SAN MARCO INTERNATIONAL CRANE SMH 322 TRIVERTER 444 3t INSTRUCTION FOR ASSEMBLY, ERECTION DISASSEMBLY USE MAINTENANCE ORIGINAL INSTRUCTIONS (2006/42/EC) EDITION 02/2008 ~ FROM CRANE SERIAL NUMBER 32/514 SAN MARCO INTERNATIONAL ~ EVEN PARTIAL REPRODUCTION PROHIBITEDISAN MARCO) INTERNATIONAL ___ CRANE SMH 322 ~ EDITION 02/200 ~ 3t INDEX INDEX.. 01. DESCRIPTION INTRODUCTION 01.1. CRANE IDENTIFICATIO! 01.2. INTENDED USE... 01.3. GENERAL INFORMATIOI 01.3.1. SERVICE TOOLKIT. 01.4. TECHNICAL CHARA‘ 01.5. OVERALL DIMENSIONS .. 01.6. CRANE TRANSPORTING AND TOWING... ‘8) CRANE TRANSPORTING 8) CRANE TOWING. 01.6.1. LOAD ACTING ON THE AXLES. 01.6.2. TRASPORTATION ON TRUCK.. 01.7. CRANE LIFTING... 02. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION ... 02-1 02.1. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION. - 02-1 02.2. PRELIMINARY CHECKOUT .. 02-3 02.3. ERECTION PREPARATORY WORKS 02-4 02.4. FITTERS’ HELPERS. os 02-5 03-1 03-1 03-2 03-7 03-8 03. ELECTRICAL CONNECTIONS. 03.1. EARTHING INSTALLATION 03.2. ELECTRICAL CONNECTIONS. 03.3. WORK — ASSEMBLY SA1 SELECTOR SWITCH. 033.1. POSITIONS OF SELECTOR SWITCH SAI. WORK CONTROLS (SELECTOR SWITCH 10 ‘ASSEMBLY CONTROLS 444 (SELECTOR SWITCH SAI IN POS. 2)... 03-11 REMOTE WIRELESS CONTROL BOARD ~ WORK CONTROLS (SELECTOR SWITCH SAI IN POSITION 1) sense 03-12, 03.3.4, REMOTE WIRELESS JOYSTICK (OPTIONAL) ~ WORK CONTROLS (setecroR ‘SWITCH SA1 IN POS. 1).. 10 03-13 03.4. JIB POSITIONS SA2 SELECTOR SWITCH 03.5. SUMMER — WINTER SA4 SELECTOR SWITCH . 03.6. INTEGRATED RADIO CONTROL, 03.7. SLEWING SPEED ADJUSTEMENT .. 03.8. HOISTING SPEED ADJUSTEMENT 03.9. TROLLEY SPEED ADJUSTEMENT. 03.10. WIRING DIAGRAMS . 04, HYDRAULIC SYSTEM 04.1. HYDRAULIC DIAGRAM .... 04.2. ADJUSTMENT OF THE HYDRAULIC SYSTEM MAX. PRESSURI 04.3. OVERCENTRE VALVES ADJUSTMENT. 2 ~ INDEX - IA BNE rors) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 04.4, REGULATING THE OIL FLOW (TOWER LOWERING) 04-5 04.5. REGULATING THE OIL FLOW (JIB CYLINDER) 04-6 04.6. PRELIMINARY OPERATIONS ON HYDRAULIC 5 04.6.1. CHECKS PRIOR TO CRANE ERECTION.. 04.6.2. CHECKS BEFORE CRANE DISASSEMBLY. 05. BALLAST... 05.1. BALLAST BLOCKS. 05-1 05.1.1. TOTAL BALLAST. 7 7 aan . 5-1 05.1.2, ASSEMBLY BALLAST... aa 5-2 05.1.3. OPERATING BALLAST 7 7 eeeerers cs} 06. CRANE POSITIONING AND LEVELLING... 06.1. CRANE POSITIONING.. 06.2. LEVELLING THE CRANI 07. OPERATIONS PRELIMINARY TO CRANE ERECTION 07.1. DANGER ZONES. 07.2. SPLIT PINS.. 07.3. SLEWING RELEASE. 07.4, JIB AND LOAD BLOCK UNLOCKING .. 07.5. JIB SAFETY DEVICES ... 07.6. BOOM 29 M (REDUCED RANGE) 07.7. TIE RODS, CUSPS AND BRACES. 07.7.1. TURNING THE CUSP INTO OPERATING POSITION ..... 07.8. OPERATING THE CRANE WITH INCLINED BOOM 07.9. TROLLEY CABLE 07.10. HOISTING CABLE.. 07.11. DERRICK CABLE FOR LIFTING BALLAST BLOCKS 7.11.1. ASSEMBLY THE DERRICK... 07.12. ASSEMBLING THE CLAMPS. 07.13. LOAD INDICATOR FLAGS ... 07.13.1. ASSEMBLING THE LOAD INDI 07.13.2. LOAD INDICATOR FLAGS WITH HORIZONTAL 7.13.3. LOAD INDICATOR FLAGS WITH INCLINED BOOM.. 07.13.4. LOAD INDICATOR FLAGS WITH FOLDED JIB 07.14. LOADING DIAGRAMS ... 07.14.1, HORIZONTAL BOOM ~ LOADING DIAGRAMS 1)” 32 BOOM RANGE 8) 291 BOON RANGE 07.14.2. INCLINED BOOM ~ LOADING DIAGRAMS .. 07.14.3. FOLDED JIB ~ LOADING DIAGRAMS 08. CRANE ERECTION .. 08.1, ASSEMBLY PREPARATIONS ... 08.2. ASSEMBLING THE TOWER.. 08.3. LOADING THE OPERATING 08.4. JIB UNFOLDING... 08.5. ASSEMBLY COMPLETED ~ PREPARATION FOR OPERATING THE CRANE. 08.6. JIB CONFIGURATIONS a ~ INDEX -TUL) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t j 09. ADJUSTEMENT AND SETTINGS OF SAFETY DEVICES. | 09.1. SAFETY DEVICES.. 09.2. HOISTING LIMIT SWITCH ADJUSTMENT (FCS).... 09.2.1. SLOWING DOWN LIMIT SWITCH ADJUSTEMENT... 09.2.2. PUT-DOWN STOP LIMIT SWITCH ADJUSTEMENT. 09,3. HOISTING SAFETY DETECTOR (SSS) | 09.4. ANTI-FLEETING DEVICE (SAS) .. 09.5. SETTING THE SLEWING LIMIT SWITCH (FCR) 09.6. SETTING THE MAX. LOAD CAPACITY LIMITER (LCM). | 09.7. SETTING THE SPEED LIMITERS. 1 09.7.1. MIDDLE SPEED LIMITER (LMV). 09.7.2. _ FAST SPEED LIMITER (LGV) . | 09.8. SETTING THE MAX. DYNAMIC AND STATIC MOMENT T LIMITERS, 088.1. MAX. DYNAMIC MOMENT LIMITER (LMMO). MAX. STATIC MOMENT LIMITER (LIM)... 09.9, TROLLEY AND POSITIONING LIMIT SWITCHES. 09,10. OTHER SAFETY DEVICES 09.11. HOISTING MOTOR BRAKE ADJUSTMENT (FMS) 09.12. TROLLEY MOTOR BRAKE ADJUSTMENT . 09.13. SLEWING MOTOR BRAKE ADJUSTMENT (FMR). 09-1 09-1 j 10. GENERAL RULES FOR CORRET CRANE EMPLOY 10.1. OPERATOR REQUISITES . 10.2. GENERAL PRESCRIPTIONS FOR THE USER. 10.3. GENERAL PRESCRIPTIONS FOR THE OPERATOR 10.3.1. OPERATING THE CRANE..... 10.3.2. _ SHUT-DOWN CRANE 11. GENERAL RULES FOR CRANE MAINTENANCE .11-1 11.1. CABLE MAINTENANCE, : 111.2. CABLE CHARACTERISTIC 11.1.2, EXECUTION OF CABLE MANTENANCE 11.1.3. CABLES REPLACEMENT... '8) BROKEN WIRES. B) WER rn ©) CORROSION. 5) CABLES NEED REPLACEMENT IN ONE OF THE FOLLOWING CASES 11.1.4, HOISTING HOOK (3,000 KG) i 11.2. MAINTENANCE 11.2.1. DAILY MAINTENANCE. 11.2.2. WEEKLY MAINTENANCE, 11.2.3, AT EACH CRANE ERECTI 11.24, TIGHTENING BOLTS... 11.3, MAINTENANCE INTERVENTIONS } 11.4. AUTO-TUNING OF THE HOISTING MOTOR 11.5. LUBRICATION... 11.5.1, HYDRAULIC STATION TANK 11.5.2. GEAR REDUCTION UNITS 11.5.3. GEAR REDUCTION UNITS CLEANIECT) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 11.5.4, CYLINDERS Rops. 1155. 115.6, 11.5.7, 12. CRANE DISASSEMBLY. 12.1, PRELIMINARY OPERATIONS 12.2. FOLDING THE JIB... 12.3, UNLOADING THE OPERATING BALLAST BLOCKS 12.4. DISASSEMBLING THE TOWER... 12.5. TRANSPORTATION ARRANGEMENTS. 12.6. TRANSPORTING AND TOWING INSTRUCTION: 13. RESIDUALS RISKS. 13.1, RESIDUALS RISKS 14. REPAIRING THE MOST COMMON FAILURES... 14.1. IRREGULARITIES DURING CRANE ASSEMBLY AND DISASSEMBLY 14.2. IRREGULARITIES DUE TO ENVIRONMENTAL. FACTORS 14.3. IRREGULARITIES DURING CRANE EMPLOY 14.4. OPERATIONS IN AN EMERGENCY SITUATION A) TOLOWER THE LOAD. esis B) TO ROTATE THE CRANE. css veneer © INCASE THE TROLLEY SHOULD STOP BUE TO & FaitURE 15. OPTIONAL... 15.1, STEERING REAR AXLE. 15.2. HEADLIGHT... 15.3. ANEMOMETER... iV ~ INDEX -01. DESCRIPTION INTRODUCTION 01.1. CRANE IDENTIFICATION. 01.2. INTENDED USE.. 01.3. GENERAL INFORMATION. 01.3.1, SERVICE TOOL-KIT. 01.4, TECHNICAL CHARACTERISTICS. 01.5. OVERALL DIMENSIONS 01.6. CRANE TRANSPORTING AND TOWING.. 01.6.1. LOAD ACTING ON THE AXLES.. 01.6.2, TRASPORTATION ON TRUCK... 01.7. CRANE LIFTING...i ais CRANE SMH 322 ~ EDITION 02/200 — 3t INTRODUCTION a) All rane assembling, cisassembly and maintenance operations must be always carried out by skiled, Properly trained and qualified operators only, aware of the crane characteristics and familar with the Contents of the present instruction manual. INTERWATIONAL ) Should the instructions of the present manual not be strictly followed or properly carried out, the ‘manufacturer declines all responsibilty for any damages occurred to or caused by the crane, Se uring assembly operations, with moving structures, operators and all exposed persons must keep out of {he danger zone. Shouid it be necessary to approach the crane for inspections or adjustments, stop the Crane and check that the structural parts are stable and well balanced before operating. 2 Aly gualified, tained and sklled personnel with the necessary qualifications to operate in total safety and famiiar with the content and prescriptions of the present instruction manual are allowed to vse te Freee my information oF instruction not available In the present handbook, please immediately contact the Technical Department of the manufacturer. ©) th the Purpose of maintaining the crane in good operating conditions, the bulding yard manager wil reserve the Present handbook in is integrity in a safe place as cose as possible to the machinery, easily fans end ktown to all operators. Moreover, itis recommenced to consult it whenever requite, strict” following the instructions contained therein, In case of loss or deterioration, please contact the manuiccture: for a second copy of the manual. CRANE MANUFATURER: SAN MARCO INTERNATIONAL s.r... Via Principe Umberto, 42/b 28021 Borgomanero (Novara - Italy) MARK: ce CRANE MODEL: ‘SMH 322 VERSION: TRIVERTER 444 CRANE SERIAL NUMBER: acre ‘YEAR OF MANUFACTURE: ‘an English-speaking Country and the User Manual is Juently installed in or re-sold to another EU Country. IF quest a further copy to SAN MARCO INTERNATIONAL In which the crane will be employed. - 01. DESCRIPTION - o1-1EnrGrs) INTERNATIONAL ___CRANE SMH 322 ~ EDITION 02/200 — 3t 01.1. CRANE IDENTIFICATION Nameplate on rotary baseframe CE mark on electric cabinet door | | CE || | / (sae J ae IDENTIFICATION DATA z a METAL NAMEPLATE AFFIXED TO THE ELECTRIC CABINET DOOR, © Name of the crane manufacturer > Crane model Crane serial number © Year of manufacture | © Crane main characteristics © Reference standards for structural work calculation o CE mark METAL NAMEPLATE AFFIXED TO THE SLEWING BASE-FRAME 7 ‘© Name of the crane manufacturer Crane mode! Crane serial number 01-2 ~ 01. DESCRIPTION -24 22 23 ISAN MARCO INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 01.2, INTENDED USE ‘The crane model SMH 322 for building yard must be used only and exclusively for the intended urposes of this crane type and in compliance with the service factors prescribed by standards UNI 7670 and 150.4301 further on indicated, The crane is employed for the vertical hoisting (lifting and lowering) of unitary loads, and for their handling within the area covered by the crane arc of slewing and by the traverse radius of the boom trolley. Any lifting device eventually supplied with the crane must be used in strict respect of the prescribed ‘employ limits, and precisely: © Bucket, for lifting concrete, mortar or sand, © Box, for lifting bricks, roofing and wall tiles, © Fork, only and exclusively for dovinioading pallets from vehicles onto the ground or vice versa with @ maximum allowed lifting height of 1.5 m. In any case, the lifted loads must be perfectly balanced and never spill over the lifting device. 