IR1874 Operators Manual en

Operators Manual
Part 1
Crane Type: P167L – Super
Work No.: IR1874
Location: TPEP, Paita,

Peru.
October 2013
Liebherr Container Cranes

Killarney
Co. Kerry
Republic of Ireland
Copyright by
Operational Manual IR1874 - Peru
This page is intentionally blank
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TABLE OF CONTENTS
TABLE OF CONTENTS _____________________________________________________________________3
COMMISSIONING _______________________________________________________________________7
AFTER SALES SERVICE ____________________________________________________________________9
STATEMENT OF LEGAL AUTHORITY _______________________________________________________ 10
GENERAL SAFETY PRECAUTIONS _________________________________________________________ 13
1 INTRODUCTION ___________________________________________________________________ 15
2 G. A. DRAWING AND CRANE LEGEND _________________________________________________ 17
2.1 GENERAL ASSEMBLY DRAWING ______________________________________________________ 19

2.2 CRANE LEGEND _________________________________________________________________ 21
3 SUMMARY OF SPECIFICATION _______________________________________________________ 23
3.1 MAIN TECHNICAL DATA ___________________________________________________________ 23

3.1.1 Standards & Classification ___________________________________________________ 23
3.1.2 Safe Working Load_________________________________________________________ 24
3.1.3 Maximum Permissible Container Eccentricity ___________________________________ 24
3.1.4 Lifting Equipment__________________________________________________________ 24
3.1.5 Physical Dimensions _______________________________________________________ 25
3.1.6 Trim System (± 5º) / List System (± 5º) / Skew System (± 5º) ________________________ 25
3.1.7 Number of Crane Wheels and Max Wheel Loads (In-Service) _______________________ 26
3.1.8 Operational Limitations _____________________________________________________ 27
3.2 DRIVE UNITS ___________________________________________________________________ 29
3.2.1 Hoist Unit ________________________________________________________________ 29
3.2.2 Trolley Unit _______________________________________________________________ 29
3.2.3 Long Travel Unit ___________________________________________________________ 29
3.2.4 Derrick Unit ______________________________________________________________ 29
3.2.5 Limit Switches ____________________________________________________________ 29
3.2.6 Derrick Rope Drum_________________________________________________________ 29
3.2.7 Hoist Gear _______________________________________________________________ 30
3.2.8 Positioning Encoders _______________________________________________________ 30
3.2.9 Ground Level Control Station ________________________________________________ 30
3.3 ELECTRICAL / ELECTRONIC FEATURES___________________________________________________ 31
3.3.1 Power Supply _____________________________________________________________ 31
3.3.2 Fault Condition Monitor ____________________________________________________ 31
3.3.3 EMS Digital Display ________________________________________________________ 31
3.3.4 Anemometer _____________________________________________________________ 31
3.3.5 Hour Meters ______________________________________________________________ 31
3.3.6 Automatic Boom Control ____________________________________________________ 31
3.3.7 Floodlight System _________________________________________________________ 31
3.3.8 Long Travel Anti-Collision System _____________________________________________ 31
3.4 MISCELLANEOUS DESIGN FEATURES ___________________________________________________ 33
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3.4.1 Energy Chain Trolley Supply System ___________________________________________ 33

3.4.2 Lattice Structure for Beam and Boom __________________________________________ 33
3.4.3 Cabin Cleaning Platform ____________________________________________________ 33
3.4.4 Cabin ___________________________________________________________________ 33
3.4.5 Manual Storm Pins / Automatic Rail Brakes _____________________________________ 33
3.4.6 Machinery / Electrical House_________________________________________________ 33
3.4.7 Personnel Lift _____________________________________________________________ 34
3.4.8 Stair System ______________________________________________________________ 34
3.4.9 Maintenance Beams _______________________________________________________ 34
3.4.10 Chain Hoist _______________________________________________________________ 34
3.4.11 Overload System __________________________________________________________ 34
3.4.12 Hoist Rope Support Trolleys _________________________________________________ 34
3.4.13 Mirrors __________________________________________________________________ 35
3.4.14 Tools ____________________________________________________________________ 35
3.4.15 Fire Prevention ____________________________________________________________ 35
4 LAYOUT OF CONTROLS _____________________________________________________________ 37
4.1 DRIVER'S CABIN EQUIPMENT ________________________________________________________ 37

4.1.1 Drivers Control Consoles ____________________________________________________ 37
4.1.2 EMS Display ______________________________________________________________ 37
4.1.3 Auxiliary Switchgear Panel __________________________________________________ 37
4.1.4 Spreader Indicator Panel ____________________________________________________ 37
4.1.5 Cabin Light _______________________________________________________________ 37
4.1.6 Emergency Lights __________________________________________________________ 38
4.1.7 Floodlight ________________________________________________________________ 38
4.1.8 Crane Lighting Control ______________________________________________________ 38
4.1.9 Air Conditioning / Cabin Filtration ____________________________________________ 38
4.1.10 Socket ___________________________________________________________________ 38
4.1.11 Telephone________________________________________________________________ 38
4.1.12 Signal Horn_______________________________________________________________ 38
4.1.13 Public Address System ______________________________________________________ 38
4.1.14 Fire Extinguisher __________________________________________________________ 38
5 PUTTING THE CRANE INTO SERVICE___________________________________________________ 65
6 PUTTING THE CRANE OUT OF SERVICE ________________________________________________ 69
7 OPERATING THE CRANE DRIVE UNITS _________________________________________________ 71
7.1 HOIST UNIT OPERATION ___________________________________________________________ 71

7.1.1 Operation ________________________________________________________________ 71
7.1.2 Overload Protection System _________________________________________________ 71
7.1.3 Limit Switches ____________________________________________________________ 72
7.1.4 Single Motor Operation _____________________________________________________ 73
7.1.5 Heavy Lift Operation _______________________________________________________ 73
7.1.6 Hoist Height Position _______________________________________________________ 73
7.1.7 Hoist Inching _____________________________________________________________ 73
7.1.8 Hoist E-Drive _____________________________________________________________ 73
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7.2 TROLLEY DRIVE SYSTEM OPERATION ___________________________________________________ 75

7.2.1 Operation ________________________________________________________________ 75
7.2.2 Limit Switches ____________________________________________________________ 75
7.2.3 Trolley Position ___________________________________________________________ 77
7.2.4 Trolley Auto Park __________________________________________________________ 77
7.3 LONG TRAVEL DRIVE SYSTEM OPERATION _______________________________________________ 79
7.3.1 Operation ________________________________________________________________ 79
7.3.2 Limit Switches ____________________________________________________________ 79
7.3.3 Storm Anchors / Rail Clamps _________________________________________________ 79
7.3.4 Travel Operation - Ground Level ______________________________________________ 81
7.4 BOOM HOIST / DRIVE SYSTEM OPERATION ______________________________________________ 83
7.4.1 Preparation ______________________________________________________________ 83
7.4.2 Switching On Boom Hoist Drive System ________________________________________ 83
7.4.3 Operation ________________________________________________________________ 83
7.4.4 Parking Boom In "Up" Position _______________________________________________ 83
7.4.5 Parking Boom In "Down" Position _____________________________________________ 84
7.4.6 Switching Off At The Control Console __________________________________________ 84
7.4.7 Boom Inching _____________________________________________________________ 84
7.4.8 Limit Switches ____________________________________________________________ 85
7.4.9 Boom E-Drive _____________________________________________________________ 86
7.5 SPREADER BEAM OPERATION _______________________________________________________ 87
7.5.1 Operation ________________________________________________________________ 87
7.5.2 Adjusting Spreader Twin Lift Positions _________________________________________ 88
7.6 HOOK BEAM (HEAVY LIFT) OPERATION _________________________________________________ 89
7.7 TRIM / LIST / SKEW OPERATION _____________________________________________________ 91
7.7.1 Function _________________________________________________________________ 91
7.7.2 Operation ________________________________________________________________ 91
7.8 MAINTENANCE CRANE / RE-REEVING WINCH OPERATION____________________________________ 93
7.8.1 Function _________________________________________________________________ 93
7.8.2 Operation ________________________________________________________________ 93
7.8.3 Limit Switches ____________________________________________________________ 93
8 CHANGING LIFTING EQUIPMENT _____________________________________________________ 95
SAFETY INSTRUCTIONS___________________________________________________________________ 97
9 EMERGENCY FEATURES ____________________________________________________________ 99
9.1 GENERAL EMERGENCY STOPS ________________________________________________________ 99

9.2 HIGH-TENSION EMERGENCY STOPS____________________________________________________ 99
9.3 EXIT IN EMERGENCY _____________________________________________________________ 101
9.4 FIRE ________________________________________________________________________ 103
10 SAFETY PROCEDURES AND SAFETY SIGNS ___________________________________________ 105
10.1 OPERATING SAFETY PROCEDURES ____________________________________________________ 105

10.2 ENVIRONMENTAL PROTECTION _____________________________________________________ 114
10.3 WARNING SIGNS _______________________________________________________________ 117
5
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COMMISSIONING
The crane commissioning year is: 2013
7
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AFTER SALES SERVICE

Liebherr has a “Service Department” which acts as a single contact
point for all customers with service related queries on Liebherr
Container Crane products.
A summary of services available from the Service Department are:
a) Technical Support
b) Process Warranty Claims
c) Spare Parts Provision
d) On-site Training Courses
e) Crane Inspection Reporting
f) Crane Refurbishing / Upgrading
g) Maintenance Agreements
CONTACT DETAILS:
After Sales and Technical Support:
Tel. No.: +353 (0)64 66 70257
e-mail: service.lcc@liebherr.com
Warranty Claim:
Tel. No.: +353 (0)64 66 70257
e-mail:
warranty.lcc@liebherr.com
Spare Parts:
Tel. No.: +353 (0)64 66 70226
e-mail: spares.lcc@liebherr.com
Common Fax (Service / Spares / Manual dep.): +353 (0)64 66 34041
LIEBHERR Container Cranes Ltd., Killarney, Co. Kerry, Ireland: +353
(0) 64 66 70200
Outside normal office hours calls to the
direct telephone numbers above will be
diverted to the relevant persons.
If you would like to make any comments on the manual:

please email to: manuals.lcc@liebherr.com
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STATEMENT OF LEGAL AUTHORITY

This Liebherr Container Crane –Operators Manual, including all
illustrations contained herein, is copyright protected.
Use of this manual by any third party in departure from the copyright
provision is forbidden.
Liebherr Container Cranes Ltd. cannot accept any responsibility for
any inaccuracies in translated documents or texts. For any needed
clarification please refer to original English language documentation.
Reproduction, translation, or electronic and photographic archiving or
alteration requires the express written consent of Liebherr Container
Cranes Ltd.
Violations are liable for damages.
The information in this manual is provided for the benefit of the user
and while every care has been taken to ensure that the information
contained herein is correct, no liability can be accepted for any loss or
damage which may occur due to omission or error, or to
misinterpretation of the contents.
The manufacturer reserves the right to make any such alterations to
this manual, as experience or technical advance may indicate without
prior notice.
© Liebherr Container Cranes Ltd. Killarney, Co. Kerry, Ireland
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GENERAL SAFETY PRECAUTIONS

The Liebherr Container Crane has been built in accordance with
relevant standards, safety rules and regulations. Nevertheless failure
to observe safe operating procedures may constitute a risk to life and
limb of port personnel or third parties, or could cause damage to the
Container Crane or other material.
The Liebherr Container Crane must only be used in perfect condition
in accordance with its designated use and the instructions set out in
the operation manual, and only by safety conscious persons who are
fully trained and aware of the risks involved in operating the crane.
Any functional disorders, especially those affecting the safety of the
Container Crane should therefore be rectified immediately.
Your Container Crane as specified and described is a high-speed
container-handling crane, of rigid portal structure type, designed for
continuous heavy-duty container operation. All motions are electrically
controlled and power supply is via a cable reeling drum system. Using
the Container Crane for purposes other than those mentioned above is
considered contrary to its designated use. The manufacturer cannot
be held liable for any damage resulting from such use. The risk of
such misuse lies entirely with the user.
The operating instructions must always be at hand at the place of use
of the Container Crane.
This hardcopy should be kept in the driver’s cabin. A softcopy of the
manual is also provided.
In addition to the operating instructions, the user should observe all
other generally applicable legal and other mandatory regulations
relevant to accident prevention and environmental protection.
These compulsory regulations may also deal with the handling of
hazardous substances, issuing and / or wearing of personal protective
equipment, work permits or traffic regulations.
Personnel entrusted with work on the Container Crane must have read
the operating instructions and in particular the chapter on safety before
starting to work.
It is the responsibility of the operator to read and understand the safety
instructions before operating the crane. You must follow these safety
instructions that take you step by step through your working day
Remember that you are the key to safety. Good safety practices not
only protect you, but also the people around you. Study the
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instructions and make them a working part of your safety programme.

Keep in mind that these instructions are specifically for this type of
crane. Practice all other usual and customary safe working
precautions, and above all – remember – safety is your
responsibility. You can prevent serious injury or death.
Reading the instructions after work has begun is too late. This applies
especially to persons working only occasionally on the machine e.g.
during setting up or maintenance.
Personnel entrusted with work on or operation of the container crane

should not consume alcohol or drugs which can affect their alertness
or co-ordination. Personnel entrusted with work or operation on the
container crane on prescription or ‘over the counter’ drugs need
medical advice on whether or not she or he can safely operate
machines.
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1 INTRODUCTION
CRANE TYPE: P167L-SUPER
CRANE WORK NO.: IR 1874
LOCATION: TPEP, PAITA, PERU.
This manual is composed of five parts:

Part 1 - Operating Manual
Part 2 - Mechanical and Maintenance Manual
Part 3 - Electrical / Electronic System
Part 4 - Sub-Supplier Manual
Part 5 - Partslist Manual
In Part 1 of this Manual, operating instructions are given for the crane.
Crane drivers must not operate this crane without a knowledge and
understanding of all these instructions, which must be carefully
adhered to. In addition to having knowledge of the function and of the
mechanical, structural and electrical parts, the crane driver must also
be familiar with the instructions, recommendations and descriptions as
included in Parts 2 and 3 of this manual. Only then can satisfactory
and safe operation of the crane be achieved and the best possible
duty and service be obtained from the crane. It is strongly
recommended that one copy of the manual (Parts 1 to 5) is stored in
the driver’s cabin (if possible) or available to the driver so that at any
time, the driver can consult the manual.
The crane must not be operated with any part defective or in a
damaged condition. Should the crane driver note a malfunctioning of
any part, device or system, they must immediately report same to the
appropriate department or person for investigation.
We would like to draw your attention to the very important fact
that wind speed exceeding 22m/s (80.0km/h) requires a stoppage
of the crane operation. The measures required for parking the crane
in such adverse weather conditions are specified in the section
“Putting the Crane Out-of-Operation”.
Note that the personnel lift is designed for operation in winds up to
25m/s (90km/h).
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The crane is fully operational with full rated load (incl. Hook Beam
Operation) in winds up to 22m/s (80.0km/h). Operation of long travel,
without load, is permitted in winds of up to 25m/s (90.0km/h) to
accommodate the correct parking of the crane.
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2 G. A. DRAWING AND CRANE LEGEND
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2.1 GENERAL ASSEMBLY DRAWING

See Attached: IR9425-000.000
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2.2 CRANE LEGEND

The Crane Legend is generic, use for reference purposes only.
ITEM DESCRIPTION DRG. NO. ITEM DESCRIPTION DRG. NO.

