57.44 53.45 52.85 50.11 47.59 44.15 41.09 39.21

Radius（m） 61 63 65 68 70
2-fall (t) 30
4-fall (t) 44.88 43.19 41.60 39.41 38.05
8-fall (t) 38.33 36.64 35.05 32.85 31.50

Techniacl Parameters T2850-120V-138Y-A02 2-7

（4） Hoisting performance of jib length 60m

Radius（m） 5 20 24.62 25 28 30 33 35
2-fall (t) 30.00
4-fall (t) 60.00
8-fall (t) 120.00 117.84 102.98 94.81 84.49 78.64

Radius（m） 38 40 45 48.64 50 52 55 58 60
2-fall (t) 30.00
4-fall (t) 60.00 58.16 55.64 52.20 49.14 47.27
8-fall (t) 70.37 66.66 57.44 51.95 50.11 47.59 44.15 41.09 39.21

（5） Hoisting performance of jib length 50m

Radius（m） 5 20 24.62 25 28 30 33 35
2-fall (t) 30.00
4-fall (t) 60.00
8-fall (t) 120.00 117.84 102.98 94.81 84.49 78.64

Radius（m） 38 40 45 48.64 50 52 55 58 60
2-fall (t) 30.00
4-fall (t) 60.00 58.16
8-fall (t) 70.37 66.66 57.44 51.95 50.11

(1) Radius and hoisting capacity above are calculated based on maximum tower height
(67m). When the tower height of the tower crane has to be exceeded to maximum
tower height without anchorage, the hoisting capacity in above tables must be
reduced.
(2) The computational method ：The hoisting capacity of calculated height= the hoisting
capacity in tables - the weight of hoisting rope per meter× (calculated height-
maximum tower height without anchorage (67m)) ×fall/1000. (the weight of hoisting
rope per meter:5.22kg/m; Unit: Height: m; Weight: t)

2-8 T2850-120V-138Y-A02 Techniacl Parameters

 ③
Transportation

Contents

1 Notice during transportation ........................................................................................ 1

2 Packing unit................................................................................................................. 2

T2850-120V-138Z-A02
 Transportation

1 Notice during transportation

The components of tower crane are dismantled into several packing modules to
simplify packing and handling for different means of transportation.
(1) All components must be fixed during transportation.
(2) Lighter components must be on the top of the heavier ones.
(3) Every component must be separated from each other by cushions or wood isolation
board to avoid mangling the painted surfaces.
(4) It is prohibited to put the unloaded components on ground directly to avoid sand and
dirt entering in the holes of the component.
(5) It is not allowed to transport components by unsuitable transportation, such as
bulldozer and lifter. The weights and sizes of components of tower crane are
introduced in the following sections.
(6) Make sure that all auxiliary devices are safe-reliable before transporting the tower
carne.
(7) Check if there are components are not tightened
(8) Check all the bandings of transportation.
(9) While transporting in public streets, observe the relational rules.
(10) Pay attention to the space, while passing underground passages, bridges and
tunnels.

Transportation T2850-120V -138Z-A02 3-1

2 Packing unit

N Unit
Name Dimensions L(m) B(m) H(m) Qty
o. weight(t)

Counter-jib section 15.57

1 12.2 2.5 3.23 1
two

Counter-jib section
one +trolleying
2 mechanism 12.5 2.62 3.22 23.10 1
+auxiliary hoisting
mechanism

3 Jib Ⅰ 11.60 2.66 3.93 27.10 1

4 Jib Ⅱ 12.58 2.60 3.70 21.61 1

5 Jib Ⅲ 12.50 2.60 3.67 18.90 1

6 Jib Ⅳ 12.54 2.60 3.65 14.20 1

7 Jib Ⅴ 12.54 2.60 3.18 11.88 1

8 Jib Ⅵ 10.44 2.60 3.15 7.59 1

9 Jib Ⅶ 10.36 2.60 3.09 5.48 1

10 Jib Ⅷ 10.24 2.60 3.02 3.54 1

11 Jib Ⅸ 5.17 2.60 2.95 1.30 1

12 Tip jib 1.98 3.02 1.70 0.98

3-2 T2850-120V -138Z-A02 Transportation

N Unit
Name Dimensions L(m) B(m) H(m) Qty
o. weight(t)

Upper support
13 3.40 4.30 1.39 13.60 1
structure

14.31 1.092 0.82 2.95 1

Climbing main 14.31 1.12 0.82 2.88 1

chord(slice
14
structure、bundle
up） 14.31 1.092 0.82 2.95 1

14.31 1.12 0.82 2.88 1

1.01 0.53 2.64 1.65 1

0.75 0.38 1.44 0.73 1

1.01 0.53 1.75 0.88 1

15 Hook block

2.87 0.37 0.79 0.98 1

0.95 0.78 2.10 1.51 1

Main trolley 2.66 1

16 Trolley 1.97 3.04 2.35

Auxiliary 2.60 1
trolley

17 Below support 4.15 4.03 1.80 18.10 1

18 Mounting beam 8.78 2.45 0.48 2.67 1

Transportation T2850-120V -138Z-A02 3-3

N Unit
Name Dimensions L(m) B(m) H(m) Qty
o. weight(t)

19 Mounting trolley 2.70 2.70 0.42 0.66 1

20 Lifting frame 3.28 3.28 1.05 1.25 1

21 Mounting hook 2.50 0.55 1.00 0.40 1

Hoisting mechanism
22 5.50 2.86 2.48 19.76 1
+rope

1.09 0.75 2.40 1.20 3

23 Slewing mechanism
1.09 0.75 2.33 1.20 1

Hang beam 4.94 0.38 0.91 1.6 2

Transit
ion
24
sectio
n Chord 6.17 0.55 1.03 2.55 4

Main chord A 6.17 0.67 0.56 2.2 22

Tower
Main chord 6.17 0.67 0.56 2.2 22
sectio
B
n、
25
base
sectio Horizontal
3.26 0.16 0.18 0.14 88
n web

Oblique web 3.76 0.26 0.2 0.27 88

Derric
26 Column 3.88 0.54 0.78 0.65 1
k

3-4 T2850-120V -138Z-A02 Transportation

N Unit
Name Dimensions L(m) B(m) H(m) Qty
o. weight(t)

Cross-beam 3.11 1.22 0.43 0.38 1

Connecting 1.80 1.80 1.35 1

4.80
sleeve

Half-beam 8.93 1.63 2.10 8.66 4

Chass
Chord 9.97 0.4 0.4 3.38 4
is
(exclu
27 de
base
Long rod 2.80 0.18 0.22 0.73 4
sectio
n)

Short rod 2.80 0.18 0.22 0.20 4

beam 2.53 0.54 0.28 0.28 2

Travelling 3.74 1.76 1.09 8

7.85
Travell assembly
ing
28
mecha
nism Balance 4.36 1.30 1.43 4
7.5
beam

Transportation T2850-120V -138Z-A02 3-5

 ④
Preparations

Contents
1 Weights and Installation Dimensions of Main Components......................................... 1
2 Counterweight ............................................................................................................. 4
2.1 Composition ....................................................................................................... 4
2.2 Counterweight Drawing ..................................................................................... 4
3 Mobile Foundation....................................................................................................... 7
3.1 Mobile Tower Crane Foundation Diagram.......................................................... 7
3.2 Precautions ...................................................................................................... 14
3.3 Grounding ........................................................................................................ 15
4 Load of T2850-120V Mobile Tower Crane Foundation .............................................. 17
5 Selection of Crane for Installation ............................................................................. 30
6 High Strength Bolt ..................................................................................................... 32
6.1 Basic Knowledge of High Strength Bolts ......................................................... 32
6.2 Checking before Erection of Tower .................................................................. 33
6.3 Application of High Strength Bolts on This Tower Crane.................................. 35
7 Installation of Split Pins ............................................................................................. 36
8 Preparations before Installation of Mobile Tower Crane ............................................ 37
8.1 Permissible Distance between Mobile Tower Crane and Buildings.................. 37

T2850-120V-138Z-A02
 Preparations

1 Weights and Installation Dimensions of Main Components

Unit weight
Name Diagram L(m) W(m) H(m) Quantity
(t)

Traveling trolley 8.1 1.8 2.9 23.12 4

Underframe
13.1 13.1 2.2 1
crossing beam

Underframe support
9.97 0.4 0.4 3.38 4
rod

Basic section I 4.2 4.2 6.4 13.55 1

Basic section II 4.6 4.6 6.2 15.43 1

Standard section 4.3 4.3 6.2 13.66 9

5.0

Transitional section 4.9 6.2 19.61 1

4-1 T2850-120V-138Y-A02 Prerequisite

 Unit weight
Name Diagram L(m) W(m) H(m) Quantity
(t)

Climbing frame +
6.40 6.40 14.30 31.91 1
pump station

Jacking crossbeam 3.80 0.24 1.90 2.42 2

Introduction system 9.70 3.20 4.0 5.65 1

Slewing support

Lower base +
4.20 4.03 2.08 23.60 1
slewing support

Upper base +
slewing mechanism 7.10 5.02 2.59 21.60 1
+ cab

Boom section I 11.60 3.09 4.72 27.10 1

Boom section II +
12.58 2.60 4.61 27.20 1
load trolley

Boom section III 12.50 2.60 3.67 18.90 1

Prerequisite T2850-120V-138Y-A02 4-2

 Unit weight
Name Diagram L(m) W(m) H(m) Quantity
(t)

1
Boom section IV 12.54 2.60 3.65 14.20

Boom section V 12.54 2.60 3.22 11.89 1

Boom section VI 10.44 2.60 3.18 7.59 1

Boom section VII 10.36 2.60 3.09 5.48 1

Boom section VIII

and IX and boom tip 15.95 2.60 3.02 5.90 1
section

Balance boom
section I + luffing
mechanism + 12.5 2.62 3.22 23.10 1
auxiliary
mechanism

Balance boom
section II + 12.2 2.5 3.23 16.50 1
tensioner

Hoisting mechanism
5.50 2.86 2.48 19.76 1
+ wire rope

Derrick mast 3.5 0.5 4.1 1.03 1

4-3 T2850-120V-138Y-A02 Prerequisite

2 Counterweight
2.1 Composition
(1) Overview
The counterweight is to be fabricated by the user.
Avoid squeezing or breaking the counterweight during transport, installation, and
use.
Only one weight specification is defined for the counterweight of this tower crane.
The counterweight configuration varies depending on different boom length
combinations. Refer to Table 4.3-1 for details. This manual provides a counterweight
fabrication drawing. However, the user can use other safe and reliable method to realize
the function of the counterweight.
(2) Counterweight Table
Table 4.2-1 Counterweight Configuration Table
Counterweight
PHZ11500 Total weight (t)
Boom

85m boom length 10 115

80m boom length 10 115

70m boom length 9 103.5

60m boom length 8 92

50m boom length 7 80.5

2.2 Counterweight Drawing

All counterweights are cast from reinforced concrete.
Refer to Figure 4.2-1 for the specific overall dimensions and reinforcing bar
arrangement of the counterweights and refer to attached Counterweight drawing for the
diagram and list of parts.
Every counterweight fabricated shall be weighed and the weight shall be
permanently stamped on the counterweight surface. The tolerance for the weights of
counterweights is ±1% and the concrete grade shall be no inferior to C25.
To ensure that the counterweights are within the specified tolerance, the height
dimension (6,000) can be changed based on the actual density of concrete during
fabrication. The density here refers to the average density of reinforced concrete. The
Prerequisite T2850-120V-138Y-A02 4-4
density varies based on the change of reinforcing bar arrangement for counterweights.
Caution:
In this manual, the overall dimensions of the counterweight for this tower
crane are designed based on the theoretic design density of 2,400kg/m3.
The user may design the counterweight at own discretion, provided that the
width and thickness dimensions (namely 2,000 and 400) and the hanging position
dimension (850) must be guaranteed and the overall height dimension can be
adjusted appropriately.
Part 9
Unfolding length at 12,800

Steel tube

Counterweight weight marking Part 1

Part 5 Part 8 Part 10 Part 11 Part 12

Unfolding length at 1,475 Unfolding length at 1,475 Unfolding length at 5,050

Figure 4.2-1 Shape and Reinforcing Bar Arrangement Diagram of 11.5t Counterweight
4-5 T2850-120V-138Y-A02 Prerequisite
 Table 4.2-2 List of Parts for Counterweight PHZ11500
No. Name Specification Material Quantity Note

Share this
1 Angle steel L50×4 Q235B 4
diagram

Shared part,
2 Angle steel L50×4-1992 Q235B 4
no diagram

Shared part,
3 Angle steel L50×4-5900 Q235B 4
no diagram

Shared part,
4 Steel tube φ102×10-1300 20 1
no diagram

Share this
5 Plate t10 Q235B 2
diagram

6 Hinge pin Welded part 1 Shared part

7 Lifting eye t25 Q345B 4 Shared part

Share this
8 Plate t10 Q235B 4
diagram

8.1 Reinforcing bar φ25 HRB400 9 This diagram

8.2 Reinforcing bar φ25 HRB400 2 This diagram

9 Reinforcing bar φ25 HRB400 8 This diagram

Share this
10 Reinforcing bar φ16 HPB300 21
diagram

11 Steel plate I t4-695×300 Q235B 2 No diagram

12 Steel plate II t4-4995×300 Q235B 2 No diagram

13 Steel plate III t4-890×300 Q235B 2 No diagram

14 Steel plate IV t4-395×300 Q235B 4 No diagram

Share this
15 Angle steel L50×4 Q235B 4
diagram

Shared part,
16 Angle steel L50×4-1992 Q235B 4
no diagram

Prerequisite T2850-120V-138Y-A02 4-6

3 Mobile Foundation
The mobile foundation must meet the load-carrying requirements of the mobile
tower crane. In response to the special situation of Kuwait airport, the airport runway
reinforced concrete thick valve plate is beneath the foundation of the mobile tower crane
and the valve plate is capable of bearing the load of tower crane foundation without any
partial subsidence. The following mobile foundation is optimally design.
3.1 Mobile Tower Crane Foundation Diagram

Building

Rail Rail
fixed fixed
stopper Anchorage Anchorage stopper

Figure 4.3-1a Mobile Tower Crane Foundation Diagram

Compacted Coarse/find Concrete

roadbed sand underlayer foundation

Figure 4.3-1b Mobile Tower Crane Foundation Diagram

4-7 T2850-120V-138Y-A02 Prerequisite

 Assembling drawing of rail trolley stopper

Collision block I Collision block II

Figure 4.3-1c Mobile Tower Crane Foundation Diagram

Anchorage diagram

Rail

Foundation concrete

View D
Anchorage

Concrete

Figure 4.3-1d Mobile Tower Crane Foundation Diagram

Prerequisite T2850-120V-138Y-A02 4-8

 Part 1 Part 2 Part 3 Part 6
Other Other Other All

Part 11 Part 14 Part 15

Other

Figure 4.3-1e Mobile Tower Crane Foundation Diagram

Table 4.3-1 List of Parts for Mobile Tower Crane Foundation Diagram
No. Name Specification Material Quantity Note

1 Steel rail QU100 U71Mn 30 This diagram

2 Pressure plate Q235B 1440 This diagram

3 Support plate t20-240×380 Q345B 598 This diagram

4 Rail sliding stopper Welded part 4

5 Rail fixed stopper Welded part 4

6 Collision block φ20 Q235B 4 This diagram

7 Baseplate t10-260×440 Q235B 4 No diagram

8 Nut M24-8 3104

9 Washer 24-200HV 1664

10 Channel steel [25a-12380 Welded part 61

11 Fishplate 56 Shared part

12 Bolt M24×160-8.8 112

Precast concrete block Reinforced

13 116
I concrete

4-9 T2850-120V-138Y-A02 Prerequisite

 No. Name Specification Material Quantity Note

14 Connecting plate t16 Q345B 236 This diagram

15 Washer t16 Q345B 944 This diagram

Precast concrete block Reinforced

16 2
II concrete

Precast concrete block Reinforced

17 2
III concrete

18 Nut M20-8 U71Mn 1888

Reinforcing bar
arrangement diagram

No. 4, No. 5, No. 6, No. 7 Prepared by user

No. 11
Unfolding length at 1,945

No. 8 Prepared by user

Unfolding length at 1,020

Prepared by user

Figure 4.3-2 Precast Concrete Block I

Table 4.3-2 Precast Concrete Block I

Prerequisite T2850-120V-138Y-A02 4-10

 No. Name Specification Material Quantity Note

1 Concrete C35 1

2 Foundation bolt M24-8.8 12

3 Support plate t20 Q235B 12

Longitudinal
4 φ25-3630 HRB400 14 This diagram
reinforcing bar I

Longitudinal
5 φ25-3450 HRB400 8 This diagram
reinforcing bar II

6 Lateral reinforcing bar I φ20-2350 HRB400 32 This diagram

Lateral reinforcing bar

7 φ20-1300 HRB400 2 This diagram
II

Erection reinforcing
8 φ12-1020 HPB300 59 This diagram
bar

9 Bolt M20×200-8.8 8

10 Washer t12 Q235B 8

11 Lifting eye φ30 Q345B 4 This diagram

4-11 T2850-120V-138Y-A02 Prerequisite

 Reinforcing bar
arrangement diagram

Prepared by user
No. 12
No. 4, No. 5, No. 6, No. 7
Unfolding length at 1,945

No. 8 Prepared by user

Unfolding length at 1,020

Prepared by user

Figure 4.3-3 Precast Concrete Block II

Table 4.3-3 Precast Concrete Block II
No. Name Specification Material Quantity Note

1 Concrete C35 1

2 Foundation bolt M24-8.8 12 Shared part

3 Support plate t20 Q235B 12 Shared part

Longitudinal
4 φ25-3630 HRB400 14 This diagram
reinforcing bar I

Longitudinal
5 φ25-3450 HRB400 8 This diagram
reinforcing bar II

6 Lateral reinforcing bar I φ20-2350 HRB400 32 This diagram

Lateral reinforcing bar

7 φ20-1300 HRB400 2 This diagram
II

Prerequisite T2850-120V-138Y-A02 4-12

 No. Name Specification Material Quantity Note

Erection reinforcing
8 φ12-1020 HPB300 61 This diagram
bar

9 Anchorage Welded part 1

10 Bolt M20×200-8.8 8

11 Washer t12 Q235B 8 Shared part

12 Lifting eye φ30 Q345B 4 Shared part

Prepared by user
No. 4, No. 5, No. 6, No. 7 No. 12
Unfolding length at 1,945

No. 8 Prepared by user

Unfolding length at 1,020

Prepared by user

Figure 4.3-4 Precast Concrete Block III

Table 4.3-4 Precast Concrete Block III

No. Name Specification Material Quantity Note

4-13 T2850-120V-138Y-A02 Prerequisite

 No. Name Specification Material Quantity Note

1 Concrete C35 1

2 Foundation bolt M24-8.8 12 Shared part

3 Support plate t20 Q235B 12 Shared part

Longitudinal
4 φ25-3630 HRB400 14 This diagram
reinforcing bar I

Longitudinal
5 φ25-3450 HRB400 8 This diagram
reinforcing bar II

6 Lateral reinforcing bar I φ20-2350 HRB400 32 This diagram

Lateral reinforcing bar

7 φ20-1300 HRB400 2 This diagram
II

Erection reinforcing
8 φ12-1020 HPB300 61 This diagram
bar

9 Anchorage Welded part 1

10 Bolt M20×200-8.8 8

11 Washer t12 Q235B 8 Shared part

12 Lifting eye φ30 Q345B 4 Shared part

3.2 Precautions
(1) The roadbed shall be compacted firmly, with the foundation load-carrying capacity at
≥0.4MPa.
(2) Periodically check during operations: ±5m rail gauge tolerance.
(3) Rail top height tolerance within one cross section: 5mm.
(4) Longitudinal rail top height tolerance is 1/1000 and total deviation is <10mm.
(5) Center distance of rail lower support plate shall be no more than 500mm.
(6) The steel rail connector clearance shall be no more than 4mm, the stagnation
distance from the connector of other rail shall be no less than 1,500mm, and the rail
top height difference at the connectors shall be no more than 2mm.
(7) The stoppers shall be installed on two ends of rails, depending on the working site
situation. Refer to Figure 4.3-1c for the installation of travel limit blocks. The limit test
shall be performed in the field to ensure the safety and effectiveness of the travel
limit switch during working.
(8) The rails shall be well grounded, with the grounding resistance at <4Ω.
Prerequisite T2850-120V-138Y-A02 4-14
(9) The bolts (Positioning dimension at 220) and lifting eye reinforcing bars for precast
concrete blocks I, II, and III shall be fixed or bundled properly as per Figure 4.3-2,
4.3-3, and 4.3-4 before casting the concrete. The strength grade of cast concrete
shall be no inferior to C35.
(10) The precast concrete blocks I, II, and III can be installed and used only after the
rated concrete strength is reached and their contact area with the support layer
beneath must be >95%.
(11) The quantities of parts listed in Table 4.3-1 are calculated based on the rail length of
180m.

(12) The roughness shall be for the machined surfaces of all parts and shall be
for all machined holes.
(13) The length of the cables is calculated as per the distance from fixing point to far end
of rails added by 15m.
(14) Depending on the construction field situation, the user shall set up four anchorage
plates on the outer sides of rail foundation to fix the tower crane in event of high wind
speed.
(15) Refer to Figure 4.3-3 and Figure 4.3-4 for the fabrication and embedment of
anchorage plates and refer to Figure 4.3-1a and Figure 4.3-1d (The dimensions
15,200 and 682 shall be controlled, otherwise it will impair the installation of the
anchorages attached in the tower crane.) for the installation positions of anchorage
plates. The anchorage positions can be determined as per the actual situation when
the tower crane is not working and the user can also take other safe and effective
anchorage method.
(16) In the foundation diagram, all main reinforcing bars for upper and lower layers are
of HRB400 and the reinforcing stirrups are of HPB300.

3.3 Grounding
(1) Before operating the tower crane, the operator must take into consideration the
lightning protection or grounding measure.
(2) Whether the lightning protection is provided for the tower crane depends on the
regulation of the relevant authority.

(1) The grounding wire shall be of insulated copper cable in sectional area of no less
4-15 T2850-120V-138Y-A02 Prerequisite
 than 16mm2, with the grounding resistance at <4Ω.
(2) The grounding part shall be embedded into the ground for a depth of no less
than 1.5m.

Prerequisite T2850-120V-138Y-A02 4-16

 The grounding wire shall not be connected with any reinforcing bar of the
tower crane or building foundation and shall be at least 500mm reach from the
foundation.

4 Load of T2850-120V Mobile Tower Crane Foundation

Figure 4.4-1a Positioning Diagram of T2850 Traveling Mechanism

Cmax - Maximum torque (Present only under working state)

4-17 T2850-120V-138Y-A02 Prerequisite

 Figure 4.4-1b Positioning Diagram of T2850 Traveling Mechanism

1. The traveling wheels are in diameter of Ø630mm.

2. A trolley includes 8 traveling wheels.
3. The sectional dimensions of traveling rails QU100 are shown in 4.4-2.

Prerequisite T2850-120V-138Y-A02 4-18

 Figure 4.4-2 T2850 Traveling Rail Diagram

4-19 T2850-120V-138Y-A02 Prerequisite

 Acting force of trolley
T max — Maximum horizontal force
R max — Maximum acting force when the boom is at three different directions.
1. 85m boom length and 85m jib length
 Acting force under working state Cmax= 3,351 kN.m

Hoisting
height
Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

989 2925 2925 2925 1957 3330

34.8 154 3330
989 2925 989 989 585 1957

1000 2981 2981 2981 1991 3396

40.5 159 3396
1000 2981 1000 1000 585 1991

1008 3040 3040 3040 2024 3468

46.2 164 3468
1008 3040 1008 1008 581 2024

1013 3102 3102 3102 2058 3544

51.9 169 3544
1013 3102 1013 1013 572 2058

1015 3168 3168 3168 2091 3625

57.6 175 3625
1015 3168 1015 1015 557 2091

1012 3237 3237 3237 2125 3713

63.3 180 3713
1012 3237 1012 1012 537 2125

1006 3311 3311 3311 2158 3806

69.0 185 3806
1006 3311 1006 1006 511 2158

Prerequisite T2850-120V-138Y-A02 4-20

  Acting force under non-working state

Hoisting
height

Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

2171 862 862 862 1516 591

34.8 287 2442
2171 862 2171 2171 2442 1516

2207 892 892 892 1550 620

40.5 309 2480
2207 892 2207 2207 2480 1550

2245 922 922 922 1583 648

46.2 331 2519
2245 922 2245 2245 2519 1583

2283 950 950 950 1617 674

51.9 353 2560
2283 950 2283 2283 2560 1617

2323 978 978 978 1650 699

57.6 375 2602
2323 978 2323 2323 2602 1650

2364 1004 1004 1004 1684 722

63.3 397 2646
2364 1004 2364 2364 2646 1684

2406 1029 1029 1029 1718 744

69.0 420 2691
2406 1029 2406 2406 2691 1718

4-21 T2850-120V-138Y-A02 Prerequisite

 2. 80m boom length
 Acting force under working state Cmax= 3159 kN.m

Hoisting
height

Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

899 3008 3008 3008 1953 3447

34.8 150 3447
899 3008 899 899 460 1953

911 3063 3063 3063 1987 3513

40.5 155 3513
911 3063 911 911 461 1987

920 3121 3121 3121 2021 3584

46.2 160 3584
920 3121 920 920 457 2021

925 3183 3183 3183 2054 3660

51.9 165 3660
925 3183 925 925 448 2054

926 3249 3249 3249 2088 3742

57.6 170 3742
926 3249 926 926 434 2088

924 3319 3319 3319 2121 3829

63.3 175 3829
924 3319 924 924 413 2121

917 3393 3393 3393 2155 3923

69.0 180 3923
917 3393 917 917 386 2155

Prerequisite T2850-120V-138Y-A02 4-22

  Acting force under non-working state

Hoisting
height
Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

2220 806 806 806 1513 513

34.8 287 2513
2220 806 2220 2220 2513 1513

2257 836 836 836 1547 542

40.5 309 2551
2257 836 2257 2257 2551 1547

2295 865 865 865 1580 569

46.2 331 2591
2295 865 2295 2295 2591 1580

2334 893 893 893 1614 595

51.9 353 2632
2334 893 2334 2334 2632 1614

2374 920 920 920 1647 619

57.6 375 2675
2374 920 2374 2374 2675 1647

2416 946 946 946 1681 642

63.3 397 2720
2416 946 2416 2416 2720 1681

2458 970 970 970 1714 662

69.0 420 2766
2458 970 2458 2458 2766 1714

4-23 T2850-120V-138Y-A02 Prerequisite

 3. 70m boom length
 Acting force under working state Cmax= 2724 kN.m

Hoisting
height
Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

842 2984 842 842 1913 3431

34.8 149 3431
842 2984 2984 2984 395 1913

854 3039 854 854 1947 3497

40.5 154 3497
854 3039 3039 3039 397 1947

863 3098 863 863 1980 3567

46.2 160 3567
863 3098 3098 3098 393 1980

868 3160 868 868 2014 3643

51.9 165 3643
868 3160 3160 3160 384 2014

869 3225 869 869 2047 3725

57.6 170 3725
869 3225 3225 3225 370 2047

867 3295 867 867 2081 3812

63.3 175 3812
867 3295 3295 3295 350 2081

860 3368 860 860 2114 3905

69.0 180 3905
860 3368 3368 3368 323 2114

Prerequisite T2850-120V-138Y-A02 4-24

  Acting force under non-working state

Hoisting
height

Lifting height Tmax Rmax

RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

2150 803 803 803 1476 524

34.8 286 2428
2150 803 2150 2150 2428 1476

2186 833 833 833 1510 553

40.5 309 2466
2186 833 2186 2186 2466 1510

2224 863 863 863 1543 581

46.2 331 2506
2224 863 2224 2224 2506 1543

2262 891 891 891 1577 608

51.9 353 2546
2262 891 2262 2262 2546 1577

2302 919 919 919 1610 632

57.6 375 2588
2302 919 2302 2302 2588 1610

2343 945 945 945 1644 656

63.3 397 2632
2343 945 2343 2343 2632 1644

2385 970 970 970 1678 677

69.0 419 2678
2385 970 2385 2385 2678 1678

4-25 T2850-120V-138Y-A02 Prerequisite

 4. 60m boom length
 Acting force under working state Cmax= 2452 kN.m

Hoisting
height

Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

814 2923 2923 2923 1868 3363

34.8 149 3363
814 2923 814 814 374 1868

826 2978 2978 2978 1902 3428

40.5 154 3428
826 2978 826 826 376 1902

835 3036 3036 3036 1936 3498

46.2 159 3498
835 3036 835 835 373 1936

841 3097 3097 3097 1969 3573

51.9 164 3573
841 3097 841 841 365 1969

843 3162 3162 3162 2003 3654

57.6 169 3654
843 3162 843 843 351 2003

842 3231 3231 3231 2036 3740

63.3 174 3740
842 3231 842 842 332 2036

836 3304 3304 3304 2070 3832

69.0 179 3832
836 3304 836 836 307 2070

Prerequisite T2850-120V-138Y-A02 4-26

  Acting force under non-working state

Hoisting
height
Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

2111 761 761 761 1436 481

34.8 286 2390
2111 761 2111 2111 2390 1436

2147 791 791 791 1469 510

40.5 308 2428
2147 791 2147 2147 2428 1469

2185 821 821 821 1503 538

46.2 330 2467
2185 821 2185 2185 2467 1503

2223 850 850 850 1536 565

51.9 352 2507
2223 850 2223 2223 2507 1536

2262 877 877 877 1570 590

57.6 374 2549
2262 877 2262 2262 2549 1570

2303 904 904 904 1603 614

63.3 396 2593
2303 904 2303 2303 2593 1603

2345 929 929 929 1637 636

69.0 419 2638
2345 929 2345 2345 2638 1637

4-27 T2850-120V-138Y-A02 Prerequisite

 5. 50m boom length
 Acting force under working state Cmax= 2027 kN.m

Hoisting
height

Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

814 2822 2822 2822 1818 3242

34.8 148 3242
814 2822 814 814 395 1818

827 2877 2877 2877 1852 3306

40.5 153 3306
827 2877 827 827 398 1852

837 2934 2934 2934 1885 3375

46.2 158 3375
837 2934 837 837 396 1885

843 2995 2995 2995 1919 3449

51.9 163 3449
843 2995 843 843 389 1919

847 3058 3058 3058 1953 3528

57.6 168 3528
847 3058 847 847 377 1953

846 3126 3126 3126 1986 3612

63.3 173 3612
846 3126 846 846 360 1986

842 3197 3197 3197 2020 3702

69.0 178 3702
842 3197 842 842 337 2020

Prerequisite T2850-120V-138Y-A02 4-28

  Acting force under non-working state

Hoisting
height
Tmax Rmax
RA RB RA RB RA RB
RD RC RD RC RD RC
(m) (kN) (kN) (kN) (kN) (kN)

2099 681 681 681 1390 388

34.8 285 2393
2099 681 2099 2099 2393 1390

2135 712 712 712 1424 417

40.5 307 2430
2135 712 2135 2135 2430 1424

2173 742 742 742 1457 445

46.2 329 2469
2173 742 2173 2173 2469 1457

2211 770 770 770 1491 472

51.9 352 2510
2211 770 2211 2211 2510 1491

2251 798 798 798 1524 497

57.6 374 2551
2251 798 2251 2251 2551 1524

2291 825 825 825 1558 521

63.3 396 2595
2291 825 2291 2291 2595 1558

2333 850 850 850 1591 543

69.0 418 2640
2333 850 2333 2333 2640 1591

4-29 T2850-120V-138Y-A02 Prerequisite

5 Selection of Crane for Installation
The installation weights and heights of the components are listed in Table 4.5-1. In
this table, h refers to the hoisting height of the top surface during installation of
component, excluding the length of slings (Hoisting straps and wire ropes). The data in
the table is for your reference during the selection of crane.

Table 4.5-1 Installation Weights and Heights of Components

No. Name Weight (t) Mobile h (m)

22 4.0

23.1 4.0
1 Traveling mechanism
22.7 4.0

22.5 4.0

Traveling underframe - Underframe 42.3 5.0

Traveling underframe - Basic section I 13.6 11.0

2
Traveling underframe - Basic section II 15.4 17.0

Traveling underframe - Support rod 4.3×4 11.0

22.5
3 Standard section (2 sections) 13.66
28.5

Prerequisite T2850-120V-138Y-A02 4-30

 No. Name Weight (t) Mobile h (m)

4 Climbing system 36.7 42.5

5 Transition section + introduction system 20 34.5

6 Slewing assembly 45.5 38.5

7 Boom section I 27.1 41.5

Balance boom section I (Including luffing

8 mechanism and auxiliary hoisting 23.1 41.5
mechanism)

9 Boom section II (Including load trolley) 27.2 41.5

10 Balance boom section II 16.5 41.5

11 Boom section III 19.1 41.5

12 Hoisting mechanism (Including wire rope) 19.8 41.5

13 Derrick mast 1.1 42.0

14 Boom section IV 14.2 41.5

15 1st counterweight 11.5 47.0

16 Boom section V 11.9 41.5

17 2nd counterweight 11.5 47.0

18 Boom section VI 7.6 41.5

19 3rd counterweight 11.5 47.0

20 Boom section VII 5.5 41.5

21 4th counterweight 11.5 47.0

22 Remaining boom 5.9 41.5

23 Remaining counterweights (6 blocks) 11.5×6 47.0

4-31 T2850-120V-138Y-A02 Prerequisite

6 High Strength Bolt
6.1Basic Knowledge of High Strength Bolts
(1) The tower crane includes a lot of high strength bolts, which are functioned to connect
structural parts and transmit load.
(2) All high strength bolts for connecting the components of the tower crane are really
important for the tower crane so that all bolt connections shall be carefully installed,
maintained, and checked.
(3) Check the high strength bolts at intervals to ensure the secure and reliable
connections. A loose bolt can probably result in damage or even the connection
failure of individual component.
(4) While choosing the nuts by self, please ensure that the strength grade of the nuts is
same with that of the bolts.
For instance:
Grade 8.8 bolts -> Grade 8 nuts
Grade 10.9 bolts -> Grade 10 nuts
Grade 12 nuts -> Grade 12.9 bolts

Prerequisite T2850-120V-138Y-A02 4-32

6.2 Checking before Erection of Tower
6.2.1 Checking of Bolt Components
Before installation, ensure to thoroughly clean and carefully check all bolted
components. The checking items include the threads of bolts and nuts and the transition
part from bolt head to threaded rod.

It’s prohibited to use any damaged bolt or nut. Do not use any bolt with rusted
threaded rod or bolt or nut with rusted thread.
6.2.2 Lubrication of High Strength Bolt Components
Before the installation each time, ensure to lubricate all bolt components by
molybdenum disulfide. While tightening the bolts, the good lubrication can provide
uniform friction force and achieve the specified tightening torque.

As shown in Figure 4.6-1, please lubricate the threads of bolts and nuts and the
contact surfaces of nuts. If the tightening torque is applied onto the bolt heads, lubricate
the contact surfaces of bolt heads as well.

4-33 T2850-120V-138Y-A02 Prerequisite

Figure 4.6-1a Application of Tightening Torque Figure 4.6-1b Application of Tightening Torque
on Nuts on Bolt Heads
Figure 4.6-1 Lubrication of Contact Surfaces
6.2.3 Reuse of High Strength Bolts
During the re-erection of the tower crane, only the bolt components that are
tightened correctly to the tightening torque can be reused. However, the precondition for
the reuse of bolt components is that no damage is detected during checking.

Prerequisite T2850-120V-138Y-A02 4-34

6.3Application of High Strength Bolts on This Tower Crane
On the tower crane, the application of high strength bolts include but not limited to
the following parts:
 Connection between lower support and slewing support
 Connection between upper support and slewing support
Bolt Tightening
Parent Tightening
Application location Specificatio torque
assembly Grade force (kN)
n (N.m)

Connection between lower

Lower support M42×435 10.9 3500 605
support and slewing support

Connection between upper

Upper support M42×480 10.9 3500 605
support and slewing support

 Under some specific working environments: Such as fixed connections of

slewing mechanism and boom.
Bolt
Tightening torque (N.m)
Specification Grade

M12 8.8 77.5

M16 8.8 190

M20 8.8 260

M24 8.8 640

8.8

M30 1300

4-35 T2850-120V-138Y-A02 Prerequisite

7 Installation of Split Pins
(1) To ensure the stop function of split pins for the hinge pins, bend both legs of the split
pins, instead of bending only the longer leg, as shown in Figure 4.7-1b.
(2) It’s unnecessary to bend completely two legs of split pins to come into contact with
the hinge pins. Bend two legs of the split pins for 15º~30º, in order to ease the
removal of split pins, as shown in Figure 7.4-1c.
(3) Do not block any leg of the split pins on other obstacle, otherwise the split pin will be
deformed or damaged during the rotation of hinge pin.
(4) In event of contact with any obstacle, completely bend two legs of the split pins, as
shown in Figure 4.7-1d.

Figure 4.7-1a Figure 4.7-1b Figure 4.7-1c Figure 4.7-1d

Figure 4.7-1 Installation Method of Split Pins

Use new split pins or split pins under good state.

Prerequisite T2850-120V-138Y-A02 4-36

8 Preparations before Installation of Mobile Tower Crane
8.1 Permissible Distance between Mobile Tower Crane and

Buildings
 The installation position of the tower crane in the construction site shall ensure a
spacing of at least 1.5m from the surrounding buildings.

87.8m (80mm boom length)

Figure 4.8-1 Dimensions of Widest Components on Tower Crane

 The installation position of tower crane in the construction side shall ensure that the
safety distance between all parts and overhead power grid meets the requirements
of Table 4.8-2 below.
Table 4.8-2 Relationship between Voltage of Overhead Power Grid and Safety Distance

Voltage (kV)
＜1 1~15 20~40 60~110 200
Safety distance (m)

Vertical direction 1.5 3.0 4.0 5.0 6.0

Horizontal direction 1.0 1.5 2.0 4.0 6.0

4-37 T2850-120V-138Y-A02 Prerequisite

 ⑤
Erection and Disassembling of Tower

Contents

1 Introduction ................................................................................................................. 1
2 Warning ....................................................................................................................... 2
3 Arrangement Diagram of Tower Crane ........................................................................ 3
4 Erection of Tower......................................................................................................... 4
4.1 Installation of Traveling Trolley .......................................................................... 6
4.2 Installation of Traveling Underframe ............................................................... 35
4.3 Installation Platform ........................................................................................ 44
4.4 Installation of Tower Body Sections................................................................. 49
4.5 Installation of Climbing Frame......................................................................... 62
4.6 Installation of Transitional Section................................................................... 73
4.7 Installation of Slewing Assembly ..................................................................... 87
4.8 Installation of Boom Section I.......................................................................... 97
4.9 Installation of Balance Boom Section I............................................................ 99
4.10 Installation of Boom Section II....................................................................... 102
4.11 Installation of Balance Boom Section II......................................................... 105
4.12 Installation of Boom Section III...................................................................... 108
4.13 Install the hoisting mechanism. ..................................................................... 109
4.14 Installation of Derrick Mast ............................................................................ 110
4.15 Installation of Boom Section IV ..................................................................... 116
4.16 Installation of 1st Counterweight ................................................................... 117
4.17 Installation of Boom Section V ...................................................................... 118
4.18 Installation of 2nd Counterweight .................................................................. 118
4.19 Installation of Boom Section VI ..................................................................... 119

T2850-120V-138Z-A01
 4.20 Installation of 3rd Counterweight .................................................................. 120
4.21 Installation of Boom Section VII .................................................................... 120
4.22 Installation of 4th Counterweight................................................................... 121
4.23 Hoisting of Remaining Boom Sections.......................................................... 122
4.24 Installation of Remaining Counterweights..................................................... 125
4.25 Installation of Hoisting Rope and Hook ......................................................... 126
4.26 Enwinding of Luffing Wire Ropes .................................................................. 131
4.27 Installation of Warning Lamp, Anemoscope, and Camera ............................ 135
5 Connection of Power Supply and Commissioning .................................................. 135
6 Automatic Magnification Change System ............................................................... 136
6.1 Change Procedure from 8X Magnification to 4X Magnification..................... 137
6.2 Change Procedure from 4X Magnification to 2X Magnification..................... 138
7 Jacking of Tower Crane........................................................................................... 141
7.1 Jacking Precautions...................................................................................... 141
7.2 Preparations before Jacking ......................................................................... 142
7.3 Leveling of Tower Crane before Jacking ....................................................... 142
7.4 Jacking Operation ......................................................................................... 147
7.5 Disassembling of Tower Body ....................................................................... 152
8 Attachments of Tower Crane ................................................................................... 158
9 Disassembling of Tower .......................................................................................... 158
9.1 Disassembling of Standard Sections ............................................................ 160
9.2 Disassembling of Warning Lamp and Anemoscope...................................... 161
9.3 Disassembling of Hook and Hoisting Wire Rope .......................................... 161
9.4 Disassembling of Luffing Wire Ropes ........................................................... 161
9.5 Disassembling of Counterweights................................................................. 161
9.6 Disassembling of Boom (From boom section VIII to boom tip section) ......... 161
9.7 Disassemble one counterweight. .................................................................. 162
9.8 Disassemble boom section VII...................................................................... 162
9.9 Disassemble one counterweight. .................................................................. 162
9.10 Disassemble boom section VI ...................................................................... 162
9.11 Disassemble one counterweight. .................................................................. 162
9.12 Disassemble boom section V ....................................................................... 162
9.13 Disassembling of Counterweights................................................................. 162
9.14 Disassemble boom section IV ...................................................................... 163

T2850-120V-138Z-A01
 9.15 Disassemble derrick mast ............................................................................. 163
9.16 Disassemble the hoisting mechanism. .......................................................... 163
9.17 Disassemble boom section III ....................................................................... 163
9.18 Disassemble boom section II. ....................................................................... 163
9.19 Disassemble boom section II ........................................................................ 163
9.20 Disassemble the balance boom section I. ..................................................... 163
9.21 Disassemble boom section I ......................................................................... 163
9.22 Disassembling of Slewing Assembly ............................................................. 163
9.23 Disassembling of Feeding System and Transitional Section ......................... 164
9.24 Disassembling of Climbing Frame and Remaining Tower Sections .............. 164
9.25 Disassemble the traveling underframe. ......................................................... 164
9.26 Disassemble the traveling mechanism. ......................................................... 164
10 Precautions after Disassembling of Tower .............................................................. 164

T2850-120V-138Z-A01
 Erection and Disassembling of Tower

1 Introduction

For successful erection and disassembling of tower, the user must carefully read and
strictly abide by the contents of this chapter.

Erection & Dismantling T2850-120V-138Z-A01 4-1

2 Warning

(1) Strictly abide by the erection and disassembling procedures of the tower.
(2) Ensure to erect and disassemble the tower under the commanding of professionally
trained personnel.
(3) During the installation and disassembling of tower crane, the wind speed (Average
instantaneous wind speed within 3s) at highest point of tower crane shall not exceed
14m/s.
(4) Check the brakes and limiters of all drive mechanisms.
(5) All safety and protection measures, such as ladders, platforms, and railings, must be
installed in place.
(6) During jacking, the operator must observe all motion components for normal relative
positions (Such as the relative positions between roller and main chord member and
between climbing frame and tower body). Upon detection of inclination of climbing
frame, stop the jacking and check and reset.
(7) The hinge pins for all mechanisms and the connecting bolts and nuts for tower body
and slewing support are special high strength parts. The user must install as per the
requirements and no replacement without permission is allowed.
(8) After the installation of boom, install the corresponding counterweights as per
specified requirements, otherwise the hoisting operation is prohibited.
(9) Start the luffing for balancing before the jacking.
(10) It’s prohibited to slew the boom during jacking.
(11) No slewing is allowed before 8 Ø105 hinge pins between the transitional section and
the tower body are not properly connected.

4-2 T2850-120V-138Z-A01 Erection & Dismantling

3 Arrangement Diagram of Tower Crane

The main components of the mobile tower crane are shown in the figure.

1-Traveling mechanism 2- Traveling underframe 3- Standard section 4- Climbing frame 5-

Jacking mechanism 6- Cylinder 7- Pump station 8- Feeding system 9- Transitional section
10- Lower support 11- Slewing support 12- Upper support 13- Cab 14- Slewing mechanism
15- Counterweight 16- Derrick mast 17- Hoisting mechanism 18- Balance boom 19- Luffing
mechanism 20- Auxiliary hoisting mechanism 21- Moment limiter 22- Boom section I 23-
Hoisting load limiter 24- Boom 25- Hook 26- Load trolley
Arrangement Diagram of Mobile Tower Crane

Erection & Dismantling T2850-120V-138Z-A01 4-3

4 Erection of Tower

Figure 4-1 Tower Erection Sequence

The installation sequence of the tower crane is shown in Figure 4-1.

After the preparations before installation of tower crane as described in previous
chapter are completed, operate as per the following sequence:
(1) Install the traveling mechanism.
(2) Install the traveling underframe.
(3) Install two standard sections.
(4) Install the climbing frame.
(5) Install the transitional section and feeding system.
(6) Install the slewing assembly (Including upper and lower supports, slewing
support, slewing mechanism, and cab).
(7) Installation of Boom Section I
(8) Install the balance boom section I (Including auxiliary hoisting mechanism and
section mechanism).
(9) Install the boom section II (Including load trolley).
(10) Installation of Balance Boom Section II
(11) Installation of Boom Section III
(12) Install the hoisting mechanism.
(13) Install the derrick mast.
(14) Installation of Boom Section IV
(15) Installation of 1st Counterweight (11.5t)
4-4 T2850-120V-138Z-A01 Erection & Dismantling
 (16) Installation of Boom Section V
(17) Installation of 2nd Counterweight (11.5t)
(18) Installation of Boom Section VI
(19) Installation of 3rd Counterweight (11.5t)
(20) Installation of Boom Section VII
(21) Installation of 4th Counterweight (11.5t)
(22) Install the remaining boom sections.
(23) Install the remaining counterweights.
(24) Enwind the hoisting wire rope and hook.
(25) Install the luffing wire ropes.
(26) Install the warning lamp and anemoscope.

Erection & Dismantling T2850-120V-138ZW-A 4-5

 4.1 Installation of Traveling Trolley

4.1.1 Introduction of Mobile Tower Crane

The T2850-120V traveling mechanism is composed of traveling trolley I, traveling
trolley II, traveling trolley III, traveling trolley IV, cable drum bracket, and cable drum
device. The performances of four traveling trolleys are same, except the orientation of
anchorages, the hydraulic rail clamp or travel switch (equipped or not), and number of
motors. Refer to Figure 4.1-1

1. Traveling trolley I 2. Hydraulic rail clamp 3. Cable drum bracket 4. Cable drum 5. Rail
6. Traveling trolley IV 7. Anchorage 8. Travel switch 9. Traveling trolley II 10. Traveling trolley III
11. Underframe
Figure 4.1-1

4-6 T2850-120V-138Z-A01 Erection & Dismantling

1) Traveling trolley I, as shown in Figure 4.1-2.

Rail

1. Secondary balance beam; 2. Driven trolley bracket; 3. Driven trolley bracket; 4. Main balance
beam; 5. Articulated yoke; 6. Drive trolley bracket; 7. Driven trolley bracket; 8. Shock absorber;
9.Travel switch; 10. drive traveling wheel；11. Anchorage；12. Reducer; 13. Motor; 14. Driven
trolley wheel; 15. Hydraulic rail clamp;
Fig 4.1-2 Traveling trolley I
The traveling trolley I is mainly composed of reducer, motors (2 pieces), main balance
beam, secondary balance beam, trolley brackets, drive traveling wheel (4 pieces), driven
traveling wheels (4 pieces), shock absorbers, anchorages, hydraulic rail clamp, and travel
switch.

Erection & Dismantling T2850-120V-138ZW-A 4-7

(1) Traveling trolley II, as shown in Figure 4.1-3

track

1. Secondary balance beam; 2. Driven trolley bracket; 3. Driven trolley bracket; 4. Main balance
beam; 5. Articulated yoke; 6. Driven trolley bracket II；7. Drive trolley bracket II；8.Encoder
mounting base; 9. Driven traveling wheel; 10. Motor; 11. Reducer; 12. Drive traveling wheel; 13.
Shock absorber; 14. Anchorage；15. Travel switch
Fig 4.1-3 Traveling trolley II
The traveling trolley II is mainly composed of reducer, motors (2 pieces), main
balance beam, secondary balance beam, trolley brackets, drive traveling wheel (4 pieces),
driven traveling wheels (4 pieces), shock absorbers, anchorages, travel switch, and
encoder mounting base.
Differing from traveling trolley I, the travelling trolley is equipped with encoder
mounting base and no hydraulic rail clamp. The other performances are same with those
of traveling trolley I.

4-8 T2850-120V-138Z-A01 Erection & Dismantling

(2) Traveling trolley III, as shown in Figure 4.1-4

1. Secondary balance beam; 2. Driven trolley bracket; 3. Driven trolley bracket; 4. Main balance
beam; 5. Articulated yoke; 6. Drive trolley bracket; 7. Driven trolley bracket; 8. Shock absorber; 9.
Driven trolley wheel; 10. Motor; 11. Reducer; 12. Driven traveling wheel; 13. Hydraulic rail clamp; 14.
Anchorage.
Fig 4.1-4 Traveling trolley III

The traveling trolley I is mainly composed of reducer, motor (1 piece), main balance
beam, secondary balance beam, trolley brackets, drive traveling wheel (2 pieces), driven
traveling wheels (6 pieces), shock absorbers, anchorages, and hydraulic rail clamp.
Differing from traveling trolley I, the traveling trolley III is equipped with 1 motor and
its reducer, 2 drive traveling wheels, and 6 driven traveling wheels and no travel switch.
The other performances are same with those of traveling trolley I.

Erection & Dismantling T2850-120V-138ZW-A 4-9

(3) Traveling trolley IV, as shown in Figure 4.1-5

1. Secondary balance beam; 2. Driven trolley bracket; 3. Drive trolley bracket; 4. Main balance
beam; 5. Articulated yoke; 6. Driven trolley bracket; 7. Driven trolley bracket; 8. Driven trolley wheel;
9.Drive traveling wheel; 10. Reducer; 11. Motor; 12. Anchorage；13. Shock absorber
Fig 4.1-5 Traveling trolley IV
The traveling trolley IV is mainly composed of reducer, motor (1 piece), main balance
beam, secondary balance beam, trolley brackets, drive traveling wheel (2 pieces), driven
traveling wheels (6 pieces), shock absorbers and anchorages.
Differing from traveling trolley I, the traveling trolley IV is equipped with 1 motor and
its reducer, 2 drive traveling wheels, and 6 driven traveling wheels and no hydraulic rail
clamp or travel switch. The other performances are same with those of traveling trolley I.

4-10 T2850-120V-138Z-A01 Erection & Dismantling

(4) Motor
The YVFSE3-160M-4-11kW motor applied is a special variable frequency motor
with electromagnetic motor. The motor is running under the variable frequency of
5~50Hz to ensure stable start without impact. During stop, the speed is reduced
automatically following the automatic reduction of frequency. At the same time, the
brake applies after a delay to guarantee stable stop without impact.
(5) Reducer
The KA/T97B-50-AG160 reducer with speed ratio at 49.16 is applied to reduce the
motor speed and increase the output torque.
(6) Hydraulic rail clamp

The hydraulic rail clamp is in model of YJJ200 and is a kind of windproof brake device.
It’s mainly used for windproof braking for diversified types of outdoor hoisting
machinery.
The structure of the rail clamp is shown in Figure 4.1-4 and its working principle is as
below: The power unit is energized to drive the hydraulic cylinder so that the pressure
oil drives the piston rod and thus drives the inward movement of caliper arms and the
brake pads expand via hinge points to relieve the clamping force. When the power
unit is de-energized to lose drive force, two caliper arms swing outward under the
action of brake spring and the brake pads close to clamp the rails and generate the
specified anti-slip force.

Erection & Dismantling T2850-120V-138ZW-A 4-11

 clamp limb limit shield manual pump Driving unit Upper support
nut

bracket spring

hydro-cylinder
assemble hole

flange
supporting wheel

bolt

subplate

track

Fig 4.1-6 Structure of Rail Clamps

(7) Travel switch

The travel switch ensures to automatically control the deceleration and stop
steadily before the tower crane reaches the rail ends in event of abnormality.
Note: The user shall not depend on the travel switch for normal stop.
(8) Warning lamp
The warning lamp sounds and flashes to alert the ground personnel and prevent
safety accidents.
(9) Anchorages

4-12 T2850-120V-138Z-A01 Erection & Dismantling

 1. Lower connecting plate; 2. Left screw; 3. Screw sleeve; 4. Right screw; 5. Upper connecting plate; 6. Steel
plate; 7. Balance rod; 8. Counterweight bracket; 9. Counterweight; 10. Hinge pin 1; 11. Short hoisting chain; 12.
Pin; 13. Bolt connector; 14. Shaft end guard plate; 15. Bolt connector; 16. Handle; 17. Hinge pin 2; 18. Pin.
Fig 4.1-7 Anchorage
When the tower crane is under non-working status, to prevent the sliding on rails or
even the rollover of the tower crane in event of possible gale, ensure to properly fix the
anchorages.
(10) Cable drums
Two cable drums are installed on the cable drum brackets. The installation
positions are shown in Figure 4.1-2. The type M cable drum is a power-driven drum
composed of torque motor, reducer, collection box, drum, wire box, and mounting
Cable drum
bracket, as shown in Figure。
Moment motor

Electrical collector box

Reducer

Wire box

Fig 4.1-8 Cable drum

(11) Rail foundation requirements
During the arrangement of rails, the safety distance between trolleys and the rail
outer buildings shall be no less than 450mm, the anchorages shall be installed on the
outer side of rails, and the motor shall be installed on the inner side of the rails. (Refer to
Figure 4.1-2).
The user may arrange the rail foundation for the mobile tower crane as per the rail
foundation drawing provided by our company. The user also can independently design
the rail foundation of tower crane as per relevant standards based on the loads provided
by our company.

4.1.2 Installation and Adjustment

When the traveling mechanism is transported to the site, every traveling trolley
includes main balance beam subassembly, 2 secondary balance beam and trolley bracket
subassemblies, anchorages, and other auxiliary materials. Please refer to Figure 4.1-9.
a) Main balance beam subassembly, mainly including main balance beam and
articulated yoke. The balance beams for 4 traveling trolleys are same. There are two

Erection & Dismantling T2850-120V-138ZW-A 4-13

 types of articulated yoke that have different orientation requirements. The top view
for 4 articulated yokes is shown in Figure 3-1 (d). Ensure that correct relative
positions of mounting holes on 4 articulated yokes.
b) Secondary balance beam and trolley bracket subassembly, mainly including
secondary balance beam, trolley bracket, motor, reducer, wheels, shock absorber,
hydraulic rail clamp, and travel switch. Notice the differences between the end parts
of secondary balance beam and trolley bracket subassemblies. Refer to Chapter II
Introduction of Travelling Trolley Structure for details.
c) The anchorages for 4 traveling trolleys are same and are composed mainly of
balance rod, counterweight, screw, and handle. Notice the orientation during
installation with reference to the Arrangement Diagram 4.1-1；
d) Other auxiliary parts, namely the hinge pins, shaft end guard plates, and bolts
required for the installation of above-mentioned parts.

（a） Main balance beam subassembly

（b）

(b) Secondary balance beam and trolley bracket subassembly (c) Anchorage

4-14 T2850-120V-138Z-A01 Erection & Dismantling

 （d）Relative positions of articulated yokes
Fig 4.1-9

4.1.2.1 Installation of Traveling Trolleys

1) Firstly, open the hydraulic rail clamp by manual pump (Refer to the
commissioning method of hydraulic rail clamp power unit for detailed method)
and hoist the trolleys to the paved rails in such manner that the motors are on
the inner side of rail gauge and the anchorages are on outer side of rail gauge.
Arrange the traveling trolley I and II and arrange the traveling trolleys III and IV
in diagonal manner respectively. In such case, the trolleys with hydraulic rail
clamp on two rails face towards one same direction, as shown in Arrangement
Diagram 4.1-1。

2) Hoist two secondary balance beam and trolley bracket subassemblies for every
traveling trolley in turn to the rails paved as per specified requirements, ensure
that two shaft holes for fit with main balance beams are in spacing of 3,560mm,
and fix steadily by small square woods and wood wedges, as shown in Figure
4.1-10(a). Notice to place the motors on the inner side of rail gauge.

3) Hoist the main balance beam subassembly onto the properly fixed secondary
balance beams (Notice the installation orientation of articulated yokes, with
reference to the Figure 4.1-10d), align the Ø160 shaft holes of main and
Erection & Dismantling T2850-120V-138ZW-A 4-15
 secondary balance beams, install the Ø160 hinge pins (The fit dimension for the
shaft holes here is Ø160H7/f6), and then tighten the shaft end guard plates by
bolts M20, as shown in Figure 4.1-10（b）。

4) Hoist the anchorage onto the main balance beam, as shown in Figure 4.1-10(c).
Notice to place the anchorages on the outer side of rail gauge and anchorage
plates on the shock absorber side.

（a）Hoisting of two secondary balance beam and trolley bracket subassemblies

（b）Hoisting of main balance beam subassembly

（c）Hoisting of anchorage

Fig 4.1-10

5) After four trolleys are assembled to the corresponding structures as per above-
mentioned procedure (Refer to Chapter 4.1.1 for the introduction of trolley
structure), ensure that the Arrangement Diagram 4.1-1 is met, the positions of
articulated yokes meet the Figure 4.1-10(d), the motors are on the inner side of
rail gauge, and the anchorages are on the outer side of rail gauge.
4-16 T2850-120V-138Z-A01 Erection & Dismantling
 6) Remove 6 sets of bolts M42×250 and two tapered pins from articulated yokes of
trolleys for future use.

7) Hoist the assembled crossing beam, align the trolley connecting plates with the
underframe connecting plates of same numbers, install the tapered pins, and
tighten the bolts M42×250. Tighten these bolts (grade 10.9) to 3,800N.m.

8) Remove 16 installation/transport outriggers from every trolley and clamp the

hydraulic rail clamps to the rails, in order to ensure the subsequent installation
safety of the tower crane.

Caution:
 Refer to the Operation Manual of Tower Crane for the assembling of
underframe.
 The relative installation positions between underframe and trolleys are
shown in Figure 4.1-1.
The main components to be hoisted and their weights are listed in Table 4.1-1.

Table 4.1-1 Main Components to be Hoisted and Their Weights

Name Unit weight Quantity

Traveling trolley I 23,114kg 1

Traveling trolley II 22,446kg 1

Traveling trolley III 22,578kg 1

Traveling trolley IV 21,908kg 1

Underframe (Approximately) 90,848kg 1

4.1.2.2 Installation of Cable Drum Brackets

The installed cable drums are two type M power-driven cable drums and are
installed on two sides of the traveling underframe symmetrically with respect to the rail
center.

The type M cable drum bracket installation includes fixing bracket and cable drum
bracket, as shown in Figure 4.1-11：

Erection & Dismantling T2850-120V-138ZW-A 4-17

 图 4.1-11a

Fig 4.1-11b

4-18 T2850-120V-138Z-A01 Erection & Dismantling

 Fig 4.1-11c
Fig 4.1-11

4.1.2.3 Installation and Commissioning of Cable Drums

1) Assembling of type M cable drums, as shown in Figure 4.1-12：

Figure 4.1-12 Type M Cable Drum Subassembly

a) The drum subassembly is shown in Figure 4.1-12. The framework and two

Erection & Dismantling T2850-120V-138ZW-A 4-19

 discs are connected securely by 12 sets of bolts M10×260 (1 bolt, 1 nut, 1
plain washer, and 1 spring washer). The flange and disc are connected
securely by 12 sets of bolts M10×55 (1 bolt, 1 nut, 1 plain washer, and 1 spring
washer).
b) Align the mounting holes on the turntable of reducer output shaft with the
flange and tighten by bolts.
c) Connect the torque motor output shaft to the worm key slot in the reducer and
fix the end face of torque motor to the top face of reducer by bolt.
d) Fit the mounting holes on the collection box housing with the reducer output
shaft and fix to the end face of reducer base by bolts.
e) Check the oil level of the reducer. If the oil level is below the center of
observation port, add HL30 lubricating oil.
2) Installation of cable drums, as shown in Figure 4.1-11：

a) Install the cable drums to the cable drum brackets;

b) Install the wire box brackets;

c) Adjust the locations of cable drum bracket and wire box brackets to align the
reels with wire boxes and at the same time align with the cable anchorages.
3) Wiring of type M cable drums, as shown in Figure 4.1-11：

a) Straighten the cable and let it completely loose without any twist. Adjust the
cable length in such manner that at least 3~4 turns of cable are left on the
drum when the limit position is reached;
b) Open the collection box cover, feed the traveling cable along the direction
shown in Figure 3-3 via wire box into the reel of the cable drum, feed this cable
from framework into the reducer output shaft bore and the collection box, and
connect the wires of traveling cable to the internal wiring posts of collector ring
securely. Then, lead the main cable of tower crane from external wiring posts
of collector ring via cable outlet of collection box to the switch box. Properly
install the collection box cover.
Caution: The null lines must be connected to one same slip ring.
4) Requirements for cable anchorage points of type M cable drum：
4-20 T2850-120V-138Z-A01 Erection & Dismantling
 Two type M cable drums are used. Two cable anchorage points can be any two
points symmetric with respect to the rail centerline on the lines AB and CD on two
sides of the rail gauge centerline (Refer to Figure 4.1-13). When the cable anchorage
points are any two points (Except the end points A, C, B, and D) on the centerlines AB
and CD, the cable length is the distance from cable anchorage point to rail far end
added by 15m.

