Provision Crane Manual

INSTRUCTION MANUAL
& FINAL DRAWING FOR

ELEC. PROVISION CRANE
MESSRS : SPP SHIPBUILDING CO., LTD
SHIP OWNER : JAKO SHIPPING
HULL No. : H4100.
TITLE : ELEC. PROVISION CRANE
TYPE : EPC-3580
SHIP KIND 50,300 DWT CRUDE/PRODUCT OIL/CHEMICAL TANKER
APPROVED
H.S.AHN
NOTE BY
REVIEWED
□ FOR YARD APPROVAL J.W.HWANG
BY
□ FOR CLASS APPROVAL DESIGNED
M.H.KIM
□ FOR WORKING BY
■ FOR FINAL
DWG. NO. P05005-000000
* HAMAN FACTORY *
#1166-94, Moogi-Ri, Chilwon-Myun, Haman-Gun, Gyeongnam, Korea
Tel : 82-55-589-3092 Fax : 82-55-587-4810
Homepage : www.spp.co.kr
FOR SAFETY OPERATION (CRANE)
If Cranes and operated erroneously, dangers like unexpected falling

of the hung cargo, unexpected catching in to the machines, electricity
shocks are expected.
Before the installation of machinery, and before operation of the

machine, please read well this brochure "For safety operation"
and related "Instruction manuals", and then operate the machinery
in good order.
Please operate machines, after obtaining thorough knowledge about

the machines, about safety and cautions related.
In this brochure, items are separated into two categories,

"Danger" and "Caution".
In case the machine is operated erroneously,

Danger serious injury or fatality is expected.
In case the machine is operated erroneously,

slight injury or middle level of injury is
Caution expected, or damage on/around the machine only is
expected.
Remarks : Even in items marked with caution there
are cases in winch serious or fatal accidents might
occur depending on the situations. It is
therefore, also important to observe items marked
with caution
Mark with "positive" printing

Square & Triangle : This is to announce that there "exists" a
danger or a dangerous thing to winch
attention is to be paid to. The actual
contents of the danger is shown in the
mark or near around the mark. This sample
shows there exist a danger of electric shock.
Circle with a Bar : This is announce "prohibition" The

actual contents of the prohibition is shown
in the mark, or near around the mark.
Mark with "negative" printing

Circle (with an This is to "force" or "instruct" actions.
Exclamation mark) The contents of the actual constraint/
instruction is shown in the mark, or near
around the mark. This sample shows electric
grounding is necessary.
"Please keep this brochure at a place where the persons related

can easily get access.
1/136
1. In General
Danger
※ Nobody should handle this machine, who has not acquired
the thorough knowledge on "this brochure", related
"instruction manuals" and the contents on each
warning plate.
※ Nobody, who has not been assigned, should operate
a crane or do lashing of the cargo of a crane.
※ Please be sure to effect the inspections stipulated or

voluntary, before respective works or operations.
※ Please be sure to effect the inspections after the
operation of the machine.
2. Installation
Danger
※ Installation should not be made by any other party
than a specialized party who has specialized knowledge
on this machine.
※ Please be sure to effect electric grounding.
※ Please be sure that the please have enough physical

strength, where cranes are installed.
Caution
※ Before starting a running operation of the crane,
Please confirm the crane moves to the same
direction as the push button switch indicates by
an inching operation.
※ Before starting a running operation of the crane,
please make sure of the movement of the each limit
switch.
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3. Operation
Danger
※ Please do not operate, while the lashing devices crane are set.
※ Please do not hoist a cargo whose weight exceeds the fixed limit.
Remarks : The fixed limit of the weight is shown on the name
plate of the hook block.
※ Please do no hoist a cargo with a person.
Remarks : Please do no use the crane for the purpose for lifting
persons.
※ Please do no let persons slip in under the cargo hung.
※ When persons are within the range a crane can reach,
please do not operate.
※ Please do not hang a cargo just over the heads of persons.
※ Please do not leave the place of operation, while a cargo is hung.
※ Please do not divert attention from the cargo, while in operation.
※ Please do not operate on such a way as to swing the
cargo or hook block.
※ Please do not operate in such a way as limit switch
for upper hoisting limit always functions.
※ Please do not hoist a cargo with the hoisting wire athwart.
Remarks : After the crab comes right over a cargo,
please hoist the cargo.
※ Please do not use for such purposes as to jerk the
vessel's structure.
※ Please do not lower a cargo, nullifiying the limit
switch of the hoisting lower limit.
※ Please do not turn the cargo, while it is hung.
※ Please do not touch moving/;revolving parts of a
crane, while in operation.
※ Please do not hoist a cargo, nullifying the limit
switch for the upper limit of hoisting.
※ Please make sure of the functions of the push button
switch, and when push button switch does not move
smoothly, please do not operate.
※ When the crane moves in the different direction form
the push button switch indicates, please stop the
operation instantly.
※ Before starting operation, please make sure of the
function of the brake. In case the brake does not
function for sure, please do not operate.
※ When the crane is damaged, and when abnormal
vibrations or noises are observed, please do not operate.
※ When the following abnormities are observed at "Wire
ropes", please do not operate.
◉ Twisting, deformation and corrosion are observed.
◉ Lessening of the strands, wear-down exceeding each
limit are observed.
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Danger
※ Please do not effect electric-welding on the cargo
which is hung by the crane.
※ Please do not connect the grounding cable of an
electric welding machine with the wire rope of the
crane.
※ Please do not let the electric of an electric
welding machine touch the wire rope of the crane.
Caution
※ Please do not use at other electricity than stipulated.

※ Please do not operate while the safety catch for hook
will be damaged.
※ Please do not effect excessive inching, or sudden
reverse operations.
※ Please do not let a cargo entangled with other
structures, or with other wiring.
※ Please do not let the push button switch entangled
with other things, and please do not pull strongly
the push button switch.
※ Please take care that crane body and crab may not
hit the vessel's structures and the stoppers of the crane.
※ Please do not use the crane with more frequency than stipulated.
※ In case name plates or labels which show danger or
caution are smeared or lost, please immediately replace
them with new ones.
※ Please do not touch the electric part of the control box
※ Before starting operation, please make sure that the

hook block swivels smoothly.
※ Please hang lashing materials properly on the hook.
※ Please take care of operation, when a cargo comes
※ near to the limit switch for upper hoisting.
※ Please stop hoisting once, when the wire rope has
been strained.
※ Please keep the push button switch always clean, and
handle it with care.
※ After the operation, be sure to shut off electricity.
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4. Accommodation
Caution
※ Please be sure to set clamping devices for travelling

and for traversing.
5. Inspection and Modification

Danger
※ Please do not modify the equipment and the spare parts.
※ Please do not use other parts than our genuine
spare parts.
※ Please do not paint the revolving parts.
※ Please do not use other wire ropes than stipulated.
※ Please check periodically the fixing ends of the

wire rope.
※ Please shut off electricity before maintenance
inspection and repairing.
※ Maintenance inspection and repairing should be
effected by a specialized party designated by the
user.
※ In case to effect maintenance inspection or
repairing, please be sure the crane is not loaded
with a cargo.
※ When an abnormity is observed at the time of
maintenance inspection, please do not use it as
it is, and immediately repair.
Caution
※ In case to effect maintenance inspection or repair,
please exhibit a sign board, like "Under inspection"
or "No electricity admitted".
5/136
Caution
※ In case an inspection involves the disassembling/assembling of
the equipment, please advise us in advance.
Reference : ☐ Head Office

#1166-94, Moogi-Ri, Chilwon-Myon, Haman-Gun, Gyeongnam, Korea
TEL : +82-55-589-3092, FAX : +82-55-587-4810
Please read well the related "Instruction manuals" and operate

in good order.
6/136
C O N T E N T S
Page
1. General precautions for operation
1-1. Do not lift load exceeding the specified value -------- 2/11
1-2. Do not remove safety device --------------------------- 2/11
1-3. Precautions at the time of operations ----------------- 3/11
2. Operation manual
2-1. Preparation before operation ------------------------- 4/11
2-2. Description of operation------------------------------ 4/11
2-3. After operation--------------------------------------- 5/11
3. Inspection and maintenance
3-1. General precautions for maintenance and inspections --- 6/11
3-2. Parts of steel structure ------------------------------ 7/11
3-3. Lubrication ------------------------------------------- 8/11
3-4. Gear -------------------------------------------------- 8/11
3-5. Wire rope --------------------------------------------- 9/11
3-6. Sheave ------------------------------------------------ 11/11
3-7. Hook -------------------------------------------------- 11/11
3-8. Painting ---------------------------------------------- 11/11
1/11
7/136
1. General precautions for operation
1-1. Do not lift load exceeding the specified value.
Never apply the load exceeding the capacity prescribed in the
specifications.
The crane has been designed to be most economical when working
efficiently under the specified load. The more the crane is
used overloaded, the shotter the life of the crane.
Be sure to avoid such abuse.
Observe the limit load at the maximum working radius
prescribed in the specification by the hoist of the jib,
as in the case of this crane. Overturning, upsetting or
breakage due to overload and over-radius are often seen in the
jib type cranes.
Lifting loads exceeding the prescribed value may result
in damage to the machine, breakage of rope, down fall of
the load, or injury or death.
Pulling obliquely will apply unnatural force to various
parts, shorten the life of the machine and lead to a
serious accident. Pay sufficient care to safety.
1-2. Do not release safety devices.
It is liable to cause accidents if you should turn safety
relief valve to suspend overload, release hoisting limit
valve to extend lift.
The safety devices supplied are carefully adjusted and
fixed at specific locations. Do not remove them, nor change
the adjusted locations, unless anything unusual happens.
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1-3. Precautions at the time of operation
(1) Safety operation
Crane handles heavy cargo. If cargo falling from a height,
or is shaken, serious accidents may occur.
Considering the weight and size of the cargo, or other people
or things which might be in the way of operation, operate the
crane with sufficient care. While repairing the crane,
previous arrangement between workers and operator is required.
Moving the crane without warning may hurt or kill others.
Be extremely cautions concerning their safety.
When winding up all the lift, the limit switch is actuated
at the upper limit and the hook stops automatically.
Be sure to wind quietly with sufficient care.
(2) Smooth operation
Do not start or stop with a jerk, but operate the crane
smoothly : it will reduce the wear of various parts and prolong
the life of the machine.
Avoid operating the machine with full load and at full speed,
or starting stopping more often than is necessary.
(inching operation)
While operating, the operator should be alert to any abnormal
sound, vibration or generation of heat.
If any abnormality arises, stop the operation immediately,
examine the causes and the countermeasure.
3/11
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2. Operation manual
2-1. Preparation operation
During voyage, the jib must be placed on a rest.
Prepare according to the procedure before operaiton.
(1) Power "on" the main power switch on the shipside and
starter panel before 10 hours from operation for
remove the humidity in electric motor by space heater.
(2) Check the oil-gauge and greasing point.
(3) Switch "ON" of R.P.B (Remote push button)
(4) Release lashing device of hook.
(5) Raise jib without load.
Make sure that each limit switch properly operates

(6)
without load.
Make sure that there is noting wrong with each motor

(7)
and brake.
2-2. Description of operation
After competing preparation, operate the crane as follows ;
(1) Hoisting & lowering operation.
Hoisting : Push the 'hoisting' button.
Lowering : Push the 'lowering' button.
Attention! Operate softly and slowly.
A jerk is very dangerous, because it may give big shock to the
crane especially when load is being suspended under the jib.
(2) Luffing operation
Jib up : Push the 'up' button.
Jib down : Push the 'down' button.
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(3) Slewing operation
Slewing to right : Push the 'right' button.
Slewing to left : Push the 'left' button.
2-3. After operation (Operation for rest)
If finished all work, has to rest the safety of crane

as follws.
Also, This work should be carried out no load.
Slew the crane to the rest position by means of

(1)
the 'right' or 'left' button.
Luffing down the crane on the jib rest by means of

