Professional Documents
Culture Documents
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.: XK21—110—0204. 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.
Tel: +86-0757-86795321、86795328
Fax: +86-0757-86778582
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 Driver’s 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
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 driver’s 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.
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
user’s 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.
● In case the length of compound jib is 60m, 7 pieces of counterweight should be adopted, totaling 17.5 Ton
Working radius of 3~ 15 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
1. Technical performance
1.1 Table of load characteristics
10.00 9.40 8.19 7.24 6.47 5.83 5.29 4.84 4.44 4.10 3.80 3.54 3.30 3.09 2.89 2.72 2.56 2.41 2.28 2.16 2.04 1.94 1.84 1.75
5.00 5.00 5.00 5.00 5.00 5.00 5.00 4.89 4.49 4.15 3.58 3.59 3.35 3.14 2.94 2.77 2.61 2.46 2.33 2.21 2.09 1.99 1.89 1.80
● In case the length of compound jib is 55m, 6 pieces of counterweight should be adopted, totaling 15 Ton
Working radius of 3~ 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 55
10.00 8.38 7.41 6.88 5.97 5.42 4.95 4.55 4.21 3.90 3.63 3.38 3.17 2.97 2.79 2.63 2.48 2.35 2.22 2.10 2.05
for Self-Raising Tower Crane QTZ 125
Contents of Operating Instruction Manual
5.00 5.00 5.00 5.00 5.00 5.00 5.00 4.60 4.26 3.95 3.68 3.43 3.22 3.02 2.84 2.68 2.53 2.40 2.27 2.15 2.10
● In case the length of compound jib is 50m, 5 pieces of counterweight should be adopted, totaling 12.5Ton
10.00 8.68 7.67 686 6.19 5.62 5.14 4.73 4.37 4.05 3.77 3.52 3.30 3.09 2.91 2.74 2.59 2.45
5.00 5.00 5.00 5.00 5.00 5.00 5.00 4.78 4.42 4.10 3.82 3.57 3.35 3.14 2.96 2.79 2.64 2.50
Machinery Co., Ltd.
Foshan Nanhai Golden Construction
Foshan Nanhai Golden Construction Contents of Operating Instruction Manual Page 5
Machinery Co., Ltd. for Self-Raising Tower Crane QTZ 125 of 64
a=2 a=4
6 Hoisting speed m /min.
0~40 0~80 0~20 0~40
Model YRTE180M2 -4
Motor Power kW 41
Liquid coupling ——
Specs. and model 185JXL1B Braking moment 185N·m Field voltage AC24V
Derricking
mechanism
Motor YTLEJB2L-185-4
Motor Y132M-4B5
Jacking device
Hydraulic power unit Rated pressure P=25Mpa Maximum pressure P=31.5MPa
1.4 External dimensions part names and weight of the tower crane(please refer to Figure 1)
5100
4000
Figure 2. Horizon distance between tower crane and building when the tower crane is attached
30 m
20 m
20 m
20 m
2 0m
20 m
20 m
22. 5m
2 7. 5m
Figure 3.Vertical distance between every two sets of attaching devices in case tower crane is attached
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 driver’s cab and guardrail etc.,
which are designed for mounting the slewing mechanism, slewing limitator, electric control cabinet, and the
operator’s 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.
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.
GOLDEN
6. Safety device of tower crane
Foshan Nanhai Golden Construction
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.
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:
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)
Pinion
(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.
(5) Heave tight the top ping lift till the trolley does not slip in case it is heavily loaded.
(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.
7.2 Tower crane’s place of erection
7.2.1 Reference dimension of erection site for tower crane (please refer to Figure 15)
Buiding
6 2 00 0 16000
4 0 0 0~ 8 0 00
1950
1 9 50
6000
6 0 00
1800
120
1600
6000
5000
5000
6000
4- pipe-pile ≥φ400 or
≥φ800 manual excavated pile
For the erection sequence of tower crane, please refer to Figure 18.
6. Erect the tower cap 13. Erect the other 5 pieces of counterweight
7. Erect the counterjib 14. Reel the hoisting wire rope and top ping lift.
of 64
Page 29
Page 30 Contents of Operating Instruction Manual Foshan Nanhai Golden Construction
of 64 for Self-Raising Tower Crane QTZ 125 Machinery Co., Ltd.
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
1800
1950
2800
A B
8.3 Erection of the bell socket frame (please refer to Figure 21)
8.4 Erection of the upper/ lower coupling and driver’s cab (please refer to Figure 22)
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.
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.
8.6.1 Properly assemble the components of tower cap, including the platform, access ladder, jib boom, short
armtie, long clamping plate, counterjib transition armtie (please refer to Figure 25), counterjib armtie (hole
center pitch of 6650mm), and weight limiting device etc.
8.6.2 Lift up the tower cap onto the transition section, align the direction (the upright end of main limb of the
tower cap should be the erecting direction of the jib boom), align the holes in the tower cap and the flange of
transition section, connect the tower cap and transition section by high-strength hexagonal head tap bolt M33
×125, and then tighten the double nuts.
