operating nanual new part I - 140T Jamalpur...

1997 DESIGN 140T GOTTWALD/JAMALPUR CRANE ISSUE 1997

Railway Crane User’s Manual

Operation


Railway Crane Operating Manual

Table of Contents (P-1/3)

1. Instruction on How to use the Operating Manual 2. General Notes 2.1 Preface 2.2 General Safety Instructions 2.3 Legend for Notices, Danger and Prohibiting Signs

3. Description 3.1 Technical Data 3.2 Lifting Capacity Charts 3.2.0 Special Notations on the Lifting Capacity Charts 3.2.1 Main Hoist – 5.5 m counterweight radius: - free on wheels; - propped at 6.0 m; 3.2.2 Main Hoist – 5.5 m counterweight radius: - propped at 6.0m and 2.9 m; 3.2.3 Main Hoist – 6.5 m counterweight radius: - free on wheels; - propped at 6.0 m; 3.2.4 Main Hoist – 5.5 m counterweight radius - free on wheels; elevated curves at 25 mm - 140 mm; 3.2.5 Auxiliary Hoist with retracted main hoist hook block - 5.5 m counterweight radius: - free on wheels; - propped at 6.0 m 6.5 m counterweight radius: - free on wheels; 3.2.6 Auxiliary Hoist-5.5 m counterweight radius: - free on wheels; - propped at 6.0 m; 6.5 m counterweight radius: - free on wheels; 3.2.7 Auxiliary Hoist with retracted main hoist hook block- 5.5 m counterweight radius: - propped at 5.0 m; - propped at 2.9 m; 3.2.8 Auxiliary Hoist – 5.5 m counterweight radius - propped at 5.0 m;

- propped at 2.9 m; 3.2.9 Main Hoist – 5.5 m counterweight radius: - free on wheels; 3.2.10 Main Hoist – 5.5 m counterweight radius: - free on wheels; 3.3 General Drawing including dimensions 3.4

4. Check Lists

4.1 Check Lists for Operation 4.1.1 Crane Operation with Crane Propped 4.1.2 Crane Operation with Crane Free-on-wheels

4.2 Check Lists for Emergency Operation 4.2.1 In the Train Formation 4.2.2 Out of Train Formation

4.3 Check Lists for Emergency Operation

4.3.1 Check Lists for Emergency Diesel Engine 4.3.2 Safe Load Indicator




5. Operating Instructions

5.1 Rigging 5.1.1 Couple/Uncouple Match Truck 5.1.2 Suspension Blocking Cylinder/ Engage/Disengage Travel Gear 5.1.3 Transport Position 5.1.4 Lower/Raise Counterweight Support/ Lock/Unlock Superstructure 5.1.5 Brake System 5.1.6 Outriggers 5.1.7 Re-railing 5.1.8 Counterweight 5.1.9 Pick up and Set Down Counterweight 5.1.10 Increase/Decrease Counterweight Radius 5.1.11 Raise/ Lower Boom 5.1.12 Retract Main Hoist Hook Block to Boom

5.2 Set-Up Requirements 5.2.1 Hydraulics 5.2.2 Diesel Engine System 5.2.3 Battery Main Switch 5.2.4 Fuel Supply 5.2.5 Undercarriage Hydraulics on/ off 5.2.6 Ropes 5.2.7 Hoist and Lowering Limit Switches 5.2.8 Boom Length Sensor, Angle Sensor 5.2.9 Emergency Diesel Engine 5.3 Emergency Diesel Engine System 5.3.1 Start/Stop Emergency Diesel Engine 5.4 Diesel Engine System 5.4.1 “Start / In-Operation/ Stop” Diesel Engine 5.4.2 Accelerator 5.5 Travel Operation 5.5.1 Travel Forward / In Reverse 5.5.2 Brake 5.6 Crane Operation 5.6.1 Slew Right / Left 5.6.2 Derrick In / Out 5.6.3 Hoist / Lower Using Main Hoist 5.6.4 Hoist / Lower Using Auxiliary Hoist 5.6.5 Lifting Beam and Slings




