[En]

WA7025-12E Tower Crane

Instruction Manual

WA7025-12E-138EN-B03
 WA7025-12E-138EN-B03

Manufacturer:
Zoomlion Heavy Industry Science & Technology Co., LTD
361 Yinpen(s) Road
Changsha, Hunan 410013
P.R. China

Contact us:
Home page: en.zoomlion.com
Email: [email protected]

熊洁文 2023-03-22
 WA7025-12E-138EN-B03 INTRODUCTION

INTRODUCTION
This document has been issued for the crane as defined at the time of ordering. Please read
carefully the instructions therein before any crane operation.

Make sure that one complete copy of this document is always present at the location provided
for on the crane, especially in case of crane rental or resale.

The safety signals, rating plates and instruction plates as well as this document are integrated
part of the crane. In case of loss or damage of this instruction material you have order a new one
from the manufacturer indicating the serial number and the crane type.

IMPORTANT: In case of a technical crane modification, please make sure that this instruction
material will be updated.

The present document is only usable in complete original version or in complete reproduction.
ZOOMLION denies all responsibility concerning the consequences of using a partial reproduction
or an adaptation of the present document.

This document consists of 7 parts. The “safety instructions” part must compulsorily be read and
under-stood by every operator. The other parts give specific instructions to the concerned
operators for doing their tasks.

Part name Part intended for:

1 DOCUMENTS The crane operator

2 SAFETY INSTRUCTION Everybody

3 TECHNICAL DATA OF CRANE AND SITE Everybody

4 ERECTION/ADJUSTMENT/DISMANTLING The fitter

5 OPERATION AND CONTROL The crane driver

6 MAINTENANCE AND INSPECTION The maintenance technician

7 SPARE PARTS Everybody

1
INTRODUCTION WA7025-12E-138EN-B03

Development of the technical instructions

ZOOMLION reserves the right, without prior notice, to improve the content and the form of this
document. For each technical modification ordered or carried out after delivery, an updating
will be supplied. On receipt of these new chapters, please insert them at the indicated space.

Warnings

The safety rules and the important observations which you must compulsorily observe are
marked in the various parts of this documents by the following symbols:

Signaling of an important risk of body injuries and even mortal danger, if

the described instructions are not observed.

Indicates the risk of equipment damage if the described instructions are

not observed.

Important information

Note

2
WA7025-12E-138EN-B03 TOWER CRANE VOCABULARYS

TOWER CRANE VOCABULARIES

(1) Outrigger (2) Base tower section

(3) Tower section (4) Passageway J
(5) Passageway H (6) Climbing equipment
(7) Climbing mechanism (8) Climbing hydraulic cylinder
(9) Pump station (10) Hose assembly
(11) Erection platform (12) Mounting device
(13) Transition section (14) Slewing support
(15) Slewing ring (16) Turntable
(17) Slewing mechanism (18) Slewing limiter
(19) Counter jib (20) Counter ballast
(21) Derrick (22) Hoisting mechanism
(23) Cabin (24) Trolley mechanism
(25) Jib (26) Trolley
(27) Hook (28) Stationary chassis
(29) Tower section (30) Powered wheel bogie
(31) Idler wheel bogie (32) Travelling chassis
(33) Cbale drum (34) Central ballast

3
GRAPHIC SYMBOLS WA7025-12E-138EN-B03

GRAPHIC SYMBOLS
SYMBOLS SUBJECT

FORBIDDEN

STOPPING THE MOVEMENT

COMPULSORY SAFETY HARNESS

AUTHORIZED

PARALLEL

LEVEL

LISTEN

WEATHERVANE

4
 WA7025-12E-138EN-B03 GRAPHIC SYMBOLS

SYMBOLS SUBJECT

SLEWING

SLEWING LEFT

SLEWING RIGHT

HOISTING

HOISTING UP

FALLING DOWN

TROLLEYING

TROLLEY OUT

TROLLEY IN

5
GRAPHIC SYMBOLS WA7025-12E-138EN-B03

SYMBOLS SUBJECT

TRAVELLING FORWARD

TRAVELLING BACKWARD

CREEP SPEED

LOW SPEED

HIGH SPEED

SM (2-fall rope reeving, used in 2-fall)

DM (4-fall rope reeving, used in 4-fall)

TIGHTEN-LOCK-PRESS

LOOSEN-UNLOCK

6
WA7025-12E-138EN-B03 METRIC SYSTEM AND IMPERIAL SYSTEM

METRIC SYSTEM AND IMPERIAL SYSTEM

1. CORRESPONDENCES
1.1 GEOMETRIC UNITS
Metric system Imperial system
Values
Unit Symbol Unit Symbol
Lengths − distances
inch in 1 m = 39.3700787 in
foot ft 1 m = 3.2808399 ft
meter m
yard yd 1 m = 1.0936133 yd
mile mi 1 m = 0.0006214 mi
Area or surface
square inch in2 1 m2 = 1 550.0031 in2
square meter m2 square foot ft2 1 m2 = 10.7639104 ft2
square yard yd2 1 m2 = 1.195990 yd2
Volume
square inch cu in / in3 1 m3 = 61 023.7438368 in3
square meter m3 square foot cu ft / ft3 1 m3 = 35.3146666 ft3
square yard cu yd / yd3 1 m3 = 1.3079506 yd3
Flat angle
radian 1 r = 2 π rad
revolution r
degree 1 r = 360 °
radian 1 ° = 0.0174533 rad
degree ° minute 1 ° = 60’
second 1 ° = 3600”

7
METRIC SYSTEM AND IMPERIAL SYSTEM WA7025-12E-138EN-B03

1.2 MECHANICAL UNITS

Metric system Imperial system
Values
Unit Symbol Unit Symbol
Flow rate
mile per hour mph 1 m/s = 2.2369 mph
meter per second m/s foot per second ft/s 1 m/s = 3.28084 ft/s
inch per second in/s 1 m/s = 39.3701 in/s
Radian frequency
radian per second rad/s radian per second rad/s 1 rad/s = 1 rad/s
revolution per
r.p.m. revolution per minute rpm 1 tr/min = 1 rpm
minute
Acceleration
meter per square foot per square
m/s2 ft/s2 1 m/s2 = 3.2808399 ft/s2
second second

Force
kilogram force kgf 1 daN = 1.0197162 kgf
Newton N
pound force lbf 1 daN = 2.248 lbf
Moment of force
Newton meter N·m force pound foot lb−ft 1 N·m = 0.7375621 lb−ft
Energy. work. quantity of heat
Joule J Watt−second Ws 1 J = 1 Ws
Power
Joule per second J/s 1 W = 1 J/s
kg−force meter per kgf. 1 W = 6.1182973
Watt W
minute m/min kgf.m/min
horsepower (metric) hp 1 W = 0.00135962 hp
Pressure. stress
pound per square
psi 1 Pa = 0.000145038 psi
inch
bar bar 1 Pa = 0.00001 bar
Pascal Pa kg−force per square
kgf/m2 1 Pa = 0.1019716 kgf/m2
meter
Newton per square
N/cm2 1 Pa = 0.0001 N/cm2
centimeter

8
WA7025-12E-138EN-B03 METRIC SYSTEM AND IMPERIAL SYSTEM

1.3 MASS UNITS

Metric system Imperial system
Values
Unit Symbol Unit Symbol
Mass
pound lb 1 kg = 2.2046226 lb
kilogram kg
ton (short) ton 1 kg = 0.0011023 ton
Mass per unit length
pound per inch lb/in 1 kg/m = 0.055997 lb/in
kilogram per meter kg/m pound per foot lb/ft 1 kg/m = 0.6719689 lb/ft
pound per yard lb/yd 1 kg/m = 2.015905 lb/yd
Surface mass
pound per square 1 kg/m2 = 0.2048161
lb/ft2
foot lb/ft2
kilogram per pound per square 1 kg/m2 = 0.0014223
kg/m3 lb/in2
square meter inch lb/in2
pound per square 1 kg/m2 = 1.8433451
lb/in2
yard lb/yd2
Density
pound lb 1 kg = 2.2046226 lb
kilogram kg
ton (short) ton 1 kg = 0.0011023 ton
Mass per unit length
kilogram per meter kg/m pound per inch lb/in 1 kg/m = 0.055997 lb/in

9
METRIC SYSTEM AND IMPERIAL SYSTEM WA7025-12E-138EN-B03

1.4 UNITS OF TIME

Metric system Imperial system
Values
Unit Symbol Unit Symbol
Time (duration)
second s second s
minute min minute min 1 min = 60 s
hour h hour h 1 h = 60 min = 3600 s
day d day d 1 d = 24 h = 1440 min
Frequency
Hertz Hz Hertz Hz 1 Hz = 1 s−1

1.5 ELECTRIC UNITS

Metric system Imperial system
Values
Unit Symbol Unit Symbol
Strength
Ampere A Ampere A
Voltage
Volt V Volt V
Power
Volt−Ampere VA Volt−Ampere VA
kiloVolt−Ampere kVA kiloVolt−Ampere kVA
Watt W Watt W
Electric resistance
Ohm Ω Ohm Ω
Quantity of electricity. load
Coulomb C
Coulomb C
Ampere·hour Ah 1 Ah = 3600 C
Capacity
Farad F Farad F

10
WA7025-12E-138EN-B03 METRIC SYSTEM AND IMPERIAL SYSTEM

1.6 THERMAL UNITS

Metric system Imperial system
Values
Unit Symbol Unit Symbol
Temperature
Kelvin K °K = (°F + 459.7)/1.8
kelvin K Celsius C °C = 5/9 * (°F − 32)
Fahrenheit F °F = (9/5 * °C) + 32

1.7 ACOUSTIC UNITS

Metric system Imperial system
Values
Unit Symbol Unit Symbol
Sound pressure and acoustic power
decibel dB(A) decibel dB(A) 1dB=0.1B

2. EQUALITY BETWEEN FREQUENTLY USED UNITS

2.1 LENGTHS−DISTANCES
Metric system Imperial system
1 centimeter (cm) = 10 millimeters (mm) = 0.3937008 inch (in)
1 decimeter (dm) = 10 centimeters (cm) = 3.937008 inches (in)
1 meter (m) = 10 dm = 100 cm = 1.0936133 yards (yd)
1 kilometer (km) = 1 000 meters (m) = 0.6213712 mile (mi)
Imperial system Metric system
1 inch (in) = 2.54 cm
1 foot (ft) = 12 inches (in) = 30.48 cm
1 yard (yd) = 3 feet (ft) = 36 inches (in) = 0.9144 m
1 mile (mi) = 1 760 yards (yd) = 1.609344 km

11
CONTENTS WA7025-12E-138EN-B03

CONTENTS

INTRODUCTION ................................................................................................................... 1
TOWER CRANE VOCABULARIES ...................................................................................... 3
GRAPHIC SYMBOLS ............................................................................................................ 4
METRIC SYSTEM AND IMPERIAL SYSTEM ....................................................................... 7
CONTENTS ......................................................................................................................... 12
1 DOCUMENTS.......................................................................................................................... 20
1.1 Sound pressure ............................................................................................................. 20
1.2 Commissioning report ................................................................................................... 21
2 SAFETY INSTRUCTION ......................................................................................................... 22
2.1 Foreword ....................................................................................................................... 22
2.2 Intended use, misuse .................................................................................................... 23
Intended use ....................................................................................................... 23
Foreseeable misuse ............................................................................................ 24
2.3 General conditions of use.............................................................................................. 25
Climatic and geographical conditions ................................................................. 25
Conditions relative to crane design ..................................................................... 29
Crane installation conditions ............................................................................... 31
Handling conditions ............................................................................................. 32
2.4 General safety instructions ............................................................................................ 33
Requirements for personnel/qualification and duties .......................................... 33
Duties and responsibilities .................................................................................. 33
Workplaces.......................................................................................................... 40
Instructions relative to operating conditions ........................................................ 42
Instructions relative to specific danger ................................................................ 43
Safety instructions relative to the preparation of each operating phase ............. 44
2.5 Residual hazards, basic safety instructions .................................................................. 45
Dangers on the crane.......................................................................................... 46
Disposal and environmental protection ............................................................... 53
Dangers during transport .................................................................................... 53
Dangers during assembly ................................................................................... 54
2.6 Safety signaling ............................................................................................................. 60
Explanation ......................................................................................................... 60
Terminology ......................................................................................................... 60
Signaling panels .................................................................................................. 61
Audio and luminous signals ................................................................................ 65
Safety controls .................................................................................................... 66
2.7 Storm wind speed-out of service ................................................................................... 66

12
 WA7025-12E-138EN-B03 CONTENTS

General Notes ..................................................................................................... 66

Speed table ......................................................................................................... 66
3 TECHNICAL DATA OF CRANE AND SITE ............................................................................. 67
3.1 Foreword ....................................................................................................................... 67
3.2 Technical characteristics ............................................................................................... 68
Load curves ........................................................................................................ 68
Characteristics of the crane ................................................................................ 73
3.3 Mast composition .......................................................................................................... 77
General notes ..................................................................................................... 77
Mast composition ................................................................................................ 78
3.4 Dimensions and weights of parts for transportation ..................................................... 80
Matters need attentions of transportation ........................................................... 80
Slewing parts ...................................................................................................... 81
Mast parts ........................................................................................................... 85
Base parts ........................................................................................................... 87
3.5 Auxiliary lifting equipment ............................................................................................. 89
General notes ..................................................................................................... 89
Hook height ......................................................................................................... 89
3.6 Data sheet ..................................................................................................................... 93
Hoisting rope....................................................................................................... 93
Trolley rope ......................................................................................................... 94
Data sheet of hook.............................................................................................. 95
3.7 Counter ballast .............................................................................................................. 96
General notes ..................................................................................................... 96
Configuration ...................................................................................................... 96
Fabrication .......................................................................................................... 96
3.8 Central ballast ............................................................................................................. 104
Configuration .................................................................................................... 104
Making .............................................................................................................. 105
3.9 Foundation ...................................................................................................................115
Foundation of stationary outrigger tower crane .................................................115
Foundation of stationary chassis tower crane .................................................. 121
Foundation of travelling chassis tower crane ................................................... 124
Loads on foundation of crane ........................................................................... 129
Corner pressure for the chassis crane with climbing equipment ...................... 147
3.10 Power supply ............................................................................................................ 165
Definition ......................................................................................................... 165
Current supply ................................................................................................ 166
4 ERECTION/ADJUSTMENT/DISMANTLING ......................................................................... 170
4.1 Foreword ..................................................................................................................... 170

13
CONTENTS WA7025-12E-138EN-B03

4.2 Note on safety regarding erection ............................................................................... 171

Erection instructions .......................................................................................... 171
Fitting the split pins ........................................................................................... 172
Fitting the high-strength bolt ............................................................................. 173
The diagram of erection .................................................................................... 174
4.3 Installing the tower section and climbing equipment assembly .................................. 176
Tower section .................................................................................................... 176
Climbing system ................................................................................................ 180
Installing ............................................................................................................ 182
4.4 Installing the slewing assembly ................................................................................... 185
Description ........................................................................................................ 185
Installing ............................................................................................................ 187
4.5 Installing the counter jib............................................................................................... 187
Description ........................................................................................................ 187
Assemble the Front counter-jib section ............................................................. 188
Assemble the counter jib ................................................................................... 188
Assemble the Rear counter-jib section ............................................................. 189
Sling the Rear counter-jib section ..................................................................... 189
Installing the first 3.0 t counter ballast ............................................................... 190
4.6 Installing the jib assembly ........................................................................................... 191
Assembling the jib ............................................................................................. 191
Reeling the trolley rope ..................................................................................... 194
Installing the jib assembly ................................................................................. 195
4.7 Installing the remaining counter ballast ....................................................................... 198
4.8 Electronic control system installation .......................................................................... 198
Frequency converter self-learning .................................................................... 199
4.9 Power line connection of mechanism .......................................................................... 201
4.10 Winding the hoisting rope .......................................................................................... 201
4.11 Power connection and test run .................................................................................. 203
4.12 Fall-changing system ................................................................................................ 204
4.13 Climbing operation .................................................................................................... 205
Pre-climbing preparation ................................................................................. 205
General notices of climbing operation............................................................. 206
Keep the tower crane in balance before climbing ........................................... 206
Climbing operation .......................................................................................... 208
Rung ladder (old style) and Inclined ladder add tower section ....................... 210
4.14 Chassis stationary tower crane ................................................................................. 211
Installing the crossed-beamed of chassis stationary ...................................... 211
Installing the base tower section and incline tie rod ....................................... 213
4.15 Travelling tower crane ............................................................................................... 215

14
 WA7025-12E-138EN-B03 CONTENTS

Traveling mechanism structure introduction ................................................... 215

Installation and test ......................................................................................... 217
4.16 Safety devices ........................................................................................................... 223
Foreword ......................................................................................................... 223
Limiters ........................................................................................................... 226
Overload protection device ............................................................................. 238
Anemometer and obstruction light setup ........................................................ 249
Trolley safety protection device ...................................................................... 250
Hook safety device ......................................................................................... 251
4.17 Test............................................................................................................................ 252
Function test without load ............................................................................... 252
Load tests ....................................................................................................... 253
4.18 Tower anchored onto the building ............................................................................. 256
Description ...................................................................................................... 256
Layout of the anchored devices ...................................................................... 259
Range of the anchored devices ...................................................................... 262
Matters need attention .................................................................................... 263
Three Stay bar anchored device .................................................................... 264
Scheme of tower anchored onto building ....................................................... 265
4.19 Dismantling ............................................................................................................... 268
General notes ................................................................................................. 268
Dismantling sequences .................................................................................. 269
Preparations before dismantling ..................................................................... 269
5 OPERATION AND CONTROL .............................................................................................. 271
5.1 Driving safety requirements for tower crane ............................................................... 271
5.2 Attention for operation ................................................................................................. 271
5.3 Specific safety instructions ......................................................................................... 272
5.4 Preparation before operation ...................................................................................... 273
Inspection before operation .............................................................................. 273
Check after power on ....................................................................................... 275
Tower crane startup .......................................................................................... 275
Safety device calibration ................................................................................... 277
Tower crane operation ...................................................................................... 277
Alarm ................................................................................................................. 281
Other alarms ..................................................................................................... 285
5.5 Instruction of control unit ............................................................................................. 286
Overview ........................................................................................................... 286
Control panel, control instrument, man-machine interface description ............ 287
How to operate ................................................................................................. 288
Driving box ........................................................................................................ 290

15
CONTENTS WA7025-12E-138EN-B03

Main control cabin ............................................................................................. 292

Resistance box .................................................................................................. 295
Seat adjustment ................................................................................................ 296
5.6 Parameter adjustment of electrical components and instruments .............................. 299
5.7 Slewing brake use and weathervane release method ................................................ 300
Overview of slewing brakes .............................................................................. 300
Slewing electromagnetic brake logic description .............................................. 301
Rotary weathervane release instructions .......................................................... 301
5.8 Cable drum adjustment method .................................................................................. 303
The cable anchorage point is in the middle of the track ................................... 303
The cable anchorage point is on the left side of the track ................................ 303
The cable anchorage point is on the right side of the track .............................. 304
5.9 Operation after working ............................................................................................... 304
5.10 Operation cautions .................................................................................................... 305
Checks to be carried out before operation ...................................................... 305
Checks to be carried out after erection ........................................................... 308
Operating safety instructions .......................................................................... 308
Combined operation ........................................................................................ 314
Starting up and brake movement .................................................................... 314
Stopping crane ................................................................................................ 315
6 MAINTENANCE AND INSPECTION ..................................................................................... 316
6.1 Lubrication ................................................................................................................... 316
Lubricants table ................................................................................................. 317
Lubrication for bearing ...................................................................................... 318
6.2 Safety notes ................................................................................................................ 318
Requirement on personnel ................................................................................ 318
Safety measures ............................................................................................... 319
Protective equipment for personnel .................................................................. 319
6.3 Required maintenance and inspections ...................................................................... 319
6.4 Hoisting mechanism .................................................................................................... 322
Overview ........................................................................................................... 322
Adjustment and maintenance of the brake ....................................................... 323
Maintenance of the motor ................................................................................. 329
Maintenance of the reducer .............................................................................. 331
Coupling ............................................................................................................ 334
Method of rope arrangement problem of hoisting mechanism ......................... 334
6.5 Trolley mechanism ...................................................................................................... 336
Overview ........................................................................................................... 336
Trolley brake ...................................................................................................... 337
Maintenance of trolley reducer .......................................................................... 342

16
 WA7025-12E-138EN-B03 CONTENTS

Maintenance of trolley motor ............................................................................ 343

6.6 Slewing mechanism .................................................................................................... 344
Overview ........................................................................................................... 344
Slewing brake ................................................................................................... 344
Maintenance for slewing ring ............................................................................ 352
6.7 Rope............................................................................................................................ 353
Basic Knowledge of Rope ................................................................................ 353
Rope List ........................................................................................................... 359
The length of the rope ....................................................................................... 360
Installation of the Rope ..................................................................................... 362
Discard Criteria of Rope ................................................................................... 365
Replace the rope .............................................................................................. 371
Maintenance of Rope ....................................................................................... 374
6.8 Maintenance of pulley assembly ................................................................................. 375
Examination of pulley assembly ....................................................................... 375
Pulley scrap ...................................................................................................... 375
6.9 Maintenance of travelling chassis parts ...................................................................... 377
Maintenance of driving/driven dollies ............................................................... 377
Maintenance of traveling motor ........................................................................ 378
Maintenance of the cable drum ........................................................................ 379
Bearing model................................................................................................... 380
6.10 The high strength bolts ............................................................................................. 381
Basic knowledge of the high strength bolt ...................................................... 381
Checking the bolts and bolt connection sets .................................................. 381
Lubricating the high strength bolt assembly ................................................... 381
Recycling the high strength bolt ..................................................................... 382
6.11 Pins and holes of the tower section .......................................................................... 383
6.12 Hook .......................................................................................................................... 385
Check the locking of the hook ........................................................................ 385
Opening Degree of the Hook .......................................................................... 385
Wear ............................................................................................................... 386
Corrosion ........................................................................................................ 386
Check hook anti-tripping device ..................................................................... 386
Oil hook bearing.............................................................................................. 386
6.13 Trolley ....................................................................................................................... 387
Routine inspection of trolley rollers................................................................. 387
Routine inspection of side rollers of trolley ..................................................... 387
6.14 Steel structure ........................................................................................................... 388
Foreword ......................................................................................................... 388
Description ...................................................................................................... 388

17
CONTENTS WA7025-12E-138EN-B03

Description ...................................................................................................... 389

Maintenance .................................................................................................... 389
6.15 Maintenance of electronic control system ................................................................. 393
Electrical equipment inspection ...................................................................... 393
Maintenance for cabin ..................................................................................... 396
Maintenance for safety device ........................................................................ 396
6.16 Spare parts list .......................................................................................................... 397
Spare parts list of mechanism ......................................................................... 397
Spare parts list of electrical control system..................................................... 399
Spare parts list of structure ............................................................................. 400
6.17 Appendix troubles and troubleshooting ..................................................................... 401
7 SPARE PARTS ...................................................................................................................... 415
7.1 Foreword ..................................................................................................................... 415
7.2 Configuration of the tower crane ................................................................................. 415
7.3 Jib ................................................................................................................................ 418
JibⅠ .................................................................................................................. 420
JibⅡ .................................................................................................................. 425
JibⅢ .................................................................................................................. 426
JibⅣ .................................................................................................................. 427
JibⅣ .................................................................................................................. 428
JibⅥ .................................................................................................................. 429
JibⅥ .................................................................................................................. 430
JibⅥ .................................................................................................................. 431
JibⅧ .................................................................................................................. 432
Jib End ............................................................................................................ 433
7.4 Counter Jib .................................................................................................................. 437
7.5 Derrick ......................................................................................................................... 441
7.6 Turntable...................................................................................................................... 443
7.7 Slewing Support .......................................................................................................... 445
7.8 Trolley .......................................................................................................................... 447
Trolley without Maintenance Cage .................................................................... 448
7.9 Hook ............................................................................................................................ 451
Upper Part of the Hook ..................................................................................... 452
Lower Part of the Hook ..................................................................................... 453
Load Hook ......................................................................................................... 455
7.10 Climbing Equipment .................................................................................................. 456
Climbing Equipment Structure ........................................................................ 460
Climbing Operation Platform ........................................................................... 462
Jacket Stop Shoe Mechanism ........................................................................ 463
7.11 Slewing Mechanism ................................................................................................... 464

18
 WA7025-12E-138EN-B03 CONTENTS

S75CA-130LB12/14A...................................................................................... 464
S75CN-130LB12/14A ..................................................................................... 466
7.12 Trolley Mechanism .................................................................................................... 468
T55FC70-b ...................................................................................................... 468
T55FC70-b(D) ................................................................................................. 470
7.13 Hoisting Mechanism.................................................................................................. 471
7.14 Transition Section ..................................................................................................... 474
7.15 Erection Platform ...................................................................................................... 476
7.16 Mounting Device ....................................................................................................... 478
Lifting Device .................................................................................................. 479
7.17 Mast (Rung ladder) ................................................................................................... 481
Base Tower Section (L68G23) ........................................................................ 481
Tower Section ................................................................................................. 483
Passageway ................................................................................................... 487
Stationary Chassis .......................................................................................... 489
Travelling Chassis........................................................................................... 492
7.18 Mast (Incline ladder) ................................................................................................. 495
Base Tower Section (L68G23-C) .................................................................... 495
Tower Section ................................................................................................. 497
Stationary Chassis .......................................................................................... 501
Travelling Chassis........................................................................................... 503
7.19 Powered Wheel Bogie .............................................................................................. 505
7.20 Idler Wheel Bogie ...................................................................................................... 508
7.21 Cable Drum ............................................................................................................... 510
Bolt Package ....................................................................................................511

19
DOCUMENTS WA7025-12E-138EN-B03

1 DOCUMENTS
1.1 Sound pressure
The sound pressure (LpA) is measured at the level of the crane driver’s ears by means of a
microphone under the most unfavorable conditions: noisy winch, short counter jib.

Cranes with cabs:

Air conditioning at maximum level, windows closed, hoisting mechanism at low speed,
hoisting/lowering with maximum load.
Air conditioning at maximum level, windows closed, hoisting mechanism at high speed,
hoisting/lowering without load.
The highest value is taken for determining the sound pressure at the control unit.

Cranes with radio control:

The sound pressure level is given for a control unit which is at least 15 m away from the hoisting
mechanism.

Sound pressure level measured in the cab or on the ground:

Crane with winch in the
LpA (dBA) Crane with winch in the jib
counter - jib
Not soundproof cab V140C Sound pressure level = 79 Sound pressure level = 72
or V140S dB(A) dB(A)
Sound pressure level = 76 Sound pressure level = 70
Sound proof cab V140SX
dB(A) dB(A)
Sound pressure level lower
Control from the ground
than 70 dB(A)

20
 WA7025-12E-138EN-B03 DOCUMENTS

1.2 Commissioning report

21
SAFETY INSTRUCTION WA7025-12E-138EN-B03

2 SAFETY INSTRUCTION
2.1 Foreword
The Safety Instructions describe the measures to be observed in order to reduce the risk of
personal or material accidents when operating a crane. They are of utmost importance and must
be consulted, comprehended, and applied by all parties intervening on the crane. A version
translated into the language understood by the person consulting those instructions shall be
supplied by the crane manager, if necessary.
Safety instructions figuring in the present chapter and based on the current state of knowledge
at the time of their establishment are to be considered as simple guide−lines for the reader:
ZOOMLION cannot anticipate in an exhaustive manner all the dangerous situations that may
arise. Consequently, safety operation of the crane is a responsibility incumbent to yourselves.
Local regulations that are valid at moment of crane utilization may stipulate adherence to
instructions that are more stringent than the present instructions, in which case those local
regulations shall prevail.
The crane is a hoisting device destined for handling suspended loads on a protected operational
site. It shall consequently be used exclusively for that purpose (cf. general utilization conditions
chapter).
The crane has been designed in compliance with EC directives concerning safety, and to be used
by professionals that are physically apt and qualified for the operation, assembly, piloting, and
maintenance of this type of equipment (identified in the present manual as “competent persons”).
These persons must know the technical data (Chapter 3 <TECHNICAL DATA OF CRANE AND
SITE>) so as not to exceed the utilization limits described in this manual.

The illustrations of this part are general and do not correspond to your crane.

22
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

2.2 Intended use, misuse

The following describes the intended use of this ZOOMLION tower crane and warns against
foreseeable misuse. Although the crane has been designed and manufactured according to the
state of the art, it is not possible to completely eliminate all hazards that may occur during
operation. The residual hazards, basic safety instructions, therefore draws particular attention to
this.
Hazard prevention is carried out by:
◼ warning signs on the crane directly at the danger point,
◼ basic safety instructions for instructing the individual groups of persons in the operating
instructions,
◼ action-related safety instructions before the activities described in the operating instructions.

Intended use
The design, manufacture, materials, equipment, operation, and maintenance of the ZOOMLION
tower crane correspond to the state of the art, based on proven knowledge from science and
technology. Nevertheless, its use may cause danger to life and limb of the user or third parties
or damage to the crane and other property.
You may only use the crane in a safety-conscious and hazard-conscious manner, and in
compliance with the operating instructions.
You may only use it for lifting, lowering, and horizontal load movements! You may only transport
the load when it is freely suspended on the load hook! Damage and malfunctions which may
impair safety must be rectified immediately!
Only skilled, instructed, and trained personnel may operate and monitor the crane from the crane
operator's cabin and with radio operation.
The intended use, in particular the permissible loads for the crane components, is entered in the
load tables in Section 3.7. They must not be exceeded under any circumstances! Immediately
rectify damage and malfunctions which may impair safety!

You may only use base elements for this crane which have been approved by the manufacturer.
When selecting the installation site for stationary cranes, it is essential to maintain safety
distances
from overhead electrical cables, solid objects in the vicinity (structures, stacks of material, etc.),
and embankments. When preparing the installation site for stationary cranes, be sure to observe
the design guidelines for foundation construction.

23
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Foreseeable misuse
The previous section describes the intended use of the crane.
Any other use or use going beyond this is not in accordance with the intended use and must be
refrained from.
In the event of foreseeable misuse or improper handling of the crane, the manufacturer's EC
declaration of conformity and thus the operating permit automatically expire.

Examples of misapplications:
◼ Pull loads horizontally over the ground,
◼ Increase load when it has left the solid base,
◼ Transport of swinging loads (use guide ropes),
◼ Overload from non-observance of the permissible load capacity,
◼ Diagonal pull,
◼ Tearing loads up and/or loose from stacks or jammed loads,
◼ Carriage of persons during load transport or on the reception facilities,
◼ Attach load hook, operation with slack rope,
◼ Assembly / disassembly of the crane at wind speeds above 14 m/s = 50 km/h,
◼ Continue working despite error/malfunction messages,
◼ Inadequate, removed, bypassed safety devices and indicators.

Improper use includes:

◼ Lifting of persons in normal operation,
◼ Use for demolition work such as with grab or wrecking ball,
◼ Modifications of the steel structure,
◼ Attachment of additional wind-impact surfaces (such as advertising boards) without the
manufacturer's approval,
◼ Incorrect maintenance work and repairs,
◼ Omitted replacement of wearing parts,
◼ Maintenance intervals not observed,
◼ Operation without the necessary double safety devices,
◼ Operation at temperatures below -20 °C,
◼ Operation without required supervision/instruction personnel when the crane operator has
little or no visibility of the load,
◼ Failure to carry out the inspection by an expert after each new installation/conversion, but
at least once a year,
◼ Failure to carry out the inspection by an expert.

24
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

2.3 General conditions of use

The purpose of these general conditions is to explain the conditions indicated in Chapter 3
<TECHNICAL DATA OF CRANE AND SITE>. In the event of unforeseen conditions, please
contact us.
Certain critically important information on crane driving is represented in illustrated form in
Chapter 4 <ERECTION/ADJUSTMENT/DISMANTLING> of the present manual.

Climatic and geographical conditions

A. Wind
Out of service, the crane operating conditions, i.e.: free standing height, ballast, reaction, and
pressure under slab are determined by the storm reference wind speed measured at the crane
installation site.
The storm wind speeds are described in the Section 2.7.
a) Specific conditions
Some conditions or configurations require prior study on your part to determine the storm
reference wind speed to be accounted for at the crane installation site. Please contact us when
in possession of such data.
These conditions are:
◼ absence of map,
◼ national or local regulations,
◼ altitude higher than that indicated on your map if that is specified,
◼ bottom of hollow, narrow valley, hill top,
◼ isolated hill or mountain,
◼ cliff top,
◼ crane installed on a building,
◼ constructions: refer to the examples below.

25
SAFETY INSTRUCTION WA7025-12E-138EN-B03

b) Table for determination of crane operating conditions

c) Assembly, dismantling, change of configuration

Assembly, dismantling, change of configuration operations are possible only if the maximum wind
speed (gust) measured at top of crane (cathead or strut) is lower than 14 m/s.

d) Crane in service
Use of the crane is possible only if the maximum wind speed (gust) measured at top of crane
(cat head or strut) is lower than 20 m/s.

e) Surface exposed to the wind of the load handled

The surface exposed to the wind of the loads handled is considered as being less than or equal
to 1 𝑚2 /t. If this value exceeded, the “in service” wind speed must be limited to a value lower
than 20m/s. The value to be taken into accounting is given in the table “Maximum admissible
wind speed for a load surface higher than 1 sq. m/t” (see Chapter 3 <TECHNICAL DATA OF
CRANE AND SITE>).

For surface areas greater than those provided in the table, please consult us.

26
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

B. Ambient air temperature measured under cover

This corresponds to the temperature measured within a non−closed shelter,

protected from wind and rainfall, located 2 m above ground and within a max.
100 m radius.
Except for specific provisions defined by contract (E.g.: country specifications), the range of
temperatures for crane use is as follows:
◼ Crane in service: − 20 °C to + 40 °C:

In case of temperatures out of the above range, cease any work with the
crane (risk of malfunctioning or destruction of the components by
abnormal overheating).
◼ Crane out of service: − 25 °C to + 55 °C:

In the case of planned temperatures out of the above range, it is

preferable to dismantle the crane. In every case, apply the instructions
concerning the extended standstill of the crane in the maintenance part.

C. Humidity / rainfall
The maximum rate of humidity for crane use (in service and out of service) is of 95% without
condensation, excepting specific contractual provisions.
The maximum rate of humidity for a stored crane (dismantled) is of 95%.

D. Height above sea level

The operation height above sea level should be less than 1000m. The type of motor and electrical
device should be increased.

E. Chemical environment
The requirement of chemical environment refers to urban industrial standard.

F. Electromagnet environment
The electrical field intensity should lower than 10V/m, extra design is needed when the television
tower or other intense electrical field exists.
The nylon rope is recommended when the tower crane locates near the transmit tower.
The requirements above are general requirements; extra appointment is needed when dealing
with special requirements.

G. Frost, ice, or snow

Frost, ice, or snow increase the weight of the structure and its surface exposed to wind. Those
conditions may generate damage to moving parts. They can also cause personnel to fall when
accessing the drivers stand.

27
SAFETY INSTRUCTION WA7025-12E-138EN-B03

It is strongly recommended to avoid using a crane when the latter is

covered with frost, ice, or snow.

H. Lightning
Lightning can generate current circulation in the crane framework and lead to a risk of
electrocuting any person in direct or indirect contact with the crane. E.g.: on part of the steel
structure, on a ladder, on ground when touching the crane or load.
Lightning may interfere with the operating of radio controls.

In the event of risk of storm, cease work and set crane to idle mode. Do
not access the crane during a storm.

In the case where the driver does not have time to leave the crane (sudden
storm), he should never attempt to leave the crane during the storm. The driver
runs less risk if he stays in the driving cab if he avoids touching any controls.

I. Sand storms
After a sand storm, sand may have penetrated internal electrical and mechanical elements and
plugged orifices.

Before restarting the crane, completely clean the electrical and

mechanical elements and remove moving parts if necessary.

J. Flooding / tidal waves

The above conditions are not accounted for, excepting specific contractual provisions.
In the case of flooding or tidal waves crane stability is reduced, thus cease any work with the
crane.

K. Earthquake
The crane is not designed to be seismic−resistant whatever the magnitude of the earthquake,
excepting specific contractual provisions.

L. Special installations
The crane is not designed to be installed on moving foundations such as off−shore platform,
barge, floating bin, etc. excepting specific contractual provisions.

M. Crane supports
Crane supports shall be designed to withstand the forces indicated in the crane technical data
and implemented in strict compliance with the tolerances provided.

28
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Conditions relative to crane design

A. Appropriateness of crane to the operating site
Appropriateness of the crane to the operating site is incumbent to the user.

B. Crane power supply

The crane has been designed to work with a power supply the values and tolerances of which
must be strictly adhered to Section 3.8.

Non−adherence to the values indicated can lead to malfunctioning of the

crane.

C. Driver control stand

According to options, the crane is driven from the cab or the control station on the ground. Driving
can be radio−controlled or remotely controlled.
Safety devices (force, movement, speed limiters) prohibit use of the crane out of its normal
operating conditions.

D. Safety devices
Safety devices (force, movement, speed limiters) prohibit use of the crane out of its normal
operating conditions.

Never modify safety device settings, nor hinder their functioning or

neutralize them.

E. Load indicator
The load indicator shall not be employed as a measurement tool.

F. Protective elements
Protective elements or devices prohibit access to dangerous areas. They must never be
suppressed.

Never start up a crane before all the protective elements (e.g.: housings,
life−lines, handrails, trap−doors etc...) are set in place.

G. Nominal crane life duration

The nominal crane life duration corresponds to the minimum life duration accounted for when
calculating the crane fatigue factor.

29
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Except for specific contractual provisions, that nominal life duration is in conformity with the
classification FEM 1.001 version 3.
It is evaluated separately and differently for the complete crane and its individual mechanisms.

H. Nominal steel structure life duration

This is expressed in hoisting cycles (1 hoisting cycle = hoisting of a load, slewing and/or trolleying
of that load, lowering for laying down).
The classification group for single tower cranes is A4.

I. Nominal mechanism life duration

This is expressed in operating hours of the given mechanism.
The classification group for mechanisms depends on the type of crane and the given movement.
The classification group determines a nominal life duration according to mechanism
load−supporting state.
The different values above are provided in Chapter 3 <TECHNICAL DATA OF CRANE AND
SITE>.

J. Mechanism working factor

The mechanism working factor is expressed by the percentage of: mechanism usage time /
mechanism usage time + rest time) measured over 20 cycles per hour.
The working factor indicated for mechanisms in Chapter 6 <MAINTENANCE AND INSPECTION>
must in no case be exceeded.

K. Weathervane
The crane shall be able to weathervane through 360°. If that is not possible, please consult us.

L. Customer advertising plates

The dimensions of these plates shall not exceed planned dimensions.
Installation of advertising plates in areas other than those specifically provided is prohibited
without the written authorization of the manufacturer.
Attachment of plates is entirely incumbent to the customer.

M. Fire extinguisher
The supply and implementation of a fire extinguisher in the cab is incumbent to the user.

N. Modifications of the crane / welding

Without written agreement of the manufacturer, it is prohibited:
➢ to modify crane construction (E.g.: addition or renovation d of elements, blow−torch work,
welding, etc...),
➢ to adapt non−authorized accessories,
➢ to modify crane settings (E.g.: modification of pressures, tares, adjustment values, etc...),

30
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

➢ to perform welding operations on the crane.

Welding work under the load is prohibited if the load is not secured by
electrically insulated slings.

O. Adaptation of equipment / Replacement of parts

Any adaptation of equipment not supplied or recommended by the manufacturer and any
replacement by parts which are not genuine spare parts or parts authorized by the manufacturer
will be carried out under the entire responsibility of the user.
The user also has the responsibility for the consequences of these adaptations and replacements.

P. Surveillance of the crane / verifications

To ensure the crane is monitored, is kept in good working order, and is used safely, it shall be
submitted to the verifications (frequent, periodical, and extended) described in Chapter 6
<MAINTENANCE AND INSPECTION>.
If they are stricter, the verifications and directives related to local regulations shall take priority
over the instructions in this manual.
Update the crane’s maintenance records according to the instructions supplied in the manual.

Q. Scrapping
Eliminate all used products such as oil, grease, batteries in conformity with the regulations
prevailing at the site where the crane is used.

Crane installation conditions

A. Distance between crane and fixed obstacle
Adhere to the minimum regulatory distance between the pointing mobile part of the crane and
fixed obstacles. In the absence of regulations, that distance shall be of at least 0.5 m on ground
and 2 m for above ground elements.

B. Distance between crane and overhead electric line

Adhere to the safety distances imposed by the regulations at the operating site, concerning
hoisting devices with suspended loads, between crane elements and overhead electric lines. In
the absence of regulations, that distance shall be of at least 3 meters for voltages less than or
equal to 50000 V, with the addition of 1cm per additional 1000 V above 50000 V.

C. Distance between 2 cranes

If several cranes are close to each other, the minimum safety distance between any individual
part of a crane or its load must be greater than 2 m in relation to any individual part or load of
another crane.

31
SAFETY INSTRUCTION WA7025-12E-138EN-B03

D. Safety distance at track extremities

Adhere to the safety distances imposed by the regulations at the operating site concerning
hoisting devices with suspended loads, for track extremities.
In the absence of regulations, provide for a track length exceeding the end position planned for
the crane by 6m, in order to account for the stopping distance and the safety distances for
installation of end dampers.

E. Aircraft limiting lights

Use of the crane in areas close to airports or aerodromes, in the aircraft taking off or landing
cone, dictates the necessity of daytime and/or nighttime limiting light installations.
Apply the regulations prevailing at the operating site.

Handling conditions
A. Handling equipment
The crane is destined for load handling with use of its hook.
The use of any hoisting equipment generating dynamic effects such as, for example,
electromagnets, clutches, hammers, gathering buckets is prohibited.

B. Load handling
◼ Never hoist an incorrectly secured load.
◼ Never drag a load in oblique direction. The load must always be
hoisted in line with the trolley.
◼ Never hoist a load adhering to the ground or other elements.
◼ Never increase the weight of a load when suspended on the hook.
◼ Never swing the load to rest it out of the admissible range.
◼ Never leave the driving stand with a load suspended on the hook.
C. Handling with 2 cranes
The use of 2 cranes to hoist one and the same load is prohibited.

D. Hoisting of persons
The crane is not designed for hoisting persons. Such usage, which may be authorized by national
regulations concerning suspended−load hoisting devices, is the entire responsibility of the user.

E. Ballasting derricks
Ballasting derricks are reserved for the handling of ballast blocks and accessories provided for
in the present manual. Any other utilization is prohibited.

F. Maintenance derricks
Their use is strictly reserved for loads lower than those indicated on the derrick.

32
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

2.4 General safety instructions

Requirements for personnel/qualification and duties

This section describes the required qualifications of the personnel

employed. Only specially authorized personnel may work on the crane.

The contractor may only employ persons for independent work on the crane who:
◼ have reached the age of 18,
◼ are physically and mentally fit,
◼ have been instructed in the field of activity and have demonstrated their competence, know
and be able to apply the applicable accident prevention regulations and safety instructions
for crane operation,
◼ have understood the contents of the safety chapter and are able to apply and implement
them in practice,
◼ have been trained and given practical instruction on the tower crane in accordance with their
responsibilities, tasks and activities, have understood the associated technical
documentation and can implement it in practice,
◼ reliably perform the tasks assigned to them as expected,
◼ a specialist is someone who is able to assess the tasks assigned to him and recognize
hazards on the basis of his specialist training, knowledge, and experience,
◼ In your own specialist responsibility, you may only carry out activities for which training has
been proven.

Duties and responsibilities

The following duties exist:
◼ of the operator in relation to the personnel deployed,
◼ of the personnel vis-à-vis the employer/operator.
Duties and responsibilities are divided:
◼ Operator/entrepreneur,
◼ Supervisors/department heads,
◼ Crane operator,
◼ Other personnel for transport, assembly, dismounting, maintenance and repair, slingers,
banksmen, and experts.

Obligations of the entrepreneur

As the operator, the employer must designate a supervisor who is responsible for ensuring that
the personnel assemble, dismounts, or converts the crane in accordance with the
assembly/disassembly instructions.

33
SAFETY INSTRUCTION WA7025-12E-138EN-B03

The operator of this crane must ensure that the personnel:

◼ complies with the necessary safety and monitoring measures,
◼ attaches safety signs to the workplaces,
◼ attaches and makes known any necessary internal safety and work instructions,
◼ obtains and uses required personal protective equipment,
◼ is trained and instructed according to its responsibilities, tasks and activities on the crane,
especially in all safety aspects and the avoidance of risks from, fatigue, and mental stress,
◼ has the technical documentation available,
◼ has the necessary work equipment at its disposal,
◼ maintains cleanliness and clarity on the crane,
◼ keeps maintenance and inspection intervals.

2.4.2.1.1 Accident prevention

In addition to the information given in this manual, observe the regulations applicable in the
respective country of use.
Accident prevention regulations are primarily aimed at the employer and are intended to help him
to implement his obligations arising from state occupational health and safety regulations, and to
show him ways of preventing occupational accidents, occupational diseases, and work-related
health hazards.
The employer can assume that he will achieve the required protection goals if he follows the
recommendations of the accident prevention regulations. Other solutions are possible if they
ensure safety and health protection in the same way. If special committees have identified
technical rules for the specification of national occupational health and safety regulations,
observe them as a matter of priority.

2.4.2.1.2 Periodic inspections

Observe the manufacturer's inspection instructions in the operating manual.
The entrepreneur must ensure that:
◼ a competent person inspects the crane as required, but at least once a year, depending on
the conditions of use and the operating conditions,
◼ in addition, a competent person inspects the crane each time it is assembled and after each
conversion,
◼ An expert inspects the crane at least every 4 years,
◼ in the 14th and 16th year of operation, and after that, an expert inspects the crane annually.

Duties of the superior

The supervisor / group leader of the personnel of this crane must ensure that:
◼ the corporate duties have been implemented and complied with, see Section 2.4.2.1.

34
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

In particular, he must ensure that the authorized personnel:

◼ is trained and instructed according to his responsibilities, tasks, and activities on the crane,
◼ is instructed and trained in all safety aspects, and observes the safety aspects,
◼ observes the specifications of the technical documentation,
◼ has received and is using the required personal protective equipment,
◼ uses the necessary work equipment,
◼ maintains cleanliness and clarity on the crane,
◼ keeps maintenance and inspection intervals,
◼ rectifies reported safety deficiencies immediately.

Duties of personnel
The personnel working on the crane is obliged to:
◼ observe internal safety and work instructions,
◼ report safety deficiencies immediately to the appropriate supervisor or department head,
◼ keep the required safety signs visible/readable at the workplace,
◼ work on the crane only in accordance with its responsibilities, tasks and authorized activities,
◼ avoid risks from noise, fatigue, and mental stress,
◼ observe the specifications of the technical documentation,
◼ use the required personal protective equipment,
◼ to use the necessary work equipment,
◼ maintain cleanliness and clarity on the crane.

Duties of the crane operator

Before starting work
◼ Check crane for obvious defects.
◼ Check brakes and emergency end stop devices.
◼ Check assignment of control unit and crane with wireless controlled tower cranes.
◼ Check the function of the hook safety device on the load hook.
◼ Check track system and running gear, if present.
◼ Before releasing the energy supply to the drive units, set all control devices to zero or idle
position.
During operation
◼ Record inspections and defects found in the control book.
◼ Operate control devices only from control stands.
◼ Watch the load during all movements, or the pick-up devices during empty runs if this could
cause hazards. If this is not possible, the crane operator may only steer the crane on the
signal of a banksman.
◼ Give warning signs if necessary.
◼ Loads attached by hand may only be moved when there is a clear signal from the slinger,
the banksman, or another responsible person designated by the employer. If you have to
use signals, agree on them beforehand with everyone involved. If loads are improperly

35
SAFETY INSTRUCTION WA7025-12E-138EN-B03

attached, they must not be transported under any circumstances.

◼ As long as a load is suspended from the crane, you must have the control devices within
reach.
◼ Do not accept an overload after the load moment limit switch has tripped.
◼ It must be possible stop started driving or turning movements without danger.
◼ Report all defects on the crane to the responsible supervisor, and when changing the crane
operator, also to the person taking over.
Avoid the following:
◼ Pulling loads at an angle, swinging.
◼ Tearing loose fixed loads.
◼ Permit the transport of persons with the load or the lifting device, (exception: for example,
concrete bucket with stand for operating personnel; however only with the approval of the
competent supervisory authority).
◼ Carrying loads over people. Use pick-up devices that hold the load by magnetic, frictional,
or suction forces without additional securing. In general, loads must not be carried over
persons.
◼ Approach of end positions limited by end switches.
Stop the crane operation under the following conditions if:
◼ you cannot safely hold and take off the load in windy conditions;
◼ the wind speed exceeds the permissible limit of 20 m/s;
◼ the temperature falls below -20° C;
◼ defects occur that endanger operational safety.
At the end of work
◼ Before leaving the control stand, unhook loads, sling or pick-up equipment, pull up hooks,
release slewing gear brake, move trolley into rest position, set control equipment to zero or
idle, shut off power supply.
◼ Secure the control unit for wireless control against unauthorized switching on before putting
it down.
◼ Do not leave loads hanging on the unoccupied crane.
◼ Activate wind release.
◼ Fasten track-operated tower cranes with rail tongs; put crane in "out of service" position.
Regular maintenance
◼ Maintain ropes.
◼ Check ropes for damage.
◼ Check load display control device.
◼ Check protective covers.
◼ Check safety switches.

36
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Expert
Observe the regulations on experts applicable in the country of use!
Only persons authorized by the supervisory authority (Employer's Liability Insurance Association)
are deemed to be experts for the periodic inspection of tower cranes. Immediately send the test
report to the supervisory authority responsible for the contractor (Employer's Liability Insurance
Association).

Competent persons
Competent persons carry out periodic inspections on tower cranes.
A competent person is a person who, on the basis of its professional training and experience,
has sufficient
knowledge of tower cranes and is familiar enough with the relevant state occupational health
and safety/accident prevention regulations, guidelines, and generally recognized rules of
technology
to be able to assess the safe working condition of tower cranes.
In addition to the competent persons, you can also use specially trained personnel as experts,
provided
they have experience and sufficient knowledge to assess the safe condition of the crane to be
inspected.

Crane operator
The crane operator is primarily responsible for the intended use of the crane. His responsibility
must be precisely defined and adhered to, also in the case of traffic route regulations. Instructions
from third parties are not binding on him.
Keep and store tools, operating materials, and loose objects safely. Keep ascents, handholds,
railings, and platforms clean and, in winter, free of ice and snow.
The crane driver must familiarize himself with the conditions at the construction site at the location.
Obstacles in the work area must be known, and the construction site must already be secured to
public traffic.

Any working method endangering the crane stability is prohibited!

After work, the crane operator must ensure that all operating elements and equipment are
switched
off or set to the neutral position.
Before leaving the crane, the crane operator must secure it against accidental and
unauthorized use.
See corresponding sections in Chapter 5 <OPERATION AND CONTROL>.

37
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Banksman
The use of a banksman is mandatory when transporting loads that you cannot see.
The banksman gives instructions to the crane driver for certain operations. He must be able to
observe the entire process without danger. The banksman must devote himself exclusively to
control the work processes and the safety of persons being in the vicinity. He also pays attention
to safety distances and danger areas which he closes off and secures them if necessary.
The banksman must be easily recognizable to the crane operator. Clothing should be
conspicuously colored (signal color), preferably uniform, and be reserved for the banksman.
Communication takes place by means of defined hand signals, or radio telephony. Radio is best.
If the working areas of several cranes overlap, you must define, plan, and coordinate the
processes with all parties involved.

Slinger
The slinger attaches a wide variety of loads to the hook.
For the smooth transport of load, only the signs of the banksman are decisive, who must observe
the slinger closely and follow his signs. They communicate by means of defined hand signals, or
radio telephony. Radio is best used when you cannot see the slinger or the banksman.

Loads may only be attached by instructed, trained, and authorized persons who have been
instructed in the execution and function of the lifting equipment.

Assembly personnel
Only trained personnel instructed by ZOOMLION may be used to assemble a crane. The foreman
is responsible for supervision and has the authority to issue instructions.
The installation personnel must always observe the local regulations and occupational health
and safety when working.

Supervisor
The employer must designate a supervisor who is responsible for ensuring that the personnel
assemble, dismounts, or converts the crane in accordance with the Erection instructions.

Maintenance/repair personnel
Specialists maintain and repair the crane. They can use work stands or platforms if they cannot
work from the ground (accessible area on the crane).
However, this does not apply when the crane is switched on and during work:
◼ there is no danger of crushing or falling,
◼ there is no danger of touching live parts of electrical installations and equipment,
◼ voice or line-of-sight communication with the crane operator is possible.

38
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Miscellaneous tasks
Danger from electrical voltage
The employer and the crane operator must ensure that persons in the vicinity of live parts of
electrical systems and equipment can work safely on the crane.

Repairs of/modifications to the crane and its working area

Whenever repairs, maintenance, or modifications are carried out on the crane or in its working
area, the employer must also order and monitor the following safety measures:
◼ Switch off crane, secure against unauthorized restart;
◼ Secure the danger area under the crane by blocking or by warning posts;
◼ Secure the crane so that other cranes cannot approach it;
◼ Inform the drivers of neighboring cranes about the type and location of the work.
This also applies to shift changes.
If these safety measures are inappropriate or inadequate for operational reasons, the employer
has to order and supervise other, additional, or specifically prescribed safety measures.

Recommissioning after repairs and modifications

You may only operate the crane after the entrepreneur has released it. Prior to release, the
entrepreneur or his representative shall satisfy himself that:
◼ the work is completed,
◼ the crane is again in a safe condition,
◼ all persons involved in the work have left it,
In case of modifications, an expert must approve the crane; see special instructions in the other
chapters of this manual.

39
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Workplaces
This section describes the workplaces that are directly or indirectly related to the crane.

Personal protective equipment against falls from a height (PPE)

For many maintenance/repair jobs on the crane such as on jibs, you cannot use workman
baskets/ working platforms, etc., to work safely. Therefore, use your personal protective
equipment against falls from a height (PPE) when doing so, and during any assembly /
dismounting or retrofitting.

Caution about impact by heavy parts, missteps in areas without railings,

tripping, wind, movement of the standing surface, etc. when you work at
great heights.

Death, personal injury, or property damage are the result.

◼ Use a safety harness everywhere on the crane where you can fall, for example when you
leave the railing-secured areas!
◼ Always use the safety ropes/braces fitted for securing.

Observe and comply with the regulations applicable in the country of use!

Accident prevention regulations are primarily addressed to the employer. They are to assist him
to implement obligations arising from state occupational health and safety and/or insurance
regulations, and show him how to avoid occupational accidents, occupational diseases, and
work-related health hazards.
Before selecting and using PPE, the employer must determine the hazard(s). In doing so, he
identifies hazards which technical or organisational measures can neither prevent nor minimise.
The employer must specify the characteristics for the PPE in order to protect against the hazards
mentioned. The hazards which arise or may arise from the use of the PPE must be taken into
account.
If workplace conditions change, the employer must review the investigations.
The employer must document his findings on the basis of the risk assessment. If work
characteristics and hazards are comparable, he can create joint documentation for several users.
The PPE to be used must comply with the relevant regulations on the safety and health of users
at work. Thereafter, an EC type examination must be carried out, a CE marking must exist, and
a manufacturer's declaration of conformity must be available.

Before selecting the PPE, the employer must evaluate the products he intends to use to
determine whether they:
◼ protect against the dangers to be averted without posing a greater danger by itself,
◼ are suitable for the prevailing workplace conditions,
◼ meet the user's ergonomic requirements and health needs,

40
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

◼ can be adapted to the user if this is required by the nature of the personal protective
equipment against falls from a height.

Notes on the selection

Do not combine different fall arrest systems with each other!
For the use of PPE, the employer must draw up operating instructions containing all the
information required for safe use, in particular the hazards according to the risk assessment, the
behaviour during use and in the event of any defects found.

Instruction
The employer must instruct users before first use and as required, but at least once a year. The
instruction must include at least:
◼ detection of damage;
◼ the specific requirements of the individual equipment;
◼ proper wearing;
◼ intended use;
◼ proper storage.

Maintaining / cleaning / storing PPE

The employer must ensure that defective parts of PPE are only replaced by parts that correspond
to the original part.
Clean and maintain all PPE equipment as necessary and in accordance with manufacturer's
instructions.

Keep your personal protective equipment safe and comply with the respective
manufacturer's instructions.

Inspections
Users must visually inspect their PPE for proper condition and operation before each use.
Depending on the conditions of use and the operating conditions, the employer must have the
equipment inspected by a competent person as required, but at least once a year, to ensure that
it is in perfect condition.
By way of derogation from this, the contractor shall have fixed guides for the installation of
equipment (rails and ropes) inspected by a competent person as required, but at least once a
year, to ensure that they are in perfect condition.

41
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Instructions relative to operating conditions

A. Regulations relative to suspended-load hoisting devices
◼ Adhere to local regulations concerning suspended−load hoisting devices for matters
covering:
➢ roadway traffic,
➢ fire−fighting equipment,
➢ protection of the environment,
➢ radio−control transmission−reception frequencies,
➢ periodical verifications.

The dangers linked to the utilization and configuration of the machine

must be taken into accounting by the security services and rescue
services during the analysis carried out by the inspection authorities.

B. Climatic circumstances
◼ Establish a procedure relative to the behavior to be adopted in the case of particularly
climatic circumstances (E.g.: reduced−function operation, evacuation of the area).
That procedure may be supported by a system of climatic condition forecasting
implemented by the local meteorological department.

C. Access to crane / driving stand

◼ Access the driving stand via the access path provided, with the crane stopped.
◼ Access the driving stand with an elevated cab or personnel elevator only when the
crane is stopped and in adherence to the maximum authorized carrying capacity.
◼ Keep the access paths and control station perfectly clean. In particularly, remove all
waste, traces of grease or oil, spare parts, tools, etc. Store tools, accessories, and
parts in the positions provided for that purpose.
◼ Access the crane with hands unhindered by any object, facing the crane and always
maintaining contact at 3 points with its elements: ladders, railing, stairs, catwalks,
handrails, etc... (e.g.: 2 feet and 1 hand, 2 hands and 1 foot).

D. Malfunctioning
◼ In the case of malfunctioning, stop the crane until the risk has been assessed by a competent
person.
◼ Immediately correct any malfunctioning liable to compromise safety.
◼ Enter all malfunctions in the crane’s maintenance records.

E. Electric lines
◼ Define the procedure to be applied in the case of accidental contact between crane
and electric lines under voltage (direct contact or start of an electric arc).

42
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

◼ Examples:
➢ Do not leave the crane,
➢ Do not touch the metallic structure,
➢ Warn all persons outside that they must avoid approaching or touching the crane,
➢ Withdraw the crane from the danger zone,
➢ Have the electric line powered off then leave the crane.

F. Conditions for visibility

◼ Adapt the communication means to the visibility conditions at the site where the crane is
operated, for example use transceivers or video systems.
◼ In the case of low light, do not use the crane without an appropriate artificial lighting.

Instructions relative to specific danger

A. Installation
◼ Make sure that the electrical system is complete and undamaged.
◼ Make sure that the electrical system has no condensation and humidity.
◼ The lifting lugs are recommended to be used during removals.
◼ The cabinet is recommended to be installed in predesigned position, and the number of
fasten needs to meet the designer’s needs.
◼ Fasten the screws with required torque (see details on Section 6.9), using recommended
plane pad or spring washer.
B. Wiring
◼ Confirm the power is off and no residual voltage.
◼ Wiring should be conducted by professional.
◼ Do not wiring when wearing loose clothes or jewelry.
◼ Avoid the damage of wires.
◼ Wiring with required wiring diagram.
◼ Wiring with required wires.

C. Test run
◼ Confirm the validity of the cabinet’s installation; turn on the power after closing the cabinet’s
door. DO NOT open the cabinet’s door when operating.
◼ Confirm the tower and mechanisms operate in allowable range.

D. Maintenance and Checking

◼ High-voltage exists in the high-voltage terminal, please DO NOT touch them.
◼ Turn off the cabinet’s door when operating. Close the related breakers and confirm no
residual voltage when disassembling the elements.
◼ DO NOT maintenance, check or replace the element unless an appointed specialist. Take
off the metal jewelry (watch, rings) before operating, using insulated tools when operating.

43
SAFETY INSTRUCTION WA7025-12E-138EN-B03

◼ Apply extra braking methods when checking any brake.

◼ DO NOT wiring or remove wires when the power is on.
◼ DO NOT Maintenance or checking when the weather is bad.
◼ Maintenance and checking are recommended to carry on in 20 minutes after power-off, the
residual voltage or high temperature exists in some elements.
◼ DO NOT reform the electrical system.

E. Additional
◼ DO NOT operate other mechanism when climbing.
◼ DO NOT operate when the safety device is not installed or debugged.
◼ The operator should pass through professional training.

Safety instructions relative to the preparation of each

operating phase
A. Transport
◼ Provide for access to the site where the crane is operated, suited to crane transport
conditions and, if necessary, the transport of auxiliary equipment used for
assembly−dismantling (ground resistance, climatic conditions, access ramp, maneuvering
zone, etc.).
◼ Install signaling equipment before any transport by road.

B. Preparation of the site

◼ Ensure that the site where the crane is used meets all crane characteristics and utilization
conditions.
a) Crane installation area
◼ Before installing the crane, study the constraints related to its operating site, such as:
➢ local regulations concerning work above public buildings or other, above roads, railroads,
fluvial canals, etc.
➢ proximity to other cranes, to an airport, to electric lines, to a transmitter of electromagnetic
waves, etc.
➢ configuration of the terrain, resistance of ground, excavations, slope, underground structure,
etc.
➢ storage zones for elements used in crane assembly or dismantling, positioning of handling
equipment, in order to determine the optimal crane position, in compliance with
assembly−dismantling and operating conditions.
b) Power supply
◼ Ensure that the power supply conforms to crane data and possesses the mandatory
protections.

44
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

C. Assembly-dismantling part
a) Preparation of assembly−dismantling
◼ Establish a document, for the attention of the personnel at the crane operating site, that
details the risks of assembly, dismantling or change of configuration operations and the
appropriate protective measures.
◼ Before any assembly, dismantling, change of configuration (e.g.: raising on supports,
passage to raised jib) of the crane, ensure with the relevant authorities that wind speeds will
not exceed the maximum authorized speed (refer to utilization conditions) throughout the
entire operation.
◼ Stake out the safety areas (zones for storage, handling, assembly, ...) when assembling,
dismantling, or testing the crane, with the use of signaling prohibiting access to
non−authorized personnel.
b) Assembly − dismantling − change of configuration
◼ Do not use the crane during assembly, dismantling or change of configuration operations.
◼ For any assembly or dismantling operations not covered by the normal procedures (example:
constraints related to the crane operating site, malfunctioning during assembling or
dismantling), please consult us.

D. Maintenance part
a) Preparation for maintenance
◼ Stake out a safety area in the case of crane malfunctioning or during maintenance
interventions, with the use of signaling prohibiting access to non−authorized personnel.
◼ Inhibit re−start of the crane on stoppage for intervention and signal that inhibition of re−start
by a warning attached to the main switch.
b) Maintenance
◼ Do not use the crane during maintenance operations.
◼ For any non−standard maintenance operation, please consult us.

2.5 Residual hazards, basic safety instructions

The hazards were determined during the design and manufacture of the crane by a risk
assessment in accordance with DIN EN ISO 12100 and EN 14439, and the risks were evaluated.
Constructively unavoidable residual hazards are named and explained
◼ in the basic safety instructions,
◼ and in individual chapters situation and/or action-related (specific warnings).

The safety briefing contains basic safety instructions to permanently influence your
behavior in a positive way. Information of results and interrelationships promotes your
understanding and leads to safety-conscious behavior.

45
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Observing and practical implementation of generally valid specifications in the country of use will
give you further suggestions and tips, such as:
◼ Accident Prevention Regulation "Principles of Prevention".
◼ Accident prevention regulation "Cranes".
◼ Accident prevention regulation "Winches, lifting, and pulling devices".
◼ Accident prevention regulation "Load handling attachments with hoist operation".
◼ EC Directive 89/391/EEC "Measures to encourage improvements in the safety and health
of workers at work".
◼ EC Directive 89/655/EEC "Minimum safety and health requirements for the use of work
equipment by workers at work".
◼ EC Directive 92/58/EEC "Minimum requirements for the provision of safety and/or health
signs at work".

In particular, note the following in addition:

◼ Machine/system-specific safety regulations by the operator.
◼ Safety instructions in the suppliers' operational documentation.

Basic safety instructions with information on residual hazards are structured according
to target groups and can be found for:
◼ All persons in this chapter.
◼ Storage and transport personnel in this chapter and in the Section 3.4.
◼ Assembly personnel in this chapter and in Chapter 4
<ERECTION/ADJUSTMENT/DISMANTLING>.
◼ Crane operators in the Safety section in Chapter 5 <OPERATION AND CONTROL>.
◼ Dismounting personnel in the Safety section in Chapter 4
<ERECTION/ADJUSTMENT/DISMANTLING>.
◼ Maintenance personnel in the Safety section in Chapter 6 <MAINTENANCE AND
INSPECTION>.

Dangers on the crane

The operating manual is an essential part of the crane for safe and efficient operation, therefore:
◼ observe the operating instructions;
◼ keep operating instructions available on the crane;
◼ forward the operating instructions to all subsequent users.

An employee is an authorized person if it is instructed by the employer and informed

about the dangers/hazards.

All persons on or near the crane are exposed to the following hazards:
◼ DANGER! Incorrect lifting accessories.

46
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Loads fall down if inadequate/defective lifting accessories break.

Death, personal injury, or property damage are the result.
► Close off and monitor hazardous areas.
► NEVER work under suspended loads.
► NEVER swing loads over people. In exceptional cases, give a warning signal to clear the area.
► Only use sufficient, intact, and tested lifting accessories.
► Secure the load so that it neither slips nor tips. If the balance point shifts, overloaded lifting
accessories tear.
► Regularly check and maintain ropes and lifting accessories.

◼ DANGER! Incorrect slinging

Loads crash if you sling them at unsuitable positions and a part break.
Death, personal injury, or property damage are the result.
► Only attach loads to the intended and marked slinging points.
► Secure inserted outriggers.
► Close off and monitor hazardous areas.
► NEVER work under suspended loads.
► NEVER swing loads over people. In exceptional cases, give a warning signal to clear the area.

◼ DANGER! Loose parts of overhead loads

Loads crash when parts detach and fall off.
Death, personal injury, or property damage are the result.
► Secure loads so that they neither slip nor tip.
► NEVER deposit loose parts on the load! Remove loose parts, transport, or secure them
separately if necessary.
► Close off and monitor hazardous areas.
► NEVER work under suspended loads.
► NEVER swing loads over people. In exceptional cases, give a warning signal to clear the area.

