Grove Crane TMS 9000E Superstructure Operator Manual – PDF DOWNLOAD

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Grove Crane TMS 9000E Superstructure Operator Manual – PDF DOWNLOAD

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Grove Crane TMS 9000E Superstructure Operator Manual – PDF DOWNLOAD

Language : English
Pages : 668
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane TMS 9000E Superstructure Operator Manual – PDF DOWNLOAD

General:

• 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.
• With this thought in mind, this information has been provided to assist you, the operator,
  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.
• IMMEDIATELY report all accidents, malfunctions, and equipment damages to your
  local Manitowoc distributor. Following any accident or damage to equipment the
  local Manitowoc distributor must be immediately advised of the incident and consulted
  on necessary inspections and repairs. Should the distributor not be immediately
  available, contact should be made directly with Manitowoc Crane Care. The
  crane must not be returned to service until it is thoroughly inspected for any evidence
  of damage. All damaged parts must be repaired or replaced as authorized by
  your local Manitowoc distributor and/or Manitowoc Crane Care.

TABLE OF CONTENTS:

Grove Crane TMS 9000E Superstructure Operator Manual – PDF DOWNLOAD

1 SAFETY PRECAUTIONS....................................................................................................... 17
	1.1 Safety Messages.................................................................................................... 17
	1.2 General............................................................................................................ 18
		1.2.1 Location of Serial Numbers................................................................................... 19
	1.3 Operator’s Information............................................................................................. 20
	1.4 Operator’s Qualifications.......................................................................................... 21
	1.5 Crane Stability/Structural Strength................................................................................ 22
		1.5.1 Load Charts.................................................................................................. 24
		1.5.2 Work Site.................................................................................................... 25
		1.5.3 Lifting Operations........................................................................................... 25
		1.5.4 Counterweight................................................................................................ 28
		1.5.5 Multiple Crane Lifts......................................................................................... 28
	1.6 Pile Driving and Extracting Operations............................................................................. 29
		1.6.1 Crane Equipment.............................................................................................. 30
		1.6.2 Crane Inspection............................................................................................. 30
	1.7 Rated Capacity Limiting (RCL) Systems.............................................................................. 30
		1.7.1 Two-Blocking................................................................................................. 32
	1.8 Electrocution Hazard............................................................................................... 33
		1.6.1 Set Up and Operation......................................................................................... 35
		1.6.2 Electrocution Hazard Devices................................................................................. 36
		1.6.3 Electrical Contact........................................................................................... 37
		1.6.4 Special Operating Conditions and Equipment................................................................... 38
	1.7 Crushing Hazards................................................................................................... 38
	1.8 Traveling.......................................................................................................... 39
	1.9 Accidents.......................................................................................................... 41
	1.10 Maintenance....................................................................................................... 41
		1.10.1 Service And Repairs......................................................................................... 42
		1.10.2 Lubrication................................................................................................. 43
		1.10.3 Tires....................................................................................................... 43
		1.10.4 Wire Rope................................................................................................... 44
	1.11 Batteries......................................................................................................... 47
	1.12 Engine............................................................................................................ 48
	1.13 Work Practices.................................................................................................... 48
		1.13.1 Crane Access................................................................................................ 48
		1.13.2 Job Preparation............................................................................................. 49
		1.13.3 Working..................................................................................................... 50
		1.13.4 Lifting..................................................................................................... 50
	1.14 Transporting the Crane............................................................................................ 53
	1.15 Cold Weather Operation............................................................................................ 53
	1.16 Temperature Effects on Hydraulic Cylinders........................................................................ 54
	1.17 Temperature Effects on Hook Blocks................................................................................ 55
	1.18 Pile Driving and Extraction....................................................................................... 56
		1.18.1 Operation of Pile Driving and Extracting Equipment.......................................................... 56
		1.18.2 Crane Equipment............................................................................................. 57
		1.18.3 Crane Inspection............................................................................................ 57
	1.19 Overload Inspection............................................................................................... 57
