Grove Crane GMK 3050B Driving & Crane operation Operating Manual PDF

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Grove Crane GMK 3050B Driving & Crane operation Operating Manual 3113049 – PDF DOWNLOAD

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Grove Crane GMK 3050B Driving & Crane operation Operating Manual 3113049 – PDF DOWNLOAD

Language : English
Pages : 858
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Grove Crane GMK 3050B Driving & Crane operation 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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