Use Maintenance Manual M200 - 2S

M200/2
2S
Use & Maintena

ance Manua
M l Edition: Rev. 00
Origin
nal instrructions
s 04/2017

SER
RIAL NUMB
N ER 1716
Info
o: info@s
sormec.n
net s.rr.l.
C/da Sa
asi - Area Arrtigianale - 9
91011 - Alcamo(TP) - Ita
aly
ww
ww.sormec.n
net Phone +3 39 0924 5026 655 - Fax +3
39 0924 270447

Use & Maiintenance Man
nual 3

All instructio
ons, drawings and data supp plied in this m
manual are bassed on the latest informatio on on our pro
oducts,
available at tthe time of prrinting. Sormeec s.r.l. reservees the right to
o make changees at any timee without notiice and
without incurring any kind d of obligation
ns.
Authors
Technical datta and texts: SSormec s.r.l. TTechnical Dep
partment
Printing layout and electro ons: Sormec s.r.l.
onic illustratio
s.r.l.
C/da Sasi - Area Artigianale - 9101

11 - Alcamo(TP) - Italy
Phone +39 0924 50265 55 - Fax +39 0924 27047
7
www..sorme
ec.nett
info@sorrmec.net
spareparrts@sorme ec.net
acquisti@
@sormec.n net
quality@ssormec.neet
marketingg@sorme ec.net
amministtrazione@
@sormec.nnet
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1 GENERAL INFORMATIONS ...................................................................................................................................... 9
POSE OF THISS MANUAL .............................................................................................................................. 9
1.1 PURP
ARD OF USING THE CRAN
1.2 HAZA NE FOR OTHEER PURPOSE .................................................................................... 9
1.3 MANUFACTURE A
AND MACHIN
NE IDENTIFIC
CATION DATA
A ............................................................................... 10
2 TECHNICA
AL SPECIFICA
ATIONS ................................................................................................................................. 11
NE DESCRIPTIION ...................................................................................................................................... 11
2.1 CRAN
2.1.1 R
RULES AND R
REGULATIONS ...................................................................................................................... 11
2.1.2 ZZONE CLASSIFICATIONS .......................................................................................................................... 11
AMBIENT CONDITIONS ........................................................................................................................... 11
2.1.3 A
2.1.3 G
GENERAL ARR
RANGEMENTT ...................................................................................................................... 12
2.1.4 P
PROOF LOAD
D ........................................................................................................................................... 13
2.1.5 D
DYNAMIC AC
CTIONS ................................................................................................................................. 14
2.1.6 R
REST POSITIO
ON ........................................................................................................................................ 15
2.1.7 P
PEDESTAL CO
ONNECTIONSS ....................................................................................................................... 16
2.1.8 H
HPU .......................................................................................................................................................... 17
DENTIFICATION OF THE M
2.1.9 ID MAIN COMP
PONENTS ..................................................................................... 18
2.2 SAFETTY DEVICE ................................................................................................................................................. 19
2.2.1 H
HYDRAULIC LLOAD LIMITIN
NG DEVICE ....................................................................................................... 19
2.2.2 EEMERGENCY STOP .................................................................................................................................. 20
2.2.3 W H ...................................................................................................................... 21
WIRE ROPE LIMIT SWITCH
2.2.4 SSAFETY SIGNSS STICKERS .......................................................................................................................... 22
2.3 DESCR
RIPTION OF A
ACCESSORIEES ....................................................................................................................... 23
2.3.1 W
WINCH TECNICAL DATA .......................................................................................................................... 23
2.3.2 LLIFTING TACK
KLE....................................................................................................................................... 23
3 SAFETY NO
ORMS ...................................................................................................................................................... 25
3.1 SAFETTY REGULATI
TIONS AND DA
AMAGE PREEVENTION ..................................................................................... 25
3.2 OPER
RATOR’S QUA
ALIFICATION AND CONDU
UCT ............................................................................................... 31
3.2.1 O
OPERATORS ............................................................................................................................................. 31
OPERATOR’S QUALIFICATTIONS ............................................................................................................... 31
3.2.2 O
OPERATOR’S CONDUCT .......................................................................................................................... 31
3.2.3 O
4 DIRECTIONS FOR HAN
NDLING AND INSTALLATIO
ON ............................................................................................... 32
4.1 LIFTIN
NG AND TRANSPORT ............................................................................................................................... 32
4.2 OVER
RALL DIMENSSIONS FOR SH
HIPMENT .......................................................................................................... 33
4.3 STORA
AGE .......................................................................................................................................................... 34
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4.3.1 SSCOPE ...................................................................................................................................................... 34
4.3.2 P
PRIOR TO STO
ORAGE ................................................................................................................................ 34
ROCEDURE ........................................................................................................................... 34
4.3.3 SSTORAGE PR
4.3.4 P
PERIODIC CHECK ..................................................................................................................................... 34
4.3.5 SSTART‐UP ................................................................................................................................................. 34
ALLATION .................................................................................................................................................. 35
4.4 INSTA
5 OPERATIN
NG PROCEDU
URES .................................................................................................................................... 42
5.1 DESCR
RIPTION OF CONTROLS ........................................................................................................................... 42
5.1.1 SSYMBOLS .................................................................................................................................................. 42
5.2 OVER
RVIEW OF OP
PERATOR STA
ATION ............................................................................................................... 43
5.3 OPER
RATOR CONSOLE ...................................................................................................................................... 44
5.3.1 P
POWER ON 2
24V dc .................................................................................................................................. 44
MOTOR START ....................................................................................................................................... 44
5.3.2 M
MOTOR STOP ......................................................................................................................................... 44
5.3.3 M
5.3.4 M
MANUAL/REM
MOTE DRIVEE SELECTOR .....................
. ................................................................................ 44
5.3.5 EEMERGENCY STOP LIGHTT ........................................................................................................................ 44
5.3.6 EEMERGENCY STOP .................................................................................................................................. 44
5.3.7 EEMERGENCY RESET BUTTTON .................................................................................................................. 44
5.4 HYDR RIBUTOR ............................................................................................................................... 45
RAULIC DISTR
5.5 MANUAL/REMOTTE DRIVE SELECTOR .............................................................................................................. 46
BOX CONTRO
5.6 HPU B OL ......................................................................................................................................... 47
5.6.1 M
M1 MAIN CIR
RCUIT BREAK
KER ................................................................................................................... 47
5.6.2 O
OIL TEMPERA CATOR .............................................................................................................. 47
ATURE INDIC
5.6.3 2 WER ON LIGHT ..................................................................................................................... 47
230V ac POW
5.6.4 O
OIL HEATER O
ON LIGHT ............................................................................................................................ 47
5.6.5 P
POWER ON 2 PLY ................................................................................................................... 47
230V ac SUPP
5.6.6 M P .......................................................................................................................................... 48
MOTOR STOP
5.6.7 M
MOTOR AUX.. CIRCUIT ............................................................................................................................. 48
5.6.8 M RT ........................................................................................................................................ 48
MOTOR STAR
MOTOR HEATTER SWITCH ........................................................................................................................ 48
5.6.9 M
5.6.10 LOW OIL LEV
VEL LIGHT ........................................................................................................................... 48
5.6.11 LOW LOW O GHT .................................................................................................................. 48
OIL LEVEL LIG
5.6.12 EMERGENCYY STOP ................................................................................................................................ 48
6 CHECKING
G THE OPERA
ATION OF SA
AFETY DEVICEES ................................................................................................ 49
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6.1 EMER
RGENCY STOP
P .......................................................................................................................................... 49
6.2 LOAD
D LIMIT DEVIC
CE ........................................................................................................................................ 49
6.3 CHEC OCK VALVE ........................................................................................................................... 50
CKING THE LO
6.4 CHEC
CKING THE RO
OPE LIMIT SW
WITCH ............................................................................................................... 50
6.5 WINC
CH LOCK VALLVE ........................................................................................................................................ 50
7 CRANE USSE ............................................................................................................................................................. 51
7.1 RECO
OMMENDATIONS FOR CRA
ANE USE ........................................................................................................... 51
7.2 OPER
RATIVE WORK
KING SIGNALLS ...................................................................................................................... 52
CHECKS AND START UP SEEQUENCE ......................................................................................................... 53
7.3 PRE C
7.4 STOW
WING AND SH
HUTDOWN TTHE CRANE ........................................................................................................ 54
8 EMERGEN
NCY PROCEDURES ................................................................................................................................... 55
8.1 BY‐PA
ASS IN EMER
RGENCY THE SSOLENOID V
VALVE ............................................................................................ 56
8.2 COIL R
REPLACEMENT ........................................................................................................................................ 56
9 MAINTENANCE ...................................................................................................................................................... 57
OMMENDED PPE ...................................................................................................................................... 57
9.1 RECO
9.2 MAIN
NTENANCE EQ
QUIPMENT .......................................................................................................................... 58
9.3 TIGHTTEN CHECK ............................................................................................................................................... 59
9.3.1 SSLEWING RIN
NG TIGHTEN CHECK ............................................................................................................. 59
9.3.2 TTIGHTENING FITTINGS ............................................................................................................................ 61
G INACTIVITYY ............................................................................................................................................ 61
9.4 LONG
9.5 REGU
ULAR INSPECTION .................................................................................................................................... 62
9.6 SCHED
DULED MAIN
NTENANCE ........................................................................................................................... 63
9.6.1 IN
NSPECTION R
RECORDS ............................................................................................................................ 63
9.6.2 C
CRANES NOTT IN REGULAR
R USE ............................................................................................................... 63
9.7 STRUCTURE AND GENERAL IN
NSPECTION ........................................................................................................ 64
9.7.1 W
WELDING CHECKING ............................................................................................................................... 64
9.7.2 SSTRUCTURE C
CHECKING ........................................................................................................................... 64
9.7.3 B
BOLTS CHECK
K .......................................................................................................................................... 64
9.7.4 P
PAINT CHECK
K .......................................................................................................................................... 64
9.7.5 SSPECIAL OVERHAUL ................................................................................................................................ 64
9.8 WIREE ROPE MAIN
NTENANCE ........................................................................................................................... 65
9.9 BREAK‐IN PERIOD
D ........................................................................................................................................... 65
NGATION OFF THE WIRE R
9.10 ELON ROPE ................................................................................................................ 66
9.11 WIR
RE ROPE INSP
PECTION .............................................................................................................................. 66
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9.11.1 BROKEN WIRES ..................................................................................................................................... 67
G THE DIAMEETER OF THEE ROPE ......................................................................................... 67
9.11.2 MEASURING
9.12 WIR RROSION ............................................................................................................................... 68
RE ROPE COR
9.13 WIR
RE ROPE LUBR
RICATION ............................................................................................................................. 68
9.14 GRO
OOVED PULLEEYS AND DRU
UM INSPECTTIONS ............................................................................................ 69
RE ROPE CHANGING ................................................................................................................................. 70
9.15 WIR
9.16 WIN
NCH DRUMS MAINTENAN
NCE PLANNIN
NG ................................................................................................ 71
9.16.1 ROUTINE MAINTENANCE ...................................................................................................................... 71
9.16.2 SPECIAL MA
AINTENANCE ....................................................................................................................... 71
9.17 HOO OK BLOCKS ............................................................................................................................ 71
OK AND HOO
9.18 SLEW
WING RING A
AND FASTEN
NERS .................................................................................................................. 72
9.19 ELEC
CTRIC MOTO
ORS ........................................................................................................................................ 72
PECTION OF TANKS AND STEEL COMP
9.20 INSP PONENTS ...................................................................................... 73
9.21 HYD
DRAULIC OIL LLEVEL CHECK
K ....................................................................................................................... 74
9.22 CHA
ANGE OF HYD
DRAULIC OIL ......................................................................................................................... 75
9.23 OIL FFILTER MAIN
NTENANCE ............................................................................................................................ 77
9.24 MOTTOREDUCTIO
ON GEAR HYD
DRAULIC OILL .................................................................................................... 78
9.25 BASEE LUBRICATIION ....................................................................................................................................... 80
9.26 FLEX
XIBLE PIPES ............................................................................................................................................... 81
9.27 ROC
CKING TESTS ....................
. ......................................................................................................................... 82
10 PART REPLACEMENTT ........................................................................................................................................... 94
RE PARTS .................................................................................................................................................. 94
10.1 SPAR
10.2 PIPEE REPLACEMEENT ...................................................................................................................................... 94
10.3 COILL REPLACEMENT ...................................................................................................................................... 94
11 SAFETY P
PRECAUTION
N .......................................................................................................................................... 95
NCH....................................................................................................................................... 95
11.1 USE OF THE WIN
11.2 LIFTTING TACKLE ....................
. ......................................................................................................................... 95
11.3 COU
UNTERWEIGH
HT ......................................................................................................................................... 96
11.4 LOAD HANDLING
G........................................................................................................................................... 96
NDULUM EFFEECT ...................................................................................................................................... 96
11.5 PEN
11.6 LOAD HOISTING ............................................................................................................................................ 97
11.7 WIR
RE ROPES AND BELTS APP
PLIED TO THEE HOOK ........................................................................................ 97
11.8 HOO
OK ............................................................................................................................................................. 97
11.9 OPEERATIONAL P
PERFORMANC
CE ..................................................................................................................... 97
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12 TROUBLE SHOOTING
G .......................................................................................................................................... 98
13 RECURREENT TESTING
G ........................................................................................................................................ 100
1
D OUT ............................................................................................................................... 101
14 INSPECTION CARRIED 1

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1 GENERA
AL INFORMATIONSS
1.1 PURPO
OSE OF TH
HIS MANUA
AL
Along with each new crane our Compan ny supplies th
he Customer w with this USE A
AND MAINTEN NANCE manuaal
in order to provide the op perator with th he necessary aand essential directions concerning the ccrane use, daiily
maintenancee, lubrication, tests and adjustments.
This manual has been draw wn up by the Manufacturer and is enclosed with the m machine.
The informattion contained d is intended for skilled opeerators.
This manual defines the purpose for which the machine
m has been
b manufaactured and ccontains all the necessaryy
information for safe, correect use.
Constant obsservance of the stated standards guarantees both m machine and p personnel safeety, economicc running and d
longer working life.
To facilitate its reading, it has been divided into thirtteen sections pointing out tthe most impo ortant operations.
For a quick reesearch of thee topics, it is rrecommended d to consult th
he table of contents.
INFORMATIO ON! The imagges shown he ere are for illu
ustrative purposes only an nd the craness illustrated iin the figuress
may differ frrom the mode el you purchaased.
To better strress the impo ortance of som me basic passages, they haave been writtten in heavy type and marrked by somee
preceding syymbols:

1.2 HAZAR
RD OF USING THE CR
RANE FOR OTHER PU
URPOSE
This Sormec crane is conceeived for vertical hoisting o of unconstrain
ned free loadss. This machine is only destined to the
h it has been cconceived. An
use for which ny other use iss to be regard
ded as being im mproper and hazardous.
The Manufaccturer shall no ot be regarded d as liable for any damagess caused by im mproper, wron ng and unreassonable use.
The Manufaccturer is only responsible fo or the machin ne according to its original cconfiguration..
No actions altering the strructure or thee operating cyccle of the macchine shall be allowed unleess they are caarried out or
authorized b
by the Techniccal Departmen nt.
Improper uses of the cran ne:
 Ioad
d dragging;
 Ioad
d pushing;
 consstrained load ho
oisting;
 use of devices otheer than hook (cllamshell bucketts, grappes and
d log graps) in ccase such use haas not been pro
ovided for;
 use in explosive environments;
 peop
ple hoisting,(if tthere is not thee man‐riding function in the w
winch).
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1.3 MANU
UFACTUREE AND MAC
CHINE IDEN
NTIFICATIO
ON DATA
The serial nuumber is printeed on a suitab
ble plate locatted on the craane column, in
n a visible possition.
The data con ntained in the plate are:
A ‐ the manu ufacturer;
B ‐ designatioon of the macchinery;
C ‐ designatioon of series or type;
D ‐ serial num
mber;
E ‐ year of manufacture;
F ‐ EC‐type examination ceertification nuumber;
G ‐ load charrt;
H ‐ compliance marking fo ollowed by ideentification nu
umber of notiffied body.

