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OPERATING MANUAL

- Topless crane JT 152.8 -


Page 1 / 5 JT152.8
Contents

Contents
Foreword

1 Fundamental safety instructions

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 4
1.6 Transporting the slewing tower crane 6
1.7 Maintenance of the slewing tower crane 6
1.8 Warning of special dangers 7
1.9 Hydraulic and pneumatic equipment 8
1.10 Noise 8
1.11 Oil, grease and other chemical substances 8
1.12 Measuring system 9

2 Technical data

2.1 General 2
2.1.1 Crane components 2
2.1.2 Jib lengths - Tower TH15.2 3
2.1.3 Modular system for jib configurations 4
2.1.4 Jib configurations 5
2.1.5 Counter jib ballast 6
2.1.6 Ballast weight 2,8t 7
2.1.7 Ballast weight 1,8t 8
2.1.8 Ropes dimensions and constructions 9
2.1.9 Maximum admissible wind speeds 10
2.1.10 Packing list - jib length 60,0m 11
2.2 Crane on foundation anchors 12
2.2.1 Foundation loadings for Jib 30,0 m - 40,0m 12
2.2.2 Foundation loadings for Jib 45,0 m - 60,0 m 13
2.2.3 Foundation anchors FH 2.2 14
2.2.4 Foundation anchors FH 2.4 15
2.2.5 Conditions with use of telescopic cage 16
2.3 Crane on foundation cross – stationary FC4.6 17
2.3.1 Ballast configuration 17
2.3.2 Corner determination and jib position 18
2.3.3 Corner pressures 18
2.3.4 Foundation block 2,5 t 19
2.3.5 Base block 5,0 t 20
2.3.6 Standard block 5,0 t 21
2.3.7 Standard block 2,5 t 22
2.4 Earthing 23
2.5 Electric power supply 24

Contents.doc Editor: AJ Updated: 25.07.2011


Page 2 / 5 JT152.8
Contents

3 General instructions for assembly

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 Prohibited crane moves 6
3.8 Assembly and disassembly advice 7
3.9 Safety precautions 7
3.10 Hand signals 8
3.11 Warning signs 9

4 Assembly

4.1 General assembly information 2


4.2 General data - Tower TH 15.2 10
4.3 Assembly of fixing plates 11
4.4 Assembly of tower TH 15.2 11
4.5 Assembly of turntable, slewing support and slewing unit 12
4.6 Preassembly of slewing support 12
4.7 Preassembly of turntable 13
4.8 Assembly of jib section 1 13
4.9 Preassembly of jib section 1 14
4.10 Preassembly of hoist rope Ø12mm 15
4.11 Preassembly of trolley ropes Ø8mm 15
4.12 Assembly of counter jib 1 16
4.13 Preassembly of counter jib 1 16
4.14 Assembly of counter weight 17
4.15 Preassembly of jib - 30,0m 17
4.16 Preassembly of jib - 35,0m 17
4.17 Preassembly of jib - 40,0m 17
4.18 Preassembly of jib - 45,0m 18
4.19 Preassembly of jib - 50,0m 18
4.20 Preassembly of jib - 55,0m 18
4.21 Preassembly of jib - 60,0m 18
4.22 Reeving of hoist rope 19
4.23 Reeving of trolley rope 19
4.24 Assembly of jib 30,0m - 45,0m 20
4.25 Assembly of jib 50,0m - 60,0m 21
4.26 Assembly of remaining counterweight 22
4.27 General instructions for crane disassembly 22

5 Safety devices

5.1 General 2
5.2 Audible warnings 2
5.2.1 Acoustic signals as a warning to the crane operator 2
5.2.2 Acoustic signals as a warning to other people 2
5.2.3 Acoustic signals as a warning to other people 2

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Contents

5.3 Position of safety devices 3


5.4 Safety switches on control lever 4
5.4.1 Automatically zero positioning 4
5.4.2 Forced zero positioning 4
5.5 Dead-man switch 4
5.6 Hoist limit switch 5
5.7 Trolley travel limit switch 6
5.8 Load moment limiter and Load limiter 7
5.9 Adjusting of load lifting diagram 7
5.9.1 Adjusting the limit switch 7
5.9.2 Testing the settings 8
5.9.3 Load limiter 8
5.10 Load test 8
5.11 Key switch operation/mounting 9
5.12 Trolley travel blocking 9
5.13 Rope retaining brackets 9
5.14 Load hook 9
5.15 Slewing unit 10
5.15.1 Countering protection 10
5.15.2 Weathervane mode 10

6 Crane operation

6.1 Prior to initial crane operation 2


6.2 Taking the crane into operation 2
6.3 Crane control desk 3
6.4 Control of hoist unit 4
6.5 Control of trolley unit 5
6.6 Control of slewing unit 6
6.7 Instructions for crane operation 7
6.8 Taking the crane out of operation 8
6.9 Taking the crane out of operation when a gale is approaching 9
6.10 Changing of hoist rope reeving from 4-fall to 2-fall operation 11
6.11 Changing of hoist rope reeving from 2-fall to 4-fall operation 12
6.12 Digital indication outreach 13
6.13 Electrical Adjustment 14
6.13.1 Starting the system 14
6.13.2 Installing the system 21
6.13.3 System settings 28
6.13.4 Log files (optional module) 33
6.13.5 WAZ/ACS settings (optional module) 35

7 Maintenance

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 Trolley Gear & Brake 9
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Contents

7.10 Hoist gear 10


7.11 Slewing gear Orthobloc 11
7.12 Slewing brake FCM / FCO 11
7.13 Slipring translator 11
7.14 Switch cabinet – control house (CACON) 11
7.15 Electrical cables 12
7.16 Contactor and switch contacts 12
7.17 Slewing ring 12
7.18 Shorter lubrication intervals 12
7.19 Steel structure 13
7.20 Inspection & Maintenance of the painting 13
7.21 Supervision of forged load hooks as per DIN 15401 13
7.22 Rope maintenance 14
7.23 Handling of wire ropes 15
7.24 Time for replacing wire ropes 16
7.25 Drawing-in wire ropes 17
7.26 Addendum 18
7.26.1 Trolley gear - SEW 18
7.26.2 Hoist gear - SEW 18
7.26.3 Slewing gear - Leroy Somer 18

8 Electrical equipment

8.1 Standards & Calculation 2


8.2 Electrical connection 29
8.3 Cross-section 29
8.4 F.I.-Protection switch with TT-Network 30
8.5 Wiring diagram 31
8.5.1 Feeding part 31
8.5.2 PLC 35
8.5.3 Hoist unit 22/30kW 39
8.5.4 Trolley unit 3,0kW 43
8.5.5 Slewing unit 2x50Nm 46
8.5.6 Control panel 52
8.5.7 Cable loop 56
8.6 Parts list 65

9 Climbing

9.1 External Climbing 2


9.1.1 General data 2
9.1.2 Weight & dimensions 2
9.1.3 Load chart for balancing 2
9.1.4 Preparation for Climbing 3
9.1.5 Inserting the tower in the rail 4
9.1.6 Balancing of crane 4
9.1.7 First climbing step 5
9.1.8 Next steps on tower section 2 6
9.1.9 Next steps on tower section 3 8
9.1.10 Final step for Climbing 9
9.1.11 Opening of front wall 10
9.1.12 Moving of tower section 11
9.1.13 Installation of tower section 12
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Contents

9.1.14 Fixing of top crane 13

9.2 Internal Climbing 14


9.2.1 General data 14
9.2.2 Load chart for balancing 14
9.2.3 Required parts for internal climbing 15
9.2.4 Preparation for climbing 16
9.2.5 Internal climbing sequences 1+2 17
9.2.6 Internal climbing sequence 3 18
9.2.7 Internal climbing sequence 4 19
9.2.8 Internal climbing sequence 5 20
9.2.9 Internal climbing sequence 6 21

Contents.doc Editor: AJ Updated: 25.07.2011


Page 1 / 1 JT152.8
Foreword

Foreword

These operating instructions are designed to familiarize the user with the topless tower
crane and its designated use.

The instruction manual contains important information on how to operate the topless
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 topless 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 on location wherever the topless
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 topless 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
topless tower crane, the generally recognized technical rules for safe and proper working
must also be observed.

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Page 1 / 9 JT152.8
Chapter 1 Fundamental safety instructions

1 Fundamental safety instructions

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 4 
1.6  Transporting the slewing tower crane 6 
1.7  Maintenance of the slewing tower crane 6 
1.8  Warning of special dangers 7 
1.9  Hydraulic and pneumatic equipment 8 
1.10  Noise 8 
1.11  Oil, grease and other chemical substances 8 
1.12  Measuring system 9 

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Chapter 1 Fundamental safety instructions

1.1 Warnings and symbols


Do not operate the crane if the instructions and procedures outlined in the manual are
not clearly understood. Should there be any doubt, ask for the intervention of technical
service.

JOST 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

JOST Cranes JT models are tower cranes with upper slewing. They are devised only and
exclusively for lifting, moving 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.

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Chapter 1 Fundamental safety instructions

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.

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

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

1.3.8 Never make any modifications, additions or conversions, which might affect safety
without the approval of the supplier/manufacturer. This also applies to the installation and
adjustment of safety devices as well as to welding work on load-bearing elements.

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.

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Chapter 1 Fundamental safety instructions

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 and skilled
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 Repetition of product-relevant Information is essential for the crane operator and
associated personnel authorized to give instructions to other operating personnel.

1.4.7 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.

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

1.4.9 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.

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

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Chapter 1 Fundamental safety instructions

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 start-up 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 marshal 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 behaviour) 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.

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Chapter 1 Fundamental safety instructions

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.

1.7 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:
- 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

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Chapter 1 Fundamental safety instructions

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.

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Chapter 1 Fundamental safety instructions

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.

1.10 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).

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Chapter 1 Fundamental safety instructions

1.12 Measuring system


Please note: New valid units according to the "Sl-unit system".
All data in SI-units are converted and rounded-off values.

Mass = kg, t
x = Direction of attack parallel to jib
Force in N (Newton) Y = Direction of attack rectangular to
jib
Former unit kp; Mp; dyn G = Dead weight
1 kp 10 N* = 1 daN P = Load
1 Mp 10 000 N* = 10 kN A = Starting force
1 dyn = 10-5 N M = Load moment
W = Wind force
Torque in Nm (Newtonmeter) D = Pressure
Z = Pulling force
Former unit kpm
1 Nm 0. 1 0 kpm*
1 kpm 10 Nm* = 1 daNm
MX = Crane moment from G, P, M
Energy, work in kWh (kilowatthours) and W
MY = Crane moment from G, P, M
Former unit PSh (BHPh) and W
1 kpm 10 Nm* = 1 daNm MT = Torsion moment from P, G and W
1 kWh = 1.36 PSh* (HPh) N = Vertical force from G and P
S = Vertical force per corner strut
Power in kW (Kilowatt) Q = Horizontal force from P, G and W
HO = Top horizontal force
Former unit BHP HU = Bottom horizontal force
1 kW = 1.36 BHP HM = Horizontal force per corner strut
1 BHP = 0.736 kW* from M
HQ = Horizontal force per corner strut
Pressure in bar (Bar) from Q
HMT = Horizontal force per corner strut
Former unit kp/cm2 from MT
1 bar ~ 1 kp/cm2 H = Sum of all horizontal forces
E = Maximum strut force
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, for instance: - Nm -

* The conversation factors are rounded


off according to DIN 1333.
Signification of codes and signs (structural
analysis)

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Page 1 / 24 JT152.8
Chapter 2 Technical Data

2 Technical Data

2.1  General 2 
2.1.1  Crane components 2 
2.1.2  Jib lengths - Tower TH15.2 3 
2.1.3  Modular system for jib configurations 4 
2.1.4  Jib configurations 5 
2.1.5  Counter jib ballast 6 
2.1.6  Ballast weight 2,8t 7 
2.1.7  Ballast weight 1,8t 8 
2.1.8  Ropes dimensions and constructions 9 
2.1.9  Maximum admissible wind speeds 10 
2.1.10 Packing list - jib length 60,0m 11 

2.2  Crane on foundation anchors 12 


2.2.1  Foundation loadings for Jib 30,0 m - 40,0 m 12 
2.2.2  Foundation loadings for Jib 45,0 m - 60,0 m 13 
2.2.3  Foundation anchors FH 2.2 14 
2.2.4  Foundation anchors FH 2.4 15 
2.2.5  Conditions with use of telescopic cage 16 

2.3  Crane on foundation cross – stationary FC4.6 17 


2.3.1  Ballast configuration 17 
2.3.2  Corner determination and jib position 18 
2.3.3  Corner pressures 18 
2.3.4  Foundation block 2,5 t 19 
2.3.5  Base block 5,0 t 20 
2.3.6  Standard block 5,0 t 21 
2.3.7  Standard block 2,5 t 22 

2.4  Earthing 23 

2.5  Electric power supply 24 

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Page 2 / 24 JT152.8
Chapter 2 Technical Data

2.1 General

2.1.1 Crane components

8 3 10 15 9 16 1 14

2 4
13 6
11 5
7
12 22
17
19 21

18 20

1 Jib 13 Hoist rope


2 Counter jib 14 Trolley rope
3 Tie bar - counter jib 15 Load moment limiter
4 Turntable 16 Rope support
5 Slewing support 17 Tower
6 Trolley 18 Foundation anchor
7 Hook-block 19 Foundation cross 4.6m
8 Counter weights 20 Foundation block
9 Cabin - control house 21 Basic ballast block
10 Hoist unit 22 Standard ballast block
11 Trolley unit
12 Slewing unit

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Page 3 / 24 JT152.8
Chapter 2 Technical Data

2.1.2 Jib lengths - Tower TH15.2

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Page 4 / 24 JT152.8
Chapter 2 Technical Data

2.1.3 Modular system for jib configurations

JOST Cranes JT-series of topless cranes include cranes JT132.8, JT152.8 and JT182.8.

