Derrick manual

Derrick 200 DR 5/10

Instruction Manual

200DR_Deckblatt-en.doc

Serial No. 51 204 Year of construction 2013

Derrick 200 DR 5/10

200DR_Deckblatt-en.doc

Serial No. 51 204 Year of construction 2013

DR00 05

20,6

m

19,4

m16

,5m

15,1

m5,3 m

5,1 m

6,0 m

5,8 m

12,6

m

2,1

m

3,2

m

20,6 m

21,0 m

24,8 m

25,0 m

10,6

m

4,0 m

4,0 m 1805,6 m

7,5 m

Derrick

DIN

Printed in Germany.

Konstruktionsnderungen vorbehalten!Subject to alterations! / Sous rserves de modifications!Si fa riserva di modifiche! / Sujeto a modificaciones!Salvo modifio da construcao!

Smtliche Angaben erfolgen ohne Gewhr. / This information is supplied without liability.Ces renseignements sont sans garantie. / Le indicazioni contenute si intendono salvo errori ed omissioni.Declinamos toda responsabilidad derivada de la informacin proporcionada. / Declinamos qualquerresponsabilidade quanto informao fornecida.

2

110 P 4856 H1 B3 DIN 15018 BGL C.1.31.1020 04.07 / 6

LiebherrWerk Biberach GmbH, Postfach 16 63, D88396 Biberach an der Riss+49 73 51 410, ax: +49 73 51 41 22 25,F www.liebherr.com, EMail: [email protected] DR00 05

Ausladung und Tragfhigkeit Radius and capacity / Porte et charge / Sbraccioe portata /Alcances y cargas / Alcance e capacidade de carga

1 x 5,0 kW FU

37 FUkW1,3 min.

U/min0 0,8 sl./min

tr./min

Antriebe Driving units / Mcanismes d'entranement / / Mecanismos / MecanismosAzionamenti

m/kg

m m/kg

25,0 6,0 20,05000 5000

9890

5000

10000

11,0

25,0

21,0

21,0

5,8 10,910000

5,3 21,05000

5,1 11,110000

5000

8830

5000

9050

12,0

5000

7960

5000

8190

13,0

5000

7220

5000

7450

14,0

5000

6600

5000

6820

15,0

5000

6060

5000

6280

16,0

5000

5590

5000

5810

17,0

5000

5180

5000

5390

18,0

5000

4810

5000

5020

19,0

4700

4190

5000

21,0

450020,6 m

3800

25,0

4250

23,0

4480

3920

22,0

330024,8 m

m/kg

m m/kg

25,0 6,0 25,05000 5000

10000

5000

10000

11,0

25,0

21,0

21,0

5,8 19,010000

5,3 21,05000

5,1 20,610000

5000

10000

5000

10000

12,0

5000

10000

5000

10000

13,0

5000

10000

5000

10000

14,0

5000

10000

5000

10000

15,0

5000

10000

5000

10000

16,0

5000

10000

5000

10000

17,0

5000

10000

5000

10000

18,0

5000

10000

5000

10000

19,0

5000

8980

5000

21,0

1000020,6 m

5000

25,0

5000

8150

23,0

5000

8550

22,0

750024,8 m

37 kW FU

72,0

45 kW FU

4WIW 260 MZ 4075 kW FU

LayersCouchesStratiCamadasCapas

Lagen10

/ stepless / rgl. continu / regl. progressiva / sin escalones / sem degrausstufenlos

kg m/min

4900200

00

441721

100001000

00

221001

max. 633 m

0

2000

5000

0 50 100 150 200

kg

m/min

Gang / Speed / VitesseMarcia / VelocidadVelocidade

1

00 20 40

kg

Gang / Speed / VitesseMarcia / VelocidadVelocidade

1

633,0 m

4000

3000

1000

4000

10000

8000

6000

2000

kg m/min

317,0 m

60 80 m/min100

180

kVA

mit StiffLegs / with stiff legs / avec stifflegs con StiffLegs / con stifflegs / com tirante rgido

ohne StiffLegs / without stiff legs / sans stifflegs senza StiffLegs / sin stifflegs / sem tirante rgido

Zug/Druckkrfte an den Verankerungspunkten auf Anfrage. / Tension/compression forces at anchoring points on request. / Forces de traction/compression aux points d'ancrage sur demande. / Sforzi di trazione e pressione sui punti di ancoraggio, su richiesta. / Fuerzas de traccin ycompresin sobre los puntos de anclaje, consulta previa. / Foras de trao e compresso nos pontos de ancoragem, mediante consulta.

vorwort_Derrick_en.doc Introduction Safety indications Symbols

NOTE

All details specified in this instruction manual are only valid for the corresponding components configurations and erection versions with the respective anchoring forces in chapter 2 and 3.

Liebherr-Werk Biberach GmbH, P.O. Box 1663, D-88396 Biberach an der Ri

Our After-Sales-Service can be contacted as follows:

Tel. +49 (0) 73 51 / 41 20 00 Fax +49 (0) 73 51 / 41 27 27

Internet: http://www.liebherr.com

Technical After-Sales-Service: [email protected] Spare-parts sales: [email protected] Technical Documentation: [email protected]

Should you have any queries regarding stability, please contact the Structural calculation department directly:

Tel. +49 (0) 73 51 / 41 40 02 Fax +49 (0) 73 51 / 41 28 79

E-Mail: [email protected]

Introduction Safety indications Symbols vorwort_Derrick_en.doc


INTRODUCTION

This manual is intended to help you operate the crane safely and to make full use of all its

permitted facilities and methods of working. The manual also provides information on the

operating principle of major assemblies and systems, and can be consulted if spare parts

have to be ordered.

The instruction manual consists of:

Specifications

Applications engineering

Erection

Ropes

Operation

Electrical equipment

Maintenance

Please ensure that only trained and qualified personnel is employed on this crane. The

operating instructions and all relevant legal requirements and similar directives (for

example accident prevention regulations) must be complied with.

Disregarding these instructions may cause accident or injury.

Special attention must be paid to the safety devices installed on the crane. They must be

regularly checked to ensure that they are in good working order. The crane must not be

operated if they have failed or become unreliable. Always remember:

Safety first!

If you receive any further information on the crane from us, for instance technical

information circulars, always note the contents carefully and insert the information in the

relevant section of the manual without delay.


Notes on Safety

Avoiding dangers

Liebherr cranes are constructed around state-of-the-art technology and the approved safety-technical regulations. Should the cranes be operated improperly, however, the user or a third party could be exposed to serious danger, and the crane or other tangible assets could sustain damage.

In order that these dangers may be avoided, Liebherr cranes may only be used: - for the purpose for which they are intended. - in adherence to the complete crane documentation. - in adherence to the valid, on-site accident-prevention guidelines. - if in a sound condition which complies with the safety regulations.

Use as intended

Liebherr cranes may be utilisated for the lifting and lowering, as well as the horizontal transport of loads suspended freely from the load hooks. The crane must be positioned on firm ground when the load is lifted, and may not exceed the maximum load specified in the respective load diagram. The crane must be erected and operated in compliance with the specifications in the operating instructions. Any other use, or excessive use, is not considered use as intended and is strictly prohibited.

The following, in particular, are strictly prohibited: - pulling off fixed loads. - horizontal displacement of not freely suspended loads. - the transporting of persons with the load or with the load carrying gear. - adding weight to loads already lifted. - the utilisation of inappropriate ropes which do not comply with specifications in the instruction

manual. - utlisation of non-original crane components. - bridging and modification of limit switch settings. - modification of the crane configuration depicted in this instruction manual. - installing advertising billboards and accessories, as well as undertaking modifications, without

the express permission of the manufacturer. - non-adherence to guidelines specific to the respective crane type. Prohibitions must be strictly

observed. See the chapter, Operation: "Operating instructions"

The manufacturer is not liable for any damages which occur as a result of negligence of the aforementioned points.

Strict adherence to the maintenance and inspection requirements is also considered use as intended.


Personnel qualifications

Operation, maintenance and inspection may only be carried out by a skilled crane operator.

Assembly, disassembly and repair tasks may only be carried out by trained, specialist personnel.

Tasks to the electrical equipment of the crane may only be undertaken by an electrical specialist in accordance with the electro-technical regulations.

Only personnel with specific knowledge and experience of hydraulics may work on the hydraulic equipment.

Specific hazard areas

Jeopardising stability

Very different prerequisites for stability could arise depending on the configuration of the crane. The documentation "Corner pressures, foundation loadings, ballast data", or chapter 2 "Stability" is only valid for the configurations specified. The user must apply for the static data for any configurations not specified from Liebherr-Werk Biberach.

