Kobelco 7250-2F Crane Operation & Maintenance Manual S2JD01002ZE25 – PDF DOWNLOAD
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Kobelco 7250-2F Crane Operation & Maintenance Manual S2JD01002ZE25 – PDF DOWNLOAD
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Pages : 500
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Kobelco 7250-2F Crane Operation & Maintenance Manual S2JD01002ZE25 – PDF DOWNLOAD
SAFE OPERATING PRACTICES FOR MOBILE CRANES:
INTRODUCTION:
- Because cranes have the ability to lift heavy loads to great heights, they also have a potential
for accidents if safe operating practices are not followed. This book will help you prevent
accidents that could result in inju- ry, death, or property damage. - General safe practices for working on machinery must be followed as well as the safe operating
practices rec- ommended here.
OPERATOR’S RESPONSIBILITY:
The operator is the best safety feature in any crane. Safety must always be the operator’s most
important concern. He must refuse to operate when he knows it is unsafe and consult his supervisor
when safety is in doubt.
- He must read and understand the Operator’s Manual and see that the machine is in proper order
before op- erating. - He must understand how to read the rating plate and know that his machine can safely lift each load
before attempting to lift it. - He must never lift a load without knowing the length of the boom, the weight of the load, and the
load radius or boom angle. - Never attempt to operate the crane at conditions ex- ceeding those shown on the rating chart. Such
opera- tion can cause tipping or structural failure of the crane that can result in damage, injury,
or death. - He must be alert, physically fit, and free from the influ- ences of alcohol, drugs, or medications
that might af- fect his eyesight, hearing, reactions, judgment. - He must see that unnecessary people, equipment, and material are kept out of the work area. The
area around the machine should be properly barricaded. - When an operator’s vision is restricted or when operat- ing in hazardous places such as near
electrical power lines or around people, a signalman must be used. Be- cause the operator is not
always in the best position to judge distances and can not see all parts of the jobsite, a
signalman may also be necessary at other times. Op- erators must understand standard crane signals
and take signals only from designated signalmen.
TABLE OF CONTENTS:
Kobelco 7250-2F Crane Operation & Maintenance Manual S2JD01002ZE25 – PDF DOWNLOAD
COVER............................................................................................ 1 TABLE OF CONTENTS................................................................................ 3 IMPORTANT INFORMATION............................................................................ 9 1. SAFE OPERATING PRACTICES FOR MOBILE CRANES.................................................... 19 2. OPERATION..................................................................................... 39 2.1 TERMINOLOGY OF MACHINE EACH PART......................................................... 39 2.1.1 CRANE ATTACHMENT................................................................... 39 2.1.2 LUFFING JIB ATTACHMENT............................................................. 40 2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS................................................ 41 2.2.1 OPERATING SWITCHES................................................................. 45 2.2.2 GAUGE CLUSTER CONFIGURATION........................................................ 55 2.2.3 OPERATING THE AIR CONDITIONER...................................................... 70 2.2.4 AM/FM RADIO (OPTION)............................................................... 72 2.2.5 1WAY CALL (TRANSMITTER) (OPTION)................................................... 74 2.3 CRANE OPERATION.......................................................................... 75 2.3.1 ADJUSTING THE OPERATOR'S SEAT...................................................... 75 2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION.............................................. 75 2.3.3 STARTING AND STOPPING THE ENGINE................................................... 76 2.3.4 FUNCTION LOCK LEVER................................................................ 79 2.3.5 PROPELLING OPERATION............................................................... 80 2.3.6 SWINGING OPERATION................................................................. 82 2.3.7 BOOM RAISING/LOWERING OPERATION.................................................... 85 2.3.8 HOOK RAISING/LOWERING OPERATION.................................................... 87 2.4 TOWER CRANE OPERATION.................................................................... 90 2.4.1 HOISTING TOWER CRANE ATTACHMENT.................................................... 91 2.4.2 HOISTING JIB....................................................................... 93 2.4.3 HOOK HOIST DRUM CONTROL............................................................ 94 2.5 FREE FALL OPERATION (CRANE ONLY : OPTION)................................................ 96 2.6 CLAMSHELL OPERATION (OPTION)............................................................. 