24 25 26 27 The assembly devices supplied with the crane have the only purpose to handle the structural parts the crane is composed of at the installation stage; it is strictly forbidden to employ them for any other purpose or as ancillary lifting means. In particular, the tower and the jib can be opened or closed only with no load on the hook. It is forbidden to use the crane for any purpose other than specified. In particular, and specifically it is absolutely forbidden to employ the crane for lifting up persons. The use conditions of H4 hoisting structures (DIN.15018) require that every 200,000 working cycles, the crane must undergo complete overhauling and worn-out components replacement. The use conditions of M3-class lifting mechanisms (150.4301) establish a limit of 1,600 service hours with frequent lifting at maximum load and usual lifting at moderate load. After said service time, the lifting mechanisms must be fully overhauled and worn-out components replaced, [ uN WARNING! Non-observation of the given instructions and improper use of the crane might cause serious amages to the crane structure and to its electrical and mechanical components. 2.8 During crane handling, erection, disessembling, use and maintenance, the operators and all exposed persons must wear the personal protective equipment (PPE, i.e. helmet, gloves, safety shoes, belts, etc.) in any case prescribed by laws and regulations to ensure the required safety levels, 2.9 Crane operation is allowed to qualified, trained and skilled personnel only, specially trained and duly authorised to operate on the crane. 2.10 To contro! the crane, it is possible to arrange, at user's care, a type-approved remote wireless Control board, suitable to the technical features of the crane. ~ 01, DESCRIPTION - 01-3¥ ISAN MARCO INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 01.3. GENERAL INFORMATION 3.1 Fast self-assembling crane with rotary base-frame, variable speed drive-controlled operating movements, equipped with: © four load hoisting speeds; © four slewing speeds; © four trolley displacement speeds, 3.2 Main load capacities and boom ranges of the crane: BOOM RANGE with horizontal boom LOAD CAPACITY f soiree ree 1000 kg 7 l 12.6 m 3000 ka Possibility of operating the crane with shortened boom (the load capacity at the boom tip increases): ‘REDUCED BOOM RANGE with horizontal boom LOAD CAPACITY 29m 1100 kg 33 The crane can be employed with inclined boom, and traveling troley with constant max. hoisting capacity along the boom length. z INCLINED BOOM TIP HEIGHT ‘MAX. LOAD CAPACITY _ 30.6 m 700 kg 3.4 The crane is designed to operate with folded jib and constant hoisting capacity. MAXIMUM OVERALL DISTANCE with folded jib me (slewing axis ~ horizontal boom projection) elena 15.2 m 2000 kg Operating the crane with this configuration, the boom cannot be inclined. — 3.5. In order to feed the electric motors, the power required is about 20 kW, 380 V three-phase current. 3.6 Assembly with the slewing base-frame oriented in any direction. Jib unfolding possible with crane erected and fully ballasted only. 3.7 The crane is equipped with ready-to-use cables and safety devices. 3.8 Crane equipped with cement ballasts. The ballast is composed as follows: © assembly ballast: 5700 kg (2 blocks 1850 kg each one, 2 blocks 1000 kg each one); © operating ballast 14300 kg (11 blocks, 1300 kg each one); © total ballast 20000 kg. (continued on nett page) 01-4 ~ 01. DESCRIPTION -Riis [SAN MARCO INTERWATIONAL 39 3.10 Ball 32 CRANE SMH 322 - EDITION 02/200 - 3t Equipped with rubberised axies, capable of supporting the crane weight without the cement ‘assembly ballast, for transporting the crane around the building yard; the axles, fixed to the upper base-frame and to the tower, can be removed. ‘The crane is finished with a double coat of paint; hot galvanised tower and boom. It is forbidden to employ the crane in a potentially explosive or corrosive or oxidative atmosphere, or in the risk of fire. When calculating the structures, seismic effects and snow loads have not been taken into consideration. 01.3.1. SERVICE TOOL-KIT The crane is supplied complete with a tool kit inside @ casing, consisting of: © electric cabinet opening key; © padlock for the electric cabinet; © pliers; © screwdriver; © 17/19 spanner for safety devices adjustment © 24 spanner for operating ballast tie-rods; © 50 spanner for assembly ballast tie-rods; © 60 spanner for stabilizer arms; © load indicator flags (if not already fitted on the boom). "= 01. DESCRIPTION - 01-5ISAN MARCO) INTERWATIONAL ! CRANE SMH 322 ~ EDITION 02/200 - 3t 01.4. TECHNICAL CHARACTERISTICS 30.35 m, 29.75 m na RE alt 12.58m 3000 kg 2000 kg 25.60 m 3.80x380m [ Employ class of frames and structures | Hi 63 DIN I50i6 = Lifting class, Hi Average loading rate B3 frequency of use 200000 working cycles ‘Machine class (ISO 4303/1) _ ‘A4-02 (Kp=0.25) U4 (250000 working cycles) Lifting mechanism class M4 (150. 4301/3) ‘Operating condition “T4 (3200 service hours) {2 (Km=0.25) subject to frequent max load but generally seers ‘moderate load ‘Siewing mechanism class ma (1S. 4301/3) Operating condition T3 (1600 service hours) ‘Load rate 13 (Km=0.50) [rolley displacement mechanism M2 (ESO 4301/3) ‘Operating condition T2 (800 service hours) ‘Load rate 12 (Km=0.25 (continued om mat page) 01-6 ~ 01. DESCRIPTION -sit SAN MARCO) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t ie TECHNICAL FEATURES: ‘Maximum capacity 3000 ig — Range max. capacity 1000-kg = 1,100 kg ‘Constant capacity with folded boom 2000 kg Constant hoisting capacity with inclined boom 700 kg ‘Maximum load at micro speed 3000 kg ‘Maximum load at slow speed z 3000 kg Maximum load at middle speed 1600 kg Maximum load at fast speed 1000-(800) kg z Erection motor power 2.2 kW sas Hoisting motor power 111 kW with variable speed drive Slewing motor power 2.3 KW with veriable speed drive Trolley motor power 1.8 kW with variable speed drive Micro hoisting speed [9 m/min Peete 1 Slow hoisting speed =| 20 m/min Middie hoisting speed [32 m/min Fast hoisting speed 42 m/min Slewing speed r 0.25-0.5-0.75-1 rpm “Trolley displacement speed 10-20-30-40 m/min ‘Maximum power consumption 20 KW (three-phase feeding) Required power supply _ E [380 Volts 5% (three-phase feeding) ‘Control circuits voltage [48 Volts | Measured A-weighted sound pressure level 87.1 dB(A) a a Ensured A-weighted sound pressure level 91.0 d8(A) Height under hook 22.30-30.35 m Maximum range : “Total ballast weight Crane total weight with assembly ballast ‘Crane total weight without assembly ballast Front axle total load without assembly ballast Rear axle total [oad without assembly ballast Maximum crane displacement speed Maximum wind speed allowed when | Maximum wind speed at standstill ”102/130/150 km/h Maximum wind speed when erecting [20 kmh ‘Acoustic level measurements with a 3000 kg maximum load at lifting and lowering speeds of 20 m/min (slow | speed). - 01. DESCRIPTION - 01-7Coats Saat CRANE SMH 322 ~ EDITION 02/200 ~ 3t 01.5. OVERALL DIMENSIONS coh eseeeestogeascueuuoyeeseuusuueEEey uu guneemizaasanaaenns O=im 01-8 - 01. DESCRIPTION -SAN MARCO) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t | 01.6. CRANE TRANSPORTING AND TOWING snitAE atleet | | wanna Slog kt Soiree tint » Before starting any transport or towing operations, check that the lower section base-frame is firmly secured to the upper section by means of the slewing lock-pins (paragraph 07.3). > All the crane displacement, transporting or towing operations may be executed only by qualified, formed and informed operators, who know about the technical characteristic of the crane, A) CRANE TRANSPORTING 6.1 The crane can be transported by 2 vehicle of adequate dimensions and capacity. To reduce crane 4 height during transport, disassemble the axles. | B) CRANE TOWING 6.2 Crane towing is allowed within the building yard only (do not tow the crane on the road) by means of a vehicle of adequate dimensions. 6.3 The crane can be towed without ballast and for short distances only, within the building yard. 6.4 Before starting crane towing, it takes to accomplish the following tasks: © unload the complete ballast; a © lock the load biock to the trolley, to avoid damages to the cable and carefully secure all the mobile parts of the crane; © check the tyres pressure; ‘ © check the tightness of the wheel nuts; © check the fixing pins rotating base frame ~ axles and thelr relevant split pins and the fixing pin axle ~ drawbar and its relevant split pins. i B65 check that al wamings an Indicator signs, in compliance wth regulations relating to crane towing, are correctly positioned. 