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Grove Crane GMK 5250L Driving & Crane Operation Operating Manual – PDF DOWNLOAD
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Grove Crane GMK 5250L Driving & Crane Operation Operating Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual – PDF DOWNLOAD
Language : English
Pages : 950
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual – PDF DOWNLOAD
Intended use:
The GMK 5250L is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 5250L truck crane may only be used when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 5250L truck crane may only be operated without the correspond- ing special equipment within
the permitted temperature range; à Technical
data, p. 1 – 7. - The GMK 5250L truck crane is designed solely for lifting loads which are within the permitted GMK
5250L lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes:
– observing the entire crane documentation, consisting of the operating manual(s), the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.
The GMK 5250L may only be operated with parts of equipment which are permitted by Manitowoc Crane
Group Germany GmbH and which are labelled with the serial number of the GMK 5250L.
The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK
5250L truck crane. The user alone bears the
risk.
TABLE OF CONTENTS:
Grove Crane GMK 5250L Driving & Crane Operation Operating Manual – PDF DOWNLOAD
Part1 - Driving.................................................................................. 1 Additional Pages............................................................................. 11 Hoist rope travel limitation............................................................. 3 Hoist rope travel limitation menu.................................................... 4 Entering values...................................................................... 5 Switching monitoring function on/off................................................. 5 Driving with rigged truck crane.......................................................... 7 Adjustable head sheave................................................................... 9 Anemometer display ...................................................................... 11 Telescoping emergency programme.......................................................... 13 Main boom intermediate lengths........................................................... 15 Unbenannt................................................................................ 17 1 Overview................................................................................... 23 1.1 Accidents............................................................................ 23 1.2 Branch offices....................................................................... 25 1.2.1 Manitowoc Crane Care........................................................... 25 1.2.2 Dealer list.................................................................... 25 1.3 Warranty specifications.............................................................. 25 1.4 Terms used........................................................................... 26 1.5 Technical data....................................................................... 29 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 29 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 30 Dimensions....................................................................... 31 Weight and axle loads............................................................ 31 1.5.3 Dimensions and weights of removable parts...................................... 32 Spare wheel...................................................................... 32 Outriggers....................................................................... 32 Main boom........................................................................ 33 Hook blocks and hook tackle...................................................... 33 Hook blocks, split............................................................... 34 Auxiliary hoist.................................................................. 35 Counterweight parts.............................................................. 35 1.5.4 Carrier........................................................................ 36 Engine........................................................................... 36 Transmission..................................................................... 36 Transfer case.................................................................... 36 Axle lines....................................................................... 36 Steering......................................................................... 36 Tyres............................................................................ 37 Electrical system................................................................ 37 Tool............................................................................. 37 Towing couplings................................................................. 37 Driving speeds................................................................... 37 Climbing ability................................................................. 37 Outriggers....................................................................... 38 Turning radii.................................................................... 39 1.5.5 Superstructure................................................................. 40 Main hoist....................................................................... 40 Auxiliary hoist.................................................................. 40 Slewing gears.................................................................... 40 Derricking gear.................................................................. 40 Main boom........................................................................ 41 Lattice extension................................................................ 41 Operating speeds................................................................. 41 Noise emission................................................................... 41 1.6 Documentation supplied............................................................... 43 1.6.1 Questions on documentation..................................................... 44 1.7 Notes on the operating manual........................................................ 45 1.7.1 What do the symbols used mean?................................................. 45 1.7.2 How is the operating manual structured?........................................ 47 Division......................................................................... 47 Structure of the chapters........................................................ 47 Structure of the pages........................................................... 48 1.7.3 How do I find the information I need?.......................................... 49 Cross-references example......................................................... 50 1.7.4 What information is available for operations planning?......................... 52 1.8 Conversion table for US measuring units.............................................. 53 1.9 Training – Information............................................................... 55 1.10 Identification...................................................................... 56 1.11 EC Declaration of Conformity........................................................ 58 2 Basic safety instructions.................................................................. 61 2.1 Intended use......................................................................... 61 2.1.1 Improper use................................................................... 62 2.2 Organisational measures.............................................................. 63 2.3 Personnel qualifications............................................................. 65 2.4 Safety instructions for driving the truck crane...................................... 66 2.5 Safety instructions for crane operation.............................................. 67 2.6 Notes on transporting persons........................................................ 69 Equipment for lifting persons........................................................ 69 Personnel............................................................................ 69 Operation............................................................................ 70 Truck crane.......................................................................... 71 3 Operating elements for driving............................................................. 75 3.1 Overview of the operating elements................................................... 75 3.1.1 On the outside of the truck crane.............................................. 76 3.1.2 Cab............................................................................ 80 Overview......................................................................... 80 Behind the cover................................................................. 84 In the rear of the driver's cab.................................................. 84 3.1.3 Instrument panel............................................................... 85 Left/right....................................................................... 85 Middle........................................................................... 86 On-board computer time correction................................................ 88 3.1.4 On-board computer.............................................................. 89 3.1.5 Steering column/steering wheel................................................. 90 3.1.6 Transmission operating elements................................................ 91 3.1.7 Tachograph..................................................................... 92 3.1.8 Control unit CCS............................................................... 93 3.1.9 Display CCS – start menu....................................................... 94 3.1.10 CCS – overview of menu groups................................................. 96 Carrier menu group............................................................... 