Slewing Gantry Crane With Double-Link System: Operating Instruction

Hai An Operating instruction
24 2009 3543
24 2010 3544
Slewing gantry crane

with double-link system
20/40/45 t x 32/32/29 ... 8 m
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© Copyright by KIROW Ardelt AG 2010
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Table of contents
1. GENERAL ................................................................................................................................................... 4
1.1 INFORMATION ON THE OPERATION MANUAL .............................................................................................. 4
1.2 COPYRIGHT............................................................................................................................................ 6
1.3 FIELD OF UTILISATION AND PROPER USE .................................................................................................. 6
1.4 W ARRANTY ............................................................................................................................................ 7
1.5 SYMBOLS USED ...................................................................................................................................... 9
2. SAFETY CONCEPT .................................................................................................................................. 10
2.1 SAFETY SYSTEMS ................................................................................................................................. 10
2.2 EMERGENCY CUT-OUT FUNCTION .......................................................................................................... 12
2.3 TOTAL LIFE .......................................................................................................................................... 13
2.3.1 Classification of the crane ........................................................................................................... 13
2.3.2 Assessment and evaluation of the state of the crane ................................................................. 14
3. INFORMATION ON INDUSTRIAL SAFETY ............................................................................................. 15
3.1 GENERAL INFORMATION ........................................................................................................................ 15
3.2 SAFETY SYSTEMS ................................................................................................................................. 16
3.3 OPERATION AND HANDLING ................................................................................................................... 16
3.4 MECHANICAL PART ............................................................................................................................... 17
3.5 ELECTRICAL PART ................................................................................................................................ 17
4. TECHNICAL DATA ................................................................................................................................... 18
4.1 CHARACTERISTICS ............................................................................................................................... 18
4.2 OPERATING CONDITIONS....................................................................................................................... 19
4.3 MECHANICAL PART ............................................................................................................................... 20
4.3.1 Hoisting gear ............................................................................................................................... 21
4.3.2 Slewing gear ............................................................................................................................... 22
4.3.3 Luffing gear ................................................................................................................................. 23
4.3.4 Travelling gear ............................................................................................................................ 24
4.3.5 Ropes .......................................................................................................................................... 25
4.3.6 Load attachment ......................................................................................................................... 25
4.4 ELECTROTECHNICS/ELECTRONICS ........................................................................................................ 26
4.4.1 Nominal voltages ........................................................................................................................ 26
4.4.2 Energy balance ........................................................................................................................... 26
5. STRUCTURE AND FUNCTION ................................................................................................................ 27
5.1 MAIN COMPONENTS .............................................................................................................................. 28
5.2 GENERAL ............................................................................................................................................. 29
5.2.1 Design principle .......................................................................................................................... 29
5.2.2 Stairs concept ............................................................................................................................. 29
5.2.3 Mechanical parts ......................................................................................................................... 30
5.2.4 Electrical control .......................................................................................................................... 30
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5.3 POWER SUPPLY ................................................................................................................................... 31

5.3.1 Current flow Gantry ..................................................................................................................... 31
5.3.2 Current flow Crane ...................................................................................................................... 33
5.3.3 Crane switch ............................................................................................................................... 34
5.3.4 Motor protection and fuses ......................................................................................................... 34
5.3.5 Lighting........................................................................................................................................ 34
5.3.6 Heating, ventilation, sockets ....................................................................................................... 35
5.3.7 Measuring instruments, signalling system etc ............................................................................ 35
5.4 MECHANICAL SYSTEM OF THE DRIVES .................................................................................................... 36
5.4.1 Grab hoisting gear ...................................................................................................................... 36
5.4.2 Slewing gear ............................................................................................................................... 37
5.4.3 Luffing gear ................................................................................................................................. 37
5.4.4 Gantry travelling gear.................................................................................................................. 38
5.4.5 Rail tongs .................................................................................................................................... 39
5.4.6 Motor cable drum power supply .................................................................................................. 39
5.4.7 Motor cable drum spreader / motor grab ................................................................................. 39
6. ASSEMBLY AND FIRST PUTTING INTO OPERATION ......................................................................... 40
7. OPERATION AND HANDLING................................................................................................................. 41

7.1 OPERATING ELEMENTS CRANE CONTROL CHAIR ................................................................................... 41
7.2 PUTTING INTO OPERATION .................................................................................................................... 43
7.2.1 Switching in of the crane ............................................................................................................. 44
7.2.2 Functional test ............................................................................................................................. 45
7.3 CRANE OPERATION ............................................................................................................................... 47
7.3.1 Control of the hoisting gear ......................................................................................................... 48
7.3.2 Control of the slewing gear ......................................................................................................... 53
7.3.3 Control of the luffing gear ............................................................................................................ 53
7.3.4 Control of the gantry travelling gear ............................................................................................ 54
7.3.5 Rail tongs .................................................................................................................................... 54
7.3.6 Motor cable drum hook rotating device / spreader / motor grab ............................................... 55
7.3.7 Motor cable drum Power supply ................................................................................................. 55
7.3.9 Programmable Logic Control (SIMATIC-S7) ............................................................................... 57
7.4 SIGNAL DEVICES................................................................................................................................... 57
7.5 OPERATING INSTRUCTIONS FOR CLEAR TEXT DISPLAY TP177B .............................................................. 58
7.6 TAKING THE CRANE OUT OF SERVICE ..................................................................................................... 71
7.7 CHANGING BETWEEN GRAB AND PULLEY BLOCK ..................................................................................... 71
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1. General
The gantry slewing crane can be operated properly only if the operator is well
acquainted with the Technical Documentation.
Any person who is involved in commissioning, operating or maintaining the crane must
therefore have read and understood the complete documentation and especially the
chapter "Information on industrial safety" of the operation manual.
1.1 Information on the operation manual

This operation manual describes the structure and mode of working, the
commissioning as well as the operation and handling of the gantry slewing crane.
Necessary maintenance work is described in a separate maintenance manual.
Code of the crane:
TUKAN 1500 20/40/45 t x 32/32/29 ... 8 m
Gantry slewing crane with double-link system 20 t x 32 ... 8 m

40 t x 32 ... 8 m
45 t x 29 … 8 m
Abbreviations are used in the text. When they are used for the first time in a
chapter the abbreviated terms will be written in full. The corresponding
abbreviation will appear behind the term in brackets
Example: Operation manual (BA).
Pages, tables and figures are numbered consecutively.
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The text contains cross references which guide the reader to complementary or
more detailed information. Cross references to figures must be understood as
follows:
1/3
item number
current number of the figure
For safety relevant information the BA uses a special structure.
General safety information on dangers which occur in principal during the

operation of the gantry slewing crane are contained in chapter 3.
Special information on possible dangers which may occur during a certain activity or
sequence of activities are presented at the relevant place in the text.
This BA is not subject to the updating service. If the producer carries out
alterations of the crane in connection with technological progress the user will
be responsible for integrating the supplied additional or updated sheets into
this BA.
In case of disturbances of the operation of the gantry slewing crane please follow the
information under „09182 IS“ or contact our customer service department at the
following address.
Manufacturer's Address:
KIROW ARDELT AG
Niederlassung Eberswalde
Heegermühler Str. 64
D-16225 Eberswalde
Germany
Phone: 0049 / (0) 3334 / 62 0 (Zentrale)

Fax: 0049 / (0) 3334 / 62 2121
E-Mail: [email protected]
Website: www.ARDELT.de
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When contacting our service personnel please provide always the following information
which you find on the name plate of the crane:
Product: TUKAN 1500 20/40/45 t x 32/32/29 ... 8 m
Drawing No.: 09182
Order No.: 24 2009 3543

24 2010 3544
Code word: Hai An
1.2 Copyright
This BA is protected under copyright law.
It must not be neither partially nor in full be reproduced, multiplied, disseminated or

used by unauthorised persons for competitive purposes or divulged to others.
© All rights reserved.
1.3 Field of utilisation and proper use

The crane must be operated only as described in this operation manual.
The crane is designed for handling bulk-goods by means of a four-rope two-

blade bar grab, for the handling of general cargo by means of hook of the
spreader rotating device and for handling containers by means of a spreader.
Only load attachments mentioned in item 4.3.6 should be used.
The crane may be operated only, if technical and operational condition perfect. All
requirements and limit values given in the chapter "technical data" must be strictly
observed during the handling process. This applies in particular to the maximum
carrying capacities and radii.
Proper use also includes to observe the rules for the prevention of accidents.
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Any further use is not considered to be in line with the intended use. This includes for
instance the pushing or pulling of objects like vehicles, wagons and ships, the diagonal
pulling or breaking loose of cargo, the lowering of the load attachment into or onto
goods using a high speed, running into rigid walls or objects by means of parts of the
crane.
It is forbidden put the crane out of operation after the goods handling process is
finished without securing the crane against being driven off by wind.
Any transport of persons by the crane is strictly forbidden.
1.4 Warranty
The manufacturer guarantees that this BA has been produced in correspondence with
the technical and functional parameters of the supplied crane. The manufacturer
reserves to himself the right to add complementary information to this BA.
The manufacturer provides for the crane a warranty as stated in the contract.
The manufacturer warrants an undisturbed operation of the crane only if the
requirements of this BA are adhered to and if the crane is used exclusively for
the purpose it is intended for.
The manufacturer will not be liable for damage which results from misuse of the
crane or violation of the requirements and rules of behaviour contained in
this BA.
Warranty and liability claims against the manufacturer are excluded if the crane's
functional design has been altered without the written consent of the manufacturer.
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Warranty and liability claims for damage to persons and/or property are further
excluded if they can be traced back to one or several of the causes mentioned below:
• use of the crane for purposes for which it was not intended
• violation of the requirements of this BA and the maintenance manual with respect to
commissioning, operation, control and maintenance
• operation of the crane with disabled protection systems
• operation of the crane with a dynamic pressure of more than 250 N/m²
• removal of parts or installation of spare parts or additional parts which were not
supplied or approved by the manufacturer
• unauthorised adjustments of the safety systems
• unauthorised alterations of the PLC program and of the converter parameters
• inadequately made repairs
• foreign body impact in case of catastrophes or higher force
• wrong operation
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1.5 Symbols used
Symbol for an imminent danger
You will find this symbol in all instructions on the operating safety, if there is an
imminent danger for the life and health of persons.
Any disregard of those instructions may result in heavy or critical injuries with fatal
consequences.
Symbol for indirect danger
This symbol indicates situations of indirect danger.

