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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 : 970
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
Part 1 – Driving................................................................................. 1 Additional Pages............................................................................. 5 Slewing gear freewheel................................................................... 3 CCS – Datalogger......................................................................... 5 Additional menu and program.......................................................... 5 Additional menu.................................................................. 5 Export data...................................................................... 6 Display the data................................................................. 6 Slewable spotlights...................................................................... 11 Automatic load tracking.............................................................. 11 Hoist rope travel limitation............................................................. 13 Hoist rope travel limitation menu.................................................... 14 Entering values...................................................................... 15 Switching monitoring function on/off................................................. 15 Driving with rigged truck crane.......................................................... 17 Counterweight............................................................................ 19 Setting down the base plate.......................................................... 19 Adjustable head sheave................................................................... 21 Different positions depending on the reeving......................................... 21 Main boom intermediate lengths........................................................... 23 Derricking cylinder pressure monitoring.............................................. 23 Telescoping emergency programme.......................................................... 25 Additional checks.................................................................... 25 Anemometer display ...................................................................... 27 Extended function.................................................................... 27 1 Overview................................................................................... 33 1.1 Accidents............................................................................ 33 1.2 Branch offices....................................................................... 35 1.2.1 Manitowoc Crane Care........................................................... 35 1.2.2 Dealer list.................................................................... 35 1.3 Warranty specifications.............................................................. 35 1.4 Terms used........................................................................... 36 1.5 Technical data....................................................................... 39 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 39 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 40 Dimensions....................................................................... 41 Weight and axle loads............................................................ 41 1.5.3 Dimensions and weights of removable parts...................................... 42 Spare wheel...................................................................... 42 Outriggers....................................................................... 42 Main boom........................................................................ 43 Hook blocks and hook tackle...................................................... 43 Hook blocks, split............................................................... 44 Auxiliary hoist.................................................................. 45 Counterweight parts.............................................................. 45 1.5.4 Carrier........................................................................ 46 Engine........................................................................... 46 Transmission..................................................................... 46 Transfer case.................................................................... 46 Axle lines....................................................................... 46 Steering......................................................................... 46 Tyres............................................................................ 47 Electrical system................................................................ 47 Tool............................................................................. 47 Towing couplings................................................................. 47 Driving speeds................................................................... 47 Climbing ability................................................................. 47 Outriggers....................................................................... 48 Turning radii.................................................................... 49 1.5.5 Superstructure................................................................. 50 Main hoist....................................................................... 50 Auxiliary hoist.................................................................. 50 Slewing gears.................................................................... 50 Derricking gear.................................................................. 50 Main boom........................................................................ 51 Lattice extension................................................................ 51 Operating speeds................................................................. 51 Noise emission................................................................... 51 1.6 Documentation supplied............................................................... 53 1.6.1 Questions on documentation..................................................... 54 1.7 Notes on the operating manual........................................................ 55 1.7.1 What do the symbols used mean?................................................. 55 1.7.2 How is the operating manual structured?........................................ 57 Division......................................................................... 57 Structure of the chapters........................................................ 57 Structure of the pages........................................................... 58 1.7.3 How do I find the information I need?.......................................... 59 Cross-references example......................................................... 60 1.7.4 What information is available for operations planning?......................... 62 1.8 Conversion table for US measuring units.............................................. 63 1.9 Training – Information............................................................... 65 1.10 Identification...................................................................... 66 1.11 EC Declaration of Conformity........................................................ 68 2 Basic safety instructions.................................................................. 71 2.1 Intended use......................................................................... 71 2.1.1 Improper use................................................................... 72 2.2 Organisational measures.............................................................. 73 2.3 Personnel qualifications............................................................. 75 2.4 Safety instructions for driving the truck crane...................................... 76 2.5 Safety instructions for crane operation.............................................. 77 2.6 Notes on transporting persons........................................................ 79 Equipment for lifting persons........................................................ 79 Personnel............................................................................ 79 Operation............................................................................ 80 Truck crane.......................................................................... 81 3 Operating elements for driving............................................................. 85 3.1 Overview of the operating elements................................................... 85 3.1.1 On the outside of the truck crane.............................................. 86 3.1.2 Cab............................................................................ 90 Overview......................................................................... 90 Behind the cover................................................................. 94 In the rear of the driver's cab.................................................. 94 3.1.3 Instrument panel............................................................... 95 Left/right....................................................................... 95 Middle........................................................................... 96 On-board computer time correction................................................ 98 3.1.4 On-board computer.............................................................. 99 3.1.5 Steering column/steering wheel.................................................100 3.1.6 Transmission operating elements................................................101 3.1.7 Tachograph.....................................................................102 3.1.8 Control unit CCS...............................................................103 3.1.9 Display CCS – start menu.......................................................104 3.1.10 CCS – overview of menu groups.................................................106 Carrier menu group...............................................................108 Suspension/level adjustment menu.................................................109 Driving menu.....................................................................110 Settings menu group..............................................................111 Menu for setting the display brightness and date/time............................112 Information menu group...........................................................113 Operating hours menu.............................................................114 Engine/ transmission error menu..................................................115 Crane operation error menu.......................................................116 Operating additional equipment...................................................117 3.1.11 Outrigger control units.......................................................118 3.1.12 Heating/Air-conditioning system...............................................119 Standard heating system..........................................................119 Auxiliary water heater...........................................................120 Auxiliary air heater.............................................................121 3.1.13 Sockets for hand-held control.................................................122 3.1.14 Outrigger control units.......................................................123 3.2 Short