OOppeerraattiinngg aanndd AAsssseemmbbllyy

IInnssttrruuccttiioonnss ffoorr

SSlleewwiinngg JJiibb CCrraannee PPFFSSPP

with maintenance instructions

and spare parts list

valid from date of manufacture: 29/12/2009

Transmit these instructions to the respective representatives and

communicate them to the persons in charge of assembly, operation and maintenance of the crane.

Keep it for future use!

Original operating instructions according to EC Machinery Directive 2006/42/EC

Scope of these instructions:

The model series with designation “PFSP“

Slewing jib crane, manually swivelling with a swivelling range up to 270 degrees

From date of manufacture: 29/12/2009

The detailed scope of supply and equipment is described in the accessory purchase order documents. Characteristic technical data of the crane shall be taken from the master data list of the crane in the inspection records.

Lifting capacity Outreach in mm in kg 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000

50

80

125

200

250

400

500

800

1000

1600

2000

2500

Assembly I

Assembly II

Assembly III

Assembly IV

Assembly V

Drawing 1

Annotation type designation

PFSP 500 – 4.5 / 2.8 F – So

Model series

Lifting capacity [kg]

Outreach [m]

Lower edge boom [m]

Design differing from standard

F = Outdoor operation

So = Special equipment

Other special designations: vz –Zinc coated; HA – Hoisted boom; Ex – Application in explosive surrounding

The slewing jib crane PFSP consists basically of the following elements:

Boom

Power supply

Crane column Main switch

Hoisting gear

Control unit and crane switch

Drawing 2

You can find all dimensional data in the measure table (Annex A)

Technical changes reserved!

Table of contents Page

Introduction

Part A – Operating instructions

1.

Information on intended use

A1

2. Usage limits A2

3. Warning of improper use A2

4. Description of dangers and warning of remaining risks A4

5. Operation of the crane A5

5.1 Control elements A5

5.1.1 Power supply switch A5

5.1.2 Control switch A5

5.1.3 Crane switch / EMERGENCY Stop A6

5.1.4 Locking device of boom A6

5.2 Operational elements A7

5.2.1 Stops for limitation of cross travel motion A7

5.2.2 Slewing brake for adjustment of the stiffness A7

5.2.3 Stops for limitation of slewing A8

6. Commissioning A9

7. Decommissioning A9

7.1 Emergency situation A10

7.2 Danger to steadiness and operating reliability A10

7.3 Closedown A10

7.4 Disposal A11

8. Non permitted use – Ban on operation A11

9. Security advices A11

9.1 Responsibility of operating company A12

9.2 Working environment A12

9.3 Choice of personnel and personnel’s qualification A13

9.4 Security advices to operating phases A13

9.4.1 Transport and Storage A13

9.4.2 Normal operation A14

9.4.3 Maintenance works A14

9.4.4 Welding works on cranes A15

9.5 Advices to special types of risks A15

Table of contents Page

10.

Maintenance

A16

10.1 General information A16

Part B – Assembly instructions

11.

Important requirements

B1

11.1 Welding works on cranes B1

11.2 General assembly advices B2

12. Overview of crane B3

12.1 Types of anchorage B4

12.2 Equipment of the crane B5

12.3 Marking on crane B5

13. Assembly crane pillar B6

14. Assembly boom B8

15. Assembly equipment B9

15.1 Assembly hoisting gear B9

15.2 Assembly cross travel stop B10

15.3 Assembly slewing brake B11

15.4 Assembly slewing stops B11

15.5 Assembly locking of boom B13

16. Assembly electricity B14

16.1 Assembly basic electricity B15

16.2 Assembly power supply switch B15

16.3 Assembly grounding unit on boom B16

16.4 Power supply round cable B17

16.5 Power supply trailing cable B18

17. Information on fine adjustment B19

18. Start of operation B20

19. Safety distances to slewing jib crane B21

20. Additions and notes B22

Part C – Annex

A Dimension sheet B Spare parts list C Declaration of Conformity D Declaration of Incorporation

Introduction

This document must be read by personnel in charge before the assembly and the initial operation as

well as before maintenance works. Provided that the complete instruction manual in not available, the

manufacturer shall be contacted. If required, the operating company shall translate the instruction

manual to user’s language. A safe operation and and a long fatigue life can be only ensured with a

proper use of the crane.

This instruction manual is intented for the use of slewing jib cranes with booms which can only be

slewed manually.

A hoisting gear can be assembled on a crane boom solidly or with a carriage, which does not exceed,

according to data sheet, the maximum permissible values for load bearing capacity, dead weight, as

well as lifting and cross travel speed and has a rated capacity limiter. For reasons of steadiness, the

crane can not lift from the floor, according to data sheet, more than 1.4 times the lifting capacity of the

crane. During the operation, the maximum permissible lifting load is limited to the nominal load,

according to the marked load bearing capacity. Higher loads are forbidden.

In the European Union, the legislators demand from the operators that instruction manuals shall be

always available and must be communicated to all users. In the Federal Republic of Germany it is

necessary to attach additionally a summary of the Accidents Prevention Regulations BGV D6 with the

essential security advices in a good visible manner directly on the work station of the crane operator.

Operators of crane units as well as the maintenance personnel must have knowledge of the

regulations and rules applying for this. Those are in the Federal Republic of Germany in particular:

- Accidents Prevention Regulations Cranes BGV D6

- Accidents Prevention Regulations Winches, Hoist and Traction Machines BGV D8

- BGR 500 – Load suspension device at hoisting gear operation

Part A – Operating instructions

1. Information on intended use

- The operator shall catch up on the intended use of the crane before start up. Improper

use is forbidden.

- The crane may be only started up, when the assembly and the equipments comply

with the valid regulations. (Declaration of Conformity is available, CE- mark is

attached, acceptance inspection or regular inspection is visible on the test seal and

still valid)

- The crane must be only assembled in an appropriate working environment. An

accident-proof operation must be ensured.

- The assembly must be executed perpendiculary on a floor which is permanently

capable of bearing, plane, vibration- and oscilliation-free.

- In the Federal Republic of Germany, only persons who meet the requirements

according to UVV (accident prevention regulations) BGV D6 §29 can be appointed as

crane operators.

- The application and the use of the crane are permitted according to classification in

hoisting class and loading group according DIN 15018 (see information in test book).

- The slewing jib crane is intended to lift and drive (in each case power-operated or

manually) loads on the boom using a hoisting gear. The slewing of the boom may be

only executed manually, whereby the load must be guided by another person.

- Only hoisting gears which have a dead weight that does not exceed the limiting value,

according to dimensions table [Annex A], may be used on the lifting arm to lift and

drive loads.*

- The maximum permissible lifting speed of hoisting gears on the crane is 8.0 m/min. *

- The maximum permissible driving speed of power-operated trolley gears is

20.0 m/min*

- Only hoisting gears with an effective rated capacity limiter (e.g. safety clutch) may be

used.

- The slewing jib crane is designed for a temperature range between –10°C and +40°C.

- Only slewing jib cranes with additional mark “F” in their type designation are designed

for an outside operation and can be operated till wind force 4, provided that the

operating instructions are observed.

- Only slewing jib cranes with the additional mark “ex” in their type designation are

designed for the operation in potentially explosive areas and can be used in the

respective area according to their marking on the device and in the test book.

- Under operating conditions above the corrosion-protection class C2 or in the

environment of aggressive mediums, special models are required.

*) If higher values are permitted, thanks to special designs, they are recorded by the manufacturer in the additional data sheet. The additional data sheet is a component of the test book.

- A1 -

g. Loose of stucked loads, removal of covers of containers under residual vacuum

2. Usage limits

The use of slewing cranes is limited by the number of load alternations (frequency), the load spectrum

(load distribution) as well as by the design (execution) of the crane. The use of the crane outside of

the intended range can result in dangers to and damages on the crane.

Characteristic usage limits are:

- Higher dynamic load:

Use of hoisting gears and load suspension devices, which require a higher classification

into loading group and hoisting class, according to DIN 15018, as designated in the test

book of the crane, e.g. during grab or magnet operation.

- Tendency to fractures of brittle materials, e.g. glass panels

The boom bounces because of the elastic deflection. A gentle set-down is, according to

the self-supporting length (column + boom), only possible to a limited extend.

