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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 : 998
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302418 – PDF DOWNLOAD
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
Part 1 – Driving................................................................................. 1 Additional Pages............................................................................. 3 Additional page GMK – Reduction of slewing speed......................................... 3 1 Reduction of slewing speed – can be switched on and off............................ 3 1.1 Important notes.............................................................. 3 With reduction switched on................................................... 3 With reduction switched off.................................................. 3 1.2 Operation.................................................................... 4 1.2.1 Additional and modified operating elements............................. 4 1.2.2 Switching reduction off and on......................................... 5 CCS display.............................................................................. 7 Menu changes......................................................................... 7 Start menus...................................................................... 7 Displays for the counterweight................................................... 8 Slewing gear freewheel................................................................... 11 CCS – Datalogger......................................................................... 13 Additional menu and program.......................................................... 13 Additional menu.................................................................. 13 Export data...................................................................... 14 Display the data................................................................. 14 Slewable spotlights...................................................................... 19 Automatic load tracking.............................................................. 19 Hoist rope travel limitation............................................................. 21 Hoist rope travel limitation menu.................................................... 22 Entering values...................................................................... 23 Switching monitoring function on/off................................................. 23 Driving with rigged truck crane.......................................................... 25 Counterweight............................................................................ 27 Setting down the base plate.......................................................... 27 Adjustable head sheave................................................................... 29 Different positions depending on the reeving......................................... 29 Main boom intermediate lengths........................................................... 31 Derricking cylinder pressure monitoring.............................................. 31 Telescoping emergency programme.......................................................... 33 Additional checks.................................................................... 33 Anemometer display ...................................................................... 35 Extended function.................................................................... 35 Counterweight............................................................................ 37 Information on weight specifications................................................. 37 Telescoping emergency programe........................................................... 39 Outrigger control units.................................................................. 41 Switching over the display between metre/feet and percent............................ 41 1 Overview................................................................................... 47 1.1 Accidents............................................................................ 47 1.2 Branch offices....................................................................... 49 1.2.1 Manitowoc Crane Care........................................................... 49 1.2.2 Dealer list.................................................................... 49 1.3 Warranty specifications.............................................................. 49 1.4 Terms used........................................................................... 50 1.5 Technical data....................................................................... 53 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 53 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 54 Dimensions....................................................................... 55 Weight and axle loads............................................................ 55 1.5.3 Dimensions and weights of removable parts...................................... 56 Spare wheel...................................................................... 56 Outriggers....................................................................... 56 Main boom........................................................................ 57 Hook blocks and hook tackle...................................................... 57 Hook blocks, split............................................................... 58 Auxiliary hoist.................................................................. 59 Counterweight parts.............................................................. 59 1.5.4 Carrier........................................................................ 60 Engine........................................................................... 60 Transmission..................................................................... 60 Transfer case.................................................................... 60 Axle lines....................................................................... 60 Steering......................................................................... 60 Tyres............................................................................ 61 Electrical system................................................................ 61 Tool............................................................................. 61 Towing couplings................................................................. 61 Driving speeds................................................................... 61 Climbing ability................................................................. 61 Outriggers....................................................................... 62 Turning radii.................................................................... 63 1.5.5 Superstructure................................................................. 64 Main hoist....................................................................... 64 Auxiliary hoist.................................................................. 64 Slewing gears.................................................................... 64 Derricking gear.................................................................. 64 Main boom........................................................................ 65 Lattice extension................................................................ 65 Operating speeds................................................................. 65 Noise emission................................................................... 65 1.6 Documentation supplied............................................................... 67 1.6.1 Questions on documentation..................................................... 68 1.7 Notes on the operating manual........................................................ 69 1.7.1 What do the symbols used mean?................................................. 69 1.7.2 How is the operating manual structured?........................................ 71 Division......................................................................... 71 Structure of the chapters........................................................ 71 Structure of the pages........................................................... 72 1.7.3 How do I find the information I need?.......................................... 73 Cross-references example......................................................... 74 1.7.4 What information is available for operations planning?......................... 76 1.8 Conversion table for US measuring units.............................................. 77 1.9 Training – Information............................................................... 79 1.10 Identification...................................................................... 80 1.11 EC Declaration of Conformity........................................................ 82 2 Basic safety instructions.................................................................. 85 2.1 Intended use......................................................................... 85 2.1.1 Improper use................................................................... 86 2.2 Organisational measures.............................................................. 87 2.3 Personnel qualifications............................................................. 89 2.4 Safety instructions for driving the truck crane...................................... 90 2.5 Safety instructions for crane operation.............................................. 91 2.6 Notes on transporting persons........................................................ 93 Equipment for lifting persons........................................................ 93 Personnel............................................................................ 93 Operation............................................................................ 94 Truck crane.......................................................................... 95 3 Operating elements for driving............................................................. 99 3.1 Overview of the operating elements................................................... 