erection drawing details assembly instructions / spare ... · erection drawing details assembly...

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Erection drawing details Assembly instructions / spare parts list

for pillar-mounted slewing cranes, type M Meister

Main instructions, issue 10.2006 EN Scope of a pillar-mounted slewing crane of standard / basic design:

Slewing range max. 360° (infinite) or limited mechanically by stops Manual slewing Power supply by means of cable supporting tube or round trailing cable

Note: When the slewing crane features other accessories such as an electrical slewing drive, the power supply is modified and additional components are required. For such case supplementary instructions are provided.

Table of content

1. General.....................................................................................................................2 2. Pillar assembly ......................................................................................................8 3. Pre-assembly of jib.............................................................................................11 4. Jib completion .....................................................................................................13 5. Assembly instructions for trolley end stops..............................................14 6. Round power supply cable (with cable supporting tube) ....................22 7. Round power supply cable (with cable tensioning rope) .....................23 8. Final jib assembly...............................................................................................25 9. Precise alignment of pillar and jib ...............................................................27 10. Installation of electrics without slip-ring unit..........................................28 10. Installation of electrics with slip-ring unit ................................................29 12. Assembly of the slip-ring unit ........................................................................30 13. Electrical installation of the mains connection switch ..........................32 14. Slewing end stop .................................................................................................33 15. Undergrouting and anchorage (system ANKERFIX)...........................36 16. Putting into operation.......................................................................................38 17. Technical information ......................................................................................39 18. Spare parts list.....................................................................................................40


1. General

1.1 Standard / basic crane design - schematic diagram (Execution: design with chain hoist and round trailing cable power supply)

For customized slewing cranes this documentation will be completed by a layout drawing and a circuit diagram, if required. For the exact type of crane, please refer to the order acknowledgement and the documentation included in the supply. Slewing cranes, models M and TS shall only be equipped with hoist units with a rated capacity of max. 1.6 times the crane’s SWL (load capacity). The total weight shall not exceed the permissible total weight as specified in the master data sheet. The illustrations in the present manual are symbolic and may deviate from the actually supplied equipment.

Pos./Item Benennung Designation Standsäule Pillar

S1 Säule Pillar S2 Fußflansch Foot flange S3 Säulenring Pillar ring S4 Kopfplatte Top plate

Ausleger Jib

A1 Trägerprofil Girder profile A2 Auslegerstütze Jib support A3 Rollenkasten mit

Lagerung Roller box with bearing

M Mittelzapfen mit Lagerung

King pin with bearing

A15 Hebezeug Hoist

M A1

A15 A2

A3

S4

S3

S1

S2


1.2 General information for crane installation

1.2.1 The cranes and crane components are designed for single shift operation under normal

operating conditions. These instructions refer to the first assembly of the crane at its place of destination. Dismantling and re-erection of the crane are subject to additional inspection works. Please contact the manufacturer!

1.2.2 Field of application The cranes and crane components are designed for single shift operation under normal operating conditions. In case of higher demands on the cranes or special ambient conditions (i.e. higher frequency of use, high ambient temperature, radiation and explosion hazards, aggressive or abrasive atmosphere), the use of the crane and its components must be checked!

1.2.3 Requirements on supporting structures for slewing cranes

o Slewing cranes only work perfectly on a horizontal surface of sufficient strength and rigidity.

o Deformations of the supporting surface provided by the customer shall not exceed 1/1000 the distance of the surface in all slewing end positions with nominal load. Open sections such as double tee booms are subject to torsion and, if necessary, have to be reinforced.

o Important: The effective direction of cutting forces changes in the slewing positions!

o Contact or supporting surfaces must be even in the horizontal and vertical direction, respectively. The admissible deviation shall not exceed 1/1000 of the largest distance.

o Even floor bases must be available if crane pillars are mounted on anchor plates, top

and compact anchor pads, intermediate plates, machines or steel structures! Generally, cranes designed for concrete footing (standard design) do not provide an even surface!

o The supporting structure must not be subject to vibrations and oscillations.

o We are not liable for supports, columns, walls, bracings, floors, etc. provided by the

customer. Therefore, the supporting structure must be checked by the customer prior to the crane installation. Cutting forces are specified in our data sheets, catalogues, offers and order confirmation or are available on request.

o We will refuse any claims resulting from an insufficient supporting structure or from imperfect fastening.

o We expressly refer to the national and regional building regulations, the directives of building authorities etc..


1.2.4 The installation has to be carried out by experienced expert companies or qualified

technicians (see BGV D6, § 26). In case of questions, please contact your supplier.

1.2.5 Slewing cranes only work perfectly, if they are erected in accordance with this manual and on

the condition that inspections and maintenance works are executed on a regular basis.

1.2.6 The non-observance of the assembly instructions, operating instructions and regulations of the Industrial Employers' Mutual Insurance Association present a risk to the safety of the operation and result in a refusal of claims.

1.2.7 Only use factory-supplied spare parts.

1.2.8 Prior to start the assembly, check centrelines and heights at site and compare same with the

crane design. Observe the specified safety distances.

1.2.9 Observe the manufacturer’s instructions for hoist units and slewing drives as well as for any other accessories.

1.2.10 For the outdoor use, hoists and slewing drives must be weather-protected. Appropriate shielding is available from the manufacturer/supplier.

1.2.11 The electrical installation works must only be carried out by a qualified specialist.

1.2.12 The assembly shall only be carried out when the power is off.

1.2.13 For cranes operated outdoors, the cable openings for earth and supply cables in the jib need additional sealing.

1.2.14 Install hoist unit and trolley strictly in compliance with the manufacturer’s/supplier’s

instructions.

1.2.15 Observe manufacturer’s instructions in respect of electrical protection.

1.2.16 Follow the inspection instructions according to § 19 of EN 60204-32.

1.2.17 After completion of assembly, carefully check all functions. The direction of motions must match the symbols of the control panel.

