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Grove Crane GMK 3060L Operating Manual 3302949 – PDF DOWNLOAD
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Description
Grove Crane GMK 3060L Operating Manual 3302949 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 3060L Operating Manual 3302949 – PDF DOWNLOAD
Language : English
Pages : 928
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 3060L Operating Manual 3302949 – PDF DOWNLOAD
Intended use:
- The GMK3060L truck crane is constructed in accordance with the latest technology
and the recognised 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 be modified only with the consent of
Manitowoc Crane Group Germany GmbH. - The GMK3060L truck crane may be used only 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 GMK3060L truck crane may only be operated without the corresponding
special equipment within thepermitted temperature range; àTechnical data,
p. 1 – 7. - The GMK3060L truck crane is designed solely for lifting loads which are within
the permitted GMK3060L 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
manual(s), 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 GMK3060L may only be operated with parts of equipment that have been
approved by Manitowoc Crane Group Germany GmbH and which are labelled with
the serial number of the GMK3060L. - The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK3060L truck crane. The user alone bears the risk.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 3060L Operating Manual 3302949 – PDF DOWNLOAD
1 Overview.................................................................................................... 35 Accidents................................................................................................. 35 Branch offices............................................................................................ 37 Manitowoc Crane Care.................................................................................. 37 Dealer list........................................................................................... 37 Warranty specifications................................................................................... 37 Terms used................................................................................................ 38 Technical data............................................................................................ 41 Maximum lifting capacity (DIN/ ISO/ EN)............................................................... 41 Dimensions and weights of the truck crane, axle loads................................................. 0 Dimensions........................................................................................ 43 Weight and axle loads............................................................................. 43 Dimensions and weights of removable parts............................................................. 44 Spare wheel....................................................................................... 44 Outriggers........................................................................................ 44 Hook blocks....................................................................................... 44 Counterweight sections............................................................................ 45 Auxiliary hoist................................................................................... 46 Carrier............................................................................................... 47 Engine............................................................................................ 47 Transmission...................................................................................... 47 Transfer case..................................................................................... 47 Axle lines........................................................................................ 47 Steering.......................................................................................... 48 Tyres............................................................................................. 48 Turning radii..................................................................................... 48 Outriggers........................................................................................ 49 Electrical system................................................................................. 50 Tool.............................................................................................. 50 Towing couplings.................................................................................. 50 Driving speeds.................................................................................... 50 Climbing ability.................................................................................. 50 Superstructure........................................................................................ 51 Main hoist........................................................................................ 51 Auxiliary hoist................................................................................... 51 Slewing gear...................................................................................... 51 Derricking gear................................................................................... 51 Main boom......................................................................................... 52 Lattice extension................................................................................. 52 Operating speeds.................................................................................. 52 Documentation supplied.................................................................................... 53 Questions on documentation............................................................................ 54 Notes on the operating manual............................................................................. 55 What do the symbols used mean?........................................................................ 55 How is the operating manual structured?............................................................... 57 Division.......................................................................................... 57 Structure of the chapters......................................................................... 57 Structure of the pages............................................................................ 58 How do I find the information I need?................................................................. 59 Cross-references example.......................................................................... 60 What information is available for operations planning?................................................ 62 Conversion table for US measuring units................................................................... 63 Training – Information.................................................................................... 65 Identification............................................................................................ 66 EC Declaration of Conformity.............................................................................. 68 Notes on the engine....................................................................................... 69 Information on the engine............................................................................. 69 2 Basic safety instructions................................................................................... 71 Intended use.............................................................................................. 71 Improper use.......................................................................................... 72 Organisational measures................................................................................... 73 Personnel qualifications.................................................................................. 75 Safety instructions for driving the truck crane........................................................... 76 Safety instructions for crane operation................................................................... 77 Instructions on transporting persons...................................................................... 80 Equipment for lifting persons......................................................................... 80 Personnel............................................................................................. 81 Operation............................................................................................. 81 Truck crane........................................................................................... 82 3 Operating elements for driving.............................................................................. 83 Overview of the operating elements........................................................................ 83 On the outside of the truck crane..................................................................... 84 Driver's cab – Overview............................................................................... 88 Overview.......................................................................................... 88 Front overview.................................................................................... 90 Side overview..................................................................................... 91 Rear overview..................................................................................... 92 Overview of doors................................................................................. 93 Steering column/steering wheel........................................................................ 94 Instrument panel...................................................................................... 95 Left/right........................................................................................ 95 Middle............................................................................................ 