Main Crane_Manuale U M - M1702S - GENER

Prévia do material em texto

Marine Crane 
 
M170/2S 
 
 
 
 
 
 
 
 
 
 
 
Use & maintenance manual 
Documentation book 
 
SORMEC s.r.l. 
 C.da Sasi area artigianale, ALCAMO (TP) ITALY 
 ++39-924-502655 FAX ++39-924-27047 
 
INDEX 
 
SORMEC s.r.l. 
MAINTENANCE MANUAL 
 
1 CRANE DESCRIPTION 
1.1 INTRODUCTION 
1.2 WORKING TEMPERATURE 
1.3 INDICATION OF THE CRANE MODEL 
1.4 GENERAL ARRANGMENT 
1.5 HYDRAULIC POWER PACK 
1.6 STRENGTH CALCULATION 
1.7 IDENTIFICATION OF THE MAIN COMPONENTS 
1.8 CRANE ACTUATION 
 
2 DIRECTION FOR THE USE OF THE 
CRANE 
2.1 RECOMMENDACTIONS FOR THE USE 
2.2 OPERATIVE WORKING SIGNALS 
 
3 SAFETY NORMS 
4 INSTALLATION OF A SORMEC 
CRANE 
5 MAINTENANCE 
5.1 REGULAR INSPECTION 
5.2 ANNUAL INSPECTION 
5.3 DEFICIENCIES ARISING FROM INSPECTION 
5.4 INSPECTION RECORDS 
5.5 CRANES NOT IN REGULAR USE 
5.6 TRAINING AND RULES OF MAINTENANCE AND 
OPERATING STAFF 
5.7 ROPES 
5.8 ROPES MAINTENANCE PLANNING 
5.9 WINCH DRUMS MAINTENANCE PLANNING 
5.10 WINCH BRAKES 
5.11 HOOK AND HOOK BLOCKS 
5.12 SLEWRING BEARING AND FASTENERS 
5.13 WELDED PEDESTAL 
5.14 BOLTED PEDESTAL 
5.15 BOOMS 
5.16 ELECTRIC MOTORS 
5.17 HYDRAULIC OIL - FILTER CLEANING 
5.18 CHANGE OF HYDRAULIC OIL 
5.19 CONTROL VALVES BLOCK 
5.20 BLOCK VALVES 
5.21 HYDRAULIC CONNECTIONS 
5.22 LUBRICATION 
 
 
6 FUNCTIONAL INSPECTION 
6.1 PUMP FUNCTIONAL CHECK 
6.2 SETTING OF THE CONTROL VALVES BLOCK 
7 LOAD MOMENT LIMIT – OPTIONAL 
SAFETY DEVICE 
7.1 FUNCTIONAL SYSTEM 
7.2 MAINTENANCE 
8 HOISTING ACCESSORIES 
8.1 WORKING AT HOOK 
8.2 WORKING AT WINCH 
8.3 NUMBER OF WIRE ROPE REEVES 
8.4 COUNTERWEIGHT 
8.5 HOOK 
8.6 STOWING POSITION 
8.7 END STROKE DEVICE 
8.8 USE OF THE WINCH 
8.9 LOAD HANDLING 
8.10 PENDULUM EFFECT 
8.11 LOAD HOISTING 
8.12 LOAD APPLICATION 
8.13 HOOK SAFETY LATCH 
8.14 OPERATIONAL PERFORMANCES 
8.15 WIRE ROPE REEVES 
9 TROUBLE SHOOTING 
10 HYDRAULIC CIRCUIT 
11 ELECTRIC CIRCUIT 
 
 
SORMEC s.r.l. 
MAINTENANCE MANUAL 
1 
1. CRANE DESCRIPTION 
1.1 INTRODUCTION 
The Sormec marine cranes are hydraulic lifting appliances suitable for installation 
on quay, deck, on offshore platforms, driven by electro-hydraulic power units. 
The Sormec marine crane’s structure is composed of welded box type girders 
made from high tensile steel, the booms are of telescoping type, stiff boom type 
and knuckle boom type. The manufacturing materials comply with the 
requirements of the Leading Classification Societies such as R.I.N.A. L.R.S. 
Bureau Veritas, ABS, DNK etc.. 
The welding and the welders are in accordance with the ASME NORMS. 
All Sormec cranes are designed and calculated in accordance to DIN 15018. 
Strength verifications in compliance with other standards are available upon 
request. 
 
1.2 WORKING TEMPERATURE 
Sormec marine cranes can normally operate at 
temperatures varying from -10°C to + 40°C. 
For more severe weather conditions the crane has to be 
built with special materials and components. 
 
1.3 INDICATIONS OF THE CRANE MODEL 
At one side of the crane column, in a visible position, a manufacturing-plate will be 
attached, indicating all necessary details for the identification of the crane. 
Herebeside, a manufacturing plate fac-simile is shown. 
 
 
 
 
 
 
 
 
 
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MAINTENANCE MANUAL 
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1.4 GENERAL ARRANGEMENT 
 
 
 
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MAINTENANCE MANUAL 
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1.5 HYDRAULIC POWERPACK 
 
 
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MAINTENANCE MANUAL 
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1.6 STRENGTH CALCULATION 
 
 
 
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MAINTENANCE MANUAL 
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1.7 IDENTIFICATION OF THE MAIN COMPONENTS 
A sketch of the crane is shown here below, from which all crane components can 
be identified: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
1 Pedestal 7 1st Extension 
2 Slewing Ring 8 2nd Extension 
3 Crane Column 9 1st Extension Cylinder 
4 Boom 10 2nd Extension Cylinder 
5 Boom Cylinders 11 Sheave Block 
6 Winch 12 
 
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MAINTENANCE MANUAL 
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1.8 CRANE ACTUATION 
Even if the operator has previous experience in driving lifting equipments, we 
would recommend the complete reading of this hand book. Sormec declines all 
responsibility in case of damages caused by an untrained operator. 
Sormec marine cranes are equipped with hand operated hydraulic control valves. 
Each control handle corresponds to a given motion. When released it returns back 
to its “neutral” position, thus stopping the crane motion. 
By manoeuvring the handle mildly, the crane will work smoothly and without any 
sudden acceleration. 
Cranes booms and hydraulic extensions are driven by double acting hydraulic 
cylinders. 
The rotation of the crane is executed by a toothed crown and a pinion system in 
which: 
• The pinion is operated by an oleodinamic reduction gear which is integral with 
the boom foot. 
• The toothed crown is made up of a slewing ring bearing with ball/rolling where 
the external crown is integral with the boom foot, the internal section is integral 
with the pedestal and is complete of the toothed crown coupled with pinion. 
 
