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GROVE Crane TMS9100-2 Operator Manual – PDF DOWNLOAD
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Description
GROVE Crane TMS9100-2 Operator Manual – PDF DOWNLOAD
FILE DETAILS:
GROVE Crane TMS9100-2 Operator Manual – PDF DOWNLOAD
Language : English
Pages : 404
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
GROVE Crane TMS9100-2 Operator Manual – PDF DOWNLOAD
GENERAL:
- This manual provides important information for the operator of the Model TMS9100-2 Series Grove
Crane. - The mobile crane carrier incorporates an all welded steel frame. The 8 x 4 x 4 carrier utilizes two
drive axles and two steer axles. Axle steering is provided by a power steering pump, and power
steering gear. The engine is mounted in the front of the carrier and provides power through an 11
speed forward and 3 speed reverse manual or optional automatic transmission. - Hydraulic, two-stage double box telescopic beam with jack cylinder outriggers are integral with the
carrier frame. The outriggers are utilized in four positions; fully extended, mid- extended,
partial extended, and fully retracted (100%, 79%, 57% and 0%). The carrier is also equipped with a
center front jack with a permanently installed pad. - The superstructure is capable of 360° rotation in either direction. All crane functions are
controlled from the fully enclosed cab. The crane is equipped with a 11.2 m to 51.6 m (36.7 to 169
ft) five section boom. - Lifting is provided by a main and auxiliary hoist. Swingaway hydraulically offsettable and manually
offsettable boom extensions are available. - It is impossible to compile a list of safety precautions covering all situations. However, there
are basic principles that must be followed during your daily routine. Safety is your primary
responsibility, since any piece of equipment is only as safe as the person at the controls. - Read and follow the information located in Model Specific Information near the end of this section.
This information has been provided to assist in promoting a safe working atmosphere for yourself
and those around you. It is not meant to cover every conceivable circumstance
which could arise. It is intended to present basic safety precautions that should be followed in
daily operation. - Because you are the only part of the crane that can think and reason, your responsibility is not
lessened by the addition of operational aids or warning devices. Indeed, you must guard against
acquiring a false sense of security when using them. They are there to assist, not direct the
operation. Operational aids or warning devices can be mechanical, electrical, electronic, or a
combination thereof. They are subject to failure or misuse and should not be relied upon in place
of good operating practices. - You are the only one who can be relied upon to assure the safety of yourself and those around you.
Be a professional and follow the rules of safety. - Remember, failure to follow just one safety precaution could cause an accident that results in
death or serious injury to personnel or damage to equipment. You are responsible for
the safety of yourself and those around you.
TABLE OF CONTENTS:
GROVE Crane TMS9100-2 Operator Manual – PDF DOWNLOAD
See end of this Manual for Alphabetical Index.................................................................................... 5 Introduction..................................................................................................................... 13 General...................................................................................................................... 13 Ambient Operation Temperature............................................................................................ 13 Customer Support......................................................................................................... 13 Safety Information................................................................................................... 13 New Owners........................................................................................................... 13 Safety Information............................................................................................................... 17 Safety Messages.............................................................................................................. 17 General.................................................................................................................. 17 Safety Alert Symbol...................................................................................................... 18 Signal Words............................................................................................................. 18 General...................................................................................................................... 18 Safety Decals............................................................................................................ 18 Accidents.................................................................................................................... 18 Operator Information......................................................................................................... 18 Operator Qualifications...................................................................................................... 19 Operational Aids............................................................................................................. 20 Rated Capacity Limiter (RCL) Systems (If Equipped)....................................................................... 20 Anti-Two-Blocking Device................................................................................................. 20 Working Area Limiter (If Equipped)....................................................................................... 21 Crane Stability/Structural Strength.......................................................................................... 22 Load Charts.............................................................................................................. 22 Work Site................................................................................................................ 22 Wind Forces.................................................................................................................. 23 Wind Speeds.............................................................................................................. 23 Determination of 3-second wind gust speed at boom tip height:........................................................ 26 Size and Shape of the load:.......................................................................................... 26 Determining Wind Drag Coefficient (Cd)............................................................................... 27 Maximum Permissible Wind Speed....................................................................................... 28 Example and Sample Calculations (metric)......................................................................... 30 Example 1: Crane Configuration:.................................................................................. 30 Load example 1.1:................................................................................................ 31 Load example 1.2:................................................................................................ 31 Load example 1.3a:............................................................................................... 31 Load example 1.3b:............................................................................................... 31 Example and Sample Calculations (Non-metric)......................................................................... 34 Example 2:....................................................................................................... 34 Load example 2.1:................................................................................................ 35 Load example 2.2:................................................................................................ 35 Load example 2.3a:............................................................................................... 35 Load example 2.3b:............................................................................................... 35 Lifting Operations....................................................................................................... 36 Counterweight............................................................................................................ 37 Outrigger Lift Off....................................................................................................... 37 Multiple Crane Lifts..................................................................................................... 37 Tilt-Up Panel Lifting.................................................................................................... 37 Pile Driving and Extracting.................................................................................................. 38 Crane Equipment.......................................................................................................... 38 Crane Inspection......................................................................................................... 38 Electrocution Hazard......................................................................................................... 39 Set-Up and Operation..................................................................................................... 40 Electrocution Hazard Devices............................................................................................. 40 Electrical Contact....................................................................................................... 41 Special Operating Conditions and Equipment............................................................................... 41 Grounding the Crane...................................................................................................... 41 Personnel Handling........................................................................................................... 42 Environmental Protection..................................................................................................... 43 Maintenance.................................................................................................................. 43 Service and Repairs...................................................................................................... 43 Lubrication.............................................................................................................. 44 Tires.................................................................................................................... 45 Hoist Rope................................................................................................................... 45 Synthetic Hoist Rope..................................................................................................... 45 Wire Rope................................................................................................................ 45 Sheaves.................................................................................................................. 46 Batteries................................................................................................................ 47 Super Capacitor (If Equipped)............................................................................................ 47 General Maintenance...................................................................................................... 47 Transporting the Crane....................................................................................................... 48 Travel Operation............................................................................................................. 48 Work Practices............................................................................................................... 49 Personal Considerations.................................................................................................. 49 Crane Access............................................................................................................. 49 Job Preparation.......................................................................................................... 49 Working.................................................................................................................. 50 Lifting.................................................................................................................. 51 Hand Signals............................................................................................................. 52 Boom Extension............................................................................................................... 54 Parking and Securing......................................................................................................... 54 Shut-Down.................................................................................................................... 54 Cold Weather Operation....................................................................................................... 54 Temperature Effects on Hook Blocks........................................................................................... 55 Temperature Effects on Hydraulic Cylinders................................................................................... 55 Overload Inspection.......................................................................................................... 56 Boom Inspection.......................................................................................................... 58 Superstructure Inspection................................................................................................ 60 Carrier Inspection....................................................................................................... 62 Operating Controls and Indicators................................................................................................ 