ABG

CHAPTER

OPERATION

3.1

INTRODUCTION--REFER TO ELECTICAL MANUAL

3.2

SAFETY DEVICES AND EMERGENCY PROCEDURES

3.2.1
3.2.2
3.2.3
3.2.4

3.3

DOs and DONTs for CRANES

3.3.1
3.3.2

3.4

O&M Manual
Mechanical

DOs for CRANES

DONTs for CRANES

STEP BY STEP OPERATING INSTRUCTION

3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
3.4.10
3.4.11
3.4.12
3.4.13

3.5

WIND WARNING ALARM SYSTEM

LOAD RELATED ALARM SYSTEM
LOCATION OF EMERGENCY STOPS
CRANE STORAGE/ANCHORING

BEFORE START
BOOM LOWERING OPERATION
START UP OPERATORS CABIN
TROLLEY OPERATION
MAIN HOIST OPERATION
GANTRY OPERATION
BASIC CONTAINER HANDLING OPERATION
TRIM/LIST/SKEW OPERATION
SINGLE/TWIN 20 MODE OPERATION
BOOM RAISING OPERATION
SHUT DOWN
ELEVATOR
AUXILIARIES

TROUBLESHOOTING

ABG

3.1 INTRODUCTION

O&M Manual
Mechanical

ABG

3.2 SAFETY DEVICES AND EMERGENCY

PROCEDURES

O&M Manual
Mechanical

3.2.1

WIND WARNING ALARM SYSTEM

3.2.2

LOAD RELATED ALARM SYSTEM

3.2.3

LOCATION OF EMERGENCY STOPS

3.2.4

CRANE STORAGE/ANCHORING

ABG
3.2 SAFETY DEVICES AND EMERGENCY PROCEDURES
3.2.1

WIND WARNING ALARM SYSTEM

1) Warning Mode
If the wind speed is greater than 15 m/sec for a preset adjustable
time, initially set for 10 seconds, a High Wind Warning lamp(red)
begins to blink on the left hand console.
Operator shall prepare for crane shutdown. If need, move to the
storage area of dock and stowage pins shall be locked manually by
maintenance staff.
When the wind speed falls below the warning level the light stops
blinking.
2)

Shutdown Mode
Wind speed is greater than 14 m/sec for longer than a preset
adjustable time, initially set for 10 seconds, the High Wind Warning
lamp(red) is solid on the left hand and signal buzzer on right hand
console will begin to sound.
If the gantry motion is running under this condition, it is stopped
with a normal regenerative stop and the rail brakes are set 1 to 10
seconds(adjustable) after the gantry motor brakes are set. Gantry
motion is inhibited until the shutdown condition is removed.
High wind bypass Mode
During shutdown conditions gantry motion is permitted only while
the Gantry Bypass push-button(Black) on the left hand console is
depressed, and a gantry run is permitted. At this time the alarm will
be silenced but the High Wind Warning lamp(red) will continue to
light. After all rail brakes are released, operator can move the crane
to the storage area of dock and stowage pins shall be locked
manually by maintenance staff.
When driving into very strong gusts above 14 m/sec, move trolley
to parking position before gantry starts.

O&M Manual
Mechanical

ABG
3.2.2

LOAD RELATED ALARM SYSTEM

The pressure transducer detect load in the cylinders, located on girder
end, trim/list/skew assembly.
Net weight of load is displayed on load display in operators cab.
The system will detect the load under the spreader.
The activated warning signal or trip hoisting motion as shown below ;
1) Main hoist rope slack
When hoisting :
When the hoist rope load sensors indicate rope slack; the hoisting
speed shall be reduced to a predetermined level (25%). The speed
level can be adjusted.
After the hoist rope slack disappears, the main hoist reference shall
be released after a time delay (adjustable 0 to 5 seconds) and
allowed for full speed hoisting.
When lowering :
If rope slack is sensed, the main hoist shall be disabled from
lowering.
Bypass mode :
Lowering is possible with the Hoist Rope Slock Bypass push
button (red) of the left side console in operators cab to bypass the
main hoist slack rope protection interlock.
2) Snag load :
In case of snag event, the main hoist drive shall immediately
regenerate at current limit to stop while simultaneously setting the
brakes. Control power shall then be de-energized.
At the same time, snag protection device at girder end
automatically activates snag hydraulic cylinder to retract to absorb
snag energy.
On left side console, Snag Activated lamp (red) is blinking.