All cranes motions are protected by pilot operated counterbalance valves which 
automatically prevent slippage and load drop in case of pipe failure or burst hoses. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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MAINTENANCE MANUAL 
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2. DIRECTIONS FOR THE USE OF THE CRANE 
2.1 RECOMMENDATIONS FOR THE USE 
• When starting up the crane, especially in cold weather, it is advisable to carry 
out some manoeuvres without load in order to reach the correct fluidity inside 
the hydraulic circuit and verify the regular crane working. When working with 
the crane, once the control handle is at its end stroke, release the handle 
immediately to avoid unnecessary oil overheating. 
 
• Avoid any sudden stop of the crane movements when the load is hanging on. 
Because this, during the lowering manoeuvres mainly, may damage and 
unnecessarily stress the crane. 
 
• Avoid sudden and abrupt manoeuvres. 
Operate the control levers smoothly and 
gradually. 
 
• Operate the crane control levers following 
the instructions shown on the knob labels. 
 
• Never drag loads along the deck or the 
ground, but slew them raised from deck or 
ground. 
 
• In case of welding to be carried out on 
pieces suspended by the crane hook: never 
use the crane hook, never use the crane 
structure as the weld earth path. 
 
• Make sure that the loads lifted, in relation to the outreaches, do not exceed the 
load chart ratings. 
 
 
 
 
 
 
 
 
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• The crane load chart must be carefully respected especially in case the manoeuvre to 
be executed is that to lift a load close to the crane and move it far away. Never trust on 
the intervention of the overpressure valves, which might be unset or out of order if 
not constantly inspected 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
• Crane must be properly maintained so as to overcome possible periodical 
inspections made by the Inspection Bodies. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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2.2 OPERATIVE WORKING SIGNALS 
In case the crane’s operator, from this operating spot, cannot see the load to be 
handled, a communication with another operator is then necessary. 
For that purpose the following system of clear visual signals is advisable: 
 
 
Should the operator not clearly understand the signals, the crane must not be 
activated. The operator and the signalman can decide, before starting any loading 
operation, to use a different communication system. 
 
 
 
 
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3. SAFETY NORMS 
Before manoeuvring the crane, make sure that the hook and omega are perfectly 
efficient. 
 
Make sure that the lifted loads, in relation to the outreaches, do not exceed those 
stated on the diagram. 
Please remember that the load diagram gives maximum lifting capacities and in 
case of supplementary equipments (such as grabs, power blocks, supplementary 
hooks etc.) it is necessary to deduce the weight of the accessories from the ratedloads. 
 
 
Never walk under an overhanging load and 
never stand in the crane operating area. 
Never tamper with the crane hydraulic 
circuit. Please make sure that nobody 
stands or walks in the crane operating 
area. 
 
 
 
 
 
It is Strictly forbidden to hoist (with the winch) higher loads than the ones given on the 
load diagram. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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MAINTENANCE MANUAL 
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4. INSTALLATION OF A SORMEC CRANE 
The crane arrives complete with supports for installation and screws. 
 
PROCEDURE OF INSTALLATION: 
 
1. Position the pedestal in the location pre-arranged for the installation. 
2. Weld the pedestal along the whole contour. 
 
3. Position the crane on the pedestal and start tightening all bolts . 
4. Rotate the column to create a coincidence between the hole in the column 
plate (detail A) and the bolts head. 
5. Tighten the bolts with a torque as report in the Page 13, by a dynamometric 
key. 
 
 
 
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MAINTENANCE MANUAL 
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The bolt connection is crucial to the slew bearing function and life. A proper 
fastening of the slew bearing is required by relevant calculation. This calculation 
determines the quantity and preload force of the fastening bolts. 
Proper preload is met with: 
 
1. High precision torque wrench 
2. Hydraulic tensioning equipment 
3. length measure on calibrated bolts 
 
 
The torque is affected by: bolt quality and grade thread connection friction nad 
friction between the contact surfaces of bolt head, nut and parts themselves. 
 
 
The bolts must be carefully tightened crosswise to the specified preload. 
 
 
 
 
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MAINTENANCE MANUAL 
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The tightening torque MA to pre-load FM, for a medium friction value of μG ≈ μK = 
0.14, is indicated in the following table. 
 
Strength class to DIN/ISO 
898 
8.8 10.9 12.9 
Yield limit Rp 0,2 N/mm2 640 for ≥ M 16 
660 for > M 16 
940 1100 
Metric 
ISO- 
thread 
DIM 13 
Cross section 
of area under 
stress 
 
AS 
mm2 
Cross section 
of thread 
 
 
AT 
mm2 
Clamping force 
 
 
FM 
N 
For hydr. 
and electric 
torque 
wrench 
Mλ 
Nm 
Ma' 0.9 Ma * 
For spanner 
 
 
Mλ' 
Nm 
Clamping force 
 
 
FM 
N 
For hydr. 
and electric 
torque 
wrench 
Mλ 
Nm 
Ma' 0.9 Ma * 
For spanner 
 
 
Mλ' 
Nm 
Clamping force 
 
 
FM 
N 
For hydr. 
and electric 
torque 
wrench 
Mλ 
Nm 
Ma' 0.9 Ma * 
For spanner 
 
