I Instruction

QTZ160 (6516) tower crane, is my company and scientific research units after
comprehensive research, combining the development trend of construction industry in our
country and the specific situation of the construction team, according to the standard
JG/T5037-93 "classification of tower crane retrofit design of new type tower crane for the
third time.
QTZ160 for horizontal boom of tower crane and the car horns. In turn, jack-up multi-
purpose tower crane. The tower crane has the following features:
1. The performance parameters and technical indicators leading domestic, the
maximum working range of65meters, 2 meters long than existing domestic similar products.
(including performance parameters are shown in table 1, 2, 3).
2. The machine is on the basis of fixed, wall attachment. Independent lifting height of 50
meters, the attachment is 180 meters. For the convenience of users to design the two basic
types:
A. is overall foundation, its installed base.
B. is based, four small foundation combined with chassis, the chassis has weight. Weight
block can be repeated use, save money.
3. The machine arm length 65.9 meters, the biggest 65 m, the biggest can lift heavy 1.6
tons, also can be made according to customer's need to arm length 61 595549 meters,
the biggest 49 meters, the biggest can lift heavy 2.769 tons.
4. This machine has high working speed, good performance of adjustment, stable work.
USES the tower crane hoist motor, can obtain a variety of speed, less than 5 meters per
minute and slow speed in place, has realized the overloading at low speed, light load high
speed, safe and reliable. Slewing mechanism with double swing mechanism, planetary
reducer, hydraulic coupling configuration, 0-0.61 r/min can be obtained rotary speed, high
bearing capacity, smooth braking, reliable operation. Trolleying mechanism with double
speed motor cycloidal pinwheel reducer assembly for the straight line type, installation of
hoist boom of the oblique abdominal rod, compact structure, easy maintenance.
5. Rigid double rod hanging large crane boom. Fluctuation of hoist boom of the main
chord, oblique abdominal rod, straight section from the root to the nodes, specifications
gradually decreases, and the lifting beam cross section is small, light weight, good rigidity,
reasonable force, beautiful appearance.
6. Safety equipment is complete, the agencies have brake or stop, can ensure safe and
reliable working mechanism, the machine is equipped with lifting height limiter, rotary
limiter, amplitude limiter, lifting weight limiter, crane torque limiter, the car is broken, broken
shaft safety protection device.
7. Flexible cab independent offset type, open the window, ventilation, bright, nice view.
Room is the bottom of the window, can see a small hoisting. Interior space is big, can match
the air conditioning when necessary. The driver chamber for the operator to create a better
working environment.
8. Easy to use, simple maintenance, the machine of electric control system and all
accessories, are all easy to purchase, and domestic and imported components, performance
and good work safe and reliable, low failure rate, simple maintenance.

1
 The machine installation convenient and quick, only a 40 tons crane, can be done to install
and remove.

Because this machine have the characteristics of the above, so is widely used in high-rise
hotel, residential, high-level industrial buildings, large span and high tower building
construction, also can be used in port, wharf, yard handling and loading and unloading
operation.

II Lifting technical performance

1.lifting performance table
Max. 65 meters radius with a=2
Radius m 3-26 27 28 29 30 31 32 33 34 35
Load t 5 4.821 4.623 4.44 4.268 4.108 3.958 3.817 3.684 3.559
Radius m 36 37 38 39 40 41 42 43 44 45
Load t 3.441 3.329 3.214 3.123 3.028 2.937 2.851 2.769 2.691 2.616

Radius m 46 47 48 49 50 51 52 53 54 55
Load t 2.544 2.476 2.411 2.348 2.287 2.23 2.174 2.12 2.069 2.019
Radius m 56 57 58 59 60 61 62 63 64 65

Load t 1.972 1.926 1.881 1.838 1.797 1.757 1.718 1.681 1.645 1.601

a=4

Radius 3-14 15 16 17 18 19 20 21 22 23 24
m
Load t 10 9.426 8.785 8.219 7.716 7.267 6.862 6.496 6.163 5.86 5.582
Radius 25 26 27 28 29 30 31 32 33 34 35
m
Load t 5.326 5.09 4.871 4.668 4.479 4.303 4.139 3.984 3.839 3.703 3.574
Radius 36 37 38 39 40 41 42 43 44 45 46
m
Load t 3.453 3.338 3.229 3.126 3.028 2.935 2.847 2.762 2.682 2.605 2.531
Radius 47 48 49 50 51 52 53 54 55 56 57
m
Load t 2.461 2.394 2.329 2.267 2.208 2.151 2.096 2.043 1.992 1.943 1.896
Radius 58 59 60 61 62 63 64 65
m
Load t 1.85 1.814 1.764 1.723 1.683 1.644 1.607 1.511

61meters a=2
Radius m 3-27 27 28 29 30 31 32 33 34 35
Load t 5 4.922 4.787 4.596 4.418 4.251 4.095 3.948 3.809 3.679

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Radius m 36 37 38 39 40 41 42 43 44 45
Load t 3.556 3.439 3.329 3.224 3.125 3.030 2.940 2.854 2.772 2.694
Radius m 46 47 48 49 50 51 52 53 54 55
Load t 2.619 2.547 2.479 2.413 2.349 2.289 2.230 2.174 2.120 2.067

Radius m 56 57 58 59 60 61
Load t 2.017 1.968 1.921 1.876 1.832 1.793

a=4

Radius 3-14.5 15 16 17 18 19 20 21 22 23 24
m
Load t 10 9.755 9.092 8.507 7.987 7.522 7.103 6.724 6.380 6.065 5.777
Radius 25 26 27 28 29 30 31 32 33 34 35
m
Load t 5.512 5.267 5.040 4.830 4.634 4.451 4.280 4.120 3.969 3.827 3.693
Radius 36 37 38 39 40 41 42 43 44 45 46
m
Load t 3.567 3.448 3.334 3.227 3.125 3.028 2.936 2.847 2.763 2.683 2.606
Radius 47 48 49 50 51 52 53 54 55 56 57
m
Load t 2.533 2.462 2.394 2.329 2.267 2.207 2.149 2.094 2.040 1.988 1.939
Radius 58 59 60 61
m
Load t 1.890 1.844 1.799 1.727

59 meters a=2
Radius m 3-27.5 28 29 30 31 32 33 34 35 36
Load t 5 4.966 4.768 4.584 4.412 4.251 4.099 3.956 3.822 3.695

Radius m 37 38 39 40 41 42 43 44 45 46
Load t 3.575 3.461 3.353 3.250 3.152 3.059 2.971 2.886 2.805 2.728
Radius m 47 48 49 50 51 52 53 54 55 56
Load t 2.654 2.583 2.515 2.449 2.387 2.326 2.268 2.212 2.158 2.106

Radius m 57 58 59
Load t 2.056 2.008 1.977

a=4

Radius 3-15 16 17 18 19 20 21 22 23 24 25
m
Load t 10 9.405 8.801 8.265 7.785 7.353 6.962 6.607 6.283 5.985 5.712

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Radius 26 27 28 29 30 31 32 33 34 35 36
m
Load t 5.459 5.226 5.008 4.806 4.618 4.441 4.276 4.120 3.974 3.836 3.706
Radius 37 38 39 40 41 42 43 44 45 46 47
m
Load t 3.583 3.466 3.355 3.250 3.150 3.055 2.964 2.877 2.794 2.715 2.639
Radius 48 49 50 51 52 53 54 55 56 57 58
m
Load t 2.566 2.496 2.429 2.365 2.303 2.244 2.186 2.131 2.078 2.026 1.977
Radius 59
m
Load t 1.906

55 meters a=2
Radius m 3-28.5 29 30 31 32 33 34 35 36 37
Load t 5 4.941 4.751 4.573 4.407 4.251 4.103 3.965 3.834 3.710

