Manitowoc Grove Crane GHC 75 Operating & Maintenance Manual 519-04

Description

Manitowoc Grove Crane GHC 75 Operating & Maintenance Manual 519-04 – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove Crane GHC 75 Operating & Maintenance Manual 519-04 – PDF DOWNLOAD

Language : English
Pages : 570
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc Grove Crane GHC 75 Operating & Maintenance Manual 519-04 – PDF DOWNLOAD

1 Safety 13
1 1 Presentation of safety information 13
1 2 Danger sources 14
1 3 National and international regulations 14
1 4 Intended use 14
1 5 Impermissible use 17
1 6 Crane categorization 18
1 7 Requirements on personnel 18
1 8 Work operation 20
1 8 1 Boarding or exiting the crane safely 25
1 8 2 Emergency exit 25
1 8 3 Regulations for applications planning 26
1 8 4 Ramming tasks or pulling sheet pile walls 27
1 8 5 Deployment on a pontoon 28
1 8 6 Start-up 30
1 8 7 Operation 31
1 8 8 Travelling 31
1 8 9 Decommissioning 32
1 8 10 Setup tasks 32
1 9 Maintenance 33
1 10 Transport 34
1 11 Responsibilities of the owner 35
1 12 Protective devices 36
1 13 Machine labelling 37
1 14 Warnings and information signs 38
2 Overview 59
2 1 Overall machine 59
2 2 Undercarriage 60
2 3 Cab 61
2 4 Uppercarriage 62
2 5 Telescopic boom 66
2 6 Winch 67
2 7 Counterweight (ballast) 68
3 Technical data 69
3 1 Basic machine 69
3 2 Permissible ground pressure 72
3 3 Diesel fuel 74
3 4 Engine oil 75
3 5 Permissible wind speeds 76
3 5 1 Procedure when reaching the limit value “wind in operation” 76
3 5 2 Procedure when reaching the limit value “wind not in operation” 76
3 6 Dimensions of the basic machine 77
3 7 Safe working load reduction due to load-handling devices 78
3 8 Conversion factors 80
3 9 Hooks 81
4 Start-up 83
4 1 Initial start-up 84
4 2 Checks before start-up 84
4 3 Switching on the battery disconnect switch 86
4 4 Machine start 87
4 4 1 Fastening the seat belt 87
4 4 2 Starting the diesel engine 89
4 4 3 Selecting setup status 92
4 4 4 Bringing the machine to operating temperature 93
4 4 5 Jump start 94
4 5 Switching off engine 95
4 6 Decommissioning the machine 96
4 7 Preservation and storage 97
4 8 Starting up the machine after long-term storage 98
5 SENCON 2 0 99
5 1 Overview of controls 100
5 1 1 Quick selection icons 101
5 1 2 Menu icons 102
5 2 Start screen 103
5 2 1 Operating status 104
5 2 2 Telescopic boom and slew uppercarriage notification icons 106
5 2 3 Diesel engine notification and warning icons 108
5 2 4 Load moment limitation notification and warning icons 110
5 2 5 Overall machine notification and warning icons 111
5 2 6 Working diagram 112
5 2 7 Winch parameters 113
5 3 Set-up status 114
5 3 1 Entering uppercarriage inclination 116
5 3 2 Entering undercarriage ballast 117
5 3 3 Entering winch reeving 118
5 3 4 Setting travel speed 119
5 3 5 Entering track width 120
5 3 6 Entering attachments and configuring setup program 121
5 3 7 Entering counterweight 123
5 4 Setup 124
5 5 Setting language 127
5 6 Setting brightness 128
5 7 Setting date and time 130
5 8 Configuring units 132
5 9 USB 134
5 10 Request access 134
5 11 Histogram 135
5 12 Login information 136
5 13 General information 137
5 14 Diagnostics 138
5 14 1 Active faults engine 139
5 14 2 Active faults machine 140
5 14 3 Active faults RCL 145
6 Operation 147
6 1 Cab 150
6 1 1 Driver seat 153
6 2 Uppercarriage locking mechanism 155
6 3 Tilting the cab 157
6 4 Operating elements in the cab 158
6 4 1 Safety lever 159
6 4 2 Assignment of the joysticks and pedals 161
6 4 3 Storage compartment, right of the driver seat 162
6 4 4 Control panels, right 163
