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Grove Crane TMS990-2 Operator Manual – PDF DOWNLOAD
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Description
Grove Crane TMS990-2 Operator Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane TMS990-2 Operator Manual – PDF DOWNLOAD
Language : English
Pages : 390
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane TMS990-2 Operator Manual – PDF DOWNLOAD
GENERAL:
- This manual provides important information for the operator of the Model TMS990-2 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.
IMAGES PREVIEW OF THE MANUAL:
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TABLE OF CONTENTS:
Grove Crane TMS990-2 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 Warning Signs............................................................................................................ 18 Accidents.................................................................................................................... 18 Operator Information......................................................................................................... 18 Operator Qualifications...................................................................................................... 19 Operational Aids............................................................................................................. 20 Rated Capacity Limiter (RCL) Systems..................................................................................... 20 Anti-Two-Blocking Device................................................................................................. 20 Working Area Limiter (If Equipped)....................................................................................... 21 Crane Stability/Structural Strength.......................................................................................... 21 Load Charts.............................................................................................................. 22 Work Site................................................................................................................ 22 Wind Forces.................................................................................................................. 23 Wind Speeds.............................................................................................................. 23 Lifting Operations....................................................................................................... 23 Counterweight............................................................................................................ 24 Outrigger Lift Off....................................................................................................... 24 Multiple Crane Lifts..................................................................................................... 25 Tilt-Up Panel Lifting.................................................................................................... 25 Pile Driving and Extracting.................................................................................................. 25 Crane Equipment.......................................................................................................... 26 Crane Inspection......................................................................................................... 26 Electrocution Hazard......................................................................................................... 26 Set-Up and Operation..................................................................................................... 27 Electrocution Hazard Devices............................................................................................. 28 Electrical Contact....................................................................................................... 28 Special Operating Conditions and Equipment............................................................................... 29 Grounding the Crane...................................................................................................... 29 Personnel Handling........................................................................................................... 30 Environmental Protection..................................................................................................... 31 Maintenance.................................................................................................................. 31 Service and Repairs...................................................................................................... 31 Lubrication.............................................................................................................. 32 Tires.................................................................................................................... 32 Hoist Rope................................................................................................................... 32 Synthetic Hoist Rope..................................................................................................... 32 Wire Rope................................................................................................................ 33 Sheaves.................................................................................................................. 34 Batteries................................................................................................................ 34 Super Capacitor (If Equipped)............................................................................................ 35 General Maintenance...................................................................................................... 35 Transporting the Crane....................................................................................................... 35 Travel Operation............................................................................................................. 36 Travel with trailing boom................................................................................................ 37 Work Practices............................................................................................................... 37 Personal Considerations.................................................................................................. 37 Crane Access............................................................................................................. 37 Job Preparation.......................................................................................................... 37 Working.................................................................................................................. 38 Lifting.................................................................................................................. 38 Hand Signals............................................................................................................. 39 Boom Extension............................................................................................................... 41 Parking and Securing......................................................................................................... 41 Shut-Down.................................................................................................................... 41 Cold Weather Operation....................................................................................................... 41 Temperature Effects on Hook Blocks........................................................................................... 42 Temperature Effects on Hydraulic Cylinders................................................................................... 42 Overload Inspection.......................................................................................................... 43 Boom Inspection.......................................................................................................... 45 Superstructure Inspection................................................................................................ 47 Carrier Inspection....................................................................................................... 49 Operating Controls and Indicators................................................................................................ 51 Carrier Cab Controls and Indicators.......................................................................................... 53 Transmission Shift Lever................................................................................................. 54 Spare Switch/Indicator................................................................................................... 54 USB Ports................................................................................................................ 54 12 Volt Outlet........................................................................................................... 54 Fire Extinguisher........................................................................................................ 54 Horn Button.............................................................................................................. 54 Turn Signal/Headlight High Beam Low Beam Lever........................................................................... 54 Steering Column Tilt/Telescope Lever..................................................................................... 54 Cab Circulating Fan...................................................................................................... 54 Windshield Wiper and Washer.............................................................................................. 54 Camera Display........................................................................................................... 54 Dome Light............................................................................................................... 54 Air Horn................................................................................................................. 54 Throttle Pedal........................................................................................................... 54 Brake Pedal.............................................................................................................. 55 Clutch Pedal............................................................................................................. 55 Steering Wheel........................................................................................................... 55 Headlights Switch........................................................................................................ 56 Dimmer Switch............................................................................................................ 56 Beacon Light Switch (Optional)........................................................................................... 56 Engine Brake On/Off Switch............................................................................................... 56 Engine Brake High/Low Switch............................................................................................. 56 Exhaust System Cleaning Initiate Switch.................................................................................. 57 Engine Idle Increment/Decrement Switch................................................................................... 57 Remote Control On/Off Switch............................................................................................. 57 Remote Control Indicator................................................................................................. 57 ABS/ATC Switch........................................................................................................... 57 Hill Start Aid (HSA) Switch (Optional)................................................................................... 57 HSA Indicator (Optional)................................................................................................. 57 Inter-Axle Lock Switch................................................................................................... 57 Cross-Axle Lock Switch (Optional)........................................................................................ 57 Suspension Inflation Switch.............................................................................................. 57 Tire Inflation Switch.................................................................................................... 57 Heater/Air Conditioner Fan Switch........................................................................................ 57 Heater/Air Conditioner Control........................................................................................... 58 Heater/Air Conditioner Select Switch..................................................................................... 58 Ignition Switch.......................................................................................................... 58 Parking Brake Control.................................................................................................... 58 Dual Air Pressure Gauge.................................................................................................. 58 Trailing Boom Trailer Emergency Brake Control (Optional)................................................................. 58 Control Panel Indicator and Gauge Display................................................................................ 