2 DESCRIPTION OF CRANE..................................................................................................... 59
	2.1 Overview of the superstructure cab operating and display instruments............................................... 59
		2.1.1 Overview of the crane section................................................................................ 59
		2.1.2 Overview of crane cab........................................................................................ 62
		2.1.3 Operating elements on the front panel........................................................................ 64
		2.1.4 Operating elements on the side panel......................................................................... 65
		2.1.5 Control consoles............................................................................................. 70
		2.1.6 Control lever configuration.................................................................................. 72
		2.1.7 At crane control display..................................................................................... 74
		2.1.8 Main menu of the crane control display....................................................................... 76
		2.1.9 Crane control display - submenus............................................................................. 78
		2.1.10 RCL display – main menu..................................................................................... 91
		2.1.11 RCL display – submenus...................................................................................... 92
	2.2 Functional description of the display and operating elements.......................................................100
		2.2.1 Diesel engine................................................................................................100
		2.2.2 Crane control................................................................................................103
		2.2.3 Counterweight submenu........................................................................................112
		2.2.4 Hoists.......................................................................................................115
		2.2.5 Swing gear...................................................................................................118
		2.2.6 Lifting gear.................................................................................................121
		2.2.7 Telescoping mechanism........................................................................................124
		2.2.8 Hydraulic system.............................................................................................134
		2.2.9 Rated capacity limiter (RCL).................................................................................136
		2.2.10 Electricity, lighting, windscreen wiper / washing system....................................................149
		2.2.11 Heating.....................................................................................................151
		2.2.12 Other operating elements of the crane cab...................................................................158
	2.3 Functional description of the operational aids.....................................................................162
		2.3.1 Rated capacity limiter (RCL).................................................................................162
		2.3.2 Lowering limit switch........................................................................................164
		2.3.3 Lifting limit switch.........................................................................................165
		2.3.4 Dead man's switch and seat contact switch....................................................................167
3 CRANE OPERATION..........................................................................................................169
	3.1 Superstructure Inspections and Adjustments Prior to Crane Operation................................................169
		3.1.1 PRE-STARTING CHECKLIST: When Truck Crane is Rigged...........................................................169
		3.1.2 Adjusting the front console and the crane cab seat...........................................................176
		3.1.3 Checking the condition of the truck crane....................................................................177
		3.1.4 Checking the operators aids..................................................................................180
		3.1.5 Pre-warming the hydraulic oil................................................................................183
		3.1.6 Switching the houselock on / off.............................................................................185
	3.2 Starting and stopping the diesel engine............................................................................188
		3.2.1 When starting the engine the first time in the day...........................................................188
		3.2.2 Inspections after starting the diesel engine.................................................................192
		3.2.3 Shutting down the diesel engine..............................................................................195
	3.3 Operating the Rated Capacity Limiter (RCL).........................................................................196
		3.3.1 Switching on the RCL.........................................................................................196
		3.3.2 Entering the Rigging Mode....................................................................................200
		3.3.3 Inspections Before Operating the Crane.......................................................................207
		3.3.4 Displays During Crane Operation..............................................................................210
		3.3.5 RCL Early Warning and RCL Shutdown...........................................................................213
		3.3.6 RCL Shutdown.................................................................................................213
		3.3.7 Displaying the Lifting Capacity Table........................................................................217
		3.3.8 Entering the Time/Date.......................................................................................219
	3.4 Crane Work with the Main Boom......................................................................................220
		3.4.1 External Influences While Working with the Crane.............................................................220
		3.4.2 Permissible Swing Ranges and Working Positions for Crane Work................................................225
		3.4.3 Main Hoist...................................................................................................228
		3.4.4 Auxiliary Hoist..............................................................................................233
		3.4.5 Lifting Gear.................................................................................................235
		3.4.6 Swing Gear...................................................................................................239
