QTZ4208 tower crane

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Summarize QTZ4208 tower crane is designed by JINAN JIHONG MACHINERY Co., LTD. It makes full use of the grouping technology, composite design technology and finite element analysis technology, which is the newest lifting transportation machinery in domestic and designed with the tower crane microcomputer platform as the tool. This machine is horizontal arm, truck derricking, and upper-circumgyrating hydraulic climbing tower crane. Maximum lifting capacity is 3t, Maximum lifting torque is 385 kN•m. The main features of this tower crane: (1) Performance parameters and technical indexes have reached the domestic and international advanced level. The maximum working range is 42 m, which increases the working space of the tower. (2) The shape is international popular form, beautiful and generous. (3) Working mode various, widely using range. It has two working ways, basic fixed and wall attachment. It is suitable for various construction objects. The independent hoisting height is 28 meters, the attached height is 120 meters (a=2) and 60 meters (a=4) (4) It has high speed, good performance, high efficiency and working stability. There are many single speed motor and winding speed reducer, which can achieve high speed and heavy load, the maximum speed can reach 65.14 m/min. Truck derricking mechanism in horizontal arm traction car horns, has a good performance in installation. By using winding motor rotation, planetary gear reducer and hydraulic coupling, it has high bearing capacity, smooth, reliable working capacity and good ability wind resistance. (5) Crane arm used rigid dual pull rods, which has good rigidity, small light weight, and small wind resistance, even strength and artistic appearance. (6) Various safety devices could ensure the machine work safe and reliable. (7) The hoisting box stands alone and side and has clear view. (8) It is convenient to use and easy to maintenance. The deadweight of the machine is 17.5t; the total installed capacity is 25.7 kW. This machine is always applied to large-scale construction of high-tower buildings, like the high-level hotel, the residential building, which is the ideal construction machinery to the building enterprise. 2. Technical characteristic 2.1 Hoisting performance table Rang(m) a=4(kg) a=2(kg) 3～11 3850 2000 12 3652 2000 13 3357 2000 14 3104 2000 15 2885 2000 16 2693 2000 17 2523 2000 18 2373 2000 19 2238 2000 20 2117 2000 20.97 2011 2000 21 2008 1997 22 1908 1899 23 1817 1809 24 1734 1727 25 1657 1652 26 1586 1582 27 1521 1518 28 1460 1458 29 1403 1402 30 1350 1350 31 1300 1301 32 1254 1256 33 1210 1213 34 1169 1172 35 1131 1134 36 1094 1098 37 1080 1084 38 1075 1080 39 1065 1075 40 1000 1000 41 900 900 42 800 800 2.2Technical feature Project Unit a=2 a=4 Rated load moment kN•m 315 Max. hoisting capacity T 2 3 Rated radius m 3~42 Hoisting height Freestanding m 30 Attaching 120 60 Exterior dimensions of full crane Underbed m 4.6×4.6 Height(Freestanding) 38.36 Distance between the head of counter-jib and swing center 43 Distance between the end of counter-jib and swing center 10.685 Net weight of full crane Structure weight (Freestanding) t 19.405 Counter weight 43.65 Total capacity of the motor kW 25.7 Allow working temperature ℃ -20~+40 Power supply parameter 50Hz ~380V±10% 2.3 The main technique parameters Mechanism loadability Hoisting mechanism JC 40% Slewing mechanism JC 40% Trolley winch JC 40% Hoisting Mechanism Motor Type YZTD225-4/8/24 Running speed r/min 1440 720 220 Power kW 15 15 4 Reducer Distance between center points mm 460 Transmission ratio i 12.5 Winch drum Diameter mm Φ273 Layers 层 5 Rope m 280 Running speed r/min 115 57 17 Brake Type YWZ-250/45-10 Braking force N 450 Wire rope Traction force N 10000 Specification 6×19-11-1770-Ⅰ甲镀右交 Hoisting speed m/min 53.3/26.0 26.4/13.2 15.7/16.9 Rated hoisting capacity T 1/2 2/4 2/4 Min. stabilized load-lowering speed m/min ≤7 Total weight T 1.2 Slewing mechanism Motor Type YZR132M2-6 Running speed r/min 908 Power kW 3.7 Reducer Type XJL-80 Transmission I 195 Output torque N•m 8000 Slewing bearing Type 011.40.1120 Gear Modulus m 10 Tooth counting z 13 Addendum coefficient x +0.5 Torque counverter Type YOX250A Slewing speed r/min 0-0.62 Hydraulic climbing mechanism Hydraulic pump Working pressure MPa 20 Power kW 4 Type of oil pump GB306 Climbing cylinder Rated pressure MPa 20 Diameter of cylinder mm Φ125 Diameter of rod mm Φ90 Stroke mm 1300 Installing distance mm 1700 Climbing speed m/min 0.4 Max. climbing force T 24.6 2.4 Hoisting Characteristic Diagram a=2 a=4 2.5 Power parameters: 2.5.1 Machine total power: 25.7 kW 2.5.2 Power supply voltage: 380V ± 10%, 2.5.3 Power frequency: frequency: 50Hz 3. General introduction of crane construction QTZ4208 self-erecting tower crane is comprised of base, metal structure, working mechanism, electrical control and safety protection device(Fig 1). The structure and characteristic introduction of every part are as follows: Fig1 3.1 General arrangement Before the working height is up to 28m, freestanding is used. When the height exceeds 28m, the attachment is available. When using the attachment, the free height between the top attachment and the focus should less than 22m. The height of the tower is made up of heights of foundation sections and the standard sections. Free standing includes 12 tower sections (1 foundation sections and 11 standard sections). When the max. Hoisting height 120m, which will be made up of 54 tower sections (6 foundation sections and 48 standard sections), meanwhile with 6 attachment devices. The attachment embedded parts are buried in the well counted position，so as to attach the tower to the building with attachment stay bar. In the special concrete base, there is the well prepared stone bolt connected with the underbed. The top of the underbed connects with the tower. The top of the tower connects with the lower bracket and the top of lower bracket connects with the outline of swing bearing. Fastening the inside of the swing bearing is the slewing sections, which includes upper bracket, swing tower, tower head, lifting jib, counter jib, derricking trolley, hook, counter weight, hoisting mechanism, slewing mechanism and the hoisting cab, etc. All these parts could slew 540°around the tower’s axes line on its own plane. The root of the lifting jib connects with the slewing tower and wind connects with the tower head by two lifting jib pull rods. The counter jib foot connects with the slewing tower pin roll and the end are connected to tower head by two counter jib pull rods. Climbing mechanism is set up the central back of counter jib and the slewing mechanism lies in the two sides of upper bracket, the right front of it is hoisting cab. The derricking trolley and hook are pulled by the derricking mechanism to do reciprocating movement along the longitudinal axis of the hoist boom. The climbing mechanism is composed of climbing frame and hydraulic climbing device. The climbing frame is framework steel structure, which connects with the lower bracket with pin roll. The back of it is hydraulic climbing mechanism including climbing cylinder and climbing beam. The hydraulic station sets up to the frame working plate. When climbing, frame lower bracket and the upper section climbs are been as the tower axes line. A tower section is added when the cylinder climbs twice. 