99 2.7 HANDLING OF HYDRAULIC TAGLINE (OPTION)...................................................101 2.8 HANDLING OF VIBROHAMMER..................................................................103 2.9 HANDLING OF REEVING WINCH (OPTION).......................................................105 3. LOAD SAFETY DEVICE............................................................................107 3.1 ARRANGEMENT OF EQUIPMENTS................................................................107 3.2 TYPE AND FUNCTIONS OF EQUIPMENTS.........................................................111 3.3 CONNECTING PROCEDURE OF WIRING...........................................................119 3.3.1 CRANE ATTACHMENT...................................................................119 3.3.2 TOWER ATTACHMENT...................................................................125 3.4 FUNCTION OF CONTROLLER/MONITOR...........................................................131 3.5 OPERATING PROCEDURE OF CONTROLLER........................................................135 3.5.1 SETTING SCREEN.....................................................................136 3.5.2 SETTING OF THE CRANE CONFIGURATION.................................................142 3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING.................................................147 3.5.4 SETTING OF WORKING AREA LIMIT VALUE................................................148 3.5.5 SETTING OF THE TIME................................................................152 3.6 WARNING ALARM AND AUTOMATIC STOP.........................................................154 3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP..........................................154 3.6.2 CONTENTS OF AUTOMATIC STOP.........................................................156 3.6.3 RELEASE OF AUTOMATIC STOP..........................................................160 3.7 INSPECTION...............................................................................167 3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED.......167 3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT...........................................173 3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE..............................................175 3.9 INDICATION OF ERRORS AND REMEDY..........................................................176 3.10 INDICATION OF MESSAGE AND ALARM.........................................................177 3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE.........................................179 4. UNLOADING/LOADING THE BASIC MACHINE...........................................................181 4.1 STABILITY IN SWINGING AND TRAVELING......................................................182 4.2 TRANSLIFTER..............................................................................184 4.2.1 COMPOSITION OF THE TRANSLIFTER.....................................................184 4.2.2 HANDLING TRANSLIFTERS (1) - (4)....................................................185 4.3 UNLOADING THE BASE MACHINE...............................................................187 4.3.1 LOADING BASE MACHINE...............................................................191 5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE.........................................................195 5.1 INSTALLATION/REMOVAL OF CRAWLER..........................................................196 5.1.1 INSTALLATION OF CRAWLERS...........................................................196 5.1.2 REMOVAL OF THE CRAWLERS............................................................201 5.2 ERECTING/LOWERING THE GANTRY.............................................................206 5.2.1 ERECTING THE GANTRY................................................................206 5.2.2 LOWERING THE GANTRY................................................................207 5.2.3 HANDLING OF GANTRY CYLINDER SUPPORT CHAIN..........................................208 5.3 HANDLING OF THE ELECTRIC CABLE DURING GANTRY INSTALLATION AND REMOVAL....................209 5.3.1 HANDLING OF THE ELECTRIC CABLE DURING GANTRY INSTALLATION..........................209 5.3.2 HANDLING OF THE ELECTRIC CABLE DURING GANTRY REMOVAL...............................210 5.4 INSTALLATION,REMOVAL OF THE COUNTERWEIGHT................................................211 5.4.1 INSTALLATION/REMOVAL OF THE CARBODY WEIGHT.........................................212 5.4.2 INSTALLATION OF THE COUNTERWEIGHT..................................................213 5.4.3 REMOVAL OF THE COUNTER WEIGHT......................................................216 6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT......................................................217 6.1 ASSEMBLING ATTACHMENTS...................................................................219 6.1.1 ARRANGEMENT OF BOOM/LONG/GUY LINE..................................................219 6.1.2 ARRANGEMENT OF JIB AND GUY LINE....................................................228 6.1.3 SETTING OF STEEL PLATES FOR ERECTING AND LOWERING THE BOOM.........................229 6.1.4 INSTALLING THE BACKSTOPS...........................................................230 6.1.5 INSTALLING THE BOOM BASE...........................................................231 6.1.6 REEVING OF BOOM HOIST WIRE ROPE....................................................233 6.1.7 INSTALLING THE UPPER AND LOWER SPREADER............................................234 6.1.8 