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Grove Crane GMK 5200-1 Driving & Crane Operating Manual 3302421 – PDF DOWNLOAD
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Grove Crane GMK 5200-1 Driving & Crane Operating Manual 3302421 – PDF DOWNLOAD
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Description
Grove Crane GMK 5200-1 Driving & Crane Operating Manual 3302421 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5200-1 Driving & Crane Operating Manual 3302421 – PDF DOWNLOAD
Language : English
Pages : 926
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5200-1 Driving & Crane Operating Manual 3302421 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
The GMK 5200-1 is a state-of-the-art truck crane, designed in accordance with approved 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 only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 5200-1 truck crane may only be used 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 GMK 5200-1 truck crane may only be operated without the correspond- ing special equipment
within the permitted temperature range; à Technical
data, p. 1 – 7. - The GMK 5200-1 truck crane is designed solely for lifting loads which are within the permitted GMK
5200-1 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 GMK 5200-1 may only be operated with parts of equipment which are permitted by Manitowoc Crane
Group Germany GmbH and which are labelled with the serial number of the GMK 5200-1.
The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK
5200-1 truck crane. The user alone bears the
risk.
TABLE OF CONTENTS:
Grove Crane GMK 5200-1 Driving & Crane Operating Manual 3302421 – PDF DOWNLOAD
Hoist rope travel limitation................................................................. 3 Hoist rope travel limitation menu........................................................ 4 Entering values.......................................................................... 5 Switching monitoring function on/off..................................................... 5 Correction sheet............................................................................. 7 Driving with rigged truck crane.......................................................... 7 1 Overview................................................................................... 13 1.1 Accidents............................................................................ 13 1.2 Branch offices....................................................................... 15 1.2.1 Manitowoc Crane Care........................................................... 15 1.2.2 Dealer list.................................................................... 15 1.3 Warranty specifications.............................................................. 15 1.4 Terms used........................................................................... 16 1.5 Technical data....................................................................... 19 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 19 1.5.2 Maximum lifting capacity (ASME B 30.5)......................................... 19 1.5.3 Dimensions and weights of the truck crane, axle loads.......................... 20 Dimensions....................................................................... 21 Weight and axle loads............................................................ 21 1.5.4 Dimensions and weights of removable parts...................................... 22 Spare wheel...................................................................... 22 Outriggers....................................................................... 22 Main boom........................................................................ 23 Hook blocks and hook tackle...................................................... 23 hook blocks, split............................................................... 24 Auxiliary hoist.................................................................. 25 Counterweight parts.............................................................. 25 1.5.5 Carrier........................................................................ 26 Engine........................................................................... 26 Transmission..................................................................... 26 Transfer case.................................................................... 26 Axle lines....................................................................... 26 Steering......................................................................... 26 Tyres............................................................................ 27 Electrical system................................................................ 27 Tool............................................................................. 27 Towing couplings................................................................. 27 Driving speeds................................................................... 27 Climbing ability................................................................. 27 Outriggers....................................................................... 28 Turning radii.................................................................... 29 1.5.6 Superstructure................................................................. 30 Main hoist....................................................................... 30 Auxiliary hoist.................................................................. 30 Slewing gears.................................................................... 30 Derricking gear.................................................................. 30 Main boom........................................................................ 30 Lattice extension................................................................ 31 Operating speeds................................................................. 31 Noise emission................................................................... 31 1.6 Documentation supplied............................................................... 33 1.6.1 Questions on documentation..................................................... 34 1.7 Notes on the operating manual........................................................ 35 1.7.1 What do the symbols used mean?................................................. 35 1.7.2 How is the operating manual structured?........................................ 37 Division......................................................................... 37 Structure of the chapters........................................................ 37 Structure of the pages........................................................... 38 1.7.3 How do I find the information I need?.......................................... 39 Cross-references example......................................................... 40 1.7.4 What information is available for operations planning?......................... 42 1.8 Conversion table for US measuring units.............................................. 43 1.9 Training – Information............................................................... 45 1.10 Identification...................................................................... 46 1.11 EC Declaration of Conformity........................................................ 48 2 Basic safety instructions.................................................................. 51 2.1 Intended use......................................................................... 51 2.1.1 Improper use................................................................... 52 2.2 Organisational measures.............................................................. 53 2.3 Personnel qualifications............................................................. 55 2.4 Safety instructions for driving the truck crane...................................... 56 2.5 Safety instructions for crane operation.............................................. 57 2.6 Notes on transporting persons........................................................ 59 Equipment for lifting persons........................................................ 59 Personnel............................................................................ 59 Operation............................................................................ 60 Truck crane.......................................................................... 61 3 Operating elements for driving............................................................. 65 3.1 Overview of the operating elements................................................... 65 3.1.1 On the outside of the truck crane.............................................. 66 3.1.2 Cab............................................................................ 70 Overview......................................................................... 70 Behind the cover................................................................. 74 In the rear of the driver's cab.................................................. 74 3.1.3 Instrument panel............................................................... 75 Left/right....................................................................... 75 Middle........................................................................... 76 On-board computer time correction................................................ 78 3.1.4 On-board computer.............................................................. 79 3.1.5 Steering column/steering wheel................................................. 80 3.1.6 Transmission operating elements................................................ 81 3.1.7 Tachograph..................................................................... 82 3.1.8 Control unit CCS............................................................... 83 3.1.9 Display CCS – start menu....................................................... 84 3.1.10 CCS – overview of menu groups................................................. 86 Carrier menu group............................................................... 88 Suspension/level adjustment menu................................................. 89 Driving menu..................................................................... 90 Settings menu group.............................................................. 91 Menu for setting the display brightness and date/time............................ 92 Information menu group........................................................... 93 Operating hours menu............................................................. 94 Engine/ transmission error menu.................................................. 95 Crane operation error menu....................................................... 96 Operating additional equipment................................................... 97 3.1.11 Outrigger control units....................................................... 98 3.1.12 Heating/Air-conditioning system............................................... 99 Standard heating system.......................................................... 