5.7 General Operating Functions 5.7.1 Safe Load Indicator 5.7.2 Lighting 5.7.3 Signal Horns 5.7.4 Screen/Wiper System 5.7.5 Fans 5.7.6 Seat 5.7.7 Parking Crane Safety 5.7.8 Safe Load Indicator Emergency Operation 5.7.9 Additional Equipment 5.7.10 Recovery Winch

6. Operation Diagrams

6.1 Control Stand Diagram 6.2 General Crane Diagram



Instructions on How to Use the Operating Manual 1 (P-1/1)

This Operating Manual is complied in such a way that by folding out the side wings you have the most important components in front of you without unnecessary skimming the pages to and fro. All sections drawn up in the manual have been numbered. This numbering is maintained throughout, which means that in the respective section number applies to the same component or function in the Table of Contents, the Operating Instructions and the Operation Diagrams. This Operating Manual makes up the first part of User’s Manual consisting of several sections, which you have purchased along with your crane. This Operating Manual provides you with two options for obtaining the information you desire. 1. You are unfamiliar with the crane and wish to famillarise yourself in turn with all the controls. To

do so, refer to the sections listed in the Table of Contents. By following this procedure, you will become familiar with all the safety instructions, the checks required prior to daily start-up and the individual operating steps.

2. You are familiar with the crane and the necessary information. You wish to know the procedure for a particular term. Turn to the Index or the Table of Contents in this manual and you will find the information and / or the function of the operating instrument on the indicated page or in the section number.

4. Check Lists 5. Operating Instructions 7.Operation Diagram

Fold out the check lists to the left. You will find all the operating points itemised according to catchwords here. In addition, the check and safety instructions as well as the type of indicating instruments for the individual operating modes can be found here.

Section 5,” Operating Instructions “, is set up in such a way that the location (red arrow and item number) of the operating instrument is shown in the diagram. Above every set of operating instructions, there are safety instructions to be heeded for the operating steps being described. A warning symbol is located adjacent to the safety instructions. Always observe the General Safety Instructions indicated in section 1.2. The symbol (s) located next to the operating instructions can be found on the control lever or control button in the diagram.

Fold out the Operation Diagram successively to the right. You will find the location of all the item numbers listed in Operating Instructions here.



General Notes 2 (P-1/1)

2.1 Preface 2.2 General Safety Instructions 2.3 Legend for Notices, Danger and Prohibiting Signs



Preface 2.1 (P-1/1)

Proper operation and regular maintenance in accordance with these instructions is essential for smooth crane operation. For this reason, the above manuals should always be available for the operating and maintenance personnel. This is especially important as otherwise improper operation or irregular maintenance can cause considerable damage which is not covered by the warranty. This is why you should read this Operating Manual thoroughly before start-up and act according to the information in the particular sections. Later, when you are familiar with and have mastered the individual functions of the crane, you need only observe the information in the sections before start-up.

However, not only for cost-effectiveness, but also for safety reasons, proper operation and maintenance of the crane are absolutely imperative. It can only be ensured that persons will not be injured and property not damaged if the crane is in perfect technical order. The built-in safety devices did not, however, completely rule out all risks. Should clearly obvious or recognisable deviations occur, have the equipment checked. Observe without fail all the safety instructions provided during operation and maintenance work. With caution and adherence to the relevant instructions, accidents can be avoided. As not all the same precautions apply for all work, special safety instructions are specified before each individual description of the operating steps.

The safety instructions are accentuated with a warning symbol.

Observe the Lubricants chart in the Maintenance Manual when the respective maintenance precautions are carried out to which your attention is drawn in the Operating Manual. Use only the lubricants listed for the particular piece of equipment. The application of unsuitable lubricants and fuels can lead to considerable consequential damage, which is not covered under our warranty. Therefore, read through the Maintenance Instructions before performing such work. We have endeavoured to produce clear and comprehensible Operating Instructions. When you have read the “Instructions on how to use this Operating Manual”, you will easily find and be able to carry out the various Operating Points. Should gaps appear in the consecutive numbering of the sections, the contents of these sections did not conform with the crane model you have requested. This manual was drawn up based on all the information available at hand at the time of crane dispatch. Should any changes, retrofits or modifications have occurred since then, which must be documented, the owner must ensure that documentation is provided or altered to accommodate these differences by the company providing subsequent services or additional equipment.



