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Hydraulic boom crane, SWL 75 t (Technical supply specification)


1. General Data (Operating Conditions)

The boom crane operates reliably under the following conditions:

  • Year-round operation.
  • Ambient operating temperature range from -45 °C to +45 °C.
  • High airborne dust concentration (>4 mg/m³).
  • Wind pressure up to 15 kPa.
  • Maximum wind speed:
    • operational: 20 m/s;
    • non-operational: 31 m/s.
  • Snow load up to 85 kPa.
  • Outdoor operation without shelter, exposed to environmental factors (temperature, snow load, rain, dust, etc.).
  • Annual equipment utilization factor = 0.80 (crushing duration = 292 days/year).
  • Operation in temperate and cold climate areas.

Crane duty group A3 according to GOST 34017-2016 (heavy-duty operation).

Design service life is not less than 25 years.


2. Purpose

The boom crane is designed for handling operations during various technological and maintenance procedures. The unit incorporates state-of-the-art technical solutions matching leading global manufacturers.

Hydraulic boom crane, SWL 75 t. General arrangement drawing, side view.
Hydraulic boom crane, SWL 75 t. General arrangement drawing, side view.

About

Continuous Installation in Industrial Environments

Large-scale production facilities routinely require the handling of heavy equipment components, including crushing and screening assembly sections, steel structures, and process modules. Operations are frequently carried out adjacent to live production lines. In these environments, precise positioning within confined spaces is critical, alongside the lifting capacity itself, to prevent disruption to the primary process.

Limitations of Conventional Solutions

Standard crane solutions often present integration challenges within modern production layouts. They can require dedicated infrastructure, complex power and control interfaces, or fail to provide the necessary control precision. Furthermore, enterprises face risks related to import dependency, resulting in extended equipment lead times, as well as complicated servicing and spare parts procurement.

Equipment Capable of Meeting These Demands

Industrial enterprises require a crane that integrates seamlessly as part of the technological system. It must maintain stable operating parameters, interface directly with industrial networks without complex conversions, and transmit data to automation systems.

Solution Implementation in Modern Crane Design

The hydraulic boom crane features a 75 t main hoist capacity, a 10 t auxiliary hoist capacity, a hydraulic drive, a 360° continuous slewing range, and wireless control. The equipment is designed to connect to a 380 V industrial power supply, with a total installed power rating of up to 160 kW.

Such solutions are currently engineered by companies including Izhora Hydrosystems, with a specific focus on integration into live operational production complexes.

Evidence of Practical Efficiency

The control system monitors equipment operating parameters, enables load-dependent operating limits, and interfaces directly with enterprise automation systems. Delivery within a complete scope of supply simplifies installation and reduces commissioning timelines. The modular scalability of the electrical equipment allows the unit to be tailored to specific production tasks.

Broader Industrial Impact

Utilizing domestic crane equipment reduces dependence on foreign OEMs, making modernization schedules more predictable and simplifying service maintenance. At the same time, the equipment effectively handles critical heavy-duty material handling tasks without introducing additional complexity to operations or infrastructure.


3. Scope of Supply

3.1 Hydraulic Boom Crane 75 t x 10 m (10 t x 12.5 m)

3.1.1 Product Composition

ComponentQuantity
Hydraulic boom crane 75 t x 10 m (10 t x 12.5 m), complete unit1 pc.
Column1 pc.
Crane boom1 pc.
Boom luffing cylinder1 pc.
Slewing drive1 pc.
Hydraulic power unit (HPU)1 pc.
Main hoist winch1 pc.
Hook block, 75 t, with matching wire ropes1 pc.
Auxiliary hoist winch1 pc.
Hook block, 10 t, with matching wire ropes1 pc.
Heated cabin with operator seat and control console (heated windows equipped with wipers)1 pc.
Wireless control unit (operating range 50 m)1 pc.
Power cabinet1 pc.
Floodlight (jib-tip mounted)1 pc.
Crane housing1 pc.
Ladder1 pc.
Walkway with handrails1 pc.
Machinery room1 pc.
Hydraulic oil heating and cooling system1 pc.
CCTV system1 set
Electrical equipment (shock- and vibration-resistant LED lights, lanterns, and floodlights for cargo operation area illumination, etc.)1 set
Fasteners for boom crane installation and assembly on the crushing and screening plant steel structure (support column), with a 10% margin for each item1 set
Cable package (length to be specified during detailed design of the crushing and screening plant)1 set
Piping, hosing, high-pressure hoses, and other components for hydraulic and electrical equipment connection1 set
Spare parts kit (commissioning and trial run period)1 set
Wear parts kit for 1 year of operation (composition to be finalized after contract award, during detailed design documentation development)1 set
Consumables (lubricating oils, fluids, etc.) for initial filling1 set
Hydraulic boom crane, SWL 75 t. General arrangement drawing, top view.
Hydraulic boom crane, SWL 75 t. General arrangement drawing, top view.