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1
2 TECHNIICAL SPEC
CIFICATION
NS
2.1 CRANE DESCRIPTION
The Sormecc crane, mod del M200/2S,, is a crane wwith a telescoopic boom. TThe maximumm outreach wwith the
boom in horizontal posiition will be o of 20 meterss, instead the
e minimum rradius is abo
out 2,3 meterrs.
Steel materrials used forr the crane sttructure are:
 S355 for pedestal and column;;
 S690 for the boom.
The estimatted weight oof fully assem
mbled crane iincluding its accessories is about 140000 Kg.
The crane iss designed to
o work in harrbour or in o
offshore mod de with max significant wwave height 11,6m and
max Heel‐Trim 6° / 3° or 3° / 6°.

The crane M
M200/2S is designed with h BUREAU VEERITAS CODEE as per ship p classificatio
on, supplied aas a unique
package inccluding pedestal, operatoor station, winch, HPU (HHydraulic Powwer Unit) witth one 45kWW electrical
motor.
Main technical data of tthe crane:
 SSWL(Harbourr): 5t@ 20m;
 S
SWL(Offshore e, SWH= 0,5m): 3,5t@ 20m / 4,1 t @ 15,5 5m;
 S
SWL(Offshore e, SWH= 1m): 3,1t@ 20m / 3,8 t @ 15,5m m;
 S
SWL(Offshore e, SWH= 1,6m): 2,5t@ 20m / 3,4 t @ 15,5 5m;
 W
Working cond dition: Harbou ur / Offshore
 Max working radius: 20m;
 Min. working radius: aboutt 2,3m
 Boom luffing angle: 0 ‐78°;;
 S
Slew angle: 3660° unlimited angle;
 O
Oil tank capaccity: 600l;
 Design tempeerature: ‐20° C C to + 40° C;
 A
Atmosphere: high in salinitty up to 85% hhumidity;
 Z
Zone classifica
ation: Safe Zoone;
 Design: BUREAU VERITAS C CODE

2.1.1 RULESS AND REGULATIONS
The crane M
M200/2S is designed with h BUREAU VEERITAS CODEE as per ship p classificatio
on, supplied aas a unique
package inccluding pedestal, operato
or station, winch , HPU (H
Hydraulic Power Unit) wiith one 45kW W electrical
motor.
2.1.2 ZON
NE CLASSIFIC
CATIONS
The crane iss designed to
o work only iin safe zone..
WARNING! Never use tthe crane in hazardous zone this cou
uld cause serrious triggering explosions and fires
2.1.3 AMBIENT CONDITTIONS
The crane is designed to w work in tempeerature ‐20°C tto +40°C and in atmospherre with high in n salinity up to
o 85%
humidity.
CAUTION! Inn case of stro
ong wind it is recommendeed to lower the load to th
he ground and
d put the crane in parkingg
position.
WARNING! D ne during storms.
Do not operatte to the cran
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2.1.3 GENERAL ARRANG
GEMENT
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3
2.1.4 PROO
OF LOAD

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4
2.1.5 DYNA
AMIC ACTION
NS

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2.1.6 REST P
POSITION

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2.1.7 PEDESSTAL CONNEECTIONS
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2.1.8 HPU

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2.1.9 IDENTTIFICATION O
OF THE MAIN
N COMPONEENTS
A sketch of tthe crane is sshown here beelow, from wh
hich all crane components ccan be identiffied:
1 Pedes
stal 8 Winch
2 Man-Hole 9 1° Extension
3 Slewing Ring 10 1° Ex
xtension cyllinder
4 Operation station 11 2 Extension
2°
5 Colum
mn 12 2° Ex
xtension cyllinder
6 Boom Cylinders 13 S
Sleave bloc
ck
7 Boom
m 14 Hook
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2.2 SAFETTY DEVICE
2.2.1 HYDRAULIC LOAD D LIMITING D DEVICE

The hydraulic load limiter device is aa safety deviice installed on the cranee. It is has the function to
o stop the
crane once it is reaches the 10% mo ore of the maaximum load d(110% max load) the craane may lift d disabling
ng functions::
the followin
• boom low wer ;
• telescopicc extend;
• hoisting u
up winch.

It constantlyy checks that the weightt of the load raised with tthe crane do
oes not exceeed the safetyy working
load. (refer to the load cchart)
The hydraulic load limiter device, coonnected to the column hydraulic cyllinder, checkks constantlyy the oil
pressure onn the hydraulic cylinder aand it activattes automatically by blocking some crrane functions as soon
as it reaches the maxim mum pressuree prestabiliteed in factory in referencee to the safetty working lo
oad. In this
case the craane is in overrload.
WARNING! For this reasson must be careful to never insist on the lever ccontrol "boom hoist" whe en you
reach the lim
mit on the fuunctions beccause this leaads to increase the hydraaulic oil presssure in the column
hydraulic cyylinder by activating the hydraulic loaad limiter de evice also witthout load on the boom. In this case
to unlock alll crane functtions, it is neecessary to lo
ower the oil pressure in tthe hydraulicc cylinder coolumn by
using simulttaneously thhe function ““boom lowerr” and the fu unction “telescopic retracct” if it is tele
escopic
crane or thee function “wwinch lowerr” in case of ccrane with fixed boom.

If a discontinuous alarm
m starts ringin ng informs th
he crane ope
erator that th
he crane hass exceeded tthe
maximum lo oad limit and
d it is in overrload.
REMEMBER R! To disablee the load limmit device in order to resstore all cran
ne functions iit is very imp
portant to
put down th d on the deck by using th
he lifted load he functions that are not disabled succh as the "winch lower"
or "telescop
pic retract" (if it is telesco
opic crane).

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2.2.2 EMER
RGENCY STOP
P
In case of d
danger it is possible to stop the crrane througgh the appro
opriate red push butto
on
“Emergenccy stop”(A) located:
 on the operattor console;
 on the HPU bo
ox;
 on the radio remote conttrol.

INFORMATTION! The eemergency push button turns off tthe 24V ten nsion comm mands of the e crane and
d
stop the HPU motor.
The orangee light "Emeergency sto
op light"(C) on the operrator conso
ole will switcch on to con
nfirm that
an emergeency stop was used.
WARNING G! Before releasing the push butto
on, make sure that all d
dangerous cconditions hhave been
eliminatedd.

of the emergency stop button follo
After use o ow these in he crane functions:
nstructions tto restart th
 Unblock the em
mergency sto
op button(A) used by turning it clockw
wise as indiccated by the arrows;
 Preess the emerrgency reset button(B) on
n the operator console;
 Preess the start button to reestart the eleectrical moto
or.

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1
2.2.3 WIRE ROPE LIMITT SWITCH
When the ccrane is provided with a w winch, two m micro switche
es are mounted which haave the funcction of
locking the rise and fall of the rope at end of strroke.
‐ MICRO SWWITCH HOOK K UP LIMIT
The "micro switch hookk up limit" b
block the fun
nction "winch
h hoist" when whole wiree rope is wraapped on
drum.
the winch d
REMEMBER
R! In this casee it is possible to use onlly the "winch
h lower" funcction.
‐ MICRO SW WITCH HOOK K DOWN LIM MIT

The "micro switch hookk down limitt” block the ffunction "win nch lower" w when the maaximum posssible of wire
rope is releeased.
REMEMBER R! In this casee it is possible to use onlly the "winch
h hoist" funcction.
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2
2.2.4 SAFETTY SIGNS STICKERS
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2.3 DESCR
RIPTION OF ACCESSO
ORIES
2.3.1 WINCCH TECNICAL DATA
The winch is an extremeely useful atttachment haaving the purrpose of liftin
ng load. It co
onsists of a ro
otary drum
driven by a hydraulic motor, a wire rope is wounnd around thhe drum and the load is aapplied to su uch rope.
WARNING! Do not swin
ng the hangin
ng load.
INFORMATION! Do not drag the loaad.
For the use and mainten
nance of thee winch, follo
ow the directtions indicateed on this manual.
DATI TECNICI
T MA
AIN WINCH TECN
NICAL SPEC
CIFICATIONS
Diametro
o tamburo 275 mm Drum diam
meter
Peso verricello
v 190 kg Winch weight
Diame
etro fune 14 mm Rope diam
meter
C
Carico minimo
o di rottura fu
une 195 kN Rope
e minimum b
breaking load
d
2.3.2 LIFTIN
NG TACKLE
The tackle is a set madee up of statio
onary sheavees connectedd to the end o of the crane boom by mmeans of a
pulley blockk, and of mobile sheaves contained inn a rope blocck. This systeem has the fuunction of m
multiplying
the winch faall and drivin
ng the rope. The compossition of the llifting tackles depends on the numbe er of falls
required to hoist the loaad.
The configu
uration of thee lifting tacklles provided by Sormec ccannot be ch
hanged.
WARNING! is absolutelyy forbidden decrease thee number of lifting tacklees to increasee the speed of lifting
because thee weight of tthe load to lifft might exceeed the maximum lifting capacity of tthe winch.
R! The crane load chart shows the configuration o
REMEMBER of the lifting tackles.
INFORMATION! The craane operatorr has to ensu
ure that the configuratio
on of the lifting tackles co
orrespond
to the configuration pro
ovided by SO
ORMEC.
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1- SINGLE
E FALL 2- DOUBL
LE FALL 3- DOU
UBLE FALL
LEGEND:
A. WIRE ROPEE
B. COUNTERW
WEIGHT FOR LLIMIT MICROSSWITCH
C. COUNTERW
WEIGHT FOR W
WIRE ROPE
D.. HOOK
E. SHEAVE ‐ H
HOLDING BLOC
CK
F. UPPER SHEEAVE ‐ HOLDIN
NG BLOCK
G.. LOWER SHEAVE ‐ HOLDING BLOCK
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3 SAFETY
Y NORMS
3.1 SAFETTY REGULA
ATIONS AND DAMAG
GE PREVENTION
FIGURE 1 Beefore startin ng any operation with thee crane, check for the weear
state of thee connection pins betweeen the cranee and the equipments (w wire
rope, hook,, eyebolt, sh
hackle, sheave holding block)
b and make
m sure that
they are held back by th he suitable saafety rings.
Also make sure that the hook may m rotate freely without too mu uch
clearance, the safety latch hookk is perfectly efficient and that the
t
fastening nu ut to the eyeebolt is lockeed with the spring pin.
In addition you must alw ways operatte in compliaance with the e regulationss in
force on saffety at work..
FIGURE 2 Apply
A the ho
oisting ropess to
the hook so
s as not to t damage the
hook safetyy; make suree that the ho
ook
a well as the
is perfectlyy efficient as
slings and the different clamp ping
devices used.
FIGURE 3 Make
M sure that the weight
of the load to be lifted
d, in relation
n to
the axis disstance of thee column, do oes
not exceed those speciffied on the lo oad
chart of thee crane(see lo oad chart).
WARNING! Never ho oist any loaads
exceeding tthe values in ndicated on tthe
load chart.
REMEMBER R! The load cchart informss to
the operattor the maaximum liftting
capacities of
o the crane and in casee of
supplementtary equipm ments (such as
grabs, pow wer blocks, supplementtary
hooks etc.) it is necesssary to dedu uce
the weight of the accessories from tthe
rated loads.
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FIGURE 4 Do
D not operate the cran ne with suddden
movementss, operate th he control leevers gently aand
gradually. TThe crane is cconceived fo or load hoisting,
do not hoisst loads slanttwise, do no ot drag the lo oad
on the deckk by means of the telesscoping cylin
nder
or the slew
wing system. These functions are only
o
allowed when the load is hanging ovver ground.
FIGURE 5 W
WARNING! H
Hoisting consstrained load
ds is
forbidden.

FIGURE 6 Keeep out of th
he crane worrk area, whicch must be circumscribedd by suitablee guards.
WARNING! Make sure tthat there arre no people in the crane e operating aarea.
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FIGURE 7 Do not operatte the crane during storm
ms.
FIGURE 8 Do not pass under suspen
nded loads.
FIGURE 9 W When the winnd speed excceeds more than 25

knots stop the work and set thee crane in stowed
position.
FIGURE 10 Do not drive the loads or the cranee boom
over the control stationn.

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FIGURE 11 TThis sign means that you
u must wear personal pro
otections.
WARNIN
NG! Always w when operating with the
wear the saffety helmet w e crane.

FIGURE 12 W
WARNING! O Operating with the cranee is
forbidden w
when visibilitty is not such
h as to allow the
whole operating range o of the crane to be clearlyy seen.
FIGURE 13 D
DANGER! Do
o not work near electric llines.
Comply with the minimum distancee stated by th
he table belo
ow:
Rate
ed
Minim
mum distanc
ce from elec
ctric lines
voltage U
(kV)) Unsh
hielded cables (m) Shielde
ed cables (m
m)
U≤1
1 2 0,5
1<U≤4
45 3 1,5
U≥11
10 5 5
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FIGURE 14 WWARNING! A After any acccidental shocck or damage
e suffered byy the crane, a careful che
eck should
be carried o
out by an autthorized personnel.
FIGURE 15 V
Verify that th
he release lo
oad area is ap
ppropriate fo
or support th
he load to layy on deck.

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FIGURE 16 Check that aall aircraft waarning light, floodlight an
nd any otherr luminaries and their enclosures
used on thee boom are ssecurely in pllace, free of damage and d that they fu
unction correectly. (if Insta
alled)

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1
3.2 OPERA
ATOR’S QU
UALIFICATIION AND C
CONDUCT
3.2.1 OPERA
ATORS
The personnel authorizeed to work w
with a crane are:
 peo
ople specificallly encharged;
 cran
ne operator;
 train
nees directly ssupervised byy a suitably deesignated persson;
 maintenance and
d testing operators (where appropriate, w
when carryingg out their tassks);
 insp
pectors (cranees);
 Iubrrication workeers;
ersonnel not included in th
CAUTION! Pe he above‐liste
ed shall not be allowed to enter the cran
ne work area.
3.2.2 OPERA
ATOR’S QUA ALIFICATIONS
The personnel charged to use the crrane shall haave the follow
wing minimu
um qualificattions:
 to b
be able to und
derstand and tto interpret alll stickers, ope
erator’s manu
uals and safetyy procedures;
 to kknow the emeergency proced
dures and how
w to actuate tthem;
 to b
be able to use the specific eequipment;
 to b
be familiar witth the relevan
nt standards;
 to b
be aware of th
he responsibiliity for the crane maintenan
nce requiremeents;
 to kknow well the crane and its control functtions;
 understand the operating procedures staated by the manufacturer.
to u
he crane operrator qualificaation shall be referred to the country ru
CAUTION! Th ules where thee crane is ope
erating.
3.2.3 OPERA
ATOR’S CON
NDUCT
The operatorr during the crane use:
 musst not attend tto any other aactivity that co
ould distract h
him;
 shalll not leave th
he lifted load u
unattended, u
unless any spe
ecific precautions have been adopted and actuated;
 shalll not use the crane when h
he is drunk;
 shalll clean the deeck by spreadiing some abso
orbing material (sand, sawd
dust)in case o
of oil leakage.

