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Grove Crane GMK 3050B Driving & Crane Operating Manual 3113049 – PDF DOWNLOAD
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Description
Grove Crane GMK 3050B Driving & Crane Operating Manual 3113049 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 3050B Driving & Crane Operating Manual 3113049 – PDF DOWNLOAD
Language : English
Pages : 858
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 3050B Driving & Crane Operating Manual 3113049 – PDF DOWNLOAD
Basic safety instructions:
2.1 Intended use
- The GMK 3050B is a state-of-the-art truck crane, designed in accordance
with approved safety regulations. Nevertheless, the operator or third parties
can still be endangered and the crane or other property put at risk while
using it. - The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK 3050B truck crane may only be used when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards. - Any malfunctions that could impair safety must be eliminated immediately.
- The GMK 3050B truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
data, p. 1 – 7. - The GMK 3050B truck crane is designed solely for lifting loads which are
within the permitted GMK 3050B lifting capacities. The load must be slung
as prescribed to a hook block which is positioned vertically over the load
prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
- The GMK 3050B may only be operated with parts of equipment which are
permitted by Manitowoc Crane Group Germany GmbH and which are labelled
with the serial number of the GMK 3050B. - The manufacturer is not liable for any damage caused by improper or
unauthorized use of the GMK 3050B truck crane. The user alone bears the
risk.
TABLE OF CONTENTS:
Grove Crane GMK 3050B Driving & Crane Operating Manual 3113049 – PDF DOWNLOAD
Part 1 – Driving................................................................................ 1 1 Overview.................................................................................. 7 1.1 Accidents........................................................................... 7 1.2 Branch offices...................................................................... 9 1.2.1 Manitowoc Crane Care.......................................................... 9 1.2.2 Dealer list................................................................... 9 1.3 Warranty specifications............................................................. 9 1.4 Terms used.......................................................................... 10 1.5 Technical data...................................................................... 13 1.5.1 Maximum lifting capacity (DIN/ISO/EN)......................................... 13 1.5.2 Maximum lifting capacity (ASME B 30.5)........................................ 13 1.5.3 Dimensions and weights of the truck crane, axle loads......................... 14 Dimensions...................................................................... 15 Weight and axle loads........................................................... 15 1.5.4 Dimensions and weights of removable parts..................................... 16 Spare wheel..................................................................... 16 Outriggers...................................................................... 16 Hook blocks and hook tackle..................................................... 16 Counterweight parts............................................................. 17 1.5.5 Carrier....................................................................... 18 Engine.......................................................................... 18 Transmission.................................................................... 18 Transfer case................................................................... 18 Axle lines...................................................................... 18 Steering........................................................................ 18 Tyres........................................................................... 19 Outriggers...................................................................... 19 Electrical system............................................................... 20 Tool............................................................................ 20 Towing couplings................................................................ 20 Driving speeds.................................................................. 20 Climbing ability................................................................ 20 Turning radii................................................................... 21 1.5.6 Superstructure................................................................ 21 Main hoist...................................................................... 21 Auxiliary hoist................................................................. 22 Slewing gears................................................................... 22 Derricking gear................................................................. 22 Main boom....................................................................... 22 Lattice extension............................................................... 22 Operating speeds................................................................ 23 1.6 Documentation supplied.............................................................. 25 1.6.1 Questions on documentation.................................................... 26 1.7 Notes on the operating instructions................................................. 27 1.7.1 What do the symbols used mean?................................................ 27 1.7.2 How are the operating instructions structured?................................ 29 Division........................................................................ 29 Structure of the chapters....................................................... 29 Structure of the pages.......................................................... 30 1.7.3 How do I find the information I need?......................................... 31 Cross-references example........................................................ 32 1.7.4 What information is available for operations planning?........................ 34 1.8 Conversion table for US measuring units............................................. 35 1.9 Training – Information.............................................................. 37 1.10 Identification..................................................................... 38 1.11 EC Declaration of Conformity....................................................... 40 2 Basic safety instructions................................................................. 43 2.1 Intended use........................................................................ 43 2.1.1 Improper use.................................................................. 44 2.2 Organisational measures............................................................. 45 2.3 Personnel qualifications............................................................ 47 2.4 Safety instructions for driving the truck crane..................................... 48 2.5 Safety instructions for crane operation............................................. 48 2.6 Notes on transporting persons....................................................... 51 Equipment for lifting persons....................................................... 51 Personnel........................................................................... 51 Operation........................................................................... 52 Truck crane......................................................................... 53 3 Operating elements for driving............................................................ 57 3.1 Overview of the operating elements.................................................. 59 3.1.1 On the outside of the truck crane............................................. 60 3.1.2 Driver's cab.................................................................. 62 Overview........................................................................ 62 Behind the cover................................................................ 64 Page............................................................................ 65 Doors........................................................................... 66 Front........................................................................... 67 3.1.3 Instrument panel.............................................................. 68 Middle.......................................................................... 68 Left/right...................................................................... 70 3.1.4 Transmission operating elements............................................... 71 3.1.5 Display, driving mode......................................................... 72 3.1.6 Steering column/steering wheel................................................ 73 3.1.7 Tachograph.................................................................... 74 3.1.8 Standard heating.............................................................. 75 Auxiliary water heater.......................................................... 76 Auxiliary air heater............................................................ 77 3.1.9 Control unit CCS.............................................................. 78 3.1.10 Display CCS – Start menu..................................................... 80 3.1.11 CCS – Overview menu groups................................................... 81 Carrier menu group.............................................................. 82 Suspension/level adjustment menu................................................ 83 Driving menu.................................................................... 84 Settings menu group............................................................. 85 Menu for setting the display brightness and date/ time.......................... 86 Information menu group.......................................................... 87 Operating hours menu............................................................ 88 Engine/transmission error menu.................................................. 89 Crane operation error menu...................................................... 90 Operating additional equipment.................................................. 