(2)
the 'down' button.
(3) Park the hook.
(4) If the crane exactly park on the jib rest, surely lashing
the hook with suitable tension in hoist wire rope for
protect moving of due to pitching and rolling of the hull.
(5) Switch "Off" of R.P.B box.
(6) When not in use the crane, the motor space heater should be
always switch "ON". If the heater is "OFF", that should be
switch "ON" prior to 10 hours before operating the crane.
5/11
11/136
3. Inspection and maintenance
3-1. General precautions for maintenance and inspections
Interval of inspections of crane parts vary depending on
frequency or conditions of use.
Determine the intervals after actual use of crane. It is
recommended to mark the date of inspection in the schedule.
According to the marked schedule, spare parts can be ordered
or purchased smoothly.
In order to perform cargo works smoothly, earlier detection
of abnormal is desired by maintenance and inspection.
Inspection are classified into daily inspection and regular
inspection.
(1) Daily inspection
Daily inspection is carried out before the start of operation.
Inspect the lubrications, generation of heat, noise, looseness
of clamping, contact areas of electric equipment, brake,
lifting hook and wire rope and, if any abnormality is found,
repair or replace with a new part.
The operator should perform the daily inspection before and
after the operation without fail and, if any abnormality is
detected while operation, stop the operation immediateyl to
inspect the suspected part.
If there is no full time operator, perform daily operation
once a week at least.
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(2) Regular inspection
Regardless of the existence of defects or abnormality,
overhaul inspection of major parts is performed at regular
interval, where, such defects can be found that are not detected
in daily inspection.
The inteval of regular inspections should be determined
depending on the frequency of use and work amount.
Annual major inspection and monthly inspection are required
at least.
3-2 Parts of steel structure
Part of steel structure are rarely damaged if the crane is
used properly.
But inspect them carefully in the annual inspection with
respect to the looseness of bolts, bent condition of member,
crack or corrosion etc.
After use for a long time, coupling bolts may be loosened or
welds may be cracked.
Inspect with test hammer and repair suspect parts earlier.
Where rust occurs on members, these will become thinner and
strength will be reduced.
When designing members, no such allowance has been made.
Repaint immediately if rust is found.
(Refer to the description below regarding painting.)
7/11
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3-3 Lubrication
Proper or incorrect lubrication will have a direct effect on
the life of ball bearings and roller bearings.
Make up a schedule about the selection of the lubricating oil
and amount and intervals of lubrication.
Refer to the attached list regarding the selection of lubricant
and lubricating intervals.
(1) Grease lubrication
Grease lubrication is employed for slewing ring, sheave bearing
is not desired by lubrication for oilless bearing.
Ball bearing and roller bearing do not required replenishing
for a long time after once being lubricated, different from
plain bearing, though it depends on degree of use.
Life of grease is usually 2,000 hours approximately.
Select fixed dates of replenishing on the basis of this hours.
(2) Oil lubrication
Oil lubrication has been employed for ball bearing and roller
bearing of reduction gears for luffing , hoisting and slewing.
Dirty oil in gear casing has adverse effects on gears and
bearings.
Inspect the stain of oil regularly as well as oil mount.
3-4 Gear
The engagement of gears can be detected from the noise.
Listen to the noise from the start of operation.
Substitute gears when the thickness of teeth has reduced by
20~25％ at the pitch circle usually, but substitution is

8/11
14/136
recommended for luffing gear and hoisting gear at the time of
10~15％ in wear.
Damage of teeth of these gears may lead to severe accidents.
Substituting a pair of pinion and gear provided good engagement
and little noise, and prolongs the life of gear.
When opening the casing cover to change the oil and inspect
the gear, remove the cover carefully to avoid dust or foreign
matter from entering.
3-5 Wire rope
Accidents through breakage of wire rope are the major cause
of crane accidents together with hook accidents.
Pay special attention to daily inspection, lubrication and
handling.
(1) Limit of use of wire rope
Substitute wire rope under the following conditions :
-1 When the diameter of the rope has reduced by 7%
-2 When 10 strands have been cut in 1 m of the rope.
-3 When a kink caused at some part of the rope does not restore
to the original state.
-4 When the rope is reduced in length partially or is twisted
out of shape.
-5 When the rope is deemed unusable because of rust or corrosion.
9/11
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(2) Substitution of wire rope
When substituting wire rope, pay attention to the following
points :
-1 Use the one of specified length. When winding down the maximum
lift, at least two turns should be still wound around the drum.
-2 Wind the rope in the correct way to prevent kink of the rope.
-3 Wipe the rope clean with cloth while widing to remove
foreign matter.
-4 Fix the end on the drum side with cotter so as not to loosen
with vibration.
-5 Apply sufficient oil
(3) Precaution in use
-1 Idling for new rope
When using new rope after substituting, apply about a half load
instead of full load and make the machine idle a few times.
-2 Deviation of rope
Take care that the rope is not deviated from the block and
the groove of the drum.
If the rope is used in deviated state, the rope gets appreciably
out of shape and kinking or breakage will be caused.
-3 Caution in use
Do not give strong jerks to rope in use. It has an adverse
effect on rope and other parts also.
10/11
16/136
3-6 Sheave
While using sheave, the groove in contact with the rope wears.
Especially if obliquely, flange wears faster and is damaged.
When the groove has worn remarkable, or the flange has got out
of shape or broken, they should be substituted.
3-7 Hook
The part on which the rope for rigging is suspended wears and
becomes concave and the opening becomes larger after long use.
Inspect the materials, which may have been hardened, become
brittle, or cracked, at the annual inspection.
If the partial wear of the part to be suspended with rope for
rigging is not too far gone, with grinder.
Smooth to an even surface. If worn remarkably or cracked,
substitute a new one. Never repair the crack by welding.
3-8 Painting
Undercoating for rust proofing has been applied once and finish
coating twice. Durable period is about one to two years.
When rust or blister has caused on about 10% of the coated
area, recoating is required.
Before recoating, remove the rust completely. Select a day of
fine weather, and check there is no oil or grease on the face
to be coated.
When coating repeatedly, coat after undercoating has dried
completely (about 12 hours).
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18/136
SAFETY PRECAUTIONS
Before carrying out installation, operation or maintenance of a 3-phase marine motor with brake,
read this instruction manual and related document, and operate it properly according to those
instructions. Obtain sufficient knowledge and operation skill of the motor and familiarize yourself
with safety precautions given in this manual.
The safety precautions are classified into "DANGER" and "WARNING".
If not correctly followed, there is a high probability of serious injury or

◇
! DANGER
death to personnel.
If not correctly followed, there is a probability of minor or moderate

◇
! WARNING
injury to personnel, or of damage to material. In some cases, however,
there is a high probability of serious accident.
The operator of the equipment is expected to strictly observe the Safety Precautions.
◇
! DANGER
【General】
・ Never use the motor in such ambient conditions as may lead explosion. If it is unavoidable
to install it in that conditions, use an EXPLOSION PROOF type motor. There is a danger
of a fire and personnel injury.
・ Do not carry out maintenance work while the power is connected. Always turn off the
power before starting work. There is a danger of electric shock.
・ Transportation, installation, piping, wiring, operation and inspection of the motor must be
carried out by qualified personnel. There is a probability of electric shock and injury to
personnel, and occurrence of a fire.
【Piping and Wiring】

・ Connect the motor with power cables following the connection diagram enclosed in the
terminal box or given in the instruction manual. There is a danger of electric shock and
occurrence of a fire.
・ Do not bend, pull or insert power cables and lead wires forcibly. There is a danger of
electric shock.
19/136
◇
! DANGER
【 Installation and Adjustment 】

・ Connect earth terminal to the ground without fail. There is a danger of electric shock.
・ In case of installing the motor on the ceiling or on the wall, make sure the applicable
installation range for the motor by referring to catalogues or technical data. If it is to be
installed outside the applicable installation range, it may fall down, and result in injury to
personnel.
・ For a deck-watertight type motor, do not remove any eye bolts attached to it. Otherwise,
rain may enter the inside of the motor and cause electricity leakage. There is a danger of
electric shock.
・ For a deck-watertight type motor, tighten firmly all set screws and bolts for the cover of
terminal box. Otherwise, rain may enter the inside of the motor and cause electricity
leakage. There is a danger of electricity shock.
・ For a deck-watertight type motor, tighten firmly bolts on the brake cover and on the
insertion hole. Otherwise, rain may enter the inside of the motor and cause electricity
leakage. There is a danger of electricity shock.
【 Operation 】
・ Do not operate the motor with the terminal box cover detached. Whenever carrying out
maintenance work, always restore the terminal box cover after the work is finished.
Otherwise, there is a danger of electric shock.
・ During motor operation, absolutely avoid to reach or contact revolving sections(such as

shaft). Otherwise there is a danger of being drawn in the motor and seriously injured.
・ At electricity break down, turn off the power switch without fail. Otherwise, there is a
danger of being injured.
【 Inspection and Maintenance 】

・ Carry out connection with power cables according to the connection diagram placed in the
terminal box or the one given in the instruction manual. There is a probability of electric
shock and a fire.
・ When reassembling a deck-watertight type motor after it has been overhauled, apply
waterproof agent to the spigot joint portions of both brackets and attach them back in
place. Otherwise rain may enter the inside of the motor and cause electricity leadage.
There is a fear of electric shock.
20/136
◇
! WARNING
【 General 】
・ Do not use the motor by any specifications other than designated. Otherwise, there is a
probability of electric shock and injury to personnel, and occurrence of a fire.
・ Do not put your fingers or anything into an opening of the motor. There is a probability of
electric shock and injury, and occurrence of a fire.
・ Do not use the motor if it is damaged. It may cause a fire and injury to personnel.
・ Name plates must be clearly visible; do not place any obstacle on a name plate. Never
remove name plates from their original positions.
・ Any modification of the motor by the customer is out of our guarantee. We are not held
responsibility for it.
【 Transportation 】
・ During transportation, use great care to avoid fall down and turnover of the motor. If the
motor has eye bolts, use them to lift the motor. After the motor has been installed to its
mating machine, however, do not use eye bolts to lift the whole machine.
・ Before lifting, check the weight of the motor referring to its pertinent materials such as
name plate, package, catalogue or overview drawing. Use a lifting device of which rated
load exceeds the weight of the motor.
【 Unpacking 】
・ Mack sure Up/Down of the package, and unpack it paying attention to nails on it.
Otherwise you may get injured.
・ Check if the delivered motor conforms with your order. If a wrong motor is installed, there
is a probability of equipment damage and injury to personnel.
21/136
◇
! WARNING
【 Installation and Adjustment 】

・ In case of star-delta starting, select a motor with electromagnetic switch on 1교 side
(3-contactor system) because there is a danger of a fire.
・ In case of driving by 400 V class inverter, install a suppression filter or reactor in the
inverter, or use a heavily insulated motor in order to prevent damage due to
breakdown and a fire.
・ Do not put an obstacle to ventilation route or combustible around the motor because it
may prevent cooling, thus causing abnormal heating, a fire or burn.
・ When connecting the motor with load, centering, belt tensioning and parallelism of
pulleys must be carried out with great care. In case of direct connection, connection
accuracy is very important. When fitting belt, adjust belt tension properly. Prior to
running the motor, tighten set bolts of pulleys and couplings firmly. There is a
probability of equipment damage or injury to personnel due to splash of broken pieces.
・ Avoid contact with the rotating portion by putting a protection cover on it. There is a
probability of injury to personnel.
・ In case of rotating the motor solely, remove the key of main shaft. Otherwise there is
a probability of injury to personnel.
・ Check toe rotating direction of motor before coupling it to a mating machine. Otherwise
the machine may be damaged.
・ Never mount on or hang from the motor. The motor may be broken and there may be
injury to personnel.
・ Do not touch the key slot of motor shaft end with bare hand. There is a probability of
injury.
【 Installaion, inspection and maintenance 】

・ Do not remove eye bolts because it may cause a trouble on the motor, resulting in
electric shock and injury to personnel.
・ Do not lift a weight heavier than the motor by using eye bolt. Eye bolt is required to
be attached to motor by the Technical Standard of electric Installation. For the purose
of burn and fire protection, it is recommended to install the other protection device as
an earth leakage breaker, in addition to an overload protection device.
22/136
◇
! WARNING
【 Operation 】
・ The motor is heated to a high temperature during running. Avoid contact of hand or body
with the heated motor. There is a high probability of burn.
・ Stop running immediately when a trouble happens. Otherwise, there is a danger of electric
shock, injury or occurrence of a fire.
【 Inspection and Maintenance 】