description of the operating elements..........................................125 3.2.1 Definition of direction information............................................126 Basic rule.......................................................................126 Switches and buttons.............................................................126 3.2.2 General rules for buttons and symbols on the display...........................127 3.2.3 Engine.........................................................................128 Steering column..................................................................128 On the steering wheel............................................................128 Instrument panel.................................................................129 3.2.4 AdBlue system (DEF)............................................................130 Instrument panel.................................................................130 CCS display......................................................................131 3.2.5 Battery master switch..........................................................131 3.2.6 Electrical system..............................................................132 3.2.7 Crane control CCS..............................................................133 3.2.8 Transmission...................................................................137 Transmission control unit........................................................137 Display, driving mode,...........................................................138 3.2.9 Reverse camera.................................................................140 3.2.10 Final drive...................................................................141 3.2.11 Brakes........................................................................143 Service brake....................................................................143 Additional brakes................................................................143 Parking brake....................................................................144 3.2.12 Steering/separate steering....................................................146 Instrument panel.................................................................146 CCS display......................................................................147 Driver's door....................................................................148 3.2.13 Suspension....................................................................149 CCS display......................................................................149 Outrigger control units..........................................................149 3.2.14 Lighting/windscreen wipers/horn...............................................150 Steering column..................................................................150 Steering wheel...................................................................150 Instrument panel.................................................................150 CCS display......................................................................152 Roof.............................................................................152 3.2.15 Level adjustment system.......................................................153 3.2.16 Tachograph/speedometer........................................................155 Tachograph.......................................................................155 Speedometer......................................................................155 3.2.17 Diagnostics...................................................................156 3.2.18 On-board computer.............................................................157 3.2.19 Windows, doors, keys..........................................................159 Window winder....................................................................159 Doors............................................................................160 Keys.............................................................................160 3.2.20 Front flap....................................................................161 4 Starting/turning off the engine for driving................................................165 4.1 Starting the engine from the driver's cab............................................165 4.1.1 CHECKLIST: Starting the engine.................................................165 4.1.2 CHECKLIST: At low temperatures.................................................168 4.1.3 Ladders and access ladders.....................................................168 Access ladders...................................................................168 Ladders..........................................................................169 4.1.4 Refuel.........................................................................171 Standard tank....................................................................171 Dual tank........................................................................172 AdBlue...........................................................................173 4.1.5 Checks before starting the engine..............................................174 On hydraulic tank................................................................174 Battery master switch............................................................175 Checking the hand-held control...................................................175 4.1.6 Switching on the ignition......................................................175 4.1.7 Lamp test/equalisation of the switching states.................................176 Lamp test........................................................................176 Switching state alignment........................................................176 4.1.8 Display – setting the brightness...............................................177 4.1.9 Starting the engine............................................................178 4.1.10 Checks after starting the engine..............................................180 Checking in the main menu........................................................180 Indicator lamps on the instrument panel..........................................181 4.1.11 Monitoring elements...........................................................183 Instrument panel.................................................................183 4.1.12 Start menu....................................................................184 4.1.13 Setting idling speed..........................................................185 4.2 Turning off the engine...............................................................187 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....187 After turning off................................................................187 4.2.2 Using the emergency stop switches..............................................188 Resetting the emergency stop switch..............................................188 4.3 Air intake inhibitor.................................................................189 Releasing the air intake inhibitor...................................................189 5 Driving....................................................................................193 5.1 Before driving.......................................................................193 5.1.1 CHECKLIST: Checks before on-road driving.......................................193 5.1.2 Checking the condition of the truck crane......................................199 Electrical system................................................................199 Adjusting the mirrors............................................................199 Warning plates for vehicle width.................................................201 Displaying vehicle height........................................................201 Supply pressure..................................................................202 Parking brake....................................................................203 5.1.3 Adjusting the seat and the steering column.....................................204 Driver's seat....................................................................204 Passenger's seat.................................................................205 Steering column, adjusting.......................................................206 5.1.4 Switching the suspension on/off................................................207 Open menu........................................................................207 Switching on the suspension......................................................208 Switching off the suspension.....................................................208 5.1.5 Setting the tachograph.........................................................209 Prerequisites....................................................................209 In the event of malfunctions.....................................................209 Setting the tachograph...........................................................210 5.1.6 Entering the time/date.........................................................214 5.1.7 Displaying and resetting operating hours.......................................215 5.2 Operating the transmission...........................................................217 5.2.1 Switching on...................................................................217 5.2.2 Switching the transmission to neutral position.................................218 5.2.3 Selecting the direction of travel and starting gear............................219 Selecting the driving direction..................................................219 Selecting the starting gear......................................................220 5.2.4 Changing the operating mode....................................................221 Changing to automatic mode.......................................................221 Change to manual mode............................................................221 5.2.5 Starting.......................................................................222 5.2.6 Driving and changing gears.....................................................223 In automatic operating mode......................................................223 In manual operating mode.........................................................224 5.2.7 Changing the driving direction.................................................225 5.2.8 Stopping.......................................................................225 Stopping for along period oftime...............................................225 5.2.9 On the roller type dynamometer.................................................226 5.2.10 Preheating transmission.......................................................226 5.3 Driving and turning off the truck crane..............................................227 5.3.1 Checks while driving...........................................................227 Immediately after you start to move..............................................227 While driving....................................................................229 5.3.2 Cruise control.................................................................230 Switching on.....................................................................230 Switching off....................................................................231 5.3.3 Temposet.......................................................................232 Switching