Operating Instruction of

K30.30 Tower crane

Installation Manual

Shenyang Construction Machinery co.,Ltd

 k30/30 Tower crane

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LOAD DIAGRAMS
Jibs

Mounting possibilities

Consult us

k30/30 self-raising tower crane is manufactured by means of combining introduction of foreign

advanced technology with the experiences we got from operation of our own-designed tower crane for
several decades, tower crane with top-slewing, having novel design, advanced mechanism and rellable
performance, can provide you with 4-type:travelling attached, stationary. And inside-climbing. The
crane’s max. working range is 70m, max, hoisting capacity 12t max, load-moment 2952kN.m. the max,
height under hook is 155.2m when the tower crane in stationary, max height 56.6m when the tower
crane in travelling, max. height 265m when the tower crane in climbing. Welcome to purchase.
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SUMMARY

FIRST PART

SECOND PART

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FIRST PARST

PREPARING THE SITE

RECEIVING THE CRANE

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A1_PREPARING THE SITE

1. SPACE REQUIREMENTS FOR ERECTION

2. TRACKS
3. “OUT OF SERVICE”ANCHORAGE TO THE FROUND
4. ANCHORAGE PAD FOR CHASSIS
5. CONCRETE PAD FOR FIXING ANGLES
6. ELECTRICAL INSTALLATION
7. BASE BALLAST
8. COUNTER-JIB BALLAST
9. ANCHORAGES TO THE BULDING

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SPACE REQUIREMENTS FOR ERECTION

1 Introduction

2 Complete Crane

3 Fixing angles and chassis

4 Tower

5 Tower head

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INTRODUCTION

This brochure contains the dimensions for the space requirements of the crane.
It is split up into two groups:

1°——The general crane lay-out with the main dimensions {page 2}

2°——The crane is represented in three parts:

a) fixing angles and chassis {pages3/1 and 3/2}

b) mast tower {page4}
c) mast head {page5}

The dimensions are detailed in such a way that the setting up of the machine can be
prepared in a more precise and complete manner.

ATTENTION: the indicated dimensions being theoretical ,especially they do not take
into account the deformations without load or with load.

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TRACKS

1 Choosing the track

2 Track laying

3 Track widths and radii of curvature

4 Tracks on concrete strips or on slabs

5 Track on wooden sleepers

6 Rail stops

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CHOOSING THE TRACK

The track dimensions must correspond to the requirements imposed either by :

the material which determines.

a) the rail width.

b) a pressure per bogie depending on the working height of the crane.

The rail width and the maxi bogie pressure are shown on the following table and in the
data sheet.
Certain conditions under which the machine will be used may require and 《Out of

service》anchorage pad. In such a case, refer to the manual treating of 《Out of service

anchorage》for the construction of such pads.

Or by the ground

Homogeneity or non homogeneity of its pressure.

Types of tracks

Two types of tracks are possible, i.e.:

Track on concrete strips

Track on wooden sleepers

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TRACK LAYING
RAIL TO BE USED :

The rail section must be suitable for the wheels it will support; maximum head width 67mm.The best

rail to use is one which is slightly worn as this has a good bearing surface. It is preferable to use

standardized material {rails and accessories} as shown in the table below.

The user must choose the other dimensional characteristics of the rail according to how latter will be

connected to the concrete strips or to the broad flanged girder (HEB) and according to the maximum

vertical or horizontal reactions.

The horizontal reaction amounts to about 10% of the vertical reaction.

Good slightly new rail poor bearing over worn rail rail worn on one side
worn rail surface wheels wear poor bearing surface

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TRACK LAYING

The track must be carefully designed and laid. It must be:

- perfectly horizontal {longitudinally and transversely}.
- well bedded down on a solid base.
- perfectly straight and with the rails absolutely parallel.
- made up of the same type of rails throughout its length.
- fitted with rail stops placed at least 1m before the end sleeper.
- Correctly earthed {according to the standards of the country considered}.

- For the erection, a minimum length of track is required {see drawing 《Site

dimensions for erection》}.

- The centre portion of the track must be banked up to the level of the rail foot so as to
ease the travelling of the site machines.

《 The following drawings are given as an indication only. They exclusively apply

to a homogeneous soil with a resistance of at least 2 kg/cm2. The crane user is

responsible for the laying of the track which must be perfectly level and capable to take

the maximum bogie reaction of the machine without causing any local subsidence》.

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TRACK WIDTHS AND RADII OF CURVATURE

The table opposite gibes the various track widths depending on the chassis used. The
dimensions 6-8m etc. are the widths between the rail axes.

The radii of curvature are the recommended minimal radii.

Any greater radius can be negotiated without any gauge correction. It is recommended
to use the minimal radius in case of real necessity.

Travelling over the curves stated is only possible if the chassis are equipped
accordingly.

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SPURWEITEN UND KURVENRADIUS

TRACK WIDTHS AND RADII OF CURVATURE

TRACKS RADII OF CURVATURE

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6M track widths
Radii of curvature

Track uncorrected Track corrected

Minimum inner radius : 19 m Minimum inner radius : 12 m

See page : 2A.0.021.16

8M Track widths
Radii of curvature YA

Track corrected
Track uncorrected

Minimum inner radius : 30 m Minimum inner radius : 20 m

See page : 2A.0.021.17

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Installation upon Longitudinal Concrete Cross Sleeper

Symbol and description

Quantity of steel enforcement bar

High strength linking steel enforcement bar
Diameter of steel enforcement bar (mm)

Length of each steel enforcement bar (mm)

Spacing (cm)

Bottom layer
Top layer
Middle layer
Lap joint between steel enforcement bar of top and bottom
layer
Maximum vertical force borne by longitudinal sleeper is 45
kn
Maximum vertical force borne by longitudinal sleeper is 55
to 75 kn
Weight of steel rail per meter (kg)
Model of steel rail

Model number of cement: 325, proportion of concrete: 350kg/m3

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Shrunk on neoprene bearing (8 time)

Washer Φ
Soft
SLEEPERS 25ep 2.5 SLEEPERS
isorel

Threaded rod Φ33 HR 1

Lower
lager

Upper lager

ASSEMBLING THE LONGITUDINAL SLEEPERS

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LONGITUDINAL SLEEPER CONNECTIONS

VERY IMPROTANYT : The distance between longitudinal sleeper

connections is equal to the distance between centres of the track.

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RAILS ON TIMBER SLEEPERS

Explanation and symbols

The elements used for the track construction are determined in relation to the R reaction

Maximum ground pressure 2kg/cm2 {in all cases}

R :: Maximum
Maximumreactions
reactionsatatTT
HEB :: Height
Heightin in
mmmm
H.B. : Height
Height of ballastininmm
of ballast mm
P.R. :: Weight
Weight of rail per metreininkgkg
of rail per metre
B :: Oak
Oak sleepers
sleepers
P.C.C : Compacted broken stones 40/60
T.R. : Type of rail

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RAIL STOPS
We remind you that the crane when approaching the track end must be stooped before
hitting the safety devices which are not working systems.

The three safety devices are fitted as indicated in the following drawing. They consist
of :
a) a travel limit switch.
b) a sprung stop {buffer} .
c) a fixed stop welded on the rail.

The above devices are prescribed by the Safety Authorities and must be designed and
fitted with particular care. Periodically make sure that they are working correctly.

The mounting of system (a) is described in the relevant section of the handbook. Check
that the ramp (a) is parallel to the rail so that the limit switch roller does not leave the
ramp.

The supply and fixing of the devices (a), (b) and (c) are the responsibility of the user.

Different models for device (b), clamped onto the rail, are available from specialized
suppliers. When choosing the appropriate devices, pay attention to the crane weight
(buffering capacity) and the buffer height which must correspond to that of the stop on
the bogies.

Device (c) must be welded on the rail and have appropriate dimensions so as to prevent
the crane from running off the track. The following schematic drawing serves as an
indication only.

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Minimum length 3m or 6m on the travelling speed

Free travelling length

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CONCRETE BLOCKS FOR FIXING ANGLES

1 Conditions of preparation
2/1 Table 《Forces-Stresses》

2/2 Table《Ground pressure and choice of concrete blocks》

3 Dimensional characteristics of the fixing angles

4 Fitting the fixing angles
5 Explanation and symbols

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CONDITIONS OF PREPARATION

A- BY THE CUSTOMER

The table of forces and stresses, the dimensional characteristics of the fixing angles,
the fitting of the fixing angles in the block on the following pages are necessary and
adequate to determine a concrete block (dimensions and reinforcement).

FOR STABILITY REQUIREMENTS OF THE MACHINE, WE INSIST UPON

MINIMUM DIMENSIONS ON THE GROUND EQUAL TO THOSE OF THE
BLOCKS DESCRIBED IN THIS BROCHURE.
FOR ALL OTHER DIMENSIONS CONSULT US.

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CONDITIONS OF PREPARATION

B ACCORDING TO POTAIN REGULATIONS: justifiable by French Standards.

If not fit for use abroad, realise the concrete blocks according to the information
for case 《A》or consult us.
HOW TO CHOOSE:
It is the permissible ground pressure of the site which determines, for the final
height to be reached and for each type of machine, the best type of block to use.
For any height, choose the block with a ground pressure equal to or lower than
that of the ground of the site, see page 2/2.

FITTING THE FIXING ANGLES:

Bad fitting of the fixing angles can lead to serious incidents using the machine
(perpendicularity not respected, distortion of the mast assembly planes).
It is absolutely essential to use the fitting elements provided. Operating
instructions are given as an indication on page4.
REALISATION OF THE BLOCKS:
The drawings effected by the Company CORNILLON are justifiable for the
maximum stresses given for each case.

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FORCES-STRESSES

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

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Fixing reaction

ES HS
R R
C H P M ET P M ET
TRACTCOMP TRACTCOMP
m Kg mKg Kg Kg KG Kg mKg Kg Kg Kg
1+0+1 9.75 72032 176035 2073 47991 84007 72839 158041 5102 41044 77463
1+1+1 12.75 73522 180947 2205 49461 86222 74329 158041 5527 40671 77836
1+2+1 15.75 75012 186258 2338 51079 88585 75819 158041 5952 40299 78208
1+3+1 18.75 76502 191968 2471 52848 91099 77309 158041 7282 39926 78581
1+4+1 21.75 77992 198076 2604 54765 93761 78799 158041 7707 39554 78953
1+5+1 24.75 79482 204582 2737 56832 96573 80289 158041 8132 39181 79326
1+6+1 27.75 80972 211487 2870 59048 99534 81779 158041 8716 38809 79698
1+7+1 30.75 82462 218790 3002 61414 102645 83269 158041 9301 38436 80071
1+8+1 33.75 83952 226492 3135 64293 106269 84759 158041 9885 38064 80443
1+9+1 36.75 85442 234592 3268 68044 110765 86249 158041 10469 37691 80816
1+10+1 39.75 86932 243091 3401 71890 115356 87739 158041 11054 37319 81188
1+11+1 42.75 88422 251988 3534 75833 120044 89229 158041 11638 36946 81561
1+12+1 45.75 89912 261284 3667 79871 124827 90719 183468 12223 46106 91466
1+13+1 48.75 91402 270978 3799 84006 129707 92209 219804 12807 59357 105462
1+14+1 51.75 92892 281070 3932 88236 134682 93699 257894 13392 73266 120115

COUPLE DE TORSION MAXIMUM : 25923m/kg

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Fixing pressions

C 81 101 142 126 169 205 276

H(m)
PS PS PS PS PS PS
1+0+1 9.75 **** 1.45 1.36 1.13 1.15 1.06 0.9
1+1+1 12.75 **** 1.49 1.39 1.15 1.17 1.03 0.91
1+2+1 15.75 **** 1.53 1.41 1.18 1.19 1.01 0.92
1+3+1 18.75 **** 1.57 1.44 1.2 1.21 1.02 0.93
1+4+1 21.75 **** 1.62 1.48 1.23 1.23 1.04 0.95
1+5+1 24.75 **** 1.67 1.52 1.26 1.26 1.06 0.96
1+6+1 27.75 **** 1.72 1.55 1.3 1.29 1.08 0.98
1+7+1 30.75 **** 1.78 1.59 1.33 1.31 1.1 0.99
1+8+1 33.75 **** 1.84 1.64 1.37 1.34 1.12 1.01
1+9+1 36.75 **** 1.91 1.68 1.41 1.36 1.15 1.03
1+10+1 39.75 **** 1.98 1.73 1.45 1.41 1.17 1.11
1+11+1 42.75 **** 2.06 1.79 1.49 1.44 1.19 1.17
1+12+1 45.75 **** 2.14 1.84 1.54 1.48 1.22 1.12
1+13+1 48.75 **** 2.23 1.9 1.59 1.52 1.25 1.11
1+14+1 51.75 **** 2.33 1.97 1.65 1.56 1.28 1.13

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DIMENSIONAL CHARACTERISTICS OF THE FIXING ANGLES

The fixing angles must be fitted symmetrically in relation to the axes of the block and
form a square of 1.6 m or 2 m according to the dimension of mast they are to receive.

