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2

Dangers, Warnings, Cautions, Notices

Dangers, Warnings, Cautions, and Notices are used throughout this manual to emphasize importantand critical instructions. Dangers, Warnings, and Cautions always precede the paragraph or item to

which they apply; Notices always follow the paragraph or item to which they apply. For the purpose

of this manual Dangers, Warnings, Cautions, and Notices are defined as follows:

! DANGER

Danger indicates an imminently hazardoussituation which, if not avoided, will result in death or

serious injury. This signal word is to be limited to themost extreme situations.

! DANGERWARNING

Warning indicates a potentially hazardous situationwhich, if not avoided, could result in death or

serious injury.

! DANGERCAUTION

Caution indicates a potentially hazardous situationwhich, if not avoided, may result in minor or

moderate injury. It may also be used to alert againstunsafe practices.

NOTICE

Notice is used to notify people of installation, oper-

ation, or maintenance information which is impor-tant but not hazard-related.

COPYRIGHT

Under the copyright laws, this document may not be copied, photocopied, reproduced, translated, or

reduced to any electronic medium or machine readable form, in whole or part, without the priorwritten consent of Morris Material Handling.

Copyright 2001 Morris Material Handling, Oak Creek, Wisconsin, USA 53154

All rights reserved. Printed in the United States.

Published by: Publications Department

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Table of Contents

Table of Contents

SAFE OPERATING PRACTICESSTRAIGHT TRACK PORTAL CRANES v

FOREWORD vOPERATOR QUALIFICATIONS v

General vOperator Tests v

PHYSICAL AND MENTAL CONDITION vLOCKOUT/TAGOUT PROCEDURES vi

INSPECTION AND MAINTENANCE viGeneral vi

DAILY. vi

MONTHLY viiINSPECTION AS REQUIRED. viii

TROUBLESHOOTING viiiSAFETY RECOMMENDATIONS viii

1-1INTRODUCTION 1-1

SCOPE 1-1INSPECTION REPORT FORM 1-1GENERAL INFORMATION 1-1

SAFETY 1-1WARRANTY 1-1

PURCHASED COMPONENTS 1-1DESCRIPTION 1-1

General 1-1TERMINOLOGY 1-2

2-1CONTROLS AND CRANE OPERATION 2-1

GENERAL 2-1

SAFE OPERATING PRACTICES 2-1General Crane Safety 2-1

Safe Operating Practices 2-1On-ground Inspections And Boarding Checks2-3

Start-up Checks 2-3Shutdown Procedure 2-4

OPERATING CONTROLS 2-8Operational Notes, Log Handling Cranes 2-9

CRANE OPERATION 2-10General 2-10Hoist Operation 2-10

Gantry Operation 2-11Trolley Operation 2-11

Grapple Operation 2-11MATERIAL HANDLING 2-11

General 2-11Unloading Trucks 2-12Reclaiming Wood From The Log Pile 2-12

Transporting Wood With The Crane 2-12Loading The Log Deck 2-13

3-1LUBRICATION & PREVENTIVEMAINTENANCE 3-1

GENERAL 3-1LUBRICATION 3-1

General 3-1BOLT TORQUES 3-4

MAINTENANCE / LUBRICATION 3-4No Lubrication Required 3-5

EACH SHIFT MAINTENANCE CHECKS 3-5

General 3-5Inspect, Wire Rope 3-5

Lubricate Grapple 3-6DAILY MAINTENANCE CHECKS 3-6

General 3-6Cable Reel, General Inspection 3-6

Check Level, Grapple Reservoir 3-6Grapple, General Inspection 3-6Lubricate, Block Adapter/Rotate Bearing 3-6

Inspect Wheels 3-6WEEKLY MAINTENANCE CHECKS 3-7

General 3-7Check Level, Gantry Drive Gear Case 3-7Check Level, Trolley Drive Gear Case 3-7

Check Level, Hoist Gear Case 3-7Lubricate, External Lower Gantry Drive Gears

3-7Lubricate, Sheave Bearings 3-7

Lubricate, Gantry Wheel Bearings 3-7

Lubricate, Trolley Wheel Bearings 3-7Lubricate, Drum Pedestal Bearings (If Applica-

ble) 3-7Lubricate, Festoon Carrier Wheel Bearings

(If Applicable) 3-7Cable Reel, General Inspection 3-7

Grapple, General Inspection 3-8MONTHLY MAINTENANCE CHECKS 3-8

General 3-8Wire Rope 3-8Lubricate, Wire Rope 3-8

Handling Wire Rope 3-9Replace Air Filter, Grapple Reservoir 3-10

Lubricate, Drive Motors 3-10Cable Reel, Tension Adjustment 3-10

Lubricate, Miscellaneous Pins / Linkage 3-10GEAR INSPECTION 3-10

General 3-10

Gear Terminology 3-10Inspection and Wear Patterns 3-12

SEMI-ANNUAL MAINTENANCE CHECKS 3-14General 3-14

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Cleaning, General Crane Assembly 3-14Lubricate, Swivel Thrust Bearings 3-14

Change Oil, Gantry Drive Gear Case 3-14Change Oil, Trolley Drive Gear Case 3-14

Change Oil, Hoist Gear Case 3-15Change Oil, Cable Reel Gearcase 3-15

Change Oil, Grapple Reservoir 3-15

Grapple, General Inspection 3-15ANNUAL MAINTENANCE CHECKS 3-16

General 3-16Inspect / Clean, Drive Motors 3-16

Cable Reel, General Inspection 3-16GENERAL DISASSEMBLY 3-16

GENERAL INSPECTION AND REPAIR 3-16GENERAL ASSEMBLY 3-17

CRANE INSPECTION PROCEDURES 3-19GENERAL 3-19CRANE STRUCTURE 3-19

General 3-19

Welds 3-19

Bolted Connections 3-19Pin Connections 3-19Trolley Rails 3-19

Rail Clips 3-19Walkways 3-19Bumper Assemblies 3-19

Lighting Fixtures and Mountings 3-19RUNWAY 3-19

General 3-19Alignment 3-19

Inspection / Maintenance 3-20REFERENCED DOCUMENTS. 3-20

Materials 3-20

Metal Track Materials 3-20RECOMMENDED INSPECTION 3-22

Level of Inspection 3-22Maintenance 3-22

Alignment 3-22Track Maintenance 3-22Rail Failures 3-23

Portal Crane Operator Shift (Daily) Check List3-35

Crane PC-29014 3-35Portal Crane Mechanical Shift (Daily) Check

List 3-36

Crane PC-29014 3-36Portal Crane Electrical Shift (Daily) Check List

3-37Crane PC-29014 3-37

Routine Outage Mechanical Inspection Check-list PC-29014 3-38

Routine Outage Electrical Inspection ChecklistPC-29014 3-39

4-1

TROUBLESHOOTING 4-1GENERAL 4-1

5-1GANTRY DRIVE SYSTEM 5-1

GENERAL 5-1

DRIVE MOTOR 5-1MOTOR BRAKE 5-1

DRIVE REDUCTION GEAR CASE 5-1WHEEL ASSEMBLIES 5-1

General 5-1Removal 5-1Installation 5-2

EQUALIZER, AND TRUCK PINS AND BUSHINGS(16 WHEEL CRANES) 5-3

General 5-3Removal - (16 Wheel Cranes Only) 5-3

Installation. 5-4WHEEL ALIGNMENT 5-4

Equipment Required - (16 Wheel Cranes) 5-4For 8 Wheel Cranes with Swivel Leg Ends 5-4Analysis of Reading - (16 Wheel Cranes) 5-5

SHIMMING WHEELS 5-5General 5-5

Wheels with capsule type housings (used until1987) 5-5Wheels with MCB type housings (used after

1987) 5-6Traverse Reducer Manual (Brook Hansen) follows.