96 Driving mode display..............................................................................100 Transmission operating elements.......................................................................101 Tachograph............................................................................................102 Heating and air-conditioning system...................................................................103 Standard heating system...........................................................................103 Auxiliary water heating system....................................................................104 CCS control unit......................................................................................105 CCS – Menu-independent displays.......................................................................106 CCS – Start menu......................................................................................107 CCS – Overview of menu groups.........................................................................108 Carrier menu group....................................................................................110 Suspension/level adjustment menu..................................................................111 Driving menu......................................................................................112 Exhaust system menu...............................................................................113 Air intake inhibitor menu.........................................................................114 Settings menu group...................................................................................115 Set display brightness menu.......................................................................116 Information menu group................................................................................117 Operating hours menu..............................................................................118 Engine/ transmission error menu...................................................................119 Crane operation error menu........................................................................120 Various controls menu group...........................................................................121 Outrigger control units...............................................................................122 Brief description of the operating elements...............................................................123 Definition of direction information...................................................................124 Basic rule........................................................................................124 General rules for buttons and symbols on the display..................................................125 Engine................................................................................................126 Steering column...................................................................................126 Multipurpose switch...............................................................................126 Instrument panel..................................................................................127 CCS display.......................................................................................128 AdBlue (DEF) system/Exhaust gas emission control system...............................................129 Instrument panel..................................................................................129 CCS display.......................................................................................130 Air intake inhibitor..................................................................................131 Battery master switch.................................................................................133 Electrical system.....................................................................................133 Crane control CCS.....................................................................................134 Transmission..........................................................................................136 Transmission control unit.........................................................................136 Driving mode display..............................................................................139 Reverse camera........................................................................................140 BirdView system 270°..................................................................................141 Final drive...........................................................................................142 Brakes................................................................................................144 Service brake.....................................................................................144 Additional brakes.................................................................................145 Parking brake.....................................................................................146 Steering/separate steering............................................................................147 Instrument panel..................................................................................147 Driver's door.....................................................................................147 CCS display.......................................................................................148 Suspension............................................................................................151 CCS display.......................................................................................151 Lighting/windscreen wipers/horn.......................................................................152 Steering column...................................................................................152 Instrument panel..................................................................................152 CCS display.......................................................................................155 Roof..............................................................................................155 Level adjustment system...............................................................................156 CCS display.......................................................................................157 Tachograph/speedometer................................................................................158 Tachograph........................................................................................158 Cover.............................................................................................158 Speedometer.......................................................................................158 Diagnostics...........................................................................................159 Front flap............................................................................................159 Windows and doors.....................................................................................160 Window winder.....................................................................................160 Doors.............................................................................................160 Access ladders and ladders............................................................................161 4 Starting/stopping the engine – for driving..................................................................165 Starting the engine – from the driver's cab...............................................................165 CHECKLIST: Starting the engine........................................................................166 CHECKLIST: At low temperatures........................................................................169 Refuelling............................................................................................170 Fuel tank.........................................................................................170 AdBlue (DEF) tank.................................................................................172 Checks before starting the engine.....................................................................173 At the hydraulic tank.............................................................................173 Battery master switch.............................................................................174 Switching the ignition on.............................................................................174 Lamp test/comparison of the switching states..........................................................175 Lamp test.........................................................................................175 Comparison of the switching states................................................................175 Display – setting the brightness......................................................................176 In the driver's cab...............................................................................176 In the crane cab..................................................................................176 Adjusting the brightness..........................................................................176 Temperature on the display........................................................................176 Starting the engine...................................................................................177 Without flame start system........................................................................178 With flame start system...........................................................................179 Checks after starting the engine......................................................................180 Starting the engine – at the outrigger control units......................................................182 Prerequisites.........................................................................................182 Starting the engine...................................................................................182 Switching off the engine..................................................................................184 In the driver's cab...................................................................................184 After switching off...............................................................................184 On the outrigger control units........................................................................184 With emergency stop switches..........................................................................185 Resetting the emergency stop switch...............................................................185 Air intake inhibitor......................................................................................186 Opening the air intake inhibitor......................................................................186 5 Driving mode................................................................................................187 Before driving............................................................................................187 CHECKLIST: Checks before on-road driving..............................................................187 Checking the condition of the truck crane.............................................................192 Electrical system.................................................................................192 Adjusting the mirrors.............................................................................192 Warning plates for vehicle width..................................................................194 Checking the vehicle height.......................................................................194 Supply pressure...................................................................................195 Parking brake.....................................................................................196 Third brake light.................................................................................197 Adjusting the seat and the steering column............................................................198 Adjusting the driver's seat.......................................................................198 Adjusting the passenger seat......................................................................200 Adjusting the steering column.....................................................................201 Storage compartment...............................................................................201 Switching the suspension on/off.......................................................................202 Opening the menu..................................................................................202 Switching on the suspension.......................................................................203 Switching off the suspension......................................................................203 Setting the tachograph................................................................................204 Prerequisites.....................................................................................204 In the event of