 
Mλ' 
Nm 
M12 84.3 76.2 38500 87 78 56000 130 117 66000 150 135 
M14 115 105 53000 140 126 77000 205 184 90000 240 216 
M16 157 144 72000 215 193 106000 310 279 124000 370 333 
M18 193 175 91000 300 270 129000 430 387 151000 510 459 
M20 245 225 117000 430 378 166000 620 558 194000 720 648 
M22 303 282 146000 580 522 208000 830 747 243000 970 873 
M24 353 324 168000 740 666 239000 1060 954 280000 1240 1116 
M27 459 427 221000 1100 990 315000 1550 1395 370000 1850 1665 
M30 561 519 270000 1500 1350 385000 2100 1890 450000 2500 2250 
M33 694 647 335000 
Determined bolt 
through yield 
measurement 
480000 
Determined bolt 
through yield 
measurement 
560000 
Determined bolt 
through yield 
measurement 
M36 817 759 395000 560000 660000 
M39 976 913 475000 670000 790000 
M42 1120 1045 542000 772000 904000 
M45 1300 1224 635000 905000 1059000 
M48 1470 1377 714000 1018000 1191000 
M52 1760 1652 857000 1221000 1429000 
M56 2030 1905 989000 1408000 1648000 
M60 2360 2227 1156000 1647000 1927000 
* Mλ will change with deviating μG ≈ μK 
 
Dry threads require higher tightening torques, heavily oiled threads require lower 
tightening torques. 
 
It is absolutely necessary to tighten the bolts to the required preload. It is to be 
ensured that the necessary bolt torque data are maintained over the whole time of 
operation. We recommend to check the torque after 3 month of operation and than 
after 1 year. 
 
NOTE: In no case securing elements such as loch and spring washers may be 
used. Only the preloading force of the bolt serves to secure the bolt. 
 
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MAINTENANCE MANUAL 
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Boom connecting Instructions ( If Present ) 
 
 
 
Connect the boom and tighten the bolts (following the sequence shown in the draw 
above) with a torque as report in the Page 13 by a dynamometric key. 
 
5. MAINTENANCE 
These maintenance planning identify: 
a. Deficiencies which could reduce the capability and operational safety of the 
crane. 
b. Actions required to correct deficiencies to maintain good operational 
capability 
It is envisaged that this Recommended Practice will assist Operators in 
development of their own Inspection and Maintenance schedules according to 
their specific equipment and its location and operational use. Where established 
Inspection and Maintenance schedules are in place, the Operator may use this 
Recommended Practice to support or complement such schedules as appropriate. 
It is expected that the crane and its elements, particularly those of high utilization 
such as prime mover, gearboxes, pumps, motors etc. would be maintained on the 
basis of condition. The frequency of Inspection and levels of Maintenance stated 
in this Recommended Practice are for guidance only. 
 
 
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5.1 REGULAR INSPECTION 
For cranes in regular service, the inspection intervals are dependent upon the 
nature of the cranes components or systems and of the degree of their exposure 
to wear, deterioration or malfunction and of the consequences to operational 
safety. Two inspection categories have been assigned herein 'frequent' and 
'periodic' 
a. Frequent inspection - visual daily to monthly intervals 
b. Periodic inspection - at stated intervals which shall include daily and monthly 
inspection. 
 
5.2 ANNUAL INSPECTION 
Each crane shall be inspected fully every 12 months by a qualified inspector, 
whereby all remedial work will be identified and cleared prior to issue of an 
inspection certificate. Annual inspection shall include regular inspection 
schedules. 
 
5.3 DEFICIENCIES ARISING FROM INSPECTION 
a. All deficiencies arising from inspections shall be carefully examined for 
impairing safe operation. In such instances the crane shall be taken out 
of service or its operation limited to remove the unsafe condition 
'CAUTION' notices shall be positioned at the control cabin and at the 
prime mover as appropriate. 
b. Where cranes have been subjected to major repair or modification to either 
structural members or to the main functional services, the cranes shall be 
thoroughly inspected and function/load tested by a qualified inspector. 
 
5.4 INSPECTION RECORDS 
a. Inspection details which include reports as well as records of repairs and 
modifications carried out on the cranes shall be dated and signed for monthly, 
quarterly and annual inspection. These records shall be kept readily available 
by the operator. 
 
5.5 CRANES NOT IN REGULAR USE 
Cranes which have been idle for a period of one month up to six months, shall be 
inspected according to the periodic requirements of Regular Inspection. 
 
 
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5.6 TRAINING AND RULES OF MAINTENANCE AND OPERATING 
STAFF 
Maintenance of Offshore and Harbour Lifting Equipment will primarily involve 
platform maintenance staff, crane driver and crane manufacturers staff. Such 
personnel should be competent in the services they provide. The minimum 
requirements expected of maintenance and operating personnel are as follows: 
 
• Maintenance Staff 
a. Understand fully the Crane Manufacturers procedures as described in the 
Maintenance and Instruction Manuals. 
b. Conversant with the cranes safe operational envelope e.g., lifting duties, 
safety systems/limits and of emergency recovery and safe shutdown 
procedures. 
c. Where appropriate to have received training and instruction on more 
specialized aspects of maintenance. 
d. Understand the effects of dynamic loading. 
 
• Crane Driver 
a. Physicallyable to operate the crane; able to judge distances heights and 
clearances during day and night operation under all weather conditions. 
b. Adequately trained for the type of crane being driven. The training should 
cover instruction at the crane manufacturer's works/test site followed by 
instruction by a qualified driver on the crane at it's location. 
c. Familiar with the cranes safe operational envelope e.g. lifting duties, safety 
systems/limits and of emergency recovery and safe shut down procedures. 
d. Correctly respond to all crane warning systems. 
e. Trained in day to day crane inspection including routine checks on lubrication 
levels, rope condition, loose or damaged components, healthy status check on 
safety systems and general wear and tear. 
f. Trained to perform routine maintenance tasks including all crane lubricants, 
rope change-out, hook/block change-out and general rigging. 
g. Fully conversant with the duties and instructions of the slinger 
h. Have an understanding of dynamic loading and effects on the crane 
 
 
 
 
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5.7 ROPES 
Crane ropes used for luff and load hoist systems, are often spooled onto their 
drums in multiple layers and, as such, they need to be tolerant to crushing and 
abrasion. The load hoist rope will usually be of non-rotating, multi-strand 
construction. Both rope types should incorporate an independent wire core with all 
wires in the construction galvanised. Galvanising gives added protection to the 
rope when in store whilst enhancing its fatigue life in operation. 
 
