Tower Crane FL30/30

Contents

1.General…………………………………………………………………………………………………….3
1.0 Introduction……………………………………………………………………………….......................3
1.0.1 Brief introduction……………………………………………………………………………………...4
1.0.2 Load diagrams……………………………………………………………………………....................5
1.0.3 Main technical parameters……………………………………………………………………………..6
1.1 Main components……………………………………………………………………… ……………….7
1.1.1 Slewing mechanism……………………………………………………………………………………7
1.1.2 Counter-jib……………………………………………………………………………………………..7
1.1.3 Towerhead……………………………………………………………………………………………..7
1.1.4 Hoisting mechanism……………………………………………………………………………………7
1.1.5 Luffing mechamism……………………………………………………………………………………7
1.1.6 Jib…………………………………………………………………………………………...................7
1.1.7 Mast……………………………………………………………………………………………………7
1.1.8 Cab…………………………………………………………………………………………………….7
1.1.9 Anti-overturn device…………………………………………………………………………………..7
1.2 Safe operation…………………………………………………………………………… ………………7
1.2.1 Operation’s qualifications………………………………………………………………………………7
1.2.2 Operation’s notes……………………………………………………………………………………….8
1.2.3 Losd control…………………………………………………………………………………………….8
1.2.4 Security maintenance………………………………………………………………………………….10
2. Erecting the crane……...............................................................................................................................11
2.1 Receiving the crane…………………………………………………………………………...................11
2.1.1 Introduction……………………………………………………………………………………………11
2.1.2 Checks to be carried out after receiving the crane…………………………………………………….11
2.2 Installation accessories…………………………………………………………………………………..11
2.2.1 General…………………………………………………………………………………………………11
2.2.2 Mobile crane……………………………………………………………………………………………11
2.2.3 Erecting tools…………………………………………………………………………………………..11
2.2.4 Anchorages to the building…………………………………………………………………………….11
2.3 Erecting the crane – General…………………………………………………………………………….12
2.4 Erecting the crane………………………………………………………………………………………..13
2.4.1 Preparing the site…………………………………………………………………………....................13
2.4.2 Foundation treatment of stationary crane/ Fitting the fixing angles and removable anchor………….17
2.4.2.1 Forces-stresses………………………………………………………………………………………17
2.4.2.2 Concrete foundations………………………………………………………………………………..19
2.4.2.3 Fixing angles…………………………………………………………………………………………23
2.4.2.3.1 Conditions of preparation………………………………………………………………………….23
2.4.2.3.2 Dimensional characteristics of the fixing angles…………………………………………………..24
2.4.2.3.3 Fitting the fixing angles……………………………………………………………………………25
2.4.3 Counter-jib ballast……………………………………………………………………………………..26
2.4.4 Erecting the crane……………………………………………………………………………………..30
2.4.4.1 General instructions for erection…………………………………………………………………….30
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 Tower Crane FL30/30
2.4.4.2 Erection………………………………………………………………………………………………32
2.4.5 Adding the mast section………………………………………………………………………………..59
2.4.6 Checks to be carried out after erection…………………………………………………………………83
2.5 Dismantling the crane (stationary type)………………………………………………………………….91
2.5.1 Introduction……………………………………………………………………………………………91
2.5.2 Preparing before dismantling………………………………………………………………………….91
2.5.3 Dismantling the crane tower………………………………………………………………………….91
2.5.4 Removing the counter-jib ballast………………………………………………………………………96
2.5.5 Dismantling the jib…………………………………………………………………………………….96
2.5.6 Dismantling the stru……………………………………………………………………………………96
2.5.7 Dismantling the ballast…………………………………………………………………………………96
2.5.8 Dismantling the counter-jib…………………………………………………………………………….96
2.5.9 Dismantling the towerhead, basic mast, telescopic cage………………………………………………96
2.6 Installation methods of other erecting types ……………………………………………………………97
2.7 Fitting the dismountable telescopic cage………………………………………………………………..97

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 Tower Crane FL30/30

1. General
1.0 Introduction
The crane is systematically designed according to different requirements, it has 4-type: Stationary, traveling,
inside-climbing, and anchoring.
The instruction contains the stationary and anchoring type. For other types, consult us.

The jib combination allows to obtain the jib length used corresponding to the rated hoisting load and rotation
radius. The three mechanisms (hoisting, luffing and slewing mechanism) adopt frequency control.

The erection of the crane requires at least a mobile crane. The crane can meet the height requirement by means
of the addition of the mast sections.

The slewing mechanism and counter-jib, jib and tower-head, cabin, ballast are connected by shafts. The
mechanism can turn 360 degrees (not exceed 3-turn; turn backward when reaching the limitation).

The counter-jib is fitted with the hoisting mechanism, luffing mechanism, electric cabinet and ballast.

The towerhead is connected with the counter-jib by shafts, and fitted with the luffing pulley block.

The jib section is in full steel tube welded structure, connected by the pins according to different length. The
manufacturer can provide the jib section as the standard length.

The mast is 2mx2m. The mast sections are connected by shafts. The mast includes the rest platforms and
ladders.

The counter-jib ballast is made up of the cast iron block. These blocks are suspended under the counter-jib nose.

Accord with human engineering design of the cab makes the work efficiency high in any case of climates and
regions.

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 Tower Crane FL30/30
1.0.1 Brief introduction
The crane (FL30/30)’s maximum working range is 50 m; elevation angle of the jib is 15°~84°. Maximum
hoisting weight is 12 t; when working range is 50 m, hoisting weight is 3 t.

1.0.1.1 Characteristics

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 Tower Crane FL30/30
1.0.2 Load diagrams

载荷特性

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 Tower Crane FL30/30
1.0.3 Main technical parameters

Load-moment (KN.m)

Max. hoisting capacity (kg) Max. height (m) Stationary

Max. working range(m)

Weight (kg) Speed (m/min) Weight (kg) Speed (m/min)

Hoisting speed &
Working speed

property 4-Fall 2-Fall

Slewing speed r/min

Telescoping speed r/min

Luffing speed 15°- 86°, 3 minutes

Motor Reducer
Name
Type Power(KW) Speed (r/min) Q Type Q Ratio Remarks
Mechanisms & parts

Hoisting

Slewing
Luffing
Telescoping

Cylinder Pump station YZ-3

Hoisting
Rope Φ16 35wx7 P=1960N/mm2
Luffing Φ18 6x29Fi+IWR P=1960N/mm2
Working wind pressure (Po) Slewing ring
Non-working wind pressure (Po) Stationary
Overall weight (kg)
(Standard height)
Telescoping wind pressure (Po)

Counter- Jib (m) Necessary electric

weight Weight (t) power

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 Tower Crane FL30/30
1.1 Main components
1.1.1 Slewing mechanism
The upper support is connected by the slewing ring to the lower support using the high strength bolts. The
mechanism is fastened to the slewing mechanism by shafts.

1.1.2 Counter-jib
The counter-jib is connected with the slewing mechanism by the shafts. The counter-jib is fitted with the
towerhead, jib, hoisting mechanism, luffing mechanism, electric cabinet and counter-weight.

1.1.3 Towerhead
The towerhead is connected with the counter-jib by shafts. The towerhead is fitted with the luffing pulley block,
guide pulley.

1.1.4 Hoisting mechanism

The hoisting mechanism, as the drive system, provides the different hoisting speed according to the loads lifted.

1.1.5 Luffing mechanism

The mechanism can realize the luffing of jib, meet the different turning radius.

1.1.6 Jib
The jib is a structural member welded by the high strength steel pipe. The jib sections are linked by shafts. The
length of jib can be varied by adding or reducing the jib sections as needed. The manufacturer can provide the
corresponding jib according to client’s demand.

1.1.7 Mast
As the supporter of the upper member, slewing mechanism, etc., it has strong strength in anti-twisting and
anti-compressing, can meet the height required.

1.1.8 Cab
Ergonomically designed cabin makes the work efficiency high in any case of climates and working condition.
All windows are safety glass; and the side window can be opened to provide ventilation. All control actions are
awfully handy. The driver chair is adjustable so as to provide more comfort and best perspective.

1.1.9 Anti-overturn device

The device is used to prevent the jib from overturning backward when the jib is at 84°.

1.2 Safe operation

The importance of safe operation is beyond doubt. If the operators, supervisors, slingers and directors are
careless, perhaps it may lead to serious casualties and loss of property.
The manual is only to guide and assist the qualified operator to ensure the safety of operation.