66 nro case a towing speed of 25 km/h wil be ‘exceeded; in presence of uneven ground, speed ‘ ‘must be considerably reduced to avoid damaging the crane or the axles. Do not tow the crane on ; rough or loose ground. Max gradient allowed 5%, } } 6.7 During crane transport frequently check the tyre temperature, stop frequently to allow the tyres to 4 cool down and check for tightness of wheel nuts, d a eases [AK | wannancr % Never execute slewing operations being the crane disassembled., without removing the xing pin : ‘upper base frame ~ lower base frame. i > Never transport the crane without locking the two parts of the base frame. { %___An improper crane towing on the road, besides being subject to road traffic code penalties, might ; ’ oo. (continued on mexct paps) "= OL. DESCRIPTION - 01-9ISAN MARC! INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t seriously damage wheels, axles ete; ‘Transporting a ballasted crane would cause breakages or deformations of its structural parts. Excessive speed, crashing against Kerbs and holes might seriously damage the driving gears and components. 01.6.1. LOAD ACTING ON THE AXLES Rapa geee etka tpnttritaen ee mee Pee 43.90 m : 2 b Bs = 7 245m 2.10 m 2.35 m_4.05 m 7.10 m 1.90 m* * Narrow rear axle OPTIONAL 5 ")__ CRANEAT TRANSPORT ___ without assembly ballast Front axle PA. 1800 kg Rear axle P2 9300 kg TOTAL 11100 kg WARNING! For transport on the road, the crane must be equipped with suitable braking axles. The towing drawbar eyelet must be securely fixed to the towing hook of the vehicle by means of a > sturdy pin, vertically positioned and secured by a spring split pin preventing it from accidentally slipping off > When towing the crane, remove the pins locking the drawbar vertically and the rear axle horizontally; these lock-pins shall only be inserted when hitching and unhitching the front axle from the base-frame. ESTIMATED EFFORTS AT THE TOWING HOOK —_Max. traction effort 20000 N | Ma 2000 N z : a te etna om were page) 01-10 ~ 01. DESCRIPTION -Bear) CRANE SMH 322 ~ EDITION 02/200 - 3t INTERNATIONAL 01.6.2, TRASPORTATION ON TRUCK Ker OOO ‘Transporting the crane with the axles disassembled = OL. DESCRIPTION - 1-11nfs ISAN MARCO} INTERNATIONAL ae CRANE SMH 322 ~ EDITION 02/200 ~ 3t 01.7. CRANE LIFTING > , All the crane hooking and lifting operations may be executed only by qualified, formed and informed operators, who know about the technical characteristic of the crane. No operator must pass of stay under the lifted load 7.1. The crane can be lifted by means of @ hoisting device of adequate dimension and capacity. 7.2. The crane is provided with hooking plates; apposite stickers affixed to the machine indicate hooking/slinging points. We. = 11100 kg (without assembly ballast) { 7.3 Lift the’crane by means of four metal cables, 6-8 m long, min braking load value 22000 kg each, equipped at each end with U-clamps of the same capacity. 7.4 Before lifting up, make sure the load is perfectly balanced. 01-12 - 01. DESCRIPTION -02. PRELIMINARY INSTRUCTIONS FOR | CRANE ERECTION 02.1. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION. 2, PRELIMINARY CHECKOUT... .3, ERECTION PREPARATORY WOR! FITTERS’ HELPERS...iii vdennaina SAN MARCO) TERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 02.1, PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION 4a 12 To select a suitable positioning site, take into consideration the mechanical strength the ground ‘must have to withstand the stresses transmitted by the crane's structure and supports. Verify the ground strength and, if insufficient, take all the necessary measures to prevent any subsidence, such as adding gravel or concrete castings of adequate thickness. ‘GROUND MIN. STRENGHT 3.5 kg/cm 13 14 In the table above there’s the ground minimum strength value. Never install the crane on loose made ground, in presence of fitering or flowing waters, by slopes and excavations, ete. ‘The selection of the erection site must also consider the presence of live electric lines in the vicinity When erecting and operating the crane, it is recommended that its frames and suspended loads ust be at least at the distance indicated in the table below fer away from the electric lines; Consider the lowest point of the catenaries, described by the electric line from a pole to another one, displaced laterally of 30° as regards to the vertical, under the effect of the wind pushes. On no ‘account, the structures of the crane and the lifted loads have to pass over the lines. In presence of high-voltage lines, the distance must be reasonably increased, considering that, under certain Grrcumstances, an electric arc can be sparked off between the wire and the structure of the crane, even if the distance is considerable. ‘MIN.DISTANCE FROM THE LIVE ELECTRIC LINES |” 3 1s __5 m (middle point of the catenaries with an angle of 30°) = This distance has to be increased! in presence of high-voltage fines. The crane must be positioned in such a manner during the siewing of its moveable part, along the entire circumference, the distance between its farthest reach point and the building or any other obstacle (i.e. poles, trestles, scaffolding, machinery, heaps of material) is not lower than 60-70cm at any point. MIN. DISTANCE FROM THE BUILDING AND FROM OTHER OBSTACLES 16 17 18 {along the entire slewing circumference, for the point with max. space occupied) 60-70 cm Furthermore, make sure that, all along the entire arc of slewing of the crane, there subsist no risks Of crushing any structural part against any kind of obstacles. Itis the responsibility of the purchaser of the crane to choose a suitable installation site (see CRANE LOGBOOK). When two or more cranes are installed at 2 short distance from each other, the min. range between their structurals parts never must be lower than 2 meters. When this prescription cannot be Fespected because of binding technical reasons,, it takes to resort and implement appropriate Gevices in order to prevent the interference between the structural parts, the cables or the lifted loads, ——______________(confimusd on next paga) ~ 02. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION - 02-1BE EGr) __INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t ‘WARNING! 02-2 ~ 02. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION - CNRS iSReNNNAnReee caecemmsaeesncnrenne (Stic Rt RNAs eesatteetecemene| ih Ex INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 22 23 24 25 26 27 28 29 DE) 02.2. PRELIMINARY CHECKOUT WARNING! » Before starting the first crane erection, as well as before any following one, it compulsory to carry out all the following checks and inspections. General checks of the electrical system. In particular, check that the electrical components have not been damaged during transport or use. Check that the connecting cables are efficent and their connection intact. Verify that all connections have been correctly made and are properly tightened. Check that the brakes of the electric motors are efficient and properly set Check the hoisting and displacing cables of the trolley, as well as the load and ballast Pulling cables. Specifically, check that cables show no sign of damages suffered during transport Or use on their whole length. Check good efficiency of end wedge clamps and thimbles. Make sure that all cables are clean and greased, that their path is correct, and finally that the cables are Correctly engaged in the grooves of their respective sheaves. Check sheaves for trolley lifting and displacement. In particular, check that all sheaves rotate freely and show no signs of rust or scales. Make sure that there are no signs of breaks or cracks due to use or transport. Check that hooks safety locks are present and in good working efficiency. Check winches. In particular, inspect oll level inside gearboxes and make sure that the bolts fastening the gear reduction units to their supports are securely tightened, Check that there are no Ol leaks and that the cables are correctiy wound on their drums; carefully check bearings condition, General structural inspection. Particularly check that none of the frame has suffered any abnormal deformations caused by use or transport. Make sure that all mechanical parts are protected by grease and that everything is ready for a quick end safe erection. Check the connecting elements; make sure that the pins are locked by the relevant split pins and that nuts are firmly tightened. Check that the water drains from galvanised pipes are free from any foreign matter. After 3200 service hours of lifting gears and mechanisms, the winch must undergo a complete Overhaul, and all worn-out or over-stressed components must be replaced with original ones. Effect a general and complete crane lubrication, with particular care for cables, sheaves, bearings, bronze bushings, articulated pins and for all those components subject to excessive wear and tear. Inspect the hydraulic equipment; lubricate the lock-pins of the hydraulic cylinders by means of the apposite greasers; check the oil level inside the station tank. Check rubber pipes for integrity, ‘make sure the valves are in working order and check the pressure set point of the hydraulic station (max. service pressure 280 Bar), Check that the position limit switches enabling opening and closing of the boom sections is efficient; inspect that the trolley is placed by micro-switch enabling its operation. ~ 02. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION - 02-3SAN MARCO} __IRPenexTonat CRANE SMH 322 ~ EDITION 02/200 ~ 3t 02.3. ERECTION PREPARATORY WORKS 3.1 Select the most suitable place for positioning the crane (paragraph 02.1). : 3.2 If required, consolidate the ground with gravel or concrete (paragraph 02.1). ; 3.3 Provide the cement blocks for the ballast, as indicated in the attached drawings. 