Krupp Crane KMK 6160 Operating Instructions Manual 2085625 - PDF DOWNLOAD

Operating instructions KMK6160

Crane identification number:

15.04.91 2 085 625 en

Index

Index Foreword ..

ii- 1

1.

Introduction

1- 1

1.1

Instructions for use

1-

1

1.2

Contents . . . . . .

1-

2

1.3

Vehicle identification

1-

3

1.4

General drawing of the truck crane

1-

4

1.5 1.5.1 1.5.2

Technical description of the truck crane Carrier . . . .

Superstructure . . . . . . . . . . . . . .

111-

5 5 9

2.

Safety regulations

2- 1

2.1

Road safety

. . . .

2- 1

2.2

Accident prevention

2- 2

2.3

Reliability

2- 3

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 2.4.11

General safety regulations Servicing and maintenance Prior to working with the crane When working with the crane .

Hand signals for the banksman Load bearing capacity of the ground; outriggers Safe distance from slopes and pits . . . . . .

Safe distance from electric cables . . . . . . .

Earthing (grounding) the truck crane and load Counterweight . . . . . . . . . . . .

Hoisting capacity and lifting capacity Effect of wind on crane operations

2- 4 2- 4 2- 4 2- 5 2- 6 2- 7 2- 8 2- 9 2- 10 2- 11 2- 12 2- 12

2.5

Operating errors

2- 15

2.6

Load moment limiting system (SLI)

2- 16

3.

Driving

3- 1

3.1

Prescribed condition for driving the truck crane on roads

3- 1

3.2 3.2.1 3.2.2

Driver's cab on carrier Front instrument panel Side instrument panel

3- 5 3- 7 3 - 11

. . . . . .

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Operating instructions KMK 6160

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Index

3.3 3.3.1 3.3.2 3.3.3 3.3.4

Heating the driver's cab .

Heating the driver's cab .

Ventilating the driver's cab Fresh air blower (optional equipment) Additional water heating system (optional equipment)

3-14 3-14 3-15 3-15 3-16

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 3.4.10 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

Before setting off . . . . . . . . . . . . . . . . . . . .

Setting up the prescribed condition for driving on roads In winter . . . . . . . . . . . . . . . . . .

Visual inspection of the entire crane . . . . . .

Checking the oil level in the driving engine . .

Checking the oil level in the automatic gearbox Checking the coolant level . . . . . . . . . . .

Checking the tyres . . . . . . . . . . . . . . .

Checking the windscreen washing system reservoir Switching on the battery master switch . . . . . . .

Adjusting the driver's seat, steering column and mirrors Placing a 24-hour recording disk in the tachograph .

Switching on the ignition . . . . . . . . . . . . . . .

Changing the transfer case to the "on-the-road gear" Checking the suspension system . . . . . . . . . .

Checking that the level of the carrier is correct for driving on roads Checking that the carrier's electrical system is functioning Starting the driving engine . . . . . . . . . . . . . . . . . . . . .

Starting the driving engine with starter spray (optional equipment) Driving engine is running - checking the instruments . .

Checking the compressed air system and brake system Refuelling

3-18 3-18 3-18 3- 18 3-19 3-19 3-20 3-20 3- 21 3- 21 3-22 3-22 3- 23 3-24 3-25 3-26 3- 26 3- 27 3-28 3-29 3- 30 3- 31

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

During the journey . . . . . . .

Testing the brakes . . . . . . .

Gears of the automatic gearbox Automatic gearbox - alternative modes Starting and stopping . . . . . . . . .

Changing gear manually . . . . . . . .

Checking the instruments while you are driving Driving downhill Driving uphill . . . .

3- 32

3.6

After each journey Stopping the vehicle Switching off the battery master switch for long stops

3- 43 3- 43 3- 45

Driving off-the-road . . . . . . . . . . . . . .

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

Longitudinal differential lock in transfer case Longitudinal differential lock on the transfer drive axle Driving the first axle line . . . . . . . . . . .

Transverse differential locks in the axle lines . . . . .

3- 46 3- 46 3-47 3- 48 3- 49 3- 50

3.6.1 3.6.2

3.7 3.7.1

3.7.2 3.7.3 3.7.4 3.7.5

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3- 32 3- 32 3- 34 3-35 3- 36

3-37 3- 41 3- 42

Operating instructions KMK 6160

Index

3.7.6 3.7.7

Carrier level adjustment . . . . . . . . . . .

Freeing the carrier when it is stuck in terrain

3- 51 3- 54

3.8.2

Towing the crane and tow starts Tow starts . . . . . . . . . . . . . . .

Towing the crane

3- 55 3- 55 3- 55

3.9

Trailer operation (optional equipment)

3- 59

4.