58 Control Panel Indicator and Gauge Display.................................................................................... 59 Cross-Axle Locked Indicator.............................................................................................. 59 Inter-axle Locked Indicator.............................................................................................. 60 Suspension Deflated Indicator............................................................................................ 60 Traction Control Indicator............................................................................................... 60 Tire Inflation On Indicator.............................................................................................. 60 Left Turn Signal Indicator............................................................................................... 60 Lights On Indicator...................................................................................................... 60 High Beam Indicator...................................................................................................... 60 Parking Brake Engaged Indicator.......................................................................................... 60 Battery Charge Indicator................................................................................................. 60 Low Air Pressure......................................................................................................... 60 Emergency Stop........................................................................................................... 60 Right Turn Signal Indicator.............................................................................................. 60 System Fault Indicator................................................................................................... 60 Anti-lock Braking System (ABS) Indicator................................................................................. 60 Check Transmission (Automated Transmission Only)......................................................................... 61 Malfunction Indicator Lamp............................................................................................... 61 Low Oil Pressure......................................................................................................... 61 Engine Stop Indicator.................................................................................................... 61 Engine Warning Indicator................................................................................................. 61 OK Button................................................................................................................ 61 Menu Button.............................................................................................................. 61 Fuel Gauge............................................................................................................... 61 Speedometer.............................................................................................................. 61 Low Fuel Level Indicator................................................................................................. 61 High Exhaust System Temperature.......................................................................................... 61 Engine Temperature Indicator............................................................................................. 62 Cruise Control........................................................................................................... 62 Engine Coolant Temperature Gauge......................................................................................... 62 Down Button.............................................................................................................. 62 Up Button................................................................................................................ 62 Tachometer............................................................................................................... 62 Exhaust System Cleaning.................................................................................................. 62 LCD Display.............................................................................................................. 62 Outrigger Controls and Indicators............................................................................................ 64 Outrigger Control Summary................................................................................................ 64 Outrigger Control Panel.................................................................................................. 64 Outrigger Beam Selector Switch....................................................................................... 64 Extend Switch........................................................................................................ 64 Center Front Jack Switch............................................................................................. 65 Jack Selector Switch................................................................................................. 65 Emergency Stop Switch................................................................................................ 65 Retract Switch....................................................................................................... 65 Power Indicator...................................................................................................... 65 Auto Switch.......................................................................................................... 65 Superstructure Cab........................................................................................................... 66 Superstructure cab....................................................................................................... 66 Side panel........................................................................................................... 68 Superstructure cab, rear............................................................................................. 69 Control panels........................................................................................................... 70 Left Hand Armrest Controls........................................................................................... 70 Right Hand Armrest Controls.......................................................................................... 71 Control levers........................................................................................................... 72 Heating system........................................................................................................... 73 Operator display module (ODM)/CCS control unit........................................................................... 74 CCS – Home screen........................................................................................................ 76 Alert Icons.............................................................................................................. 78 Short description of the operating elements of the crane control system...................................................... 79 Definition of direction information...................................................................................... 80 Basic rule........................................................................................................... 80 On the carrier....................................................................................................... 80 On the superstructure................................................................................................ 80 General rules for buttons and symbols on the display..................................................................... 80 Changing Menus....................................................................................................... 81 Crane Control System......................................................................................................... 81 Display CCS.............................................................................................................. 81 Warning message/error message display area........................................................................... 82 Open Error menu...................................................................................................... 82 Exiting the menu/input mode.......................................................................................... 82 Enter the values with jog dial....................................................................................... 82 Enter values on the control panel CCS................................................................................ 83 Input confirmation................................................................................................... 83 Other indicators on the ODM CCS display.............................................................................. 83 Display temperature sensor........................................................................................... 83 Emergency stop switch................................................................................................ 83 To switch displays................................................................................................... 83 Settings menu groups................................................................................................. 84 Menu for setting the time............................................................................................ 85 Switch units menu.................................................................................................... 87 Set control lever characteristic curve menu.......................................................................... 88 Power unit speeds menu............................................................................................... 89 Operating hours menu................................................................................................. 90 Displaying the operating hours........................................................................................... 90 Displays............................................................................................................. 90 Crane operation error menu........................................................................................... 92 Software version menu................................................................................................ 93 CCS – Overview menu groups............................................................................................... 94 Superstructure lock menu............................................................................................. 96 Counterweight menu................................................................................................... 97 Outrigger menu....................................................................................................... 98 Telescoping semi-automation menu.....................................................................................100 Manual telescoping menu..............................................................................................101 ODM Working Range Limiter (WRL)......................................................................................101 WRL Overall height menu..............................................................................................104 WRL- Boom Angle Limits menu..........................................................................................106 WRL-Working radius menu..............................................................................................108 WRL-Swing angle menu.................................................................................................110 WRL-Virtual walls menu...............................................................................................112 Exhaust System Cleaning menu.........................................................................................114 Bi-fold Boom Extension menu..........................................................................................115 Telescoping emergency program............................................................................................115 Open Submenu Emergency program.......................................................................................116 Access telescoping emergency program menu........................................................................117 Determining the error type...........................................................................................118 Error on length indicator............................................................................................120 Checks before telescoping........................................................................................120 Retracting and locking a telescopic section..........................................................................121 Unlocking the telescoping cylinder...............................................................................122 Extending and locking the telescoping cylinder...................................................................123 Tables for approaching the locking points............................................................................123 Locking