INSTALLING THE LONG BOOM TIP.......................................................237 6.1.9 INSTALLATION OF THE BASIC GUY LINE.................................................238 6.1.10 MAIN HOIST WIRE ROPE REEVING......................................................239 6.1.11 CONNECTING THE INSERT BOOMS.......................................................243 6.1.12 INSTALLING THE CABLE ROLLERS......................................................250 6.1.13 CONNECTING THE BOOM GUY LINES.....................................................251 6.1.14 CAUTION FOR CANTILEVER............................................................253 6.2 ERECTING THE ATTACHMENT..................................................................254 6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT........................................254 6.2.2 CONFIRMATION OF EACH LIMIT SWITCH OPERATION........................................255 6.2.3 ERECTING THE ATTACHMENT............................................................255 6.3 LOWERING THE ATTACHMENT..................................................................257 6.3.1 LOWERING THE ATTACHMENT............................................................257 6.4 DISASSEMBLING THE ATTACHMENT.............................................................258 6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING.........................................258 6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES.....................................258 6.4.3 REMOVING THE BOOM GUY LINE.........................................................259 6.4.4 REMOVAL OF THE COUNTERWEIGHT.......................................................260 6.4.5 LOWERING THE GANTRY................................................................260 6.4.6 DISASSEMBLING THE BOOM TIP AND INSERT BOOM.........................................260 6.4.7 REMOVING THE UPPER AND LOWER SPREADERS.............................................262 6.4.8 REMOVING THE LOWER BOOM............................................................263 6.5 ASSEMBLY AND DISASSEMBLY OF THE LONG BOOM................................................265 6.5.1 ASSEMBLY OF THE LONG BOOM..........................................................265 6.5.2 DISASSEMBLY OF LONG BOOM...........................................................270 6.6 INSTALLING AND REMOVING THE AUXILIARY SHEAVE.............................................271 6.6.1 INSTALLING THE AUXILIARY SHEAVE....................................................271 6.6.2 REMOVING THE AUXILIARY SHEAVE......................................................273 6.7 ASSEMBLY AND DISASSEMBLY OF THE JIB......................................................274 6.7.1 ASSEMBLING THE JIB.................................................................274 6.7.2 REEVING OF REAR DRUM...............................................................277 6.7.3 DISASSEMBLING THE JIB..............................................................279 6.8 CAUTION WHEN TRANSPORTING BOOM...........................................................281 6.9 PROCEDURE OF THE BOOM NESTING (OPTION)...................................................282 6.9.1 NESTING PROCEDURE..................................................................282 6.9.2 UNNESTING PROCEDURE................................................................283 6.9.3 NESTING CONFIGURATION OF BOOM AND TOWER JIB IN CASE OF LONGEST BOOM ARRANGEMENT....284 7. ASSEMBLY/DISASSEMBLY OF TOWER CRANE ATTACHMENT................................................285 7.1 ASSEMBLING TOWER ATTACHMENT..............................................................288 7.1.1 PREPARATION OF TOWER BOOM/JIB/GUY LINE.............................................288 7.1.2 CHANGE OF BASIC MACHINE TO TOWER CRANE ATTACHMENT..................................295 7.1.3 ASSEMBLY OF TOWER ATTACHMENT.......................................................295 7.1.4 ASSEMBLY OF TOWER JIB..............................................................311 7.1.5 FUNCTION CHECK OF EACH LIMIT SWITCH................................................324 7.2 ERECTING THE TOWER ATTACHMENT............................................................325 7.2.1 ERECTING THE TOWER BOOM............................................................325 7.2.2 ERECTING THE JIB...................................................................332 7.2.3 INSPECTION BEFORE USE..............................................................334 7.3 LOWERING THE TOWER.......................................................................336 7.3.1 LOWERING THE JIB...................................................................336 7.3.2 LOWERING THE TOWER.................................................................339 7.4 DISASSEMBLY OF THE TOWER.................................................................343 7.4.1 DISCONNECT OF THE JIB..............................................................344 7.4.2 DISASSEMBLY OF THE JIB.............................................................349 7.4.3 DISASSEMBLY OF TOWER GUY LINE AND TOWER............................................350 8. WIRE ROPE.....................................................................................359 8.1 UNREELING WIRE ROPE......................................................................359 8.1.1 UNREELING WIRE ROPE................................................................359 8.1.2 WINDING WIRE ROPE ONTO DRUM........................................................360 8.1.3 INSTALLING THE ROPES...............................................................362 8.1.4 SPECIFICATION OF WIRE ROPE.........................................................363 8.1.5 WIRE ROPE LENGTH...................................................................364 9. MAINTENANCE...................................................................................367 9.1 INSPECTIONS..............................................................................372 9.1.1 UPPER STRUCTURE PARTS AND DEVICES TO BE INSPECTED..................................372 9.