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Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302419 – PDF DOWNLOAD
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Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302419 – PDF DOWNLOAD
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Description
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302419 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302419 – PDF DOWNLOAD
Language : English
Pages : 1002
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual 3302419 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
- The GMK 5250L is a state-of-the-art truck crane, designed in accordance
with approved safety regulations. Nevertheless, the operator or third parties
can still be endangered and the crane or other property put at risk while
using it. - The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK 5250L truck crane may only be used when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 5250L truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
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 3302419 – 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 programe........................................................... 47 Anemometer display ...................................................................... 35 Extended function.................................................................... 35 Rigging the special outrigger span....................................................... 37 For removal/installation of the rear outrigger cylinders............................. 37 Rigging the outrigger span....................................................... 37 Information...................................................................... 39 Note on error messages........................................................... 40 Telescoping emergency programme.......................................................... 41 Return run of the telescoping cylinder............................................... 41 Outrigger control units.................................................................. 43 Switching over the display between metre/feet and percent............................ 43 1 Overview................................................................................... 53 1.1 Accidents............................................................................ 53 1.2 Branch offices....................................................................... 55 1.2.1 Manitowoc Crane Care........................................................... 55 1.2.2 Dealer list.................................................................... 55 1.3 Warranty specifications.............................................................. 55 1.4 Terms used........................................................................... 56 1.5 Technical data....................................................................... 59 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 59 1.5.2 Maximum lifting capacity (ASME B 30.5)......................................... 59 1.5.3 Dimensions and weights of the truck crane, axle loads.......................... 60 Dimensions....................................................................... 61 Weight and axle loads............................................................ 61 1.5.4 Dimensions and weights of removable parts...................................... 62 Spare wheel...................................................................... 62 Outriggers....................................................................... 62 Main boom........................................................................ 63 Hook blocks and hook tackle...................................................... 63 hook blocks, split............................................................... 64 Auxiliary hoist.................................................................. 65 Counterweight parts.............................................................. 65 1.5.5 Carrier........................................................................ 66 Engine........................................................................... 66 Transmission..................................................................... 66 Transfer case.................................................................... 66 Axle lines....................................................................... 66 Steering......................................................................... 66 Tyres............................................................................ 67 Electrical system................................................................ 67 Tool............................................................................. 67 Towing couplings................................................................. 67 Driving speeds................................................................... 67 Climbing ability................................................................. 67 Outriggers....................................................................... 68 Turning radii.................................................................... 69 1.5.6 Superstructure................................................................. 70 Main hoist....................................................................... 70 Auxiliary hoist.................................................................. 70 Slewing gears.................................................................... 70 Derricking gear.................................................................. 70 Main boom........................................................................ 71 Lattice extension................................................................ 71 Operating speeds................................................................. 71 Noise emission................................................................... 71 1.6 Documentation supplied............................................................... 73 1.6.1 Questions on documentation..................................................... 74 1.7 Notes on the operating manual........................................................ 75 1.7.1 What do the symbols used mean?................................................. 75 1.7.2 How is the operating manual structured?........................................ 77 Division......................................................................... 77 Structure of the chapters........................................................ 77 Structure of the pages........................................................... 78 1.7.3 How do I find the information I need?.......................................... 79 Cross-references example......................................................... 80 1.7.4 What information is available for operations planning?......................... 82 1.8 Conversion table for US measuring units.............................................. 83 1.9 Training – Information............................................................... 85 1.10 Identification...................................................................... 86 1.11 EC Declaration of Conformity........................................................ 88 2 Basic safety instructions.................................................................. 91 2.1 Intended use......................................................................... 91 2.1.1 Improper use................................................................... 92 2.2 Organisational measures.............................................................. 93 2.3 Personnel qualifications............................................................. 95 2.4 Safety instructions for driving the truck crane...................................... 96 2.5 Safety instructions for crane operation.............................................. 97 2.6 Notes on transporting persons........................................................ 99 Equipment for lifting persons........................................................ 99 Personnel............................................................................ 99 Operation............................................................................100 Truck crane..........................................................................101 3 Operating elements for driving.............................................................105 3.1 Overview of the operating elements...................................................105 3.1.1 On the outside of the truck crane..............................................106 3.1.2 Cab............................................................................110 Overview.........................................................................110 Behind the cover.................................................................114 In the rear of the driver's cab..................................................114 3.1.3 Instrument panel...............................................................115 Left/right.......................................................................115 Middle...........................................................................116 On-board computer time correction................................................118 3.1.4 On-board computer..............................................................119 3.1.5 Steering column/steering wheel.................................................120 3.1.6 Transmission operating elements................................................121 3.1.7 Tachograph.....................................................................122 3.1.8 Control unit CCS...............................................................123 3.1.9 Display CCS – start menu.......................................................124 3.1.10 CCS – overview of menu groups.................................................126 Carrier menu group...............................................................128 Suspension/level adjustment menu.................................................129 Driving menu.....................................................................130 Settings menu group..............................................................131 Menu for setting the display brightness and date/time............................132 Information menu group...........................................................133 Operating hours menu.............................................................134 Engine/ transmission error menu..................................................135 Crane operation error menu.......................................................136 Operating additional equipment...................................................137 3.1.11 Outrigger control units.......................................................138 3.1.12 Heating/Air-conditioning system...............................................139 Standard heating system..........................................................139 Auxiliary water heater...........................................................140 Auxiliary air heater.............................................................141 3.1.13 Sockets for hand-held control.................................................142 3.1.14 Outrigger control units.......................................................143 3.2 Short description of the operating elements..........................................145 3.2.1 Definition of direction information............................................146 Basic rule.......................................................................146 Switches and