Extent and intensity of the damages depend on the course of originated
events and the way of reaction of the effected persons.
Any disregard of those instructions may result in damages or destruction of crane

parts or the whole crane, of other material value or in minor injuries..
Symbol for proper handling and information
This symbol points out to the necessity of complying with guidelines and
rules as well as on the proper course of works to be executed.
Additional information is given to assist you in the

optimum use of all functions of the crane.
Any disregard of those instructions may result in damages or destruction of the

crane and/or other parts of the equipment.
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2. Safety concept
2.1 Safety systems
The gantry slewing crane has been developed, designed and manufactured in
correspondence with the regulation 2006/42/EG of the European Parliament and
Council - machinery directive - and other harmonised and national standards,
directives and technical specifications for hoisting equipment listed in the EU-
conformity declaration.
The safety systems have been produced in accordance with acknowledged technical
rules for safety equipment and represent the state of the art.
The technological and constructional safety concept of the crane is designed in

such a way that residual sources of hazards result in only little risks for
persons and objects due to the employment of efficient safety equipment.
When the crane is operated, all safety systems must be installed and must be
fully operational. Altering or removing safety equipment or manipulating signal
transmitters connected with safety equipment is not permitted.
Table 1 illustrates the safety equipment being effective on the crane.
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Table 1: Safety systems
Safety equipment Protective function
Emergency cut-outs Protection of persons and material values
Limit switches Stop of motions, when the end positions are reached,
protection of persons and material values
Centrifugal switch Stop of motions when exceeding the maximum speeds,

beginning of operation of the mechanical brakes, protection of
persons and material values
Centrifugal switch Stop of motions when exceeding the maximum speeds,

beginning of operation of the mechanical brakes, protection of
persons and material values
Non-operation heating Heating of the panels and motors to prevent damages by

condensation, even with switched-off crane disconnecting
switch, protection of material values
Load moment safety device Blocking of all risk-increasing movements in case of

with overload safety device exceeding the permissible loads during hoisting and luffing
out; protection of persons and material values
Temperature control of Protection against thermal overload, signalisation in case of

the driving motors too high temperature, protection of material values
Wind speed measurement Optical and audible warning signal, when the max.
permissible wind speed is exceeded, protection of persons
and material values
Fuses, circuit breakers Over current; short-circuit protection
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2.2 Emergency cut-out function

The emergency cut-out function is installed for cases of imminent
danger (risk to life and limb or damage to property).
Emergency cut-out buttons are installed at the following places of the crane:
• at the gantry, landside (=0+P-S01)

• at the gantry, waterside (=0+P-S02)
• at the panel +PE1 on the gantry (=0+PE1-S03)
• at the local control of the hoisting gear (=1+MT-S05)
• in the machinery house (=0+M-S06)
• at the panel +EE1 in the electrical container (=0+EE1-S07)
• in the gantry girder (=0+PR-S08)
• in the driver’s cabin (=0+KS-S09)
• at the luffing gear (=0+D-S012)
Upon actuation of any emergency cut-out button:
• all motors and motions of the crane will be switched off

• the brakes of the driving gears will act and the crane will be stopped in its present
position
• the control will be put out of operation
When the emergency cut-out is pressed, this is signalised by the signal light "Fault"
(=0+KS-H11) on the right board in the crane cabin.
Restarting the crane is permissible only after the source of danger has been removed
and after de-blocking the emergency cut-out button.
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2.3 Total life

2.3.1 Classification of the crane
- Steel structure acc. to FEM 1.001:

Grab operation 20 t A8, U7, Q3
General cargo operation up to 45 t A6, U6, Q2
- Driving gears acc. to FEM 1.001
Driving gear Driving gear Load collective Operation

group class class
Hoisting gear
Grab operation 20 t M8 L3 T7
General cargo / container

operation up to 40 t M6 L2 T6
General cargo / container

operation up to 45 t M5 L2 T5
Rope sheave like

system and hoisting
hinged points gear
Luffing gear
Grab operation 20 t M7 L3 T6
General cargo operation 45 t M6 L2 T6
Slewing gear and M7 L2 T7

roller bearing ring
Gantry travelling gear M5 L3 T4
By the classification of the crane, the load, strain and tension collectives of the
corresponding dimensioning rule are pre-set.
Dimensioning of the driving gears and components has been made acc. to the a.m.
classification.
A safe operation of the driving gears and components is guaranteed within the
foreseen total life.
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2.3.2 Assessment and evaluation of the state of the crane
During repeated checks one has to assess, whether the conditions of use indicated by
the manufacturer, correspond to the existing conditions and whether the useful life lies
within the indicated total useful life.
For this, the indicated maintenance and inspection measures should be observed.
If during the real work of the crane results a higher strain, Kirow Ardelt AG should be
asked, because in that case the useful time till a necessary general overhaul or till the
carrying out of special measures will reduce.
All driving mechanisms are equipped with operating hour counters, which can be
retrieved on the text display.
Recording of the actual operating hours of the hoisting gear

Switch cabinet +EE5 of the electrocontainer include a lifetime counter for the hoisting
and closing gear. The meter reading indicates the number of full load hours for which
the crane has been in operation so far. Thus it shows when the limit of the safe
operating period of the drive has been reached.
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3. Information on industrial safety

The following information on industrial safety provides general statements concerning
potential hazards which may occur during the operation of the crane. For this reason
they must be respected and the personnel of the contractor must always adhere to
them.
3.1 General information

• Any person who is involved in commissioning, operating or repairing the crane must
therefore have read and understood the complete documentation and especially the
chapter "Information on industrial safety" of the operation manual. We recommend
the contractor to have this confirmed in writing.
• The crane has been produced in line with the state of the art and the generally
acknowledged safety rules. However, inexpert handling or improper use may
generate hazards to health or life and/or lead to damages.
• Responsibilities of the personnel for commissioning, operating, maintaining and
repairing the crane must be defined clearly.
• The crane must be stopped immediately if the operating safety is impaired. Only
after the sources of the hazard or the shortcoming have been abolished and the
supervisor has agreed, the crane may be re-started.
• Personal protective equipment (helmet, gloves, etc.) must be worn when carrying
out repairs at the crane.
• Carrying out of certain work by the crane may require additional lighting of the
working area.
During operation, no person is allowed to stay outside the driver's cabin without
prior communication with the crane driver.
Any transport of persons with the crane is strictly forbidden.
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3.2 Safety systems
• Before the crane is started all safety systems must be installed, complete,
undamaged and fully functioning.
• The crane operator or the responsible technical personnel must check all safety
systems regularly for their safe functioning.
• In no way whatsoever, safety devices should be shunted, removed, rendered
ineffective or bypassed.
3.3 Operation and handling

• The contractor shall operate the crane only in a perfect technical and operational
condition, in conformity with the crane's purpose of operation and by qualified
personnel fully realising safety regulations and potential dangers.
• The crane should be operated by persons only, who have been instructed to
operate the crane, given proof of its qualification to do so and who, furthermore,
fulfil the legally necessary requirements.
• The crane driver is obliged to inform the responsible person, without any delay, on
changes on the crane affecting the safety.
• In case of any defect, which endangers the operational and labour safety, the crane
driver has to stop any operation immediately.
• The crane must not be operated if the dynamic wind pressure is higher than
250 N/m² or if wind speed is higher than 20 m/s.
• The crane must not be operated with more than the indicated maximum lifting
capacity.
• Leaving stropped loads in unattended suspension is not admissible.

• The crane driver must always observe the load and the working area upon all and
any movements.
• Movement shall begin only after the striker has left the dangerous area.
• The striker shall approach loads only from the side.
• If a striker is employed for assisting in crane operations, the crane driver shall carry
out crane motions only in accordance with the striker's signals. Clear and
unambiguous communication between the striker and the crane driver must be
guaranteed at any time.
• Persons must not stay within the slewing range of the crane and under
suspended loads.
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• Loads must not be moved over persons.

• During the operation of the crane all local accident prevention rules and safety
regulations must always be adhered to.
3.4 Mechanical part
Rotating parts are provided with safety devices preventing unintentional

touching. They must not be removed.
Arbitrary changing of the pre-set braking moments of the holding brakes is

forbidden.
Pay attention to any change of noise of the drives, and stop the crane, if necessary.
Further comments on the operating safety are included in the "Maintenance" and
"Repair" documentation and should be observed.
In order to increase the operating safety, a "Control plan for Operation" has been
made. The checks indicated there, have to be carried out and certified by a protocol.
3.5 Electrical part
Works on the electrical system may be carried out only by special personnel and
when the crane is tension-free. After finishing this work the protective measures
have to be checked for their effectiveness.
• The electrical houses should always be locked.