		3.4.7 Telescoping Mechanism........................................................................................246
		3.4.8 Possible Movement Combinations...............................................................................286
		3.4.9 High-Speed Mode..............................................................................................287
		3.4.10 Cooling the Hydraulic Oil...................................................................................289
	3.5 Adjustments and Displays While Operating the Crane.................................................................290
		3.5.1 Adjusting the Brightness of the Display......................................................................290
		3.5.2 Setting Characteristic Curves for the Control Lever..........................................................291
		3.5.3 Adjusting Power Unit Speeds..................................................................................293
		3.5.4 Setting a Constant Engine Speed..............................................................................295
		3.5.5 Tilting the Crane Cab........................................................................................297
		3.5.6 Adjusting the Windscreen Wiper Stroke Interval...............................................................298
		3.5.7 Using the Directional Spotlight for the Working Area.........................................................299
		3.5.8 Display the Operating Hours..................................................................................300
		3.5.9 Warning Message Submenu......................................................................................302
		3.5.10 Error Menu..................................................................................................304
	3.6 Working Range Limiter..............................................................................................305
		3.6.1 Opening the Working Range Limitation Submenu.................................................................306
		3.6.2 Reading Current Settings.....................................................................................307
		3.6.3 Entering a Limit Value for a Maximum Overall Height..........................................................309
		3.6.4 Entering a Limit Value for a Maximum Working Radius..........................................................310
		3.6.5 Entering Limit Values for Maximum Swing Angles...............................................................311
		3.6.6 Entering Point Data for Objects..............................................................................314
		3.6.7 Entering Limit Values Manually...............................................................................318
		3.6.8 Switching Monitoring On and Off..............................................................................321
		3.6.9 Shutdown Caused by Working Range Limiter.....................................................................323
	3.7 Work break.........................................................................................................325
		3.7.1 During short work breaks.....................................................................................325
		3.7.2 Work breaks lasting longer than 8 hours......................................................................326
	3.8 Heating and ventilating the crane cab..............................................................................327
		3.8.1 Heating......................................................................................................327
		3.8.2 Air-Conditioning System......................................................................................337
4 Rigging work.............................................................................................................341
	4.1 Checklists for rigging work for crane operation with main boom.....................................................341
		4.1.1 CHECKLIST: Rigging...........................................................................................341
		4.1.2 CHECKLIST: Unrigging.........................................................................................344
	4.2 Choosing a suitable site...........................................................................................346
		4.2.1 Load bearing capacity of the ground and the outriggers.......................................................347
		4.2.2 Safe distance from banks and pits............................................................................350
		4.2.3 Earthing of the truck crane..................................................................................351
		4.2.4 Safe distance from electrical lines..........................................................................352
	4.3 Switching Positions................................................................................................354
		4.3.1 Switching off the boom floating position.....................................................................354
	4.4 Trailing Boom Carrier Option.......................................................................................355
		4.4.1 Description..................................................................................................355
	4.5 Trailing Boom Trailer Emergency Brake Control (Optional)...........................................................355
		4.5.1 Operation....................................................................................................356
		4.5.2 Preparation for Highway Travel...............................................................................357
		4.5.3 Returning to Normal Crane Operation..........................................................................360
		4.5.4 Parking the Trailing Boom Carrier............................................................................360
		4.5.5 Switching off boom pre-tensioning............................................................................360
		4.5.6 Switching off rotating gear freewheel........................................................................361
	4.6 Rigging add-on parts in position for crane operation / driving.....................................................363
		4.6.1 Folding mirrors in and out and adjusting them................................................................363
	4.7 Outriggers.........................................................................................................365
		4.7.1 CHECKLIST: Extending the outriggers..........................................................................365
		4.7.2 CHECKLIST: Retracting the outrigger..........................................................................367
		4.7.3 Permissible outrigger spreads................................................................................369
		4.7.4 Preparing the truck crane....................................................................................371