98 Suspension/level adjustment menu................................................. 99 Driving menu.....................................................................100 Settings menu group..............................................................101 Menu for setting the display brightness and date/time............................102 Information menu group...........................................................103 Operating hours menu.............................................................104 Engine/ transmission error menu..................................................105 Crane operation error menu.......................................................106 Operating additional equipment...................................................107 3.1.11 Outrigger control units.......................................................108 3.1.12 Heating/Air-conditioning system...............................................109 Standard heating system..........................................................109 Auxiliary water heater...........................................................110 Auxiliary air heater.............................................................111 3.1.13 Sockets for hand-held control.................................................112 3.1.14 Outrigger control units.......................................................113 3.2 Short description of the operating elements..........................................115 3.2.1 Definition of direction information............................................116 Basic rule.......................................................................116 Switches and buttons.............................................................116 3.2.2 General rules for buttons and symbols on the display...........................117 3.2.3 Engine.........................................................................118 Steering column..................................................................118 On the steering wheel............................................................118 Instrument panel.................................................................119 3.2.4 AdBlue system (DEF)............................................................120 Instrument panel.................................................................120 CCS display......................................................................121 3.2.5 Battery master switch..........................................................121 3.2.6 Electrical system..............................................................122 3.2.7 Crane control CCS..............................................................123 3.2.8 Transmission...................................................................127 Transmission control unit........................................................127 Display, driving mode,...........................................................128 3.2.9 Reverse camera.................................................................130 3.2.10 Final drive...................................................................131 3.2.11 Brakes........................................................................133 Service brake....................................................................133 Additional brakes................................................................133 Parking brake....................................................................134 3.2.12 Steering/separate steering....................................................136 Instrument panel.................................................................136 CCS display......................................................................137 Driver's door....................................................................138 3.2.13 Suspension....................................................................139 CCS display......................................................................139 Outrigger control units..........................................................139 3.2.14 Lighting/windscreen wipers/horn...............................................140 Steering column..................................................................140 Steering wheel...................................................................140 Instrument panel.................................................................140 CCS display......................................................................142 Roof.............................................................................142 3.2.15 Level adjustment system.......................................................143 3.2.16 Tachograph/speedometer........................................................145 Tachograph.......................................................................145 Speedometer......................................................................145 3.2.17 Diagnostics...................................................................146 3.2.18 On-board computer.............................................................147 3.2.19 Windows, doors, keys..........................................................149 Window winder....................................................................149 Doors............................................................................150 Keys.............................................................................150 3.2.20 Front flap....................................................................151 4 Starting/turning off the engine for driving................................................155 4.1 Starting the engine from the driver's cab............................................155 4.1.1 CHECKLIST: Starting the engine.................................................155 4.1.2 CHECKLIST: At low temperatures.................................................158 4.1.3 Ladders and access ladders.....................................................158 Access ladders...................................................................158 Ladders..........................................................................159 4.1.4 Refuel.........................................................................161 Standard tank....................................................................161 Dual tank........................................................................162 AdBlue...........................................................................163 4.1.5 Checks before starting the engine..............................................164 On hydraulic tank................................................................164 Battery master switch............................................................165 Checking the hand-held control...................................................165 4.1.6 Switching on the ignition......................................................165 4.1.7 Lamp test/equalisation of the switching states.................................166 Lamp test........................................................................166 Switching state alignment........................................................166 4.1.8 Display – setting the brightness...............................................167 4.1.9 Starting the engine............................................................168 4.1.10 Checks after starting the engine..............................................170 Checking in the main menu........................................................170 Indicator lamps on the instrument panel..........................................171 4.1.11 Monitoring elements...........................................................173 Instrument panel.................................................................173 4.1.12 Start menu....................................................................174 4.1.13 Setting idling speed..........................................................175 4.2 Turning off the engine...............................................................177 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....177 After turning off................................................................177 4.2.2 Using the emergency stop switches..............................................178 Resetting the emergency stop switch..............................................178 4.3 Air intake inhibitor.................................................................179 Releasing the air intake inhibitor...................................................179 5 Driving....................................................................................183 5.1 Before driving.......................................................................183 5.1.1 CHECKLIST: Checks before on-road driving.......................................183 5.1.2 Checking the condition of the truck crane......................................189 Electrical system................................................................189 Adjusting the mirrors............................................................189 Warning plates for vehicle width.................................................191 Displaying vehicle height........................................................191 Supply pressure..................................................................192 Parking brake....................................................................193 5.1.3 Adjusting the seat and the steering column.....................................194 Driver's seat....................................................................194 Passenger's seat.................................................................195 Steering column, adjusting.......................................................196 5.1.4 Switching the suspension on/off................................................197 Open menu........................................................................197 Switching on the suspension......................................................198 Switching off the suspension.....................................................198 5.1.5 Setting the tachograph.........................................................199 Prerequisites....................................................................199 In the event of malfunctions.....................................................199 Setting the tachograph...........................................................200 5.1.6 Entering the time/date.........................................................204 5.1.7 Displaying and resetting operating hours.......................................205 5.2 Operating the transmission...........................................................207 5.2.1 Switching on...................................................................207 5.2.2 Switching the transmission to neutral position.................................208 5.2.3 Selecting the direction of travel and starting gear............................209 Selecting the driving direction..................................................209 Selecting the starting gear......................................................210 5.2.4 Changing the operating mode....................................................211 Changing to automatic mode.......................................................211 Change to manual mode............................................................211 5.2.5 Starting.......................................................................212 5.2.6 Driving and changing gears.....................................................213 In automatic operating mode......................................................213 In manual operating mode.........................................................214 5.2.7 Changing the driving direction.................................................215 5.2.8 Stopping.......................................................................215 Stopping for along period oftime...............................................215 5.2.9 On the roller type dynamometer.................................................216 5.2.10 Preheating transmission.......................................................216 5.3 Driving and turning off the truck crane..............................................217 5.3.1 Checks while driving...........................................................217 Immediately after you start to move..............................................217 While driving....................................................................219 5.3.2 Cruise