buttons.............................................................146 3.2.2 General rules for buttons and symbols on the display...........................147 3.2.3 Engine.........................................................................148 Steering column..................................................................148 On the steering wheel............................................................148 Instrument panel.................................................................149 3.2.4 AdBlue system (DEF)............................................................150 Instrument panel.................................................................150 CCS display......................................................................151 3.2.5 Battery master switch..........................................................151 3.2.6 Electrical system..............................................................152 3.2.7 Crane control CCS..............................................................153 3.2.8 Transmission...................................................................157 Transmission control unit........................................................157 Display, driving mode,...........................................................158 3.2.9 Reverse camera.................................................................160 3.2.10 Final drive...................................................................161 3.2.11 Brakes........................................................................163 Service brake....................................................................163 Additional brakes................................................................163 Parking brake....................................................................164 3.2.12 Steering/separate steering....................................................166 Instrument panel.................................................................166 CCS display......................................................................167 Driver's door....................................................................168 3.2.13 Suspension....................................................................169 CCS display......................................................................169 Outrigger control units..........................................................169 3.2.14 Lighting/windscreen wipers/horn...............................................170 Steering column..................................................................170 Steering wheel...................................................................170 Instrument panel.................................................................170 CCS display......................................................................172 Roof.............................................................................173 3.2.15 Level adjustment system.......................................................174 3.2.16 Tachograph/speedometer........................................................176 Tachograph.......................................................................176 Speedometer......................................................................176 3.2.17 Diagnostics...................................................................177 3.2.18 On-board computer.............................................................178 3.2.19 Windows, doors, keys..........................................................180 Window winder....................................................................180 Doors............................................................................181 Keys.............................................................................181 3.2.20 Front flap....................................................................182 4 Starting/turning off the engine for driving................................................185 4.1 Starting the engine from the driver's cab............................................185 4.1.1 CHECKLIST: Starting the engine.................................................185 4.1.2 CHECKLIST: At low temperatures.................................................188 4.1.3 Ladders and access ladders.....................................................188 Access ladders...................................................................188 Ladders..........................................................................189 4.1.4 Refuel.........................................................................191 Standard tank....................................................................191 Dual tank........................................................................192 AdBlue...........................................................................193 4.1.5 Checks before starting the engine..............................................194 On hydraulic tank................................................................194 Battery master switch............................................................195 Checking the hand-held control...................................................195 4.1.6 Switching on the ignition......................................................195 4.1.7 Lamp test/equalisation of the switching states.................................196 Lamp test........................................................................196 Switching state alignment........................................................196 4.1.8 Display – setting the brightness...............................................197 4.1.9 Starting the engine............................................................198 4.1.10 Checks after starting the engine..............................................200 Checking in the main menu........................................................200 Indicator lamps on the instrument panel..........................................201 4.1.11 Monitoring elements...........................................................203 Instrument panel.................................................................203 4.1.12 Start menu....................................................................204 4.1.13 Setting idling speed..........................................................205 4.2 Turning off the engine...............................................................207 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....207 After turning off................................................................207 4.2.2 Using the emergency stop switches..............................................208 Resetting the emergency stop switch..............................................208 4.3 Air intake inhibitor.................................................................209 Releasing the air intake inhibitor...................................................209 5 Driving....................................................................................213 5.1 Before driving.......................................................................213 5.1.1 CHECKLIST: Checks before on-road driving.......................................213 5.1.2 Checking the condition of the truck crane......................................219 Electrical system................................................................219 Adjusting the mirrors............................................................219 Warning plates for vehicle width.................................................221 Displaying vehicle height........................................................221 Supply pressure..................................................................222 Parking brake....................................................................223 5.1.3 Adjusting the seat and the steering column.....................................224 Driver's seat....................................................................224 Passenger's seat.................................................................225 Steering column, adjusting.......................................................226 5.1.4 Switching the suspension on/off................................................227 Open menu........................................................................227 Switching on the suspension......................................................228 Switching off the suspension.....................................................228 5.1.5 Setting the tachograph.........................................................229 Prerequisites....................................................................229 In the event of malfunctions.....................................................229 Setting the tachograph...........................................................230 5.1.6 Entering the time/date.........................................................234 5.1.7 Displaying and resetting operating hours.......................................235 5.2 Operating the transmission...........................................................237 5.2.1 Switching on...................................................................237 5.2.2 Switching the transmission to neutral position.................................238 5.2.3 Selecting the direction of travel and starting gear............................239 Selecting the driving direction..................................................239 Selecting the starting gear......................................................240 5.2.4 Changing the operating mode....................................................241 Changing to automatic mode.......................................................241 Change to manual mode............................................................241 5.2.5 Starting.......................................................................242 5.2.6 Driving and changing gears.....................................................243 In automatic operating mode......................................................243 In manual operating mode.........................................................244 5.2.7 Changing the driving direction.................................................245 5.2.8 Stopping.......................................................................245 Stopping for along period oftime...............................................245 5.2.9 On the roller type dynamometer.................................................246 5.2.10 Preheating transmission.......................................................246 5.3 Driving and turning off the truck crane..............................................247 5.3.1 Checks while driving...........................................................247 Immediately after you start to move..............................................247 While driving....................................................................249 5.3.2 Cruise control.................................................................250 Switching on.....................................................................250 Switching off....................................................................251 5.3.3 Temposet.......................................................................252 Switching on.....................................................................252 Switching off....................................................................252 5.3.4 Driving downhill...............................................................253 Starting.........................................................................253 Inspections when driving downhill................................................254 Downshifting.....................................................................254 Additional