Operating Instruction 2013

USETER CRANES CO., LTD.
Operating Instructions
Luffing Crane JL186-12（Ⅰ）
Type JL186-12
Serial No. JL186-1305-024
Year of manufacture 2013
JL186-12 Operating instructions
Edition 00 – 05/2013
Contents
Chapter
Foreword
Record book 0
Fundamental safety instructions 1
Technical data 2
General instructions for assembly 3
Assembly – disassembly 4
Safety devices 5
Crane operation 6
Maintenance 7
Electrical equipment 8
JL186-12 Contents
Edition 00 – 05/2013
Foreword
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.
JL186-12 Foreword
Edition 00 – 05/2013
Record book Chapter 0
0.1 Master sheet 2

0.2 Preliminary remark 3
0.3 General data, driven motors and gears 5
0.4 Electric control, brakes and accessories 6
0.5 Ropes and load hook 7
JL186-12 Record book

Edition 00 – 05/2013 Page 1
0.1 Master sheet
Manufacturer USETER CRANES CO., LTD.
Type: JL186-12
Serial No.: JL186-1305-024
Year of manufacture: 2013
Classification according ISO 4301 (FEM-DIN 15018): A3
Type of crane according DIN 15001, sheet 1: Crane with luffing jib
Application of crane according DIN 15002, sheet 2: Tower crane
Kind of operation: Fixing control station
SHENYANG:
(Manufacturer)

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.
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 they are 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.

0.3 General data, driven motors and gears
General data Safety device

Type JL186-12 Maximum load limiter existent
Horizontal / Load moment limiter existent

Jib
Luffing existent Horn existent
Warning
device
Radius 55 m Light existent
Capacity 2,2t Hook locking existent
Position cabin Turntable Hoist emergency limit switch existent
Driven kind El. motor Inclination limit switch existent
Power: Alternative current 380V - 50 Hz/440V-60Hz Luffing emergency limit switch existent
Control voltage 110 V - 50 Hz
Construction weight 64140 kg
Motors
Power Degree of r.p.m.

HZ Duty cycle % Type Position
kW protection U/min
Hoist unit 45 50 40 DV 225M4 IP 55 M1B 1440
YTLEJ112L-95-4F1
Slewing unit 2x95Nm 50 40 IPW23 V1 1400
YTLEJ112L-95-4F2
Luffing unit 45 50 60 DV 225M4 IP 55 M1B 1440
Gears
Type Transmission Remarks
Hoist unit K 157 38.02
Slewing unit JH08 164 M = 10; T =12
Luffing unit K 127 27.68

0.4 Electric control, brakes and accessories
Control house
Kind Circuit diagram-No.: Power Serial-No.:
Feeding part Contactor contr.
Hoist unit Contactor contr.

E - 211050 76 kW / 400 V
Slewing unit Contactor contr.
Luffing unit Contactor contr.
Brakes
Brake moment
Kind Type
Nm
Hoist unit Disc brake BM62 600
Disc brake
Slewing unit FCO-YTLEJ112L-95 35
Eddy current brake
Luffing unit Disc brake BM62 600
Luffing unit
Disc brake SB50 10000
emergency
Accessories
Type Remarks
M = 10
Slewing ring 300/1720
T = 188
Torque Limiter
Height Limit DXZ-453
Luffing Limit DXZ-210
Slewing Limit DXZ-46

0.5 Ropes and load hook
Ropes
d Length Construction
Application Manufacturer Remarks
mm m of the rope
Min. breaking load
Hoist rope 16 550 35Wx7-1960-16 JIANGSU CITY 181kN
SAFETY STEEL
6x29Fi+FC-1910- ROPE CO., LTD Min. breaking load
Luffing rope 16 270
16 158 kN
Load hook
Y Capacity
Application Classification Manufacturer
mm t
Hoist unit 80 12 Shanghai XIHUA Lifting Equipment Co., Ltd.

Fundamental safety instructions Chapter 1
1.1 Warnings and symbols 2

1.2 Basic operation and designated use 2
1.3 Organizational measures 3
1.4 Selection and qualification of personnel - basic responsibilities 4
1.5 Safety instructions governing specific operational phases 5
1.6 Transporting the slewing tower crane 6
1.7 Maintenance of the slewing tower crane 7
1.8 Warning of special dangers 8
1.9 Hydraulic and pneumatic equipment 9
1.10 Noise 10
1.11 Oil, grease and other chemical substances 10
1.12 Measuring system 11
JL186-12 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.
Cranes GmbH reserves the right to make changes to specifications or to modify the crane at
any time without prior notice.
The following signs and designations are used in the manual to designate instructions of
particular importance.
Danger - refers to orders and prohibitions designed to prevent injury or extensive damage.
Forbidden - important note to prevent accidents or heavy material damages.
USE OF THE CRANE
Cranes hoisting machines JL model are tower cranes with upper slewing. They are devised
only and exclusively for lifting, 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, should 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.
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.
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
environmental 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 supervising 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
instructions 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
operating instructions and paying attention to risks and safety factors.
Observe all safety instructions and warnings attached to the slewing tower crane.
1.3.6 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.
1.3.7 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.

1.3.9 Spare parts must comply with the technical requirements specified by the
supplier/manufacturer. 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.
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.
Statutory 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.

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.

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
environment 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/concrete 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.
1.5.8 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 hook.
1.5.11 The fastening of loads and the instructing of crane operators should be entrusted to
experienced 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.

1.5.16 Crane operation must be stopped whenever wind-forces are prejudicial to safety. The
maximum 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
unauthorized 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,
- swinging 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.
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 information 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 climbing 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.

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.
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.

1.8 Warning of special dangers

1.8.1 Electric energy
1.8.2 Use only original fuses with the specified current rating.
1.8.3 Keep an adequate distance from overhead power lines with the slewing tower crane
When working close to overhead power lines, the slewing tower crane and its load must not
come close to the lines. Keep informed of prescribed safety clearances.
1.8.4 After contacting power lines:

- remain in the slewing tower crane,
- drive the slewing tower crane out of the danger zone,
- warn uninvolved persons not to come nearer or to touch the slewing tower crane,
- have the voltage switched off,
- never leave the slewing tower crane until the contacted/damaged line has been
switched off with absolute certainty.

1.8.5 Work on electrical systems or equipment may only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such an
electrician. and in accordance with the applicable electrical engineering rules.
1.8.6 If provided for in the regulations, the power supply to parts of machines and plants, on
which maintenance work is to be carried out must be cut off.
1.8.7 Before starting work, check the de-energized parts for the presence of power and
ground or short-circuit them in addition to insulating adjacent live parts and elements.
1.8.8 The electrical equipment of a slewing tower crane is to be inspected at regular intervals.
Defects, such as loose connections or damaged cables, must be rectified immediately,

1.8.9 Necessary work on live parts and elements must be carried out only in the presence of
a second person - with whom constant visual and verbal contact must be ensured - who can
cut off the power supply in case of danger by actuating the emergency shut-off or main power
switch. Secure the working area with a red-and-white safety chain and a warning sign. Use
insulated tools only.
1.8.10 Before starting work on high-voltage assemblies and after cutting out the power supply,
the feeder cable must be grounded and components, such as capacitors, short-circuited with a
grounding rod.
1.9 Hydraulic and pneumatic equipment

1.9.1 Work on hydraulic and pneumatic equipment may be carried out only by persons with
special know-how and experience in hydraulic systems.
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, compressed-
air 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
connections 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 operating 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).

Information for the operating personnel.

Edition 00 – 05/2013 Page 10
1.12 Measuring system
Please note Signification of codes and signs
(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 dyn = 10-5 N
Torque in Nm (Newtonmeter)
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, daNm.
Composite units are written, with interspaces, f.inst.:
- Nm -
Edition 00 – 05/2013 Page 11
*
The conversation factors are rounded off according to DIN 1 333.

Edition 00 – 05/2013 Page 12
Technical data Chapter 2
2.1 General 2
2.1.1 Crane components 2
2.1.2 Jib lengths, Load diagrams, Speeds 3
2.1.3 Tower configuration, Hook heights, Erection sequence 4
2.1.4 Jib and tie bar configurations 9
2.1.5 Counter jib ballast 10
2.1.6 Ropes dimensions and constructions 10
2.1.7 Packing list 11
2.1.8 Balancing weight 12
2.2 Foundation loadings 14
2.2.1 Foundation loadings 14
2.2.2 Preparation of foundation plate 15
2.2.3 Earthing 29
2.2.4 Electric power supply 29
2.2.5 Out of service 30
JL186-12 Technical data

Edition 00 – 05/2013 Page1
2.1 General
2.1.1 Crane components
Hoisting 45 kW Slewing Traveling

Luffing 45 kW Fi
P max 6.0 - 12.0 [t] 95N.mx2 4x3,4kW
Load [to] 2.5 3.8 6.00 0,60 25

t=1.7min
V [m/min] 70.4 52.8 35.3 rpm m/min
Power requirement Power requirement

Load [to] 5.0 7.6 12.00
(upper part)
V [m/min] 35.2 26.4 17.6 106KVA

2.1.2 Jib lengths, Load diagrams, Speeds

2.1.3 Tower configuration, Hook heights, Erection sequence
2.1.3.1 Mast Composition
2.1.3.1.1 Free Standing Cranes
- The mast composition 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 “TELE-SCOPIC”.
The assembling order is that given in paragraph 2.1.3.1.3 for reasons of strength.
These documents deal with the opimum composition of the crane tower which is not
allowed to be lower. But it is possible to fit stronger sections (*).
·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 specific to this operation.
·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 × mast sections (**).
(**) Compulsorily consult us
IMPORTANT: The very high cranes are subjected to a downgrading of the load, see
chapter “Special Characteristics”.
2.1.3.1.2 A set of recommended mast sections
L68J1（Ф65） Sections of 7.5m length
Cross section 2 x 2 m − length 7.5 m − Upright L 200x20 + Ф80 − Monoblock mast section −
with jacking steps − Lower fish joint D65 − upper fish joint D65.
L68J （Ф65-Ф55）Sections of 7.5m length
Cross section 2 x 2 m − length 7,5 m − Upright L 200x20 +Ф65 − Monoblock mast section −
with jacking steps − Lower fish joint D65 − upper fish joint D55.
L68B2 Sections of 3m length
Cross section 2 x 2 m − length 3 m − Upright L 200x20 − Mast section made up of panels−

with jacking steps.

2.1.3.1.3 Mast composition and stresses for climbing crane
Mast composition
HT height Mast sections
L68J1（Base mast） L68J（Base mast） L68B2(Mast)
15.1 1 1
18.1 1 1 1
21.1 1 1 2
24.1 1 1 3
27.1 1 1 4
30.1 1 1 5
33.1 1 1 6
36.1 1 1 7
39.1 1 1 8
42.1 1 1 9

2.1.3.4 MAST COMPOSITION (HIGH CRANE)
MAST COMPOSITION (VERY HIGH CRANE) AND REACTIONS ON THE ANCHORAGES
IN SERVICE OUT OF SERVICE

R1(kN) 149 R1(kN) 282
R2(kN) 127 R2(kN) 80

2.1.3.1.5 MAST COMPOSITION (CLIMBING)
D: DISANCE BETWEEN COLLARS
P: WEIGHT
R1: STRESS IN THE UPPER COLLAR
R2: STRESS IN THE LOWER COLLAR
A. JIB LENGTH: 45m - 50m
STRESSES FOR CLIMBING CRANE (Cont’t)
Ⅰ In Service Ⅱ Out of Service

Rear Wind/Jib
D P R1 R2 P R1 R2
m KG KG KG KG KG KG
15.00 73862 14886 -11769 63862 22324 -10073
15.50 14406 -11269 21604 -9352
16.00 13955 -10838 20929 -8677
16.50 13533 -10416 20295 -8043

B. JIB LENGTH: 30m - 35m - 40m
STRESSES FOR CLIMBING CRANE (Cont’t)
Ⅰ In Service Ⅱ Out of Service

Rear Wind/Jib
D P R1 R2 P R1 R2
m KG KG KG KG KG KG
15.00 75483 15200 -11876 65483 23811 -10740
15.50 14817 -11493 23464 -10393
16.00 14457 -11133 23139 -10068
16.50 14120 -10796 22834 -9763
17.00 13803 -10479 22547 -9476
17.50 13503 -10179 22276 -9205
18.00 13220 -9896 22021 -8950

2.1.4 Jib and tie bar configurations
Lengths of jib sections:

1 – 9.2m
2 – 10.3 m
3 – 10.3 m
4 – 10.3 m
5 – 5.155m
6 – 11.53 m

2.1.5 Counter jib ballast
Jib reach Ballast

55.0m 4 t x 5= 20t
50.0 m 4 t x 5= 20t
45.0 m 4 t x 5= 20t
40.0 m 4 t x 4 +2.5 t x1 = 18.5 t
35.0m 4 t x 4 +2.5 t x1 = 18.5 t
30.0 m 4 t x 4+2.5 t x1 = 18.5 t
2.1.6 Ropes dimensions and constructions
Hoist rope *
Rated diameter: 16 mm
Code No: 35Wx7
Standard: Q/320201PE004-2005
Surface of wires: bright (NAT)
Rated strength of wires: 1960 MPa
Minimum breaking load: 181 kN
Type of lay and its direction: cross lay, right-handed (ZS)
Luffing rope *
Rated diameter: 16mm
Code No: 6x29Fi+FC
Standard: Q/320201PE004-2005
Surface of wires: bright (NAT)
Rated strength of wires: 1910 MPa
Minimum breaking load: 158 kN
Type of lay and its direction: cross lay, right-handed (ZS)
Lengths in m
Drum
Jib length 30 35 40 45 50 55
capacity
Hoist rope 65 70 75 80 85 90 550
Luffing rope 249 249 249 249 249 249 270
* contact manufacturer if using other makers

2.1.7 Packing list
Part Piece Description L (m) B (m) H (m) Kg*
1 Jib section 01 9.2 1.45 1.40 1320
3 Jib section 02 10.30 1.45 1.40 800
1 Jib section 03 5.23 1.45 1.40 400
1 Jib section 04 11.55 1.45 1.40 1100
1 Tower top 12 1.5 0.8 3900
1 CRADLE OF TOWER TOP 9.9 1.5 0.5 900
2 SUPPORT BAR OF TOWER TOP 5.66 0.16 0.1 200

UPPORT PART
1 DAMP BAR 3.3 1.45 0.24 290
1 Counter jib 6.5 1.55 0.76 4900
1 Hoist winch 2.4 1.81 0.93 2200
1 Luffing winch 2.2 1.84 1.2 2300
1 Slewing Table+Slewing Support 2.28 2.28 2.4 7800
1 Cabin+Platform 3.2 1.98 4100 2000
1 Hook Block 0.82 0.48 1.42 352
9 L68B2 2.14 2.1 3.26 1700

TOWER
1 L68J 2.17 2.17 7.74 4120
1 L68J1 2.17 2.17 7.74 4660

2.1.8 Balancing weight

2.2 Foundation loadings
2.2.1 Foundation loadings
Total P
HT No. Foundation loading Foundation plate
weight Ground
height Of
Nc Mc H L H Nf Nc+Nf P
m tower
kN KN.m KN m m KN KN KN/M2
18.1 1 669 1315 74 4.8 1.5 829 1498 144
24.1 3 697 1733 85 5.0 1.35 900 1597 159
33.1 6 725 2250 93 5.90 1.70 1420 2145 132
42.1 9 753 2838 108 6.45 1.70 1697 2450 127
These Loading are valid for free slewing crane out of service
Slewing Moment Ms = 125KNm (for jib lengths 30-40)

Slewing Moment Ms = 194KNm (for jib lengths 40–50)
Slewing Moment Ms = 238KNm (for jib lengths 55)
Calculation of the foundation plate

NT  NC  N F
MT  MC  H h N F  L2  h  24
First condition : Excentricity e  M T / NT  L / 3 c  L/2 e
Second condition: Ground pressure p  2  NT / 3 L  c
The admitted ground pressure must be checked by the customer.

2.2.2 Preparation of foundation plate
2.2.2.1 Installation on fixing angles
The following tables define:

- the loads and the reaction 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.
□ CONDITION OF EXECUTION
·BY THE CUSTOMER
The table 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 or dynamic
coefficient 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 STABILITY OF THE

CRANE MINIMUM DIMENSIONS ON THE GROUND AREPRESCRIBED AS WELL AS A
MINIMUM MASS WHICH ARE EQUAL TO THOSE OF THE SMALLEST PERMISSIBLE
CONCRETE BLOCK ( 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 used for 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.
·Execution of the concrete blocks
The plan described in chapter 18A is in compliance with the maximum loads given for each case.

2.2.2.2 Substructure 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 reaction applied on the fixing angles are
given in the brochure
·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 RENFORCEMENT IS GIVEN ON THE FOLLOWING PAGES AS AN
INDICATION AND CAN BE CARRIED OUT DIFFERENTLY, IF NECESSARY, UNDER THE
RESPONSIBILITY OF A COMPETENT SPECIALIST

2.2.2.2.1 Installing the not reusable fixing angles
·Fitting the not reusable fixing angles

Dimensions of the fixing angles
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 ASSEMNLING THE FIXING ANGLES AND THE TEMPLATE, MAKE
SURE THAT 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-Figure 1)
- 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 4×2 shafts (4) Block
the shafts (4) by means of the pins (5); Fix the pin with split pins (Detail C-Figure 1)
- Position the assembly comprising the fixing angles, the template and standard mast
section in the reinforcement arranged in the ditch and carry out an adjustable
wedding(1) under the plates of the fixing angles (Detail A-Figure 2)
IT IS ESSENTIAL TO OBSERVE THE DIMENSION OF 150mm (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

2.2.2.2.2 Installing the reusable fixing angles
Dimensional characteristics of the fixing angles
Installing the fixing angles
-The dimension, number and fitting of the fixing rods of the fixing angles onto the concrete block
(or any other structure) are on the user’s responsibility. The loads and reactions are given in
chapter 006.
-It is possible to use the constructor’s standard of concrete blocks for the information of mass,
dimensions and ground pressure. The concrete blocks are defined for the plate−type fixing
angles. Therefore, it is compulsory to adapt them to the reusable fixing angles and to the
connecting method between the fixing angles and the concrete block. The adaptation of the
reusable fixing angles to these concrete blocks is on the user’s responsibility (the reinforcement
type is to be adapted to the fixing rods used).
-Near the fixing angle, never cut reinforcing steels nor reduce their number given.
-The fixing angles can be supplied before the delivery of the crane in order to use them as
positioning jig for the fixing rods of the fixing angles. The template can also be supplied before
the delivery of the crane.
-The template is only used for fitting the fixing angles.
-Fitting this equipment increases the hook height by 290 mm in comparison with the standard
fixing angles to be set in concrete.
-Take care that the fixing angles are correctly earthed
Determination of a fixing
-The tables of the chapter 009 give the tensile load, compression and shearing forces applied
on the fixing angles for the various working heights. These information allow carrying out the
calculation of the fitting of the fixing angles are adapted to your case of use, knowing that the
shearing force is always taken up by two fixing angles.
-In general, it can be indicated that, in case of fixing by screw connections or by high−strength
tie rod, class 10−9 (elastic limit of 90 kg/mm2), a correct assembling will be obtained by
observing the following data, that is to say:
F − maximum static load under tensile strength on 1 fixing angle.
Fe − the capacity corresponding to the elastic limit of the tie rod.
-Definition of the number of rods (N) to be used per fixing angle.
F/0.3Fe=N（to be rounded）
-The number of the rods is always even: 4 or 6, and symmetrical with respect to the upright.
Note: Considering a permissible load per rod, equal to 0,3 of the elastic limit, taking up the
moment given by the shearing force and the various dynamic coefficients are integrated.
-Prestress Fp to be applied on the high−strength rod (Fp = 0.5 Fe)
Important: Besides these information concerning the number and the quality of the rods,
choosing and fitting workmanlike the fixings are entirely on the user’s responsibility.
Installing the rods
-Fitting the rods varies depending on the number of rods used:

-4 rods − use the holes 1, 3, 4, 6 (Figure 1)
-6 rods − use the holes 1, 2, 3, 4, 5, 6 (Figure 1)

Installing the fixing angles
-Arrange the fixing angles (1) by observing their distance (Detail A − Figure 2).
-Engage the template (2) into the 4 fixing angles, lower it until it comes to rest onto the fixing
angles (Detail C − Figure 2).
-Then pin−connect it by means of 4 x 2 shafts (3); lock the shafts (3) by means of pins (4), fix
the pins with split pins (Detail C − Figure 2).
-Tighten the nuts of the fixing rods according to the supplier’s instructions.
-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).
-Tolerance of surface evenness: 1/400 of the mast cross−section
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.

