CRANE OPERATOR’S MANUAL

FOR
12 UNITS OF ERTGs
FOR APM TERMINALS AT CALLAO, PERU

(ZP12-1934)

Shanghai Zhenhua Heavy Industries Co., Ltd.

June 3, 2014
 Crane Operator’s Manual

Safety Symbol Legend

Indicates a procedure, practice, condition,

or statement that, if not strictly observed,
could result in personal injury or death.

Indicates a procedure, practice, condition,

or statement that, if not strictly observed,
could result in damage to or destruction
of equipment.

Indicates an essential or important

procedure, practice, condition, or statement.

We reserve all rights in this document and in the information contained herein.
Reproduction, use of disclosure to third party without express authority is strictly
forbidden. (C) ZPMC, Shanghai Zhenhua Port Machinery Co., LTD.
 Crane Operator’s Manual

Table of Content
1.  About This Manual ............................................................................................................................. 1 

2.  Operating Rules.................................................................................................................................. 2 

2.1  General Rules .............................................................................................................................. 2 

2.2  Safety Information and Safety Related Crane Functions ............................................................ 3 

2.2.1  Personal Safety ......................................................................................................................................3 

2.2.2  Housekeeping.........................................................................................................................................5 

2.2.3  Crane stowage .......................................................................................................................................5 

2.2.4  Wind alarm ............................................................................................................................................5 

2.2.5  Crane overload ......................................................................................................................................6 

2.2.6  Emergency stops ....................................................................................................................................6 

2.2.7  Fire extinguishers ..................................................................................................................................7 

2.2.8  Other safety features..............................................................................................................................7 

2.2.9  Watch for abnormal events and conditions............................................................................................7 

3.  Main Particulars.................................................................................................................................. 8 

3.1  Main Dimensions, Clearance & Performances............................................................................ 8 

3.2  Operating Rated Speeds ............................................................................................................. 9 

4.  Crane Operating Instructions.......................................................................................................... 11 

4.1  Operator’s Cabin........................................................................................................................ 11 

4.2  Definition of Switches, Indicators and Alarms ........................................................................... 12 

4.2.1  Left console devices .............................................................................................................................12 

4.2.2  Right Console Devices .........................................................................................................................17 

4.2.3  RTG & Spreader status Indication Box ...............................................................................................29 

4.2.4  Touch panel .........................................................................................................................................30 

4.3  Starting the Engine .................................................................................................................... 30 

4.4  Put the Crane into Operation ..................................................................................................... 34 

4.4.1  Permission ...........................................................................................................................................34 

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 Crane Operator’s Manual

4.4.2  Control power on.................................................................................................................................34 

4.4.3  Start spreader and headblock ..............................................................................................................34 

4.4.4  Ready for operation .............................................................................................................................34 

4.5  Take the Crane Out of Operation .............................................................................................. 35 

4.6  Main Hoist Operation ................................................................................................................. 35 

4.6.1  Operation from operator’s cabin.........................................................................................................35 

4.6.2  Hoist permissions.................................................................................................................................36 

4.6.3  Speed control .......................................................................................................................................36 

4.6.4  Working limits......................................................................................................................................37 

4.6.5  Over travel back-out ............................................................................................................................37 

4.6.6  Slack rope protection ...........................................................................................................................37 

4.6.7  Hoist overload protection ....................................................................................................................37 

4.6.8  Eccentric load protection.....................................................................................................................37 

4.6.9  Operating mode ...................................................................................................................................38 

4.7  Trolley Travel Operation ............................................................................................................ 38 

4.7.1  Operation from operator’s cabin.........................................................................................................38 

4.7.2  Trolley travel permissions ...................................................................................................................39 

4.7.3  Trolley travel speed .............................................................................................................................39 

4.7.4  Working limits......................................................................................................................................39 

4.7.5  Over travel back-out ............................................................................................................................40 

4.7.6  Loss of trolley home position ...............................................................................................................40 

4.8  Gantry Travel Operation ............................................................................................................ 40 

4.8.1  Operation from operator’s cabin.........................................................................................................40 

4.8.2  Gantry travel permissions....................................................................................................................41 

4.8.3  Gantry travel speed..............................................................................................................................41 

4.8.4  Working limits and anti-collision protections......................................................................................41 

4.8.5  Gantry warning devices .......................................................................................................................42 

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 Crane Operator’s Manual

4.9  Lifting Devices ........................................................................................................................... 42 

4.9.1  Spreader...............................................................................................................................................42 

4.10  Wheel Turning Hydraulic System .............................................................................................. 44 

5.  Auxiliary Functions .......................................................................................................................... 46 

5.1  Lightings..................................................................................................................................... 46 

5.1.1  Floodlights...........................................................................................................................................46 

5.1.2  Walkway lights.....................................................................................................................................47 

5.1.3  Indoor lighting .....................................................................................................................................47 

5.1.4  Emergency lights .................................................................................................................................48 

5.2  Air Conditioning ......................................................................................................................... 48 

5.3  Communication System............................................................................................................. 48 

5.4  Laud speaker and controller system.......................................................................................... 49 

5.5  Horn ........................................................................................................................................... 50 

5.6  Outlets........................................................................................................................................ 50 

6.  Emergency egress program............................................................................................................ 51 

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 Crane Operator’s Manual

1. About This Manual contents be disclosed to any third party

without the written approval of ZPMC.
This manual is compiled in expectation of
your proper and safe operation of twelve 1. This manual is intended to
(12) 41 tons Electrification Rubber Tyred benefit the persons operating the
Gantry cranes that are designed and built
crane. It also provides useful
by Shanghai Zhenhua Heavy Industries
information for the maintenance
Co., Ltd. (ZPMC) for APM Terminal at
Callao, Peru. personnel. But it is not intended
to cover the maintenance
This manual is written for the new requirements of the crane.
operators. For those who are
experienced operators some of the 2. This manual is very important
information presented may serve as a for the other operators, thus
refresher. Even if some features seem
please put this book back to
familiar, there are often subtle differences
original position in the cabin after
between cranes. All operators and
maintenance persons who have reason to your reading!
drive the crane are strongly encouraged
to read these instructions carefully.

This manual covers the daily operation of

the crane, but do not purport to cover all
details or variation in equipment, or to
provide for every possible contingency to
be met during the operation and
maintenance. If further information is
desired or if particular problems arise that
are not covered sufficiently for the
purchaser’s purpose, the matter should be
referred to ZPMC.

This document contains proprietary

information of ZPMC and is furnished to
its customer solely to assist that customer
in the operation and/or maintenance of
the equipment described. ZPMC retains
all intellectual property and other rights in
or to the information contained herein,
and such information may only be used in
connection with the operation of your
cranes. This document shall not be
reproduced in whole or in part nor shall its
1

