24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Travel Operation 42 The drive and supply systems must always be checked prior to travel operation. Travel operation is not permitted until these checks have been carried out. As an aid, you can use the “General Drawing with Check Locations”, which indicates the installation locations of the items listed here. Nonon " 12 13 Wheels and tyres... Auxiliary power supply . Diesel engine system. Fuel system. ‘Tower / boom system Superstructure hydraulic system Stabilisers Superstructure / chassis locking device External power supply Electrical system... 2424 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Travel Operation 42 A Checks The drive and supply systems must always be checked prior to travel operation. Travel operation is not permitted until these checks have been carried out. As an aid, you can use the “General Drawing with Check Locations”, which indicates the installation locations of the items listed here. 1 Wheels and tyres Safety instructions: Before the checks are started, it must be ensured that the crane cannot be operated. The tyres and wheels must be in perfect condition. The tyre pressure must be 10 bar. After a wheel rim has been changed, all the wheel nuts must be tightened to 650 Nm with a torque wrench; after a short running time they must be retightened to the same torque. ‘Warning. Danger of bursting. Before changing a defective tyre, deflate it. Visual check: With twin tyres, a check between the tyres is required. Any objects jammed between the tyres must be carefully removed to avoid damage. Damaged tyres must be immediately replaced by a qualified workshop, as sand particles and other foreign bodies that have penetrated into cuts can destroy the tyre carcass. The rims must also be inspected for external damage. Check the tyre pressure and, if necessary, inflate the tyres. The tyre pressure must be 10 bar. If the tyre pressure is too low, the tyres will be destroyed. Ensure that nobody is standing in front of the tyres when they are being inflated. Always check that the wheel nuts are tight prior to travel operation. Check the correct tyre pressure. 3 400 V/ 50 Hz auxiliary power supply Safety instructions: Before the plug of the auxiliary power supply is removed, all electrical equipment and the diesel engine must be switched off. The cable and plug must be undamaged. Ensure that the cable is de-energised before connecting it. As all the heaters and preheaters, the PLC and the battery charger are run on the auxiliary power supply when the crane master switch is switched off, the auxiliary power supply must be plugged in if the crane is to be left with no external power supply connected. The harbour-side connection must be protected with 63 A fuses. Operation: The auxiliary power supply must not be connected during travel operation. The connection is located on the chassis. When the auxiliary power supply is plugged in, the red indicator lamp in the driver's cab will light up. Disconnecting the auxiliary power supply: Loosen the retaining ring and pull out the plug. Then firmly close the plug's protective cover again to prevent moisture and dirt entering. 2224 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Travel Operation 42 A 4 Diesel engine system Safety instructions: Danger of bums. The engine, coolant, engine oil and exhaust system become hot during operation. For checks and maintenance work, the engine must be shut down and secured against restarting. Wait for the engine to cool down before you touch it Operation: Visual check: Check the diesel engine and the corresponding radiator unit in the superstructure for visible damage and external leaks. Engine air filter: Check the clogging indicators. If one or both indicator rings is / are in the red zone, the air filter / filters in question will have to be replaced even if the normal maintenance interval has not elapsed. Oil level: Check the oil level on the oil dipstick. The exact oil level is not indicated until the engine has been stationary for at least 20 minutes. Caution. Some engines have two marks, one for idling and one for standstill. Ensure that you refer to the correct mark. Additional check points: If any of the following faults occurs, it will be indicated in the cabs: coolant level too low or too high, coolant temperature too high, diesel engine oil pressure too low. In the tower cab, a fault message will appear on the monitor and a buzzer on the operating panel will sound. In the event of any of these fault indications, switch off the diesel engine and remedy the fault. If you do not switch off the diesel engine, it will be switched off automatically shortly after the fault is indicated. On the diesel engine room control panel, the various statuses are shown on the display when the corresponding keys are pressed. The following points must be recorded by the crane operator and the maintenance department advised accordingly: Low oil pressure Low output High coolant or oll temperature Unusual noises Heavy smoke Excessive consumption of coolant, fuel or oil Fuel or oil system leaks NOOeONS 2324 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Travel Operation 42 A 6 Fuel system Safety instructions: The fuel tank must under no circumstances be allowed to run completely empty. If the tank does run empty, a very time-consuming start-up procedure for the diesel engine system will have to be followed. In addition, for safety reasons, ensure that the fuel level is sufficient for the planned work, as a dangerous situation could arise if the diesel engine comes to a standstill during crane or travel operation. During refuelling the diesel engine must be shut down. Operation: The fuel system comprises the main tank in the chassis, the filling pump, and the day tank in the diesel engine room. The day tank is equipped with fill level sensors that switch the filling pump on when the fuel level is too low and switch it off again when the day tank is full. The main tank also has fill level sensors which will trigger a fault message on the work monitor when the fuel falls below a certain level and trip a limit switch which can be connected to the fuel tanker and used to switch off the refilling process when the tank is full. The fuel level is indicated as a percentage on the work monitor and on the display instrument in the driver's cab. Tower Cab: Fuel shortage is indicated on the monitor as a fault message and by means of a buzzer on the operating panel. When the fault message appears, there are approximately 330 litres of fuel left in the day tank, which is sufficient for approximately 4 hours of operation at average loading. Refuelling: The filler neck is located in the middle of the chassis. Open the cover of the filer neck, connect up the hose, plug in the plug for the switch-off contact, and open the shut-off valve. When the tank is full, the red lamp next to the filler neck lights up and the fuel feed from the tanker is shut down. Stop refuelling and replace the cap. 7 Tower /| boom system Safety Instructions: During operation, there must be no one on the stairways and platforms. When you leave the tower cab, always lock the door. The crane travel must not be travelled with the boom lowered. The crane must not be travelled with a load. To ensure uniform loading of the axles, the crane may be travelled only with the boom at the specified radius. Visual check: Before each start-up, check the stairways, platforms and handrails for firm seating. Check the rope guide in the tower head rope pulley set. Check also for loose bolted connections and any other damage to the tower. 