Ilovepdf Merged

CHAPTER 1 PAGE No.
1-1
1. – SPECIFICATIONS OF THE CRANE
ORIGINAL MANUAL
1.0 – MANUFACTURER
Benazzato Gru S.p.A. – Via Santo Stefano, 103 – 28047 Oleggio (NO)
Phone +39.0321.94734
Telefax +39.0321.94824
E-mail: [email protected]
URL: http://www.benazzatogru.it
th
March 28 2012
Crane sold or hired on ...............................………..….…….. to:
GADBJERG MASKINVÆRKSTED A/S

COMPANY ……...............................................................................................………..
STREET ……..…….......................................................................................…
TOWN DENMARK
..................................………............…….... STATE .............…………..
Ph. .....................................................
1.0.1– TOWER CRANE MODEL
THE BUILDING TOWER CRANE, according to the standards UNI - ISO 4306-1, is a
machine for non-continuous operation, designed to hoist from a rigid base and
handle in space a single not-guided load which is hung on the hook directly or by
means of allowable hoisting or slinging devices.
Crane model BENAZZATO 205 20 26.600

……………….….……...................................……….........
Construction No 5480
.............................
Month and year of construction 03 / 2012

.............................
SERIAL 205 CRANE Instruction Manual Edition 03/12

CHAPTER 1 PAGE No. 1-2
1.0.1.1.– FACSIMILE OF THE PLATE
OFFICES-FACTORY: 28047 OLEGGIO (NO)

VIA S. STEFANO 103 - Ph.(0039)(321)93535-94734
-Fax.(0039)(321)94824
TOWER CRANE
DEFINITION: discontinuous working lifting apparatus conceived for lifting and moving in the space an
undriven load hanging directly on the hook or with the interposition of lifting devices.
CRANE TYPE CONSTRUCTION YEAR

205 2012
MODEL SERIAL NUMBER
20-26-600 5480
CAPACITY LOAD AND JIB LENGHT
WITH JIB m 26 CAPACITY LOAD 600
9,8 (2 ROPES) Kg 1800
5 3000
WITH JIB m CAPACITY LOAD
(4 ROPES) Kg
CAPACITY LOAD WITH JIB IN HIGHT POSITION

HIGH POSITION JIB DEGREES 15 CONSTANT CAPACITY Kg 600
HIGH POSITION JIB DEGREES 24 CONSTANT CAPACITY Kg 350
MAX. LIFTING SPEED

WITH 2 ROPES WITH 4 ROPES
UP TO Kg 900 m/m’ 30 UP TO Kg m/m’
1800 15
1800 4
3000 4
ENGINE POWER WEIGHTS

LIFTING Kw 5,5 / 6,6 / 1,8 CRANE WEIGHT Kg 7100
SLEWING daN m 1,5 BASE BALLAST Kg 12100
TROLLEY Kw 1,84 COUNTERJIB BALLAST Kg
TRANSLATION Kw / MAX. HEIGHT m 20
TOTAL REQUIRED POWER Kw 15 MAX. REACTION Kg 11000
FOR THE USE AND MAINTENANCE OF THE CRANE, PLEASE FOLLOW THE ”INSTRUCTION HANDBOOK”
THAT MUST BE KEPT WITH THE CRANE UNDER CARE AND RESPONSIBILITY OF THE BUILDING YARD CHIEF.

2. - PURPOSE, FUNCTION AND LIMITATION OF THE MANUAL
2.1 - INTRODUCTION
This manual is intended only for qualified operators, suitably trained, in order to provide a
collection, as complete as possible, of data, directions and advice to optimise operation,
management and maintenance of the crane.
In addition, this manual contains all warnings and instructions required by the EEC Directive
2006/42 intended to provide the following information:
- marking of the crane, serial number,
- expected operating conditions, including those which can be reasonably imagined.
In addition it contains the instructions to carry out, with the lowest possible risk which can be
achieved with the current state of the art:
- putting the crane into service,
- transport, with the mass of the machine,
- erection and dismantling,
- adjustment,
- maintenance and repair,
- training of personnel.
These instructions have been written in the language of the manufacturer, that is the Italian
language.
Any translation in any other language, unless carried out or authorised by the manufacturer, is to
be considered not official and may be a source of errors.
2.2 - HOW TO KEEP THE MANUAL

The manual must be kept in a protected place in the building site where the equipment is
operated and under the site head's custody. The site head is responsible both to preserve it in
good conditions and to make it available for reference.
In case the manual is damaged by accident, even if it can still partially be read, the responsible
holder must get a new copy.
2.3 - UPDATES OF THE MANUAL

The manual reflects the state of the technology when the crane is sold, therefore it is not to be
considered inadequate or insufficient because of subsequent modifications or additions
suggested by new experiences.

BENAZZATO GRU S.p.A. reserves the right to update its production and the respective
instruction manuals because of the evolution of technology or new experiences, without the
obligation to update the machines sold previously and their respective manuals.
BENAZZATO GRU S.p.A. may in any case modify or add parts to the instruction manuals or to
the products sold previously, if deemed to be suitable for any reasonable ground.
In such a case update or modification sheets will be sent to the first owner of the equipment.
Such sheets are to the considered part of the instruction manual and must be kept with care
together with this booklet and, if needed, sent to the new owners of the crane, if the equipment
was sold.
2.4 - LIMITATION OF LIABILITY

BENAZZATO GRU S.p.A., as manufacturer, refuses all direct and/or consequential responsibility
due to:
- improper usage (operation) of the crane,
- usage (operation) by unqualified personnel,
- usage not in compliance with current safety regulations,
- preparation work of the building site,
- features of the ground,
- power supply faults,
- lack of maintenance,
- tampering with the equipment,
- usage of non original spare parts,
- partial or total non-compliance with the instructions of this manual,
- force majeure cases.
2.5 - USER'S CO - OPERATION WITH THE MANUFACTURER

The manufacturer requests the user's co-operation both to improve the contents of the manual
with suitable suggestions when advisable and to send any addition to the new user, in case the
equipment was sold.

3 – EXPECTED OPERATING CONDITIONS
3.1 – IDENTIFICATION OF THE EQUIPMENT
The tower crane is a hoisting and handling equipment designed for professional usage.
The nomenclature of the components of the crane in its normal arrangements is intended for
qualified personnel.
The identification of the components of the equipment starts from the base of the crane
(stabiliser plates, plinth-buried section or mooring plates, in case of fixed crane; rail wheels or
tired wheels if movable crane) and ends at the end of the equipment, that is the hook of the
pulley block hoisting the load.
It is not considered part of the crane proper any object between the ground and the
stabiliser plates and any hoisting device between the hook and the load to be lifted.
3.2 – AVAILABLE ERECTION CONFIGURATIONS
There are four available erection configurations:
a) Jib with around 4 degrees gradient (normal gradient),

b) Jib with maximum luffing of 15 degrees
c) Jib with maximum luffing of 24 degrees
d) Folded jib.
The configurations are shown in Fig. 1.3, 2.3 and 3.3, with the values of jib lengths, heights,
capacities, counterweights, ground reactions, main overall sizes and main performance
capabilities.
SERIAL 205 Instruction Manual Edition 03/12

DIAGRAM OF THE EQUIPMENT
m 28,4
VERSION 20-26-600 Kg
24°
CONSTANT
CAPACITY 350
m 23,9
m 18,9
m 24,6
15°
CONSTANT Kg
Kg CAPACITY 600
1800
m 25,3
m 11,2
∗ Capacity admitted only in exceptional cases

See § 4.8.6.1 for the use instructions
Kg
600
Kg
∗ Kg
3000
1800 m 26
m 9,8
m 20,2
m 5,0
0,8 m
Assembling ballast Kg 3.300 Fig. 1.3

(saddle 3300 Kg )
Completion ballast Kg 9.000
(no. 2 blocks of 1200 Kg each + no. 6 slabs of 1100 Kg each)
Total ballast Kg 12.300
Mass of the whole equipment,
C1
C2
axles included Kg 7.100 Z= 12,3 t

R= 2,1 m
m 3,2
m 3,30
11
m 3,2

DIAGRAMS OF THE LOAD Fig. 2.3
VERSION 20-26-600
Kg.350
Kg 3000
24°
200
0
8 10 12 14 16 18 20 22
23,9 m
2000
1000
Kg.600
400
0
0 2 4 6
200
∗ Capacity admitted only in exceptional cases

5,0 m
15°
0
See § 4.8.6.1 for the use instructions 8 10 12 14 16 18 20 22 24 26
25,3 m
Kg 1800 Kg 1800
1700
1600
1500 1500
1400
1300
1200
1100
1000 1000
900
800
700
Kg 600
500
0 2 4 6 8 10 8 10 12 14 16 18 20 22 24
11,2 m 9,8 m 26 m

PERFORMANCE OF THE CRANE

Fig. 3.3
3 SPEED MOTOR
m/min. 30 max. 900 Kg
15° m/min. 25 max. 600 Kg
24° m/min. 25 max. 350 Kg
CONTROLLED r.p.m. 0.4 – 0.9 max. 3000 Kg

SLEWING
3.3 – CLASSIFICATION ACCORDING TO CALCULATION STANDARD
 Structure calculation standard: DIN 15018

 Hoisting class: H1
 Stress groupi B2-B3
 Expected total number of cycles: 200.000
 Stability calculation standard: DIN 15019
 Standard for calculation of the effects of the wind on the structure: UNI-ISO 4302

CHAPTER 3 PAG. No 3-5
3.4 - EXPECTED ENVIRONMENT
The Model 205 BENAZZATO CRANE may be installed and used under the following conditions:
 Environmental temperature: from -3° to 50° C

 Maximum speed of wind during service: 72 km/h
 Maximum speed of wind out of service: 158 Km/h jib with 4° slope
 Maximum speed of wind out of service: 144 Km/h luffed jib with 15° slope or 24° slope
 Speed of wind during erection: 30 Km/h
 Lighting condition: Lights must be adequate to allow good visibility, so
that the objects and their features may be
distinguished and the distances in the range of the
crane may be estimated correctly.
 Usage in an environment with risk of explosion, corrosion or fire: Not allowed.
 Thermal effects, snow loads, earthquake effects: Not taken in consideration in design.
Note: The division of the territory of the country into wind zones is described in § 3.4.1
3.4.1 - DIVISION OF THE TERRITORY OF THE COUNTRY INTO WIND ZONES
SEE CURRENT REGULATIONS IN CASE THE CRANE

IS USED OUT OF THE ITALIAN TERRITORY

3.5 - ALLOWED CONCURRENT MOVEMENTS
The model 205 crane, in the fixed version, may carry out at the same time the three
movements:
 Hoisting,
 Slewing,
 Trolley (horizontal) movement
The only obligation is that a movement may be started only when the second and/or the third
have already been started.
The same holds for stopping a movement, this should not take place concurrently with the stop
of the second and/or the third movement.
3.6 - INTERFERENCE WITH OTHER EQUIPMENT
In case of cranes close one to the other, the following directions must be observed:
3.6.1 The vertical distance between the lowest part of one crane (counterweight of the higher
crane or its hook in the highest position) and the highest part of the other crane must be
at least 2 m (see Fig. 5.3).
Fig. 5.3
3.6.2 The minimum distance to keep between the two cranes, in the closest proximity, must be
at least 2 m taking into account the oscillation of the load or of the structure under the
load (see Fig. 6.3).

Fig. 6.3
3.6.3 In case of cranes moving on rails, or tired cranes, special devices must prevent approach
of the cranes to a distances smaller than those stated in the § 3.6.1, § 3.6.2 and § 3.6.4.
3.6.4 In case of cranes whose working areas are one above the other, suitable devices must
prevent that the hoisting rope of the higher crane interferes with the work area of the
lower crane, with at least 2 m of safety distance (see Fig. 7.3).
Fig. 7.3
VERTICAL PART FARTHEST AWAY

FROM THE SLEWING AXIS

3.6.5 All cranes must be installed with the slewing part, free to move under the wind, in
accordance with the conditions of the § 3.6.1 and 3.6.2.
3.6.6 In case the equipment is close to power lines, the minimum distance between the farthest
projection rotating part of the crane and closest cable of the power lines is 5 m, or m
3+0.010 X where X is the voltage of the line in kV.
3.7.1 - Button control box for all service movements.
3.7.2 - Button control box (same button control box of § 3.7.1) for erection movements: the
movement stops when the button is released.
3.7 - DESCRIPTION OF CONTROL DEVICES

The control (maneuvering) devices of the equipment, which cannot be operated unintentionally,
are of four types:
3.7.1 Button control box for all service movements and for erection or dismantling operations.
The button control box is of active-command (hold) type.
In case there is no command (button released) there is an automatic reset and stop of
the movement.
A mechanical lock prevents concurrent pressing of one movement and its opposite.
The buttons, with the exception of the emergency stop, are flush mounted in order to
prevent unwanted pressing.
3.7.2 Hydraulic distributor for sorting the hydraulic power during the different phases of erection.
This device permits to select, thanks to a hand lever, one of the two direction of the oil,
leaving out the other one.
The hydraulic distributor is on the turning platform and can be activated with a turn of the
hand lever.
3.7.3.1 Selector of operation/erection.

This is the only control device which is located inside the electric panel and may be
actuated only when the door of the electric panel is open, the machine is still and there is
no power supply.
It can be turned to one of three positions:
Service
 Middle Zero (no power supply in service and erection)
 Erection
The selection of the position is unmistakable and the positions are labelled.
NOTE. The selector on § 3.7.3.1 in the position «erection» allows selection of operation with
crane in «reverse kit» configuration.

3.7.3.2 Max load selector “1800 kg / 3000 kg”.

This selector is described in § 4.8.6.1.
It arranges the electric panel at working with max. load of 1800 kg, or with max. load of
3000 kg, activating their proper load limiting devices. (see chap. 9).
3.7.4 Main switch, to power off the equipment and allow setting out of service or any required
maintenance.
The switch is located to the outside of the electric panel.
3.8 - HOW TO STOP THE CRANE AND STOP DEVICES

The equipment is equipped with two emergency stops.
 The first is located on the electric panel of the crane, see § 3.7.4.
 The second is located on the button control box and is of red mushroom type with lock in
the pressed-stop position and manual reset.
The emergency control reduces the delay before stop of vertical movements, since it bypasses
all electrical braking intermediate actions: for instance the reduction of rpm of the hoisting motor
from 2800 to 1400, before actuating the mechanical stop brake.
Since shorter braking times cause additional structural stress, such stop means should be used
only in case of emergency.
The times for stopping the horizontal slewing and trolley horizontal travelling movements are not
changed remarkably in the emergency stop, since they depend only on the calibration of the
mechanical brake.
3.9 - OPERATOR'S POSITION
The operator's position for the crane 205 is on the ground (or the most suitable position).
The operators may not stand in the area of rotation of the platform, that must be in any case
fenced in.
Of course the operator may never be located on board of any part of the crane.
3.10 - CONTROL OF THE PATH OF MOVING ELEMENTS

The position of the operator must be such to allow total control of the path of moving elements,
both handled loads and structural moving parts.
The operator must be able to control the whole work cycle in all its stages:

CHAPTER 3 PAG. No 3 - 10
 Hooking the load

 Hoisting and horizontal handling of the load
 Lowering the load
 Laying down the load
In case direct vision is not possible, a suitable signalling system should be set up with the help
of the personnel of the building site, in order to indicate constantly the path of the moving part
and if it is possible to go on with the movement.
The area of the movement of the rotating platform supporting the counterweight must always be
fenced in adequately to prevent entrance. (see § 5.11)
3.11 - SURFACE EXPOSED TO THE WIND ALLOWABLE FOR THE LOAD

The surface exposed to the wind allowable for the suspended load is one square meter/1000
Kg of actual load. As actual load, we mean all which is hung from the hook of the pulley block.
3.12 - HOW TO PUT THE CRANE OUT OF SERVICE

In order to put the crane out of service, unlock the slewing brake and turn off power, so
that the crane may turn freely under the wind without being hindered in its rotation.
The trolley must be brought to a safe position near the tower with the pulley block as
high as possible, in order to reduce the risk of getting entangled with any lower object.
3.13 - ALLOWABLE HOISTING DEVICES

The hosting devices must have a carrying capacity adequate to the weight of the loads to be
lifted.
In general, passive accessories interposed between the hook and the load are allowable.
They must be used in accordance with the manufacturer's directions.
The mass of the devices must be deducted from the nominal carrying capacity of the crane in
order to calculate the mass of the useful load.
Hoisting devices are not allowed if they:
 can release suddenly the load
 can cause excessive dynamic stress and accidental overloads
 limit the free movement of the load
 are restrained by guiding cables
 are equipped with motors
 etc.
In addition, self-loading devices are forbidden.

3.14 - FORESEEABLE UNALLOWABLE USAGES OF THE CRANE

Fig. 8.3
1
EURO GRU
Kg
18
Kg
60
0
Do not lift loads which exceed the
00
carrying capacity of the crane.
Kg 2500 Kg 1000
2 Do not lift at high speed loads

EURO GRU
exceeding the allowable weight.
Kg 1500
3 Do not pull with slanting

EURO GRU
hoisting rope or pull the load.
4 Do not lift any load tied to the

EURO GRU
ground (rooting out trees, piles,

pile shoes, demolition work, etc.)

Fig. 9.3
5 Do not lift loads tied to the

EUROGRU
ground by frost or ice.
6 Do not release the load suddenly,

EUROGRU
do not use devices with allow

sudden release of the load, etc.
The slings of the load may not be
cut while the rope is tight.
7 Do not lay down the load

EUROGRU
suddenly, by bringing it to the

ground with the maximum
descent speeds.
8 Do not hoist the load suddenly,

EUROGRU
raising it from the ground with the

maximum raising speeds.

Fig. 10.3
9
EUROGRU
Do not lift the load from unstable
surfaces (shaky scaffolding,
ships, etc.)
10 Do not lift loads hooked out of

EUROGRU
their center of gravity, if they may

capsize or oscillate greatly.
11 Do not let the hing load swing in

EUROGRU
order to reach a point out of the

range of the crane.
12 Do not carry out ascent or

EUROGRU
descent operations in case of risk

of collision with obstacles of any
type.

