Assembly & Commissioning

of Mobile Harbour Cranes

Based on a G HMK 6407
 Transport via rhine port
Dsseldorf-Reisholz

Overnight transport of crane Direct delivery by motor coaster to

components by low-loader and rail customers in Europe
Worldwide shipping via the sea ports in
to the nearby Rhine port Rotterdam-Schiedam or Antwerp
2
Option: Assembly at the Terex
Service Centre in Antwerp, Belgium (I)

Assembly in the seaport of Antwerp Commissioning and testing at the

Excellent support provided by the Terex assembling site in Antwerp
Service Centre

3
Option: Assembly at Terex
Service Centre in Antwerp, Belgium (II)

Commissioned and tested crane is ready-for-operation

RoRo or heavy-load ship transport to the customer

4
Unloading and positioning of components (I)
Day 1

G HMK 6407 Assembly Requirements

Equipment sufficient to lift:
Chassis weight [t] 94
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
radius [m] 15
hook height [m] 21
Tower weight [t] 60
radius [m] 12
hook height [m] 45
Boom weight [t] 33
radius [m] 15
hook height [m] 26
Counterweight weight [t] 33.8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5.6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Manlift, approx. height 20 m
Further requirements:
Approx. required assembly area 80 m x 20 m
Container, empty 20 ft.
Power supply 380 V; 63 A

Required assembly area: 80 m x 20 m

5
Unloading and positioning of components (II)
Day 1

For unloading the components of a
G HMK 6407 a 400-t-crane* or sufficient
ship crane or Terex Gottwald Harbour
Crane is needed
All components have to be positioned in
the assembly area according to
assembly process
The superstructure should be mounted
onto chassis during unloading operation
If required, the crane can travel to the
assembly area under own power
This operation is possible after
superstructure and chassis are bolted
together and connections from
superstructure and chassis are fixed

6
Mounting superstructure onto chassis
Day 1

G HMK 6407 Assembly Requirements

Equipment sufficient to lift:
Chassis weight [t] 94
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
radius [m] 15
hook height [m] 21
Tower weight [t] 60
radius [m] 12
hook height [m] 45
Boom weight [t] 33
radius [m] 15
hook height [m] 26
Counterweight weight [t] 33.8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5.6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Manlift, approx. height 20 m

Cleaning the slew ring

Preparation of bolts to mount superstructure onto chassis
Guiding pins are used to avoid damage to bolts when superstructure
lowered onto chassis
Bolts tightened by means of torque equipment
7
Mounting tower onto superstructure (I)
Day 1 to Day 2

G HMK 6407 Assembly Requirements

Equipment sufficient to lift:
Chassis weight [t] 94
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
radius [m] 15
hook height [m] 21
Tower weight [t] 60
radius [m] 12
hook height [m] 45
Boom weight [t] 33
radius [m] 15
hook height [m] 26
Counterweight weight [t] 33.8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5.6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Manlift, approx. height 20 m
Further requirements:
Approx. required assembly area 80 m x 20 m
Container, empty 20 ft.
Cleaning the tower flange Power supply 380 V; 63 A
Preparation of bolts to mount tower onto superstructure

8
 Mounting tower onto superstructure (II)
Day 1 to day 2

Assembly crane begins with 26.8 t load

Assembly crane required capacity: 61 t

Tailing crane load: 32.7 t

Assembly crane required

capacity: 41 t

Please note:
For all tandem-lift operation, the lifting
capacities of all the assembly cranes
may only utilise 80% of the lifting
capacity chart with 75% tipping moment.
Therefore: Allow a safety margin of 20%
for each lifting crane.

To lift tower in an upright position, two cranes are needed

The first crane lifts tower onto the superstructure. The second crane backs up first
crane during tailing operation.

