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Grove Crane GMK 5150 Operating Instruction Manual 3302627 – PDF DOWNLOAD
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Description
Grove Crane GMK 5150 Operating Instruction Manual 3302627 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5150 Operating Instruction Manual 3302627 – PDF DOWNLOAD
Language : English
Pages : 990
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5150 Operating Instruction Manual 3302627 – PDF DOWNLOAD
Intended use:
The GMK5150 truck crane is constructed in accordance with the latest tech- nology and the
recognised safety regulations. Nevertheless, the operator or third parties can still be endangered
and the crane or other property put at risk while using it.
- The truck crane may be modified only with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK5150 truck crane may be used only when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK5150 truck crane may only be operated without the corresponding special equipment within the
permitted temperature range; à Technical
data, p. 1 – 7. - The GMK5150 truck crane is designed solely for lifting loads which are within the permitted GMK5150
lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating manual(s), the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.
- The GMK5150 may only be operated with parts of equipment which approved by Manitowoc Crane Group
Germany GmbH and which are labelled with the serial number of the GMK5150. - The manufacturer is not liable for any damage caused by improper or unau- thorized use of the
GMK5150 truck crane. The user shall take on full responsibility for any such use.
TABLE OF CONTENTS:
Grove Crane GMK 5150 Operating Instruction Manual 3302627 – PDF DOWNLOAD
Additional pages ............................................................................. 25 Installing/removing the outrigger beams................................................... 3 Driving with a rigged crane............................................................... 23 CCS – Datalogger.......................................................................... 25 Additional menu and program........................................................... 25 1 Overview.................................................................................... 35 1.1 Accidents............................................................................. 35 1.2 Branch offices........................................................................ 37 1.2.1 Manitowoc Crane Care............................................................ 37 1.2.2 Dealer list..................................................................... 37 1.3 Warranty specifications............................................................... 37 1.4 Terms used............................................................................ 38 1.5 Technical data........................................................................ 41 1.5.1 Maximum lifting capacity (DIN/ISO/EN)........................................... 41 1.5.2 Maximum lifting capacity (ASME B 30.5).......................................... 41 1.5.3 Dimensions and weights of the truck crane, axle loads........................... 42 Dimensions........................................................................ 43 Weight and axleloads............................................................. 43 1.5.4 Dimensions and weights of removable parts....................................... 44 Spare wheel....................................................................... 44 Outrigger......................................................................... 44 Hook blocks and hook tackle....................................................... 44 Auxiliary hoist................................................................... 45 Counterweight parts.............................................................. 45 1.5.5 Carrier......................................................................... 46 Engine............................................................................ 46 Transmission...................................................................... 46 Transfer case..................................................................... 46 Axle lines........................................................................ 46 Steering.......................................................................... 46 Tyres............................................................................. 47 Outrigger......................................................................... 48 Electrical system................................................................. 49 Tool.............................................................................. 49 Towing coupling.................................................................. 49 Driving speeds.................................................................... 49 Climbing ability.................................................................. 49 Turning radii..................................................................... 50 1.5.6 Superstructure.................................................................. 50 Main hoist........................................................................ 50 Auxiliary hoist................................................................... 51 Slewing gear...................................................................... 51 Derricking gear................................................................... 51 Main boom......................................................................... 51 Lattice extension................................................................. 51 Operating speeds.................................................................. 52 1.6 Documentation supplied................................................................ 53 1.6.1 Questions on documentation...................................................... 54 1.7 Notes on the operating manual......................................................... 55 1.7.1 What do the symbols used mean?.................................................. 55 1.7.2 How is the operating manual structured?......................................... 57 Division.......................................................................... 57 Structure of thechapters......................................................... 57 Structure of thepages............................................................ 58 1.7.3 How do I find the information I need?........................................... 59 Cross-references example.......................................................... 60 1.7.4 What information is available for operations planning?.......................... 62 1.8 Conversion table for US measuring units............................................... 63 1.9 Training – Information................................................................ 65 1.10 Identification....................................................................... 66 1.11 EC Declaration of Conformity......................................................... 68 2 Basic safety instructions................................................................... 71 2.1 Intended use.......................................................................... 71 2.1.1 Improper use.................................................................... 72 2.2 Organisational measures............................................................... 73 2.3 Personnel qualifications.............................................................. 75 2.4 Safety instructions for driving the truck crane....................................... 77 2.5 Safety instructions for crane operation............................................... 79 2.6 Instructions on transporting persons.................................................. 83 Equipment for lifting persons......................................................... 83 Personnel............................................................................. 84 Operation............................................................................. 84 Truck crane........................................................................... 85 3 Operating elements for driving.............................................................. 89 3.1 Overview of the operating elements.................................................... 89 3.1.1 Exterior of the truck crane..................................................... 90 3.1.2 Driver's cab.................................................................... 94 Front overview.................................................................... 94 Rear overview..................................................................... 96 Behind the cover................................................................. 97 3.1.3 Steering column/steering wheel.................................................. 99 3.1.4 Instrument panel................................................................101 Left/right........................................................................101 Middle............................................................................102 3.1.5 Transmission operating elements.................................................104 3.1.6 On-board computer...............................................................105 3.1.7 Tachograph, on-board computer time correction...................................106 3.1.8 Heating and air-conditioning system.............................................107 Standard..........................................................................107 Auxiliary water heating system..................................................108 Auxiliary air heater.............................................................109 3.1.9 CCS control unit................................................................110 3.1.10 CCS display – Start menu.......................................................111 3.1.11 CCS – Overview menu groups.....................................................112 Carrier menu group................................................................114 Suspension/level adjustment menu.................................................115 Driving menu.....................................................................116 Settings menu group...............................................................117 Menu for setting the display brightness anddate/time.............................118 Switch units menu.................................................................119 Information menu group............................................................120 Operating hours menu.............................................................121 Engine/transmission error menu...................................................122 Crane operation error menu.......................................................123 Operating additional equipment....................................................124 Emergency operation...............................................................125 3.1.12 Outriggers control units.......................................................126 3.2 Brief description of the operating elements...........................................127 3.2.1 Definition of direction references..............................................127 Basic rule........................................................................127 