Manitowoc Grove RT9150E Operator Manual - PDF DOWNLOAD

Manitowoc Grove RT9150E Operator Manual - PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT9150E Operator Manual - PDF DOWNLOAD

Language : English
Pages :328
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove RT9150E Operator Manual - PDF DOWNLOAD

Table of Contents 5
SECTION 1 13
Introduction 13
General 13
Overview of Manuals 13
Delivery Report 13
Customer Support 13
New Owners 14
Safety Information 14
General Crane Design 14
Specific Crane Description 14
Lifting Capacities (Load Chart) 14
Basic Components 14
Axle Weight Distribution 14
Serial Number Location 14
Transportation and Lifting Data 14
Noise/vibration test results 15
Noise Level Test Results 15
Vibration Level Test Results 15
List Of Specifications 16
General 16
Dimensions 16
Capacities 16
Torque Converter 16
Transmission 16
Engine 16
Cummins QSC 16
Axles 16
Brakes 16
Wheels and Tires 16
Swing Gearbox 16
Boom 16
Swivel Assembly 16
Hydraulic Pumps 17
Pump #1 17
Pump #2 17
Pump #3 17
Pump #4 17
Hoists 17
Wire Rope (Hoist Cable) 21
General 21
Environmental Conditions 21
Dynamic Shock Loads 21
Lubrication 21
Precautions and Recommendations During Inspection or Replacement 21
Wire Rope Inspection (Running Ropes and Pendant Cables) 22
Keeping Records 22
Frequent Inspection 22
Periodic Inspection 23
Wire Rope Inspection/Replacement (All Wire Rope) 23
Seizing Wire Rope 23
Method 1 23
Method 2 24
Installing 35x7 Class Wire Rope 24
SECTION 2 27
Safety Information 27
Safety Messages 27
General 27
Safety Alert Symbol 28
Signal Words 28
General 28
Warning Signs 28
Accidents 28
Operator Information 28
Operator Qualifications 29
Operational Aids 30
Rated Capacity Limiter (RCL) Systems (If Equipped) 30
Anti-Two-Blocking Device 31
Working Area Limiter (If Equipped) 31
Crane Stability/Structural Strength 32
Load Charts 32
Work Site 32
Wind Forces 33
Wind Speeds 33
Determination of 3-second wind gust speed at boom tip height: 36
Size and Shape of the load: 36
Determining Wind Drag Coefficient (Cd) 37
Maximum Permissible Wind Speed 38
Example and Sample Calculations (metric) 40
Example 1: Crane Configuration: 40
Load example 11: 41
Load example 12: 41
Load example 13a: 41
Load example 13b: 41
Example and Sample Calculations (Non-metric) 44
Example 2: 44
Load example 21: 45
Load example 22: 45
Load example 23a: 45
Load example 23b: 45
Lifting Operations 46
Counterweight 47
Outrigger Lift Off 47
Multiple Crane Lifts 47
Tilt-Up Panel Lifting 47
Pile Driving and Extracting 48
Crane Equipment 48
Crane Inspection 48
Electrocution Hazard 49
Set-Up and Operation 50
Electrocution Hazard Devices 50
Electrical Contact 51
Special Operating Conditions and Equipment 51
Earthing the Crane 51
Personnel Handling 52
Environmental Protection 53
Maintenance 53
Service and Repairs 53
Lubrication 54
Tires 55
Hoist Rope 55
Synthetic Hoist Rope 55
Wire Rope 55
Sheaves 56
Batteries 57
Super Capacitor (If Equipped) 57
General Maintenance 57
Transporting the Crane 58
Travel Operation 58
Work Practices 59
Personal Considerations 59
Crane Access 59
Job Preparation 59
Working 60
Lifting 61
Hand Signals 62
Jib 64
Parking and Securing 64
Shut-Down 64
Cold Weather Operation 64
Temperature Effects on Hook Blocks 65
Temperature Effects on Hydraulic Cylinders 65
Model Specific Information 67
Crane Access 67
Boom Inspection 68
Superstructure Inspection 70
Carrier Inspection 72
SECTION 3 75
Operating Controls And Procedures 75
Operational Aids 77
Rated Capacity Limiter System 77
Working Range Limitation 77
Anti-Two-Block Device 77
RCL Boom Alarm (CE Units) 77
Control Lever Lockout System 77
Steering Column 78
Transmission Shift Lever 78
Turn Signal Lever 78
Windshield Wiper/Washer Control 78
Horn 78
Ignition Switch 78