- Operation at temperatures under -10°C and over +40°C

- Use under extreme ambience conditions, e.g. smelting furnances, acid baths and areas

with strong vibrations.

- Actions which influence the static of the crane and its stability, e.g. extensions or

shortenings of the boom or the column, modifications of attachments, modification of the

load bearing capacity, subsequent installation of a hoisting gear, bigger or heavyer as

intended or unapproved welding works.

3. Warning of improper use

The following use of the crane is forbidden. A nonobservance can

result in risks for the operator and its environment as well as

damages on the crane structure.

a. The use of a crane which is assembled improperly or an equipped crane without

manufacturer’s certifications (Declaration of Conformity, CE mark) or test badge.

b. The use of a crane which is clearly damaged or defective, maybe also ignoring the

blocking and prohibition signs.

c. Transport of unpermitted loads, such as passenger transportation, transport of fused

materials, transport of loads which are heavyer than the permitted load bearing

capacity of the crane

d. Stay under suspended loads

e. Diagonal pulling, trailing or sliding of loads

f. If not perpendicular under the hook or if hoisting gear “Open” – inching operation of

the hoisting gear – then release of uncontrolled movements of the boom or the

hoisting gear by fixing the load, swing up of the boom by operation of the hoisting gear

or interventions on the suspended load

- A2 -

h. Slewing of the boom by pulling the control switch

i. Welding works on suspended loads

j. Lifted loads – must not be exceeded by additional load, must be set-down during a

stoppage of the transport process, must not rest in the suspended position if they are

unattended, must not tilt or knock over into the load cable because of a movement of

the center of gravity.

k. During a use on the open air ground only such loads (dead weight, geometry, surface)

may be used, which may be reasonably controlled by the user with the available

means under the respective wind forces.

l. Hooking of the crane hook in loads of fixed points and “tightening” of the load-carrier

for the protection against unintentional movements.

m. Unpermissible high operating heights or operating distances – the crane operator

must be able to operate the manual operated crane in every position in a save

manner and to slow the load down.

n. Uncontrolled drive to final positions with a high manual speed

o. Improper anchoring or fastening of the crane, in particular with anchor bolts in the

bottom flange holes on the column tube

p. Additions not intended or authorised by the manufacturer or design modifications on

the crane

q. Fitting or mounting to air, water or landcrafts or other moveable machines not intended

or authorised by the manufacturer. (also cranes)

The slewing jib crane is not designed for continuous operation (continuous

load changes in automatic processes).

- A3 -

4. Description of dangers and warning of remaining risks

List of dangers according to EN 14121-1 for slewing cranes

N° Danger potentials Danger Solution / Warning

1 Mechanical dangers 1.1 Crushing of operator / of third persons by the load Observe safety distances , Observe swing of the load and braking distances

of operator by the boom Observe safety distances Attach stops

of operator by boundaries on the final positions (arrestors)

Observe safety distances Observe operating instructions Mark danger areas

of operator / foot by the load Observe safety distances, Observe swing of the load, Keep passing places free

1.2 Shearing of operator / hand by the boom, column, wall, support

Observe safety distances Observe operation instructions Mark danger areas

1.3 Impact of user by swing of the load Observe safety distances of operator / third persons by the boom Observe safety distances,

Warnings on the boom of operator / third persons by unexpected / unintended start

Use additional attachments (slewing brake, adjustment device of boom) Observe safety distances Observe operation instructions

1.4 Fall down of pieces of operator / third persons by the load Observe safety distances of operator by unintended operation Observe safety distance,

Observe operating instructions 1.5 Stability of operator by underground floor / wall / slab Leave danger area,

If possible, lower the load immediately, Stop the crane, Only dispose the load on sufficiently sustainable underground

1.6 Stumble and falling of operator / third persons Keep operation ways free, safeguard tripping points if necessary Ensure sufficient stability, Warnings in the working area

2. Electric dangers 2.1 Electric shock of operator by a damaged coating of electric conductors

Stop operation, Switch power off, Replace defective lines

2.2 Error on power supply, functional disorder of the control system

of operator / third persons Activate emergency stop and Start measures for fault clearance by a qualified person

4. Noise dangers 4.1 Discomfort, stress, failure of the voice communication

of operator / third persons by warn parts or grinding surfaces

Stop operation, Fix the error

7. Material / substance dangers 7.1 Operating supply items (oils, greases,

lubricants) of operator /third persons / environment by the hoisting gear

See special operating instructions manual for hoisting gears and drives

7.2 Fire and explosion of operator / third persons by electrical operated crane

Use only cranes designed for outside areas Observe device categories and zone classification according to the document on explosion protection of the operating company

8. Ergonomic dangers 8.1 Inadequate local illumination of operator / third persons Ensure adequate illumination

8.2 Human error of operator Training 9. Dangers by operational environment 9.1 Lightning of operator / load Stop operation immediately,

Lower the load immediately, Stop the crane

9.2 Wind of operator / third persons by an uncontrolled drift of the load

Stop operation immediately, If possible, lower the load immediately, Stop the crane

9.3 Frost of operator by unexpected crane movements and starts

Observe temperature range

9.4 Exterior effect of operator by e.g. other means of transportation Observe crane, load and environment attentively 10. Combination of dangers 10.1 Failure or incorrect arrangement of protective

measures of operator Take measures to reduce the danger potential

10.2 Start and stopping device of operator by control switch Push emergency stop in the case of a defective control switch, switch the machine neutral, replace parts

10.3 Security symbols / signals Information and warning devices

of operator by faulty labelling Hold labelling readable

10.4 Turn-off devices of power supply of operator by power supply switch and emergency stop

Check on functioning before starting the work

10.5 Emergency measures working area / operating company Push emergency stop, if the danger can be reduced with this action

10.6 Equipment for a safe adjustment and / or maintenance

of operator Prior to all maintenance and repair works on the crane, lock the power supply switch up in position “Off”

10.7 Failure assembly of operator Stop operation, fix the errors

Table 1

- A4 -

5. Operation of the crane / operation modes / intervention processes of the operating person

Basis for the operation of the crane are the operating manuals for crane and hoisting gear as well as the

UVV cranes (BGV D6). These documents shall be displayed on place by the operating company of the

machine. These instructions, advices and directives shall be observed.

5.1 Control elements

5.1.1 Power supply switch

The power supply switch (drawing 3) is located on the

crane column. Normally, it is attached into the column

tube, so that only the lockable operation device is

accessable for the operator. It has 2 settings:

- “0“ the contacts are opened, the crane is

currentless

- “1“ power supply on crane available

The power supply switch cuts the crane from the power

supply (all phases). In “0“ position it is possible to secure

the turn knob by hinging a padlock.

Drawing 3

Drawing 4

5.1.4 Control switch The hoisting gear is operated via the control switch (drawing 4). Normally,

the control switch is located on the hoisting gear and connected with it via

the control line. The control line serves for the signal transmission from the

control switch to the control system of the crane and has a strain relief which

avoids a tearing due to the dead weight. The control switch must NOT be

used to slew the boom.

At the trim line “ideal controlling” the control switch is not attached on the

hoisting gear but is located on a control trailer, which is movable in a

separate sliding rail on the boom, independently of the hoisting gear.

The control switch is equipped with operation elements to control the crane

movements as well as with a crane switch (EMERGENCY Stop).

For further function descriptions see operating manual of the hoisting gear.

5.1.4 Crane switch / EMERGENCY Stop

The red marked crane switch (EMERGENCY Stop) (Drawing 5) stops with operation

(pushing) all power-driven functions. By a short clockwise turning the red switch goes

back to its starting position and all functions are operational again.

Drawing 5 - A5 -

Abb. 6

Never operate the EMERGENCY Stop together with other operation element –

this could result in movements of the crane.

5.1.4 Locking device of the boom (special equipment, serial at operation in oper-air ground)

The locking device of the boom (drawing 6) serves for the secure fixing of the boom in one or more fixed

positions of the slewing range. At cranes which are designed for the use on open-air ground, the locking

device of the boom serves for the wind bracing on one boom position minimum. The operation (Loosening /

Locking) is allowed till approx. wind force 4. Beyond that, very high operating forces occur and the drifting

boom is potential danger. For this reason, only loose the locking device if there is no danger of drifting

booms due to wind.

