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Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
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Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
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Description
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
Language : English
Pages : 922
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
The GMK 5250L 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 5250L 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 5250L 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 5250L truck crane is designed solely for lifting loads which are within the permitted GMK
5250L 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 5250L 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 5250L.
The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK
5250L truck crane. The user alone bears the
risk.
TABLE OF CONTENTS:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
Part1 - Driving.................................................................................. 1 Additional Pages............................................................................. 0 Telescoping emergency programme.......................................................... 3 1 Overview................................................................................... 9 1.1 Accidents............................................................................ 9 1.2 Branch offices....................................................................... 11 1.2.1 Manitowoc Crane Care........................................................... 11 1.2.2 Dealer list.................................................................... 11 1.3 Warranty specifications.............................................................. 11 1.4 Terms used........................................................................... 12 1.5 Technical data....................................................................... 15 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 15 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 16 Dimensions....................................................................... 17 Weight and axle loads............................................................ 17 1.5.3 Dimensions and weights of removable parts...................................... 18 Spare wheel...................................................................... 18 Outriggers....................................................................... 18 Main boom........................................................................ 19 Hook blocks and hook tackle...................................................... 19 Hook blocks, split............................................................... 20 Auxiliary hoist.................................................................. 21 Counterweight parts.............................................................. 21 1.5.4 Carrier........................................................................ 22 Engine........................................................................... 22 Transmission..................................................................... 22 Transfer case.................................................................... 22 Axle lines....................................................................... 22 Steering......................................................................... 22 Tyres............................................................................ 23 Electrical system................................................................ 23 Tool............................................................................. 23 Towing couplings................................................................. 23 Driving speeds................................................................... 23 Climbing ability................................................................. 23 Outriggers....................................................................... 24 Turning radii.................................................................... 25 1.5.5 Superstructure................................................................. 26 Main hoist....................................................................... 26 Auxiliary hoist.................................................................. 26 Slewing gears.................................................................... 26 Derricking gear.................................................................. 26 Main boom........................................................................ 27 Lattice extension................................................................ 27 Operating speeds................................................................. 27 Noise emission................................................................... 27 1.6 Documentation supplied............................................................... 29 1.6.1 Questions on documentation..................................................... 30 1.7 Notes on the operating manual........................................................ 31 1.7.1 What do the symbols used mean?................................................. 31 1.7.2 How is the operating manual structured?........................................ 33 Division......................................................................... 33 Structure of the chapters........................................................ 33 Structure of the pages........................................................... 34 1.7.3 How do I find the information I need?.......................................... 35 Cross-references example......................................................... 36 1.7.4 What information is available for operations planning?......................... 38 1.8 Conversion table for US measuring units.............................................. 39 1.9 Training – Information............................................................... 41 1.10 Identification...................................................................... 42 1.11 EC Declaration of Conformity........................................................ 44 2 Basic safety instructions.................................................................. 47 2.1 Intended use......................................................................... 47 2.1.1 Improper use................................................................... 48 2.2 Organisational measures.............................................................. 49 2.3 Personnel qualifications............................................................. 51 2.4 Safety instructions for driving the truck crane...................................... 52 2.5 Safety instructions for crane operation.............................................. 53 2.6 Notes on transporting persons........................................................ 55 Equipment for lifting persons........................................................ 55 Personnel............................................................................ 55 Operation............................................................................ 56 Truck crane.......................................................................... 57 3 Operating elements for driving............................................................. 61 3.1 Overview of the operating elements................................................... 61 3.1.1 On the outside of the truck crane.............................................. 62 3.1.2 Cab............................................................................ 66 Overview......................................................................... 66 Behind the cover................................................................. 70 In the rear of the driver's cab.................................................. 70 3.1.3 Instrument panel............................................................... 71 Left/right....................................................................... 71 Middle........................................................................... 72 On-board computer time correction................................................ 74 3.1.4 On-board computer.............................................................. 75 3.1.5 Steering column/steering wheel................................................. 76 3.1.6 Transmission operating elements................................................ 77 3.1.7 Tachograph..................................................................... 78 3.1.8 Control unit CCS............................................................... 79 3.1.9 Display CCS – start menu....................................................... 80 3.1.10 CCS – overview of menu groups................................................. 82 Carrier menu group............................................................... 84 Suspension/level adjustment menu................................................. 85 Driving menu..................................................................... 86 Settings menu group.............................................................. 87 Menu for setting the display brightness and date/time............................ 88 Information menu group........................................................... 89 Operating hours menu............................................................. 90 Engine/ transmission error menu.................................................. 91 Crane operation error menu....................................................... 92 Operating additional equipment................................................... 93 3.1.11 Outrigger control units....................................................... 94 3.1.12 Heating/Air-conditioning system............................................... 95 Standard heating system.......................................................... 95 Auxiliary water heater........................................................... 96 Auxiliary air heater............................................................. 97 3.1.13 Sockets for hand-held control................................................. 98 3.1.14 Outrigger control units....................................................... 