Jost-208 Manual

OPERATING MANUAL
- Topless luffing crane JTL 208.12 -

Foreword
These operating instructions are designed to familiarize the user with the slewing tower crane
and its designated use.
The instruction manual contains important information on how to operate the slewing tower
crane safely, properly and most efficiently. Observing these instructions helps to avoid danger,
to reduce repair costs and downtimes and to increase the reliability and life of the slewing
tower crane.
The instruction manual is to be supplemented by the respective national rules and regulations
for accident prevention and environmental protection.
The operating instructions must always be available on location wherever the slewing tower
crane is in use.
These operating instructions must be read and applied by any person in charge of carrying out
work with and on the slewing tower crane, including operations such as assembly, dismantling,
troubleshooting in the course of work and care, maintenance (servicing, inspection, and repair)
and/or transport.
In addition to the operating instructions and to the mandatory rules and regulations for
accident prevention and environmental protection in the country and place of use of the
slewing tower crane, the generally recognized technical rules for safe and proper working must
also be observed.
JTL208.12 Foreword
Edition 01/2008 Page 1
CONTENTS
Foreword
1 Fundamental safety instructions
1.1 Warnings and symbols 2

1.2 Basic operation and designated use 2
1.3 Organizational measures 3
1.4 Selection and qualification of personnel - basic responsibilities 4
1.5 Safety instructions governing specific operational phases 4
1.6 Transporting the slewing tower crane 6
1.7 Maintenance of the slewing tower crane 6
1.8 Warning of special dangers 7
1.9 Hydraulic and pneumatic equipment 8
1.10 Noise 8
1.11 Oil, grease and other chemical substances 8
1.12 Measuring system 9
2 Technical Data
2.1 General 2
2.1.1 Jib lengths & Tower 2
2.1.2 Crane components 3
2.1.3 Jib configurations 4
2.1.4 Counter jib ballast 4
2.1.5 Ballast weight 5,5 t - concrete 5
2.1.7 Ballast weight 6,0 t - steel 6
2.1.8 Rope dimensions and quality 7
2.1.9 Packing list - jib length 55,0m 8
2.2 Crane on foundation - Tower TH 15.3 9

2.2.1 Foundation Loadings Jib 30,0 - 40,0 m 9
2.2.3 Foundation plate 11
2.2.4 Foundation anchors for TH 15.3 - length 6,0m 12
2.2.5 Foundation anchors for TH 15.3s - length 12,0m 13
2.2.6 Earthing 14
2.2.7 Electric power supply 14
JTL208.12 Contents
3 General instructions for assembly
3.1 Introduction 2
3.2 Ground consistency 2
3.3 Crane installation area 2
3.4 More cranes on the site 3
3.5 Inspection of the building yard 4
3.6 General instruction for crane operator and assembly team 5
3.7 Prohibited crane moves 6
3.8 Assembly and disassembly advices 7
3.9 Safety precautions 7
3.10 Hand signals 8
3.11 Prevention signs 9
4 Assembly
4.1 General assembly information 3

4.1.1 Bolt connections on tower crane 3
4.1.2 Parts belonging to a bolt connection 4
4.1.3 Bolts 4
4.1.4 Nuts 4
4.1.5 Washers 5
4.1.6 Checking the different parts of bolt connections
prior to installation 5
4.1.7 Tensioning of bolt connections 6
4.1.8 Inspection of installed bolt connections 7
4.1.9 Table 1: Starting torques 9
4.1.10 Table 2: Wrench sizes 10
4.2 General data - weights and heights 11
4.3 Assembly of foundation anchor 12
4.4 Assembly of tower 12
4.5 Preassembly of slewing support 13
4.6 Preassembly of turntable and hoist winch 13
4.7 Connecting of hoist winch on turntable 14
4.8 Preassembly of CACON and hydr. pump 14
4.9 Connecting of CACON on turntable 15
4.10 Preassembly of tower top 15
4.11 Preassembly of tower top with cylinder 15
4.12 Preassembly of counter jib and ballast basket 16
4.12.1 Preassembly of Jib 01 17
4.13 Preassembly of base part 17
4.13.1 Preassembly of jib extensions 18
JTL208.12 Contents
4.14 Assembly of top crane 20
4.14.1 Lifting of turntable, slewing unit, hoist unit 20
4.14.2 Lifting of CACON, hydr. pump 20
4.14.3 Lifting of tower top, hydr. cylinder 20
4.14.4 Lifting of base part 21
4.15 Lifting of 6,0t counter weight block 21
4.16 Reeving of hoist rope 22
4.17 Lifting of jib extensions 22
4.18 Lifting of counter weight 23
4.19 Adjustment of safety devices 23
5 Safety devices
5.1 General 2
5.2 Position of safety devices 2
5.3 Automatically zero positioning 2
5.4 Dead-man switch 3
5.5 Audible warning signals 3
5.6 Hoist limit switch 3
5.7 Luffing control 4
5.8 Maximum load and load moment limiter 4
5.9 Rope retaining brackets 4
5.10 Load hook 4
5.11 Key switch operation / mounting 5
6 Crane operation
6.1 Prior to initial crane operation 3

6.2 Taking the crane into operation 3
6.3 Crane control desk 4
6.4 Control of hoist unit 5
6.5 Control of luffing system 6
6.6 Control of slewing unit 7
6.7 Instructions for crane operation 8
6.8 Taking the crane out of operation 9
6.9 Taking the crane out of operation when a gale is approaching 10
6.10 Changing of the hoist rope reeving from
4-fall rope to 2-fall operation 12
6.11 Changing of the hoist rope reeving from
2-fall to 4-fall rope operation 13
6.12 Electrical Adjustment 14
6.12.1 Starting the System 14
6.12.1.1 The different main screens 14
JTL208.12 Contents
6.12.2 The 0-point 15
6.12.3 Changing the wind speed unit 16
6.12.4 Changing the language 16
6.12.5 Info & error messages 16
6.12.6 Service info 18
6.12.6.1 Error list 19
6.12.6.2 Device info 19
6.12.6.3 Connection info 20
6.12.6.4 Check codes 20
6.13 Installing the System 21
6.13.1 Login 21
6.13.2 The install screen 22
6.13.3 Angle Parameter 23
6.13.4 Trolley Parameter 24
6.13.5 Speed Parameter 25
6.13.6 Luffer parameter 25
6.13.7 Hook parameter 26
6.13.8 Load parameter 27
6.13.9 Switching the modes (75% or 100%) 27
6.14 System settings 28
6.14.1 Clock settings 28
6.14.2 Screen settings 29
6.14.3 System password 31
6.14.4 Server address 31
6.14.5 Changing the password 32
6.14.6 Modules 32
6.15 Log files (optional module) 33
6.15.1 Log files features 33
6.15.2 Export 34
6.16 WAZ/ACS settings (optional module) 35
6.16.1 Crane dimensions 36
6.16.2 Safety distances 36
6.16.2.1 Learning 37
6.16.3 Slewing 38
6.16.4 Working area 39
6.16.4.1 Polygon settings 40
6.16.4.2 WAZ options 41
6.16.5 ACS settings 42
6.16.6 Export 43
JTL208.12 Contents
7 Maintenance
7.1 Lubrication - General 2

7.2 Oil change intervals 2
7.3 Position of lubrication points 3
7.4 Lubrication plan 4
7.5 Lubricants, operation liquid, quantity 5
7.6 Gear oil 6
7.7 Maintenance schedule 7
7.8 Motors and generators 8
7.9 Hoist gear 9
7.9.1 Slewing gear 9
7.10 Slipring 10
7.11 CACON – Cabin & Control house 10
7.12 Electrical cables 11
7.13 Contactor and switch contacts 11
7.14 Slewing ring 11
7.15 Shorter lubrication intervals 11
7.16 Steel structure 12
7.17 Inspection and maintenance of the painting 12
7.18 Supervision of forged load hooks as per DIN 15 401 13
7.19 Rope maintenance 14
7.20 Time for replacing wire ropes 16
7.21 Drawing-in wire ropes 17
8 Electrical equipment
8.1 Standards & Calculation 2

8.2 Electrical connection 29
8.3 Cross-section 29
8.4 F.I.-Protection switch with TT-Network 30
8.5 Wiring diagram 31
8.5.1. Feeding part 31
8.5.2. PLC overload 36
8.5.3. Hoist unit 45 KW FC 4-0-4 38
8.5.4. Luffing unit 18,5 KW FC 4-0-4 42
8.5.5. Slewing unit 2x50 Nm FC 4-0-4 46
8.5.6. Control panel 50
8.6 Control panel 51
8.7 Cable loop 55
8.8 Certificates 62
JTL208.12 Contents
1 Fundamental safety instructions
1.1 Warnings and symbols 2

1.2 Basic operation and designated use 2
1.3 Organizational measures 3
1.4 Selection and qualification of personnel - basic responsibilities 4
1.5 Safety instructions governing specific operational phases 4
1.6 Transporting the slewing tower crane 6
1.7 Maintenance of the slewing tower crane 6
1.8 Warning of special dangers 7
1.9 Hydraulic and pneumatic equipment 8
1.10 Noise 8
1.11 Oil, grease and other chemical substances 8
1.12 Measuring system 9
JTL208.12 Fundamental safety

1.1 Warnings and symbols
Do not operate the crane if the instructions and procedures outlined in the manual are not
clearly understood. Should there be any doubt, ask for the intervention of technical service.
JOST Cranes GmbH reserves the right to make changes to specifications or to modify the crane
at any time without prior notice.
The following signs and designations are used in the manual to designate instructions of
particular importance.
Danger - refers to orders and prohibitions designed to prevent injury or extensive

damage.
Forbidden - important note to prevent accidents or heavy material damages.
USE OF THE CRANE
JOST Cranes JTL models are tower cranes with upper slewing. They are devised only and
exclusively for lifting, level luffing and lowering loads as described and specified in this manual.
The use and configuration of the crane described in this manual are the only ones approved by
the manufacturer. The crane must only be used according to the instructions herein.
The intended uses of the crane can be assured only if its structural and mechanical
components are properly maintained and all systems are working well.
1.2 Basic operation and designated use

1.2.1 The slewing tower crane has been built in accordance with state-of-the-art standards
and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the
user or of third parties, or cause damage to the machine and to other material property.
1.2.2 The slewing tower crane must only be used in technically perfect condition in
accordance with its designated use and the instructions set out in the operating manual, and
only by safety-conscious persons who are fully aware of the risks involved in operation. Any
functional disorders, especially those affecting safety, should therefore be rectified
immediately.
1.2.3 The slewing tower crane is designed exclusively for the lifting and lowering and horizontal
transport of loads freely suspended from the load hook. The load may be picked up only from a
firm base.
Operating the machine within the limits of its designated use also involves observing the
instructions set out in the operating manual and complying with the inspection and
maintenance directives.

1.3 Organizational measures
1.3.1 The operating instructions must always be at hand at the place of use of the slewing
tower crane (in the tool compartment or tool-box provided for that purpose).
1.3.2 In addition to the operating instructions, observe and instruct the user in all other
generally applicable legal and other mandatory regulations relevant to accident prevention
and environmental protection.
These compulsory regulations may also deal with the handling of hazardous substances, issuing
and/or wearing of personal protective equipment, or traffic regulations.
1.3.3 The operating instructions must be supplemented by instructions covering the duties
involved in supervising and notifying special organizational features, such as job organization,
working sequences or the personnel entrusted with the work.
1.3.4 Personnel entrusted with work on the slewing tower crane must have read the operating
instructions and in particular the chapter on safety before beginning work. Reading the
instructions after work has begun is too late. This applies especially to persons working only
occasionally on the machine.
1.3.5 Check constantly that the personnel are carrying out the work in compliance with the
operating instructions and paying attention to risks and safety factors.
1.3.6 Observe all safety instructions and warnings attached to the slewing tower crane.
1.3.7 In the event of safety-relevant modifications to the slewing tower crane or changes in its
behaviour during operation, stop the slewing tower crane immediately and report the
malfunction to the competent authority/person.
1.3.8 Never make any modifications, additions or conversions, which might affect safety
without the approval of the supplier/manufacturer. This also applies to the installation and
adjustment of safety devices as well as to welding work on load-bearing elements.
1.3.9 Spare parts must comply with the technical requirements specified by the
supplier/manufacturer. Spare parts from original equipment manufacturers can be relied upon
to do so. The user must compare the data in the spare-parts catalogue prior to installation of a
spare part.
1.3.10 Replace hydraulic hoses and pneumatic lines within stipulated and appropriate intervals
even if no safety-relevant defects have been detected.
1.3.11 Prescribed intervals for routine checks and inspections must be adhered to operating
instructions.
1.3.12 For the execution of maintenance work, tools and workshop equipment adapted to the
task on hand are absolutely indispensable.

1.4 Selection and qualification of personnel - basic responsibilities
1.4.1 Any work on/with the slewing tower crane must be executed by reliable personnel only.
Statutory minimum age limits must be observed.
1.4.2 Employ only trained or instructed staff and set out clearly the individual responsibilities of
the personnel for operation, transport, assembly, inspection, maintenance, repair and
dismantling.
1.4.3 Make sure that only authorized personnel works on the slewing tower crane.
1.4.4 Define the crane operator's responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse instructions by third parties that are
contrary to safety.
1.4.5 Do not allow persons to be trained or instructed or persons taking part in a general
training course to work on or with the slewing tower crane without being permanently
supervised by an experienced person.
Product-relevant / Repetition essential as special safety warning/concrete safety warning.