		4.7.5 Pinning/Unpinning outrigger beam for crane operations........................................................372
		4.7.6 Checking the alignment of the truck crane....................................................................377
		4.7.7 Leveling the truck crane on outriggers.......................................................................382
	4.8 Counterweight Rigging..............................................................................................386
	4.9 Rigging work on the main boom......................................................................................386
		4.9.1 Hook block on the bumper.....................................................................................386
		4.9.2 Hook block on a separate vehicle.............................................................................387
		4.9.3 Reeving and unreeving the hoist rope.........................................................................390
		4.9.4 Installing / Removing the lifting limit switch...............................................................400
		4.9.5 Locking the lifting limit switch / Releasing the lock........................................................406
		4.9.6 Anemometer and air traffic control light.....................................................................407
5 COUNTERWEIGHT RIGGING....................................................................................................411
	5.1 Counterweight parts................................................................................................411
		5.1.1 Counterweight parts..........................................................................................411
		5.1.2 Counterweight versions/combinations..........................................................................414
		5.1.3 Slinging points at the counterweight sections................................................................418
		5.1.4 CHECKLIST: Rigging the counterweight.........................................................................420
		5.1.5 CHECKLIST: Unrigging the counterweight.......................................................................422
		5.1.6 Lower 3,000 lb tray plate on the counterweight platform......................................................423
		5.1.7 Check the position of the locking pins for 3000 and 5,000 lb counterweight sections..........................424
		5.1.8 Assembling counterweight versions/combinations‘..............................................................425
		5.1.9 Counterweight hoist unit.....................................................................................428
		5.1.10 Rotating with the rigged counterweight......................................................................434
6 MALFUNCTIONS ON THE SUPERSTRUCTURE.......................................................................................435
	6.1 Emergency-stop devices for crane operation.........................................................................435
		6.1.1 Carrying out emergency-stop operations.......................................................................435
		6.1.2 Resetting the emergency-stop switch..........................................................................437
	6.2 Procedure in the event of a malfunction during crane operation.....................................................438
	6.3 Fuses on the superstructure........................................................................................439
		6.3.1 Fuses on the turntable.......................................................................................440
		6.3.2 Fuses in the crane cab.......................................................................................442
		6.3.3 RCL fuses....................................................................................................444
	6.4 Finding and eliminating malfunctions at the power units............................................................445
		6.4.1 Malfunctions in the diesel engine during crane operation.....................................................445
		6.4.2 Malfunctions in the outriggers...............................................................................446
		6.4.3 Malfunctions in the main hoist...............................................................................447
		6.4.4 Malfunctions on the auxiliary hoist..........................................................................449
		6.4.5 Lifting gear malfunctions....................................................................................451
		6.4.6 Malfunctions in the swing gear...............................................................................453
		6.4.7 Malfunctions in the counterweight hoist unit.................................................................455
		6.4.8 Malfunctions in the hydraulic system / hydraulic oil cooler..................................................456
		6.4.9 Malfunctions on the turntable lock...........................................................................456
		6.4.10 Malfunctions in the telescoping mechanism...................................................................457
	6.5 Finding and eliminating malfunctions at the RCL....................................................................461
		6.5.1 General malfunctions.........................................................................................461
		6.5.2 Error messages in the Monitoring submenu.....................................................................462
		6.5.3 Displays in the Error submenu................................................................................464
		6.5.4 Table – error messages.......................................................................................466
	6.6 Finding and eliminating malfunctions at the crane control..........................................................470
		6.6.1 General malfunctions.........................................................................................470
		6.6.2 Error messages on the crane control display..................................................................471
	6.7 Emergency operations and programs..................................................................................473
		6.7.1 Emergency retraction operation...............................................................................474
		6.7.2 Emergency telescoping program submenu........................................................................478
		6.7.3 Entering telescoping values after emergency operation........................................................490
		6.7.4 Emergency operation in the event of a failure of the operating elements in the crane cab.....................493
	6.8 Hydraulic emergency operation......................................................................................494
		6.8.1 Important instructions for hydraulic emergency operation.....................................................494