O&M Manual
Mechanical

ABG
In the snag mode, hoisting is not possible before reset but only
lowering of slow speed is permitted.
Operator shall immediately call mechanic by ussing paging system
for inspection and also inform to ground/ship crew.
The technician in charge should inspect all the components related
to snag load path. The following should be inspected before
resetting and resuming the operation.
* To find out the snag load path, check which side the snag
cylinders were retracted.
* Any damage or leakage of hydraulic components.
* Any damage of sheaves, pins, wire ropes of snag load path.
* Any damage of main hoist brake
* Any damage of main hoist drum shaft, bearing, pillow block.
* The damage of headblock (twistlock, sheaves, pins ) and
spreader should be checked after lowering them to ground.
Snag mode can only be reset by depressing the Snag reset push
button on the left console or key switch at T/L/S control station at
girder end after inspection of crane technician.
3) Eccentric load :
If there is a displayed load difference of 16.4 m.ton between left side
and right side rope load, the hoisting is stopped but lowering is
permitted.
4) Over load :
If the load exceeds a preset over load level (100%), after adjustable
time delay (0 to 5 seconds) the hoist overload warning lamp(red)
on the left hand console is blinking and signal buzzer sound.
If the load exceeds a preset overload level (110%), hoisting is
disabled after an adjustable time delay (0 to 5 seconds) and
O&M Manual
Mechanical

ABG
concurrently the hoist overload warning lamp(red) on the right
hand console is solid lighting.
Lowering is possible to release the load.
It is possible to bypass the overweight shutdown temporarily
depressed the overload bypass push button(red) on the left hand
console. This push button shall only be used during annual crane
overweight certification under supervision.

3.2.3

LOCATION OF EMERGENCY STOPS

#1 Leg Gantry Inter. Equalizer Beam
#2 Leg Gantry Inter. Equalizer Beam
#3Leg Gantry Inter. Equalizer Beam
#4 Leg Gantry Inter. Equalizer Beam
Landside Gantry Control Station
Trolley
Operators Cab. Console (Right hand control console)
Headblock
Boom Control Station
Boom Tip
Girder End
T/L/S Local Control Station at Girder End
M-House Local Control Station
PLC Panel Door in Electrical Room
Beside M-House Entrance Door in Machinery House
Under Axial Fan in Machinery House

O&M Manual
Mechanical

ABG
3.2.4

CRANE STORAGE/ANCHORING

A. GENERAL
There are two (2) sets of stowage pin assembles per crane. Each one under
center of sill beam. Each pin assembly has one (1) pin and operated by a manual
lever. A interlock limit switch is provided for each pin assembly.
When the crane is out of operation, the stowage pins should be lowered and
engaged properly to the stowage pockets on existing dock.
There are totally six (6) tie downs. Four (4) tie downs are located at water side
rail and two (2) tie downs are located at land side rail.
These tie downs are secured to gantry truck frame during normal operation.
When the crane is out of operation for a long time and high wind is expected,
these tie downs should be connected to tie down anchors provided on existing
dock.
To engage the tie down, the link can either be raised or lowered by a
ratchet handle provided at turnbuckle of the tie down. After engagement of tie
down links with pin, slightly tighten turnbuckle to positive tension to the link. For
waterside tie downs which has two (2) per corner, care should be taken to give
same amount of tension on both tie downs.
For more information refer to 2.4.3 Stowage Pin & Tie Down of the operation and
maintenance manual.

B. STOWAGE PROCEDURE
1. Travel the gantry to the stowage area.
2. Retract spreader to 20 ft position and position spreader to give
approximately 1 m (3 feet) clearance between the floor level of the
operators cab and highest structure of headblock.
3. Position the trolley at its stowed position and engage trolley storm anchor.

O&M Manual
Mechanical

ABG
4. At the boom control station, raise boom to stowage position and lock in
latches. Visually ensure that the boom is properly latched.
5. Position the gantry at the exact spot for ground personnel to manually
engage the stowage pins.
6. If flood lights are on, turn off.