65 Carrier Cab Controls and Indicators.......................................................................................... 67 Transmission Shift Lever................................................................................................. 68 Spare Switch/Indicator................................................................................................... 68 USB Ports................................................................................................................ 68 12 Volt Outlet........................................................................................................... 68 Fire Extinguisher........................................................................................................ 68 Horn Button.............................................................................................................. 68 Turn Signal/Headlight High Beam Low Beam Lever........................................................................... 68 Steering Column Tilt/Telescope Lever..................................................................................... 68 Cab Circulating Fan...................................................................................................... 68 Windshield Wiper and Washer.............................................................................................. 68 Camera Display........................................................................................................... 68 Dome Light............................................................................................................... 68 Air Horn................................................................................................................. 68 Throttle Pedal........................................................................................................... 68 Brake Pedal.............................................................................................................. 69 Clutch Pedal............................................................................................................. 69 Steering Wheel........................................................................................................... 69 Headlights Switch........................................................................................................ 70 Dimmer Switch............................................................................................................ 70 Beacon Light Switch (Optional)........................................................................................... 70 Engine Brake On/Off Switch............................................................................................... 70 Engine Brake High/Low Switch............................................................................................. 70 Exhaust System Cleaning Initiate Switch.................................................................................. 71 Engine Idle Increment/Decrement Switch................................................................................... 71 Remote Control On/Off Switch............................................................................................. 71 Remote Control Indicator................................................................................................. 71 ABS/ATC Switch........................................................................................................... 71 Hill Start Aid (HSA) Switch (Optional)................................................................................... 71 HSA Indicator (Optional)................................................................................................. 71 Inter-Axle Lock Switch................................................................................................... 71 Cross-Axle Lock Switch (Optional)........................................................................................ 71 Suspension Inflation Switch.............................................................................................. 71 Tire Inflation Switch.................................................................................................... 71 Heater/Air Conditioner Fan Switch........................................................................................ 71 Heater/Air Conditioner Control........................................................................................... 72 Heater/Air Conditioner Select Switch..................................................................................... 72 Ignition Switch.......................................................................................................... 72 Parking Brake Control.................................................................................................... 72 Dual Air Pressure Gauge.................................................................................................. 72 Trailing Boom Trailer Emergency Brake Control (Optional)................................................................. 72 Control Panel Indicator and Gauge Display................................................................................ 72 Control Panel Indicator and Gauge Display.................................................................................... 73 Cross-Axle Locked Indicator.............................................................................................. 73 Inter-axle Locked Indicator.............................................................................................. 74 Suspension Deflated Indicator............................................................................................ 74 Traction Control Indicator............................................................................................... 74 Tire Inflation On Indicator.............................................................................................. 74 Left Turn Signal Indicator............................................................................................... 74 Lights On Indicator...................................................................................................... 74 High Beam Indicator...................................................................................................... 74 Parking Brake Engaged Indicator.......................................................................................... 74 Battery Charge Indicator................................................................................................. 74 Low Air Pressure......................................................................................................... 74 Emergency Stop........................................................................................................... 74 Right Turn Signal Indicator.............................................................................................. 74 System Fault Indicator................................................................................................... 74 Anti-lock Braking System (ABS) Indicator................................................................................. 74 Check Transmission (Automated Transmission Only)......................................................................... 75 Malfunction Indicator Lamp............................................................................................... 75 Low Oil Pressure......................................................................................................... 75 Engine Stop Indicator.................................................................................................... 75 Engine Warning Indicator................................................................................................. 75 OK Button................................................................................................................ 75 Menu Button.............................................................................................................. 75 Fuel Gauge............................................................................................................... 75 Speedometer.............................................................................................................. 75 Low Fuel Level Indicator................................................................................................. 75 High Exhaust System Temperature.......................................................................................... 75 Engine Temperature Indicator............................................................................................. 76 Cruise Control........................................................................................................... 76 Engine Coolant Temperature Gauge......................................................................................... 76 Down Button.............................................................................................................. 76 Up Button................................................................................................................ 76 Tachometer............................................................................................................... 76 Exhaust System Cleaning.................................................................................................. 76 LCD Display.............................................................................................................. 76 Outrigger Controls and Indicators............................................................................................ 78 Outrigger Control Summary................................................................................................ 78 Outrigger Control Panel.................................................................................................. 78 Outrigger Beam Selector Switch....................................................................................... 78 Extend Switch........................................................................................................ 78 Center Front Jack Switch............................................................................................. 79 Jack Selector Switch................................................................................................. 79 Emergency Stop Switch................................................................................................ 79 Retract Switch....................................................................................................... 79 Power Indicator...................................................................................................... 79 Auto Switch.......................................................................................................... 79 Superstructure Cab........................................................................................................... 80 Superstructure cab....................................................................................................... 80 Side panel........................................................................................................... 82 Superstructure cab, rear............................................................................................. 83 Control panels........................................................................................................... 84 Left Hand Armrest Controls........................................................................................... 84 Right Hand Armrest Controls.......................................................................................... 85 Control levers........................................................................................................... 86 Heating system........................................................................................................... 87 Operator display module (ODM)/CCS control unit........................................................................... 88 CCS – Home screen........................................................................................................ 90 Alert Icons.............................................................................................................. 92 Short description of the operating elements of the crane control system...................................................... 93 Definition of direction information...................................................................................... 94 Basic rule........................................................................................................... 94 On the carrier....................................................................................................... 94 On the superstructure................................................................................................ 94 General rules for buttons and symbols on the display..................................................................... 94 Changing Menus....................................................................................................... 95 Crane Control System......................................................................................................... 95 Display CCS.............................................................................................................. 95 Warning message/error message display area........................................................................... 96 Open Error menu...................................................................................................... 96 Exiting the menu/input mode.......................................................................................... 96 Enter the values with jog dial....................................................................................... 96 Enter values on the control panel CCS................................................................................ 97 Input confirmation................................................................................................... 97 Other indicators on the ODM CCS display.............................................................................. 