Fig. 11.3
13
EUROGRU Do not lay the hosting block onto
the ground.
14
EUROGRU
Do not let any load hung (if not
expressly expected) when the
crane is out of service
15 Do not carry out any opposite

EUROGRU
operation if the dynamic effects

of the previous one have not
exhausted.
16 Do not let the load move over

EUROGRU
people.

Fig. 12.3
17 Do not carry out any operation, if
EUROGRU
the load is in a non visible

position.
18 Do not affix to the equipment any

EUROGRU IM PR ES A XX X
sign, placard or any other
X
X
unexpected object, which would
X
increase the surface under the
wind and the mass of the crane.
19 Do not lift loads with surface under

EUROGRU
the wind greater than allowed.
20 Do not use the equipment if it is

EUROGRU
not completely serviceable.

Fig. 13.3
STOP
21 Do not use the end-switches as
EUROGRU
control devices to stop

methodically the load in a
required position.
22 Do not insist raising loads very

EUROGRU
near to the maximum allowable,

if this causes too frequent
triggering of the limiters.
23 Do not use the stop button to

EUROGRU
stop the normal movement of the

crane.
STOP
STOP
STOP
24 Do not use the crane with folded

EUROGRU
jib if the jib is not completely

closed.

CHAPTER 4 PAGE No 4-1
4 – TECHNICAL DESCRIPTION
4.1 – DESCRIPTION OF THE COMPONENTS OF THE CRANE
WEIGHT NO. SIZE

POS. NAME
EACH m
Kg. ± 5%
01 Manual teleskopic jack 13 4 ø 0.25 x 0.27
02 Undercarriage – main frame 425 1 1.00 x 1.00 x 0.39
03 Mobile legs 160 4 1.90 x 0.27 x 0.32
04 Slewing ring with no. 24 + 24 screws 100 1 ø 0.85 x 0.07
05 Slewing platform 625 1 2.93 x 1.15 x 0.96
06 Hydraulic distributor hand lever 2 1 0.13 x 0.10 x 0.08
07 Gooseneck 80 1 1.13 x 0.70 x 0.15
08 Steering unit with axle 82 1 0.66 x 0.66 x 0.67
09 Front wheel (type 10.0/75-15.3) 41 2 ø 0.73 x 0.28
10 Towing bar 38 1 1.48 x 0.48 x 0.08
11 Back axle 164 1 2.30 x 0.45 x 0.36
12 Back wheel (type 10.0/75-15.3) 41 2 ø 0.73 x 0.28
13 Lower tower 695 1 7.03 x 0.72 x 0.73
14 Tower cylinder 200 1 2.07 x 0.17 x 0.21
15 Long connecting rods on lower tower 16 2 0.95 x 0.03 x 0.13
16 Hammer for connecting rods 44 1 0.49 x 0.25 x 0.13
17 Short connecting rods on upper tower 10 2 0.54 x 0.03 x 0,13
18 Tower struts 95 2 7.48 x 0.11 x 0.12
19 Upper tower 865 1 10.19 x 0.75 x 0.83
20 Derrick upper joint 16 1 0.40 x 0.19 x 0,12
21 Derrick tie rope – ø 8 mm 2 1 2.68 x 0.02 x 0,05
22 Derrick fly jib 24 1 2.02 x 0.32 x 0,08
23 Derrick lower joint 3 1 0.24 x 0.08 x 0,06
24 Derrick – block hoisting the completion ballast slabs 5 1 0.31 x 0.09 x 0,06
25 Derrick – link to the pulley block of the crane 2 1 0.22 x 0.09 x 0,02
26 Lower tie with moment limiters 27 1 2.96 x 0.33 x 0.06
27 Lower tie without moment limiters 16 1 2.96 x 0.08 x 0.05

Description of the components of the crane, continue:
WEIGHT NO. SIZE

POS. NAME
EACH m
Kg. ± 5%
28 Tie for raising jib 65 1 2.12 x 0.59 x 0.08
29 Lower double tie ropes ø 24 (see § 4.4.1) 17 2 2.37 x 0.12 x 0.05
30 Assembling tie rods – external part 19 2 2.36 x 0.10 x 0.03
31 Assembling tie rods – internal part 14 2 1.47 x 0.11 x 0.05
32 Back ties connecting fork 55 1 1.22 x 0.66 x 0.12
33 Upper single tie rope ø 32 (see § 4.4.2) 55 1 6.33 x 0.16 x 0.07
34 Butt joint to the counterjib 20 1 0.95 x 0.14 x 0.12
35 Counterjib, first tie 14 1 0.75 x 0.14 x 0.10
36 Counterjib, second tie 25 1 1.50 x 0.12 x 0.17
37 Counterjib, first strut – teleskopic bar 22 1 1.49 x 0.12 x 0.07
38 Counterjib first strut – fixed part 27 1 1.13 x 0.12 x 0.23
39 Counterjib, second strut with cylinder link 90 1 1.82 x 0.15 x 0.73
40 Counterjib strut cylinder 15 1 0.82 x 0.12 x 0.15
41 Counterjib, third tie 30 1 1.28 x 0.15 x 0.05
42 Counterjib, fourth tie 40 1 1.72 x 0.15 x 0.11
43 Counterjib, fifth tie 18 1 0.64 x 0.14 x 0.07
44 Jib, first section 650 1 11.55 x 1.25 x 0.68
45 Internal jib cylinder 55 1 1.41 x 0.16 x 0.25
46 Jib, second section 72 1 1.25 x 0.66 x 0.65
47 External jib cylinder 53 1 1.34 x 0.16 x 0.25
48 Screw coupling for trolley ropes 3 1 0.38 x 0.15 x 0.06
49 Jib, third section 290 1 10.24 x 0.68 x 0.65
50 Jib, fourth section 65 1 1.88 x 0.35 x 0.65
51 Connecting rod for jib-tip tipping over 3 1 0.67 x 0.05 x 0.02
52 Jib, fifth section (pusher with cranks) 48 1 1.93 x 0.39 x 0.71
53 Trolley (steel structural work only) 50 1 0.88 x 0.40 x 0.80
54 Pulley block (steel structural work only) 30 1 0.46 x 0.41 x 0.10
55 Trolley drum 18 1 ø 0.23 x 0.44
56 Trolley reduction gear 17 1 0.21 x 0.18 x 0.24

Description of the components of the crane, continue:
WEIGHT NO. SIZE

POS. NAME
EACH m
Kg. ± 5%
57 Trolley motor 25 1 0.36 x 0.22 x 0.19
58 Slewing motor 27 1 0.42 x 0.24 x 0.20
59 Motive pulley 2 1 ø 0.067 x 0.073
60 Belts 0.2 2 1.03 x 0.01 x 0.01
61 Idle pulley 0.3 1 ø 0.098 x 0.037
62 Slewing device case 16 1 0.70 x 0.62 x 0.18
63 Slewing reduction gear 45 1 ø 0.215 x 0.41
64 Slewing pinion 2.5 1 ø 0.108 x 0.06
65 Hoisting drum 21 1 ø 0.32 x 0.38
66 Hoisting reduction gear 58 1 0.37 x 0.69 x 0.26
67 Hoisting motor 55 1 0.56 x 0.25 x 0.30
68 Hydraulic central unit case 6 1 0.45 x 0.34 x 0.45
69 Central unit motor 29 1 ø 0.25 x 0.40
70 Hydraulic central unit 27 1 0.50 x 0.32 x 0.49
71 Button control box with electrical cable 8 1 0.40 x 0.15 x 0.08
72 Electric cabinet 38 1 0.88 x 0.65 x 0.25
73 Completion ballast slabs 1100 6 2.25 x 0.28 x 1.20
74 Base ballast saddle for ballast blocks 3300 1 2.25 x 0.50 x 1.20
75 Completion ballast blocks 1200 2 0.80 x 0.75 x 1.20
Note! These positions refer to Fig. 1.4

47
52 51 50 49 48
44 46
41 42 43
45
36
40 55 53
35 Fig. 1.4
56 54
34
57
39
19 61 60
38
62 59
37 20
21
63 58
25
33 22 64
23 65
16
18
24 66
17
31
30 71 67
15
32
14
72
68
29 69
13
12
06
70
05
28 11
04
27 73
03
26
07
10 02
08 75
74
09
01

4.2 - STRUCTURE
The structure of the jib is made of welded square-section tubes and round-section cross tubes.
The structure of the tower is of closed tubular type with octagonal section.
The slewing platform is made of connected and electrowelded profiles.
The undercarriage is made of oxygen-lance cut and electrowelded steel sheet.
Jib, tower, slewing platform and undercarriage are painted first with rust preventer and then with
finish paint.
In case of zincing, this concerns only the jib and the tower; slewing platform, undercarriage and
the other accessories are painted as described above.
4.3 – DESCRIPTION OF THE STRUCTURAL PARTS
4.3.1 – GRIPPING DEVICE
Fig. 2.4-A
13
01 12
11
02 10
03
09
04
05 06 07 08

The gripping device is made of the set PULLEY BLOCK – HOOK. The PULLEY BLOCK is
composed by two sheets connected by pins. The pins contain the fleeting pulleys of the hoisting
rope and the turning part of the hook. The manufacturer's certificates of HOOK and CHAIN are
delivered together with this manual.
This crane with two fall reeving (II fall) and 3000 Kg maximum capacity has the configuration
shown in fig. 2.4-A.
Key to symbols 1 – parts of the greeping device (see fig. 2.4-A)
POS. NAME No.

01 Hoisting rope ø 9 mm 1
02 Eyebolt nut 1
03 Thrust bearing 1
04 Pivoting hammer 1
05 Eyebolt 1
06 Hook 1
07 Anti-release spring device 1
08 Chain 1
09 Self-locking nut for the locking screw 2
10 Locking screw of the pulley pin 2
11 Anti-fleet device 2
12 Pulley pin ø 30 mm 2
13 Hoisting rope fleeting pulley ø 200 mm 2
Key to symbols 2 – features of the greeping device
 Number and inner diameter of the pulleys 2 of 200 mm

 Diameter of the pulley pins 30 mm
 Total mass without ropes 45 Kg
 Type of hook UNI-ISO 4779 or UNI 4395
 Capacity of the hook 3,2 t
 Chain breaking load 16500 daN
 Load anti-release device spring
 Minimum number of chain links 3
 Chain wire diameter 24 mm
 Eyebolt thread diameter M 30
 Internal diameter of the thrust bearing 30 mm
 Rope anti-fleet device rope-guard plates
 Colour: same colour of the crane with yellow and black strips

4.3.2 – TROLLEY
640
Fig. 2.4-B
02
01
Ø 88
Ø75
08 03
05
07 JIB TIP
650
04
06

The trolley is composed by a framework of structural steel and runs over the lower elements of
the jib thanks to four rollers.
You can see the configuration of the trolley in the following picture (fig. 2.4-B): it is mounted on
crane having II fall reeving and 3000 Kg maximum load.
Key to symbols 1 – main parts of the trolley (see fig. 2.4-B)
POS. NAME No.

01 Trolley frame 1
02 Hoisting rope ø 9 mm 1
03 Running rollers with pin and bearing 4
04 Trolley rope ø 6 mm, front section 1
05 Fleeting pulleys of the hoisting rope, ø 200 inner diameter 2
06 Rope-ends of the trolley rope 2
07 Trolley rope ø 6 mm, back section 1
08 Stops 4
Key to symbols 2 – features of the trolley
 Gauge 65 cm
 Rollers' distance between centres 64 cm
 No. 4 rollers diameter 8,8 cm
 Number and inner diameter of the pulleys 2 of 200 mm each
 Diameter of the pulleys' pins 30 mm
 Rope anti-feet device rope-guard plates
 Diameter of the rollers' pins 25 mm
 Total weight (rope not included) 70 Kg

4.4 – LINKAGE
Crane type 205 has a linkage that allows the automatic erection and permits the machine to
work.
4.4.1 – BACK LINKAGE

The back linkage of crane type 205 is composed by round-section rods, flat links or ropes
articulated one another and connected with pins. (see Fig. 3.4-A and Fig. 3.4-B)
There are also two double ties made of round-section rods used to lift the jib and active during
the erection only. These tie rods are connected at one end to the lower tower and at the other
end to the main ties, as shown in Fig. 3.4-A.
Features of the tie ropes:
a) Lower double tie ropes (n° 2 sections)

(see position 29 in Fig. 1.4 at § 4.1)
Lenght m 2.25
Nominal diameter mm 24
Unit strenght Kg/mm² 220
Minimum breaking load Kg 53800
Maximum acting load Kg 13000 on each section
Maximum diameter of external wires mm 1.55
Forming 6 x 36 WS COMPRESSED
Finish galvanized
b) Upper single tie rope

Lenght m 6.17
Maximum acting load Kg 26000
Forming 6 x 36 WS COMPRESSED
Finish galvanized

CHAPTER 4 PAGE No. 4 - 10
Insertion of the upper single tie into the fork (see Fig. 3.4-B)
2250 1350 Fig. 3.4-A

Ø 45
Ø 40 Ø 30 Ø 30 Ø 45
Connection to the lower tower

1085
TRIPLE JOINT
Ø 40 Double erection ties (no. 2 sections)
Fork
2250
Double tie ropes ø 24 mm

283
Ø 30
Configurations for rear-jib (see § 8.4)
284
2015
Tie adjusting the rear-jib
Ø 30
Lower double ties

2860
MAX. MOMENT limiters (electric board side)

The upper for 1800 Kg – the lower for 3000 kg
Ø 30
Link to the slewing platform
4.4.2 – COUNTERJIB LINKAGE

The counterjib linkage of crane type 205 is composed by round-section rods, flat links or square-
section tubular bars (struts) articulated one another and connected with pins. (see Fig. 3.4-B)
One hydraulic cylinder assembles the linkage before the erection of the crane.

1090 1535 460
Ø 60 Ø 60 Ø 60 Ø 60
Horizontal counterjib tie (3 jointed sections)
S TR
UT C
TRIPLE JOINT
Ø 60 YLIN
DER
Ø 45
ST
JIB, 1 SECTION
15
25 nd
2 counterjib strut (activated by hydraulic cylinder)
Vertical counterjib (2 jointed sections)

1355
40
14
D Ø 50
O SE
Ø 45 CL
Fig. 3.4-B
600
Ø 60
UPPER TOWER
Ø 60
TRIPLE JOINT
800
st
1 counterjib strut (telescopic in 2 sliding parts)
Ø 45
Butt joint to the counterjib

6170
Single tie rope ø 32 mm
Ø 45
Connection upper single tie to the fork (see Fig. 3.4-A)

4.5 - ROPES
Installation diagrams and rope paths are shown in the chapter "15. – SPECIAL MAINTENANCE
WORKS".
4.5.1 – HOISTING ROPE

D
Fleeting pulleys on trolley
Fig. 4.4-A
"E"
Rope-end at jib-tip
Fleeting pulleys on pulley block

E
"A"
Fleeting pulley on tower head
Guide pulleys at half tower
The rope comes out from behind

Hoisting drum
C

 The hoisting rope is connected to the drum thanks to wedge and cover, and to the turning rope-
end of the jib by means of clamps and thimbles.
 The drum and the pulleys housing the rope are equipped with suitable protections against fleeting.
 Fig. 4.4-B shows the main passages of the hoisting rope.
No. 2 pulleys ø 160 mm inner diameter No. 1 pulleys ø 200 mm inner diameter
"C"
"B"
“B” ROPE-GUIDE AT HALF TOWER “C”ROPE-GUIDE AT TOWER HEAD
Fig. 4.4-B
"D"
“D” ROPE-END AT JIB-TIP
- Features of the hoisting rope:

Lenght m 100
Finish galvanized
Rope Right cross lay

SERIAL 205 Instruction Manual
4.5.2 – TROLLEY TOWING ROPE

FRONT SECTION – TROLLEY FAR
Fleeting pulley at jib-tip
Fleeting pulley at turnbuckle
Turnbuckle
A B C D F
E
"B"
"E"
CHAPTER
"A"
Fig. 5.4-A
4PAGE No.
Fleeting pulleys at jib joint
No. 3 pulleys ø 120 mm inner diameter
Edition 03/12
Rope-end at trolley – front section
4 - 14
Trolley travel drum. the rope comes out
from UNDER on the SUPPORT SIDE
BACK SECTION – TROLLEY NEAR
Fleeting pulley at jib-foot
G A E
"E"
CHAPTER
"A"
Fig. 5.4-B
4PAGE No.
Edition 03/12
Rope-end at trolley – back section
4 - 15
Trolley travel drum: the rope comes out
from UNDER on the REDUCTION GEAR SIDE
 The trolley travel ropes are composed by two parts (front and back sections) which are both
fixed to the drum by means of wedge and cover, and to the trolley by means of clamps and
thimbles.
 The drum and the pulleys housing the ropes are equipped with suitable protections against
accidental fleeting.
 Fig. 5.4-C shows the main passages of the trolley travel rope.
Turnbuckle with no. 1 pulley No.1 pulley ø 120 mm inner diameter
"C"
"D"
“C” AND “D” ROPE-GUIDE AT TURNBUCKLE
Fig. 5.4-C
No. 1 pulley ø 160 mm inner diameter No. 1 pulley ø 120 mm inner diameter
"F" "G"
“F” ROPE-GUIDE AT JIB-TIP “G”ROPE-GUIDE AT JIB-FOOT

- Features of the travel trolley ropes:

Lenght (front section) – FAR m 55.5
Lenght (back section) - NEAR m 33.5
Finish galvanized

4.5.3 – BALLASTING DERRICK ROPE
Fleeting pulleys for derrick rope A Fig. 6.4-A
Tie rope of the derrick

Hoisting rope of the crane
B
Link to the hook of the crane
Derrick rope
D
C1
C2
Block of the derrick

C
Completion ballast slab

 Crane type 205 can be equipped with self-ballasting derrick.

