ASSEMBLY INSTRUCTION FOR

CRANE
DOCUMENTS

English 02011470850010-0.ORD 27.01.2020

- - CC004518 -

Original instructions 020114708500102001-0 PS05063 27-01-2020

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

Table of contents

1 CRANE COMPONENTS .................................................................................................................... 3

1.1 Double girder crane with a service platform (Wire rope hoist) ......................................................................3
2 FESTOON ASSEMBLY...................................................................................................................... 4
2.1 Power supply for double girder hoist ............................................................................................................4
2.1.1 Trolley for pendant controller (Double girder hoist) ..................................................................................5
3 TRAVELING MACHINERY ASSEMBLY............................................................................................. 6
3.1 Top running crane, fixing of the machinery size 3 ........................................................................................6
4 CRANE TOWING ARM ASSEMBLY .................................................................................................. 7
4.1 Crane Towing Arm (EBN11/14/16/ECN11/14/16/20/25/32 end carriages) ..................................................7
5 HOIST POWER TOWING ARM ASSEMBLY ..................................................................................... 9
5.1 Double girder trolley (Wire rope hoist) ..........................................................................................................9
6 TWO-STEP TRAVELING LIMIT SWITCH ASSEMBLY .................................................................... 11
6.1 Double girder trolley (Wire rope hoist) ........................................................................................................11
6.2 Crane limit switch assembly, top running end carriages ............................................................................12
7 BRIDGE PANEL ASSEMBLY........................................................................................................... 13
7.1 Double girder crane with a service platform (Wire rope hoist) ....................................................................13
7.1.1 Movable bridge panel for double girder crane ........................................................................................14
8 JOINT PLATE ASSEMBLY .............................................................................................................. 16
8.1 Joint plate assembly, top running end carriages ........................................................................................16
8.1.1 Top joints (A3, A4, A6, B4, B6, L3-L6,H4-H9,K4-K9) .............................................................................16
9 CABLE PLUGS AND PATHS ........................................................................................................... 17
9.1 Double girder crane plug layout and cable paths (Wire rope hoist) ...........................................................17
9.2 Plug diagram, (Wire rope hoist) ..................................................................................................................18
10 CRANE CABLE WAYS ................................................................................................................. 19
10.1 Assembly examples ....................................................................................................................................19
10.2 Common assembly methods ......................................................................................................................20
11 STICKER PLACING ...................................................................................................................... 22
11.1 Crane side without service platform or energy chain ..................................................................................22
11.2 Crane side with service platform .................................................................................................................23
11.3 Crane side with energy chain .....................................................................................................................24
CRANE FAT INSPECTION REPORT (SP11-12) ................................................................................... 26
FAT ANNEX 1 - SERIAL NUMBERS ...................................................................................................... 27
FAT ANNEX 2 - NON-CONFORMITY (NC) LIST ................................................................................... 28
FAT ANNEX 3 - TROLLEY FOR SP11-12 .............................................................................................. 29
CRANE SAT INSPECTION REPORT (SP11-12) ................................................................................... 31
CRANE SAT INSPECTION REPORT (SP11-12) ................................................................................... 32
CRANE SAT INSPECTION REPORT (SP11-12) ................................................................................... 33
SAT ANNEX 1 - NON-CONFORMITY (NC) LIST ................................................................................... 34
SAT ANNEX 2 - TROLLEY INSPECTION SP11-12 ............................................................................... 35
SAT ANNEX 3 - ASSESSMENT OF HEALTH AND SAFETY RISKS ..................................................... 36

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

1 CRANE COMPONENTS

1.1 Double girder crane with a service platform (Wire rope hoist)

Pos. Name Pos. Name

1 Festoon assembly 9 Load display (option)
2 Radio (option) 10 Flashing light (option)
3 Horn (option) 11 Crane power towing arm
4 Hoist power towing arm 12 Bridge traveling machinery
5 Hoist 13 Light
6 Pendant (option) 14 Service platform (option)
7 Main girders 15 Bridge panel
8 End carriage

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

2 FESTOON ASSEMBLY

2.1 Power supply for double girder hoist

D1= 200 D2= 2000 D3= max. 2000 D4= 800 D5= Span

Pos. Name Specification Further information

1 Bracket for support arm 020286 Included in the crane steel structure.
2 Support arm 020276-0xxx The length of support arm is order-specific. Lengths 420, 650, and 840
are used. Cut the support arms to the required length if needed.
3 Track coupler 023210 or 024150 Selected according to rail size.
4 Track support 23226 or 024122 Selected according to rail size.
5 C-rail 023201-4 or 024100-4 The innermost C-rail W3 is needed only with the moving pendant
controller. Selection of C-rails for hoists is order-specific.
Support arms in the cable trolley gathering end of the festoon: The spacing between the support arms shall be 800 mm throughout the length
of gathered cable trolleys. In addition, two extra support arms with the same 800 mm spacing are needed.