3.4 Provide 28 hard wood beams of the size indicated in the table below. The beams are used as a base for the stabilizers at the crane erection stage. HARD WOOD BEAMS FOR THE STABILIZERS Quantity Length Width I Height 28 80cm 20m —[___is.en a 3.5 Connect the earth terminal of the crane to the earthing plate network of the building site. 3.6 Provide the required equipment to connect the crane electrically in strict observance of the safety | regulations; specifically operate in compliance with the provisions of CEI..64:17 standard. For connecting’ the electric cabinet of the building site to the crane’s, provide an HO7RN-F-type rubberised cable with the following characteristics: j ‘CONNECTING CABLE CABINET OF THE BULDING SITE — CABINET OF THE CRANE { | i WITHLIGHTENING LAMP | | WITHOUT LIGHTENING LaMP pence 1 Distance it __(R+S+T+PE) L Cable cross section ; Upto 50m 4x10 mm Between 50 m and 100 m 4 me 3.7 The cable way between branching and user points must be the shortest possible, with no useless turns or rolls of excess cable. 3.8 Make sure that the supply voltage is 380 V (three-phase current) and that the mains upstream are such not to cause any voltage variations of the motors, at maximum absorption conditions. Measure the feeding power with and without load: Voltage variations shall not exceed 45% with and without load. 3.9 Erection and disassembly operations must be carried out in windless conditions, Maximum wind ‘speed allowed: 10 km/h. At the middle boom opening stage, never rotate the crane. ane > Non-observance of the safety distance from electrical lines might engender the risk of electro- shock. It is reminded here that an electric discharge between the aerial conductor and the crane may occur even without physical contact, since an electric arc may strike even when the crane parts | | are at a certain distance from the conductor. To calculate the safety distance, consider the lowest | Point in the wire span, considering anyway that the wind could move it by 30° to the vertical. | > Non-observance of the safety distance from obstacles may cause the risk of crushing, > Feeding voltages higher or lower than the max. rated tolerances may lead to crane malfunctioning 25 well as to serious damages of the electric equipment, 02-4 = 02. PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION - _ @3t ase lige os AGE (iii se 4a 42 ISAN MARCO INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 02.4, FITTERS’ HELPERS During CRANE ASSEMBLY PREPARATION, ASSEMBLY, DISASSEMBLY PREPARATIONS and DISASSEMBLY, it may be necessary that the building contractors concerned by the crane assembly, Place some operators at fitters’ disposal. These operators are called FITTERS’ HELPERS. ‘These operators must: © be chosen and charged to the specific task of fitters’ helpers by the responsible of the building site, delegated by the building contractors and regular employees of the building contractors; © have the task of fitters’ helpers included in the tasks that the operator may perform and be qualified to; © have the physical and psychical characteristics necessary in order to operate in conditions of safety; be formet and informed about the specific operations to execute, in particular about the risks that may happen; ° have available and use the personal protective equipment, necessary in order to preserve their health and sfatey; © Perform operations at ground level only; the operations to be executed never must require to Climb the structural parts of the crane at a level higher than 2 meters. "02, PRELIMINARY INSTRUCTIONS FOR CRANE ERECTION > 02-503. ELECTRICAL CONNECTIONS 03.1. EARTHING INSTALLATION .. POSITIONS OF SELECTOR SWITCH SAI. WORK CONTROLS (SELECTOR SWITCH SAi IN POS. 1).. ser ‘ASSEMBLY CONTROLS 444 (SELECTOR SWITCH SAI IN POS. 2) 3-11 REMOTE WIRELESS CONTROL BOARD ~ WORK CONTROLS (SELECTOR SWITCH SAI IN POSITION 1) ns 03-12 REMOTE WIRELESS JOYSTICK (OPTIONAL) ~ WORK CONTROLS (SeLEcTOR ‘SWITCH SAI IN POS. 1).. .4. JIB POSITIONS SA2 SELECTOR SWITCH . . SUMMER — WINTER SA4 SELECTOR SWIT( . INTEGRATED RADIO CONTROL .. ‘SLEWING SPEED ADJUSTEMENT . HOISTING SPEED ADJUSTEMENT . TROLLEY SPEED ADJUSTEMENT. 03.10. WIRING DIAGRAMS...a date iis di atlbiaa ase | INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t al 12 13 14 15 03.1, EARTHING INSTALLATION To earth the crane, use galvanised shoes 1.5 m long, A copper plait conductor with 50mm? cross- Section will be used to connect the galvanised shoes to the earthing terminal situated on the crane frame. Setting up of the earth plate network shall be in conformity with standards and regulations in force and it will be effected by qualified, trained and skilled personnel only. The earth resistance value must comply with the values prescribed by regulations and must be controlled before and after crane erection at regular intervals thereafter, and during crane operation, In particular, special care shall be taken in ensuring that contact surfaces are perfectly clean and free from scale, rust, paint, concrete, etc, Effect the hearting connection before connecting the crane electrical equipment to the electric cabinet of the building site. Furthermore, the earth wire of the cable connecting the crane to the electric cabinet of the building site should be connected to the earthing system of the building site, To protect the crane from lightening flashes follow the procedure indicated by CEI 81-1 standard, Copper cable Cross section 50 mm? f=DNut ZIOLLIZZ Washer—t— VILEY I), Cable washer RU, co tee Galvanized shoes nor ~ 03, ELECTRICAL CONNECTIONS - 03-1 a PERSE22 WAN WARNING! Pe ISAN MARCO) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.2. ELECTRICAL CONNECTIONS The operations of electrical connections m technician only. Install an overload magneto-thermal switch with upstream differential protection inside the electric cabinet of the building site. If the crane is supplied with a plug, rated differentcl current of intervention must be lower than 30 miliampere. Connect to the switch a rubberised cable of the HO7RN-F type, with the following characteristics: CONNECTING CABLE CABINET OF THE BULDING SITE — CABINET OF THE CRANE WATiour LIGHTENING Law | _ HH LIGHTENING [AMP Distance ‘tases ee | (R+S+T+PE) (R+S+T+PE+N) Cable cross section Cable cross section Upto 50m 4x10 mm" —_ 5x10 mm 23 24 25 26 27 28 29 03. Between 50 m and 100 m 4x16 mm" 5x16 mm Open the cover of the main power switch situated on the longitudinal beam of the fixed base-frame. Insert the rubber connecting cable into the disconnector switch through the cable gland, and then Connect the three phase wires R S T and the fourth PE external protection wire (along with the 5" wire N eventually present) to the respective terminals in the disconnector switch terminal board. ‘The equipment is fitted with a phase sequence relay (KSF); connect RS T wires in the correct test sequence and, if this is the case, the yellow led situated on KSF is lighted up. If the crane does not work (led OFF) invert two wires. ‘Accurately tighten the terminal screws and close the cover of the disconnecting switch, When the main switch fitted on the electric cabinet of the building site is closed, the following parts are alive: © the cable connecting the building site cabinet; © the disconnector switch on the crane base-frame with the relevant inlet terminals. When the main switch on the crane base-frame is closed, the following parts are alive: © the cable connecting the building site cabinet; © the disconnector switch on the crane base-frame with the relevant inlet terminals, © the cable connecting the base-frame disconnector switch to the crane electric cabinet; © its connecting terminal boards inside the crane electric cabinet; © the wires inside the cabinet up to the main power switch on the crane electric cabinet door When the main switch of the electric cabinet of the building site is closed, the following parts are alive: 2 ~ = 03. ELECTRICAL CONNECTIONS - csi ; : ia — nacactn naccla iinet aay: ES ECE INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t Inlet terminals of the main switch; the cable connecting the base-frame disconnector switch to the crane electric cabinet; its connecting terminal boards inside the crane electric cabinet; the wires inside the cabinet up to the main power switch on the crane electric cabinet door; ‘The whole electric cabinet of the crane, ~ 03. ELECTRICAL CONNECTIONS - 03-3BGs) INTERNATIONAL. Grane electric cabinet YY | lg Connecting cable to the site power distribution unit, 4x10 (4x16) or 5x10 (5x16) mm? Seer HOTRN-7 So Cabinet door main switch 0,032.4 | Base-frame main switch | { | Position 0 CONTACT OPENED | ~~ 1 Postion E CONTACT CLOSED | i i | Magneto-thermal switch : L co Our 03-4 ~ 03. ELECTRICAL CONNECTIONS> Bris INTERNATIONAL, CRANE SMH 322 ~ EDITION 02/200 ~ 3t [AN | warmer a The electrical equipment has been designed and manufactured for an operating temperature between ~5°and +50°. Should the temperature exceed this range, it is responsiblity of the user to install suitable shields in order to maintain the specified environmental temperature limits, The crane storing temperature is comprised between ~25° and +55°C. ie LIMIT TEMPERATURES FORTHE CRANE Min. temperature T Max. temperature Operating the crane “5°C = +50 °C Crane at standstill 25°C +55°C | 7 = (Ama The electric cabinet of the crane should always be locked with the apposite padlock supplied, and the key entrusted to the building site manager. ‘The supply voltage requires, with or without load, @ maximum tolerance of +5%; voltage values lower or higher than specified may damage the electrical equipment. Strictly observe the given instructions. Any non-observance might cause the following crane