EOT Crane Maintenance Manual

CIMOLAI Technology spa
Special Equipment
USAGE AND MAINTENANCE MANUAL
MACHINE:
OVERHEAD CRANE
Mod.”OHC005/2-SLAVE”
CAPACITY: 500 TON.
Serial N°: 14 01 OHC005/2-SLAVE

Year: 2015
Work order: 14 01 REV.0
E.OHC005.00A.00
OVERHEAD CRANE
INSTRUCTION MANUAL
Compiled in compliance with:
Enclosure 1 - Paragraph 1.7.4 of the Regulations machines 2006/42/CE
The instruction manual is divided into chapters.
The manual herewith described is, in its frame, aimed at adequately

trained staff who have specific knowledge in carrying out and
maintaining large installations.
Any potential certification released by CIMOLAI Technology spa to

technical users CONFIRMS SUCH PREPARATION.
The chapters processed in the manual contain the specifications and

descriptions reported in the index.
The present manual constitutes integrating part of the machine and

must follow the same throughout its life.
It must therefore be kept with care and stored in places easily accessible
in order to allow consultation as required to guarantee its
preservation.
CLASSIFIED PROPERTY. ANY REPRODUCTION, HOWEVER PARTIAL, IS FORBIDDEN WITHOUT WRITTEN AUTHORISATION FROM CIMOLAI Technology spa
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INDEX OF CONTENTS
1. INTRODUCTION – GENERAL WARNINGS
1.1. Introduction ..................................................................................................................... pag.1.1

1.2. General information on safety ....................................................................................... pag.1.2
1.2.1 Manufacturer liability ...................................................................................................... pag.1.4
1.2.2 Validity, contents and preservation of the manual .......................................................... pag.1.4
1.2.3 Manufacturer’s note ........................................................................................................ pag.1.5
1.2.4 Compliance with the directives ........................................................................................ pag.1.5
1.3. Machine identification data ............................................................................................. pag.1.5
2. DATA AND TECHNICAL CHARACTERISTICS
2.1. Dimensions and machine measures ................................................................................ pag.2.1

2.2. Configuration of the machine .......................................................................................... pag.2.2
2.3. Powers.............................................................................................................................. pag.2.2
3. INSTALLATION
3.1. General prescription for the installation of the machine ................................................ pag.3.1
3.2. Sub-division and movement of the packages .................................................................. pag.3.2
3.3. Acceptance and storing of the machine .......................................................................... pag.3.2
3.3.1 Storing of machine ........................................................................................................... pag.3.2
3.4. Unpacking......................................................................................................................... pag.3.2
3.5. Lifting................................................................................................................................ pag.3.3
3.6. Assembly operations ........................................................................................................ pag.3.3
3.7. Electrical Connections ...................................................................................................... pag.3.4
3.8. Cleaning............................................................................................................................ pag.3.5
3.9. Reinstallation ................................................................................................................... pag.3.5
3.10. Demolition and disposal................................................................................................... pag.3.5
4. INSTRUCTIONS FOR THE OPERATOR
4.1. Electrical board ................................................................................................................ pag.4.1

4.2. Control panels .................................................................................................................. pag.4.3
4.3. Start up............................................................................................................................. pag.4.4
4.4. Halt ................................................................................................................................... pag.4.8
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4.5. Master/slave connection ................................................................................................. pag.4.9
5. FUNCTIONING AND USE
5.1. Scheduled and not scheduled use, agreed uses .............................................................. pag.5.1
5.2. Information on safety ...................................................................................................... pag.5.1
5.2.1 General safety standards ................................................................................................. pag.5.1
5.3. Perimeter accessibility and work emplacement .............................................................. pag.5.3
5.4. Dangerous areas .............................................................................................................. pag.5.4
5.5. Risks, danger and avoidable risks..................................................................................... pag.5.5
5.5.1 Residual risks .................................................................................................................... pag.5.5
5.5.2 Unavailable dangers and risk which can occur when the machine is working ................ pag.5.9
5.5.3 Risks of general type and due to dangerous combinations ............................................. pag.5.10
5.6. Safety warning signs......................................................................................................... pag.5.11
5.6.1 Safety warning signs in the work yard ............................................................................. pag.5.11
5.6.2 Safety sign list and description......................................................................................... pag.5.11
5.6.3 Layout of safety labels applied to the machine ............................................................... pag.5.15
5.7. Protection devices............................................................................................................ pag.5.16
5.7.1 Personal protection equipment (P.P.E.) ........................................................................... pag.5.16
5.7.2 Operator protection device .............................................................................................. pag.5.17
5.7.3 Devices for safety and reability of the machine ............................................................... pag.5.18
5.8. Displacement of the machine .......................................................................................... pag.5.19
5.9. Lifting/descent movements ............................................................................................. pag.5.20
5.9.1 Weighing system .............................................................................................................. pag.5.23
5.10. Main trolley movements .................................................................................................. pag.5.24
5.11. Aux hoist........................................................................................................................... pag.5.25
5.11.1 Weighing system ................................................................................................................ pag.5.26
6. REGULATION AND SUBSTITUTIONS
6.1. General warnings ............................................................................................................. pag.6.1

6.2. Substitution of the ropes ................................................................................................. pag.6.1
6.2.1 Development and put in force of new ropes .................................................................... pag.6.1
6.2.2 Substitution of the ropes .................................................................................................. pag.6.2
6.2.3 Tying of the fixed head ..................................................................................................... pag.6.2
6.2.4 Adaptation of the ropes to the conditions of work .......................................................... pag.6.2
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7. ORDINARY AND PLANNED MAINTENANCE
7.1. Procedure of maintenance operations ............................................................................ pag.7.1

7.2. Instruments required ....................................................................................................... pag.7.2
7.3. Maintenance operation ................................................................................................... pag.7.2
7.3.1 Maintenance .................................................................................................................... pag.7.2
8. MACHINE LUBRICATION INSTRUCTIONS
8.1. Lubrication process .......................................................................................................... pag.8.1

8.1.1 Lubrication during machine installation .......................................................................... pag.8.1
8.1.2 Lubrication during prolonged stoppage ........................................................................... pag.8.2
8.1.3 Oil change and internal reduction gear clean .................................................................. pag.8.2
8.1.4 Oil change for planetary reduction gear .......................................................................... pag.8.2
8.1.5 Oil filtering........................................................................................................................ pag.8.2
8.1.6 Scheduled oil level check .................................................................................................. pag.8.3
8.1.7 Permanently lubricated reduction gears .......................................................................... pag.8.3
8.1.8 Disposal of waste oil......................................................................................................... pag.8.3
8.2. Machine lubrication ......................................................................................................... pag.8.4
8.2.1 Symbol used in the lubrication table ................................................................................ pag.8.4
8.2.2 Lubrication table .............................................................................................................. pag.8.4
8.2.3 Identification of machine lube points............................................................................... pag.8.5
8.3. Lubrication points ............................................................................................................ pag.8.6
8.4. Characteristics and adherence lubricants ........................................................................ pag.8.7
8.5. Electrical hoist lubrication................................................................................................ pag.8.8
9. DIAGNOSTICS
9.1. Problem - Cause – Remedy .............................................................................................. pag.9.1
10. EXTRAORDINARY MAINTENANCE
10.1. Extraordinary maintenance ............................................................................................. pag.10.1

10.2. Verification of the ropes .................................................................................................. pag.10.2
10.2.1 Criteria of verification and substitution of the ropes ....................................................... pag.10.2
10.2.2 Breakage of the wires ...................................................................................................... pag.10.2
10.2.3 Usage of wires .................................................................................................................. pag.10.2
10.2.4 Corrosion .......................................................................................................................... pag.10.2
10.2.5 Damage and deterioration of the rope (in accordance with ISO 4309) ........................... pag.10.2
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10.3. Criteria for verification of the ropes ................................................................................ pag.10.11

10.3.1 Breakage of the wires ...................................................................................................... pag.10.11
10.3.2 Wear out of the wires....................................................................................................... pag.10.11
10.3.3 Corrosion .......................................................................................................................... pag.10.11
10.3.4 Damage and deterioration of the rope ............................................................................ pag.10.11
10.3.5 Verification points ............................................................................................................ pag.10.12
10.3.6 Position 1: Drum ............................................................................................................... pag.10.12
10.3.7 Position 2: Fixed pulleys ................................................................................................... pag.10.12
10.3.8 Position 3: Mobile pulleys ................................................................................................ pag.10.12
10.3.9 Position 4: Tie up point ..................................................................................................... pag.10.12
10.4. Rope maintenance ........................................................................................................... pag.10.12
11. DECOMMISSIONING, DEMOLITION AND DISPOSAL
11.1. Decommissioning ............................................................................................................. pag.11.1

11.2. Demolition and disposal................................................................................................... pag.11.1
12. SPARE PARTS CATALOGUE
13. ATTACHMENTS
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E.OHC005.01A.00
Introduction - General warnings - 1
CHAPTER1.: INTRODUCTION – GENERAL WARNINGS
1.1. Introduction
- The present manual addresses the staff who, at various levels of RESPONSIBILITY and COMPETENCE
IS AUTHORISED TO OPERATE THE MACHINE. The operation by persons not familiar with the process
could result in DANGEROUS situations.
- The instructions supplied are in accordance with such type of operations.

Any other use or application is considered improper and therefore DANGEROUS.
- It is important that the warnings and the instructions contained in the present manual are read
CAREFULLY, as they provide important recommendations regarding the safe use and maintenance
of the machine.
- In the event the part of the aforementioned “manual” should result NOT clear, you can contact the
Technical and Assembly Service Center at CIMOLAI Technology spa who will supply:
- Clarification regarding the documentation supplied.

- Clarification regarding the supply of spare parts and procedure
- particular with regard to maintenance.
- Intervention by CIMOLAI Technology spa technical staff to assist with repair or revision of
special undertaking.
- Clarification of possible encumbrances not described in the present
- manual.
- Possibility to carry out training instructives.
To such scope we supply our address herewith:
CIMOLAI Technology spa

Operating Office: Via Dell’industria e dell’Artigianato, 17
35010 Carmignano di Brenta (PD) – ITALY
Tel. +39 049 9404539 – Fax +39 049 5973960
E-mail : technology@cimolai.com
1.1
E.OHC005.01A.00
1 - Introduction - General warnings
1.2. General information on safety
The manufacturer cannot be held responsible for any eventual damage or accidents caused by improper,
wrong or unauthorised usage.
Only explicitly authorised personnel must use the machine.

The use by personnel not familiar with the process could generate situations of danger.
In the event of need for technical assistance, address exclusively to the assistance service of the
Manufacturer or to authorised centres, in order to request original spare parts.
Under no circumstances should elements or sealed parts of the machine be tampered with. Such
operations, which would allow the opening of protections, access to spaces and the variation of calibration,
would provoke dangerous situations.
In order to guarantee the efficiency of the machine and its correct functioning it is essential that the
instructions supplied by the Manufacturer in the matter of cleaning and ordinary maintenance as contained
in the present handbook be adhered to.
The cleaning operation and ordinary maintenance are to be effected by the user through trained and
authorised personnel.
The section “replacement parts” is supplied exclusively for the scope of facilitating the service technical
assistance and is therefore destined to authorised and professionally qualified personnel.
The user is not authorised under any circumstances to intervene on the machine except for the running
operations and ordinary maintenance explicitely outlined in the present handbook.
For eventual repair service, the user must address exclusively the after sales service centre of the
manufacturer or the centers explicitely authorised by the same.
The use of non-original replacement parts can compromise the security of the machine and is therefore not
authorised.
Any tampering or modification of the machine not authorised by the manufacturer will clear the latter of
any damages provoked by and on the machinery and referable to the aforementioned acts.
Check that during the normal functioning no condition of danger is identified. Immediately stop the
machine in the event irregular functions are discovered and consult the service centre of the manufacturer
or a technical service centre, which is explicitly authorised by him.
The warning or prescription labels are integral elements of the machine on which are applied, therefore
must be requested and substituted in the event they should be damaged or missing.
The cleaning and maintenance operations must be effected in conditions of maximum security.
- Before effecting the maintenance /cleaning operations, it is compulsory to disconnect the electrical
supply of the machine and put the general switch to the OFF position. Disconnect any other form of
energy connected to the machine for operations of maintenance and/or cleaning.
1.2
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- In the event of access to the inside of the machine, disconnect any source of energy connected to the
machine; make also sure that the internal temperature has come down to an acceptable level (Max
30°C).
- It is absolutely forbidden to remove the fixed protection whilst the machine is in operation or
connected.
This symbol , which is found on many pages of the present manual, represents an important
warning. It is therefore advisable to give the maximum attention to the operations or the indications
evidenced by the same symbol.
It is advisable for the staff operating and maintaning the machine, to attend a specific course held by the
manufacturer of the same machine. The staff appointed to attend the course should have a basic
knowledge of the machine.
After unpacking and after verifying the good condition of the machine, check that no parts appear to be
damaged. If in doubt, do not install/use the machine and contact the after sales sevice centre of the
manufacturer.
The packaging components (plastic, polystyrine, nails, screws, wood, etc.,) must be kept in unaccessible
areas.
All the soiled and not biodegradable materials must be returned to the appropriate places of collection.
In the event that the machine ceases to be used, it is advised to make the machine unoperative by
disconnecting the electrical supply. In addition, all those parts, which could be dangerous, or pollutable,
such as oils or lubrication oil, plastic components or other materials labelled by the laws in force for
disposable material, should be taken care of.
Scrap the structures and the components placing the composites in the designated collection centres.
The manual reflects the state of the technology at the time of marketing the machine and cannot be
considered inadequate if following new practices are subsequently updated. In such event, the
manufacturer reserves the right to update production and previous manuals, if not in exceptional cases.
1.3
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1.2.1 Manufacturer liability
The manufacturer hereby declares that the machine is compliant with state-of-the-art standards at the
moment of its construction in regards to its design, manufacture and intended use.
The manufacturer shall not be liable for any failures or inconveniences whenever these are linked to
tampering and/or improper applications and/or incorrect use of the machine.
- The customer must follow the requirements in this user's manual, and in particular:
- use the machine within its limits of design;
- carry out constant and diligent maintenance;
- properly instruct and train personnel having proven abilities and aptitude to use the machine;
- Exclusively use the manufacturer's original spare parts.
Any modifications, adaptations or other changes to the machines released on the market
do not oblige the manufacturer to perform any work on the machine previously supplied nor consider it
and the user's manual incomplete and inadequate.
The instructions in this manual are integrations to the Employer's requirements governing compliance with
the laws in force on hazard prevention and safety, and in no way replace these.
1.2.2 Validity, contents and preservation of the manual
The manual reflects the machine's state-of-the-art standards at the moment of manufacture and shall
remain valid for the entire life cycle of the machine.
All customers may contact the manufacturer for additional information and also make proposals for
improvement so that this manual better meets the needs for which it is intended.
The manual must be kept in a place that is suitable for its preservation and can be accessed by the:
- Employer;
- Machine Operator;
- Maintenance Technician;
- Assembly Technicians;
- Personnel charged with demolition and scrapping.
These instructions have been carefully translated into the customer's language.
In order to prevent possible accidents from occurring to persons or objects, due to improper translation of
the instructions, we advise the customer to:
- refrain from performing operations or manoeuvres on the machinery if there are any doubts or
uncertainties on the operations to be performed;
- request details on the instructions at issue by contacting the Technical Assistance-Assem- bly
Service of CIMOLAI TECHNOLOGY SpA.
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1.2.3 Manufacturer's note

