Chapter 1 Survey of Tower Crane

1.1 Survey
Thank you for choosing the product of Huaxia Group. Please read the Manual
carefully to know the tower crane well, rapidly install and correctly use it. Please follow
the methods and requirements of the Manual to handle the tower crane.
5810 tower crane is a new type tower crane jointly designed by our company and
Changsha Building Machine Academe according to the latest version of JG/T5037-93
Tower Crane Classification.
The crane is a multipurpose tower crane with horizontal jib, trolley radius-changing
function, top swing function and automatic rising function. The crane has the following
features:
1. Its functional parameters and technical indexes are leading in China and up to
international advanced level. Its maximum working radius is 58m.
2. The crane has the beautiful outline and is very popular to customers.
3. The crane has two working models: the anchoring model and the climbing
model. The hoisting height of the anchoring crane is 40m and that of the climbing one is
up to 140m through adding standard sections and supporting devices.
4. It has high working speed, good speed adjustment function and stable working
state. Its swing mechanism adopts planet reducer and its top-rising mechanism has
compact structure and high efficiency. They are easy to maintenance and safe to
operate.
5. It has reliable safety devices, which are mechanical and electrical devices and
are adaptable to bad outdoor environment.
6It has double-bar hanging jib with good rigidity and small weight. It has beautiful
figure and small wind resistance.
7The cab is installed separately with big space and visual field.
8It has no center collector ring so as to prevent from rain, short circuit and other
failure. It is easy for operate to go through.
For the above features, it is suitable for high civil buildings, bridges, workshops and
high wall buildings such as chimneys.

1.2 Safety Notice of the Manual

1.2.1 The Manual is only for usual installations. The installation under the following
conditions may cause damage of crane and casualty of workers:
A) The anchorage of the crane is not done according to the Manual;
B) The space between two cranes is less than the space in 2.4.4;
C) The hoisting height exceeds the stipulated height in the Manual;
D) The jib is not assembled according to the assembly method.
1

1.2.2 For the change of crane parts or renewal of relevant standards and criteria,
the crane may has small changes. We shall make complementary notice for the major
changes and shall not make that for minor changes. Please check the Manual with
parts nameplates and overall structure outline.

1.3 Main Technical Parameters

Please see Figure 1-1 for main technical parameters and see Figure 1-2 for parts
technical parameters.

Figure 1-1 Main Technical Parameters

Load Ratio

Hoisting Mechanism

M5

Swing Mechanism

M4

Traction mechanism

M4

HeightM

Max loadingt
Radiusm
Hoisting
mechanism

Ratio
Speedm/m
in
Hoisting
weightt

PowerkW

Swing Mechanism

Traction Mechanism
Top Rising Mechanism

Banlance Weight

Ratio

Anchor height

=2

Free standing
height
40

=4

40

80

58m jib

52m jib

46m jib

6
Max. Radius
Min. Radius
=2
8.5
40

140

58
2.5
80

4.25

=4
20

40

1.5

5.4

24

24

5.4

24

24

Speedr/min

0-0.6

MomentN.m

95

Speed(m/min)

20

40

Power(kW)

2.2

3.3

Speed(m/min)

0.55-0.7

Working Pressure(MPa)

25

Power(kW)

7.5

Length of Jib(m)

Banlance Weight(t)

58

14.2

Total Power(KW)

52
12.5
46
10.8
34.8(Excluding Top rising Mechanism Power)

WorkingTemperature()

-5-40
3

Figure 1-2 Technical Parameters of Main Parts

Hoisting Mechanism
Hoisting
Mechanism

Item
Rated Rope Tension
Wire rope
Model
drum
Rope capacity
motor
Model
Power
Rev

Unit
t
m
kW
r/min

Parameters
1.5
4V*39S+5FC-13-1770
340(4 layers)
YZTD225M3-4/8/32
24/24/5.4
1440/700/140

Radius mechainism

Radius mechanism
Item
Wire
rope

Unit
Model
length

46m
jib
52m
jib
58m
jib

Radius speed
motor model
Power
Rev.
Max radius Loading

parameters
7.7-NAT-6*19FC1570-ZS-GB8918
Wire
94
Wire
60
rope
rope
108
66
I
II

M
M
M

117

m.min
kW
r/min
T

40/20
YEZS132S-4/8
3.3/2.2
1440/720
6

72

Swing Mechanism

Swing mechanism
Item
Motor

Unit

Model
Power
Rev.
Model
Reduction Ratio
Output Torque
Output Speed

Reducer

Output Gear
Parameters

Kw
r/min
N.m
r/min

Pattenm

Parameters
YZR132m-4
22.2
908
XX4-100
157.5
10000
5.765
10

No. of Gear z
Modification coefficient x
Main Motor Ratio
Main Motor Rev

15
+0.5
1596.56
0~0. 6

58755

7010

14838

To Boom Root 14270

41190
To Slewing center 58000

40038

To Ground 39000

To Boom Root

Figure 1-3 TC5810 Tower Crane (Free Standing)

