Grove Crane TMS 9000E Superstructure Operator’s Manual 218-03 – PDF DOWNLOAD

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Grove Crane TMS 9000E Superstructure Operator’s Manual 218-03 – PDF DOWNLOAD

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Grove Crane TMS 9000E Superstructure Operator’s Manual 218-03 – PDF DOWNLOAD

Language : English
Pages : 678
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Grove Crane TMS 9000E Superstructure Operator’s Manual 218-03 – 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.
• Read and follow the information located in Model Specific Information near the end of this section.
  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 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 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.

-04-2011, Control # 218-03
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.
Read and follow the information located in Model Specific Information near the end of this section.
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 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 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.

OPERATOR’S INFORMATION:

• You must read and understand this Operator’s Manual and the Load Chart before operating your new
  crane. You must also view and understand the supplied safety video. This manual and Load Chart must
  be readily available to the operator at all times and must remain in the cab (if equipped) or
  operator’s station while the crane is in use.
• The Operator’s Manual supplied with and considered part of your crane must be read and completely
  understood by each person responsible for assembly, disassembly, operation and maintenance of the
  crane.
• No personnel shall be allowed to climb onto the crane or enter the crane cab or operator’s station
  unless performance of their duties require them to do so, and then only with knowledge of the
  operator or other qualified person.

TABLE OF CONTENTS:

Grove Crane TMS 9000E Superstructure Operator’s Manual 218-03 – PDF DOWNLOAD

1 Safety Precautions.......................................................................................................................... 11
	1.1 Model Specific Information............................................................................................................ 44
		1.1.1 Location of Serial Numbers...................................................................................................... 45
	1.2 Crane Overload Inspection............................................................................................................. 47
2 Description Of Crane........................................................................................................................ 55
	2.1 Overview of the superstructure cab operating and display instruments.................................................................. 55
		2.1.1 Overview of the crane section................................................................................................... 55
		2.1.2 Overview of crane cab........................................................................................................... 58
		2.1.3 Operating elements on the front panel........................................................................................... 60
		2.1.4 Operating elements on the side panel............................................................................................ 61
		2.1.5 Control consoles................................................................................................................ 66
		2.1.6 Control lever configuration..................................................................................................... 68
		2.1.7 At crane control display........................................................................................................ 70
		2.1.8 Main menu of the crane control display.......................................................................................... 72
		2.1.9 Crane control display - submenus................................................................................................ 75
		2.1.10 SLI display – main menu........................................................................................................ 89
		2.1.11 SLI display – submenus......................................................................................................... 90
		2.1.12 Switch boxes for outrigger / electronic level / outrigger pressure display..................................................... 98
	2.2 Functional description of the display and operating elements..........................................................................100
		2.2.1 Diesel engine...................................................................................................................100
		2.2.2 Crane control...................................................................................................................102
		2.2.3 Counterweight submenu...........................................................................................................112
		2.2.4 Hoists..........................................................................................................................115
		2.2.5 Swing gear......................................................................................................................119
		2.2.6 Lifting gear....................................................................................................................121
		2.2.7 Telescoping mechanism...........................................................................................................124
		2.2.8 Hydraulic system................................................................................................................134
		2.2.9 Safe load indicator (SLI).......................................................................................................136
		2.2.10 Electricity, lighting, windscreen wiper / washing system.......................................................................150
		2.2.11 Heating........................................................................................................................152
		2.2.12 Other operating elements of the crane cab......................................................................................160
	2.3 Functional description of the operational aids........................................................................................164
		2.3.1 Safe load indicator (SLI).......................................................................................................164
		2.3.2 Lowering limit switch...........................................................................................................166
		2.3.3 Lifting limit switch............................................................................................................167
		2.3.4 Dead man's switch and seat contact switch.......................................................................................169
	2.4 Overview of the carrier cab operating and display instruments.........................................................................169
3 Crane operation.............................................................................................................................171
	3.1 Superstructure inspections and adjustments prior to crane operation...................................................................171
		3.1.1 PRE-STARTING CHECKLIST: When truck crane is rigged..............................................................................171
		3.1.2 Adjusting the front console and the crane cab seat..............................................................................178
		3.1.3 Checking the condition of the truck crane.......................................................................................179
		3.1.4 Checking the operators aids.....................................................................................................182
		3.1.5 Pre-warming the hydraulic oil...................................................................................................185
		3.1.6 Switching the houselock on / off................................................................................................187
	3.2 Starting and stopping the diesel engine...............................................................................................190
		3.2.1 When starting the engine the first time in the day..............................................................................190
		3.2.2 Inspections after starting the diesel engine....................................................................................194
		3.2.3 Shutting down the diesel engine.................................................................................................197
	3.3 Operating the safe load indicator (SLI)...............................................................................................198
		3.3.1 Switching on the SLI............................................................................................................198
		3.3.2 Entering the rigging mode.......................................................................................................202
		3.3.3 Inspections before operating the crane..........................................................................................209
		3.3.4 Displays during crane operation.................................................................................................212
		3.3.5 SLI early warning and SLI shutdown..............................................................................................215
		3.3.6 SLI shutdown....................................................................................................................215
		3.3.7 Displaying the lifting capacity table...........................................................................................219
		3.3.8 Entering the time/date..........................................................................................................221
	3.4 Crane work with the main boom.........................................................................................................222
		3.4.1 External influences while working with the crane................................................................................222
		3.4.2 Permissible swing ranges and working positions for crane work...................................................................227
		3.4.3 Main hoist......................................................................................................................230
		3.4.4 Auxiliary hoist.................................................................................................................235
		3.4.5 Lifting gear....................................................................................................................237
		3.4.6 Swing gear......................................................................................................................241
		3.4.7 Telescoping mechanism...........................................................................................................249
		3.4.8 Possible movement combinations..................................................................................................290
		3.4.9 High-speed mode.................................................................................................................291
		3.4.10 Cooling the hydraulic oil......................................................................................................293
	3.5 Adjustments and displays while operating the crane....................................................................................294
		3.5.1 Adjusting the brightness of the display.........................................................................................294
		3.5.2 Setting characteristic curves for the control lever.............................................................................295
