(WITH_ COVER) OWNER SOGALIST REPUBLIC OF VIETNAM DATE NOTE MINISTRY OF INDUSTRY MAR2000 | REVO ELECTRICITY OF VIETNAM APR 2000 | REV.1 HAM THUAN-DA MI HYDROPOWER PROJECT LOT H3-H : HYDROMECHANICAL EQUIPMENT HT. 165 FOR_HAM_ THUAN SCHEME o 4 OPERATION & MAINTENANCE INSTRUCTION FOR INTAKE GANTRY CRANE = Hitachi Zosen HITACHI ZOSEN CORPORATION — OSAKA JAPAN — STEEL STRUCTURE DESIGN DEPARTMENT pate MAR.2000 PREPAREDBY “ \ SHEETNo. GC-M-01 A CUECKEDEY / ‘ DRAWINGNo. APPROVEDBY ‘MPG.No. ‘TOTAL,AHYUNDAI HEAVY INDUSTRIES CO_L7D. DOCUMENT NO : HTDM-MM-GC-Ot ISSUED DEPT : INDUSTRIAL MACHINERY DEPT (210) OPERATION & MAINTENANCE INSTRUCTION FOR INTAKE GANTRY CRANE PROJECT NAME = HAM THUAN-DA MI H.P.P W/O NO = W98051 ADDRESS : 1 CHEONHA-DONG, ULSAN, KOREA TEL + 82-52-200-3926, 3990 FAX + 82-52-200-3274 1 2000. 1.7] A | HZ'S COMMENTS |JO.HONG| JBLEE | Y.W.LEE 0 | ‘9011.12] NWA | FIRST ISSUED |JOHONG} JBLEE | Y.W.LEE REV. | REV. PREPARED | REVIEWED | APPROVED No. | DATE Note DESCRIPTION BY BY BY ‘A: CUSTOMER'S COMMENTS Bt HHI'S DESIGN CHANGES + HHI'S CONVENIENCE D: CHANGES TO QUALITY SYS. E: CHANGES TO STANDARD/CODE —-F : RESULTS OF MEETING G : OTHERSAHYUNDAI HEAVY INDUSTRIES EDL. DOC.NO. : HTDM-OM-Gc-01 (OPERATON & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA MI HPP. REVISION NO. : 1 CONTENTS SECTION PAGE 1. GENERAL -- 2. SPECIFICATION OF YOUR NEW CRANE --- 3. DETAIL DESCRIPTION FOR EACH EQUIPMENT 3.1 GANTRY -. 3.2 GANTRY FRAMES AND SILL BEAM 3.3 TRAVERSING TROLLEY ---- 3.4 OPERATION CABIN 3.5 TRAVELING, TRAVERSING AND HOISTING EQUIPMENT 3.6 ELECTRICAL CABINET 3.7 GRAB 3.8 RAKE 4, CONTROLS AND WIRING 4.1 CONTROL SYSTEM ~~. 4.2 WIRING --- 4.3 POWER PANEL & OPERATOR'S BOX - 4.4 ALARM EQUIPMENT 5. OPERATION INSTRUCTION 5.1 CAUTION ABOUT CRANE OPERATION 5.1.1 GENERAL CAUTION ABOUT CRANE OPERATION §.1.2 CAUTION BEFORE OPERATION -- 5.1.3 ACTIONS UNDER OPERATION 5.1.4 ACTIONS AFTER OPERATION -: 5.1.5 CAUTIONS FOR ELECTRIC SHOCK ++ ©oxaarnoaanAHYUNDAI HEAVY INDUSTRIES CO,170- Doc. No. ‘OPERATION & MANTENANDE INSTFUGTION FOR HAM THUAN-DA MI HPP, REVISION NO. + HTDM-OM-GC-01 5.1.6 ROPE WIRING AND SLING WIRE 5.2 USER'S RESPONSIBILITIES - 5.2.1 GENERAL -- 5.2.2 TRAINING OF PERSONAL «. 5.23 CRANE TECHNICAL CONSIDERATION 5.2.4 WARRANTY - 5.3 SAFE OPERATING PRACTICES - 5.3.1 GOOD PRACTICE 5.32 COMPANION PERSONS --. 5.3.3 OPERATOR'S RESPONSIBILITY 5.4 DESCRIPTION OF THE CRANE AND ITS USE -- 5,5 EMERGENCY STOP ---. 5.6 STEP BY STEP OPERATING INSTRUCTIONS 5.6.1 PRE-START BEFORE CRANE OPERATION $.6.2 LIGHTING CONTROL 5.6.3 CRANE CONTROL - MAIN HOIST 5.6.4 CRANE CONTROL - RAKE HOIST & OPEN/CLOSE 5.6.5 CRANE CONTROL ~ GRAB HOIST & OPEN/CLOSE 5.6.6 CRANE CONTROL - GANTRY & TROLLEY TRAVEL -. 5.6.7 AUXILIARIES 5.7 TROUBLE SHOOTING * FIGURE 1. CRANE’S GENERAL ARRANGEMENT + FIGURE 2. CRANE SPECIFICATION -- » FIGURE 3. METER BOX ARRANGEMENT + FIGURE 4. OPERATOR'S BOX S88 BRkBB BB 8 + FIGURE 5, POWER PANEL ARRANGEMENT - 55 » FIGURE 6, CONTROL PANEL ARRANGEMENT - 56 6. MAINTENANCE INSTRUCTION 87 6.1 INSPECTION SCHEDULE 59 6.1.1 HOISTING ASSEMBLY 62AHYUNDAI HEAVY INDUSTRIES CO_UTD. DOC. NO. = HTDM-OM-GC-01 OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA Mi HPP. REVISION NO. 1 6.1.2 TRAVERSING ASSEMBLY, 65 6.1.3 TRAVELLING ASSEMBLY 67 6.1.4 HOOK BLOCK ASSEMBLY - 69 62 ACCEPTABLE LIMIT FOR DAMAGE AND ABRASION .-... 70 6.2.1 ACCEPTABLE LIMIT FOR DAMAGE AND ABRASION 70 6.22 TRAVELLING RAILS SET-UP AND TREATMENT --- 72 63 INSPECTION/REPAIR FOR STEEL STRUCTURE AND PAINT --- 74 6.3.1 INSPECTION/REPAIR FOR STEEL STRUCTURE ~~ 74 6.3.2 INSPECTION/REPAIR FOR PAINT -. 74 64 CAUTIONS FOR SEPARATION AND ABLATION 7 6.4.1 GENERAL -. 7 6.4.2 ANTI-FRICTION BEARING 79 6.4.3 GEAR -- 81 6.4.4 WHEELS - 4 6.4.5 BREAK LINING -- 86 6.4.6 KEY AND KEY HOLE 87 6.4.7 WIRE ROPE 89 6.4.8 ROPE PULLEY SHEAVE -- 7 6.5 LUBRICATION MANUAL 99 6.5.1 OIL & GREASE LIST FOR MAIN HOISTING 101 6.5.2 OIL & GREASE LIST FOR RAKE HOISTING 102 6.5.3 OIL & GREASE LIST FOR GRAB HOISTING 103 6.5.4 OIL & GREASE LIST FOR TRAVELLING UNITS 104 6.6 WEAR LIMIT & BOLT TIGHTENING TORQUE 105 6.6.1 WEAR LIMIT 105 6.6.2 BOLT TIGHTENING TABLE - 106 67 MAINTENANCE TOOLS LIST & SPARE PARTS LIST 67.1 MAINTENANCE TOOLS LIST ---- 107 6.7.2 SPARE PARTS LIST --- 108AHYUNDAI HEAVY INDUSTRIES CO. 170. DOC. NO. HTDM-OM-GC-01 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA Mi HPP. REVISION NO. = ' 68 