OPERATOR TRAINING

Note: pictures used in this slide show can differ from your machine or application / pls contact us if clarifications are needed
 Table of Contents

OPERATOR TRAINING 3
CRANE CONTROLS 7
CAB CONTROLS Seat / Joysticks General 8
CAB CONTROLS Seat / Joystick Functions 9
CAB CONTROLS Seat / Functions on Sticks 10
CAB CONTROLS Cabin / Foot Pedals Gantry ctrl 11
CAB CONTROLS Cabin / Foot Pedals Gantry ctrl 12
CAB CONTROLS Seat / right Console 13
CAB CONTROLS Rear Seat Controls 14
CAB CONTROLS Cabin Overload indication 15
CAB CONTROLS Pilot Control on/off 16
CAB CONTROLS EMM Display for Upper 17
CAB CONTROLS Crane Travel (Rail) 20
CONTROLS UPPER POWER UNIT on E12 22
CONTROLS LOWER POWER UNIT 28
EMM Control System Block Diagram 29
EMM MENU Structure 30
EMM Basic Screens General Information 31
EMM Display Icons 32
EMM Display Icons 33
EMM Display Icons 34
EMM basic Screen 1 Information 35
EMM Basic Screen 2 5 36
EMM Basic Screen 6 en 7 37
EMM Basic Screen Travel 38
EMM Real Time Crane Status (Primary) 42
EMM Real Time Crane Status (Secondary) 43
EMM overview different Setting Screens 44
EMM General Settings 45
EMM Underload - Boom Float Setting 46

May 21, 2015 BASIC: OPERATOR TRAINING 4

 Table of Contents

EMM Settings Screen Height Offset + Stick Angle Setting 47

EMM Settings Screen - Tare Setting 48
EMM Setting User Angle 49
EMM Semi-Automatic Cycle 50
EMM Weigh Scale Settings 51
EMM Other Settings Screens 52
EMM Reset Service Indication 53
E-Crane monitored Status & Securities UPPER 54
E-Crane monitored Status & Securities Gantry 55
Working with the Crane 56
STARTING the E-Crane 58
OPERATING an E-Crane combine Movements ! 59
OPERATING an E-Crane think proactive 60
OPERATING an E-crane Cleaning the Hold 61
MOVING LOADER into or out of a Ships Hold 62
MOVING LOADER into or out of a Ships Hold 63
MOVING LOADER into or out of a Ships Hold 64
GRAB CHANGE Step-by-Step Procedure 66
GRAB CHANGE Step-by-Step Procedure 67
GRAB CHANGE Step-by-Step Procedure 68
GRAB CHANGE Step-by-Step Procedure 69
GRAB CHANGE Step-by-Step Procedure 70
DAILY MAINTENANCE & CHECKS 71
FILLING LEVELS - Hydraulic Tank Lower Power Unit 72
FILLING LEVELS - Hydraulic Tank Upper 73
FILLING LEVEL Splitter Box Upper 74
FILLING LEVEL Swing drive(s) 76
FILLING LEVEL Swing Drive(s) Brake 77
FILLING LEVEL Crane Travel Gearbox(es) 78
FILLING LEVELS Central lubrication Pump(s) 79

May 21, 2015 BASIC: OPERATOR TRAINING 5

 Table of Contents

CHECK LUBRICATION SYSTEM(S) Blocked Line 80

CHECK LUBRICATION SYSTEM(S) restart after empty Reservoir 81
CHECK LUBRICATION SYSTEM(S) Square Gantry 83
CHECK LUBRICATION SYSTEM(S) Upper 85
CHECK LUBRICATION SYSTEM(S) Manual 86
MANUAL GREASING Connection Pins Cylinders 87
MANUAL GREASING Swing Bearing Gear 88
MANUAL GREASING - LMI & Grab Suspension 89
MANUAL GREASING Grab Rotator 90
MANUAL GREASING Grab Rotator 91
MANUAL GREASING Grab Rotator 92
MANUAL GREASING Two Cylinder Grab 93
MANUAL GREASING Orange Peel Grab 94
E-Crane PRE & POST Inspection Lists 95
success 96

May 21, 2015 BASIC: OPERATOR TRAINING 6

 CRANE CONTROLS

Check the manual for detailed information.

