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Grove Crane GMK 5250L Driving Operating Manual 3302419 – PDF DOWNLOAD
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Description
Grove Crane GMK 5250L Driving Operating Manual 3302419 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250L Driving Operating Manual 3302419 – PDF DOWNLOAD
Language : English
Pages : 998
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250L Driving Operating Manual 3302419 – 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 corresponding
special equipment within the permitted temperature range; àTechnical
data, p. 1 – 7. - The GMK 5250L truck crane is designed solely for lifting loads which are
within the permitted GMK 5250L lifting capacities. The load must be slung
as prescribed to a hook block which is positioned vertically over the load
prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
manual(s), the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
- The GMK 5250L may only be operated with parts of equipment which are
permitted by Manitowoc Crane Group Germany GmbH and which are
labelled with the serial number of the GMK 5250L. - The manufacturer is not liable for any damage caused by improper or
unauthorized use of the GMK 5250L truck crane. The user alone bears the
risk.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 5250L Driving Operating Manual 3302419 – PDF DOWNLOAD
Part 1 – Driving................................................................................. 1 Additional pages............................................................................. 3 Additional page GMK – Reduction of slewing speed......................................... 3 1 Reduction of slewing speed – can be switched on and off............................ 3 1.1 Important notes.............................................................. 3 With reduction switched on................................................... 3 With reduction switched off.................................................. 3 1.2 Operation.................................................................... 4 1.2.1 Additional and modified operating elements............................. 4 1.2.2 Switching reduction off and on......................................... 5 CCS display.............................................................................. 7 Menu changes......................................................................... 7 Start menus...................................................................... 7 Displays for the counterweight................................................... 8 Slewing gear freewheel................................................................... 11 CCS – Datalogger......................................................................... 13 Additional menu and program.......................................................... 13 Additional menu.................................................................. 13 Export data...................................................................... 14 Display the data................................................................. 14 Slewable spotlights...................................................................... 19 Automatic load tracking.............................................................. 19 Hoist rope travel limitation............................................................. 21 Hoist rope travel limitation menu.................................................... 22 Entering values...................................................................... 23 Switching monitoring function on/off................................................. 23 Driving with rigged truck crane.......................................................... 25 Counterweight............................................................................ 27 Setting down the base plate.......................................................... 27 Adjustable head sheave................................................................... 29 Different positions depending on the reeving......................................... 29 Main boom intermediate lengths .......................................................... 31 Derricking cylinder pressure monitoring.............................................. 31 Telescoping emergency programe........................................................... 43 Anemometer display ...................................................................... 35 Extended function.................................................................... 35 Rigging the special outrigger span....................................................... 37 For removal/installation of the rear outrigger cylinders............................. 37 Rigging the outrigger span....................................................... 37 Information...................................................................... 39 Note on error messages........................................................... 40 Telescoping emergency programme.......................................................... 41 Return run of the telescoping cylinder............................................... 41 1 Overview................................................................................... 49 1.1 Accidents............................................................................ 49 1.2 Branch offices....................................................................... 51 1.2.1 Manitowoc Crane Care........................................................... 51 1.2.2 Dealer list.................................................................... 51 1.3 Warranty specifications.............................................................. 51 1.4 Terms used........................................................................... 52 1.5 Technical data....................................................................... 55 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 55 1.5.2 Maximum lifting capacity (ASME B 30.5)......................................... 55 1.5.3 Dimensions and weights of the truck crane, axle loads.......................... 56 Dimensions....................................................................... 57 Weight and axle loads............................................................ 57 1.5.4 Dimensions and weights of removable parts...................................... 58 Spare wheel...................................................................... 58 Outriggers....................................................................... 58 Main boom........................................................................ 59 Hook blocks and hook tackle...................................................... 59 hook blocks, split............................................................... 60 Auxiliary hoist.................................................................. 61 Counterweight parts.............................................................. 61 1.5.5 Carrier........................................................................ 62 Engine........................................................................... 62 Transmission..................................................................... 62 Transfer case.................................................................... 62 Axle lines....................................................................... 62 Steering......................................................................... 62 Tyres............................................................................ 63 Electrical system................................................................ 63 Tool............................................................................. 63 Towing couplings................................................................. 63 Driving speeds................................................................... 63 Climbing ability................................................................. 63 Outriggers....................................................................... 64 Turning radii.................................................................... 65 1.5.6 Superstructure................................................................. 66 Main hoist....................................................................... 66 Auxiliary hoist.................................................................. 66 Slewing gears.................................................................... 66 Derricking gear.................................................................. 66 Main boom........................................................................ 67 Lattice extension................................................................ 67 Operating speeds................................................................. 67 Noise emission................................................................... 67 1.6 Documentation supplied............................................................... 69 1.6.1 Questions on documentation..................................................... 70 1.7 Notes on the operating manual........................................................ 71 1.7.1 What do the symbols used mean?................................................. 71 1.7.2 How is the operating manual structured?........................................ 73 Division......................................................................... 73 Structure of the chapters........................................................ 73 Structure of the pages........................................................... 74 1.7.3 How do I find the information I need?.......................................... 75 Cross-references example......................................................... 76 1.7.4 What information is available for operations planning?......................... 78 1.8 Conversion table for US measuring units.............................................. 79 1.9 Training – Information............................................................... 81 1.10 Identification...................................................................... 82 1.11 EC Declaration of Conformity........................................................ 84 2 Basic safety instructions.................................................................. 87 2.1 Intended use......................................................................... 87 2.1.1 Improper use................................................................... 88 2.2 Organisational measures.............................................................. 89 2.3 Personnel qualifications............................................................. 91 2.4 Safety instructions for driving the truck crane...................................... 92 2.5 Safety instructions for crane operation.............................................. 93 2.6 Notes on transporting persons........................................................ 95 Equipment for lifting persons........................................................ 95 Personnel............................................................................ 95 Operation............................................................................ 96 Truck crane.......................................................................... 