Double girder crane, dimensions for placing the festoon C-rails

Hoists on bridge Shielded cables L1 min. L2 min. L3 min. L4 min. Length of Part 2
1 No 170 190 - 60 420
1 Yes 200 250 - 60 650
2 No 170 190 200 60 650
2 Yes 200 250 300 60 840

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ASSEMBLY INSTRUCTION FOR CRANE

2.1.1 Trolley for pendant controller (Double girder hoist)

To notice when assembling a festoon for a double girder hoist:
 Assemble the trolley for pendant controller in the inner C-rail from the crane.
 Tighten the strain relief wires on both sides of the plug so that the pendant cable is either on loop or on
pleat. When looped, there will be better possibilities on adjusting the cable length.
 Tighten the wire clamp.

Pendant

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ASSEMBLY INSTRUCTION FOR CRANE

3 TRAVELING MACHINERY ASSEMBLY

3.1 Top running crane, fixing of the machinery size 3

Note: Remove the protective sticker from bearing flange surface.

Note: Clean dirt, rust, paint and grease from the mating surfaces before fitting by using a scraper or
grinding paper and solvent.

Pos. Name Specification Amount

1 End carriage 2
2 Washer DIN125-A8-A3F 4+4
3 Screw DIN912-M8x85-8.8-A3F 4+4
4 Traveling machinery 2

 Grease the shaft lightly before assembly

 You can use a plastic hammer to slide drive in. Do not use any metal or lead hammer
 Tightening torques M8 - 25 Nm
 Remove the protection pin from the breather plug.

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ASSEMBLY INSTRUCTION FOR CRANE

4 CRANE TOWING ARM ASSEMBLY

4.1 Crane Towing Arm (EBN11/14/16/ECN11/14/16/20/25/32 end carriages)

Pos. Name Specification Fixing variation Amount

1 Towing arm CQ-L514W40H200 I & II 1
2 Washer DIN125-A12-A3F I & II 2
3 Screw DIN931-M12X45-8.8-A3F I 2
4 Fixing plate CQP-L150W140H12 II 1
5 Washer DIN125-A10-A3F II 4
6 Screw DIN933-M10X25-8.8.-A3F II 4
7 Screw DIN933-M12X20-8.8.-A3F II 2
8 Towing arm CQ-L195W120H135 A 1
9 Towing arm CQP-L440W41H80 B 1

 I is the standard assembly, II is an optional fixing with a plate (4).

 A is the standard assembly (with part 8), B is for special cases only (with part 9).
 The vertical portion of the towing arm is delivered as a complete assembly separate from the horizontal
tube.
 If necessary, cut off excess length of square tubes.
 The end carriage model number (11-32) refers to the size of the driving wheel (for example 11 stands for
110 mm).

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

5 HOIST POWER TOWING ARM ASSEMBLY

5.1 Double girder trolley (Wire rope hoist)

The fixed cable trolley and fixing part for shielded cables (parts marked with X) are delivered ready fixed on the
cable assembly.
Pos. Name Specification Amount
1 Fastener CQT-L225W30T6 1
2 Plate CQ-L130H40T4 1
3 Chain CQ-L1830 1
4 Towing arm CQT-Lxxxx 1
5 Tube (square tube) CQT-L550W50H50T2 1
6 Fixing plate CQP-L80W80H6 3
7 Fixing plate CQ-L94W30H85-FEZN 2
10 Washer DIN125A-8.4-140HV-A2F 8
11 Screw DIN931-M8X140-8.8-A3F 4
13 Nut DIN985-M8-8-A3F 4
14 Screw DIN933-M10X30-8.8-A3F 4
15 Washer DIN127-A10-A3F 4
16 Washer DIN125A-10.5-140HV-A3F 4

If necessary, cut off excess length of square tubes.