malfunctioning and risks. The use of a supply cable with an incorrect cross-section will result in an excessive voltage drop with ‘consequent possible malfunctioning of the hoisting winch and the whole electrical equipment. | ‘An unsuitable power supply cable will make correct connections impossible, with consequent Possible malfunctions of the electrical equipment and risks of electric shock for the exposed persons. ‘An electric cable laid with useless turns and not with the shortest path between the building site and the crane electric cabinets, or, otherwise, rolled up due to its excessive length, will result in an excessive voltage drop with consequent possible malfunctioning of the whole electrical equipment. A faulty insulation of the crane feeding cable will engender the risk of electroshocks to the exposed persons. By switching off and on the power supply-disconnecting device on the crane electric cabinet, the electric cabinet with the equipment downstream of it are disconnected or alive, as the case may’ be. By switching off and on the power supply-disconnecting device fitted on the crane base-frame, the Connecting cable, the disconnecting device and all components downstream are disconnected or alive, according to the case. By switching off and on the power supply-disconnecting device on the building site power | Cistribution board, the base frame disconnecting device, the building site cabinet and all components downstream are off or alive. Failure in connecting the metallic mass of the crane to the earth plates generates a condition of extreme danger in case of leaks in the electrical system. The same hazard situation is produced in ‘ase of inefficient connection or a lack of continuity of the earthing system. Failure in locking the electric cabinet doors by means of the apposite padlock makes it possible for unauthorised personnel to tamper with the electrical components, with the consequent risk of serious damages to persons and things. The missing installation of protection devices against lightening flashes may engender the tisk of electroshock for all exposed persons. "= 03. ELECTRICAL CONNECTIONS - 035 |BL 32 INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.3. WORK — ASSEMBLY SA1 SELECTOR SWITCH ‘The cabinet houses the three position selector switch SA 1: ERECTION (1) and ASSEMBLY (2). © By turning the selector switch to WORK position (1), are enabled all controls relevant to the ‘operative functions of the crane fitted on the control board. © By turning the same selector switch to ASSEMBLY position (2), all controls for tower and jib assembling are enabled. The push buttons on the relevant contro! board available in the three different operating conditions are described at the following pages. 3.3. To assemble (or disassemble) the crane: © turn OFF (0 position) the power switch on the cabinet door and then turn the outer key to open the door; © tum the selector SA2 switch to position 2 "ERECTION" to lift (or lower) the tower and unfold (or fold) the jib; © close the door and turn the main selector switch back to position 1 ON; © turn the key outside the door to close it; © depress the green START push button on the control board to start the hydraulic unit pump at high speed; © by acting on UP or DOWN push buttons, extend or retract the hydraulic cylinders for tower erection. Operate on NEAR and FAR push buttons to fold or unfold, as the case may be, the first section of the jib. 3.4 Completed the erection, to enable work controls of the crane: © depress STOP push button; ‘© tun the main switch on the electric cabinet door to position O, turn the key and open the door; © tum selector switch SA2 to position 1 “WORKING”, then close the door and switch the power on; © close the door and turn the external switch SA4 to position 1 "ON"; © tum the key outside the door to close it; eee eee (continued om nant page) (03. ELECTRICAL CONNECTIONS - 03-7[SAN MARCO} INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t © depress START push button; © act on UP or DOWN push buttons to lift or lower the block; operate NEAR or FAR push buttons to displace the trolley near to or away from the tower. > The crane can be erected, dismantled, used to work correctly only if all the switchers on the crane are in the position written on the Manual for the various functions. Failure in respecting these procedures would jeopardize the correct working and the integrity of the crane, and also can cause anomal functionings and sudden stops. 03-8 ~ 03. ELECTRICAL CONNECTIONS - ial iii a isi[SAN MARCO) INTERNATIONAL _ CRANE SMH 322 ~ EDITION 02/200 ~ 3t 03.3.1. POSITIONS OF SELECTOR SWITCH SA1 * The crane can be correctly erected, disassembled and used if all switches and selectors installed on the machine are in the function positions indicated in the present instruction manual. Failure in Complying with the given instructions will cause anomelous operations or machine stops, thus | Prejudicing its integrity and proper functioning, - 03. ELECTRICAL CONNECTIONS ~ 03-9INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.3.1. WORK CONTROLS (SELECTOR SWITCH SA1 IN POS. 1) w@ 1) LINE STOP It disconnects power supply tothe electric equipment, TURN TO RELEASE 2) LINE START AND ALARM It switches the power on and actuates the acoustic warning. DEPRESS TO SWITCH THE POWER ON AND TO SIGNAL. '3) LOAD BLOCK UP By depressing it, the block is lifted up. 1 pressing postion micro speed; If pressing position siow speed. 4) LOAD BLocK DOWN, By depressing it, the block is lowered down, | pressing positon micro speed; TI pressing postion slow speed. 5) HOISTING By depressing it after starting a lifting or a lowering ‘operation at iow speed, it switches the current movement speed to: ‘idle speed (1 pressing position) or fast speed (IL pressing position), 6) SLEWING By depressing it after starting 2 left or right slewing at slow speed, it switches the current movement speed to: ‘migele speed (I pressing position) or fast speed (II | pressing position 7) LEFT SLEWING By depressing it, the crane is rotated letwards. pressing postion: micro speed; II pressing position: slow speed. 8) RIGHT SLEWING By depressing it, the crane is rotated rightwards. 1 pressing postion: micro speeds; II pressing position: slow st 9) RANGE FAR By depressing it, the trolley is displaced towards the tip of the boom. 110. | | toes poston: micro speed; i pressing postion sow 9 speed 30) RANGE NEAR eee To dspace the troy towards the tower. Tpresing positon: mre speed I! pesing postion: sow ] soe. 23) RANGE 112 | | Bydenressno& ater starting afr / ner dplacement of 1 the oey at sew spec, sitches the current a movement speed to ees) My mide speed (pressing postion or fat sped (1 pressing poston. 12) FREE AY warnanc! » The red push-button to the left on the depressed, the power supply to the equipment ACTUATE IMMEDIATELY IN AN EMERGENCY SITUATION. top of the control board is an EMERGENCY STOP, If t is disconnected and all motors instantly stopped. J 03-10 ~ 03, ELECTRICAL CONNECTIONS -BaEoGrr HUTERNATIONAT a CRANE SMH 322 ~ EDITION 02/200 ~ 3t 03.3.2. ASSEMBLY CONTROLS 444 (SELECTOR SWITCH SA1 IN POS. 2) a 7 1) LINE STOP : | It disconnects power supply to the electric equipment. TURN TO RELEASE. 2) LINE START AND ALARM 2 It switches the power on and actuates the acoustic Eq warning. DEPRESS TO SWITCH THE POWER ON AND TO [tower | SIGNAL. a TOWER 3) TOWER ERECTION-UP By depressing it, the tower islited up. aN 1 pressing position: it causes the hydraulic cylinder Za w 4 stem, which lifts the tower, to emerge. II pressing Position: disabled. SZ 4) TOWER ERECTION-DOWN } eee By depressing it, the tower is lowered. 1 pressing position: it causes the hydraulic cylinder o stem to retract. II pressing position: disabled, _| { = Kk a '5) DISABLED | 6) SLEWING 5 4 | Su 6 By depressing it after starting a left or right slewing | 27 at slow speed, it switches the current movement. = Wa speed to: middle speed (1 pressing position) or fast speed (II pressing position), 7) LEFT SLEWING BY depressing it, the crane is rotated leftwards. 7] CAD] 24, fs | | Pere pecan ats ier position: slow speed. 8) RIGHT SLEWING By depressing it, the crane is rotated rightwards, | pressing position: micro speed; II pressing pestion’ dow Speed a 9) 18-FaR 9 PoP |fto | | Rovestes i oening. 1 pressg poston dab ee 10) JIB-NEAR ma It operates jib folding. position: disabled. 1 12 11) DISABLED ee 12) FREE MN WARNING! * The red push-button to the left on the top of the contro! board is an EMERGENCY STOP. 1f Gepressed, the power supply to the equipment is disconnected and all motors instantly stopped. ACTUATE IMMEDIATELY IN AN EMERGENCY SITUATION. 03. ELECTRICAL CONNECTIONS - 03-11i ECCT) TERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.3.3. REMOTE WIRELESS CONTROL BOARD — WORK CONTROLS (SELECTOR ‘SWITCH SA1 IN POSITION 1) ] A) LINE STOP Tt sconnects power supply tothe electric equipment. TURN TO RELEASE B) LINE START AND ALARM Testes the poner on and actuates the accuse waming. DEPRESS TO SWITCH THE POWER ON AND TO SIGNAL i) LOAD BLOCK UP BY depressing i, the block i ited up. | 1 pressing position micro speed; It pressing poston slow speed. 2) LOAD BLOCK DowN By depressing it, the block is lowered down, *| Tpressing postion micro speed; I! pressing postion stow | speed. _—_ By depressing it ater starting a lifting or a lowering operation at slow speed, suitches the current movement speed to: middle speed (1 pressing poston) or fast speed (11 Bressing postion) 4) SLEWING By depressing it after starting 2 let or right stewing at slow speed, it switches the current movement speed to: middle speed (I pressing positon) or fest speed (It '5) LEFT SLEWING By depressing it the crane is rotated leftward. 