97 3 Operating elements for driving.............................................................101 3.1 Overview of the operating elements...................................................101 3.1.1 On the outside of the truck crane..............................................102 3.1.2 Cab............................................................................106 Overview.........................................................................106 Behind the cover.................................................................110 In the rear of the driver's cab..................................................110 3.1.3 Instrument panel...............................................................111 Left/right.......................................................................111 Middle...........................................................................112 On-board computer time correction................................................114 3.1.4 On-board computer..............................................................115 3.1.5 Steering column/steering wheel.................................................116 3.1.6 Transmission operating elements................................................117 3.1.7 Tachograph.....................................................................118 3.1.8 Control unit CCS...............................................................119 3.1.9 Display CCS – start menu.......................................................120 3.1.10 CCS – overview of menu groups.................................................122 Carrier menu group...............................................................124 Suspension/level adjustment menu.................................................125 Driving menu.....................................................................126 Settings menu group..............................................................127 Menu for setting the display brightness and date/time............................128 Information menu group...........................................................129 Operating hours menu.............................................................130 Engine/ transmission error menu..................................................131 Crane operation error menu.......................................................132 Operating additional equipment...................................................133 3.1.11 Outrigger control units.......................................................134 3.1.12 Heating/Air-conditioning system...............................................135 Standard heating system..........................................................135 Auxiliary water heater...........................................................136 Auxiliary air heater.............................................................137 3.1.13 Sockets for hand-held control.................................................138 3.1.14 Outrigger control units.......................................................139 3.2 Short description of the operating elements..........................................141 3.2.1 Definition of direction information............................................142 Basic rule.......................................................................142 Switches and buttons.............................................................142 3.2.2 General rules for buttons and symbols on the display...........................143 3.2.3 Engine.........................................................................144 Steering column..................................................................144 On the steering wheel............................................................144 Instrument panel.................................................................145 3.2.4 AdBlue system (DEF)............................................................146 Instrument panel.................................................................146 CCS display......................................................................147 3.2.5 Battery master switch..........................................................147 3.2.6 Electrical system..............................................................148 3.2.7 Crane control CCS..............................................................149 3.2.8 Transmission...................................................................153 Transmission control unit........................................................153 Display, driving mode,...........................................................154 3.2.9 Reverse camera.................................................................156 3.2.10 Final drive...................................................................157 3.2.11 Brakes........................................................................159 Service brake....................................................................159 Additional brakes................................................................159 Parking brake....................................................................160 3.2.12 Steering/separate steering....................................................162 Instrument panel.................................................................162 CCS display......................................................................163 Driver's door....................................................................164 3.2.13 Suspension....................................................................165 CCS display......................................................................165 Outrigger control units..........................................................165 3.2.14 Lighting/windscreen wipers/horn...............................................166 Steering column..................................................................166 Steering wheel...................................................................166 Instrument panel.................................................................166 CCS display......................................................................168 Roof.............................................................................169 3.2.15 Level adjustment system.......................................................170 3.2.16 Tachograph/speedometer........................................................172 Tachograph.......................................................................172 Speedometer......................................................................172 3.2.17 Diagnostics...................................................................173 3.2.18 On-board computer.............................................................174 3.2.19 Windows, doors, keys..........................................................176 Window winder....................................................................176 Doors............................................................................177 Keys.............................................................................177 3.2.20 Front flap....................................................................178 4 Starting/turning off the engine for driving................................................181 4.1 Starting the engine from the driver's cab............................................181 4.1.1 CHECKLIST: Starting the engine.................................................181 4.1.2 CHECKLIST: At low temperatures.................................................184 4.1.3 Ladders and access ladders.....................................................184 Access ladders...................................................................184 Ladders..........................................................................185 4.1.4 Refuel.........................................................................187 Standard tank....................................................................187 Dual tank........................................................................188 AdBlue...........................................................................189 4.1.5 Checks before starting the engine..............................................190 On hydraulic tank................................................................190 Battery master switch............................................................191 Checking the hand-held control...................................................191 4.1.6 Switching on the ignition......................................................191 4.1.7 Lamp test/equalisation of the switching states.................................192 Lamp test........................................................................192 Switching state alignment........................................................192 4.1.8 Display – setting the brightness...............................................193 4.1.9 Starting the engine............................................................194 4.1.10 Checks after starting the engine..............................................196 Checking in the main menu........................................................196 Indicator lamps on the instrument panel..........................................197 4.1.11 Monitoring elements...........................................................199 Instrument panel.................................................................199 4.1.12 Start menu....................................................................200 4.1.13 Setting idling speed..........................................................201 4.2 Turning off the engine...............................................................203 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....203 After turning off................................................................203 4.2.2 Using the emergency stop switches..............................................204 Resetting the emergency stop switch..............................................204 4.3 Air intake inhibitor.................................................................205 Releasing the air intake inhibitor...................................................205 5 Driving....................................................................................209 5.1 Before driving.......................................................................209 5.1.1 CHECKLIST: Checks before on-road driving.......................................209 5.1.2 Checking the condition of the truck crane......................................215 Electrical system................................................................215 Adjusting the mirrors............................................................215 Warning plates for vehicle width.................................................217 Displaying vehicle height........................................................217 Supply pressure..................................................................218 Parking brake....................................................................219 5.1.3 Adjusting the seat and the steering column.....................................220 Driver's seat....................................................................220 Passenger's seat.................................................................221 Steering column, adjusting.......................................................222 5.1.4 Switching the suspension on/off................................................223 Open menu........................................................................223 Switching on the suspension......................................................224 Switching off the suspension.....................................................224 5.1.5 Setting the tachograph.........................................................225 Prerequisites....................................................................225 In the event of malfunctions.....................................................225 Setting the tachograph...........................................................226 5.1.6 Entering the time/date.........................................................230 5.1.7 Displaying and resetting operating hours.......................................231 5.2 Operating the transmission...........................................................233 5.2.1 Switching on...................................................................233 5.2.2 Switching the transmission to neutral position.................................234 5.2.3 Selecting the direction of travel and starting gear............................235 Selecting the driving direction..................................................235 Selecting the starting gear......................................................236 