General Safety Instructions 2.2 (P-1/4)

Special safety instructions have been indicated in advance of the specific instructions for maintenance work in this Maintenance Manual. These instructions are to be interpreted as a supplement and do not exclude the general safety instructions mentioned! Before any work is carried out on the electrical system, ensure that the system is not under power and, if applicable, the diesel engine must be switched off. It must be ensured that all the above equipment is safeguarded against re-starting. Should the power supply have to be established again for functional checks, ensure that the complete power supply is switched off again before work is resumed. Prior to performing work on the air pressure or hydraulic system, ensure that these systems are not under pressure. Note that when work is carried out to the hydraulic system, the system is under pressure and the hydraulic oil is hot. When subjected to fire or naked light, hydraulic oil is inflammable. As the crane must be operational for pressure, temperature and leakage checks, there is a high degree of danger involved. During or after maintenance work on the crane, the pre-set hydraulic pressures must not be altered. Special qualified personnel and utmost care for this work are essential. Before maintenance work is started, ensure that the crane can not be switched on by unauthorised persons.

Caution! Certain parts of the system are still under pressure even when the crane is at a standstill! Ensure without fail that waste oil from the hydraulic system, diesel engine and the emergency diesel engine and the condensation containing oil from de-airing and cleaning work is disposed of according to regulations!

Special caution is required when maintenance work is carried out on the diesel engine or the emergency diesel engine directly after operation. Engine oil, engine housing and exhaust system are still hot. As the crane must be operational for functional and sealing tests, there is an increased degree of danger as with the hydraulic system. When work to the diesel engine system is carried out, ensure without fail that the engine cannot be started by unauthorized persons. Ensure that ear protection is worn when maintenance work is carried out on the running diesel engine.

The diesel engine and the emergency diesel engine must not be operated in enclosed areas- Danger of intoxication though exhaust fumes! No smoking, no naked flame or light, sparks or glowing ashes near the fuel or diesel engine system- Danger of explosion and fire! It is forbidden to climb up onto the crane when the crane is in operation. In addition, ensure that all respective statutory safety regulations are observed during all work! This applies, in particular, to tests on the tank and pipe systems. Observe the information provided by the manufacturer for systems requiring monitoring during operation and maintenance.




Operating Personnel

A crane is a highly technical and sophisticated machine. Safe and competent operation requires a sense of responsibility and skill on the part of the crane operator. Likewise, he should be in good mental and physical condition to ensure completely safe operation.

Proper and Due Operation

The GS 140.08 H crane has been developed exclusively for crane work. This means that, for example, conveyance of loads or persons is not permissible in crane operation, only one person per seat may be conveyed with the crane. Only lifting gear and accessories which have been supplied or approved expressly by the crane manufacturer may be used. It is prohibited to use the crane for any other purpose other than for what it was designed for. It is assumed that the ambient conditions for the work zone of the crane meets the requirements so that the information provided in “Technical Data” can be adhered to without any danger occurring. Caution! - Please note the various lifting capacities for the individual modes of operation. These lifting capacities can be found in the section “Technical Data” and in the Lifting Capacity Charts. In addition, it should be noted that the information provided here applies especially to your crane, i.e. crane of the same type can have different features. Limit switches must not be bridged. Mean figures for outside temperature, air humidity and degree of dust have been used as a basis for these data. Should the figures be higher, the maintenance intervals must be stepped up accordingly. Observe the information provided by the respective lifting gear manufacturer! Endeavour to reduce any remaining risks by applying any suitable measures at crane site.

Use of Skilled Personnel

Operation, maintenance, service and repairs may only be carried out by specially trained and initiated personnel who have provided respective evidence of their knowledge to the crane operating company. It must be ensured that the skilled personnel employed not only have the corresponding technical knowledge, but in addition are also informed about all relevant Safety and prevention of Accident Directives and can apply same. Furthermore, the persons selected by the operating company must be qualified for the works they are to perform.