1.2.1 Operator’s qualifications

The crane operator shall be full qualified, as follows:
1) Operator assigned, attend a training course and pass an examination.
2) Learner, under supervision of the operator assigned.
3) Operation is carried out under the supervision of the supervisory, maintenance and testing personnel when
necessary.
Note: Only the crane operator shall be in the crane cab during the operation. Make sure that no person different
to crane operator and unauthorized personnel is on or near the crane.
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 Tower Crane FL30/30
The qualified person, i.e., after training, is able to operate the crane skillfully and handle the crisis, and adapt
the work in physical and mental.
The client is responsible for the operator’s training.

1.2.2 Operator’s notes:

1) The operator should not partake in other activities when operating the crane.
2) Do not to operate the crane when the operator feels the mental or physical discomfort, including impairment
from alcohol or drugs.
3) The operation of crane should be under the direct control of the operators. If there is some doubt in safety
aspect, the operators have the rights to stop the service until these problems are solved.
4) The operators should have full knowledge of the maintenance for crane. Such as: the crane may need
adjustment or repair; examine the crane looking for damage to safety operation, stop crane operation until all
faults are repaired.
5) Before starting the day’s work, the operator must determine:
a. Daily service and maintenance has been carried out.
b. All control switches are turned off; all brake switch and locking device are locked.
c. The track and the surroundings are free from obstructions.
6) Before starting the work, the operator should check the control devices, limiters and communication system,
and solve problems.
7) Do not start any crane operation when the load and the signalman are out of sight.
8) The operator should respond to the signalman. When the signalman is not there, the operator should obey the
stop signals, and whoever sends a signal. Do not start any crane operation until receiving the pertinent signals
from the signalman.
9) The operator should comply with the load table.
10) Before leaving the cab, the operator must:
a. Park the crane in the appropriate place in order to avoid being hit by other device on the work site.
b. Lower the loads to the ground
c. Turn off the control switches.
11) If power or control fails in service, the operator should:
a. lower the load to the ground.
b. turn off the control switches.
12) When operating the crane at night, for security’s sake, the site should have adequate lighting in the cab and
working area.
13) Mist, rainfall or snowfall will impair the visibility. Do not start the crane in bad weather,
14) The operator or director should reduce the hoisting speed, tacking account of the influence of wind. Unless
otherwise noted, operations should cease in following conditions.
a. The strong wind blew the load out of the working radius or the hinge point of jib foot, lower the load to
the ground.
b. The wind speed exceed the rated value, lower the load to the ground.
15) When assembling the jib or towerhead on the ground or dismantling them, whether with and without the
supporting, bind them from dropping to the ground. It was forbidden to stay under the crane when dismantling
the connecting pins.

1.2.3 Load control

A. Load weight
- The weight must not exceed the rated load.
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 Tower Crane FL30/30
- The operator or director should confirm that the weight loaded is in the correct radius.
- The load weight table is placed in the cab.
B. Hanging
- Hanging the load must use the suitable slings. The hook’s tongue should work properly, don’t open it
using the guy cable.
- Hanging the load must use the safety slings. The rated hoisting load of the slings must correspond to
the load be handled.
- Don’t hang the load by winding method.
- If the slings are in contact with the sharp edge of the load, proper measures should be taken to protect
the slings.
- If more slings are used, but only a sling is needed, the other ropes should be protected.
C. Hoisting, moving the load
1) Before hoisting or moving the load, the operator or director must check the following:
a) Lift the load a few centimeters from the ground to ensure the balance of load.
b) Make sure that the path of the hoisting and slewing is free from any person and obstacles.
c) Make sure that the load lifted is free from obstacles.
d) Never shorten a sling by means of knots, otherwise cause damage
e).When more slings are used, make sure the slings are not entangled.
f) Ensure the load will not rotate or swing.
g) Ensure the hoist rope is wound correctly on the drum and guide pulley.
2) When lifting the load, the operator should have the following preventative measures:
a) Slowly decelerate or accelerate to prevent the stress caused by the jib and slewing mechanism.
b) Always operate the crane smoothly, avoid sudden braking or acceleration. In order to prevent the load
straying from the working radius, control the slewing speed, reduce the swing range.
c) Use a hand rope to “guide” the load, if required.
d) Do not lift any load heaver than the load specified by the manufacturer for a given working radius.
e) Maker sure the load, jib or any part of the crane are free from obstacles.
f) No person shall stand on the load or hook when lifting, lowering or slewing.
g) No person shall be allowed to work under the hook.
D. Controlling the load
When the load is suspended in the air, the operator should have the following warning:
- Keep the load under control.
- No person shall stay or pass under the suspended load.
- Turn off the control switch.
E. Signaling
1) It is necessary to signal to the operator.
2) The signals shall be established according to an approved signaling scheme. The operator may not to respond
to unapproved signals.
3) When signaling to the operator, the movements of crane shall be stopped.
4) The signalman should
a) be able to operate the crane and fully understand the signals.
b) stand in the field of view of crane operator and attentively look at the load, crane and working area.
c) ensure that no person is under the path of lifting load.
d) ensure that no person is in the working area.
F. Getting on or off the crane
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 Tower Crane FL30/30
1) Getting on or off the crane should be in the specified area when the crane operation is stopped.
2) When climbing the crane ladder, don’t hold anything in your hand. These things can not be placed in the
pockets or belt, lift them by a rope or the elevator.
G. Cab, ladders and catwalk
1) In order to not block the path to the cab or influence the crane operation, the operator should put the clothes
and personal things in their proper place.
2) Place the tools and devices in the tool box; don’t place the aforementioned goods in the cab, cat-walk or
ladders at random. Remove junk.
H. Fire extinguisher
1) The cab should be equipped with a portable fire extinguisher.
2) The operator and maintainer should know how to use and maintain the fire extinguisher.

1.2.4 Security maintenance

Attention: The crane owner should have the qualified maintenance technicians
1) Before starting repair work, the following movements must be carried out:
a. Stop the crane at the place where the crane will not interfere with the other equipment.
b. Lower the load to the ground.
c. Turn off the control switches and brakes, stop the crane operation.
d. Hang the warning sign on the control panel to let know the crane is being serviced.
Note: Don’t move the warning sign before putting into service.
2) Unless absolutely necessary, don’t try to repair the parts of the crane when the power supply is turned on.
Keep your body away from the rotating parts if have to repair it. The maintenance personal should keep in touch
with the operator.
3) The maintenance personal should wear tight clothes and require a belt.
Note: Don’t wear loose clothes.
4) The maintenance personal should wear the safety helmets and eye shields.
5) When climbing the crane, for these things can not be placed in the pockets or belt, lift them by a rope or the
elevator.
6) Use the leather gloves, avoiding contact with the wire rope directly.
7) Only the clean, nonvolatile, non-flammable liquid can be used.
8) For the heavy parts, lift them using the lifting jack.
9) When welding on the crane, cover pipeline or parts by the fire blanket to avoid the fires or damage.
10) When assembling and dismantling the jib or towerhead on the ground, it was forbidden to stay under the jib.
11) Keep the crane neat. Plastocene, tarpaulin, paper and other dirt not only will effect the normal operations,
but it can cause fires.
12) Place the tools, spare parts and devices in the tool box. Don’t place the aforementioned goods in the cab,
cat-walk at random.
13) Inflammables are forbidden on the crane.
14) After maintenance, put the crane into service until the tools, parts, high-pressure pipe and safety device are
well organized.
15) A functional test should be carried out after maintenance.

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2. Erecting the crane

2.1 Receiving the crane

2.1.1 Introduction
Check and find out which part is broken or missed as quickly as possible after receiving the crane. The parts
damage more easily in transit, so, it is important to inspect the parts for damage before assembling. Thus this
will not affect the safe operation and crane strength.
If the parts should arrive in a damaged condition, please inform us at once so as to repair or replace them.

2.1.2 Checks to be carried out after receiving the crane

1. Check the delivery is complete according to the product list and specification.
2. To be on the safe side, note down the damage.
3. Adequate support must be provided for parts in order to avoid sludge and water damage in storing.
4. The structure should not have deformation.
5. Check the rope is clean, lubricated properly and stored on its drum.
6. Check that the pins, washers and fasteners are fitted, lubricated properly and ready to begin
installation.
7. Check the repairing of the paint scratched.

2.2 Installation accessories

2.2.1 General
It requires an auxiliary mobile crane when erecting the crane. First, fit the basic mast and the upper parts of the
crane.

2.2.2 Mobile crane

The customer must consider the following conditions when choosing the dimension and capacity of the mobile
crane.
1) For the site, the customer has to think about the site condition, access road, slope and space requirements for
erection.
2) The capacity of lifting the heaviest part of crane.
3) The customer has to think about the hoisting height and working radius of the mobile crane.

