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Self-Raising Tower Crane QTZ125

Operating Instructions for

Manufacturing License No.: TS 2410619-2008

Foshan Nanhai Golden Construction Machinery Co., Ltd.

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Brief introduction to the Company

Foshan Nanhai Golden Construction Machinery Co., Ltd. is situated at the juncture between Guangzhou and Nanhai, with superior geographic environment and easy access. Land transportation conditions include Guangzhou-Foshan Expressway, Guangzhou East/South/West Ring Expressway, and National Highway. Waterways transport conditions includes Sanshan Port of Nanhai and several sailing-off ports of Guangzhou within easy reach.

Our Company specializes in manufacturing of builder's lifts, self-raising tower cranes, and maintenance and erection of tower cranes, with registered capital of 3,200,000 Yuan. Our Company began to manufacture tower crane QTZ63 in 1994, which passed the product appraisal held by Guangdong Provincial Construction Committee in the same year. In 1995, the Company successfully passed the Comprehensive Examination of quality assurance system for manufacturing license of tower crane held by Ministry of Construction, and it was awarded with production license on December 31, 1995, with license No.: XK211100204. Over 30 sets of tower crane have been sold to the foreign countries, and presently the tower cranes manufactured by the Company have been spread all over the whole Zhujiang Delta. On July 1, 2003, our Company was awarded with the Manufacturing licenses for the new self- raising tower cranes QTZ 250, QTZ 200, QTZ 160, QTZ 125, QTZ 100, QTZ 80, and QTZ 63, with manufacturing license No. IS 2410619-2008.

Our enterprise has over 30 technicians and managerial personnel, approximately 100 manufacturing employees, and over 20 erectors and service mechanics. In order to meet the demands of its clients and ensure top-quality maintenance services, it plans to recruit a number of qualified technicians and workers from the society at present.

Address: Northern Side of Wudou Bridge, Pingzhou, Nanhai, Foshan Guangdong P.R. China

Contact: Mr. Mingzhuo Pan Tel: +86-0757-8679532186795328 Fax: +86-0757-86778582 Zip Code: 528251

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Foshan Nanhai Golden Construction

Contents of Operating Instruction Manual

 

Page 1

Machinery Co., Ltd.

for Self-Raising Tower Crane QTZ 125

of 3

 

Contents

General……………………………………………………………………………………

1

Explanation, important statement, and safety precautions………………………………

2

I. Explanation…………………………………………………………………………….

2

II. Important statement…………………………………………………………………...

2

III. Safety precautions…………………………………………………………………….

3

1.

Technical performance………………………………………………………………...

4

  • 1.1 Table of load characteristics…………………………………………………………..

4

  • 1.2 Technical performance parameters…………………………………………………

5

  • 1.3 Technical parameters of the operating mechanisms…………………………………..

6

  • 1.4 External dimensions part names and weight of the tower crane……………………...

7

2.

Basic types of tower crane……………………………………………………………..

8

  • 2.1 Overall layout…………………………………………………………………………

8

  • 2.2 Independent type……………………………………………………………………...

8

  • 2.3 Attached type………………………………………………………………………….

8

3.

Metal structure…………………………………………………………………………

10

  • 3.1 Foundation section……………………………………………………………………

10

  • 3.2 Standard section………………………………………………………………………

10

  • 3.3 Bell socket frame…………………………………………………………………...

10

  • 3.4 Lower coupling……………………………………………………………………….

10

  • 3.5 Upper coupling………………………………………………………………………..

11

  • 3.6 Transition section……………………………………………………………………..

11

  • 3.7 Drivers cab…………………………………………………………………………..

11

  • 3.8 Tower cap……………………………………………………………………………..

11

  • 3.9 Counterjib and counterjib armtie kit………………………………………………….

11

3.10 Jib boom and jib-boom armtie kit…………………………………………………...

11

4.

Attaching device and earthing device………………………………………………….

12

  • 4.1 Attaching device……………………………………………………………………..

12

  • 4.2 Earthing device……………………………………………………………………….

12

5.

Operating mechanism………………………………………………………………….

14

5.1

Hoisting mechanism…………………………………………………………………..

14

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Contents of Operating Instruction Manual

Foshan Nanhai Gaoda Construction

 

of 3

for Self-Raising Tower Crane QTZ 125

Machinery Co., Ltd.

  • 5.2 Slewing mechanism and slewing bearing………………………………………….

14

  • 5.3 derricking mechanism……………………………………………………………...

14

  • 5.4 Jacking device……………………………………………………………………...

15

6.

Safety device of tower crane………………………………………………………...

17

  • 6.1 Load moment limiter……………………………………………………………….

18

  • 6.2 Load-lifting limiter…………………………………………………………………

19

  • 6.3 Hoisting altitude, slewing angle, and derricking travel limitator…………………..

20

7.

Preparations before erection of tower crane…………………………………………

24

  • 7.1 Preparations and precautions……………………………………………………….

24

  • 7.2 Tower cranes place of erection………………………………………………….

25

  • 7.3 Foundations for the tower crane………………………………………………….

26

  • 7.4 Anchor bolt preembedding…………………………………………………………

26

Concrete pile foundation for tower crane………………………………………….

27

Tower crane foundation………………………………………………………….

28

8.

Erection tower crane………………………………………………………………...

29

  • 8.1 Erection of foundation section……………………………………………………..

30

  • 8.2 Erection of the standard section……………………………………………………

31

  • 8.3 Erection of the bell socket frame…………………………………………………..

32

  • 8.4 Erection of the upper/ lower coupling and drivers cab……………………………

33

  • 8.5 Erection of transition section………………………………………………………

34

  • 8.6 Erection of tower cap………………………………………………………………

35

  • 8.7 Erection of the counterjib…………………………………………………………..

36

  • 8.8 Erection of the jib boom……………………………………………………………

40

9.

Late-stage tasks related to erection of tower crane………………………………….

45

  • 9.1 Connection of electric wiring………………………………………………………

45

  • 9.2 Reeling of hoisting rope (please refer to Figure 35)……………………………….

45

  • 9.3 Reeling of top ping lift……………………………………………………………..

46

  • 9.4 Test run before jacking section adding…………………………………………..

46

  • 9.5 Properly adjust the moment limiting device and load-lifting limiter according to the requirements for safety device debugging listed in the instruction manual

46

  • 9.6 Items to be checked once erection is completed…………………………………...

47

  • 10. Jacking of tower crane……………………………………………………………..

48

10.1 Preparations before jacking operation…………………………………………….

48

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Contents of Operating Instruction Manual

 

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Machinery Co., Ltd.

for Self-Raising Tower Crane QTZ 125

of 3

  • 10.2 Jacking operation of tower crane……………………………………………………

48

  • 10.3 Precautions for the process of jacking operation……………………………………

48

11.

Operation of tower crane………………………………………………..……………

51

  • 11.1 Safety regulations for operation of tower crane…………………………………….

51

  • 11.2 Electrical system of tower crane and its operations…………………………………

52

  • 11.3 Operation…………………………………………………………………………….

52

  • 11.4 Precautions for operation……………………………………………………………

53

  • 11.5 Mounting positions of electrical devices…………………………………………….

53

12.

Tower crane dismantling……………………………………………………………...

54

  • 12.1 Preparation before dismantling……………………………………………………...

54

  • 12.2 Tower mast dismantling……………………………………………………………..

54

  • 12.3 Hoisting rope dismantling…………………………………………………………...

54

  • 12.4 Jib boom dismantling………………………………………………………………..

54

  • 12.5 Wind up the hoisting ropes and remove the electric cable of hoisting mechanism

54

  • 12.6 Dismantle the counterweight and counterjib………………………………………...

57

  • 12.7 Tower cap dismantling………………………………………………………………

57

  • 12.8 Transition section dismantling………………………………………………………

57

  • 12.9 Dismantle the upper/lower coupling and driver's cab……………………………….

57

  • 12.10 Bell socket frame dismantling……………………………………………………...

57

  • 12.11 Standard section dismantling………………………………………………………

57

  • 12.12 Foundation section dismantling……………………………………………………

57

13.

Repair and maintenance of tower crane………………………………………………

58

  • 13.1 Routine maintenance and servicing…………………………………………………

58

  • 13.2 major failures of tower crane and relevant recipe…………………………………..

59

14.

Transport of tower crane……………………………………………………………..

60

Attached table I. Table of oil sites………………………………………………………..

61

Attached table II. Detailed list of bearings……………………………………………….

62

Attached table III. Detailed list of wearing parts…………………………………………

62

Appendix. Transform method for multiply factor of hoisting ropes……………………...

63

Attached technical documents…………………………………………………………….

64

Attachment tools…………………………………………………………………………..

64

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Contents of Operating Instruction Manual

Page 1

Machinery Co., Ltd.

for Self-Raising Tower Crane QTZ 125

of 64

 

General

Self-raising tower crane QTZ125, which is a new-style elevating machinery specially designed for the construction of tall buildings and equipment installation, is a type of self-raising multi-purpose tower crane equipped with level arm support, and it allows trolley derricking and upper slewing. its jib length is 60m (or assembled as 55m or 50 m), with maximum lifting load of 10Ton and rated load moment of 125Ton·m. Main features of the tower crane are given below:

1. The tower crane is provided with comprehensive adaptability. It can fully satisfy the requirements of both the civil building construction in medium/small-size cities and construction of tall/multistory civil buildings in large/medium-size cities. Furthermore, it is also applicable to the construction of multi-story wide-span industrial premises and tower structures such as chimney stalks and silos etc. constructed as per slip-form techniques, or the handling operations at harbors or freight yards.

2. It allows easy erection and disassembly. Hydraulic jacking device is adopted to increase or reduce the number of standard sections for the tower mast so that the hoisting altitude of tower crane may adapt to the change in building height.

3. It is characterized for high operating speed, perfect speed regulation performance, stable operation, high efficiency, and its hoisting mechanism may basically realize heavy load low speed or light load high speed. Its trolley traction mechanism may operate at either two speeds so as to satisfy the requirement of tasks; its slewing mechanism is equipped with normal-open electromagnetic stopper so that the tower crane may be set in place accurately for the sake of safe operation.

4. It is equipped with complete, sensitive, and reliable safety protection system, such as weight limiting device, moment limiting device, hoisting altitude limitator, derricking travel limitator, and slewing angle limitator etc.; its hoisting rope is equipped with antitwist device, derricking trolley is equipped with rope breakoff preventor, shaft breakoff preventor, hoist rope guide, derricking/ hauling rope tensioner etc. so as to ensure normal operation of the tower crane. In addition, it is also equipped with the labor-safety protective equipment such as broadstep and guardrail etc.

5. Its independently external drivers cab is equipped with interlock console for control all relevant mechanism, and it is characterized for capaciousness, coziness, safety, handiness, and a wide field of vision. The tower crane should be delivered in its basic height (independent type) of 50m; if user plans to apply it in the construction of tall buildings, it is allowed to increase the quantity of the standard sections and attachment devices and fulfill the maximum design height is 200m of the tower crane.

(Both the independent height of 50m and the attachment height of 200m are the maximum hoisting altitude of hook of the tower crane.)

The Company reserves its rights to update or improve the product. Some structures or parameters of the product the user purchased might not conform to this operating instruction manual. If any, please contact the Company immediately.

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Contents of Operating Instruction Manual

Foshan Nanhai Golden Construction

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for Self-Raising Tower Crane QTZ 125

Machinery Co., Ltd.

 

Explanation, important statement, and safety precautions

I. Explanation

User of tower crane must strictly abide by current national laws and decrees, the safety regulations/criteria issued by the labor safety department, and all prescriptions about safety listed in this operating instruction manual.

To erection or dismantle the tower crane, it is required to mark out a job region that should be guarded by specially assigned person so as to debar the non-operators to access to the said region.

Tower crane driver must have a certificate for operation of tower crane; otherwise it may be considered as the users serious infringe of regulations, and the serious consequences should be undertaken. At any moment in the process of operation, tower crane driver should concentrate on the tasks and pay attention to the safety, and he should be serious and responsible, and keep his eyes peeled.

The manufacturer should not undertake any responsibility for any personal safety/equipment accident due to violation of the safety requirements and operation specifications we set forth hereby.

II. Important statement

 

The manufacturer should not be responsible for any civil or criminal responsibility for the unworkability of tower crane, equipment damage, structural damage, or accident due to the following causes.

All parts assembled in the tower crane are not the parts provided by the manufacturer;

In case the tower crane was modified or repaired without the permission and approval of the superintendent of engineering department of the manufacturer and the person specially assigned by the manufacturer;

Erection or operation is not carried out as per the explanations and requirements listed in this Operating instruction manual;

In case the operation violates the current national safety regulations.

 

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Contents of Operating Instruction Manual

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Machinery Co., Ltd.

for Self-Raising Tower Crane QTZ 125

of 64

III. Safety precautions

  • 1. Before the erection of tower crane, it is required to verify that space of the erection site may allow the erected tower crane to carry out free revolve.

  • 2. Tower crane should be erected on flat ground; in case there is any spot, which is below the bottom of foundation, nearby the reinforced concrete foundation, it is required to ensure that the ground should be safe against the hazards such as subsidence or landsliding.

  • 3. It is necessary to regularly check the availability and susceptibility of the safety devices; it is not allowed to revise or adjust the safety device as one pleases; it is strictly prohibited to dismantle or disable the safety devices.

  • 4. Regularly check the foundation of tower crane, the attachment device, and the error of perpendicularity of tower mast etc.

  • 5. It is not allowed to lift up objects aslant.

  • 6. It is not allowed to push or pull objects by the tower crane. It is not allowed to lift up any objects that are built in the ground, clamped under other objects, or rounded by other objects, for fear of accident due to severe overload caused by the increase of extraneous force.

  • 7. When the tower crane is carrying out jacking, tower mast raising, or tower mast lowering, it is strictly prohibited to perform slewing action when the lower coupling is withdrawn from the standard section. To lift up the standard section, it is required to lay the lower coupling onto the standard section, and it is only allowed to lift up one piece of standard section once at one go within a distance of 10m.

  • 8. To lift up objects from a spot that the sight line of the driver may not reach, there will have to be person specially assigned for command and low-speed operation, and it is required to be ready for shutdown at any moment.

  • 9. Pay attention to the wind speed. In case the maximum wind speed is approximately equal to 15m/seconds (approximately strong breeze), it is required to lift down the objects immediately, raise the hook to approximately the maximum hoisting altitude, let the derricking trolley regress to smaller radius, stop operation, and cut off the general supply.