1.2.18 Crane operating instructions have to be attached on the crane, e.g. on the pillar, and shall be easily perceptible.

1.2.19 Prior of the start-up of motorized cranes and cranes with a capacity of more than 1000 kg, carry out the inspections according to the applicable regulations, e.g. UVV-Cranes BGV D6 , §25.

1.2.20 Observe manufacturer’s instructions for the operation and maintenance of cranes, hoists, slewing drives and other items. Please ask us for missing manuals/instructions prior to start the installation or start-up activities.


1.3 Parts list (applicable to all crane designs; for parts marked grey see separate instructions)

Mechanical equipment

Pillar King pin bearings S1 Pillar M1 King pin S2 Foot flange M2 Bearing cover plate or S3 Pillar ring Nilos ring S4 Top plate M3 King pin bearing S5 Gear ring M4 Supporting washer S6 Access opening/cover M5 Retaining ring S7 Slip ring assembly retaining plate M6 Support section S8 Mains connection switch opening for slip-ring assembly Mains connection switch retaining

plate

Trolley end stops Jib K1 UNI-trolley end stops K2 Inner end stop A1 Jib profile K3 Bottom end stop A2 Jib support A3 Roller plate Roller box A4 Roller Base plate fastening A5.1 Steel roller cover V1 M27 anchor bolt A5.2 Plastic roller cover V2 M27 adjusting nut A5.3 Cap for HT screw V3 Washer 28 A6 Front end plate V4 Supporting ring A7 Rear end plate V5 M27 hex. nut A8 M16/M20 hex. screw V6 M16 locknut A9 Spring washer A16/A20 V7 Compact anchor A10 Motor support plate V8 M27 HT screw A11.1 Safety ring V9 HT washer A11.2 Safety tape V10 M27 threaded rod A12 Hex. screw V11 98 x 6 washer A13 Spring washer V12 Top bolt A14 Hex. nut V13 Hexa. screw M27 A15 Hoist V14 Washer 28

Information plates Auxiliary items (by others)

B1 Type plate H1 Supply line provided by the customer

B2 UVV – plate H2 Bearing block B3 Name plate H3 Strip of timber approx.

100 x 500 B4 Load capacity H4 Wooden wedge B5 Danger strip H5 G clamp H6 Round steel/screwdriver H7 Spacer ring


Slewing drive A Slewing drive B AA1 Hollow shaft gearbox

with motor AB1 Solid shaft gearbox

with motor AA2 Connecting element AB2 Pinion AA3 Thick washer (t=10mm) AB3 Cover plate AA4 Spring washer AB4 Spring washer AA5 Hex. screw (l=40mm) AB5 Hex. screw AA6 M8 hex. screw AB6 Hex. screw, long AA7 A8 spring washer AB7 Hex. screw, short AA8 Torque bracket AB8 Spring washer AA9 Hex. screw AB9 Hex. nut AA10 Washer AB10 Split sleeve AA11 Hollow shaft AB11 Pinion cover AA12 Slotted nut AB12 Washer AB13 Hex. nut, flat AB14 Solid shaft gearbox

with manual drive element

AB15 Adjusting screw AB16 Distance washer AB 17 Spacer sleeve AB18 Locknut AB 19 Cover Mechanical slewing stop SM1 Slewing stop, welded

type, complete with rubber buffer

SM2 Slewing stop, screw-type, complete with rubber buffer

SM3 M12 hex. screw SM4 A12 spring washer SM5 End stop cam Slewing limit switch SE1 Slewing limit switch cpl.

with support bracket

SE2 T section SE3 C-rail SE4 M8 hex. screw SE5 Washer 8,4 SE6 M8 locknut SE7 M6 hex. screw SE8 A6 spring washer SE9 Square nut SE10 M6 pin SE11 Hexagonal nut M6


Electrical equipment E1 Supply cable E2 Flush-mounted mains

connection switch E3 Slip-ring assembly E4 Twist-type cable entry gland E5 Earthing lead E6 Cable ties with eye E7 Cable tube E8 Cable supporting tube E9 Clips 1 E10 Clips 2 E11 Clips 3 E12 Supporting arm E13 Supporting arm (alt. mount.) E14 Clamp, flat E15 Cable ties E16 Eye bolt E17 Rope E18 Ferrule E19 Round cable carriage E20 Supporting arm E21 Supporting arm (alt. mount.) E22 C-rail E23 Connector E24 Clamp, round E25 Fixed suspension E26 Flat cable trolley E27 Flat cable end clamp E28 Towing trolley E29 Engaging stirrup E30 Terminal box E31 On-board terminal box E32 Ideal control carriage with

terminal box E33 Ideal control carriage with

plug-type connection E34 End stop E35 Control panel E36 Contactor control box E37 Filler plates

We reserve the right to pre-assemble individual components! Due to the variety of products (different crane models) some electrical accessories included items may not be required for the assembly of your crane!


2. Pillar assembly

Pillars may be fastened as follows:

Fastening on ANCHOR BOLTS / foundation Fastening on COMPACT ANCHORS / foundation *) Fastening on TOP ANCHORS / foundation Fastening on RESIN BOLTS / concrete floor *) Special fastening methods *)

2.1 Installation on anchor bolts (system ANKERFIX)

2.1.1 Note: Please check prior to the installation whether the foundation has been executed in accordance with foundation instructions and preset minimum dimensions. Remove the anchor bolt template if still in place! Anchor bolts shall not be dressed by heat treatment! Caution! Pillars featuring screw pitch circle DL shall not be directly fastened with resin bolts, dowels or equivalent fastening material! Compound anchor bolts require larger plates of a special type (Please contact us for details). In case of non-observance the crane risks to turn over!