on.....................................................................232 Switching off....................................................................232 5.3.4 Driving downhill...............................................................233 Starting.........................................................................233 Inspections when driving downhill................................................234 Downshifting.....................................................................234 Additional brakes................................................................235 5.3.5 Driving uphill.................................................................236 Starting.........................................................................236 Driving..........................................................................236 5.3.6 Warning messages in the start menu.............................................237 5.3.7 Warning or malfunction messages on the instrument panel........................238 Meaning of the lamps.............................................................238 5.3.8 Messages on the on-board computer display......................................239 5.3.9 Indicator lights in the on-board computer display..............................241 5.3.10 Override torque reduction.....................................................243 5.3.11 Turning off the truck crane...................................................244 Securing against rolling away....................................................244 When stationary for more than 8 hours............................................245 5.3.12 Folding berth.................................................................246 5.4 Off-road driving.....................................................................247 Adjustments to the transmission......................................................247 Connections..........................................................................247 Changing the vehicle level...........................................................247 Rocking the vehicle free and towing..................................................247 5.4.1 Longitudinal and transverse differential locks.................................248 5.4.2 Operating the level adjustment system..........................................250 Open menu........................................................................250 Setting the onroad level........................................................251 Pre-selecting suspension struts..................................................251 Changing the vehicle level.......................................................252 Viewing the current inclination..................................................252 Exiting the menu.................................................................253 5.4.3 Freeing truck crane stuck in terrain...........................................254 Rocking the truck crane free.....................................................254 Towing free forwards.............................................................255 Towing free in reverse gear......................................................255 5.5 Separate steering....................................................................257 5.5.1 Switching to separate steering.................................................257 Manual...........................................................................258 Automatic........................................................................259 5.6 Heating and air-conditioning system..................................................261 5.6.1 Standard heating system,.......................................................261 Switching on.....................................................................261 Heating..........................................................................261 Air distribution.................................................................262 Examples.........................................................................263 Switching off....................................................................263 5.6.2 Air-conditioning system........................................................264 Information......................................................................264 Switching on/off.................................................................264 Cooling..........................................................................265 Drying...........................................................................265 5.6.3 Auxiliary water heater.........................................................266 Preheating the engine............................................................266 Preheating the driver's cab......................................................267 Switching on the auxiliary heater................................................268 Switching off the auxiliary heater...............................................269 Setting time and weekday.........................................................269 Saving automatic heating start...................................................270 Setting the heating period.......................................................271 Switching the automatic heating start on and off.................................271 Setting the remaining time.......................................................272 5.6.4 Auxiliary air heater...........................................................273 Switching on.....................................................................273 Temperature......................................................................274 Switching off....................................................................274 Other functions..................................................................274 5.7 Towing a trailer.....................................................................275 Effects on the axle loads............................................................275 Coupling the trailer.................................................................276 Connecting the supply lines..........................................................277 Removing the supply lines............................................................278 Uncoupling the trailer...............................................................278 Checking the braking force...........................................................280 6 Driving modes and rigging for on-road driving..............................................283 6.1 Driving modes........................................................................283 Information about the axle loads.....................................................283 6.1.1 Information on how to use the tables...........................................284 6.1.2 Tables for a maximum axle load of 12t.........................................285 For 385/95 R25 tyres.............................................................285 For 445/95 R25 525/80 R25 tyres..................................................286 6.1.3 Maximum permitted speeds with an axle load of over 12t........................287 6.2 Rigging work for driving with a trailer..............................................288 6.2.1 Switching on the slewing gear freewheel........................................289 6.2.2 Switching on the boom floating position........................................290 6.2.3 Switching on boom pre-tensioning...............................................291 6.3 Main boom, removing/installing.......................................................292 Additional equipment required........................................................292 6.3.1 CHECKLIST: Removing the main boom..............................................293 Prerequisites....................................................................293 Checklist........................................................................293 6.3.2 CHECKLIST: Mounting the main boom..............................................295 Prerequisites....................................................................295 Checklist........................................................................295 6.3.3 Slinging the main boom.........................................................297 Marking..........................................................................297 Installing the lifting gear......................................................297 Removing the lifting gear........................................................298 6.3.4 Retracting/fitting the derricking cylinder head pin............................299 Operating the lifting device.....................................................299 Retracting the derricking cylinder head axle.....................................300 Fitting the derricking cylinder head axle........................................301 6.3.5 Retracting/extending the boom pivot pin........................................302 Before retracting................................................................302 After extending..................................................................303 Retracting/ extending the pivot pin..............................................304 6.3.6 Disconnecting/connecting hydraulics/electrical.................................305 Detachment.......................................................................305 Establishing.....................................................................306 6.3.7 Lifting the main boom off/on the turntable.....................................307 Lifting from the turntable.......................................................307 Lifting on to the turntable......................................................308 6.3.8 Aligning the connecting points.................................................308 6.3.9 Transporting the main boom.....................................................309 6.3.10 Inspections after main boom mounting..........................................310 6.4 Installing/removing outrigger beams..................................................311 6.4.1 CHECKLIST: Removing the outrigger beams........................................312 6.4.2 CHECKLIST: Installing the outrigger beams......................................314 6.4.3 Preparing the truck crane......................................................316 Prerequisites....................................................................316 For removal......................................................................316 6.4.4 Removing/attaching outrigger pads..............................................317 Removing the outrigger pads......................................................317 Attaching the outrigger pads.....................................................318 6.4.5 Disconnecting/establishing the hydraulic connection............................319 6.4.6 Disconnecting/establishing the electrical connection...........................320 6.4.7 Unscrewing/screwing in the spacers.............................................321 Unscrewing.......................................................................321 Screwing in......................................................................322 6.4.8 Disconnecting/establishing the connections to the outrigger box................323 6.4.9 Extending/retracting the outrigger beam........................................323 Extending the outrigger beam.....................................................323 Inserting the outrigger