The part 2 is ready fixed under the last moving cable trolley on the cable assembly.
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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

6 TWO-STEP TRAVELING LIMIT SWITCH ASSEMBLY

6.1 Double girder trolley (Wire rope hoist)

Pos. Name Specification Further information

1 Fixing plate CQP-L80W80H6
2 Fastener CQT-L215W80H90T4
3 Trigger QA-L340W120H30T3 Cut to suitable length if necessary.
4 Track support bracket 024155 or 023222-1 Selected according to C-rail size.
5 Washer DIN125A-8.4-140HV-A2F
6 Screw DIN931-M8X80-8.8-A3F
7 Nut DIN985-M8-8-A3F
8 Screw DIN912-M5X40-8.8-A3F
9 Nut DIN985-M5-8-A3F
10 Washer DIN125A-5.3-140HV-A2F

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

6.2 Crane limit switch assembly, top running end carriages

Limit switch part list

Pos. Name Specification Amount
1 Limit switch XC... 1
Fixing plate QA-L180W105H95 1
Fixing plate CQP-L80W80H6 4
Trigger fixing part
Pos. Name Specification Amount
2 Trigger CQK-L463W80H145T5 or CQK-W463H140T5 4
Beam clip KC-020180-08 4
Fixing set
Pos. Name Specification Amount
1+2 Limit switch assembly set L109 1

Assemble the crane limit switch to the towing arm of the crane. If necessary, it is possible to assemble the limit
switch also to the horizonal tube of the crane towing arm set.
The trigger is assembled to the runway beam.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

7 BRIDGE PANEL ASSEMBLY

7.1 Double girder crane with a service platform (Wire rope hoist)

Fixing support piece to the bridge panel

Fig. 1 Name Specification Amount per
cubicle
Fixing plate CQP-L81W50H58T8 4
Screw (use thread locking compound) DIN913-M8x25-45H 4
Washer DIN125-A12-A3F 4
Washer DIN125-A8-A3F 4
Nut DIN985-M8-8-A3F 4
Fixing bridge panel to the C-rail
Fig.2 Name Specification Amount per
cubicle
C-rail KC-020276-2200 (or 4000) 2
Square nut CQ-W25T6L30 4
Screw DIN933-M8x25-8.8-A3F 4
Washer DIN125-A8-A3F 4
Fixing C-rail to the vertical support

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ASSEMBLY INSTRUCTION FOR CRANE

Fig.3 Name Specification Amount per

vertical
support
Square nut CQ-W25T6L30 2
Screw DIN933-M8X25-8.8-A3F 2
Washer DIN125-A8-A3F 2
Fixing cable tray
Fig.4 Name Specification Amount
Cable tray 2200X220X60 1
Fixing plate CQ-L94W30H85 3
Screw DIN933-M8x25-8.8-A3F 3
Washer DIN125-A8-A3F 3
Nut DIN985-M8-8-A3F 3

 The position of the cubicle support may vary from the one shown in the figure.
 Fig. 1: The screw (DIN913-M8x25-45H) must be assembled first to the threaded sleeve on the back wall of the
cubicle. Tightening torque of the screw is 10Nm. Use a thread locking compound to secure the fixing of the
screw. Tightening torque of the M8-nut is 25Nm.
 Fig. 2: Tightening torque of the M8-screw is 25Nm.

Check hoist electrical documentation for the number and the order of the electric panels.

7.1.1 Movable bridge panel for double girder crane

For more compact packaging for transportation, you can slide the bridge panel to location A.
Note: Before transporting or moving the bridge panel, you must detach the fixings of cable tray. Cable tray is
located under the bridge panel.
This figure shows the panel fixing in operation location (slided outside), location B.

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ASSEMBLY INSTRUCTION FOR CRANE

A: Panel fixing in transport location (slided inside)

B: Panel fixing in operation location (slided outside)
C: End frames
D: Mid frames
E: Welded to handrail, fillet weld a3
F: Flat bar, for example FL 8x50-75

Pos. Name Specification Amount for one frame

1 Washer DIN125-17-A3F 4
2 Nut DIN934-M16-8-A3F 2
3 Screw DIN933-M16*40-8.8-A3F 2

Note: Parts C, D, 1, 2, and 3 are not included in the component package delivery.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

8 JOINT PLATE ASSEMBLY

8.1 Joint plate assembly, top running end carriages

8.1.1 Top joints (A3, A4, A6, B4, B6, L3-L6,H4-H9,K4-K9)

 Position the friction springs to the top holes of the end truck (figure 1).
 Make sure that the friction springs are positioned correctly. Approximately three-quarters of the top spiral
should be located outside of the bolt hole (figure 2).
 Position the joint plate (welded to the end of the main girder) on top of the end truck. Make sure that the friction
springs stay on their positions.
 Hit guiding pins (pos. 6) through the joint plate and the end carriage top flange. Make sure that the friction
springs stay on their positions (figure 3).
 Fix bolts, washers and nuts (fig 4). Use hand holes on the side of the truck to fix the bolts (fig 5, pos. B).
 Measure the bolt size and tighten the bolts to the correct torque according to the table “Recommended
tightening torques”.
 Tightening of the bolts must be checked after crane tests.