Drawing 6

The operation takes place by pulling the

operating rod (A1) till the return stop (A2)

below the bearing plate is visible and the

locking bolt (A3) releases the boom (1). Now

the run-back of the locking pin (A3) is avoided

by a 90 degree turning of the operating rod

(A1). The boom can slew freely. If the boom

shall be locked, it shall be slewed manually to

a locking position till the locking bolt (A3) is

located under a drilling / locking strap (A5).

The locking of the bolt takes place in reverse

order.

- A6 -

5.2 Operational elements

All stops are designed as EMERGENCY end stop and must not be arrived during normal operation. (see

also BGV D6 § 30).

5.2.1 Stops for limitation of cross travel motions

The pictured stops of cross travels are exemplary and can differ according to hoisting gear make.

Drawing 7

5.2.2 Slewing brake for adjustment of the stiffness

Drawing 8

As special equipment, the slewing brake (drawing 8) serves for the adjustment of the stiffness of the boom

(see mounting instructions paragraph 15.3). Slewing brakes are intended for cranes in closed halls.

- A7 -

5.2.3 Stops for limitation of slewing

According to installation size, crane equipments and intended use, they are a component of the crane

construction or the special equipment (take information from the order documents or the additional data list

in the test book of the crane).

Stops for limitation of slewing shall be employed to:

- avoid a crash of the crane boom or of pieces of the equipment assembled on the boom (hoisting

gear, power supply etc.) on the interference contours in the environment of the crane (e.g. walls,

supports, other cranes)

- limit the working area or the boom

- safe attachment parts against crashes on the crane column

Depending on the function 2 types of stops for limitation of slewing are differentiated:

a) Stop for limitation of slewing with buffer rod for clamping on the boom (counter stops in the

environment of the crane)

Drawing 9

b) Stop for limitation of slewing for assembling on the crane basis (counter stop is the crane itself)

Drawing 10

All stops are designed as EMERGENCY end stop and must not be arrived during

normal operation. (see also BGV D6 § 30).

- A8 -

6. Commissioning

- the statutory acceptance tests (according to UVV BGV D6 § 25) must have taken place before the

initial operation

- the crane must be evidently in a safe and functional condition

- the operator must have read and understood the operating manual

Steps before commissioning

- visual inspection that all parts are free of external damages and reliably operating

- activate the power supply switch on the crane column

- unlock the EMERGENCY Stop button on the control panel

- loosen the locking (if existing on the crane)

- use boom and hoisting gear

Transport of loads

- Select adequate slinging means for the choosen load and the transport.

- Hinge the load hook and the boom above the load centre into the load or the slinging mean and

tighten the load cable carefully.

- Always lifting the load from the floor in fine motion. Use a faster lifting speed for the lifting to the

desired height not before the load is hanging safely.

- At manually operated cranes, all moves shall be realised by guiding the load or the load cable. The

crane operator must drive manually and partially power operated cranes so, that he is able to stop

the released travels and rotations without any danger.

EMERGENCY Stops (stops) must not be arrived non-braked.

- If a direct guiding of the load is impossible, additional guiding aids (e.g. ropes, chains or guiding

rods) shall be attached on the load, the load hook or the boom.

- Keep the transport process shortly and put the load in a safe position and completely down.

Hang the load hook out and bring it to a safe stand-by position.

7. Decommissioning

The crane shall be stopped at the end of work or longer stoppages of work as well as in cases of

recognized damages or occuring critical situations.

- Hoisting gear in standby position

- Push power supply switch to 0 condition

In cases of interruptions, shutdown or wind force >4, the booms of cranes in operation on open air ground

shall be locked by a serial locking in its standby position.

- A9 -

7.1 Emergency situation

An emergency situation exists, if the crane movement does not stop or is impeded, e.g. by jamming or

catching loads.

Acting in case of emergency situations

- Activate the existing EMERGENCY – STOP devices on the control switch or the power

supply switch!

- Inform immediately the competent authorities of the company!

- Safeguard the danger area!

7.2 Danger to steadiness and security of operation

The steadiness is not ensured:

- if there are cracks on welding seams of the crane column or the boom,

- if there are loosen attachments or screw joints,

- if buildings – floor, wall, slab, supports, frames can not absorb the fet forces anymore

The security of operation is not ensured:

- in case of a high wear of components; breakage, cracks, deformation, corrosion of load bearing

components on the crane or in load bearing means (ropes, chains, hooks),

- in case of a damage on electrical equipment,

- if loads can not be hold (rated capacity limiter and/or brakes faulty or worn)

- if there are damaged functional components (stops for limitation of cross travel motion, slewing

limitation stops, etc.),

- in case of a overload of the crane by exceeding the permissible lifting capacity or e.g. by inching

the control switch frequently during the lifting or lowering movement, which results in a higher

dynamic pressure. (“inching operation is forbidden!“)

7.3 Closedown

A closedown of the crane shall be carried out in case of:

- damages or wear till the repair is carried out

- achievement of the theoretic remaining service life,

- absence of the required maintenance and quality inspections (see inspection plate on crane)

After the closedown another use of the crane must be excluded, e.g. by locking the power supply switch in

“Off” condition with a padlock.

- A10 -

7.4. Disposal

After the end of the operation period or irreparable damages on the crane the same must be shut down and

disposed as steel scrap. The disassembly shall be only executed by a competent person. Electric

components on the crane shall be disposed environmentally friendly.

8. Non permitted use – Ban on operation

No Transportation of persons!

No Transport of fused materials!

No Diagonal pulling, trailing and loose of stucked loads!

No Slewing of loads or moving of the crab by pulling the control switch!

No Stay in danger area during the crane operation!

No Stay under suspended loads!

No Use of damaged load bearing mediums and load handling devices!

No Transport of unsecured loads!

No Loads which exceed the indicated load bearing capacity and the classification!

No Unintentional crane movements due to faulty operation, unsufficient braking

efficiency!

No Load lifting by inching operation or swinging up of the boom as a result of external

influences!

No Rest of the loads in suspended positions without control!

No Welding works on suspended loads!

No Fixing of hoisting gear or boom by insertion of the hook and “lifting opened” so that

the system is permanently loaded

Please note: Note on paragraph 3. Warning of improper use

9. Security advices

The slewing jib crane is designed and constructed according to the state of technology / the valid safety

requirements*. It meets the demands of the EC Machinery Directive. Using the crane as intended the

dangers to life and limb of the operator and third persons as well as of the material values are low. Thereby

a sensible handling with regard to security and dangers according to the operating manual of the crane and

the hoisting gear is assumed.

The crane must be stopped immediately if defects or irregularities are determined at the function. The

safety distances shall be observed obligatory according to the valid directives BGV D6 §11.

*) At the date of placing on the market

- A11 -

9.1 Responsibility of the operating company

- Right selection and load of the crane

- Sure function and fixation on crane and loads

- Sure operating condition of the crane

- Sure operation and use by the operating personnel

- Initiate required acceptance tests and recurring inspections

You, as operating company, are responsible for the acceptance of the crane and for recurring inspections

(maintenance) according to BGV D6 and BGV D8.

All persons who are authorised with the operation and maintenance of this crane must have read carefully

and understood this operation manual. Any non-compliance and act in opposition can result in accidents

and dangers.

Additional to the operation manual, the operating company of crane units must also observe and instruct

the general laws and provisions for the prevention of accidents and to the environmental protection.

The following protection devices exist on the slewing jib crane:

1. Stops for limitation of cross travel motion on boom (emergency stop device)

2. Slewing limitation stop (partial special equipment)

3. Protective conductor of boom and crane column (only cranes with electric equipment)

Due to special local conditions or cases of operations, situations could exist or appear, which are not

considered in this operating manual. In such cases the required measures for the security of the operator

shall be decided and initiated.

The operating manual shall be completed by the operating company with instructions regarding work

organisation, working processes, authorised personnel, obligations of supervision and to inform etc.

9.2 Working environments

The slewing jib cranes are remote-controlled cranes. That results, that the operator must know the working

environment, especially with regard to obstacles in working and transport area, possible tripping points and

existing control elements and safety devices (e.g. emergency stop switch).

Release and swing of loads are forbidden. Manual operated cranes shall be guided on the load hook

and/or the load. Safety distances to stacked material must be observed. The guiding of loads on ramps,

chambers or towers is dangerous. There is a risk of falling. Here, the operating company arranges

additional safety measures.