3.2 Metal structure Metal structures mainly include underbed, stay bar, tower, climbing frame, upper and lower bracket, swing tower, lifting-jib, counter-jib, Pull rod of lifting-jib, pull rod of counter-jib, derricking trolley, cap head and attaching device, etc. 3.2.1 Underbed (Shown in Fig 2) Underbed is beam structure of “cross” form. a whole beam, two half beams are connected with upper and lower board with 24 bolts. And they are fixed on the foundation with 28 anchor bolts which are in the foundation originally. Welded 4 ear-pedestals are on cross beam, which is bevelled braced on the second standard section individually with 4 bevel rods by ear-pedestals. There are 4 rectangle flanges on the cross beam connected to tower with reinforcing section. Fig 2 Underbed 3.2.2 Tower (shown in Fig. 3) Fig 3 diagrammatic of tower sections There are two kinds of tower section including 1 foundation sections and 12 standard sections. They have the same outline dimensions except for the thickness of their main boom-walls. Reinforcing sections should be install foundation sections successively when used. Upper surface and lower surface of standard section are connected individually by 8 bolts of M27 (10.9 grade) with high strength. There are ladders on each standard section for persons and some standard sections have platforms for rest which are set. 3.2.3 Climbing frame (shown n Fig. 4) Climbing frame mainly includes frame structure, platform, hydraulic, climbing system and standard sections pulling-in device, etc. The climbing operation mainly depends on this climbing frame. Climbing oil cylinder is installed on the beam which lies on the back of climbing frame. Hydraulic pump station lies on the platform at the side of hydraulic cylinder. Climbing frame lies on the outer of tower, the top of which is connected to the lower bracket. Pulling-in window is arranged on the half top of the front climbing frame so as to add standard section. There are 16 rolling wheels inside the climbing frame braced at the outer of tower main robs which serve as leading and supporting components. There is a kelly working platform on the frame to the needs of installation and safety of climbing. When climbing, the workers stand on the platform to operate the hydraulic system to finish the climbing and add the standard sections and strengthen the tower bolts. Fig 4 diagrammatic of climbing frame 3.2.4 Lower bracket, Upper bracket, Hoisting box, Swing tower(shown in Fig 5) The lower bracket has the structure of whole-box. The under part of lower bracket is connected to tower standard section and climbing frame separately. The top surface is tightly connected with the under surface of housing washer of swing bearing which is not swing by high reinforcing bolts. The upper bracket has the structure of plate-shell. Flange with swing mechanism is welded on its left and right sides. Working platform is arranged on three sides of upper bracket. Hoisting box is installed on the front of right working platform. There are lamp socket for searchlight and bracket for swing limiter. The top surface of upper bracket is connected with slewing tower by 4 orthogonal pivots. Swing tower has the structure of whole frame. There is double-ear plate on 4 corners of its top surface connecting to tower head, lifting-jib and counter-jib with pivots. There are 4 orthogonal pivots connected with upper bracket. Fig. 5 3.2.5 Tower head (shown in Fig. 6) Tower head has the structure of front-slope rectangular pyramid. Pulling plate frame, pull plate of lifting-jib and pull plate of counter-jib are welded on its top, connecting with lifting-jib and counter-jib by combined rigid pull rods and pivots. To install each pull rod, working platform is arranged on the cat head connecting with cat head by pivots. Platform can be disassembled when transporting. There are a hoist rope-guiding pulley bracket on the upper section of tower head and a pulley for installation of lifting-jib pull rod onto top of cat head. Ladder with guard ring to cat head is arranged at the back of top tower for convenient installation and maintenance. The bottom of cat head is connected with swing tower by 4 pivots. Fig 6 diagrammatic of tower head 3.2.6 Counter-jib (shown in Fig. 7) Counter-jib has the structure of whole plane. Guard-rail and aisle are arranged on counter-jib. Operating platform is get up at the end of counter-jib. One end of counter-jib is connected with swing tower by 2 pivots. The other end is connected with cat head by 2 combined rigid pull rods. There’re counter-weight and load-lifting mechanism installed at the end of counter-jib. Resistance box and electric control box are set up at the front side. Lifting mechanism has its independent Underbed itself and is fixed on counter-jib by 4 groups of ear-plates and pivots. Fig 8 3.2.7 Lifting-jib (shown in Fig.9) Upper booms of lifting-jib are made of seamless steel tube. Lower booms are rectangle tube welded by two angle irons. The whole jib frame has the section of isosceles triangle divided into 7 sections. Sections are connected by pivots for convenient disassembly and assembly. In order to improve lifting performance and reduce the weight of lifting-jib, lifting-jib adopts double hanging points. Lower chord changes the section into space truss structure. Traction mechanism is set on the second of lifting-jib. Hoisting basket is designed for trolley for convenient installation and maintain. The first section of the root jib frame is connected to swing tower with pivots. Two hoisting points are arranged separately on the third and the eighth section, by which pull rods are connected with top tower. When assembling lifting-jib, tag and assembly must be strictly carried out according to the serial number of each jib. Don’t allow to assemble in wrong position or at will. According to the practical situation, if the length of the lifting-jib needs to be changed, you can change the jib by changing the section number of lifting-jib, the length of the pull rod and the number of the counter weight. Attentions: Upper boom, lower boom of lifting-jib and pull rod pivots are special components. They must not be replaced. Fig 9 diagrammatic of lifting jib 3.2.8 Derricking trolley(Fig. 10) Derricking trolley and lifting hooks are driving along the longitudinal axis items hoist boom reciprocating motion of steel structure, which possesses 4 walking pulleys and 4 directing pulleys and each side has two pulleys. The orbit they running is the lower boom pole of the counter jib. Fig 10 3.2.9 Hook(Fig. 11) The purpose of pulley rate device is to double lifting ability of hoisting mechanism and lower hoisting speed down to 1/2 times. Therefore hoisting mechanism can more flexibly satisfy the demand of construction. The ratio of hoisting pulley can be changed into 2 or 4 by changing the position of active pulley. The ratio of trolley and hoisting hook pulley is 4 when they are out of factory. Fig 11 3.2.10 Attaching device (shown in Fig.12) When the hoisting height is surpassing the freestanding height 30m, we should use attaching devices to fix the tower and the building. The attaching points are shown in Fig. 1. When using the attaching, the free height between the top attaching and the hinge point should no more than 22m. Every set of attaching device includes attaching frames and four supporting rods. Attaching frame is composed of two sets of half-ring beams and 16 sets of bolts of M24, nuts and washers fixed tightly. Four comer points of anchorage splice four brace rods. Frame is hinged with 4 supporting robs at its 4 corner points. Adjustable bolts are arranged on 4 supporting robs at the hinging points to adjust the length of supporting rods. There are big ear-rings at the end of four supporting rods hinging with building. Four supporting rods should be kept at the same level, pushing a head block to fix tower by adjusting bolts. Attaching frame is arranged according to the distance of 4m between crane centre line and building. If the real value isn’t equal to design value, supporting rods can be lengthened or shortened appropriately. But the value must be calculated strictly. They way of connection between supporting rods and building varies according to the facts. According to the project demand, clients and installation departments should appropriately arrange the attaching work of crane and building based on the dimension and structure attaching device and the offered data of intensity load. Fig 12 3.3 Working mechanism Working mechanism of crane includes load-lifting mechanism, swing mechanism, trolley derricking mechanism and climbing mechanism. Brief introduction of them is shown as follows. 