There are two types of fixing angles:

in L200x20 plate of 600 mm for 2 m mast

in L 180x18 plate of 500 mm for 1.6 m mast

In every case, respect the 150 mm dimension of fish-plating of the fixing angles.

Take care earth them correctly.

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according to frame

Earthing

To the tight of a fixing angle , neither cut nor reduce the

given amount of reinforcing irons.

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FITTING THE FIXING ANGLES

The material necessary in order to perfectly anchor the fixing angles comprises:

4 fixing angles and 8 pins

1 fixing frame and 8 pins
1 standard mast section
a plumb line or slighting device

THE FIXING ANGLES, FRAME AND STANDARD MAST SECTION CAN BE

SUPPLIED BEFORE DELIVERY OF THE CRANE.

Assemble the fixing angles with the frame.

Position the fixing angle/frame assembly in the reinforcement and adjust it by wedging
under the angle support plates.
Fit the standard mast section on the frame and check perpendicularity in both directions.
Pour the concrete block and wait until it is completely dry before unfitting the mast
section and the frame.

THE FRAME IS USED ONLY TO ANCHOR THE FIXING ANGLES.

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Plumb line

Standard section

2 pins in each corner

Fixing frame

2 Pins in each corner

4 Fixing angles

Reinforced concrete

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EXPLATION AND SYMBOLS (Example)

Designation of a concrete block (M74N)

M : concrete block
74N: weight of the concrete block in tons

The reinforcement of a concrete block is composed of an upper and a lower layer

connected by pins. Each layer comprises two crossed beds.

26 : number of bars

Upper bed HA : round steel with high adherence

20 : diameter of iron in mm

26 HA 20 x 540 (e:19)
540 : unit length of iron in cms
Lower bed

e : space between bars or pins in cms

ep: pir. D: density V: volume in m3 L: length I: width h: height in cms

Concrete mixed for 350kg/m3 Quality of cement: CPA 325 or equivalent

CONCRETE BLOCKS CALCULATED ACCORDING TO

CM 66—CC BA 68—DTU 13-1 RULES

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L： 625 I ：625 h： 135

V：53m3

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L： 590 I ：590 h： 170

V：59m3

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L： 645 I ：645 h： 170

V：71m3

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ELECTRICAL INSTEALLATION

1 Contents

2 Electrical power table

2 Cable winders

3 Earthing

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—The electrical installation of the site must be carried out as per the standards in force
in the considered country.
—The required electrical power depends on the crane equipment. It is stated on the
technical data sheet to be consulted for each machine.
—The following tables allow to determine the section of the supply cable and the cable
winder type to be used for each static or travelling crane.
—In the case of a travelling crane, the allowable track length is always twice the
smallest value stated:
L-i.e. the maximum cable length considering any voltage drop or CE-i.e. the cable
winder capacity for a given cable section. L is measured starting form the central supply
point of the track to the cable winder.
—For a static crane, L can represent the maximum distance between the main supply
switch and the crane.
—The “Operating Manuals” specify for each crane the conditions for the use of
auto-transformers.
—If the crane is supplied by means of a generating set, please consult us.

—The tracks and the crane must be earthed (see example on page 3/1) .

VERY IMPORTANT: the electric power shown in the technical data sheets for the
mechanisms is a minimum which must be available on the connection point of the cable
winder (central point of the track).

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TABLEAU DES PUISSANCES LEISTUNGSTABELLE ELECTRICAL

POWER TABLE

P : Power in KVA
S : Cable section in mm2
L : Length of cable in m
CE : Cable winder capacity
LV : Track length
X : 8 to 10 m minimum provided by customer for supply between cable winder and the crane’s
isolating switch

Equipment for PC hoist winch

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L.C: length of cable T.C: Type of cable A.V: Travelling length

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L.C: length of cable T.C: Type of cable A.V: Travelling length

The aforementioned cable winders have been modified (index A)

Correctly identify the old cable winder from the new one which vary according to their
dimensions

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EARTHING

ATTENTION —The earth circuit of the crane must neither include a fuse nor a switch.
The neutral wire on the supply cable is not connected to the earth.

1— Tube Φ33/45 length 1,5 m (5) to 2 m (7)

2— Earth spike.
3— Inspection hole protecting the head of the spike and allowing
the spike to be watered.

Earth plate made of sheet steel or stretched metal

Of an area of 1 m2 buried vertically.

Copper conductor section 28 mm2 or iron 50 mm2 in shallow trench

extending over a long length depending on the resistivity of the
soil.

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ELECTRICAL JOINTS 2 or 3

Each rail section must be earthed. Link them by electrical joints 2 or 3

The actual earthing can be done by :

A Earth spikes
B Earth plates
C Buried wires

NOTE The earth wires designed to be bolted in position must have a terminal
tag soldered to them. (5)

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BASE BALLAST

1 Introduction

2 Base ballast table

3 Ballast block details

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INTRODUCTION

The base ballast is made up of one or several reinforced concrete blocks which are
placed symmetrically on the chassis. Each layer consiste of blocks identified by letters
A or B or C etc…

These blocks must be positionned on the chassis as shown in the figures and the
corresponding table, i.e. between the attachment points of the ballast fixing device, if
latter is required.

The reinforcing of the concrete blocks, except the one shown in the figure, is left
up to the customer who has also the responsibility for the ballast preparation. No supply
from us .

THE REACTION ACTING ON THE BOGIE IS GIVEN FOR A FORCE PASSING

THROUGH

THE BOGIE/FORK HINGE BOLT.

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CP: Mast composition.

HC: Hook height.
NR: Number of layers.
ND: Number of blocks.
LE: Minimum ballast required.
LO: Ballast obtained.
R.ES: Stresses in service.
R.HS: Stresses out of service.
RH: Horizontal stresses.

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Section A-A

Tolerances of ± 1cm overall dimensions

Rep: Mark
Φ: Diameter
N: Number
L.u: Unit length
L.t: Total length
Forme: Form

Dimensions in cm
Reinforced concrete P: 2800kg D: 2,3

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Section A-A

Tolerances of ± 1cm overall dimensions

Rep: Mark
Φ: Diameter
N: Number
L.u: Unit length
L.t: Total length
Forme: Form

Dimensions in cm

Reinforced concrete P: 2500kg D: 2,3

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COUNTER-JIB BALLAST

1 Introduction

2 Counter-jib ballast table

3 counter-jib ballast plan

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INTRODUCTION

The counter-jib ballast is made up of several C,D,E or F blocks in reinforced concrete.

Their combination allows to obtain the various weights. Corresponding to each jib
length used. These blocks are suspended, one by one, under the counter-jib nose.

The block’s reinforcement as well as the device used to lift and to suspend the blocks on
the counter-jib is to be determined and to be prepared by the user in such a way that the
blocks do not chip off or get loose when handling them or operating the crane.

The following pages give the constructional and functional dimensions required to
install the lifting and suspension device.

As an indication, an example concerning the manufacture of the lifting and suspension

device is given on page 3.

To obtain the required weight with + or –50 kg per block . vary the dimension X as a
fonction of the density of the aggregate used (see table).

We recommend to weigh the blocks and to mark the weight with paint on one of their
sides.

For the examples of reinforcement on page 3, the dimensions and the number of
S-shaped hooks are determined for a density of 2,2.

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Blocks EFT

Links HA

Welding detail
Round bar_Plates 1_2

DIMENSIONS IN mm.

1
Plates 120x20 cut : 790415
2

3 Round bar Φ50_ Length : 1700

4 Plate 345x220x3 _Holes Φ51

Recommended steel quality E24_3

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Blocks F-S9

Links HA

Welding detail
Round bar_Plates 1_2

DIMENSIONS IN mm.

1
Plates 120x20 cut : 790415
2

3 Round bar Φ50_ Length : 1700

4 Plate 345x220x3 _Holes Φ51

Recommended steel quality E24_3

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ANCHORAGES TO THE BUILDING

1 Introduction

2 Instructions

3 Crane towers and anchorages

4 Fitting the anchorage frame

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INTRODUCTION

Beyond its free travelling or free standing height, the crane must be connected either to
the ground by means of guy ropes or to the building using rigid anchorages.

The present brochure deals only with the rigid anchoring to the building.

For anchoring by guy ropes, consult our After-Sales Service; besides, another brochure
deals with this device.

Pages (2) define the anchoring positions.

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INSTRUCTIONS

Preparing the crane:

—When it is a crane on rail travelling chassis, move it to its static position, tighten the
rail clamps and disconnect the travelling mechanism.

—In certain cases it is necessary to telescope an additional mast section so that the
anchorage frame can be fitted (see page 3).

VERY IMPORTANT:
Under these conditions the crane is no longer normally autonomous, and it is forbidden
to work and to leave the crane free out of service.

When telescoping, check the perfect perpendicularity of the crane in both planes in
order to avoid any variation of distance between crane tower and building.

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INSTRUCTIONS (cont’d)

In order to ensure good connection between frame and crane tower and to prevent the
mobile wedges (1) from falling down, it is essential to turn the pieces carrying the
welded wedges (2) so that the fitting corresponds to the sketch.

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CRANE TOWERS AND ANCHORAGES

The heights given in the table opposite are the heights on anchoring feet, measured with
regard to the joining surface. For any use of anchorages on cranes with chassis, consult
us.

The mast composition is given for the case of optimum use of the anchorage frame, i.e.
in its lowest position with a maximum of telescoped mast sections above it.

As the client is responsible for the beams connecting the anchorage frame to the
building, consult us when carrying out these beams in order to inform you of the
stresses on the level of the frame(s).

A : Free standing height B: 1 anchorage C: 2 anchorages D : 3 anchorages E : 4

anchorages NDA : Number of mast sections above the last anchorage HSC : Hook
height NEA : Number of mast sections between two anchorages

﹡ : Anchorages tightened Anchorages released

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Free standing height 1 anchorage 2 anchorages

Number of mast sections above the last anchorage . 12 HSC—Hook height

Number of mast sections between two anchorages. 9 * Anchorages tightened

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FITTING THE ANCHORAGE FRAME

—Remove the standard ladder from the mast section which will be fitted with the
anchorage frame.
—On the ground , place the two lateral girders (1) and (2) onto the front girder (3)
(insert shaft (4)only in order to facilitate spacing girder (1)and (2)).
—Sling and raise the assembly until it reaches the right position on the mast (with the
side of the anchoring beam attachment (3) towards the building).
—to facilitate fitting, use 2 cords for guiding.

— Hook the front girder (3) onto the horizontal bracings located in the middle of the
mast section (detail A).
— Fold back lateral girders (1) and (2) and pin them using shafts (5).

— Sling and raise rear girder (6), position it and pin-connect it to the lateral firders
using shafts (7).
— Raise and place successively brackets (8),(9),(10)and (11), then pin them onto the
girders.
— Place and pin diagonal bracing bar (12).

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FITTING THE ANCHORAGE FRAME (cont’d)

— Check the horizontal position of the frame, re-adjust if required.

— Place outer wedges (1) and act on them in order to bring the frame into contact with
the mast uprights.
— Place outer wedges (2) and drive them in (detail A).

— Having carried out these operations, check that there is no play remaining between
the wedges and the mast uprights.
— Fit the ladder supplied with the frame instead of the standard ladder, then equip it
with the two back loop parts (detail B).

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A2. RECEIVING THE CRANE

1 CHARACTERISTICS OF THE MOBILE CRANE

2 PACKING

3 LOADING PLAN

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CHARACTERISTICS OF THE LORRY MOUNTED

CRANE-WEIGHT OF THE MAIN COMPONENTS

1 Introduction

2 Weights and hook heights

3 Travelling-mechanism

4 Chassis

5 Mast

6 { Cat
Strut-Cab-mast-Pivot
head

7 Counter-jib

8 Jib

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hm: Theoretical height of the

package once positioned

f : Trailing bogie

m: Motor bogie

VD: Straight track

VV: Curved track

3) Jib DM

Rail level

Travel of the lorry mounted crane

(1) Add 9 or 18 m according to the mast height C— Parcels P— Radius

(2) Weight of blocks Hm— Height Pkg—Weight

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hm: Theoretical height of the

package once positioned

Rail level

* Motor Travel of the lorry mounted crane

Weight of blocks See brochure

Subject to alterations
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INTRODUCTION

The weights, radii, heights in the tables of page 2 have been calculated considering the
different possibilities as to :
—the site conditions,

—the mobile crane available.

