smk308 Us

PEINER
TOWER CRANES
SMK 308
DIN 15018
Factory No. 0
Year of Construction 199
Operating Instructions
TEREX PEINER GmbH

Gottbillstraße 1-7 • D-54294 Trier • 0651-81008-0 • FAX: 0651-87640 •
http://www.peiner.com
Typ Chapter
PEINER Operating Instructions SMK 308
TOWER CRANES
gültig ab Werk - Nr.: 001 gültig bis Werk - Nr.: Ausgabe 2/93 Seite 2
valid from crane nr.: 001 valid to crane nr.: Edition Page
valide de grue no.: 001 en valide de grue no.:
Table of Contents
LOADS 6
NOTES ON BASIC VERSION 7
NOTES ON THE DRIVE SYSTEMS 8
00 PREFACE 9
0.1 TRANSPORTING THE CRANE 10
01.01 Package List 10
01.03 Attachment points for crane loading 12
01.04 Road running gear KSL 20/1 13
01.04 Road transport 14
02 CONSTRUCTION SITE PREPARATION 21
02.01 Crane assembly City version (R = 2.5 m) 21
02.02 Crane assembly Normal version (R = 3.6 m) 24
02.03 Space requirements for erection phase (jib) 27
02.04 Crane on support foundations 29
02.05 Crane on cross stack of wood 32
02.07 Crane on rail system 33
02.08 SRS Crane track system 38
02.09 Timber sleeper construction 39
02.10 Track plan 41
03 CRANE ASSEMBLY 42
03.01 Preliminary comments 42
03.02 Crane erection - spindle support 43
03.03 Crane erection - travel gear 44
03.04 Electrical connections 46

Typ Chapter
TOWER CRANES
03.05 Control cable connection 47
03.06 Ballast plan 48
03.08 Lifting capacity plates 49
03.09 Preparation for crane erection 51
03.10 Erecting the tower package 54
03.11 Loading ballast weights 56
03.12 Jib assembly 59
03.13 Lower working positions 66
Lower working positions 68
03.14 Tensioning the trolley rope 69
03.15 Setting the jib 70
03.17 Crane steep position 30° 71
04 SAFETY DEVICES 73
04.02 Location and arrangement of safety devices 73
04.03 Setting the load torque switch 74
04.04 Maximum load switch on hoist units 75
04.05 Setting the hoist limit switch 76
04.06 Setting the trolley limit switches 77
04.07 Setting the gear switch 78
04.08 Assembly switches 79
04.09 Trolley rope breakage safeguard 80
04.10 Evening position 45° 81
05 OPERATION AND CRANE OPERATION 85
05.01 Starting up and closing down 85
05.02 General notes on operating the controllers 87
05.03 Controller with cable 95
05.04 Changing the hook tackle in 2/4-rope hoisting operation 96

Typ Chapter
TOWER CRANES
05.05 Putting the crane out of service at high wind speed 97
06 VARIANTS 98
06.02 Ballasting variant upper carriage extension 98
06.03 Converting from 30 m to 36/40/42 m jib 99
Converting from 30 m to 36/40/42 m jib 104
06.04 Converting to travel gear 105
06.05 Cabin in the inner tower 107
06.06 Lighting equipment on crane 108
06.07 Setting the slewing range limiting device 109
06.08 Radio remote control 112
06.09 Hour meter 113
07 MAINTENANCE 114
07.01 Maintenance instructions 114
07.02 General lubrication chart 116
07.03 Rope routing diagram for hoist and assembly rope 118
07.04 Installing the hoist and assembly ropes 119
07.05 Rope routing diagram for trolley rope 121
07.06 Installing the trolley rope 122
07.07 Rope routing diagram for jib assembly rope 123
07.08 Table of ropes used 124
07.09 Notes on handling wire ropes 127
08 DISMANTLING 136
08.01 Dismantling the jib 136
08.02 Unloading the ballast weights 139
08.03 Laying down the tower package 141
08.04 Preparation for removal 142
08.05 Control cable connection 143

Typ Chapter
TOWER CRANES
08.06 Electrical connection 144
08.07 Dismantling the crane - travel gear 145
08.08 Dismantling the crane - spindle support 146
08.09 Comments 147
09 MAINTENANCE 148
09.01 Brakes used or fitted to SMK cranes 148
09 APPENDIX 151
09.02 Setting the F.A.S.T. brake 151
09.03 Setting the BM brake 152
09.04 Setting the FCO brake 154
09.05 HOLEC brake system 155
09.06 Setting the F7p brake 156
09.07 Setting the FM brake 157
09.08 Setting the F 215/1 brake 158
09.09 Setting the FCPL brake 160
09.10 Setting the F 215/6 brake 161
09.11 Setting the FCL brake 163
09.12 Type 14.448 spring-loaded brake for hoist unit 164

Type Chapter
TOWER CRANES
valid from crane no.: 001 valid to crane no.: Edition Page
Loads
Hoist rope 2/4 reeving
Ausladung m 15.54 18.87 24.25 30.00

Radius - Portée ft 51'-0'' 61'-11'' 79'-7'' 98'-5'' m kg
ft lbs
kg 2500 2500 2500 2350 26.2 1100
Jib length
lbs 5500 5500 5500 5170 85'-11'' 2400
30 m 5000 4000 3000 2350

--- ---
98'-5'' 11000 8800 6600 5170
Ausladung m 14.53 17.62 22.61 27.14 36.00

Radius -Portée ft 47'-8'' 57'-10'' 74'-2'' 89'-0'' 118'-1'' m kg
ft lbs
kg 2500 2500 2500 2350 1750 31.4 1100
Jib length
lbs 5500 5500 5500 5170 3850 103'-0'' 2400
36 m 5000 4000 3000 2350 1750

--- ---
118'-1'' 11000 8800 6600 5170 3850
Ausladung m 13.11 15.86 20.30 25.37 32.20 40.00

Radius -Portée ft 43'-0'' 53'-0'' 66'-7'' 83'-3'' 105'-8'' 131'-3'' m kg
ft lbs
kg 2500 2500 2500 2350 1750 1750 34.9 1100
Jib length
lbs 5500 5500 5500 5170 3850 3850 114'-6'' 2400
40 m 5000 4000 3000 2350 1750 1750

--- ---
131'-3'' 11000 8800 6600 5170 3850 3850
Ausladung 11.77 14.02 18.13 22.33 28.86 35.56 42.00

m
Radius -Portée 38'-7'' 46'-0'' 59'-6'' 73'-3'' 94'-8'' 116'-8'' 137'-9'' m kg
ft lbs
2500 2500 2500 2350 1750 1750 1100 36.6 1100
Jib length kg
5500 5500 5500 5170 3850 3850 2400 120'-1'' 2400
42 m 5000 4000 3000 2350 1750 1750 1100

--- ---
137'-9'' 11000 8800 6600 5170 3850 3850 2400
Type Chapter
TOWER CRANES
Notes on basic version
Basic equipment
As delivered, the crane can be assem-

bled together with the ballast, which is
not included in the basic version. The
version of the ballast depends on the
type of ballasting (standard or city bal-
lasting). The basic equipment has an
extensible jib (for the relevant load dia-
gram see the type sheet).
The crane can assume all working posi-

tions in the basic version and with full
ballast:
• upper working position: hook height

28 m / 91'-10''
• steep position 30° - at upper tower

working position
• lower working position: hook heights

21.0 m / 68'-11''and 24.0 m / 78'-9''.
The basic version also includes the

loading arm for stacking the ballast
blocks. A controller with cable is pro-
vided for controlling the crane.
The basic unit is fitted with spindle sup-

ports.
Road and rail running gear and the

cabin, which can be fixed to the inside
of the tower mast at a working height of
approx. 25.0 m / 82'-0'', are optional ex-
tras.
Type Chapter
TOWER CRANES
Notes on the drive systems
Drive systems
Trolley unit
The trolley unit is driven by a double

pole changing squirrel-cage motor. It
is controlled in two stages. The
travel limits of the trolley are each
monitored by an emergency limit
switch. The holding brake is auto-
matically opened on reaching one of
them. The trolley is blocked in the
direction of the jib end when the
maximum permitted load torque as
well as the maximum permitted lift-
ing capacity is exceeded.
Slewing gear
The slewing drive consists of a spe-

cial squirrel-cage motor with a me-
chanical disk brake, an eddy current
brake and a planetary gear. It is
controlled via the master switch of
the controller, in conjunction with the
SRA system, for exact positioning.
Running gear
The running gear is driven by a

squirrel-cage motor through con-
tactors in I - 0 - I steps. In the „0“
lever position the holding brake en-
gages. The running gear is switched
off at the ends of the running track
by a roller lever limit switch acting on
two sides. When the limit switch is
reached, the brake engages directly.
Hoist unit
The hoist drive consists of a triple

pole changing motor, combined with
a spur gear, in conjunction with the
hoist and assembly drum.
Type Chapter
TOWER CRANES
00 Preface
Type Chapter
PEINER Operating Instructions SMK 308 01.01
TOWER CRANES
0.1 Transporting the crane
01.01 Package List
Length Width Height Unit

No. Description Dimensioned drawing (L) (W) (H) weight
m m m (kg)
ft ft ft lbs
Jib base, trolley with
15.53 0.94 2.05 1400.0
1 rope, gantry support,
50'-11'' 3'-1'' 6'-8'' 3080
pendulum support
Jib tip 14.84 0.89 1.45 870.0
1
rope sustainer 48'-8'' 2'-11'' 4'-9'' 1910
6.10 0.89 0.70 272.0
1 Jib extension
20'-0'' 2'-11'' 2'-3 ½'' 600
4.03 0.80 0.66 126.5
1 Jib extension
13'-3'' 2'-8'' 2'-2'' 280
6.03 0.80 0.66 170.0
1 Jib extension
19'-10'' 2'-8'' 2'-2'' 370
Inner and outer tower,
ballasting arm, 15.67 1.22 2.30 6050.0
1
sheaves, mast gan- 51'-5'' 4'-0'' 7'-7'' 13300
tries
Outer tower, ballasting
13.60 1.22 1.55 3270.0
1 arm, sheaves, mast
44'-7'' 4'-0'' 5'-1'' 7190
gantries
15.23 1.05 2.18 2780.0
1 Inner tower
49'-11'' 3'-5'' 7'-2'' 6120
Rotating radius R = 2.50 m
8'-2''
Upper and lower car-
riage, electrical panel,
5.02 2.47 2.00 3520.0
1 hoist unit, slewing
16'-6'' 8'-1'' 6'-6'' 7740
gear, live ring, bolt
jack compl.
11'-10''
8'-2''
Upper carriage, elec-
3.50 1.64 1.22
1 trical panel, hoist unit,
11'-6'' 5'-5'' 4'-0''
slewing gear, live ring
11'-10''
Type Chapter
TOWER CRANES
Package List
Length Width Height Unit

No. Description Dimensioned drawing (L) (W) (H) weight
m m m (kg)
ft ft ft lbs
5.02 2.47 0.57 2280.0
1 Lower carriage
16'-6'' 8'-1'' 1'-10'' 5020
1.52 0.36 0.53 341.0

1 Bolt jack compl.
5'-0'' 1'-2'' 1'-9'' 750
317.0
700
without
Wheel houses with 1.52 0.61 0.64 drive
1
travel gear 5'-0'' 2'-0'' 2'-1'' 337.0
740
with
drive
Road running gear
1.60 2.50 1.40 990.0
1 KSL 20/1,
5'-3'' 8'-3'' 4'-7'' 2180
front axle without
forked draw-bar
Road running gear
2.10 2.50 1.00 1160.0
1
KSL 20/1, 6'-11'' 8'-3'' 3'-3'' 2550
rear axle
1.50 1.00 2.28 400.0

1 Cabin
4'-11'' 3'-3'' 7'-6'' 880
Boxes with small

parts, load hooks,
180.0
1 anchoring ropes, con- -- -- --
400
troller and cables,
bolts, lighting etc.
Type Chapter
TOWER CRANES
Ausgabe 1/93 Seite 12
gültig ab Werk - Nr.: 001 gültig bis Werk - Nr.: Edition Page
valid from crane no.: 001 valid to crane no.:
01.03 Attachment points for crane

loading
The crane attachment points are located at

the projecting ends of the two longitudinal
girders on the lower carriage. The butt
straps for transport axles may be used as
attachment points. In order not to squeeze
the folded-over jib tip with the attachment
rope, the hanging rope, which should be as
long as possible, must be run through the
latticework of the jib on the appropriate
side.
Attachment weight without ballast:

18.5 t (40 700 lbs)
Type Chapter
TOWER CRANES
01.04 Road running gear KSL 20/1
Rear axle
Front axle
1920 2160
2500
Total permissible axle load

KSL 20/1
20 500 kg (45 100 lbs)
Front axle: 8 500 kg (18700 lbs)
Rear axle: 12 000 kg (26 400 lbs)
Dead weight:
Front axle: 1 040 kg (2 300 lbs)
Rear axle: 1 080 kg (2 400 lbs)
Tyre table
Tyre size Pressure Wheel nut torque
Front axle 300 - 15 18 PR 9.0 bar 350 Nm
Rear axle 900 - 20 14 PR 7.5 bar 430 Nm
Maximum speed 25 kph
NOTE:
When wheels have been newly
mounted, tighten the wheel nuts to the
prescribed torque after the first few
kilometers!
Type Chapter
TOWER CRANES
01.04 Road transport
The SMK 308 can be driven with its full

construction weight using the KSL 20/1
road running gear.
A fully equipped lighting bracket is re-

quired for correct road transport.
NOTE:
The wheelbase extension (adapter)

must be inserted between the rear axle
and the lower carriage. In the event of
non-compliance, the vehicle is not in
accordance with the general operating
permit.
The adapter is always supplied with the
KSL 20/1 running gear.
An intermediate adapter (3) must also

be fitted. To do this, proceed as follows:
• Disconnect jack (1) from flange (2).
• Attach intermediate adapter (3) to

the flange (2) using the existing
bolts.
• Attach the jack (1) to the intermedi-

ate adapter (3) with two M 12 bolts.
• The rod for the pump lever must be

extended by means of the two ex-
isting flat bars (4), by mounting the
two parallel flat bars one after the
other in one fixed line using an M 16
bolt.
Type Chapter
TOWER CRANES
Road transport
330
4000
3900 3140 3240
16300
Actual axle load: (weighed data)
Crane without ballast
Front axle: 8 200 kg ( 18 000 lbs)
Rear axle: 12 000 kg ( 26 400 lbs)
Gross weight: 20 200 kg (44 400 lbs)

Type Chapter
TOWER CRANES
Road transport
The crane may only be transported on the

road without ballast.
CAUTION!
The particular provisions of the "General

Operating Permit" must be complied with!
Towing vehicle:
• Lighting for road traffic, 12 V, 7-pin plug

(truck with special equipment must be
adapted).
• The overall length must not exceed 25

m / 82 ft.
• (§ 42 German Regulations Authorizing

the Use of Vehicles for Road Traffic):
The towing vehicle must have a gross
vehicle weight rating of at least 10 t /
22000 lbs. The towing capacity must not
exceed the value given by the manu-
facturer of the towing vehicle.
• Motor performance of the towing vehicle

(§ 35 Regulations Authorising the Use of
Vehicles for Road Traffic):
For trucks: 4.4 kW/t
Motor performance required = 4.4 x (truck

gross vehicle weight rating + gross weight of
crane in transport condition).
Type Chapter
TOWER CRANES
Road transport
For tractors: 2.2 kW/t
Motor performance required = 2.2 x (truck

gross vehicle weight rating + gross weight of
crane in transport condition).
For towing vehicles with design allowing a

maximum speed of not more than 25 km/h
(15.5 mph), § 35 Regulations Authorizing
the Use of Vehicles for Road Traffic is not
applicable.
These provisions do not apply if the vehicle

registration documents contain other provi-
sions.
Type Chapter
TOWER CRANES
Road transport
The crane may only be transported on pub-

lic roads if it has been prepared according to
the notes in the instructions and according
to the special requirements given in the cur-
rent German Road Traffic Act.
• Bolt the ballasting arm with the locating

strap to the tower.
• The anchoring rope and the ropes of the

ballast arm are hung in the hooks spe-
cially provided for them in the tower.
• Bolt the upper and lower carriages to

prevent them turning during road trans-
port.
Type Chapter
TOWER CRANES
Road transport
• Secure the outer tower and upper car-

riage with bolts.
• Couple the front and rear axles of the

road running gear and put on the hand-
brake by means of the crank on the rear
axle.
• Lift the crane by manually operating the

lifting and lowering device.
a) Fold in the bracing spars.

b) Bolt the bracing spars in transport po-
sition.
Type Chapter
TOWER CRANES
Road transport
• Mount the lighting bracket together with

all components, such as:
- yellow lateral rear lights
- deflector rods
• Check that the transport dimensions are

adhered to.
• Check all rope guides, attachments and

movable assemblies to ensure they are
correctly located for transport.
• Hitch to the towing vehicle with the re-

quired weight and the required motor
performance.
• Connect brake hoses and vehicle light-

ing cables.
• Test the lighting for correct functioning.
• Test the brakes for correct functioning.
• Release the handbrake on the rear axle

using the crank.
Type Chapter
TOWER CRANES
02 Construction site preparation
02.01 Crane assembly City version

(R = 2.5 m / 8'-2'')
• Small construction site
• Space requirements for setting up

tower
3000
6000
3000
1000 9920
10920
• Rotation radius and dimensions for

setting up and dismantling
2500
6000
3000
10920
Type Chapter
TOWER CRANES
Crane assembly City version

(R = 2.5 m / 8'-2'')
• Loading space for ballast.
• Keep ballast ready on loading arm

side if possible.
• Load ballast approximately on the lon-

gitudinal axis of the upper carriage.
Travel range of load hook on loading arm.

