Instruction Manual Free Standing Jib Crane Model A360 XXXX ......Tag & Decal Location drawing, pg 35). Permit only authorized, qualified persons, to install, operate, maintain, and

Instruction Manual

Free Standing

Jib Crane

Model A360 XXXX

Serial Number XX-XXXXX

Date

Krane-King ® THE CALDWELL GROUP

2


3

Your new KRANE-KING®, free standing Jib Crane is for specific tasks, withstanding forces based on the unit’s rated capacity when loaded correctly. The installation, operation, and maintenance instructions in this manual are typical of the KRANE-KING®, free standing Jib Crane. Please note that your Jib Crane may differ from the pictorial examples in this manual. Use the following guidelines in this manual for your protection, and for optimal operation of your equipment. The safety precautions listed in the man-ual are not all-inclusive. The owner/user is responsible for understanding and acting according to indus-try standards and any other required local, city, state, or federal regulations. In addition, refer to the Manufacturer’s instruction manuals for more detailed product information on other attachments or com-ponents used with your equipment. This manual contains important information to help you install, operate, maintain, and service your Jib Crane from The Caldwell Group. We recommend that you study its contents thoroughly before putting the crane into use. Properly installing, applying correct operating procedures, and by practicing the rec-ommended inspection and maintenance suggestions, you can expect maximum service from your equipment. When ordering replacement parts, include your unit’s model and serial number with your order. This information is located the manual’s front cover and on your Jib Crane’s I.D. tag (see Caldwell I.D. tag, page 35). The following information and recommendations in this manual are guidelines for installing, operating, inspecting, and maintaining your Jib Crane and general in nature. If specific information is required and not in this manual, contact THE CALDWELL GROUP: Toll Free (800) 628-4263, Customer Service (815) 229-5667 fax (815) 229-5686 www.caldwellinc.com

PREFACE

Preface 3

Safety Information 5

Installation

Supporting Structure 11

Mast Installation 12

Taper Bearing Installation 13

Head Installation 14

Roller Shim Installation 15

Boom Installation 16

Head Beam Shim Installation 18

Safety Bar and Safety Pipe Installation 19

Optional Accessories 20

Slip Ring Assembly 21

Tagline Kit 22

Trolley and Hoist 23

Rotational Stops 24

Anchor Bolts 24

Roto-Max and Roto-Mate 25

Jib Crane Motorization Instructions-ROTO-MATE™ 26

Lubrication 34

Tag and Decal Location 35

Inspection & Maintenance 36


5

DANGER indicates a hazardous Situation which, if not avoided, will result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

This is the safety alert symbol. It is used to alert you to potential

hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

SAFETY INFORMATION

SAFETY


6

SAFETY

The fundamental objective of the following safety suggestions is to protect authorized, qualified persons responsible for installation, operations, and inspection of the A360 Jib Crane from serious injury or death. The owner or user is responsible for providing all proper devices, tools and methods that may be necessary to effectively protect each employee from recognized hazards, during installation, operation, maintenance, or servicing. The safety precautions stated in this manual are not all-inclusive. The owner/user is responsible for understanding and acting according to industry standards and regulations—and any other applicable local, city, state, or fedral ordinances.

GENERAL

Authorized, qualified individuals need comprehensive training in the use of protective equipment, safe-guards, and safe operation of the A360 Jib Crane.

Permit only authorized, qualified people to operate and maintain your A360 Jib Crane.

Personal protective equipment is required whenever there are hazards that can do bodily harm through physical contact. The construction requirements of all personal protective equipment must be concurrent to the work performed.

PERSONAL PROTECTION

TRAINING

SAFETY INFORMATION


7

Read this manual before preparing the support structure, installing, operating, or inspecting the A360 Jib Crane.

Allow only qualified persons to install, operate, inspect, maintain, and service your Model A360 Jib Crane.

Check your unit upon arrival, ensuring no damage or lost parts occurred during transit. Contact the carrier’s agent, reporting loss or damage.