  • 10. Once the tower crane stops operation, it is strictly prohibited to hang any object onto the hook; in addition, the hook should be positioned nearby the derricking trolley (ensuring that the tower crane must not collide with the building or other objects in case the tower crane performs free rotation; its horizon distance from high tension power line should be 10 m or more while the vertical distance from high tension power line must not be less than 5m), and the derricking trolley should be positioned at smaller radius (it is advisable to be 10m).

  • 11. Once the tower crane stops operation, it is required to cut off the general supply immediately.

 
  • 12. Regularly maintain the tower crane carefully. Carefully check the wearing parts such as brake, wire rope and pulley etc, and carry out necessary calibration or replacement.

  • 13. Made a practice of necessary lubrication, and the shaft of rope guide pulley should be applied with grease every day in particular.

  • 14. Regularly check the temperature rise of motor, resistance box and reducing unit, and regularly check and tighten the electrical connections.

  • 15. To maintain or repair the tower crane, it is required to cut off the general supply of tower crane, especially before repair or electric wiring.

  • 16. To repair or calibrate the tower crane, it is necessary to wear work clothes and hardhat; to operate at a spot without working platform, it is required to properly tie in the safety belts that satisfy the safety requirements and chuckle the safety belts according to relevant stipulations.

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Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125

Foshan Nanhai Golden Construction Machinery Co., Ltd.

2.45 2.50 2.59 2.64 2.74 2.79 2.91 2.96 3.09 3.14 3.30 3.35 3.52 3.57 3.77 3.82
2.45
2.50
2.59
2.64
2.74
2.79
2.91
2.96
3.09
3.14
3.30
3.35
3.52
3.57
3.77
3.82
4.05
4.10
4.37
4.42
4.73
4.78
5.14
5.00
5.62
5.00
6.19
5.00
686
5.00
7.67
5.00
8.68
5.00
10.00
5.00
● In case the length of compound jib is 50m, 5 pieces of counterweight should be adopted, totaling 12.5Ton
Working radius of
50
20
34
32
18
16
3 ~
30
36
26
40
38
48
46
28
22
24
42
44
50 52 38 40 44 46 46 48 42 44 34 ● In case the length
50
52
38
40
44
46
46
48
42
44
34
● In case the length of compound jib is 55m, 6 pieces of counterweight should be adopted, totaling 15 Ton
1.75
1.80
1.84
1.89
1.94
1.99
2.04
2.09
2.16
2.21
2.28
2.33
2.41
2.46
2.56
2.61
2.72
2.77
2.89
2.94
3.09
3.14
3.30
3.35
3.54
3.59
3.80
3.58
4.10
4.15
4.44
4.49
4.84
4.89
5.29
5.00
5.83
5.00
6.47
5.00
7.24
5.00
8.19
5.00
9.40
5.00
10.00
5.00
54
2.10
55
2.05
50
2.35
3.90
3.95
5.97
5.00
5.42
5.00
4.95
5.00
4.55
4.60
3.38
3.43
4.21
4.26
8.38
5.00
2.97
3.02
10.00
5.00
3.17
3.22
3.63
3.68
7.41
5.00
2.48
2.53
2.63
2.68
2.79
2.84
6.88
5.00
2.22
2.27
Table of load characteristics
● In case the length of compound jib is 60m, 7 pieces of counterweight should be adopted, totaling 17.5 Ton
Working radius of
Working radius of
15
58
54
56
52
2.15
3~
60
16
2.40
48
16
20
3~
38
20
40
36
28
28
18
32
32
26
36
30
26
18
34
2.10
30
42
22
24
22
24

Technical performance

1.1 Table of load characteristics

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Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125

Page 5 of 64
Page 5
of 64
Weight of counterweight 3 Working radius Rated load moment 12 Foundation dimensions 13 Deadweight of tower
Weight of counterweight
3
Working radius
Rated load moment
12
Foundation dimensions
13
Deadweight of tower crane
Rear slewing radius
14
Maximum lifting load
15
Weight of the complete appliance
8
Derricking speed
9
Jacking speed
10
Front-end slewing radius
6
73.84(independent type)
56.34 (independent type)
0~20 0~40
a=4
Maximum hoisting altitude (attached type)
Maximum hoisting altitude (independent type)
4
5
11
Hoisting speed
7
Slewing speed
1.2 Technical performance parameters
No.
Name
1
2
/min.
m
6×6×1.6
Ton
17.5
Ton
Ton
Rpm
m
14.6
60
9
30
m
/min.
0.5
m
61.8
Unit
m
50
m
200
m
/min.
0~40 0~80
a=2
0~0.6
Parameter
3~60
Ton·m
125
Ton
10
m
m

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Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125

Foshan Nanhai Golden Construction Machinery Co., Ltd.

YRTE180M 2 -4 i=35.6/17.8 500 6×19-14-170-I-A-Righthand a=2 a=4 0~80 0~20 0~40 55RCS25 —— 41 1440 Built-in
YRTE180M 2 -4
i=35.6/17.8
500
6×19-14-170-I-A-Righthand
a=2
a=4
0~80
0~20
0~40
55RCS25
——
41
1440
Built-in Brake
Field voltage AC24V
6×19-9-170-I-A –Plated-righthand
Y132M-4B5
Y132M-4B5
Maximum pressure P=31.5MPa
Travel 1600
YLEW112M 3 –6-KB5
Mounting distance2200
Rated pressure P=25Mpa
Jacking device
mechanism
YTLEJB2L-185-4
Derricking
Braking moment 185N·m
Built-in normal-open electromagnetic limit stop DC24V
mechanism
2.5
Braking moment=10000N·m
0~40
m
mechanism
N·m
r/min
kW
1.3 Technical parameters of the operating mechanisms
Hydrocylinder
Brake
Braking
moment
Motor
Wire rope
GB1102-74
185JXL1B
Motor
Hydraulic power unit
Model
Specs. and model
Maximum lifting load
t
5
Specs. and model
XT100A
Motor
Brake
Liquid coupling
Multiply factor
10
5
i=195
——
Reducing unit
Ratio of speed
Winding drum
Rope capacity
Wire rope
Specs. and model
Hoisting speed
m/min
GB1102-74
Specs. and model
Model
Power
Motor
Rotating speed

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Foshan Nanhai Golden Construction Machinery Co., Ltd. Contents of Operating Instruction Manual for Self-Raising Tower Crane
Foshan Nanhai Golden Construction
Machinery Co., Ltd.
Contents of Operating Instruction Manual
for Self-Raising Tower Crane QTZ 125
Page 7
of 66
1.4 External dimensions part names and weight of the tower crane(please refer to Figure 1)
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Page 8 of 64 Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125 Foshan
Page 8
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Contents of Operating Instruction Manual
for Self-Raising Tower Crane QTZ 125
Foshan Nanhai Golden Construction
Machinery Co., Ltd.
2. Basic types of tower crane
2.1
Overall layout
The one-piece construction of tower mast is composed of standard sections. Lower part of the tower mast is
closely connected to the foundation via the square flange of the foundation section, and its lower part is
connected to the upper slewing part tower crane via the lower coupling, slewing bearing, and the upper
coupling. Driver’s cab is located on the right side of the upper coupling, the hoisting mechanism is located on
the counterjib, the two slewing mechanisms are separately located on the right/left side of the upper coupling,
and the derricking mechanism is located on one section of the jib, which lays close to the end of tower cap.
Both the jib boom and the counterjib are connected to the tower top by rigid rods so as to ensure the level
position. Derricking trolley is pulled by the derricking mechanism via top ping lift so that is may travel along
the lower chord of jib boom back and forth. Bell socket frame is located at the lower end of the lower
coupling, which should be fit over the tower mast and designed for adding (reducing) the number of standard
sections in the process of tower crane jacking so as to satisfy the requirements of hoisting altitude of tower
crane.
2.2
Independent type
In case the hoisting altitude is less than or equal to 50M, tower crane may be operated as independent type
(namely free of all other auxiliary devices such as Attaching devices or bracing etc.).
2.3
Attached type
In case the hoisting altitude of tower crane is greater than 50M, it is required to fit on the auxiliary devices for
the sake of normal operation. By means of fitting on the attachment devices, effective hoisting altitude of the
tower crane may be up to 200M.
Structural arrangement of attached-type tower crane is the same as that for independent type; in order to
enhance the global stability and rigidity of the tower crane, 8 sets of Attaching devices should be mounted in
the total height (200M) of the tower crane. Different number of Attaching device sets determines different
effective hoisting altitude (please refer to Figure 3).
For the clearance between the slewing center of tower crane and the building, the vertical distance between
every two sets of Attaching device (Reference value only, allowing adjustment as per actual conditions), and
the erection method, please refer to Figure 2.
The distance from the tower crane's topmost Attaching device to the linkage point of Jib boom is namely the
cantilevered end freedom of the tower crane. To mount any set of Attaching device, cantilevered end freedom
must not exceed 30M.
5100
slewing center of tower crane
Figure 2. Horizon distance between tower crane and building when the tower crane is attached
4000

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Foshan Nanhai Golden Construction Machinery Co., Ltd. Contents of Operating Instruction Manual for Self-Raising Tower Crane
Foshan Nanhai Golden Construction
Machinery Co., Ltd.
Contents of Operating Instruction Manual
for Self-Raising Tower Crane QTZ 125
Page 9
of 64
Figure 3.Vertical distance between every two sets of attaching devices in case tower crane is attached
27.5m
22.5m
20m
20m
20m
20m
20m
20m
30m

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Contents of Operating Instruction Manual

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Machinery Co., Ltd.

3. Metal structure

Metal structure includes the foundation feet, standard section, bell socket frame, lower coupling, upper coupling, transition section, tower cap, jib boom, counterjib, rigid rod and Attaching device etc.

  • 3.1 Foundation feet

Foundation feet of the tower mast includes 4 independent parts. One part of foundation feet is a welded cancelled structure that adopts 1 piece of square steel pipe as principal chords and large square flange and fortified plate. Insert 32Pcs. of preembedded anchor bolts M36×1300 into the bolt holes in the large square flange and tighten them, and the foundation section is then closely connected to the concrete foundation.

  • 3.2 Standard section and Fortified standard section

 

Standard section of the tower mast adopts the cancelled structure welded with square steel pipes and seamless steel pipes, and its sectional dimension should be 1.95×1.95M, 2.8M in height. Among the four pieces of principal chords, two of them are separately welded with two pieces of pedals designed for section adding in case of self-raising. 8pcs. of bushing are accordingly welded onto the lower/upper ends of the pedals, which are connected to the standard section, foundation feet, or lower coupling by 8pcs. of high-strength hexagonal head tap bolts M39×3×360 and 16pcs. of high-strength hexagonal nuts. Each standard section is equipped with vertical access ladder and broadstep.

Fortified standard section is based upon standard section added one bushing. Each tower crane admeasure 3pcs.fortified standard section. Fortified standard section without broadstep.

  • 3.3 Bell socket frame

Bell socket frame adopts constructional frame structure, and it consists of bell-socket frame structure, platform, and guardrail etc.

Bell socket frame should be fit over the outside of standard section, with sectional dimension of 2.3M×2.3 M, and 5.8M in height. The upper-end flange is connected ot the lower coupling flange by high-strength hexagonal head tap bolt pairs. Upperhalf of the front of bell socket frame is not fitted with web members so as to lead in the standard section. Jacking oil cylinder should be mounted on the oil-cylinder transverse member at rear side of the bell socket frame. Hydraulic jacking mechanism should be positioned on the working platform.

Inner side of the bell socket frame is fitted with 16pcs. of adjustable roller. in case of Jacking operation, the rollers support on the outside of principal chord of the tower mast and act as guides and bearing members..

Bracing is located at both ends of oil-cylinder transverse member laying close to the principal chord, which may be positioned at the footboard notch of standard section for support so as to unload the oil cylinder and retract the piston rod.

The bracing may support the upper-part structure of the tower crane during jacking operation so that the working steps of oil cylinder may be conveniently changed.

  • 3.4 Lower coupling

Lower coupling adopts box type construction. Its lower part is connected to the jacking bell socket frame with φ50mm axis pin via hole pin. Its lower part is connected to standard section with high-strength hexagonal head tap bolt pairs via the bushing. Outer race of the slewing bearing is connected to its upper plane by 36pcs. of high-strength hexagonal head tap bolt pairs M24×180.

  • 3.5 Upper coupling

Upper coupling adopts box type construction. Its lower plane is connected to the inner race of slewing bearing by 36pcs. of high-strength hexagonal head tap bolt M24×190, and its upper part is connected to the transition section by high strength bolts M33 × 125. Thereon it is equipped with mounting flange for slewing mechanism, mounting support for slewing limitator, supporting U-bar for drivers cab and guardrail etc., which are designed for mounting the slewing mechanism, slewing limitator, electric control cabinet, and the operators cab.

  • 3.6 Transition section

Transition section adopts integral frame structure. It is welded into cancelled structure by square steel pipes and seamless steel pipes. Its lower part is mounted onto the upper coupling. Its upper part is connected to the tower cap. Transverse members in front of/behind the transition section are welded with ears, which are separately connected to the counterjib and jib boom by jib pins. Hoisting-rope guide pulley is mounted inside the front transverse member.

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  • 3.7 Drivers cab

Frame of the drivers cab is fabricated with merchant bar, and the frame is covered with sheet. There is a glass window in the front panel of the drivers cab, with field of vision. The drivers cab is characterized for its roominess, well ventilation, handiness, and coziness. Its lower part is securely position on the upper coupling by means of supporting U-bar and connecting bolts. The driver's cab is equipped with the general supply switch, interlock console for electric control, signalling devices, and seats, allowing controlling the complete appliance for normal operation.

  • 3.8 Tower cap

Tower cap adopts oblique rectangular pyramid cancelled structure. Clamping plate on its top is fitted with the transition armtie connecting the counterjib armtie and the head armtie for connecting jib boom armtie. Its top closing board is fitted with wire-rope sheaves for erection, and obstacle light is fitted on the outside of its top clamping plate. Right-hand upper part of the tower cap is equipped with erection platform, and a stairway equipped with protecting ring is downward mounted at the rear of the platform. Load-lifting limiter is mounted at the upper part of the structure, which also acts at wire-rope guide pulley; mechanical moment limiting device is mounted on the inner side of rear principal chord at the lower part. Its bottom is connected to the transition section by flange and 16pcs. of high-strength hexagonal head tap bolt pairs M33×125.

  • 3.9 Counterjib and counterjib armtie kit

  • 3.9.1 Counterjib is a plane framework paved with alleyway web-plate on the top, and its two sides

is

equipped with safety guardrail.

