TCS 5000 TechSim

RTG Konecranes Crane Model

ver. 1.5

Trainee Manual
Issue Date: May, 2015
Copyright: © Transas MIP Ltd. 1991–2015. All rights reserved.
The information contained herein is proprietary to Transas MIP Ltd. and shall not be duplicated in whole or in part. The technical details
contained in this manual are accurate at the date of issue but are subject to change without notice.
Transas MIP Ltd. pursues a policy of continuous development. This may mean that the product delivered has additional enhancements
not yet covered by the latest version of this manual.
The names of actual companies and products mentioned herein may be the trademarks of their respective owners.
TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual



Contents
1. Printing House Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Purpose of the Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2. Crane Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Crane Control in the Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1. Left Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1.1. Crane and Trolley Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.2. Spreader Micromovements Control . . . . . . . . . . . . . . . . . . . . . . . 6
4.2. Right Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.1. Lifting and Tilting Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.2. The Wheel Position Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.3. Auxiliary Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3. Diag Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4. Consoles of the CCTV Monitoring Cameras . . . . . . . . . . . . . . . . 10
4.5. 3D Visualization Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6. Standard Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.1. Preparing the Crane for Work . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.2. End of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Instructor’s Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Printing House Conventions
Purpose of the Simulator
1. Printing House Conventions
Examples Comments on use
of notation
<F10> To highlight names of keyboard keys
Start
User
To highlight names of windows, pages, buttons etc.
To highlight a path to a file, a folder
2. Introduction
2.1. Purpose of the Simulator
The crane simulator is used for developing practical skills
at controlling contemporary cranes. The simulator is a
universal tool for training operators to develop skills and
reflex motor activities during the control of the selected
crane model in daily and critical situations under various
visibility conditions and hurdles in loading operations in
order to:
• Provide safe movement of load in containers of dif-
ferent types;
• Provide the safety of containers and shore objects;
• Develop the optimal movement path and efficient
methods and sequences of operations on moving
containers;
• Minimize load on the construction, a number of
controlling impacts and provide the permitted dy-
namics of load movement.
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3. Crane
3.1. General Description
A rubber-tyred gantry crane is modelled in the simulator;
the crane can be used on any flat working ground. High
functional flexibility of the crane allows performing load-
ing/unloading operations on any ground, particularly for
stowage operations on the container terminal.
The rubber-tyred gantry crane is an autonomous system.
The crane is equipped with its own diesel AC (alternating-
current) generator which generates power for all electric
drives of the movement and lifting mechanisms.
The construction of the rubber-tyred gantry crane allows
its operation by one crane operator. No rigger is required
for fixing the container on the spreader.
The container crane is equipped with the necessary num-
ber of projectors which allow performing operations at
night or in low visibility conditions.
RTG Konecranes Crane
The RTG Crane – a rubber-tyred ‘KONECRANES’ model is
used as a prototype for modelling.
This crane model is basic and can be easily modified in
any crane model of this type.
3.2. Crane Model
The crane model is based on real physical properties of
the respective equipment. The model considers dynamic
and kinematic features of mechanisms and loads and pro-
vides tracking possible physical contacts (collisions, im-
pacts, blocking, shaking, friction etc.) for displaying these
factors while simulating real loading operations.
Physical collisions and subsequent accidents are tracked,
but not simulated. The simulator models real environ-
ment if operator’s actions are correct, but does not model
consequences of operator’s incorrect actions.
Besides main features of the equipment construction and
the response to movements of controls, movement pa-
rameters of the equipment are influenced by the following
factors:
• The wind direction and speed (set by the Instructor);
• Resistance while lifting heavy loads (can be set by the
Instructor);
• The dynamics of load behavior during abrupt move-
ment of controls;
• Collisions with other objects, including friction;
• The dynamics of travel mechanisms.
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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
Left Control Console

4. Crane Control in the Simulator

4.1. Left Control Console 4
The left control console is located on the left armrest of
the chair of the Trainee workstation on a mobile platform
or on the left touchscreen of the Trainee workstation in
the class. The console contains: 1
• 1 CCTV cameras – panel with two images from the
crane cameras installed above the wheel pairs (see
the paragraph 4.4 on page 10); the upper image is from
the cameras in front of the cabin, the lower one is
from the cameras behind the cabin; 2
• 2 Cargo weight – indicator with an arrow and digital
indication of the container weight in tons; when the 5
arrow is in the red area of the scale, the weight of
load exceeds the permitted value;
• 3 Wind speed – indicator with an arrow and digital in-
dication of wind speed in m/sec (wind rushes are set
by the Instructor for training in complicated ambient
conditions);
3 6
• 4 Crane/Trolley movement controller – is the simulation
of the joystick; the control of the running mechanism
by using the joystick is duplicated on the touchscreen
and vice versa; see the paragraph 4.1.1 on page 6;
• 5 CONTAINER SIZE SWITCH – panel with two illuminated
buttons with for selecting a 20-ft or a 40-ft container;
when pressed, the button lights up, and the spreader
slides in or telescopes according to size selection;
-- Spreader in place lights up when the spreader is placed the yellow lamp lights down when the spreader lifts the
• 6 SPREADER PANEL – comprising light indicators: on the container, the yellow lamp lights up on the container from the ground;
-- Locks open: lights up when the locks of the spreader spreader; if at the same time the green lamp lights -- Locks closed lights up when the locks of the spreader are
are open; a green lamp lights up on the spreader top; up on the spreader, grabbing is allowed; after clos- closed, and the spreader has grabbed the container.
ing the locks on the spreader, the red lamp lights up;

