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STT293

TOWER CRANE

I. ERECTION MANUAL

Fushun Yongmao Construction Machinery Co. Ltd.

ST
ST

3
86-413-7648899 7649988 7648989
86-413-7649999

STT293
STT293

2
3
4

6- 200C 400C
20m/sA3

-20C

FORWARD
Dear Valued Customer:
It is highly appreciated and warmly welcome to your kind
purchase of ST series tower crane manufactured by Fushun
Yongmao Construction Machinery CO., Ltd.
Before your installation and operation of our companys ST series
tower crane, do please read the relevant contents of this Operation
Manual carefully. (This Operation Manual is composed of three
parts: .Erection Manual; . Operation & Server Manual; .
Spare Parts Handbook).
Any

problem

occurred

during

the

installation

and

the

operation ,do please contact with our companys Technical


Department without any hesitation.( Company Address: No.3
Yuanda Road, Shuncheng District, Fushun, liaoning, China,
Telephone No.: 86-413-7648899, Fax No.: 86-413-7649999)
With the continuous technical updating and product improvement
on tower crane both at home and abroad, we will innovate and
modify our product timely. Therefore, the technical specifications
listed here in this Operation Manual is subject to modifications
without notice.
This Operation Manual has provided detailed instruction on each
and every parts and structures of STT293 tower crane including
instruction on the installation operation and maintenance of the
machine. It is strongly recommended that you should read this
Operation Manual carefully before using Yongmaos STT293

tower crane. Please contact with us at any time if you encounter


any questions or problems concerning the machine.

Important Notice
1/The guaranteed period of our product is six month from the date
of delivery .The tower carne should be used strictly according to
the grade regulation of tower crane.
2/During the guaranteed period, our company will be responsible
for the damages occurred on the parts and components owing to
the manufacturing defects and workmanship.
3/Our company will not be responsible for the guarantee of the
easy-worn parts but will provide service on replacement.
4/Our company will not be responsible for the damages on the
tower crane caused by rude operation and neglect on periodical
maintenance.
5/Our company will not be responsible for the damages on the
parts and components caused by natural disaster and
unconformity with the requirement on electric power voltage.
6/The operation environmental temperature of the tower crane
is : -20C40C; The Max. operating wind speed is 20m/s; and
the operation grade of the machine is A3.

Warning to End Users within cold Area (below 20C)


All of the instructions and requirements stipulated in this
Operation Manual must be observed strictly if the machine is to
operate during winter time. Otherwise, all the loss and bad results
thus caused will be borne by the user.

STT293 TOWER CRANE OPERATION MANUAL

TABLE OF CONTENTS

PART I.

ERECTION MANUAL

TOWER CRANE PARAMETER 1A-1


ERECTION 2A-1
TELESCOPING 3A-1
PUTTING INTO SERVICE 4A-1
DISMANTLING 5A-1
Attached 1/
2/
3/
4/

Concrete blocks for fixing angles STT293-1


Concrete blocks for chassis ST6014-5
Base ballast ST6014-3
Counter-jib ballast T742719-1 T742719-2 T742719-3

STT293 TOWER CRANE OPERATION MANUAL

PART II.

OPERATION AND SERVICE

TOWER CRANE PARAMETER 1B-1



THE SAFETY RULES OF THE CRANE 2B-1
OPERATION 3B-1

ELECTRIC SUPPLY AND DIAGRAMS 4B-1
HOISTING WINCH 5B-1
SLEWING MECHANISM 6B-1
TROLLEYING WINCH 7B-1
Attached: Electric diagram

SAFETY DEVICE 8B-1


HYDRAULIC SYSTEM 9B-1

FIXING AND TESTING RULES FOR ROPE 10B-1
SLEWING RING 11B-1
MAINTENANCE 12B-1

STT293 TOWER CRANE OPERATION MANUAL

PART III.

SPARE PARTS HANDBOOK

FIXING ANGLES C-2

TRAVELING BOGIE C-3

CHASSIS C-7

7.5m BASIC MAST C-9

MAST C-10

JACKING CAGE C-11

HOISTING WINCH C-14

LOWER SLEWING SUPPORT C-15


UPPER SLEWING MECHANISM C-17
CAB MAST C-19
CAT HEAD C-21
COUNTER JIB C-23
ACCESSORIES C-27
LIFTING DEVICE C-28
JIB C-30
TROLLEY C-35
PULLEY BLOCK C-38
HOISTING WINCH C-40
TROLLEY WINCH C-52
SLEWING REDUCER C-56
CONNECTING ASSEMBLY C-59

STT293 TOWER CRANE ERECTION MANUAL

CHAPTER I. General Instruction

Characteristics Table 1A-2


Preparing The Site1A-6
1 Space Requirements For Erection 1A-6
2 Track 1A-18
3 Earthing 1A-31

Concrete Blocks For Fixing Angles 1A-33


1 Preparation Conditions 1A-33
2
Ground Pressure And Choice of Concrete Blocks 1A-34
3 Dimensional Characteristics Of The Fixing Angles 1A-35
4 Fitting The Fixing Angles 1A-36
5 concrete blocks for fixing angles 1A-38

Base Ballast 1A-39


1 Introduction 1A-39
2 Ballast Block Details 1A-40

Counter-jib Ballast1A-42
1 Introduction 1A-42
2 Dimension Of Counter-jib Ballast 1A-43

Anchorages To The Building1A-45


1 Introduction 1A-45
2 Instructions 1A-46
3 Crane Towers And Anchorages 1A-47
4 Fitting The Anchorage Frame 1A-49

1A-1

STT293 TOWER CRANE ERECTION MANUAL

Characteristics Table
2 0 .2 m

7 6 .0 m

18t

74m

3.6m

3 .5 m
18t

2 .7 t

70m

64m

60m
54m

40m

3 .7 t

4 .0 t

4 .6 t

50m
44m

3 .0 t

5 .3 t

7 .0 t

8 .0 t

6x6m

Fig.1-1-1a
Table 1-1-1a
R
74
70
64
60
54
50
44
40

Fall

R(max)
m
14.3
25.9
14.6
26.7
15.7
29.1
15.6
29.1
15.7
29.6
16.3
31.0
18.2
35.0
18.5
35.9

C(max)
t
18.00
9.00
18.00
9.00
18.00
9.00
18.00
9.00
18.00
9.00
18.00
9.00
18.00
9.00
18.00
9.00

30

34

40

44

50

54

60

64

70

74

7016
7660
7420
7920
8300
8800
8300
8800
8400
8900
8600
9000
10100
9000
10350
9000

6160
6660
6390
6890
7080
7580
7360
7860
7230
7730
7640
8140
8750
9000
9000
9000

5050
5550
5250
5750
5830
6330
5840
6340
5950
6450
6300
6800
7280
7780
7500
8000

4480
4980
4660
5160
5190
5690
5200
5700
5300
5800
5620
6120
6500
7000

3800
4300
3960
4460
4420
4920
4430
4930
4520
5020
4800
5300

3430
3930
3580
4080
4010
4510
4020
4520
4100
4600

2980
3480
3110
3610
3490
3990
3500
4000

2720
3220
2840
3340
3200
3700

2390
2890
2500
3000

2200
2700

1A-2

STT293 TOWER CRANE ERECTION MANUAL


H
209.65m

H(m)
19 64.15
18 61.15
17 58.15
16 55.15
15 52.15
14 49.15
13 46.15
12 43.15
11 40.15
10 37.15
9 34.15
8 31.15
2x2m 7 28.15
L69B1 6 25.15
5 22.15
4 19.15
3 16.15
2 13.15
1 10.15

H(m)
49.1m

57
56
55
54
53
52

57
56
55
54
157.5m
53
52

45
44
43
42
41
40

45
44
43
121.5m 42
41
40

45
44
43
42
41
40

33
32
31
30
29
28

33
32
31
85.5m 30
29
28

33
32
31
30
29
28

33
32
31
85.5m 30
29
28

20
2.0x2.0m 19
18
L69B1 17
16

21
20
19
49.5m 18
17
16

21
20
19
18
49.5m
17
16

21
20
19
18
49.5m
17
16

21
20
19
18
17
16

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

H
137.65m

H
101.65m

2x2m
L69B1
3m

H
62.65m

3m

1.5m

3m

69
68
67
66
65
64

H
173.65m

3m

20 62.65
19 59.65
18 56.65
17 53.65
16 50.65
15 47.65
14 44.65
13 41.65
12 38.65
11 35.65
10 32.65
9 29.65
8 26.65
2x2m 7 23.65
L69B1 6 20.65
5 17.65
4 14.65
3 11.65
2 8.65
1 5.65

H(m)

6x6m

1-1-2a
F2

F3

1-1-2a

F1

F2
F3

195t
122t

191t
187t

F1

105t

117t

Reaction in service

103t
117t


reaction out of service
weight for free height (not include weight of
counterweight and weight of blocks)

Mechanisms Specifications
Table 1-1-3a

Name

code

Hoisting

75LFV45

Trolleying

Slewing

18t

m/min

m/min

038
046
076

9.0
6.0
3.0

019
023
038

18.0
12.0
6.0

Kw

550m
>550m*

75

7.5DFV08

069

7.5

RTC290

00.8 rpm

2 x 145N.m

YMD100

00.8 rpm

2x10.5

* Consult us
1A-3

STT293 TOWER CRANE ERECTION MANUAL


2 0 .2 m

7 6 .0 m
74m

12t

3.6m

12t
3 .5 m

2 .7 t

70m

64m

60m
54m

40m

3 .7 t

4 .0 t

4 .6 t

50m
44m

3 .0 t

5 .3 t

6 .5 t

7 .5 t

6x6m

Fig. 1-1-1b
Table1-1-1b
R
74
70
64
60
54
50
44
40

R(max)
m

C(max)
t

30

34

40

44

50

54

60

64

70

74

20.2

12.0

7500

6160

5045

4480

3800

3430

2975

2720

2390

2200

37.3

6.0

6000

6000

5545

4980

4300

3930

3475

3220

2890

2700

20.7

12.0

7720

6390

5245

4655

3955

3575

3105

2840

2500

38.5

6.0

6000

6000

5745

5155

4455

4075

3605

3340

3000

22.3

12.0

8430

7245

5830

5185

4420

4005

3490

3200

41.9

6.0

6000

6000

6000

5685

4920

4505

3990

3700

22.1

12.0

8370

7195

5840

5195

4430

4015

3500

42.0

6.0

6000

6000

6000

5695

4930

4515

4000

22.3

12.0

8460

7275

5950

5300

4020

4100

42.7

6.0

6000

6000

6000

5800

5020

4600

23.2

12.0

8880

7645

6265

5620

4800

44.8

6.0

6000

6000

6000

6000

5300

25.9

12.0

10100

8715

7170

6500

44.0

6.0

6000

6000

6000

6000

26.4

12.0

10345

8930

7500

40..0

6.0

6000

6000

6000
1A-4

STT293 TOWER CRANE ERECTION MANUAL


H
209.65m

H(m)
H
173.65m

57
56
55
54
157.5m
53
52

45
44
43
42
41
40

45
44
43
121.5m 42
41
40

45
44
43
42
41
40

33
32
31
30
29
28

33
32
31
85.5m 30
29
28

33
32
31
30
29
28

33
32
31
85.5m 30
29
28

20
2.0x2.0m 19
18
L69B1 17
16

21
20
19
49.5m 18
17
16

21
20
19
18
49.5m
17
16

21
20
19
18
49.5m
17
16

21
20
19
18
17
16

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

H
101.65m

H
62.65m

3m

6x6m
F2

F3

69
68
67
66
65
64

57
56
55
54
53
52

H
137.65m

3m

3m

19 64.15
18 61.15
H(m)
17 58.15
49.7m
16 55.15
15 52.15
14 49.15
13 46.15
12 43.15
11 40.15
10 37.15 2x2m
9 34.15 L69B1
8 31.15
2x2m 7 28.15
L69B1 6 25.15
5 22.15
4 19.15
3 16.15
2 13.15
1 10.15