- A12 -

9.3 Choice of personnel and personnels qualification

According to UVV BGV D6 § 29 the following directive applies:

“To operate and maintain the crane independently the operating company may only authorise persons,

- who are physically and mentally suitable

- who are likely to fullfill their tasks reliable

- who are instructed in driving and maintain the crane and have demonstanted their competence

- who have reached 18 years of age.

Only adequate qualified personnel may be deployed for repairs and maintenance works.

Works on electric equipment may only be executed by an authorised electrician or by instructed personnel

and under the direction and supervision of an authorised electrician.”

9.4 Security advices for operating phases

9.4.1 Transport and storage

The slewing jib cranes must be transported and stored as demounted components. Hereby the essential

components, crane column and boom, are not stable due to their geometry. For this purpose the

components are provided ex works with adequate disposable transport aids (pallets, square timbers,

stretch tapes). This transport aids shall not be removed before the assembly. During the transport, the

packing units shall be secured on the transport mean against slipping and tilting (e.g. load restraint

assemblies in case of delivery with truck).

In case of a later assembly of the crane the components crane column and boom shall be put for transport

and storage on adequate stable transport aids and shall be additionally secured against tilting, rolling and

slipping with load restraint assemblies and support blocks.

During the storage, the components should be secured against atmospheric influences. The storage should

take place between –20°C and +45°C.

9.4.2 Normal operation

Emissions

Noise emission: At motor driven hoisting gears the noise emissions vary from low up to high noise levels.

Please read the information in manufacturer’s operating manual of hoisting gear for advices on emissions

of hoisting gears. Other emissions are not known till this day.

- A13 -

- A14 -

Observe the following security advices during the daily operation:

- Only work with a safe and functional crane. All EMERGENCY Stop devices and control

elements must be available and meet the requirements.

- Only work with the crane if you know the limits of the machine (load bearing capacity, allowd

speeds, working areas) and you are familiar with the operation. (function of control elements

and safety devices)

- Refrain from actions which endanger the stability of the crane.

- Ensure a safe working environment and refrain from risky actions.

- Check the crane minimum once per shift for externally visible defects and faults.

- Stop the crane in case of visible faults or abruptly changed operating performance (see

operating manual chapter 7) and act according to operating manual point 9.4.3.

9.4.3 Maintenance works

Observe the following security advices during works on the crane:

- The maintenance means measures for maintenance, inspection and repairs. These works may

only be executed by qualified personnel.

- The adjustment and maintenance works as well as inspection intervals, including information

on replacement of components, specified in this operating manual, shall be observed.

- The crane unit shall be stopped during all works and secured against unintentional or

unauthorised start. (lock power supply switch with padlock and/or attach warning plate on the

switch) If necessary, the working area shall be protected.

- Ensure that the electric components and cables are dead-voltage before working on electrical

installations and facilities of the crane unit.

- During the assembly, single parts and bigger components must be safety attached with

adequate hoisting gears. Do not stay under suspended loads.

- During assembly works over 1.80 m an adequate access method (ladders, work scaffoldings,

platforms for lifting persons) shall be used and a fall protection shall be worn. Do not use parts

of the crane as climbing aids.

- If a temporarly disassembly of safety devices is necessary, they shall be reattached before

commissioning.

- Check all screw fittings on the crane for tight hold during maintenance works.

- After finishing all works on the gear the operating company may release the gear not before

inspection to proper condition. If necessary, a competent person or authorised expert shall be

commissioned with it.

- A15 -

9.4.4 Welding works on cranes

You may only weld on cranes if:

- it is required and described in the assembly instructions

- the manufacturer has authorised this welding works

- all requirements for the welding are complied with.

Requirements for welding works on cranes:

- obtain a written approval of the operating company (hot-work permit)

- observe UVV BGV D1 " welding, cutting and allied processes "

- observe VDI – Directive 2382 / 1990 – 08 " Maintenance of crane units; welding, stitching,

flame cutting, drilling"

- qualification of manufacturer class E according to DIN 18800-7:2002 (steel structures) required

- valid welder’s performance qualification according to DIN EN 287-1 of the working welder

required

9.5 Advices to special types of risks

Dangers by crushing hazard at the slewing jib crane

During operation:

- by swinging or falling loads

- by a run over of indoor cranes

- by moving crane parts during the arrangement of parts of the construction in working and

transportation area

During maintenance:

- by unlocked, slewing booms

- by unsufficient stability of the crane

Dangers by electric power (electric shock)

- faulty electric connections

- Parts of the construction which are energised because of defect coating

- unsufficient distance to aerial cables or open current bars of indoor cranes

- during maintenance works on energised parts

Dangers due to the hoisting gear

- due to unintended movements due to errors or defects on the electric installation or

controller (e.g. independently running motor movements or incorrect rotating direction of

drives)

- A16 -

10. Maintenance

Maintenance works on the trestle crane serve for the maintenance of the operating reliability and the

functionality and increase the fatigue life of the machine. The maintenance must be carried out regulary

and by experienced qualified companies and/or qualified persons according to BGV D8 §23 and BGV D6

§26.

10.1 General information

Even though the crane is extensively maintenance free, the components which are subject to a wear must

be checked regulary.

With an intended assembly and use of the crane, the service life of any wear parts amounts normally to 10

years. In case of a stress above average as a result of external influences the service life can be

shortened, so that the wear parts must be replaced early.

Components which are essential for a sure operation must be checked per working day

and before every use.

Inspection interval: The inspection intervals are fixed on 12 months for all parts according to the design

of the crane for the entire service life.

The following components must be checked regulary:

Daily inspection / before commissioning – X

Inspection every 12 months – O

Components

Pos. N°

Check for

Measures

Wear parts:

Buffer stops for cross travel motions 51 Functionality / wear Replace the buffers,

If necessary, correct fitting and fixation X Stop buffer for slewing stops 51 Functionality / wear Replace the buffers,

If necessary, correct fitting and fixation O

Slide ring 21 Wear Replace slide ring O

Slewing brake 4 Wear of the brake pad, Pretension of the disc springs

Replace the brake pads Replace the disc springs O

DU bushes 50 Too much clearance Replace the DU bushes O

Locking of boom Breaking of the spring, Wear of the locking pins

Replace spring Replace locking pins X

Electrical components: State of cables and electric lines

Correct operation and coating Stop the crane and repair defective installation by

a qualified electrician

O

State of main switch 224 and/or

301

Correct operation and locking capability

Stop the crane and repair by a qualified electrician

X

- A17 -

Components

Pos. N°

Check for

Measures

Other components:

Marking of load bearing capacity

150

Correct marking of load bearing capacity on crane and hoisting gear

Attach right marking

X

Check of corrosion protection

Defects Refit corrosion protection O

Screw joints / Attachments

Tight fitting and existing locking devices / Tightening torque

Tighten the screw joints with dynamometric key, add locking devices

O

Weld seams

Cracks (especially foot flange) Stop the crane and inform qualified personnel for

repair

O

Important advices:

Table 2

- The boom shall be locked against unintentional motions

- Only execute maintenance and repair work on the unloaded crane

- Switch off and lock the main switch

- Observe instructions of accident prevention regulations

- Maintenance work shall be documented in the inspection records (according to BGV-

D6 §27)

- After end of service life of the hoisting gear a general overhaul shall be executed

- Manufacturer’s operating manuals for the hoisting gears shall be observed

Part B – Assembly Instructions

11. Important requirements

These assembly instructions apply to the installation of a slewing jib crane.

Please read the operating manual before starting the assembly. The drawings stated in the

manual are exemplary and may differ from the model provided.

The following safety instructions shall be observed during a proper assembly:

For assembly personnel

- The assembly work must be executed by qualified personnel only and shall be coordinated

between the operator and the operating company.

- The assembly personnel shall be protected against local dangers during the assembly of

the column and the boom.

- Auxiliary material shall be used in a manner that danger to person due to unintended use

will be prevented.

- Only adequate and certified tools shall be used during the assembly of the slewing jib

crane.

- The work steps described below shall be observed.

- The stay under suspended loads is forbidden.

- The unit shall be activated considering the electrotechnical instructions and only

assembled in zero potential condition.

For assembly site

- The working and danger area shall be sufficiently secured.

- Customer specific instructions shall be observed

- Hoisting gears and auxiliary material, adequate for the assembly, must be available,

certified and in proper state and shall be used according to the intended use.