2.2.3 Erecting tools

1) These important parts, such as: The mast, ballast, counter jib, jib, hoisting and luffing mechanism all have
lifting lugs.
2) The customer should have the appropriate slings, lifting belt, pulley blocks, etc., in the site, and these tools
should be in accordance with local laws and regulations.
3) Don’t use the chain on the jib because they are made of thin-wall pipe.
4) The telescoping yoke must have appropriate intensity and be in accordance with the regulations of relevant
authority.

2.2.4 Anchorages to the building

The building support the mast by the anchorage frames.
The anchorage frames shall be fitted at the specified position.
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 Tower Crane FL30/30
2.3 Erecting the crane – General
The customer must consider the following items before erecting.
1) Check the crane parts and make sure they are in accordance with operating conditions.
2) The customer should have the appropriate lifting handling equipment, including lifting belt, erecting tools.
3) Man power and tools.
4) Installation and commissioning work should be carried out under the direction of a service engineer.
5) For telescoping, always slew the jib to the opening of the telescoping cage, i.e., side where the masts are
introduced.
6) The mast sections must be lifted or lowered as close as possible to the tower.
7) Lowering and dismantling the telescoping cage after finishing the telescoping.
8) In assembling crane, all the pinning bolts should be firm; the pins and shafts should be covered with grease
before fitting them; let the split-pins open.
Note: When wind speed is over 13 m/s, or there will be bad weather, stop the erecting or telescoping operation.

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2.4 Erecting the crane
2.4.1 Preparing the site
2.4.1.1 Characteristics/space requirements for erection/weight of parts

A B C

710mm 175mm 50m

a. Space requirements and weight

The weights, radii, heights in the tables have been calculated considering the different possibilities as to:

- the site conditions,

- the mobile crane available.

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

The height H, for a crane on fixing angles, is the hook height of the mobile crane.

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

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

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b. The structure, dimensions, & weights of the main components

DESCRIPTION Q FIGURE

Fixing angle

Basic mast

Mast section

Telescopic cage

Slewing assembly

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名称
DESCRIPTION 数量
Q
简 图
FIGURE L l h p(kg)
l
Counter-jib
平衡臂 1 75801879 1380 5518

左、右平
Left & right platform l
69151142 1167 1054
台及栏杆 1
Grab-rail

l
起升机构 1
Hoisting mechanism 2180 2448 1655 3000

l
Luffing mechanism
变幅机构 1 21431438 1765 2200

Strut l 48301350 11022 6606

塔顶撑杆 1

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名称
DESCRIPTION 数量
Q 简FIGURE
图 L l h p(kg)

臂架根部
Jib foot 1 l
1 10000 1440 1405 1627
第一节

Jib section 2 l
臂架第二节 1 10000 1303 1348 1214

l
Jib section 3
臂架第三节 1 10000 1326 1337 978

l
Jib section 4
臂架第四节 1 5416 1326 1293 433

臂架5.76 l
5.76 m Jib section
1 5416 1326 1293 418
米节

3 m Jib section l 3000 1326 1358 358

臂架3米节 1

l
Jib nose
臂端节 1 2117 1326 2745 565

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 Tower Crane FL30/30
2.4.2 Foundation treatment of stationary crane / Fitting the fixing angles and removable anchor

2.4.2.1 FORCES – STRESSES

a Explanation and symbols

C: Mast composition (stationary)

ES: In service
HS: Out of service
H: Hinge point height of jib in m
P: Weight in ton
M: Bending moment in ton/m
ET: Shearing stress in ton
R: Stresses in ton
F1: Tension in ton
F2: Tension in ton

Mast (Example)

1+0+1

Above standard mast

Standard mast
Basic mast section

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50 m Jib TM

ES HS
R R
C H P M ET P M ET
F1 F2 F1 F2

1+0+1 10 63.42 257.4 1.065 83.44 117.6 62.2 17.2 4.686 -10.38 23.83
1+1+1 13 65.24 265 1.065 85.90 121.1 64.02 36.5 4.686 -3.35 31.86
1+2+1 16 67.06 272.7 1.215 88.40 124.6 65.84 61.9 5.346 6.07 42.29
1+3+1 19 68.88 281.8 1.365 91.48 128.7 67.66 91.3 6.006 17.04 54.25
1+4+1 22 70.7 292 1.515 93.94 134.2 69.48 124.6 6.666 29.56 67.77
1+5+1 25 72.52 303.1 1.665 98.81 138 71.3 161.9 7.326 43.62 82.83
1+6+1 28 74.34 314.2 1.815 102.61 142.8 73.12 203.1 7.986 59.22 99.44
1+7+1 31 76.16 327.3 1.965 107.26 148.5 74.94 248.3 8.646 76.38 117.6
1+8+1 34 77.98 341.5 2.115 112.80 154 76.76 297.4 9.306 95.08 137.3
1+9+1 37 79.8 356.7 2.265 117.74 161 78.58 350.6 9.966 115.33 158.5
1+10+1 40 81.62 372.9 2.415 123.57 167.8 80.4 407.6 10.63 137.13 181.3
1+11+1 43 83.44 390.2 2.565 129.79 175 82.22 468.7 11.29 157.97 208.2
1+12+1 46 85.26 352.8 2.715 120.0 159.4 84.04 452.3 11.95 154.94 198.4
1+13+1 49 87.08 372.2 2.865 127.13 167.5 85.86 518.2 12.61 180.2 224.7

b. Ground pressure (P) and choice of concrete blocks (50 jib)

C H M169N M205N M278N

1+0+1 10 1.15 1.09 1.05
1+1+1 13 1.19 1.12 1.1
1+2+1 16 1.24 1.16 1.13
1+3+1 19 1.30 1.21 1.18
1+4+1 22 1.39 1.27 1.24
1+5+1 25 1.48 1.33 1.32
1+6+1 28 1.60 1.41 1.37
1+7+1 31 1.75 1.51 1.44
1+8+1 34 1.94 1.62 1.51
1+9+1 37 2.19 1.77 1.6
1+10+1 40 1.95 1.7
1+11+1 43 2.2 1.84
1+12+1 46 1.98
1+13+1 49 2.15

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2.4.2.2 Concrete foundations
The reinforcement of a concrete block is composed of an upper and a lower layer connected by pins. Each layer
comprises two crossed beds

Upper bed
33: number of bars
HA: Round steel with high adherence
25: diameter of iron in mm

33 HA 25 × 620 (e: 17)

e: space between bars or pins in cm
620: unit length of iron in cm

D: density
V: volume in m3
L: length in cm
I: width in cm
H: height in cm
Concrete mixed for 350 kg/m3
Quality of cement: CPA 325 or equivalent

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Upper layer M169N

2nd bed 55HA20×710

1st bed 33HA25×620

2nd bed 55HA25×700

Lower layer
1st bed 55HA25×710

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M205N

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 Tower Crane FL30/30

M278N

2nd bed 69HA25×815

Upper layer
1st bed 69HA25×815

Lower layer 2nd bed 69HA25×815

1st bed 69HA25×815

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 Tower Crane FL30/30
2.4.2.3 Fixing angles
2.4.2.3.1 Conditions of preparation
a. By the customer
The table of forces and stresses, the dimensional characteristics of the fixing angles, the fitting of the fixing
angles in the block on the following pages are necessary and adequate to determine a concrete block
(dimensions and reinforcement).
For stability requirements of the machine, we insist upon minimun dimensions on the ground equal to those of
the blocks described in this brochure.
For all other dimensions consult us.
b. How to choose:
It is the permissible ground pressure of the site which determines, for the final height to be reached and for each
type of machine, the best type of block to use. For any height, choose the block with a ground pressure equal to
or lower than that of the ground of the site.
c. The fittings of the fixing angles is very important, we must make certain:
1) The center line of the 4-pinhole (at the same height) of the 4 fixing angles shall be at the same plane,
allowable tolerance is equal to or less than 1/6500 of the space between holes, the absolute tolerance
between holes is equal to or less than 0.3.
2) Dimension 150 ± 25
3) The perpendicularity tolerance between the main angle bar and the foundation: ≤ 1/1000
4) The planeness tolerance of the foundation in the plane of 2 m × 2 m: ＜3
5) Take care to earth them correctly.
Attention: The earth circuit of the crane must neither include a fuse nor a switch. The neutral wire on the
supply cable is not connected to the earth.