Standing in the slewing range is prohibited. Likewise unauthorised persons must not be in or on the crane during operation, including travel operation. Loads must be lifted properly, i.e. diagonal pull and breaking loose of loads are prohibited.




Duties of the Crane operator

The crane operator has the following duties:

• He must check whether the brakes and the emergency limit switches function prior to commencing work. He must watch the condition of the crane for any visible defects.

• He must see to it and ensure that the power to the overhead lines is switched off prior to commencing

work on the crane. •••• When he notices any defects, which could be dangerous for operating safety, he must stop crane

operation. •••• He must report any defects on the crane to the supervisor responsible and to his replacement on shift

change. • He must ensure that all the controls are brought into neutral or idling position prior to supplying

power to the drive assemblies. • He must ensure that all the controls are brought into neutral or idling position and that the power is

shut off prior to exiting the control stand. • He must ensure that the crane is parked safely according to regulations when crane operating and

crane travel operation have been completed. He must check whether the safety equipment such as the hoist height and swing- out section limits must be activated prior to commencing crane operation. If the crane operator can not observe the load during all crane motions or the lifting gear when there is no load is on the hooks, he may only operate the crane based on the instructions of a banksman. The crane operator must provide warning signals, when required. Loads or lifting gear must not be moved above persons during any crane motions. The crane operator may only move loads attached manually when he has received a signal from the person attaching the load, or the hand signaller or the person nominated by the crane operating company. If signals must be used to communicate with the crane operator, these signals must be agree upon between the crane operator and the person responsible for the signals before the signals are applied.

As long as a load is suspended on the hook, the crane operator must keep his hands near the controls.

The emergency limit switches must not be activated intentionally during operation.

The crane operator must ensure that all the door are closed and locked during travel.

Loadings Cranes may not be subjected to stress beyond the respective highest permissible loading.




Work Performed with Several Cranes If the working range of several cranes overlap, the crane operating company or his representative must laid down the work procedure beforehand and must ensure that the communication runs smoothly among the crane operators.

Entering and Exiting the Crane

It is prohibited to allow any unauthorized persons to enter in or on the crane or its working range. Cranes, which are occupied by a crane operator, may not be entered and exited until permission has been received from the crane operator and the crane has come to a standstill. Only authorised persons may move onto or off the footboards when the crane operator has been notified accordingly.

Conveyance of Persons The conveyance of persons on the load or lifting gear is prohibited.

Ambient Conditions Ensure as to whether the erection surface can withstand the required crane support pressures and the ground is suitable for working with the crane safely. Should the crane have to be travelled, the route must be checked beforehand. Please take into consideration clearance widths, heights and the crane weight.



Legend for Notices Danger and Prohibiting Signs 2.3 (P- 1/1)

Keep out of the slewing range.

Keep out of the slewing

range



Operating Instructions 3 (P-1/1)

3.1 Technical Data 3.2 Lifting Capacity Charts 3.3 Crane General Drawing including Dimensions



Technical Data 3.1 P-1/3

Dimensions Track gauge 1.676mm Rim diameter in new condition 920mm Wear limit 840mm Wheel Set arrangement (2A)( A2) Distance between bogie pivots 7,500mm Distance between twin wheel set 3,000 (1,500) mm Length ahead of buffer 13,290mm Draw and buffing gear side buffers and screw couplings Minimum Travel able curve 175mm Maximum towing speed 100 km/h Maximum wheel set load 200 kN Total weight in train formation 120.0 t Height in transport position 3,900mm Width in transport position 3,100mm Elevated curves 140 mm Brake System Primary Dual –VD-P-12 x 10 m.Z. Secondary 12 wheel disk-operated brakes Ø 780 mm Parking brake spring-loaded brakes on 6 wheels sets Outriggers Base 11.6m x 6.0m Maximum support force 2,200 kN Outrigger cylinder stroke 500 mm Free on wheels base 7.5mm x 1.7mm Maximum wheel force 350 kN Travel Gear Driven wheel sets on each bogie 1 Speed 20 km/h Superstructure Cab 1 seat/and 1 emergency seat Over-rear radius 5.5m/6.5m Diesel Engine Type Cummins NTA 855 Model 6-cylinders in series Water-cooled Exhaust turbo charger Out put 205 kW at 1,800 rpm Torque 1,158 Nm at 1,400 rpm Cubic capacity 1,400 ccm Fuel supply 900 l Generator 28 V 55 A