◼ DANGER! Overhead loads

Suspended loads moving in a controlled or uncontrolled way strike persons or objects.
Death, personal injury, or property damage are the result.
► Close off and monitor hazardous areas.
► NEVER work under suspended loads.
► NEVER swing loads over people. In exceptional cases, give a warning signal to clear the area.
► Loads must not swing in order to keep the danger area small. Always use the guide rope.
► Wear safety helmet and safety shoes!

◼ DANGER! Overhead loads

Suspended loads can bump or crush people / objects. Slings come loose. Load slips, tips, or
crashes.

47
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Death, personal injury, or property damage are the result.

► Have the danger area cleared before hoisting the load.
► Be aware of the balance point when hoisting the load.
► The crane operator, banksman, and slinger must ensure that you can hoist the load safely.
► Lower the load and have it realigned/newly slung if it is suspended incorrectly.
► Hoist loads gently until the hoisting rope is taut. Jerky hoisting activates the overload protection
and puts excessive stress on the load hook, hoisting rope, and crane.

◼ DANGER! Danger of collision and tipping due to new cranes in the working area!
When you set up other cranes, the working areas may overlap.
There is a danger of collision.
Death, personal injury, or property damage are the result.
► The working areas of all cranes are to be coordinated and limited if necessary.
► Limit the working range.
► Notify site supervisors and service personnel.

Falling objects
◼ DANGER! Falling objects
Objects such as dismounted components, tools, etc., fall due to wind, impact, or movement of
the crane.
Death, personal injury, or property damage are the result.
► Collect tools and assembly materials such as pins and split pins, and stow them properly! Do
not store or transport loose parts on the load!
► Persons without an order to work on the crane are not allowed to enter the construction site!
► Block off the danger area under the crane widely from unauthorized access, or secure it with
warning posts.
► Wear safety helmet and safety shoes!

◼ WARNING! Falling objects

Inadequately fixed advertising boards fall from a great height.
Death, personal injury, or property damage are the result.
◼ Adequately secure advertising boards.
◼ Also check the attachment of the advertising boards during inspections before putting the
crane into service.

High voltage
◼ DANGER! Overhead lines, electrical high voltage
When the crane approaches or touches electrical lines, it is live. If someone leaves or enters it,
it discharges through the body.
Death, personal injury, or property damage are the result.
► Always work with a banksman when working near overhead lines. From the best possible

48
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

vantage.
point, it makes sure you stay within limits, and warns you immediately if you exceed them.
► Move the crane slowly near overhead lines. To prevent the load from swinging: Use
polypropylene guide ropes. Manila or nylon ropes are unsuitable as they absorb moisture and
conduct electrical voltage.
► After contact with the overhead line:
◼ Act prudently and in accordance with your instructions!
◼ Do not leave or enter the crane! Keep a safety distance of at least 5 m, cordon off and secure
the danger area.
◼ Warn outsiders not to approach or touch the crane!
◼ Do not leave or enter the crane until the touched / defective cable has been safely de-
energized!
► The crane driver initiates further measures.

Fig. 2-1 Charging by electromagnetic fields - Ground the crane

◼ WARNING! Radio waves

The crane jib charges itself like an antenna in the electromagnetic field of adjacent radio towers.
If someone leaves or enters it, the voltage discharges through the body.
Death, personal injury, or property damage are the result.
◼ Ground the crane!

49
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Lightning
◼ DANGER! Lightning
Lightning can strike the crane during a thunderstorm. If someone leaves or enters it, the voltage
discharges through the body.
Death, personal injury, or property damage are the result.
► Ground the crane in accordance with applicable legal requirements.
► Observe the local regulations for lightning protection when constructing the foundations.
Check with the local acceptance authorities.
► Do not leave or enter the crane during thunderstorms.
► After a lightning strike, check the crane for damage (power supply, grounding).

Electrical voltage
DANGER! Electrical voltage
Dangers arise in electrical operating areas and on components:
◼ Live parts.
◼ Live parts due to faulty conditions.
◼ Parts under high voltage.
◼ Electrostatic processes and charges.
◼ Thermal radiation, ejection of molten particles, or chemical processes during short circuits
or overload.

Death, personal injury, or property damage are the result.

► Only authorized electricians may work on electrical systems and their parts.
► Before working on electrical equipment/parts:
◼ Comply with legal and local regulations.
◼ Disconnect from power supply and check that no voltage is present.
◼ Secure against restarting.
◼ Cover adjacent live parts.

Danger of falling
◼ DANGER! Falling
If you lose your footing or balance, you will fall. Causes: Misstep in areas without railings, tripping,
wind, inattention, etc.
Death, personal injury, or property damage are the result.
► Unauthorized persons are NOT allowed to ascend the crane or use it.
► Notify the crane operator before entering the crane.

◼ WARNING! Danger of falling

If you lose your footing or balance while ascending/descending, for example on slippery ascents,
due to misstep, stumbling, wind, inattention, etc., you will fall.
Death, personal injury, or property damage are the result.

50
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

► Use the railing!

► Check steps and railings regularly for safety and clean them.

Wind
◼ DANGER! Strong wind, gusts
You can no longer move bulky, large, and light parts in a controlled manner.
Death, personal injury, or property damage are the result.
► DO NOT lift light, large, bulky loads in strong, gusty winds!

Dangers from crushing and drawing in

◼ WARNING! Crushing/drawing in
Danger of crushing and drawing in from unintentional start-up of the drive.
Death, personal injury, or property damage are the result.
► Before starting work, switch off the main crane switch, and secure it against being switched
on again.
► Make sure that all drives are in a free of voltage.
◼ WARNING! Crushing/drawing in
Danger of crushing/traction between gear ring and multi-turn actuator.
Death, personal injury, or property damage are the result.
► Only work on the gear ring when it is at a standstill! Switch off crane without wind release,
secure against restarting: Lock the crane disconnector. Brakes on the slewing gear are closed.
Place a sign at the switch-on point indicating that maintenance is required.
► Keep clothing and hands away from the rotating drive. Wear tight-fitting work clothes and a
hair net if required.
◼ WARNING! Crushing/drawing in
Danger of crushing/pulling in between the hoisting rope and drum on the hoist gear.
Death, personal injury, or property damage are the result.
► Only work on the hoisting rope, brake, and rope drum when the machine is at a standstill.
Switch off crane, secure against restart: Lock the crane disconnector. Put a sign at the switch-
on point indicating that maintenance is required.
► Keep clothing and hands away from the rotating drive. Wear tight-fitting work clothes and a
hair net if required.
◼ WARNING! Crushing/drawing in
Danger of crushing and pulling in between trolley rope and rope drum when the trolley gear is
rotating. Death, personal injury, or property damage are the result.
► Only work on the trolley rope and rope drum when the machine is at a standstill. Switch off
crane, secure against restart: Lock the crane disconnector. Put a sign at the switch-on point
indicating that maintenance is required.
► Keep clothing and hands away from the rotating drive. Wear tight-fitting work clothes and a
hair net if required.

51
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Other hazards
DANGER! Dangerous crane movements
During operation, the crane moves in a dangerous way. The cab protects the crane operator.
Other persons on the crane are at risk.
Death, personal injury, or property damage are the result.
► Unauthorized persons are NOT allowed to ascend the crane!
► Notify the crane operator before allowing authorized persons to ascend or descend!
► The crane operator must interrupt or stop the crane operation to exclude any danger!

Large hook heights

For cranes with large hook heights, the weight of the hoisting rope reduces the maximum load
that can be lifted; for details see Chapter 3 <TECHNICAL DATA OF CRANE AND SITE>.
Liftable load = permissible load - additional weight of the hoisting rope.

Fire hazard
◼ WARNING! Stability is endangered
If flammable or explosive substances ignite on the crane, they will damage the steel structure.
Stability is then no longer guaranteed, and the crane falls over.
Death, personal injury, or property damage are the result.
► Do not store any:

fire-promoting,

combustible, or

explosive
substances in the vicinity of the crane!

NOBODY is allowed to enter or work in hazardous or work areas under the influence of
alcohol, drugs, or mind-expanding substances!

52
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Disposal and environmental protection

Environmental protection.
Recycle environmentally hazardous substances in accordance with the national
regulations of the country of use.

Dispose of operating and auxiliary materials as well as replacement parts safely

and in an environmentally friendly manner.

According to Directive 2002/96/EC on Waste Electrical and Electronic

Equipment (WEEE) of the European Parliament, do not dispose of this
equipment with your normal household waste. Use the appropriate take-back
systems of the municipality or a specialist disposal company with separate
collection for electrical and electronic equipment.

Directive 2002/95/EC on the restriction of the use of certain hazardous

substances in electrical and electronic equipment (RoHS) of the European
Parliament prohibits the introduction onto the European market of new electrical
and electronic equipment containing more than the maximum permitted levels
of lead, cadmium, mercury, hexavalent chromium, fire retardant polybrominated
biphenyl (PBB), and polybrominated diphenyl ether (PDBE).

Dangers during transport

◼ WARNING! Wrong shelves
Transported loads fall or tip if they are placed on uneven or insufficiently stable surfaces.
Death, personal injury, or property damage are the result.
► Only place loads on level and sufficiently stable surfaces.
► Use a suitable base on soft ground.

◼ WARNING! Danger of falling

If you work above body height, you will fall when you lose your footing or balance.
Death, personal injury, or property damage are the result.
► When working above body height, use appropriate safety access aids and working platforms.
► DO NOT use machine parts as climbing aids.

53
SAFETY INSTRUCTION WA7025-12E-138EN-B03

◼ CAUTION! Sharp-edged machine parts

Sharp-edged machine parts cause serious injuries.
► Wear the required personal protective equipment during assembly/dismounting and repair.

Protective gloves Safety shoes or boots

Safety helmet Safety belt

◼ WARNING! Incorrect lifting accessories

Loads fall down if inadequate/defective lifting accessories break.
Death, personal injury, or property damage are the result.
► Close off and monitor hazardous areas.
► NEVER work under suspended loads.
► Do not swing loads over people. If this is exceptionally necessary, give a warning signal to
clear the area.
► Only use intact lifting accessories which are sufficient for the load.
► Secure the load so that it neither slips nor tips. If the balance point shifts, overloaded lifting
accessories tear.
► Check and maintain ropes and lifting accessories regularly.

Dangers during assembly

General
◼ DANGER! Incorrect assembly sequence, assembly interruption, crane falls over.
If the assembly sequence is not observed or is interrupted, you endanger the stability of the crane.
Death, personal injury, or property damage are the result.
► Adhere to the sequence of the individual assembly steps.
► Do not interrupt the assembly in order not to endanger the stability of the crane, for example
in the event of a storm.
► From the step "Removing the concrete counter ballasts" to the step "Dismantling the counter
jib", work must be carried on continuously!
► Place the required central ballast before erecting the tower and mounting the counter jib!

◼ DANGER! Incorrectly loaded crane

An incorrectly loaded crane falls over.
Death, personal injury, or property damage are the result.
► Insert the counter ballasts into the counter jib AFTER assembling the jib.
Exception: Insert the necessary counter ballasts of the intermediate ballasting before jib
assembly.

54
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

◼ DANGER! Strong wind, gusts

Wind speeds above authorized speed endanger the stability of the crane during the assembly!
You can no longer move loads in a controlled manner. These loads are not statically permissible.
Death, personal injury, or property damage are the result.
► Crane assembly is prohibited at these wind speeds!
► As the assembly of a crane takes longer, inform yourself about the wind conditions on site; if
necessary, postpone the work!

◼ DANGER! Larger wind attack areas

Additional advertising boards or other objects increase the area exposed to wind. These
additional forces endanger the stability; the crane can fall over.
Death, personal injury, or property damage are the result.
► Only attach additional signs with the approval of the manufacturer.
► Check the statics.

◼ DANGER! Unsuitable components

Unsuitable base, tower, or connecting elements endanger the stability.
Death, personal injury, or property damage are the result.
► Only use tested base elements, such as foundations, cross frames, cross frame elements, or
undercarriages.
► Holes of the tower elements wear out. Tower elements are arranged according to the accuracy
of fit of the holes. Use elements with larger deviations in the upper part of the tower.
Permissible Deviations: Chapter 3 <TECHNICAL DATA OF CRANE AND SITE>.

◼ WARNING! Wrong shelves.

Loads will fall or tip if you place them on uneven/unstable surfaces.
Death, personal injury, or property damage are the result.
► Only place loads on level and sufficiently stable surfaces.
► Use a suitable base on soft ground.

◼ CAUTION! Jib bends due to attachment to top boom.

The jib bends to the point of being unusable.
► Always suspend the jib only by the bottom boom, and lift it horizontally from the assembling
trestles.

◼ WARNING! Key switch.

Key switches override safety settings. Functions which are not permitted in regular operation are
possible.
Death, personal injury, or property damage are the result.
► Make keys available only to authorized, trained personnel who know and control the risks.

55
SAFETY INSTRUCTION WA7025-12E-138EN-B03

◼ WARNING! ASSEMBLY MODE

In assembly mode, limit switch and overload limitations are not active. Too heavy a load, and
movements with inadmissible radii will cause the crane to fall over.
Death, personal injury, or property damage are the result.
► Use specially trained personnel who are aware of the particular hazards!
► Observe the load table for the rope line variant and hoist gear!
► DO NOT lift loads which exceed the crane's load capacity!
► Only approach permissible radii!

◼ DANGER! Incorrect calibration, crane falls over

An incorrectly calibrated load measuring axis endangers the crane stability. This also produces
incorrect monitoring of the maximum load and load torque. You can lift loads that are too heavy
- the crane falls over.
Death, personal injury, or property damage are the result.
► Enter the known test load and the correction value carefully and without errors!
► To determine an unknown test load, use a calibrated crane scale between the load hook and
the test load.

◼ CAUTION! Driving positions not limited.

Do not limit either trolley or load hook travel positions in assembly mode; they will collide with the
trolley or ground.
If the trolley and load hook are defective, do NOT operate the crane!
► Do not move the load hook against the trolley nor on the ground.
► DO NOT move the trolley to the inner and outer mechanical limits.

◼ DANGER! Activating safety devices.

Activate safety devices after making adjustments. Otherwise, neither the limit switches nor the
overload limitations are active. Movements into impermissible areas will cause the crane to fall
over, or lead to collisions with objects.
Death, personal injury, or property damage are the result.
The crane is not ready for operation until:
► PROGRAMMING and/or ASSEMBLY OPERATION are switched off in the touch panel.
► all safety devices are adjusted and checked;
► the slewing gear brakes are ready for operation (brakes unlocked).

Foundations
◼ DANGER! Improper foundations, crane falls over
Improper foundations endanger the crane stability.
Death, personal injury, or property damage are the result.
► The crane operator's structural engineer determines the foundation loading and its calculation!
► The building contractor makes the foundation.

56
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

► Wait for curing time before putting load on the foundation!

► Keep a safety distance of 2 - 3 m between the crane and surrounding objects!
► The foundation dimensions are determined by the permissible subsoil pressures, the type of
subsoil at the construction site, and the foundation load. See Section 3.7!
► Check the horizontal alignment before erecting the tower. It may only deviate by max. 1 ‰,
i.e. on a measured length of 1 meter, the permissible deviation is 1 mm!

◼ DANGER! Electrical voltage

Danger from:
► Voltage differences between conductive parts.
► Red-hot compensating currents.
► Lightning.
Death, personal injury, or property damage are the result.
► Comply with the local regulations for lightning protection when making foundations.
Check them with the local acceptance authorities.
► Ground the foundation and establish equipotential bonding.

◼ DANGER! Improper foundation, crane falls over

Improper foundation anchors endanger the crane stability.
Death, personal injury, or property damage are the result.
► Check the foundation anchors before erecting the tower.
► Grout foundation anchors until the top edges of the concrete and the foundation anchor plate
are in a line. Before, during, and after filling the concrete, ensure that neither foundation
anchors nor reinforcement slip.
► For the calculation of the foundation anchors, we considered concrete with strength grade C
25/30 as per EN 206-1/ DIN 1045-2 for the foundations.
► The tower attachment points may deviate by a maximum of 1 ‰, i.e. for a measured length of
1 meter, the permissible deviation is 1 mm.

◼ DANGER! Improper rail system, crane falls over

Improper rail systems endanger the crane stability.
Death, personal injury, or property damage are the result.
► Execution and calculation are determined by the crane operator's structural engineer!
► Keep a safety distance of 2 - 3 m between the crane and surrounding objects!
► The foundation dimensions are determined by the permissible subsoil pressures, the type of
subsoil at the construction site, and the foundation load. See Section 3.7!
► Lay rails at excavation pits in such a way that the pit slope does not collapse.
► Check the horizontal alignment of the rail system before erecting the tower.

57
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Checking tower and connecting elements

◼ DANGER! Hole tolerances in components exceeded, crane falls over
Exceeded hole tolerances cause the load limits of the components to be exceeded.
Death, personal injury, or property damage are the result.
► Holes in tower elements exceeding the specified maximum hole dimensions must NOT be
used any more to construct the tower!

Equipment-specific
Observe the special instructions depending on the components used.
◼ DANGER! Improper climbing equipment, crane falls over
Improperly installed climbing equipment endangers the stability.
Death, personal injury, or property damage are the result.
► Information about climbing equipment: see separate climbing equipment description!
► Install the climbing equipment parallel to the building; the tower elements must also be
installed parallel to the building!
► For climbing cranes, pay attention to the position of the arresting hooks/climbing plates!

◼ DANGER! Lateral anti-twist devices missing, crane falls over

If there are no lateral anti-twist devices, the stability of the crane is at risk. The influence by lateral
forces shifts the cross frame. Without lateral securing, it slips off the individual foundations – the
crane falls over.
Death, personal injury, or property damage are the result.
► Observe the assembly instructions!
► At all corners, secure the cross frame on three sides each so that it does not move!

Assembly with external climbing equipment

◼ WARNING! Climbing equipment mounted to the tower during operation
If the climbing equipment remains mounted to the top of the tower during operation, it endangers
the crane stability.
Death, personal injury, or property damage are the result.
► The climbing equipment is only an assembly device. Do NOT leave it on the top of the tower
during crane operation! After completion of the assembly, dismount the climbing equipment.
► Ask the manufacturer for static data for towers with climbing equipment.

Pre-assembling the counter jib and assembly

◼ DANGER! Missing stay rods
Without stay rods, the counter jib will crash down.
Death, personal injury, or property damage are the result.
► Always assemble the counter jib with guy rods.

58
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

◼ DANGER! Incorrect assembly sequence, crane falls over

If you do not adhere to the assembly sequence, you endanger the stability.
Death, personal injury, or property damage are the result.
► Adhere to the sequence of the individual assembly steps!
► Place the required central ballast before erecting the tower and mounting the counter jib!

◼ DANGER! Interrupted assembly, crane falls over

If you interrupt the assembly, you endanger the stability of the crane.
Death, personal injury, or property damage are the result.
► Carry out the assembly continuously from the work step "Assembling the counter jib" until
completion of the work step "Inserting concrete counter ballasts"!

Pre-assembling the counter jib and assembly

◼ CAUTION! Loose trolley ropes.
Loose trolley ropes activate the rope failure lock or collide with parts of the jib.
The jib may be damaged.
If the trolley and load hook are defective, do NOT operate the crane!
► The long trolley rope must always be sufficiently taut:
Check the tension regularly, retighten if necessary.

Installing the hoisting rope

◼ CAUTION! Risk of collision.
Do not limit either trolley or load hook travel positions in assembly mode; they will collide with the
trolley or ground.
If the trolley and load hook are defective, do NOT operate the crane!
► Do not move the load hook within the radius or on the ground.
► DO NOT move the trolley to the inner and outer mechanical limits.

◼ DANGER! RESET key switch

Use the RESET key switch to bypass safety functions. Functions which inadmissible in regular
operation are now possible.
Death, personal injury, or property damage are the result.
► Only authorized and trained personnel may operate the RESET key switch as they are aware
of the risks.

◼ CAUTION! Slack rope.

Keep the load hook in the air when lowering; otherwise the hoisting rope will slacken and not
wind up accurately.
This causes damage to the hoisting rope.
► Carefully lower the load hook and move it to the ground!

59
SAFETY INSTRUCTION WA7025-12E-138EN-B03

2.6 Safety signaling

Explanation
Safety and health−hazard signaling corresponds to determined object, activity or
situation−related signals providing an indication or provision relative to safety or health matters.
That signaling is materialized, according to circumstances, by a panel, a color, an audio or
luminous signal.
Safety signaling can be broken down into 5 categories, each identified by a color code.
◼ Prohibition (red)
◼ Warning (yellow or orange−hue yellow)
◼ Mandatory (blue)
◼ Rescue and first−aid (green)
◼ Fire−fighting material or equipment (red)

Terminology
◼ Panel: signal providing a given indication via the combining of a geometrical shape and
certain colors with a symbol or a pictogram.
➢ Prohibition panel: prohibits behavior liable to generate running of a risk or provoking danger.
➢ Warning panel: warns of a risk or of danger.
➢ Mandatory panel: prescribes a given behavior to be adopted.
➢ Rescue and first−aid panel: provides indications relative to emergency exits or to rescue
and first−aid resources available.
➢ Fire−fighting panel: provides indications relative to the location of fire−fighting resources and
evacuation in the case of fire.
◼ Additional panel: panel used conjointly with another panel and providing complementary
indications.
◼ Symbol or pictogram: image describing a situation or prescribing a given behavior to be
adopted, and which is employed on a panel or a luminous surface.
➢ Luminous signal: signal emitted by a device composed of transparent or translucent material,
internally or back−lighted, in a way it stands out itself as a luminous surface.
➢ Audio signal: a coded audible signal emitted and broadcast by an ad hoc device, without the
use of a human or synthesized voice.

60
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Signaling panels
The signaling panels below are general signals for all the crane towers. The specific
panels on your tower crane may be less or more according to your special configuration.

Drawing Instruction

WARNING: Live parts!

Electrical installation, connection work and
maintenance must be done only by
authorized, properly qualified personnel.

Don’t stand under the working radius.

Prohibit climbing!

Danger of rolling!

Danger of falling down!

Wear and use a safety harness!

Emergent stop

61
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Drawing Instruction

Carefully read this handbook before

handling the machine!

The tower crane needs to be able to slew

freely when it is out of service

Very hot, do not touch!

Danger of crushing!

Insert pins while the crane climbing!

62
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Drawing Instruction

Keep watching!

WARNING: floating loads!

Wear safety helmet!

Check ropes

Lubricate!

Check metal structures!

Check brakes for clearance!

Keep safety devices workable!

63
SAFETY INSTRUCTION WA7025-12E-138EN-B03

Drawing Instruction

Adjust the brakes

Adjust the height limiter!

High strength connection bolt of M36

High strength connection bolt of M30

Maximum load on maintenance cage

Always close the hatches!

Prohibit standing!

Caution!

64
 WA7025-12E-138EN-B03 SAFETY INSTRUCTION

Drawing Instruction

Tie safety belt!

Audio and luminous signals

A. Audio signals
The following dangers are signaled by automatic activation of an audio alarm:
◼ Crane start−up: short tone.
◼ Activation of MSWL (maximum safe working load) cut−out or moment cut−out: continuous
tone.
◼ Crane traveling mode: continuous dual tone during the complete duration of movement.
◼ Specific danger is signaled by voluntary action on the audio alarm in accordance with code
defined by local regulations or by the crane manager, such as for example: moving of loads
above persons, specific situations.
◼ Acquire knowledge of the tones and duration corresponding to each signal.

B. Luminous signals
According to the instructions or regulations on crane utilization site, luminous signals may be
used to indicate specific danger:
◼ Operating wind speed pre−alarm (adjustable): flashing orange light.
◼ Pre−alarm limit: 90% of MSWL or MSWL moment:
➢ GMA: flashing orange light
➢ GME: orange light in control station
◼ Working area limiter not operating or neutralized: flashing red light.

C. Associated audio and luminous signals

According to the instructions or regulations on crane utilization site, audio signals associated to
luminous signals may be used to indicate specific danger:
◼ Maximum operating wind speed (adjustable): 2−tone signal with flashing orange and red
lights.
◼ (GMA) Pre−alarm limit: 95% of MSWL or MSWL moment: continuous−tone signal with
flashing orange light.
◼ (GMA) Activation of the MSWL limiter or MSWL moment limiter: continuous signal plus
2−tone signal with flashing orange and red lights.

65
SAFETY INSTRUCTION WA7025-12E-138EN-B03

D. Location of safety signaling:

Positioning on the crane and references of luminous or audio panels and devices are provided
in the Chapter 7 < SPARE PARTS >.

Safety controls
The control console and the maintenance areas at winch proximity (in the case where the control
console is not portable) are equipped with a mechanically−lockable red emergency stop button.

The storm wind reference speeds are determined according to the FEM 1.004 / Edition 07/2000
standard.

Pressing one of those buttons generates immediate interruption of all

movements.

The emergency stop button must be used only in the case of danger and
not for interrupting movements.

2.7 Storm wind speed-out of service

General Notes
The storm wind reference speeds are determined according to the FEM 1.004 / Edition 07/2000
standard.

Speed table

Height Wind speed Dynamic pressure

Height 0−20 m above the ground 130 km/h (36 m/s) 800N/𝑚2

Height 20−100 m above the ground 150 km/h (42 m/s) 1100 N/𝑚2

Height higher than 100 m above the ground 165 km/h (46 m/s) 1300 N/𝑚2

66
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

3 TECHNICAL DATA OF CRANE AND SITE

3.1 Foreword
The crane and site data group the assembly of technical information and characteristics
together which are necessary to mount and use the crane in full safety and especially to:
◼ Prepare the operating site (for ex: mains supply, access),
◼ Calculate and carry out the crane ground supports,
◼ Carry out the ballast of the crane,
◼ Choose the handling equipment which is necessary to carry out the loading and unloading
of the crane.

Certain data given in this part correspond to the maximum characteristics of the
crane type. For an appropriate use, take into accounting the crane configuration
must as defined at the time of order.

67
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

3.2 Technical characteristics

Load curves
The following load curves are specific to the WA7025-12E in 2/4-fall. The tables are separated for different jib length.

Load curves for 70~57.5m jib at 2-fall

10~35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5 70.0
6.00 5.67 5.24 4.86 4.52 4.22 3.95 3.71 3.49 3.29 3.10 2.93 2.78 2.63 2.50

10~35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5
6.00 5.97 5.52 5.12 4.77 4.46 4.18 3.92 3.69 3.48 3.29 3.11 2.95 2.80

10~ 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0
6.00 5.77 5.35 4.99 4.66 4.37 4.11 3.87 3.65 3.45 3.27 3.10

10~ 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5
6.00 5.97 5.55 5.17 4.84 4.54 4.27 4.02 3.79 3.59 3.40

10~40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0

6.00 5.71 5.32 4.98 4.67 4.39 4.14 3.91 3.70

10~40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5

6.00 5.83 5.44 5.09 4.77 4.49 4.23 4.00

68
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Load curves for 55~45m jib at 2-fall

10~42.5 45.0 47.5 50.0 52.5 55.0

6.00 5.64 5.28 4.96 4.66 4.40

10~42.5 45.0 47.5 50.0 52.5

6.00 5.80 5.43 5.10 4.80

10~42.5 45.0 47.5 50.0

6.00 5.91 5.54 5.20

10~45 47.5

6.00 5.70

10~45

6.00

69
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Load curves for 70~55m jib at 4-fall

10~17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5 70.0

12.00 11.78 10.27 9.07 8.10 7.30 6.62 6.05 5.55 5.12 4.74 4.41 4.11 3.84 3.59 3.37 3.17 2.99 2.82 2.66 2.52 2.39

10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0 67.5

12.00 10.78 9.53 8.52 7.68 6.98 6.38 5.86 5.41 5.01 4.66 4.34 4.06 3.81 3.58 3.37 3.18 3.00 2.84 2.69

10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5 65.0

12.00 11.23 9.93 8.88 8.01 7.28 6.66 6.12 5.65 5.24 4.88 4.55 4.26 3.99 3.76 3.54 3.34 3.15 2.99

10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0 62.5

12.00 11.61 10.27 9.19 8.29 7.54 6.90 6.34 5.86 5.43 5.06 4.72 4.42 4.15 3.90 3.68 3.47 3.29

10~20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5 60.0

12.00 11.91 10.54 9.44 8.52 7.75 7.09 6.52 6.03 5.59 5.21 4.87 4.56 4.28 4.03 3.80 3.59

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0 57.5

12.00 10.76 9.63 8.69 7.91 7.24 6.66 6.16 5.72 5.32 4.97 4.66 4.38 4.12 3.89

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5 55.0

12.00 11.13 9.97 9.00 8.19 7.50 6.91 6.39 5.93 5.53 5.17 4.84 4.55 4.29

70
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Load curves for 52.5~37.5m jib at 4-fall

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0 52.5

12.00 11.42 10.23 9.24 8.41 7.71 7.10 6.57 6.10 5.69 5.32 4.99 4.69

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5 50.0

12.00 11.63 10.42 9.41 8.57 7.85 7.23 6.69 6.22 5.80 5.42 5.09

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0 47.5

12.00 11.95 10.70 9.68 8.81 8.08 7.44 6.89 6.40 5.97 5.59

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0

12.00 11.97 10.73 9.70 8.83 8.10 7.46 6.91 6.42 5.99

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5

12.00 11.92 10.68 9.65 8.79 8.06 7.42 6.87 6.39

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0

12.00 11.78 10.55 9.54 8.69 7.96 7.33 6.79

10~22.5 25.0 27.5 30.0 32.5 35.0 37.5

12.00 11.71 10.49 9.48 8.63 7.91 7.29

71
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Load curves for 35~30m jib at 4-fall

10~22.5 25.0 27.5 30.0 32.5 35.0

12.00 11.53 10.33 9.34 8.50 7.79

10~22.5 25.0 27.5 30.0 32.5

12.00 11.39 10.20 9.21 8.39

10~22.5 25.0 27.5 30.0

12.00 11.23 10.06 9.09

72
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Characteristics of the crane

The overall characteristics
Tower crane working
A4
grade
Hoisting Slewing Trolleying
Mechanisms working mechanism mechanism mechanism
grade
M4 M5 M4

Rated hoisting moment

2500
(kN·m)
Maximum hoisting
3000
moment (kN·m)

Free-standing
With
Maximum tower height Stationary Stationary Travelling attachments
(m) outrigger chassis chassis

60 60.5 61.5 300

Minimum Maximum
Working radius (m)
2.8 70

Jib length (m) 70 67.5 65 62.5 60 57.5 55 52.5 50

Counter jib length (m) 23.5 23.5 22.3 21.8 21.8 21.8 21.8 21.0 20.5

Jib length (m) 47.5 45 42.5 40 37.5 35 32.5 30 /

Counter jib length (m) 19.3 19.3 18.8 17.5 15.0 14.5 14.5 13.3 /

Maximum load (t) 12

Power Supply ~380V(±10%) / 50Hz

0~95
Hoisting speed (m/min)
6 (Minimum stably descending speed)

Slewing speed (r/min) 0~0.8

Trolley speed (m/min) 0~75

Travelling speed (m/min) 0~25

Total Power (kW)

(without climbing 65.5
mechanism)

73
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Hoisting mechanism characteristics

Type H45FC30-600C

Maximum traction (N) 35000

Specification ZLHHK-14-1960
Rope
Maximum line speed (m/min) 190

Rope roll layers 6/7

Drum
Maximum capacity (m) 605(6 layers)/725(7 layers)

Type YZPFME225L-4-Z

Motor Power (kW) 45

Rotating speed (r/min) 1473

Type ZTQ130W40-301
Reducer
Reduction ratio 39.5

Coupling Type GR55-120-12T-C

Minimum stably descending linear speed at
≤10
rated load (m/min)
Minimum stably descending speed rotating
≤125
speed at rated load (r/min)

Slewing mechanism characteristics

S75CA-130LB12/14A
Type
S75CN-130LB12/14A

YTRVF132M2-4F1/B/BM1
Type
Motor YTRVF132M2-4F2/B/BM1

Power /kW 7.5×2

Type XX5-130.195LB-12/14

Reduction ratio 195

Reducer
Teeth [z] 12
Pinion
Module [m] 10

74
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Trolley mechanism characteristics

Type T55FC70-b/ T55FC70-b(D)

Maximum traction /N 12100

Trolley travelling range /m 70

Specification 6x19-9.3-1700-Ⅱ-sZ

Rope Reference weight/kg·m-1 0.305

Maximum line speed m/min 50

Bottom diameter /mm Ф520

Drum
Rotate speed r/min 31.7

Type YVFE132S-4B5(HJ)

Motor Power /kW 5.5

Rotate speed r/min 1428

Type XX2-15.43

Reducer Ratio 43

Equivalent ratio 44

75
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Climbing mechanism
Type BZ-11-31.5F

Flux (l·min) 19
Pump station
Working stress (MPa) 31.5

Oil tank capacity (L) 110

Type YE2-160M-4V1
Motor
Power (kW) 11

Type YG180/125-2160/1640-31.5

Cylinder diameter (mm) 180

Rod diameter (mm) 125

Climbing
hydraulic Installing distance (mm) 2160
cylinder
Travelling distance (mm) 1640

Maximum hoisting force (t) 80.5

Hoisting speed (m/min) 0.69

Travelling mechanism
Travelling speed /m·min-1 0~25

Travelling wheel diameter /mm 400

Type YTXZ112M2-2B

Motor Power /kW 5.2

Bake moment /N·m 40

Type PX25 (or C2738980)

Reducer
Reduction ratio 140.2

76
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

3.3 Mast composition

General notes
Free standing cranes
The mast compositions are given for free standing heights IN SERVICE and OUT OF SERVICE
and for the static and rail−mounted versions indicated in the data sheet.
The assembling order is that given in paragraph for reasons of strength. The given mast
composition presents the optimum crane tower as concerns its composition. It is forbidden to
use mast section of low strength. But it is possible to fit mast sections of higher strength. These
documents deal with the optimum composition of the crane tower which is not allowed to be
lower. But it is possible to fit stronger sections.

Unusual cases

The very high cranes may be subjected to a downgrading of the load.

The standard mast composition for hook heights (HUH) higher than 100 m
are defined with wind gusts up to 165km/h. It is on the user’s responsibility
to make sure that this limiting value is not exceeded for very high cranes
(hook height over 200m, for ex.). Otherwise, please contact us
compulsorily.

Reducing the free-standing height due to the telescopic cage

If, for reasons of later increase in height, the telescopic cage is to be left at the top of the masts,
it is necessary to reduce the free-standing height” IN SERVICE” and” OUT OF SERVICE” by
removing X mast sections. Please consult us COMPULSORILY.

With rigid anchorages to the building

The mast compositions and the reactions on the anchorages are given in the chapter specific to
this operation.

With climbing inside the building

The mast compositions and the stresses applied on the frames are given in the chapter specific
to this operation.

With anchorage by guy ropes

Please consult us compulsorily.

77
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Mast composition
Outrigger stationary tower crane
H.U.H Rung ladder Incline ladder
(m) L68G23 L68A4 L68G23-C L68A1A
27 1 6 1 6
30 1 7 1 7
33 1 8 1 8
36 1 9 1 9
39 1 10 1 10
42 1 11 1 11
45 1 12 1 12
48 1 13 1 13
51 1 14 1 14
54 1 15 1 15
57 1 16 1 16
60 1 17 1 17

Stationary chassis tower crane

H.U.H Rung ladder Incline ladder
(m) L68B7A L68A4 L68B7A-C L68A1A
27.5 1 6 1 6
30.5 1 7 1 7
33.5 1 8 1 8
36.5 1 9 1 9
39.5 1 10 1 10
42.5 1 11 1 11
45.5 1 12 1 12
48.5 1 13 1 13
51.5 1 14 1 14
54.5 1 15 1 15
57.5 1 16 1 16
60.5 1 17 1 17

78
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Travelling chassis tower crane

H.U.H Rung ladder Incline ladder
(m) L68B7A L68A4 L68B7A-C L68A1A
28.5 1 6 1 6
31.5 1 7 1 7
34.5 1 8 1 8
37.5 1 9 1 9
40.5 1 10 1 10
43.5 1 11 1 11
46.5 1 12 1 12
49.5 1 13 1 13
52.5 1 14 1 14
55.5 1 15 1 15
58.5 1 16 1 16
61.5 1 17 1 17

When assembling tower section, please strictly follow the operation instruction.
Tower section L68A1A, L68A4, L68B7A and L68B7A-C use inner assemble
method.

79
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

3.4 Dimensions and weights of parts for transportation

Matters need attentions of transportation
The components of tower crane have been taken apart into many delivery units in order to
facilitate the packing and adapting to the means of transportation.
1) All components must be well securely fixed during the means of transportation.
2) Light delivery units must be put on the heavier ones.
3) In order to prevent damage to the painted surface, the cushions or wooden segregation
boards should be set between the delivery sets.
4) It must be ensured that no parts of tower crane are in direct contact with the ground when
unloading, so as to prevent sand and oil etc., into the holes of the structure.
5) Do not use inappropriate means of transportation to move the parts of tower crane, such as
bulldozers or elevators. The weight and dimension of all parts of ZOOMLION tower crane
are described in detail in later chapters.
6) Before transport the tower crane, to make sure the safe transportation of all the auxiliary
equipment.
7) Check whether the transportation ties are tight or not.
8) Check the strapping of cargos for transportation.
9) When the carrier vehicle drives on the public streets, please obey the relevant laws.
10) When the carrier vehicle passes the underground tunnel, bridge and tunnel, please pay
attention to have enough space.

80
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Slewing parts
Overview

81
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Dimensions and weights of the slewing parts

The weights of the winches or of assemblies comprising winches are indicated without ropes.
Rope weight:
Part Sketch / Designation L(m) B(m) H(m) G(kg) Qty

Ⅰ 11.0 1.27 2.49 3764 1

Front counter-jib section

Ⅰ 8.08 1.45 0.56 1454 1

Rear counter-jib section

Ⅰ 2.03 0.40 2.44 260 1

Derrick

Ⅱ 1.54 2.03 1.13 2860 1

Hoisting mechanism

Ⅲ 2.08 1.30 2.16 480 1

Cab

Ⅲ 2.00 2.40 2.26 4600 1

Slewing unit

0.42 0.42 1.48 351 1

Ⅲ
0.42 0.42 1.33 340 1
Slewing mechanism

82
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Part Sketch / Designation L(m) B(m) H(m) G(kg) Qty

1.31 0.73 0.61 308

Ⅳ 1

1.16 0.73 0.60 291

Trolley mechanism

Ⅳ 10.32 1.15 2.55 3146 1

Jib section Ⅰ

Ⅳ 10.33 1.49 2.46 2436 1

Jib section Ⅱ

Ⅳ 10.31 1.49 2.42 1702 1

Jib section Ⅲ

Ⅳ 10.20 1.15 2.35 1384 1

Jib section Ⅳ

Ⅳ 2.69 1.15 1.87 352 1

Jib section Ⅳ

Ⅳ 10.17 1.15 1.87 1002 1

Jib section Ⅵ

Ⅳ 5.16 1.15 1.85 406 1

Jib section Ⅵ

Ⅳ 2.66 1.15 1.83 226 1

Jib section Ⅵ

83
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Part Sketch / Designation L(m) B(m) H(m) G(kg) Qty

Ⅳ 10.15 1.15 1.83 574 1

Jib section Ⅷ

Ⅳ 0.87 1.15 2.06 106 1

Jib end

Ⅴ 1.07 0.23 1.81 529 1

Hook

Ⅵ 2.10 1.39 1.04 385 1

Trolley
⭐Tolerance on the weight: ±5%.

84
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Mast parts
Overview

85
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Dimensions and weights of the mast parts

Part Code Sketch / Designation L(m) B(m) H(m) G(kg) Qty

Ⅰ L68C3B 2.61 2.52 2.26 1630 1

Transition section

WA7527-
Ⅰ 7.20 2.54 2.78 3966 1
20D.11

Climbing equipment

TCT6527-
Ⅰ 2.90 0.40 1.93 920 1
16E.12A
Climbing mechanism

Ⅰ BZ-11-31.5F 1.00 0.72 0.45 240 1

Pump station

Ⅱ L68A4 2.10 2.10 3.27 1610 17

Ⅱ L68B7A 2.10 2.10 3.27 1800 1

Ⅱ L68A1A 2.10 2.10 3.27 1708 17

Ⅱ L68B7A-C Tower section 2.10 2.10 3.27 1900 1

L68G23 7.77 2.10 2.10 4200 1

Ⅱ
L68G23-C 7.77 2.10 2.10 4268 1
Bast mast section

⭐Tolerance on the weight: ±5%.

86
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Base parts
Overview

87
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Dimensions and weights of the base parts

Part Sketch / Designation L (m) B (m) H (m) G (kg) Qty

Ⅰ 1.19 0.55 0.55 0.23 4

Stationary outrigger

Ⅱ 8.94 0.90 1.38 2190 1

Whole beam

Ⅱ 4.33 0.42 1.27 1060 2

Half beam

Ⅱ 5.19 0.29 0.28 420 4

Strut

Ⅱ 0.85 2.20 2.20 750 1

Cable

Ⅱ 1.25 1.35 0.90 820 2

Powered wheel bogie

Ⅱ 1.25 0.60 0.90 680 2

Idler wheel bogie

⭐Tolerance on the weight: ±5%.

88
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

3.5 Auxiliary lifting equipment

General notes
The minimum characteristics of the auxiliary lifting equipment are determined by:
◼ The hoisting height of the jib
◼ The weight of the jib
◼ A minimum radius of 10 m from the slewing axis of the auxiliary of the auxiliary lifting equipment.

Hook height
The hook height of height of the auxiliary lifting equipment (H1) is equal to the hook height (H2)
of the crane to be erected plus X m depending on the packages.
The H2 height is given with respect to the ground support level of the crane.

If the auxiliary lifting equipment does not work at the same level as the
erection area of the crane, or due to special site conditions, adjust the
height and the radius to determine correctly the characteristics of the
auxiliary lifting equipment.

H1 must not be obtained in the upper limit switch position of the auxiliary lifting equipment.

89
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Erection by means of a mobile crane

The crane is completely erected to its free-standing height by means of the mobile of the mobile
crane.

Lifting height H (m)

Weight
No. Designation Outrigger Stationary Travelling
(t)
stationary type chassis type chassis type

1 Powered/idler wheel bogie 0.9 - - 1.2

2 Whole beam 2.2 - 0.9 1.7
3 Half beam 1.1×2 - 0.9 1.7
4 Base tower section 4.1 - 5.4 6.3
5 Chassis tie bar 0.2×4 - 0.9 1.7
6 Strut 0.4×4 - 5.4 6.2
7 Central ballast YZ3900 3.9×4 - 1 1.8
8 Central ballast YZ4500 4.5×20 - 4.1 4.9
9 Base tower section 4.2 8.5 - -
Climbing unit assembly
(including climbing equipment,
10 transition section, 2 tower sections, 11.0 20.0 16.9 17.8
climbing hydraulic cylinder, pump
station)
Slewing unit assembly
(including turntable, slewing
11 6.52 22.9 19.8 20.7
mechanism, slewing ring, slewing
support, cabin, electric control cabinet)
12 Front counter-jib section 3.76 22.9 19.8 20.7
Rear counter-jib section
13 (including hoisting mechanism, 6.0 22.9 19.8 20.7
platforms, railings, etc.)
14 The first counter ballast 3.0 25.9 22.8 23.7

90
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Lifting height H (m)

Weight
No. Designation Outrigger Stationary Travelling
(t)
stationary type chassis type chassis type

70m 12.3
67.5m 12.1
65m 11.9
62.5m 11.7
60m 11.7
57.5m 11.5
55m 11.3

Jib assembly 52.5m 11.1

15 (including trolley, trolley 50m 10.8 22.9 19.8 20.7
mechanism, etc.) 47.5m 10.5
45m 10.3
42.5m 10.1
40m 9.8
37.5m 8.7
35m 8.4
32.5m 8.3
30m 8.0
70m 20.5
67.5m 20.5
65m 19.3
62.5m 18.8
60m 18.8
57.5m 18.8
55m 18.8
52.5m 18.0
16 The rest counter ballasts 50m 17.5 25.9 22.8 23.7
47.5m 16.3
45m 16.3
42.5m 15.8
40m 14.5
37.5m 12.0
35m 11.5
32.5m 11.5
30m 10.3

91
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Erection by climbing
A. Mounting of the telescopic cage using the auxiliary lifting equipment
The crane is erected by means of the auxiliary lifting equipment at low height. Then the telescopic
cage is fitted onto the mast from above before mounting the slewing crane part. The free-standing
height is reached by climbing of 5.7m mast sections with lugs.
B. Fitting the telescopic cage by means of the crane
The crane is erected by means of the auxiliary lifting at low height.

Add at least one additional mast section by means of the auxiliary lifting
equipment so that the telescopic cage can be fitted by means of the
crane.

Then the telescopic cage is fitted into the mast from the side by means of the crane. The free-
standing height is reached by climbing 5.7m mast sections with lugs. Adjust the characteristic of
the mobile crane height accordingly.

92
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

3.6 Data sheet

Hoisting rope

DATA SHEET – HOISTING ROPE

Rope identification 1090101550 (ZLHHK-14-1960)
Maximum Load 35kN
Minimum breaking load 169kN
Construction 24Wx7
Number of external wires 7
Core： Steel core
Rope diameter 14mm
Strength of wire 1960MPa
Stranding:
sZ(Right-hand regular lay) sZ
zZ(Right-hand langs lay)
Weight per meter 1.18 kg/m

93
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Trolley rope

DATA SHEET – TROLLEY ROPE

Rope identification 1090100080 (6×19-9.3-1700-Ⅱ-sZ)
Maximum load 12.1kN
Minimum breaking load 46.495kN
Construction 6×19
Number of external wires 6
Core： Steel
Rope diameter 9.3
Strength of wire 1700MPa
Stranding:
sZ(Right-hand regular lay) sZ
zZ(Right-hand langs lay)
Weight per meter 0.3045

Hoisting rope is configured as rotary resistance rope. In addition, the following

requirements must be met: (D is the theoretical diameter of the rope)

◼ The minimum breaking tension of the hoisting rope is not less than 169kN, and the trolley
rope minimum breaking tension of the variable amplitude rope is not less 46.495KN;
◼ For the hoisting rope and the trolley rope, the diameter of any section is between 1.02d
and 1.04d. The noncircular error is within 0.03d.
◼ Anti-torsion performance of hoisting rope is not more than 360°.
◼ The lateral pressure stability of the hoisting rope is not more than 0.01d.
◼ The diameter shrinkage of the hoisting rope is not more than 0.01d.

94
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Data sheet of hook

Hook identification 000209606A1702200

Model number 8
Class P
Length (L) 780 mm
Nominal diameter (D) 100 mm
Weight 76kg
Greasing yes
Passage with hook safety path (Pal) 147mm
Dimension h 96 mm
Dimension e 115.5 mm

95
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

3.7 Counter ballast

General notes
The Counter ballast comprises several reinforced concrete blocks. Their combination allows the
different weights to be obtained, which are proper to each jib length used. There are three types:
The PHZ3000N, PHZ2500L, PHZ1300G blocks, weight 3000 kg, 2500 kg and 1300 kg; they are
directly placed on the counter jib.

Configuration
(Front → Rear) 8 counter ballast (t)
Jib length
The first The rest Total
70m 3.0 3.0 3.0 3.0 3.0 3.0 3.0 2.5 23.5
67.5m 3.0 3.0 3.0 3.0 3.0 3.0 3.0 2.5 23.5
65m 3.0 3.0 3.0 3.0 3.0 3.0 3.0 1.3 22.3
62.5m 3.0 3.0 3.0 3.0 3.0 3.0 2.5 1.3 21.8
60m 3.0 3.0 3.0 3.0 3.0 3.0 2.5 1.3 21.8
57.5m 3.0 3.0 3.0 3.0 3.0 3.0 2.5 1.3 21.8
55m 3.0 3.0 3.0 3.0 3.0 3.0 2.5 1.3 21.8
52.5m 3.0 3.0 3.0 3.0 3.0 3.0 3.0 / 21.0
50m 3.0 3.0 3.0 3.0 3.0 3.0 2.5 / 20.5
47.5m 3.0 3.0 3.0 3.0 3.0 3.0 1.3 / 19.3
45m 3.0 3.0 3.0 3.0 3.0 3.0 1.3 / 19.3
42.5m 3.0 3.0 3.0 3.0 3.0 2.5 1.3 / 18.8
40m 3.0 3.0 3.0 3.0 3.0 2.5 / / 17.5
37.5m 3.0 3.0 3.0 3.0 3.0 / / / 15.0
35m 3.0 3.0 3.0 3.0 2.5 / / / 14.5
32.5m 3.0 3.0 3.0 3.0 2.5 / / / 14.5
30m 3.0 3.0 3.0 3.0 1.3 / / / 13.3

Fabrication
The ballast blocks must be carried out according to the following drawings. It is recommended to
observe the outer dimensions of the blocks and the functional dimensions, especially the position
of the suspension holes, the position of the raising device and its dimensions.
The reinforcement of the blocks including the raising device will be determined and carried out
by the crane user to avoid the crumbling and dislocation of the blocks when handling and during
crane work.

96
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Weight tolerance
All the counter ballasts are cast with reinforced concrete. For detailed specification, refer to Fig.
3-1, Fig. 3-2, Fig. 3-3. Respectively, for spare parts layout, see Table 3-1, Table 3-2, and Table
3-3.

◼ It is advised to use steel mould to cast the concrete counter ballast to assure
the dimension of it and the flatness of every surface.
◼ It is advised to weigh every counter ballast manufactured and engrave the
weight permanently on the surface, with permitted weight tolerance of ±1％
and concrete grade is no less than C20 (recommended C25). It must be
pounded firmly and the curing time should be more than 14 days.
◼ The dimensions can be changed according to the density (average density)
of reinforced concrete for the tolerance. The density will change with the
change of distribution of reinforced bar in counter ballast.
◼ In this manual, the outline size of counter ballast for this tower crane is
designed according to the concrete design density which is based on the
theoretical value of 2400 kg/m3.
◼ Customers can also design counter ballast themselves. Make sure the
width, thickness and dimensions of counter ballast is right to hang, you can
adjust the length to appropriate value.

Steel
Es: Longitudinal modulus of elasticity of steel: 200000 N/mm2 i.e. 200000MPa
Type 1: Reinforcement with high adherence obtained by hot−rolling of natural high−carbon steel.
Quality: Fe E 40 i.e. fe=400MPa

If the above rules are not applicable, refer to the rules applied in the user
country.

97
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Preparing the block PHZ3000N

◼ WEIGHT = 3000 kg ± 2% − Average density of reinforced concrete: C20
◼ Dimensions in cm-General tolerance: ±1cm except

98
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Fig. 3-1 Counter ballast PHZ3000N

Table 3-1 Spare part list of PHZ3000N

No. Designation Specification Qty Material Remarks

1 Angle Steel L40×4-940 4 Q235B

2 Angle Steel L40×4-3500 4 Q235B
3 Fixed Plate t8 4 Q235B
4 Rebar Φ14 6 HPB300
5 Rebar Φ14 12 HPB300
6 Rebar Φ14 12 HPB300
7 Ear Board t16 1 Q235B
8 Round Steel Φ30-950 1 Q345B
9 Angle Steel L40×4 4 Q235B
10 Angle Steel L40×4-290 2 Q235B
11 Concrete 1

99
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Preparing the block PHZ2500L

◼ WEIGHT = 2500 kg ± 2% − Average density of reinforced concrete: C20
◼ Dimensions in cm-General tolerance: ±1cm except

100
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Fig. 3-2 Counter ballast PHZ2500L

Table 3-2 Spare part list of PHZ2500L

No. Designation Specification Qty Material Remarks

1 Angle Steel L40×4-940 4 Q235B

2 Angle Steel L40×4-2920 4 Q235B
3 Fixed Plate t8 4 Q235B
4 Rebar Φ14 6 HPB300
5 Rebar Φ14 10 HPB300
6 Rebar Φ14 12 HPB300
7 Ear Board t16 1 Q235B
8 Round Steel Φ30-950 1 Q345B
9 Angle Steel L40×4 4 Q235B
10 Angle Steel L40×4-290 2 Q235B
11 Concrete 1

101
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Preparing the block PHZ1300G

◼ WEIGHT = 1300 kg ± 2% − Average density of reinforced concrete: C20
◼ Dimensions in cm-General tolerance: ±1cm except.

102
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Fig. 3-3 Counter ballast PHZ1300G

Table 3-3 Spare part list of PHZ1300G

No. Designation Specification Qty Material Remarks

1 Angle Steel L40×4-940 4 Q235B

2 Angle Steel L40×4-1520 4 Q235B
3 Fixed Plate t8 4 Q235B
4 Rebar Φ14 6 HPB300
5 Rebar Φ14 6 HPB300
6 Rebar Φ14 12 HPB300
7 Ear Board t16 1 Q235B
8 Round Steel Φ30-950 1 Q345B
9 Angle Steel L40×4 4 Q235B
10 Angle Steel L40×4-290 2 Q235B
11 Concrete 1

103
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

3.8 Central ballast

Chassis stationary and travelling tower crane need configure central ballast.

Configuration
The tower crane has two types of central ballast: YZ3900(3.9t) and YZ4500(4.5t).

Table 3-4 Central ballast configuration for different height

Number of sections Working height /m

Weight/t YZ3900 Qty YZ4500 Qty
(Exclude chassis) Stationary Travelling

1+6 27.5 28.5 51.6 4 8

1+7 30.5 31.5 51.6 4 8

1+8 33.5 34.5 60.6 4 10

1+9 36.5 37.5 60.6 4 10

1+10 39.5 40.5 69.6 4 12

1+11 42.5 43.5 69.6 4 12

1+12 45.5 46.5 78.6 4 14

1+13 48.5 49.5 87.6 4 16

1+14 51.5 52.5 87.6 4 16

1+15 54.5 55.5 96.6 4 18

1+16 57.5 58.5 105.6 4 20

1+17 60.5 61.5 114.6 4 22

104
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Making
All the central ballasts are cast with reinforced concrete. For detailed specification, refer to Fig.
3-4 and Fig. 3-5, the spare parts see Table 3-5 and Table 3-6.
In this Operation Manual, the central ballasts detailed specification shall be design according to
theoretical value 2400kg/m3. In the production process, the density is different from this, so the
dimension of the pressure thickness direction can be adjusted accordingly to maintain the same
weight.
It is advised to weigh every central ballasts manufactured and engrave the weight permanently
on the surface, with permitted weight tolerance of ±2％and concrete grade is no less than C25.
It must be pounded firmly and the curing time should be more than 14 days.

Center Ballast YZ4500

◼ The perron, which supports the whole weight of the centre ballast, must be made smoothing.
◼ The No.2,5,9,12,15,18,21,24 are below reinforements, they have the same diameter Φ16.
The No.1,4,8,11,14,17,20,23 are upper reinforements, they have the same diameter Φ12.
Don't mistake using.
◼ The concrete strength is C30. Stamped concrete, the curing period of the counter-weight
must not be less than 14 days after pouring.
◼ The positions of the locating perron(140x140x50) and the locating hole (180x180x50) must
be correct.

105
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

106
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

107
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

108
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Fig. 3-4 Center Ballast YZ4500

109
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Table 3-5 Spare parts of Center Ballast YZ4500

No. Designation Specification Qty Material
1 Reinforcement Φ12-3500 1 HPB235
2 Below reinforcement Φ16-3550 1 HPB235
3 Hooped reinforcement (1) Φ6-3100 2 HPB235
4 Reinforcement Φ12-3100 1 HPB235
5 Below reinforcement Φ16-3150 1 HPB235
6 Additional reinforcement Φ6-3520 2 HPB235
7 Hooped reinforcement (2) Φ12-2680 1 HPB235
8 Reinforcement Φ16-2730 1 HPB235
9 Below reinforcement Φ6-3660 10 HPB235
10 Hooped reinforcement (3) Φ12-2500 1 HPB235
11 Reinforcement Φ16-2140 1 HPB235
12 Below reinforcement Φ20-2150 2 Q235B
13 Hooped reinforcement (4) 1 C30
14 Reinforcement Φ12-3500 1 HPB235
15 Below reinforcement Φ16-3550 1 HPB235
16 Hooped reinforcement (5) Φ6-3100 2 HPB235
17 Reinforcement Φ12-3100 1 HPB235
18 Below reinforcement Φ16-3150 1 HPB235
19 Hooped reinforcement (6) Φ6-3520 2 HPB235
20 Reinforcement Φ12-2680 1 HPB235
21 Below reinforcement Φ16-2730 1 HPB235
22 Hooped reinforcement (7) Φ6-3660 10 HPB235
23 Reinforcement Φ12-2500 1 HPB235
24 Below reinforcement Φ16-2140 1 HPB235

110
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Center Ballast YZ3900

◼ The perron, which width and depth is 380×20mm, supports the whole weight of the ballast,
and must be made smoothing.
◼ The concrete strength is C30. Stamped concrete, the curing period of the Ballast must not
be less than 14 days after pouring.
◼ The positions of the locating perron(140×140×50) and the locating hole(180×180×50) must
be correct.

111
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

112
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Fig. 3-5 Center Ballast YZ3900

113
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Table 3-6 Spare parts of Center Ballast YZ3900

No. Designation Specification Qty Material
1 Concrete 1 C30
2 Additional reinforcement (1) Φ16-1100 2 HPB235
3 Additional reinforcement (2) Φ16-2020 10 HPB235
4 Upper reinforcement (1) Φ12-5916 7 HPB235
5 Below reinforcement (1) Φ18-6120 7 HPB235
6 Hooped reinforcement Φ6-2820 24 HPB235
7 Upper reinforcement (2) Φ12-300 2 HPB235
8 Below reinforcement (2) Φ18-300 2 HPB235
9 Upper reinforcement (2) Φ16-5160 1 HPB235
10 Additional reinforcement (4) Φ18-5360 1 HPB235
11 Additional reinforcement (4) Φ16-1790 4 HPB235
12 Lifting ear Φ20-1950 2 Q235B

114
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

3.9 Foundation
Foundation of stationary outrigger tower crane
Calculation
◼ Calculate of eccentricity

Fig. 3-6 Load of foundation

As Fig. 3-6, the stability condition of tower crane as the following:
M+H∗h L
𝑒= ≤
V+G 3
In the formula:
e-eccentricity, that is the distance between the resultant ground reaction and the base center,
m;
G—the gravity of the concrete foundation, kN.

115
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

◼ Calculation of earth bearing pressure

Earth endurance should not exceed the maximum permissible stress of the ground!
Earth endurance checking formula:
2∗(V+G)
σB = ≤ σBp
3∗L∗c

L
c= −e
2
In the formula:
σB —Calculation the com pressive stress on the ground, MPa;
σBp —Allowable compressive stress on the ground, MPa: It shall be determined by the
situation officed investigation and foundation treatment.

Foundation drawing
The ground foundation is the precondition to ensure safe operation of the crane. It is made of
reinforced concrete as shown in Fig. 3-7. Basic requirements are shown as follows:
◼ Excavate a trench to hard formation until the ground bearing pressure accords with the value
in the following table, and make the bottom level. And then backfill and tamp 100mm gravel
stratum. After making formwork or laying bricks for the side walls, pour concrete into pre-
made reinforced rod net. The concrete block surface should be 100mm higher than
neighboring ground for the drainage of storm water, then removal the formwork and backfill
the neighboring ground with gravels.
◼ The depth of the concrete cover of the main reinforcement is 40mm. Fix the embedded
anchors on the locating reinforcement bar and make sure that the verticality of the
embedded anchors centerlines and horizontal plane is less than 1.5/1000. Concrete filling
rate around the embedded anchors must be over 95%.
◼ The concrete strength grade shall be no less than C35. The curing duration of concrete is
more than 15 days.
◼ If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside, but
must not be reduced or cut off.
◼ No.6 which must drive 1.5m into the ground. Not connected with the steel reinforcement of
the building foundations.
◼ The No.10 is insulated copper cable with at least 16mm.
◼ This foundation is supposed to be applied for WA7025-12E tower crane with the standard
free-standing height of 60m and for WA7025-12E tower crane which is attached to the
building and in accordance with the requirement in the user's manual. The load on the
foundation can be found in the user's manual. The load-bearing capacity of the foundation,
the dimension L of the foundation and the layout of the reinforcement are all designed in
accordance with the standard FEM. The foundation can be produced under instruction of
the following table, the adjustment according to the actual situation is also allowed:

116
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Main Main Ground Concrete Qty.

a Weight
L reinforcement reinforcement resistance volume of
(mm) (t)
A B (MPa) (m3) No.5

Lengthwise Lengthwise
7000 and crosswise: and crosswise: 6920 0.20 78.4 188.2 324
35×Ф25 35×Ф25
Lengthwise Lengthwise
7500 and crosswise: and crosswise: 7420 0.16 90 216 361
35×Ф25 38×Ф25
Lengthwise Lengthwise
8000 and crosswise: and crosswise: 7920 0.13 102.4 246 400
40×Ф25 40×Ф25

If the modified bearing capacity of foundation is less than 0.1 MPa, the
pile foundation must be adopted. The pile foundation can also be
adopted, when the block foundation cannot be produced as above due
to the size limitation or other inevitable reasons.

117
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

118
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

119
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Fig. 3-7 The foundation for stationary outrigger tower crane

Table 3-7 Spare part list of stationary outrigger tower crane foundation

No. Description Specification Qty Material Remarks

1 Main Reinforcement A Φ25 70 HRB400

2 Main Reinforcement B Φ25 70 HRB400

3 Reinforcement Bar Φ12-1720 324 HPB300

4 Locating Reinforcement Bar Φ25-3050 8 HRB400
5 Concrete 1 C35
6 Earthing Rod 1 Weldment
7 Bolt M12×40-8.8 1
8 Washer 12 1 65Mn
9 Nut M12-8 1
10 Earthing Cable 1

120
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Foundation of stationary chassis tower crane

Make the foundation of stationary chassis tower crane according to the technical requirements
and drawings below:
◼ Foundation must be dug to original soil. the foundation load-bearing capacity is more than
0.2Mpa. Carry out leveling and refilling 100mm pebbles and tamping them before rebar
binding, then place concrete the concrete surface is more 100mm higher than the foundation
around it for better water drainage. If concrete placing within form, refill pebbles and tamp
them for torsion resistance after form dismantling.
◼ 40mm main rebar protection layer. Ground bolts to be embedded at the above-shown
position through pallets holes. Embedment positions shall be concrete, and filling rate
around pallets is >95%.
◼ Concrete grade C35, curing period longer than 15 days.
◼ Foundation pit 1200×1200×800, with water drainage pipe at the pit bottom.
◼ No.10 must be inserted into the ground for at least 1.5m. Not connected with the steel
reinforcement of the building foundations.
◼ The No.9 is insulated copper cable with at least 16mm 2.
◼ The foundation is fit for WA7025-10E/WA7025-12E tower crane.
◼ All materials and parts should be provided by user.

121
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Fig. 3-8 The foundation of stationary chassis tower crane

122
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Table 3-8 Spare part list of stationary chassis crane foundation

No. Description Code Specification Qty Material

1 Concrete 4 C35

2 Rebar φ16-3080 60 HRB400

3 Rebar φ16-3080 60 HRB400

4 Bolt GB/T5782-2000 M24×300-8.8 16
5 Nut GB/T6170-2000 M24-8 32
6 Washer GB/T97.1-2002 24-200HV 16
7 Pallet t20 4 Q235B
8 Washer t20 16 Q235B
9 Earthing cable 1
10 Earthing rods 1 焊件
11 Bolt GB/T5783-2000 M12×40-8.8 1
12 Spring washer GB/T93-1987 12 1 65Mn
13 Nut GB/T6170-2000 M12-8 1

123
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Foundation of travelling chassis tower crane

◼ The ground foundation must be tamped solid, its bearing pressure must be larger than
0.2MPa;
◼ During working, users should check the track on time: The distance error of 2 tracks is less
than ±5mm; Track height error in the same section is less than 5mm; The longitudinal error
of the track height is less than 1/1000, The total height error is less than 10mm.
◼ The joints of two tracks should be staggered upon 1500mm.
◼ The buffer stop must be set at the end of the track according to the specific situation of
building site, the buffer for the travel limit switch must be set on the site shown in the drawing,
travel limit test should be done in advance to ensure its safety in the process of working.
◼ The rails must be earthed at both ends. If the rail track is more than 20m long, additional
earthing points should be installed every 20 meters. If there are no other earthing devices
available one earthing rod which must be driven at least 1.5m into the ground will suffice for
each point. The earth resistance must be less than 4Ω.
◼ There must be placed a connection link between two rails.
◼ The account in the specification sheet is counted base on the track which is 100m.

◼ The degree of finish of the machining face is .The degree of finish of the machining

hole is .
◼ The length of cable is the distance which from the fixed point to the further track end plus
15m.
◼ Setting 4 anchoring boards outside of the rail track. The boards are used for fixing the crane
when the wind speed is higher;
◼ Manufacturing and locating method of the board are shown in the drawing to the drawing,
the
◼ location of the equipment based on the practical situation; the user can also take some other
◼ effective and safe methods to anchor;
◼ The main reinforcements on the drawing are twisted steel (HRB335), the hoop
reinforcements are twisted steel (HPB235).

124
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

125
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

126
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Fig. 3-9 The foundation for travelling chassis tower crane

127
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Table 3-9 Spare part list of travelling chassis tower crane foundation
No. Description Specification Qty Material
1 Rail 50kg/m 16 U71Mn
2 Press plate 804 Q235B
3 Fishplate 28 B7
4 Base plate t20-240×340 368 Q235B
5 Bolt M24×160-8.8 84
6 Nut M24-10 168
7 Washer 24-200HV 168
8 Bumper Φ20 4 Q235B
9 Base plate t10-260×350 4 Q235B
10 Slip bumper 4 Weldment
11 Stop bumper 4 Weldment
12 Embedded bolt M20-8.8 804
13 Nut M20-8 1608
14 Washer 20-200HV 804
15 Channel steel [16a-6340 17 Weldment
16 Plate t20 804 Q235B
17 Ear plate t24 4 Q235B
18 Plate A t20-50×130 16 Q235B
19 Plate B t20-130×130 4 Q235B

128
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation of crane

T Torque M Bending moment H Horizontal force V Vertical force

In the following configuration, there is no climbing equipment. If the crane

is erected with climbing equipment, lower it to the bottom after erection.

◼ The description of Number of sections is: quantity of base section + quantity

of tower section.
◼ The maximum loads appear at the maximum free-standing height in service
state. The tower crane with attachment, the moment, horizontal force,
torque mainly transmitted to the building by the attachment frame, the load
on the foundation no additional.

