TOWER CRANE MANUAL

Model ZT 6016-10

ZENO VIET NAM CO.,LTD

HCM OFFICE
Add: 11th floor, Nguyen Lam building, No.133, Duong Ba Trac St., Ward.1, Dist.8
Tel: (84)86 2515 828 Email: [email protected] Web: www.zenovietnam.com
HANOI BRANCH
Add: No.36, Dai An st.,Van Quan Ward, Ha Dong Dist., Hainoi
Tel: (84)46 2956 944
 TABLE OF CONTENTS

CHAPTER 0 – RECORD BOOK

0.1 MASTER SHEET 2
0.2 PRELIMINARY REMARK 2
0.3 EC -MANUFACTURER'S DECLARATION 4
0.4 GENERAL DATA, DRIVEN MOTORS AND GEARS 5
0.5 ELECTRIC CONTROL, BRAKES AND ACCESSORIES 6
0.6 ROPES AND LOAD HOOK 7

CHAPTER 1 - FUNDAMENTAL SAFETY INSTRUCTIONS

1.1 WARNINGS AND SYMBOLS 8
1.2 BASIC OPERATION AND DESIGNATED USE 8
1.3 ORGANIZATIONAL MEASURES 9
1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES 10
1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES 11
1.6 TRANSPORTING THE SLEWING TOWER CRANE 12
1.7 MAINTENANCE OF THE SLEWING TOWER CRANE 13
1.8 WARNING OF SPECIAL DANGERS 14
1.9 HYDRAULIC AND PNEUMATIC EQUIPMENT 14
1.10 NOISE 14
1.11 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES 14
1.12 MEASURING SYSTEM 15

CHAPTER 2 - TECHNICAL DATA

2.1 GENERAL 16
2.2 CRANE ON FOUNDATION 37

CHAPTER 3 - GENERAL INSTRUCTIONS FOR ASSEMBLY

3.1 INTRODUCTION 56
3.2 GROUND CONSISTENCY 56
3.3 CRANE INSTALLATION AREA 56
3.4 MORE CRANES ON THE SITE 57
3.5 INSPECTION OF THE BUILDING YARD 58
3.6 GENERAL INSTRUCTION FOR CRANE OPERATOR AND ASSEMBLY TEAM 59
3.7 UNALLOWED CRANE MOVES 60
3.8 ASSEMBLY AND DISASSEMBLY ADVICES 61
CHAPTER 4 - ASSEMBLY & DISASSEMBLY
4.1 GENERAL ASSEMBLY INFORMATION 64
4.2 ERECTION CRANE TOWER P16B (1.6m) 71
4.3 PREPARING THE MAST SECTIONS 77
4.4 FITTING CHASSIS SB16 (1.6m) 84
4.5 ELESCOPING 1.60M (ASSEMBING THE TELESCOPIC CAGE) 101
4.6 ANCHORAGE FRAME FOR 1,60 m CRANE TOWER FOR VERY HIGH CRANES 116
4.7 CLIMBING INSIDE THE BUILDING BA45A 122
4.8 BALANCING THE CRANE FOR TELESCOPING 136
4.9 TELESCOPING 136

CHAPTER 5 SAFETY DEVICES

5.1 GENERAL 143
5.2 POSITION OF SAFETY DEVICES 143
5.3 AUTOMATICALLY ZERO POSITIONING 144
5.4 DEAD-MAN SWITCH 144
5.5 AUDIBLE WARNING SIGNALS 144
5.6 HOIST LIMIT SWITCH 144
5.7 TROLLEY TRAVEL LIMIT SWITCH 145
5.8 LOAD MOMENT LIMITER 145
5.9 MAXIMUM LOAD LIMITER 24KW 147
5.10 TROLLEY TRAVEL BLOCKING 148
5.11 ROPE RETAINING BRACKETS 148
5.12 LOAD HOOK 148
5.13 SLEWING UNIT – COUNTERING PROTECTION 148

CHAPTER 6 CRANE OPERATION

6.1 PRIOR TO INITIAL CRANE OPERATION 149

6.2 TAKING THE CRANE INTO OPERATION 149
6.3 CRANE CONTROL DESK 24 KW 150
6.4 CONTROL OF HOIST UNIT 151
6.5 CONTROL OF TROLLEY TRAVEL UNIT 152
6.6 CONTROL OF SLEWING UNIT 152
6.7 INSTRUCTIONS FOR CRANE OPERATION 153
6.8 TAKING THE CRANE OUT OF OPERATION 153
6.9 TAKING THE CRANE OUT OF OPERATION WHEN A GALE IS APPROACHING 154
6.10 CHANGING OF THE HOIST ROPE REEVING FROM 4-FALL ROPE TO 2-FALL OPERATION 156
6.11 CHANGING OF THE HOIST ROPE REEVING FROM 2-FALL TO 4-FALL ROPE OPERATION 157
CHAPTER 7 MAINTENANCE

7.1 LUBRICATION - GENERAL 158

7.2 OIL CHANGE INTERVALS 158
7.3 POSITIONOFLUBRICATIONPOINTS 159
7.4 LUBRICATION PLAN 160
7.5 LUBRICANTS, OPERATION LIQUID, QUANTITY 161
7.6 GEAR OIL 162
7.7 MAINTENANCE SCHEDULE 163
7.8 MOTORS AND GENERATORS 164
7.9 HOIST GEAR 165
7.10 BRAKE TYPE FCM FOR THE SLEWING UNIT & TROLLEY 166
7.11 DISK BRAKE TYPE FCPL FOR HOIST 37KW MOTOR 172
7.12 SLIP RING TRANSLATOR 173
7.13 SWITCH CABINET 173
7.14 ELECTRICAL CABLES 173
7.15 CONTACTOR AND SWITCH CONTACTS 174
7.16 EMERGENCY LIMIT SWITCHES 147
7.17 SLEWING RING 174
7.18 SHORTER LUBRICATION INTERVALS 175
7.19 STEEL STRUCTURE 175
7.20 INSPECTION AND MAINTENANCE OF THE PAINTING 175
7.21 SUPERVISION OF FORGED LOAD HOOKS AS PER Q/SZ1-2001 175
7.22 ROPE MAINTENANCE 176
7.23 TIME FOR REPLACING WIRE ROPES 178
7.24 DRAWING-IN WIRE ROPES 179
INTRODUCTION
These operating instructions are designed to familiarize the user with the slewing tower crane and
its designated use.

The instruction manual contains important information on how to operate the slewing tower crane
safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce
repair costs and downtimes and to increase the reliability and life of the slewing tower crane.

The instruction manual is to be supplemented by the respective national rules and regulations for
accident prevention and environmental protection.
The operating instructions must always be available wherever the slewing tower crane is in use.

These operating instructions must be read and applied by any person in charge of carrying out
work with and on the slewing tower crane, including operations such as assembly, dismantling,
troubleshooting in the course of work and care, maintenance (servicing, inspection, repair) and/or
transport.

In addition to the operating instructions and to the mandatory rules and regulations for accident
prevention and environmental protection in the country and place of use of the slewing tower
crane, the generally recognized technical rules for safe and proper working must also be
observed.

1
CHAPTER 0 – RECORD BOOK

0.1 MASTER SHEET

Manufacturer Zeno globlal CO., LTD

Type ZT6016-10
Serial No 4310-10C41-2015-0033
Year of manufacture 2016
Classification according ISO 4301 (FEM-DIN 15018) A3
Type of crane according DIN 15001, sheet 1 Crane with trolley jib
Application of crane according DIN 15002, sheet 2 Tower crane
Kind of operation Fixing control station

0.2 PRELIMINARY REMARK

When carrying out inspections on tower cranes the following shall be observed:
The national accident prevention rules.
Standards and Directives.
The completeness of the crane test record book (the existence of all sheets indicated) shall be
checked by the experienced technicians or expert engineers (see ISO 9927-1). The crane test
record book shall be completed accordingly.
Repeat order of blank sheets for the periodical inspection is possible.

Inspections
Inspections prior to first use and after major modifications:

1. The user shall ensure that power driven cranes are tested by an expert engineer before being
operated for the first time or before return to service following major modifications. Sentence 1
applies also to other cranes with a load capacity exceeding 1000 kg.

2.Testing prior to first use of a new crane as required by Para. 1 include correct assembling,
equipment and readiness for commissioning.

3. Testing before initial operation of a new crane as required by Para. 1 is not necessary if the
crane is delivered ready for commissioning and accompanied by evidence of type testing
(EC type-Examination) or the EC-Declaration of conformity.

2
Periodic inspections

1. The user shall ensure that in accordance with their operating conditions and local circumstances at
appropriate intervals, but at least once a year, cranes are subjected to all necessary inspections by an
experienced technician. The user shall further ensure, that tower crane is inspected by an experienced
technician each time when being re-erected or converted to a new configuration.

2. The user shall ensure, that:

a) Power driven tower cranes
b) Power driven mobile cranes,
c) Power driven derrick cranes, which change their places of operation,
d) Truck-mounted loading cranes are inspected by an expert engineer at least every 4 years.

3. The user shall ensure, that power driven cranes beyond Para. 2 are inspected in the 18th year and
then each year by an expert engineer.

4. Para. 2 does not apply for permanent erected truck-mounted loading cranes.

Crane test record book

1. The user shall ensure that the results of the inspections carried out as specified above are
entered into a test record book.

Expert engineers

These can be member of a government run or authorised technical inspecting office or persons
nominated by the industrial insurance authorities. These inspections do not cover other required
by authorities, e.g. the highway code.

3
 0.3 EC -MANUFACTURER'S DECLARATION

Herewith declare that the design of the below described components, in the execution they are
supplied, are determined for installation in a crane and that it is forbidden to take the crane into
operation until it has been proved that the components which are to be installed in the crane are
in accordance with the determinations comprised in the EC directive for machines 98 / 37 / EC.

Designation of machine / Construction crane with trolley jib

part machine / machine part

Manufacturer / Type ZT6016-10

Serial No. 4310-10C41-2015-0033

Year of manufacture 2016

Applied EN 292-1 and EN 292-2

harmonized standards: DIN EN 60204-part 32

Applied national standards and technical Rules applicable in Germany until date,
specifications according to Machine Directory Oct. 92 to GSG

Particularly: ISO 4301

DIN 15018 / DIN 18800
DIN 15020
BGV D 6

Examination of the actual applications of the related harmonized standards, see above and
confirmation that all documents are in accordance with the regulations as per attachment VI.

Specifications for signer: Civil engineer, crane specialist

4
0.4 GENERAL DATA, DRIVEN MOTORS AND GEARS

GENERAL DATA SAFETY DEVICE

Type Maximum load limiter Existent

TT6016-10
Horizontal Load moment limiter Existent
Existent
Jib
Luffing Horn Existent
Warning
device Light
Radius 60,0 m Existent

Capacity 1,6 t Trolley limit switch Existent

Position cabin Turntable Emergency limit switch Existent

Driven kind El. motor Load moment indicator Existent

Power: Alternative current 380 V - 50 Hz Slewing limit Existent

Control voltage 48 V - 50 Hz Anemometer Existent

Construction weight 19470kg

MOTORS
Duty cycle Type Degree of
Power HZ
% protection
Position r.p.m.(U/min)

Hoist unit 37KW 50/60 S3-40% Y7TDE180M4- 2/4/16 IP44 IMB5 2800/1410/300

95N.m 50/60 S3-40% YTLEJ112L- 95-4F2 IPW23 IMB5 0-1250/ 0-1500

Slewing unit
95N.m 50/60 S3-40% YTLEJ112L - 95-4F3 IPW23 IMB5 0-1250/ 0-1500

Trolley unit 95N.m 50/60 S3-40% YTLEJ112L- 95-4 IPW23 IMB5 0-1250/ 0-1500

GEARS

Type Transmission Remarks

Hoist unit 37LVF 36.4

Slewing unit JH08 164.29

Trolley unit 95BLX65 35.84

5
0.5 ELECTRIC CONTROL, BRAKES AND ACCESSORIES

CONTROL PANELS

Kind Circuit diagram-No Power Remarks

Hoist unit
Inverter cont SYPM140-001-1 380V / 48V
Trolley unit
Contactor SYPM140-001-2 380V / 48V
Slewing unit
RCV control SYPM140-001-3 380V / 48V
Feeding part
Contactor SYPM140-001-4 380V / 48V

BRAKES
Kind Type Brake moment (Nm)

Hoist unit Disc brake PL-Y7TDE180M4-2/4/ 180

Disc brake
Slewing unit FCO- YTLEJ112L-95 40
ddy current brake
Trolley unit Disc brake FCO-YTLEJ112L-95 40
ddy current brake

ACCESSORIES
Type Remarks
M = 10
Slewing ring 1250.40
Z = 144
Slip ring transmitter SRT-001/ 002

Limit switch Hoist unit DXZ 418

Trolley unit DXZ 417

Load & Moment limiter XCK-J.C

6
0.6 ROPES AND LOAD HOOK

ROPES

Application d Length Construction

Manufacturer Remarks
mm m of the rope
JIANGSU CITY SAFETY STEEL
Hoist rope 14 305 1770 ZS Min. breaking load 124 kN
ROPE CO., LTD
129 JIANGSU CITY SAFETY STEEL Min. breaking load
Trolley rope 7.7 1770 ZS
71 ROPE CO., LTD 30.2 kN

Load hook

Application Standard Capacity Remarks

t

Hoist unit Q / S Z 1 - 2001 10.0

7
CHAPTER 1 - FUNDAMENTAL SAFETY INSTRUCTIONS
1.1 WARNINGS AND SYMBOLS

Do not operate the crane if the instructions and procedures outlined in the manual are not clearly
understood. Should there be any doubt, ask for the intervention of technical service. Zeno global
Co.Ltd. Reserves the right to make changes to specifications or to modify the crane at any time
with out prior notice.

The following signs and designations are used in the manual to designate instructions of particular
importance.

Refers to orders and prohibitions designed to prevent injury or extensive damage.

Danger

Important note to prevent accidents or heavy material damages.

Forbidden

USE OF THE CRANE

Zeno Global Co.Ltd TT model are tower cranes with upper slewing. They are devised only and
exclusively for lifting, level luffing and lowering loads as described and specified in this manual.
The use and configuration of the crane described in this manual are the only ones approved by
the manufacturer. The crane must only be used according to the instructions herein.
The intended uses of the crane can be assured only if its structural and mechanical components
are properly maintained and all systems are working well.

1.2 BASIC OPERATION AND DESIGNATED USE

1.2.1 The slewing tower crane has been built in accordance with state-of-the-art standards and the
recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of
third parties, or cause damage to the machine and to other material property.

1.2.2 The slewing tower crane must only be used in technically perfect condition in accordance with
its designated use and the instructions set out in the operating manual, and only by safety-conscious
persons who are fully aware of the risks involved in operation. Any functional disorders, especially
those affecting safety, therefore be rectified immediately
1.2.3 The slewing tower crane is designed exclusively for the lifting and lowering and horizontal
transport of loads freely suspended from the load hook. The load may be picked up only from a firm
base.Any functional disorders, especially those affecting safety, therefore be rectified immediately

Operating the machine within the limits of its designated use also involves observing the instructions
set out in the operating manual and complying with the inspection and maintenance directives.

Product-relevant / Repetition essential as special safety warning/concrete safety warning. Information

for the user enterprise and its personnel authorized to give instructions for the operating personnel.

8
 1.3 ORGANIZATIONAL MEASURES

1.3.1 The operating instructions must always be at hand at the place of use of the slewing tower
crane (in the tool compartment or tool-box provided for that purpose).

1.3.2 In addition to the operating instructions, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and environ-
mental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing
and/or wearing of personal protective equipment, or traffic regulations.

1.3.3 The operating instructions must be supplemented by instructions covering the duties
involved in supe vising and notifying special organizational features, such as job organization,
working sequences or the personnel entrusted with the work.

1.3.4 Personnel entrusted with work on the slewing tower crane must have read the operating
instructions and in particular the chapter on safety before beginning work. Reading the instruc-
tions after work has begun is too late. This applies especially to persons working only occasionally
on the machine.

1.3.5 Check constantly that the personnel are carrying out the work in compliance with the operat-
ing instructions and paying attention to risks and safety factors.

1.3.6 Observe all safety instructions and warnings attached to the slewing tower crane

1.3.7 In the event of safety-relevant modifications to the slewing tower crane or changes in its
behaviour during operation, stop the slewing tower crane immediately and report the malfunction
to the competent authority/person.

1.3.8 Never make any modifications, additions or conversions, which might affect safety without
the approval of the supplier/manufacturer. This also applies to the installation and adjustment of
safety devices as well as to welding work on load-bearing elements. Product-relevant / Repetition
essential as special safety warning/concrete safety warning. Information for the user enterprise
and its personnel authorized to give instructions for the operating personnel.

1.3.9 Spare parts must comply with the technical requirements specified by the supplier/manufac-
turer. Spare parts from original equipment manufacturers can be relied upon to do so. The user
must compare the data in the spare-parts catalogue prior to installation of a spare part.

1.3.10 Replace hydraulic hoses and pneumatic lines within stipulated and appropriate intervals
even if no safety-relevant defects have been detected.

1.3.11 Prescribed intervals for routine checks and inspections must be adhered to operating
instructions.

1.3.12 For the execution of maintenance work, tools and workshop equipment adapted to the task
on hand are absolutely indispensable.
9
 1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES

1.4.1 Any work on/with the slewing tower crane must be executed by reliable personnel only.Stat-
utory minimum age limits must be observed.

1.4.2 Employ only trained or instructed staff and set out clearly the individual responsibilities of the
personnel for operation, transport, assembly, inspection, maintenance, repair and dismantling.

1.4.3 Make sure that only authorized personnel works on the slewing tower crane

1.4.4 Define the crane operator's responsibilities - also with regard to observing traffic regulations
- giving the operator the authority to refuse instructions by third parties that are contrary to safety.

1.4.5 Do not allow persons to be trained or instructed or persons taking part in a general training
course to work on or with the slewing tower crane without being permanently supervised by an
experienced person. Product-relevant / Repetition essential as special safety warning/concrete
safety warning.
Information for the user enterprise and its personnel authorized to give instructions for the operat-
ing
personnel.

1.4.6 Work on the electrical system and equipment of the slewing tower crane must be carried out
only by a skilled electrician or by instructed persons under the supervision and guidance of a
skilled electrician and in accordance with electrical engineering rules and regulations.

1.4.7 Work on mechanical components, such as gearboxes, chassis, braking and steering
systems, may be carried out by specially trained personnel only.

1.4.8 Work on hydraulic systems must be carried out only by personnel with special knowledge
and experience of hydraulic or pneumatic equipment.
Product-relevant / Repetition essential as special safety warning/concrete safety warning. Infor-
mation for the user enterprise and its personnel authorized to give instructions for the operating
personnel.

10
1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES

1.5.1 Operation

1.5.2 Observe the regulations applicable to the respective location.

1.5.3 Prior to starting work, get to know the on-site working environment. The working environ-
ment includes, for example, obstructions in the working and driving range, the load capacity of the
soil and any barriers needed to separate the site from the area accessible to the general public.

1.5.4 Take the necessary precautions to ensure that the slewing tower crane is used only when in
a safe and reliable state. Product-relevant / Repetition essential as special safety warning/con-
crete safety warning Information for the user enterprise and its personnel authorized to give
instructions. Instructions for the operating personnel.

1.5.5 Before starting up or setting the slewing tower crane in motion, make sure that nobody is at
risk.

1.5.6 Operate the slewing tower crane only if all protective and safety-oriented devices, such as
removable safety devices, emergency shut-off equipment are in place and fully functional.

1.5.7 Never operate the crane in any way that might be prejudicial to safety.

.5.8 During startup and shutdown procedures always watch the indicators in accordance with the
operating instructions.

1.5.9 The crane operator must always have a good view of the working range and the load. In poor
visibility or darkness, adequate lighting must be provided on the site.

1.5.10 Never work in any way that might prejudice the stability of the slewing tower crane. The
crane steering system must not be switched off when a load is suspended from the

1.5.11 The fastening of loads and the instructing of crane operators should be entrusted to experi-
enced persons only. The marshall giving the instructions must be within sight or sound of the operator.

1.5.12 Check the slewing tower crane at least once per working shift for obvious damage and
defects. Report any changes (incl. changes in working behavior) to the competent organization/
person immediately. If necessary, stop the slewing tower crane immediately and lock it. In the
event of malfunctions, stop the slewing tower crane immediately and lock it.

1.5.13 Have any defects rectified immediately.

1.5.14 Always keep tools and loose objects in a safe place.

1.5.15 Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and
ice. Product-relevant / Repetition essential as special safety warning/concrete safety warning.
Information for the user enterprise and its personnel authorized to give instructions. Instructions
for the operating personnel.
11
1.5.16 Crane operation must be stopped whenever wind-forces are prejudicial to safety. The max-
imum wind velocity at which the slewing tower crane may be operated is 20 m/s, corresponding
to wind-force 8. It should be borne in mind that gusts of wind may reach as much as 20 m/s even
with a moderate wind velocity of 12 to 13 m/s (wind-force 6).

1.5.17 When leaving the slewing tower crane, always secure it against inadvertent and unauthor-
ized use and ensure that it is left in the state specified in the operating instructions.

1.5.18 Any other or farther-reaching use, such as:

Pulling away loads that are not standing free

Horizontal movement of loads that are not freely suspended
Increasing the load after it has already been lifted from the firm ground
Singing or vibrating the load
Any loading beyond the authorized load rating
Oblique pulling,
Carrying persons on the load or on the load-holding device is not a designated use and is
accordingly prohibited.

1.6 TRANSPORTING THE SLEWING TOWER CRANE

1.6.1 Prior to transport, check that the transport devices (self-erecting crane), such as axles
brakes, steering, signal and lighting systems, are in working order.

1.6.2 Prior to transporting the slewing tower crane, always check that the accessories are
safely stowed away and that all loose parts are fixed.

1.6.3 When driving on any public highways, tracks or places, observe the valid regulations and
ensure in advance that the slewing tower crane complies with regulations authorizing the use of
vehicles for road traffic.

1.6.4 When driving through underpasses, bridges or tunnels or below overhead power lines,
always ensure that there is adequate clearance (headroom).

1.6.5 Never drive with the suspension mechanism transversely positioned. Always keep well clear
of building pits and slopes.

1.6.6 Product-relevant / Repetition essential as special safety warning/concrete safety warning.

Information for the user enterprise and its personnel authorized to give instructions. Instructions
for the operating personnel.

12
 1.7 MAINTENANCE OF THE SLEWING TOWER CRANE

1.7.1 Special work in conjunction with utilization of the slewing tower crane and maintenance and
repairs during operation; disposal of parts and consumables.

1.7.2 Observe the adjusting, maintenance and inspection activities and intervals set out in the
operating instructions, including information on the replacement of parts and equipment. These
activities may be executed by skilled personnel only

1.7.3 Brief operating personnel before beginning special operations and maintenance work, and
appoint a person to supervise the activities.

1.7.4 In any work concerning the operation, conversion or adjustment of the slewing tower crane
and its safety-oriented devices or any work related to inspection, maintenance and repair, always
observe the start-up and shut-down procedures set out in the operating instructions and the infor-
mation on maintenance work.