3.1.2 Main Parameters

ParameterValue
Crane drive typeHydraulic
Main hoist load capacity, t75
Auxiliary hoist load capacity, t10
Main hoist reeving factor6
Auxiliary hoist reeving factor4
Main hoist hook lifting height, m15
Auxiliary hoist hook lifting height, m15
Outreach, mUp to 12
Main hoist hook speed, m/s0.13
Auxiliary hoist hook speed, m/s0.2
Crane slewing speed during single motion, rpm1
Crane slewing speed during combined motions, rpm0.5
Slewing angle, °360 (continuous)
Crane duty group during main hoist operation according to GOST 34017-2016A3
Crane duty group during auxiliary hoist operation according to GOST 34017-2016A3
Crane controlFrom heated cabin
Crane controlVia wireless control unit (operating range 50 m)
Total crane mass (without hydraulic fluid), t, max.120
Current type and voltageAC 50 Hz; 380 V
Installed electric motor power, kW, max. (including main pump unit electric motor)160
Seismicity of the installation area on the MSK-64 scale, points, max.8
Climate design of the equipmentUHL1 (temperate and cold climate)
Hydraulic oil type for the crane hydraulic systemAUP

3.1.3 Spare Parts Kit (ZIP)

Spare parts kit according to manufacturer standard for 1 year of operation — 1 set.

3.1.4 Documentation

DocumentQuantity
Data sheet (Passport)1
Installation, operation and maintenance manual1
List of spare parts1
Factory acceptance test report1
Shipboard test procedure and program1

3.1.5 Certificates

Certificates, declarations of conformity with the Technical Regulations of the Customs Union / Rostekhnadzor permit for commissioning, industrial safety expertise conclusion for the supplied equipment.


4. Additional Requirements

  • Type of cargo handled: piece goods (machine parts (cone crusher, apron feeders, hopper liners, oil drums, etc.) and modular units of the crushing and screening plant (frames, columns, beams, etc.)).
  • The boom crane is designed with a sufficient margin of safety to withstand lateral, torsional, and bending loads, as well as vibration and shock loads.
  • The color scheme shall be coordinated with the Customer during the detailed engineering stage. Painted surfaces shall be resistant to corrosion, aggressive environments (lubricating oils and fluids, abrasive dust), atmospheric precipitation, impact from small stones during dump truck unloading, and sharp ambient temperature fluctuations.
  • Preservation coating systems ensure an indoor shelf life of 12–18 months.
  • Hydraulic system operating fluid — AUP. Hydraulic fluid cleanliness class according to GOST 17216-71, not lower than 12.
  • Equipment is delivered in packaging suitable for handling by both crane and forklift, road transport, and storage in open areas under shelter.
  • The boom crane is supplied complete with a power control cabinet featuring integrated soft starters and variable frequency drives (VFD), providing power supply and control for all connected equipment (VFDs and soft starters for connected equipment may be supplied as standalone cabinets, not integrated into the main power cabinet assembly).
  • Layout solutions for the power cabinet and the final control philosophy shall be coordinated with the Customer during the engineering stage.
  • The list of equipment supplied complete with soft starters/VFDs is subject to additional coordination with the Customer.
  • High-quality circuit breakers from leading global manufacturers are used (proposed equipment shall be coordinated with the Customer).
  • Panels (cabinets) are designed with a 20% future expansion capacity to accommodate additional equipment (circuit breakers, terminal blocks, intermediate relays).
  • Panels (cabinets) feature mains voltage signaling, as well as normal operation and alarm indication for electrical equipment, with alarms routed to the local automation control system.
  • Cabinets are equipped with a documentation pocket (general arrangement, specification, schematic diagram, data sheet), internal lighting, and 230 V socket outlets.
  • Distribution boards and low-voltage switchgear cabinets feature an IP31 protection rating for installation in electrical rooms. Power and control cabinets intended for installation directly adjacent to the equipment feature an IP65 protection rating and UHL4 climate design (all cabinets, including control and power assemblies, are fabricated from stainless steel). Cabinet equipment features a modular design (mounted on DIN rails or mounting plates) with bottom cable entry/exit (cable entry/exit configurations shall be coordinated with the Customer during the engineering stage).
  • The quantity, dimensions, and arrangement of cabinets, as well as the availability of local control stations, shall be coordinated with the Customer due to limited installation space within the premises.
  • A local control station is provided for the electric drive within the housing (operator cabin). The station is resistant to aggressive environments, features equipment operation status indication, and has an IP65 protection rating. The operator cabin is mounted on vibration isolators. The cabin provides all required functionality, optimal visibility, and high ergonomics. “Start”, “stop”, and latching “emergency stop” modes are provided, along with remote (automated) equipment control (from the control room).
  • All electrical equipment, automation systems, and instrumentation are designed for operation under the environmental conditions specified in this technical specification.
  • The boom crane is equipped with the necessary maintenance walkways with handrails, as well as platforms, ladders, and access walkways leading from the crushing and screening plant steel structures to the crane cabin. The arrangement of walkways leading from the crushing and screening plant steel structures to the crane cabin shall be coordinated with the Customer during the basic engineering stage.
  • The safety integrity level is verified by matching calculations (calculations shall be performed and submitted after contract award).
  • The boom crane control system is equipped with a controller featuring the following functions:
    • Control and adjustment of unit parameters (circuit operating speeds, maintenance scheduling).
    • Interfacing with the crushing and screening plant automation system (transmission of alarms, status signals, and diagnostic data) via the Profinet protocol; the signal list shall be defined during the engineering stage.
    • Ensuring the required equipment operation monitoring (pressure, temperature, oil level, lubrication flow, etc.) while maintaining safety interlocks from both the boom crane system and external protection and interlocking systems.
    • Ensuring safe startup without requiring additional equipment or systems.
    • Displaying the rated capacity chart for the selected operating mode on the panel, along with real-time crane performance data (hook load, boom position, hook position, speeds, electrical equipment parameters, mechanism statuses, etc.).
    • Ensuring crane load moment limiting (overload protection) during main and auxiliary hook operations.
    • CCTV monitoring of primary crane assemblies and providing a clear view of the working area to facilitate cargo operations (camera installation locations shall be coordinated with the Customer).
  • Markings on all equipment are clearly legible, in Russian, and based on the metric system of weights and measures according to the International System of Units (SI).
  • All measuring instruments included in the scope of supply shall be coordinated with the Customer, registered in the State Register of Measuring Instruments, have valid type approval certificates, and be provided with a valid initial verification (with verification records entered into the Federal Information Fund for Ensuring the Uniformity of Measurements).
  • Each measuring instrument unit features a type approval mark in accordance with its certificate description, with factory (serial) numbers or alphanumeric designations applied directly to the housing.

