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Item code: 10598372

- Installation Manual Edition: 00

INSTALLATION MANUAL

Crane: BOS 4200-100 LITRONIC

00 12.07.12 Issued Stz/Ha according LIKV workflow


Edition Date Description Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
- Installation Manual Edition: 00

CONTENT:

SECTION 1 : Unpacking – Lifting – Handling – Storage 1

1.1 MARKING AND IDENTIFICATION SYSTEM 2


1.2 UNPACKING 2
1.3 LIFTING – HANDLING 3
1.4 STORAGE 4

SECTION 2 : Inspection of “As Delivered Conditions” 1

2.1 INSPECTION 1
2.2 DOCUMENTS 1

SECTION 3 : Crane Installation Instructions 1

3.1 PEDESTAL 2
3.1.1 Erection of the pedestal 2
3.1.2 Dimensional control and tolerances before welding 4
3.1.3 Installation of slip-ring collector 5
3.1.4 Installation of circumferential platform 6
3.1.5 Installation of pedestal on foundation 6
3.1.6 Welding 8

3.2 SLEWING COLUMN 9


3.2.1 Installation of luffing winch 9
3.2.2 Installation of cabin 11
3.2.3 Installation of platforms and walkways 12
3.2.4 Installation of machinery house 12

3.3 A-FRAME 14
3.3.1 Installation of mounting crane frame 14
3.3.2 Mounting of compression bar 15
3.3.3 Installation of mounting crane 17
3.3.4 Installation of tilting-back support 17
3.3.5 Installation of platforms and walkways 18
3.3.6 Mounting of A-Frame on slewing column 19

3.4 BOOM 22
No copying or duplication of this document without the permission of Liebherr.
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Item code: 10598372
- Installation Manual Edition: 00

3.5 COMPLETION OF CRANE INSTALLATION 23


3.5.1 Installation of crane on pedestal 23
3.5.2 Mounting of boom 25
3.5.3 Electrical and electronic equipment 29
3.5.4 Preparation for Start-Up 30
A) Electrical System 30
B) Preparation of prime mover 31
C) Hydraulic drive 32
D) Lubrication 32
3.5.5 Start-Up Procedure 32
3.5.6 Reeving of ropes 33

3.6 HANDING OVER REPORT 34

SECTION 4 : Referenced Drawings 1

SECTION 5 : Referenced Working Instructions and Documents 1

SECTION 6 : Packing List 1

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
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LEGEND

General Mandatory Sign

Reference to a drawing or document


The referenced drawings are attached in Section 4 of this manual.
The referenced working instructions and documents are attached in the Sections 5 – 6
of this manual.

Up, Hoisting

Slowly

Lowering the boom slowly

Down, Lowering

Attention, Danger!

Attention!

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
- Installation Manual Edition: 00

GENERAL

Scope of work of LIEBHERR Service Engineer is defined in the contract.

In case of any trouble during crane assembly preparation or assembly itself, please
do not hesitate to contact LIEBHERR-Nenzing, AUSTRIA / EUROPE.

LIEBHERR Werk Nenzing GmbH


Dr. Hans Liebherr Str. 1
A-6710 NENZING/AUSTRIA
Tel. No.: + 43 5525 606-0 TELEFAX: + 43 5525 606-200
TELEX: 052141
DEPARTMENT: Sales Administration and Project Management

IMPORTANT:

For start-up please apply for engineer at least three weeks in advance.

GENERAL DISCLAIMER

HOWEVER, LIEBHERR SHALL NOT BE RESPONSIBLE AND / OR LIABLE FOR ANY AND
ALL DAMAGES, LOSSES (INCLUDING LIQUIDATED DAMAGES / LOSSES AS WELL AS
CONSEQUENTIAL DAMAGES / LOSSES), CLAIMS, LIABILITIES, DEMANDS, COSTS,
FEES AND EXPENSES WHATSOEVER ARISING OUT OF PERSONAL INJURY,
INCLUDING FATAL INJURY AND DISEASE, TO ANY PERSON AS WELL AS LOSS OF,
LOSS OF USE OR DAMAGE TO ANYONE´S PROPERTY TO THE EXTENT THAT THE
SAME IS CAUSED DUE TO AN IMPROPER PERFORMANCE OF THE ABOVE
MENTIONED PROCEDURE / WORK.