・ Do not touch the terminal when measuring insulation resistance. There is a danger of
electric shock.
・ If a stroke(gap) of electromagnet exceeds the adjustment limit, it may cause burning of coil
due to mal-suction, or breaking of special bolts and motor bracket. Therefore, the surest
inspention and maintenance is required.
・ Do not touch the motor frame with bare hand because it is heated to a high temperature.
There is a danger of burn.
【 Repair, disassembly and modification 】

・ Repair, disassembly or modification work must be carried out by qualified technicians.
There is a probability of electric shock, injury of a fire.
【 Disposal 】
・ The motor shall be disposed be an industrial waste.
23/136
OPERATION AND MAINTENANCE OF MOTOR
1. Initial Operation
when operating the motor initially, check following before turning on starting switch.
(a) Whether the insulation resistance is a specified value when the motor has absorbed moisture
during transportation or storage.
(b) Whether screws in every part are loose.
(c) Whether rotor can revolve smoothly without any catch when turning the shaft by hand. Then
take care not to get your hand injured by key way.
(d) Whether a suitable fuse is used.
(e) Whether the motor is surely connected with power source and earth, and whether the wire
diameter of cable is proper.
(f) When the opposite revolution of mating machine can not be allowed, check the revolving
direction of the motor solely. If it is necessary to change the revolving direction, replace 2
cabled in 3 power cables(in case of general motors).
(g) Whether the motor is correctly coupled with mating machine.
2. Operation
(a) During the motor operation, do not insert your finger(s), a screw driver, or the like, through
the outer fan cover or the ventiation hole of motor bracket. If it touches a revolving part such
as fan, it may cause an injury to personnel or damage to the motor.
(b) The limit of temperature rise of coil and bearing is shown below.
Temperature Rise Limit (Ambient Temperature 45℃)
Insulation Class "E" Insulation Class "B" Insulation Class "F"

Part Resistance Thermometer
Method Method
Stator coil 75 60 75 65 95 80
55 55 65
Bearing - - -
(Surface) (Surface) (Surface)
24/136
3. Maintenance
The quality of maintenance gives a large influence to the life of motor.
(1) Planning of inspection and maintenance

(a) Since an emergency motor or a motor for gate tends to absorb moisture during a long rest,
and insulation resistance is lowered, it needs daily attention but does not need overhaul
inspection by disassembly so often.
(b) A motor continuously used for pump or fan needs disassembly for cleaning and inspection
at a short interval.
(c) Preserve the records of daily inspection, monthly inspection and overhaul for future
reference.
(2) Daily inspection

(a) Listen to sound.
Listen to the sound of every part of motor using a stethoscope bar, magnetic sound, sound
of mechanical friction or sound of abnormal bearing can be perceived.
(b) Pay attention to smell
When the motor gets overloaded or overheated due to disturbed ventilation, al special
bad-smell of burnt varnish makes you perceive a trouble.
(c) Judgement from appearance
Check for oil leakage, disturbance in the ventilation, etc.
(d) Because it is dangerous to check the temperature of bearing, frame, etc. by touching, use a
temperature measuring device such as an alcohol thermometer.
(3) Monthly inspection

(a) Measurement of insulation resistance
Check whether the insulation resistance is a specified value or higher.
(b) Surface painting
If the surface painting come off, rust takes place rapidly. Repair it immediately when the
painting has come off.
(4) Inspection and cleaning at disassembly

(a) Bearing
Remove dirt and rust on bearing and its housing.
(b) Coil and insulation
Check for the looseness of blinding strings for coils and adhesion of dust. Repair or clean if
any.
(c) Other parts
Clean off dirt.
25/136
4. Well-Keeping of Coil and Insulation
(1) When coil gets moist
In addition to at a specified time in the maintenance schedule, measure the insulation
resistance of the coil in such a case that it has absorbed moisture during transportation,
storage or rest. If the measured value is lower than the following value, dry the coil without
fail.
High voltage 1 minute value by 1000 V megger at 40℃

circuit Rated voltage[kV] + 1[MΩ]
Low voltage 1 minute value by 500 V megger at 40℃
circuit 1[MΩ]
Space heater 1 minute value(before charge) by 500 V
circuit megger at normal temperature 1[MΩ]
Dry the coil by either of the following methods until the recovery of insulation resistance is
confirmed.
(a) Dry it in a drying furnace at a temperature not exceeding 90℃.
(b) Cover the motor with canvas or a similar cover having a vent hole at the top, and dry it by
blowing in hot air or by placing a heater device or a lamp in the cover. In that case, it is
necessary to control the temperature at 90℃ max. so as to avoid local heating.
(2) In case of soiled coil

When the coil is soiled or the insulation resistance cannot recover by drying, clean it as
follows:
(a) Wipe off dust on coil, wash it with detergent and hot water or low pressure steam,
thereafter rinse it with clean water.
(b) If the dirt cannot be removed thoroughly with detergent, wash it by chloride. At that time,
take care not to be poisoned.
(c) Dry the coil in either of the methods mentioned in above (1).
(d) If possible, apply high quality varnish by brushing, spaying or dipping when the coil is
dried up and still warm.
(e) Before starting, check the insulation resistance without fail.
26/136
5. Detaching and Attaching Rolling Bearing
Refer to the structure diagram in the volume of data.
(1) Detaching rolling bearing
In case of replacing a rolling bearing, if it is detached forcibly by hammering or thrusting, a
trouble such as a bend of shaft may arise. Therefore take care fully to avoid such trouble.
(2) Attaching rolling bearing

Attach the bearing in the following manner:
Note : Because a rolling has a higher accuracy than general mechanical parts, handle it
carefully so as to prevent the entrance of dust, rusting, bruise or flaw.
(a) Before attaching the bearing, debut corner and screw portions on shaft and wash it
sufficiently with washing oil. Check the fitness of ring nut beforehand by setting it on shaft.
(b) Wash end cover, slinger, ring nut, lock washer etc. beforehand.
(c) Heat the bearing in oil to expand the inside diameter
Keep the heating temperature at 100℃ or lower. If the temperature exceeds the limit, the
proof stress of bearing steel will decrease to reduce the life of bearing.
(d) After attaching the inside end cover, insert the heated bearing and press the inner ring of
bearing fully to the shaft shoulder. After cooling it to a room temperature, tighten the ring
nut and lock it with washer.
(e) Fill grease fully in gaps between inside and outside rings and balls of the bearing. Fill the
inside end cover with grease as much as 1/3 to 1/2 the volume of the cover.
(f) Attach housings such as bracket, bearing box, etc. and the fill outside end cover with grease
as much as 1/3 to 1/2 the volume of the cover, too.
27/136
8. Troubleshooting 1
Phenomenon of Trouble Cause Disposal
No revolving 1. It is revolved in any 1. Mal-contact of switch or 1. Adjustment or replacement

at no load direction by hand. wire of contact part
2. Disconnection of one (1) 2. Check and repair or
fuse or wire replacement
3. Trouble of stator coil 3. Repair in a special factory
2. Abnormal noise 1. Single-phase condition by 1. Check of switch and

Beats lacking one (1) phase power source circuit
Beats at starting 2. Mal-contact of switch or 2. Adjustment or replacement
wire of contact part
3. Disconnection of one (1) 3. Check and repair or
fuse or wire replacement
5. Looking in motor inside 5. Repair in a special factory
(damaged of bearing and
the like)
3. No sound 1. Trouble of stator coil 1. Repair in a special factory

2. Incomplete release of an 2. Check the circuits
interlock
＊.
3 Service interruption 3. Inform the Electric
Company of it
＊4. Disconnection of two (2) 4. Check and repair or
or more fuses or wires replacement
＊5. Mal-contact of two (2) or 5. Adjustment or replacement
more points of switch of contact part
＊6. Disconnect of two (2) or 6. Check and repair of
more points of starter conduction part on starter
(＊Other than motor)
4. No revolving by hand 1. Perfect contact of stator 1. Repair in a special factory

and rotor
2. Damaged of bearing 2. Repair in a special factory
5. Protection device is 1. Mal-contact of terminal 1. Repair of contact part

actuated 2. Trouble of stator coil 2. Repair in a special factory
28/136
1. Reverse revolving 1. Misconnection 1. Check and repair of

connection
revolving at
no load 2. Protection device is 1. Trouble of stator coil 1. Repair in a special factory
actuated
3. Speed does not rise 1. Trouble of stator coil 1. Repair in a special factory
4. Beats ＊.
1 A large friction torque of 1. Repair in a special factory
motor itself
＊.
2 Irregular gap between 2. Repair in a special factory
stator and rotor
＊.
3 Trouble of stator coil 3. Repair in a special factory
4. Single-phase condition by 4. Check of switch and
lacking one (1) phase power source circuit
after starting
(＊Over current)
5. Abnomal temperature 1. Abnomal power source 1. Improvement of power

rise in no load source installation
operation 2. Disturbance in ventilation 2. Improvement in
cooler ventilation cooler
3. Reverse revolution of fan 3. Correction of revolving
direction of fan
4. Clogging of filter 4. Cleaning or replacement
of filter element
6. Rumbling or metallic 1. Trouble of bearing 1. Repair in a special factory

sound on bearing 2. Deterioration of grease 2. Replacement of grease
7. Remarkable vibration 1. Unbalance of motor side 1. Rebalancing of rotor

2. Severe vibration of a part 2. Adjustment of balance of
attached to motor attached part
3. Trouble of rotor 3. Replacement of rotor
4. Resonance of foundation 4. Reinforcement of
foundation stand
5. Deficient strength of 5. Reinforcement of
mounting stand mounting stand
6. Looseness of foundation 6. Additional tightening of
bolts foundation bolts
29/136
9. Troubleshooting 2
1. Protection device is 1. Mating machine is no 1. Adjustment of mating

actuated good machine
At loading Relay is tripped and 2. Misselection of relay or 2. Replacement of relay or
(Motor fuse melts away fuse fuse
revolved at 3. Inadequacy of using 3. Review of using condition
no load) condition
4. Overload 4. Reselection of the rating
installation
5. Abnormal power source 5. Improvement of power
source installation
2. Overheat of switch 1. Misselection of switch 1. Reselection of switch

2. Mal-contacting of switch 2. Adjustment of switch
3. Overheat of motor 1. Trouble of stator coil 1. Repair in a special factory

of motor
3. Abnormal power source 3. Improvement of power
source installation
4. Inadequacy of using 4. Review of using condition
condition
4. Speed lowers 1. Abnormal power source 1. Improvement of power

Revolving speed does source installation
not rise 2. Trouble of rotor 2. Replacement of rotor
Slow acceieration 3. Overload 3. Reselection of the rating
No revolving of motor
5. During loading- 1. Abnormal power source 1. Improvement of power

operation, temperature source installation
rises unusually 2. Ambient temperature is 2. Improvement of
too high environment
of motor
30/136
6. Overheat of bearing 1. Deviation of shaft center 1. Adjustment of centering

line
At loading
2. Incorrect bearing 2. Replacement of bearing
(Motor
3. Overgreasing 3. Qualitative adjustment of
revolved at
grease
no load)
4. Deterioration shortage of 4. Supply or replacement of
inadequate quality of grease
grease
7. Abnormal noise 1. Abnormal power source 1. Improvement of power