1 pressing postion: micro speed; I pressing poston: iow speed. 6) RIGHT SLEWING By depressing it, the crane i rotated rightwards 1 pressing positon: micro speed II pressing postion: stow | speed. eee ee 7) RANGE FAR By depressing tthe trol is esplaced towards the tin of the boom 1 pressing position: micro speed; 11 pressing position: slow | speed. | 8) RANGE NEAR ‘To dgplace the trolley towards the tower. | pressing postion: micro speed; II pressing pesiton; show | speed. 9) RANGE By depressing it after starting @ far / near displacement of the troley at siow speed, it switches the current movement speed to: middle speed (I pressing postion) or fast speed (I pressing poston). 10) FREE Hin AN | wasians The red push-button on the to P of the wireless contro! board is an EMERGENCY STOP. if sezressed, the power supply to the equipment is disconnected and all motors instantly stopped, ACTUATE IMMEDIATELY IN AN EMERGENCY SITUATION. 03-12 ~~ 03, ELECTRICAL CONNECTIONS - [open postion), | i i iINTERRATIONAL CRANE SMH 322 - EDITION 02/200 - 3t 03.3.4. REMOTE WIRELESS JOYSTICK (OPTIONAL) — WORK CONTROLS (SELECTOR SWITCH SA1 IN POS. 1) 15 As an alternative to the remote wireless control board (paraaraph..03.3.3), the crane can be equipped with a remote wireless joystick OPTIONAL, ‘A) LEFT LEVER: controls trolley and slewing. B) RIGHT LEVER: controls lifting and lowering of © Lever forwards: trolley towards the boom | the load block. tip. | ©. Lever forwards: load block lifting, © Lever backwards: trolley towards the tower. © Lever backwards: load block lowering © Lever rightwards: right slewing, co Lever leftwards: left slewing, BOTH THE LEVERS have four releases, © First pressure: movement at the micro speed. © Second pressure: movement at the slow speed. © Third pressure: movement at the middle speed. o_Fourth pressure: movement at the fast speed, 1) Key switch (left side): in the position I enables the remote control, in position © disables the remote 2) Signalling LED: fieshes slowly when the battery is charged; flashes faster when the battery is half= ‘charged; flashes faster and the alarm rings when the charge is draining away. 3) Green START push-button (left side): operate the alarm (when needed to signal the manoeuvres). 4) Disabled. 5) Disabled. 6) RED PUSH-BUTTON: Actuating it, the power supply to the equipment is disconnected and all motors instantly stopped. AN WARNING! » ‘The red push-button on the centre of the wireless control board is an EMERGENCY STOP. If Gepressed, the power supply to the equipment is disconnected and all motors instantly stopped. ACTUATE IMMEDIATELY IN AN EMERGENCY SITUATION. ~ 03. ELECTRICAL CONNECTIONS - 03-13EN rGrs) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.4. JIB POSITIONS SA2 SELECTOR SWITCH 4.1 The electrical cabinet houses the three-position SA2 selector switch: JIB UNFOLDED (1) ~ JIB FOLDED (2). © By turning the selector switch lever to position 1, the limit switch for jib forward displacement control, situated next to boom tip, is enabled. © By turning the selector switch lever in position 2 enables the position limit switch at the front end of the boom controlling the trolley forward displacement. { WARNING! | » To ensure that the position limit switch controls the trolley forward displacement in all Possible boom configurations, the lever must be moved to the position corresponding to the operating configuration in use. = 4.2 To the purpose, tum the main power switch on the electric cabinet door to position 0, and then tum the key to open the cabinet door. 4.3, Move the SA2 selector switch lever to position 2 or 2, depending on the jib configuration required. 4.4 Close the cabinet door and switch the power on. Turn the key to lock the cabinet door. Depress | START push-button on the control board. Ane * Should the SA2 selector switch not be in the position corresponding to the operating configuration | In use, the limit switch would not control correctly the trolley forward displacement, thus causing the. trolley to crash against the end stoppers, an over-traction on the trolley cable and its possible breakage. 03-14 ~ 03. ELECTRICAL CONNECTIONS -TERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.5. SUMMER — WINTER SA4 SELECTOR SWITCH ‘The electric cabinet is equipped with the two-position SA4 selector switch SUMMER-WINTER, which alternatively enables the electrical connection with a cooling fan or a heating band arranged inside, With the selector switch in SUMMER position, the fan for cabinet cooling is enabled. The cooling fan is automatically started when the main switch on the cabinet door is turned ON, With the selector switch in WINTER position, the resistance heater with the function of heating the binet up in wintertime and preventing the formation of condensation is enabled. The resistance heater is automatically started when the main switch on the cabinet door is turned ON. Os CzEzzaaEA WI brrreeereeeTED A LAN > WARNING! The selector switch must always be positioned according to the season: heating the cabinet in summer and cooling it in winter might seriously prejudice the proper functioning of the equipment, ‘or even damage it. )3. ELECTRICAL CONNECTIONS - 03-15BEIT INTER WATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 03.6. INTEGRATED RADIO CONTROL S:1 The electric cabinet is equipped with radio control integrated inside it; the receiver i marked with the indication RX. £2 When the crane is delivered, the cable contol board connection pug is plugged in socket NL. The cess control board plug CN3 is plugged in the dummy socket CN-FP, situated on the right of ‘he socket CN4. In this configuration, the crane is controlled by cable control based, ite £3 To control the crane by wireless control board, remove the cable control board plug from the Socket GNU: remove the plug CN3 from the dummy socket CNI-FP; plug the plug CHS my whe Seow i Car aeeeecTeea : a (= LI | wx wa FJ {ent Heni-rr|— ont Hons?) NB NB we) aa “aS = Bs] 83 Es] Be PEG B38 mers ses = | Grane controlled by CABLE CONTROL BOARD Grane controlled by WIRELESS CONTROL 6-4 Should the crane not be equipped with integrated radio controls (for Customer's choice), the electric cabinet Is supplied without receiver RX, while the plug CN3 is supplied all the canoe 65 ‘Should the customer require the installation of an outer radio control on a crane ‘supplied without it, the outer radio control equipment must be Plugged in CN4 for connecting the cable remote control board, (continued on tbe net pags) 03-16 ~ 03. ELECTRICAL CONNECTIONS -sex SAN MARCO INTERNATIONAL CRANE SMH 322 - EDITION 02/200 -— 3t i | > The radio control board can be employed only for operating the crane. Crane erection and isassembling must be operated by the cable control board ONLY. ||» ‘The postions and functions of the single push buttons arranged on the radio control board are described in the present manual (paracraph 03.3.3). > For any further information, refer to the employ and maintenance manual, specific for the wireless device, jointed to the technical documentation of the crane. - 03. ELECTRICAL CONNECTIONS - 03-17ISAN MARCO) INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 7a 72 73 03.7. SLEWING SPEED ADJUSTEMENT ‘The variable speed drive controlling the slewing motor is pre-set for each crane model and is controlled and eventually set-up, if required, at the assembly test of each single crane. It is not generally required to proceed with subsequent variable speed drives set-up, unless, due special crane applications, the variation of one or more parameters is needed to modify the standard performance of the equipment. ‘The particular instructions enclosed to the present technical documentation provide all the required information to set the variable speed drives; before each intervention it is recommended to refer to the particular instructions by the manufacturer. In particular, the feeding current must never, and Under no circumstance, exceed the limit value of 50 Hz. [AX = WARNING! ae aq ‘The selected acceleration and deceleration times must always be such so as not to cause oscillations | of the hoisted loads and excessive stress to the structures; the brakes intervention must always be progressive until the crane slows down. Every intervention on the variable speed drive must be carried out only and exclusively by qualified, trained and skilled personnel capable of perfectiy setting the equipment, ‘An incorrect variable speed drive setting may result in its malfunctioning with possible damages to the electrical equipment, excessive stress to the structures with consequent damages, abnormal wear, breakage of the slewing system and finally damages to the hoisting mechanisms. The variable speed drive is equipped with internal capacitors with a discharge time of few minutes. In case of maintenance interventions requiring the removal of the variable speed drive outer casings, before removing the guards and handling the internal components, wait at least five minutes after switching the equipment off, as indicated on the outer casing and in the instruction anual. Failure in operating in the indicated way will cause the risk of electric shocks. 