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    © All Rights Reserved
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    5 views34 pages

    Instruction Manual Deck Crane

    Uploaded by

    Bogdan Muresan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Instruction Manual Marine Crane MKG Maschinen- und Kranbau GmbH Daimler-Benz- Str. 6 49681 Garrel Germany Phone: +49 4474 897-0 Fax: +49 4474 897-10 E-mail: Info@MKG-Krane.de This instruction manual is not subject to the variation service 2013 Table of Contents Preface I Product Liability Chapter 1 ‘Accident Prevention Page 11 Directions for prevention of accidents Page 12 Distances to power transmission lines Page 13 Prevention of injuries by violent peessure Page 14 Behaviout in cae of defects Page 15 Chapter 2 Description of Components, ‘Valve system Substructure, slewing gear, Colum, jib system Operation of Rope winch Chapter 3 Control Units Page 3.1 Chapter 4 Crane Operation Stabilizers (hydraulichmanual) Page 4.1 Folding to transport position Page 42 Safety devices Page 43, = Overload protection Page 43 Emergency Stop Page 43, Radio remote control Page 4.3 = Bridging of emergency stop valve Page 44 = Load holding valves Page 45 Load Moment Limitation Page 4.6 Chapter 5 Chapter 6 Chapter 7 Maintenance of Crane Directive on Maintenance Work Greasing Lubricants Control of Oi! Level Oil Change High pressure Fiter Failures and their Causes Electrical Details Flectie Symbols Page 5.1 Page 52 Page 53 Page 54 Page 55 Page 5.6 Page 6.1 Page 7.1 PREFACE For operating the crane a certificate of qualification according to BVG D6 is required. This instruction manual provides information on the construction and performance of the crane as well as directives for safety at work, crane operation and maintenance. Descriptions and pictures contained herein are non-binding and we reserve the right to alter or amend any technical data or illustrations at any time. We shall not be deemed. obliged to change this instruction manual accordingly. ‘The crane corresponds to Machinery Directive 2006/42/EG, ce (CE: Symbol ‘This symbol is only valid in connection with a dectaration of conformity. If the construction of a loading crane should be modified (e.g. attachment of a rope winch, radio remote control unit, control platform or top seat et.) the CE symbol must be reissued (new declaration of conformity). Within the European Economic Area the crane is only allowed to be used with a valid CE symbol of its own as well as a valid declaration of conformity. Product liability In regard to the product liability we like to point out ‘+ Every manufacturer shall be hold lable fr is product. ‘+ -MKG Maschinen -und Kranbau GmbH excludes any ibility for damages caused by subsequent ‘modifications ofits product andlor unauthorised atachment of components sepplied by ther manufacturers, ‘© MKG is not responsible for damages caused by incorrect installation oftheir ranes including unsuitable foundations andor fixing materials. Any claims must be rejected i cases where the general rules of intemational engineering standard have not been followed. ‘The truck body manufacturer willbe liable for his product and will indemnify MKG Masehinen- und Kranbau GmbH from any liability for damages. ‘The company carying out the finalist professional accomplishment. ‘Regulations in terms of accident prevention, transport safety and operational safety are tobe observed. ‘Any furer information and regulations can be learned from the istallation guidlines ofthe respective ‘manufacturer ofthe vehicle, particularly in cases where modifications onthe vehicle are required lation of the crane wil in any ease be responsible for Chapter 1 Accident prevention ‘This operation manual should have been studied carefully before stating to opera the crane. “The erane operator must be aegusinted with all controls ofthe crane and motion nitsted as wel as all. unetions and safety devices. ‘Any precaution stickers must be placed at wel sighted locations atthe crane. “The national rls forthe prevention of accidents must be fllowed tel Allachments: Grab te ‘When the erne equipped with an atachment then the operation manual ofthe spective ‘manufacturer is valid Safety devices Under no circumstances may they be manipulated or suspended. “They have been developed for your protection to avoid accidents and ensure safety during work ‘Any sity devies, such as emergency shut-off, overload protection, load holding valve, overpressure valve et, have been adjusted by the manufacturer that way tha they ensure optimal operational safety. lation is detected on safety devices or damage onthe lead seals the manufacturer will decline any esponsibility! Directions for prevention of accidents! A manger! + ILis stietly forbidden to stay within the slewing range ofthe crane, regardless