99 3.2 Short description of the operating elements..........................................101 3.2.1 Definition of direction information............................................102 Basic rule.......................................................................102 Switches and buttons.............................................................102 3.2.2 General rules for buttons and symbols on the display...........................103 3.2.3 Engine.........................................................................104 Steering column..................................................................104 On the steering wheel............................................................104 Instrument panel.................................................................105 3.2.4 AdBlue system (DEF)............................................................106 Instrument panel.................................................................106 CCS display......................................................................107 3.2.5 Battery master switch..........................................................107 3.2.6 Electrical system..............................................................108 3.2.7 Crane control CCS..............................................................109 3.2.8 Transmission...................................................................113 Transmission control unit........................................................113 Display, driving mode,...........................................................114 3.2.9 Reverse camera.................................................................116 3.2.10 Final drive...................................................................117 3.2.11 Brakes........................................................................119 Service brake....................................................................119 Additional brakes................................................................119 Parking brake....................................................................120 3.2.12 Steering/separate steering....................................................122 Instrument panel.................................................................122 CCS display......................................................................123 Driver's door....................................................................124 3.2.13 Suspension....................................................................125 CCS display......................................................................125 Outrigger control units..........................................................125 3.2.14 Lighting/windscreen wipers/horn...............................................126 Steering column..................................................................126 Steering wheel...................................................................126 Instrument panel.................................................................126 CCS display......................................................................128 Roof.............................................................................128 3.2.15 Level adjustment system.......................................................129 3.2.16 Tachograph/speedometer........................................................131 Tachograph.......................................................................131 Speedometer......................................................................131 3.2.17 Diagnostics...................................................................132 3.2.18 On-board computer.............................................................133 3.2.19 Windows, doors, keys..........................................................135 Window winder....................................................................135 Doors............................................................................136 Keys.............................................................................136 3.2.20 Front flap....................................................................137 4 Starting/turning off the engine for driving................................................141 4.1 Starting the engine from the driver's cab............................................141 4.1.1 CHECKLIST: Starting the engine.................................................141 4.1.2 CHECKLIST: At low temperatures.................................................144 4.1.3 Ladders and access ladders.....................................................144 Access ladders...................................................................144 Ladders..........................................................................145 4.1.4 Refuel.........................................................................147 Standard tank....................................................................147 Dual tank........................................................................148 AdBlue...........................................................................149 4.1.5 Checks before starting the engine..............................................150 On hydraulic tank................................................................150 Battery master switch............................................................151 Checking the hand-held control...................................................151 4.1.6 Switching on the ignition......................................................151 4.1.7 Lamp test/equalisation of the switching states.................................152 Lamp test........................................................................152 Switching state alignment........................................................152 4.1.8 Display – setting the brightness...............................................153 4.1.9 Starting the engine............................................................154 4.1.10 Checks after starting the engine..............................................156 Checking in the main menu........................................................156 Indicator lamps on the instrument panel..........................................157 4.1.11 Monitoring elements...........................................................159 Instrument panel.................................................................159 4.1.12 Start menu....................................................................160 4.1.13 Setting idling speed..........................................................161 4.2 Turning off the engine...............................................................163 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....163 After turning off................................................................163 4.2.2 Using the emergency stop switches..............................................164 Resetting the emergency stop switch..............................................164 4.3 Air intake inhibitor.................................................................165 Releasing the air intake inhibitor...................................................165 5 Driving....................................................................................169 5.1 Before driving.......................................................................169 5.1.1 CHECKLIST: Checks before on-road driving.......................................169 5.1.2 Checking the condition of the truck crane......................................175 Electrical system................................................................175 Adjusting the mirrors............................................................175 Warning plates for vehicle width.................................................177 Displaying vehicle height........................................................177 Supply pressure..................................................................178 Parking brake....................................................................179 5.1.3 Adjusting the seat and the steering column.....................................180 Driver's seat....................................................................180 Passenger's seat.................................................................181 Steering column, adjusting.......................................................182 5.1.4 Switching the suspension on/off................................................183 Open menu........................................................................183 Switching on the suspension......................................................184 Switching off the suspension.....................................................184 5.1.5 Setting the tachograph.........................................................185 Prerequisites....................................................................185 In the event of malfunctions.....................................................185 Setting the tachograph...........................................................186 5.1.6 Entering the time/date.........................................................190 5.1.7 Displaying and resetting operating hours.......................................191 5.2 Operating the transmission...........................................................193 5.2.1 Switching on...................................................................193 5.2.2 Switching the transmission to neutral position.................................194 5.2.3 Selecting the direction of travel and starting gear............................195 Selecting the driving direction..................................................195 Selecting the starting gear......................................................196 5.2.4 Changing the operating mode....................................................197 Changing to automatic mode.......................................................197 Change to manual mode............................................................197 5.2.5 Starting.......................................................................198 5.2.6 Driving and changing gears.....................................................199 In automatic operating mode......................................................199 In manual operating mode.........................................................200 5.2.7 Changing the driving direction.................................................201 5.2.8 Stopping.......................................................................201 Stopping for along period oftime...............................................201 5.2.9 On the roller type dynamometer.................................................202 5.2.10 Preheating transmission.......................................................202 5.3 Driving and turning off the truck crane..............................................203 5.3.1 Checks while driving...........................................................203 Immediately after you start to move..............................................203 While driving....................................................................205 5.3.2 Cruise control.................................................................206 Switching on.....................................................................206 Switching off....................................................................207 5.3.3 Temposet.......................................................................208 Switching on.....................................................................208 Switching off....................................................................208 5.3.4 Driving downhill...............................................................209 Starting.........................................................................209 Inspections when driving downhill................................................210 