Wan feng

Weihai Wanfeng Group

QTZ31.5（3807）——（angle steel style）

Hydraulic Self-lifting Tower Crane

Instruction Manual

NO：
Weihai Wanfeng Building Machinery (Group) Co., Ltd.

Please read the Manual carefully before installation.

 Foreword

Thank you for your choice of our product.

Please read the Operational Manual carefully before operating the tower crane.

The Operational Manual can help you to operate the tower crane correctly,
efficiently and safely, reduce malfunction or accident and maximize your profit.

Note:
1. Please read and keep the Manual and attached documents carefully;
2. Please make groundwork for the tower crane according to the Manual;
3. The installation, disassembly and operation of the tower crane must be done
only by professionals.
4. To check the welding seam in standard sections, bottom frame and jib and
other structural parts regularly. In case of abnormal condition, make corresponding
treatment for it;
5. To make careful inspection and test of the tower crane before every
installation;
6. Reversal brake at slewing is strictly prohibited;
7. To execute GB5144-2006 Regulation on Safety of Tower Crane and
ZBJ80012-89 Regulation on Operation of Tower Crane strictly;
8. The else regular inspection, maintenance and repair must be done according to
the Manual.

Note: As technology develops, the structure and performance of the tower crane may
be improved and no additional advice for it shall be given.

Wanfeng Tower Crane is your best choice!

 Contents

Summary ……………………………………………………………………………..1
1. Overall Outline and Hoisting Performance Char… ……………………................2
1.1 Exterior Sizes………………………………………………….………………….2

1.2 Hoisting Weight Chart………………………………………..…..........................3

1.3 Main Technical Parameters………………………………………..........................3
1.4 Parameters of Mechanisms………………………………………..........................4

2. Introduction of Main Parts and Structural Parts……………....................................5

2.1 Main Parts…………………………………….………………..………………….5
2.2 Main Structural Parts……………………………………………….......................11

2.3 Lightning Protection System…………………………………...............................12

2.4 Groundwork and Erection Position……….............................................................13
3. Erection of Tower…….…………………………………………….………………14

3.1General Regulation and Attention.............................................................................14

3.2 Erection Sequence….……………….……………………………………………..15
3.3 Adjustment of Limiters…………………………………..………………………..21

3.4 Preparation before Operation………………………………………………….…..22

4. Dismantlement of Tower Crane…………………….................................................23
5. Operation, Repair and Maintenance ………………………….…………..………..25

5.1Safe Operational Regulations……………….……………………………………...25

5.2 Electric System and Operation…………………….….………………..………….28
5.3 Repair and Maintenance of Tower Crane……………............................................29

6. Main Malfunctions and Removal Methods……..……….........................................32

7. Attached Technical Document and Drawings………………………………………35
8. Additional Explanatory Note………………………………………….……………35

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 Summary

QTZ31.5 Hydraulic Self-raising Tower Crane is new hoisting equipment for construction of
high buildings and it is designed by group technology, combination design, finite element analysis
and tower crane CAD.
The crane has horizontal arm, derricking trolley and upper slewing hydraulic self-raising
system with the 38m boom, the maximum hoisting load of 3t and rated hoisting moment of
315kN.m.
Characteristics:
1. The tower crane is used widely, not only for civil construction in small and medium cities but
also for high and high-rise civil buildings in large and medium cities, big span multi-storey
workshops, slipform construction of high chimney and silo, and loading and unloading in port and
goods yard.
2. It is easy to erect and dismantle. The hydraulic climbing device can be used to increase or
reduce the standard sections of mast so that the lifting height can be adjustable according to the
height of building.
3. It is featured by high speed of operation, excellent adjustable performance, stable running
and high efficiency. The climbing mechanism can basically realize the function of carrying heavy
load at low speed and light load at high speed. The traction mechanism of trolley has two speeds
for the working condition. The slewing mechanism has a N/O stopper which can have the tower
crane precisely positioned for installation.
4. It owns the complete, sensitive and reliable safety devices which include the weight limiter,
load moment limiter, height limiter, radius limiter and slewing limiter in order to ensure the
normal condition. In addition to safety devices, there are some other protection facilities such as
rest platform and guard rails.
5. The cab is independently located side, which is spacious, comfortable, safe, convenient in
operation and nice in view.
In normal condition, this tower crane feeds goods with the basic height of 27m
(independent). If it is used in the construction of high-rise building, it is possible to increase
standard sections and anchorage devices to meet the requirements. The maximum designed height
is 80m.

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1. Overall Outline and Hoisting Performance
1.1 Overall Outline

38.5m

Fig.1: Name of Main Parts and Relation for Assembly

1. basic frame and inclining stay bar 7. cab 8.cap head
2. base section 9. counter jib
3. frame and hydraulic system 10. counter weight
4. standard section 11. pull bar of counter jib
5. lower rotating platform and slewing ring 12. boom
6. upper rotating platform 13. pull bar of boom

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1.2 Performance of Lifting Capacity
Radius (m) 2.5-11.42 14 16 18 20 22 24 25 26
Lifting Capacity (t) 3 2.41 2.08 1.83 1.63 1.46 1.32 1.26 1.20
Radius (m) 28 30 32 34 36 38
Lifting Capacity (t) 1.10 1.02 0.94 0.87 0.81 0.76
Performance Chart of Lifting Capacity and Radius
Lifting Capacity (t)

Radius (m)

1.3 Main Technical Parameters

No. Description Unit Parameter
1 Rated load moment kN.m 315
2 Maximum lifting capacity t 3
3 Working radius m 2.5～38
4 Load-lifting height (independent) m 27
5 Load-lifting height (attached) m 80
6 Load lifting speed m/min 52/27/6.2
7 Slewing speed m/min 0
8 Derricking speed m/min 16/32
9 telescoping speed m/min 0.5
10 counter weight kg 5760
11 Base (cross girder) m 4.64X4.64
Distance from base center 2846 (when erecting the standard
12 mm
to building anchorage device)
Form boom end to
13 Overall m 42.5
slewing center
Dimension
From counter jib to
14 m 10.2
slewing center
15 Overall Independent m 33.7
16 height Attached m 86.7
17 Allowed min. safety pass clearance m 0.6
18 Allowed working temperature ℃ -20～+40
19 Basic wind pressure in the state in service Pa 250
20 Basic wind pressure in the state out of service Pa 800
21 Power supply 50Hz ～380V±10%

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1.4 Technical Parameter of Main Mechanisms
Hoisting
JC40%, JC40%, JC25%
mechanism
Slewing
JC40%
Load Ratios of Mechanisms mechanism
derricking
JC40%
mechanism
Type YZTD200L2-4/8/24
motor Power kw 15/15/4
Speed r/min 1440/720/220
Type ZDJ1-200
Brake
brake moment N.m 315
Assemblage type Ⅷ
Center distance mm 460
Hoisting Gearbox
center height mm 230
Mechanism
Speed ratio i=20.49
Rope GB1102-96 6W(19)-12-1770-I- coated-right lay
Load lifting speed m/min 52 27 6.2
Rated lifting
t 0.76 1.5 3
capacity
Min. stable
m/min ≤6
lowering speed
Type YZR132S-6
motor Power kw 3.7
Speed r/min 908
Slewing
Brake N/O stopper of hydraulic thruster
Mechanism
Transmission ratio i=147
Planet reducer
Output moment N·m 6300
Slewing ring QW32.1120
Type YD112M-4/8
Derricking motor
Power kw 1.5/2.4
Mechanism
Rope GB1102-96 6X19-6.2-1700-I-Grade A-coated-right lay
Type Y112M-4
motor
Power kw 4
Rated pressure Mpa 20
Climbing Cylinder bore mm Φ125
Mechanism Rod dia. mm Φ70
Lifting cylinder
Stoke mm 1300
Mounting
mm 1700
distance

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2. Introduction of Main Parts and Structural Parts
2.1 Main Parts
2.1.1 Hoisting Mechanism
The hoisting mechanism is driven by a motor of speed-3 (YZTD200L2-4/8/24, P=15/15/4kw)
and connected with the reducing unit through a coupling. In the reducing unit, the speed is
reduced through the gear and then transmitted from output teeth to drum via the teeth coupling.
The hydraulic thruster brake is normally open (N/O) and works after power-off. The mechanism
also has DXZ multi-functional height limiting device to control the lifting rope’s extending or
winding length. Keep it in mind that the rope should be wound around the drum by at least three
circles.
In order to realize the high/low speed switch, it is possible to control the different contactor
by operating the handle of control console so as to change the mode of connection for the motor.
The motor should be started at low speed, and then switched over to middle speed and high speed
one by one. High speed refers to the speed at no load or light load; middle speed refers to the one
at rated load and low speed serves the short-time services such as start-up, stop and slow
positioning. The sustaining power-on rate at low speed should not exceed 25% at any moment.