points for the telescoping cylinder......................................................................123 Locking points for the telescopic sections.......................................................................123 Telescoping cylinder boom nose switch................................................................................124 ODM error code viewer....................................................................................................125 RDM (RCL Display Module).................................................................................................126 Resetting the current telescoping........................................................................................128 Entering current telescope position values...........................................................................128 RCL – menu groups........................................................................................................130 Enter rigging mode menu..............................................................................................131 Monitoring menu......................................................................................................132 Outrigger rigging code verification..................................................................................134 Adjusting the wiper stroke interval of the windshield wiper..............................................................134 Display – setting the brightness.........................................................................................135 Setting the characteristic curves for the control levers.................................................................136 Crane Functions Speed Control............................................................................................136 Changing values......................................................................................................137 Operating the camera.....................................................................................................137 Switching the camera.................................................................................................137 Switching the boom position indicator light (optional equipment) on and off..............................................137 Engine...................................................................................................................138 Side panel...........................................................................................................138 Ignition lock....................................................................................................138 Set idling speed.................................................................................................138 Economy mode menu................................................................................................138 Seat contact switch and dead man's switches..............................................................................138 Enabling crane functions.............................................................................................139 Disabling crane functions............................................................................................139 Superstructure cab seat..............................................................................................139 Outriggers...............................................................................................................139 Right-hand control panel.............................................................................................139 Button for outrigger preselection................................................................................139 Left-hand control panel..............................................................................................139 Retracting/extending outrigger beams pre-selection...............................................................139 In the Outrigger menu................................................................................................139 Outrigger span display...........................................................................................139 Swing gear/movements locked display..............................................................................140 Parking brake/movements locked display...........................................................................140 Function for switching outriggers................................................................................140 Extend/retract outrigger beams...................................................................................141 Extend/retract outrigger jack cylinders..........................................................................141 Inclination indicator....................................................................................................142 Anemometer display.......................................................................................................142 Counterweight menu.......................................................................................................142 Counterweight locking display........................................................................................142 Locking/unlocking the counterweight..................................................................................143 Extending/retracting the lifting cylinders...........................................................................143 Pre-tensioning pressure display......................................................................................143 Main hoist...............................................................................................................143 Right control lever..................................................................................................144 Hoist high-speed mode on/off.........................................................................................144 Hoist Speed Range Selection..........................................................................................144 Hoist rotation indicator.............................................................................................144 CCS display..........................................................................................................144 Main Hoist Enable................................................................................................144 High speed mode for the hoist....................................................................................144 Lift/lower the hoist.............................................................................................145 Warning for lowering limit switch lockout........................................................................145 Hoist Limit Lockout Indication...................................................................................145 Auxiliary hoist..........................................................................................................145 Swing....................................................................................................................145 Control panels.......................................................................................................145 Swing enable.....................................................................................................145 Left control lever...............................................................................................145 Free swing button................................................................................................146 CCS display..........................................................................................................146 Swing crane function display.....................................................................................146 Swing brake applied/released.....................................................................................146 Lifting/Lowering mechanism...............................................................................................146 Control panels.......................................................................................................146 Lifting/lowering mechanism on/off................................................................................146 Right control lever..............................................................................................146 ODM display..........................................................................................................147 Lifting/lowering crane function display..........................................................................147 Boom up override switch..........................................................................................147 Telescoping mechanism....................................................................................................147 Control panels.......................................................................................................147 Telescoping enable switch........................................................................................147 Right control lever..............................................................................................147 Left control lever- Optional.....................................................................................147 Telescoping crane function display...............................................................................148 Telescoping semi-automation menu.....................................................................................148 Open menu........................................................................................................148 Telescope diagram display........................................................................................148 Telescoping cylinder length display..............................................................................148 Main boom length display.........................................................................................149 Telescopic sections display......................................................................................149 Current telescope status display.................................................................................149 Pre-selection for all telescopic sections........................................................................149 Pre-selection individual telescopic sections.....................................................................149 Teleautomation direction display.................................................................................149 Confirm pre-selection............................................................................................149 Manual telescoping menu..............................................................................................150 Telescoping cylinder locked/released.............................................................................150 Locking/releasing the telescoping cylinder.......................................................................150 Lock/release telescopic section indication.......................................................................150 Locking/releasing the telescopic section.........................................................................150 Telescoping cylinder length display..............................................................................151 Main boom length display.........................................................................................151 Telescoping section in the telescopic section display............................................................151 Telescoping direction display....................................................................................151 Hydraulic system.........................................................................................................151 Cab tilt.............................................................................................................151 Superstructure house lock menu...........................................................................................151 Swing gear display...................................................................................................152 360 Degree Swing Lock................................................................................................152 Locking status displays..........................................................................................152 360 Degree Swing Lock............................................................................................152 Remote control...............................................................................................................152 Remote control icon......................................................................................................152 Remote Control Operation.....................................................................................................153 Scope....................................................................................................................153 System Overview..........................................................................................................153 System Components........................................................................................................154 Remote Control Components................................................................................................156 