Danger of crushing

There is a danger of becoming crushed: - in the immediate vicinity of the crane support. - at exposed running spur gears. - in the immediate vicinity of the slewing platform. - at any point of the crane during the erection and dismantling procedures. - in the immediate vicinity of the climbing equipment. All areas which pose a danger of crushing should be accordingly safeguarded or cordoned off. Should operating, erection or maintenance tasks be necessary within an area of the crane which has not been safeguarded, a second person must be called in who can shut down the respective movement immediately should a dangerous situation arise.

Dangers as a result of damaged ropes

The utilisation of unsuitable ropes can lead to serious accidents. In order that safe operation can be ensured at all times: - only use ropes which comply with Liebherr regulations. - pay particular attention to the sections of ropes which run over rope pulleys or rope drums or

are in the immediate vicinity of rope end fittings. - check the ropes carefully in order that any changes in the rope condition is recognised

immediately.


Dangers as a result of copied Liebherr crane parts

The utilisation of copied crane parts (plagiarisms) can cause the tower crane to topple, resulting in serious injury to persons or major damage to material property.

To avoid dangerous situations occurring, - on original-Liebherr crane parts may be used.

Dangers as a result of combining crane components f rom different manufacturers

Combining Liebherr crane components with components from other crane manufacturers can cause the tower crane to topple, risking serious injury to persons and major damage to material property.

The following must be ensured if safe operation is to be guaranteed: - Do not combine Liebherr crane components with components from other crane manufacturers.

Dangers as a result of electrical energy

Keep the switchgear cabinet locked at all times. Access is only permitted to authorised personnel holding a key or special tool.

- Should it be necessary to carry out tasks to parts carrying voltage, a second person must be called in to switch off the main switch in the event of an emergency.

Dangers as a result of hydraulic energy

Pressure must be dissipated from sections of systems and pressure lines which are to be opened before commencing any repair tasks.

- Replace hydraulic hose lines in appropriate time intervals, even if no defects relevant to safety have been determined.

Risk of environmental contamination

The environment could be subjected to harm if fuels and lubricants are handled carelessly.

- Proceed with the utmost of care when replacing or refilling fuels and lubricants. Under no circumstances should fuels and lubricants be permitted to leak into the ground or waterways.


Safety indications

Danger of accident! Danger of injury!

correct!

wrong!

WARNING: Live parts! Electrical installation, connection work and maintenance must be done only by authorized, properly qualified personnel.

WARNING: Suspended loads!

Danger of falling down!

Wear and use a safety harness!

Danger of crushing! Wear gloves!

Important information! Check, verify!

For maintenance and in order to maintain the guarantee, original spare parts should only be installed by authorized, properly qualified personnel!

Environmental protection: Oil, filters, brake fluid, batteries etc. must be disposed properly!

Explosion hazard! Always close the passage flaps!


1+2+3

Key to symbols

Sequence!

Erection! (bottom-slewing cranes)

Operation! (bottom-slewing cranes)

Control steps!

Direction!

Movement stop!

Rotating! Direction of rotation! Once-through rotation!

Brake applied!

Brake released!

2-fall operation / 4-fall operation!

Weight! Load!

Speed!

Balance the crane! (e.g.: Climbing the crane)

"Light on"!

"Out"!

Wind direction! Wind speed!

Automatic control!

Manual operation!

Maintenance interval!

Check oil level!

Grease lubrication!

Clean!

Keep free from oil and grease!

Torque wrench!

Hook wrench!

Bleeding!

200DR_inh-en.doc Table of contents

LiebherrLiebherrLiebherrLiebherr----Werk Biberach GmbHWerk Biberach GmbHWerk Biberach GmbHWerk Biberach GmbH

D-88396 Biberach/Ri, Tel. (07351) 41-0

Specifications


Erection sequence

Ropes

Operation

Electrical equipment

Maintenance

Accessories

Netzversorgung_Klima_Obendreher_08_2012_en.doc Ambiance / climatisation

Mains power supply, ambient and storage conditions for top-slewing cranes Mains power supply:

Notice! The mains power supply must always comply with the connected loads of the crane! Please contact the Technical Office (TB) in the event of differing connected loads!

Network tolerances:

Distribution voltage: 3x 400V +10% /- 5% Frequency: 50 Hz +/- 1%

Distribution voltage: 3x 480V + 5% / - 10% Frequency: 60 Hz +/- 1%

Ambiance:

Working temperature for cranes, see "Climate control for switchgear cabinets", in chapter "Electrical equipment"

Storage temperature (crane dismantled) - 50C to +65C (At temperatures below -25C, electronic components must be heated!)

Maximum relative humidity 93% (IEC 68-2-3 during storage / transport)

Maximum relative humidity 95% non-condensing operation Maximum height above sea level 1000 meters without effecting

a reduction in output Storage of crane components with switchgears:

Notice! Avoid moisture and condensation in the switchgears (switchgear cabinets)! Moisture or condensation in switchgears can cause direct damage to assemblies of the electrical equipment!

To prevent moisture and condensation from occurring in the switchgear cabinets, the crane cabin, as well as all other switchgears (e.g. hoist gear switchgears or luffing gear switchgears, etc.) must be stood upright during storage.

If the crane cabin is laid flat during storage, all access and exit points, as well as the side windows and front windscreen must be closed. To protect the crane cabin against atmospheric influences, structural elements must be covered whenever they are laid flat during storage.

200DR_Drehbereich-en.doc 200 DR Slewing range

Permissible slewing range: without (1) and with stifflegs (2) (not standard)

(1)

(2)

200DR_fb_en.doc Applications engineering 2-1


The loading specifications are exclusive of impact factors.

Configuration without stifflegs:

Foundation loadings ...........................................................................................2-3

Configuration with stifflegs:

Foundation loadings..........................................................................................2-13

2-2 Applications engineering 200DR_fb_en.doc

Montagebeschreibung_Deckblatt_en.doc Erection

Derrick 200 DR 5-10

Erection

Depending on the load-bearing capacity of the auxiliary crane and the specifications or prerequisites on the building site (static dismantling procedure can only be arranged or determined on the building site while respecting the local conditions.

Erection and dismantling of the derrick crane therefore, can only be carried out by specially trained and instructed assembly personnel!

Erection Montagebeschreibung_Deckblatt_en.doc

Montagebeschreibung_Deckblatt_en.doc Erection

Table of contents

Content Page List: Smallest possible erection package units Erection information 3-1

1.0 Undercarriage assembly 3-2

2.0 Installing the outriggers 3-3

3.0 Installing the slewing platform with ball slewing ring 3-5

4.0 Installing the slipring assembly 3-6

5.0 Installing the slewing gear 3-7

6.0 Installing switchgear cabinet S1 3-8

7.0 Connecting switchgear cabinet S1 3-9

8.0 Installing the luffing gear frame complete with luffing gear 3-10

9.0 Luffing gear frame: Setting the stop position to the slewing platform 3-11

10.0 Installing the hoist gear frame complete with hoist gear 3-12

11.0 Installing the pulley block 3-13



13.0 Installing the ballast frame 3-16

14.0 Tower configuration 3-17

15.0 Preparing the tower for installation 3-18

16.0 Installing the tower 3-22

17.0 Installing the slipring assembly in the 1st tower section (not featured as standard)

3-24

18.0 Boom configuration 3-25

18.1 Preparing the boom for installation 3-27

19.0 Installing the boom 3-35

20.0 Installing the counter-jib guying ropes 3-37

21.0 Ballasting the counter-jib 3-38

22.0 Electrical crane erection 3-43

23.0 Reeving the luffing rope 3-44

24.0 Reeving the hoist rope 3-47

25.0 Removing the boom erection rope 3-53

26.0 Attaching the platforms (not featured as standard) 3-54

27.0 Installing the stifflegs (not featured as standard) 3-57

28.0 Setting the sensors and limit switches 3-70

Erection Montagebeschreibung_Deckblatt_en.doc

Packing list Smallest possible erection package units 200 DR 5-10

F:\bal2\Derrick 200DR5-10\Kap-3_Montage\Kolliliste Derrick 20.11.08_en.doc Page 1 of 3

Designation Pos. Qty. L (m) B (m) H (m) kg kg compl.