whether the eran is slewing with or without load, Prohibitive fences shouldbe arranged to prevert anybody o enter the slewing range of the eran. ‘+ Bulk goods may only be handled by the crane if'secured by nets or any other suitable means of protect ‘Bulk goods handled by fork lift attachment in higher altitude should be secured very caefill and ‘may only be offloaded after the erane as come to & complete standstill Danger! + Iimay be perilous or eause serious harm to use any damaged fixtures to secu the load, Caution! + Its essential o switch off the hydraulic pump. Otherwise, excessive amount of oi wil build-up 2 high pressure by to high motor speeds. This may caus lifting up of the boom and accidents Caution! ‘+The loading capacity isnot allowed to be increased by any measures as fr instance the hanging up and subsequent release of bad measurable loads, The erane vehile/Veselcovd tit over or unt "uncontgoled movements and deformations can appear. Danger ‘+ Incase of damaged seals at overpressure valves andor overload protection devices operation of the «zane i subject fo prior inspection by an authorised person ‘The crane operator signs responsible for untouched seals on the safety systems of the crane. Page 12 Distances to power transmission lines ‘At many operational areas there are dificult conditions because of power transmission lines. They mean fn increased danger to life during the whole crane operation. When lines are touched or when the load ofthe erane comes near tthe lines, then electric power wil pass over. Due to this the crane operator and the euxiliry personnel will get in danger tite Caution! In this case you have to induce that power supply is cut-off Ifitis not possible to stop power supply you have to keep a sufcient safety distance to the electrical lines. 7 Conceming heavy current plants and their oveshea lines you have to keep te following safety distances to the parts which are energized: Rated circuit voltage Safety distances Upto 1000 volts 100m “More than 1000 110000 volts 3.00.m, “More than 110000220000 volts 400m “More than 220000380000 volts 5.00, Atunknown voltage 5.00.m For contact lines of electri railways the following data apply’ Upto 1000 volts ac 100m More than 1000 volts ac som Upto 1500 volts de 100m ‘More than 1500 volts de som ‘nevertheless it has come to aflashover, the following instruction apply: ‘Danger to lifet «= Keep calm, do not leave the driver's cabin ‘Warn outside observers and urge them that they shall by no means touch the crane, the vehicle or the load = If possible try to bring the crane out ofthe danger zone by slewing it out ani then retract the ‘extensions. Ifthe crane is not working anymore, please do not leave the erane or the vehicle until ‘the power supply has been stopped. Page 13 jolent pressure Avoid situations where bystanders or you yourself could be squashed by the crane or the load ‘The situations shown below are not considered hazardous if these minimal clearances are observed and secured by safety measure. A Caution! ‘The non-abservance of these eleara or even danger to life, ss may lead to injuries juired minimum clearance: Body Les Foot am and Fae 500 mm | | 180 mm 120 mm 100 mm |[_25mm Permissible wind speed Depending onthe position of boom, boom length and the load area exposed to wind, crane operation up toa Beaufort force 6 wind (39 - 49 km/h) is permissible, Page 14 Behaviour in case of defects During work with the crane, always wate for mafunetion, Immediately cease crane operation when you notice the following faults on the rane, the load holding attachments or the carrying vehicle: ‘defects, damages or cracks on losd-beaing pats, bearings, hydraulic components or safety devices, + unusual noise unusually quick or slow crane movements ‘+ mulfuetion ofthe control system Operation of the crane is no longer safe when such disturbances ‘occur and may prove dangerous or even fatal. Page 1s Chapter 2 Description of Components 01.03. 02 1. Valve system 2: Substructure and slewing gear 5. Column 2 ibsystem 5: Hook «Winch The crane consists of the following six main groups: 1. Valve system 2 Substructure and slewing gest 3.Columa 4. Sib system 5. Wined 1. Valve Svstem All eylinders are double-ating, that means ol pressure can be given to both sdesof the piston Directional control valves in longitudinal bar construction allow astep-ess, senstive regulation of| ‘working speed which is obtained by a special separation independent of pressur-— of the feed flow of the pump in a consumer active-low and a residual ol low ld into the retum system, Heavy and bulky loads can be moved precisely. Additonaly, the lowering speed of the lifting and buckling cylinders in the valve blocks is limited ‘The way control block consists ofa terminal block, the single valve segments anda limit plate, These pars are held