Technical Data 3.1 P-2/3

Emergency Diesel Engine Type Kirloskar HA 294 Model 2- Cylinder in series Air cooled exhaust turbo charger Output 16.9 kW at 1.800 rpm Cubic capacity 1,884 ccm Main Hoist Type 3-stage planetary hoist with spring-loaded multi disk brake Rope diameter 26mm Rope speed max- 72m/min. Hoist speed max- 4m/min. Hook block 18 strand 140 t Hoist range above track 17.0 m below track 4.0 m Auxiliary Hoist Type 2- stage planetary hoist with spring-loaded multi disk brake Rope diameter 22 mm Rope speed max- 60m/min. Hoist speed max- 15m/min. Hook block 4 strand 25 t Hoist range above track 18.0 m below track 3.0 m Slewing Gear Type 3-stage planetary hoist with spring-loaded multi disk brake Roller slew ring with external teething Superstructure speed 0-1.0 rpm Derricking Gear Type 3- stage planetary hoist with spring-loaded multi disk brake Rope diameter 26 mm Rope speed max- 28m/min. Derricking Time approx – 165 s Rope tension 2 x 14 strand 2,200 kN Counterweight

3 Sections Slab 1 (transported on the Match Truck) 24.0 t Slab 2 (transported on the Match Truck) 15.0 t Slab 3 (transported on the undercarriage) 8.0 t Boom Length to the main hook 18.75 m Length to the auxiliary hook 19.5 m Main hook working range 5.5 m- 17.0 m Auxiliary hook working range 6.5m - 18.0 m



Technical Data 3.1 (P-3/3)

Match Truck Length beyond buffer 16.0 m

Distance between Wheel Sets 2.0 m

Track gauge 1,676 mm

Distance between bogie pivots 11.30 m

Draw and buffing gear side buffers and screw couplings

Turing Radius 175 m

Maximum towing speed 100 km/h

Maximum wheel set load 200 kN

Total Weight loaded 80.0 t



Lifting Capacity Chart 3.2 (P-1/1)

The lifting capacity charts for each propping base can be found on the next pages. The maximum crane lifting capacity charts are shown in tonnes as a function of the transverse swing -out angle and as a function of the radius beyond buffer in meters. The following outrigger bases as a function of the load are available for work with the crane. Caution: All the data in the lifting capacity as well as the data on the counterweights, working

range and hoisting heights must always be observed - Danger of accidents and mortal danger!

3.2.0 Remarks on the Lifting Capacity ChartsTechnical DataLifting Capacity Charts 3.2.1 Main Hoist – 5.5 m counterweight radius: - free - on wheels; - propped at 6.0 m; 3.2.2 Main Hoist – 5.5 m counterweight radius - propped at 6.0 m and 2.9 m; 3.2.3 Main Hoist – 6.5 m counterweight radius: - free – on- wheels; - propped at 6.0 m; 3.2.4 Main Hoist – 5.5 m counterweight radius - Free- on wheels, elevated curves at 25 mm . 140 mm; 3.2.5 Auxiliary Hoist with retracted main hoist hook block -

5.5 m counterweight radius: - free – on- wheels; - propped at 6.0 m;

6.5 m counterweight radius: - free-on wheels; 3.2.6 Auxiliary Hoist 5.5 m counterweight radius: - free – on wheels; - propped at 6.0 m 6.5 m counterweight radius: - free on – wheels, 3.2.7 Auxiliary Hoist with retracted main hoist hook block - 5.5 m counterweight radius: - propped at 5.0 m; - propped at 2.9 m; 3.2.8 Auxiliary Hoist 5.5 m counterweight radius - propped at 5.0 m;

- propped at 2.9 m; 3.2.9 Main Hoist - 5.5 m counterweight radius; - free –on – wheels; 3.2.10 Main Hoist - 5.5 m counterweight radius: - free-- on-- wheels;