brakes................................................................255 5.3.5 Driving uphill.................................................................256 Starting.........................................................................256 Driving..........................................................................256 5.3.6 Warning messages in the start menu.............................................257 5.3.7 Warning or malfunction messages on the instrument panel........................258 Meaning of the lamps.............................................................258 5.3.8 Messages on the on-board computer display......................................259 5.3.9 Indicator lights in the on-board computer display..............................261 5.3.10 Override torque reduction.....................................................263 5.3.11 Turning off the truck crane...................................................264 Securing against rolling away....................................................264 When stationary for more than 8 hours............................................265 5.3.12 Folding berth.................................................................266 5.4 Off-road driving.....................................................................267 Adjustments to the transmission......................................................267 Connections..........................................................................267 Changing the vehicle level...........................................................267 Rocking the vehicle free and towing..................................................267 5.4.1 Longitudinal and transverse differential locks.................................268 5.4.2 Operating the level adjustment system..........................................270 Open menu........................................................................270 Setting the onroad level........................................................271 Pre-selecting suspension struts..................................................271 Changing the vehicle level.......................................................272 Viewing the current inclination..................................................272 Exiting the menu.................................................................273 5.4.3 Freeing truck crane stuck in terrain...........................................274 Rocking the truck crane free.....................................................274 Towing free forwards.............................................................275 Towing free in reverse gear......................................................275 5.5 Separate steering....................................................................277 5.5.1 Switching to separate steering.................................................277 Manual...........................................................................278 Automatic........................................................................279 5.6 Heating and air-conditioning system..................................................281 5.6.1 Standard heating system,.......................................................281 Switching on.....................................................................281 Heating..........................................................................281 Air distribution.................................................................282 Examples.........................................................................283 Switching off....................................................................283 5.6.2 Air-conditioning system........................................................284 Information......................................................................284 Switching on/off.................................................................284 Cooling..........................................................................285 Drying...........................................................................285 5.6.3 Auxiliary water heater.........................................................286 Preheating the engine............................................................286 Preheating the driver's cab......................................................287 Switching on the auxiliary heater................................................288 Switching off the auxiliary heater...............................................289 Setting time and weekday.........................................................289 Saving automatic heating start...................................................290 Setting the heating period.......................................................291 Switching the automatic heating start on and off.................................291 Setting the remaining time.......................................................292 5.6.4 Auxiliary air heater...........................................................293 Switching on.....................................................................293 Temperature......................................................................294 Switching off....................................................................294 Other functions..................................................................294 5.7 Towing a trailer.....................................................................295 Effects on the axle loads............................................................295 Coupling the trailer.................................................................296 Connecting the supply lines..........................................................297 Removing the supply lines............................................................298 Uncoupling the trailer...............................................................298 Checking the braking force...........................................................300 6 Driving modes and rigging for on-road driving..............................................303 6.1 Driving modes........................................................................303 Information about the axle loads.....................................................303 6.1.1 Information on how to use the tables...........................................304 6.1.2 Tables for a maximum axle load of 12t (26,500lbs)............................305 For 385/95 R25 tyres.............................................................305 For 445/95 R25 525/80 R25 tyres..................................................306 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)...........307 6.2 Rigging work for driving with a trailer..............................................308 6.2.1 Switching on the slewing gear freewheel........................................309 6.2.2 Switching on the boom floating position........................................310 6.2.3 Switching on boom pre-tensioning...............................................311 6.3 Main boom, removing/installing.......................................................312 Additional equipment required........................................................312 6.3.1 CHECKLIST: Removing the main boom..............................................313 Prerequisites....................................................................313 Checklist........................................................................313 6.3.2 CHECKLIST: Mounting the main boom..............................................315 Prerequisites....................................................................315 Checklist........................................................................315 6.3.3 Slinging the main boom.........................................................317 Marking..........................................................................317 Installing the lifting gear......................................................317 Removing the lifting gear........................................................318 6.3.4 Retracting/fitting the derricking cylinder head pin............................319 Operating the lifting device.....................................................319 Retracting the derricking cylinder head axle.....................................320 Fitting the derricking cylinder head axle........................................321 6.3.5 Retracting/extending the boom pivot pin........................................322 Before retracting................................................................322 After extending..................................................................323 Retracting/ extending the pivot pin..............................................324 6.3.6 Disconnecting/connecting hydraulics/electrical.................................325 Detachment.......................................................................325 Establishing.....................................................................326 6.3.7 Lifting the main boom off/on the turntable.....................................327 Lifting from the turntable.......................................................327 Lifting on to the turntable......................................................328 6.3.8 Aligning the connecting points.................................................328 6.3.9 Transporting the main boom.....................................................329 6.3.10 Inspections after main boom mounting..........................................330 6.4 Installing/removing outrigger beams..................................................331 6.4.1 CHECKLIST: Removing the outrigger beams........................................332 6.4.2 CHECKLIST: Installing the outrigger beams......................................334 6.4.3 Preparing the truck crane......................................................336 Prerequisites....................................................................336 For removal......................................................................336 6.4.4 Removing/attaching outrigger pads..............................................337 Removing the outrigger pads......................................................337 Attaching the outrigger pads.....................................................338 6.4.5 Disconnecting/establishing the hydraulic connection............................339 6.4.6 Disconnecting/establishing the electrical connection...........................340 6.4.7 Unscrewing/screwing in the spacers.............................................341 Unscrewing.......................................................................341 Screwing in......................................................................342 6.4.8 Disconnecting/establishing the connections to the outrigger box................343 6.4.9 Extending/retracting the outrigger beam........................................343 Extending the outrigger beam.....................................................343 Inserting the outrigger beam.....................................................345 6.4.10 Transporting the outrigger beams..............................................347 6.5 Rigging the auxiliary hoist..........................................................349 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................349 Prerequisites....................................................................349 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................351 Prerequisites....................................................................351 6.5.3 Slinging the auxiliary hoist...................................................353 6.5.4 Slinging the rigging frame.....................................................353 6.5.5 