11.1 Welding works on cranes

You only may weld on cranes if:

- It is required and described in the assembly instructions

- We, as manufacturer, have allowed the welding works

- All requirements are complied with (see 9.4.4)

- B1 -

- B2 -

11.2 General assembly advices

- Slewing cranes only operate correctly if they are assembled according to this manual.

- Statutory tests and maintenances must be executed at regular intervals.

- Before every assembly, the installation conditions on site and the crane and installation

height due to the design shall be checked. The statutory safety distances shall be

observed.

- Only slewing jib cranes with additional mark “F” in their type designation are designed for

an outside operation and shall be assembled and operated there.

- Only slewing jib cranes with the additional mark “ex” in their type designation are designed

for the operation in potentially explosive areas.

- For the included hoisting gears, the respective operating manuals of the manufacturer shall

be observed.

- After finishing the assembly, execute all crane functions carefully and check the proper

function.

- Operating instructions shall be attached on the crane in a clearly legible manner.

- At power operated cranes and all cranes with a load bearing capacity higher than 1000 kg,

checks must be executed according to UVV- Cranes BGV D6 §25 before initial operation.

- All checks shall be executed according to §19 of IEC 60204-32.

Slewing brake

12. Overview of crane

Constructional design

Axle support Swivel axis Power supply

Slewing stops Cross travel buffers

Hoisting gear

Boom

Main switch

Control device

Foot flange

Power supply

Round cable Trailing cable Ideal control system

Possible anchorages

Foundation anchorage Bolt anchorage (Intermediate base plate)

Mobile unit (displaceable)

Drawing 11

- B3 -

12.1 Types of anchorage

Additionally, it is possible to anchor the crane with a base plate or a foot flange on an adequate

substructure, for example:

- On a floor slab using straight fitting and counter plates

- On a steel construction with adequate screw or weld joint

The requirements on this substructure result from the individual technical parameters (loads and moments),

as well as from the general requirements on the anchorage of the crane.

For effective loads on the on site anchorage see the purchase order documents or consult the

manufacturer. Information of general dimension and data sheets only apply to standard designs with foot

flange and till the construction height specified there.

Requirements on the foundation – Check before assembly!

- Foundation must be sufficiently hardened (clearance through the supervising company)

- Foundation shall be checked on compliance with provided outer dimensions

- Position, number and arrangement of the anchor bolts shall be checked according to

dimension sheet

- Number of the drilled holes in the foot flange must conform to the anchor bolts

- Diameter and screw thread of the anchor bolts shall be checked

Requirements on the bolt plate – Check before assembly!

- Evenness and straightness of the floor

- No grooves in the area of the bolt plate and respect of the edge distances according to the

admission requirements for anchor bolts (see assembly instructions “Standard and

intermediate base plates for the bolt anchorage“)

- According to the processing guidelines of anchors, the temperature of the anchorage

basement must be between +5°C and +25°C

- The minimum requirement on the concrete quality and the contrete thickness of the

anchorage basement shall be checked according to the admission requirements and

documented in the assembly record

Requirements on the supporting structure on site:

- Must be free of oscillation and vibration

- Must be able to take load and stiff

- Open profiles (such as I profiles) are flexible in torsion and so they must be sufficiently

dimensioned and require, if necessary, a bracing to the box girder

- The joint and supporting surfaces must be even and horizontal

- B4 -

- B5 -

12.2 Equipment of the crane

Standard equipment

Special equipment

• Crane column with foot flange

• Boom

• Swivel axis

• Cross travel buffers

• Equipment and small components

• Slewing brake

• Locking device of boom (standard for outside operation)

• Slewing stops

• Hoisting gear

• Main switch

• Power supply

Table 3

Mark of the load bearing capacity (on both sides)

12.3 Marking on the crane

The following markings must be attached on

the crane:

Warning mark (on both sides)

Operating instruction

Main switch

Type plate

CE Mark

- CE Mark

- Mark of the load bearing capacity

- Warning mark

- Type plate

- Operating instruction

- Main switch If these markings do not exist on the crane,

they must be amended.

(see annex B – spare parts list)

Drawing 13

13. Assembly crane column

Firstly, deposit the crane column along with the desired position and check the following points:

- Foundation (if existing) Æ

- Foot flange of crane column Æ

Is it enough hardened?

Is the grommet inserted and the feed

cable long enough – cable de-

energised?

Check diameter and number of drilling

hole!

- Anchor bolts Æ Distance and number

Diameter M

Functioning of the screw thread

Straigthness

Please note introduction “FOUNDATIONS – planning and building“

In case that the anchor bolts are not in the prescribed state, the number and the distances

are not correct or the screw thread is damaged, the crane column must not be assembled.

A sufficient stability is not ensured anymore. The occurred faults shall be fixed before

beginning of the assembly.

Foundation

Grommet

Drawing 14

Remove the hexagonal nut (F2) and the flat washer (F1) after the inspection. Now you can remove the

former plate (F3). This former plate can be disposed (Steel scrap).

Adjust the lock nut so that it is flush with the ground (hall floor). The foot flange of the crane column should

be flush with the hall floor.

- B6 -

- B7 -

Power supply

Drawing 15

With an adequate hoisting gear and slinging mean, lift the crane column carefully in a vertical position.

Now, guide the power supply through the column till the hole for the main switch and draw it through the

hole.

Set the column carefully down and pay attention to an insertion of the anchor bolts as gentle as possible to

avoid damages on the threaded end. Fix the column with hexagonal nut (F6), flat washer (F5) and counter

nut (F7).

Security advice: Observe tightening torques for hexagonal nut (see table 5)!

With a water level, check on several points on the diameter of the swivel axis if it is

perpendicular. Check in the area of the lower console if it is horizontal.

The adjustment takes place by loosing and tightening (F4) and (F6) carefully.

The fine adjustment of the crane must take place after assembly of the boom and the hoisting gear as well

as with completely assembled equipment and in hardened foundation (see chapter 16.6)

Tightening torques for hexagonal nut

Dimension

Tightening torques for hexagonal nut (F2)

M20

184 Nm

M27

470 Nm

M30

635 Nm

Table 5

14. Assembly of the boom

The following parts are loosely enclosed for the assembly of the boom (1):

1x Swivel axis (20) 1x Safety plate (22) 2x Hexagon head screw (120) 4x Flat washer (121) 2x Hexagon nut (122) 1x Slide ring (21)

Clean the upper and lower sliding bearing (DU bush (100)) and remove heavy solings on mechanical parts.

The bearings are ex factory fitted to the boom tube and should not be disassembled.

Assembly:

Drawing 16

1. By loosing (120) to (122), disassemble the swivel axis (20) and the safety plate (22) from the crane

column. - Caution: Fall hazard of the swivel axis during the removing of the safety plate!

Keep these parts because they are needed later for the assembly of the boom.

2. Lift the boom (1) carefully. Make sure that the boom is protected against fall and is lifted

horizontally.

3. Move the boom laterally between the upper and the lower console of the slewing column (2) –

Caution! Higher risk of crushing!

4. Insert the slide ring (21) carefully between lower console and boom. Pay attention to the higher risk

of crushing!

5. Insert the pre-assembled slewing brake between the guide brackets on the lower bearing console

(only with special equipment “slewing brake“).

6. Guide the swivel axis (20) from below through the provided drilled hole of the lower console– slide

ring – swivelling tube – drillet hole of the upper console.

- B8 -

7. Protect the swivel axis (20) against fall out, using the safety plate (22). Fix the safety plate with the

positions (120) to (122).

8. Slew the boom to all possible final positions, according to the local conditions, and check if the

boom stops in all positions. Should this not be the case, observe the possibilities of adjustment

(see chapter 17)

15. Assembly equipment

The supplementary equipment offered by us is the permitted equipment for the crane. We, as crane

manufacturer, adjust our equipment to the crane and certify the belonging in the inspection records on the

additional master data list. In addition, the crane is intended for the use with hoisting gears and load

handling devices which meet the national accident prevention regulations as well as the current EC

Machinery Directive. During the choice of the hoisting gears, the limitations according to chapter 1

(intended use) and the data sheets shall be observed.

