jib crane assembly manual

Transcription

English
Original instructions
SI
JIB CRANE ASSEMBLY MANUAL
- - - -
-
Error! No document variable supplied.
Work Number -
R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
Table of contents
1 GENERAL INTRODUCTION................................................................................................................ 4 1.1 Foreword: About This Manual ................................................................................................................... 4 1.2 Symbols Used In This Manual ................................................................................................................... 4 1.3 Warnings Key ............................................................................................................................................ 4 1.4 Questions And Comments: ....................................................................................................................... 5 1.5 Exclusion Of Warranty............................................................................................................................... 5 1.6 Manual Use ............................................................................................................................................... 5 1.7 Terminology .............................................................................................................................................. 5 1.8 Standards And Directives .......................................................................................................................... 7 1.8.1 CE/CSA/UL/CCC................................................................................................................................... 7 2 INSTRUCTIONS FOR THE CRANE ASSEMBLER ............................................................................. 8 3 SAFETY FIRST! ................................................................................................................................. 10 3.1 Personal Protective Equipment (PPE) ..................................................................................................... 10 3.1.1 Fall Protection ..................................................................................................................................... 10 3.2 Fire safety ............................................................................................................................................... 11 4 PRE-REQUISITES FOR ASSEMBLY ................................................................................................ 12 4.1 Assembly environment requirements ...................................................................................................... 12 4.2 Tool requirements ................................................................................................................................... 13 4.3 Personnel requirements .......................................................................................................................... 15 5 CRANE COMPONENTS .................................................................................................................... 16 5.1.1 Over braced wall-mounted jib crane, I-profile ...................................................................................... 16 5.1.2 Over braced wall-mounted jib crane, UKA-profile ................................................................................ 16 5.1.3 Under braced wall-mounted jib crane, I-profile .................................................................................... 17 5.1.4 Over braced pillar-mounted jib crane, I-profile ..................................................................................... 18 5.1.5 Over braced pillar-mounted jib crane, UKA-profile .............................................................................. 19 5.1.6 Under braced pillar-mounted jib crane, I-profile ................................................................................... 20 5.2 Signs ....................................................................................................................................................... 21 5.2.1 Safety Signs ........................................................................................................................................ 21 5.2.2 Information Signs Used On The Crane ................................................................................................ 21 6 CRANE ASSEMBLY .......................................................................................................................... 24 6.1 Installing the pillar with anchor bolts ........................................................................................................ 24 6.2 Installing the pillar with chemical bolts ..................................................................................................... 27 6.3 Installing wall supports secured with two bolts ........................................................................................ 29 6.4 Installing wall supports secured with four bolts ........................................................................................ 31 6.5 Installing the jib arm to the pillar .............................................................................................................. 34 6.6 Installing the jib arm to the pillar .............................................................................................................. 37 6.7 Installing the jib arm to the pillar .............................................................................................................. 40 6.8 Installing the jib arm to wall supports ....................................................................................................... 44 6.9 Installing the jib arm to wall supports ....................................................................................................... 49 6.10 Installing the jib arm to wall supports ....................................................................................................... 54 6.11 Installing power supply (UKA) ................................................................................................................. 59 6.12 Installing power supply (UKA) ................................................................................................................. 60 6.13 Installing power supply (I-profile, c-rails, pillar/wall) ................................................................................. 61 6.14 Installing power supply (I-profile, c-rails, pillar/wall) ................................................................................. 65 6.15 Assembling the hoist and other crane components (UKA) ...................................................................... 68 6.16 Assembling the hoist and other components (I-profile) ............................................................................ 69 7 COMMISSIONING ............................................................................................................................. 70 8 AFTER COMMISSIONING................................................................................................................. 73 8.1 Disposal of waste material ...................................................................................................................... 74 9 TIGHTENING TORQUES .................................................................................................................. 75 2/76
R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
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AT SITE INSPECTION FOR JIB CRANES .............................................................................................. 76 3/76
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1.1
GENERAL INTRODUCTION
Foreword: About This Manual
This manual offers guidance to enable safe and efficient assembly of the crane or crane components.
a crane assembler, taking the time to read this manual will help you to safely and efficiently assemble cranes.
Cranes are designed to be safe when assembled correctly. However, there are potential hazards associated with
incorrect assembly which can be avoided when you know how to recognize and anticipate them.
Crane assemblers must be properly trained and, at all times, comply with all of the applicable and prevailing safety
and other standards, rules and regulations. This manual is not intended a substitute for proper training but
provides recommendations and methods for safe and efficient assembly.
1.2
Symbols Used In This Manual
Readers should familiarize themselves with the following symbols which are used in this manual.
NOTE: Indicates items which require special attention by the reader. There is no obvious risk of injury
associated with notes.
1.3
Warnings Key
The following symbols are used in this manual to indicate potential safety hazards.
Safety Alert Symbol is used in this manual to indicate hazards and to alert the
reader to information that should be KNOWN, UNDERSTOOD, and FOLLOWED
in order to avoid DEATH or SERIOUS INJURY.
CAUTION
Indicates a potentially hazardous situation, which if not avoided, MAY result in
minor or moderate injury. It may also be used to alert against unsafe practices.
WARNING
Indicates a potentially hazardous situation, which if not avoided, COULD result
in death or serious injury.
DANGER
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
NOTICE
Shall
Should
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Addresses situations not related to personal injury, such likely or possible damage to equipment.
Indicates that a rule is mandatory and must be followed.
Indicates that a rule is a recommendation, the advisability of which depends on the facts in each situation.
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1.4
Questions And Comments:
Any questions or comments relating to the content of this manual should be directed to www.rmhoist.com
1.5
Exclusion Of Warranty
THE MANUFACTURER MAKES ABSOLUTELY NO WARRANTY WHATSOEVER WITH REGARD TO THE
CONTENTS OF THIS MANUAL, EXPRESS OR IMPLIED, WHETHER ARISING BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
1.6
Manual Use
Every person exposed to the manufacturer’s products must, prior to ASSEMBLING, OPERATING, SERVICING
AND/OR MAINTAINING SUCH PRODUCTS, read and understand the contents of this manual and strictly adhere
AND CONFORM THEIR CONDUCT WITH AND TO THE INFORMATION, RECOMMENDATIONS AND warnings
provided herein.