 In this case, in order to place the ballast blocks on the turning platform you use the rope moved by
the hoisting motor, as shown in Fig. 6.4-A.
 Fig. 6.4-B shows the main passages of the derrick rope.
JOINT ON UPPER TOWER ROPE-GUIDE ON FLY JIB
"A" "B"
Fig. 6.4-B
ROPE-GUIDE ON LOWER TOWER DERRICK BLOCK
C1
C2
"D"
"C"

TOW - PROP
NOTE !
While towing the crane, the fly jib of
"E" the derrick is propped by a connection
to the lower tower made of shackles.
REMEMBER TO FREE THE FLY JIB
BEFORE GOING ON ERECTING THE
CRANE.
Features of tie rope and rope of the derrick:

a) Derrick tie rope
Lenght m 2.625
Forming 7 x 19 + A. M.
Finish galvanized
b) Derrick rope (hoisting of ballast blocks)

Lenght m 24
Forming 6 x 25 + A. M.
Finish galvanized
Features of the derrick rope turn:

 Number and inner diameter of the pulleys 4 of 200 mm each
 Pins' diameter of the pulleys 30 mm
 Mass of the steel structural work only 50 Kg
 Total mass of the derrick (rope not included) 70 Kg
4.6 - MECHANICAL DEVICES
Crane 205 is sold in the fixed version only and cannot therefore move on rails.
4.6.1 – HOISTING DEVICE

“UP/DOWN” limit switch
Drum for hoisting rope
Belleville washers
“MAX. LOAD 1800 kg” limit switch
“MAX. LOAD 3000 kg” limit switch
“LOAD / SPEED” limit switch
Hoisting reduction gear
3 - speed hoisting motor
Hoisting motor brake
4.6. – HOISTING REDUCTION GEAR

 Type: with coaxial shafts; spur gears and helical toothing
 Lubrication: permanent with oil; content around lt. 4.
-Model Ruggeri RS 2-C
-Gear ratio 1 : 35,7
-Flange diameter mm 250
-Input shaft diameter mm 32
-Output shaft diameter mm 48

4.6.1.2 – HOISTING DRUM

 Capacity: no. 2 layers + some turns on the 3rd layer.
-Bottom diameter mm 218
-Flange external diameter mm 320
-Useful lenght mm 330
-Lenght at hubs mm 390
-Groove pitch mm 9.6
4.6.1.3 – HOISTING MOTOR

 Type: asynchronous, threephase and 3 speed model “GOVONI“
-Nominal power Kw 6,6 / 5,5 / 1,8
-Rotation speed giri/min. 2800 / 1400 / 330
-Frequency Hz 50
-Υ-connection power supply V 400
-Υ-connection pick-up torque Nm 65 / 105 / 70
-Υ-connection absorption A 20,0 / 15,0 / 10,0
-Υ-pick-up current A 95 / 85 / 18
-Intermittence (run factor) % 50
- Max. no. of operations/hour No. 150
-Insulation class F
-Protection of boards IP 23
-Service S3
-Ventilation Not required
4.6.1.4 – HOISTING BRAKE

 Type: 140 MD CEI-2-3 (1988)
-Type of disc with 2 braking surfaces
-No. of discs n° 2
-Static braking torque Nm 190
-Air gap mm 0,5 ÷ 0,7
-Unlock device Not required
This motor is a short-circuited rotor type.

The brake acts directly on the motor shaft.
In case there is no motive power the brake is closed by reaction springs which press with adjustable load.
Brake lining are free from asbestos.

Braking force adjustment nuts Pressure springs

1 6
No. 2 braking discs with

7
No. 4 breaking surfaces
Housing
2
Nuts to adjust the air gap

3 Motor frame
and fasten the magnet 8
Fastening studs Brake anchor

4 9
Magnet Air gap = 0.5 ÷ 0.7 mm

5 10
4.6.2 – TROLLEY TRAVEL DEVICES

Trolley travel limit switch
Drum
Trolley travel reduction gear
Trolley travel motor

4.6.2.1 – TROLLEY TRAVEL REDUCTION GEAR

 Type: worm screw.
 Lubrification: permanent with oil; content lt. 1.
-Model Ruggeri RCGm-2

-Gear ratio 1 : 30
-Input shaft diameter (of the motor) mm 19
-Output shaft diameter (of the drum) mm 32
4.6.2.2 – TROLLEY TRAVEL DRUM

 Capacity: no. 1 layer.
-Bottom diameter mm 161
-Flange external diameter mm 225
-Useful lenght mm 370
-Lenght at hubs mm 424
-Groove pitch mm 6.5
4.6.2.3 – TRAVEL TROLLEY MOTOR

 Type: asynchronous threephase and 1 speed model “GOVONI“
-Nominal power Kw 1.84

-Speed r.p.m. 1400
-Frequency Hz 50
-Υ-connection pick-up torque Nm 23
-Υ-connection absorption A 2,5
-Υ-connection pick-up current A 22
-Max. no. of operations/hour No. 150
-Insulation class F
-Service S3

4.6.2.4 – TROLLEY TRAVEL BRAKE

 Type: 90 M CEI-2-3 (1988)
-Type of disc with 2 braking surfaces

-No. of discs n° 1
-Air gap mm 0,5 ÷ 0,7
-Unlock device Not required
The motor is short-circuited rotor type.

The brake acts directly on the motor shaft. In case there is no motive power the brake is closed by
reaction springs which press with adjustable load.
Braking power adjusting nuts Pressure springs

1 6
Setscrew
11
No. 1 brake disk with no. 2 braking surfaces
7
Housing
2
Nuts to adjust the air gap

3 and fasten the magnet
Motor frame
8
Fastening stud Brake anchor

4 9
Magnet Air gap = 0.5÷0.7 mm

5 10

4.6.3 – SLEWING DEVICES
Housing for slewing motor reduction gear Slewing limit switch
Slewing reduction gear
Slewing motor
Brake unlock
No.2 belts of type “A 39”
Motive sheave
Idle sheave
Out-pinion

4.6.3.1 – SLEWING REDUCTION GEAR

 Type: Epicycloidal
 Lubrication: permanent with oil; content lt. 2.
-Model Ruggeri RE-2P

-Gear ratio 1 : 154.3
-Input shaft diameter mm 30
-Output shaft diameter (with pinion) mm 55
-No. of tooth of out-pinion z= 16
-Out-pinion toothing module m= 6
-Height of the pinion's toothed belt mm 70
4.6.3.2 – BELTS AND SHEAVES

-External idle sheave diameter mm 95
-External motive sheave diameter mm 67
-Type of belts A 39
-Lenght of belts mm 1025
-No. of belts no. 2
4.6.3.3 – SLEWING MOTOR

 Type: asynchronous threephase with short-circuited rotor, 1 speed model“Govoni tipo 90“
-Nominal power Kw 1.5

-Speed r.p.m. 1400
-Frequency Hz 50
-Υ-connection nominal torque Nm 10
-Max. no. of operations/hour No. 120
-Insulation class F
-Service S3
-Shaft with pinion mm ø 24

4.6.3.4 – SLEWING BRAKE

 Type: T 90 CEI-2-3 (1988)
 Unlock device: with screw knob
-Disc type with 1 braking surface
-No. of discs No. 1
-Air gap mm 0,5 ÷ 0,7
The disc brake acts on the motor shaft.
The brake closes automatically when the motive power lacks thanks to compression springs with
adjustable load.
Screw knob to lock / unlock braking (see ✹ )
Control rod
Motor frame
Brake disk with 1 braking surface Brake anchor
Air gap 0.5÷0.7 mm

Pressure springs
Nuts to adjust the

Magnet
braking force
Release of the slewing brake for the
turning of the crane with wind Fastening stud
Housing Nuts to adjust air gap and

fasten the magnet
✹ THE SCREW KNOB (item 12) HAS THE FOLLOWING FUNCTIONS:

 KNOB SCREWED IN TO THE END = SLEWING BRAKE IS FREE: THE CRANE IS FREE TO TURN WITH
THE WIND.
 KNOB FULLY UNSCREWED = CRANE SERVICE.

4.6.4 – ERECTION MECHANICAL DEVICE

 The locations on the crane of the hydraulic cylinders, of the central unit and the distributor are shown
in § 4.1.
✹ to jib cylinders
see Fig. 7.4.1
✹ to the distributor
see Fig. 7.4.2
Solenoid valves Fig. 7.4
Hydraulic central unit Manometer
Fill-in cap
Motor
Solenoid valves
Hydraulic pump Oil level window
Filter
Drain cap
4.6.4.1 – HYDRAULIC CIRCUIT OF THE JIB CYLINDERS
INNER JIB CYLINDER
OUTER JIB CYLINDER
No.2 nipples 3/8”-1/4”

Overcenter valve VBSO DE NN Male-Male No.2 nipples 3/8”-1/4”
Male-Male
Overcenter valve VBSO DE NN
No.2 pipes – L = 0.35 m (1/4”)

Fittings ¼” female
No.2 T - fittings
¼” male No. 2 pipes – L = 4,10 m (1/4”)
No.2 pipes – L = 9.00 m (1/4”) fittings ¼” female
fittings ¼” female
No.2 fittings
¼” male
No.2 pipes – L = 20.50 m (1/4”)

Fig. 7.4.1
No. 2 nipples 3/8”-1/4”

male-male
Solenoid valves

4.6.4.2 – HYDRAULIC CIRCUIT OF THE DISTRIBUTOR
No. 2 nipples 3/8”-1/4” No. 2 pipes – L = 0,40 m (5/16”)

male-male fittings ¼” female
Fig. 7.4.2
No. 2 nipples 3/8”-1/4”
✹ to the tower cylinder

male-male
see Fig. 7.4.3

HYDRAULIC DISTRIBUTOR
✹ to the strut cylinder

Solenoid valves
see Fig. 7.4.4

4.6.4.2.1 – HYDRAULIC CIRCUIT OF THE TOWER CYLINDER
TOWER CYLINDER
No. 2 nipples 3/8”-1/4”

male-male
Strangler ø 0.9 Fig. 7.4.3
No. 2 nipples 3/8”-1/4”

No.2 pipes – L = 6,10 m (1/4”)
male-male
Fittings ¼” female
Hydraulic distributor

4.6.4.2.2 – HYDRAULIC CIRCUIT OF THE COUNTERJIB STRUT CYLINDER

No. 2 nipples 3/8”-1/4”
male-male
No. 2 nipples 3/8”-1/4”

male-male
STRUT CYLINDER
Hydraulic distributor

Fig. 7.4.4
No. 2 pipes – L = 20,10 m (1/4”)

4.6.4.3 – CENTRAL UNIT MOTOR

 Type: asynchronous threephase and 1 speed, model “LEPORIS“
 Flange diameter: ø 250; output shaft diameter: ø 28
-Nominal power Kw 3
-Speed r.p.m. 1400
-Frequency Hz 50
-Max. no. of operations/hour n° 150
-Insulation class F
-Service S3
4.6.4.4 – HYDRAULIC DISTRIBUTOR

 Type DH 5 / 6B / G3/8 (six-way)
4.6.4.5 - DISTIBUTOR
 No. 3 directional solenoid valves On/Off

4.6.4.6 – CENTRAL UNIT

-Oil content lt. 40
-Pump delivery lt./min. 5
-Max. pressure valve calibration KPa 320 x 10²
-Max. pressure allowable on pump KPa 320 x 10²
-Manometer full scale Bar 400
4.6.4.7 – HYDRAULIC PIPES

• Hydraulic pipes to the cylinders 1/4" NORME SAE 100 R-7:
Fittings: 1/4” Female
• Hydraulic pipes to the distributor 5/16" NORME M4009M (pipe type "FM030" version "ECO"):
• Connections between hydraulic pipes:
T-Fittings: 1/4” Male - Fittings: 1/4” Male
• Connections between hydraulic pipes and cylinders – unit solenoid valves – distributor:
Nipples: 3/8”- 1/4” Male – Male
• Fittings cylinders – unit solenoid valves – hydraulic distributor:
4.6.4.8 – HYDRAULIC CYLINDERS

TOWER CYLINDER
 Safety device: Overcenter valve “Oil Control type VBSO DE NN” cod. 05.42.47.10.02.35.000
 Control device: unidirectional strangling valve ø 0.9 “Fluid Press FPRU 1/4”
-Bore mm 150
-Stem diameter mm 90
-Excursion mm 1460
-End-pivot diameters mm 60
JIB CYLINDERS (No. 2 pieces)

-Bore mm 80
-Back cylinder excursion mm 1077
-Front cylinder excursion mm 1007
-Cylinder head diameter mm 40
-Cylinder neck diameter mm 45
COUNTERJIB STRUT CYLINDER

-Bore mm 45
-Cylinder excursion mm 460
-End-pivot diameters mm 20

CHAPTER 4 PAGE No 4 - 34
4.6.5 – SLEWING RING
Greaser Screw TCEI
Pinion
Stop nuts
Slewing ring Plain washer
4.6.5.1 – FEATURES OF THE SLEWING RING

-Type of ring Rothe Erde I-1-085-200
-External diameter mm 850
-Ring thickness mm 67
-No. of teeth z= 110
-Toothing module m= 6
-Toothing primitive diamater mm 660
-Internal ring boring diameter mm 705
-No. of holes of the internal ring n° 24
-Diameter of holes of the internal ring mm 17
-External ring boring diameter mm 820
-No. of holes of the external ring n° 24
-Diameter of holes of the external ring mm 17

4.6.5.2 - FASTENING BOLTS ON EXTERNAL AND INTERNAL RING
-no. 24 + 24 Allen screws Material 10.9 M 16 x 100

-no. 24 + 24 stop nuts Material 8.G M 16 high
-no. 24 + 24 plain washers R40 ø 17 x ø 30 x 3
-Tightening torque Nm 265
4.6.5.3 - MAXIMUM PLAY ALLOWABLE ON SLEWING RING
 The initial play of the slewing ring is such to ensure easy and safe operation.
 The maximum allowable play is 2.5 mm.
 When this value is exceeded the slewing ring must be replaced.
 In any case the slewing ring must be replaced after 6000 hours of service.
4.7 - SYSTEMS
4.7.1 - ELECTRIC SYSTEM
(see following pages)
WARNING!
The electrical equipment is endowed with a system that regulates the slewing by
means of a frequency variation device (inverter).
This device is adjusted by the manufacturer at the final testing of the crane.
No work may be carried out on the equipment unless by specialised
technicians.
The manufacturer is not responsible for any damage caused by any
modification of the original adjustment.

16 17 18 19
14 15
14 14
14
4.7.2 – HYDRAULIC SYSTEM
SERIAL 205 CRANE Instruction Manual

A B A B
13
A B A B
12 12
P T P T
A B
CHAPTER
11
Adjustment 320 bar P T
4
P3/8" T3/8"
10 09
08
RO 5 Lt/1' 06 U0
M
V0
PAGE No
02
03 3 W0 01
07
4Hp
04
05 Unit capacity: 36 l.
4 - 36
Edition 03/12
POS. NAME No. TYPE

01 Tank 1 See following drawing
02 Pump 1 1D5RO GAS
03 Fill-in cap 1 TCF4-3/4 GAS
04 Oil level window 1 LVA1TA
05 Intake filter 1 ST12/90
06 Spider 1 L201W142+AC1003
07 Fitting 1 SG124+R100E+SG101M
08 Motor 1 4 Hp Three-phase – 4 Poles
09 Manometer 1 MGRABS63/400
10 Exclusion device 1 290-14
11 Solenoid valve 1 “Duplomatic“ MD1D-2TA/55 or DS3-SA2/10N
12 Solenoid valve 2 “Duplomatic“ MD1D-S3/55 or DS3-S3/10N
13 Six-way manual distributor 1 DH5/6B – 3/8“
14 Overcenter valve 4 Oil Control VBSO DE NN 05.42.47.10.02.35.000
15 Fixed trottle valve 1 Fluid Press FPRU 1/4 ø 0.9
16 Counterjib strut cylinder 1 Bore ø 45 – Stem ø 25 – Excursion 460
17 Tower cylinder 1 Bore ø 150 – Stem ø 90 – Excursion 1460
18 Inner jib cylinder 1 Bore ø 80 – Stem ø 40 – Excursion 1077
19 Outer jib cylinder 1 Bore ø 80 – Stem ø 40 – Excursion 1007
Central unit motor
Manometer
Oil level window

300
Tank
3/8"
Drain cap
160
Solenoid valves
A
300
B
Maximum pressure valve
Fill-in cap
500

4.8 – CONTROL DEVICES
4.8.1 – BUTTON CONTROL BOX

The crane is always equipped with a button control box, necessary to operate the machine. The
instructions are given in the following three tables:
FUNCTION OF BUTTONS (“OPERATION” MODE)

“CM” switch position (see § 4.8.6) on “1”
1 - START 2 - RED, MUSHROOM-HEAD; STOP

3 - 2 / 3 FAST 4 - YELLOW, ALARM
5 - 1 DOWN 6 - 1 UP
7 - 1 / 2 RIGHT 8 - 1 / 2 LEFT
9 - NEAR 10 - FAR
Note!:
Button pairs are mechanically interlocked to prevent concurrent opposite
movements.
FUNCTION OF BUTTONS (“ERECTION – STRUT CYLINDER” mode)

Position hydraulic distributor hand lever (see § 4.8.7) on “1’”
1-GREEN, RUN 2-RED, MUSHROOM-HEAD; STOP

3-DEENERGIZED 4-YELLOW, ALARM
5-COUNTERJIB FOLDING 6-COUNTERJIB UNFOLDING
7-DEENERGIZED 8-DEENERGIZED
9-JIB FOLDING 10-JIB UNFOLDING
Note!:
movements.
FUNCTION OF BUTTONS (“ERECTION – TOWER CYLINDER” mode)

Position hydraulic distributor hand lever (see § 4.8.7) on “2’”
1-GREEN, RUN 2-RED, MUSHROOM-HEAD; STOP

3-DEENERGIZED 4-YELLOW, ALARM
5-TOWER FOLDING 6-TOWER UNFOLDING
7-DEENERGIZED 8-DEENERGIZED
9-JIB FOLDING 10-JIB UNFOLDING
Note!:
movements.