The manufacturer has provided all the information required to use the machine correctly when drafting this
manual. It is understood that this information cannot replace the operator's experience and knowledge
related to the machine's use.
1.2.4 Compliance with the directives

The machine has been designed and manufactured in compliance with the regulations on the
EC declaration of conformity provided as annex.
1.3. Machine identification data

A fixed nameplate that contains the following identifies each machine:
- the name and address of manufacturer

- designation of the series or the type (model)
- serial number (matriculation)
- year of construction
- CE label
- net weight
- Maximum capacity
- Power
The nameplate is made of brushed aluminium and screen printed in blue and grey. The information
concerning the machine to which it is applied are stamped during machine testing at CIMOLAI
TECHNOLOGY SpA.
1.5
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Pic.1-1
1. 6
E.OHC005.02A.00
Data and technical characteristics - 2
CHAPTER 2: DATA AND TECHNICAL CHARACTERISTICS

2.1. Dimensions and machine measures
SEE ATTACHMENTS
(Section 13)
Pic.2-1
2.1
E.OHC005.02A.00 2
2 - Data and technical characteristics
2.2. Configuration of the machine
Technical Data
Type: OVERHEAD CRANE

Model: OHC005/2 - SLAVE
Wheels n°: 16 (8 driving wheel and 8 no driving wheel)
Winches n°: 3 (2 main winches and 1 aux winch)
Machine Colour
External surface: Yellow RAL1028

Products produced: Prefabricated elements
Lifting point’s n°: 2
Rated capacity: 500Ton + 80Ton
Environment temperature
In order not to compromise the safety and the proper functioning of the machine, conform to the
following values:
- Store temperature -10°C 70°C

- Functioning environment temperature -5°C 70 °C
2.3. Powers
Installed Power
Power 200 kW
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Installation - 3
CHAPTER 3: INSTALLATION
3.1. General prescriptions for the installation of the machine

Machine
All of the tools / cranes made available by the Client (transporters, cranes, cables / ropes, slings, clamps)
have to be certified and homologated, to guarantee safety and accident prevention protection (based on
the required loads as advised by Cimolai Technology SpA); besides, they have to be suitable for being used
in the specific work conditions in the installation areas as advised by Cimolai Technology SpA. Cimolai
Technology SpA waives any and whatsoever responsibility for accidents caused by non-compliance with the
above requirements.
ATTENTION: All the lifting methods and transport used should be compatible with
the working environment; therefore methods which emit polluting exhaust gases
are to be excluded.
Recommendations
It is recommended to strictly follow the instructions provided hereafter during the installation of the
machine:
- Organise the worksite to comply with the applicable regulations in force; affix signs which
indicate the state of work in progress, highlighted by the personnel in charge;
- Install scaffolds, ladders, etc. in accordance with safety prescriptions; access to areas of work
must be limited to the personnel in charge of works;
- The personnel in charge of assembly works must be equipped with clothes and material for their
own safety etc.
- Verify the weight of various parts of the machine on the shipment label, use appropriate lifting
equipment
- Ascertain that the position of the machine does not create difficulty and/or danger to the
installations and other machines or the personnel in charge;
- Verify that the opening and the passages for the moviment of the machine are adequate;
- Supply a lighting system of the work area, minimum 150 lux.
CIMOLAI Technology spa is not responsible for damages to persons or things if the
regulations of above reported prescriptions are not respected.
3.1
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3 - Installation
3.2. Sub-division and movement of the packages

- Based on the transport equipment and contractual agreement terms, the shipment of the
machine can be carried out by means of lorries, ships, containers, in cages and in crates.
- The machine is shipped without packaging if transported by road or packed in the event of
shipment by sea or air.
- To move it whilst it is packed, use a truck-crane of a size adequate to the weight of the Machine
ATTENTION! In the event of moving of the packaged machine using forklifts, the
maximum lift from the ground allowed is of cm.40.
3.3. Acceptance and storing of the machine

Once the machine reaches its destination, it is recommended that the Client performs the following
verifications:
- Check that the material delivered corresponds to that listed on the packing list.
- In the event of missing or damaged pieces, immediately contact and lay forth complaint to the
Insurance company which issued the policy to cover the delivery of the material.
- The machine and/or its components that have reached their final destination and are awaiting
installation should be stored in a dry, covered and clean environment, away from corrosive
agents until they are ready for use.
- The responsibility for the packages and their contents is with the Client who remains
responsible for their intactness
3.3.1. Storing of machine

In the event of prolonged storing, leave the machine protected from rain and wind and if possible in
a dry place.
Carry out possible intervention of lubrication as detailed under paragraph “LUBRICATION IN THE
EVENT OF PROLONGED STORAGE” of the chapter LUBRICATION.
It is not advisable to cover the machine with a waterproof tent because it would prevent the
evaporation of eventual humidity.
Humidity, in fact, can cause corrosion to the hardware, whilst the exposure of the machine to the
sun’s rays can bring about yellowing of the painted parts.
3.4. Unpackaging
To unpack the machine, follow scrupulously the following procedure:
1 Partially open and lift the cover of the pallet.

2 Remove the lateral walls of the pallet.
3 Unscrew the fixing screws of the pallet.
4 Pay attention not to damage the chassis or the covers of protection, lift the machine from
the pallet using adequate belts.
5 Take off the protective film, the hygroscopic bags from the electrical parts.
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Installation - 3
6 Check that the supply corresponds with the order or to the accompanying document. In the
event of mistake immediately inform CIMOLAI Technology spa or its area rappresentatives.
7 Check that there are no damaged parts, in such event, follow instructions as per point 6.
8 If the supply comprises of more pallets, for every pallet, follow instructions as per points 7.
ATTENTION: Do not spread the packaging material around the work place. For the
disposal of the packaging material (tarred paper, film etc.), contact the appropriate
disposal agencies.
3.5. Lifting
ATTENTION: All loads with weight in excess of 30 Kg must be lifted with special
lifting gear.
The methods indicated for the lifting are crane, overhead crane and undercarriage elevator and
must have a capability adequate to the weight to be lifted. All equipment must have indication of
the maximum load admissable.
For the lifting use capable bands or ropes, check that the capability indicated on the same is
superior to the weight to be lifted.
ATTENTION: During the lifting operations and transportation of the machines and
of the relative groups, pay particular attention to the equilibrium of the load and to
potruding parts.
3.6. Assembly operations

Personnel assigned to the assembly and necessary equipment.
The personnel required for assembly is generally established at contractual phase since the
number of persons and type of qualification required depends on the size and complexity of the
machine.
The equipment required for the standard assembly is for the Client’s account, save in the event of
specific contract terms and conditions, and includes standard tools that will thereafter be used for
the maintenance operations to be performed on the machine at fixed intervals.
Along a general line, the supervision staff is not equippped with own equipment, unless this is
specifically requested.
WARNING: CIMOLAI personnel must carry out the activities described in the
present paragraph.
WARNING: the machine must be positioned on the ground/floor capable of

supporting the loads declared by the constructor and mentioned in paragraph
“DATA AND TECHNICAL CHARACTERISTICS”
3.3
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3 - Installation
3.7. Electrical Connections
WARNING: Prior to carrying out works on the machine it is necessary to switch off
the electrical supply by the main switch, as prescribed by the safety norms.
For electrical connections, conform to the general rules of installation for the preparation and
operation of electrical systems, Norms EN 60439-1 and Norms EN 60204-1.
Furthermore adhere to the design of the electric management supplied with the machine, or to the
system which the machine is included, on which are reported the sections of feeding cables and
the specific characteristics for their employment and use.
IMPORTANT:
Before starting the machine up, the site manager will have to ascertain and verify that the
equipotential connection of all of the installation’s huge masses has been made, checking,
via the instrument designed for this purpose, that continuity is respected and falls within
the limits imposed by the standards in force in the country of installation.
CIMOLAI Technology SpA will not be held liable in the event of non-respect of the above.
0: Switched off
I: Switched on
Pic.3-1
3.4
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Installation - 3
3.8. Cleaning
ATTENTION: Before carrying out an operation on the machine, it is necessary to
switch off the electrical supply positioning to OFF the general isolator as specified
in the safety norms.
Following complete installation of the machine (fixing, connections and lubrication), carry out an
accurate clean of all the groups. Do not use metallic equipment or abrasive materials.
The cloths utilised for the cleaning, must be disposed of in the collection points provided respecting
the ecological laws in force in the Country where the machine is installed.
3.9. Reinstallation
WARNING: exclusively the staff of CIMOLAI Technology spa must carry out the dis-
assembling and re-assembling for an eventual re-installation of the machine. For guidance
to request intervention of the technical staff of CIMOLAI Technology spa, please refer to
instructions in chapter 01.
WARNING: Following the dis-assembling carried out by CIMOLAI Technology spa staff all
further packaging and moving operations, for an eventual reinstalment of the machine,
must be carried out exclusively by qualified staff. For the new put in place and connection,
refer to relative paragraphs of the present manual.
3.10. Demolition and disposal

Directives
In various Countries, there are different legislations in force, therefore the directives imposed by
laws and authorities of the Country where the demolition takes place must be strictly observed. At
the action of the machine being put out of service, it must be disconnected from the electrical net,
hydraulic and from the compressed air. Furthermore possible dangerous areas must be blocked
(drops, cuts, traps). The machine-awaiting disposal must be kept as long as possible in area
protected from diverse weather conditions or at least should be kept covered.
WARNING: qualified staff must carry out the dis-assembling operations for the
disposal.
Machine identification plate

For the said machine it is not required to be registered with the public offices, therefore it is not
mandatory that the machine is accompanied by documents which are given back to the overseeing
agency. Before the disposal, it is only advisable to send to the constructor of the machine, the
identifying plate specifying that the machine will be scrapped.
Disposal of the oils

Some of the components of the machine, such reducers and oleodynamic pumps, contain some
lubricating oil, which, at the time the machine is out of service, must be collected and disposed of
in accordance with the guidelines of the norms in force.
Disposal of diesel oil

As far as the electricity generating group is concerned container of combustible (diesel) , at the
time the machine is out of service , must be collected and disposed of in accordance with the the
guidelines of the norms in force.
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3 - Installation
WARNING: Never disperse in the environment exausted oils, grease, combustible

or other polluted fluids.
Disposal of the production refuse

For bay components such as electric cables, electric motors, rubber (gasket, transport belts),
plastic materials, to carry out a subdivision for tipology, then entrust for the disposal, agencies
authorised for single tipology. For the remainder, the machine results built predominantly in
common steel and stainless steel (Aisi 304) for which there are no particular disposal procedures
in place.
3.6
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Istruction for the operator - 4
CHAPTER 4: INSTRUCTIONS FOR THE OPERATOR