Note: Keep these instructions in a safe, accessible location for future reference by personnel operating the
crane or exposed to crane operation.
WARNING
Failure to read and understand the contents of this manual prior to
ASSEMBLING, OPERATING, SERVICING AND/OR MAINTAINING the crane
COULD result in death or serious injury.
Manufacturer shall not be liable for and owner and READER shall release, and hold manufacturer, harmless from
any and all claims, demands, AND damages, regardless of their nature or type losses and expenses , whether
known or unknown, present or future, any and all liability, of and from any and all manner of actions, cause[s] of
actions, all suits in law, in equity, or under statute, State or Federal, of whatever kind or nature, third party actions,
including suits for contribution and/or indemnity on account of or in any way arising out of acts or omissions of the
Owner or READER and relating in any way to this MANUAL or THE PRODUCTS referenced herein, including, but
not limited to the Owner’s or READER’S use thereof or any other cause identified herein or that may be reasonably
inferred HEREFROM.
1.7
Terminology
The following terms and definitions are used in this manual:
Countertorque (plugging) braking
Eddy-current braking
Mechanical load brake
ANSI
ISO
Authorized personnel
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A method of controlling speed by reversing the motor supply polarity or phase sequence to
create torque opposite to the motor rotation direction.
A method for controlling or reducing speed by using electrical induction a load brake.
An automatic unidirectional mechanical friction brake which controls the descent speed of loads.
The mechanical load brake does not impose additional load on the motor when it is raising a
load but motor torque is required to lower loads.
American National Standards Institute
International Organization for Standardization
Persons who are authorized by the owner and who have the necessary training to carry out
operation or service actions.
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Experienced service man authorized by the A person with service experience who is authorized by the crane manufacturer to perform
manufacturer of the crane.
service actions.
CE marking
The crane’s CE-marking is displayed on the door of the bridge electric panel or on the jib
(boom). The symbol indicates that the crane complies with the appropriate CE regulations.
Check
A visual and functional assessment (not a test) of the crane without dismantling.
Floor-operated crane
A crane which is controlled by an operator using a pendant station which is suspended from the
crane.
Manually operated crane
A crane whose hoist or travelling movements are manually controlled, for example by pulling an
endless chain.
Jib crane
A crane with an arm which slews on a fixed bearing at one end. The hoist travelling movements,
along the arm or around the pivot, are usually manually controlled.
Wall-mounted jib crane
A jib crane in which the jib arm is fixed to a wall (concrete) or column (concrete/steel) which is
part of the building structure. The nominal rotating angle is 180˚.
Pillar-mounted jib crane
A jib crane in which the jib arm is fixed to a steel pillar which is delivered with the jib arm. The
nominal rotating angle is 270˚.
Outdoor crane
An outdoor overhead or gantry crane that cannot be stored indoors or protected from adverse
weather conditions. A crane that may operate outdoors on a periodic basis is not classed an
outdoor crane.
Overhead crane
A crane with a single or multiple girder movable bridge carrying a movable or fixed hoisting
mechanism and trolley and travelling on an overhead fixed runway structure.
Power-operated crane
A crane which is driven by electric, pneumatic, hydraulic, or internal combustion means.
Remote-operated crane
A crane which is controlled by an operator using an operating station which is not attached to
the crane (for example, radio control).
Standby crane
A crane which is used only occasionally or intermittently.
Top-running crane
An overhead or gantry crane that travels on top of the runway structure.
Under-running crane
An overhead crane that travels under the runway structure, also known underhung or
underslung.
Wall console crane
A crane having a cantilever frame with or without trolley, and supported from a side wall or line
of columns of a building. It is a travelling type and operates on a runway attached to the side
wall or columns.
Dynamic braking
A method of controlling speed by using the motor a generator, with the energy being dissipated
in resistors.
Emergency brake
A brake that can be applied by the operator, or automatically upon loss of power.
Electric panel
Power is controlled to the crane motors through the electric panel.
Holding brake
A friction brake for a hoist that is applied automatically and prevents motion when power is not
connected to the brake.
Parking brake (storm lock)
A brake that can be applied either automatically or manually and prevents horizontal travel
motion of the trolley or bridge travel.
Regenerative braking
A method of controlling speed in which the electrical energy generated by the motor is fed back
into the power system.
Crane operator
Person operating the crane for the purpose of handling loads.
Inching
Making very small movements of the crane by repeatedly and momentarily pressing the
direction control.
Bridge
The bridge (main girder) moves along the runway
Main girder
The main girder (bridge) moves along the runway
Main isolation switch
The main isolation switch is the power switch which the operator should normally use to turn off
the crane.
Hoist
Drive mechanism for lifting and lowering the load.
Inspection
Looking at the crane for defects and checking the operation of the controls, limiting and
indicating devices without loading the crane. This is much more than a check but does not
normally require any part of the crane to be dismantled other than for removal or opening of
covers or housings.
Owner’s manual
Principal means by which the manufacturer provides information or instructions concerning the
crane which are relevant to the crane owner.
Operator’s manual
Principal means by with the manufacturer provides information or instructions concerning the
crane which are relevant to the crane operator.
Power distribution
Power is supplied to the motors via the power distribution.
Controller
The pendant or other type of controller is used by the operator to give commands to the crane.
Qualified personnel
One with necessary qualification, based on theoretical and practical knowledge of hoists or/and
cranes, for required activities listed in operating instructions. The person must be in a position
to assess the safety of the installation in conjunction with the application. Persons with the
authority to undertake certain maintenance work on products of manufacturers include
manufacturers’ service engineers and trained fitters with corresponding certification.
Maximum capacity
Load that the crane is designed to lift for a given operating condition (e.g. configuration, position
of the load).
Runway
The whole crane rides on or under the runway.