Downshifting.....................................................................210 Additional brakes................................................................211 5.3.5 Driving uphill.................................................................212 Starting.........................................................................212 Driving..........................................................................212 5.3.6 Warning messages in the start menu.............................................213 5.3.7 Warning or malfunction messages on the instrument panel........................214 Meaning of the lamps.............................................................214 5.3.8 Messages on the on-board computer display......................................215 5.3.9 Indicator lights in the on-board computer display..............................217 5.3.10 Override torque reduction.....................................................219 5.3.11 Turning off the truck crane...................................................220 Securing against rolling away....................................................220 When stationary for more than 8 hours............................................221 5.3.12 Folding berth.................................................................222 5.4 Off-road driving.....................................................................223 Adjustments to the transmission......................................................223 Connections..........................................................................223 Changing the vehicle level...........................................................223 Rocking the vehicle free and towing..................................................223 5.4.1 Longitudinal and transverse differential locks.................................224 5.4.2 Operating the level adjustment system..........................................226 Open menu........................................................................226 Setting the onroad level........................................................227 Pre-selecting suspension struts..................................................227 Changing the vehicle level.......................................................228 Viewing the current inclination..................................................228 Exiting the menu.................................................................229 5.4.3 Freeing truck crane stuck in terrain...........................................230 Rocking the truck crane free.....................................................230 Towing free forwards.............................................................231 Towing free in reverse gear......................................................231 5.5 Separate steering....................................................................233 5.5.1 Switching to separate steering.................................................233 Manual...........................................................................234 Automatic........................................................................235 5.6 Heating and air-conditioning system..................................................237 5.6.1 Standard heating system,.......................................................237 Switching on.....................................................................237 Heating..........................................................................237 Air distribution.................................................................238 Examples.........................................................................239 Switching off....................................................................239 5.6.2 Air-conditioning system........................................................240 Information......................................................................240 Switching on/off.................................................................240 Cooling..........................................................................241 Drying...........................................................................241 5.6.3 Auxiliary water heater.........................................................242 Preheating the engine............................................................242 Preheating the driver's cab......................................................243 Switching on the auxiliary heater................................................244 Switching off the auxiliary heater...............................................245 Setting time and weekday.........................................................245 Saving automatic heating start...................................................246 Setting the heating period.......................................................247 Switching the automatic heating start on and off.................................247 Setting the remaining time.......................................................248 5.6.4 Auxiliary air heater...........................................................249 Switching on.....................................................................249 Temperature......................................................................250 Switching off....................................................................250 Other functions..................................................................250 5.7 Towing a trailer.....................................................................251 Effects on the axle loads............................................................251 Coupling the trailer.................................................................252 Connecting the supply lines..........................................................253 Removing the supply lines............................................................254 Uncoupling the trailer...............................................................254 Checking the braking force...........................................................256 6 Driving modes and rigging for on-road driving..............................................259 6.1 Driving modes........................................................................259 Information about the axle loads.....................................................259 6.1.1 Information on how to use the tables...........................................260 6.1.2 Tables for a maximum axle load of 12t.........................................261 For 385/95 R25 tyres.............................................................261 For 445/95 R25 525/80 R25 tyres..................................................262 6.1.3 Maximum permitted speeds with an axle load of over 12t........................263 6.2 Rigging work for driving with a trailer..............................................264 6.2.1 Switching on the slewing gear freewheel........................................265 6.2.2 Switching on the boom floating position........................................266 6.2.3 Switching on boom pre-tensioning...............................................267 6.3 Main boom, removing/installing.......................................................268 Additional equipment required........................................................268 6.3.1 CHECKLIST: Removing the main boom..............................................269 Prerequisites....................................................................269 Checklist........................................................................269 6.3.2 CHECKLIST: Mounting the main boom..............................................271 Prerequisites....................................................................271 Checklist........................................................................271 6.3.3 Slinging the main boom.........................................................273 Marking..........................................................................273 Installing the lifting gear......................................................273 Removing the lifting gear........................................................274 6.3.4 Retracting/fitting the derricking cylinder head pin............................275 Operating the lifting device.....................................................275 Retracting the derricking cylinder head axle.....................................276 Fitting the derricking cylinder head axle........................................277 6.3.5 Retracting/extending the boom pivot pin........................................278 Before retracting................................................................278 After extending..................................................................279 Retracting/ extending the pivot pin..............................................280 6.3.6 Disconnecting/connecting hydraulics/electrical.................................281 Detachment.......................................................................281 Establishing.....................................................................282 6.3.7 Lifting the main boom off/on the turntable.....................................283 Lifting from the turntable.......................................................283 Lifting on to the turntable......................................................284 6.3.8 Aligning the connecting points.................................................284 6.3.9 Transporting the main boom.....................................................285 6.3.10 Inspections after main boom mounting..........................................286 6.4 Installing/removing outrigger beams..................................................287 6.4.1 CHECKLIST: Removing the outrigger beams........................................288 6.4.2 CHECKLIST: Installing the outrigger beams......................................290 6.4.3 Preparing the truck crane......................................................292 Prerequisites....................................................................292 For removal......................................................................292 6.4.4 Removing/attaching outrigger pads..............................................293 Removing the outrigger pads......................................................293 Attaching the outrigger pads.....................................................294 6.4.5 Disconnecting/establishing the hydraulic connection............................295 6.4.6 Disconnecting/establishing the electrical connection...........................296 6.4.7 Unscrewing/screwing in the spacers.............................................297 Unscrewing.......................................................................297 Screwing in......................................................................298 6.4.8 Disconnecting/establishing the connections to the outrigger box................299 6.4.9 Extending/retracting the outrigger beam........................................299 Extending the outrigger beam.....................................................299 Inserting the outrigger