9
Mounting tower onto superstructure (III)
Day 1 to day 2

G HMK 6407 Assembly Requirements

Equipment sufficient to lift:
Chassis weight [t] 94
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
radius [m] 15
hook height [m] 21
Tower weight [t] 60
radius [m] 12
hook height [m] 45
Boom weight [t] 33
radius [m] 15
hook height [m] 26
Counterweight weight [t] 33.8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5.6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Manlift, approx. height 20 m
All bolts are placed and tightened up temporarily
Further requirements:
Bolts then tightened by means of torque equipment Approx. required assembly area 80 m x 20 m
After that, high-capacity assembly crane no longer Container, empty 20 ft.
Power supply 380 V; 63 A
required

10
 Assembly of stabiliser beams and pads (I)
Day 3 to day 4

G HMK 6407 Assembly Requirements

Equipment sufficient to lift:
Chassis weight [t] 94
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
radius [m] 15
hook height [m] 21
Tower weight [t] 60
radius [m] 12
hook height [m] 45
Boom weight [t] 33
radius [m] 15
hook height [m] 26
Counterweight weight [t] 33,8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5,6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Manlift, approx. height 20 m
Further requirements:
Approx. required assembly area 80 m x 20 m
Container, empty 20 ft.
Power supply 380 V; 63 A

Assembling of stabiliser beams using a 40 t crane or a forklift

11
Assembly of stabiliser beams and pads (II)
Day 4 to day 5

G HMK 6407 Assembly Requirements

Equipment sufficient to lift:
Chassis weight [t] 94
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
radius [m] 15
hook height [m] 21
Tower weight [t] 60
radius [m] 12
hook height [m] 45
Boom weight [t] 33
radius [m] 15
hook height [m] 26
Counterweight weight [t] 33.8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5.6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Manlift, approx. height 20 m
Further requirements:
Approx. required assembly area 80 m x 20 m
Assembling of stabiliser pads using a forklift Container, empty 20 ft.
Installation of all hydraulic and electric connections Power supply 380 V; 63 A

Final adjustments of e.g. proximity switches performed during commissioning

12
Assembly of tower cab
Day 5 to day 6

Hook height: 31.6 m

Cab weight: 3.5 t

Electrics are tested before tower cab is fitted to

tower
For mounting tower cab onto tower,
a 40 t crane is required
Cables from the tower are connected to the
tower cab

13
Preparation of boom (I)
Day 6 to day 7

Boom root and boom head are bolted together at quay level
Bolts are tightened by means of torque equipment
Bolts are protected against corrosion by applying paint
Installation of electrical cables throughout the entire boom

14
Preparation of boom (II)
Day 7 to day 8

Mounting cable reel and installation on boom head

Connecting cables from boom to cable reel
Mounting of lamp fixtures onto boom

15
Assembly of luffing cylinder and boom (I)
Day 9 to day 10
Required capacity: 15.5 t Required capacity: 25.5 t G HMK 6407 Assembly Requirements

Crane 2 Crane 1
Equipment sufficient to lift:
Chassis weight [t] 94
12.3 t 20.3 t
radius [m] 15
hook height [m] 15
Superstructure weight [t] 98
Length approx. radius [m] 15
10.5 m hook height [m] 21
Tower weight [t] 60
Weight incl. cylinder: 32.5 t radius [m] 12
hook height [m] 45
Boom weight [t] 33
2 x 8 m sling (double lay = 4 m long) 2 x 10 m sling radius [m] 15
Force of each: 6.7 t (double lay 5 m long) hook height [m] 26
Force of each: 10.8 t
Counterweight weight [t] 33.8
radius [m] 14
hook height [m] 16
Cylinder weight [t] 5.6
radius [m] 15
hook height [m] 8
Forklift, approx capacity 15 t
Boom must be turned over before being attached to Manlift, approx. height 20 m

tower Further requirements:

Approx. required assembly area 80 m x 20 m
Two cranes required for lifting boom Container, empty 20 ft.
A third lifting machine required to turn over boom to its Power supply 380 V; 63 A
assembling position

16
Assembly of luffing cylinder and boom (II)
Day 9 to day 10

One end of the luffing cylinder attached to the turned-

over boom
Other end of the luffing cylinder secured to the boom
using sling

17
Mounting boom onto tower (I)
Day 9 to day 10

Two cranes lift boom and luffing cylinder onto tower

First, luffing cylinder is attached to tower

18
Mounting boom onto tower (II)
Day 9 to day 10

Then boom root attached to tower

Electric cables, hydraulic and grease system connected

19
Mounting counterweight onto superstructure
Day 10 to day 11

2 slings, min. length: 4 m

Each with force of 19.3 t

Max. 35 t HC2 shackle

Counterweight slabs, weighing

Approx. 16,000 mm
max. 33.75 t each, mounted
Counterweight slabs secured and bolts
tightened by means of torque wrench