Display Components.......................................................................................................157 Preparing for Remote Control Operation...................................................................................159 Operating Remote Control.................................................................................................160 Superstructure Horn..................................................................................................160 Emergency Stop.......................................................................................................160 Engine Start/Stop/Throttle...........................................................................................161 Starting/Stopping Engine.........................................................................................161 Changing Engine Speed............................................................................................161 Exiting Start/Stop/Throttle Screen...............................................................................161 Outrigger Beams......................................................................................................163 Outrigger Jacks......................................................................................................165 Hoist Control (Main and Aux).........................................................................................167 Boom Lift............................................................................................................169 Swing and 360° Swing Lock............................................................................................171 Swinging.........................................................................................................171 Operating 360° Swing Lock........................................................................................171 Exiting Swing/360° Swing Lock Screen.............................................................................171 OPT (options)........................................................................................................173 Luffing Boom Extension...........................................................................................173 Boom Extension Assist............................................................................................173 Counterweight....................................................................................................173 Exiting OPT Screen...............................................................................................173 Information..........................................................................................................174 Rated capacity limiter (RCL).............................................................................................174 Control unit control console.........................................................................................174 Exiting the menu/input mode......................................................................................174 Entering values..................................................................................................174 RCL Status Indicators............................................................................................174 Sensor for brightness............................................................................................174 Sensor for temperature...........................................................................................175 Display RCL..........................................................................................................175 After a standstill of up to 2 hours..............................................................................175 Enter rigging mode menu..............................................................................................175 Enter RCL code...................................................................................................175 Enter reeving....................................................................................................176 Enter outrigger span.............................................................................................176 Enter counterweight..............................................................................................176 Confirming the rigging mode......................................................................................177 Boom system entry................................................................................................177 Monitoring menu......................................................................................................177 Boom system setup display........................................................................................177 Counterweight display............................................................................................178 Outrigger span display...........................................................................................179 Display of the lattice extension offset angle....................................................................179 Current main boom angle display..................................................................................179 Current swing angle display......................................................................................179 Current load display.............................................................................................179 Maximum load display.............................................................................................179 Current degree of utilization display............................................................................180 GPL licensing screen.............................................................................................181 Exiting the menu.................................................................................................181 Limits Override......................................................................................................181 Hoist limits override............................................................................................182 External Limit Bypass Switch.....................................................................................182 External displays....................................................................................................182 Status display...................................................................................................182 Economy Mode.................................................................................................................182 Terminology..............................................................................................................183 Requirements.............................................................................................................183 Operation................................................................................................................184 Benefits.................................................................................................................184 Electrical system............................................................................................................184 Voltage monitoring warning...............................................................................................184 Sockets 12 V.............................................................................................................184 Lighting, windshield wiper/washing system....................................................................................185 Lighting.................................................................................................................185 Superstructure Cab Work Lights on/off................................................................................185 Boom Lights..........................................................................................................185 Rotating Boom Lights Control.........................................................................................185 Cab lighting.........................................................................................................185 Reading lamp.........................................................................................................185 Windshield wiper/washing system......................................................................................186 Windshield wiper on/off..........................................................................................186 Skylight wiper on/off............................................................................................186 Windshield/Skylight washing system...............................................................................186 Wiper stroke interval menu.......................................................................................186 Adjusting the wiper stroke interval..............................................................................186 Windows..................................................................................................................186 Open window (A)......................................................................................................186 Close window (B).....................................................................................................186 Rear window..........................................................................................................187 Opening..........................................................................................................187 Closing..........................................................................................................187 Superstructure cab door..................................................................................................187 From outside.........................................................................................................187 Unlock...........................................................................................................187 Lock.............................................................................................................187 Open/close.......................................................................................................187 Inside door operation............................................................................................188 CraneSTAR® system............................................................................................................188 Overview.................................................................................................................188 Position of the components...............................................................................................188 Operating Procedures.............................................................................................................191 Breaking-in A New Carrier....................................................................................................192 Pre-Starting Checks..........................................................................................................192 Fuel Supply..............................................................................................................192 Engine Oil...............................................................................................................192 DEF Fluid Level..........................................................................................................192 Engine Coolant...........................................................................................................193 Batteries................................................................................................................193 Hydraulic Reservoir and Filter...........................................................................................193 Wire Rope................................................................................................................193 Hook Block and Headache Ball.............................................................................................193 Seats....................................................................................................................193 Seat Belts...............................................................................................................193 Seat Belt Maintenance................................................................................................193 Cleaning Seat Belt Webbing...........................................................................................193 Signal and Running Lights................................................................................................193 Service and Parking Brakes...............................................................................................193 Tires....................................................................................................................193 Wheels...................................................................................................................193 Other Equipment..........................................................................................................193 Daily Lubrication........................................................................................................193 Cold