 
 
 
 
 
 
 
 
 
Where non-rotating rope is used, the following should be noted: 
 
a. Failure of non-rotating rope can occur suddenly and without apparent warning 
and is usually initiated by breakages of the inner wires of the construction. 
Total failure could therefore occur without showing any visible indication at the 
outer wires Evidence of one broken external wire, is a strong indicator that the 
rope may already have several broken internal wires and could therefore be 
close to total failure. 
b. Loss or drying-out of the lubricant accelerates corrosion and fatigue of the 
internal wires Such conditions will promote early failure of the rope. Close 
proximity of gas turbine exhausts and flare radiation effects in addition to a 
saline environment, will serve to exacerbate the problem. 
 
WIRES BREAK 
(BREAKAGES DUE TO FATIGUE 
STRENGTH) 
WIRES BREAK 
(BREAKAGES DUE TO EXCESSIVE 
TENSILE STRESS) 
REPEATED TEARING STRESSES CAN 
CAUSE WIRES RUN OUT OF THE ROPE
THE WIRE ROPE IS DEFORMED IN SUCH A WAY 
THAT THE INTERNAL SIDE IS VISIBLE OR RUST 
IS APPEARING 
 
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The following practices should be observed: 
 
The outer and inner wires of the rope should be inspected for any visible breaks. 
The internal wires should be examined by twist-opening the strands with rope 
grips or lever clamps. For non-rotating rope constructions, the ropes should be 
discarded if broken wires are found and /or corrosion is evident. For the rope, use 
discard criteria according to national regulations. Example: 
 
a. Ropes should be lubricated with a penetrative lubricant- oil with viscosity of 30 
SAE is recommended. The lubricant should be applied by pressure lubricator. 
It is essential that the lubricant penetrates the inner wires particularly on non-
rotating ropes. Never use viscous (thick/heavy) lubricants on wire rope, these 
create a harmful 'barrier' effect leading to corrosion and rapid failure of the 
internal wires. 
b. Rope change-out (according to rope condition or prevailing statutory 
requirements) should be undertaken only in accordance with the crane/rope 
manufacturers procedures. Where provided, dedicated spooling or rope 
change- out drums should always be used. 
c. Pendant ropes should be inspected and lubricated as for running ropes with 
particular attention paid to the condition of the wires local to the entry point at 
the terminations. With the application of good lubrication/inspection 
procedures pendant rope can be expected to remain in service for 3/5 years. 
d. Other ropes on the crane, which are not in the primary load path but which 
have important functions such as, safety harness wires, boom handrail wires, 
boom back stop support wires, constant tension wires (e.g., supporting 
temperature sensors in the luff system) etc. should be checked as part of the 
drivers daily routine, with a more thorough examination every three months. 
e. All rope terminations and anchor points should be examined on the same 
frequency as wire ropes. 
 
 
 
 
 
 
 
 
 
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5.8 ROPES MAINTENANCE PLANNING 
• Daily – Monthly 
a. Check rope is spooling evenly on drums without loss of pattern and without 
undue gapping. 
b. Check rope for condition - abrasion, particularly at flanges and cross-over 
points; crushing, usually due to slackly spooled rope corrosion, signs of rust; 
loss of lubricant, particularly on active sections e.g., continued use around 
sheaves; broken wires. 
c. Check rope for other abnormalities, e.g., spiralling, basketing etc. 
d. Check terminations for condition and security 
e. Check levels of lubrication at the rope and its terminations 
 
• Monthly - 3 Monthly 
Lubricate ropes using a penetrative lubricant with viscosity of 30 SAE by a 
pressure lubricator. For sections of rope which are difficult to access, such as 
'dead lengths' and terminations, lubricate by hand. 
 
• 3 Monthly - 12 Monthly 
Inspect the internal wires of the rope for corrosion, broken wires and lubricant 
quality. Use the correct tools - twist-grips and procedures as specified by the rope 
manufacturer only for this operation. 
 
• Change-Out 
According to rope condition and/or discard assessment . 
a. Check that the replacement rope is the correct size (diameter and length) and 
construction. Ensure these details are as specified by the crane manufacturer. 
b. Check that the test certificate clearly identifies with the rope and that the rope 
taken from store was on a 'first in', 'first out' basis. 
c. Only use change-out practices specified by the rope/crane manufacturer. 
d. Ensure new rope is not dragged over the ground/deck or fouls obstacles or 
any part of the crane structure when spooling onto the winch drums. Where 
possible use dedicated rope spooling gear. 
e. Check that 'turn' is not induced during spooling. 
f. Ensure all terminations are compatible with the rope 
 
 
 
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5.9 WINCH DRUMS MAINTENANCE PLANNING 
• Daily - Monthly 
a. Check drum flanges and kicker strip if fitted, for undue rope scrubbing or 
heavy wear. 
b. Check drum flanges for spreading or splaying. 
c. Check drum mountings for general condition and security. 
d. Check condition of all external lubrication/environmental seals. 
e. Check brake drums/discs for scoring or uneven wear. 
f. Check for condition and security of rope termination clamps at drum flanges 
 
• Monthly - 6 Monthly 
a. Check all major fasteners associated with the drum against the 
manufacturers recommended. Typically and where applicable, such fasteners 
would be: 
i. Main drum unit foundation bolts 
ii. Bolted/screwed-on drum flanges 
iii. Bolted/screwed-on back stops or brake drums/discs. 
iv. Bolted/screwed-on back stops or spragg clutches 
v. Bolted/screwed-on ratchet (boom hoist drum only) 
b. Check condition and securement of final drive gear/chain pinions/wheels. 
c. Visually check for 'cracks' at all main weld areas on drum and drive mounting; 
this may be indicated initially by local paint cracking. 
 
 After 1000 hours of winch operation (with average operating cycles at 60% 
nominal load) a full service of the negative brake is mandatory. This work 
must be done by the Producer. 
 
