01 MG15 Ed 10 2011 Rev 0.001 ENG

USER INSTRUCTIONS
INSTALLATION – USE - MAINTENANCE
DOUBLE GIRDER BRIDGE CRANE
TECHNICAL SPECIFICATIONS
Lifting capacity: 50000/32.000 Kg
Register number: C5020
Area: 36X - 40X
Span: 22,4 m
Type: DOUBLE GIRDER BRIDGE CRANE
Code manual: MG15 ed 10/2011 rev. 0.001
Year: 2011
BASIC INFORMATION OF THE CUSTOMER
Name: FIAT Automobili SRBIJA DOO KRAGUJEVAC
Address KOSOVSKA 4, 34000 KRAGUJEVAC, REPUBLIKA SRBJA
Place of installation: FIAT Automobili SRBIJA DOO KRAGUJEVAC,
KOSOVSKA 4, 34000 KRAGUJEVAC, REPUBLIKA SRBJA
1 / 103
USER INSTRUCTION – Installation, use and maintenance
- Impianti di sollevamento
Via Manzoni,8 – 10092 Beinasco (TO)
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http://www.cerrato.it E-mail: info@cerrato.it
Contents
1BASIC INFORMATIONS.............................................................................................................7
1.1CONTENT AND DESCRIPTION OF THE USER INSTRUCTION...................................7
1.2HOW TO READ THE INSTRUCTION................................................................................7
1.3INSTRUCTION UPDATE – CLIENT COOPERATION......................................................8
1.4APPROPRIATE DIRECTIVES.............................................................................................8
1.5PRODUCER RESPONSIBILITY AND WARRANTY........................................................8
2DOUBLE GIRDER CRANE.......................................................................................................10

2.1USE......................................................................................................................................10
2.2CRANE PARTS...................................................................................................................11
2.2.1 Structure......................................................................................................................11
2.2.2 Painting........................................................................................................................11
2.2.3 Moving unit – Endcarriages .......................................................................................11
2.2.4 Winch shifting unit......................................................................................................12
2.2.5 Lifting unit...................................................................................................................12
2.2.6 Load limiter.................................................................................................................13
2.2.7 Electrical devices.........................................................................................................14
2.2.8 Electrical control.........................................................................................................15
2.2.9 Remote control............................................................................................................15
3TECHNICAL INFORMATION..................................................................................................17
3.1REGULATIONS..................................................................................................................17
3.2CONDITIONS OF MACHINE FUNCTIONING...............................................................17
3.3PROTECTION AND ISOLATION OF ELECTRICAL PARTS.........................................17
3.4ELECTRICAL POWER......................................................................................................18
3.5NOISE..................................................................................................................................18
3.6ALLOWED TOLERANCE WHILE MOVING..................................................................18
3.7CRITERIA IN USE..............................................................................................................18
4INSTRUCTIONS FOR ASSEMBLING AND INSTALLATION...............................................20

4.1PRELIMINARY ASSEMBLY ACTIVITIES......................................................................20
4.1.1Preparing the construction site (done by the client).....................................................20
4.1.2Packing, transportation, unloading and shifting...........................................................22
4.1.3Cable installation..........................................................................................................24
4.1.4Adjustment of the winch lifting and lowering switch..................................................26
4.1.5Adjusting the translation limit switches.......................................................................28
4.2GENERAL INFORMATIONS............................................................................................29
4.2.1 Marking.......................................................................................................................29
4.2.2 Positioning of wiring diagrams...................................................................................30
4.3TESTING OF THE CRANE................................................................................................30
4.4OTHER ACTIVITIES..........................................................................................................32
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4.4.1Storage..........................................................................................................................32
4.4.2Recovery after storage..................................................................................................33
5INSTRUCTIONS FOR USE AND MAINTENANCE ..............................................................35

5.1FUNCTIONS OF THE BRIDGE CRANE..........................................................................35
5.1.1Intended use - Planned use...........................................................................................35
5.1.2Loads allowed and not allowed....................................................................................36
5.1.3Lifting Accessories.......................................................................................................37
5.1.4Remote control (extract from the manual Autec).........................................................37
5.2ENABLING.........................................................................................................................40
5.3OPERATION.......................................................................................................................41
5.3.1Operating environment.................................................................................................41
5.3.2Lighting........................................................................................................................42
5.3.3Operators......................................................................................................................42
5.3.4Lifting capacity.............................................................................................................42
5.3.5Maneuvers....................................................................................................................43
5.3.6Lifting...........................................................................................................................43
5.3.7Trolley and sliding bridge............................................................................................44
5.3.8Interlocking..................................................................................................................44
5.3.9Safety devices...............................................................................................................44
5.3.10Inhibitions...................................................................................................................45
5.4POWERING OFF................................................................................................................45
5.5WHAT TO DO ALWAYS....................................................................................................46
5.5.1Planned use, the criteria and precautions for use.........................................................46
5.6WHAT NOT TO DO, NEVER!...........................................................................................49
5.6.1Use unforeseen, unintended use, improper use predictable and unpredictable,
Contraindications for use......................................................................................................49
5.7MAINTENANCE................................................................................................................55
5.7.1How to access the crane...............................................................................................55
5.7.1.1Access to crane.....................................................................................................55
5.7.1.2Access to crane runways.......................................................................................56
5.7.1.3Access to crane runways Cart...............................................................................56
5.7.1.4Case of trolley stop in unexpected location..........................................................56
5.7.1.5Residual risks........................................................................................................56
5.7.2Ordinary check.............................................................................................................58
5.7.3Periodic inspections......................................................................................................59
5.7.3.1Verification of the rope and fasteners...................................................................59
5.7.3.2Sheaves block.......................................................................................................61
5.7.3.3Hook.....................................................................................................................62
5.7.3.4Drum.....................................................................................................................63
5.7.3.5Wheels..................................................................................................................63
5.7.3.6Buffers..................................................................................................................64
5.7.3.7Lifting reducer......................................................................................................65
5.7.3.8Lifting motor.........................................................................................................66
5.7.3.9Translation travel drives.......................................................................................67
5.7.3.10Drum brakes........................................................................................................76
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5.7.3.11Lifting and moving limit switch.........................................................................81

5.7.3.12Load limiter........................................................................................................81
5.7.3.13Electrical equipment...........................................................................................82
5.7.3.14Plates...................................................................................................................82
5.7.3.15Horns..................................................................................................................82
5.7.3.16Structural Elements.............................................................................................83
5.7.4Timing and deadlines...................................................................................................85
5.8CLEANING - LUBRICATION...........................................................................................86
5.8.1Cleaning the crane and lubrication plan.......................................................................86
5.9ADJUSTMENT...................................................................................................................88
5.10REPLACING PARTS........................................................................................................88
5.11TROUBLESHOOTING.....................................................................................................88
5.11.1Basic failures and disfunctions...................................................................................88
5.11.2Possible failures and repaires.....................................................................................89
5.11.2.1Faults - Causes - Remedies inverter Schneider..................................................90
5.11.2.2Faults - Causes - Remedies inverter Sew LTE-B................................................96
5.11.2.3Faults - Causes - Remedies inverter Sew LTE-P................................................98
5.11.3Authorized and qualified people..............................................................................100
5.11.4Temporarily putting the crane out of order – putting off..........................................100
5.11.5Definite putting the machine out of order - (Putting off / Destroying)....................101
5.12SPARE PARTS.................................................................................................................102
6CONTROL CHECK DIARY.....................................................................................................103
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1 BASIC INFORMATIONS
1.1 CONTENT AND DESCRIPTION OF THE USER INSTRUCTION
This technical user instruction, with the code "MG15 ed 10/2011 rev. 0.001", refers to “Double girder
bridge crane”, produced by:
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The instruction contains techical and functional characteristics and performances, as well as the
istallation, use and maintenance instruction. The instruction should be used by:
• Resposible person in the firm, works or construction site
• Qualified persons for transporting, shifting and installation
• Qualified persons for use of cranes
• Qualified persons for maintenance
The instruction should be kept by an authorized and responsible person, on a available place, so that
everyone could read it at any time.
In case of losing or damaging the instruction, the same should be immediately requested from the
producer, giving the code given at the beginning of this istruction..
The producer withholds the copyrights for this istruction and its issue. Every
unauthorized publication or reproduction in part or as a whole is punishable by law.
1.2 HOW TO READ THE INSTRUCTION

This instruction uses several symbols in order to get the reader’s attention to certain remarks which are
of great importance.
In the following table are given the symbols and their meanings in the instruction.
SYMBOL MEANING DESCRIPTION

• Danger of accidents, even with deadly results
• Disrespecting advice and instructions which are
given by the symbol can result endangering for
• Danger
the workers and people who are exposed.
• Strict holding to the advice and instructions
given by this symbol.
• Represents a remark for a possible danger
because of some machine part or worker
• Attention carelessness.
• Important warning which should be paid
attention to.
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• Represents a warning or a remark on the

• Warning machine functioning or an important
information.
• The symbol of an eye should draw the reader’s
attention to the following:
• A visual check should be performed
• Visual notice
• An operating procedure must be performed
• Measures of value should beread, and
signalisation checked.
1.3 INSTRUCTION UPDATE – CLIENT COOPERATION

The crane user instruction respects all regulations and laws and it is in accordance with all standards
which are expected for this machine; all its later versions in terms of updating iformation are considered
an adequate manual.
All modifications andchanges which are made later on the crane do not have to be put ito this user
istruction, but can be considered as its supplement andcomponent.
The producer is always available to his clients for further information about improving or updating
information from the manual which makes this instruction adequate.
In the case of selling or moving the crane, the first user should inform the producer about the new client
so that he could deliver the new client an appropriate instruction manual which might have been updated
in someparts.
1.4 APPROPRIATE DIRECTIVES

The crane which is the subject of this manual is in accordance with the CE standard and is built so that
it satisfies all conditions which are given in “The basic safety requests” directive 2006/42/CE about
machines and according to to the 17/2010 law.
All partson the crane are in accordance with the Directives and CE standard. Electrical components are
in accordance with the Low-Voltage Directive 2006/95/CE of the European Parliament and Council, as
well as with the Directive 73/23/CE of the 791/77 law, which has been changed to 626/96 law, and the
277/97 law, as well as with the Directive about Electromagnetics (EMC) 2004/108/CE of the 194/07 law.
The original manual about the user instruction for the crane was written in italian and it is in accordance
with the standard UNI EN ISO 12100:2010 – chapter 6 - passage 4- Machine directive 2006/42/CE, the
parts about safety 1.7.4 i 4.4.2 Attachment I
1.5 PRODUCER RESPONSIBILITY AND WARRANTY

In accordance with what is given and described in the instruction manual the CERRATO firm is not
responsible in the following cases:
• Usage which is not in accordance with the safety and security laws
• Inadequate terrain and works preparation or its structures, where the crane is planned to work.
• Failure of the power network and inadequate voltage
• Wrong interpretation or misunderstanding of the instructions.
• Unauthorized interventions o the machine
• The machine is used by incompetent and unqualified persons.
For the client to be able to use the warrenty given to him by the producer, as it is stated on the coupon “
Warrenty conditions”, attached to this manual, he must strictly adhere the following:
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• Always work with limited machine load

• Always handle the machine properly
• The machine is always used by qualified and expert persons who are familiar with the manual
instructions.
• always use original spare parts suggested by the producer.
• Correct use and planned machine configuration.

• Don’t try to use the machine in other purposes except the one given
• Instructions given in this manual respect all regulations and are in accordance
with safety and security standards
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2 DOUBLE GIRDER CRANE
2.1 USE
The double girder crane is designed for moving and shifting goods inside a work or construction site.
The crane lifts a load vertically with the help of a lifting hook of the winch; cranes move a load along the
rails with the help of a cart andtwo housings on the bridge with engines. The crane bridge moves along
rails with the help of wheels so that the space underneath it is always free and available for other
activities.
Figure 2.1.
LEGEND
1 Girders
2 Bridge travel units
3 Winch travel units
4 Cable winch
5 Electrical cabinet
6 Festoon cable
7 Emergency push button
8 Lifting reducer
9 Drum
10 Lifting motor
11 Brake
Figure 2.2 12 Brake joint
13 Drum jont
14 Anti-derailment of the rope
15 Radio receiver
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2.2 CRANE PARTS
2.2.1 Structure
The structure of the double bridge crane is made of a welded rectangular box; The two beam are linked
to the travel units by high resistance bolts. On the upper part of the beam, the rail for the winch is placed.
At the end of each rail there are 4 rubber bumpers with high absorber capacity.
High quality material have been used in the constructions of the main structural parts. The metal sheets
are welded togher with submerged arc welding to ensure the best functioning and safety working
conditions of the crane.
2.2.2 Painting
All parts that make the metal structure of the crane have a surface protection, so that there wouldn ’t be
any rust, peeling or corrosion. The process of painting means applying one layer of anticorrosive water
paint (RAL 7035) and and another layer of painting in yellow colour (RAL 1021) for the crane and winch to
protect them from external effects and wearing.
2.2.3 Moving unit – Endcarriages

Endcarriages are made from sheet metal which is specially bent and welded. They are fixed to main
beams by plates and joints with tight fastenings which give excellent orthogonality between the rails and
the head and offer safety and security. On external parts, housings or heads have appropriate bumpers of
high absorptio which dulls hits and collisions. Every housing head has two wheels with doble edges made
from carbo steel.
• The wheels rotate on lubricated bearings and they have a special system for lubricating with
grease.
• Shifting or moving is done by motor reducers. One of the two wheels is the operating one and it
moves with the help of motor reducer.
• The motor is selfbraking with squirrel cage rotor and controlled by a frequency converter.
• The brake of the selfbraking engine automatically reacts in the case of falling or lack of voltage.
Figure 2.3 Figure 2.4
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2.2.4 Winch shifting unit