together by tension rod and are seafed with O-rings Inthe terminal block there are connections for pressure and return pipes, manometer connection as well asthe main pressure relief valve which contols the complete hydraulic plant of te erane to keep the pressure allowed Gaution: If the crane is operated with several functions a the same time, attention must be aid that te working speed ofthe other fuetion is increased when one function is switched off The segments of iting jb, slewing, extension and possible by-pass valves are equipped secondary with firmly adjusted pressure limiting valves. These ensure that the specific pressures rated are kept and serve ‘as shock valves. That means tha the pressure peaks which are caused by sudden shocks will be absorbed. Pressure canbe checked in such a way thatthe single working cylinders wll be driven to their ‘stop limit and the pressure is readable on a manometer then, Page 22 Inorder to avoid falling down of the boom in case of pipe fracture, an open-circuit guard is installed on the main boom at the connections ofthe lifting pipe. ‘Load holding valves atthe extension cylinders prevent an undesirable retraction of the extensions. The overcenter valves at lifting and jib arm have gota similar function. They ensure tat the lifting and jb ‘arm can only be lowered when the control valve starts the proces of lowering, Moreover, these bverventer valves ae reliable overload protection Substructure and slewing gear The substrcture of a crane is made of a solid steel construction which serves as sappoet forthe ball bearing slewing ring and the ol rotor. They are the hydraulic joint connecting element between the stationary andthe turing part of the erane. ‘An oil motor is diving a planetary gear by means ofa hydraulic brake. On the driving shaft ofthis gear there is a taothed wheel which engages with a ball bearing slewing ring with intemal toothing. Column The column serves as suppor forthe lifting cylinder, the lifting arm, the rope winch, the fop seat or cabin and the slewing gear and is made of solid steel construction, too. Jib System ‘The jib system consists ofthe main element lifting and jib arm with extension tubes manually or hydraulically extendable ‘Movement ofthe lifting arm is being effected by lifting cylinders which are fixedto the column. They are double-actng ike all cylinders and can therefore effectively support aperatio ofa grab, for example. ‘The jib cylinder is placed between lifting arm and jib arm. The outreach ofthe jbarm can be extended by either hydric or manual extensions which are siding on special plates. Page 23 5. Operation of Rope Winch “The rope has always tobe unreeled so far that twill not be damaged when the hy. extensions are moving out 2) Intermediate rolls have tobe mounted at manual extensions Jerky contol movements without any load have to be avoided Frmaton of lvps) «) The indicated load capacity data of the manual extensions must strictly be adhered to 4) possible the rope shouldbe reeled up under load 6 The rope has o be reeled up completey new every 4 weeks £) Rope, rope hook and fastenings have to checked or ifnecessary renewed regully 4) The il level ofthe winch has tobe checked weekly During lifting the load you have to pay attention that pul is vertical (angular pull). Page 24 Chapter 3 Control units ‘Control ofthe ene is caried out by either th hand lever atthe contro valve, the radio remote control ‘or by eable remote contol In the following the motion symbols wit the correspending motion directions ae showed Emergency control unit on column f slewing ight left — C f~ f Jing arm up down f f 5b arm up/ down { emsdeccnmn i 7 7 winch dos op For operating the radio remote control unit please refer to the manual of the remote control. Chapter 4 Start-Up In order to stant operation of the crane you have to actin compliance with the following order: 1. Before starting the auxiliary drive the parking brake has o be set; when woking at stopes 8 ‘cock has to be placed under the wheels 2. Stat auxiliary tive for hydraulic pump and increase motor speed to rotations which are necessary forthe pump 3. Forunfolding the crane, the msin boom mst be brought toa steep position 44. Then completely pl up the outer boom. 5. Now, the extension must be extended about 200 mm for unlocking the outer boom. 6, Then bing the outer boom into operating positon. 7. Nov, the single hydraulic extensions can be extended up to ther operating position. 