1.5m

3m

20 62.65
19 59.65
18 56.65
17 53.65
16 50.65
15 47.65
14 44.65
13 41.65
12 38.65
11 35.65
10 32.65
9 29.65
8 26.65
2x2m 7 23.65
L69B1 6 20.65
5 17.65
4 14.65
3 11.65
2 8.65
1 5.65

H(m)

Fig.1-1-2b

F1

Table 1-1-2b

F2

195t

191t

F3

122t

187t

F1

105t

117t

103t
117t

Mechanisms Specifications

Name

Code

Hoisting

55LFV30

Trolleying

Slewing

12t

m/min

m/min

044
053
088

6.0
4.5
1.5

022
027
044

12.0
9.0
3.0

Kw

570m
>570m*

55

DTC185

068

185N.m

RTC290

00.8 rpm

2x 145N.m

YMD100

00.8 rpm

2x10.5

* Consult us
1A-5

STT293 TOWER CRANE ERECTION MANUAL


1
1

1.1)
1.2)

PREPARING THE SITE


1 SPACE REQUIREMENTS FOR ERECTION
1)

Introductions

This brochure contains the dimensions for the space requirements of the crane.
It is composed of two groups:
1.1) The general crane layout with the main dimensions
1.2) The crane is represented in three parts:
a) Fixing angles and chassis
b) Mast tower
c) Cathead
The dimensions are detailed in such a way that the setting up of the machine can be
prepared in a more precise and complete manner.
ATTENTION: The indicated dimensions being theoretical, especially they do not
take into account the deformations without load or with load.

1A-6

STT293 TOWER CRANE ERECTION MANUAL

2 COMPLETE CRANE
19.2m

74.0m

2.1m

18

19

17

16

11

9
8

10

15

13

12

14

2.0x2.0x3.0m
2
2.0x2.0x3.0m

4
6x6m

1-2-1

NO.
1
2

3
4

Name

NO.

Fixing angle

Base ballast support (base ballast or


traveling)
,
Base ballast (base ballast or
traveling prepare by user)
Traveling
bogie(traveling)

Name

11

Tower head

12

Jib

13

Trolley mechanism

14

Trolley

Mast section

15

Hook assy.

Telescoping cage

16

Counter jib

Telescoping mechanism

17

Hoisting mechanism

Lower slewing

18

Electric control system

Upper slewing

19

Counterweight
(Prepare by user)

1A-7

STT293 TOWER CRANE ERECTION MANUAL

3 Dimension and weight

2045

a, FIXING ANGLES

40
0

4x235kg

400

1-2-2

1150

b,Traveling bogie (include outfit)

11

70

4x610kg

1050

Fig 1-2-3

1A-8

STT293 TOWER CRANE ERECTION MANUAL

c, Base ballast chassis

7248

3190
3690

4340

6000

3690
3190

12372kg

6000
7160

Note: weight not include base ballast blocks and traveling bogie

Side member for chassis

6900

Basic mast

3600kg

2500

2402kg

168kg

2480
710

640

1150

2X1452kg

Strut tie

240

Cross beam for chassis

240

7140

Diagonal strut

2440

518kg

ladder

332
40kg

4445

Fig1-2-4
1A-9

370

3140

349

3800

2500

STT293 TOWER CRANE ERECTION MANUAL

d, Mast

20

00

3305

1906kg

2000

Connect angle iron


4x425kg

Resting platform

42
2

1420

77kg

72
4

10
0

100

3300

2x21kg

1038

mast section

1950

1950

ladder

ladder
31kg

71

71
6

3050

3050

29kg

849

ladder support

849

Fig 1-2-5

1A-10

3kg

STT293 TOWER CRANE ERECTION MANUAL

e, Telescoping cage

43
00

7260

5170kg

4044

Telescoping cage

Front door
474kg

Side platform
of upper

Rear platform
Of upper

110kg

80kg

3223kg

830

29
3

2710

29
3

862

20

2550

2861

3700

2216

24
66

7260

Front platform
Of lower

80kg

Side platform
Of lower

110kg

Rear platform of
lower
2710

4300

5kg

210

2216

Fig.1-2-6
1A-11

29
3

924

29

1000

24
9

400

2520

14kg

Safty stud

Ladder
5100

172kg

Stud

106

Support

862

930

29
3

2710

85kg

331

53kg

STT293 TOWER CRANE ERECTION MANUAL

f, Slewing assy.

2500

24
9

2247

7154kg

Lower slewing

Upper slewing
2453kg

21
60

24
94

1092

805

2884kg

2500

2494

Monorail

Trolley
129kg

84
6

351

32
0

545

131kg

2082

4425

Fig.1-2-7

1A-12

STT293 TOWER CRANE ERECTION MANUAL

5369

g, Cat head

28

87

4260kg

3530

Cabin

Platform
of cabin

1908

240kg

1427

700kg

13
00

2050

5369

3223kg

43

Cathead2500

28

87

2942

platform

upper ladder
590

100kg

lower ladder
16kg

1361

92

50

1992

30
0

1146

9kg

1970

housing

Lnk

335

Grab rail

9kg

8kg

19kg

655

Grab rail

1008

1017

1
11

96

65
8

966

12kg

1113

1254

Fig.1-2-8
1A-13

1454

STT293 TOWER CRANE ERECTION MANUAL

h, Jib

2479

14
00

22000kg

74885

T2112-3 jib

T2112-4 jib
4059kg

3232kg

10351
2430

2480

10299

1400

T2112-5 jib

1400

T2112-6 jib
10259

2101kg

2600kg

T2112-7 jib

1770

1400

2350

2395

10231

1400

T2112-8 jib
1622kg

1240kg

10168
1730

1750

10223

1400

1400

1A-14

STT293 TOWER CRANE ERECTION MANUAL

T2112-9 jib

T2112-10 jib
958kg

315kg

4118

1715

1726

10158

1400

1400

pulley support
110kg

383

603

T2112-11 jib nose

775

1400

1180

724

163kg

tie bar

pulley support
30kg

618

126

230

1676

Fig.1-2-9

1A-15

210

30kg

STT293 TOWER CRANE ERECTION MANUAL

i, Trolley and hook


front trolley support

rear trolley support


369kg

1240

1240

342kg

1596

1866

1866

1596

basket

spanner
9kg

1630

80

45kg

620

1173

600

front lock

rear lock
5kg

93

93

5kg

500

135

135

500

hook

special hook
1767

140

32

1743

1130

555kg

Fig.1-2-10
1A-16

166

10kg

STT293 TOWER CRANE ERECTION MANUAL

j, Counter jib
T2116-2 counter jib

T2116-3 counterweight jib


6243kg

3252kg

2551

2430

8351

2200

1700

grab rail

11516

grab rail
12kg

1000

1000

20kg

1674

3852

Fig.1-2-11

1A-17

STT293 TOWER CRANE ERECTION MANUAL

2.
1)


a)
b)

2.

TRACK

1)

CHOOSING THE TRACK

The track dimensions must correspond to the requirements imposed either by


the material which determines
a)

the rail width

b)

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

The rail width and the maxi bogie pressure are shown on the following table and in
the data sheet.
or by the ground.
Homogeneity or non homogeneity of its pressure.
Types of tracks
Two types of tracks are possible, i,e
Track on concrete strips
Track on wooden sleepers

1A-18

STT293 TOWER CRANE ERECTION MANUAL

2)

70mm

10%
2) Track laying
RAIL TO BE USED
The rail section must be suitable for the wheels it supportsMaximum head width
70mm.The best rail to use is one which is slightly worn as this has a good bearing
surface. It is preferable to use standardized material (rails and accessories) as shown
in the table below.
The user must choose the other dimensional characteristics of the rail according to
how latter will be connected to the concrete strips or to the broad flanged girder (HEB)
and according to the maximum vertical or horizontal reactions.
The horizontal reaction amounts to about 10% of the vertical reaction.

GoodSlightly worn rail

(a)

New railPoor bearing surface

(b)

Over worn rail

(c)
Fg.1-2-6

1A-19

Worn on one side

(d)

STT293 TOWER CRANE ERECTION MANUAL

1m
()

( 20N/cm2
)
The track must be carefully designed and laid. It must be
-perfectly horizontal ( longitudinally and transversely.)
-well bedded down on a solid base.
-perfectly straight and with the rails absolutely parallel.
-made up of the same type of rails throughout its length.
-fitted with rail stops placed at least 1m before the end sleeper.
-correctly earthed (according to the standards of the country considered).
-For the erection, 2 minimum length of track is required (see fig.Site dimensions for
erection).
-The center portion of the track must be banked up to the level of the rail foot so as to
ease the traveling of the site machines.
(The following drawings are given as an indication only. They exclusively apply to a
homogeneous soil with a resistance of at least 20N/cm2. The crane user is responsible
for the laying of the track which must be perfectly level and capable to take the
maximum bogie reaction of the machine without causing any local subsidence).

1A-20

STT293 TOWER CRANE ERECTION MANUAL

3 Track widths
6.0m
The track width depending on the chassis used is 6.0m.

6.0m

Fig.1-2-7

1A-21

STT293 TOWER CRANE ERECTION MANUAL

HA 2 2
3 HA 10x1100 e 15

10 (mm)
1100 (cm)
e

LB

LH

ZN

AHB

LR

(cm)

45 t max 45 t

LR55t75t max 55 t 75 t
PR

(kg/m)

350kg/m3

4) TRACKS ON CONCTETE STRIPS OR ON SLABS


3

Explanation and symbols (Examlpe)

number of bars

HA round steel with high adherence


3 HA 10x1100 e 15

10

iron diameter in mm

1100 unit length of iron in cm


e

spacing in cm

LB

lower layer

LH

upper layer

ZN

neutralized zone

AHB

overlapping upper and lower steel

LR

45 t max longitudinal sleeper for vertical reactions 45t max.

LR55t75t max longitudinal sleeper for vertical reactions from 55t to 75 max
PR

weight of rail per me tre in kg

Concrete proportioning: 350kg/m3

1A-22

STT293 TOWER CRANE ERECTION MANUAL

50

40

50
5x3HA16x1100

75

45

2x3HA10x1100

30

2nd L.B 5x3HA16x1100


1st L.B 5x3HA20x1100
5x3HA14x1100

70

140

70

70

252HA8 x 230
252HA8 x 195 35
18
252HA8 x 160
150HA10 x 195 20 135 20
e = 20x49

e = 20x49

e = 20x49

e = 12x83

e = 12x83

e = 12x83

50

50
50

50

50
10.00

10.00

50
10.00

30.00
225

225

A.H.B.

ZN

ZN

LR = 75 t
PR = 50kg
Fig.1-2-8
1A-23

100 t

STT293 TOWER CRANE ERECTION MANUAL

60

40

50
5x3HA14x1100

40

90

50

2x3HA10x1100
3rd L.B 2x3HA16x1100
2nd L.B 5x3HA20x1100
1st L.B 5x3HA20x1100
5x3HA14x1100

85

160

85

85

252HA8 x 260
252HA8 x 225 35
18
252HA8 x 190
150HA12 x 215 20 155 20
e = 20x49

e = 20x49

e = 20x49

e = 12x83

e = 12x83

e = 12x83

50

50
50

50

50

10.00

50

10.00

10.00

30.00
225

225

A.H.B.

