Terex CBR 40H-4 Operating and maintenance manual

Self-Erecting
Tower Crane
CBR 40H– 4
REV.000-1
Operating Instructions - Installation
Maintenance

FOREWORD
CBR page 0.01
rev. 05.05 CBR_0i_01
This publication must be read carefully by the personnel assigned to the crane before taking
any action.
Only by meticulously following the instructions given in this manual will the crane be able
over time to provide the high performance for which it has been designed and constructed.
The manual highlights important information for the safety of persons and conservation of
the machine with the following wording:
WARNING: When failure to observe or incorrect observation of the prescribed instructions
can put the safety of persons at risk and cause mortal accidents.
CAUTION: When failure to observe or incorrect observation of the prescribed instructions
can cause damage to the machine.
NOTICE: This is used to draw attention to particular technical aspects or to refer to other
available information.
The manual is split into 4 sections:
1 MAIN CHARACTERISTICS
2 SITE PREPARATION - TRANSPORT
3 ERECTION - USE - DISMANTLING
4 MAINTENANCE
The Comedil After-Sales Service Organization is at the customer's disposal for any
problems relating to use of the crane and for any necessary advice.
Edition 2010 - Gru Comedil s.r.l.
The content of this manual belongs to exclusively Gru Comedil.
No part of this publication may be duplicated without prior written approval from Gru
Comedil.

TABLE OF CONTENTS
CBR page 0.02
rev. 05.05 CBR_0i_02
TABLE OF CONTENTS
1 MAIN CHARACTERISTICS page
1.1 MARKING 1.01
1.1.1 MANUFACTURER 1.01
1.1.2 TYPE OF MACHINE 1.01
1.1.3 CE MARKING 1.02
1.1.4 NOISE EMISSION MARKING 1.02
1.1.5 IDENTIFICATION PLATE 1.03
1.2 FOREWORD 1.04
1.2.1 SCOPE AND LIMITS OF THE MANUAL 1.04
1.2.2 WHERE AND HOW TO CONSERVE THE MANUAL 1.04
1.2.3 SUPPLEMENTS AND UPDATES TO THE MANUAL 1.05
1.2.4 USER COOPERATION 1.05
1.2.5 EXCLUSION OF RESPONSIBILITY 1.05
1.3 INTENDED CONDITIONS OF USE 1.06
1.3.1 DESCRIPTION OF THE EQUIPMENT 1.06
1.3.2 CLASSIFICATION ACCORDING TO THE CALCULATION STANDARD 1.06
1.3.3 RANGE OF CONTEMPLATED SET-UPS 1.06
1.3.4 OPERATING ENVIRONMENT 1.10
1.3.5 PERMITTED MOVEMENTS AND THEIR SIMULTANEITY 1.10
1.3.6 POSSIBILITY OF INTERFERENCE WITH OTHER EQUIPMENT 1.10
1.3.7 CONTROL STATION 1.10
1.3.8 OPERATIONAL CONTROL 1.11
1.3.9 CONTROL ELEMENTS 1.12
1.3.9.1 PUSHBUTTON PANEL WITH CABLE 1.12
1.3.9.2 MAIN SWITCH 1.12
1.3.10 OPERATING MODE SELECTORS 1.12
1.3.11 STOPPING MOVEMENTS 1.13
1.3.12 CHARACTERISTICS OF PERMISSIBLE LOADS 1.13
1.3.13 PERMISSIBLE HOISTING ACCESSORIES 1.14
1.3.14 DECOMMISSIONING THE CRANE 1.14
1.3.15 POTENTIAL NON-PERMISSIBLE USES OF THE CRANES 1.15
1.4 TECHNICAL DESCRIPTION 1.19
1.4.1 MAIN COMPONENTS 1.19
1.4.2 DESCRIPTION OF THE STRUCTURES 1.20
1.4.3 LOAD-HANDLING DEVICE 1.20
1.4.4 CHARACTERISTICS OF THE ROPES 1.20
1.4.4.1 DIAGRAM OF THE ROPES 1.21