1. motor
2. coupling
3. hydraulic thruster brake
4. cylindrical geared-transmission
5. drum
6. height limiter
Fig 2: Sketch of Hoisting Mechanism

Service and Maintenance of Hoisting Mechanism:

⑴ This mechanism is not allowed to work or stay in the caustic environment such as acid and
alkaline gases, or to run at the condition of over rated load. The working temperature should range
from -20oC to 40 oC. If the motor works continuously at middle or high speed, the sustaining
power-on rate should be no more than 40%. The protection grade of motor is IP44. Regard the
norm service system of motor, high and middle speeds are S3-40% and low speed is S3-25%. The
calcium grease of bearing in the motor should be renewed every 6 months.
⑵ Before the installation of this mechanism, it is required to check if all bolts are fastened
and the wires are normal after power-on.
⑶ Use the clamp plate to fix the end of rope onto the drum.
⑷ Before its service, add grease to the reducing unit till it reaches to what is graduated. The
grease must be renewed after the first 7 to 20 days’ use; and for later use, renew the grease every
3 to 4 months according to the needs. The grease shall be middle-duty industrial gear oil, N100
for winter and N150 for summer. As for the oil renewal, firstly, discharge the old one; secondly,

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clean the reducing unit carefully; and finally, add new one.
⑸ After installing the mechanism, switch on the power and conduct commissioning. Adjust
the brake carefully and check if the oil in the hydraulic brake is sufficient.
⑹ If the reducing unit works out of order, such as sounding abnormally or too high
temperature, it is required to stop and check it. It can not continue to work until the error is
removed.
⑺ The height limiter should be adjusted in accordance with the manual and checked every
month. If it works in abnormal condition or its stroke switch is out of order, adjust or repair it
immediately.
⑻ The brake must be checked every day. Inappropriate adjustment for brake may not only
affect its performance seriously, but also damage the surface of brake wheel soon. The brake band
must be changed when the least thickness is less than 3mm or the thickness at the middle part is
less than 4mm. The brake wheel must be changed when the surface has been damaged by 1.5mm
in thickness.
2.1.2 Slewing Mechanism and Slewing Ring
The slewing mechanism is driven by a YZR132S-6，3.7kW motor, with the power transferred
from the hydraulic coupling to the slewing ring through the planet reducer and driving gear. The
coupling has such advantages as slewing start, stable stop, small inertia, high transmission
efficiency and long service life so that the work of this tower crane has been improved. In order to
realize precise slewing for stop, this mechanism is specially furnished with a set of
electromagnetic stopper. The brake can only works after the slewing motor stops working and the
boom’s turning tends to stop. After braking, the brake should be kept open. In one word, the brake
works after power-on and keeps open after power-off. In the state out of service, the boom can
turn around with wind.

Fig. 3: Assembly Drawing of Slewing

Mechanism and Slewing Ring
1. slewing motor; 2. hydraulic coupling;
3. planet reducer; 4. driving gear;
5. slewing ring; 6. electromagnetic brake

Service and Maintenance of Slewing Mechanism:

⑴ This mechanism is not allowed to work or stay in the caustic environment such as acid and
alkaline gases. The working temperature should range from -20oC to 40 oC. The sustaining
power-on rate of the motor should be no more than 40%. The working grade of motor is M5. The
calcium grease of bearing in the motor should be renewed every 6 months.
⑵ Before the installation of this mechanism, it is required to check if all bolts are fastened

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and the wires are normal after power-on.
⑶ As for the assembly of reducing unit and upper rotating platform, it is required to fasten
them with bolts in order to ensure the output gear to parallel and mesh with the slewing ring.
⑷ The grease shall be middle-duty industrial gear oil, N100 for winter and N150 for summer.
The grease must be renewed after the first 3 months’ use; and for later use, renew the grease every
1500 hours according to the needs. As for the oil renewal, firstly, discharge the old one; secondly,
clean the reducing unit carefully; and finally, add new one.
⑸ It is forbidden to use the electromagnetic brake for long time during operation in order to
damage it soon.
2.1.3 Derricking Mechanism
In order to realize the outward and inward change in radius for the trolley, this mechanism
uses the motor YD112M-4/8 for rotating the derricking drum through the worm gear reducer and
switches the control circuit by operating the handle of control console.
The derricking rope has the parameter of 6X19-6.2-1770-I-right lay, and its winding method
is as follows:

Fig. 4: Derricking Mechanism and Method of

Winding with Rope
1. derricking drum; 2. motor;
3. derricking trolley; 4. rope;
5. derricking pulley

In order to prevent the trolley from slipping along boom after the rope is broken under pull
force, the rocking beams are installed at its both ends. So the rope should be wound through the
iron ring at the end of rocking beams.
Service and Maintenance of Derricking Mechanism:
⑴ This mechanism is not allowed to work or stay in the caustic environment such as acid and
alkaline gases, or to run at the condition of over rated load. The working temperature should range
from -20oC to 40 oC. The sustaining power-on rate of the motor should be no more than 40%. The
working grade of motor is M5. The calcium grease of bearing in the motor should be renewed
every 6 months.
⑵ Before the installation of this mechanism, it is required to check if all bolts are fastened
and the wires are normal after power-on.
⑶ Use the clamp plate to fix the end of rope onto the drum. The rope should be wound around
the drum by at least three circles.
⑷ The reducing unit shall be lubricated with the lithium grease (EP) or Gear-Syn GS (4430).
The grease must be renewed after the first 7 to 20 days’ use; and for later use, renew the grease

10
every 3 to 4 months according to the needs. The bearing seat of drum should be filled with ZN-3
sodium grease once a month.
⑸ It is required to check the abrasion of electromagnetic brake frequently. If it fails, replace it
immediately to ensure the safety.
⑹ If the reducing unit works out of order, such as sounding abnormally or too high temperature,
it is required to stop and check it. It can not continue to work until the error is removed.
⑺ The radius limiter should be adjusted in accordance with the manual and checked every month.
If it works in abnormal condition or its stroke switch is out of order, adjust or repair it
immediately.
⑻The hoisting rope and derricking rope will be extended after use, so it is required to have them
stressed again.
2.1.4 Hydraulic Climbing Mechanism

Fig. 5: Hydraulic Climbing System

1. motor; 2. overflow valve;
3. manual reversal valve;
4. oil tank; 5. vernier;
6. balanced valve; 7. cylinder
8. oil pipe; 9. oil pipe
10. pressure gauge;
11. climbing beam

A. Structure
The system consists of hydraulic pump station, working cylinder and hydraulic hoses. The
cylinder drives the climbing beam to move up and down.
The system is installed on the climbing frame.
B. Working Principle
The motor pulls the gear pump so that the hydraulic oil will be pumped from the oil tank to
the manual group valve. When putting the handle atⅠ, the high-pressure oil will flow into the
upper chamber of hydraulic cylinder through the manual group valve, hydraulic hose and
balanced valve; and then the piston rod will extend out. At this time, the low-pressure of lower
chamber of hydraulic cylinder will return to the oil tank through the manual group valve.
When failures happen, the oil pressure will rise and exceed the adjusting pressure of overflow
valve of the manual group valve, and the overflow valve will be open to discharge the

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high-pressure oil into the oil tank, protection system and working devices.
When putting the handle at Ⅱ, the high-pressure oil pumped by the gear pump will flow to
the lower chamber through the manual group valve; at this time, the high-pressure will open the
balanced valve, and the hydraulic oil of upper chamber will flow into the oil tank through the
manual group valve.
When putting the handle at “0”, the hydraulic oil pumped by the gear pump will return oil
tank directly through the manual group valve. The hydraulic cylinder does not work at this time.

1. oil tank
2. oil filter
3. motor
4. gear pump
5. pressure gauge switch
6. pressure gauge
7. hydraulic hose
8. hydraulic cylinder
9. balanced valve
10. adaptor
11. manual group valve
12. oil filter
13. oil gauge

Fig.6: Schematic Diagram of Hydraulic

Cylinder

C. Adjustment of Overflow Valve

The manual group valve consists of overflow valve and manual reversal valve. The valve
body has a adjusting bolt for adjusting the safe pressure of overflow valve.
Before the hoisting operation of tower crane, it is required to adjust the overflow valve in
order to obtain nice safe pressure.
For adjusting the overflow valve, follow the steps as below: open the motor until the gear
pump start working; turn on the switch of pressure gauge; loosen the adjusting bolt; put the
handle atⅠso that the upper structure of tower crane can be hoisted; slightly tighten the adjusting
bolt to make the discharging pressure a little higher than the normal working pressure of hydraulic
cylinder. The pressure is about 18MPa, which can be read from the pressure gauge.
If the pressure exceeds 20MPa, stop hoisting and then check the frame and climbing system
to see if the requirements of balance is satisfied, the wheel is held or the climbing system fails.
D. Assembly and Disassembly
Connect the balanced valve with the hydraulic cylinder. Connect the other parts with each
other into a whole by the hydraulic hoses and adaptors whole called as hydraulic station.