5.2.4 Changing the operating mode....................................................237 Changing to automatic mode.......................................................237 Change to manual mode............................................................237 5.2.5 Starting.......................................................................238 5.2.6 Driving and changing gears.....................................................239 In automatic operating mode......................................................239 In manual operating mode.........................................................240 5.2.7 Changing the driving direction.................................................241 5.2.8 Stopping.......................................................................241 Stopping for along period oftime...............................................241 5.2.9 On the roller type dynamometer.................................................242 5.2.10 Preheating transmission.......................................................242 5.3 Driving and turning off the truck crane..............................................243 5.3.1 Checks while driving...........................................................243 Immediately after you start to move..............................................243 While driving....................................................................245 5.3.2 Cruise control.................................................................246 Switching on.....................................................................246 Switching off....................................................................247 5.3.3 Temposet.......................................................................248 Switching on.....................................................................248 Switching off....................................................................248 5.3.4 Driving downhill...............................................................249 Starting.........................................................................249 Inspections when driving downhill................................................250 Downshifting.....................................................................250 Additional brakes................................................................251 5.3.5 Driving uphill.................................................................252 Starting.........................................................................252 Driving..........................................................................252 5.3.6 Warning messages in the start menu.............................................253 5.3.7 Warning or malfunction messages on the instrument panel........................254 Meaning of the lamps.............................................................254 5.3.8 Messages on the on-board computer display......................................255 5.3.9 Indicator lights in the on-board computer display..............................257 5.3.10 Override torque reduction.....................................................259 5.3.11 Turning off the truck crane...................................................260 Securing against rolling away....................................................260 When stationary for more than 8 hours............................................261 5.3.12 Folding berth.................................................................262 5.4 Off-road driving.....................................................................263 Adjustments to the transmission......................................................263 Connections..........................................................................263 Changing the vehicle level...........................................................263 Rocking the vehicle free and towing..................................................263 5.4.1 Longitudinal and transverse differential locks.................................264 5.4.2 Operating the level adjustment system..........................................266 Open menu........................................................................266 Setting the onroad level........................................................267 Pre-selecting suspension struts..................................................267 Changing the vehicle level.......................................................268 Viewing the current inclination..................................................268 Exiting the menu.................................................................269 5.4.3 Freeing truck crane stuck in terrain...........................................270 Rocking the truck crane free.....................................................270 Towing free forwards.............................................................271 Towing free in reverse gear......................................................271 5.5 Separate steering....................................................................273 5.5.1 Switching to separate steering.................................................273 Manual...........................................................................274 Automatic........................................................................275 5.6 Heating and air-conditioning system..................................................277 5.6.1 Standard heating system,.......................................................277 Switching on.....................................................................277 Heating..........................................................................277 Air distribution.................................................................278 Examples.........................................................................279 Switching off....................................................................279 5.6.2 Air-conditioning system........................................................280 Information......................................................................280 Switching on/off.................................................................280 Cooling..........................................................................281 Drying...........................................................................281 5.6.3 Auxiliary water heater.........................................................282 Preheating the engine............................................................282 Preheating the driver's cab......................................................283 Switching on the auxiliary heater................................................284 Switching off the auxiliary heater...............................................285 Setting time and weekday.........................................................285 Saving automatic heating start...................................................286 Setting the heating period.......................................................287 Switching the automatic heating start on and off.................................287 Setting the remaining time.......................................................288 5.6.4 Auxiliary air heater...........................................................289 Switching on.....................................................................289 Temperature......................................................................290 Switching off....................................................................290 Other functions..................................................................290 5.7 Towing a trailer.....................................................................291 Effects on the axle loads............................................................291 Coupling the trailer.................................................................292 Connecting the supply lines..........................................................293 Removing the supply lines............................................................294 Uncoupling the trailer...............................................................294 Checking the braking force...........................................................296 6 Driving modes and rigging for on-road driving..............................................299 6.1 Driving modes........................................................................299 Information about the axle loads.....................................................299 6.1.1 Information on how to use the tables...........................................300 6.1.2 Tables for a maximum axle load of 12t (26,500lbs)............................301 For 385/95 R25 tyres.............................................................301 For 445/95 R25 525/80 R25 tyres..................................................302 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)...........303 6.2 Rigging work for driving with a trailer..............................................304 6.2.1 Switching on the slewing gear freewheel........................................305 6.2.2 Switching on the boom floating position........................................306 6.2.3 Switching on boom pre-tensioning...............................................307 6.3 Main boom, removing/installing.......................................................308 Additional equipment required........................................................308 6.3.1 CHECKLIST: Removing the main boom..............................................309 Prerequisites....................................................................309 Checklist........................................................................309 6.3.2 CHECKLIST: Mounting the main boom..............................................311 Prerequisites....................................................................311 Checklist........................................................................311 6.3.3 Slinging the main boom.........................................................313 Marking..........................................................................313 Installing the lifting gear......................................................313 Removing the lifting gear........................................................314 6.3.4 Retracting/fitting the derricking cylinder head pin............................315 Operating the lifting device.....................................................315 Retracting the derricking cylinder head axle.....................................316 Fitting the derricking cylinder head axle........................................317 6.3.5 Retracting/extending the boom pivot pin........................................318 Before retracting................................................................318 After extending..................................................................319 Retracting/ extending the pivot pin..............................................320 6.3.6 Disconnecting/connecting hydraulics/electrical.................................321 Detachment.......................................................................321 Establishing.....................................................................322 6.3.7 Lifting the main boom off/on the turntable.....................................323 Lifting from the turntable.......................................................323 Lifting on to the turntable......................................................324 6.3.8 Aligning the connecting points.................................................324 6.3.9 Transporting the main boom.....................................................325 6.3.10 Inspections after main boom mounting..........................................326 6.4 Installing/removing outrigger beams..................................................327 6.4.1 CHECKLIST: Removing the outrigger beams........................................328 6.4.2 CHECKLIST: Installing the outrigger beams......................................330 6.4.3 Preparing the truck