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
- Installation Manual Edition: 00

INSTALLATION MANUAL

SECTION 1 :

Unpacking – Lifting –
Handling – Storage

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
- Installation Manual Edition: 00

1. UNPACKING – LIFTING – HANDLING - STORAGE

The delivered items and components shall be handled according to their


a) size
b) weight
c) volume
d) nature (i.e. electrical, hydraulic, electronic, mechanical steel, plastic etc.)

For transport, safety and protection reasons, attachment parts (walkways, mounting cranes,
all type of electrical and electronic equipment) are removed and dismantled from the
primary crane parts and are delivered in separate packages.

Preparation, unpacking, lifting and handling operations shall be done by skilled


and experienced operator and according to “good operator’s practice”.

No copying or duplication of this document without the permission of Liebherr.


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1.1 MARKING AND IDENTIFICATION SYSTEM

In the shipping document, the following information is given for item identification:
All shipping items are grouped in sections and marked in the “Packing List”, with
their position given in the drawing “Delivered Items”.

Steel made items such as walkways, platforms, railings etc. are grouped and palletised for
easy handling.

All electrical, electronic and other sensitive equipment are packed in suitable boxes
according to working instruction “Preservation for Storage and Shipping”, included in
Section 5 of this manual.

If not otherwise specified and agreed in a contract specification, every package is clearly
marked for easy identification. In each package, one fully complete packing list is included
in a waterproofed envelope.

The packing list includes the following item data:


 Item location number
 Package number for corresponding item
 Part description
 LWN-Identification Number (9-Digit-Number Id.No. xxxxxxxxx)
 Weight
 Item dimensions (L x W x H)
 Volume (if required)

1.2 UNPACKING

Attention shall be paid to package markings, package weight, warning marks and other
standard international signs on the packages. Unpacking is to be done in the storage area
which suits the package size and item nature or in open air according to the environment
atmospherically and weather conditions.

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
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1.3 LIFTING – HANDLING

The safe and careful handling, especially during lifting up of the delivered packages, must
be observed.

The crane main component lifting points, (pad eyes) weight of the main items and
SWL of main equipment (required for safe lifting and handling) is shown in the
drawing “Delivered Items”.

Lifting must proceed with equipment (hooks, slings, shackles, turnbuckles etc.) of
corresponding safe working load and using pad eyes as shown in the above
mentioned drawing.

The operator is fully responsible for complete lifting preparation and co-ordination
during lifting operation and handling as well as for supervising and during
operation.

Palletised packages, as well as boxes, shall be treated in the same manner.

Important:

The transport conditions, as well as responsibility and insurance, before, during


and after shipping of the goods, are defined in the contract.
LIEBHERR waive any responsibility for any damage, accident or injury caused:

 due to the harsh environment conditions


 unskilled handling, preparation, lifting and handling, or
 due the lack of information in documentation supplied regarding any specific
condition not covered by these instructions, or not known to LIEBHERR at the
time of compilation and preparation of these instructions.

For any further information, required before or during preparation, do not hesitate
to contact LIEBHERR.

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
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1.4 STORAGE

Storage of the main components of crane and package crates delivered, are to be treated
in different ways:

Crane Main Components: Pedestal Adapter / Slewing Column / Boom /


Crates with steelwork (e.g. platforms)
Crane main components are to be stored in places or areas, which are prepared
as storage areas. Such areas may be sheltered or open air areas but must be
remote from any aggressive source and its environment such as:

 Sandblasting equipment
 Welding or flame-cutting equipment
 Burners, open flame equipment
 Exhaust gases
 Adverse chemicals

The storage area must have an AC current source to enable operation or heating
system. The heating system complies from:

 Stand-still heater of the slip-ring collector


 Space heaters in the Slewing Column
 Stand-still heater of electric motor
Make sure that the heating system is connected to the power source and remain switched
on all the time during crane storage.
Corrosion preservation for shipping will be applied to provide a temporary corrosion
protection for an outdoor storage period of maximum 12 month.

Attention:
If the storage period will exceed 3 month (including time for shipment) there must
be taken specific action regarding the crane system (start of power unit, winches,
motors etc) required. For details contact Liebherr Service Department.
If this measurement will not be taken, this can result in major damages of
components or systems. The complete operation has to be recorded properly.

Check the physical protection (plastic covers, timber covers) and corrosion protection on
weather exposed items and repair or renew it if necessary.