图 4.1-13a
Track

Cable anchoring point

Bracket

Track Cable drum Cable drum bracket

Fig 4.1-13b
5) Commissioning of type M cable drums:

The commissioning shall be performed after the installation of traveling

underframe, traveling mechanism, cable drums, and traveling electronic control system.
The commissioning is mainly intended to determine the correct rotation direction of

Erection & Dismantling T2850-120V-138ZW-A 4-21

 cable drums and adjust the cable tension during the release and retraction of cable.
At the start of tower crane traveling mechanism, the torque motor of the cable drum
starts synchronously. After the speed reduction by the reducer, the torque motor transmits
the torque via the turntable and flange on the reducer output shaft to the drum so that the
drum rotates at low speed towards the retraction direction of cable. When the tower crane
is far away from the cable anchorage points, the torque motor is still energized to, by
dragging the cable to overcome the friction force in the reducer, drive the rotation of disc
and automatically release the cable. At the stop of the tower crane, the cable drum motor
shall be de-energized after a 3~5s delay, in order to prevent the inertia of traveling
mechanism from causing loose cable.
Firstly, inch at low speed the mechanism. The cable drum shall rotate towards the
retraction direction of cable. If not, adjust the rotation direction of torque motor.
Secondly, after the installation and commissioning of all limiters, operate the
traveling mechanism along full length of rails back and forth and observe the cable
tension during the release and retraction of cable. The cable tension shall ensure the
smooth release and retraction of cable without overheating the motor, otherwise the
output torque of the cable drum shall be adjusted to adjust the cable tension.
The detailed adjustment procedure is as below. Refer to Figure 4.1-14a and Fig
4.1-14b：

Fig 4.1-14a Fig 4.1-14b

Unscrew the stop block (near the connecting surface between reducer and motor)
from the reducer housing, observe whether the groove of the reducer adjustment nut is

4-22 T2850-120V-138Z-A01 Erection & Dismantling

aligned with the mounting hole of stop block (As shown in Figure 4.1-14a), insert the stop
block into the hole, and rotate the turntable by hand. Standing on the outer side of drum,
rotate the turntable clockwise to increase the output torque and cable tension. Rotate the
turntable counter-clockwise to reduce the output torque and cable tension. Adjust the
output torque repeatedly to change the cable tension, till the cable is released and
retracted smoothly without overheating the motor.
Note: During normal working, unplug the stop block and screw the threaded end of
stop block into the mounting hole on the reducer as per Figure 4.1-14b.

4.1.2.4 Installation and Adjustment of Hydraulic Rail Clamps

clamp limit shield manual Driving nut Up bracket

limb pump unit

bracket spring

hydro-cylinder
Assemble hole

flange

bolt Supporting

wheel
Friction piece

subplate

track
Fig 4.1-15

1) Installation of rail clamps

a) Checking before installation
 Check the rail clamps for complete parts；
 Check the rail model for consistency with rail clamp nameplate；
 Check and ensure that the groove width N of rails meets the requirements of Table
4.1-2；
 Check friction pad surfaces for presence of oil dirt and other impurities influencing the
performance；
 Ensure that the oil tank of the power unit is already filled with specified hydraulic oil.
Upon detection of any abnormality, ensure to solve before starting installation.
Erection & Dismantling T2850-120V-138ZW-A 4-23
 Table 4.1-2 Shape and Installation Dimensions of Rail Clamps (Unit: mm)
Dimension
A B C K-d E1 E2 F M N P G
Model

YJJ200 730 1140 595 8-￠26 60 140 95 40 350 22 820

Needed space
Minimum groove width

Fig 4.1-16

b) Installation of rail clamps

Install the rail clamps as per the following procedure and method (Refer to Figure
4.1-15)：
 Remove the shield and then open the rail clamp by power unit manual pump (Refer
to Figure 4.1-16) (Refer to previous section for the manual opening and closing of the
hydraulic rail clamps)；
 Move (Hoist and move) the opened rail clamp steadily to the installation position by
a forklift (or sling), correctly support the support wheels on the rails (Refer to Figure
4.1-16), align the mounting holes of the rail clamp bracket with mounting holes of the
mating device end flange, and connect by bolts (Refer to Table 4.1-3 for bolt
specification). After the connection by bolts, relieve the pressure by power unit
manual pump to naturally close the rail clamp and tighten the connecting bolts (Refer
to Table 4.1-3 for tightening torque) to complete the installation (Refer to the manual
4-24 T2850-120V-138Z-A01 Erection & Dismantling
 of the power unit in next section for the manual opening and closing method of
hydraulic rail clamp).

！！！The rail clamp brackets shall be paralleling with the rails,

otherwise the adjustment is required before tightening the
connecting bolts!!!

Table 4.1-3 Technical Specification of Rail Clamp and Specification of Mounting

Bolts
Anti-slip Opening Specification Quantity of Tightening
Clamping force
Model pressure of mounting connecting torque of
force (KN)
（KN） (MPa) bolts (mm) bolts bolts (N.m)

M24-grade
YJJ200 200 100 10 8 380~450
8.8

Electric installation and control requirements of rail clamps

！！！The working voltage will endanger the personal life!!!

！！！All electric operations shall be fulfilled only by qualified
personnel!!!

The rail clamp is provided with a travel switch to feed back the working status during
electric opening of rail clamp and the linkage control of traveling mechanism.
The travel switch is properly installed and commissioned before the delivery of the
tower crane. Before use, please check accordingly and connect relevant flexible cables
as per the electronic control requirements. Upon detection of any abnormality, adjust as
per the method described in “4.1.3.6”.
The internal contacts of the travel switch are shown in Figure.

Fig 4.1-17

2) Adjustment of rail clamps

Erection & Dismantling T2850-120V-138ZW-A 4-25
a) Adjustment of opening limit switch
Adjustment method of travel switch (Refer to Figure 4.1-18): Loosen the set screw
on the rocker arm by an Allen wrench, rotate the rocker arm in such manner that the travel
switch outputs a signal at the electric opening of rail clamp and outputs no signal at the
closing, and finally tighten the set screw.

plate limit switch

rocker arm Locking bolt

Fig 4.1-18
Caution: The tower crane is already adjusted before the delivery. During the
erection of tower, ensure that the signal conforms to the logic, otherwise it will
probably result in working failure of traveling electronic control system.

b) Adjustment of friction pad clearance and equal clearance

Before the operations, adjust the friction pad clearance (clearance between tooth
face of friction pad and side face of rail under released status) of rail clamps to the range
specified in Table 4.1-4. If beyond the specified range, adjust as per following method
(Refer to Figure 4.1-19): Place the rail clamp under naturally closed status, rotate the
adjustment bolts in such manner that the value S is same on two sides and conforms to
the requirements of Table 4.1-4, and finally tighten the lock nuts.

Locking Adjust bolt

Fig 4.1-19

Table 4.1-4
Model YJJ200

S(mm) 14.2

One-sided opening clearance (mm) 3

4-26 T2850-120V-138Z-A01 Erection & Dismantling

c) Functional adjustment of hydraulic rail clamps
Open and close the rail clamps for several times and check for following problems：
 Check whether the opening release pressure of rail clamps meets the requirements
of Table 4.1-3. If not, adjust with reference to the adjustment section of power unit
(next section)；
 Check whether the limit switch outputs a signal when the rail clamp opens. If not,
check for intact components and correct wiring and adjust as per above-mentioned
method；
 Check whether the clearances of friction pads from two sides of the rails meet the
requirements of Table 3-4 when the rail clamp opens. If not, adjust as per the
method described in 4.1-4.
3) Structure and commissioning of power unit
a) Overview
DD power unit is mainly used for the drive and control of the rail clamps (mostly used
for control of individual windproof device). The normally open solenoid valve is a ball seat
valve with certain pressure holding function. The system is provided with a manual pump
for emergency use in event of power failure or malfunction.
b) Structure and working principle of power unit
 The structure of the power unit is shown in Figure 4.1-20

Fig 4.1-20

Erection & Dismantling T2850-120V-138ZW-A 4-27

1. Motor 2. Gear pump 3. Oil suction filter 4. Air filter 5. Manual pump 6. Solenoid valve

7. Pressure relay 8. Oil tank 9. Coupling 10. Valve block 11. Oil filler port 12. Oil

drainage port 13. Relief valve 14. One-way throttle valve

 The hydraulic schematic diagram of the power unit is shown in Figure 4.1-21

Fig 4.1-21

1. Relief valve 2. Pressure relay 3. Electromagnetic reversing valve 4. One-way throttle valve

5. Manual pump 6. Pressure gauge 7. Rail clamp cylinder

 The electronic control schematic diagram of the power unit is shown in Figure
4.1-22

Fig 4.1-22

4-28 T2850-120V-138Z-A01 Erection & Dismantling

 QF1: Air switch; KM1: AC contactor; FR1: Thermal relay; M1: Motor;
FU1: Fuse; SP: Pressure relay; YV1: Electromagnetic reversing valve
 The system parameters are listed in Table 4.1-5
Table 4.1-5
Rated Motor Control
System flow Capacity
Model of working power power of oil Note
power unit pressure (L/Min)
(Kw) (Kw) tank (L)
(MPa)
Rexroth pressure
DD11-06 11 5.6 1.5 0.1 4 relay and ABB
motor

c) Working principle
Automatic control
 Opening: After the electronic control system of the power unit receives the opening
control command from master control system, the motor is energized to start and
the solenoid valve is energized from normally open status to closed status so that
the hydraulic oil is supplied via one-way throttle valve to the no-spring chamber of
brake cylinder and the hydraulic force overcomes the spring force to fulfill the
opening motion.
 Closing: When the opening signal is cut, the motor stops running and the solenoid
valve is powered off from closed status to normally open status. Under the action of
the spring in the cylinder, the hydraulic oil in the no-spring chamber of the cylinder
returns to the oil tank via one-way throttle valve and solenoid valve to fulfill the
closing motion. The closing speed can be adjusted by adjusting the throttle valve.
 Pressure holding: When the brake valve (cylinder) is completely opened, the
solenoid valve is still energized and the motor is powered on and off under the
control of pressure relay to hold the pressure of the system.
Manual control
In event of malfunction or power failure of automatic control circuit, the brake can
be opened and closed by manual control mode. The detailed work procedure is as
below:
 Opening: Rotate rightward to tighten the adjustment hand wheel of one-way throttle
Erection & Dismantling T2850-120V-138ZW-A 4-29
 valve, operate vertically the handle of manual pump so that the pressure oil is
supplied to the brake via manual pump, and observe the reading of pressure gauge
in the system. When the pressure reaches the opening pressure of the brake, stop
operating the handle of manual pump to complete the opening motion.
 Closing of brake: Rotate leftward to loosen the adjustment hand wheel of one-way
throttle valve . Under the action of the spring in the cylinder, the hydraulic oil in the
no-spring chamber of the cylinder returns to the oil tank via throttle valve and
solenoid valve to fulfill the closing motion. The closing speed can be adjusted by
adjusting the throttle valve.

To minimize the rollover risk of tower crane under extreme condition

(Such as the sudden power failure during operations), the closing
time shall be adjusted to approximately 40s and shall be basically
same for two rail clamps.

d) System adjustment
 Adjustment of relief valve pressure
Power off the hydraulic station, tighten the adjustment screw of pressure relay
by 2~3 turns, increase the pressure of system motor, loosen adjustment nut of
relief valve, adjust the pressure of relief valve to meet the requirements of Table
4.1-7. While rotating the relief valve adjustment rod, power off the power unit. After
each adjustment, power on and observe the system pressure. If not qualified,
power off and adjust again, till the requirement in Table 4.1-7 is met. Restore the
pressure relay adjustment screw and finally tighten the lock nut on the relief valve
adjustment rod.
 Adjustment of relay switchover pressure
Power on the motor and observe the system pressure on the pressure gauge. After
the system pressure meets the requirements of Table 4.1-3, the pressure relay switch
actuates to control the stop of motor. If the relay changeover pressure is incorrect, power
off and rotate the pressure changeover adjustment screw on the pressure relay to meet
the requirements of Table 4.1-3. The detailed adjustment method is as below:
If the motor doesn’t stop when the system pressure is higher than the pressure
4-30 T2850-120V-138Z-A01 Erection & Dismantling
setting specified in Table 4.1-3 by approximately 1MPa, rotate counter-clockwise the
adjustment screw of pressure relay, till the motor stops. If the motor stops before the
system pressure reaches the setting specified in Table 4.1-3, rotate clockwise the
adjustment screw of pressure relay in such manner that the motor restarts and then
stops after the requirement is met.
 Adjustment of system flow (Closing speed)
The one-way throttle valve is properly adjusted and marked before the delivery
of traveling trolleys. If the adjustment of the closing speed of rail clamps is required
in the field, rotate clockwise the adjustment screw of one-way throttle valve and
observe the closing speed, till the closing time is adjusted to approximately 40s.

Periodically check the closing time. After every maintenance or

manual control, the adjustment of closing time is required.

4.1.2.5 Adjustment of safety devices

The stop blocks shall be set on both ends of rails depending on the situation of the
working site. The travel limit blocks shall be installed on both ends of rails and correspond
to the positions of drive trolleys I and II. Please refer to the rail and foundation diagram
for details.
The travel switch is triggered in event of driver’s mis-operation or system
malfunction or when the tower crane is moved to the rail end so that the tower crane
automatically decelerates and stops by brake to prevent the rollover risk of tower crane
due to derailing arising from the high speed impact with the end stop block.

This travel switch is a double trigger switch installed on the outer side of drive trolley.
One travel switch is installed on the drive trolleys I and II respectively.
1) Adjustment of travel switch
Adjust the travel switch under no-load condition of the tower crane：
After the travel switch is installed on the switch bracket of drive trolley I as per Figure
4.1-23a, adjust the lengths of two impact bars of the travel switch as per Figure 4.1-23b.

Erection & Dismantling T2850-120V-138ZW-A 4-31

 Fig 4.1-23a Fig 4.1-23b

Fig 4.1-23

Travel switch (Anti-collision): Used for electronic control orientation.

Travel switch (Travel limit): When the traveling mechanism approaches one rail end,
the primary impact block of travel switch on the outer side of drive trolley I, which is
installed on the outer limit position of the rail, is triggered so that the traveling mechanism
realizes low speed traveling via electric shift. When the secondary impact block on the
outer limit position of rail is triggered secondarily, the traveling mechanism is powered off
(so that the tower crane can move only towards the opposite direction). In such case, the
primary brake applies braking immediately and the secondary brake applies the braking
after a delay to realize stable stop. The double-trigger switch is reset during return.
When the traveling mechanism approaches the other rail end, the primary impact
block of travel switch on the outer side of drive trolley II, which is installed on the outer
limit position of the other rail, is triggered so that the traveling mechanism realizes low
speed traveling via electric shift. When the secondary impact block on the outer limit
position of rail is triggered secondarily, the traveling mechanism is powered off (so that
the tower crane can move only towards the opposite direction). In such case, the primary
brake applies braking immediately and the secondary brake applies the braking after a
delay to realize stable stop. The double-trigger switch is reset during return.
Run the traveling mechanism near two rail ends for three times respectively. The
motion results shall be consistent.
During stop, the minimum spacing is 1m between end shock absorber of trolley and
sliding stop block of rail and is 1m between sliding stop block of rail and fixed stop block
4-32 T2850-120V-138Z-A01 Erection & Dismantling
of rail.

4.1.2.6 Installation positions of rail outer impact blocks

Install the primary and secondary impact blocks as per the diagram

Buffer Sliding
First Retaining Second along track Buffer fixed
plate Retaining plate on track
Retaining
plate
Track

Fig 4.1-24

Caution:
 The travel switch is a protection device against mis-operations and can’t be used to stop

at limit positions during normal operations, namely the driver shall decelerate and cut off

the power supply prior to the limit position depending on the actual situation.

 Due to high gravity center of mobile tower crane, it’s prohibited to start the traveling in

opposite direction before the traveling mechanism is completely stopped, in order to

prevent rollover of tower crane.

 The installation position diagram of the impact blocks is a schematic diagram. For the

official drawing, please refer to the rail foundation drawing provided by our company.

4.1.2.7 Adjustment of anchorages

The anchorages have two statuses, namely anchored status and released status.
1) Anchored status (When the tower crane is under non-working status or is possibly
under gale) (Figure 4.1-25a)
When the driver is off-duty and leaves the tower crane, ensure to fix the anchorages,
in order to prevent the sliding on rails or even rollover of the tower crane under the action
of gale.
Erection & Dismantling T2850-120V-138ZW-A 4-33
 In such case, connect the lower connecting plates of anchorages to the anchorage
baseplates near the rails by hinge pins 2, in order to ensure that four trolleys are securely
connected to the rail foundation.
Electromechanical interlocking function: The anchorages and the contacts of travel
switches above the anchorages are disengaged so that the tower crane can’t be powered
on for traveling.

Fig 4.1-25a
2) Released status (When the tower crane is working) (Figure 4.1-25b).

Fig 4.1-25b
During working, fold upward the lower connecting plate of anchorage so that the
anchorage plate comes into contact with the anchorage travel switch to get energized
and insert the lock pin to fix the anchorage with trolley beam bracket.
3) Adjustment of anchorage counterweight (Refer to Figure 4.1-25c）：

Fig 4.1-25c
4-34 T2850-120V-138Z-A01 Erection & Dismantling
 The counterweights on left and right sides of the anchorage can be adjusted at the
user's needs. Move the counterweight on the balance rod along the balance rod to one
appropriate position of four locating holes, fix the counterweight on the balance rod by
hinge pin 1, and insert the split pin (Sufficiently expand the pin opening).
4) Adjustment of anchorage point position：

During the anchoring, if the locating plate of anchorage is not aligned with the
anchorage baseplate near the rails so that the anchorage positions of four trolleys are
incorrect, rotate the handle (Figure 4.1-25c) to adjust the positions by adjusting the
lengths of left and right screws.

4.2 Installation of Traveling Underframe

4.2.1 Assembling of Traveling Underframe

1) As shown in Figure 4.2-1, connect four half beams to integral one by connecting
sleeves and fix by 8 hinge pins Ø120×700/810.

Erection & Dismantling T2850-120V-138ZW-A 4-35

 Figure 4.2-1 Assembling of Underframe Beam

No. Name Specification Quantity

1 Half beam I 1

2 Half beam II 2

3 Half beam III 1

4 Connecting sleeve 1

5 Hinge pin XZ04E-120×700/810 8

6 Lock pin Φ20 8

7 Lock pin Φ20 8

8 Pin 6.3×40 32

2) As shown in Figure 4.2-2, hoist the long and short pull rods and install the long and
short pull rods onto the underframe beam in turn by 16 hinge pins Ø50×90/130.

4-36 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.2-2 Hoisting and Installation of Pull Rods

No. Name Specification Quantity

1 Long pull rod 4
2 Short tie rod 4
3 Hinge pin XZ01D-50×90/130 16
4 Pin 10×80 16

3) Install the basic section I and basic section II. Refer to section 4.4 for the assembling
of basic section I and basic section II. Hoist the assembled basic section I to the
assembled underframe beam and connect it to the short outriggers of underframe
beam by 8 Ø105 hinge pins. Knock till the shoulders fit closely to the surfaces of chord
members and then insert small hinge pins and spring pins into the hinge pins. Install
the assembled basic section II onto the basic section I, as shown in Figure 4.2-3.

Erection & Dismantling T2850-120V-138ZW-A 4-37

 Figure 4.2-3 Hoisting and Installation of Basic Section I and Basic Section II

No. Name Specification Quantity

1 Basic section I 1
2 Basic section II 1
3 Hinge pin XZ-105-365/480 16
4 Lock pin XZ03C-30×240/270 16
5 Spring pin d1=6.3 32

4) Hoist the struts and connect the struts to the basic section II and half beams by 8
hinge pins Ø140×405/525, as shown in Figure 4.2-4.

4-38 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.2-4 Hoisting and Installation of Struts

No. Name Specification Quantity

1 Strut 4

2 Hinge pin XZ04E-140×405/525 8

3 Lock pin Φ25 8

4 Hinge pin Φ25 8

5 Pin 6.3×40 32

5) Install the cable drum brackets onto the underframe beam, as shown in Figure 4.2-5.

Erection & Dismantling T2850-120V-138ZW-A 4-39

 Figure 4.2-5 Hoisting and Installation of Cable Drum Brackets

No. Name Specification Quantity

1 Cable drum bracket 2
2 Bolt M24×100 8
3 Washer 24 16
4 Nut M24 16

6) Install the ladder. Cling the ladder onto the half beam I and connect by hinge pins, as
shown in Figure 4.2-6.

4-40 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.2-6 Installation of Ladder

No. Name Specification Quantity

1 Ladder 1

2 Pin 10×80 4

Erection & Dismantling T2850-120V-138ZW-A 4-41

 4.2.2 Hoisting of Traveling Underframe
After the installation is completed, the traveling underframe is in gross weight of
approximately 88.5t so that it’s unnecessary to place ballasts. Then, hoist the traveling
underframe onto traveling trolleys, fix by 24 high-strength bolts M42, and tighten the bolts
to 3,500N.m (The corresponding tightening force is 605kN), as shown in Figure 4.2-7.

Figure 4.2-7 Hoisting of Traveling Underframe

4.2.3 Split Hoisting of Traveling Underframe

If the working site or hoisting machine is restricted, the slewing assembly can also
be hoisted separately.
1) Assemble the underframe and long and short pull rods as per the underframe
assembling method described in 4.2.1 and hoist as per Figure 4.2-8.

Figure 4.2-8 Hoisting of Underframe

2) Assemble the basic section I and basic section II as per the assembling method

4-42 T2850-120V-138Z-A01 Erection & Dismantling

 described in section 4.4. After assembling, hoist the basic section I and basic
section II onto the underframe separately, as shown in Figure 4.2-9.

Figure 4.2-9 Hoisting and Installation of Basic Section I and Basic Section II

3) Install the struts, ladder, and cable drum brackets as per section 4.2.1. The
completed installation is shown in Figure 4.2-10.

Figure 4.2-10 Installation of Struts, Ladder, and Cable Drum Brackets

Erection & Dismantling T2850-120V-138ZW-A 4-43

 4.3 Installation Platform

4.3.1 Assembling of Installation Platform

Figure 4.3-1 Assembling of Installation Platform

(1) Assemble the platform and railings.

(2) Assemble the platform and brackets by 4 groups of bolts M12×210-8.8.

4.3.2 Hoisting of Installation Platform

The installation platform can be installed onto the outrigger subassembly, basic
section (standard section), and transitional section. Install the installation platform to the
topmost horizontal web member of tower body (outrigger subassembly, basic section,
standard section, and transitional section), as shown in Figure 4.3-2.

4-44 T2850-120V-138Z-A01 Erection & Dismantling

 Outrigger subassembly Standard section Transitional
Basic section
section

Figure 4.3-2 Hoisting and Installation of Installation Platform

(1) Hoist the installation platform to the topmost horizontal web member of tower
body.
(2) Fix the installation platform onto the tower body by Ø20 pins and spring pins.
Erection & Dismantling T2850-120V-138ZW-A 4-45
4.3.3 Main Function of Installation Platform
4.3.3.1 Connection between outrigger subassembly and basic section

Figure 4.3-3 Use of Installation Platform (I)

(1) Hoist the basic section to be installed to be above the installed outrigger. The operator
can stand on the installation platform and outrigger platform to align all main chord
members of outrigger and basic section.

4-46 T2850-120V-138Z-A01 Erection & Dismantling

(2) Install 8 Ø105 hinge pins by pin puller. Please refer to 4.4.4 for the detailed operations
of pin puller.
4.3.3.2 Connection between Standard Section (Basic section) and Standard
Section

Basic section Standard

section

Footplate

Figure 4.3-4 Use of Installation Platform (II)

(1) Hoist the basic section to be installed to be above the installed standard section (or
basic section). The operator can stand on the installation platform and standard
section (or basic section) platform to align all main chord members of two basic
sections (or standard section and basic section).
(2) Install 8 Ø105 hinge pins by pin puller. Please refer to 4.4.4 for the detailed operations
of pin puller.
Caution: Notice the orientation of installation platform.

Erection & Dismantling T2850-120V-138ZW-A 4-47

4.3.3.3 Connection between Transitional Section and Lower Support

Figure 4.3-5 Use of Installation Platform (III)

(1) Hoist the lower support (or slewing assembly) to be installed to be above the installed
transitional section. The operator can stand on the installation platform and
transitional section platform to align all main chord members of transitional section
and lower support.
(2) Install 8 Ø105 hinge pins by pin puller. Please refer to 4.4.4 for the detailed operations
4-48 T2850-120V-138Z-A01 Erection & Dismantling
 of pin puller.

4.4 Installation of Tower Body Sections

4.4.1 Installation of Basic Sections

The detailed assembling procedure of basic sections is as below:
1) As shown in Figure 4.4-1, assemble the main chord member A, main chord member
B, two horizontal web members, and two inclined web members to form the piece A.
The parts required for assembling are listed in Table 4.4-1 (Please notice the
orientation of footplate in the diagram).

Footplate

Figure 4.4-1 Assembling of Piece A

Table 4.4-1 Table of Parts for Assembling of Basic Section (I)

No. Name Specification Quantity

1 Main chord member A 1
2 Hinge pin Φ50×230 4

3 Split pin 10×90 8

4 Hinge pin Φ60×250 4

5 Horizontal web member 2

6 Inclined web member 2

7 Main chord member A 1

Erection & Dismantling T2850-120V-138ZW-A 4-49

2) Assemble the remaining main chord member B, two horizontal web members, and
two inclined web members to form piece B, as shown in Figure 4.4-2. The required
parts are listed in Table 4.4-2.

Figure 4.4-2 Assembling of Piece B

Table 4.4-2 Parts for Assembling of Basic Section (II)

No. Name Specification Quantity

1 Hinge pin Φ50×270 2

2 Split pin 10×90 4

3 Horizontal web member 2

4 Inclined web member 2

5 Main chord member B 1

6 Hinge pin Φ60×290 2

3) Place the piece A on the ground and hoist the piece B. Fix the positions of inclined
web members of piece B by hangers and assemble the piece B. During installation,
adjust the positions of inclined web members by the threaded buckles on the hangers

4-50 T2850-120V-138Z-A01 Erection & Dismantling

 to ensure that the hinge pins of inclined web members can be installed correctly. As
shown in Figure 4.4-3, the required parts are listed in Table 4.4-3.

Threaded buckle

Figure 4.4-3 Assembling of Piece A and Piece B

Table 4.4-3 Parts for Assembling of Basic Section (III)

No. Name Specification Quantity

1 Hanger 2

2 Hinge pin Φ50×270 2

3 Split pin 10×90 4

4 Hinge pin Φ60×290 2

4) Assemble the remaining main chord member A, two horizontal web members, and
two inclined web members to form piece C, hoist the assembled piece C, and
assemble it with piece A and piece B. While connecting the hinge pins of inclined web

Erection & Dismantling T2850-120V-138ZW-A 4-51

 members and adjust the threaded buckles on the hangers to ensure that the hinge
pins of inclined web members can be assembled smoothly. As shown in Figure 4.4-
4, the required parts are same with Table 4.4-2 and 4.4-3.
5) At completion of installation, disassemble the auxiliary hangers to ease the
subsequent assembling of standard sections.

Threaded buckle

Figure 4.4.4 Assembling of Piece C, Piece A, and Piece B

6) Assemble the remaining horizontal web members and inclined web members. Please
refer to Figure 4.4-5. The required parts are listed in Table 4.4-4.

4-52 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.4-5 Assembling of Remaining Horizontal Web Members and Inclined Web Members

Table 4.4-4 Parts for Assembling of Basic Section (IV)

No. Name Specification Quantity

1 Inclined web member 2

2 Hinge pin Φ50×270 4

3 Split pin 10×90 8

4 Horizontal web member 2

5 Hinge pin Φ60×290 4

Erection & Dismantling T2850-120V-138ZW-A 4-53

7) Install the inclined struts (Fixed struts and adjustment struts) and adjust the struts in
such manner that the diagonal line error of basic section is ≤1.5mm, in order to ensure
that the basic section can be installed successfully with the outrigger subassembly.
The installation method is shown in Figure 4.4-6 and the assembled parts are listed
in Table 4.4-5.

4-54 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.4-6 Assembling of Inclined Struts

Table 4.4-5 Parts for Assembling of Basic Section (V)

No. Name Specification Quantity

1 Adjustment strut 2

2 Nut M36-8 2

3 1040300090 36-200HV 2

4 Adjustment bolt 2

5 U-plate 2

6 Connecting plate 1

7 Hinge pin 45×120 4

8 Split pin 8×71 8

9 Hinge pin 45×100 4

10 Fixed strut 2

8) As shown in Figure 4.4-7, install the platform and railings, long and short ladders,
nameplate bracket, specification nameplate mounting bracket, and hinge pin box.
Caution: Notice the orientations of platform, ladders, and
footplates.

Erection & Dismantling T2850-120V-138ZW-A 4-55

 Figure 4.4-7 Assembling of Platform and Ladders

4.4.2 Assembling of Standard Section

Assemble the standard section as per the assembling method of basic section
(section 4.4.1).

4.4.3 Hoisting of Standard Section

Connect the traveling underframe and standard section by 8 hinge pins Ø105×480,
8 lock pins Ø30×270, and 16 spring pins (d1=6.3). Prepare the related parts before
hoisting of standard section. Hoist the standard section as per Figure 4.4-8. The
installation platform can be used to assist the hoisting of standard section. Refer to
section 4.4.3 for details.
Caution:

4-56 T2850-120V-138Z-A01 Erection & Dismantling

 The tower body access port shall be on same side of the standard section
feeding side, as shown in Figure 4.4-8, in order to ensure the successful jacking
and addition of section.

Figure 4.4-8 Hoisting of Standard Section

To ensure the smooth installation of climbing frame, as shown in Figure 4.4-9, hoist
two standard sections.
Caution: The orientations of the standard section footplates and the platform
ladder shall be consistent with the traveling underframe, in order to ensure the
non-obstructed passage.

Erection & Dismantling T2850-120V-138ZW-A 4-57

 Figure 4.4-9 Hoisting of Two Standard Sections

4.4.4 Use of Pin Puller

The pin puller is required to install the hinge pins of tower body during the erection
of tower. The pin puller is composed of pump station, jack, sleeve, and support seat.
Before installation, install the pin puller. The detailed procedure is as below:
1) As shown in Figure 4.4-10, fix the pin puller on the horizontal web member of standard
section and fix the support seat by lower and upper hinge pins. Caution: The
distances between hinge pin centers of tower body and horizontal web members vary.
While installing the lower hinge pins, insert the upper hinge pins of pin puller into
“Support frame lower hole”. While installing upper hinge pins, insert the upper pins of
pin puller into “Support frame upper hole”.

4-58 T2850-120V-138Z-A01 Erection & Dismantling

 Sleeve
Support seat
upper hole

Support seat
lower hole

Hinge pin

Support
seat

Fix by hinge
pins

Figure 4.4-10 Installation of Sleeve and Support Frame

2) Install the pump station, jack, screw, and tower body hinge pins and get prepared for
pulling of pins. Caution: It’s necessary to add thrust sleeve in the sleeve, in order to
prevent pulling the pins beyond the preset position, as shown in Figure 4.4-11.

Pump station Jack

Tower body
hinge pin

Thrust sleeve

Figure 4.4-11 Complete Installation of Pin Puller

3) Start the pump station and perform the first pin pulling step, as shown in Figure 4.4-
12. The jack returns after one travel. Add a sleeve in front of the jack to reduce the
Erection & Dismantling T2850-120V-138ZW-A 4-59
 screwing depth of the nut.

Sleeve

Figure 4.4-12 First Pin Pulling Step

4) As shown in Figure 4.4-13, perform the second pin pulling step.

4-60 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.4-13 Second Pin Pulling Step

5) As shown in Figure 4.4-14, perform the third pin pulling step. This step only requires
15mm to pull the hinge pins into due positions. When the hinge pin comes into contact
with the thrust sleeve and can't be pulled further, the hinge pin has reached the preset
position and the pin pulling is completed.

Erection & Dismantling T2850-120V-138ZW-A 4-61

 Thrust sleeve

Figure 4.4-14 Third Pin Pulling Step

6) Remove the pin puller. Install other connecting hinge pins of tower body as per above-
mentioned procedure.

4.5 Installation of Climbing Frame

4.5.1 Assembling of Climbing Frame

The climbing frame is composed of climbing frame structure, platform, ladder, and a
set of hydraulic jacking system. The jacking and addition of sections for the tower crane
are mainly completed by this component.
The jacking cylinders are installed on the left and right crossbeams (namely two
footplate sides of standard section) of the climbing frame and the hydraulic pump station
is placed on the middle platform. The climbing frame internally includes 16 rollers and the
rollers close to the outer side of tower body main chord members to play the guiding role
during jacking.
To ease the jacking and installation and for the safety purpose, the climbing frame
has three layers of platforms to ease the operations of hydraulic system by personnel to
complete the jacking and feeding of standard section and installation of tower body hinge
pins.
1) Install the rear structure of climbing frame, as shown in Figure 4.5-1. Place the main
chord members horizontally on the sleepers and connect the inclined web members,

4-62 T2850-120V-138Z-A01 Erection & Dismantling

 straight web members, and crossbeams to the main chord members. The required
parts are listed in Table 4.5-1.

Figure 4.5-1 Installation of Climbing Frame Rear Structure

Table 4.5-1 Table of Parts Required for Installation of Climbing Frame Rear Structure

No. Name Specification Quantity

1 Main chord member A 1

2 Straight web member A 1

3 Main chord member B 1

4 Inclined web member A 4

5 Straight web member B 2

6 Crossbeam A 1

7 Inclined web member B 4

8 Crossbeam B 1

9 Hinge pin φ60×205 30

10 Split pin 10×90 30

2) Install the left and right structures of climbing frame, as shown in Figure 4.5-2, and
connect the left and right structures to the rear structure. The required parts are listed
in Table 4.5-2.

Erection & Dismantling T2850-120V-138ZW-A 4-63

 Figure 4.5-2 Installation of Climbing Frame Left and Right Structures

Table 4.5-2 Table of Parts Required for Installation of Climbing Frame Left and Right Structures

No. Name Specification Quantity

1 Straight web member A 2

2 Inclined web member A 2

3 Straight web member B 4

4 Inclined web member C 2

5 Crossbeam C 2

6 Inclined web member D 2

7 Inclined web member B 2

8 Crossbeam B 2
9 Hinge pin φ60×205 18

10 Split pin 10×90 26

11 Hinge pin φ70×240 8

12 Hinge pin 4

13 Hinge pin 4

14 Split pin 6.3×50 8

3) Install the front structure of climbing frame, as shown in Figure 4.5-3. Place the main

4-64 T2850-120V-138Z-A01 Erection & Dismantling

 chord members horizontally on the sleepers and connect the inclined web members,
straight web members, and crossbeams to the main chord members. The required
parts are listed in Table 4.5-3.

Figure 4.5-3 Installation of Climbing Frame Front Structure

Table 4.5-3 Table of Parts Required for Installation of Climbing Frame Front Structure

No. Name Specification Quantity

1 Moveable strut 1

2 Main chord member C 1

3 Crossbeam B 2

4 Inclined web member B 4

5 Straight web member B 1

6 Main chord member D 1

7 Bolt M16×80-8.8 8

8 Nut M16-8 8

9 Washer 16-200HV 8

10 Hinge pin φ60×205 18

11 Split pin 10×90 18

4) Install the front piece of climbing frame, as shown in Figure 4.5-4. Hoist the front piece
horizontally and slowly to the connections of left and right structures and connect the
left and right structures to the front piece. The required parts are listed in Table 4.5-4.

Erection & Dismantling T2850-120V-138ZW-A 4-65

 Figure 4.5-4 Installation of Climbing Frame Front Piece

Table 4.5-4 Table of Parts Required for Installation of Climbing Frame Front Piece

No. Name Specification Quantity

1 Front piece 1
2 Inclined web member A 2
3 Inclined web member C 2
4 Inclined web member D 2
5 Inclined web member B 2
6 Hinge pin φ60×205 18
7 Split pin 10×90 18
8 Hinge pin φ70×240 8
9 Hinge pin 4
10 Hinge pin 4
11 Split pin 6.3×50 8

5) Place the ladder of the climbing frame, as shown in Figure 4.5-5 and firstly fix the
ladder to the rear structure of climbing frame by clamping device and wire rope (or
hemp rope). The required parts are listed in Table 4.5-5.

4-66 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.5-5 Placement of Climbing Frame Ladder

Table 4.5-5 Table of Parts Required for Placement of Climbing Frame Ladder

No. Name Specification Quantity

1 Ladder A 1
2 Clamping device 1
3 Ladder B 1

6) Assemble the roller subassemblies of the climbing frame. The climbing frame totally
has 16 roller subassemblies, as shown in Figure 4.5-6. The required parts are listed
in Table 4.5-6.

4:1 Rotate

Figure 4.5-6 Assembling of Climbing Frame Roller Subassemblies

Erection & Dismantling T2850-120V-138ZW-A 4-67

 Table 4.5-6 Parts Required for Assembling of Climbing Frame Roller Subassemblies

No. Name Specification Quantity

1 Guard plate 16
2 Washer 12 32
3 Bolt M12×30 32
4 Oil cup M6×1 16
5 Roller shaft 16
6 Bushing 16
7 Roller 16

7) Assemble the jacking mechanism, as shown in Figure 4.5-7. The required parts are
listed in Table 4.5-7.

Figure 4.5-7 Assembling of Jacking Mechanism

4-68 T2850-120V-138Z-A01 Erection & Dismantling

 Table 4.5-7 Table of Parts Required for Assembling of Jacking Mechanism

No. Name Specification Quantity

1 Cylinder seat 4
2 Hinge pin A φ90×280 4
3 Pin 13×125 12
4 Jacking cylinder 4
5 Hose assembly A F02WA0A0181806-13000 4
6 Hose assembly B F02WA0A0181806-10000 4
7 Hinge pin B XZ03E-90×235/315 4
8 Safety pin 4
9 Spring pin 4

8) Install the jacking mechanism, platform, railings, and pump station, as shown in
Figure 4.5-8. Slowly hoist the climbing frame structure to vertical status and install the
jacking mechanism, platforms, railings, and pump station in turn. The pump station
shall be installed to the pump station mounting base of the middle platform.
Caution:
 Temporarily fix the climbing frame before hoisting the jacking mechanism,
in order to prevent the rollover accident.
 After the installation of jacking mechanism, bind the hanger crossbeams
to the inclined web members nearby by ropes, in order to prevent
damaging the cylinders during the hoisting of climbing frame.

Erection & Dismantling T2850-120V-138ZW-A 4-69

 Figure 4.5-8 Installation of Jacking Mechanisms, Platforms, and Pump Station

9) Install the footplate change devices and joysticks, as shown in Figure 4.5-9. The
installation personnel can stand on the middle platform to install the footplate change
hangers to the jacking crossbeams. The required parts are listed in Table 4.5-9.

4-70 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.5-9 Installation of Footplate Change Devices and Joysticks

Table 4.5-9 Table of Parts Required for Installation of Footplate Change Devices and Joysticks

No. Name Specification Quantity

1 Hanger 4

2 Pin 10×90 GB/T91-2000 8

3 Hinge pin 4

Footplate change
4 4
joystick

5 Hinge pin 4

6 Pin 5×40 GB/T91-2000 4

4.5.2 Hoisting of Climbing Frame

1) After the climbing frame is assembled, slowly attach the climbing frame to the outer
side of standard section, as shown in Figure 4.5-10.
Caution:
 The jacking cylinders and tower body footplates must be on two same sides.
 The orientation of the climbing frame front piece determines the orientation of
boom and shall be determined depending on the actual situation of the working
Erection & Dismantling T2850-120V-138ZW-A 4-71
 site.
2) Place the footplate change push rods on the climbing frame onto the 4th footplate
pair (Counted from bottom to top) and properly adjust the clearance (2~3mm)
between 16 climbing rollers and standard section, namely the clearance between
main chord members of tower body and the corresponding main chord member of
climbing frame shall be basically equal.
3) If the weight of the climbing frame is beyond the permissible hoisting range, remove
the pump station and some platforms and then assemble them in the air.

Footplate

4-72 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.5-10 Hoisting of Climbing Frame
Climbing frame upper platform

Standard section
footplate

Standard section
ladder

Standard section
footplate

Climbing frame
opening side
Feeding direction

Figure 4.5-11 Orientation of Climbing Frame Feeding Side

4.6 Installation of Transitional Section

4.6.1 Assembling of Transitional Section

1) As shown in Figure 4.6-1, connect two main chord members and the horizontal
and inclined web members and assemble them to a piece of transitional section.
The parts required for assembling are listed in Table 4.6-1 below.

Erection & Dismantling T2850-120V-138ZW-A 4-73

 Figure 4.6-1 Assembling of Transition Section Piece

Table 4.6-1 Parts Required for Assembling of Transitional Section Piece

No. Name Specification Quantity

1 Main chord member A 1

2 Horizontal web member 2

3 Main chord member B 1

4 Inclined web member 1

5 Hinge pin φ50×270 4

6 Pin φ10×90 12

7 Hinge pin φ60×290 8

8 Horizontal web member A 1

9 Inclined web member A 2

Assemble other two main chord members and the inclined and horizontal web
members as per above-mentioned method.
2) Place the transitional section piece (Piece A) onto the ground, assemble three
horizontal web members and one inclined web members on another piece (Piece
B), hoist the piece B to be above the piece A, and keep the inclined and horizontal
web members under vertical status. Refer to Figure 4.6-2 for details.

4-74 T2850-120V-138Z-A01 Erection & Dismantling

 Transitional
section piece B

Transitional
section piece A

Figure 4.6-2 Hosting of Transitional Section Piece B with Horizontal and Inclined Web Members

above Piece A

3) Slowly lower the transitional section piece B to appropriate position and connect
the lower end of inclined web member to the corresponding position of transitional
section piece A on the ground by 1 hinge pin Ø60×290 and 1 split pin 10×90, as
shown in Figure 4.6-2. After the connection of inclined web member, slowly move
the piece B in the air along the main chord member, as shown in Figure 4.6-3.

Erection & Dismantling T2850-120V-138ZW-A 4-75

 Transitional
section piece B

Transitional
section piece A

Figure 4.6-3 Movement of Piece B and Connection of Horizontal Web Members between

Piece A and Piece B

4) Move the piece B to appropriate position and connect the horizontal web members
to piece A by 3 hinge pins Ø50×270 and 3 split pins 10×90. The connected status
is shown in Figure 4.6-4.

Transitional
section piece B

Transitional
section piece A

Figure 4.6-4 Connected Horizontal and Inclined Web Members between Piece A and Piece B

4-76 T2850-120V-138Z-A01 Erection & Dismantling

 5) As per the numbers 1~6 in Figure 4.6-5, install the inclined and horizontal web
members in turn. For the installation of inclined and horizontal web members, use
the hinge pins and split pins of same models used in above two steps.

Figure 4.6-5 Installation of Inclined and Horizontal Web Members as per Numbers 1~6

Caution: If the working site is not restricted by hoisting equipment, the user
may assemble by self depending on the actual situation.
6) Install the inclined struts (Fixed and adjustment struts) and adjust the adjustment
struts in such manner that two diagonal line errors of transitional section is ≤1.5mm.
(The list of parts for the inclined struts is same with that for standard section).
7) Install the hanger beams by 8 hinge pins Ø75×510 and 16 split pins 13×125, as
shown in Figure 4.6-6.

Erection & Dismantling T2850-120V-138ZW-A 4-77

 Figure 4.6-6 Installation of Hanger Beams on Transitional Section Structure

8) Install the ladder, platforms, struts, and bolts and install other small parts such as
hinge pin boxes. The assembled status is shown in Figure 4.6-7. (Please refer to
the installation of platforms and ladder of standard section for detailed installation
procedure)

4-78 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.6-7 Transitional Section with Ladder, Platforms, Struts, and Small Parts Installed

9) Install the feeding beam and feeding trolley onto the transitional section, as shown
in Figure 4.6-8.
Caution: a. Refer to section 4.6.3 for the composition of feeding system.
b. Temporarily do not install the railings on the feeding system.

Erection & Dismantling T2850-120V-138ZW-A 4-79

 Figure 4.6-8 Installation of Feeding Beam, Feeding Trolley, and Platforms

4.6.2 Hoisting of Transitional Section and Feeding System

1) Hoist the transitional section to be above the erected tower body, slowly lower the
transitional section to insert the lower lugs of standard section into the main chord
members of transitional section, and connect by 4 mounting hinge pins Ø104×480 (1
for each main chord member), 4 lock pins Ø30×270, and 8 spring pins (d=6.3), as
shown in Figure 4.6-9.

4-80 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.6-9 Hoisting of Transitional Section and Feeding System
Erection & Dismantling T2850-120V-138ZW-A 4-81
2) While placing the transitional section, notice the orientation of transitional section with
respect to the standard section and climbing frame: The feeding direction for
transitional section shall be consistent with that for standard section and climbing
frame. In addition, notice to keep the passage from standard section to transitional
section non-obstructed, as shown in Figure 4.6-10.

Transitional section
hanger beam

Transitional section
ladder

Climbing frame upper

platform

Standard section
footplate

Standard section
ladder

Standard section
footplate

Climbing frame
Feeding direction opening side

Figure 4.6-10 Diagram of Passage and Feeding Direction

4-82 T2850-120V-138Z-A01 Erection & Dismantling

3) As shown in Figure 4.6-9, start the jacking cylinder of climbing frame. After the
climbing frame slowly rises to appropriate position, connect the climbing frame and
transitional section by 4 hinge pins Ø90×345, 4 hinge pins Ø20×120, 8 hinge pins 5,
and 1 split pin.
4) Connect the remaining connecting holes between transitional section and standard
section by 4 hinge pins Ø105×480, 4 lock pins Ø30×270, and 8 spring pins (d=6.3),
knock out 4 mounting hinge pins Ø104×480 installed in previous step, and securely
connect the transitional section and standard section by 4 hinge pins Ø105×480, 4
lock pins Ø30×270, and 8 spring pins (d=6.3).
Caution: To guarantee the normal use of pin puller, while installing 8 hinge
pins Ø105×480 beneath the transitional section, the orientation of hinge pins
differs from that for standard section in such manner that 4 hinge pin threaded
holes of vertical feeding crossbeams face outward, as shown in Figure 4.6-11.

Transitional section
ladder

Hinge pin threaded

hole

Hinge pin threaded

hole

Feeding direction

Figure 4.6-11 Installation Orientation of Connecting Hinge Pins between Transitional Section and
Erection & Dismantling T2850-120V-138ZW-A 4-83
 Standard Section

4.6.3 Assembling of Feeding System

1) Install the trolley to the middle position of feeding beam, install 4 pulley blocks to the
front and rear pulley seats, and install the traction mechanism onto the feeding beam
by 4 hinge pins. Refer to Figure 4.6-12 for the assembling of feeding system. The
parts required for the assembling are listed in Table 4.6-2.

Pulley block
8 pieces

Figure 4.6-12 Assembling of Feeding System

Table 4.6-2 Table of Feeding System Parts

No. Name Specification Quantity

1 Traction mechanism 1

2 Feeding beam 1

3 Hinge pin Φ30×60/90 4

4 Split pin 8×71 4

5 Feeding trolley 1

6 Pulley seat subassembly 4

7 Bolt M16×55 24

8 Washer 16 24

9 Nut M16 24

2) As shown in Figure 4.6-13, fix the feeding trolley to the feeding beam end far away
4-84 T2850-120V-138Z-A01 Erection & Dismantling
 from the tower body by the pins at the traction mechanism and enwind the wire rope.

Handwheel
Pin

Drum
Front pulley
Rear pulley

Feeding trolley

Figure 4.6-13 Enwinding of Wire Rope for Feeding System

3) Install the railings, as shown in Figure 4.6-15 and Figure 4.6-16.

Figure 4.6-14 Installation of Railings and Railing Clamping Plates

Table 4.6-3 Table of Parts for Railings and Railing Clamping Plates

No. Name Specification Quantity

1 Railing LGA700 2

2 Railing LG500 4

3 Railing LG3500 1

4 Railing LGA430 2

5 Railing 2

6 Bolt M12×74-8.8 9

Erection & Dismantling T2850-120V-138ZW-A 4-85

 No. Name Specification Quantity

7 Nut M12-8 9

8 Washer 12-200HV 9

9 Washer 12 9

10 Railing clamping plate t5 18

Figure 4.6-15 Combination Status of Transitional Section and Feeding System

Figure 4.6-16 Installation Status of Transitional Section and Feeding System

4-86 T2850-120V-138Z-A01 Erection & Dismantling

 4.7 Installation of Slewing Assembly
The slewing assembly is composed of upper support, slewing mechanism, slewing
support, lower support, slewing limiter, cab, resistor cabinet (Slewing, luffing, and auxiliary
hoisting mechanisms), slewing control cabinet, luffing control cabinet, auxiliary hoisting
mechanism control cabinet, and power supply control cabinet.

4.7.1 Assembling of Upper Support Assembly

1) Composition and assembling of upper support
The upper support mainly includes upper support structure and three platforms, as
shown in Figure 4.7-1 and Table 4.7-1.
The boom section 1 is connected to the upper supply by 4 Ø180 hinge pins.
Three platforms are left platform, right platform, and cab platform located on left and
right sides of the upper support and are connected to upper support by Ø30 and Ø40
hinge pins.

Erection & Dismantling T2850-120V-138ZW-A 4-87

 Figure 4.4-1 Assembling of Upper Support

4-88 T2850-120V-138Z-A01 Erection & Dismantling

 Table 4.4-1 Table of Main Parts for Upper Support Assembly

No. Name Specification Quantity No. Name Specification Quantity

1 Railing 1 22 Washer 10-200HV 36

2 Railing 1 23 Washer 10 36

3 Left platform 1 24 Nut M10-8 36

4 Railing 1 25 Limiter shield 1

5 Railing 6 26 Bolt M10×24-8.8 14

Slewing
6 Hinge pin 30×110 4 27 mechanism 4
shield

7 Pin 6.3×50 8 28 Nylon sleeve 1

Upper support
8 1 29 Pin 8×80 27
structure

9 Ladder A 1 30 Bolt M16×50-8.8 8

10 Right platform 1 31 Nut M16-8 8

11 Railing 1 32 Washer 16 8

12 Hinge pin1 40×230 4 33 Nut M12-8 18

Railing
13 Hinge pin 20×200 2 34 t5 16
clamping plate
14 Pin 5×45 2 35 Bolt M12×70-8.8 8

15 Cab platform 1 36 Washer 12 8

16 Ladder 1 37 Railing H 1

Central
17 Railing 1 38 1
lubrication device

18 Wiring channel Tb4 1 39 High strength bolt M42×3×480 80

19 Bolt M24×70-8.8 96 40 High strength nut M42×3 80

High strength
20 Washer 24 96 41 42 160
washer

21 Bolt M10×34-8.8 22

Caution: The cab platform is located on the right side of the upper support in
boom direction.
2) Installation of slewing mechanism
There are four sets of slewing mechanisms, of which three sets are provided with
brake and one set is not provided with brake. The slewing mechanisms are uniformly
Erection & Dismantling T2850-120V-138ZW-A 4-89
 distributed on two sides of the upper support based on the working needs. During the
installation, directly fix the slewing mechanisms onto the upper support flange plate by
bolts M24×70.
Caution: Notice that the deflection angle for the slewing mechanisms is
approximately 25º (Figure 4.7-2).
Slewing mechanism
installation orientation
Cab platform side
slewing mechanism

Slewing Approximately 25°

mechanism

Approximately 25°

Figure 4.7-2 Arrangement Diagram of Slewing Mechanisms

3) Installation of resistor cabinet and electronic control cabinet

The resistor cabinet is connected to left platform by 8 sets of bolt subassemblies
M10×35-8.8, the slewing control cabinet and luffing control cabinet are connected
to left platform by 8 sets of bolt subassemblies M10×35-8.8, and the auxiliary
hoisting control cabinet and power supply cabinet are connected to cab platform by
8 sets of bolt subassemblies M10×35-8.8, as shown in Figure 4.7-3.

4-90 T2850-120V-138Z-A01 Erection & Dismantling

 Slewing control cabinet Resistor cabinet (Slewing, luffing, and
auxiliary hoisting mechanisms)

Auxiliary hoisting and power

supply control cabinet
Luffing control cabinet

Figure 4.7-3 Arrangement Diagram of Resistor Cabinet and Control Cabinet

4) Installation of slewing support

a. Bolt
(1) The upper support structure is connected to inner race of slewing support by 80
sets of bolt subassemblies M42×480-10.9 (Each bolt subassembly includes 1
bolt, 1 nut, and 2 washers).
(2) The lower support structure is connected to inner race of slewing support by 80
sets of bolt subassemblies M42×435-10.9 (Each bolt subassembly includes 1
bolt, 1 nut, and 2 washers).
(3) The bolts for slewing support are of grade 10.9 as per GB/T3098.1-2010.
(4) The nuts are of grade 10 in mechanical performance as per JG/T5057.40.
(5) The washers are of 300HV performance grade as per JG/T5057.40 and are
quenched and annealed. It’s prohibited to use spring washers.
(6) The tightening force for the bolt subassemblies used for the connection of
slewing support is 605kN (Tightening torque is 3,500N.m).
b. Installation
(1) Before installation, ensure to thoroughly clean the installation datum surfaces of
Erection & Dismantling T2850-120V-138ZW-A 4-91
 slewing support and the mounting planes of upper and lower supports and remove
oil dirt, burrs, paint, and other impurities.
(2) During installation, the external marking “S” and the steel ball installation plug hole of
the slewing support (As shown in Figure 4.7-4) shall be located in infrequently loaded
zone or no-load zone.

Figure 4.7-4 Slewing Support

(3) After the slewing support is hoisted in place, check the planeness of support plane
by a feeler gauge.
(4) Tighten the studs symmetrically and continually in 180º direction, as shown in Figure
4.7-5, and finally tighten once to ensure same tightening force for all studs on the
circumference.
(5) Tighten the bolts by a hydraulic bolt tensioning jack.

4-92 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.7-5 Installation Sequence of Slewing Support Bolts

c. Lubrication and maintenances

(1) The slewing support shall be periodically applied with lubricating grease (Refer
to maintenance schedule for details). Under special working environments, such
as tropic zone and the environments with high humidity, heavy dusts, and large
temperature variation, the lubrication interval shall be shortened. Ensure to add
a sufficient amount of new lubricating grease before and after the long-time non-
use of tower crane. During every lubrication operation, ensure to fully fill the
raceway with lubricating grease, till the lubricating grease overflows from the
seals. While applying the lubricating grease, slowly rotate the slewing support to
ensure the uniform filling of grease.
(2) Check the tightening force of bolts after the first 100 working hours of the slewing
support and afterwards check once every 500 hours to maintain sufficient
tightening force.
(3) During the use, it’s prohibited to directly flush the slewing support by water, in
order to prevent the water ingress into raceway.
(4) Frequently check the intactness of seals. Any damaged sealing strip detected
shall be timely replaced.
Erection & Dismantling T2850-120V-138ZW-A 4-93
 4.7.2 Assembling of Lower Support Structure and Upper Support

Assembly
1) Connect the lower support ladder to the lower support structure by 4 bolts.
2) Connect the lower support structure and slewing support by 80 sets of bolt
subassemblies M42×435-10.9 (Each bolt subassembly includes 1 bolt, 1 nut, and 2
washers).
3) Connect the slewing support and the upper support structure for upper support to the
inner race of slewing support by 80 sets of bolt subassemblies M42×480-10.9 (Each
bolt subassembly includes 1 bolt, 1 nut, and 2 washers), as shown in Figure 4.7-6.
Slewing mechanism Upper support Slewing mechanism Cab

Slewing
support

Slewing limiter
Lower
support

Figure 4.7-6 Assembling Diagram of Slewing Assembly

4.7.3 Hoisting of Slewing Assembly

As shown in Figure 4.7-7, hoist this assembly in place above the transitional section
and connect it to the transitional section by 8 Ø105 stepped pins.

4-94 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.7-7 Hoisting of Slewing Assembly

Caution: The feeding direction of lower support shall be opposite to the fixed
cable net bag of wire rope.

4.7.4 Split Hoisting of Slewing Assembly

If the working site or hoisting machine is restricted, the slewing assembly can also
be hoisted separately.
1) Connect the lower support ladder to the lower support structure by 4 bolts.
2) Connect the lower support structure and slewing support by 80 sets of bolt
subassemblies M42×435-10.9 (Each bolt subassembly includes 1 bolt, 1 nut, and 2
washers).
Erection & Dismantling T2850-120V-138ZW-A 4-95
 3) As shown in Figure 4.7-8, hoist the assembled lower support and slewing support
in place above the transitional section and connect it to the transitional section by 8
Ø105 stepped pins.

Figure 4.7-8 Hoisting of Lower Support and Slewing Support Subassembly

4) Assemble the upper support assembly (Including slewing mechanism, platforms,

cab, resistor cabinet, and control cabinet) as per section 4.7.1.
5) Hoist the upper support assembly, as shown in Figure 4.7-9, and connect the upper
support and slewing support by 80 sets of bolt subassemblies M42×480-10.9 (Each
bolt subassembly includes 1 bolt, 1 nut, and 2 washers).

4-96 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 4.7-9 Hoisting of Upper Support Assembly

4.8 Installation of Boom Section I

4.8.1 Assembling
The boom section I is of integral framework structure that includes the lug plates for
installation of boom section II and balance boom and is connected with upper support by
four hinge pins on the bottom.
(1) Install the luffing pulleys, hoisting pulleys, and pulley covers.
(2) Install the moment limiter.
(3) Install the railings.

Erection & Dismantling T2850-120V-138ZW-A 4-97

 Figure 4.8-1 Assembling of Boom Section I

4.8.2 Hoisting
As shown in Figure 4.8-2, hoist the boom section I and connect it to the upper support
securely by 4 Ø180 hinge pins.

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 Connected to
balance boom Connected to boom

Figure 4.8-2 Hoisting of Boom Section I

Caution: Notice to differentiate the orientations of balance boom and boom

during installation.

4.9 Installation of Balance Boom Section I

The balance boom section I assembly includes the balance boom section I, luffing
mechanism, auxiliary mechanism, platforms, and railings.

4.9.1 Assembling
1) As shown in Figure 4.9-1, connect the luffing structure and boom section I by 4
hinge pins Ø60-75/115 and tighten 4 bolts M12×30 and nuts M12 to prevent the
lateral play of luffing mechanism.

Erection & Dismantling T2850-120V-138ZW-A 4-99

 Figure 4.9-1 Installation of Luffing Mechanism

2) As shown in Figure 4.9-2, connect the auxiliary structure and boom section I by
4 sets of bolt subassembly M20×70.

Figure 4.9-2 Installation of Auxiliary Mechanism

3) As shown in Figure 4.9-3, install the platforms by 5 Ø20 hinge pins, insert the
railings into railing seats, fix by 32 split pins 8×71, and fix the railing clamping
plates between railings and tighten by bolts M12×70.

Figure 4.9-3 Installation of Platforms and Railings on Boom Section I

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 4.9.2 Hoisting
As shown in Figure 4.9-4, while hoisting the balance boom section I, slightly tilt
upward the rear part of boom section I to ease the installation of 2 Ø180 hinge pins for
upper chord members. After the installation of 2 Ø180 hinge pins for upper chord
members, slowly lower the hook to rotate the boom section I around the Ø180 hinge pins.
After 2 Ø50 hinge pins for lower chord members of boom section I are inserted into the
pinholes on the balance boom section I, tighten 2 bolts M30 to 1,300N.m. Connect the
balance boom section I and the railings on the boom section I by railing clamping plates
and bolts M12.
Caution: Do not tilt upward the balance boom section I excessively, otherwise
the railings on balance boom will interfere with the railings on the boom section I.

Hinge pin

Hinge pin

Figure 4.9-4 Hoisting of Balance Boom Section I

Erection & Dismantling T2850-120V-138ZW-A 4-101

 4.10 Installation of Boom Section II

4.10.1 Assembling
1) Assembling of trolley
The load trolley is composed of main trolley, auxiliary trolley, and two connecting
beams. Install the auxiliary and main trolleys from the rear of boom and connect by two
connecting beams and four hinge pins. The installation diagram of main and auxiliary
trolleys is shown in Figure 4.10-1.
a) To prevent lifting and luffing wire ropes from wearing with frames of main and
auxiliary trolleys under non-working status, the towing roller devices are
designed.
b) To prevent the gliding of trolley in event of breakage of luffing wire ropes, the
rope anti-breakage device is designed.
c) To ensure the normal working of main and auxiliary trolleys on main chord
members of boom, the side roller devices are designed.
d) To guarantee the uniform force application of main and auxiliary trolleys on the
main chord members of boom and qualified roller pressure, the hanger beam
devices are designed. The main and auxiliary trolleys totally have 16 rollers.
e) To ease the enwinding of hoisting wire rope during the erection of tower, the
hoisting wire rope pressure plates are designed, as shown in Figure 4.10-1.
f) To ensure the change of magnification for main and auxiliary trolleys, the
magnification change platform and the access ladder are designed.

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 Rope anti-
Hanger beam Towing Auxiliary breakage Connecting Main Magnification Side
roller trolley device roller
beam trolley change platform

Hoisting wire rope

pressure plate

Hoisting wire rope Hoisting wire rope

Luffing wire rope

Luffing wire rope

Figure 4.10-1 Load Trolley Diagram

g) To ensure the safe and easy connection between hook upper crossbeam and main
and auxiliary trolleys, the magnification change platform and the special
magnification change fixing device are designed, as shown in Figure 4.10-2.
h) The shaft anti-breakage protection is designed on the pillars, as shown in Figure
4.10-2.

Erection & Dismantling T2850-120V-138ZW-A 4-103

 Pillar Boom Crossbeam Longitudinal Shaft anti-breakage
beam protection device

Magnification change
fixing device
Load trolley Ladder Magnification
change hinge pin

Figure 4.10-2 Structure of Trolleys

2) Assemble the boom section II and trolley.

Fix the trolley onto the root of boom section II by two Ø40 hinge pins, as shown in
Figure 4.10-3a.

φ40 Fixing
hinge pin

a - Connection and fixing between trolley and b - Connection and fixing between trolley and
boom section I
boom section II

Figure 4.10-3 Fixing of Trolley and Boom

Caution: After the installation of tower crane is completed, timely remove this
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hinge pins timely and place them on the boom section I (As shown in Figure 4.10-
3b). Please verify whether these hinge pins are removed before the luffing of trolley.

4.10.2 Hoisting
As shown in Figure 4.10-4, while hoisting the boom section II, slightly tilt downward
the rear part of boom section II to ease the installation of 2 Ø200 hinge pins for upper
chord members. After the installation of 2 Ø200 hinge pins for upper chord members,
slowly lower the hook to rotate the boom section II around the Ø200 hinge pins. After 2
Ø50 hinge pins for lower chord members of boom section I are inserted into the pinholes
on the boom section II, tighten 2 sets of bolts M30 to 1,300N.m.