2424 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Travel Operation 42 A 9 Superstructure hydraulic system Safety instructions: The hydraulic oil becomes very hot during operation. Do not touch pipes or hydraulic units. Please note that parts of the system are under high pressure. Leaks and other faults in the hydraulic unit must be repaired only by suitably qualified maintenance personnel. Visual check: The hydraulic oil tank in the superstructure is equipped with a fill level sensor and a temperature sensor. If the fault message “oil level too low” appears, travel ‘operation must be started only when the required oil quantity has been added. If the fault message “oil temperature too high” appears, check the oil cooler, the circulating pump and the cooler fan. The oil level as read in the sight glass is dependent on the temperature of the oil and the position of the boom. Depending on the oil temperature and whether the boom has been set down on the ground or is at the smallest radius, it is necessary to read off the oil level at the corresponding symbol in the sight glass. Add oil if necessary. Also check the visual clogging indicators on the filters. When the system is running, none of the indicator pins must be visible. Check the hydraulic unit, the valve blocks, the rotary lead-through, the travel drive motors, the steering, the brake system and the stabilisers as well as pipes and hoses for leaks and damage. The stopcocks in the feed and return lines are electrically monitored and have to be open. 10 Stabilisers Safety instruction: Use caution near the stabilisers. Danger of crushing. For safe travel operation, it must be ensured that the stabiliser pads cannot become detached from the jack cylinders. When the ground is very uneven, the stabiliser pads may have to be lashed to the stabiliser beams to prevent them from swinging. Description: The stabilisers consist of the stabiliser pads, extension cylinders, the jack cylinders and the stabiliser pads. The stabiliser beams are extended and retracted by means of extension cylinders. Lowering of the stabiliser pads to the ground and propping (raising) of the crane are carried out by the jack cylinders, as is the reverse process. For travel, the stabiliser pads must be fully raised and the stabiliser beams must be retracted until a message is given by the sensors. Visual check: Check all the extension cylinders, jack cylinders, stabiliser pads and electrical and hydraulic connections for firm seating, damage and leaks. Winter operation: ‘At subzero temperatures, there is a danger that the entire stabiliser pad area may freeze to the ground if itis damp. in this case, itis not permitted to raise the stabiliser pads. 2524 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Travel Operation 42 11 Superstructure / chassis locking device Safety instruction: The locking device can be unlocked only when the crane is propped. In addition, it is not permitted to unlock it in winds exceeding force 9 on the Beaufort scale, Description: The superstructure / chassis locking device protects the crane in travel operation. When parked, the crane must be locked for protection against storms. The crane can be locked in the forward and rearward longitudinal positions. The correct longitudinal position is indicated on the monitor. Locking is possible only when 0.0 or 180 degrees are indicated, i.e. the longitudinal position has been reached. The mechanical locking device is actuated by means of a hydraulic cylinder and monitored by means of limit switches. 12 External power supply with cable reel (option) Safety instructions: It is imperative that the external power supply is connected / disconnected by qualified personnel only. The crane must be de-energised. Check the external fuse and the voltage before starting the extemal power supply. Itis imperative that only extemal power supply connections in perfect condition are connected and that the cable strain relief devices are used properly. Operation: With the external power supply, the crane’s internal electrical system can be supplied with power from an extemal electrical system. The diesel engine and the generator are switched off when the external power supply is being used. Travel operation is possible to the maximum extent of the cable. When the maximum travelling distance of approximately 50 metres has been covered, travel operation switches off. The 3/PE~440V/60Hz external power supply must have external protection. The external power supply cable and the external fuse must be designed for the maximum power capacity of the crane. To connect the external power supply: With the crane running in generator mode, position it at the power supply-in point such that it will require as little steering as possible when it travels along the quay in mains mode. Leave the diesel engine and the crane master switch on and coil the cable manually using the buttons on the cable deflector. To do so, activate the key-operated switch and then press the uncoil button until the required length of cable is uncoiled. Then switch off the crane master switch, shut down the diesel engine and set the changeover switch to its neutral position, Next, plug in the plugs and, if necessary, switch on the two isolating switches in the electrics box. Then, set the changeover switch to mains mode and switch on the crane master switch. Continued on next page 2624 1704 00 G HMK 4406 Mobile Harbour Crane Opera’ g Manual Requirements for Travel Operation 42 To disconnect the external power supply: With the crane running in mains mode, position it at the power supply-in point such that as little cable as possible will need to be coiled. Switch off the crane master switch and set the changeover switch to its neutral position. Now you can disconnect the plugs of the external power supply. Then set the changeover switch to generator mode and start the diesel engine. Now switch on the crane master switch and coil the cables manually with the buttons on the cable deflector. To do so, activate the key-operated switch and then press the coil button until the cables are coiled. 