Crates – Packages

All other equipment packed in crates or card-boxes are to be stored in dry, enclosed, fully
sheltered stores/warehouses. Inside the crates/boxes the items are treated by VCI
compounds providing the corrosion protection for a shipping and storage period up to
maximum 12 month.

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
- Installation Manual Edition: 00

INSTALLATION MANUAL

SECTION 2 :

Inspection of
“As Delivered Conditions”

No copying or duplication of this document without the permission of Liebherr.


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Item code: 10598372
- Installation Manual Edition: 00

2. INSPECTION OF DELIVERED ITEMS (“AS DELIVERED CONDITIONS”)

2.1 INSPECTION

The inspection of the delivered items has to be performed by customer, his


operator, operator involved or by a third party involved.

The inspection shall include:

 a comparison of the delivered packages under consideration of the shipping document


 the condition of the delivered items regarding damages, missing parts etc.

Notice:
If any parts are missing or damaged, please contact LIEBHERR – Werk Nenzing under
consideration of the following reference data:
 customer name
 crane type
 series number
 package and LIEBHERR item number
 a short description of the damage occurred if possible documented by help of photos

2.2 DOCUMENTS

Inspection shall be provided using the following documents:

 Shipping documents including packing list


 Installation instructions as given in Section 3 of this manual
 Delivered Items

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
- Installation Manual Edition: 00

INSTALLATION MANUAL

SECTION 3 :

Crane Installation
Instructions

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Item code: 10598372
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3. CRANE INSTALLATION INSTRUCTIONS

Important:

 Personnel have to wear appropriate PPE (Personnel protection equipment).


 Local procedures, rules and regulations have to be observed.
 Always refer to the crane instruction manual.
 This procedure is only a guideline and should not be considered as complete.
 Only competent personnel should be allowed to carry out the above mentioned scope of
work.
 LIEBHERR recommends to use a LIEBHERR service engineer to execute overload tests.
 During mounting, wind is taken into account with 10 m/s. If wind is stronger, all free-
standing parts have to be temporarily fixed against tilting.
 The sketches in this manual serve only to show particular crane components and will not
always represent “Your crane one hundred percent”. Look at the drawings in Section 4 if
you need detailed information.
 All deviations from the given installation instructions and sequences (i.e. Single Lift of
crane as a whole) must be clarified with LIEBHERR Service Department.

Bolt fastening by torque wrench pre-tensioning:

For all bolted flange connections the following steps must be done prior the installation and
the bolt fastening:

1. Clean both contact surfaces of the flange connection. The connections must be free of
moisture, grease, oil, painting or any dirt.
2. Install the bolt into the hole, install the washer plates and thread the nuts.
3. Bolts must be properly fastened/pre-tensioned by using torque wrench with torque-wrench
tightening moment.

For data and values regarding required pre-tensioning torque refer always to the
mentioned drawings only. Any other value found in other documents or sketches
may not be valid. In case of doubt revert to LIEBHERR.

If not otherwise mentioned in the contract, torque wrench may be, on client request,
supplied by LIEBHERR for extra cost.
If torque wrench is supplied by a client, it must be of an approved and calibrated
type, equipped with an indication scale.

After pre-tension is completed, a corrosion protection of all bolts exposed to the


environmental conditions must be provided.

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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3.1 PEDESTAL

3.1.1 Erection of the pedestal

Image 01:

For the weight of pedestal refer to the

Drawing No.:
2278 995 69 01 000 00X

Image 02:

Image 03:

To put the pedestal into upright position lift the


pedestal by using ...

a) two Cranes with hoist lines


or
b) one Crane with two hoists

of adequate capacity!

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Image 04:

Image 05:

Image 06:

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Image 07:

Image 08:

3.1.2 Dimensional control and tolerances before welding

Image 09:

1. Visual control of welding bevel preparation (no


damages allowed)
2. Control roundness of pedestal at interface
level
3. Control flange flatness according to Working
instruction “Flatness Control”

Drawing No.:
2278 060 17 00 000 00X
2278 061 17 00 000 00X

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3.1.3 Installation of slip-ring collector

Image 10:

Installation of slip ring collector


according to Drawing No.
2278 541 05 00 000 00X

Image 11:

Image 12:

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3.1.4 Installation of circumferential platform

Image 13:

Installation of circumferential platform


according to Drawing No.
2276 006 34 00 000 00X

3.1.5 Installation of pedestal on foundation

Image 14:

Image 15:

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Image 16:

Image 17:

In order to be able to put the boom


onto the boom rest during installation
of the boom, be sure that the pedestal
is put on in the right orientation

Orientation according to Drawing No.