6 4 5 Control panel, top right 165
6 5 Slewing ring lubrication (option) 166
6 6 Central lubrication system (option) 167
6 6 1 DEF/system for reducing nitrogen oxide (Tier 4f engines) 168
6 6 2 Exhaust aftertreatment system regeneration (Tier 4f engines) 170
6 6 3 Control panel – automatic air conditioning 173
6 6 4 Camera system 176
6 7 Load moment limitation (LML) 177
6 7 1 LML function 177
6 7 2 Audible and visual warning device statuses 178
6 7 3 Operation 179
6 7 4 Mode selection 179
6 7 5 Bypassing the load moment limitation (LML) 180
6 7 6 Operating modes table 181
6 7 7 Safety components 183
6 8 Working area limiter 187
6 9 Special equipment 188
6 9 1 Remote radio control (option) 188
6 9 2 Visual warning device 199
6 10 Work implementation 200
6 10 1 Crane operation 201
6 10 2 Securing bottom hook block for drive mode 202
6 10 3 Moving the machine 204
6 10 4 Travel with suspended load 207
6 10 5 Moving on inclines and ramps 208
6 10 6 Slewing the uppercarriage 209
6 10 7 Lifting and lowering loads 214
6 10 8 Hook operation with both winches 216
6 10 9 Luffing the boom 218
6 10 10 Extending/retracting the boom 219
6 10 11 Turning on the supplemental hydraulic system (option) 220
6 10 12 Operating the clamping tongs (option) 221
6 10 13 Operating the soil drill (option) 222
6 10 14 Refuel the machine 223
6 10 15 Checking the DEF level and refilling (Tier 4f engines) 227
7 Setup tasks 229
7 1 Mounting/removing walkways 230
7 2 Access ladders 232
7 3 Setup operating mode 233
7 4 Changing the track width 235
7 4 1 Track width markings 235
7 4 2 Increasing the track width 237
7 4 3 Decreasing the track width 239
7 5 Mounting / dismounting the undercarriage ballast 241
7 6 Counterweight / ballasting 244
7 6 1 Counterweight components 245
7 6 2 Preliminary tasks – ballasting 246
7 6 3 Attaching the counterweight 250
7 6 4 Mounting and securing the ballasting rods 252
7 6 5 Ballasting 255
7 6 6 Dismounting a counterweight 259
7 6 7 Setting up the slewing range safety 261
7 6 8 Connections for clamping tongs and soil drill at boom head (option) 264
7 6 9 Attaching the clamping tongs (option) 265
7 6 10 Slewing the soil drill (option) into working position 266
7 6 11 Slewing the soil drill into transport position (option) 267
7 7 Attaching the fly boom 268
7 7 1 Attachment – deflection sheave 268
7 7 2 Attaching the fly boom 270
7 8 Folding the fly boom into transport position 274
7 8 1 Folding the fly boom into working position 284
7 8 2 Folding the fly boom from 0° to 20° 293
7 8 3 Folding the fly boom from 0° to 40° 294
7 8 4 Folding the fly boom from 20° to 40° 296
7 8 5 Folding the fly boom from 40° to 20° 298
7 8 6 Folding the fly boom from 20° or 40° to 0° 300
7 8 7 Attaching the fly boom extension (7 m) 302
7 9 Attaching the auxiliary jib 306
8 Transport 311
8 1 Controls for unloading the machine 313
8 2 Switching on the battery disconnect switch 314
8 3 Unload machine 314
8 3 1 Configuring the setup program in the SENCON 315
8 3 2 Moving the machine off the transport vehicle 318
8 4 Lashing points 321
8 4 1 Lashing the machine 321
8 5 Transport dimensions and weights 322
8 5 1 Overall machine 322
8 5 2 Attachments 323
8 6 Lifting the machine 325
9 327
9 1 Cleaning tasks 329
9 2 Oils and lubricants 332
9 2 1 Disposing of lubricants and operating fluids 333
9 3 Coolant 334
9 4 Welding 338
9 5 Diesel engine 339
9 5 1 Engine oil 340
9 5 2 Air filter 343
9 5 3 Combination cooler 348
9 5 4 Diesel prefilter 350
9 5 5 Diesel fine filter 353
9 5 6 Air intake system 353
9 5 7 Belt drives 353
9 6 Hydraulic system 354
9 6 1 Hydraulic hose lines 356