3.3.1 Lifting mechanism (shown in Fig.13) Fig 13 Lifting mechanism 3.3.2 Swing mechanism (shown in Fig. 14) Fig. 14 Transmission system of swing mechanism 3.3.3 Trolley derricking mechanism（Fig. 15） Fig. 15 Trolley derricking mechanism 3.3.4 Climbing mechanism (shown in Fig. 16) Fig. 16 The climbing mechanism is composed of hydraulic system pump station, climbing cylinder and soft tube with high pressure, etc. And special hydraulic oil is filled in it. It can lift and descend the upper section of tower frame and keep it at any position to make assembly and disassembly of standard section more convenient. This hydraulic device is of compact structure, high efficiency, convenient application and maintenance, safety and reliability. 3.4 Safety device and debugging Safety device mainly include load moment, lifting capacity, hoisting height, swing and derricking limiter and anemoscope. FKDK multifunctional limiter can efficiently limit load moment. Lifting height and working range. 3.5 Working mechanism Working mechanism of crane includes load-lifting mechanism, swing mechanism, trolley derricking mechanism and climbing mechanism. Brief introduction of them is shown as follows. 3.5.1 Lifting mechanism The type of motor in the lifting mechanism is YZD225-4/8-15/15/4KW. The mechanism can get the hoisting feature of light load and high speed, heavy load and low speed. When hoisting things are in the highest position, the lifting mechanism can stop automatically. 3.5.2 Swing mechanism Swing mechanism is double driven. They are arranged symmetrically on both sides of swing gearing. The type of motor is YZR132M2-6，3.7kW. Swing limiter is installed on the upper bracket, meshing with swing gear ring by small gear to control lifting-jib swing in about 540° to prevent twisting the cable. According to the practical brake effect in application, adjusting nut (part 1) will shorten the distance between brake disc and friction wafer when braking moment is not enough. When the brake moment is too excessive, adjusting nut will increase the distance between brake disc and friction wafer. Trying operation for several times after adjustment is completed each time. Ensure the components 4.6.7 sliding on guiding bolt 5 without resistance and accurate shut and open action. Spring 5 should be replaced when it rusts seriously. 3.5.3 Trolley derricking mechanism Trolley derricking mechanism utilizes motor of YD100L2-4/6 2.2/1.5KW to drive the reduction unit in winding drum to make trolley do derricking movement at 40/22 m/min speed. The whole structure is compact. One end of two rope is separately fixed on the winding drum and the other end is fixed on the load trolley to make the trolley operate normally by tightening and loosing the rope when derricking. 3.5.4 Climbing mechanism The climbing mechanism is composed of hydraulic system pump station, climbing cylinder and soft tube with high pressure, etc. And special hydraulic oil is filled in it. It can lift and descend the upper section of tower frame and keep it at any position to make assembly and disassembly of standard section more convenient. This hydraulic device is of compact structure, high efficiency, convenient application and maintenance, safety and reliability. Application, maintenance and attentions of hydraulic system are shown in detail in instruction manual of accessory components. 4. Crane installation Clients should read the instruction manual to install correctly and quickly. Truck of 20t is needed when crane is installed. It takes least time to hoist with truck if we can coordinate the steps of installation and assembly properly and assign crane-installed personnel reasonably and coordinate the relation between aisle and installation spot. 4.1 Attentions of assembly 4.1.1 Installation of crane can be carried out when the wind is below 4 grades. 4.1.2 The company, who is responsible for installation and removal of the crane, should possess certificates of qualification. During the installation and removal of cranes, the technicians should draw up the written the installation and disassembly procedures and operations according to the according to the site actual situation, then present all these to the crane operators. 4.1.3 Prepare all protective devices before installation and carry out security examination when necessary. 4.1.4. Pay attention to the choice of hanging points; choose handling devices which are of proper length and liability according to hoisted parts. 4.1.5. All dismountable pivots of every crane component, bolts for tower and nuts are special parts. Clients can’t replace them at will. 4.1.6 Installation, assembling good pin shaft ends in accordance with the provisions of the split cotters must open. Axial end flap bolts, and other bolt rope card connecting bolts should be strong and reliable and conform to the relevant provisions. 4.1.7 highstrength bolt connection surface is not greasy, should have the gush arenaceous or steel wire brush to clean. 4.1.8 jack-up, prohibit rotary hoist boom, banned cars, and prohibit moving range start lifting mechanism. 4.1.9 Installation site of the size and the relative position of building foundation (see figure 17, site should level off without sundry and obstacles. .4.1.10 Installation location of crane worksite must ensure the distance of above 10m between max. Swing sections of lifting-jib and hook way from wine. Fig 17 4.2 Foundation and ballast This crane adopts holistic concrete foundation or is used together with ballast. Soil of foundation should be massive. Intensity grade of concrete is C35 (GB50164-92). The resistance force of concrete foundation shouldn’t be less than 3.2 the setting value in table 4. The flatness error of concrete foundation surface can’t exceed 2mm. 4.3 Grounded device Grounding of crane lightning rod and protective grounding should conform to related regulations, and the material for grounding, installation and maintenance etc. are not supplied by factory. 4.3.1 Connect cable of grounding protective device with bolts of any main rod and clean the paint of bolts and nuts. 4.3.2 Underbed on the ground can’t be used for lighting rod of grounding. 4.3.3 The resistance of protective lighting device can’t exceed 4Ω. 4.3.4 Grounding device should be installed by professionals because resistance ratio will vary largely with time and condition. And it needs instrument with light efficiency and precision to measure resistance. Check grounding wire and resistance periodically. 4.4 Installation process of crane 4.4.1 Installation of Underbed Assemble cross beam of Underbed and put it on the platform of concrete foundation. Install press plate and screw the foundation bolts, and measure the bracket parallelism of four lips and four inclining rods. Its error should be within 1.6 mm. If the error exceeds 1.6mm, we should adjust the surface between bottom plate and foundation to level with wedge and iron plate. Keep the wedge fixed firmly. Don’t allow the wedge to loose and screw grounding bolts again. (Double nuts resisting loose) 4.4.2 Installation of standard sections (shown in Fig. 18) Reinforcing section is hoisted to climbing frame. Connect it to climbing frame with 16 grade M27 reinforcing bolts connects the underbed and foundation sections. （pretightening moment of the bolt is 1350N.m）then, two sets of foundation sections are hung stalled. The foundation sections are connected by 8 grade M27 reinforcing bolts. Attentions：Put hydraulic climbing pump station on the climbing frame platform near climbing cylinder. Fig 18 Fig 19 Fig 20 4.4.3 Installation frame (shown in Fig 19) Installation of the frame includes the fix of the frame platform, the climbing cylinder, and the lifting of the climbing frame. 