Switches and buttons.............................................................128 3.2.2 General rules for buttons and symbols on the display............................128 3.2.3 Crane control CCS...............................................................129 3.2.4 Engine..........................................................................134 Steering column...................................................................134 On the steering wheel.............................................................134 Instrument panel..................................................................135 3.2.5 AdBlue system...................................................................136 Instrument panel..................................................................136 CCS display.......................................................................137 3.2.6 Battery master switch...........................................................137 3.2.7 Electrical system...............................................................138 3.2.8 Transmission....................................................................139 Transmission control unit.........................................................139 Display driving mode..............................................................141 3.2.9 Reverse camera..................................................................142 3.2.10 BirdView system 270 ...........................................................143 3.2.11 Transfer case..................................................................145 3.2.12 Final drive....................................................................146 3.2.13 Brakes.........................................................................148 Service brake.....................................................................148 Parking brake.....................................................................148 Additional brakes.................................................................149 3.2.14 Steering / separate steering...................................................150 Instrument panel..................................................................150 CCS display.......................................................................152 3.2.15 Suspension.....................................................................154 CCS display.......................................................................154 Outriggers control units..........................................................154 3.2.16 Lighting/windscreen wipers/horn................................................155 Steering column...................................................................155 Steering wheel....................................................................155 Instrument panel..................................................................155 CCS display.......................................................................157 Roof..............................................................................157 3.2.17 Level adjustment system........................................................158 3.2.18 Tachograph/speedometer.........................................................160 Tachograph........................................................................160 Speedometer.......................................................................160 3.2.19 Diagnostics....................................................................161 3.2.20 On-board computer..............................................................162 3.2.21 Push-up roof...................................................................163 3.2.22 Windows and doors..............................................................164 Window winder.....................................................................164 Doors.............................................................................165 3.2.23 Front flap.....................................................................166 4 Starting/switching off the engine – for driving.............................................169 4.1 Starting the engine from the driver's cab.............................................169 4.1.1 CHECKLIST: Starting the engine..................................................169 4.1.2 CHECKLIST: At low temperatures..................................................172 4.1.3 Ladders.........................................................................173 Folding ladder....................................................................174 4.1.4 Refuelling......................................................................175 Fuel tank.........................................................................175 AdBlue tank.......................................................................177 4.1.5 Checks before starting the engine...............................................178 At the hydraulic tank.............................................................178 Battery master switch.............................................................179 Checking the hand-held control....................................................179 4.1.6 Switching on the ignition.......................................................179 4.1.7 Lamp test/equalisation of the switching states..................................180 Lamp test.........................................................................180 Alignment of theswitching statuses...............................................180 4.1.8 Display brightness..............................................................181 4.1.9 Start the engine................................................................182 4.1.10 Inspections after starting the engine..........................................184 Main menu and on-board computer display...........................................184 Instrument panel..................................................................185 4.1.11 Adjust idling speed............................................................187 4.2 Switching off the engine..............................................................189 4.2.1 At the ignition lock and with the outrigger control units.......................189 After turning off................................................................189 4.2.2 With emergency stop switches....................................................190 Resetting the emergency stop switch...............................................190 4.3 Air intake inhibitor..................................................................191 Releasing the air intake inhibitor....................................................191 5 Driving mode................................................................................195 5.1 Before driving........................................................................195 5.1.1 CHECKLIST: Checks before on-road driving........................................195 5.1.2 Checking the condition of the truck crane.......................................201 Electrical system.................................................................201 Adjust the mirrors................................................................201 Warning plates for vehicle width..................................................202 Displaying vehicle height.........................................................203 Supply pressure...................................................................204 Parking brake.....................................................................205 5.1.3 Adjusting the seats and steering column.........................................207 Adjusting the driver's seat......................................................207 Adjusting the passenger's seat...................................................208 Steering column, adjusting.......................................................209 5.1.4 Switching the suspension on/off.................................................210 Open menu.........................................................................210 Switching the suspension on......................................................211 Switching off the suspension.....................................................211 5.1.5 Setting the tachograph..........................................................212 Prerequisites.....................................................................212 In the event of malfunctions......................................................212 Setting the tachograph...........................................................213 5.1.6 Entering the time/date..........................................................217 5.1.7 Displaying and resetting operating hours........................................218 5.2 Operating the transmission............................................................219 5.2.1 Switching on....................................................................219 5.2.2 Switching the transmission to the neutral position..............................220 5.2.3 Selecting the direction of travel and starting gear.............................221 Selecting the driving direction..................................................221 Selecting the starting gear ....................................................222 5.2.4 Changing the operating mode.....................................................223 Changing to automatic mode........................................................223 Changing to manual mode...........................................................223 5.2.5 Starting........................................................................224 5.2.6 Driving and changing gears......................................................225 In automatic operating mode.......................................................225 In manual operating mode..........................................................226 5.2.7 Changing the driving direction..................................................227 5.2.8 Stopping........................................................................227 Stopping for a long period of time...............................................227 5.2.9 On the roller type dynamometer..................................................228 5.2.10 Preheating transmission........................................................228 5.3 Driving and turning off the truck crane...............................................229 5.3.1 Checks while driving............................................................229 Immediately after you start to move...............................................229 While driving.....................................................................231 5.3.2 Cruise control..................................................................232 Switching on......................................................................232 Switching off.....................................................................233 5.3.3 Temposet........................................................................233 Switching on......................................................................233 Switching off.....................................................................234 5.3.4 Driving downhill................................................................235 Starting..........................................................................235 Inspections when driving