Lowering/raising the rigging frame.............................................354 Prerequisite.....................................................................354 6.5.6 Placing the auxiliary hoist on the counterweight combination...................354 6.5.7 Establishing/disconnecting the hydraulic connection............................355 6.5.8 Making/breaking the electrical connection......................................356 6.5.9 Creating the connection to the turntable.......................................357 Establishing the connection......................................................357 Disconnecting....................................................................359 6.5.10 Securing the hoist rope.......................................................360 6.5.11 Transporting the auxiliary hoist..............................................361 6.5.12 Check that the auxiliary hoist is functioning properly........................362 Slewing direction................................................................362 Slewing indicator................................................................362 7 Malfunctions in driving mode...............................................................365 7.1 Emergency stop switch................................................................365 7.2 What to do when a malfunction occurs in road traffic.................................367 7.3 Towing the truck crane...............................................................369 7.3.1 Towing after engine/transmission damage........................................370 Compressed-air supply............................................................370 Electric power supply............................................................371 On the transmission..............................................................371 Axle drives......................................................................372 Parking brake....................................................................372 Towing the truck crane out of the danger area....................................373 7.3.2 Tow starting...................................................................373 7.4 Other emergency operations...........................................................375 7.4.1 Externally starting the truck crane............................................375 7.4.2 Battery charger................................................................376 Prerequisites....................................................................376 7.5 Wheels and tyres.....................................................................377 7.5.1 Wheel change...................................................................377 Removing a damaged wheel.........................................................378 On the spare wheel holder........................................................378 Mounting a wheel.................................................................379 7.5.2 Inflating the tyres yourself...................................................381 Connecting the filling hose......................................................381 Inflating the tyres..............................................................382 Removing the filling hose........................................................382 7.6 Fuses................................................................................383 Notes on changing fuses..............................................................383 7.6.1 Fuses in the driver's cab......................................................384 Group F1.........................................................................384 Group F2.........................................................................385 Group F3.........................................................................385 Group F4.........................................................................386 Other fuses......................................................................386 Group F7.........................................................................387 Group F8.........................................................................387 Group F9.........................................................................388 Group F10........................................................................388 7.6.2 Fuses in the battery box.......................................................389 7.7 Troubleshooting......................................................................391 7.7.1 Malfunctions on the engine.....................................................391 7.7.2 Faults on the AdBlue (DEF) system..............................................393 7.7.3 Malfunctions in the transmission...............................................394 7.7.4 Malfunctions of the service brake..............................................395 7.7.5 Malfunctions of the steering...................................................396 7.7.6 Differential lock malfunctions.................................................397 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................397 7.7.8 Malfunctions on the suspension.................................................398 7.7.9 Malfunctions of the level adjustment system....................................398 7.7.10 Malfunction in the CCS control unit...........................................398 7.8 Warnings in the start menu...........................................................399 Symbols in the display area..........................................................399 7.8.1 Engine/transmission error menu.................................................404 Open menu........................................................................404 Exiting the menu.................................................................404 7.9 Procedure in the event of malfunctions...............................................405 7.9.1 Procedure during engine malfunctions...........................................405 7.9.2 Procedure during transmission malfunctions.....................................406 8 Index......................................................................................409 A........................................................................................411 B........................................................................................411 C........................................................................................412 D........................................................................................415 E........................................................................................416 F........................................................................................418 H........................................................................................418 I........................................................................................419 K........................................................................................419 L........................................................................................419 M........................................................................................420 O........................................................................................421 P........................................................................................422 R........................................................................................422 S........................................................................................424 T........................................................................................425 V........................................................................................427 W........................................................................................427 Part 2 – Crane operation.........................................................................431 Additonal pages .............................................................................433 Additional page GMK – Reduction of slewing speed.........................................433 1 Reduction of slewing speed – can be switched on and off............................433 1.1 Important notes..............................................................433 With reduction switched on...................................................433 With reduction switched off..................................................433 1.2 Operation....................................................................434 1.2.1 Additional and modified operating elements.............................434 1.2.2 Switching reduction off and on.........................................435 CCS display..............................................................................437 Menu changes.........................................................................437 Start menus......................................................................437 Displays for the counterweight...................................................438 Slewing gear freewheel...................................................................441 CCS – Datalogger.........................................................................443 Additional menu and program..........................................................443 Additional menu..................................................................443 Export data......................................................................444 Display the data.................................................................444 Slewable spotlights......................................................................449 Automatic load tracking..............................................................449 Hoist rope travel limitation.............................................................451 Hoist rope travel limitation menu....................................................452 Entering values......................................................................453 Switching monitoring function on/off.................................................453 Driving with rigged truck crane..........................................................455 Counterweight............................................................................457 Setting down the base plate..........................................................457 Adjustable head sheave...................................................................459 Different positions depending on the reeving.........................................459 Main boom intermediate lengths ..........................................................461 Derricking cylinder pressure monitoring..............................................461 Telescoping emergency programe...........................................................471 Anemometer display .....................................................................465 Extended function....................................................................465 Rigging the special outrigger span.......................................................467 For removal/installation of the rear outrigger cylinders.............................467 Rigging the outrigger span.......................................................467 Information......................................................................469 Note on error messages...........................................................470 Telescoping emergency programme.......................................................... 0 Return run of the telescoping cylinder............................................... 0 Outrigger control units.................................................................. 