C. ANCHORING PROCEDURE FOR HIGH WIND

(1)

BEFORE STORM

1. Warning of storm should be communicated to operators and

maintenance staffs as early as possible to have enough time to prepare
for storm.
2. Move the trolley at parking position.
3. Check the gantry rail condition if the rail is slippery due to rain.
4. Travel the crane to the anchorage area.
5. Retract all the hydraulic cylinders of trim/list/skew system and telescopic
spreader.
6. Inspect for any tools and/or materials that would be blown away during
storm.
7. Check any parts (especially flood lights) which is not securely fastened.
8. Secure trolley with trolley storm anchor.
9. Boom up.
10. Turn off all lights. Close all doors shut.
11. Access the Apex and check the followings.
1) Boom latches are securely latched.
2) Boom stop bumpers are duly compressed against boom.
12. Engage gantry stowage pins.
13. Check rail brakes are firmly closed.
O&M Manual
Mechanical

ABG
14. Secure and tighten tie-downs to anchors.
15. Cover all gantry motors, reducers, rail brake hydraulic power units with
plastic sheets to prevent penetration of spray seawater.

(2)

AFTER STORM

1. Check damages of parts and reports, if any.

2. Check gantry reducer oil whether any water is inside.
3. Check and re-grease all gantry truck bearing and open gears.
4. All insecure temporarily secured parts during storm.

O&M Manual
Mechanical

ABG

3.3

O&M Manual
Mechanical

DOs and DONTs for CRANES

3.3.1

DOs for CRANES

3.3.2

DONTs for CRANES

ABG
3.3 DOs AND DONTs FOR CRANES
3.3.1

DOs FOR CRANES

(1) GENERAL
Ensure that all anchor pins are at disengaged position.
Ensure that a utility power plug is disconnected before starting normal
operation.
Ensure that all switches are appropriate before operating the joystick in
the operators cabin.
Check to see that main hoist, trolley and boom hoist wire ropes are in
good condition and the wire ropes are in the rope sheaves.
Function test on main hoist, trolley, boom and gantry brakes for
effectiveness before actual operation.
Ensure that the door to operators cabin is closed.
Stop operating the crane while communicating with maintenance
personnel.
Report any abnormalities and to maintenance personnel.
After operation, park the trolley at parking position and ensure the
spreader is at 20 ft mode and is raised high enough to clear the portal
beams.

(2) GANTRY TRAVEL

Ensure that all anchor pins and tie-downs are at Disengaged position.
Ensure that there are no obstacles (Objects like pallets, oil pit cover,
vehicles, etc.) on or near the rails before travelling. Watch for ships
obstacle such as gangways, gears, ship cranes davits,
superstructures, etc.
When gantry travel with boom partially raised, gantry travel speed
should be less than 50% of rated speed.
At the end of operation, raise the boom to stowed position before gantry
travelling.

O&M Manual
Mechanical

ABG
When braking, always allow for safe braking distance. The crane has
momentum and can not stop immediately when travelling fast.
In an emergency case, make use of the emergency stop pushbutton to
stop the crane.
Ensure that the alarm gong and lamps at each leg are ringing and
lighting when the crane travels. If not, call maintenance personnel.
For gantry travel with a rated load, avoid this unless the specific
instructions to do so are given. In such an instant, ensure that the path
is clear and travelling speed is slow to prevent the load from swing.
When the gantry rail is wet due to rain, be careful for gantry wheel slip.
To prevent wheel slip, start gantry when trolley is near or in-between
landside and waterside support beam.
If any abnormal noise is heard during travelling, stop immediately and
report to maintenance personnel.
Ensure that the operators cabin is at the center of the crane or at
parking position so that obstructions on the ground are visible before
travelling.
On completion of operation, park the crane correctly to enable safe
departure of a vessel

(3) TROLLEY TRAVEL

Ensure that anchor pin on trolley is at disengaged position.
Ensure that Trolley Mechanical Stopper is raised to have enough
clearance for parts on trolley.
Ensure that there are no obstacles ahead and no persons on the trolley.
During trolley travel, always ensure that the spreader and load can keep
the clearance over the ship, the crossbeam on cranes leg, or any other
obstacles.
Trolley should slow down when approaching the forward end of the
boom or the back reach of the crane.
To change the direction from trolley forward to reverse or vice versa,
always return the joystick lever to zero notch to stop trolley movement
before commencing to change direction.
O&M Manual
Mechanical

ABG
If any abnormal noise is heard during trolley travel, stop the operation
immediately and call maintenance personnel.
In an emergency case, make use of the emergency stop pushbutton to
stop the crane.

(4) BOOM HOIST

Ensure that trolley is at parking position.
Ensure that there are no obstacles in the way when the boom is being
lowered or raised.
Ensure that there are no loose obstacles like tools, cable drums, rags,
etc. on the boom before the boom is raised.
If any abnormal noise is heard, boom hoist operation should be stopped
immediately and the cause of noise checked and reported to
maintenance personnel.
In an emergency case, make use of the emergency stop pushbutton to
stop the boom hoist operation.
Ensure that boom latches are properly engaged after boom fully raised.