downhill................................................236 Downshifting......................................................................236 Additional brakes.................................................................237 5.3.5 Driving uphill..................................................................239 Starting..........................................................................239 Driving...........................................................................239 5.3.6 Warning or malfunction messages on the instrument panel.........................240 Meaning of thelamps..............................................................240 5.3.7 Messages on the on-board computer display.......................................241 5.3.8 Indicator lights in the on-board computer display...............................243 5.3.9 Overriding the torque reduction.................................................245 5.3.10 Warnings in the start menu.....................................................246 5.3.11 Switching the truck crane off..................................................247 Secure it against rolling away....................................................248 When stationary for more than 8hours.............................................249 5.3.12 Fold-up berth..................................................................250 5.4 Off-road driving......................................................................251 Adjustments to the transmission.......................................................251 Connections...........................................................................251 Changing the vehicle level............................................................251 Rocking the vehicle free and towing...................................................251 5.4.1 Transfer case – switching the off-road gear on/off..............................252 Neutral position..................................................................252 5.4.2 Longitudinal and transverse differential locks..................................253 5.4.3 Operating the level adjustment system...........................................255 Open menu.........................................................................255 Setting the on-road level........................................................256 Pre-selecting suspension struts..................................................256 Changing the vehicle level........................................................257 Viewing the current inclination...................................................257 Exiting the menu.................................................................258 5.4.4 Freeing an immobilized truck crane..............................................259 Rocking the truck crane free.....................................................259 Towing free to thefront.........................................................260 Towing free in reverse gear......................................................260 5.5 Separate steering.....................................................................261 5.5.1 Switching to separate steering..................................................262 5.5.2 Switching to normal steering mode...............................................265 5.5.3 Switching units of measure......................................................266 5.6 Heating and air-conditioning system...................................................267 5.6.1 Standard heating system.........................................................267 Switching on......................................................................267 Heating...........................................................................267 Air distribution..................................................................268 Examples..........................................................................269 Switching off.....................................................................269 5.6.2 Air-conditioning system.........................................................270 Information.......................................................................270 Switching on/off..................................................................270 Cooling...........................................................................271 Drying............................................................................271 5.6.3 Auxiliary water heating system..................................................273 Preheating theengine............................................................273 Preheating the driver's cab......................................................274 Switching on......................................................................274 Adjusting thedateand time.......................................................276 Storing the heating start........................................................277 5.6.4 Auxiliary air heater............................................................279 Switching on......................................................................279 Setting the heating level........................................................280 Setting the day and time.........................................................281 Setting the preselection time.....................................................281 Deleting preselection times.......................................................283 Switching off.....................................................................283 5.7 Towing a trailer......................................................................285 Effects on the axleloads.............................................................285 Coupling thetrailer.................................................................286 Connecting the supply lines..........................................................287 Removing supplylines...............................................................288 Uncoupling thetrailer...............................................................288 Checking the braking force............................................................290 6 Driving modes...............................................................................293 6.1 Driving modes.........................................................................293 Information on the axle loads.........................................................293 6.1.1 How to use the tables:.........................................................294 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs)..............................295 385/95 R25 tyres..................................................................295 445/95 R25 tyres..................................................................296 525/80 R25 tyres..................................................................297 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs)............298 6.2 Weighing the truck crane..............................................................299 Axle groups...........................................................................300 Weighing procedure....................................................................301 Evaluation............................................................................302 6.3 Rigging work for driving with a trailer...............................................303 6.3.1 Switching on the slewing gear freewheel.........................................304 6.3.2 Switching on the boom floating position.........................................305 6.3.3 Switching on boom pre-tensioning................................................306 6.3.4 Raising/lowering the 3rd axle line for towing a trailer.........................307 Lifting...........................................................................307 Lowering..........................................................................307 6.4 Rigging the main boom.................................................................309 Additional equipment required.........................................................309 6.4.1 CHECKLIST: removing the main boom...............................................310 Prerequisites.....................................................................310 Checklist.........................................................................310 6.4.2 CHECKLIST: installing the main boom.............................................313 Prerequisites.....................................................................313 Checklist.........................................................................313 6.4.3 Slinging the main boom..........................................................316 Marking...........................................................................316 Installing the lifting gear.......................................................316 Removing the lifting gear.........................................................317 6.4.4 Switching the pressure relief on/off............................................318 6.4.5 Retracting/fitting the derricking cylinder head pin.............................319 Retracting the derricking cylinder head axle......................................320 Fitting the derricking cylinder head axle.........................................321 6.4.6 Extending/retracting the boom pivot pin.........................................322 Before pulling itout.............................................................322 After pushing it in...............................................................322 Pulling out the pivot pin.........................................................323 Pushing the pivotpin in..........................................................324 6.4.7 Removing/attaching the clamps...................................................326 6.4.8 Disconnecting/connecting hydraulics/electrical..................................327 Disconnecting.....................................................................327 Connecting........................................................................328 6.4.9 Aligning the connecting points..................................................329 6.4.10 Securing/releasing the derricking cylinder.....................................330 6.4.11 Transporting the main boom.....................................................330 6.4.12 Inspections after main boom mounting...........................................331 6.5 Installing/removing the auxiliary hoist...............................................333 6.5.1 Slinging the auxiliary hoist....................................................333 6.5.2 CHECKLIST: Installing the auxiliary hoist.......................................334 6.5.3 CHECKLIST: Removing the auxiliary hoist.........................................335 6.5.4 Making/breaking the connection between the auxiliary hoist and the turntable....336 6.5.5 Establishing/disconnecting the hydraulic connection.............................337 6.5.6 Establishing/disconnecting the electrical connection............................338 6.5.7 Making/breaking the connection to the central lubrication.......................339 6.5.8 Transporting the auxiliary hoist................................................340 6.5.9 Check that the auxiliary hoist is functioning properly..........................341 Slewing direction.................................................................341 Slewing