4.4.4 The assembly of slewing parts (shown in Fig. 20) Slewing complement includes the lower bracket, sewing bearing, upper bracket, slewing mechanism and hoisting box. The lower and upper bracket, slewing mechanism and slewing bearing has been installed as a whole part when out of factory. (Fig 20) Assembling the lower bracket, swing bearing, upper bracket, slewing mechanism and the hoisting box to be as a whole on the ground. Lifting the slewing part, aims to the upper base to tower section and fixes them with 72 sets of 10.9 grade M20 reinforcing bolts. At this time, the power cord should be near to the hoisting box, and switch on the power to try and reserve. 4.4.5 Install the tower head(shown in Fig. 21) As Fig 7, connect the tower head platform with the ladder and tower head body. The top ear board of the counter jib pull rod and the first rod should be connected to the tower head withφ70 pin rolls (pay attention to the wite roll between ear boards). Then hang return the tower head to slewing tower and connect them with 4 setsφ50×105 pin rolls. When lifting, the upright side of the tower head towards to the lifting jib Fig. 21 Fig.22 Fig. 23 4.4.6 Install the counter jib Assemble the first and second section together and inserting the rail to the floor installation point split cotters. After the well installation all the rails, use the bolts and splint connecting them together. Join well every part cables, and assembles the jack box and the second section of counter jib rod on the counter jib main body. Tie a long hemp rope at the end of the counter jib to control the direction and position of it. Tie well the rope to the lifting eye. Lift the counter jib and test the stability of the hoisting. Then install it withφ50×179 pin roll to swing tower. Raise tail of the counter jib to some angle and install well, then set level the hoist and release the hook(Fig. 22). Hoisting two counter jibs, set to the end of the counter position and fixes. Switch on the power, try and use(Fig 23). 4.4.7 Lifting jib and the lifting jib rod installed: Carefully check the fastener pin shaft, use correctly, connection, split cotters installed correctly. Check whether the circuit on the arm. Note: 1.the car, car maintenance and installation with the crane cage should be on the same side. In XiaXian into single head should pin shaft axis plane with arms frame mounting holes inside the stop position of board, avoid pin shaft will stop board top off or welding, if this will happen in the work of installing the serious accident hoist boom. Fig 24 Rope round horn wear Fig 25 Combined arms with pin shaft connecting rod, suspended in the arms bend after the stem rod rack, and protect wire securely. To prevent the hoist boom in installing a process, can be in the proper rod down with wire rod and location will be bent frame pole arm tied 1-2, to install hoist boom bars and will cut wire. Inside the car, make its move to rely on the brake block hoist boom, with one end of the rope will be fixed in the car, traction institutions drum drum, rope around the other side guide wheel root from arm, through the wirerope break through the protector of wire rope clamps, use fixed in luffing cars. The car before drawing rope around: will wear in the rope end fixed in the drum drum, around 3-5 laps, end through the arm shelf wheel, wirerope break through the protector of wire rope clamps, use fixed in a car(Fig. 24). In the integral hoisting hoist boom should be done before the following: Please confirm that the plane before lifting arm positioning pin shaft internodes, check whether the axial end flap welding normal, Will load car platform truck in the car on the installation, In the arms of a long twine, facilitate ground control in the direction of hoist boom. Fasten the hemp rope should be paid attention to when disassembled. Hoist boom on the linkage connected pin shaft hoisting rope should stay away from the position, or in a rod with rope interference occurs when, easy cause accidents. Note: the sling should hang lever nodes in bend before or after, cannot be hanged in the oblique flank rod. Do not put in the tension between the hoisting ropes. (Fig. 25) Hoist boom will lift from 100mm to check whether the balance, and adjust to balance position will sling. Attention to find balance position and well marked down when the towers, ready to use. Lifting the hoist boom to the connection with rotary mai, use 2 φ 50×163 with shoulder turn head pin shaft and towers connected, insert split cotters lock. Hoist boom will end up certain Angle, according to the chart shown around the rope in 36, and start lifting mechanism, using lifting rope traction to three rate lever upper hoist boom will be connected to the tower of hole traction, packed tassel, then slowly pin shaft hoist boom will release lever to force (Fig. 26) Fig. 26 Fig. 27 Rope round tightrope Fig. 28 Climbing frame 4.4.11 Electrical installation and debugging 4.4.11.1 Electrical installation a. After crane installation completely, electric can be installed, referring to principle figures, external wiring diagrams, controlling wiring diagrams. Join up the circuits of controlling and power cable, brake cable, safety device, grounding device, obstacle light, search light anemoscope etc. b. Before supplying electricity, Check electric system and conform to the requirements. c. All circuit must be correct. Cable needs to be fixed should be mounted reliably to avoid destroying cable when crane is moving. d. Before electrify, insulated checking should be done. The main circuit and controlling circuit’s dielectric resistance to ground is more than 0.50hm. Ground resistance for tower should be below 4 OHM. e. Main cable (ground and hoisting box’s cable) should be through guard ring before entering hoisting box and reserve appropriately length to prevent cable when crane slews one and a half circle and crane is climbing. f. Put all operating mechanism of hoisting box on safety position. And put main switch on power failure position; finally connect power cable of ground. 4.4.12.2 Electrify debugging a. Turn on the power, supply electricity for hoisting box be sure that three-phase power is be three-phase balance and the voltage is 380v±10% (Ground electrical not supply enough capacity to make sure motor’s normally ) b. Loosen height limiter and derricking limiter, coordinate machine installation, wind rope of lifting trolley. c. Debugging of lifting mechanism Firstly operate lifting handle, then observe the conditions. When derricking handle pulled inward the hook moves upward. Otherwise the hook moves downward if not adjust the phase order of power for lifting motor. d. After lifting debugging completed operate swing handle and derricking handle respectively. Swing handle pull award trolley goes inward otherwise go outward. If not adjust, the phase order of each power should. 4.4.12 Climbing tower sections 4.4.12.1 Preparation before climbing a. testing all the connection is comply with regulations and ensure all connections to be correct b. Fill hydraulic pump with oil in regular pump station. c. Check whether the components for lifting and in normal condition. d. Clean each of standard sections, smear butter on upper standard section. Line up the standard sections that are going to be added to tower in a row under cargo boom lying on climbing position. Firstly, install strengthen section in order, then install standard section unreversed. It can save time in the whole progress of adding section without swing mechanism. e. Check the cable length and ensure the adequate used length. f. Swing cargo boom to front of climbing frame and counter-jib lies back of frame (climbing oil cylinder lies rear of frame). 