Weather Operation.......................................................................................................193 Derated capacities for each °F below -40°F...............................................................................194 Derated capacities for each °C below -40°C...............................................................................194 Crane Warm-up Procedures.....................................................................................................194 Engine...................................................................................................................195 Transmission.............................................................................................................195 Hoist....................................................................................................................195 Swing Drive and Turntable Bearing........................................................................................195 Axles....................................................................................................................195 Hydraulic Oil System.....................................................................................................195 Heating and ventilating the superstructure Cab...............................................................................196 Heating system...........................................................................................................196 Switching on.........................................................................................................196 Heating System Manual Operation..........................................................................................197 Temperature..........................................................................................................197 To increase the temperature......................................................................................197 To reduce the temperature........................................................................................197 Fan..................................................................................................................197 Increasing the air volume........................................................................................197 Reducing the air volume..........................................................................................197 Fresh air/recirculated air...........................................................................................198 Fresh air........................................................................................................198 Recirculated air.................................................................................................198 Air distribution.....................................................................................................198 Air vents on the windshield and in the center....................................................................198 Air vents on the cab floor.......................................................................................198 All air vents....................................................................................................198 Adjusting the air vents..........................................................................................198 Heating System Automatic Operation.......................................................................................199 Setting the day and time.............................................................................................199 Storing the heating start............................................................................................199 Setting the heating period...........................................................................................199 Switching the heating start on and off...............................................................................200 Switching off........................................................................................................200 Setting the remaining time...........................................................................................200 Air-conditioning system..................................................................................................200 Switching on.........................................................................................................200 Operation............................................................................................................201 Drying the air.......................................................................................................201 Switching off........................................................................................................201 Anti-Lock Brake System (ABS).................................................................................................201 ABS Power-Up Sequence....................................................................................................202 ABS Switch Operation.....................................................................................................202 Automatic Traction Control (ATC) Functional Overview.........................................................................202 ATC Operation............................................................................................................203 System Operation.........................................................................................................203 Component Function.......................................................................................................203 Traction Control Power-Up Sequence.......................................................................................203 Traction Control Switch Operation........................................................................................203 Thermal (Brake Heat) Protection..........................................................................................203 ABS/ATC Partial Shutdown.................................................................................................203 Engine Operation.............................................................................................................203 Starting Procedure.......................................................................................................203 Cold Weather Starting....................................................................................................204 Idling the Engine........................................................................................................204 Particulate Filter Maintenance at Idle — Unexpected Idle Speed Increase..............................................204 Racing the Engine........................................................................................................204 Shutdown Procedure.......................................................................................................204 Exhaust System Cleaning..................................................................................................204 Faults on the DEF system.............................................................................................205 Crane Travel Operation.......................................................................................................205 Active Restraints........................................................................................................205 Seat Belts...........................................................................................................205 Traveling - General......................................................................................................206 Axle Weight Distribution Table...........................................................................................207 Manual Transmission Clutch Operation.....................................................................................209 Shifting Gears...........................................................................................................209 Initial Start-up.....................................................................................................210 Upshifting...........................................................................................................211 Downshifting.........................................................................................................211 Shifting to Reverse..................................................................................................212 Driving Tips.........................................................................................................212 Automatic Transmission (Optional)........................................................................................212 Gear Display.........................................................................................................212 Start-up.............................................................................................................213 Power Down...........................................................................................................213 Reverse Mode.........................................................................................................213 Drive Mode...........................................................................................................213 MANUAL Mode..........................................................................................................214 MANUAL / Hold Mode...................................................................................................214 Transmission Manual Override.....................................................................................214 LOW Mode.............................................................................................................215 Transmission LOW Override........................................................................................215 Hill Start Aid (HSA) (Optional-Only available with automated transmission)...........................................215 Differential Control Switches............................................................................................216 Operating the Differential Locks.....................................................................................216 Brakes...................................................................................................................216 Engine Brake.............................................................................................................217 Recommended Crane Shutdown Procedures....................................................................................217 Unattended Crane.............................................................................................................217 Superstructure Cab Platform..................................................................................................217 Proper Leveling of the Crane.................................................................................................218 Bubble Level Adjustment..................................................................................................218 Using the Outriggers.........................................................................................................218 Setting the Outriggers...................................................................................................218 Auto Level Procedure.................................................................................................219 Engaging the Partial/Mid Extension Lock Pin..............................................................................219 Outrigger Monitoring System (OMS) CCS Display............................................................................220 Stowing the Outriggers...................................................................................................220 Stowing the Partial/Mid Extension Lock Pin...............................................................................220 Stowing the Center Front Jack............................................................................................221 Crane operation..............................................................................................................221 Before operating the crane...............................................................................................221 Checking the position of the hoist ropes.............................................................................222 Checking the electrical system.......................................................................................222 Adjusting the crane cab seat and front control panel.................................................................222 Crane cab seat...................................................................................................222 Front panel......................................................................................................223 Checking operator aids...............................................................................................223 Rated capacity limiter...........................................................................................223 Anti-two block switch............................................................................................223 Emergency stop