The structure of the winch is made of electrowelded profiles. Shifting the cart is done with the help of 4
wheels, of which two are operating, with double edges and rotating on bearings. Operating wheels are
moved by a reducer with a selfbraking motor, which is placed on the wheel axis.
2.2.5 Lifting unit

• The structural part are made of electrowelded profiles.
• Wheels of the winch: the translation is done by 4 wheels, two motorized, made of steel with
double edges, rotating on bearings. These are lubricated by grase nipples.
• Travel motors: the two motorized wheels are linked to travel drives with parallel axes. Motors are
selfbraking with squirrel cage rotor and controlled by a frequency converter.
• Lifting gearbox: Cast iron box with carbon steel and tempered gears; Shafts rotate on lubricated
bearings.
• Lubricating: is assured by the constant shaking of the oil.
• Drum: rolled steel tube with machined helical grooves. The output shaft driven directly from the
axis of the reducer, the connection between the gearbox and drum is made by a toothed
coupling. On the opposite side to the gear, the drum is supported by a support bearing oscillating
rollers. The two principles drum wraps both ends of the rope, so the hook does not undergo
lateral displacement (eccentricity) during its vertical travel.
• Lifting motor: with specific characteristics for lifting, is the three-phase asynchronous squirrel-
cage-controlled frequency converters.
• Lifting brake: driven by an electrohydraulic servo, acting on a pulley keyed on the axis shaft,
connected to the engine via a coupling peg.
• Lifting limit switch: worm screw type, driven by the drum, ensures the arrest in the positions of
maximum and minimum of the hook. And 'driven directly from the slower axis of the drum.
• Lifting rope: forming a high flexibility and high resistance to wearing, has been selected with the
coefficient of safety more than 5 and in relation to the group of use in which the crane is classified
according to ISO rules and the FEM. The pull of the winch rope is eight; consequently are
mounted on the trolley pulleys and the necessary balancing.
• Hook: double forged swivel is mounted on a thrust bearing and through the yoke, on the block
with pulleys.
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2.2.6 Load limiter

The electric wire rope hoist is equipped with a device for limiting the load to a threshold. They indicates
through a horn the achievement of the overload inhibits further lifting the load, but not the descent. When
the descent of the load in the position reached by the crane could lead to dangerous situations from the
point of view of security or integrity of people, materials, or the crane moved, is allowed to make limited
movements with the cart and / or bridge, to make possible the removal from the position it was in the
crane. The load limiter consists of a strain gauge mounted on the pivot pulley balance. The tensions
caused by the loads and overloads are measured and converted into electrical signals. Through a
dedicated electronic control unit are sent to the auxiliary control equipment.The verification of calibration
values of the decoupling limit of the thresholds of the load limiter must be made as provided in rule FEM
9,761, at least once a year through the use of masses of known value properly prepared and / or using a
load cell display values of stress.The results of annual audits should be entered on the register specially
crafted.
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Figure 2.11.
2.2.7 Electrical devices

Electrical devices consist of:
• Electrical cabinet: is placed on the external part of the rail, ad is made of sheet metal. Inside the
control panel there are conductors and fuses for controls for all crane movements, as well as
protection from short circuit. Electrical circuit of the controls have low voltage (110 Volt), which is
received over a protected trasformator. The switch for connecting to the electrical network with
fuses offers simplicity in handling and safety in connecting cables to all functions on the crane,
which allows easier controls and possible interventions.
• Electric networks for powering the carts and hoists and which are made of multipolar flexible
cables of flat shape, and which hang on the beam or rail on which the carts move.
• Hanging keyboard with controls, made of termoplastic material resistant to hits. The keyboard
hangs along the rail on the crane, over the beam and is connected to the electrical network by a
multipolar flexible cable of flat shape and a multipolar cable of a round shape. The keyboard also
has a fast connector of a certain polarity koji allows easier installation and possible keyboard
change.
• Limit switches on all movements, which works through support electrical circuit with low voltage
• Alarm which is controlled with the “alarm” button on the keyboard, and whiose function is to warn
in possible dangerous situations while working with the crane by giving a sound signal.
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2.2.8 Electrical control

The use of the drive with electronic control, such as "inverters", allows you to select the scroll speed of
the crane and lift and adjust the acceleration and deceleration.
Accelaration and deceleration of the crane occur so gradually and smoothly due to the programming of
acceleration and braking ramps, according to the changed operating requirements.
This way you can reduce the oscillation of the load in case of sudden stop or reversal of the sliding of
the crane. The mechanical brake built into the engines, operates only when the crane is stopped and will
serve as a parking brake or emergency and will not be subject to wearing.
NB: Please note that varying the parameters of the increasing device performance
(higher speeds, etc..) Amounts to change the intended use and expected the same and
can prejudice the safety of use ; the Cerrato Srl disclaims all liability in this case
relating to security and of each other.
2.2.9 Remote control

The industrial remote control is used to control the machine from a remote location without a physical
connection between the operator and the machine (eg, wires or cables). It is composed of a portable
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transmitter, from which the operator can remotely control the machine, and a receiver installed on the
machine itself.
Using the remote control must be in compliance with applicable laws and regulations in the State where
it is used.
The personnel using the machine with remote control must be instructed on the use of the machine, the
remote control, and safety features and emergency measures.
Figure 2.14
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3 TECHNICAL INFORMATION
3.1 REGULATIONS
Planning and constructing of a crane by CERRATO is done in accordance to the following laws and
regulations:
General directives
• Directive 2006/42/CE is about “ the machine”
• Directive 2006/95/CE (ex 73/23/CEE) “Electrical materials with low voltage”
• Directive 2004/108/CE ”Electromagnetic compatibility”
Technical standards and regulations
• UNI EN ISO 12100:2005 part one and two: “Basic regulations on planning”
• UNI EN ISO 13849-1:2007 “Parts of the controlling systems about safety”
• UNI EN 12077-2:2008 “Devices for limitations and readings”
• UNI EN 14492-1:2006 “Lifting unit- Part one: Winch with engine”
• UNI EN 14492-2:2006 “Lifting unit- Part two: hoist with engine”
• UNI EN 60204-32:2006 “ Safety electrical devices on the lifting machine”
• UNI EN 60529:1992 “Step protection of the wrapping (Code IP)”
• UNI ISO 4301-1:1986 “Lifting unit.Classification.General characteristics”.
• UNI ISO 4308-1:2003 “Choosing the wire cable - General characteristics”
• DIN 15401 “Choosing the lifting hooks ”
• UNI 9466:1994 “The rolling pin of the Drum. General characteristics”
• FEM 1.001/98 “Calculation of the lifting unit”
• FEM 9.511/86 ”Classification of the mechanism”
• FEM 9.661/86 “Choosing the Drum, wire cable and pulley”
• FEM 9.683/95 “Choosing the lifting engine and translatory moving”
• FEM 9.755/93 “Safety work time”
• FEM 9.761/93 “Load limiter”
• FEM 9.941/95 “Symbology of controls”
3.2 CONDITIONS OF MACHINE FUNCTIONING

Cranes of the firm Cerrato are made for work under the following conditions:
• External temperature: from min 0 C to max +40 C
• Humidity : <80%
• Max height : 1000 s.l.m.
3.3 PROTECTION AND ISOLATION OF ELECTRICAL PARTS

The use of the crane CERRATO is provided for places which are protected from external influences. If
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the machine is being used in the open, protection and isolation can be asked from the manufacturer
afterwards.
3.4 ELECTRICAL POWER

Cranes of the firm Cerrato are powered by three-phase electricity of 230 / 400 V (50 Hz) ± 10% with
engines with one speed or 400 V (50Hz) ± 10% with engines with two speeds. The line of the elctrical
power must have appropriate voltage. If the voltage and the frequences differ from the electrical power
network on the construction site, the manufacturer should be informed.
3.5 NOISE
The noise produced during the work of all parts of the Cerrato crane is not higher than 80db (A).
3.6 ALLOWED TOLERANCE WHILE MOVING

ISO 8306:1985 “Cranes -- Overhead travelling cranes and portal bridge cranes -- Tolerances for cranes
and tracks”
3.7 CRITERIA IN USE

To guarantee proper functioning of the crane and all its operating regimes while working, it is necessary
to determine its operating limitations in a proper way. The regulation FEM. 9.511 allows classifying the
mechanism of the crane during its functioning in given conditions. Necessary parameters to determine the
limitation of crane usage is, apart from the capacity and straining, the average time of the daily
functioning during lifting, translatory shifting and moving.
The crane in question is classified as a class M7.

This class M7 can be determined by:
• A maximum working time T5 (= <to 6300 hours) and the L4 system load (average load of
between 50% and the maximum reach.
• A maximum working time T6 (= <of 12500 hours) and the loading rate from L3 (average load of
between 25% and 50% of maximum).
The loading takes into account the loads handled. It is defined by the average durations and loads of
individual operations.
Straining condition:
FOR LIFTING OPERATIONS
Ce=Vertical stroke of the hook Ch=Number of cicles Ti=Time of usage V=Lifting speed
Average of the real liftings Is the quantity (n) of the complete is the time (in hours) of use of the is the main speed (m / min) of the
works of ascent and descent which crane during the day lifting
takes place in an hour
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For the cranes in question are taken into account the two conditions of employment highlighted:
CONDIZIONI DI IMPIEGO
L1: Light L2: Medium L3: Heavy L4: Very Heavy
For cranes that handle rarely the For cranes that move at about the For cranes that move frequently For cranes that move regular close
maximum load, and especially same ratio max, average and low max load and usually reduced to the max load.
small loads. loads. loads.
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4 INSTRUCTIONS FOR ASSEMBLING AND INSTALLATION
• The crane CERRATO are delivered, as far as possible, pre-assembled in their main
parts.
• The activities of installation, putting into service and testing are handled by trained
personnel and highly trained employees and / or instructed by the manufacturer.
• The manual therefore contains, in this section, the only issue instructions for the task
of the client.
4.1 PRELIMINARY ASSEMBLY ACTIVITIES
4.1.1 Preparing the construction site (done by the client)
To allow installation of the crane must first run the following listed in the order
confirmation CERRATO related to:
• Verification of the necessary structures (pillars or walls) in relation to actions and reactions
related to the use of cranes (Figure 4.1-4.2-4.3-4.4).
Figure 4.1: Figure 4.2:
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• verify suitability of the structure when the crane is installed in addition to another already existing
one.
• installation and monitoring of the suitability of its runways and spaces of maneuver available for
the cranes on runways (Figure 4.5).
• check presence of other cranes are operational and if present provide the required crane anti-
collision systems.
• control of auxiliary anchorages, those on the walls and runways (Figure 4.8).
• Control of the efficiency of assembly of the runways.
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• verify of span that will be useful in at least three measured points of the building (near the two
ends and a centrally located).
• verify suitability and proper functioning of the electrical: power line, power outlet, distribution
panel, circuit breakers, which must be able to interrupt the short circuit current (IEC 64-8
Appendix D), phase control section, power, cable length and line grounding system in accordance
with EN 60204-1 and EN 69204-32.
• section of the cable line is determined on the basis of the following parameters:
◦ maximum current drawn by the motors of the crane (specified on the nameplate of the
cabinet)
◦  V allowable power line + / - 10% (depending on the length of the power line and armored
cable to the cabin)
• preparing the masses for dynamic load tests equal to 1.1 x nominal and masses equal to 1.25 x
rated capacity for static load tests, and equipment to sling the load.
• installation of appropriate signage in accordance with ISO 7000, indicating the presence of crane
operations on the move (Figure 4.9).
Figure 4.9:
4.1.2 Packing, transportation, unloading and shifting
Carry out a visual inspection of goods before moving the load to determine if
any breakage or damage.
• The crane is delivered pre-assembled in its main parts, are therefore excluded in the delivery,
packaging or special protections.
• The material, stored under appropriate conditions, can be stored for a period of about two years
covered in environments where the temperature is between -20 ° C to + 70 ° C with relative
humidity of 80%. For several environmental conditions must be specific packaging.
• If you want to make the storage of the crane you see instructions in section 4.4 OTHER
ACTIVITIES.
• The transport must be made by carriers qualified to ensure proper handling of the material
transported. CERRATO The company assumes no liability in the case of transport by the
customer or selected by the same transporters (Figure 4.10)
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• Prepare an area bounded and adequate, with floor or surface for unloading and assembly of the
crane to the ground (Figure 4.12). Prepare appropriate wooden bars of a size suitable to be
placed below the beams and encarriages; consider in this case the proper endcarriages height
(including wheels) - (Figure 4.13).
The horizontal attitude of the structures and guarantees maximum stability must be
maintained at every stage of handling, transport and storage.
It is forbidden to tilt or back up the parts in an upright position or on the side if not
after them properly attached and / or checking their stability.
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4.1.3 Cable installation
To install the rope of the winch, proceed as follows:
Carry the rope unwinding the coil (when allowed by weight), or turning his head around to discharge the
tension (Figure 4.14-4.16).
CORRECT WRONG
Figure 4.14:
Figure 4.15:
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Do not carry the rope pulling the head of the coil.
• Pass the rope sheaves in the of the block and the balance of the winch as shown in the sequence
shown (Figure 4.18).
• Attach one end of the rope, with the appropriate terminals on the drum stick, leaving the end of
the rope for about 3 cm from the clamp (Figure 4.19).
• Attach the other end of the rope, with the appropriate terminals, making sure the drum, again, to
let the ends stick out of the end of the rope for about 3 cm from the clamp
• Actuate the the lifting motor and around the two ropes on the drum holding taut the rope to avoid
the ban of the rope.
Use the appropriate cable assembly protection (gloves) to avoid the risk of
lacerations to the hands in contact with the rope. (Figure 4.20).
Figure 4.20:
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4.1.4 Adjustment of the winch lifting and lowering switch.
• Place the feedback cam rotating switches located inside the worm screw up and down, in the
most appropriate positions, so that the limit comes when the hook is at the desired height (Figure
4.21).
• Bring the hook block in a position of maximum lift, performing this maneuver, observe the
direction of rotation of the cam switches (Figure 4.22).
• The cams are numbered, and the screws have the same numbers (Figure 4.23).
• Unlock the cam acting on the central screw (Figure 4.24).
• Operate the selected contact to the upward movement by rotating in the same sense in which the
cam rotated during the corresponding upward movement (Figure 4.25).
• Lock the cam acting on the central screw (Figure 4.26).
• Perform the same procedure to adjust the overtravel cam rise.
Figure 4.21: Figure 4.22: Figure 4.23:
• Bring the hook block position of maximum slope (Figure 4.27).

