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Description
Grove Crane RT 9150E Operator Manual 614-00 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane RT 9150E Operator Manual 614-00 – PDF DOWNLOAD
Language : English
Pages : 326
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
DESCRIPTION:
Grove Crane RT 9150E Operator Manual 614-00 – PDF DOWNLOAD
SAFETY INFORMATION:
General:
- The importance of safe operation and maintenance cannot be over emphasized. Carelessness or neglect on the part of operators, job supervisors and planners, rigging personnel, and job site workers can result in their death or injury and costly damage to the crane and property.
- To alert personnel to hazardous operating practices and maintenance procedures, safety messages are used throughout the manual. Each safety message contains a safety alert symbol and a signal word to identify the hazard’s degree of seriousness.
- It is impossible to compile a list of safety precautions covering all situations. However, there
are basic principles that MUST be followed during your daily routine. Safety is YOUR PRIMARY
RESPONSIBILITY, since any piece of equipment is only as safe AS THE PERSON AT THE
CONTROLS. - This information has been provided to assist in promoting a safe working atmosphere for yourself and those around you. It is not meant to cover every conceivable circumstance which could arise. It is intended to present basic safety precautions that should be followed in daily operation
- Because you, the operator, are the only part of the crane that can think and reason, your
responsibility is not lessened by the addition of operational aids or warning devices. Indeed, you
must guard against acquiring a false sense of security when using them. They are there to assist,
not direct the operation. Operational aids or warning devices can be mechanical, electrical,
electronic, or a combination thereof. They are subject to failure or misuse and should not be
relied upon in place of good operating practices. - You, the operator, are the only one who can be relied upon to assure the safety of yourself and
those around you. Be a PROFESSIONAL and follow the RULES of SAFETY. - REMEMBER, failure to follow just one safety precaution could cause an accident that results in
death or serious injury to personnel or damage to equipment. You are responsible for the safety of
yourself and those around you.
TABLE OF CONTENTS:
Grove Crane RT 9150E Operator Manual 614-00 – PDF DOWNLOAD
Table of Contents........................................................................................... 5 SECTION 1................................................................................................... 13 Introduction............................................................................................ 13 General............................................................................................. 13 Overview of Manuals............................................................................. 13 Delivery Report................................................................................. 13 Customer Support................................................................................ 13 New Owners.................................................................................. 14 Safety Information.............................................................................. 14 General Crane Design............................................................................ 14 Specific Crane Description...................................................................... 14 Lifting Capacities (Load Chart)................................................................. 14 Basic Components................................................................................ 14 Axle Weight Distribution........................................................................ 14 Serial Number Location.......................................................................... 14 Transportation and Lifting Data................................................................. 14 Noise/vibration test results........................................................................ 15 Noise Level Test Results........................................................................ 15 Vibration Level Test Results.................................................................... 15 List Of Specifications.............................................................................. 16 General......................................................................................... 16 Dimensions...................................................................................... 16 Capacities...................................................................................... 16 Torque Converter................................................................................ 16 Transmission.................................................................................... 16 Engine.......................................................................................... 16 Cummins QSC................................................................................. 16 Axles........................................................................................... 16 Brakes.......................................................................................... 16 Wheels and Tires................................................................................ 16 Swing Gearbox................................................................................... 16 Boom............................................................................................ 16 Swivel Assembly................................................................................. 16 Hydraulic Pumps................................................................................. 17 Pump #1..................................................................................... 17 Pump #2..................................................................................... 17 Pump #3..................................................................................... 17 Pump #4..................................................................................... 17 Hoists.......................................................................................... 17 Wire Rope (Hoist Cable)............................................................................. 21 General......................................................................................... 21 Environmental Conditions........................................................................ 21 Dynamic Shock Loads............................................................................. 21 Lubrication..................................................................................... 21 Precautions and Recommendations During Inspection or Replacement................................ 21 Wire Rope Inspection (Running Ropes and Pendant Cables)......................................... 22 Keeping Records............................................................................. 22 Frequent Inspection......................................................................... 22 Periodic Inspection......................................................................... 23 Wire Rope Inspection/Replacement (All Wire Rope)................................................ 23 Seizing Wire Rope............................................................................... 23 Method 1.................................................................................... 23 Method 2.................................................................................... 24 Installing 35x7 Class Wire Rope................................................................. 24 SECTION 2................................................................................................... 27 Safety Information...................................................................................... 27 Safety Messages..................................................................................... 27 General......................................................................................... 27 Safety Messages..................................................................................... 