For each crane, the sketch shown represents the component to be lifted (with all its
equipments and connecting accessories such as shafts or bolts).

The height H, measured from the rail level, applies to a travelling crane on chassis. For
a crane on fixing angles, the height of the chassis is to be deducted.

The height H includes the sling length which varies according to the crane parts.

The other pages specify the weights of the main components for their handling on the
site so that the complete packages to be lifted can be constituted

If you wish, the packages (2) and (5) —each containing 3 mast sections —can be put
in place by the mobile crane used provided that its charactenistics allow for it

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CHASSIS

Traverse

Traverse

Fork
Block

Fork

Traverse

Traverse

Fork

Side member

Strut tie

Basic mast unit

Obliqual legs

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Equipped strut

Strut without
acessories

Tie bar

Cab-mast

Cab-mast

Cab

Pivot

Pivot

Monorail

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COUNTER JIB

HOIST WINCH

HOIST WINCH

HOIST WINCH

COUNTER JIB FOOT

COUNTER JIB NOSE

COUNTER JIB FOOT CONTER JIB NOSE

GRAB RAIL SUPPORT

TIE BAR CAT WALK

YOUKE

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Second part

ERECTION

DISMANTLING

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B1. ERECTION USING A MOBILE CRANE

1— ERECTION SEOUENCES
2— FUTTING THE BOGIES ON THE TRACK
3— MOUNTING AND BALLASTING THE CHASSIS
4— FITTING THE CABLE WINDER
5— MOUNTING THE BASIC MAST
6— MOUNTING THE TOWERHEAD/MAST CABIN
7— FITTING THE CAT-HEAD
8— ASSEMBLING THE JIBS AND COUNTER-JIBS
9— FITTING THE JIB, ROLLEYS AND FULLEY BLOCKS
10— FITTING THE JIBS AND COUNTER-JIB
11— REEVING THE HOIST ROPE
12— FITTING THE COUNTER-JIB BALLAST
13— MAST COMPOSITION
14— FITTING THE ACCESS MEANS
15— PREPARING THE TELESCOPING
16— SALANCING FOR TELESCOPING
17— TELESCOPING
18— PUTTING INTO SERVICE

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ERECTION SEQUENCES USING A LORRY MOUNTED CRANE

1 Introduction

2 General Instructions for erection

3 Erection

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INTRODUCTION

This erection procedure allows to rapidly assemble your crane until it reaches its
telescoping position.

It requires an auxiliary mobile crane, the characteristics of which must correspond to the
parts to be handled.

Reducing to a minimum the time the auxiliary crane is used on site involves a good
co-ordination between the erection and assembling sequences, the erector teams, and
appropriate accesses and assembling area.

This erection procedure needs no electrical power up to the moment the telescoping
sequence starts.

The object of this brochure is to make you well acquainted with all the erection
operations which are separately dealt with and detailed in small specialized brochures.

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GENERAL INSTRUCTIONS FOR ERECTION

1. All the handling operations using the lorry mounted crane must be

carried out safely. For this:

- properly pack up the crane

- do not over load the crane

- use slings in good order and of correct lengths according to

the weights of the parts to be lifted

- respect the slinging points

2. The erection operations must be carried out in the order listed.

3. Make sure that protection and safety means are fitted and used, such as:

ladders, platforms, guard-rails, safety rope etc ……

4. It is absolutely forbidden to lift a load if the counter –jib ballast is not

fitted.

5. The crane must not be telescoped up with a wind exceeding 60 km/h.

6. Before starting any telescoping operation, make sure that the pins

connecting the towerhead to the telescopic cage are inserted and

secured by split-pins.

7. It is essential that the amounts of counter-jib ballast indicated

according to the jib lengths are respected (see corresponding

brochure).

8. For telescoping, always slew the jib to the opening of the telescoping

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cage (side where the masts are introduced).

9. The mast sections must be lifted (or lowered) as close as possible to

the tower.

10.It is forbidden to slew the jib, operate the jib trolley and use the load

hook (hoisting or lowering) as long as the telescopic cage is lifted or

being lifted.

These instructions also apply to

- the erection

- the height increase of the crane

- the dismantling.

For any particular problem as to the erection organization or other

difficulty, do not hesitate to call upon the assistance of our After-Sales

Service.

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ATTENTION: This reeving serves only for the tie bar tightening by

tilting the strut and in no case or lowering the jib.

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PUTTING THE BOGIES ON THE TRACK

1 Putting the bogies on the track

2 Slinging and weights

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PUTTING THE BOGIES ON THE TRACD

- The bogies must be positioned on the track taking account of the space

the erection sequence requires.

- Rest the bogies on the rails at the 4 corners of a square having the

dimensions of the chassis (4.5x4.5m)-(6x6m)-(8x8m).

- ON CURVED OR S-SHAPED TRACK the motor bogies are located on

the rail with the greatest radius of curvature (A).

- ON STRAIGHT TRACK the motor bogies can be mounted on the same

rail or diagonally (B 2), but NEVER ON THE SAME CROSSBEAM.

- Tighten the bogies to the track using rail clamps (detail C); pack them

up, if necessary, to deep them horizontal.

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SLINGING AND WEIGHTS

- If still necessary, rest the bogie on its wheels.

- Fit slings (1) onto hooks (2) provided for this purpose.

- Lift up the bogie which will remain perceptibly horizontal in the lateral

plane. Longitudinally, the motor side of the bogie will tilt down in the

case of a motor bogie, without however impairing the putting on track.

- When placing on the track, fit the bogies with dimension (A) (bigger

dimension with regard to the wheel shaft on the inner side of the track).

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ASSEMBLING AND BALLASTING THE TRAVELLING CHASSIS

1 Description and weight

2 Cross-beam equipment

3 Fitting the crossbeams and side members

4 Fitting the basic mast or the basic mast unit

5 Ballasting-Ballast attachment

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DESCRIPTION AND WEIGHTS

There exist 2 chassis units made up of:

a / for straight track chassis (V.D.)

-2 cross-members (1)carrying on either end a fixed fork (3).

b/ fir straight/curved track chassis (V.V.)

-2 cross-member (2) carrying on one end a fixed fork (3) and on the

other end a sliding fork (4).

All the remaining parts of the parts of the equipment are common to

both chassis units. These parts are:

-one longitudinal member block (5)and the bolts (6)to fix it onto the

cross-members.

-four struts (7) and connecting pins (8) and (9)

-one basic mast unit (10)and the bolts (11)fixing it into the

longitudinal members.

-four oblique legs (13)and pins (14)and (15)

The following table specifies the weights of the main parts and lists the

connecting means (bolts and pins ) depending on the chassis type used.

These chassis can be equipped with:

1-《Out of service 》 anchoring device

2- Equipment for traveling at 90º

As regards the use of this special equipment, refer to the supplementary

brochures.

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Weights. Dimensions
Rep Nb
Description 1.6m 2m

1 2 Traverse RT400 1110kg 1500kg

3 RT500
RT600

2
RT400
3 2 Traverse 1580kg 1860kg
RT500
4
RT600

5 1 Side member 1200kg 2140kg

6 16 Bolt H24x62 H24x62
7 4 Strut tie 65kg 205kg
8
9 8 Pin 90x170L 90x170L
10 1 Basic mast unit 2240kg 3780kg
11 16 Bolt H30x85 H30x85
12 16 Washer W27 W27
13 4 Oblical legs 350kg 620kg
14 4 Pin 90x280L 90x280L
15 4 Pin 110x220L 110x220L

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CROSS-BEAM EQUIPMENT

FIXED FORK: there are two mounting types

a/ with ball thrust bearing and compression spring

b/ with torch-cut washer

MOBILE FORK C/-It comprises:

A fork (1), a spacer (2) equipped with a grease nipple (3), a ball thrust

bearing (4), a compression spring (5), a mobile block (6) equipped with

a spring pressure system (7), two half washers (8) and (9), a protecting

plug (10) with screws and washers (11), a locking plate (12) with

screws and washers (13).

Ex-works ,the cross-beams are initially fitted for a given chassis type,

no mounting is to be carried out on site.

Before fitting on the bogies, check the cleanness of the parts being in

contact, clean and re-grease if required, make sure that they work

correctly by turning and sliding the forks.

IMPORTANT: Before the 1st putting into service on curved track,

check the state of the track (eveness, local ground subsidences, fitting

and connecting of the rails etc.); a bad installation may cause

break-downs.

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MOUNTING THE CHISSIS ONTO THE BOGIES

- ATTENTION: The ladder position of the basic mast (A) and the chassis

(B) determines the telescoping direction (F).

- Make sure that the chassis position allows to obtain one of the two

possible telescoping directions F1or F2.

- Fit slings around the cross-members and raise them; slew the forks, if

required, and remove the locking plate (1).

- Engage the forks onto the bogies, dimension A (widest side with regard

to the bogie pivot axis) on the inside of the track (detail C).

- Make sure that the bogie pivot axis is always in the axis of the wheel

rolling path (detail D).

- Drive in the shaft until its neck reaches the position allowing to

introduce and to fix the locking plate (1) by means of screws and washers

(2) (see detail E).

- Pack up the cross-member in order to keep them in horizontal position,

fit slings around the side member block (3), raise it and place it onto the

cross-members; fix it using 4x4 bolts (4) but do not tighten.

- Place the 4 strut ties (5) by means of 4x2 shafts (6),

- If required, set the mast section upright which is slung by means of 4

rope lines from the top and place it into the side member block, lining up

the ladder attachments. It will be fitted by means of 4 fishplate bolts

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H30x85 P36 (7) at each corner, with the nut on the side of the side

member plate. Make sure that the bearing surface are clean and ensure

correct tightening.

- Lift up the oblique legs (9) by slinging them at the 2nd plate (10) from

the end fitted with part (11) (photograph B).

- Pin this end onto the basic mast unit by means of a shaft (12); the part

(11) serves to hold the shaft in position without assistance of a 2nd erector.

- Pin-connect with the cross-members by means of a shaft (12).

- Tighten the bolts (4) of the side-member/cross-member assembly.

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CHASSIS EQUIPMENT

A/ FITTING THE LADDERS

Group the ladder components: the 3.60m ladder (1), the 1.50m ladder

(2), the fixing means (3) and the locking wedges (4), the hand-rail (5)

and its fixing brackets (6). Unfold the back loops of ladder (1)

pivoting them downwards; then fit in the following order:

Ladder (1), then ladder (2) onto the ladder supports using the fixing

means (3) and the locking wedges (4). After fitting the basic mast,

install the hand-rail (5)and place the brackets (6) (see detail).

B/ ELECTRICAL CONTROL PANEL

This panel, mounted onto a support (7) is fastened onto a strut or

onto the basic mast opposite to the cable winder, if any. These same

supports are used to fix the panel onto the basic mast if the crane is

mounted on anchoring feet. This panel includes: an inlet for the

mains supply coming from the cable winder, one plug for the remote

control, two plugs supplying the traveling mechanism, the isolating

switch, one output with 4 wires, each fitted with a socket and the

electric weathervaning device. On a equipped with a 2 speed or RCT

traveling mechanism, an auxiliary control panel is necessary. This

control panel (8) will be fitted beside the first one.

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BALLASTING

We recommend to ballast the machine depending on its working

height and according to the indications of the 7A1

Base Ballast Brochure observing the block positioning on the

longitudinal member (blocks with blunted corners on the mast side).

If the total ballast is not available, ensure at least the ballasting

provided for its minimum height.

The remaining ballast can be placed later on (before telescoping)

using the crane. Certain standards require the ballast to be fixed on

the chassis. For cranes supplied in countries submitted to theses

standards, there are two devices:

A/ Device with safety bars, see page 5/1.

B/ Device with safety ropes, see page 5/2.

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BALLASTING

A/ The device comprises for each side:

- 2 uprights (1) equipped with fastening plates (2) -2 uprights (3) -2

fastening parts (4) for the uprights (1) on the chassis (5) -2 bars (6) -1

bar (7).

Fit uprights (1) onto the longitudinal member (2 shafts 20x40 C, mark

8) and connect them with the basic mast unit by means of parts (4)

using shafts (20x40 C, mark 9); split-pin. BALLAST.

Complete the device by fitting uprights (3),then bars (6) and bar (7).