1.7.5 Ensure that the maintenance area is adequately secured.

1.7.6 If the slewing tower crane is completely shut down for maintenance and repair work, it must
be secured against inadvertent starting by.

1.7.7 Locking the principal control elements and removing the ignition key and/or attaching a
warning sign to the main switch.

1.7.8 For carrying out overhead assembly and maintenance work always use specially designed
or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climb-
ing aid.

1.7.9 If safety devices have to be dismantled in assembly, maintenance or repair work they must
be reinstalled and checked immediately on conclusion of the work.

1.7.10 To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable
and technically perfect lifting gear and suspension systems with adequate lifting capacity. Prod-
uct-relevant / Repetition essential as special safety warning/concrete safety warning. Information
for the user enterprise and its personnel authorized to give instructions. Instructions for the oper-
ating personnel.

1.7.11 Never work or stand under suspended loads.

1.7.12 Always tighten any screwed connections that have been loosened during maintenance and
repair.

1.7.13 Before cleaning the slewing tower crane with water, steam jet (high-pressure cleaning) or
detergents, cover or tape up all openings which - for safety and functional reasons - must be
protected against water, steam or detergent penetration. Special care must be taken with electric
motors and switchgear cabinets, limit switches, ball bearings and slewing ring.

13
1.7.14 After cleaning, remove all covers and tapes applied for that purpose.

1.7.15 Rectify any defects immediately. Check that all safety devices are in working order. Check
that hydraulic and pneumatic lines are not leaking.

1.7.16 After cleaning, examine all electrical, hydraulic and pneumatic lines for chafe marks
and damage.

1.7.17 Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact. Product-relevant / Repetition essential as special safety warning/concrete
safety warning. Information for the user enterprise and its personnel authorized to give instruc-
tions. Instructions for the operating personnel.

1.8 WARNING OF SPECIAL DANGERS

1.8.1 Electric energy

1.8.2 Use only original fuses with the specified current rating.

1.9 CHECK

1.9.2 Check all lines, hoses and screwed connections regularly for leaks and obvious damage.
Repair damage immediately. Splashed oil may cause injury, environmental pollution and fire.

1.9.3 Depressurize all system sections and pressure pipes (hydraulic system, compressedair
system) to be removed in accordance with the specific instructions for the unit concerned before
carrying out any repair work.

1.9.4 Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connec-
tions are interchanged. The fittings, lengths and quality of the hoses must comply with the technical
requirements.

1.9.5 Product-relevant / Repetition essential as special safety warning/concrete safety warning.

Information for the user enterprise and its personnel authorized to give instructions for the operat-
ing personnel.

1.10 NOISE

1.10.1 During operation, all sound baffles on the slewing tower crane must be closed.

1.11 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES

1.11.1 When handling oil, grease and other chemical substances, observe the product related
safety and environmental protection regulations.

1.11.2 Be careful when handling hot consumables (risk of burning or scalding). Product-relevant /
Repetition essential as special safety warning/concrete safety warning. Information for the user
enterprise and its personnel authorized to give instructions. Instructions for the operating personnel.

14
1.12 MEASURING SYSTEM

Please note Signification of codes and signsm (structural analysis)

New valid units according to the "Sl-unit system".
All data in SI-units are converted and rounded- x = Direction of attack parallel to jib off values.
Y = Direction of attack rectangular to jib
G = Dead weight
P = load
Mass = kg, t A = Starting force
M = load moment
W = Wind force
Force in N (Newton) D = Pressure
Z = Pulling force
Former unit kp; Mp; dyn
1 kp 10 N* = 1 dan
1 Mp 10 000 N* = 10 kN
1 dan = 10-5 N
Torque in Nm (Newton meter)
M = Crane moment from G, P, M and W
Former unit kpm MX = Crane moment from G, P, M and W
1 Nm 0. 1 0 kpm* MT = Torsion moment from P, G and W
1 kpm 10 Nm* = 1 daNm N = Vertical force from G and P
S = Vertical force per corner strut
Energy, work in kWh (kilowatthours)
Q = Horizontal force from P, G and W
HO = Top horizontal force
Former unit PSh (BHPh)
HU = Bottom horizontal force
1 kpm 10 Nm* = 1 daNm HM = Horizontal force per corner strut from M
1 kWh = 1.36 PSh* (HPh) HQ = Horizontal force per corner strut from Q
HMT = Horizontal force per corner strut from MT
Power in kW (Kilowatt)
H = Sum of all horizontal forces
E = Maximum strut force
Former unit BHP
1 kW = 1.36 BHP
1 BHP = 0.736 kW*
Pressure in bar (Bar)
Former unit kp/cm2
1 bar ~ 1 kp/cm2
Speed in 1/min (rotations per minute)
Former unit rpm
1/min = 1 rpm
1 rpm = 1/min
Prefixes are placed without space in front of the unit sign, for example, dan m.
Composite units are written, with interspaces, f.inst.: - Nm -
* The conversation factors are rounded off according to DIN 1 333
15
CHAPTER 2 - TECHNICAL DATA
2.1 GENERAL

2.1.1 Crane components

1 Jib 12 Trolley unit

2 Counter jib 13 Slewing unit
3 Tie bar counter jib 14 Hoist rope
4 Turntable 15 Trolley rope
5 Support for slewing ring 16 Load moment Limiter
6 Trolley 17 Load moment Limiter
7 Hook block 18 Tower
8 Counter jib ballast 19 Fixing angles
9 Cabin 20 Telescopic cage
10 Panel for feeding trolley, slewing 21 Chassis frame
11 Hoist unit 22 Foundation block

16
2.1.2 Jib Lengths, Load diagrams, Speeds

OVERALL DIMENSION

14m 61.2m

60m

11.6m 60m
10t 1.8m 1.6t

HUH 45.6m
55m
2.0t

50m
2.5t

45m
3.0t
12 x 3.0m

40m
3.5t

35m
4.2t

30m
5.1t

1.6m
7.5m

0.44m

17
LOAD DIAGRAMS

Max.Load Jib Reach

Jib
t m 10 15 18 20 23 25 30 35 40 45 50 55 60
5.00 21.5 5.00 5.00 5.00 5.00 4.66 4.22 3.71 3.10 2.65 2.30 2.02 1.79 1.60
60m
10.0 11.6 10.0 7.78 6.32 5.60 4.76 4.32 3.47 2.87 2.43 2.08 1.81 1.59 1.40
5.00 24.2 5.00 5.00 5.00 5.00 5.00 4.84 3.90 3.42 2.93 2.55 2.25 2.00
55m
10.0 13.1 10.0 8.73 7.18 6.37 5.44 4.94 4.00 3.34 2.84 2.46 2.15 1.90
5.00 26.3 5.00 5.00 5.00 5.00 5.00 5.00 4.32 3.78 3.25 2.83 2.50
50m
10.0 14.3 10.0 9.53 7.89 7.01 5.99 5.45 4.42 3.70 3.15 2.73 2.40
5.00 27.6 5.00 5.00 5.00 5.00 5.00 5.00 4.57 4.01 3.44 3.00
45m
10.0 15.0 10.0 10.0 8.27 7.39 6.32 5.75 4.67 3.91 3.34 3.10
5.00 28.1 5.00 5.00 5.00 5.00 5.00 5.00 4.65 3.88 3.50
40m
10.0 15.3 10.0 10.0 8.41 7.51 6.43 5.85 4.75 3.98 3.40
5.00 29.3 5.00 5.00 5.00 5.00 5.00 5.00 4.91 4.10
35m
10.0 16.0 10.0 10.0 8.85 7.91 6.77 6.16 5.01 4.20
5.00 30.0 5.00 5.00 5.00 5.00 5.00 5.00 5.00
30m
10.0 16.1 10.0 10.0 8.93 7.98 6.88 5.27 5.10

MAST SECTION

18
TOWER CONFIGURATION

Tower m Working Not working

Body condition condition
H1 33.0
H4 H2 24.0
H3 34.5
H4 34.5
H5 15.0
H3 H6 24.5
H2

H1 H1

MECHANISM’S SPECIFICATION

Mechanism’s Specification m Motor Remark

t 1.25 2.5 5 2.5 5 10 Inverter

Hoisting 37LVF 500 37Kw control
m/min 0 - 94 0 - 62 0 - 36 0 - 47 0 - 31 0 - 18 (45Kw)

Trolleying 95JXL1 m/min 0 - 58 95Nm

Slewing RCV95 r/min 0 - 0.8 95NmX2

Power Supply 380V 50Hz/440v 60Hz

Necessary Electric Power 90KVA

19
2.1.3 Tower configurations, hook heights, erection sequence

2.1.3.1 MAST COMPOSITION

2.1.3.1.1 Free standing cranes

− The mast compositions on pages 2.1.3.1.3 are given for free standing heights IN SERVICE and
OUT OF SERVICE and for the static and rail−mounted versions indicated in the data sheet
”TELESCOPIC”

. The assembling order is that given in paragraph 2.1.3.1.3 for reasons of strength. These
documents deal with the optimum composition of the crane tower which is not allowed to be lower.
But it is possible to fit stronger sections (*).

Specific to this operation.

· UNUSUAL CASES
· With rigid anchorages to the building

− The mast compositions and the loads applied on the frames are given in the chapter 2.1.3.1.3

· With anchorage by guy ropes

Please consult us

· With climbing inside the building

− The mast compositions and the loads applied on the frames are given in the chapter 2.1.3.1.3
specific to this operation.
(*) Please consult us

· REDUCING THE FREE STANDING HEIGHT DUE TO THE TELESCOPIC CAGE.

If, for reasons of later increase in height, the telescopic cage is to be left at the top of the masts, it
is absolutely necessary to reduce the free standing height ”IN SERVICE” and ”OUT OF SERVICE”
by removing
X mast sections (**). (**) COMPULSORILY consult us

IMPORTANT: The very high cranes are subjected to a downgrading of the load, see chapter
”Special characteristics”.

20
2.1.3.1.2 A set of mast sections

· SECTIONS OF 7,5 m LENGTH

− L68J Cross section 2,00 x 2,00 m − length 7,5 m − Upright L 200x20 − Monoblock mast section
− with lugs.
allows starting telescoping with mast sections of 3 m length − Lower joint Ø 50 − upper joint Ø 50.

· SECTIONS OF 3 m LENGTH
− L68A1 Cross section 2,00 x 2,00 m − l e n g t h 3 m

·SECTIONS OF 7,5 m LENGTH

− L46J Cross section 1,60 x 1,60 m − length 7,5 m − Upright L 180x18 − Monoblock mast section
− with lugs.
allows starting telescoping with mast sections of 3 m length − Lower fish joint Ø 50 − upper fish joint
Ø 50.

· SECTIONS OF 7,5 m LENGTH

− L46A1 Cross section 1,60 x 1,60 m − length 3 m − Upright L 180x18
Allows starting telescoping with mast section of 7.5m length-Lower fish
Jointφ50-upper fish jointφ50.

21
2.1.4 Jib and tie bar configurations

22
2.2.2.1 INSTALLATION ON FIXING ANGLES
The following tables define:
- the loads and the reactions applied on the fixing angles in service and out of service.
- the calculation of the concrete blocks
- the choice of the concrete blocks and the pressure under the concrete blocks
There is one table for each type of installation as described in the DATA SHEETS.
The dimensions of the fixing angles, the setting of the fixing angles in the concrete blocks as well
as the execution plans are shown in a brochure corresponding to this type of installation.

CONDITIONS OF EXECUTION
BY THE CUSTOMER
The tables of reactions and loads, the dimensions of the fixing angles and the setting of the fixing
angles in the concrete block are necessary and sufficient in order to determine a concrete block
(dimensions and reinforcement).
The indicated reactions and loads do not include coefficients for dead weights nor dynamic coeffi-
cient for the lifting load.
It is appropriate to take into consideration the usual or standardized safety coefficients valid for the
indicated loads and reactions. If not, it is advised to apply at least a safety coefficient of 1,5.

IMPORTANT: FOR THE REQUIREMENTS REGARDING THE GROUND STABILITYOF THE

CRANE MINIMUM DIMENSIONS ON THE GROUND AREPRESCRIBED AS WELL AS A MINI-
MUM MASS WHICH ARE EQUALTO THOSE OF THE SMALLEST PERMISSIBLE CONCRETE
BLOCK(SEE CHAPTER 17A−0230 “Pressure under the concrete blocks”)GIVEN IN THE BRO-
CHURE CONCRETE BLOCKS AND FIXINGANGLES (Chapter 18A Execution of the concrete
blocks) AND COM-PATIBLE WITH THE GROUND PRESSURE AT THE ERECTION SITE.(SEE
CHAPTER “Pressure under the concrete blocks”). FOR ANY OTHER DIMENSIONS WHICH DO
NOT OBSERVE THESE RECOMMENDATIONS PLEASE CONSULT US.

· ACCORDING TO THE PRESCRIPTION OF POTAIN: in compliance with

French Standards
If not usable abroad, prepare the concrete block according to the paragraph or consult us.

· Choosing procedure
The permissible ground pressure of the site determines the optimum type of concrete block to be
usedfor the final height to be obtained and for the each type of installation and crane. For all cases
of height,choose the concrete block which has a ground pressure less than or equal to the ground
pressure of the site (see
paragraph 3.3 of the tables).

· Execution of the concrete blocks

The plan described in chapter 18A is in compliance with the maximum loads given for each case
23
2.1.3.1.5 mast composition (climbing)

MAST COMPOSITION (CLIMBING INSIDE THE BUILDING)-BA45A

HSC: HEIGHT UNDER HOOK
D: DISTANCE BETWEEN COLLARS
P: WEIGHT
R1: STRESS IN THE UPPER COLLAR
R2: STRESS IN THE LOWER COLLAR

STRESSES FOR CLIMBING CRANE (Cont’d)

I In service II Out of service I
Read wind/Jib

HSC D P R1 R2 P R1 R2
m m KN KN KN KN KN KN

13.00 622 101.73 76.15 522 177.18 73.68

13.50 97.96 72.39 170.62 67.12
14.00 94.46 68.89 164.53 61.03
14.50 91.20 65.63 158.85 55.35
15.00 88.16 62.59 153.56 50.06
15.50 85.32 59.75 148.60 45.11
16.00 82.65 57.08 143.96 40.46
16.50 80.15 54.58 139.60 36.10
17.00 77.79 52.22 135.49 31.99
17.50 75.57 50.00 131.62 28.12
18.00 73.47 47.90 127.96 24.47
18.50 71.48 45.91 124.51 21.01
19.00 69.60 44.03 121.23 17.73
19.50 67.82 42.25 118.12 14.62

24
2.1.3.1.6 Erection sequence

25
26
2.1.5 Counter jib ballast

27
28
29
30
31
32
33
34
2.1.7 Ropes dimensions and constructions

Hoist rope *

Rated diameter 4 mm

Code No: 35Wx7

Standard: Q/320201PE004-2005

Surface of wires: bright (NAT)

Rated strength of wires: 1770 Mpa

Minimum breaking load: 138 kN

Type of lay and its direction: Cross lay, right-handed (ZS)

Trolley rope *

Rated diameter: 7.7 mm

Code No: 6X19W

Standard: GB/T 8918

Surface of wires: bright (NAT)

Rated strength of wires: 1870 Mpa

Minimum breaking load: 30.20 kN

Type of lay and its direction: Cross lay, right-handed (ZS)

Lengths in m

Jib length 30 35 45 40 50 55 60 Drum capacity

Hoist rope 50.0 55.0 65.0 60.0 70.0 75 80 50.0

Front 69.0 79.0 99.0 89.0 109.0 119 129 63.0

Trolley rope Rear 41.0 46.0 56.0 51.0 61.0 66 71 63.0

* Contact manufacturer if using other makers

² - for determination of total length of hoist rope add to dead length:
2-fall rope - add 2 times of hook height
4-fall rope - add 4 times of hook height

35
2.1.8 Packing list

36
 2.2 CRANE ON FOUNDATION

2.2.1 Foundation loadings

1.6M MAST SECTION JIB LENGTH 30

Hook Foundation loading Foundation place Total Weight P Ground

height Nc Mc H I h NF NC +NF P
H
kN kNm kN m m kN kN kN/m2
17 395.4 1427 63.9 4.8 1.50 829 1224.4 147.1
23 419.0 1703 68.5 5.0 1.50 900 1319.0 155.5
29 442.6 2021 74.0 5.2 1.50 973 1415.6 165.9
35 466.2 2379 80.1 5.5 1.50 1089 1555.2 164.9
41 489.8 2790 86.4 5.8 1.50 1211 1700.8 165.2
47 523.4 3190 93.4 6.25 1.50 1406 1929.4 147.1

JIB LENGTH 35-40-45

Hook Foundation loading Foundation place Total Weight P Ground

height Nc Mc H I h NF NC +NF P
H
kN kNm kN m m kN kN kN/m2
17 477 1456 65.2 4.8 1.50 829 1306.0 149.9
23 500.6 1738 69.9 5.0 1.50 900 1400.6 157.7
29 524.2 2061 75.6 5.2 1.50 973 1497.2 167.2
35 547.8 2427 81.7 5.5 1.50 1089 1636.8 166.4
41 571.2 2849 88.2 5.8 1.50 1211 1782.4 166.9
47 595.0 3239 95.4 6.25 1.50 1406 2001.0 148.8

JIB LENGTH 50-55-60

Hook Foundation loading Foundation place Total Weight P Ground

height Nc Mc H I h NF NC +NF P
H
kN kNm kN m m kN kN kN/m2
17 514.4 1428 66.5 4.8 1.50 829 1343.4 148.4
23 538.0 1716 71.3 5.0 1.50 900 1348.0 156.4
29 561.6 2047 77.1 5.2 1.50 973 1534.6 166.1
35 585.2 2421 83.4 5.5 1.50 1089 1674.2 165.9
41 608.8 2849 90.0 5.8 1.50 1211 1819.8 166.8
47 632.4 3243 97.3 6.25 1.50 1406 2038.4 149.0

37
2.0M MAST SECTION JIB LENGTH 30

Hook Foundation loading Foundation place Total Weight P Ground

height Nc Mc H I h NF NC+NF P
H kN kNm kN m m kN kN kN/m 2
12 384 1072 61.7 4.8 1.50 810 1213.44 117.01
15 398.8 1190 63.9 4.8 1.50 810 1228.24 126.07
18 413.6 1308 66.2 4.8 1.50 810 1243.04 136.17
21 428.4 1427 68.5 5.6 1.35 1010 1444.46 98.37
24 443.2 1565 71.2 5.6 1.35 1010 1459.26 104.55
27 458.0 1703 74.0 5.6 1.35 1010 1474.06 111.28
30 472.8 1862 77.1 5.6 1.35 1010 1488.86 119.80
33 487.6 2021 80.1 5.6 1.35 1010 1503.66 129.34
36 502.4 2200 83.2 5.6 1.35 1010 1518.46 141.54
39 517.2 2379 86.4 5.6 1.35 1010 1533.26 155.70
42 532.0 2582 89.9 5.6 1.35 1010 1548.06 174.90
45 546.8 2790 93.4 6.25 1.35 1260 1812.43 127.52
48 561.6 2990 95.8 6.25 1.35 1260 1827.23 137.46
51 576.4 3190 98.2 6.25 1.50 1420 1982.65 146.68
54 591.2 3757 101.2 6.25 1.50 1420 1997.45 175.05
57 606.0 4192 103.7 6.25 1.70 1690 2303.38 177.46
60 620.8 4646 106.8 6.25 1.70 1690 2318.18 205.24

JIB LENGTH 30-40-45

Hook Foundation loading Foundation place Total Weight P Ground

height Nc Mc H I h NF NC+NF P
H kN kNm kN m m kN kN kN/m 2
12 434 1096 63.1 4.8 1.50 810 1244 120.39
15 446 1214 65.2 4.8 1.50 810 1256 129.16
18 458 1332 67.3 4.8 1.50 810 1268 138.94
21 470 1456 69.9 5.6 1.35 1010 1480 100.71
24 482 1596 72.0 5.6 1.35 1010 1492 106.81
27 494 1738 75.6 5.6 1.35 1010 1540 113.67
30 506 1895 77.7 5.6 1.35 1010 1516 121.93
33 518 2016 81.7 5.6 1.35 1010 1528 131.90
36 506 2241 83.8 5.6 1.35 1010 1516 144.57
39 542 2427 88.2 5.6 1.35 1010 1552 159.09
42 554 2632 90.3 5.6 1.35 1010 1564 178.69
45 566 2849 95.4 6.25 1.35 1260 1826 130.32
48 578 3025 97.5 6.25 1.35 1260 1838 139.19
51 590 3239 99.6 6.25 1.50 1420 2010 149.15
54 604 3757 101.7 6.25 1.50 1420 2024 181.69
57 614 4192 103.8 6.45 1.70 1690 2309 178.79
60 634 4646 105.9 6.45 1.70 1690 2324 208.64

38
 JIB LENGTH 50-55-60

Hook Foundation loading Foundation place Total Weight P Ground

height Nc Mc H I h NF NC+NF P
H kN kNm kN m m kN kN kN/m 2
12 471 1079 62.8 4.8 1.50 810 1280 120.5
15 483 1182 66.5 4.8 1.50 810 1312 128.0
18 495 1285 68.9 4.8 1.50 810 1305 136.0
21 507 1428 71.3 5.6 1.35 1010 1407 100.7
24 519 1560 74.4 5.6 1.35 1010 1529 106.3
27 531 1716 77.1 5.6 1.35 1010 1431 113.4
30 543 1856 80.5 5.6 1.35 1010 1553 120.5
33 555 2047 83.4 5.6 1.35 1010 1528 131.2
36 567 2189 86.7 5.6 1.35 1010 1577 140.2
39 579 2421 90.0 5.6 1.35 1010 1668 157.4
42 591 2605 93.6 5.6 1.35 1010 1601 173.8
45 603 2849 97.3 6.25 1.35 1260 1863 130.2
48 615 3012 100.9 6.25 1.35 1260 1875 138.2
51 627 3243 104.5 6.25 1.50 1420 2047 149.2
54 641 3757 108.4 6.25 1.50 1420 2061 180.4
57 655 4192 112.3 6.45 1.70 1690 2345 178.5
60 669 4646 115.6 6.45 1.70 1690 2359 207.5

TECHNICAL PARAMETER
These Loading are valid for free slewing crane out of service
Slewing Moment Ms = 100KNm (for jib lengths 30)
Slewing Moment Ms = 141KNm (for jib lengths 35 – 40)
Slewing Moment Ms = 182KNm (for jib lengths 45 – 50)
Slewing Moment Ms = 210KNm (for jib lengths 55 – 60)

39
TT6016-10 TOWER CRANE
Foundation Calculation

Static Crane

1.6M MAST SECTION

Reverse Force of Fixing Angle--Working Condition：

Reverse Force of Fix Angle

Height (H)
F1(ton) F2(ton F3(ton) F4(ton)
7.5m 82 -56 14 14
13.5m 90 -64 15 15
19.5m 98 -65 16 16
25.5m 110 -74 17 17
31.5m 122 -88 18 18
37.5m 132 96 19 19
43.5m 145 105 20 20

40
Reverse Force of Fixing Angle--Non-working Condition：

Reverse Force of Fix Angle

Height (H)
F1(ton) F2(ton) F3(ton) F4(ton)
7.5m 76 -50 13 13
13.5m 84 -56 14 14
19.5m 98 -62 15 15
25.5m 112 -78 16 16
31.5m 125 -92 17 17
37.5m 146 -105 18 18
43.5m 160 120 19 19

2.0M MAST SECTION

Reverse Force of Fixing Angle--Working Condition：

Reverse Force of Fix Angle

Height (H) F1(ton) F2(ton) F3(ton) F4(ton)
7.5m 75 -42 15 15
13.5m 83 -46 16 16
19.5m 90 -52 17 17
25.5m 98 -58 18 18
31.5m 106 -64 19 19
37.5m 115 -70 20 20
43.5m 121 -78 21 21
49.5m 130 -86 22 22
55.5m 138 -94 23 23
61.5m 152 -106 24 24

Reverse Force of Fixing Angle--Non-working Condition：

Reverse Force of Fix Angle

Height (H) 41
F1(ton) F2(ton) F3(ton) F4(ton)
7.5m 88 -45 11 11
13.5m 98 -70 12 12
19.5m 108 -78 13 13
25.5m 116 -83 14 14
31.5m 125 -90 18 18
37.5m 136 -98 19 19
43.5m 148 -107 20 20
49.5m 160 -115 21 21
43.5m 172 -126 22 22
49.5m 180 -135 23 23

41
2.2.2 Preparation of foundation plate
2.2.2.1 INSTALLATION ON FIXING ANGLES
The following tables define:
- the loads and the reactions applied on the fixing angles in service and out of service.
- the calculation of the concrete blocks
- the choice of the concrete blocks and the pressure under the concrete blocks
There is one table for each type of installation as described in the DATA SHEETS.
The dimensions of the fixing angles, the setting of the fixing angles in the concrete blocks as well
as the execution plans are shown in a brochure corresponding to this type of installation.