Hinge pin φ200

Hinge pin φ50

Figure 4.10-4 Hoisting of Boom Section II

4.11 Installation of Balance Boom Section II

4.11.1 Assembling
The parts to be assembled for balance boom section II include tensioner, platform,
Erection & Dismantling T2850-120V-138ZW-A 4-105
 ladder, pump station, derrick mast, and railings.
1) As shown in Figure 5.11-1, connect the tensioner and boom section II by 4 hinge
pins Ø50×190/245.

Figure 5.11-1 Installation of Tensioner

2) As shown in Figure 5.11-2, install 4 small platforms by 16 Ø20 hinge pins, install
2 large platforms by 8 Ø30 hinge pins, insert the railings into railing seats, fix by
60 split pins 8×71, and fix the railing clamping plates between railings and tighten
by bolts M12×70.

Small platform
mounting pin Large platform
mounting pin

Figure 5.11-2 Installation of Boom Section II Platforms and Railings

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 3) As shown in Figure 5.11-3, install the ladder by 4 bolts M16×50, install the derrick
mast by 6 bolts M30×110, and install the pump station by 4 bolts M10×35.

Figure 5.11-3 Installation of Ladder and Pump Station

4.11.2 Hoisting
As shown in Figure 5.11-4, while hoisting the balance boom section II, slightly tilt
upward the rear part of boom section II to ease the installation of 2 Ø180 hinge pins for
upper chord members. After the installation of 2 Ø120 hinge pins for upper chord
members, slowly lower the hook to rotate the boom section II around the Ø120 hinge pins.
After 2 Ø50 hinge pins for lower chord members of balance boom section I are inserted
into the pinholes on the balance boom section II, tighten 2 bolts M30 to 1,300N.m.
Connect and fix the railings on the upper layer of balance boom section II by railings, split
pins 8×71, and railing clamping plates and bolts M12.

Erection & Dismantling T2850-120V-138ZW-A 4-107

 Hinge pin φ120

Hinge pin φ50

Figure 5.11-4 Hoisting of Balance Boom Section II

4.12 Installation of Boom Section III

4.12.1 Hoisting
With reference to the hoisting method of boom section II, as shown in Figure 4.12-1,
hoist the boom section III.
Hinge pin φ180

Hinge pin φ50

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 Figure 4.12-1 Hoisting of Boom Section III

4.13 Install the hoisting mechanism.

As shown in Figure 4.13-1 and Figure 4.13-2, hoist the hoisting mechanism, align it
with four lug seats on the balance boom section II, and connect by 4 Ø60 hinge pins and
8 split pins 10×100.
Main hoisting lugs Auxiliary hoisting
Two auxiliary hoisting lugs on motor on underframeaV lugs on reducer

Figure 4.13-1 Diagram for Hoisting Point Locations of Hoisting Mechanism

Erection & Dismantling T2850-120V-138ZW-A 4-109

 Mounting lug plate of hoisting mechanism
Hinge pin φ60

Figure 4.13-2 Hoisting of Hoisting Mechanism

4.14 Installation of Derrick Mast

T2850-120V flat-top tower crane is fitted with SBG2900 manual derrick mast mainly
used for hoisting and repairs of hoisting motor.

4.14.1 Assembling of Derrick Mast

The diagram of assembled derrick mast is shown in Figure 4.14-1.

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 Long rope

Short rope

Drum

Handwheel
Ladder strut

Locating pin Tower crane

location balance boom
Short rope

Long rope

Handwheel
Auxiliary
pulley V Wire rope to auxiliary hoisting mechanism

1. Slewing seat subassembly 2. Bolt connector 3. Special hinge pin 4. Derrick mast pillar 5.

Support shaft subassembly 6. Pulley block ① 7. Rope guard bar ① 8. Pull rod subassembly

9. Derrick mast cantilever beam 10. Pulley block ② 11. Rope guard bar ② 12. Luffing trolley

13. 3t sling 14. Eye ring subassembly 14. Manual luffing mechanism 16. Bolt connect 17.

Locating pin subassembly

Figure 4.14-1 Enwinding of Hoisting Rope

Caution: Adjust the screw sleeve on the pull rod subassembly (Part 8) to adjust
the derrick mast cantilever beam to upslope status from left to right, with the height
difference at approximately 20mm. Ensure that, under the actual hoisted load of
2,900kg, the maximum range of 2,500mm, and the upslope status from left to right
of the derrick mast cantilever beam, the height difference is no higher than 10mm.

4.14.2 Hoisting of Derrick Mast

As shown in Figure 4.14-2, hoist the derrick mast and fix it to the derrick mast
mounting seat on the balance boom by 6 high strength bolts M30.

Erection & Dismantling T2850-120V-138ZW-A 4-111

 Bolt M30

Derrick mast
mounting seat

Figure 4.14-2 Hoisting of Derrick Mast

Caution: Tighten the bolt connectors (Tightening torque for bolts M30 is
1,300N.m) by a torque wrench and afterwards check once every 300 working hours
to maintain sufficient tightening torque.

4.14.3 Enwinding of Derrick Mast Wire Rope

1) Enwinding of derrick mast hoisting wire rope
The power unit of the derrick mast is the auxiliary mechanism on the balance boom
section I. While enwinding the derrick mast hoisting wire rope, as shown in Figure 4.14-
3, enwind the wire rope from the auxiliary mechanism in turn through the auxiliary pulley
2 on the balance boom section I, the pulley 3 (right beneath the derrick mast mounting
base) on the balance boom section II, and the middle of derrick mast pillar to the deflecting
pulley 4 on the top of derrick mast, then enwind the rope through pulley 5 on derrick mast
boom tip to trolley pulley 6 and through hook 7 and trolley pulley 8, and finally fix the wire

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rope to the eye ring 9 on the derrick mast boom root by rope clamps.
2) Enwinding of derrick mast long luffing wire rope
As shown in Figure 4.14-3, enwind the long luffing wire rope from the left side of drum
through the luffing pulley 10 of boom root and the pulley 11 of boom tip and then fix it to
the eye ring 12 on the right side of trolley by rope clamps.
3) Enwinding of derrick mast short luffing wire rope
As shown in Figure 4.14.3, enwind the derrick mast short luffing wire rope from the
right side of drum through the luffing pulley 10 of boom root and directly fix it to the eye
ring 6 on left side of trolley.

Long rope
Short rope

Drum

1. Auxiliary mechanism 2. Boom section I auxiliary pulley 3. Boom section II pulley 4. Derrick

mast deflecting pulley 5. Derrick mast boom tip pulley 6. Derrick mast trolley pulley ① 7.

Derrick mast hook 8. Derrick mast trolley pulley ② 9. Derrick mast boom roof rope clamp 10.

Derrick mast boom roof luffing pulley 11. Derrick mast boom tip luffing pulley 12. Derrick mast

trolley rope clamp

Figure 4.14-3 Enwinding of Derrick Mast Wire Ropes

Caution:
(1) The installation of derrick mast long and short luffing wire ropes on the
drum is shown in Figure 4.14-4a. Install the long rope on the side near the hand
wheel (Enwind for 6 turns) and install the short rope on the side far away from the
hand wheel (Enwind for 3 turns).
Erection & Dismantling T2850-120V-138ZW-A 4-113
 (2) The fixing of rope clamps for wire ropes and eye rings is shown in Figure
4.14-4b.

Drum
Short rope

Long rope

Hand wheel

Figure 4.14-4 Derrick Mast Luffing Wire Ropes

4.14.4 Use of Derrick Mast

1) 2X magnification sling
During use with 2X magnification sling, the rated hoisting load is 2,900kg. As shown
in Figure 4.14-5a, pull out the wire rope of auxiliary hoisting mechanism from the far side,
enwind it through the auxiliary pulley, pull it out beneath the derrick mast connecting seat
of balance boom through the middle of derrick mast pillar, enwind it in turn through the

top of pulley block ①, the top and bottom of pulley block ②, the top of left pulley in the

luffing trolley, the bottom of pulley in the 3t sling, and the top of right pulley in the luffing
trolley to the eye ring in the eye ring subassembly, and lock tightly the rope clamps as per
Figure 4. At completion of above operation, the loads can be hoisted.
2) 1X magnification sling
During use with 1X magnification sling, the rated hoisting load is 1,450kg. As shown
in Figure 4.14-5b, pull out the wire rope of auxiliary hoisting mechanism from the far side,
enwind it through the auxiliary pulley, pull it out beneath the derrick mast connecting seat
of balance boom through the middle of derrick mast pillar, enwind it in turn through the

top of pulley block ①, the top and bottom of pulley block ②, the top of right pulley in the

luffing trolley, and for one turn on the pulley in the 3t sling, and lock securely the rope
clamps as shown in Figure 5. At completion of above operation, the loads can be hoisted.
Caution: The 1X magnification sling can be only used for hoisting of loads and can’t
be used for luffing. To enable the luffing during hoisting of loads, ensure to re-enwind the
wire rope as per Figure 4.14-3.

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 Diagram of connections at boom root
hoisting rope collars

a. Fixing of derrick mast 2X magnification b. Fixing of derrick mast 1X magnification

hoisting rope hoisting rope

Figure 4.14-5 Fixing of Derrick Mast Hoisting Wire Ropes with Different Magnifications

4.14.5 Checking, Commissioning, and Precautions of Derrick Mast

1) Checking and commissioning of structure
Check all parts before installation and repair the cracking, permanent deformation,
and paint flaking (if any) before use.
During the use, periodically check all parts and timely solve any looseness, cracking,
or abnormality of bolt connections and hinge pin connections (if any).
2) Checking and commissioning of mechanism
a) Check the slewing support in the slewing seat subassembly before installation
and during use for lubrication status, flexible rotation without noise, and fastening
status of bolt connections and timely repair and adjust the abnormalities (if any).
b) Check the damage and lubrication status of manual luffing mechanism, luffing
trolley, 3t sling, bearings in pulleys, and wire ropes. If the lubricating oil is
insufficient or dry, add or apply oil. (Refer to Maintenances)
c) Check slewing mechanism for flexible rotation without noise and check the wear
status of wire ropes and fastening status of bolt connections before installation
and during use and timely repair and adjust abnormalities (If any).
d) During the use, check and adjust the upward deflection of the derrick mast
cantilever beam. While hoisting the rated load, reduce the gradient of the luffing
trolley, namely the derrick mast cantilever beam will be under upslope status from
left to right at the maximum range of 2,500mm and it’s better to adjust the height
Erection & Dismantling T2850-120V-138ZW-A 4-115
 difference to no more than 10mm.
3) Precautions
a) The derrick mast must be operated by designated person and the operator
shall understand the structural performance and get familiar with the
operation safety regulations.
b) When the sling is hoisted to the highest point, ensure to operate with
cautions and keep sling away from any mechanism on the top. While
lowering the sling, ensure to maintain at least 3 turns of wire rope on the
drum of auxiliary hoisting mechanism and keep the sling off the ground.
c) Positioning on the slewing seat subassembly by locating pins (there are 24
locating holes) helps the installation and disassembling works at certain
fixed hoisting position and prevents the free rotation of manual derrick
mast in event of high wind speed.
Warning:
(1) Ensure to operate within rated load and never overload.
(2) The hoisting sling can be used only for vertical hoisting and can’t be used
for hoist obliquely or draw horizontally any load.
(3) All personnel are prohibited to stand beneath the hoisted load while
hoisting a load.
(4) It’s prohibited to hoist a load in the air for a long time.

4.15 Installation of Boom Section IV

4.15.1 Hoisting
With reference to the hoisting method of boom section II, as shown in Figure 4.15-1,
hoist the boom section IV.

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 Hinge pin φ160

Hinge pin φ50

Figure 4.15-1 Hoisting of Boom Section IV

4.16 Installation of 1st Counterweight

As shown in Figure 4.16-1, hoist the first 11.5t counterweight, lower the
counterweight hinge pins to the inclined surface of counterweight support plate on the
balance boom, and allow this counterweight to compress its front plane against the F150
straight web member on balance boom section II under the action of gravity.

Counter weight hinge pin

Counter weight support plate

Straight web member F150

Figure 4.16-1 Hoisting of First Counterweight

Erection & Dismantling T2850-120V-138ZW-A 4-117

4.17 Installation of Boom Section V

4.17.1 Hoisting
With reference to the hoisting method of boom section II, as shown in Figure
4.17-1, hoist the boom section V.

Hinge pin φ200

Hinge pin φ50

Figure 4.17-1 Hoisting of Boom Section V

4.18 Installation of 2nd Counterweight

4.18.1 Hoisting
As shown in Figure 4.18-1, hoist the second 11.5t counterweight, lower the
counterweight hinge pins to the inclined surface of counterweight support plate on the
balance boom, and allow this counterweight to compress its front plane against the rear
plane of first counterweight under the action of gravity.

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 Counter weight hinge pin

Counter weight support plate

Figure 4.18-1 Hoisting of Second Counterweight

4.19 Installation of Boom Section VI

4.19.1 Hoisting
With reference to the hoisting method of boom section II, as shown in Figure
4.19-1, hoist the boom section VI.
Hinge pin φ160

Hinge pin φ50 Bolt M30

Figure 4.19-1 Hoisting of Boom Section VI

Erection & Dismantling T2850-120V-138ZW-A 4-119

4.20 Installation of 3rd Counterweight

4.20.1 Hoisting
As shown in Figure 4.20-1, hoist the third 11.5t counterweight, lower the
counterweight hinge pins to the inclined surface of counterweight support plate on the
balance boom, and allow this counterweight to compress its front plane against the rear
plane of second counterweight under the action of gravity.

Counter weight hinge pin

Counter weight support plate

Figure 4.20-1 Hoisting of Third Counterweight

4.21 Installation of Boom Section VII

4.21.1 Hoisting
With reference to the hoisting method of boom section II, as shown in Figure
4.21-1, hoist the boom section VII.

4-120 T2850-120V-138Z-A01 Erection & Dismantling

 Hinge pin φ130

Hinge pin φ50 Bolt M30

Figure 4.21-1 Hoisting of Boom Section VII

4.22 Installation of 4th Counterweight

4.22.1 Hoisting
As shown in Figure 4.22-1, hoist the fourth 11.5t counterweight, lower the
counterweight hinge pins to the inclined surface of counterweight support plate on the
balance boom, and allow this counterweight to compress its front plane against the rear
plane of third counterweight under the action of gravity.

Counter weight hinge pin

Counter weight support plate

Figure 4.22-1 Hoisting of Fourth Counterweight

Erection & Dismantling T2850-120V-138ZW-A 4-121

4.23 Hoisting of Remaining Boom Sections

4.23.1 Assembling
As shown in Figure 4.23-1, assemble the remaining boom section VIII, boom section
IX, boom tip section, and the hoisting railing.
Connect the boom section VII with the boom section IX upper chord members by
Ø50 hinge pins, connect the boom section VIII with the boom section IX lower chord
members by bolts M30, and tighten the bolts M30 to 1,300N.m.
Connect the boom section IX with the boom tip section by bolts M30, tighten the bolts
M30 to 1,300N.m, and lock the boom tip section by bolts M30.

Hinge pin φ90 Hinge pin φ50 Bolt M30 Bolt M30 Hinge pin φ50

Boom section VIII Boom

section IX

Boom tip Hoisting

section railing

Figure 4.23-1 Assembling of Remaining Boom Sections

4.23.2 Hoisting
With reference to the hoisting method of boom section II, as shown in Figure 4.23-
2, hoist the remaining boom sections.
Hinge pin φ90

Hinge pin φ50 Bolt M30

Figure 4.23-2 Hoisting of Remaining Boom Sections

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Warning: After the installation of boom tip section, ensure to tighten the boom tip
lock bolts.

4.23.3 Installation of Wind Shields

1) When the 60m boom is installed, to increase the windward area of the boom side, it’s
necessary to install one wind shield near the boom tip on the boom. When the 50m
boom is installed, to increase the windward area of the boom side, it’s necessary to
install two wind shields near the boom tip on the boom.
2) The wind shields shall be fabricated by the user. For the connection between wind
shields and boom, the U-bolt connection (Each bolt subassembly includes 1 U-bolt
M16, 2 plain washers, 2 spring washers, and 2 nuts M16) is recommended. Drill the
holes accordingly on the wind shields for every web member to connect with the boom.
The user may also adopt other connection method depending on the actual situation
of the working site, provided that the wind shields are fixed securely without damaging
the boom.
3) Install the wind shields near the boom tip on the boom, as shown in Figure 4.23-3.
Drill the U-bolt mounting holes on the wind shields to guarantee the successful
installation of wind shields.

60m boom length

50m boom length

(1) Wind shield; (2) U-bolt M16; (3). Baseplate.

Figure 4.23-3 Installation of Wind Shields

Erection & Dismantling T2850-120V-138ZW-A 4-123
4) The fabrication diagram of wind shields is shown in Figure 4.23-4. Drill the U-bolt
connecting holes on the wind shields after the wind shields are properly fitted with the
boom. Connect the wind shields to every inclined web member of the boom and drill
the connecting holes on the upper and lower special pipes.

4 pieces

4 pieces

Figure 4.23-4 Fabrication of Boom Wind Shields

No Name Specification Quantity Material

1 Special pipe A □40×20×2.4-2000 2 Q235A

2 Special pipe B □40×20×2.4-5420 2 Q235A

3 Round steel A φ16-1920 3 Q235A

4 Round steel B φ16-1339 8 Q235A

5 Plate t3-2000×5500 1 Q235A

6 Closure plate t3-20×40 4 Q235A

5) Refer to Figure 4.23-5 for the fabrication of U-bolts and baseplates.

Surrounding area

U-bolt Zn.D

Figure 4.23-5 Fabrication of U-Bolts and Baseplates

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 4.23.4 Precautions for Hoisting of Boom
Special Notice: It’s prohibited to drag obliquely while hoisting the boom, as shown in
Figure 4.23-6.

Figure 4.23-6 Notice for Hoisting Locations of Boom

4.24 Installation of Remaining Counterweights

As shown in Figure 4.24-1, hoist the remaining counterweights based on the length
of boom in use strictly as per the Counterweight Configuration Table in Chapter IV.

Counter weight hinge pin

Counter weight support plate

Figure 4.24-1 Hoisting of Remaining Counterweights

Erection & Dismantling T2850-120V-138ZW-A 4-125

 Load trolley Boom tip and hoisting railing

Figure 4.24-2 Completed Installation of Machine

4.25 Installation of Hoisting Rope and Hook

4.25.1 Enwinding of Hoisting Rope

Refer to section 4.25.3 for the composition of diversified magnification hook
subassembly for T2850-120V. After the basic components are installed, as shown in
Figure 4.25-1a, enwind the wire rope of auxiliary mechanism.

Figure 4.25-1a Enwinding of Auxiliary Mechanism Wire Rope

Figure 4.25-1b Enwinding of Hoisting Wire Rope

1 - Hoisting drum 2 - Hoisting wire rope 3 - Cable net bag 4 - Upper luffing pulley of balance boom
4-126 T2850-120V-138Z-A01 Erection & Dismantling
section II 5 - Upper chord member luffing pulley of boom section I 6 - Lower hoisting pulley of boom

section I 7 - Auxiliary mechanism deflecting pulley of boom section II 8 - Hoisting load limiter 9-

Boom tip twist control device 10 - Hook lower pulley block 11 - Main trolley fixed pulley 12 - Hook

upper pulley block 13 - Hook pulley block 14 - Auxiliary trolley fixed pulley 15 - Hook crossbeam

16 - Auxiliary mechanism 17 - Auxiliary wire rope

(1) Lead out the Ø13mm wire rope from the auxiliary mechanism, enwind it in sequence
of 16-4-5-7-11-12-10-13-14-6-8-3 into the hoisting mechanism, and connect the
Ø32mm hoisting wire rope to the Ø13mm wire rope by connecting net covers, as
shown in Figure 4.25-2.

Figure 4.25-2 Connecting Net Cover

(2) Slowly start the auxiliary mechanism and connected hoisting mechanism at the
same time and ensure the consistent running linear speed for the drums of two
mechanisms. When the hoisting wire rope is dragged to the fixed pulley position of
main trolley, remove the net cover, and fix the hoisting wire rope on the trolley, as
shown in Figure 4.25-3. Slowly start the hoisting mechanism and luffing
mechanism in cooperative manner at the same time. The linear speed of the
hoisting mechanism wire rope can be slightly higher than the traveling speed of
the trolley to ensure that the hoisting wire rope is not tensioned. Till the trolley
moves to the boom tip position, fix the hoisting wire rope to the twist control device,
as shown in Figure 4.25-4.
Caution:
While enwinding the hoisting wire rope, observe the running status of hoisting
wire rope by someone at all times to prevent tensioning the wire rope.
(3) As shown in Figure 4.25-1b, fix the hoisting wire rope from hoisting mechanism in
sequence of 1-8-6-14-13-10-12-11-9 to the twist control device.

Erection & Dismantling T2850-120V-138ZW-A 4-127

 Hoisting wire rope Wire rope clamp Wedge connector

Roller lug plate

Main trolley crossbeam

(4)
Figure 4.25-3 Fixing Method between Hoisting Wire Rope and Trolley

Boom tip section

Hoisting wire rope

Rope clamp 32KTH Wedge

Figure 4.25-4 Fixing Method between Hoisting Wire Rope and Twist Control Device

4.25.2 Operation Method of Cable Net Cover

Compress the rear end of cable net cover to expand the cable net cover, attach it
onto the object to be dragged, and gradually compress the rope guide to attach step by
step in such manner that the net cover clings closely to the wire rope to be dragged. After
the net cover is completely attached (It's allowed to leave a space), bundle up the opening
of rope guide tightly by cable tie or steel wire. Loosen the cable tie and compress the rear
end of net cover to expand it step by step to take out the net cover.
Caution:
(1) At the start of dragging, check and ensure that the net cover is completely
tensioned on the wire rope to be dragged before the normal use.

4-128 T2850-120V-138Z-A01 Erection & Dismantling

 (2) The cut sharp corners of the wire rope to be dragged shall be wrapped or
ground to prevent cutting the rope sleeve or influencing the expansion/shrink of
net cover.
(3) At the start of dragging, a tiny partial slide of net cover is a normal
symptom.
(4) Before and during use, notice to check the net cover for broken wire and
check the operation scope of rope guide (auxiliary mechanism). The net cover with
broken wire shall be timely scrapped and the net cover beyond the operation scope
can't be used.
(5) Timely take out the net cover after use and preserve properly to prevent
damage of wire/strand and other parts.

4.25.3 Installation of Hook Subassembly

Installation procedure of 8X magnification hook:
(1) Hoist the lower pulley block to the stirrup and then hoist the pulley block to the
stirrup, as shown in Figure 4.25-5.

Pulley block

Lower pulley block

Figure 4.25-5 Installation of 8X Magnification Hook (I)

(2) Hoist the upper pulley block to the lower pulley block and connect it to the lower
pulley block by hinge pins. The operator can stand on the stirrup platform to connect the
connecting hinge pins between upper and lower pulley blocks, as shown in Figure 4.25-
6.

Erection & Dismantling T2850-120V-138ZW-A 4-129

 Pulley block Upper pulley block

Hinge pin

Lower pulley block

Figure 4.25-6 Installation of 8X Magnification Hook (II)

(3) On the basis of step (2), the operator can enwind the wire rope.
(4) After enwinding the wire rope, hoist the pulley blocks by hoisting mechanism,
hoist the crossbeam onto the stirrup, and connect the pulley blocks to the crossbeam, as
shown in Figure 4.25-7.

Pulley block Upper pulley block

Lower pulley block

Figure 4.25-7 Installation of 8X Magnification Hook (IV)

(5) After the connection of crossbeam, connect the hook body. In such case, the
installation of 8X magnification hook subassembly is completed, as shown in Figure 4.25-
8.

4-130 T2850-120V-138Z-A01 Erection & Dismantling

 Pulley block Upper pulley block

Lower pulley block

Figure 4.25-8 Installation of 8X Magnification Hook (V)

The installation procedure for 4X magnification hook is to hoist the pulley block and
fix it onto the auxiliary trolley and connect the upper and lower pulley blocks to the hook
body subassembly after the installation step (3) for 8X magnification hook.
The installation procedure for 2X magnification hook is to hoist the pulley block and
upper pulley block and fix them onto the auxiliary and main trolleys respectively and
connect the lower pulley block to the hook body subassembly after the installation step
(3) for 8X magnification hook.

4.26 Enwinding of Luffing Wire Ropes

Caution: While enwinding the luffing wire ropes by auxiliary mechanism,
ensure to enwind the long luffing wire rope before enwinding the short luffing wire
rope.

4.26.1 Enwinding of Long Luffing Wire Rope

(1) Lead out the Ø13mm wire rope from the auxiliary mechanism, enwind it in
sequence of 11-3-5-7-10-9-8-6-4-1-12 into the luffing mechanism, and connect the
Ø26mm long luffing wire rope to the Ø13mm wire rope by connecting net covers, as
shown in Figure 4.26-1.

Erection & Dismantling T2850-120V-138ZW-A 4-131

 a. Enwinding of Long Luffing Wire Rope for 85m/80m Boom

b. Enwinding of Long Luffing Wire Rope for 70m/60m Boom

c. Enwinding of Long Luffing Wire Rope for 50m Boom

1 - Tension pulley for long luffing wire rope 2 - Tension pulley for short luffing wire rope 3 - Pulley

for short luffing wire rope of balance boom section II 4 - Pulley for long luffing wire rope of balance

boom section II 4 - Pulley for short luffing wire rope of boom section I 6- Pulley for long luffing

wire rope of boom section I 7 - Luffing pulley for lower chord member of boom section I 8 - Luffing

pulley for boom 9 - Boom tip luffing pulley 10 - Trolley pulley 11 - Auxiliary mechanism 12 -

Luffing mechanism

Figure 4.26-1 Enwinding of Long Luffing Wire Rope

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 2) Slowly start the auxiliary mechanism and connected luffing mechanism at the
same time and ensure the consistent linear speed for the drums of two mechanisms.
When the luffing wire rope is led to one end of main trolley, remove the net cover and fix
the luffing wire rope onto the main trolley.

4.26.2 Enwinding of Short Luffing Wire Rope

As shown in Figure 4.26-2, lead out the short luffing wire rope from the luffing
mechanism, enwind in sequence of 12-2-3-5-7 into the main trolley, and then fix the short
luffing wire rope to the main trolley.

Figure 4.26-2 Enwinding of Short Luffing Wire Rope

4.26.3 Operations of Tension Device

1) Structure of tension device
The luffing wire ropes of T2850-120V are tensioned by two sets of same tension
devices, which are used to tension the long and short luffing wire ropes respectively, as
shown in Figure 4.26-3.

Guide groove
Front

Rear

Pulley
hinge pin

Erection & Dismantling T2850-120V-138ZW-A 4-133

 1 - Lock nut 2 - Adjustment nut 3 - Washer 4 - Fixed bracket 5 - Stop pin 6 - Split pin I 7 -

Bolt

8 - Rope guard pin 9 - Luffing pulley 10 - Movable bracket

Figure 4.26-3 Enwinding of Long Luffing Wire Rope

2) Operations of Tension Device

As shown in Figure 4.26-3, to tension the luffing wire rope, loosen the lock nut (Part
1) and tighten the adjustment nut (Part 2) by a crowbar to drive the bolt (Part 7) and move
backward the movable bracket (Part 10) along guide slot on the fixed bracket (Part 4).
After the wire rope is tensioned properly, tighten the lock nut.
3) Replacement of tension pulley
As two tension devices for tensioning of long and short luffing wire ropes are near, to
ease the change of luffing pulley, please operate as per following procedure.
(1) Loosen the lock nut and adjustment nut on the other tension device, take out the
split pins (Part 6), and unplug the stop pin (Part 5) and rope guard rod (Part 8), as shown
in Figure 4.26-3.
(2) Lift up the bolt and rotate it along with the movable bracket around the pulley
hinge pin, as shown in Figure 4.26-4.

Figure 4.26-4 Rotation of Movable Bracket and Bolt

(3) Move backward the movable bracket and bolt of the luffing pulley to be replaced,
till the pulley hinge pins can be knocked out from the guide slot in the fixing bracket of the
other tension device, as shown in Figure 4.26-5.

4-134 T2850-120V-138Z-A01 Erection & Dismantling

 Hinge pin of pulley to be replaced

Figure 4.26-5 Rotation of Movable Bracket and Bolt

Caution: 450mm≤D≤580mm

4.27 Installation of Warning Lamp, Anemoscope, and Camera

(1) Install the warning lamp I at position I shown in Figure 4.27-1.
(2) Install the camera II at position II shown in Figure 4.27-1.
(3) Install the anemoscope III at position III shown in Figure 4.27-1.

Figure 4.27-1 Installation of Warning Lamp, Camera, and Anemoscope

Caution:
(1) Install the warning lamp, camera, and anemoscope after all counterweights
are installed.

5 Connection of Power Supply and Commissioning

When the installation of the machine is completed as per above-mentioned

Erection & Dismantling T2850-120V-138ZW-A 4-135

procedure, under the condition of no-load and <3m/s wind speed, check the
perpendicularity of the tower body. The permissible lateral perpendicularity tolerance for
the axis of tower body (Tower body above highest attachment point under attached status)
under independent status is 4/1000 and the permissible perpendicularity tolerance of the
axis of tower body beneath the highest attachment point is 2/1000. Power on all electric
circuits as per the requirements of electric circuits, run all mechanisms and check them
for correct running. In addition, check all wire ropes for normal working status and for
interference with structural parts and solve the abnormalities (if any).

6 Automatic Magnification Change System

The combinations between hook and trolley with double-trolley 8X magnification,
single-trolley 4X magnification, and single-trolley 2X magnification are shown in Figure 6-
1.
The magnification change is performed at the boom root under the condition of no-
load, low speed, and no-swing. No matter which magnification change is operated, ensure
to rotate the bypass switch to bypass status to disable the height limit. At completion of
change, ensure to restore bypass switch to original status.

Double-trolley 8X magnification Single-trolley 4X magnification Single-trolley 2X

magnification

Figure 6-1 Trolley Magnification Diagram

4-136 T2850-120V-138Z-A01 Erection & Dismantling

 6.1 Change Procedure from 8X Magnification to 4X

Magnification
a. Slowly move the load trolley to the boom root and connect the auxiliary trolley to
the boom root outrigger by 2 hinge pins, as shown in Figure 4.10-3.
b. Place the hook subassembly on the stirrup, remove the connecting hinge pins
between hook body subassembly and crossbeam, and start the hoisting mechanism to
hoist the pulley block and crossbeam and place them onto the ground, as shown in Figure
6.1-1.

Upper pulley Wire rope

Pulley block block
Pulley Upper pulley
block block
Lower pulley
block
Crossbeam Lower pulley
Hook body block
subassembly
Crossbeam

Connecting
hinge pin

Figure 6.1-1 Change from 8X Magnification to 4X Magnification (I)

c. As shown in Figure 6.1-2, remove the connecting hinge pins between pulley block
and crossbeam, place a ballast of no less than 4t onto the crossbeam, and slowly hoist
the pulley block. Caution: The weight of individual wire rope between the magnification
change surface of the main pulley block and the main trolley shall be less than the weight
of auxiliary pulley block divided by its magnification. Slowly hoist the pulley block to a
position capable for connection with auxiliary trolley so that the operator can stand on the
trolley platform to connect the connecting hinge pins.

Erection & Dismantling T2850-120V-138ZW-A 4-137

 Pulley block
Wire rope

Upper pulley
block

Counter
weight Lower pulley
block

Crossbeam

Figure 6.1-2 Change from 8X Magnification to 4X Magnification (II)

d. As shown in Figure 6.1-3, remove the connecting hinge pins between lower pulley
block and crossbeam, hoist the pulley block onto the stirrup and connect it with the hook
body subassembly, and connect the connecting hinge pins. In such case, the change
from 8X magnification to 4X magnification is completed.
Wire rope

Wire rope
Upper pulley block

Upper pulley block

Lower pulley block
Connecting hinge pin
Lower pulley block Hook body subassembly
Counter weight

Crossbeam

Figure 6.1-3 Change from 8X Magnification to 4X Magnification (III)

6.2 Change Procedure from 4X Magnification to 2X

Magnification
a. Slowly move the main trolley to the boom root and connect the main and auxiliary
trolleys.
b. Slowly lower the hook onto the stirrup, remove the connecting hinge pins between
hook body subassembly and lower pulley block, and hoist to separate the upper and lower
pulley blocks, as shown in Figure 6.2-1.

4-138 T2850-120V-138Z-A01 Erection & Dismantling

 Wire rope

Wire rope
Upper pulley block

Upper pulley block

Lower pulley block

Lower pulley block

Connecting hinge pin

Hook body subassembly Hook body subassembly

Figure 6.2-1 Change from 4X magnification to 2X magnification (I)

c. Move away the hook body subassembly from the stirrup, readjust the stirrup, and
hoist the upper and lower pulley blocks onto the stirrup. The operator can stand on the
stirrup platform to remove the connecting hinge pins between upper and lower pulley
blocks.

Upper pulley block

Upper pulley block

Connecting hinge pin

Lower pulley
block Lower pulley block

Figure 6.2-2 Change from 4X magnification to 2X magnification (II)

d. Slowly hoist the upper pulley block. Caution: The individual wire rope between the
magnification change surface of main pulley lower hanger and the main trolley shall be
less than the weight of upper hanger divided by its magnification. Slowly hoist the upper
pulley block to a position capable for connection with main trolley so that the operator can

Erection & Dismantling T2850-120V-138ZW-A 4-139

stand on the trolley platform to connect the connecting hinge pins.

Figure 6.2-3 Change from 4X magnification to 2X magnification (III)

e. Hoist the lower pulley block, readjust the stirrup, place the hook body subassembly
onto the stirrup, and connect the connecting hinge pins between lower pulley block and
hook body subassembly. In such case, the change from 4X magnification to 2X
magnification is completed.

Hook body subassembly

Figure 6.2-4 Change from 4X magnification to 2X magnification (IV)

4-140 T2850-120V-138Z-A01 Erection & Dismantling
 The change from 2X magnification to 4X magnification is the reverse procedure of
change from 4X magnification to 2X magnification and the change from 4X to 8X is the
reverse procedure of change from 8X to 4X.

7 Jacking of Tower Crane

7.1 Jacking Precautions
(1) The slewing part of the tower crane must be leveled before jacking.
(2) The jacking operation is prohibited if the wind speed at the highest point of tower
crane is higher than 14m/s (Level 6).
(3) Before jacking operation, ensure to check the jacking system for normal working
(Refer to 6.4 for the checking method).
(4) It’s prohibited to hoist a load (lifting or lowering) when the jacking system is
jacking or is already jacked.
(5) It’s prohibited to luff the boom when the jacking system is jacking or is already
jacked.
(6) During jacking, ensure that the boom is in same direction with the fed standard
section (or reinforcement section), brake the boom by slewing mechanism brake,
and stop the boom at the leveled angle.
(7) To add several standard sections continuously, after the addition of every section,
ensure to connect the main chord members of tower body and transitional
section by 4 Ø104 hinge pins before hoisting the next standard section by tower
crane. It's allowed to connect one main chord member of standard section with
transitional section by one Ø104 hinge pin only in this case.
(8) The footplates on the standard section added must be aligned with the footplates
of the installed standard section (or reinforcement section) in longitudinal
direction.
(9) No matter the jacking is completed or not, before the transitional section and
tower body are connected by Ø105 hinge pins, it’s prohibited to slew, luff, or
hoist the boom.
(10) During the jacking, in event of any abnormality of the hydraulic jacking system,
immediately stop the jacking, retract the cylinder, lower the transitional section
Erection & Dismantling T2850-120V-138ZW-A 4-141
 onto the top of tower body, connect the transitional section with tower body
securely by 8 Ø105 hinge pins, and then solve the malfunction of hydraulic
system.
(11) At completion of jacking, all standard sections are connected by 8 standard
hinge pins respectively and the topmost standard section and the transitional
section are connected by 8 Ø105 hinge pins.

7.2 Preparations before Jacking

(1) Remove the ropes used to bundle the hanger crossbeams, connect the pump
station oil pipes and electric circuits, add hydraulic oil into the oil tank as per the
requirements of hydraulic pump station, and ensure that the motor wiring is
correct, the fan is rotating rightward, and the manual valve joystick operates
flexibly without stagnation.
(2) Clean all sections of tower body. Apply grease to the inside of tower body section
connecting sleeve and arrange the standard sections to be added in a row on
the ground beneath the boom at the jacking position, in order to prevent the use
of slewing mechanism during the jacking and addition of sections and shorten
the time required for jacking and addition of sections.
(3) Release the cable in such manner that the length is slightly larger than the total
jacking height and fix securely the cable.
(4) Rotate the boom to the front direction of climbing frame and the balance boom
to the rear direction of climbing frame (In such case, the jacking cylinders are
exactly located on the left and right sides of the balance boom) and brake the
boom by the slewing mechanism brake.
(5) Prepare 8 Ø105 hinge pins on the middle platform of climbing frame.
(6) Remove the movable struts (Part 1 in Figure 4.5-3).

7.3 Leveling of Tower Crane before Jacking

7.3.1 Assembling of Hoisting Frame

Assemble the hoisting frame as per Figure 7.3-1. The required parts are listed in Table
7.3-1.

4-142 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 7.3-1 Assembling of Hoisting Frame

Table 7.3-1 Table of Parts Required for Assembling of Hoisting Frame

No. Name Specification Quantity

1 Support bracket 1

2 Hinge pin XZ01C-30×140/170 4

3 Split pin 8×71 GB/T91-2000 4

4 Hoisting beam 2

5 Shackle S-DW6.3 JB8112-1999 8

6 Hanger 4

7.3.2 Hoisting of Standard Section

(1) Select the feeding magnification based on the magnification used for the working.
(2) As shown in Figure 7.3-2, directly install the special feeding hook to the hook
subassembly.
(3) As shown in Figure 7.3-3, detach the special hook from the hoisting frame.

Erection & Dismantling T2850-120V-138ZW-A 4-143

 Figure 7.3-2 Placement of Hoisting Frame on Feeding Trolley

4-144 T2850-120V-138Z-A01 Erection & Dismantling

 Special feeding hook

Hooked at hinge pin

Hoisting
bracket

Figure 7.3-3 Detachment between Special Hook and Hoisting Frame

(4) Before leveling the tower crane, ensure to hoist a standard section (Install the
platforms of standard section and fix the platform railings and ladder) to the feeding
crossbeam of transitional section (Refer to Figure 7.3-4 for the hoisting of standard
section on feeding trolley. Hang the wire rope on the opposite hoisting lugs of the standard
section). As per Table 7.3-5, move the load trolley to the appropriate position for leveling
and remove the connecting hinge pins between four outriggers of transitional section and
standard section.
Caution: During leveling, hoist one standard section (Fix the installation
platforms, platform railings, and ladder), which is in weight of approximately
13,680kg.

Erection & Dismantling T2850-120V-138ZW-A 4-145

 Figure 7.3-4 Hoisting of Standard Section on Feeding Trolley

Figure 7.3-5 Leveling for Jacking

Under diversified boom lengths, the range of load trolley and the
corresponding hoisting load during jacking and leveling are listed in Table 7.3-2
(For reference only):
Table 7.3-2 Range of Load Trolley and Hoisting Load during Leveling under Diversified Boom

Lengths (8X magnification)

Boom length Boom length Boom length

L(m) L(m) L(m)
(m) (m) (m)
85 50.1 80 54.9 70 52.4

4-146 T2850-120V-138Z-A01 Erection & Dismantling

 60 52.6 50 55.5

(5) Push the joystick of hydraulic jacking system to “Jacking direction” to jack the
climbing frame, till the outriggers of transitional section detach exactly from the main
chord members of tower body.
(6) Check whether the connecting outriggers between transitional section and
standard section are on one same vertical line with the main chord members of tower
body and observe whether the clearances between 16 rollers of climbing frame and main
chord members of tower body are basically same, in order to check the balance of tower
crane. If not, adjust the range of load trolley, till the balance is achieved and the upper
gravity center of tower crane is at the jacking crossbeam.
(7) Record the leveling position of load trolley. However, be noted that this position
changes along the length of boom.
(8) Operate the hydraulic system to lower the climbing frame and connect the
connecting hinge pins between transitional section and standard section of the tower body.

7.4 Jacking Operation

Note: A downward arrow of the cylinder denotes the extending of cylinder and an
upward arrow of cylinder denotes retraction of cylinder (This rule applies to all
subsequent figures).

Erection & Dismantling T2850-120V-138ZW-A 4-147

 Figure 7.4-1 Jacking of Tower Crane (I)

1) Use the slewing brake on the slewing mechanism to lock the superstructure of the
tower crane against slewing.

2) As shown in step ① of Figure 7.4-1, remove 8 Ø105 connecting hinge pins between

top of tower body and transitional section and properly arrange them on the upper
platform.

3) As shown in step ② of Figure 7.4-1, rotate downward the footplate change joystick

(1) to swing outward the footplate change hangers to inclined status, in order to
prevent the interference with the footplate during jacking. After the proper rotation as

per step ③, push the footplate change joystick against the footplate change hangers

to prevent rotation.

4) Start the hydraulic jacking system, extend the cylinder as per step ④ to attach the

jacking crossbeams (2#) to the grooves of nearest group of standard section

footplate A, and insert the safety pins (3#), as shown in the step ⑤ of Figure XX.

Caution: Assign a special person standing in the middle platform to observe

whether the jacking crossbeams are attached into the footplate grooves and
insert the safety pins.
5) After the attachment of jacking crossbeams into the footplate grooves is confirmed
and the safety pins are inserted, continue the jacking to hoist the climbing frame and
its structure above for 10~50mm and then stop the jacking.
Caution: Maintain this status for approximately 20min and check and ensure
there is no abnormality, including noise, misplacement, or deformation in
force transmission parts of climbing frame (Such as jacking crossbeam) and
the automatic retraction of cylinder piston rods, before continuing the jacking.
6) After the normal status of all parts is confirmed, continue the jacking in such manner
that the jacking frame drives the footplate change hangers (4#) to be slighter higher
than footplates E of standard section and then stop the jacking.

7) As shown in steps ⑥ and ⑦ of Figure 8.4-1, rotate upward the footplate change

4-148 T2850-120V-138Z-A01 Erection & Dismantling

 joystick to rotate the footplate change hangers inward to vertical status and slowly
retract the cylinders to place four hangers into the grooves of footplates E.

Figure 7.4-2 Jacking of Tower Crane (II)

8) Ensure that four footplate change hangers are accurately compressed onto the
footplate grooves and are carrying the weight of the climbing frame and its structure
above, without any abnormality such as partial deformation and noise. After the

normal status is confirmed, as shown in step ① of Figure 7.4-2, unplug the safety

pins of jacking crossbeam, fully retract the cylinder pistons as per step ②, jack the

jacking crossbeams to attach into the nearest group of footplate grooves B above,

and insert the safety pins, as shown in step ③ of Figure 7.4-2.

9) As shown in step ④ of Figure 7.4-2, rotate downward the footplate change joystick

to swing outward the footplate change hangers to inclined status, in order to prevent
Erection & Dismantling T2850-120V-138ZW-A 4-149
 the interference with the footplate during jacking. After the proper rotation as per step

⑤ , push the footplate change joystick against the footplate change hangers to

prevent rotation.

10) Extend the cylinder again as per step ⑥ to jack the climbing frame in such manner

that the footplate change hangers are slightly higher than footplates F. As shown in

steps ⑦ of Figure 7.4-2, rotate upward the footplate change joystick to rotate the

footplate change push rods inward to vertical status and slowly retract the cylinders

to place footplate change hangers into the grooves of footplates F as per step ⑧.

11) Ensure that four footplate change hangers are accurately compressed onto the
footplate grooves and are carrying the weight of the climbing frame and its structure
above, without any abnormality such as partial deformation and noise. After the
normal status is confirmed, unplug the safety pins, fully retract the cylinder pistons,
jack the jacking crossbeams to attach into the nearest group of footplate grooves C
above, and insert the safety pins.
12) Operate as per the jacking steps 10~11 to attach the jacking crossbeams into to the
standard section footplates G and insert the safety pins. In such case, when the
jacking cylinders are fully extended, there is a space slightly larger than the volume
of standard section above the tower body, as shown in Figure 7.4-2.

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 Figure 7.4-3 Jacking of Tower Crane (III)

13) As per step ① of Figure 7.4-3, rotate the handwheel of feeding system to feed the

standard section on the feeding crossbeam of lower support to the top the tower body,

slowly retract he cylinders slowly as per step ② till the new standard section comes

into contact with the connectors of top standard section of tower body, and then
retract the cylinders to align the connecting pins of standard section and tower body.

14) As per step ③ of Figure 7.4-3, connect securely the upper and lower standard

sections by 8 Ø105 hinge pins and knock them into the holes. Notice to basically
align the mounting holes on the ends of hinge pins with the small holes on the
standard section before the knocking. After installation, insert small hinge pins and
spring pins.
15) Disconnect the standard section hoisting lugs and wire rope subassembly as per

step ④ of Figure 7.4-3. Rotate the handwheel of feeding system to push out the
Erection & Dismantling T2850-120V-138ZW-A 4-151
 hoisting frame along the feeding crossbeam, as shown in step ⑤ of Figure 7.4-3.

16) Continue to retract the cylinders as per step ⑥ , align the connecting pinholes

between new standard section and transitional section, and insert 8 Ø105 hinge pins
and knock them into holes. Notice to basically align the mounting holes on the ends
of hinge pins with the small holes on the transitional section before the knocking.

After installation, insert small hinge pins and spring pins, as shown in step ⑦ of

Figure 7.4-3.
17) In such case, the addition of one standard section is completed. To add several
standard sections continuously, repeat above-mentioned procedure.
The last standard section shall be installed in such manner that one end is
fixed to the tower body and the other end is fixed to the transitional section.

7.5 Disassembling of Tower Body

1) Slew the boom to the feeding direction of standard section (namely the climbing
frame side with opening), brake the slewing brake, level the tower crane (Refer to
Section 7.3 for detailed leveling procedure), and stop the load trolley at leveled
position (Namely, the leveling position of load trolley is same with that during the
jacking and addition of section during installation of tower crane).

4-152 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 7.4-1 Disassembling of Tower Body (I)

2) As per step ① of Figure 7.4-1, extend the cylinders to attach the jacking

crossbeams into the grooves of footplates F, insert the safety pins, and remove the
connecting hinge pins between topmost standard section and transitional section

as per step ② of Figure 7.4-1. Caution: As shown in steps ③ and ④ of

Figure 7.4-1, rotate downward the footplate change joystick to swing outward
the footplate change hangers to inclined status, in order to prevent the
interference with the footplate during jacking. After the proper rotation, push
the footplate change joystick against the footplate change hangers to
prevent rotation.

Erection & Dismantling T2850-120V-138ZW-A 4-153

 3) Observe the balance status. If the balance is confirmed, slowly extend the jacking

cylinders as per step ⑤ of Figure 7.4-1 and jack the climbing frame and its

structure above. In such case, the topmost standard section is separated from the
transitional section. Continue to extend the jacking cylinder, till the space between
topmost standard section and transitional section is sufficient to feed the feeding

trolley. As per the step ⑥ of Figure 7.4-1, rotate the handwheel on the feeding

system to feed the feeding trolley to be above the standard section in the climbing
frame, adjust the cylinder length, and connect the wire rope to the hoisting lugs of

topmost standard section by 4 shackles as per step ⑦ of Figure 7.4-1. In such

case, remote the connecting hinge pins between topmost standard section and the

second topmost standard section as per step ⑧ of Figure 7.4-1.

4-154 T2850-120V-138Z-A01 Erection & Dismantling

 Figure 8.4-2 Disassembling of tower body (II)

4) As per step ① of Figure 7.4-2, slowly extend the jacking cylinders to hoist the

standard section already connected with the hoisting frame, till two standard
sections are completely separated. In such case, stop the jacking and rotate the

handwheel of feeding system to push out the standard section as per step ② of

Figure 7.4-2. Then, retract the jacking cylinders to appropriate position as per steps

④ and ⑤ of Figure 7.4-2 and rotate the footplate change joystick to lower the

footplate change hangers onto the footplates I.

5) Ensure that four footplate change hangers are accurately compressed onto the
grooves of footplates I and are carrying the weight of the climbing frame and its

Erection & Dismantling T2850-120V-138ZW-A 4-155

 structure above. Unplug the safety pins of jacking crossbeams as per step ⑥ of

Figure 7.4-2, extend the cylinders to attach the jacking crossbeams onto the

grooves of footplates E as per step ⑦, and insert the safety pins.

6) Slowly extend the cylinders in such manner that the footplate change hangers are
slightly higher than the top plane of footplates I, rotate the footplate change joystick
to swing outward the footplate change hangers to inclined status. After the proper
rotation, push the footplate change joystick against the footplate change hangers
to prevent rotation.
7) Retract the cylinders to appropriate position, rotate the footplate change joystick to
swing inward the footplate change hangers to vertical status and lower the

footplate change hangers onto the footplates H as per step ⑧ of Figure 7.4-2.

Figure 7.4-3 Disassembling of Tower Body (III)

4-156 T2850-120V-138Z-A01 Erection & Dismantling
 8) Operate as per the steps 5~7, till the footplate change hangers are attached to the
grooves of footplates E and the jacking crossbeams are finally attached to the

grooves of footplates C. Slowly extend the cylinders as per step ① of Figure 7.4-

3 and jack the climbing frame in such manner that the footplate change hangers
are slightly higher than the footplates E of standard section. Rotate the footplate

change joystick as per steps ② and ③ of Figure 7.4-3 to swing outward the

footplate change hangers to inclined status. After the proper rotation, push the
footplate change joystick against the footplate change hangers to prevent rotation.

Extend the cylinders as per step ④ of Figure 7.4-3 to attach the jacking

crossbeams onto the grooves of footplates B. Continue to retract the cylinders as

per step ⑤ of Figure 7.4-3 till the transitional section is placed on the standard

section of tower body, align the connecting holes, and knock 8 Ø105 hinge pins
into the holes. Notice to basically align the mounting holes on the ends of hinge
pins with the small holes on the transitional section before the knocking. After

installation, insert small hinge pins and spring pins, as shown in step ⑥ of Figure

7.4-3.
9) Start the hoisting mechanism to lower the leveling standard section (or other load)
onto the ground, start the luffing mechanism, and hoist the standard section to the
ground by trolley hook and special feeding hook. To disassemble several standard
sections continuously, 8 Ø105 connecting hinge pins between tower body and
lower support can be replaced by 8 temporary hinge pins smaller than standard
hinge pins (Caution: Install 1 pin for every outrigger). Repeat the operations with
reference to above-mentioned procedure. At completion of disassemble, bear in
mind to replace the 4 temporary hinge pins with 8 standard connecting hinge pins.
Caution: While lowering the climbing frame, ensure to assign special
personnel to observe the jacking crossbeams, footplate change hangers,
and guide wheels and observe for blockage of any obstacle during lowering
of climbing frame, in order to ease the smooth lowering of the climbing frame.
10) Repeat above-mentioned operations to disassemble the standard sections of
Erection & Dismantling T2850-120V-138ZW-A 4-157
 tower body one by one.
11) After the tower body is disassembled to the installation height, continue to
disassemble the head (Such as balance boom and boom) of tower crane. Refer to
subsequent sections for details.

8 Attachments of Tower Crane

None in this chapter.

9 Disassembling of Tower
Precautions for disassembling of tower
1) Before disassembling the tower of the tower crane, as the jacking mechanism is
not used for a long time, perform the maintenance and test run for the jacking
system.
2) During the test run, intentionally check the reliability of limiters and slewing
mechanism brake.
3) It’s prohibited to operate the slewing mechanism, luffing mechanism, and hoisting
mechanism before the transitional section and the tower body are connected by
high strength hinge pins when the standard sections of the tower crane are
disassembled.
4) The disassembling of tower crane is a heavy-load continuous operation for the
jacking mechanism. Therefore, frequently check the main load-carrying parts of
the jacking mechanism.
5) During the working of jacking mechanism, all operation personnel shall
concentrate to observe all relative motion parts for normal relative positions (Such
as the motions between rollers and main chord members and between climbing
frame and tower body). In event of any deflection between climbing frame and
tower body during the lifting of climbing frame, stop the jacking and immediately
lower the climbing frame.
6) The wind speed at highest point of tower during disassembling shall not exceed
14m/s. As the constructions are completed and the working site is restricted during
the disassembling of tower crane, notice the hoisting and piling positions of

4-158 T2850-120V-138Z-A01 Erection & Dismantling

 workpieces. Take cautions during operations, otherwise it will easily result in
personal safety accidents.
Warning:
1) While disassembling the tower, the user shall strictly operate as per the
requirements of this manual. The operation personnel of the tower crane must be
trained personnel with corresponding certificate. Any negligence will result in
machine damage and personal casualties.
2) Four footplate change hangers probably can’t automatically restore to level status
due to causes such as rust. While feeding or disassembling the standard sections,
pay special attention to the footplate change hangers and check and maintain in
advance.
3) Rotate the tower crane to the disassembling zone. The disassembling zone shall
be free of any obstacle that will influence the operations. Disassemble the tower
crane in sequence shown in Figure 9.1-1. This procedure is reverse to the
assembling procedure for erection of tower. Ensure to strictly abide by the
requirements of this operation manual. Any violation is strictly prohibited.

Figure 9.1-1 Disassembling of Tower Crane

The disassembling procedure of tower crane is as below:

(1) Disassemble the standard sections.
(2) Disassemble the warning lamp, anemoscope, and camera.
Erection & Dismantling T2850-120V-138ZW-A 4-159
 (3) Disassemble the hook and hoisting wire rope.
(4) Disassemble the luffing wire ropes.
(5) Disassemble the counterweights and maintain four 11.5t counterweights.
(6) Disassemble the boom assembly (From boom section VIII to boom tip section).
(7) Disassemble one counterweight.
(8) Disassemble boom section VII.
(9) Disassemble one counterweight.
(10) Disassemble boom section VI
(11) Disassemble one counterweight.
(12) Disassemble boom section V
(13) Disassemble one counterweight.
(14) Disassemble boom section IV
(15) Disassemble derrick mast.
(16) Disassemble the hoisting mechanism.
(17) Disassemble boom section III
(18) Disassemble the balance boom section II.
(19) Disassemble the boom section II and load trolley.
(20) Disassemble the balance boom section I.
(21) Disassemble boom section I
(22) Disassemble the upper support assembly.
(23) Disassemble the lower support and slewing support.
(24) Disassemble the transitional section and feeding system.
(25) Disassemble the climbing frame.
(26) Disassemble the remaining tower sections.
(27) Disassemble the traveling underframe.
(28) Disassemble the traveling mechanism.

9.1 Disassembling of Standard Sections

Disassemble the standard sections one by one as per procedure in 7.5.

4-160 T2850-120V-138Z-A01 Erection & Dismantling

 9.2 Disassembling of Warning Lamp and Anemoscope
(1) Disassemble the warning lamp at position I in Figure 4.27-1.
(2) Disassemble the camera at position II in Figure 4.27-1.
(3) Disassemble the anemoscope at position III in Figure 4.27-1.

9.3 Disassembling of Hook and Hoisting Wire Rope

The disassembling of hoisting wire rope is reverse to the enwinding procedure.
Please refer to section 4.25.
(1) Move the load trolley by luffing mechanism to the boom tip and lower the hook
onto the prepared temporary bracket on the ground to relieve the tension of wire rope.
(2) Fix the hoisting rope by fixed rope clamps onto the load trolley and remove the
wedge connector from the twist control device.
(3) Slowly start the hoisting mechanism to lift the hook by approximately 1m off the
ground and check the hoisting rope for secure fixing.
(4) Move the load trolley by luffing mechanism to the boom root and lower and fix the
hook onto the temporary bracket.
(5) Disconnect the hoisting rope and wedge connector and loosen the fixed rope
clamps.
(6) Slowly start the hoisting mechanism, remove the hoisting wire rope from hook,
pulley block of load trolley, hoisting load limiter pulley, and tower top guide pulley in turn,
and finally retract it to the hoisting mechanism.

9.4 Disassembling of Luffing Wire Ropes

Fix the trolley to the root of boom section II by 2 hinge pins and disassemble the long
and short luffing wire ropes in reverse sequence of the Figure 4.26-1 and Figure 4.26-2.

9.5 Disassembling of Counterweights

Fix the trolley to the boom root and disassemble the counterweights with the use of
an auxiliary crane. In reverse sequence of the installation procedure of counterweights,
remove the counterweights in turn and only leave four counterweights (46t).

9.6 Disassembling of Boom (From boom section VIII to boom tip

Erection & Dismantling T2850-120V-138ZW-A 4-161

 section)
(1) Hoist the boom by a truck crane or other crane as per section 4.23.
(2) Remove two high strength bolts M30 from lower chord members of boom section
VII and boom section VIII.
(3) Slightly hoist the boom, till two Ø51 pin holes on the lower chord member of
boom section VIII are unplugged from two Ø51 pins on lower chord member of boom
section VII.
(4) Disassemble one Ø90 hinge pin from upper chord members of boom section
VIII and boom section VII.
(5) Lower the boom and place it on the prepared support.

9.7 Disassemble one counterweight.

Fix the trolley to the boom root and disassemble the counterweights with the use of
an auxiliary crane. In reverse sequence of the installation procedure of counterweights,
remove the counterweight and leave three counterweights (34.5t).

9.8 Disassemble boom section VII

The disassembling method is same with section 9.6.

9.9 Disassemble one counterweight.

The disassembling method is same with section 9.7

9.10 Disassemble boom section VI

The disassembling method is same with section 9.6

9.11 Disassemble one counterweight.

The disassembling method is same with section 9.7

9.12 Disassemble boom section V

The disassembling method is same with section 9.6

9.13 Disassembling of Counterweights

The disassembling method is same with section 9.7

4-162 T2850-120V-138Z-A01 Erection & Dismantling

 9.14 Disassemble boom section IV
The disassembling method is same with section 9.6

9.15 Disassemble derrick mast

Refer to section 4.14 for the disassembling of derrick mast.

9.16 Disassemble the hoisting mechanism.

Refer to section 4.13 for the disassembling of derrick mast.

9.17 Disassemble boom section III

The disassembling method is same with section 9.6

9.18 Disassemble boom section II.

Disassemble the balance boom section II in reverse sequence of the procedure in
section 4.11.

9.19 Disassemble boom section II

The disassembling method is same with section 9.6

9.20 Disassemble the balance boom section I.

Disassemble the balance boom section II in reverse sequence of the procedure in
section 4.9.

9.21 Disassemble boom section I

(1) Arrange the wire rope as per Figure 4.8-2 and remove four Ø180 hinge pins
between boom section I and upper support.
(2) Lower the boom and place it on the prepared support.

9.22 Disassembling of Slewing Assembly

(1) Remove the connecting cables and control cables between slewing assembly and
tower crane.
(2) Remove the connecting hinge pins between lower support and transitional section.
(3) Hoist the slewing assembly and place it onto the ground.
(4) Alternatively, disassemble the upper support assembly, lower support, and
slewing support assembly in reverse sequence of the procedure in section 4.7.

Erection & Dismantling T2850-120V-138ZW-A 4-163

 9.23 Disassembling of Feeding System and Transitional Section
(1) Hoist the feeding system by a truck crane, remove the connecting hinge pins
between feeding system and transitional section, and hoist the feeding system and place
it onto the ground.
(2) Hoist the climbing frame by a truck crane, remove the connecting hinge pins
between climbing frame and transitional section, support the footplate change hangers
onto the 5th footplates of tower body (Counted from top to bottom), and remove the
connecting hinge pins between transitional section and standard section.
(3) Hoist the transitional section and place it onto the ground.

9.24 Disassembling of Climbing Frame and Remaining Tower

Sections
(1) Hoist the climbing frame slowly along the main chord members of standard
section and place it onto the ground.
(2) Hoist out the remaining tower sections in turn.

9.25 Disassemble the traveling underframe.

Disassemble the traveling underframe to basic section, struts, and underframe
with reference to section 4.2 and place them onto the ground.

9.26 Disassemble the traveling mechanism.

Break up the traveling mechanism with reference to section 4.1 to ease the
transportation.

10 Precautions after Disassembling of Tower

(1) After the disassembling of tower crane, check by engineering technicians and
professional repair personnel.
(3) Check the main load-carrying structural parts for metallic fatigue, weld cracking,
and structural deformation and check all parts of tower crane for damage and collision.
(3) After checking, repair the defects and potential problems and take the anti-rust
treatment or apply paint.

4-164 T2850-120V-138Z-A01 Erection & Dismantling

 ⑦
Operation & Safety

Contents

1 Operation guide........................................................................................................... 1
1.1 Pre-check before the operation .......................................................................... 1
1.2 Requirement to the operators ............................................................................ 3
1.3 Attention for operation........................................................................................ 4
1.4 Attention of out-of-service .................................................................................. 6
2 Safety device............................................................................................................... 7
2.1 Summary............................................................................................................ 7
2.2 Adjusting ............................................................................................................ 8
2.3 Test ........................................................................................ 错误!未定义书签。
3 Cabin......................................................................................................................... 26
3.1 Cabin structure................................................................................................. 26
3.2 Driver operation action ..................................................................................... 28
4 Spare parts list ................................................................................ 错误!未定义书签。
4.1 Transmission mechanism ...................................................... 错误!未定义书签。
4.2 Electrical control system ........................................................ 错误!未定义书签。
4.3 Others .................................................................................... 错误!未定义书签。

T2850-120V-138Y-A02
 Operation & Safety

1 Operation guide
1.1 Pre-check before the operation

Checking item Checking description

(1) Check all connecting bolts and pressure plates of foundation for proper
installation and secure locking.
Foundation (2) Check the safety distance between power transmission line and maximum
rotating part of tower crane.
(3) Check the orientation of cables and check for damages.
(1) Check the connecting hinge pins of standard section for proper installation
Tower body
and secure locking.
(1) Check the connection status with transitional section .
(2) Check the rollers and footplate push rods for high flexibility and reliability
Climbing frame and for secure connection.
(3) Check the fastening status of walkways and railings.
(4) Check the feeding trolley for high flexibility and reliability.
(1) Check the fastening status of connecting bolts for slewing support.
(2) Check the orientation of cables.
(3) Check the installation status of connecting hinge pins between upper
Upper/lower support support and balance beam and between lower support and transitional
Cab section.
(4) Check the connection status of cab.
(5) It’s prohibited to store lubricating oil, oil cotton yarn, or other inflammable
in the cab.
(1) Check the installation correctness of all connecting hinge pins, washers,
and split pins.
Boom (2) Check the installation and operation status of load trolley.
(3) Check the enwinding and fastening status of hoisting and luffing wire
ropes.
(1) Check the fastening status of balance boom.
Balance boom (2) Check the installation status of balance boom railings and walkways and
ensure that the walkways have no sundries.
(1) Check the magnification change device and the rope falloff limiter of hook
for safety and reliability.
(2) Check the hook subassembly for presence of defect that influences the
Slings operation.
(3) Check the specifications and models of hoisting and luffing wire ropes
against the requirements.
(4) Check the wear status of wire ropes.
Mechanisms (1) Check the installation and operation status of all mechanisms.
(2) Check the brakes of all mechanisms for appropriate clearance.
(3) Check whether at least 3 safety turns of wire rope are left on the drum of
traction mechanism when the load trolley is operated to the minimum and
Operation & Safety T2850-120V-138Y-A02 7-1
 Checking item Checking description

maximum ranges.
(4) Check the compressed ends of all wire ropes for looseness.
(1) Check and ensure that all safety protection devices are properly adjusted
as per the requirements of this manual.
Safety devices
(2) Check the installation and fastening status of all ladders, railings, and rest
platforms on the tower crane.
(1) Ensure the intactness of all wire ropes.
(2) Ensure that all wire ropes are correctly enwound in the pulley grooves.
(3) Check the wire ropes for well lubrication.
Wire ropes (4) Ensure that the wire ropes are correct enwound on the drums.