129
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 70m jib

Table 3-10 Loads on foundation for 70m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2534.3 25.1 903.6 723.9
1+6 27.0
Out of service -1194.7 99.0 716.1 0.0
In service 2640.1 26.6 919.2 723.9
1+7 30.0
Out of service -1204.0 105.5 731.8 0.0
In service 2758.0 28.1 934.9 723.9
1+8 33.0
Out of service 1311.4 112.0 747.5 0.0
In service 2886.6 29.6 950.6 723.9
1+9 36.0
Out of service 1673.1 118.5 763.1 0.0
In service 3026.8 31.1 966.3 723.9
1+10 39.0
Out of service 2060.8 125.0 778.8 0.0
In service 3179.5 32.5 982.0 723.9
1+11 42.0
Out of service 2476.1 131.6 794.5 0.0
In service 3345.8 34.0 997.6 723.9
1+12 45.0
Out of service 2920.7 138.1 810.2 0.0
In service 3527.0 35.5 1013.3 723.9
1+13 48.0
Out of service 3396.5 144.6 825.9 0.0
In service 3724.8 37.0 1029.0 723.9
1+14 51.0
Out of service 3905.9 151.1 841.5 0.0
In service 3940.7 38.5 1044.7 723.9
1+15 54.0
Out of service 4451.4 157.6 857.2 0.0
In service 4177.2 40.0 1060.4 723.9
1+16 57.0
Out of service 5036.2 164.2 872.9 0.0
In service 4436.6 41.4 1076.0 723.9
1+17 60.0
Out of service 5663.9 170.7 888.6 0.0

130
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 67.5m jib

Table 3-11 Loads on foundation for 67.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2515.5 25.1 901.4 681.5
1+6 27.0
Out of service -1333.3 99.0 714.1 0.0
In service 2621.0 26.6 917.1 681.5
1+7 30.0
Out of service -1343.6 105.5 729.8 0.0
In service 2738.5 28.1 932.7 681.5
1+8 33.0
Out of service -1355.4 112.0 745.5 0.0
In service 2866.6 29.6 948.4 681.5
1+9 36.0
Out of service 1529.4 118.5 761.2 0.0
In service 3006.3 31.0 964.1 681.5
1+10 39.0
Out of service 1915.2 125.0 776.9 0.0
In service 3158.4 32.5 979.8 681.5
1+11 42.0
Out of service 2328.3 131.6 792.5 0.0
In service 3324.1 34.0 995.5 681.5
1+12 45.0
Out of service 2770.4 138.1 808.2 0.0
In service 3504.6 35.5 1011.1 681.5
1+13 48.0
Out of service 3243.4 144.6 823.9 0.0
In service 3701.4 37.0 1026.8 681.5
1+14 51.0
Out of service 3749.6 151.1 839.6 0.0
In service 3916.4 38.5 1042.5 681.5
1+15 54.0
Out of service 4291.6 157.6 855.3 0.0
In service 4151.7 39.9 1058.2 681.5
1+16 57.0
Out of service 4872.4 164.2 870.9 0.0
In service 4409.9 41.4 1073.9 681.5
1+17 60.0
Out of service 5495.6 170.7 886.6 0.0

131
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 65m jib

Table 3-12 Loads on foundation for 65m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2686.8 25.2 890.1 628.8
1+6 27.0
Out of service -1258.1 99.0 703.9 0.0
In service 2794.0 26.7 905.8 628.8
1+7 30.0
Out of service -1267.7 105.5 719.6 0.0
In service 2913.6 28.2 921.5 628.8
1+8 33.0
Out of service 1245.6 112.0 735.2 0.0
In service 3044.0 29.7 937.2 628.8
1+9 36.0
Out of service 1606.2 118.5 750.9 0.0
In service 3186.2 31.1 952.8 628.8
1+10 39.0
Out of service 1992.6 125.0 766.6 0.0
In service 3341.1 32.6 968.5 628.8
1+11 42.0
Out of service 2406.4 131.6 782.3 0.0
In service 3509.8 34.1 984.2 628.8
1+12 45.0
Out of service 2849.0 138.1 798.0 0.0
In service 3693.7 35.6 999.9 628.8
1+13 48.0
Out of service 3322.6 144.6 813.6 0.0
In service 3894.2 37.1 1015.6 628.8
1+14 51.0
Out of service 3829.2 151.1 829.3 0.0
In service 4113.2 38.5 1031.2 628.8
1+15 54.0
Out of service 4371.5 157.6 845.0 0.0
In service 4352.8 40.0 1046.9 628.8
1+16 57.0
Out of service 4952.5 164.2 860.7 0.0
In service 4615.6 41.5 1062.6 628.8
1+17 60.0
Out of service 5575.5 170.7 876.4 0.0

132
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 62.5m jib

Table 3-13 Loads on foundation for 62.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2725.4 25.2 882.6 585.3
1+6 27.0
Out of service -1301.4 99.0 697.0 0.0
In service 2832.9 26.7 898.2 585.3
1+7 30.0
Out of service -1311.2 105.5 712.7 0.0
In service 2952.6 28.2 913.9 585.3
1+8 33.0
Out of service -1322.4 112.0 728.4 0.0
In service 3083.3 29.7 929.6 585.3
1+9 36.0
Out of service 1560.6 118.5 744.1 0.0
In service 3225.7 31.2 945.3 585.3
1+10 39.0
Out of service 1946.3 125.0 759.7 0.0
In service 3380.8 32.6 961.0 585.3
1+11 42.0
Out of service 2359.0 131.6 775.4 0.0
In service 3549.7 34.1 976.6 585.3
1+12 45.0
Out of service 2800.5 138.1 791.1 0.0
In service 3733.8 35.6 992.3 585.3
1+13 48.0
Out of service 3272.7 144.6 806.8 0.0
In service 3934.4 37.1 1008.0 585.3
1+14 51.0
Out of service 3777.7 151.1 822.5 0.0
In service 4153.5 38.6 1023.7 585.3
1+15 54.0
Out of service 4318.0 157.6 838.1 0.0
In service 4393.1 40.0 1039.4 585.3
1+16 57.0
Out of service 4896.6 164.2 853.8 0.0
In service 4655.8 41.5 1055.0 585.3
1+17 60.0
Out of service 5516.9 170.7 869.5 0.0

133
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 60m jib

Table 3-14 Loads on foundation for 60m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2809.2 25.3 882.8 615.5
1+6 27.0
Out of service -1295.8 99.0 697.3 0.0
In service 2917.7 26.8 898.5 615.5
1+7 30.0
Out of service -1305.5 105.5 713.0 0.0
In service 3038.7 28.2 914.2 615.5
1+8 33.0
Out of service -1316.7 112.0 728.6 0.0
In service 3170.8 29.7 929.9 615.5
1+9 36.0
Out of service 1566.5 118.5 744.3 0.0
In service 3314.8 31.2 945.6 615.5
1+10 39.0
Out of service 1952.2 125.0 760.0 0.0
In service 3471.6 32.7 961.2 615.5
1+11 42.0
Out of service 2365.1 131.6 775.7 0.0
In service 3642.6 34.2 976.9 615.5
1+12 45.0
Out of service 2806.7 138.1 791.4 0.0
In service 3828.8 35.6 992.6 615.5
1+13 48.0
Out of service 3279.0 144.6 807.0 0.0
In service 4031.9 37.1 1008.3 615.5
1+14 51.0
Out of service 3784.1 151.1 822.7 0.0
In service 4253.8 38.6 1024.0 615.5
1+15 54.0
Out of service 4324.6 157.6 838.4 0.0
In service 4496.5 40.1 1039.6 615.5
1+16 57.0
Out of service 4903.4 164.2 854.1 0.0
In service 4762.6 41.6 1055.3 615.5
1+17 60.0
Out of service 5523.9 170.7 869.8 0.0

134
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 57.5m jib

Table 3-15 Loads on foundation for 57.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2734.9 25.2 880.7 571.1
1+6 27.0
Out of service -1419.7 99.0 695.3 0.0
In service 2842.4 26.7 896.4 571.1
1+7 30.0
Out of service -1430.4 105.5 711.0 0.0
In service 2962.2 28.2 912.0 571.1
1+8 33.0
Out of service -1442.6 112.0 726.7 0.0
In service 3092.9 29.7 927.7 571.1
1+9 36.0
Out of service 1438.1 118.5 742.3 0.0
In service 3235.3 31.2 943.4 571.1
1+10 39.0
Out of service 1822.1 125.0 758.0 0.0
In service 3390.5 32.6 959.1 571.1
1+11 42.0
Out of service 2233.1 131.6 773.7 0.0
In service 3559.4 34.1 974.8 571.1
1+12 45.0
Out of service 2672.5 138.1 789.4 0.0
In service 3743.5 35.6 990.4 571.1
1+13 48.0
Out of service 3142.4 144.6 805.1 0.0
In service 3944.1 37.1 1006.1 571.1
1+14 51.0
Out of service 3644.8 151.1 820.7 0.0
In service 4163.2 38.6 1021.8 571.1
1+15 54.0
Out of service 4182.2 157.6 836.4 0.0
In service 4402.8 40.0 1037.5 571.1
1+16 57.0
Out of service 4757.5 164.2 852.1 0.0
In service 4665.4 41.5 1053.2 571.1
1+17 60.0
Out of service 5374.1 170.7 867.8 0.0

135
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 55m jib

Table 3-16 Loads on foundation for 55m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2712.8 25.2 878.5 524.1
1+6 27.0
Out of service -1538.1 99.0 693.3 0.0
In service 2819.9 26.7 894.2 524.1
1+7 30.0
Out of service -1549.6 105.5 709.0 0.0
In service 2939.2 28.2 909.9 524.1
1+8 33.0
Out of service -1562.8 112.0 724.7 0.0
In service 3069.4 29.7 925.6 524.1
1+9 36.0
Out of service -1577.7 118.5 740.4 0.0
In service 3211.3 31.1 941.2 524.1
1+10 39.0
Out of service 1698.0 125.0 756.1 0.0
In service 3365.8 32.6 956.9 524.1
1+11 42.0
Out of service 2107.1 131.6 771.7 0.0
In service 3534.0 34.1 972.6 524.1
1+12 45.0
Out of service 2544.5 138.1 787.4 0.0
In service 3717.2 35.6 988.3 524.1
1+13 48.0
Out of service 3012.1 144.6 803.1 0.0
In service 3916.9 37.1 1004.0 524.1
1+14 51.0
Out of service 3511.8 151.1 818.8 0.0
In service 4134.9 38.6 1019.6 524.1
1+15 54.0
Out of service 4046.3 157.6 834.5 0.0
In service 4373.3 40.0 1035.3 524.1
1+16 57.0
Out of service 4618.3 164.2 850.1 0.0
In service 4634.5 41.5 1051.0 524.1
1+17 60.0
Out of service 5231.2 170.7 865.8 0.0

136
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 52.5m jib

Table 3-17 Loads on foundation for 52.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2807.5 25.3 867.7 481.0
1+6 27.0
Out of service -1511.2 99.0 683.5 0.0
In service 2915.3 26.7 883.4 481.0
1+7 30.0
Out of service -1522.4 105.5 699.2 0.0
In service 3035.5 28.2 899.1 481.0
1+8 33.0
Out of service -1535.1 112.0 714.9 0.0
In service 3166.6 29.7 914.8 481.0
1+9 36.0
Out of service -1549.5 118.5 730.6 0.0
In service 3309.6 31.2 930.5 481.0
1+10 39.0
Out of service 1724.9 125.0 746.3 0.0
In service 3465.2 32.7 946.1 481.0
1+11 42.0
Out of service 2134.0 131.6 761.9 0.0
In service 3634.6 34.2 961.8 481.0
1+12 45.0
Out of service 2571.3 138.1 777.6 0.0
In service 3819.0 35.6 977.5 481.0
1+13 48.0
Out of service 3038.5 144.6 793.3 0.0
In service 4020.0 37.1 993.2 481.0
1+14 51.0
Out of service 3537.8 151.1 809.0 0.0
In service 4239.4 38.6 1008.9 481.0
1+15 54.0
Out of service 4071.6 157.6 824.7 0.0
In service 4479.1 40.1 1024.5 481.0
1+16 57.0
Out of service 4642.7 164.2 840.3 0.0
In service 4741.7 41.6 1040.2 481.0
1+17 60.0
Out of service 5254.3 170.7 856.0 0.0

137
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 50m jib

Table 3-18 Loads on foundation for 50m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2751.0 25.2 858.5 446.7
1+6 27.0
Out of service -1608.0 99.0 675.1 0.0
In service 2857.8 26.7 874.1 446.7
1+7 30.0
Out of service -1619.7 105.5 690.8 0.0
In service 2976.8 28.2 889.8 446.7
1+8 33.0
Out of service -1633.0 112.0 706.5 0.0
In service 3106.5 29.7 905.5 446.7
1+9 36.0
Out of service -1648.2 118.5 722.1 0.0
In service 3247.7 31.2 921.2 446.7
1+10 39.0
Out of service 1622.8 125.0 737.8 0.0
In service 3401.4 32.7 936.9 446.7
1+11 42.0
Out of service 2030.1 131.6 753.5 0.0
In service 3568.6 34.1 952.5 446.7
1+12 45.0
Out of service 2465.3 138.1 769.2 0.0
In service 3750.6 35.6 968.2 446.7
1+13 48.0
Out of service 2930.2 144.6 784.9 0.0
In service 3948.8 37.1 983.9 446.7
1+14 51.0
Out of service 3426.8 151.1 800.5 0.0
In service 4164.9 38.6 999.6 446.7
1+15 54.0
Out of service 3957.4 157.6 816.2 0.0
In service 4400.9 40.1 1015.3 446.7
1+16 57.0
Out of service 4524.7 164.2 831.9 0.0
In service 4659.2 41.5 1030.9 446.7
1+17 60.0
Out of service 5131.9 170.7 847.6 0.0

138
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 47.5m jib

Table 3-19 Loads on foundation for 47.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2892.4 25.3 842.8 476.5
1+6 27.0
Out of service -1537.8 99.0 660.9 0.0
In service 3000.3 26.8 858.5 476.5
1+7 30.0
Out of service -1548.7 105.5 676.5 0.0
In service 3120.5 28.3 874.2 476.5
1+8 33.0
Out of service -1561.2 112.0 692.2 0.0
In service 3251.5 29.8 889.8 476.5
1+9 36.0
Out of service -1575.3 118.5 707.9 0.0
In service 3394.3 31.2 905.5 476.5
1+10 39.0
Out of service 1694.5 125.0 723.6 0.0
In service 3549.6 32.7 921.2 476.5
1+11 42.0
Out of service 2102.2 131.6 739.3 0.0
In service 3718.5 34.2 936.9 476.5
1+12 45.0
Out of service 2537.7 138.1 754.9 0.0
In service 3902.2 35.7 952.6 476.5
1+13 48.0
Out of service 3002.8 144.6 770.6 0.0
In service 4102.3 37.2 968.2 476.5
1+14 51.0
Out of service 3499.3 151.1 786.3 0.0
In service 4320.3 38.7 983.9 476.5
1+15 54.0
Out of service 4029.6 157.6 802.0 0.0
In service 4558.3 40.1 999.6 476.5
1+16 57.0
Out of service 4596.3 164.2 817.7 0.0
In service 4818.6 41.6 1015.3 476.5
1+17 60.0
Out of service 5202.5 170.7 833.3 0.0

139
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 45m jib

Table 3-20 Loads on foundation for 45m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2795.2 25.3 846.8 431.5
1+6 27.0
Out of service -1636.2 99.0 664.5 0.0
In service 2902.2 26.8 862.5 431.5
1+7 30.0
Out of service -1647.9 105.5 680.2 0.0
In service 3021.2 28.2 878.2 431.5
1+8 33.0
Out of service -1661.2 112.0 695.9 0.0
In service 3150.9 29.7 893.9 431.5
1+9 36.0
Out of service -1676.4 118.5 711.6 0.0
In service 3292.2 31.2 909.6 431.5
1+10 39.0
Out of service -1693.4 125.0 727.3 0.0
In service 3445.9 32.7 925.2 431.5
1+11 42.0
Out of service 1998.6 131.6 742.9 0.0
In service 3613.0 34.2 940.9 431.5
1+12 45.0
Out of service 2432.8 138.1 758.6 0.0
In service 3794.8 35.6 956.6 431.5
1+13 48.0
Out of service 2896.4 144.6 774.3 0.0
In service 3992.7 37.1 972.3 431.5
1+14 51.0
Out of service 3391.4 151.1 790.0 0.0
In service 4208.4 38.6 988.0 431.5
1+15 54.0
Out of service 3920.1 157.6 805.7 0.0
In service 4443.8 40.1 1003.6 431.5
1+16 57.0
Out of service 4485.0 164.2 821.3 0.0
In service 4701.3 41.6 1019.3 431.5
1+17 60.0
Out of service 5089.4 170.7 837.0 0.0

140
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 42.5m jib

Table 3-21 Loads on foundation for 42.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2757.7 25.3 833.1 391.1
1+6 27.0
Out of service -1646.0 99.0 652.0 0.0
In service 2863.7 26.7 848.8 391.1
1+7 30.0
Out of service -1657.5 105.5 667.7 0.0
In service 2981.6 28.2 864.4 391.1
1+8 33.0
Out of service -1670.6 112.0 683.4 0.0
In service 3109.9 29.7 880.1 391.1
1+9 36.0
Out of service -1685.5 118.5 699.1 0.0
In service 3249.6 31.2 895.8 391.1
1+10 39.0
Out of service -1702.2 125.0 714.8 0.0
In service 3401.5 32.7 911.5 391.1
1+11 42.0
Out of service 1986.4 131.6 730.4 0.0
In service 3566.5 34.1 927.2 391.1
1+12 45.0
Out of service 2419.8 138.1 746.1 0.0
In service 3745.8 35.6 942.8 391.1
1+13 48.0
Out of service 2882.3 144.6 761.8 0.0
In service 3940.9 37.1 958.5 391.1
1+14 51.0
Out of service 3375.9 151.1 777.5 0.0
In service 4153.3 38.6 974.2 391.1
1+15 54.0
Out of service 3902.8 157.6 793.2 0.0
In service 4384.9 40.1 989.9 391.1
1+16 57.0
Out of service 4465.6 164.2 808.8 0.0
In service 4638.0 41.6 1005.6 391.1
1+17 60.0
Out of service 5067.3 170.7 824.5 0.0

141
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 40m jib

Table 3-22 Loads on foundation for 40m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2762.2 25.3 815.2 350.9
1+6 27.0
Out of service -1581.3 99.0 635.8 0.0
In service 2867.6 26.8 830.9 350.9
1+7 30.0
Out of service -1592.0 105.5 651.5 0.0
In service 2984.7 28.2 846.6 350.9
1+8 33.0
Out of service -1604.3 112.0 667.1 0.0
In service 3112.1 29.7 862.2 350.9
1+9 36.0
Out of service -1618.1 118.5 682.8 0.0
In service 3250.7 31.2 877.9 350.9
1+10 39.0
Out of service 1646.1 125.0 698.5 0.0
In service 3401.3 32.7 893.6 350.9
1+11 42.0
Out of service 2052.3 131.6 714.2 0.0
In service 3564.8 34.2 909.3 350.9
1+12 45.0
Out of service 2485.7 138.1 729.9 0.0
In service 3742.3 35.6 925.0 350.9
1+13 48.0
Out of service 2948.1 144.6 745.5 0.0
In service 3935.2 37.1 940.6 350.9
1+14 51.0
Out of service 3441.4 151.1 761.2 0.0
In service 4145.0 38.6 956.3 350.9
1+15 54.0
Out of service 3967.6 157.6 776.9 0.0
In service 4373.6 40.1 972.0 350.9
1+16 57.0
Out of service 4529.4 164.2 792.6 0.0
In service 4623.0 41.6 987.7 350.9
1+17 60.0
Out of service 5129.5 170.7 808.3 0.0

142
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 37.5m jib

Table 3-23 Loads on foundation for 37.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2761.9 25.3 777.2 308.7
1+6 27.0
Out of service -1516.8 99.0 601.2 0.0
In service 2865.9 26.8 792.9 308.7
1+7 30.0
Out of service -1526.5 105.5 616.9 0.0
In service 2981.2 28.3 808.5 308.7
1+8 33.0
Out of service -1537.5 112.0 632.6 0.0
In service 3106.6 29.7 824.2 308.7
1+9 36.0
Out of service -1550.0 118.5 648.2 0.0
In service 3242.7 31.2 839.9 308.7
1+10 39.0
Out of service 1709.1 125.0 663.9 0.0
In service 3390.3 32.7 855.6 308.7
1+11 42.0
Out of service 2114.7 131.6 679.6 0.0
In service 3550.4 34.2 871.3 308.7
1+12 45.0
Out of service 2547.1 138.1 695.3 0.0
In service 3723.8 35.7 886.9 308.7
1+13 48.0
Out of service 3008.0 144.6 711.0 0.0
In service 3911.9 37.2 902.6 308.7
1+14 51.0
Out of service 3499.0 151.1 726.6 0.0
In service 4116.1 38.6 918.3 308.7
1+15 54.0
Out of service 4022.3 157.6 742.3 0.0
In service 4338.0 40.1 934.0 308.7
1+16 57.0
Out of service 4580.0 164.2 758.0 0.0
In service 4579.5 41.6 949.7 308.7
1+17 60.0
Out of service 5174.9 170.7 773.7 0.0

143
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 35m jib

Table 3-24 Loads on foundation for 35m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2650.3 25.2 767.9 275.8
1+6 27.0
Out of service -1565.2 99.0 592.8 0.0
In service 2752.9 26.7 783.6 275.8
1+7 30.0
Out of service -1575.0 105.5 608.5 0.0
In service 2866.3 28.2 799.3 275.8
1+8 33.0
Out of service -1586.2 112.0 624.1 0.0
In service 2989.6 29.7 814.9 275.8
1+9 36.0
Out of service -1598.9 118.5 639.8 0.0
In service 3123.3 31.2 830.6 275.8
1+10 39.0
Out of service 1657.9 125.0 655.5 0.0
In service 3268.2 32.7 846.3 275.8
1+11 42.0
Out of service 2062.4 131.6 671.2 0.0
In service 3425.1 34.1 862.0 275.8
1+12 45.0
Out of service 2493.7 138.1 686.9 0.0
In service 3595.1 35.6 877.7 275.8
1+13 48.0
Out of service 2953.3 144.6 702.5 0.0
In service 3779.4 37.1 893.3 275.8
1+14 51.0
Out of service 3442.7 151.1 718.2 0.0
In service 3979.1 38.6 909.0 275.8
1+15 54.0
Out of service 3964.0 157.6 733.9 0.0
In service 4196.0 40.1 924.7 275.8
1+16 57.0
Out of service 4519.4 164.2 749.6 0.0
In service 4431.8 41.5 940.4 275.8
1+17 60.0
Out of service 5111.6 170.7 765.3 0.0

144
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Loads on foundation for 32.5m jib

Table 3-25 Loads on foundation for 32.5m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2585.8 25.2 767.5 235.6
1+6 27.0
Out of service -1586.3 99.0 592.4 0.0
In service 2687.6 26.7 783.1 235.6
1+7 30.0
Out of service -1596.2 105.5 608.1 0.0
In service 2800.3 28.2 798.8 235.6
1+8 33.0
Out of service -1607.5 112.0 623.7 0.0
In service 2922.6 29.7 814.5 235.6
1+9 36.0
Out of service -1620.4 118.5 639.4 0.0
In service 3055.2 31.1 830.2 235.6
1+10 39.0
Out of service 1636.0 125.0 655.1 0.0
In service 3198.9 32.6 845.9 235.6
1+11 42.0
Out of service 2040.3 131.6 670.8 0.0
In service 3354.5 34.1 861.5 235.6
1+12 45.0
Out of service 2471.3 138.1 686.5 0.0
In service 3523.1 35.6 877.2 235.6
1+13 48.0
Out of service 2930.4 144.6 702.1 0.0
In service 3705.6 37.1 892.9 235.6
1+14 51.0
Out of service 3419.5 151.1 717.8 0.0
In service 3903.6 38.6 908.6 235.6
1+15 54.0
Out of service 3940.3 157.6 733.5 0.0
In service 4118.4 40.0 924.3 235.6
1+16 57.0
Out of service 4495.3 164.2 749.2 0.0
In service 4352.0 41.5 939.9 235.6
1+17 60.0
Out of service 5086.9 170.7 764.9 0.0

145
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Loads on foundation for 30m jib

Table 3-26 Loads on foundation for 30m jib
Number of H.U.H Operation M H V T
sections (m) status (kN·m) (kN) (kN) (kN·m)
In service 2600.7 25.2 750.6 206.7
1+6 27.0
Out of service -1511.0 99.0 577.1 0.0
In service 2702.2 26.7 766.3 206.7
1+7 30.0
Out of service -1520.2 105.5 592.8 0.0
In service 2814.3 28.2 782.0 206.7
1+8 33.0
Out of service -1530.7 112.0 608.4 0.0
In service 2935.9 29.7 797.7 206.7
1+9 36.0
Out of service -1542.5 118.5 624.1 0.0
In service 3067.8 31.2 813.4 206.7
1+10 39.0
Out of service 1712.3 125.0 639.8 0.0
In service 3210.6 32.6 829.0 206.7
1+11 42.0
Out of service 2116.9 131.6 655.5 0.0
In service 3365.1 34.1 844.7 206.7
1+12 45.0
Out of service 2548.1 138.1 671.2 0.0
In service 3532.3 35.6 860.4 206.7
1+13 48.0
Out of service 3007.2 144.6 686.8 0.0
In service 3713.2 37.1 876.1 206.7
1+14 51.0
Out of service 3496.1 151.1 702.5 0.0
In service 3909.3 38.6 891.8 206.7
1+15 54.0
Out of service 4016.5 157.6 718.2 0.0
In service 4121.8 40.1 907.4 206.7
1+16 57.0
Out of service 4570.6 164.2 733.9 0.0
In service 4352.7 41.5 923.1 206.7
1+17 60.0
Out of service 5161.0 170.7 749.6 0.0

146
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Corner pressure for the chassis crane with climbing

equipment

➢ Case 1：

➢ Case 2：

In the following tables, negative numbers indicate tension and positive numbers
indicate pressure.

Since tower crane can rotate in 360°, every support point has the
possibility to endure any load in the table above

147
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 70m jib with climbing equipment

Table 3-27 Reaction force for 70m jib with climbing equipment
Number Case 1(kN) Case 2(kN)
H.U.H Operation
of
(m) status RA RB RC RD RA RB RC RD
sections
In service 164.2 580.7 580.7 164.2 372.4 670.2 372.4 74.6
7 27.5
Out of service 424.1 227.0 227.0 424.1 325.6 186.2 325.6 464.9
In service 160.2 592.5 592.5 160.2 376.3 686.2 376.3 66.5
8 30.5
Out of service 428.6 230.3 230.3 428.6 329.5 189.2 329.5 469.7
In service 177.4 627.2 627.2 177.4 402.3 725.4 402.3 79.2
9 33.5
Out of service 455.3 255.6 255.6 455.3 355.4 214.2 355.4 496.7
In service 171.9 640.6 640.6 171.9 406.2 743.7 406.2 68.7
10 36.5
Out of service 460.1 258.7 258.7 460.1 359.4 217.0 359.4 501.8
In service 187.6 676.8 676.8 187.6 432.2 785.3 432.2 79.1
11 39.5
Out of service 230.5 540.1 540.1 230.5 385.3 635.9 385.3 134.8
In service 180.4 691.8 691.8 180.4 436.1 806.2 436.1 66.0
12 42.5
Out of service 204.1 574.5 574.5 204.1 389.3 688.2 389.3 90.3
In service 194.4 729.8 729.8 194.4 462.1 850.5 462.1 73.6
13 45.5
Out of service 197.7 632.8 632.8 197.7 415.2 765.9 415.2 64.6
In service 207.4 768.7 768.7 207.4 488.1 896.4 488.1 79.7
14 48.5
Out of service 189.3 693.1 693.1 189.3 441.2 846.9 441.2 35.5
In service 197.3 786.7 786.7 197.3 492.0 921.8 492.0 62.2
15 51.5
Out of service 156.7 733.6 733.6 156.7 425.9 928.7 425.9 0
In service 208.0 827.9 827.9 208.0 518.0 971.1 518.0 64.8
16 54.5
Out of service 143.8 798.4 798.4 143.8 415.4 1053.7 415.4 0
In service 217.5 870.3 870.3 217.5 543.9 1022.3 543.9 65.6
17 57.5
Out of service 128.4 865.7 865.7 128.4 400.7 1186.9 400.7 0
In service 225.6 914.2 914.2 225.6 569.9 1075.6 569.9 64.2
18 60.5
Out of service 110.4 935.7 935.7 110.4 381.5 1329.0 381.5 0

148
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 67.5m jib with climbing equipment

Table 3-28 Reaction force for 67.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 165.2 578.6 578.6 165.2 371.9 667.5 371.9 76.3
7 27.5
Out of service 435.1 215.1 215.1 435.1 325.1 169.5 325.1 480.6
In service 161.2 590.4 590.4 161.2 375.8 683.4 375.8 68.2
8 30.5
Out of service 439.7 218.3 218.3 439.7 329.0 172.5 329.0 485.5
In service 178.5 625.1 625.1 178.5 401.8 722.6 401.8 81.0
9 33.5
Out of service 466.4 243.5 243.5 466.4 355.0 197.3 355.0 512.6
In service 173.0 638.4 638.4 173.0 405.7 740.9 405.7 70.5
10 36.5
Out of service 471.3 246.5 246.5 471.3 358.9 200.0 358.9 517.8
In service 188.7 674.6 674.6 188.7 431.7 782.5 431.7 80.9
11 39.5
Out of service 498.2 271.4 271.4 498.2 384.8 618.5 384.8 151.2
In service 181.6 689.6 689.6 181.6 435.6 803.3 435.6 67.9
12 42.5
Out of service 215.7 561.9 561.9 215.7 388.8 670.6 388.8 106.9
In service 195.6 727.5 727.5 195.6 461.6 847.5 461.6 75.6
13 45.5
Out of service 209.5 620.0 620.0 209.5 414.7 748.0 414.7 81.5
In service 208.6 766.4 766.4 208.6 487.5 893.3 487.5 81.7
14 48.5
Out of service 201.3 680.1 680.1 201.3 440.7 828.7 440.7 52.7
In service 198.6 784.3 784.3 198.6 491.4 918.6 491.4 64.2
15 51.5
Out of service 168.9 720.4 720.4 168.9 442.9 892.7 442.9 0
In service 209.4 825.4 825.4 209.4 517.4 967.8 517.4 67.0
16 54.5
Out of service 156.3 784.9 784.9 156.3 432.7 1017.0 432.7 0
In service 219.0 867.8 867.8 219.0 543.4 1018.9 543.4 67.9
17 57.5
Out of service 141.2 852.0 852.0 141.2 418.4 1149.5 418.4 0
In service 227.2 911.5 911.5 227.2 569.4 1072.1 569.4 66.6
18 60.5
Out of service 123.4 921.7 921.7 123.4 399.7 1290.7 399.7 0

149
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 65m jib with climbing equipment

Table 3-29 Reaction force for 65m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 148.2 589.9 589.9 148.2 369.1 684.7 369.1 53.4
7 27.5
Out of service 426.3 218.7 218.7 426.3 322.5 175.7 322.5 469.3
In service 144.1 601.9 601.9 144.1 373.0 700.8 373.0 45.2
8 30.5
Out of service 430.9 222.0 222.0 430.9 326.4 178.7 326.4 474.1
In service 161.2 636.7 636.7 161.2 399.0 740.2 399.0 57.7
9 33.5
Out of service 457.6 247.2 247.2 457.6 352.4 203.7 352.4 501.1
In service 155.6 650.2 650.2 155.6 402.9 758.7 402.9 47.0
10 36.5
Out of service 462.3 250.3 250.3 462.3 356.3 206.4 356.3 506.2
In service 171.1 686.6 686.6 171.1 428.8 800.6 428.8 57.1
11 39.5
Out of service 489.3 275.3 275.3 489.3 382.3 624.9 382.3 139.6
In service 163.8 701.8 701.8 163.8 432.8 821.7 432.8 43.9
12 42.5
Out of service 206.7 565.8 565.8 206.7 386.2 677.2 386.2 95.2
In service 177.6 739.9 739.9 177.6 458.7 866.2 458.7 51.2
13 45.5
Out of service 200.4 623.9 623.9 200.4 412.2 754.6 412.2 69.7
In service 190.3 779.1 779.1 190.3 484.7 912.4 484.7 57.0
14 48.5
Out of service 192.2 684.1 684.1 192.2 438.1 835.4 438.1 40.9
In service 180.0 797.2 797.2 180.0 488.6 938.1 488.6 39.2
15 51.5
Out of service 159.7 724.4 724.4 159.7 428.5 911.4 428.5 0
In service 190.5 838.6 838.6 190.5 514.6 987.7 514.6 41.5
16 54.5
Out of service 147.0 789.1 789.1 147.0 418.2 1035.8 418.2 0
In service 199.8 881.3 881.3 199.8 540.6 1039.2 540.6 41.9
17 57.5
Out of service 131.9 856.1 856.1 131.9 403.9 1168.3 403.9 0
In service 207.6 925.4 925.4 207.6 566.5 1092.9 566.5 40.2
18 60.5
Out of service 114.1 925.9 925.9 114.1 385.2 1309.6 385.2 0

150
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 62.5m jib with climbing equipment

Table 3-30 Reaction force for 62.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 143.1 591.3 591.3 143.1 367.2 687.4 367.2 47.0
7 27.5
Out of service 428.2 213.4 213.4 428.2 320.8 168.9 320.8 472.7
In service 139.0 603.2 603.2 139.0 371.1 703.4 371.1 38.7
8 30.5
Out of service 432.7 216.7 216.7 432.7 324.7 171.9 324.7 477.5
In service 156.1 638.0 638.0 156.1 397.1 742.9 397.1 51.2
9 33.5
Out of service 459.5 241.9 241.9 459.5 350.7 196.8 350.7 504.5
In service 150.4 651.6 651.6 150.4 401.0 761.4 401.0 40.5
10 36.5
Out of service 464.3 244.9 244.9 464.3 354.6 199.5 354.6 509.7
In service 166.0 688.0 688.0 166.0 427.0 803.3 427.0 50.6
11 39.5
Out of service 491.2 269.9 269.9 491.2 380.6 617.9 380.6 143.3
In service 158.6 703.2 703.2 158.6 430.9 824.4 430.9 37.3
12 42.5
Out of service 208.8 560.2 560.2 208.8 384.5 670.0 384.5 99.0
In service 172.4 741.3 741.3 172.4 456.8 869.0 456.8 44.6
13 45.5
Out of service 202.6 618.3 618.3 202.6 410.5 747.3 410.5 73.6
In service 185.1 780.5 780.5 185.1 482.8 915.2 482.8 50.4
14 48.5
Out of service 194.4 678.4 678.4 194.4 436.4 828.0 436.4 44.8
In service 174.8 798.7 798.7 174.8 486.7 940.9 486.7 32.5
15 51.5
Out of service 162.1 718.6 718.6 162.1 430.9 899.7 430.9 0
In service 185.3 840.1 840.1 185.3 512.7 990.5 512.7 34.9
16 54.5
Out of service 149.5 783.1 783.1 149.5 420.8 1023.7 420.8 0
In service 194.5 882.8 882.8 194.5 538.7 1042.1 538.7 35.3
17 57.5
Out of service 134.5 850.0 850.0 134.5 406.7 1155.8 406.7 0
In service 202.4 926.9 926.9 202.4 564.6 1095.8 564.6 33.5
18 60.5
Out of service 116.9 919.6 919.6 116.9 388.2 1296.6 388.2 0

151
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 60m jib with climbing equipment

Table 3-31 Reaction force for 60m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 136.2 598.2 598.2 136.2 367.2 697.2 367.2 37.3
7 27.5
Out of service 427.8 213.9 213.9 427.8 320.9 169.6 320.9 472.1
In service 132.1 610.3 610.3 132.1 371.2 713.4 371.2 28.9
8 30.5
Out of service 432.3 217.2 217.2 432.3 324.8 172.6 324.8 476.9
In service 149.1 645.2 645.2 149.1 397.1 753.0 397.1 41.3
9 33.5
Out of service 459.1 242.4 242.4 459.1 350.7 197.6 350.7 503.9
In service 143.3 658.8 658.8 143.3 401.1 771.7 401.1 30.5
10 36.5
Out of service 463.8 245.5 245.5 463.8 354.7 200.3 354.7 509.1
In service 158.7 695.3 695.3 158.7 427.0 813.7 427.0 40.4
11 39.5
Out of service 490.8 270.5 270.5 490.8 380.6 618.6 380.6 142.6
In service 151.2 710.6 710.6 151.2 430.9 835.0 430.9 26.9
12 42.5
Out of service 208.3 560.8 560.8 208.3 384.6 670.8 384.6 98.3
In service 164.9 749.0 749.0 164.9 456.9 879.8 456.9 34.0
13 45.5
Out of service 202.2 618.9 618.9 202.2 410.5 748.1 410.5 72.9
In service 177.5 788.3 788.3 177.5 482.9 926.2 482.9 39.6
14 48.5
Out of service 194.0 679.0 679.0 194.0 436.5 828.8 436.5 44.2
In service 166.9 806.7 806.7 166.9 486.8 952.2 486.8 21.5
15 51.5
Out of service 161.6 719.2 719.2 161.6 430.3 901.1 430.3 0
In service 177.3 848.3 848.3 177.3 512.8 1002.0 512.8 23.5
16 54.5
Out of service 149.1 783.7 783.7 149.1 420.2 1025.2 420.2 0
In service 186.3 891.2 891.2 186.3 538.7 1053.9 538.7 23.6
17 57.5
Out of service 134.1 850.6 850.6 134.1 406.0 1157.4 406.0 0
In service 193.9 935.5 935.5 193.9 564.7 1107.9 564.7 21.5
18 60.5
Out of service 116.4 920.2 920.2 116.4 387.6 1298.2 387.6 0

152
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 57.5m jib with climbing equipment

Table 3-32 Reaction force for 57.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 141.8 591.6 591.6 141.8 366.7 688.0 366.7 45.4
7 27.5
Out of service 437.5 203.2 203.2 437.5 320.4 154.7 320.4 486.1
In service 137.7 603.5 603.5 137.7 370.6 704.1 370.6 37.2
8 30.5
Out of service 442.1 206.4 206.4 442.1 324.3 157.6 324.3 491.0
In service 154.8 638.4 638.4 154.8 396.6 743.5 396.6 49.7
9 33.5
Out of service 468.9 231.6 231.6 468.9 350.3 182.4 350.3 518.1
In service 149.1 651.9 651.9 149.1 400.5 762.1 400.5 38.9
10 36.5
Out of service 473.8 234.6 234.6 473.8 354.2 185.0 354.2 523.3
In service 164.7 688.3 688.3 164.7 426.5 804.0 426.5 49.0
11 39.5
Out of service 500.8 259.5 259.5 500.8 380.1 209.5 380.1 550.8
In service 157.3 703.5 703.5 157.3 430.4 825.1 430.4 35.7
12 42.5
Out of service 505.9 262.2 262.2 505.9 384.1 655.0 384.1 113.2
In service 171.1 741.7 741.7 171.1 456.4 869.7 456.4 43.0
13 45.5
Out of service 212.7 607.4 607.4 212.7 410.0 732.1 410.0 88.0
In service 183.8 780.8 780.8 183.8 482.3 915.9 482.3 48.8
14 48.5
Out of service 204.6 667.4 667.4 204.6 436.0 812.5 436.0 59.5
In service 173.5 799.0 799.0 173.5 486.3 941.6 486.3 30.9
15 51.5
Out of service 172.5 707.4 707.4 172.5 439.9 874.4 439.9 5.4
In service 184.0 840.5 840.5 184.0 512.2 991.2 512.2 33.3
16 54.5
Out of service 160.1 771.7 771.7 160.1 435.5 992.5 435.5 0
In service 193.2 883.2 883.2 193.2 538.2 1042.8 538.2 33.6
17 57.5
Out of service 145.4 838.4 838.4 145.4 421.7 1124.0 421.7 0
In service 201.1 927.3 927.3 201.1 564.2 1096.5 564.2 31.9
18 60.5
Out of service 128.0 907.7 907.7 128.0 403.6 1264.0 403.6 0

153
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 55m jib with climbing equipment

Table 3-33 Reaction force for 55m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 143.1 589.2 589.2 143.1 366.2 684.9 366.2 47.4
7 27.5
Out of service 446.8 192.9 192.9 446.8 319.9 140.4 319.9 499.4
In service 139.0 601.1 601.1 139.0 370.1 700.9 370.1 39.2
8 30.5
Out of service 451.5 196.1 196.1 451.5 323.8 143.2 323.8 504.4
In service 156.2 635.9 635.9 156.2 396.1 740.3 396.1 51.8
9 33.5
Out of service 478.3 221.2 221.2 478.3 349.8 167.9 349.8 531.6
In service 150.5 649.4 649.4 150.5 400.0 758.9 400.0 41.1
10 36.5
Out of service 483.3 224.1 224.1 483.3 353.7 170.4 353.7 536.9
In service 166.1 685.8 685.8 166.1 425.9 800.7 425.9 51.2
11 39.5
Out of service 510.4 248.9 248.9 510.4 379.7 194.8 379.7 564.5
In service 158.8 701.0 701.0 158.8 429.9 821.7 429.9 38.0
12 42.5
Out of service 515.6 251.5 251.5 515.6 383.6 196.9 383.6 570.3
In service 172.6 739.1 739.1 172.6 455.8 866.3 455.8 45.4
13 45.5
Out of service 222.6 596.5 596.5 222.6 409.5 716.8 409.5 102.3
In service 185.4 778.2 778.2 185.4 481.8 912.3 481.8 51.3
14 48.5
Out of service 214.8 656.2 656.2 214.8 435.5 797.0 435.5 74.0
In service 175.1 796.3 796.3 175.1 485.7 938.0 485.7 33.5
15 51.5
Out of service 182.8 696.1 696.1 182.8 439.4 858.7 439.4 20.2
In service 185.7 837.7 837.7 185.7 511.7 987.5 511.7 35.9
16 54.5
Out of service 170.7 760.1 760.1 170.7 450.1 961.3 450.1 0
In service 195.0 880.3 880.3 195.0 537.7 1038.9 537.7 36.4
17 57.5
Out of service 156.1 826.6 826.6 156.1 436.7 1092.1 436.7 0
In service 203.0 924.3 924.3 203.0 563.6 1092.5 563.6 34.8
18 60.5
Out of service 139.0 895.7 895.7 139.0 418.9 1231.5 418.9 0

154
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 52.5m jib with climbing equipment

Table 3-34 Reaction force for 52.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 132.6 594.4 594.4 132.6 363.5 693.3 363.5 33.7
7 27.5
Out of service 442.2 192.7 192.7 442.2 317.4 141.0 317.4 493.8
In service 128.4 606.3 606.3 128.4 367.4 709.4 367.4 25.4
8 30.5
Out of service 446.8 195.9 195.9 446.8 321.3 143.9 321.3 498.8
In service 145.5 641.2 641.2 145.5 393.4 748.9 393.4 37.8
9 33.5
Out of service 473.6 221.0 221.0 473.6 347.3 168.7 347.3 526.0
In service 139.8 654.8 654.8 139.8 397.3 767.5 397.3 27.0
10 36.5
Out of service 478.5 223.9 223.9 478.5 351.2 171.2 351.2 531.3
In service 155.3 691.2 691.2 155.3 423.2 809.4 423.2 37.1
11 39.5
Out of service 505.6 248.8 248.8 505.6 377.2 195.6 377.2 558.8
In service 147.9 706.5 706.5 147.9 427.2 830.6 427.2 23.7
12 42.5
Out of service 510.8 251.5 251.5 510.8 381.1 640.6 381.1 121.6
In service 161.6 744.7 744.7 161.6 453.1 875.3 453.1 31.0
13 45.5
Out of service 217.9 596.3 596.3 217.9 407.1 717.5 407.1 96.7
In service 174.3 783.9 783.9 174.3 479.1 921.5 479.1 36.7
14 48.5
Out of service 210.1 656.0 656.0 210.1 433.1 797.7 433.1 68.4
In service 163.9 802.1 802.1 163.9 483.0 947.3 483.0 18.8
15 51.5
Out of service 178.1 695.8 695.8 178.1 437.0 859.3 437.0 14.6
In service 174.4 843.6 843.6 174.4 509.0 996.9 509.0 21.0
16 54.5
Out of service 166.0 759.9 759.9 166.0 442.2 967.5 442.2 0
In service 183.6 886.3 886.3 183.6 535.0 1048.6 535.0 21.4
17 57.5
Out of service 151.5 826.4 826.4 151.5 428.8 1098.2 428.8 0
In service 191.4 930.5 930.5 191.4 560.9 1102.3 560.9 19.6
18 60.5
Out of service 134.4 895.4 895.4 134.4 411.1 1237.3 411.1 0

155
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 50m jib with climbing equipment

Table 3-35 Reaction force for 50m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 134.9 587.4 587.4 134.9 361.2 684.4 361.2 37.9
7 27.5
Out of service 448.1 182.6 182.6 448.1 315.3 127.6 315.3 503.0
In service 130.8 599.3 599.3 130.8 365.1 700.5 365.1 29.7
8 30.5
Out of service 452.7 185.7 185.7 452.7 319.2 130.4 319.2 508.0
In service 148.0 634.1 634.1 148.0 391.0 739.8 391.0 42.3
9 33.5
Out of service 479.6 210.8 210.8 479.6 345.2 155.1 345.2 535.3
In service 142.3 647.6 647.6 142.3 395.0 758.3 395.0 31.6
10 36.5
Out of service 484.6 213.7 213.7 484.6 349.1 157.6 349.1 540.7
In service 158.0 683.9 683.9 158.0 420.9 800.0 420.9 41.8
11 39.5
Out of service 511.7 238.5 238.5 511.7 375.1 181.9 375.1 568.3
In service 150.7 699.0 699.0 150.7 424.9 821.0 424.9 28.7
12 42.5
Out of service 516.9 241.1 241.1 516.9 379.0 184.0 379.0 574.0
In service 164.6 737.1 737.1 164.6 450.8 865.5 450.8 36.1
13 45.5
Out of service 544.4 265.6 265.6 544.4 405.0 703.2 405.0 106.8
In service 177.5 776.1 776.1 177.5 476.8 911.5 476.8 42.1
14 48.5
Out of service 216.8 645.2 645.2 216.8 431.0 783.2 431.0 78.7
In service 167.2 794.2 794.2 167.2 480.7 937.0 480.7 24.4
15 51.5
Out of service 185.0 684.8 684.8 185.0 434.9 844.5 434.9 25.2
In service 177.9 835.4 835.4 177.9 506.7 986.3 506.7 27.0
16 54.5
Out of service 173.0 748.6 748.6 173.0 451.0 941.5 451.0 0
In service 187.4 877.9 877.9 187.4 532.7 1037.6 532.7 27.7
17 57.5
Out of service 158.8 814.9 814.9 158.8 437.9 1071.4 437.9 0
In service 195.5 921.8 921.8 195.5 558.6 1090.9 558.6 26.3
18 60.5
Out of service 142.0 883.6 883.6 142.0 420.7 1209.8 420.7 0

156
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 47.5m jib with climbing equipment

Table 3-36 Reaction force for 47.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 119.2 595.2 595.2 119.2 357.2 697.1 357.2 17.4
7 27.5
Out of service 438.7 184.8 184.8 438.7 311.8 132.2 311.8 491.3
In service 115.1 607.2 607.2 115.1 361.2 713.2 361.2 9.1
8 30.5
Out of service 443.4 188.0 188.0 443.4 315.7 135.1 315.7 496.3
In service 132.2 642.1 642.1 132.2 387.1 752.7 387.1 21.5
9 33.5
Out of service 470.2 213.1 213.1 470.2 341.6 159.9 341.6 523.4
In service 126.4 655.7 655.7 126.4 391.0 771.3 391.0 10.8
10 36.5
Out of service 475.0 216.1 216.1 475.0 345.6 162.4 345.6 528.7
In service 141.9 692.1 692.1 141.9 417.0 813.2 417.0 20.8
11 39.5
Out of service 502.1 241.0 241.0 502.1 371.5 186.9 371.5 556.2
In service 134.5 707.3 707.3 134.5 420.9 834.4 420.9 7.4
12 42.5
Out of service 507.2 243.7 243.7 507.2 375.5 189.1 375.5 561.8
In service 148.3 745.5 745.5 148.3 446.9 879.1 446.9 14.7
13 45.5
Out of service 214.8 588.0 588.0 214.8 401.4 708.1 401.4 94.7
In service 161.0 784.7 784.7 161.0 472.9 925.2 472.9 20.5
14 48.5
Out of service 207.1 647.7 647.7 207.1 427.4 788.1 427.4 66.6
In service 150.7 802.9 802.9 150.7 476.8 951.0 476.8 2.6
15 51.5
Out of service 175.3 687.3 687.3 175.3 431.3 849.5 431.3 13.1
In service 161.2 844.3 844.3 161.2 502.8 1000.5 502.8 5.0
16 54.5
Out of service 163.4 751.2 751.2 163.4 435.3 958.6 435.3 0
In service 170.5 887.0 887.0 170.5 528.7 1052.0 528.7 5.5
17 57.5
Out of service 149.1 817.4 817.4 149.1 422.3 1088.5 422.3 0
In service 178.4 931.0 931.0 178.4 554.7 1105.6 554.7 3.8
18 60.5
Out of service 132.3 886.1 886.1 132.3 405.1 1226.7 405.1 0

157
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 45m jib with climbing equipment

Table 3-37 Reaction force for 45m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 128.3 588.2 588.2 128.3 358.2 686.7 358.2 29.8
7 27.5
Out of service 447.8 177.6 177.6 447.8 312.7 121.6 312.7 503.7
In service 124.2 600.1 600.1 124.2 362.2 702.8 362.2 21.6
8 30.5
Out of service 452.5 180.7 180.7 452.5 316.6 124.5 316.6 508.7
In service 141.4 634.9 634.9 141.4 388.1 742.1 388.1 34.1
9 33.5
Out of service 479.3 205.8 205.8 479.3 342.6 149.2 342.6 536.0
In service 135.7 648.4 648.4 135.7 392.1 760.6 392.1 23.5
10 36.5
Out of service 484.3 208.7 208.7 484.3 346.5 151.6 346.5 541.3
In service 151.3 684.7 684.7 151.3 418.0 802.4 418.0 33.7
11 39.5
Out of service 511.4 233.5 233.5 511.4 372.5 175.9 372.5 569.0
In service 144.1 699.8 699.8 144.1 421.9 823.4 421.9 20.5
12 42.5
Out of service 516.6 236.1 236.1 516.6 376.4 178.0 376.4 574.7
In service 157.9 737.9 737.9 157.9 447.9 867.9 447.9 28.0
13 45.5
Out of service 544.1 260.6 260.6 544.1 402.3 696.9 402.3 107.8
In service 170.8 776.9 776.9 170.8 473.9 913.8 473.9 34.0
14 48.5
Out of service 216.8 639.8 639.8 216.8 428.3 776.7 428.3 79.9
In service 160.6 795.0 795.0 160.6 477.8 939.3 477.8 16.3
15 51.5
Out of service 185.1 679.4 679.4 185.1 432.2 837.9 432.2 26.5
In service 171.3 836.2 836.2 171.3 503.8 988.6 503.8 18.9
16 54.5
Out of service 173.3 743.1 743.1 173.3 449.8 933.2 449.8 0
In service 180.8 878.7 878.7 180.8 529.7 1039.9 529.7 19.6
17 57.5
Out of service 159.1 809.2 809.2 159.1 437.0 1062.8 437.0 0
In service 188.9 922.5 922.5 188.9 555.7 1093.2 555.7 18.3
18 60.5
Out of service 142.5 877.8 877.8 142.5 420.0 1200.6 420.0 0

158
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 42.5m jib with climbing equipment

Table 3-38 Reaction force for 42.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 127.9 581.7 581.7 127.9 354.8 679.0 354.8 30.6
7 27.5
Out of service 445.5 173.6 173.6 445.5 309.5 117.3 309.5 501.8
In service 123.9 593.6 593.6 123.9 358.7 694.9 358.7 22.5
8 30.5
Out of service 450.1 176.8 176.8 450.1 313.5 120.2 313.5 506.8
In service 141.1 628.3 628.3 141.1 384.7 734.2 384.7 35.2
9 33.5
Out of service 477.0 201.9 201.9 477.0 339.4 144.9 339.4 534.0
In service 135.6 641.7 641.7 135.6 388.6 752.5 388.6 24.7
10 36.5
Out of service 481.9 204.8 204.8 481.9 343.4 147.4 343.4 539.3
In service 151.3 677.9 677.9 151.3 414.6 794.1 414.6 35.0
11 39.5
Out of service 509.0 229.6 229.6 509.0 369.3 171.7 369.3 566.9
In service 144.1 692.9 692.9 144.1 418.5 815.0 418.5 22.0
12 42.5
Out of service 514.3 232.2 232.2 514.3 373.2 173.8 373.2 572.7
In service 158.2 730.8 730.8 158.2 444.5 859.2 444.5 29.7
13 45.5
Out of service 541.7 256.8 256.8 541.7 399.2 692.3 399.2 106.1
In service 171.2 769.7 769.7 171.2 470.4 905.0 470.4 35.9
14 48.5
Out of service 214.7 635.7 635.7 214.7 425.2 772.1 425.2 78.3
In service 161.2 787.5 787.5 161.2 474.4 930.2 474.4 18.5
15 51.5
Out of service 183.1 675.1 675.1 183.1 429.1 833.2 429.1 25.0
In service 172.1 828.6 828.6 172.1 500.3 979.2 500.3 21.5
16 54.5
Out of service 171.4 738.8 738.8 171.4 445.3 929.6 445.3 0
In service 181.8 870.8 870.8 181.8 526.3 1030.1 526.3 22.5
17 57.5
Out of service 157.3 804.8 804.8 157.3 432.7 1058.8 432.7 0
In service 190.2 914.3 914.3 190.2 552.3 1083.0 552.3 21.6
18 60.5
Out of service 140.9 873.2 873.2 140.9 416.0 1196.1 416.0 0

159
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 40m jib with climbing equipment

Table 3-39 Reaction force for 40m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 123.0 577.7 577.7 123.0 350.3 675.1 350.3 25.6
7 27.5
Out of service 436.1 174.9 174.9 436.1 305.5 120.8 305.5 490.2
In service 119.0 589.5 589.5 119.0 354.3 691.0 354.3 17.5
8 30.5
Out of service 440.7 178.1 178.1 440.7 309.4 123.7 309.4 495.1
In service 136.3 624.1 624.1 136.3 380.2 730.2 380.2 30.3
9 33.5
Out of service 467.5 203.2 203.2 467.5 335.4 148.5 335.4 522.3
In service 130.8 637.5 637.5 130.8 384.1 748.5 384.1 19.8
10 36.5
Out of service 472.4 206.2 206.2 472.4 339.3 151.1 339.3 527.5
In service 146.6 673.6 673.6 146.6 410.1 790.0 410.1 30.3
11 39.5
Out of service 499.4 231.1 231.1 499.4 365.3 175.5 365.3 555.0
In service 139.6 688.5 688.5 139.6 414.0 810.7 414.0 17.4
12 42.5
Out of service 504.5 233.8 233.8 504.5 369.2 177.7 369.2 560.6
In service 153.7 726.3 726.3 153.7 440.0 854.8 440.0 25.2
13 45.5
Out of service 531.9 258.4 258.4 531.9 395.1 696.0 395.1 94.3
In service 166.8 765.1 765.1 166.8 466.0 900.3 466.0 31.6
14 48.5
Out of service 205.1 637.1 637.1 205.1 421.1 775.8 421.1 66.5
In service 156.9 782.8 782.8 156.9 469.9 925.4 469.9 14.4
15 51.5
Out of service 173.5 676.6 676.6 173.5 425.0 836.9 425.0 13.2
In service 168.0 823.7 823.7 168.0 495.9 974.2 495.9 17.5
16 54.5
Out of service 161.7 740.3 740.3 161.7 429.5 945.1 429.5 0
In service 177.9 865.8 865.8 177.9 521.8 1024.8 521.8 18.9
17 57.5
Out of service 147.8 806.2 806.2 147.8 416.9 1074.1 416.9 0
In service 186.5 909.1 909.1 186.5 547.8 1077.4 547.8 18.2
18 60.5
Out of service 131.3 874.6 874.6 131.3 400.3 1211.3 400.3 0

160
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 37.5m jib with climbing equipment

Table 3-40 Reaction force for 37.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 113.4 568.3 568.3 113.4 340.8 665.7 340.8 15.9
7 27.5
Out of service 422.2 171.5 171.5 422.2 296.8 119.5 296.8 474.1
In service 109.5 580.0 580.0 109.5 344.7 681.5 344.7 8.0
8 30.5
Out of service 426.8 174.8 174.8 426.8 300.8 122.6 300.8 478.9
In service 126.9 614.5 614.5 126.9 370.7 720.5 370.7 20.9
9 33.5
Out of service 453.5 200.0 200.0 453.5 326.7 147.5 326.7 506.0
In service 121.6 627.7 627.7 121.6 374.6 738.6 374.6 10.7
10 36.5
Out of service 458.2 203.1 203.1 458.2 330.6 150.2 330.6 511.1
In service 137.5 663.7 663.7 137.5 400.6 779.9 400.6 21.4
11 39.5
Out of service 485.2 228.1 228.1 485.2 356.6 174.8 356.6 538.4
In service 130.7 678.4 678.4 130.7 404.5 800.3 404.5 8.8
12 42.5
Out of service 490.2 230.9 230.9 490.2 360.5 618.2 360.5 102.8
In service 145.0 716.0 716.0 145.0 430.5 844.1 430.5 16.9
13 45.5
Out of service 198.7 574.3 574.3 198.7 386.5 694.7 386.5 78.3
In service 158.4 754.5 754.5 158.4 456.5 889.3 456.5 23.7
14 48.5
Out of service 191.2 633.7 633.7 191.2 412.5 774.4 412.5 50.5
In service 148.8 771.9 771.9 148.8 460.4 913.9 460.4 6.9
15 51.5
Out of service 159.7 673.1 673.1 159.7 413.9 837.9 413.9 0
In service 160.3 812.5 812.5 160.3 486.4 962.2 486.4 10.6
16 54.5
Out of service 148.1 736.6 736.6 148.1 405.3 958.8 405.3 0
In service 170.6 854.1 854.1 170.6 512.3 1012.2 512.3 12.5
17 57.5
Out of service 134.3 802.4 802.4 134.3 393.1 1087.2 393.1 0
In service 179.6 897.0 897.0 179.6 538.3 1064.1 538.3 12.5
18 60.5
Out of service 118.1 870.5 870.5 118.1 376.9 1223.5 376.9 0

161
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 35m jib with climbing equipment

Table 3-41 Reaction force for 35m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 120.3 556.8 556.8 120.3 338.5 650.4 338.5 26.6
7 27.5
Out of service 424.1 165.4 165.4 424.1 294.7 111.8 294.7 477.7
In service 116.5 568.4 568.4 116.5 342.4 666.0 342.4 18.8
8 30.5
Out of service 428.7 168.6 168.6 428.7 298.6 114.8 298.6 482.5
In service 134.0 602.8 602.8 134.0 368.4 704.9 368.4 31.9
9 33.5
Out of service 455.4 193.8 193.8 455.4 324.6 139.7 324.6 509.6
In service 128.8 615.8 615.8 128.8 372.3 722.7 372.3 21.9
10 36.5
Out of service 460.2 196.9 196.9 460.2 328.5 142.4 328.5 514.7
In service 145.0 651.6 651.6 145.0 398.3 763.8 398.3 32.8
11 39.5
Out of service 487.1 221.9 221.9 487.1 354.5 167.0 354.5 542.1
In service 138.3 666.2 666.2 138.3 402.2 783.9 402.2 20.5
12 42.5
Out of service 492.1 224.7 224.7 492.1 358.4 169.3 358.4 547.5
In service 152.8 703.5 703.5 152.8 428.2 827.4 428.2 29.0
13 45.5
Out of service 201.0 567.8 567.8 201.0 384.4 686.5 384.4 82.3
In service 166.5 741.8 741.8 166.5 454.1 872.2 454.1 36.1
14 48.5
Out of service 193.5 627.2 627.2 193.5 410.4 766.0 410.4 54.7
In service 157.2 759.0 759.0 157.2 458.1 896.5 458.1 19.7
15 51.5
Out of service 162.1 666.5 666.5 162.1 414.3 826.8 414.3 1.8
In service 168.9 799.2 799.2 168.9 484.0 944.3 484.0 23.8
16 54.5
Out of service 150.6 729.9 729.9 150.6 407.7 945.6 407.7 0
In service 179.5 840.5 840.5 179.5 510.0 993.9 510.0 26.2
17 57.5
Out of service 137.0 795.5 795.5 137.0 395.7 1073.6 395.7 0
In service 189.0 883.0 883.0 189.0 536.0 1045.2 536.0 26.7
18 60.5
Out of service 121.0 863.4 863.4 121.0 379.7 1209.4 379.7 0

162
 WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Reaction force for 32.5m jib with climbing equipment

Table 3-42 Reaction force for 32.5m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 125.5 551.3 551.3 125.5 338.4 642.8 338.4 34.0
7 27.5
Out of service 425.7 163.5 163.5 425.7 294.6 109.2 294.6 480.1
In service 121.8 562.9 562.9 121.8 342.3 658.3 342.3 26.3
8 30.5
Out of service 430.3 166.8 166.8 430.3 298.5 112.2 298.5 484.9
In service 139.4 597.2 597.2 139.4 368.3 697.1 368.3 39.5
9 33.5
Out of service 457.1 192.0 192.0 457.1 324.5 137.1 324.5 512.0
In service 134.2 610.2 610.2 134.2 372.2 714.8 372.2 29.6
10 36.5
Out of service 461.8 195.0 195.0 461.8 328.4 139.8 328.4 517.1
In service 150.4 645.9 645.9 150.4 398.2 755.7 398.2 40.6
11 39.5
Out of service 488.8 220.0 220.0 488.8 354.4 164.3 354.4 544.5
In service 143.8 660.4 660.4 143.8 402.1 775.8 402.1 28.4
12 42.5
Out of service 493.8 222.8 222.8 493.8 358.3 166.7 358.3 550.0
In service 158.5 697.7 697.7 158.5 428.1 819.1 428.1 37.0
13 45.5
Out of service 521.1 247.5 247.5 521.1 384.3 683.8 384.3 84.8
In service 172.3 735.8 735.8 172.3 454.0 863.8 454.0 44.3
14 48.5
Out of service 195.3 625.2 625.2 195.3 410.3 763.3 410.3 57.2
In service 163.1 752.9 752.9 163.1 458.0 887.9 458.0 28.0
15 51.5
Out of service 163.9 664.5 664.5 163.9 414.2 824.0 414.2 4.4
In service 174.9 792.9 792.9 174.9 483.9 935.6 483.9 32.3
16 54.5
Out of service 152.5 727.9 727.9 152.5 410.2 940.2 410.2 0
In service 185.7 834.1 834.1 185.7 509.9 984.9 509.9 34.9
17 57.5
Out of service 138.8 793.4 793.4 138.8 398.2 1068.0 398.2 0
In service 195.3 876.4 876.4 195.3 535.9 1036.0 535.9 35.7
18 60.5
Out of service 122.9 861.3 861.3 122.9 382.3 1203.7 382.3 0

163
 TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Reaction force for 30m jib with climbing equipment

Table 3-43 Reaction force for 30m jib with climbing equipment
Number Tower Case 1(kN) Case 2(kN)
Operation
of height
status RA RB RC RD RA RB RC RD
sections (m)
In service 120.0 548.4 548.4 120.0 334.2 640.4 334.2 28.0
7 27.5
Out of service 415.7 165.9 165.9 415.7 290.8 114.1 290.8 467.5
In service 116.3 559.9 559.9 116.3 338.1 655.9 338.1 20.3
8 30.5
Out of service 420.3 169.2 169.2 420.3 294.7 117.2 294.7 472.3
In service 133.9 594.2 594.2 133.9 364.1 694.6 364.1 33.6
9 33.5
Out of service 446.9 194.5 194.5 446.9 320.7 142.2 320.7 499.2
In service 128.8 607.2 607.2 128.8 368.0 712.3 368.0 23.7
10 36.5
Out of service 451.7 197.6 197.6 451.7 324.6 144.9 324.6 504.3
In service 145.1 642.9 642.9 145.1 394.0 753.1 394.0 34.8
11 39.5
Out of service 478.5 222.6 222.6 478.5 350.6 169.6 350.6 531.5
In service 138.6 657.2 657.2 138.6 397.9 773.1 397.9 22.7
12 42.5
Out of service 483.5 225.5 225.5 483.5 354.5 612.6 354.5 96.4
In service 153.3 694.5 694.5 153.3 423.9 816.3 423.9 31.4
13 45.5
Out of service 192.5 568.5 568.5 192.5 380.5 689.0 380.5 71.9
In service 167.1 732.5 732.5 167.1 449.8 860.9 449.8 38.8
14 48.5
Out of service 185.0 627.9 627.9 185.0 406.4 768.5 406.4 44.4
In service 158.0 749.5 749.5 158.0 453.8 884.8 453.8 22.7
15 51.5
Out of service 153.6 667.1 667.1 153.6 401.9 837.8 401.9 0
In service 170.0 789.4 789.4 170.0 479.7 932.3 479.7 27.1
16 54.5
Out of service 142.2 730.5 730.5 142.2 393.5 958.3 393.5 0
In service 180.9 830.5 830.5 180.9 505.7 981.5 505.7 29.9
17 57.5
Out of service 128.6 796.0 796.0 128.6 381.6 1086.0 381.6 0
In service 190.7 872.7 872.7 190.7 531.7 1032.4 531.7 30.9
18 60.5
Out of service 112.6 863.9 863.9 112.6 365.8 1221.5 365.8 0

164
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

3.10 Power supply

Definition
Nominal power
This is the sum of the nominal powers (operating powers consumed simultaneously by the three
movements) of:
◼ hoisting mechanism
◼ trolley mechanism
◼ slewing mechanism

Starting power
This is the sum of the powers consumed temporarily by these same three movements under the
following conditions:
◼ starting power of the mechanism with the highest current consumption (in general: the
hoisting mechanism)
◼ nominal power of the two other mechanisms

Nominal current intensity

Results from the nominal power

Starting current intensity

Results from the starting power.
Nominal Nominal
Mechanism Frequency Type of mechanism
power in kW intensity at A
Hoisting
50Hz H45FC30-600C 45 82
mechanism
Trolley T55FC70-b /
50Hz 5.5 11.6
mechanism T55FC70-b(D)
Slewing S75CA-130LB12/14A
50Hz 2*7.5 34.6
mechanism S75CN-130LB12/14A

165
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Current supply
Characteristic of the site power supply
The electrical equipment of the tower crane must comply with relevant regulations to
ensure normal operation of equipment and safety of personnel. The equipment must
conform to the current standards of the country where it is located. There is an example
of overall current supply arrangement below:

(1) Power grid (2) Counted by voltmeter

(3) Enforced isolation (4) Auto-break device
(5) Local grounding plug (6) Distributing box

The protection of power grid should include:

A distributing box after the voltage-meter, which has built-in automatic breakers and leakage
protection device, which is adjustable, to turn off the circuit.
The distributing box, included in tower crane electrical system should configure multistage switch.
The switch can be locked at off-location, in order to maintenance or dealing with accident.