		3.5.3 Adjusting power unit speeds.....................................................................................................297
		3.5.4 Setting a constant engine speed.................................................................................................299
		3.5.5 Tilting the crane cab...........................................................................................................301
		3.5.6 Adjusting the windscreen wiper stroke interval..................................................................................302
		3.5.7 Using the directional spotlight for the working area............................................................................303
		3.5.8 Display the operating hours.....................................................................................................304
		3.5.9 Warning message submenu.........................................................................................................306
		3.5.10 Error menu.....................................................................................................................308
	3.6 Working range limiter.................................................................................................................309
		3.6.1 Opening the Working range limitation submenu....................................................................................310
		3.6.2 Reading current settings........................................................................................................311
		3.6.3 Entering a limit value for a maximum overall height.............................................................................313
		3.6.4 Entering a limit value for a maximum working radius.............................................................................314
		3.6.5 Entering limit values for maximum swing angles..................................................................................315
		3.6.6 Entering point data for objects.................................................................................................318
		3.6.7 Entering limit values manually..................................................................................................322
		3.6.8 Switching monitoring on and off.................................................................................................325
		3.6.9 Shutdown caused by working range limiter........................................................................................327
	3.7 Work break............................................................................................................................329
		3.7.1 During short work breaks........................................................................................................329
		3.7.2 Work breaks lasting longer than 8 hours.........................................................................................330
	3.8 Heating and ventilating the crane cab.................................................................................................331
		3.8.1 Heating.........................................................................................................................331
		3.8.2 Air-conditioning system.........................................................................................................340
		3.8.3 Crane Transmission..............................................................................................................343
4 Rigging work................................................................................................................................351
	4.1 Checklists for rigging work for crane operation with main boom........................................................................351
		4.1.1 CHECKLIST: Rigging..............................................................................................................351
		4.1.2 10. With optional equipment, switch off the superstructure lock if necessary; à Switching the houselock on / off, p. 3 - 17.....352
		4.1.3 CHECKLIST: Unrigging............................................................................................................354
	4.2 Choosing a suitable site..............................................................................................................356
		4.2.1 Load bearing capacity of the ground and the outriggers..........................................................................357
		4.2.2 Safe distance from banks and pits...............................................................................................360
		4.2.3 Earthing of the truck crane.....................................................................................................361
		4.2.4 Safe distance from electrical lines.............................................................................................361
	4.3 Switching Positions...................................................................................................................364
		4.3.1 Switching off the boom floating position........................................................................................364
		4.3.2 Switching off boom pre-tensioning...............................................................................................365
		4.3.3 Switching off rotating gear freewheel...........................................................................................366
	4.4 Rigging add-on parts in position for crane operation / driving........................................................................368
		4.4.1 Folding mirrors in and out and adjusting them...................................................................................368
	4.5 Outriggers............................................................................................................................370
		4.5.1 CHECKLIST: Extending the outriggers.............................................................................................370
		4.5.2 CHECKLIST: Retracting the outrigger.............................................................................................372
		4.5.3 Permissible outrigger spreads...................................................................................................374
		4.5.4 Preparing the truck crane.......................................................................................................376
		4.5.5 Pinning/Unpinning outrigger beam for crane operations...........................................................................377
			Setting The Outriggers............................................................................................................377
				Engaging the Mid Extension Lock Pin...........................................................................................378
			Outrigger Monitoring System (OMS) LMI Display (Optional—Standard in North America)................................................379
			STOWING THE OUTRIGGERS............................................................................................................382
				Stowing the Mid Extension Lock Pin............................................................................................385
			SETTING THE CENTER FRONT STABILIZER...............................................................................................385
			STOWING THE CENTER FRONT STABILIZER...............................................................................................386
		4.5.6 Checking the alignment of the truck crane.......................................................................................386
		4.5.7 Leveling the truck crane on outriggers..........................................................................................391
	4.6 Counterweight Rigging.................................................................................................................395
	4.7 Rigging work on the main boom.........................................................................................................395
		4.7.1 Hook block on the bumper........................................................................................................395
		4.7.2 Hook block on a separate vehicle................................................................................................396
		4.7.3 Reeving and unreeving the hoist rope............................................................................................399
		4.7.4 Installing / Removing the lifting limit switch..................................................................................406
		4.7.5 Locking the lifting limit switch / Releasing the lock...........................................................................412
		4.7.6 Anemometer and air traffic control light........................................................................................413
5 Counterweight rigging.......................................................................................................................417
	5.1 Counterweight parts...................................................................................................................417
		5.1.1 Counterweight parts.............................................................................................................417
		5.1.2 Counterweight versions/combinations.............................................................................................419
		5.1.3 Slinging points at the counterweight sections...................................................................................423
		5.1.4 CHECKLIST: Rigging the counterweight............................................................................................425
		5.1.5 CHECKLIST: Unrigging the counterweight..........................................................................................427
		5.1.6 Lower 3,000 lb tray plate on the counterweight platform.........................................................................428
		5.1.7 Check the position of the locking pins for 3000 and 5,000 lb counterweight sections.............................................429
		5.1.8 Assembling counterweight versions/combinations‘.................................................................................430