  • 3.9.2 Hoisting mechanism pedestal is welded nearby the rear of the counterjib, which is designed for fixing

the hoisting mechanism. Large square hole is reserved in its rear part, which is designed for placing the

counterweight block. Rope-guide pulley gear is mounted in front of the counterweight block.

 
  • 3.9.3 Counterjib armtie is divided into two kits, and each kit contains three pieces of armtie, which are

separately connected to the tower cap and lifting lugs at the rear of counterjib by armtie pins and clamping

plate etc. so that the counterjib is suspended to its level position.

 

3.10 Jib boom and jib-boom armtie kit

Jib boom consists of 11 sections of triangular trussed, 60.8M in total length. Height of center of the Triangular profile is 1.2M. Centroid distance between two lower chords is 1.34M. Both the top booms and web members are fabricated with seamless steel pipe #20; each piece of lower chord is welded by two pieces of equal leg angle, with derricking trolley tracks.

Derricking mechanism is mounted at the back end of the second section nearby the root of jib boom. Obstruction light is mounted on the top boom at front end of the first section of jib (tip of the jib) of the jib boom.

Upper ends of the two jib-boom armtie kits are connected to the head armties on the tower cap by purpose- made armtie pins and clamping plates, and lower ends of the two jib-boom armtie kits are separately connected to the lifting-point pin holes in the jib-boom top boom by tailor-made lifting-point pins and transition armtie.

Lifting points are located in the eighth and third section of the jib, and they are accordingly 16.1M and 46.30M to the linkage point at jib root (in case jib boom of 50M is adopted, position of the faroff lifting point is 41.3M).

Jib boom armtie is fabricated in segments. In the process of erection or transportation, do not bend, deform, bump, or scratch the armties.

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4. Attaching device and earthing device

 

4.1 Attaching device (please refer to Figure 2 and Figure 3)

Attaching device consists of frame, three pieces of bracing, axis pins, high-strength bolt pairs, and preembedded ironworks etc.

The frame consists of 4 sets of anchor ears and 4 pieces of joining beams, which are connected into one piece by high strength bolts; the 4 sets of anchor ears separately inclasp 4 pieces of principal chord of standard section.

All bracings are fitted with adjusting bolts and locking nuts so as to adjust the length of bracing. Bracings of the Attaching device should be adjusted according to the actual conditions.

To carry out mounting, firstly fix the frame onto the tower mast, then connect the bracing to the frame by axis pins, and the other end of the bracing should be connected to the lug of preembedded ironworks of the building by axis pins. The three pieces of bracing should be maintained in one horizontal plane; in addition, the medium bracings must be alternately mounted onto each set of Attaching device, and they must not be mouted in same direction.

Preembedded positions of the preembedded ironworks should be determined according to the actual conditions in the field.

4.2 Earthing device (please refer to Figure 4)

 
  • 4.2.1 According to the prescription in Clause 8.1.3 of GB -5144-94 Safety regulations for tower cranes, the

metal structure of crane, metal enclosure of all electric apparatus, and all metal wire ducts etc. must be earthed

securely.

  • 4.2.2 Earth resistance must not be higher than 4 ohm. It is required to construct according to Figure 4 so as to

satisfy all requirements.

  • 4.2.3 precautions for connecting the earthing devices:

 
  • A. Coating at the joint should be removed.

  • B. Cable of lightning-earth protective device may be connected to bolt of any piece of principal chord, and the coating on the bolts, nuts, and bushing should be removed.

  • C. The undercarriage, which is connected to the groundwork in rivet clasp mode, must not serve as earthed pole for lighting protection; It is required to set up another lightning earthing device outside the foundation of the tower crane.

  • D. Resistance of the lightning-earth protective device must not be greater than 20 ohm.

  • E. Even if other safety protection systems such as highly-sensitive differential relay (automatic circuit breaker) are available, it is also required to set up this kind of earth protective device according to relevant stipulations.

  • F. Earthing device should be mounted by person specially assigned because earthing resistivity may significantly vary as per time factors and different local conditions and high-precision instruments are required for determining the resistance.

The manufacturer of the tower crane should not provide materials of thunder-arresting facilities and the erection and maintenance of the equipment.

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Ground protection cable
Insulating ceramic pipe
Lightning arrester is fabricated with galvanized pipes, with
minimum pipe diameter of Φ60mm; the pipe length varies
as per specific earthing resistivity (as a general rule, the
pipe should reach the aquifer depth).
Figure 4. Earthing device

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5. Operating mechanism

 

Operating mechanism of tower crane includes the hoisting mechanism, slewing mechanism, derricking mechanism, and jacking device.

  • 5.1 Hoisting mechanism

 

Hoisting mechanism consists of motor , reducing unit, winding drum, and multifunctional travel limitator etc.

Driven by two set of motor (brake with backset), reducing unit rotate such that the hoisting winding drum is driven consequently.

For the method of multiply factor of hook assembly, please refer to the Appendix.

  • 5.2 Slewing mechanism and slewing bearing

 

Slewing mechanism is the propulsion system design for rotation of tower crane, and this tower crane is driven by double slewing mechanisms. Slewing mechanism is mounted on the left/right side of the upper coupling, and it consists of motor, slewing limit stop, slewing pinion, and slewing limitator etc.

It is strictly prohibited to operate the limit stop when the Slewing motor is powered on or is just powered off!

It is strictly prohibited to shut down the crane by limit stop! It is not allowed to shut down the machine by reversal!

The operator should undertake any sequence due to violation of the above-mentioned prescriptions.

  • 5.3 derricking mechanism

 

Derricking mechanism is designed for pulling the trolley for back-and-forth movement so as to realize loaded derricking.

The ends of the wire rope are fixed to both ends of the winding drum. When the derricking trolley goes over to the two travel limit positions of the jib, there should be 3-4 coils of wire rope left on the winding drum. Motor is connected to the reducing unit via elastic coupling. Enclosure the reducing unit is the winding drum. Derricking travel limitator is fitted at one end of the winding drum so as to ensure automatic cut-out of power supply and stop derricking movement when the derricking trolley travels to the maximum radius or minimum radius.

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5.4 Jacking device

Hydraulic jacking device is designed for self-raising section adding (reducing) so as to increase or reduce the height of the tower crane.

Hydraulic jacking device consists of hydraulic power unit, jacking oil cylinder, high-pressure hose, and special-purpose hydraulic oil.

To erect the tower crane, firstly assemble the oil cylinder with the oil-cylinder transverse member of the bell socket frame, connect the oil cylinder to the jacking transverse member, and then erect it along with the bell socket frame. To prevent oil cylinder from swaying, it is necessary to temporarily fasten its assembly onto the bell socket frame.

Before erection of bell socket frame of the tower crane, lift up the hydraulic power unit (including oil tank, motor and reversing valve etc.) onto the platform, and then erect it together with the bell socket frame. After that, remove the working fastening for hydraulic cylinder assembly bell socket frame, connect 2 pieces of high-pressure hose, and carry out test run if no fault is detected. To check it, firstly allow the hydraulic cylinder to stretch out and draw back for several times in no load mode, check if there is any abnormal occurrence, and air out the hydraulic system.

5.4.1 Preparations before the operation of hydraulic system (1) Cleaning treatment of liquid oil

 

Firstly unscrew the air filter, fit in a portable filter with filtering accuracy of 10u, and allow it filter the hydraulic oil till the oil level reaches the upper limit of oil gage in oil tank of the oil pump. Start up the oil pump motor, and check if the rotation direction of the motor is consistent with that marked on the pump base.

(2) Connection of system pipelines

Firstly check the cleanliness of high-pressure rubber hose orifice, then connect the orifice A and B of hydraulic power unit to the oil cylinder via high-pressure rubber hose, and tighten the joints.

(3) System air bleeding

  • A. Air bleeding of hydraulic power unit air bleeding: Loosen the spillover valve handle, unscrew the high-

pressure rubber hose joint at orifice A, set the handle of hand-operated direction valve to its position UP, actuate the motor, air bleeds out of the orifice A; sound of oil pump is normal without abnormal noise; allow it work till the liquid oil is free of bubble.

  • B. Air bleeding of oil cylinder: When the Oil cylinder is in nonload mode, pull the handle of hand-operated

direction valve so that the piston rod stretch out and draw back for several times so as to push the air from the

oil cylinder into the oil tank via oil tube for complete air bleeding. Precautions in the process of operation:

 

When the piston rod moves to the upper (or lower) extreme position, it is necessary to turn the handle back to the medium position immediately and keep it there for some time, and carry out the next motion once the air bubbles in the hydraulic oil that was pushed into the oil tank collapse.

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5.4.2 Maintenance and servicing of hydraulic system and precautions

 

Hydraulic system belongs among the ultrahigh-pressure or high-pressure hydraulic device, and it is required to strictly perform the oil charge, adjustment, and operation of the hydraulic system according to the prescriptions listed in this operating instruction manual.

(1) Adjustment of high-pressure throttle valve

 
  • A. Before operation, unscrew the nut on adjusting handle of the high-pressure spillover valve so that the

hand-operated direction valve is set to the UPposition, and then tighten the nut gradually till the oil cylinder is ready for jacking operation. After that, tighten it once more for 1/4~1/2 turn so as to ensure that the oil cylinder may work in normal mode.

  • B. Under any circumstances, the adjustment pressure must not exceed the rated operating pressure of the

hydraulic power unit.

(2) Oil for hydraulic system

 
  • A. For the southern regions, hydraulic system should adopt anti-wear hydraulic oil (anti-wear hydraulic oil

N32), which is provided the advantages such as wear resistance and defoaming etc. In the northern regions,

synthetic spindle oil (GB 442-64) should be adopted.

 
  • B. Oil charge of hydraulic system: The oil tank should be filled up for the first oil charge; start up the

machine so as to outreach the piston rod of oil cylinder and then retract the piston rod, and replenish oil into

the oil tank till the oil level reach the upper limit of oil gage.

 
  • C. The hydraulic system belongs among ultrahigh-pressure or high-pressure hydraulic system, and every

aspects of it should be strictly performed. Therefore, cleanliness of liquid oil is definitely required. liquid oil must be cyclically filtered by portable filter for 4-6 hours and the cleanliness index fulfils Grade 7-8 (NAS 1683) before application.

  • D. Once the operating hours of hydraulic system reaches 2,400 hours, it is necessary to carry out complete

oil change. Once its operating hours reach 200 hours, it is necessary to replenish some clean oil.

  • E. Heat dissipation conditions of hydraulic system is poor, the machine should be immediately shut down in

case no task is assigned in order to avoid too high temperature rise that may affect normal operation.

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6. Safety device of tower crane
The mounted position of safety device of tower crane is presented in the figure.
GOLDEN
Figure 10. The mounted position of safety device of tower crane
1.Hoisting mechanism (Brake, hoisting altitude limitator)
2. Load-lifting limiter
3.Moment limiting device
4. Slewing angle limitator
5. derricking mechanism (Brake, derricking travel limitator)
6. Derricking trolley (rope-breakoff protective device for top ping lift, and shaft-breakoff protective device)

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Safety protection system of tower crane mainly includes load limiter and travel limitator. Load limiter includes: Load moment limiter, load-lifting limiter.

Travel limitator includes: Hoisting altitude limitator, slewing angle limitator, and derricking travel limitator.

6.1 Load moment limiter

 
  • 6.1.1 Functions

The tower crane is designed according to the constant maximum-load moment that must not be exceeded in operation. The moment limiting device may ensure that the tower crane is only allowed to pick up the loads within relevant range when the tower crane is set to a certain radius; furthermore, derricking can be only performed within relevant radius when the load is certain so as to prevent over-momental operation or even accident.

  • 6.1.2 Structure and operating principle:

 

Moment limiting device is shown in figure 11.

Page 18 Contents of Operating Instruction Manual Foshan Nanhai Golden Construction of 64 for Self-Raising Tower
 

Figure 11. Mechanical moment limiting device

1. Bent steel sheet

2. Adjusting bolt pair

3. Travel switch

Mechanical moment limiting device is securely welded to the lower part of inner side of main limb at right back corner of tower cap by the two-end connected steel plate. Due to the loading of hoisted object, the main limb at the backside (close to the counterjib) of tower cap is in tension and slightly lengthen along the directions of arrow X-X shown in the figure; through the medium of amplified action of the two pieces of bent steel plate (1), the medium clearance of the bent steel plate will be visibly decreased along the directions of arrow Y-Y. Appropriately adjust the clearance from head of adjusting bolt (2) to contactor of travel switch (3) such that the normally closed contact of travel switch is ejected so as to cut off relevant motion control circuit when the tower crane reaches 100-105of its rated load moment, and the tower crane may not perform uprise or outward derricking motion. At this moment, descend or inward derricking motion of the tower crane may be normally carried out so that the tower crane may immediately unburden load or decrease moment of load immediately so as to avoid over-momental operation of tower crane and ensure safety of the tower crane.

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  • 6.1.3 Adjustment methods:

 

Adjustment should be carried out according to the test procedures for moment limiting device in Appendix of GB9462-1999 Technical provisions of tower cranes. Each method should be triplicated.

(1) Adjustment as per constant radius variable speed:

 

A. Let the tower crane to lift up 1.8 Ton at normal operating speed and maximum operating radius 60M. Adjust screw 6 so that the normally closed contactor of travel switch 4 opens and cuts off the power supply for tower crane to perform uprise or outward derricking motion; tighten the adjusting nut, let the tower crane to lift up schedule weight of 1.8 Ton at the same radius, and verify that the operation mode is normal. Let the tower crane to lift up 1.98 Ton at the lowest speed, and the moment limiting device should be actuated and cut off the power supply.

B. When the radius is 20.57 M, let the tower crane to lift up 7.0 ton at 4 times the normal speed, and verify that the tower crane is capable of normal operation. Let the tower crane to lift up 7.7 Ton at the lowest speed, and the moment limiting device should be actuated and cut off the power supply.

(2) Adjustment as per constant speed variable radius:

 

A. The 4 multiply-factor maximum load-lifting capacity of the tower crane is 10 Ton, with the operating radius Rm = 15M, Rm×1.1=16.5M; determine and mark this on the ground. Let the tower crane to lift up for lower than 1M a heavy object of 10Ton 10M away from it, and verify that the tower crane is capable of normal derricking when it is required to perform outward derricking up to 15M. Let it return to radius of 10M and perform derricking motion at normal speed, and it should automatically stop derricking motion when the distance is not over 16.5M.

B. Load-lifting capacity at the radius of 41.32M should be 3.0Ton (0.3 times the maximum load-lifting capacity). Let the tower crane to lift up 3Ton at 30M and derrick to 41.32M at low speed, and the moment limiting device does not actuate. Let the tower crane return to 30M, and the moment limiting device is actuated and cut off the power supply for outward derricking before derricking of the tower crane reaches 45.45M, and it should be considered as acceptable.