Radius m 38 39 40 41 42 43 44 45 46 47
Load t 3.592 3.481 3.375 3.274 3.178 3.087 3.000 2.916 2.837 2.760
Radius m 48 49 50 51 52 53 54 55
Load t 2.687 2.617 2.549 2.485 2.422 2.362 2.305 2.28

a=4

Radius 3-15.5 16 17 18 19 20 21 22 23 24 25
m
Load t 10 9.717 9.095 8.543 8.048 7.603 7.200 6.834 6.500 6.194 5.912
Radius 26 27 28 29 30 31 32 33 34 35 36
m
Load t 5.652 5.411 5.187 4.979 4.784 4.602 4.432 4.272 4.121 3.979 3.845
Radius 37 38 39 40 41 42 43 44 45 46 47
m
Load t 3.718 3.598 3.483 3.375 3.272 3.174 3.080 2.991 2.905 2.824 2.745
Radius 48 49 50 51 52 53 54 55
m
Load t 2.670 2.598 2.529 2.463 2.399 2.338 2.279 2.206

49 meters a=2
Radius m 3-30 30 31 32 33 34 35 36 37 38
Load t 5 4.918 4.735 4.563 4.402 4.251 4.108 3.973 3.845 3.724

Radius m 39 40 41 42 43 44 45 46 47 48
Load t 3.609 3.500 3.396 3.297 3.203 3.113 3.027 2.945 2.867 2.791
Radius m 49

4
 Load t 2.769

a=4

Radius 3-16 17 18 19 20 21 22 23 24 25 26
m
Load t 10 9.389 8.820 8.311 7.853 7.438 7.062 6.717 6.402 6.112 5.844
Radius 27 28 29 30 31 32 33 34 35 36 37
m
Load t 5.596 5.366 5.151 4.951 4.764 4.588 4.423 4.268 4.122 3.984 3.853
Radius 38 39 40 41 42 43 44 45 46 47 48
m
Load t 3.729 3.612 3.500 3.394 3.293 3.196 3.104 3.016 2.932 2.852 2.775
Radius 49
m
Load t 2.691

2. Technical Performance
2.1 technical parameters
technical parameters table

Max. lifting torque kN.m 1600

working radius m 3-60

Max. lifting load t 10

independent 55
lifting m
height
attached 180

a=2 80/40
lifting m/min
speed
a=4 40/20

rotating speed r/min 0.61

trolley speed 58.6/29.3/8.79

jacking speed m/min 0.4

min. decline speed 5

chassis square
63.03
independent

dimension

machine

height attached M 190.5

distance from 66.71
jib end to the rotating center
distance from 14.82
balance arm end to rotating center
independent t 54.515
Counter

5
Machi weight attached 112.37
ne
weigh balance 60
t 20.4
weight Max. radius 60 m

total power capacity kW 60.5

allowed working temperature -20+40

power supply parameters 50Hz 380V10%

2.2 configuration

lifting mechanism M5
mechanical loading rate rotating mechanism M4
trolley mechanism M4
type YZRDW250M-4/8
motor
(kW)power 37/37
type FKDX-G
height limiter
Lifting mechanism

specification 6X37-15-1770-
steel rope
(N)max. traction 25000
rate a=2 a=4
lifting 80 40 40 20
speed (m/min)
rated 2.5 5 5 10
load(t)
m/min 5
Min. decline speed
type YZR160M1-6

motor power (kW) 5.52

rotating speed(r/min) 908

Rotating mechanism

type XX4-120AI
reducer
trans ratio 195
type YOX280A
hydraulic coupling
mod m 12
teeth z 17
Rotating pinion
modification coefficient 0.5
rotating r/min 0.61
speed
type 011.45.1400
Rotati

beari

ng

ng

mod m 12

6
 teeth z 131

modification coefficient 0.5

type Y132M2-4
motor
powerKW 7.5
Hydraulic jacking mechanism

Rated pressure of Mpa 25
cylinder
T 63
Max. jacking force
Mm 1600
Cylinder travel
Mm 2100
Install distance
Mm 180
Cylinder diameter

Piston rod Mm 125
diameters
jacking m/min 0.4
speed
type YZTDE180M-4/8/24
motor
Trolley mechanism

power(kW) 5/3.7/1.1

type XX3-14.40
reducer
trans ratio 39.7

steel rope specification 619-9.3-1550
trolley m/min 58.6/29.3/8.79
speed

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III. QTZ160Structure of the tower crane

Diagram of tower crane structure

Structure outline of tower crane

3.1.Metal structure
3.1.1 Under frame
For the convenience of users chassis for well construction, through 16 root embedded in the
foundation anchor bolt, on the basis of fixed on the chassis has four brackets by connecting
sleeve section and the tower foundation.

8
 underframe diagram
3.1.2 Tower body

The tower is supported by standard section , , support section, attached section. The tower
section, the main limb lateral size is 1.615 * 1.615 m, four types of tower section length of
each section are 3 meters, eight M33 is used between each section high strength bolt
connection.

9
QTZ63 tower free-standing tower height is 37.5 meters, the towers are standard section by
section 4 , verse 10 tower standard section, the section of support section, a total of 15
tower section, the most in the next section are connected to the chassis standard section,
section one, three, four, five is standard section, section 6 to fifteenth day is the standard
section, the most in the previous section section connected to the turntable. Figure (2).
M33 high-strength bolted to the tightening torque of 2600 n. M.

wer height of the tower independent combination, should adhere to, in light of the actual
engineering within the scope of the allow attachment spacing, install the attached two
section, replace the standard section .

Tower crane tower height of 152 meters, QTZ63 tower standard section by section 4 and
55 tower sections of standard section, section 1 support section, a total of 60 tower section.
As shown in figure (a)

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 Jacking frame diagram

3.1.3 Jacking frame

Jacking frame mainly by the set of rack main body, working platform, the introduction of
platform etc, of the crane jack-up movement main parts to complete. Jacking frame on the
outside of the tower, the upper with four pin that goes with the turntable, installing a set of
rack opening direction should be top of the ear plate with the standard section in the
opposite direction. Jacking frame in the central section introduced platform installation,
jacking frame has workbench, up and down for the jack-up staff introduction section and a
fixed standard section with the connecting bolt and operate a hydraulic jack-up institutions.
Jacking frame inside have 16 adjustable roller, top bearing guide role. As shown in figure (3).

3.1.4 Attachment
Attached device is composed of four poles and a set of ring beam, through which the
tower anchorage on the building, in order to increase the rigidity and stability of the tower.
From the tower building 5 meters, through the adjustable poles structure, adjustable to
receive strength evenly in the length of poles.

11
3.1.5 Rotary platform
Upper and lower rotary table is located in the lower part of tower crane can't rotate the
tower and the upper can the transition between the rotary parts of the structure, they are
made by steel plate welding and become, has good rigidity. Next below the rotary table with
eight M39 high strength bolts are connected to the tower, with 40 m24 high strength bolts
connected with rotary bearing. The four turntables under lower bracket pin shaft connected
to the set. On the turntable with 40 m24 high strength bolts are connected to the rotary
bearing, with eight M39 tower above standard section connecting bolts, combined with
rotating tower. On both sides of the turntable is decorated with slewing mechanism, and the
rotary bearing big ring gear meshing, drive rotary body rotation, rotary limiter is arranged
on the turntable, the turntable around the platform, for the use of maintenance, platform
room to install the driver. Between rotary table, there is a corresponding pin shaft hole and
pin, jack-up homework, moving up and down the pin to live, to prevent the upper tower
crane turning, at the end of the jack-up, pull pin out in a timely manner.
3.1.6 Tower Cap

Using variable cross-section tower cap structured space truss structure.

Tower crown of the anemometer installation, before and after that with the ear plate and jib
arm pull rod connecting rod and balance, at the top of the arms, tie rod before and after
working platform for installing.