Some pictures might differ from your machine please contact us in case clarification is needed.

May 21, 2015 BASIC: OPERATOR TRAINING 7

CAB CONTROLS Seat / Joysticks General
JOYSTICK FRONT BUTTON - TRIGGER JOYSTICK TOP BUTTONS

LEFT RIGHT
May 21, 2015 BASIC: OPERATOR TRAINING 8
CAB CONTROLS Seat / Joystick Functions
LEFT JOYSTICK RIGHT JOYSTICK

Slewing = free slewing

Slewing = Positive torque
control based on position of
stick

position of the stick

determines the acceleration or
brake torque

Counter slew to decelerate

Proportional speed control

ON / OFF control

Control the swing movement is like driving your car.

While approaching the target take the foot of the accelerator pedal
(stick = 0) and let it decelerate on the engine. Closer to the target
you apply the brake pedal ( counter slew with joystick)

May 21, 2015 BASIC: OPERATOR TRAINING 9

CAB CONTROLS Seat / Functions on Sticks
BATCH LOADING CONTROL ACTIVATE RADIO OVERRIDE the user FINE CONTROL
defined angle stops.
Add / subtract the actual When this button is Reduces max working
grab content of the preset pressed, the crane e.g. to lift a bobcat speeds of boom and stick
value in the EMM screen driver can speak over over the hopper. e.g. grab change.
(#6). the mobile radio in
the cab Grab and swing excluded
(if radio available)

LEFT RIGHT
May 21, 2015 BASIC: OPERATOR TRAINING 10
CAB CONTROLS Cabin / Foot Pedals Gantry ctrl
GANTRY Forward / Reverse

May 21, 2015 BASIC: OPERATOR TRAINING 11

CAB CONTROLS Cabin / Foot Pedals Gantry ctrl

FINE CONTROL

Foot pedal = identical to

joystick control button
reduces max speed boom &
Stick only

SEMI-AUTOMATIC CYCLE

Automatic movement of boom

and stick to a preprogrammed
point (eg a hopper).
(if option is available)

May 21, 2015 BASIC: OPERATOR TRAINING 12

CAB CONTROLS Seat / right Console

Windshield wiper and wiper wash control

cab light
Stop main motor
(remove key)

RUN position

START
Main
motor
UPPER

OVERRIDE OVERLOAD SECURITIES MOTOR UPPER

ON/OFF
Limited speed (fine control when switch = active)!
Momentary switch!
Ask your supervisor for the key!

May 21, 2015 BASIC: OPERATOR TRAINING 13

 CAB CONTROLS Rear Seat Controls
SWING BRAKE LOCK WORK MODE SELECT User defined FLOOD LIGHTS
option Lower & Upper
Lock the swing brake HOOK mode = reduced
e.g. during grab change speed for boom & stick Eg Cablift / grab
or lowering bobcat in = no grab function = rotation
the ship increased lifting
capacity

See your lifting chart

May 21, 2015 BASIC: OPERATOR TRAINING 14

CAB CONTROLS Cabin Overload indication
100 % ALARM SWL
&
90 % WARNING SWL Max Underload condition

WIND SPEED INDICATION

STOP = 74 kmh 45Mph

May 21, 2015 BASIC: OPERATOR TRAINING 15

CAB CONTROLS Pilot Control on/off

Step out lock, before leaving the seat push safety lever
down..

