Manitowoc GBT35 Cranes Supplement Operator Manual PDF

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Manitowoc GBT35 Cranes Supplement Operator Manual – PDF DOWNLOAD

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Manitowoc GBT35 Cranes Supplement Operator Manual – PDF DOWNLOAD

Language : English
Pages : 82
Downloadable : Yes
File Type : PDF

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Manitowoc GBT35 Cranes Supplement Operator Manual – PDF DOWNLOAD

FRONT COVER.........................................................................................................................................................15
TOC.................................................................................................................................................................17
SECTION 1...........................................................................................................................................................21
	Introduction....................................................................................................................................................21
		General.....................................................................................................................................................21
			Supplemental Information................................................................................................................................21
			Safety Information......................................................................................................................................21
			Basic Nomenclature......................................................................................................................................21
SECTION 2...........................................................................................................................................................25
	Safety Precautions..............................................................................................................................................25
		Diesel Engine Exhaust Hazard................................................................................................................................25
		Battery Posts, Terminals, And Related Accessories Hazards...................................................................................................25
		Safety Messages.............................................................................................................................................25
			General.................................................................................................................................................25
			Safety Alert Symbol.....................................................................................................................................25
			Safety Definitions......................................................................................................................................25
		General Information.........................................................................................................................................25
		Operator’s Qualifications...................................................................................................................................26
		Operator’s Information......................................................................................................................................26
		Operational Aids............................................................................................................................................26
			Load Charts.............................................................................................................................................27
			Wind Forces.............................................................................................................................................27
			Multiple Crane Lifts....................................................................................................................................27
			Two-Blocking............................................................................................................................................28
			Crushing Hazards........................................................................................................................................28
		Electrocution Hazard........................................................................................................................................29
		Electrical Contact..........................................................................................................................................30
		Special Operating Conditions and Equipment..................................................................................................................30
		Personnel Handling..........................................................................................................................................30
		Transporting the Crane......................................................................................................................................31
		Maintenance Practices.......................................................................................................................................31
			Service and Repair......................................................................................................................................31
			Lubrication.............................................................................................................................................32
			Tires...................................................................................................................................................32
			Batteries...............................................................................................................................................32
			Engine..................................................................................................................................................32
		Work Practices..............................................................................................................................................32
			Crane Access............................................................................................................................................33
			Lifting.................................................................................................................................................33
		Cold Weather Operation......................................................................................................................................33
			Temperature Effects On Hydraulic Cylinders..............................................................................................................34
			Outrigger Lift Off......................................................................................................................................34
			Hand Signals............................................................................................................................................35
SECTION 3...........................................................................................................................................................37
	Controls and Operating Procedures...............................................................................................................................37
		Truck Cab Controls..........................................................................................................................................37
			Truck Cab Ignition Switch...............................................................................................................................37
			Power Take Off..........................................................................................................................................37
			Park Brake..............................................................................................................................................37
			Engine Speed Governor...................................................................................................................................37
			Neutral Start/Safety Switch.............................................................................................................................37
		Outriggers..................................................................................................................................................37
			Outrigger Controls......................................................................................................................................37
			Crane Level Indicators..................................................................................................................................37
			Outrigger Controls......................................................................................................................................38
		Crane Controls..............................................................................................................................................39
			Load Chart..............................................................................................................................................39
			Handheld Outrigger Controls.............................................................................................................................39
			Swing Brake Pedal.......................................................................................................................................41
			Boom Telescope Pedal (Optional).........................................................................................................................41
			Foot Throttle Pedal.....................................................................................................................................41
			Display Panel...........................................................................................................................................41
			LMI and 3rd Wrap Bypass Switch..........................................................................................................................42
			Hydraulic Oil Indicator.................................................................................................................................42
			Swing Brake Indicator...................................................................................................................................42
			Main Winch 3rd Wrap Indicator...........................................................................................................................42
			Main Winch Speed Switch.................................................................................................................................42
			Hand Throttle Control...................................................................................................................................42
			Emergency Stop Switch...................................................................................................................................42
			Crane Ignition Switch...................................................................................................................................43
			Aux Winch Speed (Optional)..............................................................................................................................43
			Auxiliary Winch 3rd Wrap Indicator (Optional)...........................................................................................................43
			AC/Heater Vent..........................................................................................................................................43
			Receptacle..............................................................................................................................................43