46m Hoisting Load Function DiagramForm 1-1

Rm

Qt

Rm

Qt

Rm

Qt

2.5
16.2
6.00

17

18

19

20

21

22

23

24

25

26

27

5.70

5.35

5.04

4.75

4.50

4.27

4.06

3.87

3.69

3.53

3.38

28

29

30

31

32

33

34

35

36

37

38

39

3.24

3.12

3.00

2.88

2.78

2.68

2.59

2.50

2.42

2.34

2.27

2.20

40

41

42

43

44

45

46

2.13

2.07

2.01

1.96

1.90

1.85

1.80

8.1.2 52 m Hoisting Load Function DiagramForm 1-2

Rm

Qt

Rm

Qt

Rm

Qt

Rm

Qt

2.5
15.1
6.00

16

17

18

19

20

21

22

23

24

25

26

5.62

5.25

4.92

4.63

4.37

4.14

3.92

3.73

3.55

3.39

3.34

27

28

29

30

31

32

33

34

35

36

37

38

3.10

2.97

2.85

2.74

2.64

2.54

2.45

2.37

2.29

2.21

2.14

2.07

39

40

41

42

43

44

45

46

47

48

49

50

2.01

1.95

1.89

1.83

1.78

1.73

1.68

1.64

1.59

1.55

1.51

1.47

51

52

1.43

1.40

8.1.3 58 m Hoisting Load Function DiagramForm 1-3

Rm

Qt

Rm

Qt

Rm

Qt

Rm

Qt

2.5
13.2
6.00

14

15

16

17

18

19

20

21

22

23

24

5.61

5.18

4.82

4.50

4.22

3.96

3.74

3.53

3.35

3.18

3.03

25

26

27

28

29

30

31

32

33

34

35

36

2.89

2.76

2.64

2.53

2.42

2.33

2.24

2.15

2.08

2.00

1.93

1.87

37

38

39

40

41

42

43

44

45

46

47

48

1.80

1.74

1.69

1.64

1.59

1.54

1.49

1.45

1.41

1.37

1.33

1.29

49

50

51

52

53

54

55

56

57

58

1.26

1.23

1.19

1.16

1.13

1.10

1.08

1.05

1.02

1.00

Chapter 2 Safety Rules and Safety Notice

2.1 Summary
2.1.1 Here are the safety rules and safety notice of installation and operation of tower
crane. All maters unmentioned herein shall be done according to relevant laws,
regulations, rules and standards issued by state or ministries. If there are discrepancies
between the context and relevant laws, regulations, rules and standards issued by state
or ministries, the later shall prevail.
2.1.2 The tower crane is operated by the consol in cab on top of mast. The cab has
wide visual field of hooked materials. The operation mechanism is very flexible and
reliable.
2.1.3 The crane has complete safety devices such as moment limiter, weight limiter,
hoisting height limiter, radius limiter and swing limiter, etc.

2.2 Preparation before Using

Before using the crane, fill lubricants of Chart 7-3 Crane Lubricants in parts. Fill
enough lubricating grease in swing abutment. Make through checkup and necessary
test of all parts and make serious debugging of mechanisms and safety devices to
prevent from accidents and ensure of normal use and operation.
2.2.1 Checkups after Erecting the Tower Crane

Checkup Name

Checkup Contents

Bottom frame
Mast
Mast frame
Upper and
lower swivel
tables
Cab

Top

Jib

Balance Beam

Hoisting
devices

Mechanism

Safety devices
Lubrication

Check anchoring bolts.

Check the 5m-space between electrical wire and jib
radius and check electrical wire conditions.
Check the bolts between standard sections.
Check the joint of lower swivel table.
Check the joint of supporting pin axles at top rising.
Check passage and handrails.
Check the bolts of swing abutment.
Check electrical wire.
Check platform handrails.
Check the joint of cab.
Dont store lubricant, cotton yarn or other tinder.
Check the installation of jib, balance beam and pull bars.
Check ladder, platform and handrail.
Ensure of correct wire rope arrangement.
Check pin axles, gaskets and split pins.
Check the installation and operation of trolleys and check
the hanging basket.
Check the arrangement of hoisting and radius-changing
wire ropes.
Check fixing of balance beam.
Check the installation of balance beam handrails and
passage to ensure of clear passage.
Check hook.
Check the hoisting wire rope and radius-changing wire
ropes.
Check the abrasion of wire ropes.
Check installation and operation of all mechanism.
Check the space between brakes of mechanisms.
Check if wire ropes are loose.
Check the adjustment of all safety devices.
Check the installation and fixing of all ladders, handrails
and platforms.
Check lubrication of all parts according to the Manual
and make necessary lubrication.

2.2.2 Make the following tests in turn after assembling the tower crane:
(1) Operation test without load: make several operations of all mechanisms
separately and then make three times of integrative operations. If there is any

10

abnormal condition, check and remove it.

(2) Static operation test with load: after passing operation without load, make static
operation with load. Hang 6t at 13.2m point of jib and hang 1.0t at 58m point of jib
over land by 0.5m high for ten minutes. Unload the weight and check metal
structure and welding seams.
Test of hoisting load: make several tests of hoisting load for every mechanism. Until
everything is ok, put the tower crane into use.

2.3 Safety Notice

For you attention to safety, we make the following illustrations for users to follow.
Or, there may be loss to you such as breaking parts or personal injury, even crane
damage and personal casualty.

2.3.1 Before installing the crane, be sure that the space is big enough
for crane to circle with wind in 360freely when it is out of work.

2.3.2 The groundwork of the crane must be solid. Digging that may
cause groundwork to sink or collapse is not allowed. Pay much
attention to flood or tide, which erodes the groundwork of the crane.

2.3.3 Safety
randomly.
prohibited.
such as bigger
Otherwise, we
accidents arising herein.

devices are prohibited to adjust

Disassembling safe devices randomly is
Dont change bigger hoisting container
concrete container or brick container.
shall take no responsibility for any

2.3.4 Check safety devices and limiter switches regularly to ensure of accurate and
reliable working.

11

2.3.5 Gradient hoisting or pulling is prohibited.

2.3.6 Dont use swing mechanism or jib trolley to move or pull heavy objects on ground. Dont
hoist the heavy object out of working radius of the crane.

2.3.7 Dont hoist the object adhering to or embedded in ground. Dont hoist the
heavy object joining with other object. In winter, be cautious of the objects icing to
land
2.3.8 Work hard not to hoist the heavy objects out of visual
field. If the crane operator cannot see heavy object well,
there should be a person to help him.

2.3.9 Notice wind speed. If the wind speed is near the max.
working wind speed 20m/s, please stop working.

2.3.10 When work stops, dont hang heavy object o hook.

2.3.11 When work stops, drive trolley to the jib root and raise the hook close to the trolley for
the jib frame circling with wind.

12

2.3.12 When work stops, cut off power supply (including power in cab and power supply).

2.3.13 Maintain the crane well and check wearing parts such as brakes and wire ropes carefully.
2.3.14 When repairing, installing or disassembling the crane, all
operators shall follow relevant safety regulations to dress safety
belt and helmet.

2.3.15 Check electric system regularly and systematically to

ensure it of normal working state.