97 Display temperature sensor........................................................................................... 97 Emergency stop switch................................................................................................ 97 To switch displays................................................................................................... 97 Settings menu groups................................................................................................. 98 Menu for setting the time............................................................................................ 99 Switch units menu....................................................................................................101 Set control lever characteristic curve menu..........................................................................102 Power unit speeds menu...............................................................................................103 Operating hours menu.................................................................................................104 Displaying the operating hours...........................................................................................104 Displays.............................................................................................................104 Crane operation error menu...........................................................................................106 Software version menu................................................................................................107 CCS – Overview menu groups...............................................................................................108 Superstructure lock menu.............................................................................................110 Counterweight menu...................................................................................................111 Outrigger menu.......................................................................................................112 Telescoping semi-automation menu.....................................................................................114 Manual telescoping menu..............................................................................................115 ODM Working Range Limiter (WRL)......................................................................................115 WRL Overall height menu..............................................................................................118 WRL- Boom Angle Limits menu..........................................................................................120 WRL-Working radius menu..............................................................................................122 WRL-Swing angle menu.................................................................................................124 WRL-Virtual walls menu...............................................................................................126 Exhaust System Cleaning menu.........................................................................................128 Bi-fold Boom Extension menu..........................................................................................129 Telescoping emergency program............................................................................................129 Open Submenu Emergency program.......................................................................................130 Access telescoping emergency program menu........................................................................131 Determining the error type...........................................................................................132 Error on length indicator............................................................................................134 Checks before telescoping........................................................................................134 Retracting and locking a telescopic section..........................................................................135 Unlocking the telescoping cylinder...............................................................................136 Extending and locking the telescoping cylinder...................................................................137 Tables for approaching the locking points............................................................................137 Locking points for the telescoping cylinder......................................................................137 Locking points for the telescopic sections.......................................................................137 Telescoping cylinder boom nose switch................................................................................138 ODM error code viewer....................................................................................................139 RDM (RCL Display Module).................................................................................................140 Resetting the current telescoping........................................................................................142 Entering current telescope position values...........................................................................142 RCL – menu groups........................................................................................................144 Enter rigging mode menu..............................................................................................145 Monitoring menu......................................................................................................146 Outrigger rigging code verification..................................................................................148 Adjusting the wiper stroke interval of the windshield wiper..............................................................148 Display – setting the brightness.........................................................................................149 Setting the characteristic curves for the control levers.................................................................150 Crane Functions Speed Control............................................................................................150 Changing values......................................................................................................151 Operating the camera.....................................................................................................151 Switching the camera.................................................................................................151 Switching the boom position indicator light (optional equipment) on and off..............................................151 Engine...................................................................................................................152 Side panel...........................................................................................................152 Ignition lock....................................................................................................152 Set idling speed.................................................................................................152 Economy mode menu................................................................................................152 Seat contact switch and dead man's switches..............................................................................152 Enabling crane functions.............................................................................................153 Disabling crane functions............................................................................................153 Superstructure cab seat..............................................................................................153 Outriggers...............................................................................................................153 Right-hand control panel.............................................................................................153 Button for outrigger preselection................................................................................153 Left-hand control panel..............................................................................................153 Retracting/extending outrigger beams pre-selection...............................................................153 In the Outrigger menu................................................................................................153 Outrigger span display...........................................................................................153 Swing gear/movements locked display..............................................................................154 Parking brake/movements locked display...........................................................................154 Function for switching outriggers................................................................................154 Extend/retract outrigger beams...................................................................................155 Extend/retract outrigger jack cylinders..........................................................................155 Inclination indicator....................................................................................................156 Anemometer display.......................................................................................................156 Counterweight menu.......................................................................................................156 Counterweight locking display........................................................................................156 Locking/unlocking the counterweight..................................................................................157 Extending/retracting the lifting cylinders...........................................................................157 Pre-tensioning pressure display......................................................................................157 Main hoist...............................................................................................................157 Right control lever..................................................................................................158 Hoist high-speed mode on/off.........................................................................................158 Hoist Speed Range Selection..........................................................................................158 Hoist rotation indicator.............................................................................................158 CCS display..........................................................................................................158 Main Hoist Enable................................................................................................158 High speed mode for the hoist....................................................................................158 Lift/lower the hoist.............................................................................................159 Warning for lowering limit switch lockout........................................................................159 Hoist Limit Lockout Indication...................................................................................159 Auxiliary hoist..........................................................................................................159 Swing....................................................................................................................159 Control panels.......................................................................................................159 Swing enable.....................................................................................................159 Left control lever...............................................................................................159 Free swing button................................................................................................160 CCS display..........................................................................................................160 Swing crane function display.....................................................................................160 Swing brake applied/released.....................................................................................160 Lifting/Lowering mechanism...............................................................................................160 Control panels.......................................................................................................160 Lifting/lowering mechanism on/off................................................................................160 Right control lever..............................................................................................160 ODM display..........................................................................................................161 Lifting/lowering crane function display..........................................................................161 Boom up override switch..........................................................................................161 Telescoping mechanism....................................................................................................161 Control panels.......................................................................................................161 Telescoping enable switch........................................................................................161 Right control lever..............................................................................................161 Left control lever- Optional.....................................................................................161 Telescoping crane function display...............................................................................162 Telescoping semi-automation menu.....................................................................................162 Open menu........................................................................................................162 Telescope diagram display........................................................................................162 