Undercarriage (without pins) 10 1 1,42 1,42 0,56

1140 (988)

-

Pin 11 4 0,526 0,120 0,120 38 152

Outrigger 12 4 2,399 0,400 0,425 376 1504

Support 13 4 1,410 0,110 0,090 95 380

Slewing platform with

slewing ring + bolts 14 1 1,66 1,615 0,61 1050 -

Slewing gear 15 1 1,254 0,360 0,360 170 -

Switchgear cabinet S1 16 1 0,900 0,662 2,050 323 -

Switchgear cabinet S2 17 1 1,520 0,828 1,551 407 -

Switchgear cabinet S4

18

1 1,520 0,828 1,551 332 -

Luffing gear frame complete 21 1 2,17 2,17 1,32 1850 1850

Luffing gear frame 22 2,17 1,16 1,32 1380 -

Luffing gear frame 23 2,17 1,16 0,73 590 -

Luffing gear 24 2,09 0,87 0,92 1240 -

Luffing gear motor 25/25a 1 1,08 0,45 0,52 470 -

Luffing gear

without motor 26 0,87 1,104 0,91 770 -

Luffing gear frame complete with

secondary brake 21a 1 2,17 2,17 1,5 2360 2360

Luffing gear frame secondary brake 22a 2,17 1,16 1,5 1890 -

Luffing gear frame secondary brake 23a 2,17 1,16 0,87 640 -

Luffing gear secondary brake

with motor 24a 2,08 1,115 1,115 1430 -

Luffing gear secondary brake without motor

26a 1,057 1,115 1,115 960 -




Pulley block 27 1 1,625 1,104 2,105 128 -

Hoist gear frame complete 31 1 2,12 2,01 1,65 2170 2170

Hoist gear frame 32 2,12 1,17 1,65 1640 -

Hoist gear frame 33 2,12 1,17 0,74 600 -

Hoist gear with motor 34 1,99 1,05 1,06 1540 -

Hoist gear motor 35 1 1,14 0,45 0,52 530 -

Hoist gear

without motor 36 1,042 0,966 1,056 1010 -

Hoist gear frame complete with

secondary brake 31a 1 2,18 2,09 1,83 - -

Hoist gear frame secondary brake 32a 2,18 1,23 1,83 - -

Hoist gear frame secondary brake 33a 2,12 1,17 0,95 - -

Hoist gear secondary brake

with motor 34a 1,99 1,42 1,42 - -

Hoist gear secondary brake without motor

36a 1,42 0,966 1,42 - -

Ballast frame 41 1 1,208 1,099 0,612 310 -

Ballast block 42 8 1,06 0,81 0,16 1000 8000

Pivot tower section 51 1 1,10 1,265 2,01 267 -

Tower section 52 1 1,255 1,10 2,03 360 -

Tower section 53 1 1,255 1,10 2,03 292 -

Tower section 54 1 1,334 1,10 2,03 296 -

Tower section 55 1 1,410 1, 341 1,205 229 -

Tower head (without ladders) 56 1 1,389

1,273 (1,10)

2,210 868 -




Retaining frame 57 1 1,168 1,04 0,979 47 -

Movable upright 58 2 1,975 0,255 0,160 60 120

Pivot section

B without platform 0,31m 61 1 1,910 1,379 1,435 152 -

Intermediate section B without platform 0,31m 62 8 2,230 1,379 1,070 152 1216

Intermediate section B without platform 0,31m 63 1 2,230 1,379 1,149 154 -

Intermediate section 64 1 2,230 1,379 1,149 197 -

Intermediate section without support


Support 64a 1 0,920 0,510 0,173 46 -

Head section


Wire-rope pulley

block 66 1 0,947 1,136 0,740 140 -

Bottom hook block 67 1 0,815 0,418 1,464 360 -

Head section 71 2 0,915 0,390 0,390 85 170

Intermediate section 72 8 2,004 0,390 0,390 160 1280



Foot section 75 2 0,961 0,390 0,390 90 180

Support shoe 76 2 0,796 0,500 0,236 95,5 191

Erection support 77 1 2,924 0,410 0,204 53

Strut 78 2 4,000 0,290 0,320 182 364

Slewing assembly platform 81 1 1,900 1,016 1,223 - 198

82 1 4,400 0,800 1,283 -

Counter-jib platforms

1 1,845 0,800 1,200 - 393

Bearing block (reel) 91 1 1,06 0,908 0,964 90 -

! Hoist rope 1,6 kg/m

200DR_Montage-en_1.docx Erection 3-1

Erection:

The individual erection steps can vary depending on the erection and/or transport possibilities (e.g. depending on the lifting capacity of the auxiliary crane).

Example 1: Undercarriage, outriggers, slewing platform with ball slewing ring, 1st tower section (folded down into the transport position), slipring assembly in the 1st tower section (not featured as standard) and slewing gear are assembled as one transport unit.

Example 2: Smallest possible assembly units

etc. see following pages.

1. Undercarriage 2. Outrigger 2.1 Outriggers

3. Slewing platform + 4. Slipring assembly

5. Slewing gear 6. Switchgear cabinet

3-2 Erection 200DR_Montage-en_1.docx

Erection (standard):

The derrick crane may only be erected on sites capable of withstanding the foundation loadings for this crane!

1.0 Undercarriage 1.1 Set down the undercarriage: Horizontal (1) and onto all bearing surfaces (2).

Maximum inclination: 1% When installing the outriggers and the connecting struts for the stifflegs (optional equipment), the assembly tolerances (3) must be met. If necessary, prop up the undercarriage!

The undercarriage must not be bolted to the underground!

Spirit level, not standard!

(1)

(2)

Weight: 990 kg

(3)


2.0 Installing the outriggers 2.1 Application options without stifflegs:

Application options with stifflegs:

2.2 Insert the outrigger (1), secure it with the pin (2), secure the pin (3) and adjust

the respective angle with the threaded rod of the support (4) (see point 2.1).

90 90 0 180 180 18090 120 120 120

90 90 0 180 180 18090 120 120 120

Weight: 380 kg

(1)

(3)

(2)

(4)


2.3 Insert all outriggers (1), pin, secure and set the respective angle using the

threaded rods (see point 2.1 and 2.2). 2.4 Push all outriggers upwards all the way to the stop (3) using the adjusting

screws (8 x) (2) and lock (4). 2.5 Prop up the outriggers as required (5). Check the exact position of all outriggers!

2.6 Anchor all outriggers to the building in accordance with the foundation loadings (6). Foundation loadings see chapter 2 "Applications engineering"

(2)

(3)

(4)

(1)

(5)

(3)(6)


3.0 Installing the slewing platform with ball slewing ring 3.1 Set down the slewing platform (with ball slewing ring) precisely onto the

undercarriage and bolt.

The bolt connections of the slewing platform to ball slewing ring connection (2) may not be loosened!

Weight: 1 050 kg

48 x M 20x140 10.9 ISO 4014 48 x washer 21 DIN 6916 48 x hexagon nut M 20 ISO 4032

See following page for installation of the slipring assembly.

High-tensile bolt connections: Observe the tightening torques! (1)

(2)


4.0 Installing the slipring assembly

4.1 Installing the slipring assembly (standard) (1). Respect the variants: whether the slipring assembly should be installed in the first tower section for a special crane application, for example (2).

(1)

(2)


5.0 Installing the slewing gear

5.1 Set down the slewing gear precisely and bolt (1).

Observe the marking (2)!

Weight: 170 kg

(2)

10 x M 16x45 10.9 ISO 4017 10 x washer VS 16-galv. DIN 6916

(1)


6.0 Installing switchgear cabinet S1

6.1 Hook the switchgear cabinet onto the slewing platform (1), pin both sides (2) and secure with spring plugs (3).

Weight: 323 kg

(1)

(2)

(3)


7.0 Connecting switchgear cabinet S1

7.1 Establish plug connection between slipring assembly (1) in the slewing platform and switchgear cabinet S1 (2).

Respect the variants: If the slipring assembly is to be installed in the first tower section for a special crane application (3), for example, connection may only be established following installation of the first tower section.

(2)

(3)

(1)


8.0 Installing the luffing gear frame complete with luffing gear

8.1 Insert the luffing gear frame complete with luffing gear in into the slewing platform (1), pin both sides (2) and secure the pin on each side (3).

Weight: 1750 kg

Variant featuring secondary brake: Weight 2 050 kg

(1)

(3)

(2)

(2)

(2)


9.0 Luffing gear frame: Setting the stop position to the slewing platform

9.1 Lift the slewing gear frame slightly and adjust the stop bolts (1) on both sides so that neither pin (2) is positioned at the far end of either slotted hole (3)+(4).

(3) (4)

(1)

(2)


10.0 Installing the hoist gear frame complete with hoist gear

10.1 Insert the hoist gear frame complete with hoist gear into the slewing gear frame (1), pin on both sides (2) and secure the pin on each side with spring plug (3).

Weight: 2170 kg (without secondary brake)

(1)

(2) + (3)


11.0 Installing the pulley block

11.1 Set the pulley block down onto the luffing gear frame (1), pin at the top (2) on both sides (3) and secure the pin on each side (4).