Information for the user enterprise and its personnel authorized to give instructions for the
operating personnel.
1.4.6 Work on the electrical system and equipment of the slewing tower crane must be carried
out only by a skilled electrician or by instructed persons under the supervision and guidance of
a skilled electrician and in accordance with electrical engineering rules and regulations.
1.4.7 Work on mechanical components, such as gearboxes, chassis, braking and steering
systems, may be carried out by specially trained personnel only.
1.4.8 Work on hydraulic systems must be carried out only by personnel with special knowledge
and experience of hydraulic or pneumatic equipment.
1.5 Safety instructions governing specific operational phases

1.5.1 Operation
1.5.2 Observe the regulations applicable to the respective location.
1.5.3 Prior to starting work, get to know the on-site working environment. The working
environment includes, for example, obstructions in the working and driving range, the load
capacity of the soil and any barriers needed to separate the site from the area accessible to
the general public.
1.5.4 Take the necessary precautions to ensure that the slewing tower crane is used only
when in a safe and reliable state.
1.5.5 Before starting up or setting the slewing tower crane in motion, make sure that nobody is
at risk.

1.5.6 Operate the slewing tower crane only if all protective and safety-oriented devices, such
as removable safety devices, emergency shut-off equipment are in place and fully functional.
1.5.7 Never operate the crane in any way that might be prejudicial to safety.
1.5.8 During start up and shutdown procedures always watch the indicators in accordance
with the operating instructions.
1.5.9 The crane operator must always have a good view of the working range and the load. In
poor visibility or darkness, adequate lighting must be provided on the site.
1.5.10 Never work in any way that might prejudice the stability of the slewing tower crane. The
crane steering system must not be switched off when a load is suspended from the hook.
1.5.11 The fastening of loads and the instructing of crane operators should be entrusted to
experienced persons only. The marshal giving the instructions must be within sight or sound of
the operator.
1.5.12 Check the slewing tower crane at least once per working shift for obvious damage and
defects. Report any changes (incl. changes in working behaviour) to the competent
organization/person immediately. If necessary, stop the slewing tower crane immediately and
lock it. In the event of malfunctions, stop the slewing tower crane immediately and lock it.
1.5.13 Have any defects rectified immediately.
1.5.14 Always keep tools and loose objects in a safe place.
1.5.15 Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow
and ice.
1.5.16 Crane operation must be stopped whenever wind-forces are prejudicial to safety. The
maximum wind velocity at which the slewing tower crane may be operated is 20 m/s,
corresponding to wind-force 8. It should be borne in mind that gusts of wind may reach as
much as 20 m/s even with a moderate wind velocity of 12 to 13 m/s (wind-force 6).
1.5.17 When leaving the slewing tower crane, always secure it against inadvertent and
unauthorized use and ensure that it is left in the state specified in the operating instructions.
1.5.18 Any other or farther-reaching use, such as
- pulling away loads that are not standing free,

- horizontal movement of loads that are not freely suspended,
- increasing the load after it has already been lifted from the firm ground,
- swinging or vibrating the load,
- any loading beyond the authorized load rating,
- oblique pulling,
- carrying persons on the load or on the load-holding device
is not a designated use and is accordingly prohibited.

1.6 Transporting the slewing tower crane
1.6.1 Prior to transport, check that the transport devices (self-erecting crane), such as axles,
brakes, steering, signal and lighting systems, are in working order.
1.6.2 Prior to transporting the slewing tower crane, always check that the accessories are
safely stowed away and that all loose parts are fixed.
1.6.3 When driving on any public highways, tracks or places observe the valid regulations and
ensure in advance that the slewing tower crane complies with regulations authorizing the use of
vehicles for road traffic.
1.6.4 When driving through underpasses, bridges or tunnels or below overhead power lines,
always ensure that there is adequate clearance (headroom).
1.6.5 Never drive with the suspension mechanism transversely positioned. Always keep well
clear of building pits and slopes.
1.7 Maintenance of the slewing tower crane

1.7.1 Special work in conjunction with utilization of the slewing tower crane and maintenance
and repairs during operation; disposal of parts and consumables.
1.7.2 Observe the adjusting, maintenance and inspection activities and intervals set out in the
operating instructions, including information on the replacement of parts and equipment. These
activities may be executed by skilled personnel only.
1.7.3 Brief operating personnel before beginning special operations and maintenance work,
and appoint a person to supervise the activities.
1.7.4 In any work concerning the operation, conversion or adjustment of the slewing tower
crane and its safety-oriented devices or any work related to inspection, maintenance and
repair, always observe the start-up and shut-down procedures set out in the operating
instructions and the information on maintenance work.
1.7.5 Ensure that the maintenance area is adequately secured.
1.7.6 If the slewing tower crane is completely shut down for maintenance and repair work, it
must be secured against inadvertent starting by:
- locking the principal control elements and removing the ignition key and/or
- attaching a warning sign to the main switch.
1.7.8 For carrying out overhead assembly and maintenance work always use specially
designed or otherwise safety-oriented ladders and working platforms. Never use machine parts
as a climbing aid.
1.7.9 If safety devices have to be dismantled in assembly, maintenance or repair work they
must be reinstalled and checked immediately on conclusion of the work.

1.7.10 In order to avoid the risk of accidents, individual parts and large assemblies being moved
for replacement purposes should be carefully attached to lifting tackle and secured. Use only
suitable and technically perfect lifting gear and suspension systems with adequate lifting
capacity.
1.7.11 Never work or stand under suspended loads.
1.7.12 Always tighten any screwed connections that have been loosened during maintenance
and repair.
1.7.13 Before cleaning the slewing tower crane with water, steam jet (high-pressure cleaning)
or detergents, cover or tape up all openings which - for safety and functional reasons - must be
protected against water, steam or detergent penetration. Special care must be taken with
electric motors and switchgear cabinets, limit switches, ball bearings and slewing ring.
1.7.14 After cleaning, remove all covers and tapes applied for that purpose.
1.7.15 Rectify any defects immediately. Check that all safety devices are in working order.
Check that hydraulic and pneumatic lines are not leaking.
1.7.16 After cleaning, examine all electrical, hydraulic and pneumatic lines for chafe marks and
damage.
1.7.17 Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact.
1.8 Warning of special dangers

1.8.1 Electric energy
1.8.2 Use only original fuses with the specified current rating.
1.8.3 Keep an adequate distance from overhead power lines with the slewing tower crane.
When working close to overhead power lines, the slewing tower crane and its load must not
come close to the lines. Keep informed of prescribed safety clearances.
1.8.4 After contacting power lines:

- remain in the slewing tower crane,
- drive the slewing tower crane out of the danger zone,
- warn uninvolved persons not to come nearer or to touch the slewing tower crane,
- have the voltage switched off,
- never leave the slewing tower crane until the contacted/damaged line has been
switched off with absolute certainty.
1.8.5 Work on electrical systems or equipment may only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such an
electrician and in accordance with the applicable electrical engineering rules.
1.8.6 If provided for in the regulations, the power supply to parts of machines and plants, on
which maintenance work is to be carried out must be cut off.

1.8.7 Before starting work, check the de-energized parts for the presence of power and
ground or short-circuit them in addition to insulating adjacent live parts and elements.
1.8.8 The electrical equipment of a slewing tower crane is to be inspected at regular intervals.
Defects, such as loose connections or damaged cables, must be rectified immediately,
1.8.9 Necessary work on live parts and elements must be carried out only in the presence of a
second person - with whom constant visual and verbal contact must be ensured - who can cut
off the power supply in case of danger by actuating the emergency shut-off or main power
switch. Secure the working area with a red-and-white safety chain and a warning sign. Use
insulated tools only.
1.8.10 Before starting work on high-voltage assemblies and after cutting out the power supply,
the feeder cable must be grounded and components, such as capacitors, short-circuited with
a grounding rod.
1.9 Hydraulic and pneumatic equipment

1.9.1 Work on hydraulic and pneumatic equipment may be carried out only by persons with
special know-how and experience in hydraulic systems.
1.9.2 Check all lines, hoses and screwed connections regularly for leaks and obvious damage.
Repair damage immediately. Splashed oil may cause injury, environmental pollution and fire.
1.9.3 Depressurize all system sections and pressure pipes (hydraulic system, compressed- air
system) to be removed in accordance with the specific instructions for the unit concerned
before carrying out any repair work.
1.9.4 Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no
connections are interchanged. The fittings, lengths and quality of the hoses must comply with
the technical requirements.
1.10 Noise
1.10.1 During operation, all sound baffles on the slewing tower crane must be closed.
1.11 Oil, grease and other chemical substances

1.11.1 When handling oil, grease and other chemical substances, observe the product-related
safety and environmental protection regulations.
1.11.2 Be careful when handling hot consumables (risk of burning or scalding).

1.12 Measuring system
Please note: Signification of codes and signs
New valid units according to the "Sl-unit (structural analysis)
system". All data in SI-units are converted
and rounded-off values.
x = Direction of attack parallel to jib
Mass = kg, t Y = Direction of attack rectangular to jib
G = Dead weight
Force in N (Newton) P = Load
A = Starting force
Former unit kp; Mp; dyn M = Load moment
1 kp 10 N* = 1 daN W = Wind force
1 Mp 10 000 N* = 10 kN D = Pressure
1 dyn = 10-5 N Z = Pulling force
Torque in Nm (Newton meter)
Former unit kpm MX = Crane moment from G, P, M and W

1 Nm 0. 1 0 kpm* MY = Crane moment from G, P, M and W
1 kpm 10 Nm* = 1 daNm MT = Torsion moment from P, G and W
N = Vertical force from G and P
Energy, work in kWh (kilowatt-hours) S = Vertical force per corner strut
Q = Horizontal force from P, G and W
Former unit PSh (BHPh) HO = Top horizontal force
1 kpm 10 Nm* = 1 daNm HU = Bottom horizontal force
1 kWh = 1.36 PSh* (HPh) HM = Horizontal force per corner strut
from M
Power in kW (Kilowatt) HQ = Horizontal force per corner strut
from Q
Former unit BHP HMT = Horizontal force per corner strut
1 kW = 1.36 BHP from MT
1 BHP = 0.736 kW* H = Sum of all horizontal forces
E = Maximum strut force
Pressure in bar (Bar)
Former unit kp/cm2

1 bar ~ 1 kp/cm2
Speed in 1/min (rotations per minute)
Former unit rpm

1/min = 1 rpm
1 rpm = 1/min
Prefixes are placed without space in front of

the unit sign, for example: daNm.
Composite units are written, with
interspaces, f.inst.: - Nm -
* The conversation factors are rounded off according

to DIN 1333.
2 Technical Data
2.1 General 2
2.1.1 Jib lengths & Tower 2
2.1.2 Crane components 3
2.1.3 Jib configurations 4
2.1.4 Counter jib ballast 4
2.1.7 Ballast weight 6,0 t - steel 6
2.1.8 Rope dimensions and quality 7
2.1.9 Packing list - jib length 55,0m 8
2.2 Crane on foundation - Tower TH 15.3 9

2.2.3 Foundation plate 11
2.2.4 Foundation anchors for TH 15.3 - length 6,0m 12
2.2.5 Foundation anchors for TH 15.3s - length 12,0m 13
2.2.6 Earthing 14
2.2.7 Electric power supply 14
JTL208.12 Technical Data

2.1 General
2.1.1 Jib lengths & Tower

2.1.2 Crane components

2.1.3 Jib configurations
2.1.4 Counter jib ballast

2.1.5 Ballast weight 5,5 t - concrete
Weight tolerance ±1 %
2.1.6 Ballast weight 1,7 t - concrete


2.1.7 Ballast weight 6,0 t - steel

2.1.8 Rope dimensions and quality
Hoist rope 1
Rated diameter: 14 mm
Construction: nearly twistless, similar to DIN 3071 SE; Casar - Starlift
Surface of wires: bright (bk) or tinning (ZnK)
Rated strength of wires: 1960 N / mm²
Minimum breaking load: 197,2 kN
Type of lay and its direction: cross lay, right-handed (sZ) or

long-lay; right-handed (zZ)
Number of carried wires in
the out strand: min. 112
Finish of rope ends: both ends welded and pointed
Rope end fastening: - rope joint size Gr. 4 (Demag)
- rope wedge size Gr. 4 (Demag)
- wire rope clips DIN 1142 S 14
Lengths in m
Jib length m 30.0 35,0 40,0 45,0 50,0 55,0 Drum capacity
Hoist rope 1 37,0 32,0 47,0 52,0 57,0 62,0 560,0
1 for determination of total length of hoist rope add to dead length:

2-fall rope - add 2 times of hook height
4-fall rope - add 4 times of hook height

2.1.9 Packing list - jib length 55,0m
Piece Description L (m) B (m) H (m) Kg*
1 Jib section JTL 01 11,46 1,34 2,17 4110

1 Jib section JTL 02 11,89 1,10 1,89 2200
1 Jib section JTL 03 8,05 1,10 1,60 1160
1 Jib section JTL 04 5,21 1,10 1,56 640
1 Jib section JTL 05 5,20 1,10 1,55 500
1 Jib section JTL 06 5,18 1,10 1,31 380
1 Jib section JTL 07 5,15 1,10 1,27 350
1 Jib section JTL 08 5,13 1,10 1,26 280
1 Jib end 12,0t 1,86 1,18 2,35 235
1 Hook-block 12,0t 1,01 0,38 1,87 425
1 Counter jib + Platform 7,51 1,18 2,01 1710

1 Ballast Basket 1,80 2,81 1,98 730
1 Tower top 5,61 1,16 2,50 4120
1 Turntable + slewing unit 3,43 2,10 2,49 5370

1 Hoist unit + rope 1,73 1,71 1,17 1700
1 Platform with CACON + Hydr.pump 4,80 1,61 2,60 2000
1 Tower TH 15.3 6,00 1,70 1,74 3300
1 Counter weight 6,0t 1,74 0,65 0,80 6000

3 Counter weight 5,5t 1,74 0,80 1,65 5500
2 Counter weight 1,7t 1,74 0,50 0,80 1700
(*) Weight per piece

2.2 Crane on foundation - Tower TH 15.3
2.2.1 Foundation Loadings Jib 30,0 - 40,0 m

Tower TH 15.3
Tower Tower Foundation loading Foundation plate

height no. NC MC H l h P Ground
m A B kN kNm kN m m kN / m²
12,2 2 691,1 2703 31,8 6,4 1,60 118,92
18,2 3 616,8 2968 62,3 6,6 1,60 118,01
24,2 4 647,7 4250 88,0 7,4 1,60 117,81
30,2 5 678,7 4935 96,2 7,8 1,60 116,50
36,2 6 709,7 5710 104,3 8,1 1,60 119,19
42,2 7 740,7 6588 112,5 8,5 1,60 118,61
48,2 6 1 771,6 7587 120,7 8,9 1,60 118,54
A = Tower section - 6,0 m - weight 2,4 t - Bottom 2 bolts M 48
B = Tower section - 12,0 m - weight 4,8 t - Bottom 4 bolts M 48
Tower height = Found. anchor 0,2 + Tower section
These loadings are valid for free slewing crane out of service
Slewing Moment M S = 268 kNm
Calculation of the foundation plate: NT= NC+NF N F = L² * h * 24

MT = MC + H * h
First condition: Eccentricity e = MT / N T < L / 3 c=L/2-e
Second condition: Ground-pressure p= 2*NT /3*L*c
The admitted ground pressure must be checked by the customer.