control.................................................................220 Switching on.....................................................................220 Switching off....................................................................221 5.3.3 Temposet.......................................................................222 Switching on.....................................................................222 Switching off....................................................................222 5.3.4 Driving downhill...............................................................223 Starting.........................................................................223 Inspections when driving downhill................................................224 Downshifting.....................................................................224 Additional brakes................................................................225 5.3.5 Driving uphill.................................................................226 Starting.........................................................................226 Driving..........................................................................226 5.3.6 Warning messages in the start menu.............................................227 5.3.7 Warning or malfunction messages on the instrument panel........................228 Meaning of the lamps.............................................................228 5.3.8 Messages on the on-board computer display......................................229 5.3.9 Indicator lights in the on-board computer display..............................231 5.3.10 Override torque reduction.....................................................233 5.3.11 Turning off the truck crane...................................................234 Securing against rolling away....................................................234 When stationary for more than 8 hours............................................235 5.3.12 Folding berth.................................................................236 5.4 Off-road driving.....................................................................237 Adjustments to the transmission......................................................237 Connections..........................................................................237 Changing the vehicle level...........................................................237 Rocking the vehicle free and towing..................................................237 5.4.1 Longitudinal and transverse differential locks.................................238 5.4.2 Operating the level adjustment system..........................................240 Open menu........................................................................240 Setting the onroad level........................................................241 Pre-selecting suspension struts..................................................241 Changing the vehicle level.......................................................242 Viewing the current inclination..................................................242 Exiting the menu.................................................................243 5.4.3 Freeing truck crane stuck in terrain...........................................244 Rocking the truck crane free.....................................................244 Towing free forwards.............................................................245 Towing free in reverse gear......................................................245 5.5 Separate steering....................................................................247 5.5.1 Switching to separate steering.................................................247 Manual...........................................................................248 Automatic........................................................................249 5.6 Heating and air-conditioning system..................................................251 5.6.1 Standard heating system,.......................................................251 Switching on.....................................................................251 Heating..........................................................................251 Air distribution.................................................................252 Examples.........................................................................253 Switching off....................................................................253 5.6.2 Air-conditioning system........................................................254 Information......................................................................254 Switching on/off.................................................................254 Cooling..........................................................................255 Drying...........................................................................255 5.6.3 Auxiliary water heater.........................................................256 Preheating the engine............................................................256 Preheating the driver's cab......................................................257 Switching on the auxiliary heater................................................258 Switching off the auxiliary heater...............................................259 Setting time and weekday.........................................................259 Saving automatic heating start...................................................260 Setting the heating period.......................................................261 Switching the automatic heating start on and off.................................261 Setting the remaining time.......................................................262 5.6.4 Auxiliary air heater...........................................................263 Switching on.....................................................................263 Temperature......................................................................264 Switching off....................................................................264 Other functions..................................................................264 5.7 Towing a trailer.....................................................................265 Effects on the axle loads............................................................265 Coupling the trailer.................................................................266 Connecting the supply lines..........................................................267 Removing the supply lines............................................................268 Uncoupling the trailer...............................................................268 Checking the braking force...........................................................270 6 Driving modes and rigging for on-road driving..............................................273 6.1 Driving modes........................................................................273 Information about the axle loads.....................................................273 6.1.1 Information on how to use the tables...........................................274 6.1.2 Tables for a maximum axle load of 12t.........................................275 For 385/95 R25 tyres.............................................................275 For 445/95 R25 525/80 R25 tyres..................................................276 6.1.3 Maximum permitted speeds with an axle load of over 12t........................277 6.2 Rigging work for driving with a trailer..............................................278 6.2.1 Switching on the slewing gear freewheel........................................279 6.2.2 Switching on the boom floating position........................................280 6.2.3 Switching on boom pre-tensioning...............................................281 6.3 Main boom, removing/installing.......................................................282 Additional equipment required........................................................282 6.3.1 CHECKLIST: Removing the main boom..............................................283 Prerequisites....................................................................283 Checklist........................................................................283 6.3.2 CHECKLIST: Mounting the main boom..............................................285 Prerequisites....................................................................285 Checklist........................................................................285 6.3.3 Slinging the main boom.........................................................287 Marking..........................................................................287 Installing the lifting gear......................................................287 Removing the lifting gear........................................................288 6.3.4 Retracting/fitting the derricking cylinder head pin............................289 Operating the lifting device.....................................................289 Retracting the derricking cylinder head axle.....................................290 Fitting the derricking cylinder head axle........................................291 6.3.5 Retracting/extending the boom pivot pin........................................292 Before retracting................................................................292 After extending..................................................................293 Retracting/ extending the pivot pin..............................................294 6.3.6 Disconnecting/connecting hydraulics/electrical.................................295 Detachment.......................................................................295 Establishing.....................................................................296 6.3.7 Lifting the main boom off/on the turntable.....................................297 Lifting from the turntable.......................................................297 Lifting on to the turntable......................................................298 6.3.8 Aligning the connecting points.................................................298 6.3.9 Transporting the main boom.....................................................299 6.3.10 Inspections after main boom mounting..........................................300 6.4 Installing/removing outrigger beams..................................................301 6.4.1 CHECKLIST: Removing the outrigger beams........................................302 6.4.2 CHECKLIST: Installing the outrigger beams......................................304 6.4.3 Preparing the truck crane......................................................306 Prerequisites....................................................................306 For removal......................................................................306 6.4.4 Removing/attaching outrigger pads..............................................307 Removing the outrigger pads......................................................307 Attaching the outrigger pads.....................................................308 6.4.5 Disconnecting/establishing the hydraulic connection............................309 6.4.6 Disconnecting/establishing the electrical connection...........................310 6.4.7 Unscrewing/screwing in the spacers.............................................311 