~~ 24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Table of Contents 1 2. 24 22 23 24 25 26 3. 3.1 3.2 3.3 4, 4a 42 43 44 45 46 4.6.1 47 48 “4.9 5. 54 5.11 BAZ 513 5.14 524 522 5.23 61 614 6.1.2 6.1.3 6.1.4 6.21 6.2.2 6.2.3 6.24 6.2.5 6.2.6 6.27 How to Use this Manual.. General Notes Preface General Safety Instructions. Hints on Saving Energy Description of the Crane Technical Data. Lifting Capacity Chart. General Drawing with Dimensions Start-up General Drawing with Check Locations Requirements for Travel Operation Requirements for Crane Operation Generator / Mains Changeover Switch Main Battery Switch .. Starting / Stopping the Diesel Engin Log-in. Crane Master Switch ON / OFF. Maintenance / Inspection Switch Visumatic Symbols Travel Operation.. Conditions for Travel Operation ‘Superstructure / Chassis Locking for Travel Operation Radius for Travel Operation Operating the Stabisers for Travel Operation from the Tower Cab Operating the Stabilsers for Travel Operation from the Driver's Cab. Travelling ..... Steering Braking Crane Operation... Conditions for Crane Operation Automatic Propping for Crane Operation... Levelling the Crane .. Manual Propping for Crane Operation Superstructure / Chassis Locking for Crane Operation . Slewing Hoisting / Loweri Luffing in / Luffing out. Boom Cable Reel Safe Load Indicator: Wind Load Table .. Parking the Crane Safe!24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Table of Contents 63 6.3.2 6.3.3 634 635 6.3.6 6.37 638 6.3.9 6.3.10 63.11 6.3.14 iz TA 72 73 74 75 76 77 78 79 7M 7A2 7A3 TA4 TAS 7.16 TAT 718 7.19 7.20 721 7.22 8. 8.2 8.24 8.3 84 85 8.6 9. 11. Lifting Gear . ‘Attaching the Hook Rotator. Rotator Hook Rotating / Fixed / Freewheeling .. ‘Attaching the Automatic Spreader Telescoping the Automatic Spreader to Container Size . ‘Automatic Spreader Centre of Gravity Compensation ‘Automatic Spreader Flippers UP / DOWN.. Locking / Unlocking Automatic Spreader Twistiocks Picking Up / Setting Down Containers with the Automatic Spreader. ‘Attaching the Grat Opening / Closing the Gral Setting Down the Lifting Gear Safely.. General Operating Functions 90 the Tower Cab Windscreen. Emergency Stop Buttons .. Earth Fault Warnin Tower Cab Seat Adjustment Fault Messages.. Locking System. Work Monitor. Driver's Cab Seat Adjust men Selecting Language / Setting the Time. Fault Statistics. Production Statistics ‘Smoke Detector System Lightning Protection Emergency Descent Device. Slewing Gear Speed... Limit Switch Preset General Diagrams Diagram of Tower Cab Control Panels Diagram of Tower Cab Operating Panel ‘Superstructure Diagram Chassis Diagram Diagram of Diesel Engine Room Control Box Diagram of Machinery Room Control Box Remote Control Final DisposalG HMK 4406 Mobile Harbour Crane Operating Manual How to Use this Manual 1. ‘This Operating Manual is the first part of the User's Manual for the harbour crane you have purchased. There are two possibilities for finding the information you require. 4. tfyou are unfamiliar with the crane and wish to familiarise yourself in 1 ‘yh all the controls, you should refer to the sections in the order in which they are listed in the Table of Contents. You will then be introduced if 2 eystematic manner to all the safety instructions, the checks required before daily start-up, and the individual operating steps. it must be noted that the section numbering may not be continuous; certain sections may not be included in the manual ifthe features they describe are not present in your crane. The section number in the grey bar at the top of each page is also given in the Table of Contents and in the diagrams in section 8 at the end of the manual. 2. Ifyou are familiar with the crane and wish to find out about a particular procedure, turn to the index or Table of Contents. Then refer to the page. FF section indicated in this manual to find the information or operating function you require. (On each page in these sections, the location of the control is indicated by a red arrow in the diagram. Each operating description is preceded by the A necessary safety instructions for the operations described. The safety instructions are highlighted with the attention symbol shown adjacent. . ‘Adjacent to many of the operating descriptions, you will see symbols that correspond to those beside the joystick or button in question. The serial number of your crane is shown in the bottom left comer of each page. Thus, you can either start at the beginning and work your way through the manual, or - after consulting the Table of Contents - go straight to those sections of the manual that contain the specific information you seek. Se Ten Mag Harbour Crane parang Section Diagram 24 1704 0024 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Preface 24 The documentation supplied with your crane comprises the following books, which will either be delivered with the crane or sent to Gottwald Port ‘Technology's local representative or direct to you. User's Manual Part | (Operating Manual), User's Manual Part I! (Maintenance Manual); manual for the diesel engine, manuals for the generator and the drive motors of the hoist, slewing gear and hydraulic pump, manual for lifting gear, manuals — depending on the crane model — for the control components, PLC S7, software and printer, spare parts catalogue and electrical drawings. Please note that, in the case of a legal dispute, only