Weight: 130 kg

(1)

(3) + (4)

(3) + (4)

(2)



11.1 Insert switchgear cabinet S4 (1), fit handle pins on both sides (2) and secure with spring plugs (3).

Weight: 340 kg

(2)

(1)

(3)



12.1 Insert switchgear cabinet S2 (1), fir handle pins on both sides (2) and secure with spring plugs (3).

Weight: 410 kg

(2)

(1)

(3)


13.0 Installing the ballast frame

13.1 Insert the ballast frame (1), pin on both sides (2) and secure with spring plug (8 x) (3).

Weight: 310 kg

(2)

(1)

(3)

(3)


14.0 Tower configuration

Tow

er h

eel p

iece

(267

kg)

B

201.

002-

511.

000

Hin

ged

uprig

hts

(eac

h 60

kg)

B

201.

001-

512.

000

Ladd

er

B20

1.00

1-51

1.11

2 La

dder

B

201.

001-

521.

112

Ladd

er

B20

1.00

1-52

1.11

2 La

dder

B

201.

001-

521.

112

Ladd

er (3

x)

B20

1.00

1-53

1.11

2

Ret

aini

ng fr

ame

(50

kg)

Tow

er s

ectio

n (3

60 k

g)

B20

1.00

2-52

1.00

0 To

wer

sec

tion

(292

kg)

B

201.

002-

522.

000

Tow

er s

ectio

n (2

96 k

g)

B20

1.00

2-52

3.00

0 To

wer

sec

tion

(229

kg)

B

201.

002-

531.

000

Tow

er h

ead

(870

kg)

B

201.

002-

541.

000

Ladd

er (2

x)

B20

1.00

1-53

1.11

2

Flig

ht w

arni

ng c

ontro

l lig

ht

and

anem

omet

er (n

ot

feat

ured

as

stan

dard

)


15.0 Preparing the tower for installation

15.1 - Lay out the second tower section (.521) (1): Set down the tower section onto the squared timbers to prevent the deflection pulley (2) from becoming damaged.

- Insert the tower heel piece (3) precisely into the forks of the second tower section, pin (4) and secure with linch pins (8 x) (5).

15.2 - Attach the access ladders (6) and bolt to the tower sections (7).

(1)

(2)

(3)

(4)+(5)

(7)

(6)


15.0 Preparing the tower for installation 15.3 - Insert the other tower sections .522 / .523 / .531 precisely into the forks, then

pin and secure. Attach the access ladders and bolt them to the tower sections. See points 15.1 and 15.2.

Respect correct arrangement of tower sections and ladders! See point 14.0.

15.4 - Insert the tower head (8) precisely into the forks, then pin and secure. Insert

the access ladders (2 x) (9) and bolt them to the tower head . See points 15.1 and 15.2.

15.5 - Bolt the anemometer (10) (not featured as standard) and flight warning

control light (11) (not featured as standard) to the tower head. 15.6 - Lay the electric cables (12) in the tower, secure with cable ties and connect

the consumers (10 + 11). The counter-jib guying ropes can either be pinned to the tower now, or following erection of the tower, see point 20.1.

(8)

(9)

(12)

(10)

(11)


15.0 Preparing the tower for installation 15.7 - Lift the tower by the lifting lugs (13) until the retaining frame (14) can be

inserted precisely, pinned (15) and secured (16). 15.8 - Bolt the "Boom positioned at 80" limit switch (17) to the tower.

Lay the electric cable in the tower, secure with cable ties and connect the limit switch.

(13)

(14) (15)

(16) (17)

Weight: 50 kg


15.0 Preparing the tower for installation 15.9 - Insert both hinged uprights (18) on the tower heel piece, then pin (19) and

secure (20).

(18)

(19)

(20)

Individual weight: 60 kg


16.0 Installing the tower 16.1 - Set the tower down precisely onto the slewing platform (1). - Caution: Danger of crushing! - Guide the tower when setting down!

Weight: 2500 kg

(1) Ensure that the anemometer (not featured as standard) and the flight warning control light (not featured as standard) do not become damaged when lifting the tower!


16.0 Installing the tower 16.2 - Pin the tower to the slewing platform and secure (2).

(2) (2)


17.0 Installing the slipring assembly in the 1st tower section (not featured as standard)

17.1 Install and connect the slipring assembly (1) and transmission (actuator,

propeller shaft etc.) (2). See point 7.0 "Connecting switchgear cabinet S1"

Not featured as standard(1)

Standard

(2)


18.0 Boom configuration, page 1 of 2

330

kg

197

kg

152

kg

152

kg

152

kg

154

kg

152

kg

152

kg

152

kg

152

kg

152

kg

152

kg

140

kg

Boo

m li

fting

lug

9695

038

01

Boo

m re

tain

ing

rope

8.5

m

1016

863

7

Pulle

y bl

ock

9694

598

01

Boo

m li

fting

lug

9695

038

01

Ere

ctio

n re

tain

ing

rope

15.

1 m

10

16 8

640

Wei

ght:

2.35

t (b

oom

wei

ghed

)


18.0 Boom configuration, page 2 of 2

330

kg

197

kg

152

kg

152

kg

154

kg

152

kg

152

kg

152

kg

152

kg

152

kg

140

kg

Boo

m li

fting

lug

9695

038

01

Boo

m re

tain

ing

rope

4.6

5 m

10

168

638

Pulle

y bl

ock

9694

598

01

Boo

m li

fting

lug

9695

038

01

Ere

ctio

n re

tain

ing

rope

15.

1 m

10

16 8

640

Wei

ght:

2.00

t (b

oom

wei

ghed

)


18.1 Preparing the boom for installation 18.1 Prepare the intermediate boom section (1) (insert timbers underneath).

Insert the boom pivot piece (2) precisely into the intermediate boom section, then pin (3) and secure (4).

- Caution: Danger of crushing! - Always remain on the outside of the boom sections when

guiding or holding!

Weight: 152 kg

When inserting and securing: Do not damage the angle sensor!

Weight: 152 kg

(1)(2)

(3)

(4)


18.2 Prepare the additional intermediate boom sections (1) (insert timbers

underneath), then insert, pin (2) and secure (3).

Respect arrangement of the intermediate boom sections! See boom configuration, onwards of point 18.0.


guiding or holding!

(1)

(2)

(3)

4x


18.3 Insert the intermediate boom section (.631) in the mounted boom (1), then

insert, pin (2) and secure (3). 18.4 Lift the boom, insert the boom head section (.641) in the mounted boom (1),

then pin (2) and secure (3). 18.5 Set the down boom on the supports (5) on the boom head section.

Fold the twist compensator (4) to point in the same direction as the boom when setting down the boom to ensure that the twist compensator does not become damaged!


guiding or holding!

(1)

(2)

(3)

4x

(.631) (.641)

(4)

(5)


18.6 Set the deflection pulley support (approx. 50 kg) (1) for the hoist rope down

on the mounted boom and then bolt (2). 18.7 Bolt the flight warning control light (not featured as standard) (3) to the fixture

on the boom head section (4). 18.8 Establish electric cabling (inductive sensor (5), load-measuring axle (6) and

flight warning control light (3)) and lay the lines precisely in the cable channels (7).

(1)

(2)

(3)

(7)

(6)

(5)

(4)

Weight: approx. 50 kg


18.9 Insert all catwalks (B201.001-6??.200) (1) in the fixtures on the boom (2) and

then bolt (3).

(3)

-611. -612. -612. -612. -612. -612. -612. -612. -612. -612. -631. -641.


18.10 Set the pulley block (140 kg) (1) down precisely on the boom and secure

against slipping (2). 18.11 Attach the boom retaining ropes (2 x 8.5 m) (3) in the balance of the pulley

block, then pin (4) and secure (5). 18.12 Attach the boom retaining ropes (2 x 8.5 m) (3) to the fixed points (both

sides), then pin (6) and secure (7).

(2)

(1)

(3)

(4) + (5)

(3)

(6) (7)

Weight: 140 kg


18.13 Attach the boom erection retaining ropes (2 x 15.1 m) (1) to the fixed points

(2), then pin (3) and secure (4).

(4)

(1)

(1)

(2)

(2)

(3)


18.14 Bolt the boom lifting lugs (4 x) (1) to the top chords of the boom (2) and

secure (3).

Centre of gravity and weights depending on the boom length, see onwards of point 18.0.

(1)

(1)

(2) + (3)

(1)(1)


19.0 Installing the boom 19.1 Secure the lifting slings onto the lifting lugs (1), lift the boom, insert in the

slewing platform (2), pin on both sides (3) and secure the pins on the inside and on the outside with axle supports (4).

- Caution: Danger of crushing! - It is prohibited to remain between slewing platform and boom!