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E. Maintenance
1) If there is any failure during hoisting, stop the hydraulic cylinder, and then remove the
troubles immediately to prevent it from being supported for long time.
2) During disassembly, it is proposed to use clean screw plugs to plug up all pipe adaptors in
order to prevent foreign substance from entering oilway.
3) In the course of assembling the tower crane, it is required to check the oil tank by
observing the oil level gauge to see if oil is enough.
4) Check the oil level once 200 hours.
5) For the first hoisting after each assembly, it is required to check the hoisting pressure and
adjust the overflow valve. The normal working pressure and the safe pressure for overflow valve
are about 18MPa and 20MPa respectively. If the oil pressure exceeds either of the two values, it is
required to check if there is something wrong in the system. ,
6) The oil in the system should be renewed every 2400 hours. Before adding oil, firstly, check
whether the filter is all right; secondly, filled up the filter with oil; thirdly, start the gear so as to
have the hydraulic cylinder telescope with no load several time; and finally, check the oil level.
Notice:
1) If the system has not worked for over half year, it is required to check the oil quality by the
professionals before the re-use. If the oil goes bad or is not clean, replace it immediately.
2) The connection for motor should be well done in order that the gear can turn correctly, i.e.,
turning anticlockwise, as watched from the input shaft (refer to the turning sign of motor).
2.1.5 Lifting Rope
The lifting rope has the parameter of 6X19-12-1700-I-right lay, and it is wound as per the
Fig. 7.
Service, Maintenance and Discarding of Rope
Ropes should be used in compliance with the provisions under Safety Rules of Tower Crane
(GB5144-2006). The correct use of ropes can realize safe and reliable work for the tower crane
and extend their service life as well.

1.guide pulley of cap head;

2. guide pulley of boom;
3. pulley block of trolley;
4. pulley block of hoisting hook;
5. drum of hoisting mechanism

Fig. 7: Winding Principle for Lifting Rope

⑴ Rope should be kept in the dry and noncorrosive environment. During use, the rope should not
be tied, loose, pulled on ground or get dirty. Keep the rope’s surface clean.
⑵ The rope should be correctly wound through the pulley or groove of drum. When winding the
rope around the drum, there should be 10% anti-pull force under the inner layer of rope in order to

13
ensure the outer one under the force of load will not be embedded into the inner one.
⑶ For the first use of rope, it is required to put only 10% rated load on it at first, and then
gradually increase to the full rated load.
⑷ For the new rope, it is required to add lubricating grease after first 200 hours. The quality of
lubricating grease must be same or similar to the one as formerly added. For later use, the
lubricating grease shall be regularly added according to the working condition. The surface of
rope should be often cleaned after use.
⑸ The rope should be checked once a week and discarded under any of the following
circumstances:
a）Yarn breakage. In one length of lay, if the quantity of broken yarn exceeds ten, the rope must
be replaced by new one.
b）Worn out or corroded. Due to the worn or corroded surface, the diameter of rope has been
reduced by 7%, in which circumstance the rope must be replaced even if no yarn breakage
occurs. If yarn breakage occurs in the fixed end of rope, it is proposed to truncate the rope and
then fix the end. However, the length of roped should be enough to be able to be wound
around the drum by at least three circles.
c）Out of order. The rope must be replaced by new one if any of following happen: the rope gets
waving or crushed; the yarn strand or wire becomes extruded; or the diameter is partially
reduced.
2.2 Main Structural Parts
2.2.1 Basic Frame
The basic frame is made up of cross beams which are welded with I-bars. The long and
short beams are coupled through cross pins. The basic frame is fixed onto the foundation through
pre-embedded foundation bolts (M30) and pressure bars. It is connected with the base section
through the high-strength bolts (M30X110). The outer end of basic frame is connected with the
standard section through the tilting stay bar.
2.2.2 Standard Section of Tower
The standard sections tower shall be welded with steel pipes or angle steels and connected
with the standard section (2200mm high) and lower rotating platform through connecting sleeve
and bolts.
2.2.3 Frame
The frame consists of framework, platform, rail, adjusting wheel and cross pins.
2.2.4 Lower Rotating Platform
The upper part of lower rotating platform is of box structure made up of plates. The legs of
lower part are connected with the standard section and frame respective through cross pins.
2.2.5 Upper Rotating Platform
The upper rotating platform shall be connected with the slewing mechanism and slewing
support. The four top corners are connected with the cap head. The slewing mechanism and rail of
cab platform are at both sides of the upper rotating platform. The control console and power box
are set in the cab.

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2.2.6 Cap Head
The cap head is welded with angle steel, with the hinge bolt at the top connecting with the
arm ties of counter jib and boom. It is also furnished with a guide pulley through which the lifting
rope is wound. The top is furnished with obstruction light and lightning rod. The grounding
device for lightning rod should be manufactured in accordance with the specification (see the
section of “lightning facility”). The manufacturer shall not provide the services of installation and
maintenance for the earthing protection facilities.
2.2.7 Boom and Its Tie Bars
1. The boom is made up of triangular truss with every section of 7m and end of 4.8m. The
sections are connected with each other through pin shaft.
2. The boom consists of five tie bars of 6160mm (each), one of 5366mm and another of 4673mm.
These tie bars are connected with each other through pin shafts. They should not be bended,
distorted or damaged during installation and transportation.
2.2.8 Counter Jib and Its Bars
1. The counter jib is made up of the planes of walk grid board. When assembling it on ground,
fix the hoisting mechanism in the tail.
2. There are four tie bars of 5100mm (each) connected with each other through pin shaft. They
should not be bended, distorted or damaged during installation and transportation.
2.2.9 Anchorage Device of Tower
The anchorage device of steel-pipe tower consists of four stay bars, anchor ear and
wall-attached seat. One end of stay bar is connected with mast through the anchor ear while
another is connected with the building by pin shaft through the wall-attached seat. There are
adjustable bolts at the middle of stay bar.
The anchorage device of angle steel tower consists of three stay bars, framework and
wall-attached seat. One end of stay bar is connected with mast through the anchor ear while
another is connected with the building by pin shaft through the wall-attached seat. There are
adjustable bolts at the middle of stay bar.
The part embedded in wall will be determined by the actual situation in the site.
2.3 Lightning Facilities (See Fig.8)
1. The top of cap head should be furnished with lightning rod. The paint at connection should be
cleared.
2. The cable of earthing protection device can be connected with the bolt of any main chord. The
paint at bolt or nut should be cleared.
3. The chassis anchored with foundation should never be used as the earthing lightning device. It
is required to set an additional one at the foundation of tower crane.
4. The resistance of earthing protective lightning device should not exceed 20ohm.
5. The earthing protection device should be always installed as prescribed even if other
protection device is used like the sensitive differential relay (automatic breaker).
6. Earthing device should be installed by professionals because the earthing resistance rate varies
with the time and local condition. Resistance should be tested with high-precise apparatus.

15
7. The manufacturer shall not provide the services of installation and maintenance for the
lightning facilities and materials.
8. The earthing device of lightning rod should be manufactured as per Fig. 8.

Fig. 8: Earthing Device of Lightning Rod of Tower

1、Earthing protective cable
2、Insulating ceramic pipe
3、Lightning rod made up of galvanized pipe: The min. diameter is 400mm; the length of pipe
varies according to the earthing resistance (normally, it is required to be able to reach the
aquifer).
2.4 Groundwork and Erection Position
2.4.1 Groundwork
(1) The soil of foundation of groundwork should be hard and firm, and the bearing capacity
should be more than 200kN/m².
(2) The strength grade of concrete should be above C30. The ordinary steel bars and bearing steel
bars are distributed in the foundation where foundation bolts are embedded. The foundation
should be strictly fabricated as per the attached drawing.
(3) The foundation surface should be flat and level, with the planeness degree no more than
≤2/1000.
(4) The back plate at the connection between the foundation and main limb of base section should
be kept level, which can be tested with gradienter. The height difference should be no more than
1/500.
2.4.2 Erection Position
(1) The size of site where erect tower crane should be referred to the Fig.9.
(2) In order to make full of the boom’s effective radius and lifting capacity, the tower crane should
be erected near the building and the place where the largest prefabricated part is installed or it is
convenient for assembly and disassembly of tower crane.
(3) The longest rotating parts, such as the boom and lifting hook, should be far from the

16
transmission line by more than 10m in order to prevent the accidents like hurt by electric shock or
mechanical accidents.
Keep it in mind that the least safety distance of tower crane should not be less than 1m.
Try to install the tower crane near the building, with the best distance of 2846mm.