99 Auxiliary water heater...........................................................100 Auxiliary air heater.............................................................101 3.1.13 Sockets for hand-held control.................................................102 3.1.14 Outrigger control units.......................................................103 3.2 Short description of the operating elements..........................................105 3.2.1 Definition of direction information............................................106 Basic rule.......................................................................106 Switches and buttons.............................................................106 3.2.2 General rules for buttons and symbols on the display...........................107 3.2.3 Engine.........................................................................108 Steering column..................................................................108 On the steering wheel............................................................108 Instrument panel.................................................................109 3.2.4 AdBlue system (DEF)............................................................110 Instrument panel.................................................................110 CCS display......................................................................111 3.2.5 Battery master switch..........................................................111 3.2.6 Electrical system..............................................................112 3.2.7 Crane control CCS..............................................................113 3.2.8 Transmission...................................................................117 Transmission control unit........................................................117 Display, driving mode,...........................................................118 3.2.9 Reverse camera.................................................................120 3.2.10 Final drive...................................................................121 3.2.11 Brakes........................................................................123 Service brake....................................................................123 Additional brakes................................................................123 Parking brake....................................................................124 3.2.12 Steering/separate steering....................................................126 Instrument panel.................................................................126 CCS display......................................................................127 Driver's door....................................................................128 3.2.13 Suspension....................................................................129 CCS display......................................................................129 Outrigger control units..........................................................129 3.2.14 Lighting/windscreen wipers/horn...............................................130 Steering column..................................................................130 Steering wheel...................................................................130 Instrument panel.................................................................130 CCS display......................................................................132 Roof.............................................................................133 3.2.15 Level adjustment system.......................................................134 3.2.16 Tachograph/speedometer........................................................136 Tachograph.......................................................................136 Speedometer......................................................................136 3.2.17 Diagnostics...................................................................137 3.2.18 On-board computer.............................................................138 3.2.19 Windows, doors, keys..........................................................140 Window winder....................................................................140 Doors............................................................................141 Keys.............................................................................141 3.2.20 Front flap....................................................................142 4 Starting/turning off the engine for driving................................................145 4.1 Starting the engine from the driver's cab............................................145 4.1.1 CHECKLIST: Starting the engine.................................................145 4.1.2 CHECKLIST: At low temperatures.................................................148 4.1.3 Ladders and access ladders.....................................................148 Access ladders...................................................................148 Ladders..........................................................................149 4.1.4 Refuel.........................................................................151 Standard tank....................................................................151 Dual tank........................................................................152 AdBlue...........................................................................153 4.1.5 Checks before starting the engine..............................................154 On hydraulic tank................................................................154 Battery master switch............................................................155 Checking the hand-held control...................................................155 4.1.6 Switching on the ignition......................................................155 4.1.7 Lamp test/equalisation of the switching states.................................156 Lamp test........................................................................156 Switching state alignment........................................................156 4.1.8 Display – setting the brightness...............................................157 4.1.9 Starting the engine............................................................158 4.1.10 Checks after starting the engine..............................................160 Checking in the main menu........................................................160 Indicator lamps on the instrument panel..........................................161 4.1.11 Monitoring elements...........................................................163 Instrument panel.................................................................163 4.1.12 Start menu....................................................................164 4.1.13 Setting idling speed..........................................................165 4.2 Turning off the engine...............................................................167 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....167 After turning off................................................................167 4.2.2 Using the emergency stop switches..............................................168 Resetting the emergency stop switch..............................................168 4.3 Air intake inhibitor.................................................................169 Releasing the air intake inhibitor...................................................169 5 Driving....................................................................................173 5.1 Before driving.......................................................................173 5.1.1 CHECKLIST: Checks before on-road driving.......................................173 5.1.2 Checking the condition of the truck crane......................................179 Electrical system................................................................179 Adjusting the mirrors............................................................179 Warning plates for vehicle width.................................................181 Displaying vehicle height........................................................181 Supply pressure..................................................................182 Parking brake....................................................................183 5.1.3 Adjusting the seat and the steering column.....................................184 Driver's seat....................................................................184 Passenger's seat.................................................................185 Steering column, adjusting.......................................................186 5.1.4 Switching the suspension on/off................................................187 Open menu........................................................................187 Switching on the suspension......................................................188 Switching off the suspension.....................................................188 5.1.5 Setting the tachograph.........................................................189 Prerequisites....................................................................189 In the event of malfunctions.....................................................189 Setting the tachograph...........................................................190 5.1.6 Entering the time/date.........................................................194 5.1.7 Displaying and resetting operating hours.......................................195 5.2 Operating the transmission...........................................................197 5.2.1 Switching on...................................................................197 5.2.2 Switching the transmission to neutral position.................................198 5.2.3 Selecting the direction of travel and starting gear............................199 Selecting the driving direction..................................................199 Selecting the starting gear......................................................200 5.2.4 Changing the operating mode....................................................201 Changing to automatic mode.......................................................201 Change to manual mode............................................................201 5.2.5 Starting.......................................................................202 5.2.6 Driving and changing gears.....................................................203 In automatic operating mode......................................................203 In manual operating mode.........................................................204 5.2.7 Changing the driving direction.................................................205 5.2.8 Stopping.......................................................................205 Stopping for along period oftime...............................................205 5.2.9 On the roller type dynamometer.................................................206 5.2.10 Preheating transmission.......................................................206 5.3 Driving and turning off the truck crane..............................................207 5.3.1 Checks while driving...........................................................207 Immediately after you start to move..............................................207 While