4.4.12.2 Climbing operation Firstly fix four inlet rollers on four corners of tower standard section on ground. Then hoist standard section and put it on external frame of platform. Disassemble high strengthen bolts of M27 between lower pedestal and standard section. Put two axial heads of climbing beam in grooves of pedals precisely and hold it uprightly. Let climbing beam as near tower as possible. Keep it possible in a level with longitudinal axis of oil cylinder, start up hydraulic system and let piston rod stretch out 20-30mm. separate barely the surface of lower bracket and the standard section, then hook moves outwards from root of arm at the same time. When the gap between sixteen guide wheels around climbing frame and tower is basically symmetrical, stop the derricking trolley. (Fig. 29) Fig. 29 Continue to start hydraulic system to stretch out piston rod about 1280mm. Withdraw piston rod slightly and put guide claw on the pedal of standard section, then piston of oil cylinder withdraws completely. Emplace the axial ends of climbing beam renewably and accurately in groove of the previous group of pedals of standard section and hold it uprightly again. Stretch piston rod of oil cylinder again until there is just space for a standard section at the top of tower. Standard section can be pulled to the right top of tower by rolling wheel. Locate dummy club of standard section and withdraw oil cylinder until dummy clubs of upper and lower standard section are connected rightly. At this time, conjunct upper and lower standard sections firmly with eight reinforcing bolts of M27. Demount rolling wheel and adjust the stretching length of oil cylinder. Connect lower bracket with standard sections firmly to complete the work of adding a standard section. If several standard sections need to be added continuously, repeat the process several times according to above steps. 4.4.13.3 Attentions: a. When climbing the wind speed should no more than 13m/s, wind power should be less than 4. b. The former should make them turn in the braking condition; absolute organization does not allow having the rotary motion. C. In climbing process, in addition to its own needs hoisting installation, tower cranes are not allowed hoisting working. d. Before the operation of the climbing cylinder, should check if bolts been released between the lower bracket and tower. e. Swing mechanism brake is needed in the process of climbing. Brake lifting-jib and prevent lifting-jib from swing to make it sure that the lifting-jib and pulled standard section come in the same direction. f. Professional personnel need to hold climbing beam upright and make it sure that axle ends in pedal grooves are in its precise position in climbing process for safety. g. If several standard sections need to be added continuously, each main rod of tower and lower bracket must be connected with bolt of M33 after adding a section and before hoisting the next section. If sections aren’t continued to be added, the eight bolts with high strength between lower braked and standard section must be connected well. h. Pedals of the added standard sections must be adjusted well to the existing standard sections. 4.4.13.4 Install 4 inclining supporting rods (shown in Fig. 37) After adding the second standard sections, tighten eight bolts between lower bracket and standard sections. Install upper ear bracket of four motive supporting rods on four main rods of the second section. Then connect four inclining supporting rods separately to the direction of diagonal line between Underbed and tower with pivots. 4.4.13.5 Texting and inspection after installation After adding sections, slew jib frame to different angle to examine the tightening state of each connection point of tower, Underbed, reinforcing sections and ground bolts. (Tighten the nut when the main rod lies under the counter-jib and in this way tighten all nuts down to up, and use double nuts to prevent loosening for connection.) At this time, the whole installation of crane is completed. But perpendicular alignment of tower should be checked and the allowable error is 2/1000. And then crane gets into normal working state after debugging. Sections can be added in the above mentioned way if necessary. Put climbing frame down to the bottom of tower or the attaching frame and tighten it after the climbing work is accomplished. 5. Safety device and debugging Safety device mainly include load moment, lifting capacity, hoisting height, swing and derricking limiter and anemoscope. FKDK multifunctional limiter can efficiently limit load moment. Lifting height and working range. Detailed debugging can be shown in operation instruction. Install position of safety device. (Shown in Fig.30) Fig. 36. Disassembly of crane 6.1 Disassembly attentions 6.1.1 Before crane is withdrawal from worksite. Maintain and try operating climbing mechanism because of out of use for a long time. 6.1.2 In the course of operating the liability of limiter and brake of swing mechanism should be examined for purpose. 6.1.3 After standard sections of tower have been disassembled and before climbing frame and tower have not come to a whole body prohibit using swing mechanism. 6.1.4 It’s a continuous heave load work for climbing mechanism to disassemble crane. Therefore, components suffered loads of climbing mechanism should be often examined. 6.1.5 When climbing mechanism is in operation all operating personnel should relative position of relative moving parts normal or not. (For example, position between rolling wheel and main rod position between climbing frame and tower.) If there is deflection between climbing frame and tower when climbing frame is ascending, stop climbing and descend at once. 6.2 Crane removal methods: Remove tower is a very dangerous, the former should make full tower of preparation. Remove oxides balance weight and balance, hoist boom should strictly according to the arms of a program, in order to prevent when removed a part, when installing lose balance tipping accident. 6.2.1 Open the preparation before tower Open the tools and tower crane tower, and made the same. Clean up the ground site to open to the ground when installing component plenty of space. When the weather conditions do not disassemble tower when homework. 6.2.2 Disassembly method of crane Disassembly order of tower crane is reversed process of installation. That is, components of subsequent installation should be disassembled first and those of previous installation should be disassembled later. Because disassembly of crane is always carried out after project is almost completed or unused for a long time. There may be some problems in device technological state and good condition. Therefore, attentions should be focused on the preparing work during disassembly of crane. Disassembly of crane can be carried out based on strict inspection and enough preparation after liable measure has been taken according to practical condition. Attentions during disassembly of crane are shown as follows: （1）Carefully Check main components suffered load whether they are in good condition before disassembly of crane, welded position in normal state or not, each bold of fixed position in good condition or not, each pivot and choke in complete state or not. （2）Carefully Check electrical system whether in normal and good state and liable or not. （3）Check the operation of each mechanism, especially hydraulic climbing mechanism whether they are in normal condition or not and its technological state liable or not. （4）Slew counter-jib to the direction of window four pulling standard section and locate liably with devices such as swing limiter. （5）Disassemble down eight bolts connecting the top standard section with lower bracket, and start pump station and stretch out the piston rod of oil cylinder. The axial ends of climbing beam are in the corresponding pedal groove of the second standard section and hold if upright. Make climbing beam lie as near as possible to tower and at the same surface with longitudinal axis of oil cylinder. Hoist upper mechanism of crane slightly and when lower surface of lower bracket and the first standard section just separated then hook moves out from jib root. Observe the gap between front-back guiding wheel of climbing frame and tower, when the gap is basically even (1.5¬2mm or so). Namely basic balance, the trolley will stop. (record the