Fig.9: Tower Crane Installation Site

★ In the state out of service, it is forbidden to fix the slewing mechanism
manually in order to prevent boom from swinging with gale, otherwise the
tower may be twisted so as to cause the accident of reverse lifting.
★If a structure whose length exceeds the height of tower crane stands in the
range of boom’s turning radius, the tower crane in the state out of service is
forbidden to turn. In such case, it is required to drop the lifting hook and fix it
onto ground in order to prevent boom from colliding the structure.
3. Erection of Tower
Before the erection of tower, the users should read this manual carefully so as to install the
tower crane correctly and quickly.
A wheel crane is needed for assisting to erect tower. Its performance should adapt to the
lifted goods. The time to use auxiliary crane can be minimized if various installations and erecting
professionals (pass through the passages and assembly site) are well arranged.
3.1 General Regulation and Attention
1. The truck-mounted crane (≥16) or other cranes as the hoisting equipment.
2. In order to ensure security when using the auxiliary crane, the following should be followed
(1) Crane must be well cushioned.
(2) Not allow to work with overload
(3) Choose the reliable load-handling device with appropriate length according to the lifted goods.
(4) Choose an appropriate hoisting point.
3. The protective and safety facilities like rope must be installed and use.
4. The tower crane is forbidden to work with band in the case of gale with a magnitude of over
four.
5. It is forbidden to rotate boom during climbing installation.

17
6. The tower crane installation professionals should have relevant quality of installation and
maintenance.
3.2 Erection Sequence
1. Installation of Basic Frame
Firstly, place the basic frame on the qualified concrete foundation, with the four edges in the
appropriate places; secondly, connect the long and short beams through the pin shaft, and keep the
basic stable and firmed; keep the four flange surfaces level through the level gauge or
communicating pipe, with the levelness error less than 1mm; finally, fix the basic frame with the
clamp plate and foundation bolt.
2. Installation of Tower
Firstly, with hoisting equipment, connect the base section with basic frame through the
high-strength bolt (M30X110, prestressing moment: 1420 N.m). Secondly, add four standard
sections to the base section through the high strength bolts (M30X265, prestressing
moment:1420N.m), with the tilting stay bar connecting with basic frame and standard section
through the pin shaft, and lock the split pin. Fasten them with high strength bolts. Keep the
standard section vertical with theodolite (error≤1.5/1000).
When installing the standard section, in order to ensure the hoisting and sections adding to
be successful, attention should be paid to the installing direction of step
3. Installation of Frame
⑴ Assembly the cylinder and climbing beam into frame on ground. To prevent the cylinder from
swinging, its members should be fixed at the frame temporarily.
⑵ Connect the working platforms with the frame in turn.
⑶ Fix the hydraulic station onto the working platform of hydraulic cylinder.
⑷ Fix the slewing ring onto the lower rotating platform tightly with the high-strength bolt
(M22X165, prestresssing moment: 580 N.m).
⑸ Connect the lower rotating platform with frame through pin shaft, and lock the split pin.
⑹ Have the oil pipes and temporary cables well connected.
⑺ Hoisting the frame and lower rotating platform to the tower, and fasten them with
high-strength bolts. The direction of cylinder of frame should be same as that of tower step.
⑻ Check if the two wheels are on the diagonal, and then turn the adjustable bolt to adjust the
position of wheels, making it be against the main chord of tower. The extending lengths of two
adjustable bolts of each wheel should be same in order to ensure the idler wheel to be on the
diagonal. In addition, all the 16 adjustable bolts of 8 wheels should have the same length in order
to ensure the main chords have the same distance between frame and tower. The final 16
adjustable bolts should stand back by 1 to 2mm in order that the gap between the wheels and main
chord of tower is kept 2 to 3mm.
4. Installation of Upper Rotating Platform
⑴ Fix the slewing mechanism onto the upper rotating platform tightly with bolt.
⑵ Hoist the cab onto the upper rotating platform, and connect them by bolt.
⑶ Connect the cables.

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⑷ Install the parts of upper rotating platform onto the slewing ring, and tighten them by the
high-strength bolts (M22X185, prestresssing moment: 580 N.m)
5. Installation of Cap Head

Fig. 10: Schematic Diagram of Installation under Cap Head

⑴ Assembly the ladder of cap head and guard ring, and install them onto the cap head.
⑵ Hoist and connect the platform with the cap head.
⑶ Couple the arm tie at the top of cap head, two pull bars of counter jib and two pull bars of
boom through pin shaft, and lock the split pins.
⑷ Hoist and connect the cap head with the upper rotating platform through pin shaft, and lock the
split pin.
6. Installation of Counter Jib
⑴ Firstly, install the hoisting mechanism, switchboard and guard rail in the counter jib in turn,
and then fasten the. Secondly, connect the cables. 。
⑵ Connect the rest pull bars with the counter jib through pin shaft, and lock the split pin.
⑶ Firstly, lift the counter jib horizontally (mark the hoisting point for later tower disassembly).
Secondly, direct the counter jib with the pulling rope, and connect the counter jib with cap head
through the pin shaft. Thirdly, lift the counter jib slightly, and connect the pull bars through pin
shaft, and lock the split pins. Finally, keep the counter jib horizontal and have the pull bar
stressed.
⑷ Hoist and install two counter weights into the frame of counter jib in turn, and fasten the part
where the counter weights are near the cap head (See the Fig. 11: Schematic Diagram of
Installation of Counter Jib).
★ Install two counter weights first before installing boom while the rest four
ones must be installed after the boom installation. Otherwise, the tower may
collapse due to the too heavy or too light weight of counter weights.

19
 Fig. 11: Schematic Diagram of Counter Jib Installation
7. Hoist and Install Boom
⑴ Couple the six booms through the pin shaft, and lock the split pin.
⑵ Fix the trolley into the root of boom.
⑶ Install the derricking mechanism onto the boom, and wind the derricking rope.
⑷ Couple the pull bars of boom, transition plate, arm tie and hoisting point plate of boom through
the pin shaft, and lock the split pin. Wind the iron wire through the upper chord pipe of boom.
⑸ Hoist the assembled boom horizontally (mark the two hoisting points of boom for the later
tower disassembly). Direct the boom by the pulling rope. Hoist and install the boom in the
transition section, couple them through the pin shaft, and lock the split pin.
Notice:
(1) Before hoisting the boom, tie a directing rope at its end in order to control its direction.
The directing rope should be easy to be dismantled.
(2) Check the position of hoisting cable. It shall be installed either before the section point of
upper chord of boom or after that, but never in the middle of the web member (See the Fig. 13).
At the hoisting point, do not have the rope pushed against the tie bar.

Directing Rope

Fig. 12: Schematic Diagram of Boom Hoisting

Correct Correct Wrong

Fig. 13

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⑹ Lift the boom by a certain angle, release the tying iron wire, couple the tie bar through the pin
shaft and lock the split pin. Lay the boom flat slowly.

Fig. 14: Schematic Diagram of Boom Installation

⑺ Hoist and install the rest four counter weights onto the counter jib.
8. Wiring for Electric Parts and Installation for Accessories
（1） Shut off power and temporary wires to finish the wiring for all electric parts of the
machine (see the principle and wiring diagram of electric parts). After wiring, test all the
ground isolation resistances. Finally, turn on the power supply.
（2） Modulate all mechanism and conduct commissioning with no load. Check to see if all
technical requirements are satisfied.
（3） Wind the lifting rope, install the lifting hook and fasten it with rope clamp.
（4） Finish the installations of all accessories.
9. Lifting Standard Section (Fig. 15)
（1） Check if the parts in tower crane have been correctly assembled, and if the bolts, pin
shafts and split pins are reliably fastened.
（2） Conduct the test runs such as hoisting, slewing and derricking.
（3） Check the hydraulic climbing system:
A. Check the oil level of oil tank (by observing the oil window). Check whether the oil goes bad
or is polluted or not. If it is, replace it by new one.
B. Check whether any foreign substance enter the pipe adaptor or oilway. If it is, clean them
carefully.
C. Check if the type of hydraulic oil is correct (normally, use the YA-N32 one; in the case of low
temperature, use the YC-N32 l one).
D. Check if the turning direction of motor is in line with the one required by the hydraulic pump.
E. Check the hoisting pressure and adjust the overflow valve. The normal hoisting pressure shall
be 20MPa. If the oil pressure exceeds this value, check if there is any trouble in the system.
（4） Before hoisting, run the hydraulic system under no load, and then operate the manual
reversal valve. Make the hydraulic cylinder telescopic several times and discharge air from the
system. Check if the parts are running freely. After that, the operation of hoisting is allowed.
★ It is forbidden to turn the pressure-adjusting bolt of safety valve when
hoisting and adding sections. In case of failure, stop the hydraulic cylinder, and

21
then remove the troubles immediately to prevent it from being supported for
long time.
（5） Adjust the boom, making it to be obverse (in the same direction of lead-in beam). Hoist
the standard section till it is under boom at the front of tower crane. Hoist and place the standard
section on the rolling shaft of lead-in beam (the stepping direction should be same as that of
tower). After that, demount the eight high-strength bolts (M30) between the lower rotating
platform and standard section. Place the axle heads at both ends of climbing beam into the
stepping slot. Run the hydraulic system so that the piston rod is extended by 20 to 30mm, and
once the lower rotating platform and standard section are just separated, the hoisting will be
stopped. Hoist another standard section, getting it move outside from the boom root. The trolley
will stop when the gap between the eight wheels and tower is uniform (about 2mm). The driver
should observe it carefully and mark this balance point.