Further information for tower erection see original operating manual from
tower manufacturer.

2.2.2 Foundation Loadings Jib 45,0 - 55,0 m
Tower TH 15.3
Tower Foundation loading Foundation plate

height Tower NC MC H l h P Ground
m A B kN kNm kN m m kN / m²
12,2 2 595,9 3020 63,3 6,6 1,60 119,11
18,2 3 626,9 3452 69,2 6,9 1,60 118,68
24,2 4 657,9 5065 97,6 7,8 1,60 118,68
30,2 5 688,8 5825 105,8 8,2 1,60 117,29
36,2 6 719,8 6683 113,9 8,5 1,60 119,93
42,2 5 1 750,8 7653 122,1 8,9 1,60 119,34
A = Tower section - 6,0 m - weight 2,4 t - Bottom 2 bolts M 48

B = Tower section - 12,0 m - weight 4,8 t - Bottom 4 bolts M 48
Tower height = Found. anchor 0,2 + Tower section
These loadings are valid for free slewing crane out of service
Slewing Moment M S = 268 kNm
Calculation of the foundation plate: NT= NC+NF N F = L² * h * 24

MT = MC + H * h
First condition: Eccentricity e = MT / N T < L / 3 c=L/2-e
Second condition: Ground-pressure p= 2*NT /3*L*c
The admitted ground pressure must be checked by the customer.

Further information for tower erection see original operating manual from
tower manufacturer.

2.2.3 Foundation plate
Tower TH 15.3
Anchor Anchor l total

Pos. d (mm) L1 (cm) L2 (cm) L3 (cm) l (cm) f.angle total (m)
1 28 20 176 8 400 12 48 192,0
2 28 20 143 8 334 12 48 160,0
3 28 20 109 8 266 12 48 128,0

2.2.4 Foundation anchors for TH 15.3 - length 6,0m

2.2.5 Foundation anchors for TH 15.3s - length 12,0m

2.2.6 Earthing
The user is responsible for the installation of the protective bonding system and must ensure that
the minimum requirements established by the standard are observed.
As for sizes, installation, test and maintenance of the protective earthing system against
atmospheric discharges, the laws and standards of the country, where the crane is assembled
are to attend.
2.2.7 Electric power supply
The electric equipment of the crane must always be connected to the bonding circuit.
The user must provide the necessary electrical supply and wiring/connections for the crane to
meet its electric energy needs, adhere to the specifications described herein, and conform to
standard electrical codes as well as conform to the norms for electrical installations in the place
and country where the crane in being installed.

3 General instructions for assembly
3.1 Introduction 2
3.2 Ground consistency 2
3.3 Crane installation area 2
3.4 More cranes on the site 3
3.5 Inspection of the building yard 4
3.6 General instruction for crane operator and assembly team 5
3.7 Prohibited crane moves 6
3.8 Assembly and disassembly advices 7
3.9 Safety precautions 7
3.10 Hand signals 8
3.11 Prevention signs 9
JTL208.12 General instructions

3.1 Introduction
The responsibility for the preparation of the crane building yard rests entirely with the crane user.
Any clearing, levelling, building up or reinforcing of the ground where the crane will be
positioned and operated will be carried out by him as well as the verification of feasibility of the
different crane installation proposed by the manufacturer.
3.2 Ground consistency
The primary requirements to be met on the building yard before the arrival of the crane are the
installation of the base platform or travelling rails, depending on the configuration chosen.
The installation of such elements depends particularly on the type of ground and foundation on
which these assemblies are to be placed, as well as on the configuration characteristics of the
crane.
The Buyer therefore must carry out a careful inspection and analysis of the ground consistency
on which the crane is to stand.
3.3 Crane installation area
When choosing the location for the crane at the building yard, the Client must be particularly
careful to ensure that the crane is not obstructed during its operational movements. Likewise he
has to verify that, when the crane is under no-working conditions, its free slewing doesn’t allow
coming in contact with existing buildings, buildings under construction, stored materials,
scaffolding, adjacent cranes, machines, installations, cables, trees, etc.
Nearby electrical lines must be at a minimum safety distance of 5 m from the slewing
unit of the crane.
In any case, the local electricity board must be contacted to verify the minimum safety
distance recommended from high intensity electrical power cables or transformers.

3.4 More cranes on the site
When two or more cranes are working at close range (inferior to the respective jib lengths sum)
in the same building yard can interfere each other. The following precautions must be taken:
Jibs must be offset to avoid collision of any structural parts considering the maximum
oscillation amplitude and a reasonable safety distance.
The minimum distance between the two cranes must anyhow be great enough to
prevent the cables and loads of the higher crane from interfering with the lower
crane.
In case of interfering cranes electrical or radar anti-collision devices can be installed

to limit the crane working range. Always consult the manufacturer for the installation
of this safety device, once ascertained it really serves the purpose.
Remember that cranes must be always staggered in height to avoid any interference when
under no-working conditions.

3.5 Inspection of the building yard
Before starting work, the supervisor of the crane assembly is obliged to inspect the building yard
and ensure that everything has been properly arranged.
The person in charge of the building yard shall be advised of any insufficiency so that the
problem can be resolved.
Assembly of the crane shall proceed only if the building yard conforms to the points listed
below.
Before the crane is installed, the supervisor shall check that:
a) the manoeuvring area of the crane is free of obstacles (trees, buildings, electric lines,
telephone lines, etc.);
b) the curing time of the foundation plate, base and ballasts is adequate;
c) the ballast and calibration weights correspond to the required specifications;
d) the travelling stop buffers are available and assembled when installing a travelling crane;
e) the electric connections are adequate;
f) mobile crane suitable for the work to be carried out;
g) the slinging devices (ropes, slings, chains), which are to be used for lifting the crane
components.
The supervisor must inform the mobile crane operator of the exact weight of the parts
that are to be hoisted.
The mobile crane operator is fully responsible for the slinging and hoisting of the loads.
The weights of the crane components see chapter 4 - Assembly.

3.6 General instruction for crane operator and assembly team
The crane must be used only by skilled crane operator with license.
The operator is authorized to carry out only those operations described herein below attaining
to the relative instructions.
As the crane can perform more than one movement at a time, it’s upon the operator to control
this simultaneousness according to the visibility of the suspended load.
The operator must be able to follow the trajectory of the moving load at any moment.
If not, he must take precautions; in particular, he must be assisted by other people who, with
verbal and / or hand signals, provide him with all the information necessary to work in safety.
For a correct use of the crane, the operator must observe the crane maintenance rules and
carry out periodical inspections of the whole system as described in chapter 7 - Maintenance.
The use of original spare parts or spare parts however recommended by the manufacturer
plays a prominent part in the correct use of the crane.
Any subsidiary material necessary to the building yard, such as buckets, belts, etc. and
belonging to the buyer must be suitable for the correct use of the crane and in conformity with
the territorial regulation in force.
- All national and local safety standards must be adhered to.
- May wind speed during the assembly – see chapter 4 – Assembly.

3.7 Prohibited crane moves

3.8 Assembly and disassembly advices
Assembly and disassembly of the crane must be done by skilled supervisor, who have attended
a specific training course.
Crane users are advised to contact (manufacturer or his agents) for qualified supervisor.
Should the user employ other supervisors, their ability should be verified before handling the
crane. In this case crane manufacturer declines any criminal and public liability.
For the crane assembly and disassembly at least three skilled technicians are
needed: Two in charge of the overhead assembly, one of the co-ordinations of the
operations on the ground.
3.9 Safety precautions
The supervisor must observe the following safety precautions before starting the assembly or
disassembly of the crane:
a) he must not operate with inclement weather conditions;
b) he must operate in perfect psychophysical conditions and he must check that the
individual and personal accident prevention devices are available and serviceable;
c) he must wear a safety helmet which is integral;
d) he must wear an approved safety belt which is in perfect condition;
e) he must wear accident-prevention shoes;
f) he must use tools equipped with electric insulation;
g) should the components pre-assembled on the ground be wet or damp, he must not
carry out the overhead assembly of the crane;
h) for the safety of people and things, the supervisor must be sure that barriers are
placed around the assembly and disassembly area and that there are no
unauthorized people allowed into the working area.

3.10 Hand signals
Supervisor must explain the hand signals to his technicians.
Danger Horizontal distance
Start Moving to the Left
Moving to the right

Stop
End Lifting
Vertical distance Lowering

3.11 Prevention signs
If it’s possible the supervisor shall post the mandatory and prohibitive signs when the crane is
present on the building site.
Caution: Suspended loads No passage
No passage or standing within

Safety helmet the crane’s radius of action.
Do not remove protective

Safety belt And safety devices
Use by unauthorized
Protective gloves Personnel forbidden
Protective shoes Do not work on moving parts

4 Assembly
4.1 General assembly information 3

4.1.1 Bolt connections on tower crane 3
4.1.2 Parts belonging to a bolt connection 4
4.1.3 Bolts 4
4.1.4 Nuts 4
4.1.5 Washers 5
4.1.6 Checking the different parts of bolt connections
prior to installation 5
4.1.7 Tensioning of bolt connections 6
4.1.8 Inspection of installed bolt connections 7
4.1.9 Table 1: Starting torques 9
4.1.10 Table 2: Wrench sizes 10
4.2 General data - weights and heights 11
4.3 Assembly of foundation anchors 12
4.4 Assembly of tower 12
4.5 Assembly of climbing cage 12
4.6 Preassembly of slewing support 13
4.7 Preassembly of turntable and hoist winch 13
4.8 Connecting of hoist winch on turntable 14
4.9 Preassembly of CACON and hydr. pump 14
4.10 Connecting of CACON on turntable 15
JTL208.12 Assembly
4.11 Preassembly of tower top with cylinder 15
4.12 Preassembly of counter jib and ballast basket 16
4.12.1 Preassembly of Jib 01 17
4.13 Preassembly of base part 17
4.13.1 Preassembly of jib extensions 18
4.14 Assembly of top crane 20
4.14.1 Lifting of turntable, slewing unit, hoist unit 20
4.14.2 Lifting of CACON, hydr. pump 20
4.14.3 Lifting of tower top, hydr. cylinder 20
4.14.4 Lifting of base part 21
4.15 Lifting of 6,0t counter weight block 21
4.16 Reeving of hoist rope 22
4.17 Lifting of jib extensions 22
4.18 Lifting of counter weight 23
4.19 Adjustment of safety devices 23
JTL208.12 Assembly
4.1 General assembly information
4.1.1 Bolt connections on tower crane
Particularly bolt connections with high-strength pretension. (HV bolt connections)
General information
There are numerous bolt connections on a tower crane. It is their task to connect crane
components and to transfer forces.
Particular attention must be paid to the bolt connections with high-strength pretension.
AII bolt connections belong to those parts of the tower crane which are highly important for the
operational safety of the crane. Consequently, all these bolt connections must be executed,
maintained and checked with the greatest of care.
Bolt connections which are tensioned manually with a wrench
Definition
Such bolt connections are connections which are tightened manually with a wrench.
They must be checked regularly in order to make sure they are tight and cannot loosen
unintentionally. If such a bolt connection Ioosens up, this may lead to accidents and damage,
e.g. if a part of this bolt connection falls down.
Bolt connections with high-strength pretension
Definition
A bolt connection with high-strength pretension is a bolt connection consisting of bolts, nuts,
washers and possibly also distance bushes, all parts of this connection being made of high-
strength material.
AII such bolt connections must be tensioned to their prescribed torque. In order to do this, a
torque spanner is required to accomplish said prescribed torque.
Places of application
Bolt connections with high-strength pretension are used anywhere where great forces must be
transferred from one crane component to another.
Speaking in terms of a tower crane, such components are:
• Slewing ring
• Tower sections
• Possibly also drive units Iike slewing units and hoist or Iuffing units erection
JTL208.12 Assembly
4.1.2 Parts belonging to a bolt connection
All parts of a bolt connection are marked separately. Regulations concerning quality and
identification are established by national and international standards.
4.1.3 Bolts
Bolts must be identified according to the international standard ISO 898 part.
Property class, e.g. 8.8, 10.9 or 12.9 must be stamped on the bolt head as indicated in
illustration:
Furthermore the bolts must be marked with a sign of origin of the bolt manufacturer. Normally
this sign is placed close to the property class stamp example given in illustration below:
4.1.4 Nuts
All nuts must be identified according to international standards ISO 898 part 2. Its property class
must be indicated either on the support surface or impressed in a key surface, e.g. 8, 10 or 12.
According to ISO 898 part 2 symbols are also permitted for identification of the property class of
nuts, however due to their multifariousness it is not possible to Iist them alI in this technical
description. Only nuts of the property class as stated in ilIustration below are permitted for use in
a high-strength bolt connection.
JTL208.12 Assembly
Furthermore the nuts must also be furnished with a sign of origin from the nut manufacturer.
Normally such identification is placed close to the identification of the property class.
When making your choice of nuts, please make sure their property class are in
conformity with the strength property class of the bolt.
Example: Nut 8 - bolt 8.8