beam.....................................................325 6.4.10 Transporting the outrigger beams..............................................327 6.5 Rigging the auxiliary hoist..........................................................329 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................329 Prerequisites....................................................................329 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................331 Prerequisites....................................................................331 6.5.3 Slinging the auxiliary hoist...................................................333 6.5.4 Slinging the rigging frame.....................................................333 6.5.5 Lowering/raising the rigging frame.............................................334 Prerequisite.....................................................................334 6.5.6 Placing the auxiliary hoist on the counterweight combination...................334 6.5.7 Establishing/disconnecting the hydraulic connection............................335 6.5.8 Making/breaking the electrical connection......................................336 6.5.9 Creating the connection to the turntable.......................................337 Establishing the connection......................................................337 Disconnecting....................................................................339 6.5.10 Securing the hoist rope.......................................................340 6.5.11 Transporting the auxiliary hoist..............................................341 6.5.12 Check that the auxiliary hoist is functioning properly........................342 Slewing direction................................................................342 Slewing indicator................................................................342 7 Malfunctions in driving mode...............................................................345 7.1 Emergency stop switch................................................................345 7.2 What to do when a malfunction occurs in road traffic.................................347 7.3 Towing the truck crane...............................................................349 7.3.1 Towing after engine/transmission damage........................................350 Compressed-air supply............................................................350 Electric power supply............................................................351 On the transmission..............................................................351 Axle drives......................................................................352 Parking brake....................................................................352 Towing the truck crane out of the danger area....................................353 7.3.2 Tow starting...................................................................353 7.4 Other emergency operations...........................................................355 7.4.1 Externally starting the truck crane............................................355 7.4.2 Battery charger................................................................356 Prerequisites....................................................................356 7.5 Wheels and tyres.....................................................................357 7.5.1 Wheel change...................................................................357 Removing a damaged wheel.........................................................358 On the spare wheel holder........................................................358 Mounting a wheel.................................................................359 7.5.2 Inflating the tyres yourself...................................................361 Connecting the filling hose......................................................361 Inflating the tyres..............................................................362 Removing the filling hose........................................................362 7.6 Fuses................................................................................363 Notes on changing fuses..............................................................363 7.6.1 Fuses in the driver's cab......................................................364 Group F1.........................................................................364 Group F2.........................................................................365 Group F3.........................................................................365 Group F4.........................................................................366 Other fuses......................................................................366 Group F7.........................................................................367 Group F8.........................................................................367 Group F9.........................................................................368 Group F10........................................................................368 7.6.2 Fuses in the battery box.......................................................369 7.7 Troubleshooting......................................................................371 7.7.1 Malfunctions on the engine.....................................................371 7.7.2 Faults on the AdBlue (DEF) system..............................................373 7.7.3 Malfunctions in the transmission...............................................374 7.7.4 Malfunctions of the service brake..............................................375 7.7.5 Malfunctions of the steering...................................................376 7.7.6 Differential lock malfunctions.................................................377 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................377 7.7.8 Malfunctions on the suspension.................................................378 7.7.9 Malfunctions of the level adjustment system....................................378 7.7.10 Malfunction in the CCS control unit...........................................378 7.8 Warnings in the start menu...........................................................379 Symbols in the display area..........................................................379 7.8.1 Engine/transmission error menu.................................................384 Open menu........................................................................384 Exiting the menu.................................................................384 7.9 Procedure in the event of malfunctions...............................................385 7.9.1 Procedure during engine malfunctions...........................................385 7.9.2 Procedure during transmission malfunctions.....................................386 8 Index......................................................................................389 A........................................................................................391 B........................................................................................391 C........................................................................................392 D........................................................................................395 E........................................................................................396 F........................................................................................398 H........................................................................................398 I........................................................................................399 K........................................................................................399 L........................................................................................399 M........................................................................................400 O........................................................................................401 P........................................................................................402 R........................................................................................402 S........................................................................................404 T........................................................................................405 V........................................................................................407 W........................................................................................407 Part 2 – Crane operation.........................................................................411 Additional Pages.............................................................................415 Slewing gear freewheel...................................................................413 CCS – Datalogger.........................................................................415 Additional menu and program..........................................................415 Additional menu..................................................................415 Export data......................................................................416 Display the data.................................................................416 Slewable spotlights......................................................................421 Automatic load tracking..............................................................421 Hoist rope travel limitation.............................................................423 Hoist rope travel limitation menu....................................................424 Entering values......................................................................425 Switching monitoring function on/off.................................................425 Driving with rigged truck crane..........................................................427 Counterweight............................................................................429 Setting down the base plate..........................................................429 Adjustable head sheave...................................................................431 Different positions depending on the reeving.........................................431 Main boom intermediate lengths...........................................................433 Derricking cylinder pressure monitoring..............................................433 Telescoping emergency programme..........................................................435 Additional checks....................................................................435 Anemometer display.......................................................................437 Extended function....................................................................437 9 Operating elements for crane operation.....................................................443 9.1 Overview of the operating elements...................................................443 9.1.1 Exterior of the truck crane....................................................444 9.1.2 Crane cab......................................................................448 Side panel.......................................................................450 Crane cab, rear..................................................................452 9.1.3 Control panels.................................................................454 Left.............................................................................454 