2.4 Safety Rules and Other Matters

2.4.1 The working temperature of tower crane is 2040. The
wind speed at crane top should not exceed 20m/s when it works and that should not exceed
13m/s when installing, raising or lowering tower crane.
2.4.2 After the crane is installed, notice weather forecast. When hearing storm wind forecast over
8 degree, you must lower the crane or anchor it. Or, there may be an accident. Lower the jib
frame of tower crane without wall-supporting devices to near ground and lower that of tower
crane with wall-supporting devices to near building top. It can be reinforced by anchoring mast.
All these measures must ensure the jib frame of free circling with wind.
2.4.3 The max. swing radius of crane shall be over 3m away from low voltage aerial cable and
over 6m away from high voltage aerial cable.
2.4.4 When two tower crane work at same time, the jib nose of the lower tower crane shall be at
least 2m away from the mast of the other crane. Be sure that in any case the vertical space
13

between two tower cranes is not less than 2m.

2.4.5 The space between moving parts of tower crane and building and its outer attachments
should not be less than 1m.
2.4.6 There should be specially assigned person to take charge of the crane. Other any person is
not allowed to enter cab or operate the crane. The crane operator should have special training
and get operator license from labor authority. The person except installation staffs or
maintenance staffs is prohibited to climb the crane. Furthermore, the operator should get on or
get down the crane through ladder.
2.4.7 The operator shall estimate the weight of hoisting object and working radius to avoid
overload or over moment. There should be special guider, who has operator certificate issued by
labor authority. The safety devices are for the purpose of avoiding wrong operation.
2.4.8 If there is strange sound during installation, top rising or operation, stop the crane
immediately and check it. Dont go on working with failure.
2.4.9 After debugging safety devices, anyone is prohibited to adjust them or cancel them
randomly.
2.4.10 After new installation of the crane in a new field, all tests such as test without load, test
with statistic load or test of hoisting load shall be done. And all debugging of safety devices shall
be done.
2.4.11 Dont put lubricant, oil cotton yarn or other tinder in cab. Be careful of fire when heating
by electric oven in winter.
2.4.12 Avoid shocking mast or damaging parts of crane by harp starting. Reverse mechanism
only after motor stops and inertia disappears. Sudden reversion is prohibited.
2.4.13 The gear with many speeds shall operate from low speed to high speed or from high
speed to low speed gradually. Every speed should be over 4sec., which is subject to mechanism
performance, parameters, operators skill or relay of mechanism.
2.4.14 Dont use the crane to hoist person.
2.4.15 The load of cab should not exceed 150kg. When operating or maintaining the crane, not
more than 2 persons in the cab.
2.4.16 when hoisting, no person is allow to stand on ladder or platform. When the crane works,
dont adjust or maintain mechanisms or electric devices.
2.4.17 When hook touch ground, dont loose hoisting wire rope any long.

2.5 Electric Safety

2.5.1 After every installation of the crane, make electric checkup carefully and necessary
debugging. Only confirming everything is ok, the crane can be put into use.
2.5.2 Before the crane starts to work, check the electric circuit. After connecting power supply,
check it, cut-off button and electric bell.
2.5.3 The tower crane shall be earthed well. The resistance of earth-plate shall be not over 4
ohms. The number or earth-plates is subject to field conditions and they shall be embedded in
14

humid land. If the land is not electric well, pour some brine in the land. Check the earth
resistance once in spring and once in autumn.
2.5.4 When working at night, the mast, jib and tower top shall have lightings and the field also
needs lightings.
2.5.5 After installing the crane, the user shall fix the main cable on mast by insulation fixers at
every 3m point.
2.5.6 The electrician shall fix the cable through upper and lower swivel tables well. Check the
cable before every starting of the crane to avoid loose.
2.5.7 Cut off power before leaving cab and lock the door of the cab. After getting down the
crane, cut off the power supply. The operator shall make maintenance record and shift record. He
shall tell the next operator about all problems face-to-face.

2.6 Notice to Well-supporting Devices

2.6.1 If the working height exceeds the height of anchoring crane. Embed bolts in wall (please
refer to Figure 1-1). The max. working height of anchoring crane with wall-supporting devices is
40m.
2.6.2 The max. hoisting height of the crane is 140m. It hoists at 2x or 4x speed if the working
height is less than 70m. If the working height exceeds 70m, it can hoist only can at 2x speed.

15

Chapter 3 Tower Crane Structure

3.1 Metal Structure
3.1.1 Anchorage (Figure 3-1 4)
The anchorage is the abutment of the crane and is made of steel bars and concrete. The
connection of anchoring bolts embedded in anchorage and tower crane body shall be fabricated
strictly according to Anchorage Chart.
Requirements for anchorage:
(1) The anchorage shall be near the biggest prefab piece.
(2) The anchorage shall be as close to the building as possible.
(3) The surface shall be even with the evenness error less than 0.5mm.
The tower crane body is connected to the anchorage by sixty bolted embedded in the anchorage.
16

3.1.2 Standard mast section (Figure 3-2)

The cross mast section is 1.6m*1.6m. Every standard section is 2.8m long and they are
connected to each by eight M30*330 strong bolts. The section bar is made of 135*12 Square
tube steel.
3.1.3 Mast Frame(Figure 3-3)
Mast frame consists of frame, hydraulic top-rising mechanism and standard section
inserting device. The mast frame covers standard sections and connects to lower swivel table by
pin axles. It is 5.98m high and its cross section is 2.042m 2. It has a operation platform for toprising installation. There are eight idler wheels in its upper frame and inner frame to support it to
mast bars.
3.1.4 Lower Swivel Table
The table is in shell shape. Its bottom connects to standard section and mast frame and its
top connects to swing abutment by strong bolts.
3.1.5 Upper swivel table (net weight: 1745kg)
The table is in shell shape and there is a supporting bar welded on its left for installation of
cab and a swing mechanism on its right. It also has a platform and handrail.
3.1.6 Tower top(Figure 3-4)
The top is in the shape of quadrangular taper. The pull bars on the upper end of top keep jib
and balance beam at balance. Its bottom connects to upper swivel table with 4 pin axles. On the
top there are idler pulleys to enlace hoisting rope. On the top, there is a platform connecting to
the tower top with bolts. The platform can be removed. There is a moment limiter in the front of
tower top and a ladder on the rear to the platform.

1500

1500

17

5000

1465

500

500

226

226

1465

5000

1.The reaction of anchorage is not less than 0.2MPa.