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4 DIRECTTIONS FOR
R HANDLIN
NG AND IN
NSTALLATTION
4.1 LIFTIN
NG AND TR
RANSPORT
Before transport, the crrane and its ccomponentss are fastened with a apppropriate sup
pports to avo
oid damage
during the ttransport.
ntaining the accessories of the crane.
The crane iss shipped witth a case con
Before liftin
ng or unloadiing, the operrator shall kn
now:
 the overall dimen
nsions of each
h componentss(see enclosurres);
 the weight of thee crane or each componentts (see enclosu
ures);
The lifting o
of the crane sshall be carried out by m
means of suitaable lifting eequipment, the crane hass to be lift
from top byy hanging up the suitablee connections on the maiin boom pad d eyes(FIGUR
RE 1).
REMEMBER
R! mount the
e shackle in tthe lifting po
oints.
Big cranes aare carefully disassembleed for the traansport. In th
his case for the lifting of each compo
onent use
the approprriate lifting p
point.
Before unlo oading the caase containin
ng crane acceessories checck its weightt and then un
nload by usin
ng a suitable
forklift(FIGU
URE 1).

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3
4.2 OVERA
ALL DIMEN
NSIONS FO
OR SHIPMEENT
INFORMATION! The overall dimenssions for ship
pping also incclude the sup
pports for th
he transport.
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4.3 STORA
AGE
4.3.1 SCOPEE
The purposse of this procedure is to aid and give guidan
nce in minimmizing possiible damage e of Sormecc
supplied eq
quipment du ue to prolonged storagge and durinng the instaallation. Exteended storaage requiress
monthly insspections and d preventivee maintenancce.
4.3.2 PRIOR R TO STORAG GE

All crane co
omponents which are subjected
s to
o mechanicaal movementt, motor redduction gears for cranee
rotation forr the slewingg ring, motor reduction ggears for the e winch, the wire ropes, must be greeased at thee
time of goin ng into extended storage. These com mponents ab bove mentioned should be packed fu ull of greasee
prior the storage. Proteect the unpainted parts, including the telescopic elements off the cylinde ers, with rustt
preventers, and repeat the operatio on wheneverr the protecttive coat is to
o be reneweed. The fan coooler shouldd
be packed w with plastic ffilm to avoid
d contaminattion by atmo ospheric agents, dust andd insects. We suggest too
cover everyy electrical coonnectors an nd sensors ussing insulatin
ng gel.
4.3.3 STOR RAGE PROCEDURE
All compon nents shouldd be storedd indoors whenever
w poossible, wheere shock aand dust is reasonablyy
maintained. If componeents are to be stored outtside, they sh hould be covvered with a water‐resistant materiall
and also prrotected from
m any accidental impactts. Cover eaach element to protect ccoatings and
d to preventt
from any fo oreign materrial or moistu ure. To prevent any kind d of deterioraation, storagge conditionss should nott
exceed 90°FF and 70% reelative humiidity. The eq quipments sh hould be stoored on a cleean, dry floor or blocked d
up off the gground on blo ocks to preveent unit from
m setting in aany water orr directly on tthe ground.
4.3.4 PERIOODIC CHECK
Monthly th he equipmen nt should be
b checked to ensure that
t it has remained in n an accepttable stored
d
condition. The
T pinions, racks and the t wire roppes should be
b rotated several
s timess while addiing enough
h
grease to coover the surffaces with freesh grease. NNote that evven when full of grease, tthese greased parts tend d
to take on moisture if the storagee environment is not maaintained at constant teemperature. Do not usee
high‐pressu ure lube equipment as th his may dam
mage the beaaring seals. C Consult the items manufactured forr
proper storage and lubrrication if thee unit was su upplied with one.
4.3.5 STARTT‐UP
When the ittems are remmoved from sstorage, check for corrossion or damaage and even ntually debris inside. All
greased com mponent sho ould be purged and covered with fressh grease as per the lubrrication decaal. Every
single part o
of the crane should be innspected prio or to re‐instaallation and u
use. The mottors and the pressurized
parts must be checked p prior the insttallation to vverify that th
he technical ffeatures are still at a satisfactory
level compaared to the vvalue recordeed prior to sttorage.

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4.4 INSTA
ALLATION
The crane aarrives complete with sup pports and screws for the e installation
n.
The lifting o
of the crane sshall be carried out by m
means of suitaable lifting eequipment.
Lift the cran
ne (or each ccomponents)) using the ap ppropriate lifting point too avoid damage to people or goods
during the installation oof the crane.
The crane innstallation on the ship shhall be only ccarried out b
by an qualifieed and authoorized personns.
INFORMATION! After th he crane hass been installed on the shhip, carry outt the tests provided for b
by the
regulations in force in eeach individuual country.
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5 OPERATTING PRO
OCEDURESS
5.1 DESCR
RIPTION OF CONTRO
OLS
5.1.1 SYMB
BOLS
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3
5.2 OVERV
VIEW OF O
OPERATOR
R STATION

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4
5.3 OPERA
ATOR CONSOLE

1 Auxx. 24Vdc Powe er ON
2 Start H
HPU electric m
motor 3 Stop p HPU electric motor 4 Manual/Remote selector
5 EEmergency sto
op light 6 Em
mergency stop p 7 Emergency reset buttton
5.3.1 POWEER ON 24V d dc
White led light(1) indicaates the pressence of 24V
Vdc voltage.
5.3.2 MOTOOR START
Green push button(2). If pressed will start up the HPU moto
or. The signall light shows that the mo
otor is
running.
5.3.3 MOTOOR STOP
Red push bu utton(3). If p
pressed it sto
ops the HPU motor. If the
e red light tu
urns on it sign
nals a thermal
protection iintervention on the HPU motor.
5.3.4 MANUUAL/REMOTTE DRIVE SELLECTOR
The crane h
has the optio
on to work bby remote control. To use the remote control it is necessaryy enable thee
switch “Local/Remote selector”(4) o
on the operaator console.
5.3.5 EMER
RGENCY STOP P LIGHT
he operator console will switch on to
The orange light "Emerggency stop light"(5) on th o confirm thaat an
emergency stop was used.
5.3.6 EMER RGENCY STOP P
In case of emergency it is possible to
o stop the crrane through
h the approp
priate push b
button “Emerrgency
stop”(6) loccated on the operator coonsole. After used the “Em
mergency sttop” button ppress the button
“Emergencyy reset”(6) too restores th
he crane’s functions.
5.3.7 EMER
RGENCY RESEET BUTTON
utton “Emergency reset button”(7) rrestores the normal crane functions aafter use of tthe
The push bu
“EMERGENCY STOP” bu utton.

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5
5.4 HYDRA
AULIC DISTTRIBUTOR
1 Rotation functions 2 Extension fu
unctions 3 Boom functtions 4 Wincch functions
5
5 Pressure g auge 6 LS Pillot electric valve 7 Main electric valvee
It is recommended to pay special attention tto the crane e controls aand to the function asssigned to
each leverss in order to o prevent aany acciden nts during the cargo haandling .
About theeirs function ns of you shhould referr to the instructions inddicated on each lever. When the
lever used is released, it returns to the neuttral position n by blocking the function used .
REMEMBEER! Operatee the levers gradually to o avoid anyy incorrect mmovements of the load d .
WARNING G! Never insist on the leevers contro ol when you u reach the limit , this lleads to inccrease in oil
pressure thhat could caause damagge to the hyydraulic systtem.
Periodically check thee correct function of th he levers. TTheir return to the neutral position n have to
be automaatically. In ccase of obsttruction you u should lubricate the joints of the levers, if necessary.
Check regu ularly the hyydraulic disttributor, an ny oil leaking must be p present.
In the casee of oil leakking , is neceessary to dissassemble tthe elements of the hyydraulic disttributor.
Pay particular attentiion to the aassembly, you must tigght the boltss by using the dynamometric key
and a correect tightening
The pressu ure gauge(6 6) allows thee constant m monitoring of the hydrraulic oil preessure acco ording to
the used crane functio ons.
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6
5.5 MANU
UAL/REMO
OTE DRIVE SELECTOR
R
1 Rotation functioons 2 Winch fuunctions 3 Extension functions 4 Boom functioons
1
5 Start(left) /Stop(right) Electric motors
6 Swwitch increase orr reduction of thee levers speedineess 7 Emergency SStop Button 8 Power ON / Emer
P rgency reset 9 Spare
10 Socket plug to con
S nnect by wire thee remote control to the receiver 1 11 Socket plug fo
or radio remote coontrol on the pedestal
The crane h
has the optio
on to work byy radio or wire remote co
ontrol.
To use the rradio remotee control it iss necessary:
 turrn the switch ““manual‐remote selector” on the operator console in
n remote;
 cheeck that the emergency sto
op button on tthe radio rem
mote control (7
7) is released;
 pussh the button(8) “POWER O
ON” to turn o
on the radio re
emote controll;
Warning! O
Once the rem
mote control is activated, the comman
nds in the op
perator conssole are disab
bled.
The crane ccan be maneeuvered also by wire rem mote control. To use the wire contro ol it is necesssary removee

the batteryy to the radioo remote co ontrol and th hen to conne ect the cablee from the ssocket plug o on the radio o
remote conntrol(10) to the socket plug(11) on the receive
er. Turn the switch on tthe operator console in
n
“REMOTE” to use the w wire remote ccontrol.
Warning! O ne works by wire control, the commaands in the o
Once the cran operator console are disaabled.

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7
5.6 HPU B
BOX CONTR
ROL

1 Main Circuitt Breaker 2 Oil ttemperature indicator 3 230Vac Power On 4 OOil heater ON 55 230Vac Supply
6
6 Motor Stop 7 Motor Aux circu
uit 8 Motor Starrt
9 Hydraulic ooil heater Switch 10 Low Oil Leve
el light 11 Low Loww Oil Level light
12 Emergency Resset
5.6.1 M1 M MAIN CIRCUITT BREAKER
The main circuit breake ers (1) situatted on the H
HPU control panel set in “zero position” turn offf the voltagee
to all crane’’s controls.
WARNING! Even if the main disconnect switch h is set in “zero
“ positio
on” be carefful because on HPU boxx
oltage originated from th
there is a vo he vessel.
Remember to remove the voltage o originated fro
om the vesse el before perrforming anyy maintenancce operation n
on HPU boxx.
5.6.2 OIL TEEMPERATUR RE INDICATOOR
The displayy(2) on the co
ontrol panel shows the h
hydraulic pow
wer unit oil temperature. It is also po
ossible to sett
and maintain the correcct hydraulic o
oil temperature(Usually is setted to 5
5°C).
5.6.3 230V ac POWER O ON LIGHT
The white leed light (3) in
ndicates the presence off 230V ac voltage.
5.6.4 OIL HEEATER ON LIIGHT
The green leed light “Oil Heaters ON”(28) will sw
witch on to co
onfirm that tthe oil heaters are activated.
5.6.5 POWEER ON 230V ac SUPPLY
The white led light (5) indicates thee 230V ac volltage from barge.
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5.6.6 MOTO OR STOP
The red pussh button “MMotor Stop”((6) if pressed d stops the H
HPU electric motor. If thee red led ligh
ht turned on
n
indicates a tthermal prottection interrvention on tthe HPU elecctric motor.
5.6.7 MOTO OR AUX. CIRC
CUIT
The selecto
or “Motor Au
ux. Circuit ”((7) enables the electric m
motor contro
ol circuit startt / stop.
5.6.8 MOTO OR START
The green push button
n ”Motor Sttart”(8), allo
ows the startting of the HPU
H electricc motor. The
e signal lightt
shows that the motor iss running.
5.6.9 MOTO OR HEATER SSWITCH
The crane iss designed too operate in lower tempeerature, for tthis reason tthe hydraulicc power unitt is equipped d
with an heaating system for the hydrraulic oil in caase of tempe eratures undder °C.
The hydraulic oil heater is activated d by a selecttor “OIL HEA ATERS”(9) placed on thee HPU contro ol panel and d
the green leed light “Oil Heaters ON””(4) will swittch on to con nfirm that the oil heater aare activated
d.
REMEMBER R! Switch in position "1"" the M1 Maain Circuit B Breaker(1) sittuated on th he HPU conttrol panel to o
turn on the voltage to aall crane's controls.
The hydraulic oil heatin ng system haave a thermo ostat which maintains sttable the pro ogrammed ttemperaturee
and deactivvates the heating
h elem
ments when n the oil re
eaches the correct tem mperature. In
I case thee
temperaturre will decreaase under 0°C the heatin ng system willl start to woork automatically.
In case the oil temperatture in the taank will decrease the heaating system automatically restart.
It is possible to control the hydraulic oil temperature by the display(2) on the HPU U control pannel. It is also
o
possible to set and main ntain the corrrect hydraulic oil tempe erature by ussing the oil teemperature indicator on n
the control panel.(Usually is setted tto 5°C).
Attention: iis very imporrtant to activvate the oil h
heaters one h hour before starting opeerate with the crane.
Remember! First turn o on the main d disconnect sw witch placed d on the HPUU BOX.
CAUITION! The crane caan start operating normaally and with
hout problem
ms only when
n the hydrau
ulic oil in thee
tank has reaached the op
perative tem
mperature.
5.6.10 LOWW OIL LEVEL LLIGHT
The red led “Low Oil leevel light”(110) indicates to the operaator that theere is low oil level in the H
HPU tank. In
discontinuou
this case a d us alarm starrts ringing. Reestore oil levvel.
5.6.11 LOW W LOW OIL LEEVEL LIGHT
The red led d “Low low o oil level light”(11) indicaates to the o operator that there is insufficient oil in the HPU U
tank. In this case a discontinuous alarm startss ringing. If the
t oil level is insufficieent in the HPU tank thee
electrical mmotor turn offf automaticaally, and is no ot possible to o turn on till when the right oil level is restored.
5.6.12 EMERGENCY STO OP
In case of emergency it is possible to
o stop the crrane through
h the approppriate push b
button “Emerrgency
stop”(12) loocated on the HPU control panel. Aftter used the “Emergencyy stop” butto on press the button
“Emergencyy reset” on tthe operatorr console to rrestores the crane’s funcctions.

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9
6 CHECKIING THE O
OPERATIO
ON OF SAFETY DEVIC
CES
6.1 EMERGENCY STO
OP
Press the em
mergency pu
ush button m
making sure tthat the cran
ne stops all m
movements.
6.2 LOAD LIMIT DEV
VICE
The load lim
miting devicee has the function to stop once it is reaches the 10%
p the crane o % more of th
he maximum
m
load(110% mmax load) thhe crane mayy lift, disablin
ng the follow
wing functionns:
- boom lower;
- nch;
hoisting up win
- tellescopic exttend.
Verify perio
odically the ccorrect functioning of
this safety ssystem by lifting a load with 10%
more of thee maximum load(fig. 1).
REMEMBER R! To get craane in operattion again
ut down the cargo on
is very important to pu
the deck using the functions not yet
disabling suuch as the winch lower.