2278 061 17 00 000 00X

Image 18:

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3.1.6 Welding

Image 19:

The welding preparation is shown in


Drawing No.
2278 060 17 00 000 00X

The welding must be performed according to


Working instruction
“weld assembly 10225362”.

Dimensional control and tolerances after welding

Image 20:

Control flange flatness according to Working


instruction “Flatness Control”

Control inclination of the pedestal’s


centre line (maximum allowed
tolerance ± 0,5°)

No copying or duplication of this document without the permission of Liebherr.


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3.2 SLEWING COLUMN

For the required hooking arrangements as well as required site crane capacities refer to the
following technical documents:

Delivered Items 2278 995 69 01 000 00X


Packing List

3.2.1 Installation of luffing winch

Image 21:

Installation of luffing winch


according to Drawing No.
2276 304 05 01 000 00X

Image 22:

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This document has been issued electronically and is valid without signature.
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Image 23:

Image 24:

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3.2.2 Installation of cabin

Image 25:

Installation of cabin according to


Drawing No.
2267 491 12 01 000 00X

Image 26:

Image 27:

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3.2.3 Installation of platforms and walkways

Image 28:

Installation of platforms and


walkways according to Drawing No.
2278 516 04 00 000 00X

3.2.4 Installation of machinery house

Image 29:

For the weight of the machinery


house see Drawing No.
2278 995 69 01 000 00X

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Image 30:

Installation of machinery house


according to Drawing No.
2276 440 01 02 000 00X
2277 440 01 01 000 00X
2277 440 01 02 000 00X

Image 31:

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3.3 A-FRAME

3.3.1 Installation of mounting crane frame

Image 32:

Image 33:

Installation of mounting crane


frame according to Drawing No.
2278 516 03 00 000 00X

Image 34:

Insert the bolts

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Image 35:

Fix the frame with slings against falling


down.

Image 36:

3.3.2 Mounting of compression bar

Image 37:

Installation of compression bar


according to Drawing No.
2278 125 01 00 000 00X

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Image 38:

Image 39:

Remove the fixing slings of the


mounting crane frame.

Image 40:

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3.3.3 Installation of mounting crane

Image 41:

Installation of mounting crane


according to Drawing No.:
2278 543 01 00 000 00X

3.3.4 Installation of tilting-back support

Image 42:

Installation of tilting-back support


according to Drawing No.:
2278 126 01 00 000 00X

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Image 43:

Image 44:

3.3.5 Installation of platforms and walkways

Image 45:

Installation of platforms and


walkways according to
Drawing No.
2278 516 03 00 000 00X
2278 125 02 00 000 00X

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3.3.6 Mounting of A-Frame on slewing column

Image 46:

For the weight of the complete A-Frame


see Drawing No.:
2278 995 69 01 000 00X

Be sure that you hoist the A-


Frame with the correct lifting
lugs like shown in the image
(upper lugs).

Lift the A-Frame with a cross


bar to avoid transversal force
onto the lifting lugs.

No copying or duplication of this document without the permission of Liebherr.


This document has been issued electronically and is valid without signature.
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Image 47:

Image 48:

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Image 49:

Mounting of A-Frame
according to Drawing No.:
2278 125 01 00 000 00X

Image 50:

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Image 51:

3.4 BOOM

The boom as a whole is completely assembled (inclusive walkway, platforms, winches etc),
before it is connected to the slewing platform.

To assembly the boom sections refer to the drawings:

Gangway Pivot Piece – left 2277 544 05 17 000 00X 10516104


Mounting Material – Pivot Piece - left 2278 544 33 01 000 00X 10576067
Gangway Intermediate Section – 12m 2277 544 05 15 000 00X 10517042
Mounting Material – Interm. Section 12m 2278 544 33 04 000 00X 10594251
Gangway Head Section 2278 544 02 03 000 00X 10516549
Mounting Material – Head Section 2278 544 33 05 000 00X 10594252
Gangway Head Section 2267 544 10 02 000 00X 992935914
Mounting Material – Head Section 2278 544 25 02 000 00X 10595930
Gangway Pivot Piece – right 2277 544 05 18 000 00X 10516105
Mounting Material – Pivot Piece - right 2278 544 33 07 000 00X 10594261
Bolting Pivot 2276 514 01 00 000 00X 990274414
Mounting Material – Pivot Piece 2277 215 01 00 000 00X 990284214
Mounting Material – Boom Sections 2272 235 01 00 000 00X 919933614