(5) MAIN HOIST AND SPREADER

Always slow down hoisting speed when the spreader is approaching
the upper limit of hoisting or when it is approaching the deck of the
wharf ship or top of a container.
Allow for stopping distance when reducing from full speed to stop.
When picking up a container, ensure that the Spreader Landed lamp
(white) on spreader and indication lamp on left console is illuminated
before locking the twist lock.
Toggle the joystick for twist lock and wait for the Twist Locks Locked
lamp(red) on spreader and indication lamp on left console is
illuminated. i.e. Confirm the twistlock pins are in locked position and all
four twistlocks are inside the corner casting of the containers.
Make sure that container twistlocks are locked prior to hoisting
container.

O&M Manual
Mechanical

ABG
On lowering the container again ensure that the Spreader Landed
lamp(white) on spreader and indication lamp on left console is
illuminated before unlocking the twistlocks pins. Toggle the joystick for
twist unlock and make sure that the Twist Locks Unlocked
lamp(green) on spreader and indication lamp on left console is
illuminated before hoisting up the empty spreader.
On the wharf, make sure that the container is not locked to the chassis
or on deck, make sure that all lashing have been removed before the
spreader picks up the container.
When using a overheight frame with the spreader, lower and raise the
spreader slowly. On positioning the overheight container, ensure that
the spreader does not come into contact with the content of the
overheight container.
Ensure that the appropriate 20, 40 or 45ft mode of spreader are used
for picking up the hatch covers.
Ensure that the hatch covers do not hit the cranes leg when
loading/discharging off-center hatch covers.
Ensure that when using a 40ft mode spreader, a 40 feet container is
being picked up and not two 20 feet containers.
Before entering the cell guides of vessel, ensure that all the flippers are
raised.
Check the spreader for obvious damage or leaks.
Report to
maintenance personnel if the spreader is leaking hydraulic oil.
Ensure that spreader is raised at slow speed at end of operation.

O&M Manual
Mechanical

ABG
3.3.2

DONTs FOR CRANES

(1) GENERAL
Do not day-dream during operations.
Never leave the operators cabin while the crane is in operation. Never
leave the operators cabin with CONTROL POWER ON.
Do not litter the operators cabin.
Do not leave the operators cabin door open.
Do not smoke in the operators cabin, elevator, electrical room and
machinery house.
Do not enter the walkway to cab docking platform during crane
operation.
(2) GANTRY TRAVEL
Do not gantry travel if there are obstacles on the way.
Do not stop suddenly when the crane is travelling at full speed unless
it is an emergency case.
Do not gantry travel when the storm anchor pins are engaged.
Do not gantry travel when the boom is being raised or lowered.
Do not gantry travel when in doubt. Seek guidance from the wharf
Supervisor or ship supervisor.
Do not gantry travel with a load on the spreader unless instructed to
do so. In this case, the crane should travel at slow speed and
operator should ensure that the path ahead is clear
Try to avoid gantry travel at trolley near maximum outreach and
backreach area with load on spreader. This may cause gantry wheel
slip at light corner.
Do not gantry if utility power is plugged in.

O&M Manual
Mechanical

ABG
(3) TROLLEY TRAVEL
Do not trolley in high speed when approaching the forward end of the
boom or the backreach of the crane.
Do not trolley travel if the spreader and the load cannot clear the ships
railing or the cranes leg or any other obstacles on the way.
Do not attempt to trolley travel if any abnormal noise is heard, Inform
maintenance personnel to call technicians.
(4) BOOM HOIST
Dont do any other operation while the boom is going up or down.
Dont attach the load to the spreader while the boom is going up or
down.
Never leave boom hoist control station while the boom hoist is in
operation.
Do not raise the boom if there are personnel or any unsecured objects
(tools, debris ) on the boom.
(5) MAIN HOIST AND SPREADER
Do not operate the spreader if hydraulic oil is leaking badly from the
spreader. Inform maintenance personnel.
Do not hoist up the spreader at full speed when handling the
overheight containers or overheight frame.
Never force a spreader into corner castings of hatch covers or
distorted containers.
Do not hoist up the spreader at full speed when it is the ships cell
guides. Do it in stages.
Never force a spreader into the corner castings of any containers, if
the twistlocks cannot enter the corner castings after 4 attempts.
Report to supervisor.