4.8.2 – JOY-STICK CONTROLLER

It replaces the button control box and allows, for cranes equipped with regulation system, to change
gradually the spped work parameters of the machine. It is a standard device for cranes with regulation
system.
For instructions see the documents supplied by the manufacturer of the controller.
4.8.3 – REMOTE RADIO CONTROLS

Crane 205 may be controlled with a button box radio control, as long it is of approved type,
compatible with the electric equipment of the crane. In particular the following commands on the
button control box must be on different buttons: 'UP – DOWN' and 'SLOW – FAST'.
For instructions of this device see the documents supplied by the manufacturer of the radio control.
4.8.4 – ERECTION/DISMANTLING SOLENOID VALVES

(see the picture in the following page)
 THREE valves positioned on the tank of the hydraulic central unit.

 The lower valve works as interlocking device and is called “SELECTOR SOLENOID VALVE”.
 Mounted on this valve there is the “PRESSURE LIMITER VALVE”; the operator can act on this valve to increase
the pressure calibration of the hydraulic system (see the instructions given at the bottom of the following page).
 Upwards you can see the “SOLENOID VALVE POWERING THE HYDRAULIC DISTRIBUTOR HAND LEVER“,
which activates the “TOWER PISTON” or the “COUNTERJIB STRUT PISTON”, according to the position of the
hand lever of the hydraulic distributor itself.
 Upwards again, you meet the “SOLENOID VALVE POWERING THE JIB PISTONS”.

 All the valves, close the pistons when excited in their left side (DI and CI) and open the pistons when excited on
their right side (SA and CA).
E1 E1
E5 CI JIB PISTONS SOLENOID VALVES CA E4
E1 T1 P1 E1
E3 DI TOWER PISTON SOLENOID VALVE
AND COUNTERJIB STRUT PISTON
SA E2
THROUGH HYDRAULIC DISTRIBUTOR
T2 P2 E1
E6
RECYCLE SOLENOID VALVE
+
PRESSURE LIMITER VALVE
HEXAGON LOCK NUT
SOCKET HEAD SCREW
P1 – DELIVERY SIDE TO OPEN JIB

P2 – DELIVERY SIDE TO OPEN TOWER or COUNTERJIB (through hydraulic distributor)
Operations to increase the calibration pressure of the circuit:
 Loosen the lock nut: now you can act on the screw with the suitable setscrew wrench.
 Turning CLOCKWISE you increase the maximum hydraulic pressure of the pistons.

4.8.5 – GENERAL ISOLATING SWITCH

It is inside the electric cabinet and is maneuverable from outside thanks to the knob on the door.
According to the standard EN 60204 the isolating switch can be operated with a special key even if the
door is open; this operation must be carried out by expert personnel only. Before closing the door, the
knob must be turned to the position ˆ0˜.
OPEN CLOSED
I ON I ON
OFF OFF
0 0
4.8.6 – WORK / ERECTION OPERATION MODE SELECTOR
POSITION: WORK POSITION: ERECTION AND

1 2 DISMANTLING
It is a switch placed inside the electric panel and named ˆCM˜. It can be operated with open door only,
therefore with electric system NOT alive.
1) Switch turned on “WORK”: all the electric motors of the crane are powered.
2) Switch turned on “ERECTION”: the electric motor flange-mounted on the hydraulic unit is the only
powered.

4.8.6.1 – MAX. LOAD SELECTOR 1800 kg / 3000 kg
MAX. LOAD 1800 kg MAX. LOAD 3000 kg

Standard version
1800 3000 Strengthened version
It is a switch placed inside the electric panel and named ˆSA 1˜. It can be operated with open door only,
therefore with electric system NOT alive.
Attention! Depending on the position of this switch, there is a different procedure for setting the
load limiter devices, as explained in Chapter 9.
4.8.7 – THREE-WAY HYDRAULIC MANUAL DISTRIBUTOR

It intervenes during the erection-phase only in order to sort the hydraulic energy produced by the high-
pressure oil; it is a control that works only when the "WORK / ERECTION" switch (see § 4.8.6) is
positioned on "ERECTION". It is placed on the turning platform of the crane and can be operated thanks
to a hand lever corresponding to two different positions.
In particular, the two positions have the following functioning features:
POS.1) Hand lever turned COUNTERCLOCKWISE from the operator's point of view; the
“STRUT PISTON” is powered and so the counterjib can fold or unfold.
POS.2) Hand lever turned CLOCKWISE from the operator's point of view; the “TOWER
PISTON” is powered and allows the vertical unfolding or folding of the machine.
HAND LEVER TURNED HAND LEVER TURNED

COUNTERCLOCKWISE CLOCKWISE
1 2
STRUT PISTON TOWER PISTON
SUPPLY SUPPLY

4.8.8 - COUNTERWEIGHT
The only counterweight admitted on crane BENAZZATO 205 is Kg 12.300.
This counterweight is composed by ballast blocks and slabs of reinforced concrete of the type
delivered by the manufacturer.
IT IS STRICTLY FORBIDDEN TO REPLACE THIS TYPE OF COUNTERWEIGHT WITHOUT THE
AUTHORIZATION OF “Benazzato Gru S.p.A.”
The mass of the ballast, having total weight of 12.300 Kg, is composed by (see the following picture):
no. 1 BASE BALLAST SADDLE: Kg 3300 TOTAL Kg 3300
no. 2 BALLAST BLOCKS: Kg 1200 (each) TOTAL Kg 2400
no. 6 BALLAST SLABS: Kg 1100 (each) TOTAL Kg 6600
TOTAL WEIGHT Kg 12.300
BALLAST COMPOSITION CHART
Kg 1100
Kg 1100
Kg 1100
Completion ballast slabs

Kg 1100
Kg 1100
Kg 1100
Kg 1200 Kg 1200
Completion ballast blocks
Kg 3300
Base ballast block
(SADDLE FOR TOWING)
Spigots for base block on platform

5. - PREPARATION OF THE BUILDING SITE
The preparation of the building site is to be carried out by the user before the crane is
brought to the building site.
The user is responsible for all works concerning preparation of the building site.
5.1 - STABILIZER BASE

 The maximum reaction on each base is 11 t
 The minimum mechanical resistance of the ground must be 1.5÷2 daN/cm2
 We recommend to set a plinth under the stabilisers of the crane. Plinths should be placed
at the vertexes of a square with 3.20 m side.
 Plinths must be set on solid ground and far from digging areas (at least 2 meters away).
 Plinth size must be such that the pressure on the ground does not exceed the pressure
allowed.
5.1.1 – CALCULATION OF THE BEARING PLINTHS FOR THE SOCKET

The Benazzato Gru S.p.A. supplies just by way of example a possible bearing
diagram on the ground of the 4 terminal legs.
We remind that it is sized for a ground with a 2 Kg/cm² capacity and it is reported on the
instructiuon manual just as example.
In practise this account should be execute for every kind of socket by an exeperienced
technician respecting the ground characteristics and the reaction coming from the
lifting device.
Without the specifications could be undertaken the following admissible pressures in
Kg/cm² on the ground:
- rocky ground: 20
- compact coarse gravel 4
- dry compact gravel 3
- dry clay 3
- stratify gravel with sand’s traces 3
- sand and compact clay 2
- wet compact sand 1,5
- tilled ground 0,3

Example: plinths (n° 4 plinths for 4 ground bases)
650
n° 5 irons ø 14
THE NUMBER ARE EXPRESSED IN mm
Attention! THE SIZE IS VALID FOR A

2 Kg/cm2 CAPACITY GROUND IRON DETAILS
450
n° 5 irons ø 14
3200
CHAPTER
MAX. PRESSURE IN WORK: 11 t
700
700
5
3200 500
100
PAGE No.
Edition 03/12
1000 1000
5-2
CONCRETE class 220
CONCRETE class 100
5.2 - POWER OUTLET

 The crane requires 50 Hz three-phase alternate voltage.
 The voltage which can be used is: 400 V.
 Note: Voltage must be measured at the equipment line terminals during hoisting of
the maximum load.
 The power required for the operation of the crane is 10 KVA with 400 V voltage.
 The power outlet supplying the crane must be equipped with ground wire connected to
the equipotential circuit of the building site.
 The electric panel of the building site must be equipped with a suitable main switch with
fuses capable of interrupting any short-circuit current which may take place at the site of
installation.
 The plug, in red colour with a power of 16 Amp. mounted on the crane carriage, is made
of 4 poles (THREE POLES, + EARTH TERMINAL CABLE) (see Fig. 5-A).
♦ The EARTH CONNECTION POLE is bigger than the others and it is at the bottom of
the power outlet.
♦ THE CONNECTION TO THE ELECTRIC BOX HAS ALREADY
BEEN CARRIED OUT BY BENAZZATO GRU S.P.A. USING A 4 x
6 mm2 CABLE.
5.3 - POWER SUPPLY CABLE

The sections of the power supply cable are indicated for a tight horizontal cable suspended
over the ground.
In case of underground cable, cable on trees or wound cable, the section should be
increased as suitable.
Three-wire + ground rubber-jacket cable in perfect conditions.
400 V cable section Cable length

4 x 6 mm2 up to 50 m
4 x 8 mm2 50 m up to 80 m
The manufacturer recommends not to exceed the max. length indicated in the table.
It is forbidden to put the cable without adequate protection in areas which may be crossed by
vehicles and/or people.
 The wiring harness of the input plug (see Fig. 5-B) supplied by Benazzato Gru S.p.A.
is in red colour too.

L2 Fig. 5-A
PLUG TYPE FOUR POLES
L3
EARTH CONNECTION L1
L2
L1 L3
Fig. 5-B
EARTH CONNECTION

5.4 - GROUNDING
Grounding is to be carried out by qualified personnel before connecting the crane to the
mains, in compliance with applicable regulations in force.
The ground the ground electrode is to be driven into must not be filling or sand and must be
always kept humid. The contact surfaces between terminal (clamp) and the base must be
cleaned and scraped well before connection.
The grounding system must be in any case connected to the grounding system of the
building-site protection circuit to which the electric system of the crane is already
connected.(see § 5.2)
EXAMPLE OF HOW TO SET THE LEG ONTO THE GROUND
BASE IN SEASONED WOOD
PLINTH OF SUITABLE SIZE IN ACCORDANCE WITH

THE RESISTANCE OF THE GROUND (IF REQUIRED)

EXAMPLE OF GROUNDING
TO THE EXISTING
GROUNDING SYSTEM
clip P E
5*L
5*L
5.5 - STANDARDS CONCERNING PROTECTION FROM ATMOSPHERIC LIGHTNING

See the standards EN 60204 or DIN 0675 or similar documents according to the regulations
in force in each country.
Usually, it is enough to set up dischargers with adequate sections in the building-site electric
panel, placing them on each phase of the line.
5.6 - COUNTERWEIGHT
There is only one configuration (arrangement) allowed: (see § 4.8.8)
- COUNTERWEIGHT IN REINFORCED CONCRETE:

This is made of: No 1 base ballast slab weighing 3.300 + No 2 blocks ballast each
weighing 1200 Kg + No 6 slabs ballast each weighing 1100 Kg.
TOTAL COUNTERWEIGHT Kg 12.300

5.7 - ERECTION TOTAL SIZES

SIZES IN METERS
m 34
32
30
28
26
24
22
20
S .p. A.
18
16
14
12
10
0
6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 m 28
5.8 - TOWING MEANS

The means allowed for towing the crane in the building site must weigh at least the same as
the towed crane. The connections must be such to prevent unwanted release of the pinion
between the towing hitch of the tractor and the ring of the towing bar of the crane.
The diameter of the pinion must not be less then the internal diameter of the towing ring.

5.9 - ERECTION MEANS

Building-site fork-lift truck with minimum capacity of 1200 Kg and 3.80 m height of forks
(height of last stop plus 50 cm sling). The sling is made of three ties with L = 0.6 m and
capacity of Kg 500 each.
5.10 - TEST LOADS

Static or dynamic tests are not required, since they have been already carried out at the 1st
testing.
In order to adjust the load limiters the following loads are needed:
 Limiter of static moment and dynamic moment – STANDARD VERSION

(trolley far and hoisting UP – see § 9.7.1)
Kg 600 + 10% = 660 Kg
 Limiter of static moment and dynamic moment – STRENGTHENED VERSION

(trolley far and hoisting UP – see § 9.8.1)
3000 Kg
 Limiter of maximum load (hoisting UP – see § 9.7.2) – STANDARD VERSION

Kg 1800 + 10% = 1980 Kg
 Limiter of maximum load (hoisting UP – see § 9.8.2) – STRENGTHENED VERSION

Kg 3000 + 10% = 3300 Kg
 Limiter of load/speed (hoisting FAST – see § 9.7.4)

Kg 900 + 10% = 990 Kg
 Load limiter with jib raised of 15° (hoisting UP – see § 9.7.3)

Kg 600 + 10% = 660 Kg
 Load limiter with jib raised of 24° (hoisting UP – see § 9.7.3)

Kg 350 + 10% = 380 Kg
With weights increased of 10% the cut-outs of the limiters must trip and interrupt the
movement.
Note! Refer to chapter 9 for the position of the above mentioned limiters on the crane
and the instructions for their adjustment.

5.11 - FENCING OF THE AREA OF ROTATION OF THE COUNTERWEIGHT

The area with a radius of 0.70 m greater than the maximum radius of rotation of the
counterweight along the whole path of 360 degrees must be fenced in order to prevent access.
Fencing must surround the whole area or rotation of the counterweight and there must be a door
with door lock whose key must be kept only by authorised personnel who may enter the internal
area only when the crane is still and disconnected from the power mains. (see diagram)
Example of fence to be erected to protect the area of rotation of the crane
0.70 m
ENTRANCE DOOR
R = 2.1 m
1.1 m
5.12 - ACCIDENT-PREVENTION SIGNS

The head of the building site must affix all notices required when there is a crane.
Here are a few examples:
 BEWARE! OVERHANGING LOADS
 HEAD PROTECTION
 DO NOT STAND IN THE RANGE OF THE CRANE
 DO NOT REMOVE THE SAFETY DEVICES
 AUTHORIZED PERSONNEL ONLY

6 – INSTRUCTIONS FOR TOWING AND MOVING
The 205 crane may not be towed on the street; it may only be moved in the building site at
slow speed (max. 10 Km/h) and on solid and compact ground.
6.1 – CRANE TOWING ARRANGEMENT

The right towing arrangement of the crane is shown in the following pictures; the ballast
saddle for the erection is still placed on the carriage.
The pictures give also weight, center of gravity, size and overall dimension, reaction on the
rubber axles and some of the possible configurations for hoisting and towing the crane.
6.1.1 – TOWING ARRANGEMENT: WEIGHT AND CENTERS OF GRAVITY (Saddle = Kg 3300)
1.50 2.20
2.00
0.95
SLEWING AXLE
A
B
BAR 1
BAR 2
C D
2.67 m 2.67 m
A) Crane without base saddle nor axles (jib and tower galvanization): W = 6600 Kg
B) Towing saddle: W = 3300 Kg
C) Front axle with shaft: W = 260 Kg
D) Complete back axle: W = 240 Kg
BAR. 1) Crane with axles, without towing saddle: W = 7100 Kg

BAR. 2) Crane in standard towing arrangement, including towing saddle: W = 10400 Kg

6.1.2 – TOWING ARRANGEMENT: SIZE AND OVERALL DIMENSION (Saddle= Kg 3300)

m 3.10
m 6.36
m 12.30
m 2.67
m 5.34
SLEWING AXLE
m 2.67
m 0.6
m 1.90
m 2.40

6.1.3 – TOWING ARRANGEMENT: REACTION ON THE AXLES (Saddle= Kg 3300)

RA + RP = 10400 Kg
HOISTING OF THE CRANE IN TOWING ARRANGEMENT

SLING CHAIN SECTION “A”: No. 2 x 3.35 m ca.
0.95 SLING CHAIN SECTION “B”: No. 2 x 4.35 m ca.
MAXIMUM LOAD Kg 3500 each
SECTION “B”
SECTION “A”
SLEWING AXLE
CHAPTER
6
RA = 3400 Kg
PAGE No.
RP = 7000 Kg
Edition 01/12
m 2.67 m 2.67
m 5.34
6-3
RA + RP = 10000 Kg
HOISTING OF THE CRANE WITHOUT AXLES

SLING CHAIN SECTION “A”: No. 2 x 3.35 m ca.
SLING CHAIN SECTION “B”: No. 2 x 4.35 m ca.
0.95 MAXIMUM LOAD Kg 3500 each

SECTION “B”
SECTION “A”
SLEWING AXLE
CHAPTER
m 2.90
6
6.1.4 – HOISTING OF THE CRANE WITHOUT AXLES (Saddle= Kg 3300)

PAGE No.
Edition 01/12
6-4
6.2 - DETACHED SECTIONS
The 205 crane has no detached sections, with the exception of the axles, whose masses
are indicated at § 4.1 (see Fig. 1.4).
6.3 - ALLOWABLE LOADS ON AXLES/TOWING BAR
The maximum allowable load on the steering axle is: Kg 4700

The maximum allowable load on the back fixed axle is: Kg 7200
The maximum allowable towing load on the towing ring is: Kg 4000
NOTE! The above mentioned loads are the maximum allowable loads for transfer inside
the yard at a max. speed of 10 Km/h.
In the right towing configuration, the mass at ground of the towed machine is RA+RP =
10400 Kg and the reactions at axles are RA = Kg 3400 on the steering axle and RP = Kg
7000 on the back axle, as shown in § 6.1.3.
Note! Do not tow the crane when the completion ballast is on the towing saddle: the
total weight may exceed the maximum allowable load on the axles.
6.4 - TYRES
Steering axle:
No. 2 of type: 10.0/75–15.3

sizes: ø 730 x 280
inflation pressure: 5.25 bar
studs: No. 6 M 18 (Mat.10.9)
tightening torque: daNm 36.5
Back axle:
No. 2 of type: 10.0/75–15.3
sizes: ø 730 x 280
inflation pressure: 5.25 bar
studs: No. 6 M 18 (Mat.10.9)
tightening torque: daNm 36.5

6.5 - INSTRUCTIONS FOR TOWING

The crane may be towed only inside the building site to move it from one operation location
to the other. The path must be on solid and compact ground and with speed slower than 10
Km /h.
The maximum slope which can be overcome in the forward direction of movement is 7.5 %.
The maximum side slope allowed is 5%.
Usually the crane is not equipped with braking system or parking brakes, therefore wedges
must be ready available to stop the wheels in case of emergency.
6.6 - SPECIAL NOTICE FOR TOWING

Before towing the crane must be locked so that it does not rotate. In order to do this, make
sure that the slewing motor brake is locked.
Make sure that the hoisting block is fastened to the jib of the crane before towing.
All ropes must be arranged so that they cannot be damaged by bending against cutting
edges, crushing, etc.
6.7 - TOWING OPERATIONS WHICH ARE NOT ALLOWED

The following operations are not allowed:
 exceed the max. speed of 10 Km/h,
 tow with wheels sinking into the ground,
 tow with connection with any other part than the towing bar,
 tow with inadequate inflation pressure,
 tow with force exceeding the load allowed at the towing bar,
 tow with loose parts or parts which may detach,
 transport people on board of the machine,
 tow the crane in work arrangement (erected crane).
6.8 - LIFTING AND MOVING
Lifting and moving may be carried out by slinging the crane on the 4 points marked with
relevant labels (chain links - two on each side of the crane), these points are shown in
the diagram on the page referred to on § 6.1.3 and § 6.1.4.
Lifting is to be performed with ropes or chains with adequate capacity for the mass to be
lifted, this mass can be calculated from the data contained on § 6.1.3 and § 6.1.4 also.