(1) Ensure to readjust the limiter after each jacking operation.

Height limiter (2) Ensure to readjust the limiter after change of boom length.
(3) Adjust the limiter after a period of use of wire ropes.
(1) Ensure that the insulation resistance of main circuit control circuit to
ground is no less than 0.5MΩ.
Electric system
(2) Ensure that the grounding resistance of the tower body is no more than
4Ω.
(1) Check the wind speed.
 The maximum permissible wind speed during working of tower crane is
20m/s (Level 8).
 The maximum permissible wind speed during erection and jacking of
tower is 14m/s (Level 6).
(2) Check the environment temperature. The temperature range for the
normal working of tower crane is -20~+40ºC.
(3) Ensure that the working voltage of the tower crane is 380±10%.
(4) Check the spacing of tower crane from surrounding buildings.

Routine checking

(5) Ensure that the all ballasts and counterweights meet the quantity
requirement and are correctly arranged.
(6) Check the tower crane foundation for intactness.
(7) Ensure that all safety labels are intact and legible.
(8) Ensure that all gears (such as slewing support) are well lubricated.
(9) Check all safety devices for reliability.
(10) If the lightning protection device is installed, ensure the correct ground of
the tower crane.

7-2 T2850-120V-138Y-A02 Operation & Safety

1.2 Requirement to the operators

(1) Operators must be aged over 18.

(2) Operators should have healthy body and mind.
(3) The tower operator must have been trained, be familiar with the tower cranes and
qualified.
(4) No drinking or taking psychotropic drugs before operating the tower crane.
(5) Operators must comply with the regulations of the country where the tower crane is.
(6) Operators must make record of the tower crane usage, maintenance and shift
handover.

Operation & Safety T2850-120V-138Y-A02 7-3

1.3 Attention for operation

(1) Operate the crane only if all of the safety devices are in good condition.
(2) Adjust the limiters according to the instruction handbook strictly.
(3) Sufficient lighting shall be provided to the working area for night working.
(4) Keep all platforms, rung ladders, rails and handrails from dirt.
(5) No unauthorized persons are allowed to climb the crane!
(6) People who have been approved can climb up or down the tower crane after the
tower operators stopping the crane!
(7) Try running before working, work after confirming the tower crane is in good
condition.
(8) Whistle before action every time.
(9) Don’t lay the hook onto the ground in order to avoid disordering the ropes.
(10) Operators should give some relevant warning signals on occasion.
(11) Stop working immediately once some defects harming tower crane operation safety
are found.

(12) People are strictly prohibited from standing under the jib when the jib is
hoisting!
(13) It is forbidden to dismantle the connecting pivots between slewing support
and tower section when the tower crane is unbalanced.
It is forbidden to dismantle the connecting pivots between slewing support
and tower section when the climbing frame and slewing support is not
connected.
(14) Loading persons is forbidden.
(15) No over loading even if overload protector is installed.
(16) Avoid any operation that might be a risk to the stability of the crane, for
example:

7-4 T2850-120V-138Y-A02 Operation & Safety

 Loading a fixed object. Increasing the load after Loading at an angle.
lifting it.

Loading pendulously. Loading beyond the

rated lifting capacity

(17) Shift gears slowly from low gear to high gear during the operation, and
braking reversely during slewing and braking suddenly are forbidden.
(18) Don’t leave jobs when some hoisting loads are being lifted off the ground.
(19) Stop all hoisting operations barging up against thunderstorm, heavy rain,
thick mist or the top wind speed of the crane is higher than 20m/s.
(20) The operator must be able to observe the working area and the load.

(21) It is strictly forbidden to change the tower crane without permission of the
manufacturers!

Operation & Safety T2850-120V-138Y-A02 7-5

1.4 Attention of out-of-service

(1) Release the weathercock brake when the crane is out of service to let the
tower crane slew freely!
(2) For the travelling tower crane, fix the tower crane on the track using the rail
clamping device to avoid the crane move along the track!

7-6 T2850-120V-138Y-A02 Operation & Safety

2 Safety device
2.1 Summary

The safety device of the tower crane mainly consists of the travelling limiter and load
limiter. The former consists of the hook height limiter, slewing limiter, luffing limiter device.
The load limiter consists of the hoist load limiter and overload limiter.
The installation position of the safety devices on the tower crane are shown in
Fig.7.2-1.

Fig.7.2-1 Safety devices of the tower crane

Table 7.2-1 Note of the safety devices
No. Designation Position

1 hoisting height limiter Hoisting mechanism

2 Luffing Limiter Luffing mechanism

3 Ancillary hoisting height limiter Ancillary Hoisting mechanism

4 Mechanical load moment limiter Oblique beam of jib Ⅰ

5 Load cell Jib Ⅱ

6 Mechanical load limiter Jib Ⅱ

7 Slewing limiter turntable

Operation & Safety T2850-120V-138Y-A02 7-7

2.2 Adjusting Safety device

2.2.1 Multiple-function limiter

2.2.1.1 Adjustment procedure of multiple-function limiter

Hoisting height limiter、Luffing Limiter、 Ancillary hoisting height limiter and Slewing limiter
of this tower crane are respectively DXZ-A-W-Z2(1:274) 、 DXZ-A-W-Z2(1:274) 、
DXZ-A-W-Z2(1:274)、DXZ-A-W-Z2A(1:46), refer to Fig.7.2-5.

Fig.7.2-2 Limiter

Adjustment procedures of multiple-function limiter are as follow:

(1) Dismantle the upper cover, check and screw down 2-M3×55 screws.
(2) Unscrew M5 nuts.
(3) Drive the mechanism under control to a designed position (without load) for
requirements. At this time, the micro-switch should make transient change-over

7-8 T2850-120V-138Y-A02 Operation & Safety

 corresponding to the action of this mechanism i.e. adjust the corresponding axle (Z)
to make the memory gear (T) press down the contact point of the micro-switch (WK).
(4) Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will
occur).
(5) Make the mechanism operate under no-load condition again and again to check
memorized positions for accuracy (repeat the above adjustments in the case of
deviations);
(6) Make sure that the position is specified. Screw down M5 nuts and install the cover;
(7) After the mechanism working normally, check the position of the memory control
position for deviations in order to correct the deviations.

2.2.1.2 Adjustment method for the hoisting height limiter

Adjust in the no-load condition.

(1) Adjust as per the adjustment procedure in (1).

(2) Press down micro-switches (3WK and 4WK) to check the hoisting or lowering
micro-switch for correct actions.
(3) Ensure the distance between the hook and rope fixing end is not less than L1 (L1=4m
for 8 fall, L1=6m for 4 fall, L1=10m for 2 fall), then adjust axes (3Z) to make the cam
(3T) act to press down the micro-switch (3WK) which make the hoisting speed
instantaneous shift from 5 to 1, refer to Fig.7.2-3.
(4) In condition of L2 (L2=1m for 8 fall, L2=1.1m for 4 fall, L2=1.2m for 2 fall) between the
hook and rope fixing end, adjust axes (4Z) to make the cam (4T) act to press down
the micro-switch (4WK) to stop power of the hoisting motor in movement, screw down
the nut M5, refer to Fig.7.2-3.
(5) Customers could adjust the lowering limiter by 2WK to avoid operation errors and
make the hoisting hook stop lowering movement before the hook touching the ground
(no less than three-round steel ropes on the wire drum). The micro-switch (1WK)
which make the hoisting speed instantaneous shift from 5 to 1, The adjustment
method is the same as this section.
Operation & Safety T2850-120V-138Y-A02 7-9
 Fig7.2-3 Adjustment for hoisting height limiter

Readjust the height limiter after changing fall, otherwise it may lead to hook
crushing into the jib, rope breaking, machine damage, personal injury even death.

2.2.1.3 Adjustment Method for Slewing Limiter

a. Adjust the slewing limiter while the cable is under free status.
b. Perform the adjustment under unloaded condition. Push down the micro-switch (WK)
by finger one by one to ensure that the micro-switch (WK) for left/right direction
control works normally.
c. Slew to the left for 360° (1 rounds). Adjust the axes (3Z) to make the cam (3T) turn to
the micro-switch (3WK) for the motor speed instantaneous shift from 5 to 1.Go on
continue slew to the left for 180° (0.5 rounds). Adjust the axes (4Z) to make the cam
(4T) turn to the micro-switch (4WK) for the motor stopping instantaneously.
7-10 T2850-120V-138Y-A02 Operation & Safety
d. Rotate 900° to right (2.5 rounds). Adjust the axes (1Z) to make the cam (1T) turn to
the micro-switch (1WK) for the motor speed instantaneous shift from 5 to 1.Go on
continue slew to the right for 180° (0.5 rounds). Adjust the axes (2Z) to make the
cam (2T) turn to the micro-switch (2WK) for the motor stopping instantaneously. And
screw down M5 nuts.
e. Check whether the left and right slewing is correct.

2.2.1.4 Adjustment Method for Range Limiter

a. Outward luffing deceleration and boom tip limit

Move the load trolley to the position 5m reach from the limit outrigger of boom tip,
adjust the shaft (1Z) to rotate the memory cam (1T) to the actuation changeover of
micro-switch (1WK) ( During the adjustment, overlap the cam (3T) with cam (1T) in order
to prevent the deceleration interference before braking), and tighten the nuts M5. Then,
move the load trolley to the position 200mm reach from the limit outrigger of boom tip,
adjust the shaft (2Z) as per the procedure to rotate the memory cam (2T) to the actuation
of micro-switch (2WK), and tighten the nuts M5.
b. Inward luffing deceleration and boom root limit
The adjustment method is same with “a”. Adjust the deceleration and boom root limit
(3Z-3T-3WK and 4Z-4T-4WK) at the positions 5m and 200mm reach from the limit
outrigger of boom root respectively. And screw down M5 nuts.
c. Verify and correct.

2.2.1.5 Adjustment Method for Auxiliary Hoisting Limiter

The adjustment method for auxiliary hoisting limiter is same with that for hoisting
limiter.

Operation & Safety T2850-120V-138Y-A02 7-11

2.2.2 Load moment limiter

2.2.2.1 Mechanical load moment limiter

1-Mounting block 2-Spring plate 3-Travel switch 4-Adjustment screw 5-Lock nut
Figure 7.2-4 Moment Limiter
This machine is equipped with mechanical moment limiter. When the hoisting
moment reaches approximate 90% of the rated value, the pre-warning lamp of the cab
turns on. When the moment reaches 100%~110% of the rated value, the lifting and the
outward luffing of the trolley will be disabled and the overload warning tone will sound.
As shown in Figure 7.2-4, the moment limiter is composed of two spring plates 2,
four travel switches 3, and four adjustment screws 4 and is fixed on the chord member at
the rear of the tower top by mounting block 1. If the tower top is deformed during the
working of the tower crane, the spacing between two spring plates is shortened to move
the adjustment screw and the adjustment screw touches the travel switch so that the
corresponding moment alarm will sound and the lifting circuit of tower crane and the
outward luffing circuit of the trolley will be cut off, which plays the protection role of
7-12 T2850-120V-138Y-A02 Operation & Safety
moment limiting.
(1) Adjustment of moment limiter
Inspection method and requirements: Take the value as per Appendix D Safety
Device Test Method to the Tower Crane and measure the ranges under no-load
condition by the fixed-range variable-load method and fixed-load variable-range
method respectively.

 Adjustment by fixed-range variable-load method

Hoist the rated hoisting load Q0 (19.74t) at maximum working range R0 (85m) and

normal working speed and adjust the screw III in Figure 7.2-4. The moment limiter shall
not actuate and the hoisting is allowed. After the unloading, hoist a load 1.1 times of the

rated hoisting load (1.1 Q0 (21.71t)) at lowest speed. The moment limiter shall actuate so

that the hoisting is restrained and a warning signal is outputted. b) Hoist a load 0.7 times

of rated hoisting load (0.7 Qm (84t)) at maximum permissible working range R0.7

(30.1m) and normal working speed. The moment limiter shall not actuate and the
hoisting is allowed. After the unloading, hoist a load 0.77 times of the rated hoisting load

(0.77 Qm (92.4t)) at lowest speed under same range. The moment limiter shall actuate

so that the hoisting is restrained and a warning signal is outputted.

Adjust in the 8-fall condition.

a) 100% load moment limit adjustment
adjusting screw

Ⅰ Ⅱ Ⅲ Ⅳ Load moment limit switch response

Jib Response Three-

Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light
85 19.74 85 - - - 1~4 di-di √ - yellow

80 25.74 80 - - - 1~4 di-di √ - yellow

70 31.50 70 - - - 1~4 di-di √ - yellow

60 39.21 60 - - - 1~4 di-di √ - yellow

Operation & Safety T2850-120V-138Y-A02 7-13

 50 50.11 50 - - - 1~4 di-di √ - yellow

Note：
 “-” means no limitation.
 “×” means no permission.
 “1~4” means only shift 1~4 of permission.
b) 110% load moment limit adjustment
adjusting screw

Ⅰ Ⅱ Ⅲ Ⅳ Load moment limit switch response

√
Jib Response Three-
Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light

85 21.71 85 × 1 1 × di-di-di-di √ √ red

80 28.31 80 × 1 1 × di-di-di-di √ √ red

70 34.65 70 × 1 1 × di-di-di-di √ √ red

60 43.13 60 × 1 1 × di-di-di-di √ √ red

50 55.12 50 × 1 1 × di-di-di-di √ √ red

Note：
 “-” means no limitation.
 “×” means no permission.
 “1” means only shift 1 of permission.

c) 0.7 Qm 1 load moment limit adjustment

adjusting screw

Ⅰ Ⅱ Ⅲ Ⅳ Load moment limit switch response

Jib
Response Three-
lengt Load Hoisting Hoisting Luffing Luffing Warning
point Buzzer Horn color
h W(t) up down inward outward light
R1(m) light
(m)

85 84 30.1 - - - 1~4 di-di √ - yellow

80 84 33.2 - - - 1~4 di-di √ - yellow

70 84 33.2 - - - 1~4 di-di √ - yellow

60 84 33.2 - - - 1~4 di-di √ - yellow

50 84 33.2 - - - 1~4 di-di √ - yellow

Note：
 “-” means no limitation.
7-14 T2850-120V-138Y-A02 Operation & Safety
  “×” means no permission.
 “1~4” means only shift 1~4 of permission.

d) 0.7 Qm 110% load moment limit adjustment

adjusting screw

Ⅰ Ⅱ Ⅲ Ⅳ Load moment limit switch response

Jib Response Three-

Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light

85 92.4 30.1 × 1 1 × di-di-di-di √ √ red

80 92.4 33.2 × 1 1 × di-di-di-di √ √ red

70 92.4 33.2 × 1 1 × di-di-di-di √ √ red

60 92.4 33.2 × 1 1 × di-di-di-di √ √ red

50 92.4 33.2 × 1 1 × di-di-di-di √ √ red

Note：
 “-” means no limitation.
 “×” means no permission.
 “1” means only shift 1 of permission.

(2) Variable radius with constant load

The maximum rated weight Qm of the maximum rated weight is the value of the work

amplitude 0.8 Rm 、0.9 Rm 、 Rm 及 1.1 Rm and is marked on the ground.

a) 80% load moment limit adjustment

Load moment limit switch
response
Load moment limit switch response
Ⅰ Ⅱ Ⅲ Ⅳ

√
Jib Response Three-
Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light

85 120 17.84 - - - 1~4 - √ - yellow

80 120 19.70 - - - 1~4 - √ - yellow

70 120 19.70 - - - 1~4 - √ - yellow

Operation & Safety T2850-120V-138Y-A02 7-15

 60 120 19.70 - - - 1~4 - √ - yellow

50 120 19.70 - - - 1~4 - √ - yellow

Note：
 “-” means no limitation.
 “×” means no permission.
 “1~4” means only shift 1~4 of permission.

b) 90% load moment limit adjustment

Load moment limit switch
response
Load moment limit switch response
Ⅰ Ⅱ Ⅲ Ⅳ

√
Jib Response Three-
Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light

85 120 20.07 - - - 1~4 di-di √ - yellow

80 120 22.16 - - - 1~4 di-di √ - yellow

70 120 22.16 - - - 1~4 di-di √ - yellow

60 120 22.16 - - - 1~4 di-di √ - yellow

50 120 22.16 - - - 1~4 di-di √ - yellow

Note：
 “-” means no limitation.
 “×” means no permission.
 “1~4” means only shift 1~4 of permission.

c) 100% load moment limit adjustment

Load moment limit switch
response
Load moment limit switch response
Ⅰ Ⅱ Ⅲ Ⅳ

Jib Response Three-

Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light

85 120 22.30 - - - 1~4 di-di √ - yellow

80 120 24.62 - - - 1~4 di-di √ - yellow

70 120 24.62 - - - 1~4 di-di √ - yellow

7-16 T2850-120V-138Y-A02 Operation & Safety

 60 120 24.62 - - - 1~4 di-di √ - yellow

50 120 24.62 - - - 1~4 di-di √ - yellow

Note：
 “-” means no limitation.
 “×” means no permission.
 “1~4” means only shift 1~4 of permission.

d) 110% load moment limit adjustment

Load moment limit switch
response
Load moment limit switch response
Ⅰ Ⅱ Ⅲ Ⅳ

√
Jib Response Three-
Load Hoisting Hoisting Luffing Luffing Warning
length point Buzzer Horn color
W(t) up down inward outward light
(m) R1(m) light

85 120 22.30~24.53 × 1 1 × di-di-di-di √ √ red

80 120 24.62~27.08 × 1 1 × di-di-di-di √ √ red

70 120 24.62~27.08 × 1 1 × di-di-di-di √ √ red

60 120 24.62~27.08 × 1 1 × di-di-di-di √ √ red

50 120 24.62~27.08 × 1 1 × di-di-di-di √ √ red

Note：
 “-” means no limitation.
 “×” means no permission.
 “1” means only shift 1 of permission.

2.2.2.2 Leading Seal of the load moment limiter

Assembly the protection cover of load moment limit switch after adjustment and
verification, pass the wire through the hole of the protection cover and apply lead
sealing.

2.2.3 Load limiters

The hoisting load limiter is shown in Figure 7.2-5. 8X magnification is used during

Operation & Safety T2850-120V-138Y-A02 7-17

adjustment.

1, 3, 5, 7 - Screw adjustment device 2, 4, 6, 8 - Micro-switch

Figure 7.2-5 Hoisting Load Limiter

The load limiter consists of arch plates, four limiters, adjusting screws and so on,
shown in Fig.7.2-5. To make the tower crane work at safety load by adjusting the
distance between the screws and limiters.
Adjusting mechanical load limiter for hoisting

(1) Ⅴ-speed adjustment

a. Hoist and lower the hook for one time at positions II, III, IV and V respectively. The
failure to hoist or lower the hook at any position is disallowed.

b. 6.7% rated load at high speed

adjusting screw
1 3 5 7 起重量限制器动作
√
Three-
Load Sling point Hoisting Hoisting Luffing Luffing Warning
fall Buzzer Horn color
W(t) R1(m) up down inward outward light
light
2 2 10 - - - - - - - -
4 4 10 - - - - - - - -
8 8 10 - - - - - - - -
Note：
 “-” means no limitation.

7-18 T2850-120V-138Y-A02 Operation & Safety

c. 7% rated load at high speed
adjusting screw
1 3 5 7 起重量限制器动作
√
Sling Three-
Load Hoisting Hoisting Luffing Luffing Warning
fall point Buzzer Horn color
W(t) up down inward outward light
R1(m) light
Over
2 2.1 10 1~4 1~4 - - - √ - gears
yellow
Over
4 4.2 10 1~4 1~4 - - - √ - gears
yellow

Over
8 8.4 10 1~4 1~4 - - - √ - gears
yellow

Note：
 “-” means no limitation.
 “1~4” means only shift 1~4 of permission.

(2) Ⅳ-speed adjustment

a． Hoist and lower the hook for one time at positions II, III, and IV respectively. The
failure to hoist or lower the hook at any position is disallowed.
b． 25% rated load at high speed
adjusting screw
1 3 5 7 Load limit switch response
√
Sling Three-
Load Hoisting Hoisting Luffing Luffing Warning
fall point Buzzer Horn color
W(t) up down inward outward light
R1(m) light
Over
2 7.5 10 1~4 1~4 - - - √ - gears
yellow
Over
4 15 10 1~4 1~4 - - - √ - gears
yellow

Over
8 30 10 1~4 1~4 - - - √ -
gears

Operation & Safety T2850-120V-138Y-A02 7-19

 adjusting screw
1 3 5 7 Load limit switch response
√

yellow

Note：
 “-” means no limitation.
 “1~4” means only shift 1~4 of permission.

c．26.5% rated load at high speed

adjusting screw
1 3 5 7 Load limit switch response
√
Sling Over
Load Hoisting Hoisting Luffing Luffing Warning
fall point Buzzer Horn gears
W(t) up down inward outward light
R1(m) yellow

1~4 1~4 Over

2 7.95 10 1~3 1~3 - √ - gears
yellow

1~3 1~3 1~4 1~4 Over

4 15.9 10 - √ - gears
yellow

1~3 1~3 1~4 1~4 Over

8 31.8 10 - √ - gears
yellow
 “-” means no limitation.
 “1~3” means only shift 1~3 of permission.
 “1~4” means only shift 1~4 of permission.

(3) Ⅲ-speed adjustment

a. Hoist and lower the hook for one time at positions II and III respectively. The failure to
hoist or lower the hook at any position is disallowed.
b. 50% rated load at high speed
adjusting screw
1 3 5 7 Load limit switch response
√
Sling
Load Hoisting Hoisting Luffing Luffing Warnin Three-
fall point Buzzer Horn
W(t) up down inward outward g light color light
R1(m)
Over gears
2 15 10 1~3 1~3 1~4 1~4 - √ -
yellow

7-20 T2850-120V-138Y-A02 Operation & Safety

 adjusting screw
1 3 5 7 Load limit switch response
√
Over gears
4 30 10 1~3 1~3 1~4 1~4 - √ -
yellow

Over gears
8 60 10 1~3 1~3 1~4 1~4 - √ -
yellow

Note：
 “-” means no limitation.
 “1~3” means only shift 1~3 of permission.
 “1~4” means only shift 1~4 of permission.

c. 52.5% rated load at high speed

adjusting screw
1 3 5 7 Load limit switch response
√
Sling Three-
Load Hoisting Hoisting Luffing Luffing Warning
fall point Buzzer Horn color
W(t) up down inward outward light
R1(m) light
Over gears
2 15.75 10 1~2 1~2 1~3 1~3 √ - yellow
bumming
Over gears
4 31.5 10 1~2 1~2 1~3 1~3 √ - yellow
bumming
Over gears
8 63 10 1~2 1~2 1~3 1~3 √ - yellow
bumming
 “-” means no limitation.
 “1~2” means only shift 1~2 of permission.
 “1~3” means only shift 1~3 of permission.

(4) Ⅱ-speed adjustment

a. Hoist and lower the hook for one time at position II. The failure to hoist or lower the
load is disallowed.
b. 100% rated load at low speed
adjusting screw
1 3 5 7 Load limit switch response

Sling Three-
Load Hoisting Hoisting Luffing Luffing Warning
fall point Buzzer Horn color
W(t) up down inward outward light
R1(m) light

Operation & Safety T2850-120V-138Y-A02 7-21

 adjusting screw
1 3 5 7 Load limit switch response

2 30 10 1~2 1~2 1~3 1~3 Di √ - yellow

4 60 10 1~2 1~2 1~3 1~3 Di √ - yellow

8 120 10 1~2 1~2 1~3 1~3 Di √ - yellow

 “-” means no limitation.

 “1~2” means only shift 1~2 of permission.
 “1~3” means only shift 1~3 of permission.

(5) 110% rated load at low speed

a. Hoist and lower the hook for one time at position Ⅰ. The failure to hoist or lower the

load is disallowed.
c. 110% rated load at low speed
adjusting screw
1 3 5 7 Load limit switch response
√
Sling Three-
Load Hoisting Hoisting Luffing Luffing Warning
fall point Buzzer Horn color
W(t) up down inward outward light
R1(m) light

2 33 10 × 1 1~3 1~3 di-di-di √ - red

4 66 10 × 1 1~3 1~3 di-di-di √ - red

8 132 10 × 1 1~3 1~3 di-di-di √ - red

 “-” means no limitation.
 “×” means no permission.
 “1” means only shift 1 of permission.
 “1~3” means only shift 1~3 of permission.

2.2.4 Twist Control Device

(1) Structure of Twist Control Device
Its structure is shown in Figure 7.2-6, of which the right end is connected to boom
section VI by Ø65 hinge pin and the left wedge connector is connected to the hoisting
rope.

7-22 T2850-120V-138Y-A02 Operation & Safety

 Wedge connector

Wire rope clamp 32

Hoisting rope

Lock bolt

Figure 7.2-6 Structure of Twist Control Device

(2) Enwinding of Hoisting Rope (As shown in Figure 7.2-7)

Figure 7.2-7 Enwinding of Hoisting Rope of Twist Control Device

(3) Precautions
 If the hoisting rope is of no-rotation (twist-proof) wire rope, lock the lock bolt M20×90
of this twist control device while the tower crane is under working status.
 After the replacement with new wire rope, the hook will rotate under the unloaded
working condition. In such case, unlock the twist control device till the wire rope
rotates freely to be consistent with the hook.
 If the twist control device is under locked status, the long-term unloaded running will

Operation & Safety T2850-120V-138Y-A02 7-23

 generate twist along the full length of the wire rope, till the hook can’t rotate further.
 After the tower crane is under operation for a long period, the wire rope will elongate
and generate slight twist. In such case, temporarily unlock the twist control device
and tension the wire rope before re-locking the twist control device.
 Once the wire rope has any broken strand, the twist control device will accelerate the
destruction of the wire rope. In such case, timely replace the wire rope.
 The wedge connector on the twist control device is a non-standard connector
so that the GB/T5973-2006 conventional connectors can be used here. Our
company will not be liable for any consequence arising from the user’s use
without permission.

2.3 Test
Perform the following tests (even at the transfer of working site) in turn after the
assembling of the tower crane.

2.3.1 No-Load Test

Operate all mechanisms individually for several cycles and then in combination for
three cycles. All mechanisms shall be free of any abnormality during running and the
brakes, control systems, interlock devices, and limiters for all mechanisms shall motion
correctly and reliably. All malfunctions detected shall be timely solved.

2.3.2 Loaded Test

Hoist the loads 25%, 50%, 75%, and 100% of the rated hoisting load respectively at
the maximum working range and test as per the requirements of (1). All mechanisms
shall be free of any abnormality during running and the brakes, control systems, interlock
devices, and limiters for all mechanisms shall motion correctly and reliably.
(1) Static 25% Overload Test (8X magnification)
Perform the static overload test after the no-load test and the loaded test are
qualified. The test loads for the overload static test under diversified boom lengths are
listed in Table 7.2-2.
Table 7.2-2 Table of Range-Hoisting Loads for Static 25% Overload Test

Item
Range I (m) Hoisting load I (t) Range II (m) Hoisting load II (t)
Boom length

85m 22.30 150 85 24.68

7-24 T2850-120V-138Y-A02 Operation & Safety
 80m 24.62 150 80 32.18

70m 24.62 150 70 39.38

60m 24.62 150 60 49.01

50m 24.62 150 50 62.64

Hoist the corresponding hoisting loads at above-mentioned ranges I and II

respectively and lowest safe speed for 100~200mm off the ground, gradually add load to
the hook in turn to 1.25 times of rated hoisting load, and hold for 10min. After unloading,
check the metal structure and welds for permanent cracking, permanent deformation,
and loose connection. Caution: No luffing or slewing is allowed for the static overload
test.
(2) Dynamic 10% Overload Test (8X magnification)
Under the conditions of 85m range, 85m boom length, and 21.71t hoisting load, as
shown in Table 7.2-3, operate all mechanisms within corresponding full-travel ranges for
3 cycles. All mechanisms shall motion flexibly and the brakes shall motion reliably. All
mechanisms and structural parts shall be free of abnormality and all connections shall be
free of looseness and damage.
Table 7.2-3 Table of Range-Hoisting Loads for Static 10% Overload Test

Item
Range I (m) Hoisting load I (t) Range II (m) Hoisting load II (t)
Boom length
85m 22.30 132 85 21.71

80m 24.62 132 80 28.31

70m 24.62 132 70 34.65

60m 24.62 132 60 43.13

50m 24.62 132 50 55.12

Operation & Safety T2850-120V-138Y-A02 7-25

3 Cabin

The Topless tower crane T2850-120V configures cabin CP8S.

3.1 Cabin structure

1-Console 2-Windscreen wiper 3-Display 4-Top guard rail 5-Sling point

6-Electric control cabinet 7-Door
Fig.7.3-1 Cabin structure

7-26 T2850-120V-138Y-A02 Operation & Safety

 Fig.7.3-2 Glass of cabin

Table 7.3-1 Glass of cabin

No. Name of Glass Symbol Code Qty.

1 Front-down glass BL-CP8-QX 1139803057 1

2 Front-up glass BL-CP8-QS 1139803056 1

3 Top glass BL-CP8S-U 1139803309 1

4 Left side-up glass BLX-CP-CS/L 1139803380 1

5 Left side-middle glass BLX-CP-CT/L 1139803384 1

6 Left side-down glass BLX-CP-CX/L 1139803382 1

7 Glass for door BL-CP-M 1139802468 1

8 Right side-up glass BLX-CP-CS/R 1139803381 1

9 Right side-middle glass BLX-CP-CT/R 1139803385 1

10 Right side-down glass BLX-CP-CX/R 1139803383 1

Operation & Safety T2850-120V-138Y-A02 7-27

3.2 Driver operation action

Fig.7.3-3 Left combined operation board

Table7.3-2 Symbol explanation on the left combined operation board

Weather vane brake

Start indicator

Slewing braking

Bypass

Slewing anticlockwise

Slewing clockwise

7-28 T2850-120V-138Y-A02 Operation & Safety

 Luffing inward

Luffing outward

Fig.7.3-4 Right combined operation board

Table7.3-3 Symbol explanation on the right combined operation board

Horn

Emergency stop switch,

main power supply

going off

Restarting

Operation & Safety T2850-120V-138Y-A02 7-29

 Hoisting downwards

Hoisting upwards

7-30 T2850-120V-138Y-A02 Operation & Safety

 ⑨
Maintenances
Contents
1 Necessary Maintenances .................................................................................................... 1
1.1 Components Requiring Maintenances:.................................................................... 1
1.2 Checking during First Use of Tower Crane and before Each Erection of Tower .. 1
1.3 Daily Checking ........................................................................................................... 1
1.4 Weekly Maintenances................................................................................................ 2
1.5 Monthly Maintenances............................................................................................... 2
1.6 Half-Yearly Maintenances ......................................................................................... 2
1.7 Year Maintenances: ................................................................................................... 2
1.8 After 2,000 Working Hours or Two Years................................................................. 2
1.9 After 10,000 Working Hours...................................................................................... 3
1.10 Daily Maintenance .................................................................................................... 3
1.11 Introduction of Lubrication........................................................................................ 3
2 Maintenances of Hoisting Mechanism ............................................................................... 4
2.1 Overview ..................................................................................................................... 4
2.2 Maintenances of Motor .............................................................................................. 5
2.3 Maintenances of Reducer ......................................................................................... 7
2.4 Checking of Coupling................................................................................................. 7
2.5 Cause Analysis and Troubleshooting for Wire Rope Arrangement Problem of
Hoisting Mechanism ................................................................................................. 8
2.6 Adjustment of Main Brake ......................................................................................... 9
3 Maintenances of Luffing Mechanism................................................................................ 10
3.1 Overview ................................................................................................................... 10
3.2 Maintenances of Luffing Brake ............................................................................... 10
3.3 Maintenances of Motor ............................................................................................ 15
4 Maintenances of Main Brake and Safety Brake Caliper System................................... 17
4.1 Maintenances of Main Brake .................................................................................. 17
4.2 Maintenances of Safety Brake Caliper System..................................................... 36
4.3 Installation and Maintenances of Proximity Switch............................................... 50
5 Maintenances of Slewing Mechanism.............................................................................. 52
5.1 Overview ................................................................................................................... 52

T2850-120V-138Z-A02
 5.2 Slewing Brake .......................................................................................................... 53
5.3 Maintenances ........................................................................................................... 54
6 Maintenances of Traveling Mechanism ........................................................................... 57
6.1 Maintenances of Trolley .......................................................................................... 57
6.2 Maintenances of Motor............................................................................................ 57
6.3 Maintenances of Cable Drum ................................................................................. 62
6.4 Bearing Model .......................................................................................................... 63
6.5 Maintenances of Rail Clamps ................................................................................. 63
7 Maintenance of Auxiliary Mechanism .............................................................................. 71
7.1 Overview ................................................................................................................... 71
7.2 Adjustment and Maintenances of Brake................................................................ 72
7.3 Maintenances of Motor............................................................................................ 76
7.4 Maintenances of Reducer ....................................................................................... 76
7.5 Checking of Coupling .............................................................................................. 76
7.6 Cause Analysis and Troubleshooting for Wire Rope Arrangement Problem of
Auxiliary Mechanism .............................................................................................. 76
8 Lubrication .......................................................................................................................... 77
8.1 Overview ................................................................................................................... 77
8.2 Table of Lubricants .................................................................................................. 77
8.3 Lubrication of Slewing Support............................................................................... 77
9 Common Malfunctions and Troubleshooting................................................................... 79
10 Wire Rope ....................................................................................................................... 82
10.1 Basic Knowledge of Wire Rope............................................................................. 82
10.2 List of Wire Ropes .................................................................................................. 87
10.3 Length of Wire Ropes ............................................................................................ 88
10.4 Installation of Wire Ropes...................................................................................... 90
10.5 Scrap of Wire Rope ................................................................................................ 90
10.6 Maintenances of Wire Ropes ................................................................................ 97
11 Maintenances of Pulley Blocks......................................................................................... 98
11.1 Checking of Pulley Block Bearings ..................................................................... 98
11.2 Checking of Pulleys ................................................................................................ 99
11.3 Lubrication of Pulley Bearings............................................................................... 99
12 Hook .............................................................................................................................. 100
12.1 Opening Degree of Hook ..................................................................................... 100
12.2 Wear ...................................................................................................................... 100

T2850-120V-138Z-A02
12.3 Surface Cracking .................................................................................................. 100

T2850-120V-138Z-A02
 Maintenances
1 Necessary Maintenances
1.1 Components Requiring Maintenances:
(1) Hoisting mechanism
(2) Slewing mechanism
(3) Slewing support
(4) Climbing device
(5) Luffing mechanism
(6) Traveling mechanism
(7) Auxiliary mechanism
(8) Hook
1.2 Checking during First Use of Tower Crane and before Each
Erection of Tower
(1) Slewing support: Lubricate the raceway and gear teeth by grease.
(2) Check the wire rope and its fixed end.
(3) Check the hook.
(4) Climbing device: Lubricate the hinge pins and rollers by grease.
(5) Check the wire rope twist control device during the erection of tower each time.
(6) Ensure to apply lubricating grease to all hinge pins during the erection of tower each
time.
(7) Check all structural parts and connectors for intactness and completeness.
(8) Check all electronic control and safety parts for intactness and completeness.
(9) Check the oil quality and volume of hoisting reducer.
(10) Check the oil quality and volume of jacking pump station.
(11) Check jacking mechanism for intactness and completeness.
1.3 Daily Checking
(1) Slewing mechanism brake
(2) Luffing mechanism brake
(3) Hoisting mechanism brake
(4) Traveling mechanism brake

Maintenances T2850-120V -138Z-A02 9-1

1.4 Weekly Maintenances
(1) Slewing support - Lubricate the gear teeth by grease.
(2) Check the electronic control room.
(3) Check the electronic control parts, electric wires, and cables for intactness.
(4) Check the safety devices (Including torque limiter, weight limiter, luffing travel limiter,
hoisting height limiter, and slewing limiter) for intactness.
1.5 Monthly Maintenances
(1) Check and lubricate the wire rope by grease.
(2) Check and lubricate the pulleys by grease.
(3) Check and lubricate the drum bearings by grease.
(4) Add working hydraulic oil to the jacking pump station.
(5) Check the tightening torque of high strength bolts at least within 1 month after the erection
of tower.
(6) Add oil to the hoisting mechanism reducer.
(7) Check the main load-carrying structural parts, critical welds, and connectors
(including bolts and hinge pins).
1.6 Half-Yearly Maintenances
(1) Lubricate all lubricating nozzles.
(2) Motor bearings: Replace oil once every 1,500 working hours or at least once a year.
1.7 Year Maintenances:
(1) Check and lubricate high strength bolts.
(2) Check the hook.
(3) Check the wire rope twist control device.
(4) Check the hinge joints of cab forward sliding window for flexibility and lubricate
periodically.
1.8 After 2,000 Working Hours or Two Years
(1) Replace oil for slewing mechanism reducer.
(2) Replace oil for hoisting mechanism reducer.
(3) Replace oil for luffing mechanism reducer.
(4) Replace oil for traveling mechanism reducer.
(5) Replace oil for hoisting mechanism brake system.
(6) Replace oil for jacking mechanism after 2,400h.

9-2 T2850-120V-138Z-A02 Maintenances

1.9 After 10,000 Working Hours
Lubricate the bearings on electric system.
1.10 Daily Maintenance
Pulleys
1.11 Introduction of Lubrication
Only the lubrication by professionals as per operation manual can guarantee the
best lubrication performance and prevent errors and other problems.
On the use of high performance brand lubricating oil can guarantee the lubrication
performance.

Maintenances T2850-120V -138Z-A02 9-3

2 Maintenances of Hoisting Mechanism
2.1 Overview
The standard hoisting mechanism for this tower crane is in model of
H132FL150-1230D and is under variable frequency control by a frequency converter,
with the motor in model of YZTPF400L2-8(25Hz). 5 control positions are provided each
for lifting and lowering, of which the control positions I and II are transition control
positions that can be used for slow orientation.
Table 9.2-1 Technical Specification of Hoisting Mechanism

Magnification α＝2 α＝4 α＝8

Control position V IV III II V IV III II V IV III II
Hoisting capacity (t) 2 7.5 15 30 4 15 30 60 8 30 60 120
Speed (m/min) 100 68 40 20 50 34 20 10 25 17 10 5
Rope capacity of
1230 (7 layers)
drum (m)
Minimum stable
≤4.8
speed (m/min)

The hoisting mechanism is controlled by the frequency converter and the main
brake is of normally closed type. When the hoisting mechanism starts, the main brake
releases. Upon receipt of the released signal of the brake, the frequency converter
powers on the motor. The structure of the hoisting mechanism is shown in Figure 9.2-1:

9-4 T2850-120V-138Z-A02 Maintenances

 1-Motor 2-Brake 3-Coupling 4-Reducer 5-Drum 6-Height limiter 7-Bearing block
Figure 9.2-1 Structural Diagram of Hoisting Mechanism

2.2 Maintenances of Motor

2.2.1 Periodical Checking and Maintenances of Motor
(1) If the motor doesn’t rotate after the “ON” command is given, check the frequency
converter for setting of output frequency, appropriate setting of
acceleration/deceleration time, and proper selection of V/f mode. If the electronic
thermal protection is provided, check for correct given calibration. If the motor still
doesn’t rotate, check the wiring and load of the motor.
(2) After the start of motor, pay attention to observe the indications of the motor, drive
unit, manufacturing machinery, and frequency converter panel. In event of any
abnormality, stop the motor immediately and find out and solve the malfunction
before restart.
(3) The temperature rise during the normal running of the motor shall not exceed the
permissible limit. Measure the temperature rise of iron core or housing by a
thermometer. The temperature rise shall generally not exceed 950ºC and the
temperature rise for bearings shall generally be no more than 60K. During the
running, frequently monitor the temperature rise in all parts.
Maintenances T2850-120V -138Z-A02 9-5
(4) The smell, vibration, and noise of the motor shall be cautioned. The winding will
generate insulation burning smell due to over-high temperature. Some malfunctions,
especially the mechanical malfunctions, will rapidly be reflected as vibration and
noise. Therefore, upon detection of burning smell or abnormal vibration or collision
sound, over-high buzz noise or other noise, stop the motor for checking
immediately.
(5) Frequently check for bearing heating and oil leakage and notice to periodically add
or replace lubricating grease. Generally, the 2# lithium-based lubricating grease is
used. Whenever possible, use one same lubricating grease during lubrication. The
temperature of the lubricating grease in the bearing chamber shall preferably not
exceed 70% of the specified temperature.
(6) Pay attention to maintain the cleanliness of the motor and keep the water drops, oil
stains, and foreign materials away from the ingress into the motor. The air inlet and
outlet of the motor must be guarded against obstruction.
(7) If the mechanism is to be unused for a long time, notice to take dust-proof and
water-proof measures for the exposed parts of the reducer. During the reuse,
perform the mechanical checking and check all parts for complete assembling and
check all fasteners for looseness before the installation. Thoroughly remove
accumulated dusts and impurities (if any) and when necessary blow clean by dry
compressed air. Before use, ensure to measure the insulation resistance between
stator winding and housing by a 500V megameter. If the measurement is below
0.5 MΩ, the drying measure must be taken for the motor. It’s allowed to charge the
winding with low voltage for drying. The winding temperature shall not exceed
125ºC during baking. To prevent the rusting of reducer, after disassembling and
checking, apply a film of clean anti-rust oil to all fit surfaces and threaded fasteners
(Except grounding bolt) before the assembling and ensure that all fasteners are
attached with spring washers to prevent automatic falloff. After assembling, rotate
the high speed shaft by hand. The high speed shaft shall rotate flexibly without any
friction.

The rotary encoder installed on the tail of the motor shall be guarded against
collision and knocking, in order to prevent damage. During the use and
maintenance, check the encoder for correct and secure installation, ensure that
9-6 T2850-120V-138Z-A02 Maintenances
the wire output port faces downward and is guarded against direct water sprinkle.
2.3 Maintenances of Reducer
The user shall periodically maintain the reducer, check the working status of
lubricating oil, remove the dusts and impurities from the ventilation plug and reducer
surfaces, and keep clean the reducer, in order to guarantee the normal running of the
reducer. Follow the Table 9.2-2 for the checking items:
Table 9.2-2 Checking Items of Reducer
Checking Items Interval
Check oil temperature. Daily
Check reducer for abnormal noise. Daily
Check oil level. Monthly
Check reducer for oil leakage. Monthly
Check water content in oil. At least once a year after 400 working hours
First oil replacement after start After 400 working hours
Oil replacement afterwards Once every 18 months or 5,000 working hours
Clean oil filter. Once every 3 months
Clean ventilation screw. Once every 3 months

If the mechanism is to be unused for a long time, notice to take dust-proof and
water-proof measures for the exposed parts of the reducer. During the reuse,
perform the mechanical checking and check all parts for complete assembling
and check all fasteners for looseness before the installation. Thoroughly remove
accumulated dusts and impurities (if any) and when necessary blow clean by dry
compressed air. To prevent the rusting of reducer, after disassembling and
checking, apply a film of clean anti-rust oil to all fit surfaces and threaded
fasteners (Except grounding bolt) before the assembling and ensure that all
fasteners are attached with spring washers to prevent automatic falloff. After
assembling, rotate the high speed shaft by hand. The high speed shaft shall rotate
flexibly without any friction.
2.4 Checking of Coupling
(1) Daily check the deviations of motor axis at the coupling with respect to the input
shaft of the reducer. The permissible deviation is ≤4mm in axial direction, ≤1.5mm in

Maintenances T2850-120V -138Z-A02 9-7

 radial direction, and is ≤1º in angle and the permissible radial run-out of brake wheel
is ≤0.7mm. If beyond above values, please adjust to the specified range or contact
our after-service personnel.
(2) Periodically check the coupling elastomer and the half-coupling. Upon detection of
damage or cracking in elastomer or half-coupling, stop the motor for replace or
contact our after-service personnel for checking and replacement.
2.5 Cause Analysis and Troubleshooting for Wire Rope
Arrangement Problem of Hoisting Mechanism
2.5.1 Wire Rope Arrangement of Hoisting Mechanism
The hoisting mechanism for the tower crane is of multi-layer winding mode and the
drum in use is a double fold line drum. The double fold line groove drum is a drum
suitable for multi-layer winding of wire rope and is characterized in such manner that the
most rope grooves on the drum are of straight line groove and the arrangement of one
wire rope layer plays a significant guide role for the arrangement of the wire rope layer
above to prevent the wire rope climbing and disorder problems and help the orderly
arrangement of multi-layer wire rope. The diagram for the winding of wire rope on this
mechanism is shown in Figure 9.2-2:

Fold line

Straight line

Rope direction

Figure 9.2-2 Structural Diagram of Drum

9-8 T2850-120V-138Z-A02 Maintenances

2.5.2 Summary and Solution for Arrangement Problems of Wire Rope
Table 9.2-3 Summary for Wire Rope Arrangement Problems of Hoisting Mechanism
Problem
Cause analysis Solution
description
Check lubrication status of pulley. Upon
detection of dried grease, remove
manually and then apply new lubricating
Stagnation of pulleys and poor
grease. If the environment temperature is
guide function due to improper
too low or the lubricating grease viscosity
lubrication of guide pulley
is too high, add the thin oil to the pulley
(Check daily and if necessary apply thin
oil before power-on).
Inclined installation of hoisting Check underframe for inclination and
mechanism adjust the inclination.
Poor arrangement or
Non-alignment between Adjust the mounting base of mechanism
disorder of wire rope
centerlines of hoisting mechanism to align the centerlines of drum and
on drum
drum and balance beam balance beam.
Uneven installation of hoisting Check underframe levelness and adjust if
mechanism underframe not-level.
Check the first layer of wire rope for tight
arrangement. If not tight, ensure to wind
the first layer of wire rope tightly and
Compression of wire rope into
whenever possible apply a certain load
lower layer on the drum
(2% of the minimum breaking tensile
force of wire rope or 10% of current rated
load) for the arrangement of wire rope.

 The lubrication status of wire rope plays a certain influence on the wire
rope arrangement of the hoisting mechanism. Periodically check the
lubrication status of the wire rope. Upon detection of dried grease on wire
rope, remove manually and then apply new lubricating grease.
 After the adjustment of disordered wire rope, ensure to manually arrange
properly and tightly the first layer of wire rope and whenever possible
apply a certain load (2% of the minimum breaking tensile force of wire
rope or 10% of current rated load) for the arrangement of wire rope.
2.6 Adjustment of Main Brake
Refer to the subsequent Section 4.

Maintenances T2850-120V -138Z-A02 9-9

3 Maintenances of Luffing Mechanism
3.1 Overview
The luffing mechanism for this tower crane is in model of T185FC87, of which the
structure is shown in Figure 9.3-1:

1-Motor 2-Travel limit switch 3-Reducer 5-Drum

Figure 9.3-1 Structure of Luffing Mechanism

3.2 Maintenances of Luffing Brake

2 3 4 5 6

7
1-Brake disc 2-Hollow bolt 3-Armature 4-Mounting screw 5-Magnetic yoke subassembly
6-Spring 7-Lead wire
Figure 9.3-2 Structure of Brake

9-10 T2850-120V-138Z-A02 Maintenances

3.2.1 Braking and Release of Brake

Figure 9.3-3a Braking of Electromagnetic Brake Figure 9.3-3b Release of Electromagnetic

Brake

3.2.2 Adjustment of Brake Air Clearance

Before operations, ensure that the main motor, brake, and axial flow fan are powered off.
The normal working clearance of brake is 0.6mm and the maximum working clearance is
1.2mm. Upon detection of braking failure or that the air clearance is beyond maximum air
clearance, the adjustment of brake air clearance is required.

(1) As shown in Figure 9.3-4a, unscrew the fastening screw ① of axial flow fan and

take out the axial flow fan ②.

(2) As shown in Figure 9.3-4b, loosen the mounting screws ③ of brake, adjust the

hollow nut ④ to adjust the working air clearance to 0.6mm, and then tighten the

mounting screws ③ of brake.

Maintenances T2850-120V -138Z-A02 9-11

 4 3
1
2

Figure 9.3-4a Figure 9.3-4b

(3) As shown in Figure 9.3-4c, install the axial flow motor ② and tighten the fastening

screws ① of axial flow fan.

Figure 9.3-4c

If the air clearance is not properly adjusted, repeat step 2, till the air clearance
is adjusted to 0.6mm and the surrounding clearance is basically consistent.
3.2.3 Maintenances
(1) Fulfill the maintenance once every 450 hours or 3 months.

9-12 T2850-120V-138Z-A02 Maintenances

(2) Adjust the air clearance: The standard working air clearance б for the
electromagnetic brake of a three-phase asynchronous motor with electromagnetic
brake is 0.6mm, as shown in Figure 9.3-5.

I
检查气隙
Check clearance 4:1
δ

Figure 9.3-5 Adjustment of Air Clearance

Please ensure that the electromagnetic brake contains no impurities (Such as

cement, sand, and oil/grease).
3.2.4 Maintenances
If the one-sided wear of the brake pad approaches the metal end face of brake disc,
the brake pad must be replaced. Before operations, ensure that the main motor, brake,
and axial flow fan are powered off. The procedure is as below:

(1) As shown in Figure 9.3-6a, unscrew the fastening screw ① of axial flow fan and

take out the axial flow fan ②.

(2) As shown in Figure 9.3-6b, unscrew the mounting screws of brake ⑤ and take out the

brake ⑥.

(3) As shown in Figure 9.3-6c, take out the retainer ⑦ and take out the brake pad and

spline sleeve ⑧.

Maintenances T2850-120V -138Z-A02 9-13

(4) As shown in Figure 9.3-6d, replace with new brake pad and spline sleeve ⑧ and

install the retainer ⑦.

(5) As shown in Figure 9.3-6e, install the brake ⑥ and brake mounting screws ⑤

(Adjust the air clearance as per section 4.3.2).

(6) As shown in Figure 9.3-6f, connect the brake power lead wires, install the axial flow

fan ②, and tighten the fastening screws ① of axial flow motor.

1 6 5
2

Figure 9.3-6a Figure 9.3-6b

8 8
7 7

Figure 9.3-6c Figure 9.3-6d

9-14 T2850-120V-138Z-A02 Maintenances

 1
6 5 2

Figure 9.3-6e Figure 9.3-6f

3.3 Maintenances of Motor

3.3.1 Storage of Motor
Store the motor in a dry and well-ventilated place, cover the entire motor with
waterproof cloth, keep the motor clean, guard the inside of motor against the ingress of
water beads, oil dirt, dusts, and corrosive gas, and periodically remove dusts from inside
and outside of the motor.
For a motor stored for more than 1 year, remove the impurities from the inside of
motor, dry the internal moisture, and apply a film of clean anti-rust oil to the bearings and
all fit surfaces and threaded fasteners (Except the grounding bolts).
Properly cover the cover plate on the end cap, junction box cover, and non-used
wire output ports against the ingress of harmful substances, such as water, dust, oil, and
emulsion, and guard the coils against the damage caused by rats.
3.3.2 Maintenances before Reuse of Motor
(1) For a motor stored for more than 1 year, carefully check the bearings and the
bearing locations for presence of rust and immediately replace any rusted one
before use. Before restarting the motor, thoroughly clean the bearings and apply
clean lubricating grease, in order to prevent the noise and damage of bearings due
to dried lubricating grease of bearings.
(2) Perform the mechanical checking before installation. Check all parts for complete
assembling, check fasteners for looseness, thoroughly remove internal dusts and
impurities (if any), and when necessary blow clean by dry compressed air.
(3) For a motor not used for a long time, ensure to measure the insulation resistance
between stator/rotor winding and housing or rotating shaft by a 500V megameter

Maintenances T2850-120V -138Z-A02 9-15

 before use. If the measurement is below 0.5 MΩ, the drying measure must be taken
for the motor. It’s allowed to charge the winding with low voltage for drying. To
prevent rusting of motor, during the assembling after disassembling and checking,
apply a film of clean anti-rust oil to all fit surfaces and threaded fasteners (Except
the grounding bolts) and attach all fasteners with spring washers to prevent
spontaneous falloff. After assembling, rotate the rotor by hand. The rotor shall rotate
flexibly without any friction.
(4) After the installation of motor, check the electromagnetic brake for reliable actuation
and release. Upon the power-on of brake, rotate the motor rotor by hand. The rotor
shall rotate flexibly.
(5) During the assembling of coupling, remove the anti-rust layer of motor shaft. Do not
knock it heavily, in order to prevent damaging the bearings.
(6) The grounding bolts are provided in the junction box. Ensure the reliable grounding
after installation.
(7) Connect the wires of the motor strictly as per the external wiring method specified by
this technical document, otherwise the motor can’t work normally or even burns.
(8) After the installation, idle the motor for 30~40min. If the idling is normal, apply the
load and check the stability of power supply. The motor is allowed to run under
rated condition if the voltage of power supply (under rated frequency) deviates from
the rated value for no more than ±5%, or the frequency of power supply (under rated
voltage) deviates from the rated value for no more than ±1%, or both voltage and
frequency deviate at positive deviation and the sum is no more than 6%, or the
voltage and frequency deviate at negative deviation or in opposite direction and the
sum of their absolute deviations is no more than 5%.

9-16 T2850-120V-138Z-A02 Maintenances

4 Maintenances of Main Brake and Safety Brake Caliper
System
4.1 Maintenances of Main Brake
The model and related specification of the main brake installed for the hoisting and
luffing mechanisms are shown in Table 9.4-1.
Table 9.4-1 Related Specification of Hoisting Brake

Braking Recommended
Mechanism Mechanism model Model of brake torque braking torque
(N.m) (N.m)
Hoisting YP31-Ed2000-710×30-Ⅰ
YZTPF400L2-8(25Hz) 7600 5800±100
mechanism A-WL.H

Before any adjustment of the main brake, ensure that the drum will not
accidently rotate to cause accident.
4.1.1 Structure of Brake
The structural diagram of the disc brake is shown in Figure 9.4-1:

1-Equal adjuster 1.1-Equal adjustment nut 1.2-Lock nut 2-Brake pad automatic compensator
2.1-Compensation adjustment nut 2.2-Square shaft 2.3-Compensation screw 2.4-Compensation
sleeve 3-Triangular plate subassembly 4-Limit switch 4.1-Opening limit switch 4.2-Closing limit
switch 4.3-Manual release limit switch 4.4-Wear limit switch 5-Manual release device 5.1-Jack
5.2-Extension rod 6-Electrohydrualic thruster 7-Spring subassembly 7.1-Torque scale 7.2-Torque

Maintenances T2850-120V -138Z-A02 9-17

 adjustment nut 8-Brake arm subassembly 9-Brake shoe 9.2-Brake pad
Figure 9.4-1 Structure of Disc Brake
4.1.2 Installation of Brake
1) Checking before installation of brake
Check whether the information on the brake nameplate is consistent with that of
model selection (Including voltage, frequency, and model of thruster).
(1) Check the end face run-out of brake disc. The end face run-out shall be no more
than 0.15 if the disc diameter is ≤500 and shall be no more than 0.2 if the disc
diameter is >500.
(2) The surface roughness for two end faces of the brake disc is 3.2. Check the surface
cleanliness of brake disc and ensure the disc surfaces are clean without dirt,
oil/grease, or electric welding damage.
(3) Check the locations of brake mounting holes and the smoothness and cleanliness of
the mounting surfaces.
(4) The positional tolerance of the mounting surface and holes of the brake base with
respect to the brake disc (refer to Figure 9.4-2) shall not exceed the provisions of
Table 9.4-2 and Table 9.4-3.

Brake disc

Brake pad

Installation base

Figure 9.4-2

9-18 T2850-120V-138Z-A02 Maintenances

 Table 9.4-2
Parallelis
m
Central between
Center height h1 K1 K2 deviatio base
Brake n surface
specification and brake
disc axis
Nomina Toleranc Nomina Toleranc Nomina Toleranc
S a
l value e l value e l value e
YP31-Ed2000-
280 ±2 180 ±0.5 180 ±0.5 1 1.0
6

Table 9.4-3 (Unit: mm)

d2 d3 P
710 610 225

1) Alignment of brake
Before installation (Refer to Figure 9.4-1), rotate the torque adjustment nut
counter-clockwise (Part 7.2) to adjust to minimum braking torque (Work length of spring),
remove the mounting screws of compensation sleeve (Part 2.4), and take out the
compensation sleeve. For type II brake, clockwise rotate the clearance adjustment nut
(Part 2.1) to increase the clearance between brake shoes. Open the brake and ensure
that the clearance between brake pad and brake disc is 3~5mm.

The compensation sleeve must be removed before rotating the clearance

adjustment nut to increase the clearance between brake pad and brake disc at any time.
While rotating the clearance adjustment nut, do not completely unscrew the
compensation screw from the threaded sleeve of the compensator.
(1) Move the opened brake steadily into the installation position of brake.
(2) The centerline of brake disc must be consistent with the centerline of brake,
with the deviation no more than 1mm.
(3) The outside diameter of brake disc must be larger than the brake pad by
0.5~5mm.
Caution: It denotes the outer edge of brake pad, not the pad seat.
(4) After the basic orientation of brake, loosen the lock nut (Part 1.1) on the
connecting bolt of equal adjuster (Part 1) to relieve the restraint of equal lever,
Maintenances T2850-120V -138Z-A02 9-19
 attach the washers, insert the founding bolts (The bolt specification is listed in
Table 5. The bolts and washers are not provided by our company), and attach
the nuts.
Caution: Do not tighten the nuts in this step.
(5) Rotate clockwise the clearance adjustment nut (Part 2.1) to clamp the brake
disc by two brake pads and lift the thruster push rod by approximately 5mm.
4.1.3 Commissioning of Brake
1) Setup of braking torque
Adjustment method: Rotate the torque adjustment (Part 7.2 in Figure 9.4-1)
clockwise by a wrench to reduce the working length of spring and increase the braking
torque and counter-clockwise to reduce (Refer to Figure 9.4-3). Adjust the torque as per
the design requirement of the mechanism and ensure that the upper edge of spring seat
is paralleling with the graduation line of the scale.

While adjusting the braking torque, do not exceed the range specified by the
braking torque nameplate, otherwise the brake will probably work abnormally.

Rotate adjustment nut clockwise

to increase torque

Minimum torque
place (Adjust
braking torque
under closed
status)

Figure 9.4-3
2) Setup of thruster compensation travel

9-20 T2850-120V-138Z-A02 Maintenances

 The compensation sleeve must be removed before rotating the clearance
adjustment nut to increase the clearance between brake pad and brake disc in all
cases.
Refer to Figure 9.4-4 and Table 9.4-4 for the compensation travel of the thruster.
(1) To increase the compensation travel for type II brake, rotate the clearance
adjustment nut (Part 2.1) counter-clockwise, till the thruster piston rod reaches
the required position.
(2) To reduce the compensation travel for type II brake, rotate the clearance
adjustment nut (Part 2.1) clockwise, till the thruster piston rod reaches the
required position.

Closed status of brake Opened status of brake

Figure 9.4-4
Table 9.4-4

Minimum
Compensation Push rod Rated Push rod Lining
Model of compensation travel
travel head size travel head size clearance
brake hb
hb S H S0 δ
min
YP31 10 150 60 200 0.9±0.2 5

Note: Refer to (Figure 9.4-4) for the lining clearance δ. The above values are theoretic
calculations and actual measurements will differ.
After all works are completed, ensure that the compensation sleeve (Part 2.4) is
reinstalled correctly. The shifting pin (Part 2.5) must be in the hole of the compensation
sleeve (Part 2.4) (The Figure 9.4-5 shows the closing status).

Maintenances T2850-120V -138Z-A02 9-21

 Figure 9.4-5
3) Adjustment of parallelism between two pads and brake disc
Adjustment method: Power on the thruster to open the brake and observe the brake
pads and brake disc (Figure 9.4-6a) for inverted herringbone shape. If yes, knock the
upper portion of brake shoe by a rubber hammer to close the upper portion of pad to the
brake disc (Refer to Figure 9.4-6b). Open and close the brake for 2~3 times. Under the
action of the automatic follow-up device, the brake pads automatically parallel with the
brake disc (Refer to Figure 9.4-6c).

9-22 T2850-120V-138Z-A02 Maintenances

 Knocking Knocking
point point

Follow-up
device

Figure 9.4-6
4) Adjustment of equal clearance device
The equal clearance device (Part 1) is functioned to ensure the uniform clearance
and no contact between brake pads and brake disc on two sides (Refer to Figure 9.4-7)
when the brake opens. Adjustment method of equal device: If the clearance on the
adjustment rod (Part 1.3) side is small after the brake opens, loosen the lock nut (Part
1.2), slowly rotate the adjustment nut (Part 1.1) clockwise, and observe the clearances of
the brake pads, till the clearance is same between two sides. Finally, tighten the lock nut.
If the clearance on the adjustment rod (Part 1.3) side is large after the brake opens,
loosen the lock nut (Part 1.2), slowly rotate the adjustment nut (Part 1.1)
counter-clockwise, and observe the clearances of the brake pads, till the clearance is
same between two sides. Finally, tighten the lock nut.

If the clearances of the brake pads are different when the manual device
opens and when the electrohydraulic thruster opens, the clearance adjusted when
the electrohydraulic thruster opens shall prevail.