13 Electrical system Safety instructions: The operating company must ensure that only qualified electricians enter the electrics room, Before visual checks are started, disconnect the auxiliary power supply and remove the main battery switch handle and take it with you. ‘Observe the information in the manuals on the essential components: the crane master switch, the Simoregs, the changeover switch and the PLC. In addition, carry out the maintenance instructions outlined in these manuals. Checks: ‘Check all components for external damage and firm seating. Check the generator for unusual noises and proper ventilation. Before operation, check all emergency stop buttons and lighting for proper functioning. Summary After you have checked all the points listed and ensured there are no faults, you must also ensure that the following conditions are satisfied: If you wish to begin travel operation, the superstructure must be in the desired longitudinal position and locked to the chassis. The description can be found in section 5.1.1. The boom must be in the prescribed position for the attached lifting gear. The lifting gear must be secured against swinging. The jack cylinders must be completely retracted. The description can be found in section 5.2.1. The auxiliary power supply must not be plugged in. The external power supply must not be connected. The instructions can be found in section 4.2 (3 and 12). The individual operating steps can be found in the following sections. Continue with section 4.4. 2724 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 This section describes the checks that must be performed, and requirements that must be met, if you wish to start your work with crane operation. The item numbers below refer to the item numbers in the “General Drawing with Check Locations” in section 4.1. The drawing shows the installation locations of the components to be checked. Before the checks are started, switch off the crane master switch if it is on (section 4.7) and then switch off the diesel engine if it is running (section 4.6). eNoanon " 12 13 Central lubrication system ‘Auxiliary power supply... Diesel engine system. Ropes Fuel system. Tower / boom system. Limit switches... - ‘Superstructure hydraulic system Stabilisers 7 Superstructure / chassis locking device External power supply Electrical system. 2824 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 A Checks The drive and supply systems must always be checked before crane operation. Crane operation is permitted only after these checks have been carried out. As an aid, you may use the General Drawing with Check Locations, in which you will find the locations of the items listed, 2 Central lubrication system Safety instructions: Danger. If a fault message appears, the crane must be shut down and the fault remedied immediately. If the pivot points are not adequately lubricated, damage will result. Operation: Display: {f insufficient grease is indicated on the monitor in the tower cab or by the buzzer, the grease level and the function of lubricating nozzles must be checked immediately by qualified maintenance personnel. To check the grease level: Open the grease supply tank covers in the superstructure. If approximately 2/3 of the grease has been used, the grease must be topped up immediately by qualified maintenance personnel. 3 400 V/ 50 Hz auxiliary power supply Safety instructions: Before the plug of the auxiliary power supply is removed, all electrical equipment and the crane diesel engine must be switched off. As all the air conditioners, heaters, preheaters, the PLC and the battery charger are run on the auxiliary Power supply when the crane master switch is switched off, the auxiliary power ‘supply must be plugged in if the crane is to be left with no external power supply connected. The harbour-side connection must be protected with 63 A fuses. Operation: Ensure the auxiliary power supply is not connected during crane operation. The connection is located on the chassis. When the auxiliary power supply is Plugged in, the red indicator lamp in the driver's cab will light up. Disconnecting the auxiliary power supply: Loosen the retaining ring and pull out the plug. Then firmly close the plug’s Protective cover again to prevent moisture and dirt entering. 2924 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 A 4 Diesel engine system Safety instructions: Danger of burns. The engine, coolant, engine oil and exhaust ‘system become hot during operation. For checks and maintenance work, the engine must be ‘shut down and secured against restarting. Wait for the engine to cool down before you touch it. Operation: Visual check: Check the diesel engine and the corresponding radiator unit in the ‘superstructure for visible damage and external leaks. Engine air filter: Check the clogging indicators. If one or both indicator rings is / are in the red Zone, the air filter / filters in question will have to be replaced even if the normal maintenance interval has not elapsed Oil level: Check the cil level on the oil dipstick. The exact oil level is not indicated until the engine has been stationary for at least 20 minutes. Caution. Some engines have two marks, one for idling and one for standstill. Ensure that you refer to the correct mark. Additional check points: If any of the following faults occurs, it will be indicated in the cabs: coolant level too low or too high, coolant temperature too high, diesel engine oil pressure too low. In the tower cab, a fault message will appear on the monitor and a buzzer on the operating panel will sound, In the event of any of these fault indications, ‘witch off the diesel engine and remedy the fault. If you do not switch off the diesel engine, it will be switched off automatically shortly after the fault is indicated. On the diesel engine room control panel, the various statuses are shown on the display when the corresponding keys are pressed. The following points must be recorded by the crane operator and the maintenance department advised accordingly: Low oil pressure Low output High coolant or oil temperature Unusual noises Heavy smoke Excessive consumption of coolant, fuel or oil Fuel or oil system leaks NOgaene 3024 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 A 5 Ropes Safety Instructions: Before start-up, always carry out a thorough visual check. Danger. Maintain sufficient distance between yourself and the rope when carrying out checks during operation. The ropes are not to be touched under any circumstances. Visual check Before start-up, and when function tests are being Performed, watch out for damage such as crushing it 6 Fuel system Safety instructions: The fuel tank must under no circumstances be allowed to run completely empty. travel operation. Operation: Zqhe fuel system comprises the main tank in the chassis, the filing pump, and the day tank in the diesel engine room. The day tank is equipped with fil level ‘sensors that switch the