28 General......................................................................................... 28 Safety Alert Symbol............................................................................. 28 Signal Words.................................................................................... 28 General............................................................................................. 28 Warning Signs................................................................................... 28 Accidents........................................................................................... 28 Operator Information................................................................................ 29 Operator Qualifications............................................................................. 29 Operational Aids.................................................................................... 30 Rated Capacity Limiter (RCL) Systems (If Equipped).............................................. 30 Anti-Two-Blocking Device........................................................................ 31 Working Area Limiter (If Equipped).............................................................. 31 Crane Stability/Structural Strength................................................................. 32 Load Charts..................................................................................... 33 Work Site....................................................................................... 33 Wind Forces......................................................................................... 33 Wind Speeds..................................................................................... 34 Determination of 3-second wind gust speed at boom tip height:............................... 36 Size and Shape of the load:................................................................. 36 Determining Wind Drag Coefficient (Cd)...................................................... 37 Maximum Permissible Wind Speed.............................................................. 38 Example and Sample Calculations (metric)................................................ 40 Example 1: Crane Configuration:......................................................... 40 Load example 1.1:....................................................................... 41 Load example 1.2:....................................................................... 41 Load example 1.3a:...................................................................... 41 Load example 1.3b:...................................................................... 41 Example and Sample Calculations (Non-metric)................................................ 44 Example 2:.............................................................................. 44 Load example 2.1:....................................................................... 45 Load example 2.2:....................................................................... 45 Load example 2.3a:...................................................................... 45 Load example 2.3b:...................................................................... 45 Lifting Operations.............................................................................. 46 Counterweight................................................................................... 47 Outrigger Lift Off.............................................................................. 47 Multiple Crane Lifts............................................................................ 47 Tilt-Up Panel Lifting........................................................................... 47 Pile Driving and Extracting......................................................................... 48 Crane Equipment................................................................................. 48 Crane Inspection................................................................................ 48 Electrocution Hazard................................................................................ 49 Set-Up and Operation............................................................................ 50 Electrocution Hazard Devices.................................................................... 50 Electrical Contact.............................................................................. 51 Special Operating Conditions and Equipment...................................................... 51 Personnel Handling.................................................................................. 51 Environmental Protection............................................................................ 52 Maintenance......................................................................................... 53 Service and Repairs............................................................................. 53 Lubrication..................................................................................... 54 Tires........................................................................................... 54 Hoist Rope.......................................................................................... 54 Synthetic Hoist Rope............................................................................ 54 Wire Rope....................................................................................... 55 Sheaves......................................................................................... 56 Batteries....................................................................................... 56 Engine.......................................................................................... 57 Transporting the Crane.............................................................................. 57 Travel Operation.................................................................................... 57 Work Practices...................................................................................... 58 Personal Considerations......................................................................... 58 Crane Access.................................................................................... 58 Job Preparation................................................................................. 59 Working......................................................................................... 59 Lifting......................................................................................... 60 Hand Signals.................................................................................... 61 Jib................................................................................................. 63 Parking and Securing................................................................................ 63 Shut-Down........................................................................................... 63 Cold Weather Operation.............................................................................. 63 Temperature Effects on Hook Blocks.................................................................. 64 Temperature Effects on Hydraulic Cylinders.......................................................... 64 Model Specific Information.......................................................................... 66 Crane Access.................................................................................... 66 Boom Inspection................................................................................. 67 Superstructure Inspection....................................................................... 69 Carrier Inspection.............................................................................. 71 SECTION 3................................................................................................... 73 Operating Controls And Procedures....................................................................... 73 Operational Aids.................................................................................... 75 Rated Capacity Limiter System................................................................... 75 Working Range Limitation.................................................................... 75 Anti-Two-Block Device....................................................................... 75 RCL Boom Alarm (CE Units)....................................................................... 