PAINTING PROCEDURE 69 DRAWING (MECHANICAL) 6.10 DETAILS INSTRUCTION OF MAIN ITEMS FOR MECHANICAL, 6.10.1 MOTOR 6.10.2 CYCRO REDUCER 6.10.3 HORIZONTAL REDUCER 6.10.4 CHANGE GEAR 6.10.5 SLACK ROPE DETECTOR 6.10.6 GRAB 6.10.7 BRAKE 6.10.8 CABLE REEL 6.10.9 COUPLING 6.10.10 CABIN 6.10.11 TRANSMITTER 6.10.12 DIFFERENTIAL LIMIT SWITCH 6.10.13 VENTILATION FAN 6.10.14 CHAIN & SPROCKET 6.11 DETAILS INSTRUCTION OF MAIN ITEMS FOR ELECTRICAL 6.11.1. PROGRAMMABLE LOGIC CONTROLLER 6.11.2 INVERTER 6.11.3 MOLDED CASE CIRCUIT BREAKER 6.11.4 MAGNETIC CONTACTOR & AUXILIARY RELAY 6.11.5 PANEL & SWITCHBOARD METER 6.11.6 ELECTRIC OVER CURRENT RELAY 6.11.7 CABLES 6.11.8 LIGHTING 6.11.9 INDICATOR 6.11.10 JOYSTICK 7. APPENDIX INPUT & OUT PUT MODULE SPECIFICATIONA NEAVY INDUSTRIES CO.U70. DOC. NO. : HTDM-OM-Gc-91 ‘OPERATION & MAINTENANCE INSTAUCTION FOR HAM THUAN-OA Mi HEP, REVISION NO. = 1 1. GENERAL The crane has very important role in industry as crane working of materials and products, Recently, from increasing of cargo work, Crane's specification are getting frequent and the reason of that the crane have to get more efficient working abilities with importance of repair and check. The condition of the crane’s using method and operation contro! are good or not, has great effects for productivity and process. so, any kind of careless shall make @ great disturbance Safe operation, perfect repair for crane’s best condition need a great deal of effect, but once crane has some problems, it shall effect not only the working but the worker's life. From that, every time the users have to have maximum interest about checking, lubricating, repairing and adjusting for productivity and efficiency, A’so, the users may consider to have prevention methods for no unexpected disorder and no accidents. From now, the outline for general specification about operation, check, repair and for this crane's each parts shall begin, so the users had better read carefully and lake the great care of crane’s best condition. This manual covers the daily operation (clause 5) and maintenance (clause 6) instructions for the intake gantry craneAHYUNDAI NEAVY INDUSTRIES 62,70. DOG. NO, : HTDM-OM-GC-01 (OPERATION & MANTENANCE INSTRUCTION FOR HAM THUAN-DA MI HPP. REVISION No. 1 2. SPECIFICATION OF YOUR NEW CRANE ~ Type : Multi-purpose gantry crane with double hook, rake & grab ~ Span = 18 m ~ Stroke : 16.41 m (Traveling), 9 m (Traversing) ~ Main Hoist a, Gate weight with lifting beam : 77 tons b. Lifting load including various resistance : 91.5 tons c. Lowering load at down pulling : 120 tons d. Speed : 1.0 m/min e, Lift + 55m - Rake a, Material to be handled : Debris and trash b. Capacity : 2 tons (2m3) c. Speed : 3 m/min Grab a. Material to be handled : Drifting wood or others b. Capacity : 1 ton (1m3) Trolley travel (traversing) a. Type = Two motor drive synchronized electrically b. Speed : 20 m/min Gantry travel a. Type : Two motor drive synchronized electrically b. Speed : 13 m/min ~ Electric power source =: AC 400V, 50HZ, 3 phases4a HYUNDAI DOC. NO. + HTDM-OM-GC-01 OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA MI HP. REVISION NO. + 1 3. DETAIL DESCRIPTION FOR EACH EQUIPMENT 3.1 GANTRY 3.2 GANTRY FRAMES AND SILL BEAM 3.3 TRAVERSING TROLLEY 3.4 OPERATION CABIN 3.5 TRAVELING, TRAVERSING AND HOISTING EQUIPMENT 3.6 ELECTRICAL CABINET 3.7 GRAB 3.8 RAKEABYUNDAL DOC. NO. : HTDM-OM-GC-01 ‘OPERATION 8. MAINTENANCE NSTRUCTION FOR HAM THUAN-OA Mi HPP, REVISION NO, = 1 3. DETAIL DESCRIPTIONS FOR EACH EQUIPMENT 3.1 GANTRY The gantry crane, grab and raking equipment consist of gantry frames, hoisting, traversing and traveling equipment, grab, rake, guide frames, traversing trolley, electrical cabinet, operation cabin, rail safety clamps, controls, limit switches, wire fopes and all other necessary components for its safe, proper and efficient operation. 