the official German version of this document / manual / contract shall apply. Translations are intended for information purposes only. Correct usage and regular maintenance in accordance with the manuals are prerequisites for trouble-free operation of the crane. The manuals must therefore be available to the operating and maintenance personnel at all times. This is especially important as incorrect usage and irregular maintenance can result in major consequential damage not covered by the warranty. You should therefore read this Operating Manual carefully before starting the crane, and always follow the instructions in each section. However, correct usage and maintenance of the crane are imperative not only for reasons of cost-effectiveness but also for safety reasons. Only if the crane is ina perfect technical condition can it be ensured that persons and property will not be injured or damaged. The built-in safety equipment cannot, however, ‘eliminate all risks. If clearly visible or otherwise evident deviations occur, have the equipment checked. During operation and maintenance, always observe the safety instructions given. By exercising caution and observing the instructions, you can help prevent accidents. As different tasks require different precautionary measures, special safety instructions are given before each operating description. Each set of safety instructions is highlighted with an attention sign. Continued on next page24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Preface 24 When carrying out the maintenance work indicated in this Operating Manual, please refer to the Service Fluids Table in the Maintenance Manual. Please use only the lubricants indicated in the table. Use of unsuitable lubricants and fuels can result in major consequential damage to the crane, which will not be covered by the warranty. You must therefore consult the maintenance manual before carrying out such work. Once you have read "How to Use the Operating Manual’, you should have no difficulty finding the operating instructions you require and performing the operations described. This manual is based on the information available at the time of writing, i.e. when the crane was dispatched from the factory. If any changes, retrofits or modifications are subsequently made that need to be documented here, the operating company must ensure that the manuals are ‘supplemented or adapted. ‘Terex MHPS GmbH Terex Port Solutions Forststrasse 16 40597 Disseldorf Germany24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual General Safety Instructions 2.2 Operating Personnel ‘Acrane is a technically complex machine. Safe, competent operation requires skill and a sense of responsibility on the part of the crane operator. Also, to ‘ensure safe operation, the crane operator must be in a good mental and physical state. In addition, the crane operator must not be under the influence of alcohol or drugs, and he must be at least 18 years old. The operating company must select a crane operator who can be expected to carry out his duties reliably. The crane operator must also + be instructed in the operation or maintenance of the crane and have provided valid qualification of his skills to the operating company In addition, the crane operator must be made familiar with the material in the following manual + *Safe Operation of Cranes in accordance with ISO 12480" “This means that the Accident Prevention Regulations and training requirements applicable in the respective country of operation must be fulfiled. Use for the intended purpose The crane must only be used for lifting loads. The attachment and proper use of all lifting gear not approved by the manufacturer and compliance with national regulations during operation of this ‘equipment is the responsibility of the operator. The information provided by the lifting gear manufacturer must be observed. {tis prohibited to use the crane for any other purpose than that for which it was designed, It is assumed that the working environment of the crane complies with the regulations of your country. You may leave the crane only when itis propped. Please note that, during crane work, the crane must be propped, and the permissible maximum loadings in the various operating situations given in the Technical Data must not be exceeded. The crane may be propped only at the propping base specified in the Technical Data. When operating the stabilisers manually, ensure that the stabiliser beams are evenly and fully extended. Limit switches must not be bypassed. The data given are based on average values of outside temperature, air humidity and dust joad. If the actual values are higher, the maintenance intervals must be reduced to prevent damage to the crane. Transporting persons Conveying persons in or on lifting gear is prohibited. Transport of persons in baskets or work on work platforms is only permitted if the crane is certified for this purpose. Continued on next page24 1704 00 G HMK 5506 Mobile Harbour Crane Operating Manual General Safety Instructions 22 Tandem Lifting The crane is not prepared for tandem lifting operation, i.e. lifting a load with several cranes. For this, adjustments must be made based on country-specific regulations. Use of qualified personnel Maintenance, servicing and repairs may be carried out only by specially trained or instructed personnel. Appropriately qualified personnel