2.1.2 Place pillar (S1) next to the foundation, lead the cable (H1) internally through the pipe and pull it out from the switch opening (S8).

2.1.3 Screw in an adjusting nut (V2) on every anchor bolt (V1), put in place a steel washer (V3) and a supporting ring (V4). Make sure that all rings (V4) are exactly on the same level! The difference in height between a top edge of the ring and another must not exceed 1/1000 of the respective distance!

It is not allowed to set up the pillar on just a few (e.g. 4) adjusted rings!

2.1.4 Position pillar (S1) onto adjusting nuts (V2), apply washers (V3) and rings (V4). 2.1.5 Secure pillar (S1) by means of washers (V3) and nuts (V5). Tighten lower adjusting nuts

(V2) as well.

2.1.6 Align pillar vertically (S1) by using a level, align it with the adjusting nuts (V2) and tighten the bolts (V5). Attention: In order to avoid that only one anchor bolt gets under excessive strain during the alignment, adjust the neighbouring nuts (V2) accordingly! The alignment of the pillar with the water level is only preliminary and rough. The crane is precisely aligned when the jib is fitted. This alignment is described in chapter 9.

2.1.7 Remove adhesive tapes on the pillar ring (S3), if any. *) Refer to separate assembly instructions


When setting up the pillar (S1) please provide easy access to the main switch opening (S8) and the main switch (E2), respectively!


Illustration: Fastening with anchor bolts (prior to undergrouting): Detail X

Detail Supporting ring

Supporting ring

flexible ring


3. Pre-assembly of jib

3.1 Components (A1) Jib(profile) (H2) Bracket (A2) Jib support (H3) Timber strip min. 100 x 500 (A3) Roller plate / box (H4) Wooden wedge (A4) Roller (H5) G clamp (A5) Roller cover (M1) King pin (A6) Front end plate (M2)-(M5) Bearings, cpl. (A7) Rear end plate (E3.2) Slip-ring assembly, centre part (A8,A9) Hex. screw, spring washer (E7) Cable tube (A15) Hoist (E8) Cable supporting tube (E10) Clips 2 Note: In order to safely position the jib, use two trestles (H2). If necessary,

additionally use squared timber (H3).

3.2 Jib pre-assembly

A8,A9

E3.2

A3

M4

M1

M2

A7

A4

M3

M5

H3

A2

H2

H5 K1

A6

A8,A9

H2


3.2.1 Align the jib (A1) in the horizontal position.

3.2.2 Place jib (A1) on suitable trestles (H2) and / or (H3)

3.2.3 Secure the jib (A1) with a clamp (H5) or similar tools against tilting.

3.2.4 Remove front plate (A6), insert hoist unit (A15), and attach front plate (A6).

3.2.5 Mount the trolley end stops (K1)

- Observe instructions (refer to item 5)

- Precisely adjust runways. - Do not exceed rated outreach.

3.2.6 Position hoist unit (A15) in the front trolley area.

3.2.7 Remove any dirt from king pin (M1), put on bearing cover (M2), bearing (M3) and shim (M4) onto the king pin (M1) and secure by means of the retaining ring (M5) . (Items (M1) - (M5) are factory-assembled and packed in oiled paper.)

3.2.8 Mount the body of the slip ring assembly (E3.2) (see also item 12).

Note: For the pre-assembly of the jib and the completing works, the hoist unit can also be positioned at the other jib end next to the jib supporting beam.


4. Jib completion 4.1 Items:

(B3) Type plate (E7) Cable tube (B4) SWL plate (E8) Cable supporting tube (B5) Danger strip (E10) Clips 2

4.2 Jib completion

4.2.1 Attach type plate (B3), SWL plate (B4) and danger strip (B5) on both sides of the jib.

4.2.2 Fasten the cable tube (E7) and cable supporting tube (E8) with clips (E10) on the jib (A1) (only for crane model with round power cable).

4.2.3 Fasten cable tube (E7) with clips (E10) on the bottom flange of the jib (A1) and on

the front plate of the jib support (A2) with clips (E10) (only for crane model featuring drive A).

4.2.4 Attach roller cover (A5), if any.

A1M6

E4

B3 B4 B5

E8,E10E7,E10

H3

H5

H2

A3

A4

A8,A9

A7

E3.2

E7,E10

A2

K1

A5.1: Dl<=430mm

A5.2: Dl>=530<=730mm

A5.3: Dl>=830<=1100mm


5. Assembly instructions for trolley end stops

5.1 UNI trolley end stop (K1)

The UNI trolley end stop (trolley end stop) is exclusively suitable for: Girder sections featuring parallel flanges with thicknesses from 8 - 25 mm and

girder widths from 91 to 300 mm Load capacities as specified Travel speeds as specified

Load capacity (kg)

Max. perm. hoist weight (kg) Max. perm. approach speeds m/min

125 through 2000 180 28 2500 225 25 3200 225 22 4000 325 20 5000 600 16 6300 600 14 8000 1500 12 10000 1500 10

All components of the UNI trolley buffer are galvanized, the frame plates and clamping sections are additionally passivated and do not need any other corrosion protection.

For each slewing crane, two UNI trolley end stops (K1) are supplied. 5.1.1 Screw 2 locknuts (K1.7), 2 nuts (K1.5) and 2 washers (K1.6) onto threaded rod

(K1.4) towards the centre. Ensure even distribution on the right and on the left. 5.1.2 Place two frame plates (K1.1) on the right and on the left, as shown in the figure, on

threaded rod (K1.4) and push them into the girder section. 5.1.3 Push 2 clamping sections (K1.2), each, from the outside onto threaded rod (K1.4) and

tighten by hand, use washers (K1.6), nuts (K1.5) and locknuts (K1.7).