There are four ear plate, lower tower hat through four pin is combined with rotating tower
(see figure 4)

12
Cap at the back of the tower (balance arm side) on the main limbs with mechanical bow plate
torque limiter.

Tower cap

3.1.7 Rotating section

Rotating section is composed of steel compound lattice space truss structure, with the tower
under the connecting bolts into the on the turntable, the pin shaft into the boom and arm,
respectively as shown in figure (5)

13
3.1.8 Cab
Cab on the turntable platform installation, flexible and open the window, eye shot is
open, especially near the room is equipped with glass, ascend a hoisting objects can be
observed near the tower. Interior is equipped with lighting, lighting for night work.

3.1.9 Trolley
The trolley is made up of steel welded together, four roller frame, placed in the bottom
chord of hoist boom of the luffing mechanism of a wire rope traction before and after
implementation transformer, hoisting frame bottom is equipped with pulley, connected by
hoisting wire rope with the hook, the upper frame also has amplitude rope tensioning device,
prevent broken rope device, the broken shaft device etc.

3.1.10 Boom and pull rods

Lifting beam section width of 1.37 meters, height of1.25 m is isosceles triangle, maximum
length of 65.9 m is divided into12, 8 and 9 of the jib and lift arm in the 3th quarter section is
equipped with lifting point respectively.

Sections between boom and jib root connected to the rotating tower adopts pin connection,
convenient for dismantling and transport, crane boom end and the roots have a stop.

Luffing mechanism is installed on the crane boom the second quarter, the traction rope
fixed on both ends of range of the car. Pulling the car along the crane boom before and after

14
exercise. Lifting beam bottom chord is composed of Angle button side. Upper chord for

seamless steel tube, CHS is seamless steel tube, chord and welded CHS space truss.

The machine lift arm producer form is 65.9 meters, can also be produced according to the
need of construction of 61595549 meters long.

Lifting beam is divided into nine section, the section on the bottom chord types are different,
so the joint with the pin shaft is different, must be installed according to the order shall not
be misplaced.

Before the pull rod from 6 section length of 5.863 meters of tie rod with even plate and pin
shaft link. After rod section length from 2 to 6.25 meters from even plate and pin shaft link
rod, tie rod before and after the pin shaft with connection plate connection, are connected by
a connection plate with cap towers.

Lift arm pull rod in the process of assembly and transportation, there should be no bending
deformation and collision phenomenon.

3.1.11 Balance arm, pull rod and counter

15
Balance arm of main body is channel steel, CHS is the Angle of plane truss, on the railing and
footpath. Balance arm roots in phi 60 pin with rotating tower connection, back through the
balance arm pull rod connected to the tower hat.

16
Balance arm pull rod consist of three and three sets of bar length of 0.89 meters of the plate
can be connected with the pin shaft. The total length of 15.22 meters, about two, respectively
connected to the balance arm and the tower caps on both ends.

Lifting mechanism is installed in the balance arm after the festival, with a counter weight at
the end of the balance arm, counter weight 8 pieces, a total of 22.5 tons.

3.2. Work mechanisms

The work mechanisms of the tower crane include lifting mechanism, trolley mechanism and
slewing mechanism.

3.2.1 Lifting mechanism

The machine adopts JD63E type tower crane with a lifting mechanism.

The lifting mechanism of rated lifting weight and average rated

lifting speed is as follows:

rate 4 2 4 2 4 2
rated
6 3 3 1.5 1.5 0.75
loadt

jacking 17.18 34.36 25.82 51.46 52.18 104.36

speedm/min
drum rope capacity320m
roll diameter495 mm
steel rope bw(19)-12.5-1700--
GB1102-74
motor YZTD 225L24/8/32
rated rotating speed 1388/700/150r/min
rated power 24/24/5.4kw
DXZ-1/274
On the drum hoist bearing installs height limiter DXZ - 1/274 type.

3.2.2 Trolley mechanism

trolley mechanism consists of the following parts

17
 motorYEZS132S4/8
power3.3/2.2kw rotating speed1440/700r/min
brakeTJ2-100 MED-100
reducerBL22-43-3.3 ratio 43
drum diameter 410mm
trolley steel rope: 619-7.7-1550- GB1102-74
Trolley mechanism on both ends of the wire rope and the range of the car before and after
two connected respectively, traction transformer car back and forth movement. Trolley speed
of 30/20 m/min amplitude limiter and drum shaft.

3.2.3 Slewing mechanism

Made up of following parts:

18
 motorYZR132M26
power 3.7KWx2 rotating speed908r/min
hydraulic coupling:YOX280A
The often open electromagnetic brake
reducerTX83Z-147
small opinionm=12z=12
rotating support : QWA.40.1250

This institution adopts the wound rotor motor, hydraulic coupler drive, smooth braking,
brake ensures that often have in place a reliable wind at work and non-work lift arm can
rotate with the wind. Rotary speed is: 0 ~ 0.63 r/min

3.3. Hydraulic jacking mechanism

Composition and working principle of the system, see the system specifications, the
technical parameters of the system in the following table:

3.3.1 Main technical parameters of the hydraulic pump

pressure
Model
flow
power capac
H(MPa) B(MPa) MPa L/min JB1885-96
KW ity
QT63Z-10 20 5 25 14 5.5 10H-2MA 70L

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3.3.2Main technical parameters of the jacking cylinder

rod
pressure cylinder travel
model diameter R R
MPa diameter
QT63G 20 160 110 1600 60 60


model
QT63G 70 60 2150

3.3.3 Main technical parameters between the hydraulic pump and jacking cylinder


m/min t
QT63Z-10 QT63G 0.5 40

3.4 Rope
3.4.1 lifting rope diagram
3.4.2
2-3
Range of rope in the winding to tighten and drum each side to keep security number for
2-3 times.

20
3.5. Safety devices
The tower crane has weight limiter, torque limiter, hoisting height limiter, amplitude
limiter, rotary limiter.
Lifting weight of hoist boom of limiter installed in the root. By adjusting the bolt will
have weight limit under a certain speed. Three speed for lifting mechanism including, four
ratio limit: 10t, 5 t, 2.5t. Two ratio limit: 5 t, 2.5 t, 1.75 t.
Torque limiter, installed on the tower hat main chord. Crane moment limiter bow plate
deformation, bolt on the appropriate adjustments to make alarm when lifting torque rating
of 90% 110% stop ascending direction and outward flow of work
Hoisting height limiter, installed on the drum shaft hoist, can restrict different lifting
height. The hook at about 1 meter away from the car frame stop lifting motion, adjustment
method in accordance with the specifications.
Amplitude limiter, installed on the drum shaft of trolley mechanism, to limit maximum
and minimum amplitude adjustment method according to the specifications (DXZ type
multi-functional stroke limiter).
Rotary limiter: installed on the turntable, by the end of the pinion and the rotary bearing
large gear mesh. Rotary motion to the multi-function stroke limiter. Can be limited turning
around 540 .