CONDITIONS OF EXECUTION
BY THE CUSTOMER
The tables of reactions and loads, the dimensions of the fixing angles and the setting of the fixing
angles in the concrete block are necessary and sufficient in order to determine a concrete block
(dimensions and reinforcement).
The indicated reactions and loads do not include coefficients for dead weights nor dynamic coeffi-
cient for the lifting load.
It is appropriate to take into consideration the usual or standardized safety coefficients valid for the
indicated loads and reactions. If not, it is advised to apply at least a safety coefficient of 1,5.

IMPORTANT: FOR THE REQUIREMENTS REGARDING THE GROUND STABILITYOF THE

CRANE MINIMUM DIMENSIONS ON THE GROUND AREPRESCRIBED AS WELL AS A MINI-
MUM MASS WHICH ARE EQUALTO THOSE OF THE SMALLEST PERMISSIBLE CONCRETE
BLOCK(SEE CHAPTER 17A−0230 “Pressure under the concrete blocks”)GIVEN IN THE BRO-
CHURE CONCRETE BLOCKS AND FIXINGANGLES (Chapter 18A Execution of the concrete
blocks) AND COM-PATIBLE WITH THE GROUND PRESSURE AT THE ERECTION SITE.(SEE
CHAPTER “Pressure under the concrete blocks”). FOR ANY OTHER DIMENSIONS WHICH DO
NOT OBSERVE THESE RECOMMENDATIONS PLEASE CONSULT US.

· ACCORDING TO THE PRESCRIPTION OF POTAIN: in compliance with

French Standards
If not usable abroad, prepare the concrete block according to the paragraph or consult us.

· Choosing procedure
The permissible ground pressure of the site determines the optimum type of concrete block to be
usedfor the final height to be obtained and for the each type of installation and crane. For all cases
of height,choose the concrete block which has a ground pressure less than or equal to the ground
pressure of the site (see
paragraph 3.3 of the tables).

· Execution of the concrete blocks

The plan described in chapter 18A is in compliance with the maximum loads given for each case
42
2.2.2.2 SUBSTRUCTURE ON FIXING ANGLES

INSTALLATION ON FIXING ANGLES

· GENERAL NOTES
There is only one type of fixing angles:
− Not reusable fixing angles; they are set into the concrete block
The choice of the concrete block and the loads and reactions applied on the fixing angles are given
in the brochure 17A

· FITTING THE FIXING ANGLES

A bad mounting of the fixing angles may cause serious troubles when using the crane
(perpendicularity not observed, warpage of the fitting surfaces of the mast)
An operating method is given as indication in paragraph 18A−0420 for not reusable fixing angles
The fitting elements (frame, standard mast section) recommended in the operating method can be
supplied at the same time as the fixing angles and before the crane
NOTE: The frame is only used for fitting the fixing angles

· EXECUTION OF THE CONCRETE BLOCKS

The plans described on the following pages are in compliance with the maximum loads given for
each case

IMPORTANT : The reinforcement is given on the following pages as an indication and can be
carried out differently, if necessary, under the responsibility of a competent specialist

43
DIMENSIONS OF THE FIXING ANGLES (10A)

44
DIMENSIONS OF THE FIXING ANGLES (10B)

45
DIMENSIONS OF THE FIXING ANGLES

6
2

3
5

3 3

3
5

5 5 3

46
46
· SETTING INTO CONCRETE OF THE FIXING ANGLES
In order to set perfectly into concrete the fixing angles, following components are necessary:
- 4 fixing angles and 8 shafts - 1 template - 1 sighting device
The fixing angles and the template can be supplied before the delivery of the crane
The fixing angles must be symmetrically set into concrete with regard to the axes of the concrete
block and form a square according to the dimension of the masts to be fitted
Tolerance of surface evenness: 1/400 of the mast cross−section
Near the fixing angle, NEVER CUT REINFORCING STEELS NOR REDUCE THEIR NUMBER
GIVEN
Take care that the fixing angles are correctly earthed (see Operating Instructions)
The template is only used for fitting the fixing angles

IMPORTANT: When assembling the fixing angles and the template, make sure that the bearing
surfaces of borings and shafts are clean and free from any smear
− Outside or inside the ditch, arrange the fixing angles (1) by observing their distance (Detail A −
Figure1) −
Engage the template (2) into the 4 fixing angles; lower it until it comes to rest onto the fishplates at
(a) (Detail C − Figure 1)
− Engage the standard mast section (3) into the fishplates of the fixing angles (Detail B − Figure 1)
Raise the template (2) in order to pin−connect the 4 x 2 shafts (4) Block the shafts (4) by means of
the pins (5); fix
the pins with split pins (Detail C − Figure 1)

− Position the assembly comprising the fixing angles, the template and standard mast section in the rein-
forcement arranged in the ditch and carry out an adjustable wedging (1) under the plates of the fixing angles
(Detail A − Figure 2)
IT IS ESSENTIAL TO OBSERVE THE DIMENSION OF 150 mm (Detail B − Figure 2)
− Check the perpendicularity of the assembly by means of the sighting device
− Pour the concrete block and wait that it is completely dry before dismantling the template and the standard
mast section
47
2.2.2.4 PREPARING THE CONCRETE BLOCKS

· FABRICATION RULES FOR REINFORCED CONCRETE

Concrete and reinforcement determined according to the BAEL (reinforced concrete boundary condition)
Rules, 1983

· CONCRETE
− ftj = characteristic tensile strength of the j days old concrete
− fcj = characteristic compressive strength of the j days old concrete
NOTE 1 − In any case, the compressive strength is measured by axial pressure of the cylinder having a
periphery of 200 cm2 cross section and a height which is the double of its diameter (16 cm) These dimen-
sions suppose an aggregate size of at least equal to 40 mm, a condition generally fulfilled for reinforced
concrete
NOTE 2 − The dimensions and characteristics of the reinforcements and of the concrete for the execution
of concrete works indicated in this manual, are defined by a compressive strength value at 28 days old (j =
28)
Reinforced concrete mixing of 350 kg/m3 − CPA45 that means, for 1 m3 of sand with gravel:
350 kg PORTLAND cement 45 For a vibrated concrete correctly prepared, we obtain:
fc28 = 20Mpa ft28 = 0,6+0,06fc28 = 1,8MPa
P = Weight of reinforced concrete in daN
D = Average density of reinforced concrete equal to about 2,35

·STEEL (except other indications)

Es: Longitudinal modulus of elasticity of steel: 200000 N/mm2
ie 200000 MPa
Type 1: Reinforcement with high adherence obtained by hot−rolling of natural high−carbon steel
SHOULD THE ABOVE RULES NOT APPLY, REFER TO THE RULES APPLIED IN THE USER COUNTRY

· EXPLANATION AND SYMBOLS

Designation of a concrete block (M54N)
- M: Concrete block
- 54: Weight of the concrete block in tons
- N: Internal coding
The reinforcement of a concrete block is composed of an upper and a lower reinforcing cage connected by
pins Each cage comprises two crossed layers

Upper layer Lower layer

ep: Pin
D: Density
V: Volume in m3
L: Length in cm
l: Width in cm
H: Height in cm
1LH : First upper layer
1LB : First lower layer
2LH : Second upper layer
2LB : Second lower layer

48
· D CONCRETE BLOCK（ M109N）

49
· E CONCRETE BLOCK（ M121N)

50
· E CONCRETE BLOCK（ M140N）

51
· E CONCRETE BLOCK（ M169N）

52
FORCES-STRESSES

C Mast composition
H Hoot height in m – See data
P W eight
M Maximum moment
ET Shearing stress
R Stresses
TRACT Tension
COMP Compression
ES In service
HS Out of service

ES HS
R R
H P M ET P M ET
TRACT COMP TRACT COMP
C
m kg mkg kg kg kg kg mkg kg kg kg
1+0+1 8.8 51200 98596 1631 33740 59340 41200 72760 3988 24045 44645
1+1+1 11.8 52350 102840 1764 35457 61632 42350 72760 4413 23757 44932
1+2+1 14.8 53500 107486 1897 37362 64112 42500 72760 4838 23470 45220
1+3+1 17.8 54650 112529 2030 39455 66780 44560 72760 6013 23182 45507
1+4+1 20.8 55800 117970 2162 41736 69636 45800 72760 6438 22895 45795
1+5+1 23.8 56770 123571 2284 44137 72522 46770 72760 6827 22652 46037
1+6+1 26.8 57740 129537 2406 46711 75581 47740 72760 7362 22410 46280
1+7+1 29.8 58710 135868 2527 49457 78812 48710 84478 7897 27699 52054
1+8+1 32.8 59680 142563 2649 52374 82214 49680 108852 8432 38962 63802
1+9+1 35.8 60650 149623 2770 55464 85789 50650 134832 8967 50982 76307
1+10+1 38.8 61620 157047 2892 58727 89537 51620 162415 9502 63760 89570
1+11+1 41.8 62590 164837 3013 62161 93456 52590 191603 10036 77295 103590
1+12+1 44.8 63560 172990 3135 65767 97547 53560 222395 10571 91588 118367
1+13+1
1+14+1
1+15+1
1+16+1
1+17+1
1+18+1
1+19+1
1+20+1

53
2.2.3 Earthing

The user is responsible for the installation of the protective bonding system and must ensure that the mini-
mum requirements established by the standard are attent.
As for the sizes, installation, test and maintenance of the protective earthing system against atmospheric
discharges, the laws and standards of the country, where the crane is assembled are to attend.

Conductor must be connected on one of the fixing plates

54
2.2.4 Electric power supply
The electric equipment of the crane must always be connected to the bonding circuit. The user
must provide the necessary electrical supply and wiring/connections for the crane to meet its elec-
tric energy needs, adhere to the specifications described herein, and conform to standard electrical
codes as well as conform to the norms for electrical installations in the place and country where the
crane in being installed.

For the dimensions of the connection see the maximum wire lengths and cross-sections diameters
of the conductors according to the electrical load applied.

Results depicted in the table use the following requisites as the basic for making the calculations:
symmetrical and balanced three-phase system with 380 V voltage, 50 Hz frequency, 0.8 (cos j)
power factor and power cable capable of withstanding a continuous working temperature of 60°C.

For exposed cables or cables routed through underground conduits, it is suggested to use NIVVK
fire retardant type cable. For other type of installation, such as using a cable reel, it is advisable to
select the most suitable type basing on the sectional area, length, weight and bending radius, if
any.

The electrical power source must meet the requirements for the particular crane and likewise
comply with the established standards

CEI EN 60204 standards are applicable to the electrical equipment of the crane: therefore, voltage
requirements must be within a 10% maximum tolerance, and the maximum marginal frequency
variance for a short period of time is 2% (cf. CEI EN 60204 4.3.1).

The user must ensure that the power source voltage and frequency requirements meet the specifi-
cations and standards necessary to operate the crane. Remember that the frequency requirement
is particularly important should generating sets be used for feeding the crane.

Manufacture’s technical department is at customers’ disposal for any needed assistance, clarifica-
tions, or for providing service for any special need that could arise at the building yard.

Adequate overload protection for the mains must be provided depending on the electrical require-
ments of the crane. Fuses used for line protection must be “aM” type. If thermal or differential
cut-out circuit breakers are used to protect the line input, the electrical protection curve of these
protection devices must be like that of starting squirrel-cage motors (D curve).

The connection between carne and the earth bounding circuit must be completed before the crane
is connected to the main power supply.

55
CHAPTER 3 - GENERAL INSTRUCTIONS FOR ASSEMBLY
3.1 INTRODUCTION

The responsibility for the preparation of the crane building yard rests entirely with the crane user. Any clear-
ing, leveling, building up or reinforcing of the ground where the crane will be positioned and operated will be
carried out by him as well as the verification of feasibility of the different crane installation proposed by the
manufacturer

3.2 GROUND CONSISTENCY

The primary requirements to be met on the building yard before the arrival of the crane are the installation
of the base platform or travelling rails, depending on the configuration chosen.

The installation of such elements depends particularly on the type of ground and foundation on which these
assemblies are to be placed, as well as on the configuration characteristics of the crane.

The Buyer therefore must carry out a careful inspection and analysis of the ground consistency on which
the crane is to stand.

3.3 CRANE INSTALLATION AREA

When choosing the location for the crane at the building yard, the Client must be particularly careful to
ensure that the crane is not obstructed during its operational movements. Likewise he has to verify that,
when the crane is under no-working conditions, its free slewing doesn’t allow coming in contact with existing
buildings, buildings under construction, stored materials, scaffolding, adjacent cranes, machines, installa-
tions, cables, trees, etc.

Nearby electrical lines must be at a minimum safety distance of 5 m from the slewing
unit of the crane.

In any case, the local electricity board must be contacted to verify the minimum safety distance recommend-
ed from high intensity electrical power cables or transformers.

56
 3.4 MORE CRANES ON THE SITE

When two or more cranes are working at close range (inferior to the respective jib lengths sum) in
the same building yard can interfere each other. The following precautions must be taken:

Jibs must be offset to avoid collision of any structural parts considering

the maximum oscillation amplitude and a reasonable safety distance.

The minimum distance between the two cranes must anyhow be great enough to
prevent the cables and loads of the higher crane from interfering with the lower crane.

In case of interfering cranes electrical or radar anti-collision devices can be installed

to limit the crane working range. Always consult the manufacturer for the installation
of this safety device, once ascertained it really serves the purpose.

Remember that cranes must be always staggered in height to avoid any interference when under
no-working conditions.

57
 3.5 INSPECTION OF THE BUILDING YARD

Before starting work, the supervisor of the crane assembly is obliged to inspect the building yard
and ensure that everything has been properly arranged.

The person in charge of the building yard shall be advised of any insufficiency that the problem can
be resolved.

Assembly of the crane shall proceed only if the building yard conforms to the points listed below.

Before the crane is installed, the supervisor shall check that:

a) the manouvering area of the crane is free of obstacles (trees, buildings, electric lines, telephone
lines, etc.);
b) the curing time of the foundation plate, base and ballasts is adequate;
c) the ballast and calibration weights correspond to the required specifications;
d) The travelling stop buffers are available and assembled when installing a travelling crane;
e) The electric connections are adequate;
f) mobile crane suitable for the work to be carried out.
g) The supervisor shall inspect the slinging debices (ropes, slings, chains), which are tobe used for
lifting the crane components.

The supervisor must inform the mobile crane operator of the exact weight of the
parts that are to be hoisted.

The mobile crane operator is fully responsible for the slinging and hoisting of the loads
The weights of the crane components see chapter 4 in Assembly – disassembly.

58
 3.6 GENERAL INSTRUCTION FOR CRANE OPERATOR AND ASSEMBLY TEAM

The crane must be used only by skilled (crane operator with licence).
The operator is authorized to carry out only those operations described herein below attaining to
the relative instructions.

As the crane can perform more than one movement at a time, it’s upon the operator to control this
simultaneousness according to the visibility of the suspended load.

The operator must be able to follow the trajectory of the moving load at any moment.

If not, he must take precautions; in particular, he must be assisted by other people who, with verbal
and / or hand signals, provide him with all the information necessary to work in safety.

For a correct use of the crane, the operator must observe the crane maintenance rules and carry
out periodical inspections of the whole system as described in chapter 7 - Maintenance. The use
of original spare parts or spare parts however recommended by the manufacturer plays a promi-
nent part in the correct use of the crane.

Any subsidiary material necessary to the building yard, such as buckets, belts, etc. and belonging
to the buyer must be suitable for the correct use of the crane and in conformity with the territorial
regulation in force.
- All national and local safety standards must be adhered to.
- May wind speed during the assembly – see chapter 4 – Assembly.

59
3.7 UNALLOWED CRANE MOVES

60
 3.8 ASSEMBLY AND DISASSEMBLY ADVICES

Assembly and disassembly of the crane must be done by skilled supervisor, who have attended a
specific training course.

Crane users are advised to contact (manufacturer or his agents) for qualified supervisor.

Should the user employ other supervisors, their ability should be verified before handling the crane.
In this case crane manufacturer declines any criminal and public liability.

For the crane assembly and disassembly at least three skilled technicians are needed:
Two in charge of the overhead assembly, one of the coordinations of the oerations on
the ground.

3.8.1 Safety precautions

The supervisor must observe the following safety precautions before starting the assembly or disas-
sembly of the crane:

a. he must not operate with inclement weather conditions;

b. he must operate in perfect psychophysical conditions and he must check that the individual and
personal accident prevention devices are available and serviceable;
c. he must wear a safety helmet which is integral;
d. he must wear an approved safety belt which is in perfect condition;
e. he must wear accident-prevention shoes;
f. he must use tools equipped with electric insulation;
g. should the components pre-assembled on the ground be wet or damp, he must not carry out the
overhead assembly of the crane;
h. for the safety of people and things, the supervisor must be sure that barriers are placed around
the assembly and disassembly area and that there are no unauthorized people allowed into the
working area.

61
3.8.2 Hand signals

Supervisor must explain the hand signals to his technicians.

Danger Horizontal distance

Start Moving to the Left

Stop Moving to the right

End Lifting

Vertical distance Lowering

62
3.8.3 Prevention signs

If it's possible the supervisor shall post the mandatory and prohibitory signs when the crane is
present on the building site.

Caution:Suspended loads No passage

Safety helmet No passage or standing within

the crane’s radius of action.

Safety belt Do not remove protective

And safety devices

Protective gloves Use by unauthorized

Personnel forbidden

Protective shoes Do not work on moving parts

63
CHAPTER 4 - ASSEMBLY & DISASSEMBLY

4.1 GENERAL ASSEMBLY INFORMATION

4.1.1 Bolt connections on tower crane

Particularly bolt connections with high-strength pretension. (HV bolt connections)

General information
There are numerous bolt connections on a tower crane. It is their task to connect crane compo-
nents and to transfer forces.
Particular attention must be paid to the bolt connections with high-strength pretension. AII bolt co
nections belong to those parts of the tower crane which are highly important for the operational
safety of the crane. Consequently, all these bolt connections must be executed, maintained and
checked with the greatest of care.

Bolt connections which are tensioned manually with a wrench

Such bolt connections are connections which are tightened manually with a wrench. They must be
checked regularly in order to make sure they are tight and cannot loosen unintentionally. If such a
bolt connection Ioosens up, this may lead to accidents and damage, e.g. if a part of this bolt co nec-
tion falls down. Bolt connections with high-strength pretension

Definition
A bolt connection with high-strength pretension is a bolt connection consisting of bolts, nuts, wash-
ers and possibly also distance bushes, all parts of this connection being made of high-strength
material.
AII such bolt connections must be tensioned to their prescribed torque. In order to do this, a torque
spanner is required to accomplish said prescribed torque.

Places of application
Bolt connections with high-strength pretension are used anywhere where great forces must be
transferred from one crane component to another.
Speaking in terms of a tower crane, such components are:
● Slewing ring
● Tower sections
● Possibly also drive units Iike slewing units and hoist or trolley units erection

4.1.2 Parts belonging to a bolt connection

All parts of a bolt connection are marked separately. Regulations concerning quality and identifica-
tion are established by national and international standards.

64
4.1.3 Bolts

Bolts must be identified according to the international standard ISO 898 part. Property class, e.g.
8.8, 10.9 or 12.9 must be stamped on the bolt head as indicated in illustration:

4.1.4 Nuts
All nuts must be identified according to international standards ISO 898 part 2. According to ISO
898 part 2 symbols are also permitted for identification of the property class of nuts, however due
to their multifarious ness it is not possible to Iist them alI in this technical description. Only nuts of
the property class as stated in illustration below are permitted for use in a high-strength bolt con-
nection.

Furthermore the nuts must also be furnished with a sign of origin from the nut manufacturer. Nor-
mally such identification is placed close to the identification of the property class.

When making your choice of nuts, please make sure their property class is in
conformity with the strength property class of the bolt.

Example: Nut 8 - bolt 8.8

Nut 10 - bolt 10.9
Nut 12 - bolt 12.9
65
4.1.5 Washers

Since there are no ISO standards for washers as yet, washers produced for high strength bolt con-
nections are identified with RV in Germany, as shown in illustration below.

Only washers made of high-strength material may be used for high-strength bolt
connections. Such material must be in accordance with the material listed in
paragraph "Bolts and nuts'. We recommend only to use washers supplied by
BKT.
If washers of other makes are used, please make sure that their property class is
in accordance with the property class of the mating bolts and nuts.

Washers for bolt connections must have one side chamfered in order to avoid
any damage of the filleting of the bolt head.
For this reason the chamfered must always point towards the bolt head.

Distance bushes
For some high-strength bolt connections distance bushes are required for constructional reasons.
These are part of manufacturers scope of delivery. They must be installed according to the instruc-
tions in this operation manual.

4.1.6 Checking the different parts of bolt connections prior to installation

Condition of parts belonging to a bolt connection

All parts of a bolt connection must be cleaned and checked visually before they are fitted.
This visual check must comprise the threads of the bolt, the threads of the nut, the seat of the nut
on the bolt and the comer surface of the bolt shaft to the bolt head support.

Damaged bolts or nuts must never be used. Bolts with corrosion on shaft and in
their thread as weIl as rusty nuts must not be used. Damaged bolts or nuts or
bolts and nuts with only signs that they may be damaged must not be used.