• Unlock the cam acting on the central screw (Figure 4.28).
• Operate the selected contact by turning down the movement in the opposite direction from the
cam to the upward movement, the cam corresponding (Figure 4.29).
• Lock the cam acting on the central screw (Figure 4.30).
• Perform the same procedure to adjust the overtravel cam down.
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• Experiment repeated up and down by operating the switch and make the appropriate corrections,
if necessary by repeating the operations described in the previous sections.
The cams are used to limit overtravel of the safety function. They operate in
the event of failure of the switch function (up or down).
• In the end rising position the cavity of the hook must stop at that shown on the overall design of
the machine.
• Slide the block for the whole predetermined hook run and verify that it stop once you reach the
point of feedback up and down.
• The adjustment of the switch down will not allow the lower edge of the hook falls below a distance
of 500 mm from the ground as shown on the overall design of the machine (Figure 4.31).
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Figure 4.31:
Figure 4.32:
Stroke adjustment of the hook in the position of maximum descent must be such as
to always guarantee a minimum of 2 turns of the cable is completely wound on the
drum (Figure 4.32).
4.1.5 Adjusting the translation limit switches
• Pressing the buttons "up / down" scroll through the bridge along its course and verify that it stop
(Figure 4.33).
• Check the correct positioning of the findings of the limit of the bridge, to ensure adequate space
"overtravel" and avoid risk of collision between the bridge and fixed stop (Figure 4.33).
• Perform the same procedure to adjust the overtravel cam.
Circuit breakers switches are emergency devices that should not be subjected to
regular operation. If there is this need to be installed any additional limit switches for
continuous service arranged in advance of acting as security.
Figure 4.33.
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4.2 GENERAL INFORMATIONS
4.2.1 Marking
On the crane there are plates affixed:
• summary label manufacturer's data and "CE", fixed on the bridge structure
• plaque summary of the scope, the number of factory and of the "CE" in large letters;
• directional plate
Figure 4.34.
Legibility and conservation of plates:

• The plates must be legible relatively to all data by providing clean them regularly.
• If a plate is deteriorating and / or no longer legible, even in a single set of data elements, it is
recommended to ask for another manufacturer to quote the data contained in this manual and
replace it.
The plates should never be removed and is absolutely prohibited to affix on

the crane other plates without the prior permission of the manufacturer.
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4.2.2 Positioning of wiring diagrams
In the pocket, within the cabinet, (Figure 4.35) are laid out wiring diagrams that include
diagrams, control and power:
Figure 4.35:
All utilities and cable are shown and numbered on the components. (Topographical diagram attached)
4.3 TESTING OF THE CRANE

• The testing of the crane requires a precise sequence of operations, described below,
is scrupulously respected by CERRATO technicians, to ensure the safe and optimal
functional performance of the crane.
• The operations of functional testing, performed by technicians CERRATO, are also
reported in the "test report / acceptance of the crane" (attached to this manual).
After performing the functional tests to "empty" to proceed to perform the dynamic tests and these tests
are carried out with masses of value corresponding to the nominal capacity of crane overload increased
of the coefficient of 1.1 (load equal to 110% of rated load) . The static tests are carried out with load equal
to 125% of rated load (overload coefficient of 1.25).
• Dynamic test: 55000 kg

• Static test: 62500 kg
All test must be perforemed in absence of wind.
Carry out functional tests to "empty" as follows:
• turn on the power switch
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• put the emergency stop button in the position "startup allowed” (D button for the remote control)
• when using the remote control perform activation shown, otherwise, if you use the emergency
pendant push button, go to the next point:
◦ to turn on the transmitter, insert the ignition key (A) and turn it in position "I"
◦ to initiate functions of the remote, press the "START" (H) for 1-2 seconds; after the start lights
always green LEDs.
• press the "start / alarm" (E)
• Verification of the function of lifting winch by pressing the buttons "up / down"
• verification of the drive function by pressing the "left / right"
• verification of the scrolling function by pressing the bridge "forward / back"
• verify the operation of all movements at two speeds
• verification of the limit of sliding movement and translation
Proceed to the dynamic tests as follows:
• provide adequate evidence for mass load equal to: 55000 kg and equipment suitable for slinging
and lifting the load
• sling load, taking care to place the hook on the upright to prevent oblique shots
• pressing the "up" to tighten the hook without causing tears, slowly lift the load and verify that this
is done without difficulty and no noisily abnormal apparent deformation or structural failure
• verify the functionality of the end stops of "up and down"
• verify the functionality of the brake, checking that the mass to be braked in time there are no
adequate and slippage of the load, after releasing the button
• perform the same checks for the movement of bridge, trolley and sliding occurring, limit the
functionality of "right and left" and "back and forth", without carrying the load to the maximum
height (raised one meter above the ground) .
• working first with slow speeds and then repeat the tests running at maximum speeds above
checks
• verify the correct flow of the truck and heads on the beams of the bridge along a track and make
sure you do not noisily, visible permanent deformation or structural failure abnormal.
• verify the operation of the button "STOP" (D) must inhibit all movement. Each function of the
crane must stop in the shortest time and space as possible, without evidence of skidding,
dangerous oscillations, etc.. will affect its stability.
control the braking distances and stopping movements during the lifting, sliding bridge and
carriage movement.
• The width of these spaces is determined as follows:
◦ in the movement of descent with maximum load is about 9 cm.
◦ during sliding bridge is about 150 cm at a speed of 7 m / min.
◦ In both cases you should not trigger substantial fluctuations of the load
◦ the translation movement of the truck is about 50 cm.
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Proceed to the static tests as follows:
• lift the load used for the dynamic tests, stop in position suspended at a height of 50 cm., gradually
apply the masses about it for a load of 62500 kg, 25% more than the rated capacity, allow for
suspended time of 10 minutes.
• verify that the sprung mass (nominal load and overload) will not give (the electric winch brake
should not slip) and not experience, obvious permanent deformation and sagging of the abnormal
structure.
• control the operation of the winch load limiters, it must exclude and disable the rise and activate
the buzzer.
• During the static test load limiter must only take action by disabling the
operation of the upward movement.
• The movements of descent, moving and sliding are not disabled by the
operation of the load limiter, however, they must never be actuated during the
static test.
4.4 OTHER ACTIVITIES
4.4.1 Storage
Before storage, check that:
• There is no damage to the heads of the plates and beams and avoid scratching the machined
surfaces of the plates themselves (Figure 4.36) and cause damage to the threads (Figure 4.37).
• The materials can be stored up to a maximum period of two years in a protected environment
with the following characteristics (Figure 4.38):
◦ protected from the elements
◦ relative humidity not exceeding 80%
◦ temperatures: minimum - 20 ° C, maximum +70 ° C
• For storage period of more than two years require procedures of conservation to the
manufacturer
• If these values were to change during storage will be necessary to carry out preliminary checks
before putting into operation the crane (see "Recovering from storage" 4.4.2)
• If the place of storage temperature exceeds or falls below the indicated values and the relative
humidity is greater than 80% prepare for packages packed with protective barrier bags and
hygroscopic salts.
• For storage in open areas include:
◦ clogs up from the floor for all the packages without pallets
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◦ protect all the hills in barrier bags and hygroscopic salts

◦ structural parts do not require special protection, unlike the parts machined on machine tools
(machined parts, wheels, bolts, etc..) and rails (Figure 4.39-4.40) have
◦ be protected with antioxidant products (transparent paints, grease, etc..).
◦ provide storage areas to delimit the material (Figure 4.41).
4.4.2 Recovery after storage
Before the putting into service of cranes that have undergone a long period of
storage on site is necessary to do the following:
Structure:
• remove traces of paint or grease on the structure and rails
• clean the holes joining any residual grease
• clean the mating surfaces at joints
• to repair any damage to the structure (corners bent, scratched surfaces, peeling paint, etc..)
Mechanisms:
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• check for leaks of lubricants and provide for the replacement of defective gaskets
• restore levels of lubricants
• check the proper tightening of the bolts according to CNR UNI 10011/88
• eliminate traces of rust from sliding accessory of the controls
• check the integrity of the ropes / chains and provide clean and lubricate the same, the drums /
nuts and pulleys / sprockets of hoists / winches
• check the integrity and functionality of the hoist load limiters / electric wire rope winches
• lubricate the thrust bearings of the mechanical hooks and unpainted (shafts, couplings, rods
maneuver)
• eliminate any residual water in the concave parts of the structure and mechanics.
Electrical work:
• remove any condensation inside the engine from sucking in terminal open, dry with air jets
• check the integrity and functionality of the disc brakes. Restore the exact value of air gap
• thoroughly clean the surfaces of brakes and strains conical eliminating traces of moisture and / or
paint.
• check the integrity and functionality of all limit switches
• verify the integrity of the parts and electrical components. Remove any condensation, wipe the
contacts of contactors and spray equipment to deal with all electrical components. Thoroughly
clean and smear Vaseline on the filming surface sealing and threaded caps on all containers.
• perform dielectric strength test at 2000 V
• control the smoothness of the power lines festoon
• fully test the functionality of the control pendant
For all operations always use appropriate safety devices protective equipment (PPE
= gloves, shoes, etc..)
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5 INSTRUCTIONS FOR USE AND MAINTENANCE
5.1 FUNCTIONS OF THE BRIDGE CRANE
5.1.1 Intended use - Planned use

Double girder overhead cranes are made for the movement of goods within the factory or a
construction site.
The cranes lift the load vertically into space by the hook of the lifting unit and through the accessories
suitable for this operation; translate this load along the transverse and longitudinal axes by means of the
motorized cart and the endcarriages of the bridge.
The cranes run on rails placed at a height above the ground, which remains completely free and
available for productive activities.
The functions are realized through three main movements:
• vertical load is raised by the winch rope
• transversal travel of the load by movement of the trolley hoist.
• longitudinal sliding of the crane along the runways
These movements are activated via the buttons on the remote control or the emergency push
buttonand specifically (Figure 5.1-5.3):
• Up & down buttons for the lifting movement of the winch
• LEFT and RIGHT buttons to control the movement of carriage movement
• FORWARD and BACK buttons to control the sliding movement the crane
Buttons activate the function when pressed and held, when there are two speed buttons are activated
with the type to "scale up" to two shots, one for control of speed "slow" the second step to control the
"fast" .
The button STOP / EMERGENCY is shaped like a mushroom, red, and activates the STOP function
when it is fully depressed (Figure 5.2). To allow the operation of the crane is necessary to rotate the
button STOP / EMERGENCY and bring in the "raised" the consensus map (Figure 5.4) and then press
the green button the START / ALARM.
The ALARM button, when pressed, activates the siren located on the control panel.
It 'a good practice to raise the alarm at the beginning of each maneuver of sliding, in
any case it must be activated every time the operator sees a potential danger to
exposed persons, or must signal the passage of the cranes in areas where visibility is
not complete.
The emergency push button is hanging and is operated by the operator from the ground along the
sliding movement the crane (FORWARD / REVERSE).
It is forbidden to use the crane remained on board the same
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Figure 5.1.
Figure 5.2.
Figure 5.3. Figure 5.4.
When the crane is controlled by remote control the panel is free and is not bound to
the crane, the operator must always maintain the maximum attention during operation
without ever losing sight of the work area and the load to avoid compromising their
safety and / or that of those exposed.
5.1.2 Loads allowed and not allowed

Loads must be:
• Shape, size, mass, balance and temperature suitable to the characteristics of the place in which
they must be moved and must be compatible with the performance the crane and its components.
• Slung with appropriate accessories that prevent accidental fall.
• Stable and should not be subject to change their static configuration during the lifting operation.
It is not allowed to move the following loads:

• whose weight exceeds the rated capacity of the crane.
• with surfaces that are not sufficiently resistant to pressure from the outlet
• that, for their physico-chemical characteristics, are classified as hazardous
(eg.: flammable materials, explosives, etc..).
• that can change their configuration, static and / or their center of gravity or
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their chemical-physical state, when handling

• not equipped with accessories that the next step
5.1.3 Lifting Accessories

They are generally accepted:
• Slings made of ropes and / or chains and / or fiber bands, together with any suspension rings and
hooks from terminals
• Lifting accessories that are interposed between the load and the lifting hooks such as equalizers,
cross magnets and electromagnets, etc..
• The use of these accessories must be in accordance with the manufacturer of the same.
• Their weight must be deducted from the value of the nominal capacity the crane to determine the
payload can be lifted.
Are generally not allowed:

• accessories whose functional / performance could lead to the crane dynamic
stresses higher than those eligible.
• that allow an immediate release of the load and may therefore cause undue
stress dynamics and / or accidental overloads.
• that restrict the free movement of the load.
• lines that are connected to independent power
5.1.4 Remote control (extract from the manual Autec)