For the completion of the boom assembly also refer to the drawings:

General Arrangement 2278 001 69 01 000 00X


Delivered Items 2278 995 69 01 000 00X
Packing List

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3.5 COMPLETION OF CRANE INSTALLATION

3.5.1 Installation of crane on pedestal

Image 52:

For the weight of the complete slewing


column with A-Frame see Drawing No.
2278 001 69 01 000 00X

Be sure that you hoist the crane with


the correct lifting lugs like shown in the
image (lower lugs).

Lift the crane with a cross bar to avoid


transversal force onto the lifting lugs.

Image 53:

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Image 54:

Installation of crane on pedestal


according to Drawing No.
2278 551 02 00 000 00X

For bolt fastening also refer to working


instruction “Pre-Tensioning of Bolts via
Hyrd. Tensioning Tool”.

Image 55:

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3.5.2 Mounting of boom

Image 56:

For weight of boom see


Drawing No.
2278 995 69 01 000 00X

Image 57:

Provide boom slings or


Ropes for hoisting. Assure
that the Ropes don’t
damage the paint work.

Image 58:

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Image 59:

Image 60:

Image 61:

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Image 62:

For pin connection of boom


refer to Drawing No.:
2276 514 01 00 000 00X

Installation remark:
Pins, bushings and bores
must be cleaned,
dried and shall not be
greased or oiled before
installation !

Image 63:

Image 64:

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Image 65:

Image 66:

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3.5.3 Electrical and electronic equipment

Due to transport reasons a number of items of electrical and electronic equipment


such as lighting, warning lights, alarm devices, junction boxes, limit switches etc.
were disconnected and are delivered as separate packages.

To locate, install and connect electrical equipment in appropriate position, refer to


the drawings:

Outline Power Supply 2278 600 69 00 031 00X 10597929


Search Light Installation – Cabin Platform 2276 528 04 00 000 00X 992032814
Search Light Installation – A-Frame 2278 530 02 00 000 00X 919648014
Search Light Installation – A-Frame 2276 531 10 00 000 00X 10533543
Search Light Installation – Boom Head 2276 529 08 00 000 00X 992937214
Search Light Installation – Boom 2276 531 07 00 000 00X 993820314
Helicopter Lamp Instal. – Aux. Hoist Boom 2276 537 01 01 000 00X 990695314
Helicopter Lamp Instal. – Boom 2276 537 02 01 200 00X 990844514
Helicopter Lamp Instal. – A-Frame 2276 537 01 02 000 00X 990695414
Helicopter Lamp Instal. – A-Frame add. 2276 537 02 02 200 00X 990844714
Wind Transmitter Installation 2265 526 01 00 000 00X 919332214
Camera Equipment – Boom Head 2289 552 03 02 000 00X 994546214
Camera Equipment – Luffing Winch not in this crane not in this crane
Wind Sock Installation not in this crane not in this crane
Fire Extinguisher System not in this crane not in this crane

All adjustments of the limit switches and potentiometers shall be carried out or
checked by a LIEBHERR Engineer.

No copying or duplication of this document without the permission of Liebherr.


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3.5.4 Preparation for Start-Up

Refer to the drawings:

Drive Unit 2267 410 06 00 000 00X


Central Power Unit Cpl. 1 2267 412 04 00 000 00X
Central Power Unit Cpl. 2 not in this crane

The crane is usually delivered with dry tanks and piping systems and with equipment
temporary protected for transport.

A) Electrical System

 Connect electrical cables from platform/ship main supply to the junction box, located in
the pedestal adapter. Refer to the drawing:

Outline Power Supply 2278 600 69 00 031 00X

 Connect all electrical cables

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B) Preparation of prime mover

Electric motor

In general, electric motors are ready for the start when the main power is connected. Before
you run the power pack or start-up the crane, the following steps are necessary for electrical
system start-up:

 Remove all transport protection from the equipment (the power pack frame is fastened to
the supporting structure by means of bolts as transport safety).

 Before the initial start-up of the electric-motor or in case that the electric-motor was out of
service for a longer period, the insulation resistance of motor is to be checked in order to
prevent short circuit damage of rotor and stator due to residual humidity, moisture, oil or
dirt between rotor and stator  please contact LIEBHERR Service Department.