Special Notations for the Lifting Capacity Charts 3.2.0 (P-1/2)

Caution! When the lifting capacity charts marked with **) are selected, work is only permitted when the 3rd counterweight (8t) is lying on the undercarriage (frame mechanism is folded in!) in opposite direction to working position – otherwise the crane stability will be reduced – Danger of accidents! Figure above: Work when crane propped; Figure below: Work when crane free-on-wheels;



Special Notations for the Lifting Capacity Charts 3.2.0 (P-2/2)

Caution! When the lifting capacity charts marked with ****) are selected, the following must be observed: When the crane carries out work free-on-wheels in elevated curves of 40 mm or higher, the attached loads must be secured against pendulous swinging by means of the recovery winch or an auxiliary rope designed for the loading - as otherwise the standing stability of the crane is endangered - Danger of accidents !

This means:

As soon as a load is attached in rail line direction and the crane is slewed to the downhill side, the recovery winch rope or an auxiliary rope designed for the loading must prevent the increase in radius which otherwise would occur on the downhill side!

(See figure above)



Main Hoist 3.2.1 (P-1/1)









Main Hoist 3.2.4 (P- 1/1)



Auxiliary Hoist with Retracted Main Hoist Block 3.2.5 (P-1/1)



Auxiliary Hoist 3.2.6 (P-1/1)















General Operating Drawing 3.3 P-1/1



Check Lists 4 (P-1/1)

4. Check Lists

Note: The points in these check lists are not a replacement for the descriptions, instructions and safety instructions in the Operating Manual!

The daily checks laid down in the Maintenance Manual are not included in the

following check lists. 4.1 Check Lists for Operation 4.1.1 Propped Crane Operation 4.1.2 Free-On-Wheel Crane Operation

4.2 Check List for Rigging 4.2.1 In Train Formation 4.2.2 Out Train Formation



4.1 Check List for Operation 4.1.1 Propped Crane Operation (p.1/2) Number in the Instructions

Operation Check & Safety Instructions

Indicator Notes

5.1.10 Raise boom 5.1.1 Match truck is uncoupled 5.1.2 Engage travel gear 5.2.6 Check main hoist & auxiliary hoist

ropes

5.2.6 Check luffing gear rope 5.2.6 Check recovery winch rope 5.2.2 Perform diesel engine check 5.2.1 Perform visual control of hydraulics 5.2.3 Switch main battery switch to “ON” Move all control levers to “neutral

position”

5.4.1 “Start” diesel engine 5.7.1 Safe load indicator switches on

automatically

5.4.2 Regulate accelerator 5.5.2 Check air pressure (min, 5 bar) Pressure

gauge in cab

5.1.5 If required, release parking brake and remove drag shoes.

5.2.5 Set hydraulics selector switch to “undercarriage”

5.7.1 Enter code for rigging (1-1-1-1) Safe load indicator

5.1.6 Extend outrigger beams to selected position

5.1.6 Extend jack cylinders 5.7.1 Select propping base Safe load

indicator

5.2.5 Set hydraulics selector switch to “counterweight hydraulics”

5.1.8 If required, pick up counterweight 5.7.1 Select counterweight combination Safe load

indicator

5.1.9 If required, increase / decrease counterweight radius

5.7.1 Select 5.5 m or 6.5 m counterweight radius

Safe load indicator

5.2.5 Set hydraulics selector switch to “ crane operation”

5.1.11 Retract main hoist hook block to boom



4.1 Check List for Operation 4.1.1 Propped Crane Operation (p.2/2) Number in the Instructions


Indicator Notes

5.7.1 Select main hoist hook position Safe load indicator

If required, attach lifting gear 5.6.3/4 Raise / lower hoist rope Safe load

indicator

5.6.1 Slew right/ left Safe load indicator

5.6.2 Derrick in and out boom Safe load indicator

Move all control levers to “neutral position”

On completion of work, observe section 5.7.7 “Parking Crane Safely”