Beats source installation
Sliding noise 2. Obstruction in ventilation 2. Reselection of the rating
route of motor
of motor
4. Incorrect bearing 4. replacement of bearing
5. No good grease 5. Supply or replacement of
grease
6. Trouble of rotor 6. Replacement of rotor
7. Contact of rotor core with 7. Repair in a special factory
stator core
8. Contact of rotor with 8. Repair in a special factory
stator or a part of outer
cover
9. Insufficient tightening of 9. Retightening
a part such as bracket,
fan, etc.
8. Excessive vibration 1. Incorrect centering of 1. Repeat of direct coupling

direct coupling Direct coupling by
recentering: Consider the
tolerance for thermal
expansion
2. Impact transmitted from 2. Examination of mating
mating machine machine
9. The pointer of ampere 1. Abnormal power source 1. Improvement of power

meter swings source installation
2. Fluctuation of load 2. Modification of load
3. Periodical run out with 3. Inspection and repair of
beats, or trouble of stator stator or rotor
or rotor
31/136
INSTRUCTION MANUAL PROVISION CRANE
INDEX
OPERATION INSTRUCTION.
. EMERGENCY MANUAL OPERATION
. MECHANICAL BRAKE SYSTEM
. MAG. DISC BRAKE INSPECTION & MAINTENANCE.
32/136
33/136
3. Slewing
(1) Move position of MCCB switch of control panel “OFF”.
(2) Tie ropes to the jib head.
(3) Hold the ropes in order to prevent from rotating the jib
(4) Open the brake cover of the slewing winch.
(5) Release brake torque by unfastening set screws.
(6) Rotate the jib by pulling ropes.
(7) After completion, set back screw in original position.
ATTENTION: For manual slewing of the jib must be well secured by two
ropes on both sides before releasing the brake torque.
34/136
MECHANICAL BRAKE SYSTEM
1. Lifting
(1) The driving shaft①activates ②
(2) The made screw on the end of ③ is nesting in the female screw on
the end of ②
(3) The friction disc④ and the pinion gear shaft③ is connected with
serrated joint.
(4) When hoisting② and ④ clamp the friction disc⑤ in the middle by
the function of the screws on② and③
(5) At this stage②③④ and⑤ rotate as one unit.
(6) In this case, the ratchet wheel and ratchet becomes free.
2. Lowering
(1) This disc⑤ is stopped by the ratchet⑥
(2) The gear② and the outer disc④ rotates on the thread in loosening
direction. Then the friction disc becomes free to rotate.
(3) When the load forces the rotation of the pinion gear above its
synchronous speed. The friction disc automatically tightens and controls
the lowering speed.
35/136
3. Stopping
(1) The pinion gear shaft① stops and the load forces the ratchet⑥ locks
the load in position.
(2) The spring⑦ maintains a tight contact between⑤ and④
[MECHANICAL BRAKE ASS’Y]
36/136
MAGNATIC BRAKE INSPECTION & MAINTENANCE.
1. FUNCTION OF ELECTRO-MAGNETIC BRAKE
The spring-operated electro-magnetic brake is suitable as a fail-safe
brake to hold the load in the case of a power failure or a fuse blow. The
electro-magnetic brake is also suitable for vertical movement of a hoist
system.
(1) BRAKE RELEASE
When the magnet① is energized, the moving armature② is attracted
to the magnet① and the spring③ is compressed. As a result, the
pressure on the facing(lining)④ is diminished and the brake is
released, the shaft begins to revolve and starts the hoisting or lowering
operation.
37/136
(2) Braking
The attractive force of the magnet① is lost when the current is cut
off. At the same time, the spring pushes the armature in the direction of
the facing(lining), the armature returns to its former position.
As the result, the brake force is applied to the facing, the revolution of
the shaft is stopped, and the hoisting and lowering operation is stopped.
2. INSPECTION AND ADJUSTMENT
Before beginning the inspection, be sure to disconnect the electric
current by turning the power switch OFF.
Otherwise, a serious accident might occur.
(Above rule applies at the time of adjustment as well)
- The adjustment or renewed of new brake ass’y should be done according to
following procedure.
(1) The distance of magnet and armature should be 0.5 mm all around. If
they don’t maintain this gap, loose the gap fixing bolt⑤ and adjust the
distance with gap regulation⑥ screw.
(2) The electro-magnetic brake is operated by facing(lining). If it is stained
with oil or moisture, it loses its functions and will slip.
(3) Before the trial run, supply the current to the magnet coil only, and
confirm that the running shaft is operating without any resistance.
Then make a trial run after the supplying the current.
38/136
(4) If the slip occurs in the middle of operation, it can be blamed to
enlarging gaps between brake disc and lining. In that case, adjust the
abt. 0.5~0.7mm by thickness gauge
(5) Initial setting distance of adjusting screws from the surface of magnet
coil is abt. 2~3mm
(6) If you want a larger torque, tighten the screw⑥ clockwise(CW).
(7) CAUTION
A. Please be sure that friction discs and lining discs on its stud bolts
and clutch gear must be moved smoothly.
B. When replacing the parts of brake, after assembling some
clearance (abt. 2~3mm) between clutch gear and amateur must be
kept.
It should be confirmed by visual checking.
If there is no clearance, the position of clutch gear to be re-adjusted
with fixing screw.
39/136
B. INSPECTION & MAINTENANCE

1. GENERAL PRECAUTION FOR MAINTENANCE & INSPECTION
Inspection intervals of crane parts vary depending on the frequency or
condition of use.
Determine the interval after actual crane use.
It is recommended that the projected inspection date be marked on the
schedule sheet. Spare parts can be ordered in accordance with such
schedule accordingly.
In order to ensure smooth cargo loading/unloading operation, an earlier
detection of abnormality through routine maintenance and inspection is
desired.
Inspections are classified into daily inspection and regular inspection.
1.1 Daily Inspection
Daily inspection is carried out before the start of each day’s operation.
Inspect the lubrication, oil leakage, heat generation, noise, loose
clamping, contact area of electric equipment, brake, lifting hook and wire-
rope deterioration.
Immediately repair or replace the parts if any abnormal noise is heard.
The operator should immediately stop the operation and re-inspect the
crane in the middle of operation if any abnormality is detected.
In case a full-time operator is not available, perform the daily inspection
routine at least once a week.
40/136
DAILY INSPECTION TABLE
No Inspection Item Explanation

Check for any hindrances standing
1 Check for any obstacles in the working area.
in the way of hoist.
Check for the correct releasing of
2 Check the releasing of clamping device
locking rack
Check whether the stopper on both ends of the rail
3 is deformed or lost or its connection bolts are
loosened.
Check for broken grounding wire of metallic
pushbutton station and loose cable connection. Extra-caution is required since the
4
Also check for abnormalities in the through parts of electric shock hazard is Involved.
the pushbutton switch cable.
Working condition of control switches. Check for switch jam.
5
Interlocking circuit. Can the switch be reset by itself?
Hoisting up, Slewing, telescoping
6 Check for proper functioning of all limits switches
jib, Travelling both end.
Less than 10% of the total number
Strands break.
of strands within one twist.
Wire Kinky rope, deformation, and corrosion.
7 Rope Split cotter pin-abnormalities such
Anchor, fitting, pin, and heave.
as wear.
Corrosion of fittings. Under-lubrication at the roots,
breakage, and corrosion.
Hook and shackle nut tightening. Split-pin & set screw slip-off
Hook Sheave damages. Groove damage & wear
8
Block Damages and loose connections in
Loose set screws.
sheave case, key plate (name plate).
9 Crack, wear and deformation of hook. Visual inspection

10 Check the oil leakage on drive Visual inspection.
Check the grease on rack & pinion and sliding pads
11 Visual inspection
on telescopic jib
Grounding condition of runway beam and traveling Inspect grounding wire.
12
wheels Check for loose wire connection.
No-load trial operation.

Check for sufficient braking performance.
13
Check for full winding of wire-rope to the drum.
Check for abnormal noise and vibration.
41/136
OVER LOAD LIMITER
User’s Manual
MODEL No
BFL-210D
BAN DO FA
42/136
Table of Contents
1 Foreword 1
2 Cautions Before Using 2
3 Product Features 3
4 Product Specifications 4
5 How-To-Use Instructions 5
5-1 How to Wire 5
5-2 How to Set up Data 6
Explanation of
5-3 8
Product Motions
Names and Functions of

5-4 9
Control Panel
6 Quality Warranty 10
7 Wirings 11
Circuit Diagram and

8 14
Parts Specifications
9 Assembly Drawing 21
10 Outside Drawing 23
Product and Main Parts

11 28
Images
43/136
1 Foreword
This product has been manufactured with excellent performance and accurate and
safe features, having been through various load tests and strict testing for each one
under the strict quality control.
Our Load Limiter is electric safety equipment that protects mechanical shock by the
overweight of crane and hoist from overload.
In manufacturing of the product, with plentiful operating and various motor-
diagnosing features, it has been manufactured and designed to be compatible well
with cranes in various industrial sites and with secure and elegant exterior design.
Also, we have manufactured the product focusing on the convenience of users while
using it and since we put on a digital display that helps users understand how to use,
anyone can easily operate the product.
We hope you use this product properly after you have read this user’s manual
carefully so that you can make use of the features of this product satisfactorily.
Thank you.
Copyright © 2006 All rights reserved designed by BAN DO FA R&D

44/136
2 Cautions before Using
1. Operating HOIST button on the crane more then two consecutive times a second
causes malfunction.
2. Do not apply excessive power on DATA button since soft touch is enough for it to
operate.
3. Be careful of shock while carrying the product and check if it is damaged.
4. Check if this product matches your ordered specifications.
5. Check specifications such as motor power, operating power, rated current and
rated load in Product Order.
6. Install the product transversely or perpendicularly.
7. Be careful since repeated turning ON/OFF the input controlling power of the
product may initialize or cause malfunction, and be sure to connect to the front panel
of emergency switch and use while power is put in all the time.
8. Do not remove operating power at your discretion since the lifting, driving and
transverse movement of crane stop in case of the malfunction of the product or the
removal of operating power using this product.
9. Permitting voltage other than one indicated in specifications causes burn-out for
this product uses exclusively fixed voltage for operation,
10. For the pressure-resistance testing of crane control panel connected to this
product at more than AC1500V, do it after disconnecting all terminal wires of this
product.
Copyright © 2006 All rights reserved designed by BAN DO FA R&D

45/136
3 Product Features
1. User can check the operating status of crane at any time for the front panel window of the
product displays the current used by hoisting motor while using crane.
2. This product has a feature of automatic restoration when crane stops due to overweight
only if there is descending operation for the time as much as lifting time for it memorizes the
lifting time of crane accurately.
3. Its current indicator can display 0.1A-999A in DIGITAL TYPE so it is applicable to all
kinds of cranes regardless of capacity.
4. With its control current setup in two steps, You can set the speed at the first step for low
speed and the second for high speed in 2 SPEED crane for each usage of crane you can set up
and control each motor input signal in 2 MOTOR crane.
5. Operator can discern the current operating status at a distance with LED lamp showing
the product operating status on the lower part. (Green-POWER, Red-BREAK)
6. In case of alarm sounding due to overload, operator can work safely since alarm with
intermittent sound calls his attention.
7. Operator can work safely since safety circuit in the product operates and all operations
except descending movement of crane stops when he disconnects product operating power at
his discretion.
8. The product is safe because it has been manufactured to protect the product from water,
dust and moisture.
9. The product has been manufactured for anyone to use easily as DATA value can be set up
with three buttons simply.
10. Installation and operation are convenient for it is small and light.
Copyright © 2006 All rights reserved designed by BANDO FA R&D

46/136
4 Product Specifications
No. Name Details

Name of Danger
1 Crane and Hoist
Machines
Name of Protection
2 Protection Device ( J-2 Electric)
Equipment
3 Model Name BFL- 210D
4 Motor Voltage Applied AC 220V – AC 480V
Rated Current Used
5 0.1A-999A / used
and Limit
6 START TIME 0.1SEC – 9.9SEC
7 SHOCK TIME 0.1SEC – 9.9SEC
8 RESET TIME 0.1SEC – 9.9SEC
9 Operating Power AC 110V/220V ( AC 48V, Custom-built Specification)
Upon POWER ON, N0 Output Point of Contact
10 Output Point of Contact
(250V 5A Resistance Load )
Automatic restoration while descending
11 Restoration Method
as much as Reset Time set
200,000 Times at the Normal State of Product
12 Electrical Life
(Output Point of Contact )
Temperature and Humidity Temperature around -15˚ - +50˚
13
for Use Relative humidity below 80%
14 Voltage-Resistance AC 1500V for 1 Minute
15 Power Consumed 1.5VA
16 Exterior Size Width 115, Length 1143, Height 47 ( Unit: mm )
Waterproof, Dustproof 2m/m Mechanical–String(Soft Rubber)
17
Processing Method O-RING Processed
18 Product Weight Approximately 1.2 Kg
Copyright © 2006 All rights reserved designed by BANDO FA R&D