 
 
 
 
 
 
 
 
 
 
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5.10 HOOK AND HOOK BLOCKS 
• Daily- Monthly 
a. Check safety catch functions correctly without hang-up. 
b. Check that hook swivels smoothly and that by 'feel' there are no signs of 
bearing 'catch' or brinnelling. 
c. Check hook for increased admittance dimension, undue flattening (burring) 
'nicks' and cracks. 
d. Check that all split pins securing hook swivel nut and rope guards are intact. 
e. Ensure rope anchor points are in good order and properly secured. 
f. Visually check that all sheave and hook shank bearing seals are sound. 
g. Ensure all rope guards are secure and are set at correct clearances from 
Sheaves. 
h. Check sheave tread profiles for undue wear and damage. 
i. Ensure all lubricant channels (grease points) are clear, undamaged and 
provide free flow of lubricant. 
 
5.11 SLEWRING BEARING AND FASTENERS 
• Monthly to 6 Monthly 
a. Check the tension in four bolts (one in each quadrant) at slewring to pedestal 
and slewring to crane according to crane manufacturers procedures as show 
in the chart on page 15. 
b. Check bolt tension in any associated retaining device. 
c. Check that the main bearing environmental seals are in good condition. 
Renew immediately if damaged or distorted. 
d. Check final drive slew gear teeth for undue wear - tearing and plucking. 
e. Ensure pinion drive has full face width contact and correct pitch line setting - 
check backlash. 
f. Ensure all guards are in place, correctly fitted and secure. 
g. Check rocking clearances. 
h. Ensure all lubrication points are undamaged and provide free flow of lubricant. 
 
• 6 Months to 12 Months 
a. Remove at least one fastener from each mounting circle and examine for 
corrosion and stress corrosion cracking. Renew rather than replace the bolt. 
b. Check lubricant for water content and particle content. 
 
 
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5.12 WELDED PEDESTAL 
• Every 6 - 12 Months 
Visually inspect all welds for cracks and corrosion - if in doubt, use NDT 
inspection methods 
• Every 5 Years 
Blast clean selective welds and fully inspect using NDT procedures. This 
inspection should also extend into the pedestal column/stand and deck 
structure. The scope of this inspection should be developed by a competent 
Structural Engineer 
 
5.13 BOLTED PEDESTAL 
• Monthly to 6 Monthly 
a. Check the tension in four bolts (one in each quadrant) at slew ring to pedestal 
and slew ring to crane according to crane manufacturers procedures as show 
in the chart on page 15. 
b. Check bolt tension in any associated retaining device. 
• 6 Months to 12 Months 
a. Remove at least one fastener from each mounting circle and examine for 
corrosion and stress corrosion cracking. Renew rather than replace the bolt. 
b. Check lubricant for water content and particle content. 
 
5.14 BOOMS 
• Daily - Monthly 
a. Check that all aircraft warning , floodlighting and any other luminaries and their 
enclosures used on the boom are securely in place, free of damage and that 
they function correctly. (if Installed) 
b. Ensure all appendages are secure and that all pins, bolts, split pins, etc., are 
in good condition. 
c. Check condition of sheave treads and bearing seals and security of rope 
guards. 
d. Check condition and security of rope anchor and load sensor points. 
e. Ensure all walkways and handrail systems are secure and are in good order. 
f. Check visually for undue cracking of paint at welded joints - investigate further 
if in doubt. 
 
 
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• 6 Monthly - 12 Monthly 
a. Remove and examine for corrosion and thread condition one fastener from 
one lower boom section flange joint. Replenish with new bolt. 
b. By hand check sheaves for smooth rotation, and lateral movement - this is 
best done at time of rope change-out. 
c. Check rope guards for wear 
• Every 5 Years 
Overhaul beam completely and fully NDT inspect selected welded joints. The 
scope of this inspection should be developed by a competent Structural Engineer. 
 
 
5.15 ELECTRIC MOTORS 
• Daily - Monthly 
a. Ensure all guards are secure and correctly fitted 
b. Check all locally mounted gauges/instruments are functioning 
c. Check for condition, security and chaffing of locally run electrical cables 
d. Check for correct function of local start/stop and emergency stop controls 
e. Check for securement and performance of ancillary equipment i.e., 
compressors etc. 
 
 
5.16 HYDRAULIC OIL-FILTER CLEANING 
For proper crane functioning, use hydraulic oil of HLP 
type, ISO viscosity, to be selected according to the outside 
temperature as per table below: 
 
 
 
-15 °C ÷ 0 °C VG 15 
0 °C ÷ +40 °C VG 46 
+40 °C < °C VG 68 
 
 
 
 
 
 
 
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24 
 
 
OUTSIDE TEMPERATURE 
 -15°C ÷ 0°C 0°C ÷ +40°C > +40°C 
AGIP OSO15 OSO 48 OSO 68 
ESSO NUTO H 16 NUTO H 46 NUTO H 68 
IP HIDRUS OIL 15 HIDRUS OIL 46 HIDRUS OIL 68 
MOBIL DTE 22 DTE 25 DTE 26 
SHELL TELLUS 22 TELLUS 46 TELLUS 68 
 
 
 
 
For proper crane functioning, a filter must be installed on the electro-hydraulic power 
pack. The return line filter between the control valves block and the oil tank is 30 microns. 
The filter must be cleaned after 8 working hours and subsequently every 50 working 
hours. 
The cartridges must be washed with solvents and air sprayed. 
The filter body must show no impurities and no cracks. 
If this occurs it is necessary to replace the cartridge with another one having similar 
features. 
 