4.1 Check List for Operation 4.1.2 Free-On-Wheel Crane operation (p.1/2) Number in the Instructions


Indicator Notes

5.1.10 Raise boom 5.1.1 Uncouple match truck 5.1.2 Engage travel gear 5.2.6 Check main hoist & auxiliary hoist

ropes

5.2.6 Check derricking rope 5.2.6 Check recovery winch rope 5.2.2 Perform diesel engine check 5.2.1 Perform visual control of hydraulics 5.2.3 Switch main battery switch to “ON” Move all control levers to “neutral

position”

5.4.1 “Start” diesel engine 5.7.1 Safe load indicator switches on

automatically

5.4.2 Regulate accelerator 5.5.2 Check air pressure (min. 5 bar) Pressure

gauge in cab

5.1.5 If required, release parking brake and remove drag shoes.

5.2.5 Set hydraulics selector switch to “counterweight”

5.7.1 Enter code for rigging (1-1-1-1) 5.1.8 If required, pick up counterweight 5.7.1 Select counterweight combination Safe load

indicator

5.1.9 If required, increase /decrease counterweight radius

5.7.1 Select 5.5 m or 6.5 m counterweight radius

Safe load indicator

5.2.5 Set hydraulics selector switch to “crane operation”

5.1.11 Retract main hoist hook block to boom Safe load indicator

5.7.1 Select main hoist hook block position If required, attach lifting gear 5.6.3/4 Raise / lower hoist rope Safe load

indicator

5.6.1 Slew right / left Safe load indicator



4.1 Check List for Operation 4.1.2 Free-On-Wheel Crane Operation (p.2/2) Number in the Instructions


Indicator Notes

5.6.2 Derrick in and out boom Safe load indicator


On completion of work, observe section 5.7.7 “Parking Crane Safely”



4.2 Check List for Rigging 4.2.1 In Train Formation (p.1/3)

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Indicator Notes

5.2.2 Perform diesel engine check 5.2.1 Perform hydraulic system check 5.1.2 Engage travel gear undercarriage 5.2.6 Check main hoist & auxiliary hoist ropes 5.2.6 Check derricking gear and recovery winch ropes 5.7.10 Coil recovery winch rope 5.2.3 Switch battery main switch to “ON”


5.2.5 Set hydraulics selector switch to “crane operation” 5.4.1 “Start” diesel engine 5.7.1 Safe load indicator switches on automatically 5.4.2 Regulate accelerator 5.5.2 Check air pressure (min. 5 bar) Pressure

gauge in cab

5.1.5 If required, release parking brake undercarriage 5.2.5 Set hydraulics selector switch to “undercarriage”

Hydraulics

5.1.6 If required, retract outriggers undercarriage 5.7.1 Select propping base 1 Safe load

Indicator

Approach match truck Boom is in straight-ahead position

5.1.1 Couple match truck Move counterweight to match truck side 5.2.5 Set hydraulics selector switch to “crane operation” 5.1.11 If required, release main hoist hook block from boom 5.7.1 Select main hoist hook block position 1 (freely

suspended) Safe load

Indicator

5.2.5 Set hydraulics selector switch to “counterweight hydraulics”

5.1.9 Lower boom onto frame mechanism




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Indicator Notes

5.1.10 Extend counterweight support completely (to resting position)

5.7.1 Select counterweight radius – 1 – (6.5m) Safe load Indicator

5.7.1 Select counterweight configuration –1- (without c/w) Safe load Indicator

5.2.5 Set hydraulics selector switch to “crane operation” 5.6.1 Rotate superstructure 180

5.6.2 Derrick in further, bridge limit switch for rigging (5.1.11)

Boom in steepest working position

Ram shorn is located above counterweight support 5.1.9 Picking up entire counterweight and raise somewhat 5.1.9 Fold in frame mechanism 5.1.9 Lower entire counterweight onto undercarriage

centering device

5.1.8 Release connection between counterweights 2 & 3 5.6.2 Derrick out until counterweights 1 & 2 are above

match truck

5.1.8 Set down counterweights 1 & 2 onto match truck, release connection

5.1.9 Store counterweight 1 on match truck as per regulations

5.1.9 Counterweight 3 remains on undercarriage ahead of the cab

5.6.2 Lower boom until hook is vertical to the storage place on match truck

5.6.4 Lower auxiliary hoist hook Set down auxiliary hoist hook on undercarriage and

secure

5.6.3 Lower main hoist hook Set down main hoist hook on undercarriage and

secure

5.6.2 Lower boom further, bridge limit switch for rigging (5.1.11)

5.6.3/4 Simultaneously slacken main & auxiliary hoist rope Insert rope retainer bar 5.6.2 Lower boom to boom support 5.6.3/4 Simultaneously slacken main & auxiliary hoist ropes