R1 = minimum rotation radius of load hook
on loading arm.
R2 = maximum rotation radius of load hook
on loading arm.
R3 = Slew radius of upper carriage with
ballast.
R4 = Safety radius min. 0.5 m (1'-7 ¾'')
clearance from slew radius of upper car-
riage.
R1 = 2455 mm / 8'- ½''

R2 = 3555 mm / 11''-8''
R3 = 2500 mm / 8'-2''
R4 = 3000 mm / 9'-10''
Type Chapter
TOWER CRANES
Crane assembly City version

(R = 2.5 m / 8'-2'')
• Crane in working position
• Crane in 30° steep working position

Type Chapter
TOWER CRANES
02.02 Crane assembly Normal ver-

sion (R = 3.6 m / 11'-10'')
• Space requirements for setting up

tower
4100
8200
4100
1000 9920
10920
• Rotation radius and dimensions for

setting up and dismantling
3600
8200
4100
10920
Type Chapter
TOWER CRANES
Crane assembly Normal version

(R = 3.6 m / 11'-10'')
• Loading space for ballast.
• Keep ballast ready on loading arm

side if possible.
• Load ballast approximately on the

longitudinal axis of the upper car-
riage.
Travel range of load hook on loading

arm.
R1 = minimum rotation radius of load
hook on loading arm.
R2 = maximum rotation radius of load
hook on loading arm.
R3 = Slew radius of upper carriage with
ballast.
R4 = Safety radius min. 0.5 m (1'-7 ¾'')
clearance from slew radius of upper car-
riage.
R1 = 2455 mm / 8'- ½''

R2 = 3555 mm / 11''-8''
R3 = 3600 mm / 11'-10''
R4 = 4100 mm / 13'-5 ½''
Type Chapter
TOWER CRANES
Crane assembly Normal ver-

sion (R = 3.6 m)
• Crane in working position
• Crane in 30° steep working position

Type Chapter
TOWER CRANES
02.03 Space requirements

for erection phase (jib)
Jib development - telescoping

Type Chapter
TOWER CRANES
Space requirements for erection

phase (jib)
Jib development - lowering

Type Chapter
TOWER CRANES
02.04 Crane on support foundations
R1 = 2.5 m / 8'-2'' - corner load

max. 330 KN
R2 = 3.6 m / 11'-10''- corner load

max. 308 KN
Foundation arrangement
Spindle distance
Edge of building, scaffolding

or the like
Corner load
Non-slip base (wood)

VDE 0100
responsible power station
Earth
Type Chapter
TOWER CRANES
Crane on support foundations
In certain situations (in complicated

conditions) in the area of the floor sur-
face of the crane, for example:
• sloping, uneven surfaces
• embankments
• critical (aquiferous) soil layers
• proximity to slopes
• difficult ground conditions
or as a reliable measure for longer

parked duration, support foundations
made of unreinforced concrete are very
suitable.
If the ground conditions in the area of

the erection site are different, the indi-
vidual foundations may also vary in their
dimensions. It is important that the axes
of the foundations should be exactly
aligned and that the crane supports
should be properly centered. The di-
mensions of the foundations are not
only dependent on the permitted soil
pressure but also on the concrete
strength class.
Type Chapter
TOWER CRANES
Crane on support foundations
Reference values for foundation dimen-

sions (unreinforced).
Permitted
Foundation dimensions for centered supporting force
soil
pressure a x a [m / ft] h min for concrete strength class
[kp/cm²] Ballast R1 Ballast R2 B5 B10 B15 B25 B35
1.80x1.80 1.75x1.75 0.75 0.55 0.45 0.45 0.45
1
5'-10''x5'-10'' 5'-9''x5'-9'' 2'-5 ½'' 1'-9 ½'' 1'-5 ¾'' 1'-5 ¾'' 1'-5 ¾''
1.30x1.30 1.25x1.25 0.55 0.45 0.35 0.35 0.30
2
4'-3''x4'-3'' 4'-1''x4'-1'' 1'-9 ½'' 1'-5 ¾'' 1'-1 ¾'' 1'-1 ¾'' 0'-11''
1.05x1.05 1.00x1.00 0.35 0.35 0.30 0.25 0.20
3
3'-5''x3'-5'' 3'-3''x3'-3'' 1'-1 ¾'' 1'-1 ¾'' 0'-11'' 0'-9 ¾'' 0'-7 ¾''
Through systematic reinforcement of

the support foundations as required, the
ground plan dimensions cannot be re-
duced, but the thickness of the concrete
slab can be reduced considerably. The
exact execution is not the responsi-
bility of the crane manufacturer!
Type Chapter
TOWER CRANES
02.05 Crane on cross stack of

wood
Supporting the crane on stacks of

wood is a flexible option that can
be implemented quickly. If the
structure and type of subsoil mean
that the load carrying capacity with
the support forces cannot be guar-
anteed, the support area must be
improved using suitable measures
(e.g. filling with load-carrying layers
of crushed stones and gravel).
The dimensions of the area a x a,

in accordance with the supporting
foundations, apply as an orientation
for laying out the lower layer of the
stack.
Suggestion for the substructure with a maxi-
To ensure adequate load distribu-
mum permissible ground load of 3 kp/cm²
tion, the stack of wood must consist
of at least two layers. On the other
hand it should not be more than
three layers, which must be leveled
and secured against slipping.
The squared timber must comply

with quality class II in accordance
with DIN 4074, and their dimen-
sions must be such that they can
reliably transmit the maximum
supporting force to the subsoil.
Type Chapter
TOWER CRANES
02.07 Crane on rail system
Basic preconditions
NOTE:
The crane operator is responsible for the

execution of the crane track system! The
contractor responsible for crane operation is
exclusively liable for any accidents that oc-
cur through incorrect laying of the crane
tracks!
Execution depends on the ground conditions
and the maximum corner load of the crane
(see "Technical Data"). The crane track
must always be laid at a safe distance from
the excavation, since collapsing excavation
walls can cause the crane to topple over.
The horizontal location of the track system
in longitudinal and transverse directions is of
great importance for correct crane opera-
tion. The load-bearing capacity of the
ground must be tested before beginning the
construction of the rail system. Uneven
ground is to be evened out by filling up with
gravel and sand and compressing this.
Ground pressure
The surface pressure between the sleeper

and the ground must not exceed the per-
mitted values (in accordance with DIN
1054).
Example:
Foundation Fine to med. sand Coarse sand - gravel
1. Grown, non-binding, sufficiently firm soil: depth at min. foundation depth (in m)
daN/cm² below
0.4 1.0 5.0 10 0.4 1.0 5.0 10
ground 1'-3'' 3'-3'' 16'-5'' 32'-10'' 1'-3'' 3'-3'' 16'-5'' 32'-10''
level
up to 0.5 m
1.5 2.0 2.5 3.0 2.0 3.0 4.0 5.0
1'-8''
1.0 m
2.0 3.0 4.0 5.0 2.5 3.5 5.0 6.0
2.0 3'-3''
2. Grown, binding soil: daN/cm² 2.0 m
2.5 3.5 5.0 6.0 3.0 4.5 6.0 8.0
6'-6''
very soft soft stiff semi-firm hard

0 0.4 1.0 2.0 4.0
Type Chapter
TOWER CRANES
Crane on rail system
Track tolerances
It is essential that the track tolerances

should be observed, and monitored at
regular intervals in the event of longer op-
eration.
A = nominal track gauge

Track may not be laid as bend
A +/- 0.2 %
Height: longitudinal slope of one rail

max. 0.2 %
Difference in height of the two opposing

rails
B = a x 0.001
Inclination of rails to each other

(offset)
With completely level rails, the points of

contact of the wheels are 1 - 2 - 3 and 4. At
the level formed by points 1, 2 and 3, point
4 a differs from this level by dimension "h"
in the event of the rail subsiding or being
raised.
Permissible height deviations of one contact

point upwards or downwards:
h = A x 0.002
Deviation of the rail head from the horizon-

tal vertex:
D = E x 0.008
Type Chapter
TOWER CRANES
Earthing crane tracks
• Earthing is recommended as lightning

protection for fast-erection cranes on
construction sites.
• Each rail of the track must be earthed

at each end, and every 20 m / 65' if the
rail is longer than 20 m / 65' .
• If no other earthing device is available,

one earthing rod each with a immersion
depth of at least 1.5 m / 4'-11'' is suffi-
cient.
• In constructions with steel reinforcement

in the foundations, a connecting lead
must be established between the rein-
forcement and one rail.
• Equipment, machines, metal pipelines

within a radius of up to 20 m / 65'
around the track must be connected to
the rails. 1 Galvanised steel strip
2 Bolt with lock washer
• Galvanized steel strips 30 mm x 3.5 3 Earthing rod
mm / 0'-1'' x 0'-0.1'' are sufficient as
leads to the earthing rods and connect-
ing leads. The connections must be es-
tablished with the help of two bolts with
lock washers.
• Rail joints connected with steel straps

do not have to be bridged for protection
against lightning.
Type Chapter
TOWER CRANES

The buffer height must be
adapted to the wheel
bolster.
Rail limit stops
End piece
At both ends of the crane track, rail limit
stops must be mounted at the same level.
Rail limit stops consist of buffers. They must
be mounted at an adequate safety distance
from the end of the rail.
If the limit stops are displaced in the longi-

tudinal direction of the crane track, the
crane will come to a halt at an angle when it
reaches the limit stops. This results in in-
creased strain on the load-bearing construc-
tion and increased wear on the wheel
flanges.
For this reason, the offset of the limit stops

in relation to each other must not be more
than +/- 0.2 % of the track.
The distance (a) must be selected so that

there is at least one sleeper behind the limit
stop.
Type Chapter
TOWER CRANES
Leading rail for emergency end stop

switch
• The leading rail for the emergency end

stop switch must be positioned in such a Switching
way that when the end stop switch is guide
actuated, the crane comes to a halt ap-
prox. 1.0 m / 3'-3'' from the rail limit
stop.
Type Chapter
TOWER CRANES
02.08 SRS Crane track system
The "SRS crane track system" is a kind of

prefabricated rail system. The rails are laid
on short concrete sleepers located closer or
further apart, depending on the load placed
on them by the crane.
Track rods are used as spacers.

1 Buffer stop - end piece
This system can only function well if the 2 Concrete sleeper
ballast of the track is designed in accor- 3 Buffer stop - sliding part
dance with the maximum corner load. 4 Ballast of track
5 Rail fixture
6 Rail
7 Gravel
8 Track rod
9 Connecting strap
Type Chapter
TOWER CRANES
02.09 Timber sleeper construction
General notes:
• The length of the sleepers is to be se-

lected in such a way that the sleeper
ends project beyond the rails by approx.
0.5 m / 1'-7 ½''.
• Half sleepers are permissible if the

wheel load is reliably transmitted; proper
tracking stability must be guaranteed.
To achieve this, sufficient regularly ar-
ranged continuous sleepers must be
used.
• The rail joints must be located on two

adjacent sleepers and must be correctly
strapped on both sides.
• The use of rail spikes is forbidden.
• The dimensions of the sleepers and the

formation of the ballast depend on the
ground conditions (in the area of the en-
tire track system).
• Timber sleepers must be of timber qual-

ity class II DIN 4074, and must be im-
pregnated.
• Particular caution is called for when

constructing a rail system in the vicinity
of a banking. Short sleepers must be
avoided here, and subsidence of the
track systems must be adequately
checked.
Type Chapter
TOWER CRANES
Timber sleeper construction
• The track system must be properly

earthed and the rail joints must be con-
nected with copper wire (50 mm² / 0.775
inch2) to ensure they are conductive.
Strap bolts must not be used here.
Ballast right
• The rail must be designed in such a way wrong
that it is adequately dimensioned to ab-
sorb the maximum wheel loads, and
that its head width fits the profile of the
wheel within the framework of permissi-
ble tolerances.
Examples of head widths (KB):

Rail S 33 = 58 mm / 0'-2 ¼''
Rail S 49 = 67 mm / 0'-2 ½''
Type Chapter
TOWER CRANES
02.10 Track plan
Edge of building, scaf- Rotating

Rail joint folding or the like radius
Track gauge 4500
must be exactly
adhered to
Buffer
Switching travel
Leading rail for
running gear switch
Safety travel
Type Chapter
TOWER CRANES
03 Crane assembly
03.01 Preliminary comments
A precondition for the erection of the crane

is a prior examination to ensure its proper
and safe functioning.
CAUTION !
A crane with road running gear parked with-

out a tractor must always be secured
against running away by means of the
handbrake (crank on the rear axle).
To be able to erect the crane on its prepared

assembly surface, the crane must be moved
exactly to its required position on the instal-
lation area (especially with fixed support
foundations or track systems), for after the
road running gear has been dismantled the
supported crane cannot change its position
itself.
In exceptional cases the crane should be

positioned by another lifting device. The
longitudinal projecting ends of the lower car-
riage should be used as attachment points
(see Chapter "Attachment points for crane
loading").
Type Chapter
TOWER CRANES
03.02 Crane erection - spindle support
• Secure the crane against rolling away

by using the brake shoes (if required).
• Raise the crane by means of the hy-
draulic lowering device.
• Disconnect the compressed air lead and
remove the lighting equipment.
• Move out the bracing spars from trans-
port position to support position and bolt
them to the lower carriage.
• Center the support spindle bases (e.g.
timber stack) under all four supports.
• Unscrew the spindles to approximately

the same length each.
• Use the hydraulic lowering device to
lower the crane from the road running
gear onto the spindle disks.
• Release the bolted connections between
the lower carriage and the road running
gear at the front and rear axles.
• Remove the road running gear.
• Level the lower carriage exactly hori-
zontally in longitudinal and transverse
directions by adjusting the spindles
Type Chapter
TOWER CRANES
03.03 Crane erection - travel gear
• At one front end of the track system the

spaces between the sleepers is filled
with gravel or laid out with boards (ap-
prox. 10 m / 32'-10''). The crane is
moved exactly centered between the
rails. (Pay attention to the tyre track
gauge!)
• Secure the crane against rolling away
by using the handbrake.
• Raise the crane by means of the hy-
• Disconnect the compressed air lead and
remove the lighting equipment.
• Move out the bracing spars on the lower
carriage and position the rail wheels
above the rail heads.
• Use the hydraulic lowering device on

the road running gear to lower the wheel
guards on the rear axle.
• Use the hydraulic lowering device to
align the front axle and lower the wheel
guards as well.
Type Chapter
TOWER CRANES
Crane erection - travel gear
• Removal of the road running gear
• Positioning the rail clamps
• Mounting the cable drum.

• Setting up the limit switch (pivot lever
by 180° and secure).
• Check switching guide and track limit
stop.
Type Chapter
TOWER CRANES
03.04 Electrical connections
• Earth the crane.