Unscrewing.......................................................................311 Screwing in......................................................................312 6.4.8 Disconnecting/establishing the connections to the outrigger box................313 6.4.9 Extending/retracting the outrigger beam........................................313 Extending the outrigger beam.....................................................313 Inserting the outrigger beam.....................................................315 6.4.10 Transporting the outrigger beams..............................................317 6.5 Rigging the auxiliary hoist..........................................................319 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................319 Prerequisites....................................................................319 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................321 Prerequisites....................................................................321 6.5.3 Slinging the auxiliary hoist...................................................323 6.5.4 Slinging the rigging frame.....................................................323 6.5.5 Lowering/raising the rigging frame.............................................324 Prerequisite.....................................................................324 6.5.6 Placing the auxiliary hoist on the counterweight combination...................324 6.5.7 Establishing/disconnecting the hydraulic connection............................325 6.5.8 Making/breaking the electrical connection......................................326 6.5.9 Creating the connection to the turntable.......................................327 Establishing the connection......................................................327 Disconnecting....................................................................329 6.5.10 Securing the hoist rope.......................................................330 6.5.11 Transporting the auxiliary hoist..............................................331 6.5.12 Check that the auxiliary hoist is functioning properly........................332 Slewing direction................................................................332 Slewing indicator................................................................332 7 Malfunctions in driving mode...............................................................335 7.1 Emergency stop switch................................................................335 7.2 What to do when a malfunction occurs in road traffic.................................337 7.3 Towing the truck crane...............................................................339 7.3.1 Towing after engine/transmission damage........................................340 Compressed-air supply............................................................340 Electric power supply............................................................341 On the transmission..............................................................341 Axle drives......................................................................342 Parking brake....................................................................342 Towing the truck crane out of the danger area....................................343 7.3.2 Tow starting...................................................................343 7.4 Other emergency operations...........................................................345 7.4.1 Externally starting the truck crane............................................345 7.4.2 Battery charger................................................................346 Prerequisites....................................................................346 7.5 Wheels and tyres.....................................................................347 7.5.1 Wheel change...................................................................347 Removing a damaged wheel.........................................................348 On the spare wheel holder........................................................348 Mounting a wheel.................................................................349 7.5.2 Inflating the tyres yourself...................................................351 Connecting the filling hose......................................................351 Inflating the tyres..............................................................352 Removing the filling hose........................................................352 7.6 Fuses................................................................................353 Notes on changing fuses..............................................................353 7.6.1 Fuses in the driver's cab......................................................354 Group F1.........................................................................354 Group F2.........................................................................355 Group F3.........................................................................355 Group F4.........................................................................356 Other fuses......................................................................356 Group F7.........................................................................357 Group F8.........................................................................357 Group F9.........................................................................358 Group F10........................................................................358 7.6.2 Fuses in the battery box.......................................................359 7.7 Troubleshooting......................................................................361 7.7.1 Malfunctions on the engine.....................................................361 7.7.2 Faults on the AdBlue (DEF) system..............................................363 7.7.3 Malfunctions in the transmission...............................................364 7.7.4 Malfunctions of the service brake..............................................365 7.7.5 Malfunctions of the steering...................................................366 7.7.6 Differential lock malfunctions.................................................367 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................367 7.7.8 Malfunctions on the suspension.................................................368 7.7.9 Malfunctions of the level adjustment system....................................368 7.7.10 Malfunction in the CCS control unit...........................................368 7.8 Warnings in the start menu...........................................................369 Symbols in the display area..........................................................369 7.8.1 Engine/transmission error menu.................................................374 Open menu........................................................................374 Exiting the menu.................................................................374 7.9 Procedure in the event of malfunctions...............................................375 7.9.1 Procedure during engine malfunctions...........................................375 7.9.2 Procedure during transmission malfunctions.....................................376 8 Index......................................................................................379 A........................................................................................381 B........................................................................................381 C........................................................................................382 D........................................................................................385 E........................................................................................386 F........................................................................................388 H........................................................................................388 I........................................................................................389 K........................................................................................389 L........................................................................................389 M........................................................................................390 O........................................................................................391 P........................................................................................392 R........................................................................................392 S........................................................................................394 T........................................................................................395 V........................................................................................397 W........................................................................................397 Part 2 - Crane operation.........................................................................401 Additional Pages.............................................................................411 Hoist rope travel limitation.............................................................403 Hoist rope travel limitation menu....................................................404 Entering values......................................................................405 Switching monitoring function on/off.................................................405 Driving with rigged truck crane..........................................................407 Adjustable head sheave...................................................................409 Anemometer display.......................................................................411 Telescoping emergency programme..........................................................413 Main boom intermediate lengths...........................................................415 Setting down the base plate..............................................................417 9 Operating elements for crane operation.....................................................423 9.1 Overview of the operating elements...................................................423 9.1.1 Exterior of the truck crane....................................................424 9.1.2 Crane cab......................................................................428 Side panel.......................................................................430 Crane cab, rear..................................................................432 9.1.3 Control panels.................................................................434 Left.............................................................................434 Right............................................................................435 9.1.4 Control lever configuration....................................................436 Version 1........................................................................436 Version 2........................................................................437 9.1.5 Control unit CCS...............................................................438 9.1.6 CCS – Start menu...............................................................441 