Consult a qualified, professional engineer to assess the supporting structure stability, which will support the weight of the hoisting equipment, platform, and load; and obtain written approval. The supporting structure’s stability deter-mines whether or not the jib crane is secure and plumb.

Designate only qualified persons to properly erect the jib crane and platform.

Inspect equipment before installing, ensuring possession of all components.

Install and plumb the mast .

Confirm the unit is assembled correctly.

Inspect the crane, confirming all:

equipment is plumb

fasteners are tight

tapered bearing, located on the mast spindle, is well lubricated .

Before Installing

Before initial operation

Installing

Receiving

SAFETY INFORMATION

WARNINGWARNING


8

SAFETY INFORMATION

WARNINGWARNING

Verify each operator is qualified or certified.

Request each operator to demonstrate proper hoisting techniques, using the jib crane.

Verify the travel path is clear.

Test the jib crane before initial use, confirming proper trolley movement.

Barricade people from swing zones, fall zones, and crush zones.

Confirm the combined weight of the load and hoist does NOT exceed the crane’s rated capacity.

Confirm all lifting devices: chains, ropes, or slings are free from twists, kinks, or any damages.

Confirm all lifting devices: chains, ropes, slings, are completely seated in the hook.

Center the hoist in-line with the load’s center of gravity.

Inspect the load, making sure nothing can fall from the load, during the lifting or transporting cycle.

Verify all equipment adjustments are correct and secure.

Do NOT lift loads over people.

Do NOT lift people.

Prohibit any person from riding on the load or crane.

Obey stop signals from anyone.

Lift or transport only properly balanced loads.

Confirm the load is ready for the lifting or transporting cycle.

Verify the transport area is clear of people and physical obstructions before the lifting cycle begins.

Operating Practices


9

Lifting Cycle

Departing

Inspecting &

Maintaining

Pick up all loads with the hoist line vertical.

Start lifting the load slowly and gently.

Raise, lower, or transport the load ONLY over specified areas.

Avoid swinging loads—Transport the load slowly.

Do NOT use shock loading or side loading.

Do NOT drag loads along the ground.

Prohibit people from standing under a suspended load.

Prohibit operators from leaving a suspended load unattended.

Set the load down gently.

Establish a regular inspection and maintenance schedules:

—operator visually examines before and during each lift

—visual examination by operator or designated person:

1. Normal Service—monthly

2. Heavy Service—weekly to monthly

3. Severe Service—daily to weekly

4. Special or Infrequent Service—a qualified person shall recommend before and after each occurrence

—visual inspection by a qualified person,

recording external conditions.:

1. Normal Service—yearly

2. Heavy Service—semi-annually

3. Severe Service—quarterly

4. Special or Infrequent Service—a qualified person shall recommend before and after each occurrence

Keep the jib crane clean and operational at all times.

Disconnect all power when the crane is not in use.

SAFETY INFORMATION

WARNINGWARNING


10

Inspecting

Modifying

Keeping Records

Establish a regular inspection schedule.

Inspect the jib crane regularly for malfunctions, wear, damages, or missing parts.

Inspect equipment regularly for worn, damaged, or missing: ID tag, product safety labels, rated capacity, or weight markings.

Prohibit warning label and identification tag removal or concealment.

Contact The Caldwell Group for complimentary replacement tags: ID tag, product safety labels, rated capacity, or weight markings.

Remove the jib crane from service and tag the jib crane “OUT OF SERVICE” when regular inspection reveals :

-malfunctions

-wear

-damage

-missing parts

-worn, damaged, or missing —

ID tag

product safety labels

rated capacity markings.

Secure written approval from The Caldwell Group before making any alterations or

modifications to the jib crane.

Keep complete records on your jib crane: instructions, inspections, maintenance,

service, and modifications.