switch............................................................................................224 Seat contact switch..............................................................................................224 Preheating the hydraulic oil.............................................................................................225 Using the swing system...............................................................................................225 Switching the 360° lock on/off...........................................................................................225 Switching on the 360° lock...........................................................................................225 Switching off the 360° lock..........................................................................................225 Operation of the rated capacity limiter......................................................................................226 Switch on the RCL........................................................................................................226 Switching on.........................................................................................................226 Lamp test............................................................................................................226 After a standstill of up to 2 hours..................................................................................227 After a standstill of more than 2 hours..............................................................................227 Enter rigging mode.......................................................................................................228 Entering individual components.......................................................................................228 Switching on input mode..............................................................................................228 Selecting values.....................................................................................................229 Counterweight........................................................................................................229 Boom system..........................................................................................................230 Outrigger span display...............................................................................................230 Outrigger span.......................................................................................................230 Swing range..........................................................................................................231 Entering the RCL code................................................................................................231 Entering the reeving.................................................................................................232 Accepting the rigging code...........................................................................................232 Checks before operating the crane....................................................................................233 Open the menu....................................................................................................233 Checks...........................................................................................................233 Hoists display...................................................................................................234 Example of how to switch over the display........................................................................234 Displays during crane operation......................................................................................234 The current overall height.......................................................................................234 The current lattice extension angle..............................................................................235 The current lattice extension length.............................................................................235 The counterweight................................................................................................235 The current swing angle..........................................................................................235 The currently raised load........................................................................................236 The maximum load.................................................................................................236 The degree of utilization........................................................................................236 RCL early warning....................................................................................................236 RCL shutdown.........................................................................................................236 Shutdown due to overload.........................................................................................236 Canceling a shutdown.............................................................................................237 Display in the event of errors.......................................................................................237 RCL override.........................................................................................................237 External Light Bar (Optional)....................................................................................238 When rigging.....................................................................................................238 RCL override.....................................................................................................238 Anti-two block switch override...................................................................................238 After overriding.................................................................................................238 Canceling the override...........................................................................................238 To raise the boom................................................................................................238 Raise main boom..................................................................................................238 Switch off function..............................................................................................239 In emergencies...................................................................................................239 Canceling a shutdown.............................................................................................239 Canceling the override...........................................................................................239 Crane operation with main boom...........................................................................................239 Main hoist...........................................................................................................239 Switching on the main hoist......................................................................................240 Lifting and lowering.............................................................................................240 Switching off the main hoist.....................................................................................241 Auxiliary hoist......................................................................................................241 Switching on the auxiliary hoist.................................................................................241 Lifting and lowering.............................................................................................241 Switching off the auxiliary hoist................................................................................242 Anti-Two Block switch and lowering limit switch......................................................................242 Anti-Two Block...................................................................................................242 Anti-two block switch override...................................................................................243 Switching on the lifting/lowering mechanism......................................................................243 Raising and lowering.............................................................................................244 Switching off the lifting/lowering mechanism.....................................................................244 Telescoping mechanism................................................................................................244 Manual telescoping...............................................................................................244 Telescoping with semi-automation.................................................................................244 Extending with the main boom configuration.......................................................................244 Overview.........................................................................................................244 Telescoping process..............................................................................................245 Assignment for display...........................................................................................247 Fixed length, intermediate length, telescoping length............................................................247 Main boom fixed length...........................................................................................247 Main boom intermediate length....................................................................................248 Main boom telescoping length.....................................................................................248 Telescoping......................................................................................................248 Telescoping sequence.............................................................................................248 Inspections prior to starting operations.........................................................................248 Switching on the telescoping mechanism...........................................................................248 Function of the control lever....................................................................................248 Switching off the telescoping mechanism..........................................................................249 Manual telescoping...............................................................................................250 Checking the initial position....................................................................................250 Current telescoping..............................................................................................250 Position of the telescoping cylinder.............................................................................250 Position of the locking pins.....................................................................................251 Unlocking the telescoping cylinder...............................................................................251 Extending/retracting the telescoping cylinder....................................................................252 Extending/retracting.............................................................................................252 Lock telescoping cylinder........................................................................................252 Lock.............................................................................................................253 Unlocking the telescopic section.................................................................................253 Telescoping the telescopic section...............................................................................254 Locking the telescopic section...................................................................................254 Locking the telescopic section for on-road driving...............................................................255 Telescoping with semi-automation.................................................................................255 Semi-auto Mode...........................................................................................................255 Introduction.........................................................................................................255 Semi-auto Mode basic operating procedures............................................................................257 Semi-auto Mode for shifting cylinder within fully retracted boom.....................................................259 Semi-auto Mode requiring boom to be retracted........................................................................259 Semi-auto Mode screen refresh........................................................................................259 Semi-auto Mode warning indications...................................................................................259 Semi-auto Mode telescoping function shut-down........................................................................260 Semi-auto Mode lost boom configuration...............................................................................260 Reset telescoping configuration......................................................................................260 Semi-auto Mode vs. Manual Mode.......................................................................................261 Telescoping with main boom configuration.........................................................................262 