03-18 | = 03. ELECTRICAL CONNECTIONS -ECT) | INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t i j 03.8. HOISTING SPEED ADJUSTEMENT ih 8.1 The variable speed drive controlling the hoisting motor is pre-set for each crane mode! and is Controlled and eventually set-up, if required, at the assembly test of each single crane. HM 82 __ It is not generally required to proceed with subsequent variable speed drives set-up, unless, due iH Special crane applications, the variation of one or more parameters is needed to modify the standard Performance of the equipment. 8.3 The particular instructions enclosed to the present technical documentation provide all the required Information to set the variable speed drives; before each intervention it is recommended to refer to the particular instructions by the manufacturer. In particular, the feeding current must never, and Under no circumstance, exceed the limit value of 50 Hz. 8.4 The hoisting variable speed drive is equipped with the hoisting safety detector (paraaraph 09,3). [AX | WARNING! - ! > The selected acceleration and deceleration times must always be such so as not to cause oscillations | Of the hoisted loads and excessive stress to the structures; the brakes intervention must always be i Progressive until the crane slows down, { y Every intervention on the variable speed drive must be carried out only and exclusively by b | qualified, trained and skilled personnel capable of perfectly setting the equipment. > An incorrect variable speed drive setting may result in its malfunctioning with possible damages to the electrical equipment, excessive stress to the structures with consequent damages, abnormal ‘Wear, breakage of the slewing system and finally damages to the hoisting mechanisms. > The variable speed drive is equipped with internal capacitors with a discharge time of few minutes, In case of maintenance interventions requiring the removal of the variable speed drive outer ‘asings, before removing the guards and handling the internal components, wait at least five minutes after switching the equipment off, as indicated on the outer casing and in the instruction ‘manuel. Fallure in operating in the indicated way will cause the risk of electric shocks, ~ 03. ELECTRICAL CONNECTIONS - 03-19oa 82 93 Berar INTERNATIONA CRANE SMH 322 ~ EDITION 02/200 - 3t 03.9, TROLLEY SPEED ADJUSTEMENT The variable speed drive controlling the trolley motor is pre-set for each crane model and is Controlled and eventually set-up, if required, at the assembly test of each single crane. It is not generally required to proceed with subsequent variable speed drives set-up, unless, due Special crane applications, the variation of one or more parameters is needed to modify the standard performance of the equipment. ‘The particular instructions enclosed to the present technical documentation provide all the required information to set the variable speed drives; before each intervention it is recommended to refer to the particular instructions by the manufecturer, In particular, the feeding current must never, and under no circumstance, exceed the limit value of 50 Hz. 03-20 WARNING! ‘The selected acceleration and deceleration times must always be such so as not to cause oscillations of the hoisted loads and excessive stress to the structures; the brakes intervention must always be progressive until the crane slows down. Every intervention on the variable speed crive must be carried out only and exclusively by qualified, trained and skilled personnel capable of perfectly setting the equipment. An incorrect variable speed drive setting may result in its malfunctioning with possible damages to the electrical equipment, excessive stress to the structures with consequent damages, abnormal Wear, breakage of the slewing system and finally damages to the hoisting mechanisms, ‘The variable speed drive is equipped with internal capacitors with a discharge time of few minutes. In case of maintenance interventions requiring the removal of the variable speed drive outer sings, before removing the guards and handling the internal components, wait at least five minutes after switching the equipment off, as indicated on the outer casing and in the instruction ‘manual. Failure in operating in the indicated way will cause the risk of electric shocks, ~ 03. ELECTRICAL CONNECTIONS -CRANE SMH 322 ~ EDITION 02/200 - 3t 03.10, WIRING DIAGRAMS Wiring diagrams jointed on the following pages. ‘A copy of the wiring diagrams can be found inside the electric cabinet of the crane. ~ 03. ELECTRICAL CONNECTIONS - 03-2104. HYDRAULIC SYSTEM HYDRAULIC DIAGRAM .... ADJUSTMENT OF THE HYDRAULIC SYSTEM MAX. . OVERCENTRE VALVES ADJUSTMENT.. REGULATING THE OIL FLOW (TOWER LOWERING)... - REGULATING THE OIL FLOW (JIB CYLINDER) 04.6. PRELIMINARY OPERATIONS ON HYDRAULIC SYSTEI 04.6.1. CHECKS PRIOR TO CRANE ERECTION 04.6.2. CHECKS BEFORE CRANE DISASSEMBL}BU nary) ___CRANE SMH 322 ~ EDITION 02/200 - 3 INTRODUCTION 4) All crane assembling, disassembly and maintenance operations must be always carried out by skilled, properly trained and qualified operators only, aware of the crane characteristics and familiar with the Contents of the present instruction manuel. 'b) Should the instructions of the present manual not be strictly followed or properly carried out, the ‘manufacturer dectines all responsibilty for any damages occurred to or caused by the eran. ©) During essembly operations, with moving structures, operators and all exposed persons must keep out of the danger zone. Should it be necessary to approach the crane for inspections or adjustments, stop the ‘crane end check that the structural parts are stable and well balanced before operating 4) Only qualified, tained and skilled personnel with the necessary qualifications to operate in total safety ‘and familiar with the content and prescriptions of the present instruction manual are allowed to use the rene. For any information or instruction not available in the present handbook, please immediately contact the Technical Department of the manufacturer. €) With the purpose of maintaining the crane in good operating conditions, the building yard manager will Preserve the present handbook in its integrity in a safe place 2s close as possible to the machinery, easily accessible and known to all operators. Moreover, itis recommended to consult it whenever required, strictly following the instructions contained therein, In case of loss or deterioration, pleese contact the manufacturer for @ second copy of the manual. CRANE MANUFATURER: SAN MARCO INTERNATIONAL s.r. Via Principe Umberto, 42/6 28021 Borgomanero (Novara - Italy) MARK: ce CRANE MODEL: ‘SMH 322 VERSION. TRIVERTER 444 CRANE SERIAL NUMBER’ YEAR OF MANUFACTURE: Agee | ATTENTION: This crane is sold and delvered in an English-speaking Country and the User Manual is therefore written in English. The crane may be subsequently installed in or re-sold to ancther EU Country, It this is the cese, the re-seller or the contractor must request a further copy to SAN MARCO INTERNATIONAL uly tansiated into the official language of the country in which the crane will be employed. ~ 01. DESCRIPTION -INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 ~ 3t 04.1, HYDRAULIC DIAGRAM z 3 TANK 40 L ‘SUCTION FILTER PUMP 3,2 cm’ JOINT i ELECTRIC MOTOR 2,2 kW 4 POLES 1 (CHECK VALVE RELIEF VALVE ‘SOLENOID VALVE LC1-A2-48 VOLTS FLOW RATE VALVE 10 ‘OVERCENTRE VALVES ON HYDRAULIC CYLINDERS: a1 (OIL LEVEL INDICATOR 12 MANOMETER MGR 400 13 OIL FILL-IN PLUG 10) 00) onfun] soo no] DESCRIPTION SUANTTE 1 1 1 1 1 1 2 1 3 1 1 1 = 04. HYDRAULIC SYSTEM - 04-1SAN MARCO, INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 04.2, ADJUSTMENT OF THE HYDRAULIC SYSTEM MAX. PRESSURE 21 The crane hydraulic system has been designed and sized for max. ‘operating pressures of 280 bar. 2.2. Should the system pressure gauge indicate a service pressure other than the ‘machine setting, the pressure can be regulated by operating on the adjusting screw situated at the base of the station motor. 23 To proceed with pressure adjustment of the pump, go through he following steps: A PoNes adlustment must be caried out with the crane at stand stl (the hydraulic station can be on, but the hydraulic cylinders must be at rest), Tae nEue Proper functioning of the hydraulic station, check for motor lection of rotation, veriying that it corresponds to the sense indicated by the errow an the onthe motors rear air grating, Incorrect setting of the maximum pressure may cause damages to the crane structures, to its hydraulic parts or lead to crane malfunctioning at its erection stage. Only qualifed, trained and skilled personnel shall perform adjustment interventions. Please bear in ‘mind that the max. set pressure must not exceed 280 bar. gating the hydraulic system at a pressure higher than the limit value of 280 bar might seriously damage the hydraulic or structural components of the crane. Should crane erection or disassembly operations be carried out in hot weather, remove the hydraulic station motor cover to allow for its cooling down, © Femove the protection carter of the hydraulic unit; © remove the cap of the screw; © loosen the lock nut, 10 spanner; : © act with a 5 mm Allen wrench on the socket head screw: loosen the screw to reduce the max. Pressure, tighten the screw to increase the max. pressure; ‘once completed the adjustment, tighten the lock nut, 10 spanner. 10 SPANNER, 5 ALLEN MAX. PRESSURE ADJUSTEMENT SCREW SEIS ALLEN MAX. PRESSURE ADJUSTEMENT SCREW / ‘WARNING! J 04-2 ~ 04, HYDRAULIC SYSTEM -Brat CRANE SMH 322 ~ EDITION 02/200 - 3t TERNATIONAL - 04.3. OVERCENTRE VALVES ADJUSTMENT 3.1 The overcentre valves fitted on the hydraulic cylinders have the function to control the load, to Prevent any uncontrolled movements and to stop them in any position. 