ZN

ZN
LR = 115 t
PR = 54 kg
Fig.1-2-9
1A-24

130 t

STT293 TOWER CRANE ERECTION MANUAL

LONGITUDINAL SLEEPER CONNECTIONS

4
200

150
6

200

Fig. 1-2-10


VERY IMPORTANT The distance between longitudinal sleeper connections is
equal to the distance between centers of the track .
1A-25

STT293 TOWER CRANE ERECTION MANUAL

R
20N/cm2()
R

HEB

mm

HB

mm

PR

kg

PCC
TP

40/60mm

5)RAILS ON TIMBER SLEEPERS

Explanation and symbols

The elements used for the track construction are determined in relation of the R
reaction.
Maximum ground pressure 20N/cm2 ( in all cases )
R

Maximum reactions at t

HEB

Height in mm

HB

Height of ballast in mm

PR

Weight of rail per meter in kg

Oak sleepers

PCC Compacted broken stones 40/60 in mm


TP

Type of rail

1A-26

STT293 TOWER CRANE ERECTION MANUAL

6m

0.6m 0.6m

0.2mx0.2m

1m

12x100

1.2m

HEB

HB

PCC

1.6
m.

45

11.5

20.5

320

HEB320

300

Fig. 1-2-11
Table

1-2-4

HEB

HB

PR

110t

320

350

50

100t

320

300

50

90t

320

250

50

1A-27

STT293 TOWER CRANE ERECTION MANUAL

6m

0.6m 0.6m

0.2mx0.2m

1m

12x100

1.2m

HEB

HB

PCC

1.6
m.

45

Fig. 1-2-12

Table 1-2-5

HEB

HB

PR

130t

360

400

54

120t

360

350

54

110t

360

300

54

1A-28

STT293 TOWER CRANE ERECTION MANUAL

1-2-13
a/
b/
c/

(a)(a)
abc,
(b)
()

(c)
6) RAIL STOPS
WE remind you that the crane when approaching the track end must be stopped
before hitting the safety devices which are not working systems.
The three safety devices are fitted as indicated in the fig. 1-2-13.They consist of
a/ a travel limit switch
b/ a sprung stop ( buffer )
c/ a fixed stop welded on the rail
The above devices are prescribed by the Safety Authorities and must be designed and
fitted with particular care . Periodically make sure that they are working correctly.
The mounting of system (a) is described in the relevant section of the handbook.
Check that the ramp (a) is parallel to the rail so that the limit switch roller does not
leave the ramp .
The supply and fixing of the devices ( a ) , ( b ) and ( c ) the responsibility of the user.
Different models for device (b) , clamped onto the rail, are available from specialized
suppliers. When choosing the appropriate devices , pay attention to the crane weight
( buffering capacity ) and the buffer height which must correspond to that of the stop
on the bogies .
Device (c) must be welded on the rail and have appropriate dimensions so as to
prevent the crane from running off the track. The following schematic drawing serves
as an indication only.

1A-29

STT293 TOWER CRANE ERECTION MANUAL

c
b

50

120

1m

m
-6
3m

3m 6m
Minimum length 3m or 6m depending on the
traveling speed.

288

50

40

170

100

Fig. 1-2-13

1A-30

100

Free traveling
length

STT293 TOWER CRANE ERECTION MANUAL

3 EARTHING

ATTENTIONThe earth circuit of the crane must neither include a fuse nor a
switch. The neutral wire on the supply cable is not connected to the earth.
There are three types of earthing:
A33x4.5 1.5m
L70x70 1.5m
Earth substance is made of normal earth stake, either use
33x4.5mm( length: 1.5m) tube or L70x70 length 1.5m
angle.
Fig. 1-2-14(a)
B 1m2
1.5m
Earth plate made of sheet steel or stretched metal with an
area of 1m2, distance surface 1.5m to be buried vertically.
Fig. 1-2-14(b)
C28 mm2 50 mm2

Copper conductor with section 28 mm2 or iron


conductor with section 50 mm2, to be buried in shallow
trench extending over a long length depending on the
resistivity of the soil
Fig. 1-2-14(c)
25mm2

4
In any case, the section of the copper conductor coming from earth substance should
be 25mm2. If the electric conduction of the soil is not good, sodium chloride
(common salt) might be buried in the earth, and pour into some water, for traveling
tower crane, each section of steel rail must be earthed. Link them by electrical joints.
The maximum earthing resistance is 4.
1A-31

STT293 TOWER CRANE ERECTION MANUAL

AB

AB
Fig. 1-2-15

1-2-16 (b) 1-2-16 (c)


Each rail section must be earthed, link them by electrical joints. See Fig 1-2-16 (b)
and 1-2-16 (c).
A earth spike
B earth plate
C buries wires
1-2-16 (d) .
NOTE: the earth wires designed to be bolted in position must have a terminal tag
soldered to them
(a)
Not well

(c)
well

(b)
well

(d)

Fig.1-2-16
1A-32

STT293 TOWER CRANE ERECTION MANUAL

A
1-3-1

1-3-2


( )

CONCRETE BLOCKS FOR FIXING ANGLES


1. PREPARATION CONDITION
ATO BE PREPARED BY THE CUSTOMER
The table of forces and stresses, the dimensional characteristics of the fixing angles,
the fittings of the fixing angles in Table 1-3-1 are necessary and adequate to determine
a concrete blocks dimensions and reinforcement.
FOR STABILITY REQUIREMENTS OF THE MACHINE, WE INSIST UPON
MINIMUM DIMENSIONS ON THE GROUND EQUAL TO THOSE OF THE
BLOCKS DESCRIBED IN THIS BROCHURE.
FOR ALL THE OTHER DIMENSIONS PLEASE CONSULT US WITHOUT
HESITATION.

1A-33

STT293 TOWER CRANE ERECTION MANUAL

2 Ground pressure and concrete blocks


Mv

e=

Fh
h

Fv

M v + Fh h b

Fv + Fg
3

Fg

pB =

kNm
Torque
(kN)
Crane weight
(m)
Jib length

Types of concrete blocks

In service
(m)
Linear eccentricity
(kN/m2)
Ground pressure

Mt
Fv
L
YM:
ES
e
pB

H
(m)

n
74

70

64

Mv
Fh
n
Fg
HS
b
[pB]

2( Fv + Fg )

[ pB ]

3bl

(kNm)
Over turning moment
(kN)
Horizontal force

NO. of mast section (stationary)


(kN)
Concrete block weight

Out of service
(m)
Dimension of concrete blocks
(kN/m2)
Permissible ground pressure
Table 1-3-1

Es

Hs

L(m)

L(m)

60

54

50

44

40

74

70

64

60

54

50

44

40

Mv 4296 4370 4591 4522 4528 4576 4795 4773 5132 5033 4861 4846 4660 4544 4228 4118
62.65 20

Fh

42

42

42

42

42

41

41

41

152 151 150 150 148 148 147 146

Fv 1207 1194 1178 1158 1125 1122 1085 1072 1027 1014 998 978 945 942 905 892
503 503 503 503 503 503 503 503

Mt

Table1-3-2
H
(m)

62.65

20

YM173N

YM206N

YM235N

YM270N

YM307N

Fg

1730

2060

2350

2700

3070

pB

3.0

2.1

1.7

1.5

1.3

6.0

6.5

7.0

7.5

8.0

2.0

2.0

2.0

2.0

2.0

1A-34

STT293 TOWER CRANE ERECTION MANUAL

3 DIMENSIONAL OF THE FIXING-ANGLES


, 2.0

150mm( 1-3-1)
The fixing angles must be fitted symmetrically in relation to the axes of the block and
form a 2m square according to the dimension of mast they are to receive.
Do please respect the 150mm dimension of the fishplate of the fixing-angles. See
Fig. 3-3-1.

2000

240

240

2000

.
To the right of a fixing angle, neither cut nor reduce the given amount of
reinforcing irons.
Fig.1-3-1

1A-35

STT293 TOWER CRANE ERECTION MANUAL

4 8
1
1

2mm,

4 FITTING THE FIXING-ANGLES


The material necessary to perfectly anchor the fixing-angles comprises

4fixing-angles and 8 pins


1fixing frame and 8 pins
1standard mast section
a plumb line or sighting device
Assemble the fixing-angles with the frame. (Attention: Before put into using, it is
necessary to check the frame for any deformations caused by transportation,
insure that the difference between the diagonals and the difference between the
plane heights are not larger than 2mm.)
Position the fixing-angle/frame assembly in the reinforcement and adjust it by
wedging under the angle support plates.
Pour the concrete block and wait until it is completely dry before erection.

1A-36

STT293 TOWER CRANE ERECTION MANUAL

Plumb

Fig.1-3-2
1A-37

Mast section

STT293 TOWER CRANE ERECTION MANUAL

5 Fixing concrete blocks


( STT293-1)
See the attached drawing in detail (Fixing concrete blocks STT293-1)

1A-38

STT293 TOWER CRANE ERECTION MANUAL

BASE BALLAST
1 INTRODUCTION

C D
2.0kg/cm2

The base ballast is made up of several reinforced concrete blocks, which are placed
symmetrically on the chassis. Each layer consists of blocks identified by letters C or D.
Required min ground pressure: 2.0kg/cm2
These blocks must be positioned on the chassis as shown in the figures and the
corresponding table, i.e. between the attachment points of the ballast fixing device, if
latter is required.
The reinforcing of the concrete blocks, except the one shown in the figure, is left
up to the customer who has also the responsibility for the ballast preparation. No
supply from us.
2+1+1

HUH
(m)
10.15

2+2+1

13.15

6C+6D

31.8

73.20

48.35

7.3

2+3+1

16.15

6C+6D

31.8

74.46

45.85

7.5

2+4+1

19.15

6C+6D

31.8

75.77

43.79

7.6

2+5+1

22.15

6C+6D

31.8

77.14

41.49

7.7

2+6+1

25.15

6C+6D

31.8

79.93

41.40

8.0

2+7+1
2+8+1

28.15

6C+6D

31.8

80.40

36.89

8.0

31.15

6C+6D

31.8

81.99

40.57

8.2

2+9+1

34.15

6C+6D

31.8

83.52

44.60

8.4

2+10+1

37.15

6C+6D

31.8

85.15

48.88

8.5

2+11+1

40.15

6C+6D

31.8

86.85

53.40

8.7

2+12+1

43.15

6C+6D

31.8

88.59

58.15

8.9

2+13+1

46.15

8C+8D

42.4

90.40

63.15

9.0

2+14+1

49.15

12C+12D

63.6

95.17

71.03

9.5

2+15+1

52.15

14C+14D

74.2

97.08

76.50

9.7

2+16+1
2+17+1

55.15

16C+16D

84.8

99.04

82.22

9.9

58.15

10

20C+20D

106

101.06

88.17

10.1

2+18+1

61.15

11

22C+22D

116.6

111.88

102.31

11.2

2+19+1

64.15

11

22C+22D

116.6

118.20

129.45

11.8

CP

C\P: Mast composition


HUH: Hook height
NR: Number of layers
ND: Number of blocks
LD: Ballast obtained
R.ES: stresses in service
R.HS: stresses out of service
RH: horizontal stresses

Fig.1-4-1

1A-39

6C+6D

LD
(t)
31.8

RES
(t)
71.88

RHS
(t)
48.77

RH
(t)
7.2

NR

ND

STT293 TOWER CRANE ERECTION MANUAL

2. BALLAST BLOCK DETAILS

540

420

250

900

150

1500

750
2

450

250

750

100

2
1

1cm
All dimensions tolerances: 1cm
Rep
Serial No.