2.2.2.3 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
NOTE1- 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 dimensions suppose an aggregate size of at least equal
to 40 mm, a condition generally fulfilled for reinforced concrete
NOTE2- 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 350kg/m3 –CPA45 that means, for 1m3 of sand with
gravel : 350kg PORTLAND cement 45
For a vibrated concrete correctly prepared, we obtain:
Fc28= 20Mpa
Ft28= 0.6+0.06fc28=1.8 Mpa
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
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 (Example)
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
In both direction

C CONCRETE BLOCK (M142N)

D CONCRETE BLOCK (M170)

2.2.3 Earthing
The user is responsible for the installation of the protective bonding system and must
ensure that the minimum requirements established by the standard are attended.
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.
Fixing plates
Conductor min.
cross sectional
area 16 mm2
Connection
with nut M10
Conductor must be connected on one of the fixing plates.
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 electric 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
specifications 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,

clarifications, 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
requirements 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.
2.2.5 Out of service
Jib length
30 40 45 50 55
(m)
Distance D
24~ 30 34~ 40 39~ 45 44~ 50 49~ 55
(m)
Jib angle
65°~ 70° 65°~ 70° 65°~ 70° 65°~ 70° 65°~ 70°
α°

General instructions for assembly Chapter 3
3. Preparation of the building yard 2

3.1 Introduction 2
3.2 Ground consistency 2
3.3 Crane installation area 2
3.4 More cranes on the site 3
3.5 Inspection of the building yard 4
3.6 General instruction for crane operator and assembly team 5
3.7 Unallowed crane moves 6
3.8 Assembly and disassembly advices 7
JL186-12 Assembly instructions

3. Preparation of the building yard
3.1 Introduction
The responsibility for the preparation of the crane building yard rests entirely with the
crane user. Any clearing, 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,
installations, 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 recommended from high intensity electrical power cables or transformers.

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.

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 so 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 devices (ropes, slings, chains), which are to
be 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.

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 prominent 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.

3.7 Unallowed crane moves

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 co-ordinations of the
operations on the ground.
3.8.1 Safety precautions
The supervisor must observe the following safety precautions before starting the
assembly or disassembly 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.

3.8.2 Hand signals
Supervisor must explain the hand signals to his technicians.
Danger Horizontal distance
Moving to the Left

Start
Moving to the right

Stop
End Lifting
Vertical distance Lowering

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
Do not work
Protective shoes
on moving parts

Assembly Chapter 4
4.1 General assembly information 2

4.2 Erection crane tower (2.0m) 10
4.3 Preparing the mast sections 14
4.4. Installing VB chassis 21
4.5 Assembling the telescopic cage 44
4.6 Anchorage frame 60
4.7 Climbing inside the buliding 67
JL186-12 Assembly
4.1 General assembly information
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
components and to transfer forces.
Particular attention must be paid to the bolt connections with high-strength pretension.
AII bolt connections 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 connection falls down.
Bolt connections with high-strength pretension

Definition
A bolt connection with high-strength pretension is a bolt connection consisting of bolts, nuts,
washers 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
identification are established by national and international standards.
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:
JL186-12 Assembly
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 multifariousness 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 connection.
Furthermore the nuts must also be furnished with a sign of origin from the nut manufacturer.
Normally 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
JL186-12 Assembly
4.1.5 Washers
Since there are no ISO standards for washers as yet, washers produced for high strength bolt
connections 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 instructions 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.
Grease to be applied on the threads of bolts and nuts and the support surface of
the nut.
JL186-12 Assembly
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
ourselves 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 pretensioned 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 in thus the pretension achieved.
A torque which is too high or too Iow 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

pretensioned 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 torques are required, multipliers must be used. Such multipliers are also called
power drivers.
JL186-12 Assembly
With such multipliers torques up to 9 500 Nm (950 mkg) can be achieved.
These torque wrenches must be checked from time to time and adjusted if necessary.
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 pretensioned bolt
connections loosen up, this may Iead to complete or partly Ioss of the pretension. lf the
pretension gets completely or partly Iost, this Ieads 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 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 assured that the connection is ok. If it is
possible to retension 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 paragraph "Condition of the bolt connection elements".
Upon having done so, the bolt is relubricated, reinserted and tensioned to prescribed
torque.
JL186-12 Assembly
Visual inspection
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
incipient fractures are discovered, then all bolts on this connecting level must be replaced.
Regulations for prevention of accidents
Regular, scheduled inspections are prescribed in all regulations for prevention of

accidents and it is emphasized 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.
JL186-12 Assembly
4.1.9 Table 1
Starting torques：
Property Property Property

Class Class Class
8.8 （8G） 10.9 (10K) 12.9 (12K)
Thread DIN 931/933 DIN 6914 DIN 931/933 DIN 931/933
DIN 912 DIN 912 DIN 912
mkg Nm mkg Nm mkg Nm mkg Nm
M12 5.2 51 9.8 96 7.4 73
M14 8.4 82 13.0 127

M16 14.0 137 24.7 242 19.1 187
M18 18.0 177 26.0 255
M20 25.9 254 48.3 474 37.0 363
M22 35.8 351 66.0 647 51.1 501
M24 44.9 439 83.0 814 64.0 628
M27 70.0 686 123.0 1206 100.0 981
M30 95.8 939 136.8 1342
M33 130.9 1284 187.0 1834 230.8 2264
M36 167.3 1641 239.0 2344 296.1 2904
M39 217.3 2131 310.4 3044 383.6 3762
M42 268.4 2632 383.4 3760 476.3 4670
M45 335.4 3289 479.1 4693 594.8 5833
M48 403.6 3958 576.6 5655 717.8 7039
M56 900.0 8830
JL186-12 Assembly
4.1.10 Table 2
Wrench sizes across flats “s”
Bolts as per DIN 6914 and their mating nuts according DIN 6915 have a bigger wrench
size across t1ats than bolts as per DIN 931 and their mating nuts according DIN 934.
The wrench sizes across flats "s" are listed in the table below:
Rated Wrench size across Wrench size across Wrench size across
diameter falts for bolts flats and bolts flats for inner
Of thread according 931/933 according DIN 6914 hexagon blots
for nuts according and nuts according according DIN 912
DIN 934 DIN 6915
mm mm mm
mm
M12 19 22 10
M14 22 - 12
M16 24 27 14
M18 27 - 14
M20 30 32 17
M22 32 36 17
M24 36 41 19
M27 41 46 19
M30 46 50 22
M33 50 - 24
M36 55 60 27
M39 60 - -
M42 65 - 32
M45 70 - -
M48 75 - 36
M56 85 - -
JL186-12 Assembly
4.2 Erection crane tower (2.0m)
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 representation.
- 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 equipped
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 mast L68J
No. Quantity Name L i h P（Kg）

Complete base section L68J1 2100 2100 7740 4120
1 1 base section 2100 2100 7740
2 1 Ladder with back loops (°) (°) (°)
Reference channel size
standard access(3m length)
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4.2.2.2 Basic mast L68J1
No. Quantity Name L i h P（Kg）

Complete base section L68J 2100 2100 7740 4660
1 1 base section 2100 2100 7740
Reference channel size
standard access(3m length)
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4.2.3 Tower section L68B2(3.0m)
Mark Qty DESIGNATION L l h P (daN)

Complete tower section L68B2 2120 2120 3260 1700
1 1 Unequipped tower section L68B2 2120 2120 3260
2 1 Access
4.2.4 Standard access (3m length)

Standard access 730 1082 3040 30
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Resting platform

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 2 Grab rail 980 30 1000
4.2.5 Access to the towerhead

Resting platform 1255 1280 3040 110
1 1 Unequipped platform 1255 1280 200
2 1 Equipped ladder 730 1082 1540
3 1 Grab rail 1195 34 1000
4 2 Grab rail 1290 80 595
5 4 Support 575 195
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4.3 Preparing the mast sections
Important: Before using the mast sections, carry out a visual check of the bars and welds.
Sections which show deformations or having the bars distorted or the welds cracked, must be
returned to the workshop for repairing.
4.3.1 Assembling the mast sections L68B2
- 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 12 special fishplate bolts. In all cases, the bolt heads are located
on the inside.
- The mast sections are assembled together by 8 shafts connected 2 x 2 by 4 pins and equipped
with an access assembly.
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4.3.2 Assembling the mast sections
Stage5 Turn over

Installing the panel with lug with ladder fixing
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4.3.3 Access
4.3.3.1 Resting platform
The resting platform assembly comprises:

- A platform (1)
- A ladder (2), 3 m length
- A ladder fixing device (3)
- 3 grab rails (4)
- Various fitting devices
4.3.3.2 Access to the towerhead
The complete access to the towerhead comprises:

- A platform (1) equipped with a trap door
- An ladder (2), 3 m length.
- Two grab rails (3)
- Two grab rails SP (4).
- One grab rail (5).
- Various fitting devices (6).
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4.3.3.3 Standard access
The standard access assembly comprises:

- An ladder (1), 3 m length
- An ladder attachment (2)
Various fitting devices
4.3.4 Assembling access
4.3.4.1 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 )。
- Make sure that the ends (3) are clean and not twisted.
- Introduce the ladder 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).
- Fit the 2 grab rails (11) and lock
them with safety pins (12) (Detail
C ). 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.
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4.3.4.2 Assembling the Towerhead access
- 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 by
means of the shaft ∅10 (2); fix with split pin (Detail A).
- Make sure that the ends (3) are clean (no earth or similar in the holes) and not twisted.
- Introduce the ladder (with the back 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)
(Detail B ). Fold down the back loops (7).
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- Fit the platform (8) (opening on the side of the lugs) into the mast section; fix it onto the mast
diagonals by means of the flanges (9) and lock it with the screw bolts HM10 (10) and the
washers W10 (11) (Detail A ).
- Fit both grab rails (12) onto the platform (8) and fix them with the split pins (13) (Detail B ).
Assemble the grab rail (14) and fix it onto the grab rails (12) by means of split pins (15) (Detail
C ).
- Fit both grab rails (16) onto the platform (8) and fix them by means of the split pins (17) (Detail
D ), then lock them onto the grab rails (12) by means of the pipe clamps (18) and the screw
bolts (19) (Detail E ).
- In order to avoid oscillating of the ladder (3) in the mast section during the erection, the ladder
must be fixed by an iron wire.
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4.3.5 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, drive in until it abuts against the fishplates (Detail A).
- The two shafts are locked by means of a pin; block the pin using a split pin (Detail B).
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4.4. Installing VB chassis
4.4.1 Dimension and weight

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
- 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 accessories, etc. is not taken into account.
4.4.1.2 Dimension and weight of the bogies
Code Quantity Name L I H P(KG)

1 4 Motor bogie RT544 1360 770
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4.4.1.3 Dimension and weight of the bogies connecting accessories
On RT544 Travelling mechanism

Connecting accessories of
1
VD travelling gear
4 Equipped fixed bogie fork 220
Connecting accessories of
2
VV travelling gear
2 Equipped fixed bogie fork 220
2 Equipped mobile bogie fork 420
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4.4.1.4 Dimension and weight of VB chassis

1 Complete VB chassis 6440 6700 10075
1 1 Unequipped VB basic mast 2380 2460
unit
2 2 Chassis bearer 2310 6700 700 1596
3 4 Strut of 2 m chassis + shafts
4 1 Access ladder + support 580 370 1200 13.7
5 1 Equipped 3 m ladder 740 730 3040 19
6 1 Guard rope 730 225 1685 14
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4.4.1.5 General dimension of VB chassis
A=6700 Overall dimensions 6700

B=6440 Overall dimensions 6440
*Side with lugs for telescopic version
4.4.1.5.1 On RT544 Travelling mechanism
RT544 travelling mechanism − Wheel _ 430 − A = 835 mm

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4.4.1.5.2 On concrete stools
4.4.1.5.3 On bed plate
Ground level
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4.4.1 Assembling VB 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), flat (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 .
- Equip the chassis with its accessories.
4.4.2.1 Installing VB 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 foundation chapter. For rail−mounted cranes, the track end buffers
must be installed.
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4.4.2.2 Installing the bogie on the track
4.4.2.2.1 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 ).
Important: In case of travelling gears with two motor bogies, place them onto the rail
showing the greater radius of curvature (Detail F − Figure 1). Under no circumstances they
must be located on the same half−bearer.
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4.4.2.2.2 Curvedrack 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 ) 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).
- 1 fork (5) receiving the bogie.
- 1 ball thrust bearing (6) with dust guard (7).
- 1 ring (8) used for centering the ball thrust bearing (6) onto the fork end.
- 1 fork−bogie connecting shaft (9).
- 1 locking ring (10) keeping the fork (5) on the ball thrust bearing (4).
- 1 shaft (11) locking the rotation of the central part of the ball thrust bearing (4) for straight
track travelling or for 90° track changing (Detail D and E − Figure 3 ).
Important: In case of travelling gears with two motor bogies, place them onto the rail
showing the greater radius of curvature (Detail F ). Under no circumstances they must be
located on the same half−bearer.
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4.4.2.3 Installing the accessories
4.4.2.3.1 Installing on concrete stools

Introduce the stools (1) onto the fixing rods (2), then fasten them by means of the washers (3)
and the nuts (4), without locking them. The final tightening will be carried out after fixing the
chassis with the bolts (5) onto the stools (1).
Check the level of the stools
4.4.2.3.2 Installing the chassis 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 ). It will be secured by means of lateral locking devices (1) of which the
number is to be determined by the user (Detail B ).
-Check the level of the supports .
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4.4.2.4 Installing VB chassis
- Sling and raise the chassis assembly (1), then position it according to Detail A
- In case of a rail−mounted crane onto a straight track or curved track travelling gear
according to Detail B
- 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).
- Or on four concrete blocks, previously levelled and dimensioned depending on the
reactions of the machine and the permissible ground pressures (Detail D ).
- Install the access ladder (2), fit it onto the chassis by means of the flanges (3), the screws
(4), the washers (5) and the nuts (6) (Detail E − Figure 1).
Fit the electrical equipment.
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4.4.2 Installing base mast
- This additional access is supplied with the chassis.

- Fitting the guard rope (1) for the access to the basis mast.
- Engage the feet of the guard rope (1) for the access to the basic mast into the top of the
ladder of the basic mast unit (Detail A).
- Fix the other end of the guard rope (1) at the angle irons of the basic mast with the pliers (2),
the screw bolts (3) and the washers (4) (Detail B).
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4.4.4 Ballasting VB chassis
- Ballast the chassis (1) by observing the ballast block position and the ballast weight
according to chapter 4.4.5
-Introduce the fixing rod (2) into the ballast blocks (3) until the threaded part juts from the
ballast support (4) of the chassis (Detail A).
- Install the upper crossbeam (5) on the fixing rod (2), and lock at the upper part by means
of the plates (6) and the shaft (7); fix with split pin (Detail B ).
- At the lower part, lock by using the plate (8), the washer (9) and the nut (10) (Detail A ).
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4.4.5 Rail track tolerances
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4.4.6 General date weights and heights
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4.4.6.1 Assembly of telescopic cage (Drawing 1)
If the crane must be climing.install Telescopic cage over Basic Mast.Assembly of telescopic
cage-see chapter 9-climing.
4.4.6.2 Assembly of turntable (Drawing 2)
4.4.6.3 Assembly of Platform of cabin (Drawing 3)
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4.4.6.4 Assembly of Counter jib (Drawing 4)
4.4.6.5 Assembly of Hoist winch (Drawing 5)
4.4.6.6 Assembly of Luffing winch (Drawing 6)
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4.4.6.7 Assembly of tower top (Drawing 7)
4.4.6.7.1 According to the following program, fit the tower top, cradle of tower top, support bar of
tower top and damp bar together on the ground.(Drawing 7-1)
4.4.6.7.2 Make a pin connection between tower top and top of slewing. (Drawing 7-2)
4.4.6.7.3 Connect the cradle of tower top with support bar of tower top, the cradle of tower top
with counter jib, and the support bar of tower top by pins.(Drawing 7-3)
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4.4.6.8 Assembly of Counter weight (Drawing 8)
4.4.6.9 Assembly of Jib (Drawing 9)
4.4.6.9.1 Assembly of Jib 55m(Drawing 9-1)
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4.4.6.10 Assembly of Guy rope (Drawing10)
4.4.6.10-1 Preassembly of Guy rope (Drawing10-1)
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4.4.6.11 Assembly of Counter weight (Drawing 11)
4.4.6.12 Reeving of luffing rope (Drawing12)
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4.4.6.13 Reeving of hoist rope (Drawing13)
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4.4.6.14 Untie the guy rope
Turn the jib to approximately 45°,take the guy rope apart in Ⅰ,one is 3×4.48m, fixed it on
the head of tower (as A),the other is 2×4.48m+26.6m, fixed it on the jib (as B).
4.4.6.15 Adjustment of safety devices
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4.5 Assembling the telescopic cage
□ General Notes
- The telescoping assembly consists of main parts remaining on the crane and of a certain
number of accessories used during telescoping on it.
- For fitting the telescoping assembly. Two cases are possible:
- Fitting of the complete assembly during normal erection of the crane
Partial fitting for increase in height
- The following pages describe the fitting of the telescoping 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 the upright position, it has to be anchored by guy ropes.
- For assembling the main parts of the telescoping equipment, refer to the corresponding detail
spare parts brochure.
- In order to fit the parts making up the telescoping assembly, see paragraph 21A.
□ Equipment of the trolley and the pulley blocks
- According to the equipment fitted onto the crane , it must be adapted to the telescoping
operations.
4.5.1 General instructions
-The slewing crane part must be balanced compulsorily when the telescoping assembly is lifted
or being lifted and during the introduction of a mast section.
Jib length (m) 30 40 45 50 55