filling pump on when the fuel level is too low and switch it off again when the day tank is full. The main tank also has fill level sensors which will trigger a fault message on the work monitor when the fuel falls below 2 certain level and trip a limit switch which can be connected to the fuel tanker and used to switch off the refiling process when the tank is full, The fuel level is indicated as a percentage on the work monitor and on the display instrument in the driver's cab. Tower Cab: Fuel shortage is indicated on the monitor as a fault message and by means of a buzzer on the operating panel. When the fault message appears, there are approximately 330 litres of fuel left in the day tank, which is sufficient for approximately 4 hours of operation at average loading. Refuelling: The filler neck is located in the middle of the chassis. Open the cover of the filer eck, connect up the hose, plug in the plug for the switch-off contact, and open the shut-off valve. When the tank is full, the red lamp next tothe filer neck lights P.and the fuel feed from the tanker is shut down. Stop refuelling and replace the cap. 3124 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 A 7 Tower / boom system Safety Instructions: During operation, there must be no one on the Stairways and platforms. When you leave the tower cab, always lock the door. The crane travel must not be travelled with the boom lowered, The crane must not be travelled with a load, The crane must only be travelled when the boom is at the Specified radius in Order to ensure that the load on the axles is evenly distributed Visual check: Seating. Check the rope guide in the tower head rope Pulley set. Check also for loose bolted connections and any other damage to the tower. 8 Limit switches Safety instructions: Warning. Function tests before the start of actual work must always be Performed without a load. It must be ensured that there are No persons in the danger area. Limit switches must not be bypassed, Description: Slack rope switch: Uf the load or the liting gear is set down and the lowering motion is continued, the last rope loop wil ft off the drum and actuate the slack rope Init euren This will cause the lowering motion to be switched off. tnate corresponding fault message is displayed, tur the key-operated switch on the machinery room control box to the rigging mode position” Then, using the Hotetieg ontol operate the hoist until the ropes are correctly coiled again: Hoisting and lowering limit switches: jen the rope is being coiled on or uncolled from the rope drum, the hoist ‘speed Boom limit switch: Fitted to the tower of the crane are an incremental encoder and an angle encoder, which communicate the boom position and angle to the crane control and the electronic overioad cut-out system in a dual modular redundant system. If the boom is luffed to the maximum or minimum radius, the luffing speed is reduced shortly before the limit position, and then, at the limit position, the luffing Motion is stopped. Operation: Function test: Zhe limit switch functions must be checked before crane operation is started, For this, slowly approach the pre-imit and main limit positions with no load ancl check whether the programmed “limit switches" switch off property, Continued on next page 3224 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Limit switch test Safety instructions: The software-type limit switches may only be triggered without a load. \rregularities during speed reduction or switch-off must be reported immediately io Gottwald Port Technology's Customer Services Department. If any such irregularities should occur, the crane must not be operated Operation: Limit switch test Press F8 to switch from the start screen no. 1000, to screen no. 8000, and then press F to switch to screen no. 8500. Now keep Fé pressed and trigger the limit Sanches so that the switch symbols change from green to red. Acknowledge with F8 and move away from the limit positions again, Emergency limit switch When the hoist limit switch is triggered, fault message F19 is output by the hoist Simoreg (11.H-G11). For safety reasons, this fault message can be set only by tuming the key- poetated "Bypass Limit” switch (1) and then pressing the acknowledge button on the control panel on the Simoreg unit. 3324 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 9 Superstructure hydraulic system 43 Safety instructions: A The hydraulic oll becomes very hot during operation. Do not touch pipes or hydraulic units. Please note that parts of the system are under high pressure. Leaks and other faults in the hydraulic unit must be repaired only by suitably qualified maintenance personnel. Visual check: The oll level as read in the sight glass is dependent on the temperature of the oil ind the position of the boom. Depending on the oil temperature and whether the boom has been set down on the ground or is at the smallest radius. it is Recessary to read off the oil level at the corresponding symbol in the sight glass. Add oil if necessary. Also check the visual clogging indicators on the filters, When the system is running, none of the indicator pins must be visible. Check the hydraulic unit, the rotary lead-through, the travel drive motors, the steering, the brake system and the stabilisers as well as pipes and hoses for leaks and damage. The stopcocks in the feed and retum lines are electrically monitored and have to be open. 10 Stabilisers Safety instructions: Danger. After automatic propping, itis imperative you ensure the crane is level, If necessary, adjust the stabilisers to level the crane. Danger. The stabilisers may not be raised in winds exceeding force 9. The inclination of the Propping area imust not exceed 2.5%. Use caution near the stabilisers. Danger of crushing. Description: The stabilisers consist of the stabiliser pads, extension cylinders, cylinders and the stabiliser pads. The stabiliser beams are exten the jack ded and retracted by means of extension cylinders. Lowering of the stabiliser pads to the ground and propping (raising) of the crane are carried out by the jack cylinders, as is the reverse process. For crane operation, the crane must be propped to a height such that there is no id acting on the wheels. Adjust the individual stabilisers unti the crane is in the horizontal position. This is possible using the automatic levelling function after the automatic propping process. Visual check: Check all the extension cylinders, jack cylinders, stabiliser pads and electrical and hydraulic connections for firm seating, damage and leaks. Winter operation: At subzero temperatures, there is a danger that the entire stabiliser pad area may freeze to the ground if tis damp. In this case, itis not permitted to raise the stabiliser pads.24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 A 11 Superstructure / chassis locking device Safety instructions: The locking device can be unlocked only when the crane is propped. In addition, itis not permitted to unlock it in winds exceeding force 9 on the Beaufort scale’ Description: The superstructure / chassis locking device protects the crane in travel operation. When parked, the crane must be locked for protection against storms. The crane can be locked in the forward and rearward longitudinal positions The correct longitudinal position is indicated on the monitor. Locking is possible only when 0.0 or 180 degrees are indicated, i.e. the longitudinal position has been reached. The mechanical locking device is actuated by means of a hydraulic cylinder and monitored by means of limit switches. 