Maintenances T2850-120V -138Z-A02 9-23

 Figure 9.4-7
5) Checking and adjustment of limit switch
Adjustment method of limit switch: Loosen the lock nut or pipe clamp on the
proximity switch, move the proximity switch longitudinally to an appropriate position, and
tighten the lock nut or pipe clamp. Alternatively, loosen the lock nut on the proximity
switch, rotate the proximity switch forward or backward to an appropriate position, and
then tighten the lock nut.

Do not disable the limit switches by any means, otherwise the brake can’t
work safely.
(1) Opening/closing limit switch
The opening limit switch (Part 4.1) and the closing limit switch (Part 4.2) are installed
on the electrohydraulic thruster. While the brake closes, the push rod head of the
electrohydraulic thruster is on the bottommost position, the opening limit switch is exactly
at the neutral position, and the touch plate sensing zone exactly triggers the closing limit
switch. When the brake opens, the electrohydraulic thruster is powered on, the push rod
head extends, the opening limit switch is exactly triggered by the touch plate sensing
9-24 T2850-120V-138Z-A02 Maintenances
zone, and the touch plate moves out from the sensing zone of closing limit switch to
neutral position (Refer to Figure 9.4-8).

(2) Manual release limit switch

The manual release limit switch (Part 4.3) is installed on the spring square pipe.
When the manual release device is not working, the manual release device is under
retracted position and the touch plate sensing zone can’t trigger the manual release limit
switch so that the manual release limit switch is under neutral position. When the manual
release device is working, the jack is under extended position so that the touch plate
sensing zone exactly enters into the triggering zone of manual release limit switch (Refer
to Figure 9.4-8).
(3) Brake pad wear limit switch
The brake pad wear limit switch (Part 4.4) is tightened to the square shaft of the
brake pad automatic compensator. During the normal use of the brake, the triggering rod
of the brake pad wear limit switch is far away from the limit switch so that the switch is
not triggered. Following the increased wear of the brake pad, the triggering rod slowly
closes to the limit switch. Once the thickness of the brake pad reaches the dangerous
value, the triggering rod enters into the triggering zone of the brake pad wear limit switch
so that the switch is triggered (Refer to Figure 9.4-8).

Brake under closed status Brake under opened status

Figure 9.4-8

Maintenances T2850-120V -138Z-A02 9-25

4.1.4 Operation of Brake
1) Operation of manual release device:

Please ensure that all things are under control during the use of manual
release device.
Relieve the hoisted load of the crane, ensure no safety device is working, and
slowly release the brake.
Ensure that the additional load is within control range, otherwise there is a
lethal danger.
When the manual release device is in use, no safety device is working.
Please ensure that the mechanism will not rotate accidently when the brake is
under opened state, otherwise there is a lethal danger.
The manual release device for this brake model is a hydraulic jack (Part 5.1). If the
use of hydraulic jack is not required, the unloading screw (Part 5.5) shall be under
counter-clockwise loose state (Refer to Figure 9.4-9). If the use of hydraulic jack (Part
5.1) is required to open or close the brake, the method to open the brake is to tighten the
unloading screw (Part 5.5) clockwise and operate the hydraulic jack by lever (Part 5.4) to
open the brake. In such case, the touch plate sensing zone enters into the triggering
zone of manual release limit switch (Part 5.3). The method to close the brake is to
counter-clockwise loosen the unloading screw (Part 5.5) to unload the hydraulic jack and
close the brake.

9-26 T2850-120V-138Z-A02 Maintenances

 Rotate
counter-clockwise to
unload

Caution

Figure 9.4-9

2) Run-in of brake pad

Start the run-in only after all brake adjustments are completed and the contents of
this section are carefully read. Ensure to run in after the replacement with new brake pad
or brake disc or before the use of brake after first installation. Otherwise, the braking
torque specified on the nameplate can’t be guaranteed.
The run-in is required for the brake pads before use. The run-in can achieve the
uniform surface contact between brake pads and brake disc. Before the run-in of brake,
check the following items:
(1) Check the brake for correct and qualified installation.
(2) Check and ensure that the model, voltage, frequency (Refer to nameplate) and
the wiring of the thruster meet the requirements.
(3) Check and ensure that the commissioning of the brake meets the
commissioning requirements.
Maintenances T2850-120V -138Z-A02 9-27
 (4) Check and ensure that the working length of brake spring meets the
requirements.
(5) Check and ensure that the surfaces of the brake disc and brake pads are clean
without oil dirt.
3) After all checking items are normal, run in as per the following method:
(1) Run in under no-load for 25~30 cycles (Apply the braking for 25~30 cycles after
the dive motor of the mechanism to be braked accelerates from low speed
gradually to the rated speed under the no-load condition (regardless of the
horizontal movement mechanism).
(2) Under 50% braking load condition (regardless of the horizontal movement
mechanism), accelerate the drive motor as per work mode a, operate the brake
for 20~25 cycles, and observe for stable braking state (Namely the braking
distance is basically consistent for all cycles). If the braking state is stable,
perform the full-load test for 10~15 cycles.
(3) If the braking distance for every full-load test cycle meets the requirements and
is basically consistent, the brake can be put into official use. If not, repeat the
run-in as per the steps a and b, till the requirements are met.
(4) During the run-in, check the following conditions at any time:
① Fit between brake pads and brake disc.
② Temperature of brake disc (No more than 350ºC).
③ Looseness of threaded connectors.
④ Normal switching signals.
⑤ Normal braking and running sound.
⑥ The brake can be put into official use only after the normal run-in.
4.1.5 Repairs of Brake

Please ensure that the mechanism will not accidentally rotate under the released
state of the brake. Otherwise the mechanism will probably be damaged and even there
is a lethal danger.

Affix an “In Service” warning label during the repairs of the brake. The use of any
spare part incompatible with this brake will probably cause brake malfunction or brake

9-28 T2850-120V-138Z-A02 Maintenances

damage. Please only use the spare parts supplied or approved by our company.
1. Periodical Maintenance
1) Checking period
(1) Once every 50~150 working hours.
(2) Once every 450 working hours or month (for maintenances of brake)
(3) When the brake is not used for 6 months.
2) Checking of brake status
(1) Brake shoes: Check/readjust the brake shoes.
(2) Wear status of brake pads: If the friction material thickness of brake pads is
less than 3mm, replace the brake pads.
(3) Brake disc status: Replace the brake disc in event of following condition:
(4) Cracking on brake disc or >1mm wear on two sides of brake disc.
(5) If the grooves appear, it’s prohibited to machine either side of the brake disc
for >1.5mm.
(6) Thruster compensation travel: Check/readjust the compensation travel of the
thruster.
(7) Flexible rotation of connecting hinge pins: Upon detection of stagnation,
solve or replace bushing.
(8) Spring force (Braking torque): Check/readjust the braking torque.
(9) Limit switches (Including manual limit and other optional limit switches).
Check limit switches for normal working and replace any abnormal switch.
(10) Check the automatic compensator.
(11) Ensure to open the split pins to prevent looseness.
3) Checking of brake status
Upon detection of following condition, please check the brake besides routine
checking:
(1) The braking time or distance is increased under same condition.
(2) The limit switch indicates the wear of brake pad or the insufficient release
travel.
(3) The brake or motor is not working for a long time.
(4) There is any noise or leakage.
2. Lubrication
As all main hinge joints of the brake are installed with self-lubricating bushing, no

Maintenances T2850-120V -138Z-A02 9-29

lubricating oil is required. In event of any inflexible rotation of connecting hinge pin, solve
the stagnation problem or replace the bushing.
3) Replacement of brake pad automatic compensator

Two operators are required to replace the brake pad automatic compensator. During
the replacement of compensation screw, carefully separate two brake arms of the brake
to prevent falloff.
The replacement procedure is as below (Refer to Figure 9.4-10):
1) Remove the compensation sleeve (Part 2.4) of the compensator.
2) For type II brake, rotate the nut (Part 2.1) clockwise to separate the
compensation screw (Part 2.3) from the large square shaft (Part 2.2). In such
case, two brake arms (Part 8) are separated.
3) Remove the set screw (Part 2.7) on the rotary nut (Part 2.1).
5) The compensation screw (Part 2.3) can be integrally withdrawn from the square
shaft (Part 2.9) in the middle of triangular plate.
6) Replace with new compensator.
7) Insert the compensator through the square shaft (Part 2.9) in the middle of
triangular plate. Bear in mind to install the small butterfly spring (Part 2.8) and
conical washer (Part 2.10).
8) Tighten the rotary nut (Part 2.1) in such manner that the rotary nut can be
rotated by 3~5N.m torque.
9) Install the set screw (Part 2.7) on the rotary nut (Part 2.1).
10) For type II brake, rotate counter-clockwise the nut (Part 2.1) to connect together
two brake arms (Part 8).
11) Finally adjust the brake.

9-30 T2850-120V-138Z-A02 Maintenances

 Figure 9.4-10
4) Replacement of brake pads.

During the working of the brake, the temperature of the brake disc and the brake
pads will rise so that there is a scalding danger. Before replacing the brake pads, cool
down the brake disc and brake pads.

Replace the brake pad if the friction material thickness is less than 3mm. Replace
both brake pads at the same time, otherwise the brake probably can’t work normally.
The replacement procedure is as below (Refer to Figure 9.4-11):
1) Remove the compensation sleeve (Part 2.4) of the compensator.
2) Disable the brake pad automatic compensator (Part 3).
3) Use manual release device (Part 5) to open the brake.
4) For type II brake, rotate the nut (Part 2.1) clockwise to increase the clearance
between brake pad and brake disc to approximately 5mm.
5) Loosen two lock bolts (Part 9.5) on the brake shoe (Part 9) to separate from the
brake pad (Part 9.2).
6) Fix the brake pad by one hand-held hole on the upper end of brake pad.
7) While removing the brake pad, notice the weight of brake pad (Approximately
4kg) to prevent falloff.
8) Withdraw the brake pad from the flat key (Part 9.4) installation.
9) Remove the used brake pad.
10) Check the cleanliness of new brake pad and ensure its cleanliness.
11) Clamp the new brake pad into the flat key, install it properly, and tighten the
screws (Part 9.5). Bear in mind to install the washers (Part 9.6).
12) Finally adjust the brake and run in the brake pads.

Maintenances T2850-120V -138Z-A02 9-31

 Figure 9.4-11
5. Replacement of limit switch
I. Replacement procedure of opening/closing limit switch:
1) Disconnect the signal wire.
2) Loosen the lock nuts.
3) Remove damaged (used) limit switch.
4) Install new limit switch.
5) Install the lock nuts, but do not tighten the nuts.
6) Slowly tighten the inward lock nuts.
7) Connect the switch signal wire.
8) To adjust the opening limit switch, the brake shall be under opened status. To
adjust the closing limit switch, the brake shall be under closed status.
9) Move the switch, till it’s correctly triggered (4~5mm).
10) Tighten the lock nut on the inner side.
11) Tighten the lock nut on the outer side.
12) Open and close the brake for several times and check for correct settings.
II. Replacement procedure of manual release switch:
1) Disconnect the signal wire.

9-32 T2850-120V-138Z-A02 Maintenances

 2) Loosen the lock nuts.
3) Loosen the mounting pipe clamp of sensing switch.
4) Remove damaged (used) limit switch.
5) Install new limit switch.
6) Connect the switch signal wire.
7) Open the brake by manual release switch (Jack).
8) Move the switch, till it’s correctly triggered (4~5mm).
9) Tighten the mounting pipe clamp of sensing switch.
10) Tighten the lock nut on the inner side.
11) Tighten the lock nut on the outer side.
12) Open and close the brake by manual release device for several cycles to check
the setting.
III. Replacement procedure of brake pad wear limit switch
1) Disconnect the signal wire.
2) Loosen the lock nuts.
3) Unscrew damaged (used) limit switch.
4) Screw new limit switch.
5) Ensure that the trigger surface is consistent with the bore.
6) Connect the switch signal wire.
7) Tighten the lock nuts.
6. Replacement of bolts and bushing
If the replacement of bushing is required, ensure to break down the brake:
1) Relieve the spring force, loosen the corner connecting bolts, and remove the
brake.
2) Remove all connecting bolts and nuts to completely break down the brake.
3) Before removing the bushing, notice the location of the bushing to be replaced.
4) While removing the bushing, do not damage the base hole.
5) If necessary, clean the mounting hole and notice the installation direction of
bushing. Refer to the explosive view in section 8.
6) While compressing the bushing into the mounting hole, do not damage the
bushing.
7) Finally assemble the brake and re-set up the operation parameters of the brake
with reference to section 3.

Maintenances T2850-120V -138Z-A02 9-33

 7. Replacement of brake
Replacement procedure of thruster (Refer to Figure 9.4-12):
1) If the opening limit switch (Part 4.1) is installed, remove it.
2) Disconnect the power supply of electrohydraulic thruster (Part 6).
3) Use manual release device (Part 5) to open the brake.

When the connecting hinge pin of the thruster upper hinge joint is unplugged, the
thruster will probably incline and fall. Ensure that the thruster has no accidental
movement or harm danger.
4) Remove the upper hinge pin (Part 6.1) of thruster (Part 6).
5) Connect the thruster hoisting rope to appropriate hoisting device.
6) Remove the lower hinge pin (Part 6.2) of thruster.
7) Replace the thruster.
8) Reinstall the brake.
9) Connect new thruster cables.
10) Install opening limit switch.
11) Unload by manual release device to close the brake.
12) Finally adjust and test the brake.

Figure 9.4-12
8. Replacement of spring subassembly

9-34 T2850-120V-138Z-A02 Maintenances

 Replacement procedure of spring subassembly (Refer to Figure 9.4-13):
1) Remove the jack (Part 5.1) and manual release limit switch (Part 4.3) of manual
release device.
2) Rotate counter-clockwise the torque adjustment nut (Part 7.2) to relieve the
spring force.
3) Knock out the elastic round pin (Part 7.3) from the slotted nut (Part 7.2) on the
spring pull rod (Part 7.4).
4) Loosen and remove the slotted nut (Part 7.2).
5) Remove the split pins and washers from the lower hinge pin (Part 7.5) of the
spring tube (Part 7.7).
6) Pull out the hinge pin from the hinge bore of spring tube.
7) Move upward the spring tube slightly, move outward the lower corner of square
tube, and pull out downward the triangular plate square shaft (Part 3.2).
8) Reinstall the new spring subassembly.
9) Reinstall the brake as per following procedure and install the slotted nut.
10) Slightly lubricate the washers.
11) Pass the brake pull rod (Part 7.4) through the square shaft (Part 3.2) of
triangular plate and then connect the lower hinge pin (Part 7.5) of spring square
tube.
12) Tighten the slotted nut (Part 7.2) to 400N.m.
13) If the elastic round pin hole (Part 7.3) is not aligned with the groove of slotted
nut (Part 7.2), tighten further.
14) Ensure that the elastic round pin can be installed successfully.
15) Reinstall the jack (Part 5.1) and manual release limit switch (Part 4.3) of manual
release device.
16) Finally adjust the braking torque and test the brake.

Maintenances T2850-120V -138Z-A02 9-35

 Slightly lift up the spring tube
and move outward the lower
part of spring tube

Figure 9.4-13

4.2 Maintenances of Safety Brake Caliper System

The SBD160-D single-station double-caliper safety brake caliper system
(T2850-120V) equipped on this tower crane is of single-station double-caliper structure,
in which the hydraulic pump station supplies high pressure oil to the safety brake calipers.
The pump station model is YZBA10-11B and the safety brake caliper model is
SBD160-D-II. The structure is shown in Figure 9.4-14:

9-36 T2850-120V-138Z-A02 Maintenances

1-Pump station 2-Straight end adjustable T joint 3-Hose assembly (4m) 4-Hose assembly (5m)
5-Pipe clamp 6-Articulated joint 7-Safety brake caliper
Figure 9.4-14 SBD160-D Single-Station Double-Caliper Safety Brake Caliper Assembly
4.2.1 YZBA10-11B Hydraulic Station
4.2.1.1 Overview
This series hydraulic station is mainly functioned for the drive and control of the SB
series hydraulic caliper disc brake. It's also functioned for the drive control of the
single-acting cylinders in other mechanical mechanisms. The system is provided with
pressure maintaining function and certain leakage compensation capability. This system
is installed with manual pump for use in event of power failure emergency.
4.2.1.2 System Structure
(1) The hydraulic schematic diagram is shown in Figure 9.4-15:

Maintenances T2850-120V -138Z-A02 9-37

 Figure 9.4-15 Hydraulic Schematic Diagram
(2) The hydraulic station specification is listed in Table 9.4-4:
Table 9.4-4 Hydraulic Station Specification

Low High Regulated

Parameter Working Motor Oil tank
Flow pressure pressure pressure of
pressure power capacity
(L/Min) relay relay relief valve
Model (MPa) (KW) (L)
SP1.1(bar) SP1.2(bar) (bar)

YZBA10-11B 10 11 3 20 100 120 125

4.2.1.3 Work principle

1) System control
When the working of the mechanism is required, the master control room closes the
master control switch in the electric cabinet. In such case, the motor (8) is electrified and
started. When the system pressure reaches the 120bar setting of the high pressure relay
SP1.2, the motor stops and the system maintains the pressure. When the system
pressure drops to be less than 100bar setting of the low pressure relay SP1.1, the motor
restarts.
(1) Opening of brake: If the opening of brake is required, the master control system
sends an opening signal to the hydraulic pump electric cabinet. As shown in
Figure 9.4-8, the solenoid valve (3) is electrified from normally open status to
closed status and the hydraulic oil flows to the no-spring chamber of brake
cylinder via one-way throttle valve (4) so that the hydraulic force overcomes the

9-38 T2850-120V-138Z-A02 Maintenances

 spring force to fulfill the opening motion. At the same time, the brake outputs an
opening signal to the master control system.
(2) Closing of brake: As shown in Figure 9.4-8, the opening signal is cut and the
solenoid valve (3) is powered off from closed status to normally open status.
Under the action of the spring in the cylinder, the hydraulic oil in the no-spring
chamber of the cylinder returns to the oil tank via one-way throttle valve (4) and
solenoid valve (3) to fulfill the closing motion. The closing speed can be
adjusted by adjusting the throttle valve (4).

If the mechanism is not to work for a long time or the machine is parked under
unattended condition, cut off the master control and the opening control in the
electric cabinet, in order to prevent the leakage of oil pipeline due to long-time
pressure-maintaining of the motor and the burnout of motor due to frequent start.
2) Control
In event of malfunction of system electric control circuit or power failure, the brake
can be opened and closed by manual control mode. The detailed work procedure is as
below:
(1) Opening: Rotate rightward to tighten the adjustment handwheel of one-way
throttle valve (4), operate vertically the handle of manual pump (5) so that the
pressure oil is supplied to the brake via manual pump, and observe the reading
of pressure gauge in the system. When the pressure reaches the opening
pressure of the brake, stop operating the handle of manual pump (5) to
complete the opening motion.
(2) Closing of brake: Rotate leftward to loosen the adjustment hand wheel of
one-way throttle valve (4). Under the action of the spring in the cylinder, the
hydraulic oil in the no-spring chamber of the cylinder returns to the oil tank via
throttle valve (4) and solenoid valve (3) to fulfill the closing motion. The closing
speed can be adjusted by adjusting the throttle valve (4).
3) System adjustment
(1) Adjustment of relief valve pressure
Power off the hydraulic station, tighten the adjustment screw of pressure relay (9) by
2~3 turns, increase the pressure of system motor, loosen adjustment nut of relief valve
(2), and adjust the pressure of relief valve to meet the requirements of Table 9.4-4.
Maintenances T2850-120V -138Z-A02 9-39
Before rotating the relief valve adjustment rod, power off the hydraulic station. After each
adjustment, power on and observe the system pressure. If not qualified, power off and
adjust again, till the requirement in Table 9.4-4 is met. Restore the pressure relay
adjustment screw and finally tighten the lock nut on the relief valve adjustment rod.
(2) Adjustment of relay switchover pressure
Power on the motor and observe the system pressure on the pressure gauge (With
reference to above table). The motion of the pressure relay switch shall be capable of
controlling the start and stop of the motor. If the switchover pressure of the relay is
incorrect, power off and rotate the adjustment screw on the pressure relay to meet the
requirement of Table 9.4-4.
(3) Adjustment of system flow (Closing speed)
The one-way throttle valve (4) is under completely opened status at the delivery of
the hydraulic station. If the adjustment of the closing speed (Only slower) of the wind
safety device is required in the field, clockwise rotate the adjustment nut of the one-way
throttle valve (4) to adjust the closing speed to appropriate range. On the contrary, to
restore the closing speed to original status, rotate counter-clockwise the adjustment nut
of the throttle valve, till the throttle valve completely opens.
4.2.1.4 Maintenances
The good maintenances can reduce the malfunction rate and prolong the life of the
hydraulic station.
1) Preparations before use
(1) After the installation of hydraulic connecting pipes between brake and hydraulic
station, repeatedly flush the pipelines. Connect the pipeline to the oil outlet port of
hydraulic station only after the pollution degree of flushing oil reaches grade NAS8,
otherwise the impurities in the pipeline will probably cause serious damage to the
hydraulic system.
(2) Before the first use, verify the voltages of power supply and control signal and check
the motor for correct rotation direction. The correct rotation direction is clockwise.
(3) To add oil into the oil tank, use an oil filter and add approximately 20L oil, till the oil
level is above 2/3 of the oil tank level gauge. Periodically check the oil tank level
gauge. The oil level of the oil tank shall be no less than 1/2 of the level gauge.
2) Daily checking
Check the following items once every 100~150 working hours:

9-40 T2850-120V-138Z-A02 Maintenances

(1) Check the oil level by the level gauge.
(2) Check all pipeline connections for looseness.
(3) Check for presence of oil permeation/leakage.
(4) Check motor, pump, and valve groups for normal running sound.
(5) Upon detection of any abnormality, stop the working of hydraulic station and solve
the malfunction before further use.
3) Replacement of hydraulic oil and cleaning of system
(1) Replace hydraulic oil (ISO46 or ISO32. Refer to corresponding nameplate) and
clean the system (Including filter and oil tank) after the first 6 working months of
hydraulic station.
(2) During the normal use, replace the hydraulic oil and oil suction filter (depending on
the use frequency) at least once every year or one and half years. During the
replacement of oil, fully drain the oil from the oil tank via the oil drainage valve on the
bottom of oil tank, thoroughly remove all impurities from the bottom and inner walls
of the oil tank, and remove the tiny particles from the corners and bottom by a paste
or plaster. While adding oil, use an oil filter to ensure that the oil added into the oil
tank is clean. The filter element for the oil filling filter shall be no higher than 20μ.
Add the oil, till the oil level reaches 2/3 of the level gauge.
4.2.2 Maintenances of SBD160-D Safety Brake Caliper
4.2.2.1 Overview
SBD160-D low speed brake caliper (Hereafter referred to as brake caliper) is a new
low speed brake used as emergency safety brake for main hoisting mechanism and
boom luffing mechanism of large and medium cranes. Applied by Belleville spring and
released by hydraulic station drive, this brake is an advanced and high-efficiency
emergency brake product, featuring compact structure, less maintenances, and no
harmful substance (such as asbestos) in friction material.
The structure of the brake is shown in Figure 9.4-16 and the related technical
specification is listed in Table 9.4-5. The work principle is as below: The pressure oil in
the hydraulic station is supplied under the control of the solenoid valve into the brake
cylinder to further compress the Belleville spring and drive the piston rod, which drives
two brake arms to open towards two sides and eliminate the braking torque. When the
solenoid valve is powered off and reset, the hydraulic oil returns under the action of
A
spring force to the oil tank of hydraulic station and the spring force is applied onto the

Maintenances T2850-120V -138Z-A02 9-41

braked disc via piston rod and brake arms to build up the specified braking torque.
View A (Rotation)

1. Eye bolt 2. Lock nut 3. Brake screw (Push rod) 4. Limit switch push rod 5. Plug 6.
Nameplate 6. Hydraulic cylinder (with internal Belleville spring) 8. Frame 9. Brake arm 10.
Clearance lock nut 11. Clearance adjustment screw 12. Follow-up device 13. Brake pad 14.
Brake arm 15. Limit switch
Figure 9.4-16 Structure of Safety Brake Caliper
Table 9.4-5 Technical Specification of Brake (Table below)
Rated clearance of brake Rated clamping
shoe on each side force Braking force Release pressure
Specification
(kN) (MPa)
(mm) (kN)
SBD160-D 1.5 160 115 7.5/10

4.2.2.2 Installation and Adjustment

The brake shall be correctly installed, otherwise the design performance can’t be
achieved. Therefore, the user shall strictly follow the methods and procedures of this
manual during installation and commissioning.
1) Preparation before installation
(1) Check and ensure that the brake nameplate is consistent with the requirements
before the installation.
(2) Check all brake parts for completeness (If the hydraulic station is installed,
check all connectors and optional parts for completeness).
(3) Check all movable hinge joints for present of rust and seizure.
(4) Check brake pad surfaces for presence of oil dirt and other impurities
influencing the friction performance.

9-42 T2850-120V-138Z-A02 Maintenances

 (5) The brake disc surfaces shall be free of defects such as rust, oil dirt, welding
damage, and unevenness and it’s prohibited to use any cracked or seriously
defective brake disc.
Upon detection of any abnormality, ensure to solve before starting installation.
2) Installation
While hoisting the brake, it’s prohibited hoist by the cylinder or piston rod (brake
screw) of the brake. The mounting bracket shall have sufficient strength and stiffness
and its shape and dimensions are shown in Figure 9.4-17. Directly connect to the base
by bolts.
View A (Rotation)

Figure 9.4-17 Structural Diagram of Safety Brake (SBD160-D)

The specification, quantity, and performance grade of the connecting bolts shall
meet the requirements of the Table 9.4-6.
Table 9.4-6 Specification, Quantity, and Performance Grade of Bolts

Connection between brake and mounting bracket

Brake specification
Bolt specification Quantity Performance grade Tightening torque

SBD160-D M36 4 ≥8.8 1800

Install the brake as per the following procedure and method:

(1) Before installing the brake, install the hydraulic station in place, properly
arrange the hydraulic pipeline (The difference among the pipeline lengths
between brakes and hydraulic station shall be minimized), and properly connect
the electric control circuits.
(2) Connect the brake with mounting bracket by bolts.
(3) Ensure that the distance between brake pads is larger than the brake disc
Maintenances T2850-120V -138Z-A02 9-43
 thickness by >3mm.
(4) Move the brake opened and installed with mounting brake into the installation
position and notice to place the brake oil port on the hydraulic pipeline side (As
the brakes are generally installed in pair, place two oil ports in symmetric
manner). After aligning the installation position, close the brake to clamp the
brake disc and then check the brake for correct position.

Ensure that the brake pads are paralleling with two side faces of brake disc. If
the parallelism can’t be guaranteed, adjust by adding shims to the junction
surface between mounting bracket and brake.
(5) Connect the hydraulic pipeline to the oil inlet port of the brake cylinder. The oil
inlet port of the brake cylinder is of female thread M18×1.5.
(6) Properly connect the travel switch cables (Signal indicator) as per the
requirements of the main unit PLC.
3) Adjustment
The adjustment is required mainly after the first installation (before use) and the
replacement with new brake pad. During the first installation, adjust as per the following
sequence.
(1) Adjustment of brake shoe clearance and clamping force: The clearance of
brake shoe (The clearance betw
(2) of hydraulic station for relevant instructions). Rotate the adjustment nut (Refer
to Figureeen brake pad and braking surface of brake disc under released status)
directly influences the clamping force of the brake. Before use, ensure to adjust
to the specified rated value. The brake shoe clearance is related to the value X
and clamping force. Firstly, observe whether the dimension X of brake under
closed status meets the requirement of Table 9.4-7. If not, adjust as per
following method. Firstly, open the brake (There are two methods to open the
brake in all cases):
① Power on the hydraulic station to supply the pressure oil, in order to open the
brake.
② Operate the manual hydraulic pump (in the hydraulic station) to open the brake
(Refer to the attached manual 9.4-18) towards brake arm to reduce the value X
(Clearance) and increase the clamping force and rotate in opposite direction to
9-44 T2850-120V-138Z-A02 Maintenances
 increase the value X (Clearance) and reduce the clamping force (Refer to Table
9.4-8 for the rated clamping force of brake). Adjust one adjustment, close the
brake and observe the value X. If not qualified, open the brake again and adjust,
till the requirement is met. After proper adjustment, tighten the lock nut.

Table 9.4-7 Rated Clearance and Corresponding Value X of Brake Shoe

Rated clearance of brake shoe on
Specification Corresponding value X (mm)
each side (mm)
SBD160-D 2 160-0.5

An indicative label of measurement locations and values is affixed on the

cylinder barrel near the hydraulic cylinder oil port. Notice to refer to this label
during adjustment.

Piston rod End cover

Figure 9.4-18 Adjustment of Brake Shoe Clearance

Table 9.4-8 Rated Clamping Force and Value X of Brake

Model of brake Rated clamping force (KN) X(mm)

SBD160-D 160 160-0.5

(3) Adjustment of brake follow-up: Two brake shoes are installed with tension
spring type brake shoe automatic follow-up device. Before the installation of
brake, loosen the follow-up set screw to loosen the follow-up spring. After the
proper installation of brake, tighten the follow-up set screw under the clamped
status of the brake. Generally, no adjustment is required for the follow-up spring
during normal working. Upon detection of abnormal follow-up during working,
Maintenances T2850-120V -138Z-A02 9-45
 the follow-up spring is probably loose. Reinstall or replace with new follow-up
spring and adjust as per above-mentioned method.
(4) Adjustment of equal clearance: The adjustment is required during the first
installation or when the brake pads are worn. During adjustment, release the
brake to normal release status and observe the clearance between two brake
shoes and brake disc for uniform clearance. If non-uniform, adjust to equal
clearance. Adjustment method: Loosen the lock nuts of clearance adjusters on
both sides, rotate inward the adjustment screw on the larger clearance side
(Caution: In such case, there shall be a clearance between the adjustment
screw on the smaller clearance side. If there is no clearance, loosen this screw
to leave a sufficient clearance) till the clearance is basically equal (by visual
observation) between two sides, and then rotate the adjustment screw on the
smaller clearance side till the distance to the base side wall is 0.2~0.5mm.
Finally, tighten the lock nuts on both sides.
(5) Adjustment of release limit switch: Every brake is provided with a travel switch
for indication of brake release signal. After all adjustments are completed,
adjust the travel switch. Adjustment method: With reference to Figure 9.4-19,
close the brake and measure the distance between switch head and sensor by
a vernier caliper. The measurement shall be approximately 3mm. If not, loosen
(but do not remove) two lock screws on the switch base, move the switch
longitudinally to meet the requirement, repeat the closing and release motions
repeatedly for several times till the switch signal is stable, and tighten the lock
screws.

Closed status Opened status

9-46 T2850-120V-138Z-A02 Maintenances

 Figure 9.4-19 Adjustment of Travel Switch

4.2.2.3 Operation and Maintenance

1) Operations
Please check as below before the use of brake. The brake can be put into use after
all checking items are normal.
(1) Check the brake for correct and qualified installation.
(2) Check and ensure all adjustment items meet the technical requirements.
(3) Check the surfaces of brake pads and brake disc for cleanliness without any oil
dirt.
(4) Check for damaged paint and repair the damaged paint (if any). The paint repair
shall not contaminate the following locations: Hinge joints, braking surfaces of
brake pads and brake disc, and shaft surfaces.
2) Maintenances
Check the brake once every 7~10 days (Depending on the actual situation). The
checking items are as below:
(1) Check via the brake hydraulic cylinder observation port for cracking of Belleville
spring and leakage of hydraulic oil to Belleville spring. Upon detection of cracking
or oil leakage of Belleville spring, ensure to replace with new parts or repair (The
brake hydraulic cylinder is design optimized, with the theoretic work life up to
500,000 cycles).
(2) Disassemble the brake hydraulic cylinder as per following procedure: Open the
brake, loosen the adjustment nuts (Loosen for at least 10mm), remove the lock nut,
close the brake (to eliminate the spring force), remove the connecting hydraulic
pipeline, and remove the connecting pin on the rear base of cylinder to remove the
hydraulic cylinder. Install the new hydraulic cylinder as per reverse sequence. After
the replacement with new hydraulic cylinder, readjust the new cylinder properly
before use.
(3) Check the travel switch collision bar for looseness and correct motion.
(4) Check the dimension X for elongation due to wear of brake pads. The elongation will
reduce the clamping force. Ensure to adjust the dimension X to specified value.

The hydraulic cylinder incorporates special internal structure and proprietary

connection technology. Do not disassemble it by self. Consult with our company
Maintenances T2850-120V -138Z-A02 9-47
to prevent the spring-out of Belleville spring from causing personal injuries.
It’s recommended to replace integrally the malfunctioned hydraulic cylinder and
deliver the replaced hydraulic cylinder to our company for repairs!

The brake parts have a certain weight. Please guard against falloff and
personal injuries during replacement. During the replacement of brake pads,
ensure that the brake is under opened status and has no sudden closing
possibility.
4.2.2.4 Analysis and Troubleshooting of Common Malfunctions
1) No motion (no release) of brake after sending of electrifying command:
(1) The solenoid valve of the drive hydraulic station is not electrified due to the
circuit or control malfunction. Check the circuit or control system step by step
and solve the relevant malfunction.
(2) The no motion of solenoid valve is caused by open-circuit of control solenoid
valve coil. Measure by a multimeter to verify the open-circuit of coil and, upon
detection of open-circuit, replace with new solenoid valve coil.
(3) The brake can’t be opened due to under-low pressure setting of relief valve.
Observe the reading of pressure gauge on the hydraulic station for consistency
with the release pressure indicated on the brake nameplate. If below the
specified value, increase the system pressure to the required pressure with
reference to the operation manual of the hydraulic station.
(4) The motor is burnt. Measure the motor by a multimeter. If the motor is damaged,
replace with the motor of corresponding specification and model.
(5) The hydraulic oil is inapplicable for local environment temperature so that the oil
suction of the oil pump fails. Replace with hydraulic oil of corresponding
specification (It’s recommended to use L-HM46 or DTE25 hydraulic oil if the
environment temperature is 0~+30ºC and use L-HV32 or L-HS low temperature
hydraulic oil if the environment temperature is -20~+25ºC.
Malfunction precautions
Keep related control circuit units under good status (It’s better to set up over-voltage
protection for the motor and solenoid valve coil to prevent the burnout of coil due to
transient over-voltage), keep the hydraulic oil clean, and do not adjust any part or

9-48 T2850-120V-138Z-A02 Maintenances

component on the hydraulic station at will during normal working.
2) Non-equal clearance between two sides and floating fit onto brake disc on one
side
(1) The installation of brake is seriously inclined so that the brake center offsets
towards one side (installation error). Correct the transition connecting plate or
add adjustment shim between mounting bracket and transition connecting plate
for adjustment.
(2) The adjustment is improper during installation. Adjust as per above-mentioned
method.
3) Travel switch motion malfunction
(1) The distance is adjusted improperly. Adjust the limit switch barrel and push rod
to appropriate positions.
(2) The hydraulic oil is inappropriate for the change of seasons so that the hydraulic
oil viscosity is increased under low temperature and the brake can’t be opened
completely in place. Timely replace the hydraulic oil or appropriately adjust the
pump pressure of hydraulic station (Do not exceed 1.3 times of rated working
pressure).
4) Precaution
Adjust correctly during installation, check push rod for looseness during spot
checking, and choose hydraulic oil applicable for local working environment.

Maintenances T2850-120V -138Z-A02 9-49

4.2.2.5 List of Wearing Parts

Specification/drawing
Model Name Quantity Remarks
number
Dust ring AY4045 P5008 1 Parker
U-ring AU3 120135U 1 Oilcon
Wearing ring BS 50705 14.8×165 1 Oilcon
Wearing ring BS 50704 9.5×395 1 Oilcon
Step seal AS150450 1 Oilcon
SBD160-D Step seal AS1 301200 1 Oilcon
Steel wire 4×488 1
Wool felt 4X6-465 1
Belleville spring A 140-1(140×72×8) 11
O-ring 125×3.55 1
O-ring 40×3.5 1
Composite bearing SF-1 2535 2
Brake pad ZW270.2 2

4.3 Installation and Maintenances of Proximity Switch

4.3.1 Installation of Proximity Switch
The installation diagram of proximity switch is shown in Figure 9.4-20:

Center circle of sensing disc gear

Drum web

Disc gear
Proximity switch adjustment nut
Proximity switch mounting bracket
Proximity switch

Figure 9.4-20 Installation Diagram of Proximity Switch

9-50 T2850-120V-138Z-A02 Maintenances

 The installation requirements of proximity switch are as below:
(1) Adjust the double nut on the proximity switch in such manner that the distance A
from sensing face of proximity switch to the convex of disc gear is 12mm.
(2) The distance B from convex of disc gear to baseplate (End plate of drum) is 24mm
(which can be achieved by adding shim between disc gear and baseplate).
(3) Adjust the position of proximity switch in the kidney hole of the proximity switch
bracket, till the axis center of proximity switch is aligned with the center circle of
sensing disc gear tooth.
4.3.2 Maintenances of Proximity Switch
The hoisting mechanism (H132FL150-1230D) of T2850-120V tower crane is fitted
with a safety brake directly applied on the drum and controlled by proximity (over-speed
protection) switch. When the drum speed exceeds the maximum design speed, the
proximity (over-speed protection) switch for measurement of drum speed sends a signal
and the control system sends a power-off command so that the safety brake is powered
off to close, in order to prevent the safety accidents due to extreme conditions such as
failure of main brake and breakage of drive chain.
The maximum speeds of drums for luffing mechanism and hoisting mechanism and
the corresponding recommended actuation settings of over-speed protection switches
are listed in Table 9.4-10:
Table 9.4-10 Maximum Speed of Drums for Mechanisms and Recommended Actuation Settings of
Over-Speed Protection Switches

Maximum drum speed Speed setting of over-speed

Mechanism Mechanism model
(r/min) protection (r/min)
Hoisting
H132FL150-1230D 37 45
mechanism

Maintenances T2850-120V -138Z-A02 9-51

5 Maintenances of Slewing Mechanism
5.1 Overview
On T2850-120V tower crane, two slewing mechanism are arranged on the opposite
sides of the slewing upper support. The detailed specification is as below:
Table 9.5-1 Specification of Slewing Mechanism

Slewing mechanism HPW185F1.130A HPW185F2.130A

Model of motor YTRVFW180L1-4F1-18.5KW YTRVFW180L1-4F2-18.5KW

Rated output torque of
35000N.m
reducer
Pinion specification m=20，z=13，b=170，x=0.5

Figure 9.5-1 HPW185F1.130A

9-52 T2850-120V-138Z-A02 Maintenances

5.2 Slewing Brake
5.2.1 Work principle
The slewing brake is an electromagnetic brake that applies the braking once being
powered off, as shown in Figure 9.5-5.

Figure 9.5-5a Applied Status of Brake Figure 9.5-5b Released Status of Brake
Figure 9.5-5 Working Status of Brake
5.2.2 Clearance Adjustment

Figure 9.5-6 Maintenances of Slewing Brake

Maintenances T2850-120V -138Z-A02 9-53

 Ensure that the brake is internally free of other objects (Such as cement, sand,
and oil/grease). It’s preferable to take 0.8~1.2mm for air clearance E of the slewing
brake.

(1) As shown in Figure 9.5-7a, remove ①, ②, ③, ④, ⑤, and ⑥.

(2) As shown in Figure 9.5-7b, unscrew ⑦ to fit ⑧ closely to the ⑨.

Figure 9.5-7a Figure 9.5-7b

(3) As shown in Figure 9.5-7c, push down ⑦ and screw ⑧ to 3rd position.

(4) As shown in Figure 9.5-7d, reinstall ⑥, ⑤, ④, ③, ②, and ① and lock ⑦.

Figure 9.5-7c Figure 9.5-7d Maintenances

5.3 Maintenances
Adjust the brake under following conditions:
(1) After checking and repair of brake.

9-54 T2850-120V-138Z-A02 Maintenances

(2) Upon detection that the brake is incompletely released by manual release, as shown
in Figure 9.5-8.
(3) The signal lamp fails to turn on.

Maintenances T2850-120V -138Z-A02 9-55

 Figure 9.5-8 Manual Slewing Checking Method

(1) Check the wind vane for normal working and when necessary readjust. If the
clearance is higher than 1.2mm, timely adjust the clearance. The
recommended clearance is approximately 0.8mm.
(2) Timely replace the brake pad if a brake pad is worn for more than 3mm.
(3) For properly adjusted electromagnetic brake and electric wind vane, check
the manual release function, electric release function, and braking function
for normal functioning and ensure the normal functioning before use.

9-56 T2850-120V-138Z-A02 Maintenances

6 Maintenances of Traveling Mechanism
6.1 Maintenances of Trolley
(1) Daily check all connectors and ensure their secure and reliable connections.
(2) Daily check the reliability of clamps and hinge pins for rail clamps and timely
handle any abnormality detected.
(3) Daily check all travel switches and ensure their flexible and reliable motions.
(4) Check the functions of hydraulic rail clamps and traveling trolley control system
and the intactness of parts once every two working weeks and timely handle
any abnormality detected.
(5) Add lubricating oil to all lubricating points once every one working month. The
distribution of lubricating points is shown in Figure 9.6-1:
4 point
2 point

4 point

8 point

16 point

Figure 9.6-1
(6) Check the wheels once every two working months and scrap the wheel in event
of any of the following conditions:
① Cracking.
② The wheel tread thickness is worn to 15% of original thickness.
③ The wheel rim thickness is worn to 50% of original thickness.
6.2 Maintenances of Motor
The structure of the motor is shown in Figure 9.6-2. Fulfill the following maintenance
works for the motor periodically:

Maintenances T2850-120V -138Z-A02 9-57

 Second
brake First brake

1. Flange end cap 2. Bearing 3. Stator 4. Rotor 5. Wiring box 6. Bearing 7. Friction plate
subassembly 8. Brake disc 9. Friction plate subassembly 10. Armature (I) 11. Field core (I)
12. Primary brake 13. Release nut 14. Screw subassembly
Figure 9.6-2

6.2.1 Maintenances and Repairs of Motor

(1) Keep dry the working environment, keep clean the motor surfaces, and guard the air
inlet port against the obstruction of impurities such as dusts and fibers.
(2) If the short-circuit protection or frequency converter protection of the motor is
triggered frequently, check whether the malfunction is caused by motor or overload,
under-low rating of protection device, or inappropriate setting of frequency converter.
The motor can be put into use only after the malfunction is solved.
(3) Ensure the good lubrication of the motor during running. Add or replace lubricating
grease once every approximately 5,000h for general motors (It’s unnecessary to
replace lubricating grease for enclosed bearings throughout the lifecycle). Upon
detection of bearing overheating or lubricating grease deterioration during running,
timely replace the lubricating grease. While replacing the lubricating grease, remove
used lubricating grease, thoroughly clean bearings and bearing cap oil grooves by
gasoline, and fill 2/3 of the cavity between inner and outer races of bearings by ZL-2
lithium-based lubricating grease.
(4) While disassembling the motor, take out the rotor from either shaft extension end or
other end. While taking out the rotor from stator, take cautions to prevent damaging

9-58 T2850-120V-138Z-A02 Maintenances

 the stator winding or insulation.
6.2.2 Storage and Transport of Motor
(1) During the storage of motor, keep dry and avoid the sudden change of environment
temperature.
(2) Do not pile up too high during storage of motors, in order to prevent influencing the
ventilation and damaging the packages of lower layer motors.
(3) Prevent the inclination and offset or inverted arrangement during storage and
transport.
6.2.3 Precautions for Long-Term Non-Use of Motor
If the mechanisms are to be unused for a long time, take the dustproof and
waterproof measure for exposed parts of motor. During reuse, perform the mechanical
checking before installation. Check all parts for complete assembling, check fasteners
for looseness, thoroughly remove internal dusts and impurities (If any), and when
necessary blow clean by dry compressed air. Before use, ensure to measure the
insulation resistance between stator winding and housing by a 500V megameter. If the
measurement is below 0.5MΩ, the drying measure must be taken for the motor. It’s
permissible to charge low voltage to the winding for drying (The baking temperature shall
preferably not exceed 125ºC). To prevent rusting of motor, during the assembling after
disassembling and checking, apply a film of clean anti-rust oil to all fit surfaces and
threaded fasteners (Except the grounding bolts) and attach all fasteners with spring
washers to prevent spontaneous falloff. After assembling, rotate the rotor by hand. The
rotor shall rotate flexibly without any friction.
6.2.4 Wiring of Motor
(1) The motor shall be properly grounded. A grounding device is provided on the right
lower corner in the junction box. When necessary, ground by the foundation bolts or
flange fastening bolts of motor.
(2) The wiring board of motor has 10 wiring posts, as listed in Table 9.6-1.
Table 9.6-1 Wiring Posts on Wiring Board of Motor

Phase sequence A B C F1, F2 F3, F4

Head U1 V1 W1
Secondary brake Primary brake
Tail U2 V2 W2

(3) Connect the variable frequency motor to △ or Y form as per the wiring method

Maintenances T2850-120V -138Z-A02 9-59

 specified on the nameplate, as shown in Figure 9.6-3.

△ Wiring Method Y Wiring Method

Figure 9.6-3
When the phases A, B, and C of the power supply correspond to wiring post signs
U1, V1, and W1, the motor rotates clockwise (observed from the extension end of main
shaft). When the phase sequence of the power supply is changed, the motor rotates in
opposite direction.
6.2.5 Maintenances of Motor Brakes
The structural diagram of brake is shown in Figure 9.6-4:

Second
brake First brake

1. Brake pad subassembly; 2. Brake disc; 3. Friction plate subassembly; 4. Armature (I); 5. Spring
block (III); 6. Field core (I) with housing; 7. Brake spring (I); 8. Spring block (II); 9. Spring chamber; 10.
Brake spring (II); 11. Locating screw (II); 12. Field core (II) with housing; 13. Armature (II); 14. Spring
block (I); 15. Locating screw (I); 16. Spring bushing.
Figure 9.6-4

9-60 T2850-120V-138Z-A02 Maintenances

6.2.5.1 Adjustment of brake air clearance:
The brake pads will wear after long-time use to enlarge the air clearance between
electromagnet and armature, increase the spring length, reduce the spring pressure, and
lower the braking torque. In addition, the enlarged air clearance will increase the
actuation voltage of armature or even cause actuation failure of armature and increase
the noise and vibration of the motor. Therefore, frequently check and adjust the air
clearance.
6.2.5.1.1 The adjustment procedure of secondary brake is as below:
(1) Completely cut off all power supplies.
(2) Unscrew the locating screw (I) by a straight screwdriver.
(3) Screw a wrench into the spring chamber to compress the brake spring (I) and brake
spring (II) and ensure that the static braking torque reaches the specified 27N.m.
(4) Insert a tool (such as a screwdriver) into the air port of field core (I) with housing and
move leftward (Observed from the tail of brake) the tooth space on the perimeter of
the armature (I), till the armature (I) fits closely to the field core of main brake. Insert
the locating screw (I) into field core, push it against the armature (I), move rightward
slowly the armature (I), and find out the position of first hole between the armature (I)
and locating screw (I). By taking this hole as start point, continue to move armature
(I) to 4th hole and tighten the locating screw (I). In such case, the air clearance δ2
between armature (I) and field core is approximately 0.8mm.
Description: 12 small holes are distributed uniformly on the circle of same radius
with locating screw hole on the armature (I) and field core and the connecting threads
between armature (I) and brake disc are in pitch of 3mm.
6.2.5.1.2 The adjustment procedure of first brake is as below:
(1) Completely cut off all power supplies.
(2) Unscrew the locating screw (II) of primary brake by a straight screwdriver.
(3) Screw a wrench into the spring chamber to compress the brake spring (I) and brake
spring (II) and ensure that the static braking torque reaches the specified
(27+8.5)N.m.
(4) Insert a tool (such as a screwdriver) into the kidney hole of field core (II) with
housing (As shown in View A of Figure 5.4) and move leftward (Observed from the
tail of brake) the tooth space on the perimeter of the armature (II), till the armature (II)
fits closely to the field core of secondary brake. Insert the locating screw (II), push it

Maintenances T2850-120V -138Z-A02 9-61

 against the armature (II), move rightward slowly the armature (I), and find out the
position of first hole between the armature (II) and locating screw (II). By taking this
hole as start point, continue to move armature (II) to 6th hole and tighten the locating
screw (II). In such case, the air clearance δ1 between armature (II) and field core of
secondary brake is approximately 0.8mm.
Description: 12 small holes are distributed uniformly on the circle of same radius
with locating screw hole on the armature (II) and field core and the connecting threads
between armature (I) and brake block (I) are in pitch of 2mm.
6.2.5.2 Replacement procedure of brake pads:
(1) Completely cut off all power supplies.
(2) Unscrew the spring chamber and take out the brake spring (II).
(3) Unscrew the connecting bolts between field core (I) with housing and motor rear end
cap, carefully move the field core (I) with housing (Notice to protect the lead wires of
excitation coil. In such case, the field core (I) with housing is connected integrally
with the field core (II) with housing), and take out the friction plate subassembly and
brake disc.
(4) Remove the friction plate from the housing and replace with new friction plate of
same specification.
(5) Remove the brake pad affixed on the friction plate, replace with new brake pad of
same specification, and bond securely and reliably.
(6) Install the brake disc, friction plate subassembly, field core (I) with housing, brake
spring, and spring chamber in reserve sequence of steps a~e.
(7) Adjust the static braking torque and air clearance as per the adjustment procedures
of primary brake and secondary brake.
Caution:
a. To stop the machine, the primary brake is applied firstly and the
secondary brake is applied after a time delay. Determine the braking
sequence of brakes.
b. The brake shall be under intactness and its clearance shall meet the
requirement, otherwise the machine can’t be stopped timely to cause
safety accident.
6.3 Maintenances of Cable Drum
(1) Ensure to replace the lubricating oil of reducer after the first working month.

9-62 T2850-120V-138Z-A02 Maintenances

(2) Check the reducer oil level once every 2 months. If the oil level is below the center
of observation port, add HL-30 lubricating oil.
(3) Check the connection and fastening status of collector ring electric units once every
2 months and ensure the good contact and reliable connection of cable connectors.
In addition, measure the insulation status and ensure that the insulation resistance
is no less than 5MΩ.
(4) Ensure to replace the oil of reducer once every year. During replacement, unscrew
the hexagon screw plug near the bottom to fully drain the dirty oil and at the same
time unscrew the retainer. After the dirty oil is thoroughly drained, tighten the
hexagon screw plug, add clean HL-30 lubricating oil, and then tighten the retainer.
(5) Keep the surfaces of collector ring, motor, and reducer clean.
(6) Upon detection of deteriorated performance of any part due to excessive wear,
timely replace the part.
Caution:
a. Power off before opening the collector ring.
b. During working, it’s prohibited to insert the retainer into the nut slot.
c. The oil level in the reducer must be above the center of observation port.
d. When the main machine moves towards the power supply, the motor of
the cable drum shall start synchronously with the traveling mechanism of
the main machine and the motor of cable drum shall power off
simultaneously.
6.4 Bearing Model
Wheel bearing model:
GB/T283-1994 cylindrical roller bearing NJ232, 16 pieces for every trolley.
Traveling motor bearing model:
GB/T276-94 deep groove ball bearing 6306-2RS, 2 pieces for every motor.
6.5 Maintenances of Rail Clamps
Caution: During the repairs of rail clamps, affix a warning label In Service . The use of
any spare part inapplicable for this rail clamp will probably result in malfunction or
damage of the rail clamp. Please only use the spare parts supplied or approved by our
company.
6.5.1 Periodical Maintenances
1) Checking period
Maintenances T2850-120V -138Z-A02 9-63
(1) Once every 7~10 working days.
(2) When the rail clamp is not used for 6 months.
2) Checking of rail clamps and rails
(1) Opening clearance of rail clamp friction pads
Check/readjust the opening clearance.
(2) Thickness and wear status of friction pads
The tooth face thickness for the friction pads is 3.5mm. If the wear exceeds 1.5mm,
timely replace.
(3) Flexible rotation of connecting hinge pins
Upon detection of any stagnation, solve the stagnation or replace the bushing.
(4) Limit switches
Check limit switches for normal working and adjust or replace any abnormal switch.
6.5.2 Replacement of Friction Pads

！！！The surfaces of friction pads for rail clamps are of zigzag structure.
Guard against scratches during replacement.

！！！Any friction pad worn for >1.5mm must be replaced.

！！！The friction pads must be replaced by pair, otherwise the rail clamp
probably can’t work normally.

The replacement procedure is as below (Refer to Figure 9.6-5):

(1) Remove the power unit shield.
(2) Remove the connecting cable between rail clamp and main machine and manually
open the rail clamp (With reference to the operation manual of power unit).
(3) Remove the rail clamp and move the rail clamp integrally to the service platform.
(4) Remove the fastening bolts of friction pads.
(5) Push out the friction pads along direction A by bolt through the hole B. Take caution
to guard against being injured, as the friction pads are of certain weight. In addition,
guard against scratch as the surfaces of friction pads are of zigzag structure.
(6) Check the cleanliness of new friction pads and ensure their cleanliness.
(7) Install new friction pads and tighten the fastening bolts.
(8) Properly install the rail clamp in reverse sequence.
(9) Adjust the rail clamp.

9-64 T2850-120V-138Z-A02 Maintenances

 Friction pad fastening bolt
Friction pad

Hole B

Figure 9.6-5
6.5.3 Replacement of Limit Switch
(1) Cut off the power supply of limit switch and disconnect the connecting wire.
(2) Remove the mounting bolts of switch.
(3) Remove damaged (used) limit switch.
(4) Install new limit switch.
(5) Tighten the mounting bolts of limit switch.
(6) Connect the switch signal wire.
(7) Adjust the limit switch, till the limit switch works normally.
6.5.4 Replacement of Spring (Refer to Figure 9.6-6)

！！！The spring has a certain weight.

！！！Properly support it during removal and installation, in order to prevent
crushing danger.

(1) Support two sides of upper support by 5t jacks from direction A.

(2) Apply the pressure slowly to open the rail clamp.
(3) Remove the split pins and hinge pins from two sides of upper support.
(4) Slowly relieve the jacks, till the spring restores to free length and relieves the spring
pressure, and remove the elastic round pins, nuts, washers, and upper support.

Maintenances T2850-120V -138Z-A02 9-65

 Upper
Connecting Hinge Split
Nut Spindle support
rod pin pin

Spring

Figure 9.6-6
(5) Take out the spring in upward direction, remove the used spring, and install new
spring.
(6) Use jacks to install the rail clamp as per reverse sequence.
(7) Adjust the rail clamp.
6.5.5 Replacement of cylinder and cylinder seals
1) Replacement of cylinder (Refer to Figure 9.6-7)
Pipeline Connecting
screw Cylinder Support roller bracket

Frame

Figure 9.6-7
(1) Remove the spring (Refer to 6.5.3).
(2) Relieve the drive pressure of power unit, cut off the power supply of power unit, and
remove the pipeline between cylinder and power unit. During this process, notice to
recover the used oil to prevent environment contamination.
(3) If there is a removal/installation space above, hoist out the support wheel bracket in
vertical direction. If not, remove the whole rail clamp and then hoist out the support
wheel bracket.

9-66 T2850-120V-138Z-A02 Maintenances

(4) Place horizontally the support wheel bracket, remove the connecting screws
between cylinder and bracket, and take out the cylinder.
(5) Replace with new cylinder and install the cylinder and spring in reverse sequence.
(6) Adjust the rail clamp.
2) Replacement of cylinder seals (Refer to Figure 9.6-8)

Figure 9.6-8

Table

No. Name No. Name No. Name

1 Oil drainage plug 5 Piston rod 9 Set screw
2 Cylinder block 6 Guide sleeve
3 Seal subassembly 7 Flange
4 Piston 8 Dust ring seat

(1) Remove the cylinder.

(2) Remove the set screw (Part 9) from the cylinder.
(3) Clamp the cylinder block (Part 2) securely by a tool, clamp the flange (Part 7) by
another tool, rotate the flange, and remove the flange (Part 7), guide sleeve (Part 6),
and piston rod (Part 5).
(4) Take out the connecting screw on the dust ring seat (Part 8), take out the dust ring
seat, and take out the seal subassembly (Part 3) in turn.
(5) Clean the piston rod (Part 5), inner walls of cylinder block (Part 2), and inner and
outer walls of guide sleeve (Part 6) by gasoline or kerosene, then clean
above-mentioned locations by high pressure water gun, and finally blow dry

Maintenances T2850-120V -138Z-A02 9-67

 above-mentioned locations by compressed air.
(6) Install new seal subassembly in turn and notice the orientation of seals. The
grooved side shall face towards the pressure oil side.
(7) Assemble the cylinder in reverse sequence of above procedure.
(8) Test under 1.5 times of rated pressure (Refer to Table 3-4 for related pressure).
(9) If there is no leakage after the pressure is applied for half hour, assemble the
cylinder to the rail clamp. Upon detection of leakage, reinstall the seals as per
above-mentioned procedure, till the leakage is eliminated.
(10) Assemble the rail clamp.
(11) Adjust the rail clamp.
6.5.6 Malfunction Analysis and Troubleshooting
Malfunction Possible cause Solution Related section
Complete closing of power Refer to operation manual of
Check and open.
Closing unit one-way cutoff valve installed power unit.
failure of rail Damage of spring Replace spring. 6.5.4
clamp
Wear or damage of friction Replacement the friction
6.5.2
pad pads.

Check and connect

Improper connection of
wiring as per specified
power unit electric wiring
requirements.
One-way cutoff valve not Refer to operation manual of
Check and open. power unit.
opened
Opening No opening pressure or Adjust power unit.
failure or insufficient pressure supplied
Replace damaged
insufficient by power unit hydraulic units.
opening
clearance of Improper connection of
Check and connect.
rail clamp hydraulic pipeline
Interference between equal
Adjust equal clearance
clearance bolt and clamp
bolt.
arm
Replace cylinder or
Oil leakage of cylinder 6.5.5
cylinder seals.

Clamping of Insufficient rail groove width Check and feed back to

rail during us.
operation Impurities on two sides of rail Check and clean.
with rail Non-equal opening
clamp Adjust equal clearance
clearance between frication
opened bolt.
pads on two sides

9-68 T2850-120V-138Z-A02 Maintenances

6.5.7 List of Spare Parts
No. Name Quantity Unit Remarks
1 Limit switch 1 Piece
2 Seal subassembly 1 Set
3 Brake spring 1 Piece
4 Friction pad 2 Piece

6.5.8 Maintenances of Power Unit

The good maintenances can reduce the malfunction rate and prolong the life of the
hydraulic station.
1) Preparations before use
(1) After the installation of hydraulic connecting pipes between brake and power unit,
repeatedly flush the pipelines. Connect the pipeline to the oil outlet port of power
unit only after the pollution degree of flushing oil reaches grade NAS8, otherwise the
impurities in the pipeline will probably cause serious damage to the hydraulic
system.
(2) Before the first use, verify the voltages of power supply and control signal and check
the motor for correct rotation direction. The correct rotation direction is clockwise.
(3) To add oil into the oil tank, use an oil filter and add approximately 4L oil, till the oil
level is above 2/3 of the oil tank level gauge. Periodically check the oil tank level
gauge. The oil level of the oil tank shall be no less than 1/2 of the level gauge.
2) Daily Checking
Check the following items once every 100~150 working hours:
(1) Check oil level.
(2) Check all pipeline connections for looseness.
(3) Check for presence of oil permeation/leakage
(4) Check motor, pump, and valve groups for normal running sound.
Upon detection of any abnormality, stop the working of power unit and solve the
malfunction before further use.
3) Replacement of power unit and cleaning system
(1) Replace hydraulic oil (ISO46 or ISO32. Refer to corresponding nameplate) and
clean the system (Including filter and oil tank) after the first 6 working months of
power unit.
(2) During the normal use, replace the hydraulic oil and oil suction filter (depending on

Maintenances T2850-120V -138Z-A02 9-69

 the use frequency) at least once every year or one and half years. During the
replacement of oil, fully drain the oil from the oil tank via the oil drainage valve on the
bottom of oil tank, thoroughly remove all impurities from the bottom and inner walls
of the oil tank, and remove the tiny particles from the corners and bottom by a paste
or plaster. While adding oil, use an oil filter to ensure that the oil added into the oil
tank is clean. The filter element for the oil filling filter shall be no higher than 20μ.
Add the oil, till the oil level reaches 2/3 of the level gauge.
4) List of Main Procured Parts
No. Name Specification Quantity Remarks
1 Oil suction port filter X-80 1 Luye
2 Gear pump CBWmba-F4.0-ALP 1 Hefei Changyuan
3 Motor M2QA90L4A (1.5KW) 1 ABB
4 Air filter C-M12 1 Liming
5 Relief valve RV10-20A-0-N-33 1 HYDRAFORCE
6 Check valve CV10-20-0-N-15 1 HYDRAFORCE
7 Solenoid valve SV10-21P-0-N-230AG 1 HYDRAFORCE
8 One-way throttle valve FC10-20A-0-N 1 HYDRAFORCE
9 Manual pump HP10-21A0-N-B 1 HYDRAFORCE
10 Pressure relay HED8 OP2X/200K14 1 REXROTH

9-70 T2850-120V-138Z-A02 Maintenances

7 Maintenance of Auxiliary Mechanism
7.1 Overview
The auxiliary mechanism for this tower crane is in model of H25FP15-440-d and is
under variable frequency control by a variable frequency motor in model of
YZPFM200L2-8(50Hz). There are two control positions each for the lifting and lowering
functions.
Table 9.7-1 Technical Specification of Auxiliary Mechanism

Magnification α＝2

Control position I II
Hoisting capacity
2.9 2.9
(t)
Speed (m/min) 6.4 20
Rope capacity of drum (m) 440(6-layer) / 359(5-layer)
Minimum stable speed (2X) (m/min) ≤6.4

Table 9.7-2 List of Main Parts for Auxiliary Mechanism

No. Name Model

1 Motor YZPFM200L2-8
2 Reducer JD610
35×7-13-1770
3 Wire ropes
or 6×29Fi+IWR-13-1770
4 Primary brake YWZ3-315/45-16
5 Self-aligning ball bearing 1314(GB/T281-1994)
6 Knuckle bearing GE60ES(GB/T9163-2001)

Maintenances T2850-120V -138Z-A02 9-71

1-Motor 2-Coupling 2-Brake 4-Reducer 5-Toothed connecting plate 6-Drum 7-Height limiter
Figure 9.7-1 Auxiliary Mechanism
7.2 Adjustment and Maintenances of Brake
7.2.1 Overview
The structure of electrohydraulic block brake is shown in Figure 9.7-2:

1. Electrohydraulic thruster 2. Lever 3. Brake spring 4. Brake arm

5. Brake shoe 6. Hinge pin 7. Base
Figure 9.7-2 Electrohydraulic Block Brake
(1) Checking before installation: Check the technical parameters (voltage and
frequency) on the thruster nameplate for consistency with working parameters
and check the technical parameters on the brake nameplate for consistency
with design requirements.
(2) Before use, ensure to add clean L-HM46 anti-wear hydraulic oil into the
electrohydraulic thruster.