In joint connection areas, marked with “A” in the picture, only workshop primer paint
NOTICE
(thickness 20 microns) is allowed.

Recommended tightening torques

Screw size Tightening torque
M16-10.9 300 Nm
M20-10.9 590 Nm

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ASSEMBLY INSTRUCTION FOR CRANE

9 CABLE PLUGS AND PATHS

9.1 Double girder crane plug layout and cable paths (Wire rope hoist)

A/B Alternative cable paths

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ASSEMBLY INSTRUCTION FOR CRANE

9.2 Plug diagram, (Wire rope hoist)

E0

01
X012.

X012
E1
X251 X211 X221 X521 X31A1 X32A1
X251. X211. X221. X521. X31A1. X32A1.

25 21 22

X212. X222.
52 31A 32A

X212 X222
H-S1 H-M1 H-M2 X511. X31A2. X32A2.

X511 X31A2 X32A2

E3 E2A

51 41E 42E 45E

X41E2. X42E2.

X41E2 X42E2
E3 E-M1 E-M2 E-S2

vs-p-l-qaqc

Symbol Definition Symbol Definition

E0 Crane power supply E3 Push Button trolley and push button
E1 Bridge panel E2A Hoist panel
H-S1 Crane limit switch E-M1 Hoist traveling motor 1
H-M1 Crane traveling motor 1 E-M2 Hoist traveling motor 2
H-M2 Crane traveling motor 2 E-S2 Hoist limit switch

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

10 CRANE CABLE WAYS

10.1 Assembly examples

A. Primary cable channel mounting location

B. Additional cable way if needed
C. Alternative cable channel mounting location
120. Cable way width 120 mm
220. Cable way width 220 mm

A. Primary cable channel mounting location

C. Alternative cable channel mounting location
1. Similar cable way (width 75) for the other travelling unit also on the other end.
2. Use cover plates (not shown here) with cable ways along end carriages.
75. Cable way width 75 mm
120. Cable way width 120 mm
220. Cable way width 220 mm

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ASSEMBLY INSTRUCTION FOR CRANE

B. Service platform

In the case of service platform there is a possibility to assemble cables of lights, limit switches, travelling
machineries etc in a cable way that situates between main girder and service platform. This cable way do not
include in standard delivery. This has to be ordered separately.

10.2 Common assembly methods

Cable ways as an angle Cable fasteners for single or few cables Assembly on top
A. Plastic cable tie

Cable ways as an angle Cover assembly Wall assembly in an angle

4pcs. (15) per cover plate

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ASSEMBLY INSTRUCTION FOR CRANE

Fastening to a C-rail Wall mounting

End fastening onto a wall Joint

 Spacing for brackets 3 and 4 is appr. 500 mm.

 Fastening with M8x16 screw & washer
 Assembly drillings M8

Pos. Name Specification

1 Cable way DEFEM 11 49_ 10
2 Cable way DEFEM 11 49_ 01
3 Bracket DEFEM 11 49_ 57
4 Bracket DEFEM 11 49_ 98
5 Fitting DEFEM 11 49_54
6 Fitting DEFEM 11 49_55
7 Fitting DEFEM 11 49_56
8 Fitting DEFEM 11 49_69
9 Screw set DEFEM 11 49_84
10 Cable fastener CADDY 4H24CT
11 Cable fastener CADDY 4H58CT
12 Cable fastener CADDY 4H91CT
13 Cover plate DEFEM 11 49_70
14 Cover plate DEFEM 11 49_71
15 Clip DEFEM 11 49_79
16 Fixing part CQ-W25T6L45
17 Washer DIN125-A8-A3F
18 Screw DIN912-M8x20-8.8-A3F

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

11 STICKER PLACING

11.1 Crane side without service platform or energy chain

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

11.2 Crane side with service platform

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

11.3 Crane side with energy chain

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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ASSEMBLY INSTRUCTION FOR CRANE

CRANE FAT INSPECTION REPORT (SP11-12)

Manufacturer: Client / Project: CC004518
Sales order: 0201147085 Crane number: -
Span: SP type: Nominal loading: Error! No document
variable supplied.
Painting system: RAL code: Dry film thickness:
Other information:
This inspection certifies that crane is in good running condition and it has been manufactured according to purchase order, specifications and other documentation.
SP-code is specific for crane type: SP11 = EOT-crane with profile main girder and SP12 = EOT-crane with box main girder.
Inspection is performed by a trained and qualified person. Inspector(s) / assembler(s) check and verify each item on the following list.