Crane Operation . . . . . . . . . . . . . . . . .

4- 1

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6

Crane operator's cab on superstructure Front instrument panel . . . . . . . . . .

Side instrument panel . . . . . . . . . .

Instrument panels at crane operator's seat Right-hand control lever . . . . . . . .

Left-hand control lever . . . . . . . . . . .

Controls of the safe load indicator (SU) . .

4- 1 4- 2 4-10 4- 11 4- 13 4- 13 4- 14

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 (optional equipment)

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

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

Before starting work on the site Ground conditions on the site . . . . . . . . . . . . .

Outriggers . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the electric power supply to the superstructure Removing the marker light from the main boom In winter . . . . . . . . . . . . . . . . .

Visual inspection of the whole crane Checking the oil level in the crane engine Checking the coolant level . . . . . . . .

Checking the windscreen washing system reservoir Releasing the superstructure lock . . .

Switching on the battery master switch Adjusting the crane operator's seat Switching on the ignition . . . . . . . .

Starting the crane engine . . . . . . .

Starting the crane engine with starter spray (optional equipment) Engine is running - checking the instruments Refuelling . . . . . . . . . . . . . . . . . .

4-18 4-18 4- 18 4- 29 4- 30 4- 30 4- 30 4- 31 4-32 4- 32 4- 33 4- 33 4- 34 4-34 4- 35 4- 36 4-37 4- 38

4.4 4.4.1

Operating the crane with/without outriggers Operating mode with outriggers . . . . . . .

4- 39 4- 39

4.5

External influences while working with the crane Preheating the hydraulic oil Cooling the hydraulic oil Wind . . .

Banksman . . . . .

4- 40 4- 40 4- 41 4-42 4- 42

3.8 3.8.1

4.5.1

4.5.2 4.5.3 4.5.4

Operating instructions KMK 6160

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Index

4-43 4-43 4-46 4- 51 4-52 4- 66 4- 75 4- 76 4- 76 4-77 4- 78 4- 80 4-82 4-84

4.6.15

Operating the crane . . . .

Picking up the hook block Reeving the hoist rope . .

Putting down the hook block Counterweights . . . . .

Safe Load Indicator (SU) Limit switches . .

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

Auxiliary hoist (optional equipment) Slewing gear . . . . . . . . . . . .

Raising/lowering the boom (derricking) Extending/retracting (telescoping) the boom Extending (telescoping out) the main boom in the horizontal position for maintenance . . . . . . . . . . . . . . . . . . . . .

Movements which can be carried out simultaneously

4.7 4.7.1 4.7.2 4.7.3

Moving the truck crane when it is rigged . . .

Ground travelled over and load on the ground Position of the boom . . . . . . . . . . .

Moving the rigged truck crane . . . . . .

4-102 4-102 4-102 4-103

4.8 4.8.1 4.8.2

Stopping work and unrigging the crane Stopping work . . .

Unrigging the crane . . . . . . .

4-106 4-106 4-107

5.

Boom extension/luffing fly jib

. . .

5- 1

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.1.11 5.1.12 5.1.13 5.1.14 5.1.15 5.1.16 5.1.17

Boom extension (optional equipment) Dimensions and weights of parts General drawing and order of installation Preparing the crane for installing the boom extension Installing the foot section Installing the intermediate section . . . . .

Installing the head section . . . . . . . . .

Passing the hoist rope to the head section Folding down the stirrup for fastening the rope end clamp Attaching the anemometer and connecting it up to the electrical system Connecting up the boom extension to the electrical system Reeving the hook block on the boom extension . . . . . . . . . . . .

Adjusting the angle of the boom extension . . . . . . . . . . . . . .

Checking that the SU, anemometer and lifting limit switch are working Raising the boom . . . . . . . .

Working with the boom extension Unrigging the boom extension . .

Transporting the boom extension

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

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4- 99 4-101

5- 1 5- 1 5- 1 5- 2 5- 2 5- 5 5- 6 5- 7 5- 8 5- 8 5- 9 5-10 5- 11 5-14 5-14 5-14 5-15 5-16

Operating instructions KMK 6160

Index

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

Auxiliary hoist {optional equipment) . . . . . . . . . .

Installing the auxiliary hoist on the main hoist . . . . . .

Connecting up the auxiliary hoist to the electrical system Connecting the auxiliary hoist to the hydraulic system Checking that the auxiliary hoist is working Removing the auxiliary hoist . .

Transporting the auxiliary hoist . . . .

5- 17 5- 17 5- 18 5- 18 5- 19 5-19 5- 20

6.

Procedure in case of malfunctions

6- 1

6.1 6.1.1 6.1.2

Malfunctions on the carrier . . . . . . . . . . . . . . . . . . . . . .

Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the vehicle from another vehicle - charging the carrier battery

6- 1

6.2 6.2.1

Malfunctions on the superstructure Electrical equipment . .

6- 6 6- 6

6.3

Tipping the driver's cab

6- 9

7.

Servicing and maintenance .

7- 1

7.1

Cleaning your truck crane ...

7- 1

7.2

General information on care and maintenance

7- 2

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7

Routine work . . . . . . . . . . . . . . . .

Daily inspection and maintenance work ..

Weekly inspection and maintenance work Monthly inspection and maintenance work Quarterly inspection and maintenance work Half-yearly inspection and maintenance work Annual inspection and maintenance work ..

Two-yearly inspection and maintenance work

77777777-

7.4 7.4.1 7.4.2

Changing the oil . . . . . . .

Oil change for carrier Oil change for superstructure

7- 6 7- 6 7- 7

7.5 7.5.1 7.5.2

Lubricating schedule Carrier . . . .

Superstructure

7- 8 7- 8 7- 9

7.6

Lubricant table

7- 10

7.7 7.7.1 7.7.2

Laying-up and conservation Work before laying-up ..

Work during stoppages .

7- 11 7- 11 7- 11

7.8

Central lubrication system

7-12

Operating instructions KMK 6160

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6- 1 6- 5

3

3 3 4 4

5 5 5

i-5

Index

8.

Technical data

8- 1

8.1

Dimensions

8- 1

8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13 8.2.14 8.2.15 8.2.16 8.2.17

Carrier Chassis Driving engine Power shift gear Transfer case ..

Axle lines Steering Wheel suspension ....

Tyres Carrier's hydraulic system . . . . . .

Outriggers . . . .

Brake system Carrier's electrical system Driver's cab ..

Tools Driving speeds Climbing ability Turning circle radii

8- 2 8- 2

8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.3.9 8.3.10 8.3.11 8.3.12 8.3.13 8.3.14 8.3.15

Superstructure ..

Turntable Crane engine . . .

Crane's hydraulic system ..

Main hoist Auxiliary hoist (optional equipment) Slewing gear Derricking gear . . . . . . . . . . . . . . . . ...

Main boom Boom extension (optional equipment) Counterweight lifting gear . .

Counterweight versions Hook blocks and hook tackle . . . . . .

Safety devices Operating speeds without a load Crane operator's cab

8.4

Tightening torques for fixing bolts

8- 2 8- 2 8- 3 8- 3 8- 4 8- 5 8- 5 8- 6 8- 7 8- 7 8- 10 8-10 8-10 8-10 8 - 11 8 - 11 8-12

8- 12 8-12 8- 13 8- 14 8- 15 8-15 8-16 8-16 8- 16 8- 17 8- 17 8- 17 8- 18

8-19 8-19

8-20

Order data sheet Circuit diagrams

. Bound separately

Operating and maintenance instructions for diesel engines

. Bound separately

Operating instructions for automatic gearbox

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. Bound separately

Operating instructions KMK 6160

Foreword

Foreword These operating instructions with lifting capacity tables and outrigger pressure tables belong to the scope of supplies of truck crane KMK 6160. They are intended first and foremost for the crane operator and contain all information required to operate truck crane KMK 6160 safely for the permitted applications, which are listed.

These operating instructions are not intended to be used as a training manual for trainee crane operators. The descriptions given have been written on the assumption that they will be read by crane operators who are fully trained for working with truck cranes.

Plan each job carefully. Make sure that you obtain all the information you need concerning the route to the site (distance, route to be followed, headroom, maximum loads permitted to cross bridges, etc.).

Find out details of the work to be performed by the crane (load bearing capacity of the ground, weight and dimensions of the loads to be lifted, required lifting heights and working radius, and buildings, etc., which will restrict movement). Assemble the equipment which will be needed (lifting tackle, counterweight, packing material for the outriggers, etc.). Organize the journey and procure any permits needed for it.

If you do not plan things properly you will be forced to improvise - and improvisation often leads to accidents!

A word of advice to all crane operators: As you know, as the crane operator you are responsible for the crane and for all work connected with it.

For the safety of those around you - and of course your own safety - please follow the advice given below: Before you use the crane for the first time, familiarize yourself with its operation in all permitted operating modes. Read these operating instructions through and compare all of the illustrations with your crane. Go through the described procedures step by step with your crane.

Always carry these operating instructions and the lifting capacity and outrigger pressure tables with you in the crane.

Pay particular attention to the crane's safety devices. Check continually that these devices are working. If you notice that a safety device is not working or is not working properly, stop work immediately.

Operating instructions KMK 6160

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