indicator.................................................................341 7 Transport...................................................................................345 7.1 Transport with transport vehicle......................................................345 7.1.1 CHECKLIST: Checks before transport..............................................346 7.1.2 Drive the truck crane on to the transport vehicle...............................348 Driving on........................................................................349 Lashing...........................................................................349 7.2 Transport by ship.....................................................................350 8 Malfunctions in driving mode................................................................353 8.1 Emergency stop switches...............................................................353 8.2 What to do when a malfunction occurs in road traffic..................................355 8.3 Towing away the truck crane...........................................................357 8.3.1 Towing after engine/transmission damage.........................................358 Compressed-air supply.............................................................358 Electric power supply.............................................................358 On the transmission...............................................................359 Axle drives.......................................................................359 Parking brake.....................................................................360 Towing the truck crane out of the danger area.....................................361 Longer towing distances...........................................................361 8.3.2 Tow starting....................................................................361 8.4 Other emergency operations............................................................363 8.4.1 Externally starting the truck crane.............................................363 8.4.2 Battery charger.................................................................364 Prerequisites.....................................................................364 8.5 Wheels and tyres......................................................................365 8.5.1 Wheel change....................................................................365 Removing a damaged wheel..........................................................366 On the spare wheel holder.........................................................366 Mounting a wheel..................................................................367 8.5.2 Inflating the tyres yourself....................................................369 Connecting the filling hose.......................................................369 Inflating the tyres...............................................................370 Remove the fillinghose..........................................................370 8.6 Tilting/lowering the driver's cab.....................................................371 8.6.1 Prerequisites and information on tilting........................................371 8.6.2 Tilting/lowering the driver's cab...............................................372 Operating the hand pump...........................................................372 Tilting the driver'scab..........................................................373 Lowering the driver's cab........................................................374 8.7 Fuses on the carrier..................................................................377 Information on replacing fuses......................................................377 8.7.1 Fuses in the driver's cab.......................................................378 8.7.2 Fuses in the battery box........................................................384 8.8 Troubleshooting.......................................................................385 8.8.1 Malfunctions on the engine......................................................385 When operating with the dual tank.................................................387 8.8.2 Faults on the Adblue system.....................................................387 8.8.3 Malfunctions of the differential locks..........................................388 8.8.4 Malfunctions in the transmission................................................389 8.8.5 Malfunctions of the steering....................................................390 8.8.6 Malfunctions of the service brake...............................................391 8.8.7 Malfunctions on the suspension..................................................392 8.8.8 Malfunctions of the level adjustment system.....................................392 8.8.9 Malfunctions in the hydraulic system/hydraulic oil cooler.......................392 8.9 CCS warning/error message.............................................................393 Symbols in the display area...........................................................393 8.9.1 Engine/transmission error menu..................................................397 Open menu.........................................................................397 Exiting the menu..................................................................397 8.10 Procedure during malfunctions........................................................399 8.10.1 Procedure during engine malfunctions...........................................399 8.10.2 Procedure during transmission malfunctions.....................................400 9 Operating elements for crane operation......................................................405 9.1 Overview of the operating elements....................................................405 9.1.1 Exterior of the truck crane.....................................................406 9.1.2 Crane cab.......................................................................410 Side panel........................................................................412 Crane cab, rear...................................................................414 9.1.3 Control panels..................................................................416 Left..............................................................................416 Right.............................................................................417 9.1.4 Control lever configuration.....................................................418 Version 1.........................................................................418 Version 2.........................................................................419 9.1.5 CCS control unit................................................................420 9.1.6 CCS – Start menu................................................................423 9.1.7 CCS – Overview menu groups......................................................424 Superstructure menu group.........................................................428 Superstructure lock sub-menu....................................................429 Counterweight menu................................................................430 Outrigger menu....................................................................431 Outrigger support beam menu......................................................433 Outrigger cylinders menu.........................................................434 Menu group Teleautomation.........................................................436 Telescoping full automation menu.................................................437 Telescoping semi- automation menu................................................438 Manual telescoping menu..........................................................439 Main boom configuration menu......................................................440 Active working range limiter menu group...........................................441 Overall height menu..............................................................442 Working radius menu...............................................................443 Slewing angle menu................................................................444 Hoist rope travel limitation menu.................................................445 Information menugroup............................................................446 Hydraulic pressure and fuel consumption menu......................................447 Engine/Driving menu group.........................................................449 Driving mode menu................................................................450 Economy mode menu.................................................................452 Remote control menu...............................................................453 Heating/air-conditioning menu.....................................................454 Spotlights menu...................................................................455 Telescoping emergency program menu group.........................................456 Unknown telescoping menu.........................................................457 Telescoping emergency program menu...............................................458 Settings menu group...............................................................459 Crane cab menu....................................................................460 Menu for setting the display brightness and date/ time............................461 Switch units menu.................................................................462 Set control lever characteristic curve menu.......................................463 Power unit speeds menu..........................................................464 Information menu group............................................................465 Operating hours menu..............................................................466 Engine/transmission error menu....................................................467 Crane operation error menu........................................................468 Program version menu..............................................................469 Operating additional equipment....................................................470 9.1.8 RCL control unit................................................................471 9.1.9 RCL – menu groups...............................................................474 Enter rigging mode menu........................................................476 Monitoring menu..................................................................477 Lifting capacity table menu.....................................................478 9.1.10 Hand-held control..............................................................479 9.1.11 Outriggers control units.......................................................480 Button............................................................................480 Outrigger button..................................................................481 Inclination and outrigger pressure display........................................482 Raise axle display................................................................483 9.2 Brief description of the operating elements...........................................485 9.2.1 Definition of direction references..............................................485 Basic rule........................................................................485 