5.1.4 Attach the rubber end stops (K1.3) to the frame plate (K1.1), use hexagonal nuts (K1.3.1) and clamps (K1.3.2). If it is possible, position the end stops at the interface of frame and crossbeam of the hoist unit. (At this end 5 optional holes are available). Rubber end stops (K.1.3) are not required if trolleys are already fitted with rubber buffers. In such a case the trolley buffers may directly run against the frame plates of the UNI end stops (K1).


5.1.5 When positioning the UNI-end stops (K1) on the boom, never exceed the nominal

outreach (=centre of the pillar up to final hook position). In any case, keep the minimum clearance of 10 mm between end of the jib and end stop.

5.1.6 Evenly tighten outer nuts (K1.5) on either side. Make sure that the frame plates (K1.1) are in contact with the girder edge.

5.1.7 Slightly tighten the inner nuts (K1.5) towards frame plate (K1.1). 5.1.8 Tighten outer nuts (K1.5) with a tightening torque of 35 Nm and secure with locknuts

(K1.7). 5.1.9 Tighten inner nuts (K1.5) with the same tightening torque and secure them as

described above. 5.1.10 If necessary, cut off protruding threaded rod (K1.4).

5.1.11 In order to test the fastening, move the hoist against UNI trolley buffer (K1).

Important!

The UNI safety end stop is important for safe operation. Therefore, regularly check the fastening of all items. If it is necessary, replace the fastening elements. In any case, the fastening of the end stop must be replaced when the end stop has reached the jib end.

Safety note:

If the failure of the UNI end stops presents a risk of personal injury, an additional safety item must be mounted (e.g. stop plate)!

A15

A1 K1


Illustration: UNI end stops

Option: In order to reduce the length of projection of the beam, the frame plate can be deleted so that the front end stop can be directly attached to the jib end plate (A6). The special plate for this mounting option will be factory-preassembled.

K1.1

K1.2

K1.3 K1.3.1 K1.3.2

K1.4

K1.5-K1.7K1.5

K1.6K1.7 K1.6K1.1

K1.5

K1.7

K1.2

K1.3 K1.3.1 K1.3.2

A6


5.2 Trolley end stops (K2) mounted on the bottom side of the beam

The trolley end stop (K2) is suitable for the following applications:

o Girder sections with parallel flanges of any thickness o Carrying capacity up to 10000 kgs o Travel speeds up to 20 m/min.

5.2.1 Attach both rubber stops (K2.5) by means of the spring washer (K2.6) and the nut

(K2.7) to the angle iron (K2).

5.2.2 Fasten the angle irons in the front and rear area, use screws (K2.1), washers (K2.2) and nut (K2.3) and secure screws with the locking nut (K2.4).. Note: The trolley end stops are factory-mounted on the beam! Option: In order to reduce the length of projection of the beam, the frame plate can be deleted so that the front end stop can be directly attached to the jib end plate (A6). The special plate for this mounting option will be factory-preassembled.

5.2.2

Katzfahrendanschlag unter dem Trägergurt

Trolley buffer attached to the bottom flange of the beam

K2 Winkelprofil K2 Angle

K2.1 Skt.-Schraube M16 K2.1 Hex.-screw M16

K2.2 Scheibe 17 K2.2 Washer 17

K2.3 Skt.-Mutter M16 K2.3 Hex.-nut M16

K2.4 Sicherungsmutter M16 K2.4 Securing nut M16

K2.5 Gummipuffer K2.5 Buffer

K2.6 Federring A10 K2.6 Spring washer A10

K2.7 Skt.-Mutter M10 K2.7 Hex.-nut M10

A6

K2.6 K2.7

K2.5

A6

K2.1

K2.2

K2

K2.2

K2.3

K2.4

K2.5-K2.7


5.3 Trolley end stop (K3) attached to the beam web

5.4 The trolley end stop (K3) is suitable for the following applications:

o Girder sections with parallel flanges of any thickness o Carrying capacity up to 10000 kgs o Travel speeds up to 20 m/min.

5.4.1 Attach both rubber stops (K3.5) by means of the spring washer (K3.6) and the nut (K3.7) to the angle iron (K3).

5.4.2 Fasten both front angle irons (K3) with screws (K3.1), washers (K3.2) and nuts

(K3.3) and secure the screws with counternuts (K3.4). (The angle irons in the rear area are already factory-welded). Note: The trolley end stops on the beam are factory-assembled).

Option: In order to reduce the length of projection of the beam, the frame plate can be deleted so that the front end stop can be directly attached to the jib end plate (A6). The special plate for this mounting option will be factory-assembled.

Katzfahrendanschlag im Trägergurt

Trolley end stop mounted at the web

K2 Winkelprofil K2 Angle K3.1 Skt.-Schraube M16 K2.1 Hex.-screw M16 K3.2 Scheibe 17 K2.2 Washer 17 K3.3 Skt.-Mutter M16 K2.3 Hex.-nut M16 K3.4 Sicherungsmutter M16 K2.4 Securing nut M16 K3.5 Gummipuffer K2.5 Buffer K3.6 Zyl.-Schraube M10 K3.6 Cyl.-screw M10 K3.7 Federring A10 K2.6 Spring washer A10 K3.8 Skt.-Mutter M10 K2.7 Hex.-nut M10

K3.1

K3.2

K3.3

K3

K3.2

K3.4

K3.5-K3.8

K3.5K3.6 K3.7 K3.8

A6


Overview of electrical components General E1

Supply cable, round – Round power supply cable – Round trailing power supply cable – Flat trailing power supply cable (or ideal control) with slip-ring

assembly – Flat trailing power supply cable (or ideal control) with limit

switches for limited slewing range

E1

Supply cable, flat – Flat trailing power supply cable (or ideal control) for limited

slewing range E2

Flush-mounted mains connection switch – 400 / 500 V 50 Hz – 20 A / 32 A / 100 A (depending on hoist) – lockable in 3 positions