6.2 Load-lifting limiter (please refer to Figure 12)

 
  • 6.2.1 Functions

Many Structural members, mechanisms, and parts of the tower crane are calculated and designed according to the preset Maximum lifting load in the process of integrated design of tower crane. Maximum load-lifting limiter is designed to prevent operation over the Maximum lifting load that may damage the tower structure, mechanisms, or parts so as to ensure the safe operation of the tower crane.

  • 6.2.2 Principle:

 

Load-lifting limiter is also referred to as proving ring, and it is fitted with pulleys for wire rope reeling. It is mounted on upper part of the tower cap, and the hoisting rope is passed through its pulley groove. The load's tensile force applied on the wire rope causes the deformation of proving ring that is connected to both ends of the pulley shaft. Once the deformation of proving ring fulfills a certain condition (namely load is increased to a certain value), the amplifier spring leaf fitted inside the proving ring is deformed such that the adjustable bolt fitted on the spring leaf moves and withdraw the normally closed contactor of travel switch that is designed for weight restriction so as to cut off the power supply to motor of Hoisting mechanism. In case the hoist rope adopts 4 multiply factor, the hoist speed is medium or low, and the hoisted load is within the range 10ton~11ton, the adjusting bolt should actuate the travel switch so as to cut off the uprise circuit, So as to realize security protection. it is allowed to control the load limit at high speed by adjusting the other adjusting bolt.

  • 6.2.3 adjusting methods (in case of 4 multiplying factor):

 

A.

Let the tower crane to lift up 11Ton within the amplitude range of maximum load-lifting capacity, adjust

the adjusting bolt so that the corresponding travel switch is actuated and cut off the uprise power supply of the tower crane. Lift down the heavy object, let the tower crane to lift up 10Ton, and verify that the crane can operate normally. In case the hoisted load is greater than 10ton and less than 11ton, the load-lifting limiter is actuated and cut off the power supply, and this should be considered as acceptable. It is necessary to repeat the test thrice, and lock the locking nuts and bolts once the requirements are satisfied.

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Figure 12. Load-lifting limiter (proving ring)
1. Proving ring
2. Clamping plate
3. Pulley
B.
In case of 2 multiply factor, rated loading capacity at high speed (80m/min) of the tower crane should be
2.5Ton. Let the tower crane to lift up 2.625Ton at approximately 20M, adjust the adjusting bolt so that the
corresponding travel switch is actuated and cut off the power supply for uprise. Lift down the heavy object,
and let the tower crane to lift up 2.5Ton at high speed, and verify that the tower crane may operate normally.
In case the hoisted load is greater than 2.5ton and less than 2.75Ton, the load-lifting limiter is actuated and cut
off the power supply, and it should be considered as acceptable. It is necessary to repeat the test thrice, lock
the locking nuts and bolts, and close cover plate of proving ring once the requirements are satisfied.
6.3 Hoisting altitude, slewing angle, and derricking travel limitator
The structure, operating principle, and adjusting methods for the hoisting altitude/slewing/derricking limitator
adopted in the tower crane are identical. It is a type of multifunctional travel limitator equipped with worm
reducer, cam shaft and microswitch. The structure and adjusting methods are presented in the following:

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  • 6.3.1 Structure (please refer to Figure 13)

 
 
Foshan Nanhai Golden Construction Contents of Operating Instruction Manual Page 21 Machinery Co., Ltd. for Self-Raising
 
  • 6.3.2 Adjustment steps:

 
  • A. Disassemble the upper cover piece.

  • B. Unscrew the nut M5.

  • C. According to need, run the controlled mechanism to the designated position (nonload). At this moment, corresponding microswitch that controls the actuation of the mechanism should switch over instantly.

Namely: Adjust the corresponding adjusting spindle so that the memory cam may hold down the contact of microswitch.

  • D. Tighten the nut M5. (The nut must be tightened; otherwise aphraxia may take place).

 
  • E. It

is

necessary to allow the mechanism repeatedly for several times so as to verify whether the

memorized position is correct or not. (Repeat the above-mentioned adjustment in case it is incorrect).

  • F. Verify that the position is up to the mustard; Tighten nut M5; Fit on the cover piece.

 
  • G. When the mechanism operates normally, it is necessary to regularly check if the memory control position is changed and carry out in immediate adjustment if any.

6.3.3

Hoisting altitude limitator

 

Hoisting altitude limitator is mounted on the bearing cover of bearer of winding drum of the hoisting mechanism, and it ensure that the input shaft of limitator and winding drum rotate at identical speed in identical direction. The signal of wire rope length reeled on the winding drum is put into the limitator; when the set value is fulfilled, cam on the cam shaft hold down the contactor of microswitch and cut off the power supply for uprise of hoisting mechanism so as to stop the uprise.

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Adjusting methods:
A.
Raise the load hook kit to a position at which the top of the hook is 1.5M from the bottom of derricking
trolley.
B.
Unscrew the locking nut M5 that is fitted at the upper part of cam inside the hoisting-altitude limiting
device mounted on the side cover of bearer of winding drum of the hoisting mechanism.
C.
Adjust the cam that controls the raising of hook so that the cam ejects the microswitch exactly (namely it
remains in offstate), and tighten the locking nut M5.
D.
Let the hook descend for a distance, and then let the hook uprise at low speed till the hoisting mechanism
and then perform automatic stopping (Note: In case no stopping takes place when the distance from hook
to trolley is already less than 1M, it is necessary to turn off the power supply immediately for manual
stopping. After that, carry out once again the above steps).
E.
Observe the clearance between the hook and trolley, if it is within the range l.2~1.8M, this indicates that
the adjustment is fundamentally up to the mustard. (The adjustment is related to the position of derricking
trolley and weight of the hook)
F.
Repeat the steps for many times, if the clearance between hook and trolley is always within the range
1.2~1.8M, this indicates that the adjustment is up to the mustard. (In case the height of tower crane is
adequate or the application height of hoisting mechanism is high, the clearance between the hook kit and
trolley should be increased)
The stop position of hook in case of descend may be determined by the user himself, and the adjusting
methods are the same as above.
6.3.4 Sewing angle limitator (please refer to Figure 14)
Locking nut
Cam
Pinion
Locating pin
Shaft coupling
Figure 14. Structural diagram of slewing angle limitator
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(1) Functions: The limitator may control the number of left-hand/right-hand turns (angle) of the tower crane so as to avoid twisting or damage of cables.

(2) Principle:

Limitator is mounted on the upper coupling of tower crane, and its Input shaft is fitted with a pinion that engages with the girth gear (as shown in figure below). In case of tower crane slewing, the signal of its number of slewing turns (angle) is input into the limitator. When the tower crane slews for 1.5 turns leftwards or rightward, corresponding cam may hold down the moving contact of microswitch and cut off the control circuit in that way so as to stop the slewing motion and realize the limitation of slewing angle.

(3) Adjustment: Adjustment should be performed in nonload mode.

 
  • A. Allow the tower crane to left-handed rotation (or right-handed rotation), manually press down the moving contact of microswitch and achieve automatic stopping so as to determine which microswitch controls the actuaction.

  • B. Return the tower crane to its midposition (Namely the position at which cable is free of twisting), and this position is usually the position when the tower crane was just erected.

  • C. Allow the tower crane to rotate one and half turn leftward (540 degrees), adjust the corresponding cam so that it may hold down the moving contact of microswitch and separate its normally closed contact. Repeat the test for several times, ensure that automatic power off and slewing stopping may occur when the tower crane rotates to the said position. The adjustment of leftward-slewing limit is finished.

  • D. Let the tower crane to rotate rightward for 3 turns (in relation to one and half turn from its midposition), adjust and repeatedly test as per the above methods; when no incorrectness occurs, the adjustment of rightward-slewing limit is finished.

6.3.5 Derricking travel limitator (1) Functions:

It may avoid the accidents such as damage of mechanisms or tensile rupture of hauling rope due to too high impact in case the derricking trolley fails to stop immediately once it reaches the front/rear end of the jib boom due to improper operation or misplay.

(2) Principle:

Operating principle of the derricking limitator is basically consistent with that of the travel limiter of hoisting mechanism. for hoisting mechanism, the travel limiter limits the upper/lower final position of hook travel, while the derricking limitator limits the front/rear extreme position of trolley travel.

(3) Adjustment methods:

  • A. Open the upper cover of multifunctional travel limiter mount on the side cover of bearer of derricking winding drum.

  • B. Run the derricking trolley approximately l.5m to the front-end or rear-end rubber bumper of jib boom, and then stop it.

  • C. Adjust the position of corresponding cam so that it may hold down the microswitch till the normally closed contact is opened.

  • D. Run the derricking mechanism so as to increase the clearance from the derricking trolley to the rubber bumper, and then allow the derricking trolley move toward the rubber bumper till its automatic stopping. (in case it fails to stop when the clearance gets very short, it is necessary to stop it manually).

  • E. Observe that the clearance from the trolley and rubber bumper should be 0.5-1M.

 
  • F. Repeat the motion for several times and carry out fine tuning so that the derricking trolley may automatically power off, reduce speed and stops running when it moves close to the cushioning device at the front/rear end of the jib boom; the adjustment is then finished.

The adjusting methods for forward/rearward travel limit of derricking trolley are completely the same.

 

Readjustment should be carried out every time the top ping lift is strained, replaced, or the tower crane is re- erected.

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7. Preparations before erection of tower crane

 

7.1 Preparations and precautions:

Before erection of tower crane, please carefully read the operating instruction manual so as to erect the tower crane correctly with leaps and bounds.

Erection requires one set of wheeled crane truck (or other hoisting equipment) that should be provided with performances satisfying the requirement of parts hoisting. in addition, properly coordinate the procedures of erection and assembling, reasonably arrange the erectors for the tower crane, manage all right all sorts of relations related to the assembling site; in this way the service time of auxiliary crane truck may be minimized.

7.1.2

Fundamental rules for erection of tower crane:

 

(1) All drivers, erectors, and lifting workers should have passed the examination held by labor and personnel department and rewarded with certificate of compliance. Any person without relevant certificates is strictly prohibited to operate, erect, or maintain the tower crane.

(2) Persons must be specially assigned for the command in the overall process of erection of tower crane. It is strictly prohibited to operate without command; it is not allowed to disobey the command or operate without authorization. It is strictly prohibited to operate the crane after drinking.

(3) All personnel who participate in the operation have got to do the following:

 
  • A. Learn about the prescription related to the process of erection in the operating instruction manual for the tower crane. It is strictly prohibited to modify the erection sequence specified in the instruction manual.

  • B. Learn about the connecting type and connection dimensions of all parts of the tower crane.

  • C. Learn about the weight position of lifting points of all parts of the tower crane.

  • D. Learn about performance and operation specifications for the applied equipment and tools.

  • 7.1.3 general stipulations about erection of tower crane

 

(1) It is required to abide by the erection sequence of tower crane. (2) It is required to set up security protection facilities, such as: Stairway, guardrail etc. (3) It is strictly prohibited to lift up any load when the counterjib is not loaded with adequate counterweight.

(4) In case wind force exceed moderate breeze, it is strictly prohibited to carry out any erection service by the tower crane.

(5) In the process of erection, it is required to connect the lower coupling, standard section and bell socket frame by bolts, and the nuts should be tightened.

(6) It is required to configure correct counterweight weight according to relevant stipulations.

(7) Before section adding, direction of the jib boom and the opening direction bell socket frame must be consistent.

(8) The standard section to be raised (or descend) must be positioned close to the tower mast as much as possible (maximum radius within 10M).

(9) In the process of standard section jacking/erection, it is strictly prohibited to rotate the jib boom, run the trolley, or allow the hook to move up and down.

The above-mentioned prescriptions are also applicable to tower mast dismantling or section reducing.

  • 7.1.4 Precautions for erection

 

(1) Check if all connecting bolts are tightened.

(2) The bolts for all parts of the tower crane are different in specifications and made of various materials, and they must not be mixed.

(3) Before erection before of the counterjib or jib boom armtie,it is necessary to check if the joints are connected securely, and check if the armties are damaged.

(4) To lift up and erect the counterjib or jib boom, never fail to lock the hoisting rope and hook of the erecting crane by rope cramp or shackles so as to prevent wire rope from unhooking in case the included angle of wire rope is too large.

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Page 25 of 64
Page 25
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7.2.1 Figure 15. Arena dimensions required of tower crane convenience in erection and disassembly of the
7.2.1
Figure 15. Arena dimensions required of tower crane
convenience in erection and disassembly of the tower crane.
62000
Reference dimension of erection site for tower crane (please refer to Figure 15)
(5) Heave tight the top ping lift till the trolley does not slip in case it is heavily loaded.
7.2 Tower crane’s place of erection
equipment damage etc.
7.2.3
4000~8000
7.2.2
Buiding
1950
1950
6000
6000
16000

(6) It is necessary to carry out test run of slewing operation before the tower crane is fitted with counterjib and jib boom.

(7) Adjust the height limitator such that the hoisting operation should be stopped once the distance from the upper limit position of the hook kit to the trolley pulley (space dimensions) is greater than l,000mm.

(8) The devices such as the moment limiting device,weight limiting device, amplitude limiter, and electric limitator etc. should be mouted and debugged according to relevant stipulations.

(9) Body structure of the tower crane, the metal enclosures of motor bedplates, all electric apparatuses, and metal duct of conductors etc. should be earthed reliably.

(10) Orientation must not be changed for the erection of standard section; otherwise the direction of climbing footboard may be misplaced, and climbing may be impossible.

(11) Jib boom, which consists of 11 sections assembled together, must be assembled according to the marks or erection sequence listed in the signs issued by the manufacturer, and no interchange is allowed.

(12) Both the upper chord pins and lower chord pins for interconnection of jib boom are dedicated tailor-made spare parts, and they must not be substituted.

(13) Once the complete appliance erection is over, it is necessary to check the error of perpendicularity of tower mast, and the allowance is 4/1000.

Tower cranes place of erection should lay close to the building as much as possible so as to takes full

advantage of the effective radius of the jib boom; in addition, it is necessary to taken into account the

The longest rotating components, such as the jib boom and the hook etc. should be kept 5M away from

the high tension power line at least in order to prevent the accidents, such as injuries due to electric shock, or

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7.3 Foundations for the tower crane

 
  • 7.3.1 Soil quality of the groundwork foundation should be solid, secure and steady, with load-carrying

capacity greater than 20Ton/m 2.