Switches..........................................................................485 9.2.2 General rules for buttons and symbols on the display............................486 9.2.3 Crane control CCS...............................................................487 9.2.4 Engine..........................................................................494 Side panel.......................................................................494 CCS display.......................................................................494 Economy mode menu.................................................................495 Left control lever................................................................495 9.2.5 AdBlue system...................................................................496 CCS display.......................................................................496 9.2.6 Seat contact switch and dead man's switch.......................................497 9.2.7 Outrigger.......................................................................499 Right-hand control panel..........................................................499 Left-hand controlpanel...........................................................499 In the Outrigger menu............................................................500 At the outrigger control units....................................................503 9.2.8 Inclination indicators..........................................................505 9.2.9 Raise axle......................................................................506 Outriggers control units..........................................................506 CCS display.......................................................................507 9.2.10 Outrigger pressure displays....................................................508 Outrigger submenu................................................................508 Outriggers controlunits.........................................................508 9.2.11 Anemometer displays............................................................508 9.2.12 Counterweight menu.............................................................510 Counterweight submenu............................................................510 9.2.13 Main hoist.....................................................................514 Control panels....................................................................514 CCS display.......................................................................514 9.2.14 Auxiliary hoist................................................................516 Control panels....................................................................516 CCS display.......................................................................516 9.2.15 Slewing gear...................................................................518 Control panels....................................................................518 CCS display.......................................................................519 9.2.16 Derricking gear................................................................520 Control panels....................................................................520 CCS display.......................................................................521 9.2.17 Telescoping mechanism..........................................................522 Control panels....................................................................522 CCS display.......................................................................522 Telescoping full automation menu..................................................523 Telescoping semi- automation menu.................................................524 Manual telescoping menu...........................................................526 Main boom configuration menu......................................................529 9.2.18 Hydraulic system...............................................................530 9.2.19 Superstructure lock/house lock menu............................................531 Superstructure lock..............................................................531 Houselock.........................................................................532 9.2.20 Remote control.................................................................533 9.2.21 Rated capacity limiter (RCL)...................................................534 Control unit control console RCL..................................................534 Display RCL.......................................................................535 Enter rigging mode menu...........................................................536 Monitoring menu...................................................................540 Lifting capacity tables menu......................................................544 RCL override – version A..........................................................545 RCL override – Version B..........................................................546 9.2.22 Electrical system..............................................................547 9.2.23 Lighting, windscreen wiper/washing system......................................548 Lighting..........................................................................548 Windscreen wiper/washing system..................................................550 9.2.24 Hand-held control..............................................................552 Sockets for hand-held control.....................................................552 Engine control panel..............................................................553 Horn..............................................................................553 Outriggers control panel.........................................................554 9.2.25 Windows and doors..............................................................556 Windows...........................................................................556 Rear window.......................................................................556 Crane cab door....................................................................557 9.2.26 Diagnostics....................................................................558 9.3 Short description of the operating elements – driving from the crane cab..............559 9.3.1 Driving mode menu...............................................................559 9.3.2 Transmission....................................................................560 9.3.3 Final drive.....................................................................561 9.3.4 Brakes..........................................................................562 CCS display.......................................................................562 Side panel from above.............................................................563 9.3.5 Steering........................................................................564 CCS display.......................................................................564 Separate steering.................................................................565 Control panels....................................................................567 10 Starting/switching off the engine – for crane operation....................................571 10.1 When starting the engine for the first time in the day...............................571 10.2 Starting the engine – from the crane cab.............................................573 10.2.1 Check the fuel level and AdBlue level..........................................573 Fuel..............................................................................573 AdBlue............................................................................573 10.2.2 Checks before starting the engine..............................................574 Checks on thecarrier............................................................574 Checking the hand-held control....................................................574 At the hydraulic tank.............................................................574 10.2.3 Switching on the ignition......................................................575 10.2.4 Alignment of the switching statuses............................................576 Alignment of theswitching statuses...............................................576 10.2.5 Display – setting the brightness...............................................577 10.2.6 Start the engine...............................................................578 10.2.7 Inspections after starting the engine..........................................579 10.2.8 Adjust idling speed............................................................580 10.3 Starting the engine – with the hand-held control.....................................581 10.4 Switching off the engine.............................................................583 10.4.1 At the ignition lock and with hand-held control................................583 After turning off................................................................583 10.4.2 With the idling button.........................................................583 10.4.3 Using the emergency stop switches..............................................584 Resetting the emergency stop switch...............................................584 11 Crane operation............................................................................587 11.1 Before operating the crane...........................................................587 11.1.1 CHECKLIST: Checks before operating the crane...................................587 11.1.2 Checking the condition of the truck crane......................................591 Fuel tank auxiliary heater........................................................591 Visual inspection.................................................................591 Checking the position of the hoist ropes..........................................592 Checking the electrical system....................................................593 11.1.3 Adjusting the crane cab seat and front control panel...........................594 Crane cab seat....................................................................594 Front panel.......................................................................595 11.1.4 Checking the safety equipment..................................................596 Rated capacity limiter............................................................596 Lifting limit switch.............................................................596 Emergency stop switches...........................................................597 Seat contact switch..............................................................598 11.1.5 Earthing the load..............................................................599 11.1.6 Preheating the hydraulic oil...................................................600 Prerequisites.....................................................................600 Preheating........................................................................600 11.1.7 Locking/unlocking the superstructure...........................................601 Locking points....................................................................601 Locking the superstructure.......................................................602 Unlocking the superstructure.....................................................602 11.1.8 Switching the houselock