In order to optimize and facilitate assembly of cranes, JOST has developed a modular
system for all possible jib configurations and at the same time has kept the number of
parts at a minimum.

In the drawing you can see which jib sections are identical for all cranes.

12 13 11 2 3 4 5 6 7 9

JT 182.8

10 11 2 3 4 5 6 7 8 9

JT 152.8

1 2 3 4 5 6 7 8 9

JT 132.8

Topless "S"

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Page 5 / 24 JT152.8
Chapter 2 Technical Data

2.1.4 Jib configurations

60,0 m
CJ 01 1 11 2 3 4 5 6 7 8 9

55,0 m
CJ 01 1 11 2 3 4 5 6 7 8

50,0 m
CJ 01 1 11 2 3 4 5 6 7

45,0 m
CJ 01 1 11 2 3 4 5 6

40,0 m
CJ 01 1 11 2 3 4 5

35,0 m
CJ 01 1 11 2 3 4

30,0 m
CJ 01 1 11 2 3

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Page 6 / 24 JT152.8
Chapter 2 Technical Data

2.1.5 Counter jib ballast

1 2

7,5 m 6,5 m 1 = 2,8t


2 = 1,8t
1
60,0 m 6 x 2,8t = 16,8t
1 1 1 1
16,8t
1

1 5 x 2,8t = 14,0t
55,0 m 1 x 1,8t = 1,8t
1 1 1 2
15,8t
1

1 5 x 2,8t = 14,0t
50,0 m 1 x 1,8t = 1,8t
2 1 1 1
15,8t
1

2 4 x 2,8t = 11,2t
45,0 m 2 x 1,8t = 3,6t
1 1 1 1
14,8t
2

1
40,0 m 5 x 2,8t = 14,0t
1 1 1
14,0t
1

1 35,0 m 3 x 2,8t = 8,4t


2 x 1,8t = 3,6t
1 2 2
12,0t
1

30,0 m 4 x 2,8t = 11,2t


1 1 1 1
11,2t

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Page 7 / 24 JT152.8
Chapter 2 Technical Data

2.1.6 Ballast weight 2,8t

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Page 8 / 24 JT152.8
Chapter 2 Technical Data

2.1.7 Ballast weight 1,8t

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Page 9 / 24 JT152.8
Chapter 2 Technical Data

2.1.8 Ropes dimensions and constructions

Hoist rope 1

Rated diameter: 12 mm
Construction: nearly twistless, similar to DIN 3071 SE; Casar - Starlift
Surface of wires: bright (bk) or tinning (ZnK)
Rated strength of wires: 1960 N / mm²
Minimum breaking load: 110,7 kN
Type of iron: steel (SE)
Type of lay and its direction: cross lay, right-handed (sZ) or long-lay; right-handed (zZ)
Number of carried wires
in the out strand: min. 112
Finish of rope ends: both ends welded and pointed
Rope end fastening: - rope joint size Gr. 3 (Demag)
- rope wedge size Gr. 3 (Demag)
- wire rope clips DIN 1142 S 14

Trolley rope 1

Rated diameter: 8 mm
Construction: similar to DIN 3066; Casar - Unilift
Surface of wires: bright (bk) or tinning (ZnK)
Rated strength of wires: 1770 N / mm²
Minimum breaking load: 38,5 kN
Type of iron: steel (SE)
Type of lay and its direction: cross lay, right-handed (sZ)
Number of carried wires
in the out strand: min. 56
Finish of rope ends: both ends welded and pointed
Rope end fastening: - rope joint size Gr. 1 (Demag)
- rope wedge size Gr. 1 (Demag)
- wire rope clip DIN 1142 S 10

Lengths in m

Drum
Jib length 25 30 35 40 45 50 55 60
capacity
Hoist rope ² 55,0 60,0 65,0 70,0 75,0 80,0 85,0 90,0 420,0
Front 60,0 70,0 80,0 90,0 100,0 110,0 120,0 130,0 63,0
Trolley rope
Rear 41,0 46,0 51,0 56,0 61,0 66,0 71,0 76,0 63,0

1 contact manufacturer if using other makes


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

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Page 10 / 24 JT152.8
Chapter 2 Technical Data

2.1.9 Maximum admissible wind speeds

Assembly

Wind from any direction

Wind Calculated dynamic


Beaufort Wind speed
direction pressure
Parallel to jib 6 14 m/s – 50 km/h 123 N/m²
Traverse to jib 6 14 m/s – 50 km/h 123 N/m²

With higher wind speeds interrupt the erection and carry out protection measures to
against overturn or overload of the crane.

Crane in operation

Calculated dynamic
Beaufort Wind speed
pressure
8 20 m/s – 72 km/h 250 N/m²

Crane out of operation

Beaufort Wind speed Calculated dynamic pressure

0 – 20 m height above ground level* 12 36 m/s – 130 km/h 800 N/m²

20 – 100 m height above ground level* 13 42 m/s – 151 km/h 1100 N/m²

More than 100 m height * 14 46 m/s – 165 km/h 1300 N/m²

* Basic values for crane calculation

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Page 11 / 24 JT152.8
Chapter 2 Technical Data

2.1.10 Packing list - jib length 60,0m

Part Piece Description H L (m) B (m) H (m) Kg*


L B
1 Jib section JT01 + Trolley & Hoist winch 11,82 2,45 2,24 6350
1 Jib section JT 11 5,35 1,10 1,65 1165
1 Jib section JT 02 10,30 1,10 1,64 1600
1 Jib section JT 03 11,25 1,10 1,58 1310
1 Jib section JT 04 5,22 1,10 1,31 545
1 Jib section JT 05 5,18 1,10 1,30 450
1 Jib section JT 06 5,17 1,10 1,30 360
1 Jib section JT 07 5,15 1,10 1,30 290
1 Jib section JT 08 5,13 1,10 1,27 250
1 Jib section JT 09 5,12 1,10 1,27 200

1 Jib end 0,53 1,22 0,95 70


UPPER PART

1 Counter jib JT 01 7,65 1,99 1,55 1400

1 Slewing Table + Slewing Support 2,27 1,90 2,57 4350

1 Cabin 3,50 2,20 1,10 1350

1 Trolley 1,40 1,40 0,93 250


1 Hook Block 0,82 0,42 0,96 342

1 Ballast Block 1 2,40 0,96 0,50 2800


1 Ballast Block 2 1,50 0,96 0,50 1800

1 Tower section TH 15.2 6,0 1,66 1,69 2450


TOWER

1 Tower section TH 15.2s 12,0 1,68 1,83 4830


1 Tower section TH 15.3 6,0 1,70 1,74 3260
1 Tower section TH 15.3s 12,0 1,74 1,90 6400

(*) Weight per piece

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Page 12 / 24 JT152.8
Chapter 2 Technical Data

2.2 Crane on foundation anchors

2.2.1 Foundation loadings for Jib 30,0 m - 40,0 m

Tower Hook Tower Foundation loadings Foundation plate


height height no. NC H MC l h P Ground
m m kN kN kNm m m kN / m²
18,2 17,2 3 438,9 51,7 1984 5,1 1,60 168,98
24,2 23,2 4 463,6 60,6 2391 5,4 1,60 173,21
30,2 29,2 5 488,2 68,0 2837 5,7 1,60 176,04
36,2 35,2 6 512,9 80,5 3506 6,2 1,60 168,09
42,2 41,2 7 526,0 84,5 3813 6,3 1,60 177,23
48,2 47,2 8 539,2 88,4 4143 6,5 1,60 174.88
51,2 50,2 8,5 552,3 97,3 4674 6,8 1,60 172,18
Tower section Length 6,0 m Weight 2,4 t Bottom 2 bolts M48
Tower height = Foundation anchor 0,2 m + Tower section

These loadings are valid for free slewing crane out of service.
Slewing Moment M S = 350 kNm.

Calculation of the foundation plate: NT= NC+NF N F = L² * h * 24


MT = MC + H * h

First condition: Eccentricity e = MT / N T < 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. For further
information on tower erection please see original operating manual from tower
manufacturer.

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Page 13 / 24 JT152.8
Chapter 2 Technical Data

Crane on foundation anchors

2.2.2 Foundation loadings for Jib 45,0 m - 60,0 m

Tower Hook Tower Foundation loadings Foundation plate


height height no. NC H MC l h P Ground
m m kN kN kNm m m kN / m²
18,2 17,2 3 465,1 53,3 1950 5,0 1,60 177,26
24,2 23,2 4 489,8 62,1 2370 5,4 1,60 170,42
30,2 29,2 5 514,5 69,5 2828 5,7 1,60 174,36
36,2 35,2 6 539,2 82,2 3519 6,1 1,60 179,94
42,2 41,2 7 552,3 86,2 3835 6,3 1,60 177,66
48,2 47,2 8 565,4 90,1 4175 6,5 1,60 175,89
51,2 50,2 8,5 578,5 99,0 4723 6,8 1,60 173,99

Tower section Length 6,0 m Weight 2,4 t Bottom 2 bolts M48


Tower height = Foundation anchor 0,2 m + Tower section

These loadings are valid for free slewing crane out of service.
Slewing Moment M S = 350 kNm.

Calculation of the foundation plate: NT= NC+NF N F = L² * h * 24


MT = MC + H * h

First condition: Eccentricity e = MT / N T < 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. For further
information on tower erection please see original operating manual from tower
manufacturer.

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Page 14 / 24 JT152.8
Chapter 2 Technical Data

2.2.3 Foundation anchors FH 2.2

Max. height deviation of all foundation anchors is 0,75mm.

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Page 15 / 24 JT152.8
Chapter 2 Technical Data

2.2.4 Foundation anchors FH 2.4

Max. height deviation of all foundation anchors is 0,75mm.

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Page 16 / 24 JT152.8
Chapter 2 Technical Data

2.2.5 Conditions with use of telescopic cage

When using a climbing cage the max. free-standing tower height must be
reduced accordingly. This rule applies to both situations, crane on foundation
anchors or crane on foundation cross/undercarriage.

More information on request.

Crane on foundation anchors:

Crane on foundation cross/undercarriage:

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Page 17 / 24 JT152.8
Chapter 2 Technical Data

2.3 Crane on foundation cross – stationary FC4.6


Foundation blocks must always be installed as part of the ballast. In case that no
foundation blocks are installed the total ballast must be increased by 10,0 tons!

2.3.1 Ballast configuration

Possible hook heights without telescopic cage:

No. No. of ballast blocks total


of Foundation Base Standard Ballast
towers 2.5t 5.0t 5.0t 2.5t t
3 4 4 2 ‐ 40
4 4 4 2 2 45
5 4 4 6 ‐ 60
6 4 4 8 ‐ 70
7 4 4 12 ‐ 90

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Page 18 / 24 JT152.8
Chapter 2 Technical Data

2.3.2 Corner determination and jib position

2.3.3 Corner pressures

Jib lengths 30,0 m - 40,0 m

No. IN service * OUT of service * Total


of Corner Horiz. Corner Horiz.
towers A B C D H MS A B C D H t
3 0 208 504 208 21,1 350 228 219 210 219 65,1 40
4 0 222 550 222 23,2 350 183 228 274 228 75,9 45
5 0 283 603 283 25,4 350 146 266 385 266 88,2 60
6 0 314 665 314 27,5 350 110 309 509 309 97,4 70
7 10 379 749 379 29,7 350 42 366 689 366 114,0 90
* all data in kN, kNm

Jib lengths 45,0 m - 60,0 m

No. IN service * OUT of service * Total


of Corner Horiz. Corner Horiz.
towers A B C D H MS A B C D H t
3 22 243 463 243 21,8 350 204 226 249 226 67,4 40
4 5 249 493 249 23,9 350 140 233 325 233 80,2 40
5 21 293 564 293 26,1 350 92 260 429 260 91,2 55
6 33 336 640 336 28,3 350 50 307 565 307 100,9 70
7 51 392 733 392 30,4 350 0 340 777 340 117,7 90
* all data in kN, kNm

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Page 19 / 24 JT152.8
Chapter 2 Technical Data

2.3.4 Foundation block 2,5 t

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Page 20 / 24 JT152.8
Chapter 2 Technical Data

2.3.5 Base block 5,0 t

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Page 21 / 24 JT152.8
Chapter 2 Technical Data

2.3.6 Standard block 5,0 t

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Page 22 / 24 JT152.8
Chapter 2 Technical Data

2.3.7 Standard block 2,5 t

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Page 23 / 24 JT152.8
Chapter 2 Technical Data

2.4 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 observed.
As for 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.