Right............................................................................455 9.1.4 Control lever configuration....................................................456 Version 1........................................................................456 Version 2........................................................................457 9.1.5 Control unit CCS...............................................................458 9.1.6 CCS – Start menu...............................................................461 9.1.7 CCS – overview of menu groups..................................................462 Superstructure menu group........................................................466 Superstructure lock menu.........................................................467 Counterweight menu...............................................................468 Outrigger menu...................................................................469 Outrigger support beam menu......................................................471 Outrigger cylinders menu.........................................................472 Teleautomation menu group........................................................474 Telescoping full automation menu.................................................475 Telescoping semiautomation menu.................................................476 Main boom configuration menu.....................................................477 Active working range limiter menu group..........................................478 Overall height menu..............................................................479 Working radius menu..............................................................480 Slewing angle menu...............................................................481 Information menu group...........................................................482 Hydraulic pressure and fuel consumption menu.....................................483 Engine/Driving menu group........................................................484 Economy menu.....................................................................485 Heating/ airconditioning menu...................................................486 Telescoping menu group...........................................................487 Manual telescoping menu..........................................................488 Telescoping emergency program menu...............................................489 Unknown telescoping menu.........................................................490 Settings menu group..............................................................491 Crane cab menu...................................................................492 Menu for setting the display brightness and date/time............................493 Switch units menu................................................................494 Set control lever characteristic curve menu......................................495 Power unit speeds menu...........................................................496 Menu group Information...........................................................497 Operating hours menu.............................................................498 Engine/ transmission error menu..................................................500 Crane operation error menu.......................................................501 Program version menu.............................................................502 Operating additional equipment...................................................503 9.1.8 Control unit RCL...............................................................504 9.1.9 RCL – menu groups..............................................................506 Menu for entering rigging mode...................................................509 Monitoring menu..................................................................510 Lifting capacity tables menu.....................................................512 9.1.10 Hand-held controls............................................................513 Outrigger control panel..........................................................514 9.1.11 Outrigger control units.......................................................516 Button...........................................................................516 Outrigger button.................................................................517 Inclination and outrigger pressure display.......................................518 Raise axle display...............................................................519 9.2 Short description of the operating elements..........................................521 9.2.1 Definition of direction information............................................521 Basic rule.......................................................................521 Switches.........................................................................521 9.2.2 General rules for buttons and symbols on the display...........................522 9.2.3 Engine.........................................................................523 Side panel.......................................................................523 Economy menu.....................................................................524 9.2.4 AdBlue (DEF) system............................................................525 CCS display......................................................................525 9.2.5 Seat contact switch and dead man's switch......................................526 9.2.6 Crane control CCS..............................................................527 9.2.7 Outrigger......................................................................533 Hand-held control................................................................533 Right-hand control panel.........................................................534 Left-hand control panel..........................................................534 In the Outrigger menu............................................................535 On the outrigger control units...................................................537 9.2.8 Inclination indicators.........................................................539 9.2.9 Raise axle.....................................................................540 Outrigger control units..........................................................540 9.2.10 Outrigger pressure displays...................................................542 Outriggers submenu...............................................................542 Outrigger control units..........................................................542 9.2.11 Anemometer displays...........................................................542 9.2.12 Counterweight menu............................................................543 Counterweight submenu............................................................543 9.2.13 Main hoist....................................................................547 Control panels...................................................................547 CCS display......................................................................548 9.2.14 Auxiliary hoist...............................................................549 Control panels...................................................................549 CCS display......................................................................550 9.2.15 Slewing gear..................................................................551 Control panels...................................................................551 CCS display......................................................................552 9.2.16 Derricking gear...............................................................553 Control panels...................................................................553 CCS display......................................................................554 9.2.17 Telescoping mechanism.........................................................555 Control panels...................................................................555 CCS display......................................................................555 Telescoping full automation menu.................................................556 Telescoping semiautomation menu.................................................557 Manual telescoping menu..........................................................559 Main boom configuration menu.....................................................562 9.2.18 Hydraulic system..............................................................563 9.2.19 Superstructure lock/Houselock menu............................................564 Superstructure lock..............................................................564 Houselock........................................................................565 9.2.20 Rated capacity limiter (RCL)..................................................566 Control unit control console RCL.................................................566 Display RCL......................................................................567 Enter rigging mode menu..........................................................569 Monitoring menu..................................................................572 Lifting capacity tables menu.....................................................576 RCL override.....................................................................576 External displays................................................................577 9.2.21 Electrical system.............................................................579 9.2.22 Lighting, windscreen wiper/washing system.....................................579 Lighting.........................................................................579 Windscreen wiper/washing system..................................................580 9.2.23 Hand-held control.............................................................582 Sockets for handheld control....................................................582 Engine control panel.............................................................583 Horn.............................................................................583 Outrigger control panel..........................................................584 9.2.24 Windows, doors, keys..........................................................586 Windows..........................................................................586 Rear window......................................................................586 Crane cab door...................................................................587 Keys.............................................................................588 9.2.25 Diagnostics...................................................................588 10 Starting/turning off the engine – for crane operation.....................................591 10.1 When starting the engine for the first time of the day..............................591 10.1.1 Checking the fuel level and AdBlue (DEF) level................................592 Fuel.............................................................................592 AdBlue (DEF).....................................................................592 10.1.2 Checks before starting the engine.............................................593 On hydraulic tank................................................................593 Checking the hand-held control...................................................594 