12 External power supply with cable reel (option) Safety instructions: {t's imperative that the external power supply is connected / disconnected by Qualified personnel only. The crane must be de-energised. Check the external Protection and the voltage before starting the external power supply. {tis imperative that only extemal power supply connections in perfect condition are connected and that the cable strain relief devices are used property. Operation: With the extemal power supply, the crane’s internal electrical system can be supplied with power from an external electrical system. The diesel engine and the generator are switched off when the external power supply is being used. Travel operation is possible to the maximum extent of the cable. When the maximum travelling distance of approximately 50 metres has been covered, travel operation switches off. The 3/PE~440V/60Hz external power supply must have external protection. The external power supply cable and the extemal fuse must be designed for the maximum power capacity of the crane. To connect the external power supply: With the crane running in generator mode, position it at the power supply-in point Such that it will require as litle steering as possible when it travels along the Guay in mains mode. Leave the diesel engine and the crane master switch on and coil the cable manually using the buttons on the cable deflector. To do so, activate the key-operated switch and then press the uncoil button until the fequired length of cable is uncolled. Then switch off the crane master switch, shut down the diesel engine and set the changeover switch to its neutral Position. Next, plug in the plugs and, if necessary, switch on the two isolating Switches in the electrics box. Then, set the changeover switch to mains mode and switch on the crane master ‘switch. Continued on next page 3524 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 To disconnect the extemal power supply: With the crane running in mains mode, position it at the power supply-in point such that as litle cable as possible will need to be coiled. Switch off the crane master switch and set the changeover switch to its neutral position. Now you can disconnect the plugs of the extemal power supply. Then set the changeover Switch to generator mode and start the diesel engine. Now switch on the crane master switch and coil the cables manually with the buttons on the cable deflector. To do so, activate the key-operated switch and then press the coll button until the cables are coiled. 13 Electrical system Safety instruction: A The operating company must ensure that the electrics room is only accessed by Qualified electricians or workers instructed by electricians. Before visual checks are started, disconnect the auxiliary power supply and remove the main battery switch handle and take it with you. Observe the information in the manuals on the essential components: the crane master switch, the Simoregs, the changeover switch and the PLC. In addition, carry out the maintenance instructions outlined in these manuals. Visual check: Check all components for external damage and firm seating. Check the generator for unusual noises and proper ventilation. Before operation, Check all emergency stop buttons and lighting for proper functioning. Gearbox Safety instructions: Before the checks, the crane must be shut down and secured against being Switched on again. Should any defects be found, these must be rectified before crane operation. Please observe the information in the manufacturer manuals. Visual checks: Slewing gear Check the slewing reduction gear unit for correct oil temperature, noise changes, sealing and correct oil level. Visual check of the brake linings and disc. Check residual stroke on the brake release device when the brake is applied (see Sibre). Check preset braking torque when the brake is applied (see Sibre). Hoist Check the correct oil level and the breather filter. Check the gearbox to ensure there are no leaks and report any changes in the behaviour of the gearbox, including noises. 3624 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Requirements for Crane Operation 43 Summary After you have checked all the points listed and ensured there are no faults, you must also ensure that the following conditions are satisfied: When you wish to begin crane operation, the crane must be propped in such a way that there is no load acting on the wheels. The instructions can be found in section 5.2.1. ‘The superstructure must be unlocked from the chassis. The instructions can be found in section 5.1.1. The auxiliary power supply must not be plugged in. The instructions can be found in section 4.3 (3). When the crane is in mains mode, the extemal power supply must be connected. The instructions can be found in section 4.3 (12). The changeover switch must be in the “mains mode" position. The instructions can be found in section 4.4. During generator operation, the extemal power supply may be connected, but the changeover switch must be in the ‘generator mode" position. The instructions can be found in section 4.3 (12) and section 4.4, Continue with section 4.4. 3724 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Changeover Switch (Option) Safety instructions: The changeover switch may only be operated when the crane is completely ‘switched off. The switch must be in the neutral position when work is performed on the electrical system. The changeover switch must be secured with a padlock. If the crane operator also operates the changeover switch, he must be trained accordingly by a qualified electrician and trained in the dangers of electrical current. Operation: The padlock must be removed to change operating modes. When the handle is tuned in the appropriate direction, the required operating mode is selected. The changeover switch can be locked in the neutral position. The changeover switch for generator and mains modes is located in the electrics room. The changeover switch has three positions: “mains”, “neutral” and “generator. When the changeover switch is in its “mains” position (3) and the external power supply is connected, all crane motions can be carried out. Travel operation is possible to the length of the cable. When the changeover switch is in the “generator” position (1), all travel and crane motions can be carried out When the changeover switch is in the “neutral” position (2) and the auxiliary power supply is not connected, the crane is de-energised. 