9.1.7 CCS – overview of menu groups..................................................442 Superstructure menu group........................................................446 Superstructure lock menu.........................................................447 Counterweight menu...............................................................448 Outrigger menu...................................................................449 Outrigger support beam menu......................................................451 Outrigger cylinders menu.........................................................452 Teleautomation menu group........................................................454 Telescoping full automation menu.................................................455 Telescoping semiautomation menu.................................................456 Main boom configuration menu.....................................................457 Active working range limiter menu group..........................................458 Overall height menu..............................................................459 Working radius menu..............................................................460 Slewing angle menu...............................................................461 Information menu group...........................................................462 Hydraulic pressure and fuel consumption menu.....................................463 Engine/Driving menu group........................................................464 Economy menu.....................................................................465 Heating/ airconditioning menu...................................................466 Telescoping menu group...........................................................467 Manual telescoping menu..........................................................468 Telescoping emergency program menu...............................................469 Unknown telescoping menu.........................................................470 Settings menu group..............................................................471 Crane cab menu...................................................................472 Menu for setting the display brightness and date/time............................473 Switch units menu................................................................474 Set control lever characteristic curve menu......................................475 Power unit speeds menu...........................................................476 Menu group Information...........................................................477 Operating hours menu.............................................................478 Engine/ transmission error menu..................................................480 Crane operation error menu.......................................................481 Program version menu.............................................................482 Operating additional equipment...................................................483 9.1.8 Control unit RCL...............................................................484 9.1.9 RCL – menu groups..............................................................486 Menu for entering rigging mode...................................................489 Monitoring menu..................................................................490 Lifting capacity tables menu.....................................................492 9.1.10 Hand-held controls............................................................493 Outrigger control panel..........................................................494 9.1.11 Outrigger control units.......................................................496 Button...........................................................................496 Outrigger button.................................................................497 Inclination and outrigger pressure display.......................................498 Raise axle display...............................................................499 9.2 Short description of the operating elements..........................................501 9.2.1 Definition of direction information............................................501 Basic rule.......................................................................501 Switches.........................................................................501 9.2.2 General rules for buttons and symbols on the display...........................502 9.2.3 Engine.........................................................................503 Side panel.......................................................................503 Economy menu.....................................................................504 9.2.4 AdBlue (DEF) system............................................................505 CCS display......................................................................505 9.2.5 Seat contact switch and dead man's switch......................................506 9.2.6 Crane control CCS..............................................................507 9.2.7 Outrigger......................................................................513 Hand-held control................................................................513 Right-hand control panel.........................................................514 Left-hand control panel..........................................................514 In the Outrigger menu............................................................515 On the outrigger control units...................................................517 9.2.8 Inclination indicators.........................................................519 9.2.9 Raise axle.....................................................................520 Outrigger control units..........................................................520 9.2.10 Outrigger pressure displays...................................................522 Outriggers submenu...............................................................522 Outrigger control units..........................................................522 9.2.11 Anemometer displays...........................................................522 9.2.12 Counterweight menu............................................................523 Counterweight submenu............................................................523 9.2.13 Main hoist....................................................................527 Control panels...................................................................527 CCS display......................................................................528 9.2.14 Auxiliary hoist...............................................................529 Control panels...................................................................529 CCS display......................................................................530 9.2.15 Slewing gear..................................................................531 Control panels...................................................................531 CCS display......................................................................532 9.2.16 Derricking gear...............................................................533 Control panels...................................................................533 CCS display......................................................................534 9.2.17 Telescoping mechanism.........................................................535 Control panels...................................................................535 CCS display......................................................................535 Telescoping full automation menu.................................................536 Telescoping semiautomation menu.................................................537 Manual telescoping menu..........................................................539 Main boom configuration menu.....................................................542 9.2.18 Hydraulic system..............................................................543 9.2.19 Superstructure lock/Houselock menu............................................544 Superstructure lock..............................................................544 Houselock........................................................................545 9.2.20 Rated capacity limiter (RCL)..................................................546 Control unit control console RCL.................................................546 Display RCL......................................................................547 Enter rigging mode menu..........................................................549 Monitoring menu..................................................................552 Lifting capacity tables menu.....................................................556 RCL override.....................................................................556 External displays................................................................557 9.2.21 Electrical system.............................................................559 9.2.22 Lighting, windscreen wiper/washing system.....................................559 Lighting.........................................................................559 Windscreen wiper/washing system..................................................560 9.2.23 Hand-held control.............................................................562 Sockets for handheld control....................................................562 Engine control panel.............................................................563 Horn.............................................................................563 Outrigger control panel..........................................................564 9.2.24 Windows, doors, keys..........................................................566 Windows..........................................................................566 Rear window......................................................................566 Crane cab door...................................................................567 Keys.............................................................................568 9.2.25 Diagnostics...................................................................568 10 Starting/turning off the engine – for crane operation.....................................571 10.1 When starting the engine for the first time of the day..............................571 10.1.1 Checking the fuel level and AdBlue (DEF) level................................572 Fuel.............................................................................572 AdBlue (DEF).....................................................................572 10.1.2 Checks before starting the engine.............................................573 On hydraulic tank................................................................573 Checking the hand-held control...................................................574 10.1.3 Switching on the ignition.....................................................574 10.1.4 Display – setting the brightness..............................................575 10.1.5 Starting the engine...........................................................576 10.1.6 Checks after starting the engine..............................................577 10.1.7 