driving....................................................................209 5.3.2 Cruise control.................................................................210 Switching on.....................................................................210 Switching off....................................................................211 5.3.3 Temposet.......................................................................212 Switching on.....................................................................212 Switching off....................................................................212 5.3.4 Driving downhill...............................................................213 Starting.........................................................................213 Inspections when driving downhill................................................214 Downshifting.....................................................................214 Additional brakes................................................................215 5.3.5 Driving uphill.................................................................216 Starting.........................................................................216 Driving..........................................................................216 5.3.6 Warning messages in the start menu.............................................217 5.3.7 Warning or malfunction messages on the instrument panel........................218 Meaning of the lamps.............................................................218 5.3.8 Messages on the on-board computer display......................................219 5.3.9 Indicator lights in the on-board computer display..............................221 5.3.10 Override torque reduction.....................................................223 5.3.11 Turning off the truck crane...................................................224 Securing against rolling away....................................................224 When stationary for more than 8 hours............................................225 5.3.12 Folding berth.................................................................226 5.4 Off-road driving.....................................................................227 Adjustments to the transmission......................................................227 Connections..........................................................................227 Changing the vehicle level...........................................................227 Rocking the vehicle free and towing..................................................227 5.4.1 Longitudinal and transverse differential locks.................................228 5.4.2 Operating the level adjustment system..........................................230 Open menu........................................................................230 Setting the onroad level........................................................231 Pre-selecting suspension struts..................................................231 Changing the vehicle level.......................................................232 Viewing the current inclination..................................................232 Exiting the menu.................................................................233 5.4.3 Freeing truck crane stuck in terrain...........................................234 Rocking the truck crane free.....................................................234 Towing free forwards.............................................................235 Towing free in reverse gear......................................................235 5.5 Separate steering....................................................................237 5.5.1 Switching to separate steering.................................................237 Manual...........................................................................238 Automatic........................................................................239 5.6 Heating and air-conditioning system..................................................241 5.6.1 Standard heating system,.......................................................241 Switching on.....................................................................241 Heating..........................................................................241 Air distribution.................................................................242 Examples.........................................................................243 Switching off....................................................................243 5.6.2 Air-conditioning system........................................................244 Information......................................................................244 Switching on/off.................................................................244 Cooling..........................................................................245 Drying...........................................................................245 5.6.3 Auxiliary water heater.........................................................246 Preheating the engine............................................................246 Preheating the driver's cab......................................................247 Switching on the auxiliary heater................................................248 Switching off the auxiliary heater...............................................249 Setting time and weekday.........................................................249 Saving automatic heating start...................................................250 Setting the heating period.......................................................251 Switching the automatic heating start on and off.................................251 Setting the remaining time.......................................................252 5.6.4 Auxiliary air heater...........................................................253 Switching on.....................................................................253 Temperature......................................................................254 Switching off....................................................................254 Other functions..................................................................254 5.7 Towing a trailer.....................................................................255 Effects on the axle loads............................................................255 Coupling the trailer.................................................................256 Connecting the supply lines..........................................................257 Removing the supply lines............................................................258 Uncoupling the trailer...............................................................258 Checking the braking force...........................................................260 6 Driving modes and rigging for on-road driving..............................................261 6.1 Driving modes........................................................................261 Information about the axle loads.....................................................261 6.1.1 Information on how to use the tables...........................................262 6.1.2 Tables for a maximum axle load of 12t (26,500lbs)............................263 For 385/95 R25 tyres.............................................................264 For 445/95 R25 tyres.............................................................265 For 525/80 R25 tyres.............................................................266 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)...........267 6.2 Rigging work for driving with a trailer..............................................268 6.2.1 Switching on the slewing gear freewheel........................................269 6.2.2 Switching on the boom floating position........................................270 6.2.3 Switching on boom pre-tensioning...............................................271 6.3 Main boom, removing/installing.......................................................272 Additional equipment required........................................................272 6.3.1 CHECKLIST: Removing the main boom..............................................273 Prerequisites....................................................................273 Checklist........................................................................273 6.3.2 CHECKLIST: Mounting the main boom..............................................275 Prerequisites....................................................................275 Checklist........................................................................275 6.3.3 Slinging the main boom.........................................................277 Marking..........................................................................277 6.3.4 Retracting/fitting the derricking cylinder head pin............................278 Operating the lifting device.....................................................278 Retracting the derricking cylinder head axle.....................................279 Fitting the derricking cylinder head axle........................................280 6.3.5 Retracting/extending the boom pivot pin........................................281 Before retracting................................................................281 After extending..................................................................282 Retracting/ extending the pivot pin..............................................283 6.3.6 Disconnecting/connecting hydraulics/electrical.................................284 Detachment.......................................................................284 Establishing.....................................................................285 6.3.7 Lifting the main boom off/on the turntable.....................................286 Lifting from the turntable.......................................................286 Lifting on to the turntable......................................................287 6.3.8 Aligning the connecting points.................................................287 6.3.9 Transporting the main boom.....................................................288 6.3.10 Inspections after main boom mounting..........................................289 6.4 Installing/removing outrigger beams..................................................291 6.4.1 CHECKLIST: Removing the outrigger beams........................................292 6.4.2 CHECKLIST: Installing the outrigger beams......................................294 6.4.3 Preparing the truck crane......................................................296 Prerequisites....................................................................296 For removal......................................................................296 6.4.4 Removing/attaching outrigger pads..............................................297 Removing the outrigger pads......................................................297 Attaching the outrigger pads.....................................................298 6.4.5 Disconnecting/establishing the hydraulic connection............................299 6.4.6 Disconnecting/establishing the electrical