Balance
1.7 0 0 0 0
weight (t)
Distance D (m) 25 40 37.8 34.8 30.4
Jib angle α° 53° 15° 36° 48° 58°
-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 the 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.
- 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.
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- These pins, connected to the telescopic cage by means of a chain, are ONLY TO BE USED
FOR TELESCOPING. They ensure the connection between the fixed towerhead or connect
mast and the last telescoped 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
connecting mast and lowering the telescopic cage, they must be replaced by the normal mast
shafts.
- IT IS STRICTLY FORBIDDEN TO CARRY OUT ANY HOISTING OPERATION BEFORE
PLACING THE NORMAL WORKING SHAFTS.
-- Interruption of telescoping:
- The last mast section must be pin-connected to the crane tower with the normal shafts.
- The towerhead or the connecting mast must be pin-connected to the last mast section of the
crane tower with the normal working shafts.
- The balancing load must be laid down.
- There is no mast section hanging from the monorail trolley. The latter must be lowered to the
ground.
- The pulley block must be raised under the trolley.
- Move the trolley away enough so that the pulley block cannot get caught by the monorail(s)
when the crane is weathervaning.
- Observe the conditions for keeping the telescopic cage at the top of the mast
- 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 may exceed the maximum load permitted for the
crane. For handling the telescopic cage, reduce its equipment so that this maximum load is not
exceeded.
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.
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4.5.3 Fitting the accessories
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 means of the shafts (2) onto the gussets (3) of the towerhead or of the
connecting mast. Fit the shafts (4) onto the plates (1) (Figure 1 – 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 monorail (6) on the plates (1) by means of the shaft (8) (Figure 1- Detail D,E).
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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) (Figure 2- Detail
E)
- Remove the shaft (4), then raise the plates (1) and refit the shaft (4) as well as the shaft (8)
(Figure 2- Detail F, G).
- Proceed in the same way for fitting the second monorail.
□ Fitting the monorails 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.
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4.5.3.2 Fitting the monorails trolley
Lifting the monorail trolley (13) with or
without mast section is carried out by
means of the telescoping hook (5)
(Figure 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 20×53 SP (16)(Figure 3-Detail B):
- When fitting on the frond 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 instructions
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 remained 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 that
the centre 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.
The indicated distances are theoretical; they especially depend on the actual weight of the
counter-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 60km/h.
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4.5.5 1.60m Telescoping sequences

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 .
- 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.
- 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
telescoping.
- Operate the lever of the hydraulic unit in
the “up” direction. Slowly telescope until
the telescoping connecting mast feet just
leave the fishplates of the basic
mast(Detail B- Figure 2).
- If required, readjust the balancing by
manoeuvring the jib trolley.
- Telescope until the telescopic cage
pawls (7), kept away from the mast, are
above the lug(c) of the basic mast (Detail
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- Figure2)
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- 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)
- Repeat this cycle 2 times in order to obtain the space required (X) for introducing the mast
section into the telescopic cage
(Detail A-Figure 5).
- The crane is in the following position:
- The fitted crane part is resting on the
- lugs of the mast (e) by means of the
telescopic 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
(Detail A and C − Figure 5).
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− Do not raise the yoke onto the lugs
located directly above.
− The crane is now in the required

position 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).
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− 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.
− Make sure that the mast section
engages properly into the fishplates of
the basic mast (Detail 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 .
− Lower and place the balancing load on the ground in order to free the telescoping hook.
− Using the telescoping hook, lower the
monorail trolley in order to fit it, if required,
onto a new mast section.
− 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
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4.5.6 End of telescoping
Having completed telescoping, the telescopic cage must be dismantled or lowered as low as
possible: 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.
4.5.6.2 Folding done or dismantling the monorails
Folding done 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 telescoping 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) (Figure
1 − Detail C, D).
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-Remove the shafts(7)and
(8)(Figure2-Detail A, B)
-Operate “Trolley out”until the
monorail(4) can be hooked to the
shaft(1),then fit the shaft(2)(Fugure
2-DetailC,D)
-Operate “Lowing”, the monorail (4)
folds down alongside the masts; free
the hook (Figure2-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 the
second monorail.
-Take off the monorail support
plates(3) and the shafts (1,2,7,10 and
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 fall) 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 fall) trolley.
The telescopic cage can be lowered:
-either by means of the hydraulic cylinder,
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-or by using the hook of the crane; for this:
-Dismantle the telescoping hook and refit the load hook.
4.5.7.2 Loweing the telescopic cage
-sling the telescopic cage at the cylinder 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 to much.

- Check that the mast sections are pinned together and linked to the telescoping mast.
- Free the telescoping yoke, and ilize it into the telescoping cage.
-Remove the shafts (1) connecting the telescope cage to 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 mast using the normal accesses.
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-Slacken the rope, the cage must lower
by its dead weight(DetailA-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, counterbalance 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 weght of the telescoping
yoke, the hydraulic cylinder and the
hydrulic unit contributes to this balance.
-Continue lowering the telescopic cage
until it reaches the lowest possible
position.
-Remove the hydralic unit and store it
away with the cylinder and telescoping
yoke.
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 φ18 slings of 3m 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).
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-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 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).
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By operating the hoisting motion, tighten the slings
(3) slightly in order to come free from the lulgs.
-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) completely, 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.
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
positon (Figure 4).
-On the ground, equip the telescopic cage (4) with its
side catwalks and the rear catwalk which possibly had
beem 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 φ
18 slings (9) equipped with shackles (10) to the rear
fishplates of the cage (4)
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(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 trifor (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 φ18 sling (9) used for raising
the telescopic cage (4). Free the tirfor as
well as the “LUGAL” tackle.
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4.6 Anchorage frame
4.6.1 Dimensions and weights
representation.
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.
4.6.2 Dimension and weight of 2m attachment
No. Quantity Name L I H P(dan)

1 2m Anchorage frame 2850 2580 670 1550
1 1 Front girder 2580 770 335 335
2 1 Rear girder 2595 490 335 225
3 2 Lateral girder 2190 420 296 108
4 1 Diagonal bracing 1568 160 170 55
5 2 Bracket 756 630 345 85
6 2 Bracket 580 630 345 75.5
7 4 Shim 415 140 670 40
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4.6.3 Attach
4.6.3.1 Preface
- 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 2
4.6.3.2 General rules
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.
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.
Instruction: In order to ensure good connection between frame and crane tower and to prevent
the mobile wedges (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 ).
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4.6.3.2 Explanation and dimension of attachment
4.6.3.2.1 Explanation
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).
4.6.3.2.2 Main dimension of 2m attachment
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4.6.4 Installation of 2m attachment
Remove the standard ladder from the mast section which will be equipped with the anchorage
frame.
On the ground, place the two lateral girders (1) and (2) onto the front girder (3) (insert shaft (4)
only in order to make the spacing of the girders (1) and (2) easier) (Detail A and B- Figure 1).
Sling and raise the assembly until it reaches the right position on the mast (with the side of the
anchoring beam attachment (3) towards the building) (Detail A-Figure 1).
In order to make fitting easier, use 2 cords for guiding.
Rest the gussets (5) of the front girder (3) onto the horizontal bracings (6) located in the middle
of the mast section (Detail C- Figure 1).
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Fold back the lateral girders (1) and (2) and pin−connect the shafts (7) (Detail A and B − Figure
2).
Sling and raise the lateral girder (8), position it and pin−connect it to the rear girders (1) and (2)
using the shafts (9) and (10) (Detail C and D − Figure 2).
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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 (13); fix with split pins (Detail 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).
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).
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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 (26) 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 ).
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4.7 Climbing inside the building
4.7.1 General notes

representation.
IMPORTANT: The sum of the weights of the main parts is lower than the weight of the
equipped com-ponent because the weight of pins, bolts, small accessories, etc.
is not taken into account.
4.7.1.1 Complete mast section L68D
Mark Qty. Desgnation L I H P(kg)

Complete mast section L68D 2100 2100 1740 3210
1 1 Unequipped mast section L68D 2100 2100 1740
2 1 Resting platform
3 1 Trap door
4 1 Access ladder + fixing
5 1 Access ladder + fixing
6 2 Grab rail L=1100
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4.7.1.2 Complete mast section L68C
Mark Qty. Desgnation L I H P(kg)

Complete mast section L68C 2000 2000 3000 2450
1 1 Unequipped mast section L68C 2000 2000 3000 2450
2 1 Access ladder with back loops
4.7.1.3 Complete standard mast section L68B2
Mark Qty. Designation L I H P(kg)

1 1 Complete mast section L68B2 2000 2000 3000 1680
2 1 Normal access
3 1 Resting platform
4 1 Access to the towerhead
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4.7.1.4 Equipped climbing collar BA65B
Mark Qty. Designation L I H P(kg)

1 1 Main beams
2 1 Main beams
3 2 Cylinder supports
4 2 Support shoes
5 2 Climbing ladder supports
6 2 Removable climbing ladders
7 1 Crossbeams
8 1 Crossbeams
9 16 Shafts of 50x70
10 16 Split pins
11 16 Bolt M33x100-8.8
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4.7.2 Climbing inside the building
To start with, the crane is used in the classical manner to permit the building of the first
floors which will take the climbing collars.
However, the crane is more often mounted on fixing angles in order to fit into the
staircase or liftshaft.
CAUTION
The beams supported oritlie load-bearing walls of the building are to be prepared by the
customer according to the reactions and dimensions between the floors. The minimum
spacing between two con-secutive climbing collars is “x”m (See chapter 4.5.5).
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.
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4.7.2.3 Composition of the crane tower
The composition of the crane tower and minimun

distance between the climbing collars 12m.
Compulsory: The reinforced mast section must

always be located just opposite to the upper
climbing collar.This must be compulsory take
into account for placing it during the erection of
the crane tower(Detail A)
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4.7.3 Summary of mast sections for crane tower 2,0m
□ Monoblock basic section- 1.500m
length
Basic section which can be tedscoped,
With lugs (1 step)(Detail A-Figure 1).
L68D - Uprights 200 thickness 20.
- Lower fishplating φ55
- Upper fishplating φ65
□ Reinforced monoblock mast
Section – 3m length
Reinforced mast section which can be
Telescoped with lugs (2 steps)
( Detail B – Figure 1)
L68C – Uprights 200 thickness 20.
- Lower fishplating φ55
- Upper fishplating φ55
□Standard mast section with panels-3m
length- with normal access
Standard mast section which can be

telescoped with lugs (2 steps) (Detail A-
Figure 2) equally equipped with a normal
access, a resting platform, an access to
the towerhead depending on the mast
composition.
L68B2-Uprights 200 thickness 20.
-Lower fishplating φ55
-Upper fishplating φ55
□Standard mast section with panels-3m
length- with normal access
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4.7.4 Installation
4.7.4.1 Opening in the floors provide for a sufficient opening in each floor in order not to
hinde the passage of the crane.
Therefore, it is essential to observe the dimensions indicated in the plan opposite.

□ THE CLIMBING COLLARS CAN BE FITTED IN TWO DIFFERENT WAYS:
·either onto two support beams provided for this purpose and prepared by the customer
according to the reactions given in the data sheet. The climbing collars will be boited onto
these beams.
·the drilling dimensions of these beams as well as their position in relation to the floor
are given in figure A on the next page.
·or directly onto the floor: in this case, these floors must take up the vertical and
horizontal reactions given in the data sheet. The climbing collars will be blocked onto the
floors by means of threaded rod or equivalent accessories. The minimum dimensions of
the opening in the floor as well as the drilling of the holes for fixing the climbing collars
are indicated in figure B on the page opposite.
Very important: It is absolutely necessary to keep free an useful area around the
opening in the floor. The dimensions of this area are given in figures A and B on the page
opposite.
CAUTION: In no case the support beams of figure A may protrude inside the opening in
the floor.
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4.7.4.3 Assembling the climbing collars
·Three climbing collars are required in order to ensure the stability and the equilibrium
of the crane tower during the climbing operations and the crane work.
According to the method of use given，i.e, either directly fitted onto the floor or onto
support beams.
·The climbing collars comprise two main beams (1) and (2) which will be positioned on
the side of the telescoping lugs. These main beams (1) and (2) carry the cylinders. They
are equipped with the cylinder supports (3), the support shoes (4), the climbing ladder
supports (5) and the removable climbing ladders (6). These beams (1) are connected
together by means of the crossbeams (7) and (8) and blocked using 2x8 shafts of 50x70
(9) and split pins (10).
·The main beams (1) and (2) show at (11) 4x3 drilled holes of diameter 36 used for
immolilizing the collars .
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4.7.4.4 Fitting the collars
CAUTION
When the collars are to be fitted onto support beams, please note that these beams can
be placed in two different ways:
□either parallel to the beams (1) and (2) according to detail A.
□or perpendicular to the beams (1) and (2) according to detail B.
But in any case observe the dimensions of the useful area around the opening in the floor.
4.7.4.4.1 Fitting
Position the collars and block them on the beams using 4x3 diameter 33 bolts, mark
(Place the guide wedges (4) into their seats (5) provided on the collars.
These wedges are used for guiding the mast when they are pinned in the “Telescoping”
position according to detail C.
The same wedges are used for locking the mast when they are pinned in the “Working ”
position according to detail D.
Observe the direction of introduction of the wedges and drive them in from top to bottom
from “Telescoping” to “Working” position, remove the shafts (6) and drive in the wedges
(4) further.
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4.7.4.5 Balancing the crane for telescoping
4.7.4.5.1 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.
The given diatances are theoretical; they depend in particular on the actual weight of the
counter-jib ballast.
Make sure that this weight corresponds to the jib and counter-jib lengths used.
The balancing positon is obtained by checking the play of the guiding wedges of the
upper climbing collar and by reading the minimum pressure required for telescoping on
the pressure 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.
4.7.5 Telescoping
In order to avoid any risk of accident, the telescoping operations must be carried out
according to the instructions given in paragraph 4.5.5…and by oberseving the following
orders:
IT IS FORBIDDENl:
□To slew the jib.
□To move the jib 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 perpendicularty of the crane.
4.7.5.2 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 hafts φ10(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 bolt (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 1.50m ladder into the mast section. Position the top of the ladder on the
ladder support (1) (Detail A – Figure 6)
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□Introduce both fixing flanges (11), fit the wedges (12) and drive them in; then trun the
lugs(13).
□Proceed in the same way for the 1.35m ladder (14). Fit the 2 grab rails (15) and lock
them with safety pins (16) (Detail C – Figure 6)
4.7.5.3 Climbing
Figure 1:
□Make sure that the wedges (1) on the collars A and B are in guiding position. ie. That
the shafts (2) and (3) are pinned according to detail 4a.
□Remove the shafts (4) connecting the mast to the fixing angles (5).
□Operate the hydraulic unit and extend the cylinder (6) by a whole stroke until the
telescoping lugs (8) are right above the support shoes (9) according to detail 1a.
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Figure 2:
□Push the support shoes (9) against the uprights of the mast.
□Lower by means of the cylinder in order to rest the telescoping lugs (8) onto the
support shoes (9) according to detail 2a.
Figure3:
□Retract the cylinder (6), so that the telescoping yoke (10) come to rest on the next
lower set of telescoping lugs.
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Figure 4 and 5:
□Telecope again and so many times as necessary until the removable ladders (1) reach
the leverl of the collar A.
□These ladders (1) have holes drilled in intervals of 200 mm so as to allow either the
upper frame or the central frame of the L68C mast section (3) to be placed on the level
with the climbing collar B.
□Pin-connect the removable ladders (1) to their respective supports (4) according to
detail 5b.
□Block the mast; to do this, remove the lower shafts (5) and drive in the guide wedges (6)
according to detail 5c.
IMPORTANT
When the crane is in “Working” position, take the support shoes (7) away from the mast.
Figure 6:
□Retract the cylinder rod (8).
□Dismantle the cylinder (8) from its support on the collar A and refit them on the upper
climbing collar B.
Assemble and mount the climbing collar C taking care to free the guide wedges (6)
completely from their seats so that they do not block the crane on the fresh concrete slab.
Figure 7:
□Fit the hydraulic unit (1) onto the floor carrying the climbing collar B. On the collar B,
install the cylinder (2) onto its support as well as the support shoes (4).
□Free the mast from the climbing collars A and B by putting the wedges (6) on the
collars A, B and C in guiding position; to do this, pin the shafts (7) and (8) according to
detail 1a.
□Place the telescoping yoke (9) onto the corresponding lugs, and with the aid of the
cylinders (2), unpin the removable ladders (11) from the ladder supports (13).
Figure 8:
Extend the cylinders (2) a complete stroke, the monoblock basic mast (15) leaves the
climbing collar A.
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Figure 9
Push the support shoes (1) against the mast according to detail 1a.
□Retract the cylinder rod (3) in order to rest the telescoping lugs onto the support shoes
(1) according to detail 2a.
□Free the telescoping yoke (5) from the lugs, retract the cylinder rod (3), the yoke lowers;
immoblilize it on the lower lugs in order to allow a new telescoping sequence to be
carried out.
□Dismantle the supports of the removable ladders and refit them onto the climbing collar
B.
□Once the concrete slab is poured which is to support the next climbing collar, dismantle
the climbing collar A and mount it onto this floor without inserting the guide wedges (7)
into their seats according to detail 3a.
□Refit the climbing collar A onto the upper floor.
□ The climbing collars are handled outside of the construction and not through the
opening in the floor.
Rollers can be fitted under the beams so as to allow them to be rolled over on the slab.
□Coutinuing the telescoping operations is carried out in the same way as described on
the preceding pages.
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Safety devices Chapter 5
5.1 General 2
5.2 Position of safety devices 2
5.3 Automatically zero positioning 3
5.4 Dead-man switch 3
5.5 Audible warning signals 3
5.6 Hoist limit switch 3
5.7 Luffing limit switch 4
5.8 Load moment limiter 4
5.9 Rope retaining brackets 5
5.10 Load hook 5
5.11 Slewing unit – countering protection 5
5.12 Load pin 5
JL186-12 Safety devices

5.1 General
The JL186 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 personell 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

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 operators cabin are spring-loaded and will return to zero
position automatically. 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.
5.7 Luffing limit switch
Luffing 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 luffing drum.
 Adjust the luffing travel limit switch by turning the trip cam.
The luffing travel limit switch must be so adjusted that the jib
travelling at full speed comes to a standstill before reaching
the buffers.
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.
5.8.1 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.

5.9 Rope retaining brackets
All rope pulleys have rope retaining brackets, which prevent the rope from jumping
out of the rope pulley. The crane must not be operated without rope retaining brackets.
5.10 Load hook
In accordance with the Accident Prevention Rules, load books are permitted on
building sites only when they have been furnished with a hook safety device.
Therefore 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 load hooks.
5.11 Slewing unit – countering protection
 Countering of slewing direction is automatially controlled by incremental

contact, which is installed in slewing motor.
 The countering is done via breaking steps of the eddy current break.
5.12 Load pin
Adjusting of load pin:
 Lift the empty hook to top position (close to swing arm) and set the touch panel in
the cabin in 0 – zero position.
 Lower the hook, hang max. load of 8.0 t on and adjust this value on “touch panel”.
The display must show 8.0 t.

Crane operation Chapter 6
Taking the crane into operation 2

6.1 Prior to initial crane operation 2
6.2 Taking the crane into operation 2
Crane operation 3
6.3 Crane control desk 45kW hoist, 45 kW luffing 3
6.4 Control of hoist unit 4
6.5 Control of luffing unit 5
6.6 Control of slewing unit 5
6.7 Instructions for crane operation 6
6.8 Taking the crane out of operation 6
6.9 Taking the crane out of operation when a gale is approaching 7
6.10 Changing of the hoist rope reeving from 4-fall rope to 2-fall operation 9
6.11 Changing of the hoist rope reeving from 2-fall to 4-fall rope operation 10
JL186-12 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.