• Plug in the supply cable to the input
plug (with master switch) on the side of
the lower carriage.
• Check the correct direction of rotation of

the motor.
• Measure the actual voltage on all three
phases at the input terminals in the
electrical panel.
• In the event of deviations in the applied
operating voltage at the control trans-
former of more than +/- 5 %, this can be
corrected at its connection terminals.
CAUTION !
Electrical connections must be carried out

by an authorized electrician!
Connected load: 34 kW / 46 HP
Back-up fuse: 63 A
Connected load of power unit: 80 kVA
Max. supply lead length AWG 6 (Cu):

100 m / 330'
Type Chapter
TOWER CRANES
03.05 Control cable connection
The controller is connected directly to the

electrical panel,
or to the lower carriage.
The connecion to the lower carriage is a

variant. For this, an additional control cable
is run from the electrical panel via the slip
ring body to a connection socket on the
lower carriage.
NOTE:
The travel gear cannot be traversed via a

control cable connection on the lower car-
riage. For reasons of safety the circuit does
not permit this.
Type Chapter
TOWER CRANES
03.06 Ballast plan
Ballast blocks
18 x 2050 = 36 900 kg / 81 350 lbs 30° jib-inclination

11 x 2050 = 22 550 kg / 49 700 lbs
17 x 2050 = 34 850 kg / 76 800 lbs
12 x 2050 = 24 600 kg / 54 200 lbs 45° out of operation
position
Normal City
Rotating radius 3.6 m / 11'-10'' Rotating radius 2.5 m / 8'-2''
JIB Counterweight Central ballast Counterweight Central ballast
30 m 22 500 kg *
98'-5'' 49 700 lbs
5 000 kg
36 m 22 500 kg *
11 000 lbs
118'-1'' 49 700 lbs 36 900 kg
0
40 m 24 600 kg * 81 350 lbs
131'-3'' 54 200 lbs
42 m
137'-9''
* 30 m / 98'-5'' jib Trolley in out of service position at tip

* 36 m / 118'-1''jib Trolley in out of service position at tip
* 40 m / 131'-3''jib Trolley in out of service position at 30 m radius
* applies only at 30° steep position
Horizontal
Normal City
Rotating radius 3.6 m / 11'-10'' Rotating radius 2.5 m / 8'-2''
JIB Counterweight Central ballast Counterweight Central ballast
30 m
98'-5''
36 m
118'-1'' 22 500 kg * 34 850 kg
0 0
40 m 49 700 lbs 76 800 lbs
131'-3''
42 m
137'-9''
Type Chapter
TOWER CRANES
03.08 Lifting capacity plates
Hoist rope reeving 2/4-part
For 42 m / 137'-9'' radius
For 40 m / 131'-3''radius
Type Chapter
TOWER CRANES
Lifting capacity plates
Hoist rope reeving 2/4-part
For 36 m / 118'-1'' radius
For 30 m / 98'-5''radius
Type Chapter
TOWER CRANES
03.09 Preparation for crane erec-

tion
NOTE:
Should you wish to use the steep posi-

tion, please note the Chapter "Crane
steep position 30°" in the Variants sec-
tion.
• Remove the transport restraints to

prevent the upper and lower car-
riages from turning in relation to
each other.
• Remove the transport restraints

between the tower and the upper
carriage.
• Remove the connecting bolts be-

tween the tower and the upper car-
riage.
Type Chapter
TOWER CRANES
Preparation for crane erection
Check to ensure that the following

points have been observed:
• The inner and outer towers have

been locked in the phase of erection
of the tower package.
• The driver and assembly drum must

be bolted to each other and se-
cured.
• The catch on the slip clutch to se-

cure slack rope must have engaged.
CAUTION !
The assembly switch in the electrical

panel must be switched to assembly.
Type Chapter
TOWER CRANES
Preparation for crane erection
• Place gantry rope in pulley.
• Check run of anchoring rope. Here

particular attention must be paid to
the run of the anchoring rope strap
of the load torque limiter.
• Check correct rope run and secure

position of hoist and assembly rope
in all pulleys under slight tension.
Type Chapter
TOWER CRANES
03.10 Erecting the tower package
The tower package is erected in two

speed stages by means of the assembly
rope. Erection can be carried out in any
position (360°) in relation to the lower
carriage. The slewing gear brake must
not be ventilated in this situation! No
ballast is required for erecting the tower
package.
Simultaneous turning while erecting the

tower package is not permitted.
• Start up the hoist unit in stage I, ac-

celerate to stage II. Switch back to
stage I before the vertical position is
reached. Stage III must not be se-
lected!
• Attention should be paid to the fol-

lowing points during the erection
procedure:
- correct guidance of the hoist and
assembly rope.
Type Chapter
TOWER CRANES
Erecting the tower package
• The gantry rope must be correctly

threaded at the head of the tower.
• The base of the outer tower must be

bolted to the upper carriage and se-
cured with cotter pins.
• The limit stop mounted on the bal-
lasting arm for transport purposes
must be removed.
• Release loading arm from its trans-
port restraint.
• The anchoring rope of the ballasting

arm must be bolted into the front
hole.
• Remove the retaining bolts of the
load block of the loading arm.
• Slacken the assembly rope and
slowly lower the loading arm until
the anchoring rope of the loading
arm is under tension.
Type Chapter
TOWER CRANES
03.11 Loading ballast weights
In order to be able to load and position the

ballast blocks in the version with the small
rotating radius (City version) and in the ver-
sion with extended rotating radius (with up-
per carriage extension), the trolley can be
transported over the required distance.
Since the trolley is moved without any inde-
pendent drive, the movement is supported
by the position of the ballasting arm. The
position of the ballasting arm can be influ-
enced by the fixing strap on the upper boom
of the ballasting arm. This is achieved by in-
serting the anchoring rope in the front or
rear hole of the fixing strap.
When the anchoring rope is bolted in the

rear hole, the loading arm is inclined down-
wards slightly towards the tip (for unloading
ballast).
When the anchoring rope is bolted in the

front hole, the loading arm is slightly raised
towards the tip (for loading ballast).
The loading arm must be adjusted in such a

way that the expected load movement can
be carried out using the inclination.
Type Chapter
TOWER CRANES
Loading ballast weights
Carrying out ballasting:
• For ballasting variant B the upper car-

riage extension is first mounted (see
chapter "Conversion to ballast variant
with upper carriage extension").
• Remove gantry rope from the load
torque limiter and keep it out of the ra-
dius of motion of the ballast arm and
hoist drum.
• Check rope guides on loading arm.
• Load ballast blocks and lift to storage

height. The load must be constantly
guided. Swiveling of the load around the
fulcrum of the loading arm on the tower
is effected manually. In ballasting vari-
ant B the first ballast block is placed on
the locating pin of the upper carriage
extension. In the City ballasting variant,
after 15 ballast blocks have been
stacked, the ballast safety frame is
bolted to the straps provided on the
outer tower. The transport restraint bolts
for the upper carriage - outer tower are
used for this purpose.
• The remaining ballast blocks are loaded

according to the ballast plan.
• After ballasting, move the load block to

the loading arm trolley and slowly fold
the loading arm towards the tower using
the assembly rope.
Type Chapter
TOWER CRANES
Loading ballast weights
NOTE:
Ensure that the anchoring rope of the load-

ing arm does not get in the way between the
loading arm and the tower, since otherwise
the loading arm cannot be bolted into posi-
tion.
• Attach retaining bolt of the load block of

the loading arm.
• Secure loading arm in its transport re-
straint.
Type Chapter
TOWER CRANES
03.12 Jib assembly
JIB ASSEMBLY 36/40/42 m

118'-9'' / 131'-3''/ 137'-9''
• After the tower has been erected and

the crane ballast has subsequently been
loaded, the jib tip must be moved from
transport position to assembly position.
To do this, first remove the tower se-
curing bolts.
• Then actuate the "Hoist up" function on
the appropriate control lever of the con-
troller to lift the inner tower by a maxi-
mum of 5 cm / 2'' in order to take the
strain off the jib assembly rope. Rope
damage may occur if the inner tower is
not lifted. If the inner tower is lifted too
far, the rope may become too slack and
lift off the individual sheaves.
• Turn the jib tip to the limit point of the jib
base.
• Lower the inner tower again by actuating
the "Hoist down" function on the appro-
priate control lever of the controller.
• The two upper booms are secured by
means of grip pins. The transport re-
straint bolt connecting the two upper
booms by means of metal plates is re-
moved and stored in the toolbox.
• Release the lock between the jib base
and the jib tip by pulling the tensioning
device (triangle) and at the same time
extending the inner tower.
• Extend the inner tower until the jib base
is above the upper hinged pulley. Move
the hinged pulley from inside to out by
means of the tensioning device (trian-
gle) and lock in position.
Type Chapter
TOWER CRANES
Jib assembly
• Jib tip with extension moves into as-

sembly position while the inner tower is
extended.
CAUTION!
Check the run of the assembly rope !
Make sure that the fork-shaped pieces click

correctly into position when they approach
the two lower booms.
• Attach and secure the triangle to the

locking pin provided.
• Transport the inner tower as far as the

limit.
NOTE:
Run the gantry rope behind the ballast.

Type Chapter
TOWER CRANES
Jib assembly
• Remove the lower boom connection

bolts.
• Hang up the assembly ladder on the

lower boom.
• Lock the upper boom connection bolts

and secure with cotter pins.
• Hang the assembly ladder in position.

Type Chapter
TOWER CRANES
Jib assembly
• Extend the inner tower to above the

lower hinged pulley, move the hinged
pulley manually from outside to inside
and lower the inner tower to the hinged
pulley again.
CAUTION !
The jib assembly rope must be located on

the hinged pulley.
• Retract the inner tower fully in order to

obtain slack for the jib extension as-
sembly rope, and unbolt this on the up-
per boom of the jib base.
• Run the jib extension assembly rope

over the deflection pulley in the direc-
tion of the jib tip.
• Remove transport restraint for locking

the rope sustainer and place it in the
toolbox.
Type Chapter
TOWER CRANES
Jib assembly
• Jib extension assembly rope on upper

boom.
• Extend inner tower until the fork-shaped

pieces of the jib base and jib tip coin-
cide, bolt them together and secure
them with lock plates.
• Remove grip pins on upper boom and

place in toolbox.
• Remove assembly ladder.

Type Chapter
TOWER CRANES
Jib assembly
• Remove trolley and hoist ropes from the

assembly guide.
CAUTION !
Check bolts with securing devices and ropes

for correct assembly!
• Bolt gantry rope to the load torque limi-

ter.
CAUTION !
Gantry rope for 24 m / 78'-9'' and

28 m / 91'-10'' HH (hook height) can be
bolted directly. For 21 m / 68'-11'' HH see
description "Lower working position".
• The tower is telescoped in stages I and

II.
• Start up in stage I and switch to stage II
if assembly is running smoothly. Switch
back to stage I in the last part of the
movement.
• With the help of the assembly rope
block and pulley, the inner tower is tele-
scoped out until only the lower back of
the claws of the two catches passes
over the supporting bolts in the inside of
the outer tower (catch strikes audibly).
• The inner tower is lowered until it has
secure contact with both catches and
the assembly rope becomes slack.
• It is essential that you should carry out a
visual check of the two catches.
Type Chapter
TOWER CRANES
Jib assembly
CAUTION !
Check to ensure that the load hook is in the

transport bracket.
• Secure the driver of the assembly drum

on the hoist drum by bolting in position.
• Tension the assembly rope lightly by

hand and secure the assembly drum
with T-screw.
CAUTION !
First change the bolts and secure the as-

sembly drum before traversing the trolley!
• Move switch on electrical panel from

assembly to operation. The hoist unit is
now ready for operation.
• Traverse the trolley as far as the trolley

unit. As this happens, the load block is
taken from the transport restraints and
released.
Type Chapter
TOWER CRANES
03.13 Lower working positions
Working position 21 m / 68'-11''
The crane is still in transport status.

• Secure a clamp on the gantry rope, di-
rectly behind the gantry rope pulley, for
hanging the traction rope.
• Remove triangular strap, fit large strap
or bolt triangular strap and intermediate
strap together (depending on the crane
version!)
• Hang traction rope onto the clamp.
• Erect tower.
• Ballast the crane.
• Mount jib for top mounting or telescop-
ing (see chapter "Jib assembly").
• Thread traction rope via sheave be-
tween the hoist unit and ballast, and fix
the loose end with 3 rope clamps to the
lowered hook of the loading arm.
• Use the load block of the loading arm to
set up the pendulum and gantry sup-
ports far enough to allow the gantry rope
to be bolted to the upper carriage or to
the load torque limiter.
• Take the tension off the traction rope
and lower the load block. Remove the
traction rope from the load block.
Type Chapter
TOWER CRANES
Lower working positions
• Fold in loading arm and secure on the

outer tower.
• Remove traction rope from pulley be-
tween hoist unit and ballast.
• Telescope the tower out until the
catches engage in the lower bolts on the
outer tower, then lower crane onto the
bolts (see also chapter "Jib assembly").
In the 21 m / 68'-11'' working position, the

crane can be set up with and without exten-
sion. A version in steep position is not avail-
able.
Type Chapter
TOWER CRANES
Lower working positions
Working position 24 m / 78'-9''
To assemble the crane in the lower working

position, proceed as for assembly in normal
position.
However:
• Replace the gantry rope between the

triangular strap and the upper carriage
with the rope for 24 m / 78'-9'' HH
working position.
l = 3270 mm / 10'-8 ¾'' crane no. 001 - 010
l = 2865 mm / 9'-4 ¾'' crane no. 011 or
higher
• Do not bolt the remaining anchoring

rope to the triangular strap until after
ballasting.
• Extend the tower until the catches in the

inner tower engage in the center bolts
on the outer tower, then lower crane
onto the bolts (see chapter "Jib assem-
bly").
Also in the 24 m / 78'-9'' working position,

the crane can be set up with and without
extension. A version in steep position is not
available.
Type Chapter
TOWER CRANES
03.14 Tensioning the trolley rope
• Lower hook tackle by approx. 5 m / 16'-5''.
• Move trolley in the direction of the jib

tip; this automatically tensions the trol-
ley rope.
Type Chapter
TOWER CRANES
03.15 Setting the jib
Basic setting
Jib horizontal under load.
Setting the jib without load
• Move trolley to widest radius. In this po- Radius 30 m 36 m 40 m 42 m

sition the hook should be dimension Y 98'-5'' 118'-1'' 131'-3'' 137'-9''
(see table) higher than in the smallest approx. Y 1.40 m 1.70 m 1.90 m 2.00 m
radius. 4'-7'' 5'-7'' 6'-3'' 6'-7''
General table of adjustment options

• If the difference is not correct, lower the
jib again and reposition the retaining Reduction Lift jib tip by mm approx.
rope on the triangular strap. at
gantry rope 30 m 36 m 40 m 42 m
98'-5'' 118'-1'' 131'-3'' 137'-9''
150 mm 900 1050 1300 1400
6'' 2'-11'' 3'-5'' 4'-3'' 4'-7''
100 mm 600 700 800 840
4'' 1'-11¾'' 2'-3½ '' 2'-7½'' 2'-9''
50 mm 300 350 400 420
2'' 1'-0'' 1'-1¾'' 1'-3¾'' 1'-4½''
Type Chapter
TOWER CRANES
03.17 Crane steep position 30°
Crane assembly in steep jib position
The steep jib position is only possible in the

upper working position. Preparation and as-
sembly are as described under upper work-
ing position.
CAUTION !
If the crane is put out of service, the trolley

may only be located at the tip of the jib!
Type Chapter
TOWER CRANES
Crane steep position 30°
Conversion from and to horizontal posi-

tion
The crane is fully ballasted and the jib is
mounted in the upper working position for
telescopic extension.
CAUTION !
In the steep position, the crane may only be
operated with 2 ropes!
Sequence of operations
• Bolt upper hook block to trolley and re-
lease hook block from the upper block.
• Replace the lower gantry rope with the
shorter rope included in the delivery:
l = 5290 mm / 17'-4 ¼'' crane no. 001 - 010
l = 4885 mm / 16'- ¼'' crane no. 011 and
higher
• The remaining crane assembly is car-
ried out as in the horizontal position (see
chapter "Jib assembly").
• The rear hinged support must move
down visibly, causing the jib assembly
rope to remain tensioned.
• Reset the maximum load switch on the
hoist unit. With a suspended load of
1100 kg / 2400 lbs + 10% the hoist unit
must switch itself off!
• The switch on the terminal strip must be
pulled out (stage II blocked!)
• All other limit switches and safety de-
vices have the same settings as in the
horizontal position.
Type Chapter
TOWER CRANES
04 Safety devices
04.02 Location and arrangement of

safety devices
Item Safety device

1 Load torque switch on gantry rope
OS11 and OS12
2 Maximum load switch on hoist units
OS1 and OS2
3 Hoist limit switch 1S1 and 1S2
4 Rear trolley limit switch 3S2
5 Front trolley limit switch 3S1
6 Trolley assembly switch 3S3
7 Carriage switch 4S1
8 Slew range switch 2S1
9 Hoist limit switch on telescope OS3
10 Rope breakage safeguard on trolley
unit
Type Chapter
TOWER CRANES
04.03 Setting the load torque

switch
Load torque switch "Hoist up" = OS11 Load curve
• Jib horizontal (normal operation)

Range AB of lifting capacity curve)
• Move trolley to widest radius. Radius Load (kg / lbs) 2/4 rope
• Load torque switch OS11 must switch Nominal load Excess load
off the "Hoist up" movements at the 30 m 2350 kg 2580 kg
loads given in the table. 98'-5'' 5170 lbs 5680 lbs
36 m 1750 kg 1920 kg
• Load torque switch OS11 is adjusted by 118'-1'' 3850 lbs 4220 lbs
means of the setscrew. 40 m 1350 kg 1480 kg
Load torque switch "Trolley forwards" = 131'-3'' 2970 lbs 3260 lbs
OS12 42 m 1100 kg 1205 kg
137'-9'' 2420 lbs 2650 lbs
• Move trolley to smallest radius.
• Lift the maximum load (2500 kg /
5500 lbs or 5000 kg / 11000 lbs) and
move the trolley in the direction of the
jib tip.
Load Radius (m/ft)

• Load torque switch OS12 must switch (kg)
off the "Trolley forwards" movements at [lbs]
the loads given in the table. 30 m 36 m 40 m 42 m
98'-5'' 118'-1'' 131'-3'' 137'-9''
• Load torque switch OS12 is adjusted by
means of the setscrew. 2500 ~28.5 ~26.5 ~23.5 ~21.0
5500 ~93' ~87' ~77' ~69'
• After the switches have been set, re- 5000 ~15.5 ~14.5 ~13.1 ~11.8
place the guard. 11000 ~50' ~47' ~43' ~39'
CAUTION ! Setscrew
After any changes to the jib, e.g. installation Hoist up
of an extension, load torque switches OS11
and OS12 must be readjusted. Under no
circumstances may an excess load of 10%
be lifted! Trolley forwards
Type Chapter
TOWER CRANES
04.04 Maximum load switch on hoist

units
Maximum load switch = OS1
Fast load stage = OS2

• Switch (OS1) maximum load for the
range B - C of the load curve - with
horizontal jib - trolley operation.
• Switch (OS2) protects the fast stage
(stage III) of the hoist motor from over-
load.
Setting switch OS1
• Move trolley to smallest radius (approx.
4 m).
• With a load of between 2500 kg / 5500 lbs
and 2750 kg / 6050 lbs or a load of be-
tween 5000 kg / 11000 lbs and 5500 kg /
12100 lbs in 2/4 rope operation, switch off
the "Hoist up" and "Trolley forwards"
movements.
• Adjustment is made with the screw.
Setting switch OS2
• When lifting a load of approx. 1550 kg /
3400 lbs in 2-rope operation, or a load
of 3100 kg / 6800 lbs in 4-rope opera-
tion, stage III of the hoist motor must be
switched off and automatically switched
to stage II.
• Adjustment is made with the screw.
OS1 OS2
• After the switches have been set, re-
place the guard.
Type Chapter
TOWER CRANES
04.05 Setting the hoist limit switch
The hoist limit switch ensures that