2. Operating Rules
2.1 General Rules
The crane operator is asked to follow the
rules and practices of an accomplished
and safe operator for efficient container
handling.
(1) Avoid abrupt and sudden movements
of a master switch when commanding
a motion. Do not attempt to
decelerate the drive by quickly
reversing direction of the master
switch.
(2) Hoist up slowly until rope slack is
removed.
(3) When engaging a container, center
the gantry and trolley directly over the
load. Do not swing the spreader to
reach a container which is not
centered under the trolley.
(4) These cranes are not designed to pull
loads sideways in either the trolley or
gantry travel direction. Keep the
hoist rope falls vertical between the
trolley and head block.
(5) Keep ground personnel away so no
one is under the lifting spreader.
Make certain that people on the
ground are aware when you are
engaging a load and planning to move
it.
(6) Do not lift loads which you know
exceed the capacity of the lifting
device or crane. When loads are
connected to a lifting spreader or
cargo beam using slings, chains, or
ropes etc., do not lift the load if you
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Crane Operator’s Manual
know that the safe working load of
these attachments if being exceeded.
(7) If you know that you are lifting a heavy
load, one that is near crane capacity,
slowly lift the load a few centimeters
and return the hoist master switch to
off position. The hoist brakes will set.
Make certain that the load holds and
does not slip through the brakes,
before moving the load.
(8) Always make sure that the load is
lifted high enough to clear personnel
and any other obstruction on the
ground, before moving it.
(9) Never leave your chair in the
operator’s cabin with a load
suspended from the crane, and the
crane control power on. If you need
to leave your chair, then discharge the
load, or at least place it on the ground.
In an emergency, if you must leave
the crane with a suspended load, then
raise the load so it is not free to swing,
and turn control power off, so hoist
motion is stopped and all brakes are
set.
(10) When you wish to normally stop a
motion, main hoist, trolley, or gantry
travel, do so by returning the master
switch or pushbutton to the off
position. This will produce a normal
smooth stop. Please do not depress
an emergency stop pushbutton or turn
control power off which will produce a
sudden fast stop. This is neither
comfortable for you, nor is it good for
the crane.
(11) If you lose electrical power,
please return all controllers and
switches to the off position, and leave
 Crane Operator’s Manual

them there until control power is manual may cause death or

re-established.
(12) Do not attempt to alter or make
repairs to any devices or parts
(electrical, mechanical, or hydraulic),
which are a part of the crane. It is
dangerous to do so. Always call
maintenance personnel who are
trained to make repairs.
serious injury to personnel
associated with the operation
of this crane.
2.2 Safety Information and Safety
Related Crane Functions

(13) Do not disable any warning or
safety devices on the crane. If you
believe that there is a problem, always
ask maintenance personnel to fix the
problem at hand.
(14) If you see an OUT OF ORDER or
DO NOT OPERATE placard or sign
anywhere on the crane, do not
remove it.
(15) Maintain a log of important
happenings during your shift on the
crane. Share the information with
the next crane operator who will
replace you, so he knows what he
needs to watch for. Share the
information with crane maintenance
so they are alert to any problems
requiring immediate attention, and
know about problems which can be
addressed during normal crane
maintenance.
Personal safety and the safety of the
crane(s) is a responsibility we cannot over
emphasize. It is a responsibility and
accountability which each of us must
embrace. Because this is a big crane
and it is powerful, we need to be alert at
all times when we are on this crane or
around it. We need to be even more
aware of safety when we operate this
crane.
2.2.1 Personal Safety
(1) You should wear a hard hat at all
times except when you are seated
inside the cabin. You should also
wear steel toed safety shoes.
(2) While seated in the operator’s cabin,
please wear a seat belt. It is easy to
fasten and easy to adjust.

Any person intending to The operator’s chair is

operate this crane must be provided with safety belt.
qualified personnel and The use of seat belts reduces
become fully familiar with all the chance of injuries in case
of the requirements and of an accident.
concepts contained within this
Crane operators must wear
manual. Failure to comply
safety belt at all time when
with instructions in this

3

operating the crane.
(3) Safety procedures require persons on
the ground and near the crane to stay
out of your trolley travel path, so that
there is never a person under a
hoisted container. Always be alert
and operate the crane defensively. If
you spot anyone in the path of your
trolley travel, please stop. Use the
horn/speaker system to instruct the
person(s) to move out of the trolley
path.
(4) When lifting a container off a road
chassis, make the lift slowly at first to
ensure that ground personnel have
completely and successfully unlocked
the container from the chassis.
Once you have confirmed that the
container is clear off the chassis you
can increase your hoist speed. If
you realize that the twistlocks on the
chassis are not fully unlocked, and
you are in fact lifting the rear wheels
of the tractor along with lifting the
container, please stop and reverse
the hoist motion to gently set the rear
wheels of the tractor and container
back down. Such commendable
defensive driving on your part can
help avoid a serious accident and
avoid potential injury to a tractor
driver.
(5) ZPMC strongly discourages smoking
in enclosed spaces on the crane.
This includes the operator’s cabin,
electrical house, engine house, and
so on. Smoking or open flames are
discouraged around equipment which
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Crane Operator’s Manual
house sensitive electrical components,
greases, or oils.
(6) If you encounter a fire and it is small,
use a fire extinguisher near you to put
the fire out. Notify ground personnel
and maintenance personnel at once.
Do not operate the crane, until the
cause of the fire is determined and
any necessary corrective action is
taken. There are fire extinguishers
located throughout the crane. A
listing of the fire extinguishers and
their locations is included in section
2.2.7.
(7) In the event of a fire which you can
not put out with a fire extinguisher,
attend to your own safety first.
Leave the scene of the fire and find a
safe place on the crane or off it.
Notify others of the problem so timely
action can be taken to counter the fire,
thus minimizing potential of injury to
persons and damage to the crane.
(8) If you are in the operator’s cabin and
there is a fire, drive the trolley to the
trolley parking position, if you consider
it safe to do so. Notify others and
leave. If you believe that you do not
have enough time to drive to the
parking position, and then you need
exit the crane following the
emergency egress program, see
section 6.
(9) If the crane loses power, or the trolley
function becomes inoperative, the
method of egress from the operator
cabin is the same as described above.
It does not matter where the trolley is
positioned along the runway.

(10) In the event you have any
symptoms of a heart attack, stroke,
seizure or otherwise become ill while
operating the crane, please take
defensive and prudent actions for you
own health and well being. Use the
radio or intercom system in the
operator’s cabin to call ground
personnel and anyone on the crane
for help. Do not take any
unnecessary risks. Drive yourself to
the trolley park position only if you feel
well enough to do so.
2.2.2 Housekeeping
The cranes have been provided with
grating walking surfaces. Many of these
walking surfaces are open weave and
more than 20 meters high at the cabin.
An object which falls from such height to
the ground below can cause serious injury
or even death if it strikes a person on the
ground. It is everyone’s duty and
responsibility to pick up any object or
debris found on the crane to avoid
accidents.
2.2.3 Crane stowage
When these cranes are not in operation
and are being left un-attended for some
hours or days, they must be stowed.
This is a safety requirement. Stowing a
crane need to move gantry to the next
available stowage pin pocket.
If you are in the operator’s cabin you will
need assistance from a trained person on
the ground to complete the stowage
process. The ground person, using
intercom or radio communication, needs
to guide you so the crane is centered over
5
Crane Operator’s Manual
the pin pockets. Then tight the stowage
rope on the crane to pockets in the wharf.
It is important for the crane operator or the
maintenance personnel to stow each
crane on the dock when the cranes are
left unattended.
If not stowed, there is danger
that in the event of a high
wind condition, the cranes
could roll down the runway in
spite of the gantry brakes.
Once in motion, a crane can
develop momentum and strike
next crane or other obstacle
and cause serious damage.
2.2.4 Wind alarm
Each crane is equipped with an wind
sensor and through PLC program to
indicate wind speed and to provide
warnings to the operator.
(1) High wind warning
The first one indicates an operating wind
warning. It is designed to give an
acoustic and visual warning when wind
speed reaches 20 m/s. This is a warning
that the crane operator should prepare to
gantry and stow the crane. However, to
accomplish this stowage you need to alert
ground personnel. Since winds can
sometimes pick up quickly in an on
coming storm, it is in the interest of your
safety to react to the warning.
(2) High wind shutdown
The second set point indicates the limit of
wind alarm and it is set at 25 m/s. The
 Crane Operator’s Manual

crane is not designed to operate in wind shown on it. Always reset the E-stop
speeds exceeding 25 m/s. All crane unless it is intentionally latched out.
motion is not allowed at this point. Otherwise control power cannot be
re-established.
Realize that a 20 m/s wind is a strong
wind and 25 m/s is a very strong wind.
For your own safety we suggest that you
have the trolley parked, and Inform
maintenance personnel to have the trolley
and gantry stowed well before you
encounter 25 m/s wind speeds, and then
come off the crane.