3824 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Main Battery Switch 45 Safety instructions: Warning. Danger of acid bums. Batteries contain acid. The main battery switch can be secured only by removing the handle and taking it with you. Operation: The main battery switch is mounted to one side of the diesel engine. Main battery switch “ON": Insert the main battery switch handle and tur it 90°. Main battery switch “OFF”: Tum the main battery switch handle 90° and pull it out. 3924 1704 00 G HM Opera K 4406 Mobile Harbour Crane ting Manual Starting / Stopping the Diesel Engine 46 wz Sat Safety instructions: Prior to starting the diesel engine, ensure that there are no persons in the danger area. To ensure proper operation of the engine, the engine must not run off-load for extended periods. After high-load operation, do not switch off the engine immediately but allow it to idle (for approximately 5 minutes) to cool down. Operation: Diesel Engine Room: “Start” diesel engine: ‘Tum the selector switch to “internal”, then insert the ignition key, turn it to the limit Position, and hold there until the engine starts. As soon as the engine starts, release the key. “Stop” diesel engine: Press the “stop” button. Then remove the key and set the selector switch to “external”. Driver's cab: “Start” diesel engine: Insert the ignition key, tum it to the limit position, and hold it there until the engine starts. As soon as the engine starts, release the key. If the engine does not start, switch off the ignition, wait 30 seconds and try starting again. “Stop” diesel engine: ‘Tum the ignition key to the “stop” position. Continued on next page 4024 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Starting / Stopping the Diesel Engine 46 correo wets &. tie : A L 0,0 Hz} ov fe al moe ps Tower Cab: “Start” diesel engine: Insert the ignition key, tum it to the limit position, and hold it there until the engine starts. As soon as the engine starts, release the key. If the engine does not start, switch off the ignition, wait 30 seconds and try starting again. “Stop” diesel engine: “| Tur the ignition key to the “stop” position. Please note the following: The cab where the ignition key was first inserted and tured out of the zero Position takes priority, i.e. this cab is active and the other is disabled. The diesel engine can be switched off from any of the above locations. The control software is booted when the diesel engine is started. While the software is starting up, the start screen no. 0000, showing the software version and the crane type, is displayed. When the control system and the computer communication are ready for operation, i.e. after approximately to 5 minutes, the software switches automatically to the start screen no. 1000. Communication readiness is indicated by the flashing frame around the screen number in the bottom right comer. ‘Screen 1000 indicates the fuel level, the voltage, which cab is currently active, and the frequency. Press F1 to switch to the crane operation screen and F2 to switch to the travel operation screen. Press F4 to switch to the service screen no. 7000 and F6 to change to the log-in screen. Press F9 to switch to the inverse image for night-time operation. Continued on next page “124 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Log-in 4.6.1 karl Kranf¥hrer Itis important to log in to the crane software so that the statistical functions can be used. In the log-in screen no. 0001, use F2 and F3 to select your shift. Use F5 and F6 to select your name and F8 and F9 to select the lifting gear currently attached. You will only be able to select lifting gear which is included in the current group. In other words, if the hook rotator is currently attached, you will only be able to select hooks 1 to 9. The same applies to the other types of lifting gear. After you have made your selection, press F1 to confirm your entries. The control system will now display the start screen no. 1000 again. The screens for creating new crane operators, shifts and lifting gear can only be used with the computer and keyboard in the electrics room. The description can be found in section 7.17 of this manual. 4224 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Crane Master Switch ON / OFF 47 Ir — rol Safety instructions: When you switch the crane master switch on or off, observe the following ‘sequence. Before switching on, ensure all the joysticks are in the zero position. Before switching off, ensure all the drives are stationary. Operation: If the maintenance / inspection switch is set to “O", the superstructure hydraulic pump and the boom cable reel will automatically switch on and off together with the crane master switch. If the maintenance / inspection switch is set to “I, the superstructure hydraulic pump and the boom cable reel must be switched on manually when required. Insert the ignition key and turn on the ignition (even in mains mode). If the diesel engine has not been started, start it. Then you can switch on the crane master switch. To switch off, press the crane master switch “OFF” button. Tower cab: The crane master switch “ON" and “OFF” buttons are located on the right-hand control panel, Crane master switch “ON" = green Crane master switch “OFF” = red Press the “ON” or “OFF” button as required. The state “ON” or “OFF” is indicated by means of LEDs on the buttons. Continued on next page24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Crane Master Switch ON / OFF 47 Driver's cab: Before the remote control in the driver's cab can be used, it must be logged in, as described in section the “Remote Control”. Press button (3) to switch the master switch ON. The two-colour LED (2) will light up green. Superstructure Electrics Room: The crane master switch “ON” and “OFF” buttons are located on a switchgear rack near the electrics room door. Crane master switch “ON" button (1) Crane master switch “OFF” button (2) | (green) (red) The “crane master switch “ON / OFF” buttons in the superstructure electrics room are intended for maintenance and repair work. |fneither of the joysticks in the tower cab is operated for a period of five minutes, the main isolator will be automatically switched off.24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Maintenance / Inspection Switch 48 Safety instructions: Ensure that the key-operated switch is in the zero position during crane operation. Operation: The maintenance / inspection switch is located in the hoist room control box next to the access door. It is a two-position key-operated switch. When the maintenance / inspection switch is in the zero position and the crane master switch is switched on, the boom cable reel is also automatically activated. If the maintenance / inspection switch is in the ON position, the cable reel must be switched on manually. This operating position is for maintenance work, The limit switch of the cable reel is bypassed when the switch is in this position. 