connection...........................300 6.4.7 Unscrewing/screwing in the spacers.............................................301 Unscrewing.......................................................................301 Screwing in......................................................................302 6.4.8 Disconnecting/establishing the connections to the outrigger box................303 6.4.9 Extending/retracting the outrigger beam........................................303 Extending the outrigger beam.....................................................303 Inserting the outrigger beam.....................................................305 6.4.10 Transporting the outrigger beams..............................................307 6.5 Rigging the auxiliary hoist..........................................................309 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................309 Prerequisites....................................................................309 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................311 Prerequisites....................................................................311 6.5.3 Slinging the auxiliary hoist...................................................313 6.5.4 Slinging the rigging frame.....................................................313 6.5.5 Lowering/raising the rigging frame.............................................314 Prerequisite.....................................................................314 6.5.6 Placing the auxiliary hoist on the counterweight combination...................314 6.5.7 Establishing/disconnecting the hydraulic connection............................315 6.5.8 Making/breaking the electrical connection......................................316 6.5.9 Creating the connection to the turntable.......................................317 Establishing the connection......................................................317 Disconnecting....................................................................319 6.5.10 Securing the hoist rope.......................................................320 6.5.11 Transporting the auxiliary hoist..............................................321 6.5.12 Check that the auxiliary hoist is functioning properly........................322 Slewing direction................................................................322 Slewing indicator................................................................322 7 Malfunctions in driving mode...............................................................325 7.1 Emergency stop switch................................................................325 7.2 What to do when a malfunction occurs in road traffic.................................327 7.3 Towing the truck crane...............................................................329 7.3.1 Towing after engine/transmission damage........................................330 Compressed-air supply............................................................330 Electric power supply............................................................331 On the transmission..............................................................331 Axle drives......................................................................332 Parking brake....................................................................332 Towing the truck crane out of the danger area....................................333 7.3.2 Tow starting...................................................................333 7.4 Other emergency operations...........................................................335 7.4.1 Externally starting the truck crane............................................335 7.4.2 Battery charger................................................................336 Prerequisites....................................................................336 7.5 Wheels and tyres.....................................................................337 7.5.1 Wheel change...................................................................337 Removing a damaged wheel.........................................................338 On the spare wheel holder........................................................338 Mounting a wheel.................................................................339 7.5.2 Inflating the tyres yourself...................................................341 Connecting the filling hose......................................................341 Inflating the tyres..............................................................342 Removing the filling hose........................................................342 7.6 Fuses................................................................................343 Notes on changing fuses..............................................................343 7.6.1 Fuses in the driver's cab......................................................344 Group F1.........................................................................344 Group F2.........................................................................345 Group F3.........................................................................345 Group F4.........................................................................346 Other fuses......................................................................346 Group F7.........................................................................347 Group F8.........................................................................347 Group F9.........................................................................348 Group F10........................................................................348 7.6.2 Fuses in the battery box.......................................................349 7.7 Troubleshooting......................................................................351 7.7.1 Malfunctions on the engine.....................................................351 7.7.2 Faults on the AdBlue (DEF) system..............................................353 7.7.3 Malfunctions in the transmission...............................................354 7.7.4 Malfunctions of the service brake..............................................355 7.7.5 Malfunctions of the steering...................................................356 7.7.6 Differential lock malfunctions.................................................357 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................357 7.7.8 Malfunctions on the suspension.................................................358 7.7.9 Malfunctions of the level adjustment system....................................358 7.7.10 Malfunction in the CCS control unit...........................................358 7.8 Warnings in the start menu...........................................................359 Symbols in the display area..........................................................359 7.8.1 Engine/transmission error menu.................................................364 Open menu........................................................................364 Exiting the menu.................................................................364 7.9 Procedure in the event of malfunctions...............................................365 7.9.1 Procedure during engine malfunctions...........................................365 7.9.2 Procedure during transmission malfunctions.....................................366 8 Index......................................................................................369 A........................................................................................371 B........................................................................................371 C........................................................................................372 D........................................................................................375 E........................................................................................376 F........................................................................................378 H........................................................................................378 I........................................................................................379 K........................................................................................379 L........................................................................................379 M........................................................................................380 O........................................................................................381 P........................................................................................382 R........................................................................................382 S........................................................................................384 T........................................................................................385 V........................................................................................387 W........................................................................................387 Hoist rope travel limitation.................................................................393 Hoist rope travel limitation menu........................................................394 Entering values..........................................................................395 Switching monitoring function on/off.....................................................395 Correction sheet.............................................................................397 Driving with rigged truck crane..........................................................397 9 Operating elements for crane operation.....................................................403 9.1 Overview of the operating elements...................................................403 9.1.1 Exterior of the truck crane....................................................404 9.1.2 Crane cab......................................................................408 Side panel.......................................................................410 Crane cab, rear..................................................................412 9.1.3 Control panels.................................................................414 Left.............................................................................414 Right............................................................................415 9.1.4 Control lever configuration....................................................416 Version 1........................................................................416 Version 2........................................................................417 9.1.5 Control unit CCS...............................................................418 9.1.6 CCS – Start menu...............................................................421 9.1.7 CCS – overview of menu groups..................................................422 Superstructure menu group........................................................426 Superstructure lock menu.........................................................427 Counterweight menu...............................................................428 