Setting idling speed..........................................................578 10.2 Starting the engine – with the hand-held control....................................579 Prerequisites........................................................................579 Starting the engine..................................................................579 10.3 Turning off the engine..............................................................581 10.3.1 During normal operation, with the ignition lock/with the handheld control....581 After turning off................................................................581 10.3.2 In emergencies, with the emergency stop switches..............................582 Resetting the emergency stop switch..............................................582 11 Crane operation...........................................................................585 11.1 Before operating the crane..........................................................585 11.1.1 CHECKLIST: Checks before operating the crane..................................585 11.1.2 Checking the condition of the truck crane.....................................589 Fuel tank auxiliary heater.......................................................589 Visual inspection................................................................589 Checking the position of the hoist ropes.........................................590 Checking the electrical system...................................................591 11.1.3 Adjusting the crane cab seat and front control panel..........................592 Crane cab seat...................................................................592 Front panel......................................................................592 11.1.4 Checking the safety equipment.................................................593 Rated capacity limiter...........................................................593 Lifting limit switch.............................................................593 Emergency stop switch............................................................594 Seat contact switch..............................................................595 11.1.5 Earthing the load.............................................................596 11.1.6 Preheating the hydraulic oil..................................................597 Prerequisites....................................................................597 Preheating.......................................................................597 11.1.7 Locking/unlocking the superstructure..........................................598 Locking points...................................................................598 Locking the superstructure.......................................................599 Unlocking the superstructure.....................................................599 11.1.8 Switching the Houselock on/off................................................600 Switching on the Houselock.......................................................600 Switching off the Houselock......................................................602 11.2 Operation of the rated capacity limiter.............................................603 11.2.1 Switch on the RCL.............................................................604 Switching on.....................................................................604 Brightness of the displays.......................................................606 Temperature on the display.......................................................606 11.2.2 Enter rigging mode............................................................607 Entering individual components...................................................608 Entering the RCL code............................................................612 Entering the reeving.............................................................613 Accepting the rigging mode.......................................................613 11.2.3 Checks before operating the crane.............................................615 Open menu........................................................................615 Checks...........................................................................615 11.2.4 Displays during crane operation...............................................618 11.2.5 RCL early warning.............................................................621 11.2.6 RCL switch-off................................................................621 Shutdown due to overload.........................................................621 11.2.7 Display in the event of errors................................................623 11.2.8 RCL override..................................................................624 Overview status display..........................................................624 When rigging.....................................................................625 To raise the boom................................................................626 In emergencies...................................................................627 11.2.9 Displaying the lifting capacity tables........................................628 11.2.10 Setting the time/date........................................................630 11.3 Crane operation with main boom......................................................631 11.3.1 Checks during crane operation.................................................631 Horizontal alignment.............................................................631 Safe distances...................................................................631 Checking the wind speed..........................................................632 11.3.2 Permissible slewing ranges and working positions..............................633 360 slewing range...............................................................633 0 to the rear working position..................................................633 180 to the front rigging position...............................................633 11.3.3 Main hoist....................................................................634 Switching on the main hoist......................................................635 Lifting and lowering.............................................................635 Maximum permissible hoist rope speed.............................................636 Switching off the main hoist.....................................................637 11.3.4 Auxiliary hoist...............................................................638 Switching on the auxiliary hoist.................................................638 Lifting and lowering.............................................................639 Maximum permissible hoist rope speed.............................................639 Switching off the auxiliary hoist................................................640 11.3.5 Lifting limit switch and lowering limit switch................................641 Lifting limit switch.............................................................641 Lowering limit switch............................................................643 11.3.6 Derricking gear...............................................................644 Switching on the derricking gear.................................................644 Maximum permissible derricking speed.............................................644 Raising and lowering.............................................................645 Re-enable raising function.......................................................646 Switching off the derricking gear................................................646 11.3.7 Telescoping mechanism.........................................................648 Overview.........................................................................649 Telescoping process..............................................................649 Assignment for display...........................................................652 Fixed length, intermediate length, telescoping length............................653 Telescoping......................................................................654 Telescoping sequence.............................................................654 Checks before starting work......................................................655 Switching on the telescoping mechanism...........................................656 Function of the control lever....................................................656 Switching off the telescoping mechanism..........................................658 Manual telescoping...............................................................659 Checking the initial position....................................................659 Unlocking the telescoping cylinder...............................................661 Extending/ retracting the telescoping cylinder...................................663 Lock telescoping cylinder........................................................664 Unlocking the telescopic section.................................................665 Telescoping the telescopic section...............................................666 Locking the telescopic section...................................................667 Locking the telescopic section for on-road driving...............................668 Telescoping with semi-automation.................................................668 Telescoping with full automation.................................................671 Telescoping with main boom configuration.........................................672 11.3.8 High-speed mode...............................................................673 Derricking gear/ telescoping mechanism...........................................673 Hoists...........................................................................674 11.3.9 Slewing gear..................................................................675 Switching on the slewing gear....................................................675 Turning..........................................................................676 Releasing locked slewing gear....................................................676 Maximum permissible slewing speed................................................677 Braking the slewing movement.....................................................678 Releasing the slewing gear brake.................................................678 Engaging the slewing gear brake..................................................678 Slewing gear freewheel...........................................................679 Switching off the slewing gear...................................................679 11.3.10 Possible movement combinations...............................................680 11.4 Settings and displays for crane operation...........................................681 11.4.1 Inclining the crane cab.......................................................681 11.4.2 Setting idling speed..........................................................682 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................682 11.4.4 Limiting the power unit speeds................................................683 11.4.5 Setting/switching on Economy mode.............................................684 Automatic........................................................................684 