Trolley (hoisting unit)
The trolley (hoisting unit) moves along the bridge (main girder).
Sling
A sling is used to attach the hook to the load when the load cannot be lifted directly by the hook.
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1.8
Standards And Directives
This state of the art product has been designed and manufactured to conform to European and international
standards and directives. The standards and directives to which the product conforms are stated in the Declaration
of Conformity or Declaration by Manufacturer.
1.8.1 CE/CSA/UC/CCC
The European standards that this product fulfils are described in the “RT Declaration by the manufacturer”. The
product also fulfils the requirements of the following standards (if applicable): CSA, UC, OSHA, CCC.
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INSTRUCTIONS FOR THE CRANE ASSEMBLER
WARNING
Only Authorized Personnel and Qualified Personnel should be permitted to
assemble the crane and, when doing so, they must strictly adhere to the
instructions and warnings provided in this manual.
Crane Assemblers SHALL:
1
2
Assemblers SHALL be trained and be competent for the task.
3
Assemblers SHALL know all the basic controls of the crane and must be able to use them correctly
and safely for the purpose of functional testing.
Assemblers can use the crane operator’s manual to familiarize themselves with the crane and
crane controls.
4
Assemblers SHALL be aware of any risk of accident posed by the assembly site.
5
Assemblers SHALL familiarize themselves with the signs and warnings marked on the crane. Selfadhesive signs are attached to the crane during assembly.
6
Assemblers SHALL always follow the local regulations.
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Assemblers SHALL learn how to assemble the crane safely before actually starting to work on the
crane.
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Crane Assemblers SHALL NOT:
1
Assemblers SHALL NOT work on the crane when under the influence of alcohol or drugs. Alcohol
and drugs can impair judgment and thereby cause a hazard.
2
Assemblers SHALL NOT work on the crane when under medication which may cause a hazard to
the assembler or others. If unsure, consult your doctor or pharmacist. Always comply with local
regulations regarding working under the influence of medication.
3
Assemblers SHALL NOT work on the crane while suffering from any illness or injury which might
impair their ability to properly construct the crane.
4
Assemblers SHALL NOT substitute parts (for example, missing items) with items sourced locally
without approval. Locally sourced parts may not meet the required specification and substituted
parts could present a variety of safety hazards.
Contact a service agent authorized by the manufacturer immediately in case of doubts!
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SAFETY FIRST!
Operators must understand and follow the safety requirements at the site.
3.1
Personal Protective Equipment (PPE)
For safety, the operator or others in close proximity to the crane may be required to wear Personal Protective
Equipment (PPE). Various types of PPE are available and must be selected according to the requirements of the
working environment. Some examples of different types of PPE are:
Typical PPE
Hard hat
Safety shoes
Hearing protection
Safety goggles
Gloves, overalls
Face mask
Flashlight for use in case of power
failure
3.1.1 Fall Protection
While personnel are performing inspection or maintenance work at heights, they must follow fall protection
procedures required by local regulations. Fall prevention practices and fall protection equipment aim to protect
personnel working on or around the equipment from exposure to falls.
If the crane does not have a service platform or handrail, personnel must use a properly fitted safety harness that is
attached to the dedicated fixing points on the building or the crane in order to prevent falls.
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If the crane does not have dedicated fixing points for fall protection, it is the owner’s responsibility to make sure that
there are suitable fixing points in the building structure.
If ladders must be used, personnel must practice setting and securing the ladders before using them for actual
work.
A typical fall protection program may include:
y Documented and established site policies and procedures.
y Conducting site assessments for fall hazards.
y Selection of the proper fall protection system and equipment.
y Training on fall protection procedures and the proper use of fall protection systems.
y Inspection and proper maintenance of fall protection equipment.
y Measures to prevent falling objects.
y Rescue Plans.
If necessary, contact your supplier or service organization for assistance with designing your fall protection
program.
3.2
Fire safety
In the event of a fire, only attempt to fight it if you can do so without putting yourself in danger. Turn the power off
first if it is possible to do so. Notify other people about the potential danger, and call help.
WARNING
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Never use a powder type fire extinguisher on high voltage.
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PRE-REQUISITES FOR ASSEMBLY
1
Allow sufficient time
Owners must ensure that sufficient time has been reserved for installation and testing.
2
Check for dimensional conformance
Immediately following installation and prior to commissioning, check that the supplied
parts conform to the drawings, instructions, parts lists and structural measurements.
Discuss any non-conformance with the crane supplier immediately.
4.1
1
Assembly environment requirements
Indoor assembly space
The assembly site must be sufficiently spacious and clear to permit the construction of
the crane. Floors must be level and the assembly site should present no avoidable
hazards to the crane assembler.
2
Prevent unauthorized access to the site
Unauthorized persons and bystanders must be prevented from walking on or below the
work site.
Ensure that the secured area is spacious enough to prevent injuries which could occur
a result of falling components or tools.
3
Minimize the risks of moving machinery
Make sure that there is no possibility for personnel or body parts to be struck, crushed
or compressed by moving machinery.
The area must be secured so that installation personnel are not at risk from the
movements of machines, automatic doors or adjacent cranes at the installation site.
Ensure that machinery and equipment cannot start up accidentally and cannot move
during installation. Maintain sufficient space in the working area to reduce the risks.
Moving parts should be properly shielded with guards to prevent entrapment. Safety
devices must never be overridden.
Be prepared in case equipment moves in the wrong direction during testing.
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4
Power supply
The assembled crane will be tested with electricity connected.
Never connect power before ensuring that you have the correct voltages, phases and
current ratings available for each crane.
5
Lifting facilities
The assembled crane is a very heavy item which itself must be erected using a fixed or
mobile crane. Make sure that a suitable crane is available and that it is capable of lifting
the total weight of the crane assembly.
6
Lighting
Make sure that you have good lighting around the assembly site. Some measurements
must be made during assembly and it is important that you can see properly so that
these are made correctly.
4.2
1
Tool requirements
General workshop tools
Standard general tools such screwdrivers, cutters and hacksaws are required during
the crane assembly process.