2.2.5 Crane overload

These cranes are designed to handle

commercial loads up to 41 tons under
spreader when handling single container.
The crane operator is requested not to Fig. 2-1 E-stop
knowingly lift loads which are more than
The emergency stops are located on the
allowable.
crane as follows:
When overload occurs, an alarm will be
 One on consoles in the
given to the operator to signal the
operator’s cabin
overload. Only lowering the load at slow
speed is allowed in this case.  Two in the electrical room
 Two at engine room side
Details see section 4.6.7.
 Two at electrical room side
2.2.6 Emergency stops
 One at left girder
Emergency stop pushbuttons (E-stops)  Two at trolley platform
are provided at locations throughout the
 One at trolley panel
crane. Pressing any one of these
pushbuttons, will disconnect control
power, stop all motions and set all brakes.
The crane has a separate
In the case of an emergency, please
press an E-stop adjacent to you. power feed for some auxiliary
devices, such as lightings,
The E-stops are maintained contact air-conditioners, convenient
meaning once depressed they will open
outlets, ventilation fans, and
the circuit, and it will remain open until it is
so on. Depressing the E-stop
reset. To reset it, you need to press and
turn it in the direction of the arrow as will not de-energize the power

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 Crane Operator’s Manual

supply to these devices. Electrical protection is provided for the

gantry moving. There is slowdown and
stop protection for gantry to gantry
collision, slowdown and stop protection for
2.2.7 Fire extinguishers gantry to truck, and stop protection for
gantry to container collision. But anyway
 ZPMC will provide temporary fire
you must take care when the gantry is
extinguishers, as appropriate, for
close to next crane or truck.
use during commissioning,
testing and crane acceptance. The main hoist is also provided with
The owner will provide his own slowdown and stop limit switches at the
extinguishers after the cranes upper and lower extremities of travel.
are accepted. Again, please ensure that you bring these
motions to a stop before reaching end of
travel. The hoist does not have bumpers
at the extreme upper and lower travel
position.

2.2.9 Watch for abnormal events and

conditions
Fig. 2-2 Fire Extinguisher
As an accomplished operator you will get
to know your crane, how it feels and how
Never risk your life to fight a the machinery sounds. In time, with
fire. Use caution. practice and experience, we expect that
you will master the crane and gain a
sense of when it is functioning properly
2.2.8 Other safety features and when it is not.

The crane is equipped with bumpers and Become watchful for unusual sounds,
limit switches to prevent collisions or over abnormal vibrations, slack wire ropes,
travel. slack electrical cable, abnormal
movements of the energy chain cable
Bumpers and electrical protection are
system, or other unusual events. Stop
provided for the trolley. Bumper stops
the crane and ask maintenance personnel
are located at the end of trolley runways.
to check and correct the problem.
Both slow down check and stop switches
are provided along the trolley runways so
that the trolley is stopped before it
contacts the bumper stops. In spite of
the bumpers and limit switches, please
use the master switch controller to stop
motion before reaching end of travel.

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 Crane Operator’s Manual

3. Main Particulars

3.1 Main Dimensions, Clearance & Performances

(1) Type of crane Electrification Rubber Tyred Gantry Crane

(2) Rated load

Single container under 41Tons

spreader

(3) Spreader type 20’ 40’ 45’ single spreader

(4) Span (gantry rail gage) 29.066 m

(5) Trolley traverse

Total length of trolley travel 20.8 m

(6) Lift

Total 21.0 m

(7) Overall height of crane Approx. 29.45 m

(8) Main power supply 480V, 3 Phase, 60 Hz

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 Crane Operator’s Manual

3.2 Operating Rated Speeds

(1) Main hoist speed

Hoisting speed with 41 Ton load 22 m/min

Lowering speed with 41 Ton load 22 m/min

Hoisting speed with empty spreader 50 m/min

Lowering speed with empty spreader 50 m/min

(2) Trolley speed 70 m/min

(3) Gantry travel speed

Gantry travel speed with 41 Ton load 30 m/min

Gantry travel speed with empty spreader 135 m/min

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 Crane Operator’s Manual

Figure 3-1 General Arrangement

10

4. Crane Operating Instructions
4.1 Operator’s Cabin
The operator’s cabin is purposefully and
ergonomically designed to serve the
crane operator. Attention was focused
on providing comfort and convenience so
you can concentrate on the serious task of
handling containers, and not be distracted
or encumbered by uncomfortable
surroundings.
The console features a comfortable chair.
There is a manual seat adjustment that
allows the seat to be moved forward of
afterward in relation to the consoles. An
adjustable seat belt and shoulder harness
are for your safety and should be used at
all times when operating the crane.
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Crane Operator’s Manual
All master switches, indicating lights,
selector switches, joy-sticks, and other
control devices have been conveniently
arranged on the left and right consoles,
side panel, and auxiliary panel on the wall.
so you can access any of them without
leaving your chair. The spreader
indicating box is in front of the cabin for
easy observing.
The left and right windows can be opened
for fresh air, and have rolling up sun
shades.
The operator’s cabin is also provided with
air conditioner, lighting, intercom etc.,
please refer to Fig. 4-1.
 Crane Operator’s Manual

Fig. 4-1 Operator’s Cabin Arrangement

4.2 Definition of Switches, Indicators and Alarms

4.2.1 Left console devices

The devices on the left control console are defined as below.

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 Crane Operator’s Manual

Fig. 4-2 Left Console

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 Crane Operator’s Manual

Fig. 4-3 Left Console

1. Master Switch: Trolley forward/backward & Gantry left/Gantry right

This master switch is used for multiple functions depending on crane

conditions as below.

The deflection of the handle initiates the load to move into the direction
matching the handle movement.

A motion can be started under the following main conditions:

 The control must be switched on

 No fault is switching off the inverter involved
 No interlock is locking the inverter involved

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 Crane Operator’s Manual

If the master switch is deflected to one direction then the motion speed will
increase according to the drive’s ramp limited up to the reference matching
the deflection position of the handle. This reference speed is continuously
adjustable from zero up to the maximum speed level currently permitted.
This means that if the drive is free, the speed can be preset from zero to
rated speed. While if there is a limitation to lower speed, the full of range of
the master switch is rated to this lower speed level.

If the master switch is brought to the opposite direction, the speed will be
electrically reduced to zero first before starting into the other direction.
During this period the brake remains opened all the time.

If the master switch is brought back to its zero position, the speed will also
be reduced electrically first until nearly zero before the brakes are applied
for smooth stopping.

There are 2 small push buttons (item 10, 11) on top of the master switch for
spare.

2. Green Illumination Push Button: Skew home position

Push this button will activate the spreader rotate to the home position.
When the spreader is at home position, this green indicator lamp will light.

3. White Illumination Push Button: GPS steering active

When the steering is selected in automation mode, if pushing this buttons

for 3 seconds, the auto steering is controlled by GPS system; or, the auto
steering will controlled by AECT system when crane is powered by AECT
system and will controlled by GPS system when crane is only powered by
engine generator set.

When the auto steering is controlled by the GPS system, this indicator is
on.

4. White Illumination Push Button: Laser steering active

When the steering is selected in automation mode, if pushing this buttons

for 3 seconds, the auto steering is controlled by AECT (Automatic
Electricity Connection System) system; or, the auto steering will
controlled by AECT system when crane is powered by AECT system and
will controlled by GPS system when crane is only powered by engine
generator set.

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 Crane Operator’s Manual

When the auto steering is controlled by the GPS system, this indicator is
on.

5. 3 Pos. selector switch: Steering Spare/Manual/Auto

When the steering is selected in automation mode, the auto steering will
controlled by AECT system when crane is powered by AECT system and
will controlled by GPS system when crane is only powered by engine
generator set.

When the steering is selected in manual mode, the steering will be

controlled by operator himself.