SAFETY INFORMATION

WARNINGWARNING


11

INSTALLATION Model A360 Free Standing Jib Crane

Upon receipt of your new Model A360, Jib Crane, fully inspect to confirm no parts were lost or damaged, during transit. The A360 is shipped in two sections: 1. the mast, 2. the head and boom attached, The hardware is packed separately. If a hoist package is a selected feature on your Jib Crane, it is also packed separately. Confirm all the tags and decals are securely fixed to your unit and clearly legible (see Tag & Decal Location drawing, pg 35). Permit only authorized, qualified persons, to install, operate, maintain, and service the A360 Jib Crane.

Supporting Structure Consult a qualified, professional engineer to assess and provide precise, supporting structure plans for your A360 Jib Crane. Prepare the supporting structure per professional instructions. Use a template to install the anchors in the correct orientation. Then, match it up to the Mast Base Plate and rotate as required. Soil Foundation The A360 Jib Crane requires a minimum of 2,500 pounds of soil pressure per square foot. Concrete Foundation The A360 Jib Crane requires a minimum of 3,000 pounds of compressive strength per square inch. Contact the concrete supplier for required cure times, achieving maximum concrete compressive strength. Grout The base plate must have thorough contact with the supporting structure. Allow approximately one inch of grout (non-shrinking, high machinery type) between the base plate and the supporting structure surface. Grout shall completely support the base plate contact area.

Base Plate


12

MAST INSTALLATION

WARNINGWARNING

Correctly plumb the Mast. When the Mast is plumbed, an assembled jib crane independently rotates, swings, or drifts with or without a load, causing death, serious injury, property damage, or all three. Do NOT plumb the Mast with a level. Use a commercial plumb fixture and plumb line.

Plumb the Mast 4. Clamp a plumb fixture securely to the Mast Spindle. 5. Secure and drop a plumb line from the plumb fixture. 6. Position the plumb line 3 inches out from the Mast Pipe

vertical edge at two locations: a. 1 inch below the Top Mast Plate lip b. at the approximate Roller center line 7. Position and measure plumb line every 60° around the

Mast, ensuring the Mast is exactly vertical. 8. Tighten alternate hold down hardware until the Mast is

plumb. 9. After all anchor bolts are tight, re-check and verify the

Mast is plumb every 60 degrees.

Position the Mast 1. Position the Mast on top of the supporting

structure.

2. Attach the Mast to the supporting structure.

3. Do NOT over tighten hold down hardware

because adjustments may be needed later.


13

WARNINGWARNING

1. Pack the taper bearing with grease.

2. Place the taper bearing on the Mast Spindle , using the correct orientation.

TAPER BEARING INSTALLATION

Taper Bearing

Mast Spindle

Mast Top Plate

CORRECT INCORRECT

Attach the taper bearing to the mast before connecting the Head


14

HEAD INSTALLATION

1. Set the Head on the Mast.

3. Lower the Head onto the Mast.

2. Line up the center of the Head’s medium bearing cup with the center of the Mast Spindle.


15

1. Add Roller Shims, if necessary, to assure the Head is plumb.

2. Loosen the Roller Shim Mounting Bolts. 3. Turn the Adjustment Screw clockwise,

which tightens the Adjustment Screw and widens the gap between the Roller Support Channel and the Roller Shim Assembly.

4. Measure the gap, making sure the gap is

wide enough for the shim to slide into place.

5. Insert the Roller Shim. Additional shims

may be required. 6. Turn the Adjustment Screw counter-

clockwise, which loosens the Adjustment Screw and relieves the pressure on the Roller Support Channel.

7. Tighten the Roller Shim Mounting Bolts

when the Head is plumb. 8. After the crane is completely assembled,

use the Roller Shim Adjustment Screw when the crane is load free.

ROLLER SHIM INSTALLATION

WARNINGWARNING

Remove the load from the crane. The adjustment screw is not designed to support a loaded crane.