Diesel power pack

When you fill the storage tanks with fuel, observe the appropriate safety
instructions. Fire or explosion may be dangerous and can kill.
To minimise system faults, make sure the fuel system is clean. Use the necessary
filters to prevent ingress of dirt and moisture into the system.

 remove all transport protections from the equipment.

 clean the fuel storage tank and fuel filters if necessary. Moisture is not allowed in the
fuel tank or in the pipes.

 fill the fuel tank according to “Utility Requirements” included in Section 5 of this
manual.

 fill the engine (oil pan and oil filters) according to “Utility Requirements” and “Table of
Lubricants” included in Section 5 of this manual.

 fill the cooling system with coolant containing the recommended additives for summer
or winter seasons according to “Utility Requirements” and “Table of Lubricants”
included in Section 5 of this manual. Use a strainer to remove dirt.

 check the batteries. Add electrolyte if necessary.

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C) Hydraulic drive

Refer to the drawing:

Hydraulic 2278 970 28 00 001 00X

Before start-up of the hydraulic-system the following steps are necessary:

 remove all transport protections from hydraulic components

 check and clean hydraulic oil tank if necessary. The tank must be dry and free of
moisture.

 fill hydraulic oil tank with hydraulic oil provided. Use a strainer to keep oil free from dirt.
For oil quantities and for oil-types refer to “Utility Requirements” and “Table of Lubricants”
included in Section 5 of this manual.

 remove blind plugs at hydraulic gears, check oil level and replace blind plugs with vent
plugs.

 connect hydraulic hoses which were disconnected for transport.

D) Lubrication

Before the start-up of the crane, it is necessary


 to check the oil level off all equipment provided (winches, hydraulic driving
motors, gears etc.)
 to check if all blind plugs are exchanged to vent plugs
 to check if all mechanical, electrical, hydraulic or other equipment which are
provided with grease nipples are fully greased.

For information about oil types and quantities please refer to “Utility Requirements” and
“Table of Lubricants” included in Section 5 of this manual.

3.5.5 Start-Up Procedure

For start up of the Power Pack please contact LIEBHERR service department.

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3.5.6 Reeving of ropes

In order to avoid torsion / twisting of the rope during handling and spooling,
please refer to the attached “Instruction for handling of crane ropes” (see Section
5 of this manual).
Read the instructions prior to the rope reeving carefully!

Image 67:

The reeving of the wire rope shall be carried out according to Drawing No.
2278 700 35 00 000 00X

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Image 68:

3.6 HANDING OVER REPORT

After completion of the installation the crane shall be checked according to the requirements
specified in the handing over report. The service engineer is responsible for completion of
this document. If not otherwise specified the tests have to be witnessed by the client and
surveyor of the nominated Certifying Authority. The scope of crane test has also to meet the
requirements of the Certifying Authorities rules for lifting appliances.

Finally the handing over report shall be signed by the

 Service Engineer
 Client representative
 Surveyor of the Certifying Authority (if applicable)

In case of findings they have to be reported in a punchlist.

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INSTALLATION MANUAL

SECTION 4 :

Referenced Drawings

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4. REFERENCED (DESIGN and FUNCTIONAL) DRAWINGS

Drawings Number System: (e.g.) xxxx 000 00 00 000 00X

Drawing Master Number


Crane Main Assembly
Sub-Assembly
Drawing Alteration Index

Caption Drawing No. Item Code

General Arrangement 2278 001 69 01 000 00X 10598370


Delivered Items 2278 995 69 01 000 00X 10598371

PEDESTAL ADAPTER
BS Weld. Constr. 2278 061 17 00 000 00X 993598914
BC Top Section Weld. Constr. Cpl. 2278 060 17 00 000 00X 993598814
Slip Ring Carrier Installation 2278 541 05 00 000 00X 10550150
BS Add-On 2278 551 02 00 000 00X 991421314
All-Around Platform RFK 2276 006 34 00 000 00X 10545380

SLEWING COLUMN
Standard Constr. Unit Instal. 2278 516 04 00 000 00X 10524546
Mounting Material - Standard Constr. Unit 2278 517 04 01 000 00X 10524547
Luffing Winch Cpl. 2276 304 05 01 000 00X 10533414
Drivers Cabin Install. Cpl. 2267 491 12 01 000 00X 10521415