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6.3 CHECK
KING THE LLOCK VALV
VE
Arrange thee crane as shown in (fig. 22), applying a
medium size load. Switcch off the HPPU electric
motor and tturn pressure off in the hhydraulic
system, by d
driving the ccontrol leverss some timess,
afterwards make sure th hat the load does not lowwer.
6.4 CHECK
KING THE R
ROPE LIMIT SWITCH
If the crane is equipped with a winch, check the operation oof the limit m
micro switchees by windingg (fig.3) and
unwinding tthe rope (fig. 4) completely. When th
he winch stops because tthe rope has reached its end of
stroke, the operator shaall reverse th
he maneuverr to reactivatte the winch.
6.5 WINCH LOCK VA
ALVE
Hoist any looad of mediu um extent. SSwitch off
the HPU electric motorr, release prressure in
the hydrau ulic system
m by actuaating the
control leveers some tim
mes, then make
m sure
that the loaad does not lower (fig.5).
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1
7 CRANE USE
7.1 RECOM
MMENDATTIONS FOR
R CRANE USE
When the ccrane is getting started, it is recommended to perform some preliminary checks befo ore using thee
winch, in paarticular veriify that the rope is placed d correctly stowed on th he pulley and d operate the e winch with h
no load, perrforming up and down m movements.
It is recommmended to perform somee preliminary maneuverss without loaad before ussing the crane, especiallyy
in case of lo
ow temperatture, in ordeer to ensure the proper o operation of the crane and to allow hydraulic oill
to reach thee right temperature and fluidity in th he circuit.
WARNING! The crane iss designed to o work in temperature ‐‐10°C to +45°°C and in atm mosphere w with high in
salinity up tto 95% humidity.
DANGER! TThe operatorr shall absolutely avoid to hoist loads, when m maneuvering,, at positions such as to o
expose him mself and the e encharged people to daanger.
WANING! TThe crane op perator mustt always havve the visibiliity of the wh hole work arrea of the craane.
WARNING! Do not drive the loads o or the crane boom over the control station.
The crane o operator sho ould always ccheck the staatus of efficiency and greeasing of thee pulleys, rop pe and hookk
connected to the ropee, as the majority
m of accidents arre caused by b poor maaintenance of o the toolss
abovementioned and byy excessive w wear of the w wire rope.
REMEMBER R! The winch is equippeed with limiit switches both
b for up and down movementss to preventt
possible acccidents or daamage to thee rope.
Following some useful recommend dations to ob der to work safely and maintain effficiently thee
bserve in ord
crane in thee long run.
ATTENTION N! Do not keeep on pushin ng on contro ol levers wheen the functio on limit is already reached, because
an increase in the oil pressure may harm the hydraulic circuit.
dling loads avoid
While hand a n maneuvers and stops,, as it would cause unnecessary sttress to the
sudden
crane structture. Use con
ntrol levers ggradually following the in
nstructions o
on the labelss.
Position thee hook directtly above thee load to be lifted, in ordder to avoid aany draggingg of the load on the deckk
or ground. TThe crane op perator shou
uld exercise eextreme caution during llifting and haandling of caargo in orderr
to avoid thee pendulum effect which h could causee accidental d damage.
If it is necesssary to perfo
orm welds too the crane sstructure it iss important tto observe the followingg rules in
order to preevent possib
ble failures:
‐ Position the ground
d cable of the welding m
machine as clo
ose as possib
ble to the wo
orkpiece;
‐ Position the ground
d cable in order to ensurre that the po
ower never h
hits the slew
wing ring;
‐ never connect the welder grou
und cable to the winch ro
ope.
Ensure thatt the load weeight to be liffted does no
ot exceed the
e one shown the load chaart.
WARNING! Please referr to the load
d chart suppllied by Sorm
mec.
The crane w
will undergo periodic maiintenance ch
hecks necesssary to ensurre the properr functioningg for a long
time. Poor m
maintenancee would resu
ult in a premaature failure of the cranee.
REMEMBEER! It is impo ortant to keeep the cran ne in prope
er condition in order to
o pass periodic
inspections by the cerrtification authorities.

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7.2 OPERA
ATIVE WORKING SIG
GNALS
In the eventt that the craane operator from its op perating locattion does no
ot have the visibility of th
he load to bee
moved, it w will be necesssary to collab
borate with aanother operator to guid de him with vvisual cues, oor you need
to install a kkeyboard forr the remotee control if th
he crane is prrepared for tthis accessorry.
For that purrpose is advisable the following systeem of visual signals:
WARNING! The crane o operator musst not move the load to b be lifted if it does not understand the

e visual
signals it receives from the signalmaan. Additionaally, the operator and the signalman may decide,, before
starting thee movement of the load, to use a commmunication system diffeerent.
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7.3 PRE CHECKS AND START U
UP SEQUEN
NCE
Before usin
ng the crane it is recomm
mend to makke the follow
wing controlss:
 In caase of temperaature under zeero C° activate the oil heating system one hour before sttarting to use the
t crane. Thee
hydrraulic oil heater is activated b
by a selector “O
OIL HEATERS”(5
5) placed on th
he HPU control panel and the green led lightt
“Oil Heaters ON”(2
2) will switch on
n to confirm that the oil heate d. REMEMBER! Switch in posittion "1" the M1
er are activated 1
Main Circuit Breakker(1) situated on the HPU co
ontrol panel to turn on the vo
oltage to all craane's controls ((See paragraph
h
9)
5.5.9
 Checck and make su
ure that all the eequipment such as wire rope, shackle, hook and safety latch hook are perffectly efficient;
 Checck Or (Verify) th
hat are no oil leeaks on the fittiings of the hydrraulic circuit;
 Checck the hydraulicc oil level.

ng the follow
After makin wing controlss you can staart using the
e crane by th
he following steps:
 Go tto the HPU conttrol panel;
 switch in position ""1" the Main C
Circuit Breaker(1) situated on the HPU contro
ol panel to turn
n on the voltagge to all crane’ss
conttrols;
 Checck if all emergeency push butto
ons(6) are unbllocked, and resset the emergency trough app
propriate push button located
d
in th
he operator con
nsole;
 switch in position "1" the selecto
or “Motor 1 Aux.
A circuit”(3) situated on th
he HPU control panel to enab
ble the electricc
motor M1 control circuit start / stop;
 Presss the green pu
ush button “Mo
otor Start”(4) tto start the M1
1 electric moto
or and the greeen light signal sshows that thee
motor 1 is running (Is possible also
o to start the electric motor M
M1 from the operator console));
 Movve the levers on
n operator conttrols to obtain tthe desired fun
nction.

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7.4 STOW
WING AND SSHUTDOW
WN THE CRA
ANE
In the stow
wed position the crane has to have tthe hydraulicc cylinders aas much retracted as posssible at thee
end of the wworking day, in order to prevent corrrosion and tto dirt from depositing oon the cylindder rods. It iss
necessary to stow the ccrane at veryy low speed,, making surre that no daamage or impact occur b between thee
crane itself and its hoistting accessorries.
In order to make it easieer for the opperator we reecommend tto lock the hooisting hook only after th
he crane hass
completely switched offf, fasten thee hook to deck by using a belt to havve a small teension in the
e winch wiree
rope.
To properlyy shut down the crane fo
ollow these ssteps:
 Put the crane in paarking position;;
 Presss the red push
h button “Moto
or stop”(1) in tthe operator co
onsole or in thee HPU control panel to stop tthe M1 electricc
motor;
 Go tto the HPU conttrol panel;
 switch in position ""0" the selectorr “Motor 1 Auxx. circuit”(2) sittuated on the H
HPU control pan
nel to disable the main motorr
M1 control circuit start / stop;
 switch in position "0" the M1 Main Circuit Bre
eaker(3) situate
ed on the HPU control panel to turn off the
e voltage to alll
ne’s controls.
cran

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8 EMERG
GENCY PRO
OCEDURES
In case of faailure of the electrovalve (W25+W26 6) it is possib
ble to continue to use the crane in em
mergency
condition in
n order to pu ut the load on the deck and put the crane in parking position.. To do this o operation is
important tto know the placement o of the electricc valves to b
by‐pass (Refeer to next piccture).

‐ EMERGENCY Y SOLENOID VA ALVE: in case of failure of the ssolenoid valvess "W25"+"W26" shown in the pictures is possible to by‐
pass it to use tthe crane in em
mergency condittion. In order to o do so press th
he steel button of the solenoidd valve and turn clockwise.
CAUTION! By‐‐pass the solen noid valve only in case of emeergency in orde er to put the loaad on the deckk and put the crrane in parkingg
position.
Refer for the emergencyy procedures in the nextt paragraphs.

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8.1 BY‐PA
ASS IN EMEERGENCY TTHE SOLEN
NOID VALVE
If the crane gets stuck completely and d
cannot be resset any more, bring a metal
body near thee cartridge of the
t emergencyy
solenoid valve and make sure s that such h
body is attraccted by the maagnetic field. Iff
this does nott occur due too power failuree
but because the
t coil is out of use, unseal
and press the steel push buttton "A" of thee
solenoid valvee, then turn clo
ockwise to lockk
it(figure 1) in
n order to usee the crane in n
emergency co ondition.
WARNING! Once the soleno oid valve is by‐‐
passed in em mergency posittion all safetyy
devices, such as load limit d device and wire e
rope limit switches, are deacctivated.
WARNING! After
A pressing the
t steel push h
button "A", be
b very carefu ul and perform m
only the man neuvers necesssary to reducee
the distance between the load and thee
crane column..
WARNING! If you are using the winch, pay aattention not to o reach the end d of stroke of th he rope, as the safety devices are disabled.
CAUTION! By‐‐pass the solen noid valve only in case of emeergency in orde er to remove th he load applied d, if any, from the crane, fold d
and set the craane in stowed p position, then tturn the steel p
push button "A A" counterclockw wise to unlock it (figure2).
CAUTION! In tthis case contact Sormec.
WARNING! It is really impo ortant restore the
t solenoid valve
v in the case the coil is faulty
f in orderr to use the crrane in normall
condition.
8.2 COIL R
REPLACEM
MENT
WARNINIG! Before starrting any parrt replacement operation n, disconnectt the power ttakeoff and tturn off
pressure in the hydrauliic circuit by m
moving somee times the ccontrol leverrs all along th
heir stroke.
To replace tthe coil of a solenoid valve follow th
hese procedu
ures:
 CAU
UTION! Shutdow
wn the crane beefore performin
ng any type em
mergency operattion;
 Checck if the M1 Maain Circuit Breaaker and M2 Main Circuit Brea
aker are in position 0 on the H
HPU box contro
ol panel;
 takee out the cap A so as to turn cu
urrent off in thee solenoid valve
e;
 Screew out the lockiing nut B;
 Takee out the coil C and fit a new o
one;
 Screew in the nut B and connect th
he cap A again.

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9 MAINTENANCE
9.1 RECOM
MMENDED
D PPE
In order to o
operate with
h the crane o
or to do main
ntenance operation the ffollowing personal prote
ective
equipment must be useed:
 High visibility vest, Coverall;
 Helmet;
 S
Safety glass;
 G
Gloves;
 S
Scaffold;
 ork at height).
Harness(to wo

The achieveement of thee areas involvved in maintenance, musst take placee through thee use of mobbile towers
made of preefabricated eelements con nsidering thee need to mo
ove quickly, tthe scope off work and not high
heights. (Seee Figure 1)

The user (client) can cho
oose the mo
ost suitable scaffold considering:
 The work area;
 The type of accesss to decks: sccale ramp, stair treads, incliined ladder, vvertical ladderr;
 The horizontal annd vertical loads that can ovverthrow it;
 The conditions off deck surfacee;
 The use of stabilizers, outriggeer and/or ballaast;
 The need of anchhors and that in any case it conforms the e UNI EN 1004 4: 2005 with th he following m
minimum
requ
uirements: Claass 3, capacityy 200 kg/m²; m max outside hheight 8 m; Acccess Type AB BCD.
The use and d disassemblly must be caarried out in full compliance with thee instruction manual thatt should be
available at the place off use and in tthe languagee of the coun ntry.
It is useful tto check the position of tthe scaffold tto avoid riskss that could impair the in
nstallation, removal,
displacement and operaational safetyy with respeect to:
 surfface deck con
nditions;
 Floo
or and aslope;
 Obsstacles;
 Winnd conditions.
Staff should
d be appointeed for the pu
urpose by the employer tthat has to p
provide them
m with inform
mation,
education aand training.
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9.2 MAINTENANCE EQUIPMEN
NT
Offshore maintenance eequipment:
 14 piece com mbination sp panners set 88‐32mm;
 combination
c n spanner 36 6mm;
 combination
c n spanner 46 6mm
 screwdriver
s set slotted &
& phillips;
 Tester;
T
 pliers set;
 lock grip plieers;
 bergen ball eend & hex allen key wren nch set extraa long 3‐22m
mm;
 14 piece boxx spanner sett 8/22;
 socket & rat
s chet set 8‐322mm+36mm m+46mm+50mm+55mm;
 metric double open end spanner 50;;
 metric double open end spanner 55;;
 Long Ring Sp panner Set 8‐‐22mm;
 Cutters;
C
 Electrical inssulating tapees, cords, tub
bes, varnishees;
 Ratchet belt;
 Drills;
 Compressor
C stations;
 Cleaning equ
C uipment;
 Welding equ
W uipment;
 Corrosion pr
C rotection equ uipment;
 Individual prrotection devvices;
 Hand protecction;
 Special shoe
S es;
 bent internaal circlip plierrs.
Special tools for offshorre maintenan
nce:
 Prelload tensioner for slewing rring bolts;
 Diall gauges(mm) for rocking teest proceduree(quantity 2);
 Caliper gauges(mmm);
 Presssure gauge foor adjusting valve;
 Mod dular storage tanks for dirty oil;
 Storrage tank for ccleaning of waastewater of tthe oil tank;
 hydraulic pump ccompleted of inlet filter for filling of oil.

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9.3 TIGHTTEN CHECK
K
9.3.1 SLEWING RING TIGHTEN CHEC CK
Periodicallyy check for prroper tighten ning of the slewing ring bbolts that seccure the cranne to the pedestal, in
particular after the first loading cyclles, after thee first 150h w
working hourrs (or after 1 month).
Afterwards,, every six m
months, checck for proper tightening o of the slewing ring bolts.
The bolt con nnection is ccrucial to thee slew bearin
ng function and life. For aa proper fasttening of the
e slew
bearing is reequired a preeload force o of the fastenning bolts by using a high
h precision toorque wrench.
For a propeer preload is necessary to o know:
 threead nominal diameter off the pin;
 streength class o
of pin;
 if th
he pin is burn
nished or galvanized;
 the type of torq
que wrench(h
hydraulic/eleectric torque
e wrench or sspanner torq
que wrench).
WARNING! It is absolutely necessarry to tighten the bolts witth the correcct preload.
R! The bolts m
REMEMBER must be careefully tighten
ned crosswisse.
ng torque of the bolts.
WARNING! It is necessaary to verify periodically tthe tightenin
We recomm mend to checck the tightening torque after 3 montth of operatiion and then n after 1 yearr.
Ensure thatt the tighteniing torque iss kept under control during the wholee period of o
operation of the crane.
WARNING! not use secu nts such as spring washe
uring elemen ers. Only the preload forcce of the boltt ensures a
proper fasteening.
WARNIG! C
Check the tigghtening of aall pins at leaast once a ye
ear by autho
orized person
nnel.