IV Crane installation and removal

QTZ160 tower crane due to the widespread adoption of pin, bolt connection, and
independent part of the lighter, so the installation is simple and convenient. Is the most
appropriate hoisting machinery tyre crane or mobile crane. Wind cannot be higher than the
level 4, when installation is the largest installed at high wind speed is not more than 13 m/s.
1.The preparing work before installation.
1.1understand the layout of the construction site and soil conditions, clear the obstacles, in
order to play dirty work. The tower foundation should be close to the building, as far as
possible the attachment center distance building 5 meters, where possible, foundation
should be set up near the maximum weight fabrication.
1.2 The basis is based on supporting all tower crane weight bearing. Construction should
strictly according to the basic diagram. And curing 10-15 Arabian can use.
1.3 prepare the hoisting machinery (40 ton truck crane) rigging, commonly used tools such

21
as rope buckle.
2.Installation order
2.1 at the end of basis beam with level leveling, keep beam on four tower block level, its
flatness tolerance is 1.5 mm. Adjust the level allowed to add gasket between the base and the
cross beam, then base plate with anchor bolt connection is good.
2.2 Standard section and support section connects with M33 high-strength bolt
connection, and lifting on the chassis. With high strength bolt connection is good. Note that
the tower on the top of the ear plate should be parallel to the direction of the building, and
the chassis of the standard section without jack-up ear plate.
2.3 Jacking frame parts of the roller, installed up and down the platform, and then lifting sets
into the tower. Insert the set of the two supporting shaft frame, card up at the top of the
tower to ear the upper plate. To set a fixed on the tower, the attention when installation
cylinder beam and the tower on top of the ear plate on the same side, and make the top of the
tower top is higher than the set, in order to install the turntable. As shown in figure (14).
2.4 the turntable, rotary support with m24 high-strength bolt connection is good, slewing
mechanism, slewing limiter mounted on the turntable. And adjust the size of the gear
meshing clearance. And then lifting on the top of the tower, with eight M33 high-strength
bolt connection is good. As shown in figure (15).

Hoist set from the two supporting shaft, pin shaft and the rotary table four bracket
connected well.

Will jack oil cylinder, the introduction of beam installed in a set of shelves, the side of the oil
cylinder hydraulic tank over platform. Operating platform lifting on the turntable with pin
connection is good, as shown in figure (15).

22
2.5 Will the driver indoor electrical equipment installed, and then lifting on the operating
table. Pin shaft fixed well. To rotate the tower crane is the highest on the turntable with eight
M33 fixed bolt connection. As shown in figure (16).
2.6 Put the cap on the guide pulley, anemometer (the user should bring along their own)
work station, connection board, balance arm pull rod nodes and other parts installed, and
then lifting to the rotating tower, with a pin shaft link. As shown in figure (17)
2.7 Install the lifting mechanism in the back of my arm, pin shaft and the ear of the balance
arm plate connection is good.

Will balance arm pull rod and balance at the end of the arm at the back of the ears on both
sides of the plate with a pin shaft connection, and flat on both sides of the balance arm, and
the wire fixed well.

Install the distribution box in balance arm front, rely on the driver side of the chamber

Looking for a good balance arm lifting weight, lift balance arm, pin shaft connected to the
rotating tower. Then about 20 camber installed balance arm pull rod, using the lever on the
pin shaft and column cap nodes connection is good, in put to the level of the balance arm. As
shown in figure (19)

Lifting a balance weight on the balance arm last department, to balance the long
boom as shown in figure (19)

2.8 On the ground will lift arm in figure (6), a or b and underlay is about 0.8 meters, installed
hoisting limiter, luffing mechanism, vice car, wear a good range of wire rope, temporary

23
power supply cord connected, make the range of the car several times back and forth, then
the small car, good weight limit for wire fixation. As shown in figure (20)

Will lift arm pull rod (7), according to drawing and jib with pin connection at one end, into
the upper chord in the ears of the fork lift arm, iron wire again.

To find a good jib lifting weight, lifting rope, tied to level of hoist boom lift to rotating tower
fork ears, with a pin shaft connection, and then the cock about 2 .

Connected lifting mechanism of temporary power supply cord, drew hoisting wire rope to
tower crown block and tackle, lead to hoist boom rod front pulley block, from the crown tie
rod front-end pulley block to tower block and tackle, draw out the rope first fixed rod before
the end of the rope ring, composed of three ratio of pulley block.

Start the lifting mechanism, pull rod before and after to tower flaps of a cap plate, with a pin
shaft connection, and then flat lifting beam, see if rod before and after the stress uniform,
otherwise should be adjusted.

Adjustment method is: before the tie front have a fan type ear plate, on which there are three
adjusting hole, tie rod manufacturing precision in the middle hole, when the rod is longer
than before, with the hole above, short-term use the hole below. As shown in figure (21)

2.9 Balance weight installation, according to hoist boom length balance weight installation

Balance weight installation, according to hoist boom length balance weight installation

When hoist boom of 52.6 meters, the biggest 52 m, install 5 piece of balance weight, total
weight 10700 kg when hoist boom of 46.6 the biggest 46 meters, remove the size of a
counterweight, install 4 block (three small) balance weight total weight 7890 kg.

2.10 Wear around the hoisting wire rope

Hoisting wire rope pull from the drum hoist, bypass tower crown pulley, arm lifting weight
limiter pulley, to bypass the range of the car and the hook on the pulley, finally fixed to the
crane boom end of the wire rope twisting device of rope ring. As shown in figure (10).
2.11Tower crane after installation commissioning
Tower crane after the installation should be done:
Electrical system is first installed according to the electrical schematic diagram and
electrical wiring diagram, hoisting, slewing, luffing three agencies to action.
Each reducer gear oil, supplying bearings and slewing bearing large gear ring with
butter, hydraulic filling the hydraulic oil tank.
Three institutions run no-load test run, to determine whether three institutions
work normally.
Transformer, check the lifting rope work is normal, in case of institutional structure
friction between wire rope and should be ruled out.

24
2.12 Installation erection process NOTES:
When installation should undertake under moderate breeze, namely the maximum
installation height wind speed is not more than 13 m/s
The machine installed back to the vertical degree is not more than 4/1000 of the
height.
Tower crane inlet connection bolt, pin shaft material is qualitative different, must not
use, bolts shall be fully tighten again finally, pin shaft end inserted into the shaft pin.

25
26
 3. The lifting component reference weight and overall dimensions are shown in table

27
 m
Name
No. weightkg LWH
1 Rotating section 880 1.81.32.03
2
2 standard sections I and 1 support 2615 1.631.637.50
section
3 beam of the under frame 1638 7.57.50.5
Hydraulic system of
4 3010 4.023.365.60
the jacking frame

Upper and lower rotating table
5 2910 2.352.371.68
,rotating support and slewing
mechanism
6 cab 354 1.342.973.10
7 tower cap 1510 1.31.446.5

8 Balance arm, lifting mechanism and 4361 13.402.251.42
pull rods of the balance arm

9 boom, trolley mechanism, pull 5729 52.61.31.1
rods of the boom and the trolley
2320big
10 each counter 1.360.2653.12
1930small

4. The installation of adding standard section for the tower body.

4.1 Check all contents of tower crane installation completed and correct
4.2 Lifting amplitude, rotary movement test run.
4.3 Jack-up heightening must be used when all of the standard section directly in front of the
crane to set the introduction of platform within 10 meters range, and screw hoist boom to
introduce standard section direction, in order to prevent the lift arm in the process of
starting rotation, insert the pin into turntable pin hole from top to bottom, top end pull out
the pin in a timely manner.
4.4 Check the hydraulic jack-up system
Check the oil level of hydraulic system of tank meets the requirements.
Hydraulic system for long-term use (more than 6 months) shall check whether the
oil deterioration or contamination and timely replacement.
Check the hydraulic oil brand is correct, generally 20 # engine oil, the temperature
low choose 10 # engine oil.
Relief valve setting pressure of 20 mpa, work may not be changed without
authorization.
Top of the hydraulic system must be empty before the test run, and then control
manual reversing valve cylinder telescopic several times, remove the air in the system,
behind the functioning jack-up operation can be performed.

28
4.5 Adjust good set of clearance between roller and the towers are the main limb rod is
usually 2 to 4 mm
4.6 In the range of about 5 m lift a standard section about 1 m high, clear bottom link set
of the dirt, and then insert the four introduce card roller shaft connection set inside, and
rotate 90 that the lower part of introduction of roller card board under the standard section
of the lower horizontal CHS. As shown in figure (24).