47/136
5 How to Use Instructions
5-1 How to Wire

1. First, check MAIN power and operating power of the crane to be installed and if the
operating power of the crane is the same as that of this product and then wire it in case of same
voltage.
2. Check all powers are OFF after cutting off MAIN switch of the crane and fix it on the
installation site not to be shaken using 8m/m bolt.
3. Wire from No. 1 to No. 6 in order as the number on the product wire using 6P 1.23m/m wire
of the product connection. [Use 8P 1.25mm for 2 Speed Type]
4. No. 1 and No. 2, the first two of the product are the operating power wire. After checking it
again if it is the same power as that of the crane and connect to the front panel of emergency
stop power of the crane so that always power is turned ON in the No. 1 and No. 2 terminals even
while emergency stop button being operated.
5. No. 3 and No. 4 lines, lift stopping output signals of the crane in the over-current operation of
the crane, should form the circuit that blocks lifting magnet. For reference, be careful the No. 3
and No. 4 terminal inputs are turned OFF and no operation is done while operation input
power is turned on this product and the product is in abnormal operation.
6. No. 5 and No. 6 lines are external C,T input signal lines. Be sure to pass C, T primary lines
through the upper and lower output lines of the crane and then connect C, T secondary wires to
No. 5 and No. 6 lines of this product.
7. No. 7 and No. 8 lines are those used for environment while 2 SPEED hoist or 2 MOTOR
crane.
Connect them in parallel with upper and lower magnet supplementary A points of contact of
crane or hoist and then set No. 7 and No. 8 lines ON in up-and-down motion, and Low speed is
detected when No. 7 and No. 8 lines are OFF while high speed detection circuit operates when
they are in ON motion. (Use turning OFF No. 7 and No. 8 terminals for normal type crane.)
8. When you judge the above connections are successfully done, turn ON the MAIN switch of
the crane after checking the connection status once again, and after checking if product
operating power is normally permitted, if up-and-down motion is normally done in the off-load
state of the crane, start normal operation setting up current value at 110% of the rated load of
the crane.
Copyright © 2006 All rights reserved designed by BAN DO FA R&D 5

48/136
5-2 How to Set up DATA
In initial power input, program initial memory sign of the product is blinking for three seconds
successively and then initial sign displays as the image below.
[ Initial display on delivery of the product]
[ ‘A’ sign is blinking. ]
A] When setting up Data of the product , turn button ON for two seconds and input as
the display below in order.
B] ● Start Time Setup [ 0.1 ~ 9.9 Sec]
Set up with and buttons.
Move to the next step with motion
C] ● Shock Time Setup [ 0.1 ~ 9.9 Sec]
D] ● Reset Time Setup [ 0.1 ~ 9.9 Sec]
● Set up restoration time in Over Load at about 0.5 seconds shorter than
set St and Sh times.

49/136
E] ● Start Amper [ Set value at the point of initial motion]
Set up with 와 and buttons.
● HP-01 [ Automatic indication 0.1 ~ 9.9A]

HP-10 [ Automatic indication 1A ~ 99A]
Move to the next step with motion.
F] Set up ON or OFF using the motion of + button
● Use 2 Motors for setting up ON. Use 1 Motor for setting up OFF.
G] ● Input the set rated current of L Motor when setting up CP-ON

● Cannot use for setting up CP-OF
Set up input value with and buttons.
H] ● Input the set rated current of H Motor when setting up CP-ON

● Operate with general motor setting when setting up CP-OF
Set up input value with and buttons.
I] ● Use 0.1A ~ 99.9A when setting up HP-01

● Use 1A ~ 999A when setting up HP-10
Set up input value with button.
● Initialized status when DATA input

is completed

50/136
5-3 Explanation of Product Motions
1. No. 3 and No. 4 lines output is automatically turned ON when power is put in to this product and
as green POWER LAMP at the lower part of the product lights, the sign of front display part shows
00, 0A value.
2. If hoisting work starts at the weight lower than rated one, load current of motor is permitted to
the primary part of C, T SENSOR passing through motor lines and signal connected to No. 5 and
No. 6 lines is put in to the secondary part of the induced C, T SENSOR, and through internal OP
AMP IC(OP072) circuit, when the signal is put in to 8bit A/D Converter, the current value is
displayed in proportion to the current permitted to (PIC16F873) IC output panel.
3. At this time, since initial operating current motor of about 5-6 times is instantly put in for the
characteristic of the motor in hoisting work, forming interior circuit to detect input signal after
initial operation in operating the motor, you can set up the operation time (0.1SEC-9.9SEC)
designating a random value for the set value of START TIME fitting the initial operating
characteristic of the motor.
4. And after motor operation has been initialized, set up SHOCK TIME for it to operate accurately
when current over the set value continues to flow by forming a SHOCK TIME circuit inside to
prevent malfunction when current over the set value flows due to sudden change in voltage or
irregular current in hoisting work with normal load. ( Set range: 0.1SEC - 9.9SEC ) The average set
value is set to 1 SEC.
5. In 110% of the rated weight(for example: hoisting work at over 55A for 50A), after the set
START TIME and SHOCK TIME have passed, as internal circuit judges it overload motion and
green lamp and alarm device attached to the lower part of the product operate and the circuit of
lifting magnet connected to No. 3 and No. 4 lines is blocked and hoisting work is stopped and the
values of set value and the permitted over-current value is displayed being HOLD at the interval of
one second on the internal display part.
6. When restoring to descending of crane work with stopped hoist, if the current value flowing on
motor is permitted to C, T SENSOR when pressing descending button, after the internal circuit
being HOLD and paused operates descending motion as much time as set RESET TIME, it
automatically restores returning to normal state.
7. This product has been manufactured for using easily 1 step control(No. 7 and No. 8 OFF) mode
and 2 step control (No. 7 and No. 8 ON) by the use of crane, and for the use over 100A, since it
passes the secondary rated 5A of the converter through product internal C, T for converting voltage
using external converter for meter, you can use it safely even at the high capacity of current used.

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5-4 Names and Functions of Control Panel
②
① ③
④
⑤ ⑥ ⑦ ⑧
① This is a digital display part of DATA input value and current, by which you can check the
indication of motor current value and the operation status when operating crane.
② This is a checking lamp showing whether the internal operating power of the product is in
motion, POWER lamp lights if input power is permitted.
③ This is a lamp that lights if there is instant change in power not overweight or SHOCK
current is permitted when using crane and when SHOCK lamp continues to display, it becomes
overload motion.
④ This is a lamp that lights if there is OVER LOAD motion due to overweight when using crane
and hoisting work is stopped with internal BUZZER alarm.
⑤ This is button manufactured for manual TEST of the product from the outside without
opening the internal cover of the product in the inspection of crane and maximum display value
of the product is permitted automatically, hoisting is blocked and alarm sounds when pressing
the button, and repeating of the button pressing restores it automatically.
⑥ This is used for putting in or memorizing set value for each operating function of the product.
How to use: since you cannot operate it from the outside for safety purpose, be sure to operate it
from the inside front opening the front cover. (Pressing the button for two seconds converts to
DATA Setup MODE)
⑦ This is button for moving the unit of set value in DATA setup mode and every time you press
the button, set display moves to indicates the unit value of the number.
⑧ This is set value input button in DATA setup mode and every time you press it, you can put in
Operating time and set current value
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6 Quality Warranty
1-1. Term of Warranty
Quality is guaranteed for one year from the first purchase date.
1-2. Details of Warranty
We guarantee this product operates normally if used under the provisions of installation,
inspection and maintenance, etc., in user’s manual distributed by BAN DO FA.
1-3. Range of Warranty
BAN DO FA warrants for the issues on the parts and performance of LOAD LIMITER.
1-4. Cases Not Guaranteed
1) Not used designated voltage
2) Not used under normal condition
3) to disassemble, assemble or rebuild or reconstruct at discretion
4) Faults after using in environment with high temperature and high humidity or
place with corrosive gas
5) Damage and faults due to abnormal voltage and external cause or careless handling.
6) Faults and incidents due to natural calamities such as fire, earthquake, flood or lightning, etc.

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- 1 -
INSTRUCTION MANUAL
ELECTRIC WINCH
This instruction manual is provided to ensure

safe and corret use crane. Improper
installation, use and repair of this product may
cause damages because of dropping, fire,
explosion, electric shock, etc. Therefore, be
sure to read through this document carefully
and handle this product. And keep it handy for
easy reference.
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SAMBU INDUSTRIAL CO.
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CONTENTS
1. Contents
2. Safety Instruction
2-1. Introduction
2-2. Announcement on Danger, Warning, Caution
2-3. Safety Instruction
3. Operation
3-1. Test Operation
3-2. Working Operation
4. Checking and Repair
4-1. Lubrication Oil
4-2. Fuse Replacement
4-3. Daily Inspection
4-4. Monthly Inspection
4-5. Yearly Inspection
5. Troubleshooting and Relevant Measure
6. Standard for Checking and Repair
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2. Safety Instruction
2-1. Introduction
As this crane is classified a device as a harmful and dangerous machine,
instrument and facility, careless handling of product may cause serious injury or
damages in a property due to a dropping object, a rotating object, a high voltage,
and a hot surface, etc.
Only a qualified and trained personnel is allowed to install, maintain, and repair the
crane according to related safety regulations and specifications. To prevent potential
danger, it is essential to read and understand the safety instruction contained in this
manual carefully.
2-2. Announcement on Danger, Warning and Caution

Signs of danger, warning and caution are described in this manual to emphasize
the important safety tips. Such attention items are defined in this manual as follows:
This sign indicates the desperate and dangerous situation which may
Danger cause a fatal injury or death in case no attention is made.
This sign indicates the potential hazardous situation which may cause a
Warning fatal injury or death in case no attention is made.
This sign indicates the potential hazardous situation which may cause a
Caution minor injury in case no attention is made.
2-3. Safety Instruction

Warning
Only the qualified and trained personnel with respect to a safety and wearing safety
gears can install, operate check and repair the crane.
Warning
Read through and execute all the contents in this manual carefully before starting
installation, operation or repair/checking.
Caution
To prevent an accident that may be caused by the unauthorized persons(e.g.,
children), establish an appropriate protection procedure.
Caution
A person who can affect the work, i.e., an intoxicated or durnken person, should
not install, operate and repair/check the product.
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3. Operation
3-1. Test Operation

(1) Be sure to check both the interference between a crane and a building and
related safety apparatus in operating the unloaded crane at the directions of up &
down and of left & right.
(2) In case of no problem in the above clause (1), be sure to check voltage,
current, speed, and lift under unloaded state. If no problem occurs, be sure to check
voltage, current, speed, and so on under loaded state(100％ loading if possible).
(3) If overheat in operation occurs in the above clause (2), be sure to check whether
a temperature exceeds a temperature upper limit or a noise occurs in a speed
reducer or a bearing. If an overhear and excessive noise, vibration, or beat(repeatedly
beating sound, etc) occurs, promptly stop the operation and call maker agency or a
customer service center at the heat office.
3-2. Working Operation

Make sure that a crane user should check an emergency stop bar, over-winding
prevention device, and brake of before use. Make sure that a crane user should
observe before working operation all safety instructions and prevention measures,
which are shown in the user's manual. If any fault in operation safety and confidence
is found, promptly stop the operation by using an emergency stop bar and remove
the fault completely by a qualified person. Then perform the operation in a safe
condition.
Caution
Be sure to designate a person in charge of handing a crane. crane can be easily
operated by any person. But a person in charge of handling should be designated to
carefully handle it. When a problem occurs, call a person in charge of repairing in
order to maintain it in a constant good condition.
Warning
Before installation or operation, please be fully aware of all contents of the user's
manual and operate it.
Danger
Do not overload the crane in the excess of the rated load. Overloading may
damage a crane, causing an abnormal abrasion of each crane part and motor
damages, reducing significantly the crane life, and causing personal and physical
damage due to a safety accident. It is strictly prohibited by the regulations as well.
Danger
Do not operate the crane right under it or do not operate the load hung above
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people's presence. It may cause a fatal injury or even death.