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The tighten
ning torquee is indicated in the folllowing table
es:
TIGHT
TENING TOR
RQUE FOR GALVANIZE
G ED PIN
THREA
AD STTENGTH CLASS
NOMINAL PITCH
8.8 10.9 12.9
DIAMETTER (mm)
(Nm) (Nm) (Nm)
M2 0.4 0.30 0.5 0.6
M3 0.5 1 1.5 2
M4 0.7 2.5 3.5 4.5
M5 0.8 5 7 9
M6 1 9 12 15
M8 1.25 20 30 35
M10 1.5 40 60 70
M12 1.75 70 100 120
M14 2 110 160 190
M16 2 170 240 250
M18 2.5 240 330 400
M20 2.5 330 470 560
M22 2.5 450 630 750
M24 3 570 810 970
M27 3 840 1200 1400
M30 3.5 1150 1600 1900
TIG
GHTENING TORQUE FO
OR BURNISHED PIN
Strength class to
t DIN/ISO 898 8.8 10.9 12.9
Yield limit Rp 0,2 N/mm2 640
0 for ≥ M 16 940 1100
660
0 for > M 16
Metric
M Cross secction Cross section Clamping force For hydr. Ma' 0.9
9 Ma * Clamping force
f For hydr. Ma' 0.9 Ma * Cla
amping force For hydr.
h Ma' 0.9 Ma *
I
ISO- of area un
nder of thread and electric For spanner and electric For spanner and electric For spanne
er
t
thread stress torque torque ue
torqu
D 13
DIM FM wrench FM wrench FM wrench
AS AT N Mλ Mλ' N Mλ Mλ' N Mλ Mλ'
2 2
mm mm Nm Nm Nm Nm Nm Nm
M12 84
4.3 76.2 38500 87 78 56000 130 117 66
6000 150 135
M14 115 105 53000 140 126 77000 205 184 90
0000 240 216
M16 157 144 72000 215 193 106000 310 279 12

24000 370 333
M18 193 175 91000 300 270 129000 430 387 15

51000 510 459
M20 24
45 225 117000 430 378 166000 620 558 19
94000 720 648
M22 303 282 146000 580 522 208000 830 747 24

43000 970 873
M24 353 324 168000 740 666 239000 1060 954 28

80000 1240 1116
M27 459 427 221000 1100 990 315000 1550 1395 37

70000 1850 1665
M30 561 519 270000 1500 1350 385000 2100 1890 45

50000 2500 2250
M33 694 647 335000 480000 60000

56
M36 817 759 395000 560000 66

60000
M39 976 913 475000 670000 79

90000
M42 1120 1045 542000 772000 90

04000
Determined bolt Determ
mined bolt Dettermined bolt through yield
M45 1300 1224 635000 through yield
d 905000 throug
gh yield 10
059000 measuremen nt
measuremen nt measuurement
M48 1470 1377 714000 1018000
0 11
191000
M52 1760 1652 857000 1221000

0 14
429000
M56 2030 1905 989000 1408000
0 16
648000
M60 2360 2227 1156000 1647000
0 19
927000
* Mλ will change with deviating μG ≈ μK
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9.3.2 TIGHTTENING FITTINGS
If any oil leeaks are nooticed througgh the fittin
ngs of the
hydraulic system,
s hten the fiittings (fig. 1). It is
tigh
advisable to check for f tighteniing of succh fittings
whenever sservicing is caarried out on n the crane.
WARNIG! C Check the tigghtening of aall pins at leaast once a
year by autthorized perssonnel.
9.4 LONG INACTIVITTY
Prevent dirtt from depossiting on the cylinder rod ds. Should
the crane be inactive fo
or a long period, set it in sstowed
position so that the cylinders are clo
osed. If this is not
possible, lubricate the rrod sections exposed to
weathering and all the u unpainted paarts (fig. 2).
REMEMBER
R! Effectuatee this operatiion every 10 days.
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9.5 REGULAR INSPEECTION
A correct m
maintenance w
will help avo
oiding the folllowing issue
es:
 failures which cou
uld reduce the
e safety of the crane;
 failures which are
e affecting the
e crane operaational capabiility.
The followin
ng recommeended proced dures will heelp the crane
e operators to
o develop th
heir inspectio
on and
maintenancce scheduless according to
o their specific equipmen nt and use.
The frequenncy and level of maintenance stated are for guidaance only.
A maintenance schedule for cranes which are reegularly in usse is vital and
d two inspecction categorries have
ned:
been assign
a. Frequent inspections ‐ visual and on a daily basis;
b. Perio ons ‐ at statted intervals of six month taking in consideration
odic inspectio c n how often the crane iss
operrated.
Frequent in
nspections arre visual cheecks to be caarried out on
n the crane prior to its use. It is imporrtant to
check the fo
ollowing item
ms before ussing the crane:
 soleenoid:
 limit switches both for up and down movem
ments;
 oil level;
 hoses and pipes;
 no hhydraulic oil leeaking;
 wiree rope and thee hook;
 pulleys;
 cable winder;
 loadd cell.
Periodic insspections no
ot only are including the aaforementio
oned checks, but also acccurate checkss to be
carried out on the follo
owing crane ccomponentss.
In case any wear or malfunction of aany component is experienced, immeediate action
n must be taken.
ng items willl be checked:
The followin
 Cran ne structure inspection;
 Oil ffilter;
 Gaskets hydraulicc cylinders;
 Oveer center valvee hydraulic cylinders;
 Fusees;
 Bracckets for hosees and pipes;
 Brasss;
 Sliding pads;
 Boltt tightening toorque;
 Pin boom and hydraulic cylinders;
 Oil ccooler;
 Coooling fan;
 Hyddraulic pump aand couplings;
 Elecctric motor;
 Elecctrical swivel;
 Hyddraulic swivel;
 Man nometer;
 Thermostat;
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9.6 SCHED
DULED MA
AINTENANC
CE
Scheduled m
maintenancee of the cran
ne to be mad
de by one or two times a year considering the am
mount of thee
working hours.
maintenancee is performeed by qualifieed inspectorrs who will reelease an inspection repo
Scheduled m ort.
The followin
ng items willl be checked:
 Cranne structure inspection;
 Repplacement of tthe wire rope if necessary;
 Redduction gears ccolumn and wwinch;
 Hyddraulic distribu
utor;
 Elecctric motor;
 Slew
wing ring;
 Repplacement or cclean‐up hydrraulic oil.
9.6.1 INSPEECTION RECO ORDS
Inspection rresults as rep n the cranes will be dateed and signed
pairs and maaintenance carried out on d on the
crane log. TThese records shall be kept available by the crane
e operator.
9.6.2 CRANES NOT IN RREGULAR USEE
Cranes whicch have been
n idle for a prolonged peeriod of time,, will be insp
pected accord
ding to the
nts of Regular Inspection.
requiremen

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9.7 STRUC
CTURE AND
D GENERA
AL INSPECTION
It is necessaary to visually check that the crane sttructure and in particular
weldings are not damagged nor affeccted by micro ocracks, thatt could causee
irreparable damages ovver time.
WARNIN! W
Wash the craane carefullyy before insp
pection.
CAUTION! DDo not turn tthe jet of the water cleaaning machin
ne on the
shunt boxes of the elecctric system (FIG.1)
9.7.1 WELD
DING CHECKING
 Eve ery 6 ‐ 12 Mo
onths
Visu
ually inspect all welds forr cracks and corrosion . Initially by vissual examinaation but if in
n doubt, usee
NDTT inspection methods. Th his inspection should also o extend to d deck structure. This insppection
sho
ould be develloped by a co ompetent Sttructural Enggineer.
9.7.2 STRUCCTURE CHEC CKING
onths
a. Insp moving paint and carryin
pect load beearing structture for corrrosion, rem ng out hammer test ass
neccessary. if co
onsidered neecessary, thee thickness of structuraal items is to
o checked by
b drilling orr
other suitable m
methods.
b. pect load beaaring structu
Insp ure for crackss and any siggns of local in
ndentation, b
buckling or u
unfairness.
c. Cheeck the condition of pulleey and wire rrope guide.
d. Cheeck the condition and seccurity of ropee anchor and
d load cell.
e. Ensure all walkw
ways and han
ndrail system
ms are secure
e and are in good condition(IF PRESEENT).
9.7.3 BOLTSS CHECK
onths
a. Check the tig
C ghten torquee in the boltss according tto crane man
nufacturers p
procedures.
b. Remove at least one bo osion and the stress corrrosion cracking. Replacee
olt for examine the corro
t
the bolts exa
amined in an
ny case.
9.7.4 PAINTT CHECK
onths
The owner and/or userr of the cran
ne is responssible for the
e good preseervation of the steelwork by regularr
n this way the
painting. In t reliabilitty and workking life of the
t crane can be guaraanteed. Dam
mage to thee
corrosion protection sysstem (paint) must be rep
paired immed
diately.
9.7.5 SPECIAAL OVERHAU UL
Every 5 yeaars the cranee must be thooroughly oveerhauled by aan authorizeed skilled technician.
The re‐testing of the craane is necesssary after succh period or after repairss, modifications have been carried
ng the strenggth or otherw
out affectin wise as required by the su urveyors.
Such overhhauling has the purposee to analyziing the overall conditio
ons of the ccrane and demonstrate
d e
satisfactoryy operation, eefficiency of overload an
nd weight loaad indicatorss, effectiveneess of limit sw
witches, etc.
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9.8 WIRE ROPE MA
AINTENANC
CE
A typical w
wire rope maay contain h hundreds of individual wires form med and con nstructed soo as to
operate neear one ano other. The w wires of the wire ropes are made o of high carb
bon steel. WWhen a wire
rope bends, each of itts countlesss wires slips and system m in the fold d so as to acccommodatte the
difference in length between thee inner fold and the outtside.
During maanufacture tthe wire rope is carefu ully lubricatted, and sub bsequentlyy during usee this
treatment should be repeated p periodically every 50h.
The winch rope must be regularlyy cleaned and maintain ned in best working co ondition. The
lubrication
n should be performed with an oil that has a vviscosity of SAE 30, in o order to ensure a
deep lubriccation of th
he rope thuss avoiding p premature w wear.
In the courrse of time ropes will eexperience aa strain thatt will bring a consequeent loss of re esistance.
So intensivve use and ppoor mainteenance can shorten the e useful lifee of the ropee.
REMEMBEER! The breaaking load is referred tto a rope that was just installed an nd is destine
ed to
decrease oover time du ue to its weear and tearr. For this reeason, the rrope should be subjected to
regular cheecks and insspections inn order to verify its efficiency and decide its rreplacemen nt if
necessary.
The breaking load of tthe rope is d determined d during a sttandard tesst in which tthe attacks are fixed
to the ends of the rop pe and the rrope is pulleed in a straight line. In case, howeever, the rop pe passes
over a curvved surface (such as a ggrooved pu ulley or a po oint of curvaature), its reesistance will
decrease. TThe extent of the redu uction will depend on the severity of the bend d. The bendding angle
must not bbe 180 °, 90 ° or even 445 °.
REMEMBEER! folds relatively smaall may causse a conside erable loss o of strength.
REMEMBEER! Never ovverload thee wire rope and never u use the ropee in the casse where the applied
load is greaater than th
he maximum m working load.
WARNING G! No wire ro ope must never be insttalled or used without knowledgee of the breaaking load
suitable for the intendded use.
WARNING G! If the ropee is worn, frrayed or torrn it has to be replaced d.
WARNING G! If it is necessary to peerform weld
ds to the crrane structu
ure never co
onnect the w
welder
ground cab
ble to the w wire rope.

K‐IN PERIO
9.9 BREAK OD
After installing a new wire rope is necessaryy to perform m some prelliminary liftting operatioons with a
light load aapplied at reeduced speeed. This allo
ows the rop
pe to compaact and adaapt to liftingg
operationss.
At this poin
nt the wire rope is lesss prone to d
damage whe
en you applly full load.
The resistaance of a wiire increasees slightly affter the break‐in period
d, but decreeases over ttime.
The elongaation structural generaally occurs d
during the fiirst 10‐20 liffting operattions.

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9.10 ELON
NGATION O
OF THE WIRE ROPE
All wire ropes will streetch to varyying degreess in the moment in wh hich it is initially applied
d the load .
The elongaation of the rope occurrs in three p phases :
1 ) Elongattion initial structural du uring the firrst period of the rope, caused by tthe compacction of the
wire rope d during the ffirsts lifting operationss. (See also ppage 45
Paragraph 11.6)
2 ) After brreak‐in it is start a longg term, the longest parrt of the life of the wiree rope, during which
there is a sslight increaase in elonggation for a long time.
This is due to normal wear and teear , fatiguee, etc. ...
3 ) From thhis point forrward, the eelongation o occurs at a faster rate. This meanss that the ro ope has
reached th he point of rrapid degradation thatt is the result of prolonged exposu ure to abrassive wear ,
fatigue, etcc. This is a w
warning thaat indicates the need fo or a rapid reeplacementt of the rope e.
9.11 WIREE ROPE INSPECTION
It is importtant carry o
out regular aand periodic
inspection made by an inspector with
experiencee in the fieldd.
WARNING G! At the end of every w work cycle,,
during winnch rope wiinding, makke sure thatt
the rope iss not damagged in any w way (fig. 1).
The abrasion, bendingg and crushing are the
main factoors for a poo or use of steeel ropes
and discovver these co onditions is tthe main
goal of a proper inspeection proceedure. The
inspection is intended d to determmine if a wiree
be able to ccontinue to be used in
rope is to b
safely or not.
Inspection criteria, inccluding the number an nd location o
of broken w
wires, wear and elongation, have
been estab blished by D DIN, ISO, CEN, OSHA, ANSI, ASME and other eentities .
CAUTION! In the even
nt that a wirre rope is to
o be removed from serrvice as no llonger suitaable for
UST NOT BE RE‐USED FO
use, IT MU OR OTHER A APPLICATIO
ONS .
Among thee conditionss that can cause probleems in a sysstem of wiree ropes are cited:
• Worn pulleys can daamage a wirre rope.
• Broken w
wires are eq
quivalent to a loss of strength .
• The twistting a wire rope damagge permaneently.
• Environm
mental facto
ors such agggressive con
nditions and
d heat can d
damage a w
wire rope.
• A lack of lubrication can significcantly reducce the serviice life of a wire rope .
• Avoid contact with eelectrical wires will dam
mage a wire
e rope.

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9.11.1 BROKEN WIRES
The frictionn of the wirre rope on tthe drum, roollers and p
pulleys involves a wear of the exteernal metal
wires. Duriing the operating cyclee of the wiree rope may occur breakage of external leads,, in most
cases it sho
ould not bee a prerequisite for the replacement of the ro ope.
It must, hoowever, mark the affeccted area an nd carefully check that there are nno other brooken wires.
Remove th he broken ends by bending the wire back and d forth alterrnately.
WARNING G! A continuous increasse of external wires bro oken meanss that the w wire rope haas reached
the maxim mum wear lim mit, and thiis requires immediate replacemen nt.
The verification of thee deteriorattion or the bbreaking of the internaal metal wirres of the w
wire rope
are the moost difficult factor to deetect. To ch
heck the state of wear oof
the internaal metal wirres, the wiree rope shouuld be comp pletely deprrived
of any load
d to allow thhe operatorr to move th he outer strrands in ord
der
to inspect the internal ones.
WARNING G! The breakking of the w wires insidee the cable involves a
sudden overload on th he outer wiires that cann cause uneexpected
breaking oof the rope.
9.11.2 MEA
ASURING THEE DIAMETER
R OF THE ROP
PE
To evaluate the reducction of the rope diameeter, it is ne ecessary to measure th he new rope e, and then
measure itt after the b break‐in perriod perform med at a spe ecific load.
This providdes a good iindication o of the value of the initiaal decrease of the ropee diameter. The
measured diameter value after the break‐in n period beccomes "the caliber of M Measureme ent."
Always com mpare the rrope diametter found in n subsequen nt inspectio
ons to "the ccaliber of
Measurem ment." If you u detect a fuurther decreease in wire e rope diammeter when measuring the rope
in the same loading co onditions, itt is often du
ue:

‐ to excessive wear orr corrosion o of the exterrnal metal wwires;
‐ to a loss o
of tightnesss of the inteernal metal wires;
‐ to a breaking of the internal meetal wires;
‐ to excessive wear orr corrosion o of the internal metal w wires;

However, tthere will always be a regular and d continuous decrease of the ropee diameter ffor the
operationaal life of thee rope. The deterioratio on of the internal metaal wires invoolves a morre rapid
decrease o of the rope d diameter, aand in thesee cases we rrecommend d a replacem
ment.

REMEMBEER! It is reco ommended to perform m measurem ments of thee diameter o of the wire rope at
different ppoints.

