Krupp Crane KMK 4080 Operating Instructions Manual 2085545 - PDF DOWNLOAD

Operating Instructions KMK4080

Vehicle - serial number:

9.6.1995

2 085 545 en

Operating Instructions

GMK4080 Die Deutsche Grove GmbH hat die Krupp - Mobilkran - "KMK" - Typenreihe ubernommen und umbenannt in eine "GMK" - Typenreihe.

In dieser Krandokumentation ist die alte Typenbezeichnung noch erhalten.

Deutsche Grove GmbH has taken over the Krupp - track crane - "KMK" - series and renamed it the "GMK" -series.

The old series name has been kept in this crane documentation.

Vehicle - serial number:

9.6.1995

2 085 545 en

Contents

Contents Foreword . . ........................... ......

ii -

1

Introduction . . .

1- 1

1.1

Instructions for use

1-

1

1.2

Conversion table for metric units of measurement

1-

3

1.3

Overview of contents . . .

1-

5

1.4 1.4.1 1.4.2 1.4.3

Truck crane identification .

Vehicle identification . . .

Identification of the two-stage swing-away lattice extension Identification of counterweight parts

1- 7 1- 7 1- 8 1 - 10

1.5

EC declaration of conformity . . . .

1 - 11

1.6

G~neral drawing of the truck crane

1 - 13

1.7 1.7.1 1.7.2

Technical description of the truck crane .

Carrier . . . .

Superstructure . . .

1 - 15 1 - 15 1 - 18

2

Safety instructions

2.1

..

.

...... .

1

2-

1

Proper use . . . . . . .

2-

1

2.2

Organizational measures

2-

3

2.3

Personnel qualifications

2-

5

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10

General Safety Regulations .

Care and Maintenance . . .

Before crane work . . . . .

Hand signals for banksmen Load bearing capacity of the ground and the outrigger Safe distance from banks and pits . .

Safe distance from electrical lines . .

Earthing the truck crane and the load Counterweight . . . . . . . . . . . .

Hoisting capacity and load bearing capacity The effect of wind on crane work .

2- 7 2- 7 2- 7 2- 8 2- 10 2- 11 2- 12 2 - 13 2 - 14 2- 15 2 - 15

2.5

Operating errors . . . . .

2- 19

2.6

Safe load indicator (SLI) .

2 - 21

Operating Instructions KMK 4080

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:

i-2

Contents

3

Driving . . . . . . . . . . . . . . . . . . . . . .

3-

1

3.1 3.1.1 3.1.2

Prescribed transport condition of the truck crane Prescribed transport condition with boom set down on truck crane Prescribed transport condition with boom set down on trailer

333-

1 3 5

3.2 3.2.1 3.2.2

Carrier driver's cab . .

Front instrument panel . . .

Side instrument panel . . .

3- 7 3- 9 3- 14

3.3 3.3.1 3.3.2 3.3.3 3.3.4··

Driver's cab heating system Heating the driver's cab . .

Ventilating the driver's cab .

Fresh air blower (additional equipment) Additional water heating system (additional equipment)

3 - 17 3 - 17 3 - 18 3 - 18 3 - 19

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9

3 - 21 3 - 21 3 - 21 3 - 21 3- 22 3- 23 3- 23 3- 24 3- 24

3.4.11 3.4.12 3.4.13 3.4.14 3.4.15 3.4.16 3.4.17 3.4.18 3.4.19 3.4.20 3.4.21 3.4.22 3.4.23

Before driving . . . . . . . . . . . . . . . .

Establishing the proper transport condition .

During the winter . . . . . . . . . . . . . .

Visual inspection of the entire crane . . . .

Checkipg the oil level in the vehicle engine Checking the oil level in the automatic gearbox Checking the coolant level in the vehicle engine Checking the tyres . . . . . . . . . . . . . . .

Checking the fluid level of the windscreen washing system Switching on the slewing gear free-float (only for on-road driving with boom set down on trailer) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching on the boom floating position (only for on-road driving with boom set down on trailer) . . . . . . . . . . . . . . .

Switching on the battery master switch . . . . . . . . .

