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Grove Crane GMK 5250L Driving Operating Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 5250L Driving Operating Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250L Driving Operating Manual – PDF DOWNLOAD
Language : English
Pages : 942
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250L Driving Operating Manual – PDF DOWNLOAD
Basic safety instructions:
2.1 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 – PDF DOWNLOAD
Additional pages ............................................................................ 7 Driving with rigged truck crane.......................................................... 3 Adjustable head sheave................................................................... 1 Anemometer display ...................................................................... 7 Telescoping emergency programme ......................................................... 9 Main boom intermediate lengths .......................................................... 11 Setting down the base plate.............................................................. 13 1 Overview................................................................................... 19 1.1 Accidents............................................................................ 19 1.2 Branch offices....................................................................... 21 1.2.1 Manitowoc Crane Care........................................................... 21 1.2.2 Dealer list.................................................................... 21 1.3 Warranty specifications.............................................................. 21 1.4 Terms used........................................................................... 22 1.5 Technical data....................................................................... 25 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 25 1.5.2 Maximum lifting capacity (ASME B 30.5)......................................... 25 1.5.3 Dimensions and weights of the truck crane, axle loads.......................... 26 Dimensions....................................................................... 27 Weight and axle loads............................................................ 27 1.5.4 Dimensions and weights of removable parts...................................... 28 Spare wheel...................................................................... 28 Outriggers....................................................................... 28 Main boom........................................................................ 29 Hook blocks and hook tackle...................................................... 29 hook blocks, split............................................................... 30 Auxiliary hoist.................................................................. 31 Counterweight parts.............................................................. 31 1.5.5 Carrier........................................................................ 32 Engine........................................................................... 32 Transmission..................................................................... 32 Transfer case.................................................................... 32 Axle lines....................................................................... 32 Steering......................................................................... 32 Tyres............................................................................ 33 Electrical system................................................................ 33 Tool............................................................................. 33 Towing couplings................................................................. 33 Driving speeds................................................................... 33 Climbing ability................................................................. 33 Outriggers....................................................................... 34 Turning radii.................................................................... 35 1.5.6 Superstructure................................................................. 36 Main hoist....................................................................... 36 Auxiliary hoist.................................................................. 36 Slewing gears.................................................................... 36 Derricking gear.................................................................. 36 Main boom........................................................................ 37 Lattice extension................................................................ 37 Operating speeds................................................................. 37 Noise emission................................................................... 37 1.6 Documentation supplied............................................................... 39 1.6.1 Questions on documentation..................................................... 40 1.7 Notes on the operating manual........................................................ 41 1.7.1 What do the symbols used mean?................................................. 41 1.7.2 How is the operating manual structured?........................................ 43 Division......................................................................... 43 Structure of the chapters........................................................ 43 Structure of the pages........................................................... 44 1.7.3 How do I find the information I need?.......................................... 45 Cross-references example......................................................... 46 1.7.4 What information is available for operations planning?......................... 48 1.8 Conversion table for US measuring units.............................................. 49 1.9 Training – Information............................................................... 51 1.10 Identification...................................................................... 52 1.11 EC Declaration of Conformity........................................................ 54 2 Basic safety instructions.................................................................. 57 2.1 Intended use......................................................................... 57 2.1.1 Improper use................................................................... 58 2.2 Organisational measures.............................................................. 59 2.3 Personnel qualifications............................................................. 61 2.4 Safety instructions for driving the truck crane...................................... 62 2.5 Safety instructions for crane operation.............................................. 63 2.6 Notes on transporting persons........................................................ 65 Equipment for lifting persons........................................................ 65 Personnel............................................................................ 65 Operation............................................................................ 66 Truck crane.......................................................................... 67 3 Operating elements for driving............................................................. 71 3.1 Overview of the operating elements................................................... 71 3.1.1 On the outside of the truck crane.............................................. 72 3.1.2 Cab............................................................................ 76 Overview......................................................................... 76 Behind the cover................................................................. 80 In the rear of the driver's cab.................................................. 80 3.1.3 Instrument panel............................................................... 81 Left/right....................................................................... 81 Middle........................................................................... 82 On-board computer time correction................................................ 84 3.1.4 On-board computer.............................................................. 85 3.1.5 Steering column/steering wheel................................................. 86 3.1.6 Transmission operating elements................................................ 87 3.1.7 Tachograph..................................................................... 88 3.1.8 Control unit CCS............................................................... 89 3.1.9 Display CCS – start menu....................................................... 90 3.1.10 CCS – overview of menu groups................................................. 92 Carrier menu group............................................................... 94 Suspension/level adjustment menu................................................. 95 Driving menu..................................................................... 96 Settings menu group.............................................................. 97 Menu for setting the display brightness and date/time............................ 98 Information menu group........................................................... 99 Operating hours menu.............................................................100 Engine/ transmission error menu..................................................101 Crane operation error menu.......................................................102 Operating additional equipment...................................................103 3.1.11 Outrigger control units.......................................................104 3.1.12 Heating/Air-conditioning system...............................................105 Standard heating system..........................................................105 Auxiliary water heater...........................................................106 Auxiliary air heater.............................................................107 3.1.13 Sockets for hand-held control.................................................108 3.1.14 Outrigger control units.......................................................109 3.2 Short description of the operating elements..........................................111 3.2.1 Definition of direction information............................................112 Basic rule.......................................................................112 Switches and buttons.............................................................112 3.2.2 General rules for buttons and symbols on the display...........................113 3.2.3 Engine.........................................................................114 Steering column..................................................................114 On the steering wheel............................................................114 Instrument panel.................................................................115 3.2.4 AdBlue system (DEF)............................................................116 Instrument panel.................................................................116 CCS display......................................................................117 3.2.5 Battery master switch..........................................................117 3.2.6 Electrical system..............................................................118 3.2.7 Crane control CCS..............................................................119 3.2.8 Transmission...................................................................123 Transmission control unit........................................................123 Display, driving mode,...........................................................124 3.2.9 Reverse camera.................................................................126 3.2.10 Final drive...................................................................127 3.2.11 Brakes........................................................................129 Service brake....................................................................129 Additional brakes................................................................129 Parking brake....................................................................130 3.2.12 Steering/separate steering....................................................132 Instrument panel.................................................................132 CCS display......................................................................133 Driver's door....................................................................134 3.2.13 Suspension....................................................................135 CCS display......................................................................135 Outrigger control units..........................................................135 3.2.14 Lighting/windscreen wipers/horn...............................................136 Steering column..................................................................136 Steering wheel...................................................................136 Instrument panel.................................................................136 CCS display......................................................................138 Roof.............................................................................139 3.2.15 Level adjustment system.......................................................140 3.2.16 Tachograph/speedometer........................................................142 Tachograph.......................................................................142 Speedometer......................................................................142 3.2.17 Diagnostics...................................................................143 3.2.18 On-board computer.............................................................144 3.2.19 Windows, doors, keys..........................................................146 Window winder....................................................................146 Doors............................................................................147 Keys.............................................................................147 3.2.20 Front flap....................................................................148 4 Starting/turning off the engine for driving................................................151 4.1 Starting the engine from the driver's cab............................................151 4.1.1 CHECKLIST: Starting the engine.................................................151 4.1.2 CHECKLIST: At low temperatures.................................................154 4.1.3 Ladders and access ladders.....................................................154 Access ladders...................................................................154 Ladders..........................................................................155 4.1.4 Refuel.........................................................................157 Standard tank....................................................................157 Dual tank........................................................................158 AdBlue...........................................................................159 4.1.5 Checks before starting the engine..............................................160 On hydraulic tank................................................................160 Battery master switch............................................................161 Checking the hand-held control...................................................161 4.1.6 Switching on the ignition......................................................161 4.1.7 Lamp test/equalisation of the switching states.................................162 Lamp test........................................................................162 Switching state alignment........................................................162 4.1.8 Display – setting the brightness...............................................163 4.1.9 Starting the engine............................................................164 4.1.10 Checks after starting the engine..............................................166 Checking in the main menu........................................................166 Indicator lamps on the instrument panel..........................................167 4.1.11 Monitoring elements...........................................................169 Instrument panel.................................................................169 4.1.12 Start menu....................................................................170 4.1.13 Setting idling speed..........................................................171 4.2 Turning off the engine...............................................................173 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.....173 After turning off................................................................173 4.2.2 Using the emergency stop switches..............................................174 Resetting the emergency stop switch..............................................174 4.3 Air intake inhibitor.................................................................175 Releasing the air intake inhibitor...................................................175 5 Driving....................................................................................179 5.1 Before driving.......................................................................179 5.1.1 CHECKLIST: Checks before on-road driving.......................................179 5.1.2 Checking the condition of the truck crane......................................185 Electrical system................................................................185 Adjusting the mirrors............................................................185 Warning plates for vehicle width.................................................187 Displaying vehicle height........................................................187 Supply pressure..................................................................188 Parking brake....................................................................189 5.1.3 Adjusting the seat and the steering column.....................................190 Driver's seat....................................................................190 Passenger's seat.................................................................191 Steering column, adjusting.......................................................192 5.1.4 Switching the suspension on/off................................................193 Open menu........................................................................193 Switching on the suspension......................................................194 Switching off the suspension.....................................................194 5.1.5 Setting the tachograph.........................................................195 Prerequisites....................................................................195 In the event of malfunctions.....................................................195 Setting the tachograph...........................................................196 5.1.6 Entering the time/date.........................................................200 5.1.7 Displaying and resetting operating hours.......................................201 5.2 Operating the transmission...........................................................203 5.2.1 Switching on...................................................................203 5.2.2 Switching the transmission to neutral position.................................204 5.2.3 Selecting the direction of travel and starting gear............................205 Selecting the driving direction..................................................205 Selecting the starting gear......................................................206 5.2.4 Changing the operating mode....................................................207 Changing to automatic mode.......................................................207 Change to manual mode............................................................207 5.2.5 Starting.......................................................................208 5.2.6 Driving and changing gears.....................................................209 In automatic operating mode......................................................209 In manual operating mode.........................................................210 5.2.7 Changing the driving direction.................................................211 5.2.8 Stopping.......................................................................211 Stopping for along period oftime...............................................211 5.2.9 On the roller type dynamometer.................................................212 5.2.10 Preheating transmission.......................................................212 5.3 Driving and turning off the truck crane..............................................213 5.3.1 Checks while driving...........................................................213 Immediately after you start to move..............................................213 While driving....................................................................215 5.3.2 Cruise control.................................................................216 Switching on.....................................................................216 Switching off....................................................................217 5.3.3 Temposet.......................................................................218 Switching on.....................................................................218 Switching off....................................................................218 5.3.4 Driving downhill...............................................................219 Starting.........................................................................219 Inspections when driving downhill................................................220 Downshifting.....................................................................220 