Fig.15 A Fig.15 B Fig.15 C

Fig.15 D Fig.15 E Fig.15 F

（6） Go on run the hydraulic system till the piston rod is extended by 1.2m, and then stop it.
Place two climbing insertion shafts on the two steps. Control the reversal valve to contract the
piston rod slowly till the climbing insertion shaft touches the step firmly. Continue contracting the
piston rod till the axle head of climbing beam can be placed in the two step slots. After that,
control the reversal valve to extend the piston rod by 1.25m or so (draw out the climbing insertion
shaft after extending the piston rod to some extent). At this time, it is possible to lead a standard
section to the upper part of tower. Bring the standard section suspending in the outside of lead-in
beam to the frame, and then fix them with eight high-strength bolts. Control the reversal valve to

22
contract the cylinder till the upper and lower standard sections and lower rotating platform firmly
touch the standard section. Fasten the eight high-strength bolts that connect with the standard
section. Install four high-strength bolts in the four corners of lower rotating platform and standard
section respectively. Finally, draw out the roller shaft.
（7） Control the reversal valve to get back the piston rod, and prepare for hoisting and adding
the next section.
（8） Repeat the process as mentioned above to add sections till reach the height as required.
Couple the lower rotating platform and standard section through eight high-strength bolts. Thus,
the installation of tower crane has been finished. After testing, it can be put into service.
（9） During hoisting, if the connecting bolts that connect the lower rotating platform and new
standard section with the tower are not tightened, it is forbidden to conduct any operation like
slewing. In the case of wind with a magnitude of four, the hoisting must be stopped, and all the
connecting bolts should be well tightened.
（10） If the service height exceeds the basic height (27m), the tower should be anchored with
the structure at every 18m (see the Fig. 16). In the case of anchorage, the free height between the
top layer and the boom root should not exceed 20m. But it is allowed to start to add sections at
20m. After hoisting, anchorage must be down
In the case of anchorage, four anchorage devices can be used. Their function is to fix the
tower on the structure to ensure the tower is stable. The anchorage devices can lock the main limb
of tower. The stretching screw can be used to adjust the length of stay bar. The stay bar connects
the anchoring seat of structure through the pin shaft. When connecting with the anchoring seat
through the pin shaft, the structure will bear the force from some horizontal load of tower crane,
so the stress under tower crane will be reduced.
Bearing capacity for foundation and anchoring point: when install the tower crane, the
bearing capacity for the anchoring point of structure and the foundation of tower crane should be
measured, and should not exceed the following values.
Load for Foundation
Description Unit Value
Vertical Load KN 270
Horizontal Load KN 55.5
Overturning Moment KN.m 595
Tensional Moment KN.m 86.6

Chart 6: Load for Anchoring Point of Structure

Load for Anchoring Point Ⅰ Ⅱ Ⅲ Ⅳ
Horizontal Tensile Force or Stress (kN) 39 51 63 74
We only provide the anchorage devices with the anchorage distance of 2.846m for
customer’s order. For the one above this specification, please contact us for the special order.

23
 Fig. 16: Schematic Diagram of Anchorage
10. Notices during Installation:
（1） Check if the connecting bolts are fastened.
（2） Since the bolts used for different parts have different quality and size, it is required to
select the proper one suiting for the part.
（3） Before installing the counter jib and arm tie of boom, check if the adaptors are tightened
reliably and whether the arm tie is damaged or not.
（4） When installing the boom and counter jib, the lifting rope and hooks must fixed with
rope clamps or shackles to prevent from falling from hook when the angle of rope is too large.
（5） Strain the rope of trolley to ensure no slip in the case of load.
（6） Before installing counter jib and boom, it is required to conduct the trial slewing.
3.3 Adjustment of Limiter
1. Adjustment of Moment Limiter:
A. Experiment
The moment limiter does not work when hoisting the load of 0.76t at the max. working
radius (38m). Put down the load, and then hoist a load of 0. 836t at the min. speed, the moment
limiter start to work (power off), and hoisting is stopped (repeat the experiment three times).
B. Experiment of Fixed Load and Change in Radius
Hoist the load of 3t at 2.5m and change the radius to 11.42m, the moment limiter does not
work. Reset it and start with the min. radius. Increase the radius to 12.5m, the moment limiter
starts (power off). At this time, the radius can not be increased anymore (repeat the experiment
three times).
24
2. Adjustment of Weight Limiter:
Experiment of Max. Rated Lifting Capacity
（1） At the min. radius, hoist the max. rated load of 3t at low speed, the weight limiter does
not work and the load continues being hoisted. Put down the load, and re-hoist a load of 3.3t, the
weight limiter starts to work (power off). At this time, the load can be not hoisted any more
(repeat the experiment three times).
（2） Within 11.42m, hoist the rated load of 3t at low speed, the weight limiter does not work
and the load continues being hoisted. If hoist it at high speed, the limiter start to work (power off).
At this time, the load can not be hoisted any more (repeat the experiment three times, and fix the
limit switch).
3. Adjustment of Height Limiter:
There are two sensitive switches on the height limiter. The lower one connects with the rising
control circuit while the upper one connects with dropping control circuit.
Run the hoisting mechanism to lift the hook. When the top of hook reaches to 1000mm
under the boom, the limiter can stop the hoisting immediately.
Run the hoisting mechanism to drop the hook to extreme, control the upper switch to shut off
the dropping-control circuit.
Repeat the above process three times until every thing is all right.
4. Adjustment of Radius Limiter:
⑴ There are two sensitive switches on the radius limiter. The lower one connects the
outward-derricking control circuit while the upper one connects inward-derricking control circuit.
⑵ If the radius limiter works, after the trolley stops, the least distance between the end of
trolley and the buffer unit should be 200mm.
5. Adjustment of Slewing Limiter:
⑴ The slewing limiter should be installed on the support at one side of the upper rotating
platform. Remove the split pin at the input shaft of limiter, start the tower crane to make the boom
turn forward and clockwise by 5400, and then stop it. Adjust the limiter to keep the sensitive
switch at power-off state.
⑵ Refix the split pin of limiter, start the tower crane to make the boom turn anticlockwise by 300
to 500, and then stop it. Check if the slewing angle is correct.
⑶ Have the tower crane turn backward, with the turning angle of 5400 against the forward
direction. If the angle is not proper, adjust the sensitive switch of limiter till it is all right.
★ The tower crane is forbidden to work in the state of no safety device or that
the safety device does not work.
3.4 Preparation before Service
Before the service, it is required to check and install the tower crane, and test the
mechanisms and safety devices so as to avoid affecting the normal working order and to prevent
safety accidents, by means of which the tower crane can run safely.
Check the following items:
Item Content
25
Foundation Check if the foundation bolts are well fastened.
Tower Check if the bolts of standard sections are well fastened
Check if the platform and rail are well coupled and fastened;
Climbing
Check the connection between climbing frame and lower revolving table;
Frame
Check if the hydraulic system is well installed and normally adjusted
It is forbidden to place lubricants, oil cotton yarns and other combustible materials
in the cab;
Cab
Check if the cab and upper revolving tower are reliably connected;
Check if the electric cables run in good condition.
Upper and
Lower
Check if the bolts are well fastened.
Revolving
Tables
Check if the boom and the connecting board of counter jib are well installed, and
Cat Head make sure that the hoisting rope is correctly winded;
Check if the platform, access ladder and rail are well connected and fastened.
Check the installation for counter jib and rail;
Make sure there is no foreign substances;
Counter jib
Check the installation for hoisting mechanism;
Check if the counterweight is well fixed.
Check if there is any defect that affects the service of hook block;
Lifting
Check if the specification and type of hoisting and derricking ropes meet the requirements;
Device
Check the abrasion condition of rope.
Check the installation and running of each mechanism;
Check if the gaps of brakes of the mechanisms are properly adjusted, and if the friction sheet
Mechanism
needs to be replaced or not;
Check if the head of each wire rope is loose or nor.
Check if each safe & protection device is well adjusted;
Safety Device
Check if all access ladders, rails or platforms are well installed and fastened.
Check if all bolts, pin shafts and split pins are reliably fastened;
Others
Check if all bearings, pulleys and mechanisms are well lubricated.
4. Dismantlement of Tower Crane
The tower crane is disassembled in the reverse sequence of assembly. Since the tower crane
is normally disassembled when the project is basically completed or after being left unused for
long time, the technical state and reliability might not be satisfactory. Therefore, much importance
shall be stressed to the preparation and process of tower’s disassembly. The disassembly can not
be conducted until careful inspection and thorough preparation are made.
(1) Before disassembly, it is required to check all mechanisms, especially the hydraulic climbing
mechanism, and see if the hydraulic oil goes bad, all the bolts and baffles of pin shaft are in order,
and if the parts under stress are in good condition. The tower can be disassembled only when
26
everything is in good condition.
(2) Rotate the boom to the lead-in beam of standard section in order to position the slewing
electromagnetic brake.
(3). The area for disassembling tower should have no obstacles that affects the disassembly.
(4). Demount the eight bolts that connect the top standard section and lower rotating platform.
Open the hydraulic station to extend the piston rod to the extreme and have the axle head of
climbing beam drop in the corresponding step of standard section, with itself slightly lifted in
order to separate the interface of the upper standard section and lower rotating platform. At this
time, the hoisted standard section is moving outward from the root of boom. The trolley will stop
when the gap between the guide wheels of climbing frames (front and rear) and tower is about 1.5
to 2mm. The balance place should be marked.
(5) Fix the roller shaft on the lead-in beam and connect it with the demounted standard sections.
Remove the eight connecting bolts between the upper and lower sections. Go on controlling the
reversal valve to extend the piston rod outward in order to have the interface of 2nd section
separated by 50mm. Push out the standard section at the top along the lead-in beam.
(6) Firstly, control the reversal valve to contract the piston rod. Meanwhile, push the climbing
insertion shaft to the climbing frame till it is gradually across the step. Secondly, lift the climbing
beam from the step slot. Thirdly, control the reversal valve to extend the piston rod till the axle
heads at both ends of climbing beam reach the next step slot, with itself lifted by 50mm to
100mm，Fourthly, draw out the climbing frame from the climbing insertion shaft in order to keep
the climbing frame dropping.
(7). Control the reversal valve to contract the piston rod till the lower rotating platform touch the
standard section firmly, with the each corners fixed by a high-strength bolt.
(8) Hoist the standard section with the hook and place it on the ground; then hoist the standard
section suspending under the lead-in beam, and finally drive the trolley to the balance point.
(9) Remove the four connecting bolts under the lower rotating platform, and repeat the processes
(5) to (8) to demount the standard sections one by one. Regarding the tower crane with anchorage
device, the anchoring frame should not be demounted too earlier. The anchorage device can be
demounted only when the lower part of climbing frame has been close to the anchoring frame.
(10) Dismantle the hook block; wind the lifting rope around the drum; remove the cables form the
boom and counter jib; and then disassembly the counter weights inside the chamber to prepare
for dismantling the boom.
★ Remove four counter weights only. Otherwise, the tower may collapse due to the too
heavy or too light weight of counter weights.
(11) In the former hoisting point (as marked before) where install the boom, lift the boom 10° to
20°. Demount the pin shafts between the 1st section and 2nd section of the front and rear tie bars
respectively. Fasten the two tie bars on the boom with the iron wire. Fix the trolley at the root of
boom. Keep the boom horizontal, demount the pin shaft at the root, and lay down the boom on
ground.
★ Before demounting the pin shaft at the root of boom, connect the horizontal web member