99 3.1.1 On the outside of the truck crane..............................................100 3.1.2 Cab............................................................................104 Overview.........................................................................104 Behind the cover.................................................................108 In the rear of the driver's cab..................................................108 3.1.3 Instrument panel...............................................................109 Left/right.......................................................................109 Middle...........................................................................110 On-board computer time correction................................................112 3.1.4 On-board computer..............................................................113 3.1.5 Steering column/steering wheel.................................................114 3.1.6 Transmission operating elements................................................115 3.1.7 Tachograph.....................................................................116 3.1.8 Control unit CCS...............................................................117 3.1.9 Display CCS – start menu.......................................................118 3.1.10 CCS – overview of menu groups.................................................120 Carrier menu group...............................................................122 Suspension/level adjustment menu.................................................123 Driving menu.....................................................................124 Settings menu group..............................................................125 Menu for setting the display brightness and date/time............................126 Information menu group...........................................................127 Operating hours menu.............................................................128 Engine/ transmission error menu..................................................129 Crane operation error menu.......................................................130 Operating additional equipment...................................................131 3.1.11 Outrigger control units.......................................................132 3.1.12 Heating/Air-conditioning system...............................................133 Standard heating system..........................................................133 Auxiliary water heater...........................................................134 Auxiliary air heater.............................................................135 3.1.13 Sockets for hand-held control.................................................136 3.1.14 Outrigger control units.......................................................137 3.2 Short description of the operating elements..........................................139 3.2.1 Definition of direction information............................................140 Basic rule.......................................................................140 Switches and buttons.............................................................140 3.2.2 General rules for buttons and symbols on the display...........................141 3.2.3 Engine.........................................................................142 Steering column..................................................................142 On the steering wheel............................................................142 Instrument panel.................................................................143 3.2.4 AdBlue system (DEF)............................................................144 Instrument panel.................................................................144 CCS display......................................................................145 3.2.5 Battery master switch..........................................................145 3.2.6 Electrical system..............................................................146 3.2.7 Crane control CCS..............................................................147 3.2.8 Transmission...................................................................151 Transmission control unit........................................................151 Display, driving mode,...........................................................152 3.2.9 Reverse camera.................................................................154 3.2.10 Final drive...................................................................155 3.2.11 Brakes........................................................................157 Service brake....................................................................157 Additional brakes................................................................157 Parking brake....................................................................158 3.2.12 Steering/separate steering....................................................160 Instrument panel.................................................................160 CCS display......................................................................161 Driver's door....................................................................162 3.2.13 Suspension....................................................................163 CCS display......................................................................163 Outrigger control units..........................................................163 3.2.14 Lighting/windscreen wipers/horn...............................................164 Steering column..................................................................164 Steering wheel...................................................................164 Instrument panel.................................................................164 CCS display......................................................................166 Roof.............................................................................166 3.2.15 Level adjustment system.......................................................167 3.2.16 Tachograph/speedometer........................................................169 Tachograph.......................................................................169 Speedometer......................................................................169 3.2.17 Diagnostics...................................................................170 3.2.18 On-board computer.............................................................171 3.2.19 Windows, doors, keys..........................................................173 Window winder....................................................................173 Doors............................................................................174 Keys.............................................................................174 3.2.20 Front flap....................................................................175 4 Starting/turning off the engine for driving................................................179 4.1 Starting the engine from the driver's cab............................................179 4.1.1 CHECKLIST: Starting the engine.................................................179 4.1.2 CHECKLIST: At low temperatures.................................................182 4.1.3 Ladders and access ladders.....................................................182 Access ladders...................................................................182 Ladders..........................................................................183 4.1.4 Refuel.........................................................................185 Standard tank....................................................................185 Dual tank........................................................................186 AdBlue...........................................................................187 4.1.5 Checks before starting the engine..............................................188 On hydraulic tank................................................................188 Battery master switch............................................................189 Checking the hand-held control...................................................189 4.1.6 Switching on the ignition......................................................189 4.1.7 Lamp test/equalisation of the switching states.................................190 Lamp test........................................................................190 Switching state alignment........................................................190 4.1.8 Display – setting the brightness...............................................191 4.1.9 Starting the engine............................................................192 4.1.10 Checks after starting the engine..............................................194 Checking in the main menu........................................................194 Indicator lamps on the instrument panel..........................................195 4.1.11 Monitoring elements...........................................................197 Instrument panel.................................................................197 4.1.12 Start menu....................................................................198 4.1.13 Setting idling speed..........................................................199 4.2 Turning off the engine...............................................................201 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....201 After turning off................................................................201 4.2.2 Using the emergency stop switches..............................................202 Resetting the emergency stop switch..............................................202 4.3 Air intake inhibitor.................................................................203 Releasing the air intake inhibitor...................................................203 5 Driving....................................................................................207 5.1 Before driving.......................................................................207 5.1.1 CHECKLIST: Checks before on-road driving.......................................207 5.1.2 Checking the condition of the truck crane......................................213 Electrical system................................................................213 Adjusting the mirrors............................................................213 Warning plates for vehicle width.................................................215 Displaying vehicle height........................................................215 Supply pressure..................................................................216 Parking brake....................................................................217 5.1.3 Adjusting the seat and the steering column.....................................218 Driver's seat....................................................................218 Passenger's seat.................................................................219 Steering column, adjusting.......................................................220 5.1.4 Switching the suspension on/off................................................221 Open menu........................................................................221 Switching on the suspension......................................................222 Switching off the suspension.....................................................222 5.1.5 Setting the tachograph.........................................................223 Prerequisites....................................................................223 In the event of malfunctions.....................................................223 Setting the tachograph...........................................................224 5.1.6 Entering the time/date.........................................................228 5.1.7 Displaying and resetting operating hours.......................................229 5.2 Operating the transmission...........................................................231 5.2.1 Switching on...................................................................231 5.2.2 Switching the transmission to neutral position.................................232 5.2.3 Selecting the direction of travel and starting gear............................233 Selecting the driving direction..................................................233 Selecting the starting gear......................................................234 5.2.4 Changing the operating mode....................................................235 Changing to automatic mode.......................................................235 Change to manual mode............................................................235 5.2.5 Starting.......................................................................236 5.2.6 Driving and changing gears.....................................................237 In automatic operating mode......................................................237 In manual operating mode.........................................................238 5.2.7 Changing the driving direction.................................................239 5.2.8 Stopping.......................................................................239 Stopping for along period oftime...............................................239 5.2.9 On the roller type dynamometer.................................................240 5.2.10 Preheating