Additional brakes................................................................221 5.3.5 Driving uphill.................................................................222 Starting.........................................................................222 Driving..........................................................................222 5.3.6 Warning messages in the start menu.............................................223 5.3.7 Warning or malfunction messages on the instrument panel........................224 Meaning of the lamps.............................................................224 5.3.8 Messages on the on-board computer display......................................225 5.3.9 Indicator lights in the on-board computer display..............................227 5.3.10 Override torque reduction.....................................................229 5.3.11 Turning off the truck crane...................................................230 Securing against rolling away....................................................230 When stationary for more than 8 hours............................................231 5.3.12 Folding berth.................................................................232 5.4 Off-road driving.....................................................................233 Adjustments to the transmission......................................................233 Connections..........................................................................233 Changing the vehicle level...........................................................233 Rocking the vehicle free and towing..................................................233 5.4.1 Longitudinal and transverse differential locks.................................234 5.4.2 Operating the level adjustment system..........................................236 Open menu........................................................................236 Setting the onroad level........................................................237 Pre-selecting suspension struts..................................................237 Changing the vehicle level.......................................................238 Viewing the current inclination..................................................238 Exiting the menu.................................................................239 5.4.3 Freeing truck crane stuck in terrain...........................................240 Rocking the truck crane free.....................................................240 Towing free forwards.............................................................241 Towing free in reverse gear......................................................241 5.5 Separate steering....................................................................243 5.5.1 Switching to separate steering.................................................243 Manual...........................................................................244 Automatic........................................................................245 5.6 Heating and air-conditioning system..................................................247 5.6.1 Standard heating system,.......................................................247 Switching on.....................................................................247 Heating..........................................................................247 Air distribution.................................................................248 Examples.........................................................................249 Switching off....................................................................249 5.6.2 Air-conditioning system........................................................250 Information......................................................................250 Switching on/off.................................................................250 Cooling..........................................................................251 Drying...........................................................................251 5.6.3 Auxiliary water heater.........................................................252 Preheating the engine............................................................252 Preheating the driver's cab......................................................253 Switching on the auxiliary heater................................................254 Switching off the auxiliary heater...............................................255 Setting time and weekday.........................................................255 Saving automatic heating start...................................................256 Setting the heating period.......................................................257 Switching the automatic heating start on and off.................................257 Setting the remaining time.......................................................258 5.6.4 Auxiliary air heater...........................................................259 Switching on.....................................................................259 Temperature......................................................................260 Switching off....................................................................260 Other functions..................................................................260 5.7 Towing a trailer.....................................................................261 Effects on the axle loads............................................................261 Coupling the trailer.................................................................262 Connecting the supply lines..........................................................263 Removing the supply lines............................................................264 Uncoupling the trailer...............................................................264 Checking the braking force...........................................................266 6 Driving modes and rigging for on-road driving..............................................269 6.1 Driving modes........................................................................269 Information about the axle loads.....................................................269 6.1.1 Information on how to use the tables...........................................270 6.1.2 Tables for a maximum axle load of 12t (26,500lbs)............................271 For 385/95 R25 tyres.............................................................271 For 445/95 R25 525/80 R25 tyres..................................................272 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)...........273 6.2 Rigging work for driving with a trailer..............................................274 6.2.1 Switching on the slewing gear freewheel........................................275 6.2.2 Switching on the boom floating position........................................276 6.2.3 Switching on boom pre-tensioning...............................................277 6.3 Main boom, removing/installing.......................................................278 Additional equipment required........................................................278 6.3.1 CHECKLIST: Removing the main boom..............................................279 Prerequisites....................................................................279 Checklist........................................................................279 6.3.2 CHECKLIST: Mounting the main boom..............................................281 Prerequisites....................................................................281 Checklist........................................................................281 6.3.3 Slinging the main boom.........................................................283 Marking..........................................................................283 Installing the lifting gear......................................................283 Removing the lifting gear........................................................284 6.3.4 Retracting/fitting the derricking cylinder head pin............................285 Operating the lifting device.....................................................285 Retracting the derricking cylinder head axle.....................................286 Fitting the derricking cylinder head axle........................................287 6.3.5 Retracting/extending the boom pivot pin........................................288 Before retracting................................................................288 After extending..................................................................289 Retracting/ extending the pivot pin..............................................290 6.3.6 Disconnecting/connecting hydraulics/electrical.................................291 Detachment.......................................................................291 Establishing.....................................................................292 6.3.7 Lifting the main boom off/on the turntable.....................................293 Lifting from the turntable.......................................................293 Lifting on to the turntable......................................................294 6.3.8 Aligning the connecting points.................................................294 6.3.9 Transporting the main boom.....................................................295 6.3.10 Inspections after main boom mounting..........................................296 6.4 Installing/removing outrigger beams..................................................297 6.4.1 CHECKLIST: Removing the outrigger beams........................................298 6.4.2 CHECKLIST: Installing the outrigger beams......................................300 6.4.3 Preparing the truck crane......................................................302 Prerequisites....................................................................302 For removal......................................................................302 6.4.4 Removing/attaching outrigger pads..............................................303 Removing the outrigger pads......................................................303 Attaching the outrigger pads.....................................................304 6.4.5 Disconnecting/establishing the hydraulic connection............................305 6.4.6 Disconnecting/establishing the electrical connection...........................306 6.4.7 Unscrewing/screwing in the spacers.............................................307 Unscrewing.......................................................................307 Screwing in......................................................................308 6.4.8 Disconnecting/establishing the connections to the outrigger box................309 6.4.9 Extending/retracting the outrigger beam........................................309 Extending the outrigger beam.....................................................309 Inserting the outrigger beam.....................................................311 6.4.10 Transporting the outrigger beams..............................................313 6.5 Rigging the auxiliary