A B C
A: 1 – tube Φ45×6 length 2 m.
2 – Earth spike.
3 – Inspection hole protecting the head of the spike and allowing the spike to be watered.
B: Earth plate made of sheet steel or stretched metal of an area of 1m2 buried vertically.
C: Copper conductor section 30mm2 or iron 50 mm2, in shallow trench extending over a long length
depending on the resistibility of the soil.
6) Do not reduce the given amount of reinforcing irons around the fixing angles.
Bad fitting of the fixing angles can lead to serious incidents using the machine (perpendicularity not respected,
distortion of the mast assembly planes).
It is absolutely essential to use the fitting elements provided.

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 Tower Crane FL30/30

2.4.2.3.2 Dimensional characteristics of the fixing angles

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

The type of fixing angles: in L 200×20 plate of 850 mm and 600×600 plate.

Take care to earth them correctly.

Plumb line

Standard section

2 pins in each corner

Fixing frame

2 pins in each corner

4 Fixing angles

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 Tower Crane FL30/30
2.4.2.3.3 Fitting the fixing angles
Place the fixing angles in the foundation and make it level, connect the four fixing angles using the tie-rod along
the diagonal direction.
Fit the reinforcing mast or standard mast on the fixing angles, sling and adjust it by wedging under the angle
support plates. Check perpendicularity in both directions using the measuring instrument. The perpendicularity
is in 1/1000.
Pour the concrete block and wait until it is completely dry before unfitting the mast section and the frame.

Note:
The pressure bearing capacity of concrete must be over 90% before erecting the crane.
The frame is used only to anchor the fixing angles. It is essential to dismantle the frame when erecting the
crane.

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 Tower Crane FL30/30
2.4.3 Counter-jib ballast
Introduction
The counter jib ballast is made up of several A, B or C blocks in reinforced concrete. Their combination allows
to obtain the various weights corresponding to each jib length used.

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

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

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

Block C

Block B

Block A

Jib （m） 35 40 45 50

Counter-jib（m） 8.65 8.65 8.65 8.65

Working and Blocks A+B A+2B A+2B+C A+2B+2C

telescoping Weight (t) 8 10 11 12

Ballast drawings (next page)

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 Tower Crane FL30/30

Block A

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BlockB

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 Tower Crane FL30/30

Block C

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

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

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

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

2.4.4.1 General instructions for erection

1) All the handling operations using the lorry mounted crane must be carried out safely. For this:

- properly pack up the crane

- do not overload the crane
- use slings in good order and of correct lengths according to the weights of the parts to be lifted
- respect the slinging points.

2) The erection operations must be carried out in the order listed. The crane must not be telescoped up with a
wind exceeding 13 m/s

3) Make sure that protection and safety means are lifted and used, such as: ladders, platforms, guard-rails, safety
rope etc.

4) Before starting any telescoping operation, make sure that the pins connecting the towerhead to the telescopic
cage are inserted and secured by split-pins.

5) For telescoping, always slew the jib to the opening of the telescoping cage (side where the masts are
introduced).

6) The mast sections must be lifted (or lowered) as close as possible to the tower.

7)) It is forbidden to slew the jib, change the jib luffing and use the load hook (hoisting or lowering) as long as
the telescopic cage is lifted or being lifted.

8) Lowering and dismantling the telescoping cage after finishing the telescoping.

9) In assembling crane, all the pinning bolts should be firm; the pins and shafts should be covered with grease
before fitting them; let the split-pins open.

10) Special attention: The jib, lifting frame and ladders should be in the same direction when erecting.

11) All operations must be stop prior to installing the power circuit breaker, ballasting, putting into service. For
telescoping, see special instruction.

12) These instructions also apply to the erection, the height increase and the dismantling of the crane.
For any particular problem as to the erection organization or other difficulty, do not hesitate to call upon the
assistance of our After-Sales Service.

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 Tower Crane FL30/30

Erection sequences

Rep Contents
1 Fitting the fixing angles;
2 Fitting the basic mast and telescopic cage on the fixing angles;
3 Mounting the slewing assembly;
4 Pin-connect the slewing support and telescopic cage;
5 Assemble the counter-jib and strut on the ground and then dismantle the strut.
Fitting the counter-jib and mechanisms (install separately);
6 Fitting the strut;
7 Fitting the counter-jib ballast;
8 Electrical wiring;
9 Assembling the jib;
10 Winding the hoist rope and luffing rope onto the drum;
11 Reeving the hoist rope;
12 Fitting jib (The crane still pull the jib after pin-connecting the counter-jib.);
13 Reeving the luffing rope (The crane release the jib after tightening the luffing rope.);
14 Fitting the anti-overturn backward device;
15 Preparing the telescoping

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 Tower Crane FL30/30
2.4.4.2 Erection
A. As above, first, fit the fixing angles.
B. Fit the basic mast

1) The basic mast assembly comprises:

- a telescopic cage (1 ) equipped with its cat-walks (2).
- a basic mast (3)
- a telescoping yoke (4)
- a hydraulic cylinder (5)

The table on the next page gives the weight of the main components depending on the mast type.

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 Tower Crane FL30/30

Rep Name Nb Weights (KG)

1 Telescopic cage 1 4090
2 Platform 7 780
3 Basic mast 1 3850
4 Telescoping yoke 1 485
5 Cylinder 1 330
Total 9535

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 Tower Crane FL30/30
2) Preparing the basic mast on the ground
Check that the basic mast assembly is equipped with the telescoping yoke and the cylinder. Otherwise, place the
cylinder, piston rod side downwards, between the cage and the basic mast and pin it onto the telescopic cage.
Position the telescoping yoke and pin it onto the cylinder.

- Fitting slings onto the basic mast as shown in figure A, tighten the slings and put the basic mast upright.
- Get hold of the packages of cat-walks and grab rails.
- Pin the supports (1) at (2) onto the cage using the 25x60 shafts.
- See fig. B concerning the position the cat-walks around the cage.
- Raise the cat-walks (3) and pin them onto the cage by means of 25x60 shafts.
- Raise the support (1) and fit them at (4) onto the cat-walks using 25x60 shafts.
- Mount the grab rails (5) and split-pin them at (6).
- Assemble the grab rails together by means of the fixing brackets (7).

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 Tower Crane FL30/30

Upper cat-walk Lower cat-walk

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 Tower Crane FL30/30
3) Fitting the telescopic cage ladders
When the ladders had been removed for transport:
Engage the 3.60 m ladders (1) into the 1.50 m ladders (2) and mount the assembly using ladder fittings (3),
fixing brackets (4), wedges (5) and pins (6).
The towerhead access, whilst telescoping, is ensured by a ladder located inside the towerhead.

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 Tower Crane FL30/30
4) Fitting the basic mast (with the telescopic cage)
Insert the basic mast right into the fixing angles (and never into the frame used to position the fixing angles
into the anchorage pad).
Pin connect the basic mast with the fixing angles by means of 8 shafts (D65) (2) secured by a locking pin (D20)
(3).

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 Tower Crane FL30/30
C. Fitting the towerhead
1) Assembling the towerhead
Fitting the platform:
According to the jib direction, fix the cab platform and the inspection platform onto the left and right of the
slewing ring usingφ30×72 shafts. Then fit the grab-rails.

Fitting the cab:

Fit the cab on the cab platform using the 4 bolts (M12×55) and 4 spring washers (specification: 12).

2) Slinging the towerhead

Fit 4 slings onto the towerhead according to detail A.
On the front-run the rope into the tie-plate holes.
On the rear-introduce the 2 shackles into the fishplate holes.
Raise the towerhead and engage it into the basic mast as shown in figure B, the monorails being located on the
open telescopic cage side.
Pin-connect the towerhead with the basic mast using shafts (1), lock the shafts by means of pins (2), then
split-pin (3) according to detail C; remove the slings.

总重: 9631Kg

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D. Fitting the counter-jib
1) Assembling the counter-jib
2) Fitting the mechanisms
3) Fitting the electric cabinet and pump station
4) Slinging and fitting the counter-jib

1) Fitting the platforms and grab-rails on the counter-jib

Fit the left and right 6-platform using 14 shafts (Φ25×90) and 28 split-pins (6.3×45).
Fit the 8-grab-rail (the grab-rail of counter-jib end will be fitted after fitting the ballast support.) using 24
split-pins (φ10×80), connect them together by means of 6 bolts (M14×75), 6 nuts (specification: 14), 6
washes (specification: 14) and 12 clamps.

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 Tower Crane FL30/30

2) Fitting the mechanisms

Fit the luffing mechanism on the counter-jib using 4 shafts (Φ50).
Fit the hoisting mechanism on the counter-jib using 4 shafts (Φ50).
Note: Fit the counter-jib first, and then lift the hoisting and luffing mechanism, if the counter-jib assembly is
beyond the lifting capacify of the auxiliary crane.