Crane operation
6.3 Crane control desk 45kW hoist, 45 kW luffing
Crane operation takes place from the control desk inside the operator’s cabin. Before the
operation 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).
The crane switch (main contactor) is switched ON 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 must only be activated when the crane is at standstill or in a case of
emergency in event that a drive does not come to a standstill although it was 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 run, otherwise the crane switch will switch off. With
permanently installed control desks this dead-man’s button may be bridged as long as
the mechanical, automatic 0-seatback is active.
The signal horn can be worked from the push-button (12) HORN with indicator lamp
brake lining hoist warn in the right part of the control lever.
The windscreen wiper is switched on by own switch.
The switchboard, which is located in the operators cabin, contains a connection for a
socket 220V AC which is supplied by means of a special transformer. Further is this
switchboard provided with terminals to connect air conditioner 110V AC and max. power
consumption of 1kVA or respectively 1kW with the transformer mentioned above.
A - control lever for hoist unit and crane travel unit

with bridged dead-man’s button
B - control lever for luffing unit and slewing unit with
push-button for slewing retaining brake
4 – Light for 95% load moment
10 – mushroom type strike button EMERGENCY-OFF
11 – illuminated push button CRANE-ON
12 – push button horn with lamp for brake lining hoist

6.4 Control of hoist unit
The hoist unit is driven by a 45 kW slip ring motor and is equipped with a retainer brake
and an eddy-current brake.
If the brake lining of the retainer brake has become worn, the indicator lamp will light up.
If the brake lining is not changed, the succeeding contact will switch off the steps 3-4-5
and it is then only possible to drive in the steps 1 and 2.
Right side
The control is accomplished over 4 switching steps in the

lowering direction and 5 switching steps in hoisting direction.
In the first two steps of each direction the eddy-current brake
is switched on. These 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 these steps, this will lead to a strong overheating of
the hoist motor and the eddy-current brake. Make sure you
switch smoothly through these steps.
The hoist unit is likewise equipped with a change-over device
SLOW-MIDDLE-FAST. This change over is accomplished
over a regulation device on the hoist gear, which will switch
over the three speeds mechanically. The switching procedure
must only take place at standstill – secured by way of a time
delay of 4 sec. during the declaration phase. It is not
necessary to lift the brake, nor is it necessary to set the load down a – lowering
when switching over. The selector switch SLOW-MIDDLE-FAST is set b – lifting
to desired position. The indicator lamp CHANGE GEAR will light up as c – dead-man
long as this procedure lasts.
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 4 and 5. Step 3 is then the highest speed that the hoist
movement will to max. permissible lifting height in.
Each position of the selector switch FAST-MIDDLE and SLOW has its own load moment
limiter. Releases the maximum load has its own load moment limiter for FAST, the hoist
unit can furthermore move in up or down direction only when the selector switch is putted
in MIDDLE or SLOW position. If the maximum load limiter has cut off in selector switch
position SLOW, 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.

6.5 Control of luffing unit Left side
The luffing unit is driven by a pole change squirrel cage motor.
The luffing unit is operated by way of the left hand control lever (B)
and in 3 steps via contactors. The steps must be switched quickly
and smoothly, but do not ever tear.
Each of the end positions is limited by way of a gear control current

emergency limit switch. Before one of the end positions 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 jib is driven outwards with load hanging in the hook, the d – luffing forwards
load momentum limiter will be activated as soon as permissible. e – luffing reverse
Either the load is set down or moved inwards again. f – slewing brake
Before the luffing 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.
The retaining brake is opened by a DC magnet. The brake is activated without delay as
soon as the drive is switched off.
6.6 Control of slewing unit

Left side
The slewing unit is driven by a squirrel cage motor with flanged-on
eddy current brake.
The slewing unit may not be driven before free positioning (wind) has
been neutralized (see paragraph “Safety devices”), so that the
retaining 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 corrections
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 broken over 3 steps. The f – Slewing brake
braking effect is increased from step 1 to step 2 and 3. The crane g – slewing left
operator must always take care that the braking action is gentle in h – slewing right
order to avoid any impacts and oscillating of the load.

If strong winds threaten to drift the jib away, the retaining brake can be activated by
pushing button in the left hand control lever. This is only permitted as long as the slewing
unit is as good as at standstill and the control lever is in zero position. When the slewing
unit is started, the retaining brake will open automatically.
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 luffing 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 1 Knurled nut
In compliance with the regulation for prevention of accidents

(VGB 9) the following points are strict provisions, which must
be adhered to in all cases:
 Lift the jib in out of service position.

Slewing
 Pull up the empty hook block until it is just short of the motor
top end position.
 Place the jib in wind direction.
 Release the slewing brake, turn the knurled nut (1) in

clockwise 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.

 Switch off the crane control by pressing the red “mushroom” type button on the
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 provide 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.
 Lift the jib in out of service position.
 Slew the jib in wind direction (with the wind).

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

 Insert all track plinch bars or secure the crane by way of other tying means.
Always follow the approach of local thunderstorms carefully.

The still prior to the first thunder squalls – these usually fall in with enormous wind forces
– must be used to put the crane to 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 measuring 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 the 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 competition 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 o
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 o
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 o
operation already at a wind speed of 55 km/h.
Do not forget to secure the crane.

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.
The crane now works with 2-fall rope. The max lifting capacity is 6.0 tons.

6.11 Changing of the hoist rope reeving from 2-fall to 4-fall rope operation
The crane now works with 4-fall rope. Max. capacity in 12.0 tons.

Edition 00 – 05/2013 Page 10
Maintenance Chapter 7
7.1 Lubrication - General 2

7.2 Oil change intervals 2
7.3 Position of lubrication points 3
7.4 Lubrication plan 4
7.5 Lubricants, operation liquid, quantity 5
7.6 Gear oil 6
7.7 Maintenance schedule 7
7.8 Motors and generators 8
7.9 Luffing gear 9
7.10 Luffing brake 10
7.11 Switch cabinet – control house 10
7.12 Electrical cables 10
7.13 Contactor and switch contacts 10
7.14 Emergency limit switches 11
7.15 Slewing ring 11
7.16 Shorter lubrication intervals 11
7.17 Steel structure 11
7.18 Inspection and maintenance of the painting 11
7.19 Supervision of forged load hooks as per DIN 15 401 13
7.20 Rope maintenance 13
7.21 Time for replacing wire ropes 16
7.22 Drawing-in wire ropes 17
JL186-12 Maintenance
7.1 Lubrication - General
The symbols in the lubrication schedule significate 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 particularly
careful maintenance. Do not grease bearings excessively, since they will then overheat
during operation. All bearings without grease nipples run without maintenance and 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 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 2 years

Slewing gear
Luffing gear
Travel gear
Eldro Oil change every 15 months
Hydraulics Oil change every 1200 hours of operation, at least once a

year
7.3 Position of lubrication points
7.4 Lubrication plan
No Lubrication positions Lubricants
(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
7 Travel wheels S2
8 every 2 weeks Pivot at travel bogie S3
9
with
grease
10 nipples Brake on hoist gear S3
every 6
weeks installed
11 Drive axle at slewing gear S2
Multipurpose
Drum and gear bearing grease
12 S2
pinion shaft travel unit
13 Roller bearings of gears S2
14
At least once a year
15
16
prior to each erection

17 (with grease nipples installed) Hinge eye of hydraulic cylinder S3
18
19 Insert all pins freshly greased S2

Adh.
20 Grease all ropes S4
Lubricant
as required, prior to each Chain drives of limit switches
21 Light
erection at hoist and luffing unit S5
lubricating
Keep all joints and guides in oil
22 S5
running order
7.5 Lubricants, operation liquid, quantity
Construction pieces and lubricants must be harmonized. Only lubricants shown in the
lubricant recommendation for cranes must be used.
Lubricants
Type Quantity (see lubricant
Liter recommendation)
Hydraulic unit EP – hydraulic

Climbing device 100 B6* oil
Hoist unit K157 31

Slewing unit JH08 ** S1 EP – gear oil
Luffing unit K 127 21
Travelling unit
Hydraulic double shoe
B7 Hydraulic oil
Brake (hoisting unit)
Exposed toothed wheels

Adhesive
of slewing connection, running wheel
S4 Lubricant
drives and wire ropes.
Anti-friction and friction bearings of the

rope pulleys, running wheels, drum
bearings, chain drives, chain wheels,
slewing connection, slip ring transmitter, Multipurpose
hook block, greases nipples at gears, grease
drive shaft axles,
motors and generators, general S2
lubrication points.
Friction bearings of the travel bogie,
central pivot, cross beam, rope
suspensions, load hook yokes, brake
linkage, jib pivots points. S3
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 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.
7.6 Gear oil
Oil weight
Ambiente Operation Operation between – 100C to + 500C Operation
Temperature under – 100C Industrial oil Car oil upper +
500C
(without AD*) (with (without (with AD*) (without (without
AD*) AD*) AD*) AD*)
Viscocity ISO ISO ISO SAE SAE ISO
according VG 68 VG 100 VG 150 30 80/90 VG 320
ISO (SAE) (150)
No EP

AGIP Balasia 68 Radula Blasia 150 Super Rotra Blasia 320
(-270C) 100 Diesel 80 W/90
15 W/40
BP Energol Energol Energol HD SAE Gear oil Energol
GR XP THB GR XP 150 30 EP SAE 80 GR XP 320
(+/-240C) 100
Cofran Mecanep 68 Cofralin Mecanep Equilux Cofrapoid Mecanep
GL e 150 C200 80 W/90 320
Equitex super
100
ELF Reductelf SP Polytelis Reductelf Elan Tranself Reductelf
68 100 SP 150 SAE 30 EP 80 SP 320
(-210C) W/90
ESSO Teresso EPV Spartan EP HDX 30 HDX 30/40 Spartan EP
32 150 320
MOBIL Mobil gear DTE Mobil gear Mobilibe Mobil Gear
626 (-240C) extra 629 C 90 632
Heavy
SHELL Omala 68 Tellus Omala 150 Dentax 80 Spirax Omala 320
(-240C) 100 EP 90
TOTAL Carter EP 68 Azolla Carter GTS GTS Carter EP
(-210C) 100 EP 150 15 W/40 15 W/40 320
 No EP: No high pressure oil; * AD: Recoil shutting
Never use high pressure oil in connection with “AD”
7.7 Maintenance schedule
Maintenance points Work
Hoist gear, slewing gear luffing
and travel gear.
Hydraulics:
daily Before every new climbing Check oil level
process.
Pressure oil pumps
Brakes Check brake linings
All bolt connections to require
Check after erection
torque moment
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 :
Clean
Running surface of slip rings
Every 6 months Slip ring :
Pivot joints at brush holder Oil lightly with acid-free oil
levers
Check the outside and
Yearly Power cables
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.
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, housing and other parts should
be cleaned at the same time. Thoroughly wash the bearings with gasoline 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 (carbon 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 ground 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.
For additional installation and maintenance information see Appendix A.
7.9 Luffing 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.
Luffing unit
1 Oil filling bolt

2 Oil drain bolt
3 Oil overflow 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", and Appendix
B.
 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.
For additional information refer to Appendix B.
7.9.1 Slewing gear
These gearboxes are permanently greased – maintenance free.
7.10 Luffing brake
The caliper SB50 disc brake is intended to work mainly as emergency stop brake. For
installation and maintenance instructions see Appendix C for further information.
7.11 Switch cabinet – control house
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.
7.12 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.
Brittled cables and lines must be replaced by new ones. Be particularly conscious about
the feeder line.
7.13 Contactor and switch contacts
Check the contactor and switch contacts for consumption. The contacts have been
furnished with a coat of silver; they mate over a large surface without any pushing or
sliding movement.
No lubrication, since oil or grease would stimulate the formation of sparks. Argentuous
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 arbentuous 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.
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Fouling and creation of craters cannot be avoided. Keep contact grease, files and emery
cloths away from the contacts. 1 fever unusual wear should occur (formation of pearls on
the contact surfaces), it is absolutely necessary to contact a specialist.
7.14 Emergency limit switches
Clean and grease tappets and rollers of the switches slightly after maintenance work has
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 and
cover seals in regular intervals; make sure no water can enter.
7.15 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 BKT 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. 15o, 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.
7.16 Shorter lubrication intervals
In tropical areas, wherever the atmospheric humidity is high, where there is considerable
accumulation of dust and dirt, substantial differences in temperature and when the crane
is stewed continuously.
When cleaning the slewing ring, please take care that no water runs into the track. After
cleaning is completed the slewing ring must be greased thoroughly.
7.17 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 weldings 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.
7.18 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.
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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.
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7.19 Supervision of forged load hooks as per DIN 15 401
 For drop forged load books as per DIN 15 401 sheet 1 and 2 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
(DIN 15 4301). 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 DIN 15 405 paragraph 5.
 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.
 Inspection of the transition

member as per DIN 685
checked round steel chain
item 5.2.1 paragraph b:
d1  d 2
dm   0,9d k
2
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.
7.20 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 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 necessary. 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
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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 luffing 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 luffing travel range in order
to eliminate the twist in the luffing 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 coloured
thread. The colour arrangement of this thread is the code of the manufacturer.
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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.
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7.21 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
Up to 50 75 100 120 140 160 180 200 220 240
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 long-lay ropes: 1 2 2 2 3 3 4 4 4 5

With lon-lay ropes: 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).
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7.22 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 reduced 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 kinkings, 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 twistfree leading rope or using the
discarded rope. Connect 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 lengthen 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 multi-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).
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Maintenance Chapter 7
7.1 Lubrication - General 2

7.2 Oil change intervals 2
7.3 Position of lubrication points 3
7.4 Lubrication plan 4
7.5 Lubricants, operation liquid, quantity 5
7.6 Gear oil 6
7.7 Maintenance schedule 7
7.8 Motors and generators 8
7.9 Luffing gear 9
7.10 Luffing brake 10
7.11 Switch cabinet – control house 10
7.12 Electrical cables 10
7.13 Contactor and switch contacts 10
7.14 Emergency limit switches 11
7.15 Slewing ring 11
7.16 Shorter lubrication intervals 11
7.17 Steel structure 11
7.18 Inspection and maintenance of the painting 11
7.19 Supervision of forged load hooks as per DIN 15 401 13
7.20 Rope maintenance 13
7.21 Time for replacing wire ropes 16
7.22 Drawing-in wire ropes 17
7.1 Lubrication - General
The symbols in the lubrication schedule significate 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 particularly
careful maintenance. Do not grease bearings excessively, since they will then overheat
during operation. All bearings without grease nipples run without maintenance and 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 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 2 years

Slewing gear
Luffing gear
Travel gear
Eldro Oil change every 15 months
Hydraulics Oil change every 1200 hours of operation, at least once a

year
7.3 Position of lubrication points
7.4 Lubrication plan
No Lubrication positions Lubricants
(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
7 Travel wheels S2
8 every 2 weeks Pivot at travel bogie S3
9
with
grease
10 nipples Brake on hoist gear S3
every 6
weeks installed
11 Drive axle at slewing gear S2
Multipurpose
Drum and gear bearing grease
12 S2
pinion shaft travel unit
13 Roller bearings of gears S2
14
At least once a year
15
16
prior to each erection

17 (with grease nipples installed) Hinge eye of hydraulic cylinder S3
18
19 Insert all pins freshly greased S2

Adh.
20 Grease all ropes S4
Lubricant
as required, prior to each Chain drives of limit switches
21 Light
erection at hoist and luffing unit S5
lubricating
Keep all joints and guides in oil
22 S5
running order
7.5 Lubricants, operation liquid, quantity
Construction pieces and lubricants must be harmonized. Only lubricants shown in the
lubricant recommendation for cranes must be used.
Lubricants
Type Quantity (see lubricant
Liter recommendation)
Hydraulic unit EP – hydraulic

Climbing device 100 B6* oil
Hoist unit K157 31

Slewing unit JH08 ** S1 EP – gear oil
Luffing unit K 127 21
Travelling unit
Hydraulic double shoe
B7 Hydraulic oil
Brake (hoisting unit)
Exposed toothed wheels

Adhesive
of slewing connection, running wheel
S4 Lubricant
drives and wire ropes.
Anti-friction and friction bearings of the

rope pulleys, running wheels, drum
bearings, chain drives, chain wheels,
slewing connection, slip ring transmitter, Multipurpose
hook block, greases nipples at gears, grease
drive shaft axles,
motors and generators, general S2
lubrication points.
Friction bearings of the travel bogie,
central pivot, cross beam, rope
suspensions, load hook yokes, brake
linkage, jib pivots points. S3
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 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.
7.6 Gear oil
Oil weight
Ambiente Operation Operation between – 100C to + 500C Operation
Temperature under – 100C Industrial oil Car oil upper +
500C
(without AD*) (with (without (with AD*) (without (without
AD*) AD*) AD*) AD*)
Viscocity ISO ISO ISO SAE SAE ISO
according VG 68 VG 100 VG 150 30 80/90 VG 320
ISO (SAE) (150)
No EP

AGIP Balasia 68 Radula Blasia 150 Super Rotra Blasia 320
(-270C) 100 Diesel 80 W/90
15 W/40
BP Energol Energol Energol HD SAE Gear oil Energol
GR XP THB GR XP 150 30 EP SAE 80 GR XP 320
(+/-240C) 100
Cofran Mecanep 68 Cofralin Mecanep Equilux Cofrapoid Mecanep
GL e 150 C200 80 W/90 320
Equitex super
100
ELF Reductelf SP Polytelis Reductelf Elan Tranself Reductelf
68 100 SP 150 SAE 30 EP 80 SP 320
(-210C) W/90
ESSO Teresso EPV Spartan EP HDX 30 HDX 30/40 Spartan EP
32 150 320
MOBIL Mobil gear DTE Mobil gear Mobilibe Mobil Gear
626 (-240C) extra 629 C 90 632
Heavy
SHELL Omala 68 Tellus Omala 150 Dentax 80 Spirax Omala 320
(-240C) 100 EP 90
TOTAL Carter EP 68 Azolla Carter GTS GTS Carter EP
(-210C) 100 EP 150 15 W/40 15 W/40 320
 No EP: No high pressure oil; * AD: Recoil shutting
Never use high pressure oil in connection with “AD”
7.7 Maintenance schedule
Maintenance points Work
Hoist gear, slewing gear luffing
and travel gear.
Hydraulics:
daily Before every new climbing Check oil level
process.
Pressure oil pumps
Brakes Check brake linings
All bolt connections to require
Check after erection
torque moment
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 :
Clean
Running surface of slip rings
Every 6 months Slip ring :
Pivot joints at brush holder Oil lightly with acid-free oil
levers
Check the outside and
Yearly Power cables
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.
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, housing and other parts should
be cleaned at the same time. Thoroughly wash the bearings with gasoline 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 (carbon 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 ground 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.
For additional installation and maintenance information see Appendix A.
7.9 Luffing 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.
Luffing unit
1 Oil filling bolt

2 Oil drain bolt
3 Oil overflow 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", and Appendix
B.
 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.
For additional information refer to Appendix B.
7.9.1 Slewing gear
These gearboxes are permanently greased – maintenance free.
7.10 Luffing brake
The caliper SB50 disc brake is intended to work mainly as emergency stop brake. For
installation and maintenance instructions see Appendix C for further information.
7.11 Switch cabinet – control house
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.
7.12 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.
Brittled cables and lines must be replaced by new ones. Be particularly conscious about
the feeder line.
7.13 Contactor and switch contacts
Check the contactor and switch contacts for consumption. The contacts have been
furnished with a coat of silver; they mate over a large surface without any pushing or
sliding movement.
No lubrication, since oil or grease would stimulate the formation of sparks. Argentuous
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 arbentuous 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.
Edition 00 – 05/2013 Page 10
Fouling and creation of craters cannot be avoided. Keep contact grease, files and emery
cloths away from the contacts. 1 fever unusual wear should occur (formation of pearls on
the contact surfaces), it is absolutely necessary to contact a specialist.
7.14 Emergency limit switches
Clean and grease tappets and rollers of the switches slightly after maintenance work has
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 and
cover seals in regular intervals; make sure no water can enter.
7.15 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 BKT 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. 15o, 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.
7.16 Shorter lubrication intervals
In tropical areas, wherever the atmospheric humidity is high, where there is considerable
accumulation of dust and dirt, substantial differences in temperature and when the crane
is stewed continuously.
When cleaning the slewing ring, please take care that no water runs into the track. After
cleaning is completed the slewing ring must be greased thoroughly.
7.17 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 weldings 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.
7.18 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.
Edition 00 – 05/2013 Page 11
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.
Edition 00 – 05/2013 Page 12
7.19 Supervision of forged load hooks as per DIN 15 401
 For drop forged load books as per DIN 15 401 sheet 1 and 2 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
(DIN 15 4301). 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 DIN 15 405 paragraph 5.
 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.
 Inspection of the transition

member as per DIN 685
checked round steel chain
item 5.2.1 paragraph b:
d1  d 2
dm   0,9d k
2
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.
7.20 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 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 necessary. 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
Edition 00 – 05/2013 Page 13
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 luffing 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 luffing travel range in order
to eliminate the twist in the luffing 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 coloured
thread. The colour arrangement of this thread is the code of the manufacturer.
Edition 00 – 05/2013 Page 14
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.
Edition 00 – 05/2013 Page 15
7.21 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
Up to 50 75 100 120 140 160 180 200 220 240
Number of visible wire breakage