Weight: 25.0 m boom: 2.35 t 20.0 m boom: 2.00 t

(1)

(2)

(3)

(3)

(4)

3-36 Erection 200DR_Montage-en_2.doc

19.2 Pull the boom erection ropes (1) to the fixed poin ts on the tower (2) using an

auxiliary rope, then pin on both sides (3) and secu re with linch pin (4). Caution: Danger of toppling!

(1)

(2)

(3)

(4)

200DR_Montage-en_2.doc Erection 3-37

20.0 Installing the counter-jib guying ropes 20.1 Pull the counter-jib guying ropes (1) to the locat ing points on the tower (2)

using an auxiliary rope, then pin on both sides (3) and secure with linch pins (4).

Caution: Danger of toppling! 20.2 Pull the counter-jib guying ropes to the locating points on the counter-jib (5),

then pin on both sides (6) and secure with linch pi ns (4).

(1)

(2)

(5)

(4)

(3)

(6)


21.0 Ballasting the counter-jib 21.1 Number of counterweights: 8 steel blocks (each 100 0 kg) = 8000 kg 21.2 Ballasting procedure: - Apply rubber strips (1). Screw in threaded rods (2) and attach

2 short guide sleeves (3).

(2)

(3)


21.3 Secure the lifting slings onto the ballast block ( 4) 21.4 fit over the threaded rods (5) and set down preci sely onto the counter-jib

(6).

Guide the ballast blocks when setting down to preve nt the threaded rods from becoming damaged!

21.5 Attach long guide sleeves (7) and rubber strips (8 ).

(5)

(6)

(7) (8)


21.6 Before continuing installing the ballast blocks, e nsure correct length of the

counter-jib guying ropes (1), adjust as necessary.

The guying rope length is correct if: - neither pin (2) is positioned at the end off the slotted h ole (3) +(4)! - Prerequisite: Both stop bolts must be free (5)!

21.6.1 See following page for adjustment of the length of the counter-jib guying

ropes.

(3) (4)

(2)

(5)


21.6.2 Adjusting the length of the counter-jib guying rop es:

- Lift the counter-jib (1) until the guying ropes are free of tension.

- Adjust the length of the guying ropes via the adjus ting screws (2).

- Lower the counter-jib into the guying once again an d check the settings on both sides, see point 21.6 (previous page).

- Repeat the procedure as necessary.

- Check the setting, see point 21.6!

- Continue to check the setting as additional balla st blocks are installed (see following page)! If necessary, discontinue the installation of further ballast blocks and readjust the guying ropes!

- Fit lock nuts to the adjustment screws (3).

(1)

(2)

(3)


21.7 Set down all ballast blocks (9) (8 blocks overall) as described between point

21.3 to 21.5.

Guide the ballast blocks as they are being set down to prevent the threaded rods from becoming damaged!

21.8 Brace and secure all ballast blocks with each othe r: - Fit the bracket (10) and washers (11), tighten th e nuts (12) and fit lock nuts

(13). - Insert the locking bar (14) and secure with cotte r pins (15).

21.9 Check the setting of the counter-jib guying ropes again, see point 21.6!

(9)

(10)

(11)

(12)

(13)

(14) (15)


22.0 Electrical crane erection Caution: Danger as a result of electrical energy!

- Work on the electrical equipment on the crane may only be carried out by an electrical specialist in compliance with the ele ctro-technical regulations.

- Distribution, earthing and protective devices mus t comply with the local guidelines!

See chapter 6 for a detailed description of the fol lowing installation points 22.1 to 22.6.

22.1 Plug in all connection lines at switchgear cabinet S1 (control / slewing gear). 22.2 Plug in all connection lines at switchgear cabinet S2 (hoist gear). 22.3 Plug in all connection lines at switchgear cabinet S4 (luffing gear). 22.4 Connect limit switches and sensors.

An inspection of the functions and correct settings can only be carried out after the electrical erection of the crane and following installation of the luffing rope and hoist rope. See the description "Reeving the luffing rope", "Re eving the hoist rope" and "Sensor and limit switch settings " on the following pages.

22.5 Installing the lightning protection and the earthin g. Respect all local

guidelines. 22.6 Plug in the power line (plug 150A) from the sliprin g assembly at the site

junction box. The entire electrical equipment of the crane is re ady for operation!


23.0 Reeving the luffing rope 23.1 Position the reel with auxiliary rope under the bo om and secure against

tipping (1).

23.2 Reeve the auxiliary rope (rope pulleys 1. to 6.) and fasten on hoist gear drum (2).

23.3 Position the reel with luffing rope under the boom and secure against tipping (3).

23.4 Connect the other end of the auxiliary rope with t he luffing rope (4)

(1)

3.

2.

1.

4.

5.

6.

(2)

(3)

(4)


23.5 Actuate "Hoist up" slowly and reeve the luffing ro pe using the auxiliary rope

(1). The rope should not be permitted to become snagged on the rope guard

pins (2) on the luffing rope pulley block (3) and i n the tower head (4)! If necessary, dismantle the rope guard pins and, when the luffing rope has been reeved, reinstall and secure the rope guard pi ns.

23.6 Wind on the luffing rope approx. 3 windings onto t he hoist gear drum (5). 23.7 Secure the luffing rope against slipping through ( by tying) (6).

(2)

(3)

(4)

(1)

(5)

(6)


23.8 - Wind off the luffing rope from the hoist gear dr um.

- Separate the luffing rope from the auxiliary rope . - Bolt the luffing rope with the luffing gear drum (1).

23.9 Remove the slip arrester (2).

Caution: The luffing rope is taut!

23.10 Pull the other end of the luffing rope to the loca ting point on the tower head using an auxiliary rope, then pin and secure (3).

23.11 Wind on the luffing rope slowly until the luffing rope pulley block lifts off the boom. Remove the protective device (see point 18.10 ) and continue to wind on the luffing rope until the boom hooks into the g uying.

Check the winding on the luffing gear drum!

(1)

(2)

(3)


24.0 Reeving the hoist rope Variants:

2-fall hoist rope

1-fall hoist rope


24.0 Reeving the hoist rope: One-fall 24.1 Manoeuvre the boom to maximum radius.

24.2 Set the hook block down on the ground at maximum r adius (1) and secure against tipping. Insert the anti-tilt devices (located in the hook block) from both sides of the hook block into the boreholes speciall y provided (2) and secure on both sides with spring plugs (3).

24.3 Set the hoist rope reel down next to the hook block and secure against tipping (4).

24.4 Wind off the erection auxiliary rope from the hois t drum and then reeve (5). The erection auxiliary rope is already wound onto t he hoist drum from the mounting of the assembly rope carried out previ ously.

24.5 Connect the erection auxiliary rope to the hoist r ope (6). (2)

(1)

(3)

(6)

(2)

(4)

(5)


24.6 Reeve the hoist rope slowly ("Hoist up") (1).

Check: The hoist rope should not be permitted to be come snagged on the rope guard pins (2)!

24.7 Wind the hoist rope onto the hoist drum approx. 3 windings (3).

24.8 Secure the hoist rope against slipping through (by tying) (4).

(2)

(3)

(4) (1)


24.9 Wind off the hoist rope from the hoist drum (1) an d separate from the erection

auxiliary rope (2).

24.10 Wind off the erection auxiliary rope from the hois t drum and wind onto reel (3).

24.11 Bolt the hoist rope to the hoist drum (4).

24.12 Remove the slip arrester (5).

Caution: The hoist rope is taut!

24.13 Wind on the hoist rope (6)

If possible, wind on under tension (10% of the max. load)! Pretensioning of the hoist rope increases life-expe ctancy of the rope!

(4)

(1)

(2)

(3)

(5)

(6)


24.14 until there are at least 2 rope windings on the reel (1).

24.15 Tie the hoist rope on the hook block (using a hemp rope) (2). Depending on the boom length and the erection heigh t, the hoist rope weight above the boom can be higher than that from the boom head section to the ground. A higher dead weight ab ove the boom would pull the hoist rope uncontrollably upward!

24.16 Wind off the rest of the hoist rope from the reeve (3).

24.17 Pin the hoist rope to the hook block (4) and secur e with linch pin (5).

(4)

(1) (2)

(3)

(5)


24.18 Continue to wind off the hoist rope slowly set dow n the hook block (1).

Caution: Danger of tipping!

24.19 Insert the anti-tilt devices in the hook block aga in (2) and secure (3).

(1)

(2)

(3)


25.0 Removing the boom erection rope 25.1 Unpin both boom erection ropes (1) on the boom, wind up and secure to the

tower.

Caution: Secure the boom erection ropes so that they cannot collide with the hoist rope (2) or other moving parts!

(1)

(2)


26.0 Attaching the platforms (not featured as standard) Page 1 of 3 26.1 Assembling the platforms.

See following pages for detailed drawings.