Overview
The radio controls are used to control industrial machines remote location. Each transmitter consists of
an industrial portable transmitter that the operator can remotely control the machine and a receiving unit
installed on the machine itself (Figure 5.5).
The transmitter unit via a radio frequency transmission, it sends a coded message. This message is a
value that address (address). Each receiver can decode only the messages coming from the transmitter
that has the same address. This excludes interference that can activate any function of the system. In
fact, if the radio transmission is disturbed, incorrect or broken, the receiver stops the entire system
yourself with the functionality of emergency passive (passive shutdown).
Figure 5.5.
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Under normal operating conditions the transmitter continues to operate with a range
of about 100m and responsiveness to commands and the STOP signal in the order of
100 ms.
For the characteristics of the radio (eg presence interference, reached the limit of
capacity), the delay between the issuance of a command and disabling the
corresponding output of up to 1 second.
You must ensure that this can never lead to a dangerous situation in the specific
application.
List of buttons and their functions:
Figure 5.6.
A STARTING KEYSWITCH D STOP PUSH BUTTON

B SIGNALLING LED E PUSHBUTTONS
C1 ROTARY SWITCH F TECHNICAL DATA PLATE,
IDENTIFICATION PLATE (in the battery
housing)
C2 TOGGLE SWITCH G BATTERY
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H START PUSH BUTTON
The transimitting units are equipped with a dual channel processing that rotect the system "radio
remote control + machine", when it is in neutral position, from unintended movements caused by possible
radio remote control single faults.
Usage notice
The operator must always observe the following:
Follow view of all movements of the machine and load the remaining al''interno
typical range of the transmitter.
Position yourself in the best conditions of direct visibility of the system "machine +
remote control" and the load.
Before you begin, and work, always check the proper functioning of the mechanical
stop switch: if this fails, do not use the remote control.
Turn off the transmitter unit when you suspend the work, instead of leaving the
suspended load (even when replacing the battery).
Never leave unattended the transmitting unit with the ignition key is inserted.
Do not turn or move ever if the transmitting unit to start working: the improper use
could result in dangerous situations.
Do not turn or move the transmitter unit in places never closed fuuori visibility or
outside the range typical
Immediate action by pressing the STOP button when there is a dangerous situation
Pay attention to the whole area of work and intervene in case of danger by pressing
the STOP button manually.
Make sure that the transmitter unit does not accumulate materials (like cement,
sand, lime, ...) that could compromise the use and safety.
In case of malfunction, dead or damaged parts, put the transmitter out of service
until the complete removal of the problem.
Transmitter Operation:
• Turning Power On and starting
◦ To turn on the transmitter, insert the ignition key (A) and turn it in position "I"
◦ To start the functions of the remote, press the START button (H) for 1-2 seconds.
◦ After starting the LED lights more and (B) the green signal.
• Powering off
◦ The Transmitter must be turned off every time you pause the job by turning the ignition key in
position "0" and pulling it out (always store it in a safe place).
◦ The transmitter can also be turned off when the battery is sufficiently charged and / or when
the transmitter is not used for about 3.5 min (see section 8 of the manual Autec).
• STOP
◦ The STOP button (D) is activated when there is a need to immediately stop the machine for
the occurrence of any danger.
◦ To immediately stop the machine, press the STOP button. To resume work, after verifying that
the working conditions are safe, rotate in the direction indicated the STOP button to switch off
and repeat the starting procedure.
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• Battery
◦ To charge a battery charger, insert it in place in one place at temperatures between 5 ° C and
45 ° C begins charging the battery indicator reported by the "CHARGE".
◦ After a maximum of three hours, the LED "CHARGE" switch off: the battery is fully charged.
Remove it from the charger (if not withdrawn, cair continues with a current maintenance).
• diagnostic unit
◦ In the event that the system "machine + remote control" does not start, you should check if
the problem affects the remote control or the car. Therefore, before any testing, connect the
emergency push button: If the car does not start, the problem is affecting the car itself.
◦ If the machine were to start only if driven by the emergency push button, the problem is with
the remote control. In this case proceed as follows:
Figure 5.7.
5.2 ENABLING
Before starting the activity with the cranes do the following:
• Make sure the correct lifting is not below what is necessary
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• turn on the power switch

• put the emergency stop button in the position "startup allowed” (D button for the remote control)
• when using the remote control perform activation shown, otherwise, if you use the emergency
pendant push button, go to the next point:
◦ to turn on the transmitter, insert the ignition key (A) and turn it in position "I"
◦ to initiate functions of the remote, press the "START" (H) for 1-2 seconds; after the start lights
always green LEDs.
• press the "start / alarm" (E)
• Verification of the function of lifting winch by pressing the buttons "up / down"
• verification of the drive function by pressing the "left / right"
• verification of the scrolling function by pressing the bridge "forward / back"
• verify the operation of all movements at two speeds
• perform the preliminary checks as described in "WHAT TO DO ALWAYS" (5.5)
Figure 5.8.
5.3 OPERATION
5.3.1 Operating environment

Must have the following characteristics:
Temperature: min. -10 ° C, Max. +40 ° C: relative humidity max. 80%
use in indoor environment: the crane should not be exposed to the elements.
The crane should not be used in areas and environments:

With vapors, fumes or dust, highly corrosive and / or abrasive (when this can not be
avoided increase maintenance cycles).
In the presence of flame and / or heat to the upper permissible temperature.
With a risk of fire or explosion and where it is prescribed the use of explosion-proof
and spark proof
In areas where they are exposed to strong electromagnetic fields that can generate
static electricity buildup.
In direct contact with food in bulk.
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5.3.2 Lighting
The crane is equipped with lighting system.
The level of ambient lighting should always be such as to ensure the operation
of the crane in the safest possible use in relation to which it is intended. In the
case of operations located in areas of maintenance and / or parts of the
machine is not sufficiently lit is required to adopt portable lighting system,
taking care to avoid shadowing, which prevent or reduce the visibility of where
you go to work or surrounding areas.
5.3.3 Operators
Are all those who carry on the crane, the following steps:
• The transport and handling of parts
• Assembly, installation, adjustment and testing
• Commissioning and use
• Cleaning, maintenance and repair
• Dismantling and decommissioning and demolition
The operator must be a person suitable to work and psycho-physically able to attend to the needs
related to the operation of the crane during all the operational phases and in particular during slinging and
handling.
The operator who uses the crane should be placed in a manner notdangerous for his own safety,
providing and / or preventing falls and thus avoiding possible movements or dangerous cargo. Must follow
the directions to get the most security for himself and for others use the machine, in particular, must
strictly observe the instructions in this manual.
The operator must not allow anyone to approach while using the crane and prevent
the use of foreign personnel (especially for children under 16 years).
It is not allowed to use the machine to unauthorized personnel or uninformed.
5.3.4 Lifting capacity

The rated capacity of crane No.C5020, 50000/32000kg, it is clearly indicated by the plate affixed
to the same and is visible from the driving position.
It should never be exceeded the capacity of the crane, even if is determined by a

large margin of safety (Figure 5.9), changing the calibration of the load limiter of the
winch.
If the weight of all lifting accessories more than 50 kg or 10% of the nominal
capacity of the crane must to be deducted by the nominal capacity.
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Figure 5.9.
5.3.5 Maneuvers
It is good to make a motion at a time, because only in this way a maneuver can be started, stopped,
and constantly followed by the operator who must also avoid running continuously repeated connection
and disconnection even in the case of small displacements.
The load to the hook of the crane and lifting accessories must be done very carefully, gently and
without tearing.
Begin slowly lifting operation by placing live up to the ropes to lift the load a few inches, stop operation
and check the soundness and stability of the same.
At the end of the movement, carefully place the load and free the hook.
• Proceed with care and diligence constantly following maneuvers and visually
checking the balance of mass
• Avoid abrupt movements unless it has ascertained, after a brief pause, the
stability and balance of the load. The maneuvers to "small tear" are very
harmful to the stability of the load due to dynamic effects that are generated.
• Never lift with sockets unbalanced or omit to grab and ensure all lifting
accessories provided or attach the load with improvise slings
5.3.6 Lifting
The operator must always be careful to maintain the lifting ropes taut, never lay on the ground or on the
hook loads to be lifted. The call can twist ropes, forming the nodes, also severely damaged and create
dangerous situations. The operator must avoid making oblique pull always dangerous and poorly
controlled, and especially oblique pull in the direction parallel to the axis of the drums that can
furthermore cause damage to the rope guide and grooves resulting in an irregular winding.
Overturning of the mold
Sequence of operations:
1. With the truck stop, lift the mold with both winch until it no longer rests on trestles;
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2. Proceed in lifting with the main winch to bring up the mold in a vertical position;
3. Release the mold from the auxiliary winch;
4. Manually rotate the mold to 180 °;
5. Hang up the mold auxiliary winch;
6. Lower the mold with the main winch, up to a horizontal position;
7. Continue the descent with both winches up on jack stands to support the mold.
• Verify before tipping operations that the weight of the mold does not exceed
the lifting capacity of the main winch!
• Never lift the mold with the auxiliary hoist if its weight is greater than the
capacity of the auxiliary winch;
• During tilting the mold should remain supported by the main hoist, the
coupling point of the mold to the main hoist must always be higher than the
point of attachment of the auxiliary hoist.
• The movements of ascent / descent of the two winches can not be made
simultaneously, but, acting on the switch on a winch for a time.
5.3.7 Trolley and sliding bridge

Avoid violent shocks from the cart or crane structure and the bumper terminals to not cause serious
repercussions on the mechanical parts. The limit switches are arranged in a position to allow full travel
when they are achieved at low speed and braking distance is as high as greater the speed, so the
operator will always have to slow down the movement of the truck or bridge near the end (Figure 5.10).
Figure 5.10.
5.3.8 Interlocking
The exclusion of power supply of the crane is switching off the power line or by pressing the "Stop"
button on the control. An electrical and mechanical interlock prevents engines on the contemporary
command in both directions of rotation, the electrical interlock placed on two-speed motors for fast and
slow speed prevents a simultaneous power.
The lack of tension causes the immediate blocking of all movements, since they have stopped.
5.3.9 Safety devices

The limit of lifting and traversing demarcate the maximum travel of the hook; they are emergency
devices and can not therefore be used systematically as arrests or service enabling devices for
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subsequent operations. The load limiter prevents the use of the winch in overload. On the lifting hook is
installed snap safety against accidental disconnection of the harness.
5.3.10 Inhibitions
The crane interested, can travel throughout the work area in a free manner, only in the proximity of the
press will activate a series of inhibitionstrolley bridge that will not allow the HOOK AND LOAD to collide
against the press.
Inhibition:
The bridge is' free to slide forward and back across the span, but if with the truck tries to pass over the
press, the bridge stops.
At this point, you can perform two operations:
• Move the trolley to the right or left to exit the 'footprint;
• Perform the opposite maneuver.
If all the conditions mentioned below are met the cart will pass over the press, but you can not make
the descent maneuver.
The hoisting limit switch is high;
If the hook is unloaded (nothing attached).
Bypass:
The removal of all inhibitions cranes entering the selector on the remote control and emergency push
button and turning the key to 1.
At this point you can use all commands, both in the work, both in the press.
this will be used to make maintenance only the press.

improper use of this option can cause serious damage to people and things placed
in the proximity of the crane.
5.4 POWERING OFF
To turn off the crane after work do the following:
• free the hook from the lifting slings used to handle the load
• shelter the crane area defined by its location during times of non-operation (if planned)
• raise the hook at an altitude of less than 250 cm. so that does not cause trouble and danger to
the movement of people and things beneath the crane
• stop the movement of the crane by depressing the red button mushroom "STOP"
• put the panel in place of "Not Disturb" (if used)
• turn off the radio by turning the ignition key to position "O" and pulling.
• remove the power supply to the crane placing the switch lever is in position "OFF" or "0" (zero) -
(Figure 5.11).
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Figure 5.11.
5.5 WHAT TO DO ALWAYS
5.5.1 Planned use, the criteria and precautions for use