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
Left Control Console
4.1.1. Crane and Trolley Control
Crane/Trolley movement controller simulates the joystick. The
control of the running mechanism by using the joystick is
duplicated on the touchscreen and vice versa. Digital in-
dicators H and V show deviation from the central position:
H – horizontally and V – vertically. The values change in the
range of -100...+100: the higher the values are, the higher
motion speed is:
The additional handle to the left of the joystick simulates
turns of the joystick, which are responsible for turning
the wheel pairs or the spreader depending on the left
button state.
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The left button on the joystick switches ON the function
for controlling the micro movements of the spreader, and
serves as the selector of the turning target.
The joystick right button has no functionality.
When pressed, the button highlights on the screen.
If the left button is depressed:
• Movements of the joystick handle cause:
-- Up/down – the trolley forward/backward;
-- To the left/right – the crane to the left/ right.
• Movements of the additional handle cause:
-- Up – turns the wheels to the right with respect to the
cabin;
-- Down – to the left with respect to the cabin.
Crane manoeuvring can be performed using the joystick
with the left button depressed: moving to the left/right
with a turn.
Attention! When the left button is pressed, the crane
and trolley movement commands are switched OFF.
4.1.2. Spreader Micromovements Control
The left button of the joystick also switches on the func-
tion for controlling the micromovements of the spreader.
The micromovements of the spreader to the right/left/for-
ward/backward are performed by tilting the handle of the
joystick in the respective direction while the left button is
pressed and held down.
Returning the joystick handle to the central position stops
the movement.
Microturns of the spreader in the simulator are per-
formed by using the additional handle to the left of the
joystick. With the left button pressed and held movements
of the additional handle cause:
• Up – a clockwise microturn with respect to the cabin;
• Down – a counterclockwise microturn with respect to
the cabin.
Returning the additional handle to the central position
stops the turn.
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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
Right Control Console

4.2. Right Control Console

The right control console is located on the right armrest of 1
the chair of the Trainee workstation on a mobile platform
or on the right touchscreen of the Trainee workstation in
the class. The console contains:
• Lift/Tilt controller – simulation of the joystick; the con-
trol of the running mechanism by using the joystick is
duplicated on the touchscreen and vice versa; see the
paragraph 4.2.1 on page 8;
• EMERGENCY CUTOFF – button; click in case of a danger to
switch off all working movements of the crane without 2
time delay;
• 1 Crane state monitor – the panel displays the current
state of mechanisms (duplicated on a separate con-
sole, see the paragraph 4.3 on page 9);
7 8
• 2 Siren – button; click for switching the siren on in un-
favorable weather conditions; 3 5
• 3 Drive OFF/Drive ON – buttons serve for switching on/
off the drive; the respective button lights up to indicate
the drive state; the lamp flashes while the ‘ON’ process
is in progress;
• 4 Diesel Stop/Diesel Start – buttons serve for switching
4 6
on/off the crane diesel; the respective button lights up
to indicate the diesel state; the lamp flashes while the
‘ON’ process is in progress;
• 5 Flippers OFF/ON – buttons serve for lifting and lower-
ing the flippers; click the red button to lift the flippers;
click the green button to lower or lift the flippers;
• 6 Spreader – switch is used for switching on/off the
spreader; the spreader is ready for work in the Auto • 7 Wheel position – switch, see the paragraph 4.2.2 on page 8;
position; • 8 AUXILIARY PANEL – controls, see the paragraph 4.2.3 on page 8.

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
Right Control Console
4.2.1. Lifting and Tilting Control
Lift/Tilt controller is simulating the joystick. The control
of the mechanism by using the joystick is duplicated on
the touchscreen and vice versa. Digital indicators H and V
show deviation from the central position: H – horizontally
and V – vertically. The values are changed in the range of
-100...+100: the higher the values are, the higher motion
speed is:
The red buttons under the handle simulate the buttons on
the joystick. When pressed, the button is highlighted on
the screen.
The right button has no functions.
The left button modifies the joystick actions.
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The functions of the joystick with left button depressed: The figures below show the positions of wheels with dif-
ferent states of the Wheel position switch:
• The handle up (push) – lower the spreader;
• The handle down (pull) – lift the spreader;
• The handle to the left – close the locks of the
spreader;
• The handle to the right – open the locks of the
spreader.
The functions of the joystick with left button pressed:
• The handle to the left – tilt the spreader to the left;
• The handle to the right – tilt the spreader to the right.
Attention! No lifting/lowering of the spreader is pos- 1-Forward 2-Turn
sible simultaneously with tilting.
4.2.2. The Wheel Position Switch
The Wheel position switch 7 has four positions:
3-Cross 4-Park
4.2.3. Auxiliary Panel Controls
The AUXILIARY PANEL 8 in the right bottom part of the
right console screen contains:
• Alarm lamps indicating on an emergency stop of the
• 1-Forward – for longitudinal movement of the crane; crane, alarms of the crane and the diesel;
• 2-Turn – for spot turn operation; • The Diesel EMRG.STOP mushroom-shaped button to
• 3-Cross – for transverse (90 degrees) movement of the stop the diesel without time delay;
crane; • Illuminated buttons for switching on/off the lighting in
• 4-Park – wheel blocking for parking. the working area of the crane; the buttons are high-
lighted if the lighting is on.
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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
Diag Console