are those who due to their technical training, knowledge and experience and their familiarity with the relevant regulations can evaluate the tasks they are given and recognise potential dangers. It must be ensured that the qualified personnel used not only have the requisite technical knowledge but are also familiar with, and can apply, all relevant safety and accident prevention regulations. If the tower has to be set down on the ground for repairs, this is only permitted in the presence of the manufacturer's qualified personnel. unauthorised persons to be in or on the crane during operation, which includes travel operation. When the crane is being operated from the tower cab, controls elsewhere on the crane must not be used. Driving or walking in, flying above and tunnelling below the standing / danger area of the crane are prohibited even when the crane is shut down. The standing / danger area of the crane is the area around the crane enclosed within a circle defined by the boom radius. The standing / danger area of the crane must not overlap any other danger areas. Loads must be lifted vertically, diagonal pull and pulling loads loose are prohibited. N Standing in the slewing range is prohibited. It is likewise prohibited for Hardware and software The hardware installed in the crane is designed exclusively for the control software. No other software may be installed. Furthermore, the drives are to be used only for the installation of the control software. Failure to comply with the above will result in the warranty becoming void. External conditions It must be ensured that the ground under the crane can withstand the propping pressure of the crane. If the crane is to be travelled, the route must be checked beforehand, Please take into consideration clearance widths, heights and the crane weight. Continued on next page24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual General Safety Instructions 2.2 Safety instructions for operation, maintenance and servicing In this Operating Manual, special safety instructions are given before each operating instruction. These instructions are supplementary to - and do not invalidate - the general safety instructions given here. Before work is carried out on the electrical system, ensure that the system is not under power. This means the auxiliary power supply is not connected and the external power supply is switched off. It must be ensured that the diesel engine cannot be started. If the power supply has to be connected for function tests, it is imperative that the entire power supply be disconnected again before the work is continued. The entire hydraulic system is under pressure. In addition, the hydraulic oll becomes hot during operation. Hydraulic oil is flammable and can be ignited by fire, naked lights, sparks and hot lamps. As the crane must be operational for pressure, temperature and leak checks, such checks will involve an increased danger of accidents. The pressures occurring are given in the hydraulic plans. The hydraulic pressures set must not be changed. It is essential that all personnel are appropriately qualified and work extremely carefully. Before other work is started, the hydraulic pump must be switched off. It must be ensured that ‘the pump cannot be switched on by unauthorised persons. Please note that some sections of the system remain pressurised even after it has been shut down. When undoing connections, please note that hydraulic oll could drain out of components above the connections. Therefore, ensure an adequately sized drip pan is positioned appropriately to prevent hydraulic oll escaping and harming the environment. It is important that waste oll from the hydraulic system is disposed of in accordance with local regulations. Special caution is required if maintenance work is to be performed on the diesel engine directly after operation. The engine oll, engine casing, cooling system ‘and exhaust system wil stil be hot. As the crane must be operational for function and leak tests, such tests will involve an increased danger of accidents, as will work on the hydraulic system. When work is being done on the diesel engine system, it must be ensured that the engine cannot be started by unauthorised persons. For all other work, the relevant legislation on safety must be observed. Continued on next pageG HMK 4406 Mobile Harbour Crane Operating Manual Legend for Notices and Warning and Prohibition Signs 23 Danger due to drawing in or coiling Danger of being crushed or struck Danger of falling Flammable materials Suspended load Danger area Danger of being crushed First-aid kit oPPPPPPP Diesel engine emergency off De-energise 24 1704 0024 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual General Safety Instructions Crane inspection book 22 Every non-rail-mounted mobile crane has a crane inspection book. The technical data of the crane in as-delivered condition are entered on the data sheets of the crane inspection book by the crane manufacturer or supplier. If significant changes are made, the data sheets must be amended or supplemented accordingly. The operating company must ensure that the results of the following inspections are entered in the inspection book by an officially appointed crane expert: + before the crane is operated for the first time, + after major modifications are made, + after recurring inspections. The inspection results must