9 6 2 Checking the oil level 357
9 6 3 Changing the hydraulic oil 358
9 6 4 Changing the return filter element 361
9 6 5 Leak oil filter – changing the filter element 362
9 6 6 Replacing the aeration filter 363
9 6 7 Replacing the HydroClean micro-filter element 364
9 6 8 Checking the pre-load of the pressure accumulator 366
9 6 9 Checking and cleaning the hydraulic oil cooler 367
9 7 Crane winch 368
9 7 1 General maintenance instructions 368
9 7 2 Checking the oil level of the winch gear 370
9 7 3 Winch gear – changing the gear oil 370
9 7 4 Maintaining the brake 371
9 8 Checking ballast elements – ballast rods 371
9 9 Structural steelwork and static load-bearing parts 372
9 9 1 Checking static load-bearing parts and steel components for damage 372
9 10 Undercarriage 373
9 10 1 Cleaning the frame and track frames 373
9 10 2 Maintaining the crawler track 374
9 10 3 Spring tensioning fixture – adjusting the chain tension 376
9 10 4 Checking the tightening torque of base plate bolts 378
9 10 5 Checking the travel drive oil level 379
9 10 6 Changing the travel drive oil 380
9 10 7 Crawler track 381
9 11 Rotary connection 383
9 11 1 Lubricating the slewing ring raceway manually 384
9 11 2 Central lubrication system (option) 385
9 12 Lubricating the slewing ring gearing 387
9 12 1 Gear spray 387
9 12 2 Slewing ring lubrication 388
9 12 3 Tightening the slewing ring bolts 390
9 13 Slewing gear 393
9 14 Electrical system 397
9 14 1 Servicing battery connections 397
9 15 Automatic climate control 398
9 15 1 Cleaning the recirculating air filter 398
9 15 2 Cleaning the fresh air filter 399
9 16 Ropes 400
9 17 Telescopic boom 401
9 17 1 Lubricating the telescopic boom 401
9 17 2 Inspection of the telescopic boom 402
9 18 Maintenance schedule, lubrication schedule 403
9 18 1 Maintenance schedule 403
9 18 2 Hydraulic oil analysis 409
9 18 3 Lubrication points 414
9 18 4 Fill quantities 417
9 18 5 Tightening torques for screws 418
10 Troubleshooting 421
10 1 Drive engine 421
10 2 Hydraulic system 422
10 3 Heating/air-conditioning system 424
10 3 1 Heat output 424
10 3 2 Cooling capacity 426
10 3 3 System very noisy 428
10 4 Slewing gear 428
10 5 Running gear / undercarriage 429
10 6 Cab 429
11 Appendix 431
11 1 Reeving Diagram 432
11 2 Handling, Installation, and Maintenance of Steel Wire Ropes 439
11 3 Driver Seat 457
11 4 Camera System 465
11 5 Radio Remote Control 472
11 6 Cleaning the Cooling System 504
11 7 Residual Useful Life of Winches 507
11 8 Installing Large Roller Bearings, Slewing Gears and Flange Connections 515
11 9 PFEIFER Pouch Lock System 519
11 10 Operating Fluids and Lubricants 528
11 11 Auger 539
11 12 Personnel Basket 549
11 13 Pole Claw 567
11 14 Reeving diagram 432
10 Appendix 439
10 1 Handling, Installation, and Maintenance of Steel Wire Ropes 439
10 1 1 Rope selection 439
10 1 2 How should wire ropes be unloaded? 439
10 1 3 How should wire ropes be stored? 440
10 1 4 Assembly of wire ropes 440
10 1 5 Maintenance of wire ropes 445
10 1 6 Inspection of wire ropes 448
10 1 7 Concluding remarks 456
10 2 Driver Seat 457
10 2 1 General Instructions 459
10 2 2 Safety instructions 459
10 2 3 Connecting data 460
10 2 4 Guarantee and liability 461
10 2 5 Seat functions and operation 461
10 2 6 Maintenance 464
10 3 Camera system 465
10 3 1 Product description 465
10 3 2 Safety Instructions 466
10 3 3 Operating and Display Elements 468
10 3 4 Commissioning 469
10 3 5 Operating Modes 469
10 3 6 Malfunctions 470
10 3 7 Maintenance 471
10 3 8 Service Information 471
10 3 9 Environmental Protection 471
10 4 Radio Remote Control 472