transmission.......................................................240 5.3 Driving and turning off the truck crane..............................................241 5.3.1 Checks while driving...........................................................241 Immediately after you start to move..............................................241 While driving....................................................................243 5.3.2 Cruise control.................................................................244 Switching on.....................................................................244 Switching off....................................................................245 5.3.3 Temposet.......................................................................246 Switching on.....................................................................246 Switching off....................................................................246 5.3.4 Driving downhill...............................................................247 Starting.........................................................................247 Inspections when driving downhill................................................248 Downshifting.....................................................................248 Additional brakes................................................................249 5.3.5 Driving uphill.................................................................250 Starting.........................................................................250 Driving..........................................................................250 5.3.6 Warning messages in the start menu.............................................251 5.3.7 Warning or malfunction messages on the instrument panel........................252 Meaning of the lamps.............................................................252 5.3.8 Messages on the on-board computer display......................................253 5.3.9 Indicator lights in the on-board computer display..............................255 5.3.10 Override torque reduction.....................................................257 5.3.11 Turning off the truck crane...................................................258 Securing against rolling away....................................................258 When stationary for more than 8 hours............................................259 5.3.12 Folding berth.................................................................260 5.4 Off-road driving.....................................................................261 Adjustments to the transmission......................................................261 Connections..........................................................................261 Changing the vehicle level...........................................................261 Rocking the vehicle free and towing..................................................261 5.4.1 Longitudinal and transverse differential locks.................................262 5.4.2 Operating the level adjustment system..........................................264 Open menu........................................................................264 Setting the onroad level........................................................265 Pre-selecting suspension struts..................................................265 Changing the vehicle level.......................................................266 Viewing the current inclination..................................................266 Exiting the menu.................................................................267 5.4.3 Freeing truck crane stuck in terrain...........................................268 Rocking the truck crane free.....................................................268 Towing free forwards.............................................................269 Towing free in reverse gear......................................................269 5.5 Separate steering....................................................................271 5.5.1 Switching to separate steering.................................................271 Manual...........................................................................272 Automatic........................................................................273 5.6 Heating and air-conditioning system..................................................275 5.6.1 Standard heating system,.......................................................275 Switching on.....................................................................275 Heating..........................................................................275 Air distribution.................................................................276 Examples.........................................................................277 Switching off....................................................................277 5.6.2 Air-conditioning system........................................................278 Information......................................................................278 Switching on/off.................................................................278 Cooling..........................................................................279 Drying...........................................................................279 5.6.3 Auxiliary water heater.........................................................280 Preheating the engine............................................................280 Preheating the driver's cab......................................................281 Switching on the auxiliary heater................................................282 Switching off the auxiliary heater...............................................283 Setting time and weekday.........................................................283 Saving automatic heating start...................................................284 Setting the heating period.......................................................285 Switching the automatic heating start on and off.................................285 Setting the remaining time.......................................................286 5.6.4 Auxiliary air heater...........................................................287 Switching on.....................................................................287 Temperature......................................................................288 Switching off....................................................................288 Other functions..................................................................288 5.7 Towing a trailer.....................................................................289 Effects on the axle loads............................................................289 Coupling the trailer.................................................................290 Connecting the supply lines..........................................................291 Removing the supply lines............................................................292 Uncoupling the trailer...............................................................292 Checking the braking force...........................................................294 6 Driving modes and rigging for on-road driving..............................................297 6.1 Driving modes........................................................................297 Information about the axle loads.....................................................297 6.1.1 Information on how to use the tables...........................................298 6.1.2 Tables for a maximum axle load of 12t.........................................299 For 385/95 R25 tyres.............................................................299 For 445/95 R25 525/80 R25 tyres..................................................300 6.1.3 Maximum permitted speeds with an axle load of over 12t........................301 6.2 Rigging work for driving with a trailer..............................................302 6.2.1 Switching on the slewing gear freewheel........................................303 6.2.2 Switching on the boom floating position........................................304 6.2.3 Switching on boom pre-tensioning...............................................305 6.3 Main boom, removing/installing.......................................................306 Additional equipment required........................................................306 6.3.1 CHECKLIST: Removing the main boom..............................................307 Prerequisites....................................................................307 Checklist........................................................................307 6.3.2 CHECKLIST: Mounting the main boom..............................................309 Prerequisites....................................................................309 Checklist........................................................................309 6.3.3 Slinging the main boom.........................................................311 Marking..........................................................................311 Installing the lifting gear......................................................311 Removing the lifting gear........................................................312 6.3.4 Retracting/fitting the derricking cylinder head pin............................313 Operating the lifting device.....................................................313 Retracting the derricking cylinder head axle.....................................314 Fitting the derricking cylinder head axle........................................315 6.3.5 Retracting/extending the boom pivot pin........................................316 Before retracting................................................................316 After extending..................................................................317 Retracting/ extending the pivot pin..............................................318 6.3.6 Disconnecting/connecting hydraulics/electrical.................................319 Detachment.......................................................................319 Establishing.....................................................................320 6.3.7 Lifting the main boom off/on the turntable.....................................321 Lifting from the turntable.......................................................321 Lifting on to the turntable......................................................322 6.3.8 Aligning the connecting points.................................................322 6.3.9 Transporting the main boom.....................................................323 6.3.10 Inspections after main boom mounting..........................................324 6.4 Installing/removing outrigger beams..................................................325 6.4.1 CHECKLIST: Removing the outrigger beams........................................326 6.4.2 CHECKLIST: Installing the outrigger beams......................................328 6.4.3 Preparing the truck crane......................................................330 Prerequisites....................................................................330 For removal......................................................................330 6.4.4 Removing/attaching outrigger pads..............................................331 Removing the outrigger pads......................................................331 Attaching the outrigger pads.....................................................332 6.4.5 Disconnecting/establishing the hydraulic connection............................333 6.4.6 Disconnecting/establishing the electrical connection...........................334 6.4.7 Unscrewing/screwing in the spacers.............................................335 Unscrewing.......................................................................335 