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Page 24 / 24 JT152.8
Chapter 2 Technical Data

2.5 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.

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Page 1 / 9 JT152.8
Chapter 3 General instructions

3 General instructions for assembly

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  Prohibited crane moves 6 
3.8  Assembly and disassembly advice 7 
3.9  Safety precautions 7 
3.10  Hand signals 8 
3.11  Warning signs 9 

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Page 2 / 9 JT152.8
Chapter 3 General instructions

3.1 Introduction

The responsibility for the preparation of the crane building yard rests entirely with the crane
operator. Any clearing, levelling, 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 crane operator 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 crane operator 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 out of service, its free slewing
does not 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 5,0 m from the
slewing unit of the crane.

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

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Page 3 / 9 JT152.8
Chapter 3 General instructions

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 they 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 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 out of service.

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Page 4 / 9 JT152.8
Chapter 3 General instructions

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 manoeuvring 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) the mobile crane is suitable for the work to be carried out;

g) 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.

For information on the weights of the crane components please refer to Chapter 4
[Assembly].

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Page 5 / 9 JT152.8
Chapter 3 General instructions

3.6 General instruction for crane operator and assembly team

The crane must be used by skilled crane operator with licence only.

The operator is authorized to carry out only those operations described herein observing
the relative instructions.

As the crane can perform more than one movement at a time, it is up to 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 he is not able to follow the trajectory he must take precautions; in particular, he must be
assisted by other people who, with audio and/or hand signals, provide him with all the
information necessary to conduct the work safely.

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 recommended by the manufacturer plays a
prominent part in the correct use of the crane.

Any material necessary for the building yard, such as buckets, belts etc. and belonging to
the operator 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.

For reference on the wind speeds during the assembly please see Chapter 4 [Assembly].

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Page 6 / 9 JT152.8
Chapter 3 General instructions

3.7 Prohibited crane moves

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Page 7 / 9 JT152.8
Chapter 3 General instructions

3.8 Assembly and disassembly advice

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

Crane operators 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 crane assembly and disassembly at least three skilled technicians are
needed: two in charge of the overhead assembly, one for the co-ordination of
operations on the ground.

3.9 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.

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Page 8 / 9 JT152.8
Chapter 3 General instructions

3.10 Hand signals


Supervisor must explain the hand signals to his technicians.

Danger Horizontal distance

Start Moving to the Left

Moving to the right


Stop

End Lifting

Vertical distance Lowering

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Page 9 / 9 JT152.8
Chapter 3 General instructions

3.11 Warning signs


If possible the supervisor shall post the mandatory and warning signs when the crane is
present on the building site.

Caution: Suspended loads No passage

No passage or standing within


Safety helmet the crane’s radius of action.

Do not remove protective


Safety belt And safety devices

Use by unauthorized
Protective gloves Personnel forbidden

Protective shoes Do not work on moving parts

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Page 1 / 22 JT152.8
Chapter 4 Assembly

4 Assembly
4.1  General assembly information 2 
4.2  General data - Tower TH 15.2 10 
4.3  Assembly of fixing plates 11 
4.4  Assembly of tower TH15.2 11 
4.5  Assembly of turntable, slewing support and slewing unit 12 
4.6  Preassembly of slewing support 12 
4.7  Preassembly of turntable 13 
4.8  Assembly of jib section 1 13 
4.9  Preassembly jib section 1 14 
4.10  Preassembly of hoist rope Ø12mm 15 
4.11  Preassembly of trolley ropes Ø8mm 15 
4.12  Assembly of counter jib 1 16 
4.13  Preassembly counter jib 1 16 
4.14  Assembly of counter weight 17 
4.15  Preassembly of jib - 30,0m 17 
4.16  Preassembly of jib - 35,0m 17 
4.17  Preassembly of jib - 40,0m 17 
4.18  Preassembly of jib - 45,0m 18 
4.19  Preassembly of jib - 50,0m 18 
4.20  Preassembly of jib - 55,0m 18 
4.21  Preassembly of jib - 60,0m 18 
4.22  Reeving of hoist rope 19 
4.23  Reeving of trolley rope 19 
4.24  Assembly of jib 30,0m - 45,0m 20 
4.25  Assembly of jib 50,0m - 60,0m 21 
4.26  Assembly of remaining counterweight 22 
4.27  General instructions for crane disassembly 22 

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Page 2 / 22 JT152.8
Chapter 4 Assembly

4.1 General assembly information


4.1.1 Bolt connections on tower crane

Particularly bolt connections with high-strength pretension.


(HV bolt connections)

General information

There are numerous bolt connections on a tower crane. It is their task to connect crane
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

Definition
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 drops down.

Bolt connections with high-strength pretension

Definition
A high-strength pretension bolt connection consists 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
• Drive units such as slewing, hoist or Iuffing units

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Chapter 4 Assembly

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:

Furthermore the bolts must be marked with a sign of origin of the bolt manufacturer.
Normally this sign is placed close to the property class stamp example given in illustration
below:

4.1.4 Nuts

All nuts must be identified according to international standards ISO 898 part 2. Its property
class must be indicated either on the support surface or impressed in a key surface, e.g. 8,
10 or 12.

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 list them all 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.

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Chapter 4 Assembly

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 are 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

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 using washers supplied by
JOST Cranes. 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 manufacturer’s 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 and nut, the seat of the nut
on the bolt and the surface of the bolt shaft to the bolt head support.

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Chapter 4 Assembly

Damaged bolts or nuts must never be used. Bolts with corrosion on shaft and in
their thread as well 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 disulphide
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.

Note!

If the prescribed starting torque is applied on the bolt head, please also lubricate 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.

However, this is 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 fulfil 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 and
thus the pretension achieved.

A torque which is too high or too low 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 consulting the abovementioned table, please bear in mind that the quality classes
as per ISO 898 part 1 and part 2 were used as basis.

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Chapter 4 Assembly

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.

With such multipliers torques up to 9500 Nm (950 mkg) can be achieved.

These torque wrenches must be checked from time to time and have to be adjusted if
necessary.

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

A further possibility is to apply required torque using a hydraulic torque wrench.

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

4.1.8 Inspection of installed bolt connections

The necessity to carry out inspections

Any bolt connection can loosen up.

This is also the case for HV-bolt collections. If these high-strength pretensioned bolt
connections loosen up, this may lead to complete or partial loss of the pretension. In case
the pretension gets completely or partially lost, this can lead 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.

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Chapter 4 Assembly

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 completion of first
erection at least. This inspection must be carried out using the same torque wrench or
multiplier.

The nut (or bolt) is then re-tensioned 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 re-tension the bolts, the connection must be loosened up completely and
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 least 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 lubricated again, reinserted and tensioned to prescribed
torque.

Visual inspections

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

Replacement of bolt connecting elements

If on any connecting level, which means anywhere where crane parts are connected to
each other (e.g. tower sections, roller bearing slewing ring) broken bolts or bolts with
incipient cracks 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.

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Chapter 4 Assembly

Bolt connections

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

4.1.9 Table 1: Starting torques

4.1.10 Table 2: Wrench sizes

Wrench sizes across flats “s”

Bolts as per DIN 6914 and their mating nuts according DIN 6915 have a bigger wrench size
across flats than bolts as per DIN 931 and their mating nuts according DIN 934.

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Chapter 4 Assembly

The wrench sizes across flats "s" are listed in the table below:

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Chapter 4 Assembly

4.2 General data - Tower TH 15.2

4 Jib section 1,
Hoist unit, Trolley unit
Trolley, Hook block
3 Turntable
Slewing support CACON, Ropes
Slewing unit
1 Installation of 2 Tower section
fixing anchors TH 15.2

5 Counter jib 6 Counter jib ballast

7 Remaining Jib sections


Jib 30,0 35,0 40,0 45,0 50,0 55,0 60,0
t 4,17 4,72 5,18 5,55 5,84 6,09 6,29

8 Adjustment of safety devices

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Chapter 4 Assembly

4.3 Assembly of
fixing plates
The 4 fixing anchors
must be connected
with tower section or
jig frame during the
installation into the
foundation plate.

Max.height deviation
of all fixing plates is
0,75 mm.

4.4 Assembly of
tower TH15.2
- Install the tower
section TH15.2
- Connect with bolts
& nuts M48
- Tighten with torque
moment 2000 Nm
- Install the erection
platform or climbing
cage.

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Chapter 4 Assembly

4.5 Assembly of
turntable,
slewing
support and
slewing unit
When installing the
turntable, take care
of position of holes
for connection of
slewing support to
tower section.

4.6 Preassembly
of slewing
support
*Connect the ladder
only after lifting of
complete turntable.

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Chapter 4 Assembly

4.7 Preassembly
of turntable
When installing the
turntable, take care
of position of holes
for connection of
slewing support to
tower section.

4.8 Assembly of
jib section 1

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Chapter 4 Assembly

4.9 Preassembly
jib section 1
• Leg
• Trolley
• Hoist winch
• Trolley winch
• Platform +
CACON35

• Platforms
• Railings

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Chapter 4 Assembly

4.10 Preassembly
of hoist rope
Ø12mm

4.11 Preassembly
of trolley
ropes Ø8mm

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Chapter 4 Assembly

4.12 Assembly of
counter jib 1

4.13 Preassembly
counter jib 1

1 1

1 2

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Chapter 4 Assembly

4.14 Assembly of
counter
weight
Install one counter
weight block 2,8t or
1,8t into last position.

See Chapter 2 -
[Technical data]

4.15 Preassembly
of jib - 30,0m
11 2 3

4.16 Preassembly
of jib - 35,0m
11 2 3 4

4.17 Preassembly
of jib - 40,0m
11 2 3 4 5

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Chapter 4 Assembly

4.18 Preassembly of jib - 45,0m

11 2 3 4 5 6

4.19 Preassembly of jib - 50,0m

11 2 3 4 5 6 7

4.20 Preassembly of jib - 55,0m

11 2 3 4 5 6 7 8

4.21 Preassembly of jib - 60,0m

11 2 3 4 5 6 7 8 9

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Chapter 4 Assembly

4.22 Reeving of hoist rope

4.23 Reeving of trolley rope

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Chapter 4 Assembly

4.24 Assembly of jib 30,0m - 45,0m

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Chapter 4 Assembly

4.25 Assembly of jib 50,0m - 60,0m

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Chapter 4 Assembly

4.26 Assembly of remaining counterweight

Install additional counter-weights according to the jib length and hoist winch. Please see
Chapter 2 [Technical data].

Installation of electrical cable connections


For installation of electrical cable connections and safety devices according to the jib
length and hoist winch, please see Chapter 2 [Technical data].

Adjustment of safety devices


Adjust safety devices according to the jib length and hoist winch. Please see Chapter 2
[Technical data].

4.27 General instructions for crane disassembly


• Establish the place on the ground, where the crane parts are to be stored.
• Ensure that there are no electric cables or other systems which could interfere with
disassembly of crane.
• Check that the mobile crane can take off the weights. See Chapter 4.2.
• The mobile crane operator is fully responsible for the slinging and hoisting of the loads.
• For safe dismantling of long parts such as jib or counter jib, use hemp rope.
• Max. wind speed during disassembly: 14 m/s (50 km/h).

Disassembly of crane

Before dismantling of the crane secure the disassembly area and prepare the
crane for disassembly.

• Loosen the electric cables.


• Dismantle the counter weights - one block must remain on the counter jib.
• Remove pinholder from top to bottom side (see pictures on the right).
• Dismantle the jib.
• Dismantle the counter jib.
• Dismantle the 1st jib and counter jib section 1.
• Dismantle the turntable.
• Dismantle the telescopic cage.
• Dismantle the tower.