The boom crane control system software meets the following requirements:

  • Provision is made for application software modifications during operation.
  • Password protection with distinct access levels (view, edit) is provided to protect the application software from unauthorized actions; login credentials and passwords shall be transferred to the competent departments of the Customer.
  • Program listings are provided in electronic format with comments in Russian.
  • Technical support for the complete application software is provided by the Supplier for at least 3 years from the commissioning date.
  • Equipment markings are made of wear-resistant materials that are resistant to abrasion and aggressive environmental conditions.
  • Equipment is manufactured from materials with proven suitability for operation under the specified environmental conditions.
  • All equipment components are designed and manufactured to ensure that maintenance and replacement can be performed without resorting to complex dismantling; specific focus is placed on the installation of bearings, articulated joints, belts, flexible coupling inserts, sealing gaskets, electrical apparatus, etc.
  • All drives and systems are arranged within the crane steel structures, without the use of standalone stations.
  • Equipment automated control systems comply with the unified system of automation standards and basic reliability concepts.
  • Hydraulic and other piping systems are designed with mechanical and thermal protection to ensure year-round operation.
  • Feeder cables are provided with mating connectors.
  • At the delivery stage, the Supplier undertakes to provide maintenance and repair schedule guidelines, as well as a list of tools, measuring devices, and fixtures required for equipment maintenance and repair (MRO) operations.
  • The supplied equipment complies with the requirements of the environmental legislation of the Russian Federation.
  • The equipment design eliminates leakage and spillage of lubricating oils and fluids.
  • The required parameters for the mounting flange shall be defined by the crane Supplier.
  • Fastener specifications for installation on the crushing and screening plant steel structures shall be defined by the Supplier and transmitted to the Customer.
  • The manufacturing plant shall perform a mandatory shop assembly and testing of all unit systems, with the preparation and submission of a test report, alongside other quality documentation and certificates. Prior to the commencement of testing, the acceptance test procedure and program shall be submitted to and coordinated with the Customer.
  • Transport limitations shall be taken into account during the design of large-scale equipment. Equipment assemblies and sections shall be provided with lifting lugs for transport unloading and installation, positioned to ensure optimal balance with uniform weight distribution, minimizing risks during lifting operations.
  • At the Customer’s request, equipment acceptance may be conducted at the Manufacturer’s assembly or production facility.
  • At the time of delivery, the boom crane shall be new and unused.

5. Manufacturer

Izhora Hydrosystems LLC


6. Warranty Period

12 months from the shipment date, unless otherwise specified in the contract.


Contacts

Phone: +7 (812) 339-61-68

Email: contact@i-hydro.tech