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Indicator Notes

5.1.6 Move the boom out of its fulcrum point Watch ropes!

Simultaneously slacking derricking rope (derrick out)

Thus, boom head slips into boom support guide Locked! 5.6.1 If required, move superstructure in 0 position 5.2.5 Set hydraulics selector switch to “counterweight

hydraulics”

5.1.4 Lower counterweight support/lower superstructure Watch ropes!

Simultaneously unlock c/w support locking device 5.6.2 Simultaneously slacken derricking rope (derrick

out)

5.2.5 Set hydraulics selector switch to “ undercarriage”

5.1.6 Dismantle the outrigger pads and store on match truck as per regulations

5.1.6 Retract the jack cylinders completely 5.1.6 Retract outrigger beams and secure 5.7.1 Select free-on-wheel propping base – 1- Safe load

indicator

5.1.5 Switch on parking brake 5.1.2 Disengage travel gear Undercarriage Shut down crane Close windows and doors Remove key and take away

It is assumed hat the ambient conditions under which the crane and match truck are parked correspond to local regulations.



4.2 Check List for Rigging 4.2.2 Out Train Formation (p.1/2)

Num

ber

in th

e In

stru

ctio

ns


Indicator Notes

5.2.2 Perform diesel engine check 5.2.1 Perform visual control of hydraulics 5.2.6 Check main hoist & auxiliary hoist ropes 5.2.6 Check derricking gear & recovery winch ropes 5.2.3 Switch battery main switch to “ON” Move all control levers to “neutral position” 5.4.1 “Start” diesel engine 5.7.1 Safe load indicator switches on automatically 5.4.2 Regulate accelerator 5.5.2 Check air pressure (min. 5 bar) Pressure gauge in

cab

5.2.5 Set hydraulics selector switch to “undercarriage” 5.7.1 Enter code for rigging (1-1-1-1) Safe load

indicator

5.1.2 Engage travel gear undercarriage 5.1.7 If required, release the crane parking brake 5.2.5 Set hydraulics selector switch to “counterweight

hydraulics”

5.1.4 Raise counterweight support unlock superstructure Watch ropes! 5.6.2 Simultaneously tension the ropes Counterweight support locking device must latch in! 5.2.5 Set hydraulics selector switch to “crane operation” 5.1.11 Unlock boom head locking device 5.6.2 Derrick in ropes Thus, the boom slips into its fulcrum point Boom head is suspended freely above boom support 5.6.3/4 If required, tension main & auxiliary hoist ropes



4.2 Check List for Rigging 4.2.2 Out Train Formation (p.2/2)

Num

ber

in th

e In

stru

ctio

ns


Indicator Notes

5.6.2 Derrick in until boom in lowest working position Watch ropes!

Caution – slacken main or auxiliary hoist ropes (lower)

5.1.6 Release hook block bracket 5.6.3/4 Raise main or auxiliary hoist Remove rope retainer bar Hook blocks are suspended freely 5.2.5 Set hydraulics selector switch to “counterweight

hydraulics”

5.1.9 Pick up counterweight 5.7.1 Select counterweight combination Safe load

indicator

5.1.9 Increase/ decrease counterweight radius 5.7.1 Select 5.5 m or 6.5 m counterweight radius Safe load

indicator

5.2.5 Set hydraulics selector switch to “ crane operation” 5.1.11 Retract main hoist hook block to boom 5.7.1 Select main hoist block position Safe load

indicator

If required, uncouple match truck Crane is ready for operation

Date post:	17-Mar-2020
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