Luffing mechanism Hoisting mechanism

变幅机构 起升机构

3) Fitting the electric cabinet and pump station

Fit the electric cabinets on the counter-jib according to the general drawings.

Pump station Electric control case

Hoisting case Slewing and luffing case

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 Tower Crane FL30/30
4) Slinging and fitting the counter-jib
Attach a cord on the counter-jib nose in order to guide the counter-jib from the ground.
Sling the counter-jib at the fixing points (4-tie-plate-hole of A-type support).
Slightly lift up from the ground and check the stability of the assembly (50 t lorry-mounted crane is
recommended).
Incline the counter-jib in order to facilitate the pivoting support pinning.
Connect the counter-jib with the pivoting support (at the top of girder) using 2 shafts (90×260) and 2 split-pins
(10×20).
Slightly lower counter-jib end, connect the counter-jib with the pivoting support (at the bottom of girder) using
2 shafts (90×260) and 2 split-pins (10×120).

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 Tower Crane FL30/30
E. Fitting the strut
1) Assembling the strut
2) Slinging and fitting the strut

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 Tower Crane FL30/30
1) Assembling the strut
a. Assembling the foreleg
Connect the upper foreleg with lower foreleg using 24 bolts (M24×110), 48 nuts, 24 spring washes.

b. Assembling the luffing pulley block, rope arrangement pulley and angle pulley
Assemble the luffing pulley block (outer diameter of pulley: φ490) at the upper foreleg using a φ75×634
shaft, a plug, a 5×70 split-pin, 6 pulleys and 12 spacer bushes.
Assemble the rope-arranging pulley block at the middle of the foreleg using a φ90×1280 pulley shaft, bolt and
nut.
Assemble the angle pulley of hoist rope at the lower foreleg using a φ60 shaft, plate pin, 2 spacer bushes, and
attach the ward-off-rope shaft.

c. Assemble the ladder, platform, grab-rail

Fit a 3 m ladder and a 2.53 m ladder at the middle and lower part of the foreleg, and fit a 3 m ladder and a 1.5 m
ladder at the upper part of the foreleg.
Fit two platforms at the upper part of the foreleg using 12 shafts (φ20×48.5), 24 split-pins (5×50), 2 struts. Fit
the grab-rail using the clamps and split-pins (10×80).

d. Assemble the rear leg

Connect two rear legs with the upper part of the foreleg using 2 shafts (φ60×73), 2 split-pins (10×100).

e. Fitting the inspection lifting-beam

First, connect the pulley (3) with lifting-beam (4) using shafts (1) and split-pin (2), and lift the lifting-beam (4)
using the roller (10), put the side plate (5) in the lifting-beam, insert the bolt (7). Place the tie-plate (6) on the
mounting stem of the rear leg. Sling and fit the lifting-beam under the mounting stem of the rear leg. Tighten the
nuts.

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 Tower Crane FL30/30
2) Slinging and fitting the strut
Sling the strut by the lifting lug of the strut, connect its foreleg with the counter-jib using 2 shafts (φ75×262),
2 plate pins and split-pins, and connect its rear leg with the counter-jib using 2 shafts (φ60×73), 2 split-pins
(10×100). Tighten the mounting stem and rear legs.

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 Tower Crane FL30/30
F. Fitting the jib
1) Assembling the jib
2) Assembling the tie-bar
3) Reeving the hoist rope and luffing rope
4) Fitting the jib

1) Assembling the jib

a. Assembling the jib foot (I)

Fit the pulley (1) (outer diameter:φ415) using a shaft (φ60×164), 2 spacer bushes, 2 split-pins (10×130).
Fit the pulley (3) (outer diameter:φ415) using a shaft (φ60×185), 2 spacer bushes (φ70×5), 2 split-pins (10
×130).
Fit the dynamometer pulley (2) (outer diameter:φ490) using a shaft (φ50×265), a spacer bush (φ60×3×75),
2 split-pins (10×100).

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 Tower Crane FL30/30
b. Assembling the jib section (II)
Fit the pulley (1) (outer diameter:φ415) using a shaft (φ60×185), 2 split-pins (10×130), 2 spacer bushes (φ
70×5×21) (fig.1).
Fit the beam support (2) of the locating tie-bar using 2 shafts (φ30×130), 4 split-pins (8×60) (fig.1).
Connect the jib section (II) with (I) using a shaft (φ50×175) (a split-pin (10×100)), 2 shouldered shafts (φ55
×112) (2 split-pins (10×100)) (fig.1).
Fit the supporting platform using 2 shafts (φ30×130), 4 split-pins (8×60). The connection is adjustable
(fig.2).

Lower member

Fig.1

Jib section II

Joint of the jib

sedtion (I) and (II)

Fig.2

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 Tower Crane FL30/30
c. Assembling the jib section (III)

Fit the tie-bar guide rod at the middle of the jib section (III). Connect the jib section (III) with jib section (II)
using a shaft (φ50×175) (a split-pin (10×100)), 2 shouldered shafts (φ55×100) (2 split-pins (10×100)). Fit
the pulley block (for installing the erecting rope) using shafts (φ60).

d. Assembling the jib section (IV)

Fit the pulley (1) (outer diameter:φ415) using a shaft (φ60×185), 2 spacer bushes (φ70×5), 2 split-pins. Fit
the tie-bar guide rod (2) near the pulley.
Connect the jib section (IV) with jib section (III) using a shaft (φ55×175) (a split-pin (10×140)), 2
shouldered shafts (φ50×90) (2 split-pins (10×100))..

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 Tower Crane FL30/30
e. Assembling the jib section (V)

Fit the tie-bar guide rod at the forepart of the jib. Connect the jib section (V) with jib section (IV) using a shaft
(φ55×175) (a split-pin (10×140)), 2 shouldered shafts (φ40×75) (2 split-pins (8×80)).
Similarly, connect the other jib section (V) with the front jib section (V).

f. Assembling the jib section (VI)

Fit the pulley (outer diameter:φ415) using a shaft (φ60×185), 2 spacer bushes (φ70×5), 2 split-pins (10×
130).
Connect the jib section (VI) with jib section (V) using a shaft (φ55×175) (a split-pin (10×140)), 2 shouldered
shafts (φ40×75) (2 split-pins (8×80)).

g. Assembling the jib section (VII)

Connect the jib section (VII) with jib section (VI) using a shaft (φ55×175) (a split-pin (10×140)), 2
shouldered shafts (φ40×75) (2 split-pins (8×80)).

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 Tower Crane FL30/30
h. Assembling the jib section (VIII)
Connect the jib section (VIII) with jib section (VII) using a shaft (φ55×175) (a split-pin (10×140)), 2
shouldered shafts (φ40×75) (2 split-pins (8×80)).

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 Tower Crane FL30/30
2) Assembling the tie-bar
a. Fit two 1.3 m tie-plates (1) on the jib section (VI) using a shaft (φ70×200), a locating rod (φ20×75), 2
split-pins (5×40). Fit a oil cup (M8×1) at the shouldered shaft end.
b. Connect the 5.1 m tie-bar (3) with tie-plate (1) using a shaft (φ60×150) (a split-pin (10×100)).
Connect the other two 5.1 m tie-bars (3) with the front tie-bar (3) in order using a shaft (φ60×70) (a split-pin
(10×100)), one for each.
c. Connect the 5.3 m tie-bar (2) with tie-bar (3) using a shaft (φ60×70) (a split-pin (10×100)).
d. Connect the 5.3 m tie-bar (2) with tie-bar (2) using a shaft (φ60×70) (a split-pin (10×100)).
Connect the 4.85 m tie-bar (1) with tie-bar (2) using a shaft (φ60×70) (a split-pin (10×100)).
Connect the 1.35 m tie-bar with 4.85 m tie-bar (1) using a shaft (φ70×125) (a split-pin (10×100)).
e. Fit the 6 luffing pulleys (outer diameter: φ490) on the pulley yoke using 2 shafts (φ75×630), 12 spacer
bushes. Connect the pulley yoke (7) with tie-bar (6) using 2 (φ70×125), 2 split-pins (10×110).

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 Tower Crane FL30/30
3) Reeving the hoist rope and luffing rope
The hoist and luffing rope is normally supplied wound up onto their drum. If not, reeve the luffing rope and
hoist rope to their drums by the rope arrangement pulley on the A-type support.