7. - HOW TO ACCESS THE STRUCTURES
Access to the top parts of the crane is not contemplated and is not allowed.
Any maintenance of the top parts of the crane is to be carried out with the machine in
towing arrangement.
In case dismantling is impossible, suitable protection means, in accordance with accident-

prevention regulations in force, must be used to access the top parts of the crane.
Access to the lower parts of the crane is never allowed when the crane is operating. In
order to prevent such access, erect the fence described in the § 5.11, so that people may
not enter the area of rotation of the platform of the crane.
Access for maintenance operation is allowed in accordance with the instructions on

chapter 13, and with due care.

8. - INSTRUCTIONS FOR POSITIONING AND ERECTION
8.1 - GENERAL NOTE

The manufacturer is not responsible for any consequence due to any non compliance with
the following instructions, which are in any case just a memo of the operations required
because of the special features of the crane.
Therefore these instructions do not replace the preparation, the experience and the special
training of professional operators.
We are not therefore responsible for any consequence which may arise from erection or
dismantling carried out by personnel who do not belong to the assistance organisation of the
company BENAZZATO GRU S.p.A.
In particular, it is mandatory to:

 Assign all erection and dismantling operations of the crane to personnel who is qualified
and with specific experience in carrying out all operations for setting up and operating the
machine;
 Check before any erection that all mechanical parts are properly lubricated. Lubricate
with oil or grease if needed according to instructions;
 Check that all welded, bolted or plugged connections are serviceable and make sure that
the mechanical parts required for erection are not damaged;
 Use only connection devices of the models supplied by the manufacturer;
 Make sure all ropes turn perfectly on the pulleys when they are tightened;
 Install the ground system before erecting the crane, since it must operate during erection
too;
 Make sure that on the hoisting drum there are always at least three turns of rope;
 Check that supports are stable and level, and make sure the base is perfectly level;
 Check before any erection, in addition to the usual routine checks according to
regulations, that the ropes are in good conditions;
 Check that the power supply is the mains (grid) one (380/400 V THREE-PHASE or
MONO-PHASE - 50 Hz);
 Carry out a few short erection and dismantling movements with the UP/DOWN button of
the button control box to make sure that the manometer is under pressure;
 Carry out all erection/dismantling operations with no wind or with wind-speed lower than
15 Km/h;
 Make sure that all the rope-ends are provided with thimbles having at least 3 clamps
and, if wedge-end, having at least one clamp (see Fig. 1.8);

3 clamps: correct connection
Rope wedge-end with one clamp

3 clamps: wrong connection
Fig. 1.8
3 clamps: wrong connection
 Check that the motor of the hydraulic unit turns in the direction of the arrow;
 Make sure that all these instructions are followed and that no non-complying operation is
carried out.
8.2 - POSITIONING OF THE MACHINE

 Before positioning the machine, make sure that the available space corresponds to which
foreseen at § 5.1.1, § 5.7 and § 5.11.
 The initial position of the crane must be with folded jib and trolley positioned at the end of
the first section jib, as shown in Fig. 2.8.
Fig. 2.8
Trolley
Pulley block
Attention! Before going on erecting the crane, remind to unhook the hook of the pulley
block hanging from the beams of the jib when transporting the crane.

 Slip off the pins connecting the four mobile legs to the central fixed frame of the
undercarriage.
 Turn the four mobile legs and fix them to the central frame of the undercarriage by
means of the pins already mentioned. Making this way, you set the crane in work position.
 Lower the 4 manual teleskopic jacks onto the supports and check that the undercarriage
is perfectly level.
 Dismount the steering axle and, by choice, also the rear axle.
The configuration is shown in Fig. 3.8.
Base ballast
Fig. 3.8
Turning platform
Undercarriage frame
Steering unit
Pin fixing the steering unit
Mobile legs
Manual teleskopic jack

Pin for fixing the legs “open – closed”
 Make connections of power supply and grounding as instructions given in § 5.2, § 5.3
and § 5.4.
 Turn the switch "WORK/ERECTION CM" inside the electric cabinet (see § 4.8.6) to the
position “ERECTION”, then press the button “RUN” (see § 4.8.1) and check the direction
of rotation of the hydraulic central unit.
In case of opposite direction, disconnect the power supply and invert two of the three
conductors in the plug placed on the undercarriage (see § 5.3).
Act neither on the motors nor on the connection to the electric equipment.

 Hoist the turning jib-tip to work position and lower the pulley block till it reaches the
ground, as shown in Fig. 4.8.
Fig. 4.8
Pulley block
8.3 - BALLAST
The required ballast for starting the erection of the crane is the Kg 3300 base saddle (see §
4.1, pos. 74).
The minimum ballast for the erection of the crane is Kg 3300. This ballast is enough for
the vertical unfolding of the towers but not for the unfolding of the jib.
Note! It is naturally possible and recommendable the installation on the base ballast
saddle of two side blocks weighing 1200 Kg each (see § 4.1, pos. 75).
Note! The jib unfolding is allowed only with crane completely ballasted.
8.4 – ERECTION START

Before starting make sure that:
 The paths of the hoisting and trolley ropes are those shown in section § 4.5.
 The ropes are inside the grooves of the pulleys and drums.
 The pulley block is at least 2 m far from the trolley.
 The hand lever of the hydraulic distributor shown at § 4.8.7 is positioned on “1 – STRUT
PISTON POWER SUPPLY".
1
STRUT PISTON
POWER SUPPLY

 Check that the counterjib linkage has the configuration shown in Fig. 5.8, with reference
to the sequence of ties and struts indicated at § 4.4.2 in Fig. 3.4-B.
The hydraulic piston moving the strut is completely closed.
07
09
04
05
02
06
08
01 10
Fig. 5.8
03
POS. NAME USEFUL LENGHT mm

01 Single tie rope ø 32 mm 6170
02 Butt joint to the counterjib 800
st
03 1 counterjib strut with teleskopic bar 1440 closed
st
04 1 counterjib tie 600
nd
nd
06 2 counterjib strut with cylinder connection 1525
rd
th
th
10 Counterjib strut cylinder 775 closed

 The capacity signs are installed on the jib as shown in Fig. 6.8:
VERSION JIB 26 m (26-600)
Kg 3000 Kg 1800 Kg 600

Fig. 6.8
m 5.0
TOWER AXIS
m 9.0
m 25.2
Kg 1800 STANDARD VERSION
Kg 3000 STRENGTHENED VERSION
 The desired jib raising has been selected by choosing the connection on the back
linkage, as indicated in Fig. 7.8 and Fig. 8.8:
Fig. 7.8
2015
284 283
Double tie ropes ø 24 mm: they can be pinned in 3 different positions

Note! See also Fig. 3.4-A at § 4.4.1 for the position of the tie controlling the raising of the jib.
Crane with jib raised of 15°
Crane with flat jib

Crane with jib raised of 24°
Fig. 8.8
Note! After having pinned the couple of tie ropes to one of the holes and replaced its
pins, make sure to lodge back the snap rings in their seats.
 Check the plates on the electric equipment and wear the required personal protection
means (hard hat, gloves and safety shoes).
8.5 - ERECTION
Verify that the instructions given at § 8.1, § 8.2, § 8.3 and § 8.4 have been followed and
check that the ballast required for the erection, indicated at § 8.3, is really on the
slewing platform.
ATTENTION!!
BEFORE OPENING THE JIB, MAKE SURE THE
TOWERS ARE COMPLETELY ERECTED AND THE
CRANE COMPLETELY BALLASTED.

Note! We recommend you to follow the sequence of the erection operations given here
below. The erection operations are shown in the following pictures and can be
summarized in 5 main phases.
1st PHASE: COUNTERJIB UNFOLDING
The counterjib linkage is folded, for the configuration see Fig. 5.8.
The counterjib strut cylinder (see Pos. 10 in Fig. 5.8) intervenes to unfold the counterjib.
At the beginning the jib-tip should be hoisted in order to create space for the unfolding,
then it will be closed again before going on with the erection of the towers.
Follow the sequence indicated here below:
 Be sure the crane is powered., then check that the mode selector “CM” inside the
electric cabinet is on “2 - ERECTION” (see § 4.8.6).
 Check that the lever of the hydraulic distributor placed on the turning platform of the
crane (see § 4.8.7) is on “1 – STRUT CYLINDER POWER SUPPLY”.
ERECTION AND STRUT CYLINDER

DISMANTLING POWER SUPPLY
1 2 1
 Close the cabinet and press the green button “RUN” on the button control box: the
hydraulic unit motor begins to work.
 Now press the button " TROLLEY FAR" on the button control box (see § 4.8.1): the jib
opens. Stop the movement when the jib has made a turn of 8 ÷ 10 degrees, reaching
the position shown in Fig. 9.8.

Fig. 9.8
8°-10°
 Press the button “UP” on the button control box (see § 4.8.1). Making this way the strut
cylinder is powered and the unfolding of the counterjib begins. Go on till the counterjib is
completely unfolded, according to the sequence shown in Fig. 10.8.
Fig. 10.8

 Press the button "TROLLEY NEAR" on the button control box (see § 4.8.1) in order to
close the jib-tip till it leans against the special support shown in Fig. 11.8. Stop the
movement when the tip element leans against the support; going on pressing the
button “TROLLEY NEAR” can damage the structure of the crane. Close the jib
before passing to the next erection phase.
Folded jib-tip
Support for jib-tip
Fig. 11.8
2nd PHASE: VERTICAL UNFOLDING OF THE TOWERS

 The mode selector “CM” still on position “2 - ERECTION” (see § 4.8.6), turn
CLOCKWISE the hand lever of the hydraulic distributor placed on the turning platform
of the crane, indicated at § 4.8.7, and bring it to position “2 – TOWER CYLINDER
POWER SUPPLY”.
ERECTION AND TOWER CYLINDER

1 2 2

 Now press the button "UP" on the button control box ( see § 4.8.1). Making this way, the
tower cylinder is powered; go on till the vertical unfolding of the towers reaches the
position indicated in Fig. 12.8.
When the tower is completely unfolded, you hear the sound of the oil passing through
the maximum pressure valve. Leave the push button.
The manometer shows the trend of the hydraulic pressure, which has to follow the
sequence indicated here below:
♦ The first part of the jib unfolding happens at 200 ÷ 220 bar.
♦ When the jib leaves its place on the upper tower the pressure reaches 300 ÷ 320 bar.
This value lasts for a while then begins to diminish slowly till the end of the operation.
S. p.A.
2nd PHASE
TOWER UP
Fig. 12.8

3rd PHASE: COMPLETE BALLASTING OF THE CRANE
ATTENTION!
BEFORE PROCEEDING WITH THE AERIAL OPENING OF THE JIB, IT IS ABSOLUTELY
NECESSARY TO COMPLETE THE BALLASTING OF THE CRANE USING THE
COMPLETION BLOCKS AND THE STANDARD SLABS ACCORDING TO THE
INSTRUCTIONS GIVEN AT § 4.8.8.
Proceed with the complete ballasting of

the crane by means of truck crane or
self-ballasting derrick, if the crane is
endowed with.
For the use of the derrick, see § 4.5.3
and Fig. 13.8.
The derrick is equipped with a hoisting
hook and therefore, before using it, it is
necessary to turn the mode selector
“CM” placed inside the electric cabinet to
the position “1 - WORK” (see § 4.8.6) and
to bring the trolley under tower.
In case you use the derrick, once the
slab has been hooked in the two proper
anchor points, remind to link also a hemp
rope having suitable lenght and section
for driving the turn of the derrick from the
ground.
Fig.13.8
ATTENTION!
C1
C2
DO NEVER USE THE DERRICK WHEN THE JIB OF THE

CRANE IS COMPLETELY UNFOLDED.
BEFORE USING THE CRANE, REMEMBER TO FREE THE
FLY JIB OF THE DERRICK FROM ITS SPECIAL TOW-PROP.

4th PHASE: COMPLETE UNFOLDING OF THE JIB
 Keeping the mode selector “CM” on position “2 - ERECTION” (see § 4.8.6), press the
button "TROLLEY FAR" on the button control box (see § 4.8.1).
Making this way, the jib begins to unfold: go on till the jib is completely unfolded (see
Fig.14.8).
Leave the push button when you hear the sound of the oil passing through the
maximum pressure valve.
♦ The maximum pressure during this phase is 200 ÷ 220 bar, value registered at the
beginning of the operation.
♦ Then the value of the pressure diminishes at 180 ÷ 200 bar.
4th PHASE
JIB UNFOLDING
S.p.A.
Fig. 14.8

5th PHASE: IDLING TEST
 Turn the mode selector “SA 1” placed inside the electric cabinet (see § 4.8.6.1) to the
position “1800” if you want use the crane in STANDARD VERSION, or to the position
“3000” if you want use the crane in STRENGTHENED VERSION.
 Turn the mode selector “CM” placed inside the electric cabinet to the position “1 -
WORK” (see § 4.8.6) and then check all the main movements of the crane.

9. - SAFETY DEVICES AND HOW TO ADJUST THEM
9.1 - POSITIONS OF SAFETY DEVICES

C
2
3
4
5
8
Fig. 1.9
B
1
7
6
A
C1
C2

Legend: (see Fig. 1.9)
POS. SAFETY DEVICE
1 Slewing limit switch RPM limiting device + gear wheel

2 Limit switch Up - Down RPM limiting device on drum
3 Load / Speed limiter Roller arm microswitch
4 Maximum load “3000 kg” limiter Piston microswitch
5 Maximum load “1800 kg” limiter Roller arm microswitch
6 Static and dynamic moment limiter for “3000 kg” Piston microswitch
7 Static and dynamic moment limiter for “1800 kg” Piston microswitch
8A Limit switch trolley near Roller arm microswitch

8B Limit switch trolley far with folded jib Roller arm microswitch
8C Limit switch trolley far Roller arm microswitch
9.2 – RPM LIMITING DEVICE
Lock screw “B”
Adjustment screw “C”

Adjustment screw “A” Microswitch “F”
Microswitch “G”
Cam “E”
Fig. 2.9
Shaft integral
with the drum
Cam “D”

9.3 - ADJUSTMENT OF UP/DOWN LIMIT SWITCH

(see § 4.6.1 and Fig. 1.9-Pos. 2 for its position on the crane)
(see Fig. 2.9 for the adjustment)
 Raise the pulley block up to around 0.7 m below the trolley.
 Remove the cover.
 Turn the cam «D» until the microswitch «F» trips (interrupts the contacts UP and keeps the
contacts DOWN).
 Lower the pulley block up to the required height (at least 4 turns of rope must be wound on
the drum) and turn the cam «E» until the microswitch «G» trips (interrupts the contacts
DOWN and keeps the contacts UP).
Note!: Cams are adjusted by loosening the lock screw «B» and turning the screws «A» and
«C»; after the adjustment lock the screw «B» again and close the cover.
Test adjustments with a few movements.
9.4 - ADJUSTMENT OF ROTATION LIMIT SWITCHES

(see Fig. 2.9 for the adjustment)
 Remove the cover.
 Turn the crane two turns to the RIGHT.
 Turn the cam «D» until the microswitch «F» trips (interrupts the RIGHT contacts and keeps
the LEFT contacts).
 Turn the crane two turns to the LEFT.
 Turn the cam «E» until the microswitch «G» trips (interrupts the LEFT contacts and keeps the
RIGHT contacts).
 Close the cover.
 Test the adjustment with a few rotations.
9.5 - ADJUSTMENT OF THE TROLLEY LIMIT-SWITCHES

(see § 4.6.2 and Fig. 1.9-Pos. 8A, 8B and 8C for their position on the crane)
Test the operation of the end limit-switches with a few movement, then fold the jib and test the
FAR trolley limit-switch operates with folded jib too.
9.6 - ADJUSTMENT OF THE LIMIT-SWITCHES OF THE HORIZONTAL TRAVELING

MOVEMENT OF THE CRANE
The crane is not available in moving (horizontally) version, therefore there is no adjustment to be
carried out.

