Manitowoc Grove Crane YB4409-2 Operator Manual PDF

Description

Manitowoc Grove Crane YB4409-2 Operator Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove Crane YB4409-2 Operator Manual – PDF DOWNLOAD

Language : English
Pages :134
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane YB4409-2 Operator Manual – PDF DOWNLOAD

See back of this manual for Alphabetical Index 5
SECTION 1 9
Introduction 9
The Manual 9
Directional Reference 9
Serial Number Plate 9
Reports 9
Disclaimer 9
Customer Support 10
New Owners 10
Specifications 10
SECTION 2 13
Safety Information 13
Safety Messages 13
General 13
Safety Alert Symbol 14
Signal Words 14
General 14
Accidents 14
Operator Information 14
Operator Qualifications 15
Operational Aids 16
Rated Capacity Limiter (RCL) Systems (If Equipped) 16
Anti-Two-Blocking Device 16
Working Area Limiter (If Equipped) 17
Crane Stability/Structural Strength 17
Load Charts 18
Work Site 18
Wind Forces 18
Lifting Operations 19
Counterweight 20
Outrigger Lift Off 20
Multiple Crane Lifts 20
Pile Driving and Extracting 21
Crane Equipment 21
Crane Inspection 21
Electrocution Hazard 21
Set-Up and Operation 22
Electrocution Hazard Devices 23
Electrical Contact 24
Special Operating Conditions and Equipment 24
Personnel Handling 24
Environmental Protection 25
Maintenance 25
Service and Repairs 26
Lubrication 27
Tires 27
Hoist Rope 27
Wire Rope 27
Synthetic Hoist Rope 28
Sheaves 29
Batteries 29
Engine 29
Transporting the Crane 30
Travel Operation 30
Work Practices 31
Personal Considerations 31
Crane Access 31
Job Preparation 31
Working 32
Lifting 32
Hand Signals 33
Boom Extension 35
Parking and Securing 35
Shut-Down 35
Cold Weather Operation 35
Temperature Effects on Hook Blocks 36
Temperature Effects on Hydraulic Cylinders 36
Overload Inspection 38
Boom Inspection 39
Superstructure Inspection 41
Carrier Inspection 43
SECTION 3 45
Operating Controls And Procedures 45
Controls, Switches, and Gauges 46
Cab Controls 46
Brake Pedal 46
Accelerator Pedal 46
Travel Select Lever 46
Transmission Shift Lever 46
Battery Disconnect Switch 46
Boom Controls 46
Swing Control 46
Telescope Control 46
Hoist Control 47
Boom Control 47
Outrigger Controls 47
Panel Switches 47
Work Light/Head Light Switch 47
Parking Brake Switch 47
Auxiliary Winch Switch (Optional) 47
Windshield Wiper Switch (Optional) 47
Windshield Washer Switch (Optional) 47
Heater/Defroster Switch (Optional) 47
Steering Selection Switch – Optional 48
Ignition Switch 48
Wait-to-Start Lamp 48
Outrigger Monitoring Indicator (OMS) (Optional— Standard in North America) 48
Turn Signal Switch 49
Horn Button 49
Gauges and Indicators 49
Fuel Gauge 49
Hourmeter 49
Low Battery Warning Light 49
Engine Warning Light (See Figure 3-12) 49
Emergency Stop Light (See Figure 3-13) 50
Transmission Low Oil Pressure Warning Light (See Figure 3-14) 50
Transmission High Temperature Warning Light (See Figure 3-15) 51
Brake System Low Pressure Warning Light (See Figure 3-16) 51
Crane Level Indicator 51
Proper Leveling of the Crane 51
Bubble Level Adjustment 52
Boom Angle Indicator 52
LSI Load Indicator Display Panel 52
LSI Rated Capacity Limiter (RCL) 52
Optional Rated Capacity Limiter (RCL) Display Panel (Wylie) 52
Operator’s Cab 53
Seat Belt 53
Seat Adjustment 53
Seat Fore and Aft Adjustment 53
Cab Door (Enclosed Cab) 53
Opening the Cab Door from the Outside (Enclosed Cab) 53
Opening the Cab Door from the Inside (Enclosed Cab) 54
Opening the Sliding Side Window (Enclosed Cab) 54
Heater/Air Conditioner and Defroster 54
Fire Extinguisher 54
Crane Operation 55
Starting the Engine 55
Normal Engine Starting 55
Engine Starting Procedure 55
Towing or Pushing the Crane to Start the Engine 56
Jump Starting the Engine 56
Crane Warm-up Procedures 57
Engine 57
Transmission 57
Hoist 57
Swing Drive and Turntable Bearing 57
Axles 58
Hydraulic Oil System 58
Cab Heater Warm-up 58
Traveling with the Crane 58
Shifting Gears (Travel Speed) 59
Steering the Crane 60
Four-Wheel Steering Indexing Procedure 61
Changing Travel Direction 61
Stopping Travel 61
Operating the Outrigger Controls 61
To Raise and Lower the Outriggers 61
Outrigger Monitoring System (OMS) (Optional— Standard in North America) 63
Operating the Boom Controls 63
Anti-Double Blocking System 63
Boom Swing Operation 64
To Rotate the Mast to the Left (Counterclockwise) 64
To Stop Rotation 64
To Rotate the Mast Right (Clockwise) 64
Boom Telescope Operation 65
To Extend the Boom 65
To Stop Extension/Retraction 66
To Retract the Booms 66
Boom Lift Operation 67