2.The anchorage groundwork covers 7X7m.
3. The intensity of concrete is not less than C35.
4. The evenness of anchorage is less than 1.55mm.
5. The ground bolts should not be welded(or packed by wire rope).
3

6. The intensity of concrete is 2.4t/m .

A-A
10

226

1 2 3

140

15 0 0

1 25 0

10

Tube Steel

Concrete

Backing Plate

Carrier Ring

2
1
Item

Nut
Ground Bolt
Name

36/Q235/L=500

20/Q235

JG/T5037.31

16

JG/T5037.21

32

45 /Quenc hi ng and T emp er ing

Materials

Concrete Groundwork Total weight G=85t

18

8
1

32
Qty

Figure 3-1 Anchorage Groundwork

Figure 3-2 Mast

Connecting to pull bars of jib

6818

5980. 0

Connecting to pull bars of balance beam

2042.0
1200

Figure 3-3 Cover Frame

Figure 3-4Tower Top

19

20

Figure 3-5 Jib

3.1.7 Jib (Figure 3-5)
The upper bars of jib are made of seamless steel tubes and the lower bars are made of V-iron.
The cross section of whole jib is in triangle shape. It is 1.06m hight, 1.324m width and 58m
long. It consists of nine sections. Sections are connected by pin axles. The jib has two hoisting
points separately on the third section and the seventh section. Radius-changing mechanism is in
the first section for easy maintenance. Jib root is connected with tower top by pin axles. And
working radius is 58m.
3.1.8 Balance Beam (Figure 3-6)
The balance beam is in trussed structure made of V-iron and angle iron in two sections. The two
sections are connected each other by pin axles. The balance beam is 12.608m long and 1.233m
wide. There are passage and handrails on it. Hoisting mechanism and ballast are on its nose and
electrical control box on its root. The root of balance beam is connected to tower top by pin
axles. The hoisting mechanism has its own abutment, which is connected to balance beam by 4
pin axles. The ballast is 14.2t (it is 12.5t at 52m point of jib, 10.8t at 46m).

12608

21

Figure 3-6 banlance boom

3.1.9 Earth Devices
The lightning rod earth and protection earth shall be done according to Figure 3-10. You
must not use the bottom frame as lightning rod earth-plate. You should set a special lightning rod
earth-plate. The crane producer does not provide lightning rod and earth-plate. And the crane use
is responsible for installation and maintenance of them. The earth-plate shall meet the following
requirements:
If the earth cable connects to any bolt of mast bar, the painting of the bolt and nut shall be
removed.
The resistance of the earth-plate should not exceed 4 ohms.
If there are other safety devices such as automatic breaker, the earth-plate is still necessary.
The earth-plate shall be installed by professional staff as the resistance of earth-plate
changes much in different time and different conditions. Check earth cable and resistance
regularly.

3.2 Arrangement of Wire Rope

3.2.1 Hoisting wire rope
Hoisting wire rope is released from roller of hoisting mechanism and goes through
pulley of loan limiter on tower top to the idler pulley at the connection of tower top and
jib root and then turns to jib nose. It goes through pulley of trolley and hook pulley block
to fix on jib nose. The Figure is 4x speed state. The hook pulley block of the tower
crane was set 4x speed when leaving factory. Taking out the pin axle in the hook, it can
22

turn to 2x speed. Please follow Figure 3-8 to fix wire rope. The number and model of
rope clips shall in conformity with Chart 3-1.

Tower Top Pulley

Trolley Pulley

Hoisting Mechanism

Hook Pulley

Figure 3-8 hoisting wire rope

3.2.2 Wire Rope of Radius-changing Mechanism (Figure 3-9)

Two ropes go from roller: one goes through idler pulley at jib root and lower bars of
jib to fix on trolley, and the other rope goes through the idler pulley between the second
and the third sections of jib and idler pulley at jib nose to fix on the other end of trolley.
The roller rolls and one-rope rolls and the other is released to move trolley and realize
radius changing. Note: avoid friction between two ropes. Fix the rope according to
Figure 3-9.

Radius Mechanism
Pulley

Trolley
Arrangement of Radius Wire Rope

Figure 3-9 Radius wire rope

Special Note: There shall be 2-3 loops of ropes on the roller when trolley is at the max.
radius or min. radius. And there shall be at least 6 loops of ropes on the roller when
23

hook is at the lowest height.

Chapter 4 Installation and

Disassembly of Tower Crane
Notice:
The process of top rising and adding(lowering)section is the worksite accident black stage.

4.1 Erectors Duties

4.1.1 Installation of tower crane is high above the ground and is dangerous. The
erectors must have high skills.
4.1.2 The installation unit must pay much attention to the installation. It should not
assign the work to illegible or irresponsible persons. All the erectors must be
responsible and obedient.
4.1.3 The user of the crane shall trust eligible installation unit to install the crane and
sign written installation contract. Or, the loss from installation shall be borne to the user.
4.1.4 The user and installation unit must follow the JG/T100-1999 Crane Operation
Regulations.
The regulations list the requirements for direction, use, operation, disassembly and
maintenance of anchoring or climbing tower crane. It includes:
(1) Operator, erectors, signalmen and their signals.
(2) Use of the crane.
(3) Working of the crane.
(4) Disassembly, top rising and anchoring of the crane.
(5) Maintenance of the crane.
(6) Others

4.2 Safety Notice

4.2.1 The wind speed at tower top shall be less than 13m/s. If the wind speed exceeds
13m/s, stop installation.
4.2.2 Follow installation process.
4.2.3 Use proper hoisting containers.
4.2.4 The user should not replace pin axles, bolts or nuts, etc. at random.
4.2.5 Take use of safety facilities such as ladder and handrails.
4.2.6 Dont change the direction of standard sections.
4.2.7 Please see Figure 4-1 for installation field.

24

Figure 4-1 installation field

4.2.8 The space between the max. radius of the crane such as jib and hook and
electrical wire is at least 5m.
4.2.9 Check concrete anchorage carefully.
(1) The Manual is only a guiding technical document about anchorage.
(2) The concrete must be solid without holes. Its rigidity shall be not less than C35
and have steel bars.
(3) The evenness tolerance of its surface shall be less than 1/1000.
(4) Only the carrying capacity of concrete anchorage is up to 90%, shall the crane
be erected.
(5) The groundwork under the anchorage shall be over 0.22Mpa (22t/m 2). The
ground under the anchorage shall be filled with concrete of 1350mm. Make
special treatment for soft ground or suffering flood or tide. Only being approved
by relevant authority, can the concreted be filled in.
(6) The concrete anchorage shall be 50mm high above ground.
(7) The loads on the anchorage are vertical load(F V), horizontal load(FH),
overturning bending moment (M) and swing torsoninal moment(Mn) (Please
see Figure 4-2). Please see Form 4-1 for loads.