  • 7.3.2 Concrete grade should be C20 or above; the anchor bolts, distribution bar and effective bar etc. should

be buried inside the foundation. the foundation should be constructed strictly according to the requirement

presented in Figure 16 and Figure 17.

 
  • 7.3.3 Total concrete amount of the concrete foundation is approximately 50m 3 , and the weight of foundation

should not be less than 120Ton.

 
  • 7.3.4 Foundation surface should be leveled, and the planeness discrepancy should be less than 1/500.

  • 7.3.5 The joint between the foundation and the steel plates at the four corners of the preembedded die holder

must be level, which should be measured by level gage; The height difference value should be less than 1/500.

Since soil quality in Guangdong Province and other coastal areas are mostly sedimentary soil of great thickness, the concrete foundation for tower crane should not be erected on the ground directly, and it is required to take corresponding technical measures according to the physical circumstances of the construction site.

Hence, the foundation for tower crane in such areas should be constructed as per procedures similar to that for groundwork of buildings. Common practice is to make a pile foundation, namely firstly complete a pile foundation by means of pile driving, pile jacking, or pile reaming. Excavate a pit for foundation of the tower crane in the field surface, and place a underlayment of vibracast concrete into the former trench after the pile heads are split (reinforcing-bar reserved). According to the requirements of foundation drawing for the tower crane, fabricate and assemble the reinforcement properly, erect the form boards, preembed the anchor bolts by means of die holders according to the procedures presented in 7.4, and vibrate the concrete till the requirements for tower crane foundation are satisfied.

Diameter of the prefabricated pipe applied in the pile driving (jacking) should not be less thanφ400mm. Diameter of the manual excavated pile should not be less than φ800mm. Specific positions of the piles are presented in Figure 16. For the drawing of reinforced concrete foundation for tower crane, please refer to Figure 17.

7.4 Anchor bolt preembedding

 
  • 7.4.1 To preembed the anchor bolts, it is required to utilize the undercarriage or the preembedding die holder

provided by the manufacturer along with the equipment

 
  • 7.4.2 The preembedding die holder should be positioned with its surface welded with angle steel facing

upward; in addition, the end of steel plate, which is welded with the character Rearshould be positioned on

the side of counterjib in when jacking operation.

 
  • 7.4.3 Separately hang 32 pieces of anchor bolt on the holes in the sheet steel at four corners of the die holder,

fit one piece of (or two pieces of) nut onto the anchor bolt each such that the length at the bottom surface and

bolt head should be 100mm.

 
  • 7.4.4 Erect the die holder such that the bottom surface of steel plate of the die holder is 20~30MM higher

above the top surface of concrete foundation to be placed.

 
  • 7.4.5 Use a level gage to level the four pieces of steel plate of the form boards till the relative error is 1/500.

  • 7.4.6 Uprear the upper part of anchor bolt to vertical mode. Inset a piece of reinforcing bar Φ25 with length

not less than 400 into the looped link at lower end of the bolt, and then take advantage of it and weld the lower

part of bolt onto the assembled reinforcing bar. Wrap the bolt heads with plastic cloth etc. for fear of foreign materials such as cement etc.

  • 7.4.7 Check the die holders positioning orientation, levelness inaccuracy, bolt verticality and fastening, and

vibrate the concrete according to the requirements for tower crane foundation listed in 7.3 if no problem is

found out.

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1800
6000
5000
4- pipe-pile ≥φ400 or
≥φ800 manual excavated pile
Figure 16. Concrete pile foundation for tower crane
5000
6000
1600
120

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Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
 
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
 
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
   
Figure 17. Foundation drawing of the tower crane
 
Figure 17. Foundation drawing of the tower crane
Figure 17. Foundation drawing of the tower crane
 
Figure 17. Foundation drawing of the tower crane
   
Figure 17. Foundation drawing of the tower crane
 
Figure 17. Foundation drawing of the tower crane

Figure 17. Foundation drawing of the tower crane

Figure 17. Foundation drawing of the tower crane
Page 28 of 64 Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125 Foshan
 
Page 28 of 64 Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125 Foshan
Page 28 of 64 Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125 Foshan
Page 28 of 64 Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125 Foshan
Page 28 of 64 Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125 Foshan

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Page 29
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8. Erection tower crane
For the erection sequence of tower crane, please refer to Figure 18.
Figure 18. Drawing of erection sequence of tower crane
1.
8.
Erect the counterjib armtie
2.
9.
3.
10.
4.
11.
5.
Erect the foundation feet
Erect three fortified standard sections
Erect the bell socket frame
Erect the upper/lower coupling and driver's cab
Erect the transition section
Erect the tower cap
Erect the counterjib
12.
6.
13.
7.
14.
Erect two pieces of counterweight
Erect the jib boom
Erect the long armtie of jib boom
Erect the short armtie of jib boom
Erect the other 5 pieces of counterweight
Reel the hoisting wire rope and top ping lift.

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Contents of Operating Instruction Manual
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Foshan Nanhai Golden Construction
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8.1 Erection of foundation feet (please refer to Figure 19a、 Figure 19b)
Use the hoisting equipment one by one to lift four foundation feet of tower mast up above the undercarriage
and align the direction (the corner without bushing towards four corners of foundation), lift down the
foundation feet gradually such that the anchor bolt holes in the large square flange at the four corners of the
foundation feet may be aligned to the anchor bolt; let the foundation feet drop till hooking off and removal of
lifting rope, fit on the double nuts for the 32 pieces of anchor bolts separately.
1800
Figure 19a. Erection of foundation feet
Figure 19b. Erection of foundation feet
1800

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8.2 Erection of the standard section (please refer to Figure 20)
8.2.1
Erect one piece of fortified standard section (without broadstep ) of the tower mast upon the erected
foundation feet of tower mast; align the direction properly (namely the direction of foot boar should be
reverse with the direction of add and push standard section); align the positioning concave at lower end of the
principal chord of standard section to the positioning lug boss at upper end of the principal chord of
foundation feet, let it drop for slight unloading, pass through the high strength bolts M39×3×360 and tighten
the double nuts. Hook off and remove the lifting tool.
8.2.2
Erect two fortified standard section of tower mast upon the erected standard section of tower mast in the
same way, and the direction of foot boar should be consistent. Pass through the high strength bolt M39×3×
360, and tighten the double nuts. Hook off and remove the lifting tool.
Notice:these three fortified standard section must be install upon the foundation feet of tower crane downmost.
1950
A
B
Figure 20. Erection of the fortified standard section
A. Erect one fortified standard section B. Erect the second and third fortified standard section
2800

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8.3 Erection of the bell socket frame (please refer to Figure 21)

 
 
Page 32 Contents of Operating Instruction Manual Foshan Nanhai Golden Construction of 64 for Self-Raising Tower

Figure 21. Erection of the bell socket frame

  • 8.3.1 Preparations for erection of the bell socket frame

 

(1) Use the hoisting equipment Lift up piece of the bell socket frame and assembled into whole (2) Lift up the bell socket frame and let it stand vertically (the end fitted with flange should face upward).

(3) Mount the twostoried operating platform onto the bell socket frame separately. Tighten the connecting bolts. (4) Properly erect the platform handrail, pass through the cotter pin (it is necessary to draw apart and bend the split end of the cotter pin).

(5) Pass the made-to-order axis pins through the top of the jacking oil cylinder and the jacking transverse member of bell socket frame, and fit on the cotter pins.

(6) Lift up the hydraulic power unit onto the end fitted with oil cylinder on the lower-layer operating platform of the bell socket frame, and fasten it properly.

  • 8.3.2 Erection of the bell socket frame

 

(1) Lift up the bell socket frame above the erected standard section of tower mast, and ensure that the end fitted with oil cylinder should be consistent with that of the footboard.

(2) Align the bell socket frame to the standard section and let it drop slowly so that the bell socket frame may fit over the standard section.

(3) Once the altitudes of top of bell socket frame and the top of the standard section are almost the same, and insert the lower parts of two pieces of bracing into the footboard notch of standard section so as to support the bell socket frame.

(4) Properly connect the two pieces of high-pressure hose between the hydraulic power unit and jacking oil cylinder.

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8.4 Erection of the upper/ lower coupling and driver’s cab (please refer to Figure 22)
Figure 22. Erection of the upper/lower coupling and driver's cab
When the tower crane leaves the factory, or in case of construction site excavation of tower crane, the
components such as the slewing bearing, upper/lower coupling, and slewing mechanism etc. are assembled
into one piece as a general rule.
8.4.1
Erect the driver’s cab onto the upper coupling, and tighten the connecting bolts.
8.4.2
Lift up the components, which have been assembled into one piece, such as the lower coupling, slewing
bearing, slewing mechanism, upper coupling, platform, and handrail etc. over the bell socket frame.
8.4.3
Align part of the attachment holes in the top of bell socket frame and in the flange at lower part of the
lower coupling, and pass the high strength hexagonal head tap bolts M30X115 into the holes.
8.4.4
Once 8 pieces of connecting bolts have been fitted at least, power on and actuate the slewing motor, and
allow it rotate, (or use a ripping bar) to align with the other holes, and pass the bolts into the holes one by one.
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  • 8.4.5 Once all bolts between the bell socket frame and flange of the lower coupling have been properly passed

through and their double nuts have been tightened, start up the jacking mechanism so that the bell socket frame and the part above the bell socket frame may be jacked till the bracing on the footboard may be removed.

  • 8.4.6 Actuate the jacking mechanism, slowly retract the oil cylinder piston; once the bell socket frame is just

to touch the standard section, pass through the connecting bolts for standard section; continue to retract the oil cylinder piston so that the internal positioning orifice in the short square steel pipe at lower end of the lower

coupling may be completely fitted over the positioning heads of the standard section, and then tighten the double nuts of standard section.

8.5 Erection of transition section (please refer to Figure 23)

 

Lift up the transition section onto the upper coupling, align the orientation, pass through the high strength bolt, and then tighten the double nuts.

 
Page 34 Contents of Operating Instruction Manual Foshan Nanhai Golden Construction of 64 for Self-Raising Tower

Figure 23. Erection of transition section

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8.6 Erection of tower cap (please refer to Figure 24)
Figure 24. Erection of tower cap
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Lift up the tower cap onto the transition section, align the direction (the upright end of
Lift up the tower cap onto the transition section, align the direction (the upright end of main limb of the
Assembling of the counterjib armtie
Properly erect the rope guide pulley gear.
Properly erect the counterjib platform handrail, and secure them by handrail clamp.
pins through, put on and open the cotter pin as required.
Lift up the hoisting mechanism onto the pedestal lug of counterjib hoisting mechanism, pass the axis
8.7 Erection of the counterjib
transition section, connect the tower cap and transition section by high-strength hexagonal head tap bolt M33
×125, and then tighten the double nuts.
tower cap should be the erecting direction of the jib boom), align the holes in the tower cap and the flange of
(1) According to the items listed in the part list of counterjib tie rod and the contents presented in Figure 25,
connect the 4 pieces of armtie (divided into two kits) with hole center pitch of 3925 to the lifting point lug
of counterjib by made-to-measure tie rod pin with φ50 hole center pitch of 80 and clamping plate with
hole center pitch of 210, and let its front end lay on the wooden beam that has been place on the handrail.
(Please refer to Figure 26)
armtie, long clamping plate, counterjib transition armtie (please refer to Figure 25), counterjib armtie (hole
center pitch of 6650mm), and weight limiting device etc.
Properly assemble the components of tower cap, including the platform, access ladder, jib boom, short
8.7.4
8.7.5
8.7.6
8.7.7
8.7.8
Let the counterjib to drop to its level position slowly, carefully check the connection of counterjib armtie,
Tie-rod axis pin
Head axis pin
Clamping plate
Transition armtie
Part list for counterjib tie rod kit
counterweight block onto the counterjib by special-purpose steel pins (please refer to Figure 29).
One by one to lift up two piece of counterweight block, erect it onto the rear of counterjib, and lay the
hook off adn remove the hoisting wire ropes if no problem is found out.
8.7.9
the two counterjib armtie kits separately (please refer to Figure 28).
Continue lifting up the counterjib, allow the rear of the counterjib to upwarp to a certain angle, connect
of lug at the jib root should be kept in one horizontal plane so as to ensure smooth erection), and properly
artculate the jib root (please refer to Figure 27).
Lift up the counterjib that has been fitted with hoisting mechanism and handrail (Note: The two pieces
two ends are connected to the hoisting ears nearby the front/rear of the hoisting mechanism by shackles, and
shackle the two pieces of wire rope sling (4 pieces) together at a point nearby the hook of crane truck. In
addition, one piece of slip rope should be tied to both the front and rear end of the counterjib so as to ensure
its stability or orientation adjustment in the process of hoisting operation.
Hang the medium section of a pair of wire rope sling≥φ20 onto the hook of the crane truck, and its
(2) Pass the cotter pinsφ10×110 through the both ends of the armtie pin, and open them as required.
2
40
34
Material
Quantity
16Mn
16Mn
1
16Mn
16
δ 16 With hole center pitch of 210
φ55 cotter pin With hole center pitch of 172
φ10×110
φ50 cotter pin With hole center pitch of 80
Specifications
δ16 weld assembly With hole center pitch of 6650
δ16 weld assembly With hole center pitch of 3925
Armtie B
8.6.1
8.6.2
8.7.1
8.7.2
8.7.3
Cotter pin
Name
Armtie A
δ16 weld assembly With hole center pitch of 900
4
16Mn
8
Cr thermal refining
1
40
Cr thermal refining

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Figure 25. Assembly drawing for counterjib armtie

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Contents of Operating Instruction Manual
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Foshan Nanhai Golden Construction
Machinery Co., Ltd.
GOLDEN
GOLDEN
Figure 26. Assembling of counterjib armtie
Figure 27. Hoisting of counterjib

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Machinery Co., Ltd.
Contents of Operating Instruction Manual
for Self-Raising Tower Crane QTZ 125
Page 39
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GOLDEN
GOLDEN
Figure 28. Raise the hook, and connect the armtie
once the rear of counterjib upwarps.
Figure 29. Hook unloading, allow the counterjib move to its level position, and
erect two pieces of counterweight nearby the rear of the counterjib.

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Foshan Nanhai Golden Construction Machinery Co., Ltd.

 

On the ground, assemble the segments of the jib boom into a complete jib boom by upper chord pins and lower chord pins according to the marks on the segments of the jib boom.

 

Support should be adopted for jib boom assembling, and the height of support should ensure that the trolley may be successfully erected.