Lubrication of the bolt connection elements

All bolts, nuts and washers must be lubricated with grease on a molybdenum desilphide basis
every time before they are fitted. This provides an even frictional resistance and this, in its turn,
guarantees a correct pretension of the bolt connection at any time.
66
 Grease to be applied on the threads of bolts and nuts and the support surface of the nut.

Note!
If the prescribed starting torque is applied on the bolt head, please do not fail to Iubricate
also the support surface of the bolt head.
Reuse of parts of the bolt connections
All parts of the bolt connections which were tensioned to the torque prescribed by our-
selves may be reused when erecting the crane anew.
This is, however, on the condition that all parts are checked according to paragraph
"Condition of elements belonging to a bolt connection" and show no damage.

4.1.7 Tensioning of bolt connections

Correct tensioning is an absolute must

A bolt connection can only fulfil1 its task provided it has been pretension to correct torque. The bolt
is lengthened through the torque and the crane parts to be connected are pressed together, thus
accomplishing an intensive tension of these parts.
The working life of a bolt depends highly on whether the correct torque was applied and thus the
pretension achieved.
A torque which is too high or too Iowa may lead to an early failure of the bolt connection.

The torque
In order to achieve the prescribed pretension, the bolt connection must be tightened using a torque
wrench.
The torque to be applied varies according to type and size of the bolts and nuts to be inserted.
Table enclosed in this operation instruction. Please confer this table for correct torque for each bolt
used.
When conferring the a.m. table, please bear in mind that the quality classes as per ISO 898 part 1
and part 2 were used as basis.
The wrench size across flats s as per enclosed table can be used to determine whether you have
a bolt as per DIN 6914, DIN 931 or DIN 912.

Non-lubricated bolts must under no circumstances be used in high-strength pretension

bolt connections.

Torque wrench
The torque prescribed in each case can only be applied using a torque wrench This torque wrench must
offer the possibility to set the torque as well as the tensioning direction.
If higher torqueses are required, multipliers must be used. Such multipliers are also called power drivers.
With such multipliers torques up to 9 500 Nm (950 m.kg) can be achieved. These torque wrenches must be
checked from time to time and adjusted if necessary.

67
 The tensioning torques must never diverge by more than +/- 10%.

A further possibility is to apply required torque using a hydraulic torque wrench When using a
hydraulic torque wrench the pressure within the hydraulic system is indicated in a manometer. To
a certain manometer pressure there is an appropriate torque.
The relation between manometer pressure and torque is to be found in the appropriate table which
is part of the information supplied for said hydraulic.

4.1.8 Inspection of installed bolt connections

The necessity to carry out inspections

Any bolt connection can loosen up.
This is also the case for HV-bolt collections. If these high-strength pretension bolt connections
loosen up, this may Lead to complete or partly Loss of the pretension. lf the pretension gets com-
pletely or partly Lost, this Leads to a premature fatigue of the bolt material. This represents a
danger of a fatigue breakage of the bolt. Also the joint may get ajar and the connection loosens up
all together.

Initial and repeated inspections of installed bolt connections

Initial inspection
Due to settlements in the bolt connections of new cranes and new crane parts this initial inspection
of all bolt connections must be carried out 3 weeks upon completed first erection at the Ieast. This
inspection must be carried out using the same torque wrench or multiplier.
The nut (or bolt) is then retensioned with a rated moment according to table 1. If no further tension
of the bolts is possible, then it may be assurred that the connection is ok. If it is possible to reten-
sion the bolts, the connection must be loosened up completely, new lubrication must be carried out.
Then fasten the bolt connection anew and apply the appropriate torque.

Repeated inspections
Repeated inspections must be carried out each time the crane is erected anew and furthermore at
Ieast once a year. If the crane works with more than one shift a day, such inspections must be
carried out with shorter intervals, as appropriate. Such inspections are carried out by loosening up
the bolt collections at random, taking out and checking the connecting bolt as specified in para-
graph "Condition of the bolt connection elements". Upon having done so, the bolt is relubricated,
reinserted and tensioned to prescribed torque.

Visual inspections
Repeated inspections by visual check ups must take place at least once every three months. It is
then sufficient to make sure no gaps have occurred between the tensioned parts, which would
mean that the bolt connections have loosened up.

Replacement of bolt connecting elements

If on any connecting level, which means anywhere where crane parts are connected to each other
(e.g. tower sections, roller bearing slewing ring) broken bolts or bolts with incipent fractures are
discovered, then all bolts on this connecting level must be replaced.
68
Regulations for prevention of accidents
Regular, scheduled inspections are prescribed in all regulations for prevention of accidents and it
is emph sized that the crane manufacturer's instructions must be strictly observed.
Such necessary, regular inspections were treated in the above paragraphs.

Bolt connections
For greased bolt connections with metrical ISO thread according DIN 13 or ISO 261 with or without
a galvanized coat the following starting torques are applicable

4.1.9 Table 1

Starting torques

Property Property Property

Class Class Class
8.8 (8G) 10.9 (10K) 12.9 (12K)
DIN 931/933 DIN 6914 DIN 931/933 DIN 931/933
DIN 912 DIN 912 DIN 912

Thread mkg Nm mkg Nm mkg Nm mkg Nm

M 12 5.2 51 9.8 96 7.4 73
M 14 8.4 82 13.0 127
M 16 14.0 137 24.7 242 19.1 187
M 18 18.0 177 26.0 255
M 20 25.9 254 48.3 474 37.0 363
M 22 35.8 351 66.0 647 51.1 501
M 24 44.9 439 83.0 814 64.0 628
M 27 70.0 686 123.0 1206 100.0 981
M 30 95.8 939 136.8 1342
M 33 130.9 1284 187.0 1834 230.8 2264
M 36 167.3 1641 239.0 2344 296.1 2904
M 39 217.3 2131 310.4 3044 383.6 3762
M 42 268.4 2632 383.4 3760 476.3 4670
M 45 335.4 3289 479.1 4693 594.8 5833
M 48 403.6 3958 576.6 5655 717.8 7039
M 56 900.0 8830

69
4.1.10 Table 2

Wrench sizes across flats “s”

DIN 931, 933, 934 DIN 912

DIN 6914, 6915

Wrench size across flats Wrench size across flats Wrench size across flats
Rated diameter
for boths according 931/933 for boths according DIN 6914 for inner hexagon bolts
of thread
for nuts according DIN 934 and nuts according DIN 6915 according DIN 912

mm mm mm mm
M 12 19 22 10
M 14 22 - 12
M 16 24 27 14
M 18 27 - 14
M 20 30 32 17
M 22 32 36 17
M 24 36 41 19
M 27 41 46 19
M 30 46 50 22
M 33 50 - 24
M 36 55 60 27
M 39 60 - -
M 42 65 - 32
M 45 70 - -
M 48 75 - 36
M 56 85 - -

70
 4.2 ERECTION CRANE TOWER P16B (1.6M)

MAST(DIMENSIONS AND WEIGHTS)

4.2.1 General notes

The dimensions and weights given in the tables on the following pages correspond to:
- The first line of each group indicates the dimensions and weight of the component assembled
with the parts as they are shown in the drawing.
- The following lines indicate the dimensions and weights of the main parts according to represen-
tation.
- The direction of dimensions L, I and h with respect to the mark concerns the main parts only.

IMPORTANT: The sum of the weights of the main parts is lower than the weight of the euipped
component because the weight of pins, bolts, small accessories, ect. is not taken into account.

4.2.2 .Basic mast

4.2.2.1 BASIC MAS L46J1 (7.5M)

Mark Qty DESIGNATION L I h P(daN)

Complete Basic Mast L46J 1670 1730 7740 2630

1 1 Unequipped Basic mast 1670 1730 7740
2 1 Ladder with back loops (*) (*) (*)
3 1 Ladder with back loops (*) (*) (*)

71
4.2.2.2 BASIC MAS L46J (7.5M)

Mark Qty DESIGNATION L I h P(daN)

Complete Basic Mast L46J 1670 1730 7740 2900

1 1 Unequipped Basic mast 1670 1730 7740
2 1 Ladder with back loops (*) (*) (*)
3 1 Ladder with back loops (*) (*) (*)

72
4.2.3 .Tower section L46A1 (3.0m)

(*) See space requieement of the accesses

Mark Qty DESIGNATION L I h P(daN)

Complete tower section L46 1670 1730 3240 1180

1 1 Unequipped tower section 1670 1730 3240
2 1 L46D
3 1 Access (*) (*) (*)

73
4.2.4 Tandara access (3m lenght)

Mark Qty DESIGNATION L I h P(daN)

Standard access 730 1082 3040 30

74
4.2.5 Resting platform

Mark Qty DESIGNATION L I h P(daN)

Resting platform 730 1640 3040 78

1 1 Unequipped platform 730 1640 210 34
2 1 Equipped ladder 730 1082 3040
3 1 Grab rail 715 80 595
4 3 Grab rail 980 30 1000

75
4.2.6 Access to the towerhead

Mark Qty DESIGNATION L I h P(daN)

Access to the towerhead 1255 1280 3040 110

1 1 Unequipped platform 1255 1280 200
2 1 Equipped ladder 730 1082 1540
3 2 Grab rail 1195 34 1000
4 2 Grab rail 1290 80 595
5 4 Support 575 195

76
 4.3 PREPARING THE MAST SECTIONS

IMPORTANT: Before using the mast sections, carry out a visual check of the bars and welds. Sec-
tions which show deformations or having the bars distorted or the welds cracked, must be returned
to the workshop for repairing.

4.3.1 Assembling themast sections L46A1

− A mast section comprises 4 panels which differ from another as follows:

- 2 panels (1 and 2) with telescoping lugs
- 2 panels (3 and 4) without telescoping lugs
− The panels equipped with the gussets for ladder fastening must face each other.
− The panels are assembled by 20 special fishplate bolts. In all cases, the bolt heads are located
on the outside.
− On the panels of mast sesction L46 A1, the plates are fitted on the outside.
− The mast sections are equipped with an access assembly.

77
4.3.1.1 ASSEMBLING THE MAST SECTIONS

78
4.3.2 Description ( resting platforn)

The resting platform assembly (Figure 1) comprises:

− A platform (1)
− An equipped ladder (2), 3 m length
− An equipped ladder fixing device (3)
− 3 grab rails (4)
− Various fitting devices (5)

79
4.3.3 . Access to the towerhead

The complete access to

The towerhead (Figure 1)
comprises:
− A platform (1) equipped
with a trap door
− An equipped ladder (2),
1. 5 m length
− Two grab rails (3)
− Two grab rails (4)
− Various fitting devices (5)

4.3.4 Standard access

The standard access assembly

(Figure 1) comprises:
- An equipped ladder (1), 3 m length
- An equipped ladder attachment (2)
- Various fitting devices (3)

80
4.3.5 Assembling the resting platform

For 3 m mast sections, assembling the accesses is carried out with the mast section in vertical
position.

− Raise the mast section, then fix the ladder support

(1) onto the gussets of the mast section (lug side) by means of the shaft _10 (2); fix with split pin
( Detail A - Figure 1 ).

− Make sure that the ends (3) are clean (no earth or similar in the holes) and not twisted.

−Introduce the ladder (with the ack loop folded up) into the mast section. Position the top of the
ladder on the ladder support (1).

− Introduce both fixing flanges (4), fit the wedges (5) and drive them in; then turn the lugs(6). Fold
down the back loops (7).

− Fit the resting platform (8) (opening on the ladder side) into the mast section and fix it by means
of the flanges (9) and the screw bolts (10)
( Detail B -Figure 1 ).

− Fit the 2 grab rails (11) and lock them with safety pins (12) ( Detail C - Figure 1 ). Position the
grab rail (13) on both grab rails (11) and fix with split pins. In order to avoid the oscillating of the
ladder, block it using an iron wire.

81
4.3.6 Assembling thr towerhead access

For 3 m mast sections, assembling the accesses is carried out with the mast section in vertical
position.

− Fit the four platform supports (1) and lock them on the mast section with 8 split pins (2).

− Fit the platform (3) (opening on the side of the lugs) into the mast section; fix it onto the supports
by means of the screw bolts (4) ( Detail A − Figure 1 ).

− Position the top of the ladder (5) (with its back loops unfolded) between the gussets of the plat-
form.

− Introduce both fixing flanges (6), fit the wedges (7) and drive them in. Then turn the lugs (8) (De-
tailB − Figure 1 ).

− Fit both grab rails (9) onto the platform (3) and fix them with split pins. Position the 2 grab rails
(10) on the 2 grab rails (9) and fix them with split pins. In order to avoid the oscillation of the ladder
in the mast section during the erection, block it by means of an iron wire.

− Fit the ladder attachment (11) on the upper part of the mast section; block it by means of the
flanges (12). Fitting the access ladder of the towerhead (13) will be carried out after mounting the
towerhead on the last mast section. Fix the ladder into the attachment (11) by means of the fixing
flanges (11), place the wedges (7) and drive them in. Then return the lugs (8). Lower it until it
comes to rest on the support (14), screw the latter onto the platform.

82
4.3.7 Fishplating

- Ensure the cleanness of the bearing surfaces of the holes and shafts which must be freed from
old grease and burrs.

- Introduce the headed shaft (1), drive in until it abuts against the fishplates (2). Proceed in the
same way for the second headed shaft (3) (Detail A − Figure 1).

- The shafts (1) and (3) are locked by means of a pin (4); block the pin (4) using a split pin (5) (De-
tail B − Figure1)

83
 4.4 FITTING CHASSIS SB16 (1.6m)

4.4.1 Dimensions and weights

4.4.1.1. GENERAL NOTES

The dimensions and weights given in the tables on the following pages correspond to:

− The first line of each group indicates the dimensions and the weight of the component assembled
with the parts as they are shown in the drawing.

− The following lines indicate the dimensions and weights of the main parts according to represen-
tation.

− The direction of dimensions L, l and h with respect to the mark concerns the main parts only.
IMPORTANT: The sum of the weights of the main parts is lower than the weight of the equipped
component because the weight of pins, bolts, small accessories, etc. is not taken into account.

4.4.1.2 DIMENSIONS AND WEIGHT OF THE BOGIES

Mark Qty DESIGNATION L I h P(daN)

1 1 Motor bogie RT324

2 2 Trailing bogie RT324

84
4.4.2 Dimensions and weight of the connecting accessories

4.4.2.1 ON RT324 − RT443 TRAVELLING GEAR

Mark Qty DESIGNATION L I h P(daN)

1 Connecting accessories of VD travelling gear

4 Equipped fixed bogie fork 550 440 460 200
2 connecting accessories of VV travelling gear
2 Equipped fixed bogie fork 550 440 460 200
2 Equipped mobile bogie fork 660 580 460 260

85
4.4.2.2. DIMENSIONA AND WEIGHT OF THE SB CHASSIS

4.5.5.1 GENERAL NOTES

The whole telescoping operations are
carried out from the cage catwalks.

Mark Qty DESIGNATION L I h P(daN)

1 Complete SB chassis 4940 5080 3610 5890

1 1 Unequipped SB basic mast unit 2065 1960 3610 2750
2 2 Chassis bearer 5080 1785 605 1100
3 4 Strut of 1.60 m chassis+ shafts 3180 250 340 200
4 1 Access ladder + shafts 580 370 1200 13.7
5 1 Equipped 3 m ladder 740 730 3040 19
6 1 Guard rope 730 225 1685 14

86
4.4.2.3 . GENERAL DIMENSIONA OF THE SB CHASSIS

4.4.2.3.1 ON RT 324 Travelling gear

RT324 travelling gear − Wheel O 315 − A = 687 mm

87
4.4.3 Assembling the sb chassis

For assembling the chassis, proceed as follows:

− Assemble both bearers (1) at the base of the basic mast unit (2) by means of shafts (3), rings (4),
flats (5), screws and washers (6).

− Fit the struts (7) by means of the shafts (8) and the shaft locks (9); block them by using the pins
(10) and fix with split pins. Take care that the long cones of the shafts are located opposite the
ballast according to (figure 1).

− Equip the chassis with its accessories.

− For the dimensioning of the shafts and bolts, etc... refer to the corresponding "Spare parts"
brochure.

4.4.3.1 . FITING THE SB CHASSIS

Connecting the chassis to the ground can be carried out in different ways:
− Rail?mounted with straight track or curved track travelling gear.
− Without travelling gear, fixed on stools.
− Without travelling gear, directly set onto concrete blocks.
Before starting fitting, make sure that the tracks or other supports comply with the instructions
given in
the brochure 23A SUBSTRUCTURE. For rail−mounted cranes, the track end buffers must be
installed.
88
4.4.3.2 PUTTING BOGIES ONTO TRACK

4.4.3.2.1 Straight track equipment

The straight track equipment comprises four identical assemblies, each made up of :
− 1 plate (1) screwed under the bearers (2) by means of screws, washers and nuts (3).

−1 ball thrust bearing (4) with dust guard (5).

− 1 fork (6) which receives the bogies.

− 1 fork?bogie connecting shaft (7).

− 1 circlips (8) which keeps the fork on the plate, allowing vertical clearance of about 30mm ( Detail
A and B ? Figure 1).

For travelling gear with two motor bogies (9), arrange them diagonally and on the fixed forks (Detail
C −Figure 1).

89
4.4.3.2.2 Curved track equipment

The curved track equipment is made up of two assemblies (A) which are identical with the straight
track assemblies, and two assemblies (B), ( Detail F − Figure 2 ) each comprising :

− 1 plate (1) screwed under the bearers (2) by means of screws and washers (3).

− 1 ball thrust bearing (4) which consists of :

. An outer part fastened onto the plate,
. A welded central part which receives the fork (Detail D and E ? Figure 2 ).

4.4.3.3 FITTING THE ACCESSORIES

4.4.3.3.1 Mounting the stools

- Introduce the stools (1) onto the fixing
rods (2), then fasten them by means of
the washers (3) and the nuts (4), with-
out locking them.

- The final tightening will be carried out

after fixing the chassis with the bolts
(5) onto the stools (1) (Figure 1).

90
4.4.3.3.2. Chassis set onto concrete blocks or bed plate

− After its assembling, the chassis is directly set onto the concrete blocks or onto the bed plate
(Detail A − Figure 1). It will be secured by means of lateral locking devices (1) of which the number
is to be determined by the user (Detail B − Figure 2).

4.4.3.3.3 Fitting

4.4.3.3.3 Fitting the sb chassis

− Sling and raise the chassis assembly

(1), then position it according to Detail
A − Figure 1:

- In case of a rail−mounted crane onto a

straight track or curved track travelling
gear according to Detail B − Figure 1.

- In case of a static crane, there are

two possibilities either on four stools
which will be fixed by means of lateral
locking devices determined by the user
(Detail C −Figure 1).or on four con-
crete blocks, previously levelled and
dimensioned depending on the reac-
tions of the machine and the permissi-
ble ground pressures (Detail D −
Figure 1).

− Install the access ladder (2), fit flang-

es (3), the screws (4), the washers (5)
and the nuts (6) (Detail E − Figure 1).

− Fit the electrical equipment; for this,

refer to the Operating Instructions.
91
4.4.4 Access to the basic mast

− Sling
This the telescopic
additional accesscage at the cylin-
is supplied with the chassis
der support beam (Detail A − Figure
- Fitting the guard rope (1) for the access 1) to the basis mast.
and hook it on the load hook. Choose
-aEngage
sling which is long
the feet of theenough and(1)
guard rope of for the access to the basic mast into the top of the ladder of
which
the the mast
basic diameter corresponds
unit (Detail to the1).
A − Figure
load to be supported.
-−Fix
Tighten the sling
the other end ofbutthe
notguard
too much.
rope (1) at the angle irons of the basic mast with the pliers (2), the
screw bolts (3) and the washers (4)are
− Check that the mast sections (Detail B − Figure 1).
pinned and linked to the telescoping
mast.
− Free the telescoping yoke, and ilize it
into the telescopic cage.
− Remove the shafts (1) connecting
the telescopic cage to the telescoping
mast (Detail B− Figure 1).
CAUTION:
− In order to carry out the lowering
operation in safety, the personnel does
not remain on the cage, but works from
inside the mast using the normal
accesses.
− Slacken the rope, the cage must
lower by its dead weight (Detail A −
Figure 2).
− Release the safety locks (1) from the
mast lugs (2) (Detail B − Figure 2) either
at each passage Over the lugs or at the
start by locking the control rod.
− During this operation, counterbal-
ance as much as possible the lateral
forces due to the sling tension so as to
prevent the telescopic cage from
getting blocked on the mast. The
weight of the telescoping yoke, the
hydraulic cylinder and the hydraulic
unit contributes to this balance.
− Continue lowering the telescopic
cage until it reaches the lowest possi-
ble position according to the instruc-
tion paragraph 31B−0740−...
(Detail A − Figure 2).
− Remove the hydraulic unit and store
it away with the cylinder and the tele-
scoping yoke.

92
4.4.6 .General date weights and heights

PB1

PB2

93
4.4.6.3 PREASSEMBLY OF JIB SECTION 1

4.4.6.4 ASSEMBLY OF JIB SECTION 1

4.4.6.5 PREASSEMBLY OF COUNTER JIB

94
4.4.6.6 ASSEMBLY OF COUNTER JIB

4.4.6.7 ASSEMBLY OF COUNTER WEIGHT

Install one counter weight block 2,8t into last position

95
4.4.6.8 PREASSEMBLY OF JIB LENGTH 30,0M - 35,0M - 40,0M - 45,0M

4.4.6.9 PREASSEMBLY OF JIB LENGTH 50,0M - 55,0M - 60,0M

96
4.4.6.10 REEVING OF HOIST ROPE

97
4.4.6.12 ASSEMBLY OF JIB LENGTH 30,0M - 35,0M - 40,0M - 45M

98
4.4.6.13 ASSEMBLY OF JIB LENGTH 50,0M - 55,0M - 60M

99
 4.5 ELESCOPING 1.60M (ASSEMBING THE TELESCOPIC CAGE)

GENERAL NOTES
- The telescoping asembly consists of main parts remaining on the crane and of a certain number
of accessories used during telescoping only.
- For fitting the telescoping assembly, three cases are possible:
- Fitting of the complete assembly during normal erection of the crane Partial fitting for increase
in height
- The following pages describle the fitting of the tetescoping assembly after normal erection of the
crane

FITTING OUT THE TELESCOPIC CAGE

- Fitting out the telescopic cage is carried out with the cage in horizontal position; If the telescopic
cage must be put in upright position, it has to be anchored by guy ropes.
- For assembling the main parts of the telescoping equipment, refer the corresponding detail
spare parts brochure.
In order to fit the parts making up the telescoping assembly, seeparagraph 21A.

EQUIPMENT OF THE TROLLEY AND THE PULLEY BLOCKS

- According to the equipment fitted onto the crane, it must be adapted to the telescoping opera-
tions ( see chapter 32B).

4.5.1. General instructions

- The slewing crane part must be balanced compulsorily when the telescoping assembly is lifted
ỏ being lifted and during the introduction of a mast section.