Screwing in......................................................................336 6.4.8 Disconnecting/establishing the connections to the outrigger box................337 6.4.9 Extending/retracting the outrigger beam........................................337 Extending the outrigger beam.....................................................337 Inserting the outrigger beam.....................................................339 6.4.10 Transporting the outrigger beams..............................................341 6.5 Rigging the auxiliary hoist..........................................................343 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................343 Prerequisites....................................................................343 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................345 Prerequisites....................................................................345 6.5.3 Slinging the auxiliary hoist...................................................347 6.5.4 Slinging the rigging frame.....................................................347 6.5.5 Lowering/raising the rigging frame.............................................348 Prerequisite.....................................................................348 6.5.6 Placing the auxiliary hoist on the counterweight combination...................348 6.5.7 Establishing/disconnecting the hydraulic connection............................349 6.5.8 Making/breaking the electrical connection......................................350 6.5.9 Creating the connection to the turntable.......................................351 Establishing the connection......................................................351 Disconnecting....................................................................353 6.5.10 Securing the hoist rope.......................................................354 6.5.11 Transporting the auxiliary hoist..............................................355 6.5.12 Check that the auxiliary hoist is functioning properly........................356 Slewing direction................................................................356 Slewing indicator................................................................356 7 Malfunctions in driving mode...............................................................359 7.1 Emergency stop switch................................................................359 7.2 What to do when a malfunction occurs in road traffic.................................361 7.3 Towing the truck crane...............................................................363 7.3.1 Towing after engine/transmission damage........................................364 Compressed-air supply............................................................364 Electric power supply............................................................365 On the transmission..............................................................365 Axle drives......................................................................366 Parking brake....................................................................366 Towing the truck crane out of the danger area....................................367 7.3.2 Tow starting...................................................................367 7.4 Other emergency operations...........................................................369 7.4.1 Externally starting the truck crane............................................369 7.4.2 Battery charger................................................................370 Prerequisites....................................................................370 7.5 Wheels and tyres.....................................................................371 7.5.1 Wheel change...................................................................371 Removing a damaged wheel.........................................................372 On the spare wheel holder........................................................372 Mounting a wheel.................................................................373 7.5.2 Inflating the tyres yourself...................................................375 Connecting the filling hose......................................................375 Inflating the tyres..............................................................376 Removing the filling hose........................................................376 7.6 Fuses................................................................................377 Notes on changing fuses..............................................................377 7.6.1 Fuses in the driver's cab......................................................378 Group F1.........................................................................378 Group F2.........................................................................379 Group F3.........................................................................379 Group F4.........................................................................380 Other fuses......................................................................380 Group F7.........................................................................381 Group F8.........................................................................381 Group F9.........................................................................382 Group F10........................................................................382 7.6.2 Fuses in the battery box.......................................................383 7.7 Troubleshooting......................................................................385 7.7.1 Malfunctions on the engine.....................................................385 7.7.2 Faults on the AdBlue (DEF) system..............................................387 7.7.3 Malfunctions in the transmission...............................................388 7.7.4 Malfunctions of the service brake..............................................389 7.7.5 Malfunctions of the steering...................................................390 7.7.6 Differential lock malfunctions.................................................391 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................391 7.7.8 Malfunctions on the suspension.................................................392 7.7.9 Malfunctions of the level adjustment system....................................392 7.7.10 Malfunction in the CCS control unit...........................................392 7.8 Warnings in the start menu...........................................................393 Symbols in the display area..........................................................393 7.8.1 Engine/transmission error menu.................................................398 Open menu........................................................................398 Exiting the menu.................................................................398 7.9 Procedure in the event of malfunctions...............................................399 7.9.1 Procedure during engine malfunctions...........................................399 7.9.2 Procedure during transmission malfunctions.....................................400 8 Index......................................................................................403 A........................................................................................405 B........................................................................................405 C........................................................................................406 D........................................................................................409 E........................................................................................410 F........................................................................................412 H........................................................................................412 I........................................................................................413 K........................................................................................413 L........................................................................................413 M........................................................................................414 O........................................................................................415 P........................................................................................416 R........................................................................................416 S........................................................................................418 T........................................................................................419 V........................................................................................421 W........................................................................................421 Part 2 – Crane operation.........................................................................425 Additional Pages.............................................................................427 Additional page GMK – Reduction of slewing speed.........................................427 1 Reduction of slewing speed – can be switched on and off............................427 1.1 Important notes..............................................................427 With reduction switched on...................................................427 With reduction switched off..................................................427 1.2 Operation....................................................................428 1.2.1 Additional and modified operating elements.............................428 1.2.2 Switching reduction off and on.........................................429 CCS display..............................................................................431 Menu changes.........................................................................431 Start menus......................................................................431 Displays for the counterweight...................................................432 Slewing gear freewheel...................................................................435 CCS – Datalogger.........................................................................437 Additional menu and program..........................................................437 Additional menu..................................................................437 Export data......................................................................438 Display the data.................................................................438 Slewable spotlights......................................................................443 Automatic load tracking..............................................................443 Hoist rope travel limitation.............................................................445 Hoist rope travel limitation menu....................................................446 Entering values......................................................................447 Switching monitoring function on/off.................................................447 Driving with rigged truck crane..........................................................449 Counterweight............................................................................451 Setting down the base plate..........................................................451 Adjustable head sheave...................................................................453 Different positions depending on the reeving.........................................453 Main boom intermediate lengths...........................................................455 Derricking cylinder pressure monitoring..............................................455 Telescoping