01. TRAVEL UNIT 1 -110.000 23. LANDSIDE CARRIER -350.000
02. TRAVEL UNIT 2 -120.000 24. PORTAL DIAGONAL -360.000
03. TRAVEL UNIT 3 -130.000 25. PERSONNEL LIFT -370.000
04. TRAVEL UNIT 4 -140.000 26. MAIN ENTRY -380.000
05. CRANE TIE DOWNS -150.000 27. SEASIDE LEG 1 -410.000
06. RAIL CLAMPS + STORM PINS -160.000 28. SEASIDE LEG 2 -420.000
07. CHECKERS CABIN -170.000 29. DERRICK BOOM CROSS BEAM -430.000
08. END-CARRIAGE SEASIDE -180.000 30. A-FRAME ACCESS -440.000
09. END-CARRIAGE LANDSIDE -190.000 31. SEASIDE CARRIER -450.000
10. MAIN BEAM -210.000 32. HOLDING ARM -460.000
11. ENERGY CHAIN/CABLE RAIL EXTENSION -220.000 33. CARRIER PLAN BRACING -470.000
12. TRIM / LIST / SKEW + PLATFORM -230.000 34. A-FRAME -480.000
13. HOIST OVERLOAD SYSTEM -240.000 35. A-FRAME BACK TIE -490.000
14. DERRICK BOOM -250.000 36. SUPPORT TROLLEY ROPE REEVING -630.000
15. HOIST ROPE DEFLECTION ARM -260.000 37. HOIST ROPE SUPPORT TROLLEY SEASIDE -640.000
16. CABIN CLEANING PLATFORM -270.000 38. TROLLEY ASSEMBLY -660.000
17. TROLLEY TRAVEL LIMIT SWITCHES -276.000 39. CABIN + ENTRY PLATFORM -670.000
18. MACHINERY / ELECTRICAL HOUSE -290.000 40. HOIST ROPE SUPPORT TROLLEY LANDSIDE -680.000
19. LANDSIDE LEG 4 -310.000 41. BINDING FOR MAIN GROUPS -700.000
20.LANDSIDE LEG 3 -320.000 42. ACCESSORIES -800.000
21. SILL BEAM 1-4 -330.000 43. CABLE CHANNELS (SITE) -850.000
22. SILL BEAM 2-3 -340.000 44. HEAD BLOCK -900.000
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3 SUMMARY OF SPECIFICATION
CRANE TYPE: P167L - SUPER
CRANE WORK NO.: IR 1874
DRAWING NO.: IR 9425-000000
LOCATION: TPEP, PORT OF PAITA, PERU.
3.1 MAIN TECHNICAL DATA

3.1.1 STANDARDS & CLASSIFICATION
The crane structure complies with F.E.M. / 1.001 – 1987 Revised 1998
The crane structure is classified as follows:
45.0 Tonnes 55 Tonnes 65 Tonnes *70 Tonnes

S.W.L.
Single Lift Twin Lift Hook Beam Heavy Hook Beam
Class of Utilisation U8 U5 U5 U4
State of Loading Q2 Q2 Q2 Q2
Group Classification A8 A5 A5 A4
*Note: Heavy hook load of 70 Tonnes is restricted to a limited trolley travel

path from 45.0m to midspan. See Section 3.1.5.
The drive mechanisms comply with F.E.M. / 1.001-1987 Revised 1998

10.01
The drive mechanisms are classified as follows:

Group Classification
Single Lift Twin Lift Hook Beam
Main Hoist Drive T8-L2-M8 T5-L2-M5 T4-L2-M4
Trolley Travel Drive T8-L2-M8 T5-L2-M5
Long Travel Drive T5-L2-M5 T5-L2-M5
Derrick Drive T4-L2-M4
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3.1.2 SAFE WORKING LOAD

The S.W.L. of the crane is as follows:
Under Telescopic Spreader. 40.00 Tonnes – Single lift

Over full trolley travel range. 55.00 Tonnes – Twin lift
65.00 Tonnes- Unrestricted Path
Under Hook Beam.
70.00 Tonnes – Heavy Lift
Restricted travel range.
Hook beam is considered to weigh 3
Tonnes. If in excess of this weight,
the SWL will be reduced accordingly.
The crane may not be loaded above its rated maximum capacity.
3.1.3 MAXIMUM PERMISSIBLE CONTAINER ECCENTRICITY

Longitudinal: 0.610m
20ft Containers:
Lateral: 0.200m
40ft Containers:
Lateral: 0.200m
45ft Containers:
Lateral: 1.370m
3.1.4 LIFTING EQUIPMENT

The lifting equipment provided with the crane is as follows:
a) One (1) Headblock, which incorporates a geared anti-sway
pulley system and sliding pin connection to Spreader Beam.
b) One (1) Telescopic Spreaders Model BROMMA STS45
Expanding Twin-lift.
c) One (1) Telescopic Spreaders Model BROMMA SSX45
Single Lift.
d) One (1) Hook Beam SWL 70.00 tonnes.
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The connection between headblock and spreader is via four sliding

pins. The electrical supply to the spreader is via a cable basket on the
headblock.
See Section 8 for details of Changing Lifting Equipment.
The headblock and spreader combination on the crane have a total
weight of approx. 18 Tonnes.
45ft Containers are handled at the 40ft or 45ft position.
3.1.5 PHYSICAL DIMENSIONS

Span 30.48m
Outreach on Waterside (From Waterside Rail Centre) 51.00m
Restricted Outreach on Waterside (From Waterside Rail 45.00m
Centre) for Heavy Lift (Hook Beam)
Outreach on Landside (From Landside Rail Centre) 17.00m
Restricted Outreach on Landside (From Waterside Rail 15.24m (midspan)
Centre) for Heavy Lift (Hook Beam)
Spreader Height above Seaside Rail 36.00m
Lowest point of Spreader below seaside rail 20.00m
Total Spreader Hoisting 56.00m
Wheel Gauge
Seaside rail 18.20m
Landside rail 18.20m
Overall length Buffer to Buffer (Buffers uncompressed) 27.00m
Clearance under Sill Beam 17.00m
Clearance between Portal Legs 16.76m
Distance Waterside Rail to Front Face of Fender 4.88m
Average Rail level difference: Landside rail lower. 0.00m
3.1.6 TRIM SYSTEM (± 5º) / LIST SYSTEM (± 5º) / SKEW SYSTEM (± 5º)
1 x 15kW A.C. Squirrel Cage Motor, which operates hydraulic
system controlling all motions
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3.1.7 NUMBER OF CRANE WHEELS AND MAX WHEEL LOADS (IN-

SERVICE)
8 wheels/corner, wheel diameter 710mm
Seaside Rail
49.16 T/Wheel; 75.00 T/Meter
Wheel Centres 1000/1000/1000/1000/1000/1000/1000
8 wheels/corner, wheel diameter 710mm

Boom Up (empty spreader) – 36.11 T/Wheel;
Landside Rail
62.50 T/Meter
Boom Down – 37.05 T/Wheel; 62.50 T/Meter
Wheel Centres 1000/1000/1000/1000/1000/1000/1000
Both rail head widths are 100mm.
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3.1.8 OPERATIONAL LIMITATIONS

o BOOM DOWN
Full operation possible with Full Load over full length (of
boom and beam) in winds up to 22m/s (80.0km/h)
o BOOM UP
Operation with Empty Spreader only over full length of beam
in winds up to 22m/s (80.0km/h)
Reduced speeds apply with boom up crane operation.
Simultaneous motions
The hoist / lowering, trolley travel and long travel can be carried out
simultaneously.
Boom shall always be in fully raised position in “out-of-service”

conditions.
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3.2 DRIVE UNITS

3.2.1 HOIST UNIT
2 x 500 kW A.C. Motors with Liebherr Speed Control
Load / speed range:
80m/min - 78.00t (55 tonne Twinlift S.W.L.)
200m/min - 18.00t (Empty Spreader)
The Hoist speeds are continuously variable and load-dependent up to
the maximum speeds quoted above.
An Emergency Drive System is installed for operating the Hoist at
reduced speed.
3.2.2 TROLLEY UNIT

4 x 55kW A.C. Motors with Liebherr Speed Control
Speed: 240 m/min (with load)
3.2.3 LONG TRAVEL UNIT

8 x 40 kW A.C. Motors with Liebherr Speed Control
Speed: 45.0m/min
3.2.4 DERRICK UNIT

1 x 180 kW A.C. Motor with Liebherr Speed Control
Derricking Time: 5min
An Emergency Drive System is installed for operating the Derrick
Boom at reduced speed.
3.2.5 LIMIT SWITCHES

All crane travel motions of the crane are protected by pre-limit and
final limit switches.
3.2.6 DERRICK ROPE DRUM

The derrick system (two ropes) for operating the boom incorporates a
multi-layer derrick drum and a double brake arrangement with an over
speed device. The secondary brake acts directly on the drum.
29
3.2.7 HOIST GEAR

The hoist gear is provided with two primary brakes fitted between the
motors and gearbox.
3.2.8 POSITIONING ENCODERS

Positioning Encoders are installed on all Main Drives, i.e. Hoist,
Derrick, Trolley and Long Travel.
3.2.9 GROUND LEVEL CONTROL STATION

A ground level control station (P20) is provided on the 1st platform of
the main entry system on Corner 4. The following features are
available;
o Hoisting, Trolleying and Long Travel at reduced speed
o Spreader Control
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3.3 ELECTRICAL / ELECTRONIC FEATURES

3.3.1 POWER SUPPLY
10.0kV, 60Hz, 3 Phase + Earth, 3 wire, earthed neutral system with
approx. 350m of cable for 600m crane travelling.
Power Rating: 1600 kVA
3.3.2 FAULT CONDITION MONITOR

A computer based Fault Condition Monitoring / Memory and Crane
Management System (DiaMon 3D) is incorporated.
3.3.3 EMS DIGITAL DISPLAY

An EMS digital display is provided in the driver’s cabin, which displays
rope and tarred load, spreader height, spreader status, wind speed,
fault information etc.
3.3.4 ANEMOMETER
An Anemometer System incorporating audible and visual alarms is
provided. Wind direction is also included.
3.3.5 HOUR METERS

Hour Meters for recording the operation time of the various drive units
are installed in the main electrical switchgear.
3.3.6 AUTOMATIC BOOM CONTROL

The boom may be raised / lowered from a separate panel in the
driver’s cabin. A monitor is provided to permit viewing of the latching
mechanism and derrick ropes.
The raising / lowering and unlocking sequence is fully automatic.
3.3.7 FLOODLIGHT SYSTEM

“High Pressure Sodium (Son)” floodlight system.
3.3.8 LONG TRAVEL ANTI-COLLISION SYSTEM

The long travel system incorporates an Ultrasonic Anti-Collision
System.
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3.4 MISCELLANEOUS DESIGN FEATURES

3.4.1 ENERGY CHAIN TROLLEY SUPPLY SYSTEM
This crane is equipped with an Energy Chain System, which contains
the electrical supply cables for the trolley. The system is running
along-side the main beam and derrick boom with the moving end
attached to a towing arm on the trolley. The fixed end is located in the
main beam where the electrical cables feed back into the main beam/
electrical house.
3.4.2 LATTICE STRUCTURE FOR BEAM AND BOOM

The crane is provided with a lattice structure for beam and boom and
uses welded down trolley rails. Special quality replaceable sections
are used at the beam / boom hinge. The boom is supported by a
single holding arm which is connected to the A-Frame head. Two back
tie members are used to support the A-Frame head connection.
3.4.3 CABIN CLEANING PLATFORM

A Cabin Cleaning Platform is located at the back reach of the crane.
3.4.4 CABIN
The crane is provided with a sophisticated driver’s cabin. It is double
glazed, insulated and air conditioned.
3.4.5 MANUAL STORM PINS / AUTOMATIC RAIL BRAKES

The crane is provided with manually operated storm pins and
automatic rail brakes, which are located underneath each End
Carriage. The crane must be parked at its parked location and storm
pins engaged into their ground sockets during out of service
conditions.
3.4.6 MACHINERY / ELECTRICAL HOUSE

A Machinery / Electrical House with insulated cladding is provided for
the hoist and derrick units, the main electrical switchgear and the H.T.
transformer. The switchgear is housed in a separate section, which is
air-conditioned. The house incorporates a 5 Tonne service crane and
re-reeving winch (located beside the service crane winch). Also
incorporated is a trap door from which parts can be hoisted or lowered.
Accessories included are a workbench with vice, a locker, waste
33
basket, ashtray, seat, coat hook, brush, first aid kit, stretcher, safety
harness and sling, ladder and a chain block for the maintenance of the
Trim/List/Skew.
The HT transformer and the HT switches are located in a separate
insulated cubicle in the machinery house.
3.4.7 PERSONNEL LIFT

The crane is provided with a 2-stop rack and pinion personnel lift,
400kg, 4 person, 0.71m/s.
3.4.8 STAIR SYSTEM

In addition to the personnel lift above, a stairs system is provided from
the ground level to the main beam.
A ladder system is provided for access to the A-Frame head.
Access is also provided to sillbeam 1-4 for the Cable Reeling Drum
(CRD).
3.4.9 MAINTENANCE BEAMS

1. A Maintenance beam is provided on the main beam for the
maintenance of the Trim / List / Skew System.
2. A swivelling Maintenance beam is provided on the top of the A-
Frame for maintenance of the pulleys and the Latching Device.
3. A Maintenance beam is provided at the head of the derrick boom
for maintenance of the hoist rope support trolley rope pulley.
3.4.10 CHAIN HOIST

One Chain Block, SWL 500kg., stored in the Machinery House is
supplied with each crane, for use on the Trim, List, Skew, A-Frame
and Derrick Boom Maintenance Beams.
3.4.11 OVERLOAD SYSTEM

The overload system, which is located at the head of the derrick boom,
incorporates two load cells.
3.4.12 HOIST ROPE SUPPORT TROLLEYS