crane......................................................332 Prerequisites....................................................................332 For removal......................................................................332 6.4.4 Removing/attaching outrigger pads..............................................333 Removing the outrigger pads......................................................333 Attaching the outrigger pads.....................................................334 6.4.5 Disconnecting/establishing the hydraulic connection............................335 6.4.6 Disconnecting/establishing the electrical connection...........................336 6.4.7 Unscrewing/screwing in the spacers.............................................337 Unscrewing.......................................................................337 Screwing in......................................................................338 6.4.8 Disconnecting/establishing the connections to the outrigger box................339 6.4.9 Extending/retracting the outrigger beam........................................339 Extending the outrigger beam.....................................................339 Inserting the outrigger beam.....................................................341 6.4.10 Transporting the outrigger beams..............................................343 6.5 Rigging the auxiliary hoist..........................................................345 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................345 Prerequisites....................................................................345 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................347 Prerequisites....................................................................347 6.5.3 Slinging the auxiliary hoist...................................................349 6.5.4 Slinging the rigging frame.....................................................349 6.5.5 Lowering/raising the rigging frame.............................................350 Prerequisite.....................................................................350 6.5.6 Placing the auxiliary hoist on the counterweight combination...................350 6.5.7 Establishing/disconnecting the hydraulic connection............................351 6.5.8 Making/breaking the electrical connection......................................352 6.5.9 Creating the connection to the turntable.......................................353 Establishing the connection......................................................353 Disconnecting....................................................................355 6.5.10 Securing the hoist rope.......................................................356 6.5.11 Transporting the auxiliary hoist..............................................357 6.5.12 Check that the auxiliary hoist is functioning properly........................358 Slewing direction................................................................358 Slewing indicator................................................................358 7 Malfunctions in driving mode...............................................................361 7.1 Emergency stop switch................................................................361 7.2 What to do when a malfunction occurs in road traffic.................................363 7.3 Towing the truck crane...............................................................365 7.3.1 Towing after engine/transmission damage........................................366 Compressed-air supply............................................................366 Electric power supply............................................................367 On the transmission..............................................................367 Axle drives......................................................................368 Parking brake....................................................................368 Towing the truck crane out of the danger area....................................369 7.3.2 Tow starting...................................................................369 7.4 Other emergency operations...........................................................371 7.4.1 Externally starting the truck crane............................................371 7.4.2 Battery charger................................................................372 Prerequisites....................................................................372 7.5 Wheels and tyres.....................................................................373 7.5.1 Wheel change...................................................................373 Removing a damaged wheel.........................................................374 On the spare wheel holder........................................................374 Mounting a wheel.................................................................375 7.5.2 Inflating the tyres yourself...................................................377 Connecting the filling hose......................................................377 Inflating the tyres..............................................................378 Removing the filling hose........................................................378 7.6 Fuses................................................................................379 Notes on changing fuses..............................................................379 7.6.1 Fuses in the driver's cab......................................................380 Group F1.........................................................................380 Group F2.........................................................................381 Group F3.........................................................................381 Group F4.........................................................................382 Other fuses......................................................................382 Group F7.........................................................................383 Group F8.........................................................................383 Group F9.........................................................................384 Group F10........................................................................384 7.6.2 Fuses in the battery box.......................................................385 7.7 Troubleshooting......................................................................387 7.7.1 Malfunctions on the engine.....................................................387 7.7.2 Faults on the AdBlue (DEF) system..............................................389 7.7.3 Malfunctions in the transmission...............................................390 7.7.4 Malfunctions of the service brake..............................................391 7.7.5 Malfunctions of the steering...................................................392 7.7.6 Differential lock malfunctions.................................................393 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................393 7.7.8 Malfunctions on the suspension.................................................394 7.7.9 Malfunctions of the level adjustment system....................................394 7.7.10 Malfunction in the CCS control unit...........................................394 7.8 Warnings in the start menu...........................................................395 Symbols in the display area..........................................................395 7.8.1 Engine/transmission error menu.................................................400 Open menu........................................................................400 Exiting the menu.................................................................400 7.9 Procedure in the event of malfunctions...............................................401 7.9.1 Procedure during engine malfunctions...........................................401 7.9.2 Procedure during transmission malfunctions.....................................402 8 Index......................................................................................405 A........................................................................................407 B........................................................................................407 C........................................................................................408 D........................................................................................411 E........................................................................................412 F........................................................................................414 H........................................................................................414 I........................................................................................415 K........................................................................................415 L........................................................................................415 M........................................................................................416 O........................................................................................417 P........................................................................................418 R........................................................................................418 S........................................................................................420 T........................................................................................421 V........................................................................................423 W........................................................................................423 Part 2 – Crane operation.........................................................................427 Additonal pages .............................................................................429 Additional page GMK – Reduction of slewing speed.........................................429 1 Reduction of slewing speed – can be switched on and off............................429 1.1 Important notes..............................................................429 With reduction switched on...................................................429 With reduction switched off..................................................429 1.2 Operation....................................................................430 1.2.1 Additional and modified operating elements.............................430 1.2.2 Switching reduction off and on.........................................431 CCS display..............................................................................433 Menu changes.........................................................................433 Start menus......................................................................433 Displays for the counterweight...................................................434 Slewing gear freewheel...................................................................437 CCS – Datalogger.........................................................................439 Additional menu and program..........................................................439 Additional menu..................................................................439 Export data......................................................................440 Display the data.................................................................440 Slewable spotlights......................................................................445 Automatic load tracking..............................................................445 Hoist rope travel limitation.............................................................447 Hoist rope travel limitation menu....................................................448 Entering values......................................................................449 Switching monitoring function on/off.................................................449 Driving with rigged truck crane..........................................................451 Counterweight............................................................................453 Setting down the base plate..........................................................453 Adjustable head sheave...................................................................455 Different positions depending on the reeving.........................................455 Main boom intermediate lengths ..........................................................457 Derricking cylinder pressure monitoring..............................................457 Telescoping emergency programe...........................................................467 Anemometer display .....................................................................461 Extended function....................................................................461 Rigging the special outrigger span.......................................................463 For removal/installation of the rear outrigger cylinders.............................463 Rigging the outrigger span.......................................................463 Information......................................................................465 Note on error messages...........................................................466 Telescoping emergency programme.......................................................... 