20
Installation of hoist ropes
Day 11 to day 13

Boom head
rope pulleys Tower head
rope pulleys

Right-handed
rope

Left-handed
rope

Rope drum,
left-handed

Rope drum

First, nylon ropes installed

By means of these nylon ropes, hoist ropes
installed

21
Preparing the hook
Day 11 to day 13

Assembly of the hook to ropes

Set limit switches of hoist and luffing gear

22
Commissioning of crane
Day 14 to day 21

Safe load indicator calibrated using test Different components, electrics and
weights mechanics checked and adjusted
Slew ring clearances checked

23
Overload and acceptance test
Day 14 to day 21

Dynamic and static overload tests using

different certified test weights (up to 110 t /
125 t)

All functions and equipment tested

Emergency stop tests performed

Safe load indicator and limit switches

tested

24
Required equipment (I)

Telescopic cranes:
100 t capacity at 15 m radius
80 t capacity at 8 m radius
50 t capacity at 8 m radius

25
Required equipment (II)

50 kVA Diesel-generator set, container, forklift (5 t)

Manlift 24 m Forklift 16 t

26
 Required equipment (III)

HMK 170 E HMK170 EG HMK 260 E HMK 260 EG G HMK 4406 G HMK 6406 G HMK 6407 G HMK 7408 G HMK 8310
Chassis weight [t] 63,0 75,0 69,0 68,7 81,5 90,0 94,0 116,0 155,2
radius [m] 10 10 10 10 15 15 15 15 15
hook height [m] 13 13 13 13 14 15 15 15 18
Superstructure weight [t] 59,0 66,0 80,o 75,4 72,0 94,0 98,0 105,0 141,2
radius [m] 10 10 10 10 15 15 15 15 15
hook height [m] 21 13 21 21 19,5 21 21 20 21
Tower weight [t] 30,5 32,0 37,0 36,0 41,5 44,0 60,0 64,0 81,5
radius [m] 11 11 11 11 11 12 12 12 12
hook height [m] 34 34 35 35 37 38,5 45 47,2 46
Boom weight [t] 16,3 22,0 28,0 28,0 30,3 33,0 33,0 42,3 60,5
radius [m] 12 12 12 12 15 15 15 15 15
hook height [m] 19 19 20 20 21 26 26 26 24
Counterweight weight [t] 17,5 ? 33,0 17,0 34,0 33,8 33,8 33,8 33,8
radius [m] 14 14 14 14 12 14 14 14 14
hook height [m] 12 12 12 12 20 16 16 16 16,5
Cylinder weight [t] 3,9 4,2 4,8 ....... 5,2 5,6 5,6 7,6 9,4
radius [m] 16 16 16 16 15 15 15 15 15
hook height [m] 14 14 14 14 8 8 8 8 8
Approx required assembly area 70 m x 25 m70 m x 20 m70 m x 25 m70 m x 25 m70 m x 25 m75 m x 25 m75 m x 25 m80 m x 25 m80 m x 25 m
Forklift, approx capacity 10 t 10 t 15 t 15 t 6t 15 t 15 t 15 t 15 t
Manlift, approx. height 19 m 20 m 20 m 20 m 20 m 20 m 20 m 25 m 25 m
Container, empty 20 ft. 20 ft. 20 ft. 20 ft. 20 ft. 20 ft. 20 ft. 20 ft. 20 ft.
Power supply 380 V; 63 A 380 V; 63 A 380 V; 63 A 380 V; 63 A 380 V; 63 A 380 V; 63 A 380 V; 63 A 380 V; 63 A 380 V; 63 A

Additional equipment:
Attachment material (slings, shackles, etc.) for lifting equipment
Certified weights for crane overload test

27
Terex Gottwald Mobile Harbour Crane
Ready for operation

28