4.1. Electrical board
The power supply network maintains the electrical equipment.
For their correct functioning, it is necessary to conform to the values as follows:
- Primary voltage: 400 V

- Primary frequency: Ac
A blindo trolley allows the connection between the supply network and the electrical board.
On the door of the electrical board, it is installed a main switch that disconnects the power supply if
the operator/maintainer needs to open the electrical board. In this way, it is possible to disconnect
the voltage and it is possible to work inside it.
ATTENTION: Before carrying out an operation in the electrical board, it is necessary

to switch off the electrical supply positioning to “0” the general isolator as
specified in the safety norms.
0: Switched off
I: Switched on
Fig.4-1
4.1
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4 - Istruction for the operator
A power supply, in the electrical board, maintains the auxiliary circuits with the following voltage:
- Secondary voltage: 24 V
- Secondary frequency: Dc
On the door of the electrical board there are some lights and selectors that allow the operator to
switch on the machine and check the presence of the voltage.
1 2 3 4 5 6
7 8 9 10 11
Fig.4-2
1: 24Vdc VOLTAGE ON
2: EMERGENCY ON
3: CRANE DRIVE READY
4: DRUM 1 DRIVE READY
5: DRUM 2 DRIVE READY
6: MAIN TROLLEY DRIVE READY
7: INTERLOCK 0 ---- 1
8: CONDITIONERS OFF ---- ON
9: OVERTRAVEL BYPASS MAIN WINCH 0 ---- 1
10: OVERTRAVEL BYPASS AUX WINCH 80 ton 0 ---- 1
4.2
E.OHC005.04A.00
4.2. Control panels

The activation of the commands is performed from the armrests placed in the cabin. From such
control panels, it is also possible to monitorize the functioning of the machine by means of the
alarm lights and check the weights lifted on the weighing system displays.
Pic.4-3
IMPORTANT
For the activation of the push buttons, the operator must refer to the function
described on the plate fastened on each of them.
4.3
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4.3. Start up
WARNING: At the start of every work shift and before starting production, carry out
a preliminary verification to ascertain a good state of functioning of the safety
systems. Below it is reported the “Daily Inspection Checklist” to be completed
before starting the working procedure.
Daily Inspection Checklist:
4.4
Daily Inspection Checklist
Work order: 14 01
Serial n°: 14 01 OHC005/1-SLAVE
Page n°: 1/1
MACHINE INSPECTION
Operations description: check if Pos Neg
1 Machine correctly positioned
2 Protection carters correctly positioned
3 Tracks clean and free of debris
4 General hardware intact and in good condition
5 Safety guards and plates undamaged

Emergency push button on right armrest control functioning and
6
undamaged
7 Emergency push buttons on wheel n°1 functioning and undamaged

Emergency push button on electric board functioning and
11
undamaged
12 Flashing light on wheel n°1 functioning and undamaged
15 Flashing light on right wheel n°4 functioning and undamaged
16 Right clamp working and undamaged
17 Left clamp working and undamaged
18 Lubrication completed as per Usage & Maintenance Manual
19 Gear case hydraulic oil levels checked and adequate
20 Remove the excess grease
21 Ropes are correctly positioned on the winches and pulleys
22 Slings, spreader and pulleys are correctly positioned
23 Any visible leaks or oil seepage

Daily Inspection Checklist
Work order: 14 01
Serial n°: 14 01 OHC005/1-SLAVE
Page n° 2/1
22 Any warning lights indicated on the electrical panel
23
24
25
26
27
32
33
Other observations/comments:
SITE CONSIDERATION
1 Good visibility / clear weather?
3 Is Area adequately delineated?
4 Any other work in the vicinity?
Other observations/comments:
Were there any conditions, which required the machine to be shut down? Yes No. If Yes,
explain below
IMPORTANT: If the answer is “NEG” to any of the above inspection items, shut down the
manipulator lock out the equipment, and seek assistance from theManipulator Supervisor
Date of examination (yy/mm/dd):
Shift: Day Afternoon Night
Name:
Signature:
E.OHC005.04A.00
- Connect the connector as shown in the following picture;
Connector on the master machine:
PLUG
Pic.4-4
Connector on the slave machine:
PLUGS
Pic.4-5
4.7
E.OHC005.04A.00
- Turn the main switch to connect the supply electrical network;
0: Switched off
I: Switched on
Pic.4-6
- Turn the line selector “0 --- LINE --- 1” clockwise (to “1”);
- Disconnect all the emergency push buttons (on wheels etc.);
- Swtich on the radio remote control pushing the START push button and keep it pushed for
enabling the commands. An acoustic alarm and the light “COMMANDS ON” will signal that
the commands are enabled.
4.4. Halt
To halt the machine adhere to the following procedure:
- Switch off the radio remote control pushing the emergency push button on it;
- Turn the line selector “0 --- LINE --- 1” to “0”.
- Turn the main switch to diconnect the supply electrical network;
4.8
E.OHC005.04A.00
4.5. Master/slave connection

The machine can work in single mode or in coupled mode with the other machine. During the
functioning in single mode, every machine is electrically and mechanically separated to each other,
in this way the operator controls one machine per time and all the emergencies and enable signals
work only on a machine.
When the machines are coupled, the machines are connected both electrically and mechanically,
the operator controls two machine per time and emergencies and enable signals work on both
machines. This means that the machines are defined: “MASTER” and “SLAVE”, the operator
controls the two machines from the “MASTER” one while the commands on “SLAVE” one will be
disable. When emergencies occur (emergency push button pushed etc,) or an enable signal is
missing both machines will stop and an alarm will show the system failure.
To connect mechanically the two machines, it is necessary to approach them and hook them by
the mechanical blocks as it is shown in the picture below.
Pic.4-7
4.9
E.OHC005.04A.00
The mechanical blocking is signaled to the system by a limit switch, it could be necessary to
approach the machines until the forward (for master) or backward (for slave) limit switch is set,
then the operator has to push the “BYPASS ANTICOLLISION” push button on the master radio
remote control and approach the master machine keeping it pushed.
IMPORTANT
The “BYPASS ANTICOLLISION” push button work only on the master radio remote
control, on the slave one, the push button have not any effect.
When the machines are mechanically connected, the operator has to connet the cable to create
the electrical connection between the two machines. The cable has to be connected between the
connector “CN115” and “CN215”:
- Disconnect the plugs;

- Connect the extensions;
Connector on the master machine:
CONNECT THE
EXTENSIONS
REMOVE THE
PLUGS Pic.4-8
4.10
E.OHC005.04A.00
Connector on the slave machine:
CONNECT THE
EXTENSIONS
REMOVE THE Pic.4-9

PLUGS
4.11
E.OHC005.04A.00
When both the connections have been carried out, the operator has to switch on the slave radio
remote control keeping pushed the “START” push button until it is possible to hear the acoustic
signal. Then it is necessary to select the coupled mode on the master radio remote control and
switch on the system as it has been described in section 4.2 only from the “MASTER” machine.
Pic.4-10
Summary:
To carry out the coupled mode, the operator has to:
- Approach the machines until the limit switches (forward limit switch for master machine or
backward limit switch for slave one) are set. When the machines are stopped, it is necessary to
push the “BYPASS ANTICOLLISION” push button on the master radio remote control and
approach the master machine to the slave one;
IMPORTANT
During the travelling movement with the “BYPASS ANTICOLLISION” push button
pushed, it is suggested to move the master slowly.
4.12
E.OHC005.04A.00
- When the machines are in right position, connect them mechanically by the mechanical blocks;
Pic.4-11
- Switch off the machines;

- Connect the machines electrically by the electrical cable;
- Switch on the slave radio remote control keeping pushed the START push button until the
operator hears the acoustic signal;
- Select the coupled mode on the master radio remote control and switch on the system.
To come back to the sigle mode, it is necessary:
- switch off the machines;

- disconnect the mechanical blocks;
- Disconnect the connectors of the extensions and connect the plugs as described above;
- Select the “SINGLE” mode on the master radio remote control.
IMPORTANT
When the machines are working in coupled mode, the “COUPLED/SINGLE” selector
will not have any effect.
During the coupled mode:
- The emergencies (emergency push button, etc.) stop all the machines;
- The operator controls the travelling of the overhead cranes, the travelling of the main trolleys
and the movements of the main hooks only from the “MASTER” one, the controls on the
“SLAVE” machine are disable;
- The movements of the auxiliary winches (80ton) and auxiliary hoists (10ton) are controlled
directly from the dedicated radio remote control;
4.13
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- If the travelling enable signal of the slave overhead crane is missing, the travelling master
overhead crane will be disable too and vice versa;
- The maximum backward limit switch stops the backward movements of all machines;
- The maximum forward limit switch stops the forward movements of all machines;
- If the lifting and descent enable signals of the slave overhead crane are missing, the lifting and
descent movements of master overhead crane will be disable too and vice versa;
- The maximum upper limit switch (main winch) on the “MASTER” overhead crane stops the
lifting movement of the “SLAVE” overhead crane too;
- The maximum upper limit switch (main winch) on the “SLAVE” overhead crane stops the lifting
movement of the “MASTER” overhead crane too;
- The maximum lowering limit switch (main winch) on the “MASTER” overhead crane stops the
descent movement of the “SLAVE” overhead crane too;
- The maximum lowering limit switch (main winch) on the “SLAVE” overhead crane stops the
descent movement of the “MASTER” overhead crane too;
- The maximum left limit switch (main trolley) on the “MASTER” overhead crane stops the
leftward movement of the “SLAVE” overhead crane too;
- The maximum left limit switch (main trolley) on the “SLAVE” overhead crane stops the leftward
movement of the “MASTER” overhead crane too;
- The maximum right limit switch (main trolley) on the “MASTER” overhead crane stops the
rightward movement of the “SLAVE” overhead crane too;
- The maximum right limit switch (main trolley) on the “SLAVE” overhead crane stops the
rightward movement of the “MASTER” overhead crane too.
If the slave radio remote control should damage during the coupled mode, it is possible to override
it by the “STOP BYPASS” selecto in the electrical board.
Pic.4-12
In this way it possible to complete the movements, obiouvsly the operator will not be able to control
the slave auxiliary winches and hoists.
4.14
E.OHC005.04A.00
IMPORTANT
REPAIR IMMEDIATELY THE DEVICES DAMAGE WITH ORIGINAL PARTS.
4.15
E.OHC005.05A.00
Functioning and use - 5
CHAPTER 5: FUNCTIONING AND USE
5.1. Scheduled and not scheduled use, agreed uses

The machine has been designed and fabricated solely to load prefabricated elements.
The number of daily operations and the maximum capacity are established during the contractual
stage. The machine should not be used with products other than those, which it has been built
with. The machine is in any case designed and built to ensure there are no risks to the operator as
long as the procedures described in this manual are respected.
It is recommended not to exceed the capacity or travel limits, because the machine can be
damaged and cause serious risks to persons and things.
In any event, of malfunction, breakdown, breakage etc., always refer to the present use and
maintenance manual before operating the machine and eventually to contact the Service
Department of CIMOLAI TECHNOLOGY spa.
WARNING: If usage does not conform to the one recommended CIMOLAI

TECHNOLOGY spa does not assume any responsibility for damages to the
machine, things or persons.
5.2. Information on safety

Compliance with the general and specific rules on security, provided in the workplace and in this
manual of use and maintenance, puts the operator in ideal conditions to work productively limiting
the risk of generating reasonably foreseeable dangers that may result in personal harm or to
others.
Before commencing work inside the plant, the operator should be made aware of the possible
danger related to the various areas of the plant depending on the activity (machine operation,
machine maintenance, dangers linked to type of material processed, etc. ..). The user must also be
aware of the function and location of all machine and operator safety devices provided in the
system.
5.2.1 General safety standards
Before analysing the possible risks specifically related to individual areas of plant operation and
relative safety measures to be taken, it is useful to provide a set of general guidelines on safety
standards to be adopted in order to limit the risks of accidents during normal work activities.
During standard work shift, all operators must typically:
- Closely observe the directions and instructions provided by the employer, by the safety
officer and by his representatives for the purpose of collective and individual safety;
- Accordingly and appropriately use all the personal protective equipment required in per-
forming the individual tasks machine operation and/or maintenance;
- Immediately report to the head of workplace security, to personnel in charge of safety and
to the employer the possible lack and/or inadequacy of the personal protective equipment
(PPE) as well as any potentially hazardous situations detected;
5.1
E.OHC005.05A.00
5 - Functioning and use
In case of emergency and as part of own personal skill set/ability, take all actions necessary to
eliminate, reduce or remedy any hazardous situation at hand.
All personnel on the workplace MUST ALWAYS:
- Keep the workplace in order: disorder and any tools used for standard maintenance may
generate risk and danger if not correctly stowed away;
- Dress accordingly: wear adequate protective apparel (standard compliant work coveralls)
that is not too loose and free of dangling parts that may tangle in moving parts. Sleeves
must be tightened around the wrists with an elastic. Do not wear rings, necklaces and
chains. Always and exclusively wear standard compliant safety footwear.. Long hair must
be tied with an elastic band and/or appropriately bundled;
- Avoid unstable positions pay close attention to your position, making sure that it is always
stable and safe with respect to the machine when performing tasks position and secure to
the machine (whether it is moving or stationary);
- Have any repairs and / or maintenance work performed by qualified personnel only:
Repairs and maintenance should be performed by qualified and trained personnel for the
purpose at hand, provided with appropriate personal protective equipment and using
original spare parts or those recommended by the manufacturer;
- Isolate sources of electrical and pneumatic supply to the machine before performing any
maintenance. Ordinary and extra-plan maintenance operations must be performed with the
machine stopped with all air and electrical supplies cut off. For this purpose, the main
power switch inside the control cab must be set in the "O" position and locked with a
padlock. The pneumatic system pressure must be relived via its shutoff valve and then
secured with padlock on the valve in the "closed" position;
- Check proper operation of the machine safety devices before the start of each work shift;
- Keep this use and maintenance manual: the manual, or a copy thereof, must be kept near
the machine so that the operator can refer to it when needed.
Employees on the workplace MUST NEVER:
- Remove, modify and/or by-pass devices safety and signalling devices applied to the ma-
chine without authorisation;
- Perform operations or actions not assigned to them that might jeopardize the security of
persons (personal or others) and the integrity of the machine;
- Climbing atop protections or over railings: It is absolutely forbidden to climb on the outer
parts of the safety railings of the stairs and walkways to move from one part of the ma-
chine. It is absolutely forbidden to climb on the moving parts of the machine (reclaimed
boom and/or conveyor belt) and fixed parts are not intended for the stationing of the
operators;
- Rest ladders, scaffolding and/or other equipment on the side of the machine structure;
- Introduce foreign objects into electrical parts. Do not put keys and tools of any inside the
covers of electric drives and inside moving parts of the machine;
- Power the machine tampering with the power switch and/or safety devices installed;
- Station on the wheel box sliding rails and/or leave the material unattended in their vicinity.
5.2
E.OHC005.05A.00
5.3. Perimeter accessibility and work emplacement