91 3.1.12 Sockets for hand-held control................................................ 92 3.1.13 Outrigger control units...................................................... 93 3.2 Short description of the operating elements......................................... 95 3.2.1 Definition of direction information........................................... 95 Basic rule...................................................................... 95 Switches and buttons............................................................ 96 3.2.2 General notes on the operating elements....................................... 96 3.2.3 General rules for buttons and symbols on the display.......................... 97 3.2.4 Engine........................................................................ 98 Steering column................................................................. 98 Multipurpose switch............................................................. 98 Instrument panel................................................................ 99 3.2.5 DEF system....................................................................101 Instrument panel................................................................101 Display, driving mode...........................................................102 CCS display.....................................................................102 3.2.6 Crane control CCS.............................................................102 3.2.7 Transmission..................................................................107 Transmission control unit.......................................................107 Display, driving mode...........................................................108 3.2.8 Reverse camera................................................................110 3.2.9 Final drive...................................................................111 3.2.10 Brakes.......................................................................113 Service brake...................................................................113 Additional brakes...............................................................114 Parking brake...................................................................115 3.2.11 Steering/separate steering...................................................116 Instrument panel................................................................116 Driver's door...................................................................116 CCS display.....................................................................117 3.2.12 Suspension...................................................................118 CCS display.....................................................................118 3.2.13 Lighting/windscreen wipers/horn..............................................119 Steering column.................................................................119 Instrument panel................................................................119 CCS display.....................................................................121 Roof............................................................................122 3.2.14 Level adjustment system......................................................123 3.2.15 Tachograph/speedometer.......................................................125 Tachograph......................................................................125 3.2.16 Diagnostics..................................................................126 3.2.17 Windows, doors, keys.........................................................127 Window winder...................................................................127 Doors...........................................................................128 Keys............................................................................129 3.2.18 Front flap...................................................................129 4 Starting/turning off the engine for driving...............................................133 4.1 Starting the engine from the driver's cab...........................................133 4.1.1 CHECKLIST: Starting the engine................................................133 4.1.2 CHECKLIST: At low temperatures................................................136 4.1.3 Ladders.......................................................................137 4.1.4 Refuel........................................................................140 Fuel tank.......................................................................140 Filling DEF.....................................................................142 Auxiliary heater tank...........................................................143 4.1.5 Checks before starting the engine.............................................144 On hydraulic tank...............................................................144 Battery master switch...........................................................145 Checking hand- held control.....................................................145 4.1.6 Switching on the ignition.....................................................145 4.1.7 Lamp test/equalisation of the switching states................................146 Lamp test.......................................................................146 Equalisation of the switching states............................................146 4.1.8 Display – setting the brightness..............................................147 4.1.9 Starting the engine...........................................................148 Without flame start system......................................................149 With flame start system.........................................................150 4.1.10 Checks after starting the engine.............................................151 Checking in the main menu.......................................................151 Indicator lamps on the instrument panel.........................................151 4.1.11 Monitoring elements..........................................................152 Instrument panel................................................................152 4.1.12 Start menu...................................................................153 4.1.13 Setting idling speed.........................................................154 4.2 Turning off the engine..............................................................155 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units....155 After turning off...............................................................155 4.2.2 Using the emergency stop switches.............................................156 Resetting the emergency stop switch.............................................156 4.3 Air intake inhibitor................................................................157 Releasing the air intake inhibitor..................................................157 5 Driving...................................................................................161 5.1 Before driving......................................................................161 5.1.1 CHECKLIST: Checks before on-road driving......................................161 5.1.2 Checking the condition of the truck crane.....................................166 Electrical system...............................................................166 Adjusting the mirrors...........................................................166 Warning plates for vehicle width................................................168 Displaying vehicle height.......................................................168 Supply pressure.................................................................169 Parking brake...................................................................170 5.1.3 Adjusting the seat and the steering column....................................171 Adjusting the driver's seat.....................................................171 Adjusting the passenger seat....................................................172 Adjusting the steering column...................................................173 Storage compartment under the driver's seat.....................................173 5.1.4 Switching the suspension on/off...............................................174 Open menu.......................................................................174 Switching on the suspension.....................................................175 Switching off the suspension....................................................175 5.1.5 Setting the tachograph........................................................176 Prerequisites...................................................................176 In the event of malfunctions....................................................176 Setting the tachograph..........................................................177 5.1.6 Entering the time/date........................................................181 5.1.7 Displaying and resetting operating hours......................................182 5.1.8 Settings/indications on the driving display...................................183 5.2 Operating the transmission..........................................................184 5.2.1 Switching on..................................................................184 5.2.2 Switching the transmission to neutral position................................185 5.2.3 Selecting the direction of travel and starting gear...........................186 Selecting the driving direction.................................................186 Selecting the starting gear.....................................................187 5.2.4 Changing the operating mode...................................................188 Change to automatic mode........................................................188 Change to manual mode...........................................................188 5.2.5 Starting......................................................................189 5.2.6 Driving and changing gears....................................................191 In automatic operating mode.....................................................191 In manual operating mode........................................................192 5.2.7 Changing