10.1.3 Switching on the ignition.....................................................594 10.1.4 Display – setting the brightness..............................................595 10.1.5 Starting the engine...........................................................596 10.1.6 Checks after starting the engine..............................................597 10.1.7 Setting idling speed..........................................................598 10.2 Starting the engine – with the hand-held control....................................599 Prerequisites........................................................................599 Starting the engine..................................................................599 10.3 Turning off the engine..............................................................601 10.3.1 During normal operation, with the ignition lock/with the handheld control....601 After turning off................................................................601 10.3.2 In emergencies, with the emergency stop switches..............................602 Resetting the emergency stop switch..............................................602 11 Crane operation...........................................................................605 11.1 Before operating the crane..........................................................605 11.1.1 CHECKLIST: Checks before operating the crane..................................605 11.1.2 Checking the condition of the truck crane.....................................609 Fuel tank auxiliary heater.......................................................609 Visual inspection................................................................609 Checking the position of the hoist ropes.........................................610 Checking the electrical system...................................................611 11.1.3 Adjusting the crane cab seat and front control panel..........................612 Crane cab seat...................................................................612 Front panel......................................................................612 11.1.4 Checking the safety equipment.................................................613 Rated capacity limiter...........................................................613 Lifting limit switch.............................................................613 Emergency stop switch............................................................614 Seat contact switch..............................................................615 11.1.5 Earthing the load.............................................................616 11.1.6 Preheating the hydraulic oil..................................................617 Prerequisites....................................................................617 Preheating.......................................................................617 11.1.7 Locking/unlocking the superstructure..........................................618 Locking points...................................................................618 Locking the superstructure.......................................................619 Unlocking the superstructure.....................................................619 11.1.8 Switching the Houselock on/off................................................620 Switching on the Houselock.......................................................620 Switching off the Houselock......................................................622 11.2 Operation of the rated capacity limiter.............................................623 11.2.1 Switch on the RCL.............................................................624 Switching on.....................................................................624 Brightness of the displays.......................................................626 Temperature on the display.......................................................626 11.2.2 Enter rigging mode............................................................627 Entering individual components...................................................628 Entering the RCL code............................................................632 Entering the reeving.............................................................633 Accepting the rigging mode.......................................................633 11.2.3 Checks before operating the crane.............................................635 Open menu........................................................................635 Checks...........................................................................635 11.2.4 Displays during crane operation...............................................638 11.2.5 RCL early warning.............................................................641 11.2.6 RCL switch-off................................................................641 Shutdown due to overload.........................................................641 11.2.7 Display in the event of errors................................................643 11.2.8 RCL override..................................................................644 Overview status display..........................................................644 When rigging.....................................................................645 To raise the boom................................................................646 In emergencies...................................................................647 11.2.9 Displaying the lifting capacity tables........................................648 11.2.10 Setting the time/date........................................................650 11.3 Crane operation with main boom......................................................651 11.3.1 Checks during crane operation.................................................651 Horizontal alignment.............................................................651 Safe distances...................................................................651 Checking the wind speed..........................................................652 11.3.2 Permissible slewing ranges and working positions..............................653 360 slewing range...............................................................653 0 to the rear working position..................................................653 180 to the front rigging position...............................................653 11.3.3 Main hoist....................................................................654 Switching on the main hoist......................................................655 Lifting and lowering.............................................................655 Maximum permissible hoist rope speed.............................................656 Switching off the main hoist.....................................................657 11.3.4 Auxiliary hoist...............................................................658 Switching on the auxiliary hoist.................................................658 Lifting and lowering.............................................................659 Maximum permissible hoist rope speed.............................................659 Switching off the auxiliary hoist................................................660 11.3.5 Lifting limit switch and lowering limit switch................................661 Lifting limit switch.............................................................661 Lowering limit switch............................................................663 11.3.6 Derricking gear...............................................................664 Switching on the derricking gear.................................................664 Maximum permissible derricking speed.............................................664 Raising and lowering.............................................................665 Re-enable raising function.......................................................666 Switching off the derricking gear................................................666 11.3.7 Telescoping mechanism.........................................................668 Overview.........................................................................669 Telescoping process..............................................................669 Assignment for display...........................................................672 Fixed length, intermediate length, telescoping length............................673 Telescoping......................................................................674 Telescoping sequence.............................................................674 Checks before starting work......................................................675 Switching on the telescoping mechanism...........................................676 Function of the control lever....................................................676 Switching off the telescoping mechanism..........................................678 Manual telescoping...............................................................679 Checking the initial position....................................................679 Unlocking the telescoping cylinder...............................................681 Extending/ retracting the telescoping cylinder...................................683 Lock telescoping cylinder........................................................684 Unlocking the telescopic section.................................................685 Telescoping the telescopic section...............................................686 Locking the telescopic section...................................................687 Locking the telescopic section for on-road driving...............................688 Telescoping with semi-automation.................................................688 Telescoping with full automation.................................................691 Telescoping with main boom configuration.........................................692 11.3.8 High-speed mode...............................................................693 Derricking gear/ telescoping mechanism...........................................693 Hoists...........................................................................694 11.3.9 Slewing gear..................................................................695 Switching on the slewing gear....................................................695 Turning..........................................................................696 Releasing locked slewing gear....................................................696 Maximum permissible slewing speed................................................697 Braking the slewing movement.....................................................698 Releasing the slewing gear brake.................................................698 Engaging the slewing gear brake..................................................698 Slewing gear freewheel...........................................................699 Switching off the slewing gear...................................................699 11.3.10 Possible movement combinations...............................................700 11.4 Settings and displays for crane operation...........................................701 11.4.1 Inclining the crane cab.......................................................701 11.4.2 Setting idling speed..........................................................702 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................702 