Base Load Form 4-1

P1
P2

Load Name
Vertical LoadkN
Horizontal LoadkN

25

780
26

M
MK

Overturning Bending MomentkN.m

Twisting MomentkN.m

1500
200

Figure 4-2
4.2.10 Check oil of reducers and fill enough oil in them.
4.2.11 Dont stop assembling or disassembling only after finishing jib or balance beam.
4.2.12 The erectors must wear safety helmet and safety belt. Non-erectors are prohibited to enter
the filed.

4.3 Assembly of Tower Crane

Use over 16t mobile crane or other crane to hoist parts according Figure 4-3.
4.3.1 Installation of Bottom Frame
Put bottom frame on concrete anchorage, fix press plate and screw anchoring bolts.
Measure the four legs of the frame and keep the evenness error within 1.5mm. You can level up
the frame by spacers. The spacers must be solid. Screw anchoring bolts tightly.
4.3.2 Installation of Reinforcement Sections and Standard Sections
Use eight M30*325 strong bolts to connect bottom frame with reinforcement section. And
then use M30*325 strong bolts to connect the second reinforcement section with the first
reinforcement section. And finally install the standard sections. The reinforcement sections are
made of 160*14 angle irons and 90*8 angle irons.
4.3.3 Assembly of Swing Abutment and Mast Frame
The lower swivel table, swing abutment and upper swivel table has been assembled
together before leaving factory. Hoist swing abutment to the top of mast frame and connect mast
frame with lower swivel table by pin axles. And then hoist them to standard section and adjust
the space between eight idler wheels of mast frame and standard section (space: 2-4mm). Use

26

eight strong bolts to connect standard section with lower swivel table.
Note: (1) You can put hydraulic top-rising pump near top-rising cylinder.
(2) Fix eight idler wheels of mast frame in advance.
(3) The big window of mast frame is adverse to the support side of standard section.
4.3.4 Installation of Tower Top
Connect top with transition section in advance on ground, and then assemble top platform,
ladder and idler pulley block on it. In order to easily install balance beam and jib, install a pull
bar for balance beam separately on the right side and on the left side of top and a pull bar on jib
nose and on jib root. Hoist tower crane to upper swivel table and use four pin axles to connect
the top with upper table. When hoisting, the vertical side of top shall be towards to the jib.
4.3.5 Assembly of Balance Beam
Connect balance beam on ground and then assemble top-rising mechanism, electric control
box, and resistance box and pull bars on it. Hoist balance beam and use pin axles to connect the
beam with tower top. Raise the beam until connecting the pull bars by pin axles. Then lower the
beam for the bars to hold it. Check joints and assembly points. At last, hoist two ballasts to the
rear of the balance beam.
Note: Dont arrange wire rope through installation knot.
4.3.6 Installation of Cab
After all electrical devices are installed in the cab, hoist the cab to the supporting bars on
upper swivel table and fix it by bolts.
4.3.7 Assembly of Jib
Assemble jib on a flat crosstie near the tower crane and lean it to a 0.6m high bracket. Fix a
hanging basket to the trolley and follow 3.3.2 and Figure 3-19 to attach the trolley to the jib root
and tighten trolley wire rope. Follow Figure 4-5 to assemble other pull bars and connect them
with hang points on jib. Use wires to fix the bars tightly.

27

28

Tower top butt plate

29

Fix rope as Figure 4-3 and try to hoist a little. Hoist jib to installation height and
connect its root with the holes on tower crane by pin axles. Raise the jib slowly until its
pull bars connect by split pins. Lower the jib to tighten these pull bars. Check these
joints and assembling points. Hoist remaining ballast to the balance beam.
Then follow Figure 3-8to arrange wire ropes. Wire rope goes out from roller of
hoisting mechanism and go through the pulley on hoisting height limiter and idler pulley
on bracket, and go through trolley and hook pulley block and finally fix on jib nose.
After completing assembly, check the verticality of mast. The tolerance shall be
less than 4/1000. Connect all power supply according to electrical diagram and try to
start very mechanism to check them. Meanwhile, check if there is rope friction.

4.4 Top Rising and Operation

4.4.1 Safety Notice
If trial operation without load is successful, you can make top rising. Please notice
the following for top rising:
1There must be special persons to make signals, to take care of power supply,
to operate hydraulic system and to screw bolts. Except operators, no person is allowed
to climb top-rising platform or turn on valve switch or other devices.
2 Only the wind speed is less than 4 th level, can top rising be done. If wind
speed is big, stop the work and fix bolts. If weather grows bad, stop work.
30

3Before top rising, make good preparation. After top rising, screw bolts tightly
and screw handle to middle and cut off hydraulic system power.
4 Top rising and Top lowing should be done at daylight. If they are done at
night, there must be enough lighting.
5Before disassembly of the crane, check and maintain the crane.
6If the upper section breaks away from lower section, you must do as follows.
Or, there may be serious accident.
A Use swing brake to brake jib and prevent it from swing and ensure it in the
same direction with standard section.
BDont start radius-changing mechanism and ensure that trolley doesnt move.
CDont start hoisting mechanism and dont hoisting load.
DAfter fixing one standard section and before hoisting the next standard section,
main bar of mast and lower swivel table must be connected by a strong bolt.
E All bracket of the standard must be straight against the former standard
section.
FWhen three standard sections are out of mast frame on the bottom, there must
four gradient supports under it.
7 Before top rising, adjust the space between idler wheels and main bars of
standard section to 2-3mm. After taking down the bolts between the lower swivel table
and standard section, check the balance of crane. If there is some trouble, connect
bolts again and move trolley.
4.4.2 Preparation for Top Rising
1 Clean every standard section, put the standard sections in a line under the
jib so as to save time.
2 Lease electrical cable longer than top rising height and fix electrical cable
well. (The user should take measure to avoid cable friction).
3Swing jib to the front of mast frame and balance to the behind of mast frame.
4.4.3 Top Rising Operation
(1) Hoist a standard section and put it in trolley.
(2) Drive the trolley to jib root and gravity center of crane top is on top cylinder.
Note: when the trolley balances, the hook should be the highest point. Adjust trolley
position according to conditions as follows: loose all nut on lower swivel table and
standard section but not take them down. Use oil cylinder to raise crane top and
set the space between lower swivel table and standard section at 20mm to see if
them meet straight. Take down the bolts.
(3) Use top rising beam to prop up the standard section, start hydraulic system to
stretch piston rod to drive support pin to standard section. (Before changing the
standard section back-up block, draw out the support pi and put it on the same level with