(6)and (7)will be inserted into the uprights and fixed at (10) by means

of 4 shafts 20x70 for (6) and 2 shafts 20x115 for (7).

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BALLASTING

B/ The device comprises for each side:

- 2 uprights (1) equipped with fastening plates (2) –2 fastening parts

(3) for the uprights (1) on the chassis (4) –2 rope (5) –2 rope guide

tubes (6) –2 tensioning device (7).

Fit uprights (1) onto the longitudinal member (2 shafts 20x40 L, mark

8) and connect them with the basic mast unit by means of parts (3)

using shafts (20x40 L, mark 9); split-pin. BALLAST.

Complete the device by fitting ropes (5) using 2 bulldog grips (10).

Pass the ropes through tubes (6). Carry out a loop on the rope ends

using 2 bulldog grips (11). Fit the tensioning devices on ropes (5),

then on the longitudinal member. TIGHTEN.

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MOUNTING THE BASIC MAST

1 Description Weights

2 Preparing the basic mast on the ground

3 Mounting the basic mast

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DESCRIPTION WEIGHTS

The basic mast assembly comprises:

- a telescopic cage (1 ) equipped with its cat-walks (2).

- a basic mast (3)

- a telescoping yoke (4)

- a hydraulic cylinder (5)

The table on the next page gives the weight of the main components

depending on the mast type.

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Weights（Kg）
Rep Nb.
1.6m 2m 2m(H)
1 1 2135 4320
2 4 430 610
3 1 2625 3510
4 1 280 480
5 1 330 330
Total 5800 9250 9250

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PREPARING THE BASIC MAST ON THE GROUND (1.6m mast

section)

Check that the basic mast assembly is equipped with the telescoping yoke

and the cylinder. Otherwise, place the cylinder, piston rod side

downwards, between the cage and the basic mast and pin it onto the

telescopic cage. Position the telescoping yoke and pin it onto the cylinder.

Depending on the type of transport, two cases may occur:

1 - The cat-walks are dismantled.

- Get hold of the packages of cat-walks and grab rails.

- Fit the supports (1) onto the cage using the HM12x35 bolts.

- Position the cat-walks (2) and fix it by means of a HM12x35 bolt at

(3) and at (4) in the articulated fork by means of a 16x85 C shaft.

- Pin the supports and the cat-walk at (5) using HM12x35 bolts.

- Place the cat-walks (6 ) and (7), connect them with the cage and

the supports (1) by means of HM12x35 bolts.

- Fit slings onto the basic mast as shown in fig. A and put it upright.

- Position the cat-walk (8) and connect it with the cage and the

supports (1) using HM12x35 bolts.

- Fit the grab rails (9) and split-pin them at (10).

- Assemble the grab rails together by means of the fixing brackets

(11).

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2 - The cat-walks (2), (6) and (7) are folded back against the basic

mast.

- Unfold the cat-walk (2), then the cat-walks (6) and (7) and fit them

using HM12x35 bolts.

- Fit slings onto the basic mast according to fig. A, put it upright and

mount the cat-walk (8) and the grab rails (9) as in the first case.

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PREPARING THE BASIC MAST ON THE GROUND (2 m mast

section)

Check that the basic mast is equipped with the telescoping yoke and the

cylinder. Otherwise, place the cylinder, piston rod downwards, between

the cage and the basic mast and pin it onto the telescopic cage. Position

the telescoping yoke and pin it onto the cylinder.

- Fit slings onto the basic mast as shown in fig. A, tighten the slings

and put the basic mast upright.

- Get hold of the packages of cat-walks and grab rails.

- Pin the cat-walk supports (1) at (2) onto the cage using 25x60 C

shafts.

- See fig. B concerning the positioning of the cat-walks around the

cage.

- Raise the cat-walks (3) and pin them onto the cage by means of

25x60 C shafts.

- Raise the supports (1) and fit them at (4) onto the cat-walks around

the cage.

- Mount the grab rails (5) and split-pin them at (6).

-Assemble the grab rails together by means of the fixing brackets (7).

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FITTING THE TELESCOPIC CAGE LADDERS

When the ladders had been removed for transport:

- Engage the 3.60m ladders (1) into the 1.50m ladders (2) and mount the

assembly using ladder fittings (3), fixing brackets (4), wedges (5) and

pins (6).

The towerhead access, whist telescoping, is ensured by a ladder located

inside the towehead.

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FITTING THE BASIC MAST

Onto the chassis:

- Lift up the basic mast and check that the fishplating surfaces and the

pin holes are clean, then position it onto the basic mast unit.

- In order to guide the basic mast, take all precautions thus ensuring a

maximum degree of safety for the personnel (form the ground, using

cords, and finally, in order to introduce it into the fishplates, from the

top of the base ballast).

- Fit the assembly at (1) using 4x2 pins (2) secured by a locking pin (3).

- Position the support (4) under the basic mast ladder and set it up onto

the chassis platform .

Onto fixing angles:

- Insert the basic mast right into the fixing angles (AND NEVER INTO

THE FRAME USED TO POSITION THE FIXING AGLIS INTO

THE ANCHORAGEPAD).

- Pin connect the basic mast with the fixing angles by means of 4x2 pins

(2) secured by a locking pin (3).

- Position the support plate (4) under the basic mast ladder and prop it

up (by means of bond stones or others) onto the concrete pad.

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MOUNTING OF TOWERHEAD_CAB MAST

1 Description _weight

2 Fitting the cab mast onto the basic mast

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DESCRIPTION – WEIGHTS

The towerhead-cab mast assembly comprises:

- A mast section (1) equipped with its grab rails (2)

- A cabin (3)

- An equipped towerhead (4)

The opposite table indicates the weight of the main parts which can be

dismantled for transport or handling, if required.

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FITTING THE CAB MAST

- Position both monorails (1) under the towerhead and pin-connect them.

With the cab mast bedded down, fit four 8 m slings Φ21.3 (2) around it

fixing the loops (3) on the cab mast ears (4) according to figure A. Set the

cab mast upright and attach a cord in order to guide it whilst raising.

Using the same sling fitting raise as shown in figure B and engage the

towerhead into the basic mast, the monorails (1) being located on the

open telescopic cage side – see figure C. Pin-connect the towerhead with

the basic mast by means of 8 shaft (5), lock these shafts using 4 pins (6)

and split-pin (7) according to the detail.

IMPORTANT: For greasing by oil bath, check that the drain plug is

closed and fill up the housing with the required oil quantity (see brochure

1 C 3). Pin-connect the cage with the towerhead according to brochure 15

B 1 “preparing telescoping”. To facilitate the following sequences, unlock

the cabin so that it can be moved depending on the mounting needs

Remove the slings.

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MOUNTING OF STRUT

1 Description – weights

2 Fitting the strut onto the cab mast

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DESCRIPTION – WEIGHTS

The complete strut comprises:

- a strut (1)

- two counter-jib tie bars (2)

- two jib tie bars (3)

The opposite table indicates the weight of the main parts which can be

dismantled for transport or handling, if required.

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WEIGHTS – 2500kg

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FITTIGN THE STRUT

Fit a 4 m sling (2) around strut (1). Raise until the position of figure B is

reached. Lower slightly in order to engage the strut feet into the cab-mast

gussets. Pin shafts (3) of the strut and as it is inclined in the right position,

pin-connect the retaining links (4) according to figure C.

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ASSEMBLING THE JIBS AND COUNTER-JIBS

1 Introduction

2 Description of the slewing crane parts

3 Assembling the counter jib

4 Various jibs

5 Connecting the jib sections

6 Assembling the jib ties

7 Jib plates

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The assembly of the jibs and counter-jibs depends on good visual

identification of the main components.

The following pages give details about the lengths of the counter-jibs

with respect to the jib lengths, the various profiles, pin dimensions or

fishplate types, tie lengths, etc.

Pay particular attention to the pins. The different pin types are shown in

the table below. Some are made of high-strength steel (*)and their use for

the connections shown is compulsory.

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WINDSAIL AND SYM PLATES

The windsail plates A and C show the name of our make, D and E are

white.

When assembling the jib and counter-jib and depending on each site , it is

recommended to respect their positions which vary according to the jib

and counter – jib lengths.

All or part of, the plates are used following the instructions of the

drawing hereafter.

On the counter-jib, the plates are to be fitted on either side of the

counter-jib and outside the grab rails. On the jib one single plate is fitted

inside a jib section.

Use the fixing brackets and cadmium-plated bolts HM6x20 with flat

washers and lock nuts so as to prevent any loosening.

For certain cranes and certain uses, the windsail and publicity panels are

stored on the counter-jib (see mark *on next page).

SYM 162
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SYM 163
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SYM 164
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SYM 165
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SYM 166
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SYM 167
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X A B C D E F
● P 42.4 Ø100 45 Ø100 50 Ø70 55 Ø65 60 Ø60
60m C 6000 5600 4950 4450 4000
● P 45.3 Ø100 50 Ø70 55 Ø65
55m C 6000 5400 4800
● P 47 Ø100 50 Ø70
50m C 6000 5600
● P 45 Ø70
45m C 6000
● P 40 Ø70
45m C 6000

●=Jib

P=Radia（m）

C=Load（kg）

SYM 168
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X A B C D E F
● P 21.7 Ø100 35 Ø100 40 Ø100 45 Ø100 50 Ø70 55 Ø65 60 Ø60
60m C 12000 6840 6000 5200 4550 4030 3600
● P 23.2 Ø100 35 Ø100 40 Ø100 45 Ø100 50 Ø70 55 Ø65
55m C 12000 7400 6310 5600 4960 4400
● P 24.1 Ø100 35 Ø100 40 Ø100 45 Ø100 50 Ø70
50m C 12000 7760 6600 5910 5200
● P 24.4 Ø100 35 Ø100 40 Ø100 45 Ø70
45m C 12000 7900 6700 5800
● P 24.6 Ø100 35 Ø100 40 Ø70
45m C 12000 7980 6800

●=Jib

P=Radia（m）

C=Load（kg）

SYM 169
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FITTING THE JIB TROLLEY AND PULLEY BLOCKS

1 Introduction

2 Use of the DM equipment

3 Fitting the jib trolleys

4 Reeving the trolley ropes

5 Working principle of the pivoting arms

SYM 170
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INTRODUCTION

Trolley and pulley block assembly.

1) Trolleying unit

a: Trolleying mechanism is installed at root of jib.

b: Towing rope.

c: Lifting unit with two kinds of fall

1) 2-rope

The front trolley and a pnlley block (see drawing A), Rear

trolley is fixed at root of jib.

2) 4-rope

connect the front trolley and rear tiolley by pin, connect the

lower pwlley blocks by joint beam (see B)

Note: 4-rope unit is nosed when adding sections. The hook

must be special hook

SYM 171
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SYM 172
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USE OF THE DM EQUEPMENT

The coupling or uncoupling of the pulley blocks is to be carried out

without load, at low speed, without swinging and at the jib foot, neither

case requires any manual operation.

The upper pulley block (1) equipped with an automatic coupling device

(2) remains hard against the jib trolley when the lower pulley block (3) is

ensuring the work in 2 fall.

The automatic coupling of the lower pulley block with the upper pulley

block is carried out by means of 2 articulated plates (4) provided with

openings (5) in which the shaft (6) engages and interlocks.

The uncoupling is controlled by an unlocking device (7) held in the upper

position by a spring (8).It acts on the plates (4) by means of a cam stop

located under the jib when the trolley is moved to the jib foot.

SYM 173
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SYM 174
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CHANGING FROM 2 TO 4 FALL

The upper pulley block (1) is hard against the trolley. The coupling plates

are closed.

The lower pulley block (2) is free in 2 fall.

Control 《hoisting》and act on the shunt button of the control unit so as to

allow the coupling of the pulley blocks.

The guidance is obtained by means of the fishtailed leading-in pieces

rigidly fitted onto the upper pulley block.

The coupling plates (6) open when they come into contact with the shaft

ends (3) which prevent he plates from opening.

The locking of the device is obtained by means of the noses (3) located

on shaft (3) which prevent the plates from opening.

Control 《lowering》,the pulley block assembly can work in 4 fall.

SYM 175
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SYM 176
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CHANGING FROM 4 TO 2 FALL

The upper pulley block (1) and the lower pulley block (2) are coupled.

Control 《hoisting》and act on the shunt button of the control unit until the

pulley blocks are hard against the trolley.

The 2 pulley blocks are in contact and, in this position, the connecting

shaft (3) located at the upper end of the opening (4) locks no longer the

coupling plates (5).

Control 《trolley in 》, act on the shunt button and move the trolley hard

against the jib foot.