Two Hoist Rope Support Trolleys are provided, one on the seaside
and one on the landside of the main trolley. They are incorporated to
provide support for the hoist ropes on their path from the landside
34
crane end to the boom head. They automatically travel at half the main
trolley speed during operation and are provided with manual
adjustment facilities.
3.4.13 MIRRORS
One rear view mirror is fitted on each side of the driver’s cabin to
monitor back reach area.
3.4.14 TOOLS
One set of tools is supplied for each crane.
3.4.15 FIRE PREVENTION

Fire Extinguishers are provided in various positions around the crane.
For more details see Section 9.
35
36
4 LAYOUT OF CONTROLS
4.1 DRIVER'S CABIN EQUIPMENT
The following equipment is incorporated in the driver's cabin.
4.1.1 DRIVERS CONTROL CONSOLES

Driver's Control Consoles; incorporates the necessary control
joysticks, push-buttons, selector switches and status lights for crane
and spreader operation. The driver’s control consoles consist of a left-
hand and right-hand console attached to a seat.
Audible and visual warning devices for high wind, electrical fault and
overload warning zone are also included.
4.1.2 EMS DISPLAY

EMS colour Display Panel: incorporating digital readout display of load
weight, spreader height, trolley location, wind speed, trim, list, skew
angle position, and status indication for spreader, i.e. twist-locks open,
twist-locks closed, and deposit points.
4.1.3 AUXILIARY SWITCHGEAR PANEL

Auxiliary Switchgear Panel S2: incorporating control elements for
spreader beam, and heating and lighting function control.
4.1.4 SPREADER INDICATOR PANEL

A Spreader Indicator Panel is located in front of the driver.
This incorporates the following status lights for the Spreader:
Twistlocks Open, Twistlocks Closed, Deposit points (i.e. spreader is
landed) and Twinlegs down.
4.1.5 CABIN LIGHT

Cabin Light is provided.
37
4.1.6 EMERGENCY LIGHTS

Emergency Light is provided.
4.1.7 FLOODLIGHT
Two (2) Floodlights are provided underneath the Cabin.
4.1.8 CRANE LIGHTING CONTROL

Crane Lighting control: incorporating push-buttons for:
1. Crane Floodlighting
2. Entry / Beam-Boom / Trolley Access Lighting
3. Push-button Switch for Cabin Lighting
4.1.9 AIR CONDITIONING / CABIN FILTRATION

An Air Conditioning System and Cabin Filtration System are provided.
4.1.10 SOCKET
2 x Socket Outlets – 230 V are provided.
4.1.11 TELEPHONE
An Intercom System is provided with connection points throughout the
crane.
4.1.12 SIGNAL HORN

Signal Horn by push-button on top of Right-hand Joystick is provided.
4.1.13 PUBLIC ADDRESS SYSTEM

Public Address System enabled by foot switch is provided.
4.1.14 FIRE EXTINGUISHER

o A Fire Extinguisher is provided.
All joystick controls, push-buttons, selector switches, indication lamps,

audio devices, and visual displays are highlighted by legend plates
identifying their corresponding functions.
38
PLEASE FIND ON THE FOLLOWING PAGES,

LAYOUTS OF CONTROLS AND A
DESCRIPTION OF THE EMS SYSTEM.
39
GRAPHICAL SYMBOLS
Gantry Travel Boom Up
Hoist Lowering Boom Down
Hoist Hoisting Boom Stop
Twistlocks Unlocked Flipper Up/Down
Twistlocks Locked Fault/Reset Button
Horn Electrical Bypass
Trolley Gate Reset/Parked
Trim Windscreen Washer
Skew Windscreen Wiper
Zero Trim / Skew  Audio Alarm
Spreader Telescope Access Lighting
Twin Telescope OUT Flood lighting
Spreader Off Overload Warning
Slow Speed High Wind Warning
Crane Disable O Off / Manual / Auto
Spreader Landed Storm Anchors Up
Auto-Park Rail Clamps Up
40
OVERVIEW OF DRIVERS CABIN
OVERVIEW OF DRIVERS CABIN

1 DRIVERS CONTROL CONSOLE 12 TELEPHONE SOCKET/HANDSET
2 EMS DISPLAY 13 HEATER
3 AUXILIARY SWITCHGEAR S2 14 2 NO. FLOODLIGHTS
4 SPREADER STATUS PANEL 15 SIGNAL HORN (EXTERNAL)
5 CABIN LIGHT 16 FIRE EXTINGUISHER
6 CRANE LIGHTING CONTROL 17 PUBLIC ADDRESS SYSTEM
7 EMERGENCY LIGHT 18 REAR VIEW MIRRORS
8 AIR CONDITIONER 19 FOLDING ANCILLARY SEAT
9 SOCKET OUTLET 20 SMOKE DETECTOR
10 WINDSCREEN WIPER/WASHER 21 VIDEO MONITOR
11 DEMISTOR 22 FOOT SWITCH
41
Flipper 1 Flipper 2
List (Forward)
(Skew) Left (Skew) Right
(Trim) Left (Trim) Right

Flipper 4 Flipper 3
(Skew/Trim) Zero
List (Backward)
(Trolley) Forward
(Flippers)
UP/DOWN
(Twistlocks)
(Twistlocks)
Open
Close
LEFTHAND CONTROL CONSOLE
(Trolley) Reverse
Auto-Park Trolley Gate

Parked Open
Rail Clamps Stormanchors Stormanchors

Up Up Position
Driver Anti
Bypass Collision
Wind High
Warning Wind
0 1 o
42
Twistlocks
Close/Open
Flippers
Up/Down
Overload Overload E-Stop

Warning Activated
(HOIST) LOWER
TRAVEL TRAVEL
LEFT RIGHT
(HOIST) HOIST
Crane ON Crane Spreader Spreader

Off Off On
RIGHTAND CONTROL CONSOLE

Spreader Spreader Spreader Spreader
20’ 40’ 2x20’ 45’
Off Man Auto Retract Expand

In Out
Set Position Set Position

Seaside Landside
Cancel Audio Electrical Boom

Alarm Alarm Fault Ready
Boom Boom Boom Boom

On Stop Up Down
43
44
GANTRY CONSOLE P20
SPARE
20’ – 40’ – 2x20’ - 45’
2 3
1 4
Flipper 1 – 2 – 3 – 4-5
-
All
2 3
SPARE
1 4
45
46
TRIM / LIST / SKEW CONTROLS

ZERO TRIM / SKEW
Side View Plan View
0°
0°
LIST
SKEW LEFT (FORWARD) SKEW RIGHT
Plan View Plan View
- 5.0° + 5.0°
JOYSTICK ON
LEFT CONSOLE
TRIM LEFT TRIM RIGHT
Side View Side View
- 5.0° + 5.0°
LIST FORWARD LIST BACKWARD
End View
End View
+ 5.0° - 5.0°
47
48
SPREADER STATUS PANEL
TWISTLOCKS
UNLOCKED
TWISTLOCKS TWISTLOCKS SPREADER TWINLIFT
UNLOCKED LOCKED LANDED
Land the spreader on a container with all twistlocks

seated in the container’s corner castings.
X4 =
All spreader deposit pins must be pushed to give the spreader landed signal.
UNLOCK
TWISTLOCKS
(TWISTLOCKS) (TWISTLOCKS)
OPEN CLOSE
JOYSTICK ON
RIGHT CONSOLE
49
50
EMS 3 INDICATOR PANEL

MONITORING SYSTEM FOR CONTAINER CRANES
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
51
EMS BUTTON FUNCTIONS
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
The EMS has 14 buttons, arranged in two rows of 7 buttons underneath the LCD display.
The upper seven buttons are denoted B1 to B7, from left to right, and are used to select crane
driver’s displays 1 to 5 and driver’s help / crane fault messages.
B1 Selects crane driver’s display 1
B6 Selects driver’s help messages
B7 Selects machine data display 1 (crane fault messages)
The lower seven buttons are used to operate the EMS menu structures.
The functions, from left to right, are as follows:
Moves the cursor to the left, or changes the display in the highlighted display section.
Moves the cursor to the right, or changes the display in the highlighted display section.
Moves the cursor upwards, or increases a value.
Moves the cursor downwards, or reduces a value.
CLEAR Changes a setting to an initial or standard value.
ENTER Activates selected menu items, or confirms value inputs.
Selects the main menu display.
52
EMS SYMBOL MEANINGS
DEVIATION DISTANCE FROM

TROLLEY POSITION
AUTOSTEERING VIRTUAL RAIL
AUTOSTEERING CORRECTION
LOAD
ANGLE
HOIST HEIGHT GANTRY TRAVEL POSITION
WIND SPEED SPREADER LENGTH
TWISTLOCKS CLOSED BOOM ANGLE (OR BOOM CONTROL ON

DISPLAY)
RELATIVE VALUE (DISTANCE TO THE

TWISTLOCKS OPEN rel REFERENCE VALUE)
SPREADER LANDED (PROBE PINS OR

DEPOSIT PINS OPERATED) ref REFERENCE VALUE
TRIM (CONTAINER INCLINATION IN THE

LONGITUDINAL DIRECTION) abs ABSOLUTE VALUE
PAGE BACK TO THE PREVIOUS DISPLAY

SKEW (SKEW ANGLE)
OR RETURN TO M AIN MENU
LIST (CONTAINER INCLINATION IN THE M ACHINE DATA DISPLAY 1

LATERAL DIRECTION) (CRANE FAULT MESSAGES)
SLEW (SLEW ANGLE) M ACHINE DATA DISPLAY 2
STACK POSITION OR
M ACHINE DATA DISPLAY 3
STACK TEACHING SCREEN
X CONTAINER CO-ORDINATE IN THE LONG TERM MACHINE DATA

X-DIRECTION (TROLLEY) DISPLAY 1 (CRANE FAULT MESSAGES)
Y CONTAINER CO-ORDINATE IN THE LONG TERM MACHINE DATA

Y-DIRECTION (TRAVEL) DISPLAY 2
Z CONTAINER CO-ORDINATE IN THE LONG TERM MACHINE DATA

Z-DIRECTION (HOIST) DISPLAY 3
53
EMS SYMBOL MEANINGS (CONTD…)
ADJUST TIME AND DATE OR

SENSOR OR SCALING DISPLAY DELETION OF MACHINE DATA
(M1, M2, M3)
PASSWORD ENTRY REQUIRED.
PARAMETER CANNOT BE CHANGED, OR
INTERBUS-S DIAGNOSIS DISPLAY
KEY-OPERATED SWITCH IN NORMAL
OPERATION
PASSWORD ENTERED CORRECTLY,
OR PARAMETER CAN BE CHANGED, OR KEY-
COM 1 DIAGNOSIS DISPLAY
OPERATED SWITCH IN THE CONFIGURATION
MODE
COM 2 DIAGNOSIS DISPLAY M AIN MENU DISPLAY

OR KEY BUTTON
EMS INFORMATION DISPLAY
SPREADER DISPLAY WITH INDICATION OF THE FLIPPERS AND TWISTLOCKS
Probe Pin not operated Spreader length in feet Probe Pin operated
and Twistlock open and Twistlock open
Flippers Up
30” Flippers Down
Probe Pin not operated Additional Twistlocks visible Probe Pin operated
and Twistlock closed Only for Twin Lift and Twistlock closed
54
EMS MAIN MENU DISPLAY SCREEN
PRESENT DATE AND TIME DIAGNOSIS MESSAGE PRESENT

AND HELP DRIVER’S HELP CODE
SELECT THE LAST
ACTIVATED DISPLAY CODE AND VERSION NO. FOR
EMS SOFTWARE
SET REFERENCE POINTS.
REF FOR ALL SENSORS.
SYMBOL FOR INDIVIDUAL SENSORS. SELECT THE MACHINE DATA
DISPLAYS DISPLAYS
SELECT THE LONG-TERM

MACHINE DATA DISPLAYS
ACTIVATE THE STANDARD DISPLAY
SETTINGS IN DISPLAYS 4 AND 5
SELECT THE BOOM RAISING
WINDOW, SCALING DISPLAY AND
SELECT THE INTERBUS-S, COM1, STACK TEACHING SCREEN
COM2 DIAGNOSIS DISPLAYS
ADJUST THE TIME
MENU ITEM FOR ENTERING THE THIS PADLOCK IS SHOWN OPEN

PASSWORD ONCE THE CORRECT PASSWORD
HAS BEEN ENTERED
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
55
EMS DISPLAY SCREEN B1 (DISPLAY SECTIONS CANNOT BE CHANGED)
TROLLEY POSITION
LOAD
HEIGHT
WIND SPEED
DEPOSIT POINTS
TWISTLOCKS CLOSED
TWISTLOCKS OPEN
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
56

(Screen is also displayed automatically when Trim / List / Skew / Slew is activated)
LOAD
TRIM ANGLE
SKEW ANGLE
LIST ANGLE
SLEW ANGLE
(if applicable)
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
57

(Screen to be used in conjunction with container stack mapping)
STACK NO. WHICH

RTG IS CURRENTLY ON
GANTRY (*) CONTAINER

POSITION IN POSITION
TROLLEY (+) LOCATION VALUE

POSITION GREATER THAN
DISPLAYED POSITION
HOIST
POSITION (-) LOCATION VALUE
LESS THAN
DEVIATION DISTANCE DISPLAYED POSITION
FROM AUTOSTEERING
VIRTUAL RAIL AUTOSTEERING
CORRECTION ANGLE
LOAD
TWISTLOCKS CLOSED DEPOSIT POINTS
TWISTLOCKS OPEN
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
58
EMS DISPLAY SCREEN B4 (DISPLAY SECTIONS CAN BE CHANGED)
LOAD
SPREADER SYMBOL WITH

INDICATION OF THE FLIPPERS,
TWISTLOCKS, PROBE PINS
AND SPREADER LENGTH
LIST ANGLE
TRIM ANGLE
SKEW ANGLE
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
59
EMS DISPLAY SCREEN B5 (DISPLAY SECTIONS CAN BE CHANGED)
LOAD
HEIGHT
TROLLEY POSITION
GANTRY POSITION
SPREADER SYMBOL WITH

INDICATION OF THE FLIPPERS,
TWISTLOCKS, PROBE PINS
AND SPREADER LENGTH
LIST ANGLE
TRIM ANGLE
SKEW ANGLE
SLEW ANGLE
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
60
EMS DISPLAY SCREEN B6 (DRIVERS HELP DISPLAY)

(The content of the help display screen can be reset).
MENU ITEM FOR DELETION OF

THE MACHINE DATA DISPLAY
TIME OF LAST DELETION
IF PADLOCK IS CLOSED
NO DELETION IS NOT ALLOWED
HELP NUMBER
AND DESCRIPTION
FREQUENCY OF FAULT
OCCURRENCE
TIME AND DATE OF LAST

OCCURRENCE
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
61
EMS DISPLAY SCREEN B7 (CRANE FAULT DISPLAY)