75 Control Lever Lockout System.................................................................... 75 Steering Column..................................................................................... 76 Transmission Shift Lever........................................................................ 76 Turn Signal Lever............................................................................... 76 Windshield Wiper/Washer Control............................................................. 76 Horn............................................................................................ 76 Ignition Switch................................................................................. 76 Left Turn Signal Direction Indicator............................................................ 76 Right Turn Signal Direction Indicator........................................................... 77 Park Brake Switch............................................................................... 77 Headlights Switch............................................................................... 77 Drive Select Switch............................................................................. 77 Hazard Lights Switch............................................................................ 77 Engine Idle Increase/Decrease Switch............................................................ 77 Steering Column Left side and Floor................................................................. 78 Steering Column Tilt/Telescope Lever............................................................ 78 Cup Holder...................................................................................... 78 360° Swing Lock Pedal........................................................................... 78 Swing Brake Pedal............................................................................... 78 Service Brake Foot Pedal........................................................................ 78 Throttle Pedal.................................................................................. 78 Right Side Console.................................................................................. 79 RCL Control Panel............................................................................... 79 RCL Override Switch (Non-CE Certified Cranes)................................................... 79 RCL Emergency Override Switch and Indicator (CE Certified Cranes)............................... 79 ECOS Control Panel.............................................................................. 80 Emergency Stop Switch........................................................................... 80 Turntable Lock Pin Control Handle............................................................... 80 Accessory Outlet................................................................................ 80 Diagnostic Connector............................................................................ 80 Level Indicator................................................................................. 80 Overhead Controls and Features...................................................................... 81 Skylight Window Latch........................................................................... 81 Skylight Wiper and Wiper Motor.................................................................. 81 Skylight Sunscreen.............................................................................. 81 Overhead Light.................................................................................. 81 Cab Circulating Fan............................................................................. 81 Right Side Window Latch......................................................................... 81 Overhead Console (Right Side)................................................................... 81 Heater/Air Conditioner Fan Switch........................................................... 81 Heater Control Switch....................................................................... 81 Air Conditioner Switch...................................................................... 82 Boom Light Switch (Optional)................................................................ 82 Skylight Wiper Switch....................................................................... 82 Work Lights Switch.......................................................................... 82 Aircraft Warning Light Switch (Optional).................................................... 82 Exhaust System Cleaning Switch (T4i Engines Only)........................................... 82 Engine Throttle Switch...................................................................... 82 Seat-Mounted Controls............................................................................... 83 Right-Hand Armrest Assembly..................................................................... 83 Seat Adjustment Lever........................................................................... 83 Seat Back Adjustment Lever...................................................................... 83 Seat Assembly Adjustment Lever.................................................................. 83 Armrest Adjustment Knob......................................................................... 83 Left-Hand Armrest Assembly...................................................................... 83 Right-Hand Armrest Controls......................................................................... 83 Main Hoist or Telescope/Boom Lift Controller.................................................... 83 High Speed Main and Auxiliary Hoist Boost Button................................................ 84 Work Horn Button................................................................................ 84 Hoist Rotation Indicators....................................................................... 84 Main Hoist (I) Switch........................................................................... 84 Boom Lift Switch................................................................................ 84 Boom Telescope Switch........................................................................... 84 Luffing Jib Switch (Optional)................................................................... 85 Cab Tilt Switch................................................................................. 85 Left-Hand Armrest Controls.......................................................................... 85 Auxiliary Hoist/Swing Gear Controller........................................................... 85 High Speed Lift/Telescope Boost Button.......................................................... 85 Swing Gear Freewheel Button..................................................................... 85 Hoist Rotation Indicators....................................................................... 86 Swing Gear Switch............................................................................... 86 Crane Function Switch........................................................................... 86 Auxiliary Hoist (II) Switch..................................................................... 86 Differential Lock Switch (Optional)............................................................. 86 Rear Steer Control Switch....................................................................... 87 Lift Switch (CE Option)......................................................................... 87 Miscellaneous Cab Controls and Features............................................................. 87 Cab Door........................................................................................ 87 Outside Handle/Latch........................................................................ 87 Inside Door Latch........................................................................... 87 Fire Extinguisher............................................................................... 87 Emergency Exit.................................................................................. 87 Dead Man’s Switch and Seat Contact Switch....................................................... 87 Jib Release Pole................................................................................ 88 RCL Lockout Alarm............................................................................... 