3.2 GANTRY FRAMES AND SILL BEAM The gantry frames are robust in construction and of all welded and built-up piate girder construction using rolled structural steel plates and shapes. It is capable of withstanding the rated loads and lateral forces, The gantry frames are mounted on the sill beams. Gantry traveling equipment is provided on the sill beam, which consist of driven motors with built-in magnetic brake, geared reducer, bearings, shafts, etc. Rall sweepers is provided for wheels, rail stoppers and the limit switch is provided for over travelling of gantry and trolley respectively, and rubber blocks are provided at the sill beam ends for shock absorbing. Reinforcement for sufficient stiffening the gantry frames is provided where necessary. The sill beam frame is equipped with manual locking rail clamps to fasten the rails and prevent movement of the crane when the gantry is not in travelling. Each access, walkways, handrails, ladders with safety hoops, platforms and other necessary accessories are provided to facilitate operation, inspection and4A HEAVY INGUSTRIESEO, UU, DOC. NO. : HTDM-OM-GC-o1 OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA MI HPP. REMISION NO, = 1 maintenance of the gantry crane. 3.3 TRAVERSING TROLLEY The traversing trolley is provided on the top of gantry frames to mount the mechanical equipment. The trolley cover consist of an internal steel framework clad with protected, profiled, insulated panels, Roof is provided to enable removal of the various items of machinery, if required, for maintenance, etc. 3.4 OPERATION CABIN One operation cabin is furnished to the gantry frame, which is located at the convenient position for hoisting and traversing operation, and the cabin is accessible with a staircase fixed to the sil beam and gantry frame. The operation cabin is of ample size and weatherproof construction and is provided whit glazed windows to give the maximum range of view, the windows are made to open and electric fan to ensure adequate ventilation. All windows are provided with locking arrangements with due water-proof. The main door of the operation cabin is provided with a keyed lock. Electric floodlights are provided in suitable positions on the gantry to illuminate the working area and lighting is provided for inside operation cabin to enable all operation at night. 3.5 TRAVELING, TRAVERSING AND HOISTING EQUIPMENT Traveling, traversing and hoisting equipment of the gantry crane conform to the specified herein, provided that such parts shall be of outdoor use type. The electric motors driving the travel wheels and traverse wheels are electrically interconnected such that crabbing of the gantry does not occur. Built-in electro-mechanical brakes are incorporated in the devices to prevent movernent of the gantry directly whenAHYUNDAI HEAVY INDUSTRIES COLO. DOC. NO. : HTDM-OM-GC-01 (OPERATON 8 MAINTENANCE INSTRUCTION FOR HAM THUAN-OA MI HPP. REVISION NO. ¢ 1 the drive motors stops or the electricity supply fails. Hoisting device for the intake, trashrack, stoplog, gate, grab and rake is simple in design and efficient in operation, and of wire rope lift type suitably mounted on the traversing trolly. The hoisting device is furnished with electromagnetic brake in addition to the motor brake for self-lock and for accurate positioning of the grab and rake at the restricted position of their travel. Opening and closing devices for the grab and take are made by electric power. All sheaves are designed to maintain the wire fopes within the rope groove when the rope goes slack. The main hoist, traverse and travel motion are normally electrically driven, but arrangements are made for manual operation should there be a power failure at any time, 3.6 ELECTRICAL PANEL electrical panels are provided to supply electric power and control the intake gantry crane. The electrical panels consist of a weather proof cubicle containing the necessary equipment and are suitable for the climatic conditions occurring, The cabinet contain a switchfuse of suitable size for the supplied equipment. The festoon cable is connected to the cabinet internally. The connection for the festoon is three core plus earth. A keyed door is provided at the front of the cabinet to give access to the equioment. 3.7 GRAB The grab device is capable of grasping the drifting woods or others. The grab is designed at the specified grabbing capacity and rated operating speed. =AHYUNDAI HEAVY INDUSTRIES €0,L70. DOG. NO. : HTDM-OM-GC-o1 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA MI HPP. REVISION NO, = 1 and the withstand the maximum hoisting force resulting from the breakdown of locked motor torque of hoist motor, which may be caused material wedged. The prongs of the grab is robust and fixed to the hub by mean of corrosion resisting steel pins, self-lubricating bearing and washers. 