the driving direction................................................193 5.2.8 Stopping......................................................................193 Stopping for a long period of time..............................................193 5.2.9 DM and RM transmission mode...................................................194 Switching on....................................................................194 Switching off...................................................................195 5.2.10 On the roller type dynamometer...............................................196 5.2.11 Preheating transmission......................................................196 5.3 Driving and turning off the truck crane.............................................197 5.3.1 Checks while driving..........................................................197 Immediately after you start to move.............................................197 While driving...................................................................199 5.3.2 Tempomat......................................................................200 Switching on....................................................................200 Switching off...................................................................201 5.3.3 Cruise control................................................................201 Switching on....................................................................201 Switching off...................................................................201 5.3.4 Driving downhill..............................................................202 Starting........................................................................202 Inspections when driving downhill...............................................203 Downshifting....................................................................203 Additional brakes...............................................................204 5.3.5 Driving uphill................................................................205 Starting........................................................................205 Driving.........................................................................205 5.3.6 Warning or malfunction messages on the instrument panel.......................206 Meaning of the lamps............................................................206 5.3.7 Notes on torque reduction.....................................................208 5.3.8 Warning messages in the start menu............................................209 5.3.9 Turning off the truck crane...................................................210 Securing against rolling away...................................................210 When stationary for more than 8hours...........................................211 5.3.10 Fold-up berth................................................................212 5.4 Off-road driving....................................................................213 Adjustments to the transmission.....................................................213 Connections.........................................................................213 Changing the vehicle level..........................................................213 Rocking the vehicle free and towing.................................................213 5.4.1 Longitudinal and transverse differential locks................................214 5.4.2 Operating the level adjustment system.........................................216 Open menu.......................................................................216 Setting the on-road level.......................................................217 Pre-selecting suspension struts.................................................217 Changing the vehicle level......................................................218 Viewing the current inclination.................................................218 Exiting the menu................................................................219 5.4.3 Freeing truck crane stuck in terrain..........................................220 Rocking the truck crane free....................................................220 Towing free forwards............................................................221 Towing free in reverse gear.....................................................221 5.5 Separate steering...................................................................223 5.5.1 Switching to separate steering................................................223 Manual..........................................................................224 Automatic.......................................................................225 5.6 Heating and air-conditioning system.................................................227 5.6.1 Standard heating system.......................................................227 Switching on....................................................................227 Temperature.....................................................................227 Fan.............................................................................227 Fresh air/recirculated air......................................................228 Air distribution................................................................228 Switching off...................................................................229 5.6.2 Auxiliary water heater........................................................230 Preheating the engine...........................................................230 Preheating the driver's cab.....................................................230 Switching on....................................................................231 Setting the day and time........................................................232 Storing the heating start.......................................................232 Setting the heating period......................................................234 Switching the heating start on and off..........................................234 Switching off...................................................................235 Setting the remaining time......................................................235 5.6.3 Auxiliary air heater..........................................................236 Switching on....................................................................236 Temperature.....................................................................237 Other functions.................................................................237 Switching off...................................................................237 5.6.4 Air-conditioning system.......................................................238 Switching on....................................................................238 Operation.......................................................................238 Drying the air..................................................................239 Switching off...................................................................239 5.7 Towing a trailer....................................................................241 Effects on the axle loads...........................................................241 Coupling the trailer................................................................242 Connecting the supply lines.........................................................243 Removing the supply lines...........................................................244 Uncoupling the trailer..............................................................244 Checking the braking force..........................................................246 6 Driving modes.............................................................................249 6.1 Driving modes.......................................................................249 Information about the axle loads....................................................249 6.1.1 Information on how to use the tables..........................................250 6.1.2 Table for a maximum axle load of 12 t (26 500 lbs)............................251 For 385/95 R25 tyres............................................................251 For 445/95 R25 tyres............................................................252 For 525/80 R25 tyres............................................................253 7 Malfunctions in driving mode..............................................................257 7.1 Emergency stop switch...............................................................257 7.2 What to do when a malfunction occurs in road traffic................................259 7.3 Towing the truck crane..............................................................261 7.3.1 Towing after engine/transmission damage.......................................262 Compressed-air supply...........................................................262 Electric power supply...........................................................262 On the transmission............................................................263 Axle drives.....................................................................263 Parking brake...................................................................263 Towing the truck crane out of the danger area...................................264 Longer towing distances.........................................................264 7.3.2 Tow starting..................................................................264 7.4 Other emergency operations..........................................................265 7.4.1 Externally starting the truck crane...........................................265 7.4.2 Battery charger...............................................................266 7.5 Wheels and tyres....................................................................267 7.5.1 Wheel change..................................................................267 Removing a damaged wheel........................................................268 On the spare wheel holder.......................................................268 Mounting a wheel................................................................269 7.5.2 Inflating the tyres yourself..................................................271 Connecting the filling hose.....................................................271 Inflating the