When over-running, the cam stop (6) pushes the unlocking device

downwards, thus acting on the coupling plates (5) which open by pivoting

around the shafts(7).

The lower pulley block is released, control 《lowering》,the lower pulley

block assembly can work now in 2 fall.

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SYM 178
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FITTING THE JIB TROLLEYS

This operation is to be carried out when assembling the jib on the ground.

The following instructions are given considering that the observer is

placed on the counter-jib and looks towards the jib nose according to the

opposite sketch.

G l.h.s. D r.h.s.

The trolleys and pulley blocks are supplied in 3 main packages:

b) (SM) or (DM) trolley equipment

c) pulley block assembly and hook

d) trolley inspection platform

When fitting the trolley onto the jib, make sure that the attachments of the

front and rear trolley ropes are located on the lefthand side.

Fit the inspection platform onto the trolley using 2 shafts (1);split-pin

them.

The trolleys are provided with a sling (2) fixed by shafts (3).

IN ORDER TO AVOID ANY UNINTENTIONAL MANOEUVER

DURING THE ERECTION OR CRANE USE, LOCK THE TROLLEY

ONTO THE JIB BY MEANS OF THE SLING BEFORE CARRYING

OUT ANY OPERATION ON THE JIB OR ON THE TROLLEY.

For certain countries the trolleys are equipped with a pivoting arm device;

its use is described on page 5.

SYM 179
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SYM 180
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REEVING THE REAR TROLLEY ROPE

Move the trolley hard against the jib foot stops.

Unwind the rear rope from the reel. This rope is defined according to the

jib length used, see table opposite.

Run the rope end without thimble over pulley (3).

Fix this end onto the drum flange using the rope anchor box (4).

Wind the rope onto the drum until the other end reaches pulley (3).

Fix the rope thimble at (5) onto the trolley using a shaft.

Tighten the rear trolley rope.

SYM 181
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SYM 182
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REEVING THE FRONT TROLLEY ROPE

Unwind the front trolley rope from the reel. This rope is defined

depending on the jib length used; see opposite table.

Run the rope over the pulleys (3),(4),(5), put 3 dead turns onto the drum

by winding up the rope from underneath and anchor its end in the rope

anchor box located on the trolley drum flange.

Fix the other end at (6) in the rope anchor box of the tensioning drum on

the trolley and wind up the rope excess until the front rope is taut.

Release the trolley locking sling.

Check the rope tension.

SYM 183
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SYM 184
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WORKING PRINCIPLE OF THE PIVOTING ARM

Certain of our cranes equipped with pivoting arms for the trolley. This

device comprises:

- 1pivoting arm (1) for the front trolley rope.

- 1pivoting arm (2) for the rear trolley rope.

This device blocks the trolley ropes

- check the good wording order of the pivoting arms.

- Run the rope through the eye (3) of the pivoting arms.

During crane work, periodically check the rope tension in order to

maintain the pivoting arms in the horizontal position.

(Fig.1)- position of the pivoting arm with rope taut.

(Fig.2)- position of the pivoting arm after rope breakage

SYM 185
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SYM 186
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FITTING THE COUNTER JIBS AND JIBS

1 Introduction

2/1a Preparing the counter-jib

2/1b Slinging and fitting the counter-jib

2/2a Preparing the counter-jib

2/2b Slinging and fitting the counter-jib foot

2/2c Slinging and fitting the counter-jib nose

3 Fitting the hoist winch-preparing the tie bars

4 Preparing the jibs

5 Fitting slings around the jibs

6/1 Mounting the jibs

6/2 Mounting the jibs

SYM 187
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INTRODUCTION

This manual describes the mounting sequences of the counter-jibs and

jibs.

There are several possibilities but only the most usual has been chosen.

These mounting operations are carried out in 3 phases:

- Preparation and equipment of the crane part to be lifted.

- Fitting the slings,

- Fitting the crane parts onto the crane.

Each of the following pages describes one of these phases, at first as

regards the counter jib and then the jib.

As regards the counter-jib, there are two possibilities:

- Fitting the complete counter-jib

- Fitting the counter-jib foot and then the nose.

As regards the jib, there are also two possibilities:

- Fitting the complete jib

- Fitting the jib foot and raising.

SYM 188
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PREPARING THE COUNTER-JIB

On the ground, assemble the counter-jib nose (1) with the counter-jib foot

(2) using 4x1 shaft (3). Fit the small connecting catwalk (4) between the

counter-jib nose and foot. Fit and assemble the ballast support (5) on the

counter-jib nose using 4x1 shaft (6). Fit or fold down the catwalks and

assemble them according to detail A. Place the lateral grab rails and

interconnect them by means of parts (7); split-pin at (8). Place both end

grab rails (9), fix them using 4x1 shaft (10) according to detail B and pin

-connect them at (11).

Fit the counter-jib plates according to brochure 8 B 1. Before raising the

counter-jib, position two 3.80m tie bars (12) which will be pin-connected

with those of the strut (13). Attach a cord at the counter-jib nose so as to

be able to guide it from the ground.

SYM 189
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SYM 190
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SLINGING AND FITTING THE COUNTE-JIB

To fit the counter-jib use two 12m slings (Φ21.3mm) (1). Run the slings

around the four points provided on the counter-jib nose.

Lift the counter-jib up from the ground and check its stability. The

counter-jib being slightly inclined towards the front, raise it and pin the

two upper shafts (2) which are already positioned in the shaft inserting

devices; split-pin.

Lower in order to pin the two lower shafts (3);split-pin. As the counter-jib

is inserted and pin-connected onto the cab mast, remove the slings (1).

SYM 191
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SYM 192
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PREPARING THE COUNTER-JIB

Fit and assemble the ballast support (1) on the counter-jib nose (2) using

4x1 shaft (3).

Fit or fold down the counter-jib nose catwalks (4) and assemble them

according to detail A.

Place the lateral grab rails (5) and interconnect them by means of parts

(6); split-pin at (7) according to details A and B.

Place both end grab rails (8), fix them using 4x1 shaft (9) according to

detail C and pin-connect them at (10). Position the lateral grab rails (11)

onto the counter-jib foot (12), interconnect them by means of parts (6)

and split-pin at (7) according to details A and B. Rest the counter-jib

plates onto the counter-jib nose until they will be fitted according to

brochure 8 B 1. Fit the counter-jib yoke (13) onto the counter-jib foot.

Before raising the counter-jib foot, position two 3.80m tie bars (14)

which will be pin-connected with those of the strut (15). Attach a cord at

the counter-jib foot so as to be able to guide it from the ground when

raising. Carry out the same operation for the counter-jib nose.

SYM 193
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SYM 194
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SLINGING AND FITTING THE COUNTER-JIB FOOT

To fit the counter-jib foot (1) use two 8m Φ21.3 slings (2). Fit these

slings between the diagonals of the counter-jib foot according to fig. A. fit

the slings so that the counter-jib foot is slightly inclined towards the front

as shown in fig. B. When raising the counter-jib foot make sure that the

counter-jib yoke (3) is attached onto the foot.

Lift the counter-jib foot up from the ground and check its stability. Raise

it by means of the mobile crane above the upper fixing points, lower and

bolt the upper pins (4).

Placed in the pin inserting devices, then split-pin. Continue lowering until

the 2 lower pins (5) can be inserted; split-pin.

Free the slings.

SYM 195
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SYM 196
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SLINGING AND FITTING THE COUNTER-JIB NOSE

To fit the counter-jib nose (1) use four 8mΦ21.3slings (2). Fit the slings

so that the counter-jib nose is slightly inclined towards the front as shown

in fig. A.

Use the slinging points (3) at the front and the winch support gussets (4)

at the rear according to fig. B.

Lift the counter-jib nose up from the ground and check its stability. Raise

it by means of the mobile crane above the upper fixing points, lower and

bolt the 2 upper pins (5).

Placed in the pin inserting devices; then split-pin.

Continue lowering until the 2 lower pins (6) can be inserted; split-pin.

Free the slings.

Fold down the connecting catwalk between the foot and the nose and fit

the grab rails stored on the counter-jib nose.

SYM 197
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SYM 198
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FITTING THE HOIST WINCH – PREPARING THE TIE BARS

On the ground, fit three 4m slings (1) on the hoist winch, and use 3

shackles to fix them at the rings of the winch platform.

Raise the winch and position it onto the counter-jib, then pin-connect it

using 4x1 shaft (2) according to detail A. Remove the slings.

Pin-connect the 3.80m tie bars (3) with the 5.77m tie bars (4) of the strut,

the whole assembly being pinned on the counter-jib yoke (5). For raising

the strut and tightening the tie bars, use a Tirfor (6) fixed at (7). Run the

Tirfor rope (8) over the yoke pulley (9) and anchor it at a point of the

counter-jib nose according to detail B.

SYM 199
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SYM 200
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PREPARING THE JIBS

Pack up the jib foot sufficiently so that the jib trolley can be fitted. Mount

the trolley, equipped with its inspection platform (see brochure 9 B 1) and

block it on the jib foot.

Fit the jib foot grab rail. Assemble the jib sections according to the

required jib length (see brochure 8 B 1). Fit the brackets (1) onto the

upper jib section member making sure that the round bar (2) of the half

collars engages properly between the diagonals in order to prevent any

tilting of the tie bar line (detail A). Onto the lower tie bars (4) mount and

fix the brackets (3) into which the upper tie bars (5) will engage (detail B).

Mount and pin-connect the lower tie bar line (4) (brochure 8 B 1) and the

upper tie bar line (5).

The lower (4) and upper tie bar lines (5) are missing the tie bars (6) and

(7) which are fitted onto the strut by means of the connecting links (8)

and (9) as shown in detail C.

Fit the safety rope (10) at the jib nose using three bulldog grips (detail D),

run it through the hooks provided on the jib and fix it on the jib foot

gusset using three bulldog grips (11) (detail E).

SYM 201
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Fasten a cord on the jib nose, thus allowing to guide the jib from the

ground.

NOTE: Before raising the jib attach the tie bars (4) and (5) onto the upper

member of the jib foot using a short sling (12) placed behind the tie bar

head according to detail F.

SYM 202
203
FITTING THE SLI NGS
The dimension marked on the jibs (see opposite sketch) corresponds to the theoretical
distance between
the center of gravity and the fib foot.

These sling points are theoretical. Raise the fib about 10 cm and adjust the slinging
Points
if necessary.

IMPORTANT:

Check that the slings are fitted either in front of (a) or behind (b)a node of the upper
member and
Not between the diagonals (c) .DO NOT JAM the tie bars between the rope lines at
the
slinging point.
Use two 8 mφ21.3 slings for E.F.G cranes and 12 m slings for H cranes.

204
205
 FITTING THE JIBS
The jib fitting is carried out in three phases.
A – Fitting the jib foot
B – Raising the jib nose
C – Tightening the tie bars

First phase A = Fit two 4 m slings (1) around the jib foot. The jib nose is
to be placed onto two cross-beams (2) in order to promote its sliding. By
means of the mobile crane raise the jib foot beyond the pinning points,
then lower so that the jib foot shafts (3) can be pinned; split-pin. Remove
the slings.

Second phase B =Drive the mobile crane to the jib nose, fit slings (4)and
raise it until the tie bars (5) and (6) can be pin-connected with those of
the strut (detail a). Operate the “Tirfor” (7) (see fitting page 3/2) in
order to tighten the counter-jib tie bars. Withdraw the shafts or links (8)
and fold the latter back onto the counter-jib.

Third phase C = Continue operating the “Tirfor”, the strut tilts backwards.
The jib tie be lines are tightened. Pin-connect the counter-jib yoke (9) to
the links (10) according to detail (b). Remove the “Tirfor” and the mobile
crane slings.

206
207
 FITTING THE JIBS
The jib fitting is carried out in three phases.
A – Raising the jib
B – Pinning the tie bars
C – Tightening the tie bars

First phase A = Fit two 12 m φ21.3 slings (1) around the jib, slinging
points indicated on page 5. Fasten two cords on the jib nose so as to guide
the jib whilst raising. By means of the mobile crane, lift the jib up beyond
the pinning points, then lower so that the two jib foot shafts (2) can be
pinned” split-pin.

Second phase B = Continue raising by means of the mobile crane until

the tie bars (3) and (4) can be pin-connected with those of the strut
(detail a). Operate the “Tirfor” (5) (see fitting page 3/2) in order to tighten
the counter-jib tie bars. Withdraw the shafts of links (6) and fold the latter
back onto the counter-jib.

Third phase C = Continue operating the “Tirfor”, the strut tilts backwards.
The jib tie bar lines are tightened. Pin-connect the counter-jib yoke (7) to
the links (8) according to detail (b) . Remove the “Tirfor” and the mobile
crane slings.