5-6

6-1TROLLEY DRIVE SYSTEM 6-1

Trolley Drive Reducer 6-1Trolley Drive Motor 6-1

Trolley Drive Brake 6-1

7-1HOIST SYSTEMS 7-1

GENERAL 7-1

MAIN HOIST UNIT 7-1Description 7-1

Drive Motor 7-1General 7-1Description 7-1

Removal 7-1Repair 7-2

Installation 7-2Motor Brake 7-2

Description 7-2Removal, Repair, And Installation 7-2

Drive Reduction Gearcase 7-3

General 7-3

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Table of Contents ii

Description 7-3Removal 7-3

Installation 7-3Disassembly 7-5

Cleaning 7-6Inspection 7-6

Repair 7-7

Assembly 7-7Seal Replacement, Drum Shaft 7-8

Pedestal Bearing 7-8Removal 7-8

Assembly 7-9Upper Equalizer Sheaves 7-9

General 7-9Removal 7-9Cleaning And Repair 7-11

Installation 7-11Lifting Beam Assembly 7-11

General 7-11Removal 7-11

Cleaning And Repair 7-12Installation 7-13

Reeving 7-13

Unreeving The Hoist Drums 7-13Reeving The Hoist Drums 7-14

Wire Rope 7-15General 7-15

Handling Wire Rope 7-15Storage 7-15

Sealing of Gear Cases 7-16

Introduction 7-161. Surface Preparation: 7-16

2. Sealant Application Procedure: 7-16

Crane Hoist Motion Gearcases I & PH Type 7-18Crane Traverse Motion Gearcase I & PH Type 7-18Crane Hoist & Traverse Motion Gearcases CI Type7-18

Crane Traverse Motion Gearcase TH Type 7-18Crane Hoist Motion Gearcase - Bucket Trolley 7-19

MACK GRAPPLE 7-19DEAD END ASSEMBLY INFORMATION 7-19

8-1DRIVE MOTORS 8-1

GENERAL 8-1

9-1BRAKES 9-1

10-1BUMPERS, SHOCK ABSORBERS ANDRAIL SWEEPS 10-1

GENERAL 10-1

GANTRY BUMPERS AND RAIL SWEEPS 10-1General 10-1

Inspection 10-1Repair 10-1

TROLLEY BUMPERS AND RAIL SWEEPS 10-1General 10-1

Repair 10-1

11-1LIMIT SWITCHES AND LIMITING DEVICES11-1

GENERAL 11-1MAIN HOIST LIMIT SWITCHES 11-1

GEARED LIMIT SWITCH 11-1Description 11-1

Adjustments 11-1Maintenance 11-2

Repair 11-2WEIGHT OPERATED LIMIT SWITCH,

TYPE HB 11-4Description 11-4Adjustment 11-4

Maintenance 11-5Repair 11-5

END OF DRUM LIMIT SWITCHES 11-6General 11-6Description 11-6

Adjustment 11-6Repair 11-7

MISCELLANEOUS LIMIT SWITCHES 11-7General 11-7

Maintenance 11-7

Repair 11-8Adjustments 11-8

Hoist Overload Load Cell System (Optional) 118

12-1COLLECTOR / CONDUCTOR / SPAN BARSYSTEMS 12-1

GENERAL 12-1GANTRY COLLECTOR / CONDUCTOR SYSTEM

12-1Festoon Conductor System 12-1

POWER CABLE REPLACEMENT 12-3General 12-3Cable Replacement 12-3

13-1CAB 13-1

GENERAL 13-1AIR CONDITIONER 13-1

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iv

14-1CONTROL SYSTEMS 14-1

GENERAL 14-1

15-1CABLE REELS 15-1

GENERAL 15-1MAIN POWER CABLE REEL 15-1

16-1MISCELLANEOUS COMPONENTS 16-1

GENERAL 16-1

WIND SPEED INDICATOR SYSTEM 16-1LOAD CELL - (Optional) 16-1

CONTROL HOUSE AIR CONDITIONER 16-1ADDITIONALLY, THE FOLLOWING PUBLICA-TIONS HAVE BEEN PROVIDED (hardcopy only):

16-1

17-1STORM BRAKES 17-1

18-1GRAPPLE 18-1

19-1TV CAMERA 19-1

20-1

WIRING DIAGRAMS 20-1

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Rev. Date 10/25/04 v

SAFE OPERATING PRACTICES

STRAIGHT TRACK PORTAL CRANES

FOREWORD

It is the desire of Morris Material Handling to assuresafe and economical use of the machinery it produces.

This manual describes preventive maintenance,inspection and specific safety recommendations.

Not all of the material presented will apply to any single

Portal Crane. However, the majority of the informationapplies to all types of Portal Cranes, and the reader isrequested to bear with those items which do notspecifically relate to their equipment.

Safety begins with properly designed and manufactured

equipment. Morris Material Handling welcomes thatresponsibility. However, the use of the equipment issubject to certain hazards that cannot be met by

mechanical means alone, but only by the exercise ofintelligence, care and common sense. Once the

equipment enters service in the field, Morris MaterialHandling has no direct control over its inspection,

maintenance, or operation. For this reason, safety inthe field is the responsibility of the user.

Most accidents involving cranes are the result ofviolating safety rules during operation and/or lack ofinspection and maintenance procedures.

Morris Material Handling recognizes that most

companies who use portal cranes have a safetyprogram in place. If a conflict exists between a rule setforth in this publication and a similar rule already set by

an individual company, the more stringent of the twoshould be followed.

OPERATOR QUALIFICATIONS

General

Only the following personnel should be permitted to

operate lifting equipment after reading this manual:

1. Appointed Qualified operators.

2. Qualified maintenance and test personnel, whenrequired to do so in the performance of their duties.

3. Crane inspectors qualified to operate a crane

OperatorTests

Every employer should require that all persons who wilbe authorized to operate lifting equipment must firs

pass an examination which accurately measures

practical knowledge of cranes and hoists and propemethods to be used in handling loads and operating thelift equipment.

PHYSICAL AND MENTAL CONDITION.

1. An operator must possess good hearing, good

vision (corrected or uncorrected) good depthperception especially where load spotting is critica

or at some distance from the operator.

2. An operator must not have any known health

condition or disability which could cause inability toreact quickly.

3. An operator who is taking medication prescribed bya doctor must present written assurance from his

doctor that the medication will not affect theoperators ability to operate the hoist in a safe

manner.

4. An operator who is known, or suspected, to be

under the influence of alcohol or drugs must not beallowed to operate a crane.

5. The operator must be safe at all times

NOTICE

Each crane operator should be held directlyresponsible for the safe operation of the crane.

Whenever there is any doubt as to safety, theoperator should stop the crane and refuse to

handle loads until safe conditions have beenrestored.

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LOCKOUT/TAGOUT PROCEDURES

Lockout/Tagout is the placement of a lock/tag on the

energy isolating device in accordance with anestablished procedure.

When taking equipment out of service to performmaintenance or repair work, always follow the lockout/

tagout procedures as required by OSHA 29 CFR Part1910.147 and outlined in ANSI Z244.1. Following these

procedures will help to ensure the safety of personnelon or around the equipment by preventing accidentalmachine start-up.

The policy shall give consideration to the followingcrane and hoist or lifting equipment areas:

1. Single crane runways or aisles.

2. Multiple crane runways or aisles.

3. Cranes on adjacent runway or aisle.

4. Runway or installation disconnecting means.5. Crane or equipment disconnecting means.

6. Work to be done on equipment.

7. Work to be done other than on a crane orequipment but within the path of a crane or

equipment where its movement creates a hazard.

INSPECTION AND MAINTENANCE

General

I t is recommended that a per iodic inspect ion,lubrication, and maintenance schedule be established

for each crane, and that this schedule be carefullyfollowed. Such a procedure will prevent minor damage

from becoming progressively more dangerous, as wellas more costly to repair.

Due to the widely varying conditions under which nearlyidentical cranes may operate, it is impossible for themanufacturer to state exact time intervals at which

inspections and/or maintenance should be performed.All inspection, maintenance, and lubrication intervals

recommended in any P&H / Morris Publicationrepresent minimum safe intervals for average

conditions, since there is no substitute for experience orfirst hand knowledge of local operating conditions.

Inspections are recommended for three basic purposesand intervals. Each is discussed in the followingparagraphs.

DAILY. This inspection should be made at the beginningof each shift, and should include, but not necessarily be

limited to, the following:

1. Be sure that the crane is properly lubricated.

2. Inspect all brakes for proper adjustment. Checkelectric motor (holding) brakes by lifting a capacityor near capacity load a few inches off the ground

and holding it suspended using the brake.

3. Operate each control to determine that it functions

properly. Report any malfunction found to properlyauthorized supervisor and notify the next operator

at the change of shift.

4. Visually inspect each component of the crane

normally used in load handling. This inspectionshould include, but again not be limited to, such

items as the following:

A.Wire rope. Inspect for kinks or broken wire and

replace damaged rope immediately. Inspect fortwisted ropes, or ropes which may have come out

of the drum grooving.

B.All functional operating mechanisms such assheaves, drums, and brakes, and all safetydevices such as upper and lower limit switches.

! DANGER

Limit switches are safety devices, not

operating controls. Never actuate themunnecessar i ly dur ing normal craneoperation. Unnecessary operation of limit

switches will cause premature limit switchfailure resulting in injury or death of

personnel.

C.The following general procedure should be used

when checking limit switches.

1). Always move the crane to an open area, away

from personnel and equipment.

2). Be sure no live load is on the hoist lines.

3). Slowly run the lifting beam up to about three

(3) feet below the limit switch trip mechanism andstop the hoist motion completely.

4). (For cranes with rotary assemblies) Rotarylimit should stop hoist travel before the lifting

beam comes in contact with final weight limit.

5). (For cranes with rotary assemblies) To check

final weight limit, lower hoist below where rotarylimit will come in contact and manually lift finallimit weight to allow final limit to open. Next, test

up mot ion on hoist to see i f final l imit isfunctioning properly. Motion should not run.

Release the weight.

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Morris Material Handling

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6). Proceed to raise the beam slowly. Thegeared/rotary limit switch should stop the hoist

prior to contact with the weight limit switch trip.

7). If the geared/rotary limit switch does not

operate at the point at which it should, lower thelifting beam out of contact with the limit switch trip

mechanism and notify properly authorized

personnel at once.