Reeving the hoist rope

Run the rope over the rope-arranging pulley and rope-passing pulley on the A-type support. When the rope
reaches the ground, reeve the rope in the following sequence (Rope: 35Wx7 -16-1960):

Reeving the hoist rope

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 Tower Crane FL30/30

4-Fall 2-Fall

Changing from 4-fall to 2-fall

Luff the jib to 45°, raise the hook assembly to the jib nose top, connect the hook assembly with the jib nose
using two shafts and 4 split-pins. Remove the shaft (D50) of the hook assembly. Now, it can work in 2-fall.
The crane can start to work from the 15 degree jib normally.

Changing from 2-fall to 4-fall

Luff the jib to 45°, raise the 2-fall hook assembly to the jib nose top, connect the hook assembly together using
the shaft (D50). Unlock the hook assembly and the jib nose. Now, it can work in 4-fall.
The crane can start to work from the 15 degree jib normally.

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Slinging and lifting the jib

Loading range The distance A between the center of gravity

Total weight G of complete jib
(Jib elevation angle a=15°) of jib and the hinge point of jib foot
50 m 6408 kg 22.54m

Run the safety rope (φ7.7) througn the safety hook on the jib and then fit it at the jib foot and nose using three
clamps separately. This rope will be used for sliding the belt of the maintainers when inspecting the jib nose.
For the slinging rope of the jib, the φ21.5 rope is recommended.
In order to tilt the jib foot downward, the front slinging rope of the jib should be 8 m, the rear slinging rope of
the jib 10 m.
Check that the slings are fitted either in front of (a) or behind (b) a node of the upper member and not between
the diagonals (c) .DO NOT JAM the tie bars between the rope lines at the slinging point.
Fill lithium base grease into the oil cup in the shafts at the joint of the jib tie-bar and jib end before slinging the
jib.
Fasten a cord on the jib foot so as to guide the jib from the ground. Lift the jib until it reaches the luffing pulley
block of the tie-bar above the pivoting support (Meanwhile, release the hoist rope on the drum when slinging
the jib.).

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 Tower Crane FL30/30
Reeving the luffing rope

Release two sets of rope on the luffing drum. Run the rope successively over the luffing pulley block (6-pulley)
on the strut, luffing pulley block (6-pulley) on the jib tie-bar. Fix it at the strut.
Bring the rope to the strut top, run the rope over the fixed pulley and luffing pulley block on the jib according
the 12-reeving. Lock the rope end at the strut top. See below, fix the wedging sleeve and clamp at the rope end
and pin-connect the wedging sleeve with the lug of of the strut, split-pin.

Luffing pulley block

Strut pulley block

Luffing drum

Luffing rope: 6x29Fi+IWR-18-1960; length: 223 m

4) Fitting the jib

Connect the jib with counter-jib using two shafts (φ90×283), two clamp plates (-12×70×200), four bolts
(M20×45), four spring washes.
Place the jib slowly, and tighten the luffing rope to straighten the tie-bar. Withdraw the hoist hook.

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G. Fitting the ballast
1) Fitting the ballast
2) Fitting the ballast support and rear grab-rail

1) Fitting the ballast

Fit the supporting frame, sling the ballast block and place them, one by one, on the counter-jib nose.
Fit the jib when mounting half of the ballast blocks; mount the other ballast blocks after fitting the jib.
Ballast type:
Example: for 50 m jib, the ballast is 12 t.
Concrete block: 6000kg×1+2000kg×2+1000kg×2
Sling the concrete block, one by one, and fit them by two sets of the ballast holder assembly.

Ballast holder assembly

The ballast holder assembly is shown in the following figure:

No.1: fixing piece; No.2 &3: shaft (φ30×100) and split-pin(5×60).
The lever 4 is adjustable, so, No. 1, 2, 3 is adjusted according to the ballast heigh.

2) Fitting the ballast support and rear grab-rail

Fit the ballast support on the counter-jib end using 4 shafts (φ35×115) and 8 split-pins (8×60).
Fit the rear grab-rail of the counter-jib using the clamps.
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 Tower Crane FL30/30
H. Fitting the elastic buffer device of the jib
1) Principle

In order to ensure that the jib has a buffer when luffing to the extreme position, the main member of the strut
has two elastic buffers stalled. When luffing to a certain angle, the front roller of elastic buffer will make contact
with the lower member of jib. As the luffing angle increases, the spring in the elastic buffer is compressed until
closed. Meanwhile, the jib reaches the maximum luffing angle. So the jib is buffered.
The buffer is equipped with a limiter, when the spring in the elastic buffer is compressed, the rod, on the pad
connecting with the buffer spring, will make contact with the limiter on the support, the alarm is raised, the jib
will stop working.

2) Elastic buffer comprises:

The buffer support (1), welded on the main member of the strut, is connected with the support (4) of the buffer
by means of the 4-M16×70 bolt (2) and nut (3). The support (4) of the buffer is connected with the buffer (5)
by means of the M16 bolt and nut.

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Jib

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 Tower Crane FL30/30
2.4.5 Adding the mast section
1) Assembling the mast panels:

The mast section comprises 4 panels and 4 horizontal members.

. 2 panels (1 and 2) without telescoping lugs

. 2 panels (3 and 4) with telescoping lugs
- 2 horizontal members (5 and 6) without ladder fasteners
- 2 horizontal members (7 and 8) with ladder fasteners

The panels are assembled by means of the 4 flat head pins and split pins.
The panels provided with the ladder fastenings must be face to face.

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 Tower Crane FL30/30
2) Fitting the accesses
The fitting of the accesses in the mast sections is carried out on the ground.

Three access types are used; they comprise:

— A access: a ladder with back loop

— D access: a ladder with back loop and landing-place
— E access: a ladder with back loop and platform
Latter, fitted on the last mast section to be telescoped, allows the towerhead to be reached.

The following table shows for each crane height the distribution of each of theses access types. It should be
observed that, when the final working height is attained in several phases, the access of the last mast section
will be adapted when telescoping, i.e, it is to be removed and replaced by an A or D access.

All the ladders are fitted on the mast panels equipped with the telescoping lugs.

The A and D accesses must be positioned according to the instructions given in the following table.

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 Tower Crane FL30/30

All the ladders are fitted on the mast panels equipped with the telescoping lugs.

1+27+1 E
1+26+1 E D
1+25+1 E A A
1+24+1 E A A A
1+23+1 E A A A A
1+22+1 E D D D D D
1+21+1 E A A A A A A
1+20+1 E A A A A A A A
1+19+1 E A A A A A A A A
1+18+1 E D D D D D D D D D
1+17+1 E A A A A A A A A A A
1+16+1 E A A A A A A A A A A A
1+15+1 E A A A A A A A A A A A A
1+14+1 E D D D D D D D D D D D D D
1+13+1 E A A A A A A A A A A A A A A
1+12+1 E A A A A A A A A A A A A A A A
1+11+1 E A A A A A A A A A A A A A A A A
1+10+1 E D D D D D D D D D D D D D D D D D
1+9+1 E A A A A A A A A A A A A A A A A A A
1+8+1 E A A A A A A A A A A A A A A A A A A A
1+7+1 E A A A A A A A A A A A A A A A A A A A A
1+6+1 E D D D D D D D D D D D D D D D D D D D D D
1+5+1 E A A A A A A A A A A A A A A A A A A A A A A
1+4+1 E A A A A A A A A A A A A A A A A A A A A A A A
1+3+1 E A A A A A A A A A A A A A A A A A A A A A A A A
1+2+1 E D D D D D D D D D D D D D D D D D D D D D D D D D
1+1+1 E A A A A A A A A A A A A A A A A A A A A A A A A A A
1+0+1 E A A A A A A A A A A A A A A A A A A A A A A A A A A A
1+ 0+ 1+ 2+ 3+ 4+ 5+ 6+ 7+ 8+ 9+ 10+11+12+13+14+15+16+17+18+19+20+21+22+23+24+25+26+ 27

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Fitting the accesses
A ACCESS
— Put the mast section upright.
— Fit the ladder support (1) on the mast gussets using Φ10 shaft (2); split-pin.
— Check that the ladder ends (3) are clean (no earth or other matters in the holes) and not crooked.
— Manually introduce the ladder (with the back loops folded back) into the mast section.
— Position the ladder top onto the ladder support (1).
— Introduce the two fixing brackets (4), insert wedges (5), drive them in and bend the ends (6) outwards.
— Unfold the back loops (7).
— In order to prevent the ladder from swinging in the mast when fitting, block it using a cord or a steel wire.