When the steering is selected in spare mode, the steering will be controlled
by operator himself.

6. 2 Pos. selector switch: TSS enable OFF/ON

There is a laser guided stack profiling system in the crane. It is used to

avoid the hanged container hitting to the stack container when trolley is
moving. The laser guided stack profiling system can be selected of or on by
this 2 position selector switch.

7. Buzzer: Fault buzzer

The buzzer is used to indicate multiple conditions as follows:

 If an equipment fault or interlock occurs while Control on

 If an overload condition occurs
 If the crane is at the position of AECT extend or retract zone, the buzzer
will be on at a different frequency.
8. Microphone

This microphone is use to call or warning the ground person nearby.

9. Foot step switch: Horn

When the operator begin to move trolley, hoist or gantry, he must alarm the
personnel near around by push this foot step switch, the horn outside the
operator cabin will sound.

10. 4 position joystick switch: Forward/Black/Left/Right

This joystick is used to control the headblock to do the micro moving.

11. 2 position joystick switch: Twin extend/retract

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 Crane Operator’s Manual

When the spreader is in twin mode, this joystick is used to control the
spreader extend or retract.

12. Spare

13. Spare

14. 2 way key switch: TSS bypass

There is a laser guided stack profiling system is RTG. It is used to avoid the
hanged container hitting to the stack container when trolley is moving. The
laser guided stack profiling system can be bypassed by this 2 way key
switch.

15. Buzzer: Fault alarm

The buzzer is used to indicate multiple conditions as follows:

 If an equipment fault or interlock occurs while Control on

 If an overload condition occurs

4.2.2 Right Console Devices

The devices on the 错误！未找到引用源。 (错误！未找到引用源。4) are defined as below.

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 Crane Operator’s Manual

Fig. 4-4 Right Console

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 Crane Operator’s Manual

Fig. 4-5 Right Console

1. Master Switch: Hoist down/Hoist up/Skew left/ Skew right

This master switch is used for multiple functions depending on crane

conditions as below.

When the master switch is moved at forward or backward direction, then it

is used to control the hoist at down or up direction. The deflection of the
handle initiates the load to move into the direction matching the handle
movement.

A motion can be started under the following main conditions:

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 Crane Operator’s Manual

 The control must be switched on

 No fault is switching off the inverter involved
 No interlock is locking the inverter involved
If the master switch is deflected to one direction then the motion speed will
increase according to the inverter’s ramp limit up to the reference matching
the deflection position of the handle. This reference speed is continuously
adjustable from zero up to the maximum speed level currently permitted.
This means that if the inverter is free, the speed can be pre-set from zero to
rated speed while if there is a limitation to lower speed, the full range of the
master switch is rated to the lower speed level.

If the master switch is brought to the opposite direction, the speed will be
electrically reduced to zero first before starting into the other direction.
During this period the brake remains opened all the time.

If the master switch is brought back to its zero position, the speed will be
reduced electrically first until nearly zero before the brakes are applied for
smooth stopping.

There are 2 small push buttons (item 9, 10) on the top of the master switch
for spare.

When the master switch is moved at left or right direction, then it is used to
control the spreader for skew function at CCW or CW direction. The
maximum angle of skew is 5 degree. The headblock pump shall be run
before head for the skew function.

2. Thumb button at Master switch: Twistlocks lock(red)/unlock(black)

When the spreader is landed and the spreader function is OK, then these
two thumb buttons can be used to control the spreader twistlocks lock or
unlock.

3. White indicator: Crane switch On

When the RTG is switched on and ready for control, this indictor will be on.

4. 2 Pos. key switch: Crane switch Off/On

This 2 way key switch is used to switch on or off the main power to
inverters. Only when the RTG is in switch on status can the operator
control the RTG. When the control system is switch off, RTG can not be
operated.

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 Crane Operator’s Manual

Switching on the main supply for inverters with this key switch is possible
only under the following conditions:

 No any E-Stop push button is pressed

 No any E-Stop limit switch is active or it has been bypassed
5. 2 position Joystick: Steering Far side/Near side

This 2-Pos joystick can be used for manual steering of the crane gantry.
Steering of the crane is done by putting different speed levels to the
inverter which drives different side gantry motors.

The crane will turn to counter-clockwise direction when the gantry running
to left with gantry steering “Near side” and will turn to clockwise direction
when the gantry running to right with gantry steering “Near side”.

The crane will turn to clockwise direction when the gantry running to left
with gantry steering “Far side” and will turn to counter-clockwise direction
when the gantry running to right with gantry steering “Far side”.

6. Mushroom Head Push Button: Emergency stop

This mushroom head type push button should be pressed at once

whenever an abnormal condition in crane operation is found.

Pressing this button effects an immediately shutdown of the crane function,

i.e.

 All motion are stopped mechanically

 Control is switched off and locked until being switched on again.
To release the emergency stop push button turn its head clockwise until it
lifts by spring force.

7. Red Illumination Push Button: Fault reset

When there is fault occurred, the red indicator will light. If this fault is
removable, press this push button will reset the control system. If this fault
can not be removed after press this push button, the operator shall inform
the maintenance personnel to solve this fault.

8. Foot step switch: Telecom

This foot step switch is to control the microphone of the intercom on or off.

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 Crane Operator’s Manual

Fig. 4-6 Side control station

1. Green Illumination Push Button: Headblock pump ON/OFF

This push button is used to control the headblock pump and spreader
3-phase power contactor on or off, if the headblock pump and spreader
3-phase power contactor are on, then the green indicator is on. The
headblock pump and spreader 3-phase power contactor must be on before
head for the skew function and spreader function..

2. 3-Pos. selector switch: Maintenance/Spreader/Cargo

When this switch is in AUX, position, the push button Diesel start and
Diesel stop is used to control the auxiliary diesel.

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 Crane Operator’s Manual

3. Black push button: Spreader Bypass

This black push button is used to bypass such situation:

 spreader landed signal;

 twistlocks locked signal;
 twistlocks unlocked signal;
 headblock connected signal;
 spreader mode, maintenance mode, cargo mode;

4. Green Illumination Push Button: Spreader 20FT

This push button is used to retract the spreader to 20 feet position. If the
spreader is in 20 feet position, the green indicator will be on.

5. Green Illumination Push Button: Spreader 40FT

This push button is used to retract the spreader to 40 feet position. If the
spreader is in 40 feet position, the green indicator will be on.

6. Green Illumination Push Button: Spreader 45FT

This push button is used to retract the spreader to 45 feet position. If the
spreader is in 45 feet position, the green indicator will be on.

7. Black push button: Overdrive Bypass

This black push button is used to bypass such situation:

 hoist over travel limit switch;

 trolley over travel limit switch;
 gantry to obstacle anti collision sensor; gantry to gantry anti collision
system; gantry to container anti collision limit switch (but in this
situation, the gantry can only move to the counter direction not move to
the same direction);
 high wind alarm;
 when the spreader is not in home position, the trolley is not permitted
enter the slow down area, but used this bypass, the trolley can enter the
slow down area.
 trolley over load interlock;

8. White push button: Lamp test

This white push button is used to test all the indicators and buzzer inside
operator cabin except those for diesel generator set.

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Fig. 4-7 Auxiliary panel

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 Crane Operator’s Manual

Fig. 4-8 Auxiliary panel

1. Red Indicator: Half fuel level

When the fuel tank level is under half, this red indicator will on as for alarm.

2. Red Indicator: Empty fuel

When the fuel tank level is almost empty, this red indicator will on and the
engine will shut down after 10 seconds delay. The delay time can be set in
the engine control panel.

3. Red Indicator: D-G set fault

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 Crane Operator’s Manual

When there is any fault in diesel or generator, this indicator will be on and
diesel engine will shut down.

4. 3-Pos. selector switch: Diesel(manual) Off/0/On

When the engine controller on the engine control panel is selected in

maintenance mode, this selector switch can be used to control the engine
start or stop.