27
at the root of boom with the transitional section through a rope. This can prevent the
counter jib from tilting after the removing the pin shaft because of the wrong hosting point
of counter jib, which may cause collision.
(12). Remove the rest two counter weights on the counter jib. In the former hoisting point (as
marked before), lift the counter jib by 10° to 20°. Demount the pin shafts between the 1st section
and 2nd section of the two tie bars respectively. Fasten the two tie bars on the counter jib with the
iron wire. Keep the counter jib horizontal, demount the pin shaft at the root, and lay down the
counter jib on ground.
★ Before removing the pin shaft at the root of counter jib, connect the horizontal web
member at the root of counter jib with the transition section through a rope. This can
prevent the counter jib from tilting after the removing the pin shaft because of the wrong
hosting point of counter jib, which may cause collision.
(13) Remove all the pin shafts connecting the cap head and upper rotating platform, and place the
cap head on the ground.
(14). Dismantle the cab’s electric cables which have not removed. Remove all the bolts
connecting the upper rotating platform and slewing ring. Use the truck to place the upper rotating
platform, cab and slewing mechanism on the ground together.
(15). Demount the oil pipe connecting the cylinder and hydraulic station. Place the climbing beam,
cylinder and hydraulic station onto the ground. Draw out the lower rotating platform, slewing ring
and frame from the standard sections, and drop them on the ground.
(16). Demount the stay bars, standard sections, base section and basic frame in turn.
(17). On the ground, demount the connecting bolts, pin shafts and electric parts which haven’t yet
disassembled.
(18). Tidy up the structural parts and elements according to the list, and sort and keep them
5. Operation, Repair and Maintenance
The tower crane is controlled through the control console in the cab installed in the upper
part of tower crane. The cab can provide pantoscopic vision. The process of hoisting should be
always able to be watched by the operator. The operation mechanisms should be flexible, reliable
and be furnished with safety & protection devices such as the weight, moment and height devices
to ensure the safe running.
The operator should estimate the lifted load and working radius precisely.
Before the tower crane is put into service, it is required to check and modulate it carefully.
The tower crane should be furnished with reliable grounding devices with excellent
performance.
5.1 Safe Operational Regulations:
1. It is required to comply with relevant provisions under the Operational Rules of Tower Crane,
for example, drivers and hoisting operators must pass the examination made by the safety
inspection department at provincial level and are awarded with qualification certificates.
2. The tower crane shall be taken care of by the personnel specially appointed. The driver should
have received professional training and have relevant certificates issued by provincial security

28
 inspection department. Driving without certificate or after drinking is forbidden. One who
does not install, repair and drive the tower crane shall never climb on the tower crane. After
cutting off of the main ground power, it is required to check whether the metal structure of
tower crane is power on with a test pencil, and the personnel can take the stair only after the
security test.
3. Before using, daily and routine maintenance shall be conducted according to the instructions,
reliability inspection shall be carried out to all security protection devices, if not met the
requirements, don’t carry out the operation.
4. The driver shall check the electric current and voltage of the tower crane, if not met the
requirements, don’t carry out the operation.
5. The tower crane should be frequently inspected, for example, check if the bolts are loosened,
the running is normal, roller and rope are in good condition, the end of rope is compacted, the
lubrication parts are lack of oil, and so on. If there is any problem, dispose of it before the
operation.
6. During the operation, irrelevant person is forbidden to walk into the operation area, and
anyone shall be forbidden to stand under the boom.
7. During the operation, special personnel shall be appointed to contact with the driver or to
guide the hoisting work (interphones shall be provided by the user).
8. The driver shall give the alarm when hoisting heavy goods over the superjacent air space over
any personnel, and shall keep concentrated in mind during the whole operation.
9. It is forbidden to work with overload. The driver must operate the tower crane in accordance
with the Technical Performance Chart and the Lifting Performance Curve. It is forbidden to
operate the tower crane after removing the safety devices. The tower crane should not engage
in the work such as slewing and hoisting until the connecting bolts are fastened.
10. The tower crane shall neither be used to pull or hoist heavy goods in an inclined manner, nor
to pull state or conduct other similar operations, nor to hoist goods without knowing the exact
weight, nor to hoist the objects as frozen in the ground in winter.
11. In the mechanism with forward and inverse rotation, when inverse rotation is needed, the
motor must be stopped, and the inverse switch can be started up only when the inertial force is
disappeared. It is forbidden to start the forward and inverse switch suddenly.
12. Strictly follow the operation sequence. In the mechanism with fast and slow gears, it should
be from slow gear to fast gear, and when stopping, the order shall be from fast to slow one by
one. Operation crossing over gears shall be forbidden, and the elapsed time from one gear to
the next shall be about 2-4 seconds.
13. Before the rotation action of the boom is completely stopped, never use the rotation brake.
14. Never use the hook of tower crane to carry persons.
15. The load of the maintenance hoisting railing on the trolley shall not exceed 100kg, and during
the operation and maintenance, the number of persons in the hoisting railing shall not exceed
two.
16. During the hoisting operation, people shall not stand on the ladder or platform of the tower