D.Visually inspect the entire crane for signs ofdamage which might cause unsafe operation.

E.Visually inspect gear cases, motors, and brakes.Look for oil leaks, loose or missing hardware and/

or parts, and visually check the brake air gaps.Repair oil leaks, tighten bolts, replace missing or

damaged hardware and/or parts, and have themaintenance department adjust the brake airgaps as necessary.

F. Visually inspect the general condition of the

conductor system. Report any damage to theappointed person.

G.Inspect the mainline power cable reel for properoperation and alignment. During the inspection ofthe cable reel observe the following:

1). Observe that the cable picks up and pays out

under proper tension.

2). Inspect the alignment of the cable guide

rollers.

3). Listen for unusual noise during cable reel

operation. Report any abnormal or unusual

operation to the appointed person.Refer to Main Power Cable Reel information formore detai led instruct ions regarding theinspection of the cable reel.

H.Check the runway system for debris. Move thecab in-line with each runway rail, and visually

inspect for debris laying across the tracks.Remove any debris which may interfere with the

operation of the crane, or obstruct its movementalong the runway.

Visually inspect the condition of the track itself.Look for obvious damage or misalignment. Do

not operate the crane if damage or noticeablemisalignment is evident.

I. Check the rail cleaning bricks attached to thegantry rail sweeps. If brick surface is dirty, flipbricks to clean side or replace with new cement

bricks.

J. Check the hydraulic oil level in the grapplereservoir. Add oil as necessary to bring the oillevel up to proper operating capacity.

K. Remove wheel chocks, and/or tie downs if used

L. Release storm brakes from cab prior to use.

The above visual and operational checks will take only

a few minutes at the beginning of each shift, and areabsolutely necessary to ensure safe operation.

MONTHLY. It must be recognized that, while a PortaCrane is designed and manufactured with a factor o

safety, every machine begins to wear on the day it startsworking. This process will inevitably continue until, atsome future date, the machine will no longer be capable

of its' original workload, unless all parts subject to weaor damage are regularly inspected and repaired o

replaced as needed.

The following monthly inspection is intended to

determine the need for repairs required to keep themachine in approximately new condition.

The monthly inspection should not be limited to the

items detailed below. This inspection procedure isconsidered minimum. Knowledge of local conditionsage and condition of a particular machine, and the

severity of operation, as well as the possible effects ofailure, all combine to determine the degree oinspection for continued safe operation.

The results of the monthly inspection should be

carefully recorded in a suitable log book, in full detailand should be dated and signed by the inspector.

The purpose of the monthly inspection is to find andcorrect any wear or damage, which could affect the safeoperation of the crane. This should include the items

listed under the daily inspection as well as the following

1. Inspect the entire crane for structural damage.

2. Inspect for cracked or worn sheaves, drums

wheels, and rails.

3. Inspect for worn, cracked, or distorted components

such as pins, bushings, bearings, shafts, and gears

4. Inspect for excessive wear of brake system parts

and linings.

5. Check the condition of the fire extinguisher, i

furnished.

6. Inspect all motors, controls, and conductosystems, which might in any way affect the safety othe machine.

7. Visually inspect the condition of the track itselfLook for obvious damage or misalignment. Do no

operate the crane i f damage or not iceablemisalignment is evident. Inspect the track for wear.

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viii STRAIGHT TRACK PORTAL CRANES

8. Inspect the entire crane structure for damage.During inspection of the structure observe the

following:

A. Check that the gates and platforms are securely

anchored.

B. Check that the stairways and stairway landings

are securely anchored to the gantry legs.C.Look for broken or cracked welds, missing or

damaged hardware, and missing or damagedstructural parts. Repair or replace any missing, or

damaged parts or hardware.

INSPECTION AS REQUIRED. The th i rd t ype o f

inspection is to be done after incidents of sudden andunusual shock loads, unusual stress, or if damage is

suspected due to any cause. All incidents which mightaffect operation of the crane should be followed by

immediately taking the crane out of service and

performing a thorough inspection of the crane, using allnecessary nondestructive test methods. All repairs

should be made before the machine is returned toservice.

TROUBLESHOOTING

The first step to be taken before a troubleshooting

procedure is started, is to communicate with all personsthat the equipment is being removed from operation and

secure any/all lockout tagout procedures. Failure tostrictly follow this warning may lead to the injury or death

of personnel. See Lockout/Tagout Procedures on page

-vi before proceeding with Inspections.Troubleshooting a crane or a hoist is a special conditionof inspection which is not always addressed in a regularinspection or preventive maintenance schedule.

Troubleshooting is usually done as a result of acomplaint of an unknown source of abnormal operation

or noise, or any other ind icat ion of unusualperformance.

Special procedures for troubleshooting should beestablished to perform the function safely for all

personnel concerned.

SAFETY RECOMMENDATIONS

The following safety recommendations represent theaccumulated experience of Morris Material Handling

regarding the most likely causes of personal injury anddamage to equipment. Compliance with the followingrecommendations will prevent the majority of common

accidents.

1. Before leaving the control station of the crane, thefollowing precautions must be observed:

A.Stop the crane at the approved location forentering or leaving the crane. (Note: crane

should be parked with the grapple in the highestposition. This will prevent damage to the crane if

the crane is blown down track in severe weather.)

B.Lower the load to the ground, and remove it from

thehead block and grapple.

C.Place all controls in the OFF position.

D.Place the main power switch in the OFF position.

E.Make a visual check for any abnormal ordangerous condition. Correct or report any which

are found.

F. Outdoor cranes must have the wind anchors

secured so as to prevent movement caused bywind.

G.Crane operators should never leave the craneduring the work shift unless it is absolutely

necessary. When necessary to leave, notify theproper authority and properly secure the crane.

NOTICE

Never depend on a holding brake to suspend a

load unless the operator is at the controls, alert,and in a position of readiness to handle the

load.

2. An operator must not eat, read, sleep, or otherwisedivert his attention while operating a crane.Practical jokes are absolutely forbidden, and theuse of alcohol or other intoxicants is not to be

tolerated. An operator who is given a prescriptiondrug by a physician should obtain written assurance

that it will not prevent him from operating the cranein a safe manner, before returning to work.

3. The operator or person in charge should see that:

A.All loose items such as tools or debris areremoved from the crane before beginning the lift.

B.The load does not contact any obstruction whilelifting or traveling.

C.Sudden starts and stops must be avoided.Bumping into runway and/or trolley stops is

prohibited.

D.The hoist line is vertical before starting the lift,

slack in the line is removed slowly, and that allpersonnel are clear of the area before beginningthe lift.

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Morris Material Handling

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E.No load should ever pass over the heads ofpersonnel or in any way endanger their safety.

Nonoperating personnel should be warned, ortold to leave the immediate area, when making

lifts.

F. Riding the lifting beam or grapple is prohibited.

The crane is not intended to be used as a

passenger elevator.

G.Only the operator rides the crane while it is inoperation. Visitors may ride in the cab only, with

the permission of the operator.

4. ALL stop signals must be obeyed, regardless of

who gives them.

5. Other than stop signals, signals are accepted from

only one person at a t ime, unless specialarrangements are made in advance for a specific lift

only.

6. Standard crane signals are used and loads are notmoved unless the standard signals are clearlygiven, seen and understood (see Figure 1).

7. The operator should test the holding brake bymoving the controller to the OFF position when a

load is first lifted, and when the load is only a fewinches above its starting position, to assure the

ability of the brakes to hold the load. If the load isheld, the brake is operating properly. If the brakedoes not function properly, maintain control of the

load using the hoist motor and lower it slowly to rest.Report the condition to the appropriate supervisor

immediately and do not make any other lifts until the

condition has been corrected.

8. Never get on or off a crane when it is in motion.Never attempt to adjust, repair, or lubricate moving

machinery.

9. Keep the machine clean and in good working order.

Oil or grease can cause serious falls, and dirt inworking parts will cause accelerated wear and

consequent possible malfunction.

10. Lower the grapple to the ground before attempting

any repairs or adjustments.

11. Always replace all protective guards and panelsbefore operating the crane or hoist.

12. Keep wire ropes in good operating condition, paying

particular attention to the following:

A.A kinked wire rope is no longer safe. When a new

wire rope has been installed, work light loads fora short period of time to allow the wire rope to

adjust itself to work strains.

B. Inspect all wire ropes for kinked or broken wireson a regular basis, preferably daily.

13. Never exceed the rated capacity of the crane.

14. Never use a crane for side pulling. It was nodesigned nor intended for such use. This practice

may cause electrical as well as mechanical damage

and will endanger personnel.15. If a wire rope has been allowed to become slack

make sure that the rope is properly seated on thedrum and in the sheaves before a load is lifted.

16. Never lower the lifting beam to a point where less

than two full wraps remain on the drum. If all wirerope is removed from the drum, be sure it isrewound in the correct direction to prevent wire rope

damage and to ensure correct operation of the hoistlimit switches.

17. Never block out safety devices, such as limi

switches, in order to allow operation of the crane ina manner not intended by the manufacturer.

18. If electrical power fails, place all controllers in the

OFF position and keep them there until power isrestored. This will prevent sudden and unexpected

movement when power is restored.