Nut 10 - bolt 10.9
Nut 12 - bolt 12.9
4.1.5 Washers
Since there are no ISO standards for washers as yet, washers produced for high strength bolt
connections are identified with RV in Germany, as shown in illustration below.
Only washers made of high-strength material may be used for high-strength bolt
connections. Such material must be in accordance with the material listed in
paragraph "Bolts and nuts'. We recommend only using washers supplied by JOST
Cranes. If washers of other makes are used, please make sure that their property
class is in accordance with the property class of the mating bolts and nuts.
Washers for bolt connections must have one side chamfered in order to avoid any
damage of the filleting of the bolt head.
For this reason the chamfered must always point towards the bolt head.
Distance bushes
For some high-strength bolt connections distance bushes are required for constructional
reasons. These are part of manufacturer’s scope of delivery. They must be installed according
to the instructions in this operation manual.
4.1.6 Checking the different parts of bolt connections prior to installation
Condition of parts belonging to a bolt connection
All parts of a bolt connection must be cleaned and checked visually before they are fitted.
This visual check must comprise the threads of the bolt, the threads of the nut, the seat of the
nut on the bolt and the surface of the bolt shaft to the bolt head support.
JTL208.12 Assembly
Damaged bolts or nuts must never be used. Bolts with corrosion on shaft and in their
thread as well as rusty nuts must not be used. Damaged bolts or nuts or bolts and nuts
with only signs that they may be damaged must not be used.
Lubrication of the bolt connection elements
All bolts, nuts and washers must be lubricated with grease on a molybdenum disulphide basis
every time before they are fitted. This provides an even frictional resistance and this, in its turn,
guarantees a correct pretension of the bolt connection at any time.
Grease to be applied on the threads of bolts and nuts and the support surface of
the nut.
Note! If the prescribed starting torque is applied on the bolt head, please do not fail to
Iubricate also the support surface of the bolt head.
Reuse of parts of the bolt connections
All parts of the bolt connections which were tensioned to the torque prescribed by ourselves
may be reused when erecting the crane anew.
This is, however, on the condition that all parts are checked according to paragraph "Condition
of elements belonging to a bolt connection" and show no damage.
4.1.7 Tensioning of bolt connections
Correct tensioning is an absolute must
A bolt connection can only fulfil its task provided it has been pretensioned to correct torque.
The bolt is lengthened through the torque and the crane parts to be connected are pressed
together, thus accomplishing an intensive tension of these parts.
The working life of a bolt depends highly on whether the correct torque was applied and thus
the pretension achieved.
A torque which is too high or too Iow may lead to an early failure of the bolt connection.
The torque
In order to achieve the prescribed pretension, the bolt connection must be tightened using a
torque wrench.
The torque to be applied varies according to type and size of the bolts and nuts to be inserted
(table enclosed in this operation instruction). Please confer this table for correct torque for each
bolt used.
When conferring the a.m. table, please bear in mind that the quality classes as per ISO 898
part 1 and part 2 were used as basis.
JTL208.12 Assembly
The wrench size across flats “s” as per enclosed table can be used to determine whether you
have a bolt as per DIN 6914, DIN 931 or DIN 912.
Non-lubricated bolts must under no circumstances be used in high-strength

pretensioned bolt connections.
Torque wrench
The torque prescribed in each case can only be applied using a torque wrench. This torque
wrench must offer the possibility to set the torque as well as the tensioning direction.
If higher torques are required, multipliers must be used. Such multipliers are also called power
drivers.
With such multipliers torques up to 9 500 Nm (950 mkg) can be achieved.
These torque wrenches must be checked from time to time and adjusted if necessary.
The tensioning torques must never diverge by more than +/- 10%.
A further possibility is to apply required torque using a hydraulic torque wrench.
When using a hydraulic torque wrench the pressure within the hydraulic system is indicated in a
manometer. To a certain manometer pressure there is an appropriate torque. The relation
between manometer pressure and torque is to be found in the appropriate table which is part
of the information supplied for said hydraulic.
4.1.8 Inspection of installed bolt connections
The necessity to carry out inspections
Any bolt connection can loosen up.
This is also the case for HV-bolt collections. If these high-strength pretensioned bolt connections
loosen up, this may Iead to complete or partial Ioss of the pretension. lf the pretension gets
completely or partly Iost, this Ieads to a premature fatigue of the bolt material. This represents a
danger of a fatigue breakage of the bolt. Also the joint may get ajar and the connection
loosens up all together.
Initial and repeated inspections of installed bolt connections
Initial inspection
Due to settlements in the bolt connections of new cranes and new crane parts this initial
inspection of all bolt connections must be carried out 3 weeks upon completed first erection at
the Ieast. This inspection must be carried out using the same torque wrench or multiplier.
JTL208.12 Assembly
The nut (or bolt) is then retensioned with a rated moment according to table 1. If no further
tension of the bolts is possible, then it may be assured that the connection is ok. If it is possible to
retension the bolts, the connection must be loosened up completely; new lubrication must be
carried out. Then fasten the bolt connection anew and apply the appropriate torque.
Repeated inspections
Repeated inspections must be carried out each time the crane is erected anew and
furthermore at Ieast once a year. If the crane works with more than one shift a day, such
inspections must be carried out with shorter intervals, as appropriate. Such inspections are
carried out by loosening up the bolt collections at random, taking out and checking the
connecting bolt as specified in paragraph "Condition of the bolt connection elements". Upon
having done so, the bolt is relubricated, reinserted and tensioned to prescribed torque.
Visual inspections
Repeated inspections by visual check-ups must take place at least once every three months.
It is then sufficient to make sure no gaps have occurred between the tensioned parts, which
would mean that the bolt connections have loosened up.
Replacement of bolt connecting elements
If on any connecting level, which means anywhere where crane parts are connected to each
other (e.g. tower sections, roller bearing slewing ring) broken bolts or bolts with incipent
fractures are discovered, then all bolts on this connecting level must be replaced.
Regulations for prevention of accidents
Regular, scheduled inspections are prescribed in all regulations for prevention of accidents and
it is emphasized that the crane manufacturer's instructions must be strictly observed.
Such necessary, regular inspections were treated in the above paragraphs.
Bolt connections
For greased bolt connections with metrical ISO thread according DIN 13 or ISO 261 with or
without a galvanized coat the following starting torques are applicable:
JTL208.12 Assembly
4.1.9 Table 1: Starting torques
JTL208.12 Assembly
4.1.10 Table 2: Wrench sizes
Wrench sizes across flats “s”
Bolts as per DIN 6914 and their mating nuts according DIN 6915 have a bigger wrench size
across flats than bolts as per DIN 931 and their mating nuts according DIN 934.
The wrench sizes across flats "s" are listed in the table below:
JTL208.12 Assembly
4.2 General data - weights and heights
JTL208.12 Assembly
4.3 Assembly of
foundation anchors
The four foundation anchors
must be connected with tower
section or jig frame during the
installation into the foundation
plate.
When connecting the

foundation anchors, take care
of position of climbing plates on
tower - important for Climbing!
Max. height deviation of all

fixing plates is 1 mm.
4.4 Assembly of tower

- Install the tower section TH15.3
- Connect with bolts & nuts M60

Tighten with torque moment
4000 Nm.
- Install the erection platforms, if

no climbing cage is used.
4.5 Assembly of
climbing cage
- If the crane must climb, install
the telescopic cage over two
tower sections.
- For preassembly of telescopic

cage see chapter 9 - Climbing
JTL208.12 Assembly
4.6 Preassembly
of slewing
support
4.7 Preassembly
of turntable
and
hoist winch
JTL208.12 Assembly
4.8 Connecting
of hoist winch
on turntable
4.9 Preassembly
of CACON
and hydr.
pump
JTL208.12 Assembly
4.10 Connecting
of CACON
on turntable
4.11 Preassembly
of tower top
with cylinder
JTL208.12 Assembly
4.12 Preassembly of counter jib and ballast basket
JTL208.12 Assembly
4.12.1 Preassembly of Jib 01
4.13 Preassembly of base part
JTL208.12 Assembly
4.13.1 Preassembly of jib extensions
JTL208.12 Assembly
JTL208.12 Assembly
4.14 Assembly of
top crane
4.14.1 Lifting of
turntable,
slewing unit,
hoist unit
4.14.2 Lifting of
CACON,
hydr. pump
4.14.3 Lifting of
tower top,
hydr. cylinder
JTL208.12 Assembly
4.14.4 Lifting of base part
4.15 Lifting of 6,0t counter weight block
JTL208.12 Assembly
4.16 Reeving of hoist rope
4.17 Lifting of jib extensions
JTL208.12 Assembly
4.18 Lifting of counter weight
4.19 Adjustment of safety devices
JTL208.12 Assembly
5 Safety devices
5.1 General 2
5.2 Position of safety devices 2
5.3 Automatically zero positioning 2
5.4 Dead-man switch 3
5.5 Audible warning signals 3
5.6 Hoist limit switch 3
5.7 Luffing control 4
5.8 Maximum load and load moment limiter 4
5.9 Rope retaining brackets 4
5.10 Load hook 4
5.11 Key switch operation / mounting 5
JTL208.12 Safety devices

5.1 General
The JTL 208.12 is equipped with all safety devices prescribed on the delivery day. The purpose of
the safety devices is to prevent damage to the crane, caused by operation faults, which
endangers the life of all personnel on the building site.
During crane operation, the individual limit switches must not be contacted.
The response of the safety device is always an emergency stop. Only at the beginning of the
crane operation should the correct functioning of the limit switches be checked.
5.2 Position of safety devices
5.3 Automatically zero positioning

The push button "Crane on" is locked via zero contacts of the control lever. The main contactor
can only be switched on when all control levers are in zero position.
This ensures that no drive unit can be switched on unintentionally.

5.4 Dead-man switch
Both control levers in operator’s cabin are

spring loaded and will return to zero position
automatically. The right hand side control level
is equipped with dead-man switch. When
releasing the dead-man all crane functions will
stop. 1 A
2
5 Dead-man switch 10 11 12
5
5.5 Audible warning signals

From control stand in operators cabin a
warning horn can be activated via push
button.
For cranes on travelling bases a warning horn is

activated when crane is in motion.
A Control lever for travel unit and hoist unit

10 Emergency switch
11 Crane ON
12 Horn
5.6 Hoist limit switch

The top and bottom end position of the hook
block are limited by way of a limit switch.
This limit switch is activated from the hoist gear. 1
z When setting the cam disks, please do

not forget to include the deceleration
distance.
z The limit switches must be set in such a

way that they switch off in the bottom hook
position; two rope windings (safety windings)
must then remain on the hoist drum.
z For the movement in up direction, a

prelimit switch exists. The adjustment must be
done so that the hook slows down to step 1,
three meters before the maximum hook height 1 Hoist limit switch
is reached.

5.7 Luffing control
Luffing control is conducted automatically by software in operator´s cabin (CACON), when one
of the following jib positions is reached:
2° Luffing is shut off at bottom jib end position

10° Luffing speed is reduced
45° Slewing moment is being reduced
78° Luffing speed is reduced
84° Luffing is shut off at top jib end position
5.8 Maximum load and load moment limiter
5.9 Rope retaining brackets

All rope pulleys have rope retaining brackets, which prevent the rope from jumping out of the
rope pulley. The crane must not be operated without rope retaining brackets.
5.10 Load hook

In accordance with Accident Prevention Rules, load hooks are permitted on building sites only
when they have been furnished with a hook safety device. Therefore the load hooks have a
special safety flap, which must never be removed.
See also DIN 14505 (sheet 1) standards: Load hook for hoisting equipment – Supervision when
using forged load hooks.

5.11 Key switch operation / mounting
The key switch operation / mounting is positioned in the CACON near the transformer.
It is only permitted to switch the key switch from operation over to erection when erection and
maintenance work is being carried out and hoist rope reeving from 2-fall to 4-fall.
Upon having completed crane mounting or the necessary work, the key switch must
under all circumstances be switched back to “operation” position.
All security devices (load limiter, hoist limit switch, inclination sensor) are out of service, when the
key switch is switched to MOUNTING.
The electronic equipment for the load limiter is installed in the CACON. The signals from a load
measuring pin and an inclination sensor are processed in the electronics. The inclination sensor
is designed as redundant for safety reasons.
It is very important that the boom length set at the electronics corresponds to the
boom length actually mounted on the crane.
In case of erection modifications or change of boom length, the electronic must be adjusted
as per chapter - 6.12 Electrical Adjustment -.
All security devices (load limiter, hoist limit switch, inclination sensor) are out of
service, when the key switch is switched to MOUNTING.