29
 crane, and the equipment shall not be modified or maintained.
17. If temporary troubles appear on the tower crane and maintenance is needed, the main ground
power must be cut off. Inspection and maintenance with power on is not permitted.
18. When the hoisting hook is landed, the craning rope shall not be loosened any more.
19. In the filed with multiple tower cranes, the space interference shall be prevented.
20. The tower crane shall avoid high-voltage power distribution wire, and when the hoisting hook
conflicts with ordinary power line or illumination line, security measures shall be conducted
before operation.
21. Before getting off work, the driver must finish the following work:
(a) Raise the hook over the height of surrounding buildings, or make the hook be away from this
range, and set the trolley at a place 15-18m away from the tower body center.
(b) Put all operational switches at the zero position, cut off the indoor main power, lock the door,
and cut off the main ground power after getting off the tower crane.
22. When the hoisting mechanism hoists heavy goods at low speed, the total running time with
full load shall not be too long, generally not exceeding 2 minutes in every 10 minutes, for
avoiding the burnout of motor.
23. When the wind's magnitude is above 4, it is forbidden to dismantle and install the tower crane;
if there is thunder storm, rainstorm, heavy fog or wind with a magnitude of above 6, the tower
crane is forbidden to be operated; and when being informed by the weather forecast that the
wind will be of magnitude IV, the tower crane should be reinforced by wind rope.
24. Good measures shall be taken for the grounding of tower crane. The grounding resistance
should be no more than 10Ω. In the condition of thunder storm, it is forbidden to run the tower
crane.
25. Sufficient illumination facilities must be provided during lighting operation or erection.
26. It is forbidden to storage flammable and explosive articles. Prevent fire hazard when get warm
during winter.
27. It is not allowed to run the tower crane if there is any problem. Electric problems shall be
handled by two professional personnel.
28. The normal working temperature of tower crane is in the range of -20℃ to 40℃.
29. If the tower crane needs to be reinstalled after overhaul or being transferred to a new site,
check if all the connecting elements are reliable, the transmission parts has been interfered by
others, the metal structures has been damaged, and the electric equipment and safety &
protection devices are reliable. If there is no problem, the equipment can be installed or used
according to this User’s Manual.
30. If the power supplied to tower crane is cut suddenly, examine the reason firstly. If there is no
power for a long time, it is required to take measures, laying down the loads on ground slowly
(manually control the electromagnet of hoisting brake).
31. If the brake is out of order during operation of tower crane, firstly, the driver shall be sober in
mind; secondly, send out the warning signal; thirdly, transfer the loads to spacious no-person
area. Lay down the loads on the ground by means of controlling the electric motor. It is

30
 forbidden to let it slip down freely because of its own gravity.
32. In the range of slewing radius, if there is a structure or high-voltage line higher than the tower
crane, it is required to fix the slewing mechanism and forbidden to have tower crane to slew
freely in the state of service in order to avoid the boom’s collision against the structure.
5.2 Electric System and Operation
(I). Introduction
The electric system is used for the transmission, control, illumination devices, various safety
& protection devices and alarm devices.
The power supply for tower crane: 50HZ, 380V (AC). The error of voltage is 5%.
The crane’s power cable extending to the electric control box supplies power to various
mechanisms through the QF1 air switch. The hoisting, slewing and derricking motors can be
controlled in the cab.
In order to ensure the safe use of tower crane, the machine is furnished with "zero"
protection device, height limiter, derricking terminal (front/back) limiter, weight limiter and
moment limiter (for overload). The air switches are used for protecting the lifting motor, slewing
motor and derricking motor from overload and short circuit.
(II). Illumination
The illumination for tower crane uses the power of 220V AC. The illuminating lumps are
provided in the ends of boom, cat head and tower. The driver can control the lumps in the cab
which has a standby socket.
(II) Notices:
(1) The hoisting mechanism is directly started by the 3-speed motor. So the power supply is
required not to exceed ±5%.
(2) When changing the speed of main motor, it is required to accelerate it step by step, rather than
to change it from zero speed to high speed directly. Meanwhile, reverse brake is not allowed.
(3) When adjusting the speed-adjusting motor, it should be correctly wired according to the wire
diagram.
(4) For ensuring the tower crane to work in order, it should be reliably grounded (repeated several
times). In addition, the housings of motors, electric parts and main hoister should be also
grounded to avoid creepage.
(5) After hoisting, the hoisting power supply must be shut off.
(6) All motors and electric parts should be frequently checked and repaired. As for the main motor,
it is proposed to often observe the condition of temperature rise.
(IV) Installation
（1） The slewing limiter should be installed beside the slewing mechanism. Ensure it to
normally mesh with the slewing gear ring.
（2） The control box and control console should be installed in the cab. In case of special
condition, the control box can be fixed on the counter jib, but waterproof treatment should
be done.
（3） The height limiter should be installed round the drum of hoist. During installation, the

31
 distance between the fluted disc and drum should be appropriately adjusted in order to
ensure good junction and separation. The movable nut on leadscrew should be adjusted
according to the height of hoisting hook, keeping the contact of limit switch to work at the
max. height. The limiter should be water proof.
（4） The illuminating lump for boom should be installed at the end of boom. It should be red
and water-proof.
（5） The illuminating lump for cap head should be installed at the top of cap head. It should be
red and water-proof.
（6） The illuminating lump for tower should be installed under the cab. It should be water
proof.
（7） The trolley limiter should be installed as per the max. radius and min. radius. It should be
water proof.
（8） The installation of moment limiter shall be referred to the Description of Product.
5.3 Repair, Maintenance and Lubrication of Tower Crane
In order to operate the tower crane safely and efficiently, the tasks such as maintenance,
repair and lubrication should be completed carefully.
5.3.1 Repair and Maintenance
1. Replace all the oil every 3 to 4 months due to the frequent consumption of oil in the reducing
unit. When replacing the oil, the inside should be cleaned. The oil type and volume shall be in
accordance with the prescriptions under the User’s Manual.
2. If 5% rope has been broken or 5% surface diameter of rope is worn, it is required to be
replaced by new wire rope.
3. The climbing mechanism shall make use of the hydraulic system. Frequently add butter into
the nozzle on the supporting pin of cylinder and piston rod.
4. The climbing pulley of cat head, derricking pulleys of the boom, pulley and idler wheel of
trolley and pulley of hook block shall be lubricated with oil every month.
5. The slewing ring must be lubricated with calcium lubricant before use. New calcium lubricant
shall be filled in it every 3 to 4 months.
6. Oil shall be added in the closed roll bearing or butter nozzle such as derricking drum bearing,
plane ball bearing of hoisting hook and bearings of all electric motors after completion of each
works.
7. Make adjustment on the brakes of hoisting mechanism, slewing mechanism and derricking
mechanism since they are often worn during service. If their performances fail to meet the
requirements due to abrasion, adjust or replace them.
8. The hoisting rope and derricking rope will be extended after use, so it is required to adjust the
height limiter so as to have them stressed again.
9. All the electric switches and contact points shall be checked frequently. If they have loose
contact with others or are out of order, repair or replace them in time. Particularly, the switch
of limiter is not allowed to be out of order.
10. When the tower crane has been used for two weeks, the elements should be fastened such as

32
 connecting bolts, clamping boards of ropes, and rope clamps.
11. During service, the articulating points and supporting ears that bear much force shall be often
checked, such as the root of boom and counter jib, articulating points at arm ties of boom and
counter jib, and the pulley base. If any crack is found in those places, stop working and repair
it in time.
12. Replace those elements that are worn due to long service and improper maintenance.
13. The slewing limiter shall be readjusted every time if the tower crane is transferred to another
site, otherwise, the tower crane can not turn clockwise and anticlockwise by 1.5 circles
respectively.
14. All components shall be dedusted and painted if the tower crane has been used for a project
period.
15. Keep the complete equipment clean frequently and clear dusts timely.
16. Check the oil volume of each reducer and timely fuel it with oil.
17. Much attention should be paid to the iron rope and see if it is loose, broken or frayed. Replace
it timely when it fails to meet the requirements
18. Check the efficiency and gap of brake and ensure that it has reliable sensitivity.
19. Check various joints of bolts, especially the standard sections. Refasten them after being used
for some time.
20. Check if the press board of rope or rope clamp is loose. If it is, fasten it timely.
21. When discarding the ropes, drums, pulleys and hooks as useless, the GB51144 and other
relevant standard shall be strictly followed.
22. Check the metal elements in the rods, web members and welded seam to see if there is any
crack, especially the area where paint falls off. It is most dangerous that the paint is stripped
off by 45°. So it is required to find out the reasons and handle with it in time.
23. The overall machine and metal mechanism shall be dedusted or painted after being put into
service for a project.
24. Make sure that the anti-falling devices of hoisting hooks are safe and reliable.
25. Observe various electric contacts and see if they are oxidized or burned. Repair or replace
them if they are in the condition of poor contact.
26. Various limit switches and buttons shall be all right. Replace the components if they are rusted
or damaged.
27. The insulation between switches and switch board must be in sound condition, with the
insulation resistance no less than 0.5MΩ.
28. Check if bolts fastening various electric components are loose and if cables and other wires
are broken, and remove these troubles if really happen
29. As for the care and maintenance for the accessory mechanisms, please refer to Section 2.1
5.3.2 Lubrication
1. Key parts to be lubricated include the hoisting mechanism, derricking mechanism, slewing
mechanism, slewing bearing, hydraulic system, climbing frame, wire rope, hoisting hook blocks
and trolley.