beam.....................................................301 6.4.10 Transporting the outrigger beams..............................................303 6.5 Rigging the auxiliary hoist..........................................................305 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................305 Prerequisites....................................................................305 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................307 Prerequisites....................................................................307 6.5.3 Slinging the auxiliary hoist...................................................309 6.5.4 Slinging the rigging frame.....................................................309 6.5.5 Lowering/raising the rigging frame.............................................310 Prerequisite.....................................................................310 6.5.6 Placing the auxiliary hoist on the counterweight combination...................310 6.5.7 Establishing/disconnecting the hydraulic connection............................311 6.5.8 Making/breaking the electrical connection......................................312 6.5.9 Creating the connection to the turntable.......................................313 Establishing the connection......................................................313 Disconnecting....................................................................315 6.5.10 Securing the hoist rope.......................................................316 6.5.11 Transporting the auxiliary hoist..............................................317 6.5.12 Check that the auxiliary hoist is functioning properly........................318 Slewing direction................................................................318 Slewing indicator................................................................318 7 Malfunctions in driving mode...............................................................321 7.1 Emergency stop switch................................................................321 7.2 What to do when a malfunction occurs in road traffic.................................323 7.3 Towing the truck crane...............................................................325 7.3.1 Towing after engine/transmission damage........................................326 Compressed-air supply............................................................326 Electric power supply............................................................327 On the transmission..............................................................327 Axle drives......................................................................328 Parking brake....................................................................328 Towing the truck crane out of the danger area....................................329 7.3.2 Tow starting...................................................................329 7.4 Other emergency operations...........................................................331 7.4.1 Externally starting the truck crane............................................331 7.4.2 Battery charger................................................................332 Prerequisites....................................................................332 7.5 Wheels and tyres.....................................................................333 7.5.1 Wheel change...................................................................333 Removing a damaged wheel.........................................................334 On the spare wheel holder........................................................334 Mounting a wheel.................................................................335 7.5.2 Inflating the tyres yourself...................................................337 Connecting the filling hose......................................................337 Inflating the tyres..............................................................338 Removing the filling hose........................................................338 7.6 Fuses................................................................................339 Notes on changing fuses..............................................................339 7.6.1 Fuses in the driver's cab......................................................340 Group F1.........................................................................340 Group F2.........................................................................341 Group F3.........................................................................341 Group F4.........................................................................342 Other fuses......................................................................342 Group F7.........................................................................343 Group F8.........................................................................343 Group F9.........................................................................344 Group F10........................................................................344 7.6.2 Fuses in the battery box.......................................................345 7.7 Troubleshooting......................................................................347 7.7.1 Malfunctions on the engine.....................................................347 7.7.2 Faults on the AdBlue (DEF) system..............................................349 7.7.3 Malfunctions in the transmission...............................................350 7.7.4 Malfunctions of the service brake..............................................351 7.7.5 Malfunctions of the steering...................................................352 7.7.6 Differential lock malfunctions.................................................353 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................353 7.7.8 Malfunctions on the suspension.................................................354 7.7.9 Malfunctions of the level adjustment system....................................354 7.7.10 Malfunction in the CCS control unit...........................................354 7.8 Warnings in the start menu...........................................................355 Symbols in the display area..........................................................355 7.8.1 Engine/transmission error menu.................................................360 Open menu........................................................................360 Exiting the menu.................................................................360 7.9 Procedure in the event of malfunctions...............................................361 7.9.1 Procedure during engine malfunctions...........................................361 7.9.2 Procedure during transmission malfunctions.....................................362 8 Index......................................................................................365 A........................................................................................367 B........................................................................................367 C........................................................................................368 D........................................................................................371 E........................................................................................372 F........................................................................................374 H........................................................................................374 I........................................................................................375 K........................................................................................375 L........................................................................................375 M........................................................................................376 O........................................................................................377 P........................................................................................378 R........................................................................................378 S........................................................................................380 T........................................................................................381 V........................................................................................383 W........................................................................................383 Part 2 - Crane operation.........................................................................387 Additional Pages............................................................................. 0 Telescoping emergency programme..........................................................389 9 Operating elements for crane operation.....................................................395 9.1 Overview of the operating elements...................................................395 9.1.1 Exterior of the truck crane....................................................396 9.1.2 Crane cab......................................................................400 Side panel.......................................................................402 Crane cab, rear..................................................................404 9.1.3 Control panels.................................................................406 Left.............................................................................406 Right............................................................................407 9.1.4 Control lever configuration....................................................408 Version 1........................................................................408 Version 2........................................................................409 9.1.5 Control unit CCS...............................................................410 9.1.6 CCS – Start menu...............................................................413 9.1.7 CCS – overview of menu groups..................................................414 Superstructure menu group........................................................418 Superstructure lock menu.........................................................419 Counterweight menu...............................................................420 Outrigger menu...................................................................421 Outrigger support beam menu......................................................423 Outrigger cylinders menu.........................................................424 Teleautomation menu group........................................................426 Telescoping full automation menu.................................................427 Telescoping semiautomation menu.................................................428 Main boom configuration menu.....................................................429 Active working range limiter menu group..........................................430 Overall height