Adjusting the driver's seat, steering column and mirrors Inserting the 24-hour disc in the trip recorder Activating the ignition . . . . . . . . . . . . . . . . . .

Checking the suspension system . . . . . . . . . . . .

Checking the functions of the truck crane's electrical system Checking the carrier level adjustment system for on-road driving Checking the steering system for driving on roads (additional equipment) .

Starting the vehicle engine . . . . . . . . . . . . . . . . . . . . . .

Starting the vehicle engine with starter spray (additional equipment) Vehicle engine running - check instruments . . .

Checking the compressed air and brake system .

Refuelling . . . . . . . . . . . . . . . . . . . . .

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3.4.10

3- 25 3- 26 3- 27 3- 28 3- 28 3 - 29 3 - 29 3- 30 3- 30 3 - 31 3 - 31 3- 32 3 - 33 3- 34 3 - 35

Operating Instructions KMK 4080

Contents

3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8

While driving . . . . . . . . . . . . . . . .

Testing the brake . . . . . . . . . . . .

Driving ranges of the automatic gearbox .

Automatic gearbox driving modes Starting and stopping . . . . . . . . . . .

Manual selection . . . . . . . . . . . . .

Monitoring the control instruments while driving Driving on downhill slopes Driving on uphill slopes .

3.6

After driving . . . . . . . .

Parking the vehicle . . . .

Switch off the battery master switch if the truck crane is idle for a longer period of time . . .

3.6.1 3.6.2

3- 37 3- 37 3 - 37 3 - 39

3- 40 3 - 41 3- 42

3 - 45 3- 46 3- 47 3- 47 3 - 49

Off-road driving . . . . . . . . . . . . . . . . . .

Off-the-road gear . . . . . . . . . . . . . . . . .

Longitudinal differential lock in the transfer case .

Longitudinal differential lock in transfer drive axle (additional equipment, _s x 8 drive only) . . . . . . . . . . . . . . . .

Drive of the 2nd axle line . . . . . . . . . . .

Transverse differential locks in the axle lines .

Carrier level adjustment system . . . . . . .

Freeing an immobilized vehicle . . . . . . . .

3 - 55 - 3 - 56 3 - 57 3 - 60

3.8.1 3.8.2 3.8.3

All-wheel steering, crab travel mode (additional equipment) .

Switching the steering system to all-wheel steering, crab travel mode .

Steering the 3rd and 4th axle lines . . . . . . . . . .

Setting the steering system to normal steering mode

3 - 61 3 - 63 3 - 64

3.9

Towing a trailer (additional equipment)

3 - 67

4

Crane operation . . . . . . . . . . . . . . .

4-

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6

Superstructure crane operator's cab .

Front instrument panel . . . . . . . .

Side instrument panel . . . . . . . .

Instrument panel at crane operator's seat Control lever right . . . . . . . . . . . . .

Control lever left . . . . . . . . . . . . .

Operating instruments of safe load indicator (SU)

4- 1 4- 2 4- 8 4- 9 4 - 11 4 - 12 4 - 13

4.2 4.2.1 4.2.2 4.2.3

Heating system for the crane operator's cab Heating the crane operator's cab . . . . . . .

Ventilating the crane operator's cab . . . . .

Additional water heating system (additional equipment)

4 - 15 4 - 15 4 - 16 4 - 16

3.7 . 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.7.7

3.8

Operating Instructions KMK 4080

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3 - 51 3 - 51

3- 53 3- 54

3 - 61

1

i- 4

Contents

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10 4.3.11 4.3.12 4.3.13 4.3.14 4.3.15 4.3.16 4.3.17 4.3.18

Before crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching off boom floating position (only for on-road driving with the boom resting on the trailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching off slewing gear access (only for on-road driving with boom resting on the trailer) . . . . . . . . . .

Condition of the ground on-site . . . . . . . . . . . . . . . .

Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the electrical connection to the superstructure During the winter . . . . . . . . . . . . .

Visual inspection of the entire crane . . .

Checking the oil level in the crane engine Checking the coolant level . . . . . . . .

Checking the fluid level of the windscreen washing system Releasing the mechanical superstructure lock Switching on the battery master switch .