With long-lay ropes: 1 2 2 2 3 3 4 4 4 5

With lon-lay ropes: 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).
Edition 00 – 05/2013 Page 16
7.22 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 reduced 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 kinkings, 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 twistfree leading rope or using the
discarded rope. Connect 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 lengthen 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 multi-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).
Edition 00 – 05/2013 Page 17
Electrical equipment Chapter 8
1、Explaning of circuit diagram … … … … … … … … … … … … … … … … … … 2

2、Electrical drawing … … … … … … … … … … … … … … … … … … … … … … 11
3、Frequency converter test and maintenance … … … … … … … … … … … … … 30
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1.1 Species of components
K 800
Species of components
Touch-screen
A
I/OModule
Measurement ring
Sensor
B Coder
Travelling switch
Temperature switch
Approach switch
Capacitor
C
Video recorder
Heater
E Air conditioner
Lighting
Window wipers
Fuse
F Miniature fuse
Surge absorber
Thermal relay
G Dry cell
Generator
Relay
CPU
Phase rotation relay
K
Time relay
Electromagnetic valve
Filter
Eddy-current brake
Reactor
L Inductance coil
- 2 -
Species of components
Motor
M
Air blower
Horn
Signal lamp
Display unit
P Voltmeter
Amperemeter
Counter
LED
Sound signal device
Circuit breake
Contactor
Q Fuse switch
Motor starter
High power transistor
Silicon control
Diode
R
Resistor
Control switch
T Button
S
Change-over switch
KV stabilization device
Mutual inductor
T Transformer
Transducer
Signal transducer
Telephone
V Rectifier
Cable
W Line
Communication Bus
Optical communication
Connecting terminal
X
Plug and socket
Y Brake
- 3 -
1.2 Species number
Species numbers include three digits, as follows.
K 800 M
Species number
100-199 Power
100-129 Main power
130-149 Auxiliary power
150-169 Cable drum power
170-189 Lift type cabin power
200-299 Central control checking system
300-399 Signal devices and cabin devices
300-319 Signal lamp
320-329 Alarm, buzzer
330-339 Monitor
340-349 Window wipers, Glass cleaner
350-359 Lighting devices
360-369 Air conditioner, Heater
370-375 Plug
400-499 Hoist
400-409 Administrator
410-414 Up
415-419 Down
420-429 Second gear control /second gear control speed
430-439 Third gear control /third gear control speed
440-449 Fourth gear control /fourth gear control speed
450-459 Fifth gear control /fifth gear control speed
400-499 Different from the components of direction/speed
500-599 Walking
510-514 Walk forward
515-519 Walk back
- 4 -
Species number
600-699 Slewing
610-614 Slewing turn to right
615-619 Slewing turn to left
700-799 Luffing Trolley
710-714 Up
715-719 Down
740-749 Fourth gear control /fourth gear control speed
750-759 Fifth gear control/ fifth gear control speed
800-899 Trolley
810-814 Trolley forward
815-819 Trolley back
900-999 Assembly-helping expand the winch

910-919 Keep the jib
920-929 Expand the jib
930-959 Assembly, hoist
960-969 Aids of winch
970-989 Hydraulic expand jib
990-999 Pin disassembly hydraulic tools
- 5 -
2. Electrical sysmbol
2.1 Accessories
Buzzer Resister Fuse
Alarm Cabin heater Impact fuse
Anti-interference
Electronic Window resisitor
valve swiper
Lighting Signal lamp 3P Fan
Single
Autotransformer
phase
accessory
Transformer Transformer
Transformer 3P Inductor
Power Filter
2.1 Switches
2 4 6 1
Power switch Emergency stop button

1 3 5 2
2 4 6
1 3 5 7
3P Circuit breaker 4P Switch

I> I> I> 2 4 6 8
1 3 5
- 6 -
1 3
2P circuit breaker 3P switch

2 4
1
1P circuit breaker 0℃thermostat contactor
2 Ⅰ
Limit switch closed
20℃thermostat contactor
contactor Ⅱ
Limit switch break
40℃thermostat contactor
contactor Ⅲ
Button 50℃thermostat contactor
Ⅳ
Power off delay
disconnect closed contactor Closed contactor
1 3 5 7
Sensor 4P circuit breaker

I> I> I> I>
2 4 6 8
Power off delay connect

break contactor
Break contactor
Delay disconnect
Relay/contactor coil
break contactor
Switchgroup Power delay
contactor electronic devices
Switch change Power off delay
contactor electronic devices
Sencond knob
Power delay relay coil
break contactor
Second knob
Power off delay relay coil
closed contactor
Ground Terminal
Plug connector Reference arrow point
Socket connector
Connection plug Connection socket

M F
- 7 -
2.4 Electron
Potentiometer with
Tempreture sensor
zero
Varistor Potentiometer
Rectifier Diode Rectifier bridge
Progressive start Rectifier bridge
Photoelectric
Electronic component
encoder
2.5　Ｍｏｔｏｒ
Magnet coil/DC Speed measuring

conducting coil motor
Velometor Double winding motor
Single coil
DC induction motor electromagnetic
brake
Electromagnetic Double coil

buffer electromagnetic
brake
- 8 -
- 9 -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A A
Firma: USETER CRANES

Project: JL186-12
Schaltplan Nr:
B EDV Nr: B
5
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Datum: 2013.5.11
JL186-12-1305-024 RW10083 Gezeichnet:
C C
Feeding: 2-3 BLACK(BK): main power 415V 50HZ
Hoist unit: 4-6 RED(RD): control voltage 110 VAC
D Luffing unit: 7-9 WHITE(WH): zero potential D

BLUE(BU): control voltage 24 VDC
Slewing unit: 10-12
VIOLET(VT): termistor
Control desk: 13
E ORANGE(ORN): exterol voltage E
G box wiring diagram: 14-16
GREEN/YELOW(GN/YE): ground
Lectric wiring on crane: 17
F Drawn = F
by USETER JL186-12 cover sheet Project JL186-12-01 +
Checked Luffing Crane Project No.: Page 1
State Revision Date Name Norm Norm Original Ers. f. Ers. d. Schaltplan Drwg. No.: of 20p
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
AC 415V 50HZ BK-16
/4. A1
BK-16
/4. A1
A BK-16
/4. A1 A
1 3 5 BK-16
/7. A1
BK-16
/7. A1
Q101 BK-16
/7. A1
Surge arrester /3.7D 2 4 6 BK-2.5
BK-6
BK-2.5 /10. A1
B BK-2.5 BK-6
B
/10. A1
BK-10
BK-10
BK-10
1 3 5 BK-6
/10. A1
F101
L1 L2 L3 10A 2 4 6
V500 BK-1.5
BK-35
BK-35
BK-35
BK-1.5
BK-1.5
BK-1.5
C BK-1.5 C
GN/YE-16
1 3 5 Q108 1 3 64 74
F100
BK-1.5
1 3 5
GV2ME32
16A
Q101
24-32A 2 4 /3. D7 73
63
BK-1.5
BK-1.5
BK-6
BK-6
BK-6
415V
BK-1.5
415V
BK-1.5
BK-1.5
BK-1.5
Q100
415V
380V
380V
380V 1 2 5 1 2 5
225A I> I> I> I> I> I> T101 1 2 5
1 2 3 T100 T102
110V
24V
2 4 6 2 4 6 2000VA
0V
0V
K180 630VA
220V
3 4
0V
630VA 3 4
D 3 4
1
D
18 1
RD-4
1
F103
RD-4
/3. B2 15
F102 16 2
F104 2
2 10A 32A
BK-6
BK-6
BK-6
25A 1 2
相序检测器
WH-2.5
BK-2.5
~ ~
BK-35
BK-35
BK-35
Phase detector
WH-1.5
V100 DC AC
RD-1.5
-
+
PE
PE
114 PE
3
GN/YE-1.5
4 BU-4 DC20V /11. A1

115
116
117
ST0
G1 G2
1
2
3
4
BU-1.5
BU-1.5
E BU-4 0V E
/3.1A
/3.1E
/11. D1
M108
144
145
顶升泵
25
33
34
24
26
27
28
29
30
31
32
15KW
G2
Hydraulic unit
PE
PE
PE
PE
L1
L2
L3
驾驶室电源力矩安全监控装置
power supply 415V 50HZ Cab power Moment Protector
雨刷器电源
3X70+1X25 Windscreen wiper
F Drawn = F
by USETER JL186-12 wiring diagram Project JL186-12-02 +
Checked Luffing Crane feeding part Project No.: Page 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
AC110V50HZ RD-1.5
/2. E10
A A
1 83
S101 Q101
K180 15 emergency stop 2 D7 84
/2. D8 急停
16 18 3
B 0 S100 P300 3
B
crane on crane on
S400 启动
4
控制电源 S320
00 horn 4 21
0 喇叭
K401 ST2
/5.1A
S600 /5. D4 22
00
C C
G2
1
6
54
ST1
/5. A1
Q101
D7 53
122
D G2 D
A1
Q101 P320
123
OV A2 G2 STO
WH-1.5
/2. E11 /5. E1
1 2
/2. B1
3 4
/2. B2 5
E /2. B2
6 E
53 54
D8 63 64
/2. C12 73 74
/2. C13
83 84
A15
F Drawn = F
Checked Luffing Crane feeding part Project No.: Page 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BK-16 AC 415V 50HZ
/2. A16
/2. A16 BK-16
BK-16
A /2. A16
2 4 6 BU-1.5
A
R400 43
Q400 6.4R 35KW 43 43 43 21 43 K402 15
ABS203B 制动电阻 K450 K410 K415 K440 K430 K430 /6. D15
Brake resistor /5. D14 /5. D4
150A 44 44 /5. D5 44 /5. D12 44 /5. D10 22 /5. D10 44 16 18
I> I> I>
1 3 5
BU-1.5
BU-1.5
BU-1.5
BU-1.5
BU-1.5
BU-1.5
43
2 4 6 K420
BK-16
B /5. D7 B
Q401 44
/6. D2 1 3 5
BK-2.5
BK-16
BK-16
BK-16
BK-2.5
BK-2.5
F400 1 3 11
1 3 5
13
C 6A Q402 L1 L2 L3 PE R+ R- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 C
AO1+
AO1-
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
GND
GND
CMA
CMB
AI1+
AI2+
2 4 12 14
AI1-
AI2-
14
24V
24V
+10
GV2ME06
BK-1.5
/6. C14
/6. C2
1-1.6A I> I> I> NXOPT-A1

1 3 5
2 4 6 NXP01055G2H1SSVA1A3A5
Q409 T400 NXOPT-A5
BU-1.5
/6. D11 2 4 6
DIC1 A+
DIC2 B+
DIC3 Z+
DIC1 A-
DIC2 B-
DIC3 Z-
ENC1Q
BK-1.5
BK-1.5
BK-1.5
+24V
DIC4
GND
D 1 2 3 4
NXOPT-A3 D
V400 AC DC U V W PE 21 22 23 25 26 28 29 1 2 3 4 5 6 7 8 9 10
BME 13 14 15
BK-16
BK-16
BK-16
GN/YE-6
BU-1.5 BU-1.5
G2
46
47
48
49
50
51
G1 LRG LBG
05
14
15
16
01
01
04
06
02
02
03
LG
11 11
12 12
13 13
5
6
7
/6. A11
/6. B11
/6. B13
/6. A13
L
14
15
16
U V W U V W PE
E BU
E
WH R460 3 6 4 7 5 8
T
UB
RD
BM62
M410 M400 A A B B C C
yellow
Y400 B400
green
white
black
blue
red
Motor brake 风机起升电机热敏电阻
编码器 Encoder
Fan Hoist motor DV225M4 45KW 86A 1470rmp Thermistor
F Drawn = F
Checked Luffing Crane Hoist unit 45LVF30 Project No.: Page 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ST2 AC110V50HZ RD-1.5 ST2
/3. B16 /6. A1
/3. C16
ST1 ST1 /6. A1
5 5 5 5 5 5
A G2 A
01 17 17 73 72
4 4 4 4 4 4
3 下 3 下 3 下 3 下 3 下 3 下
G2 1 2 1 2 1 2 1 2 1 2 1 2
1 1 1 1 1 1
125
DG S410 0
S415 0
S420 0
S430 0
S440 0
S450 0 G2
D 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2
3 上 3 上 3 上 3 上 3 上 3 上
D1 1 4 4 4 4 4 4
G2 G2 G2 G2 G2
10
11
12
1
42 8
9
5 5 5 5 5 5
B400 G2 B460
力矩 100% 2
D1 >50° 2
01 126 74 18 18 02
LG
7 07
B load moment 100%
D
B
L
G2
01 35 7
DG 1
G2 B415
G2 LG 下降限位
G2 L limit lowering 2
1
1
PG B410 L
08 8
P LG 14 44 44
1
1 上升限位
B411 limit lifting
2
G2
43
C 最大起重量 L K441 K451 C
2
2
K404 13 43 43
Max load P /6. D4 /6. D6 /6. D7
02
127 02 2
LG
PG
36
G2
G2 67
K401
14 D2
68
K405 22 22
/6. D7
D 13 K415 K410 M460 D
D5 21 D4 21
A1 A1 A1 A1 A1 A1 A1
124
G2
K401 K410 K415 K420 K430 K440 K450
STO A2 A2 A2 A2 A2 WH-1.5 A2 A2 STO
/3. E16 /6. E1
13 14 13 14 /6. B5 13 14 13 14 13 14 13 14 13 14
/6. C5
21 22 21 22 21 22 21 22 21 22 21 22 21 22
E /3. B13 31 32 D5 31 32 D4 31 32 31 32
/4. A13
/6. C6
31 32
/6. D8
31 32 31 32 E
43 44 43 44 43 44 43 44 /4. A14 43 44 43 44 /4. A10 43 44
/4. A11 /4. A11 /4. B13 /4. A12
03 04 03 04 03 04 03 04 03 04 03 04 03 04
/6. C14 /6. D14 /6. D14
55 56
67 68
D4
上升下降 2档 3档 4档 5档
准备好
Hoist on lift lower 2 step 3 step 4 step 5 step
F Drawn = F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
/5. A16 /8. A1
A 67 A
37
G2
138
G2 Q401
128
130
G2 G2
38
G2 D2 68
PG PG
03
05
11 22 26
P P
03
LG
5
B401 /4. E9 T400
3
B441 1 B451 1 12 23
/4. E10
25 44
安全监控系统力矩 100%
D
moment protectors 100%

负载 75% 负载 50%
3
K403
Max load 75% Max load 50%
B B430
1
P
2
P
2 D13 43 B
04 4
06 6
上升减速限位 13
2 PG PG 13
Prelimit up
129
131
D 04 4 K415 G2 G2 Q401
14
LG /5. D5 D2 14 14
139
G2
G2 Q402
39
/4. C5 13
G2
05 40
14
C 11 LG 03 C
F400 D K403
14 K401
5
/4. C2 1 D13
14 B435 14 31 14 21
13
/5. D2 04
2 K410
下降减速限位
Prelimit down /5. D4 K441 K430 K451 K440
D 04
06 6
D6 13 /5. D10 32 D8 13 /5. D12 22

LG 13 K410 03 04
41
G2 /5. D4
K415
D D
/5. D5 03
A1 A1 A1 A1 A1 A1 A1 Y1 A1
Q401 K404 K441 K451 K405 Q409 K403 K402
STO A2 A2 A2 A2 A2 A2 A2 A2
/5. E16 /8. E1
1 2 13 14 13 14 13 14 13 14 1 2 13 14 18
/4. B7 /5. C10 C6 C7 /5. D2 21 /4. D1 C11 /4. A15 15
3 4 21 22 21 22 21 22 22 3 4 21 22 16
E /4. B7
/4. B7
5 6 31 32 31 32 31 32 31 32 /4. D1 5
/4. D2 13
6 31 32 E
B11 13 14 43 44 /5. C12 43 44 /5. C14 43 44 43 44 14 43 44
21 22 /8. C6 21 22 B14
03 04 03 04 03 04 03 04 03 04
55 56
67 68
A14
力矩 100% 起升制动变频报警变频器闭锁
起升准备好 load moment 100% Hoist Brake Fc ready Transducer closed
Hoist on
F Drawn = F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BK-16 AC 415V 50HZ
/2.16A
/2.16A BK-16
A /2.16A
BK-16 A
2 4 6 BU-1.5
R700
BK-16
21 K702 15
Q700 6.4R 35KW 13 03 03 13 K730 K730 13
制动电阻 K750 K710 K715 K740 /8. D14 /9. D8
ABS203B /8. D14
Brake resistor /9. D3 14 /8. D4 04 /8. D9 04 /9. D2 14 22 14 16 18
150A I> I> I>
1 3 5 14
BK-10
BU-1.5
BU-1.5
BU-1.5
BU-1.5
BU-1.5
BU-1.5
B 2 4 6 K720 B
Q701 /8. D10 13
/8. D2 1 3 5
BK-2.5
BK-16
BK-16
BK-16
BK-2.5
BK-2.5
1 3 5 1 3 5 13 F700 1 3 11
C 6A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
C
L1 L2 L3 PE R+ R-
AO1+
14 2 4
AO1-
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
12
GND
GND
CMA
CMB
AI1+
AI2+
14
AI1-
AI2-
24V
24V
+10
BK-1.5
/9. C7
/8. D2
I> I> I> I> I> I> 1 3 5 NXOPT-A1
Q707 2 4 6 Q702 2 4 6 Q709
GV2ME14 GV2ME08
/9. D5 2 4 6
BU-1.5
NXP01055G2H1SSVA1A3A5
T700 NXOPT-A5
6-10A 1 3 5 2.5-4A
DIC1 A+
DIC2 B+
DIC3 Z+
DIC1 A-
DIC2 B-
DIC3 Z-
ENC1Q
1 2 3 4
BK-1.5
BK-1.5
BK-1.5
D Q706 D
+24V
DIC4
GND
NXOPT-A3
/9. D9 2 4 6 V700 AC DC U V W PE 21 22 23 25 26 28 29 1 2 3 4 5 6 7 8 9 10
BU-1.5
13 14 15 BU-1.5
GN/YE-6
BK-16
10 BK-16
11 BK-16
G2
67
68
66
70
31 89
32 90
PE 91
69
71
30 88
DG G1
12
11
12
13
14
15
16
DBG
05
DRG
01
02
01
04
06
02
03
11
12
13
14
15
D
34
35
36
37
16
E Y U V W U V W PE E
1
2
3
blue /9.5A
/9.5A
/9.6A
/9.6A
white R760 3 6 4 7 5 8
T
UB
M710 red M700 A A B B C C
Y Y700
yellow
B700
green
white
black
blue
red
紧急制动控制盒风机制动电机变幅电机热敏电阻
Fan DV225M4 45KW 86A 1470rmp
Emergency brake Box Brake motor Luffing motor Thermistor 编码器 Encoder
F Drawn = F
Checked Luffing Crane Luffingfunit 45FVF30 Project No.: Page 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
/6.16A /9.1A
07 133 132
ST1 G2 RD-1.5 ST1 /9.1A
/6.16A
5 5 5 5
A G2 13 4 4 4 4 13 A
3 down 3 down 3 down 3 down
PG
21 77
K715 1 2
1
1 2
1
1 2
1
1 2
1
G2 Q706
P 1 G2
01 19 19 75
B711 7 D9 S715 S720 S730 DG /9. D9
14 S710 0
1
0
1
0
1
0
1 14
紧急限位 85° 2 2 DG 2 2 2 2 2 2
21
2 3 up 3 up 3 up 3 up D
P D 4 4 4
9 09 135 134 08 8
Emergency up 85° 4
01
PG G2 5 5 5 5 D3
13
D2 1
G2 B700 32 B702
力矩 100%
09 64
G2 K705 力矩 80% G2
15
16
G2 G2
B B
14
Load moment 100% 2 G2 /9. D12 Load moment 80% 2 DG
PG
B716 G2 31
62
P 1 D2 G2 D
02
03 58
9
G2
01 56
紧急限位 15° D3
02
13 DG
07
Emergency down 15°
DG
DG
2 K710 Y
20 20
D D D
5
B730
3
P
136 10 10
1 1 D
22
D4 14 D DG B715 44
1
PG B710 1
下降限位
上升减速限位 43 DG
22
G2 上升限位 G2 2 Prelimit up 2
76
14 Limit lowering K705 D
78
43 G2
5 05 60 59 04 4
Limit lifting 2 D K715
63 08 8
44
140
G2 /9. D12 DG
C D K705
44 C
02 2
9 DG D9 Y
142
6
B701 DG 13 G2 G2
64 /9. D12 K405 43
G2 G2
D
57
10
moment protectors 110% G2 /6. D7 DG 13
安全监控系统力距 110% 10 K710 22
22
D B703
DG
10
K710 1
141
G2 C2 63 B735 44 moment protectors 90%