• during operation the load block cannot
be run against the trolley, and
• that there are still at least two windings
of rope on the hoist drum when the load
block is lowered.
Setting switch "Hoist up" 1S1

• Move load block approx. 800 mm / 2'-7¼''
under the trolley.
• Set the operating cam so that switching
contact "A" in the limit switch is inter-
rupted.
• Lower the load block and raise again to
check correct cutout.
• In 2/4-rope hoist operation, the setting
must be carried out with 4 times reeved
lifting rope.
Setting switch "Hoist down" 1S2

• Set counter-contact "B" in the limit
switch so that after the hoist rope has
been lowered from the drum and after
the switching contact has been inter-
rupted there are still at least two wind-
ings of rope on the drum or that the
switching contact is interrupted when the
required lowest hook position has been
reached.
Carry out a test hoist without load - at fast

and at slow speed.
Type Chapter
TOWER CRANES
04.06 Setting the trolley limit switches
The trolley limit switches must be set so that

the switching guides of the trolley cause re-
liable actuation of the limit switches.
Type Chapter
TOWER CRANES
04.07 Setting the gear switch
The gear limit switch must switch off the

crane drive so that the crane comes to a
standstill before it reaches the rail end limit
stops.
Mode of operation:
1 3
• Lever (2) swivels when getting in con-
tact with the switching guide (3) and in- 30 mm / 1 1/4''
terrupts the power supply to the crane 2
drive unit. min. 2500 mm / 8' ca. 80-100 mm / 3' - 4'
Switching guide:
• Nail one switching guide onto the sleep-

ers before each end of the crane track.
• Dimension - 30 mm / 1 ¼'' - must be

exactly adhered to.
• The cutout function must be tested!
• The switching guide must be long

enough to ensure that even after the
crane comes to a standstill at the end of
the track the lever is still in switch-off
position.
Type Chapter
TOWER CRANES
04.08 Assembly switches
The assembly/dismantling fittings are lo-

cated in or at the electrical panel.
Jumper pushbutton Ob2

• is located on the right outside the elec-
trical panel.
• This pushbutton jumpers the "Maximum
load" limit switch (OS1) and the "Rear
trolley" limit switch (3S2).
It is required for:
• dismantling
Assembly switch OSO Jumper pushbutton Ob2
• evening position
Assembly switch OSO

• is located in the electrical panel and has
two settings, the positions "Assembly"
and "Operation".
• The assembly switch has the following
functions:
• reversing the direction of rotation of the
hoist motor.
• jumpering the "Hoist up" (1S1) and
"Hoist down" (1S2) limit switch contacts.
• switching off the trolley drive unit.
Assembly switch OSO
• Switching off the third hoist stage.
Type Chapter
TOWER CRANES
04.09 Trolley rope breakage

safeguard
The rope breakage safeguard prevents un-

controlled movement of the trolley in the
event of a breakage of the trolley rope.
If the jib has a slight upward or downward

inclination in the upper and lower working
positions, the trolley would start moving in
the direction of the inclination in the event of
rope breakage. With simultaneous load
movement, this can lead to unpredictable
hazards. These become even more serious
in the steep position.
In the event of a rope breakage, two arrest-

ing levers on the guide rod directed towards
the tower automatically engage and catch in
the struts of the lower boom. This ensures
that the movement of the trolley is stopped
in both directions.
Type Chapter
TOWER CRANES
04.10 Evening position 45°
! Caution
With the maximum jib length (42 m) the evening position 45° may only be implemented
in the "City" ballast variant.
! Caution
Evening position may only be set in 4-rope operation.
If necessary convert to 4-rope operation, see chapter Operation and Crane Operation "Con-
version of hook tackle in 2/4-rope hoist operation".
Note:
Before evening position is realized, the crane should be turned in the direction of the wind.
! Caution
During adjustment work and in the evening position of the jib, the crane may only be ro-
tated at low rotating speed (stage I). Rotating at higher speeds can lead to plastic de-
formation of parts of the jib.
Setting evening position
• Actuate the function "Trolley backwards" with the appropriate control lever of the controller
until the trolley triggers the limit switch (see diagram).
Type Chapter
TOWER CRANES
Evening position 45°
• Press the assembly jumper pushbutton at the electrical panel and at the same time enable
the function "Trolley back" using the appropriate control lever of the controller until the
trolley is located at the rear limit stop.
• Lower the hook tackle by enabling the "Hoist down" function using the appropriate control
lever of the controller.
• Climb up the ladder inside the tower of the crane as far as the fixed point of the jib assem-
bly rope on the inner tower.
• Take the eyelet of the jib assembly rope out of the fixed point and hang it into the load
hook (see diagram).
Type Chapter
TOWER CRANES
• Raise the jib tip with any fitted extension at low speed (stage I) by enabling the "Hoist up"
function using the appropriate control lever of the controller. In this way the tip of the jib
can be raised to an angle of 45° from the horizontal.
! Caution
Do not pull the hook tackle against the
trolley (hoist limit switch is out of serv-
ice!). The trolley and the load hook must
be observed very carefully during the en-
tire adjustment procedure.
Type Chapter
TOWER CRANES
! Caution
It is forbidden to work while the crane is in 45° evening position.
Setting the working position
• Lower the jib tip with any fitted extension at low speed (stage I) by enabling the "Hoist
down" function using the appropriate control lever of the controller.
• Climb up the ladder inside the tower of the crane as far as the fixed point of the jib assem-
bly rope on the inner tower.
• Take the eyelet of the jib assembly rope out of the load hook and hang it into the fixed
point (see diagram). Then leave the tower.
• Raise the hook tackle by enabling the "Hoist up" function using the appropriate control
lever of the controller.
• Enable the "Trolley forwards" function using the appropriate control lever of the controller
until the trolley has passed the rear limit switch.
The crane is now ready for operation.

Type Chapter
TOWER CRANES
05 Operation and Crane Opera-

tion
05.01 Starting up and closing down
Checks before starting up:
• Voltage on all three phases

• Direction of rotation of motors
• All limit switches and overload safety
devices
• All brakes on the drive units
• Condition (replacement state of wear)
of the ropes, of the crane tracks, the
rail limit stops, the crane traversing
limit switches, earthing etc.
• Condition of ballast
• Oil level of gears and lubrication
• Bolts and screwed connections
• Inclination of the jib (see chapter "Set-
ting the jib")
Measures for starting up:

• Establish power connection, but first
zero master switch on lower carriage
and control lever on controller.
• Switch on master switch on lower car-
riage. Press "On“ button on the con-
troller.
• Release and fold up rail clamps (for
version with travel gear).
• Move vented slewing gear brake into
position.
Type Chapter
TOWER CRANES
Starting up and closing down
Measures for closing down
• Pull up load hook as far as it will go

• In upper/lower working position move
the trolley to the center of the jib, and
in steep position move the trolley to
the tip.
• Vent slewing gear brake.
• Press "Off" button on controller, switch
off master switch on lower carriage
and disconnect power supply (con-
struction site distribution board).
• Fit and tighten rail clamps (in version
with travel gear).
• If there is a risk of storms, or in the
event of longer interruptions in opera-
tion in working position with steep jib
position, the trolley must be moved to
the tip, and it is essential that the cen-
tral ballast in normal radius should be
secured at the lower carriage by two
weights of 2.5 t / 5500 lbs each.
Type Chapter
TOWER CRANES
05.02 General notes on operating

the controllers
Precondition
The crane operator must be authorized

and able to operate the crane in accor-
dance with current regulations. He must
be familiar with the obligations of a
crane operator, the technical principles
of hoists and the handling of loads and
load suspension devices. This also in-
cludes correct communication between
the crane operator and the hitcher.
"Up" "Down" "Slow"
"Stop" "Stop - Danger !"

"Start"
Standard signs in crane operation for communication between the crane operator and the
hitcher.
Type Chapter
TOWER CRANES
General notes on operating

the controllers
The crane can be operated and driven

by two different controllers, but only one
controller can be connected at a time.
Controller - radio remote control
All movements can be triggered and

changed from the controller. The pa-
rameters given in the table apply for the
individual functions.
Control
lever
Stage
m/min kg m/min kg
fpm lbs fpm lbs
Raising
52 1500 26 3000
and III
205 fpm 3300 lbs 102 fpm 6600 lbs
Lowering
26 2500 13 5000
II A
102 fpm 5500 lbs 51 fpm 11000 lbs
6.0 m/min 3.0 m/min
I
24 fpm 12 fpm
Crane v = 25 m/min
I A
movement 98 fpm
I
n = 0 - 0.85 rpm
Slewing II B
0 - 1.02 rpm
III
v = 45/22/ m/min
I
Trolley v = 177 / 87 fpm
B
traverse v = 22 m/min; 1,100 kg (30°- jib inclination)
II
v = 87 fpm: 2400 lbs
Both controllers are connected to the

electrical panel using the same 24-pin
plug. Correct functioning can only be
guaranteed if genuine controllers, ca-
bles and connectors are used. Improper
interference with and changes to these
parts or the electrical panel may lead to
serious hazards and consequences, for
which the crane manufacturer can ac-
cept no responsibility.
Type Chapter
TOWER CRANES

the controllers
During operation it is important to re-

member that the movements of the
crane should be controlled at speeds
that correspond to the experience of the
crane operator and that are possible
without endangering operation. In par-
ticular, this applies when several func-
tions are being carried out at the same
time. Theoretically, the crane can carry
out up to four functions simultaneously:
• Slewing
• Raising/lowering
• Trolley traverse
• Crane movement (if mounted on
travel gear)
The compulsory zeroing contact ensures
that the crane can only be started from
the center position of the control switch.
In order to ease operation in certain cir-
cumstances, some control elements of
the crane are designed internally and
independently of operation. This means
that certain switching stages or se-
quences are blocked or continued for a
while. This does not exempt the crane
operator from his responsibility to oper-
ate the crane without risk in a suitable
manner. Excessively fast switching, in
particular with greater loads, produces
extreme knocks and impacts in the drive
and in the structure, leading to prema-
ture wear.
Type Chapter
TOWER CRANES

the controllers
Raising and lowering
In operating condition, the crane can

raise and lower loads in three speed
stages. While suddenly releasing the
control lever during the lifting phase
automatically causes the crane to switch
immediately to 0 from all stages, inter- Rope drive Load at which stage III
nal delays have been incorporated for "Lift" is blocked
the lowering phase. A sudden release 2-rope > 1500 kg / 3300 lbs
from stages II or III causes the crane to 4-rope > 3000 kg / 6600 lbs
switch immediately to stage I, and then
after a certain time interval to 0, thus
reducing the impact effect. Similarly,
when switching up from 0 or I to III, a
short delay is incorporated after reach-
ing stage II to allow stage III to take ef-
fect. A limitation of dynamic influences,
which is important for the stability of the
crane, is thus achieved, and on the
other hand this leads to running on dur-
ing lowering.
A similar safety element is integrated in

the hoisting movement. Stages I and II
can be started immediately from zero
position, while there is a forced delay in
the reaction of stage III. Furthermore,
stage III is blocked completely when the
load exceeds a certain magnitude.
The crane operator must ensure that

from a standstill loads are only lifted at
stage I, and that stages II and III only
cut in when the load is moving.
Since several functions are imple-

mented with the hoist/assembly rope,
this must also be taken into account
when operating the crane. In the func-
tion raising and lowering, the operation
of the control lever defines the direction
of movement of the rope.
Type Chapter
TOWER CRANES
General notes on operating the con-

trollers
Slewing
The crane can be moved in both direc-

tions of rotation in three speed stages.
The behavior of the crane during slew-
ing is dependent on various influencing
factors:
• Hook with or without load; if with
load the weight and balance of the
load are also of importance.
• Movement interference from rais-
ing/lowering and trolley movement
or - if mounted on travel gear -
crane movement.
• Wind influences such as
- wind strength
- wind direction
- load surface exposed to wind
• Ballasting variants
• Alignment of the crane on the in-
stallation area (exact position of the
axis of rotation)
It is expected of the crane operator that
he should take account of the individual
influences in how he operates the crane.
Aids to counter extreme operator errors
are incorporated into the controller. For
example, when switching from 0 to
stage III it is possible to switch to each
specific stage, but there is always a
programmed delay when switching from
stage II to stage III. This also takes ef-
fect if the crane operator switches
quickly from 0 to III. A second aid takes
effect when the crane is switched from
one direction of rotation to another.
Here too, there is a short delay until the
opposite direction of rotation is enabled.
While the transitions between stages I to
III are effectively regulated via the
power supply, an additional electric
brake that actively slows down the
movement of the crane takes effect
when switching to 0.
Type Chapter
TOWER CRANES
General notes on operating the

controllers
When the control lever is released, it is

automatically returned to zero position
by means of return springs, and the ro-
tation movement is thus slowed down. A
pushbutton on the controller can be
used to activate the mechanical holding
brake, which holds the jib of the crane in
a fixed position.
! Caution
Due to its powerful braking effect, the
holding brake must not be used as an
operating brake.
Provided that the crane operator has

sufficient experience, he can also
brake rotating movements of the crane
by countering with stages I and II of the
opposite direction. Although the counter-
movement of the electric brake is sus-
pended in stages I and II, the active
braking effect from these stages is
greater. "Countering" should be under-
stood here as premature switching in the
opposite direction of rotation. This
means that while the crane is slowing
down in the original direction of rotation,
the opposite direction of rotation is be-
ing enabled.
Note:
Do not switch to stage III when counter-

ing. Even though stage III only takes
effect with a certain delay, as described,
this still results in an excessive strain on
the structure and possibly - particularly
with suspended load and high load
torque - critical operating states may
occur.
Type Chapter
TOWER CRANES
General notes on operating the

controllers
Trolley unit
Stage I 22 m/min. / 87 fpm
The trolley can be traversed in normal Stage II 45 m/min. / 177 fpm
position in both directions in two speed
stages.
Between the stages of one direction and

also with changing directions, the
switching command is implemented di-
rectly. The movement of the trolley can
be differentiated better with the two
trolley speeds.
If correctly used, on the other hand, it is

easier to dampen pendulum movements
at jib level. Through short, rapid com-
pensation of the pendulum movement it
is possible to stabilize the load better.
Particularly at high load torque levels
the crane operator must ensure stable
load movements (e.g. nominal load at
the tip of the jib).
In the steep jib position of 30° the load

is limited to a maximum of 1100 kg /
2400 lbs over the whole jib length. In
addition, trolley speed stage II is
blocked.
This is effected by means of a switch

located in the electrical panel on termi-
nal strip X3. Before using this in opera-
tion, the tension of the trolley unit ropes
must be checked by carrying out a trol-
ley test run.
Terminal strip X3 Switch

Type Chapter
TOWER CRANES

the controllers
Operating the travel gear

(not for SMK 201 and SMK 202)
The crane can be driven in both direc-

tions with its travel gear. The crane op-
erator must keep a constant eye on the
crane track in order to be able to brake
the crane movement in good time if re-
quired. Type
SMK
"Countering" with the opposite direc-
201 ----
tion of travel is not permitted!
202 ----
The length of the track system must be 203/1 20 m/min - 65 fpm
designed in such a way that the crane
can carry out all alternations of load 206 25 m/min - 81 fpm
without having to use the travel limit 308 30 m/min - 98 fpm
switch. The travel limit switch is an
emergency switch, which must not be
used by the crane operator as an oper-
ating limit switch.
This additional crane movement option

requires increased attention on the part
of the operator. In particular, travel with
the long control cable must not lead to
the control cable running unchecked
over rails in the travel range, otherwise
it may be damaged or crushed by the
crane in operation.
Type Chapter
TOWER CRANES
05.03 Controller with cable
The controller with its 5 m / 16'-3½'' long

control cable and 24-pin plug-in unit is a
component part of the basic equipment.
Operation may be effected from freely
selectable locations within a radius of 5 m/
16'-3½'' from the connection. For installa-
tion in the cabin, the tower cable must be
used.
In free locations the controller may be held
by the operator by using a carrying belt,
while there is a special compartment in the
cabin. If the control cable is connected di-
rectly to the electrical panel, ensure that
the crane does not overstretch the cable in
the event of large rotational movements.
The control cable must always be kept
slack. For this reason it is advantageous to
connect the control cable to the lower car-
riage in the event of large rotational
movements, because then the rotational
movements of the upper carriage have no
effect.
NOTE:
This version is, however, not available if

the crane is fitted with travel gear.
Type Chapter
TOWER CRANES
05.04 Changing the hook tackle in