Diameter mm
N

Quantity
Lu
Unit length cm
Lt Total length cm
Form
Form
M

Material

mm
40

10

90

720

10

220

880

10

160

480

REP

R10

R20

220

R3
0

R30

()

115

220

L.u

L.t

50

100

Reinforced concrete

Fig. 1-4-2

1A-40

Form

Q235-B

500

P2800kg D2.3

STT293 TOWER CRANE ERECTION MANUAL

500

500

540

420

250

900

150

750

1500
3

250

450

750

100
500

2
1

mm
40

10

90

720

10

220

880

10

160

480

REP

R10

R20

220

R3
0

R30

()

115

220

L.u

L.t

50

100

Reinforced concrete

Fig. 1-4-3

1A-41

Form

Q235-B

1cm
All dimensions tolerances: 1cm
Rep Serial No.

Diameter
N
Quantity
Lu Unit length cm
Lt Total length cm
Form Form
M
Material

P2500kg D2.3

STT293 TOWER CRANE ERECTION MANUAL

1
(AB C)

+50
0

kg )

COUNTER-JIB BALLAST
1. Introduction
The counter-jib ballast is made up of several AB or C blocks in reinforced concrete.
The weight of the blocks depends on the length of the jib. These blocks are suspended,
one by one , under the counter-jib tail .
The blocks reinforcement as well as the device used to lift and to suspend the blocks
on the counter-jib is to be determined and to be prepared by the user in such a way
that the blocks do not chip off or get loose when handling them or operating the crane.
The constructional and functional dimensions required to install the lifting and
suspension device are given on the following page.
To obtain the required weight with

+50
0

kg allowance or error per block, vary the

dimension X if the density of the concrete blocks are different from each other.
We recommend to weigh the blocks and to mark the weight with paint on one
side of the concrete block.

1A-42

STT293 TOWER CRANE ERECTION MANUAL

2 DIMENSION OF COUNTER-JIB BALLAST

Length of jib

Length of counter jib

Blocks

During
working and
kg
telescoping
weight

Type of Blocks

A
B
C

40

44

50

54

60

64

70

74

19.2

19.2

19.2

19.2

19.2

19.2

19.2

19.2

3A+C

3A+B

4A+C

4A+C

5A

5A+C

5A+B+C

6A

13000

14000

17000

17000

20000

21000

23000

24000

(t/m3)
Proportion

2.4
2.4
2.4

(kg)

Weight

Tolerance

4000
2000
1000

1%
2%
2%

(T742719-1T742719-2T742719-3)
Counterweight making following counterweight drawing in details.
(T742719-1T742719-2T742719-3)

1A-43

STT293 TOWER CRANE ERECTION MANUAL

1-6-2

ANCHORAGES TO THE BUILDING


1.

Introduction

Beyond its free traveling or freestanding height, the crane must be connected either to
the ground by means of guy ropes or to the building using rigid anchorages.
The present manual deals only with the rigid anchoring to the building.
Please consult us when anchoring with guy ropes.
The anchoring positions see fig.1-6-2.
Dismantling of the crane with anchorage frame, please consult us for relevant
instructions.

1A-44

STT293 TOWER CRANE ERECTION MANUAL

(1)
(2) 1-6-1
1

1-6-1

2. INSTRUCTIONS
PREPARING THE CRANE
hen it is a crane on rail traveling chassis , move it to the position for holding it
fast and static, tighten the rail clamps and disconnect the power supply for
traveling mechanism .
In certain cases it is necessary to telescope an additional mast section so that the
anchorage frame can be fitted.
VERY IMPORTANT
Under these conditions the crane is no longer normally autonomous, and it is
forbidden to work and to leave the crane free out of service.
When telescoping, check the perfect perpendicularity of the crane in both sides
in order to avoid any variation of distance between crane tower and building.
In order to ensure good connection between frame and crane tower and to
prevent the movable wedges (1) from falling down, it is essential to turn the
pieces carrying the welded wedges (2) so that the fitting corresponds to the sketch
1-6-1.

Note: Dismounting methods with attachment, please contact our company.


1A-45

STT293 TOWER CRANE ERECTION MANUAL

3
1-6-2

1-6-2


()

3.CRANE TOWERS AND ANCHORAGES


The heights given in Fig. 1-6-2 are the distance between fixing angle and mast top.
For any use of anchorages on cranes with chassis, please consult us for instruction.
The mast composition is given for the case of optimum use of the anchorage frames
that is to install more mast sections above the last anchorage frame.
As the client is responsible for the beams connecting the anchorage frame to the
building, please consult us when carrying out the installation of these beams for the
stresses on the level of the frame(s).
ATTENTIONIf it is required that the crane works in some special condition and
larger height, please consult us for further instructions.
VERY IMPORTANTThe height of the anchorage frame and the distance
between two anchorages must be strictly maintained. It is required to reduce the
number of mast sections above the anchorage if smaller values are needed. (The
height under hook will be badly influenced accordingly.) Please consult us for
further instruction.
1A-46

STT293 TOWER CRANE ERECTION MANUAL

H
209.65m

Anchorages tightened

69
68
67
66
65
64

H
173.65m

Anchorages released

57
56
55
54
53
52

57
56
55
157.5m 54
53
52

45
44
43
42
41
40

45
44
43
121.5m 42
41
40

45
44
43
42
41
40

33
32
31
30
29
28

33
32
31
85.5m 30
29
28

33
32
31
30
29
28

33
32
31
85.5m 30
29
28

20
2.0x2.0m 19
18
L69B1 17
16

21
20
19
49.5m 18
17
16

21
20
19
49.5m 18
17
16

21
20
19
49.5m 18
17
16

21
20
19
18
17
16

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

5
4
3
2
1

NDA 16
H
137.65m

ENA 12

H
101.65m

3m

H
62.65m

Fig.1-6-2

A Free standing height

B 1 anchorage

C 2 anchorages

D 3 anchorages

E 4 anchorages
H
The hoisting height under the hook (the other height is the height from
anchorages to fixing angle)
NDA Number of mast sections above the last anchorage
NSC Number of mast sections between two anchorages
1A-47

STT293 TOWER CRANE ERECTION MANUAL

4:
a.

b. ( 1) ( 2) ( 3) [ ( 11)
( 1) ( 2) ]

c. [ ( 3) ]
d.
e. ( 3) ( 1-6-3 )
f. ( 1) ( 2) ( 11)
g. ( 4) ( 11)
h. ( 6) ( 8) ()(11)

4 FITTING THE ANCHORAGE FRAME


a Remove the standard ladder from the mast to facilitate the installation of the
anchorage frame .
b On the ground, place the two lateral girders (1) and (2) onto the front girder (3)
(insert shaft (11) only in order to facilitate spacing girders (1) and (2)).
c Sling and raise the assembly until it reaches the right position on the mast (with
the front girder (3) of the anchorage frame towards the building).
d To facilitate fitting, use 2 pendant ropes for guiding.
e Hook the front girder (3) onto the horizontal bracings located in the middle of
the mast section (details refer to Fig. 1-6-3)
f Fold back lateral girders (1) and (2) and pin them using shafts (11).
g Sling and raise rear girder (4), position it and pin-connect it to the lateral girders
using shafts ( 11) .
h Raise and place successively brackets ( 6 ) and ( 8 ) (two for each), then pin them
onto the girders by using shafts (11).
1A-48

STT293 TOWER CRANE ERECTION MANUAL

i. (5)812
j.
k. 10
l. 7

m. 9 1-6-4
n.
o.

p. 1-6-5

i. Place and pin diagonal bracing bar (5) with bracket (8) using shafts (12).
j. Check the horizontal position of the frame, and re-adjust if required.
k. Place outer wedges (10) and knock on them in order to bring the frame into
contact with the mast uprights.
l.

Place wedges frame (7).

m. Place outer wedges (9), and drive them in (details refer to Fig. 1-6-4) .
n. Having carried out these operations, check that there is no clearance remaining
between the wedges and the mast uprights.
o. Fit the ladder supplied with the frame instead of the standard ladder, then equip it
with the two back loop parts.
p. The Fig. 1-6-5 gives the forms of the anchoring rods and its installation.

1A-49

STT293 TOWER CRANE ERECTION MANUAL

The horizontal bracings


located in the middle of the
mast section

Fig.1-6-3

1A-50

STT293 TOWER CRANE ERECTION MANUAL

10

1
11

12
5

Fig.1-6-4

1A-51

STT293 TOWER CRANE ERECTION MANUAL

1 the first form

wall

15- 45

2 the second form

wall

40- 60

Fig. 1-6-5

1A-52

STT293 TOWER CRANE ERECTION MANUAL

CHAPTER II. ERECTION

Introduction 2A-2
Erection Sequences
1 Introduction 2A-3
2 General Instructions for Erection 2A-4

Parts Installation 2A-7

Erection
1 Assembling the Travelling Bogie 2A-9
2 Assembling and Ballasting the Chassis 2A-11
3 Mounting Mast Section 2A-13
4 Fitting the Telescopic Cage 2A-14
5 Fitting Slewing Assy. 2A-15
6 Fitting the Cat Head 2A-16
7 Fitting the Trolley 2A-17
8 Fitting the Counter-Jib 2A-21
9 Fitting the Counter-Jib Ballast 2A-24

Reeving the Rope


1 Reeving the Trolley Rope 2A-27
2 Reeving the Hoist Rope 2A-32
3 Changing Falls Methods for Trolley 2A-36

Fitting the Accesses 2A-41

2A-1

STT293 TOWER CRANE ERECTION MANUAL

1
,

. INTRODUCTION
For each crane, the sketch shown represents the component to be lifted (with all its
equipments and connecting accessories such as shafts or bolts.)
The following pages specify the weights of the main components for their handling
on the site so that the complete packages can be lifted accordingly.
It you wish, the packages -each containing 3 mast sections can be put in place by the
mobile crane used provided that its characteristics allow for it.

2A-2

STT293 TOWER CRANE ERECTION MANUAL

1.


ERECTION SEQUENCES
1.

INTRODUCTION

z This erection procedure allows a rapid assemble of your crane until it reaches its
telescoping position.
z It requires an auxiliary mobile crane, the characteristics of which must correspond
to the parts to be handled.
z Reducing the operating time of the auxiliary crane to the minimum on site
involves a good coordination between the erection and assembling sequences, the
erection team, and the appropriate accesses and assembling area .
z The purpose of this manual is to make you well acquainted with all the erection
operation and erection method.

2A-3

STT293 TOWER CRANE ERECTION MANUAL

2.
1 .

2
3
4
5 13m/s

2. GENERAL INSTRUCTIONS FOR ERECTION


1) All the handling operations using the mobile crane must be carried out safely.
ATTENTION: A Properly position and hold the mobile crane
B

Do not overload the mobile crane

Use slings in good order and of correct lengths according


to the weights of the parts to be lifted

Pay special attention to all the slinging points

2) Please read this manual carefully before installation. The erection operations
must be carried out in the order listed in the manual.
3) Make sure that all necessary protection and safety means are fitted and used, such
as : ladderplatformsguard-railssafety belt etc .
4) It is absolutely forbidden to lift a load if the counter-jib ballast is not fitted.
5) The crane must not be telescoped up with a wind speed exceeding 13m/s .

2A-4

STT293 TOWER CRANE ERECTION MANUAL

7
8

9
10)

a.

b.

c.

6) Before starting any telescoping operation, make sure that the pins connecting the
slewing ring to the telescopic cage are inserted and secured by split-pins.
7) It is essential that regulations on the number of the counter-jib ballast blocks
subject to the jib lengths are observed strictly (see relative instruction) .
8) For telescoping, always turn the jib to the opening of the telescoping cage (the side
where the mast sections are introduced).
9) The mast sections must be lifted (or lowered) as close as possible to the tower.
10) It is forbidden to slew the jib, operate the jib trolley and use the load hook
(hoisting or lowering) as long as the telescopic cage is lifted or being lifted.
These instructions also apply to :
a. The erection of the crane
b. The height increase of the crane
c. The dismounting of the crane
For any particular problem or difficulties occurred during the installation of the tower
crane, do not hesitate to call upon the assistance of our After-Sale Service.