THIS DOCUMENT IS FILLED HAND IN HAND WITH ASSEMBLY / INSTALLATION WORK, ACCORDING TO BEST PRACTICE

ONCE COMPLETED WITHOUT PROBLEM: MARK “√” IN CELL “DONE”

IF THERE IS A PROBLEM: MARK “√” IN CELL “NOT OK”
AFTER SOLVING THE PROBLEM: MARK “√” IN CELL “FIXED”
IF A CHECK POINT IS NOT APPLICABLE: MARK “N/A” IN CELL “NOTES”

WRITE NOTES NEXT TO CHECK POINT OR IN “FAT Annex 2 – Non-conformity (NC) List”
ENSURE THAT ALL NON CONFORMITIES ARE RECORDED IN “NOTES”-COLUMN AND / OR IN NC-LIST-ANNEX 2

Printed by
Date:
(name & signature):

Overall checking (visually check that all components and steel structure installed properly)
NOT
ID Test name, object and method DONE FIXED NOTES
OK

F1 Wiring, no loose connections and cable markings according to the drawings

F2 Cable routing / cable ways & cable marking / plugs marking (outside of panels)

F3 Insulation testing (CSA only or according to local regulations)

F4 Grounding cables installation and continuity

F5 Enclosure locks / latches installation

F6 Visual check crane steel structure / wheels for defects, all alignments done (records available)

F7 Visual check of all equipment for any damage caused by installation

F8 Paint condition after component installation

F9 Trolley / Bridge end carriage buffers installed

F10 Visual check of structural bolts installation (according to work scope)

F11 End Carriage connection - record torque (check both sides) = Nm, no gaps > 0.5 mm

F12 Crane height (Top of runway to top of crane) = mm

F13 Visual check of motor and gear mountings

F14 All components installed & correct (light beacon, horn, flood lights, radio receiver + antenna, etc.)

F15 Serial numbers recorded in Component Serial Number List (FAT Annex 1)

F16 Greasing / lubrication, check also connection of lubrication lines if applicable

F17 Pendant cable (check enough Length acc. main drawing)

Control functional test Radio SN: Frequency: MHz

Radio Pendant
ID Test name, object and method NOTES
NOT FIXE NOT
DONE DONE FIXED
OK D OK

F18 Key operated switch

F19 Emergency stop button

F20 Horn / alarm push button

F21 Main contactor

F22 Direction commands / speeds

F23 Other controls (e.g. flood lights, control selection, micro speed)

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 25/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

CRANE FAT INSPECTION REPORT (SP11-12)

Trolley (If more than 1 trolley / hoist, print and use “FAT Annex 3”)
NOT
ID Test name, object and method DONE FIXED NOTES
OK

Trolley ID number:
Drive all motions minimum 2 times both directions, at all speeds, full travel length, or as far as practical. Record trolley
F24
travelling max speed m/min fpm

F25 Buffer alignment in relation to other trolley(s) and end stops

F26 Festoon system operation and length

F27 Verify that there is no abnormal noise, vibration, malfunction, or excessive heating

F28 Hoist and trolley brakes function

F29 Trolley limits functions

F30 Hoisting limits (check manually if unable to verify by driving)

F31 Ultimate/Hook operated limit switch (if ordered)

Hook
F34 Hook rotation and possible hook limits

F35 Hook Approach (Electric supply side mm; other side mm)

Bridge operational testing

Drive all motions minimum 2 times both directions, at all speeds. Measure and record bridge travelling max speed
F37
m/min fpm

F38 Wheels' speeds are same and according to GA drawing

F39 Bridge brakes function

F40 No abnormal noise, vibration, malfunction, or excessive heating

F41 Bridge limits function

F42 Crane anti-collision installation and functioning

Signs/labels
F43 Stickers (Nominal load, directions, CE/CSA tag, Konecranes number, manufacturing location…)

F44 All (applicable) device tags (Motors, gears, limits, panel doors, panel's components, lights, etc.)

F45 Safety stickers (caution, voltage, trip hazard, etc.)

F46 Stickers positioned according to GA-drawings

Other items to check

F47 Additional VFD features (ESR, SSL, Micro Speed, Anti-Sway, etc.)

F48 Load Measuring device (Hoist control device, etc.)