tyres.............................................................272 Removing the filling hose.......................................................272 7.6 Tilting/lowering the driver's cabin.................................................273 7.6.1 Prerequisites and information on tilting......................................273 7.6.2 Tilting and lowering the driver's cab.........................................274 Operating the hand pump.........................................................274 Tilting the driver's cab........................................................275 Lowering the driver's cab.......................................................276 7.7 Fuses on the carrier................................................................277 Notes on changing fuses.............................................................277 7.7.1 Fuses in the driver's cab.....................................................278 7.7.2 Fuses in the battery box......................................................284 7.8 Troubleshooting.....................................................................285 7.8.1 Malfunctions on the engine....................................................285 When operating with the dual tank...............................................287 7.8.2 Faults on the DEF system......................................................287 7.8.3 Differential lock malfunctions................................................288 7.8.4 Malfunctions in the transmission..............................................289 7.8.5 Malfunctions of the steering..................................................290 7.8.6 Malfunctions of the service brake.............................................291 7.8.7 Malfunctions on the suspension................................................291 7.8.8 Malfunctions of the level adjustment system...................................291 7.8.9 Malfunctions in the hydraulic system/hydraulic oil cooler.....................292 7.9 Warnings in the start menu..........................................................293 Symbols in the display area.........................................................293 7.9.1 Engine/transmission error menu................................................298 Open menu.......................................................................298 Exiting the menu................................................................298 7.10 Procedure in the event of malfunctions.............................................299 7.10.1 Switching on emergency operation in coolant circuit..........................299 7.10.2 Procedure during transmission malfunctions...................................300 Error messages..................................................................300 Displaying error codes..........................................................302 8 Index.....................................................................................305 A.......................................................................................307 B.......................................................................................307 C.......................................................................................307 D.......................................................................................310 E.......................................................................................312 F.......................................................................................313 H.......................................................................................314 I.......................................................................................314 K.......................................................................................315 L.......................................................................................315 M.......................................................................................315 O.......................................................................................316 P.......................................................................................317 R.......................................................................................317 S.......................................................................................318 T.......................................................................................319 V.......................................................................................321 W.......................................................................................321 Part 2 – Crane operation........................................................................325 9 Operating elements for crane operation....................................................331 9.1 Overview of the operating elements..................................................331 9.1.1 Exterior of the truck crane...................................................332 9.1.2 Crane cab.....................................................................334 Side panel......................................................................336 Crane cab, rear.................................................................338 9.1.3 Control panels................................................................340 Left............................................................................340 Right...........................................................................341 9.1.4 Control lever configuration...................................................342 Version 1.......................................................................342 Version 2.......................................................................343 9.1.5 Heating system................................................................345 9.1.6 Control unit CCS..............................................................346 9.1.7 CCS – Start menu..............................................................349 9.1.8 CCS – overview of menu groups.................................................350 Superstructure menu group.......................................................354 Superstructure lock menu........................................................355 Counterweight menu..............................................................356 Outrigger menu..................................................................357 Outrigger support beam menu.....................................................359 Outrigger cylinders menu........................................................360 Teleautomation menu group.......................................................362 Telescoping full automation menu................................................363 Telescoping semi- automation menu...............................................364 Main boom configuration menu....................................................365 Active working range limiter menu group.........................................366 Overall height menu.............................................................367 Working radius menu.............................................................368 Slewing angle menu..............................................................369 Information menu group..........................................................370 Hydraulic pressure and fuel consumption menu....................................371 Driving menu group..............................................................373 Driving mode menu...............................................................374 Telescoping menu group..........................................................376 Manual telescoping menu.........................................................377 Telescoping emergency program menu..............................................378 Unknown telescoping menu........................................................379 Settings menu group.............................................................380 Adjust wiper stroke interval menu...............................................381 Menu for setting the display brightness and date/time...........................382 Switch units menu...............................................................383 Set control lever characteristic curve menu.....................................384 Power unit speeds menu..........................................................385 Menu group Information..........................................................387 Operating hours menu............................................................388 Engine/transmission error menu..................................................390 Crane operation error menu......................................................391 Program version menu............................................................392 Operating additional equipment..................................................393 9.1.9 Control unit RCL..............................................................394 9.1.10 RCL – menu groups............................................................396 Enter rigging mode menu.........................................................399 Monitoring menu.................................................................400 Lifting capacity table menu.....................................................402 9.1.11 Hand-held control............................................................403 Outrigger control panel.........................................................405 9.1.12 Outrigger control units......................................................406 Button..........................................................................406 Outrigger button................................................................407 Inclination and outrigger pressure display......................................408 9.1.13 For emergency hydraulic operation............................................409 9.2 Short description of the operating elements.........................................411 9.2.1 Definition of direction information...........................................411 Basic rule......................................................................411 Switches........................................................................411 9.2.2 General rules for buttons and symbols on the display..........................412 9.2.3 