Caution
Minimize the inching operation as less as possible. In particular, an operator tends
to perform an inching work at the start of craneing and the near-end of lowering with
regard to a load. Excessive inching work may significantly increase the temperature of
a motor, a brake and a magnet, thus resulting in shortening the life of the product.
Warning
Do not let a part of your body and other objects touch a crane swinging part. It
may cause a serious bodily injury.
Warning
Do not release a wire rope in excess of a rated loft limit. Even if the wire rope of a
crane has 2-turn length of spare winding even after it is fully released to such limit, if
you lower the wire rope beyond the limit, a tension is applied to an end collar of a
rope end, causing a serious danger. Accordingly, a relevant attention should be made
in this regard.
Caution
Hang and use a load correctly. Do not start an operation with still-swinging load,
and avoid lofting an object by using the end point of a hook. Do not suspend a lond
with rope whose angle is wider than a specified one.
Caution
Do not pull a load out of a traveling way, and avoid ac excessive traversing.
Extreme pulling or traversing may cause a disorderly winding, accelerating an abrasion
and a damage in a wire rope.
Caution
Avoid a sudden reverse operation of the crane. For example, if you lift a load
abruptly which is being lowered, it may give a great impact on the crane, causing
failures in each part of the crane. So, stop a load completely, and then execute the
next operation. In addition, press the push button correctly until you feel the touch of
an end.
Caution
When you raise a load, hang in on hook, and it slowly to check if a winding status
of the wire rope is normal, and then lift the load at normal speed. Here, the load
should be hanged horizontally at the time so that the even power may be applied to
the wire rope.
Caution
Be careful when hanging a push button switch. Keep the push button cable away
from other objects during a traversing operation. Do not promptly release a push
button switch as soon as you finish using it. First place your hand right below the
crane, turn the power switch off, and then let it go. Otherwise, it may cause hazards
due to an abnormal operation or damages resulting from collision with other device,
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freights, etc.
Caution
Do not let the crane collide with a stop bar. make sure that the crane with a
traversing motor should not collide whit a stop bar. Frequent collisions with a stop bar
may shorten the life of a crane.
Caution
When hanging a load with a rope, follow the instructions below.
․ You should know the weight of the load as correctly as possible.
․ As loads have various shapes, identify the center of the load and put a rope
around it.
․ Select a safe wear being suitable for the weight and shape of the load.
․ When the binding device is a wire rope or chain, keep the hanging angle within 60 °.
The wider the hanging angle is, the greater the tension of wire rope or chain
becomes (Figure 1).
․ Do not hang a load with a single rope, which makes to it hard to keep the
balance of a load and cause too much power to apply in one side of the load.
Select a rope, a chain or auxiliary device suitable for a load weight.
Using too thick a rope for a light load is dangerous. Make sure that a failt
should not be made whit regard to a selection of a rope.
․ Do not suspend a heavy load at the end part of a hook. The center of a hook is
the strongest part; whereas if it leans to the side, it becomes weaker.
When the end part is at its center, the strength is just about 40% of strength.
3 0°
6 0°
90 ° 1 20 ° 14 0°
100 10 4 1 16 1 41 200 300
Figure 1. comparison of tension to be exerted to wire 1 of bundle wires in terms of angle
Warning
Do not alter, remove or disable the protection device in a crane such as
over-winding prevention device, over-load prevention device, emergency stop bar,
collision prevention device, traveling limit switch, and hook releasing device.
4. Checking & Repair

A method to make a crane good and to enlarge its life depends on a correct
inspection and repair. Because the inspection and repair are fully defined in the
relevant regulations related to industrial Safety & Health Act, please follow the
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regulations. The inspection and repair of Bando crane must be made in accordance
with the standard of inspection & repair, which is defined in the following explanations
and the later pages of user's manual. Please record the result of a monthly inspection
and a yearly inspection and keep the records for more than 3 years. It is convenient
to make a book for the inspection and repair of crane, which enables an immediate
inspection and repair when conditions suddenly go bad. It is particularly necessary for
factories that use many crane.
Please designate a persion in charge of a crane repair. Even though a crane can
be easily operated, to use it for a long time depends on its usage and repair. Please
make sure to designate a person in charge of a crane repair.
4-1. Lubrication Oil Replacement

Provide
Remark
Oil Q‘ty Apprication Initial
Equipment Oil Brand ISO (Refill Change
/ Set Point Filling
Interval)
Yes/No
1.OMALA OIL 220(SHELL)
2.SPARTAN EP 220(ESSO)
3.MOBIL SHC 630(MOBIL)
Replace oil after the
MOBILGEAR 630(MOBIL)
Gear Reducer first 2 week
4.MEROPA LUBRICANT 220
Casing
(CALTEX) ISO VG 220 15 LTR Gear Box Yes
(craneing & After the first oil
5.MEROPA 220(FAMM)
Traveling) change replace oil
6.ENERGOL GR-XP 220(BP)
every six months
7.ALPHA SP 220(CASTROL)
8.SUPER GEAR EP 220(SK)
9.ELF EPONA Z 220(ELF)
1.MALLEUS GL 95(SHELL)
2.SSURRET FLUID 4K(ESSO)
3.MOBILAMA 798(MOBIL)
4.CARTER FLUID M(CALTEX)
Wire Rope 5.TEXCLAD PREMIUM 2(FAMM) - 5.0 LTR Wire Rope Occasionally Yes
6.ENERGOL WRP(BP)
7.SPHEEROL SX2(CASTROL)
8.SUPER COMPOUND No.1(SK)
9.CARDREXA DC1(ELF)
1.ALVANIA GREASE EP(LF) 2
(SHELL)
2.CAZAR K2(ESSO)
3.MOBILITH SHC 460(MOBIL)
Hook, MOBILUX EP 2(MOBIL)
Bearing
T/L Shaft, 4.MULTIFAK2 GREASE(CALTEX) - 0.5 LTR Occasionally Yes
Gear
Rack & Gear 5.MULTIFAK EP 2(FAMM)
6.ENER GREASE MM-EP2(BP)
7.SPHEEROL EPL2(CASTROL)
8.CROWN GREASE EP 2(SK)
9.EPEXA 2(ELF)
*After that, it is sufficient to supply the deficiency unless there is unusual change in
quality.
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4-2. Fuse Replacement

Fuse is affixed to an operation circuit power(C phase). Fuse burning can be caused
by a low grounding, an abnormality of magnet switch or an disorder of wiring. Be
sure to check whether a push button and a cable are normal. When there is no
problem after conducting a repair and measuring insulation, be sure to replace the
fuse with a new one.

A person in charge of handling shall perform the 'Inspection before operation'
everyday in accordance with the following.
(1) whether up/down/right/left directions smoothly operate
(2) whether an abnormal noise in operation occurs
(3) whether limit switch, brake, and magnet switch are correctly operated
(4) whether there exist the disengagement of wire rope and the short circuit
(5) whether an overload prevention device (load limit) operates
(6) whether a hook safety chain is normal

Be sure to perform the monthly inspection in accordance with the following under a
user's responsibility once a month.
(1) Magnet Switch
Be sure to check the unlocking of terminal screw.
(2) Wire rope
Don' t use if any of the following is applicable.
1) Number of cuttings in a rope of wire rope is more than 10% cuttings a twist
2) Diameter decrease is more than 7% of nominal diameter
3) Wire rope is twisted or faulted
4) Shape is severely damaged or corroded
(3) Hook-Block
Be sure to check whether a hook is deformed, a hook is easily rotated, a sheave
is easily rotated, or a wire rope is easily detached.
(4) Inspection of oil & grease
Be sure to inspect oil grease case for craneing and fill them up in case of
deficiency.
(5) Others
1) Inspection of drum damage & escalation
2) Inspection on abrasion in the trolley wheel of traversing drive and on traversing
function.
3) Inspection of unlocking in each bolt
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(6) Magnet Brake ( Figure 2. )
1) Operating
① The first operating, repeats three or four times that pushed ON-OFF button of
magnet brake, and then have check the operation of the armature smoothly.
② If the magnet brake action situation is good, Provide the power supply at the
magnet brake only. And then check the motor shaft revolve smoothly by hand.
If the motor shaft revolve smoothly, The assembling is good.
Or not, It has some problem with assembling, So have to setting again.
③ If the ①.② clause has no problem, Provide the power supply at the magnet
brake and motor, and then checked any noise with lining and bearing of motor
with running.
2) Inspection
You must have to regular repair that the magnet brake want to use long time
with normal condition.
When you repair the magnet brake, turn off the power.
① Setting gap of the lining
before shipment goods, setting the best a condition. But during use for a long time
it becomes the reason of trouble because worn of the lining and a short circuit.
② How to setting gap of lining
1. Measure gap between magnet and armature by thickness gauge
2. After setting a gap, bolting the nuts both side of magnet.
3. Setting gap : 0.3㎜ ±0.05
3) Notice
① Inspection of goods
1. Please check the goods to be any damage in the middle of the conveyance.
2. Please check the nut was solved with the bolt.
3. Please check the whether became the pollution at the water and the oil.
② Condition of use
1. Using an input power supply is in ±10 % within.
2. Using avoid the water and the oil.
3. Install place is without the moisture (-15°C~50°C).
4. Using place is without an explosiveness and a corrosiveness gas.
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Figure 2. Magnet Brake
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Figure 3. Machanical Braking system
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Figure 4. Repair wire rope

User shall perform 샕Yearly Inspection & Test샖at designated period every year in
accordance with the following.
(1) Be sure to check twist of traversing channel, abrasion, unlocking of Bolt, and stop bar.
(2) Inspection of brake Disassemble
Be sure to check the abrasion of lining and the operation of guide pin for
operation core.
After assembly, be sure to check brake heating & overall function.
(3) crane Disassembly & assembly
1) Disassembly
Before the disassembling, be fully aware of function of all parts.
① Take out oil in case through drain plug.
② After disassemble, attach a tag to each part in order to distinguish.
③ Put a small-sized parts like a bolt and nut into the box in order not to lose.
④ Take care of being stained with dirt in all parts.
⑤ Particularly, be careful not to damaged in surface of gear tooth.
⑥ After disassemble, be sure to check the whole inspection(the abrasion of gear
and lining, the crack of gear case, etc), and record particulars for repair and
exchange.
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2) Assembly
Assembly is performed in a reverse process of disassembly, and care about the
particulars in disassemble.
① Before the assembling, wash all parts of winch.
② Be careful to remain a small-sized parts like a bolt and nut.
③ Tighten all bolt strongly with same force.
④ If possible, fill the gear case with new oil, otherwise fill it with used oil after
filtering out impurities.
⑤ After re-assembly is completed, please check the followings.
1. Measure overall insulation resistance.
2. Check oiling of each part and grease lubrcation.
3. Escalation & traversing operation under unloaded status.
4. Escalation & traversing operation under rate load.
(4) Motor Inspection

Be sure to check conditions on bearing, air gap between rotor and stator, end
ring, and coil, etc.
(5) Inspection of Limit Switch
Be sure to inspect abrasion at contact point, conductive part, and screw
unlocking etc., and check open & close status.
(6) Inspection of Magnet Switch

Be sure to inspect it in accordance with monthly inspection items.
(7) Inspection of Electric Traversing Drive
Be sure to check the out-diameter abrasion of trolley wheel, bearing, and internal
gear abrasion, etc.
(8) Other hook-block, hook, wire rope, and current collector shall be inspected in
accordance with 'Monthly Inspection'. Be sure to measure the insulation resistance of
each electric part. Standard value = Rated Voltage (KV) + 1Mℓ or above (at 40℃)
Caution
Only qualified and safety-trained personnel wearing safety gears can perform a
mechanical and electric check and repair, etc.
Danger
When performing a check and a repair work, be sure to establish a safety area and
install a safety chain or strip and warning light around the work place. Fatal personal
and physical damages may occur in the event of unexpected actions such as
dropping of an dbject or a mistake by others.
Warning
Do not modify to use any parts arbitrarily. Such arbitrary modification to use may
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cause a serious damage or a physical loss due to an abnormal operation.