May 21, 2015 BASIC: OPERATOR TRAINING 16

 CAB CONTROLS EMM Display for Upper
EMM SCREEN
Refer to the Separate document in the
EMM SCREEN manual for detailed information
Select the desired
information thru F -
buttons

F- BUTTON
FUNCTION
INDICATION

SELECTOR

PUSH- to select or
confirm
JOG- to adjust
setting

Screen has an information FUNCTION no direct crane control function

EMM monitors only the UPPER and NOT the GANTRY lower
May 21, 2015 BASIC: OPERATOR TRAINING 17
 CAB CONTROLS Crane Travel (Rail)

Normal travel function

Momentary switch to
override travel stop

RUN position
Stop travel motor
(REMOVE key)
START
Travel (lower) motor

The GANTRY panel is linked straight to the Input/Output module in the electrical
cabinet inside the operators cab.
May 21, 2015 BASIC: OPERATOR TRAINING 20
CONTROLS UPPER POWER UNIT on E12
E stop crane complete crane
1
Reset/ rearm E stop monitor
2
Indication light E stop LOWER activated (if available)
3
Winding temperature monitoring in main motor (if available)
4
1
bearing temperature monitoring in main motor (if available)
5

3
4

May 21, 2015 BASIC: OPERATOR TRAINING 22

CONTROLS LOWER POWER UNIT
Socket 32A - 4 pole
1 and 2

Socket 10A - 2 pole

1 2 3 and 4

Emergency Stop Lower

5

3 4
Emergency Stop Lower Reset
6 button and light

5 6

May 21, 2015 BASIC: OPERATOR TRAINING 28

EMM Control System Block Diagram

May 21, 2015 BASIC: OPERATOR TRAINING 29

 EMM MENU Structure

Push to select the menu

EMM only monitors the UPPER

part of the crane,
Gantry lower is contactor
control

May 21, 2015 BASIC: OPERATOR TRAINING 30

 EMM Basic Screens General Information
Please refer to the
PW0434.Users.Chart.EMM.Dialogue.Module.wpd
Document for complete information

Number of activ Service indicator

faults / alarms Crane needs maintenance according to the hour based
maintenance schedule

PUSH the corresponding F button to enter the

submenu

May 21, 2015 BASIC: OPERATOR TRAINING 31

 EMM Display Icons
Push <F6> to move forward to the NEXT PAGE.

Push <F1> to move back to the PREVIOUS PAGE

SETTINGS:
The checkmark symbol is used for the Settings Section. Any time
the checkmark appears over a key <F2> to <F5> then pressing
that key will cause a jump to the settings screen.

INFORMATION:
The lowercase blue i represents Information. Push <F2> to <F5>
below this symbol to jump directly to the Information Section

MAINTENANCE
The Hammer represents the Maintenance section. Push <F2> to
<F5> directly under this symbol to jump to the Maintenance
section.

May 21, 2015 BASIC: OPERATOR TRAINING 32

 EMM Display Icons
LOG IN
The E-Crane logo represents the Log In section. Push the key under this
symbol to access this area. Please Note: You must have the proper access
code to proceed past this screen!

DUTY CYCLE OR GRAB MODE

When this symbol is on the screen, the E-Crane is in Grab Mode

LIFT CRANE OR HOOK MODE:

When this symbol is on the screen, the E-Crane is in Hook
Mode, crane can lift more but the max speeds are limited.

SAVE THE CHANGED VALUEs

Push <F2> to <F5> directly below this symbol to save data
settings.

CHANGE UNITS
Push <F2> to <F5> directly below the toggle arrows to change
the unit setting

May 21, 2015 BASIC: OPERATOR TRAINING 33

 EMM Display Icons
NET / GROSS for the grab weight indication
Push <F2> to <F5> directly below the toggle arrows to change the setting.

RETURN THE SETTINGS TO USER DEFAULT

Push <F2> to <F5> directly below the toggle arrows to switch
between user and default setting.