8. Ifthe cranes equipped with an addtional jb and winch, then proceed as per ite 1108. Before the hydraulic extensions are now brought to operating positon the additonal jib ram has to be folded out [But for this purpose it is imperative that the rope ofthe winch wil belt off slighly so thatthe folding ‘out ofthe jib (de tothe respective kinematics) doesnot lead to inadmissible fores inthe winch system ‘which may result in damages. Moreover, attention must always be paid to proper guiding ofthe rope Incase of winch operation, te limit stop for liting must be bridged over. If this is not observed, the rane will switch to overload mode, i. extension of teescopic jib cylinders, [iting and lowering of jib and lowering of it cylinder will be impossible. Page. Caution! I the crane is “controled from the base, it must never be brought to operating position from the side here iis deposited (risk of injury), but always by means ofthe opposed contol uit Folding to Transport Position elding ha to be done in reversed order. However do not forget thatthe pump histo be switched off then, ‘The remaining overpressure inthe hydraulic system can be let out by movement ofthe valve operation. A Cautio Always fold the eran tits transport position Electrie swivel range limit 2 initators which are on a tour to the rotating column, dive over a so-alled link located on base) once the set, limited traverse from, Safety Devices MKG-cranes are serially equipped with following safety devices: Overload protection ‘According to § 24 ofthe accident prevention regulation for “outriger cranes" (BYG D6), overload protection is require forall cranes. Generally, inspection records are tobe issued forthe named cranes. “The principle proceeds from the assumption that the pressute in the Hifingeyliner wil ise inad- smissbly when the load moments to high. When reaching a certain limiting value the overload protection which s controlled by the sequential valve, blocks al functions which increase the load 1, Extending of extension ms 2 Extending of jib ram 5. Retraction of iting am By thie srrangement i is prevented that the system is overloaded with the load dropping ina not influenceable manner, if fr example the eran is overloaded and the pressure rei valves respond due toa pressure thats too high Emergency Stop on Control Elements: ‘Immediately push the emergency stop in ease of uncontrolled movements or Jangerous situations! Reactvate the eran by pulling and engaging the emergency stop in its upper postion. The electric plant will then be switched on again, the emergency valve will close and the hydraulic system will be supplied with pressure A Caution! ‘When the crane is not operated, the emergency stop switch must be pressed! For cranes which are equipped with radio remote control, the key button Isto be set 1 7er0" Page 43 Bridging of the Emergency Stop Valve Inthe event of breakdown of power supply, the knurled wie tem 4) must be pressed down and ‘tumed to the ight ill engagement (bayonet lock). >) ae Bereney ep valve ed for bringing the crane in its transport position. Due to bridging ofthe valve the emergency switch won't work any more. So, no further erane operation is allowed. IMMEDIATELY inform the authorized repair shop! Paget This waring light lashes up a soon as 90 % ofthe load moment have been raced Inprevents overload and thus uncontrolled movements of ene in working situations where the load is increased by adding Saving of time! Avoid the unnecessary removal of excessive load, Optical indication of load moment Overload by lifting eylinder ‘When the main boom is brought tits maximum outreach, overload might be simulated. Now the main boom cannot be lowered any more. Tis situation canbe avoided by not extending it up ois limit stop, nevertheless this has happened the crane operator has to reduce the hydraulic pressure by means ofthe touch valve. The rane operator has to press the touch valve unl the contol lev for “lowes boom” has been unlocked again. Releasing the button, the contol valve will be closed again. See picture ‘Use push-button fo unbbek function SLOWER’ of main boom when the lifting cylinder is completely extended See operating instructions: “Overload by lifting eyinder”™ “Touch vale A Caution! ‘When working under load, the main boom must not fully be brought (ois lower limit stop as overload protection won't work inthis position Load holding valves (MKG cranes are equipped with foad holding valves tthe rams, ‘They area good protection against unintended or inadmissible drifting ofthe piston of a cylinder in load direction So, the risk of accidents caused by the drop of loads is excluded to allow safe working, Safety devices on control assemblies For preventing unintentional operation the contol units at MKGG cranes are equiped with safety bas. Page as Load Moment Limitation ( Oscillating Shift ) Principle of Load Moment Limitation ‘To avoid thatthe load moment is exceeded, the crane is equipped with a laad moment limitation. I the outer boom, independent ofthe position ofthe main boom, has reached a working position (Fig. 4) of more than (>) 0° to the horizontal, you only can continue work ‘when the load moment will be reduced, That means