Continue to improve standard section on the set of the introduction of beam. As shown in
figure (22)

4.7 Adjust the position of the range of the car make the weight of the top part is in
equilibrium, even if the tower by unbalanced curved distance to a minimum. Two kinds of
arm length cases car hook of the theoretical position is:

52.6 M long arm, the car should be at about 18 M place, such as hanging a standard section
, in about 6 M.

4.8 Start the

hydraulic jack-up system, the oil cylinder trunnion at the ends of the beam in the support
section of the ear of the upper plate.
4.9 Check set between the tower and accessibility, in the ministries and correct, down the
tower and the turntable 8 joint bolt, then the control handle is slightly a little bit up top set,
retract a supporting shaft, the positioning of the turntable and standard section caused by
convex platform, from 20 mm, observe whether positioning convex and concave hole of the
turntable under is, in the event of a deviation must adjust the position of the range of the car
for, then eight between rollers and the towers are main limbs roughly equal, an ideal location
for jack-up balance.
4.10 Control handle, the structure of the cylinder to the upper jacking, up a step (1.25 m)

Then out of supporting shaft, to the top of at the bottom of the standard section rises
above the ear plate, as shown in figure (23).

4.11 Lower back oil cylinder piston rod to the standard section jack-up ear plate, the oil
cylinder jack-up trunnion the ear plate slot on both ends of the beam, slightly jacking point
set, retract a supporting shaft, (see figure 23).

29
30
 draw-into wheel
1. handle 2. 3. hydraulic wheel 4. beam of jacking frame
5.
6. 7. 8. 9. 10.

4.12 Move on to the second step of the jack-up, wait for the height of the oil cylinder stroke
more than a standard section (2.6 m) out of supporting shaft, and will be placed on the
introduction of the standard on the beam section artificial introduction set, as shown in
figure (25).

31
4.13 Section on the following standard , pay attention to the direction of the top of the ear
plate keep consistent with the following sections, control handle slowly down, make the
standard section in place, and superior section with the following standard eight high
strength joint bolt connection.
4.14 The supporting shaft, carry on the standard section jack-up above the ear plate,
retract a cylinder piston rod, insert the jack-up trunnion on both ends of the beam section
upper jack-up ear plate groove, ready for the next work cycle.
4.16 If you need to continue raising the tower, with a hook to lift one day with four
introduced roller standard section, on the introduction of platform, must pay attention to
before the crane standard, the towers are between each main limbs and the turntable should
be superior high strength bolt, and the range of the car can run within 30 meters range.
Upper position adjustment range of the car, make jack lifting weight balance, to tear down
the connecting bolt between the turntable, go to the next work cycle, until the height of the
tower height reach need.
4.17 Finally to the towers are between the turntable and high strength bolts for standard
section, fully tighten the standard section again, high strength bolt, will up and down
between the turntable prevent jack-up tower in the process of rotary pin pulled up.
5. The use of the attachment
5.1 Tower crane hoisting height more than 40 meters, the need to adhere to the building.
When the tower crane hoisting height of 102 meters, five of the need for the attachment, the
first attachment is apart from the ground 21.65 meters, the second attachment is apart from
the first 17.2 meters, the rest every spacing are 15 meters, arm root hinge point from an
attachment on the freedom of not greater than 20 meters high, as shown in figure (a)
QTZ6160 tower crane structure diagram.
5.2 A tower of the attachment must be installed in a special section in the middle of the node

Attached to the tower center distance when using building distance of 3.5 meters.

32
Attached to the buildings on a load of attachment points shown in table (4), the attachment
structure below.

5.3 Installation order

Users according to the nine technical documents attached figure 6 random make up
with.
According to the attachment of the distance of 5.1 and the requirement of the nine
attached figure 6, it up with on the buildings of reinforced concrete beam and column, and
welding the connecting plate.
According to the distance of the attachment on the tower in lifting framework and a
half, and wire rope tied, lifting another framework, and a half to two and a half framework
with m2-m24 bolts, to the tightening torque for 650 + n. 10 m.
Adjust the eight screw on the framework to resist the towers are main limbs, the
tower is located in the center of the framework.
Up with crane boom to direction, moving range of the car make appropriate torque
balance on the tower.
In two long pole with a pin connection plate fixed at one end, to lifting frame, one
end of the pin shaft installed on the frame, on the other side will join plate with welding up
with on the floor.
Lifting two short rod, pin shaft and framework and the connecting plate fixed
respectively.
Appropriate to loosen the eight screw on the framework, and adjust the framework,
make whole attachment is in a state level, and perpendicular to the tower, the fixed locking
nut.
Twisting length rod on the adjusting screw, to keep the center line of the tower
vertical.

33
Use theodolite in two directions, tower crane installation of lateral verticality after no more
than 4/1000 meet the requirements of vertical locking nut.

6.Tower crane removal

Tower crane disassembly method and installation of the same, as long as the work
procedures and installation, on the other hand, due to the removal of buildings have been
built, the work site as spacious, when installation should be paid attention to in the process
of disassembly procedures, hoisting pile position is sloppy, otherwise accidents endangering
personal safety shall be easily.
6.1Tower crane installation removal the matters needing attention.
Tower crane installation height of largest wind speed is not more than 13 m/s, the
wind is equivalent to level 4
In the process of the work, should be in balance arm set on one side of the oil
cylinder, that is parallel to the direction of the buildings, and the turntable with a pin to lock
up and down, in case of the towers are turning.
range of the car moved so that the top part of the balance.
jack-up and disassembly process in case of jam phenomenon, hydraulic system
failure, should immediately stop up, troubleshooting rear can continue to work.
jack-up removal to end, should add shield in the hydraulic system.
6.2 The removal of the tower section. (in contrast to the installation standard section of the
program)

check the hydraulic system (4.4) with

2 check the set of shelves 16 between rollers and the towers are main limbs, generally for 2-4
mm.

adjust the amplitude (4.7) with the balance of the car position
adjust the position of the trolley
to start the hydraulic system, out of the piston rod, cylinder trunnion into on both
ends of the beam, on the second day a ear plate groove at the bottom of the section. As shown
in figure (25)
the same as 4.9
The top a bit set, supporting shaft, carry on the number of standard section above the
upper part of the ear plate in the second quarter.
Remove the number of the first and second two standard section connecting bolts.
Introduced the four roller card axis in standard section connection sleeves and rotate
90 , the introduction of roller bottom of card board under the standard section of the lower
horizontal CHS as shown in figure (24)
The top a bit set back supporting shaft, drop a bit set, make four wheel fell on the
introduction of beam.
With artificial standard section will launch, to start the range of the car, lift the
standard section put to the ground, as shown in figure (25).
Take the piston rod, to set down a step (1.25 m) Out of supporting shaft load on the

34
lower part of the second section of the ear plate
Out of the piston rod, the oil cylinder trunnion at the ends of the beam in the number
of the third quarter on the upper section of the ear plate slot.
The top a bit set, returned to the supporting shaft, recover the piston rod, to set down
the height of a standard section.
Repeat the steps from (4) to (13) until all the standard sections remove.
6.3 Demolition of the attachment

When remove the standard section until set close together on the attachment.

Then opposite 5.2 program from (7) to (3), respectively, by a sling short-long rod and two
and a half framework, gradually remove the pin shaft and bolt, and put into the ground.

6.4 Remove all tower crane parts

The towers are open to only three standard section height, as shown in figure (21)
crane under five piece of weight, with installation of the equipment with a
counterweight to balance the gibbet.
put down the hook, remove the hoisting rope fixed end, back to drum hoist wire
rope.
to wear around the hoisting wire rope, from the tower crown block and tackle to tie
front end block and tackle, composed of three ratio of pulley block.
put luffing cars and steel strapping fixed weight limit is used.
to find a good jib lifting weight, lifting rope, tied to the crane boom lift become
warped on about 2 .
Once to start the lifting mechanism, tighten the rope, remove the tie rod before and
after connection with tower hat pin, flat lifting beam. Relax hoisting wire rope, put to the rod
in the upper chord within the ear of the fork lift arm, fix and wire binding.
Being removed jib with rotating tower connecting pin, swing boom levels into the
ground.
Remove the last counter
find good balance arm lifting weight, tied rope, will become warped on balance arm
lift about 20 as shown in figure (18).
remove the balance arm pull rod section before connecting pin, then put to the level
of the balance arm. See figure (19).
remove the balance arm and rotating tower connecting pin, swing balance arm level
into the ground.
by 2.6 to 2.1 remove the cap, rotating tower, cab, turntable, set up and down, three
tower, weight, chassis. As shown in figure (17) to (12).