All the power cables must keep away from the communication cables!

166
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

Grounding
Installing grounding wire should accord with current standards, which requires:
◼ Metal parts’ grounding;
◼ Track’s grounding.
◼ All the grounding parts should be connected, the connection of the grounding circuit should
be checking in period.
◼ The grounding wire is yellow-green, which connects the “grounding” terminal of metal parts
to grounding plugs or grid. The method of grounding sees also in relative introductions of
mechanism parts, the grounding resistance should not more than 4 Ohms.

◼ It’s forbidden to replace the grounding wires with neutral wires.

◼ The grounding wires should be conducted, and isolated from any
breaker.

Power source cable

The power source cable includes 3 phase conductors, 1 neutral conductor, and 1 grounding
conductor which is yellow-green. The grounding line should be fixed on the reserved terminal.
Accident could be caused by any source line’s damage, so it’s recommended to dispose the
source lines in appropriate way to ensure that no damage on insulation of the lines.

The requirement of tower crane’s source

A. Power
The power of the source is determined by capacity of all mechanism, speed controlling manner
and working condition (With load or without load start-up).
B. Characteristic of supply voltage
◼ According to our technical specification, the supply voltage at the crane switch must be:
50 Hz in Europe
maximum voltage without load: 400 V + 6% (i.e. between 400 V and 420 V)
minimum voltage with load: 400 V - 10% (i.e. between 360 V and 400 V)
◼ The minimum voltage depends on:
the voltage supplied by the supply source with load,
the voltage drops in the supply cable,
the cable cross- section (the thicker the cable is, the lower the voltage drop will be),
the type of the cable (aluminum or copper),
the cable length between the supply source and the crane switch,
the current surge when starting the crane.
Choosing a cable cross-section
As a first approach, a cable cross- section is accepted if the current density which is passing
through is lower than 4 amperes per 𝑚𝑚2 .

167
TECHNICAL DATA OF CRANE AND SITE WA7025-12E-138EN-B03

Example: Current intensity of the crane 50 amperes:

50
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑐𝑎𝑏𝑙𝑒 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 = = 12.5𝑚𝑚2
4

◼ Take the cable cross- section (in the “Cable cross- section” rod of the table below) which is
equal or slightly bigger, i.e. 3 x 16 mm2 + N (neutral)+T (earth)

Copper Cables
Voltage drop per kilometer per ampere, V/(km·A)
No. Cable cross- section
(cos Ф= 0,8)
1 3 x 6 mm2+ N+T 6.00
2 3 x 10 mm2+ N+T 3.50
3 3 x 16 mm2+ N+T 2.20
4 3 x 25 mm2+ N+T 1.50
5 3 x 35 mm2+ N+T 1.10
6 3 x 50 mm2+ N+T 0.77
7 3 x 70 mm2+ N+T 0.57
8 3 x 95 mm2+ N+T 0.46
9 3 x 120 mm2+ N+T 0.38
10 3 x 150 mm2+ N+T 0.32
11 3 x 185 mm2+ N+T 0.28
12 3 x 240 mm2+ N+T 0.23

C. Determining the coefficient of the voltage drop

◼ Take the coefficient of the voltage drop in the table above depending on the cable cross-
section calculated before.
Calculation of the maximum supply cable length for a known cable cross-section
Data:
➢ Supply source: 50 Hz
420 V with the crane without load
390 V with the crane with load
➢ Crane: Value of the permissible minimum voltage 360 V with load.
The voltage drop must not exceed 390 V - 360 V = 30 V in the cable of length L.

The formula will be:

𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑑𝑟𝑜𝑝
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑒𝑛𝑔𝑡ℎ =
𝑐𝑜𝑒𝑓𝑓.× 𝐼𝑑

168
WA7025-12E-138EN-B03 TECHNICAL DATA OF CRANE AND SITE

with:
30 V: permissible voltage dropping,
Voltage dropping: depending on the cable cross- section,
Id: starting current intensity.
Example:

2
1. For a cable of 3 x 16 mm + N (neutral)+T (earth), the coefficient is of 2,2

2. With a starting current intensity of 190A

it is obtained:

30 30
= = 0,072 𝑘𝑚, 𝑖. 𝑒. 72 𝑚
2.2 × 190 418

0. In order to obtain a more considerable length, a bigger cable cross- section must be taken
(with a lower coefficient).
Example:

2
- For a cable of 3 x 35 mm + N (neutral)+T (earth), the coefficient is of 1,1

- With the same starting current intensity of 190 A

it is obtained:
30 30
= = 0,144 𝑘𝑚, 𝑖. 𝑒. 144 𝑚
1.1 × 190 209

Connecting the motors

Before connecting the crane, check the connection in the terminal boxes; carry out the same
operation when replacing a motor.

A. Identification of the motors

On the rating plate are indicated the supply voltage, the frequency of this voltage followed by the
sign for star or delta connection depending on the connection to be carried out for this voltage,
or there are two voltages indicated of which the lowest one corresponds to delta connection.
Furthermore, in order to call the servicemen’s attention to the motor 400 V in delta connection, a
plate is riveted on the motor stator.

B. Checking the direction of rotation of the motors

Having connected the crane to the mains, operate a” Lowering” pulse on the control unit or with
the jib retaining winch for GTMR and HDT cranes which are equipped with a LVF hoist winch;
check that the rope slackens.
◼ If yes, the direction of rotation is correct
◼ If not, interchange two wires in the plug or in the circuit breaker of the mains supply.

169
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4 ERECTION/ADJUSTMENT/DISMANTLING
4.1 Foreword

This part comprises the instructions allowing the fitter in charge with the crane installation on the site
to:

◼ erect the crane,

◼ carry out the adjustments,
◼ dismantle the crane.

According to the method applicable to the configuration(s) defined on the order.

The erection and dismantling operations of the crane must be ABSOLUTELY CARRIED OUT in
the indicated order.

This part does not comprise instructions concerning special operations.

These last operations can only be carried out by the constructor or his representative.

This part cannot be separated from the whole document: it can only be used after reading the
Chapter 2 <SAFETY INSTRUCTION> and Chapter 3 <TECHNICAL DATA OF CRANE AND
SITE>.

170
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.2 Note on safety regarding erection

The operating mode defined below allows fast and safe assembling of the crane up to its climbing
or working position (complete erection by means of a mobile crane).

The erection operations need an auxiliary lifting equipment of which the characteristics must be
adapted to the parts to be handled.

AUXILIARY LIFTING EQUIPMENT

The optimization of the operating time of the mobile crane needs a good preparation and a good
coordination between the various erection and assembling sequences, the fitter teams, the
access possibilities, and the assembling area.

This document aims to familiarize yourself with the whole erection operations of which each one
is detailed in the specific files.

Erection instructions
◼ These instructions concern:
➢ The erection of the crane
➢ The increase in height of the crane
➢ The dismantling of the crane
◼ All the handling operations must be carried out according to the instructions of this manual.
and especially:
➢ Ensure the correct supports of the loads
➢ Do not work with overload
➢ Use slings in perfect condition and dimensioned for the weight of the elements to be handled.
➢ Observe the slinging points
The erection operations can only be carried out with the wind speed below 14 m/s.
The erection operations must be carried out in the order indicated in this manual.
During the preparing steps compulsorily fit the safety equipment such as ladders, platforms, grab
rails, guard ropes, etc. in order to use them during the erection.

Any hoisting operation is absolutely forbidden if the counter ballast is not

placed.

COMPOSITION OF THE COUNTER BALLAST

171
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

FITTING THE COUNTER BALLAST BLOCKS

➢ For cranes on chassis and cross−shaped base, the ballast placed must correspond to the
hook height to be reached. In case of partial ballasting, the partial ballast must correspond
to the erection height of the crane, but must never be lower than the indicated minimum
value.

CHASSIS − BALLAST AND REACTIONS

CROSS−SHAPED BASE − BALLAST AND REACTIONS

➢ For cranes with special operating conditions, observe the given instructions.

SPECIAL CHARACTERISTICS

➢ For any particularly problem concerning the assembly organization or any other matter, do
not hesitate to ask for the technical assistance of the constructor.

For each crane, there are variable elements according to the models, versions,
options. The sketches used on the following pages represent the crane in one of
its possible configurations. When these sketches explain only a function, they
have a grey outline.

Before assembling the sections, carry out a visual check of the steel
structure parts, welds and assembling parts. Elements which show
deformations, corrosion and cracked welds must be returned to the
workshop for repairing.

Fitting the split pins

In order to ensure their pin locking function correctly, this split pin type must be fitted by opening
both split pin legs and not only the longest one (Detail B).

It is not compulsory to fold down the legs against the pin; It is sufficient to fold down each leg
according to an angle a, depending on the split pin diameter (detail C and table below). This
limited opening makes the split pin removal easier when dismantling the crane pins.

Nevertheless, it is necessary to check that the legs are not running the risk of abutting against
obstacles, what may lead to their deformation, and even their deterioration in case of shaft rotation.

In order to avoid this disadvantage, it may be necessary to fold the legs completely (Detail D).

172
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Only use new split pins or split pins in good working order.

Fitting the high-strength bolt

The preload of the high-strength bolt must be aligned with the data in the
following Table 4-1

Table 4-1 Preload of high-strength bolt

Yield
Strength of Preload F1 kN
Performance point
extension
race Rel
Rm N/mm2 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39
N/mm2

8.8 ≥800 ≥640 70 86 110 135 158 205 250 310 366 437
10.9 ≥1000 ≥900 99 120 155 190 223 290 354 437 515 615
12.9 ≥1200 ≥1080 119 145 185 229 267 347 424 525 618 738

Calculate the effective area of

157 192 245 303 353 459 561 494 817 976
the bolt

Note:
The preload value in the table is calculated as 0.7 Rel, in which Rel take the minimum value
in each gear.

173
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

The diagram of erection

◼ Chassis
➢ Installing the bogies

➢ Fit the chassis and place the ballast.

◼ Outrigger stationary foundation and one base mast section

◼ The climbing equipment assembly (include tower section, climbing equipment, mounting
device and transition section)

◼ The slewing assembly (include turntable, slewing ring, slewing support, slewing
mechanisms, cabin, electrical control cabinet and electric resistance cabinet)

◼ The counter jib assembly (include hoisting mechanism and tie bar).

174
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ The first 3t counter ballast

◼ Jib assembly (include trolley and trolley mechanism)

◼ The remainder counter ballast, electrical control system, the hoist rope and climbing
operation

◼ The installation orders based on produces standard packing and delivery

status to make the optimal efficiency installation principle
◼ The installing of each unit assembly all based on the actual requirement. In
accordance with reasonable order to install in turns after dismantling. If you
have any questions, please consult our service staff.

175
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4.3 Installing the tower section and climbing equipment

assembly
Tower section
Tower section (Rung ladder)
◼ Base tower section

There are four groups of vertical pin shaft connection holes at the top and below surfaces of the
base tower section, the top pin hole is Φ55, the below pin hole is Φ65. (shown as Fig. 4-1)

Fig. 4-1 Base tower section L68G23

All the tower section is unitary which connected and assembled with special
bolts.

176
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Tower section
Tower section L68A4 / L68B7A are piece structures (shown as Fig. 4-2), each piece of the
structure is assembled by dedicated bolts, the upper pin holes are Φ55; the lower pin holes of
L68A4 are Φ55, the lower pin holes of L68B7A are Φ65. Tower section L68A4 can also be
substituted by L68B6 /L68B6A.

Fig. 4-2 Tower section structure

Every Tower Section is equipped with channels, flat roof and ladders for human’s resting and
pass. The channels have D、A two types (as shown in Fig. 4-3).The installation of Tower Section
and channel has been done on the ground and they must be used relatively. All elbow ladders
should be installed on the side leaf of climbing pedestal. According to the height of tower body,
the bottom tower section must install Channel A, the remaining channels A and channels D
alternate installation in turn.

Fig. 4-3 Passageway H and Passageway J

177
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Tower section (Incline ladder)

◼ Base tower section
There are four groups of vertical pin shaft connection holes at the top and below surfaces of the
base tower section L68G23-C, the top pin hole is Φ55, the below pin hole is Φ60. (shown as Fig.
4-4).

Fig. 4-4 Base tower section L68G23-C

178
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Tower section
Tower section L68A1A is a piece structure, each piece is assembled by bolts, the top and below
pin hole are Φ55 (see Fig. 4-5); Tower section L68A1A can also be substituted for L68B1A
(seeFig. 4-6).

Fig. 4-5 L68A1A

Fig. 4-6 L68B1A

Tower section L68B7A-C (use for chassis stationary) is a piece structure, each piece
assembles by special bolts, the top pin hole is Φ55, and below pin hole is Φ65. (see Fig. 4-7)

Fig. 4-7 L68B7A-C

179
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Climbing system
Climbing equipment
The climbing system consists of the structure, platform, ladders, cylinder, climbing beam, pump
station and so on, shown in Fig. 4-8. The installation of platform and rail see Chapter 7 < SPARE
PARTS >.

Fig. 4-8 Climbing system

(1) Upper platform (2) Climbing equipment structure
(3) Middle-level platform (4) Cylinder, pump station
(5) Climbing beam

Transition tower section

According to the picture, mounting the platform、short ladder and ladder Ⅱ, assemble the
transition tower section.

Fig. 4-9 Transition tower section assembly

180
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Mounting device

Fig. 4-10 Assemble mounting device

(1) Transition tower section (2) Mounting device
(3) Platform

Assembling the Climbing unit

Fig. 4-11 Installation scheme 1 of Climbing unit

(1) Transition tower section (2) Climbing equipment
(3) Base tower section (4) Cylinder, pump station
(5) Climbing beam

181
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Fig. 4-12 Installation scheme 2 of Climbing unit

(1) Platform (2) Transition tower section
(3) Mounting device (4) Climbing equipment
(5) Base tower section (6) Cylinder, pump station
(7) Climbing beam

Installing
1) Assembly two tower sections;
2) Installing Transition tower section:
➢ Sling the transition tower section on the tower section, align the opening direction of the
platform in the transition tower section to the tower section, then descend slowly. It
connected with climbing equipment;
3) Installing climbing equipment (Include climbing beam and cylinder):
➢ Assembly climbing equipment (The tower mast and climbing unit assembly had been
assembled as our company require, users only need to install the accessories such as
platforms and rails);
➢ Climbing equipment slowly mounting at the outside of tower mast, the location of cylinder
must align the tower mast (same side);
➢ Climbing equipment contact with transition section through 4 sets Φ50 pins;
➢ Put the hang plate on the upper latch of the tower section.

182
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Fig. 4-13 Installing the Climbing unit

(1) Outrigger stationary foundation (2) Outrigger
(3) Climbing unit

In order to ascend and descend the tower crane successfully, please

ensure that the tower has a step plane perpendicular to the building.

When installing, pay attention to the direction of tower sections’ climbing steps;
Recommended installing the bolt from top to bottom, also install from bottom to
top according actual condition, meet the stress condition.

183
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

The base tower section and the climbing lug must be aligned.
Sling the Climbing unit, fixed it on the outrigger with 8 sets Φ65-203 pins as shown in Fig. 4-14.
Check the mast verticality through theodolite or lifting line method. The verticality error of four
side of main chord rod shall be not more than 1.5/1000.

Fig. 4-14 Pin connection

◼ The roller is adjustable. When the crane is working, adjust the gap
between the climbing equipment guide wheel and the main chord of
the tower section to the widest state; when the crane is heightening,
adjust the gap to 1~3mm.
◼ Installing the climbing hydraulic cylinder, the pump station is hoisted
on the lower platform. The oil pipe is installed. To avoid cylinder
burning-out, please check in the pump station. Make sure that the
motor fan is aligned with the direction of the label. If there is any
error, you should reconnect the motor cable;
◼ Make sure that the cylinder and the mast latch should be on the
same side. The mounting platform is opposite to the mast latch of
the tower.
◼ Put the climbing claws on the lugs of tower section
◼ The large free-standing height of M tower mast shall be lowered the
climbing equipment to the ground or reduce the use of off-working.

184
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.4 Installing the slewing assembly

Description
The main parts of slewing assembly had assembled following our company require, users only
install the Platform and rail, etc.
The slewing assembly consists of turntable, slewing ring, slewing support, slewing mechanisms,
cabin, and electrical control cabinet, as shown in Fig. 4-15. The selection of high-strength bolt for
turntable and slewing ring, slewing support, and slewing ring refer to chapter 4.3.

Fig. 4-15 Slewing assembly

(1) Electrical control cabinet (2) Resistance cabinet
(3) Turntable (4) Slewing ring
(5) Slewing support (6) Slewing mechanisms
(7) Cabin

185
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

CAUTIONS:
◼ Bolt pair for slewing ring
➢ The high-strength bolts and the preload torque see the chapter 4.2.3.
➢ Use flat washers which need hardening and tempering. Spring washers could not be used.
◼ Installation of bolt pair for slewing ring
➢ Before installing, clean the erecting datum plane of slewing ring and the erecting plane of
yoke, and wipe off wet fouling, burr, paint, and other foreign impurity.
➢ During installing, the sign “S” and the hole with steel ball blocking should be placed less
under load area or no-load area (That is, the slewing ring near the installation place).

Fig. 4-16 Soft belt of the slewing ring

Screw down the high-strength bolts in the direction of 180° symmetrically and continuously. Make
sure the preload moments are equal in screw bolts at the last time.

Fig. 4-17 The sequence of screwing down bolts

◼ Lubrication and maintenance

➢ Add grease into slewing ring regularly. Shorten the period of greasing in special working
condition such as in tropic, big humidity, too much dust and big range of temperature
changing. Add enough new grease before and after tower crane out of working over a long
period.
➢ Check the preload moment of bolts when slewing ring is in service for 100 hours. Then check
it once more after every 500 hours working time, ensuring there is enough preload.
➢ Do not sluice slewing ring by water for fear that water get in.

186
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Installing
Align 4 main chords of the slewing ring support to 4 main chords connecting sleeve of transition
section. Let them down slowly to keep slewing support contact with the transition section, as
shown in figure below. Connect it to the transition section by 8 sets Ф55 pins.

Fig. 4-18 Installing slewing assembly

4.5 Installing the counter jib

Description
Counter jib consists of Front counter-jib section, Rear counter-jib section, hoisting mechanism,
derrick and counter jib strut (the short strut fixed on the Front counter-jib section, installing with
counter jib section). The Front counter-jib section connected with turntable by 4 sets Ф70 pins,
as shown in Fig. 4-19.

Fig. 4-19 Counter jib assembly

187
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Assemble the Front counter-jib section

Before sling Front counter-jib section, each short strut connects to Front counter-jib section by 1
sets Ф50×90/130 pin, the installation as following picture.

Fig. 4-20 The Front counter-jib section

Assemble the counter jib

The Front counter-jib section connect to turntable by 4 sets Ф70×335 pins, pay attention to
washer between the bottom chord rod of counter jib and split pin to avoid the pin scrape bottom
chord rod while the tower crane in service.

Fig. 4-21 Assemble the counter jib

188
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Assemble the Rear counter-jib section

Before sling the Rear counter-jib section, in addition to install the platform、rail、derrick and
hoisting mechanism, and also necessary to install the counter jib strut, as the following picture.
The mechanism can be sling together or separately.
The main parts of counter jib (including the strut and hoisting mechanism) assembly had
assembled following our company require, users only install the Platform and rail, etc.

Fig. 4-22 Assemble the Rear counter-jib section

Sling the Rear counter-jib section

Before sling, slewing the upper of the tower crane to convenient install the counter jib section Ⅱ
position, and then sling Rear counter-jib section by the 4 ear-plate on jib, as show in the following
picture.

Fig. 4-23 Sling the Rear counter-jib section

Use 2 sets Ф55×100/150 pin connect bottom chord of counter jib section Ⅱ to bottom chord of
counter jib section Ⅰ through pin holes tie-in, and then sling the jib section slowly to make it
turn around lower chord pin, fixed the long and short strut by Ф50×90/130 pin, as show in the
following picture.

189
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Fig. 4-24 Sling the Rear counter-jib section

Finally, put the Rear counter-jib section down slowly, and then finish the installation.

Installing the first 3.0 t counter ballast

Fig. 4-25 Installing the first 3.0t counter ballast

◼ The counter ballast is placed by hoisting mechanism, positioned at the
middle of left and right, the distance between the two sides of counter jib
and the side chords is uniform.
◼ The pins of counter ballast must beyond the support plate of the counter
ballast.

190
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.6 Installing the jib assembly

Assembling the jib
The jib assembly consists of the jib structure, trolley mechanism and trolley.
Assemble the jib according to the sequence mark on each section strictly, it’s forbidden
to install them mistakenly or randomly. The jib can be assembled to be length of 70m, 67.5m,
65m, 62.5m, 60m, 57.5m, 55m, 52.5m, 50 m, 47.5m, 45m, 42.5m, 40m, 37.5m, 35m, 32.5m and
30m, refer to the Section 4.6.1.1.

CAUTION:
◼ To avoid of the hoisting and trolley pulleys touching the ground when being transported and
stored, the state of the pulleys should be like the Fig. 4-26.

Fig. 4-26 State of the hoisting and trolley pulleys in transportation

◼ When installing the hoisting and trolley pulleys of the Jib Ⅰ, adjust them to the after-installed
state. Otherwise, the hoisting and trolley ropes will wear the incline diagonal or the rope-
block rod as the Fig. 4-27.

Fig. 4-27 State of the hoisting and trolley pulleys after installed

191
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Combinations and parts of the jib

① Jib section Ⅰ(000271705CT001000) ② Jib section Ⅱ(000219705AR002000)

③ Jib section Ⅲ(000271705DT003000) ④ Jib section Ⅳ(000219705AR004000)

⑤ Jib section Ⅳ(000270505CT004000) ⑥ Jib section Ⅵ(000219705AR006000)

⑦ Jib section Ⅵ(000270505CT006000) ⑧ Jib section Ⅵ(000290505AR006000)

⑨ Jib section Ⅷ(000290505AR008000) ⑩ Jib end (000201705AL009000)

192
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

The dimensions of jib connecting pins

◼ The jib pin dimensions

Table 4-2 Pins used to connect the upper and bottom chords of each adjacent jib
Upper chord pin Bottom chord pin
Position
D [mm] L0 [mm] L [mm] D [mm] L0 [mm] L [mm]
Jib① & Jib② Ф100 290 370 Ф80 201 255
Jib② & Jib③ Ф80 270 335 Ф70 177 220

Jib③ & Jib④ Ф80 240 305 Ф70 160 205

Jib④ & Jib⑤ Φ60 200 260

Jib⑤ & Jib⑥ Φ60 190 250 Ф60 143 190

Jib⑥ & Jib⑦ Φ60 170 230

Jib⑦& Jib⑧

Jib⑧& Jib⑨ Φ60 130 190 Ф60 121 170

Jib⑨& Jib⑩

Assembling steps
1) Prepare several brackets which’s length are about 1.2m near the tower crane, for the jib
above 50m shall not be less than 4, and for the jib not more than 50m shall not be less
than 3. Each jib section is connected by a pin at the upper chord by and two pins at the
bottom chords. Assemble jib sections except jib Ⅰ first, refer to Fig. 4-28.

Fig. 4-28 Assembling jib

The assembling sequence must be strictly according to the sign on each
jib section, assembling in wrong sequence or assembling optionally are
not allowed.

The trolley mechanism motor is on the opposite side of the driver’s cab.

193
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

2) Trolley mechanism from the side before loading jib section Ⅱ, as shown in Fig. 4-29.

Fig. 4-29 Installing auxiliary mechanism

3) Jib sectionⅠ installation connected to jib assembly section, and then remove the auxiliary
mechanism to the jib sectionⅠroots and fixed, as shown in Fig. 4-30.

Fig. 4-30 Installing jib section Ⅰ

No matter how long the jib is assembled, the auxiliary mechanism should
be fixed on the guide rail of the bottom chord of the jib to prevent sliding.
The two lug ropes (the short and long ropes) are connecting with auxiliary
mechanism through the root pulley and tip pulley respectively, and then
the length of the rope is tensioned respectively.

Reeling the trolley rope

Fig. 4-31 Trolley wire rope layout plan

(1) c Pulley on jib root (2) Drum of trolley mechanism
(3) Trolley (4) Rope rollers of jib
(5) Pulley on jib end (6) Short rope
(7) Long rope

194
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ When change the double trolleys to single trolley at 2-fall, take out
the trolley rope in the safe room of the auxiliary trolley.
◼ The short and long ropes of trolley mechanism must have three
circles of safety rope on the drum under any circumstances, and a
circle of isolation rope should be left on the drum.
◼ When changing the length of jib, the excess rope is tied and fixed to
the trolley.

Installing the jib assembly

1) Operating the slewing mechanism and make it running or use the crank of slewing
mechanism to rotate the upper structure of tower crane to the position where the jib can be
conveniently installed.
2) According to the center of gravity of the jib assembly of each jib length to hang the rope, as
shown in Fig. 4-32 and Table 4-3.Try to test the sling point whether balanced, otherwise the
position of the hanging rope can be moved appropriately. The distance between the two
sling points is 8m≤d≤20m.

Fig. 4-32 Reference center of gravity of jib

Table 4-3 Reference center of gravity of jib with different lengths

Jib length/m 70 67.5 65 62.5 60 57.5 55 52.5 50
L/m 23.9 23.3 22.6 22.0 21.9 21.4 20.9 20.3 19.4
G/t 12.7 12.4 12.3 12.0 12.1 11.9 11.7 11.5 11.1
Jib length/m 47.5 45 42.5 40 37.5 35 32.5 30 /

L/m 18.6 17.2 17.7 16.7 14.9 14.1 14.0 13.1 /

G/t 10.8 11.2 10.4 10.1 9.1 8.7 8.7 8.3 /

195
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ The above data are for reference and can be adjusted according to
the actual situation on site.
◼ Record the place of hoisting point for the dismantling use.
◼ Hoisting jib by rope, as shown in Fig. 4-33, the methods of A, B, D
are right, while the methods of C is wrong.
◼ Forbid pulling aslant when hoisting jib assembly, as shown in Fig.
4-33.
◼ In order to reduce the volume and weight of the jib assembly, or
reduce degree of difficulty in the installation of air jib assembly and
can be installed the counter jib after the completion of any link first
installed jib Ⅰ section , but this may need to be done in the air
luffing rope an tension.

CAUTIONS:
◼ The above data are for reference and can be adjusted according to the actual situation on
site.
◼ Record the place of hoisting point for the dismantling use.
◼ Hoisting jib by rope, as shown in Fig. 4-33 Notice about hoisting jib, the methods of “A”, “B”
are right, while the methods of “C” is wrong.
◼ Forbid pulling aslant when hoisting jib assembly, as shown in Fig. 4-33 Notice about hoisting
jib.
◼ In order to reduce the volume and weight of the jib assembly, or reduce degree of difficulty
in the installation of air jib assembly and can be installed the counter jib after the completion
of any link first installed jib Ⅰ section , but this may need to be done in the air luffing rope
an tension.

Fig. 4-33 Notice about hoisting jib

196
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

3) Lift the jib assembly to mounting height, as shown in Fig. 4-34. Connected the jib with tower
mast by one Ф110×330/435 pin and two 90×250/320 pins

Fig. 4-34 Installing the jib assembly

Weights of different-length jibs

The weight indicated in the next table correspond to jibs equipped with:
◼ Trolley mechanism
◼ Trolley rope
Jib length (m) Weight (t)
70 11.7
67.5 11.5
65 11.3
62.5 11.1
60 11.1
57.5 10.9
55 10.7
52.5 10.5
50 10.1
47.5 9.9
45 9.7
42.5 9.5
40 9.1
37.5 8.2
35 7.9
32.5 7.8
30 7.4
⭐Tolerance on the weight: ±5%.

197
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4.7 Installing the remaining counter ballast

Install the remaining counter ballast blocks according to the Section 3.7.2.
Users have to choose a proper plate to cover the remaining empty after
installing all the counter-weight.
After install all the counter ballast, please check carefully and make sure
that all the counter ballast are fixed stable.

4.8 Electronic control system installation

◼ Please follow the attached circuit diagram to connect the circuit.
The wiring diagrams are posted on prominent positions of mechanism and electronic component
(as Fig. 4-35), the two ends of cable also attached model name, connection potion, parameters
indicate (as Fig. 4-36). Please follow the instructions to connect wire.

Fig. 4-35 Fig. 4-36

◼ The installation of electronic control system need choose good weather condition (cannot
raining/snowing/fogging). Otherwise, may damage electronic control system or personal
injury.
◼ Before the installation of the electrical control system, a preliminary inspection shall be
carried out on all components of the electrical control system to observe whether there is
damage or loss of part in the control cabinet, and whether there is damage, carbonization
and loosening of wires and cables. And please release the damaged equipment.
◼ Before the electrical control system is not connected, separate insulation tests can be
carried out on the motor, resistor, cable and other parts to judge whether there is a fault, but
insulation test cannot be carried out after the connection of the electrical control system.
◼ The wire connection and the body installation of all components in the control cabinet should
be firm and reliable, and no loosening phenomenon should occur,
◼ The display screen of the auxiliary safety monitoring system should be fixed firmly and the
communication cable connection should be reliable.
◼ Please connect the cables between the control cabinets as well as between the control
cabinets and other external wiring diagram. please note that the connection of each cable
should avoid interference with moving part, and also leave a margin for the moving part to
move. If the cable slot, please put the cable in the slot.

198
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ After wire connection, make sure circuit is correct, connection firm and reliable, no short
circuit.
◼ The cable hanging on the mast should using cable net, and set cable
net every 20m.
◼ The power cable can only extension with intermediate junction box,
directly junction is prohibited.
◼ The power cable and control cable should distribute separately, do
not close parallel installation.

Frequency converter self-learning

The tower crane is driven by full frequency conversion. When the crane is started for the first
time, after trial operation and calibration setting, and before normal operation, the frequency
converter of hoisting, slewing and trolley shall be studied and operated, so that the frequency
converter can obtain the internal mechanism and make the operation more stable and efficient.

Rectifier unit Hoisting inverter unit Slewing inverter unit Trolley inverter unit

INOBUS
P P P

N N N

Fig. 4-37 Frequency converter structure

Function lights

LED display

Operation key

Fig. 4-38 Frequency converter operation panel

199
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Key Key’s name Key’s function

Enter or quit the menu, switch the modes of

Mode key
inquiring parameters.

Add key Add the data or parameters.

Reduce key Reduce the data or parameters.

Choose the displaying parameters circularly,

Shift key
choose the spell of parameter to modify.

Enter key Enter submenu, confirm set parameters.

◼ Self-learning methods of frequency converter:

1) After the motor connected and powered on normally, first set the command source F0-02 of
the frequency converter to 0 (command and control of the operation panel);
2) Input motor type plate parameters (A0.01-A0.05), when slewing self-learning change F4-00
to 0.
3) Set function code F1-37 to 3 (static tuning) and press “Enter” to confirm. At this time, the
panel will display RUNE. Then press “Enter” on the panel and keep 3s, the frequency
converter will drive the motor to start running. Waiting for 2 mins, the screen back to normal
parameter display status, tuning done.
4) Set the frequency converter command source F0-02 to 2 (terminal control). when slewing
self-learning change F4-00 to 8.
To further improve the performance of slewing mechanism, it is recommended to continue
online tuning of the slewing frequency converter after the completion of static tuning. The
steps are as follows:
5) Set the source B8-03 to 1 (online tuning), screen display “uLoc”;
6) After confirming that there is enough room and safe operation, operate the slewing handle
to the 4th gear. At this time, the tower crane jib will rotate the 4th gear speed. The frequency
converter will successively display: UloC→LoC→Good, which indicates that the spectrum
tuning is over and normal use can be started.

Note: UloC: Start tuning online

LoC: Enter online tuning
Good: Online tuning ends

İf online self-learning fault, the frequency converter will display ‘E77.00’code. need clear the fault
and restart the self-learning process. Firstly, static tuning and make sure parameters are correct,
then start online tuning. Before online tuning, drive the boom to the place which have enough
moving distance, then start it. Change driving mode to level 3 or 4 and keep it. The screen display
‘LOCK’ means frequency locked, keep around 6 seconds, display ‘GOOD’, means tuning finished,
we can shut down tower crane.

200
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.9 Power line connection of mechanism

◼ Please refer to the attached circuit diagram for wire connection.
◼ The wiring diagrams are posted on prominent positions of mechanism, please refer to the
diagrams for wire connection.

4.10 Winding the hoisting rope

1) Moving the trolley to the jib root. It is placed below the trolley that the support is made by
customer self. The hook is fixed vertically.
2) Pull the hoisting rope out from the rope drum of hoisting mechanism, start the fall down gear
of mechanism. Drive the rope to pass through the rope roller on the counter jib, pulley with
load limiter which on the jib Ⅰ, direction-changing pulley on the jib root, and the pulley
assemblies of the trolley and hook (on the ground), as shown in
3) Fig. 4-39.

(1) c Drum (2) Load limiter

(3) Trolley (4) Anti-twist device

Fig. 4-39 The drawing of winding the hoisting rope

4) Use two clips to fix the hoisting rope to the proper position on the trolley, leaving a margin
of not less than 1.2m.
5) Remove the wedge from the anti-twist device of the jib end, tie the end of the hoisting rope
with soft rope, as shown in Fig. 4-40, and then make it rewind and secure with the fixing
rope clamp.

201
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

2
1 3

1.5d

Fig. 4-40 The drawing of rope fixing

(1) c Wire (2) Hoisting rope
(3) Wedge

1) Slowly start the hoisting mechanism. Hoist the hook to a height of 1m above the ground,
and make sure that the hoisting rope has been fixed firmly.
2) Start the trolley mechanism to open the trolley and hook to the hoisting tip jib.
3) Fix the wedge at the tip jib anti-twisting device. Slowly lower the trolley to the support below
the tip jib. And dismantle the rope clamp that fixed the hoisting the trolley, and loosen the
hoisting rope.

◼ When hoisting ropes are non-rotating ones, the anti-twist device shall
lock tightly the locking screws 3 and 5 (see Fig. 4-41) while the tower
crane is in service.
◼ When hoisting ropes are anti-rotation ones, the anti-twist device shall
unlock the locking screws when the crane is in service.
◼ When using new ropes, the hook will rotate at no-load operation. At
this time, unlock the anti-twist device.
◼ After long time using of tower crane, the wire ropes will be extended
and slightly twisted, in this case, unlock the anti-twist device
temporarily, and lock the device again when ropes have been
tensioned.
◼ Once rope has their strands loosened, the anti-twist device will
accelerate rope deterioration, so should change the deteriorated
ropes timely.

202
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

1
2

（2）

(1) c Hoisting rope (2) Wedge

(3) Lock screws① (4) Anti-twist device structure
(5) Lock screws②

Fig. 4-41 The drawing of rope fixing

4.11 Power connection and test run

Switch on power to all electrical circuits according to the electric circuit diagram and start all
mechanisms for test run. Check mechanism for proper operations. At the same time, check wire
ropes at different locations for normal working and for any interference with structure member.
Remove all abnormal cases.

203
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4.12 Fall-changing system

The fall-changing system is a pendulum system that consists a pulley assembly, when the device
is connected to the hook, the whole system is 4 falls, when the device is off from the hook and
stay at the below surface of trolley, the whole system is 2 falls. As shown in Fig. 4-42.

Fig. 4-42 The schema of the fall-changing system

(1) c Trolley (2) Upper pulley assembly
(3) Below pulley assembly

204
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

The fall-change is converted at the jib root section under the conditions of no-load, slow speed
and no swing. No matter how it is required to convert 2 falls to 4-fall or to convert 4-fall to 2-fall,
the by-pass switch must at first be turned to the by-pass status to disable the height limiter. After
conversion completion, the by-pass switch must be restored to its original status.
When needing the 2 falls, manipulate the climbing system, the hook moves towards the ground,
pull out the pivot, start the climbing system again, let the pendulum system arise for it contacts
the trolley. When needing the 4 falls, let the hook move towards the ground, put the pivot back.
If the hoisting rope is converted to 4-fall, the hoisting rope mechanism is manipulated again, the
hook is lowered to ground, and the hanging body falls back the groove of the hook. Insert the pin
and split pin, and the split pin fully open. For debugging, refer to the Chapter 5 <OPERATION
AND CONTROL>.
Advise for Fall- changing about the height of tower crane over free-standing height: to avoid 4-
fall change to 2-fall occur collide the top and the top hung body of hook do not fall on the ground,
we advise consumer change fall on the floor or platform of climbing equipment.

Please adjust the safety device before starting to use the tower crane.

4.13 Climbing operation

Pre-climbing preparation
◼ Fill the oil tank with hydraulic oil according to the requirements of hydraulic pump station.
Make sure of the electric motor circuit correctly connected and the fan rotates clockwise and
the operating lever of hand control valve working smoothly without any clogging.
◼ Set up each tower section with correct order and grease its connection pinholes. Place in
row the tower sections to be jacked just under the jib before climbing. This will enable no
slewing mechanism in the whole process of climbing operation for adding sections, thus
minimize the climbing time.
◼ Release the power cable slightly in excess of the total climbing height, and then fix the cable.
◼ Before jack-up, please random distribution of 4 core cable (one side is four phase plugs,
other is four loose thread (include 1 ground PE)) to the climbing pumping station terminal
blocks, and then insert the plug into the master four phase of tank wall socket. At the time,
switch the climbing operation switch of drive box cup cabinet door to ON status. Right now,
slewing the trolley limiter to first gear. At the time, you can through the operation of the
hydraulic pump station to handle the climbing operation.
◼ Slew the jib to the front of the climbing equipment and the counter-jib at the rear of climbing
equipment (climbing cylinder is just under the counter-jib).
◼ On the platform of the climbing equipment, prepare the pins tower mast pins.

205
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

General notices of climbing operation

◼ Keep the crane rotation part in balance.
◼ It is prohibited to operate the climbing system when the wind speed at the highest spot
exceeding 14m/s.
◼ Make sure that the climbing system works normally before climbing.
◼ It is prohibited to hoist load (up or down) while the climbing system is in operation or after
climbing.
◼ Adjust the roller gab at 1~3mm before climbing operation, then adjust the gap at maximum
after climbing finish
◼ It is prohibited to move the trolley while the climbing system is in operation or after climbing.
◼ Keep the jib in the same direction as the in-let tower section during climbing operation. Stop
the jib with the slewing mechanism brake and be sure of the trolley stopping at the jack-
balanced position.
◼ If several tower sections are to be added in succession, the main chord rods and slewing
ring support of the lower body must be connected by 8 Φ55 pins without shoulder after
adding one section and before hoisting the next section. Only in this case can 8 Φ55
shoulder-free pins be permitted for use.
◼ Keep the climbing lugs on the newly added tower section in alignment with those on the
existed section.
◼ It is prohibited to slew, change work-radius and hoist load without connection of the slewing
ring support to the tower body by 8 Φ55 shoulder-free pins.
◼ When the height has reached the demanded work height (not exceeded the independent
height), slewing the jib at different angles, check all the connections of the tower crane,
including the embedded bolts (if one main chord is below the counter jib, then fasten all the
nuts, the above-mentioned connection is all double nut to prevent loosening).

Please strictly operate the tower crane according to the operation

instructions for the climbing process is most likely to have grave
accidents.

Keep the tower crane in balance before climbing

Before keeping the tower crane in balance, hoisting device of the tower section and mounting
device must connect through 4 sets shackle, and then hoist the hoisting device and mounting
device of special hook, and put on the mounting beam of transition section (Show in Fig. 4-43).
Move the trolley to the reference balance position, show in Table 4-4. Hoist one tower section or
other weights (The trolley position in table is an approximate value, which must be adjusted
according to the actual situation in climbing), and then dismantling the pins between the transition
section and tower section.

206
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Fig. 4-43 Keep the crane in balance

(1) c Platform (2) Tower section

Table 4-5 Reference balance position of different lengths of jib

Jib length (m) Weight G (t) Radius L (m) Jib length (m) Weight G (t) Radius L (m)
70 1.61 22.8 47.5 1.61×2 24.2
67.5 1.61 27.9 45 1.61×2 26.57
65 1.61 25.7 42.5 1.61×2 26.0
62.5 1.61 22.3 40 1.61×2 24.9
60 1.61 27.4 37.5 1.61×2 24.4
57.5 1.61 40.0 35 1.61×2 25.7
55 1.61 36.4 32.5 1.61×2 26.2
52.5 1.61 35.8 30 1.61×2 24.8
50 1.61 39.7 / / /
CAUTIONS:
◼ These values are based on approximate figures only, which must be adjusted according to
the actual situation in climbing.
The balance weight above is according to the weight of tower section L68A4/L68A1
without passageways, when the tower sections are L68A1A/ L68B1A/ L68B1, the
balance position must change accordingly.
◼ Make the top structure of the tower crane at the slewing-braking state by active the brake of
the slewing mechanism. Slewing movement is not allowed.
◼ Pushing the operation handle of the hydraulic climbing system to “Climbing direction”,
extract the oil cylinder to jack the hang plate into groove near the tower section’ climbing lug,
insert the safety pin, continue to extract the oil cylinder to jack the climbing equipment to a
position where the transition section is just disengaged from the main chord rod of the tower
body.
◼ Check the support leg and tower body main chord rod connect the transition section and
tower sections to make sure that they are in the same vertical line. Check 8 guide rollers
and tower body main chord rod to make sure that they have the same clearance. This serves
to determine whether the tower crane is in balance. If not, adjust the balance position of the
trolley until balance is achieved to drop the center of gravity of the upper tower crane onto
the position of climbing cylinder beams.

207
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Record the balance position of trolley. Note: This value varies with the jib length.
◼ Operate the operation handle of the hydraulic system to fall the climbing equipment. Connect
the pivots between the transition tower section and tower section.

Climbing operation
1) First, hoist the climbing device, and install it to the mounting beam. Then hoist a tower
section, move the trolley to balance position according to the Table 4-5.
2) Use the brake on the slewing mechanism to hold the tower superstructure at a slewing
braking status, thus ensuring no slewing movements. Dismantle 4 group pins connecting
the tower head to the transition section.
3) Start up the hydraulic system to extrude the oil cylinder, lift the hanging plate into the slots
of the group of lugs of one tower section at the shortest distance (Check the climbing beam
whether in the round groove). Insert safety pins, ensuring without error, jack the climbing
equipment and the parts above it for 10~50 mm and then stop. Check the hanging beam
and climbing equipment and similar power transmission parts for abnormal noise and
deformation. Check the oil cylinder for automatic retraction and similar abnormal incidents.
In case of OK confirmed, continue to jack (see Fig. 4-44).

A special person is required to be at the lower platform and observe

whether the hanging plate is hung in the lug slots and inserting-pulling
safety pins.

Fig. 4-44 Climbing process

(1) c Climbing rod (2) Climbing cylinder
(3) Climbing hang plate (4) Climbing beam

4) Jack the climbing equipment for about the height of a little more than 1/2 tower section and
position the climbing equipment until climbing rod is above the climbing lug, automatic reset.
Stop climbing and retract the oil cylinder to let the rod down onto the lug of climbing beam.
5) Confirm that the two climbing rods lay on the top of climbing lugs and bear the weights of
climbing equipment and the upper part without any strange sound and deformation, retract
the oil cylinder completely, hoist climbing beam, put the hang plate into climbing beam circle

208
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

groove again, insert safe pins.

6) Extrude the oil cylinder again to jack the upper structure of the tower crane for about the
height of a little more than 1/2 tower section, thus there is a space for a tower mast, retract
the oil cylinder slightly, align the new introduced tower section on the upper tower head, use
4 pins to connect each long fish-plate pin holes, and then each short fish-plate pin holes
connect ed by 4 pins, install the locking pin to connect firmly the upper and below tower
sections.
7) Remove the safe pins of climbing plate, retract the oil cylinder again to put the transition
section fall on the new tower mast, line up. Use 8 pins to connect firmly the transition section
and the tower mast. At this time, one tower section has been added. If several sections are
to be added in succession, repeat the steps above. To ensure the transition section fall on
the tower mast successfully, before retracting, you can insert two guide rods (each opposite
angle have one rod) into pin holes of transition angles, and then retract oil cylinder, the
transition section falling.
8) At this time, one tower section has been added. If several sections are to be added in
succession, repeat the steps above.
9) The last tower section must be fixed between the tower body and the transition section.

209
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Rung ladder (old style) and Inclined ladder add tower

section
2.0m Rung ladder (old style) and Inclined ladder can be used interchangeably, oblique section at
the top of the distillation section rung ladder tower section mast be installation anti-dropping
device, the device can also easily mount at the bottom of the tower section (that is, platform side),
the installation method as shown in Fig. 4-45. It can easily pass and turned over specially, and
can effectively prevent people falling from the rung ladder.
It has a slight impact on the passage and can effectively avoid the risk of missing the step
because the anti-dropping device. The optional part of anti-dropping device can be purchased
according to the user’s demand. It is suggested that the tower section of rung ladder be installed
centrally, and user only need to purchase.

Fig. 4-45 Anti-dropping device

Table 4-6 Spare part of anti-dropping device

No. Code Designation Specification Qty Material Remark
Anti-dropping device 2.0m
1 1 Weldment
structure mast

2 GB/T5783-2000 Bolt M12×100-8.8 2

3 GB/T93-1987 Washer 12 2 65Mn
4 GB/T6170-2000 Nut M12-8 2
5 GB/T97.1-2002 Washer 12-200HV 4

210
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.14 Chassis stationary tower crane

Installing the chassis assembly, assemble it according to Fig. 4-46.

Fig. 4-46 Chassis stationary tower crane

Installing the crossed-beamed of chassis stationary

◼ Put the long cross beam on the foundation and fixed with bolts, as shown in Fig. 4-47.

Fig. 4-47 Installing the long cross beam

211
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ As shown in Fig. 4-48, place one end of the short cross beam on the foundation and fixed
with embedded bolts, which connect the other end with the long cross beam with 2 pins
Φ60×430. Install another short cross beam in the same way.

Fig. 4-48 Installing the short cross beam

◼ As shown in Fig. 4-49, the tie rod connected to long and short cross beam respectively by 2
Φ30×105 pins. Install another 3 tie rods as the same way.

Fig. 4-49 Installing the tie rod

212
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Installing the base tower section and incline tie rod

As shown in Fig. 4-50, put the base tower section on the crosse beam and connect them by Φ65
pins. Use 2 Φ70×200 pins to connect the incline tie rod to the base tower section and the crosse
beam. Install another 3 incline tie rods as the same way.

Fig. 4-50 Installing the base tower section

◼ The left and right numbers of central ballast keep accordance, placed
symmetrically (refer to Table 3-4 to configure the central ballast).
◼ The central ballast of 3.9t concrete protruding part to be press on the
crossed beam, about uniform.
◼ Used raise platform, positioning, and center of the platform and hole shall
be centered.

213
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Ensure that the perpendicularity of the base section is not more

than 1.5/1000 after completing pouring foundation.
◼ During the assembly, each pin with cooperate face shall scribble
lubricating grease
◼ Split pin must extend fully, bolts tighten
◼ Install the central ballast as the figure below, install the
nameplate to the base tower section by 4 M6×16 bolts.

214
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.15 Travelling tower crane

Traveling mechanism structure introduction
The traveling mechanism consists of 2 sets of driving dollies 1, 2 sets of driven dollies and cable
drum.
1) The two driving dollies 1 must be arranged on the diagonal line(rail clamp outward), two
driven dollies also must be arranged on the diagonal line (rail clamp outward), it is shown as Fig.
4-51;

Fig. 4-51 Arrangement of the dollies

2) The motor should be fixed in the inner side of track;
3) Counterweight should be assembled along track direction;
4) The safety distance between traveling dollies and outside buildings of track should not be
less than 450mm;
5) M type power drum as cable.

215
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Powered wheel bogie

The Powered wheel bogie have two wheels as figure below.

Fig. 4-52 Powered wheel bogie

The Powered wheel bogie consists 1 of brake motor, planetary reducer, traveling wheels (two
wheels or three wheels), dolly frame, rail clamp, and traveling limit switch, etc. The motor is
special frequency conversion motor with double magnet brakes. The frequency conversion is in
0～50Hz scope ensures starting smoothly without impact. When stopping, the speed reduces
automatically following the frequency reduces automatically, and at the same time, delaying the
brake works to ensure stopping smoothly without impact. The traveling limit switch can prevent
overturning of the crane caused by the impaction between dollies and end buffers by wrong
operation. When the operator is off his duty and leaves the tower crane, he must tighten the
crane by rail clamps to prevent overturning of the tower crane. Release the rail clamp during
operation, and turn the clamp upward to let pivot fall into the other end of ellipse hole. Thus,
the clamp may not turn over downward.

216
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Rail clamp
The construction of the rail clamp is shown as figure below:

1. Handle; 2. Screw rod; 3. Shaft;

4. Right semi clipper; 5. Shaft sleeve;
6. Adjusting pad; 7. Left semi clipper;
8. Washer; 9. Cotter pin.
Fig. 4-53 Tightening rail clamp Fig. 4-54 Tightening rail clamp
Adjust the quantity of the adjusting pad between left and right semi-clamp to tighten the track
according to different track width.
Note: After adjusting, assemble the clamp as Fig. 4-53 and open part 9 (cotter pin)
sufficiently.
Two conditions of the rail clamp:
1. Tightening condition (the driver is off duty and leave the tower crane), front view is shown
as Fig. 4-53;
2. Release condition during operation, side view is shown as Fig.4-55

Installation and test

This chapter introduces the installation of traveling mechanism and cable drum.
Powered wheel bogie and driven dolly
1. Lift the dolly on the track, and fix it by scantling timbers or wood wedges;
2. Disassemble 4 sets of M24×90 bolts and two B16×60 pins on the dolly connection plate for
connecting with undercarriage;
3. Lift the assembled cross undercarriage, let the dolly connection plates aim at connection
plate of the cross undercarriage, install the B16×60 pins and tighten M24×90 bolts. The
strength grade of these bolts is 8.8 grade, and pre-tightening torque is 640N.m;
4. Disassemble the four supports on each dolly, which is easy for assembling and
transportation, and then tighten the clamp track clipper and the track. Ensure the safety of
after soon tower crane installation.

217
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Cable Drum
Our company offers Normal allocation is M type cable drum with power.
◼ Cable drum introduction
M type cable drum is a drum with power, which consists of a torque motor, a reducer, a collector
box, a drum, a wire box, installation supports, etc. Shown as

Fig. 4-55 Cable drum

When the tower crane moves towards the power, the torque motor powers on, and transmits the
torque by reducer to drum through turntable and flange on the output shaft of the reducer, and
then the drum turns slowly, thus the cable is wrapped onto the drum. When the tower crane
moves far from the power, the cable is released automatically by dragging the cable to turn the
drum which can overcomes the frictional torque in reducer.
◼ Requirements of cable fixed points for the cable drum

Fig. 4-56 Chassis rail

There is carriage drive beside the orbit across the real, install traveling limit switch at the ends of
the orbit, cable fixed point simultaneously, when adopt M type cable drum, the fixed point can be
any point on AB line — track gauge center line (Shown as Fig. 4-56). When the cable fixed point
is on any point of AB line (except A, B point) should set steering impact pad, cable will be 15
meters more.
Note: There is no description on the track foundation drawing supplied to the customer
because the cable drum type and cable fixed point cannot be determined.

218
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Fig. 4-57 Arrangement of the travelling parts

◼ Installation of the cable drum
The installation of M type cable drum includes: cable drum installation, cable drum support
installation.
1. Cable drum installation
① Coil disc installation shows as Fig. 4-58. Use 12 sets of M10×260 (1 bolt, 1nut, 1 washer, 1
spring washer) bolt rod to connect the frame and two round disc. Use 12 sets of M10×55 (1 bolt,
1 nut, 1 washer, 1 spring washer) bolt to connect flange disc and round disc.

Fig. 4-58 Coil disc

② Let the installation hole on turning disc of reducer output shaft align with flange disc and
tighten it with bolts;
③ Connect the torque motor output shaft with the worm key channel in reducer. Connect the
torque motor end face and the upper face of the reducer with bolts;
④ The installation hole on collector box outer cover should match with reducer output shaft and
connect with reducer basic seat end face with bolts;
⑤ Check reducer oil level, add HL 30 lubrication oil if it is below the center of the sight hole.
2. Installation of the cable drum support
① Install fixing support;

219
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

② Install cable drum support;

③ Install wire box support
④ Install cable drum
⑤ Adjust the position of cable drum support and wire box support to let coil disc align with wire
box and cable fixed point simultaneously.

Fig. 4-59 Drum support

220
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

3. Wire connection of the cable drum

Fig. 4-60 Arrangement of the travelling chassis parts

① Straighten the cable and release it completely, the cable should not be twisted up. The cable
should have 3～4 rounds on the drum when the undercarriage run to the limit position of the track;
② Open the cover of collector box and lead cable to the drum coil disc via wire box by shown
direction in Fig.4-5a. Then introduce reducer output inner hole into collector box from frame and
connect cable wire with inner fastener of collector ring tightly;
③ Lead out main cable of tower crane from the out fastener of collector ring to switch box via
collector box cable. At last, close the collector box cover.
Note: Neutral line should be connected with the same sliding ring.
4. Test running of the cable drum
Test run the cable drum after the tower crane is installed completely. The test running main
content is to adjust cable tension and torque motor change switch when the cable is received /
released.
First, run carefully on the right / left side of fixed point, observe the running direction of torque
motor and the receiving / releasing of cable. It is correct if in the following condition: and then the
drum turns slowly, thus the cable is wrapped onto the drum. When it moves far from the direction
of power, the cable is released automatically by dragging the cable to turn the drum which can
overcomes the frictional torque in reducer.
Let the tower crane run along the track to and fro to observe receiving / releasing cable tension.
Cable tension is suitable when receive / release the cable smoothly and motor is not overheated;
otherwise, adjust output torque of motor to change cable tension.
Adjust procedures are as following, (shown as Fig. 4-61)

221
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Fig. 4-61 Adjusting the cables

Screw out the brake part (which is near reducer and motor connection surface) on the reducer
shell, observe if reducer adjusting nut indentation is aligned with the installation hole of the brake
part (shown as Fig.4-13a), then insert the brake parts into the hole, and turn the turning disc by
hand. Stand at the outside of drum and turn the disc clockwise, the motor output torque and cable
tension, vice versa. Adjust output torque repeated to change cable tension till the cable is
received / released smoothly and the motor is not overheated. Then, drag out the brake parts
and turn one end of stop part with thread into hole on installation position on reducer.

222
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

4.16 Safety devices

Foreword
The safety devices of tower crane include: moment cutouts, load limiters, traveling limiter (include
hoisting limiter, trolley limiter, slewing limiter) and weathervane.
The safety device of this tower crane, besides the above mechanical limiter, also has electronic
safety device in the auxiliary safety monitor system. The installation position of the safety devices
shows in Fig 7-69 and table 7-26.

The crane over 30 and higher than surroundings, need installed red
obstruction light on tower head and front/rear jib end, this light power not
affected by crane shutdown. İf crane higher than 50m, need install
weathervane.

The safety devices introduce in this chapter are mechanical limiter. Before calibration, turn mode
choice switch (SPM) to ‘mechanical’, then begin calibration. After calibration, turn SPM to
‘electronic.

◼ Safety devices should be the important inspection device of driver

and maintenance personal.
◼ Safety device of tower crane are designed for protecting human and
equipment safety, after calibration, shouldn’t change it.

◼ Using the equipment before safety device installation or calibration

is prohibited, otherwise will lead to equipment damage and
personnel injury even death.
◼ Only use electronic limiter without mechanical limiter calibration is
prohibited.

223
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

(1) Limiter device (2) Moment limiter

(3) Red obstruction light (4) Weathervane
(5) Load limiter

Fig. 4-62 Safety device location

224
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Table 4-7 Safety device combination

No Shape Name Location Qty

Hoisting
Hoisting limiter 1
mechanism

1
Trolley limiter Trolley mechanism 1

Slewing limiter Turntable 1

2 Moment limiter Tower head 1

Counter jib, tower

3 Red obstruction light 2
head, jib end

4 Weathervane Tower head 1

5 Load limiter Jib Ⅰ 1

225
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Limiters
The limiters of tower crane include: hoisting limiter, Trolley limiter, slewing limiter, they are
important safety devices to accomplish the traveling control and position limit of each mechanism.
Hoisting mechanism, trolley mechanism, slewing mechanism equipped electronic sensors, these
sensors will monitor mechanism position and control system will convert the position signal to
electronic limiter.
This crane can implement electronic limiter and mechanical limiter control, the solely mechanical
limiter only used for emergency and need adjust to meet the regulation.

◼ After change the rope or falls, the extreme position of hook will
change, need readjust the hoisting limiter. Otherwise, may cause
hook impact jib, rope break, and lead to fatal accident.
◼ When hook at the lowest position, need keep at least 3 circle rope on
the drum.

◼ When crane climbing to the expectation height, adjust must without

load and make sure micromove switch is correct.
◼ When change tower crane height and falls, adjusting hoisting limiter.
◼ Screw in M5 nut after adjust travelling limiter, otherwise cause
memory mess.
◼ Recovery the shell after adjusts the travelling limiter, otherwise the
limiter may damage by water.

Functions of limiter
Hoisting limiter make hook decelerate and stop hoisting when come to the safety distance from
trolley to the hook, when downward, prevent the wire rope from loosening completely and
wrapping around the drum in the opposite direction.
The Trolley limiter enables the trolley to automatically decelerate and stop before reaching the
stop block at the root or head of the boom.
The slewing limiter is used for tower cranes without slip ring to prevent the cables from being
entangled and damaged, allowing a maximum rotation of 3 turns.
◼ The working principle of the limiter
The limit device fixed on the bracket can be directly driven by the wind shaft, or driven by the
pinion gear meshing on the toothed ring. There is a deceleration mechanism in the device, which
drives several bumps to rotate (T), and these bumps control several circuit breakers (WK micro
switch) action, thereby cutting off the corresponding mechanism movement.
In addition to the mechanical limit switch, the limiter is also equipped with an encoder (non-ETI
version has no encoder). As shown below.

226
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

WK

T
BMQ

BMQ: Encoder WK: Micro switch

T: Memory cam SRZ: Input shaft
Fig. 4-63 Limiter

M5

4T

3T 4WK

3WK
2T
2WK
1WK
1T

Fig. 4-64 Inside of the limiter

227
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Adjust the shaft (1-4 Z), cam (1-4 T) and micro switch (1-4 WK), the corresponding
relationship is as follows:
1Z 1T 1WK

2Z 2T 2WK

3Z 3T 3WK

4Z 4T 4WK

◼ Traveling limiter adjustment steps:

1) Remove the upper cover and loosen the M5 nut.
2) According to the need, open the controlled mechanism to the designated position (no-load),
at this time, the corresponding micro switch is switched instantaneously when controlling
the action of the mechanism. That is, adjust the corresponding adjustment axis (Z) so that
the memory cam (T) presses the contact of the micro switch (WK).
3) Tighten the M5 nut (the nut must be tightened to prevent loosen).
4) The mechanism repeatedly runs with no load for several times to verify whether the memory
position is accurate (repeat the above adjustment if there is an error).
5) Confirm that the position meets the requirements and install the cover.
6) After the mechanism is working normally, it should always be checked whether the memory
control position has changed so as to be corrected in time.

Table 4-8 The meaning of the indication signs

Symbol Meaning

Low speed operation

Middle speed operation

High speed operation

Deceleration/ speed limited

Load

228
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Symbol Meaning

Slewing

Hoisting hook

Observation

Sound alarming

Light alarming

Trolleying

229
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Hoisting limiter
◼ Hoisting up deceleration
When the distance between the hook pulley and the trolley is H1, mobilize the (3Z) axis to make
the long cam (3T) press the micro switch (3WK), so that the hook rises at a low speed.

Fig. 4-65 Hoisting up deceleration

230
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Hoisting up stop
When the distance between the trolley and the hook pulley is H2, the (4Z) axis is mobilized to
make the long cam (4T) press the micro switch (4WK), so that the hook cannot continue to move
upward.

Fig. 4-66 Hoisting up stop

The down hoisting stop principle just same as up hoisting, adjust the switch
position.

◼ Hoisting down stop

Move the (2Z) axis to make the long cam (2T) press down the micro switch (2WK), so that the
hook can stop before it touches the ground (the hook cannot touch the ground to prevent the
wire rope from loosening on the wind).

◼ Hoisting down deceleration

Move the (1Z) axis to make the long cam (1T) press down the micro switch (1WK), so that the
hook can descend at a low speed at H2 before the lower limit position.

231
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Trolley limiter
◼ Trolleying outward deceleration
The trolley is driven to L1 from the boom tip buffer, and the (3Z) axis is mobilized, so that the long
cam (3T) presses the micro switch (3WK), so that the trolley can only run outwards at a low
speed.

Fig. 4-67 Trolleying outward deceleration

232
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Trolleying outward stop

The trolley is driven to L2 from the boom tip buffer, and the (4Z) axis is mobilized, so that the long
cam (4T) presses the micro switch (4WK), so that the trolley cannot continue to run outwards.

Fig. 4-68 Trolleying outward stop

233
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Trolleying inward deceleration

Drive the trolley to L1 from the boom root buffer, mobilize the (1Z) axis, so that the long cam (1T)
presses the micro switch (1WK), so that the trolley can only run inward at a low speed.

Fig. 4-69 Trolleying inward deceleration

234
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Trolleying inward stop

The load trolley is luffed to L2 meters away from the boom root buffer, and the (2Z) axis is
mobilized, so that the long cam (2T) presses the micro switch (2WK), so that the trolley cannot
continue to run inward.

Fig. 4-70 Trolleying inward stop

235
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Slewing limiter
◼ Slewing leftward stop
Adjust the slewing limiter when the cable is in a free state; rotate RA1 counterclockwise to 540°
(1.5 circles), mobilize the adjustment shaft (4Z) to make the long cam (4T) move until the micro
switch (4WK) is switched instantaneously, and then tighten the M5 nut.

Fig. 4-71 Slewing leftward stop

236
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Slewing rightwards stop

After completing the adjustment of the leftwards slewing stop, rotate RA2 clockwise to 1080° (3
turns), mobilize the adjustment shaft (2Z), make the long cam (2T) move to the micro switch
(2WK) momentarily switch, and tighten the M5 nut.

Fig. 4-72 Slewing rightwards stop

◼ Multi-function limiter adjusts parameters

Table 4-9 Multi-function limiter adjust parameters

Hoisting limiter Trolley limiter

Fall H1(m) H2(m) L1(m) L2(m)

5 1.5

5 0.5

3 1.5

237
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Overload protection device

Load moment limiter
◼ Function
The design of the tower crane is based on a certain maximum load moment. It is strictly forbidden
to exceed this maximum load moment when the tower crane is working.
The function of the load moment limiter is to prevent the working moment of the tower crane from
exceeding the rated maximum lifting moment.

◼ The working principle of load moment limiter

The load moment limiter is composed of a bow-shaped plate that magnifies the deformation and
several limit switches (Fig. 4-73). There are several adjustable bolts on the plate. The bolts
correspond to the travel switch. Under the action of the load torque, the adjustable bolt (6)
Contact with the travel switch (1-4) to output overload deformation signal to remind the operator
or make the operator's operation invalid.

According to the clearance between adjustable bolt and limit switch, the switch
acts within the safety control circuits subjected to load moment.

(1) Travel switch SMA2 (2) Travel switch SMA1

(3) Travel switch SML2 (4) Travel switch SML1
(5) Anti-loosen nut (6) Adjustable bolt

Fig. 4-73 Load moment limiter

238
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ The adjustment of the load moment limiter should be carried out at

the independent height! The independent height is marked in
"Technical Parameters of Tower Crane". When the adjustment is made
beyond the independent height or the large height, the weight of the
lifting weight should be subtracted from the weight of the wire rope
exceeding the height and the additional weight of the hook.
◼ After adjustment, lock the locknut.

◼ Adjustment method
Adjust the individual switches of the load moment limiter shown in the diagram above (Fig. 4-73)
according to the parameters in the table below. The specific adjustment method is shown in the
back of the table.
Table 4-10 Adjustment parameters(2-fall)
Lf/m X/kg Y/kg W/kg Ld/m Lw/m L/m L’/m
70 2500 2750 6000 28.63 32.21 35.79 39.36

67.5 2800 3080 6000 29.88 33.62 37.35 41.09

65 3100 3410 6000 30.97 34.84 38.71 42.58

62.5 3400 3740 6000 31.88 35.87 39.85 43.84

60 3700 4070 6000 32.62 36.70 40.78 44.86

57.5 4000 4400 6000 33.20 37.35 41.50 45.65

55 4400 4840 6000 34.21 38.49 42.77 47.04

Lf 52.5 4800 5280 6000 35.00 39.38 43.75 48.13

50 5200 5720 6000 35.56 40.01 44.45 48.90

47.5 5700 6270 6000 36.42 40.97 45.53 /

45 6000 6600 6000 36.00 40.50 45.00 /

42.5 6000 6600 6000 34.00 38.25 42.50 /

40 6000 6600 6000 32.00 36.00 40.00 /

37.5 6000 6600 6000 30.00 33.75 37.50 /

35 6000 6600 6000 28.00 31.50 35.00 /

32.5 6000 6600 6000 26.00 29.25 32.50 /

239
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Table 4-11 Adjustment parameters(4-fall)

Lf/m X/kg Y/kg W/kg Ld/m Lw/m L/m L’/m
70 2386 2624.6 12000 15.75 17.72 19.69 21.66

67.5 2686 2954.6 12000 16.42 18.47 20.53 22.58

65 2986 3284.6 12000 17.00 19.13 21.25 23.38

62.5 3286 3614.6 12000 17.49 19.68 21.86 24.05

60 3586 3944.6 12000 17.89 20.13 22.36 24.60

57.5 3886 4274.6 12000 18.20 20.47 22.75 25.02

55 4286 4714.6 12000 18.74 21.08 23.42 25.77

52.5 4686 5154.6 12000 19.16 21.56 23.95 26.35

Lf
50 5086 5594.6 12000 19.46 21.89 24.33 26.76

47.5 5586 6144.6 12000 19.92 22.41 24.90 27.39

45 5986 6584.6 12000 19.96 22.46 24.95 27.45

42.5 6386 7024.6 12000 19.88 22.37 24.85 27.34

40 6786 7464.6 12000 19.68 22.14 24.60 27.06

37.5 7286 8014.6 12000 19.58 22.03 24.47 26.92

35 7786 8564.6 12000 19.32 21.74 24.16 26.57

32.5 8386 9224.6 12000 19.11 21.50 23.89 26.28

30 9086 9994.6 12000 18.89 21.25 23.61 25.97

Lf: Jib length (m) Ld: 80% moment trolley distance (m)
X: Weight on jib end (kg) Lw: 90% moment trolley distance (m)
Y: Loaded weight (kg) L: 100% moment trolley distance (m)
W: Maximum rated weight (kg) L’: 110% moment trolley distance (m)

240
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Load moment deceleration

Lift the maximum rated lifting weight W at a small amplitude to 1m above the ground, and trolley
outward at a normal speed. When Ld is reached, adjust the load limiter bolt so that SMA2 (1) is
triggered, and the trolley outward automatically switch to low speed.