		5.1.9 Counterweight hoist unit........................................................................................................433
		5.1.10 Rotating with the rigged counterweight.........................................................................................439
6 Malfunctions on the superstructure..........................................................................................................441
	6.1 Emergency-stop devices for crane operation............................................................................................441
		6.1.1 Carrying out emergency-stop operations..........................................................................................441
		6.1.2 Resetting the emergency-stop switch.............................................................................................443
	6.2 Procedure in the event of a malfunction during crane operation........................................................................444
	6.3 Fuses on the superstructure...........................................................................................................445
		6.3.1 Fuses on the turntable..........................................................................................................446
		6.3.2 Fuses in the crane cab..........................................................................................................448
		6.3.3 SLI fuses.......................................................................................................................450
	6.4 Finding and eliminating malfunctions at the power units...............................................................................451
		6.4.1 Malfunctions in the diesel engine during crane operation........................................................................451
		6.4.2 Malfunctions in the outriggers..................................................................................................452
		6.4.3 Malfunctions in the main hoist..................................................................................................453
		6.4.4 Malfunctions on the auxiliary hoist.............................................................................................455
		6.4.5 Lifting gear malfunctions.......................................................................................................457
		6.4.6 Malfunctions in the swing gear..................................................................................................459
		6.4.7 Malfunctions in the counterweight hoist unit....................................................................................461
		6.4.8 Malfunctions in the hydraulic system / hydraulic oil cooler.....................................................................462
		6.4.9 Malfunctions on the turntable lock..............................................................................................462
		6.4.10 Malfunctions in the telescoping mechanism......................................................................................463
		6.4.11 Malfunctions when driving from the crane cab...................................................................................467
	6.5 Finding and eliminating malfunctions at the SLI.......................................................................................468
		6.5.1 General malfunctions............................................................................................................468
		6.5.2 Error messages in the Monitoring submenu........................................................................................469
		6.5.3 Displays in the Error submenu...................................................................................................471
		6.5.4 Table – error messages..........................................................................................................473
	6.6 Finding and eliminating malfunctions at the crane control.............................................................................478
		6.6.1 General malfunctions............................................................................................................478
		6.6.2 Error messages on the crane control display.....................................................................................479
	6.7 Emergency operations and programs.....................................................................................................481
		6.7.1 Emergency retraction operation..................................................................................................482
		6.7.2 Emergency telescoping program submenu...........................................................................................486
		6.7.3 Entering telescoping values after emergency operation...........................................................................498
		6.7.4 Emergenà p. 6 - 61cy operation in the event of a failure of the operating elements in the crane cab.............................501
	6.8 Hydraulic emergency operation ).......................................................................................................502
		6.8.1 Important instructions for hydraulic emergency operation........................................................................502
		6.8.2 Operating principle and accessories.............................................................................................503
		6.8.3 Connecting / disconnecting hoses................................................................................................505
		6.8.4 Establishing the hydraulic circuits required....................................................................................508
		6.8.5 Operating in emergency mode.....................................................................................................512
		6.8.6 After emergency operation.......................................................................................................516
7 Technical information for superstructure....................................................................................................517
	7.1 Technical data........................................................................................................................517
		7.1.1 Maximum lifting capacity (DIN/ ISO/ EN).........................................................................................517
		7.1.2 Maximum lifting capacity (85%)..................................................................................................517
		7.1.3 Dimensions, weights and axle loads..............................................................................................518
		7.1.4 Dimensions and weights of removable parts.......................................................................................520
		7.1.5 Technical data for superstructure...............................................................................................521
8 TMS9000E Important information..............................................................................................................525
	8.1 About these operating instructions....................................................................................................525
	8.2 Basic safety instructions.............................................................................................................526
		8.2.1 Warnings and symbols............................................................................................................526
	8.3 Proper use............................................................................................................................527
	8.4 Organizational measures...............................................................................................................529
	8.5 Personnel qualifications..............................................................................................................531
	8.6 Safety instructions for truck crane work..............................................................................................532
	8.7 Specifications in US units of measurement.............................................................................................534
9 Transport dimensions and weights............................................................................................................535
	9.1 Swingaway lattice extension and boom extension........................................................................................535
	9.2 Auxiliary single-sheave boom top......................................................................................................535
10 Two-stage swingaway lattice extension (optional equipment).................................................................................537
	10.1 Optional operating and display elements..............................................................................................537
		10.1.1 In the crane cabin.............................................................................................................537
		10.1.2 Operating and display instruments on the lattice extension.....................................................................540
	10.2 Identification of the two-stage swingaway lattice extension..........................................................................541
	10.3 Assembly of the lattice extensions...................................................................................................543
	10.4 Centers of gravity for slinging......................................................................................................544
		10.4.1 Manual Extension...............................................................................................................546
		10.4.2 Hydraulic Extension............................................................................................................547
	10.5 Checklists for rigging work..........................................................................................................547
		10.5.1 Overview of the required rigging work..........................................................................................547