K715 下降减速限位安全监控系统力距 90% 14
65
D4 21 G2
D9 21 2
143
Prelimit down K710
14
43 G2
D
61 06 6
F700 D4
D DG D
/7. C5 13
G2
A1 A1 A1 A1 A1
Q701 K710 K715 K720 K730
STO A2 A2 WH-1.5 A2 A2 A2 STO
/6.16E /9.1E
1 2 13 14 13 14 13 14 13 14
/7. B7 B2 A2 /7. B13 /7. A14 21 22
/7. B7 3 4 D9 21 22 21 22 21 22
5 6 D4 31 /7. A13 31 32
E /7. B7
13 14
31 32 32 31 32
43 44
E
/9. B5
21 22 D12 43 44 C12 43 44 43 44
03 04 03 04 03 04 03 04
/7. A11 /7. A11
55 56
67 68
/9. B7 /9. D7 53 54 /9. D7 53 54
63 64 63 64
2档 3档
变幅准备好 2 step 3 step
变幅上升变幅下降
Luffing on
Luffing up Luffing down
F Drawn = F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
/8.16A /12.1A
/8.16A
ST1 ST1 /12.1A
A 5 5
G2 A
79
82
4 4 G2
3 down 3 down 67 G2
80
83
1 2 1 2 23 26 G2
1 1
S740 0
S750 0 Q701
T700 DG
23
DG
25
1 1
2 2 2 2 22 25 /8. D2 68
3 up 3 up
43
23
D
27
4 4 D
5 5
K707 44
1 1
D6 B781 B791
B 13 2 2
B
17
18
G2 G2 13
D D
24
28
Q702 S705
13 /7. C4 14 14
D D
25
29
22
Q701
/8. D2 14
K704 B782
1
B792
1
D15 21
2 2
C D D C
26
30
14 54
K707 K715
24
DG
26
DG
D11 13 /8. D9 53
54 G2
81
84
G2
K710
/8. D4 53 13
K703
D D13 14 D
A1 A1 A1 A1 Y1 A1 A1 A1 A1 A1
K740 K750 Q709 K707 K702 Q706 K705 K703 K704
STO A2 A2 A2 A2 A2 A2 A2 A2 A2
8.16E /11.1E
13 14 1 2 16 1 2 STO
/7. A12 21 22 /7. A10 13 14 /7. D5 C5 13 14 /7. A15
18
15 /7. D1 /8. C4
13 14
D7
13 14 13 14
3 4 21 22 3 4
E 31 32
21
31
22
32
/7. D5 5 6 31 32
/7. D2 5 6
21 22 21
31
22
32
21
C7 31
22
32
E
/7. D5 13 /7. D2 31 32
43 44 43 44 14 43 44 13 14 /8. B13
B7 /8. A15 43 44 43 44 43 44
03 04 03 04 21 22 03 04 21 22 /8. C9
03 04 03 04 03 04
紧急制动电机手动控制紧急制动打开
4档 5档制动开变频器报警变频器闭锁紧急制动磨损
Emergency brake motor Emergency brake open
4 step 5 step Brake open FC redy Transducer closed Operation mounting
Emergency brake wear
F Drawn = F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
AC 415V 50HZ
T600 7KVA
/2. B16 BK-6 BK-2.5 AC380V50HZ
A /2. B16 BK-6 BK-2.5 A

/2. B16 BK-6 BK-2.5
BK-6
BK-6
AC 380V 1 3 5 1 3 5 13 23
Q600 Q602
14 24
GV3ME40 GV2ME06
25-40A 1-1.6A
/12. D2
/12. D4
I> I> I> I> I> I>
B 2 4 6 BK-6 2 4 6 B
BK-6 1 3 5 1 3 5
Q610 Q615
/12. E2 2 4 6 BK-6 2 4 6 /12. E4
U0
C V0 W0
C
L600 U1 V1 W2
BK-2.5
U2 V2 W2 BK-6
1 3 5
U3 V3 W3
Q620
BK-6
/12. E10
BK-6 2 4 6
BK-2.5
D D
107
108
109
106
103
105
104
G2
93
94
95
92
96
97
98
PE
PE
RA RB RA RB
01
02
03
01
02
03
04
05
06
04
05
06
U1 V1 W U1 V1 W U V W U V W
1 1
E E
M601 M602 M611 M612
回转电机 1 回转电机 2 风机 1 风机 2
Slewing Moter 1 Slewing Moter 2 Fan 1 Fan 2
YTLEJ112-95-4F2 MQ=95NM IQ=34A YTLEJ112-95-4F3 MQ=95NM IQ=34A
F Drawn = F
by USETER
JL186-12 wiring diagram Project JL186-12-10 +
Checked Luffing Crane Slewing unit RZV-95X2 Project No.: Page 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
/2. E16
A A
1 3 5 1 3 5 1 3 5 1 3 5 R600
Q609 Q611 Q621 Q612
/12. E7 /12. E5 /12. E12 /11. E16
2 4 6 2 4 6 2 4 6 2 4 6 9
8
7
B 6
B
5
4
3
2
1
C 0 C
/2. E16
D D
100
110
111
113
112
101
102
G2
99
RA RB RA RB
11
12
11
12
13
14
13
14
E E
Y601 L601 L602
回转制动 1 涡流制动 1 涡流制动 2
Stop brake Eddy curem brake Eddy curem brake
F Drawn = F
by USETER
JL186-12 wiring diagram Project JL186-12-11 +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
/9. A16 ST2 AC110V RD-1.5 AC110V
/9. A16
ST1 right right S609 S620 right S630
right
A A
S610 S615
left left left left 21
G2 19 G2 G2 G2 G2
20
23
21
22
Q610
13 E2
13 22
Q610 Q615
22
118
120
G2 G2 E2 E4
B 14 14 B
SRG SRG Q615
03
01
E4
21
1 1
B610 B615 14
5S Q609
回转左限位 2 回转右限位 2 21 68 E7
C Slewing left limit Slewing right limit Q612
13
5S
C
53 68
02
SRG E16 22 Q609

04
SRG
67 E7 Q620
119
121
G2 G2 54 E10 67
13 23
Q602 Q602 32
/10. B12 /10. B13 21
14 24 K630
D K630 1S 68 1S 68 E14 31 D
E14 22
02 02
Q615 Q610 22 Q610 67 Q615 67
E4 01 E2 01 Q620 E2 E4
E10 21
A1 A1 A1 A1 A1 A1 A1 5S A1
E Q610 1S Q615 1S Q611 Q609 Q620 1S Q621 K630 Q612 5S E
ST0 A2 A2 A2 A2 WH-1.5 A2 A2 A2
/8. E16 A2
1 2 1 2 1 2 1 2 1 2 1 2 13 14
/10. B3 /10. B5 /11. A6 /11. A2 /10. D5 /11. A10 1 2
3 4 3 4 3 4 3 4 3 4 3 4 21 22 /10. A12
/10. B3 5 6 /10. B5 5 6 /11. A7 5 6 /11. A2 5 6 /10. D5 5 6 /11. A10 5 6 D5 3 4
31 32 /10. A12 5
/10. B4 /10. B6 /11. A7 /11. A2 13 /10. D5 13 /11. A10 13 D12 6
B5 13 14 13 14 13 14 14 14 14 43 44 /10. A12 13
B7 C8 14
21 22 21 22 21 22 21 62 21 22 21 22 03 04
A16 B16 D5 21 22
D4
01
55
02
56 左 D2
01
55
02
56 右回转 1 档涡流 53 54
回转制动 55 56
回转 2 档回转 2 档涡流回转 3 档
C5
C10 55 56
D10
67 68 left D11
67 68 right 1 step 61 22 brake C14
67 68 2 step 2 step 3 step C6 67 68
0 step
F Drawn = F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
5 5
下 4 4 启动
3 左 3 下 3
down
变幅
2 left 2 down 2 S100 Crane on
1
0 回转 10 起升 10
luffing 1 slewing 1 Hoist 1
A 上 3
2 右 23 上 3
2 A
right 3
up 4 up 4
5 5 4 1
S415
S710
S715
S720
S730
S740
S750
S600
S610
S615
S620
S630
S609
S410
S420
S430
S440
S450
S400
A 4 E350
S320 3 驾驶室灯 2 X360
插座
X370
插座
1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1
喇叭
00 Horn
Cab lighting socket socket 显示屏
3 Monitor
B 2 2 2 2 2 2 00 2 2 2 2 B 2 2 2 2 2 2 0 S350 B
驾驶室灯开关 4
lighting switch
C
1
S101 1 P300
启动灯 2
2
Crane on
C 急停 C
B701
B401
B703
Emergency 控制器
stop Controller
9 11 13
E340 10 12 14
雨刷器
D Window wiper D
13 14 15 16 17 18 19 20 21 22 23 6 7 8 9 10 11 12 3 1 2 4 5
3
KVVR 24 × 1.5 =6m S340
雨刷器开关
4 switch
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
E E
S615/2
S620/2
S720/2
S740/2
S710/2
S715/2
S730/2
S750/2
S440/2
S450/2
S610/2
S630/2
S609/2
S340/4
M40
S101/1
S100/4
S101/2
P300/2
S320/4
S410/1
S410/2
S415/2
S420/2
S430/2
NO. TO
KVVR 4 × 1.5
E340
PE
PE
PE
length detector
angle detector
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
G
重量传感器
高度电位计
角度传感器
load cell
F Drawn = F
by USETER JL186-12
cab wiring diagram Project JL186-12-13 +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
F
E
B
A
D
C
State
G2
1
1
S101/1 1
S100/4 2
S101/2 3
Revision
P300/2 4
S320/4 5
S410/1
2
2
Date
S410/2 7
S415/2 8
S420/2 9
S430/2 10
3
3
S440/2 11
E350
by
S350
S450/2 12
S350 S710/2
Drawn
24 13
32
Checked
X360 25 S715/2 14
X360
X370 26 S720/2 15
X370
Name Norm Norm

4
4
E350 27 S730/2 16
S740/2
USETER
X360 28 17
X370 29 S750/2 18
30 S610/2 19
31 S615/2 20
Original
5
5
32 S620/2 21
S340 33 S630/2 22
S340
E340
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
E340 34 S609/2 23
01 LG-01 23
35
02
LG-02 23
36
6
6
KVVR 24X1.5
03
LG-03 37
23
Ers. f.
38
23
04
LG-04 39
05
LG-05 40
06
41
7
7
LG-06
07
LG 插件
KVVR 24X1.5 LG-07 42
08 LG-08 43
09 44
L BOX
10 45
Ers. d.
8
8
11 LG-11 46
M32X1.5
12 LG-12 47
13 LG-13 48
JL186-12
14 LG-14 49
15
Luffing Crane
LG-15 50
9
9
Electrical control room
16 LG-16 51
52
Control unit or cab
53
54
Schaltplan
PE
LG-PE 55
10
10
01
02 56
03 57
58
32
04
05 59
11
11
60
06
07 61
62
08
G box wiring diagram
63
09 64
12
12
10 65
11 66
12 67
13 68
Project
KVVR 32X1.5 14 69
13
13
15 70
16 71
17 72
D BOX
Drwg. No.:
DG 插件
73
Project No.:
18
M32X1.5
74
14
14
19 75
20 76
21 77
JL186-12-14
22 78
+
=
23 79
15
15
80
CAB
24 81
25 82
83
26 84
27
85
16
16
28
86
29
of 20p
87
Page 14
30 88
F
E
B
A
D
C
F
E
B
A
D
C
State
32
G2
31
11
DG-31 89
1
1
32
DG-32 90
PE
DG-PE 91
PE
1 2
Revision
RA-PE 92
01 RA-01 93
02 RA-02 94
03
2
2
M601 M611
KVVR 12X2.5 RA-03 95
RA 插件
04
Date
RA-04 96
3 4 5 6 7
05 RA-05 97
Slewing motor 1
06 RA-06 98
11 RA-11 99
8 9 10
12
3
3
Y601 L601
U1 V1 W1 U V W F3 F4 F2 F1
RA-12 100
by
14
11
RA-14 101
13
Drawn
RA-13 102
Checked
RB-PE 103
Brake resistor room
1 2
01 RB-01 104
Name Norm Norm

4
4
02 RB-02 105
USETER
03 RB-03 106
KVVR 12X2.5
RB 插件
04
M602 M612
RB-04 107
05
62
RB-05 108
3 4 5 6 7
06 RB-06 109
Slewing motor 2
Original
5
5
11 PE 110
RB-11
12 RB-12 111
8 9 10
Y602 L602
14
U1 V1 W1 U V W F3 F4 F2 F1
RB-14 112
11 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
13 RB-13 113
M108/PE114
YC 3X6+1X4
6
6
M108/U 115
M108/V 116
Ers. f.
U V W
Hydraulic unit
M108
M108/W 117
PE 01 SRG-01 118
02
SRG 插件
SRG-02 119
7
7
03 SRG-03 120
1 2 3 4
B610 KVVR 4X1.5 04 SRG-04 121

B615 P320 122
KVVR 2X1.5 P320 123
Ers. d.
M460
8
8
M460 124
Slewing limit swich

M20X1.5
B460 125 KVVR 2X1.5

01 PG-01 126
02
JL186-12
PG-02 127
03
Luffing Crane
PG-03 128
9
9
PG 插件
B460
04 PG-04
KVVR 12X1.5 129
05
32
PG-05 130
06 PG-06 131
1 2 3 4 5 6 7
07 PG-07 132
P BOX
Schaltplan
09 133
10
10
PG-08
M25X1.5
10 134
PG-09 135
10
PG-10 136
8 9 10 11
PE
PG-PE 137
B401 138
11
11
B401 139
B701 140
01 B701 141
B703 142
G box wiring diagram
02
B703 143
03
12
12
TO:T400 A5 板 AC220V 144

6X0.75 屏蔽电缆 04
LBG 插件
AC220V 145
B400 05
Hoist Encoder
06
PE
Project
13
13
01
2X0.75 屏蔽电缆 02 TO:T400 A3 板
LRG 插件
R460 03
Drwg. No.:
04
Project No.:
14
14
01
2X0.75 屏蔽电缆 02 TO:T700 A3 板
DRG 插件
JL186-12-15
R760 03
+
=
04
15
15
01
02
03
6X0.75 屏蔽电缆 04 TO:T700 A5 板
DBG 插件
16
16
B700 05
06
of 20p
PE
Page 15
Hoist Thermistor Luffing Thermistor Luffing Encoder
F
E
B
A
D
C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Brake resistor room
A A
95 2 352
10
11
12
13
14
8
1
2
3
5
6
7
4
9
B B
G1
M400/W
M700/W
M400/U
M700/U
M400/V
M700/V
PE
P-L1
P-L2
P-L3
备用
备用
PE
PE
C C
YC 3X75+1X25
YC 3X16+1X6
YC 3X16+1X6
D D
U V W U V W
Power supply
E E
M400 M700
Hiost unit motor luffing unit motor
F Drawn = F
by USETER JL186-12
G box wiring diagram Project JL186-12-15.1 +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
F
E
B
A
D
C
State
L
1
1
B410 1
B415
B435
B430
B410
B410 2
Hiost limit switch

B430
Revision
KVVR 8X1.5 3
B430 4
B435 5
2
2
B435 6
Date
B415 7
B415 8
9
3
3
10
by
KVVR 4X1.5
Fan
M410/U 11
Drawn
U V W
M410/V
M410
Checked
12
M410/W
13
Name Norm Norm

4
4
Y400-RD 14
RD
USETER
KVVR 4X1.5 Y400-WH 15
WH
Y400-BU 16
3a 4a 5a
BU
Y400
Hoist brake
D 17
Original
5
5
B710 1 18
B710 2 19
B730 3 PE 20
KVVR 8X1.5 B730 4
B715
B735
B730
B710
B735 5
6
6
B735 6
Ers. f.
Luffing limit switch
B715 7
B715 8
Y-5 9
7
7
19
LG
Y-6
M710 11
M710 12
KVVR 4X1.5 M710 13
Fan
Ers. d.
Y700 14
8
8
U V W
Y700
M710
15
Y700 16
D1
01 D1-01 17
02
JL186-12
RD D1-02 18
DG
D2
KVVR 4X1.5 01
9
9
WH D2-01 19
02
3a 4a 5a
BU D2-02 20
Luffing brake
Y700
D3
01 D3-01 21
02 D3-02 22
KVVR 2X1.5
Schaltplan
B781 23
B400
10
10
B781 24
KVVR 2X1.5 B782 25
B700 B782 26
KVVR 2X1.5 B791 27
B702 B791 28
11
11
Loadmoment Switch
KVVR 2X1.5 B792 29

B781 B792 30
Luffing Crane L/D/P box wiring diagram
KVVR 2X1.5 B706 31

B782 B706 32
12
12
KVVR 2X1.5 B706 33

Y-1 34
emergency brake open
B791 Y-2 35
KVVR 2X1.5 Y-3 36
Project
B792 Y-PE 37
emergency brake wear
13
13
KVVR 4X1.5 38
B706 39
Drwg. No.:
KVVR 8X1.5
Project No.:
Speed detector
Y
P
14
14
KVVR 2X1.5 B411

B411 1
B411 2
KVVR 2X1.5
JL186-12-16
B441 3
+
=
B441 B441 4
15
15
PG
KVVR 2X1.5 B451

Load switch
5
B451 B451 6
KVVR 2X1.5 B711 7
B711 B711 8
KVVR 2X1.5 B716
16
16
9
B716 B716 10
of 20p
PE 11
Page 17
Emergency Switch
F
E
B
A
D
C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B710
变幅限位开关
B410
起升限位开关
B730 B430 起升高度传感器
B735 B435
B715 Length detector
A 3X KVVR 2X1.5
B415 A
B400 KVVR 8X1.5
5X KVVR 2X1.5 KVVR 8X1.5 85° B411
B700
D1 B781 B711 B441
B702 B451
B
D2
D3
D
B782
B791
B792
Y L KVVR 2X1.5
P B
X 1.5
B706 R8
V
KV
KVVR 8X1.5 KVVR 4X1.5 KVVR 4X1.5
KVVR 4X1.5
KVVR 4X1.5 重量传感器
KVVR 24X1.5
KVVR 4X1.5 KVVR 2X1.5
Load cell
M700 M400 15°
Y701 角度传感器
KVVR 12X1.5
Luffing Motor Hoist Motor B716
C 变幅电机起升电机 Angle detector C
Emergency brake Motor
YC 3X16+1X6
6X0.75 L=8M
YC 3X16+1X6 L=7M
KVVR 32X1.5 L=7M
D DG DBG LG LBG LRG PG D