• The function of the existing circuits and PLC programs must not be altered.
• Damaged parts or lines have to be replaced immediately in a professional way.
Before beginning any work on motors, devices and electrical systems, but
especially before opening any covers of live parts, the crane must be
disconnected from the mains, as it is prescribed. Pay attention to the possible
existence of a special circuit.
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4. Technical data
4.1 Characteristics
Crane type ....................................... Double-link level luffing slewing crane (Tukan)
Designation of the crane ................. Gantry slewing crane with double-
........................................................ link level luffing system
Application of the crane ................... port crane
Carrying capacity/load
Grab operation ............................ 20 t x 32 ... 8 m
Motor grab operation .................. 25 t x 32 ... 8 m
General cargo operation ............ 40 t x 32 ... 8 m
General cargo operation ............ 45 t x 29 ... 8 m
Fabrication or Product No................ 24 2009 3543
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Crane No ........................................ 09182
Year of production .......................... 2010
Continuous noise level
in the crane cabin ............................ < 70 dB(A)
Dimensions
Gantry gauge ................................. 10.5 m
Wheel base .................................... 11.5 m
Distance of buffers ......................... ~ 17.3 m
Driver’s cabin – eye level
of crane driver ................................. ~ 21 m
Buffer height ................................... 250 mm
Crane rail ........................................ P 50
Power supply .................................. Cable via motor cable drum
........................................................ winding in one layer
Total weight of the crane ................. approx. 356 t
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Wheel loads jib position I (90° to the travelling direction)

max. live load acc. to
DIN 4212 ................................... 200.9 kN
min. live load acc. to
DIN 4212 ................................... 83.8 kN
Wheel loads jib position II (jib above corner B)
max. live load acc. to

DIN 4212 ................................... 220.0 kN
min. live load acc. to
DIN 4212 ................................... 64.7 kN
max. horizontal force onto one rail

out of operation in travelling direction 182.8 kN
out of operation transverse to the travelling direction 187.7 kN
Total height of the crane
(in luffed-in condition) ..................... approx. 48m
4.2 Operating conditions

Ambient temperatures .................... max. +45°C
min. 0°C
Wind load:
Warning at.................................. > 180 N/m² = 18 m/s
permissible wind pressure:
in operation ............................... < 250 N/m² = 20 m/s
out of operation .......................... 1300 N/m² = 46 m/s
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4.3 Mechanical part

Hoisting height above top
of rail .............................................. 18.0 m (grab)
25.0 m (centre of bottom block for load hook)
Lowering depth below top
of rail .............................................. 12.0 m (opened grab)
12.0 m (centre of bottom block for load hook)
Working speeds (±5%)
Hoisting
Grab operation
empty grab ................................. v = 55.0 m/min
20.0 t ......................................... v = 45.0 m/min
General cargo operation
10.0 t ......................................... v = 55.0 m/min
25.0 t ......................................... v = 40.0 m/min
................................................... (motor grab operation)
32.0 t ......................................... v = 32.0 m/min
45.0 t ......................................... v = 25.0 m/min
Slewing
< 20 t ......................................... v = 1.5 r.p.m.
< 25 t ......................................... v = 1.2 r.p.m.
> 25 t ......................................... v = 1.0 r.p.m.
Luffing
< 20 t ......................................... v = 60 m/min
> 20 t ......................................... v = 40 m/min
Travelling ....................................... v = 32.0 m/min
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4.3.1 Hoisting gear

Motors
Quantity ..................................... 2
Type .......................................... 1LG4 313-4AA60-Z
Manufacturer ............................. M/s. Siemens
Gearing
Type .......................................... planetary gearing ZHP 4.31
Manufacturer ............................. M/s. Zollern
Ratio i ........................................ i1 = 112
Brake
Quantity ..................................... 2
Type ........................................... disk brake RST 2-500 x 30 – 121/6
Braking moment ........................ 2400 Nm
Friction value .............................. 0.40
Manufacturer ............................. M/s. SHB
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4.3.2 Slewing gear
Motors
Quantity ...................................... 2
Type .......................................... 1LG4 253-4AA61-Z
Gearing
Type .......................................... slewing gearing ZHP 3.29
Manufacturer ............................. M/s. Zollern
Ratio i ........................................ 148
Number of teeth of output pinion 15
Roller bearing ring

Type .......................................... 192.45.3020.101.41.1501
Manufacturer ............................. M/s. Hoesch Rothe Erde
Number of teeth ........................ 134
Brakes
Type .......................................... drum brake
EBE 315-50/6S EBE 315-50/6
Braking moment ........................ 500 Nm 500 Nm
Friction value ............................. 0.4 0.4
Lowering time of brake lifter ....... 3.0 s -
Manufacturer ............................. M/s. SHB M/s. SHB
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4.3.3 Luffing gear

Motors
Quantity ...................................... 1
Type .......................................... 1LG4 253-4AA60-Z
Gearing
Type .......................................... spur gear K4KM11-H-160
Manufacturer ............................. M/s. Flender
Ratio i ........................................ 160
Brakes
Type .......................................... drum brake
................................................... RT 315 –50/6S RT 315-50/6
Braking moment ........................ 700 Nm 700Nm
Friction value ............................. 0.4 0.4
Lowering time brake motor ......... 1.5s -
Manufacturer ............................. M/s. SHB
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4.3.4 Travelling gear

Drive:
Quantity ...................................... 8
Type .......................................... bevel gear motor
................................................... KAD108-LA132M4W-L150/125MHA
Manufacturer ............................. M/s. Flender
Gear ratio .................................. i = 44.44
Braking moment ........................ 125 Nm
Travelling wheels
Quantity ..................................... 28
Diameter .................................... 500 mm
Rail tongs
Quantity ..................................... 2
Type: .......................................... hydraul. rail tongs CTHV-LH-150-045-LE06
Manufacturer ............................. M/s. Hillmar Industrie Ltd.
Holding force per unit ................. 150 kN
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4.3.5 Ropes
Hoisting gear
2 pcs. wire rope Q810V-32-1960sZ-bk

L1 = 100 m, poured at one rope end with a NEMAG rope socket, size 10
M./s. Teufelberger
2 pcs. wire rope Q810V-32-1960zS-bk

L1 = 100 m, poured at one rope end with a NEMAG rope socket, size 10
M./s. Teufelberger
4.3.6 Load attachment
- four-rope two-blade bar grab for a crane capacity of 20.0 t (not on scope of delivery)
- spreader rotating device

with double hook No. 25 DIN 15402
carrying capacity 45 t
(suitable for reception of a spreader or motor grab)
- motor grab for crane carrying capacity 25,0 t (not on scope of delivery)
- telescopic spreader type VATCII-G (not on scope of delivery)

M/s. Smits
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4.4 Electrotechnics/Electronics
4.4.1 Nominal voltages
Power supply ................................. 380 V, 50 Hz
Motors of driving gears .................. 380 V, 50 Hz
Brake lifters .................................... 380 V, 50 Hz
Control voltage ............................... 220 V, 50 Hz
Simatic ........................................... 24 V DC
Lighting .......................................... 220 V, 50 Hz
Heating/ventilation of cabin ............ 220 V, 50 Hz
Small voltage for signal lamps ....... 24 V DC
Non-operation heating
panels ....................................... 220 V, 50 Hz
driving gear motors .................... 220 V, 50 Hz
Windscreen wiping and
-washing system ............................ 24 V DC
Slack-rope switching-off ................. 24 V, 50 Hz
4.4.2 Energy balance

Installed capacity ............................. 450 kW
Mean current ................................... 660 A, duty factor 60 %
Peak current ................................... approx. 730 A
Main drives
hoisting, slewing, luffing and travelling gear three phase motors
Drive power
Hoisting gear ............................. 2 * 105 kW, duty factor 60 %
Slewing gear ............................. 2 * 45 kW, duty factor 60 %
Luffing gear ............................... 1 * 50 kW, duty factor 60 %
Travelling gear .......................... 8 * 7.5 kW, duty factor 40%
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5. Structure and function
10 15 9
16
11
14 3
8 12
13 1
2
5
6
Figure 1
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5.1 Main components