4524 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Visumatic Symbols 49 In the further course of this Operating Manual, the monitor screens and symbols will be shown and explained. Each symbol refers to the function key below it on the monitor housing. If you wish to change from one operating mode to another or to satisfy a condition, press the respective function key until the frame around the symbol tums green or the symbol background tus green. re Consent aa Travel operation No fault message active Fault messages active Hoist low speed Hoist high speed Automatic mode Manual mode Acknowledge fault message Caution - condition not satisfied Stabiliser menu ‘Superstructure locked to chassis Oe » Ah ss ® c ‘Superstructure unlocked from chassis ‘Screen for the boom cable reel Retum to previous screen Production statistics Anemometer Fuel indicator Electronic level Slewing gear speed: fast ‘Slewing gear speed: slow 4624 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Travel Operation 5. In this section, you will find all the information you require for travel operation. Listed in sequence below are all the menus in which settings must be made, or conditions met, before crane travel can commence. If a certain switching state or requirement has already been met, the software will skip over the respective menu. This section is divided into conditions for travel operation, and travel operation itself; which operating steps are necessary will depend on the state of the crane: 5A 5.14 5.1.2 5.1.3 514 5.2.1 5.2.2 5.23 Conditions for Travel Operation.. . Superstructure / Chassis Locking for Travel Operation. Radius for Travel Operation. Operating the Stabilisers for Travel Operation from the Tower Cab .. Operating the Stabilisers for Travel Operation from the Driver's Cab Travelling ... Steering Braking.. 4724 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Conditions for Travel Operation 51 In this section, the individual operating steps required for the operation of the crane are described. It is assumed in these sections that the checks have been carried out. If they have not, then, before you travel the crane, perform the checks as set down in section 4.2 ‘Requirements for Travel Operation”. Once you have checked to ensure everything is in proper order and have selected the conditions for travel operation using the F2 key in the start screen, the following requirements must be met: ae | 6a Ke ~~ sm 5 ba In this screen, when a condition has been satisfied, the field next to the relevant ‘symbol turns green. The following conditions must be satisfied: 1 = The service mode key-operated switch is in the zero position (see section 5.14.1 of the Maintenance Manual) 2= The auxiliary power supply is not connected (see section 4.2/4.3 (3), in the Operating Manual) 3= The tower cab ignition key is set to ON (see section 4.6 of the Operating Manual) The diesel engine is running (see section 4.6 of the Operating Manual) The cable reel symbol is shown. This means the external power supply is connected and the changeover switch is in the ‘mains mode” Position. (see section 4.4 of the Operating Manual). 5= The crane master switch is ON (see section 4.7 of the Operating Manual). 6 = The hydraulic pump is running (see section 4.7 of the Operating Manual) Once all the conditions have been satisfied, press the F1 key to jump to the crane travel operation screen. The monitor screen no. 1500 appears. (Number bottom right) Continued on next page 4824 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Superstructure / Chassis Locking for Travel Operation 5.1.1 Safety instructions: The superstructure can be slewed and unlocked only when the crane is propped. In addition, it is not permitted to unlock it in winds exceeding force 9 on the Beaufort scale. Operation: To move the superstructure to its longitudinal position relative to the chassis, it must be rotated as specified under “Crane Operation - Slewing’. To check whether the superstructure and chassis are in the correct longitudinal position, the bottom limit switch symbol (1) must light up green in the monitor display and either 0.0° or 180° must be indicated. To lock the superstructure and chassi * Check the monitor as to whether “superstructure and chassis unlocked” is indicated. The limit switch symbol (3) is green. + Press F2 on the monitor housing. The crane now turns automatically to the correct locking position, and the superstructure and chassis are locked. * Check the monitor as to whether “superstructure and chassis locked” is indicated. The limit switch symbol (2) is green. To unlock the superstructure and chassis: + Check the monitor as to whether “superstructure and chassis locked” is indicated. The limit switch symbol (2) is green. + Press F1 on the monitor housing. * Check the monitor as to whether “superstructure and chassis unlocked” is indicated. The limit switch symbol (3) is green. When the locking procedure has been completed, the monitor screen for the radius, i.e. the boom position, appears. (No. 1600). 4924 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Radius for Travel Operation 5.1.2 Safety instructions: Danger. Crane operation is prohibited in winds exceeding force 9. During crane ‘operation, it must always be ensured that there are no persons or objects in the danger area. Ensure that loads are lifted only vertically. Diagonal pull and pulling loads loose are prohibited. Operation: To ensure the required uniform axle loading, the boom positions are prescribed depending on the locking position of the superstructure (facing forward or to the rear). Two items of information regarding the radius are given on the monitor. The lower figure with the green arrow shows the required radius for travel operation clearance. The upper figure indicates the actual radius. The red arrow will indicate whether you need to luff in or out. You can move the boom to the required position using the joystick on the left- hand control panel. When you have run the boom to the correct radius figure, press F1 to move to the next display, no. 1700. If lifting gear other than that supplied with the crane is to be attached, you must find out how many tonnes the lifting gear weighs. Mark this value on the curve on the sign in the cab. The boom position required for travel operation can then be found in the numbers in the left-hand column. (Green lines serve as example). 