hoist..........................................................315 6.5.1 CHECKLIST: Installing the auxiliary hoist......................................315 Prerequisites....................................................................315 6.5.2 CHECKLIST: Removing the auxiliary hoist........................................317 Prerequisites....................................................................317 6.5.3 Slinging the auxiliary hoist...................................................319 6.5.4 Slinging the rigging frame.....................................................319 6.5.5 Lowering/raising the rigging frame.............................................320 Prerequisite.....................................................................320 6.5.6 Placing the auxiliary hoist on the counterweight combination...................320 6.5.7 Establishing/disconnecting the hydraulic connection............................321 6.5.8 Making/breaking the electrical connection......................................322 6.5.9 Creating the connection to the turntable.......................................323 Establishing the connection......................................................323 Disconnecting....................................................................325 6.5.10 Securing the hoist rope.......................................................326 6.5.11 Transporting the auxiliary hoist..............................................327 6.5.12 Check that the auxiliary hoist is functioning properly........................328 Slewing direction................................................................328 Slewing indicator................................................................328 7 Malfunctions in driving mode...............................................................331 7.1 Emergency stop switch................................................................331 7.2 What to do when a malfunction occurs in road traffic.................................333 7.3 Towing the truck crane...............................................................335 7.3.1 Towing after engine/transmission damage........................................336 Compressed-air supply............................................................336 Electric power supply............................................................337 On the transmission..............................................................337 Axle drives......................................................................338 Parking brake....................................................................338 Towing the truck crane out of the danger area....................................339 7.3.2 Tow starting...................................................................339 7.4 Other emergency operations...........................................................341 7.4.1 Externally starting the truck crane............................................341 7.4.2 Battery charger................................................................342 Prerequisites....................................................................342 7.5 Wheels and tyres.....................................................................343 7.5.1 Wheel change...................................................................343 Removing a damaged wheel.........................................................344 On the spare wheel holder........................................................344 Mounting a wheel.................................................................345 7.5.2 Inflating the tyres yourself...................................................347 Connecting the filling hose......................................................347 Inflating the tyres..............................................................348 Removing the filling hose........................................................348 7.6 Fuses................................................................................349 Notes on changing fuses..............................................................349 7.6.1 Fuses in the driver's cab......................................................350 Group F1.........................................................................350 Group F2.........................................................................351 Group F3.........................................................................351 Group F4.........................................................................352 Other fuses......................................................................352 Group F7.........................................................................353 Group F8.........................................................................353 Group F9.........................................................................354 Group F10........................................................................354 7.6.2 Fuses in the battery box.......................................................355 7.7 Troubleshooting......................................................................357 7.7.1 Malfunctions on the engine.....................................................357 7.7.2 Faults on the AdBlue (DEF) system..............................................359 7.7.3 Malfunctions in the transmission...............................................360 7.7.4 Malfunctions of the service brake..............................................361 7.7.5 Malfunctions of the steering...................................................362 7.7.6 Differential lock malfunctions.................................................363 7.7.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................363 7.7.8 Malfunctions on the suspension.................................................364 7.7.9 Malfunctions of the level adjustment system....................................364 7.7.10 Malfunction in the CCS control unit...........................................364 7.8 Warnings in the start menu...........................................................365 Symbols in the display area..........................................................365 7.8.1 Engine/transmission error menu.................................................370 Open menu........................................................................370 Exiting the menu.................................................................370 7.9 Procedure in the event of malfunctions...............................................371 7.9.1 Procedure during engine malfunctions...........................................371 7.9.2 Procedure during transmission malfunctions.....................................372 8 Index......................................................................................375 A........................................................................................377 B........................................................................................377 C........................................................................................378 D........................................................................................381 E........................................................................................382 F........................................................................................384 H........................................................................................384 I........................................................................................385 K........................................................................................385 L........................................................................................385 M........................................................................................386 O........................................................................................387 P........................................................................................388 R........................................................................................388 S........................................................................................390 T........................................................................................391 V........................................................................................393 W........................................................................................393 Additonal pages .............................................................................403 Driving with rigged truck crane..........................................................399 Adjustable head sheave...................................................................401 Anemometer display .....................................................................403 Telescoping emergency programme .........................................................405 Main boom intermediate lengths ..........................................................407 Setting down the base plate..............................................................411 9 Operating elements for crane operation.....................................................417 9.1 Overview of the operating elements...................................................417 9.1.1 Exterior of the truck crane....................................................418 9.1.2 Crane cab......................................................................422 Side panel.......................................................................424 Crane cab, rear..................................................................426 9.1.3 Control panels.................................................................428 Left.............................................................................428 Right............................................................................429 9.1.4 Control lever configuration....................................................430 Version 1........................................................................430 Version 2........................................................................431 9.1.5 Control unit CCS...............................................................432 9.1.6 CCS – Start menu...............................................................435 9.1.7 CCS – overview of menu groups..................................................436 Superstructure menu group........................................................440 Superstructure lock menu.........................................................441 Counterweight menu...............................................................442 Outrigger menu...................................................................443 Outrigger support beam menu......................................................445 Outrigger cylinders menu.........................................................446 Teleautomation menu group........................................................448 Telescoping full automation menu.................................................449 Telescoping semiautomation menu.................................................450 Main boom configuration