2
Torque wrench
Crane fastenings must be tightened to the specified torque.
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3
Painting equipment
The crane may require painting or touching up part of the assembly process.
4
Heat gun for heat-shrink sleeves
If it is necessary to terminate the cables during assembly, a suitable heat gun will
usually be needed to shrink the heat-shrink sleeves.
5
Multimeter
Normally no electrical fault-finding is required but a multimeter is possibly required
during the functional testing.
6
Power tools
It is useful to have a range of electric or compressed air power tools available. These
can include drills and powered wrenches for tightening fastenings.
If using compressed air, follow the correct procedures and be aware of the safety risks.
7
Lubricants
Some lubricants such cutting oil will sometimes be useful while assembling cranes.
Follow applicable safety guidelines for handling and storing lubricants.
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4.3
1
Personnel requirements
Number of people required
Cranes are usually assembled by at least two people.
Some tasks can be done by one person but others are much easier with two or more
people. Always be clear about who will do which task so that nothing gets overlooked.
All personnel must be properly trained for the task which they are performing.
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5
CRANE COMPONENTS
5.1.1 Over braced wall-mounted jib crane, I-profile
Note: This illustration is provided an example of a typical crane only and may not be identical to the crane
purchased by the owner. For example, the dimensions of the crane may be different and your crane may have
additional equipment such lighting or horns. Refer to the CAD drawings contained in the Owner’s manual
provided with the crane.
1
2
3
4
5
6
7
Part
Description
Jib arm (Boom)
The jib arm is attached to the support brackets. The trolley (hoisting unit) moves along the jib arm.
Bearing housing
The bearings and shaft fit inside the bearing housing.
The trolley (hoisting unit) moves along the jib arm.
Pendant controller
The hoist is operated using the pendant controller.
Power feeding system
The power feeding system supplies power to the hoist.
The main isolation switch is used to turn the electrical supply to the hoist on and off.
Support brackets
The support brackets are securely attached to the supporting structure. The jib arm is secured to
the support brackets by bearings and a shaft.
5.1.2 Over braced wall-mounted jib crane, UKA-profile
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2
3
4
5
6
7
Part
Description
Jib arm (Boom)
Bearing housing
Pendant controller
Support brackets
5.1.3 Under braced wall-mounted jib crane, I-profile
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2
3
4
5
6
7
Part
Description
Jib arm (Boom)
Bearing housing
Pendant controller
Support brackets
5.1.4 Over braced pillar-mounted jib crane, I-profile
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2
3
4
5
6
7
Part
Description
Pillar
Jib arm (Boom)
The pillar is securely attached to the floor. The jib arm is secured to the support brackets on the
pillar by bearings and a shaft.
Bearing housing
Pendant controller
5.1.5 Over braced pillar-mounted jib crane, UKA-profile
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Part
Description
1
Pillar
2
3
4
5
6
7
Jib arm (Boom)
Bearing housing
Pendant controller
5.1.6 Under braced pillar-mounted jib crane, I-profile
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2
3
4
5
6
7
5.2
Part
Description
Pillar
Jib arm (Boom)
Bearing housing
Pendant controller
Signs
The signs on the crane are presented in this section.
5.2.1
Safety Signs
Safety signs inform the operator about potential hazards and also about special features concerning crane
operation.
Failure to avoid dangers identified by these signs can result in death or serious
injury.
5.2.2 Information Signs Used On The Crane
Information signs present operational details which will help the operator to operate the crane.
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Note: The example data in the following figures is shown for illustration purposes only and does not
match the data on your crane.
Sign
Description
Product identification data plate
Location on crane
On the jib arm (1)
The crane number is stated on the crane’s data
plate which is located on the jib arm. Please
quote this number in any correspondence.
CE marking
On the jib arm (2)
Indicates that the crane complies with the
applicable European standards.
Brand logo
Positioned centrally on the jib arm (3)
Load stickers
On the jib arm (4) and on the hook block or
lifting device.
The maximum rated capacity of the crane and
hoist.
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6
CRANE ASSEMBLY
WARNING
It is the customer’s responsibility to ensure that the building structures and
crane mounting points can withstand the forces exerted by the crane. The
necessary information is provided before the crane order is confirmed. Failure
to fulfill the requirements could cause the crane to collapse, resulting in death
or serious injury.
WARNING
It is absolutely vital to use original fastenings supplied by the manufacturer.
Other fastenings may not fulfill quality requirements which may cause a
hazardous situation. This COULD result in crane collapse causing death or
serious injury.
NOTE: Illustrations used in this manual are only examples and may differ from the actual supplied equipment.
For exact technical design, see supplied drawings.
NOTE: Before starting the actual assembly, gather the crane components and other installation equipment close
to the crane assembly work site. Check that all parts are present and are in good condition.
6.1
Installing the pillar with anchor bolts
CAUTION
The crane SHALL only be assembled after the foundation concrete is
completely dry and hardened.
CAUTION
If the pillar is not sufficiently vertical, the jib arm could move by itself. This may
cause hazardous situations, for example collisions or injuries.
NOTE: In most cases the owner prepares the foundation ready for crane installation. Consequently the installer
will usually find that the first steps in the following procedure have already been completed.
NOTE: The crane base plate and fastening bolts must be accessible at all times.
1
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Before the jib crane can be erected, the template must be correctly installed into the
foundation. The template is only used to hold the anchor bolts in the correct position
until the concrete is dry.
Install anchor bolts into the template so that at least 130mm of thread will protrude
above floor level. Fasten with M27 nuts and washers on both sides of the template.
Cover the threads which will be above floor level so that they do not get splashed with
concrete.
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2
Install the power supply cable before pouring the primary foundation.
The primary foundation concrete (C25/30 quality) for the template must be at least 1m
deep and finish flush with the floor level.
3
Verify that the bolts are vertical in the foundation before it is dry.
4
After the concrete has hardened, remove the:
•protection from the bolts
•top nuts and washers
•template
Check that the remaining nuts and washers are level so that the top of the washers is
approximately 50 mm above the primary foundation.