9.7 – ADJUSTMENT OF THE LIMITERS IN STANDARD VERSION “Max. load 1800 kg”
Turn the selector described at § 4.8.6.1 on the position “1800 kg” as shown in the picture
below.
MAX. LOAD 1800 kg
Standard version
1800 3000
9.7.1 - ADJUSTMENT OF THE STATIC AND DYNAMIC MOMENT LIMITER “Max. load 1800 kg”
(see Fig. 3.4-A at § 4.4.1 and Fig. 1.9-Pos. 7 for its position on the crane)
(see § 5.10 for the proof loads to use) about 1.20 m
Kg 660
Kg 1800
FAR trolley limit switch
Piston microswitch
Reference screw

 This limiter is activated only on the FAR trolley movement and on the UP movement.
 Lift the nominal load (Kg 600) near the base of the jib then extend it to the tip of the jib till the
FAR trolley limit switch trips up.
 Bring back the trolley and add 10% to the nominal load at the tip of the jib.
 Adjust the screw to stop the trolley moving toward the tip at around 1.20 m from the position
where the FAR trolley end-switch would trip up.
 Test the adjustment with several movements, test also the adjustment of the maximum
nominal load (Kg 1800) which should stop the FAR movement of the trolley near the sign on
the jib (see Fig. 6.8 at § 8.4).
9.7.2 - ADJUSTMENT OF THE MAXIMUM LOAD LIMITER “Max. load 1800 kg”
(see § 4.6.1 and Fig. 1.9-Pos. 5 for its position on the crane and § 5.10 for the proof loads to use)
 This limiter is activated only on the UP movement.
 Bring the trolley to 4÷5 m from the tower. Lift the maximum nominal load (1800 Kg) a few feet
from the ground.
 Add the additional load of 10% and adjust the screw to stop the movement.
Roller arm microswitch
Reference screw
Kg 1980

9.7.3 - ADJUSTMENT OF THE MAXIMUM LOAD LIMITER IN CASE OF LUFFED JIB

(see § 5.10 for the proof loads to use)
 In case of luffed jib, the capacity is constant all over the jib (Kg 600 or Kg 350, in
according with the arrangement of the raised-jib; see Fig. 8.8 at § 8.4 – 15 or 24
degrees)
 Therefore the maximum load limiter must be adjuster to the value of Kg 600 or Kg 350
with an additional load of 10% according to the provisions on § 9.7.2.
 Moment limiter need not be adjusted since the load which can be lifted is constant.
24°
15°
Reference screw
C1
C2
Kg 385
Kg 660

9.7.4 - ADJUSTMENT OF THE LOAD/SPEED LIMITER

 This limiter controls the UP FAST movement.
 Lift in the permitted area a load of 900 Kg and try the UP FAST.
 Lower the load up to near the ground ad add an additional load of 10%.
 Adjust the screw to turn off the UP FAST movement and turn on the UP SLOW. Test the
adjustment with several movements.
Reference screw
Kg 990

9.8 – ADJUSTMENT OF THE LIMITERS IN STRENGTHENED VERSION “Max. load 3000 kg”
Turn the selector described at § 4.8.6.1 on the position “3000 kg” as shown in the picture
below.
MAX. LOAD 3000 kg
1800 3000 Strengthened version
9.8.1 - ADJUSTMENT OF THE STATIC AND DYNAMIC MOMENT LIMITER “Max. load 3000 kg”
(see Fig. 3.4-A at § 4.4.1 and Fig. 1.9-Pos. 6 for its position on the crane)
STOP THE LOAD
3000 kg
Piston microswitch
Kg 3000
Reference screw

 This limiter is activated only on the FAR trolley movement and on the UP movement.
 Lift the max. load (Kg 3000) until the jib foot and move it forward.
 Stop the movement of the trolley near the board with the notice “3000 Kg” placed on the
bottom part of the jib (see Fig. 6.8 at § 8.4).
 Adjust the reference screw in order to stop the trolley near the over mentioned board with the
notice “3000 Kg” and check with several movements that the movement TROLLEY FAR
really stops.
9.8.2 - ADJUSTMENT OF THE MAXIMUM LOAD LIMITER “Max. load 3000 kg”
(see § 4.6.1 and Fig. 1.9-Pos. 4 for its position on the crane and § 5.10 for the proof loads to use)
 This limiter is activated only on the UP movement.
 Bring the trolley to 4÷5 m from the tower. Lift the maximum nominal load (3000 Kg) a few feet
from the ground.
 Add the additional load of 10% and adjust the screw to stop the movement.
Piston microswitch
Reference screw
Kg 3300

9.9 - SPEED REGULATORS

The crane is not normally equipped with speed regulations since the motors are only three-
phase asynchronous. Starts and stops are controlled with the brakes (self-braking motors) on
lifting and distribution (trolley) while on slewing there is power supply controlled by variation of
the motor supply frequency (inverter). This device is adjusted by the manufacturer at the final
testing of the crane. No work may be carried out on this device unless by specialised
technicians. The manufacturer is not responsible for any damage caused by any
modification of the original adjustment.
In such a case see the additional manual supplied by the manufacturer.
9.10 - END-STOPS AND BUFFERS

They are available for the trolley only since the crane does not move horizontally.
The end-stops are welded to the jib, while the buffers are made of rubber pads installed on the
trolley.
When the jib is folded the end-stops are made of the lower stringers of the section of the
vertically folded arm.
9.11 - ALARM SIGNALS

The alarm signal is a horn with can be sounded with a button on the button control box. (see
chapter 4 § 8.1: yellow button on the button control box)
9.12 - ANTI-INTERFERENCE DEVICES (see chapter 3 § 6)

There are no devices or equipment to prevent interference with nearby equipment.
9.13 - ADDITIONAL DEVICES

There is no others additional devices on crane.

10. - BRAKES: INSPECTION AND ADJUSTMENT
Since the crane of model 205 is not available in a version capable of horizontal travel, we
describe only the brakes of hoisting, slewing and trolley travel.
10.1 – HOISTING (see chapter 4 § 6.1.4)

The adjustment of the braking torque is achieved by tightening the springs «6» with the nuts
«1».
The load adjustment must be the same for all springs and such that the braking action can
stop the descent of the maximum load within a length of around 0.5 m.
The air gap must be kept constant with a value of 0.5 ÷ 0.7 mm around all the disk. In order
to carry out adjustment, turn the nuts «3» to increase or decrease as needed the distance
between the coil with the electromagnet «9» and the brake anchor «5».
Test several times, before closing with the protection cover, that the coil can pull easily the
armature.
10.2 – SLEWING (see chapter 4 § 6.3.4)

«1».
stop the rotation at least in 6 seconds.
To unlock the brake, both through electric unlock and through manual unlock, refer to the
instruction given at § 11.3.1.
The air gap must be kept constant with a value of 0.5 ÷ 0.7 mm around the entire disk. In
order to carry out adjustment, turn the nuts «3» to increase or decrease as needed the
distance between the coil with the electromagnet «9» and the brake anchor «5».
Test several times, before closing with the protection cover that the coil can pull easily the
armature.
10.3 – TROLLEY (see chapter 4 § 6.2.4)

«1».
stop the “NEAR” movement of the trolley, with the maximum load hung on the hook, within a
length of around 0.2 m.
The air gap must be kept constant with a value of 0.5 ÷ 0.7 mm around all the disk. In order
to carry out adjustment, turn the nuts «3» to increase or decrease as needed the distance
between the coil with the electromagnet «9» and the brake anchor «5».
Test several times, before closing with the protection cover that the coil can pull easily the
armature.
SERIAL 205 CRANE Instruction Manual Edtion 01/12

11. - GENERAL INSTRUCTION FOR USAGE AND SETTING-UP OF THE EQUIPMENT
11.1 - OPERATIONS TO BE PERFORMED BEFORE EACH WORK CYCLE

 Adjust and test the moment limiters and the load limiters,
 Test that the hoisting, trolley and rotation limit switches work as expected,
 Test that all brakes work as expected under load,
 Check that the ropes wind up correctly in the pulley and in the drums, where there
should be always at least three turns of rope.
 Check that the ground connection is serviceable.
 Check that all welded, bolted or pivoted (with pins) connections are serviceable.
 Check "visually" that the load-bearing structure shape is unchanged and not deformed
in its components.
 Check "visually" that the counterweight is complete (see diagram at § 4.8.8).
11.2 - INSTRUCTIONS FOR THE CORRECT USAGE OF CONTROLS

 The button control box must be preferably laid down on a suitable surface ensuring safe
support. The control buttons must be pressed one after the other and never more than
one at the same time. The STOP button must not be used for normal control.
 The end switches and the load limiters are SAFETY devices and not OPERATING
devices. It is therefore forbidden to use them for controlling or stopping
movements.
 During erection, the structure of the tower may oscillate, especially while opening
completely the tower. In such a case stop any erection operation and resume
erection only after the oscillation have ended.
11.3 - PUTTING THE CRANE OUT OF SERVICE

At the end of each work shift, or when the wind might exceed the operating limits
(see chapter 3 § 4), the crane must be put out of service.
In order to carry out the needed operations see Chapter 3 § 12 and Chapter 4 § 6.3.4.
Make sure that the jib can rotate free without being hindered and turn it in the expected
direction of the wind.
The main switch of the electric panel must be turned to “0”.
We recommend to unplug the button control box and store it in a suitable place.

12. - DISMANTLING
The manufacturer is not responsible for any consequence due to non compliance with the
following instructions, which are in any case just a memo of the operations required because
of the special features of the crane.
Therefore these instructions do not replace the preparation, the experience and the special
training of professional operators.
We are not therefore responsible for any consequence which may arise from erection or
dismantling carried out by personnel who do not belong to the assistance organisation of the
company BENAZZATO GRU S.p.A.
The general notes of section 8 § 8.1 are otherwise applicable.
12.1 – PRELIMINARY OPERATIONS
POSITION OF THE TROLLEY ON THE JIB
FIRST SECTION JIB

Fig. 1.12
~2m

 Raise the pulley block to around 2 metres under the trolley.

 Place the trolley next the end part of the first section jib (see Pos. 44 in Fig. 1.4 at § 4.1),
as suggested in Fig. 1.12.
Attention! Pay attention to the position of the trolley: it should not be placed beyond the
hinges connecting the first and the central section of the jib, otherwise it
may be crushed during the jib folding.
 Turn the mode selector “CM” placed inside the electric cabinet to “2 - ERECTION” (see §
4.8.6).
 Close the electric cabinet and press the green button “RUN” on the button control box
(see § 4.8.1): the motor of the hydraulic unit begins to work.
 Check that the hand lever of the hydraulic distributor placed on the turning platform of
the crane (see § 4.8.7) is ABSOLUTELY turned CLOCKWISE on “2 –TOWER
CYLINDER POWER SUPPLY ”.
ERECTION AND TOWER CYLINDER

1 2 2
During the dismantling of the crane, you will carry out exactly backwards all the erection
operations. (see § 8.5).
12.2 – DISMANTLING OPERATIONS
Note! For the dismantling of the crane, we recommend you to follow the sequence of
operations listed here below. The operations of dismantling are shown in the
following pictures and can be summarized in 4 main phases.

st
1 PHASE: COMPLETE FOLDING OF THE JIB
 The jib cylinders only work during this phase and the crane strikes the work position with
folded jib (see Fig. 2.12).
Press the button “TROLLEY NEAR” on the button control box (see § 4.8.1); making this
way, the jib begins to fold. Go on till the jib tip reaches the proper bearing welded to the
jib section linked to the tower.
Release the button as soon as the jib tip section reaches the first section jib; do
not go on pushing the button "TROLLEY NEAR": this can damage the structure of
the crane.
♦ The maximum pressure during this phase is 200 ÷ 220 bar, value registered at the
beginning of the operation (at the starting).
♦ Then the value of the pressure during the jib folding diminishes at 140 ÷ 160 bar.
st
1 PHASE
FOLDED JIB
LEAN THE JIB TIP
S.p .A.
Fig. 2.12
Lean the jib tip to the proper bearing
S.p.A.

nd
2 PHASE: REMOVAL OF THE COMPLETION BALLAST IN SLABS
ATTENTION!
BEFORE CLOSING THE TOWERS, IT IS ABSOLUTELY NECESSARY TO REMOVE
THE COMPLETION BALLAST SLABS (INDICATED AT § 4.8.8) FROM THE FRAME.
THE TWO SIDE BLOCKS EACH WEIGHING 1200 Kg CAN NATURALLY BE LEFT ON
THE BASE BALLAST SADDLE.
WE REMIND YOU THAT THE BASE BALLAST (INDICATED AT § 8.3), SHOULD NOT
BE REMOVED.
Proceed with the removal of the

completion ballast in slabs by means of
truck crane or self-ballasting derrick, if the
crane is endowed with.
For the use of the derrick, see § 4.5.3 and
Fig. 3.12.
The derrick is equipped with a hoisting
hook and therefore, before using it, it is
necessary to turn the mode selector “CM”
placed inside the electric cabinet to the
position “1 - WORK” (see § 4.8.6) and to
bring the trolley under tower.
In case you use the derrick, once the slab
has been hooked in the two proper anchor
points, remind to link also a hemp rope
having suitable lenght and section for
driving the turn of the derrick from the
ground.
Fig.3.12
C1
ATTENTION!
C2
DO NEVER USE THE DERRICK WHEN THE JIB OF THE CRANE

IS COMPLETELY UNFOLDED.
ONCE THE TOWERS ARE DISMANTLED, REMEMBER TO
RESTORE THE TOW-PROP OF THE FLY JIB OF THE DERRICK.

rd
3 PHASE: FOLDING OF THE TOWERS
 The tower cylinder only works during this phase and the crane, at the end of this
operation, is in a complete dismantling arrangement (see Fig. 4.12).
Keeping the mode selector “CM” placed inside the electric cabinet on position “2 -
ERECTION” (see § 4.8.6) press the button "DOWN” on the button control box (see §
4.8.1): the tower begin to fold.
During the lowering of the tower, make sure that no cable, tie or rope gets entangled
between the towers. When the tower cylinder reaches the end of its run the hyfraulic
pressure increases till it reaches the pre-set value.
The hydraulic pressure during this stage changes from a maximum value of about 300
÷ 320 bar registered at the beginning (at the starting), to 100 bar in the last part of the
operation, when the towers are almost closed.
S.p.A.
rd
3 PHASE
TOWER DOWN
Fig. 4.12

th
4 PHASE: FOLDING OF THE COUNTERJIB
The counterjib linkage is completely unfolded and should be completely folded in order to
reach the configuration shown in Fig 5.12. move a crane having allowed overall
dimensions (see chapter 6).
The counterjib strut cylinder (see Pos. 10 in Fig. 5.12) intervenes to fold the counterjib.
07
09
04
05
02
06
08
01 10
03
Fig. 5.12
POS. NAME USEFUL LENGHT mm

01 Single tie rope ø 32 mm 6170
02 Butt joint to the counterjib 800
03 1st counterjib strut with telescopic bar 1440 closed
04 1st counterjib tie 600
05 2nd counterjib tie 1355
06 2nd counterjib strut with cylinder fitting 1525
07 3rd counterjib tie 1090
08 4th counterjib tie 1535
09 5th counterjib tie 460
10 Counterjib strut cylinder 775 closed

At the beginning the jib-tip should be hoisted in order to create space for the folding, then
it will be closed again before moving the crane.
Proceed as follows:
 Keeping the mode selector “CM” placed inside the electric cabinet on the position “2 -
ERECTION” (see § 4.8.6), turn COUNTERCLOCKWISE the hand lever of the hydraulic
distributor placed on the slewing platform of the crane, § 4.8.7 and bring it to the
position “1 – STRUT CYLINDER POWER SUPPLY ”.
ERECTION AND STRUT CYLINDER

1 2 1
 Close the cabinet and press the green button “RUN” on the button control box; the motor
of the hydraulic unit begins to work.
 Now press the button " TROLLEY FAR" on the button control box (see § 4.8.1): the jib
begins to open. Stop the movement when the jib will have carried out a turn of 8 ÷ 10
degrees, reaching the position shown in Fig. 6.12.
Fig. 6.12
8°-10°

 Press the button "DOWN" on the button control box (see § 4.8.1): the strut cylinder
begins to work folding the counterjib.
Go on till the counterjib is completely folded, as suggested in Fig. 7.12: the crane
reaches the configuration "completely folded" shown in the previous Fig. 5.12.
Fig. 7.12

 Press the button " TROLLEY NEAR" on the button control box (see § 4.8.1): the jib tip
closes. Go on till it leans on the proper bearing shown in Fig. 8.12.
Stop the movement when the tip section leans on the bearing; do not go on pushing
the button “TROLLEY NEAR": this can damage the structure of the crane. Fold
the jib before towing the crane.
Folded jib tip

Fig. 8.12
Bearing for jib tip
12.3 – FINAL OPERATIONS
 Disconnect all electric and grounding connections.

 Mount the tyred axles in order to move the crane.
 In order to permit the movement of the crane, it is necessary to remove, by a proper
mean, the two side blocks weighing 1200 Kg each, still installed on the base ballast
saddle.
Leave installed on the base frame just the base ballast saddle weighing 3300 Kg. For
the towing and the movement of the machine refer to the configurations at § 6.1.
N.B! It is absolutely not recommended to move the crane with the two side blocks
installed.
 Free the four stabilizers and fold the mobile legs.
 Slip off the pins fixing the four mobile legs to the central fixed frame of the
undercarriage.
 Fold the four mobile legs and fix them to the central frame of the undercarriage using

the pins mentioned at the previous point, as shown in Fig. 9.12.