2A-5

STT293 TOWER CRANE ERECTION MANUAL

11) FITTING THE SPLIT PIN

15-30

15-30

Bad

Bad

Good

in narrow space

Fig. 2-2-1

ATTENTIONONLY USE NEW SPLIT PINS OR SPLIT PINS IN GOOD


WORKING ORDER.

2A-6

STT293 TOWER CRANE ERECTION MANUAL

1)

2)
a.
b.
3)

a.
b.
c.
4)
a.
b.
5)
a.
b.
c.
6)
a. 23 1m 1.4m
b.
c.

2A-7

STT293 TOWER CRANE ERECTION MANUAL

ASSEMBLING THE PARTS OF CRANE


1. Fitting mast section: Connect 4 mast section panel together by bolts, fit

ladders or resting platform.


2. Assembling the telescopic cage:
a). Fit the platform and support orderly, insert the shaft and lock with split pin.
b). Fix the grab rails onto the platform using split pins, and clamp the grab rails by
using fixing brackets, bolts and nuts.
3. Assembling the upper and lower slewing: (The slewing winch has already been
installed in the upper and loser slewing abutment before leaving factory.)
a). Place the monorail to the lower slewing and pin them using shafts and split pin.
b). Fit the platform into the upper slewing and pin them using shafts and split pin.
c). Fit the grab rail onto the platform and fix using fixing brackets, bolts and nuts
4. Assembling the cab mast (cat head)
a). Fit the platform and ladder and lock them using shafts and split pin.
b). Fit the grab rails and fix using fixing bracket, bolts and nuts.
5. Assembling the counter jib:(The hoist winch and electric box have already been
installed in the counter jib before leaving factory)
a). Connect the front and back counter jib sections by using shafts.
b). Fit the side platforms and grabs rails.
c). Assembling jib suspending beams for maintenance and service.
6. Assembling the jib:
a). Prepare 2 or 3 pieces of 1m height and 1.3m(Min.) wide brackets.
b). Connect the jib sections on
the brackets and lock them
Shaft
by using shafts and split pins,
then place the trolley to the
jib and push it to the foot of
Baffle
jib No.1.

2A-8

STT293 TOWER CRANE ERECTION MANUAL

ERECTION
1 Assembling the traveling bogie
1 Putting the bogies on the track

6x6m

The bogies must be positioned on the track taking account of the space the erection
sequence requires.
Rest the bogies on the rails at the 4 corners of a square having the dimensions of the
chassis (6x6m).
On Straight track the motor bogies can be mounted on the same rail or diagonally, but
NEVER ON THE SAME CROSSBEAM. (If 4 bogies both are motor bogies, it has no
this request.)
Notice: Putting the traveling limiters according to the following figure.
Tighten the bogies to the track using rail clamps. Pack them up, if necessary, to
keep them horizontal.

Traveling limiter

2A-9

Track

STT293 TOWER CRANE ERECTION MANUAL

2) Slinging the traveling bogies


Fit slings onto hooks provided for this purpose.
Lift up the bogie which will remain perceptibly horizontal in the lateral plane.
Longitudinally, the motor side of the bogie will tilt down in the case of a motor bogie,
without however impairing the putting on track.
When placing on the track, fit the bogies with bigger dimension with regard to the
wheel shaft on the inner side of the track.

2A-10

STT293 TOWER CRANE ERECTION MANUAL

2
1) 1 2
121314 3 17
18 ( 2-4-1)
2) 212223
3) 9 10 24
4) 5

2. ASSEMBLING AND BALLASTING THE CHASSIS


1) Place the cross-members 1 onto those 4 pieces of already-made concrete blocks,
then place longitudinal member 2 onto the cross-members and pin them by using
bolts 12, nuts 13 and washers 14. Connect the cross-members to the longitudinal
member with four horizontal struts 3 and pin them by using eight shafts 17 and
lock them by using split pins 18. (See Fig.2-4-1)
2) Place and lock the basic mast onto the longitudinal member with bolts 21, nuts 22
and washers 23.
3) Connect the four backstays 9 to the chassis and basic mast with four shafts 10, four
shafts 24 and lock them by using split pins.
4) Place the base ballast according to different height of the crane, then fix the base
ballast with struts 5.

2A-11

STT293 TOWER CRANE ERECTION MANUAL

1
G

2
A

D
9

24

23

22

21

12

13

14

10

18

17

Fig. 2-4-1
2A-12

STT293 TOWER CRANE ERECTION MANUAL

3. Mounting mast section


12

Lift the assembled mast section, fit to the fixing angles or basic section of base ballast
support. Insert 1,2, pin, and lock it by split pins.

1
2

1-20 mm
2-65 mm

Fig. 2-4-2

2A-13

STT293 TOWER CRANE ERECTION MANUAL

4. FITTING THE TELESCOPIC CAGE


a.
3
Fit the cage spare parts on the telescoping cage on the ground. Must be ensured
the fixing angles (chassis) at least 3 sections before fitting cage.
b.
Sling the assembled telescopic cage and place it outside the basic mast. Connect it
on the basic mast by shoe.

Fig. 2-4-3

2A-14

STT293 TOWER CRANE ERECTION MANUAL

5. Mounting slewing assy

4
65 20 ,

The slewing assy. include: Upper and lower support of slewing, slewing support,
monorail, slewing mechanism and so on, hang 4 lugs of upper support of slewing by
sling on the ground, after balancing lift it to the mast section, insert65 pins and20
pins respectively, connect to the mast, pay attention to the consistent direction of
monorail and front part of cage.

Fig.2-4-4

2A-15

STT293 TOWER CRANE ERECTION MANUAL

6 FITTING THE CAT HEAD

(1)(2)(3)(1)(2)
(4)
Assembled the cat head on the ground, choice sling point well, lift and place the cat
head in the lug of upper support of slewing vertically (pay attention to the direction of
cat head: means cabin and slewing mechanism on different sides), then insert whorl
pin (1) and washer (2) on 4 angle respectively, use slot type of nut (3) fix the whorl
pin (1), washer (2), insert the split pin (4) and locked it.

Fig. 2-4-5

2A-16

STT293 TOWER CRANE ERECTION MANUAL

7 Fitting the trolley


1) general notes of trolley

the crane can be supplied with 2-trolley equipment or a single trolley.


4 2-4-6 A
the 2-trolley equipment allows working with 4 falls (the both trolleys
linked together) (detail A-fig. 2-4-6)
2 2-4-6 B
the trolleying equipment with only 1-trolley allows working with 2
falls(detail B-fig. 2-4-6)

Note: The 2-trolley equipment can be changed to an equipment with only 1-trolley.

A
Fig.2-4-6
2A-17

STT293 TOWER CRANE ERECTION MANUAL

2)
2-4-7composition of the trolley(see 2-4-7)
2-trolley equipment consists of:
z 1

rear trolley1

z 2

front trolley2

z 3

double pulley yoke3

z 4

single pulley yoke4

z 56
z 7

pulley block link 5and hook6

trolley platform7

5
6

Fig.2-4-7

2A-18

STT293 TOWER CRANE ERECTION MANUAL

3) fitting the trolleys


2-4-8
This operation is carried out when assembling the jib on the ground.(see 2-4-8)
1
2
Rear trolley (1), front trolley (2) +pulley block and hook.
7trolley platform (7)

important: In order to prevent any accidental manoeuvre during erection or crane


work, lock the trolley on the jib by mean of a sling before carrying out any
intervention on the jib or on the trolley.
left-hand side

counter-jib

jib nose

right-hand side

Fig.2-4-8
2A-19

STT293 TOWER CRANE ERECTION MANUAL

fitting the 2-trolley equipment onto the jib


2-4-9
place the trolleys onto the jib by observing their direction of introduction.(See
fig. 2-4-9)
1

Introduce the rear trolley (1) from one side of jib nose
2
Then introduce the front trolley (2)
Lock the trolleys together.

Fastening the trolleys on the jib foot by rope


7
Fasten the platform (7) on the rear trolley by fixed part.

Fig.2-4-9
2A-20

STT293 TOWER CRANE ERECTION MANUAL

8 Fitting jib and counter jib


1)Erection sequence
3

LP03

LP02

LJ03

Install 4 blocks

LJ03

8 4

1
LJ03

1
LJ03

1
LJ03

1
LJ03

1
LJ03

1
LJ03

4
LJ04

4
LJ04

4
LJ04

4
LJ04

4
LJ04

4
LJ04

4
LJ04

4
LJ04

10

LJ05

LJ06

LJ07

LJ08

LJ09

10

LJ05

LJ06

LJ07

LJ08

LJ09

LJ05

LJ06

LJ07

LJ08

LJ05

LJ06

LJ07

LJ08

LJ05

LJ06

LJ07

LJ05

LJ06

LJ07

LJ05

LJ06

LJ05

LJ06

2-4-10

2A-21

LJ11

LJ11

54m

50m

44m

40m

LJ11

10

9
LJ11

11

64m

60m

74m

70m

STT293 TOWER CRANE ERECTION MANUAL

2) Choosing spacer
A

+ 0 .3

A + 0 .2

B
26

- 0 .1

8 0 - 0 .3

+ 0. 6

A + 0. 3

9 0

0
C -0.5

B C -0 . 5

B-B

LJ13

B1

B2

Fig.

A-A

Drawing NO.

T2112-B2-1

45

55

28

T2112-B2-2

55

65

38

T2112-B2-3

70

80

58

T2112-B2-4

80

90

58

T2112-B1-1

45

40

T2112-B1-2

55

19

T2112-B1-3

70

15

19

/
jib/NO.

C
74m

70m

64m

60m

54m

Purpose
50m

44m

40m
LJ13 + LJ09

LJ13 + LJ08

LJ13 + LJ07

2
2

LJ11 + LJ09

LJ11 + LJ08

2
2

2A-22

LJ13 + LJ06

LJ11 + LJ07

STT293 TOWER CRANE ERECTION MANUAL

3)
1
2
3
4
5
6 7m/s
The sling position during jib erection

right.. right

wrong

3). Note for erection


1) During the jib and counter jib erection shouldnt be disconnected, so need ensure
finished all counter weight before erection.
2) Ensure the trolley must be fixed the first jib all the time.
3) Must be operated erection according to above sequence, the counter weight
erection see counter weight erection.
4) The last steps is fit other counter weight on the tail of counter weight.
5) The erection person should be tied the safety belt during operating.
Operating jib and counter jib erection in the air, the wind speed is not over 7m/s.