15.1 Assembly hoisting gear

Review and decide in advance, if you pre-assemble the cross travel winch and the hoisting gear on outside

and hang it then into the boom of if the assembly of the hoisting gear should take place directly on the

boom. Assemble the hoisting gear and the travelling winch according to the individual instructions of the

respective manufacturer of hoisting gear. Ensure the correct adjustment of the bottom flange carriage to

the width of the mounting flange of the boom. Consider the clearance on the crab gauge provided by the

manufacturer of the hoisting gear.

Advice!

Observe the instructions of the manufacturer of hoisting gear!!!

Component

Possible arrangements (in direction to the head of the boom)

Left Centre Right

Chain box X

Hoisting gear normal design X

Carriage X

Control switch on hoisting gear X

Trailing cable X or X

Round cable X or X

Terminal box on boom Arrangement according to the point where the power supply

is assembled Terminal box on carriage

Terminal box on hoisting gear Table 6

- B9 -

15.2 Assembly cross travel stops

The inner cross travel stops are tightly connected ex works with the boom. The cross travel stop on the

head of the boom is removable. They are suitable as final position limitation for numerous cross travel

winches.

ADVICE: If the function of the cross travel stops of carriages delivered to you is not

ensured, universal cross travel stops in clamping design are available as special

equipment.

The following parts are loosely enclosed for the assembly of the cross travel stops:

1x Stop angle (23) 2x Rubber buffer (110) 2x Flat washer (111) 2x Hexagon nut (112) 2x Hexagon head screw (115) 4x Falt washer (116) 2x Hexagon nut (117)

Assembly: Drawing 17

1. Fix the stop angle (23) on the head of the boom using (115) to (117).

2. Fix the rubber buffer (110) on the stop angles using (111) and (112).

By starting the carriage, ensure the function of the cross travel stops after the assembly. CAUTION: Without cross travel stop on the head of the boom, the hoisting gear (with load) moves from the boom Æ danger of fall down of the load!!!

- B10 -

40.1

40.3 40.11

41.10, 41.11, 41.12

15.3 Assembly slewing brake

The slew brake (special equipment) serves for the adjustment of the slewing rate of the boom. The brake

shoes equipped with a brake pad can be pressed on the slewing column via a manually fine adjustable disc

spring packet and as a result they avoid, according to pretension, the overtravel of the boom.

40.1 40.10

40.12

40.3 40.11

40.2

Assembly: Drawing 18

1. Position the both blocks (40.1) with the distance pieces (40.2) downwards on the lower console of

the crane column between the guide plates intended for this purpose on the lower console of the

crane column.

2. Attach 10 disc springs (40.12) in each case (according to drawing 18) on the screws (40.11) and

connect the both blocks using the scews and nuts (40.10).

3. The braking effect is adjusted by tightening the nuts (40.10) uniformly.

Is case of the subsequent equipment of cranes with slewing brakes it is necessary to refit guide plates on

the lower bearing console. In this case, please observe the separately available assembly instructions.

15.4 Assembly slewing stops

The sleving stops serves for the limitation of the slewing motion (special equipment).

Slewing stops in weldable design are provided as all-purpose

fixed stops on the head of boom.

The stops consist in each case of a steel profile as well as of a

rubber buffer (41.10) with stay bolts and a flat washer (41.11)

and a hexagon nut (41.12) for the fixation. During the welding,

the rubber buffers shall be removed from the profile.

Drawing 19

- B11 -

Slewing stops with buffer rod are provided for the assembly in

the area of the head of boom. For reasons of the optimum load

application the stops provided for clamping on the upper flange

or the end plate shall be

- Assembled max. 300 mm before end of boom

- Take effect perpendiculary on a fixed counterplot in the

environment of the crane

Drawing 20

Please review before assembly:

- Do you meet the requirements of welding on cranes?

- Allow the environmental conditions on assembly site a welding?

- Are all equipments, hoisting gears etc., relevant to define the slewing range, assembled on

the crane?

- Which interference contours in the environment of the crane shall be protected against

impact of the boom and how must the boom protected against impact?

- Decide on which point (Crane column or lower bearing plate) and in which position

(standing of lying) the universal stop must be welded to fulfil its function.

- In this connection, please take account to a maximum long weld seam (PFSP design size 1-

3 minimum 75 mm, design size 4+5 minimum 120 mm).

Assembly:

1. In the area of the projected welded seam, remove locally the existing anti-corrosion

coating.

2. Attach the buffer and check the intended function – if necessary, adjust the position of the

buffer.

3. Completely weld the buffer on (hollow weld a=3mm (size 1 to 3) and/or a=4mm (size 4 and

5).

4. Check the function of the stops with and without load on the respective final positions of

cross travel.

5. Using the included correction colour, renew the anti-corrosion coating in the area of the

welded seam.

- B12 -

15.5 Assembly locking of boom

The locking of the boom is intended for the fixation of the boom in one or more positions within the

swivelling range of the crane. At cranes for outdoor operation the locking is standard equipment and serves

for wind bracing (see also chapter 5.1.4)

The locking of the boom is pre-assembled ex works on the crane column.

During the installation of the crane and

assembly of the boom the locking of the boom

shall be adjusted in position “loosen” (control

rod A1 pulled and locked) to ensure a smooth

hanging in of the boom.

Check the locking for function after assembly

of the boom (see chapter 14) and, if

necessary, readjust the slewing bracket.

Drawing 21

During maintenance and repair works, it could be necessary to disassemble the locking to replace for

example the spiral spring. In this case the bolt (pos. A2 and A6 – called return stop) must be replaced and

the control rod can be pulled downwards out of the guide plates. Remove spring and flat washer carefully.

Caution – the return spring is under pre-tension.

The assembly proceeds in reverse order. Position the new spring (A4) and the new flat washer (A7)

between the plates and the control rod into the drilling holes of the guide plates. Lock it with bolt (A2 and

A6) and, after assembly, check locking for function.

- B13 -

16. Assembly electricity

Standard electricity

Equipment:

• Rising main

• Main switch Basic electricity

• Grounding unit for swivel column + boom

• The power supply to the hoisting gear on the boom is ensured via round cable or trailing cable

Round cable power supply Trailing cable power supply Drawing 22

• The hoisting gear is controlled via a control switch which is directly attached to the hoisting gear.

Safety instructions

In case of faulty electric power supplies there is the risk of an accident, maybe a danger for

life and limb is also possible. Never act without thinking, it is impossible to replace a human

life.

Only electricians may create electrical connections!

Observe the currently valid directives:

- UVV BGV D6

- DIN VDE 0100

- DIN EN 60204-32

- DIN VDE 0100-600

Observe the safety instructions:

- Power off

- Ensure zero potential

- Protect main switch against unauthorised switch-on (e.g. padlock)

- Pay attention to right tension and rotating direction.

In case of emergency, push the EMERGENCY BUTTON on the control swith or cut the

electric power on main switch off.

- B14 -

16.1 Assembly base electricity

After the boom is assembled, it is possible to connect the base electricity. Therefore a terminal box with an

applicable round cable is pre-assembled on the boom.

Guide the round cable through the applicable screw connection on the crane column in the tube

downwards to the main switch.

Screw connection Terminal box

Round cable

16.2 Assembly main switch

Drawing 23

The grounding unit and the necessary retaining elements are supplied loose as equipment of the main

switch.

Drawing 24

- B15 -

Assembly:

1. Using a cylinder head screw (228), a flat washer (231), a lock washer (230), a washer ring (232)

and a hexagon nut (229), attach one end of the protective earth (PE) on the lower drilling hole of

the plate of main switch on the crane column.

2. Attach the 2nd

end of the protective earth (PE) on the main switch.

3. Guide the round cable and the power supply cable through the grommet of the main switch.

4. Connect the protective earth of the both cables named above additionally with the protective earth

of the main switch.

5. Now, connect the respective 3 phase cables on main switch with (L1), (L2), (L3)

6. Assemble the main switch to the provided hole of the crane column and fix it with the provided

screws (224).

16.3 Assembly grounding unit on boom

(Only for design with trailing cable)

Assembly:

Drawing 25

1. Attach one end of the protective earth with cylinder head screw (216), flat washer (221), spring

washer (222) and lock washer (220) to the terminal box of the boom.

2. Attach the protective earth (218) on the terminal block of the terminal box (214). Make sure that the

green/yellow marked cables are connected opposite.