O&M Manual
Mechanical

ABG
Do not attempt to pick up any containers from the chassis/ships deck
if the container is still locked onto the chassis or lashing are still
attached to the containers.
Do not lock the twistlocks before the spreader had landed properly
onto the corner casting of container or the SPREADER LANDED lamp
is illuminated.
Do not hoist up the loaded spreader until the TWISTLOCKS LOCKED
lamp is illuminated.
Do not hoist up the empty spreader until the TWISTLOCKS UNLOCKED
lamp is illuminated.
Never land the spreader in the wharf/chassis/ships deck at full speed.
Do not hoist up until the wharf supervisor instructs to do so when
changing the spreader. Do not switch ON the hydraulic pump to
operate the flippers after changing the spreader until you ensure that
no worker or near the spreader.

O&M Manual
Mechanical

ABG

3.4

STEP BY STEP OPERATING INSTRUCTION

3.4.1

BEFORE START

3.4.2

BOOM LOWERING OPERATION

3.4.3

START UP OPERATORS CABIN

3.4.4

TROLLEY OPERATION

3.4.5

MAIN HOIST OPERATION

3.4.6

GANTRY OPERATION

3.4.7

BASIC CONTAINER HANDLING OPERATION

3.4.8

TRIM/LIST/SKEW OPERATION

3.4.9

SINGLE/TWIN 20 MODE OPERATION

3.4.10 BOOM RAISING OPERATION

3.4.11 SHUT DOWN
3.4.12 ELEVATOR

O&M Manual
Mechanical

ABG
3.4 STEP BY STEP OPERATING INSTRUCTIONS
3.4.1

BEFORE START

STEP

NOTES

Check whether there are no

obstructions or men on the gantry
travelling way.

* Remove any grease or big chunk of

material on gantry rails.

Lift up both storm anchor pins.

* Find anchors located inside center of

the landside and waterside sill beams.
* Lift up and stow in the up position for
gantry travel.

Check gantry rail brakes and

emergency switches.

* Remove any dirt or grease on the

braking surface of brake pads.
* Reset any depressed emergency
switches to normal position.

Disengage trolley anchor.

* Find on left side of trolley

* Disengage anchor and set it in
disengaged position.

Check main hoist, trolley and boom

hoist brakes.

O&M Manual
Mechanical

* Remove any dirt or grease on the

surface of brake disk.

ABG
3.4.2

BOOM LOWERING OPERATION

- Boom operation is possible at the boom control station.
- The boom is operated automatically and manually at the boom control
station.
- Boom control station is located at water side support beam.
- Boom operation is possible only when the trolley stops at parking
position.
STEP

NOTES

In case of night operation, turn on

Boom Latch Flood Light switch to
illuminate the boom latch area of the
boom at top beam.
Press Control On/Reset pushbutton.

* Control On/Reset lamp (green) is on.

Check pre-condition of boom lowering * Confirm Boom Control Permissive

operation
lamp (green) is on.
* Confirm Boom Latched lamp (green)
is on.
* Confirm Trolley Parking Position lamp
(green) is on.
Select Boom Operation High/Low
mode as High
Select Boom Operation mode as
AUTO

* Operation Manual Auto is selected.

Press Boom Lower pushbutton to

activate boom lowering operation

* Boom is raising slightly and stop.

* Boom latch is up.
* Boom Latch Up lamp(yellow) is on.
* Boom lowers down.
* Boom slow down and stop.
* Boom Down Level lamp(white) is on.

Press Control Off pushbutton.

Check trolley mechanical stopper is
fully raised to make a way for trolley
travelling to boom.

O&M Manual
Mechanical

* Control On/Reset lamp (green) is off.

ABG
3.4.3

START UP OPERATORS CAB

STEP

Turn on cabin light, if required.

NOTES
* A dimmer control is provided, so
lighting level can be adjusted.

Turn on air-conditioner, if required.

Press Lamp Test pushbutton to

* All lamps should be on.

check lamp condition.

Press Control On/Reset pushbutton

on the right hand console

* Control On/Reset lamp (green) will be

on to indicate crane control is possible
in operators cab.

Press Spreader Pump On pushbutton * Spreader Pump On lamp(green) will

on the right hand console.

be on to indicate spreader control is

possible.

Crane is now ready for operation.

During crane operation, always watch
for personnel and obstruction in the
way.

O&M Manual
Mechanical

* If runaway or emergency condition

happens during operation, push the
red EMERGENCY STOP pushbutton
on right hand console immediately.