RETURN to main screen

May 21, 2015 BASIC: OPERATOR TRAINING 34

 EMM basic Screen 1 Information
Please refer to the BOOM angle indication Green = both directions free
PW0434.Users.Chart.EMM.Dialogue.Module.wpd BR = BOOM raise Yellow= pre limit switch slow down
BD = BOOM down Red = limit switch STOP
Document for complete information
STICK angle indication
SO = STICK out
Scale = actual load in SI = STICK in
% of max load

CRANE MODE
Hook
Grab

Pilot control handle

Blue = lock / no operation
GROSS = net load + Green = work
grab empty weight +
rotator Swing brake:
Blue = engaged parking
Green = lifted

E MOTOR indicator FINE CONTROL mode selected

white = motor OFF white = mode not active
Yellow = starting Green = fine control active
Green = running
Red = Motor Fault

May 21, 2015 BASIC: OPERATOR TRAINING 35

 EMM Basic Screen 2 5
BASIC screen 2 BASIC screen 3

Actual stick position

Stick target position,

Position can be set by
operator.

Actual oil temp

BASIC screen 4 BASIC screen 5

Large format angle

Actual pump output readings
pressure implement
pump.

May 21, 2015 BASIC: OPERATOR TRAINING 36

 EMM Basic Screen 6 en 7
Screen 6 Screen 7

These two screens are a crane operators feature in order

to track how many tons / cycles are needed for loading and
unloading.

Basic Screen 6 is a totalizer. Screen 7 reduces from an

adjustable target weight.

For a detailed description of the functioning for weigh

supplemental see: PW0484.EMM.Weigh.
System.Supplemental_v2.wpd

May 21, 2015 BASIC: OPERATOR TRAINING 37

 EMM Basic Screen Travel
TRAVEL ENDSWITCHES
Green: OK
Orange: Warning
Red: Final stop

TRAVEL MOTOR
Green: motor is running
White: motor is off

Real Time crane status OK, Warning, Fault

crane status conditions listing
Red = Fault
Yellow = Warning
Green = OK TO WORK

May 21, 2015 BASIC: OPERATOR TRAINING 38

EMM Real Time Crane Status (Primary)
Real Time crane status OK, Warning, Fault
crane status conditions listing
Red = Fault
Yellow = warning
Green = OK TO WORK

The PRIMARY screens are succeeded by the

SECONDARY screens (refer to the next page)

Listing fault codes in primary and secondary

Primary faults generally need more urgent repair.

May 21, 2015 BASIC: OPERATOR TRAINING 42

EMM Real Time Crane Status (Secondary)

Real Time crane status OK, Warning, Fault

crane status conditions listing
Red = Fault
Yellow = warning
Green = OK TO WORK

May 21, 2015 BASIC: OPERATOR TRAINING 43

EMM overview different Setting Screens

Use the dial & push to select one of the

displayed items on the screen

May 21, 2015 BASIC: OPERATOR TRAINING 44

 EMM General Settings

Use the dial &

push to select
one of the
displayed items
on the screen

Switch between METRIC & Switch between GROSS &

IMPERIAL NETTO

Graden/Fahrenheit,
Meter/inch, Mton/USton

apr 10
May 21, 2015 BASIC: OPERATOR TRAINING 45
 EMM Underload - Boom Float Setting
Boom float can only be active when the grab
is closed AND active underload condition is
present.

After making adjustments, + (positive) value means the crane still

push F3 to save the new holds a part of the grab dead load.
setting
Force on the bottom during floating =
+ DEAD weight of the GRAB underload
setting

- (negative) value means the crane is

allowed to push on the grab

Use the dial

Push and dial to select an new setting for the
level of the floating setpoint
- Force on the bottom during floating =
DEAD weight of the GRAB + underload
setting

May 21, 2015 BASIC: OPERATOR TRAINING 46

EMM Settings Screen Height Offset + Stick Angle Setting

Set a new reference point

for the height correction Set your desired
on the basic screen 1 forearm position

Factory setting is 0 m = EG. Forearm in certain

main pivot point of the position above hopper
boom

Use the dial & push to select one of the

displayed items on the screen

May 21, 2015 BASIC: OPERATOR TRAINING 47

 EMM Settings Screen - Tare Setting

Change TARE setting, for

indication on basic
screen

Switch between GROSS &

NETTO for the correct
indication on the basis
screens

Use the dial & push to select one of the

displayed items on the screen

May 21, 2015 BASIC: OPERATOR TRAINING 48

 EMM Setting User Angle

Use the dial &

push to select
one of the
displayed items
on the screen

Switch between DEFAULT

Angles and USER
ANGLES for boom & stick.