19. Never remove a DO NOT OPERATE card from a

control without checking to see that it is safe to doso, even if you have placed the card yourself

Someone else may be depending on that card toprevent the crane from being operated.

20. Use fuses of specified size. Blown fuses provide an

indication of trouble as well as provide the mainprotection afforded by the electrical system.

21. Never contact another crane on the same runway i

it is possible to avoid doing so. When this must bedone, check first to see that all concerned areaware that it will be done and that they are properly

warned. Then, contact the crane to be pushed athe slowest possible speed and push it at very slow

speed. Never move or bump a crane or hoist thahas a warning flag or sign displayed.

22. While inspecting, repairing, cleaning, lubricating, o

maintaining any crane, a warning flag should beplaced where it is readily visible to indicate that thecrane is not to be moved. The main power switch

must be locked in the OFF position. When someoneother than the operator is doing the work, theoperator must remain at the controls, alert fo

possible danger to the workmen, unless specificallyinformed to the contrary by his supervisor.

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x STRAIGHT TRACK PORTAL CRANES

23. All Portal Cranes are equipped with a warning bellor siren, which will automatically sound when the

crane is moved.

24. When the crane is being serviced, repaired,

lubricated, or otherwise maintained, it must bemoved to a position over an area where no one will

be endangered by falling material. If this is not

possible, the area beneath the crane must be ropedoff and personnel must be warned of the reason forthe precaution.

25. Repairs and adjustments should be made only byproperly designated and authorized personnel.

When a crane is being repaired, the maintenanceperson assigned is in charge of all phases of cranemovement and operation, and his instructions

should ordinarily be obeyed without question. Onlyif his instructions are contrary to safe operating

practices should the operator question them.Under these circumstances, the maintenance

supervisor should be contacted at once for adecision.

Standard Hand Signals

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Section 1

INTRODUCTION

SCOPE

This manual provides information for the adjustment,lubrication, operation, and maintenance necessary for

the safe and efficient operation of your Morris MaterialHandling Straight Track Portal Crane. If explicit

information not contained in this manual is required,consult the Morris Material Handling Portal CraneService Department, in Birmingham, AL @ (877) 943

5734 or (800) 633-1136.

INSPECTION REPORT FORM

A crane inspection report form has been included at theback of Section 3 to aid in establishing a preventive

maintenance program. This form should be copied andcompleted whenever the crane is inspected. Written,

dated and signed inspection reports and records shouldbe made on all critical items such as the grapple, wireropes, and brakes. Reports and records should be kept

where readily available to appointed personnel.

GENERAL INFORMATION

The information, specifications, and illustrations in thispublication are based on the information for Straight

Track Portal Cranes in effect when this manual wasprinted. Continuing improvement and advancement of

product design may cause changes to the crane whichmay not be included in this publication.

Whenever a question arises regarding this crane or this

manual, please consult the Morris area representativefor the latest available information.

Part numbers may be occasionally shown in this manual

to identify various parts and assemblies. Do not usethe part numbers shown in this manual to order

repair parts. When ordering repair parts, always referto the Repair Parts Manual that has the same serialnumber as the crane for which the parts are being

ordered.

SAFETY

The safe operating practices which apply to this producare printed in the Preface at the front of this manual. It

is very important that operators and maintenancepersonnel read and be familiar with these safe operating

practices in addition the operating procedures for thisproduct. This will help to establish and preserve safeworking conditions for operators, service crews, and

other personnel in the area.

WARRANTY

The warranty that accompanies this crane clearlydefines the terms under which the crane is covered

This warranty will be voided if the crane is operatedunder any of the following conditions:

With loads in excess of the maximum rated capacity

When safe operating practices are disregarded.

With accessories not designed, furnished oapproved by Morris Material Handling.

With modifications made to the crane which were nodesigned or approved by Morris Material Handling.

PURCHASED COMPONENTS

Components which are not manufactured by Morris

Material Handling may not necessarily be covered inthis manual. Refer to the literature provided by the

manufacturer of the equipment in question for service

and repair information.

DESCRIPTION

General

The Straight Track Portal Crane consists of four basicunits, the gantry, the trolley, the hoist unit, and the

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grapple. These units are described individually below(See Figure 1-1 on page 1-5).

GANTRY. The gantry is the main structural memberused to span the width of the runway area. It travels the

length of the runway on rails secured to the runwaysupporting structure. The gantry is made up of a girder,

a fixed leg assembly, a hinged leg assembly, and two sill

beams. The sill beams serve to tie the lower ends ofeach leg set together.

TROLLEY. The trolley is a motor driven vehicle which

travels along a set of rails fastened to the gantry girderassembly. The trolley is used to support the hoist unit,

the cab assembly, and the trolley machinery.

HOIST. The hoist unit, which is mounted on the trolley

assembly, is an apparatus which exerts a force for liftingor lowering loads. It is power driven through a gearreduction drive train and a hoist drum.

GRAPPLE. The grapple is suspended from the hoist

lines. The hoist lines are reeved from the hoist drum onthe trolley structure, through the sheaves on the liftingbeam, through upper sheaves on the trolley, and

eventually are dead-ended into anchors located on thetrolley frame. See Figure 1-2 on page 1-6.

NOTICE

The reeving of the lifting beams and hoist drum

is covered more thoroughly is Section 7.

The grapple is operated by a self-contained hydraulic

system. Power for the hydraulic system is fed from the

trolley deck through an electrical cable to the liftingbeam and grapple assembly. The extra cable is storedin a cable basket located on the top of the lifting beam.

The cable basket is designed in such a manner whichallows the cable to be paid out and to be retrieved as the

grapple is raised and lowered.

TERMINOLOGY

There are a number of terms commonly associated withStraight Track Portal Cranes, relating both to theconstruction and to the function of the crane. These

terms are listed and defined as follows:

ABNORMAL OPERATING CONDITIONS.Environmental conditions that are unfavorable, harmful,or detrimental to or for the operation of a crane.

Examples include excessively high or low ambienttemperatures, exposure to adverse weather, high

winds, corrosive fumes, dust laden or moisture ladenatmospheres, and hazardous locations.

ADJUSTABLE VOLTAGE. A method of control by whichthe motor supply voltage can be adjusted or varied.

APPOINTED (Person). One assigned specificresponsibilities by the employer or the employers

representative.

AUTOMATIC CRANE. A crane which when activated

will operated through a preset cycle or cycles.BOX SECTION. The rectangular cross section ofgirders, trucks, or other members which are enclosedon four sides.

BRAKE. A device, other than a motor, used for retarding

or stopping motion by friction or power means.

BRAKE, HOLDING. A friction brake for a hoist that is

automatically applied and prevents motion when powerto the brake is off.

BRAKE, PARKING. A brake for gantry or trolley thatmay be automatically or manually applied to impede

horizontal movement.

BRAKE, SERVICE. A brake for a gantry or trolley used

by the operator, during normal operation, to apply aretarding force to the applicable drive system.

BRAKING, COUNTERTORQUE (Plugging). A methodof controlling speed by reversing the motor line voltage,

polarity, or phase sequence to develop torque in thedirection opposite the rotation of the motor.

BRAKING, DYNAMIC. A method of controlling speed byusing the motor as a generator, with the energy being

dissipated in resistors.

BRAKING, REGENERATIVE. A method of controllingspeed in which the electrical energy generated by themotor is fed back into the power system.

BUMPER (Buffer). A device for reducing impact when amoving crane or trolley reaches the end of its permitted

travel, or when two moving cranes or trolleys come intocontact. The device may be attached to the gantry,trolley, or runway.

CAB. The operators compartment on a crane.

CABLE BASKET. A device mounted on the lifting beamused to pay out and collect the electrical cable which

feeds the grapple.

CABLE REEL, MAINLINE POWER. An electrically

operated device for laying down and picking up the mainpower cable which supplies electric power to the crane.

CANTILEVER. A girder section which protrudes beyondthe outboard side of the gantry legs.

CAPACITY. The maximum rated load which a crane isdesigned to handle.

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CLEARANCE. Distance from any part of the crane tothe nearest obstruction.

COLLECTORS, CURRENT. Contacting devices forcollecting current from runway or gantry conductors.

CONDUCTORS, GANTRY. The current conductors

located along the gantry structure of a crane that

transmit power to the trolley.CONTACTORS, MAGNETIC. An electro-magneticdevice for repeatedly establishing and interrupting anelectric power circuit.

CONTROLLER. A device for regulating, in a pre-

determined way, the power delivered to a motor or otherequipment.

CONTROLLER, MANUAL. A controller having all of itsbasic functions performed by devices that are operatedby hand.

CONTROLLER, SPRING RETURN. A controller that,

when released, will return automatically to a neutral(OFF) position.

CONTROL PANEL. An assembly of components(magnetic, static, hydraulic, pneumatic, etc.) that governthe flow of power to, or from, a motor or other equipment

in response to signals from a master switch, push buttonstation, remote control, automatic program control, or

other similar device.

CRANE. A machine for lifting and lowering a load and

moving it horizontally, with the hoisting mechanism asan integral part of the machine.