Warning
Make sure to cut the power source in order to check and repair the oist.
Unexpected operation and electric shock may cause a bodily injury.
Caution
Replace the lubricant as instructed by the user manual. Be sure to replace the
lubricant as instructed by the user manual after stopping the reducer completely.
Caution
Apply grease periodically as required. When applying grease, prevent any
contarminant from being added to the grease.
Caution
Long-term use of the product may require a replcement of electrical devices (e.g.,
relay, magnet, switch, timer) on a control panel, and electrical safe devices (e.g.,
load limiter, limit switch). Therefore a regular inspection is essential.
Caution
When the life of an electrical device specified by a manufacturer is over, replace it.
If an operation is abnormal due to an expiry of lifetime, stop the supply of power
immediately by pressing an emergency switch button.
Caution
After completing an inspection, do not resume an operation until you restore all safety
covers(motor terminal cover, control panel cover, wheel cover, etc.) to their original positions.
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5. Troubleshooting and Relevant Measure for Crane
Trouble Type Cause Action No. Actions
Single-phase
(1) (1) Measure the voltage of 3 master power cables in
operation
the order of R-S, R-T and S-T and find the wire
When push where no voltage is detected. The case is rare
Low voltage (2),(3) where the internal wiring of a motor is damaged.
button is
pressed and So, check the looseness of screws of each terminal
Bad contact of and status of the cable leading to power source.
crane does not (3)
pantograph Also check if a fuse is melted or shortened.
move.
(2) Check if the rated voltage is supplied via the
Magnet brake not (22),(23) switch. If not, the low voltage results from the
working ,(24) resistance of cabling between switch and crane
body.
When push (3) In a place where much dust or powered coal
button is exists, the dust accumulated on a collector wire is
pressed and Excessive brake hardened by rain or gas, and it becomes an
(4),(22) electricity resistance material that lowers the voltage
crane does not gap
work supplied to the crane. In this case, clean the
instantaneously collector wire with sand paper or file.
(4) Adjust the gap of a magnet brake.
Single-phase (5) It occurs when a motor is overheated due to high
(1) temperature at a crane installation location. Change
operation
the installation place or set up a cooling fin.
(6) Heat is generated due to over-running of a motor
Low voltage (2)
because a brake cannot operate owing to failure of
silicon rectifier. Replace the silicon rectifier with a
High temperature new one.
at installation (5) (7) Motor was used excessively by overload operation.
location Keep the rated load.
(8) When a push button is pressed, initial current of
Excessive heat Silicon rectifier about 400-600% of rated current is applied
in motor (6),(24)
broken instantaneously. As the amount of heat generation is
in proportion to 2 times of a current, whenever you
Overload (7) press the push button, heat of about 16 ? 36 times
of the rated value is generated. So, it is natural that
Excessive inching frequent use and continuous inching generate the
(8)
operation heat in a motor.
(9) 105℃ heat at the surface of a motor is OK.
Excessive (10) Lining may be stained with oil during assembly
frequency of (9) and disassemble work. Wipe out the oil with
operation thinner, etc.
(11) The movement of a moving core became
Oil on brake lining defective because a guide pin is stained with dust
(10)
surface or dirt from lining abrasion. Open the cover about
When, upon once a month, and clean the dust and dirt, and
stopping a Moving core not apply some oil to the guide pin.
hook block, working due to (12) If leakage comes out excessively in a stop status,
(11) it means that you did not block a brake circuit. In
excessive dust or dirt on
leakage comes guide pin case of application cabling, check if the cables
out. are connected correctly, and adjust the tightening
of the terminal screw of a limit switch.
Brake circuit is
(12)
not blocked.
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Trouble Type Cause Action No. Actions
No oil in a gear
(13) (13) If there is no oil, big noise is generated.
Too much case
(14) If a gear is worn out, big noise is generated.
noise in the
Disassemble the unit and check the gear. If it is
crane Gear and shaft
(14) worn out, replace it with a new one.
are worn out.
(15) Install the ground correctly.
When uou feel (16) Pantograph collector comes off when a feeder
electricity upon Ground not cable is installed in a wrong way. Check the
(15)
grabbing a installed status of the pantograph collector.
crane hook (17) The adjustment range of our pantograph collector
is very wide. So, check the position status
Bad installation of
(16) carefully.
trolley cable
(18) Do not perform traversing operation, and consider
Pantograph
changing installation method as well.
collector comes
Defective (19) Bad usage status has caused a disorderly
off too often.
adjustment of (17) winding. Check the installation location of the crane
location as well.
(20) Apply proper amount of grease to a wire rope.
(21) When the hook block of a double-rail crane moves
Wire rope up and down, its center is moved as well. When it
contacts a drum is raised uppermost, if the center of a hook block
case or a stop is not even with that of a handy lifter, the wire
(18) rope is traversed, generating a noise due to the
lever due to
excessive contact of wires.
traversing. (22) It occurs when the gap between a moving core
and fixed core is too wide to contact each other.
Adjust the gap.
Wire wire rope Disorderly winding (18),(19) (23) Check if the screws of limit switch, magnet brake,
wears out too magnet switch, etc. are loose, and if a cable is
often. disconnected.
(Ecessive Insufficient oiling (13),(20) (24) Current cannot be applied to a brake due to
abrasion) broken silicon rectifier in the following cases
a) Abnormal voltage is supplied due to defective
When the crane is wiring of a brake circuit.
used for handy b) Incorrect wiring in case of an application
lifter, abnormal cabling.
sound is heard (21)
from wire rope
when the crane is
raised uppermost
Too wide gap (22)
Brake circuit
shorted or (23)
Magnet brake disconnected
not working
Silicon rectifier
(24)
broken
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6. Standard for Checking and Repair

Before starting every day's operation, make sure that all cranes are operated as
unloaded status and the followings are checked.
(1) whether moving up & down and traversing as specified in the indication of push
botton are smoothly perfomed
(2) whether limit switch is positively operated
(3) whether braking is good
(4) whether there is any different noise than the usual
(5) whether the sheave of a hook block is smoothly rotated, a hook is easily
rotated a wheel pin for unlocking prevention of hook nut is normal, or a wire rope is
detached from the sheave
(6) whether a wire rope is securely wound around a drum
(7) whether loads are correctly fastened
(8) whether a load limit is well operated without any troulbe
(9) whether a hook safety ring is normal

Because it is desirable to designate the inspection time of each part in accordance
with safety importance, maintenance difficulties, use frequency and expendables, the
items of crane monthly inspection are classified in the following table. It is desirable
to designate duration for crane inspection in consideration of its operation rate. The
specified table classifies operation rate as large, medium, and small from crane use
rate & starting frequency. Inspection duration, which is shown in monthly inspection
items & record (see Appendix 2), is classified at the medium of below operation rate.
Be sure to inspect crane more frequently with respect to an inspection duration for a
crane of large operation rate.
Classification Standard Operation
Important inspection items in

A One inspection per a month
terms of safety
Important inspection items in

B One inspection per three months
terms of machine repair
C Little abrasion items One inspection per half a year
90/136
- 19 -
Operation Rate Large Medium(Standard) Smal
Use Rate(%) Above 25 25~10 Below 10
Use Frequency/Day Above 1,500 1500~400 Below 400
Note)
1. Use Rate(%) = Sum of time to be applied current to motor for one hour operation (unit ːmin)×100
60 min
2. Starting frequency sets one inching between up and down as 5 times and one
day's operation is for 8 hours.
3. Surrounding temperature shall be below 40℃
4. With regard to an Environment, normal factory and warehouse, etc. are standard,
and some dangerous places with high heat, large humidity, dust or acid, alkali must
be separately considered.

crane yearly inspection is performed every year without regard to a breakdown or
defect and helps to find some faults, which are not found in daily inspection and
monthly inspection. Make sure that repairing expert or service expert shall perform
yearly inspection in accordance with yearly inspection items & record (see Appendix
3).
Warning
Only qualified and safety-trained personnel wearing safety gears can perform a
mechanical and electric check and repair, etc.
Danger
When performing a check and a repair work, be sure to establish a safety area and
install a safety chain or strip and warming light around the work place. Fatal personal
and physical damages may occur in the event of unexpected actions such as
dropping of an object or a mistake by others.
Warning
Do not modify to use any parts arbitrarily. Such arbitrary modification to use may
cause a serious damage or a physical loss due to an abnormal operation.
Warning
Be sure to turn off power before conducting a repair or opening terminal cover.
There may be a danger such as electric shock.
Caution
Replace the lubricant as instructed by the user manual. Be sure to replace the
lubricant as instructed by the user manual after stopping the reducer completely.
91/136
- 20 -
Caution
Apply grease periodically as required. When applying grease, pervent any
contaminant from being added to the grease.
Warning
In order to inspect a crane speed reducer, be sure to turn off a motor power.
Undesired operation may cause a bodily damage.
NOTE
92/136
93/136
94/136
95/136
DISTINTA BASE COMPONENTI FOGLIO
Estudio de factibilidad Component part list - Liste des pieces 00/1100 Sheet - Page 1/2
Stueckliste - Lista de despieces Seite - Hoja
Plano dimensional
Lista de repuestos
Compilata NERONI il 10.01.94 Controllata INCERTI il 10.01.94
Descrizione: SUPPORTO
Seccionado
SHAFT SUBASSEMBLY SUPPORT

ABTRIEBSGEHAEUSE SOPORTE
Tipo: EM 1065 MN
1
2
3
4
Versione: STANDARD
Realisierbakeitsstudie
Dimensionszeichnung
CODICE DENOMINAZIONE NOTE

Schnittzeichnung
P. Code - Codigo Description Q. Note - Plan

Beschreibung - Denominacion Bemerk - Notas
E.T.Mappe
001 35206614200 SUPPORTO 1

SUPPORT - SUPPORT
ABTRIEBSGEHAEUSE - SOPORTE
002 35417424000 COPERCHIO 1
COVER - COUVERCLE
1
2
3
4
DECKEL - TAPA
003 31113730600 ALBERO MASCHIO SCANALATO 1
SHAFT - ARBRE
WELLE - EJE
Plan encombrement
Etude de faisabilite
007 43107000000 SEEGER "E" ø70 UNI 7435 1

List de rechanges
CIRCLIP - CIRCLIP
Plan en coupe
SEEGERRING - ANILLO FIJACION

008 41234100000 O-RING 2-251 1
O-RING - JOINT TORIQUE
O-RING - JUNTA TORICA
011 47101600000 GHIERA KM15 M75x2x6H DIN 981 1
LOCK NUT - FRETTE
NUTMUTTER - TUERCA
1
2
3
4
012 37211346400 ROSETTA DI SICUREZZA 1

Cross sectional drawing
WASHER - RONDELLE
SCHEIBE - ARANDELA
Dimensional drawing
015 42214100000 CUSCINETTO 33215 DIN 720 1

BEARING - ROULEMENT
Feasability plan
LAGER - COJINETE
016 42213900000 CUSCINETTO 30215 DIN 720 1
BEARING - ROULEMENT
Parts list
LAGER - COJINETE
018 41133500000 ANELLO T.R.AS85x110x12 DIN3760 1 NB
OIL SEAL - JOINT D’ETANCH.
DICHTRING - RETEN
1
2
3
4
020 43843040100 SPINA ELASTICA ø12x60 4 RETTIFICATA

SPRING PIN - GOUPILLE ELAST.
SPANNSTIFT - PASADOR ELASTICO
Mod. Descrizione modifica Data Es/Ct Sostituisce la
/ P.N.
1 Complessivo 2 Dimensionale 3 Studio fattibilità 4 Esploso
G.010.00/035.2 00/1100
96/136
Component part list - Liste des pieces 00/1100 Sheet - Page 2/2

024 46107800000 VITE M8x25 8G UNI 5739 6

SCREW - VIS
SCHRAUBE - TORNILLO
025 45106400000 TAPPO SFIATO G3/8" 1 Ottone
PLUG - BOUCHON
STOPFEN - TAPON
026 45110400000 TAPPO "OIL LEVEL" G3/8" 1 Acciaio
PLUG - BOUCHON
STOPFEN - TAPON
027 46701000101 ROSETTA 8,4x14x1,6 R80 UNI6592 6
WASHER - RONDELLE
SCHEIBE - ARANDELA
028 45120400000 TAPPO "MAGNETIC" G3/8" 1 Ottone
PLUG - BOUCHON
STOPFEN - TAPON
029 45102200000 TAPPO G1/8"DIN 908 1
PLUG - BOUCHON
STOPFEN - TAPON
031 41700100100 RONDELLA DIN7603-A 10x15 - Al 1
WASHER - RONDELLE
UNTERLEGSSCHEIBE - ARANDELA
WASHER - RONDELLE
97/136
98/136
Estudio de factibilidad Component part list - Liste des pieces 61104600690 Sheet - Page 1/1
Plano dimensional
Lista de repuestos
Descrizione: FLANGIATURA
Seccionado
ADAPTOR ADAPTATION
ANBAUTEILE BRIDA
Tipo: UNIVERSALE
UNIVERSAL UNIVERSAL
1
2
3
4
Versione: IEC 100-112 STANDARD

Dimensionszeichnung

Schnittzeichnung

E.T.Mappe
001 30104624000 FLANGIA 1 (X=28)

FLANGE - BRIDE
FLANSCH - BRIDA
003 30506940100 GIUNTO 1
COUPLING - MANCHON
1
2
3
4
KUPPLUNG - ACOPLAMIENTO
005 36602249000 GUARNIZIONE 1
GASKET - JOINT
FLACHDICHTUNG - JUNTA DE PAPEL
Plan encombrement
008 43105500000 SEEGER "E" ø50 UNI 7435 1