16

1. Set the Boom on the Head. 2. Line up the Boom and Head Rear Mounting Plate holes. 3. Tighten the bolts. 4. Do NOT over-tighten because adjustments may be needed later.

BOOM INSTALLATION


17

WARNINGWARNING

CORRECT SPAN 300

BOOM INSTALLATION

Avoid deflection.

Position the boom— SPAN I 300 = distance above horizontal.

Do NOT position the Boom exactly at the head’s horizontal line.

Do NOT position the Boom the head’s horizontal line.

U P

XX TON CAP.

Crane Height

HORIZONTAL(Top of Head)

SPAN

MastCenter Line

XX TON CAP.


Crane Height

D O W N

XX TON CAP.


Crane Height

Position the Boom above the head’s horizontal line:

INCORRECT

INCORRECT

SPAN 300


18

HEAD BEAM SHIM INSTALLATION

1. Add Front Beam Shims, adjusting the Boom position above horizontal, . 2. Tighten the bolts: Front Beam Mounting Bolts, Boom and Head Rear Mounting Plate Bolts. 3. Do NOT over-tighten because adjustments may be needed later. 4. Verify the crane is plumb and the boom is above horizontal, .

5. Make adjustments as necessary. 6. Tighten the bolts: Front Shim Bolts, Boom and Head Rear Mounting

Plate Bolts, when the crane is plumb and the boom is above horizontal, .

SPAN 300

SPAN 300

SPAN 300


19

SAFETY BAR AND SAFETY PIPE INSTALLATION

Safety Bar and Safety Pipe

1. Insert the Safety Bar and Safety Pipe through the Head.

2. Fasten securely on both sides of the Head.


20

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21

OPTIONAL ACCESSORY Slip Ring Assembly

Slip Ring Assembly

The Slip Ring Assembly, providing power to the elec-tric hoist, permits continuous rotation. Depending on your Slip Ring Assembly option, top entry or bottom entry

1.Position the Slip Ring.

2. Fasten securely to the mounting plate.

3. A qualified person shall bring the source power to

the Slip Ring Assembly and from the Slip Ring

Assembly to the hoist.


22

OPTIONAL ACCESSORY Tagline Kit

TAG LINE KIT (1)

Tag Line Bracket (Ref)(2)

Eyebolt1/4-20 X 4.00 LG (2)

1/4-20 Hex Nut(4)

1/4" Flat Washer(4)

1/4" Lockwasher(2)

Closed End S Hook(5)

1/8" Wire Rope Clip(4)

1/8" Ø Aircraft Cable(1)

Using a Tagline Kit, prevents the power cord from tangling and dropping 1. Locate the tagline position on the boom 2. Field weld the tagline brackets to suit. 3. Follow AWS D1.1 standards. 4. Attach the remaining tagline kit components. 5. Make sure bolts are tight and aircraft cable is taught.


23

OPTIONAL ACCESSORY Hoist

When the hoist is attached, maintain the boom’s position. If the boom is at

horizontal or below horizontal, shim as needed.

WARNINGWARNING

Trolley and Hoist

1. Place the trolly on the boom flange.

2. Attach the hoist to the trolley.

3. Verify the boom is above horizontal after the hoist is attached.

4. Adjust as needed, maintaining the boom’s above horizontal position.

XX TON CAP.

Hoist

Shim


U P


24

OPTIONAL ACCESSORY

Anchor Bolts

Rotational Stop Blocks

J-type anchor bolts with nuts and washers are for mounting the mast to the foundation.

Rotational stop blocks limit the cranes rotational travel. If rotational stop blocks are a selected option, then, the stop blocks are shipped loose to be field welded to suit.


25

Roto-Max or Roto-Mate If the jib crane motorization package is a selected feature, the motor will be either a Roto-Max or Roto-Mate, depending on the size and rated ca-pacity of your crane. 1. Bolt the Roto-Max or Roto_Mate to the back of the Head. 2. Make sure bolts are tight. 3. Follow the manufacturer’s instructions for more detail information.