Save for the element to be handled, there is no part or accessory positioned on the ground that determine
a limit or hindrance to the access of the machine’s perimeter.
On the machine’s side, a space is to be left available to permit the passage of the personnel or of the
transport trolleys for the operation or maintenance of the machine.
Pic.5-1
WARNING: the control and the operation of the machine during normal working
conditions must happen only and solely from areas designated for this purpose.
These areas are without risk to the staff in charge of the operation and are marked as “COMMAND
AND OPERATOR CONTROL AREAS (see Pic.5-2).
Pic.5-2
5.3
E.OHC005.05A.00
5.4. Dangerous Areas

The dangerous parts of the machine are its front and its rear (because of its travelling) under the load.
When moving backwards, forwards or lowering the load, great attention must be paid as; there is
the risk of “crushing” for the operator.
WARNING: It is prohibited to enter the areas mentioned above with the machine in
operation.
WARNING: CRUSHING DANGER.
Pic.5-3
1
5.4
E.OHC005.05A.00
5.5. Risks, danger and avoidable risks

5.5.1. Residual risks
A residual risk is given by the movement of the pulleys when turning, by the ropes inside the
system, by the slings when being “tensioned” in the contact areas with the load and between hook
and sling in the event the operator during functioning involuntarily clutches onto them.
WARNING: The movement of the pulleys, the ropes and the slings can haul the
operator and provoke impact against parts of the machine.
Danger and avoidable risks
WARNING: Unavoidable Dangers and risks can occur, if the machine is not
correctly operated and these are:
5.5
E.OHC005.05A.00
DANGER CAUSE RISKS MEASURES THAT MUST BE

ADOPTED
Unloading parts of the Interference with persons, Always use the P.P.E., helmet
machine equipment, plant and/or fixed head protection.
structures. During unloading and loading
of parts of the machine the
drivers must from the
conducting cabin for the whole
of the duration of the work
Truck-cranes and forklifts Interference with persons, To use only lifting equipment
equipment, plant and/or fixed which has been approved and
structures. suitable plant for the harness.
Fall of the load and relative Mark off the area of work and
consequences: access to unauthorized
Overturning of the crane and/or personnel.
the forklifts an relative Provide appropriate signs.
consequences:
Run over, bruising or crushing of
persons, things, equipment,
structures during the lifting and
assembling operations
Suspended loads Interference with persons, No waiting near operations
equipment, plant and/or fixed with loads in suspense. Wait
structures. and pass outside of the
operations by the crane.
Provide suitable signs and
close off of the area
Work in hand Persons falling; material falling, The work in hand will be
collapse and breakdown, falling of carried out a platform or
particles and tools scaffolding developable for the
lifting of persons. The
personnel on the basket will
adapt to the latter by belt
safety
Assembly Abrasions, cuts, bruises to hands, Use the P.P.E (helmet, gloves,
fall of material from the air, run shoes with protection sole and
over, crushing of persons due to point in steel).
presence of lifted loads and
equipment in motion Keep working area orderly and
clear of superfluous material
Tightening of the screws Loss the grip of the keys, sliding Use the P.P.E (helmet, gloves,
of the same, their fall with risk of shoes with protection sole and
bruising and crushing of persons; point in steel).
damage to muscle or to joints
(arm, shoulders, wrists)
5.6
E.OHC005.05A.00

ADOPTED
Collapse of parts of the Run over, bruising or crushing of In the event of bracing being
structure during assembly persons (, things, equipment, necessary to provide an
phase when this is not yet structures) optimum dimension taking into
able to support itself and is consideration all the variables
not yet altogether solid reasonably procured. See to a
seal off the working area and
appropriate safety signs.
Use of truck-crane for the Fall down of the load during its During the lifting phases,
lifting of material; truck- lifting; run over, bruising or prohibit approach, waiting and
crane, mobile cranes, crushing of persons (or of things, the transit of persons not
ropes and service equipment or structures) during authorised on the works; if
harness, hook and chains the lifting operations and put in necessary display suitable
force of work barriers and adequate signs;
use the appropriate protection
device; prior to commencing
the works organise the working
areas and arrange for the
orderly layout of the materials
in order to enable their safe
movement and manoeuvres;
Guarantee the maximum
visibility of the amp of action of
the operator of the truck-crane,
in the event this is not feasible,
provide authorized persons for
ground signalling. It is useful in
some cases to also use,
preferably, closed circuit
distance methods of
communication; Always assure
the effective weight of the
indications of the constructor
Lifting Load falling during the lifting If for whatever reason the work
that is being done has to be
stopped, the load, the tools
and the job area must be left in
a safe state; if in the job area
there is more than one crane,
before starting to work, it is
necessary to arrange a
meeting in order to coordinate
the various operations; the
driver must be well trained on
the specific risks and on the
ways the machine must be
driven; during the operative
phase the driver must: ensure
the ground solidity and
stability; never exceed the
maximum load given by the
machine supplier; ensure that
5.7
E.OHC005.05A.00

ADOPTED
the job area is free; carry out
the lifting avoiding abrupt
and/or unexpected moves;
avoid to have the load swung;
never move sideways the
beams with the spreader.
5.8
E.OHC005.05A.00
5.5.2. Unavailable dangers and risk which can occur when the machine is working
ADOPTED
Burn and temperature Motors and exhaust pipes The motors are closed into
from hot elements contact protections to work inside of
which the operator must wear
mechanical gloves and
protective clothes.
Collisions and crushing Displacement group When the machine is moving,

the operator will be warned by
acoustic and visual alarms in
order to be able to operate at
safety distance. In case of
dangerous approach of the
machine, the operator can stop
it pushing the emergency
bottom placed in the nearest
wheels group.
Material falling from above People presence in the load area It is forbidden to stay near or
under the load hung; before
starting the operation, it is
necessary to check the chains,
the ropes and the slings’
perfect efficiency; sling the
load properly and ensure
about the real weight of the
load that has to be lifted.
Collisions with moving Machine doing displacement; It is forbidden to approach to
elements. working on the swung load. the machine on work unless it
is strictly necessary; in this
case the driver must be
warned and must stop the
machine; it is forbidden to work
on the swung load; it is
advisable to keep the cabin
glass clean in order to have
always a good vision of the
load and the route that needs
to be done; before slinging the
load it is necessary to put the
load perpendicular to the
spreader anchorage point;
before the lifting operation the
chain must be perpendicular to
the load.
People falling from the People on the spreader It is forbidden to carry or lift
spreader people on the spreader.
5.9
E.OHC005.05A.00

ADOPTED
Fall of the load Improper sling: the maximum It is necessary to sling properly
lifting capacity has been following the rules of the good
exceeded sling; to lift the load it is
necessary to use suitable and
approved devices; during the
lifting and deposit operation it
is necessary to verify that the
load is in a stable position in
order to avoid accidents due to
its fall; it is forbidden to knock
against any fixed load; it is
forbidden to exceed the
maximum lifting capacity.
Fall of material put on the Material on the load It is forbidden to put unfixed
load loads on the main load.
Crushing risk due to the Negligence from the crane driver When the load has to be put
load fall down, it is necessary to verify
that there are no operators
under the load itself; it is
forbidden to leave swung loads
without observation; it is
forbidden to stay under the
load; it is forbidden to pass
with the swung load above
people.
5.5.3. Risks of general type and due to dangerous combinations

The machine is constructed from complex parts, whose functioning can be managed from the cab
by an operator. They can command the starting, synchronisms, and regulations etc., of the
machine of the entire structure. Therefore, dangers could encountered, for example, on starting
and stopping unexpected.
5.10
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5.6. Safety warning signs
5.6.1 Safety warning signs in the work yard
To inform all staff working on the plant of the required conduct and of the residual risks present
regarding the machine, proper safety signs are applied in the workplace and on the machine as
required by Directive 92/58/EEC.
The evaluation of additional risk to safety and health carried out in the workplace and
on any other equipment used, allow the EMPLOYER to assess the need for further
warning signs in addition to those defined by CIMOLAI TECHNOLOGY SpA.
5.6.2 Safety sign list and description
CIMOLAI TECHNOLOGY SpA, upon assessment of residual risk zones on the machine and
identified rules of conduct that shall be disclosed to all staff involved, plans for the application
of warning signs (Compulsory, Prohibition and Danger) listed in the tables that follow.
Layout of the individual warning signs is shown in figure 5-4.
COMPULSORY WARNING SIGN

Ref. PICTOGRAM DESCRIPTION
A Wear protective footwear.
B Compulsory use of safety helmet.
C Compulsory use of safety glasses.
D Compulsory use of work gloves.
5.11
E.OHC005.05A.00
COMPULSORY WARNING SIGN

E See the use and maintenance manual.
F Padlock - (lock the Breaker in position “O”).
G Use safety straps and/or harnesses.
5.12
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PROHIBITION / DANGER SIGNS

Warning! Moving parts.

1
No lubrication or cleaning when moving.
2 Do not remove the protection and safety devices.
3 Access denied to unauthorized personnel.
4 Warning! Risk of crushing hands.
5 Warning! Risk of crushing.
6 Warning! Risk of tripping.
7 Warning! Risk of falling.
8 Warning! Pressurised oil.
9 Warning! General danger.
5.13
E.OHC005.05A.00

10 Warning! Cable reel maintenance.
11 Warning! Pressurised air.
12 Warning! Risk of side crushing.
13 Warning! Moving parts.
14 Warning! Danger - High voltage.
Warning! This machine is remote controlled, the operator is

15
unable see you.
Warning! Internal spinning gears risk crushing and cutting

16
your hands.
17 Warning! Risk of contact with scalding surfaces.
18 Warning! Risk of crushing feet.
5.14
E.OHC005.05A.00

19 Warning! Do not extinguish fires with water.
20 Do not climb and climb down from scaffold
21 Do not pass and stand under the crane
5.6.3 Layout of safety labels applied to the machine
The safety signs and labels listed in the tables above are applied to the machine during
installation.
Labels and the area of application shall nevertheless remain valid for all models of CIMOLAI
TECHNOLOGY SpA machines.
A suitable safety signs must be applied, by the customer, even on the outside walls of the
building in which the machine is installed.
WARNING: all safety signs on the machine and on the applied external protection
must be kept clean and in good condition. The customer is responsible for
providing timely replacement if for any reason these are damaged, lost or
unreadable.
5.15
E.OHC005.05A.00
5.7. Protection devices

WARNING: in order to safeguard their own and safety and that of others, all staff
in the vicinity of the machine and/or within the confines of the system in which
the machine is installed MUST always maintain appropriate behaviour and
coherent to the task requested, comply with the behavioural provisions issued
by the employer and properly use all safety devices (personal or specific to the
machine).
The following sections illustrate the various devices intended to safeguard the safety of the
operator when using the machine.
5.7.1. Personal protection equipment (P.P.E.)