E3

Slip-ring assembly – For infinite slewing range – 400 / 500 V 50 Hz – 16 A / 25 A / 100 A (depending on hoist)

E4

Twist-type cable entry gland – Protection of the supply cable for leading it through the king

pin

E5

Earthing lead – Earthing lead of pillar and jib

E6

Cable ties with eye

Support of the supply cable for infinite slewing range


Round power supply cable E7

Cable tube – Guide for the supply cable parallel in jib up to cable

supporting tube – Length adapted to jib

E8

Cable supporting tube – Return of supply cable vertically to jib fitted on the

jib – Length: 500 mm

E9

Clips 1 – Fastening of cable tube on upper flange of jib

(application in jib) – for girders up to IPE 360

E10

Clips 2 – Fastening of cable tube on upper flange of jib – Application either in jib or on girder flange – for girders from IPE 400

E10

Clips 2 (option for cranes featuring slewing drives) – Fastening of cable tube on bottom flange of jib or jib

support – Application optionally in the jib or on girder flange – Power supply cable for drive type A

E11

Clips 3 – Fastening of cable supporting tube on jib Cable supporting tube projects the girder at both sides


Round trailing power supply cable E12

Supporting arm – Bracket for rope guide – Fastening with clamp, flat on end plates

E13

Supporting arm (alternative mounting) – Bracket for rope guide – Fastening in rear jib area with hex. screws – Arrangement in girder

E14

Clamp, flat – Fastening of supporting arms on front and rear end

plates – 2 off/supporting arm

E15

Cable ties – Fastening of supply cable on supporting arms

E16

Eye bolt – Fastening of rope on supporting arm

E17

Rope – Running rope for round cable carriage, dia. 3 mm

E18

Ferrule – Fastening of rope on eye bolt

E19

Round cable carriage Guide of supply cable Max. SWL: 3 kg/carriage

The delivery of electrical items is customized to the crane design. It may deviate from the components specified in this list. Electrical installation works must be done by qualified personnel. In case of questions related to the installation of the electrical equipment, please contact your supplier.


6. Round power supply cable (with cable supporting tube)

6.2 The cable tubes (E7) supplied must be cut to length to suit the jib.

Cable tube (E7) and cable supporting tube (E8) are mounted on the right-hand

side on the jib, viewed from the pillar in the direction of the jib end.

6.3 Pull supply cable (E1) with twist-type cable entry gland (E4) through the king pin hole.

6.4 Fix clips (E9 or E10) on the upper girder flange.

6.5 Insert cable tube (E7).

6.6 Fasten the cable supporting tube (E8) with clips (E11) in the middle between the

trolley end stops on the upper girder flange.

6.7 Pull the supply cable (E1) through the cable tube (E7) and the cable supporting tube (E8).

6.8 Leave the cable long enough, so it will not restrict the travel path of the hoist.

Note: Cable supporting tube (E11) must be arranged so that the supply cable (E1) does not rub against the jib or the hoist!

6.8 Connect supply cable (E1) with the hoist (A15) as shown on the circuit diagram.

E1

E9,E10

E7

E8

E11

E11


7. Round power supply cable (with cable tensioning rope)

7.1 Fasten support brackets (E12) on the front end plate (11) and on the rear plate (12) with clamps (E14).

The support brackets (E12) are arranged on the right-hand side on the jib, viewed

from the pillar in the direction of the jib end. The support brackets (E12) are situated on the top of the jib. For a travel mechanism featuring a motorized trolley, mount the motor on the left-

hand side of the jib, i.e. opposite to the support brackets.

7.2 Pull supply cable (E1) with twist-type cable entry gland (E4) through the king pin hole and slide into rear supporting arm (E12).

Fasten supply cable (E1) on rear supporting arm (E12) by means of cable ties (E15).

7.3 Slide round cable carriages (E19) onto rope (E17).

Place the rope (E17) parallel to the jib.

7.4 Lead rope (E17) on both ends through ferrule (E18), the eye of eye bolt (E16) and through ferrule (E18). Compress ferrules (E18) with pliers.

7.5 Tension rope (E17) between front and rear supporting arms (E12) with eye bolt (E16).

7.6 Pull supply cable (E1) through round cable carriages (E19).

7.7 Fix supply cable (E1) and apply in loops through round cable carriages (E19) so that

the hoist can be travelled up to the tip of the jib. It must still be possible to move supply cable (E1) in this position.

Note: Rope (E17) must be arranged so that neither round cable carriages (E19) nor supply cable (E1) wear against the jib or the hoist!

7.8 Connect supply cable (E1) with the hoist unit (A15) as shown on the circuit diagram.


A6

A7

E12

E14

E14

E14E12

E17E19

E18 E16

E12

E15

E16E18

E19

E1 E17

E12E17

E1

A15


8. Final jib assembly

8.1 Loosen the rear end plate (A7).

8.2 Clean and grease the bearing seat in the top plate (S4) and the bearing (M3).

8.3 Attach the jib (A1) with a gradient of approx. 1 – 2° and position it above the pillar (S1).

8.4 Slowly lower the jib (A1).

Insert the bearing (M3) and position it onto the bearing seat by hand. Observe exact vertical line. Make sure that the bearing (M3) is not skewed. If it is necessary, use the pointed tool or other auxiliary means to correctly position the bearing. Avoid any contact of the slip ring assembly (E3) (if available) with structural items.

8.5 Fasten the rear end plate (A7) with a screw (A8) and a spring washer (A9).

A7

A8

A9

S1

A2

A15

H4 H5

A1

H1

Depending on the design and the features of the slewing crane, the assembly of the jib (A1) and the installation of the bearing (A3) can be facilitated by changing the position of the hoist unit (A15), i. e. the centre of gravity on the jib. Secure the hoist (A15) against any displacement during these installation activities!