5. 2-Pos. selector switch: Diesel(seamless) Off/On

When the engine controller on the engine control panel is selected in

automation mode, this selector switch can be used to control the engine
start or stop.

6. Green indicator: Diesel power on

When the crane is powered from diesel engine, this indicator will be on.

7. Green indicator: Diesel engine running

When the diesel engine is running, this indicator will be on.

8. White indicator: Spare

This is a spare indicator.

9. 2-Pos. selector switch: City power Off/On

When the electricity connecting trolley is connected to the city power rail,
and the engine controller is selected in automation mode, operator can turn
this 2- Pos. selector switch to “On” position to feed the city power to crane.
After the city power is fed to the crane, it is recommended to shut down the
diesel engine for save the fuel.

10. Green indicator: City power on

When the crane is powered from city power, this indicator will be on.

11. 3-Pos. selector switch: Spare

This is a spare selector switch.

12. 3-Pos. selector switch: Collect trolley Retract/Extend

There is a reflector board on the city power conduct bar. When the crane
moves to the position that the detecting laser is on the front of the reflector
board and the distance from laser to the reflector board is between

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 Crane Operator’s Manual

1050mm to 1550mm, the buzzer in the cabin will buzz in a different

frequency, then operator can use this 3-Pos. selector switch to control the
collect trolley extend to connect the conduct bar. After the collect trolley is
connected to the conduct bar, the operator shall move the crane to the
power change area. When the crane is in power change area, then the
operator can change over the feeding power from engine to the city power
with the 2-Pos. selector switch: City power Off/On. The collect trolley is
automatically retract when the crane move outside of the laser reflect
board. For seamless changeover the power, before moves the crane
outside the city power conduct bar area, the diesel generator set need to
be in running and power to the crane before head.

Fig. 4-9 City power collect trolley

13. White Indicator: City power change area

There are some limit switches installed on the city power bar for the crane
to judge the position. When the crane PLC judges the collector trolley is in
the city power change area, this indicator is light.

14. White Indicator: City power bar connect area

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 Crane Operator’s Manual

There are some limit switches installed on the city power bar for the crane
to judge the position. When the crane PLC judges the collector trolley is in
the city power bar connected area, this indicator is light.

15. White Indicator: Collector trolley retracted

When the collector trolley is retracted, this indicator is light.

16. White Indicator: Collector trolley extended

When the collector trolley is extended and up, this indicator is light.

17. Green Indicator: Wheel 0°POS.

When all the wheels are in 0°position, this indicator is light.

18. Green Indicator: Wheel 90°POS.

When all the wheels are in 90°position, this indicator is light.

19. Green Indicator: Wheel 16°POS.

When all the wheel are in 16°position, this indicator is light. Then the
crane can rotate.

20. Green Indicator: Wheel park POS.

When the 1#, 3#wheel are in 0°position and 2#,4# wheels are in 90°
position, this indicator is light. The crane shall be in this position when it is
not in operation for long time.

21. Black push button: Girder flood lights

This black push button is used to control the floodlights except gantry
floodlights on or off.

22. Black push button: Gantry flood lights

This black push button is used to control the gantry floodlights on or off.

23. Black push button: Walkway lights

This push button can be used to switch on or off all walkway lights in RTG.

24. 2-Pos. selector switch: Defogger OFF/ON

This selector is used to control the cabin defogger on or off.

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25. Green Indicator: Trolley stowed.

In the middle of each girder, there is a stow pit for trolley anchorage. When
the trolley is stowed, this indicator is light.

26. White Indicator: Spare

This indicator is spare.

27. 2-Pos. selector switch: Spare

This selector is spare.

4.2.3 RTG & Spreader status Indication Box

Fig. 4-10 RTG & Spreader Status Indication Box

Fig. 4-11 RTG & Spreader Status Indication Box

This box provides elementary information about the RTG and spreader status
with regard to twistlock movements. It is placed near the cabin ground level
located inside the operator’s view even while he is basically watching the load.

All indication elements of this box will be described below according to their
label.

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 Crane Operator’s Manual

1. Green Indicator: Unlocked

The green indicator will light if all twistlocks are unlocked.

2. White Indicator: Landed

This yellow indicator will light if all land pins of the spreader are pressed in by
the container surface on which the spreader is properly resting and the hoist
rope slack.

This is the basic precondition for any twistlock movement.

3. Red Indicator: Locked

This red indicator will light if all twistlocks are locked.

4. Green Indicator: Headblock connected

The green indicator will light if the headblock twistlocks are connected to the
spreader.

5. Green Indicator: Spreader connected

The green indicator will light if the spreader cable is connected from headblock
to the spreader.

6. Red Indicator: Overload

An overload condition will be detected if the load under the spreader or cargo
beam exceeds 110% of rated load. When overload occurs, this indicator will
be light as an alarm.

7. Red Indicator: High wind

There is a wind sensor on the trolley platform to detect the wind speed and
input to PLC, when the wind speed is more than the setting date in PLC, this
indicator will be light as an alarm.

4.2.4 Touch panel

There is a touch panel in the cabin. This touch panel is used to showing the
crane operating or alarm status to operator.

4.3 Starting the Engine

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 Crane Operator’s Manual

Fig. 4-12 Engine control panel

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 Crane Operator’s Manual

Fig. 4-13 Engine controller

Fig. 4-14 Battery isolator

Fig. 4-15 Battery

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 Crane Operator’s Manual

Before starting the diesel engine,
checking the diesel lubricant oil and
coolant to ensure no any problem exists
with current operation. Switch on the
battery isolator and then check the battery
voltage from the Gen-set controller on
engine control panel.
If the lubricant oil and the
coolant level is low,
maintenance staff should be
called to refill the lubricant oil or
coolant. If the battery voltage is
lower than 24V, maintenance
staff should be also called to
check and recharge the battery.
Engine can be controlled in this Gen-set
control Panel.
from full speed to idle speed for 2 minutes,
then engine will automatically stop.
After the diesel is running stably in speed
1800rpm, the operator shall check if the
indicate of the generator voltage and
frequency are 480VAC, 60Hz (the
operator can check the diesel speed and
voltage from the Gen-set controller
“InteliGen” display). If the diesel is running
in a working speed stably but the output
voltage and the frequency are not right,
maintenance staff should be called to
adjust the diesel-generator set. If the
indicates are OK, switching on the main
power switch. The GCB ON/OFF button
on the bottom line of the controller
“InteliGen” shall be pressed for the engine
power contactor is energized and connect
the engine power to crane.

First, the “POWER OFF/ON” key selector After finishing doing these steps, operator
switch shall be put to ON position, the shall retract the engine room inside
engine controller “InteliGen” is powered. platform, or the gantry can not move by
Then this engine controller “InteliGen” can the interlock of the inside platform limit
control the engine start or stop. switch. Then operator can go upstairs to
the cabin to continue his work.
There are four modes in the controller
“InteliGen”: STOP, MANUAL, AUTO,
TEST. Please note: the seamless
changeover between city power and
engine power can only when the mode is
selected in AUTO mode.