menu.....................................................451 Active working range limiter menu group..........................................452 Overall height menu..............................................................453 Working radius menu..............................................................454 Slewing angle menu...............................................................455 Information menu group...........................................................456 Hydraulic pressure and fuel consumption menu.....................................457 Engine/Driving menu group........................................................458 Economy menu.....................................................................459 Heating/ airconditioning menu...................................................460 Telescoping menu group...........................................................461 Manual telescoping menu..........................................................462 Telescoping emergency program menu...............................................463 Unknown telescoping menu.........................................................464 Settings menu group..............................................................465 Crane cab menu...................................................................466 Menu for setting the display brightness and date/time............................467 Switch units menu................................................................468 Set control lever characteristic curve menu......................................469 Power unit speeds menu...........................................................470 Menu group Information...........................................................471 Operating hours menu.............................................................472 Engine/ transmission error menu..................................................474 Crane operation error menu.......................................................475 Program version menu.............................................................476 Operating additional equipment...................................................477 9.1.8 Control unit RCL...............................................................478 9.1.9 RCL – menu groups..............................................................480 Menu for entering rigging mode...................................................483 Monitoring menu..................................................................484 Lifting capacity tables menu.....................................................486 9.1.10 Hand-held controls............................................................487 Outrigger control panel..........................................................488 9.1.11 Outrigger control units.......................................................490 Button...........................................................................490 Outrigger button.................................................................491 Inclination and outrigger pressure display.......................................492 Raise axle display...............................................................493 9.2 Short description of the operating elements..........................................495 9.2.1 Definition of direction information............................................495 Basic rule.......................................................................495 Switches.........................................................................495 9.2.2 General rules for buttons and symbols on the display...........................496 9.2.3 Engine.........................................................................497 Side panel.......................................................................497 Economy menu.....................................................................498 9.2.4 AdBlue (DEF) system............................................................499 CCS display......................................................................499 9.2.5 Seat contact switch and dead man's switch......................................500 9.2.6 Crane control CCS..............................................................501 9.2.7 Outrigger......................................................................507 Hand-held control................................................................507 Right-hand control panel.........................................................508 Left-hand control panel..........................................................508 In the Outrigger menu............................................................509 On the outrigger control units...................................................511 9.2.8 Inclination indicators.........................................................513 9.2.9 Raise axle.....................................................................514 Outrigger control units..........................................................514 9.2.10 Outrigger pressure displays...................................................516 Outriggers submenu...............................................................516 Outrigger control units..........................................................516 9.2.11 Anemometer displays...........................................................516 9.2.12 Counterweight menu............................................................517 Counterweight submenu............................................................517 9.2.13 Main hoist....................................................................521 Control panels...................................................................521 CCS display......................................................................522 9.2.14 Auxiliary hoist...............................................................523 Control panels...................................................................523 CCS display......................................................................524 9.2.15 Slewing gear..................................................................525 Control panels...................................................................525 CCS display......................................................................526 9.2.16 Derricking gear...............................................................527 Control panels...................................................................527 CCS display......................................................................528 9.2.17 Telescoping mechanism.........................................................529 Control panels...................................................................529 CCS display......................................................................529 Telescoping full automation menu.................................................530 Telescoping semiautomation menu.................................................531 Manual telescoping menu..........................................................533 Main boom configuration menu.....................................................536 9.2.18 Hydraulic system..............................................................537 9.2.19 Superstructure lock/Houselock menu............................................538 Superstructure lock..............................................................538 Houselock........................................................................539 9.2.20 Rated capacity limiter (RCL)..................................................540 Control unit control console RCL.................................................540 Display RCL......................................................................541 Enter rigging mode menu..........................................................543 Monitoring menu..................................................................546 Lifting capacity tables menu.....................................................550 RCL override.....................................................................550 External displays................................................................551 9.2.21 Electrical system.............................................................553 9.2.22 Lighting, windscreen wiper/washing system.....................................553 Lighting.........................................................................553 Windscreen wiper/washing system..................................................554 9.2.23 Hand-held control.............................................................556 Sockets for handheld control....................................................556 Engine control panel.............................................................557 Horn.............................................................................557 Outrigger control panel..........................................................558 9.2.24 Windows, doors, keys..........................................................560 Windows..........................................................................560 Rear window......................................................................560 Crane cab door...................................................................561 Keys.............................................................................562 9.2.25 Diagnostics...................................................................562 10 Starting/turning off the engine – for crane operation.....................................565 10.1 When starting the engine for the first time of the day..............................565 10.1.1 Checking the fuel level and AdBlue (DEF) level................................566 Fuel.............................................................................566 AdBlue (DEF).....................................................................566 10.1.2 Checks before starting the engine.............................................567 On hydraulic tank................................................................567 Checking the hand-held control...................................................568 10.1.3 Switching on the ignition.....................................................568 10.1.4 Display – setting the brightness..............................................569 10.1.5 Starting the engine...........................................................570 10.1.6 Checks after starting the engine..............................................571 10.1.7 Setting idling speed..........................................................572 10.2 Starting the engine – with the hand-held control....................................573 Prerequisites........................................................................573 Starting the engine..................................................................573 10.3 Turning off the engine..............................................................575 10.3.1 During normal operation, with the ignition lock/with the handheld control....575 After turning off................................................................575 10.3.2 In emergencies, with the emergency