V Electrical system and operation

35
Electrical system in tower crane work, take control, transmission, lighting alarm and power
function of various kinds of security devices, as shown in the electrical schematic diagram
and electrical wiring diagram.

Total power is 40.1 kw, the whole machine motor when the motor power is 34.6 kw.

1.Installation of electrical system

1.1 Main power supply system in three phase four wire system, according to the
different situation, tower crane earth or zero, grounding or zero must be strictly in
accordance with relevant provisions, tower crane motor shell, distribution box, agencies,
bridge shell console base, between each main steel structure and the grounding line or zero
line has a reliable electrical connection. Grounding device between zero and repeat
grounding device (26) regulations made according to drawing. Grounding resistance is not
greater than 4, then repeat grounding resistance is not more than 10 between zero.

Need earth protection should be the specialist is responsible for the installation, because of
different grounding resistance rate depending on the local soil changed, and the need for
dedicated instrument for measuring grounding resistance. This set of device installation,
maintenance and materials are provided by manufacturers, and will be for the scene by the
user.

1.2 Top cap should be installed on the top of the tower crane tower lightning rod, joint
should be removed coating, lightning rod and earthing device should have a reliable
electrical connection (the user should bring along their own).
1.3 Should shake test motor, electrical system after the installation of electrical
equipment in the main circuit and control circuit of insulation resistance shall be not less
than 0.5 M .
1.4 The tower crane arm beyond 5-10 meters long should not have high and low voltage
power lines.
2. Electric drive
2.1 main current use three phase four wire system 50 hz, 380 v power supply, power
supply voltage fluctuation shall not exceed 6% plus or minus external power by the air
switch QF1 into the distribution box, then through main contactor KM1, main contact and
agencies to the various motor contactor, the main contact.
2.2 motor hoist adopts YZTD225L2-4/8/32, 24/24/5.4 KW motor.
2.3 luffing mechanism motor for,3.3 YEZS132S - 4/8/2.2 KW motor, brake
electromagnet for MED1-100.
2.4 slewing gear motor for wound rotor motor, often open the electromagnetic brake,
homemade coil.
2.5 Jacking mechanism motor
3. The electrical control and safety devices
Bridge is about two console, two separate console layout, the driver line of sight, gear, with
zero protection, driver labor intensity is low, the console has a voltmeter, p acoustic, etc.
3.1 Total starting

36
Tower crane work before, the total contactor KM1 doesn't work, except the top part and
obstacle lights, the rest does not work, will always start work, agencies the main switch must
be zero.
3.2 lifting mechanism
For wound rotor motor, electric motor hoist lifting mechanism has three gear reducer, when
the ratio of two, four lifting mechanism has six working speed. Each work rate corresponding
to certain weight lifting, hoisting must strictly according to the table when the value in (1)
and (2).There are three electromagnetic clutch, reducer through switch SAS can realize the
transformation of the three gear, pay attention to the transformation must be hoisting
command switch SA1 hit zero, to shift, the lifting mechanism reducer gear shift must be
conducted in the hook rear can come to a complete stop.
Command switch SA1 control KM4, KM5, KM6 realize two motor speed conversion, when
starting from low speed to high speed gradually too. When stop gradually transition from
higher to lower.
Torque limit switch of SQ3 and SQ4 control lifting mechanism up circuit, SQ13 luffing
mechanism of control high-speed circuits. Height limit switch for SQ2, lifting height, control
(1000 mm) hook from shifting the car weight limit switch SQ1, of SQ5 and SQ6 respectively
under different speed control weight, when lifting weight reaches the rated lifting weight
SQ1, SQ5 touch off contact, often can't lifting hoist, can only decline.
Torque limiter for bow plate torque limiter, installed in the main tower caps on balance arm
side limbs, weight limit device installed in the crane boom the roots. Height limiter installed
on the drum hoist bearing.
3.3 trolley mechanism
Trolley mechanism by the main switch control contactor KN14 SQ3, KM15 to realize the
trolley motor positive and reverse, amplitude limit switch SQ9, SQ10 control range of the car
before and after the limit position.

Amplitude limiter installed on trolley mechanism drum support.

3.4 Slewing mechanism

Slewing mechanism controlled by the Lord to switch SA2 contactor KM8, KM9, KM11, KM12
to achieve positive &negative and high speed running of rotary motor, rotary limit switch
SQ7, SQ8 control about tower crane slewing does not exceed 540 , slewing mechanism
limiter mounted on the turntable.
Slewing mechanism is equipped with a constant open controller, it can only be in rotary hoist
boom has come to a full stop in the KM9 to locate, it is strictly prohibited for deceleration and
braking, electromagnet (homemade) and slewing mechanism (YB3 KM10 work can't
electricity) have electric interlocking.
3.5Jacking mechanism
Jack-up institutions directly by the automatic air switch QF2 start motor, by manual three
four-way reversing valve control cylinder expansion.
3.6 Adjustment of the safety devices
Tower
crane after the completion of installation, adjustments must be to a full safety device, make it

37
meet the design requirements.

amplitude limiter

Most significantly, and the design value error of 2%

Minimum amplitude, and the design value error of 5%

Height limiter
The biggest hoisting height not less than nominal design value.
slewing limiterLeft and right turning Angle is not greater than 540
weight limiter
Under a certain range of the rated lifting weight error is not more than plus or minus
5%
torque limiter
With the rated lifting torque error is not more than plus or minus 5%
The design parameters and lifting torque as shown in the table (1) , (2) and (3)
4. Lighting and signal
Lighting power distribution box directly by supply, voltage 220 v
4.1the driver room illume 60 w dome light a lamp that users should bring along their own
(bulbs).
4.2 the tower with 500 w the searchlight two (the user should bring along their own).
4.3 at the top of the tower crane and jib and tower hat, balance arm on one end of red
obstacle lights. Open at night, and ensure the power supply is not affected by power outages.
5. Electrical protection device
5.1 main circuit with automatic air switch QF1 protection, stable current 100 A
5.2 hoisting circuit with automatic air switch QF2 protection, stable current 80 A
5.3 trolley, rotary and jack-up circuit with automatic air switch QF3, QF4, QF5 protection,
respectively. Rated current , 10 A, 15A, 20 A, respectively.
5.4 zero protection
Hoisting, derricking and slewing command switch are three loop with zero protection,
namely the tower crane began to work, must put the command switch SA2, SA3 agencies in
zero, to manipulate the starting button SB2, in order to prevent the crane work by mistake.
5.5 fuse protection
In the control circuit, lighting, signal respectively with the fuse in the circuit, short circuit
protection.
5.6 emergency switch
Equipped with an emergency switch circuit, when the abnormal situation in tower crane
work, press the switch, total power KM1 disconnect, achieve security.
5.7 safety protection switch
Circuit has fault, the fault phase relay and the over voltage relay, owe voltage relay, achieve
security.
6. Anemometer
Arm root height more than 50 m, shall be installed on the top of the tower crane

38
anemometer (user should bring along their own), to monitor wind speed and wind speed in
more than 13 m/s and 20 m/s when displayed on the monitors, ensure the tower crane
realize wind speed is more than 13 m/s, cannot erectness, wind speed is greater than 20 m/s
can't work.