Jib length (m) 30.0 35.0 40.0 45.0 50.0 55.0 60.0
Balance weight
Tower section 2.39 2.39 2.39 2.39 2.39 2.39 2.39
on hook (t)
Balance weight 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Trolley with
Trolley distance
Tower section 13.12 13.22 13.78 14.46 15.83 14.50 16.60
D (m)
Trolley with
Balance weight 14.90 15.01 15.65 16.42 17.98 16.47 18.85

The wind speed is limited to 60 km/h.

It is forbidden:
- To slew the jib
- To operate the hoist winch (Hoisting or Lowering) when telescoping assembly is lifted or being lifted
- To move the trolley(s) when the telescoping assembly is lifted or being lifted
- To keep the telescoping assembly resting on the cylinder.
100
 Use of the safety pins when telescoping:
- The telescopic cage is equipped with 4 pins of which the diameter has been reduced by 2 mm in
order to make their fitting easier.
- These pins, connected to the telscopic cage by means of a chain, are ONLY TO BE USED FOR
TELESCOPING. They ensure the connection between the fixed towerhead or connec mast and
the last telescoped mast mast section on each mast level.
- They must be fitted on the lateral sides.
- At the end of telescoping and before disconnecting telescopic cage/ fixed towerhead or connect-
ing mast and before disconnecting telescopic cage/ fixed towerhead or connecting mast and lower-
ing the telescopic cage, they must be replaced by the normal mast shafts.
- IT IS STRICTLY FORBIDDEN TO CARRY OUT ANY HOISTING OPERATIONBEFORE PLAC-
ING THE NORMAL WORKING SHAFTS.

Interruption of telescoping:
- The last mast section must be pin-connected to the crane tower with the normal shafts.
- The balancing load must be laid down.
- There is no mast section hanging from the monorail trolley. The latter must be lower to the ground.
- The pulley block must be raised under the trolley.
- Move the trolley away enough so that the pulley block can not get caught by the monorail(s) when
the crane is weathervaning.
- Observe the conditions for keeping the telescopic cage at the top of mast (see 29A and
31B-0740-...).
- For SHIFT END, observe the instructions given in the OPERATING INSTRUCTIONS.

4.5.2 Handling the telescopic cage

The weight of the equipped telescopic cage exeed the maximum load permitted for the crane. For
handling the telescopic cage, reduce its equipment so that this maximum load is not exeeded.

FITTING THE TELESCOPIC CAGE BY SELF- MOUNTING

- This operation can only be carried out with a crane the maximum load of which exceeds the
weight of the Package to be handled

LOWERING THE TELESCOPIC CAGE BY MEANS OF THE HOOK

- This operation can only be carried out with a crane the maximum load of which exceeds the
weight of the complete telescopic cage.

- FOR CRANES WHOSE MAXIMUM LOAD IS INFERIOR, It is possible to lay down the hydraulic
unit, the hydraulic cylinder and the telescoping yoke in order to reduce the weight of the assembly
to be handled without exceeding the maximum load of the crane.

- If, despite of removing the accessories, the weight is higher than the maximum load of the crane,
THE TELESCOPIC CAGE MUST COMPULSORILY BE LOWERED AGAIN BY MEANS OF THE
HYDRAULIC CYLINDER.

101
4.5.3 Fitting the acceccories

4.5.3.1 FITTING THE MONORAILS

The monorails are fitted onto the telescoping mast. This operation can be carried out:

- In the air, before telescoping or telescoping down.

- On the ground, before fitting the towerhead or the connecting mast.

Fitting the monorails in the air

Fitting the monorails is carried out by means of the telescoping hook.

- Fit the plates (1) by mean of the shafts (2) onto the gussets (3) of the towerhesd or of the conect-
ing mast. Fit the shafts (4) onto the plates (1) (Figure1- Detail A).

- Using the telescoping hook (5), pick up the first monorail (6) by the round bar (7) and lift it until it
can be pin - connected to the plates (1) by means of the shaft (4) (Figure 1 - Detail B, C, D).

- Lock the monorails (6) on the plates (1) by mean of the shaft (8) (Figure 1- Detail D, E).

102
Lower the pulley block, the monorail folds down alongside the mast. Hook the telescoping hook (5)
to the round bar (9) placed at the end of the monorail (Figure 2− Detail A).

− Raise the monorail (6) in horizontal position (Figure 2 − Detail B), remove the shaft (8) (Figure 2
− Detail C).

− Operate "Trolley in" until the monorail (6) can be pinned to the gussets (10) by
means of the shaft (11) (Figure 2 − Detail E), then to the gussets (3) by means of the shaft (12) (Fig-
ure 2 − Detail E).

− Remove the shaft (4), then raise the plates (1) and refit the shaft (4) as well as the shaft (8) (Fig-
ure 2 − Detail F, G).

− Proceed in the same way for fitting the second monorail.

□ Fitting the monorals on the ground

The fitting operations are identical with those of fitting in the air (preceeding paragraph), on the
other hand, handling of the monorails will be carried out by means of the mobile crane and a sling
instead of the telescoping hook.

103
4.5.3.2 FITTING THE MONORALS TROLLEY

Lifting the monorail trolley (13) with or

without mast section is carried out by
means of the telescoping hook (5) (Fig-
ure 3 − Detail A).
− The monorail trolley is fixed onto the
upper mast uprights (14) by means of
the fixing brackets (15) by 4 fishplate
bolts 20 x 53 SP (16) (Figure 3 − Detail
B):
− When fitting on the ground onto the
mast sections which have been just
assembled.
− When dismantling in the crane tower
onto the standard mast section to be
dismantled.
− Observe the direction of the guides
(17) (on the side of the telescoping
lugs) and the fitting direction of the
screw bolts (16) (Figure 3 − Detail B).

4.5.4 Balancing for telescoping

4.5.4.1 GENERAL INSTRUCTINNS

Balancing for telescoping is carried out in two phases:

- Theoretical, by hanging a load at a given radius (see chapter 32B ).
- Practical, by adjusting the position of the trolley(s) (see page 31B−0640−... ).
We remind that it is strictly forbidden to SLEW the jib to MOVE the trolley to OPERATE the hoist
winch (hoisting or lowering) when the telescoping assembly is lifted or being lifted.

4.5.4.2 PARTICULAR INSTRUCTIONS

- The good working order of the telescoping assembly (cylinder and telescopic cage) needs thatthe
center of gravity of the lifted crane part is located in the cylinder axis.
- Make sure too, that one mast section is hanging from the monorails before proceeding balancing.
- Move the trolley(s), possibly with an appropriated load, to the balancing position given in the
tables of paragraph ( 32B).
- The indicated distances are theoretical; they especially depend on the actual weight of the count-
er−jib ballast. Make sure that this ballast weight corresponds to the used lengths of counter−jib and
jib.
- Furthermore, the wind has a considerable action on the crane balance, telescoping is no longer
allowed beyond 60 km/h.

104
4.5.5 1.60 m Telescoping sequences
4.5.5.1 GENERAL NOTES
The whole telescoping operations are
carried out from the cage catwalks.

4.5.5.2 PRINCIPLE
The telescoping sequence comprises a
series of operations which are repeated
several times:
− Fit the monorail trolley (1) onto a mast
section (2) chosen according to the mast
composition (see chap-ter 29A).
− Hang the monorail trolley (1) from the
telescoping hook (3), raise the assembly
and hook the trolley (1) on the monorail
(4) making sure that the telescoping lugs
of the mast are located on the crane side
(Figure 1).
− Free the telescoping hook and suspend
the balancing load (see chapter 32B).
− The crane is in balancing position.
− The yoke (5) is locked on the mast lugs
(a) by means of the shafts (6) (Detail(b) A
− Figure 2).
− Remove the shafts connecting the basic
mast to the connecting mast for telescop-
ing.
− Operate the lever of the hydraulic unit in
the "up" direction. Slowly telescope until
the telescoping con- necting mast feet just
leave the fishplates of the basic mast (De-
tail B−Figure 2).
− If required, readjust the balancing given
in chapter (32B) by manoeuvring the jib
trolley. The exact bal-ancing position is
found by verifying the alignment of the
telescopic connecting mast feet with the
basic mast fishplates and checked by
reading the minimum pressure required
for telescoping on the pres- sure gauge of
the
hydraulic unit.
− Telescope until the telescopic cage
pawls (7), kept away from the mast, are
above the lugs (c) of the basic mast (De-
tail C−Figure 2).
− Slowly operate the hydraulic unit lever
in "down" direction in order to rest the
pawls (7) onto the lugs (c) (Detail C −
Figure 2).

105
− The telescoping cage rests on the lugs
(c) by means of the pawls (7) (Detail A −
Figure 3).
− Operate slightly the hydraulic unit lever
in the "down" direction, in order to relieve
the shafts (6) of the yoke (5).
− Release the yoke (5) from the lugs (a)
by removing the shafts (6) (Detail (b) B −
Figure 3).
− Operate the hydraulic unit lever in the
"down" direction, the yoke rises (Detail C
− Figure 3).

− Continue to pull the lever in direction

"Down", in order to fix the yoke (5) onto
the lugs (b) located directly above (Detail
A and B − Figure 4).
− Lock the yoke (5) onto the lugs (b) by
means of the shafts (5) (Detail C and D −
Figure 4).

106
− Repeat this cycle 2 times in order to
obtain the space required (X) for introduc-
ing the mast section into the telescopic
cage (Detail A − Figure 5).
− The crane is in the following position:
- The lifted crane part is resting on the
- lugs of the mast (e) by means of the tele-
scopic cage pawls (7) (Detail B − Figure
5).
- The yoke (5) is locked on the mast lugs
(c) by means of the shafts (6), the cylinder
rod is almost
entirely extended and the total stroke
does not allow the upper guide rollers to
go beyond the fixed part of the mast (De-
tail A and C − Figure 5).
− Do not raise the yoke onto the lugs
located directly above.

− The crane is now in the required posi-

tion for introducing the mast section into
the telescopic cage (Detail B − Figure 6).
− Introduce the mast section (2) into the
telescopic cage using the grab provided
for this purpose (Detail B − Figure 6).
− Having introduced the mast section into
the telescopic cage, operate slightly the
hydraulic unit lever in the "up" direction in
order to free the pawls of the telescopic
cage from the mast lugs.
− Maintain the pawls far from the masts
and operate the hydraulic unit lever in
"down" direction.

107
− Make sure that the mast section
engages properly into the fishplates of
the basic mast (Deta l A − Figure 7); pin
−connect by means of 4 x 2 shafts (8),
1 pin (9) and 1 safety pin (10) (Detail B
− Figure 7).
− Free the monorail trolley (1) from the
mast section and bring it out onto the
monorail (Detail C − Figure7).

− Continue lowering and make sure

that the telescoping mast engages
properly into the fishplates of the mast
fitted before (Detail A − Figure 8); pin−
connect at (11) by means of 4 safety
shafts (see utiliza-tion paragraph 31B−
0400−...−0).
− Lower and place the balancing load
on the ground in order to free the tele-
scoping hook.
− Using the telescoping hook, lower
the monorail trolley in order to fit it, if
required, onto a new mast sec- tion.
− Repeat this telescoping procedure as
often as necessary to reach the
desired height.
− At each first cylinder stroke, do not
forget to remove the safety pins linking
the telescopic connecting mast to the
masts.
− THE LAST MAST SECTION MUST
BE FIXED: TO THE MAST ON THE
ONE HAND TO THE TOWERHEAD
FEET ON THE OTHER HAND

108
4.5.6 End of telescoping

4.5.6.1 GENERAL INSTRUCTIONS

Having completed telescoping, the telescopic cage must be dismantled or lowered as low as pos-
sible
For cranes on chassis: the telescopic cage is lowered to the level of the first mast section
Above the chassis.
- For cranes on cross−shaped base, the telescopic cage is lowered to the level of the base ballast.
- For cranes on fixing angles, the telescopic cage is lowered to the mast section
placed above the fixing angles by keeping space enough to reach the access ladders of the crane
tower.
- For very high cranes (anchored or guyed crane), the telescopic cage is always lowered to the
level of the last anchorage.
- Fold down the monorails alongside the masts.

Folding doen the monorails

In order not to hinder the trolley movement at the minimum radius, the monorails must be folded
down alongside the masts. For carrying out this operation, the pulley block must be equipped with
the telescop-ing hook.
− Remove the shafts (1) and (2), then fold down the plates (3) (Figure 1 − Detail A).
− Refit the shaft (1) onto the plates (3) (Figure 1 − Detail B).
− Pick up the first monorail (4) by the round bar (5) by means of the telescoping hook (6)
(Figure1 − Detail C, D)

109
− Remove the shafts (7) and (8) (Fig-
ure 2 − Detail A, B).
− Operate "TROLLEY OUT" until the
monorail (4) can be hooked to the
shaft (1), then fit the shaft
(2) (Figure 2 − Detail C, D).
− Operate "LOWERING", the monorail
(4) folds down alongside the masts;
free the hook
(Figure 2 −Detail E).
− Repeat the same operations for the
second monorail.

4.5.6.3 DISMANTLING THE MONORAILS

If the monorails must be removed for a

reutilization on another crane:
− Hook the monorail to the round bar
(9) (Detail A and B − Figure 3) and
raise it in horizontal position.Unpin the
shaft (1) (Detail C − Figure 3), operate
"Trolley out" and lay the first monorail
on the ground.
− Proceed in the same way for t he
second monorail.
−Take off the monorail support plates
(3) and the shafts (1, 2, 7, 10 und 11)
which will be reused.

4.5.7 Lowering the telescopic cage

4.5.7.1 PREPARING
Two cases are possible:
1. The crane is equipped with a SM (2 falls) trolley.
− It is forbidden to lower the cage by using the hook of the crane. The telescopic cage must be
compulso-rily lowered by means of the hydraulic cylinder.
2. The crane is equipped with a DM (4 falls) trolley.
The telescopic cage can be lowered:
− Either by means of the hydraulic cylinder, or by using the hook of the crane; for this:
- Dismantle the telescoping hook and refit the load hook.

110
4.5.7.2 LOWERING THE TELESCOPIC CAGE

− Sling the telescopic cage at the cylin-

der support beam (Detail A − Figure 1)
and hook it on the load hook. Choose
a sling which is long enough and of
which the diameter corresponds to the
load to be supported.
− Tighten the sling but not too much.
− Check that the mast sections are
pinned and linked to the telescoping
mast.
− Free the telescoping yoke, and ilize it
into the telescopic cage.
− Remove the shafts (1) connecting
the telescopic cage to the telescoping
mast (Detail B− Figure 1).
CAUTION:
− In order to carry out the lowering
operation in safety, the personnel does
not remain on the cage, but works from
inside the mast using the normal
accesses.
− Slacken the rope, the cage must
lower by its dead weight (Detail A −
Figure 2).
− Release the safety locks (1) from the
mast lugs (2) (Detail B − Figure 2) either
at each passage Over the lugs or at the
start by locking the control rod.
− During this operation, counterbal-
ance as much as possible the lateral
forces due to the sling tension so as to
prevent the telescopic cage from
getting blocked on the mast. The
weight of the telescoping yoke, the
hydraulic cylinder and the hydraulic
unit contributes to this balance.
− Continue lowering the telescopic
cage until it reaches the lowest possi-
ble position according to the instruc-
tion paragraph 31B−0740−...
(Detail A − Figure 2).
− Remove the hydraulic unit and store
it away with the cylinder and the tele-
scoping yoke.

111
4.5.8 Dismantling and refitting the telescopic cage

4.5.8.1 DISMANTLING THE TELESCOPIC CAGE

− Dismantle the grab rail (1) and the

catwalks (2) located on the open face
of the cage (Figure 1) and lower them
to the ground.

− Hang two Ø18 slings of 3 m length,

equipped with 2 shackles (4), from the
load hook (Figure 1).

− Fasten the shackles (4) on the rear

upper fishplates of the telescopic cage
at (5) (Figure 1).

− Fit a Tirfor of 1500 daN (6) on the

level of the beam carrying the cylinder.
This Tirfor will keep the cage hard
against the mast during the following
operations; fixed point of the mast at
(7), mobile point on the rear telescopic
cage beam at (8) (Figure 2).

− Hook a "LUGAL" type tackle (9) of

1000 daN to the upper upright of a
mast section at (10), then connect the
other end to the removable panel (11)
of the telescopic cage. This tackle will
hold the panel (11) when the cage
comes out (Figure 2).

112
By operating the hoisting motion, tight-
en the slings (3) slightly in order to
come free from the lugs.

− Tighten the Tirfor (6) so as to keep

the telescopic cage hard against the
mast.

− Unscrew the front cage panel (11),

which is now hanging from the
"LUGAL" tackle (9).

− Move out the telescopic cage (12); to

do this, operate the slings (3) and the
Tirfor (6) Simultaneously. By gravity,
the telescopic cage leaves the mast. In
case of jam, come out at the level of
the removable panel (11).

− Free the telescopic cage (12) com-

pletely, operate "TROLLEY OUT", and
lower it to the ground while operating
the Tirfor (6). When the telescopic
cage is placed onto the ground,
release the hook of the Tirfor (6) fixed
at (8) on the cage (12), and put the
Tirfor onto the ground.

− Slew the rotating crane part half a

turn in order to pick up the removable
panel (11) by means of the load hook,
then lower it and place it onto the
ground.

− In order to prevent the telescopic

cage from being damaged on the
occasion of a possible transport, refit
the front panel and bolt it.

113
4.5.8.2 REFITTING THE TELESCOPIC CAGE

If the telescopic cage is to be reused

for increasing the height or telescoping
down another crane already erected,
repeat the dismantling operations but
in the reverse order, observing the
safety instructions and proceeding as
follows:
− Hang up the fixed point (1) of the
"LUGAL" tackle (2) on a mast upright,
raise the removable front panel (3) by
means of the load hook and keep it in
waiting position (Figure 4).
− On the ground, equip the telescopic
cage (4) with its side catwalks and the
rear catwalk which possibly had been
dismantled for transport or handling
reasons. Attach the mobile point (7) of
the Tirfor (8) onto the cylinder carrier
beam; the Tirfor (8) remains in the
meantime on one of the side catwalks.
Connect two Ø18 slings (9) equipped
with shackles (10) to the rear fish-
plates of the cage (4) (Figure 4).
− Raise the telescopic cage (4) and fit
it onto the mast. Connect the other end
(11) of the Tirfor (8) to the mast. Rest
the telescopic cage (4) onto the lugs
by operating the Tirfor (8) (Figure 4).
− Replace the removable panel (3) on
the front of the telescopic cage (4) and
bolt it (Figure 5).
− Refit the front catwalk (12) and the
grab rail (13) and fix the assembly on
the front of the telescopic cage (4)
(Figure 5).
− Fit the telescoping accessories such
as telescoping yoke, hydraulic cylinder
and hydraulic unit.
− Remove the Ø18 slings (9) used for
raising the telescopic cage (4). Free
the Tirfor as well as the "LUGAL"
tackle.

114
 4.6 ANCHORAGE FRAME FOR 1,60 m CRANE TOWER FOR VERY HIGH CRANES

4.6.1 Dimensions and weights

4.6.1.1 GENERAL NOTES

The dimensions and weights given in the tables on the following pages correspond to:
− The first line of each group indicates the dimensions and the weight of the component assembled
with the parts as they are shown in the drawing.
− The following lines indicate the dimensions and weights of the main parts according to representation.
− The direction of dimensions L, l and h with respect to the mark concerns the main parts only.

IMPORTANT: The sum of the weights of the main parts is lower than the weight of the equipped
component because the weight of pins, bolts, small accesso-ries, etc is not taken into account.

4.6.1.2 DIMENSIONS AND WEIGHTS OF THE ANCHORAGE FRAME 1,60 M

Mark Qty DESIGNATION L I h P(daN)

1 Anchorage frame 1.60m 2430 52180 345 1380

1 1 Front girder 2180 770 335 278
2 1 Reagirder 2195 470 335 185
3 2 Lateral girder 1800 380 286 75
4 1 Diagonal bracing 1000 120 170 290
5 2 Bracket 756 630 345 85
6 2 Bracket 580 630 345 75.5

115
4.6.2 Anchorage

4.6.2.1 GENERAL NATES

- Beyond the free standing height of rail−mounted or static crane, the crane must be connected
either to the ground by anchorage by guy ropes or to the building by rigid anchorages.
- For each utilization of anchorages on cranes with chassis, please consult us.
- The present brochure deals only with the rigid anchorages to the building. For anchorages by guy
ropes please consult our After−Sales−Service. In addition, the device is described in another
brochure.
- The mast compositions, the position of the anchorages as well as the loads applied on the frames
are indicated in the chapter (29A).

4.6.2.2 GENERAL INSTRUCTIONS

Positioning the crane:

- When it is a crane on rail−mounted chassis, move it in its static position, tighten the
rail clamps and disconnect the travelling gear. Consult us in order to know the special conditions
for this installation.
- In certain cases it is necessary to telescope an additional mast section so that the anchorage
frame can be fitted (see Chapter 31B).

VERY IMPORTANT:
- Under these conditions the crane is no longer normally autonomous, and it is forbidden to work
and to let the crane free out of service.
- When telescoping check the perpendicularity of the crane in both planes in order to avoid any
variation of distance between crane tower and building.

INSTRUCTIONS
In oder to ensure good connection between frame and crane tower and to prevent the mobile
wed-ges (1 ) from falling down, it is essential to turn the pieces carrying the welded wedges (2) so
that the fitting corresponds ( Detail A − Figure 1)

116
4.6.2.3 DESCRIPTION AND DIMENSIONS OF THE FRAMES

4.6.2.3.1 Description

A complete frame is composed of:

− 1 front girder (1).
− 1 rear girder (2).
− 2 lateral girders (3) and (4).
− 1 diagonal bracing (5).
− 2 brackets (6) and (7) equipped with 2 shims (8) and 2 wedges (9) and fitted onto the diagonal
bracing (5).
− 2 brackets (10) and (11), 4 taper keys and various fixing shafts.
The front girder (1) has 4 holes in order to allow the fixing of the frame with the
building by means of the shafts (13).

117
4.6.2.3.2 Man dimensions of the anchorage frame 1,60m

118
Raise and place the bracket (11)
equipped with the shim (12), then pin−
connect it onto the girders (1) and (2)
by means of the shafts (2) (13); fix with
split pins (Detail (3) A and B − Figure
3).

Raise and place the bracket (14)

equipped with the shim (15), then pin−
connect it onto the girders (16) and
(17) by means of the shafts (18); fix
with split pins(Detail A and B − Figure
3).

Raise and place the brackets (19) and

(20) which are equipped with the
shims (21), then pin− Connect them
onto the girders (16) and (17) by
means of the shafts (22) (Detail A and
C − Figure 3).

Place and pin the diagonal bracing bar

(23); pin−connect it onto the brackets
(19) and (20) by means of the shafts
(24) (Detail C − Figure 3).

Check the level of the frame, readjust if

required.

Place the outer wedges (25) and act

on them in order to bring the frame into
contact with the mast uprights (Detail A
− Figure 4).

Place the inner wedges (2) and drive

them in so that the shim (27) comes
hard against the inner side of the mast
uprights (28) (Detail A − Figure 4).