8.6 Fastening of the safety ring/strip (A11)

Note:

A safety ring or safety belt must be applied if the crane features a slewing drive "A". a jib locking device is provided. special mechanical slewing end stops are provided. the crane is used outdoors. the crane is located in the area of a bridge crane.

We recommend using this safety device if the crane is located below a bridge crane and the risk of collision exists due to improper handling of the bridge crane.

Option 1 Safety ring

Option 2 Safety strip

A12

A13 A12

A13A14 A12

A13A11.2

A11.1


9. Precise alignment of pillar and jib

9.1 The pillar and the jib are precisely aligned by adjusting nuts (V2) and (V5) (see illustration

page 9). Attention: In order to avoid that only one anchor bolt gets under excessive strain during the alignment, adjust all neighbouring adjusting nuts (V2) accordingly!

9.2 Jib (A1) and pillar (S1) shall be aligned in such a way that the jib stops automatically in any

slewing position, it shall not slew on its own. (As a result of this alignment, the pillar may no longer stand vertically).

9.3 After the alignment, tighten upper nuts (V5) with a torque of Ma=100 Nm.

Note: Once proper alignment has been achieved, immediately proceed to underfill the foot flange! (see also item 14)

9.4 How to proceed to check crane alignment

9.4.1 Travel the hoist in the final front position.

9.4.2 Lower the hook to a specific height and provide a horizontal mark on the hook fittings (During the

entire measuring session, the position of hoist and load hook remains unchanged to not alter the measurement).

9.4.3 Perform a complete slewing motion to determine any deviation of the laser on the marking.

The admissible height deviation is maximum:

adm HA = 2 x outreach 1000

This means that for an outreach A being A = 4000 mm , the determined height for a slewing range being 180° may be max. 8 mm between highest and lowest point.


10. Installation of electrics without slip-ring unit

10.1 Leave supply cable (E1) hanging loose in the tube.

10.2 Fasten the earthing wire / protective earth conductor (E5) on the retaining plate (S7).

10.3 Fasten the supply cable (E1) without the strain on retaining plate (S7) with cable ties with eye (E6) and leave it hanging in the tube.

10.4. Cover the opening (S6).

E1

E5

E1

S6

S7


11. Installation of electrics with slip-ring unit

11.1 Connect the supply cable (E1) on the slip-ring side part (E3.1).

11.2 Fasten the slip-ring side part (E3.1) onto the centre of the the slip-ring unit (E3.2) through the access hole and bolt to retaining plate (S7).

11.3 Attach the supply cable (E1) without the strain on retaining plate (S7) with cable ties

with eye (E6) and leave it hanging in the tube.

11.4 Cover the opening (S6).

E1

E3

E6

E1

S6

S7

M6


12. Assembly of the slip-ring unit

A slip-ring unit is used for an unlimited slewing range (the jib slewing motion is infinite).

12.1 Dismantle the centre part (E3.2) of the slip-ring unit (E3).

12.2 Lead the supply cable (E1) and the earthing cable (E5) through the centre part of slip-

ring (E3.2).

12.3 Strip the insulation from supply cable (E1) for approx. 100 mm.

12.4 Fasten the earthing cable (E5) 1 x 4 mm² as well as the protective earth conductor on the protective earth ring (E3.8).

12.5 Connect the other three pole rings (E3.9).

12.6 Re-assemble centre part of slip-ring (E3.2).

E3.8

E3.9

E3.2 Insulator

Pole ring E3.9

Disc

Washer

Spring washer

Hexagonal nut

Insulator

Threaded rod

Tube


12.7 Pull supply cable (E1) and earthing cable (E5) through the king pin (M1) and twist-type cable entry gland (E4).

12.8 Fasten the centre part of slip-ring (E3.2) on the king pin (M1).

The centre part of the slip-ring unit (E3.2) is attached to a special tube (M6) on

the king pin (M1). Fasten the two grub screws (E3.7) to the centre part of slip-ring (E3.2). Secure the two grub screws (E3.7) with an hexagonal nut (E3.6).

12.9 Screw the hexagonal nuts (E3.4) onto eye bolts (E3.3) and tighten up to the middle.

12.10 Slide the isolating sections (E3.5) onto the eye bolts (E3.3) and fasten eye bolts

(E3.3) in the side part of slip-ring (E3.1).

Note: The thread of eye bolts (E3.3) must not project from the side part!

Position/ Item

Anzahl/ Amount

Benennung Designation

Schleifringkörper Slipring collector

E3.1 1 Seitenteil Side part E3.2 1 Mittelteil Middle part E3.3 2 Augenschraube

M8x60 Eye screw M8x60

E3.4 2 Skt.-Mutter M8 Hex.-nut M8 E3.5 2 Isolierstück Isolator E3.6 2 Skt.-Mutter M6 Hex.-nut M6 E3.7 2 Madenschraube

M6x16 Set screw M6x16

E3.8 1 Schutzleiterring Earthing ring E3.9 3 Polring Pole ring

E3.1

E3.2E3.3 E3.4 E3.5 E3.7 E3.6

E3.8

E3.9

E3.1E3.2

E3.3E3.4 E3.5

E3.6 E3.7

E3.2

E3.1


13. Electrical installation of the mains connection switch 13.1 Pull cable (H1) and supply cable (E1) through the switch opening (S8). 13.2 Fix the earthing wire onto the earthing terminal (E2.1) on the tube and of the flush-

mounted mains connection switch (E2). 13.3 Pull cables (E1 and H1) through the protecting sleeve (E2.3). 13.4 Strip the insulation from the cable wires and connect them to the switch terminal (E2.2). 13.5 Fit the mains connection switch (E2). 13.6 For cranes operated outdoors, the cable openings of the earth and supply cables in the jib

must be sealed additionally. 13.7 Carefully check all crane functions without load after the completion of the installation.