balance point ) （6）Disassemble eight connecting bolts between the first and the second standard sections. Continue to start pump station. Make piston rod of oil cylinder stretch out to climb in two steps keep the distance of two standard sections about 50mm, and then install left and right pull in pulley. Push the first standard section out to climbing frame along pull in platform. （7）Operate directior valve, shrink piston rod of oil cylinder and at the same time put climbing claw in pedal groove at proper time, until climbing beam is hoisted from the next group of pedal grooves. Operate direction valve, the piston rod of oil cylinder stretches out until the two axle ends of climbing beam are put in the next pedal grooves exactly and climbed 50¬100mm. Hoist the climbing claw to make climbing frame continuously drop. （8）Operate directior valve, withdraw piston rod of oil cylinder until the lower surface of lower bracket and top surface of the second standard section contact install a standard section connecting bolts of tower at opposite angle and fix them. （9）Put standard section hanged by main hook of tower on ground and then drive trolley to the balance spot. （10）Disassemble four bolts of lower surface of lower bracket. Repeat the action for 6¬9 times. And in this way, standard sections can be disassembled successively. Attentions: When there is attaching device, disassemble corresponding attaching device until climbing frame descends to that standard section. But the attaching device must not be disassembled earlier. （11）When climbing frame descends to the top of four inclining supporting rods, disassemble supporting rods first to lessen disassembly height. （12）When climbing frame descends to the lowest position, disassemble hoist rope and hook group and cable of lifting-jib and counter-jib. Then disintegrate counter-weight group in weight cavity and disassemble some counter-weight. Leaves a piece of counterweight at the end of counter-jib and fix it tightly and prepare to disassemble lifting-jib. （13）Elevate the lifting-jib to the angle of 10°~20° with truck of 20t at the hoisting point where lifting-jib being installed. Disassemble pivots between the first and the second pull rods respectively and tighten the pull rods of lifting-jib with iron wire, and then put the jib slowly. Disassemble pivots of jib root and put counter-jib to the ground bracket slowly. （14）Disassemble the left counterweight of counter-jib. Elevate counter-jib to the elevation angle of at the hoisting point (remark it) where counter-jib is installed. Disassemble joint pivots between the first and the second pull rods respectively and tighten two pull rods of counter-jib with iron wire and then put the counter-jib slowly. Disassemble pivots of jib root and put counter-jib to the ground slowly. （15）Disassemble the cable between hoisting box and the exterior. Disassemble hoisting box, cat head, upper bracket, lower bracket in turn. （16）Take out the climbing frame from tower section and disassemble tower sections in turn and then disassemble Underbed and its casting die. At the moment, the work of disassembling tower is basically completed. Wind should be less than four degree when disassembling because building has been built up. The worksite is not as wide as the space where crane is installed. Do pay attention to working procedure and position for disassembled things. When disassemble crane, do take care, otherwise, the accident of safety may occur. 7. Use of crane 7.1 Work before use Before use Check all-rounding and tested are necessary. Test mechanism and safety device. Prevent the crane’s use and safety from uncontrolled and insecurely accidents. 7.1.1 Check items after holding crane Table 8 Checking items after holding crane Checking items Checking content Underbed Check grounding bolts The safe distance between wire and Max. swing section of crane should be 5m and Check cable to prevent damage Tower Check standard section bolts. There is a rest platform every three standard sections. Climbing frame Check connection with lower mount. Check climbing claw flexible and liable or not. Check fastening roils. Upper and lower mount hoisting box Check fastening for bolts connecting swing ring. Check operation of cable (cable should pass from the right of upper bracket and bottom of ladder and lower steel ring) Check connection with hoisting box. Check fastening of platform and banister. Forbid preserving grease oil cotton oil and another tinder in hoisting box. Tower head Check the installation of lifting-jib and counter-jib rod. Check the installation of ladder platform and guard rail. Make sure lifting rope winds correctly. Lifting-jib Check the installation of pins washer and cotter pin. Check installation and operation of trolley and fastening of manned nacelle. Check winding and fastening of hoisting and derricking rope. Counter-jib Check fastening of counter-jib. Check installation of counter-jibs guardrail and walkway. Make sure there are not incidentals on walkway. Hoist device Check defect of lifting hook. Make sure type and specification of lifting ropes and derricking ropes being up to the mustard. Check wearing degree of rope. Mechanism Check installation and operation of each mechanism. Make sure studio gap along. Check hastening of rope head. Safety device Every safety devices must be adjusted according to the requirements in chapter5 Check installation and fastening of all ladders, guard rail and rest platform. Lubrication Check lubrication and do according to the instruction. 7.1.2 Do the following examination in turn after crane is assembled. 7.1.2.1 Unload test Each mechanism should operate for several times respectively, and then operate comprehensively for 3 times. There should not be any abnormal phenomena in operation process. Otherwise fix a breakdown timely. 7.1.2.2 Dead-load test Dead-load test should be carried out after examination without load passes. Static load test should be performed according to the 4.5 rule of GB/T5031-1994 “performance test of crane”. 7.1.2.3 Choose proper hoisting capacity and its corresponding max. range. Make dynamic load experiment under the overload of 10%. This experiment should be carried out according to addenda B of GB/T9462-1999 “technical condition of tower crane” 7.2 Safety operation instruction 7.2.1 Driver and hoisting personnel 7.2.1.1 Implementing the corresponding regulation of 《operation instruction of tower crane》. Drivers and hoisting personnel must be those who pass the examination and get the certificate according to corresponding regulations of provincial public security and inspection department. 7.2.1.2 Drivers must know about the working principle of operation. They must be familiar with the construction of crane, functions of security device and adjustment methods. They must master operation methods of each feature of crane and maintenance technology of crane. 7.2.1.3 Forbid pulling things inclined and hoisting things with unknown weight or rooted things. 7.2.1.4 Forbid carry persons with cranes. 7.2.1.5 When there’s hanging things in the sky, driver and hoisting personnel can’t leave worksite. 7.2.1.6 Commanding signal gesture and flag should comply with the regulation of GB5082-85. 7.2.1.7 Drivers must make well the operation, repairs and maintenance of crane and record the shift well. 7.2.1.8 Strictly prohibit that drivers operate crane after drinking. 7.2.2 Mechanical pacts and others 7.2.2.1 Ambient operating temperature of crane is -20℃~+40℃. Wind should be below six grades when working. 7.2.2.2 All security device of crane must be maintained at any moment strictly prohibit moving and disassembling at random and over-load application. 7.2.2.3 There should be enough lighting condition on the construction spot at night. 7.2.2.4 It should be ensured that crane supplied voltage is within the range of 380v±10%, otherwise, electrical device is inclined to be damaged. 