Having carried out these operations,

check that there is no play remaining
between the wedges and the mast
uprights.

Fit the ladder (29) supplied with the

frame instead of the standard ladder,
then equip it with its two back loop
parts (30) (Detail B − Figure 4 ).

119
 4.7 CLIMBING INSIDE THE BUILDING BA45A

4.7.1. General noyes

The dimensions and weights given in the tables on the following pages correspond to:
- The first line of each group indicates the dimensions and the weight of the component assembled
with the parts as they are shown in the drawing.
- The following lines indicate the dimensions and weights of the main parts according to represen-
tation.
- The direction of dimensions L, l and h with respect to the mark concerns the main parts only.

IMPORTANT: The sum of the weights of the main parts is lower than the weight of the equipped
component because the weight of pins, bolts, small accessories, etc. is not taken into ac-count.

4.7.1.1 COMPLETE MAST SECTION L46F

Mark Qty DESIGNATION L I h P(daN)

1 Complete mast section L46F 1730 1670 1740

1 1 Unequipped mast section L48F 1730 1670 1740 1080
2 1 Resting platform 1550 714 230 35
3 1 Trap door 1730 160 255 14.3
4 1 Access ladder + fixing 336 45 1350 4.4
5 1 Access ladder + fixing 336 45 1500 4.5
6 2 Grab railL = 950 950 27 1000 5.035

120
4.7.1.2 EQUIPPED CLIMBING COLLAR BA45 A

Mark Qty DESIGNATION L I h P(daN)

Equipped climbing collar BA45A 2450 2380 460 1040

1 1 Big beam (GM) for telescoping equipment BA45A 2380 580 460 457
2 2 Crossbeam 1500 117 225 48.5
3 1 Small beam (PM) for telesoping equipment BA45A 2380 565 410 430
4 2 Equipped pawls 500 150 375 26.7

121
4.7.1.3 EQUPPED SUPPORT BEAMS BA45A

Mark Qty DESIGNATION L I h P(daN)

1 Complete support beam 2380 580 460 578

1 2 Support beam 1750 217 440 138
2 2 Crossbeams 872 60 60 5
3 4 Support shoes 665 290 135 45
4 4 Long links 634 20 120 6
5 4 Short links 551 20 120 5
6 1 Telescoping limit stop 410 95 325 29.6

122
4.7.1.4 CLIMBING EQUIPMENT BA45A

The top and bottom end position of the hook

block are limited by way of a limit switch. This
limit switch is activated from the hoist gear.
When adjusting the cam disks, please do not
Mark Qty the decelerationDESIGNATION
forget to include distance. L I h P(daN)
The limit switches must be set in such a way
that1they switch Equipped
1 off in the bottom telescoping
hook position;yoke 1480 155 835 230
min.2 2 rope1 windings (safety
Hydraulic windings)
cylinder must (without oil)
160/110/1600 320
remain on the hoist drum.
3 1 Hydraulic unit (without oil) 6.2L/ 410B 195
For the movement in up direction, a prelimit
4 exists.1 The adjustment must
switch Cylinder supportso
be done, 200 350 930 35.3
that the hook slows down to step 1, three meters
before the maximum hook height is reached.
The top end position of the hook block must be
set in such a way that with an empty hook and
traveling at full speed, the traveling block comes
to standstill 1.5 m bellow the swing arm.

123
4.7.2 Installation

4.7.2.1 OPENING IN THE FLOORS

Provide for a sufficient opening in each floor in order not to hinder the passage of the crane.
Therefore, it is essential to observe the dimensions indicated in Figure 1 − Detail A. Climbing inside
the building can be carried out in two different ways:
- Either onto two support beams (1) provided for this purpose and prepared by the customer
according to the reactions given in the DATA SHEET (Detail B).
- Or directly onto the floor. In this case, these floors must take up the vertical and horizontal reac-
tions given in the DATA SHEET. The climbing collars will be blocked onto the floors by means of
threaded rods or equivalent accessories (Detail C).

124
4.7.2.2 FIXING THE CLIMBING COLLARS

Carry out the drilling of the floor or the support beams.

For this, align to the drilling dimensions of the climbing collar.
Drilling of the floors or the support beams: 4 x 4 holes Ø 36 according to Figure 2.

125
4.7.2.3 COMPOSITION OF THE CRANE TOWER

The composition of the crane tower and the minimum distance between the climbing collars are
given in the DATA SHEET and in chapter 29A.

COMPULSORY:
The reinforced mast section must always be located just opposite to the upper climbing collar.
This must be COMPULSORILY taken into account for placing it during the erection of the crane
tower (Detail A −Figure 1).

126
4.7.3 Summary of mast section for crane tower 1.60m- BA45A

Monoblock basic section - 1500m

length
Basic section which can be telescoped,
with lugs (1 step) (Detail A- Figure 1).
L46F- Uprights 180 thickness 18.
- Lower fishplating 50
- Upper fishplating 50

Reinforced monoblock mast sec-

tion - 3m length
Reinforced with lugs (lugs (2 steps)
(Detail B - Figure1).
L46D - Uprights 180 thickness 18.
- Lower fishplating 50
- Upper fishplating 50

127
4.7.4 Assembling

Assembling the access to the L46F mast section

- Raise the mast section, then fix the ladder supports (1) and (2) onto the gussets of the mast
section on both sides by means of 2 shafts _10 (3); fix with split pin (Detail A − Figure 6).

- Make sure that the ends (4) are clean (no earth or similar in the holes) and not twisted.

- Fit the resting platform (5) into the mast section and fix it by means of the flanges (6), the screw
bolts (7) and the washers W (8) (Detail B − Figure 6).

- Fit the trap door (9) in opposite position to the telescoping lugs. Fix it by means of the flanges (6),
the screw bolts (7) and the washers W (8) (Detail B − Figure 6).

- Introduce the 1,50 m ladder into the mast section. Position the top of the ladder on the ladder sup-
port (1) (Detail A − Figure 6).

- Introduce both fixing flanges (11), fit the wedges (12) and drive them in; then turn the lugs (13).

- Proceed in the same way for the 1,35 m ladder (14). Fit the 2 grab rails (15) and lock them with
safety pins (16) (Detail C − Figure 6).

128
4.7.5 Assembling the climbing collars

- Three climbing collars are required, two for working (1) und (2) and one in waiting position (3)
(Detail A − Figure 1).

- Each collar consists of two parts which are assembled by means of two crossbeams
(Detail B − Figure 1),

- A big beam (GM) (4),

- A small beam (PM) (5),

- Two crossbeams (6) pin−connected with 4 x 2 shafts (7) and split pins (8) (Detail C − Figure 1).

- The internal dimensions of the collars correspond to the mimimum opening to be carried out in
each floor. Therefore, observe the dimensions given in the chapter (36B−0330..) and the positions
with respect to the crane axis.

129
4.7.6 Mounting the climbing collars

- The position of the climbing collars depends on the chosen intermediate slab (during work, the
second collar must be compulsorily at right angle of the reinforced mast section).

- Two climbing collars are necessary for the first telescoping sequence, the third remains in waiting
position.

- Check before fitting the collars that the slabs are dry enough.

- Fitting consists in positioning the beams (GM) and (PM) and connecting them (according to the
fitting paragrah 3. 3. ).

- The beam (GM) with the fixing gussets (1) of the cylinder must compulsorily be positioned on the
side of the telescoping lugs (2) (Detail A − Figure 3).

- Fit rigidly the collars to the building, either by bolting directly to the slab or by means of the support
beams (according to paragraph 36B−0330...).

- Fit onto the first collar the pawls (3) and (4) by means of the shafts (5) and fix with split pins
(Detail A and B − Figure 3).

130
4.7.7 Position and mounting the guiding wedges

The guiding wedges (1) and (2) are fixed to the beam (GM) (3) by means of welded chains
(Detail A − Figure 3). On the beam (PM) ( 4) there is only one type of guiding wedes (5) connected in
the same way (Detail B − Figure 3).

- In guiding position, the wedges (1) are pin−connected to the beam (GM) by means of the shafts (6),
the wedges (2) are pin−connected by means of the shafts (7) (Detail A − Figure 3).

- In guiding position the wedges (5) are pin−connected to the beam (PM) by means of the shafts (8)
(Detail A − Figure 3).

- For reaching the tightening position, remove all the shafts from the wedges and drive them in with
the hammer. This operation ensures the blocking of the mast (9) onto the collar (10)
(Detail C and D−Figure 3).

131
4.7.8 Collar equipment for climbing

- Fit the cylinder support (1) by means of the shaft (3) onto the collar (2), fix with split pin
(Detail A − Figure 4).

- Fit the telescoping cylinder (4) by means of the shaft (5), fix with split pin (Detail A and B − Figure 4).
For choosing the cylinder to be used, see "SPARE PARTS CATALOGUE".
For its putting into service, adjustments and utilization, see "OPERATING

INSTRUCTIONS".

- Fit the telescoping yoke (6) onto the cylinder by means of the shaft (7); fix with split pin
(Detail C − Figure 4).

- Make sure, that the cylinder stop (8) is positioned between the cylinder head (4) and the yoke (6).
When the cylinder (4) comes hard against its support (1), the stop (8) prevents the pivoting of the
yoke (6) (Detail C and D − Figure 4).

- At each fitting of the hydraulic unit, cylinder and telescoping yoke onto the upper collar, do not
forget to dismantle and to refit the cylinder support (1) and the pawls (9) and (10).

- Carry out the connection between the cylinder (4) and the hydraulic unit (11).

132
4.7.9 Preparation and equipment of the mast L46F

- The telescoping mast L46F (1) is equipped with its accesses, see paragraph (36B−0360...).

- Fit the support beams (2) and (3) into the mast. These beams must come to rest onto the collar
(4) by means of the support shoes (5) at the end of the telescoping sequences (Detail A and B −
Figure 5).

- Connect the support beams (2) and (3) with the telescoping mast (1).

- For this, use the long links (6) connecting the mast feet (1) on the lower holes with the beams;
then block them by means of the threaded shafts (7), the washers (8), the slotted nuts (9) and the
split pins (10) (Detail C and D − Figure 5).

- Use the short links (11) connecting the mast feet (1) on the upper holes with the beams; then
block them by means of the threaded shafts (7), the washers (8), the slotted nuts (9) and the split
pins (10) (Detail E and D − Figure 5).

According to DIN 15019 - part 1, cranes must be taken out of operation when the wind speed which
corresponds to the total dynamic pressure as calculated from an average based on 10 seconds is
exceeded.

The dynamic pressure which represents the top limit can only be considered to correspond to the
above calculated dynamic pressure provided the crane operation can be taken out of operation
within the shortest possible time and the required safety precautions can be carried out.

When taking the crane out of operation, the following measures must be taken:
All lifting elements (including ropes and chains) must be let down and the empty hook pulled up.

Run the trolley to minimum radius.

Slew the jib in wind direction (with the wind).

Release the slewing brake and provide for free slewability of the crane, or observe corresponding
conditions / prescriptions.

Insert all track plinch bars or secure the crane by way of other tying means.
133
 4.8 BALANCING THE CRANE FOR TELESCOPING

Special instructions

For a correct operation of the climbing equipment, it is essential that the center of gravity of the
lifted crane part is in the axis of the cylinder.

This condition is fulfilled by moving the jib trolley with appropriate load, if required to the balancing
position.

This operation is determined in chapter 38B.

The given distances are theoretical; they depend in particular on the actual weight of the counter−
jib bal- last.

Make sure that this weight corresponds to the jib and counter−jib lengths used.

The balancing position is obtained by checking the play of the guiding wedges of the upperclimbing
collar and by reading the minimum pressure required for telescoping on thepressure gauge of the
hydraulic group.

DURING THE BALANCING OPERATIONS, IT IS FORBIDDEN :

- TO SLEW THE JIB.
- TO MOVE THE JIB TROLLEY.
- TO OPERATE HOISTING OR LOWERING.

4.9 TELESCOPING

4.9.1 General instructions

In order to avoid any risk of accident, the telescoping operations must be carried out accordingto
the instructions given in paragraph 36B−0620−... and by observing thefollowing orders: IT IS FOR-
BIDDEN:
- TO SLEW THE JIB
- TO MOVE THE TROLLEY.
- TO OPERATE HOISTING OR LOWERING when the crane part is being lifted.
BESIDE THE TELESCOPING OPERATIONS:
- Never let the telescoping assembly rested on the cylinder.
- Telescoping can only be carried out with a wind not exceeding 60 km/h.
After each climbing operation, check the perpendicularity of the crane.

134
4.9.2 First telescoping sequence

Rest the telescoping yoke (1) under a set of telescoping lugs (2) welded on the mast section (Detail
A − Figure 1)

Lock the telescoping yoke (1) by means of the shafts (3) (Detail B − Figure 1).

Slew the crane jib in opposite direction to the telescoping cylinder and move the trolley to thebal-
ancing position (see paragraph 38B.

Withdraw the shafts (4) connecting the part to be telescoped to the crane part remaining on he
ground (mast section or fixing angles). Extend the cylinder (5) in order to disengage the base of the
crane part to be telescoped (Detail C − Figure 1)
(These operations are only carried out during the first telescoping sequence).

Fit the telescoping limit stop (6) and block it by means of the shaft (7) and the spacer (8) on a flange
per- pendicular to the cylinder support beam (GM) (Detail D−Figure 1).

Check the balancing position; for this, it is necessary to check the play of the guiding wedges (9)
and (10) of the collar located directly above (Detail E − Figure 1). If necessary, readjust this balanc-
ing position by moving the trolley forward or backward.

- If the play is on the jib side, the trolley must be moved backward - (direction of jib foot)
- If the play is opposite to the jib, the trolley must be moved forward - ( direction of jib nose)

135
Having finished balancing, continue extending the cylinder (1) in order to allow folding down the
pawls (2) under the lugs (3) (Detail A and B - Figure 2).

Lower again in order to rest the lugs (3) onto the pawls (2) (Detail B - Figure 2).

Unlock the telescoping yoke (4) by withdrawing the shafts (5) (Detail C - Figure 2).

Retract the cylinder (1) and lock again the telescoping yoke (4) onto the next lower set of lugs.

Extend the cylinder (1) for a new stroke. Repeat these operations as often as necessary in order
to bring the crane tower base on the level of the first climbing collar.

136
Check the presence on the basic section L46F (1) of the support beams (2) with the support shoes
(3) in retracted position (Detail A - Figure 3).

At the end of the telescoping sequence, telescope slowly; as soon as the support beams (2) comes
slightly out of the collar (4), withdraw the shafts (5), pull out the support shoes (3) and repin the
shafts (5) at (6) (Detail A and B - Figure 3).

Slowly lower again until the crane comes to rest onto the collar (4) by means of the support shoes
(3) (Detail C - Figure 3).

Onto the collars (7) and (8), free the shafts (9) from the guiding wedges (10) and (11), then drive
them in with the hammer in order to put them in locking position (Detail D - Figure 3).

137
4.9.3 Folloeing telescoping sequences

Having checked that the slab is sufficiently dry, fit the third collar (1) depending on the chosen inter-
mediate slab.

Refit the hydraulic unit, the hydraulic cylinder, the telescoping yoke as well as the cylinder support
onto the next collar (2) above (Detail A - Figure 4).

Bleed the hydraulic unit and the cylinder and fix the telescoping yoke (3) by means of the shafts (4)
onto the lugs (5) of which the position is compatible with the cylinder stroke (Detail B - Figure 4).

Put the collar (1) into service, the wedges being in guiding position (Detail C - Figure 4). Put the
crane into theoretical balancing position.

138
Push slightly by means of the cylinder in order to free the wedges (6) and (7) from the two other
collars; bring them into guiding position; for this, refit the shafts (8) (Detail C − Figure 4).

IMPORTANT: Make sure, that the wedges (6) and (7) are not ejected when unlocking by pushing
with the cylinder. Unlock the wedges which are accessible from above by means of a ham−

Put them one after the other into a guiding position.

Retract the support shoes (9) of the support beams (10) (Detail D − Figure 4).

Extend the cylinder in order to allow the pawls (11) to be folded down under the lugs (12)
(Detail E − Figure 4).

Rest the crane onto the pawls (11). The crane comes to rest onto the collars (1) and (2) and is
guided.

Carry out now the dismantling of the collar (13).

139
Unlock the telescoping yoke (1), retract the cylinder, then relock the telescoping yoke (1) by means
of the shafts (3) on the next lower lugs (2) (Detail A − Figure 5).

Extend the cylinder for a new telescoping stroke.

Repeat the cycle as often as necessary, then rest the crane on the support shoes (4) of the support
beams (5) in working position; for this, remove the shafts (6), pull the support shoes (4) and repin
the shafts (6) at (8) (Detail B − Figure 5).

Retract the cylinder in order to rest the assembly onto the collar (9). Bring the wedges (10) and (11)
of the collars (12) and (13) into blocking position; for this, withdraw the shafts (14) and drive in the
wedges with the hammer (Detail C − D Figure 5).

4.9.4 Dismantling

In general, the crane cannot be lowered inside the building, and it is necessary to dismantle it into
smaller parts of reduced dimensions and weights.

Special dismantling accessories are used for these operations. However, the conditions of each site
require particular solutions. For this, it is recommended to consult our AFTER SALES SERVICE.

140
CHAPTER 5 - SAFETY DEVICES

5.1 GENERAL

The JT 140 is equipped with all safety devices prescribed on the delivery day.
The purpose of the safety devices is to prevent damage to the crane, caused by operation faults,
which endanger the life of all personnel on the building site.
During crane operation individual limit switches must not be contacted.
The response of the safety device is always an emergency stop. Only at the beginning of the crane
operation should the correct functioning of the limit switches be checked.

5.2 POSITION OF SAFETY DEVICES

141
 5.3 AUTOMATICALLY ZERO POSITIONING

The push button “Crane on” is locked via the zero contacts of the control lever.
The main contactor can only be switched on when all control levers are in zero position. This
ensures that no drive unit can be switched on unintentionally.

5.4 DEAD-MAN SWITCH

Both control levers in operator’s cabin are spring-loaded and will return to zero position automati-
cally. The right hand side control level is equipped with dead man switch. Operator has to push
down the control lever to operate the crane.

When releasing the dead-man switch, all crane functions will stop.
Dead-man switch can be by-passed on fixed operators control stands when levers are spring
loaded to return automatically to zero.

5.5 AUDIBLE WARNING SIGNALS

From control stand in operators cabin a warning horn can be activated via push button.
For cranes on travelling bases a warning horn is activated when crane is in motion.
A Control lever for travel unit and hoist unit.
12 Push button horn.

5.6 HOIST LIMIT SWITCH

The top and bottom end position of the hook

block are limited by way of a limit switch. This
limit switch is activated from the hoist gear.
When adjusting the cam disks, please do not
forget to include the deceleration distance.
The limit switches must be set in such a way
that they switch off in the bottom hook position;
min. 2 rope windings (safety windings) must
remain on the hoist drum.
For the movement in up direction, a prelimit
switch exists. The adjustment must be done, so
that the hook slows down to step 1, three meters
before the maximum hook height is reached.
The top end position of the hook block must be
set in such a way that with an empty hook and
traveling at full speed, the traveling block comes
to standstill 1.5 m bellow the swing arm.

142
 5.7 TROLLEY TRAVEL LIMIT SWITCH

Trolley travel is limited in the outer and inner

position by a gear cam limit switch. The switch
is actuated by a sprocket gear from the trolley
drum.

Adjust the trolley travel limit switch by turning

the trip cam.

The trolley travel limit switch must be so

adjusted that the trolley travelling at full speed
comes to a standstill before reaching the buf-
fers.

5.8 LOAD MOMENT LIMITER

The load moment limiter is located on the A frame of first jib section. Through the load working on
the jib end and the resulting stress upon the A-frame-corner support, switch contacts are activated
and will switch the hoist unit off in lifting direction and the trolley travel unit in outward direction
(towards jib top) as soon as max. permissible load moment is reached. The adjusting of the load
moment limiter is accomplished by way of a test load.

143
5.8.1 Adjusting of load lifting diagram

Switch 1 -”hoist up” and “trolley forwards” 105% emergency switch.

Run the load 105% of max. permissible load and working radius; refer to “Load diagram”.
“Load up” and “trolley forwards” must switch off over switch 1. Horn must switch on. Red lamp
105% must switch on.

Fix the accomplished screw and counter it with nut.

Switch 2 – “hoist up” and “trolley forwards” 100%.

Run the load 100% of max. permissible load and working radius; Lifting the load in lowest
speed is just possible. “Trolley forwards” must switch off. Green lamp 100% must switch on.

Fix the accomplished screw and counter it with nut.

Switch 3 – “hoist up” 95%.

Run the load 95% of max. permissible load and working radius; The lifting in fast speed must
switch off. “Trolley forwards” possible to 100%.

Fix the accomplished screw and counter it with nut.

5.8.2 Test loading

The load moment limiter must – apart from the annual Check-ups as prescribed in
the regulation for prevention of accidents and after any modification of the crane –
also to be checked whenever necessary, e.g.:

After frequent activation of the load moment limiter

After times of standstill

After extreme changes of weather and/or temperatures. Jib extensions are to be

understood as crane modifications.
144
 5.9 MAXIMUM LOAD LIMITER 24KW

The maximum load limiter is installed in the first jib section and is designed as a rope pull overload-
ed safety device. When lifting any load, the rope pull, which when raises will cause the belleville
spring washers to be pressed together. Depending on each hoist speed and the gear steps, the
related limit switch will be activated as soon as max. permissible rope pull is reached and the
“lifting” movement is blocked when the load is higher than permissible for the gear step. When the
maximum load limiter releases in gearshift “fast” and “middle” the hoist movement is blocked in up
and down direction.

5.9.1 Adjusting the max. load limiter

Run the trolley to approx. 5.0 m working radius.

The limit switch 1 must switch off the “Lift up” when the load is between 105% and max. 110% of
permissible load.

Adjust the switches 2-3 with according lift capacities.

Fix each cone with counter nut.

Permissible lifting capacities in each gear – see chapter 2 – Technical data.