43 Switching over the display between metre/feet and percent............................ 43 9 Operating elements for crane operation.....................................................477 9.1 Overview of the operating elements...................................................477 9.1.1 Exterior of the truck crane....................................................478 9.1.2 Crane cab......................................................................482 Side panel.......................................................................484 Crane cab, rear..................................................................486 9.1.3 Control panels.................................................................488 Left.............................................................................488 Right............................................................................489 9.1.4 Control lever configuration....................................................490 Version 1........................................................................490 Version 2........................................................................491 9.1.5 Control unit CCS...............................................................492 9.1.6 CCS – Start menu...............................................................495 9.1.7 CCS – overview of menu groups..................................................496 Superstructure menu group........................................................500 Superstructure lock menu.........................................................501 Counterweight menu...............................................................502 Outrigger menu...................................................................503 Outrigger support beam menu......................................................505 Outrigger cylinders menu.........................................................506 Teleautomation menu group........................................................508 Telescoping full automation menu.................................................509 Telescoping semiautomation menu.................................................510 Main boom configuration menu.....................................................511 Active working range limiter menu group..........................................512 Overall height menu..............................................................513 Working radius menu..............................................................514 Slewing angle menu...............................................................515 Information menu group...........................................................516 Hydraulic pressure and fuel consumption menu.....................................517 Engine/Driving menu group........................................................518 Economy menu.....................................................................519 Heating/ airconditioning menu...................................................520 Telescoping menu group...........................................................521 Manual telescoping menu..........................................................522 Telescoping emergency program menu...............................................523 Unknown telescoping menu.........................................................524 Settings menu group..............................................................525 Crane cab menu...................................................................526 Menu for setting the display brightness and date/time............................527 Switch units menu................................................................528 Set control lever characteristic curve menu......................................529 Power unit speeds menu...........................................................530 Menu group Information...........................................................531 Operating hours menu.............................................................532 Engine/ transmission error menu..................................................534 Crane operation error menu.......................................................535 Program version menu.............................................................536 Operating additional equipment...................................................537 9.1.8 Control unit RCL...............................................................538 9.1.9 RCL – menu groups..............................................................540 Menu for entering rigging mode...................................................543 Monitoring menu..................................................................544 Lifting capacity tables menu.....................................................546 9.1.10 Hand-held controls............................................................547 Outrigger control panel..........................................................548 9.1.11 Outrigger control units.......................................................550 Button...........................................................................550 Outrigger button.................................................................551 Inclination and outrigger pressure display.......................................552 Raise axle display...............................................................553 9.2 Short description of the operating elements..........................................555 9.2.1 Definition of direction information............................................555 Basic rule.......................................................................555 Switches.........................................................................555 9.2.2 General rules for buttons and symbols on the display...........................556 9.2.3 Engine.........................................................................557 Side panel.......................................................................557 Economy menu.....................................................................558 9.2.4 AdBlue (DEF) system............................................................559 CCS display......................................................................559 9.2.5 Seat contact switch and dead man's switch......................................560 9.2.6 Crane control CCS..............................................................561 9.2.7 Outrigger......................................................................567 Hand-held control................................................................567 Right-hand control panel.........................................................568 Left-hand control panel..........................................................568 In the Outrigger menu............................................................569 On the outrigger control units...................................................571 9.2.8 Inclination indicators.........................................................573 9.2.9 Raise axle.....................................................................574 Outrigger control units..........................................................574 9.2.10 Outrigger pressure displays...................................................576 Outriggers submenu...............................................................576 Outrigger control units..........................................................576 9.2.11 Anemometer displays...........................................................576 9.2.12 Counterweight menu............................................................577 Counterweight submenu............................................................577 9.2.13 Main hoist....................................................................581 Control panels...................................................................581 CCS display......................................................................582 9.2.14 Auxiliary hoist...............................................................583 Control panels...................................................................583 CCS display......................................................................584 9.2.15 Slewing gear..................................................................585 Control panels...................................................................585 CCS display......................................................................586 9.2.16 Derricking gear...............................................................587 Control panels...................................................................587 CCS display......................................................................588 9.2.17 Telescoping mechanism.........................................................589 Control panels...................................................................589 CCS display......................................................................589 Telescoping full automation menu.................................................590 Telescoping semiautomation menu.................................................591 Manual telescoping menu..........................................................593 Main boom configuration menu.....................................................596 9.2.18 Hydraulic system..............................................................597 9.2.19 Superstructure lock/Houselock menu............................................598 Superstructure lock..............................................................598 Houselock........................................................................599 9.2.20 Rated capacity limiter (RCL)..................................................600 Control unit control console RCL.................................................600 Display RCL......................................................................601 Enter rigging mode menu..........................................................603 Monitoring menu..................................................................606 Lifting capacity tables menu.....................................................610 RCL override.....................................................................610 External displays................................................................611 9.2.21 Electrical system.............................................................613 9.2.22 Lighting, windscreen wiper/washing system.....................................613 Lighting.........................................................................613 Windscreen wiper/washing system..................................................614 9.2.23 Hand-held control.............................................................616 Sockets for handheld control....................................................616 Engine control panel.............................................................617 Horn.............................................................................617 Outrigger control panel..........................................................618 9.2.24 Windows, doors, keys..........................................................620 Windows..........................................................................620 Rear window......................................................................620 Crane cab door...................................................................621 Keys.............................................................................622 9.2.25 Diagnostics...................................................................622 10 Starting/turning off the engine – for crane