88 ECOS Control Unit................................................................................... 89 Common Elements................................................................................. 89 Main Menu........................................................................................... 93 Outriggers Submenu.................................................................................. 99 Outriggers Submenu.............................................................................. 99 Swing Gear and Brake Submenu........................................................................102 Swing Gear and Brake Submenu....................................................................102 Telescope Submenu...................................................................................104 Telescoping Submenu.............................................................................104 Description of Telescope Section Views..........................................................108 Telescope Mechanism Error Messages..............................................................109 Working Range Limitation submenu....................................................................110 Entering Limit Values...........................................................................110 Working Range Limitation Submenu............................................................110 Display of the Swing Angles.................................................................114 Entering the Permissible Swing Range........................................................114 Swing Angle A...........................................................................114 Swing Angle B...........................................................................114 Entering Points and Objects.................................................................114 Representation of Points and Objects....................................................115 Entering objects........................................................................115 Deleting Points.........................................................................116 Entering Limit Values/Objects Manually..........................................................116 Overall Height/Working Radius...............................................................116 Swing Angles................................................................................116 Entering a Limit Value......................................................................116 Objects.....................................................................................117 Shutdown by Working Range Limiter...............................................................118 Monitoring submenu..................................................................................119 Monitoring Submenu..............................................................................119 Power Unit Speed Submenu............................................................................120 Power Unit Speed Submenu........................................................................120 Changing values.................................................................................120 Counterweight Submenu...............................................................................121 Counterweight Submenu...........................................................................121 Settings Submenu....................................................................................124 Settings Submenu................................................................................124 Adjusting the Brightness of the Display.........................................................129 Lamp Test.......................................................................................130 Operating Hours.................................................................................131 Operating Hours Submenu.....................................................................131 Entering the Current Telescope Status...........................................................132 Entering RCL Telescope Values...............................................................132 Approving Entered Telescope Values..........................................................132 Warning Messages....................................................................................134 Meaning of the Symbols..........................................................................134 Exiting the Submenu.............................................................................134 Warning Submenu.................................................................................135 Error Messages......................................................................................138 Opening the Submenu.............................................................................138 Exiting the Submenu.............................................................................138 Error Submenu...................................................................................138 RCL Control Unit....................................................................................140 Common Elements.................................................................................140 RCL Early Warning...............................................................................144 RCL Shutdown....................................................................................144 Shutdown Due to Overload....................................................................144 Canceling a Shutdown........................................................................145 RCL Override....................................................................................145 Overriding the RCL..........................................................................145 Canceling the Override......................................................................145 Anti Two-Block Switch Override..............................................................145 RCL Main Menu.......................................................................................147 RCL Main Menu...................................................................................147 Rigging Mode Submenu................................................................................150 Opening the Submenu.............................................................................150 Rigging Mode Menu...............................................................................150 Entering the Rigging Mode.......................................................................153 Entering Individual Components..............................................................153 To Switch ON Input Mode.....................................................................153 Selecting Values............................................................................153 Counterweight...........................................................................154 Boom System.............................................................................154 Outrigger Deployment....................................................................154 Swing Range.............................................................................155 Entering the RCL Code.......................................................................155 Entering the Reeving........................................................................155 Approve the Rigging Mode....................................................................156 Confirming Rigging Mode.................................................................156 Accepting Rigging Mode..................................................................156 Rigging Mode Monitoring Submenu.................................................................157 Rigging Mode Monitoring Menu................................................................157 RCL Monitoring Submenu..............................................................................158 Opening the Submenu.............................................................................158 Monitoring