on/off.................................................603 Switching on the houselock.......................................................603 Switching off the houselock......................................................605 11.2 Operation of the rated capacity limiter..............................................607 11.2.1 Switch on the RCL..............................................................608 Switching on......................................................................608 Brightness of thedisplays........................................................610 Temperature on the display........................................................610 11.2.2 Enter rigging mode.............................................................611 Entering individual components....................................................612 Entering the RCLcode............................................................617 Enter the reeving................................................................618 Accepting the rigging mode........................................................618 11.2.3 Checks before operating the crane..............................................620 Open menu.........................................................................620 Checks............................................................................620 11.2.4 Displays during crane operation................................................623 11.2.5 RCL early warning..............................................................626 11.2.6 RCL shutdown...................................................................626 Shutdown due tooverload..........................................................626 11.2.7 Display in the event of errors.................................................628 11.2.8 RCL override – version A.......................................................629 Overview status display...........................................................629 When rigging......................................................................630 To raise the boom.................................................................631 In emergencies....................................................................632 11.2.9 RCL override – version B.......................................................633 11.2.10 Displaying the lifting capacity tables........................................634 11.2.11 Setting the time/date.........................................................636 11.3 Crane operation with main boom.......................................................637 11.3.1 Checks during crane operation..................................................637 Horizontal alignment..............................................................637 Safe distances...................................................................637 Checking the windspeed...........................................................638 11.3.2 Permissible slewing ranges and working positions...............................639 360 slewing range................................................................639 Working position 0 to the rear...................................................639 180 to the front rigging position................................................639 11.3.3 Main hoist.....................................................................641 Switching on the main hoist.......................................................642 Lifting and lowering.............................................................642 Maximum permissible hoist rope speed..............................................642 Switching off the main hoist.....................................................643 11.3.4 Auxiliary hoist................................................................645 Switching on the auxiliary hoist.................................................645 Lifting and lowering.............................................................646 Maximum permissible hoist rope speed..............................................646 Switching off the auxiliary hoist................................................647 11.3.5 Lifting limit switch and lowering limit switch.................................649 Lifting limit switch..............................................................649 Lowering limit switch.............................................................651 11.3.6 Derricking gear................................................................652 Switching on the derricking gear.................................................652 Maximum permissible derricking speed..............................................652 Raising and lowering..............................................................653 Re-enable raising function........................................................654 Switching off the derricking gear.................................................654 11.3.7 Telescoping mechanism..........................................................656 Overview..........................................................................657 Telescoping process...............................................................658 Assignment fordisplay............................................................660 Fixed length, intermediate length, telescoping length............................661 Telescoping.......................................................................662 Telescoping sequence.............................................................662 Checks before starting work......................................................663 Switching on thetelescoping mechanism............................................664 Function of the control lever.....................................................664 Switching off thetelescoping mechanism...........................................666 Manual telescoping...............................................................667 Checking the initial position.....................................................667 Unlocking the telescoping cylinder................................................669 Extending/ retracting the telescoping cylinder....................................671 Locking the telescoping cylinder..................................................672 Unlocking the telescopic section.................................................673 Telescoping the telescopic section...............................................674 Locking the telescopic section...................................................675 Locking the telescopic section for on-road driving...............................676 Telescoping with semi-automaton...................................................676 Telescoping with full automation..................................................679 Telescoping withmain boom configuration..........................................680 11.3.8 High-speed mode................................................................681 Derricking gear telescoping mechanism............................................681 Hoists............................................................................681 11.3.9 Slewing gear...................................................................683 Switching on the slewing gear....................................................683 Releasing the slewing gear brake..................................................683 Applying the slewing gear brake...................................................684 Slewing...........................................................................684 Releasing locked slewing gear.....................................................684 Maximum permitted slewing speed...................................................685 Braking the slewing movement......................................................686 Slewing gear freewheel............................................................686 Switching off the slewing gear...................................................687 11.3.10 Possible movement combinations................................................688 11.4 Settings and displays for crane operation............................................689 11.4.1 Inclining the crane cab........................................................689 11.4.2 Adjust idling speed............................................................690 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................690 11.4.4 Limiting the power unit speeds.................................................691 11.4.5 Economy mode...................................................................692 Switching on......................................................................692 Switch off/exit...................................................................694 11.4.6 Switching units of measure.....................................................695 11.4.7 Setting the characteristic curves for the control levers.......................696 11.4.8 Using the slewable spotlights..................................................697 Manually swinging.................................................................697 Automatic load tracking...........................................................698 11.4.9 Overriding the torque reduction................................................699 11.4.10 Displaying the operating hours................................................700 11.4.11 Warnings in the start menu....................................................702 Meaning of the symbols............................................................702 11.5 Working range limiter................................................................706 11.5.1 Viewing current settings.......................................................707 11.5.2 Opening the working range limiter menu.........................................707 11.5.3 Entering limit values..........................................................710 Overall height....................................................................710 Working radius....................................................................711 Slewing angle.....................................................................711 Hoist rope travel limitation......................................................712 11.5.4 Entering limit values manually.................................................713 Limit values......................................................................713 11.5.5 Switching monitoring functions on/off..........................................715 11.5.6 Shutdown by working range limiter..............................................716 11.6 Work break...........................................................................717 11.6.1 In case of short work breaks...................................................717 11.6.2 In case of work breaks of more than 8 hours....................................718 To secure the truck crane.........................................................718 11.7 Heating and air-conditioning system..................................................719 11.7.1 Standard heating system........................................................719 Switching on......................................................................719 Heating...........................................................................719 Air distribution..................................................................720 Switching off.....................................................................720 