2/4-rope hoisting operation
In 2-rope operation, the pulley block (1) 2-rope operation

has contact with the trolley through the
hook block's own weight. Proceed as
follows to change to 4-rope operation:
• Lower hook block (2) until it touches

the ground and hold it in a vertical
position.
• Continue lowering hoist unit, which
thus lowers the pulley block (1).
When starting to lower the pulley
block (1) move the hoist unit only in
stage I since otherwise there is a
risk of rope slack forming on the
hoist drum.
• Bolt the pulley block (1) and the 4-rope operation
hook block (2) to each other (3).
• When changing from 4-rope to 2-
rope operation, it is important to
make sure that the bolt (3) is first
inserted in the pulley block (1) and
secured and this is only then raised.
Type Chapter
TOWER CRANES
05.05 Putting the crane out of service at high wind speed
• below the permitted wind speed the

The crane must be put out of service when load exposes too great a surface to the
wind (standard area 1.5 m²/ 16.2 ft²).
• the permitted wind speed of 72 kph or 20
m/sec (44.64 mph or 65.6 ft/s) is ex- Even below the permitted wind speed,
ceeded, the stability of the crane may also be
endangered in the event of incorrect
• the jib cannot be swiveled against the assessment of the influence quantity of
wind, or the slewing gear brake can no the surface exposed to the wind.
longer hold the jib,
! Caution
Besides these instructions, the accident

prevention regulations for crane opera-
tion must be observed.
Dynamic pressure q depending on wind speed v

Wind force Description Wind speed Dynamic pressure
Beaufort scale m/sec ft/s N/m² psi
(Measured at
10 m / 32'-9 ¾'')
0.0 to 0.025 0.0 to
0 calm 0.0 to 0.2 0.0 to 0.66
0.0000118
0.04 to 1.4 0.000019 to
1 light air 0.3 to 1.5 0.98 to 4.92
0.0006659
1.6 to 6.8 0.0007611 to
2 light breeze 1.6 to 3.3 5.25 to 10.82
0.0032347
7.2 to 18.2 0.003425 to
3 gentle breeze 3.4 to 5.4 11.15 to 17.71
0.0086577
18.9 to 39.0 0.0089907 to
4 moderate breeze 5.5 to 7.9 18.04 to 25.91
0.0185523
40.0 to 71.6 0.019028 to
5 fresh breeze 8.0 to 10.7 26.24 to 35.10
0.0340601
72.9 to 119.0 0.0346785 to
6 strong breeze 10.8 to 13.8 35.42 to 45.26
0.0566083
120.8 to 182.8 0.0574645 to
7 moderate gale 13.9 to 17.1 45.59 to 56.09
0.0869579
184.9 to 267.8 0.0879569 to
8 fresh gale 17.2 to 20.7 56.42 to 67.90
0.1273924
270.4 to 372.1 0.1286292 to
9 strong gale 20.8 to 24.4 68.22 to 80.03
0.1770079
375.2 to 504.1 0.1784826 to
10 whole gale 24.5 to 28.4 83.31 to 93.15
0.2398003
507.6 to 664.2 0.2414653to
11 storm 28.5 to 32.6 93.48 to 106.93
0.3159599
668.3 to 851.0 0.3179103 to
12 hurricane 32.7 to 36.9 107.26 to 121.03
0.4048207
Type Chapter
TOWER CRANES
06 Variants
06.02 Ballasting variant upper carriage extension
• To attach the extension frame, the

crane is supported on spindles or
lowered onto rails. The tower pack-
age is upright.
• The upper carriage extension is
mounted with the help of the loading
arm or of other hoisting equipment
(e.g. fork-lift truck).
• Push extension frame in horizon-
tally.
• Release load torque limiter on upper
carriage and turn by 180°.
• Bolt load torque limiter in position
again so that the limit switches are
accessible again after ballasting.
Type Chapter
TOWER CRANES
06.03 Converting from 30 m / 98'5'' to 36/40/42 m

118'-1'' / 131'-3'' / 137'-9'' jib
Crane in transport position
6.0/10.0/12.0 m
20'/32'/39'
trolley rope drum supporting roller

rear trolley rope
front trolley rope
jib tip extension

tensioning spring insulating tape 200 mm / 8''
Trolley rope drum trolley
Supporting roller
• All cranes can be converted from a

30 m / 98'-5'' jib to a 36/40/42 m /
118'-1'' / 131'-3'' / 137'-9'' jib without
the need for a new trolley rope. The
excess rope length of a 30 m /
98'-5'' jib is attached to the trolley.
• Release the front trolley rope on the
trolley and mark with insulating tape
as shown in the diagram.
• Free sufficient hoist rope depending
on the extension.
• Dismantle the traverse with deflec-
tion pulley at the flanged connection
to the jib tip.
• Bolt on the jib extension to the front
hinged connection of the jib tip at
the lower boom level.
• Mount the traverse with deflection
pulley at the flanged connection to
the jib extension.
Type Chapter
TOWER CRANES
Converting from 30 m / 98'-5'' to

36/40/42 m / 118'-1''/131'-3''/137'-9'' jib
• Move the trolley limit switch to the

jib extension, at the same time re-
lease the reserve cable length and
connect up all parts correctly (ca-
bles taut in the region of the jib ex-
tension, but in the hinge region the
cable must have a loop of approx.
30 cm / 12'' and the limit switch
must be attached so that it functions
correctly).
• Mount deflection pulley for jib ex-
tension assembly rope on the jib tip.
• Fit the jib extension assembly rope
and attach to jib extension section I.
• Attach the other end of the rope to
the jib base and tension slightly with
the turnbuckle.
• Place the trolley rope over the front
trolley rope deflection pulley and the
supporting roller on the upper boom
of the jib extension.
• Attach the front (extended) trolley
rope to the trolley using the rope
socket.
• The remaining end is then stowed
and attached to the trolley.
• Correctly adjust the trolley rope
length of the "front" rope, that is:
Extend the trolley rope by twice the jib
extension length (mark using insu-
lating tape).
• Attach trolley and hoist ropes to the
assembly strap on the jib tip with
upper boom bolts.
Type Chapter
TOWER CRANES

36/40/42 m / 118'-1''/131'-3''/137'-9'' jib
NOTES:
• Overtightening the trolley rope dur-
ing preassembly involves a risk of
rope breakage when moving out the
jib.
• Excessively loose routing of the
trolley rope can lead to unintentional
triggering of the rope breakage
safeguard. (However, the triggering
of the rope breakage safeguard is
an emergency safeguard that can-
not rule out the possibility of me-
chanical damage to the lower jib
boom when braking uncontrolled
trolley travel.)
• The length of the front trolley rope is
correctly set when the tensioning
spring is extended more than half of
the distance of its possible tension-
ing path.
• When the jib is in steep position and
the trolley rope is taut under load, it
is important to ensure that the rope
running towards the tower retains
sufficient residual tension. (If neces-
sary correct rope tension.)
• Sufficient account must be taken of
the stretching of new ropes, and
these may require retensioning after
several alternations of load.
• After conversion and the resulting
change in length of the hoist and
assembly ropes, the hoist limit
switch must be reset before startup
(see also chapter on Safety Equip-
ment).
Type Chapter
TOWER CRANES

36/40/42 m / 118'-1''/131'-3''/137'-9'' jib
Converting from 30 / 98'-5'' to 36 m /

118'-1'' (36 m /118'-5'' jib)
• Attach the deflection pulley to the jib
tip.
• Attach the jib extension assembly
rope to jib extension section I.
• Bolt the lower booms.

131'-3'' (40 m / 131'-3'' jib)
• Attach the deflection pulley to the jib
tip.
• Attach the jib extension assembly
rope to jib extension section I.
• Bolt jib extension sections I and II.
• Bolt the jib section and jib extension
section I lower booms.

137'-9'' (42 m / 137'-9'' jib)
• As for 40 m / 131'-3'' jib, but with jib
extension sections I and III.
Type Chapter
TOWER CRANES
06.04 Converting to travel gear
Conversions required:
• Remove spindle insert including
spindle.
• Fit wheel houses.
• Mount gear limit switch.
• Establish electrical connections for
gear limit switch and motor.
• Fit cable drum.
Installation of the parts:
The crane is folded together on road

running gear or is jacked up and the
spindle inserts are removed (tower
folded down).
• Fit driven wheel houses on the drive

side of the lower carriage.
• Fit non-driven wheel houses.
• Mount gear limit switch to lower car-
riage. (Determine installation height
by means of location of switching
guide.)
Type Chapter
TOWER CRANES
Converting to travel gear
• Mount cable drum on lower car-

riage.
• Install reversible contactor combi-
nation in the electrical panel and
establish electrical connection.
(Supply lead is installed in electrical
panel.)
• Connect travel limit switch to supply
lead of slip ring body and connect
travel limit switch to travel motor
using the supply lead. Check correct
motor cutout by the travel limit
switch.
Type Chapter
TOWER CRANES
06.05 Cabin in the inner tower
Subsequent installation of cabin in the

inner tower. Crane status: fully assem-
bled.
• Engage the cabin in the hook block
and lift it to assembly position.
• Press the jumper pushbutton, move
the trolley slowly in the direction of
the tower until it strikes the limit
stop, moving over the limit stop
switch.
• Suspend the cabin from the upper
welded bolt in the tower.
• Establish the lower bolted connec-
tion and secure it.
• "Hoist down" and at the same time
swivel the cabin.
• Mount and secure the rear bolt.
• Remove hook block from cabin.
• Install control cable in cabin.
Type Chapter
TOWER CRANES
06.06 Lighting equipment on crane
Required equipment:
• Floodlight lamp 1000 watts

• Transformer 1100 VA; 480/110 V
• "On - Off" switch
• Connecting cable installation
Installation of the parts:

The crane is in transport status. Floodlight lamp
• Attach floodlight lamp retaining straps
to inner tower, top right on front boom,
and then bolt on the lamp.
• Install transformer in the electrical
panel.
• Install "On - Off" switch on the narrow Electrical panel with transformer
side of the electrical panel (drilling
template provided).
• Install connecting cable from the elec-
trical panel terminals to the floodlight
lamp.
• The cable must be run over the front
erection support and loosely through
the outer tower into the inner tower to
the floodlight lamp. Electrical connec-
tion in accordance with the wiring dia-
gram. (See appendix.)
NOTE:
All of this work must be carried out by in-
structed, qualified personnel.
Type Chapter
TOWER CRANES
06.07 Setting the slewing range

limiting device
The slewing range limiting device with

the attachment parts is clamped onto
the upper carriage, so that the plastic
toothed wheel on the switch engages
reliably in the live ring on the lower car-
riage.
The electrical connection is established
in accordance with the wiring diagram.
(See appendix.) The setting must be
such that the crane reliably comes to a
standstill before it reaches the obstacle.
NOTE:
All of this work must be carried out by

trained personnel only!
The slewing range limiting device is an

emergency device, which should not be
deliberately triggered.
Type Chapter
TOWER CRANES
Setting the slewing range limiting

device
Braking sector
• The braking sector is the rotation IV III II I

angle range that the jib needs to
reach braked home position from Building, obstacle
operating rotating speed. Since the
slewing gear can be run in three
speed stages, the braking sector is
dependent on the speed stage of
the load and the actual braking ef- Run-on of load centre of gravity
fect.
α
Elastic hysteresis sector of jib Slewing gear cutout point
• When the slewing gear is braked, Rotantional axis of crane

the jib shows a reverberation in the
direction of rotation. This reverbera-
tion goes beyond the braked home
position of the jib and is also de-
I Braking sector
pendent on the speed stage of the
II Elastic hysteresis sector of jib
load and the braking effect.
III Sector of pendulum
movement of load center of
Sector of pendulum movement of
gravity
load center of gravity
IV Safety sector
α Working range of jib
• In addition to the reverberation of
the jib, the load is also subject to
decreasing pendulum movements.
The range of these movements is
dependent on the braking effect and
the length of the rope between load
and jib.
Type Chapter
TOWER CRANES
Setting the slewing range limiting

device
Safety sector
The safety sector is influenced by many

factors:
• Position and height of the obstacle
in the slewing range of the crane
• Size and bulkiness of load
• Wind influence and load surface
area exposed to the wind
• Size of working range
• Functional tolerance of switch etc.
Before the slewing range limiting device
is adjusted to local conditions, the run-
on sector of the crane should first be
determined with a test load in an uncriti-
cal working range.
NOTE:
Before starting operation, a functional
test must be carried out in stage I of the
slewing gear, without load!
The slewing range limiting device is an

emergency device, which should not be
deliberately triggered.
The slewing range switch itself is ad-

justed to the working range by the cor-
rect adjustment of two separate cam
disks by means of setscrews.
Type Chapter
TOWER CRANES
06.08 Radio remote control
In one variant, the crane can be fitted

with the necessary radio remote control
and the cable for connecting the re-
ceiver.
Mode of operation:
The functions assigned to control levers

A and B are the same as with the cable-
linked controller.
In general it must be noted that use of

the radio remote control units leads to
significant improvements for the crane
operator. In many technological situa-
tions, the high degree of independence
of location in an extended radius of ac-
tion represents a substantial advantage.
On the other hand, the crane operator

must always do his best to pay close
attention to the actuated functions. This
is why the crane operator should stay as
close as possible to the scene, in spite
of the action radius of the controller of
50 m / 164 ft to 200 m / 656 ft.
It is essential that an excessive distance

from the crane, which could adversely
affect reliable operation, should be ruled
out. For further information please refer
to the operating instructions in the
documentation of the manufacturer.
Type Chapter
TOWER CRANES
06.09 Hour meter
Hour meters are switched on and off

with the device to be monitored. They
are maintenance-free and consist of a
counter driven by a synchronous motor.
The synchronous motor and the counter
are located in a common housing.
Depending on requirements, it is possi-

ble to provide an hour meter for total
operating time or also for each individ-
ual drive unit.
The hour meters are attached to a re-

taining bracket that is located on either
the right or left-hand side of the electri-
cal panel, as required.
Depending on the number of hour me-

ters, the work involved in wiring can be
seen from the wiring diagram.
Type Chapter
TOWER CRANES
07 Maintenance
07.01 Maintenance instructions
Maintenance and inspection Work / Measures Interval

object
Brake Functional test - daily
Hoist, slewing, travel and trolley Check oil level - weekly
gears
Screwed connections Check tight fit - after every trans-
- ball bearing slewing rim port
- wheel nuts on travel gear - 50 h after initial
startup
- every 1000 service
hours
Bolted connections Check for completeness - after every trans-
- deformation port
- wear - every 1000 service
hours
Wire ropes Check for correct rope guidance - during every as-
- rope damage sembly
- rope wear - weekly or daily if
- replacement state of wear wear is perceptible
- monthly
hours
Sheaves Rope bed wear - before every new
Bearing wear assembly
Visible damage - and every 1000
service hours
- and before rope
changes
All connection terminals in the Visible check for tight fit and contact ero- - after every trans-
electrical panel sion port
- or 1 x monthly
Contactor and switch contacts Check for contact erosion and tight fit - 1 x every 6 months
Plungers and rollers of limit Clean, grease lightly or replace - after every trans-
switches and excess load limiters port
hours
Type Chapter
TOWER CRANES
Maintenance instructions
Maintenance and inspection Work / Measures Interval

object
Ventilation filters on the gear Inspect and clean - after every trans-
units port
hours
Slip rings, collectors, brushes and Inspect and clean - after every trans-
brush holders of motors port
hours
Running gear for road transport Check: - before every road
- air pressure transport
- wheel nuts
- reliable brake functioning - in accordance with
- general condition national regulations
Lighting bracket for road trans- Check: - before every road
port general condition of equipment transport
and correct functioning of the lighting
equipment
Lubrication points See lubrication chart See lubrication chart
Brake maintenance Check brake linings and set values (see See "SMK crane
"SMK crane brakes") brakes"
Travel gear Condition and wear of wheels - annually
Crane track - adherence to all bearing tolerances - before initial
- reliable functioning of limit stop and limit startup
switch - every 50 to 100
- condition of rails and sleepers service hours
Position of jib Check the existing jib rise under nominal - before initial
load startup
- after replacement
of gantry rope
Type Chapter
TOWER CRANES
07.02 General lubrication chart
Service hours
Lubricating grease: Lithium on soap basis, water-repellent NL GI2
Gear oil: See charts for the individual drive units
Lubricate disk springs of maxi-

Keep constantly lu- mum load switch on hoist unit Gear rim of ball bearing slewing
bricated with molybdenum sulphide; rim; gear rim of rail wheels
clean 1 x annually
50 Bearings of rail wheels Ball bearing slewing rim
After approx. 500 service hours a first oil change must be carried out
500 or 2,000 on all gears to be serviced. Further oil changes to be carried out
every 2000 service hours.
All pivots and bolts required for Sliding and guide surfaces in the
Before each assem-
the assembly process, telescope inner and outer tower, hinge pins
bly
catches of ballast loading arm
Hinges, hand brake spindle,
wheel bearings, brake lever
As required Road transport:
bearing, steering bolts, steering
rods, steering knuckles etc.
Keep constantly lu-
bricated with rope Hoist ropes
grease
CAUTION !
These general specifications refer to normal operation.