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Chapter 5 Safety devices

5 Safety devices

5.1  General 2 
5.2  Audible warnings 2 
5.2.1  Acoustic signals as a warning to the crane operator 2 
5.2.2  Acoustic signals as a warning to other people 2 
5.2.3  Acoustic signals as a warning to other people 2 
5.3  Position of safety devices 3 
5.4  Safety switches on control lever 4 
5.4.1 Automatically zero positioning 4
5.4.2 Forced zero positioning 4
5.5  Dead-man switch 4 
5.6  Hoist limit switch 5 
5.7  Trolley travel limit switch 6 
5.8  Load moment limiter and Load limiter 7 
5.9  Adjusting of load lifting diagram 7 
5.9.1 Adjusting the limit switch 7
5.9.2 Testing the settings 8
5.9.3 Load limiter 8
5.10  Load test 8 
5.11  Key switch operation/mounting 9 
5.12  Trolley travel blocking 9 
5.13  Rope retaining brackets 9 
5.14  Load hook 9 
5.15  Slewing unit 10 
5.15.1 Countering protection 10
5.15.2  Weathervane mode 10 

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Chapter 5 Safety devices

5.1 General
JOST cranes are 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 endangers the life of all personnel on the building site.

During crane operation, the 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 the correct functioning of the limit switches should be checked.

5.2 Audible warnings


In the case of dangerous situations on the crane audible alarms are started notifying the
crane operator and other persons within the crane operating area. In addition, the crane
operator can manually start a warning signal to alert others of the danger.

The acoustic warning signals can be divided into three


groups:

1) Acoustic signals as a warning to the crane operator


(automatically triggered by the crane controls)
2) Acoustic signals as a warning to other people
(automatically triggered by the crane controls)
3) Acoustic signals as a warning to other people
(triggered by the crane operator)

5.2.1 Acoustic signals as a warning to the crane operator


(automatically triggered by the crane controls)

Already at powering up the control voltage by means of an illuminated push button on


the control panel (see drawing), the crane operator is notified by a horn signal that the
crane is ready to work. In the case of an overload error, when the load limiter or the load
moment limiter are triggered, an alarm goes off and at the same time some control
functions are blocked (see Chapter 5.8 [Load limiter and Load moment limiter]).

5.2.2 Acoustic signals as a warning to other people


(automatically triggered by the crane controls)

When the crane is equipped with a rail chassis, an alarm is set off at the bottom of the
tower as soon as the control lever for the "crane driving forward" or "crane driving
backwards" is pushed. Thus an unnoticed approach to people standing on the rails can
be prevented.

5.2.3 Acoustic signals as a warning to other people


(triggered by the crane operator)

The crane driver can trigger the alarm horn (12) on the crane also by himself, e.g. to warn
persons at the site of dangerous situations. This requires that the illuminated push button
"Power ON + horn" on the control panel is pressed (see drawing).

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Chapter 5 Safety devices

5.3 Position of safety devices

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Chapter 5 Safety devices

5.4 Safety switches on control lever

Control lever switches:

A Control lever for travel unit


and hoist unit
10 Emergency switch
11 Crane ON
12 Horn
5 Dead-man

The joystick (control lever) on JOST-tower cranes is equipped with two safety circuits:

1. Automatically zero positioning

2. Forced zero positioning

5.4.1 Automatically zero positioning

Both control levers on the control panel support an automatic reset to zero. As soon as an
activated control lever is released, it jumps back to the zero position and the
corresponding drive will shut down. This guarantees that no active drive on the crane
continues running accidentally.

5.4.2 Forced zero positioning

The button "Crane ON" is arrested by zero contacts on the control lever. The main
contactor can be switched on only if all the control levers are in neutral position. In this
way no drive can be switched on accidentally.

5.5 Dead-man switch

Both control levers in operator’s cabin are spring loaded and will return to zero position
automatically. The right hand side control level is equipped with a dead-man switch (5).
The operator has to push down the control lever to operate the crane. When releasing the
dead-man all crane functions will stop.

Dead-man switch can be by-passed on fixed operators control stands when levers are
spring loaded to return to zero automatically.

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Chapter 5 Safety devices

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 setting 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; two rope windings (safety windings) must then 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.

Screw for adjustment


of cam disks

Note: Incorrect setting of the limit switch can result in serious personal injuries and
material damage. Therefore, adjustments may only be carried out by trained
personnel or specially trained mechanics.
After the switching from to 2- to 4-fall operation (or vice versa), the setting of the
limit switch has to be checked and corrected, if necessary.

Checking the set switching points

In order to check the set switching points the empty hook has to be driven to the top end
position at the highest speed possible a few times. The same manoeuvre has to be carried
out for the low end position, but for safety reasons at a moderate speed only, because
there is no lower limit switch. If the setting of the hoist limit switch is not correct, the
corresponding cams have to be adjusted accordingly.

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Chapter 5 Safety devices

5.7 Trolley travel limit switch


Trolley travel is limited in the outer and inner position
by a gear cam limit switch. The switch is actuated by
a sprocket gear from the trolley drum.

• Adjust the trolley travel limit switch by turning the


trip cam.
The trolley travel limit switch must be adjusted in
a way that the trolley travelling at full speed
comes to a standstill before reaching the buffers.

Adjustment:

• Move the trolley until it almost reaches (20-40cm distance) the mechanical stop at the
end of jib by pressing the function "Trolley travel forward" at the respective control levers
of the control unit. The person in the trolley cage has to notify the crane operator by
hand signals when the exact position has been reached.
• Adjust the rearmost end position of the trolley in the limit switch of the cams.
• Move the trolley back by about 1.5 meters by pressing the function "Trolley travel
backward" on the respective control lever. The person in the trolley cage has to notify
the crane operator by hand signals when the exact position has been reached.
• Adjust the pre-end position of the trolley in the limit switch of the cams.
• Move the trolley until it almost reaches (20-40cm distance) the mechanical stop at the
front of jib by pressing the function "Trolley travel backward" at the respective control
levers of the control unit. The person in the trolley cage has to notify the crane operator
by hand signals when the exact position has been reached.
• Adjust the foremost end position of the trolley in the limit switch of the cams.
• Move the trolley forward by about 1.5 meters by pressing the function "Trolley travel
forward" on the respective control lever. The person in the trolley cage has to notify the
crane operator by hand signals when the exact position has been reached.
• Adjust the pre-starting position of the trolley in the limit switch of the cams.

Note: Incorrect setting of the trolley limit switch can result in serious personal
injuries and material damage. Therefore, adjustments may only be carried out by
trained personnel or specially trained mechanics.

Checking the set switching points

In order to check the set switching points the empty trolley has to be driven from the
foremost to the rearmost end position at the highest speed possible a few times. If the
setting of the trolley limit switch is not correct, the corresponding cams have to be
adjusted accordingly.

Adjustment of display

Once the trolley limits have been set the jib reach parameters for the PLC must be
adjusted in the display (see Chapter 6.13.2.4 [Trolley parameters]).

Note: In case the Trolley parameters are not set, the PLC will not work correctly.
Incorrect setting of the Trolley parameters can result in serious personal injuries
and material damage. Please carefully observe the correct sequence for the input
of values in order to ensure a proper setting of the crane.

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Chapter 5 Safety devices

5.8 Load moment limiter and Load limiter

5.9 Adjusting of load lifting diagram

The load moment limiter is located on jib A1


directly above the ascent to the jib.
The allowable load moment of a crane may
theoretically be exceeded in two different
ways:
• Lifting of a load which is too heavy for the
used jib radius.
• Moving of trolley to a jib radius that is not
suited for the suspended load.

In order to not jeopardize the stability of the


crane the load moment limiter is activated
when the maximum load moment is
reached. Thus, the functions "Hoist" and
"Trolley forward" will be blocked.

5.9.1 Adjusting the limit switch

In order to set the limit switch, the key switch (MOUNTING) has to be set to "I" first (see
display of assembly switch) and the cover must be removed.

Note: The correct setting of the load moment limiter can only occur when the
Load parameters (see Chapter 6.13.2.8 [Load parameters]) are set and the Trolley
parameters (see Chapter 6.13.2.4 [Trolley parameters]) have been entered
correctly.

• Move the trolley to the outmost jib position.


• Attach the test load (minimum: tip load, maximum: tip load + 10%) until the display
shows a load moment of 105%.
• Press the button for "Hoisting" at the control lever.

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Chapter 5 Safety devices

• The switch must be set using the thumbscrew in a way that the function "Hoisting" is
disabled as soon as the suspended load has exceeded the maximum load.
• Fix the appropriate bolt and lock it with the nut.

5.9.2 Testing the settings

• The functions “Hoisting” and “Trolley forward” have to switch off automatically when
100% of the max. Load moment have been reached (with PLC control => Mounting
switch set to „0“).
• Move the load to 100% of the allowable working load and radius; observe the
respective load chart. The functions "Load up" and "Trolley forward" have to be
switched off by means of the limit switch automatically.
• The horn must be activated. The display shows the message "Load moment error".

5.9.3 Load limiter

The setting of the Load limiter is done by means of the display as described in Chapter
6.13.2.8 [Load parameters]. Setting of limit switches is not required in this mode.

5.10 Load test

Apart from the annual check-ups as prescribed in the regulation for prevention of
accidents and after any modification of the crane, the load moment limiter must also 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.

Note: despite the mandatory annual review stipulated in the accident prevention
regulations (BGV D6 - Cranes) the load moment limiter has to be checked after
each modification and generally as needed. Modifications to the crane are, for
example,

• Jib extensions
• changes to reeving of ropes or
• increase in tower height.

The load moment limiter has to be checked in case of

• frequent activity,
• longer standstill of the crane,
• extreme weather conditions or
• variations in temperature.

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Chapter 5 Safety devices

5.11 Key switch operation/mounting

The key switch operation/mounting is positioned in the crane cabin (CACON) near the
transformer.
It is permitted to switch the key switch from operation to erection only when erection and
maintenance work is being carried out or hoist rope reeving is changed.

Upon having completed crane mounting or the necessary work, the key switch
must under all circumstances be switched back to “operation” position.

All safety equipment (load moment limiter, hoist limit switch, angle sensor) are out of
service when the key switch is set to MOUNTING “I”.

The electronic equipment for the load limiter is installed in the CACON. The signals from
the load measuring pin and the angle sensor (JL and JTL series only) are processed
automatically by the crane control system. For safety reasons the inclination sensor and
the angle sensor are designed to be redundant (fail safe -> 2 circuits).

It is very important that the jib length set in the electronics corresponds exactly to
the jib length actually mounted on the crane.

In case of modifications during erection or changes of jib length, the electronic devices
must be adjusted as per Chapter 6.13 [Electrical Adjustment].

All security devices (load limiter, hoist limit switch, inclination sensor) are out of
service, when the key switch is switched to MOUNTING “I”.

5.12 Trolley travel blocking


Each JOST crane trolley by default contains a travel blocking device. Should the trolley
rope break, a lever is moved at 90° until stroke. This lever protrudes above the trolley and
engages in the lower jib structure thus causing the trolley to stop immediately.

5.13 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.

5.14 Load hook

In accordance with the Accident Prevention Rules, load hooks 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 DIN15405 (sheet
1) Standards: Load hook for hoisting equipment – Supervision of forged load hooks.

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Page 10 / 10 JT152.8
Chapter 5 Safety devices

5.15 Slewing unit

5.15.1 Countering protection

• Countering of the slewing direction is automatically controlled by incremental contact


which is installed in the slewing motor. The motor is released o move in the opposite
direction only after the rotation speed has dropped to approx. 10% of the rated speed.

• At inversion of direction the breaking is done through breaking steps of the eddy
current break.

5.15.2 Weathervane mode

In order for the crane in out-of-service mode to freely slew in wind direction the slewing
brakes have to be released.

Steps:

1) Turn the knurled nut on the slewing brake clockwise until it stops.

2) Now the crane is in Weathervane mode.

In order to put the crane back into operation, the abovementioned steps have to be
conducted in reverse sequence:

1) Turn the knurled nut on the slewing brake counter-clockwise until a gap of 5mm is
reached between the lid and the knurled nut.

2) The Weathervane mode is deactivated again.

Note: The crane must not be operated with the slewing brakes released. This can
result in serious personal injuries and material damage, because the slewing of
the crane cannot be stopped in this mode.

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Page 1 / 42 JT152.8
Chapter 6 Crane operation

6 Crane operation

6.1  Prior to initial crane operation 2 


6.2  Taking the crane into operation 2 
6.3  Crane control desk 3 
6.4  Control of hoist unit 4 
6.5  Control of trolley unit 5 
6.6  Control of slewing unit 6 
6.7  Instructions for crane operation 7 
6.8  Taking the crane out of operation 8 
6.9  Taking the crane out of operation when a gale is approaching 9 
6.10  Changing of hoist rope reeving from 4-fall to 2-fall operation 11 
6.11  Changing of hoist rope reeving from 2-fall to 4-fall operation 12 
6.12  Digital indication outreach 13 
6.13  Electrical Adjustment 14 
6.13.1  Starting the system 14 
6.13.2  Installing the system 21 
6.13.3  System settings 28 
6.13.4  Log files (optional module) 33 
6.13.5  WAZ/ACS settings (optional module) 35 

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Page 2 / 42 JT152.8
Chapter 6 Crane 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.