- B16 -

16.4 Power supply via trailing cable

Description:

The flat cable (213) runs parallel to the boom (1) through the running rail (205) and is connected between

terminal box (214) and terminal block to the hoisting gear. The length of the flat cable amounts 1.4 times

the boom. It is arranged ex works on the right side of the boom in the direction to end of boom.

Assembly:

1. Using the clamping shoes (202), clamp the support console (201) to the boom.

2. Attach the fixed mounting bracket (204) to the support console (201).

Drawing 26

3. Insert the running rail (205) into the fixed mounting bracket (204). In case of a higher outreach, use

the enclosed connector (207 – not displayed in drawing 26) to extend the running rail.

4. Attach the termination fitting (210) to the running rail (205)

5. Run the carrier (209) and the piped wagons (208) in the running rail (205).

6. Unscrew the screw on piped wagon (208), carrier (209) and termination fitting (210).

7. Guide the flat cable (213) through termination fitting (210), piped wagon (208) and carrier (209).

The distances between the piped wagons amount to 2x the cable sag.

8. Divide the flat cable (213) in equal distances.

9. Tighten the srews, unscrewed under point 6

10. Drive the hoisting gear carefully to the end of the boom till the cross travel stop.

11. Connect the flat cable (213) with the terminal block of the hoisting gear (according to assembly

instructions of hoisting gear manufacturer).

12. Using a screw (43.12) and a spring washer (43.13), assemble the carrier (43) to the carriage of the

hoisting gear.

- B17 -

16.5 Power supply via round cable

Description:

The round cable (319) is located up to the half length of the boom in the armoured steel tube (311) and

connected with the terminal block of the hoisting gear. The free cable sag is ¼ of the boom length. The

armoured steel tube (313) and the armoured steel crown (312) are fixed with a Stauff clip (316). It is

arranged ex works on the right side of the boom in the direction to end of boom. Arrangements on the

left side are possible in special design.

Assembly: Drawing 27

1. The armoured steel tube (311) is pre-assembled on the boom.

2. Screw the armoured steel crown (312) on the armoured steel tube (313)

3. Using the Schauff clip (313) attach the armoured steel tube (313) on the boom

4. Guide the round cable (319) through (311), (313) und (312) to the terminal block of the hoisting

gear.

5. Drive the hoisting gear to the end of the boom and connect the round cable with the terminal block

of the hoisting gear according to the instructions of the hoisting gear manufacturer.

- B18 -

17. Information on the fine adjustment

The adjustment of the crane shall take place after complete assembly of the crane inclusive the whole

provided equipment and the hoisting gear and under the expected operating conditions. Only in still air, it is

possible to adjust outdoor cranes in an optimal way.

A correctly adjusted crane with hoisting gear in stand-by position (on the crane column) and with hook in

upper position at the desired working or stand by positions should not start unintended.

Load the crane with nominal load and drive all possible courses of motions with this load in order to be able

to take into account the manufacture or assembly related settling of the crane unit or anchorages.

The adjustment is achieved by a careful loosing and tightening of the adjusting nuts (F4) and fastening nuts

(F6).

Slew again the boom without load to all positions and note where the boom stops.

Check the attachments of the crane column!

Are the nuts tightened firmly?

Æ See table “fastening torques” (chapter 13)

ADVICE: At very high cranes the adjustment of the crane column should not be carried

out on the column but the perpendicular position of the swivel axis (20) shall be checked

and, if necessary, adjusted. The readjustment is also achieved via the adjusting nuts

under the foot flange.

Please read assembly instructions – standard and intermediate base plate for bolt anchorage to adjust

cranes with bolt anchorage.

Adjust the crane column again!

Slew the boom again and note where it stops and where not.

Take other possibilities into account!

The causes of uncontrolled boom movement of manual operated booms could be due to the system.

Please check if the overtravel of the boom interferes or could endanger the operation. Please note, that

unguided loads hanging on the crane (this also could be slinging means, traverses or several) do not meet

the requirements of the intended use and require, if necessary, special equipment.

In case that the uncontrolled boom movement disturbs and/or impacts the security or the operation and if

the adjustment results no improvements, in most cases, a slewing brake (special equipment) could help.

After the adjustment of the crane the same shall be grouted according to assembly instructions

“FOUNDATIONS – planning and building”.

- B19 -

18. Start of operation

Commissioning of the crane

Take protocol of the commissioning!

The following points shall be observed at commissioning:

Electrical connection

Screw fittings

Æ

Æ

Checked by electrician? (VDE 0100 – 600)

Safe and fixed?

Ropes and chains Æ Secured on start and end, lubricated and greased?

Cross travel stops Æ Attached on boom end?

Boom

Crane column

Æ

Æ

Axle support (Pos. 22) attached?

Crane adjusted? (Chapter 17.)

Slewing brake Æ Checked for correct operation?

Boom locking Æ Safe and functioning?

Power supply Æ Free movement of the hoisting gear possible?

Foot flange Æ Bottom casting existing?

Coating Æ Correct damages?

Hoisting gear

Documentation

Æ

Æ

Observe manufacturer’s operating manual!

Hand included documents over!

Assembly site Æ Cleaned up?

Labelling Æ Complete?

Check the crane functions without load:

Working area Æ Hindered?

Slewing range Æ Limited?

Satefy distances

Function

Æ

Æ

Are they observed?

Crane, end switch, additional equipment?

Test load Æ If the evaluation is not clear, load the crane with nominal load!

Is it possible to start the crane?

Responsibility of acceptance: All cranes ≥ 1000 kg load bearing capacity

All cranes ≤ 1000 kg, from 2 power driven movements

Before initial operation and after significant modifications, power driven cranes must be checked by an

authorised expert before recommissioning. This also applies for manual or partly power driven cranes with

a load bearing capacity of more than 1000 kg.

The acceptance shall take place in compliance with BGG 905 “Principles for the inspection of cranes“

according to UVV BGV D6 “Cranes“.

- B20 -

19. Safety distances slewing jib crane

Movement Safety distances

Above (So) Below (Su) Lateral (Ss)

Manually remote-controlled 0 1) 0 0 2)

Power driven, remote-controlled stroke electric 0 1) 0 0

2)

Stroke, cross travel electric 0 1) X

3) 0 2)

a) b) c)

Table 7

0 no regulation,

100 mm recommended

X Safety distance of 500mm minimum

pretended

1)

The safety distance below must be observed for other cranes a). Für b), c) there is no regulation during the manual slewing.

2)

The lateral safety distance is not pretended.

3) In case of textile chain bag, the safety

distance relate to the housing of the chain block.

Drawing 28

- B21 -

20. Additions and notes

- B22 -

Spare parts list

Pos. N. Designation AG I AG II AG III AG IV AG V Drawing 1 1 Boom, slewed - - - - - 14,15 2 1 Column, complete - - - - - 13,14

20 1 Axis Round 35 Round 40 Round 45 Round 50 Round 65 14 21 1 Slide ring Round 60 Round 65 Round 70 Round 75 Round 90 14 22 1 Safety plate - - - - - 14 23 1 Stop angle, beveled - - - - - 15 40 1 Slewing brake - - - - - 16

40.1 2 Block - - - - - 16 40.2 2 Distance piece - - - - - 16

40.3 2 Brake pad - - - - - 16 40.10 2 Hexagon nut M8-8 M10-8 M10-8 M12-8 M12-8 16

40.11 2 Hexagon head screw M8x95-8.8 M10x100-8.8 M10x115-8.8 M12x140-8.8 M12x140-8.8 16 40.12 20 Disc spring 16 / 8.2 / 0.9 20 / 10.2 / 1.1 20 / 10.2 / 1.1 23 / 12.2 / 1.25 23 / 12.2 / 1.25 16

41 Slewing stop - - - - - 18 41.10 1 Rubber buffer 50/40 50/40 50/40 50/40 50/40 18

41.11 1 Flat washer A 10.5 A 10.5 A 10.5 A 10.5 A 10.5 18 41.12 1 Hexagon nut M10-8 M10-8 M10-8 M10-8 M10-8 18

43 1 Carrier 24 43.12 2 Hexagon head screw M8x20-8.8 M8x20-8.8 M8x20-8.8 M8x20-8.8 M8x20-8.8 24