F49 Load display

F50 Changes in electrical drawings recorded. Documentation sent to “site team” in bridge cubicle

Foreman or inspector
Date and place:
(name & signature):
Customer / 3rd party verified
Date and place:
(name & signature):

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

FAT ANNEX 1 - SERIAL NUMBERS

Manufacturer: Client / Project: CC004518
Sales order: 0201147085 Crane number: -
Span: SP type: Nominal loading: 5000
Type according to
Component drawings and PO Component serial number
DONE NOT FIXE
OK D
Hoist 1
Hoist 2
Hoist 3

Trolley 1 travelling machinery 1

Trolley 1 travelling machinery 2

Trolley 2 travelling machinery 1

Trolley 2 travelling machinery 2

Trolley 3 travelling machinery 1

Trolley 3 travelling machinery 2

Bridge travelling machinery 1

Bridge travelling machinery 2

Bridge cubicle

Foreman or inspector
Date and place:
(name & signature):
Customer / 3rd party verified
Date and place:
(name & signature):

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 27/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

FAT ANNEX 2 - NON-CONFORMITY (NC) LIST

Manufacturer: Client / Project: CC004518
Sales order: 0201147085 Crane number: -
Span: SP type: Nominal loading: 5000

All NCs have to be completed before delivery to Customer. Installation crew must be informed about the open Punch List Items
by Project Manager.

NC ID REMARKS description

Foreman or inspector
Date and place:
(name & signature):
Customer / 3rd party verified
Date and place:
(name & signature):

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 28/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

FAT ANNEX 3 - TROLLEY FOR SP11-12

Trolley ID number:
NOT
ID Test name, object and method DONE FIXED NOTES
OK

Drive all motions minimum 2 times both directions, at all speeds, full travel length, or as far as practical. Record trolley
F24
travelling max speed m/min fpm

F25 Buffer alignment in relation to other trolley(s) and end stops

F26 Festoon system operation and length

F27 Verify that there is no abnormal noise, vibration, malfunction, or excessive heating

F28 Hoist and trolley brakes function

F29 Trolley limits functions

F30 Hoisting limits (check manually if unable to verify by driving)

F31 Ultimate/Hook operated limit switch (if ordered)

F32 Trolley anti-collision functions

F33 Trolleys tandem mode functions

Hook(s)
F34 Hook rotation and possible hook(s) limits

F35 Hook Approach (Electric supply side mm; other side mm)

F36 If you have more than one trolley - check hook approach between trolleys is according to GA

Foreman or inspector
Date and place:
(name & signature):
Customer / 3rd party verified
Date and place:
(name & signature):

CRANE SAT INSPECTION REPORT (SP11-12)

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 29/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

CRANE SAT INSPECTION REPORT (SP11-12)

GENERAL DATA
Manufacturer: Client / Project: CC004518
Sales order: 0201147085 Crane number: -
Customer PO No: Contract No:
Span: SP type: Nominal loading: 5000
Other information:
The purpose of this inspection is to certify that the crane is in good running condition; and it has been manufactured properly according to the
purchase order and applicable crane specifications.
The inspection will be performed by authorized, properly trained, and qualified personnel. Inspector and assemblers will operate and check
each item of the following check list.
FILL IN THIS LIST AFTER EVERY WORK PHASE.
ONCE COMPLETED WITHOUT PROBLEM - MARK “√” IN CELL “DONE”.
IF THERE IS A PROBLEM - MARK “√” IN CELL “NOT OK”.
AFTER PROBLEM IS SOLVED, MARK “√” - IN CELL “FIXED”.
MAKE NOTES ABOUT PROBLEMS IN CELL “NOTES” or in “SAT Annex 1 – Non-conformity (NC) List”.
IF A FIELD DOES NOT APPLY TO THE CRANE SPECIFICATION, WRITE “-” IN CELL “DONE”.

Printed by (name & signature): Date:

SAT OPERATIONAL INSPECTION

NOT
ID Test name, object and method DONE FIXED NOTES
OK

Receiving inspection
S1 All applicable documents available at work place (drawings, SAT forms, PO, layout drawings, manuals.)

S2 Check condition of packaging after transportation

S3 All items received match packing lists

S4 All components (structure, hoists, bolts & nuts, connection plates) quantity according to main drawings

S5 Visually check all components and painted surfaces for any damage or rust caused by transportation

S6 Hoist / festoon / etc. tied down properly prior lifting

S7 Crane cleaned and debris removed after the erection

Preliminary checks (visually check that all components and steel structures are installed properly)
S8 Main-, trolley-, cabin-, and service panel wiring and cable markings according to the drawings

S9 End Carriage bolt torque (check from both sides) = Nm, no gaps > 0.5 mm

S10 All components installed (beacon/strobe/horn, lights, radio receiver & antenna, etc.)