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

E ACCESS
— Put the mast section upright.
— Fit the ladder supports (1) on the mast gussets using Φ 10 shafts (2), split-pin.
— Place the ladder onto the support, fit the 2 fixing brackets (3), insert wedges (4), drive them in and bend the
ends (5) outwards. Unfold the back loops.
— Fit the platform (6) in the mast section (opening on the ladder side) using clamps (7) and bolts (8). Fit the
grab rails and fixing brackets (9).
— In order to prevent the ladder from swinging in the mast when fitting. Block it using a cord or a steel wire.

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3) Preparing the telescoping
Introduction
Prepartion for telescoping consists of placing the accessories required for telescoping.

Table: Telescoping equipment

Designation
Mast 2 m
Telescoping equipment

Telescopic cage

Telescoping yoke

Mast lifting yoke

Monorail

Telescoping hook 12 T

Hydraulic group

Hydraulic ram

Pressure

These operations necessary either after erection of for a height increase are described hereinafter.

Fitting the telescoping yoke

This operation is carried out when lowering or re-raising the telescopic cage along the mast tower.

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

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

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

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Positioning the cage
Cage attachment on the towerhead:

It is recommended to carry out this operation during the erection. There are two possibilities:

— Using the ram, in the case of a short distance. Put the hydraulic system into operation following the
instructions. When the yoke is fixed on the lugs effect a stroke until the cage uprights (1) can be introduced
in the towerhead corners (2), pin-connect using 4×1 shaft (3) and split-pin them.

— Using slings. Either by means of the mobile crane during erection or using the crane itself after its putting
into service for a height increase or for dismantling. Use a sling of φ16, length 4 m which surrounds the
rear cage beam at the level of the ram attachment (4). Remove the device locking the cage on the basic mast.
Lift up and guide using a crowbar until the cage uprights are inserted in the towerhead corners (2), then
pin–connect using 4×1 shaft (3) and split-pin them.

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

Raise the monorail (2) up to its working position; trolley-in so as to slide the rear part of the monorail in
between the basic frame and the towerhead according to (B).

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

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

Move back the monorail, after removing the sling so as to be able to pin-connect shaft (3) and to split-pin it
according to detail C.

Proceed in the same manner for the other monorail.

Fitting the mast lifting yoke

If necessary, fit brackets (1) in the slide bars (2) and immobilize them by means of split pins.

The mast lifting yoke will be fitted on the upper mast (3) members. Block the fixing brackets (1) on the
members by means of the fastener (4), i. e.:

a) When erecting, on the ground, on the mast sections previously assembled,

b) When dismantling, in the mast tower, on the mast section to be dismantled.

Attention: For case a)

Make sure that the mast lifting beam is fitted on the mast section and hooked on the telescoping hook in the
right direction; the position of the telescoping lugs on the mast determines the direction in which the mast
section is introduced into the crane tower (the opening of the telescoping hook must always face the crane
tower).

Fitting the hydraulic system

Preparing the hydraulic group and ram

Hydraulic group: Packing, filling up, connections, adjustments

Hydraulic ram: Bleeding the hydraulic circuit, adjustments
For the operating requirements of the hydraulic system, see operation instructions for details.

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Fitting the monorails

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Fitting the mast lifting yoke

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4) Balancing the crane for telescoping
1/ Special instructions
2/ Balancing positions
3/ Balancing the crane

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1/ Special instructions

The crane is balanced in two stages:

- Theoretically by suspending a load at a given radius;

- Practically by adjusting the position of the jib.

We remind you that it is strictly forbidden to slew the jib, move the jib and hoist (hoist up or down) when the
telescopic cage is lifted or being lifted.

Note: The following table gives the theoretical balancing position depending on the crane type and the type of
hoist winch.

It is necessary to use a bracket (1) on the telescoping hook (2) in order to suspend the balancing load.

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

Move the jib, if require with an appropriate load, to the balancing position given in the tables.

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

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

LF m LCF m CP kg P kg D m
Jib Counter-jib Ballast Load Radius
---
50m 8.65 12000 40.5
45m 8.65 11000 40
40m 8.65 10000 41.5
35m 8.65 8000 45

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3/ Balancing the crane
- The crane can only be balanced after the towerhead feet (1) have left the mast fishplates (2).

- Operate the lever of the hydraulic group in the «hoist up» direction and telescope until the feet of the
towerhead just leave the fishplates.

- Check that the crane is balanced and readjust, if required, by moving the jib radius or load.

- The exact position is found by verifying the alignment of the towerhead feet with fishplates and checked by
reading the minimum pressure required for telescoping on the pressure gauge of the hydraulic group.

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5) Telescoping (2m×2m mast)
I. Principle
II. Introducing the mast section
III. Hanging the 2nd mast section from the monorail

I. Principle
The telescoping sequence comprises a series of operations which are repeated several times.
- The telescoping yoke (1) rests on the lug (5) by means of the cage shoes (4)). Lock it using the safety pin
(3).
- Lifting the crane part to be telescoped by extending the ram. Resting the lifted part on the lugs (6) of the
mast by means of the cage shoes (2).
- Unhook the shoe (4) assembly, release it from the lugs, and lift it up it by retracting the ram.
- Re-rest the yoke on the next pair of lugs above (7).
- Repeat this cycle three times so as to have the space (8) required for the introducing the mast section into
the telescopic cage.
- The first ram stroke is about 0.7 m in this initial telescoping phase.

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II. Introducing the mast section
The lifted crane part is resting on the upper lugs (1) of the last mast section by means of the lock shoes (2) of
the cage. The ram is almost entirely extracted and total stroke is provided in such a way that the upper guide
rollers of the telescopic cage cannot go beyond the fixed part of the mast tower.

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

Operate the hydraulic group lever in the “hoist up” direction so as to release the shoes (2) from the lugs (1).
Hold latter away from the mast using the control rod (3).

Operate the hydraulic group lever in the “hoist down” direction and make sure that the mast section (4) engages
correctly in the fishplates (5). Connect this mast section using 8 shafts (Φ55), insert locking pins and split-pin
them, see detail B. Raise the ladder which pivots in (6) up to its upper fixing position and engage the tenons of
the ladder uprights in the ladder of the lower mast section (7).

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Fig. A

1. Shaft Φ55×130 8 Pcs

2. Shaft Φ20 4 Pcs
3. Split-pin 4×30 4 Pcs

Fig.B

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nd
III. Hanging the 2 mast section from the monorail
To hang the mast section to be telescoped from the monorail, it is essential that the lifted crane parties solidly
anchored to the fixed mast tower.
To do this, operate the lever of the hydraulic group in the “hoist down” direction until the feet of the towerhead
(1) engage in the fishplates of the last mast telescoped.
Fit the 4 safety pins (2).
If required, lower the balancing load, hang the mast lifting yoke (3) from the pulley block.
Suspend another mast section fitted with its accesses on the mast lifting yoke (3) and raise it up to the monorail
(4).
Another telescoping sequence can be started. Repeat it until the required height is obtained.
It is strictly forbidden to carry out a hoisting before the normal working shafts have been put in place.
ATTENTION: The last mast section must be pin-connected to mast tower as well as to the towerhead feet.

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2.4.6 Checks to be carried out after erection

1) Introduction

All the operations concerning the putting into service to ensure the crane work under correct driving and safety
conditions.
On the whole, all these operations can be split up into three groups:
a) Checking and carrying out the mounting operations in order to avoid any hindrance as regards the
proper working order or the safety.
b) Adaptation of the crane equipment to the site requirements.
c) Adjusting the various safety devices.

2) Checks to be carried out after erection

a) Check the fixing device and power supply.

b) Check the fitting of the ladders and back loops.
c) Check that the mast connecting pins are properly fitted. Check that the electric cables are correctly
hooked from the cable support rope.
d) Check the locking of the cabin in working position. Make sure that the access ladder to the strut is
fitted.
e) Make sure that the hoist and luffing rope are properly reeved.
f) Check the counter-jib ballast fastening.
g) Check the oil level and the greasing points according to the Operating Instructions.
h) In order not to hinder the crane manoeuvring on minimum radius, it is necessary to fold down the
monorails alongside the crane tower or dismantle it after erecting the crane.

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3) Lowering the telescopic cage
Using the crane, lower the telescoping yoke and the ram down to the ground.
Run a sling (1) around the rear telescopic cage beam on the level of the ram attachment (detail A) and hook it on
the load hook. Use a sling which is long enough so that the pulley block does not lower underneath the
towerhead.
Tighten the sling but not too much. Check that the mast sections are bolted together and connected to the
tower-head.
Remove shafts (3) connecting the telescopic cage (2) to the towerhead (detail B).
Release the safety catches.
In order to carry out the lowering operation in safety, the personnel does not remain on the cage, but works from
inside the mast using the normal accesses.
Slacken the rope, the cage must lower by the action of its dead weight.