indicate: + the scope of the inspection, + information on whether any parts of the inspection still need to be performed, + faults detected, + an evaluation as to whether there is any reason not to perform the next inspection step or to operate the crane, + adecision as to whether reinspection is required. Walking on the crane Only qualified personnel are permitted to walk on the crane and only under the conditions prescribed for qualified personnel. When ascending and descending stairways and ladders, hold onto the handrails with both hands. Ladders must be descended backwards only. If walking on the chassis, stay in the middle and keep away from the edges to prevent falling off. When climbing onto or off the chassis, use only the main access route (beside the chassis driver's cab). The access route via the rear, i.e. at the opposite end of the chassis to the driver's cab, may only be used ‘emergencies, e.g. in the ‘event of an emergency stop resulting from a fault which prevents the chassis and superstructure being aligned and locked in the direction of travel, that is, towards the main access route. it is only permitted to access the crane if the crane driver has consented. The driver must actively give consent BEFORE anyone accesses the crane. It is expressly forbidden to attempt to access the crane before the driver has given his approval. Notifying the crane driver of your wish to access the crane is fot sufficient. A further condition is that the crane is at a complete standstill. It is absolutely forbidden to jump onto or off the crane while it is in motion or working. ‘At the end of the shift, the crane must be left in its secured position to enable personnel to leave and access the crane safely via the main a coess route. The crane driver must also ensure that other people can also access and leave the crane safely.24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Legend for Notices and Warning and Prohibition Signs 2.3 > @2O@P CE ® Fire extinguisher Hang-up sign: do not switch Hazardous voltage No admittance for unauthorised persons Fire, naked lights, sparks, hot lamps and smoking prohibited No admittance for pedestrians Hearing protection to be worn Boom: danger of crushing ‘Smoking prohibited No entry for persons with pacemakers "G HMK 4406 Mobile Harbour Crane Operating Manual Dead Man Circuit (Option) 24 Safety instructions: This crane can optionally be equipped with a dead man circuit. The circuit is an additional safety device designed to prevent accidents in the event that the crane operator loses control over the crane due to reasons of ill health. Operation: The system is designed in such a way that crane operation is stopped if the relevant deadman switch is not pressed. There are two buttons in the crane, one in each of the joysticks for the crane functions in the tower cab. When a crane function is carried out with one of these joysticks, the button in the joystick must always be kept depressed. 24 1704 00 1224 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Description of Slinger Hand Signals Designation Down Up Caution wies- ‘Stop =r — Stop - danger zg Up slowly A\ > Move towards % me 25 Description Move arm in circular motion with hand pointing down Move arm in circular motion with hand pointing up Hold arm extended up with palm of hand facing forwards Extend both arms out horizontally to the side Extend both arms out horizontally to the side and alternately bend and straighten them Extend both arms out horizontally with palms of hands facing down and move them up and down slightly Forearm horizontal with palm of hand facing up; move forearm up and down slightly Beckon with both arms with palms of hands pointing towards body 13G HMK 4406 Mobile Harbour Crane Operating Manual Description of Slinger Hand Signals Designation Drive off Open, release, unlock Close, grasp, lock Indication of position Direction indication Indication of distance to stopping position Down slowly 25 Description ‘Arm extended up with palm of hand facing forwards; move arm from side to side Hold arm extended horizontally to the side with half-open hand pointing down Hold arm extended horizontally to the side with closed hand pointing down Point to destination position with both hands Bend the arm showing the direction of motion and move it from side to side Hold palms of hands facing each other at distance to be indicated Forearm horizontal with palm of hand facing down; move forearm up and down slightly 1424 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Hints on Saving Energy 26 Optimising crane operation Position the crane in the best possible place for the job to reduce the extent of slewing and luffing motions. = Always use the most suitable lifting gear so you do not move heavy weights unnecessarily. = Avoid accelerating and decelerating the drives unnecessarily. = Do not raise loads higher than necessary. On the work site = As soon as itis light enough outside, turn off external lighting. ~ Only switch on the stairway lighting if it is needed. = Since you will only be using the chassis or tower cab at any one time, turn down the heating or air conditioner in the cab you are not using. During breaks - For short breaks, switch off the crane master switch. = Ifthe break is a longer one, turn off both the crane master switch and the diesel engine. 15G HMK 4406 Mobile Harbour Crane Operating Manual Technical Data 34 Dimensions Chassis length approx. 