145
5.10 TROLLEY TRAVEL BLOCKING

Each trolley contains a travel blocking device. Should a trolley rope break, a lever is moved at 90°
Air gap adjustment
until stroke. This lever protrudes above the trolley and engages in the lower jib structure.
If the brake is not release correctly, the air gap must be adjusted.
- Unscrew armature 11 completely using notches around it. The armature 11.Unscrew armature 11
5.11 ROPE RETAINING BRACKETS
comletely using notches around it. The armature then lies against the electro-magnet 9.
- Screw armature 11 while pressing on screw 24: When the 3rd nole is reached( 4th for FCM), fully
All ropescrew
tighten pulleys have rope retaining brackets, which prevent the rope from jumping out of the rope
24.
pulley. The crane must not be operated without rope retaining brackets.
Braking torque adjustment
5.12 LOADranges
Ajustment HOOK from about 20 to 100% of braking torque indicated on the nameplate. Braking
torque is easily adjusted without disassembling the brake by adjusting dimension A according to
theaccordance
In following procedure.
with the Accident Prevention Rules, load hooks are permitted on building sites only
- Make sure the air gap is correctly adjusted (see above procedure).
when they have
- Measure been B
dimension furnished
betweenwiththeaouter
hookpart
safety device.
of the brake ring 12 and the external diameter of
the electro- magnet 9 by introducing a ruler in a vent opening of the electro- magnet 9 (see draw-
Therefore
ing). the load hooks have a special safety flap, which must never be removed. See also DIN
15405 (sheet 1) standards: Load hook for hoisting equipment – Supervision when using forged
- On the diagram corresponding to the type of brake, draw aline (1) perpendicular to axis Mf for the
load hooks.
selected braking torque value up to the curve corresponding to measured dimension B. From this
intersection draw the horizontal line (2) which intersects axis A at the adjusted value of knob 26
5.13 example).
(see SLEWING UNIT – COUNTERING PROTECTION
- Loosen locknut 29; adjust A by turning knob 26 ( knob thread has a 100 pitch, ie. 1 mm per turn).
- Countering of slewing
Tighten locknut 29 after direction
adjustment.is automatically controlled by incremental contact, which is
installed in slewing motor.
Disassembly & brake motor
The countering is done via breaking steps of the eddy current break.
- Cut off power supply
- Open terminal box, locate wires (motor supply, brake supply, thermal probes, ect),
- Disconnect supply wires,
- Disassemble brake motor using the appropriate tools (hub remover, bearing extractor, leather or
plastic mallet, calibrated spanners and screwdrivers, circlip pliers).
- Remove release locknut 25.
- Unscrew locknut 29 and adjustment knob 26.
- Unscrew the 3 fixing screws 31 holding electro-magnet 9 and remove it, taking care not to
damage the power supply wires.
- Remove brake ring 12 together with armature 11 : unscrew armature to separate it from brake
ring.
- Clean all parts throughly:
.Using blower only for electrical parts (never use solvent or wet products);
.Use “ White spirit” or cold greasing without chlorine solvant for mechanical parts;
.Use acraper for fittings;
.If necessary degrease lining(s) and brake disc(s) with solvent.

146
CHAPTER 6 CRANE OPERATION

TAKING THE CRANE INTO OPERATION

6.1 PRIOR TO INITIAL CRANE OPERATION

Check the crane track plant, track end buffers, crane travel safety limit switching and the carting.

Check that the crane can move and slew absolutely unhindered over the complete height of the
building and along the complete crane track. The power feeder cable must unwind from the drum
without any problems.

Check the ballast.

Check the oil level in the gears and make sure the crane is well lubricated.

Observe the maintenance intervals as stated in paragraph “Crane Maintenance”.

Check that the ropes are lying correctly inside the pulleys and make sure they are undamaged.
The rope running grooves inside the pulleys must be free of any hardened grease, since in that
case the rope would elevate and rub against the rope holding bracket.

Check all pin and bolt connections.

Open the rail pinch bars.

Activate the slewing brake.

6.2 TAKING THE CRANE INTO OPERATION

The crane main switch and the control levers on the control desk must all be in 0 position.

Establish power connection.

Turn on the main switch on the crane.

Check all limit switches and overload safety devices.

Make sure all brakes of the drives are in perfect working order.

147
CRANE OPERATION

6.3 CRANE CONTROL DESK 24 KW

Crane operation takes place from the control panel inside the operator’s cabin. Before the opera-
tion is started, the main switch, which is installed in the door to feeder-switch cabinet, must be
switched ON and the slewing unit motors must be put back to operating position (neutralize wind
free position).

By pressing push-button CRANE ON (11); this is indicated by way of the indicator light CRANE ON
(11). It is only possible to switch on as long as the two control levers are in zero position. These
control levers are equipped with automatic 0-seatback. The crane is switched OFF by pressing the
“mushroom” type strike button EMERGENCY - OFF (10) and can only be activated when the crane
is at standstill or in a case of an emergency for instance, in event that a drive does not come to a
standstill even when it has been, switched to zero.

The dead-man’s button is installed in the control lever on the right side (A). This must be pressed
when any of the drives is on “run”, otherwise the crane switch will be switched off. With permanent-
ly installed control desks this dead-man’s button may be bridged as long as the mechanical, auto-
matic 0-seatback is active.

The signal horn can be worked from the push button (9) HORN with indicator lamp brake lining
hoist warning in the right part of the control level.

The windscreen wiper is switched on by own switch.

The switchboard, which is located in the operator’s cabin, contains a connection for a socket 220V
AC which is supplied by means of a special transformer. This special transformer has the capacity
of a maximum power consumption of 1kVA or 1kW. The switchboard also provides for terminals to
connect an air conditioner 220V AC

A Control lever for hoist unit and crane travel unit

B Control lever for trolley unit and slewing unit
with push-button for slewing retaining brake
4 Light for 95% load moment
5 Light for 100% load moment
6 Light for 105% load moment
7 Brake push button
9 Horn
10 Mushroom type strike button EMERGENCY OFF
11 illuminated push button CRANE-ON

148
 6.4 CONTROL OF HOIST UNIT

The hoist unit is driven by a 24 kW, pole change Right side

squirrel cage motor retaining brake which is opened
by a DC magnet. Brake air is 0.8mm to 1.00mm.

The brake is activated without delay as soon as the

drive is switches off.

The control is accomplished over 3 switching steps

in the lowering direction and 3 switching steps in the
hoisting direction.

The first steps are only meant for lifting off and
setting down the load and should only be used for a
short time.

They are not regarded as permanent operation

steps.If you remain in the first steps, this will lead to
a strong overheating of the hoist motor.

We have 3 speeds SLOW (1 step) –MIDDLE (2

step)-FAST (3 step a Lowering
Make sure you switch smoothly through these step. b Lifting

When the control lever is returned from lowering or hoisting to zero position, step
one switches on automatically for a short time. For the sake of saving the retainer
brake, the brake sets after the electrical braking of step one has concluded.

The top and bottom end position of the hook block is monitored by a gear limit switch with cams.
There is also a prelimit switch, which will switch off the movement a few meters below max. lifting
height in steps 3. Step 2 will then be the highest speed that the hoist movement can go to max.
permissible lifting height.

Each position of the selector switch FAST-MIDDLE-SLOW has own load moment limiter. Under
FAST, the maximum load has its own load moment limiter. The hoist unit can only move in an up
or down director when the selector switch is put in MIDDLE or SLOW position.

If the maximum load limiter has cut off, it is only possible to set down the load. A special load
moment limiter cuts off the up direction when the load exceeds the safe load limit depending of the
outreach.

149
 6.5 CONTROL OF TROLLEY TRAVEL UNIT

The trolley drive unit is driven by torque squirrel cage motor.

The trolley drive unit is operated by way of the left hand control leve Left side
(B) and in 3 steps via contactors. The steps must be switched quick
and smoothly.
Each of the end positions is limited by way of a gear control current
emergency limit switch. Before one of the end position is reached a
prelimit switch will be activated, which will switch back to step one no
matter what position the control lever is in. It is however possible to
run out of the end position quickly. This function is taken over by the
gear control current switch.

If the trolley is driven outwards with load hanging in the hook, the load
momentum limiter will be activated as soon as permissible. Either the
load is set down or moved inwards again.
Before the trolley unit is switched to zero, it should be switched to
step 1 for a short while, until the rpm of this step is reached. When
doing so, the unit is slowed down electrically and the mechanical
retaining brake is saved from wear and tear. d Trolley forwards
e Trolley reverse
The retaining brake is opened by a DC magnet. The brake is activat-
f Slewing brake
ed without delay as soon as the drive is switched off.

6.6 CONTROL OF SLEWING UNIT

The slewing unit is driven by a squirrel cage motor with flanged-on

eddy current brake. Left side
The slewing unit may not be driven before free positioning (wind) has
been neutralized (see paragraph “Safety devices”), so that the retain-
ing brake works again and can brake.
The slewing movement is controlled in 3 steps via the control lever
(B). Steps 1 and 2 should only be used for positioning and correc-
tions over short distances.
If the control lever is switched to zero, the slewing unit will stop
slowly, being braked gently. By switching the control lever in counter
direction, the slewing unit can be braken over 3 steps. The braking
effect is increased from step 1 to step 2 and 3. The crane operator
must always take care that the braking action is gentle in order to
avoid any impacts and oscillating of the load.

If strong winds threaten to drift the jib away, the retaining brake can f Slewing brake
be activated by pushing button in the left hand control lever. This is g Slewing left
only permitted as long as the slewing unit is as good as at standstill h Slewing right
and the control lever is in zero position. When the slewing unit is
started, the retaining brake will open automatically.
150
 6.7 INSTRUCTIONS FOR CRANE OPERATION

Please always observe the regulations for prevention of accidents (see paragraph
“Safety devices”).

Switch all drives smoothly and evenly, keep a distance from step to step.

Do not remain in the lower steps, since these steps are starting steps – not steps for
crane operation.

IMPORTANT
The following is forbidden:
1. Any pulling askew when lifting, travelling the crane or trolley and slewing
2. To tear loose loads that is stuck.
3. Any transport of personnel.
4. Strictly refrain from loading while traveling.

Whenever the crane or any of its drives make any unintentional movements, the
strike button “EMERGENCY-OFF” (stop) must be activated immediately.

If the crane operator feels that the crane movement or load movement might lead to danger, he
must blow the horn by pushing the appropriate button.

In case of an approaching gale or thunderstorm the crane must be taken out of

operation and secured in due course.

6.8 TAKING THE CRANE OUT OF OPERATION

In compliance with the regulation for prevention of accidents

1 Knurled nut
(VGB 9) the following points are strict provisions, which must
be adhered to in all cases:

Pull up the empty hook block until it is just short of the top
end position.
Slewing
Run the trolley to minimum radius. motor

Place the jib in the wind direction.

Release the slewing brake, turn the knurled nut (1) in clock-
wise direction until it reaches its stop (this also applies for
work breaks). The jib must be able to move like a weather
vane in the wind.

Put all control levers to zero position.

151
 Switch off the crane control by pressing the red “mushroom” type button on th control desk before
you leave the operator’s cabin.

Illumination, heating and all connected electrical devices in operator’s cabin must be switched off.
Lock the operator’s scat in working position.

Put the main switch within the switch cabinet in zero position.

Check all ropes, provide for replacement if this is required (refer to paragraph “Maintenance”).

Insert the track pinch bars and lock them.

All failures and defects noticed during crane operation must be registered in the crane log book
and immediate action taken to remedy.

Furthermore, we recommend the following:

Switch off the section switch on the mast foot or crane base (if installed).

All bearing points on winches, running wheels, motors and gears should be checked for any
unusually high temperature.

Make sure all gears are without any leaks.

Switch off the power connection on the site power distributor.

6.9 TAKING THE CRANE OUT OF OPERATION WHEN A GALE IS APPROACHING

According to DIN 15019 - part 1, cranes must be taken out of operation when the wind speed which
corresponds to the total dynamic pressure as calculated from an average based on 10 seconds is
exceeded.

The dynamic pressure which represents the top limit can only be considered to correspond to the
above calculated dynamic pressure provided the crane operation can be taken out of operation
within the shortest possible time and the required safety precautions can be carried out.

When taking the crane out of operation, the following measures must be taken:
All lifting elements (including ropes and chains) must be let down and the empty hook pulled up.

Run the trolley to minimum radius.

Slew the jib in wind direction (with the wind).

Release the slewing brake and provide for free slewability of the crane, or observe corresponding
conditions / prescriptions.

Insert all track plinch bars or secure the crane by way of other tying means.
152
Always follow the approach of local thunderstorms carefully.
The still prior to the first thunder squalls – (these usually are followed by enormous wind forces) –
During this time, the crane must be put into a favourable position, to take it out of operation and
secure it well.

In case the careful weather observation as mentioned above is completed by installing wind mea-
suring devices, such devices should generally be installed at crane’s highest point and in any case
in such a manner that it will be exposed to the wind equally from all sides without any shading
effect. Please observe that the requirements as to wind observation increase further each outmost
dynamic pressure for cranes in operation is reduced, compared to the nominal value of calculated
operational dynamic pressure.

The graphic bellow illustrates the relation between the top speed, which is decisive for when the
crane must be taken out of operation and the time required to carry out the safety measures as per
DIN 15019.

Thereafter the connection between the speed which is decisive for when the crane must be taken
out of operation and the required time for carrying out the safety measures is explained.

Calculated dynamic pressure 250 N/qm

Example:

t=3 min. time for completition of the safety measures. The crane must be taken out of
operation at a wind speed of 64 km/h.

Explained in an easy manner, the following connections can be established:

If 2 min. are required to carry out the

safety measures, the crane must be
taken out operation already at a wind
speed of 65 km/h.

If 6 min. are required to carry out the

safety measures, the crane must be
taken out operation already at a wind
speed of 60 km/h.

If 12 min. are required to carry out the

safety measures, the crane must be
taken out operation already at a wind
speed of 55 km/h.

Do not forget to secure the crane.

153
6.10 CHANGING OF THE HOIST ROPE REEVING FROM 4-FALL ROPE TO 2-FALL OPERATION

The crane can work with 2 or 4-fall reeving.

To change the reeving, first push the accomplished button for 2 or 4-fall rope.
Then change the hook blocks.

- Loosen the hoist rope

- open the pin connection
between blocks 1 and 2
- Move both blocks down to the ground
- Carefully lift block 2

- Insert pin 3 into block 1

and secure it with clip 4
1. Lower block
2 2. Upper block
3. Pin 35
1 4. Clip 7

3,4 3,4

- Pull up the upper block 2

- Check to make sure the pulley block 2 - Lift block 1 with hoist rope
is sitting close to the trolley

The crane now works with 2-fall rope. The max lifting capacity is 4.0 tons.

154
6.11 CHANGING OF THE HOIST ROPE REEVING FROM 2-FALL TO 4-FALL ROPE OPERATION

- Lower block 1 and set it to the ground - Lower block 2

2
1

- Take out pin 3

- Carefully lower block 2 on the block 1

2 1. Lower block
2. Upper block
1 3. Pin 35
4. Clip 7

3,4 3

- Connect blocks 1 and 2 with pin 3

and secure with clip 4 - Lift both blocks

The crane now works with 4-fall rope. Max. capacity is 8.0 tons.

155
CHAPTER 7 MAINTENANCE

7.1 LUBRICATION - GENERAL

The symbols in the lubrication schedule signify the type of lubricant to be used and the different
lubrication points.

Lubricate thoroughly and regularly, since lubrication carried out according to our instructions helps
to prevent failures and premature wear.

Clean grease nipples before they are greased and oil drain plugs before they are cleaned. Before
each erection, all bolts must be coated with grease.

The slewing ring, being subject to the highest stress, has the shortest greasing interval and needs
proper maintenance.

Do not grease bearings excessively, since they will prone to overheat during operation.

All bearings without grease nipples run without maintenance, thus theses bearings are stripped,
cleaned and greased with a suitable lubricant as part of the bi-annual general overhaul.

Ropes and chains as well as the slewing ring teeth must be treated regularly with acid free grease.

All guides on the overload safety device, gear support, brakes and rollers of the limit switches must
be kept smooth by coating them with light fluid lubricating oil.

Connecting elements which were separated during repair works on the machined surfaces must
be treated with a suitable anti-corrosive substance before they are fitted again.

The lubrication intervals stated in the lubrication schedule must be shortened as required when the
operational conditions are difficult, so that the crane plant is always in good working order.

Any repair and maintenance work must only be carried out after the crane has been
taken out of operation.

7.2 OIL CHANGE INTERVALS

Hoist gear Oil change every 2400 hours of operation

Slewing gear Oil change every 2 years
Trolley gear
Travel gear
Eldro Oil change every 15 months
Hydraulics Oil change every 1200 hours of operation, at least once a year

156
7.3 POSITIONOFLUBRICATIONPOINTS

Grease(bulk)
free grease points

Light lubricating oil

Grease (gun)
Plain bearings
Grease (gun)
Roller bearings

157
7.4 LUBRICATION PLAN

Lubricants
No Lubrication positions (see lubricant recommendation)
1 Toothing at slewing ring S4
2 Wheel rims at the wheels S4
Adhesive lubricant
3
4 Deflection link chain at joints S2
weekly
5 Slewing ring S2
6 Chains drives of trolley gear S2
7 Travel wheels S2
8 every 2 weeks Pivot at travel bogie S3
9
with grease
10 Brake on hoist gear S3
every 6 nipples installed
weeks Drive axle at slewing gear
11 S2
Drum and gear bearing Multipurpose grease
12 S2
pinion shaft travel unit
13 Roller bearings of gears S2
14
At least once a year
15
16

17 prior to each erection Hinge eye of hydraulic cylinder S3

(with grease nipples installed)
18
19 Insert all freshly greased pins S2
20 Grease all ropes S4 Adhesive Lubricant
as required, prior to
21 each erection Chain drives of limit switches
S5 Light lubricating
at hoist and trolley unit

Keep all joints and guides in

22 running order S5 oil

158
 7.5 LUBRICANTS, OPERATION LIQUID, QUANTITY

Construction pieces and lubricants must be harmonized. Only lubricants shown in the lubricant
recommendation for Jost cranes must be used.

Quantity Lubricants
Hydraulic unit Climbing device Type (see lubricant
Liter
recommendation)

TQY 180 80 B6* EP – hydraulic oil

Hoist unit 24PQC20T1 10
Slewing unit JH08
S1 EP – gear oil
Trolley unit 120JXL

Hydraulic double shoe Brake (hoisting unit) B7 Hydraulic oil

Exposed toothed wheels of slewing con-

Adhesive
nection, running wheel drives and wire S4
Lubricant
ropes.

Anti-friction and friction bearings of the

rope pulleys, running wheels, drum bear-
ings, chain drives, chain wheels, slewing
Multipurpose
connection, slip ring transmitter, hook S2
grease
block, greases nipples at gears, drive shaft
axles, motors and genertors,
general lubrication points.

Friction bearings of the travel bogie, central

pivot, cross beam, rope suspensions, load
S3
hook yokes, brake linkage, jib pivots
points.

All joints and guides at switches and Low-viscous

S5
contacts. lubricating oil

The oil level must only be measured by standstill of the gear. The oil filling must
be reached until the upper marking either at oil sight glass or oil overflow screw
or until the upper marking at oil stick.

* In countries with tropical climate hydraulic oil ISO VG 68 must be used!

** These gearboxes are permanently greased – maintenance free.

159
 7.6 GEAR OIL

Operation between – 100C to + 500C

Operation Operation
Ambiente
under 100C Industrial oil Car oil Above + 500C
Temperature
(without AD*) (without AD*)
(with AD*) (without AD*) (with AD*) (without AD*)
ISO ISO ISO SAE SAE ISO
Viscosity
VG 68 VG 100 VG 150 30 80/90 VG 320
according
(150)
ISO (SAE)
No EP
AGIP Balasia 68 Radula Blasia 150 Super Rotra Blasia 320
(-270C) 100 Diesel 80 W/90
15 W/40
Energol Energol Energol HD SAE Gear oil Energol
BP GR XP THB 100 GR XP 150 30 EP SAE 80 GR XP 320
(+/-240C)
Mecanep 68 Cofraline Mecanep Equilux
Cofrapoid Mecanep
Cofran GL Equitex 150 C200
80 W/90 320
100 super
Reductelf Polytelis Reductelf Elan Tranself Reductelf
ELF SP 68 100 SP 150 SAE 30 EP 80 SP 320
(-210C) W/90
Teresso Spartan EP HDX 30 HDX 30/40 Spartan EP
ESSO
EPV 32 150 320
Mobil gear DTE extra Mobil gear Mobilibe Mobil Gear
MOBIL
626 (-240C) Heavy 629 C 90 632

Omala 68 Tellus Omala 150 Dentax 80 Spirax Omala 320

SHELL
(-240C) 100 EP 90
Carter EP Azolla Carter GTS GTS Carter EP
TOTAL 68 100 EP 150 15 W/40 15 W/40 320
(-210C)

No EP: No high pressure oil; * AD: Recoil shutting

Never use high pressure oil in connection with “AD”

160
 7.7 MAINTENANCE SCHEDULE

Maintenance points Work

Hoist gear, slewing gear trolley

and travel gear.

Hydraulics: Check oil level

Daily Before every new climbing process.
Pressure oil pumps
Brakes Check brake linings
All bolt connections to require
torque moment Check after erection
After 100 hours
Climbing hydraulics oil filter Replace
Every 50 – 100 hours Breather filter on the gear Check
All connection terminals in the Check for tight seat tighten if
After 200 hours
control cabinet necessary

Climbing hydraulics: Clean

Breather filter (at least once a year)
After 1000 hours Check for tight seat and
All bolt connections tighten if necessary (at least
once a year)
Plungers and rollers of
Every 6 weeks Clean and slightly grease
emergency limit switches
Vent filter on gear Check for good working
Every 3 months Slip rings, collectors, brushes
Clean
and brush holders of the motor
Contact of relays and switches Check for consumption
Slip rings :
Every 6 months Clean
Running surface of slip rings
Slip ring :
Oil lightly with acid-free oil
Pivot joints at brush holder levers

Yearly Power cables Check the outside and replace

if necessary
Roller bearings of motors and
Dismantle and check
After 2 years generator
General overhaul Roller bearings of eddy current
Remove and check
brake

This must be done within a short period when the crane has first put in operation. It is necessary to tighten all bolts of the slewing ring
with a torque moment spanner. Fastening moment 1000 Nm see table chapter, erection M 27 10.9 DIN 931.
If one of the bolts is not exactly in order it has to be changed. After that check all slewing rings bolts and change them if necessary.

161
 7.8 MOTORS AND GENERATORS

Maintenance work must only be carried out when the electric power is shut off.

The motor and Generator roller bearings are given grease fitting in the factory which under normal
working conditions will last for approx. 4500 operating hours. The bearings should nevertheless be
checked every two years. For this purpose the motor must be dismantled, and the windings, hous-
ing and other parts should be cleaned at the same time. Thoroughly wash the bearings with gaso-
line or benzene. After the gasoline has evaporated, fill the bearings with roller bearing grease.

To avoid overheating of the bearings due to overfilling, fill only the hollows between the rollers and
the roller paths half full with grease. Also coat the shaft passages in the sealing covers with grease.

Larger motors and generators have greasing nipples and greasing instructions on the identification
tag

The slip rings, collectors, carbon brushes and brush holders should be checked regularly, at least
once every 3 months, depending on frequency of operations. Depending on dirt accumulation (car-
bon dust), cleaning is best carried out using a suction method.

Slight dirt on the contact surfaces should be removed with a non-fibrous wool cloth.

No liquid cleaner must be used!

Make sure that the slip ring or collectors are smoothly polished and clean.

The carbon brushes must have a little clearance and lie evenly with their entire contact area and
full spring tension on the slip rings or collectors, as appropriate.

Worn brushes should be replaced by new ones, which must be grounded into the appropriate
rounding with emery cloth.

Badly worn and grooved collectors and also brush burns are usually caused by poor maintenance.
In such cases a recognized specialist must be called in immediately.

This also applies to cleaning procedures in case of very dirty engine interior.