Submenu..............................................................................158 Error Messages in the Monitoring Submenu........................................................163 Error Message without Shutdown..............................................................163 Error Message with Shutdown.................................................................163 Lifting Capacity Tables Submenu.....................................................................164 Opening the Submenu.............................................................................164 Lifting Capacity Tables Menu....................................................................164 Working Range Submenu...............................................................................168 Opening the Submenu.............................................................................168 Working Range Menu..............................................................................168 Settings Submenu....................................................................................171 Opening the Submenu.............................................................................171 Cancel the Input................................................................................171 Settings Submenu................................................................................171 Error Submenu.......................................................................................173 Opening the Submenu.............................................................................173 Exiting the Submenu.............................................................................173 Error Submenu...................................................................................173 Error Codes.....................................................................................175 Operating Procedures................................................................................177 New Crane Conditioning..........................................................................177 Pre-Starting Checks.............................................................................177 Fuel Supply.................................................................................177 Engine Oil..................................................................................177 Engine Coolant..............................................................................177 Batteries...................................................................................177 Signal and Running Lights...................................................................177 Foot and Parking Brakes.....................................................................177 Daily Lubrication...........................................................................177 Hydraulic Reservoir and Filter..............................................................177 Tires.......................................................................................177 Wire Rope...................................................................................177 Hook Block..................................................................................177 Boom........................................................................................177 Air Cleaner.................................................................................177 Access Hole Covers (CE Units)...............................................................177 Wind Forces.....................................................................................177 Cold Weather Operation..........................................................................178 Operation Below -40°F.......................................................................178 Operation Below -40°C.......................................................................178 Preheating Hydraulic Oil....................................................................178 Preheating..............................................................................179 Crane Warm-up Procedures....................................................................179 Engine..........................................................................................180 Transmission....................................................................................180 Hoist...........................................................................................180 Swing Drive and Turntable Bearing...............................................................180 Axles...........................................................................................180 Hydraulic Oil System............................................................................181 Battery Disconnect..............................................................................181 Engine Operation................................................................................181 Starting Procedure..........................................................................181 Warm Engine.............................................................................181 Cold Engine.............................................................................182 Idling the Engine.......................................................................182 Racing the Engine.......................................................................182 Shutdown Procedure..........................................................................182 Diesel Particulate Filter (Tier 4 Engines Only).................................................182 Transporting Crane..............................................................................183 Crane Travel Operation..........................................................................183 Traveling — General.........................................................................183 Traveling — Towing/Pulling..................................................................184 Traveling — Being Towed/Pulled..............................................................185 Traveling with Boom Extension and/or Insert Erected.........................................185 36 ft (11 m)/59 ft (18 m) Extension.....................................................185 59 ft (18 m) Extension Plus 26 ft (8 m)/ 19 ft (6 m) Extension Inserts..................185 12 ft (3.6 m) Extension.................................................................185 Extended Travel.............................................................................186 Moving the Crane............................................................................186 Steering....................................................................................186 Front Wheel Steering........................................................................186 Rear Wheel Steering.........................................................................186 Four Wheel Steering.........................................................................186 Crabbing....................................................................................186 Secondary Steering (CE Units)...............................................................187 Traveling - Forward.........................................................................187 Traveling - Reverse.........................................................................187 Four-Wheel Drive Operation..................................................................187 Travel On Slopes................................................................................188 Travel On Slopes with or without Standard Counterweight (39,000 lb (17690 kg)) installed....188 Travel On Slopes with Optional Heavy Counterweight (63,000 lb (28576 kg)) installed.........188 Proper Operation of Differential Lock...........................................................188 General.....................................................................................189 Operation...................................................................................189 Proper Operation of Axle Oscillation Lockouts...................................................189 General Crane Operation.........................................................................190 Pump Drive..................................................................................190 