MACHINARY HOUSE
Drive Unit 2267 410 06 00 000 00X 10598437
Central Power Unit Cpl. 1 2267 412 04 00 000 00X 10579451
Central Power Unit Cpl. 2 not in this crane not in this crane
Machinery House Add-On 2276 440 01 02 000 00X 990277514
Railing Cpl 2277 440 01 01 000 00X 10519998
Mounting Material – Machinary House 2277 440 01 02 000 00X 10520082

A-FRAME
Pressure Profile Weld. Constr. Cpl. 2278 126 01 00 000 00X 990288014
Mounting Material A-Frame 2278 125 01 00 000 00X 990288514
Standard Constr. Unit Instal. 2278 516 03 00 000 00X 10520968
Mounting Material Standard Constr. Unit 2278 125 02 00 000 00X 10521682
Mounting Crane Installation – 5 to 2278 543 01 00 000 00X 990289014
Mounting Crane Installation – 0.5 to 2276 543 02 00 000 00X 990817614

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BOOM
Gangway Pivot Piece – left 2277 544 05 17 000 00X 10516104
Mounting Material – Pivot Piece - left 2278 544 33 01 000 00X 10576067
Gangway Intermediate Section – 12m 2277 544 05 15 000 00X 10517042
Mounting Material – Interm. Section 12m 2278 544 33 04 000 00X 10594251
Gangway Head Section 2278 544 02 03 000 00X 10516549
Mounting Material – Head Section 2278 544 33 05 000 00X 10594252
Gangway Head Section 2267 544 10 02 000 00X 992935914
Mounting Material – Head Section 2278 544 25 02 000 00X 10595930
Gangway Pivot Piece – right 2277 544 05 18 000 00X 10516105
Mounting Material – Pivot Piece - right 2278 544 33 07 000 00X 10594261
Bolting Pivot 2276 514 01 00 000 00X 990274414
Mounting Material – Pivot Piece 2277 215 01 00 000 00X 990284214
Mounting Material – Boom Sections 2272 235 01 00 000 00X 919933614

ELECTRIC
Outline Power Supply 2278 600 69 00 031 00X 10597929
Search Light Installation – Cabin Platform 2276 528 04 00 000 00X 992032814
Search Light Installation – A-Frame 2278 530 02 00 000 00X 919648014
Search Light Installation – A-Frame 2276 531 10 00 000 00X 10533543
Search Light Installation – Boom Head 2276 529 08 00 000 00X 992937214
Search Light Installation – Boom 2276 531 07 00 000 00X 993820314
Helicopter Lamp Instal. – Aux. Hoist Boom 2276 537 01 01 000 00X 990695314
Helicopter Lamp Instal. – Boom 2276 537 02 01 200 00X 990844514
Helicopter Lamp Instal. – A-Frame 2276 537 01 02 000 00X 990695414
Helicopter Lamp Instal. – A-Frame add. 2276 537 02 02 200 00X 990844714
Wind Transmitter Installation 2265 526 01 00 000 00X 919332214
Camera Equipment – Boom Head 2289 552 03 02 000 00X 994546214
Camera Equipment – Luffing Winch not in this crane not in this crane
Wind Sock Installation not in this crane not in this crane
Fire Extinguisher System not in this crane not in this crane

HYDRAULIC
Diagram Hydraulic 2278 970 28 00 001 00X 11216463

ROPES
Ropes 2278 700 35 00 000 00X 10598584

BALLAST
Ballast RFK not in this crane not in this crane

Notice:

 “-00X” means the latest drawing alteration index.

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 Item numbers i.e. positions in the Packing List corresponding with the positions
indicated in the drawing: Delivered Items 2278 995 69 01 000 00X. The Packing List
can be found in Section 6 of this manual.

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INSTALLATION MANUAL

SECTION 5 :

Referenced Working Instructions


and Documents

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5. REFERENCED WORKING INSTRUCTIONS AND DOCUMENTS

Document Content:

Caption Item Code

 Preservation for Storage and Shipping 982607114

 Repair Instructions of 2-Pack Paint System 982603614

 Welding 10225362

 Flatness Control 10225363

 Pre-Tensioning of Bolts via Hydr. Tensioning Tool 982608414

 Instructions for handling of Crane Ropes 10227247

 Utility requirements 10598373

 Table of lubricants 809950914

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INSTALLATION MANUAL

SECTION 6 :

Packing List

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6. PACKING LIST

Document Content:

Caption Item Code

 Packing List 10598371

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