43.13 2 Spring washer A8 A8 A8 A8 A8 24 100 2 DU bush D 35 / d 39 / 20 D 40 / d 44 / 20 D 45 / d 50 / 20 D 50 / d 55 / 20 D 65 / d 70 / 20 14 110 2 Rubber buffer 50/40 50/40 50/40 50/40 50/40 15 111 2 Hexagon nut M10-8 M10-8 M10-8 M10-8 M10-8 15 112 2 Spring washer A 10 A 10 A 10 A 10 A 10 15

115 2 Hexagon head screw

See table 9

15

116 4 Flat washer 15 117 2 Hexagon nut 15 120 2 Hexagon head screw M8x30-8.8 M8x40-8.8 M8x35-8.8 M8x35-8.8 M8x40-8.8 14 121 4 Flat washer A 8.4 A 8.4 A 8.4 A 8.4 A 8.4 14 122 2 Hexagon nut M8-8 M8-8 M8-8 M8-8 M8-8 14 150 2 Plate of load bearing capacity - - - - - 11 151 1 Warning mark left - - - - - 11 152 1 Warning mark right - - - - - 11 153 1 Type plate - - - - - 11 155 1 CE mark - - - - - 11 156 1 Operating instructions - - - - - 11 157 1 Main switch - - - - - 11

Trailing cable

201 Support console Number varies according to length of boom

24 202 Clamping jaw 24 204 Mounting bracket 24 205 1 Running rail - - - - - 24 208 Piped wagon Number varies according to length of boom 24 209 1 Carrier - - - - - 24 210 1 Termination fitting - - - - - 24 211 1 End cap - - - - - 24 212 1 Round cable - - - - - 24 213 1 Flat cable - - - - - 24 214 1 Terminal box - - - - - 24

215 1 Cylinder head screw M5x12-8.8 M5x12-8.8 M5x12-8.8 M5x12-8.8 M5x12-8.8 23

Pos. N. Designation AG I AG II AG III AG IV AG V Drawing 216 1 Cylinder head screw M5x30-8.8 M5x30-8.8 M5x30-8.8 M5x30-8.8 M5x30-8.8 23

217 2 Hexagon nut M5-8 M5-8 M5-8 M5-8 M5-8 23 218 1 Grounding unit, boom - - - - - 23

219 2 Cable shoe Assembled on grounding unit 220 1 Lock washer 5,3 5,3 5,3 5,3 5,3 23 221 1 Flat washer A5,3 A5,3 A5,3 A5,3 A5,3 23 222 1 Spring washer A5 A5 A5 A5 A5 23 223 1 Screwed joint M20 M20 M20 M20 M20 23 224 1 Main switch - - - - - 22 225 4 Flat head screw with slot M4x16 M4x16 M4x16 M4x16 M4x16 22 226 1 Grounding unit, column - - - - - 22

227 2 Cable shoe Assembled on grounding unit 228 1 Cylinder head screw M4 x 25 - 8.8 M4 x 25 - 8.8 M4 x 25 - 8.8 M4 x 25 - 8.8 M4 x 25 - 8.8 22 229 1 Hexagon nut M4-8 M4-8 M4-8 M4-8 M4-8 22 230 1 Lock washer 4.3 4.3 4.3 4.3 4.3 22 231 1 Flat washer A4.3 A4.3 A4.3 A4.3 A4.3 22 232 1 Spring washer A4 A4 A4 A4 A4 22

Round cable

301 1 Main switch - - - - - 22 302 4 Flat head screw with slot M4x16 M4x16 M4x16 M4x16 M4x16 22 303 1 Grounding unit, column - - - - - 22

304 2 Cable shoe Assembled on grounding unit 305 1 Cylinder head screw see 228 22

306 1 Hexagon nut see 229 22

307 1 Lock washer see 230 22

308 1 Flat washer see 231 22

309 1 Spring washer see 232 22

310 2 Screwed joint M20 M20 M20 M20 M20 25 311 1 Armored steel tube M25 M25 M25 M25 M25 25 312 1 Armored steel crown M25 M25 M25 M25 M25 25 313 1 Armored steel tube M25 M25 M25 M25 M25 25 314 3 Terminal sleeve M25 M25 M25 M25 M25 25 315 1 Reducer M25/M20 M25/M20 M25/M20 M25/M20 M25/M20 25 316 1 Stauf clamp, complete - - - - - 25 317 2 Cylinder head screw with slot M6x30-8.8 M6x30-8.8 M6x30-8.8 M6x30-8.8 M6x30-8.8 25 318 2 Spring washer A6 A6 A6 A6 A6 25 319 1 Round cable - - - - - 25

Table 8

Flange width [mm] Hexagon head screw Flat washer Hexagon nut

64 M8 x 30 - 8.8 A 8,4 M8 - 8

73 M10 x 30 - 8.8 A11 M10 - 8

82 M10 x 30 - 8.8 A11 M10 - 8

91 M12 x 40 - 8.8 A13 M12 - 8

100 M12 x 40 - 8.8 A13 M12 - 8

110 M12 x 40 - 8.8 A13 M12 - 8

120 M12 x 40 - 8.8 A13 M12 - 8

135 M16 x 45 - 8.8 A17 M16 - 8

150 M16 x 45 - 8.8 A17 M16 - 8

160 M16 x 45 - 8.8 A17 M16 - 8

170 M16 x 45 - 8.8 A17 M16 - 8

180 M16 x 45 - 8.8 A17 M16 - 8

Table 9

CE Declaration of Conformity

According to EC Directive 2006/42 EC, Annex II 1A, of July 2006

Herewith we,

Mechanik Taucha Fördertechnik GmbH An der Hufe 6

D-04838 Jesewitz

declare, that the design of the unit described below in the execution delivered by us corresponds with the following regulations:

EC Directives:

Machinery 2006/42 EC of 29th June 2006

Low Voltage 2006/95/ EC of 12th December 2006

EMC Directive 2004/108/ EC of 15th December 2004

Harmonized Standards:

EN 12100 part 1 version April 2004 and part 2 version April 2004 Safety of machinery-Basic concepts, General principles for design

EN 60 204 part 32 version June 1999, Electrical equipment of hoisting gears

EN 287 parts 1 + A1 of June 2006 Welder’s performance qualification

National Technical Specifications and Standards:

UVV BGV D6 “Cranes“ in version April 2001

DIN 18800 part 7, paragraph 6.2 of September 2002 + A1 of May 2006

Comprehensive Form of Verification, Class E DIN 15018 parts 1, 2 and 3 version November 1984

Graduation and Evaluation

Unauthorised modifications on the machine lead to an invalid declaration! ----------------------------------------------------------

MASTER DATA LIST

Serial N° : Crane/Unit : Year of manufacture :

Documentation officer: Andre Posnien

Technical data and function according to additional master data list. The sheets indicated in the table of contents are a part of the inspection records!

Authorised person of manufacturer: Last name, First name

Jesewitz,

Signature

Declaration of Incorporation For incomplete machines

According to EC Machinery Directive 2006/42 CE, Annex II 1B, of Juin 2006

Herewith we,

Mechanik Taucha Fördertechnik GmbH An der Hufe 6

D-04838 Jesewitz

declare, that the design of the unit described below in the execution delivered by us corresponds with the following regulations:

EC Directives:

Machinery 2006/42 EC of 29th June 2006

Low voltage 2006/95/ EC of 12th December 2006

EMC Directive 2004/108/ EC of 15th December 2004

Harmonized Standards:

EN 12100 part 1 version April 2004 and part 2 version April 2004 Safety of machinery-Basic concepts, General principles for design

EN 60 204 part 32 version June 1999, Electrical equipment of hoisting gears

EN 287 parts 1 + A1 of June 2006 Welder’s performance qualification

UVV BGV D6 “Cranes“ in version April 2001

DIN 18800 part 7, paragraph 6.2 of September 2002 + A1 of May 2006

Comprehensive Form of Verification, Class E DIN 15018 parts 1, 2 and 3 version November 1984

Graduation and Elvaluation

Unauthorised modifications on the machine lead to an invalid declaration!

----------------------------------------------------------

MASTER DATA LIST

Serial N° : Device/Crane/Unit : Year of manufacture :

Documentation officer: Andre Posnien

Technical data and function according to additional master data list. The commissioning is prohibited until vertified, that the complete crane unit meets the requirements of the valid Machinery Directive.

Authorised person of manufacturer: Last name, First name

Jesewitz,

Signature