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS...........................374 9.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS.......................379 9.1.1.3 UPPER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS.................383 9.1.1.4 UPPER STRUCTURE INSPECTIONS-WEEKLY OR EVERY 50 HOURS.........................384 9.1.2 LOWER STRUCTURE PARTS AND DEVICE TO BE INSPECTED...................................386 9.1.2.1 LOWER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS...........................388 9.1.2.2 LOWER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS.......................389 9.1.2.3 LOWER STRUCTURE INSPECTIONS-QUARTERLY OR EVERY 250 HOURS.....................391 9.1.2.4 LOWER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS.................391 9.1.3 ATTACHMENT PARTS AND DEVICES TO BE INSPECTED.......................................392 9.1.3.1 ATTACHMENT INSPECTIONS-DAILY OR EVERY 8 HOURS................................394 9.1.4 REPLACEMENT STANDARDS FOR WIRE ROPE................................................398 9.2 OIL/GREASE SUPPLY AND WATER SERVICE......................................................403 9.2.1 UPPER STRUCTURE LUBRICATION (INCLUDING WATER SUPPLY)...............................406 9.2.2 LOWER STRUCTURE LUBRICATION........................................................408 9.2.3 ATTACHMENT LUBRICATION.............................................................410 9.2.4 GREASE.............................................................................412 9.2.5 ENGINE OIL.........................................................................417 9.2.6 FUEL...............................................................................418 9.2.7 COOLANT............................................................................419 9.2.8 HYDRAULIC OIL......................................................................421 9.2.9 GEAR OIL...........................................................................423 9.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER....................................430 9.4 BATTERY INSPECTION.......................................................................441 9.5 LOCATION AND USE OF FUSE.................................................................444 9.6 OPERATION UNDER UNUSUAL CONDITIONS.......................................................446 9.7 MACHINE STORAGE..........................................................................448 9.8 TIGHTENING TORQUE VALUES.................................................................449 9.9 SECURITY PARTS TO BE REPLACED PERIODICALLY...............................................451 9.10 ADJUSTMENT..............................................................................452 9.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS...........................................452 9.10.2 ADJUSTMENT OF BOOM DRUM LOCK......................................................453 9.10.3 CRAWLER SHOES ADJUSTMENT..........................................................454 9.11 CONSUMABLE PARTS LIST...................................................................455 10. REFERENCE MATERIALS..........................................................................461 10.1 SPECIFICATION...........................................................................461 10.1.1 PERFORMANCE.......................................................................461 10.1.2 PERFORMANCE OF TOWER CRANE........................................................462 10.1.3 OUTSIDE DIMENSIONS................................................................462 10.2 DIMENSIONS AND WEIGHT OF EACH PARTS.....................................................465 10.2.1 BASE MACHINE......................................................................465 10.2.2 COUNTERWEIGHT.....................................................................466 10.2.3 ATTACHMENT........................................................................468 10.3 TRANSPORTATION POSITION.................................................................475 10.3.1 OFF-ROAD TRANSPORTATION POSITION (WITH THE BOOM BASE).............................475 10.3.2 TRAVELING KIT (OPTION)............................................................476 10.4 ALLOWBLE ANGLE OF MACHINE INCLINATION WHEN PROPELLING...................................477 10.5 SYSTEM SCHEMATIC........................................................................481 10.5.1 HYDRAULIC SYSTEM SCHEMATIC (JD03Z00002P1).........................................481 10.5.2 ELECTRIC SYSTEM SCHEMATIC.........................................................484
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