OPTIONAL ACCESSORY Roto-Max or Roto-Mate


26


27


28


29


30


31


32


33


34

LUBRICATION

1. Establish a lubrication schedule based on: a. environmental conditions b. operational frequency 2. Keep the Mast tapered bearing well lubricated.

WARNINGWARNING

Lubricate the tapered bearing before initial operation.


35

ID Tag and Product

When the markings, identification tag, or product safety labels are damaged or missing: 1. Remove the unit from service, 2. Tag the unit with an “OUT of SERVICE” label, 3. contact The Caldwell Group for complimentary replacements.

MARKINGS, ID TAG, & PRODUCT SAFETY LABELS

Warning read-understand

instruction manual

6

Made in the USA

5

Parts and Service

4

3

Product identification tag

2

Caldwell Logo 1

XX TON CAP Unit Rated Capacity

Warning Do NOT exceed

rated capacity

7

8

Warning Pinch Points

A360 JIB CRANE

XXTON CAP.

MODIFICATIONS TO YOUR LIFTING EQUIPMENT WITHOUT PRIOR

WRITTEN APPROVAL FROM THE CALDWELL GROUP, INC.

VOIDS YOUR WARRANTY.


36

Before servicing the jib crane, de-energize and disconnect all power .

WARNINGWARNING

Regular inspections may be more or less frequent for your crane, depending on the severity of use and site conditions. Regular inspections also serve as maintenance checks and identifies the need for repair or replacements. Three inspection intervals for regular service: Every Lift Inspection—operator or designate person visually examines, determining safe crane operation a. before the shift starts b. before each lift c. during each lift Frequent Inspection—operator or designated person visually examines, determining safe crane operation a. Normal Service…..monthly b. Heavy Service……weekly to monthly c. Severe Service……daily to weekly Periodic Inspection—qualified person visually inspects and evaluates units external condition, determining unit repair or component replacements a. Normal Service…...yearly (unit in place) b. Heavy Service…….semi-annually (determining further detailed inspection) c. Severe Service…...quarterly (determining further detailed inspection) d. Special or Infrequent Service—recommended by a qualified person Regularly scheduled inspection and maintenance assures reliable operation.

INSPECTION and MAINTENANCE


37

Inspect the entire crane

Check for: Condition:

Vertical Straightness Crane must be plumb

Horizontal Boom Position

Boom must be slightly above horizontal—with

out a load—SPAN I 300

Structural Damage Free from distortion, cracks, excessive wear, dents, bends, corrosion

Roller Assembly Full contact with the Mast , bolts are tight, prop-erly adjusted, free from wear, bends, cracks

Guarding Tightly secured and stable

Hooks Free from distortion, cracks, excessive throat openings

Wire Ropes-Hoist Cable-Pendant Cable Free from cracks, twists, kinks, splits, corrosion,

looseness

All Welds Free from distortion, cracks, bends

Paint Cracking or flaking may indicate metal fatigue

Hardware:

Bolts Fasteners Pins

Rollers Bearings Washers

nuts

Free from looseness, deformation, corrosion, cracks, wear—make sure all bolts and fasteners are secure.

Performance Indicators Free from excessive noise and vibration, main-tains regular operating speed

Freedom of Rotation Rotational travel is smooth

Electrical Components

Wiring is free from cracks and splits—Insulation

Is tight and free from corrosion-controls are free from deterioration and damage

Lubrication Keep Mast Tapered Bearing well lubricated

The Caldwell Group, Inc.5055 26th Avenue Phone (815) 229-5667Rockford, IL 61109 Toll Free (800) 628-4263www.caldwellinc.com Fax (815) 229-5686

A360 (Rev_00 Feb 2010)

Documents

Instruction Manual Free Standing Jib Crane Model A360 XXXX ......Tag & Decal Location drawing, pg 35). Permit only authorized, qualified persons, to install, operate, maintain, and