Making this way, the crane passes from the work configuration to the towing
arrangement.
Ballast: base slab
Fig. 9.12
Slewing platform
Undercarriage frame
Steering unit
Pins fixing the steering unit
Mobile legs
Manual teleskopic jack

Pin for fixing the legs “open – closed”
 Lower the turning jib tip: the crane strikes the towing arrangement and obeys the allowed
overall dimensions (see § 6.1), as shown in Fig. 10.12.
 Before towing the crane, lock the hook of the pulley block to the end bolsters of the jib,
as suggested in Fig. 10.12.
Fig. 10.12 Hook the pulley block

13. - MAINTENANCE INSTRUCTIONS
In addition to the normal testing in the manner provided for by current statutory
regulations, routine checks must be scheduled to be carried out by the personnel of the
maintenance company, in order to make sure that all the parts and the installation of the
crane are serviceable and well preserved.
Any maintenance operation must be performed with still crane and with main switch
disconnected. Any test with movement of the crane requires the guidance of a qualified
supervisor, who will make sure that current accident-prevention regulation are complied
with during any maintenance work.
If any check requires removal of cases, protections or safety devices, suitable measures
must be taken to highlight the danger and if possible neutralise it.
The following directions are provided as suggestions only, since the user is solely
responsible of the manner of carrying out maintenance.
We remind that both the good preservation (and therefore longer service life) and the
constant serviceability of the crane depend on scheduled maintenance.
13.1 - CHECKS AND MAINTENANCE: INSTALLATION

Check every day that:
• the structure is perfectly level;
• the ground, on which the plinths are laid, does not sink;
• the good contact of the plates of the stabilisers.
In order to carry out such checks, lift the nominal load on tip of the jib and carry out a
complete rotation: no kind of sinking of the stabiliser should be visible.
In case a support needs to be restored, operate in a way that does not overload the other
stabilizers.
13.2 - CHECKS AND MAINTENANCE: STRUCTURE

The crane operator is to check the structure visually every day.
Qualified technicians are to inspect every month all the structural components of the
crane, in order to check that:
• welding is not damaged;
• all the structural parts are well preserved and with consistent geometric shape «without
visible change»;

• the condition of preservation of the structure. Schedule any needed reconditioning and
maintenance work.
A complete check is to be carried out after erection, dismantling, testing with overload,
after any exceptional event such as collisions, backlash, etc.
Check always after erection that the single parts are not deformed or dented because of
transport, loading, unloading or wrong warehousing.
Every time the crane is dismantled, retouch paint as needed to protect suitably all exposed
metal surfaces.
13.3 - CHECKS AND MAINTENANCE: JOINTS

Check every week that the welded, bolted and pinned (pivoted) joints are well preserved
and serviceable.
We recommend to check tightening of the bolted joints weekly after erection; afterwards
they can be checked once a month.
Tightening of the bolts is to be carried out with a torque wrench, according to the following
table:
BOLT TIGHTENING TORQUE
MATERIAL M14 M16 M18 M20 M22 M24 THREAD
8.8 (8 G) 12 19 26 37 50 64 daNm
10.9 (10 K) 17 26.5 36.5 52 70 90 daNm
See the supplier's instructions for the correct usage of the torque wrench.
Make sure that the plain or spring washers under the head of the bolt or the nut are not
damaged.
Make sure that the snap rings are not damaged and that they are installed correctly with
washers between the rings and the seal surfaces.
Concerning the slewing ring, the maintenance operations described above must be
supplemented with check of the bolts.
In order to compensate settling, it must be checked that the tightening of fastening bolts
complies with the torque values indicated above. During this operation the bolted
connection must be released from any external tensile stress.
This check is to be performed with a torque wrench within the first 100 hours of
operation and afterwards we recommend to carry it out every 600 hours around or
every 3 months of operation.

The period before the following check should be reduced in case of heavy operation or in
case of equipment requiring special checking standards.
The bolts must be tightened with criss-cross procedure. Never tighten the bolts with a
pneumatic wrench.
All bolts must be replaced also in case one of them is intentionally or
unintentionally removed or loosened.
13.3.1 - LUBRICATION AND MAINTENANCE: SLEWING RING

After erection, lubricate the slewing system and the teeth.
In order to carry out any lubrication use only lubricants free from acids and resin, not
hygroscopic, with long life and with temperature range suitable for the operation of the
bearing.
RECOMMENDED SLEWING RING LUBRICANTS
ARAL ARALUB BP GREASE CASTROL SPHEROL ELF EPEXA

HLP 2 LTX-EP2 WRL 2
ARALUB ENERGOL GRIPPA CARDREXA

LFZ1 WRL 33S DC1
ESSO BEACON IP ATHESIA MOBIL MOBILUX SHELL ALVANA

EP2 EPGREASE2 EP 2 GREASE 2
SURETT CLUSIUM MOBILTAC MALLEUS

FLUID 4K FLUID D 81 FLUID C
The purpose of complete greasing is the reduction of friction, sealing and protection from
corrosion.
We recommend to grease until the grease comes out from the labyrinths of the bearing or
from the seals. During greasing the bearing should rotate. Frequency of greasing should
be in keeping with operating conditions.
Usually, lubrication would be carried out every 100 hours of operation.
We recommend to lubricate more often in tropical environments, in very humid, dusty,
impurity-filled places, in case of large and sudden changes of temperature or in case of
continuous slewing.
After and before a long period out of service, lubrication is mandatory, especially after the
winter break.
Make sure during washing that no detergent enters the slewing system or damages the
seals.

13.4 - CHECKS AND MAINTENANCE
Maintenance of the mechanical parts is performed with the following procedures:
13.4.1-ADJUSTMENT OF SAFETY DEVICES

See Chapter 9
13.4.2-ADJUSTMENT OF BRAKES
See Chapter 10
13.4.3-CHECK OF MOVEMENTS
Every week.
Check that all movements start and stop in the expected times.
13.4.4-CHECKING PINIONS (PINS)

Every week.
Check that the pinions (pins) are installed as designed.
Check that the required washers, safety-pins and/or snap rings are there.
13.4.5-CHECK THE PARTS SUBJECT TO WEAR

Every month.
Check: bearings (especially if unusual sounds are heard), pulleys, slewing pinion and ring,
belts (if any), trolley wheels, condition of hydraulic cylinders, sealing of hydraulic
distributor.
13.4.6 - LUBRICATION
Frequency is indicated for each item.
In case other lubricants are used, they must have the same features of those indicated in
the following table:

PART INSTRUCTION AGIP ESSO SHELL
Check oil level every

50 hours of
REDUCTION operation, top up if
GEARS needed. Change F1 ROTRA 85W/90 TERESSO 56 TELLOS 33
lubricant every
erection.
Check condition
weekly, keep them
always greased. SHIELD GREASE CADIUM
FIN 360 EP/F
ROPES Every erection wash COMPOUND D
N.2 FLUID
away any deposit
with Diesel oil.
Grease every 50
UNPROTECTED hours of operation.
GEARING AND Every erection wash SPRAYDOSEN SHIELD GREASE CADIUM
SLEWING RING away any deposit ROCOL OPEN GEAR N.2 FLUID COMPOUND D
TEETH with Diesel oil.
Grease every 50
GREASERS GR-MU/EP 3 BEACON 2 ALVANIA GREASE 3
hours of operation.
SURRET FLUID 30
Reinstate grease
BEARINGS OR GR-MU/EP 3 SHIELD 650 ALVANIA GREASE 3
after every erection.
BUSHING
Check oil level before OSO 46 NUTO - HC TELLUS 46
HYDRAULIC
CENTRAL UNIT every erection. OSO 32 NUTO - H 32 TELLUS 32
13.4.7 - ROPES
Current regulations require that, at least once every three months, the ropes are checked
and the result are noted down in a special crane checking register.
The maintenance operator must read the checking register in order to understand the
cause of damage to the rope and decide advisedly if the rope can still be used.
In general, the causes of deterioration of a rope may be classified in two groups:
• mechanical causes: static loads, dynamic loads, bending and denting.
• chemical causes: natural oxidation because of humidity, gases or fumes in the work
environment.
The condition of the rope may be evaluated in the first instance from some visual elements
especially breaking and oxidation of wires.

a) breaking of wires – The breaking surface may be examined to deduct if breakage was
due to fatigue, overload or wear. In the first case the surface is smooth and there is no
neck-in or wearing; in the second case there is neck-in, that is the diameter gets
smaller in the area of breakage; in the third case the wire is flattened.
b) oxidation – This examination requires considerable practice, specially for the internal
part. We recommend not to pry open the rope with a screwdriver to inspect it inside,
since some wire may be damaged and the structure of the rope may be disrupted. Just
tap it lightly and listen to the sound. In case of oxidation, since the contact between the
wires is no more tight because of the oxidised layer, the sound will be weak and dull:
you can try the difference of sound with a new rope and an oxidised rope.
13.4.7.1 - REPLACEMENT
In order to decide if the rope should be replaced, take into account the following facts:
• number of broken wires and their positions
• wear of the wires
• external and internal corrosion.
The three conditions should be taken into account at the same time: it often happens that
the general situation makes replacement necessary, even if the three elements have not
reached the minimum limit each on its own.
 Number of broken wires and their positions
It would be very practical to set the maximum number of broken wires in a rope, as a
percentage of all the wires which make up the rope, this is possible, with caution, only
with some types of ropes whose wires all of the same type. In general type and lay of
the rope should be taken into account.
The following table lists 14 types of rope and, for each, according to the type of lay, the
maximum acceptable number of broken wires in a length 6 or 30 times the diameter of
the rope.
Of course the number of broken wires should be counted in the most damaged spot.
As one can see in the table, we take into account ropes with more that 8 strands too; in
this case only external wires should be counted.

Maximum number of visible

ROPE LAY broken wires on ropes with:
STRANDED NON ROTATION Ordinary lay Lang lay rope

rope on long on long
section section
Normal Special Number of wires
in
Type No of Type No of type in the external 6d 30 d 6d 30 d
wires wires rope strands
126 E 18x7=126 12x7=84 5 10 2 4
114 S
144 N 6x19=114 114 W 6x19=114 8 16 3 6
114 F
152 S
152 W 18 36 6 12
152 F
252 E 36x7=252 18x7=126 15 30 5 10
150 F 6x31=186 8 16 3 6
222 N 6x37=222 222 S 6x37=222 30 60 10 20
246 6x41=246 35 70 11 22
336 N 6x61=366 40 80 12 24
S=SEALE W=WARRINGTON F=FILLER

Pitch of wires in the strand =(8+12)xδ where δ=Φ of the strand
Pitch of the strand in the rope =(6+10)xd where d=Φ of the rope
In case of ropes other than those in the table, the total number of broken wires in a section
6 times long the diameter of the rope, should not exceed 10% of the wires which make up
the external strands for ordinary lay and 4% for Lang lay.
Previous data, although based on reasonable expectancies, are intended as general
guidance and may be confirmed by practical testing only.
In case a strand gets broken or its minimum section on a rope step is decreased by 40%,
the rope must be replaced. Replace the rope also in case of dents, neck-in, irregular
reduction of diameter, slots (eyes), torsion knots or other serious damage. The ropes of
bridge crane winches may not be used, according to the law, when on a rope section 4
times long the step of the helix of the strand wire, the number of visible broken wires
exceeds the 10% of the wires which make up the rope.

13.4.7.2 - LUBRICATION
Each wire of a rope adheres to the others on many points (ordinary lay) or on lines (Lang
lay) and, because of the movements of the rope, each wire slides on the other wires,
which cause in a short time severe damage.
In order to reduce the problems mentioned above, the manufacturer provides initial
lubrication of the rope to protect the wires and the core which is often made of vegetal
fibers; this way the core does not impregnate with humidity and wires do not start to
decompose and oxidise. The protection of the lubricant must be kept and renovated in
time; therefore scheduled lubrication is required to get adequate protection.
A good lubricant for ropes must not contain mineral or organic acid substances, nor
alkaline residue; it must be fluid, with good density and absorbability, in addition it must not
emulsify with water. Before lubrication, clean the rope of all deposits on strand interstices,
which are due to the dust in the environment which is absorbed by the lubricant.
The rope may be cleaned with a wire brush of with air jet, as long as the rope had been
impregnated for one or two days with petroleum.
The lubricant may be poured on the rope or spread with a brush. A modern spray product
is available which is highly recommended since the lubricant can better penetrate the
interstices of the rope; this should be carried out on the rope sections which are wound on
the drums where the rope is always a little open.
13.4.8 - HYDRAULIC SYSTEM

Before erection or dismantling of the crane, check that the hydraulic cylinders of the tower
and of the jib are serviceable and well preserved.
Check the level and condition of the oil in the tank of the hydraulic unit.
The oil should be replaced every cycle of 10 erection/dismantling operations, in any case
every two years.
Check for any leak in pipe fittings, repair if needed.
Make sure that the circuit is serviceable with short movements without load. Make sure
that the motor of the unit turns in the direction of the arrow.
The hydraulic cylinders should be replaced when there are dents on the stem. Repack if
the cylinder leaks oil.
13.4.9 - ELECTRIC SYSTEM

Check often that ground circuits are continuous.
We remind that resistance should be measured from the point the crane starts, that is the
hook, to the point where the crane finishes, that is the stabilizer plates.

Check frequently the condition of insulation too, especially cable clamps, terminal boards
and electric panel of the equipment.
Make sure the motors are in perfect conditions and clean regularly the internal parts (case,
fins). After the crane has been out of service for a long time, check the conditions of the
bearings, of terminal board covers and of protection cases.
Inspect weekly the safety contact blocks, make sure they are in perfect working order and
check that all contactors are serviceable.
13.4.10 - STEEL STRUCTURES AND PROTECTION AGAINST CORROSION

Never use the crane in case of steel structures deformed or corroded more than 5% of
their thickness. The holes housing the pivots must not be strongly ovalized.
Eccentricity may never exceed 3÷4% of the diameter.
We recommend to schedule, during the service life of the crane, cleaning of rust and then
painting with an undercoat of rust-preventer and two coats of enamel.
13.4.11 - CRANE OUT OF SERVICE AND WAREHOUSING

In case the crane is out of service for a long time, house it in a sheltered place to protect it
from weather. Never leave the crane on tired wheels for a long time. It is better to secure it
on its supports and in operating condition.
When the crane is out of service for a long time, fill with lubricating oil all reduction
gears on the crane (lifting, slewing, trolley) in order to avoid condensate inside the
equipment with the consequence of oxidation of unprotected parts.
We remind to top-up oil level when the crane is to be put into service.
Always cover the crane with a large piece of canvas if the crane is left in the open air.

14. - INSTRUCTIONS FOR ORDINARY REPAIR WORKS
This chapter concerns the most common problems and failures which can be solved with
ordinary repair works.
In case these suggestions are not successful, please contact the Benazzato Gru S.p.A.
assistance service or any authorised assistance service.
The user of the crane is in any case responsible for any repair work and any consequence
of it.
14.1 - OPERATIONAL FAILURES
14.1.1 - GENERAL ELECTRIC FAILURES
Defect: The crane does not operate, the sound of opening of the mechanical
brake is not heard but its electric contactors operate.
Probable causes: The thermomagnetic switch has tripped because of overcurrent or

motor failure.
Reset the themomagnetic switch and repeat the operation.
If the situation happens again search a failure.
Defect: The commands of the control button box (controller) have no effect.
Probable causes: The mushroom-head stop button was not released (unlocked) or the
crane electric panel is not powered.
The line thermomagnetic switch may have tripped: reset it and try the
command again. Check if the plugs located on the electric panel, the
crane and the electric panel of the building site are connected
correctly.
Check the power supply cable on its whole length.
The contacts of the button control box (controller) may be oxidised.

Open the box and grind the contacts.

Defect: After pressing a control button box command, the main switch of the
building site trips up.
Probable causes: The crane current leaks to the ground. Find the cause on the power
supply line or on the motor controlled by the command which caused
the defect.
Defect: As soon as the electric panel of the crane is supplied power with the
general disconnector, the main switch of the building site trips up.
Probable causes: The control transformer or the electric panel line downstream the
general disconnector of the panel leaks current to the ground
14.1.2 - HOSTING FAILURES
Defect: "FAST" hoisting does not work.
Probable causes: The load to lift exceeds 990 Kg, the load limiter is misadjusted, or its
electric circuit is defective.
Defect: With "FAST" hoisting the thermomagnetic switch trips up.
Probable causes: The load to lift exceeds 990 Kg or the mechanic brake offers
resistance since it is not adjusted correctly.
Defect: "UP" movement does not work.
Probable causes: Check adjustment of the maximum load and moment limiters on the
"UP" movement.

14.1.3 - TROLLEY TRAVEL FAILURES
Defect: One of the movements "NEAR" or "FAR" does not work.
Probable causes: Check the motor brake, the "NEAR" and "FAR" travelling limiters and
the moment limiter on trolley travel.
Check the travelling electric circuit.
14.1.4 - SLEWING FAILURES
Defect: The "LEFT" or "RIGHT" movement does not work.
Probable causes: Check if the crane is at the end of the end of movement. In such a
case turn on the contrary directions.
Check the electric circuit.
14.2 - ERECTION FAILURES
Defect: The motor of the hydraulic central unit runs but the system pressure
does not reach the expected level.
Probable causes: The electric motor of the central unit turns in reverse. Invert the
phases on the crane power supply plug.
The gear pump is defective. Replace it, after changing the oil in the
unit and cleaning it perfectly.

Defect: System pressure reaches the expected level, but when a button of
the button control box is pressed the crane does not move.
Probable causes: Low adjustment of overload valve of the system. Turn the distributor
with the special key until the manometer, with lever turned to the
direction opposite to opening of the cylinder, reads 320 bar.
Opening of tower or jib is hampered by a mechanical obstacle:
remove it.
Defect: Erection (and dismantling) of the crane jerks along, which causes
vibration of the structure.
Probable causes: There is air inside the hydraulic circuit. Unscrew both connection on
the tower cylinder (ONE FOURTH OF TURN IS ENOUGH) until only
oils comes out from them when the distributor is opened. Tighten
them again.
Check the oil level in the central unit. Top it up.

15 – SPECIAL MAINTENANCE WORKS
15.1 – RESTORING THE TENSION OF THE TROLLEY ROPE

Carry out this operation when the tower of the crane is completely folded and the jib
completely unfolded.
This operation requires the base ballast block and may be carried out by expert personnel
only.
The tension can be restored acting on the tensioner, as shown in Fig. 1.15.
Trolley rope
Fig. 1.15
Adjusting screws
The correct tension of the rope is achieved when, with the mode selector “CM” on “1 -
WORK” (see § 4.8.6), by pressing short impulses the button “TROLLEY FAR” and then
“TROLLEY NEAR”, the movement of the trolley is uniform and without jerks.
It is forbidden to climb the crane to carry out this operation. Use a mobile scaffold or the
special external ladder.
15.2 – REPLACING THE HOISTING ROPE

This operation also may be carried out by expert personnel only, the crane arrangement
should be with towers slightly opened by the hydraulic cylinder, as shown in Fig. 2.15.