Adjusting the crane operator's seat .

Activating the ignition . . . . . . . . . .

Starting the crane engine . . . . . . . .

Starting the crane engine with the starter spray (additional equipment) Engine running - check instruments Refuelling . . . . . . . . . . . . . . . . . .

4 - 19 4 - 19

4- 20 4 - 21 4 - 21 4- 39 4- 39 4- 40 4 - 41 4- 42 4 - 42 4- 43 4- 43 4- 44 4- 44 4- 45 4- 46 4- 47 4- 47

Working position . . . . . . . . . . . . . .

Working position "Supported on outriggers"

4- 49

4.5.1 4.5.2 4.5.3 4.5.4

External influences during crane operation Heating the hydraulic oil Cooling the hydraulic oil Effects of wind Hand signals . . . . . .

4 - 51 4 - 51 4- 52 4- 53 4- 53

4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11 4.6.12 4.6.13 4.6.14 4.6.15 4.6.16

Crane operation . . . . .

Picking up the hook block Reeving the hoist rope . .

Possible reeving methods Setting down the hook block Counterweight . . . . .

Safe load indicator (SU) Limit switch . . . .

Spotlights . . . . .

Dead man's switch Main hoist . . . . .

Auxiliary hoist (additional equipment) Slewing gear Derricking . . . . . . . . . . . . . . .

Telescoping . . . . . . . . . . . . . .

Telescoping the main boom for maintenance purposes Movements which can be carried out simultaneously .

4- 55 4- 55 4- 57 4- 59 4 - 61 4- 63 4- 74 4 - 81 4- 82 4- 82 4- 83 4- 87 4 - 91 4 - 93 4 - 95 4 -100

4.4 4.4.1

4.5

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4 -101

Operating Instructions KMK 4080

Contents

4.7 4.7.1 4.7.2 4.7.3

Driving a rigged crane .

Driving route . . . . .

Position of the boom .

Driving the rigged truck crane

4 -103 4 -103 4 -104

4.8 4.8.1 4.8.2

Work breaks and unrigging the crane Work break . . . . .

Unrigging the crane . . . . . . . . . .

4 -107 4 -107 4 -108

5

Working with the lattice extension . . . . .

5-

1

5.1 5.1.1 5.1.2

55-

1 1

5.1.6 5.1. 7 5.1.8 5.1.9

Two-stage swing-away lattice extension . . . . . . . . . . . . . .

Transport condition of the two-stage swing-away lattice extension . .

Rigging mode of the truck crane when assembling and disassembling the lattice extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the 26.2 ft swing-away lattice extension on the main boom . . . . . .

Installing the 42.6 ft two-stage swing-away lattice extension on the main boom .

Inclination of the 26.2 ft swing-away lattice extension or the 42.6 ft two-stage swing-away lattice extension . . . ·Raising the boom . . . . . . . . . . . . . .

Working with the lattice extension . . . . .

Unrigging the swing-away lattice extension Checking the transport condition . . . . . .

5 - 19 5- 23 5 - 23 5 - 24 5 - 27

5.2 5.2.1 5.2.2 5.2.3 5.2.4

Auxiliary single-sheave boom top . . . . .

Moving "the auxiliary single-sheave boom top into working position Raising the main boom with the auxiliary single-sheave boom top .

Working with the auxiliary single-sheave boom top (two hook operation) Moving the auxiliary single-sheave boom top into transport position .

5 - 29 5 - 29 5 - 32 5 - 33 5 - 34

6

Dealing with malfunctions

6-

6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9 6.1.10 6.1.11

Malfunctions on the carrier .

Electrical system . . . . . .

Diesel engine malfunctions .

Automatic gearbox malfunctions Transfer case malfunctions . .

Differential lock malfunctions .

Service brake malfunctions . .

Steering system malfunctions Outrigger malfunctions . . . .

Suspension locking system malfunctions .

Level adjustment system malfunctions . .

Jump start - charging battery in the carrier (additional equipment)

6- 3 6- 3 6- 8 6 - 10 6 - 10 6 - 11 6 - 12 6 - 13 6 - 13 6 - 14 6 - 14 6 - 15

6.2 6.2.1

Malfunctions on the superstructure Electrical system . . . . . . .