5
Lay the pillar next to the assembly site. Check that the support plates for the jib arm will
be pointing in the correct direction when the pillar is raised.
Install the power supply cable through the pillar tube and pull it out from the main
isolation switch hole. Make sure that it cannot slide back into the pillar or become
trapped during assembly.
6
Lift the pillar up and align the holes of the base plate with the anchor points. Check that
the support plates for the jib arm are facing in the right direction so that the jib arm will
be pointing the right way.
When the pillar is correctly aligned with the anchor points, lower the pillar downwards,
taking care not to damage the fastenings.
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7
Adjust the pillar vertical alignment by adjusting the lower nuts on the anchor bolts
required.
Test at several places around the circumference to make sure that the pillar is not
leaning in any direction.
Measure the vertical alignment 2 m from the top of the pillar.
8
Tighten the top washers and nuts to 90 Nm.
9
Install grouting (second stage concrete) under and around the base of the pillar. Refer
to the foundation plan.
10
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After the grouting has hardened, tighten the nuts to 314Nm torque.
Use a spirit level to check that the pillar is still correctly aligned.
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6.2
Installing the pillar with chemical bolts
CAUTION
The crane SHALL only be assembled after the foundation concrete (C25/30
quality) is completely dry and hardened. The floor thickness must be at least
200mm.
CAUTION
If the pillar is not sufficiently vertical, the jib arm could move by itself. This may
cause hazardous situations, for example collisions or injuries.
NOTE: The crane base plate and fastening bolts must be accessible at all times.
NOTE: Tighten the chemical bolts to the bolt manufacturer’s specified torque.
1
Position the metal base plate in the desired position on the floor.
2
Check that the floor is level where the base plate will be installed.
3
Make a channel under the base plate for the power supply cable to run through. Be
sure to install the cable before securing the base plate to the floor.
4
Use the pillar base plate a template for drilling holes for the chemical bolts.
Drill holes for M16 bolts into the floor through the pillar base plate.
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5
Install chemical bolts into the floor according to the manufacturer’s instructions.
Minimum drying time is approximately 24 hours.
Tighten the chemical bolts to the bolt manufacturer’s specified torque.
6
Lay the pillar next to the assembly site. Check that the support plates for the jib arm will
be pointing in the correct direction when the pillar is raised.
Install the power supply cable through the pillar tube and pull it out from the main
isolation switch hole. Make sure that it cannot slide back into the pillar or become
trapped during assembly.
7
Lift the pillar up and align the holes of the base plate with the anchor points. Check that
the support plates for the jib arm are facing in the right direction so that the jib arm will
be pointing the right way.
When the pillar is correctly aligned with the anchor points, lower the pillar downwards,
taking care not to damage the fastenings.
8
Install the pillar with washers and nuts. Tighten the nuts to 314 Nm torque.
9
Make sure that pillar is vertical.
Test at several places around the circumference to make sure that the pillar is not
leaning in any direction.
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6.3
Installing wall supports secured with two bolts
CAUTION
If the wall supports are not sufficiently aligned, the jib arm could move from
side to side by itself. This may cause hazardous situations, for example
collisions or injuries.
NOTE: You must temporarily fit the wall supports to the supporting structure to ensure that they will be aligned
correctly. The supports are removed from the supporting structure and attached to the jib arm before the whole
assembly is lifted and the supports are reattached to the supporting structure.
Proper alignment cannot be achieved if you try to attach the complete jib arm assembly to the supporting
structure without first fitting the wall supports to the supporting structure and checking the alignment.
1
Place the upper wall support on the wall at the desired height and position. Make sure
that it is aligned horizontally by using a spirit level.
2
Mark the positions of the holes on the wall. Remove the support and then drill 27mm
diameter holes in the wall.
3
Fasten the upper support with bolts but do not fully tighten the bolts.
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4
Place the lower support on the wall below the upper support at distance H. The H
dimension is supplied to the end customer and depends on the load and span of the
crane.
Make sure that the lower support is aligned horizontally and is vertically aligned with the
upper support by using a spirit level.
5
After the lower support is aligned correctly, mark the hole positions on the wall.
Remove the support and then drill 27mm diameter holes in the wall.
6
Fasten the lower support with bolts but do not fully tighten the bolts.
7
Make sure that the alignments are still correct. Measure the cross dimensions between
the plates and check that they are equal to a tolerance of ±1mm.
Remove the fastenings and supports from the wall. The supports will be attached to the
jib arm before the whole assembly is fastened to the wall.
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6.4
Installing wall supports secured with four bolts
CAUTION
If the wall supports are not sufficiently aligned, the jib arm could move from
side to side by itself. This may cause hazardous situations, for example
collisions or injuries.
NOTE: You must temporarily fit the wall supports to the wall to ensure that they will be aligned correctly. The
supports are removed from the supporting structure and attached to the jib arm before the whole assembly is
lifted and the supports are reattached to the supporting structure.
Proper alignment cannot be achieved if you try to attach the complete jib arm assembly to the supporting
structure without first fitting the wall supports to the supporting structure and checking the alignment.
1
Place the upper wall support on the wall at the desired height and position. Make sure
that it is aligned horizontally by using spirit level.
2
Mark the positions of the holes on the wall. Remove the support and then drill the holes
on the wall.
3
Fasten the upper support with bolts but do not fully tighten the bolts.
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4
Place the lower support on the wall below the upper support at distance H. The H
dimension is supplied to the end customer and depends on the load and span of the
crane.
Make sure that the lower support is aligned horizontally and is vertically aligned with the
upper support by using a spirit level.
5
After the lower support is aligned correctly, mark the hole positions on the wall.
Remove the lower support and drill the holes in the wall.
6
Fasten the lower support with bolts but do not fully tighten the bolts.
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7
Make sure that the alignments are still correct. Measure the cross dimensions between
the plates and check that they are equal to a tolerance of ±1mm.
Remove the fastenings and supports from the wall. The supports will be attached to the
jib arm before the whole assembly is fastened to the wall.