31

the inner face of the support cover to avoid the collusion between the support pin and the
standard section support back-up block during top rising). Shrink piston rod to let

support beam to prop up standard section and then stretch piston road. Use trolley
to drive standard section above mast straight. Shrink piston rod to let two standard
sections connect each other. Use strong bolts to fix them. Shrink piston rod more
and take down trolley. If want to add more sections, repeat the above process.
(4) After top rising, swing jib frame to different angle to check all joints, bottom frame,
standard sections and anchoring bolts.

4.5 Disassembly of Tower Crane

4.5.1 Notice to Disassembly
(1) Make maintenance and trial operation of top rising mechanism before leaving
construction field.
(2) Check limiters and brakes of swing mechanism.
(3) Dont use swing mechanism after disassembling standard sections and before
connecting of mast frame and mast.
(4) Make regular checkup of supporting parts.
(5) When make top rising, all operators shall pay much attention to the relative position
of movable parts such as space between idler wheels and main bar and space
between mast frame and mast. If mast inclines, stop top rising and lower it.
(6) The disassembly of tower crane is adverse to the assembly. The wind speed shall
be less than 4th level. As building is completed and space becomes much smaller,
please be much careful of that.
4.5.2 Notice after Disassembly
(1) Technicians and maintenance staffs make checkup.
(2) Check metal fatigue, welding cracks, structure distortion of parts.
(3) Repair the defect parts and paint them.

Chapter 5 Safety Devices

Safety devices includes course limiters and load limiters. The course limiters
include hoisting height limiter, swing limiter and radius limiter. Load limiters include
hoisting moment limiter and hoisting weight limiter. Only after debugging all the above
limiters, can the crane be put into use. Please see Figure 5-1 for these safety devices.

5.1 Multifunctional limiter (for hoisting, radius and swing. Please see
Figure 5-2)
5.1.1 Debugging process
(1) Open their cover, loose the screw of memory cam.
32

(2) Drive the mechanism to appointed state (without load) and the inching switch cuts
off. Adjust memory cam and use the tip of cam to press inching switch.
(3) Tighten screws of cam. (the screws must be tight, or the memory may be in
disorder.)
(4) Run the mechanism for several times to check the memory. (if there is error, debug
them again.)
(5) Tighten screws and put on cover.
Check the memory cam regular.
5.1.2 Debugging of height limiter
(1) Debug it according to 5.1.1.
(2) Press inching switch by finger to see if it works well.
(3) At max. hoisting height, the space between trolley and hook shall be at least 1m.
Debug cam and make cam tip to press down inching switch. Tighten screws.
5.1.3 Debugging of swing limiter
(1) When jib is installed, debug swing limiter.
(2) Press inching switch by finger to see if it works well.
(3) Turn left for 540according to 5.1.1. Use cam tip to press down inching switch, and
then tighten screws.
(4) Turn right for 540according to 5.1.1. Use cam tip to press down inching switch, and
then tighten screws.
(5) Check the left swing and right swing.
5.1.4 Debugging of radius limiter (same as 5.1.1)
(1) Increasing radius and jib nose limit: drive trolley to 0.8m point to jib nose and use
cam tip to press down inching switch, and then tighten screws.
(2) Entad radius and jib root limit: the same with (1), drive the trolley to 0.65m point to
jib root.
(3) Check it.

5.2 Hoisting weight limiter (Figure 5-3)

It is used to prevent from overload. It uses tip switch to work. When the load exceeds
rated weight, the switch of weight limiter breaks off and the hoisting mechanism stops.

33

34

35

36

5.3 Hoisting moment limiter (Figure 5-4)

It is used to prevent the load moment from exceeding rate hoisting moment of the
crane. It consists of distortion device, adjustment bolts and course switch and is
installed on a main bar. The distortion device consists of two distortion armor plates and
cushions. When hoisting moment exceeds rate moment but less than 110%, the two
armor plates distort to drive adjustment bolts and course switch and give alarm. It will
cut the power of hoisting mechanism and the trolley power for increasing radius. The
hook only can reduce radius but cannot hoist or increase radius.

5.4 Fuse protection

The circuit has a fuse. Then electrical parts have short circuit, the fuse shall cut off
circuit to ensure of safe crane.

5.5 Wrong phase protection

When there is wrong or adverse electrical phase, the tip will break off and relay will
cut off circuit to prevent from damaging motor.
Note: Check and debug the tower crane once for every 500 hours after it is put into use.

37

Chapter 6 Electrical System

There is a set of electrical control system in the tower crane for operator to operate
the crane.

6.1 Electrical control principle

The electrical control is to convert the actions of operators into electrical signals so
as to control mechanisms.
Start-up: Before the crane is put into use, the start-up does not work and all parts
except top rising mechanism do not work. Before starting up, all parts must be static
and non-working state and all buttons are close, the SX, SH and SQ on swing switch
shall be on zero, and voltage meter is zero too.