Before the whole jib boom is properly assembled, it is necessary to hang the rollers of the derricking trolley onto the lower chord of the jib boom in advance, and erect the repair platform onto the derricking trolley securely. (Repair platform should be erected on the right side of the jib boom, namely the side that is fitted with drivers cab)

 

Name

         
 

Transition armtie

   

16Mn

 

Armtie A

     

16Mn

 

Armtie B

     

16Mn

 

Armtie C

     

16Mn

 

Armtie D

     

16Mn

 

Short Armtie

     

16Mn

 

Clamping plate

     

16Mn

 

Head armtie

     

16Mn

 
       

16Mn

 
 

Lifting-point axis

   

refining

 

Head axis pin

     

refining

 
 

Tie-rod axis pin

   

refining

 

Cotter pin

         
     

8.8 Erection of the jib boom

8.8.1 Assembling of jib boom

When the jib length is 60 M or 55 M, Quantity of parts for the tie rod kit is the same as that listed in the above table. In case the jib length us 50M, the armtie of 4730 in length is not adopted, and 2 pieces of axis pin Φ 50 ×98, 1 piece of Clamping plate With hole center pitch of 210 and 4 pieces of cotter pin Φ10×110 should be reduced.

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(4) Mount the derricking mechanism onto the mounting position at the front end of the tenth jib segment.

(5) Mount 2 pieces of transition armtie (with hole center pitch of 1250) onto jib segment 3 (46.3 M to the linkage point at root; or 41.3M in case the jib length is 50 M) and jib segment 9 (16.1M to the linkage point at root; or 13.3M in case the jib length is 50 M) by lifting-point axis pin Φ 50 (cotter pin, with hole center pitch of 164mm) separately. (Please refer to Figure 30)

(6) With reference to the assembly drawing for jib-boom tie rod (Figure 30) and part list of jib boom tie rod, properly assemble the two jib boom armtie kits, place the armtie inside the bracket of top boom of the jib boom, and tighten them properly.

Note: All top-boom axis pins, lower-chord axis pin, lifting-point axis pins, and tie rod pins at the joint between two segments must be fitted with cotter pin according to relevant stipulations.

8.8.2 Hoisting of jib boom

(1) Hang one end of the two pairs of wire rope sling ≥Φ24 of 10M and 12M in length respectively onto the hook of crane truck, and lock their beckets together by cordage shackles. And then divide 4 pieces of lifting rope into two kits, and each kit consists of one piece of long rope and one piece of short rope. From the nodal point of jib-boom top boom as shown in Figure 31, pass the longer piece through the top boom, and then connect it to the shorter piece by cordage shackles with bolt pin M24. In addition, tie slip ropes to the both ends of jib boom, and the slip rope should be long enough (please refer to Figure 31)

(2) Lift up the jib boom to a certain height, appropriately move the derricking trolley so that the both ends of the jib boom is approximately level (jib tip may be approximately 1M higher than the jib root), and then secure the derricking trolley. Furthermore, check if the tying is firm and reliable, and check if the crane truck is faulty.

(3) Lift up the jib boom. in the process of hoisting operation, it is necessary to adjust the midair position and orientation of the jib boom by crane truck and slip rope so as to avoid obstacle and ensure convenience in erection. Once the height of jib boom reaches the mounting height, it is necessary to adjust once again the midair position and orientation of jib boom; furthermore it is necessary to actuate the slewing mechanism of tower crane so as to align the connecting ears of the transition section to the ears at root of the jib boom, actuate the jib boom and ears of transition section by jib-root pins (cotter pinΦ60, with hole center pitch of 144 mm), and insert the cotter pins properly. (Please refer to Figure 32)

(4) Continue uplifting the jib boom, let the jib boom upwarp to a certain angle, and then stop running. After that, fasten the hoisting rope of hoisting mechanism (the pigtails have been formed into cable loop by wire rope clamp already) to the erection ears on the armtie by shackles; draw the two sets of jib boom armties one by one (the longer set firstly) to the top of the tower cap; use armtie pins to connect the armties and the head armties that have been mounted on the top of the tower cap, and then insert the cotter pins. (Please refer to Figure 33)

(5) Check the connectoin of each several parts; if all connections are reliable, let the jib boom slowly drop to its level position till a little hooking off. Check once again if all axis pins and cotter pins at the connection points of jib boom armtie are properly treated as required, and check if the stressing of two armtie kits is up to the mustard. (Please refer to Figure 34)

(6) If no problem is found out, hook off and remove the wire ropes for hoisting operation.

 

8.9 Erection of the rest of counterweight blocks (please refer to Figure 34)

Lift up the rest of counterweight block and erect them onto the rear of counterjib, and lay the counterweight block onto the principal chord of counterjib by special-purpose steel pins.

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Contents of Operating Instruction Manual
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Foshan Nanhai Golden Construction
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Figure 30. Assembly drawing for jib boom and jib boom armtie
a.
b.
c.
d.
Assembly drawing for jib boom of 60m in length (7 pieces of counterweight should be adopted, totaling 17.5Ton)
Assembly drawing for jib boom of 55m in length (6 pieces of counterweight should be adopted, totaling15Ton)
Assembly drawing for jib boom of 50m in length (5 pieces of counterweight should be adopted, totaling 12.5Ton)
Assembly drawing for Jib boom armtie (when jib length is 60M)

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Contents of Operating Instruction Manual
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Figure 31. Jib boom assembling and lifting rope binding
(when the jib length is 60 M)
Figure 32. Lift up the jib boom for erection

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Figure 33. Erection of the jib boom armtie kit
Figure 34. Erection of the rest of counterweight blocks, and
reeling of hoisting wire ropes and top ping lift

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9. Late-stage tasks related to erection of tower crane

 

Check if all operations in the process of erection of tower crane may satisfy the requirements of GB 5144 standard and the operating instruction manual, and carry out rectification and reform carefully.

9.1

Connection of electric wiring

  • 9.1.1 Connect the power supply for tower crane and the control circuit according to the relevant electric schematic diagram attached in this instruction manual.

  • 9.1.2 Use a megameter to check if the insulation of electric apparatus and electric wiring is 0. 5M.

 
  • 9.1.3 If no problem is found out in the process of careful checks, it is allowed to carry out test run in nonload mode.

  • 9.1.4 Carefully adjust the height limiting device, derricking limiting device and slewing limiting device, and ensure these items should be sensitive and reliable.

  • 9.1.5 Weight limiting device and moment limiting device should be adjusted when loaded operation is to be carried out once all erection works of the tower crane are completed.

9.2

Reeling of hoisting rope (please refer to Figure 35)

 
  • 9.2.1 Properly reel the hoist rope according to the contents presented in the figure.

  • 9.2.2 Fasten one end of the pigtail to the winding drum if hoisting mechanism securely as required, and fasten the other end onto the linkage-head rope pulley at the front end of jib boom, which is connected to the antitwist device. The number of wire line clips must not be less than 4, and they must be mounted according to requirements.

  • 9.3.3 Properly adjust the hoisting altitude limitator according to the requirements for debugging of safety device listed in the instruction manual.

 
Foshan Nanhai Golden Construction Contents of Operating Instruction Manual Page 45 Machinery Co., Ltd. for Self-Raising

Figure 35. Schematic diagram for reeling of hoisting ropes

 

1. Rope guide pulley 2.Winding drum of hoisting mechanism 3. Pulley of weight limiting device 4.Guide pulley of transition section 5. Pulley of hook kit 6. Pulley of derricking trolley 7. Steel cable clamp 8. Wire-rope antitwist device

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9.3

Reeling of top ping lift (please refer to Figure 36)

 
Page 46 Contents of Operating Instruction Manual Foshan Nanhai Golden Construction of 64 for Self-Raising Tower
 

Figure 36. Schematic diagram for reeling of top ping lift

 

1. Winding drum of derricking mechanism 2. Derricking pulley 3. Top ping lift 4.derricking trolley

  • 9.3.1 Return the derricking trolley back to the jib root, and fix it.

 
  • 9.3.2 Securely fix one end of the top ping lift onto the left-hand baffler of derricking winding drum, run the derricking mechanism backward, reel the wire rope into the rope grooves properly, and stop it till only 5 turns are left behind.

  • 9.3.3 Pass the other end of the Wire rope through the two derricking pulleys at the jib root, draw it to the derricking trolley, slightly tighten the wire rope and keep a certain allowance, cut off the surplus, and fix the pigtail onto the ratchet stopper.

  • 9.3.4 Reel one end of the surplus Wire rope onto the right end of the winding drum for 3-4 turns, and then fix it onto the right-hand baffler. After that, pass the other end of the wire rope forward and through the jib- boom top boom and derricking pulley at jib end; reversely draw the Wire rope along the downside of the jib boom to the derricking trolley, tighten the wire rope and cut off the surplus, and then fix it onto the lug in front of the derricking trolley by wire rope clips (3 Pcs.).

  • 9.3.5 Release the derricking trolley, and use the ratchet stopper to tighten the top ping lift.

  • 9.3.6 Properly adjust the fore-and-aft travel limitator according to the requirements for safety device debugging listed in the instruction manual.

9.4

Test run before jacking section adding

 
  • 9.4.1 Check if all contents related to the erection of tower crane are finished and correct.

  • 9.4.2 Carry out the test run of hoisting, slewing, and derricking motion etc.

 
  • 9.4.3 Check the hydraulic jacking system

(1) Check if the oil level inside the oil tank is up to the mustard (Observe the oil gage).

(2) In case the hydraulic jacking system is not operated for a long time (over 6 months), it is required to check if the liquid oil is deterorated (of dark color, or milkiness) or contaminated; otherwise oil must be changed.

(3) Check if the trademark of hydraulic oil is correct; as a general rule, it is allowed to select machine oil #20; in case of low air temperature, it is allowed to adopt machine oil #10.

(4) Check if the rotation of direction motor is correct (it should be consistent with the specified rotation direction of the hydraulic pump).

(5) Set pressure for safety valve is 25 MPa, which must not be modified without authorization (it is strictly prohibited to turn the pressure-regulating screw when operation).

9.5

Properly adjust the moment limiting device and load-lifting limiter according to the requirements

for safety device debugging listed in the instruction manual.

 

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9.6 Items to be checked once erection is completed (please refer to the table below)

 

Items to be checked once tower crane is erected

         
 

Check the tightening of anchor bolts.

   
   

Check the bolt tightening of standard sections, and check if the connections of

 

access ladder or broadstep etc. are reliable. Check if the perpendicular alignment of tower crane is up to the mustard.

   

Check if the connections of alleyway and handrail are reliable Check the connection between the bell socket frame and lower coupling. Check the connection between the bell socket frame and standard section. Check if the erection and debugging of hydraulic system are normal and reliable.

 
 

driver's cab.

Check if there is any oil material, spun cotton or other inflammable goods in the

 

Check if the connection between the driver's cab and the upper coupling is stable and reliable

 

Check the tightening of connecting bolts between slewing bearing, upper coupling, and the lower coupling.

   
 

check the wire rope reeling, and check the connection between the tower cap and transition section.

Check the connection between the tower crane, counterjib and jib-boom tie rod,

 
 

Check the debugging of brake of Hoisting mechanism. Check the erection of counterjib

Check the erection and tightening of counterjib upper flatform and handrail etc. Check if there are foreign materials in the alleyway, and check if it is smooth. Check the erection and debugging of the hoisting mechanism and rope guide pulley.

 
   

Check if the mounting of connecting axis pins and cotter pins in every quarter are

 

correct and reliable Check the erection and operating condition of derricking trolley.

Check the reeling and end fastening condition of hoisting wire rope and top ping

lift.

Check if the specs. and typpes of hoisting wire rope and top ping lift are up to the mustard. Check the worn condition wire ropes.

 

Check the lubrication, and apply lubricants according to the requirements specified in the operating instruction manual.

   
     

Before the tower crane is put into service, it is necessary to carry out overall inspection of the mechanisms and the safety devices in order to avoid breach of the normal working procedures and safety accidents so that the normal use and safe operation of tower crane may be ensured.

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10. Jacking of tower crane

 

10.1

Preparations before jacking operation

  • 10.1.1 Before jacking operation, use the hook of hoisting mechanism to lift up all standard sections for tower mast raising onto a spot that allows a shorter radius for the jib boom in the process of jacking operation (less than 10M), move the load hook to a radius of approximately 20M; At this point, the gravity center of jacking section above the tower crane passes through the linkage point of hydraulic cylinder so as to keep the balance and ensure less friction of roller in the process of jacking operation.

  • 10.1.2 Before jacking operation, it is necessary to allow the hydraulic system to test run in nonload mode, and then operate the hand-operated direction valve. Let the hydraulic cylinder to stretch out and draw back for several occasion in nonload mode so as to air out the system; check if interference phenomenon takes place between the moving parts; readjust the roller clearance; when these operations are normal, just carry out the jacking operation.

10.2

Jacking operation of tower crane (please refer to Figure 37)

 
  • 10.2.1 Firstly use the load hook to lift up one piece of standard section, stop it once the height of underside of standard section is approximately equal to the height of the inletting beam of lower coupling; move the derricking trolley to the trolley hook, and hang the middle part of the upper horizontal diagonal web member of the standard section onto the hook.

  • 10.2.2 Lift up another standard section, and move the derricking trolley to a radius of approximately 10M (radius is different for different jib length. ) (Please refer to Figure 38)

  • 10.2.3 At the beginning of jacking operation, firstly put the stub axle at two ends of jacking transverse member into the notch in the support footboard of the last-but-one standard section; remove all high-strength connecting bolt pairs of the lower coupling and standard section, and jack up the bell socket frame slightly; Observe whether the lower coupling may be precisely aligned to the bushing of standard section. Meanwhile repeatedly adjust the roller clearance to optimum mode. in case it is inaccurate, it is necessary to adjust the position of derricking trolley appropriately.

  • 10.2.4 Jack up the bell socket frame for l.3M or more. Once the lower end of bracings suspended on both ends of the transverse member of oil cylinder on bell socket frame is aligned with the notch in the turret on the standard section, retract the hydraulic cylinder piston rod, and lay all jacking load onto the bracings.

  • 10.2.5 Retract the hydraulic cylinder piston rod so that the stub axles of the jacking transverse member are located at the footboard under the uppermost standard section, and put the stub axles at both ends of the jacking transverse member into the notch in the footboard. Continue jacking the bell socket frame for approximately 1.3m or more. Once the lower end of standard section hung on the hook of inletting trolley is a little higher than the top of the erected standard section, manually push (pull) in the standard section to be added to the place above the mounted standard section inside the bell socket frame. Slowly retract the hydraulic cylinder piston rod so that the standard section to be added may be aligned with the mounted standard section, and allow it to contact the mounted standard section. Connect the standard section to be added on to the erected standard section by high strength bolt pairs M39×3×360, and tighten the double nuts. Continue to drop the bell socket frame a little, and take out the hook of inletting trolley from the level diagonal web member of standard section. (Please refer to Figure 39)

Note: In the process of standard section inletting, before the retraction of oil cylinder piston rod, it is required to place the bracings suspended on both ends of the oil cylinder transverse member into the footboard notch.