Left Turn Signal Direction Indicator 78
Right Turn Signal Direction Indicator 79
Park Brake Switch 79
Headlights Switch 79
Drive Select Switch 79
Hazard Lights Switch 79
Engine Idle Increase/Decrease Switch 79
Steering Column Left side and Floor 80
Steering Column Tilt/Telescope Lever 80
Cup Holder 80
360° Swing Lock Pedal 80
Swing Brake Pedal 80
Service Brake Foot Pedal 80
Throttle Pedal 80
Right Side Console 81
RCL Control Panel 81
RCL Override Switch (Non-CE Certified Cranes) 81
RCL Emergency Override Switch and Indicator (CE Certified Cranes) 81
ECOS Control Panel 82
Emergency Stop Switch 82
Turntable Lock Pin Control Handle 82
Accessory Outlet 82
Diagnostic Connector 82
Level Indicator 82
Overhead Controls and Features 83
Skylight Window Latch 83
Skylight Wiper and Wiper Motor 83
Skylight Sunscreen 83
Cab Circulating Fan 83
Right Side Window Latch 83
Overhead Light 83
Overhead Console (Right Side) 84
Heater/Air Conditioner Fan Switch 84
Skylight Wiper Switch 84
Heater Control Switch 84
Air Conditioner Switch 84
Work Lights Switch 84
Boom Light Switch (Optional) 84
Aircraft Warning Light Switch (Optional) 84
Exhaust System Cleaning Switch 84
DEF Gauge 85
Seat-Mounted Controls 85
Right-Hand Armrest Assembly 85
Seat Adjustment Lever 85
Seat Back Adjustment Lever 85
Seat Assembly Adjustment Lever 86
Armrest Adjustment Knob 86
Left-Hand Armrest Assembly 86
Right-Hand Armrest Controls 86
Main Hoist or Telescope/Boom Lift Controller 86
High Speed Main and Auxiliary Hoist Boost Button 87
Work Horn Button 87
Hoist Rotation Indicators 87
Main Hoist (I) Switch 87
Boom Lift Switch 87
Boom Telescope Switch 87
Luffing Jib Switch (Optional) 87
Cab Tilt Switch 87
Left-Hand Armrest Controls 87
Auxiliary Hoist/Swing Gear Controller 87
High Speed Lift/Telescope Boost Button 87
Swing Gear Freewheel Button 88
Hoist Rotation Indicators 89
Swing Gear Switch 89
Crane Function Switch 89
Auxiliary Hoist (II) Switch 89
Differential Lock Switch (Optional) 89
Rear Steer Control Switch 89
Lift Switch (CE Option) 89
Miscellaneous Cab Controls and Features 89
Cab Door 89
Outside Handle/Latch 89
Inside Door Latch 90
Fire Extinguisher 90
Emergency Exit 90
Dead Man’s Switch and Seat Contact Switch 90
Jib Release Pole 90
RCL Lockout Alarm 90
ECOS Control Unit 91
Common Elements 91
Main Menu 95
Outriggers Submenu101
Outriggers Submenu101
Swing Gear and Brake Submenu104
Swing Gear and Brake Submenu104
Telescope Submenu106
Telescoping Submenu106
Description of Telescope Section Views110
Telescope Mechanism Error Messages111
Working Range Limitation submenu112
Entering Limit Values112
Working Range Limitation Submenu112
Display of the Swing Angles116
Entering the Permissible Swing Range116
Swing Angle A116
Swing Angle B116
Entering Points and Objects116
Representation of Points and Objects117
Entering objects117
Deleting Points118
Entering Limit Values/Objects Manually118
Overall Height/Working Radius118
Swing Angles118
Entering a Limit Value118
Objects119
Shutdown by Working Range Limiter120
Monitoring submenu121
Monitoring Submenu121
Power Unit Speed Submenu122
Power Unit Speed Submenu122
Changing values122
Counterweight Submenu123
Counterweight Submenu123
Settings Submenu126
Settings Submenu126
Adjusting the Brightness of the Display131
Lamp Test132
Operating Hours133
Operating Hours Submenu133
Entering the Current Telescope Status134
Entering RCL Telescope Values134
Approving Entered Telescope Values134
Warning Messages136
Meaning of the Symbols136
Exiting the Submenu136
Warning Submenu137
Error Messages140
Opening the Submenu140
Exiting the Submenu140
Error Submenu140
RCL Control Unit142
Common Elements142
RCL Early Warning146
RCL Shutdown146
Shutdown Due to Overload146
Canceling a Shutdown147
RCL Override147