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Page 3 / 42 JT152.8
Chapter 6 Crane operation

Crane operation

6.3 Crane control desk


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 operator’s cabin, must be
switched ON and the slewing unit motors must be put back to operating position (neutral
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-setback.
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 running; otherwise the crane switch will switch off.

The signal horn can be worked from the push-button (12) HORN. Optionally the indicator
lamp of the HORN button can be installed and thus activated to indicate when the brake
lining is used up.

The windscreen wiper is switched on by the switch positioned on the left side of the control
lever.

The turn-switch (5) is used to change from 2-fall to 4-fall operation and vice versa. When
the ropes are set to 4-fall the turn-switch must also be set to 4-fall operation. Accordingly
when the ropes are set to 2-fall the turn-switch must be set to 2-fall operation.

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- Wiper switch
5- Button to switch from 2-fall to 4-fall and vv.

10 - Mushroom type strike button EMERGENCY-OFF


11 - Illuminated push button CRANE-ON
12 - Push button horn with lamp for brake lining hoist

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Page 4 / 42 JT152.8
Chapter 6 Crane operation

6.4 Control of hoist unit


The hoist unit is driven by an asynchronous motor with frequency inverter and is equipped
with a retainer brake. The control is accomplished over 4 switching steps in the lowering
direction and 4 switching steps in hoisting direction. Make sure you switch smoothly
through these steps.

The motor is powered by the frequency inverter until the torque for holding of the load is
reached. Then the retainer brake opens up. When the brake is released the inverter
applies the according rotation frequency to the motor.

Within Steps 1, 2 and 3 the speed is always constant independent of the load.

Step 4 is designed to automatically apply the speed according to the permissible load.
When Step 4 is switched on the inverter increases the rotation frequency until the
permissible speed for max. load is reached. Then the inverter measures the actual load for
a certain time period. After having measured the actual load the inverter applies the
speed according to the corresponding load.

To stop the hoist unit again you have to conduct the above steps in reversed sequence.

Right side

Optional module:

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 and 4 and then it is
only possible to drive in the Steps 1 and 2.

a – lowering
b – lifting
c – dead-man

When the control lever is returned from lowering or hoisting to zero position, Step
1 is activated automatically for a short period. For the sake of saving the retainer
brake, the brake sets after the electrical braking of Step 1 is completed.

The top and bottom end position of the hook block is monitored by a gear limit switch with
cams. There is also a prelimit switch, which will switch off the movement a few meters
below max. lifting height in Steps 3 and 4. Step 2 is then the highest speed that the hoist
movement will have up to max. permissible lifting height.

The maximum load limiter and a special load moment limiter cut off the upward
movement when the load exceeds the safe load limit depending of the outreach. Then it
is only possible to set down the load.

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Page 5 / 42 JT152.8
Chapter 6 Crane operation

6.5 Control of trolley unit


The trolley travel unit is driven by an asynchronous motor with frequency inverter.

The trolley travel unit is operated by way of the left hand control lever (B) and in 4 steps for
both directions. Make sure you switch smoothly through these steps.

The motor is powered by the frequency inverter until the torque for keeping the trolley in its
current position is reached. Then the retainer brake opens up. When the brake is released
the inverter applies the according rotation frequency to the motor.

Within steps 1, 2, 3 and 4 the speed is always constant.

To stop the trolley unit again you have to conduct the above steps in reversed sequence.

Each of the end positions is limited by way of a


gear limit switch. Before one of the end Left side
positions is reached a prelimit switch will be
activated, which will switch back to step 1 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 limit switch.

If the trolley is driven outwards with load


hanging in the hook, the load momentum
limiter will be activated as soon as permissible.
Then the load is either set down or moved
inwards again.

d – trolley forwards
e – trolley reverse
f – slewing brake

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Chapter 6 Crane operation

6.6 Control of slewing unit


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 Chapter 5 [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 braked over 3
steps. The braking effect is increased from step 1 to step 2 and 3.

Left side

The crane operator must always take care that


the braking action is gentle in order to avoid
any impacts and oscillating of the load.

If strong winds threaten to drift the jib away, the


retaining brake can be activated by pushing
the button in the left hand control lever.

This is only permitted as long as the slewing unit f – Slewing brake


is near to a standstill and the control lever is in g – slewing left
zero position. h – slewing right

When the slewing unit is started, the retaining


brake will open automatically.

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Page 7 / 42 JT152.8
Chapter 6 Crane operation

6.7 Instructions for crane operation

Please always observe the regulations for prevention of accidents (see Chapter
5 [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 and not
suitable for crane operation.

Important ! The following is forbidden:

1) Any pulling askew when lifting, travelling or slewing the crane.

2) To tear loose loads that are stuck.

3) Any transport of personnel.

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

If the crane operator feels that the crane 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.

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Page 8 / 42 JT152.8
Chapter 6 Crane operation

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 to out-of-service position.


Slewing
• Pull up the empty hook block until motor
it is almost at the 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 end
position (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 seat 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 leaks.

• Switch off the power connection on the site power distributor.

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Page 9 / 42 JT152.8
Chapter 6 Crane operation

6.9 Taking the crane out of operation when a gale is approaching

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

The dynamic pressure which represents the top limit can only be considered to
correspond to the above calculated dynamic pressure provided the crane 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 must be pulled up.

• Lift the jib to 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 calm 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 accomplished by


installing wind measuring devices, such devices should generally be installed at the
highest point of the crane 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 note 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.

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Page 10 / 42 JT152.8
Chapter 6 Crane operation

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 carrying 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/m²

Example:

t = 3 min. time for completion 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 of
operation already at a wind
speed of 55 km/h.

Do not forget to secure the crane!

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Page 11 / 42 JT152.8
Chapter 6 Crane operation

6.10 Changing of hoist rope reeving


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

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

-loosen the hoist rope


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

-insert pin 3 into block 1


and secure it with clip 4
1-lower block
2
2-upper block
1 3-pin 30
4-clip 6,3
3,4 3,4

-pull up the upper block 2


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

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

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Page 12 / 42 JT152.8
Chapter 6 Crane operation

6.11 Changing of hoist rope reeving


from 2-fall to 4-fall operation

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

-lower block 1 and


set it to the ground -lower block 2

2
1

-take out pin 3


-carefully lower block 2
on the block 1
1-lower block
2
2-upper block
1 3-pin 30
4-clip 6,3
3,4 3

-connect blocks 1 and 2 with pin 3 -lift both blocks


and secure with clip 4

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

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Page 13 / 42 JT152.8
Chapter 6 Crane operation

6.12 Digital indication outreach


Short adjustment introduction

Every time the crane is erected or retrofit, the following points have to be observed.

1) Turn the potentiometer, located in the trolley limit switch, in a way that the indicated
value runs to a smaller value. This must be done until the value suddenly jumps high.
In the following turn back the potentiometer approximately 5mm until a smaller figure
is visible again. Indicated minus values are not to be observed.

2) Get the trolley to a fixed reference point “inside” 3m to 4m radius until the trolley has
about 1m distance from the buffers. The outreach is calculated from the centre of the
tower to the middle of the trolley (for an example see table below).

Example:

Distance centre of tower to buffer = 1.5 m


Distance centre of tower to middle of trolley = 0.83 m

Noted value = 1.5 m + 0.83 m = 2.33 m

3) With the potentiometer signed with Z=0.0 (or N=0.0), which is located in the switch
gearbox in the operators cabin, the indication must be adjusted to 0.0 meter.

4) Afterwards put the trolley in the outside end position. With the potentiometer
A=Amplify (or V=Verstärkung) located in the switch gear box in the operators cabin,
the present indicated value must be adjusted to existing boom length, reduced by
the noted value under point 2) of this description. This is necessary as only the travel of
the trolley is of interest.

For example: The crane has 50m outreach, measured and noted value is 3.5m,
therefore 50m minus 3.5m = 46.5m. This value will be adjusted and the procedure
under point 5) of this description is finished, 50m is indicated on the display.

5) Afterwards put the trolley to the reference point (inside end position) and adjust with
potentiometer Z=0.0 (or N=0.0) with the noted value mentioned under point 2).

6) Please check the indication by driving several times to both end positions. Smaller
corrections, if necessary, are made for outside direction with potentiometer signed
with A or V. For inside corrections the potentiometer signed with Z or N is applicable.
All mentioned under points 4) and 5).

7) When the indicating unit is pre-adjusted (usually in the factory) the adjusting
procedure under point 6) is valid.

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Page 14 / 42 JT152.8
Chapter 6 Crane operation

6.13 Electrical Adjustment

6.13.1 Starting the system

At start of the system this screen will


appear. Click on “Operator Screen” to get
to the main screen.

The main screen will look different for each


crane family.

6.13.1.1 The different main screens


This is the default main screen of the JL
and JTL series.

This is the default main screen of the JT


series.

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Page 15 / 42 JT152.8
Chapter 6 Crane operation

This is the main screen of the JL and JTL


series if the WAZ/ACS module is activated.

This is the main screen of the JT series if the


WAZ/ACS module is activated.

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Page 16 / 42 JT152.8
Chapter 6 Crane operation

6.13.1.2 The 0-Point

If you often need to drive to a certain point which height differs from "0" you can use the
"Set 0" button to set the hook height display to "0".

Drive to the concerning point and click on the "Set 0" button. Now the display shows "0" for
the hook height.

Note: If the WAZ/ACS module is activated there is no "Set 0" button anymore (see previous
page). Instead you can click on the value itself to set the new hook height.

6.13.1.3 Changing the wind speed unit

To change the unit of the wind speed just


click on the NTK logo on the main screen to
open the context menu. Now you can
choose your preferred unit from the
submenu.

There are 3 units available:


• m/s [meter per second]
• km/h [kilometre per hour]
• mph [miles per hour]

6.13.1.4 Changing the language

To change the language (of the device)


you just have to click on the NTK logo on
the main screen to open the context menu.
Now you can choose your preferred
language from the submenu.

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Page 17 / 42 JT152.8
Chapter 6 Crane operation

6.13.1.5 Info & error messages

During runtime the following messages could appear (not all at once):

WRONG CRANE TYPE !


The display settings do not fit to the PLC settings. Either of them is wrong.

Mounting Switch
As soon as the mounting switch is switched on, this message will be displayed on the main
screen.

Loadmoment Error
This message is displayed if the load moment exceeds the allowed maximum load
moment.
This could be caused by a load which is too heavy to be lifted by the crane.
It also could be a momentum (the load multiplied with the horizontal distance of the hoist)
which exceeds the maximum allowed load moment.
This message can be reset by clicking on the NTK logo and choosing "Reset Loadmoment
Error" from the context menu.

LF Emerg. Brake SHUT


If the luffer emergency brake was shut this message appears.

LF Emerg. Brake WORN OUT


This shows that the luffer emergency brake is worn out. That means that the brake shoes
must be replaced.

HS Emerg. Brake SHUT


If the hoisting emergency brake was shut this message appears.

HS Emerg. Brake WORN OUT


This shows that the hoisting emergency brake is worn out. That means that the brake shoes
must be replaced.

Restart PLC!
If this message appears you have to restart the PLC and configure the crane again.

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Page 18 / 42 JT152.8
Chapter 6 Crane operation

Ch1, Ch2, Ch3, and/or Ch4


These are the same channel error messages which are also shown on the error list page.

Oil Temperature
This shows that the temperature of the oil is too high.

Oil Level Down


This shows that the oil level is quite low and should be refilled.

If the WAZ/ACS module is activated there


are some more messages possible.

C1 OFF, C2 OFF, C3 OFF


These messages are showing that the corresponding cranes are switched off or are not
connected.

Connection Lost
Attention: When "Connection Lost" is displayed, it means there is/are no connection(s) to
other cranes.

System Offline
Attention: When "System Offline" is displayed, it means that the system no longer engages
in crane operation. Thus, there is no longer any automatic braking or blocking. The display
continues to work.

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Page 19 / 42 JT152.8
Chapter 6 Crane operation

6.13.1.6 Service info

When having problems it is sometimes necessary to convey some special error numbers or
other information to the support people.

To open the service info page you have to


click on the NTK logo on the main page
and select "Service Info" from the context
menu.

This is the main service info page.

Error list

Here you can see some different error


values. These can be important when
analysing PLC problems.