0 Return run of the telescoping cylinder............................................... 0 9 Operating elements for crane operation.....................................................473 9.1 Overview of the operating elements...................................................473 9.1.1 Exterior of the truck crane....................................................474 9.1.2 Crane cab......................................................................478 Side panel.......................................................................480 Crane cab, rear..................................................................482 9.1.3 Control panels.................................................................484 Left.............................................................................484 Right............................................................................485 9.1.4 Control lever configuration....................................................486 Version 1........................................................................486 Version 2........................................................................487 9.1.5 Control unit CCS...............................................................488 9.1.6 CCS – Start menu...............................................................491 9.1.7 CCS – overview of menu groups..................................................492 Superstructure menu group........................................................496 Superstructure lock menu.........................................................497 Counterweight menu...............................................................498 Outrigger menu...................................................................499 Outrigger support beam menu......................................................501 Outrigger cylinders menu.........................................................502 Teleautomation menu group........................................................504 Telescoping full automation menu.................................................505 Telescoping semiautomation menu.................................................506 Main boom configuration menu.....................................................507 Active working range limiter menu group..........................................508 Overall height menu..............................................................509 Working radius menu..............................................................510 Slewing angle menu...............................................................511 Information menu group...........................................................512 Hydraulic pressure and fuel consumption menu.....................................513 Engine/Driving menu group........................................................514 Economy menu.....................................................................515 Heating/ airconditioning menu...................................................516 Telescoping menu group...........................................................517 Manual telescoping menu..........................................................518 Telescoping emergency program menu...............................................519 Unknown telescoping menu.........................................................520 Settings menu group..............................................................521 Crane cab menu...................................................................522 Menu for setting the display brightness and date/time............................523 Switch units menu................................................................524 Set control lever characteristic curve menu......................................525 Power unit speeds menu...........................................................526 Menu group Information...........................................................527 Operating hours menu.............................................................528 Engine/ transmission error menu..................................................530 Crane operation error menu.......................................................531 Program version menu.............................................................532 Operating additional equipment...................................................533 9.1.8 Control unit RCL...............................................................534 9.1.9 RCL – menu groups..............................................................536 Menu for entering rigging mode...................................................539 Monitoring menu..................................................................540 Lifting capacity tables menu.....................................................542 9.1.10 Hand-held controls............................................................543 Outrigger control panel..........................................................544 9.1.11 Outrigger control units.......................................................546 Button...........................................................................546 Outrigger button.................................................................547 Inclination and outrigger pressure display.......................................548 Raise axle display...............................................................549 9.2 Short description of the operating elements..........................................551 9.2.1 Definition of direction information............................................551 Basic rule.......................................................................551 Switches.........................................................................551 9.2.2 General rules for buttons and symbols on the display...........................552 9.2.3 Engine.........................................................................553 Side panel.......................................................................553 Economy menu.....................................................................554 9.2.4 AdBlue (DEF) system............................................................555 CCS display......................................................................555 9.2.5 Seat contact switch and dead man's switch......................................556 9.2.6 Crane control CCS..............................................................557 9.2.7 Outrigger......................................................................563 Hand-held control................................................................563 Right-hand control panel.........................................................564 Left-hand control panel..........................................................564 In the Outrigger menu............................................................565 On the outrigger control units...................................................567 9.2.8 Inclination indicators.........................................................569 9.2.9 Raise axle.....................................................................570 Outrigger control units..........................................................570 9.2.10 Outrigger pressure displays...................................................572 Outriggers submenu...............................................................572 Outrigger control units..........................................................572 9.2.11 Anemometer displays...........................................................572 9.2.12 Counterweight menu............................................................573 Counterweight submenu............................................................573 9.2.13 Main hoist....................................................................577 Control panels...................................................................577 CCS display......................................................................578 9.2.14 Auxiliary hoist...............................................................579 Control panels...................................................................579 CCS display......................................................................580 9.2.15 Slewing gear..................................................................581 Control panels...................................................................581 CCS display......................................................................582 9.2.16 Derricking gear...............................................................583 Control panels...................................................................583 CCS display......................................................................584 9.2.17 Telescoping mechanism.........................................................585 Control panels...................................................................585 CCS display......................................................................585 Telescoping full automation menu.................................................586 Telescoping semiautomation menu.................................................587 Manual telescoping menu..........................................................589 Main boom configuration menu.....................................................592 9.2.18 Hydraulic system..............................................................593 9.2.19 Superstructure lock/Houselock menu............................................594 Superstructure lock..............................................................594 Houselock........................................................................595 9.2.20 Rated capacity limiter (RCL)..................................................596 Control unit control console RCL.................................................596 Display RCL......................................................................597 Enter rigging mode menu..........................................................599 Monitoring menu..................................................................602 Lifting capacity tables menu.....................................................606 RCL override.....................................................................606 External displays................................................................607 9.2.21 Electrical system.............................................................609 9.2.22 Lighting, windscreen wiper/washing system.....................................609 Lighting.........................................................................609 Windscreen wiper/washing