Outrigger menu...................................................................429 Outrigger support beam menu......................................................431 Outrigger cylinders menu.........................................................432 Teleautomation menu group........................................................434 Telescoping full automation menu.................................................435 Telescoping semiautomation menu.................................................436 Main boom configuration menu.....................................................437 Active working range limiter menu group..........................................438 Overall height menu..............................................................439 Working radius menu..............................................................440 Slewing angle menu...............................................................441 Information menu group...........................................................442 Hydraulic pressure and fuel consumption menu.....................................443 Engine/Driving menu group........................................................444 Economy menu.....................................................................445 Heating/ airconditioning menu...................................................446 Telescoping menu group...........................................................447 Manual telescoping menu..........................................................448 Telescoping emergency program menu...............................................449 Unknown telescoping menu.........................................................450 Settings menu group..............................................................451 Crane cab menu...................................................................452 Menu for setting the display brightness and date/time............................453 Switch units menu................................................................454 Set control lever characteristic curve menu......................................455 Power unit speeds menu...........................................................456 Menu group Information...........................................................457 Operating hours menu.............................................................458 Engine/ transmission error menu..................................................460 Crane operation error menu.......................................................461 Program version menu.............................................................462 Operating additional equipment...................................................463 9.1.8 Control unit RCL...............................................................464 9.1.9 RCL – menu groups..............................................................466 Menu for entering rigging mode...................................................469 Monitoring menu..................................................................470 Lifting capacity tables menu.....................................................472 9.1.10 Hand-held controls............................................................473 Outrigger control panel..........................................................474 9.1.11 Outrigger control units.......................................................476 Button...........................................................................476 Outrigger button.................................................................477 Inclination and outrigger pressure display.......................................478 Raise axle display...............................................................479 9.2 Short description of the operating elements..........................................481 9.2.1 Definition of direction information............................................481 Basic rule.......................................................................481 Switches.........................................................................481 9.2.2 General rules for buttons and symbols on the display...........................482 9.2.3 Engine.........................................................................483 Side panel.......................................................................483 Economy menu.....................................................................484 9.2.4 AdBlue (DEF) system............................................................485 CCS display......................................................................485 9.2.5 Seat contact switch and dead man's switch......................................486 9.2.6 Crane control CCS..............................................................487 9.2.7 Outrigger......................................................................493 Hand-held control................................................................493 Right-hand control panel.........................................................494 Left-hand control panel..........................................................494 In the Outrigger menu............................................................495 On the outrigger control units...................................................497 9.2.8 Inclination indicators.........................................................499 9.2.9 Raise axle.....................................................................500 Outrigger control units..........................................................500 9.2.10 Outrigger pressure displays...................................................502 Outriggers submenu...............................................................502 Outrigger control units..........................................................502 9.2.11 Anemometer displays...........................................................502 9.2.12 Counterweight menu............................................................503 Counterweight submenu............................................................503 9.2.13 Main hoist....................................................................507 Control panels...................................................................507 CCS display......................................................................508 9.2.14 Auxiliary hoist...............................................................509 Control panels...................................................................509 CCS display......................................................................510 9.2.15 Slewing gear..................................................................511 Control panels...................................................................511 CCS display......................................................................512 9.2.16 Derricking gear...............................................................513 Control panels...................................................................513 CCS display......................................................................514 9.2.17 Telescoping mechanism.........................................................515 Control panels...................................................................515 CCS display......................................................................515 Telescoping full automation menu.................................................516 Telescoping semiautomation menu.................................................517 Manual telescoping menu..........................................................519 Main boom configuration menu.....................................................522 9.2.18 Hydraulic system..............................................................523 9.2.19 Superstructure lock/Houselock menu............................................524 Superstructure lock..............................................................524 Houselock........................................................................525 9.2.20 Rated capacity limiter (RCL)..................................................526 Control unit control console RCL.................................................526 Display RCL......................................................................527 Enter rigging mode menu..........................................................529 Monitoring menu..................................................................532 Lifting capacity tables menu.....................................................536 RCL override.....................................................................536 External displays................................................................537 9.2.21 Electrical system.............................................................539 9.2.22 Lighting, windscreen wiper/washing system.....................................539 Lighting.........................................................................539 Windscreen wiper/washing system..................................................540 9.2.23 Hand-held control.............................................................542 Sockets for handheld control....................................................542 Engine control panel.............................................................543 Horn.............................................................................543 Outrigger control panel..........................................................544 9.2.24 Windows, doors, keys..........................................................546 Windows..........................................................................546 Rear window......................................................................546 Crane cab door...................................................................547 Keys.............................................................................548 9.2.25 Diagnostics...................................................................548 10 Starting/turning off the engine – for crane operation.....................................551 10.1 When starting the engine for the first time of the day..............................551 10.1.1 Checking the fuel level and AdBlue (DEF) level................................552 Fuel.............................................................................552 AdBlue (DEF).....................................................................552 10.1.2 Checks before starting the engine.............................................553 On hydraulic tank................................................................553 Checking the hand-held control...................................................554 10.1.3 Switching on the ignition.....................................................554 10.1.4 Display – setting the brightness..............................................555 10.1.5 Starting the engine...........................................................556 10.1.6 Checks after starting the engine..............................................557 10.1.7 Setting idling speed..........................................................558 10.2 Starting the engine – with the hand-held control....................................559 