To Raise the Boom 67
To Stop Boom Movement 67
To Lower the Boom 67
Hoist Operation 69
To Raise the Drop Block 69
To Stop Drop Block Movement 69
To Lower the Drop Block 69
Optional Controls Operation 71
Auxiliary Winch 71
To Extend the Wire Rope 71
To Stop the Winch 71
To Retract the Wire Rope 71
Operating Practices 72
Handling a Load 72
Attaching the Load 72
Holding the Load 72
Moving the Load 72
Traveling with a Load (Pick and Carry) 72
Turning Clearances 72
Crane Shutdown 73
Towing a Disabled Crane 73
SECTION 4 75
Load Chart 75
Using the Load Chart 75
Determining Operating Radius 75
Determining Lift Capacity 75
Considerations 75
Determining Lifting Capacity at the Jib 76
Pick and Carry Ranges 76
SECTION 5 79
Attachments 79
Pivoting Boom Head 79
Boom Head Positions 79
Positions When No Jib Is Attached 79
Positions When A Jib Is Attached 79
Changing the Boom Head Position (No Jib) 79
Adjusting the Jib Offset 80
Hoist Block 81
Removing the Hoist Block 81
Installing the Hoist Block 81
Jib 81
Installing the Jib 81
Stowing the Jib 82
Searcher Hook Assembly 84
Installation 84
Removal 84
Down Haul Weight 85
Installing the Down Haul Weight 85
Removing the Down Haul Weight 85
Wire Rope Wedge Socket 86
Dead-end Rigging 86
SECTION 6 89
Maintenance 89
Introduction 89
General 89
Lubricants and Capacities 89
Maintenance Records 89
Special Maintenance 90
After First 50 Hours of Operation (New Cranes) 90
Cranes not in Regular Use 90
Preventive Maintenance 90
Maintenance Schedule and Checklist 90
Lubrication Points 92
Scheduled Maintenance 96
Daily (Walk-around) 96
Inspections 96
Inspect the Anti-Double Blocking System 96
Inspect the Wire Rope 96
Inspect Reeving, Clamps and Connections 97
Inspect the Lifting Hook 97
Inspect All Safety Devices 97
Check Controls Operation 97
Component/System Checks 97
Check Fuel Level 97
Check the Engine Crankcase Oil Level 97
Check the Transmission Oil Level 98
Check Engine Coolant Level 98
Drain Water from Engine Fuel Filter/ Water Separator 98
Check Hydraulic Oil Level 98
Check the Air Cleaner Restriction Indicator 99
Check the Tire Pressure 100
50 Hours of Operation 100
Clean/Inspect the Air Cleaner VacValve 100
Wire Rope and Sheave Inspection 100
Inspection 100
Grease Fittings 101
Lubricate the Boom Slides 101
Lubricate the Boom Chains 102
100 Hours of Operation 102
Check Wheel Nut Torque 102
Inspect the Fan Belts 102
250 Hours of operation 103
Inspecting the Boom Chains 103
Inspect the Boom Chain Tension 104
Inspect Hydraulic Hoses 104
Clean Battery and Cables 105
Cleaning the Radiator 105
Lubricate the Wire Rope 105
Lubricate the Swing Gear and Pinion 106
Replace the Crankcase Oil and Filter 106
Torquing Critical Bolts 106
Hoist Gearbox Mounting Bolts 106
Swing Gearbox Mounting Bolts 107
Mast Mounting Bolts 108
Front Axle Mounting Bolts 109
Rear Axle Mounting Bolts 109
500 Hours Of Operation 109
Inspect the Tires 109
Inspect the Parking Brake Pads 109
Replacing Fuel Filter 110
In-Line Fuel Filter 110
Replacing Air Cleaner Element 110
Adding Supplemental Coolant Additive (SCA) to Engine Cooling System 110
Lubricate the Outrigger Slides 110
Add Grease to the Swing Gearbox 111
Check the Axle Housing Lubricant Level 111
Check the Wheel Hub Lubricant Level 111
Check Hoist Gearbox and Brake Lubricant 112
Check Hoist Gearbox Lubricant Level (Tulsa Model 1259w) 112
Check Boom Hoist Lubricant Level (Braden Model PD12C) 112
1000 Hours of Operation 114
Replace the Transmission Oil and Filter 114
Replace the Axle Housing Lubricant 115
Replace the Axle Wheel Hub Lubricant 115
Replace the Hoist Gearbox and Brake Lubricant (Tulsa Model 1259W) 116
Hoist Brake 117
Replace the Hoist Gearbox and Brake Lubricant (Braden Model PD12C) 117
Lubricate the Rear Axle Bearings 118
Replace the Hydraulic Oil 118
Replace the Hydraulic Oil Filter 119
Check Swing Gear/Pinion Backlash 120
2000 Hours Of Operation 120
Replace the Engine Coolant 120
Inspect the Crane Structure and Booms for Damage 120
Testing the Rated Capacity Limiter (Optional) 120
Miscellaneous Maintenance 121
Batteries/Charging System 121
Checking the Charging System 121
Normal Operating Ranges 121
Charging the Battery 121
Replacing the Battery 121
Fuel System 121
Fuel Storage 121
SECTION 7 123
Adjustments 123
SECTION 8 125
Specifications 125
Lubricants and Capacities 125
Engine Oil Specifications 126
Oil Performance Recommendations 126
Oil Viscosity Recommendations 126
New Engine Break-In Oils 126
Diesel Fuel 126
General Specifications 127
Dimensions 129

Customer Support: [email protected]

S.M