S11 Crane runway in good condition (survey available if applicable)

S12 Pendant cable has proper length

S13 Check Grease in all fittings and that all lubrication lines are properly connected

Power supply, incoming voltage

S14 Main voltage Ua – Ub (L1-L2)= V

S15 Main voltage Ua – Uc (L1-L3)= V

S16 Main Voltage Ub – Uc(L2-L3)= V

S17 Phase voltage Ua – GND(L1-PE)= V

S18 Phase voltage Ub – GND (L2-PE)= V

S19 Phase voltage Uc – GND (L3-PE)= V

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 30/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

CRANE SAT INSPECTION REPORT (SP11-12)

Transformer tapping
S20 Lighting and heating transformer primary side tapped at= V

S21 Lighting and heating transformer secondary side tapped at= V

S22 Control voltage transformers primary side tapped at= V

S23 Control voltage transformers secondary side tapped at= V

S24 Check that the primary side voltage is the same as the crane input voltage

S25 Check that the secondary side output voltage is according to specification

NOT
ID Test name, object and method DONE FIXED NOTES
OK

Control functional test

Radio Pendant
ID Control functional test NOT NOT NOTES
DONE FIXED DONE FIXED
OK OK
S26 Key operated switch

S27 Emergency stop button

S28 Horn / alarm push button

S29 Direction commands / speeds

S30 Flood lights

Trolley (If you have more than 1 trolley - print “SAT Annex 2 - Trolley inspection SP11-12” as needed)
Trolley ID number:
S31 Tune trolley / hoist VFD

S32 Drive all motions minimum 2 times both directions, at all speeds, full travel length, or as far as practical

S33 Check trolley buffer alignment compared with the other trolley(s) and end stops

S34 Check festoon system operation and that it is of proper length

S35 Verify that there is no abnormal noise, vibration, malfunction or excessive heating. Check clearances

S36 Trolley anti-collision working properly

Bridge inspection
S37 Tune bridge VFD(s)

S38 Check buffer alignment with other cranes and/or end stops. Verify full buffer contact with end stops at both ends

S39 Check that bridge machinery travels freely and drive the runway 2 times, end to end, with all speeds

S40 Verify that there is no abnormal noise, vibration, malfunction or excessive heating. Check clearances

S41 Check power supply system (festoon, conductor bar, energy chain, etc.) alignment and operation

S42 Check anti-collision operation

S43 Measured crane speed with no load [ m/min] [ fpm]

S44 Measured crane speed with nominal load [ m/min] [ fpm]

S45 All wheels speeds are similar and according to the GA

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 31/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

CRANE SAT INSPECTION REPORT (SP11-12)

Hook(s)
S46 Hook(s) rotate CW/CCW

S47 Hook approach at direction 1 stop limit = mm

S48 Hook approach at direction 2 stop limit = mm

S49 If you have more than 1 trolley - check that hook approach between trolleys is according to the GA

Limit functions and brakes

Trolley Main hoist Aux hoist Bridge
ID Limit functions and brakes NOT NOT NOT NOT NOTES
DONE FIXED DONE FIXED DONE FIXED DONE FIXED
OK OK OK OK
S50 Direction 1 stop/slowdown

S51 Direction 2 stop/slowdown

S52 Brakes proper operation

Protective & safety devices

S53 Test the operation of emergency stop

S54 Check the operation of all audible alarms

S55 Check the operation of all visual alarms and signals

NOT
ID Test name, object and method DONE FIXED NOTES
OK

Load Test
S56 Record the actual weight of the test load for main hoist tons

S57 Record the actual weight of the test load for auxiliary hoist tons

S58 Test Main Hoist at [ ] % of rated capacity 1)

S59 Test Aux Hoist at [ ] % of rated capacity 1)

S60 Deflection with rated load mm 2)

S61 Deflection without load mm 2)

1) According to local rules and regulations.

2) Measured with laser from floor level to main girder bottom, middle point.

Other Crane features

(The following items shall be inspected, to ensure that the following features are properly installed and operating. Any additional
unlisted features shall also be listed and checked)
S62 Additional VFD features (ESR, SSL, MicroSpeed, Anti-Sway, etc)

S63 Load Measuring device (ControlPro, Vishay Nobel, etc)

S64 Load display

S65 All factory calibration information recorded and stored (VFD, service info, Load Measuring Device, etc)

S66

S67

S68

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 32/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

CRANE SAT INSPECTION REPORT (SP11-12)

Signs/labels
S69 Sticker showing manufacturing location, manufacturer’s number, crane nominal load and direction arrows, CE / CSA tags

S70 Visually check all device tags (motors, gears, limits, panel doors, panel's components, lights, cable ways)

S71 Safety stickers (caution, voltage, trip hazard & etc)

Documents & Overall

S72 Training of crane operators done (if applicable)

S73 Load testing done (records in SAT protocol or separate protocol created according to local regulations)

S74 Customer received all documents (drawings, instruction, maintenance instructions, crane manual, etc.)