Prerequisites........................................................................559 Starting the engine..................................................................559 10.3 Turning off the engine..............................................................561 10.3.1 During normal operation, with the ignition lock/with the handheld control....561 After turning off................................................................561 10.3.2 In emergencies, with the emergency stop switches..............................562 Resetting the emergency stop switch..............................................562 11 Crane operation...........................................................................565 11.1 Before operating the crane..........................................................565 11.1.1 CHECKLIST: Checks before operating the crane..................................565 11.1.2 Checking the condition of the truck crane.....................................569 Fuel tank auxiliary heater.......................................................569 Visual inspection................................................................569 Checking the position of the hoist ropes.........................................570 Checking the electrical system...................................................571 11.1.3 Adjusting the crane cab seat and front control panel..........................572 Crane cab seat...................................................................572 Front panel......................................................................572 11.1.4 Checking the safety equipment.................................................573 Rated capacity limiter...........................................................573 Lifting limit switch.............................................................573 Emergency stop switch............................................................574 Seat contact switch..............................................................575 11.1.5 Earthing the load.............................................................576 11.1.6 Preheating the hydraulic oil..................................................577 Prerequisites....................................................................577 Preheating.......................................................................577 11.1.7 Locking/unlocking the superstructure..........................................578 Locking points...................................................................578 Locking the superstructure.......................................................579 Unlocking the superstructure.....................................................579 11.1.8 Switching the Houselock on/off................................................580 Switching on the Houselock.......................................................580 Switching off the Houselock......................................................582 11.2 Operation of the rated capacity limiter.............................................583 11.2.1 Switch on the RCL.............................................................584 Switching on.....................................................................584 Brightness of the displays.......................................................586 Temperature on the display.......................................................586 11.2.2 Enter rigging mode............................................................587 Entering individual components...................................................588 Entering the RCL code............................................................592 Entering the reeving.............................................................593 Accepting the rigging mode.......................................................593 11.2.3 Checks before operating the crane.............................................595 Open menu........................................................................595 Checks...........................................................................595 11.2.4 Displays during crane operation...............................................598 11.2.5 RCL early warning.............................................................601 11.2.6 RCL switch-off................................................................601 Shutdown due to overload.........................................................601 11.2.7 Display in the event of errors................................................603 11.2.8 RCL override..................................................................604 Overview status display..........................................................604 When rigging.....................................................................605 To raise the boom................................................................606 In emergencies...................................................................607 11.2.9 Displaying the lifting capacity tables........................................608 11.2.10 Setting the time/date........................................................610 11.3 Crane operation with main boom......................................................611 11.3.1 Checks during crane operation.................................................611 Horizontal alignment.............................................................611 Safe distances...................................................................611 Checking the wind speed..........................................................612 11.3.2 Permissible slewing ranges and working positions..............................613 360 slewing range...............................................................613 0 to the rear working position..................................................613 180 to the front rigging position...............................................613 11.3.3 Main hoist....................................................................614 Switching on the main hoist......................................................615 Lifting and lowering.............................................................615 Maximum permissible hoist rope speed.............................................616 Switching off the main hoist.....................................................617 11.3.4 Auxiliary hoist...............................................................618 Switching on the auxiliary hoist.................................................618 Lifting and lowering.............................................................619 Maximum permissible hoist rope speed.............................................619 Switching off the auxiliary hoist................................................620 11.3.5 Lifting limit switch and lowering limit switch................................621 Lifting limit switch.............................................................621 Lowering limit switch............................................................623 11.3.6 Derricking gear...............................................................624 Switching on the derricking gear.................................................624 Maximum permissible derricking speed.............................................624 Raising and lowering.............................................................625 Re-enable raising function.......................................................626 Switching off the derricking gear................................................626 11.3.7 Telescoping mechanism.........................................................628 Overview.........................................................................629 Telescoping process..............................................................629 Assignment for display...........................................................632 Fixed length, intermediate length, telescoping length............................633 Telescoping......................................................................634 Telescoping sequence.............................................................634 Checks before starting work......................................................635 Switching on the telescoping mechanism...........................................636 Function of the control lever....................................................636 Switching off the telescoping mechanism..........................................638 Manual telescoping...............................................................639 Checking the initial position....................................................639 Unlocking the telescoping cylinder...............................................641 Extending/ retracting the telescoping cylinder...................................643 Lock telescoping cylinder........................................................644 Unlocking the telescopic section.................................................645 Telescoping the telescopic section...............................................646 Locking the telescopic section...................................................647 Locking the telescopic section for on-road driving...............................648 Telescoping with semi-automation.................................................648 Telescoping with full automation.................................................651 Telescoping with main boom configuration.........................................652 11.3.8 High-speed mode...............................................................653 Derricking gear/ telescoping mechanism...........................................653 Hoists...........................................................................654 11.3.9 Slewing gear..................................................................655 Switching on the slewing gear....................................................655 Turning..........................................................................656 Releasing locked slewing gear....................................................656 Maximum permissible slewing speed................................................657 Braking the slewing movement.....................................................658 Releasing the slewing gear brake.................................................658 Engaging the slewing gear brake..................................................658 Slewing gear freewheel...........................................................659 Switching off the slewing gear...................................................659 11.3.10 Possible movement combinations...............................................660 11.4 Settings and displays for crane operation...........................................661 11.4.1 Inclining the crane cab.......................................................661 11.4.2 Setting idling speed..........................................................662 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................662 11.4.4 Limiting the power unit speeds................................................663 11.4.5 Setting/switching on Economy mode.............................................664 Automatic........................................................................664 Manual...........................................................................664 