Engine........................................................................413 Side panel......................................................................413 CCS display.....................................................................413 9.2.4 DEF system....................................................................414 CCS display.....................................................................414 9.2.5 Seat contact switch and dead man's switch.....................................415 9.2.6 Crane control CCS.............................................................416 9.2.7 Outrigger.....................................................................422 Hand-held control...............................................................422 Right-hand control panel........................................................423 Left-hand control panel.........................................................423 In the Outrigger menu...........................................................424 On the outrigger control units..................................................426 9.2.8 Inclination indicators........................................................428 9.2.9 Anemometer displays...........................................................429 9.2.10 Counterweight menu...........................................................430 9.2.11 Superstructure lock/houselock menu...........................................432 Superstructure lock.............................................................432 Houselock.......................................................................433 9.2.12 Main hoist...................................................................435 Control panels..................................................................435 CCS display.....................................................................436 9.2.13 Auxiliary hoist..............................................................437 Control panels..................................................................437 CCS display.....................................................................438 9.2.14 Slewing gear.................................................................439 Control panels..................................................................439 CCS display.....................................................................440 9.2.15 Derricking gear..............................................................441 Control panels..................................................................441 CCS display.....................................................................442 9.2.16 Telescoping mechanism........................................................443 Control panels..................................................................443 CCS display.....................................................................443 Telescoping full automation menu................................................444 Telescoping semi- automation menu...............................................445 Manual telescoping menu.........................................................447 Main boom configuration menu....................................................450 9.2.17 Hydraulic system.............................................................451 9.2.18 Rated capacity limiter (RCL).................................................452 Control unit control console RCL................................................452 Display RCL.....................................................................453 Enter rigging mode menu.........................................................455 Monitoring menu.................................................................458 Lifting capacity tables menu....................................................461 RCL override....................................................................462 External displays...............................................................463 9.2.19 Electrical system............................................................464 9.2.20 Lighting, windscreen wiper/washing system....................................464 Lighting........................................................................464 Windscreen wiper/washing system.................................................466 9.2.21 Hand-held control............................................................467 Sockets on truck crane..........................................................467 Engine control panel............................................................468 Horn............................................................................468 Outriggers control panel........................................................469 9.2.22 Diagnostics..................................................................471 9.2.23 Windows, doors, keys.........................................................472 Windscreen......................................................................472 Rear window.....................................................................472 Crane cab door..................................................................473 Keys............................................................................474 9.3 Short description of the operating elements – driving from the crane cab............475 9.3.1 Driving mode menu.............................................................475 9.3.2 Transmission..................................................................476 9.3.3 Final drive...................................................................477 9.3.4 Brakes........................................................................478 CCS display.....................................................................478 Side panel from above...........................................................479 9.3.5 Steering......................................................................480 CCS display.....................................................................480 Steering modes..................................................................481 Separate steering...............................................................481 Control panels..................................................................482 10 Starting/stopping the engine – for crane operation.......................................485 10.1 When starting the engine for the first time of the day.............................485 10.2 Starting the engine – from the crane cab...........................................487 10.2.1 Checking the fuel level and DEF level........................................487 Fuel............................................................................487 DEF.............................................................................487 10.2.2 Checks before starting the engine............................................488 Checks on the carrier...........................................................488 Checking hand- held control.....................................................488 10.2.3 Switching on the ignition....................................................488 10.2.4 Lamp test/equalisation of the switching states...............................489 Lamp test.......................................................................489 Equalisation of the switching states............................................489 10.2.5 Display – setting the brightness.............................................490 10.2.6 Starting the engine..........................................................491 Without flame start system......................................................491 With flame start system.........................................................492 10.2.7 Checks after starting the engine.............................................493 10.2.8 Setting idling speed.........................................................494 10.3 Starting the engine – with the hand-held control...................................495 10.4 Turning off the engine.............................................................497 10.4.1 On the ignition lock/with hand-held control..................................497 After starting from the crane cab...............................................497 After starting up with the hand- held control...................................497 After turning off...............................................................497 10.4.2 Using the emergency stop switches............................................498 Resetting the emergency stop switch.............................................498 11 Crane operation..........................................................................501 11.1 Before operating the crane.........................................................501 11.1.1 CHECKLIST: Checks before operating the crane.................................501 11.1.2 Checking the condition of the truck crane....................................505 Auxiliary heater – tank.........................................................505 Visual inspection...............................................................506 Checking the position of the hoist ropes........................................506 Checking the electrical system..................................................507 11.1.3 Adjusting the crane cab seat and front control panel.........................508 Crane cab seat..................................................................508 Front panel.....................................................................508 11.1.4 Checking the safety equipment................................................509 Rated capacity limiter..........................................................509 Lifting limit switch............................................................509 Emergency stop switch...........................................................510 Seat contact switch.............................................................511 11.1.5 Earthing the load............................................................512 11.1.6 Preheating the hydraulic oil.................................................513 11.1.7 Locking/unlocking the superstructure.........................................515 Locking points..................................................................515 Locking the