stop switches..............................576 Resetting the emergency stop switch..............................................576 11 Crane operation...........................................................................579 11.1 Before operating the crane..........................................................579 11.1.1 CHECKLIST: Checks before operating the crane..................................579 11.1.2 Checking the condition of the truck crane.....................................583 Fuel tank auxiliary heater.......................................................583 Visual inspection................................................................583 Checking the position of the hoist ropes.........................................584 Checking the electrical system...................................................585 11.1.3 Adjusting the crane cab seat and front control panel..........................586 Crane cab seat...................................................................586 Front panel......................................................................586 11.1.4 Checking the safety equipment.................................................587 Rated capacity limiter...........................................................587 Lifting limit switch.............................................................587 Emergency stop switch............................................................588 Seat contact switch..............................................................589 11.1.5 Earthing the load.............................................................590 11.1.6 Preheating the hydraulic oil..................................................591 Prerequisites....................................................................591 Preheating.......................................................................591 11.1.7 Locking/unlocking the superstructure..........................................592 Locking points...................................................................592 Locking the superstructure.......................................................593 Unlocking the superstructure.....................................................593 11.1.8 Switching the Houselock on/off................................................594 Switching on the Houselock.......................................................594 Switching off the Houselock......................................................596 11.2 Operation of the rated capacity limiter.............................................597 11.2.1 Switch on the RCL.............................................................598 Switching on.....................................................................598 Brightness of the displays.......................................................600 Temperature on the display.......................................................600 11.2.2 Enter rigging mode............................................................601 Entering individual components...................................................602 Entering the RCL code............................................................606 Entering the reeving.............................................................607 Accepting the rigging mode.......................................................607 11.2.3 Checks before operating the crane.............................................609 Open menu........................................................................609 Checks...........................................................................609 11.2.4 Displays during crane operation...............................................612 11.2.5 RCL early warning.............................................................615 11.2.6 RCL switch-off................................................................615 Shutdown due to overload.........................................................615 11.2.7 Display in the event of errors................................................617 11.2.8 RCL override..................................................................618 Overview status display..........................................................618 When rigging.....................................................................619 To raise the boom................................................................620 In emergencies...................................................................621 11.2.9 Displaying the lifting capacity tables........................................622 11.2.10 Setting the time/date........................................................624 11.3 Crane operation with main boom......................................................625 11.3.1 Checks during crane operation.................................................625 Horizontal alignment.............................................................625 Safe distances...................................................................625 Checking the wind speed..........................................................626 11.3.2 Permissible slewing ranges and working positions..............................627 360 slewing range...............................................................627 0 to the rear working position..................................................627 180 to the front rigging position...............................................627 11.3.3 Main hoist....................................................................628 Switching on the main hoist......................................................629 Lifting and lowering.............................................................629 Maximum permissible hoist rope speed.............................................630 Switching off the main hoist.....................................................631 11.3.4 Auxiliary hoist...............................................................632 Switching on the auxiliary hoist.................................................632 Lifting and lowering.............................................................633 Maximum permissible hoist rope speed.............................................633 Switching off the auxiliary hoist................................................634 11.3.5 Lifting limit switch and lowering limit switch................................635 Lifting limit switch.............................................................635 Lowering limit switch............................................................637 11.3.6 Derricking gear...............................................................638 Switching on the derricking gear.................................................638 Maximum permissible derricking speed.............................................638 Raising and lowering.............................................................639 Re-enable raising function.......................................................640 Switching off the derricking gear................................................640 11.3.7 Telescoping mechanism.........................................................642 Overview.........................................................................643 Telescoping process..............................................................643 Assignment for display...........................................................646 Fixed length, intermediate length, telescoping length............................647 Telescoping......................................................................648 Telescoping sequence.............................................................648 Checks before starting work......................................................649 Switching on the telescoping mechanism...........................................650 Function of the control lever....................................................650 Switching off the telescoping mechanism..........................................652 Manual telescoping...............................................................653 Checking the initial position....................................................653 Unlocking the telescoping cylinder...............................................655 Extending/ retracting the telescoping cylinder...................................657 Lock telescoping cylinder........................................................658 Unlocking the telescopic section.................................................659 Telescoping the telescopic section...............................................660 Locking the telescopic section...................................................661 Locking the telescopic section for on-road driving...............................662 Telescoping with semi-automation.................................................662 Telescoping with full automation.................................................665 Telescoping with main boom configuration.........................................666 11.3.8 High-speed mode...............................................................667 Derricking gear/ telescoping mechanism...........................................667 Hoists...........................................................................668 11.3.9 Slewing gear..................................................................669 Switching on the slewing gear....................................................669 Turning..........................................................................670 Releasing locked slewing gear....................................................670 Maximum permissible slewing speed................................................671 Braking the slewing movement.....................................................672 Releasing the slewing gear brake.................................................672 Engaging the slewing gear brake..................................................672 Slewing gear freewheel...........................................................673 Switching off the slewing gear...................................................673 11.3.10 Possible movement combinations...............................................674 11.4 Settings and displays for crane operation...........................................675 11.4.1 Inclining the crane cab.......................................................675 11.4.2 Setting idling speed..........................................................676 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................676 11.4.4 Limiting the power unit speeds................................................677 11.4.5 Setting/switching on Economy mode.............................................678 Automatic........................................................................678 Manual...........................................................................678 11.4.6 Switching units...............................................................679 11.4.7 Setting the characteristic curves for the control levers......................680 11.4.8 Using the slewable spotlights.................................................681 11.4.9 Override torque reduction.....................................................682 