(The content of the short-term machine data screens - M1, M2, M3, can be reset. Long-term
machine data screens ML1, ML2, ML3, are laid out the same, but information cannot be deleted).
MENU ITEM FOR DELETION OF

THE MACHINE DATA DISPLAY
TIME OF LAST DELETION
IF PADLOCK IS CLOSED
NO DELETION IS ALLOWED
FAULT NUMBER
AND DESCRIPTION
FREQUENCY OF FAULT
OCCURRENCE
TIME AND DATE OF LAST

OCCURRENCE
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
62
EMS BOOM OPERATION DISPLAY SCREEN

(Screen is superimposed on any display when boom is selected. It can also be activated
manually from the Main Menu).
SWITCHING STATES OF THE

LIMIT SWITCHES RELEVANT
TO THE BOOM
NO = DEACTIVATED
YES = ACTIVATED
BOOM ANGLE RELATIVE

TO THE HORIZONTAL
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
63
REFERENCE VALUES
A reference value is presented on the bar indication for a sensor. Every sensor
on the EMS has a reference value. This can be set either in the crane driver’s
display or in the main menu.
The reference value indication is intended to make it easier for the crane driver to
return to default crane positions, and to allow the position indications to be
matched to actual physical positions relative to the reference value (relative
value).
Example 1: If the load reference value is set to the weight of the lifting equipment,
this provides a relative indication of the weight of the actual load. (Nett Load).
Example 2: If the trolley position reference value is set to the quay edge, then this
indicates the relative position both overland (-) and over ship (+).
SETTING THE REFERENCE VALUES IN THE EMS MAIN MENU DISPLAY SCREEN
The reference values of All sensors are set to the current value by highlighting
menu item REF and pressing the ENTER button.
To set a single sensor, highlight the sensor symbol and press the ENTER button.
SETTING THE REFERENCE VALUES IN DRIVER’S EMS DISPLAY SCREENS
On the selected screen, highlight the display area for the appropriate sensor and
press the ENTER button to accept the present sensor value.
The reference value is zeroed using the CLEAR button.
64
5 PUTTING THE CRANE INTO SERVICE

When putting the crane into service for any period, however short, the
following procedure must be strictly adhered to:
1. Raise storm anchors and stow in the up position.
2. At Gantry Console P20, switch ON keyswitch CRANE DISABLE
by inserting the key and turning clockwise to engage. Remove
key.
3. Ensure that all access gates to the driver’s cabin are closed -
GATE OPEN lamp on the side panel will not be lit. If a gate is
opened this lamp will light and trolley movement will be blocked.
To reset this, close the gate and press the reset button located
on the right side of the cabin. If the gates are closed but not
reset, then the gate open lamp will flash.
4. Ensure that all emergency stop stations on the crane are in the
RESET / ON position. This may be verified by checking that the
EMERGENCY STOP ACTIVATED status light on the driver's
control console is switched off. Emergency stop push buttons are
only to be used in case of emergency; they are not to be used to
switch the crane off or any other function.
5. At the driver's control console, switch on as follows:
 Ensure that all joysticks are in the zero position (neutral)
 Press the CRANE ON push button and wait until the green
CRANE ON lamp is on, this will take approx. 7 seconds due
to the start up sequence of the crane. If after this period the
CRANE ON lamp flashes slowly (1/2 Hz) then one or more
of the drives did not come on, in this case press CRANE
ON again. If condition persists then contact maintenance. If
after this period the CRANE ON lamp flashes fast (2 Hz)
then one or more of the drives have trip locked, in this case
switch off and wait for the flashing to stop before switching
the CRANE ON again. If condition persists then contact
maintenance.
 The lamps will give the driver the status of the crane. Do not
repeatedly switch on and off without waiting for the required
time.
65
 At SWITCH ON a lamp test is performed where all status

lamps are illuminated for 2 seconds.
6. Check the following after the crane is on (CRANE ON lamp is lit):
 ELECTRICAL FAULT lamp is off
 AUDIO ALARM is off
 OVERLOAD lamp is off
 HIGH WIND lamp is off
 Spreader status lamps on the spreader are on (this
indicates spreader on)
 STORM ANCHORS UP lamp is on
Test all crane motions, before starting operations.
Should ELECTRICAL FAULT Status Lamp / AUDIO ALARM be
operative, crane operation should immediately be ceased, the
reason determined and the necessary action taken.
THE CRANE IS NOW READY FOR OPERATION
SIMULTANEOUS MOTION OF THE HOIST, TRAVEL AND TROLLEY DRIVES

IS PERMITTED.
7. Fault Indication
ELECTRICAL FAULT is indicated by status lamp (right hand
console) and acoustic alarm (wall panel). When a fault is
occurring, both the status lamp and the acoustic alarm are
activated simultaneously. It is possible to cancel the acoustic
alarm by pressing AUDIO CANCEL push button, but the fault
light remains ON until it has been cleared.
In the event of a fault occurring, crane operation should be
stopped immediately, maintenance personnel should be notified
to clear fault and reset the electrical control, which prevents
normal crane operation.
Having cancelled the acoustic alarm, it is re-activated each time
a new fault occurs.
66
Some faults are re-settable by the driver. Switch CRANE OFF to reset
and check if fault has been cleared. Switch on again and proceed with
caution.
8. Wind Warning System

The following switching points / warning displays are provided as
follows:
Indication Levels:
 Indication Level 1.: Amber Status Light, Yellow Status Light
18m/s (65km/h) - WIND WARNING Switched
ON.
 Indication Level 2.: Reduced Speed Operation, Red Status
Light
22m/s (80.0km/h) - HIGH WIND
Switched ON.
Signal Horn under driver’s cabin is
sounded
There is a delay of 5 seconds built in to allow for gusting wind.
The alarm will remain active for 10 sec after the wind drops
below the level.
Crane travel above level 2 is possible to allow crane to be driven
to parking area as required. See “PUTTING CRANE OUT-OF-
SERVICE”.
The Crane must be taken "Out Of Service" if the Wind Speed Exceeds
22m/s (80.0km/h). Audio and Visual Warning Devices Indicate if this
maximum Wind Speed has been reached or exceeded.
67
Long travelling is permitted in winds up to 25m/s (90km/h) for safe

parking purpose
Boom shall always be in fully raised position in "out-of-Service"

conditions.
68
6 PUTTING THE CRANE OUT OF

SERVICE
The crane must be taken "out of service" if the wind speed exceeds
22m/s (80.0km/h). Audio and visual warning devices indicate if this
maximum wind speed has been reached or exceeded.
When putting the crane out of service for any period, however short,
the following procedure must be strictly adhered to. Only then can it be
properly ensured that the crane is safely parked and is capable of
withstanding the forces imposed by strong winds.
1. Remove load from lifting equipment.

2. Raise lifting equipment to the park position, above the 50% pre
up limit.
3. Bring the trolley to the park position, TROLLEY PARKED lamp
on.
4. Bring crane to the storm anchor position, STORM ANCHORS
POSITION lamp is on if applicable.
5. Press CRANE OFF pushbutton.
6. Switch on boom drive and raise boom to the locked position, 75º.
7. Insert storm anchors into the corresponding ground pockets.
8. The following equipment on the crane is fitted with Anti-
Condensation Heating
o Electrical Switchgear / Electronic panels. These heaters are
thermostatically controlled.
o All Drive motors. These heaters come on when the crane
drives go off.
o Cable Reeling Drum Motor / Slipring Assembly.
69
It is absolutely essential that the power supply to the anti-condensation

heating is not interrupted to prevent condensation build-up which may
damage electrical / electronic equipment and components.
The anti-condensation heating equipment must remain on at all times
when the crane is out of service.
The anti-condensation heating system should be monitored regularly
for correct operation.
THE MANUFACTURER WILL NOT ACCEPT ANY DAMAGE CLAIM RESULTING

FROM FAILURE TO COMPLY WITH THE ABOVE INSTRUCTIONS.
If the crane is to remain "out of service" for a period longer than three
weeks, special storage precautions should be taken to avoid damage
to crane components. If such circumstances arise, consult the
manufacturer for advice. Failure to comply with these precautions will
forfeit guarantee conditions.
70
7 OPERATING THE CRANE DRIVE UNITS

7.1 HOIST UNIT OPERATION
7.1.1 OPERATION
The master joysticks for Hoist / Travel and Trolley are spring return to
Zero position types.
The hoist system is controlled by means of the joystick on the right-
hand control console:
o Forward movement of the joystick is for lowering
o Backward movement for hoisting
Continuously variable speeds from creep speed to full speed may be
achieved in both directions.
To commence hoisting \ lowering, push the joystick in the desired
direction. The further the joystick is moved, the faster the hoist motion
will run.
Hoist operation may also be implemented from the control panel P20
at ground level.
7.1.2 OVERLOAD PROTECTION SYSTEM

(For further details - See Part 2, Mechanical Manual)
OVERLOAD gives a visual and audible warning when the lifted load
exceeds the safe working load of the crane / hoisting equipment.
Further hoisting of the load is prevented and the load may only be
lowered.
The overload protection system provides for the safe operation of the
crane / hoisting equipment.
The following audio / visual devices are provided:
a) OVERLOAD WARNING LAMP yellow, switched ON when load
approaches maximum load allowed.
71
b) OVERLOAD LAMP red, switched ON when load exceeds

maximum load allowed. Horn / Audio warning device switched
ON.

Limit Switches are incorporated in the hoist control system, which
provide for the proper functioning of the hoist "up" and "down"
motions.
The following limit switches are provided:
Hoist Up \ Down Drum Limit Switch
Rotary limit switch coupled to hoist rope drums, incorporating the
following functions:
o Hoist Up Pre-limitation 50%
Slows the hoist up motion to 50% of full speed close to the
maximum hoist up position
o Hoist Up Pre-limitation 10%
Slows the hoist up motion to 10% of full speed close to the
maximum hoist position
o Hoist Up Stop
Stops the hoist up motion at the maximum hoist up position
o Hoist Down Pre-limitation 50% (Overland)
Slows the hoist down motion to 50% speed when lowering
overland
Interlocked with Trolley on Boom limit switch
o Hoist Down Stop
This stops the hoist down motion at the maximum hoist down
position. Hoist down stop is when there are 3 turns left on the
hoist drum.
o Hoist Up Emergency Stop
A mechanical limit switch is mounted on the trolley, which
provides for an emergency stop hoist 'up' position. In the event of
this limit switch being activated, maintenance personnel should
be notified to reset the electrical control, which prevents further
hoist equipment motion, the hoist should then be carefully
lowered, and the cause of the failure established.
Hoist up emergency stop is 200mm above the hoist up stop.
72
7.1.4 SINGLE MOTOR OPERATION

Operation of the hoist drive using one motor is possible.
60% of the rated load may be raised / lowered in this mode of
operation.
The single motor operation is energised via a key switch fitted to the
door of the main switchgear in the Electrical House.
This key switch incorporates the following positions:
 0 - Position: Hoist Motor 1 + 2 Operative Normal Position
 1 - Position: Hoist Motor 1 Operative Only
 2 - Position: Hoist Motor 2 Operative Only
7.1.5 HEAVY LIFT OPERATION
The heavy lift operation is automatically switched ON when the
spreader cable has been unplugged and the lifting beam is within the
load /range permitted. This facility permits a service weight load of
70.00 Tonnes under Hook Beam to be lifted / transported over a
restricted length of boom and beam. Hoist and Trolley speeds are
reduced to ~40% in Heavy Lift Mode.
7.1.6 HOIST HEIGHT POSITION
A potentiometer coupled to the rotary limit switch at the hoist drum
provides for visual indication of hoisting height on the EMS display in
the driver’s cabin.
7.1.7 HOIST INCHING

The hoist inching function is only permitted from the electrical house
for maintenance purposes, i.e. greasing of ropes, changing of ropes
etc. This can only be operated by maintenance personnel.
7.1.8 HOIST E-DRIVE

An Auxiliary drive motor is fitted on the Hoist. This drive is only for use
in an emergency, and can only be operated by maintenance
personnel.
In the event of equipment malfunction, crane operation should

immediately be stopped, the exact sequence of failure noted and
maintenance personnel notified. The reason for malfunction or
failure should be determined and corrected immediately.
73
74
7.2 TROLLEY DRIVE SYSTEM OPERATION
7.2.1 OPERATION
zero position types.
The trolley system is controlled by means of the joystick on the left-
o Forward movement of the joystick is for trolley forward
motion
o Backward movement for trolley reverse motion
To commence trolleying, push the joystick in the desired direction.
The further the joystick is moved, the faster the trolley motion will run.
Trolley Operation is also available from Gantry Console P20.