8.7 Erection of the counterjib
8.7.1 Lift up the hoisting mechanism onto the pedestal lug of counterjib hoisting mechanism, pass the axis
pins through, put on and open the cotter pin as required.
8.7.2 Properly erect the counterjib platform handrail, and secure them by handrail clamp.
8.7.3 Properly erect the rope guide pulley gear.
8.7.4 Assembling of the counterjib armtie
(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)
(2) Pass the cotter pinsφ10×110 through the both ends of the armtie pin, and open them as required.
8.7.5 Hang the medium section of a pair of wire rope sling≥φ20 onto the hook of the crane truck, and its
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.
8.7.6 Lift up the counterjib that has been fitted with hoisting mechanism and handrail (Note: The two pieces
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).
8.7.7 Continue lifting up the counterjib, allow the rear of the counterjib to upwarp to a certain angle, connect
the two counterjib armtie kits separately (please refer to Figure 28).
8.7.8 Let the counterjib to drop to its level position slowly, carefully check the connection of counterjib armtie,
hook off adn remove the hoisting wire ropes if no problem is found out.
8.7.9 One by one to lift up two piece of counterweight block, erect it onto the rear of counterjib, and lay the
counterweight block onto the counterjib by special-purpose steel pins (please refer to Figure 29).
GOLDEN
GOLD EN GOLDEN
Foshan Nanhai Golden Construction
Figure 28. Raise the hook, and connect the armtie Figure 29. Hook unloading, allow the counterjib move to its level position, and
once the rear of counterjib upwarps. erect two pieces of counterweight nearby the rear of the counterjib.
of 64
Page 39
Page 40 Contents of Operating Instruction Manual Foshan Nanhai Golden Construction
of 64 for Self-Raising Tower Crane QTZ 125 Machinery Co., Ltd.
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.
(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.
a. Assembly drawing for jib boom of 60m in length (7 pieces of counterweight should be adopted, totaling 17.5Ton)
Machinery Co., Ltd.
b. Assembly drawing for jib boom of 55m in length (6 pieces of counterweight should be adopted, totaling15Ton)
c. Assembly drawing for jib boom of 50m in length (5 pieces of counterweight should be adopted, totaling 12.5Ton)
d. Assembly drawing for Jib boom armtie (when jib length is 60M)
Foshan Nanhai Golden Construction
Foshan Nanhai Golden Construction Contents of Operating Instruction Manual Page 43
Machinery Co., Ltd. for Self-Raising Tower Crane QTZ 125 of 64
9.6 Items to be checked once erection is completed (please refer to the table below)
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.
Items to be checked once tower crane is erected
Inspection
Inspection content
item
Foundation
Check the tightening of anchor bolts.
section
Check the bolt tightening of standard sections, and check if the connections of
Tower
access ladder or broadstep etc. are reliable.
mast
Check if the perpendicular alignment of tower crane is up to the mustard.
Check if the connections of alleyway and handrail are reliable
Bell socket Check the connection between the bell socket frame and lower coupling.
frame Check the connection between the bell socket frame and standard section.
Check if the erection and debugging of hydraulic system are normal and reliable.
Check if there is any oil material, spun cotton or other inflammable goods in the
Driver's driver's cab.
cab Check if the connection between the driver's cab and the upper coupling is stable
and reliable
Slewing Check the tightening of connecting bolts between slewing bearing, upper coupling,
bearing and the lower coupling.
Check the connection between the tower crane, counterjib and jib-boom tie rod,
Tower cap check the wire rope reeling, and check the connection between the tower cap and
transition section.
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.
Counterjib Check the erection and debugging of the hoisting mechanism and rope guide pulley.
Check the debugging of brake of Hoisting mechanism.
Check the erection of counterjib
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
Jib boom
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
Lubrication
in the operating instruction manual.
GOLDEN
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
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 士 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.
Repeat the above operational process; remove the standard section of tower mast successively till
Figure 44. Operational sequence diagram for tower mast descending
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.
Rope-guide iron-
3 QTZ125-15-11-02 ф280×ф100 1 Counterjib
casting pulley
Rope guide pulley of
4 QTZ125-15-11-03 Slide bearing Cast copper 8
counterjib
Wire rope
5 QTZ125-21-03-03 Q235 1 Derricking trolley
supporting roller
Attachment tools
1. Open spanner 60, two pieces
2. Open spanner 55, two pieces
3. Open spanner 46, two piece
4. Open spanner 22-24, one piece
5. Open spanner 17-19, one piece
6. Open spanner 14-14, one piece
7. Monkey wrench 300×36, one piece
8. Flat screwdriver, one piece
9. Phillips screwdriver, one piece
10. Inner hexagon spanner 5 MM, one piece
11. Inner hexagon spanner 6Mm, one piece
12. Inner hexagon spanner 8Mm, one piece
13. Test pencil, one piece
14. Insulated pliers 200, one piece
15. Grease gun, one piece
16. Tool box, one piece