10 4 1 Introduction 472
10 4 2 Safety precautions 473
10 4 3 Protection devices 474
10 4 4 Installation 475
10 4 5 Checkup before operation 476
10 4 6 Startup procedure 478
10 4 7 Operation of MFS and HL systems 479
10 4 8 Battery charger and rechargeable batteries 481
10 4 9 Battery handling 483
10 4 10 Diagnostics 485
10 4 11 Special Technical Data 486
10 4 12 Maintenance, Guarantee, Disposal 487
10 4 13 Complaint form 489
10 4 14 Abbreviations and definitions 490
10 4 15 Installation and safety test declaration 490
10 4 16 EC Declaration of Conformity 492
10 4 17 HF-Part Conformity Europe 493
10 4 18 Mounting Antennas for Feedback-Systems 501
10 4 19 Mounting instruction for directional antenna on top slewing cranes 502
10 4 20 Guarantee Conditions HETRONIC Germany GmbH 502
10 5 Cleaning the cooling system 504
10 5 1 Safety instructions 504
10 5 2 Coolant cooler 505
10 5 3 Tips for preventive maintenance 506
10 5 4 Coolant 506
10 5 5 Charge-air cooler 507
10 5 6 Oil cooler 507
10 6 Residual Useful Life of Winches 507
10 6 1 General steps required to ensure safe periods of operation 507
10 6 2 Periodic inspection of cranes 507
10 6 3 Steps required to monitor the winches 507
10 7 Installing Large Roller Bearings, Slewing Gears, and Flange Connections 515
10 7 1 General 515
10 7 2 Preparatory measures 515
10 7 3 Assembly 515
10 7 4 Tightening torques for bolts 517
10 8 PFEIFER Pouch Socket System 519
10 8 1 Preamble 519
10 8 2 Signs and symbols 519
10 8 3 Application area and intended use 519
10 8 4 General information 520
10 8 5 Installation and Assembling 522
10 8 6 Important security informations 524
10 8 7 Operation 524
10 8 8 Accessories and spare parts 525
10 8 9 Maintenance and Repair 526
10 8 10 Lifting Capacity Table 527
10 9 Operating Fluids and Lubricants 528
10 9 1 Hydraulic system 529
10 9 2 Diesel engine 530
10 9 3 Gearbox 532
10 9 4 Lubrication 534
10 9 5 Air conditioning system 537
10 9 6 Windshield washer system 538
10 9 7 Starter batteries 538
AUGER 539
Safety 539
Safety Tips – Auger Equipped Cranes 539
Auger system description 539
Speed Shift Circuit 539
Latch Circuit 539
Auger System 540
Auger Controls 540
Auger Power Switch 540
Auger Control 540
Auger Latch Switch 541
Auger Stow Control 541
Auger Operation 542
Unstow Auger 542
Operating Auger 543
Digging Depth 543
Stowing Auger 543
Machine Usage with Auger Stowed 545
Travel with Auger 545
Auger Specifications 545
Performance 545
Hydraulic System 545
Inspection 545
Daily 545
Weekly 545
Monthly 545
Periodic 545
Lubrication – Digger Drive Gear 545
Changing the Gear Oil 546
Troubleshooting 546
Personnel Basket 549
Safety 549
General Safety Requirements 549
Equipment Operator 550
Ground Crew 551
Platform Occupants 552
Communications 552
Lifting Personnel Near Power Lines 553
Condition A 553
Condition B 554
Condition C 554
Condition D 554
Inspection and Testing 554
Inspection 554
Initial Inspection 554
Regular Inspection 554
Lift Testing 557
Proof Lift 557
Trial Lift 557
Performing The Lift Test 557
Basket Type and Test Weights 558
Yoke Basket 562
Safety harnesses 562
Basket Installation 562
Basket Yoke to Main Boom Installation 563
Basket Yoke to Jib Boom Installation 563
Yoke Basket Adjustment 563
Before Making the Lift 564
Hoist Cable 564
Hoist Cable Tie Down – Turret Mounted Hoist 564
Yoke Basket Operation 564
Pole Claw 567
Safety 567
Description 568
Pole Claw System 568
Attaching the Pole Claw 568
Switching on the Supplemental Hydraulic System 569
Joystick Control 569
Operating the Clamping Tongs 569

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