2A-23

STT293 TOWER CRANE ERECTION MANUAL

9 FITTING THE COUNTER-JIB BALLAST


1 3
3 types for counter-jib ballast

A: 4000kg

B2000kg

2A-24

C1000kg

STT293 TOWER CRANE ERECTION MANUAL

2 Installation
2-4-1
A
B D C

Choice installation combination and installation position according to the jib
length, see fig.2-4-1.
In virtue of hoist hook of counter weight blocks, fit the counter jib ballast on
the counter jib by mobile crane.
When finish the counter jib ballast on the counter jib, circled the unit B
running, make unit D stop at unit C.
Check whether the counter jib ballast position is right.
A
B
C

Right

Wrong

Fig.2-4-11

2A-25

STT293 TOWER CRANE ERECTION MANUAL

Table2-4-1

(m)
Jib length

Counter jib ballast


Counter jib Jib

(kg)
Weight

74

A A A A A A

24000

A A A A A

23000

70

64

60

54

50

44

40

A A A A A

21000

A A A A A

20000

A A A A

17000

A A A A

17000

A A A

A A A
C

2A-26

14000

13000

STT293 TOWER CRANE ERECTION MANUAL

REEVING THE ROPE

When the crane is installed to the position, there is no need to use the mobile
crane any longer. Now all kinds of wire ropes can be installed accordingly.
1 Method for rope reeving
1 Methods 2-5-1 (See Fig. 2-5-1)
a 2 6
4 1
Fix the rear trolley rope end onto the trolley drum, wind up the rope from
underneath. through the jib trolley 6pulley 4 of jib foot lock on the trolley 1.
b 2 78
5 3
Fix the front trolley rope end onto the trolley drum 2, wind up the rope from
underneath. Through jib pulley 7,8, jib end pulley 5 lock on the tension wheel 3
of trolley.
6

3
5

4
1

1 trolley
4 jib foot pulley

2 trolley drum
5 jib end pulley
Fig. 2-5-1

2A-27

3 tension wheel
6~8 jib pulley

STT293 TOWER CRANE ERECTION MANUAL

Table 2-5-1

(m)
Jib length
(m)
Front rope length
(m)
Rear rope length

74

70

64

60

54

50

44

40

129

121

109

101

89

81

69

61

110

106

100

94

88

84

78

74

Table 2-5-2

The front rope

The rear rope

6x19-9.3

6x19-9.3

2A-28

With bulldog grips

With bulldog grips

STT293 TOWER CRANE ERECTION MANUAL

A
B

( 2-5-2a)
( 2-5-2b)

2) WORKING PRINCIPLE OF BROKEN ROPE BRAKING DEVICE


This device comprises: 1 rocker arm (1) for the front trolley rope
1 rocker arm (2) for the rear trolley rope
This device blocks the trolley onto the jib in the case a trolley rope is broken.
When fitting the trolley ropes:
A check for the good working order of the broken rope braking device.
B reeve the rope through the eye of the broken rope braking device.
During the operation of the tower crane, check the rope tension periodically in order
to maintain the broken rope-braking device in the horizontal position.
(Fig. 2-5-2a) position of the broken rope-braking device with rope in tension
(Fig. 2-5-2b) position of the broken rope-braking device with rope broken
Jib

b
Fig.2-5-2
2A-29

STT293 TOWER CRANE ERECTION MANUAL

3)
WORKING PRINCIPLE OF BROKEN PIN BRAKING DEVICE

The braking device is made up of bending plates 1


which welded on the column of each jib trolley.
This device can stop the jib trolley on the lower
member of jib to avoide falling if the pins of trolley
roller were broken.
a

Fig. 2-5-3

2A-30

STT293 TOWER CRANE ERECTION MANUAL

4)( 2-5-4)
operation of the rope tensioning device(see fig. 2-5-4)
11
The tensioning of the trolley ropes is ensured by the rope tensioning drum (11).

Move the trolley on the jib foot in the rear of the trolley winch.
1211

Using the lever (12) stored on the trolley, operate the rope tensioning
drum (11) and tighten the front trolley rope to a maximum.

Move the trolley several times forward and backward over the whole jib
length in order to distribute the tension as well as possible in the front
and rear rope.

Perfect the tension of the ropes, if necessary.


12
When dismantling, use the lever (12) on the rope tensioning drum in order to slacken
the ropes and to allow them to be removed.

2-5-4
2A-31

STT293 TOWER CRANE ERECTION MANUAL

2 ROPE REEVING FOR THE HOIST WINCH


1 2-5-4 Reeving the rope as shown in Fig. 2-5-5.

4
6
3
5

4
5

Hoist drum 2

dynamometric ring 3 jib foot pulley

4 trolley pulley blocks

5 hook pulley

6 jib end stretch device


Fig.2-5-5

2A-32

STT293 TOWER CRANE ERECTION MANUAL

2)

A
B
1

400m
105m
410m 74m

2) FITTING THE HOIST ROPE


The hoist rope is normally supplied wound up onto the hoist drum to facilitate
transportation when the tower crane is to be moved to another job site except that the
hoist rope must be removed for the following reasons:
A Rope worn out when dismounting the tower crane
B Rope length no long meet the requirement for a new working height .
(1) CHOICE OF HOIST ROPE
The length of the wire rope is to be selected in accordance with the working height
and working life of tower crane.
The max hoisting height of this crane supplied 400m-length rope as 4 falls under the
standard condition. The max hoisting height is 105m as 2 falls.
When the maximum anchorage height is reached, the total length of the hoist rope is
410 m (74m jib)
ATTENTION: If a certain length of wire rope is required, please contact us for
further instruction.
2A-33

STT293 TOWER CRANE ERECTION MANUAL

(2) 2-5-6
1 2

(2) REEVING THE ROPE ONTO THE HOIST DRUM (SEE FIG. 2-5-6)
This operation must be carried out to obtain the greatest distance between the new
rope reel 1 and the drum 2. This condition is automatically obtained once the
counter-jib is installed. Using a dragline to raise up the rope end and introduce it onto
the counter-jib. Reeve the rope over the pulley and fix it in the rope anchor box of the
drum. Carry out the corresponding electrical connections in order to effect the hoist
movement. Check that the rope winds up perfectly into the drum grooves.

Fig.2-5-6

2A-34

STT293 TOWER CRANE ERECTION MANUAL

3 2-5-7changing the falls of trolley(see 2-5-8)


changing from 4 falls to 2falls

Move both trolleys onto the jib foot and open the trolleying limiter.
(6)5
488

lower the hook(6), pulley blocks to the ground and rest them in upright
position, remove pin (8) connecting plate(5) and single pulley yoke (4),
replace the pin(8) on the pulley yoke and fastening by split pin.

8
Fig.2-5-7

2A-35

STT293 TOWER CRANE ERECTION MANUAL

4 2-5-8
operate hoisting, the single pulley yoke (4) leave the ground and
continue raising the inside of the orientation fork( see fig. 2-5-9)
128
2
128
91
Remove the connecting pin (8) from rear trolley (1) and front trolley (2),
then the front trolley (2) travelling to the jib nose direction, the rear
trolley (1) and the front trolley (2) separate, then install the fixed part (9)
and pin (8) on the rear trolley(1).

The equipment is in position for working with 2 falls.

Fig.2-5-8

2A-36

STT293 TOWER CRANE ERECTION MANUAL

important: if, for moving the load, only one trolley is used over a long time, the
following operations must be carried out periodically:

Return to 4-fall equipment, then move the trolley several times


foreword and backward over the whole jib length and operate
simultaneously lowering and hoisting in order to distribute twisting
of the rope over its whole length. Make sure that the swivel placed at the
jib nose rotates freely. Then return to 2-fall equipment.

2A-37

STT293 TOWER CRANE ERECTION MANUAL

changing from 2 falls to 4 falls


12
move the front trolley (1) near the rear trolley (2) on the jib foot.

Press upon the falls changing button on the control unit, then, proceeding
follow operations:
z 812

Remove the pin (8), the trolley traveling backward and the rear trolley (1)
abut against the front trolley (2).
z 8(9)12
Rear trolley (1) and front trolley (2) linked with pin (8) and fixing part (9).
4
Continue lowering, the single pulley yoke (4) lowers.
48

104

63
2-5-9
As soon as the single pulley yoke (4) reaches the ground, the single pulley yoke (4),
hook (6) and sister block yoke (3) linked together with pin (8) (10) ( see fig. 2-5-10)

The crane is in position for working with 4-fall.

2A-38

STT293 TOWER CRANE ERECTION MANUAL

4
9

Fig.2-5-9

important: Operate 2-trolley notices in case of over the free height

The 2-trolley equipment has been designed for the free standing height of
the crane considered. In case of the use for higher crane heights, the limit is
quickly reached where the balance of the weights involved makes changing the
rope reeving dangerous. If the user demands use the 2-trolley in case of the over
free standing height, please consult us. In this case, the pulley blocks must be
ballasted what leads to downgrading of the characteristics.
2A-39

STT293 TOWER CRANE ERECTION MANUAL

FITTING THE ACCESSES

A
B
A 3m 3m with four loops ladder

B Ladder without loops


D two loops ladder with platform

Type of ladder and erection position


2-6-1
All the ladder should be fit on the mast panel with telescoping lug. Must be fitted as
per table 2-6-1
Table 2-6-1
D

20
D

19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

10

11

12

13

14

15

16

17

18

19

20

2A-40

STT293 TOWER CRANE ERECTION MANUAL

CHAPTER III. TELESCOPING

Preparing The Telescoping


1 Fitting The Telescoping Equipment 3A-2
2 Checking 3A-4

Balancing For Telescoping 3A-6

Telescoping
1 Principle 3A-7
2 Introducing The Mast Section 3A-8
3 reeling the cable 3A-12

Cautions 3A-14

3A-1

STT293 TOWER CRANE ERECTION MANUAL

1
1

2
z
z

PREPARING THE TELESCOPING

1Fitting the telescoping equipment


1 First of all, install the hydraulic cylinder and hydraulic pump, then jack up the
telescopic cage by using the hydraulic cylinder and pin-connect the telescopic
cage to the under slewing. Install the telescoping yoke and support plates.
2 Fitting the monorails
The monorails are fitted onto the telescoping mast. This operation can be carried out:
z In the airbefore telescoping .
z On the ground, before fitting the slewing winch or the connecting mast.

3A-2

STT293 TOWER CRANE ERECTION MANUAL

z 213
3-1-1A
z 576
3-1-1B
41
3-1-1C
z 861

3-1-1D
z 456
9610
3-1-1E
z 1648
3-1-1F
z 3-1-1G

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


z Fit the plates (1) onto the gussets (3) of the slewing connecting plate by means
of the shafts (2). (Fig. 3-1-1_Detail A)
z Using the telescoping hook (5), pick up the first monorail (6) by the round bar
(7) and lift it until it can be pin-connected to the plates (1) by means of the shaft
(4). (As shown in Fig. 3-1-1B and Fig. 3-1-1C)
z Lock the monorail (6) on the plate (1) by means of the shaft (8). The lock of the
two shafts put the monorail in horizontal position. (As shown in Fig. 3-1-1D)
z Remove the shaft (4), and move the hook (5) forward until the monorail (6) can
be pinned into the gussets (10) by means of the shaft (9). (See Fig. 3-1-1E)
z Turn the plates (1) to the upper part of the monorail (5) and insert in the shaft (4)
as well as the shaft (8). (See Fig.3-1-1F)
z Proceed in the same order for fitting the second monorail. (See Fig. 3-1-1G).

3A-3

STT293 TOWER CRANE ERECTION MANUAL

2.
A.
B.
C.
D.

2. CHECKING

A. Check for good installation of all the telescoping accessories and put the hydraulic
mechanism into operation.
B. Check for the good connection between the telescopic cage and the under slewing.
C. Check for the good installation of the monorails and the trolley.
D. Check for the good connection between the telescoping yoke and the hydraulic cylinder.
Make sure that the support plates are slung on the telescoping lugs.

3A-4

STT293 TOWER CRANE ERECTION MANUAL

2
1
3

9
4
A

7
6

8
D

Fig. 3-1-1

3A-5

STT293 TOWER CRANE ERECTION MANUAL

(1)
(2)

(3)
(4)

(5)

BALANCING FOR TELESCOPING


(1) The crane can only be operated to accomplish the following movement after the
trolley is droved to the theoretical balancing position.
(2) Operate the lever of the hydraulic pump station in the hoist-up direction and
telescope until the feet of the slewing ring just leave the fishplates.
(3) Check that the crane is balanced and readjusts, if required, by moving the jib
trolley.
(4) The exact position can be found by verifying the alignment of the slewing ring
feet with the fishplates.
(5) This balancing position of the jib trolley can be marked on the jib by knotting a
piece of cloth around a diagonal bracing. But remember that this marked distance
depends on the jib length. Different length of jib determines different balancing
position. Consequently the mark should be removable.