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9.12 WIREE ROPE CO
ORROSION
Corrosion is a cause o of degradation of the roope difficultt to assess aand more dangerous th han
abrasion.
Normally dderived from m a absencee or lack of lubrication and often aattacks the inside of thhe wire
rope beforre it is visible to the outer surface..
The user m
must take caare to consttantly checkk that the caable is free of any corro osion that ccould causee
a sudden aand unexpected failuree of the ropee.
A high pressence of corrosion lead ds to a prem
mature weaar of the rop pe.
WARNING G! Verify thaat the cable in the area of the attack with thee accessories is free of ccorrosion
or broken wires.
REMEMBEER! Lubricate regularly to prevent premature wear of thee rope due to corrosion.
The wire roope must be regularly cleaned and d maintaine ed in best wworking condition.
The lubricaation should d be perform
med with an oil that haas a viscositty of SAE 30
0, in order to ensure a
deep lubriccation of th he rope thuss avoiding p
premature w wear.

9.13 WIREE ROPE LUBRICATION
N
The wire ro opes are thoroughly lu ubricated in the factoryy and this trreatment will provide b broad
protection for the rop pe over a reasonable period of tim me , provideed it is propeerly guarded .
After that , however, the wire ro ope must be e lubricatedd at regularr intervals eevery 50h to o ensure a
regular use e.
WARNING G! The rope must be alw ways lubriccated prope erly in order to reduce corrosion.
Re‐lubricatte wire ropee is not always a simplee task . Asid de from thee very naturre of the lub bricant ,
the old lubbricant , dirtt and other particles caan cover thee outer partt of a wire rrope to the point that
a lubricantt just applied is not able to penetrrate inside aa wire rope . In this casse, it is nece essary to
thoroughlyy clean the w wire rope oor using a high‐pressure e lubrication force thatt pushes the new
lubricant to o the insidee of the rope.
If the surfaace of the roope is clean
n , the operaation of lubrication can n be accomplished usin ng spray
cans of a luubricant speecifically deesigned thatt penetrates inside thee rope .
The proced dure and th he programm ming of the lubrication n largely deppend on thee length and d size of a
rope and the rope fro om the equipment on w which it is in
nstalled. In aany case, if it is not esttablished a
program of periodic lu ubrication , the wire roope will deteriorate mo ore rapidly.

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9.14 GROOVED PULLLEYS AND DRUM INSSPECTIONSS
Proper maintenance o of the wire ropes equip
pments has a crucial efffect on thee useful life of the wire
rope.
For this reaason it is neecessary to constantly check the state of weaar of the following com mponents:
‐ Pulleys;
‐ Winch drum;
‐ Rope guid de.
The pulleys should bee inspected periodicallyy to check the degree o of wear of the grooves that may
cause fasteer wear of tthe wire rop pe.
In the casee in which th he groove mmonsters fin
ngerprint off the rope, tthe pulley ggrooves musst be
replaced oor subjected d again to th
he machine tool and thhe machinin ng process rrestores.
Excessive w wear of the bearings or bushings o of the pulleys may cause the lockiing of the pulley and
this would lead to an abnormal aand premature wear off the rope.
REMEMBEER! Periodiccally grease the bearinggs or bushin
ngs pulleys.
REMEMBEER! During aassembly off the pulleyss as a conse equence of aa maintenance verify tthat are
perfectly aaligned. A po
oor alignmeent of the pulleys will ccause fasterr wear of wire rope and
d pulleys.
The same ccheck should be carried out periodically to th
he drum of the winch in order to m
make sure
that does n
not show signs of wearr similar.
It 'also imp
portant to check period
dically the sstate of weaar of the tefflon rope gu
uide, and in case of
excessive wwear shouldd be replaceed promptlyy.

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9.15 WIREE ROPE CH
HANGING
The rope sshould be reeplaced acccording to the numberr and positio
on of brokeen wires, the wear and
d
corrosion cconditions, and other cconsiderable damages or deteriorrations.
BROKEN W WIRES ‐ Thee following advices on nly apply to ropes whicch are used d on steel oor cast iron

n
pulleys nott coated wiith synthetiic material. It is necessary to cou unt the brokken wires yyou can seee
on the rop
pe outside,, considerinng the ropee section which
w is wo
orn the most. The rop
pe must bee
replaced when
w the number of broken
b wirees is more than
t 10% of
o the wiress making up
p the rope,,
considering a length w which is fouurfold as lon
ng as the scrrew pitch off the wire inn the strandd.
Broken wires often reemain in th
heir original position and
a do not protrude frrom the rope surface..
You can seee such breaks by removing the ggrease coating the ropee: it is advissable to rub b a piece off
softwood aalong the ro ope and; if ppossible, to bend the rope by hand, so as to ccause the w wire ends to
o
rise and bee visible.
Wear and corrosion ‐‐ Any wear o or strong coorrosion of wires foreb bodes breakkage; beyon nd a certainn

measure the wire shoould be con
nsidered ass broken, it should be therefore replaced acccording to
o
the criteriaa described
d above. Such limit can n be consid dered as atttained when the diameter of thee
wire, appraaised at sigh
ht, looks haalf the origin
nal diamete er.
Other dete
erioration m
marks ‐ Indeependently of what above, the rope shall be replaced:
 w
when its total
l diameter hass reduced by 7% with regarrd to its origin
nal diameter, eeven if in one spot only;
 w
when any stra d in such a waay that its worrking section is reduced byy
and is fully brroken, or wheen is damaged
4
40% in any sp
pot;
 w
when the rop e is dented, tw
wisted or permanently ben
nt due to damage or laying on sharp edges;
 w
when the core
e comes out o
of the rope, evven in one spo
ot only;
 w
when one or s
several strand
ds are slack orr protruding, e
even if the rop
pe is tensioneed.
If the wire rope need ds to be chaanged is neccessary to rrespect all tthe featurees of the oldd wire ropee
installed on
o the cranne. We recoommend to o contact Sormec
S afteer sales deepartment in
i order to
o
receive thee correct infformation aand instructtions. In anyy chase the replacemeent needs to o be carried
d
out by quaalified people.

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9.16 WINC
CH DRUMSS MAINTEN
NANCE PLA
ANNING
9.16.1 ROUTINE MAINTTENANCE
 M
Monthly ‐ 6
6 Monthlyy
a. Cheeck the status and leveel of lubrican
nt on a regu
ular basis an
nd top up w
when necesssary;
b. Top
p up the am
mount of greease in the d
drum suppo
ort transmisssion bearin
ng when necessary;
c. Cheeck the condition and ssecurity of tthe rope keeper on thee drum flange;
d. Cheeck the weaar of brake d
drums.
Check aall major fassteners associated witth the drum
m against th
he manufaccturers reco
ommended..
Typically and wherre applicablee, such fastteners would be:
1. Bolts of the main d
drum unit ffoundation;
2. Screw o
of the winch frame;
3. Screw o
of the winch drum;
4. Screw o
of the axis // shaft;
of the rope keeper;
5. Screw o
6. Screw o
of the reduction gear b
box / brakess.
Visuallyy check for 'cracks' at all main weldd areas on d
drum and d
drive mountting; this maay be
indicateed initially b
by local pain
nt cracking.
9.16.2 SPEC
CIAL MAINTEENANCE
After 10
000 hours o
of winch opeeration (witth average o
operating cyycles at 60%
% nominal load) a full
service of the negaative brake is mandatory. This worrk must be done by qualified perssonnel,
contact Sormec.
9.17 HOO
OK AND HO
OOK BLOCK
KS
 Daily ‐ Montthly
a. Cheeck the liftin
ng hook payying attention that the
e hook safetty latch is ffully closed,, intact and
d
functional;
b. Thee incorrect application off the rope to
o the hook ccan open thee hook safety latch. The safety latch
h
musst always retturn to its orriginal seat affter the rope
es have been
n attached;
c. Cheeck that hookk swivels smoothly;
d. Cheeck the condition of the h
hook, if samee cracks appears the hoo
ok has to be cchanged;
e. Cheeck that all sp
plit pins secu
uring hook sw
wivel nut and
d rope guidee are intact;
f. Cheeck the degreee of wear of the groovees of the pulle
ey that may cause fasterr wear of the
e wire rope;
g. Ensure all lubrricant chann
nels (grease points) are
e clear, und
damaged and provide free
f flow off
lubrricant.

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9.18 SLEW
WING RING
G AND FASTTENERS
 Mo
onthly to 6
6 Monthlyy
a. Cheeck the tigh
hten torque on the slew
wing ring faastener boltts(between pedestal and column))
acccording to crane
c manu
ufacturers procedures
p . Check thee tighten to
orque at le
east in fourr
bolts(one in eaach quadran
nt).
b. Cheeck the tighten torque on the winch bolt;
c. Cheeck the tighten torque on the hydraulic cylind
der tap;
d. Cheeck the tighten torque on the shock absorberr tap, if pressent.
e. Cheeck the condition of radial oil seal and change
e it in case is damage.
f. Cheeck the condition of the slewing riing teeth.
g. Enssure the mo
otoreductio
on gear pinion drive has full face width contact and co
orrect pitch
h
linee setting.
h. Make the rockking test.
i. Enssure all lubrrication poin
nts are undaamaged and
d provide frree flow of lubricant.
 6 M
Months to
o 12 Montths
a. Rem
move at leaast one bo
olt for exam
mine the co
orrosion an
nd the stress corrosion cracking..
Rep
place the bo
olt examineed in any casse.
9.19 ELEC
CTRIC MOTTORS
 Daily ‐ Montthly
a. ure and correctly fitted
Enssure all guarrds are secu d
b. Cheeck all locally mounted
d gauges/insstruments aare function
ning
c. Cheeck the condition, secu
urity and chaffing of loccally run eleectrical cablles
d. Cheeck the corrrect function of local sttart/stop an
nd emergen
ncy stop con
ntrols

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9.20 INSP
PECTION OFF TANKS A
AND STEEL COMPONEENTS
External insspection of tthe tank
The externaal inspection n is a visual o
one and must be undertaaken at least once every ssix months (or more
frequently d depending on operating conditions aand use).
In order to aallow for a vvisual inspecttion, prior cleeaning may b be required.
There is a visual inspecttion for:
 Leaaks
 Craack formation
 Corrrosion
 Dents due to th he applicatio on of externaal force
In the case of leaks at co omponents sscrewed into o the tank the latter are tto be re‐tightened once and this
then record nt, the contact point musst be carefully checked fo
ded. If there are still leakss at this poin or the cause
of the leakaage. Dependiing on the reesult, seals are to be rene ewed and/orr the compon nent replace ed. In the
case of leakks at flange‐mmounted com mponents, yo ou should prroceed in a similar manner.
In the case of crack form mation or leaaks at welded d seams, thee cause mustt be determin ned and rem medied.
Afterwards,, the compon nents concerrned are to b be replaced o or repaired in a professioonal mannerr.
If there are signs of an aapplication o of external foorce the causse must be d determined aand remedied.
Afterwards,, the compon nent and also adjacent components are to be cheecked for damage and asssessed
with respecct to further reliable use. If necessaryy, these components are to be replacced or repaired in a
professionaal manner.
If there aree signs of an application of external fforce on the tank, an inteernal
inspection of the tank should be un ndertaken.

If there are signs of corrrosion the co omponent is to be checked for damage and assesssed with resspect to
further reliaable use. If necessary, this componen nt is to be replaced or repaired in a pprofessional m manner.
You must in n all cases provide for corrrosion proteection.

Internal insspection of the tank
The internaal inspection is a visual in nspection of the tank on the inside an nd is generallly performed when the
oil is changeed. Oil changge will depen nd on the ressult of oil sammples taken..
In order to perform the visual inspection, you m must first of aall completely drain the ooil (refer also
o to oil
maintenancce). If there is any contam mination, intternal cleanin ng must alsoo be carried oout.
There is a visual inspecttion/inspection for:
 Corrrosion
 Craack formation
 Forreign bodies
 In tthe case of screw connecctions, you m must ensure tthat they aree sitting corrrectly
Particular characteristiccs with walk‐‐in tanks
Prerequisitee: The inspecctor must no ot suffer fromm claustrophobia and mu ust be physiccally fit enough to move
around in a confined space!
Recommendation: Befo ore commenccing the work inside a tank, you shou uld inform th
he fire departtment
and/or a first aider/paraamedic or en nsure that th hey are on standby.
If the inspecctor has to mmove his who ole body com mpletely intoo the oil tankk, he must bee suitably harnessed and
secured by at least a seccond person n outside the oil tank.
Preparation n
For his ownn safety, the inspector mu ust:
 Preepare a mean ns of rescue before entering the tankk,
 Takke off watch and jewelry,
 Weear a cap or aa hair net,
 Weear protectivve clothing (tight‐fitting o overall with zzips and no ooutside pockets),
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 A laamp suitablee for explosivve atmospheeres must be used
DANGER! R Risk of personal injury an nd damage to property!
There is a riisk of suffocaation inside ttanks.
The breathaable air in a ttank must co ontain sufficiient oxygen ffor it to remaain breathab
ble for the reelevant
personnel w without posin ng any risks.
‐> Before en ntering the ttank, open alll manholes aand access oopenings.
‐> Ensure suufficient ventilation with breathable air, if necesssary by mean ns of forced vventilation.
In the case of crack form mation at weelded seams,, the cause m must be deteermined and remedied. A Afterwards,
the welded seams concerned are to o be repairedd in a professsional manneer.
If foreign boodies are dettected they aare to be remmoved from the tank. Their origin and the cause of their
presence m must be estab blished. Depeending on the cause estaablished, suittable measurres must be introduced
to ensure saafe operation of the hydraulic powerr unit.
If there are signs of corrrosion the loocation conceerned is to be checked fo or damage an nd assessed with
respect to ffurther reliabble use. If necessary, the tank must bbe replaced o or repaired p
professionallyy. You must
in all cases provide for mmedium‐resistant corrosion protectio on.
If piping andd hose fittinggs are loose the former mmust be tightened professsionally.
If screw connnections aree loose the p parts to be seecured must sit correctlyy and the screw connection
tightened p professionallyy.
9.21 HYDR
RAULIC OIL LEVEL CH
HECK
Every day mmake sure that the oil levvel in the tan nk is includedd between th he minimumm and maximum allowed..
Restore thee oil if requireed. The filling level shoulld be checkeed at intervals of 8 operatting hours.
While the hhydraulic pow wer unit is in operation, tthe oil level w will not remaain constant.
Level changges result froom the differrent volume requirementts of plungerr and differential cylinder and/or thee
absorption//delivery of o oil in hydraulic accumulators during aa working cyycle.
Due to thee variable coonditions mentioned
m ab
bove a commplete workiing cycle off the machin ne must bee
observed w when undertaaking the visu ual inspectio
on of the oil llevel.
This will enaable you to ddetermine w whether the ooil needs to bbe refilled orr topped up, and if so, byy how much.
During operation, the o oil level musst neither exxceed the up pper mark nor fall below w the lower mark. If thee
minimum filling level is undershot, tthere is a riskk of pump faailure due to cavitation.
If the maximmum filling level is exceeeded, this may have bee en caused byy the thermaal expansion of the oil orr
by fluid entry.