The crane consists of a fixed and a slewable crane part with the following main
components:
Description of figure 1:
fixed crane part:
4 Gantry travelling gear with electrical 6 Gantry with stairs and landings
hydraulic rail tongs
5 Cable drum arrangement 7 Column with stairs and landings
Slewable crane part:
1 Hoisting gear (in pos. 12) 11 A-structure with stairs and landings
2 Slewing gear with roller bearing- 12 Machinery house with electrical
slewing ring (RDV) container
3 Luffing gear 13 Driver’s cabin
8 Jib boom 14 Rope sheave system and hinged
points
9 Tie back 15 Motor cable drum
10 Jib 16 Movable counterweight
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5.2 General
5.2.1 Design principle
The crane is electrically driven and travelling on rails by means of the gantry travelling
gear (4).
Slewing of the slewable crane part is effected by the slewing gears (2) connected to
the machinery house platform by the roller-bearing slewing ring with internal toothing.
Shifting of the jib is made by a toothed rack luffing gear (3).
The current supply to the slewable crane part is made via a slip ring body between the
machinery house platform (12) and column (7).
The machinery house platform is connected to the column and guyed in the range of
the rear radius. The hoisting gear (1) and the slewing gear (2) are arranged in the
machinery house under the roof. A repair hoist is provided in the machinery house
under roof for carrying out maintenance and repair hoist. In the range of the rear
radius, there is a counterweight box.
The supporting structure (11) as well as the lower hinge of the jib boom are connected
to the front range of the machine house platform. Furthermore, the driver's cabin (13)
is installed at the machine house platform. Sets of rope sheaves (14) of the hoisting
system with anti-friction bearings are mounted in the head of the supporting structure,
at the hinged point tie back - jib as well as at the jib tip. The hinged point of the tie back
(9) is located at the supporting structure.
The jib (10) is connected to the jib boom (8) and to the tieback.
5.2.2 Stairs concept
The main access is via stairs and intermediate landings at the landside outside up to
the gantry girder (6).
The upper platform of the gantry is accessible.
The machine house is accessible via a spiral staircase in the column (7). The machine
house provides access to the driver's cabin and the electrical container. Left hand by
the side of the lower point of the jib boom the access to the machine house roof and
further to the head of the supporting structure is located.
Stairs and landings are provided to carry out maintenance work at the hinged
points of the jib system, the rope pulleys at the jib and the motor cable drum.
Before entering these landings and stairs, the jib system must be luffed into the
lubrication position and must be blocked.
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5.2.3 Mechanical parts
All gear drives are provided with anti-friction bearings and are enclosed in oil-tight
casings.
Lubrication of the bearings and tooth flanks is made by splash lubrication of the gears
in an oil pan (splash lubrication). The travelling wheels and the rope sheaves are
equipped with anti-friction bearings and filled with a special grease. They are re-fillable
through grease nipples.
5.2.4 Electrical control
The feeding 400V mains provides power to a SINAMICS Smart Line Module (SLM).
This SLM feeds a DC rail, to which the Motor Modules (MoMo) of the holding, closing,
slewing, luffing and travelling gear are connected. By moving the corresponding
controller in the crane control stand, the speeds desired for the appropriate direction of
movement can be preset stepless. The MoMos now provide power to the drive motors
via a threephase current system of variable frequency and voltage. By this, the speed
of the motors can be continuously modified in the 4-quadrant operation.
When stopping the crane during the operation process, electrical braking is used
and at approx. 2.5% of the nominal speed the brake lifter contactor switches due to the
registration unit of zero speed and by closing the brake, the drive is finally stopped.
The drives are switched without momentum and with delay, in order to keep the load
moment during the engaging of the brakes. When switching in the drives, opening of
the brakes will made with delay in order to built up a torque.
Drives with path limitation are secured by limit switches. They are used as
preliminary, operation and emergency limit switches. When approaching the
preliminary limit switches, electrical braking is done down to approx. 20% of the
nominal speed. The operation limit switch will be approached by preliminary limit
switch speed only. At the switch point of the operation limit switch, the control unit will
check, whether the preliminary limit switch has switched. If no signal is obtained from
the preliminary limit switch, this will be recognised and shown as an error (preliminary
limit switch control). A stronger electrical braking will be carried out. At the same time,
the mechanical braking is released. One can move out of the preliminary and operation
limit switch range into the opposite direction without any limitation. If the operation limit
switch fails, the drive will be switched off by an emergency limit switch, if this is
available. It directly acts onto the crane switch (emergency stop of the crane) and the
MoMo of the drive. Before it is allowed to move out of the limit switch range, the
reasons for the failure of the preliminary and the operation limit switches must be
clarified without any doubt and this reason must be removed. During this period, crane
operation is forbidden. Moving out of the emergency limit switch must be done in
accordance with table 3.
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A Programmable Logic Control (PLC) SIMATIC S7 is used as an automation system.

The central unit S7-317-2DP is located in the panel +KE1 in the driver’s cabin. It
communicates via the field bus system PROFIBUS-DP with the de-central units
ET-200M in the other driving gear panels and other control devices. The drive control
devices (SLM, MoMo and Sensor Module SMC) are connected to the control system
via the Control Units CU320.
Input and output signals of the drive control will be pre-processed and recorded in the
Simatic S7. Two Touch Panels TP177B in the switch cabinet +EE1 and in the driver’s
cab show operation and failure messages as well as status signals.
5.3 Power supply

5.3.1 Current flow Gantry
The main current supply to the crane is made from the feeding point on the crane track
by means of a trailing cable wound onto a motor cable drum. The crane is executed
so, that the max. travelling way to both sides of the feeding point amounts to 80 m
each.
The main power line runs from the slip ring body of the cable drum to the panel +PE1
on the gantry and further to the switch frames in the gantry girder:
On the switch frame in the gantry girder are installed:
• +PRE1 Power supply Gantry, special circuit, control of motor cable drum
• +PRE2 Travelling gear, rail tongs, ET200 Gantry
The crane disconnecting switch, the circuit breaker, the main switch for the special
power and the emergency cut-out (=0+PE1-S03) are installed in the panel +PE1.
With the crane disconnecting switch =0+PE1-Q1, the whole crane may be made
tension-free except for the special circuit, which is connected in front of this switch.
The crane disconnecting switch is a circuit breaker and takes over the short-circuit
protection for the whole crane. In order to make the crane completely tension-free, the
disconnecting switch =00+PE1-F01 for the special circuit has to be switched off, too.
When carrying out maintenance and repair work on the crane, secure the crane
disconnector and the disconnector for the special current by padlocks, so they cannot
be switched in.
The disconnecting switch for the special circuit should remain switched on to feed the
non-operation heating who prevent condensation.
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The devices and the terminals of the special circuit in the panel +PE1 (panel of
crane disconnecting switch) remain live, when the crane disconnecting switch is
switched off.
When working at the panel +PE1, the whole electrical system must be made
tension-free before.
Behind the Power switch further power supply circuits for the crane are connected,
before the power runs to the slewable part of the crane via the slip ring body.
Special circuit - Non-operation heating
Special circuit
The special circuit supplies power to:

• the non-operation heating
• the stairs lighting
• the room lighting
• the aviation lamp
• the sockets 380V and 220V
• the power blocks 24VDC
• the control voltage and the non-operation heating of the air-conditioner of the
electrocontainer
Non-operation heating
Thermostats at the panel of the gantry, at and in the electrical container activate the
non-operation heating for the motors and the panels.
When the crane is out of operation, the devices and terminals belonging to the
special circuit of the non-operation heating are live.
Access to the gantry girder
The gantry girder is to be considered a self-contained electrical operating room.

Access is allowed only for instructed staff.
By the buttons =00+PR-S1 and –S2 the lighting is switched on an off.
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5.3.2 Current flow Crane
From the slip ring body in the gantry girder, the current runs to the electrical container
on the machinery house platform.
The following switch panels are situated in the electrical container:
• +EE1 Power supply (crane switch and main fuses of the driving gears)
• +EE2 Power supply, overload safety device
• +EE3 MoMo for closing and holding gear
• +EE4 MoMo for slewing, luffing and travelling gear
• +EE5 Control unit for holding and closing gear
• +EE6 Control unit for slewing, luffing and travelling gear, motor grab,
spreader
• +EE10 Special circuit
• +EE21 SLM, CU320, SMC30
Main circuits
The crane switch =0+EE1-K02 provides power to the main circuits of all drives. Before
the crane switch, the power supply for the electrical hoist in the machinery house, the
lubrication pump of the slewing ring, the ventilator of the machinery house, the air-
conditioner of the electrocontainer, the motor cable drum for the power supply line, the
rail tongs, the floodlights on the gantry as well as for the lighting and control current
transformer is tapped.
Control voltage
The control voltage for the driving gears is tapped via the transformer =0-EE1-T3 in
front of the crane switch. Difference is made between a switched and an unswitched
control voltage.
Unswitched control voltage
Control voltage necessary for switching in the crane.
Switched control voltage
All control voltages necessary for the drives will be switched with one command by the
contactor =0+EE2-K1.
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5.3.3 Crane switch
The operating elements required are situated on the right side of the crane control
stand. The crane will be switched in by the press-button "Crane switch On", =0+KS-
S011. All controllers must be in zero position and no emergency cut-out button must
be operated. Switching the crane switch off is done by the button "Crane switch Off"
=0+KS-S012. The switch conditions of the crane switch are indicated by the signal
lamps =0+KS-H1 “On” and =0+KS-H2 “Off”.
The button "Acknowledgement of faults" =0+KS-S11 is also situated on the right side
of the crane control stand.
5.3.4 Motor protection and fuses
Releasing devices take over the protection of the motors against thermal overload for
the hoisting, slewing, luffing gear and travelling gear. Together with the PTC resistor
temperature sensors installed in the motor windings, those devices are protective
devices supervising the winding temperature.
Motors, such as motors for ventilators in the machinery house, electrohydraulic brake
lifters, rail tong motors etc. are protected by motor protection switches or thermal
relays.
Automatic cut-outs take over the protection of the other electrical devices and circuits.
5.3.5 Lighting
• Working place lighting by floodlights

• Room and stairs lighting by fluorescent lamps
• accumulator emergency lamps
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5.3.6 Heating, ventilation, sockets
Motors, panels and the slip ring bodies of the cable drum are provided with a
non-operation heating to prevent condensation.
The driver’s cabin can be heated over a heater blower in the crane control chair.
The machinery house is equipped with a ventilator switched in by a thermostat.
The driver’s cabin and the electrical container are air-conditioned.
On the crane, in the houses, in panels and in the cabin, sockets of 220 V, 16A are
installed. At the gantry and in the machinery house, there is one 4-pole socket each
of 380 V, 32 A.
5.3.7 Measuring instruments, signalling system etc
One text display each is installed in the driver's cabin and in the electrical container.
Fault signals and operating signals, the total operating hours and the operating hours
of the driving gears are indicated here.
In case of faults, the signal lamp "fault" in the crane control chair flashes and in case of
thermal pre-warning of the motors a buzzer is heard simultaneously, which may be
switched off by the button "Fault acknowledgement".
A voltmeter and an appropriate change-over switch for the voltmeter are installed in
the panel of the driver’s cabin.
By means of a push-button in the master switch (left), the crane driver may give
warning signals by means of a horn.
The rotating motion of the crane is signalled with optical and acoustic warning. When
the travelling bogies are switched in, an alarm clock gives signals in short intervals and
flashing lamps at the 4 corners of the crane are flashing.
A loudspeaker system is installed in the driver’s cabin. Telephones in the driver’s

cabin, the electrical container, the machinery house and at the gantry are provided for
communication on the crane.
Lubrication pump
In case of necessity (see lubricating plan) the lubricating pump for the slewing ring can
be activated by means of the button “lubrication pump slewing gear”.
Windscreen wiping and washing system
For the cleaning of the driver's cabin windscreen a windscreen wiping and washing
system is installed. It is operated by a button in the control chair (right casing).
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5.4 Mechanical system of the drives