DEAD LOADS. The loads on a structure which remainin a fixed position relative to the structure. On a crane,

such loads include the girders, footwalks, cross shafts,drive shafts, panels, drive assemblies, etc.

DEFLECTION. Displacement due to bending or twistingin a vertical or lateral plane, caused by imposed live and

dead loads.

DESIGNATED (Person). One selected or assigned by

the employer or the employers representative as beingcompetent to perform specific duties.

DRIFT POINT. A point on a travel motion master switch

or on a manual controller that maintains the brakereleased while the motor is not energized. This allowsfor coasting.

DRUM. The cylindrical member around which the ropesare wound for lifting or lowering the load.

ENCLOSURE. A housing to contain electr icalcomponents, usually specified by a NEMA classification

number.

END APPROACH. The minimum horizontal distanceparallel to the runway, between the outermost

extremities of the crane and the centerline of the grpple

FIELD WIRING. The wiring required after erection of the

crane.

FIXED AXLE. An axle which is fixed in the truck and on

which the wheel revolves.FIXED LEG. The V shaped structure on each side othe gantry at the fixed leg end.

FLIP-OVER BRACKET. The main electrical feed pointgenerally located at the center of the crane travel, which

allows the electrical feed cable to flip-over as the cranepasses.

FOOTWALK. A walkway with a handrail attached to thegantry or trolley for access purposes.

GIRDER. The principal horizontal beams of the craneassembly which support the trolley and which is

supported by the end trucks.

HINGED LEG. The single leg structure on each side o

the gantry at the hinged leg end.

HOIST. A unit that is used for lifting or lowering a freely

suspended (unguided) load.

IDLER TRUCK. A non-powered truck traveling on the

crane rail providing support for the crane.

LIFT. The maximum safe vertical distance through

which the grapple can move.

LIFTING BEAM. The lower reeving assembly and cross

shaped structure which supports the grapple.LIVE LOAD. A load which moves relative to the structureunder consideration.

LOAD. The total superimposed weight on the grapple.

LOAD CARRYING PART. Any part of the crane in which

the induced stress is influenced by the load on thegrapple.

MAIN HOIST. The primary hoist mechanism providedfor lifting and lowering the rated load.

MATCH MARKING. The method of identification used

on non-interchangeable parts for reference duringassembly after shipment.

NEUTRAL POSITION. The OFF or middle position of a

master control switch lever.

NORMAL OPERATING CONDITIONS (Cab Operated

Cranes). Conditions during which a crane is performingfunctions within the scope of the original design. Unde

these conditions, the operator is at the operating controdevices, and there is no other person on the crane.

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PARTS OF LINE. The number of l ines of ropesupporting the grapple.

PITCH DIAMETER, ROPE. The distance through thecenter of a drum or sheave from center to center of a

rope passed about the periphery.

PORTAL CRANE. A gantry or semi-gantry crane in

which the gantry girders or trusses extend transverselybeyond the crane runway on one or both ends.

QUALIFIED (Person). A person who, by the possessionof a recognized degree or certificate of professional

standing, or who by extensive knowledge, training, andexperience, has successfully demonstrated the ability to

solve or resolve problems related to the subject matterand work.

RAIL SWEEP. A device attached to the crane andlocated in front of the cranes wheels to remove

obstructions from the runway rail.

RATED LOAD (Capacity) . The maximum loaddesignated by the manufacturer for which a crane orindividual hoist is designed and built to lift or lower

safely.

REEVING. A system in which a rope travels around

drums or sheaves.

REGULATED SPEED. A function which tends to

maintain a constant motor speed for any load for a givenspeed setting of the controller.

ROPE. Refers to wire rope unless otherwise specified.

ROTATING AXLE. An axle which rotates with the wheel.

RUNWAY. An assembly of rails, beams, girders,brackets, and framework on which the crane travels.

SERVICE CLASS, CMAA RATINGS. The following

service class rating has been taken in whole fromCMAA Specification #70, Revised 1983. It defines how

the Crane Manufacturers Association of Americaclassifies service duty of this crane.

Class F (Continuous Severe Service): This type ofservice requires a crane capable of handling loadsapproaching rated capacity continuously under severe

service conditions throughout its life. Applications may

include custom designed specialty crane essential toperforming the critical work tasks affecting the totalproduction facility. These cranes must provide the

highest reliability with special attention to ease ofmaintenance features.

SHEAVE. A grooved wheel or pulley used with a rope tochange direction and point of application of pulling

force.

SHEAVE, NONRUNNING (Equalizer). A sheave usedto equalize tension in opposite parts of the rope.

Because of its slight movement, it is not termed arunning sheave.

SIDE PULL. The portion of the hoist pull actionhorizontally when to hoist lines are not operated

vertically.

SPAN. The horizontal distance, center to center,

between the runway rails.

SPREAD. The horizontal distance, center to center,

between the trolley rails.

STOP. A device to limit travel of a trolley or crane gantry.The device normally is attached to a fixed structure andnormally does not have energy-absorbing ability.

SWITCH, LIMIT. A device that is actuated by the motionof a part of a power driven machine or equipment to

alter or disconnect the electric circuit associated with

the machine or equipment.SWITCH, MAIN (Crane Disconnect). A switch on thecrane controlling the main power supply from the cable

reel/transformer.

SWITCH, MASTER. A switch that dominates the

operation of contactors, relays, or other remotelyoperated devices.

TORQUE, FULL LOAD (Motor). The torque producedby a motor operating at its rated horsepower and speed.

TROLLEY. The unit that travels on the gantry rails and

supports the grapple.

TRUCK. A unit consisting of a frame, wheels, bearings,and axles that supports the gantry girders, and end tiesof the Straight Track Portal Crane.

WHEEL BASE. The distance from center to center ofthe outermost wheels.

WHEEL CHOCK. A wedge which prevents the cranefrom moving when unattended.

WHEEL LOAD. The load without impact on and wheelwith the trolley and lif ted load (rated capacity)

positioned to provide maximum loading.

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Figure 1-1 Straight Track Portal Crane

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Figure 1-2 Straight Track Portal Crane, Trolley

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Section 2

CONTROLS AND CRANE OPERATION

GENERAL

This section provides detailed descriptions of eachoperating control, as well as general instructions for the

recommended operation of this crane, including start-up and shutdown procedures. In addition to the safe

operating practices provided at the front of this manual,specific safe operating practices for this Straight TrackPortal Crane are also provided in this section.

SAFE OPERATING PRACTICES

General Crane Safety

The following are recommendations which should be

adhered to by all personnel in the vicinity of the crane.

1. Know how to give the EMERGENCY STOP signal.

The EMERGENCY STOP signal is defined inFigure 1 under the topic Safe Operating Practices,

in the preface of this manual.

2. Never divert the operators attention while he/she is

operating the crane.

3. Remedy and report all hazards which are found in

the operating area.

4. Be observant, and report all signs of damage or

wear to the components or runway.

5. Keep protective guards and fences in place.

6. Obey tag-out regulations, and out-of-order notices.

7. Board and leave the crane at designated boardinglocations.

8. Never ride on the Lifting Beam or Grapple.

9. Never work under a potential path of the load.

Safe Operating Practices

The following are specific safe operating practices forStraight Track Cranes, and are in addition to the Safe

Operating Practices published in the Preface.

1. Always set the storm brakes and turn the powe

OFF at the control console by depressing the

EMERGENCY STOP push button, before slidingback the operators chair.

2. Always use the seat belt.

3. Attach the chain across the walkway ladder to thetrolley platform or, if so equipped, close the

swinging gate.

4. Initiate and terminate crane motions in a smooth

fashion. Avoid start/stop/start/stop operations of thecrane motions.

5. During crane operations, should anything unusuaor unexpected happen, or for any reason the

operator feel threatened or out of control, move thecontrol levers to the OFF position, bringing the

crane to a controlled stop. If the situation dictatesdepress the EMERGENCY STOP push button shu

all crane motions down.Assess the situation. Do not over-react. Thencarefully start over.

6. The operator should always know where all groundtraffic and activity is around his crane and runway.

7. Never exceed the rated capacity of the crane.

8. Do not run the crane into the runway end stops.

9. Do not run the trolley into the girder end stops.

10. Never use limit switches to stop the gantry, trolleyor hoist. Limit switches are devices which must be

tested regularly but are not to be used as normaoperating controls. They are designed to stop a

crane motion if the operator has miscalculateddistance or speed.

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11. On all crane motions, the control levers can beimmediately returned to the neutral position for

stopping. The control is preset to provide anoptimum stopping distance for each crane motion.

The preset stopping distances can be extended bygradually moving the control levers back to neutral.

12. It is strongly recommended that every new operator

of a gantry crane familiarize himself with thestopping distances for that crane. To check thestopping distances, operate each motion at fullspeed over a safe distance and return the control

lever to neutral. Observe the actual distancerequired to come to a full stop.

13. Never raise the load any higher than necessary.

14. Do not raise a load unless the trolley is centeredover the grapple.

15. Do not drag the spreader across the ground.

16. Never raise a load of logs which are butt heavy.The logs may start to slide out of the grapple, andthe operator has no way of stopping them.