Limit switches are incorporated in the trolley control system, which
provide for the proper functioning of the trolley "forward" and "reverse"
motions.
o Forward Boom Stop
Stops the trolley forward motion at the derrick boom head
o Reverse Stop Main Beam
Stops the trolley reverse motion at the end of the main beam
o Forward Pre-limitation 25% Boom
Slows the trolley forward motion to 25% of full speed close to the
head of the derrick boom
o Forward Pre-limitation 10% Boom
Slows the trolley forward motion to 10% of full speed close to the
head of the derrick boom
75
o Forward Stop Main Beam

Stops the trolley forward motion at the boom hinge point when
the derrick boom is raised
o Trolley on Boom
The hoist slow down limit is only operable while the trolley is
over land. When the trolley is on the boom these limits are
inoperative, to allow full speed on the hoist into the cell of a ship
o Forward Pre-limitation 25% Main Beam
Slows the trolley forward motion to 25% of full speed, close to the
boom hinge point when the boom is in the raised position.
o Forward Pre-limitation 10% Main Beam
This limit slows the trolley forward motion to 10% of full speed,
close to the boom hinge point when the boom is in the raised
position. This is also the limit that is used to reset the positioning
encoder located on corner 1 of the trolley, see also Trolley Auto
Park section below.
o Trolley Parking
Determines when the trolley is positioned in the parking area
opposite trolley entry platform - necessary for operation of derrick
boom.
o Reverse Pre-limitation 25% Main Beam
Slows the trolley reverse motion to 25% of full speed close to the
back end of the main beam
o Reverse Pre-limitation 10% of Main Beam
Slows the trolley reverse motion to 10% of full speed close to the
back end of the main beam.
o Trolley Lock limit switch
No trolley movement allowed until Trolley Lock pin is dis-
engaged.
o Trolley Entry Gates
A reset push button is located on the right side of the cabin, at
the base of the stairs. When a gate is open, the Gate Open lamp
on the desk will be lit. When the gate is closed, this lamp will start
to flash after 1 second. This means the reset must be pushed
before trolley movement is allowed. At this stage the driver will
see that there is nobody on the access stairs to the cabin, and
push the button. With one or both of these access gates to the
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Trolley / Driver’s Cabin area open, trolley movement is stopped if

in motion or prevented from moving if stationary.
o Forward / Reverse Emergency Stop
Provides for an emergency stop trolley forward position at the
head of the derrick boom (seaside) and trolley reverse
emergency stop position at the end of the main beam (landside).
In the event of this limit switch being activated, maintenance
personnel should be notified to reset the electrical control circuit,
and the trolley should be carefully moved away from the
emergency stop position. The exact reason for activation of the
emergency stop limit switch should immediately be determined
and rectified.
o Heavy Lift Forward Boom
Heavy hook load of 70 Tonnes is restricted to a limited trolley
travel path from 45.0m outreach to midspan. See Section 3.1.5.
o Heavy Lift Reverse Beam

Heavy hook load of 70 Tonnes is restricted to a limited trolley
travel path from 45.0m outreach to midspan. See Section 3.1.5.
7.2.3 TROLLEY POSITION

A position encoder fitted to the trolley system provides for visual
indication of trolley position on the EMS-Display in the driver’s cabin
and also for position reference to the auto-park function.
7.2.4 TROLLEY AUTO PARK

A push button with built in status lamp (cabin side panel) provides for
automatic parking of trolley. To activate, put trolley joystick to zero and
raise the hoist above the 50% slow down position. Push AUTO-PARK
push button and the yellow lamp will come on.
Now select the direction to the park position. The trolley will
automatically slow to 25%, 10 % and stop at this position. The trolley
encoder is used for these limits. When the trolley has parked and the
joystick is returned to zero the AUTO-PARK lamp will go off.
If for any reason you want to switch off the AUTO-PARK function once
selected, push AUTO-PARK twice in quick succession.
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immediately be stopped, the exact sequence of failure noted and
maintenance personnel notified.
The reason for malfunction or failure should be determined and
corrected immediately.
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7.3 LONG TRAVEL DRIVE SYSTEM OPERATION

7.3.1 OPERATION
zero position types.
The gantry system is controlled by means of a joystick on the right-
o Left movement of the joystick is for travel left motion
o Right movement is for travel right motion
To commence travelling, push joystick in the desired direction. The
further the joystick is moved, the faster the travel motion will run.
Crane travel motion may also be implemented from the control panel
at ground level.

Limit switches are incorporated into the travel control system, which
provide for the safe functioning of the travel motions.
The following limits are provided:
o Anti-collision ultrasonic limits to provide slow down to 10% speed
and full stop.
o Buffer limits to provide a stop when buffers are compressed. This
allows the cranes to work as close together as possible during
operations.
o 10% slow down and stop at the end of the quay, before collision
with end buffers. Applicable only, to the cranes on the far left and
right of the quay.
7.3.3 STORM ANCHORS / RAIL CLAMPS

Storm Anchors are manually raised to allow travel motions left and
right. There is an indication lamp provided in the Gantry Console P20.
This STORM ANCHORS UP (green) lamp will only light when all storm
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anchors are up. If you are missing a storm anchor or a tie down, then
the lamp will not light.
Storm Anchors can only be lowered when you have the STORM
ANCHORS POSITION (yellow) lamp on, this means the storm anchors
are over the ground pockets.
Rail Clamps are automatically raised when a travel direction is
selected. The lamp RAIL CLAMPS UP (green), Gantry Console P20,
will light when they are up. They will remain in the up position for 30
seconds after travel movement is stopped.
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7.3.4 TRAVEL OPERATION - GROUND LEVEL

GROUND CONTROL PANEL P20 IS PROVIDED ON THE 1ST. LANDING LEVEL OF
THE MAIN ENTRY SYSTEM ON CORNER 4.
PREPARATION
Before putting the travel system into operation, ensure the following
procedures are implemented:
a) Ensure the Main Supply to the crane is switched on.
b) Manually lift Storm Anchors
c) Ensure all emergency stop stations on the crane are in the
RESET / ON position
d) Check that boom is parked in the UP or DOWN position
e) Switch off all controls at the driver’s control console in the driver’s
cabin and at the control panel in the machinery house.
SWITCHING ON AT THE CONTROL CONSOLE

a) Unlock cover of control console and open.
b) Reset EMERGENCY STOP push-button, (if required).
c) Switch on keyswitch CRANE DISABLE by inserting the key and
turning to engage / release.
d) Press push-button CRANE ON, built-in status lamp for same
switched on. Other status lights may also be switched on,
dependent on current status of equipment.
e) A status light for STORM ANCHOR POSITION is provided. The
storm anchors cannot be raised and / or lowered until the crane
is in the parking area, i.e. STORM ANCHOR POSITION status
light switched ON.
A self-test of approx. 2 seconds duration is initiated; where upon all
status lights on the control panel are switched ON to verify that same
are operative.
Flashing light indicates that drive has not been energised. If this
happens, further operation should be suspended, the cause
determined and rectified.
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f) A selector switch for SLOW / FAST is provided. Select position

as required.
g) Push buttons for LEFT and RIGHT are provided
Press corresponding push-button as required
h) Status lights are provided for STORM ANCHORS / RAIL
CLAMPS UP. The RAIL CLAMPS UP status light remains on for
approx. 30 seconds after travel drive has been stopped. Flashing
indicates that rail brakes have not been released / raised
SWITCHING OFF AT THE CONTROL CONSOLE

a) Press pushbutton CRANE OFF
b) Switch OFF keyswitch CRANE DISABLE. Remove Keys. Status
light for CRANE ON switched OFF.
c) Close cover of panel and lock
d) Remove all keys and stow in a safe place
If The Crane Is To Be Left “Out-Of-Service”, The Crane Must Be

Properly Parked With The Storm Anchors Lowered Into The Ground
Sockets As Provided.

immediately be stopped, the exact sequence of failure logged and
maintenance personnel notified.
The reason for malfunction or failure should be determined and

corrected immediately.
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7.4 BOOM HOIST / DRIVE SYSTEM OPERATION

THE BOOM HOIST SYSTEM IS CONTROLLED BY MEANS OF command
devices fitted to the right hand Drivers Control Console.
7.4.1 PREPARATION
Before putting the boom hoist system into operation, ensure the
following procedures are implemented:
o Service crane on A-Frame must be properly stowed.
o Remove load from lifting equipment.
o Raise lifting equipment to hoist parking area. (Above hoist 50%
slowdown limit switch)
o Park trolley in parking area at entry platform. Indication lamp
TROLLEY PARKED is switched ON.
o Check that BOOM READY status lamp is switched ON.
(See "PUTTING THE CRANE INTO SERVICE")
7.4.2 SWITCHING ON BOOM HOIST DRIVE SYSTEM

o Press BOOM ON push-button, status light for same lights up.
Other status lights may also be switched ON depending on status of
equipment.
7.4.3 OPERATION
The Boom Hoist is controlled by means of push-buttons, 1 off push-
button for BOOM UP and 1 off push-button for BOOM DOWN.
To raise or lower press corresponding push-button.
7.4.4 PARKING BOOM IN "UP" POSITION

Press push-button BOOM UP, the boom is raised to the up position
When the boom rises to an angle of approx. 67º with the horizontal, it
enters the locking zone and slows to creeping speed. The boom hoist
up operation continues until up motion stops. The boom is then
lowered to the locked position allowing the hook of the latching device
to take the boom load.
Ensure that the status BOOM UP is switched ON before switching off.
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7.4.5 PARKING BOOM IN "DOWN" POSITION

Press push-button BOOM DOWN, the boom is raised until stopped at
which point the boom hoist ropes take the load of the boom. The
latching hook now opens electro-hydraulically. The boom is then
lowered to the down position.
Ensure that the status BOOM DOWN is activated before switching off.
BOOM STOP
The boom may be stopped in an intermediate position in an
emergency situation by pressing BOOM STOP pushbutton.
To resume operation it is necessary to press corresponding
pushbutton again.
The boom holding arm must take the full weight of the boom in the
down position and the boom hoist ropes must be slack. Under any
load condition no forces must be imposed onto the boom hoist ropes.
7.4.6 SWITCHING OFF AT THE CONTROL CONSOLE

Press pushbutton CRANE OFF.
(SEE “PUTTING CRANE OUT OF SERVICE”)
7.4.7 BOOM INCHING

The boom inching function is only permitted from the electrical house
for maintenance purposes, i.e. greasing of ropes, changing of ropes
etc. This can only be operated by maintenance personnel.
Many protective and safety features and systems are incorporated in

the crane design to ensure correct and safe derrick boom operation
under normal conditions. However, considering the importance of
correct functionality and the inherent safety considerations, it is
imperative that the operation and sequencing of the derrick boom
raising or lowering operation is carefully monitored at all stages.
84

Limit switches are incorporated in the boom hoist control system,
which provide for the proper functioning of the boom 'up' and 'down'
motions.
ROTARY TYPE LIMIT SWITCH COUPLED TO THE DERRICK ROPE DRUM,
INCORPORATING THE FOLLOWING FUNCTIONS:
o Boom Down
Slows Boom Down motion to creep speed
BOOM DOWN status LED is switched on, when boom is down
and additional rope is paid out.
BOOM UP stop 1 + 2 stops BOOM UP motion.
Boom UP status LED is switched on when boom is UP.
MECHANICAL AND PROXIMITY LIMIT SWITCHES MOUNTED ON THE A-FRAME
INCORPORATING THE FOLLOWING FUNCTIONS:
o Boom Up 1 and 2
Either or both will stop ‘boom up motion’ when raising from level
or raising out of the latch.
o Boom Up Emergency Stop
Mechanical limit switches, which provides for emergency-stop
boom up position. In the event of this limit switch being activated,
maintenance personnel should be notified to reset the electrical
control circuit and the boom should be carefully lowered. The
exact reason for activation of the emergency stop should
immediately be determined and rectified.
o Boom Locked
Proximity limit switch, which indicates when the boom is in the
locked position.
o Hook Open
Proximity limit switch, which indicates when the hook is in open
position. The boom may only be lowered when the Hook has
been opened.
o Hook Closed
Proximity limit switch, which indicates when the hook is in the
closed position. The boom may only be locked when the Hook is
closed.
o Slack Rope - Left / Right
85
Proximity limit switches which ensure that boom hoist ropes

become slack when the boom is parked in the up or down
position and to prevent lowering of the boom with ropes in a
slack condition.
When the boom is parked in the up position - BOOM UP status
light is switched ON.
Should one of the slack rope limit switches be activated during
lowering of the derrick boom, the motion immediately stops.
Maintenance personnel should be notified to reset the electrical
control circuit. Raising of the boom in creep speed is now
possible. The exact reason for activation of the slack rope limit
switches should immediately be determined and rectified.
o Overspeed Switch
Coupled to the boom rope drum provides for emergency braking
of the boom motion should an overspeed condition occur.
The boom holding arm must take the full weight of the boom in the
down position and the boom hoist ropes must be slack. Under any
load condition no forces must be imposed onto the boom hoist ropes.
7.4.9 BOOM E-DRIVE

An Auxiliary drive motor is fitted on the Boom Drive. This drive is only
for use in an emergency, and can only be operated by maintenance
personnel.
86
7.5 SPREADER BEAM OPERATION

7.5.1 OPERATION
The spreader is switched on automatically with CRANE ON, fitted on
the driver’s Right–hand console.
There is an additional push-button on the driver’s Right-hand console
for Spreader Off.
Spreader functions are also available from Gantry Console P20.
The master joysticks for Hoist / Travel / Trolley and Twistlocks are
spring return to zero position types.
The twistlocks OPEN / CLOSE are controlled via Joystick fitted on the
Left-hand console. (There is an additional miniature joystick fitted on
the Right-hand console for Twistlocks Open – Closed).
o Left movement of the joystick is for Twistlocks Open
o Right movement is for Twistlocks Closed

The twistlock OPEN and CLOSED functions cannot be operated until
the spreader is properly and fully deposited on the container and the
timer has expired, the timer is set at 1.5 sec to allow for movement of
the container i.e. listing, and to ensure spreader is seated on a
container. A status light is provided on the spreader status panel on
the footrest panel to indicate when the spreader is properly deposited
on the container.
Flippers Up / Down are controlled via push-button on top of Joystick
fitted on the Left-hand console.
The flippers are pre-selected by pressing the required push-buttons on
the left-hand control console-corresponding status light for same are
switched ON.
Four Push-buttons for Spreader beam length are located on the
Right-hand control console. The following spreader lengths are
provided for: 20’ - 40’ - 2x20’ - 45’.
When 2x20’ (Twin pick) is selected, the centre twistlocks are

automatically lowered to the down position.
87
7.5.2 ADJUSTING SPREADER TWIN LIFT POSITIONS

During Twin Lift operations, a specific distance can be set between the
2x20’ center twistlocks of the spreader for both the seaside and
landside operation.
Setting Seaside Position
When over the ship, move selector switch OFF / MAN / AUTO to
MANUAL position.
To achieve the desired 2x20’ centre twistlock positions, press either
the RETRACT IN or EXPAND OUT pushbutton.
To store the set position, press SET POSITION SEASIDE. Built in
status lamp on pushbutton is switched ON denoting status.
Hoist containers and trolley back to landside.
Setting Landside Position
To achieve the desired 2x20’ landside positions, press either the
RETRACT IN or EXPAND OUT pushbutton when lowering the
containers.
To store the set position, press SET POSITION LANDSIDE. Built in
status lamp on pushbutton is switched ON denoting status.
Dis-engage the containers and move selector switch OFF / MAN /
AUTO to AUTO position.
For further cycles the twistlock centre positions will automatically move
to the set position for Seaside or Landside when the trolley crosses
the hinge point.
To disable this feature, move selector switch OFF / MAN / AUTO to
OFF position. When the switch is moved back to AUTO the most
recent set positions are still saved.
88
7.6 HOOK BEAM (HEAVY LIFT) OPERATION

The hook beam is mechanically coupled to the headblock by means of
sliding pin connections. In addition, the spreader supply cable plug
from the headblock should be plugged into the dummy socket
provided on the headblock, to avoid damage to the loose end of cable.
This also identifies that the hook beam is connected.
The heavy lift operation is automatically switched ON when the
spreader cable has been unplugged and the lifting beam is within the
load /range permitted. This facility permits a service weight load of
70.00 Tonnes under Hook Beam to be lifted / transported over a
restricted length of the boom and beam. See Section 3.1.5.
Hoist and Trolley speeds are reduced to ~40% in Heavy Lift Mode.
89
90
7.7 TRIM / LIST / SKEW OPERATION