ABG
3.4.4

TROLLEY OPERATION
STEP

NOTES

To move trolley forward, push joystick * Limit switch excessive travel will not
forward on the left hand console.
allow movement in that direction.
* Do not drive against limit switches.
* They are for safety only.
To move trolley to landside, move * Limit switch prevents excessive travel.
joystick handle backward.
Do not drive against limit switches.
They are for safety only.
To park the trolley at parking position, * When trolley is parked properly,
move the trolley slowly to entrance
TROLLEY PARKED (green) lamp on.
platform on landside leg.

NOTE : 1. Trolley operation is permitted only when the boom is horizontal

position.
2. Ensure that Trolley Mechanical Stopper is fully raised to have enough
clearance for trolley operation.
3. Trolley will not operate if entrance gates are not closed completely.
4. When trolley rail is wet due to rain, try not to perform sudden start
and stop to prevent wheel slip.

O&M Manual
Mechanical

ABG
3.4.5

MAIN HOIST OPERATION

STEP

joystick * Always slow hoist down when

handle forward on right side console.
approaching top of container.

To

lower

spreader,

NOTES
push

* A down stop limit switch stops motion

near the end of wire rope of drum.

To

joystick * Limit switch allows hoist up and stop

motion when spreader is fully raised.
handle in the backward direction.
raise

spreader,

pull

NOTE : 1. Hoist operation is fully functional only when the boom is horizontal
position.
2. For maintenance purpose only, slow speed hoisting is possible when
boom is stowed.
3. Lowering is prohibited over the sill beam both side to protect
collision accident between top of sill beam and bottom of spreader
and/or container box.

O&M Manual
Mechanical

ABG
3.4.6 GANTRY OPERATION
STEP

NOTES

Check that gantry tracks are clear and

boom is not obstructed.
To travel left, move joystick handle to * Warning light and horns will flash and
the left on the left side console.
sound (one at each corner) to warn that
the crane is moving.
To move crane right, move joystick * Warning light and horns will flash and
handle to the right
sound (one at each corner) to warn that
the crane is moving.
NOTE : 1. Gantry operation is fully functional only when the boom is horizontal
and stowed position. Avoid sudden start and stop of gantry while
boom is partially raised.
3. The rail brakes are automatically released and closed depend on
gantry operation, i.e. brakes will only be released during gantry
operation.
If wind speed is greater than 14 m/sec for longer than a preset
adjustable time, initially set for 10 seconds, the high wind warning
lamp on the left side console is solid on. If the gantry motion is
running under this condition, it is stopped with a normal regenerative
stop and the rail brakes are set 1 to 10 seconds(adjustable) after the
gantry motor brakes are set.
4. In case of emergency (failure of gantry power), crane can be possible
to move to parking position with pushing/pulling by forklift/truck etc.
after releasing gantry brakes manually.
Try to avoid gantry travel at trolley near maximum outreach and backreach
area with load on spreader. If rail is wet, this may cause gantry wheel slip at
light corner.

O&M Manual
Mechanical

ABG
3.4.7

BASIC CONTAINER HANDLING OPERATION

Operator should check main hoist up-slow-down and up-stop limit
switches. Also, check trolley travel slow-down and stop limits.
STEP

NOTES

Adjust spreader length by selector* Appropriate indicating lamp on the left

switch (Extend, Retract) on the left side side console will be illuminated.
console.
Lower flippers by operating the selector* You can use all four flippers or individual
switches on the left side console or push flipper.
button of left master switch.
Lower spreader squarely onto container. * Refer to TRIM/LIST/SKEW operation .
If spreader does not align well, use
TRIM/LIST/SKEW control switches on
the left side console.
When spreader is seated on container, * If spreader is not squarely on the
the SPREADER LANDED lamp(white)
container, twist locks will not operate.
on the spreader will be illuminated, then
move joystick to TWIST LOCK on left
side console or depress left pushbutton
of right master switch to engage the
container.
When the LOCKED lamp(red) on the* Flippers are to be lowered only when
spreader is Illuminated, raise all flippers. required for guiding onto the container
box.
Hoist container, traverse and
container onto desired position.

lower* If placing container in ships cell, ensure

flippers are retracted position.

After container is landed, move joystick* Always hoist slow to insure that all
to UNLOCK position or depress right twistlock clear the container before
push button of right master switch and advancing to full hoist speed.
wait for the UNLOCKED lamp (green)
indicating all twistlocks are unlocked.
Then hoist spreader away from container
box or chassis.