Fig. 4-74 Adjustment of trolley moment limiter

241
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Load moment early warning

If the trolley continue to outward at a low speed and reaches L w,, the adjusting load moment limiter
SMA1 is triggered, 90% moment yellow lights up and alarm.

Fig. 4-75 Adjustment of moment limiter early warning

242
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Constant load for variable radius

When the trolley reach to the position of L~L’, adjust the moment limiter to trigger the SML2(3),
then the “100% moment” light is on, and there is warning sound, the trolley out and hoisting up
movements are limited.

Fig. 4-76 Adjustment of constant load for variable radius

243
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Constant radius for variable load

The normal permit maximum load at the jib end is X, without any moment limiter being triggered,
the hoisting is normal. When the load to Y, the adjusting moment limiter SML1(4) is triggered. At
this time, the hoisting up power is cut off, the 100% moment red lights up and alarm, the hoisting
up is restricted.

Fig. 4-77 Adjustment of constant radius for variable load

◼ Seal
After adjusting and checking moment limiter, close the rain cover of moment limiter, and then
wear it with steel wire through the hole of the rain cover and add lead seal.

244
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Load limiter
◼ Function
It is prohibited to exceed the maximum load capacity of tower crane during operation. Load limit
switches are used to prevent the tower crane from exceeding the maximum load capacity.

◼ Working principle
The load moment limit switch is a dynamometric ring consisting of metal strips, adjustable screws,
several limits switch etc. Each screw corresponds to one limit switch. During HOIST operation,
certain force running over the hoisting rope is applied to the dynamometric ring, and will cause
the metal strips to deflect. This deflection of metal strips allows the adjustable screws to contact
and act on the limit switch, which would alert the crane operator in case of any overload situation
via acoustic and optical signals.
This system allows the contactors to act on the safety circuit depending on the loads to be
controlled, when appropriately adjusting the gap between adjustable screw and limit switch.

◼ This system allows the contactors to act on the safety circuit depending on
the loads to be controlled, when appropriately adjusting the gap between
adjustable screw and limit switch.
◼ The load limit switch has been pre-calibrated at the factory and needs to be
checked on site. If the deviation is too large, please adjust it according to
the following adjustment steps.

Fig. 4-78 Load limiter

245
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Installation and using of the load limiter

Fix the load limiter to the position of the jib (jib Ⅰor Ⅱ) by the hole (4) and a pin. The cover can
be opened by screw out the nut (1). You can use the adjust wrench (3) on the cover back to
adjust the adjusting switch inside. Connect the lines through the hole (2).

Fig. 4-79 Installation of load limiter

The figure above is for instruction only, it doesn’t refer to the limiter of your crane
in particular, but you can take it as a reference.

Fig. 4-80 Switch of load limiter

246
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Adjusting for High-speed hoisting

Hoisting load A at the minimum radius, the hoist speed can be reach at high speed, add 10%
weight, and then adjust load limit switch K2 is triggered. At this time, the high-speed hoisting
radius is restricted, “50% rated load” yellow lights up, the height of hoisting is restricted at low
speed.

+KG
A+10%

Fig. 4-81 High-speed hoisting for 50% rated load

247
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Adjusting for maximum hoisting load

Hoisting load B at the minimum radius, the hoist speed can be reach at low speed, add 10%
weight, and then adjust load limit switch K1 is triggered. At this time, “100% load” red lights up
and alarm, the upward hoist actions are restricted.

+KG
B+10%

Fig. 4-82 Adjusting for maximum hoisting load

◼ Adjust parameter table of load limit switch

Table 4-12 Adjust parameter table of load limit switch

Fall A (kg) A+10% (kg) B (kg) B+10% (kg)

3000 3300 6000 6600

6000 6600 12000 13200

◼ Seal
After adjusting and checking load limit switch, close the rain cover, and tightening the bolts, and
then wear it with steel wire and add lead seal.

248
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Anemometer and obstruction light setup

Anemometer setup
If tower crane height over 50m, should install anemometer. The anemometer co-work with safety
monitor system. When wind speed over the maximum in service wind speed, alarming stop
working.
Anemometer installed at the tower head. Shows in fig 7-90, the base (1) connects with tower
head through the install plate bolt. Wiring through the wire junction gate (2), and using fan (3) for
speed measurement.

Fig. 4-83 Anemometer

Waring and display record device
◼ Sound signal

For example, the signals below will produce automatically by the sound warning ways:
➢ The tower crane starts and self-checks: short buzzer sound for 5 times;
➢ Warning of over load: constant buzzer sound;
➢ The tower crane working: intermittent double buzzer sounds.

There will be special sounds according to the local regulations or rules. Know the tones and
last time of each signal!

◼ Light signals

For example, the light signals below indicate particular dangers:

➢ Wind speed warning at working: flashing orange light.
➢ Load over 90% of the rated load: flashing orange light (with buzzer warning).
➢ Limiter failure: flashing red light.

249
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Trolley safety protection device

The safety protection device of the trolley is shown in the following figure:

(1) Axle break protection device (2) Rope break protection device (3) Brake rod

Fig. 4-84 Trolley safety protection device

250
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

◼ Rope break protection device

As shown in Figure 7-91, under the normal working state of the trolley, the wire rope is in a
tensioned state, and the broken rope protection device (2) is in a horizontal state; when the rope
is broken, the broken rope protection device rotates to a vertical position under the action of
gravity at the tail. In the straight state, at this time, the brake lever (3) of the device will be in
contact with the web rod on the bottom surface of the boom, and the movement of the trolley will
be blocked and the operation will be stopped automatically.
◼ Axle break protection device
As shown in Figure 7-91, when the roller breaks the axle, the trolley loses the support of the roller
and moves downward, and the lower end of the axle break protection device (1) is in contact with
the lower chord of the boom. Under the action of the four axle break protection devices, the trolley
continues to stay on the lower string of the boom to ensure that it will not fall due to the broken
axle.

Hook safety device

The hook safety device is shown in figure (1) below, it is in close contact with the hook end face
(2) during use, and can only be opened in one direction into the hook. When lifting heavy objects,
the objects in the hook will be restrained in the hook by the safety device to prevent decoupling.

Fig. 4-85 Hook safety device

251
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4.17 Test
To confirm the tower crane's readiness, an acceptance test shall be performed. The test shall
include at least the following items:
◼ Nameplate of the tower crane and the grades;
◼ Tests of drive mechanism, limiter and indicator;
◼ Safety devices;
◼ In compliance with the load tests 4.17.1 and 4.17.2

Function test without load

All functions (such as braking, system controlling and limiting etc.) shall be tested for reliability
throughout the whole range of admissible movements up to the maximum operating speed (such
as hoisting, trolley and slewing).
◼ When testing, the temperature should be -15~40°C, the wind speed can’t be over 8.3m/s.
◼ When testing the trolley speed, total time of trolleying, slewing speed, working speed and
side perpendicularity, the wind speed can’t be over 3m/s.
◼ The error range of the power voltage should be ±10%.
◼ The participators must have relevant certification.

252
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Load tests
Nominal load tests
The load at the maximum amplitude is 25%, 50%, 75%, 100% separately to the nominal load,
the tests should comply with the acquirements in 4.17.1, all the tests should be reliable.

Static tests with load 125% of the rated capacity

After the success of the no-load test and the nominal load test, proceed the static overload tests.
The load tests result for different jib lengths show as Table 4-13.
◼ Test at 4-fall.
◼ Hoist the rated load to the position 100~200mm above ground, standstill then add the load
to 125% in several times, measure the load height, measure again after 10min, compare
the heights.
◼ There should be no ruptures, permanent deformations or damages affecting the function or
safety of the crane and parts connecting loose.

Table 4-13 Static tests with load 125% of the rated capacity
Item
RadiusⅠ(m) LoadⅠ(t) RadiusⅡ(m) LoadⅡ(t)
Jib length(m)
70 19.69 15 70 2.98
67.5 20.53 15 67.5 3.36
65 21.25 15 65 3.73
62.5 21.86 15 62.5 4.11
60 22.36 15 60 4.48
57.5 22.75 15 57.5 4.86
55 23.42 15 55 5.36
52.5 23.95 15 52.5 5.86
50 24.33 15 50 6.36
47.5 24.90 15 47.5 6.98
45 24.95 15 45 7.48
42.5 24.85 15 42.5 7.98
40 24.60 15 40 8.48
37.5 24.47 15 37.5 9.11
35 24.16 15 35 9.73
32.5 23.89 15 32.5 10.48
30 23.61 15 30 11.36

◼ It is forbidden to trolley and slew at the static overload test.

◼ It is forbidden to adjust the brake at the static overload test.
◼ It is allowed to adjust load moment limiter and load limiter at the static
overload test.

253
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Dynamic tests with load 110% of the rated capacity

The load tests result for different jib lengths shows as Table 4-14.
Test at 2-fall or 4-fall.
◼ Working condition Ⅰ: Trolley to the maximum radius of maximum load, loads by 110%
maximum load. Test method:
➢ Hoisting: Hoist up and down at the rated speed in the whole hoisting range.
➢ Trolleying: Trolley in and out at the rated speed in the whole trolleying range.
➢ Slewing: Slewing left and right at the rated speed in the whole slewing range. (for the tower
crane which can’t slew around, the slewing test angle should exceed the max angle.)
◼ Working condition Ⅱ: Trolley to the maximum radius, loads by 110% rated load at the
maximum radius. Test method:
➢ Hoisting: Hoist up and down at the rated speed in the whole hoisting range.
➢ Trolleying: Trolley in and out at the rated speed in the whole trolleying range.
➢ Slewing: Slewing left and right at the rated speed in the whole slewing range. (for the tower
crane which can’t slew around, the slewing test angle should exceed the maximum angle.)

◼ Requirements:
Test according to the indication above, check if the mechanisms are flexible and their brakes
are reliable. Check if there is any loose or break in the mechanisms or structure parts.
Table 4-14 Dynamic tests with 110% of the rated capacity
Item
RadiusⅠ(m) LoadⅠ(t) RadiusⅡ(m) LoadⅡ(t)
Jib length(m)
70 19.69 13.2 70 2.62
67.5 20.53 13.2 67.5 2.95
65 21.25 13.2 65 3.28
62.5 21.86 13.2 62.5 3.61
60 22.36 13.2 60 3.94
57.5 22.75 13.2 57.5 4.27
55 23.42 13.2 55 4.71
52.5 23.95 13.2 52.5 5.15
50 24.33 13.2 50 5.59
47.5 24.90 13.2 47.5 6.14
45 24.95 13.2 45 6.58
42.5 24.85 13.2 42.5 7.02
40 24.60 13.2 40 7.46
37.5 24.47 13.2 37.5 8.01
35 24.16 13.2 35 8.56
32.5 23.89 13.2 32.5 9.22
30 23.61 13.2 30 9.99

254
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Operation of overload test circuit

If 110% and 125% overload weight test is needed at the construction site, the following steps
should be followed for circuit operation:
1) When the tower crane is not operation, pull out the XP16 at the lower part of the driving kit
in the driver’s cab, connect the spare 100% load unlimiting test pug to XS16, and then
temporarily the mechanical limit of 105% load.
2) Rotate the mode section key switch to “Mechanical” mode, when the electronic load limit is
not involved in the control, then the overload hoisting test can be performed.
3) After the completion of test, open the mode selection key and rotate it to the
“electromechanical” mode on the interface of “load weight calibration”. Remove the “100%
weight unlimiting test plug” and connect the weight limiter plug, the system will resume
normal operation.

◼ This operation must be carried out by professional testers.

◼ The operation shall be carried out in strict accordance with the test process,
and illegal driving and taking the plane during the test are prohibited.
◼ Once test is completed, remove the “100% weight unrestricted test plug”,
◼ This “100% load unrestricted test plug” is guaranteed to be used for temporary
overload test on construction site, and must not be removed

255
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4.18 Tower anchored onto the building

When the working height of the tower crane is required to exceed its free-standing height, the
tower body shall be anchored.

Description
The 2.0m fish plate tower mast recommend adopt retractable attachment frame YWB-FZJ2000
(000209911A2600000) is mainly consist of attachment frame, inner support column, strut rods
(including strut rods double-headed screw, connecting sleeve, pin, split pin and nut.), the
Foundation support constitute, as shown in Fig. 4-86.

Fig. 4-86 The retractable attachment frame YWB-FZJ2000

Table 4-15 Spare parts of retractable attachment frame YWB-FZJ2000

No. Code Designation Order No. Qty
1 Attachment frame 000209911A0610000 FZK2000-YWB 1
2 Long strut rods 000209911A2701000 2
3 Short strut rods 000209911A2702000 2
4 Foundation support 000209911A0211650 FZJZ-S300/H160/260/Φ60 2

256
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Attachment frame
Positioning dimensions of connecting pin holes on attachment frame as show in Fig. 4-87.

Fig. 4-87 Attachment frame

Attachment rods
The 2.0m tower mast retractable attachment frame including two long and short strut rods of
each. The length of the long rod is between 4960~860mm while the length of the short rod is
between 4200~7040mm, as shown in Fig. 4-88.

Fig. 4-88 Layout of the strut rods

Table 4-16 Spare parts of long strut rods

No. Order No. Code Designation Qty
1 000209911A2701100 Strut rodsⅠ 1
2 000209910A1122601 XZ01C-60×270/305 Pin 2
3 1040500186 GB/T91-2000 Pivot 6
4 000209911A2701200 Strut rods Ⅱ 1
5 1040202429 GB/T6172.1-2000 Nut 1
6 000209911A0211900 FZLG-M80 Double-headed screw 1
7 1040202430 GB/T6172.1-2000 Nut 1
8 000209911A0211850 FZJT-M80-350Φ60 Threaded connector 1
9 000209910A4122401 XZ04C-60×240/300 Pin 1
10 000209911A1101001 Washer 2
Table 4-17 Spare parts of short strut rods

257
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

No. Order No. Code Designation Qty

1 000209911A2702100 Strut rodsⅠ 1

2 000209910A1122601 XZ01C-60×270/305 Pin 2

3 1040500186 GB/T91-2000 Pivot 6

4 000209911A2702200 Strut rods Ⅱ 1

5 1040202429 GB/T6172.1-2000 Nut 1

6 000209911A0211900 FZLG-M80 Double-headed screw 1

7 1040202430 GB/T6172.1-2000 Nut 1

8 000209911A0211850 FZJT-M80-350Φ60 Threaded connector 1

9 000209910A4122401 XZ04C-60×240/300 Pin 1

10 000209911A1101001 Washer 2

Foundation support
The pin bore position on the base seat and the base plate are as follows.

Fig. 4-89 The pin bore and the base plate

The connection between the mast-pull-frames and the building:

a) The construction organization shall design the connection between the foundation support
and building according to the support force provided in the attachment arrangement from
and carry out the corresponding calculation (including the calculation of the connection
strength and the bearing capacity of the building).
b) If used the embedded ways, it is recommendable to use the embedded plate (prepared by
customers), the material is Q355B and the thickness is no less than 25mm, length and width
not less than 600×500mm.
c) The welding between foundation support and the embedded plate are recommend to use
E5016 welding rod, height of weldment is 24mm, 9 of Φ33 hole plug welding.
d) If used the bolts to connect, position size of the embedded bolts according to bottom
foundation support from the Fig. 4-89 to assign, M30 bolt must be more than 8.8.

258
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Layout of the anchored devices

Layout form 1
As shown in the Fig. 4-90 is the layout form 1.

Fig. 4-90 layout form 1

(1) Strut rods A (2) Strut rods B
(3) Strut rods C (4) Strut rods D

The length of the Strut rods is L1, L2, L3, L4 respectively, the angle between the rod A, D and
the building is α, β respectively, the distance between the center of the tower crane and the two
sides of the building is L5 and L6, the distance between the center of the tower crane and the
center of the base seat is L7 and L8. When using this form, the layout configuration must meet
the following conditions:

a) α, β must meet: 35°≤α≤67°, 35°≤β≤67°;

b) L1, L2, L3, L4 must meet: two rods are 4960~8600mm, the others are 4200~7040mm.

The maximum reaction from the anchored points to the building is given below:

Fx1/kN Fy1/kN Fx2/kN Fy2/kN

±525 ±456 ±525 ±456

259
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Some examples when L5=L6 for the form 1:

L5=L6/mm L7/mm L8/mm

3000 5500≤L7≤6800 5500≤L7≤6800

3500 5300≤L7≤7500 5300≤L7≤7500
4000 5000≤L7≤8000 5000≤L7≤8000
4500 4600≤L7≤7800 4600≤L7≤7800
5000 4100≤L7≤7600 4100≤L7≤7600
5500 4100≤L7≤7200 4100≤L7≤7200
6000 4300≤L7≤6600 4300≤L7≤6600
6500 4500≤L7≤5900 4500≤L7≤5900
7000 4700≤L7≤4900 4700≤L7≤4900

Layout form 2
As shown in the Fig. 4-91 is the layout form 2.

Fig. 4-91 layout form 2

(1) Strut rods A (2) Strut rods B
(3) Strut rods C (4) Strut rods D

When using this form, the layout configuration must meet the following conditions:

a) α, β must meet: 35°≤α≤78°,35°≤β≤78°;

b) L1, L2, L3, L4 must meet: two rods are 4960~8600mm, the others are 4200~7040mm.

260
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

The maximum reaction from the anchored points to the building is given below:
Fx1/kN Fy1/kN Fx2/kN Fy2/kN
±512 ±645 ±524 ±640

Some examples when L5=L6 for the form 2:

L5=L6/mm L7/mm L8/mm

3000 5500≤L7≤6800 4600≤L7≤6700
3500 5300≤L7≤7500 3900≤L7≤6900
4000 5000≤L7≤8000 2700≤L7≤6500
4500 4600≤L7≤7800 2500≤L7≤6000
5000 4100≤L7≤7600 2700≤L7≤5400
5500 3300≤L7≤7200 2800≤L7≤5100
6000 2900≤L7≤6600 2900≤L7≤4700
6500 3000≤L7≤5900 3000≤L7≤4300
7000 3100≤L7≤4900 3100≤L7≤3800

Layout form 3
As shown in the Fig. 4-92 is the layout form 3.

Fig. 4-92 Layout form 3

(1) Strut rods A (2) Strut rods B
(3) Strut rods C (4) Strut rods D
When using this form, the layout configuration must meet the following conditions:

261
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

a) α, β must meet: 40°≤α≤70°,42°≤β≤85°;

b) L1, L2, L3, L4 must meet: two rods are 4960~8600mm, the others are 4200~7040mm.

The maximum reaction from the anchored points to the building is given below:
Fx1/kN Fy1/kN Fx2/kN Fy2/kN
±465 ±664 ±438 ±750

Some examples when L5=L6 for the form 3

L5=L6/mm L7/mm L8/mm
5000 4000≤L7≤7600 3900≤L8≤4700
5500 3700≤L7≤7200 3200≤L8≤5300
6000 3900≤L7≤6600 1700≤L8≤5800
6500 4000≤L7≤5900 1500≤L8≤6300
7000 4300≤L7≤4900 1600≤L8≤5800

Range of the anchored devices

Range of 2.0m tower section anchored devices as show in Fig. 4-93:

Fig. 4-93 Attachable locations on the tower section

262
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Matters need attention

a) When installing the attachment frame, use the theodolite to check the verticality of the axis
of the verticality of the axis of the tower mast. The vertical degree of the tower axis above
the highest attachment point is 4/1000, and the vertical degree of the tower axis below the
highest attachment point is 2/1000. When the deviation of the vertical degree of the tower
axis does not meet requirements and the deviation is constant, the user can adjust the length
of attachment rod to meet the requirements.
b) When installing the attachment frame, the flat surface of the frame beam should be kept
consistent with the horizontal position as far as possible, and it should be hung on the tower
section with slings such as steel rope to prevent falling.
c) The gap of attachments and height of tower above the anchored-frame should meet the
operation manual of tower crane. The top two anchored-frames must be installed with inner
strut rods. It is suggested that each attachment should be installed with inner strut rods.
d) When there is interference in the position of the attachment frame of the inner strut rods
installation, it can adjust up and down appropriately, and the distance between the
installation position and the attachment frame is within 200mm of the tower section diagonal,
the inner strut rods may not be installed.
e) The Maximum allowable axial load of the single strut rod: in service is 500 kN, out of service
is 550kN.
f) In this manual, the length of the strut rods refers to the distance from the pin hole of
attachment frame to foundation support. When installing the attachment, the levelness of
strut rods shall not exceed 1/100 of the strut rods.
g) When the gap between pin holes and pin more than 1mm, the telescopic strut is prohibited
to used.
h) If none of them is satisfied, please contact our company, the force calculation can be
provided according to the actual situation.

263
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Three Stay bar anchored device

Layout of the three strut rods anchored devices
Layout of the three strut rods anchored devices as show in Fig. 4-94

Fig. 4-94 Anchoring form

User can choose the appropriate attachment points according to the actual requirements of
construction, and the attachment height, gap of attachment and height of tower above the
anchored-frame should meet the requirements of this manual.

The level reaction of attachment points

F: Level reaction of attachment points; T:Torque; α:Angle of F and X axis

Fig. 4-95 Drawing of anchoring form

Table 4-18 level reaction of attachment points

Load
Level reaction /kN Torque/kN.m
Service state
In service 190 715.8
Out of service 410 0
◼ User can calculate strut rod force and foundation support force according to the

264
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

attachment point level reaction force

◼ Our company telescopic attachment is the same tower mast in the largest load model to
calculate the foundation support force, as the most unfavorable state, different types of
crane with the same tower mast reaction force consistent.

◼ Angle α change from 0 to 360°

◼ Torque T direction is arbitrary, which may be clockwise or counterclockwise
(where the out of service is 0), in the table 715.8kN·m is the maximum
torque value of the tower crane torque

Please consult our company for out of service level reaction against
typhoon

Scheme of tower anchored onto building

The maximum hoisting height can reach 60m, if the hoisting height must be over 60m, it must be
fastened with tie-in onto the building and mast tie frame the maximum hoisting height can reach
300m. When the height is less than 150m m, 2-fall and 4-fall are all satisfaction for the hoisting.
When the height is more than132.5m, just 2-fall is allowed.
The tower crane anchored-to-building has the same structural layout as stationary type, only for
higher hoisting height. To enhance tower crane stability and tower body rigidity, several anchors
are provided along the whole height of the tower body, the crane must be equipped with several
anchors. In case of the actual distance of the project not in compliance with this requirement, just
contact our company for further information.

Anchored technical requirements for 51m free standing height

The tower crane anchored technical requirements as show in the following table. The height of
first anchored frames h1, the height of each two Anchored frame Δh and the height of tower
above the anchored-frame have given range, and the range of height change into corresponding
number of tower sections, that worth noting, when the working height is over 100m, the allowable
maximum height of tower above the anchored-frame can be reduce appropriately. Drawing of
attachment and important dimension refer to Fig. 4-96.

265
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

Fig. 4-96 Drawing of anchored tower crane

Table 4-19 Technical requirements of attachment

Height h1 /m 33.9≤h1 ≤48.9
Below the first 8.8≤n1 ≤ 13.8
anchored frames Quantity of tower sections n1 (Including base
tower section)

Each two anchored Height Δh /m 27≤Δh1≤36

frames Quantity of tower sectionsΔn 9≤Δn≤12
Hˊ/m Hˊ≤ 47
Maximum working
Quantity of tower
height H≤100m n ≤15.7
Above maximum sections n
attachment Hˊ /m Hˊ≤44
Maximum working
Quantity of tower
height H>100m n ≤ 14.7
sections n

In this table “Hˊ” is refer to the distance of the highest anchored frame to the
bearing face of hook, “the height of tower above the anchored-frame L” is refer
to the distance of the highest anchored frame to the highest tower section of its
upper end plane.

266
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Most economic anchored-frame layout for the stationary crane

with embedded anchors

Table 4-20 Parameter of most economic anchored-frame layout

Qty of Highest The height of Height of tower Qty of Qty of
anchored- working top attachment above the anchored- base tower
frame height H/m H/m frame Hˊ/m section section
1 H1=96 h1=49 ≤47 29
2 H2=132 h2=85 ≤47 41
3 H3=168 h3=121 ≤47 53
4 H4=201 h4=157 ≤44 1 64
5 H5=234 h5=190 ≤44 75
6 H6=267 H6=223 ≤44 86
7 H7=300 H7=256 ≤44 97

267
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

4.19 Dismantling
General notes
1) Due to the climbing mechanism out of service for a long time, conduct maintenance and
test-run for the climbing mechanism before moving the tower crane out of the construction
site.
2) Before dismantling of tower crane, maintenance and test-run of the climbing mechanism is
necessary.
3) Check limiters, slewing mechanism brakes and similar for reliability during test-run.
4) It is prohibited to use the slewing mechanism, trolley and hosting mechanism before the
tower crane mast sections have been dismantled and the slewing ring support has not been
connected to the tower body by eight pins.
5) Check frequently the main stressed parts of the climbing mechanism, as the tower crane
dismantling is a heavy duty and successive work for the climbing mechanism.
6) While the climbing mechanism is working, all operating personnel are required to focus their
attention on observing the relative positions of moving parts for normal condition (e.g.
between guide rollers and main chord rods, between Telescopic cage and crane tower.). In
case of any deviation during the telescopic cage is being lifted, stop and lower climbing
immediately.
7) Carry out dismantling when the wind speed is lower than 14m/s atop the tower crane. Take
care of the stockpile location of dismantled parts because the working site is limited for tower
crane dismantling after the buildings have been constructed. Any slight carelessness might
cause serious accident.

◼ Users are required to strictly follow the Instructions-specified rules to

dismantle tower crane. Operators shall have been trained and with
certificates. Any slight neglect will cause machine damage, personal
injury or death.
◼ Pay great attention to the two moving mast lugs during inlet or
dismantle of additional mast sections. Inspect if the lugs are still in
proper level condition.
◼ Pay great attention to the two climbing latches during inlet or
dismantle of tower section. Inspect if the latches are still in proper
level condition. Slewing the tower crane to the dismantling area where
there shall be no obstacles influencing the operation. Carry out tower
crane dismantling according to the sequence. Its steps are in
opposition to the steps of tower crane erection. Strictly follow the
instructions specified rules in all cases.

268
WA7025-12E-138EN-B03 ERECTION/ADJUSTMENT/DISMANTLING

Dismantling sequences
1) Dismantle mast sections.
2) Removing the hoisting rope.
3) Dismantle counter ballasts remain from counter-jib, only keep a counter ballast block.
4) Dismantle the jib.
5) Dismantle the last counter ballast block.
6) Dismantle the counter-jib (include hoisting mechanism).
7) Dismantle tower head and slewing assembly.
8) Dismantle the transition section, climbing equipment and the mounting system.
9) Dismantle the rest tower sections and base tower section.

Preparations before dismantling

Make sure that no obstacle will interfere during the dismantling operations.
For cranes with travelling gear:
◼ Bring the crane to the dismantling area.
◼ Fold down the rail clamps of the bogies and tighten them onto the rails.

Dismantling the tower section

Remove the tower sections in turn, refer to Section 4.3.3.

When the climbing equipment is climbing down, a dedicated person must be

assigned to take charge of the hanger plate, step change climbing lever and
guide rollers, and to check if the climbing equipment is seized by obstructions,
ensuring the climbing equipment climbs down successfully.

Dismantling the hook and the hoisting wire rope

◼ Lower the hook to the ground, remove the connection between the hoist wire rope and the
anti-twisting device on the jib, start the hoist mechanism and recover all the wire ropes.

Dismantling the electrical control wire

◼ Disconnect the circuit of the electronic system that affects the lifting of the tower components
and gather it at one end.

Dismantling the part counter ballasts

◼ Dismantle the counter-weight piece by piece in reverse order of installing sequence the
counter ballast. Only leave the first 3.0t counter ballast block.

Dismantling the jib assembly

◼ Before dismantling, check the jib assembly to see if component-to-component is still
connected by power cable.

269
ERECTION/ADJUSTMENT/DISMANTLING WA7025-12E-138EN-B03

◼ Arrange hoisting rope at hook points. (reference the record point when the jib was lifting);
◼ Dismantle the connection pin and bolts of jib and counter-jib.
◼ Lower the jib and lay it down on the sleeper-cushioned support.

Dismantling the last one counter ballast

◼ Remove the last one counter ballast block, and lift it in the proper position on the ground.

Dismantling the hoisting mechanism

◼ Sling the hoisting mechanism, remove the connecting pin shaft between the hoisting
mechanism and the counter-jib, and sling it in an appropriate position on the ground.

Dismantling the counter jib

◼ Sling the counter-jib and the bracket of the counter-jib tie bar and fix it with the pivot.
◼ Take the upper chord of the counter-jib and fixed pin of the tower head as the fulcrum, slowly
lift the counter-jib, and rotate around the fulcrum, so that tie bar is in a relaxed state, the tie
bar falls on the support frame, and remove the connecting pin shaft between the long tie bar
and the short tie bar.
◼ Hook the counter-jib down onto the ground.

Dismantling tower head and the slewing assembly

◼ Sling slewing assembly (contain the tower head), dismantling the connecting pin shaft
between the slewing support and the transition section, and sling it in an appropriate position
on the ground.

Dismantling the transition section, climbing equipment and the

tower section
◼ Sling the climbing equipment, slowly hoist it out along the main chord of the tower section
to the ground.
◼ Dismantling the tower section and the mast section in turn. Chassis fixed tower crane to
remove.

◼ The dismantled crane needs to be checked and maintained by

technical personnel and trained maintenance personnel.
◼ Check main stressed structural members for metal fatigue; weld
fissure, structural deformation, etc. Check tower crane parts for
damage or collision injury.
◼ After completion of checks, repair the defects found and defects
potential. Carry out rust removing and painting.

270
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

5 OPERATION AND CONTROL

5.1 Driving safety requirements for tower crane
Please read the requirements in Chapter 2 <SAFETY INSTRUCTION> of this manual carefully.

The driver needs to read the manual before operating.

5.2 Attention for operation

◼ Operate the crane only all the safety devices are in good condition.
◼ Adjust the limiters according to the instruction handbook strictly.
◼ Sufficient lighting shall be provided to the working area for night working.
◼ Keep all platforms, ladders, rails, and handrails from dirt.
◼ No unauthorized persons are allowed climb the crane!
◼ People who have been approved can climb up or down the tower crane after the tower
operators stopping the crane!
◼ Test run before working, work after confirming the tower crane is in good condition.
◼ Whistle before action every time.
◼ Don’t lay the hook onto the ground in order to avoid disordering the ropes.
◼ Operators should give some relevant warning signals on occasion.
◼ Stop working immediately once some defects harming tower crane operation safety are
found.
◼ The tower crane driver should observer the state of the tower crane in the cabin during the
climbing and descending process, when the tower crane is abnormal, the driver should
handle the problem in time.
◼ When the tower crane rises and falls, no one is allowed stand under the tower crane without
permission

271
OPERATION AND CONTROL WA7025-12E-138EN-B03

5.3 Specific safety instructions

When the crane is in service, all the control panel doors must be locked.

The crane driver must position the jib in the direction of the wind before
any weathervane operation.

At each operation in the slewing area of the slewing crane part, the crane
driver must be extremely vigilant (crushing hazard).

It is compulsory to put the control unit out of service as soon as the crane
driver lays it down or no longer controls the crane.

272
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

5.4 Preparation before operation

Inspection before operation
Table 5-1 Check list before operation

Item Content

Check the wind speed, the maximum allowed wind speed is 20 m/s when the
tower crane is working;
The maximum allowable wind speed is 14 m/s when the tower is erected and
climbing up;

Check the environment temperature, the normal working temperature range of

the tower crane is: -20℃ ~ +40℃;
Check the working voltage of the tower crane;
Check the safe distance of the cable from the largest rotating part of the tower
crane;
Check the distance between the tower crane and surrounding buildings.

min:1.5m

Common

min:0.5m

Make sure that all central ballasts and counter ballasts are of the correct
weight, quantity, and proper placement;
Check whether the tower crane foundation is in good condition;
Make sure all gears and bearings, etc. are well lubricated, such as slewing
rings;
When in lightning area, customers need to equip their own lightning protection
devices to ensure that lightning protection devices are installed according to
local requirements and that the tower crane is properly grounded.

Check whether the connecting bolts of the outriggers and the base tower
section are correctly installed and tightened or whether the anchor bolts are
Base
tightened;
Check the cable routing to prevent damage.

Check whether the high-strength bolts between the tower sections are installed
Mast
correctly and whether the pre-tightening torque meets the requirements;

273
OPERATION AND CONTROL WA7025-12E-138EN-B03

Item Content

Check whether the ladder, platform, etc. are firmly connected.

Check the connection to the transition section;

Climbing Check whether the rollers and the support bar are flexible and reliable, and
equipment whether the connection is firm;
Check whether the ladder, platform, etc. are firmly connected.

Check whether the ladder, platform, etc. are firmly connected;

Transition
Check whether the connection with the standard section, climbing equipment
section
and slewing support is firm.

Check the tightness of the bolts connected to the slewing bearing;

Check whether the mounting device trolley is clear of obstruction;
Slewing Check cable routing;
assembly Check whether the ladder, platform, etc. are firmly connected;
Check whether the connecting pins between the turntable and slewing tower,
slewing support and the tower section are correctly installed.

Check the connection of the cabin;

Check internal circuit connections;
Cabin
It is strictly forbidden to store lubricating oil, oil cotton yarn and other
flammable items in the cabin.

Check if the connecting pins, baffles, washers and cotter are correct
installation of pins everywhere;
Jib
Check the fastening of platforms, ladders, passages, and gondolas;
Check the winding and tightening of the hoisting wire rope.

Check the correctness of the installation of connecting pins, shaft end shields
and pivots;
Counter jib Check the installation of the counter jib handrail and the walkway to ensure
that the walkway is free of debris;
The hoisting wire rope roller can rotate freely.

Check the hook for defects that affect its use;

Check whether the specifications and models of the hoisting wire rope meet
Hook
the requirements;
Check wear and tear of the wire ropes and pulleys.

Check the installation and operation of each mechanism;

Adjust the brake clearance of each mechanism right position;
Mechanism Check the trolley mechanism. When the trolley reaches the max. and min.
radius, the wire rope on the drum should have at least 3 safety rings;
Check that the wire rope is wound correctly on the drum;

274
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Item Content

Check whether the compression of each wire rope head is loose.

Check whether each safety protection device is adjusted according to the

requirements of this operation manual;
Safety
Check that all safety devices are reliable;
equipment
The limiter must be re-adjusted every time after climbing, the jib length is
changed, or after a period of use.

The insulation resistance of the main loop control loop to ground should not be
Electronic
less than 0.5 MΩ;
control
The grounding resistance of the mast to the ground should not be greater than
system
4Ω.

Lubricating Check lubrication according to Maintenance Manual.

Check after power on

After every power-on, before starting the tower crane, the operator must check the following in
the empty hook state:
◼ Whether each switch button (especially the "emergency stop button"), operating handle,
brake, travel limit and protection switch work normally;
◼ Safety monitoring system in the cabin is firmly installed, and whether the communication
cable is connected reliably;
◼ Whether the limit protection switches are well adjusted;
◼ After each limit protection switch is activated, whether the electronic control system can
perform the corresponding protection function;
◼ If any abnormality is found, it should be stopped immediately for maintenance;
◼ The tower crane shall not be put into operation until the failure or potential safety hazard
has been eliminated.
Each mechanism of this series of tower cranes uses variable frequency
speed drive, and each frequency converter will generate a certain high-
frequency leakage current during operation, which is determined by the
inherent output characteristics of the frequency converter. The leakage
current of each frequency converter may be greater than 100mA. In order
to ensure the normal use of the tower crane, the B-type (delayed) leakage
protection circuit breaker in accordance with IEC 60755 and VDE 0664-100
standards should be selected on the power supply of the construction
site, and Please ensure that all parts of the tower crane are reliably
grounded.

Tower crane startup

After confirming that the inspection and preparation are done before starting, and the main power
switch QF is closed, press the green start button of the linkage platform to start the tower crane

275
OPERATION AND CONTROL WA7025-12E-138EN-B03

directly.
The start button is located on the right linkage table panel, it is a dual function button, namely:
start and electric whistle function. When the main power switch QF of the main control cabin is
closed, the left and right linkage table handles are in the zero position, the grid voltage phase
sequence is normal, and the components of the startup circuit are running normally, press this
button to start the system.

◼ When the system starts, the green "start" indicator on the left linkage stage
is on, indicating that the electric control system is successfully powered on.
◼ The driver will hear the buzzer beep 5 times within 2 seconds, and at the
same time the alarm light on the right linkage platform flashes 5 times,
indicating that the alarm device is normal.

When the electronic control system is successfully started, the operation of each mechanism can
be carried out. When using the operating handle, the self-reset button on the top of the handle
should be pressed down to release the self-locking before pushing.
When the handle is pushed, the buzzer in the linkage station will emit a short "beep" every time
it enters a gear.
When the sound and light alarm signal occurs, the electronic control system will automatically
limit the relevant movement (such as prohibiting the movement of a certain mechanism, slowing
down the movement in a certain direction, etc.).

The requirements for the working environment are relatively high. Such as
poor quality of power supply (low or high voltage, unbalanced three-
phase), power supply fluctuation, high ambient temperature, frequency
converter overload, motor overload, frequency converter overheating,
output phase loss, output side ground fault, etc. Frequency converter
stops.
In most cases, this does not mean that the frequency converter has been
damaged, but the built-in automatic fault protection function of the
frequency converter comes into play and enters a protective shutdown
state. Under normal circumstances, after the power supply returns to the
normal range or the corresponding fault is eliminated, press the " ENTER
" key of the digital operator on the frequency converter panel, and the
frequency converter can return to the running state; or restart the power
supply after a few minutes. control system, the frequency converter can
automatically reset and enter the running state.
If the frequency converter stops frequently, first judge, if it is caused by
the poor quality of the power supply, stop working temporarily, and start
the operation after the power supply is normal; If it is caused by other
faults or unknown reasons, you should suspend use, and promptly notify
our company to send personnel to deal with it. Please do not repair or
modify parameters by yourself, so as to avoid further damage.

276
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

All internal parameters of the frequency converter are not allowed to be changed
by non-manufacturer personnel without the permission of the manufacturer's
professionals (such as designers and professional after-sales service
personnel).

Safety device calibration

Tower crane safety protection devices mainly include: moment limiter, hoisting limiter, height
limiter, trolley limiter, slewing limiter and anemograph.

Starting the tower crane for the first time, the safety protection device of
the tower crane needs to be calibrated, and the tower crane can be used
normally only after the safety protection device of the tower crane is
confirmed to be effective.

Detailed calibration methods, see Section 4.13.

Tower crane operation

Hoisting and lowering operation
The hoisting operation is controlled by the handle on the right linkage table, pull inwards when it
goes up, and push it outwards when it goes down. There are five gears for hoisting and lowering,
corresponding to five speeds, and must be switched gear by gear when changing gears.

In some occasions, the driver wants to hoist the hook to the bottom of the trolley,
but it cannot be realized due to the limiter. At this time, operator can press the
"Bypass" button on the left linkage table with his left hand, and right hand operate
the handle on the right linkage table to hoist the hook to the limit position. The
operator should pay attention to the position of the hook to avoid collision.

1) In addition to the above basic operations, it also has the following customization functions:
Micro-speed and jog functions: press the micro-speed button on the right linkage table at
any time to turn on the micro-speed function (the speed of gears 1 to 5 is reduced to about
half of the normal operating speed, subject to the actual micro-speed operating speed);
Press the micro-speed button, and then operate and keep the button pressed, after the gear
is reset to zero, activate the function of jogging without closing the brake. If there is no
hoisting action within the set time (the default setting is 5 seconds), the brake will be braked,
exit the jog mode; If you release the jog button within 5 seconds, the brake will immediately
hold the brake and exit the jog without closing mode.
2) Speed with load function: When the weight load is over 50%, it is allowed to turn the handle
to the 3rd gear of the base frequency. At this time, the frequency converter will automatically
adjust to the maximum allowable speed according to the load weight, which can improve
the hoisting efficiency.

277
OPERATION AND CONTROL WA7025-12E-138EN-B03

3) Anti-slip hook function: When the frequency conversion hoisting system is not in operation,
it still detects the state of the hoisting mechanism at all times. To maintain the relative height
of the hoisting weight, prevent the hoisting weight from falling, and issue an alarm prompt,
the up and down movement of the main hook is limited to the 2nd gear of the fundamental
frequency, and the inward and outward movement of the trolley is limited to the 2nd gear.
Left and right movement of the arm is limited to 2nd gear.

When the anti-slip hook function is on, the display shows "the tower crane
has entered the hovering anti-slip hook state ", and the system
automatically enters the hovering state. At this time, the personnel under
the tower must be immediately notified to evacuate the dangerous area,
At the safety situation, lower the hoisting weight to a suitable place on the
ground, and then notify the relevant professionals to check the cause of
the failure. When the protection function is activated, do not press the
emergency stop switch or cut off the power supply of the control system
and the hoisting frequency converter, otherwise the anti-slip hook
function will fail, and even emergency hazards will occur, which is very
dangerous!

Trolley operation
The trolley operation method is as follows: the trolley operation is controlled by the handle on the
left linkage table, when the radius is trolleyed outward, the handle is pushed forward vertically,
and when the radius is inward, the handle is pulled vertically inward. There are five gears for
outward and inward trolley. Corresponds to five speeds from low to high.

In some occasions, the driver wants to drive the trolley to the base of the arm,
but it cannot be realized due to the limiter. The handle on the linkage table can
drive the trolley to the limit position. The operator should pay attention to the
position of the trolley to avoid collision.

1) In addition to the above basic operations, it also has the following customization functions:
Trolley anti-vehicle function: During operation, shift the gear in the opposite direction of the
operation, and the anti-vehicle operation can be performed to enhance the trolley
deceleration force.
2) Trolley reduce-sway function: see Section 5.4.5.4 for details.
Slewing operation
The slewing operation is controlled by the handle of the left linkage table. When turning left, turn
the handle horizontally to the left, and when turning right, turn the handle horizontally to the right.
The left and right directions of the handle are divided into five gears, corresponding to five rotation
speeds from low to high. Gear changes also require gear-to-gear switching. During operation,
press the jog button on the side of the left linkage table handle to speed up the rotation start
speed.
In addition to the above basic operations, it also has the following customization functions:

278
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

1) Rotation anti-vehicle function: gear to the opposite direction of operation, can carry out anti
-travel operation to enhance the slewing deceleration force.
2) Slewing reduce-sway function: see Section 5.4.5.4 for details.

◼ Due to the long jib length, the inertia is high and the slewing operation
must be smooth. When accelerating, the handle must be pulled
gradually, and when decelerating, it must also be gradually
withdrawn;
◼ It is strictly forbidden to use the brake switch when the jib is not
stopped;
◼ In use, the following phenomena sometimes occur:
It is difficult to start the slewing, and the start time is long;
The tower crane shakes greatly when it turns to stop;
The slewing speed is too fast or too slow;
After working for a period of time, the rotary motor heats up seriously;
The slewing brake fails to open;
At this time, you should first check the power supply and the slewing
frequency converter. If it is normal, please notify our company to send
personnel for maintenance.

Trolley, slewing reduce-sway function description

Reduce-sway function is built in a special frequency converter, which is a set of control programs
specially developed for tower crane applications. In some workplaces where the smooth
operation of the hoisting weight is required, this function can be turned on to realize the reduce-
sway of the trolley and slewing mechanism, and the operator can effectively eliminate the motion
of hoisting weight without the need for the operator to perform complicated operations such as
following the hook. The reduce-sway function improves the safety of the operation and reduces
the work intensity and skill requirements of the tower and cable workers.
This feature can be turned on or off through an on-screen option. If the reduce-sway function is
not turned on, the tower crane's trolley and slewing will run in the normal mode.
Use of the reduce-sway function:
◼ Turn on trolley or slewing reduce-sway on the display screen, and set the length of the sling
(the distance from the hook to the center of gravity of the hoist) according to the actual
situation. The reduce-sway function of trolley and slewing can be turned on or off
respectively;
◼ After hanging the sling, hoisting the heavy object to the required height, and keeping the
hoisting weight basically in a static state, you can operate the handle to perform trolley or
slewing motion;
◼ In the reduce-sway mode, the anti-vehicle operation can also be performed to enhance the
deceleration;
◼ During the operation of the mechanism, if the deceleration limit signal is triggered, the control
system will immediately exit the reduce-sway mode and enter the normal operation mode to

279
OPERATION AND CONTROL WA7025-12E-138EN-B03

avoid the overtravel movement of the mechanism;

◼ If you need to exit the reduce-sway mode temporarily (such as jogging into position, etc.),
please press the button on the side of the handle of the left linkage table, the system will
immediately exit the reduce-sway mode and enter the normal operation mode, and the
mechanism stops running for a period of time. After a period of time, you can return to the
reduce-sway mode;
◼ Reduce-sway can be turned off via an on-screen option.

◼ Speed curve will be automatically changed according to the mathematical

model of reduce-sway during trolley or slewing operation. When the
operator starts and stops the trolley or slewing mechanism, the acceleration
and deceleration rhythm will change, and the acceleration and deceleration
distance will be extended to a certain extent. When using the reduce-sway
function, the operator should try the operation several times in advance to
adapt to the running characteristics of this mode. If you can't adapt to the
operating habits, you can turn off the reduce-sway function on the screen.
◼ In outdoor applications, the effect of wind may affect the effect of reduce-
sway function.
◼ Please set the length of the sling correctly (that is, the distance from the
hook to the center of gravity of the hoist) according to the actual situation.
◼ It is necessary to ensure that the communication of the control system is
normal.
◼ The pendulum length data sent to the trolley and slewing frequency
converters must be accurate, and the calibration pendulum length detection
system needs to be adjusted correctly in advance.
◼ When the pendulum length exceeds a certain length (usually 60 meters by
default), the system automatically turns off the anti-slewing function.

280
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Travelling operation (optional)

The travelling operation is controlled by the handle on the right linkage stage. Pull the handle to
the left to move the bogie forward, and turn the handle to the right to move the bogie back. The
left and right directions of the handle are divided into two gears, corresponding to two travelling
speeds from low to high. When starting, you should first pull the handle from the middle to the
low gear, and then pull it to the high gear; when stopping, you should first return to the low gear
from the high gear, and then return to the stop gear.

Except in emergencies, it is strictly forbidden to directly return to the stop

gear from the high gear, otherwise it will have a huge impact.

Tower crane power off

Each use of the tower crane, the hook should be raised to the top, the trolley should be moved
to the base of the jib, the "BYPASS" button and the " slewing brake" button should be pressed,
weathervane should be turned on, and the emergency stop button should be pressed to cut off
the power supply.

Alarm
When the driver uses the linkage console handle to operate, he will hear a "beep" feedback every
time he shifts gears. When operating the electronic control system, the driver should be familiar
with the following various alarm signals provided by the system:
Moment alarm signal
1) Over moment signal
When the lifting moment exceeds 103% of the maximum allowable value, the electronic control
system will respond as follows:

◼ Red on the linkage table The warning light flashes;

◼ The buzzer in the linkage station emits four continuous beeps of "di di di di".
◼ Upward movement of the main hook is inhibited, and downward movement is limited to first
gear.
◼ Outward movement of the trolley is inhibited, and inward movement is limited to first gear.
◼ Left and right slewing motion of the jib is limited to first gear.
◼ Release method: run down or inward to reduce the weight.

2) Moment warning signal

When the lifting moment exceeds 90% of the maximum allowable value, the electronic control
system will respond a s follows:

◼ Yellow icon on the linkage table flashes warning light;

◼ The buzzer of the linkage station emits two continuous beeps of "Di Di";

281
OPERATION AND CONTROL WA7025-12E-138EN-B03

◼ The up and down movement of the main hook is limited to the fundamental frequency gear,
which is generally the third gear;
◼ Outward movement of the trolley is limited to second gear, and inward movement is not
restricted.
◼ Release method: inward slewing

3) Torque warning signal

When the lifting moment exceeds 80% of the maximum allowable value, the electronic control
system will respond as follows:

◼ Yellow icon on the linkage table flashes warning light;

◼ The up and down movement of the main hook is limited to the fundamental frequency gear,
which is generally the third gear;
◼ Outward movement of the trolley is limited to second gear, and inward movement is not
restricted;
◼ Release method: inward slewing.

Lifting weight alarm signal

1) Overweight Signal
When the lifting weight exceeds 105% of the maximum allowable value, the electronic control
system will respond as follows:

◼ Red icon on the linkage table flashes warning light;

◼ The buzzer in the linkage station emits three continuous beeps of "di di di";
◼ Upward movement of the main hook is inhibited, and downward movement is limited to first
gear;
◼ Outward movement of the trolley is inhibited, and inward movement is limited to first gear;
◼ Left and right slewing motion of the boom is limited to the second gear.
◼ Release method: run down to reduce the weight.

2) Overweight warning signs

When the lifting weight exceeds 90% of the maximum allowable value, the electronic control
system will respond as follows:

◼ Yellow icon on the linkage table flashes warning light;

◼ The buzzer in the linkage station emits a continuous "beep" alarm sound;
◼ The up and down movement of the main hook is limited to the fundamental frequency gear,
which is generally the third gear;
◼ Outward and inward movement of the trolley is limited to the fundamental frequency gear;
◼ Release method: reduce the lifting weight.
3) Overweight warning signs

282
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

When the lifting weight exceeds 50% of the maximum allowable value, the electronic control
system will respond as follows:

◼ Yellow icon on the linkage table flashes warning light;

◼ The up and down movement of the main hook is limited to the fundamental frequency gear,
which is generally the third gear. (Note: The hoisting speed limit is canceled when the
hoisting speed with load function is enabled.)
◼ The outward and inward movement of the trolley is limited to the fundamental frequency
gear plus one gear.
◼ Release method: reduce the lifting weight.

4) Overweight warning signs

When the lifting weight exceeds 25% of the maximum allowable value, the electronic control
system will react as follows:
◼ The up and down movement of the main hook is limited to the fundamental frequency gear
plus one gear, generally four gears. (Note: The hoisting speed limit is canceled when the
hoisting speed with load function is enabled.)
◼ Release method: reduce the lifting weight.

Lifting alarm signal

1) Upward stop limit signal
When the lifting hook has reached the maximum allowable value and the upper stop limit is
triggered, the electronic control system will respond as follows:
◼ The upward movement of the main hook is prohibited;
◼ Release method: lower the main hook.
◼ Releasing the limit method under specific working conditions:
When the trolley enters the inner reduction area, press the "Bypass" button; the speed of
lifting and upward movement is limited to the first gear. After the working condition is
completed, lower the main hook below the upper reduction limit to release the speed limit.

2) Upward deceleration limit signal

When the hook height is close to a certain distance from the upward deceleration limit point and
the upward deceleration limit signals are triggered, the electronic control system will respond as
follows:
◼ The upward movement of the main hook is forcibly limited to the first gear.

3) Downward stop limit signal

When the height of the hook is close to the ground and the downward stop limit is triggered, the
electronic control system will respond as follows:
◼ The downward movement of the hook is prohibited;
◼ Release method: raise the main hook.
◼ Releasing the limit method under specific working conditions:

283
OPERATION AND CONTROL WA7025-12E-138EN-B03

Press the "Bypass" button; the downward movement speed is limited to 1st gear. After the
working is completed, lift the main hook above the downward limit release the speed limit.

4) Downward deceleration limit signal

When downward, when the height of the hook is close to the downward deceleration limit point
and triggers the downward deceleration limit signal, the electronic control system will respond as
follows:
◼ The downward movement of the main hook is forcibly limited to the first gear.

Radius alarm signal

1) Trolley outward stop signal
When the trolley moves outward, when the trolley has reached the jib end and the trolley outward
stop limit signal is triggered, the electronic control system will respond as follows:
◼ Outward movement of the trolley is prohibited.

2) Trolley outward deceleration signal

When the trolley moves outward, when the trolley is close to a certain distance from the jib end
and triggers the trolley outward deceleration limit, the electronic control system will respond as
follows:
◼ Outward movement of the trolley is forcibly limited to first gear.

3) Trolley inwards stops limit signal

When the trolley is going inside, when the trolley has reached the jib foot and the trolley inwards
limit is triggered, the electronic control system will respond as follows:
◼ Inward movement of the trolley is prohibited.
◼ Release method under specific conditions:
Press the "Bypass" button; the trolley inward movement speed is limited to 1st gear. After
the working is completed, the speed limit can be lifted by moving the trolley outwards beyond
the trolley inwards deceleration limit.

4) Trolley inwards deceleration signal

When the trolley is going inside, when the trolley is close to a certain distance from the jib foot
and triggers the inner reduction limit, the electronic control system will respond as follows:
◼ The inward movement of the trolley is forcibly limited to first gear.

284
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Slewing alarm signal

1) Slewing left stop limit signal
When the jib rotates to the left more than one and a half circles and the slewing left stop limit is
triggered, the electronic control system will respond as follows:
◼ Left rotation movement of the jib is prohibited.

2) Slewing left deceleration limit signal

When the jib rotates to the left for more than one and a half circles and triggers the slewing left
deceleration limit, the electronic control system will respond as follows:
◼ The rotation movement of the jib to the left is limited to first gear.

3) Slewing right stop limit signal

When the jib rotates to the right for more than one and a half circles and triggers the slewing right
stop limit, the electronic control system will respond as follows:
◼ Right rotation movement of the jib is prohibited.

4) Slewing right deceleration limit signal

When the jib rotates to the right for more than one and a half circles and triggers the slewing right
deceleration limit, the electronic control system will respond as follows:
◼ Right rotation movement of the jib is limited to first gear.

Other alarms
1) Overvoltage and undervoltage protection alarm
When the external power supply is under or over-voltage, the indicator HU is on (the indicator is
on the driving box);
When the power supply voltage is higher or lower than the local standard requirements, the
power circuit is disconnected. When the red LED (F1 light) is on, the over-voltage alarm stops;
when the red LED (F2 light) is on, the under-voltage alarm stops;
Take China as an example, when the power supply voltage is greater than 110% of the rated
voltage or lower than 90% of the rated voltage, the power supply circuit will be automatically cut
off, and the overvoltage and undervoltage indicator lights on the driving box will be on. If the
voltmeter on the drive box is in a low voltage or high voltage state for a long time, please do not
start and work the tower crane, so as to avoid mechanical shock and possible danger when the
power circuit is cut off and shutdown, and may also damage the motor and electrical element.

2) Phase sequence protection alarm

When the phase sequence of the external power supply is incorrect or lacks phase, the yellow
LED light on the phase sequence relay is off, the power circuit is disconnected, and the start
indicator light is off (the indicator light is on the linkage table).

285
OPERATION AND CONTROL WA7025-12E-138EN-B03

5.5 Instruction of control unit

Overview
The cabin is the control center of the tower crane, the main layout is shown
Fig. 5-2 Cabin:

(1) Driving box (2) Monitor

(3) Seat (4) Left linkage station
(5) Wiper (6) Right linkage station

Fig. 5-2 Cabin

286
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Control panel, control instrument, man-machine interface

description

Fig. 5-3 Linkage console

287
OPERATION AND CONTROL WA7025-12E-138EN-B03

How to operate
The linkage console in the driver's cab is the console of the tower crane, which is installed on the
left and right sides of the driver's cab seat (See the attached table for the explanation of the keys).

No. Icon Name Function Description

In case of emergency, cut off the power and control

power of the tower crane.
Emergency stop
1 Not to be used in non-emergency situations
button
After the button is pressed, it needs to be rotated
to release.

Electric
Electric whistle control button.
2 whistle/start
The power-on start button of the whole machine.
button (green)

Over 50% rated

When the hoisting weight exceeds 50% of the
lifting capacity
3 rated lifting weight, the warning light will be on, and
warning light
the buzzer will sound an alarm (see Article 7).
(yellow)

Over 105% rated When the hoisting weight exceeds 105% of the
4 lifting capacity rated lifting weight, the alarm light will be on, and
warning light (red) the buzzer will sound an alarm (see Article 7).

Over 90% rated When the load moment exceeds 90% of the rated
5 moment warning moment, the warning light will be on, and the
light (yellow) buzzer will sound an alarm (see Article 7).

Over 100% rated When the load moment exceeds 103% of the rated
6 moment warning moment, the alarm light will be on, and the buzzer
light (red) will sound an alarm (see Article 7).

Self-test beeps 5 times at startup

5 seconds every 15 seconds when there is no GPS
signal
4 beeps every 0.5 seconds when the moment is
exceeded
2 beeps every 0.5 seconds during moment warning
7 Buzzer
3 beeps every 0.5 seconds when overweight
1 sound every 0.5 seconds during weight warning
1 sound when the operating gear changes
1 sound when the weathervane is released
The linkage table stick point fault or PLC fault
buzzer keeps ringing

288
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

No. Icon Name Function Description

Walking to the left Effective with walking mechanism

8 operation direction When the right linkage table handle is operated in
indication this direction, the walking will run to the left.

Walking right Effective with walking mechanism

9 operation direction When the right linkage table handle is operated in
indication this direction, the walking will run to the right.

When the handle of the right linkage table is

Hook up operation
10 operated in this direction, the hook will run
direction indication
upwards.

Hook lowering
When the handle of the right linkage table is
11 operation
operated in this direction, the hook runs downward.
instructions

Lift function switch:

Press this switch to activate the hoisting micro-
speed function. After the hoisting operation is
Right linkage performed and the gear position returns to zero,
12 platform jog button the jog does not close the brake function is
(green) activated; until the switch is released to return to
the zero position, the hoisting brake will hold the
brake after 5 seconds, and the micro-speed will be
activated. function release.

For details, please refer to the relevant chapters of

13 Bypass button
"System Prompts and Alarm Signals"

Slewing brake button switch, see "How to use

Slewing brake
14 slewing brake and weathervane release" for
button
details.

After the whole machine is powered on, the

15 Start light (green)
indicator light is on.

Rotary
weathervane After the weathervane is released, the indicator
16
release indicator light is on.
(blue)

Inward trolley
When the left linkage table handle is operated in
17 operation direction
this direction, the trolley mechanism runs inward.
indication

289
OPERATION AND CONTROL WA7025-12E-138EN-B03

No. Icon Name Function Description

Outward trolley
When the left linkage table handle is operated in
18 operation direction
this direction, the trolley mechanism runs outward.
indication

Rotate left When the left linkage table handle is operated in

19 operation direction this direction, the slewing mechanism rotates to the
indicator left.

Rotate right When the left linkage table handle is operated in

20 operation direction this direction, the slewing mechanism rotates to the
indicator right.

Rotary jog function switch:

Left linkage table Pressing this switch will activate the jog function of
21
jog button (green) the rotation; until the handle returns to the zero
position, the jog function is released.

Driving box
The drive box is installed in the driver's cabin. It is the core part of the control system.
Components such as the controller and the intermediate relay of the safety device are installed
in the driving box.
1) The main switch devices and their functions in the cabin are shown in the table below:
Table 5-4 Driving box switch devices
Device Device
No. Remark
code function
24V power
1 QF3 protection This circuit breaker will make the tower crane inoperable
switch
It is used for short circuit protection of various lamps, fans
Cab power
and air conditioners in the driver's cab. When the lighting
leakage
2 QFE circuit breaker is closed (pull the small handle of the circuit
protection
breaker up), the lighting circuit is powered (single-phase
switch
220V)
2 working mode options: electromechanical mode,
mechanical mode.
Mode selector When the electronic safety device is not calibrated or fails,
3 SPM
switch the mechanical mode can be turned on. At this time, only
the mechanical safety device works, and the speed of
hoisting, turning and trolley is limited to 4th gear.

290
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

If the switch in the above table is an air switch, the switch handle is turned up to
be in the "on" state; if the switch in the above table is an electromagnetic
protection circuit breaker, the switch handle is rotated clockwise until the handle
is in the vertical state to be in the "on" state.

2) The device code and function description of the door panel of the driving cabin are shown
in the following table:
Table 5-5 Cabin door components

No. Device Diagram Device code Device function Notice

The normal value of the line

Power supply
1 PV voltage of the power supply
voltage indication
should be: 380V±10%

When the overvoltage and

undervoltage indicators are
Power over and
on, do not start the tower
2 HU under voltage
crane, otherwise the related
indicator
electrical equipment may be
damaged.

Climbing
3 SPP
operation switch

291
OPERATION AND CONTROL WA7025-12E-138EN-B03

Main control cabin

The main control cabin is installed on the rotary platform and is the main component of the
control system. The main power switch, hoisting controller, rotary controller, trolley controller,
heater, cooling fan and other components are installed in the main control cabin.

◼ The main switch devices and their functions in the cabin are shown in the table below:
Table 5-6 Main switch components of the main control cabin

No. Device code Device function Remark

1 QFHB Lifting brake power switch

Lifting motor cooling fan power

2 QFHC
switch
Climbing mechanism main
3 QFP
power switch
Main control cabin heating and For some models, this switch is in
4 QFFE cooling power supply circuit the driving box. Subject to the actual
leakage protection switch device arrangement.

5 QF1 Voltmeter protection switch

Transformer and Power

6 QF4
Monitor Power Switch
Controller, control circuit power
7 QF6
switch

8 QF8 Slewing brake power switch

292
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

◼ The device code and function description of the main control cabin door panel are shown in
the following table:
Table 5-7 Main control cabin door components
Device Device
No. Device Diagram Notice
code function

Rotate the handle clockwise, when

Tower crane the handle mark points to ON, the
control main power switch is closed; rotate
1 QF
system main counterclockwise, when the handle
power switch mark points to OFF, the main
power switch is cut off.

It is used to cut off the power and

control power of the tower crane in
an emergency.
Do not use the emergency stop
button to stop in non-emergency
situations. Otherwise, it will have a
great impact on the tower body
Emergency
2 SEM2 structure, and even cause more
stop button
serious safety accidents.
The button is self-locking. After
pressing, it needs to be rotated to
release. Before starting the tower
crane, please confirm that the
emergency stop button is in the
released state.

◼ Main control cabin door is only allowed to be opened when the QF

handle points to OFF. Similarly, the main control cabin door is only
allowed to be closed when the QF handle points to OFF. Don’t
violently open and close the main control cabin door to avoid
damage related parts.
◼ In an emergency, the emergency stop switch must be pressed
immediately;
◼ When the hoisting mechanism of the tower crane entering the
hovering state due to the anti-slip hook function is activated, do not
press the emergency stop button;
◼ When the driver gets off work or leaves the cab for some reason, or
when the tower crane is overhauled, the emergency stop button
must be pressed when all the tower crane mechanisms are in a
stopped state.

293
OPERATION AND CONTROL WA7025-12E-138EN-B03

◼ Heating, dehumidification and heat dissipation in the main control cabin

➢ Heater: After the power is turned on, the temperature and humidity conditions are
automatically detected, and the heater is started when the temperature is ≤ 0 ℃ or the
humidity is ≥ 80% .
➢ Cooling fan: After the power is turned on, the temperature will be automatically detected.
When the temperature is ≥ 40 ℃, the fan in the cabin will exhaust air to the outside.

◼ If the working conditions of the heater or cooling fan are reached, and the
cooling fan and heater do not work, please check whether the components
are damaged.
◼ Working power of the heater and the cooling fan is U1, N; that is, after the
power supply of the knife switch box is turned on, as long as the working
conditions of the heater and the cooling fan are reached, it will start to work.

294
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Resistance box
The resistance box is the energy release element of the tower crane control system. Its main
function is to release the residual electric energy generated by the lifting and downward
movement and the braking process of each mechanism. Please operate in strict accordance with
the precautions. Improper operation may cause the resistance box to be burned, resulting in
tower crane failure.

Fig. 5-8 Resistance box

◼ Before running the tower crane, please confirm that its wiring is
correct and reliable, otherwise it may cause equipment damage;
◼ When laying cables around the mounting bracket of the resistance
box, make sure that the distance between the cables and the outer
casing of the resistance box is at least 15cm;
◼ The resistance box is a heating component, please ensure that it is
well ventilated and must not be blocked or covered;
◼ Do not stack debris near the resistance box, otherwise it will cause
a fire hazard.
◼ The surface of the resistance box is hot, do not touch it, otherwise
there is a danger of burns.

295
OPERATION AND CONTROL WA7025-12E-138EN-B03

Seat adjustment
Main components of the linkage table seat are shown in the following figure:

(1) Left linkage station (2) Right armrest

(3) Left armrest (4) Headrest
(5) Backrest (6) Backrest adjustment handle
(7) Right linkage body (8) Base
(9) Right lift unlock handle (10) Left lift unlock handle
(11) Slide rail (12) Slide rail unlock handle

Fig. 5-9 Seat assembly

296
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Left and right armrest adjustment

◼ Adjustment range: 110°

Pull the armrest up to adjust, there are three position in total, there is a clear prompt sound, the
highest gear is pulled up and then pressed down to return to the original position.

Seat slide adjustment:

◼ Adjustment range: front and rear 0 ~ 120mm.

Pull the unlocking lever up, move the seat forward (backward) to the desired position, release
the handle, and hear a "click" sound, the slide rail can be locked.

297
OPERATION AND CONTROL WA7025-12E-138EN-B03

Seat up and down adjustment

◼ Adjustment range: There are four positions for up and down adjustment.
Press the left adjustment handle (2) to control the up and down adjustment of the entire front of
the seat, and the right (1) to control the rear up and down adjustment, release the handle to
complete the adjustment.

Backrest angle adjustment:

◼ Adjustment range: 86°~140° .

Pull the adjustment handle up, adjust the backrest to the desired position, and release the handle.

headrest adjustment

◼ Adjustment range: 0~80mm, a total of four positions.

Just lift it up and adjust it to a suitable position, adjust it down and press and hold the unlock
button (1) and adjust it to a suitable position.