The crane operator can

adjust the end angles
from boom & stick.

When USER Angles are active and the crane

operator wants to bypass the end angles. He
can do this by pressing continuously the
button on the right joystick.

May 21, 2015 BASIC: OPERATOR TRAINING 49

 EMM Semi-Automatic Cycle
Semi-Automatic Option can move only BOOM
and STICK to a pre-programmed point

How to use?

1. Move boom and stick to the desired end

position
2. Go to the SEMI AUTOMATIC CYCLE settings
screen and push F5 (Set Point) to store the
desire position
3. Push the pedal and move the RH joystick
(boom) towards the direction that the boom
must move to the endpoint to reach

Advantages !!

Improve cycle times

Improve ease of operation for the

crane operator

Improve safety while working

Increase life-time of crane

because acceleration and
breaking is better controlled As long as you push the pedal the
automatic cycle is active

May 21, 2015 BASIC: OPERATOR TRAINING 50

 EMM Weigh Scale Settings

Use the dial &

push to select
one of the
displayed items
on the screen

Resetting the REMAINING

Resetting the TOTAL WEIGHT thatis displayed
WEIGHT that is displayed on basic screen 7. The
on basic screen 6 Target Weight will be
taken over from the
setting that is done.

For a detailed description of the Weigh Scale see:

PW0484.EMM.Weigh.System.Supplemental_v2.wpd

May 21, 2015 BASIC: OPERATOR TRAINING 51

 EMM Other Settings Screens
Choosing between two settings for grab open & close.
Possible to enable a grab open soft stop function

Speed adjustments are done by E-Crane qualified personel.

Use the dial & push to select one of the

displayed items on the screen

May 21, 2015 BASIC: OPERATOR TRAINING 52

52
 EMM Reset Service Indication

Must be LOGGED IN
to reset service Use the dial &
indication (Push F5). push to select
one of the
displayed
items on the
screen

SERVICE INDICATION The following code must be entered =

Crane maintenance according to number day of the month x number month
maintenance schedule Eg.. 17/11/2008 17x11=187

OR

To reset the service

indication we must push
the checkmark button
(F3).