Entering values..................................................................................................262 High-speed mode......................................................................................................263 Hoists...........................................................................................................263 Swing gear...........................................................................................................263 Swing brake......................................................................................................263 Switching on the swing gear......................................................................................263 Releasing the swing brake........................................................................................264 Applying the swing brake.........................................................................................264 Swing............................................................................................................264 Releasing locked swing gear......................................................................................264 You can limit the maximum swing speed (1, Figure 4- 223), refer to Limiting the power unit speeds, page 4-77.....264 Braking the swing movement.......................................................................................265 Free swing mode..................................................................................................265 Switching off the swing gear.....................................................................................265 Possible movement combinations...........................................................................................266 Settings and displays for crane operation....................................................................................266 Inclining the crane cab..................................................................................................266 Switching units of measure...............................................................................................266 Setting the characteristic curves for the control levers.................................................................267 Limiting the power unit speeds...........................................................................................267 Changing values......................................................................................................268 Camera Display Setup.....................................................................................................268 Using the slewable spotlights............................................................................................269 Warnings in the start menu...............................................................................................269 Meaning of the symbols...............................................................................................269 Work break...................................................................................................................270 In case of short work breaks.............................................................................................270 In case of work breaks of more than 8 hours..............................................................................270 To secure the truck crane............................................................................................271 Trailing Boom Carrier Option.................................................................................................271 Description..............................................................................................................271 Operation................................................................................................................272 Preparation for Highway Travel.......................................................................................272 Travel Precautions...................................................................................................275 Returning to Normal Crane Operation......................................................................................275 Parking the Trailing Boom Carrier........................................................................................275 Tilt-Up Panel Procedure Using the Heavy Duty Boom Extension..................................................................275 Lubrication......................................................................................................................277 General......................................................................................................................277 Environmental Protection.................................................................................................277 Cummins Oil Registration List............................................................................................277 Arctic Conditions Below -18° C (0° F)....................................................................................277 Lubrication Points...........................................................................................................278 Standard Lubricants......................................................................................................279 Cold Weather Lubricants..................................................................................................281 Arctic Lubricants and Conditions.........................................................................................283 Temperatures Below -9°C (15°F).......................................................................................283 Cold Weather Package and Lubricants..................................................................................283 Notes Listed in the Following Tables.............................................................................283 Drivetrain Lubrication...................................................................................................284 Steering Lubrication.....................................................................................................289 Axle Lubrication.........................................................................................................289 Outrigger Lubrication....................................................................................................292 Miscellaneous Lubrication................................................................................................293 Turntable & Cab Tilt Lubrication.........................................................................................294 Hoist Lubrication........................................................................................................297 Turntable Central Lubrication............................................................................................298 Boom Lubrication.........................................................................................................299 Crane Setup..........................................................................................................299 Greaseless Boom......................................................................................................299 Monthly Lubrication Work.................................................................................................302 Pins.................................................................................................................302 Set-up and Installation..........................................................................................................303 General......................................................................................................................304 Installing Cable On The Hoist................................................................................................304 Cable Reeving................................................................................................................304 Dead-End Rigging/Wedge Sockets...............................................................................................305 Installing Wedge and Socket..............................................................................................306 Positioning/Removing the Hoist Cable.....................................................................................307 Positioning Hoist Cable..............................................................................................307 Removing Hoist Cable.................................................................................................307 Possible reevings on the main boom.......................................................................................307 With 5 Head Sheaves..................................................................................................308 5-sheave hook block..................................................................................................308 3-sheave hook block..................................................................................................308 1-sheave hook block..................................................................................................309 Hook tackle..........................................................................................................309 Auxiliary Boom Nose..................................................................................................309 Rigging work for crane operation with the main boom..........................................................................313 Rigging..................................................................................................................313 Unrigging................................................................................................................314 Removable Counterweight..................................................................................................314 Counterweight versions/combinations......................................................................................317 Lifting individual counterweight sections................................................................................317 Lifting stacked counterweight sections...............................................................................318 Slinging points at the counterweight sections........................................................................319 Rigging the counterweight................................................................................................319 Prerequisites:.......................................................................................................319 Unrigging the counterweight..............................................................................................320 Lower 3,000 lb tray plate on the counterweight platform..................................................................320 Check the position of the locking pins for 3000 and 5,000 lb counterweight sections......................................321 Locking Pin position.................................................................................................321 Assembling counterweight versions/ combinations..........................................................................322 Procedures...........................................................................................................323 Counterweight hoist unit.................................................................................................323 Extending/Retracting the lifting cylinders...........................................................................324 Pre-charge...........................................................................................................324 Automatic mode, rigging..............................................................................................324 Rotating with the rigged counterweight...................................................................................325 Extending/retracting the lifting cylinders...........................................................................325 Automatic mode rigging...............................................................................................326 Automatic mode unrigging.............................................................................................327 Cancel automatic mode................................................................................................328 Unlocking/locking the rear counterweight platform........................................................................329 Unlocking............................................................................................................329 Locking..............................................................................................................329 Swinging with rigged counterweight...................................................................................330 Rigging work on the main boom................................................................................................331 Hook block on the bumper.................................................................................................331 Picking up the hook block............................................................................................331 Attaching the hook block.............................................................................................331 