3.8 RAKE The rake is capable of scraping off the debris and trash in full width and vertical length of trashrack, and stabilizing vertically at the fully scraped condition during lifting operation so as not to drop the scraped trash and debris. The rake is designed to ride smoothly on the bar elements of trashrack, which is located not to interfere with the complete cleaning of the trashrack, in addition to the side rollers to run inside guide frames. ‘The take is designed at the specified raking capacity and rated operating speed, and to withstand the maximum hoisting force resulting from the breakdown or locked rotor toraue of hoist motor, which may be caused by material wedged in the trashracks or others. The prongs of the rake is smooth and streamlined, and be engaged with the bar elements in adequate depth up to the tie bolts to scrape choked trash and debris in the trashracks. The prongs are fixed to the rake body by means of corrosion resisting steel bolts and nuts. All rotating parts have corrosion resisting pin, self lubricating bearing and washers. aeAHYUNDAI DOC, NO, HTDM-oM-ac-o1 HEAVY INDUSTRIES CO_LTD. ‘OPERATION & MAINTENANCE NSTAUCTION FOR HAM THUAN-DA Mi HPP, REVISION NO. ¢ 1 4. CONTROLS AND WIRING 4.1 CONTROL SYSTEM 4.2 WIRING 43 CONTROL CABINET & OPERATOR'S PANEL 4.4 ALARM EQUIPMENT 3AHYUN! HEAVY INDUSTRIES €O.L7D, DOC. NO. + HTDM-OM-GC-01 ‘OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA Mi HPP, REVISION NO. = 1 4, CONTROLS AND WIRING 4.1 CONTROL SYSTEM The gantry crane is operated from the operation cabin provided on the gantry crane. The hoisting equipment is capable of raising, lowering or stopping the intake trashrack, stoplog, gate, grab and rake, and the traversing and traveling equipment is capable of handling the above equipment for use. Such all motions except for main hoist hoisting (constant speed) are controlled by multistep speed contrallers. ‘The following limit switches is provided on the gantry crane for proper operation, - Upper overtravel limit switch to stop the hoisting equipment before the grab, rake or lifting beam strikers the hoisting equipment. — Lower overtravel limit switch to stop the hoisting equipment to keep the rope wound on the hoist drums. ~ Limit switches to prevent the gantry crane overtravel ~ Limit switches to prevent the trolley overtravel ~ Slack rope & overload limit switches to stop the main hoisting equipment if a wire rope goes slack. The equipments are provided with electro-mechanical interlocking system to prevent simultaneous operation of the travelling, traversing and hoisting equioment. A flickering light is provided to give warning to the personal during any operation. An audible alarm is provided to war personal of imminent travel. 4.2 WIRING All power and control cables and/or wires with all necessary conduits, fixtures and 43>AHYUNI HEAVY INDUSTRIES CO-L- DOC. NO. : HTDM-OM-Go-01 ‘OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA MI HPP REVISION NO, = 1 accessories from the electrical terminal to the respective electrical equipment, which are necessary for the proper operation of the gantry crane, are supplied. 4.3 POWER PANEL & OPERATOR'S BOX Power/control panels and operator's box for operation of the gantry crane are provided. The operator's box is located in the cabin. The power/control panels are located on the trolly. The power/control panel are of weatherproof construction. The following instruments are mounted on or within the operator's box. - Source volt meter ~ Source pilot light ~ Load ampere meter - "Fully up” indicating light for each equipment ~ "Fully down” indicating light for each equipment ~ "Stopped at intermediate position” indicating light for each equipment ~ "Trolley traversing’ indicating light for each equipment ~ "Crane traveling” indicating tight for each equipment ~ "Crane stopped” indicating light for each equipment - "Trouble condition’ indicating light for each equipment Mullistep speed controllers for hoisting, traversing and traveling equipment “lamp test" push dutton for inspection of all indicating lights. Main hoist, Grab & rake position indicator Control switches for Food light, Ventilator fan, By-pass timer, Siren The following insttuments are mounted on or within the power/control panels = Incoming supply moulded case circuit breaker aAHYUNDAI HEAVY INDUSTRIES CO, LTD. DOC. NO. : KTDM-OM-Gc-0t ‘OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA Ml HPP. REVISION NO, 1 ~ Arrest for power ~ Starter for each motor ~ 230V convenience outlet, from own transformer 400/230V supply ‘Space heater to prevent moisture condensation with thermostatic switch Moulded case circuit breaker to protect each motor circuit and other circuits All other necessary transformer, relays, contactors, switches, and miscellaneous wiring components. 