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6.5
Installing the jib arm to the pillar
1
Check that the pillar is ready for the jib arm to be installed. Ensure that any new
concrete around the pillar foundation has been left to dry for a sufficient time.
2
Bring the jib arm close to the assembly site possible.
3
Insert the two radial spherical plain bearings (2) into the bearing housing (1).
Ensure that the edge of the inner part of each bearing is level with the end of the pipe.
4
Check that there are three screws (1) in the trimmer of the lower pillar support plate.
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5
Prepare to lift the jib arm up to the pillar.
Only use fiber slings to lift the jib arm; NEVER use chain slings!
Only lift the jib arm at the intended lifting points around the jib arm’s centre of gravity.
Be aware that the jib arm could turn or fall if it is not lifted correctly.
6
Lift the jib arm slowly into position so that the jib arm’s bearing housing is between the
upper and lower support plates.
Keep the jib arm lifted upwards so that it is kept in contact with the underside of the
upper support bracket.
7
Place the slide bearing between the trimmer on the lower support plate and the jib
arm’s bearing housing.
8
Making sure that all components are aligned, carefully push the shaft, tapered end first,
upwards through the lower support plate, slide bearing, jib arm’s bearing housing and
upper support plate.
The tapered end of the shaft will guide the articulated bearings into the correct position.
When the shaft is fully inserted, the locking groove in the shaft should be completely
visible above the upper support plate.
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9
Install the locking ring onto the top of the shaft.
After installing the locking ring, push the shaft downwards so that the locking ring is
resting on the upper support plate.
10
Install the locking plate to the upper support plate and the top of the shaft. The locking
plate prevents the shaft from turning.
Fasten the locking plate (1) to the shaft with two screws (2). Then mount the locking
plate to the upper support plate with screw (3), washer (4) and sleeve (5). Tighten the
bolts to a torque appropriate to their size.
11
Decrease the support from the lifting crane slightly, up to a point where the jib arm stays
in place and does not start to turn while the rest of the assembly and alignment work is
in progress.
12
Adjust the jib arm shaft vertical alignment by turning the adjusting screws (1) in the
trimmer on the lower support plate.
Check that the jib arm is aligned correctly (that is, that the jib arm is level) when it is
pointing in any direction.
When the alignment is correct, tighten all three screws and check the alignment again.
A correctly aligned jib arm will not have the tendency to turn by itself.
13
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Completely detach the auxiliary crane from the jib arm.
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6.6
Optionally, and if applicable, you can fit the LoadMate (LM)-rails to the jib arm before
attaching the jib arm to the pillar. See section “Installing the power supply” for more
details.
1
2
3
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5
6
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9
10
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13
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details.
6.7
1
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3
4
5
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7
8
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11
in progress.
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6.8
Installing the jib arm to wall supports
1
Check that the wall is ready for installation. Holes must have been pre-drilled in the wall
ready for installing the jib wall supports.
2
Bring the jib arm close possible to the assembly site and, if possible, lay the jib arm on
sturdy supports so that it is vertical.
3
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4
Push the shaft, tapered end first, through the bearings from underneath the jib arm.
5
Slide the upper support bracket onto the top of the shaft. The mounting holes in the
support bracket should be towards the top.
6
7
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8
Install the slide bearing into place onto the lower end of the jib arm
9
10
Slide the lower support bracket onto the shaft, the correct way up so that the three
holding screws are above the bracket.
11
Visually centre the shaft in the lower support bracket by adjusting the three holding
screws. Do not fully tighten the screws yet.
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12
Use an M10 bolt and washer to securely attach the auxiliary assembly tool (bush) to the
threaded hole at the lower end of the shaft.
The tool prevents components from sliding down the shaft and helps to keep the
support brackets parallel while the assembly is being fastened to the wall.
13
Prepare to lift the jib arm a single assembly up to the wall.
Only lift the jib arm at the intended lifting points.
14
Lift the jib arm slowly into position, supporting it with a crane, so that the jib arm’s wall
supports are aligned with the holes which have been pre-drilled into the wall.
15
Fasten the wall support brackets to the wall.
Tighten the fastenings to the recommended torque. For tightening torques, refer to
section “Technical Data”.
The fastenings will usually be M24 (10.9 hardness).
16
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Undo the bolt and remove the auxiliary assembly tool.
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17
Drill 10mm holes through the existing holes in the support brackets.
Push the supplied plugs into the holes.
18
in progress.
19
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21
details.
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6.9
Installing the jib arm to wall supports
1
2
3
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5
6
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9
10
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12
13
14
15
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17
18
in progress.
19
20
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details.
6.10 Installing the jib arm to wall supports
1
2
3
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5
6
7
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13
14
15
16
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18
in progress.
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6.11 Installing power supply (UKA)
CAUTION
To avoid the risk of electric shocks, all electrical connections SHALL be made
without electricity supplied to the crane.
1
Slide the cable trolleys into the jib. The cable trolleys are already fastened at the
correct intervals along the cable.
2
Drill holes for end stop bolts. (see main assembly drawing)
3
Assemble the junction box over the jib profile.
Place the fixing on the jib profile and fasten the fixing plate and junction box.
Connect the flat cable to the junction box.
4
Connect the round cable to the junction box.
5
Install the other end of the round cable through the lead-in rubber grommet into the
pillar. Pass it through until the end appears by the main isolator switch hole.
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6
Connect the round cable and power supply cable to the main isolator switch.
Mount the main switch to the pillar.
NOTE: It is recommended to fit the main isolator switch directly under the wall supports at an
approximate height of 1200 mm.
Make sure that the main isolator switch is accessible at all times.
6.12 Installing power supply (UKA)
CAUTION
1
Slide the cable trolleys into the jib. The cable trolleys are already fastened at the
correct intervals along the cable.
2
Drill holes for end stop bolts. (see main assembly drawing)
3
Assemble the junction box over the jib profile.
Place the fixing on the jib profile and fasten the fixing plate and junction box.
Connect the flat cable to the junction box.