emergency programme..........................................................457 Additional checks....................................................................457 Anemometer display.......................................................................459 Extended function....................................................................459 Counterweight............................................................................461 Information on weight specifications.................................................461 Telescoping emergency programe...........................................................463 Outrigger control units..................................................................465 Switching over the display between metre/feet and percent............................465 9 Operating elements for crane operation.....................................................471 9.1 Overview of the operating elements...................................................471 9.1.1 Exterior of the truck crane....................................................472 9.1.2 Crane cab......................................................................476 Side panel.......................................................................478 Crane cab, rear..................................................................480 9.1.3 Control panels.................................................................482 Left.............................................................................482 Right............................................................................483 9.1.4 Control lever configuration....................................................484 Version 1........................................................................484 Version 2........................................................................485 9.1.5 Control unit CCS...............................................................486 9.1.6 CCS – Start menu...............................................................489 9.1.7 CCS – overview of menu groups..................................................490 Superstructure menu group........................................................494 Superstructure lock menu.........................................................495 Counterweight menu...............................................................496 Outrigger menu...................................................................497 Outrigger support beam menu......................................................499 Outrigger cylinders menu.........................................................500 Teleautomation menu group........................................................502 Telescoping full automation menu.................................................503 Telescoping semiautomation menu.................................................504 Main boom configuration menu.....................................................505 Active working range limiter menu group..........................................506 Overall height menu..............................................................507 Working radius menu..............................................................508 Slewing angle menu...............................................................509 Information menu group...........................................................510 Hydraulic pressure and fuel consumption menu.....................................511 Engine/Driving menu group........................................................512 Economy menu.....................................................................513 Heating/ airconditioning menu...................................................514 Telescoping menu group...........................................................515 Manual telescoping menu..........................................................516 Telescoping emergency program menu...............................................517 Unknown telescoping menu.........................................................518 Settings menu group..............................................................519 Crane cab menu...................................................................520 Menu for setting the display brightness and date/time............................521 Switch units menu................................................................522 Set control lever characteristic curve menu......................................523 Power unit speeds menu...........................................................524 Menu group Information...........................................................525 Operating hours menu.............................................................526 Engine/ transmission error menu..................................................528 Crane operation error menu.......................................................529 Program version menu.............................................................530 Operating additional equipment...................................................531 9.1.8 Control unit RCL...............................................................532 9.1.9 RCL – menu groups..............................................................534 Menu for entering rigging mode...................................................537 Monitoring menu..................................................................538 Lifting capacity tables menu.....................................................540 9.1.10 Hand-held controls............................................................541 Outrigger control panel..........................................................542 9.1.11 Outrigger control units.......................................................544 Button...........................................................................544 Outrigger button.................................................................545 Inclination and outrigger pressure display.......................................546 Raise axle display...............................................................547 9.2 Short description of the operating elements..........................................549 9.2.1 Definition of direction information............................................549 Basic rule.......................................................................549 Switches.........................................................................549 9.2.2 General rules for buttons and symbols on the display...........................550 9.2.3 Engine.........................................................................551 Side panel.......................................................................551 Economy menu.....................................................................552 9.2.4 AdBlue (DEF) system............................................................553 CCS display......................................................................553 9.2.5 Seat contact switch and dead man's switch......................................554 9.2.6 Crane control CCS..............................................................555 9.2.7 Outrigger......................................................................561 Hand-held control................................................................561 Right-hand control panel.........................................................562 Left-hand control panel..........................................................562 In the Outrigger menu............................................................563 On the outrigger control units...................................................565 9.2.8 Inclination indicators.........................................................567 9.2.9 Raise axle.....................................................................568 Outrigger control units..........................................................568 9.2.10 Outrigger pressure displays...................................................570 Outriggers submenu...............................................................570 Outrigger control units..........................................................570 9.2.11 Anemometer displays...........................................................570 9.2.12 Counterweight menu............................................................571 Counterweight submenu............................................................571 9.2.13 Main hoist....................................................................575 Control panels...................................................................575 CCS display......................................................................576 9.2.14 Auxiliary hoist...............................................................577 Control panels...................................................................577 CCS display......................................................................578 9.2.15 Slewing gear..................................................................579 Control panels...................................................................579 CCS display......................................................................580 9.2.16 Derricking gear...............................................................581 Control panels...................................................................581 CCS display......................................................................582 9.2.17 Telescoping mechanism.........................................................583 Control panels...................................................................583 CCS display......................................................................583 Telescoping full automation menu.................................................584 Telescoping semiautomation menu.................................................585 Manual telescoping menu..........................................................587 Main boom configuration menu.....................................................590 9.2.18 Hydraulic system..............................................................591 9.2.19 Superstructure lock/Houselock menu............................................592 Superstructure lock..............................................................592 Houselock........................................................................593 9.2.20 Rated capacity limiter (RCL)..................................................594 Control unit control console RCL.................................................594 Display RCL......................................................................595 Enter rigging mode menu..........................................................597 Monitoring menu..................................................................600 Lifting capacity tables menu.....................................................604 RCL override.....................................................................604 External displays................................................................605 9.2.21 Electrical system.............................................................607 9.2.22 Lighting, windscreen wiper/washing system.....................................607 Lighting.........................................................................607 Windscreen wiper/washing system..................................................608 9.2.23 Hand-held control.............................................................610 Sockets for handheld control....................................................610 Engine control panel.............................................................611 Horn.............................................................................611 Outrigger control panel..........................................................612 9.2.24 Windows, doors, keys..........................................................614 