4.4 ALARM EQUIPMENT One set of alarm equipment consisting of warning lamp and reset push button, etc is provided on the operator's box, so that due warning for the trouble could be given for the operator. The alarm lamp will be lighted when the following each relays are actuated. = Overload relays - Motor protection relays ~ Slack rope limit switch ==AHYUNDAL 06. No. + HTDN-oM-a0-01 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA Ml HPP. REVISION NO, = 1 5. OPERATION INSTRUCTION 5.1 CAUTION ABOUT CRANE OPERATION 5.1.1 GENERAL CAUTION ABOUT CRANE OPERATION 5.1.2 CAUTION BEFORE OPERATION 5.1.3 ACTIONS UNDER OPERATION 5.1.4 ACTIONS AFTER OPERATION 5.1.4 CAUTIONS FOR ELECTRIC SHOCK 5.1.6 ROPE WIRING AND SLING WIRE 5.2 USER'S RESPONSIBILITIES 5.2.1 GENERAL 5.2.2 TRAINING OF PERSONAL 5.2.3 CRANE TECHNICAL CONSIDERATION 5.2.4 WARRANTY 5.3 SAFE OPERATING PRACTICES 5.3.1 GOOD PRACTICE 5.3.2 COMPANION PERSONS 5.3.3 OPERATOR'S RESPONSIBILITY 5.4 DESCRIPTION OF THE CRANE AND ITS USE 5.5 EMERGENCY STOP 5.6 STEP BY STEP OPERATING INSTRUCTIONS 5.6.1 PRE-START BEFORE CRANE OPERATION §.6.2 LIGHTING CONTROL 5.6.3 CRANE CONTROL ~ MAIN HOIST 5.6.4 CRANE CONTROL - RAKE HOIST & OPEN/CLOSE 5.6.5 CRANE CONTROL - GRAB HOIST & OPEN/CLOSE =AHYUNDAI HEAVY INDUSTRIES CD,U7D. DOG. NO. : HTDM-OM-Gc-01 (OPERATION 8 MAINTENANCE INSTRUCTION FOR HAM THUAN-DA MI H.P.?, REVISION NO. 1 5.6.6 CRANE CONTROL - GANTRY & TROLLEY TRAVEL 5.6.7 AUXILIARIES 5.7 TROUBLE SHOOTING * FIGURE 1. CRANE’'S GENERAL ARRANGEMENT * FIGURE 2. CRANE SPECIFICATION * FIGURE 3. METER BOX ARRANGEMENT * FIGURE 4, OPERATOR'S BOX * FIGURE 5. POWER PANEL ARRANGEMENT * FIGURE 6. CONTROL PANEL ARRANGEMENT qlA\HYUNDAI poecec: MEAVY INDUSTRIES COCO. (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA MI HPP, REVISION NO. = + HTDM-OM-GC-01 1 5.1 CAUTION ABOUT CRANE OPERATION 5.1.1 GENERAL CAUTION ABOUT CRANE OPERATION Crane operation have to be operated by well skilled operator. A. Prohibition under overload (1) Load on hoist When the crane has final operation inspection, generally use 100 percent load of the rated load for load inspection. For the reason, Crane is designed to work the most economically under the rated load. Whenever, you use the crane under overload, it shall make the crane's life short, rapidly. So, overload operation should never be happen for the long term using. (2) Lift If you hoist more than the weight indicated in specification, it shall break the allowance, From the effect, the load shall crash the girder, and break the crane’s body or drop the load cause by the breaking rope. So, shall always work within the standardized lift (3) Don't hoist diagonally Diagonal hoisting, like the loads areaway from the hook’s down right =AHYUNDAI HEAVY INDUSTRIES EO,U7D. DOC. NO. : HTDM-OM-GC-01 OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA Ml HPP. REVISION No, : 4 ‘spot or pulling transfer car shall give the crane overstress or shall make the crane’s body twist. Because do these reasons, hoisting diagonally shall be a danger, such as making the crane's life short, or making a big accident. So, please and must not use diagonally. B. Don't remove safety devices (1) Limit s/w Sometimes shall eliminate the hoist limit switch for making wide working area with increasing the lift limit. This shall make absolute reason for serious accident. So, eliminating limit switch has to be prohibited, districtly. For smooth operation, limit switch shall be checked and adjusted everytime. If the switch is unfixed or adjusting is not good, one would better call a ‘specialist to repair or to change. It is very dangerous that act careless cause you are not familiar with the crane. (2) Brake The brake have to be always perfectly adjusted, because it has very Important role to stop the under operate crane, Over breaking force not only shall make smooth stop but also shall make sever abrasion at the brake pulley or brake lining. On the contrary, insufficient braking force shall not make the crane stop timely and keep going to move. Meanwhile, sometimes shall release the ==ABYUNDAL 0c. NO. + HrOMON-co-o1 O>EFATOW& MENTING NSTRICON FOR HM THA M HEP, ——REVSONNO St brake because the user think that the crane shall be stopped by friction without braking or the control of brake is complex. All of these shall be @ dangerous reason for making big accidents. So, brake releasing has to be strictly prohibited. 