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 Lubrication Method
No. Part Place Need Lubrication Type of Lubricating Grease
& Cycle
Boil oil during
Lifting rope; derricking
1 Rope Graphite calcium lubricant large and middle
rope
repair
Gearbox of hoisting Middle-duty industrial gear
mechanism; oil
Add oil every 240
Reducing unit of Summer: N220 ， Winter:
Reducing hours’ working, and
2 slewing mechanism N150
unit replace it every
Reducing unit of
1500 hours.
derricking Lithium lubricant
mechanism
Roll bearings of
Add oil every 160
reducing unit;
hours’ working, and
3 Roll bearing Drum bearing; Calcium lubricant ZG-2
clear it every half
Thrust bearing of hook;
year.
Slewing support
Winter: Calcium lubricant
Bearing of ZG-2 Replace it every
4 All motor
motor Summer: Calcium lubricant 1500 hours.
ZG-5
Winter: Calcium lubricant
Fixed and
Hook, pulley of trolley ZG-2 Replace it every
5 stationary
and guide wheel Summer: Calcium lubricant 240 hours.
pulleys
ZG-5
Lead-in wheel, wheels
6 Wheel Calcium lubricant ZG-2 Before hoisting
of climbing frame
Add cleaning oil
every 200 hours’
Hydraulic working, and
7 Oil tank Dense hydraulic oil No.40
station replace it every
2400 hours.

+20℃ ～ +45℃: No. 20

Add cleaning oil
mechanical oil
every 160 hours’
0℃ ～ +20℃: No.10
Lifting hydraulic push working, and
8 Brake Transformer oil
brake replace it every 700
-15℃ ～ 0℃: No. 25
hours.
Transformer oil
-30℃～-15℃: Meter oil
2. Regular Lubrication
I. The new equipment (or mechanism) shall be lubricated in the first 200 hours. 。
II. Use oil gun to fill oil into the articulating points without oil nozzle, such as the latch, jaw,
connecting pin, and chain axle etc.
III. Check the oil level; keep all elements clean during oil draining and avoid staining the oil.

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IV. The oil volume must reach the lower limit of oil level.
6 Main Failures and Solution
No. Failure Reason Solution
The brake gets into The braking moment is too small; Adjust the pressure of brake
skid, which causes the surface of brake wheel is stained spring; clear the oil stain and
the hook to fall with oil and brake time is too long. adjust the gap of brake shoe.
1
down and the
trolley to move
outwards.
The brake time is too short. Adjust the gap of brake shoe in
The brake load is
The gaps between two sides of brake order to make it in balance or
2 impacted too
shoe are not uniform. increase the stroke of hydraulic
violently.
push bar.
The brake gets hot The gap of brake shoe is too small Increase the gap of brake shoe
3 and smokes during
running.
The temperature of The lubrication oil is insufficient or Adjust the oil volume (increase
4
reducer is too high. too much. or decrease)
The main reason is due to the
The temperature of excessive or insufficient lubricant; Replace the lubricant and
5 reducer bearing is Poor quality of lubricant; adjust the bearing gap, or
too high. The axial gap of bearing is not in replace the bearing.
line with requirements.
The abutted surface at connecting Replace the seal ring.
6 Reducer leaks area is not well sealed; or the seal
ring of bearing end is damaged
a. The efficiency of oil pump Repair or replace the damaged
decreases due to the abrasion of oil parts;
pump. Add sufficient oil or clean the
b. The oil in tank is insufficient or oil filter.
the oil filter is jammed.
Climbing is too
7 c. The manual steering valve rod is
slowly.
seriously frayed against the valve
hole.
d. The seal is damaged at piston rod
of cylinder, which causes the
internal leakage.
To be continued
No. Failure Reason Solution
a. Serious internal leakage is found Repair or replace the worn
Climbing is weak
8 in the oil pump. parts;
or failed.
b. The pressure set for overflow Adjust the pressure;
35
 valve is too low. Clean the hydraulic valve.
c. The manual steering valve core is
seriously frayed.
d. Overflow valve is held.
Noise and vibration
occur during
9 Oil filter is jammed Clear the oil filter
climbing and
pressurization
The climbing
The turning of motor does keep with
10 system does not Change the turning of motor.
that of oil pump.
work.
1. The air in piston rod of cylinder is Exhaust air;
not exhausted. Adjust the guide wheel.
11 Oscillate climbing
2. Obstacles exist in guide
mechanism.
1. The hydraulic lock of cylinder end
The climbing
is out of order. Remove the malfunction;
12 mechanism with
2. The seal of piston rod of cylinder Replace the sealing elements.
load falls by itself.
is damaged.
1. The operating handles are not set
at zero. 1. Reset the handle.
The chief initiation
2. Fuse wire of electric wire is burnt 2. Change fuse
13 button is out of
out. 3. Repair or replace the
order.
3 ． Bad contacts for starting button buttons.
and stop button
There is over current in the hoisting 1. Check if the climbing brake
motor, so the circuit breaker is is open and the over current
closed due to the over current; value is changed;
Tripping during The capacity of transformer in the 2. Replace the transformer or
14
hoisting starts worksite is not sufficient; thicken the electric cable.
Or the size of cable from
transformer to tower crane is not
enough.

To be continued
No. Failure Reason Solution
The hoisting 1. Wrong wiring. 1. Check the wiring diagram.
15 mechanism can not 2. The fuse wire is burnt out. 2. Check if the fuse wire’s
start 3. Such failures exist in the motor as capacity is too small. If it is,
36
 short circuit between two phases of replace it by a larger one.
winding, grounding and break. 3. Measure the voltage of
4. The voltage of motor is too low. power grid.
5. The winding is wrongly wired. 4. Find out the short circuit by
6. The electromagnetic brake is not means of power supplies at
switched off. various speed. Restore the part
7. The load is too large or the where break occurs.
transmission is out of order. 5. Check if break or blockage
exists in voltage or winding.
1. The stator and rotor rub against 1. Check if the gap between
each other due to mechanical stator and rotor is uniform.
abrasion. 2. Readjust the concentricity of
The traction 2. Electric motor is not concentric motor and reduction gear.
mechanism has with reduction gear. 3. Clean the bearing and add
16
abnormal noise and 3. The gear box lacks of oil seriously more lubrication oil, replace
violent oscillation. or is damaged. the bearing.
4. Gears are frayed. 4. Replace the gear box.
5. Whistle is produced due to the 5. Shut off the power supply
running of two phases. for check and restore.
The bearing of 1. The bearing is burnt out.
1. Replace the bearing.
17 traction mechanism 2. The lubrication grease is
2. Add lubricant as required.
is too hot. excessive or insufficient.
1. The main lead and earth line are
The traction wrongly connected. 1. Find out the reason.
18 mechanism gets 2. Poor earthing 2. Keep the earthing in good
electrified. 3. The lead of motor is scraped when condition.
earthing.
Replace the spring of brake
Brake of traction 1. The brake moment is too small. since it is broken or does not
19 mechanism does 2. The clearance due to abrasion of work;
not work. friction pad increases. Exciting voltage is not
sufficient.
Slewing mechanism Check if there is any foreign Remove the foreign
20
can not be started. substance in gear. substances.

To be continued
No. Failure Reason Solution
The temperature 1. Load is too large 1. Measure the stator’s current
21 rise of motor of 2. Load is continuous and its and if it is more than rating
traction mechanism working condition does not meet the value, reduce the load.
37
 is too much or it requirements. 2. Run in line with prescription
smokes. 3. Two phases run. 3. Measure the current of three
4. Voltage of power supply is too phases and remove the failures.
low or too high. 4. Check the input voltage and
5. The winding of motor is correct it.
grounding or short circuit occurs 5. Find out reasons and restore
between two phases. it .
6. The gap of friction pad is not 6. Adjust the gap in accordance
correct. with requirements.
7. The time of brake and release are 7. Check the voltage of brake,
not correct. delay the running of break and
8. The ventilation of motor is remove the failure.
jammed, which results in 8. Keep it well ventilated.
temperature rise.
7. Attached Technical Material and Drawing List
1. User’s Manual for QTZ31.5 Tower Crane
2. Certificate of QTZ31.5 Tower Crane
3. Delivery List
4. Customer’s Advice Book in Terms of Product Quality, Installation and Use
5. Concrete Base Drawing, Counter Weight Drawing, Circuit Drawing
6. Others
8. Other Statement

Our company shall retain the right of changing the technical parameter,

overall size and design for our products, and we will not inform the customers

if there are changes.

38
 Φ10X350, 34pieces

39
Φ10X2350, 8pieces

±
40
Technique request
1.The loading ability of the soil quality that foundation descend to 0.2 MPa, if can not reach
to request must special handle the pit slot.
2.The foundation concrete is above for C30, and the reinforcing bar protect the layer to is
not smaller 50 mm.
3.The foundation center arrives the building 2846 mm.
4.Foundation top the surface should be neat, and the degree of its level flat surface is not
over and above 1/1000.
5.The concrete measures to 12.6 m3, foundation quantity is not smaller 29 T.
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