to lft the main boom, olf the outer boom Cr to retract the hydraulic extension tubes. Figure 1 \ ——— __ ber” a) ™ Ifthe outer boom has reached a working position (Fig. 2) of less than (<) 0° to the horizontal, you also only can continue work if the load moment is reduced. That means to lower the main ‘boom, to lower the outer boom or to retract the hydraulic extension tubes, Figure 2 2 unter 0° Page 46 Chapter 5 Maintenance of crane Directive on Maintenance Work A ‘aution! Before starting any maintenance work at the erane make sure you have secured th crane booms against ‘unintended lowering of same. The pressure onal pipes and hoses must be release before starting work ‘on the hydraulic sytem, ie. shut off the pumps fully retract all hydraulic eylind's and secure seme. Make sure that no hydraulic ol an disappea into the ground, Cl binders are to be carried along. ‘Any damaged hoses must be replaced without delay. Handholds, reads and platforms are to be kept fee from dirt, oil and ie risk of skidding). (Check all serv fittings Bearings ae tobe cleaned of excessive grease Cleanings Ifthe crane is leaned with high-pressure cleaner, sufficient distance must be ket between the leaning nozzle andthe crane as otherwise the crane might be damaged, Please note tht new eranes mustn't be cleaned with a high-pressure cleaner yet a their colour Jhas’t been filly hardened yet. (for at least 3 months) A Caution! Hydraulic hoses, electric eables, electric and plastic parts, labels as well a all besings never must be cleaned with a high-pressure cleaner. ‘The temperature ofthe water usd forthe high-pressure cleaner should not exceed 60 °C. ‘Don't use cleaner solvents as they may cause porosity ofthe hoses. [Never use aggressive detergents! Important! ‘A careful and conscientious maintenance ofthe crane guarantees trouble-free opeation and an extended service life Pages. Caution! ‘The greaser nipples must be cleaned before greasing! Greasing of the erane always must be done in motion mode. Item on i 03 04 0s 06 07 08 Description column base column, toga lever Titing cylinder togele lever lifting arm toggle lever lifting arjibeylinder ‘column lifting cylinder Tifting arb arm {ib arm steering lever lifting amyjib arm lifting ann/stocring lever ibamm - extension T jib arm- extension I jb atm - extension IT jb arm extension IL jib arm - extension I jib arm - extension I jib arm extension 1 jib arm extension I columliting arm roller bea, load hook winch Frequency every week every week every week every week every week every week every week every week every week every week ‘when needed ‘when needed ‘when needed ‘when needed ‘when needed ‘when needed ‘when needed when needed every week every day every week age 52 prease grease prease wrease rease rease arease spread with grease grease spread with grease grease spread with grease srease spread with grease grease damage check srease ‘see instetion manual Lubricants Specification of hydraulic oil: Utilisation ofthe appropriate hydraulic ol sof fundamental importance in regardto the well-funeton and life-time of «crane High standards are st regarding frothing, deacation, viscosity, temperature gradint, point of emulsion, aging resistance as well s neutral reaction toward metals and seas. ‘To facilitate the right choice, different classes of viscosity have been introduced ‘The code number corresponds tothe average viscosity value (ma a 40°C). We differentiate: vor etic conditions or extremely long supply pipes vox \wintr conditions in Central Europe vos summer conditions in Central Europe or closed buildings vo ‘topical conditions or closed buildings with high temperature va 100 extremely hot climate Ex works supplicd ol is Aviatic HLP 1S0 46 Characteristis: incmatic visosity Acaore 46 mls ST) aci00°C 10 mms Pour point 248 Flashing pot 210°e Ant-corosion agent: suicient Page 53 Maximum permissible oil temperature for limit of viscosity min. 10 mm (e ST) + 80°C “Minimum stating temperature far limit of viscosity max. 1500 mms (e ST) -15°C (On marine cranes higher rust prevention degree is used Hydraulic Oil Comparison Chart Other manufacturers and ther oi types of similar viscosity classification: “ARAL —[— SHELL BP ESO) TEXACO ‘TAM GF a [TELLUS OIL 46 [BARTRAN TVG [MOBIL D.1. E25 [RANDO OU HD BG ‘The alternative! Biodegradable hydraulic oi: KAJO HEES 46 Lubricating grease BP Esso FINA MOBIL. Enerprease Exon EP Mobilux LSEP EP2 9346 Lubricants used by manufacturer: Fuchs LZR 2 for bearing, bushi multipurpose ge. with graphite for extensions “roller bearing grease L223 for base A ‘Caution! Oils alvays have tobe collected and disposed of If ol reaches the soil it will conaminate the drinking vate Important! The oil reservoirs for refilling oi have to be fre from any residues. Control, drin and

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