Telescoping cylinder length display..............................................................................162 Main boom length display.........................................................................................163 Telescopic sections display......................................................................................163 Current telescope status display.................................................................................163 Pre-selection for all telescopic sections........................................................................163 Pre-selection individual telescopic sections.....................................................................163 Teleautomation direction display.................................................................................163 Confirm pre-selection............................................................................................163 Manual telescoping menu..............................................................................................164 Telescoping cylinder locked/released.............................................................................164 Locking/releasing the telescoping cylinder.......................................................................164 Lock/release telescopic section indication.......................................................................164 Locking/releasing the telescopic section.........................................................................164 Telescoping cylinder length display..............................................................................165 Main boom length display.........................................................................................165 Telescoping section in the telescopic section display............................................................165 Telescoping direction display....................................................................................165 Hydraulic system.........................................................................................................165 Cab tilt.............................................................................................................165 Superstructure house lock menu...........................................................................................165 Swing gear display...................................................................................................166 360 Degree Swing Lock................................................................................................166 Locking status displays..........................................................................................166 360 Degree Swing Lock............................................................................................166 Remote control...............................................................................................................166 Remote control icon......................................................................................................166 Remote Control Operation.....................................................................................................167 Scope....................................................................................................................167 System Overview..........................................................................................................167 System Components........................................................................................................168 Remote Control Components................................................................................................170 Display Components.......................................................................................................171 Preparing for Remote Control Operation...................................................................................173 Operating Remote Control.................................................................................................174 Superstructure Horn..................................................................................................174 Emergency Stop.......................................................................................................174 Engine Start/Stop/Throttle...........................................................................................175 Starting/Stopping Engine.........................................................................................175 Changing Engine Speed............................................................................................175 Exiting Start/Stop/Throttle Screen...............................................................................175 Outrigger Beams......................................................................................................177 Outrigger Jacks......................................................................................................179 Hoist Control (Main and Aux).........................................................................................181 Boom Lift............................................................................................................183 Swing and 360° Swing Lock............................................................................................185 Swinging.........................................................................................................185 Operating 360° Swing Lock........................................................................................185 Exiting Swing/360° Swing Lock Screen.............................................................................185 OPT (options)........................................................................................................187 Luffing Boom Extension...........................................................................................187 Boom Extension Assist............................................................................................187 Counterweight....................................................................................................187 Exiting OPT Screen...............................................................................................187 Information..........................................................................................................188 Rated capacity limiter (RCL).............................................................................................188 Control unit control console.........................................................................................188 Exiting the menu/input mode......................................................................................188 Entering values..................................................................................................188 RCL Status Indicators............................................................................................188 Sensor for brightness............................................................................................188 Sensor for temperature...........................................................................................189 Display RCL..........................................................................................................189 After a standstill of up to 2 hours..............................................................................189 Enter rigging mode menu..............................................................................................189 Enter RCL code...................................................................................................189 Enter reeving....................................................................................................190 Enter outrigger span.............................................................................................190 Enter counterweight..............................................................................................190 Confirming the rigging mode......................................................................................191 Boom system entry................................................................................................191 Monitoring menu......................................................................................................191 Boom system setup display........................................................................................191 Counterweight display............................................................................................192 Outrigger span display...........................................................................................193 Display of the lattice extension offset angle....................................................................193 Current main boom angle display..................................................................................193 Current swing angle display......................................................................................193 Current load display.............................................................................................193 Maximum load display.............................................................................................193 Current degree of utilization display............................................................................194 GPL licensing screen.............................................................................................195 Exiting the menu.................................................................................................195 Limits Override......................................................................................................195 Hoist limits override............................................................................................196 External Limit Bypass Switch.....................................................................................196 External displays....................................................................................................196 Status display...................................................................................................196 Economy Mode.................................................................................................................196 Terminology..............................................................................................................197 Requirements.............................................................................................................197 Operation................................................................................................................198 Benefits.................................................................................................................198 Electrical system............................................................................................................198 Voltage monitoring warning...............................................................................................198 Sockets 12 V.............................................................................................................198 Lighting, windshield wiper/washing system....................................................................................199 Lighting.................................................................................................................199 Superstructure Cab Work Lights on/off................................................................................199 Boom Lights..........................................................................................................199 Rotating Boom Lights Control.........................................................................................199 Cab lighting.........................................................................................................199 Reading lamp.........................................................................................................199 Windshield wiper/washing system......................................................................................200 Windshield wiper on/off..........................................................................................200 Skylight wiper on/off............................................................................................200 Windshield/Skylight washing system...............................................................................200 Wiper stroke interval menu.......................................................................................200 Adjusting the wiper stroke interval..............................................................................200 Windows..................................................................................................................200 Open window (A)......................................................................................................200 Close window (B).....................................................................................................200 Rear window..........................................................................................................201 Opening..........................................................................................................201 Closing..........................................................................................................201 Superstructure cab door..................................................................................................201 From outside.........................................................................................................201 Unlock...........................................................................................................201 Lock.............................................................................................................201 Open/close.......................................................................................................201 Inside door operation............................................................................................202 