TABLE OF CONTENTS
CBR 40H page 0.03
rev. 12.05 40H_0i_03
1.4.5 MECHANISMS 1.22
1.4.5.1 HOISTING 1.22
1.4.5.2 TROLLEY TRAVERSING 1.23
1.4.5.3 SLEWING 1.23
1.4.5.4 ERECTION 1.24
1.4.6 HYDRAULIC DIAGRAM 1.25
1.4.7 PRECAUTIONS WHEN USING THE HYDRAULIC SYSTEM 1.26
1.4.8 CONTROL MEMBERS 1.27
1.4.8.1 MAIN SWITCH 1.27
1.4.8.2 PUSHBUTTON PANEL 1.28
1.4.9 COUNTERWEIGHT BALLAST 1.29
1.4.9.1 COMPLETION BLOCKS 1.30
2 SITE PREPARATION AND TRANSPORT
2.1 SITE PREPARATION 2.01
2.1.1 ERECTION CLEARANCES 2.01
2.1.2 SUPPORTING BASE 2.01
2.1.3 ELECTRICAL CONNECTION 2.02 2.1.4
PROTECTION FROM ELECTRIC DISCHARGE 2.03
2.1.5 GROUNDING SYSTEM 2.03
2.1.6 COUNTERWEIGHT BALLAST 2.04
2.1.7 TOWING VEHICLES 2.04
2.1.8 TEST LOADS 2.04
2.1.9 SLEWING AREA FENCING 2.04
2.1.10 SAFETY SIGNS 2.05
2.2 INSTRUCTIONS FOR TOWING AND TRANSPORT 2.06
2.2.1 CONDITIONS OF TOWING 2.06
2.2.2 TOWING SET-UP 2.06
2.2.3 DETACHED PARTS 2.07
2.2.4 PERMISSIBLE LOADS ON THE AXLES AND DRAWBAR 2.07
2.2.5 TYRES 2.07
2.2.6 SPECIAL INSTRUCTIONS 2.08
2.2.7 TOWING OPERATIONS NOT PERMITTED 2.08
2.2.8 TRANSPORT 2.09
2.3 STRUCTURES AND METHODS OF ACCESS 2.10

TABLE OF CONTENTS
CBR 40H page 0.04
rev. 12.05 40H_0i_04
3 ERECTION - USE - DISMANTLING page
3.1 INSTRUCTIONS FOR POSITIONING AND ERECTION 3.01
3.1.1 ELECTRICAL CONNECTION 3.01
3.1.2 POSITIONING THE CRANE 3.04
3.1.3 PREPARING THE JIB 3.06
3.1.4 TOWER ERECTION 3.07
3.1.5 BALLASTING 3.08
3.1.6 JIB ALIGNMENT 3.10
3.2 SAFETY DEVICES - FUNCTION AND SETTING 3.13
3.2.1 POSITIONING THE SAFETY DEVICES ON THE CRANE 3.14
3.2.2 STATIC MOMENT LIMITER 3.15
3.2.3 DYNAMIC MOMENT LIMITER 3.16
3.2.4 HIGH SPEED LIMITER 3.17
3.2.5 MAXIMUM LOAD LIMITER 3.18
3.2.6 UP LIMIT SWITCH 3.19
3.2.7 DOWN LIMIT SWITCH 3.20
3.2.8 TROLLEY LIMIT SWITCH 3.21
3.2.9 SLEWING LIMIT SWITCH 3.22
3.3 BRAKES - TESTING AND SETTING 3.23
3.4 GENERAL OPERATING INSTRUCTIONS 3.25
3.4.1 BEFORE PUTTING INTO SERVICE 3.25
3.4.2 INSTRUCTIONS FOR A RATIONAL USE OF THE CONTROLS 3.25
3.4.3 TAKING OUT OF SERVICE 3.26
3.5 SWITCHING OVER 2/4-PART LINES 3.27
3.6 DISMANTLING INSTRUCTIONS 3.28

TABLE OF CONTENTS
CBR page 0.05
rev. 05.05 CBR_0i_05
4 MAINTENANCE page
4.1 MAINTENANCE INSTRUCTIONS 4.01
4.1.1 GENERAL 4.01
4.1.2 MAINTENANCE SCHEDULE 4.01
4.1.3 SLEWING RING 4.04
4.1.4 TROLLEY ROPE TENSIONING 4.04
4.1.5 CHECKING THE ROPES 4.05
4.1.6 LUBRICATION 4.06
4.1.7 STORING THE CRANE 4.06
4.2 INSTRUCTIONS FOR ROUTINE REPAIRS 4.07
4.2.1 GENERAL TROUBLE OF AN ELECTRICAL NATURE 4.07
4.2.2 ELECTRICAL TROUBLE WITH HOISTING 4.08
4.2.3 ELECTRICAL TROUBLE WITH TROLLEY TRAVERSING 4.09
4.2.4 ELECTRICAL TROUBLE WITH SLEWING 4.09
4.2.5 OPERATIONAL TROUBLE WITH ERECTION 4.09
4.2.6 MISCELLANEOUS OPERATIONAL TROUBLE 4.10
4.3 INSTRUCTIONS FOR REMAINING HAZARDS 4.11
4.3.1 NATURE OF REMAINING HAZARDS: SAFETY MEASURES 4.11
4.4 TRAINING PERSONNEL 4.14
4.5 DEMOLISHING THE EQUIPMENT 4.15

Self-Erecting
Tower Crane
CBR 40H– 4
REV.000-1
- MAIN CHARACTERISTICS
1