Under extreme conditions, the lubrication intervals must be varied accordingly.
Type Chapter
TOWER CRANES
General lubrication chart
Oil quantity in l
System pictures of drive units Gear type Oil type Oil change
gallon
A OT 2703
40.0
up to crane
10.4
073 ISO
Hoist unit
VG 220
KA 96
18.5
crane 074 or
4.81
higher
C 1 oil change
after approx.
500 service
Trolley ISO 5.0 hours, further
unit S 72 VG 320 1.3 oil changes
after approx.
2000 service
hours
D
Crane
TLS 1100 ISO 0.5
travel gear
VG 320 0.13
B OLS 2403
(Oil or grease
Slewing ISO 3.5
lubrication,
unit VG 220 0.91
see type
plate!)
Grease Maintenance-
Ball bearing slewing rim
For-life lubrication free
Oil filler
Oil level
Oil drain
Type Chapter
TOWER CRANES
07.03 Rope routing diagram for hoist and assembly rope
Jib base Trolley
Hoist rope
Inner tower
tower tip Upper hook
block
Load block
Outer tower
Inner tower
Trolley on ballasting arm
Upper carriage
Hoist rope drum
Assembly drum
Tower pulley package
Upper carriage pulley package

Type Chapter
TOWER CRANES
07.04 Installing the hoist and assembly ropes
Installing the hoist rope
When installing the hoist rope, it must

be treated with the utmost care. To
avoid twisting, the rope to be installed Hoist rope routing
must be mounted directly from the 01 Hoist drum
winder over the pulleys in the jib, the 02 Pulley - inner tower (head)
trolley and the tower and onto the hoist 03 Pulley - jib base
drum. 04 Pulley - trolley
05 Pulley - load block
If the old hoist rope is still in position,
06 Pulley - trolley
the new rope can be linked to the old
07 Pulley - trolley
rope with the help of a rope stocking
and pulled on with the hoist rope winch. 08 Pulley - upper hook block
09 Pulley - trolley
Note: If there are twists in the mounted 10 Twist catcher
rope, there is a risk of the new rope
untwisting and thus of rope breakage!
To ensure that twisting in the old rope is

not transferred to the new hoist rope
during installation, it is recommended
that you should work with two rope
stockings that are rotatably linked to
each other.
Type Chapter
TOWER CRANES
Installing the hoist and assembly

ropes
Installing the assembly rope
When installing the assembly rope, it Assembly rope routing

must be treated with the utmost care. To 01 Assembly drum
avoid twisting, the rope to be installed 02 Pulley - outer tower
must be mounted directly from the 03 Pulley - ballasting arm
winder over the pulleys in the jib, the 04 Pulley - ballasting trolley
trolley and the tower and onto the as- 05 Pulley - ballasting block
sembly drum. 06 Pulley - ballasting trolley
07 Pulley - ballasting arm
If the old assembly rope is still in posi- 08 Pulley - outer tower
tion, after cutting off the thimble and 09 Pulley - outer tower
binding the end of the rope with adhe- 10 Pulley - outer tower
sive tape, the new rope can be linked to
11 Pulley - upper carriage
the old rope with the help of a rope
12 Pulley - outer tower
stocking and pulled on with the assem-
bly rope winch. 13 Pulley - upper carriage
Note: If there are twists in the mounted 15 Pulley - upper carriage
rope, there is a risk of the new rope 16 Pulley - outer tower
untwisting and thus of rope breakage! 17 Pulley - upper carriage
To ensure that twisting in the old rope is 19 Pulley - upper carriage
not transferred to the new assembly 20 Pulley - outer tower
rope during installation, it is recom- 21 Pulley - upper carriage
mended that you should work with two 22 Pulley - outer tower
rope stockings that are rotatably linked 23 Pulley - outer tower
to each other. 24 Pulley - inner tower
26 Pulley - inner tower
35 Pulley - fixed point outer tower
Type Chapter
TOWER CRANES
07.05 Rope routing diagram for

trolley rope
Rope route for 30 m / 98'-5'' jib:
• Front rope (I):

Fixed point (3) at the trolley (4), de-
flection pulley (5) at the jib tip, sup-
porting roller (6) at the jib base,
supporting roller (7) at the jib tip,
trolley rope drum (8)
• Rear rope (II):

Fixed point (11) at the tensioning
spring (10), deflection pulley (9) at
the jib base, trolley rope drum
1
trolley rope drum jib base
8 7
jib base II I I jib tip 5
9 3
10 11 trolley 4
Type Chapter
TOWER CRANES
07.06 Installing the trolley rope
30 m / 98'-5'' jib
• Move trolley to rearmost position

• Fold in jib tip
• Connect rope II with thimble (11) to
the tensioning spring (10)
• Run rope II around the pulley (9) at
the jib base, attach the free end to
the drum (8) and wind tightly onto
drum
• Attach rope I to point (3)
• Place rope around jib hinge, over
deflection pulley (5) at the jib tip,
over supporting roller (7) and
through the jib base over supporting
roller to the drum
• Place one coil of rope on the drum
and secure the rope. A second coil
is automatically added when the
rope is tensioned.
• For notes on setting the rope ten-
sion see "Converting from 30 m/
98'-5'' to 36/40/42 m / 118'-1''/131'-
3''/137'-9'' jib".
Type Chapter
TOWER CRANES
07.07 Rope routing diagram for jib assembly rope
Inner tower
rope sustainer
jib base
jib base
jib tip
13 effective strands
tower head inner tower
outer tower
fixed point
inner tower
Type Chapter
TOWER CRANES
gültig ab Werk - Nr.: 001 gültig bis Werk - Nr.: 010 Ausgabe 3/97 Seite 124
valid from crane no.: 001 valid to crane no.: 010 Edition Page
valide de grue no.: 001 en valide de grue no.: 010
07.08 Table of ropes used
Application Diameter Length Version

(mm) (m)
inch ft
11 202.00 11 x 1770 plain
Hoist rope
0.43'' 662'-9'' 0.43'' x 1770 plain
9 x 1770 with 1 thimble 12
9 77.00
Jib assembly rope 0.35'' x 1770 with 1 thimble 0.47''
0.35'' 252'-8''
DIN 3090 galvanized
35 x 1960 with 2 thimbles 36
Anchoring rope 35 19.32
1.37''x1960 with 2 thimbles 1.41''
Gantry rope I 1.37'' 63'-5''
DIN 3090 galvanized
HH 28 m: 35
7.255
91'-10'' HH:
Anchoring rope 23'-10'' 35 x 1960 with 2 thimbles 36
1.37''
Gantry rope 1.37''x1960 with 2 thimbles 1.41''
HH 24 m: 35
Horizontal position 3.27 DIN 3090 galvanized
78'-9'' HH:
10'-9''
1.37''
Anchoring rope 35 x 1960 with 2 thimbles 36
35 5.29
1.37'' 17'-5''
Steep position DIN 3090 galvanized
8 83.00 8 x 1770 galvanized
Trolley rope I
0.31'' 272'-4'' 0.31'' x 1770 galvanized
8 x 1770 galvanized
8 47.00
Trolley rope II 0.31'' x 1770 galvanized
0.31'' 154'-2''
with 1 M 16 threaded clamp
10 x 1960 with 2 thimbles C 10
Loading arm 10 5.70 0.39'' x 1960 with 2 thimbles
Anchoring rope 0.39'' 18'-9'' C0.39''
DIN 6899 galvanized
Safety rope at 11 20.00 11 x 1770 galvanized
20 m HH 0.43'' 65'-8'' 0.43'' x 1770 galvanized
12 7.25 12 x 1960 galvanized
Rope for jib extension
0.47'' 23'-10'' 0.47'' x 1960 galvanized
Type Chapter
TOWER CRANES
Table of ropes used
Diameter Length
Application Version
(mm) (m)
11 202.00 11 x 1770 plain
Hoist rope
0.43'' 662'-9'' 0.43'' x 1770 plain
9 x 1770 with 1 thimble 12
9 77.00
Jib assembly rope 0.35'' x 1770 with 1 thimble 0.47''
0.35'' 252'-8''
DIN 3090 galvanized
19.725 35 x 1960 with 2 thimbles 36
Anchoring rope 35
1.37''x1960 with 2 thimbles 1.41''
Gantry rope I 1.37''
64'-9'' DIN 3090 galvanized
HH 28 m: 35
6.85
91'-10'' HH:
1.37''
HH 24 m: 35
78'-9'' HH:
9'-5''
1.37''
35 4.885
1.37'' 16'
8 83.00 8 x 1770 galvanized

Trolley rope I
0.31'' 272'-4'' 0.31'' x 1770 galvanized
8 x 1770 galvanized
8 47.00
Trolley rope II 0.31'' x 1770 galvanized
0.31'' 154'-2''
with 1 M 16 threaded clamp
Anchoring rope 0.39'' 18'-9'' C0.39''
DIN 6899 galvanized
20 m HH / 67'-3'' HH 0.43'' 49'-2'' 0.43'' x 1770 galvanized
12 7.25 12 x 1960 galvanized

0.47'' 23'-10'' 0.47'' x 1960 galvanized
Type Chapter
TOWER CRANES
Table of ropes used
Application Diameter Length Version

(mm) (m)
11 202.00 11 x 1770 plain
Hoist rope
0.43'' 662'-9'' 0.43'' x 1770 plain
11 x 1960 with 1 thimble C 12
11 280.00
Assembly rope
0.43'' 918'-8'' 0.43''x1960 with 1 thimble C 0.5''
DIN 6899 galvanized
9 x 1770 with 1 thimble C 12
9 77.00
Jib assembly rope 0.39'x1770 with 1 thimble C 0.5''
0.39'' 252'-8''
DIN 6899 galvanized
7 83.00
Trolley rope I 7 x 1770 galvanized
0.27'' 272'-4''
47.00 7 x 1770 galvanized
Trolley rope II 70.27''
154'-3'' with 1 M 16 threaded clamp
35 x 1960 with 2 thimbles 36
1.37''x1960 with 2 thimbles 1.41''
Gantry rope I 1.37'' 64'-9''
DIN 3090 galvanized
HH 28 m: 35
6.85
91'-10'' HH:
1.37''
HH 24 m: 35
78'-9'' HH:
9'-5''
1.37''
35 4.885
1.37'' 16'-0''
Anchoring rope 30 11.681 30 x 1960 with 2 thimbles C 32
Pendulum support - jib base 1.18'' 38'-4'' DIN 6899 galvanized
Anchoring rope 36 x 1960 with 2 thimbles C 36
36 5.22
Pendulum support - gantry sup- 1.41''x1960 with 2 thimbles C1.41''
1.41'' 17'-2''
port DIN 6899 galvanized
Anchoring rope 24 x 1960 with 2 thimbles C 36
24 16.767
Pendulum support - rope sus- 0.94''x1960 with 2 thimbles C1.41''
0.94'' 55'-0''
tainer DIN 6899 galvanized
0.94''x1960 with 2 thimbles C1.41
Rope sustainer - jib tip 0.94'' 40'-5''
DIN 6899 galvanized
Anchoring rope 0.39'' 18'-9'' C0.39''
DIN 6899 galvanized
20 m HH / 67'-3'' HH 0.43'' 49'-3'' 0.43'' x 1770 galvanized
12 7.25 12 x 1960 galvanized
0.47'' 23'-10'' 0.47'' x 1960 galvanized
Type Chapter
TOWER CRANES
07.09 Notes on handling wire

ropes
Handling, mounting, replacement

Right
Every crane delivered ex works is fitted
with the ropes listed in the "Table of
ropes used". When handling and espe-
cially when replacing ropes, pay par-
ticular attention to the following:
• Ropes may only be replaced by

ropes of the same type and
strength.
Winder
• The new rope must be correctly and
Drum
clearly marked.
• Ropes may only be replaced by
trained and qualified personnel.
• The new rope must be subjected to
a thorough visual inspection over
the whole length, in order to WRONG
• detect influences caused by trans-
port, storage, manufacture and in-
stallation before commissioning.
• Ropes must be unwound from rings,
winders or drums in such a way that
no unacceptable twist is transferred
to the rope.
Winder
Drum
Type Chapter
TOWER CRANES
Notes on handling wire ropes
• When mounting ropes, particularly

with hoist ropes and complicated old rope new rope
rope drives, appropriate measures
must be taken to ensure that no un-
acceptable twisting can occur.
Appropriate measures are:

rope stocking rope stocking
• Fitting the new rope with the old
rope (if there was no rope breakage) hemp rope
using a connection to compensate
for twisting.
• Fitting the new rope with a thin, low- old rope new rope
twist pilot rope.
• The rope connections between the
mounting rope and the new rope
must be such that the connecting
points do not catch at restricted eyelet eyelet
points in the rope route.
hemp rope
The following can be rope connec-
tions:
• Rope stocking connections
• Rope stockings are braids made of
single strands; they are pushed over
the rope ends and secured at the
ends with adhesive tape. To allow
additional compensation for twist,
the ends of the rope stockings were
connected to an approx. 3 to 4 m
long hemp rope.
• Connections of rope ends that have
eyelets or chain links of a suitable
size welded onto the ends.
Type Chapter
TOWER CRANES
• It must be ensured that the new

rope (hoist rope) has sufficient pre-
tension when it is drawn onto the
drum (e.g. with the help of suitably
clamped wooden blocks).
• If the required piece of rope is taken
from a length of stored rope, then it
is important to ensure that in the
long term the rope strands at the
point of separation do not become
loose.
• When the wire rope is unwound
from the winder or from a ring, and
when mounting into the rope drive,
the wire rope must not be untwisted
or overtwisted, since otherwise the
rope structure will be disturbed and
kinks, twists or buckling may occur.
• The rope must be mounted exactly
according to plan and must be cor-
rectly reeved.
• The specified connecting elements
must be used for all rope connec-
tions.
• All functioning parts connected with
the rope or rope drive (e.g. safety
equipment, such as limit switches)
must be checked again before re-
starting to ensure that they function
correctly.
• All ropes must be properly greased
during mounting. It is important to
ensure that the ropes do not touch
the ground. (Dirty ropes must be
carefully cleaned, since dirt accu-
mulation has an adverse effect on
the service life of the ropes and
rope pulleys.)
Type Chapter
TOWER CRANES
Notes:
• For rope maintenance, the lubri-
cants specified under "Recom-
• New ropes must be stretched slowly mended lubricants" must be used.
when they are already mounted. For
• The lubricant used must be com-
this reason, the new rope must first
patible with the previously used lu-
be tested under low load (10% of
bricant.
full load), and then the load must be
gradually increased to maximum • Before greasing, ropes must be
load. Transport ropes must be cleaned if necessary.
moved over their entire length be-
fore commissioning.
Maintenance and care
• Wire ropes must be serviced and

lubricated regularly.
• The shorter the expected service
life of a rope is, depending on oper-
ating conditions, the more carefully
the care and maintenance meas-
ures have to be carried out. On the
other hand, an adequate
Monitoring
The safe operating condition of wire

ropes must be inspected regularly by
qualified staff. The intervals between
the inspections must be adapted to the
load and operating conditions, and they
must be regulated so that damage is
recognized in good time.
Type Chapter
TOWER CRANES
Inspections must be carried out at

shorter intervals if
• ropes show first perceptible wire

breakages
• ropes have been exposed to ex-
traordinary loads
• ropes have been newly mounted
and invisible damage is suspected
All results of inspections of this kind

must be recorded in the log book!
Objects of inspection are:
• type and number of wire breakages