Ensure that the rotating field of the crane turns clockwise.

E1

S8

E2.3

E2.1

E2.2 E2

H1


14. Slewing end stop

If it is necessary, mechanical end stops (SM1/SM2) can be provided to limit the slewing range.

14.1 Installation of the end stops - standard slewing range

14.1.1 Attach the rubber buffers to the end stops (SM1/SM2). The mounting bracket (SM5) situated on the jib support (A2) is factory-assembled.

14.1.2 Slew the jib (A1) in the end positions, keep end stop (SM1) in contact with the mounting

bracket (SM5) on the jib boom (A2) and mark the position. 14.1.3 Return the jib (A1) in its initial position. 14.1.4 Weld the end stop (SM1) on the pillar (S1)

(If it is necessary, remove the rubber buffers!)

14.1.5 Optionally, the end stop (‚SM2) can be fastened on the pillar (S1) with screws: o Proceed as described under 14.1.1 through 14.1.3 o Cut thread M12 in the pillar (S1) o Fasten end stop (SM2) with the hexagonal screw (SM3) and a spring washer (SM4)

14.1.6 Test the end stops (SM1/SM2) by slewing the jib (A1), check fastening and position of the

end stops, if it is necessary, re-align the end stops.

Unit / Pitch circle Dl

Slewing rang maximum

200 / 330 mm approx. 245° 300 / 430 mm approx..280° 400 / 530 mm approx. 280° 500 / 630 mm approx. 295° 600 / 730 mm approx. 295° 700 / 830 mm approx. 295° 800 / 930 mm approx. 305°

1000 / 1100 mm approx. 315°

A2

SM5

S1SM1 SM2

SM1

SM5

SM2

SM3

SM4


14.2 Installation of the end stops - maximum slewing range

The mechanical slewing end stops (SM1/SM2) can be positioned in such a way that the maximum slewing rang is utilized.

Proceed to the mounting of the slewing end stops (SM1/SM2) as follows:

o Attach two mounting brackets (SM5), one above the other, to the pillar o Position the end stops (SM1/SM2), one above the other, and align them with

the mounting brackets (SM5)

14.2.1 Fasten the rubber buffers on the end stops (SM1/SM2). The mounting brackets (SM5) are factory-assembled on the jib support (A2).

14.2.2 Slew jib (A1) in the end positions of end stop (SM1) on the upper bracket (SM5) and

end stop (SM2) on the bottom bracket (SM5) on the pillar (A2) and mark the positions.

14.2.3 Return the jib (A1) in its initial position. 14.2.4 Weld end stops (SM1) to the pillar (S1)

(if it is necessary, remove the rubber buffers!)

14.2.5 Optionally, the end stop (SM2) can be fastened on the pillar (S1) with screws: o Proceed as described under 14.2.1 through 14.2.3 o Cut thread M12 in the pillar (S1) o Fasten end stop (SM2) with hexagonal screw (SM3) and spring washer (SM4)

14.2.6 Test the end stops (SM1/SM2) by slewing the jib (A1), check fastening and position of the end stops, if it is necessary, re-align the end stops.


Unit / Pitch circle Dl

Slewing range maximum

200 / 330 mm approx. 300° 300 / 430 mm approx. 320° 400 / 530 mm approx. 320° 500 / 630 mm approx. 330° 600 / 730 mm approx. 330° 700 / 830 mm approx. 330° 800 / 930 mm approx. 340°

1000 / 1100 mm approx. 345°


15. Undergrouting and anchorage (system ANKERFIX)

For slewing jib base plates which are fastened with anchor bolts concrete footing must be provided!

15.1 Only proceed to pour the concrete after complete assembly and precise alignment of the jib (see item 9). Underfill the foot flange immediately after the precise alignment of the slewing crane!

15.2 The foot flange undergrouting must be done with utmost care:

o The entire surface of the crane base must be underfilled (pouring the material just around the crane base is insufficient and inadmissible)

o The crane base shall not be completely covered in order to still allow the inspection of anchor bolts.

o Minimum concrete quality: class B25 (DIN1045) or C20/25 (DINEN206-1)

15.3 ATTENTION! Only tighten the anchor nuts (V5), test the load capacity and put the crane into operation after complete concrete hardening (after 28 days according to DIN standards). The use of fast drying binder (e. g. PCI grouting mortar 50) may reduce the time before the crane’s acceptance test, if it is provided.

In case the concrete hardening time will not be respected, it may result in an excessive deflection and overloading of crane components.

15.4 When the undergrouting is drying, a small air gap (not perceptible in most of the cases) may form between the crane’s foot flange (S2) and the undergrouting due to the concrete shrinking U-shaped plates (V4) under the foot flange (S2) help filling this gap and help producing a direct tension load on the anchor bolts (V1) keeping them free of alternating stress.

15.5 How to proceed - Leave crane jib unloaded - Position hoist close to the pillar

15.5.1 Tighten all anchor nuts (V5) with a torque of Ma=400Nm by means of a torque key (A)

15.5.2 Consistently and slightly loosen the anchor nuts (V5) (approx. by 30° to 45°) (B)

15.5.3 Tighten all anchor nuts (V5) with a torque of Ma=300Nm by means of a torque key (C)

15.5.4 In a second turn re-tighten again all anchor nuts (V5) with a torque of Ma=300Nm (D)

15.5.5 Additionally, secure all anchor nuts (V5) with locking nuts (V6)

15.5.6 Outdoors, the perimeter of the crane base (S2) shall be permanently sealed (e. g. with silicone)!

A 400 Nm B 30°-45° C 300 Nm

D 300


Illustration: Fixation with anchor bolts; after completing the undergrouting


16. Putting into operation

16.1 Once the installation is completed and prior to start the crane operation the following tests need to be performed in compliance with §19 of the EN 60204-32 have to be carried out: 1. test run 2. test of earthing conductors 3. measurement of the insulating resistance

16.2 The crane and its fastening elements must remain permanently accessible for inspections. 16.3 When putting the crane into operation, coating material (zinc, paint) may accumulate on

the running surfaces of the jib beam which prevent the smooth run of the trolleys. The dirt must be removed.