11.4.4 Limiting the power unit speeds................................................703 11.4.5 Setting/switching on Economy mode.............................................704 Automatic........................................................................704 Manual...........................................................................704 11.4.6 Switching units...............................................................705 11.4.7 Setting the characteristic curves for the control levers......................706 11.4.8 Using the slewable spotlights.................................................707 11.4.9 Override torque reduction.....................................................708 11.4.10 Displaying the operating hours...............................................709 11.4.11 Warnings in the start menu...................................................710 Meaning of the symbols...........................................................710 11.5 Working range limiter...............................................................713 11.5.1 Viewing current settings......................................................714 11.5.2 Opening the working range limiter menu........................................715 11.5.3 Entering limit values.........................................................717 Overall height...................................................................717 Working radius...................................................................718 Slewing angle....................................................................718 11.5.4 Entering limit values manually................................................720 Limit values.....................................................................720 11.5.5 Switching monitoring functions on/off.........................................722 11.5.6 Shutdown by working range limiter.............................................723 11.6 Work break..........................................................................725 11.6.1 In case of short work breaks..................................................725 11.6.2 In case of work breaks of more than 8 hours...................................726 To secure the truck crane........................................................726 11.7 Heating and air-conditioning system.................................................727 11.7.1 Standard heating system.......................................................727 Switching on.....................................................................727 Heating..........................................................................727 Air distribution.................................................................727 Switching off....................................................................728 11.7.2 Air-conditioning system.......................................................729 Information......................................................................729 Switching on/off.................................................................729 Cooling, automatic...............................................................730 Cooling, maximum.................................................................730 11.7.3 Auxiliary heater..............................................................731 Switching on.....................................................................731 Setting the temperature..........................................................732 Setting the heating start/ heating duration......................................732 Switching heating start on/off...................................................733 11.8 CraneSTAR system....................................................................734 11.8.1 Overview......................................................................734 11.8.2 Position of the components....................................................734 12 Rigging work..............................................................................737 12.1 Rigging work checklists for crane operation with the main boom......................737 12.1.1 CHECKLIST: Rigging............................................................737 12.1.2 CHECKLIST: Unrigging..........................................................741 12.2 Choosing a suitable site............................................................745 12.2.1 Determining the required ground bearing area..................................745 12.2.2 Safe distance from slopes and pits............................................748 12.2.3 Earthing the truck crane......................................................749 12.2.4 Safe distance from electrical cables..........................................750 12.3 Rigging work after driving with a trailer...........................................753 12.3.1 Switching off the boom floating position......................................753 12.3.2 Switching off the slewing gear freewheel......................................754 Before slewing...................................................................754 12.3.3 Switching off boom pre-tensioning.............................................755 12.4 Connecting/disconnecting the hand-held control......................................757 12.5 Starting the engine for driving for rigging work....................................759 12.5.1 Starting/turning off the engine with the hand-held control....................759 Prerequisites....................................................................759 Starting the engine..............................................................760 Turning off the engine...........................................................760 12.5.2 Starting/turning off the engine from the outrigger control units..............761 Prerequisites....................................................................761 Starting the engine..............................................................761 Turning off the engine...........................................................761 12.6 Outrigger...........................................................................763 12.6.1 CHECKLIST: Extending the outriggers...........................................763 12.6.2 CHECKLIST: Retracting the outriggers..........................................765 12.6.3 Permissible outrigger spans...................................................766 12.6.4 Preparing the truck crane.....................................................767 In the driver's cab..............................................................767 Outrigger control units..........................................................767 12.6.5 Setting the outrigger spans...................................................768 For on-road driving..............................................................770 12.6.6 Extending/retracting outrigger beams..........................................771 From the control units...........................................................772 With the handheld control.......................................................773 From the crane cab...............................................................775 12.6.7 Moving the outrigger pads into working/driving position.......................777 12.6.8 Enlarging the ground bearing area.............................................778 12.6.9 Extending/retracting supporting cylinders.....................................779 From the control units...........................................................780 With the handheld control.......................................................781 From the crane cab...............................................................782 12.6.10 Level the truck crane on outriggers..........................................784 Inclination indicators...........................................................784 Prerequisites....................................................................785 Manual alignment.................................................................786 Automatic alignment..............................................................787 12.6.11 Levelling the free-on-wheels truck crane.....................................789 12.6.12 Outrigger pressure display...................................................791 12.7 Rigging/unrigging the counterweight.................................................793 12.7.1 Counterweight sections........................................................793 12.7.2 Identification................................................................795 12.7.3 Slinging points on the counterweight sections.................................796 12.7.4 CHECKLIST: Rigging the counterweight..........................................797 12.7.5 CHECKLIST: Unrigging the counterweight........................................798 12.7.6 Assembling counterweight combination..........................................801 12.7.7 Counterweight hoist unit......................................................809 Counterweight menu...............................................................809 Extending/ retracting the lifting cylinders......................................810 Automatic mode, rigging..........................................................811 Automatic mode, unrigging........................................................813 Cancel automatic mode............................................................814 12.7.8 Setting down counterweight for driving the truck crane........................815 12.7.9 Slewing with rigged counterweight.............................................817 12.8 Rigging work on the main boom.......................................................819 12.8.1 Hook block on the bumper......................................................819 Picking up the hook block........................................................819 Attaching the hook block.........................................................820 12.8.2 Hook block in the compartment.................................................821 Prerequisites....................................................................821 12.8.3 Hook block on a separate vehicle..............................................823 Picking up the hook block........................................................824 Setting down the hook block......................................................824 12.8.4 Hook block, separable.........................................................826 Rigging for onroad driving......................................................826 Rigging for crane operation......................................................827 12.8.5 Reeving and unreeving the hoist rope..........................................828 Version A........................................................................828 Version B........................................................................829 Reeving the hoist rope...........................................................831 Unreeving the hoist rope.........................................................834 12.8.6 Possible reeving methods on the main boom.....................................835 With 7 head sheaves..............................................................835 With 10 head sheaves.............................................................838 With 11 head sheaves.............................................................841 12.8.7 Installing/removing the lifting limit switch..................................842 Installing the lifting limit