system..................................................610 9.2.23 Hand-held control.............................................................612 Sockets for handheld control....................................................612 Engine control panel.............................................................613 Horn.............................................................................613 Outrigger control panel..........................................................614 9.2.24 Windows, doors, keys..........................................................616 Windows..........................................................................616 Rear window......................................................................616 Crane cab door...................................................................617 Keys.............................................................................618 9.2.25 Diagnostics...................................................................618 10 Starting/turning off the engine – for crane operation.....................................621 10.1 When starting the engine for the first time of the day..............................621 10.1.1 Checking the fuel level and AdBlue (DEF) level................................622 Fuel.............................................................................622 AdBlue (DEF).....................................................................622 10.1.2 Checks before starting the engine.............................................623 On hydraulic tank................................................................623 Checking the hand-held control...................................................624 10.1.3 Switching on the ignition.....................................................624 10.1.4 Display – setting the brightness..............................................625 10.1.5 Starting the engine...........................................................626 10.1.6 Checks after starting the engine..............................................627 10.1.7 Setting idling speed..........................................................628 10.2 Starting the engine – with the hand-held control....................................629 Prerequisites........................................................................629 Starting the engine..................................................................629 10.3 Turning off the engine..............................................................631 10.3.1 During normal operation, with the ignition lock/with the handheld control....631 After turning off................................................................631 10.3.2 In emergencies, with the emergency stop switches..............................632 Resetting the emergency stop switch..............................................632 11 Crane operation...........................................................................635 11.1 Before operating the crane..........................................................635 11.1.1 CHECKLIST: Checks before operating the crane..................................635 11.1.2 Checking the condition of the truck crane.....................................639 Fuel tank auxiliary heater.......................................................639 Visual inspection................................................................639 Checking the position of the hoist ropes.........................................640 Checking the electrical system...................................................641 11.1.3 Adjusting the crane cab seat and front control panel..........................642 Crane cab seat...................................................................642 Front panel......................................................................642 11.1.4 Checking the safety equipment.................................................643 Rated capacity limiter...........................................................643 Lifting limit switch.............................................................643 Emergency stop switch............................................................644 Seat contact switch..............................................................645 11.1.5 Earthing the load.............................................................646 11.1.6 Preheating the hydraulic oil..................................................647 Prerequisites....................................................................647 Preheating.......................................................................647 11.1.7 Locking/unlocking the superstructure..........................................648 Locking points...................................................................648 Locking the superstructure.......................................................649 Unlocking the superstructure.....................................................649 11.1.8 Switching the Houselock on/off................................................650 Switching on the Houselock.......................................................650 Switching off the Houselock......................................................652 11.2 Operation of the rated capacity limiter.............................................653 11.2.1 Switch on the RCL.............................................................654 Switching on.....................................................................654 Brightness of the displays.......................................................656 Temperature on the display.......................................................656 11.2.2 Enter rigging mode............................................................657 Entering individual components...................................................658 Entering the RCL code............................................................662 Entering the reeving.............................................................663 Accepting the rigging mode.......................................................663 11.2.3 Checks before operating the crane.............................................665 Open menu........................................................................665 Checks...........................................................................665 11.2.4 Displays during crane operation...............................................668 11.2.5 RCL early warning.............................................................671 11.2.6 RCL switch-off................................................................671 Shutdown due to overload.........................................................671 11.2.7 Display in the event of errors................................................673 11.2.8 RCL override..................................................................674 Overview status display..........................................................674 When rigging.....................................................................675 To raise the boom................................................................676 In emergencies...................................................................677 11.2.9 Displaying the lifting capacity tables........................................678 11.2.10 Setting the time/date........................................................680 11.3 Crane operation with main boom......................................................681 11.3.1 Checks during crane operation.................................................681 Horizontal alignment.............................................................681 Safe distances...................................................................681 Checking the wind speed..........................................................682 11.3.2 Permissible slewing ranges and working positions..............................683 360 slewing range...............................................................683 0 to the rear working position..................................................683 180 to the front rigging position...............................................683 11.3.3 Main hoist....................................................................684 Switching on the main hoist......................................................685 Lifting and lowering.............................................................685 Maximum permissible hoist rope speed.............................................686 Switching off the main hoist.....................................................687 11.3.4 Auxiliary hoist...............................................................688 Switching on the auxiliary hoist.................................................688 Lifting and lowering.............................................................689 Maximum permissible hoist rope speed.............................................689 Switching off the auxiliary hoist................................................690 11.3.5 Lifting limit switch and lowering limit switch................................691 Lifting limit switch.............................................................691 Lowering limit switch............................................................693 11.3.6 Derricking gear...............................................................694 Switching on the derricking gear.................................................694 Maximum permissible derricking speed.............................................694 Raising and lowering.............................................................695 Re-enable raising function.......................................................696 Switching off the derricking gear................................................696 11.3.7 Telescoping mechanism.........................................................698 Overview.........................................................................699 Telescoping process..............................................................699 Assignment for display...........................................................702 Fixed length, intermediate length, telescoping length............................703 Telescoping......................................................................704 Telescoping sequence.............................................................704 Checks before starting work......................................................705 Switching on the telescoping mechanism...........................................706 Function of the control lever....................................................706 Switching off the telescoping mechanism..........................................708 Manual telescoping...............................................................709 Checking the initial position....................................................709 Unlocking the telescoping cylinder...............................................711 Extending/ retracting the telescoping cylinder...................................713 Lock telescoping cylinder........................................................714 Unlocking the telescopic section.................................................715 Telescoping the telescopic section...............................................716 Locking the telescopic section...................................................717 Locking the telescopic section for on-road driving...............................718 Telescoping with semi-automation.................................................718 Telescoping with full automation.................................................721 Telescoping with main boom configuration.........................................722 11.3.8 High-speed mode...............................................................723 Derricking gear/ telescoping mechanism...........................................723 Hoists...........................................................................724 11.3.9 Slewing gear..................................................................725 Switching on the slewing gear....................................................725 