The correct use of the crane allows you to take full advantage of the benefits that it is able
to provide in complete security. These potentials are guaranteed only in strict accordance
with instructions given below, therefore:
• ALWAYS follow the information and instructions in the user manual and check the integrity of
components and parts of the crane (Figure 5.12).
• ALWAYS respect the warnings and instructions marked on the machine, the license plates
displayed on the crane warning and in areas of operation are reports and accident prevention
must always be legible (Figure 5.13).
• ALWAYS check the compliance performance of the crane in relation to the intended service.
(Cycles to work - intermittently - time of use - load to be moved) (Figure 5.14).
• ALWAYS check that the path of travel of slide is placed at a height that allows the operator to
interfere with the shape of the lifting and / or its moving parts. In case this is not possible to
provide accommodation suitable shelters or signage in the area at risk (Figure 5.15).
• ALWAYS check the suitability and operation of the electrical system, in particular check that there
are connections precarious and dangerous. Check for proper operation of all motors.
• ALWAYS check the compliance of the movements of the crane (Figure 5.16)
• ALWAYS test the functionality of the button stop / emergency (Figure 5.17).
• ALWAYS test the functionality of the button stop / emergency in case of failure of the button, pull
the switch to disconnect power immediately and contact your armored department manager and /
or charge
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Figure 5.12: Figure 5.13. Figure 5.14:
• ALWAYS check constantly, the efficiency of brakes and limit checking functionality in all crane
movements.
• ALWAYS carry out inspections of ropes, hooks, load limiters and front control panel verifying the
integrity and efficiency.
• ALWAYS make sure that the lifting hooks are not worn, damaged, lacking safety devices (hooks).
• ALWAYS check the suitability and efficiency of slings (ropes, chains, belts, etc..) Sure there are
no lacerations, crushing, broken strands or parts not lubricated (Figure 5.18).
• ALWAYS make sure you have the hook of the lifting unit centered on the perpendicular of the
load before you made the harness and handle the load.
• ALWAYS properly secure the harness to the load lifting hook, after having provided to balance
the load before lifting, putting tension on the ropes with a slow and safe maneuvers (Figure 5.19).
• ALWAYS make sure that the load during handling operations (lifting, shifting, sliding) will not be
obstructed (Figure 5.20).
• ALWAYS make sure, before starting any operation, the sliding area of the crane (runways) is
clear of obstacles.
• ALWAYS check the adequacy of the state of conservation and maintenance of overhead cranes
(cleaning, lubrication) and its main components (cables, drums, clamps, pushbutton, switches,
motors, wheels, etc..).
• ALWAYS give notice to the staff who work in the beginning of the operation of the crane handling
(Figure 5.21).
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• ALWAYS operate outside the radius of operation of the load (Figure 5.22)
• ALWAYS operate in the best light conditions and visibility of the load.
• ALWAYS operate the various movements and avoid as much as possible to carry out control
pulses in quick succession (Figure 5.23)
• ALWAYS use speed "slow" approach to operations / or positioning movements to perform at full
load (Figure 5.24)
• ALWAYS, after work, extend the crane in the position assigned to "shelter" ready for use, by
placing the hooks and the pendant, so they will not be an impact / collision.
• ALWAYS, before leaving the driving position, press the red "emergency stop" button on and off
the main switch of the crane (Figure 5.25).
• ALWAYS remove the power supply of the machine in case of inspections, repairs, maintenance
(Figure 5.26).
• ALWAYS use suitable working clothes, in compliance with safety standards.
• ALWAYS report any malfunction (bad behavior, failure, suspicion of rupture, incorrect movement
and noise outside the norm) to the department manager and put the machine out of service
conditions.
• ALWAYS respect the program of maintenance and record of any inspection, any comments on,
above all, hooks, ropes, brakes and limit switches (Figure 5.27).
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Figure 5.26. Figure 5.27:
5.6 WHAT NOT TO DO, NEVER!
5.6.1 Use unforeseen, unintended use, improper use predictable and unpredictable,
Contraindications for use.
The use of cranes for unauthorized maneuvers, its misuse and poor maintenance
may involve risk of serious danger to the health and safety of people exposed and the
operator as well as damage to the work environment and to affect the function and the
intrinsic safety of the machine.
The actions described below, which of course can not cover the entire range of
potential possibilities of "misuse" of the crane, and yet those are "reasonably" more
predictable, are strictly prohibited and therefore to be considered:
• NEVER use the crane for lifting and transport of persons (Figure 5.28).
• NEVER lift loads as people pass on the maneuvering area (Figure 5.29).
• NEVER pass, stop, operate and maneuver under the suspended load (Figure 5.30).
• NEVER allow the use of cranes or unqualified personnel under the age of 16 (Figure 5.31).
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• NEVER use the crane if you are not physically fit (Figure 5.32).
• NEVER use the crane if you do not have a suitable work clothes and / or personal protective
equipment (Figure 5.33).
• NEVER operate without the necessary attention during handling maneuvers (Figure 5.34).
• NEVER put your hands on the ropes in motion, the slings under "tensioning" in the areas of
contact between the load and hook and sling (Figure 5.35).
• NEVER leave unattended loading (Figure 5.36).
• NEVER groped or apply to lift loads that exceed the rated capacity of the crane (Figure 5.37).
• NEVER use the crane for services other than those covered by it, avoid using them for other
operations such as painting ceilings, replacement lamps, etc.. - (Figure 5.38).
• NEVER lift the load is not balanced (Figure 5.39).
• NEVER swing the load or hooks during handling (Figure 5.40).
• NEVER lay the cables of the lifting unit diagonally in a firing position (Figure 5.41).
• NEVER pull or drag loads with the crane (Figure 5.42).
• NEVER use the power of the push-button to drag the crane
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Figure 5.36:
Figure 5.37.
Figure 5.39:
Figure 5.38:

Figure 5.42:
• NEVER use the winch rope as a sling to the load (Figure 5.43).
• NEVER use slings without having checked the suitability (Figure 5.44).
• NEVER use the winch rope as a ground for welding (Figure 5.45).
• NEVER use the tip of the hook as a grip point of load (Figure 5.46).
• NEVER use the crane to keep in tension elements tied to the ground (Figure 5.47).
• NEVER lift loads "led" (Figure 5.48).
• NEVER continue the race after placing hooks the load causing the notice of the ropes.
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• NEVER cause collision between the hook and the crane and / or surrounding structures during
handling (Figure 5.49).
• NEVER hit with the load bearing structures or other machines and equipment (Figure 5.50).
• NEVER use two cranes to lift the same load, without putting in place appropriate security
procedures (Figure 5.51).
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• NEVER use the overhead cranes with two contemporary movements, waiting for movement to a
complete stop before starting another (Figure 5.52). Do not make sudden movements to change
direction on the movements of the crane
• NEVER use, shut down or relocate the crane after work in areas not protected from the elements
(rain, wind, snow, etc..) - (Figure 5.53).
• NEVER intervene in a continuous way circuit breakers limit switches (Figure 5.54).
• NEVER reach full speed and with maximum loading zones "end run" during the sliding and
translation (Figure 5.55).
• NEVER use the crane in the presence of a large voltage drop or an accidental failure of one of
three stages (Figure 5.56).
• NEVER make sudden changes of direction in the handling process (Figure 5.57).
• NEVER operate the buttons repeatedly to control the crane (Figure 5.58).
• NEVER change the functions and performance of the crane and / or its components (Figure
5.59).
• NEVER make temporary repairs or restoration work does not comply with instructions (Figure
5.60).
• NEVER use the cable of the pendant pushbutton panel to move and / or rotate loads
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Figure 5.59:
Figure 5.60:
Figure 5.58:
• NEVER use the crane in unforeseen environmental conditions (-10 ° C +40 ° C, 80%).
• NEVER use or intervene on the crane in insufficient lighting conditions and / or visibility.
• NEVER use in areas where the crane is required to use component parts explosion.
• NEVER change, stay the settings of the safety devices (limit switches, load limiters, etc..) and / or
modify.
• NEVER use non-original spare parts or not recommended by the manufacturer (Figure 5.61).
• NEVER leave maintenance and repairs to non-instructed by the manufacturer (Figure 5.62).
• NEVER leave the crane after work without having activated the security procedures (Figure 5.63).
• NEVER perform maintenance, inspection or repairs unless you put the crane out of service and
have activated the relevant procedure (Figure 5.64).
• NEVER during maintenance (Figure 5.65):
◦ use means unsuitable
◦ use the rope to hang the retained protective equipment (safety belt)
◦ support to the winch or crane scales
◦ operate without the means of personal protection
◦ intervene without removing the load lifted
• NEVER use the crane if not perfectly responsive in all its functions (Figure 5.66).
• NEVER re-activate the emergency button without having first removed the anomaly. In case of
malfunction of the crane, with emergency stop button in place of "STOP" (for example due to
bonded contacts, which causes unexpected movements) Identify the extent and type of
abnormality and possibly eliminate the first to wake the button "mushroom". If you do not remove
the cause of the defective machine back into operation with the button in the run position may
cause damage to property or persons.
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Figure 5.64:
5.7 MAINTENANCE
The maintenance plan includes interventions of ordinary type, which include inspections, checks and
verifications conducted by the operator and / or normal maintenance personnel, and company-type
operations that include regular replacement, adjustment, lubrication carried out by skilled personnel
5.7.1 How to access the crane

The on-board crane operations must be carried out safely. Compliance with this
is guaranteed only in strict accordance with instructions given. The staff should be
trained and interventions approved for the purpose.
5.7.1.1 Access to crane
To access the crane runway use only suitable lifting equipment such as ladders, bridges developable,
lift platforms and tables.
If there must be adequate runway on landing.
In carrying out activities at high altitude is required to use fall arrest systems (anchored to fixed points
known flow) and be equipped with the expected protective equipment (safety belt, lanyard hold, helmet,
gloves, shoes and accident prevention)
The harness with lanyard must be connected to the support structure and / or anchor
The helmet, not directly attributable to the fall arrest device, acts as protection from objects falling from
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above and by the impact barriers against any operator.

5.7.1.2 Access to crane runways
Using appropriate means to reach the bridge cranes on board, bringing with it the control panel and
remote control
Remove the key emergency access gate to the cart by the plant manager, the key used to unlock the
lock in case of power failure
5.7.1.3 Access to crane runways Cart
• The access to trolley is allowed in special boarding station;

• Bring the trolley at the entrance gate;
• Open the gate by pressing the open button;
• In the case of specific requirements (tests), close the gate, replace the gear, doing the maneuvers
in a safe and complete visibility of moving parts to operate;
• At the end of the planned activities, please see our walkway on the crane, using the stepladder
and pressing the button to open the gate;
• Close the gate and leave the workplace safely;
• When you reach the bridge crane for the descent to the ground again using the appropriate
means provided for this operation;
• The key management of the locks is the responsibility of the safety function of establishment;
• The maintenance functions must be performed by trained and experienced technician to specific
maintenance and ability to access work.
5.7.1.4 Case of trolley stop in unexpected location
If the truck is locked and not aligned to the access ladder, to climb the rope sling must engage with the
gulf has close to the access of the trolley
Once the truck reached safely (using appropriate equipment) to carry out the remedial measures
ensuring, in the absence of appropriate boundary protection, the bindings to fit, or in their absence to the
structural parts of the truck.
5.7.1.5 Residual risks
RESIDUAL RISKS DESCRIPTION MEASURE / SOLUTION

- Floor-mechanical elements
Risk stumble - Sewer-Electric Information / education / training
- Floor space
Risk of injury to hands Contact with abrasives / sharp Use of protective gloves
-Protruding parts of machinery
Risk Impact to the head Use of protective elemanti
-Structural parts
Ascent part of elevating means
Using the safety belt
Risk of falls suitable landing
Climb up ladder Use of safety shoes
Risk of sudden or unexpected Movement of parts due to Blocking emergency stop
movements accidental operation (depression of all the commands)
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Complete visibility of elements to

Lack of visibility
operate
Figure 5.67: Railings perimetral walkways Figure 5.68: Safety cage

onboard cranes 1.10 h fitted with end-stop at ladder access to trolley and
the foot the railing to contain any
falling
Figure 5.69: Guard protection to the top of the Figure 5.70: Free floor plates of
cart non-slip walkways
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Figure 5.71: Winching

ring used for attaching
the safety belt
5.7.2 Ordinary check

It includes the control operations that can be executed directly by the employee and trained in the use
of cranes or personnel involved into the ordinary company, maintenance as prescribed in this publication
and in the documentation and do not require use of special tools and equipment.
The routine control operations, which do not require the use of special equipment or
special tools and are divided into:
Daily operations, by operator who uses the crane:

• General visual inspection
• functional tests (test motors, test limit switches, unload brake tests, test buttons "stop running"
and other functions of the control box)
• check conditions ropes and hooks
Weekly operations, by the personnel involved in the normal company maintenance:

• visual inspection of each mechanism and any leaks
• functional control of the brakes at full load
• Control of the load limiter
• check limit switches and if necessary, provide at greasing mechanisms, levers or cam drive, to
ensure the efficient operation and limit the wear
• check panel function and integrity and cable
Monthly operations, by the normal maintenance company personnel involved:

• efficiency check ropes and rope guide
• wear check pulleys and drums
• wheel wear check
• visual inspection of the paintings in order to ascertain the presence of dust
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• check and cleaning connectors sockets / plugs

• oxidized contacts check: are held, after cleansing with a light film of Vaseline
• check greasing of mobile carts festooned line and control cables
• check efficiency and integrity of the supply line and its components
5.7.3 Periodic inspections

It includes operations of periodic inspection, performed by qualified personnel, records relating to
inspections, lubrication, and any substitutions, in relation to the timing of scheduled maintenance in the
Plan as reported in the tables "periodic maintenance and lubrication".
Before the maintenance, mechanical and / or electrical main switch must be turned
off and put a sign on the machine with the indications of "machine maintenance."
All operations of the regular checks, inspection, repair, replace:
structural components, electromechanical components and suspension elements,
ropes and hooks must be conducted by qualified personnel trained for this purpose
and it is recommended to be recorded into the control register.
For the individual parts of the crane observe the following instructions refer to the
maintenance and operation and maintenance manuals of the manufacturers:
5.7.3.1 Verification of the rope and fasteners.
Check the condition of the rope in order to judge the possible degradation; rope and rope guide are
material wear.
Regular lubrication extends life.
It can often improve the performance of the cables determine the cause of their deterioration. The
assessment is done by analyzing the rope used. The inspections must be observed carefully the parts of
the ropes that wrap around the pulleys, the pulleys near the compensation and the mounting points at the
ends.
Make a note in the register as annexed to this publication, the date and results of exams, so you can
predict the future period in which the rope must be replaced.
The decision to replace the rope, according to UNI ISO 4309, must first be determined by the number
and positions of breakage of wires making up the strands, the degree of wear and corrosion, other major
damage or tears.
The cables must be replaced when broken wires visible attain the maximum deterioration in the tables
or the statements of manufacturers of ropes.
And keep in mind that often ruptures are difficult to detect because of the broken wire ends remain in
the original position and do not protrude from the surface of the rope.
To view these breaks, remove the fat that covers the rope, slide down the rope a piece of soft wood
and, if possible, bend the rope by hand, so as to force the wire ends and to rise up to become visible.
The control cable must be "unloaded" to detect possible cracks.
During the inspection of the rope to check:
the number of broken wires - based on the characteristics of the rope you can find the maximum
permissible number of visible broken wires in any section of rope. For values greater than indicated, the
rope must be replaced.
the decrease of the diameter of the rope - if a rope has a metal core to decrease the value of the
nominal diameter equal to or greater than 10% (due to a strain in the bent area), it must be replaced.
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corrosion and wear of the rope - a rope if it reduces its diameter due to corrosion or wear an extent
equal to or greater than 10% of the nominal diameter, it must be replaced even if it has no broken wire.
the deformation of the rope - the deformations can be either helical axis of the rope, with a decrease
in diameter concentrated in short sections of rope, with flattening of the local cable or angular
deformations due to external causes of high intensity. In the first case the deformation causes of irregular
movements of the rope while dragging, the movements that are the primary cause of increased wear and
rupture of the wires in the second case the defect is common to the end of the rope.
According to the table ISO8309 the maximum number allowable for a broken wire rope type 6 (14 +7 /
7 +7 +1) WAS + IWRC crossed is equal to 38
• The operator, while checking the cable, should use gloves to avoid the danger of
puncture or perforation resulting from contact with any broken wires!
• The rope and / or fasteners must be removed from service and destroyed if they
have:
• Rope:
◦ narrowing of greater than 10%
◦ one or more broken strands
◦ dents, creases permanent infiascature, crushed
◦ the escape of the soul rope
◦ under tension, one or more strands loose and protruding
◦ the total number of broken wires, over a length of 6 diameters, over 10%
external wires of the strands
• Fastenings
◦ deformation, wear, cuts, reductions in diameter in one place more than 5%
- Impianti di sollevamento 60 / 103