			Radio Remote Switch (Optional)..........................................................................................................................43
			Crane Power Switch......................................................................................................................................43
			Boom Work Light Switch (Optional).......................................................................................................................43
			Cab Work Light Switch...................................................................................................................................43
			Skylight Wiper Switch...................................................................................................................................43
			Windshield Wiper Switch.................................................................................................................................43
			Crane Cab Climate Controls..............................................................................................................................43
			Swing Load Pedal (Optional).............................................................................................................................43
			Boom Lift Control Lever.................................................................................................................................43
			Winch Control Lever.....................................................................................................................................43
			Winch (Main and Auxiliary) Rotation Indicator...........................................................................................................44
			Telescope Control Lever.................................................................................................................................44
			Warning Horn Button.....................................................................................................................................44
			Swing Control Lever.....................................................................................................................................44
			Seat Back Adjustment....................................................................................................................................44
			Seat & Seat Frame Lever.................................................................................................................................44
			Climate Control Unit....................................................................................................................................44
			Swing Brake Switch......................................................................................................................................44
			House Lock..............................................................................................................................................44
			Heater..................................................................................................................................................44
			Adjustable Swing Speed Valve............................................................................................................................45
		Operating Procedures........................................................................................................................................46
			Equipment Familiarization...............................................................................................................................46
			Crane Cab Access........................................................................................................................................46
			Equipment Checks........................................................................................................................................46
			Cold Weather Operation..................................................................................................................................46
			Anti-two-block Check....................................................................................................................................46
			LMI Check...............................................................................................................................................47
		Winch System Operation......................................................................................................................................47
			Winch Two Speed Operation...............................................................................................................................47
		Work Site Location..........................................................................................................................................47
			Before Leaving the Truck Cab............................................................................................................................47
			Stowing and Parking.....................................................................................................................................48
			Unattended Crane........................................................................................................................................48
			Before Making the Lift..................................................................................................................................48
		Load Chart..................................................................................................................................................48
			Using the Load Chart....................................................................................................................................48
		Lifting the Load............................................................................................................................................49
		Shut Down and preparation For Road Travel...................................................................................................................49
SECTION 4...........................................................................................................................................................51
	Set-Up..........................................................................................................................................................51
		Outrigger Setup.............................................................................................................................................51
			Site Selection..........................................................................................................................................51
			Setting the Outriggers..................................................................................................................................51
		Jib Safety Information......................................................................................................................................52
		Jib Operation...............................................................................................................................................52
			Deployment Procedure....................................................................................................................................52
			Stowing Procedure.......................................................................................................................................53
		Jib Removal.................................................................................................................................................55
			Jib Maintenance.........................................................................................................................................55
		Anti-two-block Weight Installation..........................................................................................................................56
		Stow Pegs for winch cable...................................................................................................................................56
		Multipart Line Reeving......................................................................................................................................56
			Using Multiple Part Lines...............................................................................................................................56
			Lifting A 35 Metric Ton (35,000 kg) Load................................................................................................................56
		Winch Cable Installation....................................................................................................................................57
		Wedge Sockets...............................................................................................................................................58
			Terminator Wedge Installation...........................................................................................................................58
			Wedge Socket Installation...............................................................................................................................59
SECTION 5...........................................................................................................................................................61
	Lubrication.....................................................................................................................................................61
		General.....................................................................................................................................................61
			Arctic Conditions Below -18°C (0°F).....................................................................................................................61
			Chassis Grease..........................................................................................................................................61
			Extreme Pressure Multipurpose Gear Lubricant............................................................................................................61
			Open Gear Lubricant.....................................................................................................................................61
			Anti-wear Additives.....................................................................................................................................61
			Surface Protection for Cylinder Rods....................................................................................................................61
			Hydraulic Oil Inspection................................................................................................................................62
			Standard Hydraulic Oil..................................................................................................................................62
			Intermediate Hydraulic Oil..............................................................................................................................62
			Wide Range Intermediate Hydraulic Oil...................................................................................................................62
			Arctic Hydraulic Oil....................................................................................................................................62
		Lubrication Points..........................................................................................................................................63
			Winch Brake Oil.........................................................................................................................................65
			Winch Gearbox Oil.......................................................................................................................................66
			Hydraulic Oil Reservoir Level...........................................................................................................................66