298
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

5.6 Parameter adjustment of electrical components and

instruments
Voltage monitoring relay in the main control cabin is shown in Fig. 5-10.

Fig. 5-10 Main control cabin voltage monitoring relay setting value

Fig. 5-11 Device Settings Checklist

Device code Describe Set value

Cooling fan temperature setting value +40℃

ST
Heater working temperature setting value 0℃

SRH Heating humidity RH setting value +80%

Overvoltage protection value (>U): 420V

340V
Undervoltage protection value (<U):
KAU1 2S
Delay time (Time):
Reset delay + no phase
Working mode (Function):
sequence monitoring

299
OPERATION AND CONTROL WA7025-12E-138EN-B03

5.7 Slewing brake use and weathervane release method

Overview of slewing brakes
The brake of the inverter motor with weathervane is normally closed, that is, the brake is powered
off and released when it is powered on.
The slewing moment motor of tower crane is composed of main motor, brake (with weathervane).
The electromagnetic brake is a power-off brake, and its structure (see Fig. 5-12).
Release when power on:
When the electromagnetic brake excitation coil (1) is supplied with the specified direct current,
electromagnetic suction force is generated, the brake armature (3) is attracted, the friction disc
(4) is driven, and the brake spring (2) is compressed, so that the brake disc (5) is in a released
state, and the shaft can rotate freely.
Brake when power off:
When the power is off, the electromagnetic suction force disappears, and the brake spring
pushes the friction disc, so that the brake disc is in the braking state, and the shaft cannot rotate
freely.

Fig. 5-12 The slewing brake

300
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Slewing electromagnetic brake logic description

1) When the tower is slewing, the brake will be opened immediately upon electrification;
2) Operating handle is reset to zero, after a delay of 15 seconds, the rotary brake will
automatically power off and brake;
3) 15-second delay after the operation handle is reset to zero, if you encounter strong winds
or need to brake manually, you can press and hold the "wind flag release button" on the far
right on the left linkage platform for 0.5 seconds, or you can immediately use the Slewing
brake;
4) During the slewing operation, if you encounter an emergency and need to brake immediately,
you can also press and hold the "wind flag release button" on the far right on the left linkage
platform for 0.5 seconds to make the slewing brake power off and brake.
5) Whenever the brake goes from open to closed, that is, from power on to power off, a buzzer
"beep" will be heard.

When you press and hold the weathervane release button, the slewing
output will be disconnected. At this time, be sure to return the slewing
handle to the zero position as soon as possible, re-operate the slewing
gear, and the slewing brake will be automatically released.

Rotary weathervane release instructions

"Weathervane release button" (with light) is a button that can be used to realize both emergency
braking of the slewing brake and electric release of the slewing brake.
The tower crane operator needs to set the tower crane in a free rotation state after get off work
to prevent the danger of the tower falling due to strong winds.
Description: The electric weathervane is used in conjunction with the power-off brake to achieve
the electric release and manual release of the electromagnetic brake. After it’s released, even
when the tower crane is power off, the brake is open, and the tower crane can rotate freely with
the wind.
1) Rotary weathervane electric release instructions
The structure of the electric wind flag (see Fig. 5-12), when the electromagnetic brake excitation
coil is first connected to the specified DC power, and then the wind flag electromagnet excitation
coil is connected to the DC power, the wind flag armature is attracted, and then the direct current
of electromagnetic brake excitation coil is disconnected, at this time, the armature of the
weathervane supports the weathervane release lever, so that the electromagnetic brake friction
disc connected to the weathervane release lever through the release screw cannot move in the
direction of the brake disc, so that the brake disc is in a released state, and finally it should be
immediately disconnect the DC power of the weathervane electromagnet excitation coil to
achieve the function of electric release of the electromagnetic brake. (Note: The excitation coil of
the electromagnet of weathervane cannot be energized for a long time, otherwise the excitation
coil of the electric weathervane electromagnet will be burned.) The wiring instruction diagram of
the electric weathervane is shown in Fig. 5-13.

301
OPERATION AND CONTROL WA7025-12E-138EN-B03

B1, B2: Weathervane micro-move switch (keep 1, 3: Direction of weathervane release

open) lever

B3, B4: Connect to coil of the electromagnet 2, 4: Direction of weathervane push handle

Fig. 5-13 The wiring instruction diagram of the electric weathervane

Condition: The slewing gear handle is reset to zero and the slewing brake is power off.
Operation: Press and hold the "Weathervane release button" and "bypass button" at the same
time, hold for more than 1 second, the rotating vane will automatically release.
Logic: Press and hold the "weathervane release button" and "bypass button" for 1 second, the
slewing electromagnetic brake is powered on, the weathervane electromagnetic coil is powered
on after 1 second, and the slewing electromagnetic brake is powered off after 1 second, the rear
weathervane solenoid is powered off after 1 second.
Success sign: After successful release, the brake on the slewing motor with brake will be heard
twice “Dong”, and then the light of the "weathervane release" button on the left linkage platform
will turn on, indicating that the electric release is successful.
◼ Electric release can only be operated 30 seconds after the slewing
motor stops (or the handle returns to zero), otherwise it will cause
the motor brake to work abnormally, which will affect the safety of
the tower crane in serious cases;
◼ If it cannot be released successfully, please check the "Failure
Analysis" below.
2) Instructions for manual release of rotary vane
First move the release lever to the rear of the motor, then push the weathervane push handle
inward to make the weather indicator electromagnet armature support the weathervane release
lever, then release the weathervane release lever, and finally release the electric weathervane
push handle to achieve Manual release function. The functions of electric release and manual
release of the weathervane are used to keep the motor in a released state when the tower crane
is not working for a long time, so that the tower jib can rotate freely with the wind and adjust to
the downwind direction, so that the windward area of the tower jib is minimized and windward
resistance is minimized.
Manual release is a very reliable release method. If the electric release is unsuccessful, or the
electric release is not assured, manual release can be used.

302
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

5.8 Cable drum adjustment method

The cable anchorage point is in the middle of the track

The cable anchorage point is on the left side of the track

303
OPERATION AND CONTROL WA7025-12E-138EN-B03

The cable anchorage point is on the right side of the track

Note:
—— Location of cable anchorage points
L—— Limit switch position

SCW has two pairs of contacts, one is normally open and the other is normally closed
SCW action means that the normally open contact is closed and the normally closed contact is
open
SCW no action means that the normally open contact is disconnected and the normally closed
contact is closed

5.9 Operation after working

◼ Normal operation after working
Notes for non-working state:
When the tower crane is finished construction and stops being used, the hook should be raised
to a safe position to ensure that when the jib rotates freely 360°, the hook will not hang or touch
any objects on the site), keep the hook in an empty state, and the weathervane brake must be
released.
Set each operating handle to the zero position, cut off the main circuit breaker of cabin, close the
doors and windows of the cabin, and disconnect the main switch of the power box at the bottom
of the tower crane after the driver goes down to the ground.
Anti-strong typhoon safety measures and plans
◼ Please refer to our company's tower crane anti-typhoon supplementary manual.
Remove the hoisting weight, lift the hook to the highest point, and drive the trolley to the minimum
radius of the jib foot!
The weathervane brake must be released in the non-working state to ensure that the tower crane
jib rotates freely with the wind! Make sure that there are no obstacles in the slewing range of the
boom, and there are no excess objects on the hook to avoid accidents such as breaking the jib
or falling tower when the strong wind comes!
◼ For the travelling tower crane, use the rail clamp to fix the tower crane on the track to prevent
it from moving along the track!

304
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

5.10 Operation cautions

Checks to be carried out before operation

The execution of the crane erection and the safety require a certain number of operations or
checks to be carried out according to the following description:

Synopsis

Before starting work, every founded anomaly must be transmitted to the

site foreman.

305
OPERATION AND CONTROL WA7025-12E-138EN-B03

On the ground
◼ Check the presence and the position of the stops.
◼ Check that the track is freed and horizontal.
◼ Check the correct grounding at the 4 track ends
◼ Check the passage and the fixing of the supply cable.
◼ Take the key and the instructions from the site foreman.
◼ Turn the switch of the site control panel to ON
◼ Check that the wind speed does not exceed 20m/s
◼ Unlock the rail clamps
◼ Check the position and the fixing of the ballast.

On the crane tower

◼ Use the permissible accesses
◼ Check the presence and the state of the connections
◼ Check that no article hinders the access platforms

On the slewing crane part

◼ Check the position and the fixing of the ballast.
◼ From the permissible accesses, check the correct winding, the state, and the tensioning of
the ropes.
◼ Clean and grease the fleeting pulley (according to the model)

On the control unit

◼ Check the presence of the powder-type fire extinguisher
◼ Press successively upon the ON button (the horn is activated), then on the emergency stop
button (movement stop)
◼ Reset the stop button
◼ Press upon the ON button and check the functioning of all the movements by means of the
control switches
◼ Check the dead man position of the control switches
◼ Check the functioning of the displays.
◼ Check the control of the slewing brake
◼ By the means of the test button, test the functioning of the sound signal and the signal lamps
(flashing lamps) located outside the cab and on the display block (configuration according
to model and option)
◼ Check the functioning of the lighting and the windscreen wipers
◼ Check without load the functioning of the limit switches
◼ Check the state of the hook safety catch

306
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

All the operations for putting into service of the crane serve to ensure its working under correct
driving and safety conditions.
Overall, all these operations can be split up into several groups:
➢ Checking and carrying out of mounting operations in order to avoid any hindrance as regards
the good working order of the crane or safety.
➢ Carrying out the adjustments of the various safety devices and the working conditions of the
crane.

For carrying out any adjustment or maintenance operation and in order to reach the control unit,
use the devices provided on the crane.

307
OPERATION AND CONTROL WA7025-12E-138EN-B03

Checks to be carried out after erection

The execution of the crane erection and the safety require a certain number of operations or
checks to be carried out according to the following description:

Lower part
Concerned crane parts Operations to be carried out
➢ Check the fitting of the ladders and back loops, replace
Access
damaged parts.

➢ Check the fitting and locking of the mast connecting pins

Crane tower
➢ Check that the indicating plates are present and legible.

Slewing crane part

Concerned crane parts Operations to be carried out
➢ Check the correct installation of the electric supply cable
Jib and counter jib
➢ Check the correct reeving of the hoist and travelling ropes

Operating safety instructions

Requirement to the operators
◼ The crane operator is over 18 years of age.
◼ The crane operator is reliable, and is physically and mentally adept.
◼ The crane operator has been instructed in operation of the crane and is familiar with all risks
of accident.
◼ The crane operator has provided proof of qualification to the employer regarding operation
of the crane.
◼ The employer has designated the crane operator for operation of the crane is writing.
◼ The crane operator must have read and fully understand the instruction manual, in
particularly the chapters concerning notes on safety, as well as operation and control.
◼ The crane operator must have read and fully understood the local guidelines valid for
accident-prevention.
◼ The crane operator is familiar with the location and operation of fire extinguishers and has
been instructed in the onsite possibilities for fire detection and firefighting.

308
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Protective equipment
The following must be worn:

◼ Safety helmet
◼ Safety boots
◼ Safety harness (e.g. for trolley travelling in the event of power failure)

Forbidden of operation

It is strictly forbidden to lift a load the weight of which exceeds the crane
capacity. Consult the technical data for handling of loads when their
surface/lifted load ratio exceeds 𝟏𝐦𝟐 /𝐭.

◼ It is forbidden to lift an incorrectly slung load.

◼ It is forbidden to generate load swinging, to lift a load adhering to the ground and to lift a
load in oblique direction.

309
OPERATION AND CONTROL WA7025-12E-138EN-B03

◼ It is forbidden to slew a load over the staff and roads.

◼ It is forbidden to handle a load in a space lower than 2 m from the ground.

◼ It is forbidden to erect a crane without observing the prescribed distances.

310
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

◼ It is forbidden to handle a load which is not visible without somebody’s help.

◼ It is forbidden to lift a load by means of several cranes.

◼ It is forbidden to lift persons.

311
OPERATION AND CONTROL WA7025-12E-138EN-B03

◼ It is forbidden to use the crane as a pulling device for a load even a rolling one.

◼ It is forbidden to fill a grab (or other container) if this one is hooked to the crane, and to stack
big objects which could be unstable and fall to the ground.

312
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

◼ It is forbidden to lay down the pulley block and to let it on the ground, with slackened ropes.

◼ It is forbidden load hooked when crane in rest period.

◼ It is forbidden to work in dimness areas.

313
OPERATION AND CONTROL WA7025-12E-138EN-B03

◼ During the normal crane operation, do not stop the movements with the stop button.

◼ It is forbidden to work until the limit switches, so stop a little bit before.

It is forbidden to modify or to neutralize the moment cutouts, the load

limiters, the limit switches, and the interference control system.

Combined operation
By operating the handles of the linkage platform, you can conduct the combine operations of
lifting, slewing and trolleying. Pay attention to the following points during the operations:
◼ During the combined working of the mechanisms, if the system trips, it may because the
power supply have no sufficient capacity or fluctuates sharply.
◼ When there is any mechanism runs too fast and it causes the load shaking, it is not
recommended to conduct the combine operations.

Starting up and brake movement

◼ Starting up
Open the electric switch and turn on the start bottom which on the control unit to starting up the
crane.

◼ Emergency stop
Only when emergency happens, use the “EMERGENCY STOP” Button to stop all movement of
the crane.

◼ Slewing brake
Brake switch is on the control unit, use it to stop the crane slewing or release it.

314
 WA7025-12E-138EN-B03 OPERATION AND CONTROL

Stopping crane

It is strictly forbidden to hinder the slewing of the jib, as for example, by

hooking the pulley block on a fixed point. The crane must compulsorily
be in WEATHERVANE position.

◼ Position the jib in wind direction, lower the load to the ground, raise the hook without load
and move the trolley to the jib foot.

315
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

6 MAINTENANCE AND INSPECTION

This chapter has been compiled for maintenance personnel who have been designated by the
contracting company to keep the crane in nominal operating condition. The maintenance
personnel will obtain an overview of all essential maintenance and inspection tasks stipulated in
the maintenance and inspection chart.
Especially:
◼ check the good working order of the crane components.
◼ carry out the periodically checking.
◼ carry out the adjustments.
◼ identify and repair the malfunctioning or failures.
◼ carry out the greasing.

All maintenance and inspection deadlines can be planned meticulously using the interval
specifications.
This part does not comprise instructions in order to carry out:
◼ repairs requiring a specific tool or which must be carried out in the workshop.
◼ important operations like overhauling, repairing.

6.1 Lubrication
The lubrication table recommends the type of lubricant to be used and the different lubrication
points. Lubricate thoroughly and regularly, since lubrication carried out according to our
instructions helps to prevent failures and premature wear.

◼ Any repair and maintenance work must only be carried out after the
crane has been out of service;
◼ Clean grease nipples and oil drain plugs before lubricating work;
◼ Only the correct use of suitable high-quality lubricants as
recommended by a specialist supplier will ensure maximum
performance and avoid faults and their consequences;
◼ Only use high quality brand-name lubricants.

316
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Lubricants table
Table 6-1 Requirements of lubricants for ZOOMLION tower crane are shown as follows
Parts Lubricating
No. Specification of lubricants Oil
Description location
Graphite Calcium-based
Hoisting rope Cleans Spray
1 Wire rope grease
Trolley rope grease
ZG-SSY1405-65
Gearbox of
Industrial closed gear oil
hoisting
L-CKD 150
mechanism

Gearbox of
Fully synthetic gear lubrication
trolley
oil 4408 (IOS viscosity 320) According to the
mechanism
2 Gearbox label on the
gear box
1, Environmental temperature
-20℃~40℃, 000# general
Gearbox of
lithium-based grease;
slewing
2, Environmental temperature
mechanism
-50℃~-20℃, 7023B# low
temperature grease.
Drum bearing /
Rolling
3 Slewing ring Calcium-based grease
bearing /
bearing
1, Raceway,2# extreme
Raceway, pressure lithium base grease
4 Slewing ring /
Tooth surface 2, Tooth surface, Graphite
Calcium-based grease ZG-S
Winter with Calcium-based
grease ZG-2;
5 Pulley All pulley /
Summer with Calcium-based
grease ZG-5.
Anti-twist molybdic disulfide Calcium-
6 Bearing /
device based grease ZG-1
1,Environmental temperature
exceed-10℃, 2# Sodium-
7 Rope roller Pulley shaft based grease; /
2,Environmental temperature
under-10℃, grease thin oil
Hydraulic Hydraulic oil for anti-wear
8 Oil tank /
pump station L-HM 46
9 Hook Bearing Grease oil /
Electro-
10 Brake DB-25 /
hydraulic thrust

317
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Lubrication for bearing

The function of lubrication
There should be sufficient lubrication during the working hours of the bearings to achieve
effective and reliable movement. The function of bearing lubrication is as follow:
◼ Avoid or lessen direct metal contact among rolling element, raceway, and cage of a bearing
to reduce wear.
◼ Oil membrane formed on the friction surface can enlarge the bearing area of the parts and
lessen the contact stress to achieve the benefits of prolonging rolling contact fatigue life.
◼ Lubricant has a certain effect of antirust and anticorrosion.
◼ Grease can improve sealing performance and prevent the invasion of outer pollution.
◼ Lubrication has a certain effect of damping and noise-reducing.

Grease
The general used grease in the bearings of tower cranes is Calcium-based grease.1. Filling
amount of grease.
The filling amount of grease varies with the structure of bearing, space, operation speed and the
different kinds of grease. The filling amount of grease is consisting of two parts, one filled in the
inside of bearings, the other filled in the bearing seats.
The filling amount of grease could be decided by the ratio of allowed limiting rotational speed to
practical working speed. The factor shows in Table 6-2:
Table 6-2 The factor shows in table
Speed radio(limit/n=A) Filling amount
Grease accounts for 1/3 of the free space of the interior
A≤1.25
of the bearing
Grease accounts for 1/3 to 2/3 of the free space of the
1.25＜A≤5
interior of the bearing
Grease accounts for above 2/3 of the free space of the
A＞5
interior of the bearing

6.2 Safety notes

Requirement on personnel
The maintenance personnel must be designated by the operating company. Maintenance of the
crane requires specialist knowledge of crane technology. The operating company is responsible
for all damage caused as a direct result of improper maintenance.

318
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Safety measures
◼ Switch off the crane and secure against incorrect or unauthorized restart.
◼ If there is any danger of falling objects: Cordon off the danger area or secure the area with
warning signs.

Protective equipment for personnel

The following must be worn:
◼ Safety helmet
◼ Protective gloves
◼ Safety boots
◼ Safety harness when working above head height
◼ High-visibility clothing

6.3 Required maintenance and inspections

Fig. 6-1 Parts required for maintenance

1. Hoisting mechanism 2. Slewing mechanism
3. Slewing ring 4. Climbing equipment
5. Trolley mechanism 6. Hook

319
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

The designated personnel must carry out the maintenance and inspection tasks according to
task guidelines as follows:

Maintenance/inspection
Task to be performed
intervals
Slewing ring③: Grease the ball track and gear teeth
Check the wire ropes and rope end fittings
Check the hook⑥
Telescoping equipment④: Grease the Pins and guide section
rollers

Check when starting up Check the twist compensator during every erection
the crane and before every Grease all Pins during every erection
erection.
Check each framework part and connective part
Check each electric control implement and security implement
Check the quality and quantity of the oil in the reducer of
hoisting mechanism
Check the quality and quantity of the oil in the climbing
mechanism
Slewing mechanism ② brake
Trolley mechanism ⑤ brake
Daily check Hoisting mechanism ① brake
Travelling mechanism brake
Rope release implement
Slewing ring③—Grease the gear teeth, see Fig. 6-1
Check the electric control implement, cable and electric wire
Weekly maintenance
Check the security implement (load moment limiter, load limiter,
trolling limiter, slewing limiter, hoisting limiter)
Grease the wire ropes
Grease the rope pulleys
Grease the winch drum bearing
Fill with hydraulic oil in the climbing pump station
Inspect the high-tensile bolt connections 1 month after erection
Monthly maintenance
Travel gear: Grease the wheel bearings and the inside face of
the flanges
Hoisting gear①: Fill the gearbox with Oil
Check the stability of the vital framework, important weld and
connection parts (bolts and pins)

320
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Maintenance/inspection
Task to be performed
intervals
Grease all lubricating nipples
Check the twist compensator
Half-yearly maintenance
Motor bearing: change oil after 1500 operation hours, once a
year at least
Inspect the high-tensile bolt connections and grease the bolt
Check the hook⑥
Yearly maintenance
Check freedom of the movement of the hinged joint of front
window of the cabin and lubricate it regularly
Oil change in the reduction of slewing mechanism②
Oil change in the reduction of hoist mechanism①
Oil change in the reduction of trolley mechanism⑤
After 2000 operation
Oil change in the brake of hoisting mechanism ①
hours
Oil change in the trolley travel gearbox
Oil change in climbing mechanism ④ after 2400 operation
hours

Table 6-3 Common bolt pre-tightening force (friction coefficient μ=0.14)

Bolt performance grade 8.8 10.9
Actual use of pre-tightening Actual use of pre-tightening
Thread specifications
force N·m force N·m
M8 22.5 31.5

M10 44 62

M12 77.5 110

M14 120 170

M16 190 265

M18 260 365

M20 370 520

M22 500 700

M24 640 900

M27 950 1350

M30 1300 1800

321
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

6.4 Hoisting mechanism

Overview
The structure of the hoisting mechanism is shown in the figure below which layout as “一” type.
The three-phase asynchronous frequency motor with axial flow fan. The electromagnetic failure
brake installed at the empennage of the motor. Planetary reducer which motor output torque to
reducer through coupling. The reducer output end flange connected to drum by bolt. There are
five gears in the process of hoisting or falling. The first and second gears are transition gears
which can be used for slowly locating operation.

Fig. 6-2 Hoisting mechanism

(1) Motor (2) Coupling
(3) Reducer (4) Drum
(5) Frame

322
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Adjustment and maintenance of the brake

Model and relevant parameter for hoisting mechanism brake shows in Table 6-4.

Table 6-4 Relevant parameter of brake

Rated automatic Rated air Adjustment Min allowable friction
Brake
torque gap of gap sheet thickness
MB SL SLmax amin
SPZ600A (600) N.m mm mm mm
600 ≥0.5 1.2 15.8

Make sure drum not rotation unexpected leads to accidents before any
debugging for brake.

Brake wear
Brake friction plates and machinery can cause functional wear. In order to be able to operate
safely and without obstruction, it is necessary to periodically inspect, debug and replace the brake
if necessary.
The different wear causes are described in Table 6-5 below. Important influencing when
calculating the service life of the brake and determining the maintenance cycle that must be
observed.
Table 6-5 Brake wear reason statistics
Part Reason Function Factors
Operation stops
Emergency stop Friction plate
Friction plate Actual wear
Motor repeated wear in the start and wear
stop
Moving iron Moving iron core
Actual
core and Brake plate friction and static iron
friction
static iron brake
Number of
Brake disc Relative movement and collision
Meshing wear start / stop
panting between splines
cycles
Transformation
Load transformation and collision Number of
Moving iron for moving iron
between moving iron core, guide bolts start / stop
core support core, guide bolts
and screws cycles
and screws
Spring shear stress generated by axial Decline of elastic
Number of
Spring load circulation and radial reversal storage force
switch brake
clearance through the armature fatigue fracture

323
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Maintenance period of brake

To ensure safety and no fault running, please check and maintenance the brake regularly.
For the brake essential maintenance period first according to the load of brake in service. All
wear cause must be considering when calculate the maintenance period. Check brake in time
when the braking action delayed, slippery hook or alarm. SPZ type brake maintenance period
according service situation, otherwise, the maintenance period is 3 months

Readjust gap
Material loss causes the thickness of friction plate to decrease and the gap to increase. Once the
gap reaches the maximum allowable value (1.2mm), it must be adjusted. When adjusting the
gap, insert a 0.5mm feeler gauge between the static iron core and the moving plate, turn the
mounting bolt clockwise to make the feeler gauge just clamped, and then tighten the adjustment
screw clockwise to the right to make the 0.5mm feeler gauge can be pulled out, and the 0.55mm
feeler gauge can be used to check the gap. If the 0.55mm feeler gauge cannot be inserted, the
gap has been adjusted in place. Adjust all the gaps in turn to make the gap uniform.

(1) Bolt (2) Static iron core

(3) Service gap 0.5mm (4) Dynamic iron core
(5) Screw (6) Mate plate
Fig. 6-3 Adjust the service gap

The degree of wear on brakes varies from use to use. Material loss causes the thickness of
friction plate to decrease and the gap to increase. Once the thickness value of friction plate less
than 15.8mm, it must be replaced, shows in Fig. 6-4.

324
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

(1) Friction plate (2) Static iron core

(3) Dynamic iron core (4) Bolt
(5) Friction plate
Fig. 6-4 Replace friction plate

Replace friction plate

1) Unscrew the mounting bolts and remove the brake (as shown in Fig. 6-5)
2) Loosen the brake connection cable

Fig. 6-5 Dismantle the brake

3) Pull the friction plate assembly completely out of the spline sleeve.
4) Check the spline engagement. Replace if necessary (as shown in Fig. 6-6),

325
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

(1) Splines meshing (2) Splines meshing

Fig. 6-6 Check the splines meshing
5) Check the friction plate mating surface. Replace the friction plate or the mating surface when
the scratches are serious. Rework the friction surface when the friction of the bearing cap 1
is severe (as shown Fig. 6-7)
6) Install a new friction plate. Adjust the brake air gap, please refer to the brake adjustment
section.
7) Connect the cable.
8) Install the encoder

Fig. 6-7 Check the Friction plate mating surface

Debug synchronization
The SPZ brake consist of dynamic iron core 1 and dynamic iron core 2. Adjusting synchronicity
is aimed at the need to configure dynamic iron core have the same pull-in and release
synchronization (as shown in Fig. 6-8). This step is specific for the double-plate brakes, the
single-plate do not need to debug.

326
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Dynamic iron core 1 Dynamic iron core 2

Fig. 6-8 Dynamic iron core
If the operation is not synchronized, first unscrew the brake release, and appropriately adjust the
depth of the 4 set screws on the brake surface to achieve synchronization. Listen whether pull-
in and release are consistent, and the confirm the dynamic plate synchrony.

Fig. 6-9 Lock screw

Install the brake
◼ General description
1) The installation of the brake must be completed by trained and qualified technicians, and
care must be taken when working
2) During the installation planning stage, there should be enough working space around the
equipment for equipment installation and future maintenance and repairs
3) Before the start of assembly and installation, sufficient hoisting equipment should be
prepared in advance
4) The installation and connection process of the equipment should prevent the brake from
being clamped

327
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

◼ Installation basis
1) The installation surface must be horizontal or vertical and flat
2) The rigidity of the mounting surface is sufficient to bear the force acting on it
3) The installation direction of the brake should be completed carefully to avoid the wrong
installation direction to affect the actual operation

◼ Installation instructions
1) First, confirm whether the motor installation surface is flat and free of oil;
2) Then determine whether the brake is installed in the correct direction, and the position of
the release lever of the brake release is directly on the right side (as shown in
3) When installing the spline sleeve, make sure that the shaft retaining ring can clamp the
spline sleeve, and there is no looseness in the axial direction;
4) Ensure that the friction component and the spline sleeve can achieve axial relative sliding,
avoiding the friction plate from being stuck in the axial direction due to too tight fit;
5) Install the SPZ400(350) and SPZ400(400) brake on the motor by six M10 bolts through
30N·m moment. Install the SPZ600A (500) and SPZ600A (600) brake on the motor by eight
M12 bolts through 60N·m moment. The layout of single-plate brake bolts is slightly different
from that shown, installing according actual object.

(a) (b)

Fig. 6-10 Install condition for brake

Debug micro switch
The micro switch includes: action signal switch, wear monitoring micro switch, as shown in Fig.
6-11. Micro switch has been adjusted before leaving the factory. Only when switch go wrong do
you need to adjust.

1) Adjust the action signal switch

When adjusting the action signal, the brake is energized to pull on S L=0, and the jack screw is
turned to the micro switch signal trigger critical point d to the action signal trigger. 0t this time, the
jack screw is gently turned to travel 90° to overpressure 0.2mm, Finally, apply thread glue on the
nut and tighten the nut to ensure that the signal feedback is not lost.

328
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

2) Adjust the micro switch for wear monitoring

When adjusting the wear monitoring signal, the brake is energized to pull in S L=0, and the jack
screw is turned to the micro switch signal trigger critical point d to the activation signal trigger. At
this time, the jack screw is slightly turned and screwed into 3/4 turns to 0.6mm overpressure,
finally apply thread glue on the nut and tighten the nut to ensure that the signal feedback is not
lost.

Fig. 6-11a Action signal switch Fig. 6-11b Wear monitoring micro switch

(1) Action signal switch (2) Switch lever

(3) Screw (4) Nut
(5) Wear monitoring micro switch (6) Screw
(7) Nut
Fig. 6-11 Adjust action signal switch and micro switch for wear monitoring

Maintenance of the motor

Storing the motor
The motor should be stored in the dry and ventilated place and be covered by rain cloth. Keep
the motor clean, avoid any water, oil, dust, or corrosive gas get into the motor, and clean the dust
inside or outside the motor regularly.
For the motor stored over one year, clean the impurity inside and dry, apply a coat of clean anti-
rust oil to the bearing, all the fasteners (except the earthing bolts) and fitting surfaces.
The cover plate, junction box cover and unused outlet should be covered well, for avoiding things
as water, dust, oil, or emulsion get into the motor, and caution the mouse destroying the coil.

329
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Maintenance before use the motor again

1) Observe the motor and transmission after starting, if any abnormal situation occurs, stop the
motor immediately, find out the cause and solve it, then the motor can restart;
2) The increase heat of the working motor is prohibited to exceed the permission value. Using
the temperature gauge to measure the heat increase of the iron core or shell, generally the
increase can’t exceed 60°C, the increase of bearing can’t exceed 95°C, always monitor the
heat increase of the parts in the working;
3) Notice the smell, vibration, and noise of the motor. The winding will scorch with smell
because overheat. Some problems, especially the mechanism problem, will show as
vibration or noise, so the motor should be stopped immediately when the abnormal smell,
vibration, and noise occur;
4) Check if the bearing is overheating or oil-leaking constantly, and pay attention to supplement
or replace grease regularly. The grease is generally made of No,2 lithium grease. Use the
same grease as possible, the grease in the bearing room should not exceed 70%;
5) Keep the motor clean, no water, oil and impurities can fall into the motor. The air inlet and
outlet must always be unobstructed;
6) If the motor leaves unused for a long time, mind to deal with the exposed parts of the motor
by dustproof and waterproof treatment. When use again, take a mechanism check before
installing, check if the assembly is complete, if the fasteners are loose. The dust or impurities
inside should be cleaned if there are, use dry compressed air to clean if necessary. Must
use 500V megohmmeter to measure the insulation resistance between the stator winding
and the shell. If it’s lower than 0.5 MΩ, the motor must be dried, charging in low-voltage
electric is a suggested way. The temperature of the winding is not allowed to exceed 125°C.
To avoid the motor rusting, when assembling after the excreting and checking, all the
fasteners (except the earthing bolts) and fitting surfaces should be applied with a coat of
clean anti-rust oil. All the fasteners should be attached with spring washer to avoid loose.
After the assembling, rotate the rotor by hands, the rotor should roll flexibly and have no
friction.

Avoid to crash, knock the brake and rotary encoder in the tail of the
motor. Check if the brake and rotary encoder are assembled completely
and installed right, and if the fasteners are loose.

330
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Maintenance of the reducer

Period of the maintenance
Users should maintain the reducer regularly according to the items in the following table:
Table 6-6 The period of the reducer maintenance
Check items Period Remarks
Check the oil temperature Everyday
Check the abnormal noise of the reducer Everyday
Check the height of oil level Per month
Check the oil leaking of the reducer Per month
Clean the vent cover Every three months
After working four-hundred hours,
Check the water contain in oil
once a year at least
Replacing oil after starting the reducer for
After working four-hundred hours
the first time
Every eighteen months or five-
Oil replacing afterwards
thousand working hours
Clean the filter Every three months
Clean the vent cover Every three months

➢ If the mechanism leaves unused for a long time, mind to deal with the
exposed parts of the reducer by dustproof and waterproof treatment.
When use again, take a mechanism check before installing, check if
the assembly is complete, if the fasteners are loose. The dust or
impurities inside should be cleaned if there are, use dry compressed
air to clean if necessary.
➢ Paint thread locker to the reducer connecting bolt to avoid loose; paint
the thread locker again when reinstalling the bolt after taken down.
➢ The bolts connecting of the reducer refer to Table 6-3.
➢ Check the wear of spline regularly, if the wear is over 0.5mm, please
contact our after-sales service for avoiding danger.
➢ Matters need attention following Table 6-7:

Table 6-7 Matters need attention of reducer

The matter Possible reason Solution
Clean surroundings, rotate the sealing
Invalid sealing
Leaking for several circle, check again.
Broken sealing Contact our after-sales service.
Overheat Lack of grease Add specified gear lubricating grease.
Strong vibration or loud noise Problem inside. Contact our after-sales service.
lubricating grease becomes Too much water in
Replace the lubricating grease
milky white the grease

331
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Oil adding of the reducer

The structure arranging types of hoisting and trolley reducers are the same, see the figure below.

Fig. 6-12 The structure arranging type of reducer

(1) Oil inlet (2) Oil inlet
(3) Oil outlet

◼ The oil adding steps are:

1) Replace plug of the part 2 oil inlet to a vent cap, open the part 3 oil outlet and put in a tube,
clear the waste oil inside, install the plug back;
2) Open the plugs of the part 1 and 2, add the gear oil conforms to the Table 6-1 to the reducer;
3) Add oil until the oil almost spill out from the part 1 (refer to the Table 6-8);
4) Install the plug of part 1 and vent cap of part 2 back, ensure the vent cap is water-repellent
to avoid going bad of oil.

332
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

◼ Check the oil level:

After mechanism running two years or change construction site, the motor shall dismantle and
inspect as follow:
(1) Check the spline shaft, side gap about the coupling spline housing, eliminate over-wear or
deformation, and the grease spline housing and spline shaft;
(2) Check wear condition about the elastomer, if there is obvious indentation and deformation,
the elastomer recommend replace.;
(3) Check whether reducer is leaking oil, if the oil plug is leaking oil, apply moment to tighten oil
plug according to Table 6-3. and then adding the required gear grease. If the seal
components damage, please contact our after-sales service.

Table 6-8 Reference of oil adding amount of the reducer

Reducer model Oil model Reference fuel
Synthetic heavy duty industrial closed gear
ZTQ130W40-301 2L (1.8kg)
oil 4408(320#)

Too much oil may cause planetary reducer severe fever, swell and overflows when running. So
please fill the reducer with required model and oil value. Because reference fuel in the reducer
cannot reach oil mirror position, at static status cannot observe lubricating grease face through
oil mirror, only in the operation process whether there is lubricating grease can be observed.

(1) Ensure the gear oil has cool down to the surrounding temperature before
adding or replacing oil, otherwise the operator can be scalded.
(2) The lock plug of hoisting reducer refers Table 6-3.
(3) The rubber slice in the reducer vent cap shall be remove after install
mechanism.

333
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Coupling
➢ Check the mechanism weekly and listen operation situation of motor output shaft end. Such
as coupling and other parts of the abnormal sound issued, stop operating and contact our after-
sales service for replacement.
➢ Check the coupling elastomers and half- coupling regularly. If there is obvious indentation
and deformation, please replace or contact our after-sales service. Check the spline shaft, side
gap about the coupling spline housing, eliminate over-wear or deformation.

Method of rope arrangement problem of hoisting

mechanism
Rope of tower crane hoisting mechanism is multilayer coiling. The drum is Lebus drum which is
fit for multilayer rope coiling. The characteristic is most of the rope race is straight line rope race.
The under-layer rope arrangement has obvious guide effect to the upper rope arrangement. It is
not easy to lead to rope climbing and rope disordering phenomena and is helpful to arranging
multilayer rope coiling orderly. Rope arrangement of hoisting mechanism is shown in Fig. 6-13.

Fold line rope race

Straight line rope race

Rope
stretching
direction

Fig. 6-13 Drum structure

334
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Table 6-9 Rope arrangement problem summary of hoisting mechanism

Rope arrangement problem summary
Problems
Reason analysis Handling Method
description
Check the lubrication condition, if dry lubricating
Bad lubrication of A-
grease is found, wipe it off and paint new lubricating
frame guide pulley
grease. If the environment temperature is too low and
leads to clamped
viscidity of lubricating grease is too high, add thin
pulley cannot guide
grease to the pulley (Check before starting the
well.
machine and paint thin grease if necessary).
Hoisting mechanism Check whether the bracket is installed aslant, if yes,
Bad rope is installed aslant adjust it.
arrangement Center lines of
Adjust mechanism installation seat to let the center
and rope hoisting mechanism
lines of hoisting mechanism drum and counter jib be
jumping of drum and counter jib
aligned.
drum are not aligned
Bracket of hoisting
Check the flatness of the bracket. If it is not flat, adjust
mechanism is not
it.
installed flatly
Upper layer rope is Check if the first layer rope is arranged tightly, if not,
pressed under the arrange it tightly with some load (2% of the minimum
lower layer rope of broken tension of the rope or 10% of rated hoisting
the drum load)

CAUTIONS:
◼ The lubricating condition has some effects to the rope arrangement. Check the lubricating
condition of the rope. If dry lubricating grease is found, wipe it off and paint new lubricating
grease.
◼ If rope disordering occurs, arrange the first layer rope tightly and well with some load (2% of
the minimum broken tension of the rope or 10% of rated hoisting load)
◼ When the tower crane is at the height and below free-standing height, the 6×29 non-rotate
hoisting rope can be used; The height of the tower crane greater than free-standing height,
the 35W×7 rotate rope suggest to be used.
◼ Disorderly rope during the service is related to diameter and pre-tightening force of the rope.
The rope was pre-tensioned when leave factory. The first layer rope must keep-in, lined up
and as much load as possible (2% of minimum breaking load rope or 10% of rated load).
◼ In order to reduce the probability of mutual extrusion and random rope caused by more
layers around the rope, according to the construction progress, use cycle, final height, fall
change, life expectancy and other comprehensive conditions, consider the configuration of
multiple rope of different lengths, to ensure that the first layer of the drum rope has pre-
tightening force. By using short rope in the early stage, the service life of rope can be
effectively extended and the service cost of rope can be reduced.

335
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

◼ When the height of the tower crane is low, the length of the rope is suggested to use adopt
4-fall, and the pre-tightening force of the whole length can be satisfied through the load, to
prevent the phenomenon of rope sinking and chaos caused by the partial rope not being
preloaded.
◼ After the maximum length of rope is released, the rope on the drum should be retained for
at least 3 laps.

◼ When the height of tower crane reaches 180~200m, rope easy twist slip, it is recommended

to use the compacted rope, the detailed scheme please contact our after-sales service;

◼ The lubrication of the rope also has a certain influence on the arrangement of the rope. The
rope should be checked regularly. If the rope is found to have dry grease, it should be
removed manually and then smeared with new grease, see Table 6-1.

6.5 Trolley mechanism

Overview
The structure of the trolley mechanism is shown in the figure below which layout as “一” type.
The three-phase asynchronous frequency motor with axial flow fan. The electromagnetic brake
installed at the empennage of the motor. Planetary reducer which motor output torque to reducer
through coupling. The reducer output end flange connected to drum by bolt.

(1) Motor (2) Coupling

(3) Reducer (4) Drum

Fig. 6-14 Structure of the trolley mechanism

336
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Trolley brake

Fig. 6-15 Trolley brake

(1) Brake disk (2) Hollow bolt
(3) Armature iron (4) Mounting screw
(5) Magnetic yoke assembly (6) Spring
(7) Fixture wire

The apply and release of brake

Fig. 6-16a Apply the electromagnetic brake Fig. 6-16 b Release the electromagnetic brake
Fig. 6-16 Apply and release state

337
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Maintenance
◼ Maintain once for every 450 hours or three months.
◼ Adjust the air gap: the standard air gap value δ=0.6mm for the electromagnetic (2) brake
of three-phase asynchronous motor. See Fig. 6-17.

Fig. 6-17 Adjust the air gap

Ensure that there are no sundries (for example: concrete, sand, or grease)
in the electromagnetism brake.

338
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Adjust the air gap of the trolley travel gear brake

Ensure the main motor and brake are power-off!
The normal working air gap of the brake is 0.6mm, maximum gap is 1.2mm. If check out the
brake is not working or the air gap over the maximum gap value the brake need to adjust.
1) See Fig. 6-18 loosen the retaining bolts ① and remove the fan cover ②;
2) See Fig. 6-18 loosen the installing screw ③ and then adjust the hollow nut ④ to the proper
position until the gap value is 0.6mm, and then tighten screw ③.

Fig. 6-18

3) See Fig. 6-19, install the fan cover ② and tighten the retaining bolts ①.

1
2

Fig. 6-19

If the air gap is not appropriate, repeat the step 2 and adjust it to 0.6 mm, it should
be consistent in all directions.

339
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Replace the brake friction plate

When single side of friction plate wear close to the metal end brake disk about 2mm, must replace
friction plate. Make sure the motor and brake at the blackout state, step as following:
➢ See Fig. 6-20a, loosen the retaining bolts ① and remove the fan cover ②;
➢ See Fig. 6-20b, loosen the fixing screws ⑤, and remove the brake ⑥.
➢ See Fig. 6-20c, Remove the retaining ring⑦, pull out of the brake disk and the splinted
sleeve⑧

Fig. 6-20a

Fig. 6-20b

Fig. 6-20c

340
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Fig. 6-20 Replace friction plate

➢ install new brake disk and splinted sleeve and fit the retaining ring;
➢ install the brake and the mounting bolts (adjust the air gap according to Section 6.5.2.3)
➢ install the fan cover and tighten the retaining bolts.

341
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Maintenance of trolley reducer

Maintenance period
Refer to the Section 6.4.4.

Adding oil
The structure of the reducer is shown in the figure below.

Fig. 6-21 Structure of the trolley mechanism reducer

(1) Oil hole (2) Oil hole
(3) Oil hole (connecting to oil output tube)

Oil adding steps:

a) Change the oil plug of hole (2) to a vent cap, prepare the specified oil (it is forbidden to mix
different lubricants with each other)
b) Open the vent cap of the oil plug first, and then the oil plug of hole, expel all the waste oil
inside, then insert the oil plug;
c) Open the oil plugs of hole (1) and (2), add oil to the reducer according to Table 6-1;
d) Tighten the oil plugs of hole and vent cap, ensure water can’t get in the holes.
Table 6-10 Reducer fuel reference value
Reducer model Oil model Reference fuel

Fully synthetic gear lubrication oil 4408

XX2-15.43 0.28L(0.25kg)
(IOS viscosity 320)

(1) Ensure the gear oil has cool down to the surrounding temperature before
adding or replacing oil, otherwise the operator can be scalded.
(2) The lock plug of trolley reducer refers Table 6-3.
(3) The rubber slice in the reducer vent cap shall be remove after install
mechanism.

342
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Maintenance of trolley motor

The storage of motor
◼ The motor should be stored in dry and ventilative places and covered by waterproof cloth.
Keep the motor clean, and no droplet, greasy dirt, dust or erosion gas could be get into it.
Clean the inside and outside of the motor regularly.
◼ As for motors that have been stored for more than one year, clean the inside of it and dry
the inner water. Daub clean antirust oil on the bearings, all the matching surfaces and
fasteners with thread( except for grounded bolt).
◼ The covers, covers of connecting box and unused outlets on the end cover should be
covered soundly to avoid water, dust, oil or grease getting into the motor. Watch out for
mouse.
Maintenance for motor before reusing
◼ As for motors that have been stored for more than one year, check whether there is rust in
bearings and the location of bearings. If rust exist, exchange bearings immediately. Clean
and refuel the bearings before restarting to avoid damages or noise caused by dried grease.
◼ Check whether the assemble is integrated, or whether the fasteners are tight. If there are
dust or foreign materials inside, please clean up and use dry compressed air when
necessary.
◼ If the mechanism is left unused for a long time, the exposed parts of the motor should be
kept dust-free and dry. When it is to use again, perform mechanical check before installation.
Check whether the assemble is integrated, or whether the fasteners are tight. If there are
dust or foreign materials inside, please clean up and use dry compressed air when
necessary. Measuring the insulation resistance between stator winding and shell with 500V
Megohmmeter before using. When the figure is less than 0.5 megohm, the motor should be
withered and the drying treatment could be performed by bubbling low pressure air into the
winding ( the temperature should not be more than 125℃). To avoid motor rusty, it is
recommended to daub anticorrosive oil on the matching surface and fasteners with
thread( except for grounding bolts) during installing. Also, all the fasteners should be with
spring washer to avoid automatic relaxation. After installation, turn the rotor manually and it
could rotate freely with no friction.
◼ After installation, check whether the brake could close firmly or release. After energizing,
the rotor of the motor could be rotated elastically by hand.
◼ When install gear or coupling, clear the rust on the shaft first. Heavy strike should be
forbidden to avoid damages to the bearings
◼ The connection box is equipped with grounding bolts which should be grounded reliably
after installation.
◼ The method of connection of motor should be exactly the same with the requirements
offered in this technical file, or abnormal operation or even overburn will occur.
◼ After installation of motor, it should run 30~40 minutes without load. If the condition is well,
then add load and watch out for the stability of power. When deviation between the voltage
of power( the frequency is rated) and rated voltage is no more than ± 5%; or positive
deviation occurs both for voltage and frequency and the sum total of them is no more than

343
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

6%; or negative deviation occurs both for voltage and frequency or one is positive and the
other is negative, and the total sum of them of absolute value is no more than 5%, the motor
is allowed to operate in rated condition.

6.6 Slewing mechanism

Overview

Fig. 6-22 Sketch of slewing mechanism structure

Motor connects to reducer spline. Reducer flange install on the turntable, reducer output gear
driven the slewing ring. The layout of slewing mechanism depends on the model, with single or
double slewing, etc.
The braking model of the slewing mechanism is normally closed braking with weathervane. The
motor and reducer of slewing mechanism should be checked and lubricated regularly according
to the requirements of the Section 6.1 and the Section 6.3.

Slewing brake
Slewing motor brake configure with weathervane which consist of brake and electrical
weathervane; The brake can be released electrically or manual by electric weathervane. The
moment of brake is 40N·m.
Slewing brake can be divided into two type of structural arrangement. The follow-up will
respectively describe the clearance adjustment and maintenance of the two kinds of brakes.

344
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Working principle
The slewing brake is an electromagnetic brake, which will be applied once the power supply is
cut off. See Fig. 6-23

Fig. 6-23a Brake released Fig. 6-23b Brake applied

Fig. 6-23 Working state of brake

Electric release and Manual release

◼ Electric release:
First, the brake excitation iron core is fed with specified DC current, and then the weathervane
electromagnet is fed with specified DC current, and then the weathervane armature is close., and
then the DC current of the brake electromagnet should be disconnected. At this time, the
armature of the weathervane supports the weathervane release rod, so that the friction disc
connected by the release screw and the weathervane release rod cannot move towards the brake
disc, the brake disc is in the release state. Finally, the DC current of the weathervane
electromagnet should be disconnected in time. At this point, the electric release of the brake is
completed.
◼ Manual release of vane Brake:
First move the electric weathervane release handle to the tail of the motor, then push the
weathervane push handle inward to make the armature hold the weathervane release lever, and
finally release the weathervane push handle, to achieve the manual release function of the
weathervane brake

345
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Clearance adjustment and maintenance (1)

For conventional brake structure as shown in Fig. 6-24, brake friction plate (13) after long-term
use of friction losses, armature (10) and field core (9) increase the air gap δ, brake spring (16)
length increases, reduce the braking moment, because the air gap δ may increase at the same
time, the armature (10) have difficult in actuation, serious will not be able to actuation, result the
motor in braking state, and then the motor burnout. There before, it is necessary to check the air
gap δ value frequently. When the static braking moment is less than the stipulate value or greater
than 1.2mm, the δ should be adjusted in time. And if the friction plate (13) is worn to close to its
steel mail, the friction plate (13) should be replaced in time.

Fig. 6-24 Brake structure

(1) Cover (2) Adjust nut
(3) Release rod (4) Release handle
(5) Push handle (6) Armature
(7) Electromagnet (8) Field core
(9) Friction disk (10) Friction piece
(11) Locating screw (12) Release screw
(13) Spring chamber (14) Braking spring
(15) Armature

346
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

◼ Regular inspection
Regular inspection once a month, do not remove any parts, the braking opening, braking
should be metal impact sound; When the motor is running, the brake should have no abnormal
sound (friction, metal impact) and vibration.

Fig. 6-25

◼ Regular adjust

Once every 3 months, remove the weathervane cover. Flat mouth screwdriver loosens the
positioning screw and counterclockwise moving armature pull cylindrical gear, let the armature
against field core, to promote the positioning screw, make its end stick close with armature ends,
at the same time with a flat mouth screwdriver clockwise slowly moving armature pull cylindrical
gear, when the end of the armature fifth hole through the end of the positioning screw, insert and
tighten the set screw on moving (the clearance values δ: 0. 75-~1.0m). When the brake is opened
and braking, the action should be sensitive and there should be obvious metal impact. When the
motor is running, the brake has no abnormal sound (rubbing sound, metal impact sound) and
action. As shown in Fig. behind.

Fig. 6-26

347
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

◼ Regular dismantling and check

Once every 6 months, remove the whole lower vane brake and check the friction plate (13).
When its thickness (a) is less than 3mm, the friction plate must be replaced. Install the whole
windward marker brake, and adjust the clearance δ value according to the regular debugging
requirements. As shown in Fig. behind.

Fig. 6-27

◼ Replace Steps of brake friction disk

1) Put the tower crane in the safe state, ensure will not happen any accident when
Dismantling motor operation, otherwise the following operations were prohibit！
2) Cut off all power;
3) Dismantling electrical weather vane;
4) Unscrew locating screw (8);
5) Unscrew the spring chamber (15), take out the brake spring (16), unscrew the mounting
screw of the exciting iron core (9), carefully remove the exciting iron core (pay attention to
protecting the exciting iron core lead), remove the friction disc (11) and brake disc (12),
and check the friction disk mounted on the cover frame (14) and the friction disk
respectively. The friction plate on (11) if the friction plate is seriously worn, it should be
replaced immediately (13), remove the worn friction plate (13) and install a new;
6) Remove the worn friction plate and install a new one;
7) Reinstall the removed parts in the reverse order, and adjust the brake gap δ according to
the second (regular debugging), and adjust the electric weathervane according to the fifth
(adjustment steps of the electric weathervane).

◼ Adjustment steps of electric weathervane

1) Disconnect all power supplies, and adjust the brake gap δ according to the second
(regular debugging);
2) Put the motor under braking state (weathervane release lever (3) can move downwards
freely);
3) Hold down the weathervane release handle (4), and slightly loosen the adjusting nut (2) in
a counterclockwise direction, so that the weathervane armature (5) emerges about 1mm
below the weathervane release lever (3);

348
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

4) Release the electric weathervane by sounding to see if the action is normal. If the
weathervane armature (5) is blocked from free movement under the weathervane release
lever (3), the adjusting nut (2) should be loosened again at this time, if the weathervane
armature (5) If the weathervane release lever (3) cannot be supported, the adjusting nut
(2) should be properly tightened;
5) Manual and electric release several times, and then close the weathervane cover after the
action is normal.

◼ Check whether the weathervane is working properly, and readjust if

necessary. When the gap value is greater than 1.2mm, the gap value should
be adjusted in time, and the recommended gap value is about 0.8mm;
◼ When the thickness of the friction plate is less than 3mm, the friction plate
should be replaced in time;
◼ The adjusted electromagnetic brake and electric weathervane should be
checked if the manual release function, electric release function and braking
function are normal, and they can be put into use after being normal.
◼ The electromagnet of the electric weathervane cannot be energized for a
long time, otherwise it will burn the electric weathervane electromagnet.
◼ When the motor is working normally. The electric release action of the
electric weathervane cannot be used, otherwise it will cause the motor
brake to work abnormally, which will affect the safety of the tower crane in
severe cases.

349
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Clearance adjustment and maintenance (2)

Lay out of new designed slewing motor as shown the following Fig. 6-28.

Adjustment steps of electromagnetic brake

After long-term use and wear of the brake friction plate, the gap between the armature and the
excitation magnet core increases, the length of the brake spring increases, and the braking
torque is reduced. At the same time, due to the enlarged gap, it is difficult for the armature to pull
in. In severe cases, it cannot be pulled in, causing the motor to be in a braking state, and even
the motor is burned out. When the static braking torque is less than the specified value or the
gap is greater than 1.5mm, it should be adjusted in time. When the thickness of one side of the
integral friction disc is less than 1.5mm, it should be replaced in time.
The adjustment steps of electromagnetic brake gap can be divided into: adjust the gap between
static core and moving plate; adjust the gap between bottom plate of loose brake and contact
plate.

Fig. 6-28 Adjust electromagnetic brake gap

(1) Release brake bottom plate (2) Gap 2
(3) Contact plate (4) Nut
(5) Screw 1 (6) Static core
(7) Gap 1 (8) Moving plate
(9) Adjusting bolt (10) Screw 2

◼ Adjust the gap between the static core and the moving plate

➢ Put the tower crane in a safe state to ensure that the motor is operated on the premise that
no safety accident occurs during disassembly. Otherwise, the following operations are
prohibited;
➢ Disconnect all power supplies;
➢ Insert the 0.7mm feeler gauge (4) into gap 1, tighten the screw 1. When the feeler gauge is
clamped, stop screwing the screw 1; As shown in Fig. behind.

350
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Fig. 6-29
➢ Turn the adjusting bolt to the left, stop turning the adjusting bolt when the feeler gauge can
be easily taken out, and then tighten the screw 1 completely;
➢ When the feeler gauge is pulled out, there is a sense of blockage and the gap meets the
requirements. If the gap is too large, loosen the screw and adjust the bolt. Fine-tune to the
right, and then fully tighten the screw 1. On the contrary, if the gap is too small, fine-tune the
adjusting bolt to the right;
➢ Repeat the above steps to adjust the front of the remaining 2 screws.

◼ Adjust the gap between the brake release bottom plate and the contact plate

After power on, the contact plate is attracted and the contact plate is in a vertical state. The gap
(1) between the upper surface of the contact plate and the lower surface of the loose gate is
0.3~0.5mm. When adjusting the gap, first screw down the nut on the screw 2. When the gap is
too large, screw the screw 2 upwards, and when the gap is too small, screw the screw 2
downwards until the gap meets the requirements, and then tighten the nut. As shown in Fig.
behind.

Fig. 6-30

351
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

◼ Replacement of the integral friction disc

➢ The overall friction disc should be replaced by a professionally trained person, otherwise it
is easy to cause other damage;
➢ Put the tower crane in a safe state to ensure that the motor is disassembled without any
safety accidents. One step operation, otherwise, the next operation is prohibited;
➢ Disconnect all power;
➢ Remove the weathervane and brake connecting wire;
➢ Remove the parts at the rear end of the integral friction disc one by one (the entire
weathervane brake);
➢ Replace with a new integral friction disc of the same specification;
➢ Install the disassembled parts one by one, and adjust the brake according to the same
clearance adjustment procedure of the electromagnetic brake.

After adjusting the brake and electric weathervane, check whether their braking,
manual release and electric release functions are normal. After everything is
normal, the motor can be put into use.

Maintenance for slewing ring

◼ The rolling groove of the slewing ring has been filled with 2# extreme pressure lithium base
grease when leaves the factory. Add the grease once every 100 hours of operation, Addition
of lithium base grease, should make the slewing mechanism rotated slowly, while rotation,
while the oil, the grease filling evenly, until the seal a grease extrusion, said the old fat has
been replaced by. Special working environment, such as rain, humidity, dust, temperature
variation and continuous operation, it should shorten the lubrication cycle;
◼ After long time idle, enough new grease must be added to slewing ring;
◼ Exposure of tooth surface and tooth surface, often should clean the rubbish, and coated
with grease corresponding;
◼ Slewing bearing the first 100 hours of operation, should check the retightening force of bolt.
After examining every 500 hours of operation time, must keep enough preload force;
◼ The use of the process, if found, the impact of noise, power increases suddenly, should
immediately stop check, troubleshooting, remove check when necessary;
◼ Never use water directly scour slewing bearing the use of the process, to water entering the
race;
◼ To prevent the hard foreign body close to or into the meshing area;
◼ Always check the seal intact, if it is found that the sealing strip damaged should be replaced
promptly, if found off should be timely reset.

352
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.7 Rope
Basic Knowledge of Rope
1) The structure of rope
Wire rope is a spiral structure, which made up of a certain number of a layer or layers of wire
strands, see the figure below.
2) The lay of rope as the following figure

Fig. 6-31 The structure of Rope Fig. 6-32 The twist of Rope

3) Measuring the Diameter of Rope

Measure the diameter of the rope through correct method, see the figure below.

Fig. 6-33 Measuring the diameter of the rope

353
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

4) Discharge and Storage

To avoid the contingency, be careful when discharging the ropes. The wind should not go down.
It is not allowable to insert the rope by metal hook or lifter fork, see the figure below.

Fig. 6-34 Discharging the ropes

354
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Ropes should be stored in the cool and dry warehouse and cannot be in contact with the ground.
Ropes must not be stored in the location which is easy to be affected by chemistry fog, steam,
or other corrosives. Check the stored ropes regularly, and if necessary, bind the ropes up. If
outdoors storage cannot be avoided, cover the ropes to avoid the damp corroding the ropes, see
the figure below.
Thoroughly clean the discharged from the crane. Bind every rope up before storing them. The
ropes whose lengths exceed 30m should be stored on the wind.

Fig. 6-35 The storage of the rope

355
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

5) Uniting the Rope

When uniting the rope, put the rope on specified bracket or reeve a steel tube through rope
wind hole, hoist the two ends after being put rope sleeves and rotate the rope wind slowly, refer
to the figure below.

Fig. 6-36 Untiring rope from rope sheaf

356
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

357
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Fig. 6-37 Uniting rope from rope wind

6) Rope clamp
◼ Arrangement of the rope clamps
The rope clamp must be buckled on the working rope line in such a way as is shown as the
following figure. Buckle the U-shape rope clamp on the end of the rope.

Fig. 6-38 Correct method to arrange the rope clamps

◼ Number of rope clamps

For the situation according with the requirement of this standard, the minimum number of rope
clamps needed by every connecting section is as indicated in the next table.

Table 6-11 The minimum number of rope clamps needed

Nominal dimension of rope clamp mm
≤19 >19~32 >32~38 >38~44 >44~60
(nominal diameter of rope d)
The minimum number of the rope
3 4 5 6 7
clamp (suit)

358
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

◼ Interval between two rope clamps

As the figure below, the distance A between two rope clamps is about 6~7 times of the rope
diameter.

Fig. 6-39 Interval between two rope clamps

◼ The fastening method of rope clamps

Considering every rope clamp can be forced reasonably when you fasten and fix the clamps,
the farthest clamp should not be fastened and fixed firstly. The rope clamp abutting the rope
ring (the first rope clamp) should be as close to the rope ring as possible, and the rope clamp
shall be correctly tightened without damaging the outside layer of wires.

Rope List
Ropes for WA7025-12E are shown as the table below:

Table 6-12 Ropes for WA7025-12E

Nominal Minimum
Diameter length braking Fixing
Designation Specification Remark
(mm) mass force method
kg/m (kN)
The
diameters
of the
selected
ZLHHK-14-
Hoisting rope Φ14 1.18 169 Wedges ropes must
1960
meet the
requireme
nt listed in
the table
The
minimum
breaking
force of the
6×19-9.3-
Trolley rope Ф9.3 0.3045 46.495 Sleeves rope shall
1700-Ⅱ-sZ
not be less
than the
value listed
in the table

359
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

The length of the rope

The length of the selected rope must meet the use requirement of this tower crane. There must
be three rounds of rope on the terminal location of the drum at least. According to the use
condition, if it is needed to cut a section of rope from the long rope, the two ends need special
handling or adopt proper method to avoid the rope loose during cutting off the rope, see the figure
below.

Fig. 6-40 Preparation for cutting off the rope (L≥2d)

360
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Calculating the Length of the Hoisting rope

Total length required for hoisting rope
L＝L0+f×H
L0——The sum of the rope lengths of the hook on the max hoisting height, m; see the table
below.
f——Falls used;
H——Hoisting height, m.

Fig. 6-41 Calculating the Length of the Hoisting rope

Table 6-13 The length of hoisting rope for different length jibs
Jib(m) 30 35 40 45 50 55 60 65 70
L0(m) 80 85 90 95 100 105 110 115 120

The Length of the Trolley Rope

The length of trolley rope is fixed as the jib changing, see the table below:

Table 6-14 The length of trolley rope for different length jibs
Jib lengths (m) 30 35 40 45 50 55 60 65 70
RopeⅠLengths (m) 60 70 80 90 100 110 120 130 140
RopeⅡLengths (m) 45 50 55 60 65 70 75 80 85

361
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Installation of the Rope

The rope should not be disturbed during installation, when uncoiling the wire rope from a wind or
coil, every precaution shall be taken to avoid the Tweaked or tightened kink, bends etc. of the
rope.
During installation, the rope shall always bend in the same direction: i.e., pay out from the top of
the wind to the top of the drum, or from the bottom of the wind to the bottom of the drum, see the
figure below.
Care shall be taken to ensure that termination anchorages are made and secured in accordance
with the instructions in the crane manual.
If the rope rubs against any part of the crane during installation, then the points of contact shall
be suitably protected.

Fig. 6-42 The rope winding

Replacing steel rope of Tower crane should be carried out in accordance with the relevant
chapters in the tower crane operation manual to correctly wear around, and make wire rope bend
in the same direction as far as possible, otherwise will seriously affect the life of wire rope.
Wire rope should be installed at pre-tightening condition.
Before put into use wire rope on hoisting machinery, the user should ensure that all related to the
wire rope work device is installed in place and working properly.
In order to make the steel wire rope stable in place, about 10% of the rated load shall be used to
rope wheel system running operation for several times, in order to make wire rope can be
accurate and stable in the system, more joint drum steel wire rope, the rope internal release, it is
advantageous to the rope neatly, and effectively prevent the wire rope to disturb.

362
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Fixing rope head

One end of rope connected drum; another end connected jib end anti-twist device.
◼ Fixed the rope and drum
The rope is connected to drum through a wedge sleeve. (See Fig 6-29a).
1) The feeding direction should be consistent with the vertical edge of the wedge sleeve and
the drum feeding direction;
2) Wedge the wedge with a mallet or a copper rod;
3) The length of the outstretched wedge sleeve of the rope head is 65~78mm, and the length
of the tighten rope head is 20~26mm or conical fuse.

Fig. 6-43a The end of drum wedge connection Fig. 6-43b The end of jib end wedge connection
Fig. 6-43 Connected wedge
◼ Fixed the rope and the jib end
The rope is connected to jib end anti-twist device through a wedge sleeve (see Fig. 6-43b)
1) The extension direction of the force rope should be threaded through the pinhole.
2) The rope clamp specification should match the diameter of the rope.
3) Rope clamp positionis: X=70~85mm.
4) Wedge the wedge with a mallet or a copper rod.

363
 MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

◼ Anti-twist device
Adjust the anti-twist device to the state of the release (Can be free rotation) or lock (cannot free
rotation) according to the performance of the rope.
1) For the resistence rotary rope with its rotation performance less than 360°(e.g 35(W)×7),
the anti-twist device generally be in release state.
2) For the non-resistence rotary rope(e.g 6×29), the anti-twist device generally be in a lock
state.

Fig. 6-44 Anti-twist device

(1) Nut (2) Release
(3) Lock (4) Bolt
(5) Wedge sleeve (6) Anti-twist device
(7) Nut (8) Release
(9) Lock (10) Bolt

364
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Discard Criteria of Rope

1) Nature and number of broken wires
The table below take these factors into account when considered in conjunction with the factors
given in (2) to (19). So, it can be applied to all structure’s ropes.

Table 6-15 The number of visible broken wires that meet or exceed the scrap standard in single
strand wire rope and parallel twist compacted wire rope used on steel pulley
The number of visible broken wire rope Concerned with fatigue
when lifting machinery must be scrapped
Section of multi-
A section of wire rope working on a steel
layer wire rope
Kinds Number of loads pulley and mill or single layer wound on a
wound on the
of bearing wires of wind (Random distribution of wire breaks)
drum
wires the outer layer of
Working classification M1~M4 or unknown Off Working
RCN the rope n
classification classification
Interaction of twist Concurrent twist Interaction of twist
Length arranges Length arrange
>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: Silu type wires ropes with outer strands and 519 wires per share (e.g 6×1 silu type)
are listed in two rows in the table. The top row represents the number of normally placed
outer strands carrying wires.
Note 2: The above values in the multilayer wound wind section may also be applied to other
sections of the wire rope working on pulleys made of synthetic materials or having synthetic
wheel lining. However, it is not applicable to wire ropes which are specially made of synthetic
materials or which are operated on a single winding pulley consisting of a composite wheel
lining.
a. Filled steel wire in standard is not regarded as load-bearing steel wire, so it is not included
in the n value.

365
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

b. A broken wire will have two broken ends (count by one wire)
c. These values apply to sections that are damaged by interference between the jump zone
and the overlap layer duo to the effect of the entanglement angle (and not only those section
where the pulley is working and where the wire rope is not wound around the drum).
d. Two times of the number of broken wires listed above can be used for mechanisms whose
working class is known to be M5~M8. See ISO 4308-1.
e. Nominal diameter of the wire rope.

Table 6-16 Number of visible broken wires of non-rotating wire rope that meet or exceed the
scrap standard
The number of visible broken wire rope Concerned with
fatigue when lifting machinery must be scrapped
Kinds Number of loads A section of wire rope working on a
Section of multi-layer
of bearing wires of steel pulley and mill or single layer
wire rope wound on
wires the outer layer wound on a wind (Random
the drum
RCN of the rope n distribution of wire breaks)
Length arranges Length arranges
>6de >30de >6de >30de
21 4 n ≤100 2 4 2 4
3n or 4 n ≤100 2 4 4 8
at least 11 outer
layers
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

Only use ropes which correspond with the specifications in the ZOOMLION rope
list.

366
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

2) Broken wires at the termination

Broken wires at, or adjacent to, the termination, even if few, are indicative of high stresses at this
position and can be caused by incorrect fitting of the termination. The cause of this deterioration
shall be investigated and, where possible, the termination shall be remade, shortening the rope
if sufficient length remains for further use, otherwise the rope shall be discarded.

3) Localized grouping of broken wires

Where broken wires are very close together, constituting a localized grouping of such breaks, the
rope shall be discarded. If the grouping of such breaks occurs in a length less than 6d or is
concentrated in any one strand, it may be necessary to discard the rope even if the number of
wire breaks is smaller than the maximum number shown in the table above.