O&M Manual
Mechanical

ABG
3.4.8

TRIM/LIST/SKEW OPERATION
TRIM and LIST motion can be activated by small joystick on left side
console.
SKEW motion can be activated by spring return selector switch on left
side console.
All the switches are spring return type.
The motion is activating only while the switch is flipped. If you release
switch, it will return to neutral position and the motion stops.
STEP

To activate TRIM LEFT, flip the

joystick switch to TRIM LEFT
position and hold it for required angle
of TRIM.

NOTES
* TRIM LEFT will lower left side spreader
down.
* Maximum Trim angle = 5 degrees in
either direction.

TRIM RIGHT is reverse motion of

TRIM LEFT.
To activate LIST FORWARD, flip the
joystick switch to LIST FORWARD
position and hold it for required angle
of LIST.

* LIST FORWARD will lower Waterside

spreader down.
* Maximum List angle = 5 degrees in
either direction.

LIST BACKWARD is reverse motion of

LIST FORWARD.
To activate SKEW CCW, rotate the
selector switch to Count Clock-Wise
and hold it for required angle of
SKEW.
SKEW CW is reverse motion of SKEW
CCW.

O&M Manual
Mechanical

* SKEW CCW will rotate spreader to

Counter Clock-Wise.
* Maximum Skew angle = 5 degrees in
either direction.

ABG
3.4.9

SINGLE/TWIN 20 MODE OPERATION

Use SINGLE mode for normal container handling operation.
Use TWIN mode for twin 20 feet container handling operation.
STEP

NOTES

Extend or retract spreader to 40 FT * The SPREADER 40 Ft indication

position by using SPREADER EXT.
lamp(white) on the left console will on.
RET. switch on the left console.
Ensure to return the Ext./Ret. Switch to
the off position.
Select TWIN mode on the left * The
SPREADER
TWIN
MODE
console.
indication lamp(amber) on the left
console will on.
Twin 20 mode operation is ready.

O&M Manual
Mechanical

ABG
3.4.10 BOOM RAISING OPERATION
- Boom operation is possible at the boom control station.
- The boom is operated automatically and manually at the boom control
station.
- Boom control station is located at water side support beam.
- Boom operation is possible only when the trolley stops at parking
position.
STEP
NOTES
In case of night operation, turn on * Ensure that no person or unsecured
Boom Latch Flood Light switch to objects on boom.
illuminate the boom latch area of the
boom at top beam.
Press Control On/Reset pushbutton.

* Control On/Reset lamp (green) is on.

Check pre-condition of boom raising * Confirm Boom Control Permissive

operation
lamp (green) is on.
* Confirm Boom Down Level lamp
(red) is on.
* Confirm Trolley Parking Position
lamp (green) is on.
Select Boom Operation High/Low
mode as High
Select Boom Operation mode as Operation Manual Auto is selected.
AUTO
Press Boom Raise pushbutton to * Boom starts to be raised with slow
activate boom raising operation
speed until the rope is under tension,
and then full speed.
* Boom slows down when the boom
approaches near Top Beam.
* Boom Latches will be engaged to
boom latch pins with Bang sound.
(The Bang sound is normal.)
* Boom stops raising momentarily and
lowers down and stops.
* Boom Latched lamp (white) is solid
on.
* Control On/Reset lamp (green) is
Press Control Off pushbutton.
off.
Check trolley mechanical stopper is
fully lowered to prevent trolley from
travelling to boom.

O&M Manual
Mechanical

ABG

O&M Manual
Mechanical

ABG
3.4.11 SHUT DOWN
STEP

NOTES

Move trolley to the parking position

Drive crane to stowage area of dock.
Turn off cabin lights and any other
auxiliary equipment do not wish to be
left on.
Raise boom to stowed position.

* Refer to 2.3.10

Maintenance personnel or assistant

locked all locking pins on the crane
such as storm anchor on the gantry,
trolley parking pins on the trolley.

CONTROL OFF by pushing any

EMERGENCY STOP pushbutton
and release by returning the
mushroom head.

O&M Manual
Mechanical

* Other control station also.

ABG
3.4.12 ELEVATOR
STEP

NOTES

Observe elevator structure looking for

obvious damage or interference with
the proper operation of the car.
Call the car to desired landing by
pressing CALL pushbutton on control
boxes.
Enter the car and close the both * Safety interlocks prevent operation if
landing doors and the door on the car.
all doors are not completely shut.
After the elevator stops at the desired * If all doors are not closed, the car
landing, exit the car and close all
cannot be called.
doors to ensure for use by others.
If the car stops between landings, * The car can be safely lowered without
follow the posted instructions inside
power by releasing brake. The key to
the car.
release brake is located in the box on
the wall.