CraneSTAR® system............................................................................................................202 Overview.................................................................................................................202 Position of the components...............................................................................................202 Operating Procedures.............................................................................................................205 Breaking-in A New Carrier....................................................................................................206 Pre-Starting Checks..........................................................................................................206 Fuel Supply..............................................................................................................206 Engine Oil...............................................................................................................206 DEF Fluid Level..........................................................................................................206 Engine Coolant...........................................................................................................207 Batteries................................................................................................................207 Hydraulic Reservoir and Filter...........................................................................................207 Wire Rope................................................................................................................207 Hook Block and Headache Ball.............................................................................................207 Seats....................................................................................................................207 Seat Belts...............................................................................................................207 Seat Belt Maintenance................................................................................................207 Cleaning Seat Belt Webbing...........................................................................................207 Signal and Running Lights................................................................................................207 Service and Parking Brakes...............................................................................................207 Tires....................................................................................................................207 Wheels...................................................................................................................207 Other Equipment..........................................................................................................207 Daily Lubrication........................................................................................................207 Cold Weather Operation.......................................................................................................207 Derated capacities for each °F below -40°F...............................................................................208 Derated capacities for each °C below -40°C...............................................................................208 Crane Warm-up Procedures.....................................................................................................208 Engine...................................................................................................................209 Transmission.............................................................................................................209 Hoist....................................................................................................................209 Swing Drive and Turntable Bearing........................................................................................209 Axles....................................................................................................................209 Hydraulic Oil System.....................................................................................................209 Heating and ventilating the superstructure Cab...............................................................................210 Heating system...........................................................................................................210 Switching on.........................................................................................................210 Heating System Manual Operation..........................................................................................211 Temperature..........................................................................................................211 To increase the temperature......................................................................................211 To reduce the temperature........................................................................................211 Fan..................................................................................................................211 Increasing the air volume........................................................................................211 Reducing the air volume..........................................................................................211 Fresh air/recirculated air...........................................................................................212 Fresh air........................................................................................................212 Recirculated air.................................................................................................212 Air distribution.....................................................................................................212 Air vents on the windshield and in the center....................................................................212 Air vents on the cab floor.......................................................................................212 All air vents....................................................................................................212 Adjusting the air vents..........................................................................................212 Heating System Automatic Operation.......................................................................................213 Setting the day and time.............................................................................................213 Storing the heating start............................................................................................213 Setting the heating period...........................................................................................213 Switching the heating start on and off...............................................................................214 Switching off........................................................................................................214 Setting the remaining time...........................................................................................214 Air-conditioning system..................................................................................................214 Switching on.........................................................................................................214 Operation............................................................................................................215 Drying the air.......................................................................................................215 Switching off........................................................................................................215 Anti-Lock Brake System (ABS).................................................................................................215 ABS Power-Up Sequence....................................................................................................216 ABS Switch Operation.....................................................................................................216 Automatic Traction Control (ATC) Functional Overview.........................................................................216 ATC Operation............................................................................................................217 System Operation.........................................................................................................217 Component Function.......................................................................................................217 Traction Control Power-Up Sequence.......................................................................................217 Traction Control Switch Operation........................................................................................217 Thermal (Brake Heat) Protection..........................................................................................217 ABS/ATC Partial Shutdown.................................................................................................217 Engine Operation.............................................................................................................217 Starting Procedure.......................................................................................................217 Cold Weather Starting....................................................................................................218 Idling the Engine........................................................................................................218 Particulate Filter Maintenance at Idle — Unexpected Idle Speed Increase..............................................218 Racing the Engine........................................................................................................218 Shutdown Procedure.......................................................................................................218 Exhaust System Cleaning..................................................................................................218 Faults on the DEF system.............................................................................................219 Crane Travel Operation.......................................................................................................219 Active Restraints........................................................................................................219 Seat Belts...........................................................................................................219 Traveling - General......................................................................................................220 Axle Weight Distribution Table...........................................................................................221 Manual Transmission Clutch Operation.....................................................................................223 Shifting Gears...........................................................................................................223 Initial Start-up.....................................................................................................224 Upshifting...........................................................................................................225 Downshifting.........................................................................................................225 Shifting to Reverse..................................................................................................226 Driving Tips.........................................................................................................226 Automatic Transmission (Optional)........................................................................................226 Gear Display.........................................................................................................226 Start-up.............................................................................................................227 Power Down...........................................................................................................227 Reverse Mode.........................................................................................................227 Drive Mode...........................................................................................................227 MANUAL Mode..........................................................................................................228 MANUAL / Hold Mode...................................................................................................228 Transmission Manual Override.....................................................................................228 LOW Mode.............................................................................................................229 Transmission LOW Override........................................................................................229 Hill Start Aid (HSA) (Optional-Only available with automated transmission)...........................................229 Differential Control Switches............................................................................................230 Operating the Differential Locks.....................................................................................230 Brakes...................................................................................................................230 Engine Brake.............................................................................................................231 Recommended Crane Shutdown Procedures....................................................................................231 Unattended Crane.............................................................................................................231 Superstructure Cab Platform..................................................................................................231 Proper Leveling of the Crane.................................................................................................232 Bubble Level Adjustment..................................................................................................232 Using the