DRG
RA SRG
G RB
Cab
KVVR 4X1.5
KVVR 12X2.5 KVVR 12X2.5
E E
B610
B615
M601 M602
回转限位开关 Power
Slewing Limit
回转电机回转电机
Slewing Moter Slewing Moter YC 3X35+1X16 L=65M
F Drawn = F
by USETER
JL186-12 Project JL186-12-18 +
Checked Luffing Crane L/D/P box wiring diagram Project No.: Page 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
D
34
35
36
37
AC110V 50HZ
Y
2
3
4
A PE Y
A
Y Y Y
BK-1.5
BK-1.5
BK-1.5
19
20
23
8
Y
7
1 3 5 2
QF1 QF2 21 1 2
GV2ME14 1 KA1 P
B 6-19A I> I> I> Y D11 22 4 3 B
5
2 4 6 D Y Y Y
22
21
9
09 9
Y DG Y
11
13
13 43
G2 95
64
1 3 5 13 97 KA1
KM1 FR1 D11 14
C3 44
D7 96
2 4 6 14 98
C Y C
10
Y Y
12
14
FR1 YV1
G2
65
C7
DG
10 10
D
BK-1.5
BK-1.5
BK-1.5
Y Y
24
D PE D
6
A1 A1
Y
15
16
17
18
KM1 KA1
AC 0V
A2 A2
C3 1 2 13 14
C9
U1 V1 W1 C3
3 4 B7 21 22
C4 5 6 31 32 Electroralve
13 14 43 14
C4 C10
E Y701 21 22 03 04 E
Emergency brake motor
F Drawn = F
by USETER
JL186-12 wiring diagram
Luffing Crane Emergecy brake Box
Project AY-01 +
Checked Project No.: Page 1
State Revision Date Name Norm Norm Original Ers. f. Ers. d. Drwg. No.: of 3p
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Frequency Converter test and maintenance
ⅠRequirements for tower crane frequency converter： 2

ⅡFrequency converter operating notes: 2
Ⅲ Basic principles and types of Frequency converter 5
JL186-12 VACON
ⅠRequirements for tower crane frequency converter：
①Can adapt to the tower crane equipment vibrations, often working in harsh environments (dust,
humidity, salinity).
②Can adapt to the quality of the pervasive power transformer capacity is small, power cable too
long, small cross-section starts in the large-scale equipment often result in transient under-
voltage, voltage fluctuation range of big situation.
③Can adapt to the large starting torque of each unit, often over 150%. If considered the
requirements for voltage drop and overload test, during the driving accelerate, it can provide at
least 200% torque.
④In view of each unit has machinery brake device, we must fully consider the motor cut into the
action with the brake timing, to prevent the slide car.
⑤When the weight drops, the load of potential energy generated by the motor in a power
generation stat. Energy to supply-side feedback. In view of most general frequency converter do
not have energy feedback function, they must through the braking resistor to the energy
released as heat.
⑥In view of our products service all the world, the frequency converters must have CE,UL,.CSA
etc. international authentication。
Because of the Vacon frequency converter can well meet the above requirements, we believe
Vacon.
ⅡFrequency converter operating notes:
1. Warnings
1.1 The Vacon NX frequency converter is meant for fixed installations only.
1.2 Do not perform any measurements when the frequency converter is connected to the mains.
1.3 Do not perform any voltage withstand tests on any part of Vacon NX. There is a certain
procedure according to which the tests shall be performed. Ignoring this procedure may result in
damaged product.
1.4 The earth leakage current of Vacon NX frequency converters exceeds standard.
1.5 Only spare parts delivered by Vacon can be used.
1.6 Prior to measurements on the motor or the motor cable, disconnect the motor cable from the
frequency converter.
1.7 Do not touch the components on the circuit boards. Static voltage discharge may damage
the components.
JL186-12 VACON
2. Safety
2.1 The components of the power unit of the frequency converter are live when Vacon NX is
connected to mains potential. Coming into contact with this voltage is extremely dangerous and
may cause death or sever injury. The control unit is isolated from mains potential.
2.2 The motor terminals U, V, W and the DC-link/brake resistor terminals are live when Vacon
NX is connected to mains, even if the motor is not running.
2.3 After disconnecting the frequency converter from the main, wait until the fan stops and the
indicators on the keypad go out (if no keypad is attached see the indicators on the cover). Wait
5 more minutes before doing any work on Vacon NX connections. Do not even open the cover
before this time has expired.
2.4 The control I/O- terminals are isolated from the mains potential. However, the relay outputs
and other I/O-terminals may have a dangerous control voltage present even when Vacon NX is
disconnected from mains.
2.5 Before connecting the frequency converter to mains make sure that the Vacon NX front and
cable covers are closed.
3. Earthing and earth fault protection
3.1 The Vacon NX frequency converter must always be earthed with an earthing conductor
connected to the earthing terminal.
3.2 The earth fault protection inside the frequency converter protects only the converter itself
against earth faults in the motor or the motor cable. It is not intended for personal safety.
3.3 Due to the high capacitive currents present in the frequency converter, fault current
protective switches may not fuction properly.
4. Running the motor
Warning symbols
For your own safety, please pay special attention to the instructions marked with the following
symbols:
Dangerous voltage
JL186-12 VACON
General warning
Hot-surface-Risk of burn
Motor run check list
1 Before starting the motor, check that the motoris

mounted properly and ensure that the machine
connected to the motor allowas the motor to be started.
2 Set the Max. motor speed (frequency) according to the
motor and the machine connected to it.
3 Before reversing the motor make sure that this can be
done safely.
4 Make sure that no power correction capacitors are
connectedtothe motor cable.
5 Make sure that the motor terminals are not connected to
mains potential.
JL186-12 VACON
Ⅲ Basic principles and types of Frequency converter
1. The block diagram of the Vacon NX_ frequency converter
The above figure presents the block diagram of the Vacon NX frequency converter. The
frequency converter machanically consists of two units, the power unit and the control unit.
The three-phase AC-choke(1) at the main end together with the DC-link capacitor(2) from an
LC-filter, which, again, together with the diode bridge produce the DC-voltage supply to the
IGBT Inverter Bridge(3) block. The AC-choke also fuctions as a filter against High Frequency
disturbances from the mains as well as against those caused by the frequency converter to the
mains. It, in addition, enhances the waveform of the input current to the frequency converter.
The entire power drawn by the frequency converter from the mains is active power.
The IGBT Inverter Bridge produces a symmetrical, 3-phase PWM-modulated AC-voltage to the
motor.
The Motor and Application Control Block is based on microprocessor software. The
microprocessor control the motor basing on the information it receives through measurements,
parameter settings, control I/O and control keypad. The motor and application control block
controls the motor control ASIC which, in turn, calculates the IGBT position. Gate drivers amplify
these signals for driving the IGBT inverter bridge.
The control keypad constitutes a link between the user and the frequency converter. The control
keypad is used for parameter setting, reading status data and giving control commands. It is
detachable and can be operated externally and connected via a cable to the frequency
JL186-12 VACON
converter. Instead of the control keypad, also a PC can be used to control the frequency
converter if connected through a similar cable.
This machine applacation macro adopt crane dedicated macro：Mechanical brake control
ASFIFF17-V1-13, which can get applacation crane operating conditions and parameter group.
Optional I/O expander boards that increase the number of inputs and outputs to be used are
also available.
2. Type designation code
4. Indications on the keypad
The control keypad is the link between the Vacon frequency converter and the user. The Vacon
NX control keypad features an alphanumeric display with seven indicators for the Run status
(RUN, , READY, STOP, ALARM, FAULT) and three indicators for the control place (I/O term/
Keypad/BusComm). There are also three Status Indicator LEDs (green - green - red), see
Status LEDs (green – green – red) below. The control information, i.e. the number of menu,
description of menu or the displayed value and the numeric information are presented on three
text lines. The control keypad is the link between the Vacon frequency converter and the user.
The Vacon NX control keypad features an alphanumeric display with seven indicators for the
Run status (RUN, , READY, STOP, ALARM, FAULT) and three indicators for the control place
JL186-12 VACON
(I/O term/ Keypad/Bus Comm). There are also three Status Indicator LEDs (green - green - red),
see Status LEDs (green – green – red) below.
The control information, i.e. the number of menu, description of menu or the displayed value and
the numeric information are presented on three text lines.
The frequency converter is operable through the nine push-buttons of the control keypad.
Furthermore, the buttons serve the purposes of parameter setting and value monitoring.
The keypad is detachable and isolated from the input line potential.
4.1 Indications on the keypad display
4.1.1 Drive status indications
The drive status indications tell the user what the status of the motor and the drive is and
whether the motor control software has detected irregularities in motor or frequency converter
functions.
1 RUN = Motor is running; Blinks when the stop command has been given but the frequency is
still ramping down.
2 = Indicates the direction of motor rotation.
3 STOP = Indicates that the drive is not running.
4 READY = Lights when AC power is on. In case of a trip, the symbol will not light up.
5 ALARM = Indicates that the drive is running outside a certain limit and a warning is given.
JL186-12 VACON
6 FAULT = Indicates that unsafe operating conditions were encountered due to which the drive
was stopped.
4.1.2 Control place indications
The symbols I/O term, Keypad and Bus/Comm indicate the choice of control place made in the
keypad control menu M3 .
a I/O term =I/O terminals are the selected control place; i.e. START/STOP commands or
reference values etc. are given through the I/O terminals.
b Keypad = Control keypad is the selected control place; i.e. the motor can be started or
stopped, or its reference values etc. altered from the keypad.
c Bus/Comm = The frequency converter is controlled through a fieldbus.
4.1.3 Status LEDs
The status LEDs light up in connection with the READY, RUN and FAULT drive status indicators.
Ⅰ = Illuminates with the AC power connected to the drive and no faults are active.
Simultaneously, the drive status indicator READY is lit up.
Ⅱ = Illuminates when the drive is running. Blinks when the STOP button has been pushed and
the drive is ramping down.
Ⅲ = Blinks when unsafe operating conditions were encountered due to which the drive was
stopped (Fault Trip). Simultaneously, the drive status indicator FAULT blinks on the
display and the fault description can be seen, see Active Faults.
4.1.4 Text lines
The three text lines (•, ••, •••) provide the user with information on his present location in the
keypad menu structure as well as with information related to the operation of the drive.
● = Location indication; displays the symbol and number of menu, parameter etc. Example:
M2 = Menu 2 (Parameters); P2.1.3 = Acceleration time
●● = Description line; Displays the description of menu, value or fault.
●●● = Value line; Displays the numerical and textual values of references, parameters etc. and
the number of submenus available in each menu.
4.2 Button descriptions
There are nine buttons on the Vacon NX control keypad, which used for frequency (motor)
control, reset parameter and data monitoring.
= This button is used to reset active faults.
JL186-12 VACON
= This button is used to switch between two latest displays. May be useful
when you want to see how the changed new value influences some other
value.。
= The Enter button serves for:

1）confirmation of selections
2）fault history reset (2…3 seconds)
= Browser button up
Browser the main menu and the pages of different submenus.
Edit values.
= Browser button up
Browser the main menu and the pages of different submenus.
Edit values.
= Menu button left

Move backward in menu.
Move cursor left (in parameter menu).
Exit edit mode.
Hold down for 2-3 seconds to return to main menu.
= Menu button left

Move backward in menu.
Move cursor left (in parameter menu).
Exit edit mode.
= Start button.
Pressing this button start the motor if the keypad is the active control place.
(See M3 -P3.1）
= Stop button.
Pressing this button stops the motor （Unless disabled by parameter M3-
P3.4/P3.6）
JL186-12 VACON
5. Navigation on the control keypad
The data on the control keypad are arranged in menus and submenus. The menus are used for
example for the display and editing of measurement and control signals, parameter settings,
reference values and fault display. Through the menus, you can also adjust the contrast of the
display.
The first menu level consists of menus M1-M7 and is called the Main menu. The user can
navigate in the main menu using the Browser buttons up and down. The desired submenu can
be entered from the main menu using the Main buttons. When there still are pages to enter
under the currently displayed menu or page, you can see an arrow （→）in the lower right
corner of the display and by pressing the Menu button right，you can reach the next menu level.
The control keypad navigation chart is shown on the next page. Please note that the menu M1
is located in the lower left corner. From there you will be able to navigate your way up to the
desired menu using the menu and browser buttons.
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5.1 Monitoring values for frequency input/output（menu M1）
The monitoring data are the actual value of parameter , signal, status and measurement. We
can not edit the monitoring values.
You can enter the Monitoring menu from the Main menu by pushing the menu button right when
the location indication M1 is visible on the first line of the display. How to browse through the
monitored values is presented in Figure.
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The monitored signals carry the indication V#.# and they are listed in the table. The values are
updated once every 0.3 seconds.
This menu is meant only for signal checking. The values cannot be altered here.
Code Parameter Unit ID Description

V1.1 Output frequency Hz 1 Output frequency to motor
Frequency reference to
V1.2 Frequency reference Hz 25
motor control
V1.3 Motor speed rpm 2 Motor speed in rpm
V1.4 Motor current A 3 Motor real-time current
In % of the nominal motor
V1.5 Motor torque % 4
torque
V1.6 Motor power % 5 Motor shaft power
V1.7 Motor valtage V 6
V1.8 DC link voltage V 7
V1.9 Unit temperature ℃ 8 Heatsink temperature
V1.10 Voltage input V 13 AI 1
V1.11 Current input mA 14 AI 2
V1.12 DIN1，DIN2，DIN3 15 Digital input statuses
V1.13 DIN4，DIN5，DIN6 16 Digital input statuses
Digital and relay output
V1.14 D01，R01，R02 17
statuses
V1.15 Analogue I out mA 26 AO 1
V1.16 Encoder speed rpm 1501 Encoder speed in rpm
Calculated sync Calculated synchronous
V1.17 rpm 1502
speed speed
V1.18 Torque % 1125 Unfiltered motor torque
V1.19 Current A 1113 Unfiltered motor current
V1.20 DC voltage V 44 Unfiltered DC voltage
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V1.21 Status word 43 Drive status word
V1.22 Encoder 1 freq. 1124 Shaft frequency
V1.23 Fault history Hz 37 Last active fault code
V1.24 Multimonitor Multimonitor page
5.2 Edit frequency parameters（parameter menu M2）
Parameters are the way of conveying the commands of the user to the frequency converter. The
parameter values can be edited by entering the Parameter Menu when the location indication
M2 is visible on the first line of the display. The value editing procedure is presented in the
following figure:
Push the Menu button right once to move into the Parameter Group Menu (G#). Locate the
parameter group desired by using the Browser buttons and push the Menu button right again to
enter the group and its parameters. Use again the Browser buttons to find the parameter (P#)
you want to edit. From here you can proceed in two different ways: Pushing the Menu button
right takes you to the edit mode. As a sign of this, the parameter value starts to blink. You can
now change the value in two different manners:
1 Just set the new desired value with the Browser buttons and confirm the change with the
Enter button. Consequently, the blinking stops and the new value is visible in the value field.
2 Push the Menu button right once again. Now you will be able to edit the value digit by digit.
This editing manner may come in handy, when a relatively greater or smaller value than that on
the display is desired. Confirm the change with the Enter button.
The value will not change unless the Enter button is pushed. Pressing the Menu button left
takes you back to the previous menu.
Several parameters are locked, i.e. uneditable, when the drive is in RUN status. If you try to
change the value of such a parameter the text *Locked* will appear on the display. The
frequency converter must be stopped in order to edit these parameters.
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The parameters values can also be locked using the function in menu M6 (see Chapter
Parameter lock (P6.5.2)).
You can return to the Main menu anytime by pressing the Menu button left for 3 seconds.
Once in the last parameter of a parameter group, you can move directly to the first parameter of
that group by pushing the Browser button up.
Mechanical brake control application （ASFIFF17-V1-13） M2 parameter lists

Open loop parameter
Code Parameter Unit Default Cust Code Parameter Unit Default Cust
Basic parameter M2---G2.1 P2.6.6 U/f curve HZ 50.00 Auto
midpoint change
frequency
P2.1.1 Min. frequency HZ 0.00 0.00 P2.6.7 U/f curve % 100.00 Auto
midpoint change
voltage
P2.1.2 Max. frequency HZ 50.00 100.00 P2.6.8 Output % 0.00 Auto
voltage at change
zero
frequency
P2.1.3 Acceleration time S 3.0 4.00 P2.6.9 Switching HZ Varies Auto
1 frequency change
P2.1.4 Acceleration time S 3.0 2.00 P2.6.1 Overvoltage 1 1
1 0 controller
P2.1.5 Current limiter A 1.5x1 1.5x1 P2.6.1 Undervoltag 1 1
1 e controller
P2.1.6 Norminal voltage V 400 Name P2.6.1 Identification 0 2
of the motor tag 6
value
P2.1.7 Norminal HZ 50.00 Name Note：1.Mechanical brake should be cut off by
frequency of the tag hands；2.Disaasembly motor from reducer；
motor value
P2.1.8 Norminal speed of Rpm 1440 Name 3.Make the right name tag parameter of motor；
the motor tag 4.P2.6.16 setup 2, and operat control station in 20
value second, make the motor run,
P2.1.9 Norminal current A 1 Name After 2 minute auto stop；5. Idetenfication fault
of the motor tag
value
P2.1.1 Norminal power 0.85 Name show：57.
0 factor of the motor tag
value
P2.1.1 I/O reference 0 4 After auto motor identification finished, the following
1 parameter will be auto changed, running
identification will be
P2.1.1 Keypad control 2 2 All changed，if without running identification, only
2 reference change parameter of P2.9.16-P2.9.25。
P2.1.1 Fieldbus reference 3 3 Motor control parameter M2---G2.9
3
P2.1.1 Digital reference HZ 5.00 8.00 P2.9.1 Flux 10% % 10.0 Auto
4 000 change
5 001 change
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6 010 change
7 011 change
8 100 change
9 101 change
0 110 change
1 111 change
Input signal M2---G2.2 P2.9.9 Flux 90% % 90.0 Auto
change
P2.2.7. Fault reset 15 0.1 P2.9.1 Flux 100% % 100.0 Auto
1 0 change
P2.2.7. External fault 12 B.1 P2.9.1 Flux 110% % 110.0 Auto
2 closing contact 1 change
P2.2.7. Run enable 0.2 D.1 P2.9.1 Flux 120% % 120.0 Auto
4 2 change
P2.2.7. Speed select 1 0 A.4 P2.9.1 Flux 130% % 130.0 Auto
9 3 change
10 4 change
11 5 change
Output signal M2---G2.3 P2.9.1 Make flux Varies Auto
6 time change
P2.3.7. Relay output 1 17 17 P2.9.1 Make flux Varies Auto
function 7 voltage change
P2.3.8 Relay output 2 3 4 P2.9.1 Rs voltage Varies Auto
function 8 drop change
Frequency control parameter M2---G2.4 P2.9.1 Make flux Varies Auto
9 voltage change
hardware
P2.4.5 Brake chopper 1 1 P2.9.2 Ir add zero % Varies Auto
0 point voltage change
P2.4.6 Start fuction 0 0 P2.9.2 Ir add % Varies Auto
1 generator change
scale
P2.4.7 Stop fuction 1 1 P2.9.2 Ir add % Varies Auto
2 motoring change
scale
Brake control parameter M2---G2.5 P2.9.2 Iu offset 0 Auto
3 change
P2.5.1. Open loop No parameter P2.9.2 Iv offset 0 Auto
X parameter at closed loop 4 change
P2.5.1. Current limit fwd A ０.００５０％ P2.9.2 Iw offset 0 Auto
1 １ 5 change
P2.5.1. Current limit rev Ａ０.００５０％ Protections M2----G2.7
2 １
P2.5.1. Torque limit fwd ％０.００５０ P2.7.1 Speed fault 0 2
3 3 protection
P2.5.1. Torque limit rev ％０.００５０ P2.7.1 Speed fault A 10.0 1
4 4 current
P2.5.1. Frequency limit ＨＺ１.０００. ５０ P2.7.2 Response to 0 2
5 fwd 1 thermistor
fault
P2.5.1. Frequency limit ＨＺ１.０００. ５０
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6 rev
Motor control parameter M2---G2.６
P2.6.1 Motor control ００
mode
P2.6.2 Ｕ/ｆ optimisation ０１
P2.6.3 Ｕ/ｆ ratio ０ Auto
selection change
：２
P2.6.4 Field weakening ＨＺ５０.００ Auto
point change
：５０
P2.6.5 Voltage at field ％１００％ Auto
weakening point change
：１００
Mechanical brake control application （ASFIFF17-V1-13） M2 parameter lists