O&M Manual
Mechanical

ABG
3.4.13 AUXILIARIES
STEP

NOTES

Intercom

* To page, press a CALL BUTTON on the

handset and your voice will be heard
via all the loud speaker installed under
the cabin.
* When someone hold a handset at other
station, It is possible to talk like a
phone with the station after releasing
the CALL BUTTON.

Machinery house ventilation fan

* Temperature switch is located near the

machinery house local control station
in the machinery house. The fan can be
controlled manually or automatically
by selector switch on machinery house
local control station.

Walkway lights of the following

* The walkway lights are controlled by

pushbutton switch of the following
location,
- Operators cabin right console
- Checkers cabin panel(LANDSIDE)
- Machinery house local control station
- On the door of lighting distribution
panel in the E-room

location
1)Walkway lights of up to Operators
Cab elevation
2)Boom walkway
3)Girder walkway
4)Top Beam walkway
Work area flood lights groups
1)
2)
3)
4)

Under Boom area

Under Cabin/Trolley
Under Portal area
Under Girder Backreach area

O&M Manual
Mechanical

* The flood lights are controlled by

pushbutton switches at the three
location as bellows.
- Operators cabin right console
- Landside gantry control station
- Machinery house local control station
- On the door of lighting distribution
panel in the E-room

ABG

3.5 TROUBLESHOOTING

O&M Manual
Mechanical

ABG
3.5 TROUBLESHOOTING
Three main reasons prevent the crane from functioning:
1.Prevented by safety interlocks or limit switches.
2.Mechanical breakdown.
3.Electrical breakdown.
On a machine as complicated as this crane, many safety features have to be built
in. Sometime it is not obvious that one these is working. The table below lists
some of symptoms and probable causes.
Loss of power is an obvious condition. If cause is not obvious, a breakdown
requiring maintenance personnel has probably occurred. If a fault keeps
reappearing, report it to maintenance personnel. If the crane wont operate, first
go through the procedures listed in section 3.4.2 (if lowering the boom), section
3.4.3 (if operating from the operators cabin), or section 3.4.6 (if trying to gantry
from the waterside gantry station). If this fails, check the possible causes on the
following pages:
LIMIT BYPASS buttons will defeat limit switches for their respective functions and
should only as a last resort and with extreme caution.
Use a fault message indicating on the FDU (Fault Display Unit) monitor installed
in the operators cabin to find the reason of trouble.

SYMPTOM

PROBABLE CAUSE

a. Boom will not lower or rise.

1. CONTROL ON/RESET pushbutton is not pushed.

2. Main hoist is in slow down zone or stop limit
switches is activated.
3. Boom latch pins are not disengaged.
4. Trolley is not in proper-parked position.

b. Boom hoist over-speed.

Over-speed switch is tripped. Notify the

maintenance personnel before further attempting
to operate boom hoist.

O&M Manual
Mechanical

ABG
3.5 TROUBLE SHOOTING (continued)
SYMPTOM

PROBABLE CAUSE

c. Trolley will not operate.

1. CONTROL ON/RESET is selected in boom hoist

control station or landside gantry control
station.
2. Boom is not completely lowered.
3. CONTROL ON/RESET pushbutton is not pushed
in the operators cabin.
4. Trolley is at end stop limit switch.
Try other direction.

d. Main hoist will not overrate.

1. CONTROL ON/RESET is selected in boom hoist

control station or landside gantry control
station.
2. Check twistlocks locked or unlocked.
Check
headblock twistlocks locked.
3. Against limit switch. Try other direction.
4. Check loadscales fault

e. Gantry will not move.

1. Check to be sure rail brakes and storm anchor

pins are fully released and limit switches are
actuated.
2. Anti-collisions such as a ship mast, crane to
crane and cable reel over-tension limit switches
are actuated.
3. CONTROL ON/RESET is selected in landside
gantry control station.
4. Cable reel limit switch is tripped.
5. Check wind speed is exceeded of 14 m/sec.
1. Check auxiliary power distribution panel in the
E-room for tripped circuit breakers.

f. Lights do not turn on

g. CONTROL ON/RESET
pushbutton will not work

O&M Manual
Mechanical

1. Joystick in operators cabin must be in center

OFF position.
2. Motor thermal overload tripped.