6 Crane operation
6.1 Prior to initial crane operation 3

6.2 Taking the crane into operation 3
6.3 Crane control desk 4
6.4 Control of hoist unit 5
6.5 Control of luffing system 6
6.6 Control of slewing unit 7
6.7 Instructions for crane operation 8
6.8 Taking the crane out of operation 9
6.9 Taking the crane out of operation when a gale is approaching 10
6.10 Changing of the hoist rope reeving from 4-fall rope to 2-fall operation 12
6.11 Changing of the hoist rope reeving from 2-fall to 4-fall rope operation 13
6.12 Electrical Adjustment 14
6.12.1 Starting the System 14
6.12.1.1 The different main screens 14
6.12.2 The 0-point 15
6.12.3 Changing the wind speed unit 16
6.12.4 Changing the language 16
6.12.5 Info & error messages 16
6.12.6 Service info 18
6.12.6.1 Error list 19
6.12.6.2 Device info 19
6.12.6.3 Connection info 20
JTL208.12 Crane operation

6.12.6.4 Check codes 20
6.13 Installing the System 21

6.13.1 Login 21
6.13.2 The install screen 22
6.13.3 Angle Parameter 23
6.13.4 Trolley Parameter 24
6.13.5 Speed Parameter 25
6.13.6 Luffer parameter 25
6.13.7 Hook parameter 26
6.13.8 Load parameter 27
6.13.9 Switching the modes (75% or 100%) 27
6.14 System settings 28
6.14.1 Clock settings 28
6.14.2 Screen settings 29
6.14.3 System password 31
6.14.4 Server address 31
6.14.5 Changing the password 32
6.14.6 Modules 32
6.15 Log files (optional module) 33
6.15.1 Log files features 33
6.15.2 Export 34
6.16 WAZ/ACS settings (optional module) 35
6.16.1 Crane dimensions 36
6.16.2 Safety distances 36
6.16.2.1 Learning 37
6.16.3 Slewing 38
6.16.4 Working area 39
6.16.4.1 Polygon settings 40
6.16.4.2 WAZ options 41
6.16.5 ACS settings 42
6.16.6 Export 43

6.1 Prior to initial crane operation
• Check the crane track plant, track end buffers, crane travel safety limit switching and
the carting.
• Check that the crane can move and slew absolutely unhindered over the complete
height of the building and along the complete crane track. The power feeder cable
must unwind from the drum without any problems.
• Check the ballast.
• Check the oil level in the gears and make sure the crane is well lubricated.
• Observe the maintenance intervals as stated in paragraph “Crane Maintenance”.
• Check that the ropes are lying correctly inside the pulleys and make sure they are
undamaged. The rope running grooves inside the pulleys must be free of any hardened
grease, since in that case the rope would elevate and rub against the rope holding
bracket.
• Check all pin and bolt connections.
• Open the rail pinch bars.
• Activate the slewing brake.
6.2 Taking the crane into operation
• The crane main switch and the control levers on the control desk must all be in 0 position.
• Establish power connection.
• Turn on the main switch on the crane.
• Check all limit switches and overload safety devices.
• Make sure all brakes of the drives are in perfect working order.

Crane operation
6.3 Crane control desk
Crane operation takes place from the control desk inside the operator’s cabin. Before the
operation is started, the main switch, which is installed in the operator’s cabin, must be
switched ON and the slewing unit motors must be put back to operating position (neutralize
wind free position).
The crane switch (main contactor) is switched ON by pressing push-button CRANE ON (11); this
is indicated by way of the indicator light CRANE ON (11). It is only possible to switch on as long
as the two control levers are in zero position. These control levers are equipped with automatic
0-seatback.
The crane is switched OFF by pressing the “mushroom” type strike button EMERGENCY - OFF (10)
and must only be activated when the crane is at standstill or in a case of emergency in event
that a drive does not come to a standstill although it was switched to zero.
The dead-man’s button is installed in the control lever on the right side (A). This must be pressed
when any of the drives is running; otherwise the crane switch will switch off.
The signal horn can be worked from the push-button (12) HORN. Optionally the indicator lamp
of the HORN button can be installed and thus activated to indicate when the brake lining is
used up.
The windscreen wiper is switched on by the switch positioned on the left side of the control
lever.
A - control lever for hoist unit and crane travel unit

with bridged dead-man’s button
B - control lever for luffing unit and slewing unit with
push-button for slewing retaining brake
4 – Wiper switch
10 – mushroom type strike button EMERGENCY-OFF

11 – illuminated push button CRANE-ON
12 – push button horn with lamp for brake lining hoist

6.4 Control of hoist unit
The hoist unit is driven by an asynchronous motor with frequency inverter and is equipped with
a retainer brake. The control is accomplished over 4 switching steps in the lowering direction
and 4 switching steps in hoisting direction. Make sure you switch smoothly through these steps.
The motor is powered by the frequency inverter until the torque for holding of the load is
reached. Then the retainer brake opens up. When the brake is released the inverter applies the
according rotation frequency to the motor.
Within steps 1, 2 and 3 the speed is always constant independent of the load.
Step 4 is designed to automatically apply the speed according to the permissible load.
When step 4 is switched on the inverter increases the rotation frequency until the permissible
speed for max. load is reached. Then the inverter measures the actual load for a certain time
period. After having measured the actual load the inverter applies the speed according to the
corresponding load.
To stop the hoist unit again you have to conduct the above steps in reversed sequence.
Right side
Optional module: If the brake lining of the retainer
brake has become worn, the indicator lamp will light
up. If the brake lining is not changed, the succeeding
contact will switch off the steps 3 and 4 and it is then
only possible to drive in the steps 1 and 2.
When the control lever is returned from lowering or hoisting to zero position, Step 1 is
activated automatically for a short period. For the sake of saving the retainer brake,
the brake sets after the electrical braking of Step 1 has finished.
The top and bottom end position of the hook block is monitored by a gear limit switch with
cams. There is also a prelimit switch, which will switch off the movement a few meters below
max. lifting height in step 4 and 3. Then step 2 is the highest speed that the hoist movement will
have until the max. permissible lifting height is reached.

6.5 Control of luffing system
The luffing system consists of a hydraulic cylinder and hydraulic aggregate. The aggregate is
driven by an asynchronous motor with frequency inverter.
The luffing unit is operated by way of the left hand control lever (B) and in 4 steps for both
directions. Make sure you switch smoothly through these steps.
The hydraulic aggregate is powered by the frequency inverter with fixed speeds.
Within steps 1, 2, 3 and 4 the speed is always constant.
A change of direction is done by controlling the magnetic valve of the hydraulic aggregate.
To stop the luffing unit again you have to conduct the above steps in reversed sequence.
Each of the end positions and the prelimit position is controlled by the software-based PLC,
which will reduce the speed back to step 2 no matter what position the control lever is in. It is
however possible to run out of the end position quickly.
If the jib is driven outwards with load hanging in the Left side
hook, the load moment limiter will be activated as
soon as permissible. Then the load is either set down
or moved inwards again.
d – luffing forwards
e – luffing reverse
f – slewing brake

6.6 Control of slewing unit
The slewing unit is driven by a squirrel cage
Left side
motor with flanged-on eddy current brake.
The slewing unit may not be driven before free

positioning (wind) has been neutralized (see
chapter 5 - Safety devices), so that the
retaining brake works again and can brake.
The slewing movement is controlled in 3 steps

via the control lever (B).
Steps 1 and 2 should only be used for
positioning and corrections over short
distances.
f – Slewing brake
g – slewing left
h – slewing right
If the control lever is switched to zero, the slewing unit will stop slowly, being braked gently.
By switching the control lever in counter direction, the slewing unit can be braked over 3 steps.
The braking effect is increased from step 1 to step 2 and 3.
The crane operator must always take care that the braking action is gentle in order to avoid
any impacts and oscillating of the load.
If strong winds threaten to drift the jib away, the retaining brake can be activated by pushing
button in the left hand control lever. This is only permitted as long as the slewing unit is as good
as at standstill and the control lever is in zero position. When the slewing unit is started, the
retaining brake will open automatically.

6.7 Instructions for crane operation
Please always observe the regulations for prevention of accidents

(see chapter 5 - Safety devices).
Switch all drives smoothly and evenly, keep a distance from step to step.
Do not remain in the lower steps, since these steps are starting steps – not steps for
crane operation.
Important ! The following is forbidden:
1) Any pulling askew when lifting, travelling the crane or luffing and slewing.
2) To tear loose loads that are stuck.
3) Any transport of personnel.
Whenever the crane or any of its drives make any unintentional movements, the strike
button “EMERGENCY-OFF” (stop) must be activated immediately.
If the crane operator feels that the crane movement or load movement might lead
to danger, he must blow the horn by pushing the appropriate button.
In case of an approaching gale or thunderstorm the crane must be taken out of

operation and secured in due course.

6.8 Taking the crane out of
operation
1 Knurled nut
In compliance with the regulation for
prevention of accidents (VGB 9) the following
points are strict provisions, which must be
adhered to in all cases:
• Lift the jib in out of service position.

Slewing
• Pull up the empty hook block until it is motor
just short of the top end position.
• Place the jib in wind direction.
• Release the slewing brake, turn the

knurled nut (1) in clockwise direction
until it reaches its stop (this also applies
for work breaks). The jib must be able to
move like a weather vane in the wind.
• Put all control levers to zero position.
• Switch off the crane control by pressing the red “mushroom” type button on the control
desk before you leave the operator’s cabin.
• Illumination, heating and all connected electrical devices in operator’s cabin must be
switched off. Lock the operator’s scat in working position.
• Put the main switch within the switch cabinet in zero position.
• Check all ropes, provide for replacement if this is required

(refer to chapter 7 - Maintenance).
• Insert the track pinch bars and lock them.
• All failures and defects noticed during crane operation must be registered in the crane
log book and immediate action taken to remedy.
Furthermore, we recommend the following:
• Switch off the section switch on the mast foot or crane base (if installed).
• All bearing points on winches, running wheels, motors and gears should be checked for
any unusually high temperature.
• Make sure all gears are without any leaks.
• Switch off the power connection on the site power distributor.

6.9 Taking the crane out of operation when a gale is approaching
According to DIN 15019 - part 1, cranes must be taken out of operation when the wind speed
which corresponds to the total dynamic pressure as calculated from an average based on 10
seconds is exceeded.
The dynamic pressure which represents the top limit can only be considered to correspond to
the above calculated dynamic pressure provide the crane operation can be taken out of
operation within the shortest possible time and the required safety precautions can be carried
out.
When taking the crane out of operation, the following measures must be taken:
• All lifting elements (including ropes and chains) must be let down and the empty hook
pulled up.
• Lift the jib in out of service position.
• Slew the jib in wind direction (with the wind).
• Release the slewing brake and provide for free slewability of the crane, or observe
corresponding prescriptions.
• Insert all track plinch bars or secure the crane by way of other tying means.
Always follow the approach of local thunderstorms carefully.
The still prior to the first thunder squalls – these usually fall in with enormous wind forces – must be
used to put the crane to a favourable position, to take it out of operation and secure it well.
In case the careful weather observation as mentioned above is completed by installing wind
measuring devices, such devices should generally be installed at crane’s highest point and in
any case in such a manner that it will be exposed to the wind equally from all sides without any
shading effect.
Please observe that the requirements as to wind observation increase the further each out most
dynamic pressure for cranes in operation is reduced, compared to the nominal value of
calculated operational dynamic pressure.
The graphic bellow illustrates the relation between the top speed, which is decisive for when
the crane must be taken out of operation and the time required carrying out the safety
measures as per DIN 15019.
Thereafter the connection between the speed which is decisive for when the crane must be
taken out of operation and the required time for carrying out the safety measures is explained.

Calculated
Example:
t=3 min. time for completion of safety measures. The crane must be taken out of operation at a
wind speed of 64 km/h.
Explained in an easy manner, the

following connections can be
established: Relates to a dynamic pressure of 250 N/m²
If 2 min. are required to carry out

the safety measures, the crane
must be taken out o operation
already at a wind speed of
65 km/h.
If 6 min. are required to carry out

the safety measures, the crane
must be taken out o operation
already at a wind speed of
60 km/h.
If 12 min. are required to carry out the safety measures, the crane must be taken out of
operation already at a wind speed of 55 km/h.
Do not forget to secure the crane.

6.10 Changing of the hoist rope reeving
from 4-fall rope to 2-fall operation
The crane can work with 2 or 4-fall reeving.
To change the reeving, the jib must be put in 0 degree (horizontal) position. Then push
the accomplished button for 2 or 4-fall rope. Now you can change the hook blocks.
- loosen the hoist rope

- open the pin connection
- move both blocks between blocks 1 and 2
down to the ground - carefully lift block 2
- insert pin 3 into block 1

and secure it with clip 4
- pull up the upper block 2

- check to make sure the pulley
block 2 is sitting close to the
swing arm - lift block 1 with hoist rope
The crane now works with 2-fall rope. The max lifting capacity is 6.0 tons.

6.11 Changing of the hoist rope reeving
from 2-fall to 4-fall rope operation
To change the reeving, the jib must be put in 0 degree (horizontal) position.
- lower block 1and set it

to the ground - lower block 2
- take out pin 3

- carefully lower block 2
onto block 1
- connect blocks 1 and 2

with pin 3 and secure
with clip 4 - lift both blocks
The crane now works with 4-fall rope. The max lifting capacity is 12.0 tons.

6.12 Electrical Adjustment
6.12.1 Starting the System
When you are starting the system this

screen will appear. Click on “Operator
Screen” to get to the main screen.
The main screen will look different for each

crane type.
6.12.1.1 The different main screens
This is the default main screen of the JL and

JTL series.
This is the default main screen of the JT

series.

This is the main screen of the JL and JTL
series if the WAZ/ACS module is activated.
This is the main screen of the JT series if the

WAZ/ACS module is activated.
6.12.2 The 0-point
If you often need to drive to a certain point which height differs from "0" you can use the "Set 0"
button to set the hook height display to "0".
Drive to the new desired “0” point and click on the "Set 0" button. Now the display shows "0" for
the hook height at this new point.
Note: If the WAZ/ACS module is activated there is no "Set 0" button (see previous page).
Instead you can click on the value itself to set the new hook height.