3.2 They consist of a maximum pressure valve (41), a pilot system (2) and check valve (3). At the lifting stage, the oil flows freely through the check valve (3); to lower the load the oil is conveyed into the other cylinder chamber and to the pilot system. The piloting pressure generates an Fs force opposing the spring force of Fs, which keeps the cylinder closed (counterforce); the counterforce ‘can be adjusted by acting on the outer socket head screw. 33 For correct system functioning, the maximum pressure valve (1) shall be generally set at a pressure value 20-30% higher than that induced by the maximum load. 34 To set the valve, loosen the lock nut with a size 13 spanner, and then act on the middle screw by ‘means of a size 4 socket head wrench: loosen to decrease the valve opening pressure, and tighten to increase it LN WARNING! ‘= __Valves adjustment must be carried out with the crane at stand still (the hydraulic station can be on, ~ 04. HYDRAULIC SYSTEM - 04-3EAGT) INTERNATIONAL tee, CRANE SMH 322 ~ EDITION 02/200 ~ 3t but the hydraulic cylinders must be at rest), 04-4 - 04, HYDRAULIC SYSTEM -SAN MARCO} INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 04.4, REGULATING THE OIL FLOW (TOWER LOWERING) 4.1 The valve for oil flow adjustment arranged on the support of the pump solenoid valves is fitted on the return pipe of the tower cyiinder and has the purpose to control the cylinder lowering speed. 4.2. The adjusting device is composed of a 38 spanner nut, locked by 2 38 spanner lock nut. 4.3 To regulate, proceed as follows: © remove the protection carter of the hydraulic unit; © loosen the lock nut, turning it for few complete tums and moving it away from the nut; this way, the nut is unlocked; © tum the nut: bring it closer to the lock nut (counter clockwise turn) in order to increase the flux; ove it away from the lock not (clockwise turn) in order to reduce the flux; once reached the required setting, turn the lock nut until Is locked against the nut: ‘AA nee ‘Set the speed of the cylinder so that the movements are harmonious and without counterblows. Valves adjustment must be carried out with the crane at stand still (the hydraulic station can be on, but the hydraulic cylinders must be at rest). ly |® To-ensure proper functioning of the hydraulic station, check for motor direction of rotation, verifying that it corresponds to the sense indicated by the arrow on the on the motor's rear air grating, - 04. HYDRAULIC SYSTEM - 04-5CEG INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 5a 5.2 53 54 04.5. REGULATING THE OIL FLOW (JIB CYLINDER) ‘The adjustment device is controlled by 2 pair of screws, acting respectively on the delivery and the return pipes of the cylinder actuating the first section of the jib. The screws are arranged Uundemeath the support of the corresponding solenoid valves of the pump. ‘One screw controls the delivery side, the other screw controls the return side (side with the tower oil flow valve) To regulate the opening-closing speed of the jib cylinders, loosen the lock nut with a size 19 spanner e and then tighten or loosen with a 5 Allen the socket head screws fitted on the block next to the solenoid valve of the jib cylinders: © tighten the screw acting on the delivery pipe, to decrease the oil flow delivered to the cylinder and, consequently, the opening speed ofthe cylinder; loosen the screvr acting on the delivery pipe, to increase the oil flow delivered to the cylinder ‘and, consequently, the opening speed of the cylinder; © tighten the screw acting on the retum pipe, to decrease the oil flow returning from the cylinder ‘and, consequently, the closing speed of the cylinder; © loosen the screw acting on the return pipe, to increase the oil flow returning from the cylinder and, consequently, the closing speed of the cylinder. After effecting the adjustment, firmly tighten the nuts to lock the screws. DELIVERY IN | IN hssemes Set the speed of the cylinder so that the movements are harmonious and without counterbiows. = 04, HYDRAULIC SYSTEM ~Cars) INTERNATIONAL 04.6. PRELIMINARY OPERATIONS ON HYDRAULIC SYSTEM 04.6.1. CHECKS PRIOR TO CRANE ERECTION Prior to crane erection or disassembling, it is necessary, especially if the hydraulic system of the crane has been idle for a long time, to make sure there is no air or water inside it. The presence of air inside the system may be due to slight leakages from the check valves, or after eventual maintenance interventions effected to the system. CRANE SMH 322 ~ EDITION 02/200 ~ 3t Firstly, check for oil level inside the unit and make sure there is no water inside. ates [> The presence of water or air inside the station or the hydraulic system may lead to crane Uncontrolled movements, which might result in damages to the structures or in the risk of crane overturning. ‘Turn the selector switch SA1 (paragraph. 03.3) to position 2 (controlling the tower and the jib), then depress START push-button on the control board to start the hydraulic unit. 54 After few seconds of functioning of the hydraulic unit, actuate few little movements of jb unfolding and folding, acting on the FAR and NEAR push-buttons, raising the jib about 10-45° from its transport position, in order to fill up with oll the cylinder chambers. Further, actuate few little movements of tower erection and lowering, acting on the UP and DOWN | ush-buttons, raising the tower about 4-5° from its transport position, in order to fill up with oil the - gflinder chambers. Meanwhile, make sure of the service pressure inside the hydraulic unit: check the readings of the __essure gauge and inspect that the movements are regular. \ [waRwanct CLP ee Fallure in carrying out all the recommended checks on the hydraulic equipment before and during Grane erection and disassembly may result in its faulty or non-operation, thus causing uncontrolled movernents of the crane structures and possible damages or breakages to the crane. : ~ 04. HYDRAULIC SYSTEM - 04-7s BAITS INTERNATIONAL CRANE SMH 322 ~ EDITION 02/200 - 3t 67 68 04.6.2. CHECKS BEFORE CRANE DISASSEMBLY Prior to crane erection or disassembling, it is necessary, especially if the hydraulic system of the crane has been idle for a long time, to make sure there sno air or water inside it. The presence of air inside the system may be due to slight leakages from the check valves, or after eventual ‘maintenance interventions effected to the system. Firstly, check for oil level inside the unit and make sure there is no water inside. 69 6.10 611 6.12 (A ie ‘The presence of water or alr inside the station or the hydraulic system may lead to crane Uncontrolled movements, which might result in damages to the structures or in the risk of crane overturning. ‘Turn the selector switch SA1 (parearaph.03.3) to position 2 (controlling the tower and the jib), then depress START push-button on the control board to start the hydraulic unit. After few seconds of functioning of the hydraulic unit, actuate few little movements of jib folding ‘and unfolding, acting on the NEAR and FAR push-buttons, raising the jib about 10° from its unfolded position, in order to fill up with oil the cylinders chambers. Proceeding with crane disassembly, after jib complete folding and with the jib resting onto the boom tie rod, actuate few little movements of tower lowering and erection, acting on the DOWN and UP ush-buttons, lowering the tower about 4-5° from its vertical position, in order to fill up with oil the cylinder chambers, ‘Meanwhile, make sure of the service pressure inside the hydraulic unit: check the readings of the pressure gauge and inspect that the movements are regular. | wanwumct Failure in carrying out all the recommended checks on the hydraulic equipment before and during crane erection and disassembly may result in its faulty or non-operation, thus causing uncontrolled ‘movernents of the crane structures and possible damages or breakages to the crane, - 04, HYDRAULIC SYSTEM -05. BALLAST 05.1. BALLAST BLOCKS, 05.1.1, TOTAL BALLAST 05.1.2, ASSEMBLY BALLAST 05.1.3, OPERATING BALLAST .ISAN MARCO} INTERNATIONAL af CRANE SMH 322 ~ EDITION 02/200 ~ 3t 05.1. BALLAST BLOCKS 05.1.1. TOTAL BALLAST 1.1 The ballast, ensuring stability to the crane, consists of cement blocks and is composed as follows: 13 14 EE g BLOCK TYPE | BLOCK WEIGHT (QUANTITY, “TOTAL WEIGTH 400/1 D (right) 1850 kg 1 _ 1850 kg 40/3 S (left) 1850 kg 1 1850 kg ey [3520/2 D (right) 1000-kg 1 1000 kg 320/2 5 (left) 1000 ka 1 1000 kg TOTAL ASSEMBLY BALLAST 5700 kg ‘OPERATING 400/3 “1300 ii 14300 kg BALLAST TOTAL OPERATING BALLAST 14300 kg “TOTAL BALLAST. 20000 kg 12 If not delivered by the crane manufacturer along with the machine, the blocks must be built ‘according to the drawings supplied and strictly meet the specified dimensions, reinforcements and weights. In particular, consider that all the ballast blocks are in HIGH DENSITY CEMENT 3300 kg/m* (see following drawings). Never install any block on he crane when transporting it. The assembly ballast should be installed on ‘the base-frame before crane levelling and erection. The assembly ballast blocks must be lifted ‘and positioned by means of a suitable lifting means. With the only assembly ballast installed, the crane is stable in windless conditions, without load, and With the jib folded at those stages in which the tower Is erected. After erecting the tower and before Unfolding the jib, immediately fit the remaining ballast blocks. = 05. BALLAST - 05-1