It is advisable to replace all filter cartridges at any oil change 
 
 
5.17 CHANGE OF HYDRAULIC OIL 
The hydraulic oil has to be replaced with the same make or with similar one. 
To change the hydraulic oil please refer to the following operations: 
a. Remove the oil left in the tank, wash the inside of it and the filter. 
b. Fill in the tank with the same quantity of clean oil as the one removed. 
c. Close the crane cylinders completely. Make sure that the oil coming out from 
the return pipe fitted to the upper filter doesn’t flow into the tank: this oil is dirty. 
d. Fill in the oil tank with clean oil, up to the correct level 
 
 
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5.18 CONTROL VALVES BLOCK 
For the control of the crane motions, all Sormec 
marine cranes are equipped with hydraulic control 
valves block, of a proportional type. Each element 
is protected by two auxiliary valves: one on the 
suction line and one on the return line. 
The complete block is also protected by a main 
check valve (main valve). Operate the crane 
controls following the instructions placed on each 
knob. 
When the selected lever is released, it returns 
automatically to the neutral position and it stops 
the motion. Operate the lever smoothly and 
gradually to avoid abrupt movements. Sormec 
crane control banks may allow (if requested) 
several movements to be carried out 
simultaneously. When maintenance on the crane 
is carried out, verify that the handles automatically 
return to their neutral position, oil the pins on 
which the handle turns, if necessary. 
Verify that no leak appears. 
 
In case it is necessary to dismantle the control block elements of crane, when re-
assembling the whole, pay particular attention to the tightening of the fixing bolts. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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5.19 OVERCENTER VALVES 
On all boom cylinders brake valves are fitted. 
The exact name is “pilot operated counter 
balance” valves and they prevent the slippage in 
the event of a pipe failure or burst hose. 
These valves allow the oil to come out from the 
cylinder only when, from the opposite side of the 
control bank, oil is delivered to increase pressure 
and open the valve. 
In this way it is impossible to move the booms if 
the hydraulic pump is not working. 
 
Sormec’s technological aim has always been to 
create hydraulic circuits more and more reliable 
and capable of facing any problems of structural 
overload. 
To this purpose, Sormec has employed the 
“block valves”whose further function is to let the 
oil out of the cylinder each time the max, 
pressure is reached. 
 
In case of replacement, to have perfectly working 
crane and with the same performances please 
remember to assemble Sormec valves (ref. to 
spare parts list) with the same setting values. 
 
When the ordinary maintenance on the crane is 
carried out please also verify that no oil leak 
appears on the block valves. 
 
 
 
 
 
 
 
 
 
 
 
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5.20 HYDRAULIC CONNECTIONS 
The fittings used on the Sormec cranes hydraulic circuits are of type “TRIPLE-
LOK, UNFJIC 37, BSP”, according to the following approvals: SAE j 514, ASME, 
MILITARY STANDARD from MS 51500 up to MS 51534. 
Further to the above, the Sormec fittings are also accepted by the main 
classification Societies such as Lloyd’s Register, Det Norske Veritas, 
Germanischer Lloyd and R.I.Na. 
The only maintenance required is the prevention from corrosion. 
Particularly, during the first working months of the crane, it may happen that some 
oil leaks in the junction points, especially at the pipes edges. 
In this case you should first of all screw it manually to the end of the stroke and 
then tighten it with a spanner by not more that half a turn. 
If there is still oil leak from the connection, you should seek the cause in the 
coupling surfaces, as it is absolutely useless trying to achieve the perfect tightness 
by tightening the fitting more than the given instructions. 
The fittings would be then subject to a useless strain, involving very dangerous 
conditions. 
Listed below are the torque wrench settings for fittings with O’ring seals and 
revolving counter nuts. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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TORQUE WRENCH FOR O’ RING FITTING AND COUNTERNUTS 
 
Threads 
UN - UNF 
Torque 
Nm 
Threads 
GAS 
Torque 
Nm 
Threads 
metrical 
Torque 
Nm 
7/16-20 18 ÷ 20 1/8 18 ÷ 20 10 x 1 18 ÷ 20 
1/2-20 21 ÷ 24 1/4 25 ÷ 30 12 x 1,5 20 ÷ 25 
9/16-18 31 ÷ 33 3/8 45 ÷ 55 14 x1,5 25 ÷ 30 
3/4-16 58 ÷ 68 1/2 75 ÷ 96 16 x 1,5 45 ÷ 55 
7/8-14 88 ÷ 98 3/4 104 ÷ 160 18 x 1,5 50 ÷ 60 
1”1 /16-12 157 ÷170 1” 220 ÷250 20 x 1,5 70 ÷ 90 
1”7/16-12 185 ÷ 215 1”1/2 230 ÷ 260 22 x 1,5 75 ÷ 96 
1”5 /16-12 240 ÷ 270 1”1/4 350 ÷ 470 26 x 1,5 110 ÷ 130 
1”3/2-12 250 ÷ 285 27 x 2 130 ÷ 150 
1”2/2-12 370 ÷ 450 33 x 2 220 ÷ 250 
 
 
 
When a replacement of a fitting is needed, please carefully check that all 
coupling cone shaped areas are perfectly clean to guarantee the tightness. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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5.21 LUBRICATION 
The articulation’s pins and the extensions need a periodic lubrication. Such 
intervals of greasing the articulation pins vary in relationship to the use and the 
particular type of crane. In the underlying chart are show the periods of greasing 
recommended. 
 
 
Inject fat in pressure until it doesn't escape from the coupled elements so that to 
replace the old lubricant. After the lubrication, perform some complete movements 
of all the articulations of the crane and add some fat to guarantee an optimal 
lubrication. 
 
 
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Clean the hydraulic extensions from the impurities. Keep the sliding pod well 
greasing, cover the external inferior side and the external superior side from the 
telescopic arm with grease. To make sure that all the points of greasing are 
always well lubricated, using the type of suitable grease on the chart. Other 
greases having the same characteristics can be used. 
 
 
 
GREASING POINT TYPE OF GREASE 
GREASING 
PERIODS 
1 - ROTATING TURRET PIN 
Shell Albida 
GREASE 
EP 2 
50 HOURS 
2 – SLEWING RING 50 HOURS 
3 – CYLINDER PIN 50 HOURS 
4 – SHEAVE PIN 8 HOURS 
5 – SLIDING POD & 
EXTENSION 8 HOURS 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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6. FUNCTIONAL INSPECTIONS 
6.1 PUMP FUNCTIONAL CHECK 
The pump capacity must correspond, for each crane model, to the values given on 
the power pack. 
 