6.12.3 Changing the wind speed unit
To change the unit of the wind speed just

click on the NTK logo on the main screen to
open the context menu. Now you can
choose your preferred unit from the
submenu.
There are 3 measures available:

• m/s [meter per second]
• km/h [kilometres per hour]
• mph [miles per hour]
6.12.4 Changing the language
To change the language (of the device)

you just have to click on the NTK logo on
the main screen to open the context menu.
Now you can choose your preferred
language from the submenu.
6.12.5 Info & error messages
During runtime the following messages could appear (not all at once):
WRONG CRANE TYPE !

The display settings do not fit to the PLC settings. Either of them is wrong.
Mounting Switch
As soon as the mounting switch is switched on, this message will be displayed on the main
screen.

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

If the luffer emergency brake was shut this message appears.
LF Emerg. Brake WORN OUT

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

If the hoisting emergency brake was shut this message appears.
HS Emerg. Brake WORN OUT

This shows that the hoisting emergency brake is worn out. That means that the brake shoes must
be replaced.
Restart PLC!
If this message appears you have to restart the PLC and configure the crane again.
Ch1, Ch2, Ch3, and/or Ch4

These are the same channel error messages which are also shown on the error list page.
Oil Temperature
This shows that the temperature of the oil is too high.
Oil Level Down

This shows that the oil level is quite low and should be refilled.
If the WAZ/ACS module is activated there

are some more messages possible.
C1 OFF, C2 OFF, C3 OFF

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

Connection Lost
Attention: When "Connection Lost" is displayed, it means there is/are no connection(s) to other
cranes.
System Offline
Attention: When "System Offline" is displayed, it means that the system no longer engages in
crane operation. Thus, there is no longer any automatic braking or blocking. The display
continues to work.
6.12.6 Service info
When problems arise it is sometimes necessary to convey some special error numbers or other
information to the support people.
To open the service info page you have to

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

6.12.6.1 Error list
Here you can see some different error

values. These can be important when
analyzing PLC problems.
6.12.6.2 Device info
This page shows some device specific info.
Crane Type: For what type of crane this

device is set up.
PLC Number: Which crane type the PLC is

set up for.
Display Serial: The unique serial number of

the device.
Display Address: The network address of

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

6.12.6.3 Connection info
Driver Status: This shows you the status

(OK/Error) of the communication driver.
- Serial: used for normal cranes
- TCP/IP: used for WAZ/ACS
Server Address: This is the address of the

WAZ/ACS PLC the device is connected to.
6.12.6.4 Check codes
These values can be helpful if there are

problems with passwords or serial numbers.

6.13 Installing the System
To install the system you first have to login

into the system.
Click on the NTK logo on the main page to

open the context menu and choose
"Configuration".
6.13.1 Login
Now enter your password and click on the

"Enter" button.
Note: The default password depends on the

crane series:
• JL series = “JL123”
• JTL series = "JTL123"
• JT series = "JT123"
(without quotes)
Now you have to confirm your password.

Enter the password and click on the "Enter"
button.
Note: Here you have to enter your

password backwards!
Examples for the default passwords:
• JL series = “321JL”
• JTL series = "321LTJ"
• JT series = "321TJ"
(without quotes)

6.13.2 The install screen
IMPORTANT:
1. The installation has to be made in 2-rope-modus!
2. All parameters must be adjusted!
3. The parameters must be adjusted in the given order!
This is the install screen of the JL series.
The install screen of the JTL series differs in

having a Luffer button instead of the Speed
button.
This is the install screen of the JT series.

6.13.3 Angle Parameter
(this applies only to the JL and JTL series)
IMPORTANT:
Before you begin with the calibration of the "Angle Parameter" you must move the jib to both
outside positions/angles (topmost/bottommost). Thereby the mechanical range of operation of
the sensor will be adjusted.
To adjust the "Angle Parameter" just click on

the according button.
At first you have to select the "Jib Length

Type" by clicking on the value and
choosing the correct value from the
context menu.
Now you have to adjust the angle position

indicator by the following steps:
1. Move the jib to the minimal (bottom) position/angle, click on the “Data set” value to
open the input box and enter the minimal (actual) position of the jib.
2. Click on the “Set” button for the “Data Min” value to set/save the minimal value.
3. Move the jib to the maximal (top) position/angle, click again on the “Data Set” value
and enter the maximal (actual) position of the jib.
4. Click on the “Set” button for the “Data Max” value to set/save the maximal value.
That’s all for the “Angle Parameter”.

6.13.4 Trolley Parameter
(this applies only to the JT series)
IMPORTANT:
Before you begin with the calibration of the "Trolley Parameter" you must move the trolley to
both outside points (innermost/outermost). Thereby the mechanical range of operation of the
sensor will be adjusted.
To adjust the "Trolley Parameter" just click on

At first you have to select the "Jib Length

Type" by clicking on the value and
choosing the correct value from the
context menu.
Now you have to adjust the trolley distance

1. Move the trolley to the minimal (nearby) position, click on the “Data set” value to open the
input box and enter the minimal (actual) position of the trolley.
3. Move the trolley to the maximal (distant) position, click again on the “Data Set” value and
enter the maximal (actual) position of the trolley.
That’s all for the “Trolley Parameter”.

6.13.5 Speed Parameter
(this applies only to the JL series)
To adjust the "Speed Parameter" just click

on the according button.
Now you can set up the speed values and

the HLW gain by clicking on the values.
Max Hoisting Speed:

This value is the limit of the hoisting speed.
Max Luffing Speed:

This value is the limit of the luffer speed.
HLW Gain:
This is the correction factor for the horizontal load way.
6.13.6 Luffer parameter

(this applies only to the JTL series)
To adjust the "Luffer Parameter" just click on

Now you can set up all the limit and prelimit

values by clicking on the values.

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

Now you have to adjust the hook height

1. Move the hook to the minimal position (topmost, shortest rope), click on the “Data set”
value to open the input box and enter the minimal (actual) position of the hook.
3. Move the hook to the maximal position (bottommost, longest rope), click again on the
“Data Set” value and enter the maximal (actual) position of the hook.
That’s all for the “Hook Parameter”.

6.13.8 Load parameter
To adjust the "Load Parameter" just click on

Now you have to adjust the load indicator

by the following steps:
1. Attach the first (lighter) calibration load to the hook, click on the “Calibration Load”
value to open the input box and enter the actual load value.
3. Attach the second (heavier) calibration load to the hook, click again on the „Calibration
Load " value and enter the actual load value.
That’s all for the “Load Parameter”.
6.13.9 Switching the modes (75% or 100%)
With the top right button on the main configuration screen you can switch the main mode of
the crane.
A click on it switches to 75% mode, the next click switches back to the 100% mode.
The text on this button always shows the actual mode.

6.14 System settings
A click on the "System" button switches to

the system settings (shown at the left).
6.14.1 Clock settings
To set up the clock/time just click on the

button "Clock Settings".
Now you can change the date and time

values and save them with a click on the
"Save Time" button.
Note: When this screen is opened it shows

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

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

"Screen Settings" button.
Now click on "Calibrate Screen" to open

the stylus properties.
In the stylus properties switch to the tab

"Calibration" (1), click on the "Recalibrate"
button (2), and follow the instructions given
on the screen.
When the recalibration is finished, move the

properties window to the left (3) until the
OK button is visible.
Now click the OK button (4).
Hint: The pictures shown at the left are from

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

Now you have to save the new calibration
settings.
First click on "Save Settings".
Now click on "OK" and wait some seconds.
After the dialog has disappeared the

settings are saved.

6.14.3 System password
In order to access some special manufacture settings you need a special password. For this you
have to call the support.
First you have to open the system password

screen. There you can see a character
string. Call the support and tell them this
string (note if uppercase/lowercase).
The support will tell you the password

belonging to the string.
At this point do not hit the back button

anymore.
Click on the "Login" button and enter the

password given by the support.
After clicking on "Enter" you have access to

the special settings.
6.14.4 Server address

This setting is available only if the WAZ
module is activated. The server address
setting is important for the communication
with the WAZ/ACS control unit.
First you have to enter the server address of

the WAZ/ACS control unit.
You can find this number on the type plate
inside the unit.
After this you have to "Restart the Project".

6.14.5 Changing the password
To change the login password just click on

the "Password" button.
First enter the old (current) password and

click on the "Enter" button.
Now enter the new password and click

again on the "Enter" button.
Then you should get a message that the

new password was saved.
6.14.6 Modules
Modules are optional features. They must

be purchased separately and then can be
activated within this screen.
To activate a module you have to click on

the "Activate" button, enter the purchased
code and click on the "Enter" button.
Hint: The ACS module needs the WAZ

module to be activated.

6.15 Log files (optional module)
"Log Files" is an optional feature.
If it is activated the button shown at the left

is visible.
This is the main screen of the log files.
Here you can look at the cycles (incl.

runtime), errors (history), and the loads/
load moments (history).
The single features are explained below.
6.15.1 Log files features
This screen shows the single movement

cycles of the jib/hook.
The runtime and the state (running/

stopped) of the crane are shown also.

This screen shows a table with the history of
error messages.
This screen shows a table with the history of

the loads and their load moments.
6.15.2 Export
With this option you can export all log file data to an USB memory stick. The exported files are
XML files, which can be viewed with the Internet Explorer.
To export the log file data you just have to

plug in the USB memory stick into USB port
and hit the "Export Data" button.
After some seconds you get a confirmation

message and then you can pull out the USB
memory stick.

6.16 WAZ/ACS settings (optional module)
"WAZ/ACS" are two optional features,

whereas the ACS module needs the WAZ
module to be activated.
If the WAZ module is activated the button

shown at the left is visible.
This is the main screen of the WAZ/ACS

settings. The single settings are explained
below.

6.16.1 Crane dimensions
To enter the crane data, push the

corresponding button to open the page for
crane dimensions.
Crane data can now be entered as follows:
(Clicking on a value will open an input field

by means of which the value can be
changed)
Crane Type: Depending on the sensor type, the system automatically detects whether it is
installed in a "topless" or "luffing" crane. The detected type is displayed for
controls (Topless/Luffing).
System: The WAZ system and/or the ACS System can be switched on and/or off.
A tick means that the corresponding system is activated.
Note: When one of the systems is deactivated, all pertinent settings will be
deleted!
Crane Height: The crane height must be entered here (relevant for trolley cranes;
the highest point must always be indicated).
Jib Length Type: The length of the (main) jib is concerned here.
Counter Jib: Enter the length of the counter jib.
6.16.2 Safety distances
Here you have to enter the prelimits of the

jib/luffer and the slewing.
With the line offset you can control the

thickness of the polygons. It is something
like a security area in front of the line.
The direction control indicator shows "Error"

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

6.16.2.1 Learning
The slewing speed values at the top

(current/ learned max.) are just check
values.
With the next 3 settings you have to teach

the system how long the crane needs to
brake.
The learning happens by the following 3 steps:
1. Angle 1 (Coasting):
Press the first "Set" button, rotate the crane with full speed, and release the joystick. Let the
crane ran out until standstill.
2. Angle 2 (Counter 1):
Press the second "Set" button, rotate the crane with full speed, and brake the crane with the first
counter step. Wait until standstill.
3. Angle 3 (Counter 2):
Press the third "Set" button, rotate the crane with full speed, and brake the crane with the
second counter step. Wait until standstill.

6.16.3 Slewing
The direction control indicator shows "Error"

if the crane moves to the wrong direction.
The anti-collision calculation requires a

common 0-point for all cranes in the
system.
Align the crane to a point which is valid for

all cranes and press the “Set 0” button to
save the 0-point.
If only the WAZ system is active, select any

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

6.16.4 Working area
These settings are only available if the WAZ System is switched on!
Use the corresponding button to open the

page for the work area.
Determine the work area which can be

composed of 3 polygons with 10, 8 and/or
6 lines.
Use the buttons P1 to P3 to switch among
the polygons.
The colour line to the left of the active P

button indicates the colour of the current
polygon. The lower right-hand area shows
the values for distance, slewing angle and
reach.
Use buttons T1 to T3 to switch to the tables

of the polygons 1 to 3.
Unused lines always have the values 0/0.
Use the button Opt. to go to the options.
Here, the point offset can be changed and

polygons activated, deactivated and
reset.
More about it later.

6.16.4.1 Polygon settings
Important: Outlines of blocked areas must

be retracted clockwise (seen from the
blocked area).
For illustration, the displays show the

corresponding numbers (red).
As an aid: Imagine yourself in the blocked

area, look towards the line, and start
counting from the left.
For closed areas, the starting point is not

important. But it is important to count from
left to right.
The individual lines are set as follows:
1. Use trolley and slewing to first approach the starting point of the line.
2. Use a Set/Store button (1a, 2a, 3a,...) to store the entered value.
3. Then, use trolley and slewing to approach the end point of the line.
4. Finally, use the corresponding second Set/Store button (1b, 2b, 3b,...) to store the value.
These 4 steps are to be taken for each line which is needed for the area.
Note: For closed surfaces/polygons, it is a good idea to set the very last point directly at the
beginning when setting the first point. Otherwise, it will be difficult in the end to precisely meet
the first point again.

6.16.4.2 WAZ options
As already mentioned above, the WAZ

options are set here.
Point Offset:
When setting up a polygon, the end points of the lines must always be one hundred percent
congruent. Since this is technically not possible, closely adjacent points are adjusted (equated).
The line offset is used to set up to which distances points will be adjusted.
Polygon 1-3 Checkboxes:
The checkboxes are used to activate/deactivate the individual polygons. A deactivated

polygon is still displayed, but will no longer be included in the distance calculation.
Polygon 1-3 Reset Buttons:
The reset buttons are used to completely delete the individual polygons.