The oil level shall not exceed position B, otherwise the oil will leak via push rod and
other locations and after a long time the oil will breach into motor to cause malfunction
and burnout of motor.

9-72 T2850-120V-138Z-A02 Maintenances

 After being filled with oil, the thruster can be placed vertically, otherwise the oil will
breach into the motor to cause malfunction.
7.2.2 Installation and Adjustment
(1) Loosen the nut E and nut F (Refer to Figure 9.7-2) to expand brake arms
towards two sides in such manner that the brake can axially attached onto the
brake wheel.
(2) Adjustment: After the installation, the adjustment is required. Firstly, rotate the
nut E to clamp the brake shoes onto the bake wheel and then rotate further in
same direction. In such case, the right thruster push rod will lift slowly and the
installation dimension H will meet the requirement in Table 7.3-1. Rotate the nut
F in reverse direction to tighten. Secondly, rotate the nut G to compress the
spring so that the spring length meets the length requirement in Table 7.3-1.
(3) The installation dimension H shall be no less than the minimum installation
dimension in Table 7.3-1 under the clamped status.
(4) Add L-HM46 anti-wear hydraulic oil during the repair of thruster and replace
with clean oil after three continuous working months.
(5) After all checking items are normal, test the brake on the main unit under
no-load condition for several times to run in the brake pads and ensure the
good fit with the brake wheel.
Table 9.7-3 Basic Parameters and Main Dimensions

Brake lever ratio Hydraulic thruster

16
Rated thrust force N

Minimum
Rated travel mm

Weight kg

Model Wheel installatio

Clearanc
Power kW

of diamete n
Rated braking

Model

e mm
torque N·m

Installation
installation

brake r mm dimension
height H
Spring
length
1mm

Hmin
mm

YWZ3-
YT45/
315/45 315 1.25 630 196 478 465 450 60 0.12 78
6
-16

The brake installed on this mechanism is in model of YWZ3-315/45-16, with the

rated braking torque at 630N.m. For this tower crane model, the braking torque shall be
Maintenances T2850-120V -138Z-A02 9-73
adjusted to 500N.m and the installation length of the brake spring shall be 206mm.
7.2.3 Replacement of Brake Pads
(1) Open the brake to the maximum opening extent.
(2) Unscrew the pressure plate bolts on the upper end of brake pad and take out
the pressure plate and adjustment shim.
(3) Hold the brake pad by hand, push it towards the brake wheel, and pull out the
brake pad to be replaced along the circumferential direction of the brake wheel.

(4) Insert new brake pad (Notice the correct position during insertion), install ⑤,

④, ③, and ② in turn, and tighten ①, as shown in Figure 9.7-4.

The replacement brake pad shall fit closely with the brake shoe, with the clearance
at any position of the fit surface no more than 0.5mm. Its upper end shall be higher than
top face of brake shoe by 1~1.5mm, in order to compress tightly the brake pad and
ensure secure fixing.

1-Bolt 2-Spring washer 3-Pressure plate 5-Guard plate 5-Adjustment shim

Figure 9.7-4 Replacement of Brake Pad
7.2.4 Maintenances of Brake
(1) Check the brake once every 1~3 days (Depending on the actual situation). The
checking items are as below:
Check the work travel of thruster (namely clearance of brake shoe) for normality.
Check automatic compensator for wear and check compensation sleeve and set
screws for looseness.
Check work length of brake spring for change.

9-74 T2850-120V-138Z-A02 Maintenances

 Check limit switch collision plate for looseness and correct position.
Check surfaces of brake wheel and brake pads for oil contamination.
Check the wear status of brake pads. If the effective thickness of the brake pad is
worn to 3mm, replace the brake pad. Readjust and run in after every replacement of
brake pad.
Some colorful spots probably appear on the brake wheel during emergency braking.
In event of serious cracking, replace the brake wheel.
(2) Checking during use:
Timely check the following items during use:
Check for abnormal increasing of braking time or braking distance during
operations.
Check the over-speed of brake wheel during use of the mechanism.
In event of any abnormality (Such as continuous high temperature (>350ºC) or
smoking) on the brake wheel or brake pads, stop the machine, check for the cause, and
solve the malfunction before further use.
(3) Paint repair: The paint of the brake will probably be damaged during transport,
storage, installation, and use. Repair the paint timely, otherwise the
anti-corrosion performance of the structural part surfaces will be impaired.
During the paint repair for the brake and related parts, guard the following
locations against contamination:
All hinge points.
Friction surfaces of brake wheel and brake pads.
Push rod surfaces of automatic compensator and thruster.
Shaft surfaces.
(4) Lubrication: The self-lubricating composite bearings are applied for all hinge
points in the brake so that it’s unnecessary to add lubricating oil during use.
(5) Replacement of brake pad: The brake pads of the brake will wear after a period
of use. When the effective thickness of the brake pads is worn to 3mm, replace
the brake pads. The brake pads are of certain weight. Notice the safety during
replacement. Refer to 7.2.3 for the replacement method.

After the installation of new brake pads, check, run in, and test run.

Maintenances T2850-120V -138Z-A02 9-75

7.3 Maintenances of Motor
Same with the maintenances of motor for hoisting mechanism.
7.4 Maintenances of Reducer
Same with the maintenances of reducer for hoisting mechanism.
7.5 Checking of Coupling
Same with checking of coupling for hoisting mechanism.
7.6 Cause Analysis and Troubleshooting for Wire Rope
Arrangement Problem of Auxiliary Mechanism
Same with the cause analysis and troubleshooting for wire rope arrangement
problem of hoisting mechanism.

9-76 T2850-120V-138Z-A02 Maintenances

8 Lubrication
8.1 Overview
The symbols in the lubrication table indicate the type of lubricants in use and the
different lubricating points. The thorough and regular lubrication with the lubricants
specified in the operation instructions can help prevent accidents and reduce earlier
wear. Clean the oil nozzles and oil drainage port before lubrication.

All repairs must be performed under stopped status of the tower crane.
8.2 Table of Lubricants
The table of lubricants for Zoomlion tower crane is as below.
Name of lubrication
No. Part name Type of lubricant Volume
component
Hoisting wire rope Graphite calcium-based lubricating grease
1 Wire ropes
Luffing wire rope ZG-SSY1405-65
Hoisting mechanism
Industrial closed gear oil L-CKD 150
reducer
Luffing mechanism
1# lithium-based lubricating grease
reducer
Add oil as
Slewing mechanism per
2 Reducer 000# reducer lubricating grease
reducer reducer
label
Traveling mechanism
HL-30 lubricating Oil
reducer
Auxiliary mechanism
Industrial closed gear oil L-CKD 150
reducer
Drum bearing
3 Rolling bearing Calcium-based lubricating grease
Slewing support
Winter: Calcium-based lubricating grease ZG-2
4 Pulleys All pulleys
Summer: Calcium-based lubricating grease ZG-5
Hydraulic jacking
5 Oil tank U.S. ESSO AW46
pump station
Wire rope twist
6 Bearing B Molybdenum disulfide calcium-based ZG-1
control device
Wire arrangement
7 Pulley shaft 2# sodium-based lubricating grease
pulley
8 Hook Bearing Lubricating oil
Travelling wheel
9 Traveling trolley ZG-5 calcium-based lubricating grease
bearing and shaft
10 Hydraulic push rod Hoisting brake DB-25 0.87L

8.3 Lubrication of Slewing Support

As per the operation instruction of lubricants for Zoomlion tower crane, the slewing

Maintenances T2850-120V -138Z-A02 9-77

support must be lubricated by resin roller bearing lubricant completely without acid
substance. Inject the roller bearing lubricant into all bearing oil nozzles by an injection
device. Then, slew the tower crane for approximately 7.5º and then inject the lubricant
again. Repeat this process for 4~5 times, till the lubricant overflows from the gaps of
bearings.
Upon detection of any blank spot on the teeth of slewing support, the re-lubrication
is required.

9-78 T2850-120V-138Z-A02 Maintenances

9 Common Malfunctions and Troubleshooting
Malfunction
No. Malfunction cause Troubleshooting
symptom
Over-high reducer Add or reduce the oil
1 Insufficient or excessive lubricating oil
temperature appropriately.
a. Replace with appropriate
a. Mainly excessive or insufficient amount of lubricating
Over-high reducer lubricating grease grease as per
2 bearing b. Low quality lubricating grease specification.
temperature c. Disqualified axial play or damage of b. Readjust bearing
bearings clearance.
c. Replace bearings.
Reducer oil Poor fitness of the connection fit surface
3 Replace seal ring.
leakage and wear damage of shaft end seal ring
a. Wear and reduced efficiency of oil
pump
b. Insufficient oil in oil tank or blockage a. Repair or replace
of oil filter damaged parts.
4 Slow jacking
c. Serious wear of manual reversing b. Add sufficient oil or clean
valve stem and valve port oil filter.
d. Internal leakage due to damage of
cylinder piston seals
a. Serious internal leakage of oil pump
a. Repair or replace worn
b. Under-low regulated pressure of parts.
Weak jacking or relief valve
5 b. Adjust pressure as per
jacking failure c. Excessive wear of manual reversing specification.
valve core
c. Clean hydraulic valve.
d. Blockage of relief valve
Noise and
vibration during
6 Blockage of oil filter Clean oil filter.
increasing of
jacking pressure
Work failure of Incorrect rotation direction of motor and Change rotation direction of
7
jacking system oil pump motor.
Vibration and a. Incomplete bleeding of air from a. Bleed air as per
8 creepage during cylinder piston specification.
jacking b. Obstruction of guide mechanism b. Adjust guide wheel.
Automatic a. Malfunction of balance valve on
lowering at cylinder head Solve malfunction and
9
application of load replace seals.
during jacking b. Damage of cylinder piston seals

a. Place joystick to neutral

a. Joystick not in neutral
Failure of master position.
10 b. Burnout of electric cabinet fuse
starter button b. Replace fuse.
c. Poor contact of starter or stop button
c. Repair or replace button.

Maintenances T2850-120V -138Z-A02 9-79

 Malfunction
No. Malfunction cause Troubleshooting
symptom
a. Check whether the
a. Actuation of over-current breaker
hoisting brake is opened
due to over-current of hoisting motor
and check over-current
Tripping during b. Insufficient capacity of construction steady value for change.
11
hoisting motion field transformer or insufficient
b. Replace transformer or
diameter of power cable between
replace with cables of
transformer and tower crane
lager diameter.
a. Control wiring error a. Verify against wiring
b. Burnout of fuse diagram
c. Inter-phase short-circuit, ground, or b. Check fuse for sufficient
open-circuit of motor windings capacity. If not, replace
d. Under-low motor voltage with fuse of higher
capacity.
e. Winding wiring error
c. Measure the voltage of
Start failure of f. Electromagnetic brake not opened the power grid.
12 hoisting g. Over-high load or malfunction of d.
mechanism Find out the short-circuit
drive mechanism and open-circuit location
as per specification and
repair.
e. Check brake voltage and
check brake windings for
open-circuit and
blockage.
a. Mechanical friction a. Check for uniform
 Friction between stator and rotor clearance between stator
 Non-concentricity between motor and rotor.
Abnormal noise and reducer box b. Check slip ring for wear
and excessive b. Serious oil shortage or damage of and replace.
13
vibration of luffing bearings c. Clean bearings, add new
mechanism c. Insufficient oil in gearbox oil, or replace bearings.
d. Wear of gears d. Replace gearbox.
e. Two-phase running, with abnormal e. Cut off power supply,
noise check, and repair.
Overheating of a. Burnout of bearing a. Replace bearings.
14 luffing mechanism b. Excessive or insufficient lubricating b. Add lubricating grease
bearings grease as per requirements.
a. Incorrect connection of power and a. Find out and correct.
Live status of grounding wires b. Ensure good grounding
15
luffing mechanism b. Poor grounding contact.
c. Scratch or ground of motor wiring c. Find out and correct.
a. Brake spring is failed or
a. Under-low braking torque
Failure of luffing broken. Replace.
16 Increased clearance of brake pads
mechanism brake b. b. Check for insufficient
due to wear
excitation or voltage.
Start failure of
Mainly observe for blockage of impurities
17 slewing Remove impurities.
at gears.
mechanism

9-80 T2850-120V-138Z-A02 Maintenances

 Malfunction
No. Malfunction cause Troubleshooting
symptom
a. Measure the stator
current. If above rated
value, reduce the load.
b. Run as per the
a. Excessive load specification.
b. Continuous load or disqualified work c. Measure three-phase
c. Two-phase running current and solve
d. Over-high or under-low power malfunction.
Over-high voltage d. Check and correct input
temperature rise voltage.
18 or smoking of e. Grounding or inter-turn or
luffing mechanism inter-phase short-circuit of motor e. Find out and repair the
motor winding cause.
f. Incorrect clearance of brake pads f. Adjust clearance as per
g. Incorrect braking and release timing specification.
h. Blockage and increase temperature g. Check the brake voltage
of motor air duct and the actuation time of
delay breaker and solve
the malfunction.
h. Keep the air duct
non-obstructed.

Maintenances T2850-120V -138Z-A02 9-81

10 Wire Rope
10.1 Basic Knowledge of Wire Rope
(1) Measurement of Wire Rope Diameter
While measuring the diameter of wire rope, notice the correct measurement method,
as shown in Figure 9.10-1.

Incorrect

Correct

Figure 9.10-1 Measurement of Wire Rope Diameter

(2) Unloading and Storage
To prevent accidents, unload the wire rope with caution. It’s prohibited to fall the
drum or rope roll or insert metal hook or forklift forks into the wire rope, as shown in
Figure 9.10-2.

9-82 T2850-120V-138Z-A02 Maintenances

 Figure 9.10-2 Unloading
The wire rope shall be stored in a cool and dry warehouse, without any contact with
ground. It’s prohibited to store wire rope in a place vulnerable to exposure of chemical
smoke, steam, or other corrosive. Periodically check the stored wire rope and when
necessary wrap the wire rope. If the outdoor storage is absolutely necessary, cover the
wire rope to prevent rust by moisture, as shown in Figure 9.8-3.
The wire rope removed from the crane for future use shall be thoroughly cleaned.
Before storage, wrap every wire rope. All wire ropes in length of >30m shall be stored on
a drum.

Figure 9.10-3 Storage

(3) Uncoiling of Wire Rope

During uncoiling, place the rope roll on a special bracket or insert a steel tube into

Maintenances T2850-120V -138Z-A02 9-83

the rope roll hole, attach a rope to two ends of steel tube, hoist the rope roll, and slowly
rotate the rope roll, as shown in Figure 9.10-4.

Figure 9.10-4a Uncoiling from Rope Roll

9-84 T2850-120V-138Z-A02 Maintenances

Maintenances T2850-120V -138Z-A02 9-85
 Figure 9.10-4b Uncoiling from Drum
Figure 9.10-4 Uncoiling of Wire Rope
(4) Wire rope clamps
(1) Arrangement of wire rope clamps
As shown in Figure 9.10-5, clamp the clamp seats of wire rope clamps on the work
segment of wire rope and clamp the U-bolts to the tail segment of wire rope. Do not
arrange the wire rope clamps alternately on the wire rope.

Correct

Incorrect

Figure 9.10-5 Correct Arrangement Method of Wire Rope Clamps

(2) Quantity of wire rope clamps
For the applications meeting the requirements of this standard, the recommended

9-86 T2850-120V-138Z-A02 Maintenances

minimum quantity of wire rope clamps for every connection is listed in the table below:
Minimal dimension of wire rope clamps
≤19 >19~32 >32~38 >38~44 >44~60
(Nominal diameter d of wire rope)
Minimum quantity (set) of wire rope clamps 3 4 5 6 7

(3) Spacing between wire rope clamps

As shown in Figure 9.10-6, the spacing A between wire rope clamps equals to 6~7
times of wire rope diameter.

Figure 9.10-6 Spacing between Wire Rope Clamps

(4) Fastening method of wire rope clamps
While fastening the wire rope clamps, the reasonable force application of every wire
rope clamp shall be taken into consideration and the wire rope clamp farthest from the
eye ring shall not be firstly fastened separately. The wire rope clamp nearest to the eye
ring (First wire rope clamp) shall be as close as possible to the eye ring, provided that
the wire rope clamp is correctly tightened and the outer layer of wire rope is not
damaged.
10.2 List of Wire Ropes
The wire ropes used on T2850-120V tower crane are listed in the table below.
Reference Minimum
Model and Diameter Rope end
Name weight breaking
specification (mm) fastening method
(kg/100m) force (kN)
Hoisting wire Pressure plate and
35W×K7-32-1870 Φ32 522 785
rope wedge sleeve
Luffing wire 6×29Fi+IWR-22-1 Pressure plate and
Φ22 202 305
rope 870 wedge sleeve
Auxiliary
Wedge sleeve and
mechanism 35×7-13-1770 Φ13 78.6 123
wedge block
wire rope

The installed hoisting wire rope is an anti-rotation wire rope. The hoisting wire rope
and the luffing wire rope must conform to the relevant requirements of GB/T20118. In
addition, the following requirements must be met: (d is the theoretic diameter of wire
rope)

Maintenances T2850-120V -138Z-A02 9-87

(1) The minimum breaking force shall be no less than 785kN for hoisting wire rope and
no less than 305kN for luffing wire rope.
(2) For hoisting wire rope and luffing wire rope, the diameter in any section shall be
within 0.12d~1.04d and the out-of-roundness error shall be within 0.03d.
(3) The twist control performance of the hoisting wire rope shall be no higher than 360º.
(4) The lateral pressure stability shall be no higher than 0.01d for both hoisting wire
rope and luffing wire rope.
(5) The diameter shrink percentage shall be no higher than 0.01d for both hoisting wire
rope and luffing wire rope.
10.3 Length of Wire Ropes
The length of the wire ropes in use shall sufficiently meet the working requirements
of this tower crane and at least three turns of wire rope shall be kept on the end position
of the drum. Depending on the working situation, if it’s necessary to cut a segment from a
long wire rope, both cut ends shall be treated. Alternatively, appropriate method shall be
taken to prevent the looseness of wire rope during cutting, as shown in Figure 9.10-7.

9-88 T2850-120V-138Z-A02 Maintenances

 Figure 9.10-7 Preparations before Cutting of Wire Rope (L≥2d)

10.3.1 Calculation of Hoisting Wire Rope Length

Length of hoisting rope required for the tower crane:
L＝L0+f×H
L0 - Length of hoisting wire rope required when the hoisting height of tower crane is
0 (m).
f - Working magnification of tower crane.
H - Hoisting height of tower crane (m).
Length of hoisting wire rope
Boom length (m) 50 60 70 80 85
L0(m) 132 142 152 162 167

For instance: When the tower crane is operating at 4X magnification, with the boom
length at 70m and the hoisting height at 63m, the required hoisting wire rope length:
L＝152+4×63=404(m)
10.3.2 Length of Luffing Wire Rope
The luffing wire ropes for T2850-120V tower crane are installed as per 85m boom
length. For diversified ranges, the lengths of the long and short luffing wire ropes:
Lengths of Long and Short Luffing Wire Ropes under Diversified Ranges

Boom length (m) 50 60 70 80 85

Length of wire rope I (m) 160 180 200 220 230

Maintenances T2850-120V -138Z-A02 9-89

 Length of wire rope II (m) 115 125 135 145 150
10.3.3 Length of Auxiliary Mechanism Wire Rope
The length of the wire rope installed for the auxiliary mechanism is 520m.
10.4 Installation of Wire Ropes
Do not place the wire rope randomly during installation, namely do not twist inward
or outward during rotation. During installation, always bend the wire rope towards one
same direction, namely release the wire rope in same direction from top of rope roll to
top of drum or from bottom of rope roll to bottom of drum.
While fastening the rope end, take special cautions to ensure safety and reliability
and meet the requirements of the crane manual.
Upon detection of friction between any part of the crane and the wire rope during
installation, the effective protection measure shall be taken for the contact area.

Figure 9.10-8 Winding of Wire Rope with Tensioner from Bottom of Rope Roll to Bottom of Drum

10.5 Scrap of Wire Rope

(1) Characteristics and Quantity of Broken Wires

For 6-strand and 8-strand wire ropes, the broken wire commonly occurs on the
external surface. For non-rotation wire ropes, the broken wire mostly occurs in the inside
so that it’s non-visible.
The quantity of visible broken wires and the scrape criterion for the wire rope are
listed in Table 9.10-1 and Table 9.10-2.

9-90 T2850-120V-138Z-A02 Maintenances

 Table 9.10-1 Quantity of Visible Broken Wires Qualifying Scrap Criterion in Single-Strand and
Parallel-Closed Wire Ropes Used on Steel Pulleys

Quantity of visible broken wires b

Segment of wire rope used on steel pulley and/or Segment of wire rope
Categor single-layer enwound on drum (Random multi-layer enwound on
y Number of
load-carryin distribution of broken wires) d drum c
number
of wire g wires in Working grade M1~M4 or unknown grade All working grades
rope outer layer
strand a n Regular lay Lang lay Regular lay and lang lay
RCN
Length range Length range
>6de >30de >6de >30de >6de >30de
01 n≤50 2 4 1 2 4 8
02 51≤n≤75 3 6 2 3 6 12
03 76≤n≤100 4 8 2 4 8 16
04 101≤n≤120 5 10 2 5 10 20
05 121≤n≤140 6 11 3 6 12 22
06 141≤n≤160 6 13 3 6 12 26
07 161≤n≤180 7 14 4 7 14 28
08 181≤n≤200 8 16 4 8 16 32
09 201≤n≤220 9 18 4 9 18 36
10 221≤n≤240 10 19 5 10 20 38
11 241≤n≤260 10 21 5 10 20 42
12 261≤n≤280 11 22 6 11 22 44
13 281≤n≤300 12 24 6 12 24 48
n>300 0.04n 0.08n 0.02n 0.04n 0.08n 0.16n
Note 1: The Seale wire ropes with outer strand in quantity of ≤19 wires per strand (Such as 6×1
Seale type) are divided into two rows in the table, of which the top row denotes the quantity of
regularly laid outer strand load-carrying steel wires.
Note 2: The above-mentioned values for the segment of wire rope multi-layer enwound on the drum
are also applicable for other segments of wire ropes working on the pulleys made of or lined with
composite material. However, these values are not applicable for wire rope single-wire enwound on
pulleys made of or lined with composite material.
a In this criterion, the filler wires are not considered as load-carrying wires and thus are not
included in the value n.
b One broken wire has two broken ends (Counted as one wire).
c These values are applicable for the segments damaged in spring layer or due to interference
between overlap layers under the influence of the enwinding angle (Not limited to the segments of
wire rope working on pulleys or not enwound on the drum).
d The above-mentioned quantities of broken wires can be doubled for the mechanism with known
working grade at M5~M8. Refer to GB/T24811.1-2009.
e d - Nominal diameter of wire rope.

Maintenances T2850-120V -138Z-A02 9-91

 Table 9.10-2 Quantity of Visible Broken Wires Qualifying Scrap Criterion for Non-Rotation Wire
Ropes

Quantity of visible broken wires b

Segment of wire rope used on
Category Number of steel pulley and/or single-layer Segment of wire rope multi-layer
number of load-carrying wires enwound on drum (Random enwound on drum c
wire rope in outer layer distribution of broken wires) d
RCN strand a n
Length range Length range
>6de >30de >6de >30de
21 4 strands ≤100 2 4 2 4
3 or 4 strands ≤100 2 4 4 8
At least 11 outer
strands
23-1 76≤n≤100 2 4 4 8
23-2 101≤n≤120 2 4 5 10
23-3 121≤n≤140 2 4 6 11
24 141≤n≤160 3 6 6 13
25 161≤n≤180 4 7 7 14
26 181≤n≤200 4 8 8 16
27 201≤n≤220 4 9 9 18
28 221≤n≤240 5 10 10 19
29 241≤n≤260 5 10 10 21
30 261≤n≤280 6 11 11 22
31 281≤n≤300 6 12 12 24
n>300 6 12 12 24

(2) Broken wires at rope ends

Though the quantity is few, the broken wires at or near the rope ends indicate high
stress at such location, which is probably caused by the incorrect installation of rope
ends. Check for the damage cause. For further use, if the remaining length is enough,
cut short the wire rope (by cutting off the broken wire area from rope end) and refabricate
the rope end. Otherwise, the wire rope shall be scrapped.

(3) Partial concentration of broken wires

If the broken wires gather together to form partial concentration, the wire rope shall
be scrapped. If there broken wires are gathered within a rope length of <6d or are
concentrated within one strand, the wire rope shall be scrapped, even if the quantity of
broken wires is less than the values given in the Table 9.10-1 and Table 9.10-2.
9-92 T2850-120V-138Z-A02 Maintenances
(4) Increment rate of broken wires

In some application cases, the fatigue is the main cause for the damages of wire
rope and the broken wires start to appear after a period of use. When the quantity of
broken wires increases gradually and the interval becomes shorter, to judge the
increment rate of broken wires, carefully check and record the increment status of
broken wires. This “law” can be used to determine the future scrap date of wire rope.

(5) Breakage of strand

Upon detection of any broken rope strand, the wire rope shall be scrapped.
(6) Reduced rope diameter due to damage of rope core
When the actual measured diameter of a non-rotation wire rope is reduced by 3%
than nominal diameter or is reduced by 10% than other wire ropes, the wire rope shall be
scrapped, even if there is no visible broken wire.
Note: The actual diameter of a new wire rope is generally larger than its nominal
diameter.
Upon detection of any internal minor damage, check the inside of wire rope and find
out the cause. Once the damage is determined, this wire rope shall be scrapped.
(7) External wear
If the actual diameter of a wire rope is reduced by 7% or more than the nominal
diameter due to external wear, this wire rope shall be scrapped, even if no broken wire is
detected.
(8) Reduced elasticity
In some cases, the elasticity of the wire rope will be reduced remarkably and the
further use will be unsafe.
Though no broken wire is detected, the clearly difficult bending and reduced
diameter of the wire rope are more serious than those caused purely by wear of wires.
As this situation will lead to sudden breakage under application of dynamic load, the wire
rope shall be immediately scrapped.
(9) Internal/external corrosion
The external wire corrosion can be visually observed. Upon detection of deep pitting
on surface or remarkably loose wires, the wire rope shall be scrapped.
Upon detection of any internal corrosion, check the inside of wire rope by person in

Maintenances T2850-120V -138Z-A02 9-93

charge. If the serious internal corrosion is determined, the wire rope shall be immediately
scrapped.
(10) Waveform deformation
As shown in Figure 9.10-9, upon detection of waveform deformation, if the straight
linear segment of the wire rope enwound around pulley or drum is d1>4d/3 under any
load condition or the bend segment of wire rope enwound around pulley or drum is
d1>1.1d, the wire rope shall be scrapped. In above-mentioned equations, the d is the
nominal diameter of wire rope and the d1 is the enveloping diameter of deformed wire
rope.

Figure 9.10-9 Waveform Deformation

(11) Cage distortion
As shown in Figure 9.10-10, a wire rope with cage distortion shall be immediately
scrapped.

Figure 9.10-10 Cage Distortion

(12) Rope core/strand extrusion/distortion
As shown in Figure 9.10-11, a wire rope with core/strand extrusion (protrusion) or
distortion shall be immediately scrapped.

9-94 T2850-120V-138Z-A02 Maintenances

 Figure 9.10-11 Rope Core/Strand Extrusion/Distortion
(13) Wire Extrusion
As shown in Figure 9.10-12, a wire rope with wire extrusion shall be immediately
scrapped.

Figure 9.10-12 Wire Extrusion

(14) Partially increased rope diameter
As shown in Figure 9.10-13, if the actual diameter is seriously increased by >5% in
any section of wire rope, the wire rope shall be immediately scrapped.

Figure 9.10-13 Partially Increased Rope Diameter

(15) Partial flattening
As shown in Figure 9.10-14, the wire rope segment flattened by the pulley will be
damaged rapidly, which is manifested by broken wires and possible damage of pulley. In
such case, the wire rope shall be immediately scrapped.

Figure 9.10-14 Partial Flattening

(16) Kink
As shown in Figure 9.10-15, a wire rope with serious kink shall be immediately
scrapped.

Maintenances T2850-120V -138Z-A02 9-95

 Figure 9.10-15 Kink of Wire Rope

9-96 T2850-120V-138Z-A02 Maintenances

(17) Bend
As shown in Figure 9.10-16, a seriously bent wire rope, which is similar to the partial
flattening of wire rope, shall be immediately scrapped.

Figure 9.10-16 Bending of Wire Rope

(18) Damage due to thermal or arc action
A wire rope with identifiable color on surfaces due to action of special thermal effect
shall be immediately scrapped.
10.6 Maintenances of Wire Ropes
The maintenances of the wire ropes are related to the crane, the use and
environment of crane, and the types of wire ropes. Unless otherwise specified by the
crane or wire rope manufacturer, apply lubricating grease or oil to the wire ropes during
installation. Afterwards, the necessary areas of the wire ropes shall be cleaned. For the
wire ropes repeatedly used at regular intervals, especially the segments working around
the pulleys, keep them well lubricated before the dryness or rust is present.
The lubricating oil (grease) for the wire ropes shall be consistent with the original
one used by the wire rope manufacturer and must possess good permeability. If the
lubrication of wire ropes can’t be determined by the crane manual, the user shall consult
with the recommendation of the wire rope manufacturer.
The short life of wire ropes is attributed to the adequacy of maintenances, especially
when the crane is used in a corrosive environment, and the operation related causes,
such as the application prohibited for use of wire rope lubricant. In such case, the
checking interval for the wire ropes shall be shortened accordingly.

Maintenances T2850-120V -138Z-A02 9-97

11 Maintenances of Pulley Blocks
11.1 Checking of Pulley Block Bearings
Pulley

Bearing

Retainer ring

Figure 9-11.1 Structure of Pulley Block

Daily checking of bearings:
(1) Check for permeation/leakage of lubricating oil.
(2) Check shaft end seals.
(3) Check circlips.
(4) Check running noise and resistance.
(5) Check bearing clearance.
Daily maintenances of bearings:
Replace damaged bearing.
Replace damaged circlip.

9-98 T2850-120V-138Z-A02 Maintenances

11.2 Checking of Pulleys

Pulley

Figure 9.11-2 Checking of Pulleys

Check the following items:
(1) Check the pulleys for presence of cracking and indentation and immediately
replace any damaged pulley.
(2) Check the wear status of pulleys and replace any pulley worn to the
maximum degree.
The spacing between wire rope and side face of pulley groove is defined as value X.
The maximum permissible value X is 5mm.
The spacing between the theoretic bottom surface and the actual bottom surface of
the pulley rope groove is defined as value Y. The maximum permissible value Y is 3mm.
11.3 Lubrication of Pulley Bearings

Oil nozzle

Figure 9.11-3 Lubrication of Pulley Bearings

The lubricating points (oil nozzles) of the pulley bearings are shown in Figure 9.10-3.
Please lubricate timely.
Lubricant: 3# lithium-based lubricating grease.
Maintenances T2850-120V -138Z-A02 9-99
12 Hook
12.1 Opening Degree of Hook
Initial opening degree A of hook: A=180mm
(Based on the measurement before the first use of hook)
Replace the hook if the opening degree A of hook is larger than 110% A.

Figure 9.12-1 Opening Degree and Wear of Hook

12.2 Wear
Initial value: H=236mm
The hook shall not be worn for >5% in direction H. It’s prohibited to compensate the
wear of hook by welding method.
12.3 Surface Cracking
If the hook is clearly deformed, check the surface cracking of hook by appropriate
method or replace the hook.
The damage and the surface of the hook can be removed, provided that no gap is
left and the dimensions are not be beyond the permissible tolerance after removal of
cracking and damage.
If the checking of hook is impossible after installation, ensure to disassemble the
hook for checking.

9-100 T2850-120V-138Z-A02
Maintenances
 Before checking, ensure that the hook can be checked for surface cracking.

Maintenances T2850-120V -138Z-A02 9-101

 致用户 To User
如需维修或零配件,可根据本“零件图册”各部件分解视图方便地查到各零部件相应的编码和名称,直接告
知中联当地售后服务点。
If you need maintenance or fittings for your equipments, please check the code No. and the designations of the
parts you need in the spare parts manual, and then inform the local after service department of Zoomlion.

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 i

 ⑩
零件图册 Spare Parts Manual

目录 Contents

1. T2850-120V 塔式起重机组成 Tower Crane’s components (000204000ATV04000) ...............1

2. ZA110-C 行走台车Ⅰ Driving Dolly Ⅰ (000209410C0100000) ....................................... 4
3. ZA110-D 行走台车Ⅱ Driving Dolly Ⅱ (000209410D0100000) ....................................... 8
4. ZB110-C 行走台车Ⅲ Driving Dolly Ⅲ (000209410C0200000)...................................... 12
5. ZB110-D 行走台车Ⅳ Driving Dolly Ⅳ (000209410D0200000) ..................................... 16
6.行走底架 Undercarriage（000204023ATV00000） ............................................................ 20
7. X40A 标准节 X40A Tower section （000209027A0100000） ......................................... 41
8.爬升架 Climbing Frame（000204011ATV00000）............................................................. 51
9.顶升机构 Climbing system (000221612AT000000) ............................................................ 66
10.引进系统 Inlet system (000204019ATV00000) ................................................................. 67
11. X40B 过渡节 X40B Transition section（000209027A0300000） .................................... 76
12.下支座 Slewing support (000204010ATV00000) .............................................................. 84
13.上支座 Upper support (000204009ATV00000) ................................................................. 86
14.回转限位装置 Slewing limit device (000209905A0015000)............................................. 89
15. HPW185F1.350A 回转机构 Slewing Mechanism（000209271A3000000) ...................... 91
16. HPW185F2.350A 回转机构 Slewing Mechanism（000209271A4000000) ...................... 92
17. SBG2900 扒杆 Derrick（000209914A9100000) .............................................................. 93
18. H132FL150-1230D 起升机构 Hoisting Mechanism(000209196A2700000) ................... 108
19.平衡臂 Counter-jib (000204001ATV00000) ................................................................... 115
20. T185FC87 变幅机构 Trolleying Mechanism (000209334B1000000) ........................... 129
21. H25FP15-440-d 辅助机构 Auxiliary Mechanism (000209103E7000000) ....................... 132
22.臂节ⅠJib Ⅰ (000204005ATV01000) ............................................................................ 137
23.起重臂 Jib (000204005ATV00000)................................................................................. 144
24. DG120A 吊钩组 Load Hook（000209614A0100000） ................................................. 168
25. XC120C 载重小车 Trolley（000209714A0200000） .................................................... 178

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 ii

 Spare Parts Manual
1. T2850-120V 塔式起重机组成 Tower Crane’s components (000204000ATV04000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 1

 T2850-120V 塔式起重机组成 Tower Crane’s components (000204000ATV04000)
序号 编码 代号 名称 数量 备注
NO. Order NO. Code Designation Qty Remark
行走台车ⅠDriving Dolly
000209410C0100000 ZA110-C 1
Ⅰ
行走台车ⅡDriving Dolly
000209410D0100000 ZA110-D 1
Ⅱ
1
行走台车ⅢDriving Dolly
000209410C0200000 ZB110-C 1
Ⅲ
行走台车ⅣDriving Dolly
000209410D0200000 ZB110-D 1
Ⅳ
2 000204023ATV00000 T2850-120V.23 行走底架 Undercarriage 1
3 000209027A0100000 X40A 标准节 Tower section 8
4 000204011ATV00000 T2850-120V.11 爬升架 Telescopic cage 1
顶升机构
5 000221612AT000000 T3000-160V.12 1
Jacking Equipment
无分解图
顶升油缸
6 1010200441 YG250/160-2150/1650-31.5 4 No Explode
Hydraulic cylinder
Drawing
无分解图
顶升泵站
7 1011300017 BZ-37-31.5 1 No Explode
Hydraulic control station
Drawing
引进系统
8 000204019ATV00000 T2850-120V.19 1
Indraught Mechanism
9 000209027A0300000 X40B 过渡节 Transition section 1
10 000204010ATV00000 T2850-120V.10 下支座 Below Support 1
无分解图
11 1031500261 131.50（60）.3150.1.00.42FJK 回转支承 Slewing ring 1 No Explode
Drawing
12 000204009ATV00000 T2850-120V.09 上支座 Upper Support 1
无分解图
13 1130000662 CP8S 司机室 Operator Cab 1 No Explode
Drawing
000209271A3000000 HPW185F1.350A 回转机构 3
14
000209271A4000000 HPW185F2.350A Slewing Mechanism 1
无分解图
15 000221699AT010000 T3000-160V-PHZ 平衡重 Counter Weight 1 No Explode
Drawing
16 000209914A9100000 SBG2900 扒杆 Steeve 1
起升机构
17 000209196A2700000 H132FL150-1300D 1
Hoisting Mechanism
18 000204005ATV00000 T2850-120V.05 平衡臂 Counter-jib 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 2

序号 编码 代号 名称 数量 备注
NO. Order NO. Code Designation Qty Remark
变幅机构
19 000209334B1000000 T185FC87 1
Trolley Mechanism
辅助起升机构
20 000209103E7000000 H25FP15-440-d 1
Auxiliary Mechanism
无分解图
力矩限制器
21 000209904C0000000 LXB 1 No Explode
Moment Limiter
Drawing
22 000209711A0100000 XC63 起重臂臂节ⅠJib Ⅰ 1
无分解图
起重量限制器
23 000209502A0200000 TWL2 1 No Explode
Overload Limit switch
Drawing
24 000204005ATV00000 T2850-120V.05 起重臂 Jib 1
25 000209614A0100000 DG120A 吊钩组 Load Hook 1
26 000209714A0200000 XC120C 载重小车 Trolley 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 3

2. ZA110-C 行走台车Ⅰ Driving Dolly Ⅰ (000209410C0100000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 4

 ZA110-C 行走台车Ⅰ Driving Dolly Ⅰ (000209410C0100000)

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
1 1040003564 GB/T5782-2000 螺栓 Bolt M42×250-10.9 6
2 1040300208 GB/T97.1-2002 垫圈 Washer 42-200HV 12
3 1040200548 GB/T6170-2000 螺母 Nut M42-10 12
4 1040501587 GB/T118-2000 销 Pin 30×160 2
轴端挡板
5 000209410C0100001 2
Plate for stop
6 1040000287 GB/T5783-2000 螺栓 Bolt M20×65-8.8 60
7 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 68
8 1040300038 GB/T93-1987 垫圈 Washer 20 100
主平衡梁
9 000209410C0101000 1
Main beam
轴端挡板
10 000209410A0100010 4
Plate for stop
铰接叉
11 000209410C0102000 1
Hinged gantry
12 000209410C0100003 钢套 Steel thimble 2
13 000209410C0100004 轴 Shaft 1
14 1080000206 JB/T7940.1-1995 油杯 Oil Cup M10×1 14
15 000203003AR000004 XZ04C-60×145/215 销轴 Spindle 60×145 1
16 1040500248 GB/T91-2000 销 Pin 10×100 2
锚固装置
17 000209410C0103000 1
Anchoring device
次平衡梁 Secondary
18 000209410C0104000 2
beam
19 000209410C0100005 钢套 Steel thimble 4
20 000209410C0100006 销轴 Spindle 2
21 1040000055 GB/T5783-2000 螺栓 Bolt M20×60-8.8 8
22 1040600139 GB/T1096-2003 键 Bond 20×250 2
铰接叉组成
23 000209410C0105000 4
Hinged gantry
24 000209410C0100007 销轴 Spindle 4
带连接法兰减速机
25 1030200677 KA/T97B-50-AG160 2
Reduction Gears
26 000209410A0100025 轴 Shaft 2
27 1040300644 GB/T893.2-1986 挡圈 Washer 180 2
28 1050200426 GB/T276-1994 深沟球轴承 Bearing 6220-2RZ 2
29 1040600180 GB/T1096-2003 键 Bond 22×100 2
零件图册 Spare Parts Manual T2850-120V-138ZY-A01 5
序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
30 000209410A0100030 小齿轮 Gear 2
31 000209410A0100035 大齿轮 Gear 4
32 1040300775 GB/T894.2-1986 挡圈 Washer 85 2
行程开关
33 1020500695 XCR-F17 2
Limit switch
34 1040001592 GB/T5783-2000 螺栓 Bolt M5×60-8.8 8
35 1040300060 GB/T93-1987 垫圈 Washer 5 8
36 1040300048 GB/T97.1-2002 垫圈 Washer 5-200HV 16
37 1040200107 GB/T6170-2000 螺母 Nut M5-8 8
38 1040200466 GB/T812-1988 螺母 Nut M64×2 2
39 1040300418 GB/T858-1988 垫圈 Washer 64 2
40 1050200425 GB/T276-1994 深沟球轴承 Bearing 6214-2RZ 2
41 1040300776 GB/T893.2-1986 挡圈 Washer 125 2
42 000209410C0100008 钢套 Steel thimble 8
支腿Ⅰ
43 000209410A0100600 8
Supporting leg Ⅰ
轴端挡板
44 000209410A0100050 24
Plate for stop
45 1040000033 GB/T5783-2000 螺栓 Bolt M20×40-8.8 32
46 1020000150 YVFSE3-160M-4 电机 Motor 2
47 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 8
48 1040300065 GB/T93-1987 垫圈 Washer 16 20
49 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 40
减速机支撑架
50 000209410A0100060 2
Leg assembly
51 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 12
52 1040200110 GB/T6170-2000 螺母 Nut M16-8 12
主动台车架Ⅰ
53 000209410C0106000 1
Driving frame Ⅰ
被动台车架Ⅰ
54 000209410C0107000 1
Passive frameⅠ
55 000209410A0100065 轴套 Bushing 16
主动台车架Ⅱ
56 000209410C0108000 1
Driving frame Ⅱ
57 000209410A0100070 销轴 Spindle 8
轴承端盖
58 000209410A0100075 16
Bearing cap
59 1040000149 GB/T5783-2000 螺栓 Bolt M12×50-8.8 96
60 1040300054 GB/T93-1987 垫圈 Washer 12 96
61 000209410A0100080 螺杆 Bolt 16
零件图册 Spare Parts Manual T2850-120V-138ZY-A01 6
序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
62 1040200097 GB/T6170-2000 螺母 Nut M20-8 16
63 000209410A0100001 垫圈 Washer 32
主动行走轮
64 000209410A0100900 4
Driving wheel
圆柱滚子轴承
65 1050200465 GB/T283-1994 NJ232 16
Bearing
66 000209410A0100090 钢套 Steel thimble 8
被动行走轮
67 000209410A0101000 4
Passive wheel
68 000209410A0100095 轴套 Bushing 8
69 000209410A0100085 毡圈 Oil Seal 16
支腿Ⅱ
70 000209410A0101100 8
Supporting leg Ⅱ
被动台车架Ⅱ
71 000209410C0109000 1
Passive frame Ⅱ
72 1040002616 GB/T5782-2000 螺栓 Bolt M24×85-10.9 8
73 1040302325 GB/T97.1-2000 垫圈 Washer 24-200HV 16
74 1040300049 GB/T93-1987 垫圈 Washer 24 8
75 1040200102 GB/T6170-2000 螺母 Nut M24-8 8
液压式夹轨器
76 1039904847 YJJ200-L 1
Hydraulic cram
77 000209410C0100009 插销 Pin 1
78 1090100321 JB/T8108.2-1999 起重短环链 Chain φ5 3
行程开关 Limit
79 1020500676 D4N-4132 1
switch
80 1040000235 GB/T5783-2000 螺栓 Bolt M4×35-8.8 2
81 1040300044 GB/T93-1987 垫圈 Washer 4 2
82 1040300045 GB/T97.1-2002 垫圈 Washer 4-200HV 4
83 1040200100 GB/T6170-2000 螺母 Nut M4-8 2
84 1040000118 GB/T5783-2000 螺栓 Bolt M5×16-8.8 2
85 1990400158 HS3-460 缓冲器 Buffer 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 7

3. ZA110-D 行走台车Ⅱ Driving Dolly Ⅱ (000209410D0100000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 8

 ZA110-D 行走台车Ⅱ Driving Dolly Ⅱ (000209410D0100000)

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
1 1040003564 GB/T5782-2000 螺栓 Bolt M42×250-10.9 6
2 1040300208 GB/T97.1-2002 垫圈 Washer 42-200HV 12
3 1040200548 GB/T6170-2000 螺母 Nut M42-10 12
4 1040501587 GB/T118-2000 销 Pin 30×160 2
轴端挡板
5 000209410C0100001 2
Plate for stop
6 1040000287 GB/T5783-2000 螺栓 Bolt M20×65-8.8 60
7 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 68
8 1040300038 GB/T93-1987 垫圈 Washer 20 100
主平衡梁
9 000209410C0101000 1
Main beam
轴端挡板
10 000209410A0100010 4
Plate for stop
铰接叉
11 000209410C0102000 1
Hinged gantry
12 000209410C0100003 钢套 Steel thimble 2
13 000209410C0100004 轴 Shaft 1
14 1080000206 JB/T7940.1-1995 油杯 Oil Cup M10×1 14
15 000203003AR000004 XZ04C-60×145/215 销轴 Spindle 60×145 1
16 1040500248 GB/T91-2000 销 Pin 10×100 2
锚固装置
17 000209410C0103000 1
Anchoring device
次平衡梁
18 000209410C0104000 2
Secondary beam
19 000209410C0100005 钢套 Steel thimble 4
20 000209410C0100006 销轴 Spindle 2
21 1040000055 GB/T5783-2000 螺栓 Bolt M20×60-8.8 8
22 1040600139 GB/T1096-2003 键 Bond 20×250 2
铰接叉组成
23 000209410C0105000 4
Hinged gantry
24 000209410C0100007 销轴 Spindle 4
带连接法兰减速机
25 1030200677 KA/T97B-50-AG160 2
Reduction Gears
26 000209410A0100025 轴 Shaft 2
27 1040300644 GB/T893.2-1986 挡圈 Washer 180 2
28 1050200426 GB/T276-1994 深沟球轴承 Bearing 6220-2RZ 2
29 1040600180 GB/T1096-2003 键 Bond 22×100 2
零件图册 Spare Parts Manual T2850-120V-138ZY-A01 9
序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
30 000209410A0100030 小齿轮 Gear 2
31 000209410A0100035 大齿轮 Gear 4
32 1040300775 GB/T894.2-1986 挡圈 Washer 85 2
行程开关
33 1020500695 XCR-F17 2
Limit switch
34 1040001592 GB/T5783-2000 螺栓 Bolt M5×60-8.8 8
35 1040300060 GB/T93-1987 垫圈 Washer 5 8
36 1040300048 GB/T97.1-2002 垫圈 Washer 5-200HV 16
37 1040200107 GB/T6170-2000 螺母 Nut M5-8 8
38 1040200466 GB/T812-1988 螺母 Nut M64×2 2
39 1040300418 GB/T858-1988 垫圈 Washer 64 2
40 1050200425 GB/T276-1994 深沟球轴承 Bearing 6214-2RZ 2
41 1040300776 GB/T893.2-1986 挡圈 Washer 125 2
42 000209410C0100008 钢套 Steel thimble 8
支腿Ⅰ
43 000209410A0100600 8
Supporting leg Ⅰ
轴端挡板
44 000209410A0100050 24
Plate for stop
45 1040000033 GB/T5783-2000 螺栓 Bolt M20×40-8.8 32
46 1020000150 YVFSE3-160M-4 电机 Motor 2
47 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 8
48 1040300065 GB/T93-1987 垫圈 Washer 16 20
49 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 40
减速机支撑架
50 000209410A0100060 2
Leg assembly
51 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 12
52 1040200110 GB/T6170-2000 螺母 Nut M16-8 12
主动台车架Ⅰ
53 000209410C0106000 1
Driving frame Ⅰ
被动台车架Ⅰ
54 000209410C0107000 1
Passive frameⅠ
55 000209410A0100065 轴套 Bushing 16
主动台车架Ⅱ
56 000209410C0108000 1
Driving frame Ⅱ
57 000209410A0100070 销轴 Spindle 8
轴承端盖
58 000209410A0100075 16
Bearing cap
59 1040000149 GB/T5783-2000 螺栓 Bolt M12×50-8.8 96
60 1040300054 GB/T93-1987 垫圈 Washer 12 96

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 10

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
61 000209410A0100080 螺杆 Bolt 16
62 1040200097 GB/T6170-2000 螺母 Nut M20-8 16
63 000209410A0100001 垫圈 Washer 32
主动行走轮
64 000209410A0100900 4
Driving wheel
圆柱滚子轴承
65 1050200465 GB/T283-1994 NJ232 16
Bearing
66 000209410A0100090 钢套 Steel thimble 8
被动行走轮
67 000209410A0101000 4
Passive wheel
68 000209410A0100095 轴套 Bushing 8
69 000209410A0100085 毡圈 Oil Seal 16
支腿Ⅱ
70 000209410A0101100 8
Supporting leg Ⅱ
被动台车架Ⅱ
71 000209410D0109000 1
Passive frame Ⅱ
72 1040000018 GB/T5783-2000 螺栓 Bolt M8×30-8.8 4
73 1040300063 GB/T93-1987 垫圈 Washer 8 4
74 1040300066 GB/T97.1-2002 垫圈 Washer 8-200HV 8
75 1040200192 GB/T6170-2000 螺母 Nut M8-8 4
76 000209410C0100009 插销 Pin 1
77 1090100321 JB/T8108.2-1999 起重短环链 Chain φ5 3
行程开关 Limit
78 1020500676 D4N-4132 1
switch
79 1040000235 GB/T5783-2000 螺栓 Bolt M4×35-8.8 2
80 1040300044 GB/T93-1987 垫圈 Washer 4 2
81 1040300045 GB/T97.1-2002 垫圈 Washer 4-200HV 4
82 1040200100 GB/T6170-2000 螺母 Nut M4-8 2
83 1040000118 GB/T5783-2000 螺栓 Bolt M5×16-8.8 2
84 1990400158 HS3-460 缓冲器 Buffer 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 11

4. ZB110-C 行走台车Ⅲ Driving Dolly Ⅲ (000209410C0200000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 12

 ZB110-C 行走台车Ⅲ Driving Dolly Ⅲ (000209410C0200000)

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
1 1040003564 GB/T5782-2000 螺栓 Bolt M42×250-10.9 6
2 1040300208 GB/T97.1-2002 垫圈 Washer 42-200HV 12
3 1040200548 GB/T6170-2000 螺母 Nut M42-10 12
4 1040501587 GB/T118-2000 销 Pin 30×160 2
轴端挡板
5 000209410C0100001 2
Plate for stop
6 1040000287 GB/T5783-2000 螺栓 Bolt M20×65-8.8 60
7 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 68
8 1040300038 GB/T93-1987 垫圈 Washer 20 100
主平衡梁
9 000209410C0201000 1
Main beam
轴端挡板
10 000209410A0100010 4
Plate for stop
铰接叉
11 000209410C0202000 1
Hinged gantry
12 000209410C0100003 钢套 Steel thimble 2
13 000209410C0100004 轴 Shaft 1
14 1080000206 JB/T7940.1-1995 油杯 Oil Cup M10×1 14
15 000203003AR000004 XZ04C-60×145/215 销轴 Spindle 60×145 1
16 1040500248 GB/T91-2000 销 Pin 10×100 2
锚固装置
17 000209410C0103000 1
Anchoring device
次平衡梁
18 000209410C0104000 2
Secondary beam
19 000209410C0100005 钢套 Steel thimble 4
20 000209410C0100006 销轴 Spindle 2
21 1040000055 GB/T5783-2000 螺栓 Bolt M20×60-8.8 8
22 1040600139 GB/T1096-2003 键 Bond 20×250 1
铰接叉组成
23 000209410C0105000 4
Hinged gantry
24 000209410C0100007 销轴 Spindle 4
带连接法兰减速机
25 1030200677 KA/T97B-50-AG160 1
Reduction Gears
26 000209410A0100025 轴 Shaft 1
27 1040300644 GB/T893.2-1986 挡圈 Washer 180 1
28 1050200426 GB/T276-1994 深沟球轴承 Bearing 6220-2RZ 1
29 1040600180 GB/T1096-2003 键 Bond 22×100 1
零件图册 Spare Parts Manual T2850-120V-138ZY-A01 13
序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
30 000209410A0100030 小齿轮 Gear 1
31 000209410A0100035 大齿轮 Gear 2
32 1040300775 GB/T894.2-1986 挡圈 Washer 85 1
33 1040200466 GB/T812-1988 螺母 Nut M64×2 1
34 1040300418 GB/T858-1988 垫圈 Washer 64 1
35 1050200425 GB/T276-1994 深沟球轴承 Bearing 6214-2RZ 1
36 1040300776 GB/T893.2-1986 挡圈 Washer 125 1
37 000209410C0100008 钢套 Steel thimble 8
支腿Ⅰ
38 000209410A0100600 8
Supporting leg Ⅰ
轴端挡板
39 000209410A0100050 24
Plate for stop
40 1040000033 GB/T5783-2000 螺栓 Bolt M20×40-8.8 32
41 1020000150 YVFSE3-160M-4 电机 Motor 1
42 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 4
43 1040300065 GB/T93-1987 垫圈 Washer 16 16
44 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 32
减速机支撑架
45 000209410A0100060 1
Leg assembly
46 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 8
47 1040200110 GB/T6170-2000 螺母 Nut M16-8 8
被动台车架Ⅱ
48 000209410C0209000 1
Driving frame Ⅱ
被动台车架Ⅰ
49 000209410C0107000 1
Passive frameⅠ
50 000209410A0100065 轴套 Bushing 8
主动台车架Ⅱ
51 000209410C0108000 1
Driving frame Ⅱ
52 000209410A0100070 销轴 Spindle 8
轴承端盖
53 000209410A0100075 16
Bearing cap
54 1040000149 GB/T5783-2000 螺栓 Bolt M12×50-8.8 96
55 1040300054 GB/T93-1987 垫圈 Washer 12 96
56 000209410A0100080 螺杆 Bolt 8
57 1040200097 GB/T6170-2000 螺母 Nut M20-8 8
58 000209410A0100001 垫圈 Washer 16
主动行走轮
59 000209410A0100900 2
Driving wheel
60 1050200465 GB/T283-1994 圆柱滚子轴承 Bearing NJ232 16

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 14

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
61 000209410A0100090 钢套 Steel thimble 8
被动行走轮
62 000209410A0101000 6
Passive wheel
63 000209410A0100095 轴套 Bushing 8
64 000209410A0100085 毡圈 Oil Seal 16
支腿Ⅱ
65 000209410A0101100 8
Supporting leg Ⅱ
被动台车架Ⅱ
66 000209410C0109000 1
Passive frame Ⅱ
67 1040002616 GB/T5782-2000 螺栓 Bolt M24×85-10.9 8
68 1040302325 GB/T97.1-2000 垫圈 Washer 24-200HV 16
69 1040300049 GB/T93-1987 垫圈 Washer 24 8
70 1040200102 GB/T6170-2000 螺母 Nut M24-8 8
液压式夹轨器
71 1039904847 YJJ200-L 1
Hydraulic cram
72 000209410C0100009 插销 Pin 1
73 1090100321 JB/T8108.2-1999 起重短环链 Chain φ5 3
行程开关
74 1020500676 D4N-4132 1
Limit switch
75 1040000235 GB/T5783-2000 螺栓 Bolt M4×35-8.8 2
76 1040300044 GB/T93-1987 垫圈 Washer 4 2
77 1040300045 GB/T97.1-2002 垫圈 Washer 4-200HV 4
78 1040200100 GB/T6170-2000 螺母 Nut M4-8 2
79 1040000118 GB/T5783-2000 螺栓 Bolt M5×16-8.8 2
80 1990400158 HS3-460 缓冲器 Buffer 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 15

5. ZB110-D 行走台车Ⅳ Driving Dolly Ⅳ (000209410D0200000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 16

 ZB110-D 行走台车Ⅳ Driving Dolly Ⅳ (000209410D0200000)

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
1 1040003564 GB/T5782-2000 螺栓 Bolt M42×250-10.9 6
2 1040300208 GB/T97.1-2002 垫圈 Washer 42-200HV 12
3 1040200548 GB/T6170-2000 螺母 Nut M42-10 12
4 1040501587 GB/T118-2000 销 Pin 30×160 2
轴端挡板
5 000209410C0100001 2
Plate for stop
6 1040000287 GB/T5783-2000 螺栓 Bolt M20×65-8.8 60
7 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 68
8 1040300038 GB/T93-1987 垫圈 Washer 20 100
主平衡梁
9 000209410C0201000 1
Main beam
轴端挡板
10 000209410A0100010 4
Plate for stop
铰接叉
11 000209410C0202000 1
Hinged gantry
12 000209410C0100003 钢套 Steel thimble 2
13 000209410C0100004 轴 Shaft 1
14 1080000206 JB/T7940.1-1995 油杯 Oil Cup M10×1 14
15 000203003AR000004 XZ04C-60×145/215 销轴 Spindle 60×145 1
16 1040500248 GB/T91-2000 销 Pin 10×100 2
锚固装置
17 000209410C0103000 1
Anchoring device
次平衡梁
18 000209410C0104000 2
Secondary beam
19 000209410C0100005 钢套 Steel thimble 4
20 000209410C0100006 销轴 Spindle 2
21 1040000055 GB/T5783-2000 螺栓 Bolt M20×60-8.8 8
22 1040600139 GB/T1096-2003 键 Bond 20×250 1
铰接叉组成
23 000209410C0105000 4
Hinged gantry
24 000209410C0100007 销轴 Spindle 4
带连接法兰减速机
25 1030200677 KA/T97B-50-AG160 1
Reduction Gears
26 000209410A0100025 轴 Shaft 1
27 1040300644 GB/T893.2-1986 挡圈 Washer 180 1
28 1050200426 GB/T276-1994 深沟球轴承 Bearing 6220-2RZ 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 17

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
29 1040600180 GB/T1096-2003 键 Bond 22×100 1
30 000209410A0100030 小齿轮 Gear 1
31 000209410A0100035 大齿轮 Gear 2
32 1040300775 GB/T894.2-1986 挡圈 Washer 85 1
33 1040200466 GB/T812-1988 螺母 Nut M64×2 1
34 1040300418 GB/T858-1988 垫圈 Washer 64 1
35 1050200425 GB/T276-1994 深沟球轴承 Bearing 6214-2RZ 1
36 1040300776 GB/T893.2-1986 挡圈 Washer 125 1
37 000209410C0100008 钢套 Steel thimble 8
支腿Ⅰ
38 000209410A0100600 8
Supporting leg Ⅰ
轴端挡板
39 000209410A0100050 24
Plate for stop
40 1040000033 GB/T5783-2000 螺栓 Bolt M20×40-8.8 32
41 1020000150 YVFSE3-160M-4 电机 Motor 1
42 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 4
43 1040300065 GB/T93-1987 垫圈 Washer 16 16
44 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 32
减速机支撑架
45 000209410A0100060 1
Leg assembly
46 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 8
47 1040200110 GB/T6170-2000 螺母 Nut M16-8 8
被动台车架Ⅱ
48 000209410C0209000 2
Driving frame Ⅱ
被动台车架Ⅰ
49 000209410C0107000 1
Passive frameⅠ
50 000209410A0100065 轴套 Bushing 8
主动台车架Ⅱ
51 000209410C0108000 1
Driving frame Ⅱ
52 000209410A0100070 销轴 Spindle 8
轴承端盖
53 000209410A0100075 16
Bearing cap
54 1040000149 GB/T5783-2000 螺栓 Bolt M12×50-8.8 96
55 1040300054 GB/T93-1987 垫圈 Washer 12 96
56 000209410A0100080 螺杆 Bolt 8
57 1040200097 GB/T6170-2000 螺母 Nut M20-8 8
58 000209410A0100001 垫圈 Washer 16
主动行走轮
59 000209410A0100900 2
Driving wheel

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 18

序号 编码 代号 名称 规格长度 数量
NO. Order NO. Code Designation Dimension Qty
圆柱滚子轴承
60 1050200465 GB/T283-1994 NJ232 16
Bearing
61 000209410A0100090 钢套 Steel thimble 8
被动行走轮
62 000209410A0101000 6
Passive wheel
63 000209410A0100095 轴套 Bushing 8
64 000209410A0100085 毡圈 Oil Seal 16
支腿Ⅱ
65 000209410A0101100 8
Supporting leg Ⅱ
66 000209410C0100009 插销 Pin 1
67 1090100321 JB/T8108.2-1999 起重短环链 Chain φ5 3
行程开关
68 1020500676 D4N-4132 1
Limit switch
69 1040000235 GB/T5783-2000 螺栓 Bolt M4×35-8.8 2
70 1040300044 GB/T93-1987 垫圈 Washer 4 2
71 1040300045 GB/T97.1-2002 垫圈 Washer 4-200HV 4
72 1040200100 GB/T6170-2000 螺母 Nut M4-8 2
73 1040000118 GB/T5783-2000 螺栓 Bolt M5×16-8.8 2
74 1990400158 HS3-460 缓冲器 Buffer 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 19

6. 行走底架 Undercarriage（000204023ATV00000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 20

 行走底架 Undercarriage（000204023ATV00000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
半梁Ⅰ
1 000204023ATV01000 1
Short cross beamⅠ
连接套
2 000204023ATV02000 1
Connecting socket
3 000204023ATV03100 长拉杆 Long tie bar 4
000204023ATV04100 半梁Ⅱ 2
4
Long cross beam Ⅱ
000204023ATV05000 基础节Ⅰ 1
5
Base mast Ⅰ
6 000204023ATV06000 撑杆 Braced strut 4
7 000204023ATV03200 短拉杆 Short tie bar 4
8 000209910A2284051 XZ04E-140×405/525 销轴 Spindle 8
9 000204023ATV00001 锁销 Locking Spindle 8
10 1040500223 GB/T91-2000 销 Cotter Pin 6.3×40 64
11 000209910A1100901 XZ01D-50×90/130 销轴 Spindle 50×90 16
12 1040500260 GB/T91-2000 销 Cotter Pin 10×80 20
13 000209910A2247001 XZ04E-120×700/810 销轴 Spindle 8
14 000204023ATV00002 锁销 Locking Spindle 8
000204023ATV08000 基础节Ⅱ 1
15
Base mast Ⅱ
000204023ATV04200 半梁Ⅲ 1
16
Short cross beam Ⅲ
17 000204023ATV07000 短爬梯 Short Ladder 1
000204023ATV09000 电缆卷筒支架 2
18
Bracket for cable drum
19 1040000889 GB/T5783-2000 螺栓 Bolt M24×100-8.8 16
20 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 32
21 1040200102 GB/T6170-2000 螺母 Nut M24-8 32
22 000204023ATV00003 锁销 Locking Spindle 8
23 000204023ATV00004 锁销 Locking Spindle 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 21