6.2 SETTING OF THE CONTROL VALVES BLOCK 
To set the distributor proceed as follows: 
a. Check that the pressure at the power pack is normal 
b. For each control valve the following instructions must be carried out: 
1. Installation of a control manometer on the delivery. 
2. set the pressure until it reaches the service on using a screwdriver on the 
adjusting screw relative to the same control. 
3. Once the above conditions are reached, block the screw with a nut. 
4. Carry out movement tests relative to the valve 
c. Carry out the same operation on all the distributor valves. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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7. LOAD MOMENT LIMIT - OPTIONAL SAFETY DEVICE 
7.1 FUNCTIONAL SYSTEM 
Where the load moment limiting device is foreseen, proceed as follows: 
a) Be sure that the pressure at the power pack is correct. 
b) Install a manometer on the delivery . 
c) Set the pressure to reach the working pressure adapt the relative screw until the 
service pressure is reached. 
d) Once the above conditions are reached, block the screw with a lock nut. 
e) The working pressure is that shown on the table below. 
 
Please find, here following, an example on how setting has to be carried out: 
The load moment limit must intervene when, by operating the crane, the maximum 
loading point is achieved. 
If the above operation cannot be executed it means that: 
- the load moment limit is not properly set (too high values) 
- the control valve block is not properly set . 
 
In case the activation point of the load moment limit needs to be changed, adjust the 
setting of the reference valve as follows: 
- tighten it if the load moment limit actuates too early or loose it if the load moment 
limit actuates too late 
 
7.2 MAINTENANCE 
The application of the load moment limit involves the use of a filter installed close 
to the control valves block. 
This filter needs periodical cleaning, as do all other filters installed on the crane. 
 
Furthermore, it is advisable to check periodically the proper working of the load 
moment limit hydraulics as well. 
 
 
 
 
 
 
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8. HOISTING ACCESSORIES 
We believe that a paragraph of this handbook should be dedicated to the 
accessories which can be installed to the crane’s hook for lifting the load. The 
experience has taught us that unintentional accidents represent a minimum 
percentage compared to those caused by neglection or non-compliance with the 
basic safety norms. Carelessness can cause damages to properties or even worse 
injuries to people. We always recommend to verify, periodically, the integrity of the 
wire ropes and belts using for lifting the loads. When selecting their diameters 
please consider the additional stress they are subject to when not used in vertical 
position. 
8.1 WORKING AT HOOK 
Before handling the load, make sure it is balanced 
by lifting it a few centimetres only. Never store the 
ropes in wet areas and never expose them to 
excessive heat. 
Never use chains connected with screw bolts. 
The incorrect application of the rope to the hook can 
open the hook safety latch. The safety latch must 
always return to its original seat after the ropes 
have been attached. 
8.2 WORKING AT WINCH 
When the use of the crane depends on the winch, 
the operator must be much more careful during 
ordinary operations with the crane; most of the 
accidents depend on the sheave block or load 
pendulum effect or by accidental breakage of the 
wire rope. 
Here below are some recommendations which 
should be carefully respected in order to operate 
with the crane safely and to improve its efficiency in 
the long run. 
8.3 NUMBER OF WIRE ROPE REEVES 
The number of original wire rope reeves supplied by Sormec cannot be modified, 
for any reason, by the customer or third parties. 
 
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8.4COUNTERWEIGHT 
A counterweight is installed at wire rope tip in order to 
properly hoist and lower the wire rope without bringing any 
damage to the same especially when the load is not 
hanged on. In case of winches with more than one reeve 
the sheave block can replace the counterweight. 
8.5 HOOK 
The supply of the winch, installed on the crane, always 
includes the hoisting hook. The most common system to 
install the hook to the wire rope is to use a wedge shaped 
socket. 
It is one of the operator responsibility to verify, before 
starting any job, that all mentioned components, 
particularly the hook safety latch is efficient and integral. 
8.6 STOWING POSITION 
The cylinders rods must be as much protected as possible. 
The hydraulic extensions should be re-entered as much as 
possible at the end of the working day. It is necessary to 
stow the crane at very low speed, making sure that no 
damage or impact occur between the crane itself and its 
hoisting accessories. 
In order to make it easier for the operator we recommend 
to lock the hoisting hook on a fastener and to tension the 
winch wire rope. 
8.7 END STROKE DEVICE 
The supply of a winch can also include the supply of an 
automatic end stroke device both for upward and downward 
wire rope control. 
The intervention of the end of stroke device immediately 
stops the crane’s operations, avoid to use the end stroke 
device voluntarily, especially with the maximum load 
hanged on; this would imply useless stresses to the crane 
structure. 
 
 
 
 
 
 
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8.8 USE OF THE WINCH 
Avoid to use the winch if the load hook stands on the ground. The inconvenients 
involved by hoisting the load hook from ground should be an irregular overlap of 
the wire rope or the running out of the rope from the drum. 
Before starting to hoist the load, move the crane winch at empty hook. This 
operation is extremely important especially when the crane and the winch have 
been stored for several days. The empty hook operations allow a proper of control 
of the winch function and guarantee the oil filling inside the winch brake. 
When the outside temperature is rather low (+5°/ -20° C) the above operations 
have to be carried out for several minutes before starting the ordinary work with 
the winch. 
 
8.9 LOAD HANDLING 
The load to be hoisted must be placed below 
the hook vertically. It is absolutely forbidden to 
hang a load in a different way, even in case of 
a lighter load compared to the winch hoisting 
performances. 
 
8.10 PENDULUM EFFECT 
In order to decrease the pendulum effect, bring the load as close as possible to 
the crane boom tip. A minimum distance between, 
the crane boom tip and the load will allow a faster 
load handling thus reducing the pendulum effect. 
 
8.11 LOAD HOISTING 
The load hoisting from the ground must be 
executed through the winch. If the load is topped 
by the crane main topping cylinder, the load will 
immediately move sideways with a dangerous 
oscillation. This oscillation will increase 
proportionally to the increase of the boom vertical 
position. 
 