Turning..........................................................................726 Releasing locked slewing gear....................................................726 Maximum permissible slewing speed................................................727 Braking the slewing movement.....................................................728 Releasing the slewing gear brake.................................................728 Engaging the slewing gear brake..................................................728 Slewing gear freewheel...........................................................729 Switching off the slewing gear...................................................729 11.3.10 Possible movement combinations...............................................730 11.4 Settings and displays for crane operation...........................................731 11.4.1 Inclining the crane cab.......................................................731 11.4.2 Setting idling speed..........................................................732 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................732 11.4.4 Limiting the power unit speeds................................................733 11.4.5 Setting/switching on Economy mode.............................................734 Automatic........................................................................734 Manual...........................................................................734 11.4.6 Switching units...............................................................735 11.4.7 Setting the characteristic curves for the control levers......................736 11.4.8 Using the slewable spotlights.................................................737 11.4.9 Override torque reduction.....................................................738 11.4.10 Displaying the operating hours...............................................739 11.4.11 Warnings in the start menu...................................................740 Meaning of the symbols...........................................................740 11.5 Working range limiter...............................................................743 11.5.1 Viewing current settings......................................................744 11.5.2 Opening the working range limiter menu........................................745 11.5.3 Entering limit values.........................................................747 Overall height...................................................................747 Working radius...................................................................748 Slewing angle....................................................................748 11.5.4 Entering limit values manually................................................750 Limit values.....................................................................750 11.5.5 Switching monitoring functions on/off.........................................752 11.5.6 Shutdown by working range limiter.............................................753 11.6 Work break..........................................................................755 11.6.1 In case of short work breaks..................................................755 11.6.2 In case of work breaks of more than 8 hours...................................756 To secure the truck crane........................................................756 11.7 Heating and air-conditioning system.................................................757 11.7.1 Standard heating system.......................................................757 Switching on.....................................................................757 Heating..........................................................................757 Air distribution.................................................................757 Switching off....................................................................758 11.7.2 Air-conditioning system.......................................................759 Information......................................................................759 Switching on/off.................................................................759 Cooling, automatic...............................................................760 Cooling, maximum.................................................................760 11.7.3 Auxiliary heater..............................................................761 Switching on.....................................................................761 Setting the temperature..........................................................762 Setting the heating start/ heating duration......................................762 Switching heating start on/off...................................................763 11.8 CraneSTAR system....................................................................764 11.8.1 Overview......................................................................764 11.8.2 Position of the components....................................................764 12 Rigging work..............................................................................767 12.1 Rigging work checklists for crane operation with the main boom......................767 12.1.1 CHECKLIST: Rigging............................................................767 12.1.2 CHECKLIST: Unrigging..........................................................771 12.2 Choosing a suitable site............................................................775 12.2.1 Determining the required ground bearing area..................................775 12.2.2 Safe distance from slopes and pits............................................778 12.2.3 Earthing the truck crane......................................................779 12.2.4 Safe distance from electrical cables..........................................780 12.3 Rigging work after driving with a trailer...........................................783 12.3.1 Switching off the boom floating position......................................783 12.3.2 Switching off the slewing gear freewheel......................................784 Before slewing...................................................................784 12.3.3 Switching off boom pre-tensioning.............................................785 12.4 Connecting/disconnecting the hand-held control......................................787 12.5 Starting the engine for driving for rigging work....................................789 12.5.1 Starting/turning off the engine with the hand-held control....................789 Prerequisites....................................................................789 Starting the engine..............................................................790 Turning off the engine...........................................................790 12.5.2 Starting/turning off the engine from the outrigger control units..............791 Prerequisites....................................................................791 Starting the engine..............................................................791 Turning off the engine...........................................................791 12.6 Outrigger...........................................................................793 12.6.1 CHECKLIST: Extending the outriggers...........................................793 12.6.2 CHECKLIST: Retracting the outriggers..........................................795 12.6.3 Permissible outrigger spans...................................................796 12.6.4 Preparing the truck crane.....................................................797 In the driver's cab..............................................................797 Outrigger control units..........................................................797 12.6.5 Setting the outrigger spans...................................................798 For on-road driving..............................................................800 12.6.6 Extending/retracting outrigger beams..........................................801 From the control units...........................................................802 With the handheld control.......................................................803 From the crane cab...............................................................805 12.6.7 Moving the outrigger pads into working/driving position.......................807 12.6.8 Enlarging the ground bearing area.............................................808 12.6.9 Extending/retracting supporting cylinders.....................................809 From the control units...........................................................810 With the handheld control.......................................................811 From the crane cab...............................................................812 12.6.10 Level the truck crane on outriggers..........................................814 Inclination indicators...........................................................814 Prerequisites....................................................................815 Manual alignment.................................................................816 Automatic alignment..............................................................817 12.6.11 Levelling the free-on-wheels truck crane.....................................819 12.6.12 Outrigger pressure display...................................................821 12.7 Rigging/unrigging the counterweight.................................................823 12.7.1 Counterweight sections........................................................823 12.7.2 Identification................................................................824 12.7.3 Slinging points on the counterweight sections.................................825 12.7.4 CHECKLIST: Rigging the counterweight..........................................826 12.7.5 CHECKLIST: Unrigging the counterweight........................................827 12.7.6 Assembling counterweight combination..........................................829 12.7.7 Counterweight hoist unit......................................................837 Counterweight menu...............................................................837 Extending/ retracting the lifting cylinders......................................838 Automatic mode, rigging..........................................................839 Automatic mode, unrigging........................................................841 Cancel automatic mode............................................................842 12.7.8 Setting down counterweight for driving the truck crane........................843 12.7.9 Slewing with rigged counterweight.............................................845 12.8 Rigging work on the main boom.......................................................847 12.8.1 Hook block on the bumper......................................................847 Picking up the hook block........................................................847 Attaching the hook block.........................................................848 12.8.2 Hook block in the compartment.................................................849 Prerequisites....................................................................849 12.8.3 Hook block on a separate vehicle..............................................851 Picking up the hook block........................................................852 Setting down the hook block......................................................852 12.8.4 Hook block, separable.........................................................854 Rigging for onroad driving......................................................854 Rigging for crane operation......................................................855 12.8.5 Reeving and unreeving the hoist rope..........................................856 Version A........................................................................856 Version B........................................................................857 Reeving the hoist rope...........................................................859 