When select MANUAL, the green button

“start” and red button “stop” on the right
side of controller panel is used to start or
stop the engine. Press the start button will
start the engine running in idle speed for 2
minutes, then engine will automatically
running in full speed 1800 RPM. Press the
stop button will decelerate the engine
Fig. 4-16 Engine platform limit switch

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When select AUTO, the engine is
controlled by the selector switch on
auxiliary panel in cabin, please see item 5:
Diesel (seamless) Off/On. Put this
selector switch at ON will start the engine
running in idle speed for 2 minutes, then
engine will automatically running in full
speed 1800 RPM. Put this selector switch
at OFF will decelerate the engine from full
speed to idle speed for 2 minutes, then
engine will automatically stop.
If the above procedure can not
carry out, maintenance staff
should be called to check the
diesel-generator set and their
control panel.
Normally, the operator can leave
the main power switch at ON
position.
After finished all the jobs in the
engine room, the operator
should fold the engine side
platform to home position. To
fold the side platform, the rope
drum can be used.
4.4 Put the Crane into Operation
4.4.1 Permission
A number of permissions are required to
be present before the crane control can
be started.
(1) Make sure all emergency stop
pushbuttons are released.
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Crane Operator’s Manual
(2) All emergency safety limits and
switches must be in their normal state
(un-actuated). This includes over
speed switches (hoist over speed
switch) and over travel limit switches
(trolley forward over travel, trolley
reverse over travel), not any BYPASS
activated.
(3) There are no faults or warnings
presented.
Before operating the crane,
crane stowage pins on the
nearside and farside gantry
need to be released.
4.4.2 Control power on
After entry into operator’s cabin and sit in
the chair, following action shall be taken to
turn on the control power.
(1) Put the key selector switch "Crane
switch ON/OFF" on the right console
to ON position.
(2) The white indicator "Crane switch on"
will light up.
4.4.3 Start spreader and headblock
Switch on spreader 3-phase power supply
and running headblock pump by pressing
the green illuminated pushbutton
“Headblock pump ON/OFF” on the right
control console vertical penal. After the
green light is lit up, the spreader and
headblock are ready for operation.
4.4.4 Ready for operation
 Crane Operator’s Manual

After the two indicator lights “Crane switch

on” and “Headblock pump on” are lit up,
the crane is ready for operation.

You can check that all the

indicating lights are in good
working order by pressing the
“Lamp test” pushbutton on right
control console vertical panel.

4.5 Take the Crane Out of Operation

Fig. 4-17 Hoist motor
When the crane operation is complete,
following procedures shall be followed to Main hoist can be operated from the
take the crane out of operation. operator’s cabin.

(1) Put the load on the ground and 4.6.1 Operation from operator’s cabin
release it from the spreader.
When the crane control power is switched
(2) Raise the spreader to a position on from the operator’s cabin, the speed of
around 15 meters above ground and the main hoist corresponds to the master
retract the spreader to the 20’ switch on the right console. This master
position. switch is used for main hoist directions
(3) Move trolley to parking position, which and speed reference, forward to lower the
align with the operator’s cabin access load and reverse to raise the load. The
gate. master switch will spring return to center
position when release it. The operator
(4) Stow the crane properly, details
may stop the motion at any time by
please refer to 2.2.3.
returning the master switch to the center
(5) Turn off the crane control power by position. The main hoist drive will
put the key selector switch “Crane accelerate or decelerate at full capability
switch ON/OFF” on the right control in order to achieve the speed requested
console to OFF position. by the master switch.
(6) Turn off the floodlights if they are on.
During operation if you
(7) Close the door and windows of the
observe that the spreader
operator’s cabin after getting off.
cable is not spooling
4.6 Main Hoist Operation correctly, please stop
immediately and ask a
maintenance technician for

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 Crane Operator’s Manual

help.  In spreader mode, spreader

3-phase power supply is not on
and/or electrical cable not
connected.
4.6.2 Hoist permissions
 Hoist up stop and up
The hoist permission logic enables the end-of-travel position reached.
hoist to run in either direction as  Hoist overload, eccentric
commanded by the operator. The overload.
absence of a run permission will not allow
the hoist to start.

All hoist run permissions must be satisfied

before the hoist is permitted to operate in
either direction. Following are some
typical reasons prevent hoist operation:

 Control power is not on, or not

reset from the operator’s cabin.
 Operator is not in seat.
 Overload fault, or eccentric load Fig. 4-18 Hoist cam limit switch
fault.
Hoist down permission must be satisfied
before the hoist is permitted to operate in
the down direction. Following are some
typical reasons prevent hoist down
operation:

 Main hoist slack rope condition

detected.
 Spreader landed on the
container.
 Hoist down stop reached. Fig. 4-19 Hoist over travel limit switch
Hoist up permission must be satisfied
4.6.3 Speed control
before the hoist is permitted to operate in
the up direction. Following are some The main hoist speed is set manually
typical reasons prevent hoist up according to the master switch position.
operation:
In addition, the main hoist control system
 Twistlocks not fully locked or fully senses the load conditions in the hoisting
unlocked. circuit. This feature allows the hoist to

36

operate at higher speed when handling
light load, and lower speed when lifting
heavy load.
4.6.4 Working limits
Control system provides smart slowdown
and stop to prevent travel into the end
stops. At the end stops, the motion is still
operable in the opposite direction. The
automatic smart slowdown feature will
minimize the low speed travel distance
near the end stops, and increase the
overall performance of the hoist,
especially when utilizing the full hoisting
height.
4.6.5 Over travel back-out
Over travel protection is provided at up
end of main hoist travel path. The over
travel status of the hoist is detected by
hoist over travel limit switch and will
disable the main motion and set the
brakes. To back out an over travel
condition, the following steps shall be
taken.
(1) The operator must press and hold the
“Overdrive bypass” red push button
on the right control console vertical
panel.
(2) Reset the control power from the
operator’s cabin.
(3) Lower the spreader to back out the
over travel condition. In this progress,
the main hoist speed is limited.
(4) Stop hoist motion and release the
“Overdrive bypass” red button.
4.6.6 Slack rope protection
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Crane Operator’s Manual
Main hoist is equipped with a slack rope
limiting device which senses rope tension
and prevent the main hoist from paying
out wire ropes when the hoist ropes go
slack.
In the hoisting direction the device limits
the hoisting speed to approximately 20%
rated base speed until the weight of load
is fully supported by the hoist wire ropes.
Always pay attention to the
wire ropes. Do not rely on
the slack rope protection only.
While ropes go slack, hoist up
slowly and make sure the
ropes not being hooked by
any obstruction.
4.6.7 Hoist overload protection
A load weighing system is provided for
main hoist, which detects the load weight
under spreader. The load weight is
displayed on the touch panel in cabin.
An overload condition will be detected if
the load under the spreader or cargo
beam exceeds 110% of rated load. An
indicator “Overload” mounted on the
spreader status indication box in the front
bottom position of operator.
A hoist overload condition will disable all
motions, and only lowering at slow speed
is allowed.
The main hoist resets to normal speed
once the overload condition removed.
4.6.8 Eccentric load protection
 Crane Operator’s Manual

An eccentric load condition will be

detected by the load weighing system if a
non-symmetrical load is suspended under
the spreader.

A hoist eccentric load condition will

disable all motions, and only lowering at
slow speed is allowed.

4.6.9 Operating mode

The hoist is designed to operate in

maintenance, spreader and cargo modes.
These modes are selected by the
3-position selector switch on right control
console vertical panel.

maintenance mode
When spreader is removed from the
headblock, operator can select
maintenance mode to hoist the headblock.
The spreader cable should be insert the
dummy socket on headblock before head.
The hoist speed is limited in maintenance
mode.
Spreader mode
Spreader mode is the normal mode of
RTG operation. When this mode is
selected, all spreader functions are
enabled.
See section 4.9.1 for spreader operation.
Cargo mode
When operator wants to lift other cargo
but not container, he can select cargo
mode to do it.
4.7 Trolley Travel Operation
Fig. 4-20 Trolley motor
Trolley travel can be operated from the
operator’s cabin.
4.7.1 Operation from operator’s cabin
When the crane control power is switched
on from the operator’s cabin, the speed of
trolley travel corresponds to the master
switch on the left console. This master
switch is used for trolley travel directions
and speed reference, forward to move
trolley to farside and reverse to move
trolley to nearside. The master switch
will spring return to center position when
release it. The operator may stop the
motion at any time by returning the master
switch to the center position. Trolley
drive will accelerate or decelerate at full
capability in order to achieve the speed
requested by the master switch.