7.7.1 FUNCTION
The Skew System provides for rotation of the spreader beam /
container around its vertical axis by an angle of + / - 5º from its normal,
parallel to the long travel rail position.
The List System provides for the lowering or rising of one side of the
spreader beam / container with respect to the horizontal by + / - 5º.
The Trim System provides for the lowering or raising of one end of
the spreader beam / container with respect to the horizontal by + / - 5º.
7.7.2 OPERATION
The Trim / List / Skew system is switched on automatically when trim,
list or skew is selected.
Trim List and Skew control is via joystick located on the left-hand
console.
o Trim Joystick Movement Left: Left Trim
o Trim Joystick Movement Right: Right Trim
o List Joystick Movement Forward: List Forward
o List Joystick Movement Backward: List Backward
Skew control is achieved by twisting the Joystick clockwise and / or

anti-clockwise as desired.
Trim / List / Skew may be set to “ZERO” position by pressing the
ZERO pushbutton on the Joystick.
Trim, List and Skew motions are achieved by controlled shortening /
lengthening of the hoist ropes.
91
92
7.8 MAINTENANCE CRANE / RE-REEVING WINCH

OPERATION
7.8.1 FUNCTION
The re-reeving winch provides for ease of re-reeving of ropes when
fitting, removal or replacement of same when necessary.
An access hatch is provided in the machinery house base for lowering
equipment to ground level.
The maintenance crane provides for ease of maintenance and repair
work to the equipment in the machinery house.
7.8.2 OPERATION
The re-reeving winch is operated via push buttons corresponding to
the required direction on the remote push-button station attached to
same.
Long Travel and Trolley motions are also operated by pressing the
designated push-buttons.
The hoist winch of the maintenance crane is controlled by means of a
remote push-button station suspended from same. Press
corresponding push-button to commence the hoisting or the lowering
operation. A two speed control is provided.

o Hoist Up / Down
A rotary type limit switch incorporated in the hoist winch provides
for maximum hoist "UP" and "DOWN" position limitation.
o Overload
A mechanical limit switch incorporated in the hoist control system
provides for limitation of the maintenance crane loads within its
safe working load.
93
94
8 CHANGING LIFTING EQUIPMENT

GENERAL
The cranes are each provided with a headblock (pulley frame). This
headblock is provided with the four pulleys onto which the hoist ropes
are attached. The headblock is provided with a cable basket, and a
mechanical anti-sway system using interlocking gears attached to the
pulleys.
CONNECTION TO SPREADER BEAMS

The headblock is connected to the telescopic spreader by four sliding
pins, and similarly to the hook beam. Ensure that all safety devices to
retain and secure the sliding pins are fully and securely locked after
the pins are properly connected to the spreader beam or hook beam.
Ensure that the plug and socket connection between the headblock
and the spreader beam is disconnected prior to removing the
headblock from the spreader beam. When the headblock is connected
to the spreader beam, ensure that the plug and socket connection is
remade.
Personnel involved in connecting the headblock to the spreader beam
must acquaint themselves with the correct and safe method of this
operation and ensure that it is methodically and carefully carried out at
all times.
Always ensure that the electrical connection between the headblock

and the spreader beam is disconnected prior to detaching the
spreader, and reconnected when a different item of lifting equipment is
attached.
The changing of Lifting Equipment should preferably be carried out

within 5 m. of the centre of the seaside rail. This is important as it
keeps the headblock stable while the change is being carried out.
Ensure sufficient hoist rope is paid out prior to removing the headblock
to prevent upward movement following its release from the lifting
equipment.
95
LIFTING EQUIPMENT
The lifting equipment provided with the crane is as follows:
a) One Headblock, which incorporates a geared anti-sway
pulley system and sliding pin connection to Spreader Beam.
b) One (1) Telescopic Spreaders Model BROMMA STS45
Expanding Twin-lift.
c) One (1) Telescopic Spreaders Model BROMMA SSX45 Single
Lift.
d) One (1) Hook Beam SWL 70.00 tonnes.
It is recommended that each unit of lifting equipment should preferably
be stored on stands of approx. 0.6 / 0.8 m high to prevent it being
damaged and provide good access for inspection and maintenance.
When it is required to fit a spreader or hook beam, the headblock
should be carefully lowered, aligning the sliding pins with the apertures
on the spreader or hook beam. The pins are then pushed home and
secured with their locking pins and safety pins.
Care should be taken to execute this operation slowly thereby
reducing damage to any parts. The plug and socket connection should
then be completed.
A similar procedure in reverse should be adopted when taking off a
spreader or hook beam from the headblock.
Also consider the relevant information contained in this Manual,

Section 7 and in the Mechanical Manual (Part 2), Section 10.
96
SAFETY INSTRUCTIONS
a) The changing of the lifting equipment should be carried out within

approximately 5m of the seaside rail.
b) Always ensure that lifting equipment is attached to the headblock
when the trolley is travelled outside the 5m distance.
c) The utmost care is required to ensure that spreaders are properly
connected, both mechanically and electrically.
d) Under no circumstances should the spreader electrical con-
nection plug be removed while the spreader is still switched on.
97
98
9 EMERGENCY FEATURES
9.1 GENERAL EMERGENCY STOPS
The crane operation can be immediately halted in an emergency at the

following locations:
a) Driver’s Control Console (Driver’s Cabin)
b) Travel Control Panel P20 (Ground Level)
c) Push-button Station on Switchgear Panel S1 (Electrical House)
d) Push-button Station on Switchgear Panel S2 (Driver’s Cabin)
e) Four Push-button Stations at Ground Level (one per crane
corner)
f) One Push-button Station on Main Beam
g) Two Push-button Stations on Trolley (1 x Left, 1 x Right)
h) Two Push-button Stations in Machinery House
i) One Push-button Station at Stairs Entry to Driver’s Cabin
j) One Push-button Station on the Headblock
9.2 HIGH-TENSION EMERGENCY STOPS

The crane High Tension Power supply may be immediately shut down
in an emergency at the following locations:
a) Travel Unit 1 at ground.
b) Push-button Station on high-tension cubicle.
c) Push-button Station on Switchgear.
It is imperative that all personnel concerned with the crane and its
operation, i.e. crane operators, maintenance personnel, etc.
Immediately become familiar with the location and operation of all
emergency stop stations before initial operation of the crane.
99
100
9.3 EXIT IN EMERGENCY

The crane is provided with adequate means of descending to ground
level in the event of an emergency.
The reasons for using the emergency can be many and varied.
The drivers and other personnel associated with the crane should
acquaint themselves fully with what can be done in an emergency and
then when the emergency occurs, immediate positive action should be
taken without hesitation.
THE FOLLOWING FACILITIES ARE PROVIDED:

a) The machinery / electrical house can be left through the
permanently installed ladders / stairs / platforms / gangways. By
means of the lift installed at Corner 4, descent to ground level is
possible in the usual manner. *
b) If the trolley with the driver’s cabin is stopped in any position,
then the following route must be taken:
 From driver’s cabin via stairs onto the platform in the main
beam or boom.
Note: When the trolley is stopped in any position other than
its normal parked position, great care must be taken when
entering the main beam or boom platforms from the stairs
located at the side of the driver’s cabin.
 Via this platform on boom or beam to the main entry system
and then to ground level.
c) As stated above, drivers and other personnel involved with the
crane should acquaint themselves with these exits. Remember, if
a power failure occurs, these exits may have to be used in total
darkness and being an emergency form of escape, the guards,
platforms, etc. are not as conveniently placed or as ideally
located as they are in the normal entry situations.
It is imperative that the lift is not used when any likelihood of electrical
failure might occur.
101
102
9.4 FIRE
If for some reason, a fire should occur in any part of the crane, the
operator / driver should ensure that the severity or potential severity of
it is quickly assessed.
He should then adhere to the following procedure:
a) Stop the crane and all its motions.
b) Inform other personnel that a fire has occurred.
c) If it is felt that the fire can be overcome using fire extinguishers,
then these should be used.
If however, the fire is a major fire, then all personnel should leave
the crane at once. The fire department should be alerted
immediately and a brief description of the fire should be given if
possible.
d) The section “Putting the Crane Out-Of-Service” should be
complied with.
It is strongly recommended that the local fire services be informed
about the crane after erection has been completed. Then they will be
fully conversant with platforms and general access and will be in a
position to take positive action very quickly. It is also recommended
that all operating personnel be informed about the types of fire and
their proper treatment. This information will readily be given by the
local fire authority.
CARBON DIOXIDE FIRE

EXTINGUISHERS
Remove the pin and aim the gas

discharge at the base of the fire.
Do not hold the discharge funnel with
your hand to avoid freeze burn – use
handle only.
Gas discharge is VERY LOUD from CO2
extinguishers. Do not be alarmed, as
this is normal.
103
A FIRE SUPPRESSION SYSTEM IS INSTALLED IN THE ELECTRICAL HOUSE.
FIRE EXTINGUISHERS ARE LOCATED IN VARIOUS AREAS AS FOLLOWS:

o Machinery House
o Electrical House
o HT switch / transformer cubicle
o Driver’s Cabin
o Quay level
o Trolley
o Cable Reeling Drum
PLEASE FIND ON THE FOLLOWING PAGES THE

RECOMMENDED MAINTENANCE INSTRUCTIONS
FOR CARBON DIOXIDE FIRE EXTINGUISHERS.
104
Apex Fire
Maintenance Instruction
Carbon Dioxide Extinguisher Models MC2A, MC5A, MC2E and MC5E

KITEMARKED to European Standard BS EN 3
CE marked to the Pressure Equipment Directive 79/23/EC
Model MC2A MC5A MC2E MC5E

Manufacturing standard BS EN 3 BS EN 3 BS EN 3 BS EN 3
Cylinder material Aluminium Aluminium Steel Steel
Capacity 2kg 5kg 2kg 5kg
Media Carbon Dioxide Carbon Dioxide Carbon Dioxide Carbon Dioxide
Discharge time 12 Seconds 15 Seconds 12 Seconds 15 Seconds
Jet length 3 / 4.5m 3 / 4.5m 3 / 4.5m 3 / 4.5 m
Overall height 540mm 675mm 558mm 690mm
Overall width 170mm 190mm 166mm 190mm
Cylinder diameter 110mm 150mm 105mm 138mm
External finish RED RED RED RED
Operational temperature -20/+60 C -20/+60 C -20/+60 C -20/+60 C
Test pressure 215 bar 215 bar 310bar 310bar
Working pressure approx. 55 bar * approx. 55 bar * approx. 55 bar * approx. 55 bar *
Charged weight 5.1kg 11.9kg 6.75kg 14.4kg
Fire rating 34B 89B 34B 89B
___________________________________________________________________________
Page 1 of 2
Apex Fire
Maintenance Instruction
Installation Notes
These extinguishers are supplied with the swivel bend outlet horn (MC-2A), fixed horn (MC-2E) or the
hose and horn assembly (MC-5A & MC5E) packed separately in the carton. To connect the outlet
assemblies proceed as follows :
Swivel horn assembly Part No. EP31020 - Model MC-2A
1. Check that the assembly is free from obstruction by blowing through.
2. Screw the union nut onto the side outlet thread on the cylinder valve.
3. Tighten the union nut firmly with a spanner.
4. Check that the horn can be easily swiveled in a full arc yet remain in position when released.
Horn and Hose assembly Part No. EP31030 - Model MC-5A
1. Check that the assembly is free from obstruction by blowing through.
2. Insert the nylon washer into the union nut before tightening the nut
onto the side outlet thread on the cylinder valve.
3. Loop the hose and engage it in the hose stowage hook on the horn.
The wall bracket should be positioned so that the handle of the extinguisher is approximately 1m
from the floor (MC-2A & MC2E) or approximately 1m from the floor (MC-5A & MC-5E) when the
extinguisher is hanging on the wall bracket.
Weigh the extinguisher without the outlet swivel / hose and record this weight together with the
installation date on the service label (or other record) when commissioning the extinguisher.
Inspection Procedure
These extinguishers must be serviced at least annually by a trained competent person in accordance
with IS 291:2002 (The Use Siting Inspection and Maintenance of Portable Fire Extinguishers) and
the following instructions.
1. Examine the extinguisher body and head cap externally for damage and
corrosion.
2. Check that the safety pin is straight and can be removed easily (remove existing seal and replace).
3. Remove the swivel/hose and horn assembly and check for damage and
freedom from obstruction on refitting ensure nut is tightened.
4. Before replacing the swivel/hose and horn assembly check the weight of the
extinguisher against the weight recorded on the service label when first
put into service. Remove the extinguisher from site for recharging if
the weight has reduced by more than 10% of the specified CO2 content
weight.
5. Record both the weight and service date on the service label.
6. Wipe the extinguisher with a clean cloth
___________________________________________________________________________
Page 2 of 2
10 SAFETY PROCEDURES AND SAFETY

SIGNS
10.1 OPERATING SAFETY PROCEDURES
TO PREVENT SERIOUS RISK OF INJURY TO

YOURSELF AND OTHERS, OBSERVE ALL SAFETY
INSTRUCTIONS IN THIS MANUAL, ALL SAFETY SIGNS
ON THE CRANE, AND ALL RELEVANT SAFETY RULES
APPLICABLE IN THE PORT.
The following general safety rules for operating the crane are drawn
up in the event of no local regulations being in force. If local
regulations are in force concerning crane operation, then these should
be followed carefully and adhered to.
The importance of these points cannot be over-emphasised as the
accident-free, efficient operation and satisfactory functioning of the
crane and all its components is entirely dependent on their
observance. A false sense of security on the part of the crane operator
can lead to serious trouble and sometimes serious accidents.
It is vital that the crane is handled and operated gently and
without aggression. In this way, it will be seen that the loading
and unloading operation can be completed faster and without
fuss and can reduce the wear on the crane and its parts and will
be far less tiring on the driver, other crane operators and
maintenance personnel.
1. QUALIFICATIONS OF CRANE OPERATOR

Only reliable personnel of recognised ability, familiar with the
mechanical and electrical characteristics of the crane,
instructed in safety codes and standards applicable in crane
operation, may drive and operate the crane. The operator must
be over eighteen years of age, be mature in attitudes and
responses, be in good health and his background should
include both training and experience in the operation of this
type of equipment. He must possess a general knowledge of
105
the crane’s construction, be familiar with details of power supply

and electricity, hydraulics, safety devices, emergency cut-outs,
emergency exits, fire extinguishers, etc.
2. RESPONSIBILITIES OF CRANE OPERATOR

Knowledge of technical terms, parts’ identification and
maintenance is required for this work. The crane operator is
responsible for seeing that the crane is in a safe and
serviceable condition and has its maintenance the operating
instructions at his disposal at all times. He must check all parts
which are subject to wear and he must report all cases of
excessive wear without delay to the site foreman or supervisor.
He must immediately report any damage to ropes, or any
mechanical, electrical or structural faults. The crane operator
must be satisfied with the functioning of all brakes, limit
switches, safety devices, etc. He must be satisfied that the
crane is properly serviced at the recommended intervals.
3. OPERATING PROCEDURES
Always adhere to correct operating procedures. THE
CRANE DRIVER IS RESPONSIBLE FOR THE OPERATION
OF THE CRANE.
4. HANDLING OF DEFECTS / FAULTS