16.5 m Chassis width (without stabiliser pads) approx. 9.04 m Propping base, longitudinal / transverse 13.0 mx 12.5m Stabiliser pad size 4 x 2.0mx4.5m ‘Superstructure overhang to rear 715m Boom pivot point height approx. 16.7 m ‘Tower cab operator viewing height approx. 19.1 m Working range Max. radius 46.0m Min. radius 11.0m Hoisting height Hoisting height above quay level, radius 11 - 34m 420m Hoisting height above quay level, radius 35 m 415m Hoisting height above quay level, radius 36 m 40.5 m Hoisting height above quay level, radius 38 m 38.5 m Hoisting height above quay level, radius 40 m 36.0 m Hoisting height above quay level, radius 42 m 33.0 m Hoisting height above quay level, radius 43 m 31.5m Hoisting height above quay level, radius 44 m 29.5 m Hoisting height above quay level, radius 45 m 275m Hoisting height above quay level, radius 46 m 25.0m Hoisting height below quay level 120m Weights Total weight of crane including hook in operational state approx. 365.0 t Fixed counterweight approx. 95.4 t Wind loads Wind speed Crane in travel condition 24.4 mis Crane, propped, in operation 24.4 mis Crane, propped, out of operation 46.1 mis Tipping load utilisation Normal load 75.0% Special load 75.0% Grab operation 50.0% Electrical data Nominal voltage 440 V / 60 Hz / max. current input, auxiliary power supply, 63 A/ clearance between crane and overhead high-voltage lines up to 420 kV = 20 m. 24 1704 0024 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Technical Data Diesel Engine Make Model Cylinders Type of engine Cooling system Output Fuel consumption Fuel tank Capacity, main tank Capacity, day tank Possible operating time with full tank Generator Make Type Speeds Hoist Lifting capacity, high-speed 15 Lifting capacity,, high-speed 45 Lifting capacity,, high-speed 63 Lifting capacity,, low-speed 40 Lifting capacity,, low-speed 70 Lifting capacity, low-speed 100 Slewing Gear Superstructure slewing speed in normal operation Maximum peripheral speed ‘Superstructure slewing speed in heavy-load operation Luffing gear LLuffing speed in normal operation Luffing speed in heavy-load operation Travel gear Travel speed including hook in operational state Longitudinal inclination during travel Lateral inclination during travel Inclination of the propping surface Inner turning radius Outer turing radius Crab steering angle Climatic operating conditions Absolute maximum day temperature Absolute minimum day temperature: ‘Max. air humidity 34 MAN D 2842 LE 211 wiz diesel water-cooled 765 KW / 1800 rpm approx. 205 g/kWh Approx. 7800 | 4301. up to 220 hours Marelli MJB 400/LA4 440 V / 60 Hz 0-68 m/min 0-38 m/min 0-31 m/min 0-42 m/min 0-28 m/min 0-18 m/min 0 - 1.95 rpm 300 m/min 0-0.6 rpm 0-65 m/min 0-27 m/min 0-60 m/min max. 6% max. 2.5% max. 2.5% max. 4.3m max. 13.5 m max. 22.6° 45°C -20°C 100% 1724 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Technical Data 34 Noise level For this product, we guarantee a noise power level of L wa = 109 dB. The measured values were determined in accordance with DIN EN ISO 3744 for the operating conditions indicated in this manual. in accordance with EU Directive 2006/42/EC, the mean sound pressure level in the tower cab is Lpa = 70 dB. The values were determined in accordance with DIN EN 1SO 3744 for the operating conditions indicated in this manual and with the fan running at level 2. Vibrations The total of all vibrations to which the upper limbs are subjected is less than 2.5 m/s*. ‘The highest effective value of weighted acceleration to which the whole body is subjected Is less than 0.5 m/s*. EU Directive 2006/42/EC You will find the EC Declaration of Conformity at the end of this Operating Manual. This is a translation of the original German Operating Manual for your harbour crane. 18G HMK 4406 Mobile Harbour Crane Operating Manual Lifting Capacity Chart Spreader | = EH5U = 9.0t The lifting capacities are to be understood as follows: 4. Normal load, heavy load, special load = Load below hook rotator 2. Grab on ropes = Load on ropes 24170400. 3. Spreader operation = Load below spreader 3.2mr aN24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Start-up This section describes the checks that must be pet that must be met, if you ‘wish to start work with numbers below refer to the iter Locations” in section 4.1. “the drawing shows the Insta! components to be checked. ‘Before the checks are start master switch running (section 4.6). 44. General Drawing with Check Locations 4.2 Requirements for Travel Operation. 4.3. Requirements for Crane Operation 44 Generator / Mains Changeover switch: 45 Main Battery Switch... 4.6 Starting / Stopping the Diesel Engi 47 Crane Master Switch ON / OFF... 4.8 Maintenance | Inspection switch 4.9 Visumatic Symbols. ine. formed, and requirements travel operation. The item mm numbers in the “General Drawing with Check lation location: .g, switch off the crane ‘fit is on (section 4.7) and then ‘switch off the diesel engine if itisG HMK 4406 Mobile Harbour Urane Operating Manual Lifting Capacty Chart | Lifting capacities t permissible wind speed in| operation} Tipping load utilisation poleanceeesadessseeasanessss ‘Spreader | Manufacturer: Bromma The lifting capacities ¢ Type: EHSU 4, Normal load, heavy Spreader dead wight 9,0 2. Grab on ropes = Lt 24170400 Spreader liting capacity: Att 3, Spreader operatior