11.4.6 Switching units...............................................................665 11.4.7 Setting the characteristic curves for the control levers......................666 11.4.8 Using the slewable spotlights.................................................667 11.4.9 Override torque reduction.....................................................668 11.4.10 Displaying the operating hours...............................................669 11.4.11 Warnings in the start menu...................................................670 Meaning of the symbols...........................................................670 11.5 Working range limiter...............................................................673 11.5.1 Viewing current settings......................................................674 11.5.2 Opening the working range limiter menu........................................675 11.5.3 Entering limit values.........................................................677 Overall height...................................................................677 Working radius...................................................................678 Slewing angle....................................................................678 11.5.4 Entering limit values manually................................................680 Limit values.....................................................................680 11.5.5 Switching monitoring functions on/off.........................................682 11.5.6 Shutdown by working range limiter.............................................683 11.6 Work break..........................................................................685 11.6.1 In case of short work breaks..................................................685 11.6.2 In case of work breaks of more than 8 hours...................................686 To secure the truck crane........................................................686 11.7 Heating and air-conditioning system.................................................687 11.7.1 Standard heating system.......................................................687 Switching on.....................................................................687 Heating..........................................................................687 Air distribution.................................................................687 Switching off....................................................................688 11.7.2 Air-conditioning system.......................................................689 Information......................................................................689 Switching on/off.................................................................689 Cooling, automatic...............................................................690 Cooling, maximum.................................................................690 11.7.3 Auxiliary heater..............................................................691 Switching on.....................................................................691 Setting the temperature..........................................................692 Setting the heating start/ heating duration......................................692 Switching heating start on/off...................................................693 11.8 CraneSTAR system....................................................................694 11.8.1 Overview......................................................................694 11.8.2 Position of the components....................................................694 12 Rigging work..............................................................................697 12.1 Rigging work checklists for crane operation with the main boom......................697 12.1.1 CHECKLIST: Rigging............................................................697 12.1.2 CHECKLIST: Unrigging..........................................................701 12.2 Choosing a suitable site............................................................705 12.2.1 Determining the required ground bearing area..................................705 12.2.2 Safe distance from slopes and pits............................................708 12.2.3 Earthing the truck crane......................................................709 12.2.4 Safe distance from electrical cables..........................................710 12.3 Rigging work after driving with a trailer...........................................713 12.3.1 Switching off the boom floating position......................................713 12.3.2 Switching off the slewing gear freewheel......................................714 Before slewing...................................................................714 12.3.3 Switching off boom pre-tensioning.............................................715 12.4 Connecting/disconnecting the hand-held control......................................717 12.5 Starting the engine for driving for rigging work....................................719 12.5.1 Starting/turning off the engine with the hand-held control....................719 Prerequisites....................................................................719 Starting the engine..............................................................720 Turning off the engine...........................................................720 12.5.2 Starting/turning off the engine from the outrigger control units..............721 Prerequisites....................................................................721 Starting the engine..............................................................721 Turning off the engine...........................................................721 12.6 Outrigger...........................................................................723 12.6.1 CHECKLIST: Extending the outriggers...........................................723 12.6.2 CHECKLIST: Retracting the outriggers..........................................725 12.6.3 Permissible outrigger spans...................................................726 12.6.4 Preparing the truck crane.....................................................727 In the driver's cab..............................................................727 Outrigger control units..........................................................727 12.6.5 Setting the outrigger spans...................................................728 For on-road driving..............................................................730 12.6.6 Extending/retracting outrigger beams..........................................731 From the control units...........................................................732 With the handheld control.......................................................733 From the crane cab...............................................................735 12.6.7 Moving the outrigger pads into working/driving position.......................737 12.6.8 Enlarging the ground bearing area.............................................738 12.6.9 Extending/retracting supporting cylinders.....................................739 From the control units...........................................................740 With the handheld control.......................................................741 From the crane cab...............................................................742 12.6.10 Level the truck crane on outriggers..........................................744 Inclination indicators...........................................................744 Prerequisites....................................................................745 Manual alignment.................................................................746 Automatic alignment..............................................................747 12.6.11 Levelling the free-on-wheels truck crane.....................................749 12.6.12 Outrigger pressure display...................................................751 12.7 Rigging/unrigging the counterweight.................................................753 12.7.1 (15,432 lbs) (110,452 lbs)Counterweight sections..............................753 12.7.2 Identification................................................................755 12.7.3 Slinging points on the counterweight sections.................................756 12.7.4 CHECKLIST: Rigging the counterweight..........................................757 12.7.5 CHECKLIST: Unrigging the counterweight........................................758 12.7.6 Assembling counterweight combination..........................................760 12.7.7 Counterweight hoist unit......................................................767 Counterweight menu...............................................................767 Extending/ retracting the lifting cylinders......................................768 Automatic mode, rigging..........................................................769 Automatic mode, unrigging........................................................771 Cancel automatic mode............................................................772 12.7.8 Setting down counterweight for driving the truck crane........................773 12.7.9 Slewing with rigged counterweight.............................................776 12.8 Rigging work on the main boom.......................................................779 12.8.1 Hook block on the bumper......................................................779 Picking up the hook block........................................................779 Attaching the hook block.........................................................780 12.8.2 Hook block in the compartment.................................................781 Prerequisites....................................................................781 12.8.3 Hook block on a separate vehicle..............................................783 Picking up the hook block........................................................784 Setting down the hook block......................................................784 12.8.4 Hook block, separable.........................................................786 Rigging for onroad driving......................................................786 Rigging for crane operation......................................................787 12.8.5 Reeving and unreeving the hoist rope..........................................788 Version A........................................................................788 Version B........................................................................789 Reeving the hoist rope...........................................................791 Unreeving the hoist rope.........................................................794 12.8.6 Possible reeving methods on the main boom.....................................795 With 7 head sheaves..............................................................795 12.8.7 Installing/removing the lifting limit switch..................................798 Installing the lifting limit switch..............................................798 Removing the lifting limit switch................................................801 12.8.8 Locking/unlocking the lifting limit switch....................................803 