malfunctions......................................................................204 Setting the tachograph............................................................................205 Displaying and resetting operating hours..............................................................209 Settings/indicators on the driving mode display.......................................................210 Operating the transmission................................................................................211 Switching on..........................................................................................211 Switching the transmission to the neutral position....................................................212 Selecting the direction of travel and starting gear...................................................213 Selecting the driving direction...................................................................213 Selecting the starting gear.......................................................................214 Changing the operating mode...........................................................................215 Changing to automatic mode........................................................................215 Changing to manual mode...........................................................................215 Starting..............................................................................................216 Driving and changing gears............................................................................217 In Automatic operating mode.......................................................................217 In Manual operating mode..........................................................................218 Changing the driving direction........................................................................219 Stopping the truck crane..............................................................................219 Stopping for a long period of time................................................................219 DM and RM transmission mode...........................................................................220 Switching on......................................................................................220 Switching off.....................................................................................221 On the roller type dynamometer........................................................................222 Preheating the transmission...........................................................................222 Driving and parking the truck crane.......................................................................223 Checks while driving..................................................................................223 Brakes............................................................................................223 ABS system........................................................................................223 Steering..........................................................................................224 Warning messages..................................................................................224 Cruise control........................................................................................225 Switching on......................................................................................225 Switching off.....................................................................................226 Driving downhill......................................................................................227 Starting..........................................................................................227 Inspections when driving downhill.................................................................228 Downshifting......................................................................................228 Additional brakes.................................................................................229 Driving uphill........................................................................................230 Starting..........................................................................................230 Driving...........................................................................................230 Torque reduction......................................................................................231 AdBlue (DEF) supply...............................................................................231 System malfunction................................................................................232 Overriding torque reduction...........................................................................234 Cleaning the exhaust system...........................................................................235 Automatic cleaning................................................................................235 Manual cleaning...................................................................................236 Disabling cleaning................................................................................237 Parking the truck crane...............................................................................238 Securing against rolling away.....................................................................238 When stationary for more than 8 hours.............................................................239 Fold-up berth.........................................................................................240 Off-road driving..........................................................................................241 Adjustments to the transmission.......................................................................241 Connections...........................................................................................241 Changing the vehicle level............................................................................241 Rocking the vehicle free and towing...................................................................241 Longitudinal and transverse differential locks........................................................242 Operating the level adjustment system.................................................................244 Opening the menu..................................................................................244 Setting the on-road level.........................................................................245 Pre-selecting suspension struts...................................................................246 Changing the vehicle level........................................................................246 Viewing the current inclination...................................................................247 Exiting the menu..................................................................................247 Freeing a stuck truck crane...........................................................................248 Rocking the truck crane free......................................................................248 Towing free forwards..............................................................................249 Towing free in reverse gear.......................................................................249 Separate steering.........................................................................................251 Switching to separate steering........................................................................252 Switching to normal steering mode.....................................................................254 Heating and air-conditioning system.......................................................................255 Standard heating system...............................................................................255 Switching on......................................................................................255 Heating...........................................................................................255 Air distribution..................................................................................256 Examples..........................................................................................257 Switching off.....................................................................................257 Air-conditioning system...............................................................................258 Notes.............................................................................................258 Switching on/off..................................................................................258 Cooling...........................................................................................259 Drying............................................................................................259 Auxiliary water heating system........................................................................260 Preheating the engine.............................................................................260 Preheating the driver's cab.......................................................................261 Switching on......................................................................................261 Setting the date and time.........................................................................263 Storing the heating start.........................................................................264 Battery heater........................................................................................266 Radio.....................................................................................................266 Towing a trailer..........................................................................................267 Effects on the axle loads.............................................................................267 Coupling the trailer..................................................................................268 Connecting the supply lines...........................................................................269 Removing the supply lines.............................................................................270 Uncoupling the trailer................................................................................270 Checking the braking force............................................................................272 6 Driving modes...............................................................................................273 Driving modes.............................................................................................273 Information about the axle loads......................................................................273 Notes on how to use the tables........................................................................274 Table for a maximum axle load of 12 t.................................................................275 Tyres 385/95 R25..................................................................................275 Tyres 445/95 R25..................................................................................276 Tyres 525/80 R25..................................................................................277 Maximum permitted speeds with an axle load of over 12 t...............................................278 Weighing the truck crane..................................................................................279 Axle groups...........................................................................................280 Weighing procedure....................................................................................281 