• location of wire breakages
• chronological sequence of occur-
rence of wire breakages
• reduction of wire diameter during
operation
• corrosion
• wear by friction
• rope deformation
• effects of heat
• service life
see DIN 15 020 Sheet 2
Type Chapter
TOWER CRANES
Replacement state of wear
Replacement state of wear has been

reached when there is a concrete dan-
ger arising from the state of the rope, for
example:
• breakage of a strand
• occurrence of wire breakage tangles
• corkscrew-type deformation around
more than 1/3 of the rope diameter
Type Chapter
TOWER CRANES
Reaching the wire breakage figures defined in the table.
No. of Number of visible wire breakages at replacement state of wear

bearing
wires in Drive groups Drive groups
the outer 1Em, 1Dm, 1Cm, 1Bm, 1Am 2m, 3m, 4m, 5m
strands of Crosslay Parallel lay Crosslay Parallel lay
the wire over a length of over a length of over a length of over a length of
rope 3)
n 6d 30 d 6d 30 d 6d 30 d 6d 30 d
000 to 050 2 4 1 2 4 8 2 4
051 to 075 3 6 2 3 6 12 3 6
076 to 100 4 8 2 4 8 16 4 8
101 to 120 5 10 2 5 10 19 5 10
121 to 140 6 11 3 6 11 22 6 11
141 to 160 6 13 3 6 13 26 6 13
161 to 180 7 14 4 7 14 29 7 14
181 to 200 8 16 4 8 16 32 8 16
201 to 220 9 18 4 9 18 25 9 18
221 to 240 10 19 5 10 19 38 10 19
241 to 260 10 21 5 10 21 42 10 21
261 to 280 11 22 6 11 22 45 11 22
281 to 300 12 24 6 12 24 48 12 24
4)
Over 300 0.04 x n 0.08 x n 0.02 x n 0.04 x n 0.08 x n 0.16 x n 0.04 x n 0.08 x n
In rope constructions with particularly thick wires in the outer layer of the outer strands, e.g. round strand rope 6
x 19 Seale acc. to DIN 3058 or round strand rope 8 x 19 Seale acc. to DIN 3062, the number of visible wire
breakages at replacement state of wear is to be assumed two lines lower than given in the table. Drive groups
acc. to DIN 15 020 sheet 1 d = wire diameter
3) Filler wires are not regarded as load-bearing. For wire ropes with several strand layers only the strands of the
outermost strand layer are regarded as "outside strands". For wire ropes with steel insert, the insert is to be
regarded as an inner strand. 4) The calculated figures must be rounded up.
Type Chapter
TOWER CRANES
• Basket formation
• Hairpin-type emergence of wires or

groups of wires from the rope
• Reduction of rope diameter com-

pared with nominal diameter by
15 % or by 10 % with simultaneous
occurrence of corrosion and/or wear
• Loosening of rope structure
• Contraction
Type Chapter
TOWER CRANES
• Warps and crushes
• Kinks or other permanent deforma-

tions
If a rope has to be removed because of

particular damage, the causes must first
be detected and eliminated before a
new rope can be mounted. Important in-
dications here are for example wear
marks on rope pulleys or drag marks on
construction ropes. You are recom-
mended to measure the actual rope di-
ameter of the ropes used (at several
points) before initial commissioning and
to compare these figures with later con-
trol measurements (log book).
Type Chapter
TOWER CRANES
08 Dismantling
08.01 Dismantling the jib
• Pull the load block into the funnel of

the trolley.
• Move the trolley as far as the limit
stop using the jumper pushbutton on
the electrical panel.
• Engage the catch on the slip clutch
for slack rope protection.
• Reposition the driver from the hoist
unit drum onto the assembly drum
and bolt in place.
• Throw switch in electrical panel
from "Operation" to "Assembly".
• Loosen T-screw on assembly drum.
• Slowly telescope the inner tower in
stage I out of the catches until the
catches are free (horizontal posi-
tion).
• Now telescope the inner tower
downwards as far as the lower
hinged pulley.
• Bolt the upper booms together by
means of the grip pins.
• Remove the bolts from the lower
booms and place the bolts with the
lock plate in the toolbox.
• Telescope the inner tower in fully
beyond the lower hinged pulley.
• Remove the bolts from the jib ex-
tension assembly rope at the jib tip
and replace in the upper boom us-
ing the grip pins, then tension the
rope at the turnbuckle.
Type Chapter
TOWER CRANES
Dismantling the jib
• Telescope the inner tower out be-

yond the lower hinged pulley.
• Take out the upper boom bolts be-
tween the jib tip and the extension,
and insert them in the straps pro-
vided on the lower boom.
• Place the trolley and hoist ropes in
the assembly guide.
• Telescope the inner tower out be-
yond the upper hinged pulley.
• Fold upper hinged pulley inwards by
means of traction rope.
• Telescope the inner tower in. Jib is
folded in.
• Before finally folding out the jib side
onto the jib base, pull the locking
bolt by means of the traction rope.
• Fold over the jib tip fully and release
the locking bolt. The jib tip must be
locked in position.
• Create rope slack in jib assembly
rope by telescoping out the inner
tower.
• Insert bolt in upper boom strap and
tighten nut using a wrench.
Type Chapter
TOWER CRANES
Dismantling the jib
• Knock out grip pins on upper

booms.
• Turn jib tip laterally away to the
right.
• Telescope the inner tower in fully
and bolt the inner and outer towers
to each other.
Type Chapter
TOWER CRANES
08.02 Unloading the ballast weights
In order to be able to load and position

the ballast blocks in the version with the
small rotating radius (City version) and
with the extended rotating radius (with
upper carriage extension), the trolley
can be rolled over an appropriate dis-
tance. Since the trolley is moved without
its own drive unit, the shift movement is
supported by the position of the bal-
lasting arm. The position of the bal-
lasting arm can be influenced by the
fixing strap on the upper boom of the
ballasting arm. This is effected in the
front or rear hole of the fixing strap.
If the anchoring rope is bolted in the

rear hole, the loading arm is inclined
downwards slightly towards the tip
(when unloading the ballast).
If the anchoring rope is bolted in the

front hole, the loading arm is raised
slightly towards the tip (when loading
the ballast).
The loading arm is to be adjusted so

that the expected load movement is car-
ried out with the help of the inclination.
Type Chapter
TOWER CRANES
Unloading the ballast weights
Unloading the ballast
• Unbolt the loading arm from its

transport restraint.
• Remove the retaining bolts of the
load block of the loading arm.
• Unfold the loading arm slowly using
the assembly rope and move the
load block out of the trolley.
• Attach the ballast block, lift it and
move it laterally to the left and up to
the right
• Lower ballast block, disconnect and
load new block.
• Repeat the process until all blocks
have been unloaded.
• After unloading the ballast blocks,
move the load block into the loading
arm trolley and slowly fold the
loading arm towards the tower using
the assembly rope.
NOTE:
Ensure that the anchoring rope of the
loading arm does not get in the way
between the loading arm and the tower,
since otherwise the loading arm cannot
be bolted correctly.
Fit retaining bolts of loading arm load

block.
Secure loading arm in its transport re-

straint.
Type Chapter
TOWER CRANES
08.03 Laying down the tower

package
The tower package is laid down by

means of the assembly rope, in two
speed stages. It can be laid down in any
position (360°) in relation to the lower
carriage. The slewing gear brake must
not be ventilated in this situation! No
ballast is required to lay down the tower
package.
• Knock out the bolts in the upper car-

riage.
• Start up the hoist unit in stage I, ac-
celerate in stage II. Switch back to
stage I before the vertical position is
reached. Stage III must not be used.
• While the tower package is being
laid down, all ropes must be con-
stantly checked. Pull away from
tower once more.
• Ensure that when the tower is being
lowered onto the upper carriage the
tower is guided correctly and is then
located on the two supports on the
upper carriage.
Type Chapter
TOWER CRANES
08.04 Preparation for removal
• Fit the transport restraint between

the tower and the upper carriage.
• Fit the transport restraint to prevent
the upper and lower carriages from
turning in relation to each other.
• Attach the transport restraint clip for
the jib extension (if fitted).
• Remove loose ropes (gantry ropes,
auxiliary ropes) on crane.
Type Chapter
TOWER CRANES
08.05 Control cable connection
• Disconnect the control cable and

store controller with cable in the
toolbox.
Type Chapter
TOWER CRANES
08.06 Electrical connection
• Disconnect the supply cable to the

supply plug (with master switch) at
the side of the lower carriage.
• Remove protective earth from

crane.
Type Chapter
TOWER CRANES
08.07 Dismantling the crane -

travel gear
• At one end of the track system

the spaces between the sleep-
ers are filled up with gravel or
covered with wooden planks
(approx. 8 m / 26 ft). Move the
travel gear into the center be-
tween the rails. (Pay attention to
the track width of the wheels!)
• Install the road running gears.
• Dismantle the cable drum
• Remove the travel limit switch
(turn switching lever by 180°
and secure in position).
• Align the front axle and lift the
wheel houses using the hydrau-
lic lowering device.
• Lift the wheel houses on the
rear axle using the hydraulic
lowering device on the road
running gear.
• Swing in the expanding bolts on
the lower carriage.
• Connect up the compressed air
lead and attach the lighting
bracket.
• Lower the crane using the hy-
• Secure the crane against rolling
away using the handbrake.
Type Chapter
TOWER CRANES
08.08 Dismantling the crane -

spindle support
• Attach the road running gear.

• Bolt the lower carriage and road
running gear on front and rear axles
using a bolted connection.
• Lift the crane using the hydraulic
lowering device.
• Turn in the spindles until they are of
approximately the same length.
• Fold in the bracing spars from oper-
ating to transport position and bolt
them to the lower carriage.
• Connect up the compressed air
supply and remove the lighting
bracket.
• Lower the crane using the hydraulic
lowering device.
• Secure the crane against rolling
away using the brake block or
handbrake.
Type Chapter
TOWER CRANES
08.09 Comments
! CAUTION !
• A crane with road running gear

parked without a tractor must al-
ways be secured against running
away by means of the handbrake.
• All loose parts must be secured in
such a way that they cannot fall off
or endanger other road users during
transport.
Type Chapter
TOWER CRANES
09 Maintenance
09.01 Brakes used or fitted to SMK cranes
Crane Type Brake

Factory No. Hoist unit Slewing gear Trolley unit Crane travel gear
SMK 104/2 from No. 266 FCM FCO F7p F7p
SMK 104/2 from No. 371 FCL FCO F7p F7p
SMK 104/2 from No. 457 FCL FCO F.A.S.T. F7p/F.A.S.T.
SMK 106/2 from No. 125 FCL FCO FCO FCO
SMK 108/1 from No. 091 FM 158/2 FCO FCO FCO
SMK 108/2 from No. 251 FM 158/2 FCO FCO FCO

SMK 108/2 from No. 291 FCPL FCO FCO FCO
SMK 201 from No. 001 HOLEC FCO F.A.S.T. ---
SMK 202 from No. 001 Type 14.448 FCO FCO ---
SMK 203 from No. 001 FCL FCO F7p / at 30° FCO F7p
SMK 203 from No. 106 HOLEC FCO F.A.S.T. / at 30° FCO F7p/F.A.S.T.
SMK 203/1 from No. 274 HOLEC FCO FCO FCO

SMK 203/1 from No. 307 HOLEC FCO BM FCO
SMK 203/1 from No. 485 HOLEC FCO BMG FCO
SMK 204 I and from No.

FCPL FCO BMG FCO
001
SMK 205 from No. 001 F 215/1 FCO FCO FCO

SMK 205 from No. 006 F 215/6 FCO FCO FCO
SMK 205/1 from No. 021 F 215/6 FCO FCO FCO

SMK 205/1 from No. 075 FCPL FCO FCO FCO
SMK 206 I and from No.

FCPL FCO BMG FCO
001
SMK 308 from No. 001 FCPL FCL BM FCO

SMK 308 from No. 042 FCPL FCL BMG FCO
SMK 308 from No. 074 Type 14.448 FCL BMG FCO
Type Chapter
TOWER CRANES
Brakes used or fitted to SMK cranes
Maintenance of FCM, FCO, FM, FCL

and F7p brakes
Normal wear of the break linings leads

to an enlargement of the air gap be-
tween the brake rotor and the brake
magnet. If the air gap is too great, it
cannot be guaranteed that the brake will
be released properly: the brake vents,
fades, wobbles or remains blocked, and
the motor keeps running and may de-
stroy the brake; this may even lead to
motor damage.
The FCM, FCL and FM brakes in use

in the hoist unit
With brand new cranes, or after re-

placement of motors and brake parts
(brake rotor with lining (12) and bolt-
type brake lining (7)) it is essential that
each of the above-mentioned brakes
should be readjusted after approx. 1000
actuations or ten operating hours, or ap-
prox. five working days under normal
crane operating conditions.
The FCO and FCM brakes in use in

the slewing gear
During braking, the run-on at the jib tip

should be two meters. If the run-on is
greater, the brake must be readjusted.
Regardless of this, the brake must be
inspected and if necessary readjusted at
least every six months.
The FCO and F7p brakes in use in

the trolley unit
There should be no run-on when the

brake is actuated. However, the brake
must be inspected and if necessary re-
adjusted at least every three months.
Type Chapter
TOWER CRANES
disk and the magnet part must be

Brakes used or fitted to SMK cranes checked and readjusted for safety.
The F.A.S.T. brake

This replaces the F7p brake. It has
larger braking surfaces and thus less
wear. Adjustment and readjustment are
not necessary, and are not possible ei-
ther with the F.A.S.T. brake.
The F.A.S.T. brake and the Fp7 brake
are not interchangeable.
F215 brake
The braking torque remains constant.
Adjustment and readjustment are
therefore not necessary, and are not
possible either.
FCPL brake
The brake is run in after approx. five
working days under normal crane oper-
ating conditions, and it is essential that it
should then be readjusted. The brake
settings should then be checked
monthly, and readjusted if necessary (in
normal single-shift operation).
BM, BMG brakes

The brake linings of the electromagnetic
disk brakes are subject to normal wear
and tear. This causes the air gap be-
tween the rotor disk and the body of the
coil to increase during operating time.
When this air gap has reached its
maximum value, it must be readjusted
(if the air gap were to become larger,
the venting of the brake could not be
guaranteed depending on the preset
braking torque). The air gap can be re-
adjusted several times. When the lining
is worn down to a minimum limit value,
a new lining bracket must be fitted.
HOLEC brake system

The braking torque remains constant,
the braking torque of the brake linings is
regulated automatically as they wear
down. Adjustment and readjustment are
not necessary.
Type 14.448 brake

The spring-loaded brakes are closed
circuit brakes with 2 friction surfaces.
The brakes are practically maintenance-
free. The air gap Svent between the rotor
Type Chapter
TOWER CRANES
09 Appendix
09.02 Setting the F.A.S.T. brake
Mode of operation
When the motor is switched on, the
magnet, which is a component part of
the rotor, draws the brake rotor against
the brake spring and thus vents the
brake. The brake rotor and the brake
disks are connected to the rotor shaft by
means of a spline. When the motor is
switched off, the brake rotor, the brake
disks and the brake linings, which are
located between the brake disks, are
pressed against each other. The brake
linings are secured against turning in the
end shield by means of recesses.
Maintenance
Under normal circumstances the brake
linings must be replaced after 1 million
actuations. At the same time, the air
gap between the rotor package and the
rotor must be readjusted. 01 Stator
02 Brake spring
Setting the air gap 03 Brake disk
04 Spacer washer and spacer ring
The air gap is set to 0.3 mm/ 0.012'' with 05 End shield
the help of spacer washers. The air gap 06 Fan
is correctly set if one can easily insert 07 Retaining ring
one 0.2 mm / 0.0079'' spacer washer 08 Brake lining
between the rotor and the rotor pack- 09 Brake rotor
age. If two spacer washers can be in- 10 Rotor with shaft
serted, the air gap is too large.
Type Chapter
TOWER CRANES
09.03 Setting the BM brake
Setting the air gap
The fan cowl on the motor as well as the

sealing tape on the circumference of the
brake are taken off and any rubbed-off
parts removed. The hexagonal nuts
(three pieces) located on the front end
of the body of the coil are tightened
slightly so that the air gap between the
body of the coil and the rotor disks is
zero. All nuts are now turned evenly by
fractions (1/4 turns) in a counterclock-
wise direction until there is an even gap
of 0.25 / 0.01'' to 0.4 mm / 0.016'', de-
pending on the size of the brake, at the
circumference.
Changing the braking torque
The braking torque can be changed by

stages by fitting various brake springs
and by varying their number:
• Remove hand lever (if fitted).

01 Brake end shield
• Remove fan cowl, fan and sealing 02 Sealing tape
tape. 03 Brake spring
• Loosen hexagonal nuts and pull 04 Headless bolt
05 Venting lever
body of coil backwards approx. 50 06 Seal ring/cover disk
mm / 2''. 07 Fan cowl
• Change set of springs, making sure 08 Spiral tensioning pin
they’re symmetrically arranged! 09 Fan / heavy duty
10 Brake coil
• Fit the brake, setting the smallest 11 Hexagonal nut
possible working air gap, see "Set- 12 Fastening bolt
ting the air gap". 13 Body of coil
• Fit sealing tape, fan, fan cowl as 14 Rotor disk
15 Pressure ring
well as hand lever (see "Fitting hand 16 Lining brackets compl.
ventilation"). 17 Driver
18 Disk spring / Nilos ring
Type Chapter
TOWER CRANES
Setting the BM brake
Fitting hand ventilation
• Secure both locking bolts in the ro-

tor disk, using Loctite if necessary.
Insert spiral tensioning pins.
• Mount hand lever. Push taper
springs onto locking bolts.
• Screw in adjusting nuts until the
longitudinal play between the com-
pressed taper springs and the hand
lever is 1.5 / 0.06'' to 2.0 mm /
0.08''.
! CAUTION !
This longitudinal play is essential so that

the rotor disk can follow on as the brake
lining wears.
• Mount the fan and fan cowl, making

sure that the opening for hand ven-
tilation is correctly positioned. Screw
in the headless bolt or hand lever (in
the version with hand ventilation).
! CAUTION when actuating with hand

ventilation:
The fixed hand ventilation unit is al-

ready vented if a resistance can be felt
when turning the headless bolt. As the
hand ventilation unit jumps back, nor-
mal hand force is sufficient on the hand
lever. Excess strain may lead to break-
age of the hand lever.
Type Chapter
TOWER CRANES
09.04 Setting the FCO brake
Setting the air gap

A knurled nut with a spring
• Turn back the inside caliper or take may be fitted instead of the
it out completely. venting nut. Parts 4 and 5
are not required for instal-
• Turn back the coil rotor using the lation as a trolley motor.
knurl until it contacts the brake
magnet.
• Then turn the coil rotor in the oppo-
site direction again; the inside cali-
per must be pressed in. When the
inside caliper is pressed into the
third hole, tighten the inside caliper.
The air gap is then set to approx.
0.5 mm.
Setting the braking torque
If the brake should still run on after the

air gap has been set, the braking torque
can be increased by turning the
setscrew to the right (clockwise). If the
brake magnet is too strong, the braking
torque can be reduced by turning back
the setscrew.
Venting the brake by hand
If you wish to release the brake fully, 01 Brake housing

tighten the venting nut (clockwise). 02 Rotor (motor)
03 Brake fan
! CAUTION ! 04 Brake rotor with lining
05 Coil rotor
Before returning to normal operation, 06 Inside caliper
loosen the venting nut again! 07 Rain guard
08 Nut for rain guard
09 Venting nut
10 Threaded rod
11 Setscrew
12 Braking torque spring
13 Brake magnet
Type Chapter
TOWER CRANES
09.05 HOLEC brake system
Mode of operation:
The brake consists of the d.c. ring mag-

net, which is permanently connected to
the rear end shield of the motor. The
brake organs, consisting of leaf springs,
magnet segments and brake linings, are
radially fixed to the ring magnet by
means of bolts. The locking devices
limit the travel of the brake elements
and prevent damage to the brake drum
when the time has come to replace the
brake linings. When off circuit, the brake
linings are pressed against the drum by
the leaf springs, creating the braking
torque. When the motor is switched on,
the magnet receives direct current from
the rectifier and vents the brakes. When
the motor is switched off the brake en-
gages again through spring pressure.
The braking torque is regulated auto-
matically as the linings wear down.
01 Direct current ring magnet
Venting the brake manually: 02 End shield
03 Leaf springs
To vent the brake in the event of a 04 Magnet segment
power failure, a hand brake lever pro- 05 Brake lining
trudes radially through a slot in the 06 Bolts
metal cowl of the motor (not shown in 07 Locking device
the diagram). This is used to actuate a 08 Guard
ring rotatably mounted on the end
shield; over three conical sliding sur-
faces, this ring actuates three pressure
valves that are located within the lock-
ing devices and which press the ends of
the leaf springs, and thus also the brake
linings, via hardened steel rollers, radi-
ally in the direction of the ring magnet.
RESULT: the brake is thus vented.
After the hand venting lever is released,
it is returned to zero position by means
of a return spring and the braking torque
is fully effective again.
a = Venting position
1
b = Brake position
2
b = Brake linings worn
Type Chapter
TOWER CRANES
09.06 Setting the F7p brake
Setting the air gap
• Remove the fan cover and the fan.