Windows..........................................................................614 Rear window......................................................................614 Crane cab door...................................................................615 Keys.............................................................................616 9.2.25 Diagnostics...................................................................616 10 Starting/turning off the engine – for crane operation.....................................619 10.1 When starting the engine for the first time of the day..............................619 10.1.1 Checking the fuel level and AdBlue (DEF) level................................620 Fuel.............................................................................620 AdBlue (DEF).....................................................................620 10.1.2 Checks before starting the engine.............................................621 On hydraulic tank................................................................621 Checking the hand-held control...................................................622 10.1.3 Switching on the ignition.....................................................622 10.1.4 Display – setting the brightness..............................................623 10.1.5 Starting the engine...........................................................624 10.1.6 Checks after starting the engine..............................................625 10.1.7 Setting idling speed..........................................................626 10.2 Starting the engine – with the hand-held control....................................627 Prerequisites........................................................................627 Starting the engine..................................................................627 10.3 Turning off the engine..............................................................629 10.3.1 During normal operation, with the ignition lock/with the handheld control....629 After turning off................................................................629 10.3.2 In emergencies, with the emergency stop switches..............................630 Resetting the emergency stop switch..............................................630 11 Crane operation...........................................................................633 11.1 Before operating the crane..........................................................633 11.1.1 CHECKLIST: Checks before operating the crane..................................633 11.1.2 Checking the condition of the truck crane.....................................637 Fuel tank auxiliary heater.......................................................637 Visual inspection................................................................637 Checking the position of the hoist ropes.........................................638 Checking the electrical system...................................................639 11.1.3 Adjusting the crane cab seat and front control panel..........................640 Crane cab seat...................................................................640 Front panel......................................................................640 11.1.4 Checking the safety equipment.................................................641 Rated capacity limiter...........................................................641 Lifting limit switch.............................................................641 Emergency stop switch............................................................642 Seat contact switch..............................................................643 11.1.5 Earthing the load.............................................................644 11.1.6 Preheating the hydraulic oil..................................................645 Prerequisites....................................................................645 Preheating.......................................................................645 11.1.7 Locking/unlocking the superstructure..........................................646 Locking points...................................................................646 Locking the superstructure.......................................................647 Unlocking the superstructure.....................................................647 11.1.8 Switching the Houselock on/off................................................648 Switching on the Houselock.......................................................648 Switching off the Houselock......................................................650 11.2 Operation of the rated capacity limiter.............................................651 11.2.1 Switch on the RCL.............................................................652 Switching on.....................................................................652 Brightness of the displays.......................................................654 Temperature on the display.......................................................654 11.2.2 Enter rigging mode............................................................655 Entering individual components...................................................656 Entering the RCL code............................................................660 Entering the reeving.............................................................661 Accepting the rigging mode.......................................................661 11.2.3 Checks before operating the crane.............................................663 Open menu........................................................................663 Checks...........................................................................663 11.2.4 Displays during crane operation...............................................666 11.2.5 RCL early warning.............................................................669 11.2.6 RCL switch-off................................................................669 Shutdown due to overload.........................................................669 11.2.7 Display in the event of errors................................................671 11.2.8 RCL override..................................................................672 Overview status display..........................................................672 When rigging.....................................................................673 To raise the boom................................................................674 In emergencies...................................................................675 11.2.9 Displaying the lifting capacity tables........................................676 11.2.10 Setting the time/date........................................................678 11.3 Crane operation with main boom......................................................679 11.3.1 Checks during crane operation.................................................679 Horizontal alignment.............................................................679 Safe distances...................................................................679 Checking the wind speed..........................................................680 11.3.2 Permissible slewing ranges and working positions..............................681 360 slewing range...............................................................681 0 to the rear working position..................................................681 180 to the front rigging position...............................................681 11.3.3 Main hoist....................................................................682 Switching on the main hoist......................................................683 Lifting and lowering.............................................................683 Maximum permissible hoist rope speed.............................................684 Switching off the main hoist.....................................................685 11.3.4 Auxiliary hoist...............................................................686 Switching on the auxiliary hoist.................................................686 Lifting and lowering.............................................................687 Maximum permissible hoist rope speed.............................................687 Switching off the auxiliary hoist................................................688 11.3.5 Lifting limit switch and lowering limit switch................................689 Lifting limit switch.............................................................689 Lowering limit switch............................................................691 11.3.6 Derricking gear...............................................................692 Switching on the derricking gear.................................................692 Maximum permissible derricking speed.............................................692 Raising and lowering.............................................................693 Re-enable raising function.......................................................694 Switching off the derricking gear................................................694 11.3.7 Telescoping mechanism.........................................................696 Overview.........................................................................697 Telescoping process..............................................................697 Assignment for display...........................................................700 Fixed length, intermediate length, telescoping length............................701 Telescoping......................................................................702 Telescoping sequence.............................................................702 Checks before starting work......................................................703 Switching on the telescoping mechanism...........................................704 Function of the control lever....................................................704 Switching off the telescoping mechanism..........................................706 Manual telescoping...............................................................707 Checking the initial position....................................................707 Unlocking the telescoping cylinder...............................................709 Extending/ retracting the telescoping cylinder...................................711 Lock telescoping cylinder........................................................712 Unlocking the telescopic section.................................................713 Telescoping the telescopic section...............................................714 Locking the telescopic section...................................................715 Locking the telescopic section for on-road driving...............................716 Telescoping with semi-automation.................................................716 Telescoping with full automation.................................................719 Telescoping with main boom configuration.........................................720 11.3.8 High-speed mode...............................................................721 Derricking gear/ telescoping mechanism...........................................721 Hoists...........................................................................722 11.3.9 Slewing gear..................................................................723 Switching on the slewing gear....................................................723 Turning..........................................................................724 Releasing locked slewing gear....................................................724 Maximum permissible slewing speed................................................725 Braking the slewing movement.....................................................726 