6.2 Electrical control of transmission, alarm and safety devices

(1) Electrical control system of hoisting mechanism
The electrical control system of hoisting mechanism consists of swing switch,
hoisting contactor, lowering contactor, low speed contactor, high speed contactor, short
circuit contactor, brake electromagnet and hoisting brake, etc. It uses 3-phase motor
with hydraulic rod brake. SQ controls contractor KM1 and KM2 to make positive
revolution and reversal of hoisting mechanism. And SQ controls KM3, KM4 and KM5 to
adjust speed. Start it from low speed, then medium speed and finally high speed. The
stopping is reverse to start-up.
(2) Electrical control system of radius mechanism
The system consists of swing switch, radius-increasing contractor, radius-reducing
contractor and motor, etc. It has a double speed motor. SX controls contactors KM14
and KM15 to control trolley to reduce or increase radius.
(3) Electrical control system of swing mechanism
The system consists of swing switch and swing contractor, etc. It has single speed
motor. SH controls contractors KM8, KM9, KM10, KM11, KM12, KM13, KM14 and
KM15 to control the swing mechanism. SQ4 and SQ5 can swing not more than 540.
(4) Safety devices include fuse, height limiter, radius limiter, radius limiter, swing limiter,
weight limiter and moment limiter. When circuit overloads or is short, the fuse breaks
and all contractors break and hook can only lower. If load exceeds rated weight,
hoisting contractor breaks and the hoisting mechanism cannot hoist. If moment exceeds
rated moment, the moment limiter breaks and trolley only can reduce radius.
Note: When limiters work, the alarm lights shall shine.

6.3 Lighting: lighting power is supplied by switchboard with the

voltage
of 220V.
1.)There is a light of 220V and 60W on consol in the cab.
2.)There is a light of 220V and 40W on tower top and works as signal light.
38

6.4 Installation and Notice

Please attach importance to the installation. Another task of electrical system is to
test signals from safety devices and adjust relevant mechanisms.
1.) Connect cables correctly. After connection, check them thoroughly. If necessary,
refer it to circuit diagram.
2.) The tower crane uses 3-phase & 4-cable 50Hz power supply. The electrical
fluctuation should not exceed +10% or 10%. Earth cable should not connect to the
crane and it should connect to the ground with the resistance of less than 4 ohms. The
power supply must have creep age protector.
3.) There shall be a lightning rod on crane top and the lightning rod shall be earthed
well.
4.) There shall be no high voltage or low voltage wire pole within 10m away to the max.
radius of the crane.
5.) Before connecting power, measure the resistance of ground. The insulation
resistance of motor shall not be less than 0.5M ohms and that of electrical wires shall
not be less than 1M ohms.
6.) The crane shall adopt the cope wire with the cross section of not less than 16mm2.
7.) Dont work in rainy day. Check electrical parts after raining.
8.) Make regular maintenance of electrical parts such as contactors, remove the dirt on
iron core and check electrical tips and switch bolts.
9.) If there is something strange, adjust and repair them and then start to work.
10.) Follow JGJ46-88 Power Safety Technical Rules of Construction Field. There shall
be full-time eligible electricians. There shall be creep age protector in power box.

39

Chapter 7 Maintenance of the Tower Crane

The maintenance of tower crane shall be done by eligible unit.

7.1 Maintenance of Metal Parts

7.1.1 Execute Discarding Standard of Metal Parts of Crane.
7.1.2 Check the metal fatigue, welding seam crack, structural distortion and damage of
supporting parts. Check the material of key welding seams. Make the following
checkup:
(A) Daily Checkup: Make a daily checkup once for 80 working hours.
(B) If there is strange sound or wrong operation or safety device failure, check it
and make record.
(C) Technicians and maintenance staffs shall make overall and detailed checkup
after disassembling the crane.
7.1.3 Work hard to avoid distortion or collision during transportation.
7.1.4 Paint the crane once a year or half a year. Remove dust, rust and oil on metal
surface before painting.

7.2 Maintenance of Wire Rope

7.2.1 Avoid twisting, looping, bending, clinging other dust or friction with machine or
other objects.
7.2.2 Lubricate wire rope by lead grease according to Chart 7-3 after installing and
before using.
7.2.3 In case of the following situation, the wire rope should be discarded:
a. Over 5 wires of 6*19-d (d: diameter) wire rope within 6d length break or over 10
wires within 30d length break;
b. Over 10 wires of 6*37-d (d: diameter) wire rope within 6d length break or over
19 wires within 30d length break;
c. Wires stick together;
d. Abrasion is up to 40% of rope diameter or nominal diameter is reduced by 7%
or more or wire rope bends obviously;
e. Wire rope distorts such as wave, sticking, partial bigger diameter, twisting,
partial smaller diameter, bending or staving;
f. Wire rope is heated and its color changes.
Note: When hoisting melting or hot metal, acid liquor, explosive or tinder, the wire rope
with half of above broken wires shall be discarded. The situations unmentioned herein
shall be executed according to GB5972.

40

Figure 7-1 Correct Unwinding Method

(4) when unwinding wire rope in roll, try to avoid looping. If there is twisting, stop
unwinding and remove looping. The twisted wire rope is prohibited being used on
tower crane. Please see Figure 7-1 for correct unwinding method. Unwind rope roll
slowly to avoid twisting. Figure 7-2 is wrong unwinding method and is prohibited.

(5) The winding direction of wire rope is related with the arrangement direction on roll.
Keep wire rope tight on roll to avoid distortion. Please see Figure 7-3 for right
winding methods. Keep rope in order.
(6) Please see Chart 1 for model, specification and length of wire rope.

41

Chart 7-1
Location

Specification

Hoisting
mechanism
Radius
Long
mechanis Short
m

4v x 39s+5FC-13-1770
7.7-NAT-6x19FC1570-ZSGB8918

Diameter
(mm)
13

Quantity
1

Length
(m)
340

7.7

1
1

117
72

7.3 Maintenance of mechanisms

7.3.1 Daily maintenance
(1) Keep them clean, and clean dusts in time;
(2) Check oil of reducers, and fill in oil in time;
(3) Check vent-plug of reducers, and ventilate them in time;
(4) Check brakes and adjust them in time;
(5) Check bolts at joints and tighten them in time;
(6) Check safety devices and adjust them in time;
(7) Check wire ropes and pulleys and replace the damaged in time;
(8) Check lubrications and fill in lubricant in time;
7.3.2 Slight repair (after 1000 working hours)
(1) Make daily maintenance;
(2) Take down gears of transmitter and adjust space between gears;
(3) Clean and adjust gears and fill in lubricant on them;
(4) Check and adjust swing abutment;
(5) Check and adjust brakes and safety devices;
(6) Check hook, pulleys and wire rope, make necessary adjustment, repair and
amendment.
7.3.3 Medium repair (after 4000 working hours)
(1) Make all works of slight repair;
(2) Repair and amend damaged parts of axles;
(3) Repair or replace brakes;
(4) Replace wire rope or pulley;
(5) Check bolts on swing abutment. If necessary, replace them with strong bolts;
(6) Remove dust and oil.
7.3.4 Heavy repair (after 8000 working hours)
(1) Make all works of slight repair and medium repair;
(2) Repair or replace brakes;

42

(3) Repair or replace reducers;

(4) Repair or replace swing abutment.