4
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5
Install the other end of the round cable to the junction box. It is recommended that a
switch should be mounted about 120 cm from the floor.
6
Mount the main switch to the wall.
NOTE: It is recommended to fit the main isolator switch directly under the wall supports at an
approximate height of 1200 mm.
6.13 Installing power supply (I-profile, LoadMate (LM)-rails, pillar/wall)
CAUTION
1
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Make sure that all the correct dimensions are known and that the correct number
of support arms is supplied.
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2
Measure the support arm distances and mark the correct positions along the jib
where the support arms will be fitted.
3
Fasten each support arm (1) by fitting two jib clips (2) one on both sides of the jib.
Make sure that the support arm overhangs the girder by the correct distance.
Tighten the clips when the support arm is in the correct position and is square (at
90 degrees) to the girder.
Note: the length of the support arms must be sufficient to ensure that the festoons
will not collide with the moving trolley. An unnecessarily large overhang is not
desirable.
4
Insert one support bracket into each support arm.
Do not tighten the support brackets at this stage.
5
Slide LoadMate (LM)-tracks into the support brackets
LoadMate (LM)-tracks must be installed with the open side facing downwards.
Cut the LoadMate (LM)-track to the correct length if it is too long. LoadMate (LM)tracks can be joined together using track joints. The track joint fastenings must be
carefully tightened and adjusted to ensure smooth running of the festoons through
the joints.
6
Once the LoadMate (LM)-tracks are correctly positioned and straight, tighten the
fastenings on the support brackets.
7
Fit and tighten the end stop to the LoadMate (LM)-track end which is furthest from
the bearing housing.
8
Slide the festoon cable trolleys into the LoadMate (LM)-track from the end which
is closest to the bearing housing.
Start sliding with the end which will be connected to the hoist. It can be identified
by a cable trolley; the other end has a cable clamp but no trolley.
Feed on all of the cable trolleys, taking care not to twist or damage the festoon
cables.
The cable trolleys are already fastened at the correct intervals along the cable.
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9
The last element of the festoon cables is the cable end clamp (a saddle clamp
which has no cable trolley). Slide it into the LoadMate (LM)-rail and tighten it, in a
suitable position close to the end of the LoadMate (LM)-track.
10
Check that the end clamp position will not prevent the festoon cable from
stretching or compressing when the trolley is at each end of the jib. If necessary,
reposition the cable end clamp.
11
Check that the cable trolleys run smoothly through the LoadMate (LM)-tracks,
paying special attention to the track couplers where applicable. Adjust the track
couplers if necessary.
12
Fasten the junction box to the support arm closest to the cable end clamp.
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13
14
15
Install the other end of the round cable through the lead-in rubber grommet into
the pillar. Pass it through until the end appears by the main isolator switch hole.
16
Mount the main switch to the pillar.
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NOTE: It is recommended to fit the main isolator switch directly under the wall supports at an approximate
height of 1200 mm.
6.14 Installing power supply (I-profile, LoadMate (LM)-rails, pillar/wall)
CAUTION
1
Make sure that all the correct dimensions are known and that the correct number
of support arms is supplied.
2
Measure the support arm distances and mark the correct positions along the jib
where the support arms will be fitted.
3
Fasten each support arm (1) by fitting two jib clips (2) one on both sides of the jib.
Make sure that the support arm overhangs the girder by the correct distance.
Tighten the clips when the support arm is in the correct position and is square (at
90 degrees) to the girder.
Note: the length of the support arms must be sufficient to ensure that the festoons
will not collide with the moving trolley. An unnecessarily large overhang is not
desirable.
4
Insert one support bracket into each support arm.
Do not tighten the support brackets at this stage.
5
Slide LoadMate (LM)-tracks into the support brackets
LoadMate (LM)-tracks must be installed with the open side facing downwards.
Cut the LoadMate (LM)-track to the correct length if it is too long. LoadMate (LM)tracks can be joined together using track joints. The track joint fastenings must be
carefully tightened and adjusted to ensure smooth running of the festoons through
the joints.
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6
Once the LoadMate (LM)-tracks are correctly positioned and straight, tighten the
fastenings on the support brackets.
7
Fit and tighten the end stop to the LoadMate (LM)-track end which is furthest from
the bearing housing.
8
Slide the festoon cable trolleys into the LoadMate (LM)-track from the end which
is closest to the bearing housing.
Start sliding with the end which will be connected to the hoist. It can be identified
by a cable trolley; the other end has a cable clamp but no trolley.
Feed on all of the cable trolleys, taking care not to twist or damage the festoon
cables.
The cable trolleys are already fastened at the correct intervals along the cable.
9
The last element of the festoon cables is the cable end clamp (a saddle clamp
which has no cable trolley). Slide it into the LoadMate (LM)-rail and tighten it, in a
suitable position close to the end of the LoadMate (LM)-track.
10
Check that the end clamp position will not prevent the festoon cable from
stretching or compressing when the trolley is at each end of the jib. If necessary,
reposition the cable end clamp.
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11
Check that the cable trolleys run smoothly through the LoadMate (LM)-tracks,
paying special attention to the track couplers where applicable. Adjust the track
couplers if necessary.
12
Fasten the junction box to the support arm closest to the cable end clamp.
13
14
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15
Install the other end of the round cable to the junction box. It is recommended that
a switch should be mounted about 120 cm from the floor.
16
Mount the main switch to the wall.
NOTE: It is recommended to fit the main isolator switch directly under the wall supports at an approximate
height of 1200 mm.
6.15 Assembling the hoist and other crane components (UKA)
1
Fasten the limiting screw and nut through the hole on the jib arm profile. The screw
SHALL not be fastened so tight that it decreases the width of the jib arm rail opening.
2
Insert the trolley which will support the hoist assembly into the jib arm profile.
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3
Fasten the end plate to the jib arm by screwing the bolts into the threaded holes.
4
Attach the hoist assembly to the trolley which is already inserted into the jib profile.
Refer to the chain hoist owner’s manual for more details.