May 21, 2015 BASIC: OPERATOR TRAINING 53

E-Crane monitored Status & Securities UPPER
UPPER via EMM

Hydraulic filters clogged

1

2 Maintenance required interval / service reminder

3 Swing boost pressure too low

4 Oil level hydr reservoir low warning & too low stop

5 Oil temp hydraulic reservoir low/ cooling temp / overheated

6 Main pump motor softstarter various faults

7 Pressure indication Load Sensing pump

8 Actual load/ overload

9 Actual boom & stick angle including limit switch stops

10 Cable short + open loop LMI load cell

11 Joystick faults

12 Boom & stick angle encoder faults

13 Solenoid monitoring for open & short

14 Shut-off valve valve position monitoring in the pump suction line

15 Fine control active

16 Swing parking brake control

17 operating hours main motor

May 21, 2015 BASIC: OPERATOR TRAINING 54

E-Crane monitored Status & Securities Gantry
Gantry Travel - LOWER Relay Logic

1 Hydraulic filters clogged

2 Hour meter

4 Oil level hydr reservoir too low stop

5 Oil temp hydraulic reservoir cooling temp / overheated

6 Grease level check

7 Phase sequence check

8 Motor faults check

9 Shut-off Valve position monitoring in the pump suction line

10 Travel Limit Switches / end stop & Anti Collision

11 Translation parking Brake control

12 Command lighting on walkways

13 E stop lower

May 21, 2015 BASIC: OPERATOR TRAINING 55

 Working with the Crane

Check the manual for detailled information

May 21, 2015 BASIC: OPERATOR TRAINING 56

 STARTING the E-Crane
1 2 3

RESET E-stop on the upper
(after power down or E stop)
If not possible check and reset the E-
stop buttons located on the crane.
RESET E stop gantry
(after power down or E stop)
If not possible check the E-stop
buttons located on the crane.
(if available)
LOCK pilot control lever into OFF
position when starting motor
Do not touch joystics when starting.

4
Turn the key switch to START the
motor upper carriage +
gantry (if needed)

May 21, 2015 BASIC: OPERATOR TRAINING 58

OPERATING an E-Crane combine Movements !

This movie show how the grab moves while

ONLY BOOM raise is active.

e.g. When reaching for the outer wall of the

barge combine movements: stick out and
boom down.

NOTE: Using one function at a time will always result in a circular movement of the grab!
This is identical when compared with an excavator, but more important in an E-Crane because of the
long boom and stick combination!
Always combine movements to achieve a vertical or horizontal load path!

May 21, 2015 BASIC: OPERATOR TRAINING 59

OPERATING an E-Crane think proactive
Crane inertia greatly depends on the actual load and outreach.

Think in advance when working with the crane. Plan ahead when braking
/ decelerating! This becomes extremely important when using the crane slew function (swing
or crane rotation)!
Use the free slewing function when approaching the target. Apply the counter slewing
technique to stop at the desired location.

May 21, 2015 BASIC: OPERATOR TRAINING 60

 OPERATING an E-crane Cleaning the Hold
Boom float is only active after the LMI has detected an underload condition AND as long
as you keep closing the grab!

adjust the underload setting if the grab scratches the hatch bottom too hard or when
cleaning efficiency is poor.
- negative underload setting allows the crane to push down on top of the grab
+ positive underload setting requires the crane to lift a part of the grab load at all
times

May 21, 2015 BASIC: OPERATOR TRAINING 61

 MOVING LOADER into or out of a Ships Hold

Depending on the grab style, the loader type and the available
rigging & lift points the procedure has to be updated / adjusted.

Respect job-site safety regulations at all times!

May 21, 2015 BASIC: OPERATOR TRAINING 62

 MOVING LOADER into or out of a Ships Hold

1 2 3

Put the grab open on the floor Position the grab above the loader start the motor again & gently lift
stop the motor and Attach the stop the motor the loader.
rigging attach the rigging to the loader do not stay under the load
Switch to hook mode

May 21, 2015 BASIC: OPERATOR TRAINING 63

MOVING LOADER into or out of a Ships Hold

4 5

Stop the motor

disconnect all rigging on the loader
bring the loader to the Ship side
if needed use the bypass user limit return the grab to the quay to
switches button on cross the disconnect all rigging
hopper with the loader

May 21, 2015 BASIC: OPERATOR TRAINING 64

 GRAB CHANGE Step-by-Step Procedure

1 2 3

Gently open the grab completely ( Tools NEEDED Close the valves at the
do not build pressure) - heavy hammer end of the stick
Put the grab gently on level surface - open wrench 41mm
and do not push - socket wrench 32mm
- extension tube
Go to step 6 when hydraulic
shortcuts are used

May 21, 2015 BASIC: OPERATOR TRAINING 66

 GRAB CHANGE Step-by-Step Procedure

4 5 6

2x 2x 4x

Bleed the oil comming out of the Unscrew the connector cap. Loosen the locking bolt.
hose, carefully release the pressure
before removing the hose.

May 21, 2015 BASIC: OPERATOR TRAINING 67

GRAB CHANGE Step-by-Step Procedure

7 8 9

4x

4x
4x

Pull out the spring cotter pin. Pull out the locking pin. Use a hammer to loosen the twist
lock nuts.