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4.7.2 Trolley travel permissions

The trolley travel permission logic enables

the trolley to run in either direction as
commanded by the operator. The
absence of a run permission will not allow
the trolley travel to start.

All trolley run permissions must be

satisfied before the trolley is permitted to
operate in either direction. Following are
some typical reasons prevent trolley travel
operation:

 Control power is not on, or not Fig. 4-22 Cabin gate limit switch
reset from the operator’s cabin.
 Operator is not in seat.
 Trolley travel forward or reverse
end-of-travel reached.
 Trolley is anchored.
 Trolley access gate is not
properly closed.
 Cabin gate is not properly
closed.

Fig. 4-23 Trolley anchor limit switch

4.7.3 Trolley travel speed

The trolley travel speed is set manually

according to the master switch position.

4.7.4 Working limits

Control system provides smart slowdown

and stop to prevent travel into the end
stops. At the end stops, the motion is still
operable in the opposite direction. The
Fig. 4-21 Trolley end limit switch automatic smart slowdown feature will

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 Crane Operator’s Manual

minimize the low speed travel distance 4.8 Gantry Travel Operation
near the end stops, and increase the
overall performance of the trolley.

4.7.5 Over travel back-out

Over travel limit switches are provided at

both ends of trolley travel path. The
operation of any over travel limit switches
will disable the trolley motion and set the
brakes. To back out an over travel
condition, the following steps shall be
taken.

(1) The operator must press and hold the

“Overdrive bypass” red push button
Figure 4-24 Gantry motor
on the right control console vertical
panel. Gantry travel can be operated from
(2) Reset the control power from the operator’s cabin.
operator’s cabin.
4.8.1 Operation from operator’s cabin
(3) Drive the trolley in the opposite
direction and back out the over travel When the crane control power is switched
condition. In this condition, the trolley on from the operator’s cabin, the speed of
speed is limited. gantry corresponds to the master switch
on the right console. This master switch is
(4) Stop trolley motion and release the
used for gantry directions and speed
“Overdrive bypass” red button.
reference, left throwing to move gantry to
left and right throwing to move gantry to
right. The master switch will spring
4.7.6 Loss of trolley home position return to center position when release it.
The operator may stop the motion at any
Trolley travel has position limits
time by returning the master switch to the
programmed into the control system. On
center position. Gantry drive will
certain occasions, such as a power failure,
accelerate or decelerate at full capability
the control system may lose the position
in order to achieve the speed requested
limits. Under this condition, the drive is
by the master switch.
still fully safety interlocked and limited to
slowdown speed. When this occurs, it is
necessary to restore the programmed
position limits by traveling across the
home switch (also used as slow down
check switch).

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Before gantry traveling, it

Figure 4-25 Crane to crane anti
collision sensor
must be sure that the spreader
is located at such a high
position that there is no risk of
collision.

4.8.2 Gantry travel permissions

The gantry travel permission logic enables

the gantry to run in either direction as
commanded by the operator. The
absence of a run permission will not allow Figure 4-26 Gantry to container anti
the gantry to start. collision limit switch

All gantry run permissions must be

satisfied before the gantry is permitted to
operate in either direction. Following are
some typical reasons prevent gantry
travel operation:

 Control power is not switched on,

or not reset from the operator’s
cabin.
 Operator is not in seat.
 Gantry collision condition is
detected.
Figure 4-27 Gantry to obstacle anti
collision sensor

4.8.3 Gantry travel speed

When operation from the operator’s cabin,

the gantry travel speed is set manually
according to the master switch position.

4.8.4 Working limits and anti-collision

protections

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 Crane Operator’s Manual

The crane is provided with anti-collision gantry motion is running. These devices
systems to prevent collision to container, will be automatically actuated whenever
obstacle or to other crane. the gantry is traveling.

In the case of crane to crane collision the

system shall first put the crane into
reduced speed condition and then final
stop. Traveling in the opposite direction
is still allowed.

In the case of crane to obastacle collision

the system shall first put the crane into
reduced speed condition and then final
stop. Traveling in the opposite direction
is still allowed.

In the case of container to crane collision,

crane shall automatically come to an
emergency stop.

To back out of container to crane collision

condition, the operator must: Figure 4-28 Gantry warning device

(1) The operator must press and hold the

Always check gantry track in
“Overdrive bypass” red push button
case there is people or object.
on the right control console vertical
panel. DO NOT rely on the gantry
warning devices only.
(2) Reset control power, and
(3) Run the gantry in the opposite
4.9 Lifting Devices
direction.
4.9.1 Spreader
The drive will run in the opposite
direction at slow speed until the A telescopic spreader is provided for the
over travel limit resets and the crane. The spreader is capable of
key switch is returned to the handling single 20’, 40’, and 45’
containers.
normal position.

The spreader is fitted with lifting lugs.

4.8.5 Gantry warning devices When appropriate slings are attached, the
lugs can be used for handling badly
Warning lights and warning sound devices damaged containers or non-
are provided at four gantry corners to containerized cargo.
warn personnel around the crane that the

42

Fig. 4-29 Headblock and spreader
(1) 3-phase power supply
This spreader is an electrical type
spreader, Not any hydraulic power unit in
spreader.
Under normal operating conditions, the
spreader 3-phase power supply can be
switched on or off by the operator using
the pushbuttons “Headblock pump
ON/OFF” provided on the right control
console vertical panel in operator’s cabin.
Indicating lights indicate when the
3-phase power supply is provided. All
spreader functions are disabled when this
3-phase power supply is switch off.
(2) Telescoping
The spreader can telescope or retract by
using 3 illuminated push buttons:
Spreader 20ft, Spreader 40ft, Spreader
45ft on right control console vertical panel,
so that the twistlocks can mate with corner
castings of a 20’, 40’ or 45’ container.
The related green Indicators: Spreader
20ft, Spreader 40ft, Spreader 45ft will light
when the spreader is in the corresponding
position.
The following conditions must be met to
extend or retract the spreader to the
desired position:
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Crane Operator’s Manual
 3-phase power supply is
switched on,
 Spreader is not landed,
 Twistlocks are not locked,
When telescoping the
spreader, you must exercise
caution to ensure that there
are no persons or other
obstructions in the way.
(3) Twistlocks operation
Twistlocks are supplied at each corner of
the spreader and at each corner of the
center housing for latching and unlatching
onto containers. The twistlocks are
controlled by means of a 2 postion joystick
“Twistlocks lock/unlock” on the right
control console. To prevent accidental
release of the container during lifting, the
spreader must be landed before the
twistlocks are permitted to change.
Interlocks will prevent hoist operation until
all four twistlocks are either fully locked or
fully unlocked.
The status of twistlocks and landing pins
is indicated on the spreader status
indication box, which is in the front of the
operator’s cabin, see section 4.2.3.
It is unsafe for an operator to unlock the
twistlocks when there is a suspended load
under the spreader.
(4) Skew
The crane features a provision to change
the angle of the spreader. This is a
feature provided to accommodate
container handling when containers are
not level to the crane.
 Crane Operator’s Manual

This motion will rotate the spreader or manual control panels are used
container either clockwise or for maintenance use only, there
counterclockwise. only exist interlocks of wheel

The skew function is controlled by the
master switch: Skew left/Skew right on
right control console. The motion will stop
when operator release the master switch.
Green Illumination Push Button: Spreader
home position on the right control console
will re-center the spreader and bring it to
its home position. The lamp lights to
indicate that the spreader is in home
position.
lockpins unlock for wheel turning
manually, the operation should
be attended by two maintenance
staff in the same time. One is
operator and the other should be
the observer.
The operation of these two panels are the
same, please refer to the following for the
operation procedure.

4.10 Wheel Turning Hydraulic System

The control mode of wheel turning can be

set to at site or in cabin by the 2 position
switch: Wheel turn mode (Manual/Auto) in
electrical room control station.