16.4 Inspections prior to putting the crane into operation (in compliance with the accident prevention regulations UVV BGV D6)

An inspection has to be performed on cranes before putting them into operation.

The owner (operator) must ensure that cranes are inspected before being put into service for the first time by:

a) Expert engineers (authorized crane expert engineers)

Acceptance test of crane installations in acc. with DIN 15030 and UVV BGV D6 (BGG 905) cranes, test load and lifting attachments must be provided by the customer. The following crane models are subject to inspections by expert engineers:

all cranes with a capacity 1000 kg all cranes with two or more powered motions.

b) Qualified technicians The following cranes must be checked by qualified technicians:

all other cranes not checked by expert engineers

16.5 Routine inspections

Depending on the local and on the operating conditions, the owner must ensure that cranes are inspected as required, at least once a year, by a qualified crane expert.


17. Technical information

17.1 Tightening torques for fastening elements

The fastening elements for the crane base must be pre-tensioned with specified tightening torques.

The following table shows the most important tightening torques.

17.1.1 M27 anchor bolt, to DIN 1045, greased (special production of special quality for crane foundation)

Tightening torque: 300 Nm

17.1.2 HT bolts to DIN 6914, black, slightly greased

Thread size Screw quality Tightening torque

M 16 10.9 284 Nm M 20 10.9 554 Nm M 24 10.9 958 Nm M 27 10.9 1420 Nm

17.1.3 Hex. bolts to DIN 931, DIN 933 and threaded rods DIN 976, galvanized, lubricated with MoS2

Thread size Screw quality Tightening

torque M 16 8.8 179 Nm M 20 8.8 350 Nm M 24 8.8 604 Nm M 27 8.8 900 Nm

17.1.4 M16 anchor bolt, galvanized, lubricated with MoS2

17.1.5 M12 anchor bolts a) UVM dyn 100 M12/50: tightening torque: 40 Nm b) HVZ dynamic M12/50: tightening torque: 50 Nm

17.2 Safety distances (As specified in the relevant accident prevention regulations)

Safety distances in accordance with UVV Cranes BGV D6), §11 and §32 A minimum distance of 150 mm is required for the installation.


18. Spare parts list

Please provide the following information with your spare parts order:

Crane type Serial number of the crane Year of manufacture.

The spare parts listed below are only some of the standard components For spare parts of the hoist and the electrical slewing drives, please refer to the separate spare parts lists.

18.1 Mechanical components

Component pitch circle Dl

200 / dia. 330

King pin bearing Dl 330

Support washer Dl 330

Seeger ring Dl 330

Nilos ring Dl 330

Thrust roller Dl 330

Thrust roller bearing Dl 330

Seeger ring inside Dl 330

Seeger ring outside Dl 330

- Thrust roller cover sheet metal box Dl 330

Access hole cover dia. 125

300 / dia. 430



Seeger ring Dl 430

Nilos ring Dl 430





- Thrust roller cover sheet metal box Dl 430


400 / dia. 530



Seeger ring Dl 530

Bearing cover plate Dl 530






Thrust roller cover Plastic Dl 530


500 / dia. 630



Seeger ring Dl 630









600 / dia. 730



Seeger ring Dl 730









700 / dia. 830



Seeger ring Dl 830







Thrust roller cover Plastic cap Dl 830


800 / dia. 930



Seeger ring Dl 930









1000 / dia. 1100



Seeger ring Dl 1100

Nilos ring Dl 1100








Qty. fitted 1 1 1 1 2 Dl330-430: 2

Dl530-1100: 4 2 2 2 Sheet metal box: 1

Plastic: 2 1

Item as in erection instructions

M3 M4 M5 M2 A4 Fitted in A4 Fitted in A4 Fitted in A4 Fitted in A4 A5 S6


18.2 Mechanical slewing stop

Component Pitch circle 200 / dia. 330

Round buffer dia. 30 x 30 cpl. with fastening elements

Slewing stop angle bracket, weldable

Slewing stop angle bracket, screw-type cpl. with fastening elements

300 / dia. 430

Round buffer dia. 30 x 30 cpl. with fastening elements



400 / dia. 530

Square buffer 30 x 40 x 60 cpl. with fastening elements



500 / dia. 630




600 / dia. 730




700 / dia. 830




800 / dia. 930




1000 / dia. 1100




Qty. fitted 2 2 2 Item as in erection instructions

Fitted on SM1,SM2 SM1 SM2


18.3 Electrical components

Component Pitch circle

All Mains connection switch

Slip-ring assembly

C-rail S1 (1,5 mm) C-rail S1 (2,0mm) Fixed suspension

Connector Rail end cable clamp

Flat cable carriage

Towing trolley

Clamp, round End cap

Qty. fitted 1 1 Depends on outreach

Depends on outreach

Depends on outreach

Depends on outreach

1 Depends on outreach

1 Depends on outreach

1


E2 E3 E12,E13,E20,E21 E12,E13,E20,E21 E25 E23 E27 E36 E28 E24 -

All End stop Ideal control

carriage for direct control

Ideal control carriage for contactor control

Wire rope with ferrules

Round cable carriage

Cable supporting tube cpl.

Clips Clamp, flat

Qty. fitted 1 1 1 1 Depends on outreach

1 Various Various


E34 E32 E33 E17,E18 E19 E8 E9,E10,E11 E14

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