operation.....................................625 10.1 When starting the engine for the first time of the day..............................625 10.1.1 Checking the fuel level and AdBlue (DEF) level................................626 Fuel.............................................................................626 AdBlue (DEF).....................................................................626 10.1.2 Checks before starting the engine.............................................627 On hydraulic tank................................................................627 Checking the hand-held control...................................................628 10.1.3 Switching on the ignition.....................................................628 10.1.4 Display – setting the brightness..............................................629 10.1.5 Starting the engine...........................................................630 10.1.6 Checks after starting the engine..............................................631 10.1.7 Setting idling speed..........................................................632 10.2 Starting the engine – with the hand-held control....................................633 Prerequisites........................................................................633 Starting the engine..................................................................633 10.3 Turning off the engine..............................................................635 10.3.1 During normal operation, with the ignition lock/with the handheld control....635 After turning off................................................................635 10.3.2 In emergencies, with the emergency stop switches..............................636 Resetting the emergency stop switch..............................................636 11 Crane operation...........................................................................639 11.1 Before operating the crane..........................................................639 11.1.1 CHECKLIST: Checks before operating the crane..................................639 11.1.2 Checking the condition of the truck crane.....................................643 Fuel tank auxiliary heater.......................................................643 Visual inspection................................................................643 Checking the position of the hoist ropes.........................................644 Checking the electrical system...................................................645 11.1.3 Adjusting the crane cab seat and front control panel..........................646 Crane cab seat...................................................................646 Front panel......................................................................646 11.1.4 Checking the safety equipment.................................................647 Rated capacity limiter...........................................................647 Lifting limit switch.............................................................647 Emergency stop switch............................................................648 Seat contact switch..............................................................649 11.1.5 Earthing the load.............................................................650 11.1.6 Preheating the hydraulic oil..................................................651 Prerequisites....................................................................651 Preheating.......................................................................651 11.1.7 Locking/unlocking the superstructure..........................................652 Locking points...................................................................652 Locking the superstructure.......................................................653 Unlocking the superstructure.....................................................653 11.1.8 Switching the Houselock on/off................................................654 Switching on the Houselock.......................................................654 Switching off the Houselock......................................................656 11.2 Operation of the rated capacity limiter.............................................657 11.2.1 Switch on the RCL.............................................................658 Switching on.....................................................................658 Brightness of the displays.......................................................660 Temperature on the display.......................................................660 11.2.2 Enter rigging mode............................................................661 Entering individual components...................................................662 Entering the RCL code............................................................666 Entering the reeving.............................................................667 Accepting the rigging mode.......................................................667 11.2.3 Checks before operating the crane.............................................669 Open menu........................................................................669 Checks...........................................................................669 11.2.4 Displays during crane operation...............................................672 11.2.5 RCL early warning.............................................................675 11.2.6 RCL switch-off................................................................675 Shutdown due to overload.........................................................675 11.2.7 Display in the event of errors................................................677 11.2.8 RCL override..................................................................678 Overview status display..........................................................678 When rigging.....................................................................679 To raise the boom................................................................680 In emergencies...................................................................681 11.2.9 Displaying the lifting capacity tables........................................682 11.2.10 Setting the time/date........................................................684 11.3 Crane operation with main boom......................................................685 11.3.1 Checks during crane operation.................................................685 Horizontal alignment.............................................................685 Safe distances...................................................................685 Checking the wind speed..........................................................686 11.3.2 Permissible slewing ranges and working positions..............................687 360 slewing range...............................................................687 0 to the rear working position..................................................687 180 to the front rigging position...............................................687 11.3.3 Main hoist....................................................................688 Switching on the main hoist......................................................689 Lifting and lowering.............................................................689 Maximum permissible hoist rope speed.............................................690 Switching off the main hoist.....................................................691 11.3.4 Auxiliary hoist...............................................................692 Switching on the auxiliary hoist.................................................692 Lifting and lowering.............................................................693 Maximum permissible hoist rope speed.............................................693 Switching off the auxiliary hoist................................................694 11.3.5 Lifting limit switch and lowering limit switch................................695 Lifting limit switch.............................................................695 Lowering limit switch............................................................697 11.3.6 Derricking gear...............................................................698 Switching on the derricking gear.................................................698 Maximum permissible derricking speed.............................................698 Raising and lowering.............................................................699 Re-enable raising function.......................................................700 Switching off the derricking gear................................................700 11.3.7 Telescoping mechanism.........................................................702 Overview.........................................................................703 Telescoping process..............................................................703 Assignment for display...........................................................706 Fixed length, intermediate length, telescoping length............................707 Telescoping......................................................................708 Telescoping sequence.............................................................708 Checks before starting work......................................................709 Switching on the telescoping mechanism...........................................710 Function of the control lever....................................................710 Switching off the telescoping mechanism..........................................712 Manual telescoping...............................................................713 Checking the initial position....................................................713 Unlocking the telescoping cylinder...............................................715 Extending/ retracting the telescoping cylinder...................................717 Lock telescoping cylinder........................................................718 Unlocking the telescopic section.................................................719 Telescoping the telescopic section...............................................720 Locking the telescopic section...................................................721 Locking the telescopic section for on-road driving...............................722 Telescoping with semi-automation.................................................722 Telescoping with full automation.................................................725 Telescoping with main boom configuration.........................................726 11.3.8 High-speed mode...............................................................727 Derricking gear/ telescoping mechanism...........................................727 Hoists...........................................................................728 11.3.9 Slewing gear..................................................................729 Switching on the slewing gear....................................................729 Turning..........................................................................730 Releasing locked slewing gear....................................................730 Maximum permissible slewing speed................................................731 Braking the slewing movement.....................................................732 Releasing the slewing gear brake.................................................732 Engaging the slewing gear brake..................................................732 Slewing gear freewheel...........................................................733 Switching off the slewing gear...................................................733 11.3.10 Possible