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Page 20 / 42 JT152.8
Chapter 6 Crane operation

Device info

This page shows some device specific info.

Crane Type: For what type of crane this


device is set up.

PLC Number: Which crane type the PLC is


set up for.

Display Serial: The unique serial number of


the device.

Display Address: The network address of


the device.

Notice: The first two parts of the PLC number have to be the same as the first part of the
crane type (up to the dot).

Connection info

Driver Status: This shows the status (OK/Error)


of the communication driver.
- Serial: used for normal cranes
- TCP/IP: used for WAZ/ACS

Server Address: This is the address of the


WAZ/ACS PLC the device is connected to.

Check codes
These values can be helpful if there are
problems with passwords or serial numbers.

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Page 21 / 42 JT152.8
Chapter 6 Crane operation

6.13.2 Installing the system

To install the system you first have to login


into the system.

Click on the NTK logo on the main page to


open the context menu and choose
"Configuration".

6.13.2.1 Login

Now enter your password and click on the


"Enter" button.

Note: The default password depends on the


crane series:

JL series = “JL123”
JTL series = "JTL123"
JT series = "JT123"
(without quotes)

Now you have to confirm your password.


Put in the password and click on the "Enter"
button.

Note: Here you have to enter your


password backwards!

Examples for the default passwords:

JL series = “321JL”
JTL series = "321LTJ"
JT series = "321TJ"
(without quotes)

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Page 22 / 42 JT152.8
Chapter 6 Crane operation

6.13.2.2 The install screen

IMPORTANT:
1. The installation has to be made in 2-rope-modus!

2. All parameters must be adjusted!

3. The parameters must be adjusted in the given order!

This is the install screen of the JL series.

The install screen of the JTL series differs in


having a Luffer button instead of the Speed
button.

This is the install screen of the JT series.

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Page 23 / 42 JT152.8
Chapter 6 Crane operation

6.13.2.3 Angle parameter


(this applies only to the JL and JTL series)

IMPORTANT:
Before you begin with the calibration of the "Angle Parameter" you must move the jib to
both outside positions/angles (topmost/bottommost). Thereby the mechanical range of
operation of the sensor will be adjusted.

To adjust the "Angle Parameter" just click on


the according button.

At first you have to select the "Jib Length


Type" by clicking on the value and
choosing the correct value from the
context menu.

Now you have to adjust the angle position indicator by the following steps:

1. Move the jib to the minimal (bottom) position/angle, click on the “Data set” value to
open the input box and enter the minimal (actual) position of the jib.

2. Click on the “Set” button for the “Data Min” value to set/save the minimal value.

3. Move the jib to the maximal (top) position/angle, click again on the “Data Set” value
and enter the maximal (actual) position of the jib.

4. Click on the “Set” button for the “Data Max” value to set/save the maximal value.

That’s all for the “Angle Parameter”.

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Chapter 6 Crane operation

6.13.2.4 Trolley parameter


(this applies only to the JT series)

IMPORTANT:
Before you begin with the calibration of the "Trolley Parameter" you must move the trolley
to both outside points (innermost/outermost). Thereby the mechanical range of operation
of the sensor will be adjusted.

To adjust the "Trolley Parameter" just click on


the according button.

At first you have to select the "Jib Length


Type" by clicking on the value and
choosing the correct value from the
context menu.

Now you have to adjust the trolley distance indicator by the following steps:

1. Move the trolley to the minimal (nearby) position, click on the “Data set” value to open
the input box and enter the minimal (actual) position of the trolley.

2. Click on the “Set” button for the “Data Min” value to set/save the minimal value.

3. Move the trolley to the maximal (distant) position, click again on the “Data Set” value
and enter the maximal (actual) position of the trolley.

4. Click on the “Set” button for the “Data Max” value to set/save the maximal value.

That’s all for the “Trolley Parameter”.

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Chapter 6 Crane operation

6.13.2.5 Speed parameter


(this applies only to the JL series)

To adjust the "Speed Parameter" just click


on the according button.

Now you can set up the speed values and


the HLW gain by clicking on the values.

Max Hoisting Speed:


This value is the limit of the hoisting speed.

Max Luffing Speed:


This value is the limit of the luffer speed.

HLW Gain:
This is the correction factor for the horizontal load way.

6.13.2.6 Luffer parameter


(this applies only to the JTL series)

To adjust the "Luffer Parameter" just click on


the according button.

Now you can set up all the limit and prelimit


values by clicking on the values.

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Chapter 6 Crane operation

6.13.2.7 Hook parameter

IMPORTANT:
Before you begin with the calibration of the "Hook Parameter" you must move the hook to
both outside points (topmost/bottommost). Thereby the mechanical range of operation of
the sensor will be adjusted.

To adjust the "Hook Parameter" just click on


the according button.

Now you have to adjust the hook height indicator by the following steps:

1. Move the hook to the minimal position (topmost, shortest rope), click on the “Data set”
value to open the input box and enter the minimal (actual) position of the hook.

2. Click on the “Set” button for the “Data Min” value to set/save the minimal value.

3. Move the hook to the maximal position (bottommost, longest rope), click again on the
“Data Set” value and enter the maximal (actual) position of the hook.

4. Click on the “Set” button for the “Data Max” value to set/save the maximal value.

That’s all for the “Hook Parameter”.

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Chapter 6 Crane operation

6.13.2.8 Load parameter

To adjust the "Load Parameter" just click on


the according button.

Now you have to adjust the load indicator by the following steps:

1. Attach the first (lighter) calibration load to the hook, click on the “Calibration Load”
value to open the input box and enter the actual load value.

2. Click on the “Set” button for the “Data Min” value to set/save the minimal value.

3. Attach the second (heavier) calibration load to the hook, click again on the
“Calibration Load” value and enter the actual load value.

4. Click on the “Set” button for the “Data Max” value to set/save the maximal value.

That’s all for the “Load Parameter”.

6.13.2.9 Switching the modes (75% or 100%)

With the top right button on the main configuration screen you can switch the main mode
of the crane.

A click will switch to 75% mode, the next click switches back to 100% mode.

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Chapter 6 Crane operation

6.13.3 System settings

A click on the "System" button switches to


the system settings (shown at the left).

6.13.3.1 Clock settings

To set up the clock/time just click on the


button "Clock Settings".

Now you can change the date and time


values and save them with a click on the
"Save Time" button.

Note: When this screen is opened it shows


the current date and time. To reload the
actual values (e.g. because you have
changed a wrong value) you have to click
on "Read Time".

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Chapter 6 Crane operation

6.13.3.2 Screen settings

Setting up the screen is only necessary if the touch functionality of the screen does not
work correctly (i.e. you have to click besides a button to hit it).

To set up the screen just click on the


"Screen Settings" button.

Now click on "Calibrate Screen" to open


the stylus properties.

In the stylus properties switch to the tab


"Calibration" (1), click on the "Recalibrate"
button (2), and follow the instructions given
on the screen.

When the recalibration is finished move the


properties window to the left (3) until the
OK button is visible.

Now click the OK button (4).

Notice: The pictures shown at the left are


from a small touch panel. On a big touch
panel the whole properties window is visible
and must not be moved. The OK button will
always be visible.

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Chapter 6 Crane operation

Now you have to save the new calibration


settings. First click on "Save Settings".

Now click on "OK" and wait some seconds.


After the dialog has disappeared the
settings are saved.

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Chapter 6 Crane operation

6.13.3.3 System password

In order to access some special manufacture settings you need a special password. For
this you have to call the support.

First you have to open the system password


screen. There you can see a character
string. Call the support and tell them this
string (beware of uppercase/lowercase).

The support will tell you the password


belonging to the string.

At this point do not hit the back button


anymore.

Click on the "Login" button and enter the


password given by the support.

After clicking on "Enter" you have access to


the special settings.

6.13.3.4 Server address


This setting is available only if the WAZ module is activated. The server address setting is
important for the communication with the WAZ/ACS control unit.

First you have to enter the server address of


the WAZ/ACS control unit. You can find this
number on the type plate inside the unit.

After this you have to "Restart the Project".

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Chapter 6 Crane operation

6.13.3.5 Changing the password

To change the login password just click on


the "Password" button.

First enter the old (current) password and


click on the "Enter" button.

Now enter the new password and click the


"Enter" button again.

Then you should get a message that the


new password was saved.

6.13.3.6 Modules
Modules are optional features. They must be purchased separately and then can be
activated within this screen.

To activate a module you have to click the


"Activate" button, enter the purchased
code and again click the "Enter" button.

Notice: The ACS module needs the WAZ module to be activated.

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Chapter 6 Crane operation

6.13.4 Log files (optional module)

"Log Files" is an optional feature. If it is


activated the button shown at the left is
visible.

This is the main screen of the log files.

Here you can look at the cycles (incl.


runtime), errors (history) and the loads/load
moments (history).

The single features are explained below.

6.13.4.1 Log files features

This screen shows the single movement


cycles of the jib/hook.

Also shown are the runtime and the state


(running/stopped) of the crane.

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Chapter 6 Crane operation

This screen shows a table with the history of


error messages.

This screen shows a table with the history of


the loads and their load moments.

6.13.4.2 Export

With this option you can export all log file data to an USB memory stick. The exported files
are XML files, which can be viewed with the Internet Explorer.

To export the log file data you just have to


plug in the USB memory stick into USB port
and hit the "Export Data" button.

After some seconds you get a confirmation


message. Then you can pull out the USB
memory stick.

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Chapter 6 Crane operation

6.13.5 WAZ/ACS settings (optional module)

"WAZ/ACS" are two optional features,


whereas the ACS module needs the WAZ
module to be activated.

If the WAZ module is activated the button


shown at the left is visible.

This is the main screen of the WAZ/ACS


settings. The single settings are explained
below.

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Chapter 6 Crane operation

6.13.5.1 Crane dimensions

Push the corresponding button to enter the


crane data and to open the page for
crane dimensions.

Crane data can now be entered as follows (clicking on a value will open an input field by
means of which the value can be changed):

Crane Type: Depending on the sensor type, the system automatically detects
whether it is installed in a "topless" or "luffing" crane. The detected type
is displayed for controls (Topless/Luffing).

System: The WAZ system and/or the ACS System can be switched on and/or off.
A tick means that the corresponding system is activated.

Note: When one of the systems is deactivated, all pertinent settings will be
deleted!

Crane Height: The crane height must here be entered (relevant for trolley cranes;
the highest point must always be indicated).

Jib Length Type: Enter the length of the main jib.

Counter Jib: Enter the length of the counter jib.

6.13.5.2 Safety distances

Here you have to enter the prelimits of the


jib/luffer and the slewing.

With the line offset you can control the


thickness of the polygons. It is something
like a security area in front of the line.

The direction control indicator shows "Error"


if the crane (Luffer) moves to the wrong
direction.

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Chapter 6 Crane operation

Learning

The slewing speed values at the top


(current/learned max.) are just test values.

With the next 3 settings you have to teach


the system how long the crane needs to
brake.

The learning happens by the following 3 steps:

1. Angle 1 (Coasting):
Press the first "Set" button, rotate the crane with full speed, and release the joystick. Let the
crane ran out until standstill.

2. Angle 2 (Counter 1):


Press the second "Set" button, rotate the crane with full speed, and brake the crane with
the first counter step. Wait until standstill.

3. Angle 3 (Counter 2):


Press the third "Set" button, rotate the crane with full speed, and brake the crane with the
second counter step. Wait until standstill.

6.13.5.3 Slewing

The direction control indicator shows "Error"


if the crane moves to the wrong direction.

The anti-collision calculation requires a


common 0-point for all cranes in the
system.

Align the crane to a point which is valid for


all cranes and press the “Set 0” button to
save the 0-point.

If only the WAZ system is active, select any


random reference point.

The notes field can be used to enter a comment on the selected zero point.
Finally you have to define the sensor position (inside/outside) and the gear sizes.

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Chapter 6 Crane operation

6.13.5.4 Working area

These settings are only available if the WAZ System is switched on!

Use the corresponding button to open the


page for the work area.

Determine the work area which can be


composed of 3 polygons with 10, 8 and/or
6 lines.

Use the buttons P1 to P3 to switch among


the polygons.
The colour line to the left of the active
P button indicates the colour of the current
polygon.
The lower right-hand area shows the values
for distance, slewing angle and reach.

Use buttons T1 to T3 to switch to the tables


of the polygons 1 to 3.

Unused lines always have the values 0/0.

Use the button “Opt." to go to the options.


Here, the point offset can be changed and
polygons activated, deactivated and
reset.

More information to follow later.

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Chapter 6 Crane operation

Polygon settings

Important: Outlines of blocked areas must


be retracted clockwise (seen from the
blocked area).
For illustration the displays show the
corresponding numbers (red).