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5.7.3.2 Sheaves block
• Observe each pulley rotation and the regularity of operation, if imperfections are found
disassemble and check the pad.
• Check the wear of the throat.
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• Check that the pulleys are free in their rotation. Observe the slope of the unload block during the
run up and down the next. If the hook during these maneuvers had great inclination, first on one
side and then from the vertical, it means that the friction of the pulleys is excessive and therefore
need to remove the pulleys and to examine the sliding surfaces.
Replace pulleys if the reduction of wear of the throat diameter is> 5%.
Guards removed for maintenance must be relocated before the next use.
5.7.3.3 Hook
The hook mounted in the block must be examined by checking and reporting:
• Deformation, elongation, nicks, wear, corrosion, abrasion.
• The integrity and functionality of Pull-out stop safety devices (hooks)
• The hook rotates freely without excessive friction and that motion is smooth and without jerks.
Should be made to disassemble and inspect the bearing.
• The wear of the area in contact with the harnesses
Replace the hook if you experience:

• permanent deformation with a larger mouth opening> 10%
• reductions, at any point, section> 10% of the size or> 5%
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Figure 5.74.
5.7.3.4 Drum
• Check for loose screws locks and examine the rope for wear.
• Check the integrity of the thread.
• Check your cable guide and / or premifune examining the state of wear. In the case of
devices antiaccavallamento verify the correct operation of safety switch that stops the
climb.
Never act on the drum with corrective maintenance. Any extraordinary maintenance
operation on the drums must be conducted by the manufacturer or authorized by the
same
5.7.3.5 Wheels
• Check for wear on the edging and bands rolling wheels

• Check the bearings to be replaced if you experience excessive noise or show excessive friction,
rotation to "shots", difficult and / or irregular.
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• Check the tolerances between the wheel rim and the axis between the axle and gearbox, the
presence of space highlights the need to replace the shaft and / or wheels
Replace the wheels when:

• the thickness of the flange was reduced to 50%
• Rolling wear the band has more than 5 mm
Figure 5.77. Figure 5.78. Figure 5.79.
5.7.3.6 Buffers
Check that the arrests of ends are not deformed and there are signs of failure in their attachment to
structures, and that the bumper is intact and securely attached to its support.
Replace the buffers when they show signs of breakage or permanent deformation
Figure 5.80.
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5.7.3.7 Lifting reducer
It is forbidden to act on gearboxes with corrective maintenance.

Any extraordinary maintenance operation on the lifting gear must be conducted by
the manufacturer or authorized by the same
For more detailed information refer to the manual GSM.
Check frequently if there are unexplained variations in temperature and / or noise.

Seal life depends on several factors including speed, temperature and environment variable and may
be expected between 4000 and 20000 h.
• Check the gearbox every 2 years.
• Check for loose screws at the end of the run and every 2000 h.
• Check for correct closure of the oil fill cap and output (monthly).
• Periodically carry out a thorough cleaning of the external gear, to remove dirt may be deposited
over time and limits the ability to dissipate heat.
Take the necessary precautions during normal operation since surfaces are hot.
• Check the oil level on an annual basis;

• Make an initial oil change after 8000h of operation or 5 years.
• Replace the old oil in reducing hot.
• Before replacing the lubricant to ensure that the product is stationary for about 30 minutes, long
enough for the oil temperature could drop to levels not dangerous to the operator.
• Before introducing new oil flowing to the same type of oil to remove particles left inside the
casing.
• The new oil is introduced, ensuring that there are no impurities.
• Check each month that there are no leaks.
• More detailed information can be obtained from your supplier of lubricants such as through
periodic analysis of the oil.
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Figure 5.82.
Figure 5.81.
Figure 5.83. Figure 5.84. Figure 5.85.
5.7.3.8 Lifting motor
For more detailed information refer to the manual FIMET.
• It is forbidden to act on gearboxes with corrective maintenance.

• Any extraordinary maintenance operation on the lifting gear must be
conducted by the manufacturer or authorized by the same
• Clean the engine by removing the dust that settles on the carcass, which could hamper the
proper cooling, make sure the ventilation openings are not obstructed
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• Check with engine speed, noise, temperature and the presence of any games in support of the
rotor, if they are found even small gaps, temperatures near the surface to exceed those of cash
and / or enhanced noise, replace the bearings and check, with engine speed, the temperature of
the box. Temperatures above 110 ° C show, in fact, that the motor is overloaded, search for the
causes in this case inside the equipment and control the service for which the machine is
intended.
• Make sure the absorption and voltage against the nominal values given on the nameplate of each
motor.
• Check for correct mounting of the engines.
Figure 5.86.
5.7.3.9 Translation travel drives
For more detailed information refer to the manual SEW.
Motors
• Isolate the motor, brake from the power supply, before starting work,
safeguarding them against unintentional restart.
• Use only original spare parts in accordance with the list provided by the
manufacturer.
• Let the motor cool down before you start your work.
Part Time Period Operations to be performed

BE brake Every 2 years Inspecting the brake
• Measure the brake disc thickness
• Brake disc lining
• Measuring and adjusting working air gap
• Pressure plate
• Carrier/gearing
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• Pressure rings
• Sucking off any abrasion
• Inspect the switch contacts and replace them if necessary
Motor Every 4 years Inspecting the motor:
• Check rolling bearing and replace if necessary
• Replacing the oil seal
• Clean the cooling air passages
For motors fitted to the lubrication is not necessary as these are the bearings lubricated for life.
Figure 5.87.
[1] Motor with brake endshield [59] Parallel pin

[22] Hex head screw [62] Circlip
[32] Circlip [70] Carrier
[35] Fan guard [71] Key
[36] Fan [95] Sealing ring
[51] Hand lever [550] Pre-assembled brake
[53] Releasing lever [900] Screw
[56] Stud [901] Sealing
[58] Setting nut [57] Conical coil spring
Operations for inspection of motors

1. Remove fan guard [35] and fan [36]
2. Remove the stator: Remove the screws from the stator and the brake. Remove the stator from
the rotor.
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3. Remove the brake cable: Remove the cover and unplug the cable from the rectifier
4. Push the brake off the stator and carefully lift it off.
5. Pull the stator back by about 3 or 4 cm
6. Visual inspection: is there any moisture or gear oil inside the stator?
- If not, proceed with step 9
- If there is moisture proceed to step 7
- If there is gear oil, call for service.
7. If there is moisture in the stator:
- Remove the motor from the gear unit
- Remove the rotor [1]
8. Clean the winding, dry it, and check it electrically.
9. Replace the grooved ball bearings
10. Change the oil seals on the shaft
11. Change the oil seals on the stator
12. Install the motor and brake.
BE1 – BE2 brake
Figure 5.88.
[49] Pressure plate [61] Hex nut [68] Brake disk

[50] Brake spring (normal) [65] Pressure ring [69] Circular spring
[54] Magnet, complete [66] Rubber sealing contact [276] Brake spring (blue)
[60] Stud 3x [67] Counter spring [702] Friction disk
[718] Dampening plate
Adjust the brake air gap:
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1. Remove the fan guard [35]

2. Push the rubber sealing collar [66] aside. Release the clampinng strap, if necessary
3. Measure the brake disc: For dimensions, see the manual SEW "Technical data" (pag.125) and
replace if necessary.
4. Measure the air gap A (Figure 5.89); use a feeling gauge and measure at three points offset by
120 °: between the pressure plate [49] and the damping plate [718].
Figure 5.89.
5. Tighten the hex nuts [61] until the working air gap is set correctly.
6. Put the rubber sealing collar back in place and re-install the dismantled parts.
Changing the brake disc

1. Remove the fan guard [35], circlips and fan [36]
2. Remove the terminal box cover and unfasten the brake cable from the rectifier.
3. Remove the rubber sealing collar [66].
4. Loosen the hex nuts [61], carefully pull the magnet [54] and take out the brake springs [50].
5. Remove the damping plate [718], pressure plate [49] and brake disk [68]
6. Clean the brake components.
7. Install a new brake disc
8. Re-install the brake components: Remember to set the working air gap before installing the fan
and fan guard
9. With manual brake release: use the setting nuts to set the floatin clearance "S" between the
conical spring and nut.
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Figure 5.90.
BRAKE FLOATING CLEARANCE S (mm)

BE05; BE1; BE2 1,5
BE5; BE11; BE20; BE30; BE32; 2
Changing the braking torque

• The torque can be altereted in stages:
◦ By changing the type and number of brake springs
◦ By changing the complete magnet
◦ By changing the brake
For the possible braking torque steps, please refer to section "Technical data" (p. 125)
Change the brake springs

3. Remove the rubber sealing collar [66] and the manual brake release: setting nuts [58], conical
coil spring [57], studs [56]. releasing lever [53], spiral dowel pin [59]
4. Unfasten hex nuts [61] and pull off the magnet [54] of about 50 mm (watch the brake cable)
5. Change or add brake springs [50/276] arrange them symmetrically
and fan guard
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Figure 5.91.

BE05; BE1; BE2 1,5
BE5; BE11; BE20; BE30; BE32; 2
Changing the magnet

2. Remove the rubber sealing collar [66] and the manual brake release: setting nuts [58], conical
coil spring [57], studs [56]. releasing lever [53], spiral dowel pin [59]
4. Unfasten hex nuts [61], remove complete magnet [54], remove brake springs [50/276].
5. Install new magnet with brake springs. For the possible breaking torque steps, please refer to
chapter "Technical data" (p. 125) of SEW manual.
and fan guard
Figure 5.92.
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BE05; BE1; BE2 1,5
BE5; BE11; BE20; BE30; BE32; 2
Reducers
• Before working on the motor, unplug the power supply, safeguarding it against
unintentional.
• Let the gear unit cool down before starting the work.
• Unfasten the oil level and exhaust nut only with great caution.
• Do not mix synthetic lubricants with each other nor to mineral oils.
• The standard lubricant used is mineral oil.
Time interval What do I do?
• Checking oil and oil level

• Check running noise for possible bearing damage
Every 3000 operating hours, at
least once every six months • Visually check the seals for leakage
• For gear units with a torque arm: check the rubber
buffer, replace if necessary
• Change mineral oil

At least every 3 years • Replace anti-friction bearing grease
• Replace oil seal (do not install it in the same track)
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Figure 5.93.
SYMBOL MEANING
BREATHING VALVE
OIL LEVEL PLUG
OIL DRAIN PLUG
Check oil level via the oil level plug

To check the gear unit oil level, proceed as follows:
1) Place a container under the oil level plug.
2) Slowly remove the oil level plug. Small amounts of oil may leak out as the permitted max. Oil level
is higher than the lower edge of the oil level bore.
3) Check the oil level according to the following figure and the corresponding table.
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Figure 5.94.
[1] oil level bore

[2] reference oil level
Oil level bore Min and Max fill level = x[mm]

M10x1 1,5
M12x1,5 2
M22x1,5 3
M33x2 4
M42x2 5
4) If the oil level is too low, proceed as follows:

◦ Remove the breather valve
◦ Fill in additional oil of the same type via the vent hole until the oil level is at the lower edge of
the oil level bore.
◦ Re-insert the breather valve
5) Re-insert the oil level plug.
Control over oil drain plug

To check the gear oil, proceed as follows:
1) Remove a little oil from the oil drain plug.
2) Check the oil consistency.
◦ viscosity
◦If the oil is heavily contaminated it is advisable to change the oil even if this is outside the
intervals specified above.
3) Check the oil level
Change oil through drain plug and vent valve

• Let the gear unit cool down before you start your work
• However, the gear unit must still be warm otherwise the high viscosity of
excessively cold oil iwill make it harder to drain the oil properly.
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1) Place a container under the oil level plug.