5024 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Operating the Stabilisers for Travel Operation from the Tower Cab 5.1.3 faa Safety instructions: Danger. The stabilisers must not be raised and retracted in winds exceeding force 9. The inclination of the propping area must not exceed 2.5%. Use caution near the stabilisers. Danger of crushing. Please note that the emergency stop buttons on the chassis exterior stop travel operation but not stabiliser operation. The crane may only be propped at the propping base indicated in the Technical Data. The red line on the stabiliser must be positioned exactly under the vertical plate of the chassis. Operation: ‘Automatic mode: The symbol for automatic mode is displayed on the upper left-hand side of the monitor. To set the crane free-on-wheels, press F1. The four jack oylinders are now simultaneously retracted. Once the stabiliser pads have been raised, all the stabiliser beams are retracted simultaneously. When the stabilisers have been completely retracted, the next screen is invoked. Continued on next page 5124 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Operating the Stabilisers for Travel Operation from the Tower Cab 5.1.3 Manually: !f you wish to operate the stabilisers manually, press the F2 key. Manual mode is shown on the monitor on the top left-hand side. The assignment of the function keys is shown in the bottom line on the monitor. Each stabiliser can be selected individually according to its colour. When retracting the stabilisers, the crane ‘must first be lowered uniformly until the wheels touch the ground, before the stabiliser pads are fully raised, Then the stabilisers can be operated by means of the function keys. F7= arrow down: Lower stabiliser pad and prop crane. F8= arrow up: Raise stabiliser pad and set crane free-on-wheels. F6= arrows pointing in opposite directions: Extend stabiliser beams F9= arrows pointing towards each other: Retract stabiliser beams When all the stabilisers have been retracted, all the limit switch symbols (arrows) have tured green, press F1 to move to the next display. 5224 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Operating the Stabilisers for Travel Operation from the Driver's Cab 5.1.4 Danger. The stabilisers must not be raised and retracted in winds exceeding force 9. The inclination of the propping area must not exceed 2.5%. Use caution near the stabilisers. Danger of crushing. Please note that the emergency stop buttons on the chassis exterior stop travel operation but not stabiliser operation. The crane may only be propped at the propping base indicated in the Technical Data. The red line on the stabiliser must be positioned exactly under the vertical Plate of the chassis. In manual operation ensure that the stabiliser beams are extended uniformly and fully. Operatior The instructions on how to use the remote control can be found in section 9 of this manual. When the remote control is in the holder the crane can travel at normal speeds. Otherwise the speeds remain reduced. 5324 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Travelling 5.24 Safety instructions: If voice or visual contact with the banksman is interrupted, travel operation must be stopped immediately. If the crane is to be travelled on public roads, approval must be obtained from the relevant authorities. Special caution must be taken when travelling through narrow passages. Drive slowly. Travelling on ramps, embankments, etc. is prohibited. Longitudinal inclination during travel: max. 6 % Lateral inclination during travel max. 2.5% Caution - Travel operation is permissible only at wind forces up to and including 9. Travelling with load is prohibited. The lifting gear may remain on the ropes but must be lashed to the superstructure. Travel operation in the opposite direction is permissible only when the wheels have come to a stop. Before using the special travel position, the crane operator must ensure that the values set for travelling under high-voltage cables are sufficient. Operation: In the tower cab, the travel gear is operated by means of the right-hand joystick (travel joystick). If, after the travel gear has been stationary for a long time, travel Operation is disabled, operate the stabilisers briefly to refill the pressure accumulators. After terminating the travel operation you can switch the monitor to the operator guidance for crane operation by using button F1. Forwards: push the joystick away from you Reverse: __ pull the joystick towards you Continued on next page24 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Travelling 5.2.1 Driver's Cab The instructions on how to use the remote control can be found in section 9 of this manual. When the remote control is in the holder the crane can travel at normal speeds. Otherwise the speeds remain reduced. Turn on the (optional) camera monitor for reverse travel. The operation of the camera is explained in section 7.9. Travel operation The travel speed depends on how far you move the joystick towards the end Position. The further you move the joystick, the higher the crane speed. When you retum the joystick to its zero position, the travel gear hydraulics reduce the speed. Actuate the brake lever until the crane comes to a standstill. The parking brake is applied automatically when the wheels are no longer moving. Boom position If it is not possible to initiate travel operation, it might be because the boom is Not in the prescribed position. Move the boom towards the travel position. When that position is reached, the luffing gear stops and travel operation will be enabled. 5524 1704 00 G HMK 4406 Mobile Harbour Crane Operating Manual Steering 5.2.2 Safety instructions: Warning. The wheels do not automatically return to their central position. !f voice or visual contact with the banksman is interrupted, travel operation must be stopped immediately. Special caution must be taken when travelling through narrow passages. Maintain safety distances. Travelling on ramps, embankments, etc. is prohibited. When steering in mains mode, please bear in mind the position of the external power supply cable. Operation: From within the tower cab, steering is performed via the steering joystick. In the tower cab it is the joystick which has been assigned several functions for the slewing and luffing gears. The steering speed of the wheels depends on how far you move the joystick. Move the steering joystick in the direction in which you wish to travel. In other words: To move to the left: move steering joystick left ‘To move to the right: move steering joystick right When the steering joystick is released, it returns automatically to its central Position. This means that for straight-ahead travel after travelling in a curve, you must keep steering in the opposite direction until the wheels are in the straight ahead position. The instructions on how to use the remote control can be found in section 9 of this manual. When the remote control is in the holder the crane can travel at normal speeds. Otherwise the speeds remain reduced. 56