Notice: Imagine yourself in the blocked


area, look towards the line, and start
counting on the left.

For closed areas, the starting point is not


important. But it is important to count from
left to right.

The individual lines are set as follows:

1. Use trolley and slewing to first approach the starting point of the line.

2. Use a Set/Store button (1a, 2a, 3a,...) to store the entered value.

3. Then, use trolley and slewing to approach the end point of the line.

4. Finally, use the corresponding second Set/Store button (1b, 2b, 3b,...) to store the value.

These 4 steps are to be conducted for each line which is needed for the area.

Note: For closed surfaces/polygons, it is a good idea to set the very last point directly at
the beginning when setting the first point. Otherwise, it will be difficult in the end to
precisely meet the first point again.

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Chapter 6 Crane operation

WAZ options

As already mentioned above here the WAZ


options are set.

Point Offset:
When setting up a polygon, the end points of the lines must always be one hundred
percent congruent. Since this is technically not possible, closely adjacent points are
adjusted (equated). The line offset is used to set up to which distances points will be
adjusted.

Polygon 1-3 Checkboxes:


The checkboxes are used to activate/deactivate the individual polygons. A deactivated
polygon is still displayed, but will no longer be included in the distance calculation.

Polygon 1-3 Reset Buttons:


The reset buttons are used to completely delete the individual polygons.

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Chapter 6 Crane operation

6.13.5.5 ACS settings

These settings are only available if the Anti -Collision System is activated!

Use the corresponding button to open the


page for the ACS settings.

For your crane only the distance to the


(joint) zero point must be entered.

The next screen shows us the settings of a


partner crane. Up to 3 partner cranes can
be set up.

Set the (PLC) address of the ACS system of


crane 1.

Note: The PLC addresses are provided on


the type plates of the systems.

Then, enter the distance of your crane to


crane 1.

Now, orient your own jib exactly towards


crane 1 and press the "Set" button. This
stores the angle to crane 1.

The system is ready for use when all


necessary values among the cranes have
been stored.

To check it, look at the position of the


cranes in the "View" page.

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Chapter 6 Crane operation

6.13.5.6 Export

The export function provides the possibility


of storing all configuration values on a USB
memory stick.

Connect a standard USB memory stick to


the touch panel and press "Export Data".
After some seconds you will get a success
message and then you can remove the
USB memory stick.

The export function saves the settings in several XML files, one file for every settings page.
The files can be opened with the Internet Explorer by double clicking them. This is the
default behaviour for XML files on computers running Windows XP or Windows Vista.

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Page 1 / 18 JT152.8
Chapter 7 Maintenance

7 Maintenance

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  Trolley Gear & Brake 9 
7.10  Hoist gear 10 
7.11  Slewing gear Orthobloc 11 
7.12  Slewing brake FCM / FCO 11 
7.13  Slipring translator 11 
7.14  Switch cabinet – control house (CACON) 11 
7.15  Electrical cables 12 
7.16  Contactor and switch contacts 12 
7.17  Slewing ring 12 
7.18  Shorter lubrication intervals 12 
7.19  Steel structure 13 
7.20  Inspection & Maintenance of the painting 13 
7.21  Supervision of forged load hooks as per DIN 15 401 13 
7.22  Rope maintenance 14 
7.23  Handling of wire ropes 15 
7.24  Time for replacing wire ropes 16 
7.25  Drawing-in wire ropes 17 
7.26  Addendum 18 
7.26.1  Trolley gear - SEW 18 
7.26.2  Hoist gear - SEW 18 
7.26.3  Slewing gear - Leroy Somer 18 

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Page 2 / 18 JT152.8
Chapter 7 Maintenance

7.1 Lubrication - General

The symbols in the lubrication schedule indicate 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 every 2 years


Slewing gear
Luffing gear
Trolley gear
Travel gear

ELDRO® every 15 months


(Electro-hydraulic thrusters)

Hydraulics every 1200 hours of operation, at least once a year

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Chapter 7 Maintenance

7.3 Position of lubrication points

Grease (bulk)
Free grease points

Light lubricating oil

Grease (gun)
Plain bearings

Grease (gun)
Roller bearings

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Chapter 7 Maintenance

7.4 Lubrication plan

Lubricants (see lubricant


No Item Lubrication schedule Lubrication positions
recommendation)

1 Toothing at slewing ring S4

2 Wheel rims at the wheels S4 Adhesive lubricant

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

Brake on hoist gear (with


10 S3
grease nipples installed)

11 every 6 weeks Drive axle at slewing gear S2 Multipurpose grease

Drum and gear bearing


12 S2
pinion shaft travel unit

At least once a year Roller bearings of gears S2


13

prior to each erection (with


17 Hinge eye of hydraulic cylinder S3
grease nipples installed)

19 Insert all pins freshly greased S2

20 Grease all ropes S4 Adh. Lubricant

as required, prior to each Chain drives of limit switches


21 S5
erection at hoist and luffing unit
Light lubricating oil
Keep all joints and guides in
22 S5
running order

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Chapter 7 Maintenance

7.5 Lubricants, operation liquid, quantity

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

Quantity Lubricants (see lubricant


Item Type
(Liter) recommendation)
Hydraulic unit EP – hydraulic
100 B6*
Climbing device oil

Hoist unit 31

Slewing unit OLS 3403 **


S1 EP – gear oil
Trolley unit OT2503 2,8

Travelling unit

Hydraulic double shoe


B7 Hydraulic oil
Brake (hoisting unit)
Exposed toothed wheels of slewing
Adhesive
connection, running w heel drives and S4
Lubricant
wire ropes.

Anti-friction and friction bearings of the


rope pulleys, running w heels, drum
bearings, chain drives, chain w heels,
Multipurpose
slew ing connection, slip ring transmitter, S2
grease
hook block, greases nipples at gears,
drive shaft axles, motors and generators,
general lubrication points.

Friction bearings of the travel bogie,


central pivot, cross beam, rope
S3
suspensions, load hook yokes, brake
linkage, jib pivots points.
All joints and guides at switches and Low-viscous
S5
contacts. lubricating oil

The oil level must only be measured by standstill of the gear. The oil filling must reach up to
the upper marking at oil sight glass, oil overflow screw or 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.

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Chapter 7 Maintenance

7.6 Gear oil

Oil weight

0 0
Operation Operation between -10 C and +50 C Operation
below above
Brand /
-10°C +50°C
ambiente Industrial oil Car oil

(without (without (without (without


(with AD*) (with AD*)
AD*) AD*) AD*) AD*)
ISO
Viscosity
ISO VG 100 ISO SAE SAE ISO
according
VG 68 -150 VG 150 30 80/90 VG 320
ISO (SAE)
No EP *²

Balasia 68 Radula 100 Blasia 150 Super Diesel Rotra Blasia 320
AGIP
(-27°C) 15 W/40 80 W/90

Energol
Energol Energol HD SAE 30 Gear oil Energol
BP GR XP
THB 100 GR XP 150 EP SAE 80 GR XP 320
(+/-24°C)
Mecanep 68 Cofraline Mecanep Equilux Cofrapoid Mecanep
Cofran
GL Equitex 100 150 C200 super 80 W/90 320
Reductelf SP Tranself
Polytelis Reductelf Elan Reductelf
ELF 68 EP 80
100 SP 150 SAE 30 SP 320
(-21°C) W/90
Teresso EPV Spartan EP Spartan EP
ESSO HDX 30 HDX 30/40
32 150 320
Mobil gear DTE extra Mobil gear Mobilibe Mobil Gear
MOBIL
626 (-24°C) heavy 629 C 90 632
Omala 68 Tellus 100 Omala 150 Dentax 80 Spirax Omala 320
SHELL
(-24°C) EP 90

Carter EP 68 Carter GTS GTS Carter EP


TOTAL Azolla 100
(-21°C) EP 150 15 W/40 15 W/40 320

*² No EP: No high pressure oil; * AD: Recoil shutting

Never use high pressure oil in connection with “AD”

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Chapter 7 Maintenance

7.7 Maintenance schedule

Schedule Maintenance points Work

Hoist gear, slewing gear, luffing, trolley


and travel gear
Hydraulics: Before every new climbing
Check oil level
process
Daily
Pressure oil pumps

Brakes Check brake linings

All bolt connections to require torque


Check after erection
moment
After 100 hours
Climbing hydraulics oil filter Replace

Every 50 – 100 hours Breather filter on the gear Check

All connection terminals in the control Check for tight seat tighten if
After 200 hours
cabinet necessary

Climbing hydraulics: Breather filter Clean (at least once a year)


After 1000 hours
Check for tight seat and tighten if
All bolt connections
necessary (at least once a year)
Plungers and rollers of emergency limit
Every 6 weeks Clean and slightly grease
switches

Vent filter on gear Check for good working


Every 3 months
Sliprings, collectors, brushes and brush
Clean
holders of the motor

Contact of relays and switches Check for consumption

Every 6 months Sliprings: Running surface of sliprings Clean

Sliprings: Pivot joints at brush holder


Oil lightly with acid-free oil
levers
Check the outside and replace if
Yearly Power cables
necessary
Roller bearings of motors and
Dismantle and check
After 2 years generator
General overhaul
Roller bearings of eddy current brake Remove and check

This must be done within a short period when the crane is put in operation for the first time. It is necessary to tighten all bolts
of the slewing ring with a torque wrench. For torque moments please see Chapter 4 [Assembly]. If a bolt seems to be worn
down or defective it has to be changed immediately. After that check all slewing rings bolts and change them if necessary.

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Chapter 7 Maintenance

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 at minimum. 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 sliprings, 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 slipring 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 sliprings 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.

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Chapter 7 Maintenance

7.9 Trolley Gear & Brake

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. The oil viscosity suggested on the identification tag
at the gearbox is relevant for the oil selection. This refers to normal operating conditions.

Trolley gear:

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 please see "Lubrication schedule"

• Let out oil immediately after the gear comes to a standstill, so that the oil is still
operationally warm. For amount of oil filling please 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.

• Unscrew the breather to clean, wash in gasoline and blow out with compressed air.

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Chapter 7 Maintenance

7.10 Hoist gear


Oil checks and oil change:

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

Hoist gear:

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 please see "Lubrication schedule"

• Let out oil immediately after the gear comes to a standstill, so that the oil is still
operationally warm. For amount of oil filling please 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.

• Unscrew the breather to clean, wash in gasoline and blow out with compressed air.

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Chapter 7 Maintenance

7.11 Slewing gear Orthobloc

These gearboxes are greased permanently – maintenance free.

7.12 Slewing brake FCM / FCO

For additional information see Chapter 7.25 [Addendum]

7.13 Slipring translator

• The bearing requires nor maintenance neither any greasing.


• The carbon brushes have a relatively long working life due to the low rpm rate and their
hardness. Nevertheless a check of the carbon brushes should take place once every 6
months.
• The carbon brushes must in any case be replaced before metal pieces of the brush
holder or the fixing screws of the carbon brushes touch the sliprings. This must be
avoided under all circumstances. As part of this check-up it is also necessary to clean
the insulation between the sliprings from adherent carbon dust in order to avoid
tracking currents between the individual sliprings.
• Protect the slipring translator from humidity and other influences by moisture.
• If the slipring translator is equipped with nickel-plated copper-beryllium springs and
nickel-plated sliprings, these should be cleaned from adherent metal dust every 6
months.
• In order to reduce wear and tear, the sliprings should be sprayed lightly with contact oil
Cramolin "Protective".

7.14 Switch cabinet – control house (CACON)

All connection terminals in the


switch cabinet and the electrical
devices must be tensioned as
described in the maintenance
plan. Also all terminals that are not
connected have to be tensioned
since 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.
Never store any tools in the switch
cabinet.

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Chapter 7 Maintenance

7.15 Electrical cables

All cables and lines must be checked as specified in Chapter "Maintenance plan" to
make sure there is no consumption.
Brittle cables and lines must be replaced by new ones. Be particularly conscious about the
feeder line.

7.16 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 is necessary since oil or grease would stimulate the formation of sparks.
Argentous oxide, which is created through the formation of switch fire, is fully electrically
conducting as opposed to what is the case with copper oxide. The Argentous oxide which
is created must never be removed. The contacts must bum in such a way that the whole
contact surface is engaged in the conduction of current.
Fouling and creation of craters cannot be avoided. Keep contact grease, files and emery
cloths away from the contacts. If unusual wear should occur (formation of pearls on the
contact surfaces), it is absolutely necessary to contact a specialist.