2) Remove the oil level plug, the breather valve and the oil drain plug
3) Drain all the oil
4) Re-insert the oil drain plug
5) Fill in new oil of the same type via the vent hole (otherwise contact the customer service). Never
mix with each other synthetic lubricants.
◦ Fill in the amount of oil specified by the nameplate or as required by the type of construction
(see manual SEW pag. 110)
◦ Check the oil level at the oil level plug.
6) Re-insert the oil level plug and the breather valve
5.7.3.10 Drum brakes
For more detailed information refer to the manual OSTELECTRIC.
Thrustor’s stroke setting

The purpose of this adjusting is to make sure that the thrustor releases the brake by utilizing about 2/3
of its stroke, thereby preserving the remaining 1/3 for the following and progressive lining wear. To meet
this condition proceed as follows:
After having loosened the self-locking nut A at rod end, screw (or unscrew) the rod into its pin. By
screwing, the jaws get closer and closer to the drum until they tighten it. Keeping on screwing, the
thrustor piston begins rising up. Carry on this operation until the piston rod is out for 16-20mm of its
stroke. Subsequently, lock the rod through its nut by utilizing a spanner, gripped on its hold at one side
and a second spanner gripped onto the nut A. Beware from using pipe-wrench and improper tools that
could damage the rod. Keep in mind that the integrity of the rod is fundamental for the safety of the lifting
installation and the personnel care.
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Correct braking
position at 1/3 of Piston position
piston stroke at released brake
A
Hold for spanner
Rod
Ø250 D
IN15435
Wrong end position.
No braking action.
Safety of installation
at high risk!!!
Figure 5.95:
Time-by-time the linings wear, the stop position of thrustor piston at applied brake will lower more and
more until extreme position will be reached where the spring will not be able to transmit his force to the
drum. In this condition the safety of the lifting installation is exposed at high risk .Hence, a
periodical checking of the brake is important eventually to re-establish the thrustor-rod-braking position at
1/3 of its stroke as upon described.
Jaws gaping adjustment

The thrustor opening stroke results in 3-3,5mm jaws gaping that must be equally shared between the 2
brake arms. As the stop screws S limit the arm swinging, by adjusting them the condition of equality can
be met without hindering the thrustor in the performance of its whole stroke.
The best way to carry out this adjusting consists in smoothly tightening the 2 screws S until their stop
while the thrustor is on and accordingly the brake is released. During this operation the 2 brake arms
must be kept in symmetric position versus the brake drum. After adjusting, the 2 screws have to be locked
by means of their lock nuts E.
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Ø250 DIN
15435
Ø250 DIN
5 1543
Stop arm swinging Stop arm swinging

at applied brake at released brake
Figure 5.96:
Jaws replacement
Jaws replacement has to be carried out before the linings get throughout worn, in order to prevent the
jaw’s bare metal from rubbing against the braking drum and thereby damaging the drum surface.
Loosen the rod in order to move away at maximum the jaws from the drum. Remove the split pin at
one side of the pin and extract it pin from the jaw. To get the jaw free from the brake, rotate it to a
comfortable position, as showed in the picture below, and take away both jaws, before replacing them
with the new ones.
After inserting the new jaws, make sure the 2 side spring have a good grip at the jaws. Bend again the
2 tines of the split pin at the end of this operation, keeping in mind that otherwise the split pin could come
out from its seat. If so, the pin could come out as well, due to vibration on the installation and as a result
the brake would fail with great danger for the personnel safety.
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Figure 5.97:
Hydraulic filling
Thrustors are always supplied complete with their oil filling HL10 to standard DIN 51524. The most
employed oil mark is AGIP ACER MV10. Time by time, check out the oil level through the oil level control
plug and eventually add it through the oil drain plug. For HR design, utilize the oil indicated on the name
plate.
Rod wiper
Oil drain plug

Packing
Oil level control
Wiper and packing

Ball bearings
1 Packing
Ø18/25 h4,5
Th1 Up 6001 Th1
Down 6001 1 Packing
Ø18/28 h6
1 Wiper
Th2 Up 6001
Th2 Ø22/32 h7/5
Down 6201
Th3 Th3 2 Packing
Ø22/32 h7
Up 6003
Th4 Down 6201 Th4 1 Wiper
Ø30/40 h7/10
Th5
3 Packing
Th5 Up 6003 Th6 Ø30/40 h7
Down 6302
Th6
Up ball bearing
Down ball bearing
Figure 5.98:
Maintenance
Every 6 months
Check up the thrustor conditions making sure any oil leakage has not occurred. Verify the oil level and
finally restore it.
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Every 5 years
To grant the perfect function of the thrustor following components should be replaced:
• Packing
• Wiper
• Bearings
• Hydraulic filling
Replacing rod packing
Figure 5.100:
Figure 5.99:
Beware: If the
thrustor is provided
with internal spring,
safeguard yourself
against the violent Dividing
expulsion of the motor casing
cylinder racket after from
loosening the 4 cylinder-jacket
Extracting rod
wiper and packing screws of the casing.
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Re-insert the new packing and wiper and set again the thrustor following the other way around
5.7.3.11Lifting and moving limit switch
Check the status of conservation and the correct action (often manually operated stroke end.) In
particular, the limit of movement, found their operation during a normal operation at low speed testing
first.
Check the mechanical integrity of the moving parts (lever, and springs) and check the tightness of the
screws.
• The limit switches are devices that perform security functions and their failure
or malfunction may compromise the safety of people exposed!
• Do not hesitate to replace the switch in question, if the latter is unable to offer
sufficient guarantees of reliability function.
• Never improvise repairs on the limit switches!
5.7.3.12 Load limiter
For more detailed information refer to the manual CAMI.
1. The load limiter is a safety device and its failure or malfunction may seriously
compromise the safety of people exposed!
2. Do not tamper or disconnect the load limiter or change the calibration values
provided by the manufacturer!
The verification of the proper functioning of the load limiter must be made as provided in
rule FEM 9,761, at least once a year through the use of masses of known value properly
prepared and / or with the help of a load cell display stress values.
The results of annual audits should be reported in the audit log attached to this
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publication.
5.7.3.13 Electrical equipment
Contactors: Make sure the moving parts of the contactors move with minimal friction, otherwise it may
be that the strength of the electromagnet is insufficient to ensure a good contact between the contacts. it
is also necessary to check the cleanliness of the surfaces of contact between core and armature fixed to
prevent any icing used to prevent rust, gathering dust, can cause sticking of the contactor. It must also be
controlled consumption of contacts, providing they are replaced. Equal treatment should be given to
auxiliary. In case of removal, handle with extreme care to avoid damage to the coil winding, especially at
the terminals. Check periodically to avoid uncertain contacts, overheating and noise, the voltage of the
coils is of the correct value.
Fuses: Provide a regular basis for each type of fuse, so you can provide for a rapid replacement of the
same type of fuse in case of need.
Terminals: periodically check that the clamps are tight, check that the identification number is visible
and integral to the terminal, verify the integrity of the insulation material and in case of cracks or breaks
you replace
Timers: check and clean the contacts as contactors, control the shot, simulating the external
intervention in case of failure and replace the damaged part.
Push-button control: Check the condition of the buttons and selector, regularly providing clean them
from any deposits of dust, sludge and/or scaling, in particular check the functionality and integrity of the
emergency stop buttons and warning gear. Do a statistical check on the resistance to weathering (IP
protection), verifying the integrity of casing and couplings.
Power and control cables: Verify that the cables for peeling, cuts, nicks, abrasions, wire paraded,
lacerations and loss of protective sheaths of insulation. Check that the wire ropes suspending the panel
are intact and tight.
5.7.3.14 Plates
Verify the presence and proper placement of signs identifying the crane and those containing the
provisions safety and accident prevention, and if missing to proceed to their installation or replacement if
unreadable.
5.7.3.15 Horns
Check the operation of signaling device (horn)
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Figure 5.105.
5.7.3.16 Structural Elements
• WELDING
Annual visual check (no obvious signs of cracks), and every ten years to be done by a technician
testing of welds
If they are not explicitly required more frequent inspections should be performed annually to control all
the points listed below the structures.
• BEAMS
Check fully welds joining the beam-head, butt-welds in the flange and bottom flange of souls to the next
lower. Proceed addition to a control sample of welds in the corners that combine the flange below the
souls controls need to be more numerous in the central area of the beam, where the stress is greater.
Figure 5.106:
Check the welds that join the vertical sheet to the top flange under the rail.
Pay special attention (Figure 5.107) at the points where there are variations in cross-section of beams
(a - b) and the edges of any openings, such as cables steps (d) or "hatches" for inspections to 'internal
beams (c), in this' last case, remove any lids and proceed to a rigorous control at the corners, especially if
not rounded.
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(b)
(a)
(c) (d)
Figure 5.107:
• ENDCARRIAGES
Carefully check points near the wheel, where the sudden change in cross-section gives rise to marked
effects of carving.
In particular, in the case of endcarriage with "bracket", check the absence of cracks in the edge of the
media. Any damage may be present in the support (especially if made by welding two plates instead of a
bent or shaped), in the weld bead or side wall of the head.
Figure 5.108:
If the headcarriages are not made of tubular, but from a structural welded (chest, bent or welded to a
metal sheet profiles coupled CNP), make a sample check of the welding procedures similar to those
required for box beams; controls must be more numerous in the lower zone, where it has tensile stress.
In the case of heads with joint friction (recognizable by the absence of spines), also check the solder
joints between the connector plate and the side wall of the head.
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Figure 5.109:
• DRUM
Check the absence of cracks in the shaft, especially in the section and changes in the proximity of the
weld to the flange.
Also check the welds that join the mantle of the drum flanges.
Figure 5.110:
• BOLTS:
Also check the tightness of the nuts visually main (tested bolts - mounting hoist / winch to cart, wheels)
and the secondary relative to the support of raceways, festoon, push button and power winch.
• PAINTING:
Verify the absence of rust
• RAILINGS
Verify monthly the integrity of the railings and damages and / or other changes that may affect the
functionality.
5.7.4 Timing and deadlines

The frequency of maintenance is indicated in the following table. The crane in question is subject to a
service work under normal conditions provided for by ISO 4301/88 and rules for the group FEM 9,511 M7
(4m). If the use of cranes is normal and correct, its review will take place after a period of employment of
about 10 years, according to the rule FEM 9755 (SWP).
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Chart of periodical maintenance inteventions

Periodical checks
Subject of control
Daily Monthly Quarterly Half-yearly Yearly
Visual integrity check
readable plates. Visual check of
Plate symbols and light and plates and
Proper signalisation plates and
and sound signalisation signalisation
functioning signalisation
cleanliness check
Check the integrity
Structural elements / of structures, bolted,
welds weldings. Annual
check
Wearing and
Rope / fixing elements Visual checked
efficiency check
Visual check of lifting Wearing and
Lifting hooks - safety
hooks -safety check efficiency check
Wearing and
Cylinders / pulleys
efficiency check
Lifting reducers, trans. Control checks with
Noise check
motion and movement load test
Lifting engines, trans. Proper functioning Control checks with
motion and movement check load test
Lifting brakes, trans. Proper functioning Brake distance check Wearing and
motion and movement check with a full cargo efficiency check
Wearing and
Wheels and bearings
efficiency check
Proper functioning Proper functioning
Anticollision devices
check check
Bumpers on carts and wearing check and Wearing and
crane efficiency efficiency check
external damages of
Electrical devices, Proper functioning
Visual check the push button and
keyboard and cables check
the cables check
Load limiter, braking Control check and
devices callibration
Lifting walk, trans. motion Proper functioning Wearing and
and movement check efficiency check
Lubrication of cables
and mechanism.
Cleaning and lubricating Oil lubrication Oil lubrication
Check the level of the
oil
REMARK: All results write into the "Control check diary" submitted with this publication
5.8 CLEANING - LUBRICATION
5.8.1 Cleaning the crane and lubrication plan
Cleaning can be carried out by highly specialized personnel and is periodically

necessary to free the structure and elements of furniture accumulations of dust or dirt
and sludge caused by excess oils.
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Cleaning can be done simply with the use of vehicles, equipment and detergents or solvents commonly
used in cleaning industrial equipment since there is no general contraindications for the use of products
or materials.
The careful management of the lubrication mechanisms of the crane is the

necessary condition to ensure effective compliance to the service to which it is
intended, and its duration.
The most favorable conditions are obtained by making the least amount of lubrication for effective
lubrication. Over time the lubrication decreases due to stress, which must be made for the restoration or
renovation of lubricants.
The lubrication of the crane is very simple and can be performed by highly skilled personnel, in strict
accordance with instructions contained in this manual, doing the necessary checks and top ups,
according to the frequencies reported in the "lubrication" and using the types lubricant recommended or,
to them, and correspondents.
Chart of periodical lubrication
Type of lubricant
Component Period
Oil Grease
Mineral with lithium
Drum 3 months
soap
Hook thrust bearing 3 months
soap
Rope 3 months
soap
Lifting reducer Mineral grease with lithium soap
Translation gear units Mineral grease with lithium soap
Oilers, thinners, and detergents are toxic products harmful to health:

• In case of a direct contac tto the skin, they can cause iritations.
• If inhaled they can cause serious poisoning
• If they are swallowed they can cause death
These products should be handeled with great care, wearing adequate protective
equipment. Do not spill them in the working zone; their destruction is regulated by law
about destroying toxical and harmful substances.
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5.9 ADJUSTMENT
• For any kind of possible adjustment of the components or electrical

mechanisms of the lifting, movement and translatory shifting units, consult
the manual in the chapter „Instructions“ which is delivered by the
manufacturer and which is attached to this publication.
• Any other adjustments of parts or components which are not described in
the manual or attached documentation consult the technical offices of
CERRATO.
5.10 REPLACING PARTS
• For any possible replacemant of components or electrical mechanisms of

the lifting, translatory shifting and movement units consult the manual in
the chapter „Instructions“ which is delivered by the manufacturer and
which is attached to this publication.
• Any other replacement of parts or components which are not described in
the manual or attached documentation consult the technical offices of the
firm CERRATO.
5.11 TROUBLESHOOTING
5.11.1 Basic failures and disfunctions