		10.5.2 CHECKLIST: Installing the (two-stage) swingaway lattice extension..............................................................549
		10.5.3 CHECKLIST: Un-installing the (two-stage) swingaway lattice extension...........................................................551
		10.5.4 CHECK LIST: Rigging the 10 m (33 ft) swingaway lattice extension...............................................................553
		10.5.5 CHECK LIST: Unrigging the 10 m (33 ft) swingaway lattice extension.............................................................557
		10.5.6 CHECK LIST: Rigging the 17 m (56 ft) two-stage swingaway lattice extension.....................................................562
		10.5.7 CHECK LIST: Unrigging the 17 m (56 ft) two-stage swingaway lattice extension...................................................566
	10.6 Description of rigging work..........................................................................................................572
		10.6.1 Preparing the truck crane for rigging..........................................................................................572
		10.6.2 Checking the transport condition...............................................................................................574
		10.6.3 Hose drum for hydraulic supply.................................................................................................578
		10.6.4 Folding the run-up rail out/in.................................................................................................581
		10.6.5 Connections with folded lattice extension......................................................................................582
		10.6.6 Pin connections on the main boom head..........................................................................................590
		10.6.7 Pin connections on the lattice extension.......................................................................................594
		10.6.8 Swinging the lattice extension onto the main boom head.........................................................................596
		10.6.9 Swinging the lattice extension when rigging....................................................................................597
		10.6.10 Electrical connections on the lattice extension...............................................................................599
		10.6.11 Establishing/disconnecting the hydraulic connection...........................................................................601
		10.6.12 Folding out/in the deflection sheaves on the 33 ft section....................................................................602
		10.6.13 Positioning/removing the hoist cable..........................................................................................605
		10.6.14 Lifting limit switch on the lattice extension.................................................................................607
		10.6.15 Anemometer on the lattice extension...........................................................................................609
		10.6.16 Raising/lowering the lattice extension........................................................................................610
		10.6.17 Setting the Folding Offsetable Swingaway Extension............................................................................611
		10.6.18 Transportation on a separate vehicle..........................................................................................612
	10.7 Raising and setting down the main boom with rigged lattice extension.................................................................613
	10.8 Telescoping with rigged lattice extension............................................................................................614
	10.9 Operation with the lattice extension.................................................................................................615
		10.9.1 SLI shutdown...................................................................................................................615
	10.10 Driving with rigged crane and installed lattice extension...........................................................................616
		10.10.1 Driving route.................................................................................................................616
		10.10.2 Traveling with boom extension and/or inserts erected (Applies to either manual or hydraulic extensions).......................617
	10.11 Malfunctions when working with lattice extension....................................................................................620
	10.12 Maintenance work....................................................................................................................621
		10.12.1 Modules in need of protection during cleaning work............................................................................621
		10.12.2 Maintenance work M1, monthly..................................................................................................622
11 Boom extension (optional equipment)........................................................................................................625
	11.1 Identification and slinging points...................................................................................................625
		11.1.1 Identification.................................................................................................................625
		11.1.2 Slinging points................................................................................................................626
	11.2 Assembly of boom extensions..........................................................................................................627
	11.3 Checklists for rigging work..........................................................................................................628
		11.3.1 CHECK LIST: Rigging the 22 m/27 m (72 ft/89 ft) boom extension.................................................................628
		11.3.2 CHECK LIST: Unrigging the 22 m/27 m (72 ft/89 ft) boom extension...............................................................632
	11.4 Description of rigging work..........................................................................................................635
		11.4.1 Installing/removing 5 m (16 ft) sections.......................................................................................635
		11.4.2 Installing/removing the bi-fold swingaway lattice extension for the boom extension.............................................636
		11.4.3 Hydraulic connection at the boom extension.....................................................................................637
		11.4.4 Electrical connection at the boom extension....................................................................................641
		11.4.5 Unfolding/folding the deflection sheave on the 5 m (16 ft) section.............................................................643
	11.5 Maintenance work.....................................................................................................................644
		11.5.1 Maintenance work M1, monthly...................................................................................................644
12 Auxiliary Single-sheave Boom Top...........................................................................................................645
	12.1 Identification.......................................................................................................................645
	12.2 Installing/removing auxiliary single-sheave boom top.................................................................................646
		12.2.1 Installing the auxiliary single-sheave boom top................................................................................646
		12.2.2 Removing the auxiliary single-sheave boom top..................................................................................647
	12.3 Rigging the auxiliary single-sheave boom top.........................................................................................648
		12.3.1 Rigging in transport position..................................................................................................648
		12.3.2 Rigging in working position....................................................................................................650
		12.3.3 Attaching and removing the hoist rope..........................................................................................651
		12.3.4 Possible reeving methods on the auxiliary single-sheave boom top...............................................................651
		12.3.5 Lifting limit switch and anemometer............................................................................................652
13 This section/option is not used............................................................................................................653
14 Lubrication................................................................................................................................655
	14.1 GENERAL..............................................................................................................................655
	14.2 LUBRICATION POINTS...................................................................................................................655
		14.2.1 Carrier Lubrication............................................................................................................657
		14.2.2 Superstructure Lubrication.....................................................................................................664
		14.2.3 Boom, Boom Extension, and Boom Accessories Lubrication.........................................................................667
		14.2.4 Boom Locking Pins Lubrication Procedure........................................................................................672
		14.2.5 Wire Rope Lubrication..........................................................................................................677

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