Releasing the slewing gear brake.................................................726 Engaging the slewing gear brake..................................................726 Slewing gear freewheel...........................................................727 Switching off the slewing gear...................................................727 11.3.10 Possible movement combinations...............................................728 11.4 Settings and displays for crane operation...........................................729 11.4.1 Inclining the crane cab.......................................................729 11.4.2 Setting idling speed..........................................................730 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................730 11.4.4 Limiting the power unit speeds................................................731 11.4.5 Setting/switching on Economy mode.............................................732 Automatic........................................................................732 Manual...........................................................................732 11.4.6 Switching units...............................................................733 11.4.7 Setting the characteristic curves for the control levers......................734 11.4.8 Using the slewable spotlights.................................................735 11.4.9 Override torque reduction.....................................................736 11.4.10 Displaying the operating hours...............................................737 11.4.11 Warnings in the start menu...................................................738 Meaning of the symbols...........................................................738 11.5 Working range limiter...............................................................741 11.5.1 Viewing current settings......................................................742 11.5.2 Opening the working range limiter menu........................................743 11.5.3 Entering limit values.........................................................745 Overall height...................................................................745 Working radius...................................................................746 Slewing angle....................................................................746 11.5.4 Entering limit values manually................................................748 Limit values.....................................................................748 11.5.5 Switching monitoring functions on/off.........................................750 11.5.6 Shutdown by working range limiter.............................................751 11.6 Work break..........................................................................753 11.6.1 In case of short work breaks..................................................753 11.6.2 In case of work breaks of more than 8 hours...................................754 To secure the truck crane........................................................754 11.7 Heating and air-conditioning system.................................................755 11.7.1 Standard heating system.......................................................755 Switching on.....................................................................755 Heating..........................................................................755 Air distribution.................................................................755 Switching off....................................................................756 11.7.2 Air-conditioning system.......................................................757 Information......................................................................757 Switching on/off.................................................................757 Cooling, automatic...............................................................758 Cooling, maximum.................................................................758 11.7.3 Auxiliary heater..............................................................759 Switching on.....................................................................759 Setting the temperature..........................................................760 Setting the heating start/ heating duration......................................760 Switching heating start on/off...................................................761 11.8 CraneSTAR system....................................................................762 11.8.1 Overview......................................................................762 11.8.2 Position of the components....................................................762 12 Rigging work..............................................................................765 12.1 Rigging work checklists for crane operation with the main boom......................765 12.1.1 CHECKLIST: Rigging............................................................765 12.1.2 CHECKLIST: Unrigging..........................................................769 12.2 Choosing a suitable site............................................................773 12.2.1 Determining the required ground bearing area..................................773 12.2.2 Safe distance from slopes and pits............................................776 12.2.3 Earthing the truck crane......................................................777 12.2.4 Safe distance from electrical cables..........................................778 12.3 Rigging work after driving with a trailer...........................................781 12.3.1 Switching off the boom floating position......................................781 12.3.2 Switching off the slewing gear freewheel......................................782 Before slewing...................................................................782 12.3.3 Switching off boom pre-tensioning.............................................783 12.4 Connecting/disconnecting the hand-held control......................................785 12.5 Starting the engine for driving for rigging work....................................787 12.5.1 Starting/turning off the engine with the hand-held control....................787 Prerequisites....................................................................787 Starting the engine..............................................................788 Turning off the engine...........................................................788 12.5.2 Starting/turning off the engine from the outrigger control units..............789 Prerequisites....................................................................789 Starting the engine..............................................................789 Turning off the engine...........................................................789 12.6 Outrigger...........................................................................791 12.6.1 CHECKLIST: Extending the outriggers...........................................791 12.6.2 CHECKLIST: Retracting the outriggers..........................................793 12.6.3 Permissible outrigger spans...................................................794 12.6.4 Preparing the truck crane.....................................................795 In the driver's cab..............................................................795 Outrigger control units..........................................................795 12.6.5 Setting the outrigger spans...................................................796 For on-road driving..............................................................798 12.6.6 Extending/retracting outrigger beams..........................................799 From the control units...........................................................800 With the handheld control.......................................................801 From the crane cab...............................................................803 12.6.7 Moving the outrigger pads into working/driving position.......................805 12.6.8 Enlarging the ground bearing area.............................................806 12.6.9 Extending/retracting supporting cylinders.....................................807 From the control units...........................................................808 With the handheld control.......................................................809 From the crane cab...............................................................810 12.6.10 Level the truck crane on outriggers..........................................812 Inclination indicators...........................................................812 Prerequisites....................................................................813 Manual alignment.................................................................814 Automatic alignment..............................................................815 12.6.11 Levelling the free-on-wheels truck crane.....................................817 12.6.12 Outrigger pressure display...................................................819 12.7 Rigging/unrigging the counterweight.................................................821 12.7.1 Counterweight sections........................................................821 12.7.2 Identification................................................................823 12.7.3 Slinging points on the counterweight sections.................................824 12.7.4 CHECKLIST: Rigging the counterweight..........................................825 12.7.5 CHECKLIST: Unrigging the counterweight........................................826 12.7.6 Assembling counterweight combination..........................................829 12.7.7 Counterweight hoist unit......................................................837 Counterweight menu...............................................................837 Extending/ retracting the lifting cylinders......................................838 Automatic mode, rigging..........................................................839 Automatic mode, unrigging........................................................841 Cancel automatic mode............................................................842 12.7.8 Setting down counterweight for driving the truck crane........................843 12.7.9 Slewing with rigged counterweight.............................................845 12.8 Rigging work on the main boom.......................................................847 12.8.1 Hook block on the bumper......................................................847 Picking up the hook block........................................................847 Attaching the hook block.........................................................848 12.8.2 Hook block in the compartment.................................................849 Prerequisites....................................................................849 12.8.3 Hook block on a separate vehicle..............................................851 Picking up the hook block........................................................852 Setting down the hook block......................................................852 12.8.4 Hook block, separable.........................................................854 Rigging for onroad driving......................................................854 Rigging for crane operation......................................................855 12.8.5 Reeving and unreeving the hoist rope..........................................856 Version A........................................................................856 Version B........................................................................857 Reeving the hoist rope...........................................................859 Unreeving the hoist rope.........................................................862 12.8.6 Possible reeving methods on the main boom.....................................863 