6 - 17 6 - 17

6.3

Tipping device for driver's cab . . .

6 - 21

5.1.3 5.1.4 5.1.5

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5- 2 5- 3 5 - 10

1

i- 6

Contents

7

Technical data . . . . . . .

7-

1

7.1 7.1.1 7.1.2

Dimensions . . . . . . .

Weights . . . . . . . . .

Counterweight versions .

777-

1 2 4

7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9 7.2.10 7.2.11 7.2.12

Carrier . . . . . .

Vehicle engine .

Power shift gear Transfer case .

Axle lines Steering ..

Tyres . . .

Outriggers Vehicle electrical system Tools . . . . .

Driving speeds . .

Climbing ability . .

Turning circle radii

7777777777777-

5 5 5 5 5 6 6 6 6 7 7 7 7

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11

Superstructure . . .

Crane engine . . .

Crane's electrical system .

Main hoist . . . . . . . . .

Auxiliary hoist (additional equipment) Slewing gear .

Derricking gear . . . . . . . . . . . .

Main boom . . . . . . . . . . . . . .

Lattice extension (two-stage swing-away lattice extension, additional equipment) Hook blocks and hook tackle . .

Safety equipment . . . . . . . .

Operating speeds without a load

7- 9 7- 9 7- 9 7- 9 7 - 10 7 - 10 7- 10 7- 10 7 - 11 7 - 11 7 - 11 7 - 12

Circuit diagrams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

loose

Diesel engine operating instructions and maintenance manual . . . . . . . .

loose

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Operating Instructions KMK 4080

Foreword

Foreword These Operating Instructions together with the lifting capacity table form part of the delivery package for truck crane KMK 4080. They are intended principally for crane operators and contain all necessary information regarding the permissible uses and safe operation of truck crane KMK 4080.

Other crane documentation includes an outrigger pressure table, a maintenance manual and a spare parts list.

This operating manual is not a training manual for prospective crane operators! All descriptions are written explicitly for crane operators who have been trained to operate truck cranes.

Plan each application carefully. Obtain all necessary information regarding the intended journey (dis- tance, route, overhead clearance, load bearing capacity of bridges, etc.). Ascertain the conditions for the job (load bearing capacity of the ground, weight and dimensions of the loads to be lifted, required lengths of stroke and radius, restrictions on movement caused by buildings etc.). Collect the necessary equipment (lifting tackle, counterweight, materials to place beneath outriggers, etc.). Organise transportation and obtain any necessary driving permits.

Poor planning leads to improvisation and improvisation is the cause of many accidents!

A general message to all crane operators: As the driver of a truck crane, you appreciate your responsiblity for the crane and for all work carried out in conjunction with the crane.

For this reason, observe the following advice for your safety and the safety of others: Familiarize yourself with the truck crane and all of its operational states before initial use. Read through these Operating Instructions and compare the diagrams with the crane itself. Carry out the actions described on your truck crane stage by stage.

Always carry this operating manual and the corresponding lifting capacity table with you on the vehicle.

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Foreword

Take particular care to familiarize yourself with the safety equipment in the crane itself. Check the functioning of this equipment on a regular basis. Be sure to shut down the crane operation in case of breakdown or malfunction of safety equipment.

When driving on the road and operating the crane, comply with all relevant laws and regulations, such as the Accident Prevention Regulations, which are not reproduced in this manual.

These Operating Instructions contain many notes intended to draw your attention to certain dangers.

Pay close attention to these notes!

All measurements in these Operating Instructions are given in US units of measurement. Metric measurements are sometimes given.

Ensur'e the operational safety of your truck crane through careful servicing and maintenance.

Never postpone necessary repair work. Always have repairs carried out by qualified personnel.

Use only Original Krupp Replacement Parts. For ordering, use the spare parts list for truck crane KMK 4080.

The Krupp after-sales service is always at your disposal for repair work.

We will be pleased to advise you on points arising through routine operation.

We are always grateful for your comments and suggestions.

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Operating Instructions KMK 4080