7.2.2.5 When working, approached the cranes standing under the hoist boom is strictly prohibited 7.2.2.6 Prohibit driving without a license, the installation, maintenance, driving personnel shall climb oxide without permission. 7.2.2.7 The driver in the total power pen with closed must check whether there is electricity crane metal structure, ensure safety after the escalator. 7.2.2.8 Attentions before the large reparation or renewing installation for crane. a. Carefully examine each joint link and make sure whether the pines are crackle rusty and abrasive or not. b. Examine if the important parts such as rigid pulled, rope, pulley, hook etc. conform to the application condition. c. Examine if deformation of medal structure parts and welding slit conform to the application condition. d. Try to operate climbing, hoisting, derricking and swing actions until they are in good condition. 7.2.2.9 Examine whether electrical control system conforms to the requirement or not, when crane is being repaired and maintained. Cut off the total power supply and prohibit operating with electricity. Specify personnel should be assigned to command crane operation at the sites of ground, floor platform and surface of construction. Strict signal or gesture flag signal are used to contact with drivers. We’d better contact each other with walkie-talkie. 7.2.2.10 Downtime repair or maintenance, must cut off the power, forbid charged. 7.2.2.11 he ground, building, construction surface to set, and the command commanders’ tower, strict must contact the driver of signal or gestures, banner etc, had better use walkie-talkie contact. 7.2.2.12 the driver lifting weights and pass on the personnel must be sound bell warning, homework thought to highly concentrated. 7.2.2.13 Prohibit hoisting operation when encountering thunder storm, rainstorm and thick fog or wind exceeding 6 grades. When wind exceeds 10 grades, we should drop tower below the height of five standard sections or tighten it with rope to ensure safety. 7.2.2.14 when several cranes come into a construction site at the same time, the arrangement of crane should be appropriate but they can’t intervene and interfere with each other. 7.2.2.15 When drivers switch on guard power and enter hoisting box, they should check buttons. Operating handles all-around to make sure whether they are in idle state. Start the chief button if there is no problem. 7.2.2.16 The hoisting box strictly flammable and explosive substances deposit. Heating in winter, please note fire. 7.2.2.17 Driver must operate crane strictly according to crane technical performance table and hoisting feature curve. Strictly prohibit over load and forced operation. 7.2.2.18 Prohibit hook landing on the ground when crane is operated. Not to cause rope of winding drum disorderly to be damaged. Pay attention to the arrangement of winding drum rope when hook is hoisted again if hook has to land on the ground. 7.2.2.19 Hoisting hurdle on the side of trolley is used for maintenance, when a certain part of jib needs repairing, personnel can stand in the hoisting hurdle, moving to the assigned position with trolley to complete maintenance. Rated loading weight of hoisting hurdle is 100kg. Strictly prohibit persons standing in hoisting hurdle when lifting heavy-things. Strictly examine if the link between hoisting hurdle and load trolley are in good condition or not when upholding crane and installing lifting-jib on the ground. 7.2.2.20 when each mechanism needs to operate in the opposite direction, we must start motor in reversal after it stops vice versa. 7.2.2.21 Lifting mechanism with slow lifting weights, shift running time cannot too long, every 10 minutes in continuous operation shall not exceed 2 minutes, lest burned-out motor. 7.2.2.22 How to have the operation, must file organization by the slow to fast or slow, prohibited by fast to the shift operation, each time a minimum shift transition should ensure 2-4 seconds. 7.2.2.23 Cut off power at once when there is abnormal phenomenon in crane, continues to work after the malfunction has been checked up and eliminated. 7.2.2.24 after a shift of operation has been completed; lifting-jib needs to be turned to the parallel direction of building. When hook ascends to the height away from the highest building, trolley should be at minimum range of lifting-jib and leave after the total power is cut off. 7.2.2.25 Drivers must check up and tighten the pivots and bolts on the key components including the tower, jib frame, swing gearing, rigid pull rod of lifting jib, rod of counter-jib, connecting bolts of winding drum and retarder, etc. before work every day. Operation is allowed after no slack or disengage exists. 7.2.2.26 Drivers should maintain and lubricate retarder, pulley, bearing bracket etc. every day according to regulations. If there is oil leaking, do with it timely. 7.2.2.27 before formal operation, drivers must successively check the liability of security device. Prohibit forced operation when security device is not liable or out of order. 7.2.2.28 Work as brake failure tower, drivers should be calm, warning signal, a turn to empty place,  motive power control weight falls to the ground, forbidden by gravity. 7.2.2.29 When installing, first find electricity reasons, such as electricity for a long time, it should take measures, the first drop to the ground slowly, weight lifting with artificial control (brake electromagnet). 7.3 Maintenance before work every day 7.3.1 Often keep whole crane clean and clean it timely. 7.3.2 Check oil quantity of retarder fill on timely. 7.3.3 Check whether there are loose ends, broken wire and abrasion of each rope. Replace it timely if they‘re out of regulations. 7.3.4 Check the efficiency, gap of brake and ensure its liable sensitivity. 7.3.5 Check the sensitivity and reliability of each security device. 7.3.6 Check the joint points of each bolt, especially the linking bolts of tower standard. Tighten them again after they’re employed for same time. 7.3.7 Check whether press plate of ropes and clip of ropes are loose or not. Tighten them timely. 7.3.8 Scrap of rope, winding drum, pulley, hook etc. must strictly conform to the regulations of GB5144-88 and other corresponding standard. 7.3.9 Check whether there’re crackles on rods of metal components, belly rods and welding lines. Especially pay attention to the position of paint falling off. It’s very dangerous when the paint falling off is of 45° stripe. Find out the reason and do with it timely. 7.3.10 Linking bolts and nuts of crane (including the connection points between reinforcing section and Underbed) and each pivot where diameter is over ф20 are special component. They can’t be replaced in any case. 7.3.11 Bolts performance degree of tower standard section is 10.9 grade and nuts is 10grade (locknut). There must be performance degree signal on the top surface of bolts and head-top surface of nuts. Otherwise prohibit using. 7.3.12 Crane and metal mechanism should be rusted and painted after every project. 7.3.13 Lifting ropes are worn and pulled longer after they’re employed for a long time. The height limiter needs to be adjusted renewal according to regulations. 7.3.14 Examine whether each electrical head is oxidized or damaged. Repair or replace them if they are abnormal. 7.3.15 Each limiting location switch and button should not be out of order. Parts which are rusty or damaged should be replaced timely. 7.3.16 Installation of each motor switch and switch board must be in good state. Its insulation resistance should not less than 0.5MΩ. 7.3.17 Check weather tightening bolts are loose, cable and other wires are broken. If so, remove them timely. 7.4 Main troubleshooting Problems Reasons Solution 1 Because of gliding of brakes, hook gliding and derricking trolley gliding out after being braked. Brake moment is too small. Brakes surface is oiled and brake time is too long. Adjust spring pressure of brake. Clean oil and adjust brake shoe gap. 2 The shock of brakes load is too big. Brake too quickly. Gap of brakes shoes is asymmetric. Adjust the gap of brake shoes or increase stroke of hydraulic pushed. 