 基础节ⅠBase mast Ⅰ（000204023ATV05000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 22

 基础节Ⅰ Base mastⅠ（000204023ATV05000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204023ATV05200 平台及栏杆 Platform and rail 1
2 000209027A0100100 短爬梯 Short Ladder 1
爬梯撑板
3 000209027A0100002 1
Support plate for Ladder
4 000204023ATV05100 爬梯及护圈 Ladder 1
5 000209027A0100001 承重角钢 Braced angle iron 2
6 000209027A0100200 销轴盒 Spindle box 4
基础节结构
7 000209027A0204000 1
Structure of base mast
8 000209910A8213651 XZ-105-365/480 销轴 Spindle 8
9 000209910A4062401 XZ03C-30×240/270 锁销 Locking Spindle 8
10 1040501339 DIN_11024 弹簧销 Spring cotter d1=6.3 16
爬梯撑架
11 000209027A0100300 1
Support frame for Ladder
12 1040000109 GB/T5783-2000 螺栓 Bolt M6×16-8.8 4
13 1040200111 GB/T6170-2000 螺母 Nut M6-8 4
14 1040300062 GB/T93-1987 垫圈 Spring washer 6 4
15 1040300051 GB/T97.1-2002 垫圈 Washer 6-200HV 4
铭牌架
16 000209027A0200400 1
Bracket for nameplate
17 000209027A0100003 夹板 A Fixed plate A t10 1
18 000209027A0100004 卡箍 Clamp t10 1
19 1040000169 GB/T5783-2000 螺栓 Bolt M12×45-8.8 10
20 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 18
21 1040300054 GB/T93-1987 垫圈 Spring washer 12 18
22 1040200096 GB/T6170-2000 螺母 Nut M12-8 18
刀开关箱架
23 000209027A0200500 Bracket for 1
power switch cabinet
24 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 16
25 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 20
26 1040300065 GB/T93-1987 垫圈 Spring washer 16 20
27 1040200110 GB/T6170-2000 螺母 Nut M16-8 20
28 1040000018 GB/T5783-2000 螺栓 Bolt M8×30-8.8 4
29 1040200744 GB/T6170-2000 螺母 Nut M8-8.8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 23

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
30 1040300063 GB/T93-1987 垫圈 Spring washer 8 4
31 1040300066 GB/T97.1-2002 垫圈 Washer 8-200HV 4
32 1040000209 GB/T5783-2000 螺栓 Bolt M16×70-8.8 4
33 1040000899 GB/T5782-2000 螺栓 Bolt M12×70-8.8 4
34 000201213A0000006 夹板 B Fixed plate B t8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 24

 基础节结构 Structure of base mast（000209027A0204000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 25

 基础节结构 Structure of base mast（000209027A0204000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209027A0204200 弦杆体 Main chord 2
2 000221615AT001400 调节撑杆 Adjustable strut 2
3 000221615AT001700 连接板 Connecting plate 1
固定撑杆
4 000221615AT001500 2
Non-adjustable strut
水平腹杆
5 000209027A0104500 8
Horizontal diagonal
6 000209027A0101700 斜腹杆 Incline diagonal 8
7 000209027A0204400 主弦杆 Main chord 2
8 000209910A1091003 XZ01C-45×100/140 销轴 Spindle 4
9 1040500283 GB/T91-2000 销 Cotter Pin 8×71 8
10 1040300090 GB/T97.1-2002 垫圈 Washer 36-200HV 4
11 1040200276 GB/T6170-2000 螺母 Nut M36-8 2
12 000221615AT001001 调节螺栓 Bolt 2
13 000221615AT001800 U 形板 U-Shaped Plate 2
14 000210601AT000001 XZ01C-45×120/160 销轴 Spindle 45×120 4
15 000209910A1102301 XZ01C-50×230/270A 销轴 Spindle 16
16 1040500252 GB/T91-2000 销 Cotter Pin 10×90 32
17 000209910A1122501 XZ01C-60×250/290 销轴 Spindle 16
18 000209910A8213211 XZ-105-321/372 销轴 Spindle 8
19 1040302188 DIN471-2011 轴用弹性挡圈 Retaining ring 105×4 8
20 1049900334 DIN988 支撑环 Support ring 105×130 8
21 000209027A0104101 连接头 Connector 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 26

 爬梯及护圈 Ladder（000204023ATV05100）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 27

 爬梯及护圈 Ladder（000204023ATV05100）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204023ATV05110 长爬梯 Long Ladder 1
2 000209025A3000301 护条 Strip guard t5 3
3 000209009Z0001302 护圈 Hoop guard t5 8
4 1040000101 GB/T5783-2000 螺栓 Bolt M12×40-8.8 20
5 1040200096 GB/T6170-2000 螺母 Nut M12-8 20
6 1040300054 GB/T93-1987 垫圈 Spring washer 12 20
7 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 20

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 28

 平台及栏杆 Platform and rail（000204023ATV05200）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 29

 平台及栏杆 Platform and rail（000204023ATV05200）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209913A3T32150 栏杆 Rail 4
2 000204023ATV05210 平台 A Platform A 1
3 000204023ATV05220 平台 B Platform B 1
4 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 4
栏杆夹板
5 000209913A5000001 LGJB1 t5 8
Fixed plate
6 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 4
7 1040300054 GB/T93-1987 垫圈 Spring washer 12 4
8 1040200096 GB/T6170-2000 螺母 Nut M12-8 4
9 1040500381 GB/T91-2000 销 Cotter Pin 8×71 8
10 1040001595 GB/T5783-2000 螺栓 Bolt M10×35-8.8 8
11 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 8
12 1040300067 GB/T93-1987 垫圈 Spring washer 10 8
13 1040201610 GB/T6170-2000 螺母 Nut M10-8 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 30

 基础节ⅡBase mast Ⅱ（000204023ATV08000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 31

 基础节ⅡBase mast Ⅱ（000204023ATV08000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
基节Ⅱ结构
1 000204023ATV08100 1
Structure of base mast Ⅱ
2 000209027A0100100 短爬梯 Short Ladder 1
3 000209027A0103000 爬梯及护圈 Ladder 1
4 000209027A0102000 平台及栏杆 Platform and rail 1
5 000209910A8213651 XZ-105-365/480 销轴 Spindle 8
6 000209910A4062401 XZ03C-30×240/270 锁销 Spindle 8
7 1040501339 DIN_11024 弹簧销 Spring cotter d1=6.3 16
8 000209027A0100200 销轴盒 Spindle box 4
9 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 16
10 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 20
11 1040300065 GB/T93-1987 垫圈 Spring washer 16 20
12 1040200110 GB/T6170-2000 螺母 Nut M16-8 20
爬梯撑架
13 000209027A0100300 1
Support frame for Ladder
14 000209027A0100003 夹板 A Fixed plate A t10 1
15 000209027A0100004 卡箍 Clamp 1
16 1040000169 GB/T5783-2000 螺栓 Bolt M12×45-8.8 10
17 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 18
18 1040300054 GB/T93-1987 垫圈 Spring washer 12 18
19 1040200096 GB/T6170-2000 螺母 Nut M12-8 18
20 000209027A0100001 承重角钢 Braced angle iron 2
21 000201213A0000006 夹板 B Fixed plate B t8 2
爬梯撑板
22 000209027A0100002 1
Support plate for Ladder
23 1040000899 GB/T5782-2000 螺栓 Bolt M12×70-8.8 4
24 1040000209 GB/T5783-2000 螺栓 Bolt M16×70-8.8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 32

 基节Ⅱ结构 Structure of base mast Ⅱ（000204023ATV08100）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 33

 基节Ⅱ结构 Structure of base mast Ⅱ（000204023ATV08100）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204023ATV08111 弦杆体 Main chord 2
2 000221615AT001400 调节撑杆 Adjustable strut 2
3 000221615AT001700 连接板 Connecting plate 1
固定撑杆
4 000221615AT001500 2
Non-adjustable strut
水平腹杆
5 000209027A0104500 4
Horizontal diagonal
6 000209027A0101700 斜腹杆 Incline diagonal 4
7 000204023ATV08121 主弦杆 Main chord 2
8 000209910A1091003 XZ01C-45×100/140 销轴 Spindle 4
9 1040500283 GB/T91-2000 销 Cotter Pin 8×71 8
10 1040300090 GB/T97.1-2002 垫圈 Washer 36-200HV 4
11 1040200276 GB/T6170-2000 螺母 Nut M36-8 2
12 000221615AT001001 调节螺栓 Bolt 2
13 000221615AT001800 U 形板 U-Shaped Plate 2
14 000210601AT000001 XZ01C-45×120/160 销轴 Spindle 45×120 4
15 000209910A1102301 XZ01C-50×230/270A 销轴 Spindle 16
16 1040500252 GB/T91-2000 销 Cotter Pin 10×90 32
17 000209910A1122501 XZ01C-60×250/290 销轴 Spindle 24
18 000209910A8213211 XZ-105-321/372 销轴 Spindle 8
19 1040302188 DIN471-2011 轴用弹性挡圈 Retaining ring 105×4 8
20 1049900334 DIN988 支撑环 Support ring 105×130 8
21 000209027A0104101 连接头 Connector 4
22 000204023ATV08130 水平腹杆Ⅱ Horizontal diagonal 4
23 000204023ATV08140 斜腹杆Ⅱ Incline diagonal 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 34

 爬梯及护圈 Ladder（000209027A0103000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 35

 爬梯及护圈 Ladder（000209027A0103000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209027A0103100 长爬梯 Long Ladder 1
2 000209025A1000301 护条 Strip guard t5 3
3 000209009Z0001302 护圈 Hoop guard t5 12
4 1040000101 GB/T5783-2000 螺栓 Bolt M12×40-8.8 30
5 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 30
6 1040300054 GB/T93-1987 垫圈 Spring washer 12 30
7 1040200096 GB/T6170-2000 螺母 Nut M12-8 30

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 36

 平台及栏杆 Platform and rail（000209027A0102000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 37

 平台及栏杆 Platform and rail（000209027A0102000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209913A3T32150 栏杆 Rail 4
2 000209027A0102100 平台 A Platform A 1
3 000209027A0102200 平台 B Platform B 1
4 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 4
5 000209913A5000001 LGJB1 栏杆夹板 Fixed plate t5 8
6 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 4
7 1040300054 GB/T93-1987 垫圈 Spring washer 12 4
8 1040200096 GB/T6170-2000 螺母 Nut M12-8 4
9 1040500381 GB/T91-2000 销 Cotter Pin 8×71 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 38

 电缆卷筒支架 Bracket for cable drum（000204023ATV09000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 39

 电缆卷筒支架 Bracket for cable drum（000204023ATV09000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204023ATV09100 主梁 Beam 1
2 000209908A0002200 支架 Bracket 1
3 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 2
4 1040200110 GB/T6170-2000 螺母 Nut M16-8 6
5 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 6
6 1040300065 GB/T93-1987 垫圈 Spring washer 16 6
7 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 40

7. X40A 标准节 X40A Tower section （000209027A0100000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 41

 X40A 标准节 X40A Tower section（000209027A0100000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
标准节结构
1 000209027A0104000 1
Tower section structure
2 000209027A0100100 短爬梯 Short Ladder 1
3 000209027A0103000 爬梯及护圈 Ladder 1
平台及栏杆
4 000209027A0102000 1
Platform and rail
5 000209910A8213651 XZ-105-365/480 销轴 Spindle 8
6 000209910A4062401 XZ03C-30×240/270 锁销 Locking Spindle 8
7 1040501339 DIN_11024 弹簧销 Spring cotter d1=6.3 16
8 000209027A0100200 销轴盒 Spindle box 4
9 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 16
10 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 20
11 1040300065 GB/T93-1987 垫圈 Spring washer 16 20
12 1040200110 GB/T6170-2000 螺母 Nut M16-8 20
爬梯撑架
13 000209027A0100300 1
Support frame for Ladder
14 000209027A0100003 夹板 A Fixed plate A t10 1
15 000209027A0100004 卡箍 Clamp 1
16 1040000169 GB/T5783-2000 螺栓 Bolt M12×45-8.8 10
17 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 18
18 1040300054 GB/T93-1987 垫圈 Spring washer 12 18
19 1040200096 GB/T6170-2000 螺母 Nut M12-8 18
承重角钢
20 000209027A0100001 2
Braced angle iron
21 000201213A0000006 夹板 B Fixed plate A t8 2
爬梯撑板
22 000209027A0100002 1
Support plate for Ladder
23 1040000899 GB/T5782-2000 螺栓 Bolt M12×70-8.8 4
24 1040000209 GB/T5783-2000 螺栓 Bolt M16×70-8.8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 42

 标准节结构 Tower section structure（000209027A0104000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 43

 标准节结构 Tower section structure（000209027A0104000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209027A0104200 弦杆体 Main chord 2
调节撑杆
2 000221615AT001400 2
Adjustable strut
3 000221615AT001700 连接板 Connecting plate 1
固定撑杆
4 000221615AT001500 2
Non-adjustable strut
水平腹杆
5 000209027A0104500 8
Horizontal diagonal
6 000209027A0101700 斜腹杆 Incline diagonal 8
7 000209027A0104400 主弦杆 Main chord 2
8 000209910A1091003 XZ01C-45×100/140 销轴 Spindle 4
9 1040500283 GB/T91-2000 销 Cotter Pin 8×71 8
10 1040300090 GB/T97.1-2002 垫圈 Washer 36-200HV 4
11 1040200276 GB/T6170-2000 螺母 Nut M36-8 2
12 000221615AT001001 调节螺栓 Bolt 2
13 000221615AT001800 U 形板 U-Shaped Plate 2
14 000210601AT000001 XZ01C-45×120/160 销轴 Spindle 45×120 4
15 000209910A1102301 XZ01C-50×230/270A 销轴 Spindle 16
16 1040500252 GB/T91-2000 销 Cotter Pin 10×90 32
17 000209910A1122501 XZ01C-60×250/290 销轴 Spindle 16
18 000209910A8213211 XZ-105-321/372 销轴 Spindle 8
轴用弹性挡圈
19 1040302188 DIN471-2011 105×4 8
Retaining ring
20 1049900334 DIN988 支撑环 Support ring 105×130 8
21 000209027A0104101 连接头 Connector 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 44

 爬梯及护圈 Ladder（000209027A0103000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 45

 爬梯及护圈 Ladder（000209027A0103000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209027A0103100 长爬梯 Long Ladder 1
2 000209025A1000301 护条 Strip guard t5 3
3 000209009Z0001302 护圈 Hoop guard t5 12
4 1040000101 GB/T5783-2000 螺栓 Bolt M12×40-8.8 30
5 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 30
6 1040300054 GB/T93-1987 垫圈 Spring washer 12 30
7 1040200096 GB/T6170-2000 螺母 Nut M12-8 30

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 46

 平台及栏杆 Platform and rail（000209027A0102000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 47

 平台及栏杆 Platform and rali（000209027A0102000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209913A3T32150 栏杆 Rail 4
2 000209027A0102100 平台 A Platform A 1
3 000209027A0102200 平台 B Platform B 1
4 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 4
5 000209913A5000001 LGJB1 栏杆夹板 Fixed plate t5 8
6 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 4
7 1040300054 GB/T93-1987 垫圈 Spring washer 12 4
8 1040200096 GB/T6170-2000 螺母 Nut M12-8 4
9 1040500381 GB/T91-2000 销 Cotter Pin 8×71 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 48

 安装平台 Erection platform（000221631AT000000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 49

 安装平台 Erection platform（000221631AT000000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221631AT001000 支架 Frame 1
2 000209913A0004300 LGA430 栏杆 Railing 2
3 000209913A0005300 LGA530 栏杆 Railing 2
4 000209913A0050000 LG5000 栏杆 Railing 1
5 000221631AT002000 平台 Platform 1
6 000201213A0000003 弹簧销 Spring pin 2
7 000221631AT000001 插轴 Spindle φ20 2
8 1040001421 GB/T5782-2000 螺栓 Bolt M12×210-8.8 4
9 1040300756 GB/T97.1-2002 垫圈 Washer 12-200HV 12
10 1040200096 GB/T6170-2000 螺母 Nut M12-8 8
11 1040300054 GB/T93-1987 垫圈 Spring washer 12 4
栏杆夹板
12 000209913A5000001 LGJB1 t5 8
Railing locking splint
13 1040000170 GB/T5782-2000 螺栓 Bolt M12×65-8.8 4
14 1040500381 GB/T91-2000 销 Cotter Pin 8×71 14

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 50

8. 爬升架 Climbing Frame（000204011ATV00000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 51

 爬升架 Climbing Frame（000204011ATV00000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
爬升架结构
1 000204011ATV01000 1
Structure
安装平台 B
2 000221611AT018000 1
Platform B
3 000209913A0035750 栏杆 Railing 7
平台Ⅶ
4 000204011ATV11000 1
Platform Ⅶ
5 000209913A0025750 栏杆 Railing 7
平台Ⅵ
6 000204011ATV10000 1
Platform Ⅵ
7 000204011ATV02000 爬梯 A Ladder A 1
紧固装置
8 000221611AT003000 2
Retaining device
平台Ⅲ
9 000204011ATV07000 1
Platform Ⅲ
平台Ⅳ
10 000204011ATV08000 1
Platform Ⅳ
平台Ⅹ
11 000204011ATV13000 1
Platform Ⅹ
12 000209913A0031650 栏杆 Railing 6
平台Ⅸ
13 000204011ATV12000 1
Platform Ⅸ
14 000204011ATV03000 爬梯 B Ladder B 1
15 000209913A0022000 栏杆 Railing 2
平台Ⅷ
16 000204011ATV14000 1
Platform Ⅷ
17 000209913A0015000 栏杆 Railing 2
省力装置
18 000204011ATV04000 1
Saver device
19 000209913A0006300 LGA630 栏杆 Railing 4
20 000209913A0005300 LGA530 栏杆 Railing 4
平台Ⅰ
21 000221611AT005000 1
Platform Ⅰ
平台Ⅱ
22 000204011ATV06000 1
Platform Ⅱ
平台Ⅴ
23 000204011ATV09000 1
Platform Ⅴ

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 52

 安装平台 A
24 000221611AT017000 1
Platform A
25 1040500309 GB/T91-2000 销 Pin 6.3×45 24
销轴Ⅱ Pivot
26 000201111B0000002 24
Ⅱ
27 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 26
栏杆夹板
28 000209913A5000001 LGJB1 t5 52
Clamp plate
29 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 26
30 1040200096 GB/T6170-2000 螺母 Bolt M12-8 26
31 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 8
32 1040200110 GB/T6170-2000 螺母 Nut M16-8 12
33 1040000286 GB/T5783-2000 螺栓 Bolt M16×65-8.8 12
34 1040500381 GB/T91-2000 销 Pin 8×71 77
35 1040300215 GB/T853-1988 垫圈 Washer 16 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 53

 爬升架结构 Structure（000204011ATV01000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 54

 爬升架结构 Structure（000204011ATV01000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
主弦杆 A
1 000204011ATV01100 1
Main chord A
横梁 B
2 000221611AT001800 5
Beam B
斜腹杆 D
3 000221611AT001700 12
Incline chord D
主弦杆 C
4 000204011ATV01300 1
Main chord C
直腹杆 B
5 000221611AT001400 7
Straight chord B
横梁 C
6 000221611AT002100 1
Beam C
斜腹杆 A
7 000221611AT001300 8
Incline chord A
直腹杆 A
8 000221611AT001200 3
Straight chord A
斜腹杆 C
9 000211511A0001600 4
Incline chord C
横梁 A
10 000221611AT001600 2
Beam A
斜腹杆 B
11 000221611AT001500 4
Incline chord B
主弦杆 D
12 000204011ATV01400 1
Main chord D
拼装撑杆
13 000221611AT002200 1
Strut
主弦杆 B
14 000204011ATV01200 1
Main chord B
15 000201114B0001103 XZ01D-60×165/205 销轴 Pivot 84
16 1040500252 GB/T91-2000 销 Pin 10×90 108
17 000200904A0001015 XZ01C-70×185/240 销轴 Pivot 16
油缸耳座
18 000221611AT002500 4
Support
19 000201311A0003160 XZ01C-90×225/280 销轴 Pivot 4
20 1040500247 GB/T91-2000 销 Pin 13×125 4
21 000211511A0001508 销轴 Pivot 4
22 1040500260 GB/T91-2000 销 Pin 10×80 8
23 1040000108 GB/T5783-2000 螺栓 Bolt M12×30-8.8 32

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 55

24 1040301503 GB/T93-1987 垫圈 Washer 12 32
25 000211511A0001003 JB/ZQ4348 挡板 Plate 16
油杯
26 1080000005 JB/T7940.1-1995 M6×1 16
Oil cup
27 000211511A0001005 滚轮轴 Pivot 16
28 000211511A0001004 轴套 Sleeve 16
29 000211511A0001002 滚轮 Roller 16
换步挂板
30 000221611AT002400 Supporting 4
shoe
31 000201711A0001003 销轴 Pivot 4
换步操纵杆
32 000211511A0002900 4
Rod
33 1040500216 GB/T91-2000 销 Pin 6.3×50 16
34 000201711A0001002 销轴 Pivot 8
35 000211511A0001006 销轴 Pivot 8
36 1040000658 GB/T5783-2000 螺栓 Bolt M16×80-8.8 8
37 1040200110 GB/T6170-2000 螺母 Nut M16-8 8
38 1040300213 GB/T97.1-2002 垫圈 Washer 16-200HV 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 56

 换步操纵杆 Rod (000211511A0002900)

换步操纵杆 Rod (000211511A0002900)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000211511A0002901 操纵杆 Rod 1
2 000211511A0002903 销轴 Pivot 1
3 1040500233 GB/T91-2000 销 Pin 5×40 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 57

 安装平台 A Platform A (000221611AT017000)

安装平台 A Platform A (000221611AT017000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209913A0004300 LGA430 栏杆 Railing 1
2 000209913A0008000 LG800 栏杆 Railing 1
3 000221611AT017100 平台焊件 Strcture 1
4 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 1
栏杆夹板
5 000209913A5000001 LGJB1 t5 2
Clamp plate
6 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 1
7 1040200096 GB/T6170-2000 螺母 Nut M12-8 1
8 1040500381 GB/T91-2000 销 Pin 8×71 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 58

 安装平台 B Platform B (000221611AT018000)

安装平台 B Platform B (000221611AT018000)

序号 编码 代号 名称 规格 数量
NO. Order NO Code Designation Specification Qty
1 000209913A0008000 LG800 栏杆 Railing 1
2 000209913A0004300 LGA430 栏杆 Railing 1
3 000221611AT018100 平台焊件 Strcture 1
栏杆夹板
4 000209913A5000001 LGJB1 t5 2
Clamp plate
5 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 1
6 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 1
7 1040200096 GB/T6170-2000 螺母 Nut M12-8 1
8 1040500381 GB/T91-2000 销 Pin 8×71 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 59

 紧固装置 Retaining device（000221611AT003000）

紧固装置 Retaining device（000221611AT003000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000971 GB/T5782-2000 螺栓 Bolt M20×220-8.8 2
2 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 2
3 1040200097 GB/T6170-2000 螺母 Nut M20-8 2
紧固装置焊件
4 1
Strcture
5 1040000170 GB/T5782-2000 螺栓 Bolt M12×65-8.8 2
6 1040200096 GB/T6170-2000 螺母 Nut M12-8 2
7 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 60

 爬梯 B Ladder B（000204011ATV03000）

爬梯 B Ladder B（000204011ATV03000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204011ATV03100 梯子 Ladder 1
2 000221611AT004001 护条 Plate 30×5 3
3 000201111B0000032 护圈 A Guard Railing 30×5 6
4 1040000101 GB/T5783-2000 螺栓 Bolt M12×40-8.8 15
5 1040200096 GB/T6170-2000 螺母 Nut M12-8 15
6 1040300054 GB/T93-1987 垫圈 Washer 12 15

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 61

 爬梯 A Ladder A（000204011ATV02000）

爬梯 A Ladder A（000204011ATV02000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204011ATV02100 梯子 Ladder 1
2 000221611AT015001 护条 Plate 30×5 3
3 000201111B0000032 护圈 A Guard Railing 30×5 14
4 1040000101 GB/T5783-2000 螺栓 Bolt M12×40-8.8 35
5 1040200096 GB/T6170-2000 螺母 Nut M12-8 35
6 1040300054 GB/T93-1987 垫圈 Washer 12 35

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 62

 省力装置 Saver device（000204011ATV04000）

省力装置 Saver device（000204011ATV04000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204011ATV04200 拉手 B Handrail B 2
2 000221611AT016001 耳板 B Plate B t20 6
3 000204011ATV04100 拉手 A Handrail A 2
4 000211511A0032001 耳板 A Plate A t20 4
5 000204011ATV04001 限位管 Pipe φ75×6-180 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 63

 拉手 A Handle A（000204011ATV04100）

拉手 A Handle A（000204011ATV04100）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221611AT016110 支撑杆 Rod 1
2 000221611AT016101 拉杆 Handrail φ60×4 1
3 000250805AT001009 XZ01A-25×85/110 销轴 Pivot 25×85 1
4 1040500309 GB/T91-2000 销 Pin 6.3×45 1
5 000221611AT016102 滚轮 Roller 1
6 1040500046 GB/T91-2000 销 Pin 4×36 4
7 000203010AR005001 XZ01A-16×80/100 销轴 Pivot 16×80 4
8 000201711A0025014 圆钢 Steel 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 64

 拉手 B Handle B（000204011ATV04200）

拉手 B Handle B（000204011ATV04200）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221611AT016110 支撑杆 Rod 1
2 000221611AT016101 拉杆 Handrail φ60×4 1
3 000250805AT001009 XZ01A-25×85/110 销轴 Pivot 25×85 1
4 1040500309 GB/T91-2000 销 Pin 6.3×45 1
5 000221611AT016102 滚轮 Roller 1
6 1040500046 GB/T91-2000 销 Pin 4×36 2
7 000203010AR005001 XZ01A-16×80/100 销轴 Pivot 16×80 2
8 000201711A0025014 圆钢 Steel 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 65

9. 顶升机构 Climbing system (000221612AT000000)

顶升机构 Climbing system (000221612AT000000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000240801AT010002 XZ03E-90×235/315 销轴 Pivot 90×235 4
2 1040500247 GB/T91-2000 销 Pin 13×125 8
3 000221612AT001000 顶升横梁 Beam 2
4 000221612AT000010 安全销 Pin 4
5 000221612AT000001 弹簧销 Pin φ6 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 66

10. 引进系统 Inlet system (000204019ATV00000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 67

 引进系统 Inlet system (000204019ATV00000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221619AT005000 平台 Platform 1
2 000209913A0007000 LGA700 栏杆 Railing 2
3 000209913A0005000 LG500 栏杆 Railing 4
4 000209913A0035000 LG3500 栏杆 Railing 1
5 000209913A0004300 LGA430 栏杆 Railing 2
6 000204019ATV02000 牵引机构 Inlet mechanism 1
7 000221619AT000010 栏杆 Railing 2
引进专用吊钩
8 000211519A0003000 1
Inlet special hook
9 000221619AT002000 引进梁 Inlet beam 1
10 000211519A0001000 引进小车 Inlet trolley 1
11 000204019ATV01000 提升架 Lifting frame 1
12 000221619AT000020 吊杆 Hanger 4
13 1090100310 JB8112-1999 起重锻造卸扣 Shackle S-DW6.3 8
14 000204019ATV03000 滑轮组 Pulley block 2
15 000200709A0000012 XZ01A-16×30/50 销轴 Spindle 16×30 4
16 1040500097 GB/T91-2000 销 Cotter Pin 4×30 4
17 1040000177 GB/T5783-2000 螺栓 Bolt M16×55-8.8 24
18 1040200685 GB/T6170-2000 螺母 Nut M16-8 24
19 1040300065 GB/T93-1987 垫圈 Spring washer 16 24
20 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 24
21 000209910A0010056 XZ01C-40×75/110 销轴 Spindle 40×75 4
22 1040500381 GB/T91-2000 销 Cotter Pin 8×71 27
23 1040000094 GB/T5783-2000 螺栓 Bolt M12×35-8.8 2
24 1040200096 GB/T6170-2000 螺母 Nut M12-8 11
25 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 11
26 1040300054 GB/T93-1987 垫圈 Spring washer 12 11
27 000221619AT000030 连接板 Connecting plate t10 2
28 1040001604 GB/T5783-2000 螺栓 Bolt M12×75-8.8 9
栏杆夹板
29 000209913A5000001 LGJB1 t5 18
Railing Locking Splint
30 000201108B0000001 XZ01C-30×60/90 销轴 Spindle 30×60 4
31 1090100080 GB/T8918-2006 钢丝绳 Rope 6×19-9.3-1700-Ⅱ-右交 4
32 1090100081 GB/T5976-2006 绳夹 Rope clamp 10KTH 8
33 000204019ATV04000 滑轮组 Pulley assembly 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 68

 牵引机构 Inlet mechanism (000204019ATV02000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 69

 牵引机构 Inlet mechanism (000204019ATV02000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221619AT004200 支架 Bracket 1
2 000211519A0008200 卷筒 Rope drum 2
3 1040000267 GB/T5783-2000 螺栓 Bolt M8×20-8.8 2
4 1040300210 GB/T96.1-2002 垫圈 Washer 8-200HV 4
5 1040300063 GB/T93-1987 垫圈 Spring washer 8 4
6 000201708A0008001 绳卡 Rope clamp 4
7 1050200417 GB/T276-1994 深沟球轴承 Bearing 6210-Z 8
8 000211519A0008300 卷筒座 B Rope drum saddle B 2
9 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 16
10 1040300065 GB/T93-1987 垫圈 Spring washer 16 16
11 1040200110 GB/T6170-2000 螺母 Nut M16-8 16
12 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 16
13 000221619AT004100 齿轮传动轴 Gear Shaft 1
14 000211519A0008100 卷筒座 A Rope drum saddle A 2
15 000221619AT004300 连接杆 Connecting link 2
16 000200611A0100001 XZ01A-16×60/80 销轴 Spindle 16×60 4
17 1040500228 GB/T91-2000 销 Cotter Pin 4×32 4
18 1040000199 GB/T5783-2000 螺栓 Bolt M8×45-8.8 2
19 000221619AT004400 支座 Support t25 2
20 000201519AR004902 定位轴 Lock Spindle φ10 2
21 000209938A0000020 TX-5-25/30 弹簧销 Spring pin 2
22 1031000041 JB/T8108.2-1999 起重用短环链 Chain φ4-300 2
23 1040000899 GB/T5782-2000 螺栓 Bolt M12×70-8.8 6
24 1040200680 GB/T6170-2000 螺母 Nut M12-8 6
25 1040300054 GB/T93-1987 垫圈 Spring washer 12 6
26 1040300756 GB/T97.1-2002 垫圈 Washer 12-200HV 6
27 000221619AT004500 手摇 Hand crank 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 70

 引进专用吊钩 Inlet special hook (000211519A0003000)

引进专用吊钩 Inlet special hook (000211519A0003000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000211519A0003100 拉杆 Tie bar 4
2 000210110AT000001 销轴 Spindle 8
3 1040500222 GB/T91-2000 销 Cotter Pin 8×80 8
4 000211519A0003200 吊钩 Special hook 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 71

 引进小车 Inlet trolley (000211519A0001000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 72

 引进小车 Inlet trolley (000211519A0001000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000211519A0001100 车架 Trolley Frame 1
2 1040200197 GB/T6170-2000 螺母 Nut M30-8 8
3 1040300010 GB/T93-1987 垫圈 Spring washer 30 8
4 000200910B0000559 垫板 Back plate t10 8
5 000211519A0001010 定位套 Anchor cover 16
6 1050200620 GB/T276-1994 深沟球轴承 Bearing 6309-Z 16
7 1040300778 GB/T893.2-1986 挡圈 Retainer ring 100 8
8 000201708A0001020 滚轮 Trolley 8
9 000211519A0001030 滚轮轴 Trolley shaft 8
10 000201708A0001040 挂钩 Hook 4
11 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 4
12 1040200110 GB/T6170-2000 螺母 Nut M16-8 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 73

 提升架 Lifting frame (000204019ATV01000)

提升架 Lifting frame (000204019ATV01000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204019ATV01200 支撑架 Support bracket 1
2 1040500381 GB/T91-2000 销 Cotter Pin 8×71 4
3 000200914A0000011 XZ01C-30×140/170 销轴 Spindle 30×140 4
4 000221619AT001100 提升梁 Lifting beam 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 74

 滑轮组 Pulley assembly (000204019ATV04000)

滑轮组 Pulley assembly (000204019ATV04000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204019ATV04100 滑轮座 Pulley Seat 1
2 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 4
3 1040300067 GB/T93-1987 垫圈 Spring washer 10 4
4 000200305A0000163 TC5613A.05-27 轴端挡板 Shaft-end Damper 2
5 000209906A0017000 214-178-B41-80-R6 滑轮 Pulley 2
6 1050200498 GB/T276-1994 深沟球轴承 Bearing 6208-z 4
7 1040300322 GB/T893.2-1986 挡圈 Retainer ring 80 4
8 000200305A0000160 TC5613A.05-24 轴套 Shaft sleeve 4
9 000201708A0006001 销轴 Spindle 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 75

11. X40B 过渡节 X40B Transition section（000209027A0300000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 76

 X40B 过渡节 X40B Transition section（000209027A0300000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000209 GB/T5783-2000 螺栓 Bolt M16×70-8.8 4
2 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 28
3 1040300065 GB/T93-1987 垫圈 Spring washer 16 28
4 1040200110 GB/T6170-2000 螺母 Nut M16-8 28
5 1040000899 GB/T5782-2000 螺栓 Bolt M12×70-8.8 4
6 1040300041 GB/T97.1-2002 垫圈 Wahser 12-200HV 16
7 1040300054 GB/T93-1987 垫圈 Spring washer 12 16
8 1040200096 GB/T6170-2000 螺母 Nut M12-8 16
9 000209027A0100100 短爬梯 Short Ladder 1
爬梯撑板
10 000209027A0100002 t8 1
Support plate for Ladder
11 000201213A0000006 夹板 B Fixed plate B t8 2
承重角钢
12 000209027A0100001 L100×10 2
Braced angle iron
过渡节结构
13 000209027A0301000 1
Transition section structure
14 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 24
15 1040000169 GB/T5783-2000 螺栓 Bolt M12×45-8.8 8
平台及栏杆
16 000209027A0102000 1
Platform and rail
17 000209027A0303000 爬梯及护圈 Ladder 1
长爬梯撑架
18 000209027A0304000 1
Support frame for Ladder
19 000209910A8213652 XZ-105-365/530 销轴 Spindle 8
20 000209910A4062401 XZ03C-30×240/270 锁销 Locking Spindle 12
21 1040501339 DIN_11024 弹簧销 Spring cotter d1=6.3 24
22 000209910A4154501 XZ03C-75×450/510 销轴 Spindle 75×450 8
23 1040500247 GB/T91-2000 销 Cotter Pin 13×125 16
24 000209910A1182801 XZ01C-90×280/345 销轴 Spindle 90×280 4
25 000209910A4041001 XZ03A-20×100/120 销轴 Spindle 20×100 4
26 1040500063 GB/T91-2000 销 Cotter Pin 5×36 8
27 000209027A0100200 销轴盒 Spindle box 6
28 000209910A8213653 XZ-104×365/480 安装销轴 Spindle 4
29 000209027A0302000 挂梁 Beam 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 77

 过渡节结构 Transition section structure（000209027A0301000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 78

 过渡节结构 Transition section structure（000209027A0301000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209027A0104101 连接头 Connector 4
2 000209910A8213211 XZ-105-321/372 销轴 Spindle 8
轴用弹性挡圈
3 1040302188 DIN471-2011 105×4 8
Retaining ring
4 1049900334 DIN988 支撑环 Support ring 105×130 8
水平腹杆
5 000209027A0104500 10
Horizontal diagonal
6 000209910A1102301 XZ01C-50×230/270A 销轴 Spindle 20
7 1040500186 GB/T91-2000 销 Cotter Pin 10×90 52
斜腹杆 A
8 000209027A0301100 4
Incline diagonal A
水平腹杆 A
9 000209027A0301300 2
Horizontal diagonal A
10 000209910A1122501 销轴 Spindle 24
11 000209910A1091003 XZ01C-45×100/140 销轴 Spindle 4
12 000221615AT001001 调节螺栓 Bolt 2
13 1040300090 GB/T97.1-2002 垫圈 Washer 36-200HV 4
14 1040200276 GB/T6170-2000 螺母 Nut M36-8 2
15 000221615AT001800 U 形板 U-Shaped Plate 2
16 000210601AT000001 XZ01C-45×120/160 销轴 Spindle 45×120 4
斜腹杆 B
17 000209027A0301200 2
Incline diagonal B
斜腹杆
18 000209027A0101700 4
Incline diagonal
弦杆体 A
19 000209027A0301500 2
Main chord A
弦杆体 B
20 000209027A0301700 2
Main chord B
固定撑杆
21 000221615AT001500 2
Non-adjustable strut
22 000221615AT001700 连接板 Connecting plate 1
调节撑杆
23 000221615AT001400 2
Adjustable strut

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 79

 平台及栏杆 Platform and rail（000209027A0102000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 80

 平台及栏杆 Platform and rail（000209027A0102000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209913A3T32150 栏杆 Rail 4
平台 A
2 000209027A0102100 1
Platform A
平台 B
3 000209027A0102200 1
Platform B
4 1040000562 GB/T5783-2000 螺栓 Bolt M12×65-8.8 4
5 000209913A5000001 LGJB1 栏杆夹板 Fixed plate t5 8
6 1040300233 GB/T96.1-2002 垫圈 Washer 12-200HV 4
7 1040300054 GB/T93-1987 垫圈 Spirng washer 12 4
8 1040200096 GB/T6170-2000 螺母 Nut M12-8 4
9 1040500381 GB/T91-2000 销 Cotter Pin 8×71 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 81

 爬梯及护圈 Climbing stairs and hoop guard（000209027A0303000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 82

 爬梯及护圈 Climbing stairs and hoop guard（000209027A0303000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209027A0303100 长爬梯 Long Ladder 1
2 000209027A0303001 护条 Strip guard t5 3
3 000209009Z0001302 护圈 Hoop guard t5 6
4 1040000101 GB/T5783-2000 螺栓 Bolt M12×40-8.8 15
5 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 15
6 1040300054 GB/T93-1987 垫圈 Spring washer 12 15
7 1040200096 GB/T6170-2000 螺母 Nut M12-8 15

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 83

12. 下支座 Slewing support (000204010ATV00000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 84

 下支座 Slewing support (000204010ATV00000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
下支座结构
1 000204010ATV01000 1
Slewing support structure
2 1090100213 GB/T5976-1986 钢丝绳夹 Rope Cramp 12 14
3 1090100459 GB/T8918-2006 钢丝绳 Rope 6×29Fi+1WR-12-1670 154
4 000204010ATV02000 爬梯 Climbing stairs 1
5 1040200110 GB/T6170-2000 螺母 Nut M16-8 4
6 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 4
7 1040300065 GB/T93-1987 垫圈 Spring washer 16 4
8 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 4
高强度螺母
9 000221009ATQ00003 M42×3 80
High strength Nut
高强度垫圈
10 000221009ATQ00004 42 160
High strength Washer
高强度螺栓 M42
11 000204010ATV00001 M42×435-10.9 80
High strength Bolt M42
12 000209910A8213652 XZ-105-365/530 销轴 Spindle 8
13 000209910A4061341 XZ03C-30×135/170 销轴 Spindle 30×135 16
14 1040501339 DIN_11024 弹簧销 Spring pin d1=6.3 32
15 1049900334 DIN988 支撑环 Mounting plate 105×130 16
楔套
16 1090100709 GB/T5973-2006 12 1
Wedged structure
17 1090100708 GB/T5973-2006 楔 Wedge 12 1
18 000209910A1050501 XZ01A-25×50/75 销轴 Spindle 25×50 1
19 1040500040 GB/T91-2000 销 Cotter Pin 6.3×50 1
20 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
21 1040300054 GB/T93-1987 垫圈 Spring washer 12 2
22 1040200096 GB/T6170-2000 螺母 Nut M12-8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 85

13. 上支座 Upper support (000204009ATV00000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 86

 上支座 Upper support (000204009ATV00000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209913A0006800 LGA680 栏杆 Railing 1
2 000209913A0005000 LG500 栏杆 Railing 1
3 000204009ATV01000 左平台 Left platform 1
4 000209913A0030000 LG3000 栏杆 Railing 1
5 000209913A0008200 LGA820 栏杆 Railing 6
6 000209910A1061061 XZ01C-30×110/140 销轴 Pivot 30×110 4
7 1040500216 GB/T91-2000 销 Pin 6.3×50 8
上支座结构
8 000204009ATV02000 1
Upper support structure
9 000221609AT000100 爬梯 A Ladder A 1
10 000204009ATV03000 右平台 Right platform 1
11 000209913A3014000 栏杆 Railing 1
12 000201302A0000001 XZ01C-40×230/265 销轴 1 Pivot 1 40×230 4
13 000203018BR001011 XZ01A-20×200/220 销轴 Pivot 20×200 2
14 1040500005 GB/T91-2000 销 Pin 5×45 2
15 000204009ATV04000 司机室平台 Cab platform 1
16 000204009ATV00100 爬梯 Ladder 1
17 000209913A0020000 LGB2000 栏杆 Railing 1
18 000204009ATV00001 线槽 Electric cable groove Tb4 1
19 1040000488 GB/T5783-2000 螺栓 Bolt M24×70-8.8 96
20 1040300049 GB/T93-1987 垫圈 Spring washer 24 96
21 1040001595 GB/T5783-2000 螺栓 Bolt M10×35-8.8 22
22 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 36
23 1040300067 GB/T93-1987 垫圈 Spring washer 10 36
24 1040201610 GB/T6170-2000 螺母 Nut M10-8 36
限位器护罩
25 000221609AT000600 1
Retainer Protective Cover
26 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 14
回转机构护罩
27 000221609AT000800 4
Returning Machine Protective Cover
28 000221609AT000001 尼龙套 Nylon cover 1
29 1040500222 GB/T91-2000 销 Pin 8×80 27
30 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 87

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
31 1040200110 GB/T6170-2000 螺母 Nut M16-8 8
32 1040300065 GB/T93-1987 垫圈 Spring washer 16 8
33 1040200096 GB/T6170-2000 螺母 Nut M12-8 18
栏杆夹板
34 000209913A5000001 LGJB1 t5 16
Railing Locking Splint
35 1040000899 GB/T5782-2000 螺栓 Bolt M12×70-8.8 8
36 1040300054 GB/T93-1987 垫圈 Spring washer 12 8
37 000203009AR015000 栏杆 H Railing H 1
集中润滑装置
38 000221609AT000900 1
Lubricant Application Device
高强度螺栓
39 000204009ATV00002 M42×3×480 80
High strength Bolt
高强度螺母
40 000221009ATQ00003 M42×3 80
High strength Nut
高强度垫圈
41 000221009ATQ00004 42 160
High strength washer

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 88

14. 回转限位装置 Slewing limit device (000209905A0015000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 89

 回转限位装置 Slewing limit device( 000209905A0015000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209905A0015100 连接轴 Connecting shaft 1
2 000209905A0015001 齿轮 Gear 1
3 1040000690 GB/T5783-2000 螺栓 Bolt M4×30-8.8 4
4 1040200100 GB/T6170-2000 螺母 Nut M4-8 4
5 1040300044 GB/T93-1987 垫圈 Spring washer 4 4
6 000209905A0015002 长轴 Long shaft 1
7 1999900214 DXZ-4/3 行程限位器 Limit switch 1
8 1040200107 GB/T6170-2000 螺母 Nut M5-8 8
9 000201109B0000341 支架 Support 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 90

15. HPW185F1.350A 回转机构 Slewing Mechanism（000209271A3000000)

HPW185F1.350A 回转机构 Slewing Mechanism（000209271A3000000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1020004313 YTRVFW180L1-4F1-18.5kW 电机 Motor 1
2 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 4
垫圈
3 1040300065 GB/T93-1987 16 4
Spring Washer
4 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 4
减速机
5 1030201254 XX4-350.275CC-20/13 1
Reduction Gear
6 000209271A3000001 铭牌 Nameplate 1
7 1040400045 GB/T827-1986 铆钉 Rivet 2×5 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 91

16. HPW185F2.350A 回转机构 Slewing Mechanism（000209271A4000000)

HPW185F2.350A 回转机构 Slewing Mechanism（000209271A4000000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1020004314 YTRVFW180L1-4F2-18.5kW 电机 Motor 1
2 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 4
垫圈
3 1040300065 GB/T93-1987 16 4
Spring Washer
4 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 4
减速机
5 1030201254 XX4-350.275CC-20/13 1
Reduction Gear
6 000209271A4000001 铭牌 Nameplate 1
7 1040400045 GB/T827-1986 铆钉 Rivet 2×5 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 92

17. SBG2900 扒杆 Derrick（000209914A9100000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 93

 SBG2900 扒杆 Derrick（000209914A9100000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000758 GB/T5782-2000 螺栓 Bolt M30×110-8.8 6
2 1040200197 GB/T6170-2000 螺母 Nut M30-8 12
3 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 12
回转座组件
4 000209914A9101000 1
Swing seat assembly
扒杆立柱
5 000209914A9113000 1
Derrick column
支撑轴组件
6 000209914A9103000 1
Support shaft assembly
挡绳杆 1
7 000209914A9100001 1
Rope resist shaft 1
8 1040500826 Q5004035 销 Pin 4×35 6
滑轮组件 1
9 000209914A9104000 1
Sheave assembly 1
10 000209914A9105000 拉杆组件 1
扒杆悬臂梁
11 000209914A9106000 1
Derrick cantilever
12 1040000489 GB/T5783-2000 螺栓 Bolt M10×50-8.8 4
13 1040300067 GB/T93-1987 垫圈 Washer 10 12
14 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 12
15 1040200679 GB/T6170-2000 螺母 Nut M10-8 4
16 000200305A0000152 TC5613A.05-13 缓冲块 Buffering piece 2
挡绳杆 2
17 000209914A9100003 2
Rope resist shaft 2
滑轮组件 2
18 000209914A9107000 2
Sheave assembly 2
挡绳支架板
19 000209914A9100002 4
Supporting of rope resist
20 1040000090 GB/T5783-2000 螺栓 Bolt M10×30-8.8 8
21 000209914A9109000 3t 吊具 Hanger for 3t 1
变幅小车
22 000209914A9108000 1
Trolleying wagon
套环组件
23 000209914A9110000 1
Bushing assembly
手动变幅机构
24 000209914A9111000 Hand trolleying 1
Mechanism
25 1040000286 GB/T5783-2000 螺栓 Bolt M16×65-8.8 4
26 1040200110 GB/T6170-2000 螺母 Nut M16-8 4
零件图册 Spare Parts Manual T2850-120V-138ZY-A01 94
序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
27 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 8
28 1040300065 GB/T93-1987 垫圈 Washer 16 4
29 000209910A4072801 XZ03C-35×280/315 销轴 Pin mandrel 2
30 1040500040 GB/T91-2000 销 Pin 6.3×50 4
定位销组件
31 000209914A9112000 1
Dowel assembly
32 000209914A9100004 铭牌 Nameplate 1
33 1040400087 GB/T827-1986 铆钉 Rivet 3×8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 95

 回转座组件 Swing seat assembly（000209914A9101000）

回转座组件 Swing seat assembly（000209914A9101000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
下回转座
1 000209914A9101100 1
Under swing seat
2 1031500260 JB/T2300-1999 回转支承 Swing 010.25.450.03 1
3 1040000190 GB/T5783-2000 螺栓 Bolt M16×90-8.8 24
4 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 47
上回转座
5 000209914A9101200 1
Upper swing seat
6 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 23

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 96

 支撑轴组件 Support shaft assembly（000209914A9103000）

支撑轴组件 Support shaft assembly（000209914A9103000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 2
2 1040300067 GB/T93-1987 垫圈 Spring Washer 10 2
3 000209914A8203003 轴端板 Shaft end plate 2
4 1050100027 SF-1 自润滑轴承 Bearing 4040 2
5 000209914A9103001 支承轴 Suppor shaft 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 97

 滑轮组件 1 Sheave assembly 1（000209914A9104000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000090 GB/T5783-2000 螺栓 Bolt M10×30-8.8 4
2 1040300067 GB/T93-1987 垫圈 Spring Washer 10 4
3 1040300061 GB/T97.1-2002 垫圈 Spring Washer 10-200HV 4
4 000209914A9104003 压板 pressing plate t10 2
5 000209914A9104002 轴套 Bushing 2
6 000209906A0016000 240-190-B41-80-R7 滑轮 Sheave 1
滑轮轴 1
7 000209914A9104001 1
Shaft1
8 1040300125 GB/T893.1-1986 挡圈 Washer 80 2
9 1050200498 GB/T276-1994 深沟球轴承 Bearing 6208-z 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 98

 拉杆组件 Pull rod assembly（000209914A9105000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209910A4071351 XZ03C-35×135/170 销轴 Pin 3
2 1040500040 GB/T91-2000 销 Pin 6.3×50 6
右丝杆焊件
3 000209914A9105100 1
Weldment of right screw rod
4 1040200110 GB/T6170-2000 螺母 Nut M16-8 1
5 1040200289 GB/T923-1988 螺母 Nut M16-6 1
丝杆套
6 000209914A9105001 1
Bushing of screw rod
左丝杆焊件
7 000209914A9105200 1
Weldment of lelft screw rod
拉杆焊件
8 000209914A9105300 1
Weldment of pull rod
9 000209914A9105002 螺杆 Bolt 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 99

 滑轮组件 2 Sheave assembly 2（000209914A9107000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209914A9107002 轴套 Bushing 1
2 1050200498 GB/T276-1994 深沟球轴承 Bearing 6208-z 2
3 000209906A0016000 240-190-B41-80-R7 滑轮 Sheave 1
4 1040300125 GB/T893.1-1986 挡圈 Washer 80 2
滑轮轴 2
5 000209914A9107001 1
Sheave shaft 2
6 000209914A9107003 轴套 Bushing 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 100

 3t 吊具 Hanger for 3t（000209914A9109000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 4
2 1040300067 GB/T93-1987 垫圈 Washer 10 4
3 000209914A8103003 轴端板 Shaft end plate 4
挂板焊件
4 000209914A9109100 2
Weldment of plate
5 000209914A9109002 轴套 Bushing 2
6 1050200498 GB/T276-1994 深沟球轴承 Bearing 6208-z 2
7 000209906A0016000 240-190-B41-80-R7 滑轮 Sheave 1
8 1040300125 GB/T893.1-1986 挡圈 Washer 80 2
9 000209914A9109001 滑轮轴 Sheave shaft 1
10 1040200096 GB/T6170-2000 螺母 Nut M12-8 2
11 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 12
12 1040300054 GB/T93-1987 垫圈 Washer 12 8
13 000209914A9109004 撑杆 Support rod 1
14 1090100337 JB/T8112-1999 卸扣 Shackle M-DW4 1
15 000209914A9109003 轴 Shaft 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 101

 变幅小车 Trolleying wagon（000209914A9108000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 102

 变幅小车 Trolleying wagon（000209914A9108000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209914A9108001 挂板 plate t20 2
滑轮轴 Sheave
2 000209914A9108002 Shaft 4
3 000209914A9108003 滚轮 Sheave 4
深沟球轴承
4 1050200498 GB/T276-1994 Bearing 6208-z 12
轴端板
5 000209914A8203003 Shaft end plate 4
6 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 4
7 1040300067 GB/T93-1987 垫圈 Washe 10 4
8 1040200197 GB/T6170-2000 螺母 Nut M30-8 8
9 1040300074 GB/T97.1-2002 垫圈 Washe 30-200HV 16
10 1040300010 GB/T93-1987 垫圈 Washe 30 8
套环轴 Bushing
11 000209914A9108004 shaft 2
12 000209914A9108005 轴套 Bushing 4
套环 Bushing
13 1090100084 GB/T5974.1-1986 ring 10 2
滑轮轴
14 000209914A9108006 Sheave shaft 2
15 000209914A9108007 轴套 Bushing 2
16 000209906A0016000 240-190-B41-80-R7 滑轮 Sheave 2
17 1040300125 GB/T893.1-1986 垫圈 Washe 80 4
18 000209914A9108008 轴套 Bushing 2
19 1040200097 GB/T6170-2000 螺母 Nut M20-8 4
20 1040300106 GB/T97.1-2002 垫圈 Washe 20-200HV 16
21 1040300038 GB/T93-1987 垫圈 Washe 20 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 103

 套环组件 Bushing ring（000209914A9110000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 2
2 1040300067 GB/T93-1987 垫圈 Washer 10 2
3 000209914A8203003 轴端板 Shaft end plate 2
4 000209914A9110002 套 Bushing 1
钢丝绳用普通套环
5 1090100344 GB/T5974.1-2006 14 1
Bushing of steel wire rope
6 000209914A9110001 支承轴 Support shaft 1
7 000209914A9110003 套 Bushing 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 104

 手动变幅机构 Hand trolleying Mechanism（000209914A9111000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 105

 手动变幅机构 Hand trolleying Mechanism（000209914A9111000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209914A9111300 手轮 Hand wheel 1
2 1040300157 GB/T894.1-1986 挡圈 Washer 30 3
3 1040300025 GB/T893.1-1986 挡圈 Washer 55 8
4 1050200261 GB/T276-1994 轴承 Bearing 6006-2Z 4
5 000209910A0120501 XZ01A-12×50/65 销轴 Pin mandrel 2
6 1040500822 Q5003220 销 Pin 3.2×20 2
7 000209914A9111001 传动轴 Drive shaft 1
8 1040600008 GB/T1096-1979 普通平键 Bond 8×32 1
9 000209914A9111002 小齿轮 Small Gear 1
10 000209914A8103003 轴端板 Shaft end plate 7
11 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 7
12 1040300067 GB/T93-1987 垫圈 Washer 10 7
13 1040000076 GB/T5783-2000 螺栓 Bolt M6×25-8.8 1
14 1040300248 GB/T96.1-2002 垫圈 Washer 6-200HV 2
15 1040300062 GB/T93-1987 垫圈 Washer 6 2
绳卡
16 000209304A0000004 2
Rope clip
17 000209914A9111200 卷筒 Drum 1
18 1040000096 GB/T5783-2000 螺栓 Bolt M6×12-8.8 1
机构座
19 000209914A9111100 1
Mechanism seat
套2
20 000209914A9111005 2
Bushing 2
21 1040300249 GB/T848-2002 垫圈 Washer 30-200HV 4
22 000209914A8103002 滑轮 Sheave 1
23 1040301244 GB/T895.1-1986 孔用钢丝挡圈 Washer 35 4
24 000209914A9111006 滑轮轴 Sheave shaft 2
25 1050100064 SF-1 自润滑轴承 Bearing 3040 2
26 000209914A9111008 套 3 Bushing 3 2
双槽滑轮
27 000209914A9111007 1
Two groove sheave
28 1090100495 GB1102-1974 钢丝绳 steel wire rope φ6 17（m）
29 1090100175 GB/T5976-2006 绳夹 Rope clip 6KTH 6
套1
30 000209914A9111003 2
Bushing 1
31 000209914A9111004 卷筒轴 Drum shaft 1

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 定位销组件 Dowel assembly（000209914A9112000）

定位销组件 Dowel assembly（000209914A9112000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209914A8206002 定位销 Dowel assembly 1
2 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 1
起重用短环链
3 1090100559 JB/T8108.2-1999 Short link Chain for lifting φ4-252(21) 1
purposes
4 000209914A9112001 套 Bushing 1

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18. H132FL150-1230D 起升机构 Hoisting Mechanism(000209196A2700000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 108

 H132FL150-1230D 起升机构 Hoisting Mechanism(000209196A2700000)
序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1030201760 B3HH17-50-B 减速机 Gear i=49.935 1
轴端挡板
2 000209196A2700001 t10 1
Shaft end Plate
3 1040000576 GB/T5783-2000 螺栓 Bolt M24×60-8.8 1
4 1040300049 GB/T93-1987 垫圈 Spring Washer 24 5
5 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 8
6 000209196A0600100 制动器罩 Brake Cover 1
YP31-Ed2000-710×30-Ⅰ
7 1039904141 制动器 Brake 1
A-WL.H
MLL12-Ⅰ
制动盘联轴器
8 000209944A0000340 -710-ZA130×202(28)/JA9 1
Coupling
0×172(25)
9 1020004783 YZTPF400L2-8 电机 Motor 25Hz，132kW 1
10 1040000316 GB/T5782-2000 螺栓 Bolt M30×140-8.8 4
11 1040201226 GB/T6170-2000 螺母 Nut M30-8 12
12 1040301513 GB/T97.1-2002 垫圈 Washer 30-200HV 18
13 1040300010 GB/T93-1987 垫圈 Spring Washer 30 12
14 1040000281 GB/T5782-2000 螺栓 Bolt M24×100-8.8 4
15 1040200102 GB/T6170-2000 螺母 Nut M24-8 4
16 1040002440 GB/T5783-2000 螺栓 Bolt M12×45-8.8 5
17 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 10
18 1040300054 GB/T93-1987 垫圈 Spring Washer 12 5
19 1040201381 GB/T6170-2000 螺母 Nut M12-8 5
20 1040001463 GB/T5782-2000 螺栓 Bolt M36×180-8.8 6
21 1040201122 GB/T6170-2000 螺母 Nut M36-8 14
22 1040300090 GB/T97.1-2002 垫圈 Washer 36-200HV 28
23 1040300261 GB/T93-1987 垫圈 Spring Washer 36 14
调整垫 A
24 000209171A0200010 t1 1
Regulate Spacer A
调整垫 B
25 000209171A0200011 t1.5 1
Regulate Spacer B

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H132FL150-1230D 起升机构 Hoisting Mechanism (000209196A2700000)

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110
 H132FL150-1230D 起升机构 Hoisting Mechanism (000209196A2700000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
26 1040600404 GB/T1096-2003 键 Bond 56×32×780 1
27 1080000249 JB/T7940.1-1995 油杯 90°Grease Cup M10×1 2
28 000209196A2700003 轴套 A Bushing A 1
29 1040000065 GB/T5783-2000 螺栓 Bolt M16×45-8.8 24
30 1040300065 GB/T93-1987 垫圈 Spring Washer 16 32
轴承端盖 A
31 000209196A2700004 t25 1
Bearing-end Cover A
32 000209182A0000045 毡圈 B Oil Seal B 1
33 1050200868 GB/T288-1994 调心滚子轴承 Bearing 23052 1
轴承座 A
34 000209196A2703000 1
Bearing Seat A
35 1040001482 GB/T5783-2000 螺栓 Bolt M30×120-8.8 8
36 1040300251 GB/T853-1988 垫圈 Washer 30 6
轴承端盖 B
37 000209196A2700005 t25 2
Bearing-end Cover B
38 000209127A0100006 毡圈 I Oil Seal I 2
39 000209196A2700002 主轴 Shaft 1
40 1040600416 GB/T1096-2003 键 Bond 56×32×500 1
41 000209196A2702000 卷筒 Drum 1
42 000209196A2700006 轴套 B Bushing B 1
轴承座 B
43 000209196A2704000 1
Bearing Seat B
44 1050200461 GB/T288-1994 调心滚子轴承 Bearing 23148 1
轴承端盖 C
45 000209196A2700007 t25 1
Bearing-end Cover C
46 000209944A0600020 ZC60 毡圈 60 Oil Seal 60 1
47 000209944A0200021 NLT-1 尼龙套 Nylon Sleeve 1
48 000209944A0400010 限位器支架 Bracket 1
49 1040000122 GB/T5783-2000 螺栓 Bolt M10×35-8.8 2
50 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 2
51 1040300067 GB/T93-1987 垫圈 Spring Washer 10 2
52 1040000151 GB/T5783-2000 螺栓 Bolt M5×12-8.8 4
53 1040300048 GB/T97.1-2002 垫圈 Washer 5-200HV 4
54 1040300060 GB/T93-1987 垫圈 Spring Washer 5 4
55 1040500054 GB/T91-2000 销 Pin 4×40 1

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序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
56 1040400058 GB/T827-1986 铆钉 Rivet 2.5×8 4
57 000209196A2700010 H132FL150-1230D-MP 铭牌 Nameplate 1
58 000209196A2705000 挡绳杆 Rope Catch 1
59 1090100590 GB/T5976-1986 钢丝绳夹 Clip 32KTH 2
60 000209196A2701000 底架 Underframe 1
61 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 8
62 1040200110 GB/T6170-2000 螺母 Nut M16-8 16
63 1040300213 GB/T97.1-2002 垫圈 Washer 16-200HV 8
64 1040001497 GB/T5783-2000 螺栓 Bolt M36×130-10.9 8

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 制动盘联轴器 Coupling（000209944A0000340）

制动盘联轴器 Coupling（000209944A0000340）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
制动盘半联轴器
1 000209944A0000341 1
Semi-coupling
000209944A0000262 MT12-b 梅花形弹性体
2 1
Elastic spider body
凸缘半联轴器
3 000209944A0000283 1
Semi-coupling

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 安全制动钳系统 Safety Braking System（000211024AH000000）

安全制动钳系统 Safety Braking System（000211024AH000000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1010001508 YZBA10-11B 泵站 PumPing Station 1
直路端三通可调向接头
2 1140105832 LEE15LMA3C 1
Tie-in
3 1140225836 F481CACA151508-4000mm 胶管总成 Pipe 1
4 1140213179 F481CACA151508-5000 胶管总成 Pipe 1
5 1990200802 21 胶管管夹 Clamp 6
6 1140104335 SWVE15LMOMDA3C 铰接式接头 Tie-in 2
安全制动钳
7 1109900368 SBD160-D-Ⅱ 2
Safety Braking