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9.22 CHAN
NGE OF HY
YDRAULIC OIL
To assure the
t best wo orking in thee time, checck the oil an
nd replace it periodicallly. We recommend thiss
operation aafter the firstt 500 workin ng hours. Forr crane used occasionallyy, the change of oil mustt be done att
least at inteerval of one yyear, independently to th he oil properrty.
However, an oil analysiss should be p performed affter 2000 ho our of functio
oning and at interval of 5 500 hours upp
to 4000 max working ho ours. An oil aanalysis entaails drawing a sample of oil in a profeessional man nner. The oil
sample musst be checked in a suitable laboratoryy in accordan nce with the oil manufaccturer's specifications.
Depending on the result, it may be n necessary to o implement more measu ures, e.g.:
‐ Filtration ((measures)
‐ Dehydrogeenation
‐ Changing tthe oil
The use of rrecycled oil ((recovered ooil) is to be avvoided.
If the oil is cchanged, it m ned complettely. So, you must provide a collecting tank that iss large
must be drain
enough to aaccommodatte the total o oil volume.
The total vo olume of the hydraulic poower unit co omprises the volumes of the tank, thee line system
m, the
drives, etc.
As a basic p principle you should obseerve the relatted instructions for the ccomplete maachine. Unlesss otherwisee
specified in these operaating instructtions, you sh hould compleete the followwing steps:
• Avoid dan ngers caused by adjacentt machines.
• Do not allow uninvolvved persons tto remain in the area con ncerned.
• Loads sho ould be lowered or safelyy supported
• Switch offf the electriccal power andd ensure thaat it cannot b
be switched o on;
• Drain the oil into the ccollecting tan
nk.
The hydrau
ulic oil has to
o be replaced
d with the saame make or with similaar one.
WARNING! The oil chan
nge must be carried out with the craane in stowe
ed position, w
with all the ccylinders
retracted.
To change tthe hydraulicc oil please reefer to the fo
ollowing ope
erations:
 C
Close the crane
e cylinders completely. In this way the dirty o
oil goes from th
he cylinders to tthe tank;
 Prepare a vesseel having the saame capacity ass the tank;
 Removing the p
plug (see num. 1 NEXT PAGE);
 Remove the drain plug with th
he shut off valvve closed; (see n
num. 2);
 Mount a flexiblle hoses in the shut off valve;
 o
open out the sh
hut off valve an
nd empty the taank, paying atte
ention not to po
our the oil outsside; (see num. 2)
 C
Change the return oil filter(see num. 3);
 Replace the draain plug and clo
ose the shut offf valve (see num
m. 2);
 Fill the tank fro
om the plug with new hydrauliic oil, about 600
0l (see num. 1);;
 C
Check the oil level with all th
he hydraulic cyylinders crane cylinders
c d(see num.4). Turn on the crrane and makee
closed
s
some moveme nts and with all the hydraulic cylinders closed re‐check the oil level.
INFORMATION
N! The exhaustted oil shall be delivered to a Body charged with the collecction and dispo
osal of exhauste
ed oils.

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For proper ccrane functio
oning, use hyydraulic oil o
of HLP type, ISO viscosityy, to be seleccted accordin
ng to the
outside tem
mperature as per table beelow:

- 40 °C
C ÷ 0 °C VG
V 32

0 °C ÷ +40 °C VG
V 46
+ 40 °C
° < °C VGV 68
OUTSIDE TEMPER RATURE

- 40°C ÷ 0°C 0°C ÷ + 40°C > + 40°C
SHELL Tellus Arrtic 32 Tellus 46 T
Tellus 68
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9.23 OIL FFILTER MAINTENANC
CE
In the hydrraulic poweer unit is installed a 10 microns oil filter.
After the first 150 working hourss (or after 1 month) takke out and rreplace the filter cartridges
according tto the figurre 1.
Afterwardss, every 300 0 hours (or after 2 mon nths), carefu
ully clean th
he cartridgees with petrrol and air
blows. Shoould any meetal parts bee noticed, thhe cartridgees should bee replaced.
INFORMATTION! Anyw
way the carttridges musst be replace
ed at least o
once a yearr.
INFORMATTION! It is aadvisable to
o replace all filter cartriidges at anyy oil changee.
INFORMATTION! It is n
necessary to
o replace th
he cartridge with anoth
her one havving same fe
eatures.
If the return filter is e
equipped with a cloggin ng described above
ng indicatorr, carry out the servicin
when the rred sensor ggets up(fig.2
2).

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9.24 MOTTOREDUCTTION GEAR
R HYDRAULLIC OIL
Regarding the mainteenance, hydraulic oil type and quantity of thee motoreducction gear(w
winch and
rotation), rrefer to the manufactu
ure's manuaal (Brevini) tthat Sormecc has suppliied.
INFORMATTION! Check for the oiil level in th
he reducer e
every 150 h
hours.
FUNDAMEN NTAL CHARA ACTERISTICS OF THE OIL

The importaant parameters to consid
der when cho
oosing the tyype of oil aree:
 viscosity at nomin
nal operations;
 additives
The oil musst lubricate tthe bearingss and the gears and all tthese compo onents work inside the ssame box, in
n
different op
perating cond ditions. We w
will considerr the individu
ual parameteers.
VISCOSITY
Nominal viscosity is reeferred to a
a temperatu ure of 40° C, but rapidly decreases with an increase in n
temperaturre. If the opeerating temp perature is bbetween 50°° C and 70°C C, a nominal viscosity can n be chosen n
according to o the followiing guide tabble, choosingg the highestt viscosity if tthe highest ttemperature is foreseen.
Special atteention must be paid to very loaded output stagges and withh very low sspeeds(<1 rppm). In such
h
cases, alwayys use high vviscosity oils and with a ggood amountt of Extremee Pressure(EP P) additive.

n2 [rpm] 50° C 70° C
n2> 20 VG150 VG220
200>n2> 5 VG220 VG320

n2< 5 VG320 VG460

ADDITIVES
In addition to the norm mal antifoaming and antioxidant additives, it is im mportant to use lubricating oils with h
hat provide EP(extremeepressure) and antiwearr properties, according to ISO 6743‐6L‐CKC orr
additives th
DIN51517‐3 3 CLP.
Therefore it will be necessary to find
f products with EP ch
haracteristiccs all the strronger(type MOBILGEAR R
SHC) the slower the gear
g unit speeed. It shou
uld be remeember that the
t chemicaal compound ds replacingg
hydrodynam mic lubrication are form
med to the detriment
d off the original EP load. Therefore, with very low
w
speeds and high loads iit is important to respect the mainte enance perio ods so as nott to excessivvely diminish h
the lubricatting characteeristics of thee oil.
TYPES OF O OILS
The oils avaailable generally belong tto three big ffamilies:
 Min
neral oils;
 Polyy‐Alpha‐Olefin
n synthetic oils;
 Polyy‐Glycol synth
hetic oils.
The most su
uitable choicce is generally tied to thee conditions o
of use.
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Gear units that are nott particular loaded

l and with
w a discoontinuous opperating cycle, without considerable
c e
temperaturre ranges, can certainly b be lubricatedd with mineraal oil.
In case of heavy use, when the gear
g a very loaaded and in a continuo
units are ous way, with resultantt
temperaturre increase, it is best to u use polyalphaaolefin synth
hetic lubrican
nts(PAO).
Polyglycol ooils (PG) are to be used strictly in the case of ap with heavy sliding between contacts,,
pplications w
O minerali
Oli Oli sintetici Polia
alfaolefine(PAO) Olii Sintetici Poliglicoli(PG)
Produttore Mineral oils
M Poly-Alpha-Olefin synthetic
s oils(PAO) Polyyglycol synthetic oiils(PG)
Manufacturer
ISO VG 150 IS
SO VG 220 ISO
O VG 320 ISO VG
V 150 ISO VG 220 ISO VG 320 ISO VG 1550 ISO VG 220 ISO VG 320
Energol Energol E
Energol Enerssyn EPX Enersyyn EPX Enersyn EPX Enersyn SGG- Enersyn Enersyn
BP
GR-XP150 G
GR-XP220 GR
R-XP320 1
150 22
20 320
0 XP 150 SG-XP 220 SG-XP 320
Ultra Gear U
Ultra Gear Ultra Gear Tegra Synthetic Tegra Synthetic Tegra Syn nthetic HiperSYNN HiperSYN HiperSYN
CHEVRON
150 220 320 Gea ar 150 Gearr 220 Gear 320
3 150 220 320
Mobilgear M
Mobilgear Mobilgear Mobil SHC
S gear Mobil SH HC gear Mobil SHC C gear Glygoyle Glygoyle Glygoyle
MOBIL
XMP150 XMP220 X
XMP320 1
150 22
20 320
0 22 30 HE320
Omala S2 G O
Omala S2 G Ommala S2 G Omala S4 GX Omala S4 GX Omala S4
S GX Omala S4 4 Omala S4 Omala S4
SHELL 150 220 320 1
150 22
20 320
0 WE WE WE
150 220 320
e.g. in worm
ms. They must be employyed with greeat care since ot compatible with the other oils butt
e they are no
are complettely mixablee with water.. This phenoomenon is paarticularly daangerous, sin
nce it is not noticed, butt
rapidly diminishes the lu
ubricating ch
haracteristic of the oil.
In addition to the abovee, there are aalso hydraulic oils and oiils for the foood industry. The former are used forr
the commaand of negattive brakes. For better environmental protectio on these aree several bio
odegradablee
types. The latter have a specific use
u in the fo
ood industryy since theyy are special products that
t are nott
harmful to the health, Various producers
p suupply oils belonging to all the fammilies with very similarr
characteristtics. A compaarison table of the best kknown brand ds is given latter on.
CONTAMIN
NATION
During norm mal operatio on, due to run nning‐in of the surface, m metallic micrroparticles w will inevitablyy form in thee

oil. This conntamination can shorten the life of th he bearings, resulting in eearly breakd down of the ggear unit. To o
limit and co ontrol this ph
henomenon, without resorting to fre equent and costly oil changes, a suitaable auxiliaryy
oil circulatin
ng system must
m be provvided. This system
s offers the dual advantage off controlling the level off
a stabilizing the operrating tempeerature at a
contaminattion with thee use of speecial filters and a level moree
suitable forr guaranteein ng the required viscosityy. In fact, the e specific theermal capacity of the ge earbox is nott
sufficient too guarantee tthe correct, stable operaating temperrature.
For lubricattion problemms with geaarboxes intended for sp pecific appliccations, in teerms of the
eir particularr
construction or operatin ng conditions, we recommend you co ontact the Brevini Ridutttori Technicaal Service.
In this regarrd, you are reminded thaat Brevini Rid duttori has a technical aggreement witth Exxon Mo obil wherebyy
specific con nsultation is aavailable forr special applications as wwell as the m monitoring of application ns lubricated d
with MOBILL products.

INFORMATION
N! The exhaustted oil shall be delivered to a Body charged with the collecction and dispo
osal of exhauste
ed oils.

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9.25 BASEE LUBRICATTION
The articulaation pins an
nd the extensions need aa periodic lubbrication. Such intervals of greasing the
articulation pins vary in
n relationship
p to the use and the partticular type o
of crane. In tthe underlyin
ng chart are
show the peeriods of greeasing recom mmended.
WARNING! To have acccess to the grreasing pointts which cannot be reach hed from gro ound, must take place
through thee use of mob bile towers or make use oof a ladder. D
Do not climb up the crane(fig. 1).
Greasing in pressure un ntil it doesn'tt escape from

m the couple
ed elements so that to reeplace the o old lubricant..
ubrication, perform
After the lu p som
me complete movementss of all the articulationss of the cran
ne and add
d
some grease to guaranttee an optimal lubrication.
REMEMBER R! Clean the hydraulic exxtensions fro om the impurities. Keep the sliding ppod well gre easing, coverr
the externaal inferior side and the exxternal superrior side from
m the telesco opic arm with grease.

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REMEMBER R! To make ssure that all the greasingg point are aalways well lu

ubricated, ussing the type
e of suitablee
grease on th
he chart. Otther greases having the ssame charactteristics can be used.
GREA
ASING POIN
NT TYPE OF GREASE GREASIN
NG PERIODS
S
1 – SLEWING RING 50 H
HOURS
2 – ROTATINGG TURRET PIN
P 8H
HOURS
3 – WINCH BE
EARING Shell Albida
A 8H
HOURS
4 – CYLINDER
RS PIN GREA ASE 8H
HOURS
5 – MOTOR REDUCTION GEARS EPP2 8H
HOURS
6 – PINS AND PULLEY 8H
HOURS
7 – SLIDING POD
P & EXTE
ENSIONS 8H
HOURS
8 – WIRE ROPPE
9 – HOOK Oil 8H
HOURS
9.26 FLEX
XIBLE PIPESS
Check for co
onditions of the flexible pipes every 5
50 hours, in particular th
he areas nextt to the unio
ons (fig. 1).
The pipe muust be replacced wheneveer the follow
wing defects aare noticed:
‐ deteriorattion due to normal ageingg;
‐ abrasions;;
‐ piercing;
‐ slits;
‐ breaks;
deformation;;
‐ localized d
‐ swelling.
WARNING! Avoid pipe eexposure to radiant heatt and contactt with corrossive materialls.
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9.27 ROCK
KING TESTTS

SLEWING R
RING CONTTROL
The purposse of this is to draw atttention to tthe critical n
nature of sleew bearingss, the failure of which
will result in crane colllapse, and to modify ccurrent survvey requirem ments durin ng all annuaal thorough
surveys of ships’ deckk cranes fitteed with singgle or twin ball race or roller race bearings.
Cranesover ten years of age and fitted with single ball rrace bearings are mostt at risk.
With immediate effeect, the reqquirements below are e to be followed at eeach annuaal thorough
h
surveyin order to checck the cond dition of cranes’ slew bearings:
 listen to the beearing for aany signs of knocking or unwanted d noise whilst the crane
e is slewed
without anny load;
 cheeck that thee slew bearing bolts rem main tight in accordancce with the crane manufacturer’s
documenteed, recomm mended pre‐tension;
 if you have anyy concern yyou may req quire examination of grrease samp ples for any abnormal
increase in
n metallic paarticles, a siign of excesssive bearin
ng wear.
 roccking tests.
REMEMBEER!Proper luubrication w
will prevent premature
e wear of the slewing riing. To greaase every
50 hours to
o work.

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ROCKING TTESTS
The slewiing ring is a comp ponent of crane ve ery stresseed and so
ometimes wear out..
For this reaason is impoortant to ch
heck the weear of the slewing ringtthrough meeasurementts rocking.
A rocking ttest is a sim
mple test carrried out to measure th
he play betw ween theinner and outter races off
a slew bearing.
CAUTION! It Is imporrtant to effeectuate thee rocking te
est every 6 months an
nd the resullts of thesee
are to be rreviewed an
nd compareed with the recommended and do ocumented limits of we
ear to see iff
thesehave been exceeeded.
PROCEDU
URE
The first measuremen
m nt should be
b performeed when thhe crane is installed on the ship in order to
o
obtain a baase value fo
or subsequeent repeat mmeasurements.
For the firsst measurement somee reference points musst be markeed on the crane that w will be used d
also for all future meaasurementss.
Two refereence points must be m marked in the front and
d rear of thee crane colu umn, see Figg.1, around d
the basem ment (non rootating partt) must be m
marked four referencee points on fore, on staarboard, on n
aft and on port side,seee Fig.2.
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These reference pointts must be m made in waay that theyy will last all the lifetimee of the slew wing ring.