4.3. Diag Console

The Trainee workstation in the cabin on the mobile plat-
form is equipped with a separate console with a diag-
nostics screen of the crane and mechanisms state. The
screen is modelled on the right console in the Crane state
monitor window on the workstation in the class.
The monitor displays all necessary current performance
parameters of the crane.
The separate console can be set up on one of the screens
of the Trainee workstation or unavailable in the configu-
ration of the workstation in the class.

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
Consoles of the CCTV Monitoring Cameras

4.4. Consoles of the CCTV

Monitoring Cameras
The workstation in the cabin on the mobile platform is
equipped with the CCTV1 and CCTV2 consoles (closed
circuit television) which are large-scale images from
the monitoring cameras located above the wheel pairs
of the gantry.

The CCTV1 and CCTV2 consoles in the con-

figuration of the simulator on the mobile
platform are displayed on separate screens.
The consoles can be set up on one of the
Trainee’s screens or unavailable in other
Image from the CCTV1 camera
configurations of the Trainee workstation.
Images from the cameras are simulated on
the left console in the Monitoring camera
window of the workstation in the class.

Location of a camera
The CCTV1 cameras are located on the gantry in front of
the cabin.
The CCTV2 cameras are located on the gantry behind the
cabin.
The front and rear cameras are switched on automati-
cally in the direction of the crane movement. Image from the CCTV2 camera

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Crane Control in the Simulator
3D Visualization Consoles

4.5. 3D Visualization Consoles

The 3D visualization console in the centre of the Trainee’s workstation in the class and
five visualization consoles in the cabin on a mobile platform provide a realistic view of the
working area when performing exercises.

Examples of views from the cabin on the 3D console

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Alarm System
Standard Procedures

4.6. Standard Procedures 5. Alarm System

4.6.1. Preparing the Crane for Work
1. Press the Diesel Start button on the right console;
make sure that the button lights up.
2. Press the Drive ON button on the right console;
make sure that the button lights up.
3. On the right console, switch the Spreader switch to
the Auto position – the spreader is ready for work.
4. Set the wheels to the necessary position by using
the Wheel position switch on the right console.
5. If necessary, switch the lighting of the
trolley, gantry etc. on the right console.
6. Using the right joystick (or its simulation on
the right console Lift/Tilt controller), lower
the spreader (by pushing) until it can be
seen from the cabin on the 3D panel.
The crane is ready for work. Perform the exercise,
watching the position of the crane, trolley, spreader and
load on the 3D image of the working area, devices and
the camera monitoring screen on the right console and
the crane state monitor on the right console.
Note: To grab a container, close the locks by the Lift/Tilt con-
troller on the Right console. Move the handle to the left when the
Spreader in place indicator lamp illuminates.
4.6.2. End of Work The alarm system indicates to the Trainee an emergency
1. Using the right joystick (or its simulation on the situation. The respective message is displayed on the
right console Lift/Tilt controller), lift the spreader. crane state monitor, a sound signal is produced.
2. On the right console, switch the Spreader switch to The Buzzer button is flashing on the top tool bar.
the Off position – the spreader is switched off. To switch off the alarm signal, click the button.
3. On the right console, switch the Wheel position switch
to the 4-Park position – the wheels are blocked.
4. Move the trolley to the parking position.
5. Press the Drive OFF button on the right console;
make sure that the button lights up.
6. Switch off the external lighting if was on – press
the respective buttons on the right console.
7. Press the Diesel Stop button on the right console;
make sure that the button lights up.
The crane is switched off; the cabin is in the parking
position.

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TCS 5000 TechSim. RTG Konecranes Crane Model. Trainee Manual
Instructor’s Page
Standard Procedures

6. Instructor’s Page
Instructor program for the simulator TCS 5000 TechSim
is enhanced to allow training on the specific crane opera-
tions. Additional page Ins Kit is displayed on the Instruc-
tor’s Slave monitor (or on a separate monitor, if defined in
the workplace configuration). Trainees do not have access
to this page, where Instructor can select the crane work-
ing area, set weather, transport, loading parameters, etc.
Click the button to open the help file for the Ins Kit page in
a new window.

InsKit Help

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