List de rechanges
CIRCLIP - CIRCLIP
Plan en coupe

009 43202700000 SEEGER "I" ø28 UNI 7437 1
CIRCLIP - CIRCLIP
011 41127900000 ANELLO T.R. BA 60x85x10 1
OIL SEAL - JOINT D’ETANCH.
DICHTRING - RETEN
1
2
3
4
013 46213600000 VITE M12x25 8G UNI 5931 6

SCREW - VIS
SCHRAUBE - TORNILLO
Dimensional drawing
Feasability plan
Parts list
1
2
3
4

/
61104600690
99/136
100/136
Plano dimensional
Lista de repuestos
Descrizione: FLANGIATURA DI ATTACCO
Seccionado
CONNECTING FLANGE ADAPTATION

KUPPLUNGSFLANSCH BRIDA EN ENTRADA
Tipo: ED 2010
1
2
3
4
Versione: UNIVERSALE
UNIVERSAL UNIVERSAL
UNIVERSAL UNIVERSAL
Dimensionszeichnung

Schnittzeichnung

E.T.Mappe
002 34603124000 FLANGIA IN INGRESSO 1

INPUT FLANGE - BRIDE EN ENTREE
EINGANGSFLANSCH - BRIDA EN ENTRADA
003 46209400600 VITE M8x85 12K UNI 5931 6
SCREW - VIS
1
2
3
4
SCHRAUBE - TORNILLO
005 46701000101 ROSETTA 8,4x14x1,6 R80 UNI6592 6
WASHER - RONDELLE
SCHEIBE - ARANDELA
Plan encombrement
007 41700200100 RONDELLA D.13,3/19x1,5 2 Alluminio

List de rechanges
WASHER - RONDELLE
Plan en coupe
009 45104300000 TAPPO ESAG. G1/4" 2 Acciaio
PLUG - BOUCHON
STOPFEN - TAPON
1
2
3
4
Dimensional drawing
Feasability plan
Parts list
1
2
3
4

/ P.N.
31/3100
101/136
102/136
DISTINTA BASE COMPONENTI DB20/3005/C
07-Mar-2001
Descrizione: INTERMEDIATE FLANGE

Sigla Comm.: EM 1020/020/../010
Discriminante:
Pos Codice Denominazione Q.tà Note
001 34207324000 FLANGE 1
003 46111000000 SCREW 8

M10x60 UNI5737-65-8.8
009 46701100101 WASHER 8
10,5x18x2 UNI6592-69-R80
011 41700200100 SHAFT COVER 3
D.13,3/19x1,5 Alluminio
013 45104300000 PLUG 3 Acciaio
Brevini G1/4"
Note:
DB20/3005/C 1/1
DB20/3005/C 1/1
103/136
104/136
Plano dimensional
Lista de repuestos
Descrizione: RIDUZIONE EPICICLOIDALE
Seccionado
PLANETARY STAGE REDUCTION PLANETAIRE

PLANETENGETRIEBESTUFE REDUCCION EPICICLOIDAL
Tipo: ED 2010
1
2
3
4
Versione: UNIVERSALE
UNIVERSAL UNIVERSAL
UNIVERSAL UNIVERSAL
Dimensionszeichnung

Schnittzeichnung

E.T.Mappe
P01 211B4220000 PREMONTATO RIDUZIONE i=3,37 2

SUBASSEMBLED - PREMONTÉ
VORMONTIERT - PRE-MONTADO
1
2
3
4
P03 211B4270000 PREMONTATO RIDUZIONE i=6 2
Plan encombrement

List de rechanges
Plan en coupe
001 32000438300 CORONA DENTATURA INTERNA 1
RING-GEAR - COURONNE
HOHLRAD - CORONA
1
2
3
4
003 32722140300 GIUNTO CENTRALE i=3,37 1

SUN PINION - PIGNON CENTRAL

ZENTRALRITZEL - PI~
NON SOLAR
Dimensional drawing

Feasability plan
ZENTRALRITZEL - PI~
NON SOLAR
005 32722340300 GIUNTO CENTRALE i=6 1
Parts list
ZENTRALRITZEL - PI~
NON SOLAR
ZENTRALRITZEL - PI~
NON SOLAR
1
2
3
4

ZENTRALRITZEL - PI~
NON SOLAR
1 P01..P05 ERANO P10..P14; 25.02.94 AN/IR P.N.
TOLTO P20..P24
G.012G.00/031.2 SI011B50001A01 02/4012
105/136

030 42119300000 CUSCINETTO 16012 DIN 625 1

BEARING - ROULEMENT
LAGER - COJINETE
035 43106300000 SEEGER "E" ø60 UNI 7435 1
CIRCLIP - CIRCLIP
037 36610340000 O-RING SPECIALE 2
GASKET - JOINT
FLACHDICHTUNG - JUNTA DE PAPEL
042 32602941900 PIGNONE i=3,37 1
PINION - PIGNON
RITZEL - PI~
NON
043 32603041900 PIGNONE i=4,39 1
PINION - PIGNON
RITZEL - PI~
NON
044 32603141900 PIGNONE i=6 1
PINION - PIGNON
RITZEL - PI~
NON
045 32603241900 PIGNONE i=6,93 1
PINION - PIGNON
RITZEL - PI~
NON
046 32603431900 PIGNONE i=10,5 1
PINION - PIGNON
RITZEL - PI~
NON
106/136
107/136
Plano dimensional
Lista de repuestos
Seccionado

PLANETENGETRIEBESTUFE REDUCCION EPICYCLOIDAL
Tipo: EM 1065
1
2
3
4
Versione: G.C. Z=27 (B 58X53 DIN 5480)

SUN PINION PIGNON CENTRAL
ZENTRALRITZEL PI~
NON SOLAR
Dimensionszeichnung

Schnittzeichnung

E.T.Mappe
P01 211D622000N PREMONTATO RIDUZIONE i=3,5 1

1
2
3
4
Plan encombrement
P04 211D625000N PREMONTATO RIDUZIONE i=5 1

List de rechanges
Plan en coupe
P05 211D627000N PREMONTATO RIDUZIONE i=6 1
HOHLRAD - CORONA
1
2
3
4


ZENTRALRITZEL - PI~
NON SOLAR
Dimensional drawing

Feasability plan
ZENTRALRITZEL - PI~
NON SOLAR
Parts list
ZENTRALRITZEL - PI~
NON SOLAR
ZENTRALRITZEL - PI~
NON SOLAR
1
2
3
4

ZENTRALRITZEL - PI~
NON SOLAR
1 VAR. P01..P05 29.09.98 PC/AV P.N.
(ERANO .....0000) (PM 56/8)
SC111D60008A002 SF111D60008A0 00/4108
108/136

032 43106100000 SEEGER "E" ø 57 UNI 7435 1

CIRCLIP - CIRCLIP
035 41221700000 O-RING 2-175 2
109/136
110/136
Plano dimensional
Lista de repuestos
Seccionado

PLANETENGETRIEBESTUFE REDUCCION EPICYCLOIDAL
Tipo: EM 1020
1
2
3
4
Versione: G.C. Z=20 (B 40X36 DIN 5482)

SUN PINION PIGNON CENTRAL
ZENTRALRITZEL PI~
NON SOLAR
Dimensionszeichnung

Schnittzeichnung

E.T.Mappe

1
2
3
4
Plan encombrement

List de rechanges
Plan en coupe
P05 211B8270000 PREMONTATO RIDUZIONE i=6 1
1
2
3
4

HOHLRAD - CORONA
Dimensional drawing

Feasability plan
ZENTRALRITZEL - PI~
NON SOLAR
Parts list
ZENTRALRITZEL - PI~
NON SOLAR
ZENTRALRITZEL - PI~
NON SOLAR
1
2
3
4

ZENTRALRITZEL - PI~
NON SOLAR
/ P.N.
G.014S.00/024.1 00/4045
111/136


ZENTRALRITZEL - PI~
NON SOLAR
ZENTRALRITZEL - PI~
NON SOLAR
037 41220900000 O-RING 2-170 2
047 43104000000 SEEGER "E" ø36 UNI 7435 1 I=7,25
CIRCLIP - CIRCLIP
112/136
113/136
Plano dimensional
Lista de repuestos
Descrizione: FLANGIATURA INTERMEDIA
Seccionado
INTERMEDIATE FLANGE BRIDE INTERMEDIAIRE

ZWISCHENFLANSCH BRIDA INTERMEDIA
Tipo: ED 2065
1
2
3
4
Versione: STANDARD
Dimensionszeichnung

Schnittzeichnung

E.T.Mappe
001 34203624000 FLANGIA INTERMEDIA 1

INTERMED.FLANGE - BRIDE INTERMED.
ZWISCHENFLANSCH - BRIDA INTERMEDIA
003 46214800000 VITE M12x90 8G UNI 5931 10
SCREW - VIS
1
2
3
4
SCHRAUBE - TORNILLO
005 46600900100 DADO M12 8G UNI 5588 10
NUT - ECROU
MUTTER - TUERCA
Plan encombrement
007 46701200101 ROSETTA 13x20x2,5 R80 UNI 6592 10

List de rechanges
WASHER - RONDELLE
Plan en coupe
SCHEIBE - ARANDELA
WASHER - RONDELLE
013 45104400000 TAPPO ESAG. G.3/8 3 Acciaio
PLUG - BOUCHON
STOPFEN - TAPON
1
2
3
4
Dimensional drawing
Feasability plan
Parts list
1
2
3
4

/ P.N.
00/3007
114/136
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116/136
117/136
118/136
119/136
120/136
121/136
122/136
123/136
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INSTRUCTION MANUAL

& FINAL DRAWING FOR

SHIP OWNER : JAKO SHIPPING

HULL No. : H4100.

TITLE : ELEC. PROVISION CRANE

SHIP KIND 50,300 DWT CRUDE/PRODUCT OIL/CHEMICAL TANKER

If Cranes and operated erroneously, dangers like unexpected falling

Before the installation of machinery, and before operation of the

Please operate machines, after obtaining thorough knowledge about

In this brochure, items are separated into two categories,

In case the machine is operated erroneously,

In case the machine is operated erroneously,

Mark with "positive" printing

Circle with a Bar : This is announce "prohibition" The

Mark with "negative" printing

"Please keep this brochure at a place where the persons related

※ Please be sure to effect the inspections stipulated or

※ Please be sure to effect electric grounding.

※ Please be sure that the please have enough physical

※ Please do not use at other electricity than stipulated.

※ Before starting operation, please make sure that the

※ Please be sure to set clamping devices for travelling

5. Inspection and Modification

※ Please check periodically the fixing ends of the

Reference : ☐ Head Office

Please read well the related "Instruction manuals" and operate

1. General precautions for operation

1-2. Do not remove safety device --------------------------- 2/11

1-3. Precautions at the time of operations ----------------- 3/11

2-1. Preparation before operation ------------------------- 4/11

2-2. Description of operation------------------------------ 4/11

2-3. After operation--------------------------------------- 5/11

3. Inspection and maintenance

3-1. General precautions for maintenance and inspections --- 6/11

3-2. Parts of steel structure ------------------------------ 7/11

3-3. Lubrication ------------------------------------------- 8/11

3-4. Gear -------------------------------------------------- 8/11

3-5. Wire rope --------------------------------------------- 9/11

3-6. Sheave ------------------------------------------------ 11/11

3-7. Hook -------------------------------------------------- 11/11

3-8. Painting ---------------------------------------------- 11/11

1-1. Do not lift load exceeding the specified value.

Never apply the load exceeding the capacity prescribed in the

The crane has been designed to be most economical when working

efficiently under the specified load. The more the crane is

used overloaded, the shotter the life of the crane.

Be sure to avoid such abuse.

Observe the limit load at the maximum working radius

prescribed in the specification by the hoist of the jib,

as in the case of this crane. Overturning, upsetting or

breakage due to overload and over-radius are often seen in the

jib type cranes.

Lifting loads exceeding the prescribed value may result

in damage to the machine, breakage of rope, down fall of

the load, or injury or death.

Pulling obliquely will apply unnatural force to various

parts, shorten the life of the machine and lead to a

serious accident. Pay sufficient care to safety.

1-2. Do not release safety devices.