5
Connect the flat cable to the hoist
6.16 Assembling the hoist and other components (I-profile)
1
Assemble the hoist onto the I-profile.
Refer to the chain hoist owner’s manual for more details.
2
Connect the power supply cable to the hoist
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7
COMMISSIONING
Before taking the crane into use, at least carry out the inspections and adjustments listed in below. In some
cases it is appropriate to carry out a more thorough inspection. The scope of the inspection depends on the
operating range and application.
1
Check that the connections of electrical devices comply with the wiring diagrams and
meet local requirements. In particular, check connections that affect safety and control
of the crane. Check the cable ways for electrical wiring. Make sure that wires do not
snag on structures when operating the crane.
2
Check that the jib arm moves smoothly and is correctly aligned so that it does not turn
by itself. Carefully adjust the screws (1) in the trimmer if necessary.
3
Check that all parts are properly installed. Check that all nuts and bolts have been
tightened up to the right torques.
4
Check that there are no signs of damage.
5
Check that the pushbutton controller and pendant cable are in good condition. Connect
the pendant cable to the crane. Check that the pushbutton controller is at the correct
height.
Press the direction buttons on the pushbutton controller and check that the resultant
motions occur in the correct direction. Be careful because movements could occur in
the wrong direction during the test.
Check the operation of the emergency stop button.
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6
Check the hoist functionality. Refer to the hoist owner’s manual for more details.
7
Check the operation of the limit switches by running the hoist to all of the triggering
locations. This test must be conducted without a load on the hook.
8
Perform a static overload (load 125%) test.
8
Perform a static overload (load 150%) test.
9
After performing the static overload test, tighten the three adjusting screws in the
trimmer on the lower support plate and make a final check of the alignment.
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10
Listen to the sounds made when travelling, hoisting and rotating and assess whether
the sound indicates an installation error.
Check the vibration by feeling the hoist with your hand.
If abnormal noise or vibration is discovered, do not use the crane before you have
identified and eliminated the cause.
WARNING
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In case there is any doubt about the crane’s safe functionality, or that the crane
may not have been assembled correctly, contact the authorized service
personnel or manufacturer. A wrongly assembled or wrongly functioning crane
may cause hazardous situation, even potential injuries or death.
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8
AFTER COMMISSIONING
1
Check that all tools and materials used during crane assembly are removed from the
crane.
2
Ensure that the hoist operator and supervision personnel are aware of the need for user
training.
3
Check that the proper documentation is delivered with the crane.
4
Make sure that the crane testing and inspection reports are filled in and are safely
stored with the other crane documentation.
5
After the crane has passed all of the required tests and inspections, apply the CE
sticker to the crane. Refer to “Information Signs Used On The Crane” section.
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8.1
Disposal of waste material
Waste material from installation, maintenance or dismantling shall be handled according to local regulations. From
the sustainability viewpoint the preferred waste handling methods are reuse, recycling material, recycling energy
and disposal, in this order.
1
If the product is taken out of use, the metal and electrical parts should be reused or recycled by a
licensed recycling company.
2
In addition to local regulations, liquids like oil, grease and other chemicals shall never be spilled
onto the ground, soil or sewage. Used oil and grease shall be stored in containers indicated for the
purpose and disposed of by a licensed company.
More detailed information of chemical handling waste can be found in the chemical’s Safety Data
Sheet that is available from the manufacturer of the chemical.
3
Accumulators and batteries may contain hazardous substances. Accumulators and batteries should
be collected separately and recycled according to local regulations.
4
Packing materials, like plastics, wood and cardboard, should be reused or recycled.
5
Plastic parts should be either recycled material or energy (incineration). PVC plastic should be
recycled according to local regulations.
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9
TIGHTENING TORQUES
NOTE: Tighten the chemical bolts to the bolt manufacturer’s specified torque.
The recommended tightening torques for crane fastenings.
Tightening torque
Size
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Strength 8.8
Strength 10.9
Nm
Ft lb
Nm
Ft lb
M4
2.7
2
4
2.9
M5
5.4
4
7.9
5.8
M6
9.3
6.8
14
10.3
M8
23
17
33
24
M10
45
33
66
48.5
M12
77
56.6
115
84.6
M14
125
92
180
132
M16
190
140
280
206
M18
275
202
390
287
M20
385
283
550
404
M22
530
390
750
552
M24
660
485
950
699
M27
980
721
1400
1030
M30
1350
993
1900
1398
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At site inspection for Jib cranes
Customer:
Delivery address:
Manufacturer’s number:
Customer order/ref. Nr.
Remarks:
Strike out items which are not applicable to delivery.
In case of any deficiencies in the delivery, return copy of this form with comments to crane factory.
Arrival check
No
Yes
Notes
OK
Notes
Notes from dispatching
factory at other side
1. Transport damages
2. Missing items
3. Documents
4. Clean up of crane
Erection
1. Fixing of hoist during lift
2. Mounting bolt joints (torque)
Bolts size and torque
3. Pin holes and pins (wall jib)
4. Stopping bolt and end plate/end stoppers
5. Jib height and outreach measures
Height to jib bottom:
Hook outreach:
6. Axle to vertical direction
7. Earthing cable assembly
8. Power supply assembly/connecting
9. Crane connected to network
10. Signs and stickers
Functional tests
OK
Notes
1. Hoisting limit switches
2. Trolley traversing limit switches
3. Trigger plates for jib rotation limit switches
4. Jib rotation limit switches
5. Correct direction of movements
6. Operation of lifting devices
7. Rotation buffer end stops + approach dim.
8. Hoist buffer end stops + approach dim. (Inner/Outer)
9. Track clearance of trolley wheels
10. Clearances of jib operation
11. Radio controller locker + signs
Operator instructions!
12. Operation of crane power supply
13. Additional equipment:
Commissioning
OK
Notes
1. Customer inspection report
2. Training of crane operators
3. Load testing (forward direction, 100 % load)
Jib end deflection
Crane has been erected and tested listed above. Inspection report has been delivered to customer.
Date and place:
76/76
Signature:

jib crane assembly manual

Transcription

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