3A-6

STT293 TOWER CRANE ERECTION MANUAL

1
1
2
3
4
5
6
0.7

TELESCOPING
1. PRINCIPLE
(1) The telescoping sequence comprises a series of operations which should be
repeated for several times.
(2) Lift the cranes upper part to be telescoped by extraction the jacking cylinder that
rests on the telescoping yoke and the lugs.
(3) Rest the lifted part on the lugs of the mast by means of the cages lock shoes.
(4) Unhook the support plate / yoke assembly, keep it away from the lugs, and then
raise it by retracting the piston rod.
(5) Rest the assembly on the next pair of jacking lugs over again.
(6) Repeat the above jacking sequence three times so as to obtain the space required
for the introduction of the mast in the cage. The first stroke of the piston rod at
the beginning period of jacking operation is about 0.7m.

3A-7

STT293 TOWER CRANE ERECTION MANUAL

2.
1
2
3-3-1.
3

4
5-10mm

2INTRODUCING THE MAST SECTION


(1) Fit the monorail trolley onto a mast section by means of bolts. Place them under
the monorail.
(2) Use the trolley special hook instead of the hoist hook. Sling the trolley with mast
section, and introduce them into the monorail. See the Fig. 3-3-1.
(3) Move the trolley to the theoretical balancing position of the relevant jib length.
The operation must be strictly obeying the telescoping notice. Introducing
the mast section when the crane is actually balanced.
(4) Remove the shaft between the lower slewing and the basic mast. Activate the
control lever of the hydraulic cylinder in order to telescope the upper part of the
crane and make the main angles of slewing base and basic mast slightly apart
about 5-10mm. Never allow the tower crane make slewing operation before
balance is guaranteed. Observe the main angle iron of the upper support of
slewing and undersides connect main angle iron on same beeline, in order to
check the trolley balancing position whether correct. If not get to above
conditions, the balancing position can be adjusted by moving the trolley, the
crane should not do slewing and other action at this time.
3A-8

STT293 TOWER CRANE ERECTION MANUAL

5
3-3-3.
6

, 3-3-4.
7

3-3-5.

(5) If the crane is balanced, go on telescoping to a full journey. Fix the lifted part
onto the lugs of the mast by means of the cages lock shoes .See the Fig. 3-3-3.
(6) Remove the safety wedges on the cage shoes. Keep the cage shoes away from
the lugs. Raise the telescoping yoke and cage shoes to the next lugs by lifting the
cylinder. Then fix them by means of the cage shoes and pin them using the safety
pin. See the Fig. 3-3-4.
(7) Raise the control lever. Keep the cage shoes away from the lugs. Go on
telescoping to the next journey until there is enough space to introduce one mast.
(8) Introduce the mast and connect it to the lower 7.5m basic mast or mast section
using shafts. Connect the mast inserted to the lower slewing base using the
safety shafts for the telescoping of the cage. It is necessary to use the standard
mast shaft to connect the mast with the slewing base. See the Fig. 3-3-5.

3A-9

STT293 TOWER CRANE ERECTION MANUAL

Special hook

Slewing support

5-10mm

Fig.3-3-1

Mast section

Fig. 3-3-2

3A-10

STT293 TOWER CRANE ERECTION MANUAL

Lock shoe
Telescoping lug
Cylinder

Control lever

Fig. 3-3-3

Cage shoe

A-A
A

Safety shaft

Telescoping
yoke

Fig. 3-3-4

Shaft for telescoping


Fig.3-3-5

3A-11

STT293 TOWER CRANE ERECTION MANUAL

3 Reeling the cable


1 2

The telescoping operation, suspended the cable as fig.1, after mounted the last
mast section, fitting the cable as fig.2.
Open the cover of the platform for the accesses, release the cable and make it
could gliding in the cable net, fixed the cable in the middle of the ladder by nylon
cingulum.
It should be used the cable net to prevent the cable to out of damage in all
circumstances. One side of the suspended point for the cable cover in the lowering
slewing support, the other under the slewing support accesses platform.

3A-12

STT293 TOWER CRANE ERECTION MANUAL

Important:
The cable lengths increased and extended depend on the length of telescoping added
mast, it forbidden to increase overlength cable once time.
The inductance would be generating by curving cable and cable twist together. Thereby,
voltage and idle work wastage will be growing; the power factor will be decreased, the
current and voltage drop will be growing, which can occurred some phenomenon such
as: motor generate heat badly, damage the electric appliance component and tripping
operation occurred continually etc.

3A-13

STT293 TOWER CRANE ERECTION MANUAL

1
2 13m/s
3

7
3-3-5
.
. CAUTIONS FOR TELESCOPING
(1) We strongly recommend that it is strictly forbidden to SLEW the jib, to
MOVE the trolley, to OPERATE the hoist winch (hoisting or lowering)
during telescoping.
(2) If the wind speed exceeds 13m/s, the crane is not allowed to be telescoped.
(3) The balancing position of the trolley is different according to the various length of
the jib. They depend in particular on the actual counter jib ballast weight. Make
sure that this ballast weight corresponds to the counter jib and jib lengths used.
(4) Check the suspension position of the cable before telescoping. Use cable pulling
grips in order to prevent the cable getting damaged during the telescoping.
(5) Put the telescopic cage and telescoping winch on the ground using this crane after
telescoping. If the crane is base ballasting type or traveling type, put the
telescopic cage and telescoping winch to the lowermost part of the lowest 7.5m
basic mast. Fix them by using lock shoes.
(6) Beyond its free height after telescoping, the crane must be fixed using the
anchorages. At this time it isnt necessary to take the telescopic cage down. Keep
it on the slewing chassis as it is.
(7)It is a must to connect the cage shoes on the yoke to the lugs by means of the
safety wedge to avoid it falling off. See Fig. 3-3-5.After lifting the shoes, it is a
must to fit the locking ring in order to avoid the control lever falling off.

3A-14

STT293TOWER CRANE ERECTION MANUAL

CHAPTER IV. PUTTING INTO SERVICE

Checks To Be Carried Out After Erection 4A-2

Dismounting The Monorails 4A-4

Lowering The Telescopic Cage 4A-6

Fitting The Electric Supply Cable 4A-9

4A- 1

STT293TOWER CRANE ERECTION MANUAL

CHECKS TO BE CARRIED OUT AFTER ERECTION

An overall inspection should be carried out before putting the tower crane into
operation to guarantee the crane working and operating under correct driving system
and safety working situation.

Crane parts
Operations to be carried out
1
Check that there are no obstacles on the track that may hinder the
crane traveling.
2
Check the fitting of the buffers and the limit switch ramps
(according to the standards in force).
Traveling 3
Remove any wedges and anchorages.
4
Release the bogie rail clamps.
5
Make sure that the traveling mechanisms are electrically connected.
1.
Check for correct fixing attachment
2.

Check the fastenings for out of service anchorage, if any.


Chassis
3. ,.
Check that the electric cables run correctly under the chassis in
order to avoid any damage.

Access
Check for reliable fixing of the ladders and back loops, replace
all defective parts particularly the locking wedges before reusing

1.
Check the fitting of the mast pinning shafts.
Mast
2.
section
4A- 2

STT293TOWER CRANE ERECTION MANUAL

Monorail

Telescopic
cage

Cab mast

Upper part

Greasing

Check that the electric cables are correctly hooked on the cable
support rope.
3.
Check for proper fitting of the ladder joint on the basic mast.
1.
Check whether the monorail has already been folding down
alongside the mast section.
1.
Check whether the telescopic cage has been lowered down.
2.
Check the fastening of the cage ladders.
1.
Check for proper connection of the operators cabin.
2. ,
Make sure that the strut access ladder is fitted correctly.
1.
Check the fitting of the counter jibs catwalks and grab rails
2.
Check for proper reeving of hoist rope and trolley rope.
3. .
Check for proper fitting of the trolley inspection platform.
4.
Check for proper pin-connection of the strut on cathead
5. .
Check the counter jib ballast attachment.
6. .
Check for proper locking of wire rope through rope locking device
of the hoist winch.
7. ,
Check whether the catwalks are cleared of all things, which could
fall down during the operation of the tower crane.
8. .
Check for the proper installation of the safety ropes on the jib and
the strut of the cathead.

Check the level and the scale of the grease line as well as the
greasing points according to the Operation Manual.
4A- 3

STT293TOWER CRANE ERECTION MANUAL

1 a
25 b25
a 4-2-1
2
c25 d25
b a
a

3
a

1 abcde
12 t / 18t

. FOLD DOWN THE MONORAILS


In order not to hinder the trolley manoeuvring on minimum radius, it is necessary to
fold down the monorails alongside the crane tower.
Equip telescoping hook instead of the hoisting hook. Take off shafts a25and b
25of the monorails support plates (1) and fold them down in vertical position ,
pin shaft a as shown in Fig. 4-2-1.
Hook up the first monorail (2), unpin shafts c25and d25, trolley-out towards
the jib nose until the hook at the end of the monorail hooks with shaft b and then
insert shaft a.
Lower the special hook for telescoping, the monorail folds down alongside the mast
while take the shaft a as its axle, free the hook, and repeat the same operations for the
second monorail.
NOTE:

When the monorails are to be dismounted completely for use on another

tower crane, continue the aforementioned operations as follows:


Hook up the monorail by round (3), raise it in horizontal position, unpin shaft (a),
trolley-out and lower the first monorail to the ground. Proceed in the same way with
the second monorail and remove monorail support plates (1) and shafts a, b, c, d, e
for future re-use.
Take off the special hook for telescoping and equip with the 12t /18t lifting hook.
4A- 4

STT293TOWER CRANE ERECTION MANUAL

d3

c
e

1
b
a
d

3
1
b
a

Fig 4-2-1

4A- 5

STT293TOWER CRANE ERECTION MANUAL

1
2
3
4
5
6
7
8
9

LOWERING THE TELESCOPIC CAGE


3 Using a mobile crane to lower the telescoping yoke and the cylinder down to
the foot .
4 Run a sling around the rear beam of the telescopic cage that is at the same level
as the cylinder attachment.
5 Choose a proper sling.
6 Tighten the sling but not too much.
7 Check that the mast sections are bolted together and connected to the slewing
base.
8 Remove shafts connecting the telescopic cage and the slewing base.
9 Release the safety-braking device.
10In order to carry out the lowering operation safely, no personnel are allowed to
remain on the cage, and using standard access should carry out the operation.
11Slacken the rope; the cage must lower by the action of its dead weight.

4A- 6

STT293TOWER CRANE ERECTION MANUAL

A
B
ATTENTION:
During this operation counterbalance as much as possible the lateral forces due to the
sling tension so as to prevent the telescopic cage from getting blocked on the mast .The
weight of the hydraulic pump contributes to this balance.
Release the safety-braking device whenever passing through the lugs and continue
lowering the telescopic cage until it reaches the lowest position on the basic mast
without, however, obstructing the mast access. Rest the telescopic cage on a set of lugs.
Lower down the hydraulic pump and store it away with the cylinder and the
telescoping yoke.
Before the tower crane is put into service, please lower the telescopic cage to the
ground (detail A). For the crane with anchor, please lower the telescopic cage to the
anchor (detail B).