		6.8.2 Operating principle and accessories..........................................................................495
		6.8.3 Connecting / disconnecting hoses.............................................................................497
		6.8.4 Establishing the hydraulic circuits required.................................................................500
		6.8.5 Operating in emergency mode..................................................................................504
		6.8.6 After emergency operation....................................................................................509
7 TECHNICAL INFORMATION FOR SUPERSTRUCTURE.................................................................................511
	7.1 Technical data.....................................................................................................511
		7.1.1 Maximum lifting capacity (DIN/ ISO/ EN)......................................................................511
		7.1.2 Maximum lifting capacity (85%)...............................................................................511
		7.1.3 Dimensions, weights and axle loads...........................................................................512
		7.1.4 Dimensions and weights of removable parts....................................................................514
		7.1.5 Technical data for superstructure............................................................................515
8 TMS9000E IMPORTANT INFORMATION...........................................................................................519
	8.1 About these operating instructions.................................................................................519
	8.2 Basic safety instructions..........................................................................................520
		8.2.1 Warnings and symbols.........................................................................................520
	8.3 Proper use.........................................................................................................521
	8.4 Organizational measures............................................................................................523
	8.5 Personnel qualifications...........................................................................................525
	8.6 Safety instructions for truck crane work...........................................................................526
	8.7 Specifications in US units of measurement..........................................................................528
9 TRANSPORT DIMENSIONS AND WEIGHTS.........................................................................................529
	9.1 Swingaway lattice extension and boom extension.....................................................................529
	9.2 Auxiliary single-sheave boom top...................................................................................529
10 TWO-STAGE SWINGAWAY LATTICE EXTENSION (OPTIONAL EQUIPMENT)..............................................................531
	10.1 Optional operating and display elements...........................................................................531
		10.1.1 In the crane cabin..........................................................................................531
		10.1.2 Operating and display instruments on the lattice extension..................................................534
	10.2 Identification of the two-stage swingaway lattice extension.......................................................535
	10.3 Assembly of the lattice extensions................................................................................537
	10.4 Centers of gravity for slinging...................................................................................538
		10.4.1 Manual Extension............................................................................................540
		10.4.2 Hydraulic Extension.........................................................................................541
	10.5 Checklists for rigging work.......................................................................................541
		10.5.1 Overview of the required rigging work.......................................................................541
		10.5.2 CHECKLIST: Installing the (two-stage) swingaway lattice extension...........................................543
		10.5.3 CHECKLIST: Un-installing the (two-stage) swingaway lattice extension........................................545
		10.5.4 CHECK LIST: Rigging the 10 m (33 ft) swingaway lattice extension............................................547
		10.5.5 CHECK LIST: Unrigging the 10 m (33 ft) swingaway lattice extension..........................................551
		10.5.6 CHECK LIST: Rigging the 17 m (56 ft) two-stage swingaway lattice extension..................................556
		10.5.7 CHECK LIST: Unrigging the 17 m (56 ft) two-stage swingaway lattice extension................................560
	10.6 Description of rigging work.......................................................................................566
		10.6.1 Preparing the truck crane for rigging.......................................................................566
		10.6.2 Checking the transport condition............................................................................568
		10.6.3 Hose drum for hydraulic supply..............................................................................572
		10.6.4 Folding the run-up rail out/in..............................................................................575
		10.6.5 Connections with folded lattice extension...................................................................576
		10.6.6 Pin connections on the main boom head.......................................................................584
		10.6.7 Pin connections on the lattice extension....................................................................588
		10.6.8 Swinging the lattice extension onto the main boom head......................................................590
		10.6.9 Swinging the lattice extension when rigging.................................................................591
		10.6.10 Electrical connections on the lattice extension............................................................593
		10.6.11 Establishing/disconnecting the hydraulic connection........................................................595
		10.6.12 Folding out/in the deflection sheaves on the 33 ft section.................................................596
		10.6.13 Positioning/removing the hoist cable.......................................................................599
		10.6.14 Lifting limit switch on the lattice extension..............................................................601
		10.6.15 Anemometer on the lattice extension........................................................................603
		10.6.16 Raising/lowering the lattice extension.....................................................................604