Locking..........................................................................803 Releasing locking................................................................803 12.8.9 Anemometer and air traffic control light......................................804 Installing.......................................................................804 Switching the air traffic control light on and off...............................804 Removing.........................................................................805 For transport....................................................................805 12.9 Other rigging work..................................................................807 12.9.1 Railings on the turntable.....................................................807 12.9.2 Folding the lighting carrier in/out...........................................808 12.9.3 Safety harness on the main boom...............................................809 Prerequisites....................................................................810 Requirements.....................................................................810 Attaching/ detaching fall prevention safety system to/from safety harness........811 Inspecting/ replacing safety harness.............................................813 12.9.4 Slinging points for personal protective equipment.............................814 12.9.5 Cameras for crane operation...................................................815 Camera on the hoists.............................................................815 Camera on main boom..............................................................816 Operating the camera.............................................................818 12.9.6 Stair tread on the crane cab..................................................819 13 Driving with rigged truck crane...........................................................823 13.1 Driving path........................................................................823 13.2 Permissible rigging modes and axle loads............................................824 Axle load table......................................................................825 13.3 Before driving......................................................................826 13.3.1 Securing the superstructure against slewing...................................826 13.3.2 Checking tyre pressure and wind speed.........................................827 13.3.3 Putting the truck crane on the wheels.........................................828 13.3.4 Gears/connections.............................................................830 Transmission.....................................................................830 Switching on separate steering...................................................830 13.4 While driving.......................................................................830 13.5 After driving.......................................................................832 14 Transport.................................................................................835 14.1 Transport with transport vehicle....................................................835 14.1.1 CHECKLIST: Checks before transport............................................836 14.1.2 Drive the truck crane onto the transport vehicle..............................838 Drive on.........................................................................838 Lashing..........................................................................838 14.1.3 Slinging points...............................................................839 15 Malfunctions during crane operation.......................................................843 15.1 Emergency stop switch...............................................................843 15.2 What to do when a malfunction occurs during crane operation.........................845 Load can be lowered..................................................................845 Load cannot be lowered...............................................................845 15.3 Fuses in the crane cab..............................................................847 Notes on changing fuses..............................................................847 15.4 Finding and eliminating malfunctions................................................852 15.4.1 Malfunctions on the engine....................................................852 15.4.2 Malfunctions on the counterweight hoist unit..................................852 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................853 15.4.4 Malfunctions in the hoist cameras.............................................854 15.4.5 Malfunctions in the main boom camera..........................................854 15.4.6 Malfunctions on the derricking gear...........................................855 15.4.7 Malfunctions in the telescoping mechanism.....................................856 15.4.8 Malfunctions on the slewing gear..............................................858 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................859 15.4.10 Malfunctions when inclining the crane cab....................................859 15.4.11 Malfunctions when operating with the hand-held control.......................859 15.4.12 Malfunctions of the outriggers...............................................860 15.4.13 Malfunction in the CCS control unit..........................................860 15.4.14 Troubleshooting the crane control............................................861 General malfunctions.............................................................861 Symbols in the error or information display areas................................862 Displays in the Error menu.......................................................866 15.4.15 Malfunctions in the CraneSTAR system.........................................868 15.5 Emergency operations and programmes.................................................869 15.5.1 Mechanical emergency activation for retracting................................870 Prior to the emergency activation, check.........................................870 Procedure........................................................................870 Mechanical emergency activation..................................................871 15.5.2 Telescoping emergency programme...............................................873 Open submenu Emergency program...................................................873 Determining the error type.......................................................874 Error on length indicator........................................................875 Tables for approaching the locking points........................................879 15.5.3 Entering the current telescoping..............................................881 15.5.4 Emergency operation with the hand-held control................................883 Preparations.....................................................................883 Operating a power unit...........................................................884 Stopping movements...............................................................886 Stopping movements in emergencies................................................886 Turning off the engine...........................................................886 15.6 Hydraulic emergency operation.......................................................887 15.6.1 Connecting/disconnecting hoses................................................887 15.6.2 Establishing the required hydraulic circuits..................................888 Switching over valves............................................................888 For lowering.....................................................................889 15.6.3 Operating principle of emergency operation BGR 159............................891 15.6.4 Connecting/disconnecting hoses................................................892 Establishing connections.........................................................892 Disconnecting....................................................................893 15.6.5 Switching emergency operation on/off..........................................894 15.6.6 Establishing the hydraulic circuits required..................................895 Switching over valves............................................................895 For lifting/ lowering............................................................897 For slewing......................................................................898 15.6.7 Performing emergency operation................................................899 Turning..........................................................................899 Derricking.......................................................................900 Lifting/lowering.................................................................900 15.6.8 After emergency operation.....................................................901 Switching off emergency operation................................................901 Switching over to crane operation................................................901 Disconnecting the hoses..........................................................901 15.6.9 Emergency supply of another crane.............................................902 For emergency supply.............................................................902 After emergency supply...........................................................902 16 Index.....................................................................................905 A........................................................................................907 B........................................................................................907 C........................................................................................908 D........................................................................................911 E........................................................................................912 F........................................................................................914 H........................................................................................914 I........................................................................................915 K........................................................................................915 L........................................................................................915 M........................................................................................916 O........................................................................................917 P........................................................................................918 R........................................................................................918 S........................................................................................920 T........................................................................................921 V........................................................................................923 W........................................................................................923
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