Hook block on a separate vehicle.........................................................................................331 Picking up the hook block............................................................................................331 Setting down the hook block..........................................................................................332 Reeving the hoist rope...............................................................................................333 Attaching the rope end clamp.........................................................................................335 Dead-end Rigging.....................................................................................................335 Unreeving hoist rope.................................................................................................337 Installing/removing the anti-two block switch............................................................................337 Installing the anti-two block switch.................................................................................337 Removing the anti-two block switch...................................................................................339 Locking/unlocking the anti-two block switch..............................................................................341 Locking..............................................................................................................341 Removing the lock....................................................................................................341 Anemometer and boom position indicator light.............................................................................341 Installing...........................................................................................................341 Switching the boom position indicator light on and off...............................................................342 Removing.............................................................................................................342 Other rigging work...........................................................................................................342 Cameras for crane operation..............................................................................................342 Camera on the hoists.................................................................................................342 Operating the camera.................................................................................................342 Hoist maintenance platform...............................................................................................343 Slinging points for personal protective equipment........................................................................343 Boom Extensions..............................................................................................................344 Installing the Folding Boom Extension....................................................................................345 Securing Extension with Tag Line (Rope)..............................................................................346 Extension Erecting Warnings and Requirements.............................................................................346 Erecting Procedure: 35 ft (10.5 m) Base Extension........................................................................346 Erecting Procedure: 58 ft (17.6 m) Extension.............................................................................350 Extension Electrical Connections.........................................................................................356 35 ft (10.5 m) Extension Electrical Connections......................................................................356 58 ft (17.5 m) Extension Electrical Connections......................................................................356 Disconnect Electrical Connections to the 58 ft (17.5 m) Base Extension...........................................357 Connecting the Anti-Two Block Switch.....................................................................................357 35 ft (10.5 m) Extension anti-two block Installation.................................................................357 35 ft (10.5 m) Extension Anti-Two Block Removal......................................................................357 58 ft (17.5 m) Extension Anti-Two Block Installation.................................................................358 Extension Hydraulic Connections (Optional Hydraulic Extension)...........................................................358 Checking the Locking Device on the Hose Drum.........................................................................358 Unlocking the Drum...............................................................................................358 Locking the Drum.................................................................................................358 Hydraulic Hose Installation..........................................................................................359 Position for Main Boom Operation.....................................................................................359 Establishing the Hydraulic Connection................................................................................360 Disconnecting the Hydraulic Connection...............................................................................360 Folding Deflection Sheaves...............................................................................................360 Deploying the Rear Deflection Sheave.................................................................................360 Stowing Rear Deflection Sheave.......................................................................................361 Positioning/Removing the Hoist Cable.....................................................................................361 Positioning Hoist Cable..............................................................................................361 Removing Hoist Cable.................................................................................................361 Mechanical Luffing Boom Extension (Adjustable Boom Extension)............................................................363 Extension Angle Adjusting Mechanism..................................................................................363 Setting the Offset Angle with an Auxiliary Crane.....................................................................363 Setting the Offset Angle without an Auxiliary Crane..................................................................363 Entering the RCL Code............................................................................................363 Inclining the Crane..................................................................................................364 Stowing the Folding Boom Extension.......................................................................................364 Requirements for Stowing the Boom Extensions.........................................................................364 Stowing Procedure: 23 ft (7 m) Boom Fly Extension....................................................................364 Stowing Procedure: 58 ft (17.5 m) Extension..........................................................................365 Boom Extension Removal...................................................................................................369 From the side of the main boom.......................................................................................369 From the nose of the main boom.......................................................................................372 Installing and Removing the 26 ft (8 m) Extension Insert.................................................................372 Installation.........................................................................................................372 Removal..............................................................................................................373 Insert Electrical Connection.........................................................................................373 Connecting the 26 ft (8 m) Insert to the Main Boom...............................................................373 Disconnecting Main Boom Electrical Connection....................................................................374 Connecting the Folding Extension Electrical Circuit..............................................................374 Disconnecting the Folding Extension Electrical Circuit...........................................................374 Extension Hydraulic Connection.......................................................................................375 Connecting Main Boom Hydraulics..................................................................................375 Disconnecting Main Boom Hydraulics...............................................................................375 Connecting the Folding Extension Hydraulics......................................................................375 Disconnecting the Folding Extension Hydraulics...................................................................376 Folding the Deflection Sheave on the 26 ft (8 m) Extension...........................................................376 Folding Out the Deflection Sheave................................................................................376 Folding In the Deflection Sheave.................................................................................377 3.5 m (11.4 ft) Manual off-settable Heavy Duty Boom Extension................................................................377 Description..............................................................................................................377 Separating Manual Off-settable Heavy Duty Boom Extension from Lattice Extension..........................................377 Installing Manually Offsetable Heavy Duty Boom Extension.................................................................378 Setting Heavy Duty Boom Extension Manual Offset..........................................................................378 Removing the Manual Offsetable Heavy Duty Extension......................................................................378 3.5 m (11.4 ft) Hydraulic off-settable Heavy Duty Boom Extension.............................................................379 Description..............................................................................................................379 Separating Hydraulic Off-settable Heavy Duty Boom Extension from Lattice Base Extension..................................379 Removing the Hydraulic Offsetable Heavy Duty Extension...................................................................381 Auxiliary Single-Sheave Boom Nose (Optional Equipment).......................................................................382 Identification...........................................................................................................382 Installing/Removing Auxiliary Single-Sheave Boom Nose....................................................................382 Installing Auxiliary Single-Sheave Boom Nose.........................................................................382 Removing the Auxiliary Single-Sheave Boom Nose...........................................................................383 Rigging the Auxiliary Single-Sheave Boom Nose................................................................................383 Rigging in Transport Position............................................................................................383 Rigging in Working Position..............................................................................................383 Attaching and Removing Hoist Cable.......................................................................................384 Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose........................................................384 Anti-two Block Switch....................................................................................................384 In Operation.........................................................................................................384 During Transport.....................................................................................................384 Raising And Setting Down The Main Boom With Rigged Lattice Extension.........................................................384 Telescoping With Rigged Lattice Extension....................................................................................384 Operating with the Lattice Extension.........................................................................................384 Procedure if the Permissible Wind Speed is Exceeded......................................................................384 Anti-two Block Troubleshooting...........................................................................................385 Rear Axle Locking Pins.......................................................................................................386 Installing Rear Axle Locking Pins........................................................................................386 Removing Rear Axle Locking Pins..........................................................................................386
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