  • 10.2.6 Retract the piston rod, ready for the next cycle of jacking operation. Repeat the above several steps, and jack up the tower crane to the intended altitude. It is required to tighten all connecting bolts once the erection of each standard section is finished.

  • 10.2.7 Once the preset altitude is reached and jacking operation becomes unnecessary, it is necessary to slowly retract the piston rod so that the bell socket frame may drop; align the lower coupling with the mounted standard section, connect them by high-strength bolt pair M39X3X360, and then tighten the double nuts.

10.3

Precautions for the process of jacking operation

 

In the process of hydraulic jacking operation or tower mast disassembly, it is required to strictly abide by safety operation specification and pay special attention to the following items:

10.3.1

It is required to keep the balance of weight of the jacking section of the tower crane (Namely the gravity center of the jacking section should be kept at the linkage point between the oil cylinder transverse member and hydraulic cylinder).

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10.3.4 10.3.2 10.3.6 10.3.8 10.3.7 10.3.5 10.3.3 A. D. C. B. E.
10.3.4
10.3.2
10.3.6
10.3.8
10.3.7
10.3.5
10.3.3
A.
D.
C.
B.
E.

Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125

Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125
Page 49 of 64
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Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into
   
Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into
Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into
Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into
Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into
   
Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into
Figure 37. Diagram of jacking operation sequence Put the stub axle of jacking transverse member into

Figure 37. Diagram of jacking operation sequence

Put the stub axle of jacking transverse member into the footboard notch, remove the connecting bolts between standard section and lower coupling, and carry out the first jacking length of travel;

Jack up for 1.3M or more, put the lower end of bracings into the footboard notches, lay the weight of upper part onto the footboard, and allow the oil cylinder piston rod to retract;

Put the stub axle of jacking transverse member into corresponding footboard notches, and carry out the second jacking length of travel.

Jack up for 1.3 M or more, thrust in the standard section, let the piston rod to retract slightly, connect the bolts of standard section, and take out the hook of inletting trolley, on which the standard section is hung.

According to the procedures listed in b, c, and d, continue jacking up the rest of standard sections to the required altitude.

In case of seizure or abnormal occurrence in the process of jacking operation or disassembly, it is required to stop the machine for examination, and jacking operation or disassembly must not be continued before the fault is removed.

Before jacking operation a second time, stub axle at two ends of the jacking transverse member must be reliably put into the footboard notch of standard section before jacking operation so as to prevent the tower crane from overturning.

To disassemble or mount the hydraulic device, it is required to keep all elements and the overall system free from pollution, and the high/low voltage tubes must not be connected incorrectly.

Once the jacking operation or disassembly is over, it is necessary to retract the hydraulic cylinder piston rod, and put the stub axle at both ends of the jacking transverse member into the footboard notches so that the hydraulic cylinder and jacking transverse member are not under stress.

In the process of jacking operation, before the connecting bolts between lower coupling and the newly added standard section, and the connecting bolts between the newly added standard section and the tower mast are not tightened, it is strictly prohibited to carry out slewing or other operation motions; in case of moderate breeze or higher, it is required to stop the jacking operation and connect all connecting bolts properly.

Each time the tower crane reaches the intended altitude after being raised by means of jacking operation, it is required to tighten the connecting bolts between the lower coupling and the standard section.

Once the operational altitude of tower crane exceed the cardinal altitude50M, it is necessary to attached the tower mast to the building according to the requirements in the figure.

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GOLDEN
Figure 38. Lift up the standard section
GOLDEN
Figure 39. Lead in the standard section once 2
jacking length of travel is over

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11. Operation of tower crane

The tower crane should be operated via the console inside the driver's cab erected on the upper coupling. The driver's cabin allows a wide field of vision; it ensures that the hoisting operation remains within sight of the operator; the operating mechanism is flexible, reliable, and equipped with the safety protection devices torque, weight, altitude, derricking, slewing limitation etc. so as to ensure safe operation.

The operator should precisely estimate the suspended load and estimate the scale of operating radius according to the radius sign.

Once the erection of tower crane is over, it is required to carefully carry out safety inspection and necessary debugging tasks before the tower crane is put into service. Tower crane should be equipped with perfect and reliable earthing device.

11.1 Safety regulations for operation of tower crane

 
  • 11.1.1 Operators of tower crane must be trained strictly; get acquainted with the structure, performance, range of application, operation, servicing, and service regulations, and the operators must strictly perform the operation specifications of the tower crane.

  • 11.1.2 It is strictly prohibited to carry out overload operation; the driver must operate according to the prescription listed in the table of technical performance of the tower crane.

  • 11.1.3 Do not pull the hook of tower crane beyond the maximum radius so as to lift up heavy objects; do not pull the hook of tower crane aslant so as to lift up heavy objects even if within the maximum radius.

  • 11.1.4 For the mechanisms that allow both corotation reversal, it is required to stop the motor and wait till the inertia force disappears, then turn on the reversing switch for turning in reverse direction; it is strictly prohibited to reverse abruptly.

  • 11.1.5 Strictly abide by the operating sequence. For the mechanisms that allows high gear and low gear, it is required to start up operate from low gear to high gear and stop from high gear to low gear successively; it is strictly prohibited to carry out operation by means of shift skip, and the dwell time at each shift should be greater than 2-4 seconds.

  • 11.1.6 Before the driver carries out formal operation, the reliability of all safety devices should be checked, and it is not allowed to continut operation in case the safety devices are unreliable or out-of-order.

  • 11.1.7 All safety protection devices on the tower crane must be regularly checked and serviced, and they must not be moved, adjusted or disassembled without approval.

  • 11.1.8 Driver should check the current and voltage of the tower crane. In case the current or voltage is not adequate, it is strictly prohibited to carry out operation.

  • 11.1.9 Regularly check the tower crane for the items such as perpendicular alignment of tower mast, nolt looseness, operation normality, state of the winding-drum rope guide, holding-down condition of the

wire rope heads, and the oil starvation of all oil sites etc.

Any problem must be properly handled

before operation.

  • 11.1.10 Full-time personnel should be assigned to contact the driver, and command the hoisting operation.

  • 11.1.11 In case of nightwork, the field must be provided with adequate lighting devices.

 
  • 11.1.12 In case there are several sets of tower crane at the construction site, it is necessary to take measures against collission in the air.

  • 11.1.13 Tower crane should be erected far away from the high tension power lines; in case the jib or hook interfere with the power line or lighting cable, it is necessary to adopt safety precaution before operation.

  • 11.1.14 Before the driver gets off work, he must have the hook raised over the height of the neighboring buildings or let the hook avoid the radius, and cut off the general supply on the ground.

  • 11.1.15 In case it is informed by weather forecast that hurricane or higher may take place; the tower mast should be anchored by stormproof cable securely.

  • 11.1.16 In case of thunder, rainstorm, thick fog, or fresh breeze or higher, operation should be stopped.

 

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  • 11.1.17 To repair or service the tower crane because of any temporary fault, it is required to cut off the general supply on the ground, and hot-line repair is not allowed.

  • 11.1.18 After top overhaul or re-erection at a new site, it is required to strictly check the reliability of all connecting pieces, interference in the driving sections, damage of metal structure, reliability of the electric apparatus and safety protection devices before formal service.

  • 11.1.19 Once relevant task is finished and the tower crane is shut down

 
  • A. It is necessary to cut off the general supply in the distribution box and lock up it, and turn off the switch in the distribution box on the ground.

  • B. When the tower crane is in its shutdown conditions, it may turn freely with the wind. Therefore, to shut down the crane, ensure that there should be no obstructs within the range of the jib boom, which might come into collision with the jib boom or hook of the tower crane.

11.2

Electrical system of tower crane and its operations

 

11.2.1

General

  • A. Electrical system is designed for the driving, control, lighting and all security protection/alarm devices of the tower crane.

  • B. Tower crane should be fed with ac power supply of 50HZ 380V, allowing a voltage error of 5%.

  • C. Supply cable of the tower crane enters into the electric control box in the driver's cab, passes the air switch, enters into the electric control cabinet on the upper coupling platform; control cable is connected between the interlock console in driver's cab and the electric control cabinet on the upper coupling platform. With the aid the start-up/shutdown button and operating handle on the interlock console in driver's cab, the hoisting motor, slewing motor and derricking motor may be individually controlled; the jacking mechanism is directly fed by the external electrical cable, which is controlled via the small switch box mounted on the hydraulic power unit.

  • D. In order to ensure the safe operation of the tower crane, the tower crane is equipped with zero-position protection, altitude limitator, front/rear endpoint limitator for trolley derricking, slewing angle limitator, and cable-reel debouncing device; in addition, it is equipped with moment limiting device and load-lifting limiter for overload protection; Overload short-circuit protection for the hoisting motor is realized via the air switch, short circuit and overload protection of slewing motor and derricking motor is realized by air switch, and the short circuit and overload protection of jacking motor is realized by fuse and thermorelay.

11.2.2

Schematic diagram of electric wiring

 

(For details, please refer to Appendix: Schematic diagram of electrical control for tower crane QTZ125)

Tower crane control may be divided into general supply switch, hoisting motor control, derricking motor control, slewing motor control, oil-pump motor control, moment limiting device, weight limiting device, and electric lighting etc.

11.3

Operation

Turn on the master switch (air switch) in the electric box inside the driver's cab, the power supply is switched on, and the tower crane is powered on.

  • 11.3.1 Check if the supply voltage is normal. The tower crane should be fed with ac power supply of 50HZ 380V. In case the voltage is over 399V or lower than 361V, do not allow the tower crane to operate.

  • 11.3.2 Before the tower crane is brought into operation, the master starting button should be actuated, the stop button must be normally closed up, and all operating handles should be set to zero position, the moment limiting device should be powered on; At this point, press the master starting button.

  • 11.3.3 Motions of all mechanisms should be operated according to the orientation marked on the control switches.

  • 11.3.4 When the Hoisting mechanism is actuated, it is required to press the bell button so that the electric bell may give out sound as alarm.

  • 11.3.5 Just press the master stop button ZT to cut off the power supply for the complete appliance

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  • 11.3.6 In the process of jacking operation, turn on the power switch for jacking operation to power on the jacking operation control section, and the operation of the hydraulic power unit of jacking mechanism should be controlled via the button box.

  • 11.3.7 To realize emergency stop, just press the emergency stop button.

 
  • 11.3.8 In case the moment limiting device cut of the power supply due to overload operation of the tower crane, set the operating handles to their zero positions, and then press the master starting button again. At this moment, it is impossible to carry out the operations such as hoisting or outward travel of derricking trolley etc., and only the unloading or inward travel of derricking trolley (to reduce the load moment) are allowed so as to reset the contactor of moment limiting device.

  • 11.3.9 For the control operation of multi-speed motors, it is not allowed to directly set to the high gear and start it up, and it is required to operate from low speed to high speed progressively. To perform shutdown, it is required to operate from high speed to low speed progressively.

  • 11.4 Precautions for operation

Mechanisms of tower crane adopts direct starting by multi-speed motor, therefore the voltage pulsation must not exceed 5%.

Speed change of all mechanism must be progressive. it is not allowed to run it directly from zero to high speed or return to zero directly from high speed, and anti-phase braking plugging is not allowed.

Multispeed motors must be wired according to wiring diagram of the motors, and they must not be wired incorrectly.

In order to ensure the safe operation of the tower crane, the tower crane should be reliably earthed (repeatedly interative earth); electrical enclosure of all motors should be earthed, and the motor of hoisting mechanism should be earthed so as to avoid accident of creepage.

Once jacking operation is over, it is necessary to turn off the power supply for jacking operation, unplug the power plug from the electric control cabinet, and properly reel the power cable onto the hydraulic power unit and securely fix it.

All motors and electric appliances should be regularly repaired, and regularly observe the temperature rise of all motors.

  • 11.5 Mounting positions of electrical devices

Control cabinet should be mounted on upper coupling platform, with rain-proof measures. Interlock console should be mounted in the driver's cab. Hoisting altitude limitator should be mounted on aside the winding drum of hoisting mechanism, and careful adjustment is required so that the contactor of limit switch may be actuated once the hook ascends to allowable maximum height. Radius limitator of derricking trolley should be mounted aside the derricking winding drum, and careful adjustment is required so that the derricking mechanism may automatically stop operation once themaximum radius or minimum radius is reached. Moment limiting device should be mounted on inside the tower cap, and it should be repeatedly adjusted with reference to the instruction manual. Slewing angle limitator should be mounted on the upper coupling, and it is necessary to ensure that it may normally enagage with the slewing gear ring. Jib-boom obstacle light should be mounted at the end of jib boom, and it should be red water-proof light. Counterjib obstacle light should be mounted at the end of counterjib, and it should be red water-proof light. Tower-top obstacle light should be mounted at the top of the tower cap, and it should be red water-proof light.

To carry out jacking operation, it is necessary to release the welding connectors of all main cables; once the jacking operation is over, it is necessary to fit on a clip every 8.4m so as to fix the cable onto the tower mast.

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12. Tower crane dismantling (please refer to Figure 43)

 

Tower crane dismantling should be carried out strictly according to relevant regulations and the sequence of tower crane dismantling (Namely the reverse process of tower crane erection) so as to prevent incident from happening. To dismantle some parts of the tower crane such as jib boom or counterjib, it is particularly necessary to prevent the rest sections of the tower crane from offbalance that may result in capsizing case of tower crane.

12.1

Preparation before dismantling

 
  • 12.1.1 Ensure that there is no obstacle in the dismantling area, which may have influence upon the tower crane dismantling.

  • 12.1.2 Turn the jib boom to the opening side of bell socket frame.

 

12.2

Tower mast dismantling (for tower mast dropping, please refer to Figure 44)

The tower mast must be dismantled strictly according to the reverse process of tower crane erection and section- adding jacking operation correctly, and the specific procedures are given below:

  • 12.2.1 Tower mast dismantling: Above all things, ensure all equilibrator should remain in their specified positions before jacking operation of the tower crane, and dismantle the standard sections step by step till the possible minimum height according to the reverse process of tower mast raising for ease in successful tower crane dismantling.

  • 12.2.2 Counterweight dismantling: Dismantle the counterweight according to the reverse procedure of counterweight erection (Namely two pieces of counterweight should be left behind).