Outriggers.........................................................................................................232 Setting the Outriggers...................................................................................................232 Auto Level Procedure.................................................................................................233 Engaging the Partial/Mid Extension Lock Pin..............................................................................233 Outrigger Monitoring System (OMS) CCS Display............................................................................234 Stowing the Outriggers...................................................................................................234 Stowing the Partial/Mid Extension Lock Pin...............................................................................234 Stowing the Center Front Jack............................................................................................235 Crane operation..............................................................................................................235 Before operating the crane...............................................................................................235 Checking the position of the hoist ropes.............................................................................236 Checking the electrical system.......................................................................................236 Adjusting the crane cab seat and front control panel.................................................................236 Crane cab seat...................................................................................................236 Front panel......................................................................................................237 Checking operator aids...............................................................................................237 Rated capacity limiter...........................................................................................237 Anti-two block switch............................................................................................237 Emergency stop switch............................................................................................238 Seat contact switch..............................................................................................238 Preheating the hydraulic oil.............................................................................................239 Using the swing system...............................................................................................239 Switching the 360° lock on/off...........................................................................................239 Switching on the 360° lock...........................................................................................239 Switching off the 360° lock..........................................................................................239 Operation of the rated capacity limiter......................................................................................240 Switch on the RCL........................................................................................................240 Switching on.........................................................................................................240 Lamp test............................................................................................................240 After a standstill of up to 2 hours..................................................................................241 After a standstill of more than 2 hours..............................................................................241 Enter rigging mode.......................................................................................................242 Entering individual components.......................................................................................242 Switching on input mode..............................................................................................242 Selecting values.....................................................................................................243 Counterweight........................................................................................................243 Boom system..........................................................................................................244 Outrigger span display...............................................................................................244 Outrigger span.......................................................................................................244 Swing range..........................................................................................................245 Entering the RCL code................................................................................................245 Entering the reeving.................................................................................................246 Accepting the rigging code...........................................................................................246 Checks before operating the crane....................................................................................247 Open the menu....................................................................................................247 Checks...........................................................................................................247 Hoists display...................................................................................................248 Example of how to switch over the display........................................................................248 Displays during crane operation......................................................................................248 The current overall height.......................................................................................248 The current lattice extension angle..............................................................................249 The current lattice extension length.............................................................................249 The counterweight................................................................................................249 The current swing angle..........................................................................................249 The currently raised load........................................................................................250 The maximum load.................................................................................................250 The degree of utilization........................................................................................250 RCL early warning....................................................................................................250 RCL shutdown.........................................................................................................250 Shutdown due to overload.........................................................................................250 Canceling a shutdown.............................................................................................251 Display in the event of errors.......................................................................................251 RCL override.........................................................................................................251 External Light Bar (Optional)....................................................................................252 When rigging.....................................................................................................252 RCL override.....................................................................................................252 Anti-two block switch override...................................................................................252 After overriding.................................................................................................252 Canceling the override...........................................................................................252 To raise the boom................................................................................................252 Raise main boom..................................................................................................252 Switch off function..............................................................................................253 In emergencies...................................................................................................253 Canceling a shutdown.............................................................................................253 Canceling the override...........................................................................................253 Crane operation with main boom...........................................................................................253 Main hoist...........................................................................................................253 Switching on the main hoist......................................................................................254 Lifting and lowering.............................................................................................254 Switching off the main hoist.....................................................................................255 Auxiliary hoist......................................................................................................255 Switching on the auxiliary hoist.................................................................................255 Lifting and lowering.............................................................................................255 Switching off the auxiliary hoist................................................................................256 Anti-Two Block switch and lowering limit switch......................................................................256 Anti-Two Block...................................................................................................256 Anti-two block switch override...................................................................................257 Switching on the lifting/lowering mechanism......................................................................257 Raising and lowering.............................................................................................258 Switching off the lifting/lowering mechanism.....................................................................258 Telescoping mechanism................................................................................................258 Manual telescoping...............................................................................................258 Telescoping with semi-automation.................................................................................258 Extending with the main boom configuration.......................................................................258 Overview.........................................................................................................258 Telescoping process..............................................................................................259 Assignment for display...........................................................................................261 Fixed length, intermediate length, telescoping length............................................................261 Main boom fixed length...........................................................................................261 Main boom intermediate length....................................................................................262 Main boom telescoping length.....................................................................................262 Telescoping......................................................................................................262 Telescoping sequence.............................................................................................262 Inspections prior to starting operations.........................................................................262 Switching on the telescoping mechanism...........................................................................262 Function of the control lever....................................................................................262 Switching off the telescoping mechanism..........................................................................263 Manual telescoping...............................................................................................264 Checking the initial position....................................................................................264 Current telescoping..............................................................................................264 Position of the telescoping cylinder.............................................................................264 Position of the locking pins.....................................................................................265 Unlocking the telescoping cylinder...............................................................................265 Extending/retracting the telescoping cylinder....................................................................266 Extending/retracting.............................................................................................266 Lock telescoping cylinder........................................................................................266 Lock.............................................................................................................267 Unlocking the telescopic section.................................................................................267 Telescoping the telescopic section...............................................................................268 Locking the telescopic section...................................................................................268 Locking the telescopic section for on-road driving...............................................................269 Telescoping with