menu..............................................................431 Working radius menu..............................................................432 Slewing angle menu...............................................................433 Information menu group...........................................................434 Hydraulic pressure and fuel consumption menu.....................................435 Engine/Driving menu group........................................................436 Economy menu.....................................................................437 Heating/ airconditioning menu...................................................438 Telescoping menu group...........................................................439 Manual telescoping menu..........................................................440 Telescoping emergency program menu...............................................441 Unknown telescoping menu.........................................................442 Settings menu group..............................................................443 Crane cab menu...................................................................444 Menu for setting the display brightness and date/time............................445 Switch units menu................................................................446 Set control lever characteristic curve menu......................................447 Power unit speeds menu...........................................................448 Menu group Information...........................................................449 Operating hours menu.............................................................450 Engine/ transmission error menu..................................................452 Crane operation error menu.......................................................453 Program version menu.............................................................454 Operating additional equipment...................................................455 9.1.8 Control unit RCL...............................................................456 9.1.9 RCL – menu groups..............................................................458 Menu for entering rigging mode...................................................461 Monitoring menu..................................................................462 Lifting capacity tables menu.....................................................464 9.1.10 Hand-held controls............................................................465 Outrigger control panel..........................................................466 9.1.11 Outrigger control units.......................................................468 Button...........................................................................468 Outrigger button.................................................................469 Inclination and outrigger pressure display.......................................470 Raise axle display...............................................................471 9.2 Short description of the operating elements..........................................473 9.2.1 Definition of direction information............................................473 Basic rule.......................................................................473 Switches.........................................................................473 9.2.2 General rules for buttons and symbols on the display...........................474 9.2.3 Engine.........................................................................475 Side panel.......................................................................475 Economy menu.....................................................................476 9.2.4 AdBlue (DEF) system............................................................477 CCS display......................................................................477 9.2.5 Seat contact switch and dead man's switch......................................478 9.2.6 Crane control CCS..............................................................479 9.2.7 Outrigger......................................................................485 Hand-held control................................................................485 Right-hand control panel.........................................................486 Left-hand control panel..........................................................486 In the Outrigger menu............................................................487 On the outrigger control units...................................................489 9.2.8 Inclination indicators.........................................................491 9.2.9 Raise axle.....................................................................492 Outrigger control units..........................................................492 9.2.10 Outrigger pressure displays...................................................494 Outriggers submenu...............................................................494 Outrigger control units..........................................................494 9.2.11 Anemometer displays...........................................................494 9.2.12 Counterweight menu............................................................495 Counterweight submenu............................................................495 9.2.13 Main hoist....................................................................499 Control panels...................................................................499 CCS display......................................................................500 9.2.14 Auxiliary hoist...............................................................501 Control panels...................................................................501 CCS display......................................................................502 9.2.15 Slewing gear..................................................................503 Control panels...................................................................503 CCS display......................................................................504 9.2.16 Derricking gear...............................................................505 Control panels...................................................................505 CCS display......................................................................506 9.2.17 Telescoping mechanism.........................................................507 Control panels...................................................................507 CCS display......................................................................507 Telescoping full automation menu.................................................508 Telescoping semiautomation menu.................................................509 Manual telescoping menu..........................................................511 Main boom configuration menu.....................................................514 9.2.18 Hydraulic system..............................................................515 9.2.19 Superstructure lock/Houselock menu............................................516 Superstructure lock..............................................................516 Houselock........................................................................517 9.2.20 Rated capacity limiter (RCL)..................................................518 Control unit control console RCL.................................................518 Display RCL......................................................................519 Enter rigging mode menu..........................................................521 Monitoring menu..................................................................524 Lifting capacity tables menu.....................................................528 RCL override.....................................................................528 External displays................................................................529 9.2.21 Electrical system.............................................................531 9.2.22 Lighting, windscreen wiper/washing system.....................................531 Lighting.........................................................................531 Windscreen wiper/washing system..................................................532 9.2.23 Hand-held control.............................................................534 Sockets for handheld control....................................................534 Engine control panel.............................................................535 Horn.............................................................................535 Outrigger control panel..........................................................536 9.2.24 Windows, doors, keys..........................................................538 Windows..........................................................................538 Rear window......................................................................538 Crane cab door...................................................................539 Keys.............................................................................540 9.2.25 Diagnostics...................................................................540 10 Starting/turning off the engine – for crane operation.....................................543 10.1 When starting the engine for the first time of the day..............................543 10.1.1 Checking the fuel level and AdBlue (DEF) level................................544 Fuel.............................................................................544 AdBlue (DEF).....................................................................544 10.1.2 Checks before starting the engine.............................................545 On hydraulic tank................................................................545 Checking the hand-held control...................................................546 10.1.3 Switching on the ignition.....................................................546 10.1.4 Display – setting the brightness..............................................547 10.1.5 Starting the engine...........................................................548 10.1.6 Checks after starting the engine..............................................549 10.1.7 Setting idling speed..........................................................550 10.2 Starting the engine – with the hand-held control....................................551 Prerequisites........................................................................551 Starting the engine..................................................................551 10.3 Turning off the engine..............................................................553 10.3.1 During normal operation, with the ignition lock/with the handheld control....553 After turning off................................................................553 10.3.2 In emergencies, with the emergency stop switches..............................554 Resetting the emergency stop switch..............................................554 