7.17 Slewing ring

Greasing of the slewing ring must only be done using a perfect non-acid and resin roller
bearing grease and according to the lubricant recommendation for JOST cranes. Press
the roller bearing grease into all grease nipples on the slewing ring using a crease press.
Thereafter the crane is slewed by approx. 15°, then press in roller bearing grease again.
Repeat this process four to five times until grease emerges over the entire circumference
of the slewing ring at the bearing slit. This grease collar serves as a seal and must never be
removed.
Greasing intervals: Confer lubrication plan and after every standstill of any length of time.
Whenever blank spots occur on the toothing of the slewing ring it becomes absolutely
necessary to re-grease.

7.18 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 slewed 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.

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Chapter 7 Maintenance

7.19 Steel structure

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

7.20 Inspection & 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 if
formation of blisters, flaking, considerable chalking, rusty spots or subsurface corrosion has
occurred.
The occurrence of rust is to be determined as per DIN 53210 "Paintings, determination of
rust grade". When maintaining and repairing the painting, please proceed as per
DIN 55928 paragraphs 3 and 4.

7.21 Supervision of forged load hooks as per DIN 15 401

• For drop forged load hooks as per DIN 15 401 sheet 1 and 2 solely
visual checks and inspection of the hook mount is sufficient up to
and including hook group No. 5. Load hooks 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 10% related to the original measure y.

• Further instructions on check-ups 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

8,0 t

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Chapter 7 Maintenance

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 10% 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.

7.22 Rope maintenance

Correct application, assembly and care lengthen the life of wire ropes considerably. A
rusty rope endangers human life. Use rope greases according to the lubricant
recommendations for Jost cranes. Ropes with hemp cores must be greased only with
liquid lubricants which creep inside and are acid-free. This prevents the scouring of the
hemp fibres by the steel wires and at the same time keeps the hemp core soft and
provides for rope flexibility.
Careful greasing of the ropes keeps out humility which leads to internal corrosion and
growth of bacteria in the hemp. Frequent and light greasing of the ropes gives better
results than rare and ample greasing.

As soon as the grease film disappears from some places on the rope, re-greasing
becomes 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
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, petrol, paraffin, 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.

The service life of a rope which is under such 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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Chapter 7 Maintenance

7.23 Handling of wire ropes

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 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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Chapter 7 Maintenance

7.24 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:

• Break of a strand;
• Reduction of cross-section by more than 10%;
• Rust with grain formation;
• Signs of internal corrosion;
• Contact with live power cables or
• 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 up to 51 76 101 121 141 161 181 201 221
outer strands of the rope 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 cross-lay rope: 4 6 8 10 11 13 14 16 18 19
on a length of 30 x rope diameter
with long-lay ropes: 1 2 2 2 3 3 4 4 4 5
on a length of 6 x rope diameter
with lon-lay ropes: 2 3 4 5 6 6 7 8 9 10
on a length of 30 x rope diameter

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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Chapter 7 Maintenance

7.25 Drawing-in wire ropes

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

The direction of lay of a rope must always be opposite to the pitch of the drum. If
this is not observed, you risk the formation of 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. Draw-in the
rope only with the aid of a twist-free 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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Chapter 7 Maintenance

7.26 Addendum

7.26.1 Trolley gear - SEW

7.26.2 Hoist gear - SEW

7.26.3 Slewing gear - Leroy Somer

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Chapter 8 Electrical equipment

8 Electrical equipment

8.1 Standards & Calculation 2


8.2 Electrical connection 29
8.3 Cross-section 29
8.4 F.I.-Protection switch with TT-Network 30
8.5 Wiring diagram 31
8.5.1 Feeding part 31
8.5.2 PLC 35
8.5.3 Hoist unit 22/30kW 39
8.5.4 Trolley unit 3,0kW 43
8.5.5 Slewing unit 2x50Nm 46
8.5.6 Control panel 52
8.5.7 Cable loop 56
8.6 Parts list 65

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Chapter 8 Electrical equipment

8.1 Standards & Calculation

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Chapter 8 Electrical equipment

8.2 Electrical connection


The crane is equipped for connection to a three-phase supply 400V/50Hz and 480V/60Hz
+/- 5%. The connection must be carried out by an electrician who must observe the
protective measure described below. The cross-section of the supply cable and the
required fuses are indicated under Chapter 2 [Technical data].

Please note:

From electrical connection length of 40m on, the cable hanging freely in the tower should
be secured by a second cable grip, that is, without exceeding the free-hanging 40m of
cable.
If the second suspension is needed, then a loop is to be formed in the upper section of the
line in order to compensate the elongations and contractions of the rope due to weather
conditions.
The plugs of the electric cables have been disassembled, using f.inst. plastic bags and
closed with cable straps and insulating tape.

8.3 Cross-section
Cross-sections of supply cable on building site for 400 - 480 V three-phase current
Voltage drop 3,5 %, power drop cos 0,72

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Chapter 8 Electrical equipment

8.4 F.I.-Protection switch with TT-Network

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Chapter 8 Electrical equipment

8.5 Wiring diagram

8.5.1 Feeding part

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Chapter 8 Electrical equipment

8.5.2 PLC

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8.5.3 Hoist unit 22/30kW

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Chapter 8 Electrical equipment

8.5.4 Trolley unit 3,0kW

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Chapter 8 Electrical equipment

8.5.5 Slewing unit 2x50Nm

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8.5.6 Control panel

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8.5.7 Cable loop

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8.6 Parts list

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Page 1 / 21 JT152.8
Chapter 9 Climbing

9 Climbing

9.1  External Climbing 2 


9.1.1  General data 2 
9.1.2  Weight & dimensions 2 
9.1.3  Load chart for balancing 2 
9.1.4  Preparation for Climbing 3 
9.1.5  Inserting the tower in the rail 4 
9.1.6  Balancing of crane 4 
9.1.7  First climbing step 5 
9.1.8  Next steps on tower section 2 6 
9.1.9  Next steps on tower section 3 8 
9.1.10  Final step for Climbing 9 
9.1.11  Opening of front wall 10 
9.1.12  Moving of tower section 11 
9.1.13  Installation of tower section 12 
9.1.14  Fixing of top crane 13 

9.2  Internal Climbing 14 


9.2.1 General data 14
9.2.2 Load chart for balancing 14
9.2.3 Required parts for internal climbing 15
9.2.4 Preparation for climbing 16
9.2.5 Internal climbing sequences 1+2 17
9.2.6 Internal climbing sequence 3 18
9.2.7 Internal climbing sequence 4 19
9.2.8 Internal climbing sequence 5 20
9.2.9  Internal climbing sequence 6 21 

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Chapter 9 Climbing

9.1 External Climbing

9.1.1 General data

Permissible wind speed during climbing of frame:

a) Wind parallel to jib - 11 m/sec (40 km/h – wind force 5)


b) Wind right angle to jib - 11 m/sec (40 km/h – wind force 5)

9.1.2 Weight & dimensions

Total weight of Climbing cage CC 15.2 is 7,7t.


Weight of tower section TH 15.2 is 2,4t.

9.1.3 Load chart for balancing

Jib length (m) 30,0 35,0 40,0 45,0 50,0 55,0 60,0
Balance weight (t) 2,5 2,5 2,5 2,5 2,5 2,5 2,5
Distance D (m) 26,0 25,1 24,5 23,4 21,3 19,3 17,3

Tower section (t) 2,4 2,4 2,4 2,4 2,4 2,4 2,4
Distance D (m) 27,2 26,4 25,7 24,5 22,4 20,3 17,9

These values are based on approximate figures only. The crane is in balance
when all guide rollers have the same distance from the corner profiles of the
tower. During movement it can happen that the guide rollers are pressed firmly
against the corner profiles.

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Chapter 9 Climbing

9.1.4 Preparation for Climbing

1) Connect the Telescopic cage with the slewing support using pins 40mm.

2) Close front cross diagonals and apply tension.

The cross diagonals have to be always closed during climbing.

3) The slewing support is bolted to the tower.

4) The climbing traverse is fixed to locking plate B2.

5) The hydraulic cylinder is extended by 1540mm.

6) The locking foot is loose.

7) The rail for the guide roller is horizontal.

8) Moving platforms are driven out.

9) The trolley for the guiding mechanism is sitting on the rail.

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Page 4 / 21 JT152.8
Chapter 9 Climbing

9.1.5 Inserting the tower in the rail

1) Remove trolley from the rail and fix it to the tower on the ground.

2) Lift with main trolley, insert the tower section with trolley into the rail and fasten it to the
telescopic cage at approx. 2,80m.

9.1.6 Balancing of crane

Lift another tower or balancing weight and move it out to jib length D (see table from
Chapter 9.2).

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Page 5 / 21 JT152.8
Chapter 9 Climbing

9.1.7 First climbing step

1) Loosen the bolts between slewing support and tower.

2) Lift the upper crane for 20mm and check balance over climbing traverse again
(center pin). If balance is incorrect move the trolley forward and backward.

3) Extend the hydraulic cylinder to the limit – Pos. 2.

4) Insert the locking foot into plate D2 and carefully lower the hydraulic cylinder.

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Page 6 / 21 JT152.8
Chapter 9 Climbing

9.1.8 Next steps on tower section 2

1) Retract the hydraulic cylinder again – Pos. 5-6.

2) Insert the hydraulic cylinder with lever onto plate C2 – Pos. 7-8.

continued..

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Page 7 / 21 JT152.8
Chapter 9 Climbing

5. Next steps on tower section 2

1) Extend the hydraulic cylinder again – Pos. 10-11.

2) Insert the locking foot into plate A3 – Pos. 12.

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Page 8 / 21 JT152.8
Chapter 9 Climbing

9.1.9 Next steps on tower section 3

1) Repeat steps from previous chapters until the first tower section can be installed.

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Page 9 / 21 JT152.8
Chapter 9 Climbing

9.1.10 Final step for Climbing

Extend the hydraulic cylinder again. The guide roller is approx. 100mm below the tower
section.

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Page 10 / 21 JT152.8
Chapter 9 Climbing

9.1.11 Opening of front wall

Open cross diagonals and bolt them to the side.

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Page 11 / 21 JT152.8
Chapter 9 Climbing

9.1.12 Moving of tower section

Move tower with the trolley into the Telescopic cage until the trolley is positioned exactly
above the existing tower – Pos. 16.

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Page 12 / 21 JT152.8
Chapter 9 Climbing

9.1.13 Installation of tower section

1) Close and fasten cross diagonals again – Pos. 17.

2) Retract the hydraulic cylinder until the new tower section rests on the existing tower.

3) Bolt down both towers – Pos. 18.

4) Retract the hydraulic cylinder approx. 40mm until trolley can be unlocked.

5) Move the trolley out again.

9 - Climbing.doc Editor: AJ Updated: 27.07.2011


Page 13 / 21 JT152.8
Chapter 9 Climbing

9.1.14 Fixing of top crane

1) Further retract the hydraulic cylinder until the slewing support rests on the new tower
section.

2) Bolt down the slewing support and tower section with according bolts – Pos. 20.

Further climbing steps have to be conducted as indicated in drawings 1 to 11.

After completion of the climbing process dismantle the Telescopic cage or lower it
as far as possible. Retract the platforms and fold in the rail.

9 - Climbing.doc Editor: AJ Updated: 27.07.2011


Page 14 / 21 JT152.8
Chapter 9 Climbing

9.2 Internal Climbing

9.2.1 General data

Permissible wind speed during climbing of frame:

c) Wind parallel to jib - 11 m/sec (40 km/h – wind force 5)


d) Wind right angle to jib - 11 m/sec (40 km/h – wind force 5)

9.2.2 Load chart for balancing

Balance weight

33,0 m

Tower TH 15.2 V HT HB MS
Ms IN serv ice 677,7 184,1 158,7 466,0
OUT of serv ice 577,2 290,3 214,6 -
All data in kN/kNm

14,0 m

Jib length (m) 30,0 35,0 40,0 45,0 50,0 55,0 60,0
Balance weight (t) 2,0 2,0 2,0 2,0 2,0 2,0 2,0

Distance D (m) 22,9 21,7 20,5 19,0 16,3 13,9 11,3

These values are based on approximate figures only.

9 - Climbing.doc Editor: AJ Updated: 27.07.2011


Page 15 / 21 JT152.8
Chapter 9 Climbing

9.2.3 Required parts for internal climbing

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Page 16 / 21 JT152.8
Chapter 9 Climbing

9.2.4 Preparation for climbing

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Page 17 / 21 JT152.8
Chapter 9 Climbing

9.2.5 Internal climbing sequences 1+2

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Chapter 9 Climbing

9.2.6 Internal climbing sequence 3

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Page 19 / 21 JT152.8
Chapter 9 Climbing

9.2.7 Internal climbing sequence 4

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Chapter 9 Climbing

9.2.8 Internal climbing sequence 5

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Page 21 / 21 JT152.8
Chapter 9 Climbing

9.2.9 Internal climbing sequence 6

9 - Climbing.doc Editor: AJ Updated: 27.07.2011