208
209
REEVING THE HOIST ROPE FOR WORKING

1 Introduction

2 Choice of the hoist rope

3 Reeving the hoist rope

4 Fitting onto the hoist drum

210
 INTRODUCTION

The hoist rope is normally supplied wound up onto the hoist drum. For
further erections the hoist rope transport must be maintained in this
manner except that the hoist rope must be removed for the following
reasons:
. rope wear noticed when dismantling
. rope length not corresponding to the new working height.
The choice of the hoist rope is described on page 2.
The hoist rope reeving is shown on page 3.
The description for fitting the rope onto the hoist drum is given on page 4.

211
 CHOICE OF HOIST ROPE

It is most advisable to adapt the length of the rope in accordance with the
height and duration of use at that moment.
This assuming that the maximum working height will be obtained by
several phases.

The following tables illustrate the various height stages according to the
equipment of the equipment of the crane.

212
SM

120 LMD 30 DM

SM

120 LMD 30 DM 1+47

30

30
RCS

RCS
55 RCS 30
55
2+54

2+45

RCS
55
1+56

55

SA—VA PA

Cable anti

Drallfreies Seil
C a b l e a n t i d 1 8 R 1 8 R 0 4 4 11
Non spinning rope

213
 REEVING THE HOIST ROPE

Run the rope successively over the fleeting pulley (1),over the strut pulley
(2),over the load weighing pulley (3) and over the biconical roller (4).
Bring the rope to the trolley placed on the jib foot. Carry out the rope
reeving according to detail A (2 fall –4-fall). The pulley blocks are
propped up vertically on the ground so as to avoid any friction of the rope.
Equip the rope with the rope anchor box (5) and fix a bulldog grip (6) on
the dead line (detail B) . At about 1 m from the rope end, fix a pin by
means of two bulldog grips (detail C) in order to ensure a temporary fixed
point between the pulley and the rope guide when raising the pulley
blocks. Lift up the pulley blocks and move the trolley to the jib nose (if
necessary, slacken the rope by moving the control lever to
hoisting-lowering ) . Fit the rope anchor box onto the rope swivel using
shaft (7) . Split-pin. Remove the pin. Check the rotating of the rope
swivel.

214
215
 WINDING THE HOIST ROPE ONTO THE DRUM

This operation must be carried out ensuring the largest possible distance
between the reel (1) with the new rope and the drum (2) . This condition
is automatically obtained after fitting the counter-jib .
Using a cord, raise the rope end onto the counter-jib. Run the rope over
the pulley (3)and fix it in the rope anchor box (4) by means of pear (5)
(detail A) . Carry out the corresponding electrical connections so as to be
able to use the “HOIST” motion. Check that the rope winds up correctly
onto the drum grooves (2).

216
217
FITTING THE COUNTER-JIB BALLAST

1 Introduction

2 Fitting the ballast using a mobile crane

3 Fitting the ballast using the hoist winch

218
INTRODUCTION

There are two possibilities:

using a mobile crane according to the instructions on page 2
by means of the hoist winch with an appropriate rope reeving system, see
instructions on page 3

The second method b) can be applied after an erection with a mobile

crane if latter must be released or if the access to the rear of the
counter-jib is not possible.

It is to be noted that lifting the ballast with the hoist winch requires the
crane to be connected electrically, i. e. that the recommended electric
power is already installed on the rite.

On the other hand, if the hoist rope was stored on a reel, it is

recommended to wind it completely onto the hoist drum before fitting the
counter-jib. This would reduce the time for reeving the rope, especially if
it has been found in the very last moment that the ballast must be raised in
this manner.

BEFORE FITTING make sure that the types, the total weight and the
dimensions of the blocks correspond to the respective prescriptions. FOR
LACK.OF CHECKING ON THE GROUND you risk incidents when
engaging them into the counter-jib.

219
FITTING THE BALLAST USING A MOBILE CRANE

Remove the locking bar (1) located a the counter-jib nose. Position the
ballast blocks in thair fitting order ( see brochure 8 A 1) . Using sling (3 )
fitted by shaft (2) raise the first block up to the level of the ballast support
(4) . Engage the block between the upper beams as shown in fig. A and B.
Pin the shafts (5) on the attachments (6), then lower the block so that the
shafts engage into their supports (7) as shown in detail C. During this
operation, check particularly that the block does not press under the
counter-jib thus risking to lift it up.

Proceed in the same manner for the other blocks . As soon as all the
blocks are fitted, they must be locked together. To do this, slide the fixing
rods (9) through the holes of the blocks. Introduce the forks (8) onto these
rods and place them into the holes provided for this purpose. Then carry
out 1/4 turn with the rods so as to block the forks. On the inside, engage
the forks (10) into the ballast support and lock the whole assembly using
2 nuts (11) as shown in detail D. All the ballasting sequences are carried
out from the cat-walks (12). Re-fit the locking bar (1).

220
221
FITTING THE BALLAST USING THE HOIST WINCH

Position the ballast blocks under the counter-jib (see brochure 8 A 1). Fit
the ballast lifting beam (1) and lock it by means of two shafts (2) (fig . A
and B).
A—Reeving the hoist rope. Unwind the rope, run it over the pulleys (3) ,
(4) , (5) , (6) and by means of a rope anchor box (8) , pin it at (7) noto
the lifting beam using shaft (9) .
B—Raising the ballast. By means of the hoist winch lower the lifting fork
(10) and fit it using 1 shaft (11) onto the first block. Raise the block up to
the level of the ballast sup port and engage it (as shown in fig. B) by
guiding the block from the cat—walks (12) . Pin the 2 shafts (13), then
lower the block so that the shafts engage into their supports (14) as shown
in detail C. During this operation, check particularly that the block does
not press under the counter—jib which could cause anomalous forces in
the crane structure.
Displace the lifting beam and carry out the same operation for each block.
As soon as all the blocks are fitted. They must be locked together. To do
this, slide the fixing rods (16)through the holes of the blocks. Introduce
the forks (15) onto these rods and place them into the holes provided for
this purpose . Then carry out 1/4 turn with the rods so as to block the
forks. On the inside, inside, engage the forks(17) into the ballast support
and lock the whole assembly using 2 nuts (18 ) as shown in detail D .

222
223
MAST COMPOSITION

1 Introduction

2 Mast composition

3 Preparing the mast sections and accesses

224
 MAST COMPOSITION

This manual specifies the various masts with which the machines stated
in the following tables are fitted.

The crane towers are made up of telescopable mast elements with

different sections or lengths. They are:
a) Masts with pin-connections –section 1.6 m
b) Masts with pin-connections –section 2 m

The mast types a and b are defined on pages 2.

Pages 3 give details about assembling the masts of 1.6 and 2 m section
using shafts.

These mast compositions are valid only for free standing heights on
fixing angles or on chassis.
For greater heights the mast is generally reinforced at its base according
to the indications in brochure 9 A 1.

For climbing cranes, see special brochure.

For all other cases which are not mentioned, consult our
After-Sales-Service.

ATTENTION. REDUCED WORKING HEIGHT FOR FAST

TRAVELLING, SEE CATA SHEET.

225
 PA VA 654
654

226
 ASSEMBLING THE MAST PANELS

A mast section comprises 4 panels and 4 diagonal braces which differ

from one another as follows:

. 2 panels (1 and 2) without telescoping lugs

. 2 panels (3 and 4) with telescoping lugs
. 2 diagonal braces (5 and 6) without ladder fastenings
. 2 diagonal braces (7 and 8) with ladder fastenings

The panels are assembled by means of 4 headed shafts (9) and split pins.
The diagonal braces equipped with the ladder fastenings must face each
other.
The diagonal braces are fitted on the panels by means of 8 shafts (10) and
split pins.

The mast sections are assembled together by means of 8 shafts (11)

connected 2×2 by 4 pins (12) with split pins; they are equipped with an
access assembly defined in brochure 14 B 1.

227
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 FITTING THE ACCESSES

1 Introduction

2 Use of the accesses (table)

3 Fitting

229
 INTRODUCTINN

The fitting of the accesses in the mast sections ix carried out on the
ground; thus allowing when telescoping, to lift up the complete equipped
mast sections onto the introducing rails.

Three access types are used; they comprise :

—A access : a ladder with back loop
—D access :a ladder with back loop and landing-place
—E access :a ladder with back loop and platform
Latter, fitted on the last mast section to be telescoped, allows the
towerhead to be reached.
The table on page 2 shows for each crane height the distribution of
each of theses access types. It should be observed that, when the final
working height is attained in several phases, the access of the last mast
section will be adapted when telescoping, i.e, it is to be removed and
replaced by an A or D access (see table page 2).

The pages 3 give the equipment detail of the various access types.

230
 FITTING THE ACCESSES

All the ladders are fitted on the mast panels equipped with the
telescoping lugs.
The A and D accesses must be positioned according to the instructions
given in the following tables.

ATTENTION : The tables, page 2, vary depending on the countries.

NF : France and NF countries (Belgium, Luxembourg etc.)

DIN : Germany and DIN countries (Austria, Switzerland etc.)
NL : Netherlands

Find out the table you are concerned with.

231
NF

232
DIN

233
NL

234
 FITTING THE ACCESSES

A ACCESS (1.6 m . 2 m)

—Put the mast section upright.

—Fit the ladder support (1) on the mast gussets using φ10 shaft (2);
split-pin.
—Check that the ladder ends (3) are clean (no earth or other matters in
the holes) and not crooked.
—Manually introduce the ladder (with the back loops folded back )into
the mast section.
—Position the ladder top onto the ladder support (1).
—Introduce the two fixing brackets (4), insert wedges (5), drive them in
and bend the ends (6) outwards.
—Unfold the back loops (7).
—In order to prevent the ladder from swinging in the mast when fitting,
block it using a cord or a steel wire.

235
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 FITTING THE ACCESSES

D ACCESS (1.6 m . 2 m)

Put the mast section upright. Then fit the ladder support (1) on the mast
gussets using φ10 shaft (2); split-pin.
Check that the ladder ends (3) are clean (no earth or other matters in the
holes ) and not crooked.
Manually introduce the ladder (with the back loops folded back) into the
mast section.
Position the ladder top onto the ladder support (1).
Introduce the two fixing brackets (4), insert wedges (5), drive them in and
bend the ends (6) outwards. Unfold the back loops (7).
Fit the landing-place (8) in the mast section (opening on the ladder
side )using clamps (9) and bolts (10). Fit the grab rails.
In order to prevent the ladder from swinging in the mast when fitting,
block it using a cord or a steel wire.

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 FITTIN THE ACCESSES

ACCESS E · ACCESS TO THE TOWERHEAD :

· Put the mast section upright.

. Fit the ladder supports (1) and (2) on the mast gussets using φ10
shafts (3), split-pin.
· Check that the ladder ends (4) are clean (no earth or other matters in
the holes) and not crooked.
. Manually introduce the ladder (5) (with the back loops folded back)
into the mast section.
· Position the upper end of the ladder (5) onto the ladder support (1) at a
distance of some centimeters from the top.
· Introduce the 2 fixing brackets (6), insert wedges (7),drive them in and
bend the ends (80 outwards.
· Unfold the back loops (9).
· Fit the platform (10) in the mast with the opening on the side of the
ladder (5) using the clamps (11) and the bolts (12).
· Engage the lower end of the ladder (13) into the platform (10) and fix
the ladder top onto the ladder support (2), same fixing operation as for
ladder (5) on ladder support (1).
· In order to prevent the ladder (5) from swinging in the mast when
fitting. Block it using a cord or a steel wire.

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PREPARING THE TELESCOPING

1 Introduction

2 Table of telescoping accessories

3 Fltting the telescoping equipment

Putting the hydraulic group into service

4
Putting the ram into service

241
 INTRODUCTION

Preparation for telescoping consists of placing the accessories required

for telescoping.

The accessories are specific to particular crane types and are recapitulated
in the table on page 2.

Most are placed during fitting of the relevant crane part without being
《ready to work》as such.

These operations necessary either after erection of for a height increase

are described on pages 3.

How to put the hydraulic unit into service ix given on page 4.

These appliances are tested and guaranteed by the constructor. In the case
of serious breakdown, it is preferable to contact our After-Sales-Service
rather than to carry out a faulty repair which could be dangerous and
cancel the guarantee.