Overriding the RCL147
Canceling the Override147
Anti Two-Block Switch Override147
RCL Main Menu149
RCL Main Menu149
Rigging Mode Submenu152
Opening the Submenu152
Rigging Mode Menu152
Entering the Rigging Mode155
Entering Individual Components155
To Switch ON Input Mode155
Selecting Values155
Counterweight156
Boom System156
Outrigger Deployment156
Swing Range157
Entering the RCL Code157
Entering the Reeving157
Approve the Rigging Mode158
Confirming Rigging Mode158
Accepting Rigging Mode158
Rigging Mode Monitoring Submenu159
Rigging Mode Monitoring Menu159
RCL Monitoring Submenu160
Opening the Submenu160
Monitoring Submenu160
Error Messages in the Monitoring Submenu165
Error Message without Shutdown165
Error Message with Shutdown165
Lifting Capacity Tables Submenu166
Opening the Submenu166
Lifting Capacity Tables Menu166
Working Range Submenu170
Opening the Submenu170
Working Range Menu170
Settings Submenu173
Opening the Submenu173
Cancel the Input173
Settings Submenu173
Error Submenu175
Opening the Submenu175
Exiting the Submenu175
Error Submenu175
Error Codes177
Operating Procedures179
New Crane Conditioning179
Pre-Starting Checks179
Fuel Supply179
Engine Oil179
Engine Coolant179
Batteries179
Signal and Running Lights179
Foot and Parking Brakes179
Daily Lubrication179
Hydraulic Reservoir and Filter179
Tires179
Wire Rope179
Hook Block179
Boom179
Air Cleaner179
Access Hole Covers (CE Units)179
Wind Forces179
Cold Weather Operation180
Operation Below -40°F180
Operation Below -40°C180
Preheating the Hydraulic Oil180
Preheating181
Cold Climate Engine Operation181
Crane Warm-up Procedures181
Engine182
Transmission182
Hoist182
Swing Drive and Turntable Bearing182
Axles182
Hydraulic Oil System183
Battery Disconnect183
Engine Operation183
Starting Procedure183
Warm Engine183
Cold Engine184
Idling the Engine184
Racing the Engine184
Shutdown Procedure184
Exhaust System Cleaning184
Transporting Crane185
Crane Travel Operation185
Traveling — General185
Traveling — Towing/Pulling186
Traveling — Being Towed/Pulled187
Traveling with Boom Extension and/or Insert Erected187
36 ft (11 m)/59 ft (18 m) Extension187
59 ft (18 m) Extension Plus 26 ft (8 m)/ 19 ft (6 m) Extension Inserts187
12 ft (36 m) Extension187
Extended Travel188
Moving the Crane188
Steering188
Front Wheel Steering188
Rear Wheel Steering188
Four Wheel Steering188
Crabbing188
Secondary Steering (CE Units)189
Traveling - Forward189
Traveling - Reverse189
Four-Wheel Drive Operation189
Travel On Slopes190
Travel On Slopes with or without Standard Counterweight (39,000 lb (17690 kg)) installed190
Travel On Slopes with Optional Heavy Counterweight (63,000 lb (28576 kg)) installed190
Proper Operation of Differential Lock190
General191
Operation191
Proper Operation of Axle Oscillation Lockouts191
General Crane Operation192
Pump Drive192
Operating the Crane On Outriggers192
Control Lever Operation192
Preload Check192
Using Your Load Chart192
Counterweight Installation/Removal193
Extending the Lifting Cylinders193
Retracting the Lifting Cylinders194
Locking/Unlocking Counterweight Lift Cylinders194
Locking/Unlocking the Counterweight195
Crane Functions196
Operation of the Rated Capacity Limiter (RCL)196
Switching on the RCL196
After Crane Shutdown of up to 48 Hours197
After Crane Shutdown of more than 48 Hours197
Prior to Crane Operation197
Opening the Submenu Manually197
Verify Rigging198
Verify Hoists Display198
How to Switch the Hoist Display198
Verify Reeving199
Deploying the Outriggers199
Engaging the Mid-Extend Lock Pin200
Stowing the Mid-Extend Lock Pin200
Outrigger Monitoring System (OMS) RCL Display (Optional—Standard in North America)200
Fully Retracted or 0% Deployed200
Mid-Extended or 50% Deployed200
Fully Extended or 100% Deployed201