superstructure......................................................516 Unlocking the superstructure....................................................516 11.1.8 Switching the houselock on/off...............................................517 Switching on the houselock......................................................517 Switching off the houselock.....................................................519 11.2 Operation of the rated capacity limiter............................................521 11.2.1 Switch on the RCL............................................................522 Switching on....................................................................522 Brightness of the displays......................................................524 Temperature on the display......................................................524 11.2.2 Enter rigging mode...........................................................525 Entering individual components..................................................526 Entering the RCL code...........................................................530 Entering the reeving............................................................531 Accepting the rigging mode......................................................531 11.2.3 Checks before operating the crane............................................533 Open menu.......................................................................533 Checks..........................................................................533 11.2.4 Displays during crane operation..............................................536 11.2.5 RCL pre-warning..............................................................539 11.2.6 RCL switch-off...............................................................539 Shutdown due to overload........................................................539 11.2.7 Display in the event of errors...............................................541 11.2.8 RCL override.................................................................542 Overview status display.........................................................542 When rigging....................................................................543 To raise the boom...............................................................544 In emergencies..................................................................545 11.2.9 Displaying the lifting capacity tables.......................................546 11.2.10 Setting the time/date.......................................................548 11.3 Crane operation with main boom.....................................................549 11.3.1 Checks during crane operation................................................549 Horizontal alignment............................................................549 Safe distances..................................................................549 Checking the wind speed.........................................................550 11.3.2 Permissible slewing ranges and working positions.............................551 360 slewing range..............................................................551 0 to the rear working position.................................................551 180 to the front rigging position..............................................552 Free-on-wheels working position.................................................552 11.3.3 Main hoist...................................................................553 Switching on the main hoist.....................................................554 Lifting and lowering............................................................554 Switching off the main hoist....................................................555 11.3.4 Auxiliary hoist..............................................................556 Switching on the auxiliary hoist................................................556 Lifting and lowering............................................................557 Switching off the auxiliary hoist...............................................558 11.3.5 Lifting limit switch and lowering limit switch...............................559 Lifting limit switch............................................................559 Lowering limit switch...........................................................561 11.3.6 Derricking gear..............................................................562 Switching on the derricking gear................................................562 Raising and lowering............................................................563 Re-enable raising function......................................................564 Switching off the derricking gear...............................................564 Lowering the main boom to ahorizontal position.................................565 11.3.7 Telescoping mechanism........................................................566 Overview........................................................................567 Telescoping process.............................................................567 Assignment for display..........................................................570 Fixed length, intermediate length, telescoping length...........................571 Telescoping.....................................................................572 Telescoping sequence............................................................572 Checks before starting work.....................................................573 Switching on the telescoping mechanism..........................................574 Function of the control lever...................................................574 Switching off the telescoping mechanism.........................................576 Manual telescoping..............................................................577 Checking the initial position...................................................577 Unlocking the telescoping cylinder..............................................579 Extending/ retracting the telescoping cylinder..................................581 Lock telescoping cylinder.......................................................582 Unlocking the telescopic section................................................583 Telescoping the telescopic section..............................................584 Locking the telescopic section..................................................585 Locking the telescopic section for on-road driving..............................586 Telescoping with semi-automation................................................586 Telescoping with full automation................................................589 Telescoping the main boom when horizontal.......................................590 Telescoping with main boom configuration........................................590 11.3.8 High-speed mode..............................................................591 Derricking gear/ telescoping mechanism..........................................591 Hoists..........................................................................592 11.3.9 Slewing gear.................................................................593 Switching on the slewing gear...................................................593 Slew............................................................................593 Braking the slewing movement....................................................595 Engaging the slewing gear brake.................................................595 Releasing the slewing gear brake................................................595 Slewing gear freewheel..........................................................596 Switching off the slewing gear..................................................596 11.3.10 Possible movement combinations..............................................597 11.4 Settings and displays for crane operation..........................................599 11.4.1 Inclining the crane cab......................................................599 11.4.2 Setting idling speed.........................................................600 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper..................600 11.4.4 Limiting the power unit speeds...............................................601 11.4.5 Switching units..............................................................602 11.4.6 Setting the characteristic curves for the control levers.....................603 11.4.7 Using the slewable spotlights................................................604 11.4.8 Override torque reduction....................................................605 11.4.9 Displaying the operating hours...............................................606 11.4.10 Warnings in the start menu..................................................607 Meaning of the symbols..........................................................607 11.5 Working range limiter..............................................................611 11.5.1 Viewing current settings.....................................................612 11.5.2 Opening the working range limiter menu.......................................612 11.5.3 Entering limit values........................................................615 Overall height..................................................................615 Working radius..................................................................616 Slewing angle...................................................................616 11.5.4 Entering limit values manually...............................................618 Limit values....................................................................618 11.5.5 Switching monitoring functions on/off........................................620 11.5.6 Shutdown by working range limiter............................................621 11.6 Work break.........................................................................623 11.6.1 In case of short work breaks.................................................623 11.6.2 In case of work breaks of more than 8 hours..................................624 To secure the truck crane.......................................................624 11.7 Heating and ventilating the crane cab..............................................625 11.7.1 Heating system...............................................................625 Switching