Manual...........................................................................684 11.4.6 Switching units...............................................................685 11.4.7 Setting the characteristic curves for the control levers......................686 11.4.8 Using the slewable spotlights.................................................687 11.4.9 Override torque reduction.....................................................688 11.4.10 Displaying the operating hours...............................................689 11.4.11 Warnings in the start menu...................................................690 Meaning of the symbols...........................................................690 11.5 Working range limiter...............................................................693 11.5.1 Viewing current settings......................................................694 11.5.2 Opening the working range limiter menu........................................695 11.5.3 Entering limit values.........................................................697 Overall height...................................................................697 Working radius...................................................................698 Slewing angle....................................................................698 11.5.4 Entering limit values manually................................................700 Limit values.....................................................................700 11.5.5 Switching monitoring functions on/off.........................................702 11.5.6 Shutdown by working range limiter.............................................703 11.6 Work break..........................................................................705 11.6.1 In case of short work breaks..................................................705 11.6.2 In case of work breaks of more than 8 hours...................................706 To secure the truck crane........................................................706 11.7 Heating and air-conditioning system.................................................707 11.7.1 Standard heating system.......................................................707 Switching on.....................................................................707 Heating..........................................................................707 Air distribution.................................................................707 Switching off....................................................................708 11.7.2 Air-conditioning system.......................................................709 Information......................................................................709 Switching on/off.................................................................709 Cooling, automatic...............................................................710 Cooling, maximum.................................................................710 11.7.3 Auxiliary heater..............................................................711 Switching on.....................................................................711 Setting the temperature..........................................................712 Setting the heating start/ heating duration......................................712 Switching heating start on/off...................................................713 11.8 CraneSTAR system....................................................................714 11.8.1 Overview......................................................................714 11.8.2 Position of the components....................................................714 12 Rigging work..............................................................................717 12.1 Rigging work checklists for crane operation with the main boom......................717 12.1.1 CHECKLIST: Rigging............................................................717 12.1.2 CHECKLIST: Unrigging..........................................................721 12.2 Choosing a suitable site............................................................725 12.2.1 Determining the required ground bearing area..................................725 12.2.2 Safe distance from slopes and pits............................................728 12.2.3 Earthing the truck crane......................................................729 12.2.4 Safe distance from electrical cables..........................................730 12.3 Rigging work after driving with a trailer...........................................733 12.3.1 Switching off the boom floating position......................................733 12.3.2 Switching off the slewing gear freewheel......................................734 Before slewing...................................................................734 12.3.3 Switching off boom pre-tensioning.............................................735 12.4 Connecting/disconnecting the hand-held control......................................737 12.5 Starting the engine for driving for rigging work....................................739 12.5.1 Starting/turning off the engine with the hand-held control....................739 Prerequisites....................................................................739 Starting the engine..............................................................740 Turning off the engine...........................................................740 12.5.2 Starting/turning off the engine from the outrigger control units..............741 Prerequisites....................................................................741 Starting the engine..............................................................741 Turning off the engine...........................................................741 12.6 Outrigger...........................................................................743 12.6.1 CHECKLIST: Extending the outriggers...........................................743 12.6.2 CHECKLIST: Retracting the outriggers..........................................745 12.6.3 Permissible outrigger spans...................................................746 12.6.4 Preparing the truck crane.....................................................747 In the driver's cab..............................................................747 Outrigger control units..........................................................747 12.6.5 Setting the outrigger spans...................................................748 For on-road driving..............................................................750 12.6.6 Extending/retracting outrigger beams..........................................751 From the control units...........................................................752 With the handheld control.......................................................753 From the crane cab...............................................................755 12.6.7 Moving the outrigger pads into working/driving position.......................757 12.6.8 Enlarging the ground bearing area.............................................758 12.6.9 Extending/retracting supporting cylinders.....................................759 From the control units...........................................................760 With the handheld control.......................................................761 From the crane cab...............................................................762 12.6.10 Level the truck crane on outriggers..........................................764 Inclination indicators...........................................................764 Prerequisites....................................................................765 Manual alignment.................................................................766 Automatic alignment..............................................................767 12.6.11 Levelling the free-on-wheels truck crane.....................................769 12.6.12 Outrigger pressure display...................................................771 12.7 Rigging/unrigging the counterweight.................................................773 12.7.1 Counterweight sections........................................................773 12.7.2 Identification................................................................775 12.7.3 Slinging points on the counterweight sections.................................776 12.7.4 CHECKLIST: Rigging the counterweight..........................................777 12.7.5 CHECKLIST: Unrigging the counterweight........................................778 12.7.6 Assembling counterweight combination..........................................781 12.7.7 Counterweight hoist unit......................................................789 Counterweight menu...............................................................789 Extending/ retracting the lifting cylinders......................................790 Automatic mode, rigging..........................................................791 Automatic mode, unrigging........................................................793 Cancel automatic mode............................................................794 12.7.8 Setting down counterweight for driving the truck crane........................795 12.7.9 Slewing with rigged counterweight.............................................797 12.8 Rigging work on the main boom.......................................................799 12.8.1 Hook block on the bumper......................................................799 Picking up the hook block........................................................799 Attaching the hook block.........................................................800 12.8.2 Hook block in the compartment.................................................801 Prerequisites....................................................................801 12.8.3 Hook block on a separate vehicle..............................................803 Picking up the hook block........................................................804 Setting down the hook block......................................................804 12.8.4 Hook block, separable.........................................................806 Rigging for onroad driving......................................................806 Rigging for crane operation......................................................807 12.8.5 Reeving and unreeving the hoist rope..........................................808 Version A........................................................................808 Version B........................................................................809 Reeving the hoist rope...........................................................811 Unreeving the hoist rope.........................................................814 12.8.6 Possible reeving methods on the main boom.....................................815 With 7 head sheaves..............................................................815 With 10 head sheaves.............................................................818 With 11 head sheaves.............................................................821 12.8.7 Installing/removing the lifting limit switch..................................822 Installing the lifting limit switch..............................................822 Removing the lifting limit switch................................................825 