Error Code Display201
ECOS Error Reporting202
Stowing the Outriggers202
Rotating the Superstructure203
Swing Operation Prerequisites203
Rotating the Superstructure203
Rotating Superstructure with Counterweight204
Elevating/Lowering the Boom205
Boom Elevating/Lowering Operation205
Lowering the Boom to a Horizontal Position206
Lowering Boom to Horizontal with Boom Extension Installed206
Tilting the Crane Cab206
To Raise the Cab206
To Lower the Cab206
Telescoping the Boom207
Telescope Mechanism207
Fixed Length, Intermediate Length, Telescoping Length207
Current Telescope Display, (Figure 3-134)207
Telescope System Overview208
Telescoping Process208
Telescoping with Teleautomation210
To Switch on Input Mode210
To Enter Values210
Telescope Operation211
Canceling Teleautomation212
Example of Telescoping with Teleautomation212
Manual Telescoping213
Checking the Initial Position213
Current Telescope Status214
Position of the Telescope Cylinder214
Position of the Locking Pins214
Unlocking the Telescope Cylinder215
Prerequisites215
To Select Unlock215
Unlocking the Telescoping Cylinder215
Extending/ Retracting the Telescope Cylinder216
Prerequisites216
Extend/Retract216
Lock Telescope Cylinder217
Prerequisites217
To Select Lock217
Locking the Telescope Cylinder218
Unlocking the Telescopic Section218
Prerequisites218
To Select Unlock218
Unlocking the Telescopic Section219
Telescoping the Telescopic Section220
Prerequisites220
Telescoping220
Locking the Telescopic Section220
Prerequisites220
To Select Lock220
Locking the Telescopic Section221
Telescoping Main Boom in Horizontal Position221
Telescoping with Rigged Boom Extension221
Extending/Retracting the Boom221
Telescope Emergency Program222
Starting the Emergency Program222
Determining the Type of Error223
If There is an Error on the Length Indicator224
Inspections Prior to Telescoping224
Retracting and Locking A Telescopic Section225
Unlocking the Telescope Cylinder225
Extending and Locking the Telescope Cylinder226
If There is an Error at a Proximity Switch226
Required Inspection227
Retracting227
Terminating the Emergency Program227
Tables for Approaching the Locking Points228
Locking Points for the Telescoping Cylinder228
Locking Points for the Telescopic Sections228
Hoist Operation229
Lowering and Raising the Hoist Cable229
Main Hoist229
Auxiliary Hoist229
Hoist Speed Range Selection230
Boom Extensions230
Setting the RCL230
Load Bearing Capacities231
Raising and Lowering the Hydraulic Boom Extension231
Hydraulic Boom Extension Operation — Cab231
Hydraulic Boom Extension Operation — Remote Station232
Two Hook-Operation232
Stowing and Parking233
Unattended Crane233
SECTION 4235
Set-up And Installation235
General235
Accessing the Hoist area236
Travel Configuration236
Working Configuration236
Hoist Cable (Wire Rope)236
Removing the Old Cable236
Installing a New Cable237
Cable Reeving238
Dead-End Rigging/Wedge Sockets239
Installing Wedge and Socket239
Counterweight Removal and Installation246
Counterweight Stand Installation246
Standard Fabricated Counterweight Installation246
Standard Fabricated Counterweight Removal247
Heavy Fabricated Counterweight Installation248
Heavy Fabricated Counterweight Removal248
17,690 kg (39,000 lb) Cast Counterweight Installation249
17,690 kg (39,000 lb) Cast Counterweight Removal250
Heavy Cast Counterweight Installation250
Heavy Cast Counterweight Removal251
Counterweight Stand Removal252
Outrigger Removal and Installation253
Bleed Valve Operation253
Outrigger Box Removal253
Outrigger Box Installation255
Anti Two Block (A2B) Switch256
Lock256
Unlock256
Before Operation256
Cranes With Main Hoist Only256
Machines with Main and Auxiliary Hoists257
Boom Extensions258
Installing the Folding Boom Extension259