The crane operator must keep a record of any defects noticed
in a log book provided for this purpose. He must also report any
defects to the supervisor or foreman without delay, as well as
advise the relief operator when changing shifts. The supervisor
or foreman must be informed immediately should the relieving
operator fail to report on site on time.
5. “NO STORAGE” OF WASTE

The storing of rags, waste, oil or any combustible material in
any part of the crane must be prohibited.
6. NATIONAL DIRECTIVES
National directives, local by-laws, all relevant legislation and
regulations, standards and codes of practice concerning the
safe operation of cranes, if available and in force, must be
106
posted in the operator’s cabin or elsewhere - as necessity

indicates.
These compulsory regulations may also deal with the handling
of hazardous substances, issuing and/or wearing of personal
protective equipment or traffic regulations.
7. “NO TRANSPORT” OF PERSONNEL

Personnel may not be transported on containers or spreaders.
Personnel Mode should be engaged and personnel transported
on designated platform on the headblock.
8. “NO LOAD” OVER PERSONNEL

Hoisting loads over personnel on the ground is strictly for-
bidden.
9. ACCESS TO OPERATING CRANE

During operation, occupied cranes may only be entered or
exited after the crane operator has been informed and the
crane brought to a standstill and correctly parked.
No person(s) should be permitted to board or leave the crane
without first obtaining the driver's permission or the permission
of the responsible supervisor. The driver should be aware of the
precautions that are necessary while the person(s) is boarding
or leaving and should instigate them.
10. WORKING UNDER OPERATING CRANE

Working within the travelling area of the crane is strictly
forbidden. If it is imperative that work in this area has to be
done during the crane operation, then the driver has to be
consulted directly by people carrying out this work
11. REMOVAL OF TOOLS FROM CRANE

Tools or other objects must not be left lying on the track or any
part of the crane structure. They can severely damage the
crane and cause serious or fatal injury to personnel involved in
the crane operation.
107
12. OBSERVE THE OPERATION OF OTHER CRANES

When additional cranes are working closely together on the
same track even with the anti-collision system installed, the
utmost care must be taken when travelling towards the other
crane.
13. BOOM CLEARANCE

Care must be taken during long-travel (even if Boom Anti-
collision systems are installed) to ensure that the boom clears
all obstructions such as masts from ships, lamp-posts, etc.
14. POWER LINES

Standards and codes relating to the proximity of power lines
must be adhered to.
15. LOAD LIFTING

The load must be raised clearly above the surrounding structure
before any attempt to travel is made.
16. CONTAINERS TO BE UNLOCKED

If loads are taken directly from trucks, the crane driver must
ensure that the truck is completely at rest and that any devices
securing the container to the truck body are disengaged.
Containers to be lifted from the ship must be completely
unlocked and not in a “jammed” condition.
17. NO “DRAGGING” OF LOAD

The loads must always be lifted vertically. No attempt must be
made to “drag” the load by the use of the trolley or long travel.
18. CRANE SAFETY

Only use the Container Crane in a safe and reliable condition.
Damaged hoisting equipment, ropes, spreaders, etc. must not
be used but repaired or discarded as appropriate. An inspection
and preventive maintenance programme must be put in place.
19. LOAD MOVEMENT

The crane operator must watch the load and spreader at all
times during operation. Warning signals should be given before
each motion, at the beginning of a work-shift, after a rest period
and at other times, when necessary. Particular care must be
108
taken when unloading containers, which are stacked close to

the ship’s bridge. During this operation, the trolley movement
occurs very close to the ship’s bridge section and due
consideration must be given to ship’s movement, wind, etc.
20. COMMUNICATION WITH GROUND PERSONNEL

If the crane operator cannot see the loading and unloading
parts from his control platform, signals must be arranged and
given. These must be given by personnel stationed at vantage
points. Complete agreement on the signals being used must
prevail. If local regulations regarding signals are in force, then
these should be used. Only responsible and competent
personnel who are thoroughly familiar with the signalling system
in use should be allowed to give these signals.
The load may only be moved by a signal from a person respon-
sible who indicates clearly that it is safe to do so. All signal men
should wear gloves, which give high visibility.
The telephone provided should also be used to provide com-
munication for loading and unloading operation.
The agreed signals should be posted at strategic locations in
the cabin, machinery house, end-carriages and other desirable
locations, e.g. restrooms, workshops, etc.
See attached list of ‘Recommended Hand Signals for Container
Cranes’.
21. SAFETY DEVICES

The crane driver should ensure that all safety devices are
operating properly. These should be tested frequently. They
should also ensure that all structural protection systems to the
mechanical and electrical equipment are properly fitted e.g.
covers over rotating parts, crash guards, etc.
22. FIRE
Personnel working on the crane should be familiar with the
location and use of fire extinguishers, and evacuation
procedures.
109
23. MAINTENANCE
In the event of safety-relevant modifications or changes in the
behaviour of the crane, stop the container crane immediately and
report the malfunction to the competent authority/person.
24. MOTION LIMIT SWITCHES

Pre and Final stop limit switch systems are provided to protect
crane and driver in the event of an error in driver’s judgment.
These switch systems should not be considered as normal
operational switches and drivers must operate with due caution
when approaching limit switch zones. This particularly applies
to Hoist, Trolley, and Travel drives.
All motion limit switch systems must be tested for correct

operation prior to commencement of each driver’s shift, without
load on lifting equipment.
The crane must not be operated should any of the limit switch
systems be defective without prior approval of the terminal’s
safety engineers.
25. LIFTING CAPACITY OF CRANE

The overload device should not be treated as an operational
control device. The driver must clearly know what capacities the
crane can handle and must not endeavour to attempt lifts in
excess of those permitted.
The crane may not be loaded above its rated maximum

capacity.
110
26. EMERGENCY
If any trouble occurs during the crane operation, then one of the
Emergency Stop buttons should be pressed. This will abruptly
stop all motions within the crane as well as stopping the crane
itself. See Section 9 of this manual for the location of the
general and high-tension emergency stops.
27. SAFE PARKING OF CRANE

The operator must not leave the crane without ensuring that the
crane is properly parked. (See Section “PUTTING THE CRANE
OUT OF SERVICE”)
28. WARNING SIGNS AND NOTICES

At various locations on the crane and its lifting equipment,
LIEBHERR has provided Warning Signs in accordance with the
crane specification and which are considered by LIEBHERR to
meet the requirements in this respect. However, if any local
safety regulations and requirements applicable for this crane
require additional Warning Signs, Notices, Regulations,
Recommendations, or otherwise, then such requests must be
made known to LIEBHERR at the latest at crane
commissioning date. Arrangements will then be made by
LIEBHERR to meet these requests.
It is the purchaser’s responsibility to permit access to the crane
to authorised personnel only, and/or the working areas of the
crane. The purchaser / user must also ensure that this is strictly
adhered to at all times. If any of the signs provided become
dislocated or damaged, it is important that they are replaced or
repaired immediately.
111
29. SAFE WORKING LOAD SIGN

The data provided on the Safe Working Load (S.W.L.) signs
fitted to the crane and the lifting equipment must be clearly
legible and clearly understood at all times.
See applicable sign data below:
SWL -UNDER TWIN LIFT TELESCOPIC SPREADER

-SINGLE LIFT MODE - 45 TONNES
-TWIN LIFT MODE - 55 TONNES
SWL -UNDER HOOK BEAM - 70 TONNES
MANUFACTURED 2013
30. OPERATING WIND SPEED

It should be noted once again that THIS CRANE SHOULD NOT
BE OPERATED IN WIND SPEEDS EXCEEDING 22m/s
(80.0km/h). The crane must be taken out of service at such a
speed and the anchorage system properly applied.
(See Section “PUTTING THE CRANE OUT OF SERVICE”)
31. BUFFERS
All trolley buffers, crane travel buffers including their support
structures, should be kept in good condition. Note that these
buffers are considered as emergency stops only in case pre-
limit and final-limit switch system fails.
32. LONG TRAVEL LIMIT SWITCHES

As several cranes are located on the track, great care must be
taken at all times particularly when long travelling the cranes.
Long Travel limit switches are provided to ensure that long
travelling of the cranes is electrically stopped when the long
travel buffers are compressed.
Lack of constant care during this operation can lead to

serious consequences for machinery and personnel.
112
33. LIFTING EQUIPMENT

Whereas the lifting equipment provided with this crane is
designed for heavy-duty operation, it is imperative that ex-
cessive impact loadings are not applied. This applies to all
spreaders etc., which are attached to the cranes.
It is therefore essential that proper deceleration is applied to all
drive systems installed on the crane before the lifting equipment
- loaded or unloaded - comes into contact with any other item.
34. ADVERSE WEATHER CONDITIONS

Very high temperatures, storms, very low temperatures, snow,
ice, prolonged and heavy rainfall, thunder storms, extreme
sudden changes in temperature and other natural phenomena
may affect the condition of the structural components, the
electrical and mechanical equipment and the safety systems.
Due consideration should be given to this. Depending on the
severity and abnormality of such adverse weather conditions,
appropriate action should be arranged for, before putting the
crane into operation again.
35. TRIM, LIST AND SKEW SYSTEMS

It is important when lifting containers that the spreader is
lowered onto the container so that it is parallel to the container
top surface when viewed from a horizontal direction. The
spreader should not be lowered in a ‘trimmed’ condition when
the container is level, or in a ‘non-trimmed’ condition when the
container is trimmed. Carrying out container handling in the
incorrect manner described can create a situation where
incorrect signals can be got from the deposit pins and could
result in twist-lock damage and serious accidents.
113
10.2 ENVIRONMENTAL PROTECTION
Your container crane has been manufactured with the objective of

environmental protection, pollution prevention and continual
improvement. The manufacturing process has been in accordance
with the philosophy of Best Available Technology Not Entailing
Excessive Cost (BATNEEC) with strict controls over environmental
impact. The user of this crane is encouraged to continue this
philosophy.
a. When filling or draining oil reservoirs, gearboxes and hydraulic
tanks, etc., care should be taken to contain all spillages.
b. Regular preventive maintenance, e.g. cleaning/changing oil

filters, will prolong the life of the equipment and fluid and
minimise the energy required to operate the crane efficiently.
c. All waste arising from the maintenance and upkeep of the crane
should be disposed of in accordance with local waste
regulations. Recycling is recommended:
 Waste Electrical & Electronic Equipment
 Oils and grease
 Touch-up paints & solvents
 Lighting
 Etc.
114
115
116
10.3 WARNING SIGNS

The following SIGNS will be fitted to all cranes of project IR1874
(1off).
The signs for the personnel lift will be provided on a separate list.
All signs shall be adhesive with backing plates provided where
necessary. Wording will be in Spanish& English. Sizes may
depend on space required by the wording.
1. TWO SIGNS BLUE BACKGROUND WITH WHITE TEXT
MAT. NO. 1
One for each storm anchor housing.
Each approx. 350 mm. long x 350 mm. high.
Ref. No. IR 9425-820.101.
IMPORTANTE: ESTACIONAMIENTO DE LA GRÚA
Esta grúa puede operar sin restricciones a una velocidad del viento de hasta 80
Km/h.
Para asegurar el estacionamiento de manera correcta y segura consultar la
sección “out of service conditions” del manual de instrucciones.
1 RAIL CLAMPS
Los “rail clamps” localizados en el centro de cada viga transversal se

acoplan automáticamente cada vez que la grúa se detiene.
2 ANCLAJES DE TORMENTA
Cuando la grúa no esté operando, los “strom pins” deben ser

adecuadamente introducidos en sus respectivos alojamientos de
estacionamiento ubicados en el muelle. Asegurarse que esos “storm
pins” estén desenganchados antes de desplazar la grúa.
(Ver también las instrucciones de aparcado en el manual de la grúa)
1.
2. IMPORTANT : CRANE PARKING
This crane is fully operational in wind speeds upto 80Km/hr. To ensure correct
and safe parking of this crane {in “ out-of-service conditions (above 80 Km/hr)}
1 RAIL CLAMPS
The rail clamps located at the centre of each endcarriage automatically engage
with the rail head whenever the crane is stopped.
2. STORM ANCHORS
When the crane is not operating, the storm pins located at the centre of each
endcarriage must be inserted into their ground sockets, at any of the crane
parking locations provided.
Ensure that the storm pins are disengaged before crane travelling
commences.
(See also the instructions of parked in the manual of the crane)
117
2. ELEVEN SIGNS RED BACKGROUND WITH WHITE TEXT.