Whenever possible, lift a level load or a butt-lightload.

17. Do not move loads over personnel, trucks,equipment, or buildings.

18. When slack is apparent in the hoist lines, take upthe slack at a slow hoist speed until the ropes are

taut in all sheaves.

19. If the cable loop starts to fall out of the cable basket,

stop the hoisting motion, and lower the grapple until

the cable loop has corrected itself; then begin thehoisting motion again.

20. Do not let the grapple come into contact with the

deck chains. Keep the spreader a minimum of sixinches above the deck chains.

21. Do not allow excess spreader swing to develop.Swing can be minimized by allowing the spreader to

swing to one extreme, and then moving the crane ortrolley so as to catch up to the spreader.

22. Do not leave the crane cab in an electrical storm.

23. Do not operate the crane in high winds. If theweather becomes threatening, move the crane tothe parking area. Stop crane operation, tie down the

crane, and set the storm brakes.

24. If the operator looses control of the crane due to

wind forces, the s torm brakes should beimmediately set.

25. Use care when approaching the runway end stops.It can take up to 150 feet to bring the crane to a

controlled stop without wind.

26. Use the EMERGENCY STOP button in emergency

cases only. This control will set all motion brakesabrupt ly and br ing the crane to a great ly

accelerated stop.

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On-ground Inspections And BoardingChecks

The following on-ground inspections and boarding

checks should be performed on a daily basis:

1. Check for anything that will interfere with the safeand efficient operation of the crane.

2. Check runway for debris; track area must be clearbefore operating. Move the cab in line with runwayand visually check for debris or logs across the

runway.

3. Check that there are no obstructions or foreignmaterials laying in the pathway of the mainlineconductor cable reel or the conductor cable. Make

a quick visual inspection of the cable to verify thatthere are no abrasions or cuts in the cable.

4. Check the condition of the tracks. Report anyobvious damage which is found.

5. Check for fouling in the cable reel or excessivelyslack cable. Check the cable tension as described

in Section 12, Main Power Cable Reel.

6. Check TV Cameras (if supplied).

7. Check for worn or twisted hoist ropes.

8. Check grapple oil level. Do not use if low.

9. Check grapple oil temperature. Do not use if gauge

is in RED zone.

10. Remove wheel chocks and tie-downs, beforemoving crane.

11. When boarding the crane, repeat the visualinspection of the work area and the crane, from thehigher vantage point.

12. Check for loose objects across the girder, the cab,

and the walkways.

13. On the trolley, inspect gearboxes, motors and

brakes. Look for oil leaks, loose bolts and/or otherparts.

14. Check the hoist rope drum, spooling and lay of theropes on the drum.

15. Check the condition of the festoon conductorsystem, if supplied. (Not always used)

16. Check condition of the span bars and collectors.

17. Check the whisker limit switches located at theends of the drum to verify that they are in goodworking order.

18. Walk the length of the girder and visually inspect thepin connections at the legs. Verify all pin keepe

plates are in place.

Start-up Checks

CAB CHECKS. Perform the following start-up checks in

the cab, before operating the crane:1. Check the crane log entries.

2. Check the operation of the warning horn.

CONTROL CHECKS (POWER OFF). Perform thefollowing start-up checks at the control system locationbefore operating the crane:

! DANGER

Disconnect, lock open, and tag the powersource which feeds the crane to prevent

power from being applied to the crane whilerepairs are being performed. Before

beginning repairs, try the operationalcontrols to verify that the intended power

source is disconnected. Injury or death ofpersonnel will result if this precaution is not

observed.

1. Disconnect, lock open, and tag the disconnec

switch which feeds the crane to prevent power frombeing applied while repairs are being made.

2. Press the STOP button to verify that power is OFF

3. Operate each Master Switch in both directions to

verify smooth movement in all directions.

CONTROL CHECKS (POWER ON). Perform the

following start-up checks at the control system locationbefore operating the crane:

1. Energize the power system on the crane by placingthe mainline disconnect switch in the closed (ON)

position.

2. Press the START button. This function turns contro

power on, and will start the cable reel motors. Whenthe cable reel starts up, check that the reel rotates

slightly to take up the slack in the cable.

3. Raise storm brakes.

HOIST CHECKS. Check the operation of the hoist in thefollowing manner:

1. Move the grapple within five feet of the upper stop

limit, set by geared limit switch adjustment.

2. Run the grapple at medium speed into the uppe

geared limit stop position. The brake will set andhoist will quickly stop.

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3. Note response and report any failure of brake orupper geared limit switch.

4. The lower limit switch cannot be checked routinely(unless there is a hole or low spot in the yard). It

must be possible to lower the grapple, with the tineswide open, and touch the ground without tripping

the lower limit.

TROLLEY CHECKS. Check the operation of the trolley

in the following manner:

1. Move the left hand joystick control (master switch)

forward; the trolley should move forward.

2. While moving slowly, with the joystick control leverin the neutral position, momentarily depress theTROLLEY BRAKE SET push button on the left

joystick, to test trolley holding brake.

3. Move the left hand joystick back, the trolley should

move in reverse.

4. Return the control joystick to neutral to halt trolleymovement.

5. Move the trolley along the entire length of the girder,and report any unusual vibrations or bumps.

GANTRY CHECKS. Check the operation of the gantryin the following manner:

1. Move the left hand joystick control to the right; thecrane should move to the right.

2. Return the control joystick to neutral to halt gantrymovement. The brakes should apply, after a preset

time delay, when the control lever is moved to the

neut ra l pos i t ion . The gant ry b rakes w i l lautomatically release when control lever is movedto either gantry right or left position.

3. After the crane has been shut down for any lengthof time, it is advisable to check the cable reel when

the gantry is first moved. Move the trolley to aposition where the cable reel can be readily viewed;then, accelerate the gantry to the left (away from the

anchor point). Observe that the cable reel keeps upwith the crane and that the cable does not get

excessively slack. Then gantry right and observethat the cable is not under excessive tension.

Note: This crane is equipped with a traditional grapple,the term will be used to describe the function of the

device used to attach to and move loads.

GRAPPLE CHECKS: Check the operation of the

grapple (or whatever means is incorporated to lift loads)using the grapple manufacturers operating manual.

! DANGERWARNING

Do not depress the EMERGENCY STOP

push button while either the gantry or trolleyis moving. This control abruptly sets theparking brakes, which will cause flat spots

in the wheels due to brake lock up. Failure toobserve this precaution can result in

damage to the crane wheels and/or otherdrive components.

If the crane fails to operate as described in thepreceding steps, bring the crane to a full stop, depress

the EMERGENCY STOP push button to shut downoperation of the crane. Record malfunctions in the crane

log and report them to the appointed person in charge.

Shutdown Procedure

When shutting the crane down for a shift change,perform the following:

1. Bring the crane to the designated parking area andmove the trolley to the landing platform.

2. Place the grapple in the desired position for parking.

(Usually in highest position)

3. Place all controls in the OFF position (and set storm

brakes down if supplied).

4. Shut down the power to the crane by depressing the

EMERGENCY STOP push button.

5. Unbuckle the seat belt, and slide the operators

chair around.

6. Complete shift report and checklist.

7. Clean the cab area of any rubbish or trash.

8. On the way down the stairway or elevator, check forsafety hazards, and maintenance problems.

9. Turn the crane over to the next operator. Inform thenext operator of any maintenance or operating

problems, which have not yet been resolved.

When leaving the crane unattended, or shutting it down

for an extended period of time, perform the following in

addition to the checks outlined for a shift change:

1. Go to the various motor control panels, and turn offthe following breakers:

Trolley

Hoist

Control Power

Hoist Blower

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Grapple

Gantry

Cable Reel

2. Leave the light system power transformer on.

3. Descend to the ground, and connect the tie down cables to the end stop.

4. Tie the crane down by attaching the loose, open spelter socket to the equalizer truck, using the pin provided.

NOTICE

The fixed end of the tie down should already be secured to the runway mounted tie-down brackets.

Repeat this step for each truck as well as for each corner of the crane.

NOTICE

The grapple should be parked in the high position.

Figure 2-1 Armchair Assembly

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CAB PUSHBUTTON BOXELECTRICAL BRAKING

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Figure 2-3

0 -- NEUTRAL or OFF position, trolley is stopped with brakes on

1 -- Trolley moves forward at full speed

2-- Trolley moves backward at full speed

NOTE: Once trolley movement is initiated after crane start-up,the trolley brakes are off until the trolley brake parkpushbutton is pressed or the crane power is shutdown.