11.4.10 Displaying the operating hours...............................................683 11.4.11 Warnings in the start menu...................................................684 Meaning of the symbols...........................................................684 11.5 Working range limiter...............................................................687 11.5.1 Viewing current settings......................................................688 11.5.2 Opening the working range limiter menu........................................689 11.5.3 Entering limit values.........................................................691 Overall height...................................................................691 Working radius...................................................................692 Slewing angle....................................................................692 11.5.4 Entering limit values manually................................................694 Limit values.....................................................................694 11.5.5 Switching monitoring functions on/off.........................................696 11.5.6 Shutdown by working range limiter.............................................697 11.6 Work break..........................................................................699 11.6.1 In case of short work breaks..................................................699 11.6.2 In case of work breaks of more than 8 hours...................................700 To secure the truck crane........................................................700 11.7 Heating and air-conditioning system.................................................701 11.7.1 Standard heating system.......................................................701 Switching on.....................................................................701 Heating..........................................................................701 Air distribution.................................................................701 Switching off....................................................................702 11.7.2 Air-conditioning system.......................................................703 Information......................................................................703 Switching on/off.................................................................703 Cooling, automatic...............................................................704 Cooling, maximum.................................................................704 11.7.3 Auxiliary heater..............................................................705 Switching on.....................................................................705 Setting the temperature..........................................................706 Setting the heating start/ heating duration......................................706 Switching heating start on/off...................................................707 11.8 CraneSTAR system....................................................................708 11.8.1 Overview......................................................................708 11.8.2 Position of the components....................................................708 12 Rigging work..............................................................................711 12.1 Rigging work checklists for crane operation with the main boom......................711 12.1.1 CHECKLIST: Rigging............................................................711 12.1.2 CHECKLIST: Unrigging..........................................................715 12.2 Choosing a suitable site............................................................719 12.2.1 Determining the required ground bearing area..................................719 12.2.2 Safe distance from slopes and pits............................................722 12.2.3 Earthing the truck crane......................................................723 12.2.4 Safe distance from electrical cables..........................................724 12.3 Rigging work after driving with a trailer...........................................727 12.3.1 Switching off the boom floating position......................................727 12.3.2 Switching off the slewing gear freewheel......................................728 Before slewing...................................................................728 12.3.3 Switching off boom pre-tensioning.............................................729 12.4 Connecting/disconnecting the hand-held control......................................731 12.5 Starting the engine for driving for rigging work....................................733 12.5.1 Starting/turning off the engine with the hand-held control....................733 Prerequisites....................................................................733 Starting the engine..............................................................734 Turning off the engine...........................................................734 12.5.2 Starting/turning off the engine from the outrigger control units..............735 Prerequisites....................................................................735 Starting the engine..............................................................735 Turning off the engine...........................................................735 12.6 Outrigger...........................................................................737 12.6.1 CHECKLIST: Extending the outriggers...........................................737 12.6.2 CHECKLIST: Retracting the outriggers..........................................739 12.6.3 Permissible outrigger spans...................................................740 12.6.4 Preparing the truck crane.....................................................741 In the driver's cab..............................................................741 Outrigger control units..........................................................741 12.6.5 Setting the outrigger spans...................................................742 For on-road driving..............................................................744 12.6.6 Extending/retracting outrigger beams..........................................745 From the control units...........................................................746 With the handheld control.......................................................747 From the crane cab...............................................................749 12.6.7 Moving the outrigger pads into working/driving position.......................751 12.6.8 Enlarging the ground bearing area.............................................752 12.6.9 Extending/retracting supporting cylinders.....................................753 From the control units...........................................................754 With the handheld control.......................................................755 From the crane cab...............................................................756 12.6.10 Level the truck crane on outriggers..........................................758 Inclination indicators...........................................................758 Prerequisites....................................................................759 Manual alignment.................................................................760 Automatic alignment..............................................................761 12.6.11 Levelling the free-on-wheels truck crane.....................................763 12.6.12 Outrigger pressure display...................................................765 12.7 Rigging/unrigging the counterweight.................................................767 12.7.1 Counterweight sections........................................................767 12.7.2 Identification................................................................768 12.7.3 Slinging points on the counterweight sections.................................769 12.7.4 CHECKLIST: Rigging the counterweight..........................................770 12.7.5 CHECKLIST: Unrigging the counterweight........................................771 12.7.6 Assembling counterweight combination..........................................773 12.7.7 Counterweight hoist unit......................................................781 Counterweight menu...............................................................781 Extending/ retracting the lifting cylinders......................................782 Automatic mode, rigging..........................................................783 Automatic mode, unrigging........................................................785 Cancel automatic mode............................................................786 12.7.8 Setting down counterweight for driving the truck crane........................787 12.7.9 Slewing with rigged counterweight.............................................789 12.8 Rigging work on the main boom.......................................................791 12.8.1 Hook block on the bumper......................................................791 Picking up the hook block........................................................791 Attaching the hook block.........................................................792 12.8.2 Hook block in the compartment.................................................793 Prerequisites....................................................................793 12.8.3 Hook block on a separate vehicle..............................................795 Picking up the hook block........................................................796 Setting down the hook block......................................................796 12.8.4 Hook block, separable.........................................................798 Rigging for onroad driving......................................................798 Rigging for crane operation......................................................799 12.8.5 Reeving and unreeving the hoist rope..........................................800 Version A........................................................................800 Version B........................................................................801 Reeving the hoist rope...........................................................803 Unreeving the hoist rope.........................................................806 12.8.6 Possible reeving methods on the main boom.....................................807 With 7 head sheaves..............................................................807 With 10 head sheaves.............................................................810 With 11 head sheaves.............................................................813 12.8.7 Installing/removing the lifting limit switch..................................814 Installing the lifting limit switch..............................................814 Removing the lifting limit switch................................................817 12.8.8 Locking/unlocking the lifting limit switch....................................819 Locking..........................................................................819 Releasing locking................................................................819 