6.16.5 ACS settings
These settings are only available if the Anti Collision System is activated!
Use the corresponding button to open the

page for the ACS settings.
For the own crane only the distance to the

(joint) zero point must be entered.
The next screen shows us the settings of a

partner crane. Up to 3 partner cranes can
be set up.
Use Set the (PLC) address of the ACS system

of crane 1.
Note: The PLC addresses are provided on

the type plates of the systems.
Then, enter the distance of own crane to

crane 1.
Now, orient your own jib exactly towards

crane 1 and press the "Set" button. This
stores the angle to crane 1.
The system is ready for use when all

necessary values among the cranes have
been stored.
To check it, look at the position of the

cranes in the "View" page.

6.16.6 Export
The export function provides the possibility

of storing all configuration values on a USB
memory stick.
Connect a standard USB memory stick to

the touch panel and press "Export Data".
After some seconds you will get a success

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

7 Maintenance
7.1 Lubrication - General 2

7.2 Oil change intervals 2
7.3 Position of lubrication points 3
7.4 Lubrication plan 4
7.5 Lubricants, operation liquid, quantity 5
7.6 Gear oil 6
7.7 Maintenance schedule 7
7.8 Motors and generators 8
7.9 Hoist gear 9
7.9.1 Slewing gear 9
7.10 Slipring 10
7.11 CACON – Cabin & Control house 10
7.12 Electrical cables 11
7.13 Contactor and switch contacts 11
7.14 Slewing ring 11
7.15 Shorter lubrication intervals 11
7.16 Steel structure 12
7.17 Inspection and maintenance of the painting 12
7.18 Supervision of forged load hooks as per DIN 15 401 13
7.19 Rope maintenance 14
7.20 Time for replacing wire ropes 16
7.21 Drawing-in wire ropes 17
JTL208.12 Maintenance
7.1 Lubrication - General
The symbols in the lubrication schedule significate the type of lubricant to be used and the
different lubrication points.
• Lubricate thoroughly and regularly, since lubrication carried out according to our
instructions helps to prevent failures and premature wear.
• Clean grease nipples before they are greased and oil drain plugs before they are
cleaned.
• Before each erection, all bolts must be coated with grease. The slewing ring, being
subject to the highest stress, has the shortest greasing interval and needs particularly
careful maintenance.
• Do not grease bearings excessively, since they will then overheat during operation.
• All bearings without grease nipples run without maintenance and are stripped, cleaned
and greased with a suitable lubricant as part of the bi-annual general overhaul.
• Ropes and chains as well as the slewing ring teeth must be treated regularly with acid
free grease.
• All guides on the overload safety device, gear support, brakes and rollers of the limit
switches must be kept smooth by coating them with light fluid lubricating oil.
• Connecting elements which were separated during repair works on the machined
surfaces must be treated with a suitable anti-corrosive before they are fitted again.
• The lubrication intervals stated in the lubrication schedule must be shortened as required
when the operational conditions are difficult, so that the crane plant is always in good
working order.
Any repair and maintenance work must only be carried out after the crane has been
taken out of operation.
7.2 Oil change intervals
Hoist gear Oil change every 2 years

Slewing gear
Luffing gear
Travel gear
Eldro Oil change every 15 months
Hydraulics Oil change every 1200 hours of operation, at least once a year
7.3 Position of lubrication points
7.4 Lubrication plan
No Lubrication positions Lubricants

(see lubricant recommendation)
1 Toothing at slewing ring S4
2 Wheel rims at the wheels S4

Adhesive
lubricant
3
4 Deflection link chain at joints S2

weekly
5 Slewing ring S2
7 Travel wheels S2
8 every 2 weeks Pivot at travel bogie S3
9
with
grease
10 Brake on hoist gear S3
nipples
every 6 weeks installed
11 Drive axle at slewing gear S2 Multipurpose
Drum and gear bearing grease
12 S2
pinion shaft travel unit
13 Roller bearings of gears S2
14
At least once a year
15
16
prior to each erection

17 Hinge eye of hydraulic cylinder S3
(with grease nipples installed)
18
19 Insert all pins freshly greased S2

Adh.
20 Grease all ropes S4
Lubricant
as required, prior to each Chain drives of limit switches

21
erection at hoist and luffing unit S5 Light
lubricating oil
Keep all joints and guides in
22 S5
running order
7.5 Lubricants, operation liquid, quantity
Construction pieces and lubricants must be harmonized. Only lubricants shown in the lubricant
recommendation for Jost cranes must be used.
Lubricants
Component Type Quantity (see lubricant
Litre recommendation)
EP –
Hydraulic unit LD30-250
160 B6* hydraulic oil
Luffing device 18,5kW
HLP 32
Hoist unit K 127 7
S1 EP – gear oil
Slewing unit OLS 3403 **
Exposed toothed wheels

Adhesive
of slewing connection, running wheel S4
Lubricant
drives and wire ropes.
Anti-friction and friction bearings of the

rope pulleys, running wheels, drum
bearings, chain drives, chain wheels,
slewing connection, slip ring transmitter, Multipurpose
S2
hook block, greases nipples at gears, grease
drive shaft axles,
motors and generators, general
lubrication points.
Friction bearings of the travel bogie,

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

S5
contacts. lubricating oil
The oil level must only be measured by standstill of the gear. The oil filling must be reached until
the upper marking at oil sight glass or oil overflow screw or until the upper marking at oil stick.
* In countries with tropical climate hydraulic oil ISO VG 68 must be used!

** These gearboxes are permanently greased – maintenance free.
7.6 Gear oil
Oil weight
Ambient Operation Operation between – 100C to + 500C Operation

Temperature under – 100C Industrial oil Car oil upper +
500C
(without AD*) (with (without (with AD*) (without (without
AD*) AD*) AD*) AD*)
Viscosity ISO ISO ISO SAE SAE ISO
according iso VG 68 VG 100 VG 150 30 80/90 VG 320
(SAE) (150)
No EP z
Balasia 68 Radula Blasia 150 Super Rotra Blasia 320
AGIP (-270C) 100 Diesel 80 W/90
15 W/40
BP Energol Energol Energol HD SAE 30 Gear oil Energol
GR XP THB 100 GR XP 150 EP SAE 80 GR XP 320
(+/-240C)
Cofran Mecanep 68 Cofraline Mecanep Equilux Cofrapoid Mecanep
GL Equitex 150 C200 80 W/90 320
100 super
ELF Reductelf SP Polytelis Reductelf Elan Tranself Reductelf
68 100 SP 150 SAE 30 EP 80 W/90 SP 320
(-210C)
ESSO Teresso EPV Spartan EP HDX 30 HDX 30/40 Spartan EP
32 150 320
MOBIL Mobil gear DTE extra Mobil Mobilibe Mobil Gear
626 (-240C) Heavy gear C 90 632
629
SHELL Omala 68 Tellus 100 Omala Dentax 80 Spirax Omala 320
(-240C) 150 EP 90
TOTAL Carter EP 68 Azolla Carter GTS GTS Carter EP

(-210C) 100 EP 150 15 W/40 15 W/40 320
z No EP : No high pressure oil; * AD : Recoil shutting
Never use high pressure oil in connection with “AD”
7.7 Maintenance schedule
Maintenance points Work

Hoist gear, slewing gear luffing and
travel gear
Hydraulics:
Daily Check oil level
Before every new climbing process
Pressure oil pumps
Brakes Check brake linings
All bolt connections to require
Check after erection
torque moment
After 100 hours
Climbing hydraulics oil filter Replace
Every 50 – 100
Breather filter on the gear Check
hours
All connection terminals in the Check for tight seat tighten
After 200 hours
control cabinet if necessary
Climbing hydraulics: Clean

Breather filter (at least once a year)
After 1000 hours
Check for tight seat and
All bolt connections tighten if necessary (at least
once a year)
Plungers and rollers of emergency
Every 6 weeks Clean and slightly grease
limit switches
Vent filter on gear Check for good working
Every 3 months Sliprings, collectors, brushes and
Clean
brush holders of the motor
Contact of relays and switches Check for consumption
Sliprings :
Clean
Running surface of sliprings
Every 6 months Slipring :
Oil lightly with acid-free oil
Pivot joints at brush holder levers
Check the outside and
Yearly Power cables
replace if necessary
Roller bearings of motors and Dismantle and check

After 2 years generator
General overhaul Roller bearings of eddy current Remove and check
brake
This must be done within a short period when the crane has first put in operation. It is necessary to tighten all bolts of
the slewing ring with a torque moment spanner. For correct fastening moment see chapter 4 - Assembly. If one of
the bolts is not exactly in order it has to be changed. After that check all slewing rings bolts and change them if
necessary.
7.8 Motors and generators
Maintenance work must only be carried out when the electric power is shut off.
z The motor and generator roller bearings are given grease fitting in the factory which
under normal working conditions will last for approx. 4500 operating hours. The
bearings should nevertheless be checked every two years. For this purpose the motor
must be dismantled, and the windings, housing and other parts should be cleaned at
the same time. Thoroughly wash the bearings with gasoline or benzene. After the
gasoline has evaporated, fill the bearings with roller bearing grease.
z To avoid overheating of the bearings due to overfilling, fill only the hollows between
the rollers and the roller paths half full with grease. Also coat the shaft passages in the
sealing covers with grease.
z Larger motors and generators have greasing nipples and greasing instructions on the
identification tag.
z The sliprings, collectors, carbon brushes and brush holders should be checked
regularly, at least once every 3 months, depending on frequency of operations.
Depending on dirt accumulation (carbon dust), cleaning is best carried out using a
suction method.
z Slight dirt on the contact surfaces should be removed with a non-fibrous wool cloth.
z No liquid cleaner must be used!
z Make sure that the slipring or collectors are smoothly polished and clean.
z The carbon brushes must have a little clearance and lie evenly with their entire
contact area and full spring tension on the sliprings or collectors, as appropriate.
z Worn brushes should be replaced by new ones which must be ground into the
appropriate rounding with emery cloth.
z Badly worn and grooved collectors and also brush burns are usually caused by poor
maintenance. In such cases a recognized specialist must be called in immediately.
z This also applies to cleaning procedures in case of very dirty engine interior.
For additional installation and maintenance informations see Appendix A.
7.9 Hoist gear
Oil checks and oil change:
All gears requiring oil lubrication are delivered without oil (new cranes); oil must be added.
Watch the indication on the housing. Relevant for the oil selection is the oil viscosity suggested
on the identification tag at the gearbox. This refers to normal operating conditions.
Hoist unit
1 Oil filling bolt

2 Oil drain bolt
3 Oil overflow bolt
z Fill in the gear oil through the filling hole until the oil emerges at the oil overflow opening
(if installed).
z Check the oil level when the gear is at standstill and the oil is cool.
z Fill in gear oil. For oil change intervals, see "Lubrication schedule", and Appendix B.
z Let out oil immediately after the gear comes to a standstill, so that the oil is still
operationally warm. For amount of oil filling, see "operating quantity".
z Before filling in new oil, clean gearbox thoroughly and oil drain plug amply.
z If possible, replace the seal ring at the oil drain plug.
Cleaning of breather filter:
Clean the breather at the gearboxes regularly.
z Screw off the breather, to clean, wash in gasoline and blow out with compressed air.
For additional information see Chapter 7.25
7.9.1 Slewing gear
These gearboxes are permanently greased – maintenance free.
7.10 Slipring
z The bearing requires no maintenance, nor is any greasing necessary.

z The carbon brushes have a relatively long working life due to the low rpm rate and
their hardness. A cheek of the carbon brushes should nevertheless take place once
every 6 months.
z The carbon brushes must in any case be replaced before metal pieces of the brush
holder or the fixing screws of the carbon brushes touch the sliprings. This must under
no circumstances occur. As part of this check-up it is also necessary to clean the
insulation between the sliprings from adherent carbon dust in order to avoid tracking
currents between the individual sliprings.
z Protect the slipring from humidity and other influences by moisture.
z If the slipring is equipped with nickel-plated copper-beryllium springs and nickel-
plated sliprings, these should be cleaned from adherent metal dust every 6 months.
z In order to reduce wear and tear, the sliprings should be sprayed lightly with contact
oil Cramolin "Protective".
7.11 CACON – Cabin & Control house
All connection terminals in the CACON and on the electrical devices must be tensioned as
described in the maintenance plan. Tension also terminals that are not connected, since
dangerous electrical disturbances may occur if contact bolts loosen up. All terminals must be
checked after they have been repositioned. Accumulated dust must be removed with
compressed air. Do not ever store any tools in the CACON.
Cable plugs
7.12 Electrical cables
All cables and lines must be checked as specified in chapter "Maintenance plan" to make sure
there is no consumption to be found.
Brittle cables and lines must be replaced by new ones. Be particularly conscious about the
feeder line.
7.13 Contactor and switch contacts
Check the contactor and switch contacts for consumption. The contacts have been furnished
with a coat of silver, they mate over a large surface without any pushing or sliding movement.
No lubrication , since oil or grease would stimulate the formation of sparks. Argentous oxide,
which is created through the formation of switch fire is fully electrically conducting as opposed
to what is the case with copper oxide. The Argentous oxide which is created must never be
removed. The contacts must bum in such a way that the whole contact surface is engaged in
the conduction of current.
Fouling and creation of craters cannot be avoided. Keep contact grease, files and emery
cloths away from the contacts. If ever unusual wear should occur (formation of pearls on the
contact surfaces), it is absolutely necessary to contact a specialist.
7.14 Slewing ring
Greasing of the slewing ring must only be done using a perfect non-acid and resin roller bearing
grease and according to the lubricant recommendation for JOST cranes. Press the roller
bearing grease into all grease nipples on the slewing ring using a crease press. Thereafter the
crane is slewed by approx. 15°, then press in roller bearing grease again. Repeat this process
four to five times until grease emerges over the entire circumference of the slewing ring, at the
bearing slit. This grease collar serves as a seal and must never be removed.
Greasing intervals: Confer lubrication plan and after every standstill of any length of time.
Whenever blank spots occur on the toothing of the slewing ring it becomes absolutely
necessary to re-grease.
7.15 Shorter lubrication intervals