OCMl4OA

5 -- Trolley forward at half speed and crane portal moves to the right at halfspeed

6Trolley forward at full speed and crane portal moves to the right at fullspeed

OCMl40B0 NEUTRAL or OFF position, lifting beam is stopped with brakes on andgrapple does not rotate

1 Lifting beam lowered at full speed

2 grapple rotates clockwise at constant speed

3 Lifting beam raised at full speed

4 grapple rotates counterclockwise at constant speed

5 Lifting beam lowered at half speed and grapple rotates clock-wise at

TROLLEY MOVEMENT

Trolley ForwardLeftJoystickActions

1

0

2Trolley Reverse

SIMULTANEOUS TROLLEY AND CRANE MOVEMENT

Trolley Forward

LeftJoystickActions Portal

RightFull

Speed

LIFTING BEAM AND GRAPPLE MOVEMENTHoist Lower

6

5

1

3

0

RightJoystickActions

1

Gantry

Right

Gantry

Left

Hoist Raise

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OPERATING CONTROLS

The following list describes the control push buttons, the

joystick controllers, and the foot swi tches used tooperate this crane. Refer to Figure 2-1 on page 2-5 for

an illustration of the cab armchair controls.

1. JOYSTICK MASTER SWITCH, grapple SLEW/

HOIST. Use this lever to control the operation of thegrapple slew (rotation) and hoist functions. Move

this lever to the left to rotate the grapple to the left.Move this lever to the right to rotate the grapple tothe right. Grapple rotation remains constant

regardless of the amount of lever travel to the left orto the right. Pull this lever back to raise the grapple.

Move this lever forward to lower the grapple.

NOTICE

This control lever will permit the operator to varythe hoist drive speed almost infinitely between

the off position and the full-on position. Drivespeed varies proportionately with the amount ofcontrol lever movement. Slight movement away

from the vertical (neutral) position will operatethe associated drive at a slow speed, while

greater movement from the vertical (neutral)position will operate the hoist drive at a higher

speed.

2. TOGGLE SWITCH, grapple OPEN/CLOSE. Use

this toggle switch to open and close the grapple.Move the toggle switch to the LEFT to close the

grapple. Move the toggle switch to the RIGHT to

open the grapple. This switch is located on the topof the right hand joystick handle.

! DANGERWARNING

Do not depress the EMERGENCY STOPpush button while either the gantry or trolley

is moving. This control abruptly sets theparking brakes, which will cause flat spots

in the wheels due to brake lock up. Failure toobserve this precaution can result in

damage to the crane wheels and/or otherdrive components.

3. EMERGENCY STOP PUSH BUTTON. Use thispush button to disconnect power from the cranes

electrical systems. Fully depress this push buttonand release it to disconnect power from the craneterminating operation of the crane motions. This

push button when depressed will also set all motionbrakes.

4. START/RESET PUSH BUTTON. Use this pushbutton to apply power to the cranes electrical

systems. Fully depress this push button and releaseit to apply power to the crane allowing operation of

the crane motions.

5. Grapple PUMP START PUSH BUTTON. Use this

push button to apply power to the grapple pumpdrive motor. Fully depress this push button and

release it to apply power to the grapple pump drive

motor allowing operation of the grapple. Allow 5min. for grapple to warm up prior to use.

6. Grapple PUMP STOP PUSH BUTTON. Use this

push button to remove power from the grapplepump drive motor. Fully depress this push button

and release it to remove power from the grapplepump drive motor, terminating operation of thegrapple.

7. Grapple OPEN/CLOSE SELECTOR SWITCH. Usethis two position selector switch to select between

the foot pedal or thumb switch operation of the

grapple open/close feature. (Optional Feature)8. JOYSTICK MASTER SWITCH, GANTRY/

TROLLEY. Use this lever to control the operation of

the gantry and trolley drive functions. Move thislever to the left to move the crane to the left. Move

this lever to the right to move the crane to the right.Push this level forward to move the trolley forward.

Pull this lever back to move the trolley in reverse.

NOTICE

This control lever will permit the operator to varythe associated drive speed almost infinitely

between the off position and the full-on position.Drive speed varies proportionately with theamount of control lever movement. Slight

movement away from the vertical (neutral)position will operate the associated drive at a

slow speed, while greater movement from thevertical (neutral) position will operate theassociated drive at a higher speed.

9. HORN (SIREN) PUSH BUTTON. Depress and hold

this push button to sound the warning horn (siren)used on this crane.

10. TROLLEY BRAKE SET PUSH BUTTON. Depressthis push button to apply the trolley brake, for use asa parking brake. The trolley brake will then remain

applied until the trolley joystick control lever ismoved out of neutral in either direction. Trolley

brake release then occurs automatically, allowingfor movement of the trolley in either direction.

11. GANTRY POSITION RESET. (on touch screen).This resets the position control system. (Optional

Feature)

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Operational Notes, Log Handling Cranes

The following points cover general information

regarding the operation of the crane.

TROLLEY - - The following notes apply to the trolley

only. Always set the storm brakes and turn off power on

the control console by depressing the EMERGENCYSTOP push button, before sliding back the operators

chair.

Move the control lever to the full speed position

quickly (when safe to do so), using a smooth andcontrolled action. If the wheels start to spin, move thecontrol lever back to the neutral position, and

gradually bring the trolley up to speed.

To stop the trolley, allow the control lever to drop backinto neutral. The trolley will stop in a preset distance,which can be extended by moving control lever to

neutral gradually, but which cannot be shortened. To

determine actual stopping distance for a particulartrolley, start the trolley from a point which allowsoverrun and bring it up to full speed; then, drop the

control lever into neutral and observe the stoppingdistance.

NOTICE

The trolley is designed to float, and in this

manner will tend to line itself up with the load.On occasion, the trolley may overshoot the

desired position. If this happens simply move

the control lever to its slow speed position; thiswill correct the overshoot. Depressing the

trolley brake set pushbutton in the left handjoystick control lever will hold the trolley in the

desired position, such as when holding a loadover the slasher deck waiting for it to clear. The

trolley brake will release again when the pushbutton is released.

The TROLLEY BRAKE PARK push button located onthe control touch screen is only meant for use insetting the trolley brake when the trolley is to be

parked during boarding, exiting, and maintenance

procedures. The brake will automatically releasewhen the control lever is moved in either directionfrom neutral.

HOIST - - The following notes apply to the hoist only. Once the load has been secured, and it is safe to do

so, operate the hoist by moving the control lever tothe full on position. The acceleration rate is preset, so

the lever can be quickly moved to the full on positionwithout causing undue stress in the hoist drive. Theacceleration rate can be reduced by moving the

control lever more slowly. Reducing the accelerationrate is not normally needed, however.

To stop the hoist, allow the control lever to drop intoneutral. The deceleration rate is also preset, and wil

not vary significantly between no load and full loadgiven equal positions of the control lever. To

determine actual stopping distance for a particula

hoist drive, lift the hoist to a safe position and bring iup to full speed in the lower direction; then, drop thecontrol lever into neutral and observe the stoppingdistance.

Load Float will delay the brake set after coming to a

stop for up to 10 sec, allowing quick response to thenext master command. Load Float feature cranesmust follow the upper limit switch test procedure a

every shift start to assure brake surface cleaning(Optional Feature)

Do not jog the hoist controls. Allow enough time fo

the hoist motion to respond to all control commands Do not lift a swinging load. Correct load swing by

allowing the load to swing to one extreme. Then

quickly operate the gantry and/or trolley motions tomove the crane in line with the load so as to catch up

to the load.

Correct skipped grooves on the hoist drum by

opening the grapple completely, and running thegrapple down as far as it will go. Then raise the

grapple slowly, making sure that the wire ropes feedonto the drum properly.

GANTRY - - The following notes apply to the gantry only

Once the load has been secure, and it is safe to doso, operate the gantry at full speed.

To stop the gantry, allow the control lever to drop

back into neutral. The gantry will stop in a presetdistance, which can be extended by moving contro

lever to neutral gradually, but which cannot beshortened. Strong following winds can affecstopping distances and must be allowed for. To

determine actual stopping distance for a particulagantry, start the gantry from a point which allows

overrun and bring it up to full speed; then drop thecontrol lever into neutral and observe the stopping

distance. Generally, this distance is equal to two-thirds of the out-to-out distance of the legs.

Some cranes are equipped with a Plugging featureThis allows the operator to move the joystick to theopposite direction of travel and stop the motion in a

shorter distance. This improves spotting capabilityand load control. (Optional Feature)

Since the acceleration rate has been preset, thecontrol lever can usually be moved rapidly to the ful

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speed position without adverse affects. If, however,the wheels spin during acceleration, return the

control lever to neutral and move the gantry to speedmore gradually.

Grapple - - The following notes apply to the grapple only. When unloading, always keep the female (longer)

tines of the grapple towards the TV camera.

If a camera is not used, keep the female tines facing

the operator.

When laying loads down, stop the opening operation

to allow logs to settle out on the deck or storage pile.Then, after the load has settled out, raise the grapple

from the deck or storage pile.

CRANE OPERATION

General

The following paragraphs provide general instructions

on the operation of the Straight Track Portal Crane.These instructions do not try to instruct a person on how

to operate this specific crane, but are general operatingprocedures which may apply to many Straight Track

Portal Cranes.

Depress the START button to apply power to the cranes

electrical systems. This will also start the mainline cablereel. Upon start-up of the cable reel, the reel should

rotate slightly to take up the slack in the power cable. Ifnot, have maintenance inspect, and if necessary, repairthe cable reel.