VI .The use of tower crane

1.General instructions
1.1 Tower crane must be installed in 1.1 conform to the requirements on the basis of the
work, and reliable basis of adhesion and attachment according to the requirement demanded
to see the nine attached figure 5, and 6.
1.2 operating personnel training must be conducted training, obtains the corresponding
qualification certificate, the understanding of tower crane structure and performance,
familiar with maintenance and safe operating procedures, the installation machine operator
is not allowed without permission to board work.
1.3 normal working temperature is 20 - tower crane to 40 , the wind speed is lower than
20 m/s, if beyond this scope, should stop working.
1.4 every transfer site, and installed again, must be no load, static load test. Static load test
since 30% of the rated load until 50%, 80%, 100%, when overload 25% when 125% of the
rated load test, item 100 mm from the ground. The dynamic load test load of 110% rated
load.
1.5 tower crane transfer site must be grounded, after reinstall check grounding and
insulation resistance, readjust the safety device,
1.6 when working at night, should have good lighting conditions.
1.7 the driver indoor store flammable and explosive goods is prohibited.
2. jacking operations
2.1 When tower crane jacking, must have someone to command. Operation of the hydraulic
system, the introduction of standard section, tighten bolts, must be with someone who's in
charge.
2.2 jack-up operations should be carried out during the day, the wind speed is less than 13
m/s, such as wind suddenly increase, in the process of jack-up must immediately stop
operation, and tighten the tower as a whole.
2.3 Must first be relaxed before 2.3 jack-up tower vertical cable. Relax the cable length over
top of total height, in the process of jack-up plus standard section should be no cable. After
the jack-up cable fixed on the tower.
2.4 pay attention to in the process of the jack-up must turntable is an organic whole
repeatedly with a pin shaft, ensure the introduction of platform in lifting beam direction, to
prevent the tower crane in the top of rotary.
After each jack-up must do finishing work, ensure each connecting bolt fastening according
to the law in force. Fixed pin shaft end, set adjusted roller and the gap between the tower and
hydraulic system of the power cut off, and cover to cover.
3. The tower crane control
3.1 operators must strictly implement tower crane operating and maintenance regulations, it
is strictly prohibited to overload operation, according to the tower crane lifting table (1, 2)
performance and hoisting and lifting speed corresponding to the table (3) the provisions of

39
crane load.
3.2 the operator must be command signal can operate, must ring before operation, operation
must be focused.
3.3 the tower shall not sew items, must be vertical lifting hook, and banned for piles and
similar operations.
3.4 in institutions with positive &negative operation, to reverse when must stop completely,
make motor force disappears, and to open a reverse action, it is forbidden to suddenly start
the positive and negative switch, especially in the slewing mechanism stop, must not be used
for deceleration and braking, must do after the return to a full stop in the tower crane to use.
3.5 in operation with multiple gear, must from slow to fast, in turn, starting, prohibit the
operation, and each transition to the next notch time is about 2 ~ 4 seconds. When stop must
be fast to slow.
3.6 reducer group can shift, must be conducted in the hook to come to a complete stop, it is
strictly prohibited on the hook for dynamic shift when motion, must from higher to lower
when braking and braking.
3.7 before the formal operation, must first to check the reliability of the safety device, is
absolutely not allowed in safety devices unreliable or failure state force assignment, all safety
devices on the tower crane must be constantly maintained.
3.8 check should be made for tower crane voltage without meet voltage fluctuation plus or
minus 5% ban on homework.
3.9 dealing with the tower crane all moving parts regularly check, such as with or without
bolt looseness reel rope good or bad, wire head pressure, the lubrication parts is short of oil.
3.10 tower crane should contact the driver designated persons or direct and lifting work.
3.11 the driver before coming off work must be hook up and more than the height of the
surrounding buildings, and cut off the general power supply of tower crane.
3.12 if there's a thunderstorm, heavy rain or wind 6 magnitude (namely the maximum
installation height wind more than 20 m/s), shall cease to work. As learned that the weather
forecast is more than 10 class gale, took the wind tower crane application rope
reinforcement.
3.13 tower crane should steer clear of high and low voltage electrical wiring installation, in
more than one tower crane, construction site should be to prevent interference with each
other.

Tower crane appeared temporary repair or maintenance, must cut off power supply on the
ground, don't allow charged maintenance.

3.15 should pay attention to keep the various parts of the tower crane joints, erectness and
pre installation position should be paid attention to when working. It is forbidden to mix and
use different material instead.
3.16 tower crane in use process should be used to force large ground point ears checked,
whether the phenomenon such as crack, such as lifting beam, the balance arm arm root
ground points, etc., if there are any cracks, shall promptly repair can continue to use.
3.17 When not work, the trolley should stop at the lowest place.

40
VII Crane maintenance
Crane should be regular inspection, maintenance and maintenance, rotational part should
have enough oil. Fragile must often check, repair or replacement. Connecting bolts, especially
often vibrations such as the tower connecting bolts, should check whether is loose.
Otherwise, it is necessary to tighten or replace in a timely manner.
1. Mechanical equipment maintenance:
1.1 institutions brake should regularly check timely adjust the brake and brake wheel
clearance to ensure flexible and reliable, there should be no dirt on the surface of the friction
exists.
1.2 gearbox, gearbox, the outer meshing gear and so on various parts of the lubrication and
hydraulic oil according to the lubrication chart (5) to refuel and blotted out. When oil change
to remove and clean the casing iron filings, impurities, to pay attention to the oil and gas
filling degree.
1.3 should pay attention to check whether there is any broken wires on each wire rope wear,
the phenomenon such as abnormal wear and loose strands, such as more than the relevant
provisions, must be replaced immediately, once every two days check wire rope, wear,
broken strands shall be greater than 5%.
1.4
check connections of the ministries tighten situation, such as loose tight in time. The towers
are connecting bolts should be on the main limbs to check the firmness when compression.
1.5 often check whether institutions operating normally, presence of noise, such as defective
shall be immediately ruled out.
1.6 when installing slewing mechanism should guarantee the planetary reducer center line
parallel to the center line of the big gear ring.
2. Hydraulic jack-up system maintenance
2.1 use specified in the hydraulic oil must be strictly according to the lubrication chart for
refueling and replacement, and good cleaning tank internal.
2.2after the overflow valve pressure setting, no change shall be made arbitrarily, check
pressure gauge should be paid attention to when starting pressure is normal.
2.3 often should check whether the pipe is fastened tight, no leakage phenomenon.
24 the oil pump, oil cylinder and control valve such as have found leaking phenomenon
should be timely maintenance.
2.5 after the assembly and repair starting for the first time, should check whether the entry
and exit after the first. Oil pump rotation direction is correct, whether suction pipe line leak.
2.6 oil filter regularly inspect for congestion, check the overflow valve pressure adjustment
value whether to change after use.

2.7 winter when starting, starting and stopping several times to the first, for the oil
temperature rise and flexible control valve action again after the formal use. 2..

3. The metal structure maintenance.

3.1 in transit should be managed to prevent the deformation and damaged.
3.2 during the period of use, must be regular inspection and maintenance, to prevent
corrosion, the spray paint every one to two years.

41
3.3 check connections of structural bolts, weld and component damage, deformation and
looseness, if any damage, looseness and welding, should use after repair.
4. Maintenance of electrical system maintenance.
4.1 check all wire and cable with and without damage. If there should be timely bind or
replacement.
4.2 meet motor overheating phenomenon, should stop troubleshooting and then continue to
run in a timely manner
4.3 distribution box, console should be regularly swept the dust on the electrical equipment,
to keep clean.
4.4 trip switch contact closure of each safety device must be reliable, contact arc pit should
be smooth in time, it is strictly prohibited to remove safety devices, it is strictly prohibited in
the case of the safety device does not work, otherwise, the use of tower crane safety accident
ego by the user.