In tropical areas, wherever the atmospheric humidity is high, where there is considerable
accumulation of dust and dirt, substantial differences in temperature and when the crane is
stewed continuously.
When cleaning the slewing ring, please take care that no water runs into the track. After
cleaning is completed the slewing ring must be greased thoroughly.
7.16 Steel structure
Bent parts, parts which are cracked or broken must be rectified or replaced immediately.
Leave it to the crane manufacturer to decide whether damaged parts as described above
can be repaired.
Repair weldings on load bearing parts must be carried out by the crane manufacturer.
Alternatively a welding specialist from the crane manufacturer or from the technical supervisory
authorities of your country must be called in for supervision before the work is started.
7.17 Inspection and maintenance of the painting

From time to time the painting should also be checked as part of the regulations for inspection
of the structural steel components to determine their constructional condition. Check whether
the priming is shining through, if the paint has become chunky or weather-beaten or if
formation of blisters, flaking, considerable chalking, rusty spots or subsurface corrosion has
occurred.
The occurrence of rust is to be determined as per DIN 53 210 "Paintings, determination of rust
grade". When maintaining and repairing the painting, please proceed as per DIN 55 928
paragraph 3 and 4.
7.18 Supervision of forged load hooks as per DIN 15 401
z For drop forged load hooks as per DIN 15 401 sheet 1 and 2 solely visual
checks and inspection of the hook mount is sufficient up to and
including hook group No. 5. Load hooks must be replaced as soon as
their mouth width has increased by more than 10% of max. permissible
width a2 (DIN 15 4301). The same applies when a possible deformation
exceeds 10% related to the original measure y.
z Further instructions for checks for cracks in the surface, wear and tear
and corrosion are given in DIN 15 405 paragraph 5.
z These checks for deformation and wear and tear, e.g. in the hook
mount and hook shaft as well as at the transition member must take
place as required, however at least once a year.
z Inspection of the transition

member as per DIN 685
checked round steel chain
item 5.2.1 paragraph b:
90
d1 + d 2
dm = > 0,9d k
2
12,0t
Chains which average thickness of member dm, calculated from the arithmetic average
between two diameters standing perpendicularly to each other within the same cross section
must be replaced as soon as their nominal thickness has been reduced by more than 10% in
any place.
Single members may be replaced. Chains of quenched and subsequently drawn steel must be
sent for repair to a factory which is authorized for the supply of such chains.
7.19 Rope maintenance
Correct application, assembly and care lengthen the life of wire ropes considerably. A rusty
rope endangers human life. Use rope greases according to the lubricant recommendations for
Jost cranes. Ropes with hemp cores must be greased only with liquid lubricants which creep
inside and are acid-free. This prevents the scouring of the hemp fibres by the steel wires and at
the same time keeps the hemp core soft and provides for rope flexibility.
Careful greasing of the ropes keeps out humility which leads to internal corrosion and growth of
bacteria in the hemp. Frequent and light greasing of the ropes gives better results than rare and
ample greasing.
As soon as the grease film disappears from some places on the rope, re-greasing becomes
necessary. A fixed interval cannot be stated, since in rainy periods more frequent greasing is
needed than in dry warm weather. Once a year the rope must be treated with penetrating oil,
this renders solidified and crusty greases useful again. Re-greasing must take place only when
the rope is completely dry, since otherwise any humidity that maybe present is enclosed in the
rope and internal corrosion is promoted. Re-grease with a brush when the drum stands still. The
rope taking up the drum curvature is slightly open and this facilitates the penetration of the
grease into the rope interior. If necessary, render the lubricant liquid by heating it.
Crude oil, petrol, paraffin, old oil or other not chemically neutral oil must under no
circumstances be used as lubricants.
If the crane is mainly operated in a narrow limited working radius range, an increased danger
of damaging the luffing rope in this range arises. Accumulated twist over a short stretch of rope
leads to danger of a reinforcement of the twist at the drum approach. This loosens the linkage
of the strands and leads to damage.
The service life of a rope which is under such a one-sided stress can only be lengthened when
occasionally the possibility to eliminate the twist is given. Therefore the crane should from time
to time be operated load free over the whole luffing travel range in order to eliminate the twist
in the luffing rope.
Provide for sufficient lubrication of the compensating pulley, the drum and the coiled up and
off rope portion.
If peculiarities occur in a rope, then type of lay, rope structure, rope diameter and
manufacturer must be determined. The hemp core of the rope contains a coloured thread. The
colour arrangement of this thread is the code of the manufacturer.
Example of serious bending of the cable.
Basket-slacking (nest) of a multi-strand cable

(twisting resistant type) caused by forced
rotation of the cable reeving through too
narrow races or an excessive deviation angle.
Increased diameter of a parallel winding cable

which is a result of distortion to the metal core
due to sudden stress.
Corrosion and signs of wear are often noted on
the external wires.
Individual wires bend up and protrude through

the strands: serious defect due to alternating
stress.
7.20 Time for replacing wire ropes
Safety in crane operation requires that the ropes are replaced in due time. Should the ropes be
used longer, the crane operation may become dangerous.
Regardless of the make or the number of single wires, all ropes must be discarded at:
1. Break of a strand
2. Reduction of cross-section by more than 10%
3. Rust with grain formation
4. Signs of internal corrosion
5. Contact with live power cables
6. Occurrence of squeezing, bulging, buckling and similar damage.
With breakage of single wires, the number of breakages occurred in the outer strands, related
to the rope length determines when the rope is to be replaced.
The following table gives an indication of the time for replacing DIN wire ropes. For specially
constructed wire ropes, observe the manufacturer's instructions.
Regular checks of the wire ropes are very important and increase the working safety.
Max. admissible number of wire breakages before the rope must be replaced:
Number of bearing wires in the - 51 76 101 121 141 161 181 201 221
outer strands of the rope
up to 50 75 100 120 140 160 180 200 220 240
Number of visible wire breakage
w ith cross-lay rope: 2 3 4 5 6 6 7 8 9 1

on a length of 6 x rope diameter
w ith cross-lay rope: 4 6 8 10 11 13 14 16 18 19

w ith long-lay ropes: 1 2 2 2 3 3 4 4 4 5

w ith lon-lay ropes: 2 3 4 5 6 6 7 8 9 10

Plaited ropes, on the other hand, must be discarded when there are 10 wire breaks per meter.
In case of doubt, consult DIN 15020 sheet 2 (edition of April 1974).
7.21 Drawing-in wire ropes
Putting on wire ropes is to be carried out with particular care only by trained personnel. Before
putting on wire it is to be checked if the data on the delivery slip corresponds with those in
chapter "rope dimensions". When putting on, all ropes are to be generously greased with rope
grease. This also applies to galvanized ropes, since the zinc coating does protect against
corrosion, but it does not reduce the internal friction.
The direction of lay of a rope must always be opposite to the pitch of the drum. If this
is not observed, you risk the formation of kinkings, rope baskets and/or other rope
deformations, making the rope ready for renewal.
The rope should not contact the ground; it must always be resting on a suitable supporting
means. If the rope has not been supplied on a drum, always use a reel for uncoiling. Draw-in the
rope only with the aid of a twist-free leading rope or using the discarded rope. Connect
leading rope and rope to be drawn-in a rope stocking.
If the old rope is used as a leading rope then connect both rope stockings with a 3 to 4 m long
hemp rope. That way any twist existing in the old rope is not transmitted via rope stocking to the
new rope. Remove the rope stocking when the rope has been pulled through to the winch.
Wind the new rope into the drum with pretension. Pull the rope between two wood blocks
clamped together; this is particularly important for multilayer operation. No slack rope must
accumulate on the drum.
When renewing the rope at the erected tower, fasten the rope at the fastening point but not
before it has been completely drawn in and coiled up on the drum.
Grease the new rope during reeving. Do not immediately load it to maximum; the rope must
lengthen gradually. The load twist is distributed by running over pulleys thus improving the
running in of the rope. Run new hoist ropes at first with a small load from the lowest to the
highest hook position. Subsequently load the rope in slow stages up to maximum load.
During multi-fall reeving of the hoist rope and load-free operation, watch the hook block
carefully. If, with cross-lay ropes, the hook block tends to turn in sense of the rope lay, then a
twist catcher should be attached which will absorb the twist during a few hoisting with the
empty hook. The twist catcher can then be removed again.
After installing the twist catcher, the rope must be regularly inspected for changes
(slackening of the outer layer).
8 Electrical equipment
8.1 Standards & Calculation 2
8.2 Electrical connection 29
8.3 Cross-section 29
8.4 F.I.-Protection switch with TT-Network 30
8.5 Wiring diagram 31
8.5.1. Feeding part 31
8.5.2. PLC overload 36
8.5.3. Hoist unit 45 KW FC 4-0-4 38
8.5.4. Luffing unit 18,5 KW FC 4-0-4 42
8.5.5. Slewing unit 2x50 Nm FC 4-0-4 46
8.5.6. Control panel 50
8.6 Control panel 51
8.7 Cable loop 55
8.8 Certificates 62
JTL208.12 Electrical equipment

8.1 Standards & Calculation

8.2 Electrical connection
The crane is equipped for connection to a three-phase supply 400 V/50 Hz and 480 V / 60 HZ
+/- 5%. The connection must be carried out by an electrician who must observe the protective
measure described below. The cross-section of the supply cable and the required fuses are
indicated under "Technical data".
Please note:
From 40 Electrical connection m on, the cable hanging freely in the tower should be secured
by a second cable grip, that is, without exceeding the free-hanging 40 m of cable.
If the second suspension is needed, then a loop is to he formed in the upper section of the line
in order to compensate the elongations and contractions of the rope due to weather
conditions.
The plugs of the electric cables have been disassembled, using f.inst. plastic bags and closed
with cable straps and insulating tape.
8.3 Cross-section
Cross-sections of supply cable on building site for 400 - 480 V three-phase current
Voltage drop 3,5 %, power drop cos 0,72

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

8.5 Wiring diagram
8.5.1. Feeding part

8.5.2. PLC overload

8.5.3. Hoist unit 45 KW FC 4-0-4

8.5.4. Luffing unit 18,5 KW FC 4-0-4

8.5.5. Slewing unit 2x50 Nm FC 4-0-4

8.5.6. Control panel

8.6 Control panel

8.7 Cable loop

8.8 Certificates
Page
Declaration Load pin (Velomat) 63
Certificate Frequency converter (CT) 64
Declaration of Conformity (CT) 65
Declaration Potentiometer (Altmann) 66
TÜV-Certificate PLC (ABB) 67
Testing-Certification BG 68
Certificate IQNet (TER) 69
CE-Declaration (TER) 70
Certificate KEMA (TER) 71


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OPERATING MANUAL

- Topless luffing crane JTL 208.12 -

1 Fundamental safety instructions

1.1 Warnings and symbols 2

2.2 Crane on foundation - Tower TH 15.3 9

4.1 General assembly information 3

6.1 Prior to initial crane operation 3

7.1 Lubrication - General 2

8.1 Standards & Calculation 2

1.1 Warnings and symbols 2

JTL208.12 Fundamental safety

Danger - refers to orders and prohibitions designed to prevent injury or extensive

Forbidden - important note to prevent accidents or heavy material damages.

USE OF THE CRANE

1.2 Basic operation and designated use

JTL208.12 Fundamental safety

JTL208.12 Fundamental safety

Product-relevant / Repetition essential as special safety warning/concrete safety warning.

1.5 Safety instructions governing specific operational phases

1.5.2 Observe the regulations applicable to the respective location.

JTL208.12 Fundamental safety

1.5.13 Have any defects rectified immediately.

1.5.14 Always keep tools and loose objects in a safe place.

1.5.18 Any other or farther-reaching use, such as

- pulling away loads that are not standing free,

is not a designated use and is accordingly prohibited.

JTL208.12 Fundamental safety

1.7 Maintenance of the slewing tower crane

1.7.5 Ensure that the maintenance area is adequately secured.

JTL208.12 Fundamental safety

1.7.11 Never work or stand under suspended loads.

1.8 Warning of special dangers

1.8.4 After contacting power lines:

JTL208.12 Fundamental safety

1.9 Hydraulic and pneumatic equipment

1.11 Oil, grease and other chemical substances

1.11.2 Be careful when handling hot consumables (risk of burning or scalding).

JTL208.12 Fundamental safety

Torque in Nm (Newton meter)

Former unit kpm MX = Crane moment from G, P, M and W

Former unit kp/cm2

Speed in 1/min (rotations per minute)

Former unit rpm

Prefixes are placed without space in front of

* The conversation factors are rounded off according

2.2 Crane on foundation - Tower TH 15.3 9

JTL208.12 Technical Data

2.1.1 Jib lengths & Tower

JTL208.12 Technical Data

JTL208.12 Technical Data

2.1.4 Counter jib ballast

JTL208.12 Technical Data

2.1.6 Ballast weight 1,7 t - concrete

JTL208.12 Technical Data

JTL208.12 Technical Data

Type of lay and its direction: cross lay, right-handed (sZ) or

1 for determination of total length of hoist rope add to dead length:

JTL208.12 Technical Data

Second condition: Ground-pressure p= 2NT /3L*c

Second condition: Ground-pressure p= 2NT /3L*c