		10.6.17 Setting the Folding Offsetable Swingaway Extension.........................................................605
		10.6.18 Transportation on a separate vehicle.......................................................................606
	10.7 Raising and setting down the main boom with rigged lattice extension..............................................607
	10.8 Telescoping with rigged lattice extension.........................................................................608
	10.9 Operation with the lattice extension..............................................................................609
		10.9.1 RCL shutdown................................................................................................609
	10.10 Driving with rigged crane and installed lattice extension........................................................610
		10.10.1 Driving route..............................................................................................610
		10.10.2 Traveling with boom extension and/or inserts erected (Applies to either manual or hydraulic extensions)....611
	10.11 Malfunctions when working with lattice extension.................................................................614
	10.12 Maintenance work.................................................................................................615
		10.12.1 Modules in need of protection during cleaning work.........................................................615
		10.12.2 Maintenance work M1, monthly...............................................................................616
11 BOOM EXTENSION (OPTIONAL EQUIPMENT).....................................................................................619
	11.1 Identification and slinging points................................................................................619
		11.1.1 Identification..............................................................................................619
		11.1.2 Slinging points.............................................................................................620
	11.2 Assembly of boom extensions.......................................................................................621
	11.3 Checklists for rigging work.......................................................................................622
		11.3.1 CHECK LIST: Rigging the 22 m/27 m (72 ft/89 ft) boom extension..............................................622
		11.3.2 CHECK LIST: Unrigging the 22 m/27 m (72 ft/89 ft) boom extension............................................626
	11.4 Description of rigging work.......................................................................................629
		11.4.1 Installing/removing 5 m (16 ft) sections....................................................................629
		11.4.2 Installing/removing the bi-fold swingaway lattice extension for the boom extension..........................630
		11.4.3 Hydraulic connection at the boom extension..................................................................631
		11.4.4 Electrical connection at the boom extension.................................................................635
		11.4.5 Unfolding/folding the deflection sheave on the 5 m (16 ft) section..........................................637
	11.5 Maintenance work..................................................................................................638
		11.5.1 Maintenance work M1, monthly................................................................................638
12 AUXILIARY SINGLE-SHEAVE BOOM TOP........................................................................................639
	12.1 Identification....................................................................................................639
	12.2 Installing/removing auxiliary single-sheave boom top..............................................................640
		12.2.1 Installing the auxiliary single-sheave boom top.............................................................640
		12.2.2 Removing the auxiliary single-sheave boom top...............................................................641
	12.3 Rigging the auxiliary single-sheave boom top......................................................................642
		12.3.1 Rigging in transport position...............................................................................642
		12.3.2 Rigging in working position.................................................................................644
		12.3.3 Attaching and removing the hoist rope.......................................................................645
		12.3.4 Possible reeving methods on the auxiliary single-sheave boom top............................................645
		12.3.5 Lifting limit switch and anemometer.........................................................................646
13 THIS SECTION/OPTION IS NOT USED.........................................................................................647
14 Lubrication.............................................................................................................649
	14.1 Lubrication Intervals.............................................................................................649
	14.2 Environmental Protection..........................................................................................649
	14.3 Arctic Conditions.................................................................................................649
		14.3.1 Arctic Conditions to -9°C (15°F)............................................................................649
		14.3.2 Arctic Conditions to -40°C (-40°F)..........................................................................650
	14.4 Standard Lubricants Package.......................................................................................650
	14.5 Surface Protection for Cylinder Rods..............................................................................650
	14.6 Wire Rope Lubrication.............................................................................................651
	14.7 Lubrication Points................................................................................................651
	14.8 Superstructure....................................................................................................652
		14.8.1 Turntable...................................................................................................652
		14.8.2 Hoist.......................................................................................................654
		14.8.3 Central Lubrication System..................................................................................656
		14.8.4 Boom........................................................................................................658
		14.8.5 Boom Extension..............................................................................................664

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