3 Heat and smoke in the swing process of brake. Gap of brake shoes is too small. Increase gap of brake shoes. 4 Temperature of retarder is too high. Lubricant is too little or too much Pay attention to increasing or decreasing oil. 5 Temperature of retarder bearing is too high. Mainly grease is too little or too much Quality of grease is low. Axial gap of bearing can’t satisfy requirements or bearing is broken. Replace grease according to rules and adjust gap of bearing or replace bearing. 6 Retarder leaks oil. Seal of connection and seal of axial-end are damaged. Replace sealed. 7 Swing mechanism doesn’t work. Be sure that no foreign material in engaging point oil of hydraulic coupling mechanism is too little. Clean foreign material thing and increase oil. 8 Ram of swing mechanism is too big. There is too much oil in hydraulic coupling mechanism. Decrease oil properly. 9 Lifting is too slow. a. Pump is abrasive and efficiency goes down. b. Oil is too little or oil filter is blocked. c. Manually directior valve and valve opening are damaged seriously. d. The seal of cylinder piston rod is damaged and leaks inner. Repair or replace damaged parts, increase oil or clean filter. 10 No power for lifting or can’t lifting. a. Pump leaks inner seriously. b. Adjusted pressure of relief valve is too low. c. Valve core of manual directior valve is excessively abrasive. d. Relief valve is dipped. Repair or replace abrasive parts, adjust pressure according to 2.3.4.21 11 Appear noise and vibration when increase pressure of lifting. Oil filter is blocked. Clean filter. 12 Lifting system can’t work. Swing direction of motor is not the same as oil pump. Changer revolving direction of motor. 13 Appear creeping when lifting. a. There is air in piston rod of cylinder. b. There is obstacle in guide mechanism. Repeating exhaust unloaded. 14 Drop itself loaded. a. Hydraulic lock of cylinder is breakdown. b. Seal of cylinder is damaged. Remove malfunction Replace seal 15 Derricking mechanism can’t work. 1. Connection wrongly 2. Fuse fused 3. Cutting out earth correction or breaking among phases of motor winding group. 4. Voltage of motor is too low 5. Winding connection is wrong. 6. Solenoid brake doesn’t declutch. 7. Load is too big or transmission machine is breakdown. 1. Check correcting diagram 2. Check fuse capacity is too small or replace. 3. Measure the voltage. 4. Find out cutting out by supper power at different speed. Repair breaking. 5. Check voltage of brake and winding is breaking or clipped. 16 Abnormal noise appears in derricking mechanism and vibration is too big. 1. Stator rotar scrub each other. 2. Motor and retarder are not concentric 3. Bearing is short of oil seriously or damaged. 4. Gears are abrasive. 5. There is noise when two phases operating. 1. Check gap between stator rotor is uniformity 2. Readjust concentricity between motor and retarder. 3. Clean bearing increase new lubricant or replace bearing. 4. Replace retarder 5. Switch off power Check and repair it. 17 The temperature of motor of derricking mechanism is too high or smoking. 1. Load is too big 2. Load and operation don’t measure up 3. Two phase operate. 4. Power voltage is too low or too high 5. Motor winding is wiring or cutting out among phases. 6. The gap of friction plates is not proper. 1. Measure current of stator decrease load if exceeding rated valve. 2. Load according to requirement 3. Measure three-phase current and remove problem 4. Check input voltage and correct it 5. Find out reason and repair it. 6. Adjust air-gap according requirement. 7. Check brake voltage and operating time of delay brake, remove the problem. 8. Keep up air chimney. 18 Bearing of derricking mechanism is too heat. 1. Bearing burned out. 2. Crease is too much or too little. 1. Replace bearing. 2. Increase grease according to requirement. 19 Derricking mechanism electrification 1. Power cord and each connecting wrong. 2. Grounding badly. 3. Wiring of motor is grounding. 1. Check and correct it 2. Correctly grounding 20 Derricking mechanism brake is out of order 1. Brake moment is too small 2. Wearing void of friction wafer increases. 1. Spring of brake is broken or out of order to replace it. 2. Brush is broken, voltage is not enough. 21 It can’t work when the whole starting 1. Operating grip doesn’t zero adjustment. 2. Fuse burned out 3. Activate button and stop button connect badly 1. Grip zero adjustment 2. Replace fuse. 3. Repair or replace button. 22 Trip when lifting operation Check if climbing brake weather open and measuring valve changes. 23 When derricking, there is 2speed but no 1speed. 1. Connect of grip is badly. 2. Point of contactor connects badly. 3. Motor is damaged 1. Repair contact point of grip 2. Repair or replace contactor 3. Repair or replace motor 24 When derricking, there is 1speed but no 2speed. 1. Limit switch or contact point contact badly. 2. Motor is damaged. 1. Repair or replace limit switch 2. Repair or replace motor 25 Swing brake can’t work. 1. Brake switches contacts badly. 2. Rectifier burned out 3. Contact point of delay relay contacts badly 1. Repair or replace brake switch 2. Repair or replace damaged component. 26 Radius indicator with unprecise indication or indicates in an opposite direction Wrong wire connecting or bad sensitor Adjust the connecting sequence or clean the electric positioner and fasten the bolt. 27 Lifting powerless and motor can’t work. 1. Input voltage is too low. 2. Wire of AC contactor is broken. 1. Check working voltage; make sure input voltage is higher than requirement. 2. Temperature of motor is too high. 28 Temperature of motor is too high 1. Operation is too high frequency. 2. Low-speed operation time is too long or lifting brake is not open. 1. Reduce operation times properly 2. Check lifting brake. 29 Action after lifting Breakdown of component around operation platform, or internal electric component. Firstly check external components secondly check internal components of operation platform. And do with them. 8. Attaching Figures and table 8.1 Parts list of crane weight Code Name weight（kg） 1 QTZ4208.1 Underbed 681 2 QTZ4208.2 Stay bar 538 3 QTZ4208.3 Tower 6755 4 FDS125 Hydraulic system 200 5 QTZ4208.4 Frame 1815.6 6 QTZ4208.5 Lower bracket 658 7 011.40.1250 Swing bearing 318 8 FHZ12513 Slewing mechanism 215 9 QTZ4208.6 Upper bracket 1122 10 QTZ4208.7 Slewing tower 11 QTZ4208.8 Counter jib 1389 12 QTZ4208.9 Counter weight 8600 13 FQS125 Hoisting mechanism 1200 14 QTZ4208.10 Counter jib rod 208 15 QTZ4208.11 Electri system 150 16 QTZ4208.12 Tower head 1006 17 QTZ4208.13 weight limiter 5 18 QTZ4208.14 Hoisting box 266 19 FBF125 Derricking mechanism 180 20 QTZ4208.15 Lifting jib 2853 21 QTZ4208.16 Lifting jib rod 610 22 QTZ4208.17 Loading trolley 168.9 23 QTZ4208.18 Hook 135 24 QTZ4208.19 Attachment frame 3951 25 QTZ4208.20 Slewing limiter 1.5 26 QTZ4208.21 underbed 50000 8.2 Tower crane parts lubrication list Code Embellish smooth department an said Point number lubricating oil type Embellish smooth Remarks 1 Lifting mechanism brake Oil 56 hours every work with oil pot 2 Lifting mechanism transmission 3 Winter: 20 JiXieYou Summer: JiXieYou Each 240 hours on properly 1500 hours in oil 3 All the rolling bearing (except the motor bearing) Ⅲ ZG calcium grease Each work on every half hour 160 appropriately cleared 4 All motor bearing Winter: ZG - calcium grease Summer: HJ - Ⅴ calcium grease 15 hours every job change oil again Reference motor instruction 5 All the rope Graphite grease Each big, long when cooking oil 6 All the pulley Winter: ZG - calcium grease Summer: HJ - Ⅴ calcium grease Each work on 240 hours 7 Car luffing mechanism reducer rotary planetary gearhead institutions 3 40 Each work on a 15 hours of 240 hours for oil again 8 Turn o

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Jinan Jihong Machinery Co., Ltd.

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