11 Crane operation...........................................................................557 11.1 Before operating the crane..........................................................557 11.1.1 CHECKLIST: Checks before operating the crane..................................557 11.1.2 Checking the condition of the truck crane.....................................561 Fuel tank auxiliary heater.......................................................561 Visual inspection................................................................561 Checking the position of the hoist ropes.........................................562 Checking the electrical system...................................................563 11.1.3 Adjusting the crane cab seat and front control panel..........................564 Crane cab seat...................................................................564 Front panel......................................................................564 11.1.4 Checking the safety equipment.................................................565 Rated capacity limiter...........................................................565 Lifting limit switch.............................................................565 Emergency stop switch............................................................566 Seat contact switch..............................................................567 11.1.5 Earthing the load.............................................................568 11.1.6 Preheating the hydraulic oil..................................................569 Prerequisites....................................................................569 Preheating.......................................................................569 11.1.7 Locking/unlocking the superstructure..........................................570 Locking points...................................................................570 Locking the superstructure.......................................................571 Unlocking the superstructure.....................................................571 11.1.8 Switching the Houselock on/off................................................572 Switching on the Houselock.......................................................572 Switching off the Houselock......................................................574 11.2 Operation of the rated capacity limiter.............................................575 11.2.1 Switch on the RCL.............................................................576 Switching on.....................................................................576 Brightness of the displays.......................................................578 Temperature on the display.......................................................578 11.2.2 Enter rigging mode............................................................579 Entering individual components...................................................580 Entering the RCL code............................................................584 Entering the reeving.............................................................585 Accepting the rigging mode.......................................................585 11.2.3 Checks before operating the crane.............................................587 Open menu........................................................................587 Checks...........................................................................587 11.2.4 Displays during crane operation...............................................590 11.2.5 RCL early warning.............................................................593 11.2.6 RCL switch-off................................................................593 Shutdown due to overload.........................................................593 11.2.7 Display in the event of errors................................................595 11.2.8 RCL override..................................................................596 Overview status display..........................................................596 When rigging.....................................................................597 To raise the boom................................................................598 In emergencies...................................................................599 11.2.9 Displaying the lifting capacity tables........................................600 11.2.10 Setting the time/date........................................................602 11.3 Crane operation with main boom......................................................603 11.3.1 Checks during crane operation.................................................603 Horizontal alignment.............................................................603 Safe distances...................................................................603 Checking the wind speed..........................................................604 11.3.2 Permissible slewing ranges and working positions..............................605 360 slewing range...............................................................605 0 to the rear working position..................................................605 180 to the front rigging position...............................................605 11.3.3 Main hoist....................................................................606 Switching on the main hoist......................................................607 Lifting and lowering.............................................................607 Maximum permissible hoist rope speed.............................................608 Switching off the main hoist.....................................................609 11.3.4 Auxiliary hoist...............................................................610 Switching on the auxiliary hoist.................................................610 Lifting and lowering.............................................................611 Maximum permissible hoist rope speed.............................................611 Switching off the auxiliary hoist................................................612 11.3.5 Lifting limit switch and lowering limit switch................................613 Lifting limit switch.............................................................613 Lowering limit switch............................................................615 11.3.6 Derricking gear...............................................................616 Switching on the derricking gear.................................................616 Maximum permissible derricking speed.............................................616 Raising and lowering.............................................................617 Re-enable raising function.......................................................618 Switching off the derricking gear................................................618 11.3.7 Telescoping mechanism.........................................................620 Overview.........................................................................621 Telescoping process..............................................................621 Assignment for display...........................................................624 Fixed length, intermediate length, telescoping length............................625 Telescoping......................................................................626 Telescoping sequence.............................................................626 Checks before starting work......................................................627 Switching on the telescoping mechanism...........................................628 Function of the control lever....................................................628 Switching off the telescoping mechanism..........................................630 Manual telescoping...............................................................631 Checking the initial position....................................................631 Unlocking the telescoping cylinder...............................................633 Extending/ retracting the telescoping cylinder...................................635 Lock telescoping cylinder........................................................636 Unlocking the telescopic section.................................................637 Telescoping the telescopic section...............................................638 Locking the telescopic section...................................................639 Locking the telescopic section for on-road driving...............................640 Telescoping with semi-automation.................................................640 Telescoping with full automation.................................................643 Telescoping with main boom configuration.........................................644 11.3.8 High-speed mode...............................................................645 Derricking gear/ telescoping mechanism...........................................645 Hoists...........................................................................646 11.3.9 Slewing gear..................................................................647 Switching on the slewing gear....................................................647 Turning..........................................................................648 Releasing locked slewing gear....................................................648 Maximum permissible slewing speed................................................649 Braking the slewing movement.....................................................650 Releasing the slewing gear brake.................................................650 Engaging the slewing gear brake..................................................650 Slewing gear freewheel...........................................................651 Switching off the slewing gear...................................................651 11.3.10 Possible movement combinations...............................................652 11.4 Settings and displays for crane operation...........................................653 11.4.1 Inclining the crane cab.......................................................653 11.4.2 Setting idling speed..........................................................654 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................654 11.4.4 Limiting the power unit speeds................................................655 11.4.5 Setting/switching on Economy mode.............................................656 Automatic........................................................................656 Manual...........................................................................656 11.4.6 Switching units...............................................................657 11.4.7 Setting the characteristic curves for the control levers......................658 11.4.8 Using the slewable spotlights.................................................659 11.4.9 Override torque reduction.....................................................660 11.4.10 Displaying the operating hours...............................................661 