4A- 7

STT293TOWER CRANE ERECTION MANUAL

Fig 4-3-1

4A- 8

STT293TOWER CRANE ERECTION MANUAL

4-4-1a
4-4-1b
C

FITTING THE ELECTRIC SUPPLY CABLE


During telescoping the supply cable was suspended as shown in Fig. 4-3-1a. After
finishing the fitting of the last mast section, install the supply cable as shown in Fig.
4-3-1b.
Open the passage door on the access platform , slacken the electric cable by sliding it
in the cable pulling grip Cand introduce the cable sling thus formed into the access
platform opening . Bolt passage door.
Using a clamp fix the cable in the middle of the turning ladder. In all cases, use cable
pulling grips in order to prevent the supply cable from getting damaged. The fixing
points of these cable pulling grips are located under the fixed upper slewing
mechanism for one end and under the slewing ring platform for the other end.

4A- 9

STT293TOWER CRANE ERECTION MANUAL

Supply cable

Supply cable

b
Fig. 4-4-1

4A- 10

STT293 TOWER CRANE ERECTION MANUAL

CHAPTER V. DISMANTLING

Introduction 5A-2
Preparing Before Dismounting 5A-3
Dismounting 5A-4

5A-1

STT293 TOWER CRANE ERECTION MANUAL

. INTRODUCTION
As far as the final stage of dismounting is concerned, this can be carried out entirely
by the auxiliary mobile crane. If site conditions permits, it can be carried out partly by
the hoist winch, which requires the electrical installations keep untouched.
IMPORTANT ADVICE:
For certain parts removed, such as the jib, counter-jib etc., security regulations must
be observed to prevent the other parts of the tower crane from unbalancing while
dismounting some certain part.

5A-2

STT293 TOWER CRANE ERECTION MANUAL

1
2
3
4
a.
b. .
c.

. PREPARING BEFORE DISMOUNTING


1Make sure that there is no obstacle hindering the dismounting operations.
2Connect the cathead access ladder properly.
3Raise the telescopic cage to the top of the mast and pin-connect it at the 4
corners.
4Fit the telescoping accessories, considering the following points:
a. Extend the cylinder completely and pin-connect the telescoping yoke to the
lugs.
b. The telescoping yoke will be fitted on the 5th pair of lugs counting from the
cathead onwards.
c. Raise the mast lifting yoke onto the monorails and fix it onto the mast
section to be removed. Slew the jib to the open telescopic cage side.

5A-3

STT293 TOWER CRANE ERECTION MANUAL

Dismounting
1

Dismounting : Dismount the mast section in turn according to the operate


telescoping methods, can be dismount anchorage device if came across, make
the crane at the erect position before telescoping.

Fix the trolley on the foot of jib.

Dismount the hoist rope and each cable of crane.

As per counter jib and jib opposite erection sequence during erection strictly,
Dismount the counter jib ballastcounter jib and jib in turn.

Dismount cat head and slewing assy.

6
Dismount telescoping cage.
7
Dismount mast section.
8
Dismount base ballast and chassis.

()
After dismounted all spare parts, should be kept properly, the dismounted spare
parts can be disassembled on the ground, in order to travel and keep expediently.
(Dismounting method above parts is opposite to the erection method).

5A-4

STT293-1
150

98

207

1mm
Max. permitted height tolerance between feet in any axis:1mm

Bent bars
Bent bars
17740.5
ATTENTION:Check the anchoring feet
position in relation to the X and Y axes.

6.56.5 6400

7.07.0 6900
7.57.5 7400

8.08.0 7900
150

16

16

16

206

2.1

16

16

235

1.7

16

16

270

1.5

16

16

307

1.3

L 20

250
150

40

40

L 16
40

45020
2000

Lower rods

40

Upper rods

16

pB
Q
2
(t) (kg/cm )
3.0
173

ALL MEASUREMENS ARE IN MILLIMETRES

50

2000

40

40

250

15x15cm

AxA
L
(m)
(mm)
6.06.0 5900

600

25x25cm

2000

1590

XY

40
190010

40

1460 1460
50

40

45020

40

IND NUMBER
DESIGN

DOC.NO.

SIGN

DATE

DATE

Concrete resistanceC30
Min. Concrete density2400kg/cm3
Reinforing steel bar
22 Equal or more than 2 class steel bar.
Weight of foundationsQt

Permissible ground pressurepB

Concrete block

Reinforce concrete

STT293-1
DRAWING MARK

WEIGHT SCALE

1:65
PAGE

OF

YONGMAO

ST6014-5
3

Density of blocks 2.4ton/m


3
Compressive stength of soil20ton/m

A
3

3302

M64

25

500

00

2
65

2500

500

600

-0.5

66

30

25

66

25

190

900

10

1
3302

6
200

-0.5

140 -1.0

140 -1.0

2500
700
0

700

25

7
6
5
4
3
2
1

10-2500
25x700x700
M64

QT6002-10-4
GB6170-86
QT6002-10-3
QT6002-10-2
QT6002-10-1

RP C O D E

48
1
1
1
1
1
1

Q345B
Q345B
45

N A M E Q'TY MATERIAL

IND NUMBER
DESIGN

DOC.NO.

SIGN

DATE

Foundation for
base ballast crane

DATE

Steel
Plate
Nut
Block washer
Washer
Screw
Concrete block

Q235-B
Q235-B

REINFORCED CONCRETE

SINGLE TOTAL
WEIGHT

REMARK

ST6014-5
DRAWING MARK

WEIGHT SCALE

120
PAGE

OF

YONGMAO

ST6014-3
150

1500

540
1500

100

3
4

2 500
8 900
4 2200
3 1600

1000
7200
8800
4800

"D" BASE BALLAST

MATERIAL

REP

1
2

Q235-B

3
4

ST60/15ST70/30ST55/20

This block is used by ST60/15,ST70/30 and ST55/20.


Every kinds of block is made in pairs,the quantity is same.
The quantity depends on the tower crane height ,see the manual.

0
R3

220

Density of blocks2.3/

IND NUMBER
DESIGN


DIAMETER Q ' T Y SINGLE TOTAL
LENGTH LENGTH

40
10
10
10

2 500
8 900
4 2200
3 1600

1000
7200
8800
4800

TYPE

MATERIAL

Q235-B

C "C" BASE BALLAST

220

Weight of blocks2500Kg
115

0
R3

R10

40
10
10
10

TYPE

R30

R20

R10

DOC.NO.

Weight of blocks2800Kg

220

1
2


DIAMETER Q ' T Y SINGLE TOTAL
LENGTH LENGTH

115

REP

R20

500

R30

100

500

220

750

250

250

750

750

450

750

420

250

540

420

540

900

500

250

540

150

450

900

500

SIGN

DATE

DATE

Density of blocks2.3/


BASE BALLAST

REINFORECED CONCRETE

ST6014-3
DRAWING MARK

PAGE

WEIGHT SCALE

OF

YONGMAO

2480
1165
220

380

20 x 45

65

150

150

180

250

320

30

65

1195

1175

925

4
190

2270

50

325

340

110
315

105

75

10

A
370

9
50

150

80

1 : 6

190

395 -2

65

80

1570

6
320

No.91070

No.71470

Horizontal Frame

300

Vertical Frame

No.41080

No.52150

No.8210

No.61000

Technical specification
1Tolerance40001%
2Flatness1
3Concrete strengthC30

10
9
8
7
6
5
4
3
2
1

T742719-1-10
T742719-1-9
T742719-1-8
T742719-1-7
T742719-1-6
T742719-1-5
T742719-1-4
T742719-1-3
T742719-1-2
T742719-1-1

50x800
10x2940
10x1220
10x3740
10x2840
10x5140
10x3000
80x750
25x150
50x365

1
14
1
7
1
8
4
2
2
2

RP

CODE

NAME

Q'TY M A T E R I A L

IND NUMBER
DESIGN

DOC.NO.

SIGN

DATE

Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B

12.3
1.7
0.49
2.18
1.63
3.05
1.725
29.6
0.57
5.77

Counter weight block

S.W T.W
WEIGHT

Round
Round
Round
Round
Round
Round
Round
Round
Round
Round

bar
bar
bar
bar
bar
bar
bar
bar
bar
bar

REMARK

T742719-1
DRAWING MARK

WEIGHT SCALE

4000
PAGE

DATE

12.3
23.8
0.49
13.08
1.63
18.30
6.900
59.2
1.14
11.54

OF

YONGMAO

2480
1165
150 150

380

705

685

65

190

30

325

1170

227.5

150

150

110 370

9
10

80

750

50

75

340

315

80
25

800

50

50

225

435

200

250

52.5

220

395 -2

1570

A
1 : 6

320

No.71470

Horizontal frame

300

Vertical frame

No.4600

No.5:1055

No.8210

No.6390

Technical specification
1Tolerance20002%
2Flatness1
3Concrete strengthC30

No.91070

10
9
8
7
6
5
4
3
2
1

T742719-1-10
T742719-1-9
T742719-1-8
T742719-1-7
T742719-2-3
T742719-2-2
T742719-2-1
T742719-1-3
T742719-1-2
T742719-1-1

50x800
10x2940
10x1220
10x3740
10x1620
10x2950
10x2040
80x750
25x150
50x370

1
8
1
2
1
8
2
2
2
2

Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B

RP

CODE

NAME

Q'TY M A T E R I A L

Counter weight block


IND NUMBER
DESIGN

DOC.NO.

SIGN

12.3
1.7
0.49
2.18
1.0
1.82
1.26
29.6
0.57
5.77

S.W T.W
WEIGHT

Round
Round
Round
Round
Round
Round
Round
Round
Round
Round

bar
bar
bar
bar
bar
bar
bar
bar
bar
bar

REMARK

T742719-2
DRAWING MARK

WEIGHT SCALE

2000

DATE
PAGE

DATE

12.3
13.6
0.49
4.36
1.0
14.56
2.52
59.2
1.14
11.54

OF

YONGMAO

2150
1000

137.5

150

10

11

150

380

110
50

150

75

150

715

30

50
310

290

50

190

80

380

325

200

65

250

210

50
150

A
5

65

80

370

395 -2

1570

320

A
No.10905
No.9630

No.71470

Horizontal frame

300

Vertical frame

No.4150

No.5:600

Technical specification
1Tolerance10002%
2Flatness1
3Concrete strengthC30

No.6240

No.8210

1 : 5

11
10
9
8
7
6
5
4
3
2
1

T742719-1-10
T742719-3-4
T742719-3-3
T742719-1-8
T742719-1-7
T742719-3-2
T742719-2-1
T742719-3-1
T742719-1-3
T742719-1-2
T742719-1-1

50x800
10x2610
10x2060
10x1220
10x3740
10x1320
10x600
10x1140
80x750
25x150
50x370

1
4
2
1
2
1
8
4
2
2
2

RP

CODE

NAME

Q'TY M A T E R I A L

IND NUMBER
DESIGN

DOC.NO.

SIGN

DATE

Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B
Q235B

12.3 1 2 . 3 Round
Round
Round
0.49 0 . 4 9 Round
2.18
Round
Round
1.26
Round
Round
29.6 5 9 . 2 Round
0.57 1 . 1 4 Round
5.77 11.54 Round

Counter weight block

S.W T.W
WEIGHT

REMARK

T742719-3
DRAWING MARK

WEIGHT SCALE

1000
PAGE

DATE

bar
bar
bar
bar
bar
bar
bar
bar
bar
bar
bar

OF

YONGMAO

Fushun Yongmao Construction Machinery Co., Ltd.


Add.
Tel.
Fax.
Postcode
Website
E-mail

No. 3 Yuanda Road, Shuncheng District, Fushun, Liaoning, P.R. China


86-413-76488997649988
86-413-7649999
113126
http//www.yongmao.com.cn
sun@yongmao.com.cn

Manufacture License of Special Equipment No.TS24105922008

20060228