Note!: Always set a supporting element between the second section of the tower and the
slewing platform to ensure safety while performing the operation.
Deenergize the electric panel of the crane, remove the drum case and the rope to be
replaced, then install the new rope along the path shown in Fig. 2.15, making sure it fits
correctly into the grooves of the pulleys.
For a better view of the run of the hoisting rope, see § 4.5.1.
2.15 D
Guide-pulley at tower centre
2.15 C
Fig. 2.15
The run of the rope shows some points to which

you have to pay attention; they are shown in
Fig. 2.15 A, 2.15 B, 2.15 C and 2.15 D.
Fleeting pulley on tower head
2.15 B
NOTE!:
2.15 A

Fig. 2.15 A – ROPE WINDING ON THE HOISTING DRUM
Reduction gear
Rope-end: wedge + sheathing on the reduction gear side
Hoisting rope: comes out from OVER
TOWER SIDE
To wind the hoisting rope (UP), turn the drum Support

COUNTERCLOCKWISE (VIEW from the BEARING SIDE)
Fig. 2.15 B – PASSAGGE OF THE HOISTING ROPE UNDER THE FORK OF THE TIES
Upper tie rope ø 32
Fork for ties; the hoisting rope passes under
TO PULLEYS ON UPPER TOWER
FROM THE HOISTING DRUM
Triple joint (see § 4.4.1)
Assembling tie rods
Lower tie ropes ø 24

Fig. 2.15 C – WINDING OF THE ROPE ON TROLLEY AND PULLEY BLOCK PULLEYS
Trolley
Trolley (top view) JIB TIP
Rope to the jib tip
Pulleys on trolley
Rope towards the tower
Pulley block
Pulleys on the pulley block
Fig. 2.15 D – CARRY OUT THE ROPE-END AT JIB TIP BY THIMBLE + 3 CLAMPS
Thimble with 3 clamps

Eyebolt
Note!: The rope to be used for substitution must strictly have the strenght features
indicated at § 4.5.1.
Note!: After having replaced the rope, you have to adjust the UP/DOWN limit switch

15.3 – REPLACEMENT OF THE TRAVEL TROLLEY ROPES
Note!: The rope to be used for replacement must strictly have the strenght features
indicated at § 4.5.2.
The replacement of the ropes must be carried out by specialized personnel only and you
have to use ropes of the type described in § 13.4.7.1.
For a better view of the run of the travel trolley rope, see § 4.5.2.
This operation must be carried out when the crane is dismantled and the jib unfolded, as
shown in Fig. 1.15).
Note!: The trolley must strictly be kept at the end of the 1st section jib, as suggested
in Fig. 3.15. The instructions for winding the rope on the trolley (see Fig.
4.15) are applicable only when the trolley is in this position.
Fig. 3.15
st
Place the trolley at the end of the 1 section jib
Run of the trolley = 23.90 m
The installation of the ropes should follow the instructions given here below (see Fig. 4.15):
 Link one end of the rope section "B" (front section) to the wedge rope-end on the
drum placed on the bearing side; then wind up this rope section by turning the drum
carefully till all the coils are filled.
 Link one end of the rope section "A" (back section) to the wedge rope end on the
drum, placed on the reduction gear side; then wind up this rope section by turning
carefully the drum till all the coils are filled.
At the same time the rope section "B" will unwind.
 Stop the operation when you reach the configuration shown in Fig. 4.15:
♦ No. 23 coils wound for rope section "B" (towards the jib tip)
♦ No. 1 empty coil
♦ No. 32 coils wound for rope section "A"(towards the jib foot)

Bearing
Fig. 4.15
n° 23 Section "B" (front section)

wound coils
Section "A" (back section)
No. 1 empty coil

n° 32
wound coils
Reduction gear
 Install the rope section "B" (front section) along the assigned path, as shown in Fig.
6.15 at the next page.
 Tighten the rope section "B" by “Tire-Fort” connected to the trolley bush, then install the
terminal on the trolley (thimble + 3 clamps), see Fig. 5.15.
Terrminal with thimble + 3 clamps
Fig. 5.15
 Carry out the same operations to install the rope section "A" (back section) along the
path, as shown in Fig. 6.15 at the next page.

Fleeting pulley at jib tip

Trolley travel drum
Screw coupling
Rope-guide at jib joint Fleeting pulley at the tensioner
FRONT ROPE RUN SECTION "B" – TROLLEY FAR
Trolley
Fig. 6.15
CHAPTER
Fleeting pulley at jib foot
15
BACK SECTION RUN SECTION "A" – TROLLEY NEAR
PAGE No.
Edition 01/12
15 - 7
Travel trolley drum
Trolley
 The exceeding rope can be wound and fastened to the trolley.

 Adjust tension again, if needed, by the tightener described at § 15.1.
 Verify the correct reeving of the trolley ropesby trolleying back/forward till both ends,
(see Fig. 3.15) and that the travel limit swithes stop the trolley near the stop buffers.

16. INFORMATION ON RESIDUAL RISKS
16.1 - NATURE OF THE RISKS AND PROTECTION MEASURES

The crane, since it is a construction machine which operates in an environment (building
site) with several kinds of risks, may be itself cause of risks which cannot be traced back to
design or protection devices.
The existence of such risks must be taken into account, both to establish behavioural
policies and to set-up personal protection devices.
16.2 - RISKS DUE TO ERRORS IN THE PATH OF THE LOAD

The user may employ only expert and trained operators in accordance with the
provisions of Chapter 17.
The operator must look at the load during the whole path.
In case the load is too far away or there is excessive noise, a procedure should be devised
and made known to all the operators for load handling and hooking.
16.3 - RISKS DUE TO HANGING LOADS

Before starting erection of the crane make sure that no object is left on the structure of the
crane (tools, stones, etc.).
Carry out and check with the utmost care the slinging and fastness of hooking of the load.
Any means located between the hook and the load to be lifted must be absolutely safe and
manufactured by certified companies.
Never fill concrete dump buckets over the standard load. Never let the load hang over
people and always use the hooter when you start handling a load, to get the attention of
the people on site.
Hang the sign «BEWARE! HANGING LOADS» while handling the load and take care not
to collide with scaffolding, materials or the structure of the building.
16.4 - RISKS DUE TO PROJECTING PARTS OF THE CRANE

The area near the crane may not be entered for any reason during normal operation. The
crane may need to be approached during normal maintenance works. In such a case take
pay attention to projecting parts, wear hard hats and suitable clothing.

16.5 - RISKS DUE TO MOVING PARTS

Do not carry out any maintenance work with moving parts or in case of wind.
Always turn off power to the crane and never stand in the range of rotation of the crane.
16.6 - RISKS DUE TO ELECTRIC CABLES

Use as much as possible underground raceways to connect the crane to the electric panel
of the building site. If this is not possible protect the cable with anti-wear sheath.
The path of the power supply cable must be marked in the building site. In case of ground
cables, avoid locating them in areas with traffic of vehicles and or people.
Do not install ground plates with ends protruding from the ground without adequate
protection.
16.7 - RISK OF FALLING-DOWN FROM THE LOWER PARTS OF THE STRUCTURE

It is generally not allowed to climb the higher parts of the crane.
During inspections and maintenance of accessible parts of the crane take care not to fall
down.
16.8 - RISKS DUE TO STATICAL ELECTRICTY

These risks concern the cranes installed near high frequency transmitters and high
powers.
In these cases statical electricity may build up on the higher parts of the crane.
The hook may have a different potential that the ground, with the consequence of risk for
the operator when the operator touches the hook or the load connected to it.
In such a case the personnel should be informed of the risk and should wear insulating
devices (insulating shoes and gloves) before touching the load.
In addition the operator must never approach the load before it has touched the ground.
Take into account that static electricity may build up again in very short time.

17. - TRAINING OF PERSONNEL
In the following text we give some recommendations on training of crane operators. All
functions concerning special maintenance and installation of the crane are reserved to
specialised personnel.
The user of the crane is supposed to take care of training of personnel.
The standards UNI-ISO 9926/1/3 supply training basic criteria which should be observed.
17.1 - ATTITUDES AND KNOWLEDGE

All operators must be of age and bodily fit as certified by a physician.
The following aspects are important: good sight and hearing, no dizziness, no
incapacitating diseases.
The operator must not be a drug or alcohol addict, must have sense of duty and
responsibility and must keep self-control in any situation. In addition the operators must
understand the language of the instructions and of the signs of the machine.
17.2 - GOALS OF TRAINING

The goals of training are:
 Supply full knowledge of the rules concerning the hoisting equipment and the
environment where it is used for putting into service, putting out of service and safe
usage.
 Supply knowledge of hand signs, devices and techniques to handle loads in order to
be able to carry out safely all normal and emergency operations.

 Supply technical knowledge of the hoisting equipment, its features, the capacity
diagrams, the safety devices, in order to be able to identify defects, perform daily
checks, use the documents, etc.
 Achieve the ability to steer with combination and precision of movements, evaluation
of loads, distances and best use of commands.
17.3 - DURATION AND PROGRAM OF TRAINING

Duration must be adequate to achieve the set goals.
Most of time has to be spent on practical training.
The theoretical part must include the following aspects:

 Operator's attitude, role and responsibility.

 Technology of the hoisting equipment: terminology and features, operating principles
of devices (motors, brakes, reduction gears, hydraulic system), limiters and end-
switches, electric panel, control devices, ropes, safety devices, etc.
 Putting into service and out of service: check of conditions in the building site and in
the environment for putting into service and out of service.
 Usage of the equipment and safety rules: load diagrams, configurations allowed,
operating principles and tests of the load limiters, paths of the ropes, forces acting on
the equipment in service and out of service, stability, check of counterweight, place of
work and limitations (electric lines, digging, other equipment nearby), procedures to
start and stop work, forbidden or dangerous operations, usage limits, special
instructions concerning the installation site, action procedures.
 Steering criteria, steering location allowed, control from the ground by cable or radio,
correct usage of movement and combinations of movements, evaluation of distances.
 Communication and signals: hand signals.
 Handling of materials: slinging rules and devices, rules on the usage of hoisting
devices, evaluation of loads (center of gravity, balance, wind factor), preparation of
load.
 Inspection, maintenance and faults (failures): how to use the documents, checks prior
to putting into service, work tests, routine and scheduled checks and inspections,
report on failures and malfunctions, how to behave in case of malfunction.
The practical program must include the following exercises:

 Operating exercises: usage of commands, performance of movement one by one and
without load, combination of two movements with and without load, reduction of
oscillation of load, exercises to develop the capability to evaluate distances, exercises
to improve the accuracy of load pick-up and positioning, exercises to improve the
speed of movement and reduce the duration of the complete cycle to the minimum,
exercises with load not visible to the operator and with the help of a signalling person,
etc.
 Handling exercises: handling of normal loads such as buckets, pallets, etc.; handling
of loads with special equipment, exercises on load slinging and steering, exercises on
communication with hand signals.
 Exercises on usage, testing, maintenance and emergency situations: procedure to
start and stop. Check of the work area, inspections, adjustments, checks of lubrication,
stop with the emergency stop command.
The instruction program must be carried out using this manual as a reference document to
show the features, usage and maintenance of the crane.

18. - DEMOLITION OF THE EQUIPMENT
By demolition of the equipment we mean disassembling the equipment or selling the

equipment for final demolition, with recovery or disposal of the materials which make it up.
The most common reasons for demolition are the following ones:
 When the wear or maintenance condition of the equipment or one of its parts do not
allow to continue safe service and you do not intend, or is too expensive, to carry out
adequate maintenance and checking.
 The equipment has completed the number of design work cycles.
 One part has completed the number of design work cycles, and you do not intend, or
is too expensive, to carry out adequate maintenance and checking.
 You do not intend, or is too expensive, to continue service or sell the equipment
second-hand.
Demolition of the equipment must take place according to the regulations in force at the
time of demolition.
You must always take into account that:

 If the equipment was registered with any authority, demolition must be reported, and
identification plates must be handed back, voided or destroyed, according to the
regulations in force at the time of demolition.
 While waiting for demolition, the equipment must be adequately stored, so that it does
not become a source of danger for people, animals, things and does not pollute the
environment.
 Destruction must be entrusted to companies authorised to recover and dispose of the
materials which make up the equipment.
 If the owner is allowed to carry out demolition, the materials must be divided into
types, and then specialised companies must be entrusted with the disposal or
recovery of each type of material.
 Main materials which make up the equipment are: steel, cast iron, aluminium, copper,
bronze, plastics, tire rubber, mineral lube oil, hydraulic fluids, concrete mix, paints.
The above was written on the base of the regulations or data known to the manufacturer at
the time of sale of the crane. Other regulations may be in force at the time of demolition
which must be complied with by the user even if they are not in accordance with what is
stated above.

19. CHECKING REGISTER
A «checking register» is attached to this instruction manual and is part and parcel of
it; this book is to be kept and filled in with care by the user.
With this register one can:
 Write down the transfers of property and the conditions of the machine at the time of
transfer.
 Evaluate, even if approximately, how many the work cycles the equipment carried
out, the serviceability of all its mechanisms and structures, and therefore decide to
replace them in whole or in part.
 Decide advisedly, according to the remaining useful life, if the equipment should be
demolished or sold again.

OFFICES-FACTORY: 28047 OLEGGIO (NO) - ITALY
VIA S.STEFANO, 103
 (0321) 93535-94734-FAX (0321) 94824
CRANE SERIAL No. 205 VERSION 20.26.600 CONSTR. No. 5480
OPERATION INSTRUCTION MANUAL
CONTENTS
CHAPT. 1 MARKING OF THE CRANE
« 2 INTRODUCTION
« 3 OPERATING CONDITIONS
« 4 TECHNICAL DESCRIPTION
« 5 PREPARATION OF THE BUILDING SITE
« 6 INSTRUCTIONS FOR TOWING AND MOVING
« 7 HOW TO ACCESS THE STRUCTURES
« 8 INSTRUCTIONS FOR POSITIONING AND ERECTION
« 9 SAFETY DEVICES AND HOW TO ADJUST THEM
« 10 BRAKES: INSPECTION AND ADJUSTEMENT
« 11 GENERAL INSTRUCTIONS FOR SETTING-UP OF THE EQUIPMENT
« 12 INSTRUCTIONS FOR DISMANTLING
« 13 INSTRUCTIONS FOR MAINTENANCE
« 14 INSTRUCTIONS FOR ORDINARY REPAIR WORKS
« 15 SPECIAL MAINTENANCE WORKS
« 16 INFORMATION ON RESIDUAL RISKS
« 17 TRAINING OF PERSONNEL
« 18 DEMOLITION OF THE EQUIPMENT
« 19 CHECKING REGISTER

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CHAPTER 1 PAGE No.

1. – SPECIFICATIONS OF THE CRANE

GADBJERG MASKINVÆRKSTED A/S

1.0.1– TOWER CRANE MODEL

Crane model BENAZZATO 205 20 26.600

Month and year of construction 03 / 2012

SERIAL 205 CRANE Instruction Manual Edition 03/12

1.0.1.1.– FACSIMILE OF THE PLATE

OFFICES-FACTORY: 28047 OLEGGIO (NO)

CRANE TYPE CONSTRUCTION YEAR

CAPACITY LOAD WITH JIB IN HIGHT POSITION

MAX. LIFTING SPEED

ENGINE POWER WEIGHTS

TOTAL REQUIRED POWER Kw 15 MAX. REACTION Kg 11000

SERIAL 205 CRANE Instruction Manual Edition 03/12

2. - PURPOSE, FUNCTION AND LIMITATION OF THE MANUAL

2.2 - HOW TO KEEP THE MANUAL

2.3 - UPDATES OF THE MANUAL

SERIAL 205 CRANE Instruction Manual Edition 01/12

2.4 - LIMITATION OF LIABILITY

2.5 - USER'S CO - OPERATION WITH THE MANUFACTURER

SERIAL 205 CRANE Instruction Manual Edition 01/12

3 – EXPECTED OPERATING CONDITIONS

3.1 – IDENTIFICATION OF THE EQUIPMENT

3.2 – AVAILABLE ERECTION CONFIGURATIONS

There are four available erection configurations:

a) Jib with around 4 degrees gradient (normal gradient),

SERIAL 205 Instruction Manual Edition 03/12

DIAGRAM OF THE EQUIPMENT

∗ Capacity admitted only in exceptional cases

Assembling ballast Kg 3.300 Fig. 1.3

axles included Kg 7.100 Z= 12,3 t

SERIAL 205 Instruction Manual Edition 03/12

DIAGRAMS OF THE LOAD Fig. 2.3

∗ Capacity admitted only in exceptional cases

SERIAL 205 Instruction Manual Edition 03/12

PERFORMANCE OF THE CRANE

m/min. 15 max. 1800 Kg

m/min. 4 max. 3000 Kg

m/min. 25 max. 3000 Kg

15° m/min. 25 max. 600 Kg

24° m/min. 25 max. 350 Kg

CONTROLLED r.p.m. 0.4 – 0.9 max. 3000 Kg

3.3 – CLASSIFICATION ACCORDING TO CALCULATION STANDARD

 Structure calculation standard: DIN 15018

SERIAL 205 Instruction Manual Edition 03/12

3.4 - EXPECTED ENVIRONMENT

 Environmental temperature: from -3° to 50° C

3.4.1 - DIVISION OF THE TERRITORY OF THE COUNTRY INTO WIND ZONES

SEE CURRENT REGULATIONS IN CASE THE CRANE

SERIAL 205 CRANE Instruction Manual Edition 03/12

3.5 - ALLOWED CONCURRENT MOVEMENTS

3.6 - INTERFERENCE WITH OTHER EQUIPMENT

SERIAL 205 CRANE Instruction Manual Edition 03/12

VERTICAL PART FARTHEST AWAY

SERIAL 205 CRANE Instruction Manual Edition 03/12

3.7.1 - Button control box for all service movements.

3.7 - DESCRIPTION OF CONTROL DEVICES

3.7.3.1 Selector of operation/erection.