12.8.9 Anemometer and air traffic control light......................................820 Installing.......................................................................820 Switching the air traffic control light on and off...............................820 Removing.........................................................................821 For transport....................................................................821 12.9 Other rigging work..................................................................823 12.9.1 Railings on the turntable.....................................................823 12.9.2 Folding the lighting carrier in/out...........................................824 12.9.3 Safety harness on the main boom...............................................825 Prerequisites....................................................................826 Requirements.....................................................................826 Attaching/ detaching fall prevention safety system to/from safety harness........827 Inspecting/ replacing safety harness.............................................829 12.9.4 Slinging points for personal protective equipment.............................830 12.9.5 Cameras for crane operation...................................................831 Camera on the hoists.............................................................831 Camera on main boom..............................................................832 Operating the camera.............................................................834 12.9.6 Stair tread on the crane cab..................................................835 13 Driving with rigged truck crane...........................................................839 13.1 Driving path........................................................................839 13.2 Permissible rigging modes and axle loads............................................840 Axle load table......................................................................841 13.3 Before driving......................................................................842 13.3.1 Securing the superstructure against slewing...................................842 13.3.2 Checking tyre pressure and wind speed.........................................843 13.3.3 Putting the truck crane on the wheels.........................................844 13.3.4 Gears/connections.............................................................846 Transmission.....................................................................846 Switching on separate steering...................................................846 13.4 While driving.......................................................................846 13.5 After driving.......................................................................848 14 Transport.................................................................................851 14.1 Transport with transport vehicle....................................................851 14.1.1 CHECKLIST: Checks before transport............................................852 14.1.2 Drive the truck crane onto the transport vehicle..............................854 Drive on.........................................................................854 Lashing..........................................................................854 14.1.3 Slinging points...............................................................855 15 Malfunctions during crane operation.......................................................859 15.1 Emergency stop switch...............................................................859 15.2 What to do when a malfunction occurs during crane operation.........................861 Load can be lowered..................................................................861 Load cannot be lowered...............................................................861 15.3 Fuses in the crane cab..............................................................863 Notes on changing fuses..............................................................863 15.4 Finding and eliminating malfunctions................................................868 15.4.1 Malfunctions on the engine....................................................868 15.4.2 Malfunctions on the counterweight hoist unit..................................868 15.4.3 Malfunctions on the main hoist/auxiliary hoist................................869 15.4.4 Malfunctions in the hoist cameras.............................................870 15.4.5 Malfunctions in the main boom camera..........................................870 15.4.6 Malfunctions on the derricking gear...........................................871 15.4.7 Malfunctions in the telescoping mechanism.....................................872 15.4.8 Malfunctions on the slewing gear..............................................874 15.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................875 15.4.10 Malfunctions when inclining the crane cab....................................875 15.4.11 Malfunctions when operating with the hand-held control.......................875 15.4.12 Malfunctions of the outriggers...............................................876 15.4.13 Malfunction in the CCS control unit..........................................876 15.4.14 Troubleshooting the crane control............................................877 General malfunctions.............................................................877 Symbols in the error or information display areas................................878 Displays in the Error menu.......................................................882 15.4.15 Malfunctions in the CraneSTAR system.........................................884 15.5 Emergency operations and programmes.................................................885 15.5.1 Mechanical emergency activation for retracting................................886 Prior to the emergency activation, check.........................................886 Procedure........................................................................886 Mechanical emergency activation..................................................887 15.5.2 Telescoping emergency programme...............................................889 Open submenu Emergency program...................................................889 Determining the error type.......................................................890 Error on length indicator........................................................891 Tables for approaching the locking points........................................895 15.5.3 Entering the current telescoping..............................................897 15.5.4 Emergency operation with the hand-held control................................899 Preparations.....................................................................899 Operating a power unit...........................................................900 Stopping movements...............................................................902 Stopping movements in emergencies................................................902 Turning off the engine...........................................................902 15.6 Hydraulic emergency operation.......................................................903 15.6.1 Connecting/disconnecting hoses................................................903 15.6.2 Establishing the required hydraulic circuits..................................904 Switching over valves............................................................904 For lowering.....................................................................905 15.6.3 Operating principle of emergency operation BGR 159............................907 15.6.4 Connecting/disconnecting hoses................................................908 Establishing connections.........................................................908 Disconnecting....................................................................909 15.6.5 Switching emergency operation on/off..........................................910 15.6.6 Establishing the hydraulic circuits required..................................911 Switching over valves............................................................911 For lifting/ lowering............................................................913 For slewing......................................................................914 15.6.7 Performing emergency operation................................................915 Turning..........................................................................915 Derricking.......................................................................916 Lifting/lowering.................................................................916 15.6.8 After emergency operation.....................................................917 Switching off emergency operation................................................917 Switching over to crane operation................................................917 Disconnecting the hoses..........................................................917 15.6.9 Emergency supply of another crane.............................................918 For emergency supply.............................................................918 After emergency supply...........................................................918 16 Index.....................................................................................921 A........................................................................................923 B........................................................................................923 C........................................................................................924 D........................................................................................927 E........................................................................................928 F........................................................................................930 H........................................................................................930 I........................................................................................931 K........................................................................................931 L........................................................................................931 M........................................................................................932 O........................................................................................933 P........................................................................................934 R........................................................................................934 S........................................................................................936 T........................................................................................937 V........................................................................................939 W........................................................................................939
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