11.4.11 Warnings in the start menu...................................................662 Meaning of the symbols...........................................................662 11.5 Working range limiter...............................................................665 11.5.1 Viewing current settings......................................................666 11.5.2 Opening the working range limiter menu........................................667 11.5.3 Entering limit values.........................................................669 Overall height...................................................................669 Working radius...................................................................670 Slewing angle....................................................................670 11.5.4 Entering limit values manually................................................672 Limit values.....................................................................672 11.5.5 Switching monitoring functions on/off.........................................674 11.5.6 Shutdown by working range limiter.............................................675 11.6 Work break..........................................................................677 11.6.1 In case of short work breaks..................................................677 11.6.2 In case of work breaks of more than 8 hours...................................678 To secure the truck crane........................................................678 11.7 Heating and air-conditioning system.................................................679 11.7.1 Standard heating system.......................................................679 Switching on.....................................................................679 Heating..........................................................................679 Air distribution.................................................................679 Switching off....................................................................680 11.7.2 Air-conditioning system.......................................................681 Information......................................................................681 Switching on/off.................................................................681 Cooling, automatic...............................................................682 Cooling, maximum.................................................................682 11.7.3 Auxiliary heater..............................................................683 Switching on.....................................................................683 Setting the temperature..........................................................684 Setting the heating start/ heating duration......................................684 Switching heating start on/off...................................................685 11.8 CraneSTAR system....................................................................686 11.8.1 Overview......................................................................686 11.8.2 Position of the components....................................................686 12 Rigging work..............................................................................689 12.1 Rigging work checklists for crane operation with the main boom......................689 12.1.1 CHECKLIST: Rigging............................................................689 12.1.2 CHECKLIST: Unrigging..........................................................693 12.2 Choosing a suitable site............................................................697 12.2.1 Determining the required ground bearing area..................................697 12.2.2 Safe distance from slopes and pits............................................700 12.2.3 Earthing the truck crane......................................................701 12.2.4 Safe distance from electrical cables..........................................702 12.3 Rigging work after driving with a trailer...........................................705 12.3.1 Switching off the boom floating position......................................705 12.3.2 Switching off the slewing gear freewheel......................................706 Before slewing...................................................................706 12.3.3 Switching off boom pre-tensioning.............................................707 12.4 Connecting/disconnecting the hand-held control......................................709 12.5 Starting the engine for driving for rigging work....................................711 12.5.1 Starting/turning off the engine with the hand-held control....................711 Prerequisites....................................................................711 Starting the engine..............................................................712 Turning off the engine...........................................................712 12.5.2 Starting/turning off the engine from the outrigger control units..............713 Prerequisites....................................................................713 Starting the engine..............................................................713 Turning off the engine...........................................................713 12.6 Outrigger...........................................................................715 12.6.1 CHECKLIST: Extending the outriggers...........................................715 12.6.2 CHECKLIST: Retracting the outriggers..........................................717 12.6.3 Permissible outrigger spans...................................................718 12.6.4 Preparing the truck crane.....................................................719 In the driver's cab..............................................................719 Outrigger control units..........................................................719 12.6.5 Setting the outrigger spans...................................................720 For on-road driving..............................................................722 12.6.6 Extending/retracting outrigger beams..........................................723 From the control units...........................................................724 With the handheld control.......................................................725 From the crane cab...............................................................727 12.6.7 Moving the outrigger pads into working/driving position.......................729 12.6.8 Enlarging the ground bearing area.............................................730 12.6.9 Extending/retracting supporting cylinders.....................................731 From the control units...........................................................732 With the handheld control.......................................................733 From the crane cab...............................................................734 12.6.10 Level the truck crane on outriggers..........................................736 Inclination indicators...........................................................736 Prerequisites....................................................................737 Manual alignment.................................................................738 Automatic alignment..............................................................739 12.6.11 Levelling the free-on-wheels truck crane.....................................741 12.6.12 Outrigger pressure display...................................................743 12.7 Rigging/unrigging the counterweight.................................................745 12.7.1 Counterweight sections........................................................745 12.7.2 Identification................................................................747 12.7.3 Slinging points on the counterweight sections.................................748 12.7.4 CHECKLIST: Rigging the counterweight..........................................749 12.7.5 CHECKLIST: Unrigging the counterweight........................................750 12.7.6 Assembling counterweight combination..........................................753 12.7.7 Counterweight hoist unit......................................................761 Counterweight menu...............................................................761 Extending/ retracting the lifting cylinders......................................762 Automatic mode, rigging..........................................................763 Automatic mode, unrigging........................................................765 Cancel automatic mode............................................................766 12.7.8 Setting down counterweight for driving the truck crane........................767 12.7.9 Slewing with rigged counterweight.............................................769 12.8 Rigging work on the main boom.......................................................771 12.8.1 Hook block on the bumper......................................................771 Picking up the hook block........................................................771 Attaching the hook block.........................................................772 12.8.2 Hook block in the compartment.................................................773 Prerequisites....................................................................773 12.8.3 Hook block on a separate vehicle..............................................775 Picking up the hook block........................................................776 Setting down the hook block......................................................776 12.8.4 Hook block, separable.........................................................778 Rigging for onroad driving......................................................778 Rigging for crane operation......................................................779 12.8.5 Reeving and unreeving the hoist rope..........................................780 Version A........................................................................780 Version B........................................................................781 Reeving the hoist rope...........................................................783 Unreeving the hoist rope.........................................................786 12.8.6 Possible reeving methods on the main boom.....................................787 With 7 head sheaves..............................................................787 With 10 head sheaves.............................................................790 With 11 head sheaves.............................................................793 12.8.7 Installing/removing the lifting limit switch..................................794 Installing the lifting limit switch..............................................794 Removing the lifting limit switch................................................797 12.8.8 Locking/unlocking the lifting limit switch....................................799 Locking..........................................................................799 Releasing locking................................................................799 