11.7.2 Air-conditioning system........................................................721 Information.......................................................................721 Switching on/off..................................................................721 Cooling, automatic................................................................722 Cooling, maximum..................................................................722 11.7.3 Auxiliary heater...............................................................723 Switching on......................................................................723 Adjusting the temperature.........................................................724 Setting the heating start/ heating duration.......................................724 Switching heating start on/off....................................................725 11.8 CraneSTAR system.....................................................................726 11.8.1 Overview.......................................................................726 11.8.2 Position of the components.....................................................726 12 Rigging work...............................................................................729 12.1 Rigging work checklists for crane operation with the main boom.......................729 12.1.1 CHECKLIST: Rigging.............................................................729 12.1.2 CHECKLIST: Unrigging...........................................................735 12.2 Selecting the suitable site..........................................................739 12.2.1 Determining the required load-bearing area.....................................739 12.2.2 Safe distance from slopes and pits.............................................742 12.2.3 Earthing the truck crane.......................................................743 12.2.4 Safe distance from overhead power lines........................................744 12.3 Rigging work after driving with a trailer............................................747 12.3.1 Switching off the boom floating position.......................................747 12.3.2 Switching off the slewing gear freewheel.......................................748 Before slewing....................................................................748 12.3.3 Switching off boom pre-tensioning..............................................749 12.4 Connecting/disconnecting the hand-held control.......................................751 12.5 Starting the engine for rigging......................................................753 12.5.1 Starting/turning off the engine with the hand-held control.....................753 Prerequisites.....................................................................753 Start the engine..................................................................754 Switching off theengine..........................................................754 12.5.2 Starting/switching off the engine from the outrigger control units.............755 Prerequisites.....................................................................755 Start the engine..................................................................755 Switching off theengine..........................................................755 12.6 Outrigger............................................................................757 12.6.1 CHECKLIST: Extending the outriggers............................................757 12.6.2 CHECKLIST: Retracting the outriggers...........................................759 12.6.3 Permissible outrigger spans....................................................760 12.6.4 Preparing the truck crane......................................................761 Driver's cab......................................................................761 Crane cab.........................................................................761 12.6.5 Setting the spans..............................................................763 For on-road driving...............................................................765 12.6.6 Extending/retracting outrigger beams...........................................767 From the control units............................................................768 From the cranecab................................................................769 12.6.7 Moving the outrigger pads into operating/driving position......................771 12.6.8 Enlarging the load-bearing area................................................773 12.6.9 Extending/retracting supporting cylinders......................................774 From the controlunits............................................................775 From the cranecab................................................................776 12.6.10 Levelling the truck crane on outriggers.......................................778 Inclination indicators............................................................778 Prerequisites.....................................................................779 Manual alignment.................................................................780 Automatic alignment...............................................................781 12.6.11 Levelling the free-on-wheels truck crane......................................782 12.6.12 Outrigger pressure display....................................................784 12.7 Rigging/unrigging the counterweight..................................................785 12.7.1 Information on rigging.........................................................785 When rigging......................................................................786 When unrigging....................................................................787 12.7.2 Counterweight sections.........................................................788 Version 1.........................................................................788 Version 2.........................................................................788 Version 3.........................................................................789 12.7.3 Identification.................................................................790 12.7.4 Slinging points on the counterweight sections..................................791 12.7.5 CHECKLIST: Rigging the counterweight...........................................793 12.7.6 CHECKLIST: Unrigging the counterweight.........................................795 12.7.7 Assembling counterweight versions..............................................797 Setting down the 2.3 t base plate.................................................798 Setting down the top counterweight section........................................798 Version 1.........................................................................799 Version 2.........................................................................807 Version 3.........................................................................811 12.7.8 Counterweight hoist unit.......................................................819 Counterweight menu...............................................................819 Extending/ retracting the lifting cylinders.......................................820 Automatic moderigging...........................................................822 Automatic mode unrigging.........................................................824 Cancel automatic mode............................................................825 12.7.9 Removing/installing the counterweight on the turntable.........................826 Removing..........................................................................826 Installing........................................................................827 12.7.10 Setting down counterweight for driving the truck crane........................828 Version 1 and 3...................................................................828 Version 2.........................................................................830 12.7.11 Slewing with the rigged counterweight.........................................831 12.8 Rigging work on the main boom........................................................833 12.8.1 Hook block on the bumper.......................................................833 Picking up the hook block.........................................................833 Attaching the hook block..........................................................834 12.8.2 Hook block on a separate vehicle...............................................835 Picking up the hook block........................................................836 Setting down the hook block......................................................836 12.8.3 Hook block, separable..........................................................838 Rigging for on-road driving.......................................................838 Rigging for crane operation.......................................................839 12.8.4 Reeving and unreeving the hoist rope...........................................840 Version A.........................................................................840 Version B.........................................................................841 Reeving the hoist rope............................................................843 Unreeving hoist rope.............................................................847 12.8.5 Possible reeving methods on the main boom......................................848 With 6 head sheaves...............................................................848 With 8 head sheaves...............................................................850 With 9 head sheaves...............................................................854 12.8.6 Installing/removing the lifting limit switch...................................855 Installing lifting limit switch...................................................855 Removing the lifting limit switch.................................................858 12.8.7 Locking/unlocking the lifting limit switch.....................................860 Locking...........................................................................860 Unlocking........................................................................860 12.8.8 Anemometer and air traffic control light.......................................861 Installing........................................................................861 Switching the air traffic control light on and off................................862 Removing..........................................................................862 12.9 Other rigging works..................................................................865 12.9.1 Folding the mirrors in and out, and adjusting them.............................865 12.9.2 Cameras for crane operation....................................................866 Camera on mainboom...............................................................866 Camera on thehoists..............................................................868 Camera on the driver's cab........................................................868 Operating the camera..............................................................869 12.9.3 Railings on the turntable......................................................870 12.9.4 Step for the crane cab.........................................................871 12.9.5 Slinging points for personal protective