Operating the Crane On Outriggers...........................................................190 Control Lever Operation.....................................................................190 Preload Check...............................................................................190 Using Your Load Chart...........................................................................190 Counterweight Installation/Removal..............................................................191 Extending the Lifting Cylinders.............................................................191 Retracting the Lifting Cylinders............................................................192 Locking/Unlocking Counterweight Lift Cylinders..............................................192 Locking/Unlocking the Counterweight.........................................................193 Crane Functions.....................................................................................194 Operation of the Rated Capacity Limiter (RCL)...................................................194 Switching on the RCL........................................................................194 After Crane Shutdown of up to 48 Hours..................................................195 After Crane Shutdown of more than 48 Hours..............................................195 Prior to Crane Operation........................................................................195 Opening the Submenu Manually................................................................195 Verify Rigging..............................................................................196 Verify Hoists Display.......................................................................196 How to Switch the Hoist Display.........................................................196 Verify Reeving..............................................................................197 Deploying the Outriggers........................................................................197 Engaging the Mid-Extend Lock Pin............................................................198 Stowing the Mid-Extend Lock Pin.............................................................198 Outrigger Monitoring System (OMS) RCL Display (Optional—Standard in North America)..............198 Fully Retracted or 0% Deployed..............................................................198 Mid-Extended or 50% Deployed................................................................198 Fully Extended or 100% Deployed.............................................................199 Error Code Display..........................................................................199 ECOS Error Reporting........................................................................200 Stowing the Outriggers..........................................................................200 Rotating the Superstructure.....................................................................201 Swing Operation Prerequisites...............................................................201 Rotating the Superstructure.................................................................201 Rotating Superstructure with Counterweight..................................................202 Elevating/Lowering the Boom.....................................................................203 Boom Elevating/Lowering Operation...........................................................203 Lowering the Boom to a Horizontal Position..................................................204 Lowering Boom to Horizontal with Boom Extension Installed...............................204 Tilting the Crane Cab...........................................................................204 To Raise the Cab............................................................................204 To Lower the Cab............................................................................204 Telescoping the Boom............................................................................205 Telescope Mechanism.........................................................................205 Fixed Length, Intermediate Length, Telescoping Length.......................................205 Current Telescope Display, (Figure 3-134)...................................................205 Telescope System Overview...................................................................206 Telescoping Process.........................................................................206 Telescoping with Teleautomation.................................................................208 To Switch on Input Mode.....................................................................208 To Enter Values.............................................................................208 Telescope Operation.........................................................................209 Canceling Teleautomation....................................................................210 Example of Telescoping with Teleautomation..................................................210 Manual Telescoping..............................................................................211 Checking the Initial Position...............................................................211 Current Telescope Status................................................................212 Position of the Telescope Cylinder......................................................212 Position of the Locking Pins............................................................212 Unlocking the Telescope Cylinder............................................................213 Prerequisites...........................................................................213 To Select Unlock........................................................................213 Unlocking the Telescoping Cylinder......................................................213 Extending/ Retracting the Telescope Cylinder................................................214 Prerequisites...........................................................................214 Extend/Retract..........................................................................214 Lock Telescope Cylinder.....................................................................215 Prerequisites...........................................................................215 To Select Lock..........................................................................215 Locking the Telescope Cylinder..........................................................216 Unlocking the Telescopic Section............................................................216 Prerequisites...........................................................................216 To Select Unlock........................................................................216 Unlocking the Telescopic Section........................................................217 Telescoping the Telescopic Section..........................................................218 Prerequisites...........................................................................218 Telescoping.............................................................................218 Locking the Telescopic Section..............................................................218 Prerequisites...........................................................................218 To Select Lock..........................................................................218 Locking the Telescopic Section..........................................................219 Telescoping Main Boom in Horizontal Position....................................................219 Telescoping with Rigged Boom Extension..........................................................219 Extending/Retracting the Boom...............................................................219 Telescope Emergency Program.....................................................................220 Starting the Emergency Program..............................................................220 Determining the Type of Error...............................................................221 If There is an Error on the Length Indicator................................................222 Inspections Prior to Telescoping........................................................222 Retracting and