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 unit contributes to
this balance.
Release the safety catches at each passage of 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 unit and store it away with the ram and the telescoping yoke.

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4) Fitting the towerhead access ladder
The towerhead access ladder had been stored away onto the counter-jib for erection or telescoping sequences,
now it must be fitted in position so as to allow the cabin access.
To do this:
Introduce ladder (1) into the cathead and lower it into its support (2).
Immobilize it under the 6th peg using lock (3) and split-pin.
Move in the cabin and lock it in working position.

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5) Fitting the electric supply cable
During telescoping the supply cable was suspended according to figure 1. After fitting of the last mast section,
fit the supply cable as showin figure 2.

Dismantle trap door (1) of the access platform; slacken the electric cable by sliding it in thecable pulling grip (2)
and introduce the sling thus formed into the access platform opening; bolt trap door (1), see detail A.

Using a clamp (3) 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 there cable pulling grips are located on the one hand under the fixed towerhead, and under the slewing
towerhead platform on the other.

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6) Safety devices

A. Load lifting limiter

B. Hoisting mechanism
Brake
Limit switch
C. Luffing mechanism
Brake
Limit switch
D. Moment limiter
E. Jib buffering limiter
F. Ladders and platforms of the
towerhead, mast, etc.

7) Position the jib in the non-working state

In the non-working state, the elevation angle α of jib should be between 15°~64° (i.e. when the working range is
50 m, position the jib between 50 m ~21.7 m) so as to avoid the excessive wind load.

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8) Rope maintenance system
The maintenance system will install on the jib after fitting the jib. The luffing rope or pulleys may show signs of
wear after using for some time, which need to be replaced. Use the maintenance system, replace the rope or
pulleys of the luffing pulley block after fixing the jib at a certain position (elevation angle of jib: 5°~15°).

a. The system comprises:

- base plate on the A-type support
- pulley block on the jib
- rope: 35w×7-Φ18-1670 (GB/T89l8-96 L = 65m/rope, overall length: 130 m, 2pcs)
- shafts (connecting the pulley block (2) with jib)

b. Operations
- Connect the pulley block (2) with jib pulley base (28.75 m from the jib foot hinge) using shafts (φ50).
- Fix the end of the rope (3) on the left base plate of the upper support of A-type support using the wedge
sleeve.
- Run the rope over the pulley (2).
- Fix the other end of the rope (3) under the left pressplate of the upper support of A-type support using the
wedge sleeve.
- Fix the end of another rope (3) on the right base plate of the upper support of A-type support using the
wedge sleeve.
- Run the rope over the pulley (2)
- Fix the other end of the rope (3) under the right base plate of the upper support of A-type support using the
wedge sleeve.
- Reeve the rope.

Rope clamp
Rope clamp

Base plate, wedge sleeve

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2.5 Dismantling the crane (stationary type)
2.5.1 Introduction
As far as the final stage of dismantling is concerned, this can be carried out entirely by the mobile crane, but site
conditions permitting it can be carried out partly by the hoist winch, which requires that the electrical
installations must not be touched.

For dismantling certain parts, such as the jib, counter-jib … security regulations must be observed which enable
all risk of the load being out of balance with the rest of the crane to be prevented when removing the part.

Dismantling the crane should be carried out as follows:

Mast, ballast, jib buffering limiter, jib, A-type support, counter-jib, pivoting support, telescopic cage, mast.

2.5.2 Preparing before dismantling

Make sure that no obstacle blocks operations.
Fold down the bogie rail clamps and tighten them on the rails.
Raise the ladder giving access to the towerhead.
Raise the telescopic cage (1) to the top of the mast and pin-connect it at the four corners.
Fit the telescoping accessories considering the following points:
- Extend the cylinder completely and pin-connect the telescoping yoke (2) to lugs (3)
- Raise the mast lifting yoke onto the monorails and fix it onto the mast section to be dismantled.
Slew the jib to the open side of the cage. Thus the crane is now in the position of the figure shown.

2.5.3 Dismantling the crane tower

1) Carry out the balancing condition for telescoping the crane according to the instruction given in brochure. As
soon as the towerhead feet have left the fishplates by about 2 cm, stop telescoping and lock the attachments (1)
of the mast lifting yoke (2) on the mast section (3) to be dismantled. Fit the lifting yoke. Remove pins (4) and
shafts (5) connecting mast section (3) with that below. Unhook the ladder. Continue telescoping up until mast
section (3) can be pulled out from fishplates, then rest the pawl (8) or locking shoes (9) of the telescopic cage on
the lugs (10) of the mast. Move the mast lifting yoke (2) outside on the monorail so as to bring the mast out of
the cage.

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

To detelescope a mast section, the cycle must be repeated three times.

CAUTION: It is essential that the safety wedges (11) of the shoes (12) are placed when lowering.

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2) Lowering the mast section to the ground
Engage the towerhead feet (1) into the fishplates (2) of the lower mast and insert the safety pins (3) at the four
corners.
If necessary, lower the balancing load to the ground.
Fit the telescoping hook (4) on the mast lifting yoke (5); then lower the mast section to the ground.
Re-raise the mast lifting yoke (5) which will be introduced on the monorail (6); then connect it to the new mast
section to be dismantled. Repeat these operations as often as necessary until the mast tower is dismantled
completely.
Disconnect the hydraulic group, drain and lower it to the ground.
Connect the towerhead to the basic mast by means of the normal shafts used for crane work.
Remove the telescoping accessories (hydraulic unit, mast lifting yoke, etc). take down the monorails.

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2.5.4 Removing the counter-jib ballast

Dismantle the ballast support at the counter-jib end, and dismantle the ballast blocks in sequence.

2.5.5 Dismantling the jib

This dismantling requires a mobile crane with the same characteristics as those of that used for erecting. As well
as the jib, this mobile crane will carry out the dismantling of the entire machine.
Dismantle the jib as follows：
a. Sling the jib as erecting the crane/
b. Unpinning the tie bar lines, the tie-bar rest on the jib. Dismantle the luffing rope at the tie-bar foot (reeve the
complete luffing rope onto the drum).
c. Remove the shafts connecting the jib with counter-jib.
d. Sling the jib and lower the hook.
e. Lowering the complete jib down and placing it on the ground on a support..
f. Dismantle the hoist rope and reeve it onto the hoist drum.

2.5.6 Dismantling the strut

Sling the strut using a mobile crane.

Unpin the 4 shafts connecting the strut with counter-jib, and lower the A-type support to the ground.

2.5.7 Dismantling the ballast

Dismantle the ballast on the counter-jib in sequence.

2.5.8 Dismantling the counter-jib

Sling the counter-jib using a mobile crane.
Unpin the 4 shafts connecting the counter-jib with towerhead, and sling the counter-jib and lower it to the
ground.

2.5.9 Dismantling the towerhead, basic mast, telescopic cage

A. Dismantling the towerhead
Rest the telescopic cage on the locking shoes (connecting with the telescopic lug of the 1st mast section).
Sling the towerhead at 4 slinging points (the front two pinholes - connecting with the inhibiting device; the rear
two pinholes - connecting with the counter-jib) as erecting the crane. Hook the towerhead and unpin the 8 shafts
connecting it with the 1st mast section and 4 shafts connecting it with the telescopic cage. Sling the towerhead
and lower it to the ground.

B. Dismantling the telescopic cage

Sling the telescopic cage and lower it to the ground.

C. Dismantling the basic mast

Unpin the 8 shafts connecting the basic mast with the chassic mast (or fixing angles)
Sling the basic mast and lower it to the ground.

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2.6 Installation methords of other erecting types
For other erecting types of the crane, customers should consult with the manufacturer.

2.7 Fitting the dismountable telescopic cage

The dismountable telescopic cage comprises the front panel, rear panel, left pane, right panel.

Front panel Left panel Rear panel Right panel

Fig. 1
Assembling sequence (Fig. 2):

Connect the left panel (1) and the right panel (2) to the rear panel (3) using the bolt (M22x77, material: 45) (5),
washer (specification: 22) (6), nut (M22) (7), and the bolt (M22x63, material: 45) (8), washer (specification: 22)
(6), nut (M22) (7). Connect the front panel (4) to the left and right panel using the bolt (M22x62, material: 45)
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(9), washer (specification: 22) (6), nut (M22) (7).
Fit the telescopic cage (with guide rollers) on the basic mast, then fit the platform, grab rails, etc.

Fig.2

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