162
 7.9 HOIST GEAR

Oil checks and oil change:

All gears requiring oil lubrication are delivered without oil (new cranes); oil must be added. Watch
the indication on the housing. Relevant for the oil selection is the oil viscosity suggested on the
identification tag at the gearbox. This refers to normal operating conditions.

Hoist unit 24PQC20T1

1 Oil filling bolt
2 Oil drain bolt

Fill in the gear oil through the filling hole until the oil emerges at the oil overflow opening (if installed).

Check the oil level when the gear is at standstill and the oil is cool.

Fill in gear oil. For oil change intervals, see "Lubrication schedule",

Let out oil immediately after the gear comes to a standstill, so that the oil is still operationally warm.
For amount of oil filling, see "operating quantity".

Before filling in new oil, clean gearbox thoroughly and oil drain plug amply.

If possible, replace the seal ring at the oil drain plug.

Cleaning of breather filter:

Clean the breather at the gearboxes regularly.

Screw off the breather, to clean, wash in gasoline and blow out with
compressed air.

7.9.1 Slewing gear and trolley gear

These gearboxes are permanently greased – maintenance free.

163
7.10 BRAKE TYPE FCM FOR THE SLEWING UNIT & TROLLEY

FCO-FCL and FCM brake motors are compact units, which comprise an asynchronous motor and
a failsafe brake (which operates when the supply is off).

Installation
To install the brake motor, follow the COMMISSIONING procedure in the general manual.

Make sure that the brake is in the engaged (braking) position.

Power supply (see wiring diagrams)

Brake motors with built-in power supply are connected in the same way as standard motors. They
have 24 VDC coils. The brake is supplied directly from a rectifier mounted in the terminal box.

For motors with different voltages, which start at reduced voltage conditions or operate at variable
voltage or frequency, it is necessary to have a separate supply fo the brake. In this case, the bridge
rectifier must be connected to a 230 VAC supply.

To achieve a shorter brake engagement response time (compulsory for hoisting applications), it is
necessary to cut off the DC supply to the brake at the motor starte is generally used.

Manual release
As standard the brakes have a “Nylstop” release locknut (no.25). To release the brake, tighten the
locknut.

For brakes equipped with a manual release lever, push on the lever.

For brakes equipped with an automatic reset manual release device, turn the lever 45°(up to the
stop pin).

After any maintenance operation, make sure that the brake is in the engaged
position before starting up.

164
 Warning : always disconnect the motor before working on the brake

Air gap adjustment

If the brake is not release correctly, the air gap must be adjusted.
- Unscrew armature 11 completely using notches around it. The armature 11.Unscrew armature 11
comletely using notches around it. The armature then lies against the electro-magnet 9.
- Screw armature 11 while pressing on screw 24: When the 3rd nole is reached( 4th for FCM), fully
tighten screw 24.

Braking torque adjustment

Ajustment ranges from about 20 to 100% of braking torque indicated on the nameplate. Braking
torque is easily adjusted without disassembling the brake by adjusting dimension A according to
the following procedure.
- Make sure the air gap is correctly adjusted (see above procedure).
- Measure dimension B between the outer part of the brake ring 12 and the external diameter of
the electro- magnet 9 by introducing a ruler in a vent opening of the electro- magnet 9 (see draw-
ing).
- On the diagram corresponding to the type of brake, draw aline (1) perpendicular to axis Mf for the
selected braking torque value up to the curve corresponding to measured dimension B. From this
intersection draw the horizontal line (2) which intersects axis A at the adjusted value of knob 26
(see example).
- Loosen locknut 29; adjust A by turning knob 26 ( knob thread has a 100 pitch, ie. 1 mm per turn).
- Tighten locknut 29 after adjustment.

Disassembly & brake motor

- Cut off power supply
- Open terminal box, locate wires (motor supply, brake supply, thermal probes, ect),
- Disconnect supply wires,
- Disassemble brake motor using the appropriate tools (hub remover, bearing extractor, leather or
plastic mallet, calibrated spanners and screwdrivers, circlip pliers).
- Remove release locknut 25.
- Unscrew locknut 29 and adjustment knob 26.
- Unscrew the 3 fixing screws 31 holding electro-magnet 9 and remove it, taking care not to
damage the power supply wires.
- Remove brake ring 12 together with armature 11 : unscrew armature to separate it from brake
ring.
- Clean all parts throughly:
.Using blower only for electrical parts (never use solvent or wet products);
.Use “ White spirit” or cold greasing without chlorine solvant for mechanical parts;
.Use acraper for fittings;
.If necessary degrease lining(s) and brake disc(s) with solvent.

165
- Replace seals and check bearings.
- Disconnect bridge rectifier and check stator isolation (> 100 megOhms).
- Locate all faulty parts for re- ordering replacements.

Reassembly
- Open bearings should be regreased before assembling ( use grease apprppriate to the operating
conditions).
- Lightly lubricate shaft and bearing race.
- Coat seal(s) with grease, and carefully remount ( use protection sleeve over keyway).
- Coat spigots with tyhe thin layer of sealant to ensure that they are water proof.
- Screw armature 11 onto brake ring 12. The flat side of the armature must be facing outward.
- Remove locating screw 24 from the electro- magnet.
- Position brake ring 12, armature 11 and spring thrust washer 21 in the electro- magnet.
- Place compression spring 28, locknut 29 and adjustment knob 26 over release rod 27 and tighten
knob 26 a few turns into the electro- magnet.
- Position brake assembly on brake lousing 8 and screw in the 3 fixing screws 31 and washers 32,
tightening them alternately until they are all fully tightened.
- Adjust the air gap and braking torque ( see adjustment procedures).
- Screw release locknut 25 onto release rod 27.
- Reconnect the bridge rectifier, thermal probes, if required, then the motor, checking that the
wiring is correct. Close the terminal box.
- Beore reconnecting to the machine, check that the brake motor is operating correctly and make
sure that the manual release lever (if fitted) is in the correct position.

166
167
Checking bridge rectifier

Create a connections as in the diagram opposite,

using a 4.5 V battery, a short length of wire, a bulb
and 2 test probes. Disconnect the bridge recifier,
touch the red probe to positive and the green to
negative: The bulb should light up. By reversing the
2 wires, ie. red to negative and green to positive, the
bulb should not light.

FCO-FCL-FCM PARTS LIST

No. Description Qty No. Splined hub (FCM) Qty No. Rectifier cells Qty
1 Housing and wound stator 1 16 External circlip 1 46 Motor terminal block 1
2 Rotor and shaft 1 17 Brake disc keys 1 48 Motor terminal box frame 1
3 Drive-end shield 1 19 Locating screw 2 52 Brake terminal box frame 1
4 Drive-end bearing 1 24 Release locknut 1 56 Shaft end key 1
5 Assembly rods 4 25 Torque adjustment knob 1 60 Shaft end screw 1
6 Internal circlip 1 26 Release rod 1 61 Shaft end washer 1
7 Non-drive end bearing 1 27 Compression spring 1 62 Lining fixing screw 1
8 Brake housing 1 28 Locknut 1 63 Lining fixing parts 4
9 Electro-magnet* 1 29 Spacer 1 64 1
10 Seal (option) 1 30 Electro-magnet fixing screws 2
11 Armature 1 31 Brake washer 3
12 Brake ring 1 32 FCL: Fan housing 3
13 Removable lining (FCM) 1 38 1
15 Brake disc 1

Give n° engaved on the part in case of order

168
BRAKE TROUBLESHOOTING GUIDE

Brake does Check that electrical wiring is correct,

not release Adjust air gap (refer to air gap adjustment section)
Check that adjustment knob 26 is not too tight; If it is, adjust the braking
torque according to the procedure.

Voltage reading 80 to 110 V DC

- Make sure that the testing equipment is set for DC.
- Disconnect blue and rad wires from bridge rectifier and
Measure check with an ohmmetter that coil is not cut off or earthed.
voltage - Disassemble brake and clean all parts thoroughly.
between - If brake lining adheres to brake disc, order coated brake disc
red and ( for damp environments).
blue coil
supply wires Voltage reading 0 V
- Check that all terminals are tightly secured and that no wire
is cut.
- Disconnect blue and rad wires and check with an ohmmeter
that brake coil is not short- circuited or earthed.
- Replace bridge rectifier.

Brake release Adjust air gap.

but rubs Disassemble brake and clean all parts thoroughly especially grooves in brake
constantly housing 8 and notches on brake ring 12.

Brake engagement Modify wiring for shorter response time. see disgram page 3.
too slow
Check air gap and braking torque adjustment.

Disassemble - If brake lining is worn, replace brake ring 12 (FCO), brake

brake disc 15 (FCL), lined brake ring 12 and removable lining 13
(FCM).
- If brake lining is greasy, clean it with solvent and when dry
rub with fine abrasive paper. Avoid touching lining or brake
disc surface with fingers.
- Clean all parts thoroughly especially grooves in brake
housing 8 and notches on brake ring 12.

Brake release Response time between 0.05 and 0.3 sec ( depending on brake type).
too slow Is response time is longer, adjust air gap.

169
7.11 DISK BRAKE TYPE FCPL FOR HOIST 37KW MOTOR

7.11.1 Installation
To install the brake motors, follow the recommendations in the A.C. motor installation and main-
tenance manual. Ensure that the brake is applied when stopped.
7.11.2 Supply
FCPL brake are fitted with D.C. coils, the separate supply to the brake is a rectifier mounted in
the terminal box as standard.

Voltage Rectifier Nominal D.C brake

Main (V) Voltage (V) +/- 10%
380v 50HZ OV1 24V

7.113 Setting the air gap

The air-gap is the distance between the armature and the yoke when the coil is not supplied. The
air-gap must be re-adjusted when it reaches 1.2mm or when the brake can no longer be released
normally.

To adjust the air –gap, switch off the coil and remove the cover. Then release the three nuts to
move the armature towards the yoke while turning the nuts.
Adjustment is performed by inserting an 0.8mm feeler gauge for 1-disc brake, and a 1mm gauge
for 2-disc brake, between the yoke and the armature. It must be possible to slide the gauge into
the air-gap without effort and with no play at three points distributed equally around the edge of the
yoke.

After checking, tighten the three nuts. If the air gap is set correctly, the brake should be released
sharply when powered up, and the disc should not rub. Re-assemble cover.

7.11.4 Dismantling
Suitable tools should be used for dismantling

7.11.4.1 The brake disc must be changed when the thickness of one of the two lining faces is less
than 1.5mm
Remove the protection cover, and the unscrew the 3 nuts in order to slide yoke, and then discon-
nect the brake powers supply wires. Unscrew the lock nuts of spring and adjusted nuts from bolts
of brake supporting, and then slide off and brake disc.

7.11.4.2 If you want to alter the braking torque

It is rarely necessary to alter the braking torque, since it has been defined for the particular applica-
tion at the time of ordering. Modifying this involves changing certain parameters such as the brake
response time. Request an assembly instruction manual from the manufacturer if necessary.
Screw the lock nut, which will gradually slacken the springs. Select the number of spring needed
for the required braking torque.
Ensure the springs are equidistant between the yoke and the armature, according to relevant
setting detail from manufacturer. Tighten the nut to compress the springs.Then proceed to the
reassembling.
170
7.11.5 Reassembling

7.11.5.1 Fitting the disc on shaft gear of motor.

7.11.5.2 Bring the armature into bolts of the brake supported, fitting the spring and nuts of spring
into bolts of the brake supported.

7.11.5.3 Fitting the lock nut of yoke 3 pieces then install the yoke and screw the lock nuts.

7.11.5.4 Adjust the air-gap

7.11.5.5 Reconnect the brake power supply wires before replacing the cover.

7.12 SLIP RING TRANSLATOR

- The bearing requires no maintenance, nor is any greasing necessary.

- The carbon brushes have a relatively long working life due to the low rpm rate and their hardness.
A check of the carbon brushes should nevertheless take place once every 6 months.

- The carbon brushes must in any case be replaced before metal pieces of the brush holder or the
fixing screws of the carbon brushes touch the slip rings. This must under no circumstances occur.
As part of this check-up it is also necessary to clean the insulation between the slip rings from
adherent carbon dust in order to avoid tracking currents between the individual slip rings.

- Protect the slip ring translator from humidity and other influences by moisture.

- If the slip ring translator is equipped with nickel-plated copper-beryllium springs and nickel-plated
slip rings, these should be cleaned from adherent metal dust every 6 months.

- In order to reduce wear and tear, the slip rings should be sprayed lightly with contact oil Cramolin
"Protective".

7.13 SWITCH CABINET

All connection terminals in the switch cabinet and on the electrical devices must be tensioned as
described in the maintenance plan. Tension all terminals that are not connected, since dangerous
electrical disturbances may occur if contact bolts loosen up. All terminals must be checked after
they have been repositioned. Accumulated dust must be removed with compressed air. Do not
ever store any tools in the switch cabinet.

7.14 ELECTRICAL CABLES

All cables and lines must be checked as specified in chapter "Maintenance plan" to make sure
there is no consumption to be found.

Brittle cables and lines must be replaced by new ones. Be particularly conscious about the feeder line.

171
7.15 CONTACTOR AND SWITCH CONTACTS

Check the contactor and switch contacts for consumption. The contacts have been furnished with
a coat of silver; they make over a large surface without any pushing or sliding movement.

No lubrication, since oil or grease would stimulate the formation of sparks. Argentous oxide, which
is created through the formation of switch fire, is fully electrically conducting as opposed to what is
the case with copper oxide. The argentous exode which is created must never be removed. The
contacts must bum in such a way that the whole contact surface is engaged in the conduction of
current.

Fouling and creation of craters cannot be avoided. Keep contact grease, files and emery cloths
away from the contactor. If ever unusual wear should occur (formation of pearls on the contact
surfaces), it is absolutely necessary to contact a specialist.

7.16 EMERGENCY LIMIT SWITCHES

Clean and grease tappets and rollers of the switches slightly after maintenance workhas been
completed.

We would recommend using thin-bodied oil for winter operation.

All emergency limit switches must be checked for leaks at the screw connections andcover seals
in regular intervals; make sure no water can seep through.

7.17 SLEWING RING

Greasing of the slewing ring must only be done using a perfect non-acid and resin roller bearing
grease and according to the lubricant recommendation for JOST cranes.

Press the roller bearing grease into all grease nipples on the slewing ring using a crease press.
Thereafter the crane is slewed by approx. 15°, then press in roller bearing grease again. Repeat
this process four to five times until grease emerges over the entire circumference of the slewing
ring, at the bearing slit. This grease collar serves as a seal and must never be removed.

Greasing intervals: Confer lubrication plan and after every standstill of any length of time.

Whenever blank spots occur on the toothing of the slewing ring it becomes absolutely necessary
to regrease.

172
7.18 SHORTER LUBRICATION INTERVALS

In tropical areas, wherever the atmospheric humidity is high, where there is considerable accumu-
lation of dust and dirt, substantial differences in temperature and when the crane is stewed contin-
uously.

When cleaning the slewing ring, please take note that no water runs into the track.

After cleaning is completed the slewing ring must be greased thoroughly.

7.19 STEEL STRUCTURE

Bent parts, parts which are cracked or broken must be rectified or replaced immediately. Leave it
to the crane manufacturer to decide whether damaged parts as described above can be repaired.

Repair welding on load bearing parts must be carried out by the crane manufacturer. Alternatively
a welding specialist from the crane manufacturer or from the technical supervisory authorities of
your country must be called in for supervision before the work is started.

7.20 INSPECTION AND MAINTENANCE OF THE PAINTING

From time to time the painting should also be checked as part of the regulations for inspection of
the structural steel components to determine their constructional condition. Check whether the
priming is shining through, if the paint has become chinky or weather-beaten or if formation of
blisters, flaking, considerable chalking, rusty spots or subsurface corrosion has occurred.

The occurrence of rust is to be determined as per DIN 53 2 1 0 "Paintings, determination of rust

grade". When maintaining and repairing the painting, please proceed as per DIN 55 928 paragraph
3 and 4.

7.21 SUPERVISION OF FORGED LOAD HOOKS AS PER Q/SZ1-2001

- For drop forged load books as per Q/SZ1-2001 solely visual cheeks and inspection of the hook
mount is sufficient up to and including book group No. 5. Load books must be replaced as soon as
their mouth width has increased by more than 10% of max. permissible width a2 (Q/SZ1-2001).
The same applies when a possible deformation exceeds 1 0% related to the original measure y.

- Further instructions for cheeks for cracks in the surface, wear and tear and corrosion are given in
Q/SZ1-2001.

- These checks for deformation and wear and tear, e.g. in the hook mount and hook shaft as well
as at the transition member must take place as required, however at least once a year.
Chains which average thickness of member dm, calculated from the arithmetic average between
two diameters standing perpendicularly to each other within the same cross section must be
replaced as soon as their nominal thickness has been reduced by more than 1 0% in any place.
Single members may be replaced. Chains of quenched and subsequently drawn steel must be
sent for repair to a factory which is authorized for the supply of such chains.
173
7.22 ROPE MAINTENANCE

Correct application, assembly and care lengthen the life of wire ropes considerably. A rusty rope
endangers human life. Use rope greases according to the lubricant recommendations for Jost
cranes. Ropes with hemp cores must be greased only with liquid lubricants which creep inside and
are acid-free. This prevents the scouring of the hemp fibres by the steel wires and at the same time
keeps the hemp core soft and provides for rope flexibility.

Careful greasing of the ropes keeps out humility which leads to internal corrosion and growth of
bacteria in the hemp. Frequent and light greasing of the ropes gives better results than rare and
ample greasing.

As soon as the grease film disappears from some places on the rope, re-greasing becomes neces-
sary. A fixed interval cannot be stated, since in rainy periods more frequent greasing is needed
than in dry warm weather. Once a year the rope must be treated with penetrating oil, this renders
solidified and crusty greases useful again.

Re-greasing must take place only when the rope is completely dry, since otherwise any humidity
that maybe present is enclosed in the rope and internal corrosion is promoted. Re-grease with a
brush when the drum stands still. The rope taking up the drum curvature is slightly open and this
facilitates the penetration of the grease into the rope interior. If necessary, render the lubricant
liquid by heating it. Crude oils, petrols, parafins, old oils or other not chemically neutral oils must
under no circumstances be used as lubricants.

If the crane is mainly operated in a narrow limited working radius range, an increased danger of
damaging the trolley rope in this range arises. Accumulated twist over a short stretch of rope leads
to danger of a reinforcement of the twist at the drum approach. This loosens the linkage of the
strands and leads to damage. 7te service life of a rope which is under such a one-sided stress can
only be lengthened when occasionally the possibility to eliminate the twist is given. Therefore the
crane should from time to time be operated load free over the whole trolley travel range in order to
eliminate the twist in the trolley rope.

Provide for sufficient lubrication of the compensating pulley, the drum and the coiled up and off
rope portion.

If peculiarities occur in a rope, then type of lay, rope structure, rope diameter and manufacturer
must be determined. The hemp core of the rope contains a colouredthread. The colour arrange-
ment of this thread is the code of the manufacturer.

174
Example of serious bending of the cable.

Basket-slacking (nest) of a multi-strand

cable (twisting resistant type) caused by
forced rotation of the cable reeving through
too narrow races or an excessive deviation
angle.

Increased diameter of a parallel winding

cable which is a result of distortion to the
metal core due to sudden stress.

Corrosion and signs of wear are often

noted on the external wires.

Individual wires bend up and protrude

through the strands: serious defect due to
alternating stress.

175
7.23 TIME FOR REPLACING WIRE ROPES

Safety in crane operation requires that the ropes are replaced in due time.
Should the ropes be used longer, the crane operation may become dangerous.
Regardless of the make or the number of single wires, all ropes must be discarded at:

1. Break of a strand
2. Reduction of cross-section by more than 1 0%
3. Rust with grain formation
4. Signs of internal corrosion
5. Contact with live power cables
6. Occurrence of squeezing, bulging, buckling and similar damage.

With breakage of single wires, the number of breakages occurred in the outer strands, related to
the rope length determines when the rope is to be replaced.

The following table gives an indication of the time for replacing DIN wire ropes.

For specially constructed wire ropes, observe the manufacturer's instructions.

Regular checks of the wire ropes are very important and increase the working safety.

Max. admissible number of wire breakages before the rope must be replaced:

Number of bearing wires in the - 51 76 101 121 141 161 181 201 221

Outer strands of the rope 50 75 100 120 140 160 180 200 220 240
up to

Number of visible wire breakage

With cross-lay rope: 2 3 4 5 6 6 7 8 9 1

On a length of 6 x rope diameter

With cross-lay rope:

4 6 8 10 11 13 14 16 18 19
On a length of 30 x rope diameter

With long-lay ropes:

1 2 2 2 3 3 4 4 4 5
On a length of 6 x rope diameter

With lon-lay ropes:

On a length of 30 x rope diameter 2 3 4 5 6 6 7 8 9 10

Plaited ropes, on the other hand, must be discarded when there are 10 wire breaks per meter,

In case of doubt, consult DIN 15020 sheet 2 (edition of April 1974).

176
7.24 DRAWING-IN WIRE ROPES

Putting on wire ropes is to be carried out with particular care only by trained personnel. Before
putting on wire it is to be checked if the data on the delivery slip corresponds with those in chapter
"rope dimensions". When putting on, all ropes are to be generously greased with rope grease. This
also applies to galvanize d ropes, since the zinc coating does protect against corrosion, but it does
not reduce the internal friction.

The direction of lay of a rope must always be opposite to the pitch of the drum.
If this is not observed, you risk the formation of kirkings, rope baskets and/or
other rope deformations, making the rope ready for renewal.

The rope should not contact the ground; it must always be resting on a suitable supporting means.
If the rope has not been supplied on a drum, always use a reel for uncoiling.

Drawn-in the rope only with the aid of a twist free leading rope or using the discarded rope. Con-
nect leading rope and rope to be drawn-in a rope stocking.

If the old rope is used as a leading rope then connect both rope stockings with a 3 to 4 m long hemp
rope. That way any twist existing in the old rope is not transmitted via rope stocking to the new
rope. Remove the rope stocking when the rope has been pulled through to the winch. Wind the
new rope into the drum with pretension. Pull the rope between two wood blocks clamped together;
this is particularly important for multilayer operation. No slack rope must accumulate on the drum.

When renewing the rope at the erected tower, fasten the rope at the fastening point but not before
it has been completely drawn in and coiled up on the drum.

Grease the new rope during reeving. Do not immediately load it to maximum; the rope must length-
en gradually. The load twist is distributed by running over pulleys thus improving the running in of
the rope. Run new hoist ropes at first with a small load from the lowest to the highest hook position.
Subsequently load the rope in slow stages up to maximum load.

During mufti-fall reeving of the hoist rope and load-free operation, watch the hook block carefully.

If, with cross-lay ropes, the hook block tends to turn in sense of the rope lay, then a twist catcher
should be attached which will absorb the twist during a few hoisting with the empty hook. The twist
catcher can then be removed again.

After installing the twist catcher, the rope must be regularly inspected for
changes (slackening of the outer layer).

177
ZENO VIET NAM CO.,LTD
HCM OFFICE
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Tel: (84)86 2515 828 Email: [email protected] Web: www.zenovietnam.com

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