Depress the spreader START push button to start the

hydraulic system on the grapple. Allow the grapplepump to run for at least 5 minutes before attemptingoperation of the grapple. Then slowly open and close

the grapple several times to warm the grapple hydraulicsystem oil. The grapple should always be fully opened

first to synchronize both tines. During this warmupoperation of the grapple, visually check for hydraulic

system leaks. Rotate the grapple in both directions toverify that it rotates properly, and that there is no bindingduring rotation.

NOTICE

During cold weather, al low the grapple

hydraulic system to warm up for a least 10minutes before attempting grapple operation.

At the start of each shift, it is important to check the hoistupper limit switch to verify that it operates properly. The

upper geared limit switch should stop the hoist travelbefore the trip comes into contact with the final (weight

type) limit switch. If the final limit switch does not actuatein this type of test, adjust the geared limit switch. When

testing the stop limits, never operate the hoist at highspeed. Start to move the gantry at slow speed to check

mainline cable reel operation. If the cable reel does notretrieve or pay out the cable properly (excessive tension

or excessive slack), stop crane operation and refer the

problem to the maintenance personnel.

Hoist Operation

The hoist motor is an AC Inverter Rated Squerrel cage

Induction Motor and operates in conjunction with anelectric shoe brake. When stopping the load by bringing

the control lever to neutral, the shoe brake will apply tofinal stop and hold the load.

When raising the grapple, the amount of time requiredto slow the load to creep speed will be less, but the

same operating procedures used for lowering a loadshould be practiced.

The following are the suggested hoist operatingprocedures:

NOTICE

For better operator understanding, we segmentthe up control into five different positions. The

same is true of the down control. The firstsegment is indicated by a detent. Segments 2

through 5 are actually stepless.

1. Move the control lever back to raise the grapple.

When picking a load, operate in steps 1 and 2 of thecontrol handle position until slack is out of the hoist

cables, and the load appears to be properlybalanced.

Accelerate rapidly, but smoothly, through steps 3, 4and 5.

Decelerate from step 5 smoothly through to step 2,step 1, and then to neutral (OFF).

2. When lowering loads, move the control leverforward.

Use steps 1 and 2 of the control handle position tostart the load moving down.

Accelerate smoothly through steps 3 through 5.

During deceleration of the load, bring the controlsmoothly back to approximately the step 2 position.This will bring the load to a slow controlled motion.

Then, move the control lever to neutral to come to acomplete stop.

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Gantry Operation

The gantry motors are the AC squirrel cage induction

type used in conjunction with an AC electric disc typeholding brake. Once the crane has stopped, and after a

short time delay, the holding brakes are applied to holdthe crane stationary. When the gantry is moving at aslow speed and the operator wishes to spot a load,

move the control lever to the neutral (OFF) position. Thiswill allow the gantry holding brakes to come on and hold

the crane in position over the load. The gantry holdingbrakes have an adjustable timer which keeps the brakes

off for a predetermined time period after the controllever is returned to the neutral (OFF) position. The braketimer bypass footswitch cuts out the t imer and

immediately sets the gantry brakes.

Trolley Operation

!

DANGERWARNING

The EMERGENCY STOP push button when

depressed will set ALL brakes immediately.Due to the extreme shock loads which are

placed on the crane when this is done, theEMERGENCY STOP push button shouldonly be used when absolutely necessary.

The trolley controls include brake set push

buttons which will apply the trolley brakeswhen depressed. Do not depress the push

buttons while the trolley is in motion. Failureto observe this precaution can result indamage to the trolley wheels and/or drive

system.

The trolley drive motors are of the AC squirrel cageinduction type and are used in conjunction with AC disctype holding brakes. The brake circuit is designed to

keep the trolley brake released (coil energized) evenwhen the control lever is in the neutral position, unless

the brake set push button has been depressed. Whenthe operator wishes to bring the trolley to a stop, bring

the control lever back to the neutral position.

NOTICE

If for any reason the operator does not wish thetrolley to move, depressing the push button inthe left hand joystick control lever will apply the

trolley brakes.

Note that, after depressing the trolley brakepush button on the console, the trolley brake will

remain set until the joystick control lever ismoved out of the neutral position in either

direction. The push button in the joystick controllever, on the other hand, will cause the trolley

brake to remain set only so long as the pushbutton is held depressed.

Grapple Operation

Start the grapple pump, and allow it to run for 5 minutesbefore attempting grapple operation. In cold weatherincrease the warm-up time to 10 minutes.

Open and close the grapple several times. Do not allow

the cylinders to bottom out during the first fewoperations. If operation is sluggish or noisy, repeat theopening and closing operations again; this will remove

air from the hydraulic system. If, after opening andclosing the grapple 10 times, noise or sluggishness

persists, shut down the grapple operation and advisethe maintenance department for further assistance.

NOTICEStop the crane operations, and depress the

EMERGENCY STOP push button to shut downthe crane, if the grapple fails to respond to theabove preliminary tests.

To accurately position the grapple over a load, it musfirst be lowered close to the load to better judge the

distances.

When picking up a load on flat ground, the grapple musbe raised as it is being closed to avoid excessively slackcables, and to avoid digging into the ground.

Remember to slow motions down well in advance oplanned stops. No motion stops immediately.

Be familiar with the equipment which you use. This wil

aid at the time of visual inspections because things ouof the ordinary will tend to stand out. The operatoshould question anything which is out of the ordinary.

Logs, particularly hardwood logs, are extremely slipperywhen wet.

Handle loads which are balanced, or will wedge in the

grapple.

MATERIAL HANDLING

General

The following steps provide general instructions fo

unloading trucks, reclaiming wood from the log piletransporting wood with the crane, and for loading the log

deck. These instructions are general in nature and applyto all Log Handling Straight Track Portal Cranes.

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Unloading Trucks

The following paragraphs describe general practices

which may be used when unloading trucks:

1. Use the hoist, gantry, and trolley controls to position

the grapple over the truck load.

2. Rotate the grapple to line up with the load to be

lifted. Make sure that the female tines of thespreader face towards the television camera. If the

crane is not equipped with a TV Camera, face thefemale grapple tines toward the operator.

3. Position the grapple such that the heavy end of theload will be opposite the truck cab. Always pick up

the load slightly off center such that the butt ends ofthe logs will be higher than the small end of the logs

when the load is raised off the truck.

4. Lower the grapple to the point just above the load

with the tines opened to a position which places

each tine approximately two feet to the outboundside of the load.

5. After the grapple has been positioned, the crane

operator should wait for the truck driver or theappointed person to give hand signals.

NOTICE

Each site should consider how much the truckdriver will be requested to assist in the off

loading operations.

6. If the actions of the truck driver are unclear to the

crane operator, the crane operator is to stop alloperations and alert the truck driver.

7. Lower the grapple and close the tines to secure theload. The truck driver must be well away from the

load at all times when the truck is being unloaded.

NOTICE

If the trolley will not remain spotted over theload because of high winds or other reasons,

depress and hold the trolley brake set pushbutton in the left hand joystick control lever. The

trolley brake will remain set only so long as thepush button is held depressed. Release thepush button when the load is in the grapple and

the trolley must be moved.

8. Once the load has been lifted off the truck, thecrane operator should gantry back away from thetruck cab. From this point on, the crane operator has

full responsibility for the load and its disposition.

Reclaiming Wood From The Log Pile

The following paragraphs describe general practices

which may be used when reclaiming wood from a logpile:

1. To minimize log breakage in long-term storageareas, operators should try to reclaim wood from

the peaks of the log piles.

2. Lower the grapple onto the log pile. Close the

grapple to secure the load.

3. As the grapple envelopes the load, raise the hoist

slightly. This causes the logs to rotate up into thegrapple, rather than jamming in the tines.

4. When lifting a load from the pile, estimate its centerof gravity. Having the load suspended slightly off

level, with the butt ends of the logs higher than thesmaller ends, is the safest manner in which to

transport a load.

5. When the load is clear of the log pile, and it must berotated, use the grapple slew control as required.Carefully timed intermittent jogging of the slew

controller eases the load on the slew drive andprevents the logs inertia from winding-up the hoistropes.

6. Leave single logs or isolated small groups of logs

for future consolidation into a group when timepermits.

Transporting Wood With The Crane

The following steps describe general practices whichmay be observed when transporting wood with thecrane:

1. Never leave a load hanging on a crane when thecrane is unattended for any period of time.

2. Never lift more than the rated capacity of the crane.

3. Avoid dropping loads. This can be caused by: Failure to verify that the load is safely clamped in the

grapple before lifting and then traveling.

Failure to hold the grapple close during the move.

Failure to verify that the wire ropes and sheaves arein good condition. Worn sheaves can cut into ropes

and cause them to break.

4. Do not transport loads over the roadway, the log

deck, or over traffic.

5. If, when operating the hoist, the wire ropes start

jumping, the operator should stop the craneoperation and inspect the drum. It is possible that

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the ropes have doubled up or jumped the drumgrooves.

6. Avoid careless placing of logs, which may becaused by:

Failure of the operator to nest logs, resulting in highstacks which can roll away. Refer to the terminology

list in Section 1 for a definition of nesting.

Loads