5.12 CAUTIONS BEFORE OPERATION A. Caution before operation (1) Operator shall consider keeping clothes, shoes neatly and clearly. Proper clothes makes the worker operate the crane safely. (2) The operators have to discuss fully about detail work substances and sequential operation with the field director or other related person before starting the work. (3) In rope wiring, the operator also have to have enough discussion with the related person. (4) When taking turns, the workers have to take and give the job, through proper ways. (5) Before the operation, shall check the items listed below for whether the operate normally or not. B. Checking pointsABYUNRAL 00. NO. + HTOM-OM-c0-04 CAEATON 8 HARTEWCE RSTUCTEN FOR TACO MIKPR. ——FEVSN'NOL 2 t Before the operation, the items listed below have to be checked (1) Whether there are some dangerous barriers possible to crash within crane’s working area or crane’s runway. (2) Whether the fixed devices, as like crane stopper, rail clamp are released, (3) Whether lubricating spots have enough lubricant. (4) Whether all the levers, switches in a switch box are set-up at the right place. (5) Whether the wire ropes are end-plates are released and torn-off. C. Check by no load operation. After the ready to operation, have to check following items by no load ‘operation. If there are some defaults, you have to repair or adjust before operation. (1) Brake ® Travelling brake ® Hoisting brake(Main & Aux) © Traversing brake (2) Limit switch aA\HYUNI HYUNDAI DOC, NO, HTDM-OM-GC-01 ‘OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA Mi HEP. REVISION NO. : 1 ® Main, Aux limit switch (for upper/lower limitation) (3) Checking, whether each machinery parts has strange sound, vibrations and over-heating. Especially pay attention to noise with over-heating and following subject shall need special check. (A) Motor (8) Bearing (C) Wheels (0) Gear (4) If crane is vibrating or other disorders are come out, shail check the reason, throughly, (6) When you operate the crane, after quite a long time, you shall check each parts and make sure whether there are working normally or not. (6) It shall be good to operate under no-load at least once a week, while it is storing for a long time.AHYUNDAI HEAVY INDUSTRIES CO_CID. DOC. NO. : HTDM-OM-Gc-ot OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA Mi HPP. REVISION NO. : 1 5.1.3 CAUTION UNDER OPERATION. ‘A. Caution under operation (1) When the operator lifts the load, the over load limiter installed in the crane shall sense how much the load is. If the load is over the rated load, the alarm in stalled in the crane shall make sirens. (2) Operation shall follow the indicated signal-man's order and always be careful with the load and working circumstance, (3) Don't leave the cabin with the hoist is under loading. The load shall be dropped and make a serious accidents. (4) Don't stop hoisting for a long time while some subjects are lifting. (5) Don't run as hoisting the subject close with ground. (6) Don't operate the load to swing to get the crane shock, as like making controller handle full speed, suddenly or don’t make sudden stop while it is moving at full speed. Everytime, try to make smooth operations. (7) Abrasion parts, such as lining have to be saved from abrasion. (8) It is very dangerous that people rid on the load, so it has to be prohibited at everytime and everywhere.A NEAVYINGUSTRIES ED. DOC. NO, = HTDM-OM-GC-01 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA Mi HPP, REVISION NO. : 1 (9) Never do hanging any subjects just above ground worker's head, (10) Pulling the load horizontal or lifting diagonally shall make the crane over or abnormal stress. For the reason it shall make an accident or shall make the crane’s life dreadfully short. So please don’t work like that. (11) While in hoisting, running, it is very dangerous that depend on only the limit switch for hoisting or running. You'd better make to fix