Locking A Telescopic Section.............................................223 Unlocking the Telescope Cylinder........................................................223 Extending and Locking the Telescope Cylinder................................................224 If There is an Error at a Proximity Switch..................................................224 Required Inspection.....................................................................225 Retracting..............................................................................225 Terminating the Emergency Program...........................................................225 Tables for Approaching the Locking Points...................................................226 Locking Points for the Telescoping Cylinder.............................................226 Locking Points for the Telescopic Sections..............................................226 Hoist Operation.................................................................................227 Lowering and Raising the Hoist Cable........................................................227 Main Hoist..............................................................................227 Auxiliary Hoist.........................................................................227 Hoist Speed Range Selection.................................................................228 Boom Extensions.................................................................................228 Setting the RCL.............................................................................228 Load Bearing Capacities.....................................................................229 Raising and Lowering the Hydraulic Boom Extension...........................................229 Hydraulic Boom Extension Operation — Cab................................................229 Hydraulic Boom Extension Operation — Remote Station.....................................230 Two Hook-Operation..........................................................................230 Stowing and Parking.............................................................................231 Unattended Crane................................................................................231 SECTION 4...................................................................................................233 Set-up And Installation.................................................................................233 General.............................................................................................233 Accessing the Hoist area............................................................................234 Travel Configuration............................................................................234 Working Configuration...........................................................................234 Hoist Cable (Wire Rope).............................................................................234 Removing the Old Cable..........................................................................234 Installing a New Cable..........................................................................235 Cable Reeving.......................................................................................236 Dead-End Rigging/Wedge Sockets......................................................................237 Installing Wedge and Socket.....................................................................237 Counterweight Removal and Installation..............................................................244 Counterweight Stand Installation................................................................244 Standard Fabricated Counterweight Installation..................................................244 Standard Fabricated Counterweight Removal.......................................................245 Heavy Fabricated Counterweight Installation.....................................................246 Heavy Fabricated Counterweight Removal..........................................................246 17,690 kg (39,000 lb) Cast Counterweight Installation...........................................247 17,690 kg (39,000 lb) Cast Counterweight Removal................................................248 Heavy Cast Counterweight Installation...........................................................248 Heavy Cast Counterweight Removal................................................................249 Counterweight Stand Removal.....................................................................249 Outrigger Removal and Installation..................................................................251 Bleed Valve Operation...........................................................................251 Outrigger Box Removal...........................................................................251 Outrigger Box Installation......................................................................253 Anti Two Block (A2B) Switch.........................................................................254 Lock............................................................................................254 Unlock..........................................................................................254 Before Operation................................................................................254 Cranes With Main Hoist Only.................................................................254 Machines with Main and Auxiliary Hoists.....................................................255 Boom Extensions.....................................................................................256 Installing the Folding Boom Extension...........................................................257 Securing Extension with Tag Line (Rope).........................................................258 Relieving the Load on Connecting Lugs...........................................................258 Extension Erecting Warnings and Requirements....................................................258 Erecting Procedure: 36 ft (11 m) Extension......................................................258 Erecting Procedure: 59 ft (22 m) Extension......................................................261 Extension Electrical Connections................................................................264 36 ft (11m) Extension Electrical Connections................................................264 59 ft (18 m) Extension Electrical Connections...............................................264 Disconnect Electrical Connections to the 59 ft (18 m) Section...........................264 Connecting the Anti-Two Block Switch............................................................265 36 ft (11 m) Extension A2B Installation.....................................................265 36 ft (11 m) Extension A2B Removal..........................................................265 59 ft (18 m) Extension A2B Installation.....................................................265 Extension Hydraulic Connections (Optional Hydraulic Extension)..................................266 Checking the Locking Device on the Hose Drum................................................266 Unlocking the Drum......................................................................266 Locking the Drum........................................................................266 Hydraulic Hose Installation.................................................................266 Position for Main Boom Operation............................................................267 Establishing the Hydraulic Connection.......................................................267 Disconnecting the Hydraulic Connection......................................................268 Folding Deflection Sheaves......................................................................268 Deploying the Rear Deflection Sheave........................................................268 Stowing Rear Deflection Sheave..............................................................268 Deploying the Front Deflection Sheave.......................................................269 Folding In Front Deflection Sheave..........................................................269 Positioning/Removing the Hoist Cable............................................................269 Positioning