The chart below shows possible failures, defects and disfunctions and their possible causes in
accordance with the crane operativity.
FUNCTIONS ⇒ Lifting of Translatory Bridge CAUSE

FAILURES the winch shifting of movement
⇓ or tackle the cart
- contactors up/down
- up/down buttons
Does not start - winch or tackle engine
1. fuses
2. lifting and lowering walk
- walk left / righthod desno/levo
- contactor left / right
Does not start - left / right button
- engines and carts
- fuses
- walk back/ forth
- contactors back/ forth
Does not work - back/ forth button
-engines and bridge
- fusesosigurači
Does not work - power fuses
- winch / tackle
- power line
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Does not work - low voltage transformator

- line cintactor
- fuses
Workd partially Walk, contactor, or the function button that does
(only in one direction) not work
Movement cannot be - functioning walk

stopped on the walk - brakes (check gliding))
or it does not stop
where it is supposed
Movement continues - function button
although the button is - cintactor functions
pressed - "fake contacts”
Too much noise of the - lack of lubricant
reducer - reducer disfunction
Screeching sound in - dust
braking phases - too big clearance
- wearing of the braking gasket
Screeching sound of - unlinearity of the rails
the wheels (they work - lack of lubricant
with breaks) - out of order
Wheels glide on rails - wheels or rails are too much lubricated or have
paint residue
The crane is not flat - failure on engone reducer or on the bridge
engine
The crane jumps - unlinerrity of the rails on certain joints
All functions on the - power fall on the line
crane are slow and - improper power cabel
the winch lifts cargo - one electricity phase isi missing
with difficulties
There is electricity in - electrical devices
the hook - earthing
5.11.2 Possible failures and repaires

Causes of bad functioning of some parts and possible repairs
- COMPONENT - CAUSE REPAIR

TYPE OF FAILURE
Brake gliding - wearing of the brake gasket - check the distance or replace the brake
- presence of oil/grease gasket
- clean the brake gasket
- the voltage is too low - set the condition parameters to beginning
Vibrating of brakes with - single-phase current values
discs - the clearance is too big - set the clearance
- the functioning is not proper - set the condition parameters to beginning

Brakes heat up too fast - they are not properly adjusted values
- inadequate working conditions - set the brakes
Brakes do not brake - there is no power - set the values of power and brakes
- improper adjustment
Brakes stick - inadequate working conditions or the - set the proper working conditions
functioning is not proper
The walk is blocked - the functioning is not proper - clean and set parameters of adequate
- switches working conditions
Keyboard buttons are - the functioning is not proper - cleaning

blocked - check the conductors
Contactors have sticked - there is no power - set the parameters to conditions for proper
contacts - inadequate working conditions or the functioning and use
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functioning is not proper

The engine is too much - voltage variations > al 10% - set the adequate network voltage
heated - difficult cooling, cloggedair vent - set the proper air flow
- external temperatureis higher that it - coordinate engine characteristics
should be - adjust working conditions as it is intended
- use of a damaged crane
- burned-out fuse - zameniti osugurač
-the contactore has stopped powering - proveriti funkcionisanje kontaktora
The engine does not start - oveload, blocking, insufficient protection- obezbediti bolju zaštitu motora
- proveriti komandne uređaje
The engine does not turn off - voltage is lower than the nominal values - make the conditions of the power network
- improper functioning of the variator better
(inverter)
- improper functioning, rotor is connected - the repair should be performed by a
to stator professional
- one electricity phase is missing - check the electricity power network and
contactors
The engine hums and spends - reducer is blocked - request a qualified person to perform the
too much electricity intevention
- brake is blocked - start checking
- eliminate the short circuite
- request a qualified person to perform the
- short circuit in power cables intevention
- short circuit in the engine
Short circuit in the engine - Wrapping defect - wrap the engine again
Fake contact - unwanted functionactivation - check the contacts on the keyboard
5.11.2.1Faults - Causes - Remedies inverter Schneider
Drive does not start, no fault displayed

• If the display does not light up, check the power supply to the drive.
• The assignment of the "Fast stop" or "Freewheel stop" functions will prevent the drive from starting if
the corresponding logic inputs are not powered up. The ATV71 then displays [Freewheel] (nSt) in
freewheel stop and [Fast stop] (FSt) in fast stop. This is normal since these functions are active at zero so
that the drive will be stopped safely if there is a wire break.
• Make sure that the run command input or inputs are activated in accordance with the selected control
mode ([2/3 wire control] (tCC) and [2 wire type] (tCt) parameters, page 48).
Faults which cannot be reset automatically

The cause of the fault must be removed before resetting by turning off and then back on.
AnF, brF, ECF, EnF, SOF, SPF and tnF faults can also be reset remotely by means of a logic input or
control bit
(consult the CD-ROM supplied with the drive).
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Faults that can be reset with the automatic restart function, after the cause has disappeared
These faults can also be reset by turning the drive off then on again or by means of a logic input or
control bit (consult the CD-ROM supplied with the drive).
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(continued)
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(continued)
Faults that can be reset as soon as their causes disappear
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5.11.2.2Faults - Causes - Remedies inverter Sew LTE-B
Troubleshooting
Fault history
The parameter P-13 in the parameter mode holds a record of the most recent trips and/or events. Each
trip will be displayed in abbreviated text, with the most recent trip being displayed first (on entering into
the value of P-13).
Whenever a new trip occurs, this is entered at the top of the list and the other trips move down. The
oldest trip will then be removed from the trip log.
Fault codes
Tel. 011.397.12.09 – Fax 011.349.94.37 96 / 103
Tel. 011.397.12.09 – Fax 011.349.94.37 97 / 103
5.11.2.3Faults - Causes - Remedies inverter Sew LTE-P
Troubleshooting
Fault history
The parameter P1-13 in the parameter mode holds a record of the most recent 4 trips
and/or events that have occured. Each trip will be displayed in abbreviated text, with the
most recent trip being displayed first (on entering into the value of P1-13).
Whenever a new trip occurs, this is entered at the top of the list and the other trips
move down. The oldest trip will then be removed from the trip log.
Tel. 011.397.12.09 – Fax 011.349.94.37 98 / 103
Fault codes
Tel. 011.397.12.09 – Fax 011.349.94.37 99 / 103
5.11.3 Authorized and qualified people

People who are authorized to intervene in most cases or if it is not said differently, are professional and
qualified people for the areas of maintenanceof the mechanical and electrical parts. If it is said differently,
an intevention by a specialized and trained technical personnel is required.
5.11.4 Temporarily putting the crane out of order – putting off

If the crane is temporarily to be put out of order it is necessary to do the following:
• Coat the rope with a thin layer of grease
• Distance the lifting hook from the of passing through zone to avoid risky situations and dangers
• Do not position the machine hook by the walk
Tel. 011.397.12.09 – Fax 011.349.94.37 100 / 103
• Turn off the machine power supply

If the machine is registered by authorized institutions it is necessary to inform these institutions that the
machine is momentarily out of order and that its putting into function again will be performed later.
5.11.5 Definite putting the machine out of order - (Putting off / Destroying)
If the repaires of the crane were not successful, the machine is going to be put out of order writing
down the damage in the given diary of control checks; request an intervention by an authorized service.
If the machine is definitely being putt out of order (destroy), and if the machine is registered by
authorized institutions, it is necessary to inform these institutions about the intentions submitting the chart
and control check diary. If the machine has to be destroyed, it is first put out of order in a safe and secure
way. It is necessary to give a list of machine parts which may contain chemical substances; the
destruction of the machine must be perforemed in such a way that the destruction is done separately
according to the material or composition:
• metals
• oils, lubricants, grease
• plastics
• rubber
• electrical power cables
• electrical components, software
• cables, chains, hard lifting means on the machine.
The destruction should be performed in firms specialized in this kind of work and which have the
necessary legal authority for destroying, transporting and the possibilities for separate destruction
according to material and composition, which is all performed in accordance with laws about destruction
of hard industrial waste.
Cerrato has a system for environmental managing in accordance with the standard ISO 14000; that is
why we recommend our clients not to throw away waste got from destroying the crane into environment,
because it is being polluted in that way.
If the crane and its parts are defected, broken or their life time foreseen by the
manufacturer has passed, that crane should not be repaired any more, or be used and
that is when its distruction is performed.
Disassembling the crane and its parts must be performed with adequate equipment which is chosen
according to material (big scissors, oxidation flame, saws,...). All machine parts must be disposed and
destroyed after being cut into small pieces so that no one will be able to use them again.
When a crane is being destroyed or disassembled, its parts are being sorted according to material and
composition (metals, oils and lubricants, plastics, rubber,...), engaging firms that are specialized in
destroying according to material and composition, and which have the legal authority to perform the
process of destruction in accordance with regualtions on hard industrial waste destruction.
Machine parts and components which look like they are still useble, should not be
used again, because they are not considered working and appropriate for functioning
any more.
Tel. 011.397.12.09 – Fax 011.349.94.37 101 / 103
5.12 SPARE PARTS
• Cranes of the firm Cerrato are projected and built in such a way that, if they are
used and maintained in a correct way as it is described in this manual, do not
request, normal situations, spare parts which are necessary to replace parts
that are damaged or broken.
• Parts or components which are easily used or repaired, are easy to replace,
too, foe example replacement of keyboard or cable.
• Manuals and instructions about replacing of other parts (cables, hooks,
brakes) can be found in the attached documentation .
• Do not hesitate to replace parts and components because they are not able to
guarantee safetyfunctioning.
• Never perform sudden and unpredicted interventions.
If replacement of parts is necessary because of damage, only original spare parts must be used which
can be directly acquired from
CERRATO S.r.l.
Via Manzoni, 8 - 10092 Beinasco (TO)
tel. 011.3971209 - fax. 011.3499437 - e-mail: info@cerrato.it
The use of unoriginal spare parts, besides breaching the warranty, can cause
damage to crane parts an bad functioning.
Tel. 011.397.12.09 – Fax 011.349.94.37 102 / 103
6 CONTROL CHECK DIARY
As evidence of proper handling all control check and maintenance activities of the winch, and to save
written records on possible responsibilities for performed activities, in the way described in this
publication, it is advised to complete and handle the diary of the machine during the whole life time(10
years).
In the control check diary all maintenance activities must be recorded for periodical, quarterly and
yearly maintenance, in the chart “periodical maintenance and lubrication activities” (chart.5.3-5.4).
Filling the mentioned diary in all its parts. by writing down the results and possible remarks in adequate
columns, will be the responsibility of the person in charge of maintenance
Also, information aboout the person in charge of maintenance must be given clearly visible, just like the
dates of interventions.
Tel. 011.397.12.09 – Fax 011.349.94.37 103 / 103

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USER INSTRUCTIONS

INSTALLATION – USE - MAINTENANCE

DOUBLE GIRDER BRIDGE CRANE

2DOUBLE GIRDER CRANE.......................................................................................................10

4INSTRUCTIONS FOR ASSEMBLING AND INSTALLATION...............................................20

5INSTRUCTIONS FOR USE AND MAINTENANCE ..............................................................35

5.7.3.11Lifting and moving limit switch.........................................................................81

6CONTROL CHECK DIARY.....................................................................................................103

1.2 HOW TO READ THE INSTRUCTION

SYMBOL MEANING DESCRIPTION

• Represents a warning or a remark on the

1.3 INSTRUCTION UPDATE – CLIENT COOPERATION

1.4 APPROPRIATE DIRECTIVES

1.5 PRODUCER RESPONSIBILITY AND WARRANTY

• Always work with limited machine load

• Correct use and planned machine configuration.

2 DOUBLE GIRDER CRANE

2.2 CRANE PARTS

2.2.3 Moving unit – Endcarriages

Figure 2.3 Figure 2.4

2.2.4 Winch shifting unit

2.2.5 Lifting unit

Figure 2.5 Figure 2.6

Figure 2.7 Figure 2.8

Figure 2.9 Figure 2.10

2.2.6 Load limiter

2.2.7 Electrical devices

2.2.8 Electrical control

Figure 2.12 Figure 2.13

2.2.9 Remote control

3.2 CONDITIONS OF MACHINE FUNCTIONING

3.3 PROTECTION AND ISOLATION OF ELECTRICAL PARTS

3.4 ELECTRICAL POWER

3.6 ALLOWED TOLERANCE WHILE MOVING

3.7 CRITERIA IN USE

The crane in question is classified as a class M7.

L1: Light L2: Medium L3: Heavy L4: Very Heavy

4 INSTRUCTIONS FOR ASSEMBLING AND INSTALLATION

4.1 PRELIMINARY ASSEMBLY ACTIVITIES

4.1.1 Preparing the construction site (done by the client)

Figure 4.1: Figure 4.2:

Figure 4.3: Figure 4.4:

Figure 4.5: Figure 4.6:

Figure 4.7: Figure 4.8:

4.1.2 Packing, transportation, unloading and shifting

Figure 4.10: Figure 4.11:

Figure 4.12: Figure 4.13:

4.1.3 Cable installation

To install the rope of the winch, proceed as follows:

Figure 4.16: Figure 4.17:

Do not carry the rope pulling the head of the coil.

Figure 4.18: Figure 4.19:

4.1.4 Adjustment of the winch lifting and lowering switch.

Figure 4.21: Figure 4.22: Figure 4.23:

Figure 4.24: Figure 4.25: Figure 4.26:

• Bring the hook block position of maximum slope (Figure 4.27).

Figure 4.27: Figure 4.28:

Figure 4.29: Figure 4.30:

4.1.5 Adjusting the translation limit switches

4.2 GENERAL INFORMATIONS

Legibility and conservation of plates:

The plates should never be removed and is absolutely prohibited to affix on