26.2 Hook on and secure the platforms. Handrails (1) / checker plate (2) fastenings and platform supports (3)

(2)

(1) (3)


Page 2 of 3


Page 3 of 3


- The foundation loading values (tractive forces

and pressures) must be observed, see chapter 2 "Applications engineering"

- See the following pages for fixing options for the outriggers and the stifflegs!

27.0 Installing the stifflegs (not featured as standard) 27.1 Preparing the stifflegs for installation.

See the following pages for detailed drawings featuring installation dimensions and assembly instructions.

27.2 Overview:


27.3 Detailed drawings featuring installation dimensions: Page 1 of 5

3-61.1 Erection 200DR_Montage-en_3-61.1.docx

27.6.1 Detailed drawings featuring installation dimensions: Page 5 of 5

200DR_Montage-en_3-61.1.docx Erection 3-61.2


27.7 Installing the connecting struts (1 + 2) between outriggers and stifflegs (high-

tensile bolt connection).

- Do not set the connecting struts down on the ground! - Underlays must be inserted underneath the outriggers (3), see

detailed drawings featuring installation dimensions, page 1 of 4! - See the chapter "Maintenance" for details regarding high-tensile bolt

connections and tightening torques.

Weight: 182 kg

8 x hexagon bolts M24 x 60-8.8 ISO 4017 8 x nuts M24-10 ISO 4032 8 x washers VS 24

(1)

(3)

Weight: 182 kg

(2)


27.8 Installing the support shoe (1), pinning (2) and securing on both sides (3)

- Observe the fixing options and the presetting measurements (4)! The precise measurements can only be applied following subsequent assembly of the stifflegs! See detailed descriptions, point 27.6.

- Underlays must be inserted beneath the support shoes as required! See detailed descriptions, point 27.3 to 27.6.

27.9 Removing the connecting pins (4).

Weight: 100 kg

(3) (2)(1)

(4)

(4)


27.10 Preparing both stifflegs (1) for installation Page 1 of 2

- Respect the order of assembly and arrangement (top/bottom)! See fig. below.

- See the chapter "Maintenance" for details regarding high-tensile bolt connections and tightening torques.

12 x hexagon bolts M16 x 65-8.8 ISO 4017 12 x nuts M16-10 ISO 4032 12 x washers VS 16

Overall weight: 1150 kg

160 kg

160 kg

160 kg

160 kg

165 kg

160 kg

90 kg


27.10 Preparing both stifflegs (1) for installation Page 2 of 2 27.10.1 Installing (3) the erection rope (2).

- The correct angle of inclination (approx. 50- 60) can be ascertained for the following assembly by way of various fixing points (4)!

- Lock the erection ropes during crane operation (5). - Secure the guide rope (6).

(2)

(3)

(5)

(4)

(1) (6)


ca. 90

27.11 Lift the stiffleg and insert into the bearing of the tower head: 27.11.1 Turn with the crane until the boom is positioned approx. 90 to the stiffleg

(1)! 27.11.2 Observe the angle of inclination (approx. 50-60) (2) of the suspended

stiffleg! Insert the stiffleg precisely into the bearing and pin (3), see following pages!

approx. 50 - 60

(2)

(3)(1)

(4)

Overall weight: 1 150 kg


27.11.3 Insert the stiffleg precisely into the bearing using the guide rope (1).

If necessary, secure a Tirfor winch (2) to the tower head and pull the stiffleg into the exact position using the Tirfor winch and the guide rope!

27.11.4 Pin the stiffleg to the tower head (3) and secure (4).

(1)

(2)

(3)

(4)


27.11.5 Insert (2) the stiffleg precisely into the support shoe (1):

If the pinning points (3) are not correctly aligned: - Turn with the crane slowly until the boreholes align with one

another. - If no pinning can be reached by turning the crane, the stiffleg must

be lifted and the support shoe adjusted accordingly (5) via the threaded rod (4).

27.11.6 Pin the stiffleg to the support shoe (6) and secure (7):

(2)

(1)

(3)

(5)

(6)

(7)

(4)


27.11.7 Install the second stiffleg (1), as described onwards of point 27.11. 27.11.8 Turn the stops of both stifflegs on the block (2) and lock (3). 28.0 See following pages for information regarding the setting of

sensors and limit switches.

(1)

(2)

(3)

3-70 Setting the limit switches ES-Einstell_200DR-rus_en.doc

28.0 Setting the sensors and limit switches:

Content

3.8 Sensors 3-71

Angle transmitter 3-71

Wind speed 3-71

Hook level 3-72

Load measuring axle Luffing gear 3-72

Load measuring axle Hoist gear 3-72

Pulse generator Boom head 3-73

3.9 Setting the limit switches 3-74

Notes on setting the limit switches 3-74

Shutdown position 3-75

Tower position 3-76

Boom position (rotating-gear limit switch luffing gear) 3-80

Slewing gear limitation (rotating-gear limit switch slewing platform) 3-85

ES-Einstell_200DR-rus_en.doc Setting the limit switches 3-71

3.8 Sensors

3.8.1 "Angle transmitter" sensor (boom pivot section)

C+A-B5

Scaling the radius, see "Manual for PLC-controlled Derrick cranes"

Check the sensor prior to scaling and adjust as necessary: Setting "max. radius" (at 15)

Measure the distance (x) from the middle of the tower to the middle of the hook block and make a marking on the ground.

The distance (x) corresponds with scaling of the crane: - 1-fall: x = 25.25 m - 2-fall: x = 24.80 m Lower the boom until the hook block is posi-tioned exactly above the marking (from point 1). Set the angle sensor to 15 inclination. Check the settings via EMS-2 and if necessary, check with an angle spirit level.

See chapter 3.9 "Boom position" rotating-gear limit switch (luffing gear)!

3.8.2 "Wind speed*" sensor (tower head)

D+A-B2

* - not featured as standard! -

2

15

x1

3

(*)

No setting necessary!


3.8 Sensors 3.8.3 "Hook level" sensor (hoist gear)

B+A-B4

3.8.4 "Luffing gear load measuring axle" sensor (tower)

B+A-B1

3.8.5 "Hoist gear load measuring axle" sensor (boom head)

B+A-B1

Scaling of the load moment, see "Manual for PLC-controlled Derrick

cranes". Scaling, chapter 2.2.8.5

Scaling of the load, see "Manual for PLC-controlled Derrick cranes".

Scaling, chapter 2.2.8.4

Scaling the hook level, see "Manual for PLC-controlled Derrick cranes".

Scaling, chapter 2.2.8.6


3.8 Sensors

3.8.6 "Pulse generator" sensor (boom head)

D+A-B1 / PLC-input +A-KF1 E62.00

Recording of hook level, see "Manual for PLC-controlled Derrick cranes".

Scaling, chapter 2.2.8.6.1


3.9 Setting the limit switches

3.9.1 Notes on setting the limit switches Switching characteristics:

Not actuated

Switching point of the limit switch

Actuated up to (adjustment range)

Ruination (mechanical)

Optimum switching position

General checks:

Danger as a result of electrical energy!

- Setting of the limit switches may only be underta ken by authorised, specialist personnel.

- If work is necessary on voltage-carrying parts, a second person is to be introduced to switch off the main switch in the eve nt of an emergency.

Check freedom of movement!

Contamination?

Damage?

Do not open the cover!

Fastening screws tight?

Connection of cable tightly secured?


3.9 Setting the limit switches 3.9.2 "Shutdown position" limit switch (tower)

F+A-B1 (break contact) / PLC-input +A-KF2-E62.14

It is possible to set the limit switch prior to, or even during, crane erection.

"Shutdown position" setting 1. The retracted boom pushes against the articulated fall-back guard strut. 2. The fall-back guard strut actuates the "shutdown position" limit switch (F+A-B1).

3. See "Switching characteristics", point . 4. The limit switch must be set with a safeguard

against ruination! Thus, the fall-back guard strut must have

reached its mechanical end position before the limit switch has reached point .

Fall-back guard strut

Tower

F+A-B1

Fall-back guard strut

Tower

[ 1 ]

[ 2 ]

[ 3 ]

[ 4 ]

[ 4 ]



3.9.3 "Tower position" limit switch (slewing platform)

B+A-B2 (break contact) / PLC-input +EKF4 E42.00 B+A-B3 (break contact) / PLC-input +EKF4 E42.04

Hooking on the actuating lever

1. Limit switch (B+A-B2) Tower "raised " minimum radius 2. Limit switch (B+A-B3) Tower "lowered " maximum radius 3. Before commencing tower inclination

operation. The actuating lever of the limit switch must be pinned to the tower!