The proper use of appropriate personal protective equipment is always an effective solution aimed
at containing the various potential risks, preventing this may result in damage to your health. To be
effective in their purpose of protection devices must:
• be worn correctly;
• be used and stored with care.
It is also a duty of the user to report to the employer any deficiencies or damage of the protective
equipment assigned. It is possible that the personal protective equipment, despite being built in an
ergonomic design, may create minor inconveniences or be poorly tolerated by the user; these
annoyances, generally only initial, are not comparable to any incident or damage to health that
may result from their lack of use.
With reference to Figure 5-4, the recommended personal protective equipment when working near
the machine is as follows:
1. Protective footwear;
2. Safety helmet;
3. Hearing protectors [plugs or headphones in environments with sound pressure level
detected is above 85 dB (A)];
4. Safety glasses;
5. Proper apparel;
6. Respiratory mask;
7. Safety gloves.
Pic.5-4
5.16
E.OHC005.05A.00
WARNING: these must be selected in relation to the work environment and material
handled.
WARNING: as the characteristics of the operator’s area of work are not known with ac-
curacy, please consult the Safety Manager of the plant where the machine is installed and
operating for selecting the type of personal protective equipment most suitable in relation
to effective risk.
5.7.2. Operator protection devices

The machine is provided with special safety electromechanically devices to protect the operator.
• Emergency buttons: the machine is equipped with emergency mushroom buttons on

electrical board, on the radio remote control and on the wheels in positions easily accessed
by the operators. The emergency button must be pressed when there are situations of
danger for the operators and/or plant. When pressed, it immediately shuts down all drives
of the machine by cutting power to the command circuits (auxiliary circuits). The machine is
placed in a state of emergency and the button remains in position until it is manually
pressed and reset.
• Warning lights and acoustic siren: the plant is equipped with warning lights and acoustic
sirens that emit light signals and sound alerts with each start-up before the machine
actually engages movement. The light and acoustics alerts warn all staff in the vicinity of
the imminent start-up, giving the time needed to move away from any dangerous areas.
The audio alert issued prior to the start of each cycle is controlled automatically by the
system and is repeated several times with the following sequence: siren activated for 2
seconds, siren pause of 0.5 seconds.
• Protection against electrocution: all electrical parts are made and designed in such a way
as to avoid any danger from electrocution. The minimum protection rating of junction boxes
and electrical devices installed on the machine is IP55.
All electrical equipment on the machine is breaker line of the electrical panel in accordance
with EN 60204-1.
• Local commands for drive maintenance: various electric drives, that control motion, are
intercepted by a system disconnected which cuts power.
The disconnect switch shall be used for engine maintenance and operations that require
opening fixed and mobile guards. The disconnector switch is connected in series to the
batteries.
5.17
E.OHC005.05A.00
5.7.3.Devices for the safety and reliability of the machine

To guarantee the security and the reliability of the machine, it is supplied with mechanical and
electrical devices in various points and with precise functions (Pic.5-5).
- Nr.1 Limit switch on lifting, applied to the winch of rope pull.
- Nr.2 load cells for controlling the overload (2), applied to the return pulley.
- Nr.11 Emergency push buttons (3), applied to the wheels, on electrical board, on the radio
remote control and on the left armrest.
Pic.5-5
5.18
E.OHC005.05A.00
5.8. Displacement of the machine

The machine is provided with eight travelling electrical motors each one connected to a gearbox.
By the rotation of the gearboxes, the wheels start to rotate on the rail and so the machine starts to
move according to the required direction. A frequency converter in the electrical board controls the
eight electrical motors, the controlling signal is sent from the travelling joystick installed in the
control cabin.
The travelling movement is defined into two limits: the first one is the maximum forward limit and
the other one is the maximum backward limit. Because of the two overhead cranes (“MASTER”
and “SLAVE”) travel on the same rail, the maximum forward position of the “MASTER” machine
and the maximum backward position of the “SLAVE” machine are dynamic positions, so the stop
position of each machine depends on the position of the other one.
Two limit switches positioned on the beam signal these two limits. When a limit position is reached,
only the opposite movement will be possible.
To displace the machine it is necessary to move the travelling joystick towards the direction label.
The control is proportional, so the operator can regulate the speed of the machine by operating on
the joystick, either pushing more to have a higher speed or less to have a lower speed.
Pic.5-6
WARNING: During the coupled mode, “SINGLE” mode on the radio remote control
does not have any effect.
5.19
E.OHC005.05A.00
5.9. Lifting/descent movements

The machine is provided with three winches: two winches move upward or downward the main
hook with a capacity up to 500ton while the third one is an auxiliary winch that moves a hook with
capacity up to 80ton.
Aux winch Main

winches
Hook 80ton Hook

500ton
Pic.5-7
A frequency converter provided with two electrical motors each one controls the main winches.
During the normal functioning of the system, the two winches rotate at the same time in opposite
directions; the frequency converters that guarantee the right electrical shaft manage the
synchronism.
The auxiliary winch is provided with an electrical motor controlled by a dedicated frequency
converter.
The lifting and descent movements are defined into two limits: the first one is the maximum upward
limit and the other one is the maximum downward limit. A geared limit switch positioned on every
winch signal these two limits. When a limit position is reached, only the opposite movement will be
possible.
In addition to limit switches limiting the maximum allowable upward / downward movement, there
are some limit switches determining that an upward extra-travel limit has been reached: these ones
stop the machine’s operation and lock all commands. The intervention of these safety devices
mean that a malfunction is occurring on the lifting system, therefore, to restart the whole system,
the operator must:
1. Bypass these safeties, by selecting exclusion using the key selectors “OVERTRAVEL
BYPASS MAIN WINCH 0 ---- 1” or “OVERTRAVEL BYPASS AUX WINCH 80ton 0 ---- 1”
which are positioned in the electrical board;
2. Re-enable the commands;
3. Perform the descent or lifting operation in according to the hook position, for at least 1-2
meters of spreader’s travel;
4. Re-enable the safety, de-inserting the key selector;
5. Perform the controls by lowering the spreader beam from the all-up position to the all-down
position, keeping a moderate speed and making sure that the limit switches work properly.
5.20
E.OHC005.05A.00
In addition to locking the whole machine, the intervention of the safeties will be signalized also by
the lighting up of the tell-tales “EMERGENCY ON” and “MAIN WINCHES EXTRATRAVEL” or
“AUX WINCH 80Ton EXTRATRAVEL” (depend on which is the faulty winch).
If necessary, it is possible to decouple the main winches and move only a winch per time; to carry
out the decoupled mode or maintenance mode, it is necessary to:
- Open the electrical board;

- Select the winch using the key selector;
Pic.5-8
5.21
E.OHC005.05A.00
The full movements are activated only if the thermal relays of electrical motor and the weighing
system are not set.
When the thermal relays are set, it will not be possible to move the hooks upward or downward,
the switching on of the dedicated light shows the system failure: “MAIN WINCH THERMAL
RELAYS” or “AUX WINCH 80Ton EXTRATRAVEL”.
If the weighing system is set, it will not be possible to move the hooks upward but only downward,
the switching on of the dedicated light shows the system failure: “OVERLOAD ON”.
In addition, an acoustic warning signals the alarms.
To move the winches it is necessary to move the lifting joysticks towards the direction label.
Pic.5-9
The control is proportional, so the operator can regulate the speed of the machine by operating on
the joystick, either pushing more to have a higher speed or less to have a lower speed.
5.22
E.OHC005.05A.00
5.10.1. Weighing system

Two weighing systems are installed on the machine: one is dedicated to the main winches while
the other one is dedicated to the auxiliary winch; these stop the lifting movements of winches if
they are overloaded.
In case of overload, the operator must:
- put the load on the ground or on suitable supports;

- check that the load does not exceed the machine maximum capacity;
- verify that the weight is well distributed in each lifting point, if the load is included in the capacity.
Ratings performed after the testing / commissioning and to be respected for the normal use of the
machine:
Limit threshold (main winch): 525 ton;

Limit threshold (auxiliary winch): 84 ton;
The set values already include about 5% margin in respect to the rated load, in order to allow for
operating with the max load without the continuous halt caused by the load’s oscillation.
Any alarm has been set with a delay filter open at 2 sec.
The light “OVERLOAD ON” switches on in cabin as well.
5.23
E.OHC005.05A.00
5.10. Main trolley movements

The machine is provided with four electrical motors each one connected to a gearbox.
By the rotation of the gearboxes, the wheels start to rotate and so the trolley starts to move in
according with the required direction. A frequency converter in the electrical board controls the
electrical motors, the controlling signal is sent from the lifting joystick in control cabin.
The trolley movements are defined into two limits: the first one is the maximum forward limit and
the other one is the maximum backward limit. A limit switch positioned on the beam signals these
two limits. When a limit position is reached, only the opposite movement will be possible.
To move the trolleys, the operator has to move the joysticks towards the direction labels, which
indicates the direction of the travelling (FORWARD/BACKWARD TROLLEY).
The control is proportional so the operator can regulate the speed of the machine operating on the
joystick either with greater intensity to have a higher speed or with less intensity to have a lower
speed.
Pic.5-10
5.24
E.OHC005.05A.00
5.11. Aux hoist

The machine is provided with an aux hoist. This hoist can travel along the upper transversal beam
and move upward or downward a load up to 10 Ton.
Every movement (lifting/descent and forward/backward) is defined into two limits: maximum
upward and downward limit and maximum forward/backward limit.
When a limit position is reached, only the opposite movement will be possible.
The movement is enabled only if the thermal relays of electrical motors and the weighing system
are not set.
When the thermal relays and/or the weighing system are set, it will not be possible to move the
hooks upward or downward and the hoist forward or backward, the switching on of the dedicated
light shows the system failure: “HOIST THERMAL RELAYS” and “OVERLOAD ON”.
In addition, an acoustic warning signals the alarms.
Pic.5-11
5.25
E.OHC005.05A.00
5.10.1. Weighing system

A weighing system is installed on the machine; this stops the lifting movements of winch if it is
overloaded.
In case of overload, the operator must:
- put the load on the ground or on suitable supports;

- check that the load does not exceed the machine maximum capacity;
- verify that the weight is well distributed in each lifting point, if the load is included in the capacity.
Ratings performed after the testing / commissioning and to be respected for the normal use of the
machine:
Limit threshold: 10.5 ton.
The set values already include about 5% margin in respect to the rated load, in order to allow for
operating with the max load without the continuous halt caused by the load’s oscillation.
Any alarm has been set with a delay filter open at 2 sec.
The light “OVERLOAD ON” switches on in cabin as well.
5.26
E.OHC005.06A.00
Regulations and substitutions - 6
CHAPTER 6: REGULATIONS AND SUBSTITUTIONS
6.1. General Warnings

WARNING: Before intervening on the machine, it is necessary to switch off and block the
electrical maintenance, position to OFF “O” the isolator of the electric panel controls. Besides, it
is important that the personnel in charge are familiar with the “General Safety Guidelines”
provided under chapter 1 of this manual.
The duties of regulation and substitution of machine parts described in the present chapter must be carried
out by QUALIFIED personnel.
During the regulation and substitution operations to carry out the isolation of the area surrounding the
machine. Do not permit persons unfamiliar with the works to approach the machine.
Any modification or substitution of the machine parts, not authorised by the constructor, and the use of
non-original replacement parts, in addition to voiding the guarantee, can compromise the correct
operation of the machine and represent a potential risk for accident and releive the constructor from
penal and civil responsabilities.
6.2. Substitution of the ropes

6.2.1. Development and put in force of new ropes (Pic.6-1)
The rope is manufactured by the fabricator wrapped round a coil or in a roll advisably supported, in
accordance with the diameter and length of the rope or the requirements of the Client. If the rope is
wound round a coil, in its opening there will be passed through a bar of suitable diameter and length and
the ends of the bar will rest on two frames; after which the head of the rope will be pulled, unwinding it,
making sure that the rope does not become loose on the coil. If the rope is made in a roll, it will be placed
on a reel and then it will be unwound pulling it by the external head, in order that the roll turns around on
its axis.
If the roll is of small dimensions, we can proceed to the unwinding keeping firmily on the ground the
external head of the rope and unwinding it by turning the roll kept vertically on the ground.
Wrong Correct
Pic.6-1
6.1
E.OHC005.06A.00
6 - Regulations and substitutions
6.2.2. Substitution of the ropes

Before the assembling of a new rope, it is necessary ascertaining that the rims of the pulleys and of the
drum have not been worn out and deformed by the passage of the old rope. In this case, it is necessary to
re-pass the rims re-establishing the correct profile.
Furthermore, it is very important to verify that the pulleys turn freely without excessive clearance and, if
the case, substitute the bearings and the bushing.
In the event of winding on the drum (fluted and not) and when the rope is wound on more layers
overlapping, the overcoil of the condition must be well tightened, keeping the rope at a minimum tension
during all the winding, in order to avoid overlapping of the rope and unusual behaviour of the machine.
If the old rope is used to haul the new in its course on the various pulleys of the machine, it is necessary to
avoid that accumulated anomalous torsions in the old rope, are transmitted to the new, causing irregular
internal torsions, which will compromise the life of the rope or will even cause flasking or spillage of the
core.
The heads of the two ropes should not be tied solidIy between them (for example with welding or with
clips) but interposing an element capable of absorbing the torsions (for example a piece of fibre cord tied to
the heads of the ropes with clips or hose of rope).
6.2.3. Tying of the fixed head
As a general rule it is necessary to remember that all the ropes, in order to offer the best performance and
durability, must work maintaining their constructive parameters unchanged.
Therefore, their extremeties must be connected to a fastener that prevents the spins due to the revolving
brace or induced by the system.
All the lifting equipment must have determined proportions in order to oppose the revolving brace of the
ropes used in order to keep in balance the system with the extremeties of the ropes blocked.
6.2.4. Adaptation of the ropes to the conditions of work
When a new rope is mounted on a system, this must be used for a brief period, after its installation, with
loads inferior to its normal work.
It is very important, every time a new rope is installed, to let it work for a short time (15-20 days) with
complete cycles of work, in order to concur the arrangement of all its elements and the adaptation to the
normal conditions of work.
After this period, the rope must be unwound from the drum and left free, to the aim of unloading the
internal tensions and torsions provoked during the phase of installation of the trial stage. Subsequently the
fixed head of the rope is refixed to the drum like originally.
By not following this procedure of trial the rope will be immediately subjected to excessive work which
could result in premature breakages or in any case a shorter life of the rope.
6.2
E.OHC005.07A.00
Ordinary and planned maintenance - 7
CHAPTER 7: ORDINARY AND PLANNED MAINTENANCE