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19. 平衡臂 Counter-jib (000204001ATV00000)

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115
 平衡臂 Counter-jib (000204001ATV00000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
臂节一
1 000221601BT010000 1
Counter-jibⅠ
栏杆夹板
2 000240809AT000020 t6 6
Handrailing splint
3 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 3
4 1040200096 GB/T6170-2000 螺母 Nut M12-8 3
5 1040300054 GB/T93-1987 垫圈 Washer 12 3
6 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 3
7 000209913A0010000 LGA1000 栏杆 Handrailing 1
8 1040500381 GB/T91-2000 销 Pin 8×71 2
臂节二
9 000221601BT020000 1
Counter-jib Ⅱ
10 000221601AT000010 安装座 Support 1
11 1040000696 JB/ZQ4321-1997 U 型螺栓 U Bolt 33-Zn 2
12 1040300067 GB/T93-1987 垫圈 Washer 10 4
13 1040200113 GB/T6170-2000 螺母 Nut M10-8 4
14 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 4

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 臂节一 Counter-jibⅠ(000221601BT010000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

117
 臂节一 Counter-jibⅠ (000221601BT010000)

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 000209913A0010000 LGA1000 栏杆 Handrailing 1
2 000209913A0035000 LG3500 栏杆 Handrailing 3
3 000209913A3030000 LGT3000 栏杆 3000 Handrailing 2
4 1040000129 GB/T5783-2000 螺栓 Bolt M20×70-8.8 12
5 1040300038 GB/T93-1987 垫圈 Washer 20 12
6 1040200097 GB/T6170-2000 螺母 Nut M20-8 12
7 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 8
滑轮组件
8 000213005AT001060 2
Pulley assembly
9 000209913A0004300 LGA430 栏杆 Handrailing 4
XZ01C-40×75/1
10 000209910A0010056 销轴 Pin 40×75 4
10
11 000221601AT014000 平台 B Platform B 1
12 1040000108 GB/T5783-2000 螺栓 Bolt M12×30-8.8 4
13 1040200096 GB/T6170-2000 螺母 Nut M12-8 20
14 000240801AT030001 销轴 Pin φ20 5
15 1040500228 GB/T91-2000 销 Pin 4×32 5
16 1040000082 GB/T5783-2000 螺栓 Bolt M16×40-8.8 8
17 1040200110 GB/T6170-2000 螺母 Nut M16-8 8
18 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 8
19 1040300065 GB/T93-1987 垫圈 Washer 16 8
20 000221601BT012000 托辊 Roller 1
臂节一结构
21 000221601BT011000 1
Counter-jibⅠstructure
22 000221601AT013000 平台 A Platform A 1
23 1040500381 GB/T91-2000 销 Pin 8×71 36
栏杆夹板
24 000240809AT000020 t6 16
Handrailing splint
25 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 8
26 1040300054 GB/T93-1987 垫圈 Washer 12 20
27 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 20
28 1040100170 GB/T825-1988 螺钉 Screw M16 2
29 000209910A8244151 XZ-120-415/540 销轴 Pin 2
30 000209938A0000040 TX-8-30/40 弹簧销 Spring pin 2
31 000221605AT002001 插销 Pin φ30 2

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序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
32 000240805AT102172 链条 Chain D6-550 4
33 1999901480 bxk 保险扣 Safety catch 8mm 3
34 000209913A0015000 LGC1500 栏杆 Handrailing 2
35 000209910A0000507 XZF-40-68/100 销轴 Pin XZF-40-68/100 1
JB/T7940.1-199
36 1080000007 油杯 Oil cup M10×1 1
5
37 000210105A0010001 轴端挡板 Keeper plate t6 1
38 000210105A0010002 轴套 Shaft sleeve 2
滑轮组件
39 000209903A0000576 05HLZJA 1
Pulley assembly
40 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
41 1040300067 GB/T93-1987 垫圈 Washer 10 6
42 1040300252 GB/T853-1988 垫圈 Washer 20 4
43 1040000757 GB/T5782-2000 螺栓 Bolt M12×150-8.8 8
44 000221601BT013010 板 Plate t12 1
45 000221601BT013000 支架 Support 2
46 000221601AT012000 托辊 Roller 1

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 滑轮组件 Pulley assembly（000213005AT001060）

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 1080000007 JB/T7940.1-1995 油杯 Oil cup M10×1 1
2 000213005AT001004 滑轮轴 Axle 1
3 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
4 1040300067 GB/T93-1987 垫圈 Washer 10 2
轴端挡板
5 000213005AT001007 t10 1
Keeper plate
滑轮架
6 000213005AT001061 1
Block support
7 000213005AT001003 轴套 Shaft sleeve 2
金属密封圈
8 000209710A0200010 2
Seal ring
9 000209710A0200015 轴套 Shaft sleeve 2
10 1040300681 GB/T893.2-1986 挡圈 Retaining ring 160 2
710-620-B85-16
11 000209710A0200008 滑轮 Pulley 1
0-R14
12 000209710A0200009 隔套 Spacer 1
调心滚子轴承
13 1050200819 GB/T288-1994 Self-aligning roller 22218c w33 2
Bearing

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 滑轮组件 Pulley assembly（000209903A0000576）

滑轮组件 Pulley assembly（000209903A0000576）

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 000209906A0016000 240-190-B41-80-R8 滑轮 Pulley 1
挡圈
2 1040300322 GB/T893.2-1986 80 2
Retaining ring
深沟球轴承
3 1050200498 GB/T276-1994 Deep groove ball 6208-z 2
Bearing

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 托辊 Roller (000221601BT012000)

托辊 Roller (000221601BT012000)

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 000213001AT001011 托绳轮 Roller 1
2 000240801AT060003 挡板 Keeper plate t6 2
3 1040101312 GB/T70.1-2008 螺钉 Screw M6×15-4.8 12
4 1040300384 GB/T894.1-1986 挡圈 Retaining ring 75 2
5 000240801AT060004 轴套 Shaft sleeve 2
深沟球轴承
6 1050200773 GB/T276-1994 61812-2Z 2
Deep groove ball Bearing
7 1040300032 GB/T894.1-1986 挡圈 Retaining ring 60 2
8 000240801AT060005 轴套 Shaft sleeve 2
深沟球轴承
9 1050200771 GB/T276-1994 61815-2Z 2
Deep groove ball Bearing
10 000240801AT061000 半轴 Half shaft 2

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 托辊 Roller (000221601AT012000)

托辊 Roller (000221601AT012000)

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 000240801AT060001 托绳轮 Roller 1
2 000240801AT060003 挡板 Keeper plate t6 2
3 1040101312 GB/T70.1-2008 螺钉 Screw M6×15-4.8 12
4 1040300384 GB/T894.1-1986 挡圈 Retaining ring 75 2
5 000240801AT060004 轴套 Shaft sleeve 2
深沟球轴承
6 1050200773 GB/T276-1994 61812-2Z 2
Deep groove ball Bearing
7 1040300032 GB/T894.1-1986 挡圈 Retaining ring 60 2
8 000240801AT060005 轴套 Shaft sleeve 2
深沟球轴承
9 1050200771 GB/T276-1994 61815-2Z 2
Deep groove ball Bearing
10 000240801AT061000 半轴 Half shaft 2

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 臂节二 Counter-jib Ⅱ(000221601BT020000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 124

 臂节二 Counter-jib Ⅱ(000221601BT020000)

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 000209913A0004300 LGA430 栏杆 Handrailing 1
2 000221601BT020200 平台 B Platform B 1
栏杆夹板
3 000240809AT000020 t6 24
Handrailing splint
4 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 12
5 1040200096 GB/T6170-2000 螺母 Nut M12-8 13
6 1040300054 GB/T93-1987 垫圈 Washer 12 13
7 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 13
8 000221601BT020300 平台 C Platform C 1
9 000209913A0040000 LGB4000 栏杆 Handrailing 6
10 1040500381 GB/T91-2000 销 8×71 60
11 000209913A3008000 LGT800 栏杆 Handrailing 1
12 000221601BT020700 平台 F 1
13 000209913A0035000 LG3500 栏杆 Handrailing 2
14 1040500224 GB/T91-2000 销 Pin 6.3×63 24
15 000211501A0000018 销轴 Pin 16
臂节二结构
16 000221601BT021000 1
Counter-jibⅡstructure
17 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
18 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
19 1040300010 GB/T93-1987 垫圈 Washer 30 2
20 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
21 000221601BT020500 张紧装置 Tension system 2
22 000209910A1101901 XZ04C-50×190/245 销轴 Pin 4
23 1040500248 GB/T91-2000 销 Pin 10×100 12
24 000221601BT020800 爬梯 Ladder 1
25 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 4
26 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 4
27 1040300065 GB/T93-1987 垫圈 Washer 16 4
28 1040200110 GB/T6170-2000 螺母 Nut M16-8 4
29 000211501A0000019 销轴 Pin 8
30 000221601BT020600 平台 E Platform E 1
31 000209913A3015690 异形栏杆 Alien handrailing 1
32 000221601BT020400 平台 D Platform D 1
33 000221601BT020100 平台 A Platform A 1
34 000221601BT020900 栏杆 Handrailing 1

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序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
35 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
36 1040300067 GB/T93-1987 垫圈 Washer 10 4
37 000209910A0000507 XZF-40-68/100 销轴 Pin XZF-40-68/100 1
38 000210105A0010001 轴端挡板 Keeper plate t6 1
39 000209903A0000576 05HLZJA 滑轮组件 Pulley assembly 1
40 000210105A0010002 轴套 Shaft sleeve 2
41 1080000007 JB/T7940.1-1995 油杯 Oil cup M10×1 1
42 000240805AT011001 XZ03A-12×95/110 销轴 Pin 12×95 1
43 1040500228 GB/T91-2000 销 Pin 4×32 17
44 000209910A0010006 XZ01C-60×125/165 销轴 Pin 60×125 4
45 1040001595 GB/T5783-2000 螺栓 Bolt M10×35-8.8 4
46 1040300245 GB/T853-1988 垫圈 Washer 10 8
47 1040200113 GB/T6170-2000 螺母 Nut M10-8 6
48 000209913A3023300 LGC2330T 栏杆 2330 Handrailing 1
障碍灯座
49 000209915A0001000 ZADZ 1
Obstacle light Support
50 1040000696 JB/ZQ4321-1997 U 型螺栓 U Bolt 33-Zn 1
51 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 2
52 1040500233 GB/T91-2000 销 Pin 5×40 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 126

 张紧装置 Tension system（000221601BT020500）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 127

 张紧装置 Tension system（000221601BT020500）

序号 编码 代号 名称 规格长度 数量
NO Order NO. Code Designation Dimension Qty
1 1040200328 GB/T6172.1-2000 螺母 Nut M64-04 1
调节环
2 000201701A0092100 1
Regulating ring
3 000201701A0092003 垫圈ⅠWasher Ⅰ t30 1
固定架
4 000221601BT020520 1
Fixed support
5 1040500005 GB/T91-2000 销 Pin 5×45 3
XZ03A-20×245/26
6 000209708A0200010 销轴 Pin 20×245 1
5
7 000201701A0092001 螺栓 Bolt 1
活动架
8 000221601BT020510 1
Adjustable shelf
9 000209710A0200015 轴套 Shaft sleeve 2
金属密封圈
10 000209710A0200010 2
Seal ring
11 000213005AT001003 轴套 Shaft sleeve 2
12 1040300681 GB/T893.2-1986 挡圈 Retaining ring 160 2
调心滚子轴承
13 1050200819 GB/T288-1994 Self-aligning roller 22218c w33 2
Bearing
710-620-B85-160-
14 000209710A0200008 滑轮 Pulley 1
R14
15 000221601AT020540 移动垫 Moving pad 1
XZ01A-20×140/16
16 000201116A0000002 销轴 Pin 20×140 1
0
17 000209710A0200009 隔套 Spacer 1
XZ03A-16×205/22
18 000209910A0010041 销轴 Pin 16×205 1
5
19 1040500518 GB/T91-2000 销 Pin 4×35 2
20 000221601AT020501 垫圈 Washer 1
21 000209910A8182801 XZ-90-280/335 张紧销轴 Shaft 1
22 1080000250 JB/T7940.1-1995 油杯 Oil cup M10×1 1
M12×50-8.
23 1040002441 GB/T5783-2000 螺栓 Bolt 2
8
24 1040200680 GB/T6170-2000 螺母 Nut M12-8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 128

20. T185FC87 变幅机构 Trolleying Mechanism (000209334B1000000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 129

 T185FC87 变幅机构 Trolleying Mechanism (000209334B1000000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
电机
1 1020000128 YZPFE225M2-6T-18.5KW 1
Electromotor
2 1040003818 GB/T899-1988 螺栓 Bolt M18×70-8.8 6
垫圈
3 1040300028 GB/T93-1987 18 8
Spring Washer
4 1040300053 GB/T97.1-2002 垫圈 Washer 18-200HV 8
5 1040200366 GB/T6170-2000 螺母 Nut M18-8 8
弹性圆柱销
6 1040500634 GB/T879.1-2000 16×45 2
Cotter Pin
7 000209334A1000070 法兰 B Flange B 1
支承架
8 000209334B1000100 1
Support Frame
9 1040100380 GB/T70.1-2000 螺钉 Screw M12×45-8.8 12
10 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 12
11 000209334A1000060 透盖 II Hatch II 1
压板
12 000209334A1000030 6
Pressing Plate
13 1040000055 GB/T5783-2000 螺栓 Bolt M20×60-8.8 12
14 1040000095 GB/T5783-2000 螺栓 Bolt M16×60-8.8 8
垫圈
15 1040300065 GB/T93-1987 16 8
Spring Washer
16 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 8
17 000209334A1000050 法兰 A Flange A 1
18 000209334A1000090 透盖 I Hatch I 1
毡圈 160
19 000209333B0000140 1
Oil Seal 160
内齿形弹性联轴
20 000209334A1000040 1
器 Coupling
21 1040000129 GB/T5783-2000 螺栓 Bolt M20×70-8.8 20
减速机
22 1030200666 XX5-500.135 1
Retarder
弹性圆柱销
23 1040500633 GB/T879.1-2000 20×65 4
Cotter Pin
24 000209334A1000200 卷筒 Drum 1
连接套
25 000209334B1000001 1
Coupled Yoke
端盖
26 000209334A1000010 1
Head Cover

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 130

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
27 000209910A8050551 XZ-25-55/60 销轴 Pin 25×55 2
28 1040000267 GB/T5783-2000 螺栓 Bolt M8×20-8.8 4
垫圈
29 1040300063 GB/T93-1987 8 4
Spring Washer
30 1040300066 GB/T97.1-2002 垫圈 Washer 8-200HV 4
31 1040002457 GB/T5783-2000 螺栓 Bolt M5×12-8.8 4
垫圈
32 1040300060 GB/T93-1987 5 4
Spring Washer
限位器支架
33 000209331A0000600 1
Bracket
毡圈 175
34 000209333B0000100 1
Oil Seal 175
小齿轮
35 000209334A1000080 1
Gear Wheel
36 1040100386 GB/T70.1-2000 螺钉 Screw M5×16-8.8 2
调心滚子轴承
37 1050200456 GB/T288-1994 23032 1
Bearing
38 000209333B0000130 套 Yoke 1
39 000209333B0000120 调整垫片 Shim 1
40 1040000377 GB/T5783-2000 螺栓 Bolt M20×80-8.8 4
垫圈
41 1040300038 GB/T93-1987 20 36
Spring Washer
42 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 24
铭牌
43 000209334B1000002 t1 1
Nameplate
44 1040400058 GB/T827-1986 铆钉 Rivet 2.5×8 4
45 1040003819 GB/T899-1988 螺栓 Bolt M18×45-8.8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 131

21. H25FP15-440-d 辅助机构 Auxiliary Mechanism (000209103E7000000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 132

 H25FP15-440-d 辅助机构 Auxiliary Mechanism (000209103E7000000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 133

 H25FP15-440-d 辅助机构 Auxiliary Mechanism (000209103E7000000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1040000265 GB/T5782-2000 螺栓 Bolt M16×110-8.8 4
2 1040300215 GB/T853-1988 垫圈 Spring Washer 16 12
3 1040300065 GB/T93-1987 垫圈 Spring Washer 16-200HV 22
4 1040300052 GB/97.1-2002 垫圈 Spring Washer 16 24
5 1040200110 GB/T6170-2000 螺母 Nut M16-8 18
6 1020004094 YZPFM200L2-8 电机 Motor 1
MLL7-I-315YA65×142(
7 000209101E1003000 联轴器 Coupling 1
18)/ZC50×84(14)
8 1040000177 GB/T5783-2000 螺栓 Bolt M16×55-8.8 8
9 1031700166 YWZ3-315/45-16 制动器 Brake 1
10 000209103E7005000 底架 Underframe 1
制动器罩
11 000209101E1004000 1
Brake Cover
12 1040000098 GB/T5783-2000 螺栓 Bolt M8×16-8.8 10
13 1040300063 GB/T93-1987 垫圈 Spring Washer 8 22
14 1040300066 GB/T97.1-2002 垫圈 Spring Washer 8-200HV 22
15 1030200694 JD610 减速机 Gear 1
向心关节轴承
16 1050000313 GB/T9163-2001 GE60ES 1
Bearing
防尘盖
17 000209101E1000004 t2 1
Dustproof cap
18 000209101E1000002 挡圈 Detent ring t2 1
19 000209101E1000005 销轴 Pin 4
20 000209101E1000003 齿形接盘 Fluted disc 1
21 1040600016 GB/T1096-1979 键 Bond 20×80 1
22 000209101E1000019 心轴 Shaft 1
23 1040000564 GB/T5783-2000 螺栓 Bolt M24×110-8.8 4
24 1040200102 GB/T6170-2000 螺母 Nut M24-8 4
25 000209103E4006000 卷筒 Drum 1
26 000209101E1000018 轴套 Bushing 1
27 1040000018 GB/T5783-2000 螺栓 Bolt M8×30-8.8 10
28 000209101E1000008 油封 Oil Seal 1
轴承盖Ⅰ
29 000209101E1000009 1
Bearing Cover Ⅰ

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 134

 序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
30 1050200504 GB/T281-1994 调心球轴承 Bearing 1314 1
31 000209101E1000012 轴套 Bushing 1
32 1040000209 GB/T5783-2000 螺栓 Bolt M16×70-8.8 2
33 000209101E1008000 轴承座 Bearing Seat 1
34 000209101E1000013 垫圈 Spring Washer 1
35 000209101E1000015 油封 Oil Seal 1
轴承盖Ⅱ
36 000209101E1000014 1
Bearing Cover Ⅱ
37 1080000234 JB/T7940.2-1995 油杯 Grease Cup 90°M10×1 1
38 000209101E1000001 尼龙套 Nylon Sleeve 1
39 1040100956 GB/T71-1985 螺钉 Bolt M5×20-22H 1
40 1040000110 GB/T5783-2000 螺栓 Bolt M8×35-8.8 2
41 000209101E1001000 限位器支架 Bracket 1
42 1040000151 GB/T5783-2000 螺栓 Bolt M5×12-8.8 4
43 1040300060 GB/T93-1987 垫圈 Spring Washer 5 4
44 1040300048 GB/T97.1-2002 垫圈 Spring Washer 5-200HV 4
45 1040000145 GB/T5783-2000 螺栓 Bolt M16×80-8.8 2
调整垫 A
46 000209101E1000010 t1 0
Regulate Spacer A
调整垫 B
47 000209101E1000011 t1.5 0
Regulate Spacer B
48 1040000483 GB/T5782-2000 螺栓 Bolt M16×90-8.8 6
49 1040300976 GB/T894.1-1986 挡圈 Detent ring 70 1
50 000209103E7000001 H25FP15-440-d-MP 铭牌 Nameplate 1
51 1040400058 GB/T827-1986 铆钉 Rivet 2.5×8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 135

 联轴器 Coupling（000209101E1003000）

联轴器 Coupling（000209101E1003000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
凸缘半联轴器
1 000209101E1003003 1
Semi-coupling
梅花形弹性体
2 000209101E1003002 MT8-b 1
Elastic spider body
制动轮半联轴器
3 000209101E1003001 1
Semi-coupling

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 136

22. 臂节ⅠJib Ⅰ (000204005ATV01000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 137

 臂节Ⅰ Jib Ⅰ (000204005ATV01000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV01100 臂节Ⅰ结构 Jib Section 1
2 000209913A0045000 LG4500 栏杆 Railing 1
3 000209914A9110000 套环组件 1
4 000209913A0030000 LG3000 栏杆 Railing 1
5 000209913A0025000 LGC2500 栏杆 Railing 1
6 000213005AT001060 滑轮组件 Pulley Assembly 1
7 000204005ATV01010 滑轮组件 Pulley Assembly 1
8 1040000055 GB/T5783-2000 螺栓 Bolt M20×60-8.8 8
9 1040200868 GB/T6172-2000 螺母 Nut M20-8 8
10 1040300038 GB/T93-1987 垫圈 Lock Washer 20 16
障碍灯座
11 000209915A0001000 ZADZ 1
Stand for Alarm Light
12 1040000696 JB/ZQ4321-1997 U 型螺栓 U Bolt 33-Zn 1
13 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 2
14 1040200113 GB/T6170-2000 螺母 Nut M10-8 6
15 1040500233 GB/T91-2000 销 Cotter Pin 5×40 1
16 1040300067 GB/T93-1987 垫圈 Lock Washer 10 6
17 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 8
18 1040201226 GB/T6170-2000 螺母 Nut M30-8 8
19 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 8
20 1040300010 GB/T93-1987 垫圈 Lock Washer 30 8
21 1040200096 GB/T6170-2000 螺母 Nut M12-8 6
22 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 6
23 1040300054 GB/T93-1987 垫圈 Lock Railing 12 6
24 000209913A5000001 LGJB1 栏杆夹板 Railing Clamp t5 4
25 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 2
26 000204005ATV01020 小车撞块 Block 2
27 000209709C0001400 插销 Pin 2
28 000209604B0002005 XZ01A-8x50/60 销轴 Pin 8×50 2
29 000201302A0000001 XZ01C-40×230/265 销轴 Shaft 40×230 2
710-620-B85-160-R1
30 000209710A0200008 滑轮 Pulley 1
4
31 000209710A0200009 隔套 Distance Ring 1
32 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2
33 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 3
34 000213008BT000001 滑轮轴 Shaft φ90 1
35 000213008AT000006 轴套 Distance Ring 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 138

 序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
36 000209710A0200010 金属密封圈 Seal Metal Ring 2
37 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
38 000221605AT001004 轴端挡板 Shaft holder 1
39 1040001680 GB/T5783-2000 螺栓 Bolt M10×30-8.8 2
40 1039800340 GB93-87 弹簧垫圈 Lock Washer 10 2
41 000209710A0200015 轴套 Distance Ring 2
42 000209903A0000576 05HLZJA 滑轮组件 Pulley Assembly 1
43 000210105A0010001 轴端挡板 Shaft Holder t6 1
44 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
45 000210105A0010002 轴套 Distance Ring 2
46 000209910A0000507 XZF-40-68/100 销轴 Shaft XZF-40-68/100 1
47 000209716A0010010 滑轮 Pulley 1
48 1050200454 GB/T288-1994 调心滚子轴承 Bearing 23024CC/W33 2
49 000221605AT001002 轴套 Distance Ring 2
50 000221605AT001003 滑轮轴 Shaft 1
51 1040300644 GB/T893.2-1986 挡圈 Lock Ring 180 2
52 000209711B0000116 隔套 Distance Ring 1
53 000209716A0010003 金属密封圈 Metal Seal Ring 4
54 000209716A0010004 轴套 Distance Ring 2
55 1040000051 GB/T5783-2000 螺栓 Bolt M20×45-8.8 2
56 000221605AT001001 轴端挡板 Shaft holder t12 1
57 000201109B0000501 XZ03C-30×310/345 销轴 Shaft 30×310 2
58 1040500224 GB/T91-2000 销 Cotter Pin 6.3×63 6
59 000209910A4364601 XZ03E-180×460/670 销轴 Shaft 4
60 000209910A8364801 XZ-180-480/660 销轴 Shaft 2
61 000221605AT002001 插销 Pin φ30 4
62 1040100170 GB/T825-1988 螺钉 Screw M16 4
63 1999901480 bxk 保险扣 Safety Catch 8mm 14
64 000240805AT102172 链条 Chain D6-550 10
65 000209910A8405661 XZ-200-566/745 销轴 Shaft 2
66 1040500381 GB/T91-2000 销 Cotter Pin 8×71 24

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 139

 滑轮组件 Pulley Assembly（000204005ATV01010）

滑轮组件 Pulley Assembly（000204005ATV01010）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
2 000213005AT001004 滑轮轴 Shaft 1
3 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
4 1040300067 GB/T93-1987 垫圈 Lock Washer 10 2
5 000213005AT001007 轴端挡板 Shaft Holder t10 1
6 000213005AT001061 滑轮架 Frame 1
7 000213005AT001003 轴套 Distance Ring 2
金属密封圈 Metal Seal
8 000209710A0200010 2
Ring
9 000209710A0200015 轴套 Distance Ring 2
10 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
710-620-B85-160-R
11 000209710A0200008 滑轮 Pulley 1
14
12 000209710A0200009 隔套 Distance 1
13 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2
14 000200111T0000002 XZ03A-25×200/230 销轴 Pin 25×200 1
15 1040500216 GB/T91-2000 销 Cotter Pin 6.3×50 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 140

 滑轮组件 Pulley Assembly（000213005AT001060）

滑轮组件 Pulley Assembly（000213005AT001060）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
2 000213005AT001004 滑轮轴 Shaft 1
3 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
4 1040300067 GB/T93-1987 垫圈 Lock Ring 10 2
5 000213005AT001007 轴端挡板 Shaft Holder t10 1
6 000213005AT001061 滑轮架 Frame 1
7 000213005AT001003 轴套 Distance Ring 2
金属密封圈
8 000209710A0200010 2
Metal Seal Ring
9 000209710A0200015 轴套 Distance Ring 2
10 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
11 000209710A0200008 710-620-B85-160-R14 滑轮 Pulley 1
12 000209710A0200009 隔套 Distance Ring 1
13 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 141

 滑轮组件 Pulley Assembly（000209903A0000576）

滑轮组件 Pulley Assembly（000209903A0000576）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000209906A0016000 240-190-B41-80-R8 滑轮 Pulley 1
2 1040300322 GB/T893.2-1986 挡圈 Lock Ring 80 2
3 1050200498 GB/T276-1994 深沟球轴承 Bearing 6208-z 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 142

 套环组件 Sleeve Assembly（000209914A9110000）

套环组件 Sleeve Assembly（000209914A9110000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty

1 000209914A9110001 支承轴 Shaft 1

2 000209914A9110002 套 Ring 1
钢丝绳用普通套环
3 1090100344 GB/T5974.1-2006 14 1
Sleeve for Rope
4 000209914A9110003 套 Ring 1
5 000209914A8203003 轴端板 Plate 2
6 1040000114 GB/T5783-2000 螺栓 Bolt M10×25-8.8 2
7 1040300067 GB/T93-1987 垫圈 Lock Washer 10 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 143

23. 起重臂 Jib (000204005ATV00000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 144

 起重臂 Jib (000204005ATV00000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV01000 臂节Ⅰ Jib Ⅰ 1
2 000204005ATV02000 臂节Ⅱ Jib Ⅱ 1
3 000204005ATV03000 臂节Ⅲ Jib Ⅲ 1
4 000204005ATV04000 臂节Ⅳ Jib Ⅳ 1
5 000204005ATV05000 臂节Ⅴ Jib Ⅴ 1
6 000204005ATV06000 臂节Ⅵ Jib Ⅵ 1
7 000204005ATV07000 臂节Ⅶ Jib Ⅶ 1
8 000204005ATV08000 臂节Ⅷ Jib Ⅷ 1
9 000204005ATV09000 臂节Ⅸ Jib Ⅸ 1
10 000204005ATV10000 臂尖节 Jib head 1
11 000204005ATV00500 安装平台 Platform 2
12 000204005ATV00400 安装平台 Platform 2
13 000204005ATV00600 吊栏 Cage 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 145

 臂节Ⅱ Jib Ⅱ (000204005ATV02000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 146

 臂节Ⅱ Jib Ⅱ (000204005ATV02000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
臂节Ⅱ结构
1 000204005ATV02100 1
Jib Section
2 000209913A0035000 LG3500 栏杆 Railing 3
3 000240805AT102172 链条 Chain D6-550 4
4 1999901480 bxk 保险扣 Safety Catch 8mm 6
5 1040100170 GB/T825-1988 螺钉 Screw M16 2
6 000209938A0000040 TX-8-30/40 弹簧销 Spring pin 1
7 000221605AT002001 插销 Pivot φ30 2
8 000209910A8364801 XZ-180-480/660 销轴 Shaft 2
9 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
10 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
11 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
12 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
13 000203003AR000006 XZ01A-25×55/80 销轴 Pin 25×55 4
14 1040500040 GB/T91-2000 销 Cotter Pin 6.3×50 4
起重量限制器支架
15 000221605AT002200 1
Frame for Weight Limit
16 000209716A0010010 滑轮 Pulley 1
17 000209711B0000116 隔套 Distance Ring 1
调心滚子轴承
18 1050200454 GB/T288-1994 23024CC/W33 2
Bearing
19 1040300644 GB/T893.2-1986 挡圈 Lock Ring 180 2
金属密封圈
20 000209716A0010003 2
Metal seal Ring
21 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
22 000221605AT001001 轴端挡板 Shaft holder t12 1
23 1040000051 GB/T5783-2000 螺栓 Bolt M20×45-8.8 2
24 1040300038 GB/T93-1987 垫圈 Lock Washer 20 2
25 000221605AT001002 轴套 Distance Ring 2
26 000209716A0010004 轴套 Distance Ring 2
27 000200116T1000002 XZ01C-50×200/240 销轴 Shaft 50×200 1
28 1040500252 GB/T91-2000 销 Cotter Pin 10×90 1
29 1040500381 GB/T91-2000 销 Cotter Pin 8×71 24
栏杆夹板
30 000209913A5000001 LGJB1 t5 8
Railing Clamp

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 147

 臂节Ⅱ Jib Ⅱ (000204005ATV02000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 148

 臂节Ⅱ Jib Ⅱ (000204005ATV02000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
31 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 4
32 1040200096 GB/T6170-2000 螺母 Nut M12-8 14
33 1040300054 GB/T93-1987 垫圈 Lock Washer 12 14
34 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 14
35 1090100352 GB/T8918-1996 钢丝绳 Rope 6×19-7.7-1550-Ⅱ-right 1
36 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
37 000213001AT001011 托绳轮 Sleeve 1
38 000240801AT061000 半轴 Half Shaft 2
39 1040000082 GB/T5783-2000 螺栓 Bolt M16×40-8.8 4
40 1040200110 GB/T6170-2000 螺母 Nut M16-8 4
41 1040300052 GB/T97.1-2002 垫圈 Washer 16-200HV 4
42 1040300065 GB/T93-1987 垫圈 Lock Ring 16 4
43 000200901AT001310 支架 Frame 2
44 1040000503 GB/T5782-2000 螺栓 Bolt M12×130-8.8 8
45 000201109B0000501 XZ03C-30×310/345 销轴 Shaft 30×310 1
46 1040500224 GB/T91-2000 销 Cotter Pin 6.3×63 2
47 000209711B0000112 托轮轴 Shaft 1
48 000209709C0001800 轴套 Distance Ring 2
深沟球轴承
49 1050200498 GB/T276-1994 6208-z 2
Bearing
50 000209711B0000270 托轮 Sleeve 1
51 000209722A0010012 卡板 Shaft hold t10 1
52 1040000090 GB/T5783-2000 螺栓 Bolt M10×30-8.8 2
53 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 4
54 1040300067 GB/T93-1987 垫圈 Lock Washer 10 4
滑轮组件 Pulley
55 000209903A0000576 05HLZJA 1
Assembly
轴端挡板 Shaft
56 000210105A0010001 t6 1
hold
57 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
58 000209910A0000507 XZF-40-68/100 销轴 Pivot XZF-40-68/100 1
59 000210105A0010002 轴套 Distance Ring 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 149

 臂节Ⅲ Jib Ⅲ (000204005ATV03000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 150

 臂节Ⅲ Jib Ⅲ (000204005ATV03000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV03100 臂节Ⅲ结构 Jib Section 1
2 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
3 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
4 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
5 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
6 1090100352 GB/T8918-1996 钢丝绳 Rope 6×19-7.7-1550-Ⅱ-right 1
7 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
8 000209910A8324801 XZ-160-480/640 销轴 Shaft 2
9 000221605AT002001 插销 Pin φ30 2
10 000209938A0000040 TX-8-30/40 弹簧销 Spring pin 1
11 1040100170 GB/T825-1988 螺钉 Screw M16 2
12 1999901480 bxk 保险扣 Safety Catch 8mm 6
13 000240805AT102172 链条 Chain D6-550 4
14 000209710A0200008 710-620-B85-160-R14 滑轮 Pulley 1
15 000213005AT001003 轴套 Distance Ring 2
16 000213005AT001004 滑轮轴 Shaft 1
17 000209710A0200015 轴套 Distance Ring 2
金属密封圈
18 000209710A0200010 2
Metal Seal Ring
19 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2
20 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
21 000209710A0200009 隔套 Distance Ring 1
22 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
23 000213005AT001007 轴端挡板 Shaft Holder t10 1
24 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
25 1040300067 GB/T93-1987 垫圈 Lock Washer 10 2
26 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
27 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2
28 1040200096 GB/T6170-2000 螺母 Nut M12-8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 151

 臂节Ⅳ Jib Ⅳ (000204005ATV04000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 152

 臂节Ⅳ Jib Ⅳ (000204005ATV04000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV04100 臂节Ⅳ结构 Jib Section 1
2 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
3 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
4 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
5 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
6 000209910A8405251 XZ-200-525/700 销轴 Shaft 1
7 000221605AT002001 插销 Pin φ30 1
8 000209938A0000040 TX-8-30/40 弹簧销 Spring pin 1
9 1040100170 GB/T825-1988 螺钉 Screw M16 1
10 1999901480 bxk 保险扣 Safety Catch 8mm 3
11 000240805AT102172 链条 Chain D6-550 2
6×19-7.7-1550-Ⅱ
12 1090100352 GB/T8918-1996 钢丝绳 Rope 1
-right
13 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
14 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
15 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2
16 1040200096 GB/T6170-2000 螺母 Nut M12-8 3
17 000204005ATV04200 托轴装置 Shaft Support 1
18 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 1
19 000209605A0000016 XZ03A-16×220/240 销轴 Pin 16×220 1
20 1040500228 GB/T91-2000 销 Cotter Pin 4×32 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 153

 臂节Ⅴ Jib Ⅴ (000204005ATV05000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 154

 臂节ⅤJib Ⅴ（000204005ATV05000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV05100 臂节Ⅴ结构 Jib Section 1
6×19-7.7-1550-Ⅱ
2 1090100352 GB/T8918-1996 钢丝绳 Rope 1
-right
3 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
4 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
5 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
6 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
7 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
8 000213005AT001007 轴端挡板 Shaft Holder t10 1
9 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
10 1040300067 GB/T93-1987 垫圈 Lock Washer 10 2
11 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
12 000209710A0200008 710-620-B85-160-R14 滑轮 Pulley 1
13 000213005AT001004 滑轮轴 Shaft 1
14 000209710A0200015 轴套 Distance Ring 2
15 000213005AT001003 轴套 Distance Ring 2
金属密封圈 Metal Seal
16 000209710A0200010 2
Ring
17 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
18 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2
19 000209710A0200009 隔套 Distance Ring 1
20 000209910A8325001 XZ-160×500/675 销轴 Shaft 1
21 000209938A0000040 TX-8-30/40 弹簧销 Spring pin 1
22 000221605AT002001 插销 Pin φ30 1
23 1040100170 GB/T825-1988 螺钉 Screw M16 1
24 1999901480 bxk 保险扣 Safety Catch 8mm 3
25 000221605AT005001 链条 Chain D6-680 2
26 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
27 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2
28 1040200096 GB/T6170-2000 螺母 Nut M12-8 3
29 000204005ATV05200 托轴装置 Shaft support 1
30 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 1
31 000209605A0000016 XZ03A-16×220/240 销轴 Pin 16×220 1
32 1040500228 GB/T91-2000 销 Cotter Pin 4×32 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 155

 臂节Ⅵ Jib Ⅵ (000204005ATV06000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 156

 臂节Ⅵ Jib Ⅵ（000204005ATV06000）

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty

1 000204005ATV06100 臂节Ⅵ结构 Jib Section 1

6×19-7.7-1550-Ⅱ
2 1090100352 GB/T8918-1996 钢丝绳 Rope 1
-right
3 1090100358 GB/T5976-1986 绳夹 Rope clamp 8KTH 6
4 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
5 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
6 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2

7 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2

8 000209910A8264171 XZ-130×420/580 销轴 Shaft 1

9 000221605AT002001 插销 Pin φ30 1

10 000209938A0000040 TX-8-30/40 弹簧销 Spring pin 1

11 1040100170 GB/T825-1988 螺钉 Screw M16 1

12 1999901480 bxk 保险扣 Safety Catch 8mm 3

13 000240805AT102172 链条 Chain D6-550 4

14 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2

15 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2

16 1040200096 GB/T6170-2000 螺母 Nut M12-8 3

17 000204005ATV06200 托轴装置 Shaft support 1

18 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 1

19 000209605A0000016 XZ03A-16×220/240 销轴 Pin 16×220 1

20 1040500228 GB/T91-2000 销 Cotter Pin 4×32 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 157

 臂节Ⅶ Jib Ⅶ (000204005ATV07000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 158

 臂节Ⅶ Jib Ⅶ (000204005ATV07000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV07100 臂节Ⅶ结构 Jib Section 1
6×19-7.7-1550-Ⅱ
2 1090100352 GB/T8918-1996 钢丝绳 Rope 1
-right
3 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
4 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
5 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
6 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
7 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
8 000213005AT001007 轴端挡板 Shaft Holder t10 1
9 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
10 1040300067 GB/T93-1987 垫圈 Lock Washer 10 2
11 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
710-620-B85-160
12 000209710A0200008 滑轮 Pulley 1
-R14
13 000213005AT001004 滑轮轴 Shaft 1
14 000209710A0200015 轴套 Distance Ring 2
15 000213005AT001003 轴套 Distance Ring 2
金属密封圈 Metal Seal
16 000209710A0200010 2
Ring
17 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
18 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2
19 000209710A0200009 隔套 Distance Ring 1
20 000209910A8183621 XZ-90×365/485 销轴 Shaft 1
21 000221605AT007001 插销 Pin 1
22 000250318AR001002 弹簧销 Spring pin 1
23 1040100170 GB/T825-1988 螺钉 Screw M16 1
24 1999901480 bxk 保险扣 Safety Catch 8mm 3
25 000221605AT007002 链条 Chain D6-480 2
26 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
27 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2
28 1040200096 GB/T6170-2000 螺母 Nut M12-8 3
29 000204005ATV07200 托轴装置 Shaft support 1
30 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 1
XZ03A-16×220/2
31 000209605A0000016 销轴 Pin 16×220 1
40
32 1040500228 GB/T91-2000 销 Cotter Pin 4×32 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 159

 臂节Ⅷ Jib Ⅷ (000204005ATV08000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 160

 臂节Ⅷ Jib Ⅷ (000204005ATV08000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221605AT008100 臂节Ⅷ结构 Jib Section 1
6×19-7.7-1550-Ⅱ
2 1090100352 GB/T8918-1996 钢丝绳 Rope 1
-right
3 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
4 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
5 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
6 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
7 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
8 000209910A5102051 XZ04E-50×205/260 销轴 Shaft 1
9 1040500252 GB/T91-2000 销 Cotter Pin 10×90 2
10 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
11 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2
12 1040200096 GB/T6170-2000 螺母 Nut M12-8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 161

 臂节Ⅸ Jib Ⅸ (000204005ATV09000)

臂节Ⅸ Jib Ⅸ (000204005ATV09000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV09100 臂节Ⅸ结构 Jib Section 1
2 1040002359 GB/T5782-2000 螺栓 Bolt M30×130-8.8 2
3 1040201226 GB/T6170-2000 螺母 Nut M30-8 2
4 1040300010 GB/T93-1987 垫圈 Lock Washer 30 2
5 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 2
6×19-7.7-1550-Ⅱ
6 1090100352 GB/T8918-1996 钢丝绳 Rope 1
-right
7 1090100358 GB/T5976-1986 绳夹 Rope Clamp 8KTH 6
8 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 2
9 1040300054 GB/T93-1987 垫圈 Lock Washer 12 2
10 1040200096 GB/T6170-2000 螺母 Nut M12-8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 162

 臂尖节 Jib head (000204005ATV10000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 163

 臂尖节 Jib head (000204005ATV10000)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000204005ATV10100 臂尖节结构 Structure 1
2 1040001458 GB/T5782-2000 螺栓 Bolt M30×360-8.8 2
3 1040201226 GB/T6170-2000 螺母 Not M30-8 4
4 1040300010 GB/T93-1987 垫圈 Spring Washer 30 4
5 1040300074 GB/T97.1-2002 垫圈 Washer 30-200HV 4
6 000221605AT010003 挡杆 Girder 1
防扭装置 Anti-twist
7 000201705A0006300 1
device
8 1040500179 GB/T91-2000 销 Split Pin 10×120 1
9 000201705A0006303 XZ01D-65×195/245 销轴 Shaft 65×195 1
10 000213005AT001004 滑轮轴 Shaft 1
11 000209710A0200015 轴套 Distance Ring 2
12 000213005AT001003 轴套 Wahser 2
金属密封圈 Metal Seal
13 000209710A0200010 2
Ring
14 1040300681 GB/T893.2-1986 挡圈 Lock Ring 160 2
15 1050200819 GB/T288-1994 调心滚子轴承 Bearing 22218c w33 2
16 000209710A0200009 隔套 Distance Ring 1
17 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
18 000213005AT001007 轴端挡板 Shaft Holder t10 1
19 1040000116 GB/T5783-2000 螺栓 Bolt M10×20-8.8 2
20 1040300067 GB/T93-1987 垫圈 Locking Washer 10 2
21 000209710A0200008 710-620-B85-160-R14 滑轮 Pulley 1
22 000200111T0000002 XZ03A-25×200/230 销轴 Pivot 25×200 2
23 1040500216 GB/T91-2000 销 Cotter Pin 6.3×50 4
M30×388-10.
24 1040002429 GB/T5782-2000 螺栓 Bolt 2
9
25 000209910A0000515 XZ03A-12×80/95 销轴 Pin 12×80 1
26 000209938A0000010 TX-4-12/20 弹簧销 Spring pin 2
27 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 1
28 1040300054 GB/T93-1987 垫圈 Lock Washer 12 1
29 1040200096 GB/T6170-2000 螺母 Nut M12-8 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 164

 防扭装置 Anti-twist device (000201705A0006300)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000201705A0006320 连接头 A Connector A 1
2 0010031579 GB/T5782-2000 螺栓 Bolt M36×260-8.8 1
3 0010031395 GB/T301-1995 单向推力球轴承 Bearing 51410 1
4 000201705A0006301 轴套 Washer 1
5 0021105B0914 压块 Clamp 1
6 104030002108 GB/T97.1-2002 垫圈 Washer 36-200HV 1
7 104020004013 GB/T6170-2000 螺母 Nut M36-8 2
8 108000001003 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
9 000201705A0006330 连接头 B Connector B 1
10 0010031570 楔形接头 Connector JW32-250 1
11 000201705A0006303 销轴 Shaft 1
12 104050000058 GB/T91-2000 开口销 Cotter Pin 10×120 1
13 104000011068 GB/T5783-2000 螺栓 Bolt M20×90-8.8 1
14 104020004010 GB/T6170-2000 螺母 Nut M20-8 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 165

 安装平台 Platform(000221605AT000400)

安装平台 Platform(000221605AT000400)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221605AT000410 平台结构 Platform 1

2 000221605AT000420 LG2700 栏杆 Railing 1

3 000221605AT000430 LG460 栏杆 Railing 1

4 000209913A5000001 LGJB1 栏杆夹板 Railing Clamp t5 2

5 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 1

6 1040200096 GB/T6170-2000 螺母 Nut M12-8 3

7 1040300054 GB/T93-1987 垫圈 Lock Washer 12 3

8 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 3

9 1040500381 GB/T91-2000 销 Cotter Pin 8×71 5

10 1040000149 GB/T5783-2000 螺栓 Bolt M12×50-8.8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 166

 安装平台 Platform(000221605AT000500)

安装平台 Platform(000221605AT000500)

序号 编码 代号 名称 规格长度 数量
No. Order NO. Code Designation Dimension Qty
1 000221605AT000510 平台结构 Platform 1
2 000221605AT000420 LG2700 栏杆 Railing 1
3 000209913A0004600 LG460 栏杆 Railing 1
4 000221605AT000430 LG460 栏杆 Railing 1
5 000209913A5000001 LGJB1 栏杆夹板 Railing Clamp t5 4
6 1040000216 GB/T5783-2000 螺栓 Bolt M12×70-8.8 2
7 1040200096 GB/T6170-2000 螺母 Nut M12-8 4
8 1040300054 GB/T93-1987 垫圈 Lock Washer 12 4
9 1040300041 GB/T97.1-2002 垫圈 Washer 12-200HV 4
10 1040500381 GB/T91-2000 销 Cotter Pin 8×71 5
11 1040000149 GB/T5783-2000 螺栓 Bolt M12×50-8.8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 167

24. DG120A 吊钩组 Load Hook（000209614A0100000）

序号 4、8、11 和 12 系组件，爆炸图见滑轮组件、上滑轮组件、下滑轮组件和钩体组件

The NO. 4, NO. 8, NO. 11 and NO. 12 are assembling, they are explored in the pictures

of Pulley Assembling, Up-Pulley Assembling, Down-Pulley Assembling and Hook Assembling.

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 168

 DG120A 吊钩组（000209614A0100000）

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
1 000209910A4051421 XZ03A-25×145/175 销轴 Pivot 25×145 4
2 1040500309 GB/T91-2000 销 Cotter Pin 6.3×45 8
3 000209910A1244001 XZ01D-120×400/470 销轴ⅠPivotⅠ 120×400 1
下滑轮组
4 000209614A0103000 1
Down-Pulley Assembling
5 000209910A1264001 XZ01D-130×400/475 销轴ⅡPivotⅡ 130×400 2
6 000209614A0104000 横梁 Beam 1
7 000209910A1265401 XZ01D-130×540/615 销轴 Pivot 130×605 1
8 000209614A0106000 钩体组件 Hook Assembling 1
9 000209711B0000136 XZ01C-35×75/105 销轴 E Pivot E 35×75 4
10 1040500267 GB/T91-2000 销 Cotter Pin 8×45 4
副滑轮组
11 000209614A0101000 1
Sub-Pulley Assembling
上滑轮组
12 000209614A0102000 1
Up-Pulley Assembling

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 169

 DG120A 滑轮组 Pulley Assembling（（000209614A0101000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 170

 DG120A 滑轮组 Pulley Assembling（000209615A0201000）

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
1 1040003904 GB/T5782-2000 螺栓 Bolt M24×360-8.8 4
2 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 2
3 000209615A0201002 定位套 Locating Bush 2
4 000209615A0201003 轴套 1Sleeve Pipe 1 1
5 000209614A0101002 套筒 Sleeve 4
6 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 4
7 1040300049 GB/T93-1987 垫圈 Spring Washer 24 4
8 1040201048 GB/T923-1988 螺母 Nut M24 4
9 000209614A0101001 滑轮轴 Pulley Shaft 1
轴端挡板
10 000209716A0010006 t12 2
Shaft-end Damper
11 1040300038 GB/T93-1987 垫圈 Washer 20 4
12 1040000051 GB/T5783-2000 螺栓 Bolt M20×45-8.8 4
金属密封圈
13 000209716A0010003 4
Metal Seal Ring
14 000209716A0010004 轴套 Sleeve Pipe 4
15 1040300644 GB/T893.2-1986 挡圈 Washer 180 4
16 1050200454 GB/T288-1994 轴承 Bearing 23024CC/W33 4
17 000209906A0039000 950-860-B120-180-R17 滑轮 Pulley 2
18 000209711B0000116 隔套 Sleeve 2
副滑轮架
19 000209614A0101100 1
Sub-Pulley Frame

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 171

 DG120A 上滑轮组 Up-Pulley Assembling（000209614A0102000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 172

 DG120A 上滑轮组 Up-Pulley Assembling（000209614A0102000）

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
1 1040000556 GB/T5783-2000 螺栓 Bolt M20×55-8.8 4
2 1040300038 GB/T93-1987 垫圈 Spring Washer 20 4
轴端挡板
3 000209716A0010006 t12 2
Shaft-end Damper
上滑轮架
4 000209614A0102100 1
Up-Pulley Frame
5 000209614A0102003 套筒 Sleeve 4
6 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 4
7 1040300049 GB/T93-1987 垫圈 Spring Washer 24 4
8 1040201048 GB/T923-1988 螺母 Nut M24 4
9 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
10 000209614A0102002 定位套 Locating Sleeve 2
11 000209614A0102001 滑轮轴 Pulley Shaft 1
金属密封圈
12 000209716A0010003 2
Metal Seal Ring
13 000209716A0010004 轴套 Shaft Sleeve 2
14 1040300644 GB/T893.2-1986 挡圈 Washer 180 2
23024CC/W3
15 1050200454 GB/T288-1994 轴承 Bearing 2
3
16 000209906A0040002 635-545-B120-180-R17 滑轮 Pulley 1
17 000209711B0000116 隔套 Sleeve 1
18 1040000210 GB/T5782-2000 螺栓 Bolt M24×300-8.8 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 173

 DG120A 下滑轮组 Down-Pulley Assembling（000209614A0103000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 174

 DG120A 下滑轮组 Down-Pulley Assembling（000209614A0103000）

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
1 1040000556 GB/T5783-2000 螺栓 Bolt M20×55-8.8 4
2 1040300038 GB/T93-1987 垫圈 Washer 20 4
轴端挡板
3 000209716A0010006 t12 2
Shaft-end Damper
下滑轮架
4 000209614A0103100 1
Down-Pulley Assembling
5 000209614A0103002 套筒 Sleeve 2
6 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 2
7 1040300049 GB/T93-1987 垫圈 Spring Washer 24 2
8 1040201048 GB/T923-1988 螺母 Nut M24 2
9 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
10 000209615A0203002 定位套 Locating Sleeve 2
11 000209614A0103001 滑轮轴 Pulley Shaft 1
金属密封圈
12 000209716A0010003 2
Metal Seal Ring
13 000209716A0010004 轴套 Shaft Sleeve 2
14 1040300644 GB/T893.2-1986 挡圈 Washer 180 2
15 1050200454 GB/T288-1994 轴承 Bearing 23024CC/W33 2
16 000209906A0039000 950-860-B120-180-R17 滑轮 Pulley 1
17 000209711B0000116 隔套 Sleeve 1
18 1040003904 GB/T5782-2000 螺栓 Bolt M24×360-8.8 2

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 175

 钩体组件 Hook Assembling (000209614A0106000)

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 176

 钩体组件 Hook Assembling (000209614A0106000)

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
钩体夹板
1 000209614A0106100 1
Hook Splint
轴端挡板
2 000209716A0010006 t12 4
Shaft-end Damper
3 1040300106 GB/T97.1-2002 垫圈 Washer 20-200HV 8
4 1040300038 GB/T93-1987 垫圈 Spring Washer 20 8
5 1040000051 GB/T5783-2000 螺栓 Bolt M20×45-8.8 8
6 1040000134 GB/T5783-2000 螺栓 Bolt M16×25-8.8 2
7 1040300065 GB/T93-1987 垫圈 Spring Washer 16 2
8 1040301782 GB/T97.1-2002 垫圈 Washer 16-200HV 2
锁止板
9 000209614A0004007 t14 1
Locating Plate
10 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 1
11 000209614A0106001 螺扣 Nut 1
12 000209614A0106003 防尘环 Ring 1
推力圆锥滚子轴承
13 1050200436 GB/T4663-1994 99434 1
Bearing
14 000209614A0004006 销轴 Pivot 2
15 000209614A0004005 弹簧 Spring 2
防脱钩卡
16 000209614A0004003 2
Safety Stirrup
17 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 2
18 1040500253 GB/T91-2000 销 Cotter Pin 5×32 2
19 000209614A0106002 钩体 Hook 1

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

177
25. XC120C 载重小车 Trolley（000209714A0200000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

178
 XC120C 载重小车 Trolley（000209714A0200000）
序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
主小车
1 000209714A0201000 XC120C.01 1
Main Trolley
连接梁
2 000209715A0203000 2
Connect Beam
副小车
3 000209714A0202000 XC120C.02 Subordinative 1
Trolley

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

179
 XC120C.01 主小车 Main Trolley（000209714A0201000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

180
 XC120C.01 主小车 Main Trolley（000209714A0201000）

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
主小车架
1 000209714A0201100 1
Main Trolley Frame
2 1090100439 GB/T5973-2006 楔 Wedge 22 2
钢丝绳夹 Rope
3 1090100237 GB/T5976-1986 22KTH 2
Cramp
4 1040300038 GB/T93-1987 垫圈 Washer 20 2
5 1040001680 GB/T5783-2000 螺栓 Bolt M10×30-8.8 2
轴端挡板
6 000209716A0010024 t6 1
Shaft-end Damper
7 000213005AT011306 销轴 Pivot 2
8 1040500173 GB/T91-2000 销 Cotter Pin 6.3×80 2
9 000213005AT011309 板 Plate t5 2
10 1040001443 GB/T28-1988 螺栓 Bolt M24×130-8.8 2
11 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 2
12 1040200326 GB/T6178-1986 螺母 Nut M24-8 2
13 1040500233 GB/T91-2000 销 Cotter Pin 5×40 2
14 000209714A0201200 安全闸 Safety Bar 2
15 1040500555 GB/T91-2000 销 Cotter Pin 4×50 2
楔套
16 1090100296 GB/T5973-2006 22 2
Wedge Structure
轴端挡板
17 000209716A0010006 t12 1
Shaft-end Damper
18 1040000051 GB/T5783-2000 螺栓 Bolt M20×45-8.8 2
19 000209910A1041201 XZ01A-20×120/140 销轴 Pivot 20×120 1
20 1040500228 GB/T91-2000 销 Cotter Pin 4×32 1
21 000209715A0201500 销轴 Pivot 1
起重用短环链
22 000209716A0010025 JB/T8108.2-1999 φ4-400 3
Short-Chains
23 000201105B0000175 XZ01C-40×155/190 销轴 Pivot 40×155 2
24 000201105B0000177 弹簧销 Spring Pivot 2
25 000201105B0000176 锁销 Lock Pin 2
26 000209715A0201300 爬梯 Ladder 2
27 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 8
28 1040200110 GB/T6170-2000 螺母 Nut M16-8 8
29 1040300065 GB/T93-1987 垫圈 Washer 16 8
30 000209715A0201600 挂梁 B Beam B 2
31 000209715A0201007 挡绳轴 Shaft φ42.3×3.25 1
32 1040500381 GB/T91-2000 销 Cotter Pin 8×71 6

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

181
序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
33 000209716A0010021 销轴 Pivot 4
34 000200305A0000152 TC5613A.05-13 缓冲块 Buffer 4
35 1040000167 GB/T5783-2000 螺栓 Bolt M10×55-8.8 8
36 1040200813 GB/T6170-2000 螺母 Nut M10-8 8
37 1040300067 GB/T93-1987 垫圈 Washer 10 10
38 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 16
39 000209711B0000119 滚轮 Roller 8
金属密封圈
40 000209715A0201004 6
Metal Seal Ring
41 000209715A0201012 GB/T893.2-1986 挡圈 Check Ring 6
42 000209715A0201011 隔套 Sleeve 3
43 000209715A0201005 滑轮 Pulley 3
44 000209715A0201006 轴套 Shaft Sleeve 6
45 000209716A0010023 销轴 Pivot 1
46 000209716A0010016 轴套 Shaft Sleeve 2
47 000209716A0010022 托轮 Support Roller 1
深沟球轴承
48 1050200498 GB/T276-1994 6208-z 2
Bearing
调心滚子轴承
49 1050200456 GB/T288-1994 23032 6
Bearing
50 000209715A0201003 轴套 Shaft Sleeve 2
51 000209715A0201002 轴套 Shaft Sleeve 2
52 000209715A0201001 滑轮轴 Pulley Shaft 1
53 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 16
54 000209715A0201010 滚轮轴 Roller Shaft 8
深沟球轴承
55 1050200509 GB/T276-1994 6314-Z 16
Bearing
56 1040300418 GB/T858-1988 垫圈 Washer 64 8
57 1040200466 GB/T812-1988 螺母 Nut M64×2 8
58 000209715A0201200 挂梁 A Beam A 2
59 000209715A0201009 销轴 Pivot 4
60 1040300269 GB/T858-1988 垫圈 Washer 72 4
61 1040200331 GB/T812-1988 螺母 Nut M72×2 4
62 000209716A0010019 侧滚轮 Side Roller 4
深沟球轴承
63 1050200755 GB/T276-1994 6007-Z 8
Bearing
孔用弹性挡圈
64 1040301226 GB/T893.2-1986 62 8
Check Ring
65 000209716A0010020 轴套 Shaft Sleeve 8
66 1040300680 GB/T893.2-1986 挡圈 Check Ring 150 16
67 000209716A0010013 轴套 Shaft Sleeve 8
零件图册 Spare Parts Manual T2850-120V-138ZY-A01
182
 XC120C.02 副小车 Subordinative Trolley（000209714A0202000）

零件图册 Spare Parts Manual T2850-120V-138ZY-A01

183
 XC120C.02 副小车 Subordinative Trolley（000209714A0202000）

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
副小车架
1 000209715A0202100 1
Subordinative Trolley Frame
2 000209715A0201200 挂梁 A Beam A 1

3 000201105B0000175 XZ01C-40×155/190 销轴 Pivot 40×155 2

4 000201105B0000176 锁销 Lock Cotter 2

5 000201105B0000177 弹簧销 Spring Pivot 2

6 000209716A0010025 JB/T8108.2-1999 起重用短环链 Short-Chains φ4-400 5

7 000201116A0000002 XZ01A-20×140/160 销轴 Pivot 20×140 2

8 000209715A0201600 挂梁 B Beam B 1

9 000209715A0201300 爬梯 Ladder 2

10 1040000198 GB/T5783-2000 螺栓 Bolt M16×50-8.8 8

11 1040200110 GB/T6170-2000 螺母 Nut M16-8 8

12 1040300065 GB/T93-1987 垫圈 Washer 16 8

13 1040500228 GB/T91-2000 销 Cotter Pin 4×32 3

14 000209910A1041201 XZ01A-20×120/140 销轴 Pivot 20×120 1

15 000209715A0201500 销轴 Pivot 1

16 1040000051 GB/T5783-2000 螺栓 Bolt M20×45-8.8 2

17 1040300038 GB/T93-1987 垫圈 Washer 20 2

18 000209716A0010006 轴端挡板 Shaft-end Damper t12 1

19 000209715A0202300 挂梁 D Beam D 1

20 1040300050 GB/T97.1-2002 垫圈 Washer 24-200HV 1

21 1040200326 GB/T6178-1986 螺母 Nut M24-8 1

22 1040500233 GB/T91-2000 销 Cotter Pin 5×40 1

23 000209714A0201200 安全闸 Safety Bar 1

24 1040001443 GB/T28-1988 螺栓 Bolt M24×130-8.8 1

25 000209716A0010016 轴套 Shaft Sleeve 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 184

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
26 1050200498 GB/T276-1994 深沟球轴承 Bearing 6208-z 4

27 000209716A0010022 托轮 Support Roller 2

28 000209716A0010023 销轴 Pivot 2

29 000209716A0010024 轴端挡板 Shaft-end Damper t6 2

30 1040300067 GB/T93-1987 垫圈 Washer 10 8

31 1040001680 GB/T5783-2000 螺栓 Bolt M10×30-8.8 4

32 000209715A0201007 挡绳轴 Shaft φ42.3×3.25 1

33 1040500381 GB/T91-2000 销 Cotter Pin 8×71 6

34 1080000007 JB/T7940.1-1995 油杯 Oil Cup M10×1 16

35 000209715A0201002 轴套 Shaft Sleeve 2

36 000209715A0201004 金属密封圈 Metal Seal Ring 6

37 1050200456 GB/T288-1994 调心滚子轴承 23032 6

38 000209715A0201006 轴套 Shaft Sleeve 6

39 000209715A0201001 滑轮轴 Pulley Shaft 1

40 000209715A0201003 轴套 Shaft Sleeve 2

41 000209715A0201012 GB/T893.2-1986 挡圈 Check Ring 6

42 000209715A0201011 隔套 Sleeve 3

43 000209715A0201005 滑轮 Pulley 3

44 1040000167 GB/T5783-2000 螺栓 Bolt M10×55-8.8 4

45 1040200813 GB/T6170-2000 螺母 Nut M10-8 4

46 1040300061 GB/T97.1-2002 垫圈 Washer 10-200HV 12

47 000200305A0000152 TC5613A.05-13 缓冲块 Buffer 2

48 1040200466 GB/T812-1988 螺母 Nut M64×2 8

49 1040300418 GB/T858-1988 垫圈 Washer 64 8

50 000209715A0202200 挂梁 C Beam C 1

51 000209711B0000119 滚轮 Roller 8

52 000209716A0010013 轴套 Shaft Sleeve 8

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 185

序号 编码 代号 名称 规格 数量
NO. Order NO. Code Designation Dimension Qty
53 1050200509 GB/T276-1994 深沟球轴承 Bearing 6314-Z 16

54 1040300680 GB/T893.2-1986 挡圈 Check Ring 150 16

55 000209715A0201010 滚轮轴 Roller Shaft 8

56 1040200331 GB/T812-1988 螺母 Nut M72×2 4

57 1040300269 GB/T858-1988 垫圈 Washer 72 4

58 000209716A0010021 销轴 Pivot 4

59 000209716A0010020 轴套 Shaft Sleeve 8

60 000209716A0010019 侧滚轮 Side Roller 4

61 1040301226 GB/T893.2-1986 孔用弹性挡圈 Check Ring 62 8

62 1050200755 GB/T276-1994 深沟球轴承 Bearing 6007-Z 8

63 000209715A0201009 销轴 Pivot 4

零件图册 Spare Parts Manual T2850-120V-138ZY-A01 186