5.4.1 Grab hoisting gear
The grab hoisting gear situated in the machinery house serves for handling of bulk
goods in the 20 t grab operation (four-rope two-blade bar grab) or for handling of
general cargo up to 45 t on the hook of the bottom block.
When using the motor cable drum in the jib system and the hook of the swivelling
bottom block, it is also possible to use a motor grab or a spreader for container
operation.
In principle the hoisting gear consists of two identical rope winches for the two holding
and closing ropes each. The rope winches are situated one behind the other and each
of them consists of the driving motor, the elastic bolt coupling, the spur gear, the disk
brake, the rope drum, overload safety device, rope pressure device, slack rope
switching-off and limit switches.
The threephase motor is bolted to the hoisting gear frame on the bearing block and
connected with the gear shaft via the elastic bolt clutch. The motor is provided with a
pulse transmitter and a centrifugal switch. The pulse transmitter serves for recording
the speed, the centrifugal switch serves for monitoring of the speed.
The disk brake is acting as a holding brake or emergency holding brake via an
adjustable brake spring and is lifted by an electrical hydraulic brake lifter. During
operation, electrical braking is made.
The rope drum is supported in 2 bearing blocks. On one bearing clock there is a lever
system with an integrated measuring axle delivering a signal proportional to the
hoisting load to the evaluation unit of the overload or load moment device. At this rope
drum support, a gear limit switch is provided for switching off, when the hoisting height
or lowering depth is exceeded, and an integrated encoder each for one drive for the
control of the closing way or control of a gear breakdown. The other bearing block
carries the whole drive block consisting of motor, elastic bolt clutch, brake and
planetary gearing.
In order to ensure the safe winding of the ropes in case of slack rope formation,
spring-loaded pressure rollers are provided at the rope sheaves. Excessive slack rope
results in switching off the driving gear by contact rails situated under the rope drums.
To limit the end positions of the drum, a gear limit switch is provided, which is driven by
its elastic driving flange and the dog at the second drum pivot.
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5.4.2 Slewing gear

The slewable part of the crane is supported on the big tube of the gantry girder by
means of a roller bearing slewing ring with internal toothing. The roller bearing ring is
connected with the fixed and the slewable part of the crane by means of high-strength
bolts.
The two slewing gear drives stand vertically in the machine house platform. They
consist of a flanged driving motor, the planetary gear with output pinion engaging into
the tooting of the roller bearing ring, an elastic bolt coupling with brake disk and a
double shoe brake.
The double shoe brake is carried by a motor base connecting the motor flange and the
gearbox. During operation braking is effected electrically, the double shoe brakes are
acting as holding brakes.
A central lubrication system is installed to ensure the continuous supply of grease to
the path of the roller slewing gear. Control is carried out through the PLC. The crane
driver will get a message in the case of too less lubricant in the storage tank.
5.4.3 Luffing gear

Changing of the radius, that is, shifting of the jib system is made by the luffing gear.
The spur gearing of the luffing gear made of block-type design is pushed laterally on
the in-volute profile of the toothed rack pinion shaft and held against lateral shifting by
means of a shaft end disk.
The drive shaft is provided with an elastic bolt coupling, the gear-side half of which is
executed as a brake disk.
Another brake is situated on the opposite side, however it will become effective with a
time delay in order to minimise the brake shock. Both double shoe brakes are operated
by electrical hydraulic brake lifters. The braking moment is adjustable within a certain
range and is applied by a pressure spring. The brakes are designed in such a manner
that they can brake down or hold the jib system in any position. The braking during
operation, however, is made electrically by the drive motor.
The toothed rack shaft is supported in the luffing gear support at the supporting
structure by both sides of its toothing. Centre of pinion or centre of toothed rack
corresponds to centre of crane.
The limit switching driven by a dog and a simple back gearing is installed on the side of
the pinion shaft, which is opposite to the gear. The gear limit switch switches the luffing
gear off in the maximum and minimum radius as well as in case of exceeding the
permissible radius corresponding to the appropriate carrying capacity. Such
preliminary limit switching results in the fact, that the end positions can be approached
with a reduced speed only.
Additional safety is provided by a mechanical stop being the luffing way end stop at the
maximum radius.
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For maintenance, the jib system may be further luffed in beyond the smallest radius for
operation. To achieve this so-called lubrication position, the limit switch has to be
shunted from the driver’s cabin.
By blocking the jib system (pin locking jib boom/A-structure) it is possible to carry out
repairs at the luffing gear or to replace worn parts.
The toothed rack is pivoted to the jib boom in an anti-friction bearing. To achieve an
optimum contact of the tooth flanks throughout their entire width, the bolt at the
toothed rack eye may be axially shifted.
To ensure the engagement of the pinion with the toothed rack, the toothed rack is
guided in a guiding casing by means of two pressure rollers having anti-friction
bearings. One of the pressure rollers may be adjusted by an eccentric axle. Since this
back gear toothing is one of the highly stressed load-bearing parts, it has to be
controlled regularly. If pitting is found on more than 2% of the contact surface after
long-term operation, the toothing must undergo a thorough check.
An elastic luffing way end stop is provided at the toothed rack to limit the end position
of the maximum radius.
5.4.4 Gantry travelling gear
The crane is travelling with a speed of vF = 32 m/min. Under every of the four gantry
corners, a gantry travelling gear consisting of two-wheel and three-wheel bogies is
installed. The corner load is transmitted uniformly onto all wheels via main and
intermediate balancer.
The 8 driven two-wheel travelling bogies of the crane are driven by bevel-gear motors.
The torque is transmitted to the driven travelling wheels by means of pinions and
intermediate gears.
The storm protection is effected by two electrical hydraulically operated rail tongs with
a holding force of 150 kN each.
The limitation of the travelling motion is achieved by a travelling gear limit switch in the
motor cable drum.
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5.4.5 Rail tongs
The electrical hydraulic rail tongs at the travelling gear enable the crane to be
anchored at the crane rails. Thus when the crane is put out of operation, it will be
secured against drifting away by storm.
The rail tongs are opened by switching in the crane switch. Closing is made
automatically after switching off the crane switch or in case of power failure, closing of
the tongs is finished after approx. 12s.
The state of the rail tongs is indicated on the monitor. Starting of the driving gears is
not possible, when the rail tongs are closed.
5.4.6 Motor cable drum power supply

The motor cable drum serves for winding the power supply cable on a drum during
travelling. See documentation of the manufacturer.
The drive motor is connected with the mains by switching in the travelling gear before
releasing the travelling control. The limit switches of the cable drum and the cable
funnel act on the releasing of the travelling gear.
When the last but one winding is achieved during winding off, the cable drum will be
switched off, too.
5.4.7 Motor cable drum spreader / motor grab

The motor cable drum situated at the jib boom serves for winding the power supply
cable to the hook rotating device and further to the spreader or for motor grab on a
drum during hoisting and lowering the load hook. See documentation of the
manufacturer.
The cable runs via the guide roller to the guide roller at the jib tip and from there to the
plug-and-socket connection.
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6. Assembly and first putting into operation
A load test for the crane did not take place in the manufacturer's works.
The crane has been fabricated in accordance with drawings of the manufacturer's
works and standards valid at the time of construction.
The final assembly of the sub-assemblies and making the crane functioning require a
high special knowledge and will be carried out by the manufacturer.
Therefore, this work will not be described in detail in the operating instruction.
Before the first commissioning and after implementation of essential modifications, the
crane has to be subjected to a check by an expert.
The crane is permitted for operation with the parameters given in the Technical
Characteristics on the general assembly drawing.
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7. Operation and handling

7.1 Operating elements crane control chair
Figure 2
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Legend on figure 2:
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7.2 Putting into operation
Before every putting into operation the crane driver has to check the crane by
inspecting for its safe operating condition.
He has to check, that:
1. no person, beside him, is on the crane

2. no sign is prohibiting the switching in of the crane
3. no loose parts are lying on the crane
4. all visible components are in a proper condition
5. the nationally valid operating rules are fulfilled
6. when making a visual check of the gantry travelling gear, the gantry clearance and
the rail clearance is given.
7. The crane disconnecting switch and the special circuit must be switched in, check
of the stairs lighting
8. When climbing higher, all drives should undergo a visual control.
9. The operating voltage has to be checked on the voltmeter in the
driver's cabin. The no-load voltage must not be higher than 420 V.
10. With full load, the voltage must not become smaller than 380 V – 7.5% = 350 V.
11. Check the lighting and heating circuits.
12. Carry our a short functional tests of the signal horn in the crane control chair and
the windscreen wiping and washing system have to be carried out.
If all checks showed a positive result, the crane may be put into operation by carrying
out the following actions.
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7.2.1 Switching in of the crane
Switching in of the crane should be carried out in the sequence indicated in the
following.
Table 2: Operation for the daily putting into operation of the crane
No. Activity Operation sequence Explanation