 
 
 
 
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8.12 LOAD APPLICATION 
We highly recommend to always verify the integrity of the wire rope and belts in 
relation to the load to be hoisted up. When selecting the proper wire rope or belt 
diameters, please take into account superior strength the rope and belt have to 
stand when not working in vertical position. 
Before hoisting the load from ground, please verify if the load is balanced by lifting 
it up by some centimetres. Never use chains connected with screw bolts. 
 
8.13 HOOK SAFETY LATCH 
The hoisted load must be hanged to the hook 
making sure that the latch is completely closed. 
The application of wire ropes or chains in such a 
quantity that the latch cannot be closed, 
determinates a reduction of the safety 
performances as well as danger that the wire 
rope can run out of the hook with consequent 
load crash. 
 
8.14 OPERATIONAL PERFORMANCES 
1. It is absolutely forbidden to hang to the wire rope a load heavier than the winch 
hoisting capacity and trying to handle the load topping with the crane. The 
winch and all accessories would then be subject to an overstress which could 
involve the breakage or the damage of some of the components. 
2. It is absolutely forbidden to hoist with the winch a load heavier than the crane 
lifting performances, the crane should then be subject to an over stresses which 
could involve the breakage or the damage of some of the components. 
3. The maximum load at hook cannot exceed the maximum crane lifting capacity 
or the maximum winch hoisting capacity. 
 
 
 
 
 
 
 
 
 
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8.15 WIRE ROPE REEVES 
Check the sheaves, the transmission pulleys, the head pulleys very often. The 
structure must not show any deformation deriving from crashes/collisions and the 
structural strength must not be compromised by the corrosion. 
Pay particular attention to the pulley slewing motion which must not show 
excessive clearance, pay attention to the rope side walls which must not show any 
deformation, crack or breakage. 
 
 
The pulley slew on a support which needs to be periodically greased: this will 
increase the life of the bearings and decrease the 
slewing friction of the pulley itself. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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9. TROUBLE SHOOTING 
The following chapter reports some of the incovenients which might occur to the crane and the 
pertinent solutions Warning: in case of an inconvenient to the crane, never work on the hydraulic 
settings without the specific knowledge that such an action will solve the problem. 
 
FAULT CAUSE SOLUTION/REMEDY 
Noisy pump Low oil quantity inside the pump Verify the oil level (the crane must be 
folded), if necessary bring the oil inside 
the power pack to the right level 
 Dirty suction line filter the oil cannot 
flow through 
Dismount the filter, clean it or replace it 
if worn (see instructions given on the 
handbook) 
 Worn pump Verify the pump features. Compare the 
maximum pressure value shown on the 
gauge meter and the topping time of the 
main boom cylinder to the specific 
cranes data (see technical sheet 
referred to the crane hydraulic 
connections) 
 The pump support is loosen Verify the screw tightening which 
connect the pump to the electric motor 
 The bleeder vent inside the oil tank is 
plugged 
Verify that no piece of material or other 
things are left on the bleeder vent inside 
the oil tank 
The crane move jerks Low oil quantity inside the oil tank Verify the oil level (the crane must be 
folded), if necessary fill in additional oil 
which must have the same features (see 
handbook) 
 Worn pump Verify the pump features. Compare the 
maximum pressure value shown on the 
gauge meter and the topping time of the 
main boom cylinder to the specific crane 
data (see technical data sheet relative to 
the crane’s hydraulic connections) 
The crane doesn’t lift the rated loads The geometrical indications relative to 
the proper crane configuration are not 
respected 
Carefully read the handbook, chapter 
“Directions for use of the crane” 
 Insufficient pressure inside the crane 
hydraulic circuit 
Compare the maximum pressure value 
shown on the gauge meter with the 
specific crane data 
Control handle doesn’t return to the 
central seat 
Lack of lubricant on the handle linkage Remove the inferior support of the 
control handle and the cap placed i the 
opposite side of the control handle, 
Clean carefully and grease.. 
 Damage/breakage to the handle spring 
 
 
Remove the cap mounted to the 
opposite side of the control handle. 
Replace the spring, reference is shown 
on the spare parts of book 
 
 
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FAULT CAUSE SOLUTION/REMEDY 
The crane slewing doesn’t stop when 
the relativecontrol handle returns to its 
central seat 
Inefficient piloted block valve Replace the block valve with another 
one having similar properties and setting 
values 
One crane motion is slow The control valve handle doesn’t 
complete its stroke 
Verify that the handles fixing screws are 
not loosen. Verify that the rod return 
spring is opposite the control handle, on 
the control valves block tip 
 
The crane boom lowers when lifting 
rated loads 
Worn cylinder seal Identify the cylinder which moves in 
under loading. Replace the seal 
 
Replace the piloted block valve with 
another one same setting values 
 
Worn cylinder piloted block valve 
 
It’s impossible to inject grease from a 
greaser 
Broken greaser Replace the greaser, the code for order 
placing is shown on the spare parts book
 
Dismount the pin and remove the set 
grease. Inject new grease 
 The injected grease set 
Oil leakage from one hydraulic 
connection 
The connection is loosen Tighten the connection following the 
instructions given on the handbook to 
see the right torque wrench 
 A fittings has been damaged Replace the fitting: place the order giving 
the code number shown on the spare 
parts book 
Oil leakage from the bottom side of the 
crane base 
Worn slewing cylinders seals Dismount the slewing cylinders and 
replace the gaskets 
 
The crane has a winch with electro-
hydraulic end stroke device: no 
crane motion is allowed 
No electric supply to the system By means of a tester verify the right 
inlet tension in the crane electric 
circuit 
 Broken electric cable Verify the integrity of the electric 
cables and micro-switches 
 Jammed oil return electro valve At the boom of the electro valve 
there is a socket screw. Loose the 
counter nut and tighten the socket 
screw. In such a way the electro 
valve shuts mechanically. 
WARNING: with the electro valve 
off, the end stroke device does not 
work any longer, therefore such an 
operation must be done only in 
emergency cases 
 
 
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10. HYDRAULIC CIRCUIT 
 
 
 
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11. ELECTRIC CIRCUIT 
 
 
 
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