242
 SEGNATION
MAT 2 m MAT 2.15 m
ACCESSOIRES CE TELDSCOPAGE
CAGE TELESCOPIQUE P 16101—28
TRAVERSE CE TELESCOPAGE DO5110—40
CHARIOT DE MONOPAIL UO7110—40
MONORAIL A12110—88
12T Z12110 87—
CTOCCHET DE TELESCOPAGE
16T A — 19110-93
HYDRAULIC GROUP B01435—49
HYCRAULIC TAM V33467 49—
PRESSURE TO BE OBSERVED 480 b
THE MARKED. PARTS * MUST IMPERATIVELY BE USED TOGETHER.

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FITTING THE TELESCOPING EQUIPMENT

3/1 Positioning the telescoping yoke

3/2 Positioning the telescopic cage

3/3 Mounting the monorail

3/4 Fitting the telescoping hook

3/5 Fitting the mast lifting yoke

244
 POSITIONING THE TELESCOPING YOKE

This operation is carried out when lowering or re-raising the telescopic

cage along the mast tower.

Use a long double sling (1) so as to better guide the yoke against the mast
(detail A).

Position the yoke in front of a set of telescoping lugs.

Hook the yoke (2) onto the telescoping lugs (3) using support plates (4);
if required, lock it by means of stop plates (5) screwed onto the support
plates by the bolts (6)—detail B.

245
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 POSITIONING THE CAGE

Cage attachment on the towerhead:

It is recommended to carry out this operation during the erection. There
are two possibilities:
using the ram, in the case of a short distance. Put the hydraulic system
into operation following the instructions as given on pages 5. When the
yoke is fixed on the lugs effect a stroke until the cage uprights (1) can be
introduced in the towerhead corners (2), pin-connect using 4×1 shaft (3)
and split-pin them.
Using slings. Either by means of the mobile crane during erection or
using the crane itself after its putting into service for a height increase or
for dismantling. Use a sling of φ15.1, length 4 m which surrounds the
rear cage beam at the level of the ram attachment (4). Remove the device
locking the cage on the basic mast. Lift up and guide using a crowbar
until the cage uprights are inserted in the towerhead corners (2), then pi
–connect using 4×1 shaft (3) and split-pin them.
ATTENTION: During this operation compensate as much as possible for
the lateral forces due to the pull of the sling so as to prevent the cage from
getting blocked on the mast. Dismantling and the whole re-fitting
operation of the cage are dealt with in a special brochure.

247
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 FITTING THE MONORAILS

The two monorails are fitted using a double sling (1) attached to the
handle of the monorail (detail A).

Raise the monorail up to its working position; trolley-in so as to slide the

rear part of the monorail in between the basic frame and the towerhead
according to (B).

Rest the rear part of the monorail on the basic mast frame.

By hand, pull the monorail inside the mast. Using the pulley block
manoeuvre so as to ease the introduction of the monorail in its seating.

Move back the monorail, after removing the sling so as to be able to

pin-connect shaft (3) and to split-pin it according to detail C.

Proceed in the same manner for the other monorail.

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FITTING THE TELESCOPING HOOK

In order to raise the masts by means of the mast lifting yoke , the hoist hook
must be disconnect and replaced by the telescoping hook (1) provided for this
purpose.

Pin-connect hook (1) on the lower pulley block (2) using shaft (3) and split-pin
latter.

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SYM 252
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HYDRAULIC GROUP
Packing – Filling up – Connections – Adjustments

HYDRAULIC RAM

Bleeding the hydraulic circuit - Adjustments

For all these conditions of use see

the operating instructions concerning

the type of crane used.

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BALANCING THE CRANE FOR TELESCOPING

1 Special instructions

2 Balancing positions (chart)

3 Balancing the crane

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SPECIAL INSTRUCTIONS

The crane is balanced in two stages :

a/ theoretically by suspending a load at a given radius , see page 2

b/ practically by adjusting the position of the jib trolley(s) , see page 3

We remind you that it is strictly forbidden to SLEW the jib ,

to MOVE the jib trolley and
to HOIST (hoist up or down )
when the telescopic cage is lifted or being lifted .

NOTE : For each crane type there are several pages «2» giving the theoretical
balancing position depending on
1) the mast type
2) the type of hoist winch .
So consult the page corresponding to the equipment of the crane concerned .

CAUTION : It is necessary to use a bracket (1) on the telescoping hook (2) in

order to suspend the balancing load .

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SYM 256
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INTRODUCTION

The perfect working order of the telescoping assembly (cylinder and cage )
involves the center of gravity of the lifted part being in the axis of the cylinder .
Also make sure that a mast section hangs from the monorails before carrying out
the balancing operation .

Move the trolley , if required with an appropriate load , to the balancing position
given in the tables on page 2 .

The distances stated are theoretical ; they depend in particular on the actual
counter-jib ballast weight . Make sure that this ballast weight corresponds to the
counter-jib and jib lengths used .

Moreover , the wind exerts an action on the crane equilibrium which must not be
neglected . If the wind speed exceeds 60 km/h the crane must not be telescoped .

The load of 1000 kg is an arbitrary weight , the other loads correspond to the
weight of one base ballast block .

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BALANCING THE CRANE

- The crane can only be balanced after the towerhead feet (1) have left the mast
fishplates (2) .
- Operate the lever of the hydraulic group in the «hoist up» direction and
telescope until the feet of the towerhead just leave the fishplates .
- Check that the crane is balanced and readjust , if required, by moving the jib
trolley according to the various possibilities described in the manual «Use
and fitting the jib trolleys» .
- The exact position is found by verifying the alignment of the towerhead feet
with fishplates and checked by reading the minimum pressure required for
telescoping on the pressure gauge of the hydraulic group .
- This balancing position of the jib trolley can be marked on the jib by knotting
a rag around a diagonal bracing . But remember that this marked distance
depends on the jib length . Consequently the mark should be removable .

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SYM 264
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TELESCOPING

2m×2m Mast

1 Principle

2 Introducing the mast section

3 hanging the 2nd mast section from the monorail

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PRINCIPLE

The telescoping sequence comprises a series of operations which are repeated

several times .

- Lifting the crane part to be telescoped by extracting the ram which rests on
the telescoping yoke (1) and the lugs (a) .

- Resting the lifted part on the lugs (c) of the mast by means of the cage shoes
(2) .

- Resting the safety shafts (3) which lock the support plates (4) on the
telescoping lugs (a) .

- Unhook the support plate/yoke assembly , keep it away from the lugs , then
raise it by retracting the ram .

- Rest the assembly on the next pair of lugs above (b) .

- The first ram stroke is about 1 m and constitutes the initial climbing phase
according to figures A and B .

- Repeat the sequence three times so as to obtain the space (5) required for the
introduction of the mast in the cage according to figures C and D .

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INTRODUCING THE MAST SECTION

The lifted crane part is resting on the upper lugs (e) of the last mast section by
means of the support shoes (1) of the cage . The ram is almost entirely extracted
and total stroke is provided in such a way that the upper guide rollers of the
telescopic cage cannot go beyond the fixed part of the mast tower .

Slide the mast toward the tower and introduce it into the cage , see figure A .

Operate the hydraulic group lever in the “hoist up” direction so as to release the
shoes (1) from the lugs (e) . hold latter away from the mast using the control rod
(2) .

Operate the hydraulic group lever in the “hoist down” direction and make sure
that the mast section (3) engages correctly in the fishplates (4) . Connect this
mast section using 4x2 shafts , insert locking pins and split-pin them , see detail
B . Raise the ladder which pivots in (5) up to its upper fixing position and
engage the tenons of the ladder uprights in the ladder of the lower mast section
(6) .

Disconnect the mast lifting yoke from the 4 attachment points (7) and slide it out
of the cage .

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HANGING THE 2nd MAST SECTION FROM THE MONORAIL

To hang the mast section to be telescoped from the monorail ,it is essential that
the lifted crane parties solidly anchored to the fixed mast tower .
To do this , operate the lever of the hydraulic group in the “hoist down” direction
until the feet of the towerhead (1) engage in the fishplates of the last mast
telescoped .
Fit the safety pins (2) fixed to the cage by chains located on the side of the cage
ladders .
If required ,lower the balancing load ,hang the mast lifting yoke from the pulley
block .
Suspend another mast section fitted with its accesses on the mast lifting yoke (3)
and raise it up to the monorail (4) .
If required , reposition the balancing load and balance the crane .
Disconnect the safety pins (2) .
Another telescoping sequence can be started . Repeat it until the required height
is obtained .
IT IS STRICTLY FORBIDDEN TO CARRY OUT A HOISTING BEFORE
THE NORMAL WORKING SHAFTS HAVE BEEN PUT IN PLACE .
The last mast section must be pin-connected to mast tower as well as to the
towerhead feet .

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PUTTING INTO SERVICE

1 Introduction

2 Checks to be carried out after erection

3 lowering the telescopic cage

4 Accesses and safety devices

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INTRODUTION

All the operation the putting into service serve the crane work under
correct driving and safety conditions

On the whole , ale these operations can be split up into three groups:

- Checking and carrying out the mounting operations in order to avoid any
hindrance as regards the proper working order or the safety (see pages 2 and
3 ).
- Adaptation of the crane equipment to the site requirements(see brochure 9
B1) .
- Adjusting the various safety devices (see Operating instructions) .
in order to carry out the adjustments and maintenance and to reach the control
unit , use the devices provided on the crane according to the way shown on page
4.

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CHECKS TO BE CARRIED OUT AFTER ERECTION

The execution of the crane erection and safety require a certain number of
operations or checkings to be carried out according to the following description:

CONCERNED CRANE PARTS OPERATIONS TO BE CARRIED OUT

Travelling crane
- Check that there are no obstacles on the track
which may hinder the crane travelling .
- Check the fitting of the buffers and the limit
switch ramps (according to the standards in
force ) .
Travelling - Remove any wedges and anchorages .
- Release the bogie rail clamps .
- Make sure that the traveling mechanisms are
electrically connected .

Static crane :
- Check that the bogie rail clamps and any other
anchoring means possibly used are correctly fitted.

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CHECKING AFTER FITTING (cont’d)

CRANE PARTS CONERNED OPERATRIONS TO BE CARRIED OUT

- Check the cable winder installation

- Check the supply cable length with regard to the middle
point of the track.
Chassis - Check the correct ballast attachment .
- Check the fastenings for out of service anchorage, if any.
- Check that the electric cables run correctly under the
chassis in order to avoid any damage .

- Check the fixing of the ladders and back loops, replace

Access defective parts , particularly the locking wedges when
re-using .

- Check the good tightening of the mast pinning bolts .

- Check that the electric cables are correctly hooked on
Crane tower the cable support rope (see detail 2) .
- On the basic mast check the fitting of the ladder
extension of the basic mast unit (fig . B1-B2) .

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CHECKING AFTER FITTING (cont’d)

CRANE PARTS CONCERNED OPERATIONS TO BE CARRIED OUT

L 600 mast : pushing in the monorails under the

towerhead (see page 3/1)
Monorail
R 700 mast : Lowering the monorails according
to brochure 15 B 1, page 6 .

L 600 mast only : Lowering the telescopic cage .

Telescopic cage (see page 3/2 )
Check the fastening of the cage ladders .

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CHECKING AFTER FITTING (cont’d)

CRANE PARTS CONCERNED OPERATIONS TO BE CARRIED OUT

Check the hoist and trolley rope reeving.

Check the locking of hoist winch derrick (with
the nose pointing to the mast and locked in
position by a handled shaft see detail C, page 2).
Mast head Check the counter-jib ballast attachment.
Check that the catwalks are cleared of all things
which could fall down when operating crane.

Check the level and greasing points acceding to

Greasing the Operating Instructions.

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PUSHING IN THE MONORAILS

As the monorails risk to hinder maneuvering the jib trolleys at the minimum
radius, we advise you to push them in under the towerhead.

Figure A: monorail pulled out for telescoping

Figure B: monorail stored under the towerhead after telescoping

Unpin shafts (1) and (2), the links (3) and (4) lower to position B. Repin shafts
(1) at a and b; later on the monorail (5) will be supported by these shafts. Unpin
shaft (6), lift up the monorail (5) at its nose by means of the hoist yoke, pin shaft
(6) at c. Unpin shaft (7). The monorail until it can pinned at d.

Repeat the same operation for the monorail.

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LOWERING THE TELESCOPIC CAGE

Using the crane, lower the telescoping yoke and the ram to the ground. Fit a
sling (1) around the rear cage beam on the ram fastening (detail A) and hang it
from the load hook. Use a sling which is long enough so that the pulley block
does not lower underneath the towerhead . Tighten the sling but not too
much .Check that the mast sections are pin-connecter together and with the
towerhead. Remove shafts (2) connecting the telescopic cage to the towerhead
(detail B) . Release the safety locks .