The measu urements are
a taken with
w a dial gauges bettween the lower mating structure and thee
bearing boolted to the superstructture.
The measu urements should be taaken as clo
ose as possiibleto the bearing
b in o
order to minimize thee
effect of ellastic deformations in tthe system.
The dial gaauges should have an accuracy o of 0.01 mm.. Put the crrane boom in minimum m outreach h
and set thee dial gaugees to zero. A
After move the crane boom to the maximum m outreach and record d
the measurements in the point A A ‐ B (FIG. 3 ‐ 4).
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Fig.4
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The measu
urements A
A‐B shall be taken on fo
our position
ns of the slewing ring w
with boom p
pointing:
 forw ward to thee ship;
 starboard
 aft
 porrt side
(See Fig. 5))

WARNING
G!
 Whhen measurements aree to be taken the ship sshall have as little hell//trim as posssible;
 Maake sure theere are not lloads suspeended from the crane h
hook.
It is important that the same positions are

a used fo or all furtheer measureements to be able to
o
compare the result.
For maxim mum allowed d wear see ttable on page 150.
REMEMBER R!The cranee M160/2S h have a doub
ble‐row balll bearing sleewing ring. The balls d
diameter is
40 mm, thee track diam meter is 160 05 mm and the initial cclearance is 0.05 to 0.4
40 mm (man nufacturer
clearance).
In consegu uence the p permissible increase in bearing cle earance is 2 2.8 mm (seee Table 2).
When all p positions have been meeasured, reccord the base values obtained in ttable on pagge 101.
The measu urement sho ould be repeated everyy six month hs and undeer identical cconditions aas the base
measurem ment.
The differeence between the values measureed and the b base values representss the wear tthat has
occurred.
WARNING G! If the weaar is found tto have heavily increassed, the time intervals between
measurem ments should d be shortened.
In case thee wear of th
he slewing ring will over the maxim
mum alloweed is necesssary to chan
nge it.
At next pagge is possib
ble to find th
he drawing of the sleavving ring.
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10 PART REPLACEM
MENT
WARNING! Before startting any part replaceme ent operation
n, disconnecct the powerr takeoff andd turn off
pressure in the hydraullic circuit by moving som
me times the
e control leve
ers all along their stroke
e.
10.1 SPAR
RE PARTS
INFORMATION! Refer to the originaal spare parts catalogue e
equipped with the machine.
To ensure pperfect operaation of the ccrane, we recommend to o always use original spare parts. Wh
hen
ordering, fo
ollow the direections menttioned in thee spare partss catalogue.
10.2 PIPE REPLACEM
MENT
 Screew out the fittings and keeep a vessel under them in o
order
to ccollect the oil;
 Rep
place the flexib
ble hose and ttighten the fitttings.
10.3 COILL REPLACEM
MENT
 To rreplace the co
oll of a solenoid valve, take out the cap A
A so as
to turn current offf in the solen
noid valve;
 Screew out the loccking nut B;
 Takee out the coil C and fit a neew one;
 Screew in the nut B and connecct the cap A aggain.

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11 SAFETTY PRECAU
UTION
We consideer it necessaary that at leeast one secction of this manual is dedicated to accessories that can bee
installed onn the crane h hook to lift th he load. Mosst of the acciidents that o occur during handling of loads is duee
to staff neggligence, non‐compliancce with basic safety and d low maintenance cran ne accessories. This cann
cause damaage to propeerty or even w worse peoplle. We alwayys recommen nd to verify p
periodically tthe integrityy
of the wire ropes and beelts used forr the lifting o of loads.
11.1 USE O
OF THE WIINCH
If you use the
t winch fo
or lifting load
d, the cranee operator sh
hould always check the status of effficiency and
d
greasing of the pulleys,, rope and h hook connectted to the ro ope, as the majority of accidents arre caused byy
poor mainteenance of th he tools abovve mentioned d and by exccessive wear of the wire rope.
Furthermorre, the cranee operator mmust have much caution during liftin
ng and handling of cargo
o in order to
o
avoid the peendulum efffect which co
ould cause acccidental dam
mage.
Following soome useful rrecommendaations to obsserve in orde
er to work saafely and maaintain efficie
ently the
crane in thee long run.
11.2 LIFTING TACKLLE
The tackle is a set madee up of statio
onary sheavees connectedd to the end o of the crane boom by mmeans of a
pulley blockk, and of mobile sheaves contained inn a rope blocck. This systeem has the fuunction of m
multiplying
the winch faall and drivin
ng the rope. The compossition of the llifting tackles depends on the numbe er of falls
required to hoist the loaad.
The configu
uration of thee lifting tacklles provided by Sormec ccannot be ch
hanged.
WARNING! is absolutelyy forbidden decrease thee number of lifting tacklees to increasee the speed of lifting
because thee weight of tthe load to lifft might exceeed the maximum lifting capacity of tthe winch.
R! The crane load chart shows the configuration o
REMEMBER of the lifting tackles.
operator has to ensure that the configuration of the lifting taackles correspond to the
The crane o
on provided by SORMEC.
configuratio
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11.3 COUNTERWEIG
GHT
A counterw
weight is in
nstalled at wire
w rope tip
t in orderr to properlly hoist and
d lower the
e wire ropee
without brringing any damage to o the same especially when the load is not hanged on. In case off
winches with more th han one reeve the sheaave block caan replace the counterw weight.
11.4 LOAD
D HANDLIN
NG
For lift the load to be handled must bring th he crane boo om in doingg so that thee hook is po
ositioned
vertically aabove it.
WARNING G! It is absolutely forbid
dden to lift iin a differen
nt way a carrgo, even in
n case of a lighter load
compared to the wincch hoisting performancces.

11.5 PEND
DULUM EFFFECT
The pendu
ulum effect is the uncontrolled osccillation of tthe cargo haanging to th
he wire rope during
the movim
mentation.
This phenoomenon increases in prroportion too the
length of the wire rop
pe between the pulley that is
located in the head off the boom and the loaad
hanging too it.
To reduce this phenom menon, mu ust lift the lo

oad
with the w
winch bringinng as close as possible to the
head of thee crane booom in such aa way as to have
less possib
ble rope bettween the hhead of the boom
and the loaad.
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11.6 LOAD
D HOISTING
The load hoisting from m the groun nd must be executed th hrough the winch.
If the load is lifted witth the boom
m it will unddergo dange erous oscillaations which
h affect thee structure
of the cranne. The oscillations willl increase proportionallly with incrreasing verttical position of the
arm of the crane.
Is very impportant to uuse the wincch to lift thee load while
e the boom is used onlyy as supporrt.
11.7 WIREE ROPES AND BELTS APPLIED TTO THE HOOK
It is recommend to alw ways verify the integritty and the rresistance o of wire ropees and beltss load
applied to the hook inn relation to
o the weight of the load d to be lifteed.
WARNING G! The choice of the rop pes and beltts is important, it is appropriate too control th
he their
relative breeaking load
ds especiallyy when it is not working in a verticcal position..
REMEMBEER! Before liifting the lo oad from thee ground, m make sure th he load is balanced lifting it of a
few centimmeters.
WARNING G! Never usee chains connnected witth pins.
WARNING G! Never stoore the ropees in wet areeas and nevver expose tthem to exccessive heatt.
Never use chains conn nected withh screw boltts.
11.8 HOO
OK
The winch installed on n the crane always inclludes the liffting hook.
The load mmust be attaached to thee lifting hoook paying atttention thaat the hook safety latch
h is fully
closed, intaact and functional.
The incorreect applicattion of the rrope to the hook can oopen the hook safety laatch. The safety latch
must alwayys return too its original seat after the ropes h
have been aattached.
WARNING G! The addition of wire ropes or beelts to the lifting hook iin such a qu
uantity thatt the hook
safety latch cannot bee closed is p
prohibited b
because thiss reduces saafety on wo ork place. In
n this case
there is thee danger th
hat the ropees or the belts addition to the hook can exit o off with consequent
load crash..
11.9 OPER
RATIONAL PERFORM
MANCE
1. It is aabsolutely fforbidden to
o use the crrane boom to lift a load attached to the rope
e that has aa
weigght over the winch ho
oisting capaacity. The winch brakke and all accessoriess would bee
subjeect to an overstress
o w
which could
d involve th
he breakagee or the daamage of so
ome of thee
comp
ponents.
2. It 'ab
bsolutely forbidden to use the win
nch to lift lo
oads that h
has a weightt over the p
possibilitiess
of th
he crane. Th
he structuree of the craane can be subjected to an excesssive effort that could
d
lead to the breaakage or dam
mage to strructural com
mponents.
REMEM
MBER! The maximum
m l
load on thee wire rope
e cannot exxceed the m
maximum crane
c liftingg
capacityy or the maximum winch hoisting capacity.
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12 TROUBLE SHOO
OTING
This chapteer contains some of the failures o
or malfunctions which m may occur tto the crane
e with their
correspondding solutio
ons. Warnin ng! The setttings on the he crane must be
e hydraulic ssystem of th
performedd only by quualified perssonnel usingg appropriate equipmeent.
FAULT CAUSE SOLUT

TION/REME
EDY
Noisy pump Low oil quantiity inside the pump
p Verify the oil level (the cran
V ne must
b folded), if necessary bring the oil
be
innside the pow wer pack to the e right
leevel
Dirty suction line filter the oil
o cannot D
Dismount the ffilter, clean it or
o replace
flow through itt if worn (see iinstructions given on
thhe handbook))
Worn pump V
Verify the pum mp features. Co ompare
thhe maximum pressure value shown
o the gauge m
on meter and the topping
tiime of the main boom cylind der to the
s
specific craness data (see tec chnical
s
sheet referred to the crane hydraulic
h
c
connections)
The pump sup pport is loosenn V
Verify the scre ew tightening whichw
c
connect the pu ump to the electric
m
motor
The bleeder vent
v inside the
e oil tank is Verify
V that no p piece of materrial or
plugged o
other things arre left on the bleeder
b
v
vent inside the e oil tank
The crane move jerks Low oil quantiity inside the oil
o tank V
Verify the oil leevel (the crane e must be
foolded), if nece essary fill in ad dditional
o which must have the sam
oil me
feeatures (see h handbook)
Worn pump V
Verify the pum mp features. Co ompare
thhe maximum pressure value shown
o the gauge m
on meter and the topping
tiime of the main boom cylind der to the
s
specific crane data (see tech hnical
d
data sheet rela ative to the cra ane’s
h
hydraulic connnections)
The crane do
oesn’t lift the ra
ated loads The geometriccal indications s relative to Carefully
C read the handbook k, chapter
the proper craane configurattion are not “Directions for use of the cra ane”
respected
Insufficient pre
essure inside the crane Compare
C the m
maximum pres ssure
hydraulic circuuit v
value shown o on the gauge meter m with
thhe specific cra ane data
Control handdle doesn’t retu
urn to the Lack of lubricaant on the han ndle R
Remove the in
nferior supportt of the
central seat linkage c
control handle and the cap placed p i
thhe opposite siide of the conttrol
h
handle, Clean carefully and grease..
Damage/brea akage to the ha andle R
Remove the ca ap mounted to o the
spring o
opposite side o of the control handle.
h
R
Replace the sppring, referenc ce is
s
shown on the sspare parts off book
WWW
W.SORM
MEC.NET
T
nual 99
9
FAULT CAUSE SOLUT

TION/REME
EDY
The crane sle ewing doesn’t stop when Inefficient pilo
oted block valv
ve Replace the block valve with
R h another
the relative control
c handle returns to o having sim
one milar properties and
its central seat s
setting values
One crane motion
m is slow The control va
alve handle do
oesn’t V
Verify that the handles fixing
g screws
complete its stroke
s a not loosen. Verify that th
are he rod
return spring iss opposite the control
h
handle, on the control valvess block tip
The crane booom lowers wh

hen lifting Worn cylinderr seal Id
dentify the cylinder which moves
m in
rated loads u
under loading. Replace the seal
s
Replace the piloted block va

R alve with
a
another one sa
ame setting vaalues
Worn cylinderr piloted block valve

It’s impossiblle to inject gre
ease from a Broken greaser Replace the grreaser, the code for
R
greaser o
order placing iss shown on th
he spare
p
parts book
Dismount the p
D pin and remov
ve the set
g
grease. Inject new grease
The injected grease
g set
Oil leakage frrom one hydra
aulic The connectioon is loosen Tighten the connection follow
T wing the
connection in
nstructions givven on the han ndbook to
s the right to
see orque wrench
A fittings has been damage
ed R
Replace the fittting: place the
e order
g
giving the code e number show wn on the
s
spare parts boook
Oil leakage frrom the bottom
m side of Worn slewing cylinders sea
als D
Dismount the sslewing cylinders and
the crane basse replace the gaskets
The crane has

h a winch withw No electric supply
s to the system By means of a tester verrify the
B
electro-hydrraulic end strroke r
right inlet tension in the crane
device: no crane
c motion
n is e
electric circuiit
allowed
Broken electtric cable Verify the inte
V egrity of the electric
c
cables and mmicro-switche es
Jammed oil return electro valve A the boom of the electro
At o valve
there is a soccket screw. Loose
L
the counter nnut and tighteen the
s
socket screww. In such a way
w the
e
electro valve shuts mecha anically.
W
WARNING: w
with the electro valve
o the end sstroke device
off, e does
n work any longer, there
not efore
s
such an operration must beb done
o
only in emerg gency cases
FAULT CAUSE SOLUT
TION/REME
EDY
The crane sle ewing doesn’t stop when Inefficient pilo
oted block valv
ve Replace the block valve with
R h another
the relative control
c handle returns to o having sim
one milar properties and
its central seat s
setting values
WWW
W.SORM
MEC.NET
T
nual 100
0
13 RECUR
RRENT TESTING
WWW
W.SORM
MEC.NET
T
nual 101
1
14 INSPECTION CA
ARRIED OU
UT
WWW
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MEC.NET
T

s.r.l..
S
Spare parts department:
d s
spareparts@s
sormec.us
I
Info: info@so
ormec.net C/da Sasii - Area Artig
gianale - 91011 - Alcam
mo(TP) - Italy
y
w
www.sorm
mec.net Phone +39
9 0924 50265
55 - Fax +39 0924 27047
7

Use Maintenance Manual M200 - 2S

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M200/2

Use & Maintena

C/da Sasi - Area Artigianale - 9101

2.2.1 HYDRAULIC LOAD D LIMITING D DEVICE

‐ MICRO SW WITCH HOOK K DOWN LIM MIT

FIGURE 9 W When the winnd speed excceeds more than 25

4.3.2 PRIOR R TO STORAG GE

The crane ccan be maneeuvered also by wire rem mote control. To use the wire contro ol it is necesssary removee

WARNING! The crane o operator musst not move the load to b be lifted if it does not understand the

M16 157 144 72000 215 193 106000 310 279 12

M18 193 175 91000 300 270 129000 430 387 15

M22 303 282 146000 580 522 208000 830 747 24

M24 353 324 168000 740 666 239000 1060 954 28

M27 459 427 221000 1100 990 315000 1550 1395 37

M30 561 519 270000 1500 1350 385000 2100 1890 45

M33 694 647 335000 480000 60000

M36 817 759 395000 560000 66

M39 976 913 475000 670000 79

M42 1120 1045 542000 772000 90

M52 1760 1652 857000 1221000

* Mλ will change with deviating μG ≈ μK

BROKEN W WIRES ‐ Thee following advices on nly apply to ropes whicch are used d on steel oor cast iron

Wear and corrosion ‐‐ Any wear o or strong coorrosion of wires foreb bodes breakkage; beyon nd a certainn

OUTSIDE TEMPER RATURE

FUNDAMEN NTAL CHARA ACTERISTICS OF THE OIL

Gear units that are nott particular loaded

During norm mal operatio on, due to run nning‐in of the surface, m metallic micrroparticles w will inevitablyy form in thee

Greasing in pressure un ntil it doesn'tt escape from

REMEMBER R! To make ssure that all the greasingg point are aalways well lu

These reference pointts must be m made in waay that theyy will last all the lifetimee of the slew wing ring.

It is important that the same positions are

To reduce this phenom menon, mu ust lift the lo

FAULT CAUSE SOLUT

FAULT CAUSE SOLUT

The crane booom lowers wh

Replace the piloted block va

Worn cylinderr piloted block valve

The crane has

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