7.1. Procedure of maintenance operations
WARNING: All operations of scheduled maintenance and repairs must be
performed by personnel properly trained and instructed to the task of Mechanical
and Electrical Maintenance.
IMPORTANT: Before doing any ordinary maintenance operation, it is necessary to

take the following precautions:
WARNING: The use of any unoriginal spare parts may compromise machine safety
and is, therefore, not allowed.
- Ensure the equipment is stopped and no load is suspended; ensure the supply network is in 0
position – supply network disconnected;
- Place the equipment in the most suitable area to avoid interferences with other machines or
with other operations in progress;
- It is strongly suggested to limit an appropriate area to avoid any damage caused by eventual
materials falling from above during the maintenance operations at a considerable height (for
example during maintenance of the trolleys);
- If it is necessary to operate with the equipment to make some checks, the operation must be
done under the direction of a supervisor who is qualified and responsible for the maintenance
intervention.
- If it is necessary to remove the safety devices in order to have the check operations done, it is
necessary to ensure, first of all, that all the safety measures are applied to have the minimum
risk;
- It is forbidden to operate with the electrical systems while they are fed by tension;
- It is forbidden to remove or disconnect any component which belongs to the hydraulic group
when it is under pressure;
- It is always necessary to wear all the individual safety devices during the maintenance
operations;
- During the maintenance operation it is strongly suggested that the staff puts the appropriate
sign “equipment not at work”;
- When the maintenance operation is completed, before having the machine at work again, it is
necessary to reinstall all the safety devices and remove all the tools used during the
maintenance. It is also necessary to remove the signs “equipment not at work” if they had been
used.
7.1
E.OHC005.07A.00
7 - Ordinary and planned maintenance
Upon completion of maintenance:

After performing maintenance, before returning the disconnector keys to the machine operator,
the maintenance technician must ensure that:
- any parts replaced and / or the tools used for maintenance have been removed from the
machine;
- fixed guards, any security devices (switches and/or sensors etc.), if removed during
maintenance, have been replaced properly and secured.
WARNING: It is absolutely forbidden to tamper with and remove safety devices. In

case of tampering and/or removal of such devices, the manufacturer declines all
responsibility for the safety of the machine.
7.2. Instruments required

The machine adjustment and disassembly operations can be carried out using standard tools that
are found on the market and commonly available to the company.
Any special equipment (if needed) is described and represented in a specific manner during the
removal and/or adjustment of those parts of machinery that require so.
7.3. Maintenance operations

The aim of this inspection is to guarantee the safety while the equipment is working. It is necessary
to check that the equipment structure, the installations and the devices are in full efficiency.
This preliminary stage of the maintenance consists of searching out any possible anomaly,
deterioration or damage of the equipment.
Only after this first inspection, the supervisor can have a general view on the equipment efficiency
and can define if the machine can keep on working because it is in a good status or if it needs an
intervention to sort possible problems out.
A correct and well done maintenance operation can prevent possible loss of power or breaks of
components fundamental to avoid any failure of the machine.
7.3.1. Maintenance
The maintenance includes:
CLEANING – CONTROL (INSPECTION) – SUBSTITUTION – REGULATION

Cleaning
A correct and adequate cleaning lengthens greatly the life of the machine. It is extremely important
that the (periodic) cleaning is effected in a complete and accurate way The machine should be
periodically cleaned externally and internally.
Replacement
At any time that a component of the machine develops a problem of use which could compromise
the correct functioning of the same machine, the component must be immediately substituted.
Adjustment
Some components of the machine (for example: electronic controls etc.) need to be adjusted
and/or calibrated.
IMPORTANT: In order to put into effect the regular maintenance operations, a

scheduled plan has been prepared.
7.2
E.OHC005.07A.00
OPERATIONS TO BE PERFORMED EVERY THREE MONTHS OR 500H:
PROGRAMMED MAINTENANCE FOR OHC

OPERATIONS TO BE PERFORMED EVERY THREE MONTHS OR 500H
PERFORMED
POS. DESCRIPTION NOTES
Positive Negative
A CHECKS ON THE MACHINE'S STEELWORKS
Verification of the overall status and conditions of the bolts of the steelwork's main
A.01
joints
A.02 Random checks of the tightening torque of the main bolts
A.03 Overall check of the steelworks main welds
A.04 Overall check of the status and condition of the paint
B TRAVELLING GROUP
B.01 Check of the motorized wheel box’s wear condition (visual check)
B.02 Check of the non-motorized wheel box’s wear condition
B.03 Check of the oil level for the lubrification of the gearboxes of the wheel boxes
B.04 Verification of the absence of oil leaks from gearboxes
B.05 Check coupling of motor and gearbox
B.06 Check of the tightening of the screws
B.07 Check the status of electric motors / brakes / electrical connection
C LIFTING GROUP
C.01 Check of status and wear condition of the lifting ropes
C.02 Check tightening of the ropes on the winch drums
C.03 Check spooling of the ropes on the winch drum
C.04 Check status of lifting ropes' return pulleys
C.05 Check greasing of the pins of the lifting ropes' return pulleys
C.06 Check oil level in the gearboxes of the lifting winches
C.07 Verification of tightening of the winch base securing screws
C.08 Check operation and setting of the limit switches of the lifting winches
7.3
E.OHC005.07A.00

PERFORMED
Positive Negative
C.09 Verification of status of the accessories for load etching (shackles, slings, etc.)
C.10 Verification of status of the hook
C.11 Verification of status of the weighing system (calibration, damage etc.)
C.12 Check rope's greasing
D TROLLEY
D.01 Verification of wear status of the trolley sliding shoes
D.02 Verification of the travelling wheels of the top trolleys
D.03 Greasing of the sliding mechanisms for the top trolleys
D.04 Check oil level in the gearboxes of the trolley traveling system
D.05 Verification of the limit switches
D.06 Check the status of electric motors, brakes, electrical connection
E ELECTRICAL INSTALLATION
Overall check of the status of the electrical board (verification of cleansing, water
E.01
infiltrations, wiring order and so on)
Verification of operation of the commands on electrical board and from control
E.02
cabin
E.03 Verification of operation of visual signaling devices during travelling movement
Verification of operation of the acoustic intermittent signaling device during

E.04
travelling movement
E.05 Verification of operation of the horn
E.06 Verification of operation of the emergency stop buttons
Check of tightening of the wire clamps in the electrical board and junction boxes
E.07
(random check – At least 30%)
E.08 Check of securing of components inside the electrical board
E.09 Overall check of the machine board circuits
E.10 Verification of functioning of geared limit switches and relative by-pass
E.11 Verification of functioning of work lights
7.4
E.OHC005.07A.00

PERFORMED
Positive Negative
Notes:
IMPORTANT: The programmed maintenance applies to all machines of the OHC 005 / 006 series.
INTERVENTION PERFORMED BY
DATE
MACHINE
SERIAL NUMBER
FABRICATION YEAR
WORK HOURS OF THE MACHINE
7.5
E.OHC005.07A.00
OPERATIONS TO BE PERFORMED EVERY SIX MONTHS OR 1000H:

OPERATIONS TO BE PERFORMED EVERY SIX MONTHS OR 1000H
PERFORMED
Positive Negative
A CHECKS ON THE MACHINE'S STEELWORKS
Verification of the overall status and conditions of the bolts of the steelwork's
A.01
main joints
A.02 Random checks of the tightening torque of the main bolts
A.03 Overall check of the steelworks main welds
A.04 Overall check of the status and condition of the paint
B TRAVELLING GROUP
B.01 Check of the motorized wheel box’s wear condition (visual check)
B.02 Check of the non-motorized wheel box’s wear condition
B.03 Check of the oil level for the lubrification of the gearboxes of the wheel boxes
Replacement of the travelling gearboxes oil (Operation to be only performed at a

B.04
planned expiry, see Chapter 8)
B.05 Verification of the absence of oil leaks from gearboxes
B.06 Check coupling of motor and gearbox
B.07 Check of the tightening of the screws
B.08 Check the status of electric motors / brakes / electrical connection
C LIFTING GROUP
C.01 Check of status and wear condition of the lifting ropes
C.02 Check tightening of the ropes on the winch drums
C.03 Check spooling of the ropes on the winch drum
C.04 Check status of lifting ropes' return pulleys
C.05 Check greasing of the pins of the lifting ropes' return pulleys
C.06 Check oil level in the gearboxes of the lifting winches
Replacement of the lifting gearboxes oil (Operation to be only performed at a

C.07
planned expiry, see Chapter 8)
7.6
E.OHC005.07A.00

PERFORMED
Positive Negative
C.08 Verification of tightening of the winch base securing screws
C.09 Check operation and setting of the limit switches of the lifting winches
C.10 Verification of status of the accessories for load etching (shackles, slings, etc.)
C.11 Verification of status of the hook
C.12 Verification of status of the weighing system (calibration, damage etc.)
C.13 Check rope's greasing
D TROLLEY
D.01 Verification of wear status of the trolley sliding shoes
D.02 Verification of the travelling wheels of the top trolleys
D.03 Greasing of the sliding mechanisms for the top trolleys
D.04 Check oil level in the gearboxes of the trolley traveling system
Replacement of the trolley travelling gearboxes oil (Operation to be only

D.05
performed at a planned expiry, see Chapter 8)
D.06 Verification of the limit switches
Check the status of electric motors, brakes, electrical connection (brakes wear,
D.07
water presence etc.)
E ELECTRICAL INSTALLATION
Overall check of the status of the electrical board (verification of cleansing, water
E.01
infiltrations, wiring order and so on)
Verification of operation of the commands on electrical board and from control
E.02
cabin
E.03 Verification of operation of visual signaling devices during travelling movement
Verification of operation of the acoustic intermittent signaling device during

E.04
travelling movement
E.05 Verification of operation of the horn
E.06 Verification of operation of the emergency stop buttons
Check of tightening of the wire clamps in the electrical board and junction boxes
E.07
(random check – At least 30%)
E.08 Check of securing of components inside the electrical board
7.7
E.OHC005.07A.00

PERFORMED
Positive Negative
E.09 Overall check of the machine board circuits
E.10 Verification of functioning of geared limit switches and relative by-pass
E.11 Verification of functioning of work lights
Notes:
IMPORTANT: The programmed maintenance applies to all machines of the OHC 005 / 006 series .
INTERVENTION PERFORMED BY
DATE
MACHINE
SERIAL NUMBER
FABRICATION YEAR
WORK HOURS OF THE MACHINE
7.8
E.OHC005.08A.00
Instructions for machine lubrication - 8
CHAPTER 8: INSTRUCTION FOR MACHINE LUBRICATION

Forward
This chapter illustrates and describes the rules and procedure when lubricating a machine.
The lubrication of machines methodically executed, is a key factor to achieve a longer-lasting
operation under the best conditions, the highest yield and the best conditions of safety.
To that end, a lubrication schedule has been established. The warranty on the machine has value
only if the customer is in full compliance with the rules of lubrication specified in this chapter.
WARNING: In case where the machines supplied was not immediately installed,
you must execute a temporary lubrication, as shown more specifically in the
section "LUBRICATION IN CASE OF PROLONGED STOPPAGE" in this chapter.
8.1. Lubrication process

All operations of lubrication must be carried out by experienced and qualified personnel All
maintenance must act in full compliance with safety regulations and must follow the instructions in
Chapter 1, "Introduction - General Information."
WARNING: Before performing any lubrication and / or maintenance, you must

disconnect the power supply to the machine, placing the disconnector in OFF "O"
located on the electrical control panel and secure it with a padlock.
The Chief Maintenance Officer who assumes responsibility must keep the key to the lock.
When disconnecting the control panel, apply a sign reading:
WARNING! MACHINE MAINTENANCE IN PROGRESS
WARNING: Only the Chief Maintenance Technician upon completion of

maintenance, who is required to perform all preliminary checks, must start up the
machine.
8.1.1. Lubrication during machine installation