  • 12.3 Hoisting rope dismantling

 

Let the hook assembly drop down to the ground (or onto the platform of bell socket frame), move the derricking trolley forward till the tip of the jib, dismantle the rope clamp for fixing the pigtails of the hoisting rope (nearby the antitwist device at the tip of jib) one by one, actuate the hoisting mechanism and wind the wire rope onto the hoisting winding drum, have one section of wire rope left behind and wind it through the rope pulley at the head of tower cap, drag it down to the root of the jib boom, use the rope clamp to form a cable loop as standby.

  • 12.4 Jib boom dismantling

 
  • 12.4.1 Tie a slip rope onto the front and rear end of the jib boom, and let it off to the ground so as to ensure stability in the process of the jib boom descending and to adjust the horizontal angle, avoid the obstacle, and properly place it when necessary.

  • 12.4.2 According to the hoisting points and binding procedures of lifting rope applied in the erection of jib boom, let a crane truck to lift up the jib boom to a certain angle.

  • 12.4.3 Allow the hoisting rope of hoisting mechanism to held on the jib boom armtie, and remove the jib boom armtie one by one from the tower cap according to the sequence "short armtie firstly, then long armtie", lift down them onto the bracket of jib-boom top boom, and secure them properly.

  • 12.4.4 Let the jib boom slowly drop to the level position, remove one piece of jib root pin between the jib boom and transition section, insert a steel bar (or steel pipe) φ40~φ50 into the attachment hole, and then remove the other piece of jib root pin.

  • 12.4.5 Adjust the altitude of hook of the crane truck (or adjust the position of derricking trolley on the jib boom) so that the inserted steel bar or steel pipe may be directly applied to stop the crane truck ascending and descending when it is taken out; fix the derricking trolley and remove the electric cable for derricking trolley, and then remove the steel bar or steel pipe.

  • 12.4.6 Turn the crane truck appropriately so that the jib boom is withdrawn from each several parts of the tower crane, let the crane truck to decend slowly, place wooden beam on the ground, place the jib boom onto the wooden beam stably, hook off, and remove the lifting rope.

  • 12.4.7 Remove the top ping lift from the derricking trolley, and wind it onto the derricking winding drum.

  • 12.4.8 Disassemble the jib boom into transportation units, and collect the spare parts such as armties and axis pin etc.

12.5

Wind up the hoisting ropes and remove the electric cable of hoisting mechanism

12.5.1

Remove the rope clamp of wire rope at the end of the jib boom; wind up the hoist rope onto the hoisting winding drum. in the process of rope removal, it is required to check the total length of wire rope carefully.

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Foshan Nanhai Golden Construction Machinery Co., Ltd. Contents of Operating Instruction Manual for Self-Raising Tower Crane
Foshan Nanhai Golden Construction
Machinery Co., Ltd.
Contents of Operating Instruction Manual
for Self-Raising Tower Crane QTZ 125
Page 55
of 64
Figure 43. Sequence diagram of
tower crane dismantling
1.
8.
2.
9.
3.
10.
4.
11.
Dismantle the counterjib
Dismantle the tower cap
Dismantle the transition section
Dismantle the upper/lower coupling and driver's cab
5.
12.
6.
13.
7.
Dismantle the hoisting rope
Dismantle the 4 pieces of counterweight block
Dismantle the short armtie kit of jib boom
Dismantle the long armtie kit of jib boom
Dismantle the jib boom
Dismantle all counterweight blocks
Dismantle the counterjib armtie kit
14.
Dismantle the bell socket frame
Dismantle the standard section
Dismantle the foundation feet

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(1) Dismantle the upper/lower connecting bolts of standard section

(7) Jack up the transverse member, and put it into the next pair of footboard

(2) Let the bell socket frame uprise

(8) Let the bell socket frame uprise a little

Contents of Operating Instruction Manual for Self-Raising Tower Crane QTZ 125

(4) Take out the bracings (9) Take out the bracings out (3) Push out the (10)
(4) Take out the bracings (9) Take out the bracings out (3) Push out the (10)
(4) Take out the bracings (9) Take out the bracings out (3) Push out the (10)
(4) Take out the bracings (9) Take out the bracings out (3) Push out the (10)

(4) Take out the bracings

(9) Take out the bracings out

(3) Push out the

(10) Let the bell socket

standard section

out of the footboard

of the footboard

frame descend

Foshan Nanhai Golden Construction Machinery Co., Ltd.

standard section and tighten them (11) Properly insert the bolts of (6) Lay the bracings on
standard section and tighten them (11) Properly insert the bolts of (6) Lay the bracings on

standard section and tighten them

(11) Properly insert the bolts of

(6) Lay the bracings on the next pair

(12) Lift up and remove the

of footboard notch for support

(5) Let the bell socket

standard section

frame descend

Figure 44. Operational sequence diagram for tower mast descending
Figure 44. Operational sequence diagram for tower mast descending

Figure 44. Operational sequence diagram for tower mast descending

Repeat the above operational process; remove the standard section of tower mast successively till the intended height of tower mast.

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12.5.2

Dismantle the electric cables forhoisting mechanism etc. and collect them properly.

 

12.6

Dismantle the counterweight and counterjib

  • 12.6.1 Firstly lift down the counterweight block at the rear to the ground, connect the crane whip to the hoisting lug of counterjib by shackles, and lift up the counterjib to a certain angle.

  • 12.6.2 According to the reverse process for erection, remove the two kits of counterjib armtie intermediately one by one, lay back the upper segment of armtie leaning against the tower cap and fasten it. Place the lower segment of the counterjib armtie onto the wooden beam that has been fixed to the handrail in advance.

  • 12.6.3 Let the counterjib descend to level position, and remove the jib root pin according to the same procedures for jib boom dismantling.

  • 12.6.4 Let the counterjib descend onto the groundm, and remove the lifting ropes.

 
  • 12.6.5 Remove the lower segment of counterjib armtie, and collect the spare parts such as armtie etc.

12.7

Tower cap dismantling

  • 12.7.1 Tie the shorter lifting rope onto the top of the tower cap, let the crane truck to raise its hook till the slightly stressed state, and then stop the motion of the crane truck.

  • 12.7.2 Remove the connecting bolts between tower cap and the transition section, lift up the tower cap, turn the crane truck appropriately so that the tower cap may be withdrawn from the tower mast, and then let it decend onto the ground.

  • 12.7.3 Lift up the upper part of the tower cap, and place the tower cap crossly.

 
  • 12.8 Transition section dismantling

 

Lift up the transition section, remove the connecting bolts between its lower part and the upper coupling, and then drop it onto the ground.

  • 12.9 Dismantle the upper/lower coupling and driver's cab

 
  • 12.9.1 Lift up the upper coupling by lifting ropes, remove the connecting bolts between lower coupling and bell socket frame and standard section, and then lift it down to the ground.

  • 12.9.2 Remove the driver's cab and lift it down to the ground.

 

Note: In case the capacity of crane truck allows, it is possible to dismantle the transition section, upper coupling, lower coupling, and the driver's cab at one go, and then disassmble them into transport units.

12.10

Bell socket frame dismantling

  • 12.10.1 Dismantle the hydraulic pipeline, and lift the hydraulic power unit down to the ground.

 
  • 12.10.2 Lift up the bell socket frame, and then lift it down to the ground.

  • 12.10.3 Dismantle all handrails platforms, lift up the upper part of the bell socket frame, andlift down the bell socket frame to the ground crossly.

  • 12.11 Standard section dismantling

 

Lift up the standard section, remove the connecting bolts, and lift it down to the ground.

 

Note: In case the hoisting power allows, it is possible to dismantle the bell socket frame together with the standard section inside it at one go.

  • 12.12 Foundation feet dismantling

 

Dismantle the nuts on the anchor bolts that connect the flange of foundation feet to the concrete foundation, one by one lift up the foundation feet and allow it to be moved away from the foundation of the tower crane.

Check up the spare parts, cordage, and tools. Onload the parts of tower crane, and transport them to the intended place.

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13. Repair and maintenance of tower crane

 

According to relevant national regulations and standards, tower crane should be returned to the manufacturer for top overhaul and inspection of safety protection devices 4 years after tower crane left the factory.

13.1 Routine maintenance and servicing

 

Oil of all reducing units should be regularly replenished in the process of operation, and the oil should be completely changed half a year after it runs for half a year, the inside of the reducing units should be cleaned as well. The oil types and oil quantity should satisfy the prescription listed in the instruction manual.

In case broken wire of wire rope exceed 5, or crown wire abrasion exceeds 5 % of the wire diameter, it is necessary to replace it for new wire rope. In case strand breakoff occurs, it is required to replace it immediately.

Pulleys on the tower cap and transition section, derricking pulleys on the jib, pulleys and rollers of derricking trolley, and the pulley of hook kit etc, should be applied with lubricant grease once a month. Rope-guide pulley shaft should be provided with lubricant grease at any moment.

Some enclosed-type rolling bearings, such as derricking winding drum bearings, plane ball bearings of the hook, bearings of motor, and slewing bearing etc. should be oiled once a project is completed.

Brake of hoisting mechanism and the limit stop of slewing mechanism may be abraded in operation. they should be adjusted at any time, and adjust or replaced in case they fail to satisfy the performance requirements due to abrasion.

After a period of service, the hoist rope and top ping lift may be stretched. Therefore it is necessary to adjust the height limitator of hoist rope, the top ping lift should be retightened, and the derricking limitator should be adjusted.

All electrical switches or contacts should be regularly checked for poor contact or switch malfunction etc. In case of any problem, it is necessary to be repaired or replaced on time. In particular, malfunction of travel limit switch is not allowed absolutely. Regularly check the connection points in the electric circuits, and tighten them at any time. Insulating property of all circuits or transmission facilities must be reliable and free from creepage.

Two weeks after the tower crane is put into service, it is required to tighten the bolts or nuts such as connecting bolts of the parts, clamping bars or rope clamps of wire ropes etc.

In the process of service of tower crane, it is necessary to regularly check if flaws etc. occur in the stirrups at linkage point with higher stress, such as hinge points and roller seat etc. at the root of jib boom, counterjib root, jib boom armtie, and counterjib armtie etc.; if any, it is necessary to stops running and recover it immediately.

The parts of all moving parts, which are abraded and become out-of-tolerance due to long-term usage or improper servicing, should be replaced.

All limiting devices should be readjusted whenever the tower crane is moved to another site; otherwise the limitating requirements of the limiting devices might not be guaranteed.

After the tower crane is moved to a new site, it is necessary to strictly check if bump, concussion burst or bending; if any, the tower crane must not be put into service before recovery.

After one project is completed, all parts of the tower crane should be descaled and preservated.

It is necessary to regularly check if welding crack, member bar rupture, deformation, or instability etc. occurs in the metal structure of tower crane. Whenever one project is completed and the tower crane is dismantled, the above-mentioned checks should be carried out carefully. All metal structure etc. should be descaled and painted carefully.

Person specially assigned should undertake the on-site maintenance and servicing of the tower crane.

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13.2 major failures of tower crane and relevant recipe

 

13.2.1

when heavy object is lifted up, it fails to stop stably, resulting in downslide:

(1) Cause:

  • A. There is oil on the surface of the brake wheel brake shoes.

 
  • B. Excessively frequent braking results in temperature rise and reduced friction coefficient.

  • C. Improper clearance adjustment of brake spring and brake shoes

  • D. Check if overload occurs.

 

(2) Recipe:

  • A. Clean and remove oil stain on the surface.

 
  • B. Adjust the spring pressure and brake shoe clearance.

 
  • C. Reduce the braking times appropriately.

 
  • D. Control the hoisted load within the range of rated load.

 
  • 13.2.2 Slipping of brake of derricking mechanism:

 

The cause and recipe for slipping of brake of the derricking mechanism are basically identical with those presented in 13.2.1.

  • 13.2.3 Too high temperature of reducing unit:

 

(1) Cause:

  • A. Check if the oil quantity in reducing unit is overmuch or too less.

 
  • B. Check if the oil grade is correct.

 
  • C. Check if the bearing clearances of reducing unit are too small.

 

(2) Recipe:

  • A. Charge oil According to the oil grade and oil quantity specified in the operating instruction manual of reducing unit.

  • B. Check the all bearing clearances, and any problematic bearing should be replaced.

 

13.2.4

It is difficult to actuate the slewing mechanism:

(1) Cause:

  • A. Check if there is any seized object or interfering object between the bull gear and pinion.

 
  • B. Check if the liquid oil for liquid coupling is up to the mustard, or check if the oil quantity is adequate.

(2) Recipe:

  • A. Observe and remove the interfering object between the bull gear and pinion.

 
  • B. Charge satisfactory oil as per correct oil quantity.

13.2.5

Motor horsepower is inadequate, rotating speed can not go up; or heating etc.:

(1) Leading cause:

 

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  • A. Motor might run with open phase.

 
  • B. A certain phase winding short circuits with the enclosure.

  • C. Overload operation of motor.

  • D. Supply voltage is too low.

  • E. Poor ventilation, too high temperature rise of motor.

  • F. Poor welded joint, poor contact, or broken line occurs in the rotor winding or the circuit.

  • G. Rotor grits with the stator (rotor-stator friction).

 
  • H. Clearance between brake or driving parts is insufficient.

(2) According to the results of the above-mentioned items, take relevant measures to remove the fault.

14. Transport of tower crane

 
  • 14.1 Transport of tower crane should satisfy relevant requirements for transport by highway, railway and waterways.

  • 14.2 To entruck the tower crane, it should be placed securely so as to ensure that the gravity center does not deviate from hte centre-of-gravity position of the means of transport.

  • 14.3 Structural members of the tower crane should be securely bund so as to avoid damage due to dropout .

  • 14.4 Small parts of the tower crane should be packed inside container such as wooden case before transport so as to avoid losses.

  • 14.5 In the process of onloading or unloading of structural members of tower crane, it is necessary to bind them securely and ensure the stable hoisting operation; take measures against collision with other articles so as to avoid the damage of structural members or other articles of the tower crane.

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Wire rope bearings All motors 5 All guide pulleys of fixed/movable Motor No. Part name Name
Wire rope
bearings
All motors
5
All guide pulleys
of fixed/movable
Motor
No.
Part name
Name of oil site
Reducing unit of
slewing
mechanism
4
Hoist rope
Top ping lift
Reducing unit of
hoisting
mechanism
Reducing unit of
derricking
mechanism
2
Reducing unit
1
Slewing
bearing
Before erection of tower
crane, or after dismantling of
tower crane, clean and charge
oil once.
Charge oil once every 1600