May 21, 2015 BASIC: OPERATOR TRAINING 68

GRAB CHANGE Step-by-Step Procedure

10 11 12

4x

Rotate each twist lock Raise the quick change device Reposition the stick carefully while the twist
pin 90. slowly. Verify twist lock pin lock pins are sliding out of the grab top plate.
position again. Carefully combine boom & stick movements.

May 21, 2015 BASIC: OPERATOR TRAINING 69

 GRAB CHANGE Step-by-Step Procedure

13 14 15

Use an extension tube to reposition Position the rotator on the next grab, Tighten the twist locks
the rotator. align the markers . again, take the steps 5 to
10 in reverse order

NEVER use the hydraulic

rotator to reposition
because it will move too
fast!

May 21, 2015 BASIC: OPERATOR TRAINING 70

DAILY MAINTENANCE & CHECKS

Check the maintenance schedule in the manuals.

Depending on the plant organization this job list might belong to the mechanical department

May 21, 2015 BASIC: OPERATOR TRAINING 71

FILLING LEVELS - Hydraulic Tank Lower Power Unit
1 x SHIFT
LOWER Power Unit (Travel)
hydraulic tank has
1000/1500 serie: 205 liter (54 gallon) capacity
2000/3000 serie: 390 liter (103 gallon) capacity

Operating Level

Motor Shut Down Level

OEM Filled w/ TEXACO Brand

RANDO HDZ 46

May 21, 2015 BASIC: OPERATOR TRAINING 72

 FILLING LEVELS - Hydraulic Tank Upper
UPPER
Upper Hydraulic Tank
1 x SHIFT
1000/1500 serie: 1850 liter (488 gallon) capacity
2000 serie: 4000 liter (1056 gallon) capacity Filling using oil transfer pump.
3000 serie: 4200 liter (1110 gallon) capacity Fill thru water filter via hose provided
DO not put directly into tank

Operating Level

Crane position when checking oil level:

BOOM down +
Motor Shut Down Level STICK in +
GRAB OPEN

OEM Filled w/ TEXACO Brand

RANDO HDZ 46

May 21, 2015 BASIC: OPERATOR TRAINING 73

FILLING LEVEL Splitter Box Upper
1 x SHIFT

Carefully check
do NOT overfill

OEM Filled w/ TEXACO brand

MULTIGEAR 80W90 1000/1500 series

May 21, 2015 BASIC: OPERATOR TRAINING 74

 FILLING LEVEL Swing drive(s)
1 x SHIFT

Carefully check level of gear box

OIL. Oil level should be in the
middle of the sight glass (2x).
ATTENTION: when oil level drops
below sight glass the sight
glass can still contain several
drops of oil! Do not confuse
this condition with a correct
oil level condition.

OEM Filled w/ TEXACO brand

MULTIGEAR 80W90

May 21, 2015 BASIC: OPERATOR TRAINING 76

FILLING LEVEL Swing Drive(s) Brake
1 x SHIFT

Oil must be in visible inside the

glass (2x)
ATF fluid only
(Automatic Transmission Fluid)

May 21, 2015 BASIC: OPERATOR TRAINING 77

 FILLING LEVEL Crane Travel Gearbox(es)

Oil level check & oil filling

Position the drain point @ 6h

Check oil spillage on bottom bogie or floor of
the rail track. Excessive spillage indicates
the need for in depth gear box inspection. Oil drain

1 x SHIFT

May 21, 2015 BASIC: OPERATOR TRAINING 78

FILLING LEVELS Central lubrication Pump(s)
EACH SHIFT !! WHEN OPTIONAL LOW LEVEL SWITCH is installed:
Check the grease level of each grease remove grease on the sensor spot.
reservoir on the upper and lower (if
installed),
Never let it run empty!!

IN CASE of OPTIONAL LOW LEVEL SWITCH!!