In order to carry out the lowering operation in safety, the personnel must leave
the cage catwalks and work from inside the mast using the normal access .

Slacken the rope , the cage lowers due to its dead weight .

ATTENTION : During this operation compensate as much as possible the lateral

forces due to the rope tension so as to prevent the cage from being blocked on
the masts ; the weight of the hydraulic unit serves to equilibrate . Release the
safety locks when passing over the lugs , continue lowering as low as possible
on the basic mast without hindering the mast access . Support the cage onto a set
of lugs . Remove the hydraulic unit and store it away with the ram and the
telescoping yoke .

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B2-DISMANTLING USING A MOBILE CRANE

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DISMANTLING USING A MOBILE CRANE

1 Introduction
2 Preparing the dismantling
3 Dismantling the mast
4 Removing the ropes and the counter-jib ballast
5 Dismantling the jib
6 Dismantling of winch and tie bars
7 Dismantling the counter-jib
8 Dismantling of strut-Cab mast-Towerhead-Basic mast
9 Dismantling the chassis

SYM 286
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INTRODUCTION
As far as the final stage of dismantling is concerned , this be carried out
entirely by the mobile crane , but site conditions permitting it can be carried out
partly by the hoist winch . which requires that the electrical installations must
not touched .
For this purpose this brochure deals with the types of dismantling for
lowering the counter-jib ballast and dismantling of the jib .
IMPORTANT ADVICE :
For dismantling certain parts, such as the jib , counter-jib…security regulations
must be observed which enable all risk of the load being out of balance with the
rest of the crane to be prevented when removing the part .

The page opposite shows an example of safety for a jib.

This involves linking the jib to the cat-head using a sling (1) and a
shackle (2) before unpinning the jib . Depending of where it is out of balance
(towards the top or towards the bottom), sling the jib foot to a Tirfor (3) from
which the stability of the load is maintained . After tightening the Tirfor , remove
the safety sling (1) and act on the Tirfor during lowering the jib .

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PREPARING BEFORE DISMANTLING

If required :

a) Move the crane to the dismantling area and make sure that there is no obstacle
hindering the dismantling operations .
b) Fold down the bogie rail clamps and tighten them on the rails the telescopic
cage to the mast top (1) and pin-connect it to the four towerhead corners (see
brochure 16 B 1). Fit the telescoping accessories according to the instruction
given in the same brochure taking the following differences into account :

a - The telescoping yoke (2) will be fitted on the 5 th set of lugs (3) from the
towerhead

b - The mast lifting yoke will be raised on the monorail and fixed on mast
section to be dismantled .

Slew the jib to the open side of the cage .

The crane is now in the position as shown in figure A .

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DISMANTLING THE CRANE TOWER

Carry out the balancing condition for telescoping the crane according to the
instruction given in brochure 16 B 1 . As soon as the towerhead feet have left the
fishplates by about 2 cm , stop telescoping and lock the attachments (1) of the
mast lifting yoke (2) on the mast section (3) to be dismantled . For fitting the
lifting yoke , refer to brochure 15 B 1 . Remove pins (4) and shafts (5)
connecting mast section (3) with that below . Unhook the ladder . Continue
telescoping up until mast section (3) can be pulled out from fishpla s (6) , then
rest the locking shoes (7) of the telescopic cage on the lugs (8) of the mast .
Move the mast lifting yoke (2) outside on the monorail so as to bring the mast
out of the cage .

Pivot the ladders a little upwards in order to avoid that they get caught on the
inner mast . Then carry out the telescoping sequences described in brochure 17 B
1 but in the reverse order .

To detelescope a mast section , le cycle must be repeated three times . The crane
is now in the position as shown in figure A .

CAUTION : It is essential that the safety wedges (10) of the shoes (11) are
placed when lowering .

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LOWERING THE MAST SECTION TO THE GROUND

Engage the towerhead feet (1) into the fishplates (2) of the lower mast and insert
the safety pins (3) at the four corners .

If necessary , lower the balancing load to the ground .

Fit the telescoping hook (4) on the mast lifting yoke (5) ; then lower the mast
section to the ground .

Re-raise the mast lifting yoke (5) which will be introduced on the monorail (6) ;
then connect it to the new mast section to be dismantled . Repeat these
operations as often as necessary until the mast tower is dismantled completely.

Disconnect the hydraulic group , drain and lower it to the ground .

Connect the towerhead to the basic mast by means of the normal shafts used for
crane work .

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REMOVING THE ROPES AND THE COUNTER JIB BALLAST

Place the pulley block on the ground .

Unpin rope anchor box (1) from the swivel at the jib nose (2) .

When the counter-jib ballast and the jib cannot be dismantled by means of the
mobile crane , wind the hoist rope onto the hoist rope drum . Otherwise , it can
be stored away on a reel .
SEIZE THE OPPORTUNITY OF THIS DISMANTLING TO CHECK THE
ROPE OVER ITS WHOLE LOENGTH .

Lower the counter-jib ballast either using the mobile crane or the hoist winch
according to brochure 12 B 1 but in the reverse order .

Move the trolley to the jib foot , unpin the ropes from above the trolley . Wind
the rear rope(s) onto the trolley rope drum . Remove the front ropes(s) .
immobilize the trolley on the jib .

Remove all accessories . Release the electric connecting structure elements as

the safety rope or others .

Drain off the slewing ring oil reservoir if the crane is equipped with one .

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DISMANTLING THE JIB

This dismantling requires a mobile crane with at least the same characteristics as
that used when erecting . Apart from the jib , this mobile crane will allow to
totally dismantle the crane .
There are 3 operations to the dismantling .
A- Placing the nose on the ground .
B- Unpinning the ties .
C- Lowering the foot to the ground .

If the mobile crane’s capacity is adequate , sling the jib at the points indicated in
brochure 10 B 1.
There are 3 operations to the dismantling .
A- Unpinning the yoke of the counter-jib.
B- Unpinning the jib ties.
C- Lowering the jib to the ground.

Whatever the version of jib dismantling, place a safety sling connecting the jib
foot and the cab mast . If site conditions allow , the jib must be stewed to the
most favorable position .

Push the cabin in as it is situated on the jib foot trajectory .

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DISMANTING THE JIB

The jib is dismantled in three phases :

A- Lowering the nose to the ground .
B- Unpinning the ties .
C- Lowering the foot to the ground .

First phase A : Fir a 5000 kg Tirfor (1) on the counter-jib equipped with a 40 m
rope as indicated in brochure 10 B 1 . Sling the jib nose using two 4 m sling (2),
relieve of the load using the mobile crane . Operate the Tirfor to slacken the
counter-jib ties , unpin the counter-jib yoke (3) .

Second phase B : While using the Tirfor , lower the nose , the strut swings
forwards and arrives in position , pin the connecting links (4) . Raise the jib by
means of the mobile crane , unpin ties (5) and (6) . Check that the jib ties are
well inserted in the brackets and to increase the safety ,bind ties (5) and (6) on
the jib foot at (7) .

Third phase C : Lower the jib nose to the ground on two cross-beams (8) which
will help it to slide . Fit a second Tirfor (9) fixed to the nose . Free the sling (2),
move the mobile crane and sling at (10) . Unpin the shafts of the jib foot (11) .
Operate the Tirfor (9) , move out the jib foot . Lower the jib operating the Tirfor
(9) at the same which allows to free the from the tower .

SYM 298
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SYM 299
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DISMANTLING THE JIB

It is dismantled in three phases :
A- Unpinning the yoke from the counter-jib.
B- Unpinning the jib ties .
C- Lowering the jib.

First phase A : Sling the jib using two 12 m slings ¢21.3 (1) at the points
indicated in brochure 10 B 1. Fit on the counter-jib a 5000 kg Tirfor (2)
equipped with a 40 m rope as indicated in brochure 10 B 1. Operate the Tirfor to
slacken the ties, unpin the counter-jib yoke (3) .

Second phase B : Operating the Tirfor , lower the jib , the strut swings forwards
and arrives in position , pin the connecting links (4) . Raise the jib ,unpin ties (5)
and (6) . Check that the jib ties are well inserted in the brackets and to increase
safety, bind ties (5) and (6) on the jib foot at (7).

Third phase C : Bring the jib to horizontal position unpin the shafts of the jib
foot (8) . Move out the jib foot and lower the jib guiding it with cords attached to
the nose .

SYM 300
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SYM 301
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DISMANTLING THE TIES AND THE WINCH

With the counter-jib tie line slackened, the 5.77 m ties (1) are resting on the
strut . Unpin the 3.80 m ties (2) but leave them pinned to the yoke (3) . Attach
ties (2) and yoke (3) with wire on the counter-jib foot . Dismantle the
Tirfor .Unpin shafts (4) of the winch support Detail A . Sling the winch using
three 4 m slings (6) fixed to the loops provided on the winch support using 3
shackles .

Lower the winch to the ground .

SYM 302
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SYM 303
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DISMANTLING THE COUNTER-JIB

There are 2 versions for dismantling the counter-jib depending on the capacities
of the mobile crane .

A- Dismantling the complete counter-jib .

B - Dismantling the counter-jib nose.

- Dismantling the counter-jib foot .

These 2 versions of dismantling require the use of oblique wedges placed on the
counter-jib foot provided for this purpose .

In these two versions of dismantling , fit a safety sling between the counter-jin
and the cab mast .

SYM 304
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DISMANTLING THE COUNTER-JIB

For this dismantling ,the counter-jib (1) will be dismantled in a single operation .
Sling the counter-jib using 4 slings ¢ 21.3 length 8 m (2) at the slinging points
provided . To facilitate removal of the lower shafts (3), it is advisable to use
oblique wedges (4) and wedges (5) detail a . As the counter-jib is engaged , it is
difficult to unpin the lower shafts manoeuvring the mobile crane . Take out the
lower shafts (3) and leave them in the shaft-inserting devices . Unpin upper
shafts (6) manoeuvring the mobile crane , leave them in the shaft-inserting
devices . Manoeuvre with the mobile crane to move the counter-jib out from the
cab mast , free the safety sling , place the counter-jib on the ground .

SYM 305
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SYM 306
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DISMANTLING THE COUNTER-JIB

There are 2 phases to the dismantling :

a- Dismantling the counter-jib nose

b- Dismantling the counter-jib foot .

First phase : Fold back the connecting cat-walk between the nose (1) and foot
(2) .Sling the nose using four 8 m . slings ¢ 21.3 (3) ,on the slinging points
provided at the front of the nose and at rear on the gussets of the winch support .
Unpin the lower shafts (4) manoeuvring the mobile crane to facilitate their
removal . Unpin the upper shafts (5) , move the counter-jib out and place it on
the ground . Free the slings .

Second phase : Sling the counter-jib foot (2) using two 8 m slings ¢ 21.3 (6) ,
pass them between the diagonal braces of the foot . To facilitate removal of the
lower shafts (7) it is advisable to use oblique (8) and wedges (9) . As the
counter-jib is engaged , it is difficult to unpin the lower shafts manoeuvring with
the mobile crane . See detail. Unpin the upper shafts (10) , move the counter-jib
foot out from the cab-mast , free the safety sling and place the counter-jib foot
on the ground .

SYM 307
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SYM 308
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DISMANTLING THE STRUT, THE CABIN MAST , THE TOWERHEAD

AND THE BASIC MAST / TELESCOPIC CAGE ASSEMBLY

Check that no electric cable remains fitted between two successive assemblies .
- LOWERING THE STRUT : Fit a 4 m sling on the strut (1) , relieve , unpin the
retaining links (2) . Unpin the shafts of the strut , disconnect it and lower it down
to the ground . Figure A .
- LOWERING THE CABIN MAST : Fit two 8 m slings (¢ 21.3) on the cabin
mast (3) . Use the quoins and wedges provided to unpin the shafts connecting it
with the towerhead . Disconnec and lower the cabin mast to the ground . Figure
B.
- LOWERING THE TOWERHEAD : Fit slings on the telescopic cage , unpin it
from the towerhead a rest it on the lugs . Fit two 8 m sling (¢ 21.3)on the
towerhead (4) ,unpin the shafts connecting it to the basic mast , disconnect and
lower it to the ground . Figure C .
If the sift conditions allow , dismantling the cabin mast / towerhead assembly
one single operation is possible.
- LOWERING THE BASIC MAST / TELESCOPIC CAGE : fit two 8 m slings
(¢ 21.3) on the basic mast (5) , fastening the thimbles on the fishplate shafts ;
unpin the shafts which connect it with the basic mast unit , disconnect and lower
the basic mast to the ground . Figure D .

SYM 309
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SYM 310