4.5 test grounding resistance 2 times a year, shall ensure that no more than 4 .

The various parts of the tower crane lubrication chart

Lubrication Types of The
no. components lubricating oil lubrication methods
56
Luffing Each
1 mechanism of lifting machine oil after working all 56
mechanism brake all hours with the oil can
hinge point add

240
HJ20
1500
Winter: HJ - 20 machine oil
2 Reducer of the lifting For every 240 hours
HJ40
mechanism work properly
Summer: HJ - 40 machine oil
refueling ,1500 hours
oil change
160

Every
ZG ZG- working 160 hours
3
rolling bearing calcium base grease appropriate
refueling, cleared
once every six
months
4 ZG 1500
motor bearing Winter: ZG- calcium base change every
grease 1500 hours
ZV

42
 SummerZV- calcium base
grease

5 steel rope Graphite grease when large repair
with the oil cooking
240
6 roller 4 the same as No.4 add every 240
hours
240
trolley 1500
mechanism add every
7 40 40#machine oil
slewing mechanism 240 hours and
reducer change every 1500
hours
big 56
8 gear ring of the slewing 4 the same as No.4 paint after
support working 56 hours
10

hydraulic Winter: 10# machine oil
9 change every six
system cylinder 30
months
Summer30# machine oil
2500
hydraulic 22 The
10 change 2500
coupling hydraulic oil or 22 turbine oil
hours

roller of the
11 jacking frame for machine oil add before
drawing into the jacking and removal
standard sections

VIII Crane main troubleshooting methods

1. After the lifting hoist stop instability and decline.
The cause of the problem Elimination method
Brake wheel or remove surface
1
brake block surface oil stains

Hydraulic push rod brake oil without oil or oil According to the
2
quantity is little hydraulic push rod brake manual
for refueling, adjusting spring
3 Decrease the
Braking too frequently, the temperature rise, number of braking

43
 friction coefficient decline
Brake spring improper
4
adjustment
5 overload The
weight should be within the
rated load

2. Luffing mechanism brake

The agency brake as the electromagnetic brake brakes, it sliding failure causes and
elimination method is the same as 1.
3. Reducer temperature is too high, over allowed temperature.
The cause of the problem Elimination method

1 Check the gear reducer for oil or oil too much, According to the requirements of
too little reducer operating instructions
2 Oil label is correct

Reducer bearing Check the bearing

3
gap is too small clearance

4. Slewing mechanism have difficulty starting.

The cause of the problem Elimination method
As
1 Hydraulic coupling is used oil label or oil stipulated in the hydraulic coupler used
amount is correct manual refueling
Whether Watch gear mesh
2 there is interference between the size of size
the gear
5. The motor power not enough, low rotating speed, too hot etc
The cause of the problem Elimination method
Motor in two Check whether the
1
phase or single phase operation motor is lack of phase
A phase winding
2 and short circuit Check if there is a short circuit or poor
welding motor winding
Motor overload If motor overload.
3
operation
The current and voltage The voltage is in
4
are too low accordance with the requirements
5 Ventilation is not good To improve the
ventilation conditions
6
The rotor winding are poor welding or

44
 bolt with loop
7 Brake or drive Check the brake
a gap is too small clearance

XI Instruction for use the appendix

Technical performance parameters
1the use of tower crane (U5), state (Q2) and level of work (A5).
2the working condition of allowable wind pressure: installation disassembly, the maximum
installation height in an ascending or descending section takes 4 or less, the wind scale
level 6 or less work status, non-work state takes 11 level or less.
Installation
1the overall lift arm after the assembly, should check whether the connection between the
sections of pin in place, whether or not split pin has been completely open, lower chord
pin positioning plate is damaged, whether the weld crack, if found the problem, should be
replaced for repair or welding repair, etc.
2 the surface of high strength bolt connection should be dirt, paint, oil and rust, high
strength bolt tightening should check: after the first nut pre-tightening force to achieve
specified value, the second locking nut is tightened. Once every other week retightened.
3tower crane installation, increase the tower section before dealing with structure and high
strength bolts for inspection, if found the following questions should repair or replace
the rear can install
a. visual visible structure crack and weld crack;
b. fittings of shaft and hole serious wear and tear;
c. structures parent metal serious corrosion;
d. structure as a whole or local plastic deformation, pin hole plastic deformation;

4where overhead transmission line, and the safety of the transmission line distance of any
part of the tower crane should comply with the provisions in the table. As a
result of conditions can't guarantee the safe distance, in the table
should be in consultation with relevant departments, and take safety
measures is set up.

/m /KV voltage
Safe distance <1 1~15 20~40 60-110 220
vertical
1.5 3.0 4.0 5.0 6.0
direction
horizontal
1.0 1.5 2.0 4.0 6.0
direction

5 The minimum set up distance between two sets of tower crane should guarantee low
tower crane boom end and another tower crane at least 2 m of the distance between the
tower; High tower bottom parts (hook rose to the highest or the lowest part of the
balance weight) and low vertical distance between in the highest position in the tower

45
 crane parts should not be less than 2 m.
Pieces of scrap and working fixed number of year
1 tower crane, the main load-bearing structure due to corrosion or wear and make the
structure calculation of stress increase, when more than 15% of the original calculating
stress should be scrapped. For the condition of no, when the corrosion depth of 10% of
the original thickness should be scrapped.
2 tower crane, the main bearing structures such as the tower, jib, loss of overall stability
should be scrapped. Such as local damage and repair,

After repair should not be lower than the bearing capacity of the original structure.

3 of tower crane structure and cracking in welding seam, should be taken according to the
stress and crack situation or to reinforce measures such as welding, and in use on a
regular basis to observe its development, to be able to eliminate the influence of crack
should be scrapped.
4 hook repair welding is forbidden, has one of the following circumstances shall be
discarded:
a. with 20 times the magnifying glass to observe the surface crack;
b. clasps tail and threaded portion and so on dangerous cross section and the reinforced
with permanent deformation
c. hang rope section erosion rate more than 10% of the original height;
d. arbor wear is more than 5% of its diameter;
e. is value increased by 15% compared to the original size.
5drum and roller has one of the following circumstances shall be discarded:
a. crack or rim damaged;
b. volume are compared.in wear is 10% of the original wall thickness;
c. pulley rope wear tank wall thickness of wall thickness of 20%;
d. pulley groove bottom erosion rate more than 25% of the wire rope diameter accordingly.
6the brake parts has one of the following circumstances shall be discarded:
a. the crackle;
b. brake block friction liner wear is up to 50% of the original thickness;
c. brake wheel surface wear is 1.5 ~ 2 mm;
d. the spring appear plastic deformation;
e. thrust lever system spare travel more than the amount in fact 10% of stroke;
7steel wire rope
a. cable installation, maintenance, maintenance, inspection and scrap should be in
conformity with the relevant provisions of the GB/T5972;
b. the end of the wire rope fixed onto meet the following requirements:

With a steel wire rope clip fixed edge, should comply with the provisions of GB/T5976,
solid strength should not be less than 85% of the wire rope breaking force;

with a braided fixed edge, bend length should not be less than 20 times the diameter of
the wire rope; And not less than 300 mm, solid strength should not be less than 75% of

46
 the wire rope breaking force;
with a wedge joint, wedge and the wedge set shall comply with the provisions of
GB/T5973, solid strength should not be less than 75% of the wire rope breaking force;
with conical sleeve when casting solid, solid strength should be at the breaking force of
steel wire rope
use aluminum alloy to suppress connector fixed edge, solid strength should not be less
than 90% of the wire rope breaking force;

fixed edge, with press plate shall conform to the provisions of GB/T5975, solid
strength should reach the breaking force of steel wire rope.

QTZ160 (6516) TOWER CRANE

MANUAL BOOK

47
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