on....................................................................626 Temperature.....................................................................626 Fan.............................................................................627 Fresh air/ recirculated air.....................................................627 Air distribution................................................................627 Setting the day and time........................................................629 Storing the heating start.......................................................630 Setting the heating period......................................................631 Switching the heating start on and off..........................................631 Switching off...................................................................632 Setting the remaining time......................................................632 11.7.2 Air-conditioning system......................................................633 Switching on....................................................................633 Operation.......................................................................633 Drying the air..................................................................634 Switching off...................................................................634 11.8 CraneSTAR system...................................................................635 11.8.1 Overview.....................................................................635 11.8.2 Position of the components...................................................635 12 Rigging work.............................................................................639 12.1 Rigging work checklists for crane operation with the main boom.....................639 12.1.1 CHECKLIST: Rigging...........................................................639 12.1.2 CHECKLIST: Unrigging.........................................................644 12.2 Choosing a suitable site...........................................................647 12.2.1 Determining the required ground bearing area.................................647 12.2.2 Safe distance from slopes and pits...........................................650 12.2.3 Earthing the truck crane.....................................................651 12.2.4 Safe distance from electrical cables.........................................652 12.3 Connecting/disconnecting the hand-held control.....................................655 12.4 Starting the engine for rigging....................................................657 12.4.1 Starting/turning off the engine with the hand-held control...................657 Prerequisites...................................................................657 Starting the engine.............................................................658 Turning off the engine..........................................................658 12.4.2 Starting/turning off the engine from the outrigger control units.............659 Prerequisites...................................................................659 Starting the engine.............................................................659 Turning off the engine..........................................................659 12.5 Outrigger..........................................................................661 12.5.1 CHECKLIST: Extending the outriggers..........................................661 12.5.2 CHECKLIST: Retracting the outriggers.........................................663 12.5.3 Permissible outrigger spans..................................................664 12.5.4 Preparing the truck crane....................................................665 In the driver's cab.............................................................665 Outrigger control units.........................................................665 12.5.5 Setting the outrigger spans..................................................666 12.5.6 Extending/retracting outrigger beams.........................................668 From the control units..........................................................669 With the hand- held control.....................................................670 From the crane cab..............................................................672 12.5.7 Moving the outrigger pads into working/driving position......................674 12.5.8 Enlarging the ground bearing area............................................675 12.5.9 Extending/retracting supporting cylinders....................................677 From the control units..........................................................678 With the hand- held control.....................................................679 From the crane cab..............................................................680 12.5.10 Level the truck crane on outriggers.........................................682 Inclination indicators..........................................................682 Prerequisites...................................................................683 Manual alignment................................................................684 Automatic alignment.............................................................685 12.5.11 Levelling the free-on-wheels truck crane....................................687 12.5.12 Outrigger pressure display..................................................689 12.6 Rigging/unrigging the counterweight................................................691 12.6.1 Counterweight sections and identification....................................691 Counterweight sections..........................................................691 Identification..................................................................692 12.6.2 Slinging points at the counterweight sections................................693 12.6.3 CHECKLIST: Rigging the counterweight.........................................694 12.6.4 CHECKLIST: Unrigging the counterweight.......................................697 12.6.5 Assembling counterweight combination.........................................699 Combinations mounted on the turntable...........................................700 Other combinations..............................................................703 12.6.6 Counterweight hoist unit.....................................................705 Counterweight menu..............................................................705 Extending/ retracting the lifting cylinders.....................................706 Locking/unlocking counterweight.................................................708 12.6.7 Setting down counterweight for driving the truck crane.......................709 12.6.8 Slewing with rigged counterweight............................................710 12.7 Rigging work on the main boom......................................................711 12.7.1 Hook block on the bumper.....................................................711 Picking up the hook block.......................................................711 Attaching the hook block........................................................712 12.7.2 Hook block on a separate vehicle.............................................713 Picking up the hook block.......................................................714 Setting down the hook block.....................................................714 12.7.3 Reeving and unreeving the hoist rope.........................................716 Rope end fitting................................................................716 Fastening the rope end clamp....................................................717 Reeving the hoist rope..........................................................719 Unreeving the hoist rope........................................................722 12.7.4 Possible reeving methods on the main boom....................................723 With 4 head sheaves.............................................................723 With 5 head sheaves.............................................................725 12.7.5 Installing/removing the lifting limit switch.................................726 Installing the lifting limit switch.............................................726 Removing the lifting limit switch...............................................729 12.7.6 Locking/unlocking the lifting limit switch...................................731 Locking.........................................................................731 Removing the lock...............................................................731 12.7.7 Anemometer and air traffic control light.....................................732 Installing......................................................................732 Switching the air traffic control light on and off..............................733 Removing........................................................................733 12.8 Other rigging work.................................................................735 12.8.1 Folding mirrors in/out and adjusting.........................................735 12.8.2 Cameras for crane operation..................................................736 Cameras on the hoists...........................................................736 Camera on main boom.............................................................736 Operating the camera............................................................738 12.8.3 Stair tread on the crane cab.................................................739 13 Driving with rigged truck crane..........................................................743 13.1 Driving distance...................................................................743 13.2 Permissible rigging modes and axle loads...........................................744 13.2.1 To drive without a load......................................................744 13.2.2 To drive with a load.........................................................744 13.2.3 Axle loads...................................................................745 13.3 Before driving the rigged truck crane..............................................747 13.3.1 Check the tyre pressure and the wind speed...................................747 13.3.2 Securing the superstructure against slewing..................................747 13.3.3 Putting the truck crane on the wheels........................................748 13.4 Driving