• Remove the four setscrews in the
end shield.
• Insert a pin or screwdriver in the ac-
cessible holes and turn the brake
ring clockwise until the brake rotor
with lining strikes the field deviator.
• Then turn back four holes in the op-
posite direction, corresponding to an
angle of rotation of 90° (when used
in a trolley unit), or eight holes, cor-
responding to an angle of rotation of
180° (when used in travel gear) until
the threaded holes are opposite the
holes in the end shield.
• Screw in the setscrews again and
tighten them.
• Replace the fan and the protective
cover. 01 Rotor
02 Field deviator
03 Stator
04 Brake spring
05 Brake rotor with lining
06 Brake ring
07 Brake housing
08 Fan vane
09 Protective cover
10 Setscrew
Type Chapter
TOWER CRANES
09.07 Setting the FM brake
Setting the air gap

• Remove the anti-rotation lock on the
fork head and unscrew the fork
head completely. Remove the pro-
tective cover.
• The air gap can be reduced by
turning back the three adjusting
nuts, and the setting is fixed by
tightening the nuts. Then use a
feeler gauge to check that the set-
tings are correct and even all round.
The air gap must be 0.8 mm / 0.03''
all round.
Setting the brake torque

When the air gap is readjusted, it is also
necessary to correct the clamping length
of the pressure springs. This means that
the clamping length of the pressure
spring must be corrected using the ad- 01 Adjusting nut for air gap
justing nuts every time the air gap is re- 02 Protective cover
adjusted. The average clamping length 03 Retaining nut
"L" is 46.5 mm / 1.83''. 04 Adjusting nut for pressure
spring
When tightening the cover, the bolts 05 Pressure spring
must not be tightened excessively be- 06 Retaining bolts for protective
cause of the rubber seal. The fork head cover
must only be unscrewed until it has no 07 Brake disk with lining
contact and there is sufficient play and 08 Friction ring
the brake functions correctly. 09 Brake rotor with friction ring
10 Brake magnet - body of coil
Venting the brake by hand 11 Threaded rod
12 Fork head
Loosen the anti-rotation lock, tighten the 13 Anti-rotation lock
fork head clockwise until the brake rotor
is lifted by means of the threaded rod.
Type Chapter
TOWER CRANES
09.08 Setting the F 215/1 brake
Mode of operation

brake coil draws the brake rotor against
the brake spring, thus venting the brake.
When the motor is switched off, the

brake rotor with the brake lining is
pressed against the brake fan by the
brake spring. The brake is then in
closed position.
The brake fan is wedged onto the motor
shaft. The brake rotor in the brake
housing is secured against rotation by
guide cams.
Maintenance
Readjustment of the air gap on account

of brake lining wear is not necessary.
The air gap is factory-set to 0.7 mm /
01 Brake rotor with lining
0.03''. When the air gap reaches a
02 Brake fan
maximum of 4.0 mm / 0.16'', the brake
03 Motor shaft
lining must be replaced to ensure that
04 Assembly bolt
the brakes are properly vented.
05 Spacer washer
The brake lining is replaced by replacing
06 Hand venting bolts
the entire brake rotor to which the brake
07 Brake spring
lining is attached.
08 B end shield
The air gap can be checked through the
09 Brake coil
air slots or the terminal box. It is rec-
ommended that this check should be
carried out at intervals of 200 motor op-
erating hours.
Type Chapter
TOWER CRANES
Setting the F 215/1 brake
Checking correct functioning
The correct functioning of the brake

must be checked weekly by attaching a
maximum load plus 10 % overload.
How to proceed
Loosen the four assembly bolts and take

off the B end shield. After the hand
venting bolts from the brake rotor have
been loosened, the rotor can be re-
placed. Assembly is effected in the re-
verse order. The size of the air gap is
determined automatically when the B
end shield is mounted.
Venting the brakes by hand
The brake can be vented mechanically

with the help of the two hand venting
bolts. In this case, a spacer sleeve must
be pushed between the spacer disk and
the housing.
Type Chapter
TOWER CRANES
09.09 Setting the FCPL brake
Description
The FCPL brake is composed of the

following brake parts:
• a brake disk gliding on a splined hub

which is mounted on the second
shaft journal of the motor,
• a rear motor end shield, which is
used as a braking surface and three
stud bolts which are connected to
the rear flange of the motor,
• a moving rotor gliding on the stud
bolts which is movably mounted by
means of guide rings,
• an electromagnet, which is supplied
with direct current,
• a variable number of springs, which
are pretensioned by spacer sleeves.
The number of springs (2, 3, 4 or 6)
and the length of the spacer sleeves
determine the value of the braking
torque.
01 Brake disk
Function
02 Springs
03 Spacer sleeves
In idle position, no current flows through
04 Electromagnet
the coil. The brake disk is pressed be-
05 Splined hub
tween the rotor and the braking surface
06 Cover
of the motor end shield by the springs,
07 Rotor
and the rotor of the motor does not turn.
08 Adjusting nut
When the coil is energized, the rotor is
09 Locking nut
drawn to the magnets, the springs are
10 Stud bolt
compressed and the brake disk is re-
11 Guide rings
leased. The brake is thus released.
12 Motor end shield
During braking, the magnetic field is
disabled by switching off the current,
and the rotor is pressed against the
brake disk by the springs. The brake
disk in turn presses against the braking
surfaces of the motor end shield, thus
causing deceleration.
Type Chapter
TOWER CRANES
09.10 Setting the F 215/6 brake
Mode of operation

brake coil draws the brake rotor against
the brake springs, thus venting the
brake.
When the motor is switched off, the

brake rotor with the brake lining is
pressed against the brake fan by the
brake springs. The brake is then in
closed position.
The brake fan is wedged onto the motor
shaft. The brake rotor in the brake
housing is secured against rotation by
guide cams.
Maintenance
Readjustment of the air gap on account 01 Brake fan

of brake lining wear is not necessary. 02 Motor shaft
The braking torque remains constant. 03 Brake rotor with lining
The air gap is factory-set to 0.5 mm / 04 Assembly bolt
0.02''. When the air gap reaches a 05 Guide pins
maximum of 4.0 mm / 0.16'', the brake 06 B end shield
lining must be replaced to ensure that 07 Brake coil
the brakes are properly vented. 08 Brake spring
The brake lining is replaced by replacing
the entire brake rotor to which the brake
lining is attached.
The air gap can be checked through the
air slots or the terminal box. It is rec-
ommended that this check should be
carried out at intervals of 200 motor op-
erating hours.
Checking correct functioning
The correct functioning of the brake

must be checked weekly by attaching a
maximum load plus 10 % overload.
Type Chapter
TOWER CRANES
Setting the F 215/6 brake
How to proceed
Loosen the four assembly bolts and take

off the B end shield. The rotor can then
be replaced. Assembly is effected in the
reverse order. The size of the air gap is
determined automatically when the B
end shield is mounted.
Venting the brakes by hand
The brake is vented with the help of a

lever through a ventilation hole in the
motor housing.
Type Chapter
TOWER CRANES
09.11 Setting the FCL brake
Setting the air gap
• Turn back the inside caliper or take

it out completely. A knurled nut with a spring
• Turn back the coil rotor (using the may be fitted instead of the
knurl) until it contacts the brake venting nut.
magnet.
• Then turn the coil rotor in the oppo-
site direction again; the inside cali-
per must be pressed in. When the
inside caliper snaps into the third
hole, tighten the inside caliper.
• The air gap is then set to approx.
0.5 mm / 0.02''.
Setting the braking torque
If the brake should still run on after the

air gap has been set, the braking torque
can be increased by turning the
setscrew to the right (clockwise). If the 01 Inside caliper
brake magnet is too strong, the braking 02 Coil rotor
torque can be reduced by turning back 03 Hub for brake disk
the setscrew. 04 Retaining ring
05 Lock nut
Venting the brakes by hand 06 Venting nut
07 Pressure spring
If you wish to release the brake fully, 08 Setscrew
tighten the venting nut (clockwise). 09 Venting rod
10 Brake shoe
! CAUTION ! 11 Brake magnet
12 Parallel key
Before returning to normal operation, 13 Brake disk with lining
the venting nut must be loosened again. 14 Brake disk
Type Chapter
TOWER CRANES
09.12 Type 14.448 spring-loaded

brake for hoist unit
Description
The spring-loaded brakes are closed

circuit brakes with 2 friction surfaces.
The braking torque, which can be ad-
justed by a central adjusting device, is
braked
created by spring force. Venting is ef-
fected electromagnetically.
Operating principle
Braking the motor:

Through several pressure springs (2) a
contact pressure acts on the axially
movable rotor disk (1), which builds up
braking torque Mb through frictional en-
gagement. The rotor (3) with the friction
lining is connected to the shaft (5) posi-
tively but axially movably. The contact
pressure acting on the rotor disk (1)
clamps the rotor (3) between the rotor
disk (1) and the opposite friction surface
(6). The braking torque Mb is generated vented
at the two friction surfaces (1) and (6).
The motor is braked.
Starting up the motor:
Through the application of direct current

to the excitation winding, a magnetic
force acts on the rotor disk (1). The rotor
disk moves axially in the direction of the
fixed part of the magnet (7). The air gap
"Svent" is disabled. The clamped rotor is
now free to move, the braking torque is 1 Rotor disk
disabled. The motor can now run. 2 Pressure spring
3 Rotor
4 Splined hub
5 Shaft
6 Intermediate flange
7 Magnetic part
8 Hand venting
9 Adjustment ring
10 Sleeve-type bolt
11 Cover ring
12 Fastening bolts
Type Chapter
TOWER CRANES
Type 14.448 spring-loaded brake

for hoist unit
Setting the air gap:
When the maximum air gap Svent max has

been reached, the brake must be set to
the nominal value Svent nom. Carry out
adjustment as follows:
Svent nom (in mm) min. 0.2 / 0.008''

Svent max (in mm) max. 0.5 / 0.02''
• Loosen the Allen bolts (12)

• Turn sleeve-type bolts into the
magnetic part (7) using an open-
ended spanner until the same value
for Svent is measured at three points
in the circumference. The meas-
urements are taken between the
magnetic part (7) and the rotor disk
(1) using a feeler gauge.
• Then tighten the Allen bolts (12)
again.
1 Rotor disk
2 Pressure spring
3 Rotor
4 Splined hub
5 Shaft
7 Magnetic part
8 Hand venting
9 Adjustment ring
10 Sleeve-type bolt
11 Cover ring
12 Allen bolts
Type Chapter
TOWER CRANES
Type 14.448 spring-loaded brake for

hoist unit
Dismantling the brake to replace in-

dividual components.
Replacing the rotor disk and/or pres-

sure springs
• Remove cover ring (11), unscrew

Allen bolt with lock washer (12).
Take off brake and dismantle
sleeve-type bolt (10). The rotor disk
(1) and pressure springs are now
easily accessible and can be re-
placed.
• Carefully remove the magnetic part
(7) with adjustment ring (9), pres-
sure pieces and springs (2) and set
them down. Note the position of the
springs.
Additional dismantling stages when

replacing the rotor (3) or intermediate
flange (6).
• Remove the retaining ring and pull

off the rotor (intermediate flange).
• Replace the parts in question.
• Reassemble the brake in the re-
verse order.
! Caution:
After completing the assembly work,
check the air gap Svent and readjust if
necessary. 1 Rotor disk
2 Pressure spring
3 Rotor
4 Splined hub
5 Shaft
7 Magnetic part
8 Hand venting
9 Adjustment ring
10 Sleeve-type bolt
11 Cover ring
12 Fastening bolts
Type Chapter
TOWER CRANES
Type 14.448 spring-loaded brake for

hoist unit
Hand venting device:

By fitting a hand venting device (see
adjacent picture) the brake can be
vented mechanically, for example in the
event of a power failure. By pulling the
hand venting lever, the rotor disk (1) is
pulled against the magnetic part (7).
This leads to an air gap between the
Hand venting device
rotor (3) and the rotor disk (1). The rotor
can be turned easily. The brake is
vented.
Fitting the hand venting device:

The hand venting device is preassem-
bled on delivery.
! Important: When fitting the hand
venting device, the dimension "s" given
in the table below between item 15 and
the rotor disk (1) must be adhered to. It
must be set equally on both sides when
the brake is closed (braking position).
The dimension "s" is only applicable
for the factory-set torque parameter
Mk.
Svent nom (in mm) min. 0.2 / 0.008''

Svent max (in mm) max. 0.5 / 0.02''
s (in mm) 1.0 / 0.34''
! Caution:
No changes may be made later to the
setting of the hand venting device, not
even when readjusting the air gap Svent,
since this can have an adverse effect on
the safety function.

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PEINER

Year of Construction 199

TEREX PEINER GmbH

NOTES ON BASIC VERSION 7

NOTES ON THE DRIVE SYSTEMS 8

0.1 TRANSPORTING THE CRANE 10

01.01 Package List 10

01.03 Attachment points for crane loading 12

01.04 Road running gear KSL 20/1 13

01.04 Road transport 14

02 CONSTRUCTION SITE PREPARATION 21

02.01 Crane assembly City version (R = 2.5 m) 21

02.02 Crane assembly Normal version (R = 3.6 m) 24

02.03 Space requirements for erection phase (jib) 27

02.04 Crane on support foundations 29

02.05 Crane on cross stack of wood 32

02.07 Crane on rail system 33

02.08 SRS Crane track system 38

02.09 Timber sleeper construction 39

02.10 Track plan 41

03.01 Preliminary comments 42

03.02 Crane erection - spindle support 43

03.03 Crane erection - travel gear 44

03.04 Electrical connections 46

03.05 Control cable connection 47

03.06 Ballast plan 48

03.08 Lifting capacity plates 49

03.09 Preparation for crane erection 51

03.10 Erecting the tower package 54

03.11 Loading ballast weights 56

03.12 Jib assembly 59

03.13 Lower working positions 66

Lower working positions 68

03.14 Tensioning the trolley rope 69

03.15 Setting the jib 70

03.17 Crane steep position 30° 71

04.02 Location and arrangement of safety devices 73

04.03 Setting the load torque switch 74

04.04 Maximum load switch on hoist units 75

04.05 Setting the hoist limit switch 76

04.06 Setting the trolley limit switches 77

04.07 Setting the gear switch 78

04.08 Assembly switches 79

04.09 Trolley rope breakage safeguard 80

04.10 Evening position 45° 81

05 OPERATION AND CRANE OPERATION 85

05.01 Starting up and closing down 85

05.02 General notes on operating the controllers 87

05.03 Controller with cable 95

05.04 Changing the hook tackle in 2/4-rope hoisting operation 96

05.05 Putting the crane out of service at high wind speed 97

06.02 Ballasting variant upper carriage extension 98

06.03 Converting from 30 m to 36/40/42 m jib 99

Converting from 30 m to 36/40/42 m jib 104

06.04 Converting to travel gear 105

06.05 Cabin in the inner tower 107

06.06 Lighting equipment on crane 108