4) Increase rate of the broken wires

In applications where the predominant cause of rope deterioration is fatigue, broken wires will
appear after a certain period of usage, and the number of breaks will progressively increase over
time. When the time interval becomes shorter and shorter, it is recommended to conduct careful
periodic examination and recording of the number of broken wires, with a view to establishing
the rate of increase in the number of broken wires. This law may be used to confirm a future date
for discarding rope.

5) Fracture of strands
If a complete strand fracture occurs, the rope shall be immediately discarded.

6) Reduction of rope diameter resulting from core deterioration

Reduction of rope diameter results from deterioration of a fiber core or fracture of a steel core. If
rope diameters notable reduces, the rope shall be immediately discarded.
Low values of deterioration might not be so apparent from normal examination, particularly if the
rope stresses are well balanced throughout the individual strands. However, the condition can
result in a high loss of rope strength, so any suggestion of such internal deterioration shall be
verified by internal examination procedures, If such deterioration is confirmed, the rope shall be
discarded.

7) External abrasion
Abrasion of the crown wires of outer strands in the rope results from rubbing contact, under
pressure, with the grooves in the sheaves and drums. The condition is particularly evident on
moving ropes at points of sheave contact when the load is being accelerated or decelerated, and
is revealed by flat surfaces on the outer wires.
Wear is promoted by lack of lubrication, or incorrect lubrication, and by the presence of dust and
grit. Wear reduces the strength of ropes by reducing the cross-sectional area of the steel strands.
If, due to external wear, the actual rope diameter has decreased by 7% or more of the nominal
rope diameter, the rope shall be discarded even if no wire breaks are visible.

367
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

8) Elasticity decreases
Under certain circumstances usually associated with the working environment, a rope can
sustain a distinct decrease in elasticity and is thus unsafe for further use. Decreased elasticity is
difficult to detect. If the examiner has any doubt, advice shall be obtained from a specialist
in wire ropes.
While no wire breaks may be visible, the wire rope will be noticeably stiffer to handle and will
certainly have a reduction in diameter greater than that related purely to wear of individual wires.
This condition can lead to abrupt failure under dynamic loading and is sufficient justification for
immediate discard.

9) External and internal corrosion

◼ Corrosion of the outer wires can often be detected visually. When the pits appear on the
wires and the wires are quite loose, the rope should be discarded.
◼ If there is any indication of internal corrosion, the rope should be carried out internal
examination as indicated by governors. The ropes with serious internal corrosion are
sufficient to be discarded immediately.

10) Waviness distortion

As the figure below, when the waviness distortion occurs, when the rope length is no more than
25d, d1>4d/3, the rope shall be discarded. In the formula d is the nominal diameter of the rope
and d1 is the diameter corresponding to the envelope of the distorted rope.

Fig. 6-45 Waviness distortion

11) Basket or lantern deformation

Basket or lantern deformation is a result of a difference in length between the rope core and the
outer layer of strands. Ropes with a basket or lantern deformation shall be immediately discarded
as the figure below.

Fig. 6-46 Basket or lantern deformation

368
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

12) Strand protrusion

Strand protrusion usually happens with basket or lantern deformation. It shows the rope
misbalanced. Rope with strand protrusion shall be immediately discarded as the figure below.

Fig. 6-47 Strand protrusion

13) Wire protrusion

In wire protrusion, certain wires or groups of wires rise, on the side of the rope opposite to the
sheave groove, in the form of loops. Rope with wire protrusion shall be immediately discarded
as the figure below.

Fig. 6-48 Wire protrusion

14) Local increase of diameter of the rope

A local increase in rope diameter can occur and might affect a relatively long length of the rope.
This condition usually relates to a deformation of the core (in particular environments, a fiber core
can swell up owing to the effect of moisture) and consequently creates imbalance in the outer
strands, which become incorrectly oriented. If the local actual rope diameter increases seriously,
the rope shall be immediately discarded as the figure below.

Fig. 6-49 Local increase of diameter of the rope

369
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

15) Flattened portions

Flattened portions of rope results from machine accidences as the figure below. If flattened
portions of rope is serious, the rope shall be discarded immediately.

Fig. 6-50 Flattened portions

16) Kinks or tightened loops

A kink or tightened loop is a deformation created by a loop in the rope which has been tightened
without allowing for rotation about its axis. Imbalance of lay length occurs, which will cause
excessive wear, and in severe cases the rope will be so distorted that it will have only a small
proportion of its strength remaining. As the figure below showing, rope with serious kinks
tightened loop shall be immediately discarded.

Fig. 6-51 Tweaked or tightened kink

17) Bends
Bends are angular deformations of the rope caused by external influence. Rope with a severe
bend should be immediately discarded as the figure below.

Fig. 6-52 Bends

18) Local decrease of diameter of the rope
A local decrease in rope diameter usually relates to a fracture of the core. As the figure below
showing, local decrease of diameter of the rope shall be immediately discarded.

Fig. 6-53 Local decrease of diameter of the rope

370
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

19) Damage due to heat or electric arcing

Ropes that have been subjected to exceptional thermal effects, externally recognized by the
colors produced in the rope, shall be immediately discarded.

Replace the rope

When the length of rope cannot meet the use requirements or reach the scrap standard, it should
be replaced in time.
◼ Procurement
1) To ensure the quality of the rope, it is recommended to purchase from the original factory of
the main engine.
2) Rope tube should be used for storage and transport.
3) Correct handling of rope head.
➢ Truncation should be done by cone-open fusing.
➢ When conical fuse breaking is not possible due to limited conditions, it can be handled by
tying steel wire and then cutting it off, but attention should be paid to:
1) It is recommended to use medium 1mm steel wire binding, and as tight as possible.
2) Binding length l should be (2~4) d, multiply rope should be large value.
3) The distance between the two sides of the binding place should be 10~20mm.
4) It is advisable to use gas cutting or electric welding to weld the end firmly after grinding.
◼ Loading, unloading and storage

1) Loading and unloading

Loading and unloading should be done in the correct way, as shown in Fig. 6-54, Operation as
shown in Fig. 6-55 should be rejected.

➢ The correct handing and unloading method

Fig. 6-54 The correct handing and unloading

371
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

➢ The wrong handing and unloading method

Fig. 6-55 The wrong handing and unloading

2) Storage

The rope should be properly kept to prevent rust or damage caused by damp. the requirements
are as follows:
➢ The rope should be stored in a well-ventilated room, isolated from the damp ground, to
prevent direct sunlight, hot air baking and grease dripping.
➢ Avoid contact with acid, alkali and other invasive materials.
➢ Avoid the rope from being squeezed and hit.
➢ It should not be stacked in the open air. If it must be stored outdoors, it should be placed on
the dry ground with higher ground, and the air floor at the bottom is isolated and covered
with a tarpaulin.
➢ The original information of each wind of wire rope must be kept completely.
➢ For the storage of rope for a long time, generally a yearly appearance inspection, rust, oiling,
and then re-winding, to prevent improper storage of rope serious deterioration.
➢ The rope stored for more than one year can be used only after passing the qualification test
before use.

◼ Winding the rope

1) The out and in directions of rope drum and drum should be the same. (Fig. 6-56)

Fig. 6-56a Correct (Along the winding) Fig. 6-56b Wrong (rewind the winding)
Fig. 6-56 Winding the rope

372
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

2) Rope pre-tightening

When the rope is wound out of the drum, resistance should be applied to the rope drum according
to the site conditions and the principle as shown in Fig. 6-57 to prevent excess rope from being
released.

Fig. 6-57 Principle of rope pre-tightening

During rope wound into the drum, ensure that the tension of rope is not less than 1500N. If the
site condition does not be met, the length of the rope should be controlled. At the maximum fall,
the hook is in the lower limit, the rope allowance on the drum is generally not more than 2 layers.

When replacing the hoisting rope, user must configure the compactable
rope in strict accordance with the specifications required by this manual.
The wrong use of common (non- compactable) rope will cause rope
fracture, resulting in serious consequences of crane destruction and
death.

Non- compacting rope Compacting rope

There is huge difference between compacting rope and ordinary non- compacting rope. The
same diameter of compacting rope than non- compacting rope breaking pull is much larger, the
service life is longer, please be sure to configure the compacting rope according to the
requirements.
To guaranteed the quality of rope, please choose the original rope in the purchase of rope.

373
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Trolley rope must comply with relevant provisions of GB 8918-2006 <Important

Purpose Wire Rope>
Hoisting rope must comply with relevant provisions of T/CCMA 0086-2020
<Tower Crane Hoisting rope> and YB/T5359 compacting rope

In addition, the following requirements must be met; (d is the theory diameter of rope)
◼ The minimum breaking tension of the hoisting rope and trolley rope shall be complied with
requirements:
◼ The diameter allowable deviation of trolley rope is d (+1%~+5%), unevenness ≦2% and
out-of-roundness ≦3%
◼ The diameter allowable deviation of hoisting rope is d (+2%~+4%), unevenness ≦2% and
out-of-roundness ≦3%
◼ Anti-torsion performance of hoisting rope: torque coefficient KQ≦0.021, rotation degree≦
1.5r/1000d;
◼ The lateral pressure stability of the hoisting rope :ΔV≦8%;
◼ The diameter shrinkage of the hoisting rope: ≦3%.

Maintenance of Rope
Maintenance of the rope should be relative to the crane usage environment and involved rope
type. Paint lubricating grease and lubricating oil when installing the rope. The rope shall be
cleaned where necessary, and the rope being reused in regular time interval, especially before
the section of rope passing round the pulley shows signs of dryness or corrosion should be kept
in good lubricating condition.
The rope lubricating oil (grease) should be Graphite calcium base grease ZG-SSY1405-65, it
has strong penetration. A shorter working life of rope will result from lack of maintenance.
If wire rope grease on the surface dry, it should be cleaned in time, and apply new accord with
the prescribed grease.
Wire rope surface should avoid applying too much grease. Surface blotted out too much grease
may produce the following question
1) Aggravated deterioration of the rope rupture
2) Environmental pollution
3) Easy adhesion of the dust or other substances, make the wire rope from corrosion

374
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.8 Maintenance of pulley assembly

Examination of pulley assembly
Hoist pulley, trolley pulley, trolley and hook pulley are non-lubricating bearings. The pulley shaft
has no oil nozzles and does not need to be lubricating,
◼ Daily inspection of bearings:
➢ whether there is oil leakage
➢ Shaft end seals
➢ Elastic ring
➢ Operation noise and resistance
➢ Bearing clearance.
◼ Table of pulley parameters, Table 6-17
Table 6-17 Pulley parameters
Diameter Rope groove Rope groove
Designation Specification
(mm) depth (h) radius (R)
Hoisting pulley HL-450-380-80-130- R8.5 450 35 8.5

Trolley pulley 214-178-B41-80-R6 214 18 6

Pulley scrap
The main forms of pulley damage are worn and extrusion of the pulley groove caused by the
steel rope. Generally, the surface condition of the pulley groove (Fig. 6-58 and Fig 6-51), wear
depth and arc radius are the basis for judging whether the pulley is normal or not.
◼ Surface condition of rope groove
The surface of the pulley groove should be worn evenly and smoothly. When there is obvious
indentation, the pulley should be replaced.

Fig. 6-58 Example pulley indentation

375
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Fig. 6-59 Depth detection of rope groove

◼ Depth of rope groove

Due to wear, the h value of rope groove depth increases gradually. For the hoist pulley, the pulley
should be replaced when the value increases by 30%d over the theoretical value. For the trolley
pulley, the pulley should be replaced when the h value increases by 30%d over the theoretical
value.

◼ Rope groove radius

➢ Due to wear, the radius R of the rope groove will change. when the value of R exceeds
0.525d~0.6d, the pulley should be replaced.
➢ The rope groove radius detection method as shown in Fig. 6-60
➢ The radius of the pulley grooves is detected by the pulley gauge or radius gauge (R gauge).
From the beginning of the large diameter measuring tool to the arc of the measuring tool
basically coincides with the arc of the normal section of the pulley groove.

Fig. 6-60 Examples of radius detection of pulley groove arc

◼ When the pulley is found to have flange, crack and other phenomena, the pulley should also
be replaced.

376
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.9 Maintenance of travelling chassis parts

Maintenance of driving/driven dollies
◼ Check each connection parts every day, the connection should be tightened and reliable.
◼ Check reliability of rail clamps and pin shaft, and settle it if abnormality occurs.
◼ Check each traveling limit switch every day, they should be sensitive and reliable.
◼ Add lubricating oil into each lubricating point every two months. The lubricating of each dolly
is shown as

Fig. 6-61 Lubricating points of the dolly

◼ Check the wheels every 6 working months. It should be scrapped if the following conditions
occur:
➢ Cracks;
➢ The worn value of wheel surface thickness arrives 15% of original thickness;
➢ The worn value of wheel rim thickness arrives 50% of original thickness.

377
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Maintenance of traveling motor

1. Front end cover;2. Bearing; 3. Terminal box; 4. Stator; 5. Rotator; 6. Bearing; 7. Friction plate;8.
Brake disc (1); 9. Brake disc (2); 10. Armature (1); 11. Iron core with shell (1); 12. Spring block;
13. Armature (2); 14. Iron core with shell (2); 15. Spring Chamber; 16. Spring (1) 17. Spring (2)
Fig. 6-62 Parts of the traveling motor
◼ Motor structure diagram is shown as Fig. 6-62, maintain the motor periodically as
following items:
1. Check each terminal block to see if the contact is well;
2. Check insulating resistance of stator and the rotor winding with a ohmmeter, the value of the
resistances should not be below 0.5MΩ;
3. Environment should be kept clean during operation to prevent all kinds of dirt being
absorbed;
4. Motor bearing is special sealed bearing, during it using period, should not change lubricating
grease. When the life of bearing over, the oscillation and noise of motor will augment
obviously, check the radial clearance of bearing, if reaches 0.1mm, should instead of it in
time;
5. When motor is started, excitation coil is electrified at one time, brake open; when motor is
stop, the control of frequency conversion could let motor from speed of working state to zero
or adjacent zero gradually, excitation coil is cut off, it is braking state. So, the brake and
release of electromagnetism brake must be sensitive and reliable;
6. Check every part of brake periodically, clear begrime and ordure of braking disc, friction
piece, clean the outlet/inlet wind passage;
7. Check the braking moment of brake, value of clearance and friction piece periodically. When
static braking moment less than stated value 40Nm or clearance more than 1.2mm, static
braking moment and value of clearance should be adjusted in time, if friction piece wear and
near to metal surface, friction piece should be changed in time.

378
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

◼ The adjustment of static brake moment and clearance is:

1. Cut off all power; turn the down lag and locknut; take shield;
2. Screw off the orientation bolt; unscrew nut (5mm about);
3. Screw on spring chamber, compress the braking spring, let the static braking moment to the
regulate value 40Nm, screw the nut closely;
4. Using tool entering the wind window of excitation iron core poke the teeth circle of armature,
until armature keep close to excitation iron core, drill through orientation bolt, withstand
armature, poking the armature on the right slowly, find the location of the first hole of
orientation bolt drilling armature. At this moment, air clearance is 0.8 mm (armature and
orientation bolt of excitation iron core locate on the circle with the same radius, 12 holes
distribute equably, the screw pitch of whorl connected with armature and braking disc;
5. Fit on the shield; install and screw locknut closely; install lag and screw closely.
◼ Replace method of friction piece:
1. Cut off all power; unscrew lag and locknut on the left; take off shield;
2. Unscrew off orientation bolt; unscrew off locknut and release nut;
3. Unscrew the spring chamber and take-out braking spring and spring retaining pad;
4. Unscrew the bolt connecting the excitation coil iron core and shell, remove the excitation
iron core carefully (be careful of the lead of protection coil), remove the friction disc and
braking disc. (Notice: “3)” , “4)” step should not be upside down, or else attaint the
protruding desk on the hole of the bolt;
5. Take off the friction disc of shell and exchange the same standard new friction disc; remove
the friction piece on the friction disc, exchange the same standard new friction piece, and
felt hard;
6. Install braking disc, friction disc, shell body, excitation coil, spring retaining pad, braking
spring and spring chamber according contrary “3)”, ”4)”step;
7. Adjust the static braking moment and air clearance according to the adjustment method of
static braking moment and air clearance; install shield, screw the locknut;
8. Screw tow release nut, lock each other off spring chamber 5mm.
After every adjustment of electromagnetism, should check handful releasing equipment and
whether snort the armature after electrified, if it is eligible, the motor can be used.

Maintenance of the cable drum

Notice：
a) Cut off the power before open the collector ring;
b) Prohibit inserting stop parts into nut indentation during operation;
c) Lubricating oil level in reducer should be above the center position of the sight hole;
d) When the crane moves toward the direction of power, the motor of cable drum should
be started simultaneously with traveling mechanism, while the traveling mechanism
stops, the motor of the cable drum should power off after 3 seconds.
1. Must exchange lubricating oil in reducer after the first one-month operation;
2. Check the oil level of reducer every two months, when it is below center of sight hole,
and then add HL-30 lubricating oil;

379
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

3. Check the tightness of electric parts of collector ring every two months, to ensure
good contact and reliable connection of cable fittings. At same time, measure
insulation condition, the insulating resistance should not be below 5 MΩ;
4. Change lubricating oil in the reducer every year. Turn out the hexagon plug screw at
bottom to drain off dirt oil, and screw out brake parts simultaneously. Screw on the
hexagon plug screw and add clean HL-30 lubricating oil, Screw on brake parts after
cleaning the dirt oil.
5. Keep the surface of collector ring, motor, reducer cleaning;
6. Exchange parts in time if the parts are worn greatly and affect performance.

Bearing model
Wheel bearing model: GB/T288-1994 Bearing 22220C 4 wheels for each dolly.

380
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.10 The high strength bolts

Basic knowledge of the high strength bolt

◼ There are many high strength bolts, they are used to connect the components and pass
load.
◼ All the high strength bolts which are used to connect the components of the tower crane are
vital for the tower crane and must be installed, maintained, and checked seriously.
◼ Check the high strength bolts occasionally, to assure the fastness and reliability of the
connections. Looseness of the bolt may lead damage and even the stale connection of
single component.
◼ If users choose the bolts by themselves, please ensure the strength grade of the nut can
match the bolt.
For example:
8.8 grade bolt -> 8 grade nut;
10.9 grade bolt -> 10 grade nut
12.9 grade bolt -> 12 grade nut

Checking the bolts and bolt connection sets

Clean and check all the bolt connecting components before the installation. The checking
contents include bolts, nuts, thread, the transition part between the bolt head and the screw and
so on.

Using the damaged bolts and nuts is strictly prohibited! Don’t use the
bolts whose screws are rusty and the bolts or the nuts whose threads are
rusty!

Lubricating the high strength bolt assembly

Use molybdenum disulfide to lubricate all the bolt assemblies before installing them. Good
lubrication can supply uniform friction and standard preload for the bolt.

As is shown in Fig. 6 53 please lubricate the threads of the bolts and nuts
and the contact surfaces. If the preload is exerted on the bolt head, the
contact surfaces of the bolt head need to be lubricated as well.

381
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Fig. 6-63 Lubricate the contact surface

Recycling the high strength bolt

All the bolt assemblies which were exerted preload rightly can be recycled when erecting the
tower crane again. However, all the bolt assemblies recycled must have been checked and are
not damaged.

382
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.11 Pins and holes of the tower section

After assembling the tower section, please check the pins and holes as follow the steps.

◼ Before hoisting the tower section, please make certain that the surface of pin-hole and pin

is cleaned. It can use the polisher to clear the pin-hole, but grinding wheel is prohibited which

enlarges the pin-hole. After cleaning, the pin-hole should have mental luster.

Step 1: Before
hoisting, please
make sure that the
surface of pin-hole
and hinge pin are
clean.

◼ When installing the tower section, please check the pin-hole again and make sure there are
no sundries, if there are any sundries please clear it.

Step 2: When
installing, please
check the pin-
hole again.

383
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

◼ After cleaning the surface of pin-hole and pin, uniformly daubing the AG1 rusting preventive
grease on the inner surface of the pin-hole and outer surface of hinge pin. Then installing
the hinge pin. Strictly prohibit mixing the difference kinds of grease. Strictly prohibit mixing
the new AG1 with old AG1.

Step 3: Apply grease

to the pin-hole and
hinge pin, then
install the hinge pin.

◼ After dismantling, the hinge pins must be placed in the clean and waterproof box which
should be placed indoors. If the pin-hole of tower section is rusting or the grease
consolidation, firstly cleaning the pin-hole, then daubing the AG1 rusting preventive grease.
It must have adapting cushion between the tower section and ground.

Step 4: Attention
after dismantling.

◼ Check if the rabbet of the tower section main chord can shake, if it can shake, the shake
value cannot exceed 0.7mm, if it exceeds, please contact our company’s after-sales staff to
handle it before it can be used.

384
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.12 Hook
Check the locking of the hook
◼ All the fasteners of pulley pin and connecting pin are normal;
◼ The press plate on the hook nut is installed in place, without deformation, and the bolts on
the press plate are firmly fixed; The tower crane needs to be checked before use. If the fixing
bolt is loose or damaged, please tighten or replace the bolt in time.

Opening Degree of the Hook

Inspect the deformations at least once a month.

◼ The initial value of hook opening degree a 0 = 85 +−32 mm . (According to the measuring value

before the first time use of the hook)

◼ If the opening degree has been more than 110% of the initial value a 0 , replace the hook.

◼ Check the torsion deformation of the hook. When the torsion angle of the hook body exceeds
10°, replace the hook.
◼ The handle of the hook should not be plastic deformation, otherwise it should be replaced

385
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Wear
+5
The initial value: h0 = 100 − 2

The wear on hook may not be greater than 5% of the height “H”. It is not permitted to carry out
welding work on hook to repair the wear.

Check hook wear at least once a month.

◼ Surface cracks
➢ If there are obvious distortions of the hook, do the surface cracks check to
the hook using appropriate method or change the hook.
➢ Damages and surface cracks can be removed, but no gap can be left. The
hook dimension after being removed the cracks and damages should not
exceed the permissible tolerance.
➢ If the installed hook cannot be checked, dismantle it and check it.
➢ Before making checks, ensure that the surfaces are put into a condition
permitting the definite identification of surface cracks!

Corrosion
◼ The diameter d1 of hook handle cannot be corroded to be less than 95%, if the diameter is
less than 95%, change the hook.
◼ The threads on the hook cannot be corroded.

Hook defects are not allowed to be repaired by welding.

Check hook anti-tripping device

◼ Hook anti-tripping device, under normal use, anti-rope device and hook can form a closed
cavity. If the anti-tripping device and hook cannot form a closed cavity, the anti-tripping
device shall be corrected. If it cannot be corrected, shall be replaced.
◼ If the anti-tripping device or the connecting pin between the anti-tripping device and the hook
is deformed, which affects the normal use, please replace the pin.

The anti-tripping device should be check before the tower crane is used.

Oil hook bearing

Thrust ball bearing are used on the hook assembly, which are provided with lubricating oil holes
and need to be lubricated regularly.

386
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.13 Trolley
Routine inspection of trolley rollers
◼ Check roller bearings;
◼ The roller rotates normally;
◼ There is no damage or deformation of roller;
◼ Roller wear;
◼ The nut and lock washer of the roller shaft are not loose;
◼ All the rollers of the trolley are in contact with the jib;
◼ In the process of running the trolly, he roller, the roller cover and the belly rod of the jib do
not interfere

Routine inspection of side rollers of trolley

◼ Check the side roller bearings;
◼ The roller rotates normally;
◼ There is no damage or deformation of roller;
◼ Check the wear of side rollers (see Table 6-18 Side roller specification table); Replace the
side roller when the wear of the side roller reaches 5% of the diameter

Table 6-18 Side roller specification table

No. Order No. Specification
1 000209705A0001400 Ф80-30
2 000209710A0600001 Ф120-50
3 000209716A0010019 Ф140-50
4 000209705A0001200 Ф150-50

◼ There is no damage to the split pin or clamp plate used for the limit of the side roller shaft,
and it is firmly fixed

387
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

6.14 Steel structure

Foreword
This description contains the maintenance instructions for the steel structure elements of the
crane.

Description

Fig. 6-64 Steel structure of the crane

(1) Outriggers (2) Mast
(3) Climbing equipment (4) Counter jib
(5) Jib

388
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Description
The structure defines all the metallic parts constituting the crane steel structure.
◼ Cleanness / cleaning
General condition / appearance
◼ Paint / corrosion
◼ Ballast
◼ Derrick / mast / crane tower / jib / counter jib
◼ Pins / screw bolts
Steel structure ◼ Ladder / platforms / grab rails / catwalks / guard
ropes
◼ Lifting cab guiding system
◼ Greasing

Maintenance
General condition / appearance
Check the general crane aspect: cleanness (concrete, mud, and sand splashes, etc...).

Cleanness and general correct appearance of the crane avoid risks and
operating problems.

Cleanness / cleaning
The cleaning must be carried out with fresh water without detergent. Using a high−pressure
apparatus is possible if the following instructions are observed:

Never apply the squirt directly on hinges, cables, safety devices and
electrical equipment: control panel interior, cables, connectors, terminal
strips, etc..

The control panel inside must be freed from dust by means of compressed air. Remove dust from
the electrical equipment and the safety devices with a dry cloth.

After each cleaning all the required parts must be lubricated and
greased.

389
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Paint / corrosion
Carry out a visual check of the following points:

◼ In case of a drain line due to an invisible corrosion, carry out a regular check,

◼ In case of corrosion on a painted part, clean and grind the area, then apply a layer of rust
preventing agent and paint,

◼ In case of wear of the surface treatment, clean and grind the area, then apply a layer of rust
preventing agent and paint.
Steel structure
Carry out a visual check of the ballast concerning the following points:
◼ In case of cracks, fretting, too considerable wear, carry out a weighing in order to make sure
that the ballast weight is still within the tolerance.

Tolerance of the ballast weight: 0 to + 4% (base) / −2 to +2% (counter jib).

◼ In case of corrosion on the metallic ballast, clean and grind the area, then apply a layer of
rust preventing agent and paint,

◼ In case of a drain line due to invisible corrosion carry out a regular check,

◼ In case of wear of the slinging loops or their fixings to the ballast blocks including the risk of
a break, replace the ballast.

Derrick / mast / jib / counter jib

Carry out a visual check on the whole crane steel structure (deformations, cracks, damages, ...).

The crane steel structure is an essential part. As soon as an anomaly is

detected: cracks, crackled paint, deformation, anomalous noise,
compulsorily stop the crane operation and contact a ZOOMLION expert.

390
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Deformations:
◼ Deformation of the steel structure

◼ Deformation of a bracing

◼ Pressure, sinking

◼ Friction

391
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Pins / screw bolts

Carry out a visual check on all assembling points of the parts constituting the crane.

Assembling by fish joints, pins and screw bolts is of highest importance.

As soon as an anomaly is detected, stop the crane operating and solve
the problem.

◼ Pins

◼ Screw bolts.

Ladders / platforms / grab rails / catwalks / guard ropes

Carry out a careful visual check of all welding on the whole crane.

All the accesses must compulsorily be present, correctly fastened, and

free.

392
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.15 Maintenance of electronic control system

The electronic control system should be frequently maintained and maintained to eliminate faults,
eliminate safety hazards, ensure the normal operation of the whole crane, and extend the service
life of the equipment. Maintenance work should be carried out by professionals with relevant
qualifications.

Electrical equipment inspection

Table 6-19 Checklist of electrical equipment

Inspection cycle Inspection item

Electrical Equipment:
Whether the door of the electric control cabinet closes
The air switch in the cabinet
Circuit breaker
Display
Electric whistle
Sensor
Over load display
Daily operate before Moment percentage display
inspection Trolley position display
Hoisting height display
Wind speed display
Weathervane brake release
Indicator light/indicator device:
Voltmeter
Overvoltage indicator light
Cab light
Beacon light
Main power
Main power switch box
Phase sequence
Service voltage
Length and shuck of main cable
Every position for reliable earthing
Check each erection and Cable:
inspection cycle (suggest Meet a criterion
cycle is 2-3 weeks) Shuck of main cable in perfect condition, good insulation
Plugins in correct location, good contact and reliable
Cable stress relief.
Electrical device:
Air switch
Circuit breaker
Electric relay, contactor

393
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Display
Sensor
Over load and moment alarm normal
Brake, weathervane brake
External equipment connector good contact and reliable
Indicator light/indicator device:
Voltmeter
Overvoltage indicator light
Cab light
Beacon light
Electrical control cabinet
Temperature switch and humidity switch set values correctly
Power voltage control set values correctly

◼ The inspection of electrical equipment must be carried out under no-load conditions:
➢ The hook moves up and down slowly;
➢ Trolley slowly moves outwards and inwards;
➢ The tower crane slowly rotates to the left and right;
➢ All control parts run correctly and smoothly,
➢ The position of the trolley and the height of the hook on the display screen are displayed
accurately and continuously.
➢ The wind speed display value on the display is correct and reasonable
➢ The mechanism starts quickly and smoothly,
➢ Increase and decrease gears, continued, no gears, skipping, and the operating handle can
automatically return to the zero position,
➢ When running in no-load, there is no obvious special noise or vibration
◼ Check of component setting value
Temperature sensor (ST) and humidity sensor (SRH) in the main control cabinet, voltage
monitoring relay, as shown in the figure below.

Fig. 6-65 Temperature switch and humidity switch in the main control cabinet

394
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Fig. 6-66 Check set value of main control cabinet monitor electric relay

Table 6-20 Check detailed list for safety device

Code Definition Setting value
Coating fan temperature +40℃
ST
Heater working temperature 0℃
SRH Heating humidity RH +80%
Overvoltage protection value(>U) 420V
Undervoltage protection value(>U) 340V
Delay time 2S
KAU1

Operating mode Reset delay + no phase sequence

monitoring

395
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Maintenance for cabin

◼ Check if the wiper is well, glass is clean, or the vision is clear;
◼ Check if there is proper fire extinguisher in the cabin;
◼ Check if the functions of the operating panel in the cabin are well;
◼ Check if all the electrical components in the cabin are well connected.

Maintenance for safety device

Every limiter and sensor require to calibrate and recalibrate definite value during every erection.

Table 6-21 Check detailed list for safety device

Inspection cycle Inspection item

Location of limiter:
Maximum trolley position for trolley (jib length);
Minimum trolley position for trolley;
Daily operate before check Upper stop position for hook;
Hook stop position at bottom according require;
Load capacity/moment limiter: over load alarm for load limiter,
load moment;
Location of limiter:
Maximum trolley position for trolley (jib length);
Minimum trolley position for trolley;
Upper stop position for hook;
Bottom stop position for hook;
Load capacity:
Check each erection and
inspection cycle (suggest Check the accuracy of the load capacity display (Sling the

cycle is 2-3 weeks) known load);

Check the accuracy of mechanism load limiter is triggered
Check the accuracy of mechanism moment limiter is triggered
(constant load for variable radius, constant radius for variable
load);
Check the percentage accuracy of mechanism moment limiter
display (Take the mechanism moment limiter for refer);
Every mechanism requires to recheck and recalibrate when
change hoisting rope, trolley, hoisting mechanism, trolley
mechanism, load sensor and other relevant safety parts.
Out of inspection cycle
Recalibrate if the jib change length

Recalibrate after climbing operation

396
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.16 Spare parts list

The spare parts can be selected with price increase. Those adding “*” in the serial number rod
are wearing parts.

Spare parts list of mechanism

Spare parts list of hoisting mechanism

No. Order No. Designation Code Install position Qty
1 1039905711 Brake SPZ600A (600) 1
000209195A1
2 Coupling GR55-120-12T-C 1
502000
H45FC30-600C
3 1090101550 Rope ZLHHK-14-1960 -
(000209195A1500000)
4 1021500582 Limiter DXZ-4/360 1
ETF100-H
5 1020202010 Encoder 1
(Nr:851223/0.8)

Spare parts list of trolley mechanism

No. Order No. Designation Code Install position Qty
1 1031700142 Brake DLTZ3-80 1
000209321B0
2 Coupling GR28-65-1 T55FC70-b / 1
002000
T55FC70-b(D)
000209301E0 Nylon gear
3* GR28 (000209370A4400000/ 1
003002 ring
000209370A5000000)
4* 1090100080 Rope 6×19-9.3-1700-Ⅱ-sZ -
5 1029902431 Limiter DXZ-4/4 1

Spare parts list of slewing mechanism

No. Order No. Designation Code Install position Qty
1 1999900214 Limiter DXZ-4/3 1
1029805619 DDZ-175/DFB
2 /1029908241 Brake /DXM3-80XLY S75CA-130LB12/14A 1
/1039905754 /SPZ100.0 (000209289A6700000)

1039905750 DDZ-175BM-01 S75CN-130LB12/14A

Friction (000209289A6800000)
3 /1039905758 /DXM3-80XLY-02
disk
/1039905756 /SPZ100.2
4 1020202072 Encoder ECK58B(Nr:851249/10) 1

397
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Spare parts list of travelling mechanism

Table 6-22 Travelling mechanism

No. Order No. Designation Code Install position Qty

1 000209401A0000003 Buffer sleeve 000209401A0000003 -

22220C
2 1050200326 Bearing -
(1050200326)
Travelling
3 1030200210 TX25(1030200210) -
reducer
YTXZ112M2-2B- Travelling
4 1020000154 Motor -
5.2KW mechanism
Bearing seat (Only use in
5 000209401A0000034 000209401A0000034 travelling -
Ⅰ
crane)
Bearing seat
6 000209401A0000040 000209401A0000040 -
Ⅱ
Travelling
7 000209401D1000036 000209401D1000036 -
wheel
Travelling
8 1020500695 XCR-F17 -
switch
M822 cable
M822 cable
drum (Only
drum collect
9 1029901693 K530 use in 1
point ring
travelling
inner core
crane)

398
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

Spare parts list of electrical control system

Table 6-23 Spare parts list of electrical control system

No Order No Designation Code Qty

1 1020104382 Programmable controller TCH100 1

Electric measuring and monitoring
2 1020303383 CM-PVS.41 1
relay
3 1022001015 Phase sequence monitor CM-PFE 1

4 1021901007 Transformer ST10 1

5 1020005712 Frequency converter rectifier unit MD810-20M4T45G100-ZL 1

6 1020005715 Frequency converter inverter unit MD810-50M4T11G200-ZL 1

7 1020005719 Frequency converter inverter unit MD810-50M4T37G200-ZL 1

8 1020005723 Frequency converter inverter unit MD810-50M4T90G200-ZL 1

9 1020305420 Contactor DILM9-10N(230V 50/60Hz) 1

10 1020304815 Contactor DILM225A/22(RAC240) 2

11 1029905404 Relay DILM225A-XHB 5

12 1020303114 Relay seat AHN22324 5

13 1020304036 Power switch AHNA21 1

14 1020903400 Power switch CP-PX-24/10.5 1

15 1029906858 Breaker NDR-480-24 1

16 1020602716 Breaker BKN 3P C16A 1

17 1020604531 Safety monitoring system v6.0 1

399
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

Spare parts list of structure

Table 6-24 Spare parts list of structure

Install position Designation Order No. Code Qty

Trolley, Hook, Jib HL-400-340-55-

Pulley 000209906A0040028 9
section Ⅰ 110-7.5

Pulley (HL-400-340- 6212-2RS1

Bearing 1050201562 18
55-110-7.5) (GB/T276-2004)
Jib sectionⅠ, Ⅲ, Ⅴ, 214-178-B41-80-
Pulley 000209906A0017000 4
Jib end R6

Pulley(214-178-B41- 6208-2RS1
Bearing 1050201563 8
80-R6) (GB/T276-2004)
Trolley Trolley idler wheel 000209704A0100007 4
6207-RS1
Trolley idler wheel Bearing 1050201328 8
(GB/T 276-1994)
Trolley Trolley side roller 000209705A0001400 FXC08B-14 4
6004-2RS1
Trolley side roller Bearing 1050201565 8
(GB/T276-2004)
Pulley (HL-450-380-
Retaining ring 130 1040300281 GB/T893.2-1986 9
80-130-R8.5)
Pulley(214-178-B41-
Retaining ring 80 1040300322 GB/T893.2-1986 4
80-R6)
Trolley idler wheel Retaining ring 110 1040300283 GB/T893.2-1986 8
Trolley side roller Retaining ring 42 GB/T893.2-1986 8
Trolley Buffer block 000209708A0001063 4
Thrust ball
Hook 1050200505 GB/T301-1995 1
Bearing 51313

400
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

6.17 Appendix troubles and troubleshooting

Common troubles and troubleshooting of the crane
No. Trouble Troubleshooting Solution
a) Check the oil surface,
adjust the height if
The temperature
a) Excessive lubrication oil necessary.
of the reduction
1 b) Oil is old-fashioned b) Figure out the time of last
gearbox is too
c) Oil is grievously polluted oil change, change oil if
high.
necessary.
c) Change the type of oil.

The temperature a) Excessive or deficient grease.

a) Properly replace grease
of the reduction b) Poor grease quality.
b) Re-adjust the bearing
2 gearbox c) Improper axial clearance of the
clearance
bearings is too bearings or bearings is already
c) Replace bearings
high. damaged.
a) Leakage from the input and
output shaft end of the reduction
gearbox.
Oil leakage from a) Replace sealing rings.
b) The strainer of the air cleaner is
3 reduction b) Clean the strainer.
blocked.
gearbox c) Reseal.
c) The sealing rings of end covers
or the matching surface is
sabotaged.
a) Check the line of the
a) The rotary direction of the motor
motor.
is wrong.
b) Remove the main valve
b) The escape valve is blocked by
No output from and clean it with kerosene.
unclean oil.
the pump c) Remove the pipe and weld
c) Tube leakage.
station/ cannot the broken part or exchange
d) Pipe connections become
4 be adjusted to it.
flexible.
rated pressure/ d) Screw the pipe
e) The sealing parts of the pipe
the pressure is connection.
connections are broken.
not steady. e) Exchange the seal washer.
f) Coarse strainer is blocked.
f) Clean the strainer.
g) The pump station is damaged
g) Exchange the pump
by long-time over load.
station.

Climbing a) Terminals and breakers be a) Check the line and rewire

mechanism loosed. the circuit by electrical
5
motor does not b) The breaker tripped or burned schematic diagram
rotate when by overload or short circuit b) Repair or replace the

401
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

power on breaker by checking the
contacts and electromagnetic
trip;
a) Repair or replace the
a) Worn oil pump, declined
damaged parts
efficiency
b) Fill adequate oil or clean
b) Oil in the tank is insufficient or
oil filter
Climbing speed oil filter clogged
6 c) Exchange the hand-
is too slow c) Hand-operated valve rod and
operated valve or the worn
valve hole severely worn
parts.
d) Oil cylinder piston seal is
d) Reseal the oil cylinder
damaged and internal oil leakage.
piston.
a) Severe internal leakage from oil
a) Repair or replace the worn
pump
parts
Climbing force is b) Overflow valve pressure set too
b) Adjust pressure as
7 not adequate or low
required
unable to jack c) Hand-operated valve core
c) Clean hydraulic valve.
excessively worn
d) Exchange overflow valve.
d) Overflow valve clogged down
Noise and
vibration occur
during climbing
8 Oil filter clogged Clean oil filter
operation at
increasing
pressure
Climbing system Motor rotation and oil pump Change motor rotation
9
is not working rotation both in wrong directions direction
Creeping and
a) Air not completely exhausted
quivering during a) Exhaust air as required.
10 from oil cylinder piston
climbing b) Adjust guide pulleys
b) Trouble with guide mechanism
operation
Adjust guide
12# Trouble with guide mechanism Exhaust air as required.
pulleys
a) There are troubles with balance
Climbing drop valve of the cylinder head. a) Remove trouble
11
when loaded b) Piston sealing of oil cylinder is b) Replaces sealing parts
damaged
No response a) Power supply is break wrong a) Check if power supply
12 from crane when phase led to Phase Sequence quality and Phase Sequence
start button Relay action, or phase-sequence Relay is good

402
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

No. Trouble Troubleshooting Solution

relay action is caused by power b) Repair or change It;
mis phase, or power supply is c) Switch on again;
abnormal, causing the operation of d) Repair or change it;
the voltage monitoring relay e) To solve on the site;
b) Console zero switch is broken; f) Turn the emergency stop
c) Breaker QF, etc. trip; button clockwise, make it
d) Contactor KMC not fit; reset circuit;
e) Power-off; g) If the plug loose, screw up
f) Emergency stop button (locate it; The falling plug cannot
in the right console and side of indiscriminate, installing the
main control cabinet) not reset; plug according to the
g) The loose aviation plugs below installed groove;
the console or the plug had been
fallen.
a) The wrong power phase a) Check the power phase
Sequence; Sequence or after turn off the
b) Power lack phase (The circuit total power supply on the
Response from breakage or burn out insurance); box, any replacement the two
crane when start c) The bad quality of phase position of U2, V2, W2;
13 button, but Sequence Relay action and b) Contact the site to solve
cannot start undervoltage Relay action; and replace insurance;
normally d) The setting voltage range is c) Replacement;
wrong from the of undervoltage d) Adjust voltage on the
Relay action; undervoltage Relay action;
e) The bad quality of power; e) Check the power;
After pressed
the start button,
Batteries in programmable Logic
the buzzer is Inform the company rapidly
14 Controller is about to use up (life
ringing, the to change it
span is usually 5 years)
handle no any
reaction
a) The instability performance of a) Adjust voltage of the
phase Sequence Relay action or undervoltage Relay action or
The instability the undervoltage Relay action Replacement;
after starts the setting voltage range is wrong; b) If the power insufficient or
crane, total b) The instability power supply on lower approximate value,
15
contactor pops the site (insufficient or lower improve and increase the
up again and approximate value of power), (start power supply; If the power
again the motor, measure the voltage sufficient, then it needs to
value from the total power supply increase the wire cross
with the multimeter, vary greatly). section or shortened guide

403
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

The Power sufficient (start the distance.
motor, measure the voltage value c) Check each join point of
from the total power supply with the aviation plug, if it is loose,
the multimeter, very little); tighten it.
Aviation plug is loose, cause the
bad start circuit contact.
a) Replace the leakage
switch, use formal
a) Leakage switch (include total
manufacturer’s switch;
leakage switch, three-level
b) Repair motor;
leakage switch) problem;
c) Check each cable,
b) Motor insulation is damaged or
especially the cable at the
The leakage Short circuit in the interturn
16 slewing; Whether there is
switch trips c) The wear cable (Cut off the total
damage and grounding of
power supply, leakage switch still
main cable, Whether the
trips);
insulate layer of cable join is
d) Leakage protector selection is
damage;
too small;
d) Replace the leakage
protector with larger capacity;
a) Cut off power, wait 1
a) Frequency converter internal
minute and try to restart;
protect;
Hoisting b) Check the situation of
b) Rotary encoder connection wire
17 mechanism wire;
loose;
cannot start c) Check Whether the limiters
c) Load limiter, moment limiter and
wire correct, reduce load
Hoisting limiter cause;
capacity;
a) Dismantling and check,
observe whether the brake is
a) Brake not open;
open and remove stoppage;
b) Leak of oil in the coupler;
Check whether the contactor
c) Motor damage;
KSB movement;
d) The wind is strong and runs
b) Filling regulation model oil
against the wind;
for coupler;
Slewing atony or e) Slewing circuit breaker QFS
18 c) Replace the motor;
Slewing static trips;
d) When the wind is weak or
f) The damage of control parts;
downwind movement;
g) Rotary encoder connection wire
e) Re-closing switch;
loose;
f) Replace;
i) Frequency converter damage;
g) Check the situation of
j) Left(right) stop limiter trigger;
wire;
i) Replace;

404
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

No. Trouble Troubleshooting Solution

j) Reverse turn.
a) Check the uniformity of the
a) Friction between stator and clearance between stator and
rotor. rotor.
b) The shaft of the motor and the b) Check the concentricity. If
shaft of the gear box is not it is too large, adjust it.
Noise and
concentric. c) Check the circumstance of
vibration occur
19 c) Bearings are in oil deficiency or the bearings. If they are
to trolley
broken. broken, exchange them. If
mechanism
d) Gear box is in oil deficiency. they lack oil, refuel the
e) Gear friction. corresponding oil.

f) There are abnormal noises d) Refuel the stated oil.

during two-phase performance. e) Exchange the gear.
f) Cut off the power and fix it.
The temperature
of the bearings a) The bearings are broken. a) Exchange the bearings.
20 in trolley b) The grease is deteriorative or of b) Clean the bearings and
mechanism is bad quality or too few. exchange the grease.
too high.
a) The power line or the ground
a) Check the connection.
The trolley connection is wrongly connected.
b) Make sure that grounding
21 mechanism is b) Defective grounding.
condition is well.
Charged. c) The line of the motor is broken
d) Figure out and adjust.
and grounding.
The brake of the
a) The brake torque is too low.
trolley a) Exchange the brake spring
22 b) The clearance of the brake
mechanism is b) Adjust the clearance.
plate increases.
out of service.
a) Overload. a) Measure the current of the
b) Continuous load or irregular stator. If it is over rated
working. figure, reduce load.
The motor of the c) The two phases are far away. b) Operate under order.
trolley d) The voltage is too low or too c) Measure the three-phase
mechanism is high. current and clear troubles.
23
smoking or of e) Motor winding is earthed or d) Check the input voltage
high cutting-out and clear troubles.
temperature. f) The clearance between friction e) Figure out reasons and
plates is wrong clear troubles.
g) The time of braking and f) Adjust the clearance based
releasing is wrong. on regulation.

405
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

h) The air gallery of the motor is g) Check the voltage of the
blocked, so the temperature rises. brake and the movement
i) The brake is opened time of delay time chopper,
unthoroughly or is closed so that then clear troubles.
the motor is unmoved and emit h) Unblock the air gallery
heat. i) Adjust the brake under
regulation.
a) Check the lubrication of
the pulley, if the grease is
found to be dry, remove it
manually, and then apply the
new grease; If the ambient
temperature is too low and
the grease is too dry, add
a) Poor lubrication of the guide
dilute oil to the pulley (check
The bad rope pulley causes the pulley stuck and
every day, and add dilute oil
pay-off of drum unable to play a good guiding role;
24 if necessary);
and rope b) The upper layer rope of on the
b) Check whether the first
jumping drum is pressed into the lower
layer of steel rope is tight. If
layer;
not, the first layer rope must
be tight, as far as possible
with a certain load (2% of the
minimum breaking pull of
rope or 10% of the current
rated hoisting weight) to pay-
off rope 2%;
The circuit
The rate current of the switch is
25 breakers trip Replace with a larger switch
too small
frequently
a) The performance of the phase a) Adjust the voltage of the
sequence relay is unstable or the phase sequence relay or
voltage range on the phase replace it directly;
sequence relay is incorrectly set; b) If the power supply of the
The crane b) The power supply at the site is site is insufficient or small, the
started unstable; unstable: The power supply at the site shall be required to
26 the total site is insufficient or small (when improve the power supply the
contactor pops starting the motor, the multimeter is power supply, if the power
out repeatedly. used to measure the voltage supply at the site is sufficient,
fluctuation at the total power it is necessary to increase the
supply, which changes greatly); section of the wire or shorten
The power supply at the site is the distance of the wire;
sufficient (when starting the motor, c) Check the connecting

406
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

No. Trouble Troubleshooting Solution

use a multimeter to measure the points of the aviation plug,
voltage fluctuation at the total and tighten them if they are
power supply, the changes is very loose.
small)
c) The aviation plug is loose, so that
the general starting line is in poor
contact.
The hook of
There were Electromagnetic Please use Nylon sling with
27 tower crane with
transmission tower in the vicinity Standard
power
a) Limiter (Hoisting, moment, load)
does not properly connect to the a) Rewire the limiter circuit
circuit b) Rewire the circuit
b) Cooperative console bad c) Repair or replace the PLC
connected to the PLC d) Repair or replace the
28 No hoisting
c) PLC’s input point damaged cooperative console
d) Contact of Cooperative console e) Repair or replace the relay
damaged f) Repair or replace the
e) Relay fault Inverter
f) Inverter fault
a) Check the contacts of the
a) The command of the
Cooperative console; check
Cooperative console is incorrect
Lighting has no the input of the PLC
29 b) 50% Weight limit
high speed b) Check the contactor of the
c) The loose of KHH let the KHB
limiter
remain open
c) Replace the KHH
a) Adjust and check the
a) Slewing limiter;
slewing limiter and circle;
b) Cooperative console bad
b) Check whether the nut of
connected to the PLC;
the switch connector is loose;
c) Inverter fault;
d) Dismantling the string of
d) Motor rotators damage; rotators, still turning, rotators
e) The two slewing motor wiring string cutting-out; When there
Cannot turn left
30 faults; is a big gap between the
or right slewing
f) Slewing circuit breaker QFS trip; rotators three-phase voltage
g) The damage of control parts; and the nameplate voltage,
h) Rotary encoder connection wire repair the motor rotators or
loose; replace the motor;
i) Left(right) stop limiter trigger; e) Replace the Phase
j) Brake not open; Sequence of the reverse
movement motor power circle

407
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

wire;
f) Re-closing switch;
g) Replace;
h) Check the situation of
wire;
i) Reverse tur;
j) Refer the principal picture,
check the circle of the brake;
a) Replace contactor;
b) Check whether the
Contactor a) Contactor circle exist 220V;
31 interlocking contactor
cannot fit b) Contactor circle without 220V;
breakover, replace contactor
if cannot breakover;
a) Adjust the frequency of the
Slewing has not a) Wrong setting of the Inverter;
32 Inverter;
high speed b) Slewing limiter trigger;
b) Check slewing limiter
a) Repair or replace the
No braking when power off
contactor KSB; Repair or
No braking even normal operation
replace the console cable;
a) KSB cannot fit normally;
Replace slewing brake
b) Electromagnetics brake switch;
Slewing cannot
33 excessive gap;
brake b) Adjust the gap of the
c) Electromagnetics brake No Electromagnetics brake;
magnetic force;
c) Replace electromagnetics
d) The rectifier module is damaged brake;
there is no output voltage;
d) Replace rectifier module;
a) The limiter or corresponding line a) Adjust limiter or check the
is damage; circuit;
b) Input of console to PLC without b) Reconnect the circle wire
normal breakover; or replace the air cable;
c) Console contact point damage; c) Replace or repair the
d) PLC fault; console;
Trolley stop e) Trolley brake cannot open, d) Replace or repair the PLC;
34
running Incorrect brake gap e) Adjust the gap of trolley
f) The circle of the brake cable brake to 0.8~1mm;
without contacts and disconnect; f) Reconnect the cable of
g) Main contact point of KVB electromagnetics brake;
contactor damage; g) Move the KVB contactor
h) There is AC input but no DC main point;
input in the rectifier module; h) Replace the rectifier

408
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

No. Trouble Troubleshooting Solution

module;
a) Reduce the lifting weight
a) Torque limited
Trolley has not b) Normal work
35 b) Trolley limited
high speed c) Check the Cooperative
c) Cooperative console fault
console
a) Replace the bearing;
a) The bearing damage;
b) Adjust the rope rod or
Noise occurs to b) Rope interferers with pulley arc
avoid interferers or remove
36 trolley rope rod;
rope rod and re-welded it;
mechanism c) The slight interferers between
c) Replace the shorter rollers
cover(roller) and jib;
locating sleeve;
a) The bearing damage;
a) Replace the bearing;
Hook head b) There is mud between the nut
b) Clean the mud between
37 cannot rotate and beam, increasing friction the
the nut and beam;
360° nu;
c) Installed bearing correctly;
c) Bearing installed opposite;

(2) Common troubles and troubleshooting of Huichuan frequency converter

No. Trouble Troubleshooting Solution
a) The input circle of frequency a) Troubleshooting
converter exists grounding or peripheral faults
short circuit; b) Click parameter
b) The control mode is identification;
parameter identification without c) Prolong accelerated
vector; time;
c) Accelerated time too short; d) Adjust the manual
Accelerated d) Manual torque lift or V/F torque lift or V/F curve;
02#
overcurrent curve unsuitable; e) Adjust the voltage to
e) Low voltage; normal range;
f) Start the point that is being f) Start speed tracking up
rotated; or motor stop;
g) Sudden loading during g) Cancel sudden loading;
acceleration; h) Choose a more
h) Frequency converter powerful frequency
selection is small; converter;

409
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

a) The input circle of frequency
a) Troubleshooting
converter exists grounding or
peripheral faults;
short circuit;
b) Click parameter
b) The control mode is
identification;
parameter identification without
c) Prolong accelerated
Decelerate vector
03# time;
overcurrent c) Decelerate time too short;
d) Adjust the voltage to
d) Low voltage
normal range;
e) Sudden loading during
e) Cancel sudden loading;
deceleration;
f) Choose a more powerful
f) Frequency converter
frequency converter;
selection is small;
a) The input circle of frequency
converter exists grounding or a) Troubleshooting
short circuit; peripheral faults;
b) The control mode is b) Click parameter
parameter identification without identification;
Constant speed vector c) Adjust the voltage to
04#
overcurrent c) Decelerate time too short; normal range;
d) Low voltage d) Cancel sudden loading;
d) Sudden loading during e) Choose a more
operation; powerful frequency
e) Frequency converter converter;
selection is small;
a) Adjust the voltage to
a) Input voltage high; normal range;
b) During the acceleration, b) Cancel the additional
external forces drag the motor force or add brake
Accelerated
05# to run; resistance;
overvoltage
c) Accelerated time too short; c) Prolong accelerated
d) No brake unit and brake time;
resistance; d) Add brake unit and
resistance;

410
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

No. Trouble Troubleshooting Solution

a) Adjust the voltage to
a) Input voltage is high; normal range;
b) During the deceleration, b) Cancel the additional
external forces drag the motor force or add brake
Decelerate
06# to run; resistance;
overvoltage
c) Decelerate time too short; c) Prolong decelerate
d) No brake unit and brake time;
resistance; d) Add brake unit and
resistance;
a) Adjust the voltage to
a) Input voltage is high;
normal range;
Constant speed b) During the deceleration,
07# b) Cancel the additional
overvoltage external forces drag the motor
force or add brake
to run;
resistance;
Control power a) Input voltage is out of a) Adjust the voltage to
08#
damage regulation arrange; normal range;
a) Reset the fault;
a) Instantaneous power failure; b) Adjust the voltage to
b) frequency converter input normal range;
voltage is out of specified c) Seeking technical
range; support;
09# Undervoltage damage c) Bus voltage is abnormal; d) Seeking technical
d) The rectifier bridge and support;
buffer resistance are abnormal; e) Seeking technical
e) Abnormal drive board; support;
f) Abnormal control board; f) Seeking technical
support;
a) Reduce load and check
a) Heavy load or motor motor and mechanical
Frequency converter blocking; condition;
10#
overload b) Frequency converter b) Choose a more
selection is small; powerful frequency
converter;

411
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

a) Set this parameter
a) Motor protection parameters correctly;
bE.01 are incorrectly set; b) Reduce load and check
b) Heavy load or motor motor and mechanical
11# Motor overload
blocking; condition;
c) Frequency converter c) Choose a more
selection is small; powerful frequency
converter;
a) Check and eliminate the
a) Three-phase power supply is problems in peripheral
abnormal; circuits;
b) Abnormal drive board; b) Seeking technical
12# Input lack phase c) The surge protection board is support;
abnormal; c) Seeking technical
d) Abnormal main control support;
board; d) Seeking technical
support;
a) The ambient temperature is
a) Lower the ambient
too high;
temperature;
b) Air duct blockage;
b) Clean duct;
14# Module over hot c) Fan damage;
c) Replace;
d) The module thermistor is
d) Replace;
damaged;
e) Replace;
e) Inverter module damage;
a) Drive board and power
a) Replace;
17# Contactor damage supply fault;
b) Replace;
b) Contactor fault;

Current detection a) Hall device anomaly a) Replace;

18#
damage b) Abnormal drive board; b) Replace;
a) Set the correct motor
a) Motor parameter is not set parameter according to
according to the nameplate; nameplate;
19# Motor tuning damage
b) Parameter identification b) Check the down-lead
overtime; form frequency converter
to motor;

412
WA7025-12E-138EN-B03 MAINTENANCE AND INSPECTION

No. Trouble Troubleshooting Solution

a) Set the encoder model
a) The encoder model does not
according to actual
match;
situation;
20# Encoder damage b) Encoder connection error;
b) Remove circle line fault;
c) Encoder damage;
c) Replace;
d) PG card fault;
d) Replace;
The motor shorted to the
23# Ground damage Replace cable or motor;
ground;
a) Troubleshooting
a) Abnormal down-lead form
peripheral faults;
frequency converter to motor is
b) Check the three-phase
abnormal;
motor winding and remove
b) The three-phase frequency
25# Input lack phase fault;
converter output is abnormal
c) Seeking technical
when the is running;
support;
c) Abnormal drive board;
d) Seeking technical
d) Abnormal module;
support;
Check the motor
parameter setting are
If the given operation frequency
correct;
Abnormal frequency is opposite direction to the
37# Check whether the load
direction motor feedback the fault will be
heavy;
invalid by factory default;
Adjust the setting of
bC.02;
Check the motor
parameter setting are
The following error between correct;
Abnormal frequency
38# frequency and motor feedback Check whether the load
follow
frequency is too large; heavy
Adjust the setting of bC.03
and bC.04;
a) Reduce load and check
a) Heavy load or motor motor and mechanical
blocking; condition;
40# Current limiting fault
b) Frequency converter b) Choose a more
selection is small; powerful frequency
converter;

413
MAINTENANCE AND INSPECTION WA7025-12E-138EN-B03

No. Trouble Troubleshooting Solution

Check the brake circuit
connection;
The input of the loose brake Check the function
41# Loose brake fault
feedback signal is incorrect; selection of the feedback
input point of the control
loose brake;
Check the brake circuit
connection;
The input of the closed brake Check the function
42# Closed brake fault
feedback signal is incorrect; selection of the feedback
input point of the control
closed brake;
Adjust the setting of b0.00
Shaft-cooled motor and b0.01;
43# runs overtime at low Pay attention to protect
speed the motor from
overheating;
Check the peripheral
The forward and circuits at the forward and
The frequency converter
reverse operation reverse operation
44# detected forward and reverse
instruction are valid command input points;
operation instructions
simultaneously Appropriately improve the
terminal filtering time;
Ensure that the signal
from the standby normally
on input point is valid
When the frequency converter
during power-on;
45# Control rod is not zero is power on, a given frequency
Wait until the system
signal is detected;
initialization is complete
before entering
commands.

414
 WA7025-12E-138EN-B03 SPARE PARTS

7 SPARE PARTS
7.1 Foreword
Dear Users:
If you need maintenance or fittings for your equipment, please check the order number and the
designations of the parts you need in the spare parts manual at first, and inform the local after-
sales department of ZOOMLION.