		Wire Rope Lubrication.......................................................................................................................................66
SECTION 6...........................................................................................................................................................69
	Maintenance Checklist...........................................................................................................................................69
		Crane Inspection And Maintenance............................................................................................................................69
			Inspection..............................................................................................................................................69
			Special Boom Inspection.................................................................................................................................70
			Stability...............................................................................................................................................70
		winch cable Inspection And Maintenance......................................................................................................................70
			Inspection..............................................................................................................................................70
			Wire Rope Replacement...................................................................................................................................71
			Care of Wire Rope.......................................................................................................................................71
		Replacement Cable...........................................................................................................................................71
		Crane Adjustments and Repairs...............................................................................................................................72
			Boom Extension Cable....................................................................................................................................72
			Jib Jack Service and Maintenance........................................................................................................................72
			Lubrication.............................................................................................................................................72
			Rust Prevention.........................................................................................................................................72
		Hydraulic System............................................................................................................................................72
			Oil Cooler..............................................................................................................................................72
			Hydraulic System Trouble Diagnosis......................................................................................................................72
		Torque Values Grade 5 and 8 Bolts...........................................................................................................................75
		Tire Load And Inflation Table...............................................................................................................................77
		Specifications..............................................................................................................................................80
			Hydraulic System........................................................................................................................................80
			Winch System............................................................................................................................................80
			Crane Operating Speeds..................................................................................................................................80
CTRL571-00_Warm-up_Procedures--Supplement.pdf....................................................................................................................... 0
	Crane Warm-up Procedures........................................................................................................................................13
		Engine......................................................................................................................................................13
		Transmission................................................................................................................................................13
		Hoist.......................................................................................................................................................13
		Swing Drive and Turntable Bearing...........................................................................................................................13
		Axles.......................................................................................................................................................14
		Hydraulic Oil System........................................................................................................................................14
CTRL641-00_Boom Cable Tensioning-Supplement.pdf..................................................................................................................... 0
	General......................................................................................................................................................... 3
	Cable Tensioning................................................................................................................................................ 3
		Tensioning Setup Procedure.................................................................................................................................. 3
			1. Mark the front of each section with a chalk line as indicated in Figure 1............................................................................ 3
				2. Extend and retract boom several times to establish working state of cables....................................................................... 3
				3. Extend boom so scribed lines are exposed by approximately 12 inches.............................................................................. 3
				4. Measure the extension gaps between each boom section and scribed line and note values............................................................ 3
				5. Retract boom so that the scribed lines are exposed by approximately 6 inches..................................................................... 3
				6. Measure the retraction gaps between each boom section and scribed line and note values........................................................... 3
				7. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 3
				8. Adjust all corresponding cables according to Cable Tightening Sequence instructions.............................................................. 3
			Figure 1................................................................................................................................................ 3
	Cable Tension Sequence.......................................................................................................................................... 3
		Five section boom with two stage cylinder................................................................................................................... 3
			1. 321 retract cables................................................................................................................................... 3
				2. 123 extend (synchronizing) cables................................................................................................................ 3
				3. 234 extend cables................................................................................................................................ 3
				4. 432 retract cables............................................................................................................................... 3
				5. 345 extend cables................................................................................................................................ 3
				6. 543 retract cables............................................................................................................................... 4
		Four section boom with two stage cylinder................................................................................................................... 4
			1. 321 retract cables................................................................................................................................... 4
				2. 123 extend (synchronizing) cables................................................................................................................ 4
				3. 234 extend cables................................................................................................................................ 4
				4. 432 retract cables............................................................................................................................... 4
		Four section boom with one stage cylinder................................................................................................................... 4
			1. 123 extend cables.................................................................................................................................... 4
				2. 321 retract cables............................................................................................................................... 4
				3. 234 extend cables................................................................................................................................ 4
				4. 432 retract cables............................................................................................................................... 4
		Three section boom with one stage cylinder.................................................................................................................. 4
			1. 123 extend cables.................................................................................................................................... 4
				2. 321 retract cables............................................................................................................................... 4
	5 - Section Boom w/ 2 Stage Cylinder Cable Positioning.......................................................................................................... 4
		Figure 2.................................................................................................................................................... 4
		Cable Tightening Sequence 5 Section Boom with Two Stage Extend Cylinder..................................................................................... 4
		321 and 123 cable balancing................................................................................................................................. 4
		Extension................................................................................................................................................... 4
			1. Measure the extension gaps between the first and second section and the second and third section..................................................... 4
				2. Tighten 321 retract cable located at the front bottom of the base section the difference in the extension gap measurements....................... 4
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 4
				4. Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal......... 4
		Retraction.................................................................................................................................................. 4
			1. Measure the retraction gaps between the first and second section and the second and third section.................................................... 4