7.4 Use of strong bolts

7.4.1 Screw strong bolts tightly to ensure of required tightness and avoid loose. Please
see Chart 7-2 for tightness of strong bolts.
Chart 7-2 Tightness of Individual Strong Bolt (N.m)
Nominal Diameter(mm)
M16
M18
M20
M22
M24
M30
Grade
8.8
210
290
410
550
710
1450
10.9
295
405
580
780
1000
2000
7.4.2 Check tightness of bolts regularly after 100 hours of the first installation and check
them once for 500 working hours. If there are loose nut or bolt, tighten them or replace
them.
7.4.3 The strong nut or bolt in good conditions taken down only can be used for one
time. The nut or bolt in bad conditions is prohibited being used again.

7.5 Maintenance of other parts

7.5.1 In case of the following situation, the brake shall be discarded:
(1) Cracks;
(2) Abrasion of brake cushion is up to 50%;
(3) Abrasion of brake surface is up to 1.5-2mm;
(4) Spring distorts;
(5) The invalid course of lever system exceeds rated course by 10%.
7.5.2 The complementary welding of hook is prohibited. In case of the following
conditions, the hook shall be discarded:
(1) Use 20x magnifier to observe if hook surface has crack or crevasse;
(2) Permanent distortion on hook nose and whorl;
(3) Abrasion of rope groove is over 10%;
(4) Abrasion of core is over 5%;
(5) Hatch becomes bigger by 15%.
7.5.3 In case of the following situations, the roll or pulley shall be discarded:
(1) Crack or crevasse;
(2) Abrasion of roll is up to 10%;
(3) Abrasion of pulley rope groove is over 25% of rope diameter;
7.5.4 In case of the following situations, the wheel shall be discarded:
(1) Crack;
(2) Abrasion of wheel thickness is up to 15%;
(3) Abrasion of wheel brim is up to 50%;

7.6 Maintenance of swing abutment

(1) The swing abutment must be strong enough and its surface must be even. Make

43

(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

treatment for bracket before installing abutment so as to reduce abutment distortion.

The interfaces of bracket and abutment must be clean.
Pay attention to noise change and swing moment change during use.
The swing abutment can be laid or hoisted only horizontally. Dont lay or hoist them
vertically o hoisting.
Check mesh of gears before tightening bolts.
Clean the gear surface once for 10 shifts and fill lubricant.
Check tightness of bolts at 100 working hour and 500 working hour to ensure of
tight bolts. Later check bolts once for every 1000 working hours.
Adopt double strong nut and strong bolts to connect swing abutment.
Lubricate bolt screws and nut inner surface when tightening nut. Use spanner to
screw nuts for many times. All bolts shall have similar tightness.
There are four grease cups scattered equally in gear ring for adding lubricant. Fill in
enough lubricant once for 50 swinging hours.

7.7 Lubrication of Mechanisms and Structure

Please see Figure 7-3 for lubricant types and lubrication period of main parts and
mechanisms.
Please see Figure 7-4 for regularly lubricating parts of tower crane.
Chart 7-3 Lubricants of Tower Crane
Lubricating Parts
Reducer
Gears of brakes
Hoisting
mechanis
m

Swing
mechanis
m

Brakes and hydraulic

pusher
Abutment and idler
axletree
Hydraulic couplers

Swing limiter

Lubricant Name
Winter: N46 machine oil
Summer: N68 machine
oil
Machine oil

Lubricating Period
Change oil for 1500
working hours, check
oil everyday
Drop oil for 50
working hours

Winter: 25# transformer

oil
Summer: 10#
transformer oil

Change oil once for

half a year

Lubricating grease

160 working hours

Winter: 10# transformer

oil
Summer: N15 machine
oil

Check it monthly and

complement oil

Lubricating grease

160 working hours

44

Reducer
Radius
mechanis
m
Top-rising
mechanis
m
Swing
abutment
Idler
axletree

Abutment and idler

axletree
Radius limiter
Hydraulic oil cylinder

Idler pulley
Open gear
Hook axletree
Trolley axletree
Other axletrees

Winter: N46 machine oil

Summer: N68 machine
oil
Lubricating grease

Change oil for 1500

working hours, check
oil everyday
160 working hours

Lubricating grease
N46N68 hydraulic oil

160 working hours

Change oil once for
half a year

Lubricating grease
Lubricating grease
Lubricating grease

50 working hours
50 working hours
Add oil at medium
repair; add oil for
other axletrees for
every 160 working
hours and clean them
once for half a year.
Change oil for 1500
working hours
2 times a month
2 times a month
Once a month

Axletrees of all motors

Lubricating grease

All wire ropes

All pulleys
Anchoring bolts and nuts

Lead grease
Lubricating grease
Lubricating grease or
machine oil
Lubricating grease or
machine oil
Lubricating grease or
machine oil

Bolts and nuts of standard sections

Pin and pin hole of pull bars
Pin and pin hole of jib frame
Connection ring of standard sections

45

Once a month
Lubricate them after
disassembly of crane
and lubricate
regularly in
warehouse

46

47
concrete
1
6
12-1200 reinforce bar

121
5
fixed leg
4
4
25-3060 reinforce bar

8
3
upper main bar
62
2
62
1
lower main bar
item specification name
material QTY
QTZ80(5810).10
Fixed anchorage Groundwork

947

4 8

190

3 8

2972

170

1150
R5

25

60

R1

350

00

800

230

43

80

171

1119

171

171

171

194

(44.5)

800

180x14=2520

180
116

2752

Counterweight 1.7t/pc Total:2pc/set

48

(116)

44.5

171

171

80

Counterweight 2.7t/pc Total:4pc/set

49

Complementary Notes
Our company reserves the right to change technical parameters, outer sizes and
design without information in advance. If the product has difference with the Manual.
The product shall prevail. If you want to buy parts or make technical treatment, please
contact our technical department.
The new edition shall prevail.

Printed in January 2012 (The 3rd Edition)

50