the machines by controller handle. (12) Pay attention to whether the cranes each part has strange sounds, vibrations, heat and suspicious smelis while it Is working. If there are something happened, stop the operation immediately and check the reason and make never do the operation again until it is fixed. (13) If the power is cut during operation, you shall put the controller handle at off notch and tum off the main switch. After that you've better wait till the power comes again. (14) Have to pay special attention to a crash or else, in case that a crane is working nearby. (15) When a trolley is traversing the place for traversing has to be made nobody are there. ortAHYUNDAI HEAVY INDUSTRIESCO.LTD, DOC. NO. : HTDM-OM-Gc-01 OPERATION & NANTENANCE INSTRUCTION FOR HAM THUAN-DA MI HPP. REVISION NO. 1 (16) Never move the trolley hoist while it is repairing. (17) The operation makes sure whether somebody wants to get in a trolley house before operating the trolley hoist. If there is nobody then you shall operate It. (18) If an accident were happened, stop the crane by emergency switch, B. Check points under operation. The repair chief shall check fellowing items for safely, while in operation. (1) Whether motors and motor's devices, bering, shive have strange sounds, vibrations, heat. (2) Whether each part's bolts, nuts, end-plates ate release or tom off. (3) Whether the brakes are well adjusted and operate normally. (4) Whether the brake shall work smoothly and magnets shall make some strange sounds. (8) Whether the oll in the gear casing is enough and leak, and other lubricating spots have enough lubricant.AHYUNDAI HEAVY INGUSTAIESCO.U7O DOC. NO, : HTDM-OM-Gc-01 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA MI HPP. REVISION No. = 1 (6) Whether gear casing drums(wheels) have cracks or wheels have abnormal abrasions. (7) Whether the wire ropes make abnormal abrasions or be damaged. (8) Whether the limit switch’s operation is well matched with the crane’s action. All other parts need checks have to be checked and if some abnormalities were found the operators and related people have to be known to protect accidents, perviously. 5.1.4 ACTIONS, AFTER OPERATION. A. Actions after work done Actions, after work done and orders shall be like as following subjects. (1) Hooks shall be wound up maximally, trolley shall be moved to anchor position and locked by typhoon anchors. (2) Crane shall be moved to anchor position(crane stopper) and locked by typhoon anchors. (3) All the control handles shall be off position. (4) Press the push button at control stand to cut the main circuit by = 264a HYUNDAI 0.170. DOC. NO. + HTDM-OM-GC-01 ‘OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA MI HAP, REVISION NO. = ‘ breaking main panel board's ‘M’ contact. (5) Make OFF all of N,F,B(no fuse brake) in main switch box and control panel. (6) Do lubricate, all of the places need lubricating. Keep in mind, lubricating is an essential action for crane’s normal operation. Especially, sliding bearing(needs grease lubricating) shall be lubricated at least once a day. After-operation-ubricating shall be better than before-operating—lubricating, (7) Make clean all places. If you clean the places covered by oil, dusts or impurities, one shall easily find cracks, abrasions, released bolt/nuts. Accidents shall be reduced or prevented by making all places clean. (8) The work-diary shall be written about the working conditions, order for the next shift and additionally, unexpected accidents and the place accidents occurred before, also be written in the diary. (9) Check closely, whether controller and contacts are normal. 5.1.5 CAUTIONS FOR ELECTRIC SHOCK(HEREAFTER E/S) Damage from E/S shall be a serious accident, even though the e/s is insignificant, because most people are frightened then slip down from high a=AHYUNDAI DOC. NO. : HTDM-OM-GC-o1 HEAVY INDUSTRIESCO,LTO. (OPERATION & MANTENANCE INSTRUCTION FOR HAM THUAN-DA Ml HPP, REVISION NO, : 1 place, From the reason, the owners and users are better to make some E/S protection programs, with habitual care for any kinds of voltage. A) E/S protections (1) Operator shall wear some dry clothes and gloves to make minimum of exposure to the electric, Rubber shoes, and rubber gloves shall be oH good for E/S. (2) Get perfect insulation through at odd moments inspections whether electricity leakage