movement combinations...............................................734 11.4 Settings and displays for crane operation...........................................735 11.4.1 Inclining the crane cab.......................................................735 11.4.2 Setting idling speed..........................................................736 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................736 11.4.4 Limiting the power unit speeds................................................737 11.4.5 Setting/switching on Economy mode.............................................738 Automatic........................................................................738 Manual...........................................................................738 11.4.6 Switching units...............................................................739 11.4.7 Setting the characteristic curves for the control levers......................740 11.4.8 Using the slewable spotlights.................................................741 11.4.9 Override torque reduction.....................................................742 11.4.10 Displaying the operating hours...............................................743 11.4.11 Warnings in the start menu...................................................744 Meaning of the symbols...........................................................744 11.5 Working range limiter...............................................................747 11.5.1 Viewing current settings......................................................748 11.5.2 Opening the working range limiter menu........................................749 11.5.3 Entering limit values.........................................................751 Overall height...................................................................751 Working radius...................................................................752 Slewing angle....................................................................752 11.5.4 Entering limit values manually................................................754 Limit values.....................................................................754 11.5.5 Switching monitoring functions on/off.........................................756 11.5.6 Shutdown by working range limiter.............................................757 11.6 Work break..........................................................................759 11.6.1 In case of short work breaks..................................................759 11.6.2 In case of work breaks of more than 8 hours...................................760 To secure the truck crane........................................................760 11.7 Heating and air-conditioning system.................................................761 11.7.1 Standard heating system.......................................................761 Switching on.....................................................................761 Heating..........................................................................761 Air distribution.................................................................761 Switching off....................................................................762 11.7.2 Air-conditioning system.......................................................763 Information......................................................................763 Switching on/off.................................................................763 Cooling, automatic...............................................................764 Cooling, maximum.................................................................764 11.7.3 Auxiliary heater..............................................................765 Switching on.....................................................................765 Setting the temperature..........................................................766 Setting the heating start/ heating duration......................................766 Switching heating start on/off...................................................767 11.8 CraneSTAR system....................................................................768 11.8.1 Overview......................................................................768 11.8.2 Position of the components....................................................768 12 Rigging work..............................................................................771 12.1 Rigging work checklists for crane operation with the main boom......................771 12.1.1 CHECKLIST: Rigging............................................................771 12.1.2 CHECKLIST: Unrigging..........................................................775 12.2 Choosing a suitable site............................................................779 12.2.1 Determining the required ground bearing area..................................779 12.2.2 Safe distance from slopes and pits............................................782 12.2.3 Earthing the truck crane......................................................783 12.2.4 Safe distance from electrical cables..........................................784 12.3 Rigging work after driving with a trailer...........................................787 12.3.1 Switching off the boom floating position......................................787 12.3.2 Switching off the slewing gear freewheel......................................788 Before slewing...................................................................788 12.3.3 Switching off boom pre-tensioning.............................................789 12.4 Connecting/disconnecting the hand-held control......................................791 12.5 Starting the engine for driving for rigging work....................................793 12.5.1 Starting/turning off the engine with the hand-held control....................793 Prerequisites....................................................................793 Starting the engine..............................................................794 Turning off the engine...........................................................794 12.5.2 Starting/turning off the engine from the outrigger control units..............795 Prerequisites....................................................................795 Starting the engine..............................................................795 Turning off the engine...........................................................795 12.6 Outrigger...........................................................................797 12.6.1 CHECKLIST: Extending the outriggers...........................................797 12.6.2 CHECKLIST: Retracting the outriggers..........................................799 12.6.3 Permissible outrigger spans...................................................800 12.6.4 Preparing the truck crane.....................................................801 In the driver's cab..............................................................801 Outrigger control units..........................................................801 12.6.5 Setting the outrigger spans...................................................802 For on-road driving..............................................................804 12.6.6 Extending/retracting outrigger beams..........................................805 From the control units...........................................................806 With the handheld control.......................................................807 From the crane cab...............................................................809 12.6.7 Moving the outrigger pads into working/driving position.......................811 12.6.8 Enlarging the ground bearing area.............................................812 12.6.9 Extending/retracting supporting cylinders.....................................813 From the control units...........................................................814 With the handheld control.......................................................815 From the crane cab...............................................................816 12.6.10 Level the truck crane on outriggers..........................................818 Inclination indicators...........................................................818 Prerequisites....................................................................819 Manual alignment.................................................................820 Automatic alignment..............................................................821 12.6.11 Levelling the free-on-wheels truck crane.....................................823 12.6.12 Outrigger pressure display...................................................825 12.7 Rigging/unrigging the counterweight.................................................827 12.7.1 Counterweight sections........................................................827 12.7.2 Identification................................................................828 12.7.3 Slinging points on the counterweight sections.................................829 12.7.4 CHECKLIST: Rigging the counterweight..........................................830 12.7.5 CHECKLIST: Unrigging the counterweight........................................831 12.7.6 Assembling counterweight combination..........................................833 12.7.7 Counterweight hoist unit......................................................841 Counterweight menu...............................................................841 Extending/ retracting the lifting cylinders......................................842 Automatic mode, rigging..........................................................843 Automatic mode, unrigging........................................................845 Cancel automatic mode............................................................846 12.7.8 Setting down counterweight for driving the truck crane........................847 12.7.9 Slewing with rigged counterweight.............................................849 12.8 Rigging work on the main boom.......................................................851 12.8.1 Hook block on the bumper......................................................851 Picking up the hook block........................................................851 Attaching the hook block.........................................................852 12.8.2 Hook block in the compartment.................................................853 Prerequisites....................................................................853 12.8.3 Hook block on a separate vehicle..............................................855 Picking up the hook block........................................................856 Setting down the hook block......................................................856 12.8.4 Hook block, separable.........................................................858 Rigging for onroad driving......................................................858 Rigging for crane operation......................................................859 12.8.5 Reeving and unreeving the hoist rope..........................................860 Version A........................................................................860 Version B........................................................................861 Reeving the hoist rope...........................................................863 Unreeving the hoist rope.........................................................866 12.8.6 Possible reeving methods on the main boom.....................................867 With 7 head sheaves..............................................................867 With 10 head sheaves.............................................................870 