Highest filling level = 40mm below reservoir top

(11/2 ) for proper functioning of level sensor
1 x SHIFT
May 21, 2015 BASIC: OPERATOR TRAINING 79
CHECK LUBRICATION SYSTEM(S) Blocked Line
If grease is pushed out of the top of the pressure
relief valves this indicates a blocked grease
lube point / bearing on the machine
1 x SHIFT

If first aid (manual greasing) doesnt work and the

grease still exits the pressure relief valve(s)
start trouble shooting procedures. Refer to the
technical manual.

May 21, 2015 BASIC: OPERATOR TRAINING 80

CHECK LUBRICATION SYSTEM(S) restart after empty Reservoir

If the reservoir was running empty air is trapped

in the pump elements and this will never
leave just by filling the reservoir again!

Step-by-step procedure to restart after empty

empty reservoir

1 2

Put some oil in the reservoir and let the pump run
continuously for a while till level has dropped
Extensively lube each pump output manually
Refill the reservoir with grease
May 21, 2015 BASIC: OPERATOR TRAINING 81
CHECK LUBRICATION SYSTEM(S) Square Gantry
Watch out for dry points, excess grease must be
visible at all pivot points!

May 21, 2015 BASIC: OPERATOR TRAINING 83

CHECK LUBRICATION SYSTEM(S) Upper
Watch out for dry points, excess grease must be
visible at all pivot points!

MANUAL

1 x SHIFT
May 21, 2015 BASIC: OPERATOR TRAINING 85
CHECK LUBRICATION SYSTEM(S) Manual

MANUAL

Following pages will explain case by case

May 21, 2015 BASIC: OPERATOR TRAINING 86

MANUAL GREASING Connection Pins Cylinders
Manual greasing of connection pins of boom and stick
cylinders
50 hour

Check & decide if grease needs to be applied

May 21, 2015 BASIC: OPERATOR TRAINING 87

MANUAL GREASING Swing Bearing Gear
50 hour

Check & decide if grease needs to be applied

Use only Kluber Grafloscon open Gear Lubricant
Attention: during start up use higher lube frequencys (e.g. 4 hours)

May 21, 2015 BASIC: OPERATOR TRAINING 88

MANUAL GREASING - LMI & Grab Suspension
There are (5) Lube Points

1 x SHIFT
8/10 hour
May 21, 2015 BASIC: OPERATOR TRAINING 89
MANUAL GREASING Grab Rotator
Grab Suspension

1 x SHIFT
8/10 hour

apr 10
May 21, 2015 BASIC: OPERATOR TRAINING 90
MANUAL GREASING Grab Rotator
Twist lock pins (if applicable)

250 hour

Open the plug to lube the roller bearing

Rotate the rotator till the references match to reach the countersunk grease
nipple (2x- 4x)

apr 10
May 21, 2015 BASIC: OPERATOR TRAINING 91
MANUAL GREASING Grab Rotator

250 hour
Open gears apply grease and rotate

May 21, 2015 BASIC: OPERATOR TRAINING 92

MANUAL GREASING Two Cylinder Grab
Equalizer 2x (4x) Bucket hinges 4x

1 x SHIFT
8/10 hour

HE cylinder bearings 2x (4x) RE cylinder bearings 2x (4x)

(x) = larger grabs using

4 hydraulic cylinders

May 21, 2015 BASIC: OPERATOR TRAINING 93

MANUAL GREASING Orange Peel Grab

Repeat for each teeth 1 x SHIFT

Grease each cylinder bearing
Grease the tooth bushing. 8/10 hour

5x

May 21, 2015 BASIC: OPERATOR TRAINING 94

E-Crane PRE & POST Inspection Lists

Proper maintenance is THE key to the success of your

equilibrated crane. Take care for proper maintenance
and trouble shooting management.
Inspection lists ( pre + post shift inspection) make it
possible to track problems and to keep your
maintenance team organized.

May 21, 2015 BASIC: OPERATOR TRAINING 95

success