12.8.8 Locking/unlocking the lifting limit switch....................................827 Locking..........................................................................827 Releasing locking................................................................827 12.8.9 Anemometer and air traffic control light......................................828 Installing.......................................................................828 Switching the air traffic control light on and off...............................828 Removing.........................................................................829 For transport....................................................................829 12.9 Other rigging work..................................................................831 12.9.1 Railings on the turntable.....................................................831 12.9.2 Folding the lighting carrier in/out...........................................832 12.9.3 Safety harness on the main boom...............................................833 Prerequisites....................................................................834 Requirements.....................................................................834 Attaching/ detaching fall prevention safety system to/from safety harness........835 Inspecting/ replacing safety harness.............................................837 12.9.4 Slinging points for personal protective equipment.............................838 12.9.5 Cameras for crane operation...................................................839 Camera on the hoists.............................................................839 Camera on main boom..............................................................840 Operating the camera.............................................................842 12.9.6 Stair tread on the crane cab..................................................843 13 Driving with rigged truck crane...........................................................847 13.1 Driving path........................................................................847 13.2 Permissible rigging modes and axle loads............................................848 Axle load table......................................................................849 13.3 Before driving......................................................................850 13.3.1 Securing the superstructure against slewing...................................850 13.3.2 Checking tyre pressure and wind speed.........................................851 13.3.3 Putting the truck crane on the wheels.........................................852 13.3.4 Gears/connections.............................................................854 Transmission.....................................................................854 Switching on separate steering...................................................854 13.4 While driving.......................................................................854 13.5 After driving.......................................................................856 14 Transport.................................................................................859 14.1 Transport with transport vehicle....................................................859 14.1.1 CHECKLIST: Checks before transport............................................860 14.1.2 Drive the truck crane onto the transport vehicle..............................862 Drive on.........................................................................862 Lashing..........................................................................862 14.1.3 Slinging points...............................................................863 15 Malfunctions during crane operation.......................................................867 15.1 Emergency stop switch...............................................................867 15.2 What to do when a malfunction occurs during crane operation.........................869 Load can be lowered..................................................................869 Load cannot be lowered...............................................................869 15.3 Fuses in the crane cab..............................................................871 Notes on changing fuses..............................................................871 15.4 Finding and eliminating malfunctions................................................876 15.4.1 Malfunctions on the engine....................................................876 15.4.2 Malfunctions on the counterweight hoist unit..................................876 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................877 15.4.4 Malfunctions in the hoist cameras.............................................878 15.4.5 Malfunctions in the main boom camera..........................................878 15.4.6 Malfunctions on the derricking gear...........................................879 15.4.7 Malfunctions in the telescoping mechanism.....................................880 15.4.8 Malfunctions on the slewing gear..............................................882 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................883 15.4.10 Malfunctions when inclining the crane cab....................................883 15.4.11 Malfunctions when operating with the hand-held control.......................883 15.4.12 Malfunctions of the outriggers...............................................884 15.4.13 Malfunction in the CCS control unit..........................................884 15.4.14 Troubleshooting the crane control............................................885 General malfunctions.............................................................885 Symbols in the error or information display areas................................886 Displays in the Error menu.......................................................890 15.4.15 Malfunctions in the CraneSTAR system.........................................892 15.5 Emergency operations and programmes.................................................893 15.5.1 Mechanical emergency activation for retracting................................894 Prior to the emergency activation, check.........................................894 Procedure........................................................................894 Mechanical emergency activation..................................................895 15.5.2 Telescoping emergency programme...............................................897 Open submenu Emergency program...................................................897 Determining the error type.......................................................898 Error on length indicator........................................................899 Tables for approaching the locking points........................................903 15.5.3 Entering the current telescoping..............................................905 15.5.4 Emergency operation with the hand-held control................................907 Preparations.....................................................................907 Operating a power unit...........................................................908 Stopping movements...............................................................910 Stopping movements in emergencies................................................910 Turning off the engine...........................................................910 15.6 Hydraulic emergency operation.......................................................911 15.6.1 Connecting/disconnecting hoses................................................911 15.6.2 Establishing the required hydraulic circuits..................................912 Switching over valves............................................................912 For lowering.....................................................................913 15.6.3 Operating principle of emergency operation BGR 159............................915 15.6.4 Connecting/disconnecting hoses................................................916 Establishing connections.........................................................916 Disconnecting....................................................................917 15.6.5 Switching emergency operation on/off..........................................918 15.6.6 Establishing the hydraulic circuits required..................................919 Switching over valves............................................................919 For lifting/ lowering............................................................921 For slewing......................................................................922 15.6.7 Performing emergency operation................................................923 Turning..........................................................................923 Derricking.......................................................................924 Lifting/lowering.................................................................924 15.6.8 After emergency operation.....................................................925 Switching off emergency operation................................................925 Switching over to crane operation................................................925 Disconnecting the hoses..........................................................925 15.6.9 Emergency supply of another crane.............................................926 For emergency supply.............................................................926 After emergency supply...........................................................926 16 Index.....................................................................................929 A........................................................................................931 B........................................................................................931 C........................................................................................932 D........................................................................................935 E........................................................................................936 F........................................................................................938 H........................................................................................938 I........................................................................................939 K........................................................................................939 L........................................................................................939 M........................................................................................940 O........................................................................................941 P........................................................................................942 R........................................................................................942 S........................................................................................944 T........................................................................................945 V........................................................................................947 W........................................................................................947
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