from the driver's cab......................................................751 13.4.1 Preparing to drive...........................................................751 Transmission....................................................................751 Switching on separate steering..................................................751 Connections.....................................................................751 13.4.2 While driving................................................................752 13.5 Driving from the crane cab.........................................................753 13.5.1 Preparing to drive...........................................................754 13.5.2 Opening/closing the Driving mode menu........................................755 Opening.........................................................................755 Closing.........................................................................756 13.5.3 Steering system..............................................................757 Switching on....................................................................757 Adjusting the steering direction................................................757 Displays when steering..........................................................758 Normal steering.................................................................758 Separate steering...............................................................759 13.5.4 Operating the transmission...................................................761 Driving direction...............................................................761 Crane hydraulic system on/off...................................................761 Selecting the transmission mode.................................................762 13.5.5 While driving................................................................763 DMand RM transmission mode.....................................................763 Transmission mode D.............................................................763 Warning messages................................................................763 13.5.6 Possible connections.........................................................764 Longitudinal/ transverse differential locks.....................................764 13.5.7 After driving................................................................766 14 Malfunctions during crane operation......................................................771 14.1 Emergency stop switch..............................................................771 14.2 What to do when a malfunction occurs during crane operation........................773 Load can be lowered.................................................................773 Load cannot be lowered..............................................................773 14.3 Fuses in the crane cab.............................................................775 Notes on changing fuses.............................................................775 14.4 Finding and eliminating malfunctions...............................................780 14.4.1 Malfunctions on the engine...................................................780 14.4.2 Malfunctions when operating with the hand-held control.......................780 14.4.3 Malfunctions on the turntable lock...........................................781 14.4.4 Malfunctions when inclining the crane cab....................................781 14.4.5 Malfunctions on the main hoist...............................................782 14.4.6 Malfunctions in the telescoping mechanism....................................783 14.4.7 Malfunctions in the hoist cameras............................................784 14.4.8 Malfunctions in the main boom camera.........................................784 14.4.9 Malfunctions on the derricking gear..........................................785 14.4.10 Malfunctions on the slewing gear............................................786 14.4.11 Malfunctions on the counterweight hoist unit................................787 14.4.12 Malfunctions in the hydraulic system/hydraulic oil cooler...................788 14.4.13 Malfunctions when driving from the crane cab................................788 14.4.14 Malfunctions of the outriggers..............................................789 14.4.15 Troubleshooting the crane control...........................................790 General malfunctions............................................................790 Symbols in the error or information display areas...............................791 Displays in the Error menu......................................................795 14.4.16 Malfunctions in the CraneSTAR system........................................797 14.5 Emergency operations and programmes................................................801 14.5.1 Mechanical emergency activation for retracting...............................802 Prior to the emergency operation, check.........................................802 Procedure.......................................................................802 Mechanical emergency activation.................................................803 14.5.2 Telescoping emergency programme..............................................805 Open submenu Emergency program..................................................805 Determining the error type......................................................806 Error on length indicator.......................................................807 Tables for approaching the locking points.......................................811 14.5.3 Entering the current telescoping.............................................813 14.5.4 Emergency operation with the hand-held control...............................815 Preparations....................................................................815 To pre-select a power unit......................................................816 Operating a power unit..........................................................816 Stopping movements..............................................................817 Stopping movements in emergencies...............................................818 Turning off the engine..........................................................818 14.6 Hydraulic emergency operation......................................................819 14.6.1 Connect/disconnect hoses.....................................................819 14.6.2 Establishing the required hydraulic circuits.................................820 Switching over valves...........................................................820 For lifting/lowering............................................................822 14.6.3 Performing emergency operation...............................................823 14.6.4 After the emergency activation...............................................823 14.7 Hydraulic emergency operation BGR 159..............................................825 14.7.1 Operating principle..........................................................825 14.7.2 Connecting/disconnecting hoses...............................................826 For transformers................................................................826 For the hand pump...............................................................827 14.7.3 Establishing the hydraulic circuits required.................................828 Switching positions of the valves...............................................828 Switching over valves...........................................................828 For lifting/lowering............................................................830 For slewing.....................................................................831 14.7.4 Performing emergency operation...............................................831 Derricking......................................................................832 Lifting/lowering................................................................833 Slew............................................................................833 14.7.5 After emergency operation....................................................834 Switching off emergency operation...............................................834 Switching over to crane operation...............................................834 Disconnecting the hoses.........................................................834 14.7.6 Emergency supply of another crane............................................835 After emergency supply..........................................................836 15 Index....................................................................................839 A.......................................................................................841 B.......................................................................................841 C.......................................................................................841 D.......................................................................................844 E.......................................................................................846 F.......................................................................................847 H.......................................................................................848 I.......................................................................................848 K.......................................................................................849 L.......................................................................................849 M.......................................................................................849 O.......................................................................................850 P.......................................................................................851 R.......................................................................................851 S.......................................................................................852 T.......................................................................................853 V.......................................................................................855 W.......................................................................................855
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