Oil bath lubrication
All mechanisms in oil bath are supplied without lubricants.
The customer must procure the lubricant to fill the bath up to its proper level, using the amounts
and types indicated for each machine in the relative table.
Grease lubrication
All mechanisms in that are greased are supplied with lubricants.
CIMOLAI TECHNOLOGY SpA shall perform their lubrication using the recommended brands and
types of lubricant that are listed in the relative table for each machine.
WARNING: when restoring the lubricant never mix different types regardless if they
are of the same brand or not. Never mix mineral and synthetic oils. The same
advice goes for grease.
8.1
E.OHC005.08A.00
8-Instructions for the lubrication of the machine
8.1.2. Lubrication during prolonged stoppage

Machine stoppage prior to start-up
If the machine is expect to be commissioned only after 60 days upon arrival at the Customer, it is
necessary to top up (up to the filler cap) all the mechanisms to be lubricated in an oil bath, with the
exception of "PERMANENTLY LUBRICATED".
If the machine is put into operation within 12 months from topping up, simply return the oil to the
level defined for each mechanism and grease all parts lubricated with grease. If the machine is put
into operation after 12 months of topping up, replace all the oil after cleaning internal mechanisms,
and grease all the mechanisms lubricated with grease.
Machine stoppage after a production cycle

If after a production cycle the machine is expected to be stopped for over 90 days, you must top up
(up to the filler cap) all the mechanisms lubricated in an oil bath with the exception of
"PERMANENTLY LUBRICATED PARTS".
The lubricant used for each mechanism must be of the same type and brand contained in the
machine. At the commissioning of the machine, you must change the oil of every mechanism and
grease all grease lubricated mechanisms, even if they have not reached the number of hours
indicated in the lubrication table
8.1.3. Oil change and internal reduction gear clean

The oil change must be done respecting the time intervals indicated in the lubrication table.
However, you should change the oil at least once a year unless otherwise indicated
in the table.
Reduction gears, and more generally all the mechanisms with lubrication oil, must be completely
emptied and thoroughly cleaned at each change of the lubricant.
Accumulated grime is composed of a mixture of dust, metal chips and tar products, the latter by the
deterioration of the oil.
It is essential to remove the filth entirely since the abrasive particles quickly lead to wear of gear
teeth, and the oxidation products would act as a catalyst for accelerating ageing of the new oil.
Flushes require the use of special oils provided by the manufacturers (e.g. SHELL - VITRES OIL
32 or corresponding other brands) making the mechanism rotation without load for 3-4 minutes. At
the end of the operation, fully drain the lubricant and perform a second wash with a small amount
of lubricant required for the mechanism.
8.1.4. Oil change for planetary reduction gear

When introducing the oil in planetary reduction gears is necessary to remove a level plug located
at the axle of the reduction gear and in the point farthest from the load.
This operation is necessary to vent the area and perform a visual inspection of the oil filled in the
reduction gear.
The amount of oil to use is shown in the lubrication table. After the operation has been carried
out, let the reduction gear spin several times, acting on the pulley and check that the oil level
remains constant.
8.1.5. Oil filtering

When topping up and/or changing oil use a 200/300 micron mesh filter to filter it.
8.2
E.OHC005.08A.00
8.1.6. Scheduled oil level check

Check oil level in the reduction gears and tanks periodically.
If, during the oil top-up to the level, you need to add more than 20% of the amount planned for the
entire replacement, we recommend that you check for any leaks in the mechanism and providing
for their elimination.
8.1.7. Permanently lubricated reduction gears

Gearboxes, and more generally all the mechanisms indicated in the summary table of lubrication
with the words "PERMANENTLY LUBRICATED" do not require periodic lubrication as they are
lubricated with a special lubricant for their life cycle.
However, damaged or serviced parts require thorough internal cleaning and top-up with type and
quantity of lubricant indicated in the lubrication table.
8.1.8. Disposal of waste oil

Waste oil and objects impregnated with oil, grease and solvents if any, used for lubrication
operations, must be disposed of through the appropriate collection points within the law in terms of
the environment in force in the country in which the machines are installed.
WARNING: do not pollute the environment with waste oil, grease, solvents or other
liquid pollutants.
8.3
E.OHC005.08A.00
8.2. Machine lubrication
8.2.1. Symbol used in the lubrication table

The lubrication summary table uses a specific symbology to offer quick, clear and intuitive
descriptions of type of actions to be performed for the proper lubrication of the individual
components.
List and explanation of symbols used in the summary lubrication table.
Top up
Greasing with pump
Change and top-up
Drip lubrication Manual greasing
No scheduled lubrication,
Oil level visual check component already
permanently greased
8.2.2. Lubrication table

The lubrication operations to perform on the machine are summarised in the table below.
WARNING: The operations of lubrication must be carried out. For more information
consulting the manuals of the components that are in attached documents.
LUBRICATION TABLE
LUBRICANT TYPE
ITEM
COMPONENT TYPE OF
or UNIT ** GREASE or Q.ty Frequency
TYPE ACTION
OIL
Travelling AGIP BLASIA

1 OIL As needed see attached manual
gearboxes 220
Winches AGIP BLASIA

2 OIL As needed see attached manual
gearboxes 220
6 Months
Bearings and TOTAL
3 GREASE 25 kg or
mechanisms CERAN ST2
500 hours
VITALIFE WIRE 6 Months
4 Ropes GREASE ROPE LUBRICANT As needed or
or BILUBRO AERO
500 hours
8.4
E.OHC005.08A.00
LUBRICATION TABLE
LUBRICANT TYPE
ITEM
COMPONENT TYPE OF
or UNIT ** GREASE or Q.ty Frequency
TYPE ACTION
OIL
Electrical
5 – – – – –
hoist*
Note:
IMPORTANT: The lubrication operations apply to all machines of the OHC 005 / 006 series.
* : see Paragraph 8.5 for the lubrication of the electrical hoist.
** : WARNING: The lubrication operations shown in the tables and drawings of this chapter
must be applied to ALL the grease nipples, wire ropes and gearboxes on the machine.
WARNING: If lubricants with the same characteristics as those recommended are

unavailable, we recommend you consult the Cimolai Technology SpA Customer
Assistance Services, indicating the brand, type and characteristics of the oils that
you intend to use, to allow us to verify compatibility.
8.2.3. Identification of machine lubrication points

Figures on the following paragraph identify the lubrication points described in the above table
“LUBRICATION TABLE”.
WARNING: To simplify the drawings of Paragraph 8.3 the guidelines only show the
main lubrication points of each element.
8.5
E.OHC005.08A.00
8.3. Lubrication points
8.6
E.OHC005.08A.00
8.4. Characteristics and adherence lubricants

Table of the characteristics and adherence of the oils
RECOMMENDED BY CIMOLAI TECHNOLOGY:
Oil for gearboxes:
Oli minerali
Produttore Mineral oils
Manufacturer Mineralöle
Hersteller Huiles minerals
Marque Aceites minerales
Fabricante Óleos minerais
Produtor
ISO VG 220
AGIP BLASIA 220
BP ENERGOL GR-XP 220
CASTROL ALPHA SP220
CHEVRON ULTRA GEAR 220
ESSO SPARTAN EP 220
KLÜBER KLÜBEROIL GEM 1-220
MOBIL MOBILGEAR XMP 220
MOLIKOTE L-0122
OMV GEAR HST220
Q8 GOYA 220
SHELL OMALA 220
TAMOIL CARTER EP LUBRICANT 220
TEXACO MEROPA 220
TOTAL CARTER EP 220
Table of the characterists and of adherence of the grease
Grease for bearings and mechanisms: TOTAL CERAN ST2

Grease for ropes: VITALIFE WIRE ROPE LUBRICANT or BILUBRO
AERO
8.7
E.OHC005.08A.00
8.5. Electrical hoist lubrication

The following instructions are extracts of the electrical hoist manual.
8.8
E.OHC005.08A.00
8.9
E.OHC005.08A.00
8.10
E.OHC005.09A.00
Diagnosis - 9
CHAPTER 9: DIAGNOSTICS
9.1. Problem - Cause - Remedy

Preface
In the following table are reported the conditions of non functioning not displayed on the operator
panel, reasonably anticipated, relative to the single operative functions of the machine .
For every type of difficulty the possible causes are reported and the relative activities which the
operator must carry out in order to reinstate operative function.
PROBLEM CAUSE SOLUTION

LIFTING/DESCENT MOVEMENT
The machine does not carry out Lifting limit switch intervened Check the limit switch is not
the lifting movement damaged, in case replace the
component.
Check the functioning of the Replace the damaged parts
remote control
Protection of one or more than Re-enable the motor/motors

one motor intervened protections. In case of
persistent problem, check the
correct motor absorption and
possibly replace it/them.
Protection of one or more than Re-enable the brake/ brakes
one brake motor intervened motor protections. In case of
correct brake/ brakes motor
absorption and possibly
replace it/them.
Inverter breakdown Replace the inverter
Winch Encoder breakdown Replace the encoder
The machine does not carry out Descent limit switch intervened Check the limit switch is not
the descent movement damaged, in case replace the
component.
Check the functioning of the Replace the damaged parts
remote control

replace it/them.
The machine does not carry Inverter breakdown Replace the inverter
out the descent movement Winch Encoder breakdown Replace the encoder
9.1
E.OHC005.09A.00
9 - Diagnosis
STARTING UP
The machine is completely The general disconnector is not Insert the general
turned off inserted disconnector
The fuses of the line and/or Replace the damaged fuses
gear circuit are damaged
The remote control does not Verify the battery is charged
switched on and possibly replace it.
The remote control cannot shift Verify the receicer is turned on
into gear and possibly check the
protection fuse.
The line cannot be inserted The line fuse is damaged Replace the fuse
The key selector is damaged Replace the key selector
The gear cannot be inserted The emergency control unit Replace the emergency
does not work control unit
Emergency button pressed Disconnect the emergency
button
The gear meter is damaged Replace the gear meter
Check the remote control Check the feeding fuse and
receiver is fed. replace it if damaged.
Winch extra run limit switches Check the correct limit switch
intervened. calibration and verify any
possible anomaly in the winch
movement.
DISPLACEMENT
The machine does not carry The remote control does not Verify the battery is charged
out any displacement work and possibly replace it.
Verify the receicer is turned on
and possibly check the
protection fuse.
The motor brake keeps staying Check the inverter is switched
inserted on and with no alarms. Check
the brake unblock signal is
sent from the inverter to the
general meter.
replace it/them.
Limit switches damages Check the limit switched and
replace them if damaged.
9.2
E.OHC005.10A.00
Extraordinary maintenance - 10
CHAPTER 10: EXTRAORDINARY MAINTENANCE
10.1. Extraordinary Maintenance

Preface
By extraordinary maintenance we refer to the operation which is carried out after approx. 6 months,
1 year, and over, of activity by the machine, or else as required by unforeseen circumstances.
IMPORTANT: before doing any ordinary maintenance operation, it is necessary to take the
following precautions:
- Ensure the equipment is stopped and does not have any hung load; ensure the insertion
selector is in 0 position - disconnected gear;
- Place the equipment in the most suitable area to avoid interferences with other machines or
with other operations in progress;
- It is strongly suggested to limit an appropriate area to avoid any damage caused by

eventual materials falling from above during the maintenance operations at a considerable
height (for example during maintenance of the trolleys hydraulic motor).
- If it is necessary to operate with the equipment to make some checks, the operation must
be done under the direction of a supervisor who is qualified and responsible for the
maintenance intervention.
- If it is necessary to remove the safety devices in order to have the check operations done, it
is necessary to ensure, first of all, that all the safety measures are applied to have the
minimum risk;
- It is forbidden to operate with the electrical systems while they are fed by tension;
- It is forbidden to remove or disconnect any component which belongs to the hydraulic

group when it is under pressure;
- It is always necessary to wear all the individual safety devices during the maintenance
operations;
- During the maintenance operation it is strongly suggested that the staff puts the
appropriate sign “equipment not at work” (for example in the power unit);
- When the maintenance operation is finished, before having the machine at work again, it is
necessary to reinstall all the safety devices and remove all the tools used during the
maintenance. It is also necessary to remove the signs “equipment not at work” if they had
been used.
10.1
E.OHC005.10A.00
10 - Extraordinary maintenance
10.2. Verification of the ropes

10.2.1. Criteria of verification and substitution of the ropes
With reference to norm ISO 4309, the safety of exercise of a rope is guaranteed in particular by the
correct valuation of the following:
- number of breakages and their position

- use of wire
- internal and external corrosion
- damage and deterioration of the rope
10.2.2. Breakage of the wires

The broken wires of the rope externally visible must be counted, in the stretch most worn. Such a
stretch must have a length equal to 6-30 times the diameter of the rope. If the rope seems to have
broken wires, the rope itself must be replaced.
10.2.3. Usage of wires