semi-automation.................................................................................269 Semi-auto Mode...........................................................................................................269 Introduction.........................................................................................................269 Semi-auto Mode basic operating procedures............................................................................271 Semi-auto Mode for shifting cylinder within fully retracted boom.....................................................273 Semi-auto Mode requiring boom to be retracted........................................................................273 Semi-auto Mode screen refresh........................................................................................273 Semi-auto Mode warning indications...................................................................................273 Semi-auto Mode telescoping function shut-down........................................................................274 Semi-auto Mode lost boom configuration...............................................................................274 Reset telescoping configuration......................................................................................274 Semi-auto Mode vs. Manual Mode.......................................................................................275 Telescoping with main boom configuration.........................................................................276 Entering values..................................................................................................276 High-speed mode......................................................................................................277 Hoists...........................................................................................................277 Swing gear...........................................................................................................277 Swing brake......................................................................................................277 Switching on the swing gear......................................................................................277 Releasing the swing brake........................................................................................278 Applying the swing brake.........................................................................................278 Swing............................................................................................................278 Releasing locked swing gear......................................................................................278 You can limit the maximum swing speed (1, Figure 4- 223), refer to Limiting the power unit speeds, page 4-77.....278 Braking the swing movement.......................................................................................279 Free swing mode..................................................................................................279 Switching off the swing gear.....................................................................................279 Possible movement combinations...........................................................................................280 Settings and displays for crane operation....................................................................................280 Inclining the crane cab..................................................................................................280 Switching units of measure...............................................................................................280 Setting the characteristic curves for the control levers.................................................................281 Limiting the power unit speeds...........................................................................................281 Changing values......................................................................................................282 Camera Display Setup.....................................................................................................282 Using the slewable spotlights............................................................................................283 Warnings in the start menu...............................................................................................283 Meaning of the symbols...............................................................................................283 Work break...................................................................................................................284 In case of short work breaks.............................................................................................284 In case of work breaks of more than 8 hours..............................................................................284 To secure the truck crane............................................................................................285 Trailing Boom Carrier Option.................................................................................................285 Description..............................................................................................................285 Operation................................................................................................................286 Preparation for Highway Travel.......................................................................................286 Travel Precautions...................................................................................................289 Returning to Normal Crane Operation......................................................................................289 Parking the Trailing Boom Carrier........................................................................................289 Tilt-Up Panel Procedure Using the Heavy Duty Boom Extension..................................................................289 Lubrication......................................................................................................................291 General......................................................................................................................291 Environmental Protection.................................................................................................291 Cummins Oil Registration List............................................................................................291 Arctic Conditions Below -18° C (0° F)....................................................................................291 Lubrication Points...........................................................................................................292 Standard Lubricants......................................................................................................293 Cold Weather Lubricants..................................................................................................295 Arctic Lubricants and Conditions.........................................................................................297 Temperatures Below -9°C (15°F).......................................................................................297 Cold Weather Package and Lubricants..................................................................................297 Notes Listed in the Following Tables.............................................................................297 Drivetrain Lubrication...................................................................................................298 Steering Lubrication.....................................................................................................303 Axle Lubrication.........................................................................................................303 Outrigger Lubrication....................................................................................................306 Miscellaneous Lubrication................................................................................................307 Turntable & Cab Tilt Lubrication.........................................................................................308 Hoist Lubrication........................................................................................................311 Turntable Central Lubrication............................................................................................312 Boom Lubrication.........................................................................................................313 Crane Setup..........................................................................................................313 Greaseless Boom......................................................................................................313 Monthly Lubrication Work.................................................................................................316 Pins.................................................................................................................316 Set-up and Installation..........................................................................................................317 General......................................................................................................................318 Installing Cable On The Hoist................................................................................................318 Cable Reeving................................................................................................................318 Dead-End Rigging/Wedge Sockets...............................................................................................319 Installing Wedge and Socket..............................................................................................320 Positioning/Removing the Hoist Cable.....................................................................................321 Positioning Hoist Cable..............................................................................................321 Removing Hoist Cable.................................................................................................321 Possible reevings on the main boom.......................................................................................321 With 5 Head Sheaves..................................................................................................322 5-sheave hook block..................................................................................................322 3-sheave hook block..................................................................................................322 1-sheave hook block..................................................................................................323 Hook tackle..........................................................................................................323 Auxiliary Boom Nose..................................................................................................323 Rigging work for crane operation with the main boom..........................................................................327 Rigging..................................................................................................................327 Unrigging................................................................................................................328 Removable Counterweight..................................................................................................328 Counterweight versions/combinations......................................................................................331 Lifting individual counterweight sections................................................................................331 Lifting stacked counterweight sections...............................................................................332 Slinging points at the counterweight sections........................................................................333 Rigging the counterweight................................................................................................333 Prerequisites:.......................................................................................................333 Unrigging the counterweight..............................................................................................334 Lower 3,000 lb tray plate on the counterweight platform..................................................................334 Check the position of the locking pins for 3000 and 5,000 lb counterweight sections......................................335 Locking Pin position.................................................................................................335 Assembling counterweight versions/ combinations..........................................................................336 Procedures...........................................................................................................337 Counterweight hoist unit.................................................................................................337 Extending/Retracting the lifting cylinders...........................................................................338 Pre-charge...........................................................................................................338 Automatic mode, rigging..............................................................................................338 Rotating with the rigged counterweight...................................................................................339 Extending/retracting the lifting cylinders...........................................................................339 Automatic mode rigging...............................................................................................340 Automatic mode unrigging.............................................................................................341 Cancel automatic mode................................................................................................342 Unlocking/locking the rear counterweight platform........................................................................343 Unlocking............................................................................................................343 