Closed loop parameter
Code Parameter Unit Default Cust Code Parameter Unit Default Cust
Basic parameter M2---G2.1 P2.6.6 U/f curve HZ 50.00 Auto
midpoint change
frequency
P2.1.1 Min. frequency HZ 0.00 0.00 P2.6.7 U/f curve % 100.00 Auto
midpoint change
voltage
P2.1.2 Max. frequency HZ 50.00 100.00 P2.6.8 Output % 0.00 Auto
voltage at change
zero
frequency
P2.1.3 Acceleration time S 3.0 4.00 P2.6.9 Switching HZ Varies Auto
1 frequency change
P2.1.4 Acceleration time S 3.0 2.00 P2.6.1 Overvoltage 1 1
1 0 controllor
P2.1.5 Current limit A 1.5x1 1.5x1 P2.6.1 Undervoltag 1 1
1 e controllor
P2.1.6 Norminal voltage V 400 Name P2.6.1 Identification 0 2
of the motor tag 6
value
P2.1.7 Norminal HZ 50.00 Name Note：1.Mechanical brake should be cut off by
frequency of the tag hands；2.Disaasembly motor from reducer；
motor value
P2.1.8 Norminal speed of Rpm 1440 Name 3.Make the right name tag parameter of motor；
the motor tag 4.P2.6.16 setup 2, and operat control station in 20
value second, make the motor run,
P2.1.9 Norminal current A 1 Name After 2 minute auto stop；5. Idetenfication fault
of the motor tag
value
P2.1.1 Norminal power 0.85 Name show：57.
0 factor of the motor tag
value
P2.1.1 I/O reference 0 4 After auto motor identification finished, the following
1 parameter will be auto changed, running
identification will be
P2.1.1 Keypad control 2 2 All changed，if without running identification, only
2 reference change parameter of P2.9.16-P2.9.25。
P2.1.1 Fieldbus reference 3 3 Motor control parameter M2---G2.9
3
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4 000 change
5 001 change
6 010 change
7 011 change
8 100 change
9 101 change
0 110 change
1 111 change
Input signal M2---G2.2 P2.9.9 Flux 90% % 90.0 Auto
change
P2.2.7 Fault reset 15 0.1 P2.9.1 Flux 100% % 100.0 Auto
.1 0 change
P2.2.7 External fault 12 B.1 P2.9.1 Flux 110% % 110.0 Auto
.2 closed contact 1 change
P2.2.7 Run enable 0.2 D.1 P2.9.1 Flux 120% % 120.0 Auto
.4 2 change
P2.2.7 Speed select 1 0 A.4 P2.9.1 Flux 130% % 130.0 Auto
.9 3 change
.10 4 change
.11 5 change
Output signal M2---G2.3 P2.9.1 Make flux Varies Auto
6 time change
P2.3.7 Relay output 17 17 P2.9.1 Make flux Varies Auto
. 1fuction 7 voltage change
P2.3.8 Relay output 3 4 P2.9.1 Rs voltage Varies Auto
2fuction 8 drop change
Frequency control parameter M2---G2.4 P2.9.1 Make flux Varies Auto
9 voltage change
hardware
P2.4.5 Brake chopper 1 1 P2.9.2 Ir add zero % Varies Auto
0 point voltage change
P2.4.6 Start fuction 0 0 P2.9.2 Ir add % Varies Auto
1 generator change
scale
P2.4.7 Stop fuction 1 1 P2.9.2 Ir add % Varies Auto
2 motoring change
scale
Brake control parameter M2---G2.5 P2.9.2 Iu offset 0 Auto
3 change
P2.5.2. Open loop No parameter P2.9.2 Iv offset 0 Auto
X parameter at open loop 4 change
P2.5.2 Current limit A ０.０００.５１ P2.9.2 Iw offset 0 Auto
.1 5 change
P2.5.2 Torque limit Ａ０.００５０ Protections M2----G2.7
.2
P2.5.2 Frequency limit ％０.００５０ P2.7.1 Speed fault 0 2
.3 3 protection
P2.5.2 Opening delay ％０.００５０ P2.7.1 Speed fault A 10.0 1
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.4 4 current
P2.5.2 Closing frequency ＨＺ１.０００. ５０ P2.7.2 Response to 0 2
.5 1 thermistor
fault
P2.5.2 Closing delay S １.０００. ５０
.6
P2.5.2 Max. frequency ＨＺ 0.1 4
.7 when brake is
closed
P2.5.2 Mechanical brake S 0.5 0.5
.8 reaction time
P2.5.2 Start magnetizing Ａ００.５１
.14 current
P2.5.2 Start magnetizing ｍｓ０１００
.15 time
Motor control parameter M2---G2.６
P2.6.1 Motor control ００
mode
P2.6.2 Ｕ/ｆ optimisation ０１
P2.6.3 Ｕ/ｆ ratio select ０ Auto
change
：２
P2.6.4 Weak magn. ＨＺ５０.００ Auto
change：
５０
P2.6.5 Weak magn. ％１００％ Auto
voltage change：
１００
5.3 How to select control palce（keypad control parameters M3）
There are three control palce of frequency:I/O terminal，keypad and fieldbus。

We usually use I/O terminal.
5.3.1 Selection of control place
When the first line of keypad shows the M2, setup the parameter from active menu to parameter
menu. See the keypad control menu.
Keypad control menu
Code Name Min. Max. Unit Default Cust ID Note
P3.1 Control place 1 3 1 125 1=I/Oterminal
2=keypad
3=fieldbus
P3.2 Keypad reference P2.1.1 P2.1.2 HZ Frequency when
keypad control
P3.3 Motor direction 0 1 0 123 0=forward
(on keypad) 1=reverse
P3.4 Stop button 0 1 1 114 0=limited fuction of
stop button
1=stop button
always enabled
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Each control place of frequency have a symbol as follows：
Control place Symbol

I/O terminal
keypad
Fieldbus
Press Right Button to change control place, and use Browse Button to browse these selections,
at last, press the ENTER to choose the control place. See the detail as follows。
5.3.2 Keypad setting parameter P3.2 allows user edit set value of frequency.
This parameter is effective under keypad control, so under the other control do not effect the
motor speed.
Please refer to Page 11 to edit parameter, don’t need press ENTRE button。
5.3.3 Keypad setting value parameter P3.3 allows user change the motor direction. This
parameter is effective under keypad control, so under the other control do not effect the motor
direction.
5.3.4 In the case of default settings, no matter what kind of control mode, press STOP button
can stop the motor. If P3.4 assigned to 0 can cancel this fuction， only chose keypad, STOP
button can stop the motor.
Important: There are some special fuctions as follows:
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1 During the motor running, press the STOP button and keep 3 seconds, you can
choose keypad. The current frequency setting values and directions will be copied to
the keypad.
2 When the motor stop，press the STOP button and keep 3 seconds，you can choose
keypad for the current control place. The current frequency setting values and
directions will be copied to the keypad.
3 Press ENTER button and keep 3seconds，the frequency setting values will be
copied to the keypad by other control places.（I/O,fieldbus）
5.4 How to check the frequency fault records （the current fault menu M4）
When keypad shows M4 in the first line, press menu button right can go to fault menu from
active menu.
Normal，no fault
When a fault brings the frequency converter to a stop, the location indication F1, the fault code,
a short description of the fault and the fault type symbol will appear on the display. In addition,
the indication FAULT or ALARM is display and, in case of a FAULT, the red led on the keypad
starts to blink. If several faults occur simultaneously, the list of active faults can be browsed with
the browser buttons.
The memory of active faults can store the maximum of 10 faults in the order of appearance. The
display can be cleared with the reset button and the read-out will return to the same state it was
before the fault trip. The fault remains active until it is cleared with the reset button or with a
reset signal from the I/O terminal or fieldbus.
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Note! Remove external Start signal before resetting the fault to prevent unintentional restart of
the drive.
5.4.1 Fault types
In the NX frequency converter，there are four different types of faults. These types differ from
each other on the basis of the subsequent behavior of the drive. See the following table.
Fault type symbol Meaning

A （Alarm） This type of fault is a sign of an
unusual operating condition. It does
not cause the drive to stop, nor does
it require any special actions. The “A
fault” remains in the display for about
30 seconds.
F （Fault） An “F fault” is a kind of fault that
makes the drive stop. Actions need to
be taken in order to restart the drive.
AR （Fault Autoreset） If an “ AR fault” occurs the drive will
also stop immediately. The fault is
reset antomatically and the drive tries
to restart the motor. Finally, if the
restart is not successful, a fault trip
(FT, see below）occurs.
FT （Fault Trip） If the drive is unable to restart the
motor after an AR fault occurs. The
effect of the “FT fault” is basically the
same as that of the F fault: the drive
is stopped.
5.4.2 Fault codes
The fault codes and their possible causes are presented in the following sheet. When the fault
with *，you can program different responses in the application. See parameter group
Protections M2-G2.7.
Note: When contacting distributor or factory because of a fault condition, always write down all
texts and codes on the keypad display.
Fault code list

Fault Fault Fault Possible cause Correcting
code type measures
1 F Overcurrent Frequency converter has detected too - check loading
high a current（>4*I）in the motor cable: - check cables
- Sudden heavy load increase - check motor
- Short circuit in motor cables
- Unsuitable motor
2 F Overvoltage The DC-link voltage has exceeded the - Make deceleration
limits defined in NX_5 ，that：911VDC time longer.
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- too short deceleration time - check brake resistor
- high overvoltage spikes in utility is open circuit
3 * Earth fault Current measurement has detected that - check motor or

the sum of motor phase current is not cables
zero.
- Insulation failure in cables or motor.
5 F Charging The charging switch is open. When the - reset the fault and
switch START command has been given. restart
- faulty operation - should the fault re-
- component failure occur, contact the
supplier.
www.vacon.com/wwc
ontacts.html
6 F Emergency Stop signal has been given from the
stop option board
7 F Emergency Various causes： Cannot be reset from
stop -Components failure the keypad.
- Brake resistor short circuit or overload - Switch off power.
- Do not re-connect
power!
Contact factory:
- If this fault appears
simultaneously with
Fault1, check motor
cables and motor.
8 F Unknow fault The frequency converter - Contact factory
troubleshootingsystem is unable to locate
the fault.
9 * Undervoltage DC-link voltage is under the voltage limits -In case of temporary
defined in NX_5，that：333VDC supply voltage break
- most probable causes：too low a reset the fault and
supply voltage restart the frequency
- frequency converter internal fault converter. Check the
supply voltage. If it is
adequate, an internal
failure has occurred.
Contact with factory.
10 * Input line Input line phase is missing Check supply voltage
supervision and cables
11 * Output phase Current measurement has detected that Check motor cables
supervision there is no current in one motor phase. and motor
12 F Brake -no brake resistor installed -check brake resistor
chopper -brake resistor is broken -If these are ok, the
supervison -brake chopper failure chopper is faulty.
Contact factory.
13 F Frequency Heatsink temperature is under -10℃ - Improve the
converter frequency converter
undertemper ambient temperature
ature
14 F Frequency -Heatsink temperature is over 90℃ -Check the correct
converter -overtemperature warning is issued when amount and flow of
overtemperat the heatsink temperature exceeds 85℃ cooling air.
ure - Check the heatsink
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for dust.
- Check the ambient
temperature.
- Make sure that the
switching frequency is
not too high in relation
to ambient
temperature and
motor load.
15 * Motor stalled Motor stall protectionhas tripped - check motor
16 * Motor Motor overheating has been detected by - Improve the
overtemperat frequency converter motor temperature frequency converter
ure model. Motor is overloaded. ambient temperature.
17 * Motor Heatsink temperature is under -10℃ - Decrease motor
underload load.
If no motor overload
exists, check the
temperature model
parameters.
22 F EEPROM -parameter save fault
Checksum -faulty operation
fault -component failure
24 A Counter fault Counter displays error fault
25 F Microprocess -faulty operation - Reset the fault and
or watchdog -component failure restart.
fault - Should the fault re-
occur, contact the
distributor near to you.
29 * Thermistor -The thermistor input of option board has - Check motor cooling
fault detected increase of the motor and loading.
temperature. - Check thermistor
connection.
- If thermistor input of
the option board is
not in use it has to be
short circuited.
37 A Device -option board changed - Reset.
change -frequency changed Note ：Old board
settings will be used.
38 A Device - option board added - Reset
added -drive of different power rating added Note ：Old board
39 A Device - option board removed - Reset
removed - frequency removed Note ：Old board
40 F Device Unknow option board or frequency Contact the distributor
unknow near to you.
Link to ：
http://www.vacon.com
/wwcontacts
41 F IGBT IGBT Inverter overheating protection be - Check loading.
temperature found in a short time overload current - Check motor size.
42 * Brake Brake resistot overheating protection - Set the deceleration
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resistor detect overload brake time longer.
overheating
43 F Encoder fault Problem detected in encoder signals. - Check the encoder
1=lost encoder 1channel A channel connections.
2= lost encoder 1channel B - Check the encoder
3=two channel signal of encoder 1 are all board
lost
4= Reverse Encoder
51 F External fault Digital input fault.
52 F Keypad The connection between the control
communicati keypadand the frequency converter is
on fault broken.
53 F Fieldbus The connection from the fieldbus to the
communicati frequency converter is broken.
on fault
54 F SPI The connection between the component
communicati board and the control board is broken.
on fault
5.4.3 Fault time data record
When a fault occurs the information described above in the following table is displayed. By
pressing the Menu button right here you will enter the Fault time data record menu indicated by
T.1-T.13. In this menu, some selected important data valid at the time of the fault are recorded.
This feature is intended to help the user or the service person to determine the cause of fault.
The data available are:

T.1 Counted operation days d
Fault 43：Additional
code
T.2 Counted operation hh:mm:ss
hours d
Fault 43：Counted
operation days
T.3 Output frequency HZ
Fault 43：Counted hh:mm:ss
operation hours
T.4 Motor current A
T.5 Motor voltage V
T.6 Motor power %
T.7 Motor torque %
T.8 DC voltage V
T.9 Unit temperature ℃
T.10 Run status
T.11 Direction
T.12 Warnings
T.13 O speed
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5.5 Fault history menu （M5）
The fault history menu can be entered from the Main menu by pushing the Menu button right
when the location indication M5 is visible on the first line of the keypad display. Find the fault
codes in Fault codes table.
All faults are stored in the Fault history menu in which you can browse through them using the
Browser buttons. Additionally, the Fault time data record pages are assessable at each fault.
You can return to the previous menu anytime by pushing the menu button left.
The memory of the frequency converter can store a maximum of 30 faults in the order of
appearance. The number of faults currently in the fault history is shown on the value line of the
main page (H1-H#）. The order of the fault is indicated by the location in the upper left corner of
the display. The latest fault carries the indication F5.1，the second latest F5.2, etc. If there are
30 uncleared faults in the memory the next occurring fault will erase the oldest from the memory.
Pressing the ENTER button for about 2 to 3 seconds resets the whole fault history. Then , the
symbol H# will change to O.
5.6 System menu M6
The System menu can be entered from the main menu by pushing the Menu button right when
the location indication M6 is visible on the display.
The control associated with the general use of the frequency converter, such as language
selection, application selection, customized parameter sets or information about the hardware
and software are located under the System menu. The number of submenus and subpages is
shown with the symbol S (or P) on the value line。
5.6.1 Language selection
The Vacon control keypad offers you the possibility to control the frequency converter through
the keypad in the language of your choice.
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Locate the language selection page under the System menu. Its location indication is S6.1.
Press the menu button right once to enter the edit mode. As the name of the language starts to
blink you are able to choose another language for the keypad texts. Confirm the selection by
pushing the Enter button. The blink stops and all textual information on the keypad is presented
in the language you chose.
You can return to the previous menu anytime by pushing the Menu button left.
M6 The other parameters are not often used , pass over.

M7 Pass over.
JL186-12 VACON
Edition 00 – 05/2013 Page 26
沈阳优势特起重机有限公司
USETER CRANES CO., LTD.
公司地址：沈阳市沈河区青年大街 35 号邮编：110014
H. Office: No. 35 Qingnian Street, Shenhe District ,
Shenyang, 110014 P.R. China
电话（Tel）: +86-24-22745018 传真（Fax）: +86-24-22745017
Email: useter@hotmail.com http://www.useter.com

Operating Instruction 2013

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USETER CRANES CO., LTD.

Fundamental safety instructions 1

General instructions for assembly 3

The instruction manual is to be supplemented by the respective national rules and

0.1 Master sheet 2

JL186-12 Record book

Manufacturer USETER CRANES CO., LTD.

Serial No.: JL186-1305-024

Year of manufacture: 2013

Classification according ISO 4301 (FEM-DIN 15018): A3

Application of crane according DIN 15002, sheet 2: Tower crane

Kind of operation: Fixing control station

JL186-12 Record book

 The national accident prevention rules.

 Standards and Directives.

 Repeat order of blank sheets for the periodical inspection is possible.

2. The user shall ensure, that

JL186-12 Record book

These can be member of a government run or authorised technical inspecting office or

JL186-12 Record book

General data Safety device

Horizontal / Load moment limiter existent

Capacity 2,2t Hook locking existent

Position cabin Turntable Hoist emergency limit switch existent

Driven kind El. motor Inclination limit switch existent

Control voltage 110 V - 50 Hz

Construction weight 64140 kg

Power Degree of r.p.m.

Hoist unit 45 50 40 DV 225M4 IP 55 M1B 1440

Luffing unit 45 50 60 DV 225M4 IP 55 M1B 1440

Type Transmission Remarks

Hoist unit K 157 38.02

Slewing unit JH08 164 M = 10; T =12

Luffing unit K 127 27.68

JL186-12 Record book

Feeding part Contactor contr.

Hoist unit Contactor contr.

Luffing unit Contactor contr.

Hoist unit Disc brake BM62 600

Luffing unit Disc brake BM62 600

Height Limit DXZ-453

Luffing Limit DXZ-210

Slewing Limit DXZ-46

JL186-12 Record book

Hoist unit 80 12 Shanghai XIHUA Lifting Equipment Co., Ltd.

JL186-12 Record book

1.1 Warnings and symbols 2

JL186-12 Fundamental safety instructions

Forbidden - important note to prevent accidents or heavy material damages.

USE OF THE CRANE

1.2 Basic operation and designated use

JL186-12 Fundamental safety instructions

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

1.3 Organizational measures

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

1.4 Selection and qualification of personnel - basic responsibilities

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

JL186-12 Fundamental safety instructions

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

1.5 Safety instructions governing specific operational phases

1.5.2 Observe the regulations applicable to the respective location.

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

JL186-12 Fundamental safety instructions