With 7 head sheaves..............................................................863 With 10 head sheaves.............................................................866 With 11 head sheaves.............................................................869 12.8.7 Installing/removing the lifting limit switch..................................870 Installing the lifting limit switch..............................................870 Removing the lifting limit switch................................................873 12.8.8 Locking/unlocking the lifting limit switch....................................875 Locking..........................................................................875 Releasing locking................................................................875 12.8.9 Anemometer and air traffic control light......................................876 Installing.......................................................................876 Switching the air traffic control light on and off...............................876 Removing.........................................................................877 For transport....................................................................877 12.9 Other rigging work..................................................................879 12.9.1 Railings on the turntable.....................................................879 12.9.2 Folding the lighting carrier in/out...........................................880 12.9.3 Safety harness on the main boom...............................................881 Prerequisites....................................................................882 Requirements.....................................................................882 Attaching/ detaching fall prevention safety system to/from safety harness........883 Inspecting/ replacing safety harness.............................................885 12.9.4 Slinging points for personal protective equipment.............................886 12.9.5 Cameras for crane operation...................................................887 Camera on the hoists.............................................................887 Camera on main boom..............................................................888 Operating the camera.............................................................890 12.9.6 Stair tread on the crane cab..................................................891 13 Driving with rigged truck crane...........................................................895 13.1 Driving path........................................................................895 13.2 Permissible rigging modes and axle loads............................................896 Axle load table......................................................................897 13.3 Before driving......................................................................898 13.3.1 Securing the superstructure against slewing...................................898 13.3.2 Checking tyre pressure and wind speed.........................................899 13.3.3 Putting the truck crane on the wheels.........................................900 13.3.4 Gears/connections.............................................................902 Transmission.....................................................................902 Switching on separate steering...................................................902 13.4 While driving.......................................................................902 13.5 After driving.......................................................................904 14 Transport.................................................................................907 14.1 Transport with transport vehicle....................................................907 14.1.1 CHECKLIST: Checks before transport............................................908 14.1.2 Drive the truck crane onto the transport vehicle..............................910 Drive on.........................................................................910 Lashing..........................................................................910 14.1.3 Slinging points...............................................................911 15 Malfunctions during crane operation.......................................................915 15.1 Emergency stop switch...............................................................915 15.2 What to do when a malfunction occurs during crane operation.........................917 Load can be lowered..................................................................917 Load cannot be lowered...............................................................917 15.3 Fuses in the crane cab..............................................................919 Notes on changing fuses..............................................................919 15.4 Finding and eliminating malfunctions................................................924 15.4.1 Malfunctions on the engine....................................................924 15.4.2 Malfunctions on the counterweight hoist unit..................................924 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................925 15.4.4 Malfunctions in the hoist cameras.............................................926 15.4.5 Malfunctions in the main boom camera..........................................926 15.4.6 Malfunctions on the derricking gear...........................................927 15.4.7 Malfunctions in the telescoping mechanism.....................................928 15.4.8 Malfunctions on the slewing gear..............................................930 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................931 15.4.10 Malfunctions when inclining the crane cab....................................931 15.4.11 Malfunctions when operating with the hand-held control.......................931 15.4.12 Malfunctions of the outriggers...............................................932 15.4.13 Malfunction in the CCS control unit..........................................932 15.4.14 Troubleshooting the crane control............................................933 General malfunctions.............................................................933 Symbols in the error or information display areas................................934 Displays in the Error menu.......................................................938 15.4.15 Malfunctions in the CraneSTAR system.........................................940 15.5 Emergency operations and programmes.................................................941 15.5.1 Mechanical emergency activation for retracting................................942 Prior to the emergency activation, check.........................................942 Procedure........................................................................942 Mechanical emergency activation..................................................943 15.5.2 Telescoping emergency programme...............................................945 Open submenu Emergency program...................................................945 Determining the error type.......................................................946 Error on length indicator........................................................947 Tables for approaching the locking points........................................951 15.5.3 Entering the current telescoping..............................................953 15.5.4 Emergency operation with the hand-held control................................955 Preparations.....................................................................955 Operating a power unit...........................................................956 Stopping movements...............................................................958 Stopping movements in emergencies................................................958 Turning off the engine...........................................................958 15.6 Hydraulic emergency operation.......................................................959 15.6.1 Connecting/disconnecting hoses................................................959 15.6.2 Establishing the required hydraulic circuits..................................960 Switching over valves............................................................960 For lowering.....................................................................961 15.6.3 Operating principle of emergency operation BGR 159............................963 15.6.4 Connecting/disconnecting hoses................................................964 Establishing connections.........................................................964 Disconnecting....................................................................965 15.6.5 Switching emergency operation on/off..........................................966 15.6.6 Establishing the hydraulic circuits required..................................967 Switching over valves............................................................967 For lifting/ lowering............................................................969 For slewing......................................................................970 15.6.7 Performing emergency operation................................................971 Turning..........................................................................971 Derricking.......................................................................972 Lifting/lowering.................................................................972 15.6.8 After emergency operation.....................................................973 Switching off emergency operation................................................973 Switching over to crane operation................................................973 Disconnecting the hoses..........................................................973 15.6.9 Emergency supply of another crane.............................................974 For emergency supply.............................................................974 After emergency supply...........................................................974 16 Index.....................................................................................977 A........................................................................................979 B........................................................................................979 C........................................................................................980 D........................................................................................983 E........................................................................................984 F........................................................................................986 H........................................................................................986 I........................................................................................987 K........................................................................................987 L........................................................................................987 M........................................................................................988 O........................................................................................989 P........................................................................................990 R........................................................................................990 S........................................................................................992 T........................................................................................993 V........................................................................................995 W........................................................................................995
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