MAT. NO. 10659746
One for each Emergency Stop Button on Crane Legs.
Two inside Machinery House, three on the Trolley , one in the Main Beam
and one on the headblock platform .
Each approx. 300 mm. long x 200 mm. high. Ref. No. IR 8221-820.102.
PARADA DE
EMERGENCIA
EMERGENCY STOP
3. ONE SIGN
MAT. NO. 10659747
One at the entry to the stairs and personnel lift at ground level.
Approx. 350 mm. long x 250mm. high. Ref. No. IR 8221-820.103.
ENTRADA PROHIBIDA A
PERSONAS NO
AUTORIZADAS
NO UNAUTHORISED ENTRY
118
4. THREE SIGNS
MATERIAL NO. 10659748
Fitted on the main beam. Two near the trolley service entry points.
One at the Cabin entry parking location.
Approx. 300mm. long x 300 mm. high.
Ref. No. IR 8221-820.104.
ATENCION – PELIGRO MAQUINARIA MOVIL
DANGER! MOVING MACHINERY
PROHIBIDA LA ENTRADA MAS ALLÁ

DE ESTE PUNTO HASTA QUE EL
CARRO ESTÉ ESTACIONADO CON
SEGURIDAD EN FRENTE DE ESTA
PLATAFORMA.
NO ENTRY BEYOND THIS POINT UNTIL TROLLEY

IS SAFELY PARKED OPPOSITE THIS PLATFORM
119
5. ONE SIGN
MATERIAL NO. 10659749
Fitted outside the driver’s cabin at the top of the stairs.
Approx. 300 mm. long x 300 mm. high.
Ref. No. IR 8221-820.105.
ATENCION
ATTENTION
PROHIBIDO EL PASO MÁS ALLÁ DE ESTE PUNTO

HASTA QUE EL CARRO ESTÉ SEGURAMENTE
ESTACIONADO
NO ENTRY BEYOND THIS POINT UNTIL TROLLEY

IS SAFELY PARKED.
120
6. TWO SIGNS
MAT. NO. 10659750
One on each inspection platform of the main trolley.
Ref. No.: IR 8221-820.106
PELIGRO
DANGER
SOLO PERSONAL AUTORIZADO
AUTHORISED PERSONNEL ONLY
SE PROHIBE ESTRICTAMENTE TODO

MOVIMIENTO DEL CARRO MIENTRAS QUE EL
PERSONAL SE ENCUENTRE EN ESTA
PLATAFORMA
TROLLEY MOVEMENT IS STRICTLY PROHIBITED

WHILE
PERSONNEL ARE ON THIS PLATFORM
121
7. ONE SIGN
MAT. NO. 10659751
Fitted externally on the Machinery House door.
Approx. 350mm. long x 300 mm. high
Ref. No. IR 8221-820.107
ATENCION – PELIGRO MAQUINARIA MOVIL
DANGER MOVING MACHINERY
SOLO PERSONAL AUTORIZADO
AUTHORISED PERSONNEL ONLY
8. THREE SIGNS
MAT. NO. 10659752
One suspended on the Grillage surrounding the High Tension switch and
Transformer.
One on the Cable Reeling Drum.
One on the H. T. cable diverter unit at ground level.
Approx. 300 mm. long x 250mm. high.
Ref. No. IR 8221-820.108.
PELIGRO
ALTA TENSION
PELIGRO DE MUERTE
DANGER
HIGH VOLTAGE
DANGER TO LIFE
122
9. TWO SIGNS
MAT. NO. 10659753
One on the external entry door to the switchbox house.
One on the machinery side of the internal access door to the switchbox
house.
Approx. 300mm. long x 350mm. high.
Ref. No. IR 8221-820.109
PELIGRO
ALTA TENSION
DANGER
HIGH VOLTAGE
ACCESO AUTORIZADO SOLO A PERSONAL DE

MANTENIMIENTO ELÉCTRICO.
ACCESS TO AUTHORISED
ELECTRICALSERVICE PERSONNEL ONLY
10. ONE SIGN

MAT. NO. 10659754
Fitted within the Machinery House at a prominent location close to the trap
door.
Ref. No. IR 8221-820.110.
IMPORTANTE
COLOCAR GUARDA ALREDEDOR DE LA
ABERTURA CUANDO CUALQUIER ESCOTILLA
SEA RETIRADA.
IMPORTANT
FIT GUARD AROUND OPENING WHEN ANY

TRAPDOOR IS REMOVED.
123
11. ONE SIGN

MAT.NO. 10659755
Fitted on the Stairs near the driver’s cabin.
Approx. 300 m. long x 300 mm. high.
Ref. No. IR 8221-820.111.
PELIGRO
DANGER
NO SE PERMITE AL PERSONAL QUEDARSE EN

ESTA ESCALERA/PLATAFORMA MIENTRAS QUE
EL CARRO ESTA EN MOVIMIENTO.
PERSONNEL ARE NOT PERMITTED ON THIS

STAIRS WHEN TROLLEY IS IN MOTION
12. ONE SIGN

MAT. NO. 10659756
Fitted in the Driver’s Cabin.
Ref. No. IR 8221-820.112.
ATENCION
ANTES DE OPERAR ESTA GRÚA LEA Y SIGA CON

MUCHO CUIDADO LAS INSTRUCCIONES DEL MANUAL
ATTENTION
BEFORE OPERATING THIS CRANE, READ AND
CAREFULLY FOLLOW THE INSTRUCTIONS IN
THE CRANE MANUAL
124
13. TWO SIGNS

MAT.NO. 10659757
Fitted in the Machinery House.
Ref. No. IR 8221-820.113
LOS FILTROS DE AIRE DEBEN LIMPIARSE

MENSUALMENTE, Y REMPLAZARSE UNA VEZ
OBSTRUIDOS
CLEAN AIR FILTERS MONTHLY

REPLACE WHEN CLOGGED
14. TWO SIGNS

MAT.NO. 1
One on each end piece of the pulley frame.
Each approx. 300 mm. Long x 300 mm, high.
Ref. No.: IR9425-820.114.
CUIDADO
LOS 4 PINES DE CONEXIÓN Y ENCHUFE/

TOMACORRIENTE DEBEN ESTAR
CORRECTAMENTE CERRADO O ABIERTO
ANTES DE ACCIONAR EL MECANISMO DE
IZAJE.
CAUTION
ALL 4 CONNECTION PINS, ELECTRICAL
PLUGS / SOCKETS MUST BE PROPERLY
LOCKED OR UNLOCKED BEFORE HOISTING.
125
15. ONE SIGN

MAT. NO. 1
Fitted on the Main Beam of the Service Crane in the Machinery House.
Approx. 250mm. long x 150 mm. high.
Ref. No. IR 9425-820.115.
CAPACIDAD DE IZAJE 5.0

TONS.
S.W.L 5.0 TONNES
16. TWO SIGNS

MAT. NO 10659760
One near the High-Tension Emergency Stop at ground level.
One in the Machinery House near the High Tension equipment.
Each approx. 200 mm. long x 250 mm. high. Ref. No. IR 8221-820.116.
PARADA DE
EMERGENCIA DE
ALTA TENSION
HIGH TENSION
EMERGENCY STOP
126
17. ONE SIGN

MAT. NO. 10659761
Fitted on Exit Gate from Rear of Cabin.
Ref. No. IR 8221-820.117
Antes de usar la puerta de servicio, aplicar el siguiente

procedimiento:
1. Apagar la grúa
2. Activar la parada de emergencia en la cabina del
operador (S2).
Before using service gate the following procedure must

be applied:
3. Switch off crane
4. Activate emergency stop on panel S2 in cabin
127
18. TWO SIGNS

MAT. NO. 10659762
Fitted on the entry door to the Machinery House.
Ref. No. IR 8221-820.118
AVISO!
USTED ESTA ENTRANDO EN UN ÁREA DESIGNADA COMO
PELIGROSA.
WARNING!
YOU ARE NOW ENTERING A DESIGNATED DANGER AREA
Respetar Todos los procedimientos de seguridad en cada área de

trabajo, acordados por el personal de mantenimiento y detallados
en el manual de la grúa.
Prestar especial atención cuando la grúa esta encendida.
Cuando sea necesario llevar a cabo tareas de mantenimiento,

primero activar el botón de parada de emergencia en la sala de
maquinas.
All safety procedures in respect of work in such an area agreed

for maintenance personnel and instructions as detailed in the
crane manual must be adhered to.
Special attention has to be paid when crane is switched on.
When maintenance work has to be carried out, first activate
emergency stop button in machinery house.
128
19. ONE SIGN

MAT. NO. 10659763
Fitted on Access Gate at rear of cabin to Cabin Cleaning Platform.
Ref. No. IR8221-820.119
PRECAUCION!
CAUTION!
Para acceder a la plataforma de servicio de la cabina, primero el Carro

debe ser estacionado sobre dicha plataforma y la grúa inhabilitada por
la parada de emergencia. La puerta de acceso puede entonces ser
abierta presionando el pulsador correspondiente.
Deben ser respetados todos los procedimientos de trabajo respecto de
cada área, acordados por el personal de mantenimiento y detallados
en el manual de la grúa.
La puerta al frente de la plataforma de servicio debe estar
completamente levantada mientras el personal esta en la plataforma.
To access cabin service platform, the trolley must be parked over the
cabin service platform and the crane disabled by pushing emergency
stop button. The gate can then be opened by pushing the gate open
button. You then enter a designated danger area - all safety procedures
in respect of work in such an area agreed for maintenance personnel
and as detailed in the crane manual must be adhered to.
The gate at the front of the service platform must be in the fully raised
position while personnel are on the service platform.
Debe ser usado un arnés de seguridad colocado a un punto de

anclaje seguro.
A safety harness affixed to a secure anchor point must be worn
129
20. TWO SIGNS

MAT. NO. 10659764
Fitted on Access Gates to Trolley Inspection Platform.
Ref. No. IR8221-820.120
PRECAUCION!
CAUTION!
Para acceder a la plataforma de inspección del Carro, la

grúa debe estar inhabilitada por el botón de parada de
emergencia. Luego ingrese al área peligrosa señalada.
Deben ser respetados todos los procedimientos de
seguridad respecto de cada área, acordados por el
personal de mantenimiento y detallados en el manual de la
grúa.
To access trolley inspection platform crane must be

disabled by pushing emergency stop button and then safety
bar can be raised. You then enter a designated danger area
- all safety procedures in respect of work in such an area
agreed for maintenance personnel and as detailed in the
Debe ser usado un arnés de seguridad colocado a un

punto de anclaje seguro.
A safety harness affixed to a secure anchor point must be

worn.
130
21. ONE SIGNS

MAT. NO. 10659765
Fitted on Access Gate at rear of Main beam to cabin/trolley Inspection
Platform.
Ref. No. IR8221-820.121
PRECAUCION!
CAUTION!
No avance más de aquí hasta que el Carro este estacionado

en forma segura frente al acceso de la plataforma de
inspección. Luego podrá ingresar.
Deben ser respetados todos los procedimientos de trabajo
respecto de cada área, acordados por el personal de
mantenimiento y detallados en el manual de la grúa.
No entry beyond this point until trolley is safely parked over

cabin inspection platform, and platform front gate is
secured in raised position.
You then enter a designated danger area - all safety
procedures in respect of work in such an area agreed for
maintenance personnel and as detailed in the crane manual
must be adhered to.
Debe ser usado un arnés de seguridad colocado a un

punto de anclaje seguro.
A safety harness affixed to a secure anchor point must be

worn
131
22. THREE SIGNS

MAT. NO. 10659766
Fitted at the entry to Trim/list/skew, A-frame and hoist overload.
Ref. No. IR 8221-820.122
PELIGRO!
USTED ESTA ENTRANDO EN UN ÁREA PELIGROSA.
WARNING!
YOU ARE NOW ENTERING A DESIGNATED DANGER AREA
Deben ser respetados todos los procedimientos de trabajo

respecto de cada área, acordados por el personal de
mantenimiento y detallados en el manual de la grúa.
Prestar especial atención cuando la grúa esta encendida.
All safety procedures in respect of work in such an area agreed

for maintenance personnel and instructions as detailed in the
Special attention has to be paid when crane is switched on.
Debe ser usado un arnés de seguridad colocado a un punto de

anclaje seguro.
A safety harness affixed to a secure anchor point must be worn
132
23 TWO SIGN
MAT. NO. 10659767
Fitted within on the machinery house service crane the Machinery House at
a prominent location close to the trap door.
Ref. No. IR8221 -820.123.
IMPORTANTE!
ASEGURESE QUE LA GRÚA SE BLOQUEA CUANDO

DOS PINES DE ANCLAJE NO ESTAN SIENDO
UTILIZADOS.
IMPORTANT!
Ensure that the service crane is locked with the

2 pins provided when not in use.
24 TWO SIGNS BLUE BACKGROUND WITH WHITE TEXT
MAT. NO. 10659768

Fitted on the outside of the machinery house entry doors.
Ref. No. IR 8221-820.124.
IMPORTANTE!
Usar protección auditiva.
IMPORTANT!
Ear protection must be worn
133
25 ONE SIGN
MAT. NO. 10659769

Fitted on the outside of the machinery house entry doors.
Ref. No. IR 8221-820.125.
PELIGRO!
No colocar cargas sobre las escotillas.
Warning!
Do not place loads on trapdoors
26 TWENTY SIGNS
MAT. NO. 10805582
Fitted close to grease points mainly trolley and machinery house couplings
etc.
Ref. No. IR9009-820.130
GREASE POINT
PUNTO DE ENGRASE
134
This page is for customer use
135
136
137
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Operators Manual

Crane Type: P167L – Super

Work No.: IR1874

Location: TPEP, Paita,

Liebherr Container Cranes

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AFTER SALES SERVICE ____________________________________________________________________9

STATEMENT OF LEGAL AUTHORITY _______________________________________________________ 10

GENERAL SAFETY PRECAUTIONS _________________________________________________________ 13

2 G. A. DRAWING AND CRANE LEGEND _________________________________________________ 17

2.1 GENERAL ASSEMBLY DRAWING ______________________________________________________ 19

3 SUMMARY OF SPECIFICATION _______________________________________________________ 23

3.1 MAIN TECHNICAL DATA ___________________________________________________________ 23

3.4.1 Energy Chain Trolley Supply System ___________________________________________ 33

4 LAYOUT OF CONTROLS _____________________________________________________________ 37

4.1 DRIVER'S CABIN EQUIPMENT ________________________________________________________ 37

5 PUTTING THE CRANE INTO SERVICE___________________________________________________ 65

6 PUTTING THE CRANE OUT OF SERVICE ________________________________________________ 69

7 OPERATING THE CRANE DRIVE UNITS _________________________________________________ 71

7.1 HOIST UNIT OPERATION ___________________________________________________________ 71

7.2 TROLLEY DRIVE SYSTEM OPERATION ___________________________________________________ 75

8 CHANGING LIFTING EQUIPMENT _____________________________________________________ 95

9 EMERGENCY FEATURES ____________________________________________________________ 99

9.1 GENERAL EMERGENCY STOPS ________________________________________________________ 99

10 SAFETY PROCEDURES AND SAFETY SIGNS ___________________________________________ 105

10.1 OPERATING SAFETY PROCEDURES ____________________________________________________ 105

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AFTER SALES SERVICE

Tel. No.: +353 (0)64 66 70257

Tel. No.: +353 (0)64 66 70257

Tel. No.: +353 (0)64 66 70226

If you would like to make any comments on the manual:

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STATEMENT OF LEGAL AUTHORITY

© Liebherr Container Cranes Ltd. Killarney, Co. Kerry, Ireland

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GENERAL SAFETY PRECAUTIONS

instructions and make them a working part of your safety programme.

Personnel entrusted with work on or operation of the container crane

CRANE WORK NO.: IR 1874

LOCATION: TPEP, PAITA, PERU.

This manual is composed of five parts:

2 G. A. DRAWING AND CRANE LEGEND

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2.1 GENERAL ASSEMBLY DRAWING

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2.2 CRANE LEGEND

ITEM DESCRIPTION DRG. NO. ITEM DESCRIPTION DRG. NO.

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CRANE WORK NO.: IR 1874

DRAWING NO.: IR 9425-000000

LOCATION: TPEP, PORT OF PAITA, PERU.

3.1 MAIN TECHNICAL DATA

45.0 Tonnes 55 Tonnes 65 Tonnes *70 Tonnes

*Note: Heavy hook load of 70 Tonnes is restricted to a limited trolley travel

The drive mechanisms comply with F.E.M. / 1.001-1987 Revised 1998

The drive mechanisms are classified as follows:

Single Lift Twin Lift Hook Beam

Main Hoist Drive T8-L2-M8 T5-L2-M5 T4-L2-M4

Trolley Travel Drive T8-L2-M8 T5-L2-M5

Long Travel Drive T5-L2-M5 T5-L2-M5

Derrick Drive T4-L2-M4