With 11 head sheaves.............................................................873 12.8.7 Installing/removing the lifting limit switch..................................874 Installing the lifting limit switch..............................................874 Removing the lifting limit switch................................................877 12.8.8 Locking/unlocking the lifting limit switch....................................879 Locking..........................................................................879 Releasing locking................................................................879 12.8.9 Anemometer and air traffic control light......................................880 Installing.......................................................................880 Switching the air traffic control light on and off...............................880 Removing.........................................................................881 For transport....................................................................881 12.9 Other rigging work..................................................................883 12.9.1 Railings on the turntable.....................................................883 12.9.2 Folding the lighting carrier in/out...........................................884 12.9.3 Safety harness on the main boom...............................................885 Prerequisites....................................................................886 Requirements.....................................................................886 Attaching/ detaching fall prevention safety system to/from safety harness........887 Inspecting/ replacing safety harness.............................................889 12.9.4 Slinging points for personal protective equipment.............................890 12.9.5 Cameras for crane operation...................................................891 Camera on the hoists.............................................................891 Camera on main boom..............................................................892 Operating the camera.............................................................894 12.9.6 Stair tread on the crane cab..................................................895 13 Driving with rigged truck crane...........................................................899 13.1 Driving path........................................................................899 13.2 Permissible rigging modes and axle loads............................................900 Axle load table......................................................................901 13.3 Before driving......................................................................902 13.3.1 Securing the superstructure against slewing...................................902 13.3.2 Checking tyre pressure and wind speed.........................................903 13.3.3 Putting the truck crane on the wheels.........................................904 13.3.4 Gears/connections.............................................................906 Transmission.....................................................................906 Switching on separate steering...................................................906 13.4 While driving.......................................................................906 13.5 After driving.......................................................................908 14 Transport.................................................................................911 14.1 Transport with transport vehicle....................................................911 14.1.1 CHECKLIST: Checks before transport............................................912 14.1.2 Drive the truck crane onto the transport vehicle..............................914 Drive on.........................................................................914 Lashing..........................................................................914 14.1.3 Slinging points...............................................................915 15 Malfunctions during crane operation.......................................................919 15.1 Emergency stop switch...............................................................919 15.2 What to do when a malfunction occurs during crane operation.........................921 Load can be lowered..................................................................921 Load cannot be lowered...............................................................921 15.3 Fuses in the crane cab..............................................................923 Notes on changing fuses..............................................................923 15.4 Finding and eliminating malfunctions................................................928 15.4.1 Malfunctions on the engine....................................................928 15.4.2 Malfunctions on the counterweight hoist unit..................................928 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................929 15.4.4 Malfunctions in the hoist cameras.............................................930 15.4.5 Malfunctions in the main boom camera..........................................930 15.4.6 Malfunctions on the derricking gear...........................................931 15.4.7 Malfunctions in the telescoping mechanism.....................................932 15.4.8 Malfunctions on the slewing gear..............................................934 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................935 15.4.10 Malfunctions when inclining the crane cab....................................935 15.4.11 Malfunctions when operating with the hand-held control.......................935 15.4.12 Malfunctions of the outriggers...............................................936 15.4.13 Malfunction in the CCS control unit..........................................936 15.4.14 Troubleshooting the crane control............................................937 General malfunctions.............................................................937 Symbols in the error or information display areas................................938 Displays in the Error menu.......................................................942 15.4.15 Malfunctions in the CraneSTAR system.........................................944 15.5 Emergency operations and programmes.................................................945 15.5.1 Mechanical emergency activation for retracting................................946 Prior to the emergency activation, check.........................................946 Procedure........................................................................946 Mechanical emergency activation..................................................947 15.5.2 Telescoping emergency programme...............................................949 Open submenu Emergency program...................................................949 Determining the error type.......................................................950 Error on length indicator........................................................951 Tables for approaching the locking points........................................955 15.5.3 Entering the current telescoping..............................................957 15.5.4 Emergency operation with the hand-held control................................959 Preparations.....................................................................959 Operating a power unit...........................................................960 Stopping movements...............................................................962 Stopping movements in emergencies................................................962 Turning off the engine...........................................................962 15.6 Hydraulic emergency operation.......................................................963 15.6.1 Connecting/disconnecting hoses................................................963 15.6.2 Establishing the required hydraulic circuits..................................964 Switching over valves............................................................964 For lowering.....................................................................965 15.6.3 Operating principle of emergency operation BGR 159............................967 15.6.4 Connecting/disconnecting hoses................................................968 Establishing connections.........................................................968 Disconnecting....................................................................969 15.6.5 Switching emergency operation on/off..........................................970 15.6.6 Establishing the hydraulic circuits required..................................971 Switching over valves............................................................971 For lifting/ lowering............................................................973 For slewing......................................................................974 15.6.7 Performing emergency operation................................................975 Turning..........................................................................975 Derricking.......................................................................976 Lifting/lowering.................................................................976 15.6.8 After emergency operation.....................................................977 Switching off emergency operation................................................977 Switching over to crane operation................................................977 Disconnecting the hoses..........................................................977 15.6.9 Emergency supply of another crane.............................................978 For emergency supply.............................................................978 After emergency supply...........................................................978 16 Index.....................................................................................981 A........................................................................................983 B........................................................................................983 C........................................................................................984 D........................................................................................987 E........................................................................................988 F........................................................................................990 H........................................................................................990 I........................................................................................991 K........................................................................................991 L........................................................................................991 M........................................................................................992 O........................................................................................993 P........................................................................................994 R........................................................................................994 S........................................................................................996 T........................................................................................997 V........................................................................................999 W........................................................................................999
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