1 Checking before climb to the Visual control of the bogies,
crane crane track, running of the
feeding cable, rail tongs,
limit switch
2 If necessary, switch in the Operate button =00+PE15- Lighting will be switched
stairs lighting S3 (other buttons =00+T-S4, on
=00+KE1-S24)
3 If necessary, switch in the Operate button =0+PE15-S5 Gantry lighting will be
working lighting at the gantry (button in the driver’s cabin switched on
=0+KE1-S3)
4 Climb to the gantry girder.
5 Crane disconnecting switch Crane disconnecting switch Main circuit will be
and disconnecting switch =0+PE1-Q1 into position ON, connected
special circuit must =00+PE1-F01 must be in
be switched on. position „Special circuit on”
6 Stairs to the machinery
house Visual control of
drives including the brakes
and the
jib system
7 If necessary, switch in the Operate button =00+M-S29 Lighting in the
light in the machinery house machinery house will be
switched in
8 Climb further to the cabin
9 If necessary, switch in the button =00+KE1-S25 Cabin lighting will be
light in the cabin. switched in
operate
10 If necessary, switch in the Operate button =0+KE1-S3, Working place lighting
floodlights at the gantry -S22 and -S23 resp. will be switched in
alternatively jib and the
cabin.
11 Move the controllers shortly Checking of setting
one after the other into all back to zero position
directions
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Table 2: Operation for the daily putting into operation of the crane (continued)

12 Check the wind speed In the case of too high a When the LED lights
wind speed, a message is up, putting into
shown on the monitor operation has to be
interrupted immediately
13 Switch on Crane switch Switch on the key switch Crane switch switches
„Crane switch ON“ ON, an automatic lamp
=0+KS-S011 test lets for 3s all
warning lights light up
and the acoustic
warning is switched on.
If the crane switch is
switched on, =0+KS-H1
lights durably. The rail
tongs open automa-
tically, =17+KS-H1
lights.
14 Pre-select mode of operation Operate =1+KS-S2 Mode of operation will
be pre-selected
15 Operate fault Operate =0+KS-S11 Drive controls are
acknowledgement becoming ready for
operation.
7.2.2 Functional test
After switching in, the crane driver has to check all crane movements by moving the
controllers cautiously into the corresponding direction.
Safety check
When beginning to work, the proper function of the limit switches has to be
tested. For this, carry out the operations indicated in Table 3.
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Table 3: Operations for checking the safety devices - Checking of limit switches

1 Check of preliminary limit Move the controller into Drive moves until the
switches the direction to be preliminary limit switch
checked; responds; motion will be
slowed down to 20 %
2 Check of operation limit Move the controller into Drive moves until the
switches the direction to be operation limit switch
checked; responds, motion will be
electrically braked down
to zero, mechanical
Put controller to Zero, brakes start to apply
3 Check of emergency limit Press „Fault Drive is moving with
switches acknowledgement“ 20% until emergency
=0+KS-S11 and keep it limit switch responds.
pressed. Move controller Signal lamp =0+KS-H18
into the direction to be „Emergency limit switch
checked. approached“ lights.
Attention! Crane switch
will be switched off!
Energy supply and
control voltage will be
Put controller to Zero
interrupted. Motion will
be braked down to zero
by the mechanical
brakes.
4 Moving out of the emergency Press „Shunting of Drive is moving into the
limit switch range emergency limit switch“ opposite direction
=0+KS-S010 steadily, (opposite to point 1).
switch on the crane switch, By this movement, the
shortly press „Fault crane moves out of the
acknowledgement“=0+KS- emergency limit switch
S11, move the controller range, signal lamp
into the opposite direction =0+KS-H18 „Emergency
(opposite to point 1) limit switch approached“
extinguishes
The crane may be operated only, if all safety devices act properly.
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7.3 Crane operation

Crane operation includes all operation and motions necessary for the handling
process.
The crane driver has to determine the kind, scope and sequence of the necessary
crane operations in dependence on the place of taking and putting down the load. The
operations necessary for that, have to be determined by the crane driver in accordance
with the local conditions.
The functional operations and crane motions necessary for the handling process must
be selected by the crane driver by co-ordinated and smooth moving of the controllers.
When working with the crane, the following particularities and safety rules have to be
considered.
• Due to the great mass and high speed great moments of inertia occur when the
crane moves. This inertia must be counteracted by means of farsighted and timely
starting and slowing down of crane movements.
• When the grab / load hook or the stropped goods approach the ground, the
lowering speed has to be reduced. Lowering to the ground with max. speed is
prohibited.
• When putting down the load onto the ground, slack rope formation of the crane
ropes has to be avoided.
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7.3.1 Control of the hoisting gear
Control of the holding gear
By moving out controller 3 in the crane control board (right), the desired rated speed
values for the functions "Hoisting" or "Lowering" can be pre-set stepless for the
corresponding direction and speed. While doing that, the deadman’s control must be
pressed and held pressed, because otherwise a rated value “Zero” is output.
Control of the closing gear
By moving out controller 4 in the crane control board (right), the desired rated speed
values for the functions "Opening" or "Closing" can be pre-set stepless for the
corresponding opening and closing speeds. While doing that, the deadman’s control
must be pressed and held pressed, because otherwise a rated value “Zero” is output.
By programming the differential limit switching, the speeds at the ends of the
closing path are automatically adapted. If the grab is closed, the power
compensation regulation is additionally activated. The command keeps the grab
securely closed during the handling process and remains stored until the next opening
process. If the grab does not close due to a special composition of the material, the
crane driver may activate the current compensation regulation by operating the button
"current compensation" =2+KS-S15 in the left controller while lifting or lowering.
If a working cycle is carried out with the grab not completely closed, the crane
driver is solely responsible for damage caused for instance by falling material.
While the grab is closing being inside the bulk heap, the holding gear must work with
the brake open, in order to enable the sinking of the grab into the material. At the end
of the closing operation all rope lines shall hold the load. This will be supported by the
slack rope regulation, which is automatically activated during putting the grab on the
bulk and which can be stopped, if necessary, by the button =1+KS-S6 in the right
master switch during the closing operation.
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7.3.1.1 Differential limit switching/ rope compensation regulation
Before changing the mode of operation, replacing grabs or ropes, it is recommended

to switch the differential limit switching off.
After every changing the mode of operation, replacing grabs or ropes, the crane driver
has to program the differential limit switching. The appropriate operating elements
are on the left side of the crane control stand.
Proceed in accordance with the following table, when making the adjustment:
Table 4: Programming the differential limit switch/ closing path
No Activity Operation sequence Explanation

1 Select mode of Switch mode selector switch =1+KS- Mode of operation is shown
operation S2 to „Grab operation“ in the display
Operate „Differential limit switching
On“ =2+KS-S16
Operate acknowledgement button
=0+KS-S11
2 Operate „Adjustment of grab On“ „Adjustment of grab On“
=2+KS-S14 =2+KS-H14 lights statically,
„Adjustment of grab Closed “
=2+KS-H12 is flashing
3 Program Close the grab completely „Adjustment of grab Closed“
„Adjustment of =2+KS-H12 lights statically,
grab Closed “ „Adjustment of grab Open“
Operate „Adjustment of grab Closed“ =2+KS-H13 is flashing
=2+KS-S12
4 Program Open the grab completely Adjusted valued are taken
„Adjustment of over, light buttons extinguish
Operate „Adjustment of grab
grab Open“ Open“=2+KS-S13
During the general cargo operation, the differential is used to compensate possible
speed tolerances between the holding and the closing gear.
Adjustment and activation of the automatic rope compensation are described in the
following table:
Table 4: Programming of the rope compensation for general cargo operation

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1 Deselect the Switch over button =1+KS-S2 to one of Mode of operation is
general cargo mode the grab operation modes shown in the display
Switch off „Differential limit switching
ON“ =2+KS-S16
Operate the acknowledgement button
=0+KS-S11
2 Carry out a rope Move the closing ropes into the desired e.g. rope sockets at
compensation position the same height
between the holding
gear and the closing
gear
3 Select general Switch over button =1+KS-S2 to one of Mode of operation is
cargo mode the general cargo operation modes shown in the display
Switch off „Differential limit switching
ON“ =2+KS-S16
Operate the acknowledgement button
=0+KS-S11
When switching off has occurred due to a maximum rope difference during the
general cargo mode, actions to be taken are described in the following table:
Table 5: Actions in the case of maximum rope difference

1 Remove the rope Switch on the key switch =1+MT-S5 in Local control will be
difference the machinery house selected
2 Select the driving gear, by means of Rope difference is
which the difference can be removed by removed
a lowering motion (switch button
=1+MT-S1 into position „holding“ or
„closing gear“. Bring the holding or
closing ropes into the desired position
by means of the buttons =1+MT-S3 or -
S4, while watching the hook beam
3 Switch off the key switch =1+MT-S5 in
the machinery house, operate the
acknowledgement button =0+KS-S11
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Adjustment of the hoisting gear encoder (by service staff)
After a longer operation period of the hoisting gear and after the replacement of
encoders, there could occur an offset in the counting range. When reaching the
maximum recording range, a fault message is shown on the text display. Regular
adjustment of the encoders, however, will increase the operational reliability.
The following steps must be carried out for the adjustment:
Table 6: Encoder adjustment

1 Adjustment of Switch off „Differential limit switching On“ Way measurement is
encoder =2+KS-S16 deactivated
Move the hoisting gear up to the
preliminary limit switch “Hoisting”
2 Press button =91+KE1-S6 steadily, move Adjustment is finished
the hoisting gear slowly up to the limit
switch “Hoisting”
7.3.1.2 Limit switches
The holding gear is equipped with the gear limit switch =1+M-S10 and the closing gear
is equipped with the gear limit switch =2+M-S10. They contain the contacts for the
preliminary, operational and emergency limit switches for both directions of movement.
The principal reaction of the drive, when actuating the limit switches is described in
chapter 5.2.4.
7.3.1.3 Local control for the hoisting gear
A local control unit is provided for adjustment work at the mechanical part of the crane,
for the replacement of ropes of the hoisting gear and for removing slack rope faults. By
actuating the key switch =1+MT-S5, inching operation is selected, confirmed and the
press-button combination in the machinery house is released. All manual set values of
the controllers are blocked in this mode of operation. Pre-select one of the drives by
means of toggle switches. The set value is predefined by the buttons (direction1/2). If
two drives are selected, the set value output is blocked.
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The following press-buttons are available for inching operation:

Key switch Select the local control unit
Toggle switch Holding gear
Closing gear
Toggle switch Slewing gear
Luffing gear
Button Direction 1 (Hoisting, closing, right slewing, luffing out)
Direction 2 (Lowering, opening, left slewing, luffing in)
Mushroom-type button EMERGENCY STOP
During the inching operation, the driving gears may be operated with about 10% of the
nominal speed.
7.3.1.4 Slack rope
A slack rope limit switching device is situated at every hoisting gear frame. If slack
rope occurs at one of the drums, the rope will touch the slack rope rail resulting in
mechanical braking the hoisting gears. This switching-off will be shown to the crane
driver.
7.3.1.5 Overload
The overload safety device protects the crane from being overloaded. It consists of two
measuring axles, a load measuring amplifier, an angle transmitter and the evaluating
electronics for the overload (see for this the detailed description of the manufacturer).
When the overload responds, the hoisting and luffing-out process will be interrupted,
afterwards it is only possible to lower the load in order to put it down.
Switching off due to overload is shown to the crane operator on the monitor.
The overload safety device cannot registrate all dangers in time. Faults in its
function by non recognisable influences are possible. Therefor, the crane
driver has to operate cautiously and reliably considering the operating
instructions and the proper loading of the crane.
It is absolutely necessary to adhere to the operating instruction of the

manufacturer!
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7.3.2 Control of the slewing gear
By moving out controller 2 in the crane control stand (right), the desired rated speed
values for the function "slewing to the right" and "slewing to the left" can be stepless
pre-set for the corresponding direction of movement and the speed. While doing that,
the deadman’s control integrated on the controller must be pressed and held pressed,
because otherwise a rated value “Zero” is output.
7.3.3 Control of the luffing gear
By moving out controller 1 in the crane control stand (right), the desired rated speed
values for the function "Luffing out" and "Luffing in" can be stepless pre-set for the
corresponding direction of movement and the speed. While doing that, the deadman’s
control integrated on the controller must be pressed and held pressed, because
otherwise a rated value “Zero” is output.
The luffing gear is equipped with a gear limit switch =4+D-S10 acting as a preliminary
and operational limit switch for the luffing-in and luffing-out direction as well as an
emergency limit switch for the luffing-in direction. For the luffing-out direction, the lever
limit switches =4+D-S011 and =4+D-S12 resp. act as emergency limit switches.
chapter 5.2.4.
7.3.3.2. Lubrication position
In luffing-in direction, the driving gear may be moved into "lubrication position" beyond
the preliminary and operational limit switches, when this is required for maintenance
and repair purposes or for putting the crane out of operation. Actions for the actuation
are described in Table 3. In this position, one can enter the maintenance landings of
the jib system.
Moving into or our of the lubrication position must be done with absolute
cautiousness, in order not to damage the luffing gear!
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7.3.4 Control of the gantry travelling gear
By moving controller 5 in the crane control stand (left), the desired rated speed values
for the function "crane travelling" can be step less pre-set for the corresponding
direction of movement and speed. While doing that, the deadman’s control integrated
on the controller must be pressed and held pressed, because otherwise a rated value
“Zero” is output.
The limit switching for the travelling way is actuated by contacts in the motor cable
drum.
chapter 5.2.4.
7.3.5 Rail tongs
The status indication of the rail tongs is shown on the monitor.
Opening of rail tongs
By operating the button „Crane switch On“ =0+KS-S011 the rail tongs will be opened.
After the rail tongs are fully open, an indication is shown on the text display.
Closing of rail tongs
By switching the crane switch off by the button =0+KS-S012, the rail tongs close.
In case of power failure, the rail tongs close automatically. Starting of the driving gears
with the rail tongs closed is not possible
The motors of the rail tongs are protected by motor protection switches against
impermissible high temperature rise. If a switch responds, the rail tongs control
becomes inoperable.
To maintain the operating safety of the crane, please arrange for repair
immediately!
See also documentation of the manufacturer!
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7.3.6 Motor cable drum hook rotating device / spreader / motor grab
The cable drum mounted at the upper end of the jib boom serves for winding the
power supply cable for the hook rotating device, the spreader or the motor grab.
The operating elements are in the panel in the driver’s cabin. The selector switch for
the operating modes of the motor cable drum =14+KE1-3S1 has the following switch
positions:
- Automatics
- Manual operation
During normal crane operation, the switch =14+KE1-3S1 must be always in switch
position "mechanism". When changing the load attachment, the power supply cable
can be wound on or off by switching the selector switch to “manual” position and by
pressing the buttons =14+KE-3S2 and -3S3 respectively.
See documentation of the manufacturer.
7.3.7 Motor cable drum Power supply
The motor cable drum serves for winding the power supply cable on a drum. See
documentation of the manufacturer.
By switching in the travelling gear, drive motor will be switched to the mains before
releasing the travelling gear regulation. The limit switch of the cable drum acts on the
release of the travelling gear. When the last but one winding in winding-off direction is
achieved, the travelling gear switches off.
7.3.8. Modes of operation

The mode selector switch =1+KS-S2 on the right control board of the control stand has
4 switch positions:
1. Grab operation 20.0 t

2. General cargo operation 40.0 / 45 t
3. Spreader operation 40.0 / 45 t
4. Motor grab operation 25.0 t
By means of the selector switch =1+KS-S3 it is possible to switch over to 45t operation
in the general cargo and spreader modes.
Both switches have to be pre-selected in accordance with the kind of goods to be

handled. After changing over into another mode of operation, shortly press the
acknowledgement button =0+KS-S11.
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7.3.8.1 Grab operation 16 t
Description of grab operation (adjusting of grab etc.) see above.
7.3.8.2 Hook rotator
Switch the selector switch for operation modes =1+KS-S2 to general cargo, spreader
or motor grab operation and the selector switch =11+KS-S1 on the left side of the
control chair onto position „Hook rotator On“. The hook rotator must be plugged. Then
press the button „Fault acknowledgement“. The mode of operation activated is
indicated by the signal lamp =11+KS-H1. The hook rotator will be actuated by the
pedal switch =11+K-S81 (slewing to the right) or =11+K-S82 (slewing to the left)
respectively. If the pedal switch is not actuated, it is possible to slew the stropped
cargo manually by switching of =11+KS-S3 into the position „Free running“. In the
mode „grab operation“, the hook rotator is put out of action.
7.3.8.3 Spreader operation
Switch the selector switch for operation modes =1+KS-S2 to the position „Spreader
operation“. The spreader must be plugged. Then the button „Fault acknowledgement“
must be actuated. The mode of operation activated is indicated by the signal lamp
=9+KS-H1. The actuators for this mode of operation are situated in the left control
board.
7.3.8.4 Motor grab operation
Switch the selector switch for operation modes =1+KS-S2 to the position „Motor grab“.
The motor grab must be plugged before. Then the button „Fault acknowledgement“
must be actuated. The mode of operation activated is indicated by the signal lamp
=8+KS-H1. The motor grab is operated by actuating the closing lever on the right
control board.
7.3.8.5 General cargo operation / Spreader operation >40t
Switch the selector switch =1+KS-S3 into the position „General cargo operation/
Spreader operation >40t“. The selector switch for operation modes must be in the
position„General cargo operation” or “Spreader operation”. In this mode of operation
one can lift loads up to 45t, the radius is limited to 29m.
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7.3.9 Programmable Logic Control (SIMATIC-S7)
A Programmable Logic Control with the automation device S7-317-2 DP is used for the
control of all driving gears, the low-voltage system and the crane control stand.
The central control is connected to the individual panels and the crane control stand
via the electronic terminal strip ET 200.
The set values for the drives are given by digital controllers. The set values are limited,
blocked or released by the control, before they are switched to the corresponding
drives.
The central control also collects the individual faults and shows them on the text
display in the driver's cabin (see for this Fault signals).
In order to increase the operating safety, faults causing the forced switching-off of the
drives are given to the Programmable Logic Control (PLC) and are led past the PLC.
Thus it is ensured, that in case of failure of the PLC, the drives will be stopped.
7.4 Signal devices

The following signal devices indicate faults or active safety devices during putting into
operation and during the operation of the crane:
• Signal lamps in the driver’s cabin and In the crane control stand
• Text display in the electrocontainer and in the driver’s cabin (see point 7.5)
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7.5 Operating instructions for clear text display TP177B

(see also Device Manual TP177B Chap. 4)
The Touch Panel TP177 provides a display of operating and fault states of the crane
controls. During normal crane operation, important status information is displayed for
the crane operator, such as load and radius and the operational readiness of the
drives. In the case of a fault, when possible the cause of the fault is output. This
information should help with troubleshooting and the localisation of faults. Because info
texts are stored with each fault message, targeted troubleshooting is made possible. In
addition to fault states, various items of information are provided which can be called
up.
The Touch Panel TP177B is a touch-sensitive display, which can be used to call up
targeted information via a screen-guided menu control. Selection of the required
screen is achieved by touching the corresponding pictogram.
In each screen that is called up, the current operating mode is displayed in the topmost
line. Any new incoming faults are shown immediately in the currently displayed screen.
The message can be acknowledged by pressing the ACK key on the screen or the
fault acknowledgement in the control chair. All messages are logged with date and
time. By activation of the “Exclamation mark”, the screen can be changed immediately
to the message screen to display the messages which are currently present.
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Description of the screens available for selection:

Start screen:
The Start screen always appears after switching on the power supply. On this screen
are displayed the load and radius, as well as other items of additional user-specific
information. The display fields in the second line show the operational readiness of the
individual drives. A dark field indicates that the drive is operationally ready; a light field
indicates that the drive is switched off (fault or operating mode).
Through use of the lower keypad, it is possible to change over to the various sub-
menus.
Change-over keys from left:
1. Status displays:
Jump to the selection menu Load, Radius, Adjustment functions
2. Screen settings:
Change of the screen settings, Brightness, Contrast, Time, Language
3. Fault and operating messages:
Jump to the selection menu Fault and Operating messages
4. Set / Reset the TARE weight for load indication
5. Help
Information about the selection keys
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Start screen with fault message
In the case of a fault, the current fault message will be written on the current screen.
Only one fault message will be displayed each time. With the “ACK” key, each fault
message can be individually acknowledged, one after the other. After the
acknowledgement, the next current fault will be displayed. The fault acknowledgement
on the control chair acknowledges all current faults simultaneously.
The number on the Exclamation key displays the number of fault messages which are
currently present. Pressing the Exclamation key will immediately call up the current
fault message list in which all the current fault messages are entered.
For each displayed fault, an information text is stored, which can be called up with the
“Help” key. In the info text, you will find data on the device location, the page in the
circuit diagram and the associated input into the PLC or a reference to a special
chapter in the supplier documentation.
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Screen settings:
In this screen, settings can be carried out for messages and the screen using the
various entry fields.
Operating Mode: Change over the working method of the TP

Online / Offline / Serial transfer / MPI transfer
Message logging: Connection of the automatic message output to a connected
printer (optional)
Date / Time: Change of date and time. For data entry, a corresponding
keypad appears on the screen. Acceptance of the time will
occur if the “set” key is pressed within 15s
End: terminates the display program and switches over to the system
configuration of the WinCE operating system
Function keypad from bottom left:
1. Password entry
2. Change the language
3. Background illumination, darker
4. Background illumination, lighter
5. ESC – back to Start screen
Function keypad from top right:
1 Screen cleaning mode
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Fault and operating messages:
This selection menu allows you to call up the current fault and operating message lists,
the chronological fault and operating message buffers. Approximately 150 fault
messages are logged. Authorised personnel can reset the chronological buffer.
From top left:
1. Delete chronological operating message buffer

2. Display chronological operating message buffer
3. Display current operating message screen
4. Change the language (optional)
From top right:
1. Delete chronological fault message buffer

2. Display chronological fault message buffer
3. Display current fault messages
4. Print fault message buffer
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Display of current fault messages
The current fault messages are called up from the Message processing screen or via
the displayed Exclamation mark. Here, all the faults which are currently present are
displayed in a list.
With the aid of the scroll bar, the complete list can be viewed. Each fault is provided
with both a time stamp, which can be used to determine a sequence for the fault
triggering, and a display of states which shows the current fault’s display status
(K=come, Q=acknowledged, G=gone).
circuit diagram and the associated input into the PLC or the reference to a chapter in
the supplier documentation.
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Display fault message history
The TP177 stores the last 128 fault messages that have occurred, in a history file. The
history file of the fault messages is called up from the Message processing screen.
Here, the last 128 message events are displayed in a list.
With the aid of the scroll bar, the complete list can be viewed. The most recent fault
message stands at the end of the list, the oldest at the beginning. Each fault is
provided with both a time stamp, which can be used to determine a sequence for the
fault triggering, and a display of states which shows the fault’s display status (K=come,
Q=acknowledged, G=gone).
circuit diagram and the associated input into the PLC or the reference to a chapter in
the supplier documentation.
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Display of operating messages
The current operating messages are called up from the Message processing screen.
In this screen, displayed in a list are the current operating mode and the state of an
activated preliminary limit switch or operating limit switch.
With the aid of the scroll bar, the complete list can be viewed. The most recent
message stands at the end of the list, the oldest at the beginning. Each fault is
provided with both a time stamp, which can be used to determine a sequence for the
message triggering, and a display of the states which shows the fault’s display status
(K=come, Q=acknowledged, G=gone).
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Status displays:
With the status screens, the current operating states of the control can be observed.
They are required as support during adjustment work and are not generally enabled in
normal use.
Function keypad, left:
1. Display of output currents of converter

2. Display of setpoint speed – actual speed
3. Display of grab differential (for grab crane only)
4. Service (access blocked; for service personnel only)
Function keypad, right:
1. Display of load (gross, net, tare) and outreach radius.

2. Display of operating hours
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Load display:
In the Load display screen, the current load and radius can be observed. With the “Set
TARE” key, the tare weight can be stored or reset to zero. With this, it is possible to
check the current net weight.
Function keypad from bottom left:
1. Set / Reset TARE weight

2. ESC – back to Status selection screen
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Operating hours counter:
With the Operating hours counter screen, the operating hours counter built into the
SIMATIC S7 for the installed mechanisms can be simply and conveniently read out at
any time. Through the facility for connecting a printer to the TP177, these data can
also be documented.
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Output currents:
With the status screen Output currents, the actual output currents of the mechanism
converters (= motor currents) can be observed. The display is expressed as a
percentage of the set nominal motor current (= 100%). This display is used mainly
during adjustment work.
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Speeds:
With the status screen Speeds, the current setpoint and actual speeds of the motors
can be observed. The display is expressed as a percentage of the set maximum speed
(= 100%). This display is used mainly for adjustment work.
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7.6 Taking the crane out of service

When the crane is taken out of service, the hoisted load must be placed down; the
load attachment must be lifted to the maximum hoisting height and the crane should
be luffed-in to 8 m.
The jib system should be positioned longitudinally to the rail.
All controllers must be set to “Zero”.
The crane switch must be set to “Off”, which should cause the rail tongs to close.
When leaving the crane, the crane operator’s cab as well as the door to the tower
should be locked. The crane operator must check to ensure that the slewing gear
brakes are properly engaged.
The crane disconnecting switch can then be switched off at the portal switch cabinet.
After leaving the crane, the crane operator must check to ensure that the rail tongs are
properly closed.
7.7 Changing between grab and pulley block
To change from grab operation to hook operation, the grab must be placed down on
the ground and the rope connections should then be disconnected. It is recommended
to turn off the differential switching during the change.
The crane’s holding and closing ropes are then joined to the compensating ropes of
the spreader rotating device by means of rope sockets. Each of the rope ends are then
joined to the wire ropes with same lay direction. For example, the holding rope (sZ)
and the closing rope (sZ) must be joined to the equalising rope (sZ) of the spreader
rotating device.
If the ropes are incorrectly joined this will reduce the working life of the ropes! In order
to exclude mixing up the ropes, it is recommended that all rope sockets of ropes with
the same lay direction (crane ropes, grab ropes and compensating ropes of the
spreader rotating gear) are painted in the same colour; e.g. all rope sockets of the sZ
ropes painted red and the rope sockets of the zS ropes painted blue. Then, whenever
the operating mode is changed, only rope sockets of the same colour must be joined
together.
When changing the spreader rotating device on the grab, the procedure should be
carried out in the reverse order.
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Slewing Gantry Crane With Double-Link System: Operating Instruction

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Hai An Operating instruction

Slewing gantry crane

5.3 POWER SUPPLY ................................................................................................................................... 31

7. OPERATION AND HANDLING................................................................................................................. 41

1.1 Information on the operation manual

Code of the crane:

TUKAN 1500 20/40/45 t x 32/32/29 ... 8 m

Gantry slewing crane with double-link system 20 t x 32 ... 8 m

Example: Operation manual (BA).

Pages, tables and figures are numbered consecutively.

For safety relevant information the BA uses a special structure.

General safety information on dangers which occur in principal during the

Phone: 0049 / (0) 3334 / 62 0 (Zentrale)

Product: TUKAN 1500 20/40/45 t x 32/32/29 ... 8 m

Drawing No.: 09182

Order No.: 24 2009 3543

Code word: Hai An

It must not be neither partially nor in full be reproduced, multiplied, disseminated or

© All rights reserved.

1.3 Field of utilisation and proper use

The crane is designed for handling bulk-goods by means of a four-rope two-

Any transport of persons by the crane is strictly forbidden.

1.5 Symbols used

Symbol for an imminent danger

Symbol for indirect danger

This symbol indicates situations of indirect danger.

Any disregard of those instructions may result in damages or destruction of crane

Symbol for proper handling and information

Additional information is given to assist you in the

Any disregard of those instructions may result in damages or destruction of the

The technological and constructional safety concept of the crane is designed in

Table 1 illustrates the safety equipment being effective on the crane.

Table 1: Safety systems

Safety equipment Protective function

Emergency cut-outs Protection of persons and material values

Centrifugal switch Stop of motions when exceeding the maximum speeds,

Centrifugal switch Stop of motions when exceeding the maximum speeds,

Non-operation heating Heating of the panels and motors to prevent damages by

Load moment safety device Blocking of all risk-increasing movements in case of

Temperature control of Protection against thermal overload, signalisation in case of

Fuses, circuit breakers Over current; short-circuit protection

2.2 Emergency cut-out function

• at the gantry, landside (=0+P-S01)

Upon actuation of any emergency cut-out button:

• all motors and motions of the crane will be switched off

2.3 Total life

- Steel structure acc. to FEM 1.001:

- Driving gears acc. to FEM 1.001

Driving gear Driving gear Load collective Operation

General cargo / container

General cargo / container

Rope sheave like

Slewing gear and M7 L2 T7

Gantry travelling gear M5 L3 T4

2.3.2 Assessment and evaluation of the state of the crane

Recording of the actual operating hours of the hoisting gear

3. Information on industrial safety

3.1 General information

3.2 Safety systems