equipment..............................872 13 Driving with a rigged truck crane..........................................................875 13.1 Driving path.........................................................................875 13.2 Permissible rigging modes and axle loads.............................................876 Axle load table......................................................................876 13.2.1 To drive without a load........................................................878 13.2.2 To drive with a load...........................................................879 13.2.3 Axle loads.....................................................................879 13.3 Before driving the rigged truck crane................................................880 13.3.1 Check the tyre pressures and wind speed........................................880 13.3.2 Securing the superstructure against slewing....................................880 13.3.3 Putting the truck crane on the wheels..........................................881 13.4 Driving from the driver's cab........................................................883 13.4.1 Preparing to drive.............................................................883 Transmission......................................................................883 Switching on separate steering....................................................883 Connections.......................................................................883 13.4.2 While driving..................................................................884 13.4.3 After driving..................................................................885 13.5 Driving from the crane cab...........................................................887 13.5.1 Preparing to drive.............................................................888 13.5.2 Opening/closing the Driving menu...............................................888 Opening...........................................................................888 Crane hydraulic system on/off.....................................................889 Closing...........................................................................890 13.5.3 Steering.......................................................................891 Switching on......................................................................891 Steering direction................................................................891 Displays when steering............................................................892 Separate steering.................................................................892 Normal steering mode..............................................................896 13.5.4 Operating the transmission.....................................................897 Selecting the transmission mode..................................................897 13.5.5 While driving..................................................................898 DMand RM transmission mode.......................................................898 Transmission mode D...............................................................898 Warning messages..................................................................898 13.5.6 Possible connections...........................................................899 Longitudinal/ transverse differential locks.......................................899 13.5.7 After driving..................................................................901 14 Malfunctions during crane operation........................................................905 14.1 Emergency stop switches..............................................................905 14.2 What to do when malfunctions occur during crane operation............................907 The load can be set down..............................................................907 Load cannot be set down...............................................................907 14.3 Fuses in the crane cab...............................................................909 Information on replacing fuses......................................................909 14.4 Troubleshooting......................................................................914 14.4.1 Malfunctions on the engine.....................................................914 14.4.2 Malfunctions when operating with the hand-held control.........................914 14.4.3 Malfunctions on the turntable lock.............................................915 14.4.4 Malfunctions when inclining the crane cab......................................915 14.4.5 Malfunctions on the main hoist.................................................916 14.4.6 Malfunctions in the telescoping mechanism......................................917 14.4.7 Malfunctions in the hoist cameras..............................................918 14.4.8 Malfunctions in the main boom camera...........................................918 14.4.9 Malfunctions on the derricking gear............................................919 14.4.10 Malfunctions on the slewing gear..............................................920 14.4.11 Malfunctions on the counterweight hoist unit..................................921 14.4.12 Malfunctions in the hydraulic system/hydraulic oil cooler.....................922 14.4.13 Malfunctions when driving from the crane cab..................................922 14.4.14 Malfunctions of the outriggers................................................923 14.4.15 Troubleshooting the crane control.............................................925 General malfunctions.............................................................926 Symbols in the error or information display areas.................................926 Displays in the Error menu........................................................930 14.4.16 Malfunctions on the CraneSTAR system..........................................932 14.5 Emergency operations and programs....................................................933 14.5.1 Mechanical emergency activation for retracting.................................934 Prior to the emergency activation, check..........................................934 Procedure.........................................................................934 Mechanical emergency activation..................................................935 14.5.2 Telescoping emergency program..................................................937 Open the Emergency program submenu...............................................937 Determining the type of error....................................................938 If there is an error on the length indicator......................................939 Tables for approaching the locking points.........................................943 14.5.3 Entering the current telescoping...............................................945 14.5.4 Emergency operation with the hand-held control.................................947 Preparations......................................................................947 Pre-selecting a power unit........................................................948 Operating apowerunit............................................................948 Stopping movements...............................................................949 Stopping movements in emergencies.................................................950 Switching off theengine..........................................................950 14.6 Hydraulic emergency operation........................................................951 Switching over valves.................................................................951 Releasing/ securing valves............................................................952 For lowering..........................................................................953 14.6.1 Performing emergency activation................................................955 14.6.2 After the emergency activation.................................................955 14.6.3 Operating principle of emergency operation BGR 159.............................956 14.6.4 Connecting/disconnecting hoses.................................................957 Establishing connections..........................................................957 Disconnecting connections........................................................958 14.6.5 Switching emergency operation on/off...........................................959 14.6.6 Establishing the hydraulic circuits required...................................959 Switching over valves.............................................................959 For lifting/ lowering.............................................................961 For slewing.......................................................................962 14.6.7 Performing emergency operation.................................................963 Slewing...........................................................................963 Derricking........................................................................964 Lifting/lowering..................................................................964 14.6.8 After emergency operation......................................................965 Switching off emergency operation.................................................965 Switching over to crane operation.................................................965 Disconnecting thehoses...........................................................965 14.6.9 Emergency supply of another crane..............................................966 For emergency supply..............................................................966 After emergency supply............................................................966 15 Index......................................................................................969 A.........................................................................................971 B.........................................................................................971 C.........................................................................................972 D.........................................................................................975 E.........................................................................................977 F.........................................................................................978 H.........................................................................................978 I.........................................................................................979 L.........................................................................................980 M.........................................................................................980 O.........................................................................................981 P.........................................................................................982 R.........................................................................................983 S.........................................................................................984 T.........................................................................................985 V.........................................................................................987 W.........................................................................................987
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