If the control mode of wheel turning is set

to Auto, the wheel turning procedure will
be carried out automatically. The operator
can use the 4 green Illumination Push
Buttons: Wheels 0 Deg. position,
Wheels 90 Deg. position, Wheels 16 Deg.
position，Wheels park position to carry out
this function. The related indicator will
show the wheel turning status.
Fig. 4-30 Wheel turning hydraulic
If the control mode of wheel turning is set station
to Manual, the wheel turning procedure
will be carried out manually by the 2 wheel
turning control panel located in each side
of crane.

Only maintenance staff is

allowed to use these two manual
control panels. Since these two

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 Crane Operator’s Manual

Fig. 4-31 Wheel turning limit switches

Fig. 4-32 Wheel turning control station

1&2

Turn the wheels from 0° position to 90°

position:

CONTROL SWITCH ON  WHEEL

TURN MANUAL  WHEEL TURNING
PUMP ON  LOCKPINS UNLOCK 
(wheel lockpins unlocked)  1#/2# (or

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 Crane Operator’s Manual

3#/4#) WHEELS 90° (wheels turn to

90°) WHEEL LOCKPINS LOCK 
(wheel lockpins locked)  WHEEL Turn the wheels from 0° position to PARK
TURNING PUMP OFF position:

Turn the wheels from 90° position to 0° CONTROL SWTICH ON  WHEEL

position:
CONTROL SWITCH ON  WHEEL TURN
MAMUAL  WHEEL TURNING PUMP
ON  LOCKPINS UNLOCK  (wheel
lockpins unlocked)  1#/2# (or 3#/4#)
WHEELS 0° (wheels turn to 0°)
WHEEL LOCKPINS LOCK  (wheel
lockpins locked)  WHEEL TURNING
PUMP OFF
Turn the wheels from 0° position to 16°
position:
CONTROL SWITCH ON  WHEEL
TURN MANUAL  WHEEL TURNING
PUMP ON  LOCKPINS UNLOCK 
(wheel lockpins unlocked) 
LOCATEPINS LOCK  (wheel locate
pins locked)  1#/2# (or 3#/4#) WHEELS
90° (wheels turn to 16°) WHEEL
LOCKPINS LOCK  (wheel lockpins
locked)  WHEEL TURNING PUMP OFF
TURN MANUAL  WHEEL TURNING
PUMP ON  LOCKPINS UNLOCK 
(wheel lockpins unlocked)  2#, 4#
WHEELS 90° (2#, 4# wheels turn to
90°) WHEEL LOCKPINS LOCK 
(wheel lockpins locked)  WHEEL
TURNING PUMP OFF
5. Auxiliary Functions
5.1 Lightings
The crane is equipped with several types
of lights installed on the crane.
5.1.1 Floodlights
Floodlights are 200-watt fixtures mounted
on the gantry, girder, trolley platform, and
the cabin platform. Controls of the
floodlights are located at electrical room
side and in auxiliary control panel in cabin.

Turn the wheels from 16° position to 0°

position:

CONTROL SWITCH ON  WHEEL

TURN MANUAL  WHEEL TURNING
PUMP ON  LOCKPINS UNLOCK 
(wheel lockpins unlocked)  1#/2# (or
3#/4#) WHEELS 0° (wheels turn to
0°) LOCATEPINS UNLOCK  (wheel
locate pins unlocked) WHEEL

LOCKPINS LOCK  (wheel lockpins

locked)  WHEEL TURNING PUMP OFF Fig. 5-1 Floodlight

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 Crane Operator’s Manual

The whole indoor lighting including:

electrical room lights, engine room lights,
and cabin lights.

The switches control the electrical room

lights and cabin light are installed on the
wall. The switch for the engine room lights
is on the side of the engine control panel.
Fig. 5-2 Floodlight buttons

5.1.2 Walkway lights

There is a series of fluorescent lights

along the stairs, walkways and platforms.
Walkway lights are controlled by buttons
located at electrical room side, trolley
platform and in auxiliary control panel in
Fig. 5-5 Indoor light switch
cabin.
There are 2 spot lights on the cabin roof to
light the control console. The control
switch for these spot lights is a dimmer
switch on the wall.

Fig. 5-3 Walk way light

Fig. 5-6 Spot light

Fig. 5-4 Walk way light button

5.1.3 Indoor lighting

Fig. 5-6 Spot light dimmer

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 Crane Operator’s Manual

5.1.4 Emergency lights

Portable emergency lights are provided in

the electrical room and operator’s cabin to
allow personnel to exist these rooms at
night in the event of electrical power
failure.

Fig. 5-9 Air conditioner indoor unit

Fig. 5-8 Emergency light

5.2 Air Conditioning

There totally 4 air conditioners supplied Fig. 5-10 Air conditioner outdoor unit
with the crane. 3 of them are installed in
the electrical room. 2 air conditioners in 5.3 Communication System
electrical room can start to work
To permit internal communication,
automatically after power on while the
intercom stations (telephones) are
other one is as spare. The forth one is
provided on the crane at following
installed in the operator cabin. It can be
locations: operator’s cabin, electrical room,
controlled by the operator manually. The
each side under sill beam, outside engine
remote controller is located on the wall.
room and trolley platform.
The temperature can be set according to
the willing of operator.

Experience has shown that it is not

recommendable to cool the inside
temperature to more than 5°C below the
external temperature otherwise there is a
risk of the driver catching cold.

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 Crane Operator’s Manual

Fig. 5-11 Telephone and speaker

Fig. 5-12 Telephone & laud speaker
5.4 Laud speaker and controller controller
system

There is a laud speaker and controller

system in crane, which including: one laud
speaker on the outside of cabin, one
controller on the wall of operator cabin,
one microphone on right control console,
and one foot step switch at left side.
Operator can use this system to alarm or
call the personnel near around the crane.

Fig. 5-13 Laud speaker and horn

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 Crane Operator’s Manual

Fig. 5-15 Single phase service outlet

Electrical room side: 1(400VAC,16A),

2(230VAC, 16A)
Fig. 5-14 Foot step switch
Engine room side: 1(400VAC,16A),
5.5 Horn 2(230VAC, 16A)

There is a horn on the outside of cabin. Girder: 1(400VAC,16A), 2(230VAC,

The foot step switch on left side inside 16A)
cabin is used to control this horn.
Operator can alarm the personnel near
around the crane through this horn.

See Fig 5-13 and Fig 5-14

5.6 Outlets

There are several service outlets installed

for maintenance and daily work use.

Electrical room： 2(230VAC, 16A)

Engine room: 1(230VAC, 16A)

Trolley platform: 1(230VAC, 16A) Fig. 5-16 Service outlet box

Cabin: 2(230VAC, 16A) There are also some outlets for

emergency lights, and radio.

50

6. Emergency egress program
In the event of an emergency, safe egress
from the operator’s cabin is possible,
anywhere along the trolley runway.
The operator in the cabin needs to reach
the top of the trolley by climbing onto the
cabin roof using the fixed ladder
positioned at the cabin landing adjacent to
the door. From the trolley, the operator
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Crane Operator’s Manual
can climb through or over the hand rails to
reach girder walkway.
(1) From the platform of operator’s cabin,
through the ladder attached near the
outside cabin, to the top of trolley
platform.
(2) From the trolley platform, across the
handrail, to the normal walkway
Fig. 6-1 emergency egress program
Operating Instructions
For
 12 UNITS OF ERTGs

FOR APM TERMINALS AT CALLAO,

PERU

____________________________________
________________________________

Shanghai Zhenhua Heavy Industries

Co., Ltd.

___________________________________
_________________________________

3261 Dongfang Raod, Shanghai,

P.R.China

Tel: 86-21-58396666

Fax: 86-21-58399555

http://www.zpmc.com