Securing Extension with Tag Line (Rope)260
Relieving the Load on Connecting Lugs260
Extension Erecting Warnings and Requirements260
Erecting Procedure: 36 ft (11 m) Extension260
Erecting Procedure: 59 ft (22 m) Extension263
Extension Electrical Connections266
36 ft (11m) Extension Electrical Connections266
59 ft (18 m) Extension Electrical Connections266
Disconnect Electrical Connections to the 59 ft (18 m) Section266
Connecting the Anti-Two Block Switch267
36 ft (11 m) Extension A2B Installation267
36 ft (11 m) Extension A2B Removal267
59 ft (18 m) Extension A2B Installation267
Extension Hydraulic Connections (Optional Hydraulic Extension)268
Checking the Locking Device on the Hose Drum268
Unlocking the Drum268
Locking the Drum268
Hydraulic Hose Installation268
Position for Main Boom Operation269
Establishing the Hydraulic Connection269
Disconnecting the Hydraulic Connection270
Folding Deflection Sheaves270
Deploying the Rear Deflection Sheave270
Stowing Rear Deflection Sheave270
Deploying the Front Deflection Sheave271
Folding In Front Deflection Sheave271
Positioning/Removing the Hoist Cable271
Positioning Hoist Cable271
Removing Hoist Cable271
Mechanical Luffing Jib (Adjustable Boom Extension)272
Extension Angle Adjusting Mechanism272
Setting the Angle with an Auxiliary Crane272
Setting the Angle without an Auxiliary Crane272
Entering the RCL Code273
Setting an Angle of 20° or 40°273
Inclining the Crane273
Stowing the Folding Boom Extension274
Requirements for Stowing the Boom Extensions274
Stowing Procedure: 23 ft (7 m) Boom Extension274
Stowing Procedure: 59 ft (18 m) Extension275
Boom Extension Transport Condition277
Transport Condition with Extensions Installed278
With the 59 ft (18 m) Extensions Folded at the Side278
With the 23 ft (7 m) Extension Only Folded at the Side278
Installing and Removing the 26 ft (8 m) and 19 ft (6 m) Extension Inserts278
Installation278
Removal279
Extension Electrical Connection280
Connecting Main Boom to the 26 ft (8 m) Extension280
Disconnecting Main Boom Electrical Connection280
Connecting the Folding Extension Electrical Circuit281
Disconnecting the Folding Extension Electrical Circuit281
Extension Hydraulic Connection281
Connecting Main Boom Hydraulics282
Disconnecting Main Boom Hydraulics282
Connecting the Folding Extension Hydraulics282
Disconnecting the Folding Extension Hydraulics282
Folding the Deflection Sheave on the 26 ft (8 m) Extension283
Folding Out the Deflection Sheave283
Folding In the Deflection Sheave283
Positioning/Removing the Hoist Cable284
Positioning the Cable284
Removing the Cable284
Auxiliary Single-sheave Boom Nose285
Installation285
Removal285
Working Position286
Rigging the auxiliary boom nose286
Transport Position286
Heavy Duty Luffing Boom Extension287
Installation and Removal287
Heavy Duty Nose Sheave287
Work Position287
Stowed Position287
Anemometer/Aircraft warning Light288
Mounting Anemometer/Aircraft Warning Light288
Removing Anemometer/Aircraft Warning Light288
SECTION 5289
Lubrication289
General289
Environmental Protection289
Lubrication Intervals289
Standard Lubricants Package290
Arctic Conditions290
Below -9°C (15°F)290
Down to –29C° (–20°F)291
ALL Weather Package & Lubricants291
Surface Protection for Cylinder Rods293
Wire Rope Lubrication293
Lubrication Points294
CraneLUBE294
Cummins Oil Registration List294
Safety294
Steering and Suspension295
Axles297
Drive Train299
Drive Train (continued)301
Outriggers303
Hydraulic305
Turntable307
Cab Tilt309
Lift Cylinder311
Hoist313
Boom315
Boom (continued)317
Boom Extension319
Boom321
SECTION 6323
Maintenance Checklist323
General323
Instructions323
Daily or 10 Hour Check List323
Weekly or 50 Hour Check List324
Alphabetical Index325

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