Person who received above documents:

S75

Signature at site:

Crane control devices and keys left with:

S76

Signature at site:

Customer / 3rd party verified (name & signature):

Date and place:

Manufacturer’s Representative (name & signature):

Date and place:

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 33/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

SAT ANNEX 1 - NON-CONFORMITY (NC) LIST

GENERAL DATA
Manufacturer: Client / Project: CC004518
Sales order: 0201147085 Crane number: -
Customer PO No: Contract No:
Span: SP type: Nominal loading: 5000

All NC have to be completed before delivery to Customer. Installation crew must be informed about the open Punch List Items by
Project Manager.

NC ID REMARKS description

Customer / 3rd party verified (name & signature):

Date and place:

Manufacturer’s Representative (name & signature):

Date and place:

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 34/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

SAT ANNEX 2 - TROLLEY INSPECTION SP11-12

Trolley ID number:
NOT
ID Test name, object and method DONE FIXED NOTES
OK
S31 Tune trolley / hoist VFD

S32 Drive all motions minimum 2 times both directions, at all speeds, full travel length, or as far as practical

S33 Check trolley buffer alignment compared with the other trolley(s) and end stops

S34 Check festoon system operation and that it is of proper length

S35 Verify that there is no abnormal noise, vibration, malfunction or excessive heating. Check clearances

S36 Trolley anti-collision working properly

Limit functions and brakes

Trolley Main hoist Aux hoist Bridge
ID Control functional test NOT NOT NOT NOT NOTES
DONE FIXED DONE FIXED DONE FIXED DONE FIXED
OK OK OK OK
S50 Direction 1 stop/slowdown

S51 Direction 2 stop/slowdown

S52 Brakes proper operation

Load Test
S56 Record the actual weight of the test load for main hoist tons

S57 Record the actual weight of the test load for auxiliary hoist tons

S58 Test Main Hoist at [ ] % of rated capacity 1)

S59 Test Aux Hoist at [ ] % of rated capacity 1)

S60 Deflection with rated load mm 2)

S61 Deflection without load mm 2)

1) According to local rules and regulations.

2) Measured with laser from floor level to main girder bottom, middle point.

Customer / 3rd party verified (name & signature):

Date and place:

Manufacturer’s Representative (name & signature):

Date and place:

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 35/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
ASSEMBLY INSTRUCTION FOR CRANE

SAT ANNEX 3 - ASSESSMENT OF HEALTH AND SAFETY RISKS

Risk rating
Location
Existing control
activity Hazard(s) Who might be harmed SxL=R Further actions required
measures
process S L R
Training of driver
Training of slinger
Crane driver Crane maintenance log and
Falling Load certificates
Use of Mobile Customer employees Review training
Crushing Isolation of work area 3 1 3
Crane Site Contractors Review certification
Swinging Load Certified lifting tackle
Customer employees
Supervision of lifting
operations
Use of safety lines
Manufacturer’s Engineer Authorized persons only
Use of Access Collision Certified Safety harnesses to be
Equipment
Site Contractors Operator’s training 3 1 3
worn
Falling from height
Customers employees Certification 1)
Manufacturer’s safety
training Certified Safety Harnesses to
Working at height Falling Manufacturer’s Engineer 3 1 3
Safety Passport 2) Isolation be worn
of work area
Electrical Isolation of crane
reconnection of Electrical shock Manufacturer’s Engineers 3 1 3
crane Authorized personnel only
Working from access
Installation of Falling from height Manufacturer’s Engineers platform
Main power Electrical shock Contractors Use of safety lines and 3 1 3 Operator’s training Certification1)
supply Falling objects Customers employees harnesses Isolation of work
area
Certified lifting tackle
Crane Falling load Manufacturer’s Engineers
Commissioning Contractors Use of safety lines and 3 1 3 Review certification
Swinging load
and Testing harnesses Isolation of work
Entrapment Customers employees
area
Risk Ratings:
(S) Severity: 1-Low, 2-Medium, 3-High
(L) Likelihood: 1-Low, 2-Medium, 3-High
(R) Risk: 1-3-Low, 4-6-Medium, 7-9-High
1) Operator’s training certificate, employees who have successfully completed training course.
2) All personnel on site have a basic knowledge of health & safety and therefore, are able to work on site with greater safety and with lower risk to themselves and
others.

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 36/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.