switch..............................................842 Removing the lifting limit switch................................................845 12.8.8 Locking/unlocking the lifting limit switch....................................847 Locking..........................................................................847 Releasing locking................................................................847 12.8.9 Anemometer and air traffic control light......................................848 Installing.......................................................................848 Switching the air traffic control light on and off...............................848 Removing.........................................................................849 For transport....................................................................849 12.9 Other rigging work..................................................................851 12.9.1 Railings on the turntable.....................................................851 12.9.2 Folding the lighting carrier in/out...........................................852 12.9.3 Safety harness on the main boom...............................................853 Prerequisites....................................................................854 Requirements.....................................................................854 Attaching/ detaching fall prevention safety system to/from safety harness........855 Inspecting/ replacing safety harness.............................................857 12.9.4 Slinging points for personal protective equipment.............................858 12.9.5 Cameras for crane operation...................................................859 Camera on the hoists.............................................................859 Camera on main boom..............................................................860 Operating the camera.............................................................862 12.9.6 Stair tread on the crane cab..................................................863 13 Driving with rigged truck crane...........................................................867 13.1 Driving path........................................................................867 13.2 Permissible rigging modes and axle loads............................................868 Axle load table......................................................................869 13.3 Before driving......................................................................870 13.3.1 Securing the superstructure against slewing...................................870 13.3.2 Checking tyre pressure and wind speed.........................................871 13.3.3 Putting the truck crane on the wheels.........................................872 13.3.4 Gears/connections.............................................................874 Transmission.....................................................................874 Switching on separate steering...................................................874 13.4 While driving.......................................................................874 13.5 After driving.......................................................................876 14 Transport.................................................................................879 14.1 Transport with transport vehicle....................................................879 14.1.1 CHECKLIST: Checks before transport............................................880 14.1.2 Drive the truck crane onto the transport vehicle..............................882 Drive on.........................................................................882 Lashing..........................................................................882 14.1.3 Slinging points...............................................................883 15 Malfunctions during crane operation.......................................................887 15.1 Emergency stop switch...............................................................887 15.2 What to do when a malfunction occurs during crane operation.........................889 Load can be lowered..................................................................889 Load cannot be lowered...............................................................889 15.3 Fuses in the crane cab..............................................................891 Notes on changing fuses..............................................................891 15.4 Finding and eliminating malfunctions................................................896 15.4.1 Malfunctions on the engine....................................................896 15.4.2 Malfunctions on the counterweight hoist unit..................................896 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................897 15.4.4 Malfunctions in the hoist cameras.............................................898 15.4.5 Malfunctions in the main boom camera..........................................898 15.4.6 Malfunctions on the derricking gear...........................................899 15.4.7 Malfunctions in the telescoping mechanism.....................................900 15.4.8 Malfunctions on the slewing gear..............................................902 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................903 15.4.10 Malfunctions when inclining the crane cab....................................903 15.4.11 Malfunctions when operating with the hand-held control.......................903 15.4.12 Malfunctions of the outriggers...............................................904 15.4.13 Malfunction in the CCS control unit..........................................904 15.4.14 Troubleshooting the crane control............................................905 General malfunctions.............................................................905 Symbols in the error or information display areas................................906 Displays in the Error menu.......................................................910 15.4.15 Malfunctions in the CraneSTAR system.........................................912 15.5 Emergency operations and programmes.................................................913 15.5.1 Mechanical emergency activation for retracting................................914 Prior to the emergency activation, check.........................................914 Procedure........................................................................914 Mechanical emergency activation..................................................915 15.5.2 Telescoping emergency programme...............................................917 Open submenu Emergency program...................................................917 Determining the error type.......................................................918 Error on length indicator........................................................919 Tables for approaching the locking points........................................923 15.5.3 Entering the current telescoping..............................................925 15.5.4 Emergency operation with the hand-held control................................927 Preparations.....................................................................927 Operating a power unit...........................................................928 Stopping movements...............................................................930 Stopping movements in emergencies................................................930 Turning off the engine...........................................................930 15.6 Hydraulic emergency operation.......................................................931 15.6.1 Connecting/disconnecting hoses................................................931 15.6.2 Establishing the required hydraulic circuits..................................932 Switching over valves............................................................932 For lowering.....................................................................933 15.6.3 Operating principle of emergency operation BGR 159............................935 15.6.4 Connecting/disconnecting hoses................................................936 Establishing connections.........................................................936 Disconnecting....................................................................937 15.6.5 Switching emergency operation on/off..........................................938 15.6.6 Establishing the hydraulic circuits required..................................939 Switching over valves............................................................939 For lifting/ lowering............................................................941 For slewing......................................................................942 15.6.7 Performing emergency operation................................................943 Turning..........................................................................943 Derricking.......................................................................944 Lifting/lowering.................................................................944 15.6.8 After emergency operation.....................................................945 Switching off emergency operation................................................945 Switching over to crane operation................................................945 Disconnecting the hoses..........................................................945 15.6.9 Emergency supply of another crane.............................................946 For emergency supply.............................................................946 After emergency supply...........................................................946 16 Index.....................................................................................949 A........................................................................................951 B........................................................................................951 C........................................................................................952 D........................................................................................955 E........................................................................................956 F........................................................................................958 H........................................................................................958 I........................................................................................959 K........................................................................................959 L........................................................................................959 M........................................................................................960 O........................................................................................961 P........................................................................................962 R........................................................................................962 S........................................................................................964 T........................................................................................965 V........................................................................................967 W........................................................................................967
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