12.8.9 Anemometer and air traffic control light......................................800 Installing.......................................................................800 Switching the air traffic control light on and off...............................800 Removing.........................................................................801 For transport....................................................................801 12.9 Other rigging work..................................................................803 12.9.1 Railings on the turntable.....................................................803 12.9.2 Folding the lighting carrier in/out...........................................804 12.9.3 Safety harness on the main boom...............................................805 Prerequisites....................................................................806 Requirements.....................................................................806 Attaching/ detaching fall prevention safety system to/from safety harness........807 Inspecting/ replacing safety harness.............................................809 12.9.4 Slinging points for personal protective equipment.............................810 12.9.5 Cameras for crane operation...................................................811 Camera on the hoists.............................................................811 Camera on main boom..............................................................812 Operating the camera.............................................................814 12.9.6 Stair tread on the crane cab..................................................815 13 Driving with rigged truck crane...........................................................819 13.1 Driving path........................................................................819 13.2 Permissible rigging modes and axle loads............................................820 Axle load table......................................................................821 13.3 Before driving......................................................................822 13.3.1 Securing the superstructure against slewing...................................822 13.3.2 Checking tyre pressure and wind speed.........................................823 13.3.3 Putting the truck crane on the wheels.........................................824 13.3.4 Gears/connections.............................................................826 Transmission.....................................................................826 Switching on separate steering...................................................826 13.4 While driving.......................................................................826 13.5 After driving.......................................................................828 14 Transport.................................................................................831 14.1 Transport with transport vehicle....................................................831 14.1.1 CHECKLIST: Checks before transport............................................832 14.1.2 Drive the truck crane onto the transport vehicle..............................834 Drive on.........................................................................834 Lashing..........................................................................834 14.1.3 Slinging points...............................................................835 15 Malfunctions during crane operation.......................................................839 15.1 Emergency stop switch...............................................................839 15.2 What to do when a malfunction occurs during crane operation.........................841 Load can be lowered..................................................................841 Load cannot be lowered...............................................................841 15.3 Fuses in the crane cab..............................................................843 Notes on changing fuses..............................................................843 15.4 Finding and eliminating malfunctions................................................848 15.4.1 Malfunctions on the engine....................................................848 15.4.2 Malfunctions on the counterweight hoist unit..................................848 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................849 15.4.4 Malfunctions in the hoist cameras.............................................850 15.4.5 Malfunctions in the main boom camera..........................................850 15.4.6 Malfunctions on the derricking gear...........................................851 15.4.7 Malfunctions in the telescoping mechanism.....................................852 15.4.8 Malfunctions on the slewing gear..............................................854 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................855 15.4.10 Malfunctions when inclining the crane cab....................................855 15.4.11 Malfunctions when operating with the hand-held control.......................855 15.4.12 Malfunctions of the outriggers...............................................856 15.4.13 Malfunction in the CCS control unit..........................................856 15.4.14 Troubleshooting the crane control............................................857 General malfunctions.............................................................857 Symbols in the error or information display areas................................858 Displays in the Error menu.......................................................862 15.4.15 Malfunctions in the CraneSTAR system.........................................864 15.5 Emergency operations and programmes.................................................865 15.5.1 Mechanical emergency activation for retracting................................866 Prior to the emergency activation, check.........................................866 Procedure........................................................................866 Mechanical emergency activation..................................................867 15.5.2 Telescoping emergency programme...............................................869 Open submenu Emergency program...................................................869 Determining the error type.......................................................870 Error on length indicator........................................................871 Tables for approaching the locking points........................................875 15.5.3 Entering the current telescoping..............................................877 15.5.4 Emergency operation with the hand-held control................................879 Preparations.....................................................................879 Operating a power unit...........................................................880 Stopping movements...............................................................882 Stopping movements in emergencies................................................882 Turning off the engine...........................................................882 15.6 Hydraulic emergency operation.......................................................883 15.6.1 Connecting/disconnecting hoses................................................883 15.6.2 Establishing the required hydraulic circuits..................................884 Switching over valves............................................................884 For lowering.....................................................................885 15.6.3 Operating principle of emergency operation BGR 159............................887 15.6.4 Connecting/disconnecting hoses................................................888 Establishing connections.........................................................888 Disconnecting....................................................................889 15.6.5 Switching emergency operation on/off..........................................890 15.6.6 Establishing the hydraulic circuits required..................................891 Switching over valves............................................................891 For lifting/ lowering............................................................893 For slewing......................................................................894 15.6.7 Performing emergency operation................................................895 Turning..........................................................................895 Derricking.......................................................................896 Lifting/lowering.................................................................896 15.6.8 After emergency operation.....................................................897 Switching off emergency operation................................................897 Switching over to crane operation................................................897 Disconnecting the hoses..........................................................897 15.6.9 Emergency supply of another crane.............................................898 For emergency supply.............................................................898 After emergency supply...........................................................898 16 Index.....................................................................................901 A........................................................................................903 B........................................................................................903 C........................................................................................904 D........................................................................................907 E........................................................................................908 F........................................................................................910 H........................................................................................910 I........................................................................................911 K........................................................................................911 L........................................................................................911 M........................................................................................912 O........................................................................................913 P........................................................................................914 R........................................................................................914 S........................................................................................916 T........................................................................................917 V........................................................................................919 W........................................................................................919
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