Locking..............................................................................................................343 Swinging with rigged counterweight...................................................................................344 Rigging work on the main boom................................................................................................345 Hook block on the bumper.................................................................................................345 Picking up the hook block............................................................................................345 Attaching the hook block.............................................................................................345 Hook block on a separate vehicle.........................................................................................345 Picking up the hook block............................................................................................345 Setting down the hook block..........................................................................................346 Reeving the hoist rope...............................................................................................347 Attaching the rope end clamp.........................................................................................349 Dead-end Rigging.....................................................................................................349 Unreeving hoist rope.................................................................................................351 Installing/removing the anti-two block switch............................................................................351 Installing the anti-two block switch.................................................................................351 Removing the anti-two block switch...................................................................................353 Locking/unlocking the anti-two block switch..............................................................................355 Locking..............................................................................................................355 Removing the lock....................................................................................................355 Anemometer and boom position indicator light.............................................................................355 Installing...........................................................................................................355 Switching the boom position indicator light on and off...............................................................356 Removing.............................................................................................................356 Other rigging work...........................................................................................................356 Cameras for crane operation..............................................................................................356 Camera on the hoists.................................................................................................356 Operating the camera.................................................................................................356 Hoist maintenance platform...............................................................................................357 Slinging points for personal protective equipment........................................................................357 Boom Extensions..............................................................................................................358 Installing the Folding Boom Extension....................................................................................359 Securing Extension with Tag Line (Rope)..............................................................................360 Extension Erecting Warnings and Requirements.............................................................................360 Erecting Procedure: 35 ft (10.5 m) Base Extension........................................................................360 Erecting Procedure: 58 ft (17.6 m) Extension.............................................................................364 Extension Electrical Connections.........................................................................................370 35 ft (10.5 m) Extension Electrical Connections......................................................................370 58 ft (17.5 m) Extension Electrical Connections......................................................................370 Disconnect Electrical Connections to the 58 ft (17.5 m) Base Extension...........................................371 Connecting the Anti-Two Block Switch.....................................................................................371 35 ft (10.5 m) Extension anti-two block Installation.................................................................371 35 ft (10.5 m) Extension Anti-Two Block Removal......................................................................371 58 ft (17.5 m) Extension Anti-Two Block Installation.................................................................372 Extension Hydraulic Connections (Optional Hydraulic Extension)...........................................................372 Checking the Locking Device on the Hose Drum.........................................................................372 Unlocking the Drum...............................................................................................372 Locking the Drum.................................................................................................372 Hydraulic Hose Installation..........................................................................................373 Position for Main Boom Operation.....................................................................................373 Establishing the Hydraulic Connection................................................................................374 Disconnecting the Hydraulic Connection...............................................................................374 Folding Deflection Sheaves...............................................................................................374 Deploying the Rear Deflection Sheave.................................................................................374 Stowing Rear Deflection Sheave.......................................................................................375 Positioning/Removing the Hoist Cable.....................................................................................375 Positioning Hoist Cable..............................................................................................375 Removing Hoist Cable.................................................................................................375 Mechanical Luffing Boom Extension (Adjustable Boom Extension)............................................................377 Extension Angle Adjusting Mechanism..................................................................................377 Setting the Offset Angle with an Auxiliary Crane.....................................................................377 Setting the Offset Angle without an Auxiliary Crane..................................................................377 Entering the RCL Code............................................................................................377 Inclining the Crane..................................................................................................378 Stowing the Folding Boom Extension.......................................................................................378 Requirements for Stowing the Boom Extensions.........................................................................378 Stowing Procedure: 23 ft (7 m) Boom Fly Extension....................................................................378 Stowing Procedure: 58 ft (17.5 m) Extension..........................................................................379 Boom Extension Removal...................................................................................................383 From the side of the main boom.......................................................................................383 From the nose of the main boom.......................................................................................386 Installing and Removing the 26 ft (8 m) Extension Insert.................................................................386 Installation.........................................................................................................386 Removal..............................................................................................................387 Insert Electrical Connection.........................................................................................387 Connecting the 26 ft (8 m) Insert to the Main Boom...............................................................387 Disconnecting Main Boom Electrical Connection....................................................................388 Connecting the Folding Extension Electrical Circuit..............................................................388 Disconnecting the Folding Extension Electrical Circuit...........................................................388 Extension Hydraulic Connection.......................................................................................389 Connecting Main Boom Hydraulics..................................................................................389 Disconnecting Main Boom Hydraulics...............................................................................389 Connecting the Folding Extension Hydraulics......................................................................389 Disconnecting the Folding Extension Hydraulics...................................................................390 Folding the Deflection Sheave on the 26 ft (8 m) Extension...........................................................390 Folding Out the Deflection Sheave................................................................................390 Folding In the Deflection Sheave.................................................................................391 3.5 m (11.4 ft) Manual off-settable Heavy Duty Boom Extension................................................................391 Description..............................................................................................................391 Separating Manual Off-settable Heavy Duty Boom Extension from Lattice Extension..........................................391 Installing Manually Offsetable Heavy Duty Boom Extension.................................................................392 Setting Heavy Duty Boom Extension Manual Offset..........................................................................392 Removing the Manual Offsetable Heavy Duty Extension......................................................................392 3.5 m (11.4 ft) Hydraulic off-settable Heavy Duty Boom Extension.............................................................393 Description..............................................................................................................393 Separating Hydraulic Off-settable Heavy Duty Boom Extension from Lattice Base Extension..................................393 Removing the Hydraulic Offsetable Heavy Duty Extension...................................................................395 Auxiliary Single-Sheave Boom Nose (Optional Equipment).......................................................................396 Identification...........................................................................................................396 Installing/Removing Auxiliary Single-Sheave Boom Nose....................................................................396 Installing Auxiliary Single-Sheave Boom Nose.........................................................................396 Removing the Auxiliary Single-Sheave Boom Nose...........................................................................397 Rigging the Auxiliary Single-Sheave Boom Nose................................................................................397 Rigging in Transport Position............................................................................................397 Rigging in Working Position..............................................................................................397 Attaching and Removing Hoist Cable.......................................................................................398 Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose........................................................398 Anti-two Block Switch....................................................................................................398 In Operation.........................................................................................................398 During Transport.....................................................................................................398 Raising And Setting Down The Main Boom With Rigged Lattice Extension.........................................................398 Telescoping With Rigged Lattice Extension....................................................................................398 Operating with the Lattice Extension.........................................................................................398 Procedure if the Permissible Wind Speed is Exceeded......................................................................398 Anti-two Block Troubleshooting...........................................................................................399 Rear Axle Locking Pins.......................................................................................................400 Installing Rear Axle Locking Pins........................................................................................400 Removing Rear Axle Locking Pins..........................................................................................400
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