4. Actuating lever 5. Lower the tower until the actuating lever [4] can be pinned to the boom. 6. Hook the actuating lever [4] onto the boom and pin. 7. The guide rails restrict the path of the actuating lever [4]. Risk of ruination! Do not manoeuvre the actuating lever

against the "block" when in the end positions!

[ 1 ] raised

[ 2 ] lowered

[ 3 ] [ 4 ]

[ 5 ]

[ 6 ]

[ 5 ]

[ 4 ] Tower inclination

[ 7 ]


3.9.3 "Tower position" limit switch (slewing platform) Setting B+A-B2: Tower position "raised" (min. radius)

1. Loosen the fastening screws and push back the limit switch (B+A-B2). 2. Actuating lever 3. Manoeuvre the tower into the "raised " end

position. The actuating lever shifts towards the

"raised" end position. Risk of ruination!

Do not manoeuvre the actuating lever against the "block" when in the "raised" end position!

4. The actuating lever is positioned in the

"raised" final position. 5. Push the limit switch against the actuating

lever to switching point plus approx. 8 mm .

See the point regarding "Switching characteristics".

6. Tighten the fastening screws! The limit switch has been set with a

safeguard against ruination.

[ 3 ]

[ 3 ]

[ 2 ]

[ 1 ]

[ 2 ]

[ 4 ]

[ 4 ]


5,8 m

x


Setting B+A-B3: Tower position "lowered" (max. radius)

1. The maximum radius "x" is measured from the middle of the ball slewing ring to the boom head (hook).

Before setting limit switch B+A-B3, establish the maximum radius "x" and make a marking on the ground! See capacity plate [2]. 2. Capacity plate with pendulum indicator. 3. Load chart ( tower inclination operation) 4. The pendulum indicator ( radius

indicator) shows the actual radius in meters [m], as well as the actual boom inclination in degrees [].

Maximum radius = 5.8 m (~ 55) 5. Loosen the fastening screws and push back the (B+A-B3) limit switch. 6. Actuating lever 7. Manoeuvre the tower into the "lowered "

end position. The maximum radius "5,8m" (marking [1])

must correspond with the pendulum indicator [4]!

The actuating lever shifts toward the "lowered" end position, see [ 8 ]. Risk of ruination! Do not manoeuvre the actuating lever

against the "block" when in the "lowered" end position!

0m 3,6m5,1m

5,8m

90 70 6

055

200DR5-10

/ m

m kg

Radius

Hoo

k he

ight

[ 2 ]

[ 3 ]

[ 1 ]

0m 3,6m 5,1m 5

,8m

90 70 60

55

[ 4 ]

[ 2 ]

[ 5 ]

[ 6 ]

[ 7 ]

[ 1 ]



Setting B+A-B3: Tower position "lowered"

The tower is positioned in the "lowered" end position. - Radius "5.8m" reached (marking [1]). - Pendulum [4] indicates 5.8m radius. 8. Actuating lever positioned in "lowered" end

position. 9. Push the limit switch against the actuating

lever up to the switching point plus approx. 8 mm . See the point regarding "Switching

characteristics".

10. Tighten the fastening screws! The limit switch has been set with a

safeguard against ruination.

[ 9 ]

[ 6 ]

0m3,6m 5,1m 5,8m

9070 60 55



3.9.4 "Boom position" rotating-gear limit switch (luffing gear)

B+A-B1

Type: G50-050-T04/02Y, Part No. 6060 629 01

6 control elements (T 697-01-1), each control element a button featuring 1 break contact

Transmission ratio: i=1:50

Caution: With rope elongation or installing or remo ving the stifflegs, the settings must be checked, and adjusted wherever necessary!

The screwdriver for adjusting the cam plates is mounted in the housing of the rotating-gear limit switch.

Set the limit switch before scaling the sensors!

Observe rotational direction of the cams

Example: Boom is manoeuvred "downwards"

1

23

4

2L 2R

1L 4 3 2 1

1 L3 L

2 L4 L4 R2 R

1 2 3 4

Get-Einstell_200DR.dsf

Rotational direction Rotational direction


3.9.4 "Boom position" rotating-gear limit switch (luffing gear) Notes on setting the rotating-gear limit switches (manufactured by Schmersal) B+A-B1

Open the cover

Einstellung Feineinstellung

1

23

4

1

2

4

3

1

23

4

Limit switch

Setting

Control cams

Definition of the switching states!

Examples: contact position / pressed pressed passed / free

Exercise caution when elongating ropes on the luffi ng gear! Following lengthy periods of crane operation, the switching p oints of the rotating-gear limit switches may shift!

Setting Fine adjustment



Cutoff range

Boom positions:

Emergency-Stop "lowered" (4L) (boom fully lowered!) Soft limit switch "lowered"

Soft limit switch "raised"

Shutdown position See chapter 5.9 Emergency-Stop "raised" (2L) (boom fully raised!)

Cutoff "Boom raised" (Emergency-Stop function ) B+A-B1-2L (break contact) / PLC-input S4:+E-KF4 E42.00

Cutoff "Boom lowered" (Emergency-Stop function ) B+A-B1-4L (break contact) / PLC-input S4:+E-KF4 E42.04

Before scaling the sensors, set the "Emergency-Stop lowering" limit switch!

5

4 3

1

2

14

15

4 3 2 1

2 L4 L4 R2 R

1 2 3 4

1 L3 L


4L 2L

2L 90 cam (break contact) Emergency-Stop "raised" (at ~81)

4L 90 cam (break contact) Emergency-Stop "lowered" (at ~15)

Observe rotational directions of the cam plates!

B+A-B1


4 3 2 1

2 L4 L4 R2 R

1 2 3 4

1 L3 L


4L 2L

3.9.4 "Boom position" rotating-gear limit switch (luffing gear) Setting B+A-B1: Emergency-Stop "lowered" (4L)

Angle transmitter set? See chapter 3.8.1 "Angle transmitter" sensor Operating mode switch set at "Operation "! Manoeuvre the boom "downwards " into

the cutoff range. CAUTION! At least 3 safety rope windings must be wound on the rope drum! The boom has reached the 14 position. Set Emergency-Stop limit switch 4L so that

it is activated at 14 boom position. 4L (90) is pressed in the "contact

position".

Manoeuvre the boom "upwards " beyond

the cutoff range (> 15).

4L

1

1415

- When the "Emergency-Stop lowered" (4L) limit swit ch has been set, the

derrick crane must then be scaled, see "Manual for PLC-controlled Derrick cranes".

- Exercise caution when elongating ropes on the luf fing gear! Following lengthy periods of crane operation, the switching p oints of the rotating-gear limit switches may shift!

3

1415


4 3 2 1

2 L4 L4 R2 R

1 2 3 4

1 L3 L


4L 2L


Setting B+A-B1: Emergency-Stop "raised" (2L) As the Emergency-Stop limit switch "raised" can only be set in the shutdown position of the crane, the crane must first be scaled (radius).

Has the crane been scaled? See "Manual for PLC-controlled Derrick cranes".

Operating mode switch set at "Operation "! Manoeuvre the boom "upwards " into the

cutoff range. The luffing gear cuts out when the boom

reaches minimum radius. Has the "shutdown position" limit switch

been set? No! See chapter 3.9.2. Yes! Continue to point . Manoeuvre towards the "shutdown

position ".

See chapter 5.9. The crane has reached the shutdown position.

Set Emergency-Stop limit switch 2L.

Turn the control cam on switch "2L" so that it is actuated immediately upon exceeding the shutdown position, thus

preventing any damage occurring to the crane.

2L (90) is pressed "upon contact" from

a clockwise direction.

3

4

1

2

2L


3.9 Setting the limit switches 3.9.5 Limit switch (2x) "Slewing gear limitation" (spur gear)

C+D-B1 (break contact) PLC-inputs, see circuit diagram C+D-B2 (break contact) PLC-inputs, see circuit diagram

The slewing limitation must be connected and activa ted before initiating operating mode 2 (with stiffleg). It should prevent collisions between boom and stiffleg via the speed reduction and motion cutoff.

Two parallel running rotating-gear limit switches assume the speed reduction and motion cutoff of the slewing gear. The limit switches are mounted on the slewing gear and are driven via a gear-type wheel which engages the ball slewing ring.

Activating the slewing gear limitation

Before setting the limit switches, the rotating-gear limit switches must be mounted on the slewing platform of the crane. The limit switches are connected to the control via plug connection "+D-X5". Plug connection "+D-X5" and pre-selected operating mode 2 allows activation of the slewing gear limitation.

2x

Boom

Left-hand rotational direction

Right-hand rotational direction

Rotating-gear limit switch


3.9.5 Limit switch (2x) "slewing gear limitation" (spur gear) Notes on setting the rotating-gear limit switches (TER)

1. Loosen the locking screw before setting

the control cams and tighten again once the control cams have been set. 2. Adjusting screws for turning the control

cams ( to ).