To replace the rope, in addition to the broken wires, it is necessary to bear in mind that the levelling
of the wires for usage leads to their breakage over a short period. In the presence of a worn rope,
the interval between a verification and another in the counting of the broken wires must therefore
be reduced and are considered as similar those, which have undergone a reduction in diameter,
appraised on sight, of 50% inferior to the original.
10.2.4. Corrosion
The external corrosion produces a reduction of the diameter of the wires. Therefore, the rule of the
previous paragraph prevails, but applied in this case, with very prudent criteria, corrosion being a
more serious deterioration than non-wear. The assessment of the internal corrosion requires a lot
of practice. The rope can be opened with clamps advancing with care to the de-torsioning.
10.2.5. Damage and deterioration of the rope (in accordance with ISO 4309)
In addition to the assessments made previously it will have to proceed to the replacement of the
rope when:
- the diameter of the rope, even in one point only, results reduced (6-7% in respect to the
normal diameter of the rope)
- The rope has permanent crushing, torsions or bending
- the web protrudes from the rope even in a single point
The rope, even though in traction, develops one or more loosened or protruding strands.
10.2
E.OHC005.10A.00
Pic.10-1.Breakage and moving of the wires on two adjacent strands in a rope of crossed coil type.
Such condition requires its replacement.
Pic.10-1
Pic.10-2. Major usage and notable number of broken wires, in a rope of crossed coil type. Such
condition requires immediate replacement.
Pic.10-2
Pic.10-3. Broken wires on the same strand, working lightly together, in a rope of parallel coil type.
Such condition requires the removal of the broken wires, until the extremity is level with the
external profile of the rope
Pic.10-3
10.3
E.OHC005.10A.00
Pic.10-4. Broken wires in numerous strands, near a departure pulley (and at the same time hidden
by this pulley) . Such condition requires replacement.
Pic.10-4
Pic.10-5.Broken wires in two strands, for fatigue or flexion, associated to major localized use. Such
condition requires replacement.
Pic.10-5
Pic.10-6.Deformity of basket (nest) type of a multi-strands rope (anti-spin type), caused by a spin
forced because of too tight hooks or angle of excessive deviation. Such condition requires
immediate replacement.
Pic.10- 6
10.4
E.OHC005.10A.00
Pic.10-7.The expulsion of the metallic web generally associated to a deformity of basket type. Such
condition requires immediate replacement.
Pic.10-7
Pic.10-8.Only one strand is affected from expulsion of wires, even though the examination of a
stretch of rope demonstrates that the deformity is visible at regular intervals, normally equal to
stages of coiling. It is necessary to keep such defect under control.
Pic.10- 8
Pic.10-9.Deterioration of the previous defect with expulsion of the internal wires of the strands.
Major defect localised due to the application of push button loads. Such condition requires
immediate replacement.
Pic.10- 9
10.5
E.OHC005.10A.00
Pic.10-10.Localised increase of a rope of parallel winding type, determined by distorsion of the

metallic web, deriving from a sudden load. There are noted also traces of corrosion and major use
of the external wires. Such condition commands immediate replacement.
Pic.10-10
Pic.10-11.Localised increment of the diameter of the rope, due to the protruding textile web, in the
area between the external strands. Such condition requires replacement of the rope
Pic.10-11
Pic.10-12.Major twisting with the winding contorted which causes the protruding of the textile web.
Such condition requires immediate replacement.
Pic.10-12
10.6
E.OHC005.10A.00
Pic -10-13.Metallic rope which has been contorted during installation, but nevertheless put into
operation and now subject to localised wearing and loosening of the threads. Such condition
requires replacement.
Pic.10-13
Pic.10-14.Localised decrease of the diameter of the rope, since the external threads tend to
occupy the place of the textile web, which is destroyed. Such condition requires the immediate
replacement.
Pic.10-14
Pic.10-15.Flattened area, caused by localised crushing for mechanical action, which provokes
imbalance in the strands. Concurrent presence of broken wires. Such condition requires
replacement.
Pic.10-15
10.7
E.OHC005.10A.00
Pic.10-16.Flattened area of a multi-strand rope for mechanical action on a long stretch, caused by
incorrect unwinding from a drum. To note the increase of pace when winding the external strands,
with imbalance of tension under condition of load. Such condition requires its replacement.
Pic.10-16
Pic.10-17.Example of major bending. Such conditions requires replacement.
Pic.10-17
Pic.10-18.Typical example of a rope which has protruded from the groove of a pulley and is stuck.
If a flattening deformity results, with localised wear and lots of broken wires, such condition
requires immediate replacement.
Pic.10-18
10.8
E.OHC005.10A.00
Pic.10-19.Accumulative effects of more than one factor of deterioration. To note in particular the
major wear of the external wires, which provokes a loosening of the wires such as to cause a
basket type deformity with danger of protruding of the pulley. There are present also lots of broken
wires. Such condition requires immediate replacement.
Pic.10-19
1. Pic.10-20.Light flattening of external wires. Slight reduction of the diameter of the rope.
2. Pic.10-20.Continuous flattening; the metallic wires which begin to loosen, with a

assessable reduction of their diameter equal to circa 40%
Pic.10- 20
1. Pic.10-21.Start of superficial oxidation.

2. Pic.10-21.Heavily punctured surface and wires completely loosened. Major reduction of the
diameter, with game between the wires equal to more than half of their diameter.
Immediate replacement
Pic.10- 21
10.9
E.OHC005.10A.00
Pic.10-22.Example of major internal corrosion. It is in evidence the reduction of the area of many
external wires in the strands, in the contact area with the web, high volume of compression, the
lack of space between the strands and the consequent reduction of the diameter of the rope. Such
condition requires the immediate replacement
Pic.10-22
Pic.10-23.The propeller type distortion is a deformity in which the longitudinal axis of the
rope assumes the form of a propeller. Such condition requires a continuous inspection of the rope.
In the event of prolonged use, wearing and breakage of the wires can develop. If the deformity
exceeds the value indicated in, the rope must be substituted
Pic.10- 23
10.10
E.OHC005.10A.00
10.3. Criteria for verification of the ropes

The safety of exercise of the rope is guaranteed by the correct valuation of some parameters.
These are:
- number of breakages of the rope and their position

- state of wear of the wires
- corrosion
- damage and deterioration of the same rope.
10.3.1. Breakage of the wires

The broken wires visible externally of the rope must be counted, in the piece mostly worn out. Such
piece must be equal in length to 6-30 times the diameter of the rope. If the rope has any broken
wires, it is necessary to proceed to the replacement of the rope.
10.3.2. Wear out of the wires

The ultimate flattening of the wires for use preannounces their breakage over a short time.
Therefore, in the presence of worn out rope the interval of checking up time must be reduced and
to proceed if necessary to the replacement of the rope.
10.3.3. Corrosion
Any ultimate corrosion of the wires provokes the reduction of the diameter of the same wires with
consequent deterioration of the rope. Therefore, in the present of a worn out due to corrosion the
interval of checking up time must be reduced and to proceed, if necessary, to the replacement of
the rope.
10.3.4. Damage and deterioration of the rope

In addition to the assessments made previously it is necessary to proceed to the replacement of
the rope when:
- the diameter of the rope, even in one point only, results reduced (6-7% in respect to the
normal diameter of the rope)
- the rope looks crushed, has torsions or permanent folds.
- the web protrudes from the rope even only in one point
the rope, although in traction, seems to have one or more loose or protruding strands.
10.11
E.OHC005.10A.00
10.3.5. Verification points
Pic.10-24
10.3.6. Position 1: Drum
- check the tying up point of the drum
- check any defective winding on the drum
- identify breakages of wires
- check for corrosion
- identify deformities due to the load
10.3.7. Position 2: Fixed Pulleys

- check the piece of rope which winds round pulleys to reveal any breakage and wearing
of wires
10.3.8. Position 3: Mobile Pulleys

- look for breakage of the wires and artificial wear
- examine the corrosion
- carefully examine the piece which winds onto the pulleys and particularly the piece
which is on the pulley when the apparatus is under load
10.3.9. Position 4: Tie up point

- check the breakage of the wires
- identify the deformities
- check the diameter of the rope
10.4. Rope maintenance

After the installation of the rope it is necessary to check its state, every 12 working hours, for the
first 15 days. If during this verification the rope presents some deformities at its ends, it is
necessary to disconnect the cable-fix and vent the rope reinstating the correct winding.
10.12
E.OHC005.11A.002
Decommissioning, demolition and disposal - 11
CHAPTER 11: DECOMMISSIONING, DEMOLITION AND DISPOSAL
11.1. Decommissioning
"Decommissioning" implies all operations carried out in order to put the machine and / or system
under conditions of maximum security for an indefinite period.
Therefore, the customer is urged to perform the following:
- Stop the reclaimer with the hooks fully lowered and resting on the ground;
- Disconnect the system from the mains power supply.
WARNING! Assign disconnection operations from the main electrical power box to expert
and qualified personnel. Consult a technician of the electrical energy supplier if needed,
which can isolate power to the plant upstream.
- Drain, store and subsequently dispose of substances such as oils and grease contained in
the lubrication tanks (centralised lubrication units, reduction gears, drives, gearboxes,
etc...) as required by the legislation in force in the country of installation of machine
installation.
WARNING! Do not pollute the environment with waste oil, grease, solvents and/or other
Liquid pollutants.
- Deny access to areas prone to sever risk (falls, cuts, entrapment, etc...) to all personnel
and lock the entrance door to the plant.
Note: the machine in question does not require registration with public offices, so it is not
mandatory that the machine be accompanied by documents that have to be returned to the
institution responsible for surveillance.
11.2. Demolition and disposal
“Demolition and disposal” imply all operations performed to completely disassemble the machine
and clear the area of installation of all components.
IMPORTANT: Due to the size of the system, it is recommended to entrust the dismantling
demolition and disposal specialized companies and enable the demolition of large
systems, with suitable equipment.
11.1
E.OHC005.11A.00
11 - Decommissioning, demolition and disposal
The company responsible for the demolition of the machine will then have the task of:
- Performing the disassembly of the machine taking care to divide the materials, that com-
pose it according to their chemical nature (iron, aluminium, bronze, plastic, wood, etc. ...);
- covering the parts removed from the machine with insulating sheets in order to avoid
weather such as rain and moisture (if stored outdoors) from compromising the structures,
causing oxidation and rust that can infiltrate into the ground;
Pic.11-1
- Separating the disassembled machine parts according to the type of material of which they
are composed (e.g. Iron, plastic, copper, electrical and electronic components, etc...) and
then provide to their collection and differentiated disposal according to the laws in force in
the country of installation of the machine.
WARNING: should contractor requested to carry out demolition of the machine not deal
directly with the subsequent disposal of the removed component, contact specialised
companies and enable the collection and disposal of various types of materials
accumulated.
11.2

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CIMOLAI Technology spa

Serial N°: 14 01 OHC005/2-SLAVE

Compiled in compliance with:

Enclosure 1 - Paragraph 1.7.4 of the Regulations machines 2006/42/CE

The instruction manual is divided into chapters.

The manual herewith described is, in its frame, aimed at adequately

Any potential certification released by CIMOLAI Technology spa to

The chapters processed in the manual contain the specifications and

The present manual constitutes integrating part of the machine and

1.1. Introduction ..................................................................................................................... pag.1.1

2. DATA AND TECHNICAL CHARACTERISTICS

2.1. Dimensions and machine measures ................................................................................ pag.2.1

4. INSTRUCTIONS FOR THE OPERATOR

4.1. Electrical board ................................................................................................................ pag.4.1

4.5. Master/slave connection ................................................................................................. pag.4.9

5. FUNCTIONING AND USE

6. REGULATION AND SUBSTITUTIONS

6.1. General warnings ............................................................................................................. pag.6.1

7. ORDINARY AND PLANNED MAINTENANCE

7.1. Procedure of maintenance operations ............................................................................ pag.7.1

8. MACHINE LUBRICATION INSTRUCTIONS

8.1. Lubrication process .......................................................................................................... pag.8.1

9.1. Problem - Cause – Remedy .............................................................................................. pag.9.1

10. EXTRAORDINARY MAINTENANCE

10.1. Extraordinary maintenance ............................................................................................. pag.10.1

10.3. Criteria for verification of the ropes ................................................................................ pag.10.11

11. DECOMMISSIONING, DEMOLITION AND DISPOSAL

11.1. Decommissioning ............................................................................................................. pag.11.1

12. SPARE PARTS CATALOGUE

Introduction - General warnings - 1

CHAPTER1.: INTRODUCTION – GENERAL WARNINGS

- The instructions supplied are in accordance with such type of operations.

- Clarification regarding the documentation supplied.

To such scope we supply our address herewith:

CIMOLAI Technology spa

1 - Introduction - General warnings

1.2. General information on safety

Only explicitly authorised personnel must use the machine.

Introduction - General warnings - 1

1 - Introduction - General warnings

1.2.1 Manufacturer liability

1.2.2 Validity, contents and preservation of the manual

Introduction - General warnings - 1

1.2.3 Manufacturer's note

1.2.4 Compliance with the directives

1.3. Machine identification data

- the name and address of manufacturer

1 - Introduction - General warnings

Data and technical characteristics - 2

CHAPTER 2: DATA AND TECHNICAL CHARACTERISTICS

2 - Data and technical characteristics

2.2. Configuration of the machine

Type: OVERHEAD CRANE

External surface: Yellow RAL1028

- Store temperature -10°C 70°C

3.1. General prescriptions for the installation of the machine

- Supply a lighting system of the work area, minimum 150 lux.

3.2. Sub-division and movement of the packages

3.3. Acceptance and storing of the machine