Hoist Cable.....................................................................269 Removing Hoist Cable........................................................................269 Mechanical Luffing Jib (Adjustable Boom Extension)..............................................270 Extension Angle Adjusting Mechanism.........................................................270 Setting the Angle with an Auxiliary Crane...................................................270 Setting the Angle without an Auxiliary Crane................................................270 Entering the RCL Code...................................................................271 Setting an Angle of 20° or 40°..........................................................271 Inclining the Crane.........................................................................271 Stowing the Folding Boom Extension..............................................................272 Requirements for Stowing the Boom Extensions................................................272 Stowing Procedure: 23 ft (7 m) Boom Extension...............................................272 Stowing Procedure: 59 ft (18 m) Extension...................................................273 Boom Extension Transport Condition..............................................................276 Transport Condition with Extensions Installed...............................................276 With the 59 ft (18 m) Extensions Folded at the Side.....................................276 With the 23 ft (7 m) Extension Only Folded at the Side..................................276 Installing and Removing the 26 ft (8 m) and 19 ft (6 m) Extension Inserts.......................276 Installation................................................................................276 Removal.....................................................................................277 Extension Electrical Connection.............................................................278 Connecting Main Boom to the 26 ft (8 m) Extension.......................................278 Disconnecting Main Boom Electrical Connection...........................................278 Connecting the Folding Extension Electrical Circuit.....................................279 Disconnecting the Folding Extension Electrical Circuit..................................279 Extension Hydraulic Connection..............................................................279 Connecting Main Boom Hydraulics.........................................................280 Disconnecting Main Boom Hydraulics......................................................280 Connecting the Folding Extension Hydraulics.............................................280 Disconnecting the Folding Extension Hydraulics..........................................280 Folding the Deflection Sheave on the 26 ft (8 m) Extension..................................281 Folding Out the Deflection Sheave.......................................................281 Folding In the Deflection Sheave........................................................281 Positioning/Removing the Hoist Cable........................................................282 Positioning the Cable...................................................................282 Removing the Cable......................................................................282 Auxiliary Single-sheave Boom Nose...................................................................283 Installation....................................................................................283 Removal.........................................................................................283 Working Position................................................................................284 Rigging the auxiliary boom nose.................................................................284 Transport Position..............................................................................284 Heavy Duty Luffing Boom Extension...................................................................285 Installation and Removal........................................................................285 Heavy Duty Nose Sheave..........................................................................285 Work Position...............................................................................285 Stowed Position.................................................................................285 Anemometer/Aircraft warning Light...................................................................286 Mounting Anemometer/Aircraft Warning Light......................................................286 Removing Anemometer/Aircraft Warning Light......................................................286 SECTION 5...................................................................................................287 Lubrication.............................................................................................287 General.............................................................................................287 Environmental Protection............................................................................287 Lubrication Intervals...............................................................................287 Standard Lubricants Package.........................................................................288 Arctic Conditions...................................................................................288 Below 0°F (–18°C)...............................................................................288 Down to –40°F (–40°C)...........................................................................289 ALL Weather Package & Lubricants............................................................289 Surface Protection for Cylinder Rods................................................................290 Wire Rope Lubrication...............................................................................290 Lubrication Points..................................................................................291 CraneLUBE.......................................................................................291 Safety..........................................................................................291 Steering and Suspension.........................................................................292 Axles...........................................................................................294 Drive Train.....................................................................................296 Drive Train (continued).........................................................................298 Outriggers......................................................................................300 Hydraulic.......................................................................................302 Turntable.......................................................................................304 Cab Tilt........................................................................................306 Lift Cylinder...................................................................................308 Hoist...........................................................................................310 Boom............................................................................................312 Boom (continued)................................................................................314 Boom Extension..................................................................................316 Boom............................................................................................318 SECTION 6...................................................................................................321 Maintenance Checklist...................................................................................321 General.............................................................................................321 Instructions........................................................................................321 Daily or 10 Hour Check List.....................................................................321 Weekly or 50 Hour Check List....................................................................322
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