Caution: When adjusting the control cams, ensure that no other cams are moved at the same time!

3. Pointed cam: motion cutoff "left" Adjusting screw 4. Pointed cam: motion cutoff "right" Adjusting screw 5. 90 cam: speed reduction "left" Adjusting screw 6. 90 cam: speed reduction "right" Adjusting screw

Cutoff range:

The motion cutoff reduces the slewing speed to 10% of its maximum speed. It should be ensured with cutoff of the slewing gear that the stiffleg is not reached or touched when unfolding the boom, see [ 1 ] "Possible collision points".

max. 120

[ 3 ]

[ 4 ]

[ 5 ]

[ 6 ]

[ 2 ]

Boom

Stiffleg

Speed reduction "right" 90 cam

Speed reduction "left" 90 cam

Motion cutoff "right" pointed cam

Motion cutoff "left" pointed cam

Ball slewing ring (KUD)

Stiffleg

[ 1 ] Possible collision points


3.9.5 Limit switch (2x) "slewing gear limitation" (spur gear)

Setting: Pre-limit switch "left" (C+D-B1 and C+D-B2)

1. Point of speed reduction "left " 2. Point of motion cutoff "left" 3. The point of speed reduction "left" is

approx. 25 cm before the intended point of motion cutoff [2].

( measured at the ball slewing gear!)

4. Manoeuvre the boom to the point of speed

reduction "left".

5. Set the point of speed reduction "left" at both limit switches, C+D-B1 and C+D-B2.

Caution: The switching points of C+D-

B1 and C+D-B2 must be as close to one another as possible!

Setting procedure:

See "Notes on setting the rotating-gear limit switches"

6. Set the adjusting screw (90 cam) to "contact position ".

Boom

Ball slewing ring

Stiffleg

[ 1 ]

[ 3 ] [ 2 ]

Limit switches (B1+B2)

[ 4 ]

Stiffleg

[ 1 ]

C+D-B1 C+D-B2

[ 5 ]

[ 6 ]



Setting: Limit switch "left" (C+D-B1 and C+D-B2)

1. Point of motion cutoff "left" 2. The set point of speed reduction "left" reduces the slewing speed to 10% of the max. speed! Caution: Risk of collision! If the boom is manoeuvred towards the point of motion cutoff, no contact

should be made with stiffleg! 3. Manoeuvre the boom to the point of motion

cutoff "left". 4. Set the point of motion cutoff "left" on both limit switches, C+D-B1 and C+D-B2. Caution: The switching points of C+D-


Setting procedure:


5. Set the adjusting screw (pointed cam) to "contact position ".

Stiffleg

[ 2 ]

[ 1 ]

[ 3 ]

C+D-B1 C+D-B2

[ 4 ]

[ 5 ]



Setting: Limit switch "right" (C+D-B1 and C+D-B2)

1. Point of speed reduction "right " 2. Point of motion cutoff "right" 3. The point of speed reduction "right" is

approx 25 cm before the intended motion cutoff [2].

( measured at the ball slewing ring!)

4. Manoeuvre the boom to the point of speed

reduction "right".

5. Set the point of speed reduction "right" at both limit switches, C+D-B1 and C+D-B2.

Caution: The switching points of C+D-


Setting procedure:


6. Set the adjusting screw (90 cam) to "contact position ".

Boom

Ball slewing ring

Stiffleg

[ 1 ]

[ 3 ]

[ 2 ]

Limit switches (B1+B2)

[ 4 ]

Stiffleg

[ 1 ]

C+D-B1 C+D-B2

[ 5 ]

[ 6 ]



Setting: Limit switch "right" (C+D-B1 and C+D-B2)

1. Motion cutoff "right" 2. The set point of speed reduction "right" reduces the slewing speed to 10% of the max. speed!

Caution: Risk of collision! If the boom is manoeuvred towards the

point of motion cutoff, no contact should be made with stiffleg!

3. Manoeuvre the boom to the point of motion

cutoff "right". 4. Set the point of motion cutoff "right" on

both limit switches, C+D-B1 and C+D-B2.

Caution: The switching points of C+D-B1 and C+D-B2 must be as close as possible to one another!

Setting procedure:


5. Set the adjusting screw (pointed cam) to "contact position ".

Stiffleg

[ 2 ]

[ 1 ]

[ 3 ]

C+D-B1 C+D-B2

[ 4 ]

[ 5 ]

Demontagebeschreibung_Deckblatt_en.doc Dismantling 3-90.1

Dismantling:

Depending on the load-bearing capacity of the auxiliary crane and the specifications or prerequisites on the building site (static dismantling procedure can only be arranged or determined on the building site while respecting the local conditions.

Erection and dismantling of the derrick crane therefore, can only be carried out by specially trained and instructed erection personnel!

3-90.2 Dismantling Demontagebeschreibung_Deckblatt_en.doc

Demontagebeschreibung_Deckblatt_en.doc Dismantling 3-90.3

Table of contents

Content Page List: Smallest possible erection packing units 1.0 Erection / dismantling information 3-91

2.0 Dismantling the stifflegs (not featured as standard) 3-92

3.0 Dismantling the counterballast 3-102

4.0 Dismantling the hook block 3-104

5.0 Dismantling the boom 3-106

6.0 Modifying to "Tower inclination operation" 3-110

7.0 Dismantling the counterballast frame 3-120

8.0 Dismantling the boom into individual sections 3-122

9.0 Dismantling the hoist gear 3-130

10.0 Dismantling switchgear cabinet S2 and the hoist gear frame 3-134

11.0 Dismantling the tower 3-136

12.0 Dismantling the pulley block 3-144

13.0 Dismantling the luffing gear and switchgear cabinet S4 3-146

14.0 Dismantling the luffing gear frame 3-148

15.0 Dismantling switchgear cabinet S1 3-150

16.0 Dismantling the slewing gear 3-152

17.0 Dismantling the slipring unit 3-154

18.0 Dismantling the slewing platform (including ball slewing ring) 3-156

19.0 Dismantling the outriggers 3-158

20.0 Dismantling the undercarriage 3-160

3-90.4 Dismantling Demontagebeschreibung_Deckblatt_en.doc

200DR_Demontage-en_1.doc Dismantling 3-91

Dismantling:

Depending on the crane variant (see below), and depending on the dismantling and/or removal options of the individua l crane parts (e.g. dependent upon the lifting capacity of the auxiliary crane), the individual dismantling stages may vary.

1.0 Crane variants: 1.1 Without stifflegs: 1.1 With stifflegs:

3-92 Dismantling 200DR_Demontage-en_1.doc

(4)(3)

(12)

(5)

(6)

Derrick_gesamt_1_4.des

2.0 Dismantling the stifflegs (stifflegs not featured as standard)

(2) (1)


(10)

(9)

(7) (8)

(11)

Derrick_Stiffleg_Montagestuetze_1.des


DANGER: When climbing onto, or carrying out erectio n work on the tower head, there is a risk of falling! Use and wear a sa fety harness and hook it onto a suitable point!

CHECK: The following must be observed when carrying out the following erection tasks:

- The counter-boom must never (1) be turned into the direction in which an erection support (2) is installed between stiffleg and outrigger extension.

- No contact between pulley block (3) and stiffleg (4)!

Preparations:

2.1 Move the boom into the shut-down position (minimum radius) (5). Refer to chapter Operation, point 5.9 "Shut-down position".

2.2 Turn the boom toward the stiffleg being dismantled (6). CHECK: Is the pulley block (3) without contact with the stiffleg (4)?

2.3 CHECK: Is the erection support (7) installed correctly, pinned and secured with 6 spring clips (8).

2.4 Secure the tirfor winch (traction approx. 1.5 t) (9) with pins between erection support and outrigger extension (10) and apply a little tension.

2.5 Remove the fixing (11) and hook the stiffleg erection ropes into the load hook (12).


(13) (14)(15)

(16)

Derrick_Stiffleg_oben_ausbolzen.des





2.6 Secure the tirfor winch (traction approx. 1.5 t) (13) with pins between stiffleg (14)

and the tower head and apply minimal pretension. 2.7 Remove the pin (15). Slighty tighten or release the tirfor winch to ease pin

movement. 2.8 Insert the pin in the storage hole (16) and secure.


Derrick_7_1.des

(17)

(18)

(19)

(20)

(21)

(21)

(22)

(22)

(22)

(19)

(21)





CHECK: For the following erection tasks:

- No diagonal pull ! The stiffleg erection ropes may never become taut (17)!

The stiffleg may onl

Career

Derrick manual