is happened cause by wearing off wires, Even though, the leakage is very litte, so people who works on the crane can't get any shock, the ground workers for rope wiring shall get the E/S through contacting the hook. (3) Some parts shall have possibilities of E/S, such as electric machinery power equipment, or else shall be better to get some danger marks or enough lifting. (4) Power cut off at end of operation, under repait/inspection have to cut the power off. Especially, during repairing/inspection, unrelated person have to make not switch on, while somebody is repairing. Better to hang a name board “Danger! Repairing Now: at the power ‘switch.Aa HEAVY INDUSTRIES 60-70, DOC. NO. + HTDM-OM-GC-05 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-OA MI HEP, REVISION NO. = 1 (5) When it needs to repair under power is going, have to wear rubber gloves, rubber shoes and work on insulation boards with standing position: If there are bear wire with power around the repairing places, you'd better work under the places are completely covered by insulation tape or pipe. B. Actions, when the E/S accident happened. (1) Turn off the power switch immediately, if there is no switch nearby. Take off the contact subjects(power wire) from the victims’ body using by insulator, such as dry cloth, wood sticks, and plastics. At this time, the rescuer have to cared to protect the victims from dropping from high place. They shall slip or released what they grab. (2) Be careful, never try to take off the victims from power wire by bear hands because you shall be also gotten E/S. When you need to check, whether the power is going, touch the wire with back of the hand instead paim, Because, in case you get a shock, you wouldnot grab it. (3) Better to learn C, P, R (cardiopulmonary resuscitation), in case the victims are unconscious, it shall be a great help to rescue the victims. 5.1.6 ROPE WIRING AND SLING WIREAHYUNDAI HEAVY INDUSTRIES CD,LTO. DOC. NO. : HTDM-OM-GC-01 (OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUAN-DA Ml HPP, REVISION NO. : 1 Most of the accidents caused by crane are came from neglect of rope wiring and sling's own defaults. So, taking following subjects shall be very helpful to prevent accidents (1) rope wiring has to make by qualified people. (2) Weight of load shall be measured by rough estimate so, discipline for Tough estimate is very important. (3) Sling wires have to be completely checked that the thickness, lifting angle, damage are adjustable for hoisting and lifting. (4) Crane shall move :to the place where the hook is very above the center ‘of weight. Sling wire have to be tied up firmly for no leaning or slipping out the load. Never do lifting the load diagonally. (5) Don't hoisting with one rope Because it is hard to get horizontal balance and stability, From this reason, it shall be a danger crashing with other structures around there. (6) the load’'s edge shall be covered by used wood or support medals to prevent the wire rope breaking. (7) Long length subject or big volume subjects shall use some supports to get balance.AHYUNDAI HEAVY INDUSTRIES CO,L7D. DOC. NO, : HTDM-OM-GC-01 OPERATION & MAINTENANCE INSTRUCTION FOR HAM THUANSDA MI HPP. REVISION NO, = 1 (8) Signals for works have to be made by only one qualified signal man. Crane operator and rope wiring workers shall easily see the signal man from everywhere and anybody, Especially in case the crane is huge, signal man had better wear different safety hat and clothes from ordinary workers’ to help the operator's easy recognition for the signal man, because operators are way from the signal man. (9) Signal men have to make the operator sure where the load shall be going and it have to be strictly prohibit from riding the load. (10) When you lift the load from ground, first you shall slowly lift until the rope is being tight. After the sling wire is being tight, stop hoisting momently to check whether the rope’s bindings are perfect, then operate the hoist. At this time, the most caution point is the hook has to be just above the load’s weight center. Because, at the moments, the load is just lift from the ground, load shall move to other directions and then hit‘ workers or crash against structure nearby. So the balance is very important. (11) When lifting down the load, make slow down from just above the ground to on the ground. “a=