Unreeving the hoist rope.........................................................862 12.8.6 Possible reeving methods on the main boom.....................................863 With 7 head sheaves..............................................................863 With 10 head sheaves.............................................................866 With 11 head sheaves.............................................................869 12.8.7 Installing/removing the lifting limit switch..................................870 Installing the lifting limit switch..............................................870 Removing the lifting limit switch................................................873 12.8.8 Locking/unlocking the lifting limit switch....................................875 Locking..........................................................................875 Releasing locking................................................................875 12.8.9 Anemometer and air traffic control light......................................876 Installing.......................................................................876 Switching the air traffic control light on and off...............................876 Removing.........................................................................877 For transport....................................................................877 12.9 Other rigging work..................................................................879 12.9.1 Railings on the turntable.....................................................879 12.9.2 Folding the lighting carrier in/out...........................................880 12.9.3 Safety harness on the main boom...............................................881 Prerequisites....................................................................882 Requirements.....................................................................882 Attaching/ detaching fall prevention safety system to/from safety harness........883 Inspecting/ replacing safety harness.............................................885 12.9.4 Slinging points for personal protective equipment.............................886 12.9.5 Cameras for crane operation...................................................887 Camera on the hoists.............................................................887 Camera on main boom..............................................................888 Operating the camera.............................................................890 12.9.6 Stair tread on the crane cab..................................................891 13 Driving with rigged truck crane...........................................................895 13.1 Driving path........................................................................895 13.2 Permissible rigging modes and axle loads............................................896 Axle load table......................................................................897 13.3 Before driving......................................................................898 13.3.1 Securing the superstructure against slewing...................................898 13.3.2 Checking tyre pressure and wind speed.........................................899 13.3.3 Putting the truck crane on the wheels.........................................900 13.3.4 Gears/connections.............................................................902 Transmission.....................................................................902 Switching on separate steering...................................................902 13.4 While driving.......................................................................902 13.5 After driving.......................................................................904 14 Transport.................................................................................907 14.1 Transport with transport vehicle....................................................907 14.1.1 CHECKLIST: Checks before transport............................................908 14.1.2 Drive the truck crane onto the transport vehicle..............................910 Drive on.........................................................................910 Lashing..........................................................................910 14.1.3 Slinging points...............................................................911 15 Malfunctions during crane operation.......................................................915 15.1 Emergency stop switch...............................................................915 15.2 What to do when a malfunction occurs during crane operation.........................917 Load can be lowered..................................................................917 Load cannot be lowered...............................................................917 15.3 Fuses in the crane cab..............................................................919 Notes on changing fuses..............................................................919 15.4 Finding and eliminating malfunctions................................................924 15.4.1 Malfunctions on the engine....................................................924 15.4.2 Malfunctions on the counterweight hoist unit..................................924 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................925 15.4.4 Malfunctions in the hoist cameras.............................................926 15.4.5 Malfunctions in the main boom camera..........................................926 15.4.6 Malfunctions on the derricking gear...........................................927 15.4.7 Malfunctions in the telescoping mechanism.....................................928 15.4.8 Malfunctions on the slewing gear..............................................930 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................931 15.4.10 Malfunctions when inclining the crane cab....................................931 15.4.11 Malfunctions when operating with the hand-held control.......................931 15.4.12 Malfunctions of the outriggers...............................................932 15.4.13 Malfunction in the CCS control unit..........................................932 15.4.14 Troubleshooting the crane control............................................933 General malfunctions.............................................................933 Symbols in the error or information display areas................................934 Displays in the Error menu.......................................................938 15.4.15 Malfunctions in the CraneSTAR system.........................................940 15.5 Emergency operations and programmes.................................................941 15.5.1 Mechanical emergency activation for retracting................................942 Prior to the emergency activation, check.........................................942 Procedure........................................................................942 Mechanical emergency activation..................................................943 15.5.2 Telescoping emergency programme...............................................945 Open submenu Emergency program...................................................945 Determining the error type.......................................................946 Error on length indicator........................................................947 Tables for approaching the locking points........................................951 15.5.3 Entering the current telescoping..............................................953 15.5.4 Emergency operation with the hand-held control................................955 Preparations.....................................................................955 Operating a power unit...........................................................956 Stopping movements...............................................................958 Stopping movements in emergencies................................................958 Turning off the engine...........................................................958 15.6 Hydraulic emergency operation.......................................................959 15.6.1 Connecting/disconnecting hoses................................................959 15.6.2 Establishing the required hydraulic circuits..................................960 Switching over valves............................................................960 For lowering.....................................................................961 15.6.3 Operating principle of emergency operation BGR 159............................963 15.6.4 Connecting/disconnecting hoses................................................964 Establishing connections.........................................................964 Disconnecting....................................................................965 15.6.5 Switching emergency operation on/off..........................................966 15.6.6 Establishing the hydraulic circuits required..................................967 Switching over valves............................................................967 For lifting/ lowering............................................................969 For slewing......................................................................970 15.6.7 Performing emergency operation................................................971 Turning..........................................................................971 Derricking.......................................................................972 Lifting/lowering.................................................................972 15.6.8 After emergency operation.....................................................973 Switching off emergency operation................................................973 Switching over to crane operation................................................973 Disconnecting the hoses..........................................................973 15.6.9 Emergency supply of another crane.............................................974 For emergency supply.............................................................974 After emergency supply...........................................................974 16 Index.....................................................................................977 A........................................................................................979 B........................................................................................979 C........................................................................................980 D........................................................................................983 E........................................................................................984 F........................................................................................986 H........................................................................................986 I........................................................................................987 K........................................................................................987 L........................................................................................987 M........................................................................................988 O........................................................................................989 P........................................................................................990 R........................................................................................990 S........................................................................................992 T........................................................................................993 V........................................................................................995 W........................................................................................995
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