7.2 Configuration of the tower crane

Fig. 7-1 Parts indications of the WA7025-12E Tower Crane

415
SPARE PARTS WA7025-12E-138EN-B03

Table 7-1 Spare parts list of the WA7025-12E Tower Crane

No. Designation Order No. Code Notes Qty
1 Outrigger 000200615J0001000 TC6517C.15B 4/0

Base tower 000209012A2300000 L68G23 Rung ladder

2 1/0
section 000209012A9200000 L68G23-C Incline ladder

000209012A2600000 L68A4 Rung ladder 17

3 Tower section
000209012A3600000 L68A1A Incline ladder 17
4 Passageway J 000209014A1300000 L68TDJ Rung ladder 9
5 Passageway H 000209014A1200000 L68TDH Rung ladder 8/9
6 Climbing equipment 000261811AT000000 WA7527-20D.11 1
Climbing
7 000210612BT000000 TCT6527-16E.12A 1
mechanism
Climbing hydraulic YG180/125-
8 000200429A0100000 1
cylinder 2160/1640-31.5
9 Pump station 000209501A8700000 BZ-11-31.5F 1
F02WA0A0181806-
1140220834 1
3000
10 Hose assembly
F02WA0A0181806-
1140220835 1
4000
Unitary,90°
11 Erection platform 000270320BT000000 T6513-8E.20A 1
connector
12 Mounting device 000270319AT000000 T6513-8E.19 1
13 Transition section 000209012B3800000 L68C3B Unitary 1
14 Slewing support 000281710DT000000 WA7025-12E.10 1
15 Slewing ring 1031500447 QWA1600.50Z5 1
16 Turntable 000281709BT000000 W7025-12KA.09A 1

Slewing 000209289A6700000 S75CA-130LB12/14A

17 1
mechanism 000209289A6800000 S75CN-130LB12/14A

18 Slewing Limiter 000209905B0007000 HZXW.6A 1

WA7025-
19 Counter jib 000281701FT000000 1
12E(Abroad).01A
20 Central ballast 000271799AT010000 WA7025-10/12-PHZ 1
21 Derrick 000209914B0006000 TCBG1500.1A Optional 1
Hoisting
22 000209195A1500000 H45FC30-600C 1
mechanism
23 Cabin 1139804016 CM6-A 1
24 Trolley 000209370A4400000 T55FC70-b 1

416
 WA7025-12E-138EN-B03 SPARE PARTS

No. Designation Order No. Code Notes Qty

mechanism 000209370A5000000 T55FC70-b(D)
WA7025-
25 Jib 000271705CT000000 1
10E(Abroad).05
26 Trolley 000209707L0100000 XC12N 1
27 Hook 000209607A1900000 DG12H 1
000200614D1000000 TC6517B-10E.14 Rung ladder
28 Stationary chassis WA7025- Incline 1/0
000281714AT000000
12E(Abroad).14 ladder

Tower section 000209012A2800000 L68B7A Rung ladder 1/0

29
(for chassis) 000209012A4000000 L68B7A-C Incline ladder 1/0
Powered wheel
30 000209401D1000000 ZA52-D 2/0
bogie
31 Idler wheel bogie 000209402D1000000 B52-D 2/0
000200623A1000000 TC6517B-10E.23 Rung ladder
32 Travelling chassis WA7025- Incline 1/0
000281723AT000000
12E(Abroad).23 ladder
33 Cable Drum 000209940A0000010 M822 1/0
34 Central ballast 000220699A0200000 TC6517B-10E-YZ 1/0

417
SPARE PARTS WA7025-12E-138EN-B03

7.3 Jib

Fig. 7-2 000271705CT000000

418
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-2 Spare parts list of Jib (WA7025-10E(Abroad).05)

No. Order No. Code Designation Specification Qty
1 000271705CT001000 JibⅠ 1
2 000219705AR002000 JibⅡ 1
3 000271705DT003000 JibⅢ 1
4 000219705AR004000 JibⅣ 1
5 000270505CT004000 JibⅣ 1
6 000219705AR006000 JibⅥ 1
7 000270505CT006000 JibⅥ 1
8 000290505AR006000 JibⅥ 1
9 000290505AR008000 JibⅧ 1
10 000201705AL009000 Jib end 1
11 000209910A0161601 XZ03B-16×160/175 Pin 16×160 2
12 1040500228 GB/T91-2000 Split pin 4×32 4
13 000271605DT000010 Pin tray 1
14 000270505CT000010 Pin tray 1

419
SPARE PARTS WA7025-12E-138EN-B03

JibⅠ

Fig. 7-3 000271705CT001000

Components No.19 and 21 are exploded in other drawings

420
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-3 Spare parts list of JibⅠ

No. Order No. Code Designation Specification Qty
1 000271705CT001100 Jib Ⅰ structure 1
XZ04D-
2 000209910A4202903 Pin 100×290 1
100×290/370A
3 1040500646 GB/T91-2000 Split pin 13×140 2
4 000231705AT003002 Pin Φ16×110/125 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT002001 Pin 80×201/255 2
7 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
8 1040200110 GB/T6170-2000 Nut M16-8 4
9 1040300065 GB/T93-1987 Washer 16 4
10 1040300052 GB/T97.1-2002 Washer 16-200HV 8
11 000261705AT001020 Platform 2
12 1040002440 GB/T5783-2016 Bolt M12×45-8.8 14
13 1040200096 GB/T6170-2000 Nut M12-8 14
14 1040300728 GB/T95-2002 Washer 12-200HV 28
15 1040300054 GB/T93-1987 Washer 12 14
16 000261705AT001030 Platform 1
17 000209910A1081701 XZ01C-40×170/195 Pin 40×170 2
18 1040500222 GB/T91-2000 Split pin 8×80 6
19 000251705BT001800 Hoisting pulley 1
20 000209910A1081001 XZ01C-40×100/125 Pin 40×100 1
21 000261605BT001400 Trolley pulley 1
22 1040500253 GB/T91-2000 Split pin 5×32 4
23 000250801AT010003 XZ03B-20×135/155 Pin 20×135 1
24 000209910A1081301 XZ01C-40×130/155 Pin 40×130 1
25 000203003AR000006 XZ01A-25×55/80 Pin 25×55 2
26 1040500216 GB/T91-2000 Split pin 6.3×50 2
Load limiter
27 000251705BT001900 1
bracket
28 000209910A3041801 XZ03B-20×180/200 Pin 20×180 1
29 000209910A1071501 XZ01C-35×150/175 Pin 35×150 2
30 000209912A0000013 Washer 2
31 000261705AT001040 Platform 1
Detachable
32 000222705AT001010 1
bumper block
Detachable
33 000222705AT001020 1
bumper block

421
SPARE PARTS WA7025-12E-138EN-B03

Hoisting Pulley

Fig. 7-4 000251705BT001800

422
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-4 Spare parts list of Hoisting Pulley

No. Order No. Code Designation Specification Qty
1 000209910A4051421 XZ03A-25×145/175 Pin 25×145 1
2 1040500216 GB/T91-2000 Split pin 6.3×50 2
3 000209709A0001003 Plate t10 1
4 1040000090 GB/T5783-2000 Bolt M10×30-8.8 2
5 1040300067 GB/T93-1987 Washer 10 2
Hoisting pulley
6 000251705BT001810 1
bracket
HL-450-380-80-
7 000209906A0040035 Pulley 1
130-R8.5
8 1050202084 GB/T276-2013 Bearing 6312-2RS 2
9 000251705BT001801 Pin Φ60×134/176 1
10 000201105B0000402 Bushing 2
11 1040300281 GB/T893.2-1986 Retaining ring 130 2

423
SPARE PARTS WA7025-12E-138EN-B03

Trolley Pulley

Fig. 7-5 000261605BT001400

Table 7-5 Spare parts list of Trolley Pulley

No. Order No. Code Designation Specification Qty
Trolley pulley
1 000270705AT001040 1
bracket
2 000261605BT001410 Pulley 1
3 000270405DT003001 Pin Φ40×68/100 1
4 000210105A0010002 Bushing 2
5 000210105A0010001 Shaft-end baffle t6 1
6 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
7 1040300067 GB/T93-1987 Washer 10 2
8 000209910A0000515 XZ03A-12×80/95 Pin 12×80 2
9 1040500228 GB/T91-2000 Split pin 4×32 4

424
 WA7025-12E-138EN-B03 SPARE PARTS

JibⅡ

Fig. 7-6 000219705AR002000

Table 7-6 Spare parts list of JibⅡ

No. Order No. Code Designation Specification Qty
1 000219705AR002100 JibⅡ structure 1
2 000209910A4162701 XZ04D-80×270/335 Pin 80×270 1
3 1040500646 GB/T91-2000 Split pin 13×140 2
4 000231705AT003002 Pin φ16×110/125 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231705AT002001 Pin 70×177/220 2

425
SPARE PARTS WA7025-12E-138EN-B03

JibⅢ

Fig. 7-7 000271705DT003000

Table 7-7 Spare parts list of JibⅢ

No. Order No. Code Designation Specification Qty
1 000271705DT003100 Jib Ⅲ structure 1
2 000209910A4162401 XZ04D-80×240/305 Pin 80×240 1
3 1040500646 GB/T91-2000 Split pin 13×140 2
4 000231705AT003002 Pin φ16×110/125 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231705AT003001 Pin 70×160/205 2

426
 WA7025-12E-138EN-B03 SPARE PARTS

JibⅣ

Fig. 7-8 000219705AR004000

Table 7-8 Spare parts list of JibⅣ

No. Order No. Code Designation Specification Qty
1 000219705AR004100 Jib Ⅳ structure 1
2 000209910A4121601 XZ04C-60×160/220 Pin 60×160 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000270405AT002001 Pin 60×143/190 2
7 000209906A0017000 214-178-B41-80-R6 Pulley 1
8 000210105A0010002 Bushing 2
9 000210105A0010001 Shaft-end baffle t6 1
10 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
11 1040300067 GB/T93-1987 Washer 10 2
12 000270405DT003001 Pin φ40×68/100 1
Deep groove
13 1050201563 GB/T276-2004 6208-2RS1 2
ball bearing
14 1040300322 GB/T893.2-1986 Retainer ring 80 2

427
SPARE PARTS WA7025-12E-138EN-B03

JibⅣ

Fig. 7-9 000270505CT004000

Table 7-9 Spare parts list of JibⅣ

No. Order No. Code Designation Specification Qty
1 000270505CT004100 JibⅣ structure 1
2 000209910A4121801 XZ04C-60×180/240A Pin 60×180 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000270405AT002001 Pin 60×143/190 2

428
 WA7025-12E-138EN-B03 SPARE PARTS

JibⅥ

Fig. 7-10 000219705AR006000

Table 7-10 Spare parts list of JibⅥ

No. Order No. Code Designation Specification Qty
1 000219705AR006100 JibⅥ structure 1
2 000209910A4121601 XZ04C-60×160/220 Pin 60×160 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000270405AT002001 Pin 60×143/190 2
7 000209906A0017000 214-178-B41-80-R6 Pulley 1
8 000210105A0010002 Bushing 2
Shaft-end
9 000210105A0010001 t6 1
baffle
10 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
11 1040300067 GB/T93-1987 Washer 10 2
12 000270405DT003001 Pin φ40×68/100 1
Deep groove
13 1050201563 GB/T276-2004 6208-2RS1 2
ball bearing
14 1040300322 GB/T893.2-1986 Retainer ring 80 2

429
SPARE PARTS WA7025-12E-138EN-B03

JibⅥ

Fig. 7-11 000270505CT006000

Table 7-11 Spare parts list of JibⅥ

No. Order No. Code Designation Specification Qty
1 000270505CT006100 JibⅥ structure 1
2 000209910A4121301 XZ04C-60×130/190 Pin 60×130 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT008001 Pin 60×121/170 2

430
 WA7025-12E-138EN-B03 SPARE PARTS

JibⅥ

Fig. 7-12 000290505AR006000

Table 7-12 Spare parts list of JibⅥ

No. Order No. Code Designation Specification Qty
1 000290505AR006100 JibⅥ structure 1
2 000209910A4121301 XZ04C-60×130/190 Pin 60×130 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT008001 Pin 60×121/170 2

431
SPARE PARTS WA7025-12E-138EN-B03

JibⅧ

Fig. 7-13 000290505AR008000

Table 7-13 Spare parts list of JibⅧ

No. Order No. Code Designation Specification Qty
1 000290505AR008100 JibⅧ structure 1
2 000209910A4121201 XZ04C-60×120/180 Pin 60×120 1
3 1040500186 GB/T91-2000 Split pin 10×90 2
4 000270405BT007002 Pin φ16×90/105 2
5 1040500097 GB/T91-2000 Split pin 4×30 2
6 000231805AT008001 Pin 60×121/170 2

432
 WA7025-12E-138EN-B03 SPARE PARTS

Jib End

Fig. 7-14 000201705AL009000

Component No.13 is exploded in another drawing

433
SPARE PARTS WA7025-12E-138EN-B03

Table 7-14 Spare parts list of Jib End

No. Order No. Code Designation Specification Qty
1 000219705AR009100 Jib end structure 1
2 1040500215 GB/T91-2000 Split pin 5×63 1
XZ03A-
3 000209910A0000515 Pin 12×80 2
12×80/95
4 1040500243 GB/T91-2000 Split pin 5×25 4
214-178-B41-
5 000209906A0017000 Pulley 1
80-R6
6 000210105A0010002 Bushing 2
7 000270405DT003001 Pin φ40×68/100 1
Deep groove ball
8 1050201563 GB/T276-2004 6208-2RS1 2
bearing
9 1040300322 GB/T893.2-1986 Retainer ring 80 2
10 000210105A0010001 Shaft-end baffle t6 1
11 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
12 1040300067 GB/T93-1987 Washer 10 2
05FNXD
13 000209923A0002700 Anti-twist device 1
（14#）
14 000261705AT010001 Platform Tb4 1
15 000261705AT010002 Platform Tb4 1
16 1040500005 GB/T91-2000 Split pin 5×45 6

434
 WA7025-12E-138EN-B03 SPARE PARTS

Anti-twist Device

Fig. 7-15 000209923A0002900

435
SPARE PARTS WA7025-12E-138EN-B03

Table 7-15 Spare parts list of Anti-twist Device

No. Order No. Code Designation Specification Qty
1 1040000251 GB/T5783-2000 Bolt M12×60-8.8 2
2 1040200096 GB/T6170-2000 Nut M12-8 2
3 000209923A0002110 Ear seat 1
4 1040200215 GB/T6178-1986 Nut M30-8 1
5 1040500224 GB/T91-2000 Split pin 6.3×63 3
6 000200914A0000011 XZ01C-30×140/170 Pin 30×140 1
7 000209923A0002101 Pressing plate 1
Trust ball
8 1050200429 GB/T301-1995 51308 1
bearing
9 000209923A0002102 Axle 1
10 000209910A0000130 XZ01C-30×70/100 Pin 30×70 1
11 1040300074 GB/T97.1-2002 Washer 30-200HV 2
12 1140117274 14-129KN Wedge cover 1
13 1040500003 GB/T91-2000 Split pin 2.5×30 1
14 1090100354 GB/T5976-1986 Rope clip 14KTH 1
15 1080000206 JB/T7940.1-1995 Oil cup M10×1 1
16 1140117276 14-129.0KN Wedge 1

436
 WA7025-12E-138EN-B03 SPARE PARTS

7.4 Counter Jib

437
SPARE PARTS WA7025-12E-138EN-B03

Fig. 7-16 000281701FT000000

438
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-16 Spare parts list of Counter Jib (WA7025-12E(Abroad).01A)

No. Order No. Code Designation Specification Qty
Front counter jib
1 000281701FT010000 1
structure
2 000251701AT000100 Counter jib strut B 2
3 000209913C0009500 LGA950B Handrail 3
4 000209913C0020000 LGB2000B Handrail 2
5 000251701AT000200 Counter jib strut A 2
6 000281701AT000020 Support rod 1
7 000270501AT000060 Support rod 1
8 000281701BT000200 LGVI4600 LOGO railing 2
Rear counter jib
9 000281701BT020000 1
structure
10 000209913C0004300 LGA430B Handrail 4
11 000281701BT000300 Walkway t2 4
12 000209913C0030000 LGB3000B Handrail 2
13 000281701BT000400 Platform 1
14 000209913C0008200 LGA820B Handrail 1
15 000281701BT000015 Walkway t2 2
16 000281701BT000700 Platform 1
17 000271701BT000025 Walkway t2 1
18 000271701BT000300 Platform 1
19 000281701BT000800 Walkway t2 2
20 000281701BT000900 Walkway t2 2
21 000281701BT000600 Platform 1
22 000281701BT000500 Platform 1
23 000271701BT000600 Platform 1
24 000271701BT000035 Walkway t2 2
25 000281701AT000010 Cover plate 1
26 000209915A0001000 ZADZ Lamp Standard 1
27 1040500047 GB/T91-2000 Split pin 5×70 1
28 1040000696 JB/ZQ4321-1997 U-Bolt 33-Zn 1
29 1040300067 GB/T93-1987 Washer 10 2
30 1040300061 GB/T97.1-2002 Washer 10-200HV 2
31 1040200113 GB/T6170-2000 Nut M10-8 2
32 000209910A3041001 XZ03B-20×100/120 Pin 20×100 4

439
SPARE PARTS WA7025-12E-138EN-B03

No. Order No. Code Designation Specification Qty

33 000201213A0000003 Spring pin 8
34 000200111T0000204 XZ01A-16×45/65 Pin 16×45 12
35 000209938A0000060 TX-4-16/20 Spring pin 12
36 1040500186 GB/T91-2000 Split pin 10×90 10
37 000209910A1101002 XZ01C-50×100/130 Pin 50×100 6
38 1040000101 GB/T5783-2000 Bolt M12×40-8.8 114
39 1040300651 GB/T96-1985 Washer 12-140HV 196
40 1040300054 GB/T93-1987 Washer 12 131
41 1040200096 GB/T6170-2000 Nut M12-8 99
42 1040002441 GB/T5783-2000 Bolt M12×50-8.8 2
43 000251701BT000003 Pin 70×230 4
44 000251701BT000002 Pin 20×110 4
45 1040500216 GB/T91-2000 Split pin 6.3×50 6
46 1040300983 GB/T97.1-2002 Washer 20 14
47 000209910A3040901 XZ03B-20×90/110 Pin 20×90 4
48 000261701AT000002 Pin 90×250 2
49 000231701BT010002 Pin 20×140 2
50 000209910A3041101 XZ03B-20×110/130 Pin 20×110 2
51 000209910A3041601 XZ03A-20×160/180 Pin 20×160 1
52 000221101A0000002 XZ04E-110×330/435 Pin 110×330 1
53 000209910A3041301 XZ03B-20×130/150 Pin 20×130 1
54 000209910A4111001 XZ04C-55×100/155 Pin 2
55 000208899A0002076 TX-6-24/35 Spring pin φ6×117 38
56 1040000216 GB/T5783-2000 Bolt M12×70-8.8 15
57 1040300041 GB/T97.1-2002 Washer 12-200HV 34
58 000209913A6000000 LGJB2 Rail splint t2 22
59 000271701CT007000 Rope wheel 1
60 1040500005 GB/T91-2000 Split pin 5×45 16
61 000281701BT000025 Walkway t2 2

440
 WA7025-12E-138EN-B03 SPARE PARTS

7.5 Derrick

Fig. 7-17 000209914B0006000

441
SPARE PARTS WA7025-12E-138EN-B03

Table 7-17 Spare parts list of Derrick (TCBG1500.1A)

No. Order No. Code Designation Specification Qty
1 000209914B0006100 Support 1
XZ01C-
2 000209914A0006200 Pin A 30×180 1
30×180/210
3 1040500222 GB/T91-2000 Split pin 8×80 1
4 000209914A0007000 Rotational column 1
5 000209914A0006300 Pulley seat 1
6 000209914A0006400 Pulley A 1
7 000209914A0006500 Pin B 2
8 000209914A0006600 Bushing A 4
9 000209914A0006700 Pulley B 2
10 000209914A0006800 Shaft-end baffle A t6 2
11 1040000116 GB/T5783-2000 Bolt M10×20-8.8 6
12 1040300067 GB/T93-1987 Washer 10 16
JB/T7940.1-
13 1080000007 Oil cup M10×1 3
1995
14 000209914A0006900 Block bar t6 2
15 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
16 1040300054 GB/T93-1987 Washer 12 4
17 1040300041 GB/T97.1-2002 Washer 12-200HV 4
18 1040200096 GB/T6170-2000 Nut M12-8 4
19 1040300678 GB/T853-1988 Washer 12 4
20 000209914A0008100 Pin C 1
21 000209914A0008200 Shaft-end baffle B t10 1
22 000209914A0008300 Bushing B 2
23 1040000758 GB/T5782-2000 Bolt M30×110-8.8 6
24 1040200197 GB/T6170-2000 Nut M30-8 12
25 1040300074 GB/T97.1-2002 Washer 30-200HV 12

442
 WA7025-12E-138EN-B03 SPARE PARTS

7.6 Turntable

Fig. 7-18 000281709BT000000

443
SPARE PARTS WA7025-12E-138EN-B03

Table 7-18 Spare parts list of Turntable

No. Order No. Code Designation Specification Qty
1 000261709AT002000 Cabin platform 1
2 000209910A3041301 XZ03B-20×130/150 Pin 20×130 2
3 000201213A0000003 Spring pin 4
Turntable
4 000281709BT005000 1
structure
Protective
5 000200609C0000400 2
shield
6 1040000122 GB/T5783-2000 Bolt M10×35-8.8 14
7 1040300764 GB/T96-1985 Washer 10-200HV 14
8 1040300067 GB/T93-1987 Washer 10 14
9 1040200113 GB/T6170-2000 Nut M10-8 12
10 1040201105 GB/T6170-2000 Nut M27-10 96
11 1040301787 GB/T97.1-2002 Washer 27-300HV 96
12 1040002952 GB/T5782-2000 Bolt M27×230-10.9 48
XZ01C-
13 000209910A1081001 Pin 40×100 4
40×100/125
14 1040500222 GB/T91-2000 Split pin 8×80 4
15 1040000095 GB/T5783-2000 Bolt M16×60-8.8 24
16 1040300065 GB/T93-1987 Washer 16 24
17 1040300052 GB/T97.1-2002 Washer 16-200HV 24
18 000281709BT003000 platform 1
19 000270509BT000200 Handrail 1
20 000209913C0006300 LGA630B Handrail 1
21 000209913C0008200 LGA820B Handrail 1
22 000209913C0020000 LGB2000B Handrail 1
23 000212409AT000400 Handrail 1
24 000281709BT000200 Handrail 2
25 000209913C0015000 LGC1500B Handrail 1
26 000209913C0005800 LGA580B Handrail 1
Limiter
27 000280809AT004000 t8 1
mounting plate
Handrail
28 000209913A6000000 LGJB2 t6 10
locking splint
29 1040000899 GB/T5782-2000 Bolt M12×70-8.8 5
30 1040300054 GB/T93-1987 Washer 12 5
31 1040300756 GB/T97.1-2002 Washer 12-200HV 10
32 1040200096 GB/T6170-2000 Nut M12-8 5
33 000208899A0002076 TX-6-24/35 Spring pin φ6×117 18

444
 WA7025-12E-138EN-B03 SPARE PARTS

7.7 Slewing Support

Fig. 7-19 000281710DT000000

445
SPARE PARTS WA7025-12E-138EN-B03

Table 7-19 Spare parts list of Slewing Support (WA7025-12E.10)

No. Order No. Code Designation Specification Qty
Slewing support
1 000281710DT003000 1
structure
2 000281710DT002000 Ladder 1
3 1040003331 GB/T5782-2000 Bolt M27×240-10.9 48
4 1040201105 GB/T6170-2000 Nut M27-10 96
5 1040301787 GB/T97.1-2002 Washer 27-300HV 96
6 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
7 1040300065 GB/T93-1987 Washer 16 4
8 1040200110 GB/T6170-2000 Nut M16-8 4
9 1040300052 GB/T97.1-2002 Washer 16-200HV 4
10 1090100308 MZKW Hanging net 1

446
 WA7025-12E-138EN-B03 SPARE PARTS

7.8 Trolley

Fig. 7-20 000209707L0100000

Component No.1 is exploded in another drawing

Table 7-20 Spare parts list of Trolley (XC12F)

No. Order No. Code Designation Specification Qty
Trolley
1 000209707L0101000 1
(Remove Maintenance Cage)
2 000209901A0600000 DL6 Maintenance Cage 1

447
SPARE PARTS WA7025-12E-138EN-B03

Trolley without Maintenance Cage

Fig. 7-21 000209707L0101000

448
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-21 Spare parts list of Trolley without Maintenance Cage

No. Order No. Code Designation Specification Qty
1 000209707L0101100 Trolley structure 1
2 000209707L0101001 Rope rod φ33.7×3.2 2
3 1040500216 GB/T91-2000 Split pin 6.3×50 12
4 000209707L0101004 Plate support t8 4
5 1040002436 GB/T5783-2000 Bolt M12×25-8.8 8
6 1040300041 GB/T97.1-2002 Washer 12-200HV 14
7 1040300054 GB/T93-1987 Washer 12 12
8 000209707L0101002 Pulley shaft 2
9 000209707K0101004 Bushing 3
10 000209707K0101005 Bushing 1
HL-450-380-80-
11 000209906A0040035 Pulley 3
130-R8.5
12 1040300281 GB/T893.2-1986 Retainer ring 130 8
Deep groove ball
13 1050202084 GB/T276-2013 6312-2RS 8
bearing
14 000209707L0101003 Bushing 1
Deep groove ball
15 1050201562 GB/T276-2004 6212-2RS1 8
bearing
16 1040300283 GB/T893.2-1986 Retainer ring 110 8
17 000209709A0003003 Idler wheel 4
18 000209707J0101004 Bushing 4
19 000209707K0101007 Roller shaft 4
20 1040200342 GB/T812-1988 Nut M52×1.5 4
21 1040300265 GB/T858-1988 Washer 52 4
22 000209710A0600001 Side idler wheel φ120-50 4
23 1040300226 GB/T893.2-1986 Retainer ring 62 8
Deep groove ball
24 1050201944 GB/T276-2013 6206-2RS 8
bearing
Side idler wheel
25 000209710A0600002 φ30 4
axle
26 000209710A0601003 Bushing φ30-8.8 8
27 000209707K0101010 Tensioning plate 1
28 1040200096 GB/T6170-2000 Nut M12-8 6
29 000209707K0101020 Safety brake 2
30 000209719A0601008 Bushing 4

449
SPARE PARTS WA7025-12E-138EN-B03

No. Order No. Code Designation Specification Qty

31 000209910A1050701 XZ01B-25×70/90 Pin 25×70 2
32 1090100081 GB/T5976-2006 Rope clip 10KTH 1
33 000209719A0601006 Baffle t16 1
34 000209719A0601007 Bushing 2
35 000209910A1040601 XZ01B-20×60/80 Pin 20×60 1
36 1040500253 GB/T91-2000 Split pin 5×32 5
37 000209705D0000002 Bushing 1
38 1090100713 GB/T5973-2006 Wedge 10 2
39 000209719A0601010 Tensioning wheel 1
40 000209705D0000009 Bushing 1
41 000209910A4061341 XZ03C-30×135/170 Pin 30×135 1
42 1090100722 GB/T5973-2006 Wedge cover 10 1
43 000209910A0000113 XZ01A-20×45/65 Pin 20×45 1
44 000209707J0101006 Idler wheel cover t4 4
45 000209708A0001063 Buffer block 4
46 1040000489 GB/T5783-2000 Bolt M10×50-8.8 4
47 1040300559 GB/T96-1985 Washer 10 4
48 1040200679 GB/T6170-2000 Nut M10-8 8
49 1040300061 GB/T97.1-2002 Washer 10-200HV 12
50 1040300067 GB/T93-1987 Washer 10 8
51 1040002435 GB/T5783-2000 Bolt M10×35-8.8 4
52 000209705A0000900 FXC08B-9 Support wheel 3
Deep groove ball
53 1050201565 GB/T276-2004 6004-2RS1 6
bearing
Support wheel
54 000209707F0301003 φ20 3
axle
55 000209705A0001100 FXC08B-11 Bushing 6
56 1040002440 GB/T5783-2016 Bolt M12×45-8.8 2

450
 WA7025-12E-138EN-B03 SPARE PARTS

7.9 Hook

Fig. 7-22 000209607A1900000

Component No.1 and No.2 are exploded in other drawings

Table 7-22 Spare parts list of Hook (DG12H)

No. Order No. Code Designation Specification Qty
1 000209606A1701000 Upper part of the hook 1
2 000209607A1902000 Lower part of the hook 1

451
SPARE PARTS WA7025-12E-138EN-B03

Upper Part of the Hook

Fig. 7-23 000209606A1701000

Table 7-23 Spare parts list of Upper Part of the Hook

No. Order No. Code Designation Specification Qty
1 1040300067 GB/T93-1987 Washer 10 2
2 1040000116 GB/T5783-2000 Bolt M10×20-8.8 2
3 000209605A0000018 FDG08A.01-5 Plate 1
4 000209606A1401100 Pulley frame 1
HL-450-380-80-130-
5 000209906A0040035 Pulley 1
R8.5
6 000209606A1401001 Bushing 2
7 000209606A1702001 Pulley shaft 1
8 1050202084 GB/T276-2013 Bearing 6312-2RS 2
9 1040300281 GB/T893.2-1986 Retaining ring 130 2
10 000209910A1121901 XZ01C-60×190/225 Pin 60×190 1
11 1040500260 GB/T91-2000 Split pin 10×80 1

452
 WA7025-12E-138EN-B03 SPARE PARTS

Lower Part of the Hook

Fig. 7-24 000209607A1902000

Component No.11 is exploded in another drawing

453
SPARE PARTS WA7025-12E-138EN-B03

Table 7-24 Spare parts list of Lower Part of the Hook

No. Order No. Code Designation Specification Qty
1 000209607A1902100 Pulley frame 1
HL-450-380-80-130-
2 000209906A0040035 Pulley 2
R8.5
3 1040300283 GB/T893.2-1986 Retaining ring 110 4
4 1050202084 GB/T276-2013 Bearing 6312-2RS 4
5 000209605A0000018 FDG08A.01-5 Plate 3
6 1040300067 GB/T93-1987 Washer 10 6
7 1040000116 GB/T5783-2000 Bolt M10×20-8.8 4
8 000209606A1702001 Pulley shaft 2
9 000209606A1401001 Bushing 4
10 000209606A1402001 Pin 1
11 000209606A1702200 Load hook 1

454
 WA7025-12E-138EN-B03 SPARE PARTS

Load Hook

Fig. 7-25 000209606A1702200

Table7-25 Spare parts list of Load Hook

No. Order No. Code Designation Specification Qty
1 000209606A1702210 Plate 1
2 000209606A1702202 Hook nut M56 1
3 1050201632 GB/T301-1995 Bearing 51312 1
4 1080000007 JB/T7940.1-1995 Oil cup M10×1 1
5 1999904306 FCM(TPTC) Oil cup cover Φ10 1
6 000209606A1702230 Hook Chuck 1
7 000209606A1702201 Hook 1
8 000209606A1702205 Pin 10X130 1
9 1040500243 GB/T91-2000 Split pin 5×25 1
10 1040000108 GB/T5783-2000 Bolt M12×30-8.8 2
11 1040300061 GB/T97.1-2002 Washer 10-200HV 3
12 1040300054 GB/T93-1987 Washer 12 2
13 000209606A1702203 Plate t10 1

455
SPARE PARTS WA7025-12E-138EN-B03

7.10 Climbing Equipment

456
 WA7025-12E-138EN-B03 SPARE PARTS

Fig. 7-26 000261811AT000000

Components No.1, 9, 16 are exploded in other drawings

457
SPARE PARTS WA7025-12E-138EN-B03

Table 7-26 Spare parts list of Climbing Equipment (WA7527-20D.11)

No. Order No. Code Designation Specification Qty
Climbing
1 000261811AT010000 equipment 1
structure
2 000209913D0005300 LGA530B Handrail 18
3 000209913C0006300 LGA630B Handrail 9
4 000209913C0020000 LGB2000B Handrail 7
5 000261811AT020000 Flexible strut 1
6 000261811AT030000 Ladder 1
XZ01C-
7 000209910A1101301 Pin 50×130 2
50×130/160
8 1040500186 GB/T91-2000 Split pin 10×90 2
Climbing
9 000261811AT040000 1
operation platform
10 000209913C0009500 LGA950B Handrail 1
11 000209913C0015000 LGC1500B Handrail 1
12 000261811AT050000 Platform A 1
13 000261811AT060000 Platform B 4
14 000261811AT070000 Platform C 1
15 000261811AT080000 Platform D 1
Jacket stop shoe
16 000200411D0000060 1
mechanism
17 000209910A1040801 XZ01B-20×80/100 Pin 20×80 2
18 1040500253 GB/T91-2000 Split pin 5×32 2
XZ01D-
19 000209910A1141801 Pin 70×180 1
70×180/220-T
20 1040500965 GB/T91-2000 Split pin 13×110 1
21 000209913A6000000 LGJB2 Rail splint t6 68
22 1040000170 GB/T5782-2000 Bolt M12×65-8.8 34
23 1040300041 GB/T97.1-2002 Washer 12-200HV 68
24 1040300054 GB/T93-1987 Washer 12 34
25 1040200096 GB/T6170-2000 Nut M12-8 34
26 000261811AT000001 Pin 18
27 1040500097 GB/T91-2000 Split pin 4×30 18
28 000208899A0002076 TX-6-24/35 Spring pin φ6×117 72
29 1040006134 GB/T5783 Bolt M16×60-8.8 4

458
 WA7025-12E-138EN-B03 SPARE PARTS

No. Order No. Code Designation Specification Qty

30 1040300052 GB/T97.1-2002 Washer 16-200HV 16
31 1040300215 GB/T853-1988 Washer 16 4
32 1040200110 GB/T6170-2000 Nut M16-8 8
33 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
34 000261811AT000002 Roller shaft 16
35 000261811AT090000 Roller assembly 16
36 000200411D0000052 Lock pin 16
37 1040500254 GB/T91-2000 Split pin 4×25 32
38 000261811AT000003 Hanging hook t10 2
39 1040300065 GB/T93-1987 Washer 16 8

459
SPARE PARTS WA7025-12E-138EN-B03

Climbing Equipment Structure

460
 WA7025-12E-138EN-B03 SPARE PARTS

Fig. 7-27 000261811AT010000

Table7-27 Spare parts list of Climbing Equipment Structure

No. Order No. Code Designation Specification Qty
1 000210611ET015000 Junction 4
2 000261811AT010001 Square steel tube F80×5-2269 1
3 000261811AT010100 Main chord 4
4 000261811AT010002 Square steel tube F70×4-2269 4
5 000261811AT010003 Diagonal support strut F106×8 2
6 000261811AT010004 Incline diagonal Ⅰ F80×5 4
7 000261811AT011000 Horizontal beam 1
8 000210611GT010021 Rectangular tube F160×80×8-2404 2
9 000210611GT010010 Rectangular tube F160×80×8-2269 6
10 000261811AT010005 Incline diagonal Ⅱ F96×8 2
11 000261811AT010006 Incline diagonal Ⅲ F80×5 1
12 000261811AT010007 Plate t16-134×284 16
13 000261811AT010008 Plate t16 16
14 000200411D0000039 Roller stand 8
15 000261811AT010009 Plate t12 8
16 000261811AT010010 Plate t16-160×190 4
17 000261811AT010011 Plate t16-160×210 4
18 000261811AT010018 Platform erecting base A t10 8
19 000261811AT010019 Platform erecting base B t10 8
20 000261811AT010014 Connecting plate Ⅰ t10 2
21 000261811AT010015 Connecting plate Ⅱ t10 4
22 000261811AT010016 Connecting plate Ⅲ t8 8
23 000261811AT010017 Rib plate t10 4

461
SPARE PARTS WA7025-12E-138EN-B03

Climbing Operation Platform

Fig. 7-28 000261811AT040000

Table7-28 Spare parts list of Climbing Operation Platform

No. Order No. Code Designation Specification Qty
1 000261811AT040001 Expanded steel PF4×24×550×2570 1
2 000261811AT040100 Outrigger 2
3 000261811AT040002 Bent plate t4 2
4 000200111F0000430 Angle steel L50×4 3
5 000210111A0006005 Bent plate t4 2
6 000209913A4000002 Railing support Φ42×3-48 16

462
 WA7025-12E-138EN-B03 SPARE PARTS

Jacket Stop Shoe Mechanism

Fig. 7-29 000200411D0000060

Table7-29 Spare parts list of Jacket Stop Shoe Mechanism

No. Order No. Code Designation Specification Qty
1 000200911A0000081 Lock card 2
2 000200411D0000070 Jacket stop shoe 2
3 000209910A0160501 XZ01B-16×50/65 Pivot 16×50 4
4 1040500228 GB/T91-2000 Split pin 4×32 4
Movable rod of
5 000200411D0000065 M16-8 1
stop shoe
6 1040500980 GB/T91-2000 Split pin 10×60 4
7 000200411D0000063 Connecting rod 1

463
SPARE PARTS WA7025-12E-138EN-B03

7.11 Slewing Mechanism

S75CA-130LB12/14A

Fig. 7-30 000209289A6700000

464
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-30 Spare part list of Slewing Mechanism (S75CA-130LB12/14A)

No. Order No. Code Designation Specification Qty
YTRVF132M2-
1 1020005445 Motor 1
4F1/B/BM1
2 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
3 1040300054 GB/T93-1987 Spring washer 12 4
4 1040300041 GB/T97.1-2002 Washer 12-200HV 4
XX5-130.195LB-
5 1030202399 Reduction gear 1
12/14
6 000209289A6700100 Nameplate 1
7 1040400058 GB/T827-1986 Rivet 2.5×8 4

465
SPARE PARTS WA7025-12E-138EN-B03

S75CN-130LB12/14A

Fig. 7-31 000209289A6800000

466
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-31 Spare part list of Slewing Mechanism (S75CN-130LB12/14A)

No. Order No. Code Designation Specification Qty
YTRVF132M2-
1 1020005446 Motor 1
4F2/B/BM1
2 1040000101 GB/T5783-2000 Bolt M12×40-8.8 4
Spring
3 1040300054 GB/T93-1987 12 4
washer
4 1040300041 GB/T97.1-2002 Washer 12-200HV 4
Reduction
5 1030202399 XX5-130.195LB-12/14 1
gear
6 000209289A6800100 Nameplate 1
7 1040400058 GB/T827-1986 Rivet 2.5×8 4
8 1020202072 ECK58B(Nr:851249/10) Encoder 1024PPR 1

467
SPARE PARTS WA7025-12E-138EN-B03

7.12 Trolley Mechanism

T55FC70-b

Fig. 7-32 000209370A4400000

Table 7-32 Spare parts list of Trolley Mechanism (T55FC70-b)

No. Order No. Code Designation Specification Qty
Connecting angle
1 000209370A4200001 L80X8 2
steel Ⅰ
Connecting angle
2 000209370A4200002 L80X8 2
steel Ⅱ
3 000209370A4200020 Limiter support 1
4 1040000118 GB/T5783-2000 Bolt M5×16-8.8 4
5 1040300060 GB/T93-1987 Washer 5 4
6 1040300048 GB/T97.1-2002 Washer 5-200HV 4
7 1040500054 GB/T91-2000 Split pin 4×40 1
8 000209195A6500003 Pulling pin 1
9 000209195A5700004 Pressing plate t8 1
10 000209944A0200023 NLT-3 Nylon sleeve 1

468
 WA7025-12E-138EN-B03 SPARE PARTS

No. Order No. Code Designation Specification Qty

11 1040000107 GB/T5783-2000 Bolt M6×20-8.8 2
12 1040300062 GB/T93-1987 Washer 6 2
13 1059900399 GB/T7810-2017 Bearing UCFC210 1
14 000209370A4200003 Driven flange 1
15 000209370A4200004 Rope-pressing plate 8
16 000209370A4400100 Drum 1
17 1030202675 XX2-15.43 Reducer 1
18 1040300067 GB/T93-1987 Washer 10 16
19 1040100761 GB/T70.1-2000 Screw M10×30-10.9 16
20 1040100389 GB/T70.1-2000 Screw M8×30-10.9 8
21 1040100562 GB/T70.1-2000 Screw M12×25-10.9 8
22 1040000176 GB/T5783-2000 Bolt M14×45-8.8 8
23 1040300055 GB/T97.1-2002 Washer 14-200HV 8
24 1040302295 GB/T93-2000 Washer 14 8

YVFE132S- 5.5kW
25 1029805687 Motor 1
4B5(HJ) /380V/50Hz
26 1040000168 GB/T27-1988 Bolt M12×50-8.8 8
27 1040201679 GB/T6170-2000 Nut M12-8 8
28 1040300054 GB/T93-1987 Washer 12 8
29 000209370A4200030 Driver flange 1
30 000209944A0001030 GR28-65-2 Coupling 1
31 000209370A4400001 Pulling rod 4
32 1040000267 GB/T5783-2000 Bolt M8×20-8.8 4
32 1040300066 GB/T97.1-2002 Washer 8-200HV 4
33 1040300063 GB/T93-1987 Washer 8 12
34 1040006079 GB/T5783-2000 Bolt M16×45-8.8 8
35 1040303143 DIN25201 Washer NL16/M16 8
36 000209370A4400002 Nameplate 1
37 1040400058 GB/T827-1986 Rivet 2.5×8 4
38 1040300041 GB/T97.1-2002 Washer 12-200HV 8
Connecting angle
39 000209370A4200001 L80X8 2
steel Ⅰ

469
SPARE PARTS WA7025-12E-138EN-B03

T55FC70-b(D)

Fig. 7-33 000209370A5000000

Table 7-33 Spare parts list of Trolley Mechanism (T55FC70-b(D))

No. Order No. Code Designation Specification Qty
1 1040000118 GB/T5783-2000 Bolt M5×16-8.8 4
2 1040300060 GB/T93-1987 Washer 5 4
3 1040300048 GB/T97.1-2002 Washer 5-200HV 4
4 1040500054 GB/T91-2000 Split pin 4×40 1
5 000209944A0200023 NLT-3 Nylon sleeve 1
Trolley Mechanism
6 000209370A5001000 BF5293-50-550 1
assembly
7 1040000176 GB/T5783-2000 Bolt M14×45-8.8 4
8 1040300055 GB/T97.1-2002 Washer 14-200HV 4
9 1040302295 GB/T93-2000 Washer 14 4
YVFE132S- 5.5kW/
10 1029805687 Motor 1
4B5(HJ) 380V/50Hz
11 000209370A5000003 Nameplate 1
12 1040400045 GB/T827-1986 Rivet 2×5 4

470
 WA7025-12E-138EN-B03 SPARE PARTS

7.13 Hoisting Mechanism

Fig. 7-34 000209195A1500000

471
SPARE PARTS WA7025-12E-138EN-B03

Table 7-34 Spare parts list of Hoisting Mechanism (H45FC30-600C)

No. Order No. Code Designation Specification Qty
1 1020005745 YZPFME225L-4-Z Motor 380V,50Hz,45kW 1
2 1040000055 GB/T5783-2000 Bolt M20×60-8.8 8
3 1040300106 GB/T97.1-2002 Washer 20-200HV 8
4 1040300038 GB/T93-1987 Washer 20 8
5 1039905711 SPZ600A(600) Brake 1
ETF100-H ETF100-H
6 1020202010 Encoder 1
(Nr:851223/0.8) (Nr:851223/0.8)
7 1040102055 GB/T70.1-2000 Screw M16×45-10.9-DKL 40
8 000209195A1502000 GR55-120-12T-C Coupling 1
9 1030203186 ZTQ130W40-301 Reducer 1
10 000209195A1501000 Drum 1
11 000209101A6900001 Axle 1
12 1040000148 GB/T5782-2000 Bolt M16×55-8.8 8
13 1040300052 GB/T97.1-2002 Washer 16-200HV 16
14 1040000018 GB/T5783-2000 Bolt M8×30-8.8 8
15 1040300063 GB/T93-1987 Washer 8 20
16 1040300066 GB/T97.1-2002 Washer 8-200HV 20
17 000209101A6900002 Bearing cover Ⅰ 1
18 000209195A8600003 Collar 1
Self-aligning
19 1050200175 GB/T288-1994 22216 C 1
Roller Bearing
20 1040000198 GB/T5783-2000 Bolt M16×50-8.8 8
21 000209101A6900100 End cover 1
22 1040100069 GB/T70.1-2000 Screw M8×20-8.8 8
23 000209101A6900003 Bearing cover Ⅱ 1
24 000209195A5700002 Oil sealing 1
25 000209195A6500003 Pin 1
26 000209195A5700004 Pressing plate t8 1
27 1040000107 GB/T5783-2000 Bolt M6×20-8.8 2
28 1040300062 GB/T93-1987 Washer 6 2
29 000209944A0200023 NLT-3 Nylon sleeve 1
30 1040500054 GB/T91-2000 Split pin 4×40 1
31 1080000007 JB/T7940.1-1995 Oil cup M10×1 1
32 1040000151 GB/T5783-2000 Bolt M5×12-8.8 4

472
 WA7025-12E-138EN-B03 SPARE PARTS

No. Order No. Code Designation Specification Qty

33 1040300048 GB/T97.1-2002 Washer 5-200HV 4
34 1040300060 GB/T93-1987 Washer 5 4
35 000209944A0400060 XWZJ-03 Limiter support t5 1
36 1040000267 GB/T5783-2000 Bolt M8×20-8.8 4
37 000209101A7802000 Rack 1
XZ03C-
38 000200610A0007004 Pin 30×90 4
30×90/125
39 1040500040 GB/T91-2000 Split pin 6.3×50 8
Rope block
40 000209101A7804000 1
device
41 1040000170 GB/T5782-2000 Bolt M12×65-8.8 4
42 1040200096 GB/T6170-2000 Nut M12-8 4
43 1040300041 GB/T97.1-2002 Washer 12-200HV 8
44 1040300054 GB/T93-1987 Washer 12 4
H45FC30-600C-
45 000209195A1500001 Nameplate 1
MP
46 1040400058 GB/T827-1986 Rivet 2.5×8 4

473
SPARE PARTS WA7025-12E-138EN-B03

7.14 Transition Section

Fig. 7-35 000209012B3800000

474
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-35 Spare parts list of Transition Section (L68C3B)

No. Order No. Code Designation Specification Qty
Transition tower
1 000209012B3801000 1
section structure
2 000209012B3802000 Ladder 1
3 1040000095 GB/T5783-2000 Bolt M16×50-8.8 4
4 1040300052 GB/T97.1-2002 Washer 16-200HV 4
5 1040300065 GB/T93-1987 Washer 16 4
6 1040200110 GB/T6170-2000 Nut M16-8 4
7 000210610AR100001 Pin 8
8 000209012A0000003 Pin 4
9 000200610A0007401 XZ03A-20×65/85 Pin 20×65 8
10 1040500228 GB/T91-2000 Split pin 4×32 20
11 000209910A1101301 XZ01C-50×130/160 Pin 50×150 4
12 1040500252 GB/T91-2000 Split pin 10×90 4
13 000200610A0007002 Pin 4
14 1040000152 GB/T5783-2000 Bolt M10×40-8.8 4
15 1040200813 GB/T6170-2000 Nut M10-8 4
16 1040300211 GB/T96.1-2002 Washer 10-200HV 8
17 000209012A1703000 Platform 1
18 000231710BT000002 Pin 55×165 8
19 000209910A3041001 XZ03B-20×100/120 Pin 20×100 8
20 000201213A0000003 Spring pin 16

475
SPARE PARTS WA7025-12E-138EN-B03

7.15 Erection Platform

Fig. 7-36 000270320BT000000

476
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-36 Spare parts list of Erection Platform (T6513-8E.20A)

No. Order No. Code Designation Specification Qty
1 000209913B0020000 LGB2000A Handrail 2
2 000209913B0009500 LGA950A Handrail 2
3 000209913B0004300 LGA430A Handrail 4
4 000209913B0005300 LGA530A Handrail 4
5 000270320BT002000 Platform 2
Handrail locking
6 000209913A5000001 LGJB1 t5 20
splint
7 1040000216 GB/T5783-2000 Bolt M12×70-8.8 10
8 1040300041 GB/T97.1-2002 Washer 12-200HV 10
9 1040300054 GB/T93-1987 Washer 12 10
10 1040200096 GB/T6170-2000 Nut M12-8 10
11 1040500222 GB/T91-2000 Split pin 8×80 24
12 000240811AT100003 Pin 4
13 000201213A0000003 Spring pin 4

477
SPARE PARTS WA7025-12E-138EN-B03

7.16 Mounting Device

Fig. 7-33 000270319AT000000

Component No.2 is exploded in another drawing

Table 7-33 Spare parts list of Mounting Device (T6513-8E.19)

No. Order No. Code Designation Dimension Qty
1 000270319AT000100 Guide way 2
2 000200610A0007400 Lifting device 1
3 000209910A4060601 XZ03C-30×60/95 Pin 30×60 4
4 1040500222 GB/T91-2000 Split pin 8×80 8

478
 WA7025-12E-138EN-B03 SPARE PARTS

Lifting Device

Fig. 7-37 000200610A0007400

479
SPARE PARTS WA7025-12E-138EN-B03

Table 7-37 Spare parts list of Lifting Device

No. Order No. Code Designation Specification Qty
1 000200610A0007410 Lifting beam 1
2 1040100950 GB/T6563-1986 Screw M6×14 4
3 000200610A0007201 Shaft 4
4 1040300129 GB/T893.1-1986 Retaining ring 72 8
5 000200610A0007202 Roller 4
6 1050200499 GB/T276-1994 Bearing 6207-z 4
7 1040300184 GB/T894.1-1986 Retaining ring 35 4
8 1040000102 GB/T5783-2000 Bolt M14×35-8.8 4
9 1040300068 GB/T93-1987 Washer 14 4
10 1040000089 GB/T5782-2000 Bolt M20×80-8.8 4
11 1040200097 GB/T6170-2000 Nut M20-8 4
12 1040300106 GB/T97.1-2002 Washer 20-200HV 4
13 000200610A0007420 Bring-in hook 4
14 000200610A0007401 XZ03A-20×65/85 Pin 20×65 4
15 1040500222 GB/T91-2000 Split pin 8×80 8

480
 WA7025-12E-138EN-B03 SPARE PARTS

7.17 Mast (Rung ladder)

Base Tower Section (L68G23)

Fig. 7-38 000208890A0099000

481
SPARE PARTS WA7025-12E-138EN-B03

Table 7-38 Spare parts list of Base Tower Section (L68G23)

No. Order No. Code Designation Specification Qty
Base tower section
1 000209012A2301000 1
structure
Ladder and guard
2 000209014A1301100 1
ring
4.5 m ladder and
3 000209012A2302000 1
guard ring
4 000209014A1200930 Ladder joint 4
5 1040000095 GB/T5783-2000 Bolt M16×60-8.8 24
6 1040300052 GB/T97.1-2002 Washer 16-200HV 24
7 1040300065 GB/T93-1987 Washer 16 24
8 1040200685 GB/T6170-2000 Nut M16-8 24
9 000200615F0000001 Pin 8
10 000209012A0000003 Pin 4
11 1040500228 GB/T91-2000 Split pin 4×32 4
12 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
13 1040200111 GB/T6170-2000 Nut M6-8 4
14 1040300062 GB/T93-1987 Washer 6 4
15 1040300051 GB/T97.1-2002 Washer 6-200HV 4

482
 WA7025-12E-138EN-B03 SPARE PARTS

Tower Section
L68A4

Fig. 7-39 000209012A2600000

483
SPARE PARTS WA7025-12E-138EN-B03

Table 7-39 Spare parts list of Tower Section (L68A4)

No. Order No. Code Designation Specification Qty
1 000209012A1001000 Tower section piece A 1
2 000209012A1002000 Tower section piece B 1
3 000209012A2601000 Tower section piece C 1
4 000209012A2602000 Tower section piece D 1
5 000209012A0000001 Bolt 20
6 000209012A0000002 Pin 8
7 000209012A0000003 Pin 4
8 1040500228 GB/T91-2000 Split pin 4×32 4
9 000209012A0000004 Nut 20

484
 WA7025-12E-138EN-B03 SPARE PARTS

L68B7A

Fig. 7-40 000209012A5800000

485
SPARE PARTS WA7025-12E-138EN-B03

Table 7-40 Spare parts list of Tower Section (L68B7A)

No. Order No. Code Designation Specification Qty
1 000209012A5801000 Tower section piece A 2
2 000209012A5802000 Tower section piece B 1
3 000209012A5803000 Tower section piece D 1
4 000200615F0000001 Pin 8
5 000209012A0000003 Pin 4
6 1040500228 GB/T91-2000 Split pin 4×32 4
7 000209012A6000002 Nut M27 12
8 000209012A5800001 Fishplate Bolt 20
9 000209012A0000004 Nut 8

486
 WA7025-12E-138EN-B03 SPARE PARTS

Passageway
L68TDJ

Fig. 7-41 000209014A1300000

Table 7-41 Spare parts list of Passageway (L68TDJ)

No. Order No. Code Designation Specification Qty
Ladder and
1 000209014A1301100 1
guard ring
2 000209014A1200930 Ladder joint 2
3 1040000095 GB/T5783-2000 Bolt M16×60-8.8 12
4 1040300052 GB/T97.1-2002 Washer 16-200HV 12
5 1040300065 GB/T93-1987 Washer 16 12
6 1040200685 GB/T6170-2000 Nut M16-8 12

487
SPARE PARTS WA7025-12E-138EN-B03

L68TDH

Fig. 7-42 000209014A1200000

Table 7-42 Spare parts list of Passageway (L68TDH)

No. Order No. Code Designation Specification Qty
Ladder and guard
1 000209014A1200910 1
ring
2 000209012A0000610 Platform D 1
3 000209014A1200930 Ladder joint 2
4 1040000095 GB/T5783-2000 Bolt M16×60-8.8 12
5 1040300052 GB/T97.1-2002 Washer 16-200HV 12
6 1040300065 GB/T93-1987 Washer 16 12
7 1040200685 GB/T6170-2000 Nut M16-8 12
8 000209012A0000690 Platform fixing plate 4
9 1040000152 GB/T5783-2000 Bolt M10×40-8.8 4
10 1040300067 GB/T93-1987 Washer 10 4
11 1040200813 GB/T6170-2000 Nut M10-8 4

488
 WA7025-12E-138EN-B03 SPARE PARTS

Stationary Chassis

Fig. 7-43 000200614D1000000

489
SPARE PARTS WA7025-12E-138EN-B03

Table 7-43 Spare parts list of Stationary Chassis (TC6517B-10E.14)

No. Order No. Code Designation Specification Qty
1 000200614D1007000 Whole beam 1
2 000200614D1002000 Rod 4
3 000200614D1003000 Strut 4
4 000200614D1008000 Half beam 2
5 000200614D1009000 Base tower section 1
6 000200614D1006000 Short ladder 1
7 1040500252 GB/T91-2000 Split pin 10×90 8
5 m Ladder and
8 000200614C0000200 1
guard ring
9 000200614C0000010 Ladder support 1
10 1040000198 GB/T5783-2000 Bolt M16×50-8.8 4
11 1040200110 GB/T6170-2000 Nut M16-8 4
12 1040300065 GB/T93-1987 Washer 16 4
13 1040300052 GB/T97.1-2002 Washer 16-200HV 4
14 000200615F0000001 Pin 8
15 000209012A0000003 Pin 4
16 1040500228 GB/T91-2000 Split pin 4×32 4
17 000200614D1000001 XZ01C-60×385/425 Pin 4
18 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
19 1040500309 GB/T91-2000 Split pin 6.3×45 8
20 000200614C0000001 XZ01C-70×150/205 Pin 8
21 1040500250 GB/T91-2000 Split pin 12×100 8
22 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
23 1040200111 GB/T6170-2000 Nut M6-8 4
24 1040300062 GB/T93-1987 Washer 6 4
25 1040300051 GB/T97.1-2002 Washer 6-200HV 4
26 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
27 1040200744 GB/T6170-2000 Nut M8-8.8 4
28 1040300063 GB/T93-1987 Washer 8 4
29 1040300066 GB/T97.1-2002 Washer 8-200HV 4
30 1040000152 GB/T5783-2000 Bolt M10×40-8.8 2
31 1040200113 GB/T6170-2000 Nut M10-8 2
32 1040300067 GB/T93-1987 Washer 10 2
33 000200614C0000002 Pressing plate L100×10 2

490
 WA7025-12E-138EN-B03 SPARE PARTS

No. Order No. Code Designation Specification Qty

34 000200614C0000020 Ladder handrail 1
35 000209012A0000602 Ladder fixing plate 8
36 000209012A0000603 Ladder fixing clamp 8
37 000209012A0000604 Wedge 8
38 1040000267 GB/T5783-2000 Bolt M8×20-8.8 8

491
SPARE PARTS WA7025-12E-138EN-B03

Travelling Chassis

Fig. 7-44 000200623A1000000

492
 WA7025-12E-138EN-B03 SPARE PARTS

Table7-44 Spare parts list of Travelling Chassis (TC6517B-10E.23)

No. Order No. Code Designation Specification Qty
1 000200623A1001000 Whole beam 1
2 000200614D1002000 Rod 4
3 000200614D1003000 Strut 4
4 000200623A1002000 Half beamⅠ 1
Base tower
5 000200614D1009000 1
section
Bracket for M822
6 000200723C0003000 1
rope drum
7 000200614D1006000 Short ladder 1
8 1040500252 GB/T91-2000 Split pin 10×90 8
5m ladder and
9 000200614C0000200 1
guard ring
10 1040000095 GB/T5783-2000 Bolt M16×60-8.8 12
11 1040200110 GB/T6170-2000 Nut M16-8 12
12 1040300065 GB/T93-1987 Washer 16 12
13 1040300052 GB/T97.1-2002 Washer 16-200HV 12
14 000200623A1003000 Half beam 1
15 000200614C0000010 Ladder support 1
16 000200615F0000001 Pin 16
17 000209012A0000003 Pin 8
18 1040500228 GB/T91-2000 Split pin 4×32 8
19 000200614D1000001 XZ01C-60×385/425 Pin 4
20 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
21 1040500309 GB/T91-2000 Split pin 6.3×45 8
22 000200614C0000001 XZ01C-70×150/205 Pin 8
23 1040500250 GB/T91-2000 Split pin 12×100 8
24 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
25 1040200111 GB/T6170-2000 Nut M6-8 4
26 1040300062 GB/T93-1987 Washer 6 4
27 1040300051 GB/T97.1-2002 Washer 6-200HV 4
28 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
29 1040200744 GB/T6170-2000 Nut M8-8.8 4
30 1040300063 GB/T93-1987 Washer 8 4
31 1040300066 GB/T97.1-2002 Washer 8-200HV 4

493
SPARE PARTS WA7025-12E-138EN-B03

No. Order No. Code Designation Specification Qty

32 1040000152 GB/T5783-2000 Bolt M10×40-8.8 2
33 1040200113 GB/T6170-2000 Nut M10-8 2
34 1040300067 GB/T93-1987 Washer 10 2
35 000200614C0000002 Pressure plate L100×10 2
36 000200614C0000020 Handrail 1
Fixing plate for
37 000209012A0000602 8
ladder
Fixing hoop for
38 000209012A0000603 8
ladder
39 000209012A0000604 Wedge 8
40 1040000267 GB/T5783-2000 Bolt M8×20-8.8 8
41 1040300215 GB/T853-1988 Washer 16 8

494
 WA7025-12E-138EN-B03 SPARE PARTS

7.18 Mast (Incline ladder)

Base Tower Section (L68G23-C)

Fig. 7-45 000209012A9200000

495
SPARE PARTS WA7025-12E-138EN-B03

Table 7-45 Spare parts list of Base Tower Section (L68G2C)

No. Order No. Code Designation Specification Qty
Base tower section
1 000209012A9201000 1
structure
2 000209012A3608000 Long ladder 1
3 000209012A3607000 Platform 1
Ladder and guard
4 000209012A8802000 1
ring
5 1040000095 GB/T5783-2000 Bolt M16×60-8.8 8
6 1040300052 GB/T97.1-2002 Washer 16-200HV 16
7 1040300065 GB/T93-1987 Washer 16 8
8 1040200685 GB/T6170-2000 Nut M16-8 8
9 000200615F0000001 Pin 8
10 000209012A0000003 Pin 4
11 1040500228 GB/T91-2000 Split pin 4×32 4
12 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
13 1040200111 GB/T6170-2000 Nut M6-8 4
14 1040300062 GB/T93-1987 Washer 6 4
15 1040300051 GB/T97.1-2002 Washer 6-200HV 4
16 1040000169 GB/T5783-2000 Bolt M12×45-8.8 4
17 1040300054 GB/T93-1987 Washer 12 4
18 1040300041 GB/T97.1-2002 Washer 12-200HV 4
19 1040200096 GB/T6170-2000 Nut M12-8 4

496
 WA7025-12E-138EN-B03 SPARE PARTS

Tower Section
L68A1A

Fig. 7-46 000209012A3600000

497
SPARE PARTS WA7025-12E-138EN-B03

Table 7-46 Spare parts list of Tower Section (L68A1A)

No. Order No. Code Designation Specification Qty
Tower section piece
1 000209012A3601000 2
A
Tower section piece
2 000209012A3602000 1
B
Tower section piece
3 000209012A3603000 1
C
4 000209012A0000002 Pin 8
5 000209012A0000003 Pin 4
6 1040500228 GB/T91-2000 Split pin 4×32 4
7 000209012A0000004 Nut 20
8 000209012A0000001 Bolt 20
9 000209012A3608000 Long ladder 1
10 000209012A3607000 Platform 1
11 1040000169 GB/T5783-2000 Bolt M12×45-8.8 4
12 1040300054 GB/T93-1987 Washer 12 4
13 1040300041 GB/T97.1-2002 Washer 12-200HV 4
14 1040200096 GB/T6170-2000 Nut M12-8 4
15 1040000095 GB/T5783-2000 Bolt M16×60-8.8 2
16 1040300052 GB/T97.1-2002 Washer 16-200HV 2
17 1040300065 GB/T93-1987 Washer 16 2
18 1040200110 GB/T6170-2000 Nut M16-8 2

498
 WA7025-12E-138EN-B03 SPARE PARTS

L68B7A-C

Fig. 7-47 000209012A6200000

499
SPARE PARTS WA7025-12E-138EN-B03

Table 7-47 Spare parts list of Tower Section (L68B7A-C)

No. Order No. Code Designation Specification Qty
Tower section
1 000209012A6201000 2
piece A
Tower section
2 000209012A6202000 1
piece B
Tower section
3 000209012A6203000 1
piece D
4 000209012A3608000 Long ladder 1
5 1040000095 GB/T5783-2000 Bolt M16×60-8.8 2
6 1040300052 GB/T97.1-2002 Washer 16-200HV 2
7 1040300065 GB/T93-1987 Washer 16 2
8 1040200110 GB/T6170-2000 Nut M16-8 2
9 000209012A3607000 Platform 1
10 1040000169 GB/T5783-2000 Bolt M12×45-8.8 4
11 1040300054 GB/T93-1987 Washer 12 4
12 1040300041 GB/T97.1-2002 Washer 12-200HV 4
13 1040200096 GB/T6170-2000 Nut M12-8 4
14 000209012A5800001 Fishplate bolt 20
15 000209012A6000002 Nut M27 12
16 000209012A0000004 Nut 8
17 000200615F0000001 Pin 8
18 000209012A0000003 Pin 4
19 1040500228 GB/T91-2000 Split pin 4×32 4

500
 WA7025-12E-138EN-B03 SPARE PARTS

Stationary Chassis

Fig. 7-48 000281714AT000000

501
SPARE PARTS WA7025-12E-138EN-B03

Table 7-48 Spare parts list of Stationary Chassis (WA7025-12E(Abroad).14)

No. Order No. Code Designation Specification Qty
1 000281714AT001000 Whole beam 1
2 000200614D1002000 Rod 4
3 000281723AT003000 Strut 4
4 000200623A1003000 Half beam 2
Base tower
5 000281723AT001000 1
section
6 000200614D1006000 Short ladder 1
7 1040500252 GB/T91-2000 Split pin 10×90 8
Ladder and
8 000281723AT002000 1
guard ring
9 1040000095 GB/T5783-2000 Bolt M16×60-8.8 16
10 1040200110 GB/T6170-2000 Nut M16-8 16
11 1040300065 GB/T93-1987 Washer 16 16
12 1040300052 GB/T97.1-2002 Washer 16-200HV 16
13 000200615F0000001 Pin 16
14 000209012A0000003 Pin 8
15 1040500228 GB/T91-2000 Split pin 4×32 8
16 000200614D1000001 XZ01C-60×385/425 Pin 4
17 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
18 1040500309 GB/T91-2000 Split pin 6.3×45 8
19 000200614C0000001 XZ01C-70×150/205 Pin 8
20 1040500250 GB/T91-2000 Split pin 12×100 8
21 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
22 1040200111 GB/T6170-2000 Nut M6-8 4
23 1040300062 GB/T93-1987 Washer 6 4
24 1040300051 GB/T97.1-2002 Washer 6-200HV 4
25 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
26 1040200744 GB/T6170-2000 Nut M8-8.8 4
27 1040300063 GB/T93-1987 Washer 8 4
28 1040300066 GB/T97.1-2002 Washer 8-200HV 4

502
 WA7025-12E-138EN-B03 SPARE PARTS

Travelling Chassis

Fig. 7-49 000281723AT000000

503
SPARE PARTS WA7025-12E-138EN-B03

Table7-49 Spare parts list of Travelling Chassis (WA7025-12E(Abroad).23)

No. Order No. Code Designation Specification Qty
1 000200623A1001000 Whole beam 1
2 000200614D1002000 Rod 4
3 000281723AT003000 Strut 4
4 000200623A1002000 Half beam Ⅰ 1
Base tower
5 000281723AT001000 1
section
Bracket for M822
6 000200723C0003000 1
rope drum
7 000200614D1006000 Short ladder 1
8 1040500252 GB/T91-2000 Split pin 10×90 8
Ladder and
9 000281723AT002000 1
guard ring
10 1040000095 GB/T5783-2000 Bolt M16×60-8.8 24
11 1040200110 GB/T6170-2000 Nut M16-8 24
12 1040300065 GB/T93-1987 Washer 16 24
13 1040300052 GB/T97.1-2002 Washer 16-200HV 24
14 000200623A1003000 Half beam 1
15 000200615F0000001 Pin 16
16 000209012A0000003 Pin 8
17 1040500228 GB/T91-2000 Split pin 4×32 8
18 000200614D1000001 XZ01C-60×385/425 Pin 4
19 000209910A0000130 XZ01C-30×70/100 Pin 30×70 8
20 1040500309 GB/T91-2000 Split pin 6.3×45 8
21 000200614C0000001 XZ01C-70×150/205 Pin 8
22 1040500250 GB/T91-2000 Split pin 12×100 8
23 1040000109 GB/T5783-2000 Bolt M6×16-8.8 4
24 1040200111 GB/T6170-2000 Nut M6-8 4
25 1040300062 GB/T93-1987 Washer 6 4
26 1040300051 GB/T97.1-2002 Washer 6-200HV 4
27 1040000018 GB/T5783-2000 Bolt M8×30-8.8 4
28 1040200744 GB/T6170-2000 Nut M8-8.8 4
29 1040300063 GB/T93-1987 Washer 8 4
30 1040300066 GB/T97.1-2002 Washer 8-200HV 4
31 1040300215 GB/T853-1988 Washer 16 8

504
 WA7025-12E-138EN-B03 SPARE PARTS

7.19 Powered Wheel Bogie

Fig. 7-50 000209401D1000000

505
SPARE PARTS WA7025-12E-138EN-B03

Table 7-50 Spare parts list of Powered Wheel Bogie (ZA52-D)

No. Order No. Code Designation Specification Qty
1 1080000206 JB/T7940.1-1995 Oil cup M101 6
2 1040500241 GB/T119.1-2000 Split pin B1660 2
Connecting
3 000209401D1000012 t36 1
plate
4 000209401A0000023 Plate 1
5 000209401A0000031 Shaft 1
6 000209401D0000004 Steel sleeve 2
7 000209401A0000040 Bearing seat 3
8 1050200176 GB/T288-1994 Bearing 22220 C 4
9 000209401D1000038 Dust cover 4
10 000209401D1000039 Oil seal 4
Travelling
11 000209401D1000036 2
wheel
12 000209401D1000037 Shaft 1
13 1040600015 GB/T1096-2003 Bond 32110 2
14 1040300432 GB/T858-1988 Washer 90 1
15 1040200486 GB/T812-1988 Nut M902 1
16 000209401D1000056 Shaft 1
17 1040200574 GB/T6170-2000 Nut M5-8 4
18 1040300514 GB/T97.1-2002 Washer 5-200HV 4
19 1040300060 GB/T93-1987 Washer 5 6
20 1020500695 XCR-F17 Limit switch 1
21 1020400378 JD90A-L+02+R+024 Alarm light 1
22 1040100065 GB/T818-2000 Screw M516-4.8 2
23 000209401A0000061 Bracket 2
24 1040001592 GB/T5783-2000 Bolt M560-8.8 4
25 000209401A0000045 Rail clamp 1
26 000209401D1000100 Bogie frame 1
27 000209401A0000057 Bracket 2
28 1040000592 GB/T31.1-1988 Bolt M24240-8.8 1
29 1040500233 GB/T91-2000 Split pin 540 1
30 000209401A0000002 Hatch 2
31 000209401A0000003 Buffer block 2
32 000209401A0000034 Bearing seat 1

506
 WA7025-12E-138EN-B03 SPARE PARTS

No. Order No. Code Designation Specification Qty

33 000209401A0000033 Oil seal 1
34 1040000069 GB/T5783-2000 Bolt M1225-8.8 8
35 1040300054 GB/T93-1987 Washer 12 8
36 1040300067 GB/T93-1987 Washer 10 26
37 1040000931 GB/T5783-2000 Bolt M1020-8.8 18
38 000209401D1000035 Bushing 2
39 000209401A0000001 Bushing 1
40 1080000009 JB/T7940.2-1995 Oil cup 90 M101 1
YTXZ112M2-2B-
41 1020000154 Electric motor 1
5.2KW
42 1040000110 GB/T5783-2000 Bolt M835-8.8 4
43 1040300063 GB/T93-1987 Washer 8 4
44 1040300066 GB/T97.1-2002 Washer 8-200HV 4
45 1040200192 GB/T6170-2000 Nut M8-8 4
46 000209401D1000400 Motor support 1
47 000209401D1000700 Motor cover 1
48 000209401A0000032 Hatch t8 1
49 1040000114 GB/T5783-2000 Bolt M1025-8.8 4
50 1030200210 TX25 Reducer 1
51 1040200326 GB/T6178-1986 Nut M24-8 1
52 1040000198 GB/T5783-2000 Bolt M1650-8.8 16
53 1040300065 GB/T93-1987 Washer 16 16
54 000209401A0000004 Shaft-end baffle t10 2
55 000209401D1000200 Bracket 1
56 000209401D0000013 Shaft 1
57 1040000553 GB/T5783-2000 Bolt M2465-8.8 4
58 1040300049 GB/T93-1987 Washer 24 4

507
SPARE PARTS WA7025-12E-138EN-B03

7.20 Idler Wheel Bogie

Fig. 7-51 000209402D1000000

508
 WA7025-12E-138EN-B03 SPARE PARTS

Table 7-51 Spare parts list of Idler Wheel Bogie (B52-D)

No. Order No. Code Designation Specification Qty
1 1040000488 GB/T5783-2000 Bolt M2470-8.8 4
2 1040300049 GB/T93-1987 Washer 24 4
3 1040500241 GB/T119.1-2000 Split pin B1660 2
4 1040500241 JB/T7940.1-1995 Oil cup M101 7
5 000209401D1000012 Connecting plate t36 1
6 000209401A0000023 Plate 1
7 000209401A0000031 Shaft 1
8 000209401D0000004 Steel sleeve 2
9 000209401A0000040 Bearing seat 4
10 1050200176 GB/T288-1994 Bearing 22220 C 4
11 000209401D1000038 Dust cover 4
12 000209401D1000039 Oil seal 4
13 000209401D1000036 Travelling wheel 2
14 1040600015 GB/T1096-2003 Bond 32110 2
15 1040300432 GB/T858-1988 Washer 90 1
16 1040200486 GB/T812-1988 Nut M902 1
17 000209401D1000056 Shaft 2
18 000209401A0000045 Rail clamp 1
19 1040300067 GB/T93-1987 Washer 10 16
20 1040000931 GB/T5783-2000 Bolt M1020-8.8 16
21 000209401D1000035 Bushing 2
22 000209401A0000061 Bracket 4
23 1040000069 GB/T5783-2000 Bolt M1225-8.8 8
24 1040300054 GB/T93-1987 Washer 12 8
25 000209402D1000100 Bogie frame 1
26 1040000198 GB/T5783-2000 Bolt M1650-8.8 16
27 1040300065 GB/T93-1987 Washer 16 16
28 000209401A0000004 Shaft-end baffle t10 2
29 000209401D1000200 Bracket 1

30 000209401D0000013 Shaft 1

509
SPARE PARTS WA7025-12E-138EN-B03

7.21 Cable Drum

Fig. 7-52 000209940A0000010

Table 7-52 Spare parts list of Cable Drum (M822)

No. Order No. Code Designation Specification Qty
1 1020004122 YLJ112-16N.m-4KW Electric motor 1
2 1029901693 K530 Collector ring 1
3 1030200866 WC97.5-60 Reducer 1
4 1029903916 8YWD.180.008 Flange 1
5 1029903914 5YWD.223.004 Plate 2
6 1029903915 5YWD.089.003.1 Frame 1
7 1029903913 5YWD.269.003 Roller box 1
8 000209940A0000011 Bolt package 1

510
 WA7025-12E-138EN-B03 SPARE PARTS

Bolt Package

Table 7-53 Spare parts list of Bolt Package (000209940A0000011)

No. Order No. Code Designation Specification Qty
1 1040003346 8YWD.932.012 Threaded rod M10260 12
2 1040200113 GB/T6170-2000 Nut M10-8 48
3 1040300061 GB/T97.1-2002 Washer 10-200HV 52
4 1040300067 GB/T93-1987 Washer 10 52
5 1040000095 GB/T5783-2000 Bolt M1660-8.8 7
6 1040200110 GB/T6170-2000 Nut M16-8 7
7 1040300052 GB/T97.1-2002 Washer 16-200HV 7
8 1040300065 GB/T93-1987 Washer 16 7
9 1040000167 GB/T5783-2000 Nut M1055-8.8 12
10 1040000122 GB/T5783-2000 Nut M1035-8.8 16

(THE END)

Thanks for your reading!

511