				2. Tighten the 123 synchronizing cable located at the back of the base section the difference in the retraction gap measurements.................... 4
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 4
				4. Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal....... 5
		234 and 432 cable balancing................................................................................................................................. 5
		Extension................................................................................................................................................... 5
			1. Measure the extension gaps between the third and fourth section and the second and third section..................................................... 5
				2. Tighten the 234 extend cable located at the back top of the second section the difference in the extension gap measurements...................... 5
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 5
				4. Tightening until the extension gap between the third and fourth section is equal to the extension gap between the second and third section....... 5
		Retraction.................................................................................................................................................. 5
			1. Measure the retraction gaps between the second and third section and the third and fourth section.................................................... 5
				2. Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements................ 5
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 5
				4. Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section..... 5
		345 and 543 cable balancing................................................................................................................................. 5
		Extension................................................................................................................................................... 5
			1. Measure the extension gaps between the fourth and fifth section and the third and fourth section..................................................... 5
				2. Tighten the 345 extend cable located at the back top of the third section the difference in the extension gap measurements....................... 5
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 5
				4. Tightening until the extension gap between the fifth and fourth section is equal to the extension gap between the fourth and third section....... 5
		Retraction.................................................................................................................................................. 5
			1. Measure the retraction gaps between the fourth and fifth section and the third and fourth section.................................................... 5
				2. Tighten the 543 retract cable located at the front bottom of the third section the difference in the retraction gap measurements................. 5
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 5
				4. Tightening until the retraction gap between the fifth and fourth section is equal to the retraction gap between the fourth and third section..... 5
	4- Section Boom w/ 2 Stage Cylinder Cable Positioning........................................................................................................... 6
		Figure 3.................................................................................................................................................... 6
		Cable Tightening Sequence 4 Section Boom with Two Stage Extend Cylinder..................................................................................... 6
		321 and 123 cable balancing................................................................................................................................. 6
		Extension................................................................................................................................................... 6
			1. Measure the extension gaps between the first and second section and the second and third section..................................................... 6
				2. Tighten 321 retract cable located at the front bottom of the base section the difference in the extension gap measurements....................... 6
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 6
				4. Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal......... 6
		Retraction.................................................................................................................................................. 6
			1. Measure the retraction gaps between the first and second section and the second and third section.................................................... 6
				2. Tighten the 123 synchronizing cable located at the back of the base section the difference in the retraction gap measurements.................... 6
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 6
				4. Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal....... 6
		234 and 432 cable balancing................................................................................................................................. 6
		Extension................................................................................................................................................... 6
			1. Measure the extension gaps between the third and fourth section and the second and third section..................................................... 6
				2. Tighten the 234 extend cable located at the back top of the second section the difference in the extension gap measurements...................... 6
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 6
				4. Tightening until the extension gap between the third and fourth section is equal to the extension gap between the second and third section....... 7
		Retraction.................................................................................................................................................. 7
			1. Measure the retraction gaps between the second and third section and the third and fourth section.................................................... 7
				2. Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements................ 7
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 7
				4. Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section..... 7
	4- Section Boom w/ 1 Stage Cylinder Cable Positioning........................................................................................................... 7
		Figure 4.................................................................................................................................................... 7
		Cable Tightening Sequence 4 Section Boom with (1) Stage Extend Cylinder..................................................................................... 7
		321 and 123 cable balancing................................................................................................................................. 7
		Extension................................................................................................................................................... 7
			1. Measure the extension gaps between the first and second section and the second and third section..................................................... 7
				2. Tighten 123 extend cable located at the back top of the base section the difference in the extension gap measurements............................ 7
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 7
				4. Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal......... 7
		Retraction.................................................................................................................................................. 7
			1. Measure the retraction gaps between the first and second section and the second and third section.................................................... 7
				2. Tighten the 321 retract cable located at the front bottom of the base section the difference in the retraction gap measurements.................. 7
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 7
				4. Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal....... 8
		234 and 432 cable balancing................................................................................................................................. 8
		Extension................................................................................................................................................... 8
			1. Measure the extension gaps between the third and fourth section and the second and third section..................................................... 8
				2. Tighten the 234 extend cable located at the back top of the second section the difference in the extension gap measurements...................... 8
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 8
				4. Tightening until the extension gap between the third and fourth section is equal to the extension gap between the second and third section....... 8
		Retraction.................................................................................................................................................. 8
			1. Measure the retraction gaps between the second and third section and the third and fourth section.................................................... 8
				2. Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements................ 8
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 8
				4. Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section..... 8
	3- Section Boom w/ 1 Stage Cylinder Cable Positioning........................................................................................................... 8
		Figure 5.................................................................................................................................................... 8
		Cable Tightening Sequence 3 Section Boom with (1) Stage Extend Cylinder..................................................................................... 8
		321 and 123 cable balancing................................................................................................................................. 8
		Extension................................................................................................................................................... 8
			1. Measure the extension gaps between the first and second section and the second and third section..................................................... 8
				2. Tighten 123 extend cable located at the back top of the base section the difference in the extension gap measurements............................ 8
				3. Extend and retract the boom a few times and then repeat measuring the extension gaps............................................................. 9
				4. Tightening until the extension gap between the first and second section and the extension gap between the second and the third are equal......... 9
		Retraction.................................................................................................................................................. 9
			1. Measure the retraction gaps between the first and second section and the second and third section.................................................... 9
				2. Tighten the 321 retract cable located at the front bottom of the base section the difference in the retraction gap measurements.................. 9
				3. Extend and retract the boom a few times and then repeat measuring the retraction gaps............................................................ 9
				4. Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal....... 9
			Figure 6................................................................................................................................................ 9
	Cable Retention................................................................................................................................................. 9
		TORQUE VALUES for Second Nut:...............................................................................................................................10

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