Evaluation............................................................................................282 7 Transport...................................................................................................283 Transport with transport vehicle..........................................................................283 CHECKLIST: Checks before transport....................................................................284 Driving the truck crane on to the transport vehicle and lashing down..................................286 Transport by ship.........................................................................................287 8 Malfunctions in driving mode................................................................................289 Emergency stop switch.....................................................................................289 What to do when malfunctions occur........................................................................290 Procedure in the event of a malfunction in road traffic...............................................290 Warning and error messages................................................................................291 Warning and malfunction messages on the instrument panel..............................................291 Meaning of the lamps..............................................................................291 Warning messages on the driving mode display..........................................................296 Error messages....................................................................................296 Warning messages on the CCS display...................................................................298 Representation of the symbol frame................................................................298 Symbols on the CCS display........................................................................299 Error messages on the CCS display.....................................................................311 Exiting the menu..................................................................................312 Troubleshooting...........................................................................................313 Engine malfunctions...................................................................................313 Faults on the Adblue (DEF) system.....................................................................315 Differential lock malfunctions........................................................................315 Malfunctions in the transmission......................................................................316 Steering malfunctions.................................................................................317 Service brake malfunctions............................................................................318 Malfunctions of the level adjustment system...........................................................319 Malfunctions in the hydraulic system/hydraulic oil cooler.............................................319 Malfunctions in the CCS control unit..................................................................319 Emergency operation and breakdown assistance..............................................................321 Externally starting the truck crane...................................................................321 Battery charger.......................................................................................322 Prerequisites.....................................................................................322 Towing the truck crane................................................................................323 In the case of engine/ transmission damage........................................................323 Longer towing distances...........................................................................326 Tow starting......................................................................................326 Wheel change..........................................................................................327 Removing a damaged wheel..........................................................................327 On the spare wheel holder.........................................................................328 Mounting a wheel..................................................................................329 Inflating the tyres yourself..........................................................................331 Connecting the filling hose.......................................................................331 Inflating the tyres...............................................................................332 Removing the filling hose.........................................................................332 Tilting/lowering the driver's cab.........................................................................333 Prerequisites and information on tilting..............................................................333 Tilting and lowering the driver's cab.................................................................334 Operating the hand pump...........................................................................334 Tilting the driver's cab..........................................................................335 Lowering the driver's cab.........................................................................336 Fuses on the carrier......................................................................................337 Notes on changing fuses...............................................................................337 Fuses in the driver's cab.............................................................................338 Fuses in the battery box..............................................................................344 9 Operating elements for crane operation......................................................................345 Overview of the operating elements........................................................................345 Exterior of the truck crane...........................................................................346 Crane cab.............................................................................................350 Side panel........................................................................................352 Crane cab, rear...................................................................................354 Control panels........................................................................................356 Left..............................................................................................356 Right.............................................................................................357 Control lever configuration...........................................................................358 Version 1.........................................................................................358 Version 2.........................................................................................359 Heating/Air-conditioning system.......................................................................360 CCS control unit......................................................................................362 Menu-independent displays.............................................................................364 CCS – Start menu......................................................................................365 RCL display.......................................................................................366 Slewing ranges/ working radii display.............................................................367 CCS – Overview of menu groups.........................................................................368 Superstructure menu group.............................................................................372 Superstructure lock menu..........................................................................373 Counterweight menu................................................................................374 Outrigger/driving menu group..........................................................................375 Outrigger beam menu...............................................................................376 Outrigger cylinders menu..........................................................................378 Driving menu......................................................................................380 Exhaust system menu...............................................................................382 Air intake inhibitor menu.........................................................................383 RCL/Telescoping menu group............................................................................385 Enter rigging mode/telescope status menu..........................................................386 Pre-selection telescoping menu....................................................................390 Lifting capacity tables menu......................................................................392 Telescoping semi-automation menu..................................................................393 Manual telescoping menu...........................................................................394 Working range limiter menu group......................................................................395 Overall height menu...............................................................................396 Working radius menu...............................................................................397 Slewing angle menu................................................................................398 Hoist rope travel limitation menu.................................................................399 Information menu group 1..............................................................................400 Hydraulic pressure and fuel consumption menu......................................................401 Heating/Engine/Additional equipment menu group........................................................402 Remote control menu...............................................................................403 Telescoping emergency program menu group..............................................................404 Telescoping emergency program menu................................................................406 Unknown telescoping menu..........................................................................408 Settings menu group...................................................................................409 Crane cab menu....................................................................................410 Set display brightness and date/time menu.........................................................411 Switch units menu.................................................................................412 Set control lever characteristic curve menu.......................................................413 Power unit speeds menu............................................................................414 Information menu group 2..............................................................................415 Operating hours menu..............................................................................416 Engine/ transmission error menu...................................................................417 Crane operation error menu........................................................................418 Program version menu..............................................................................419 Various controls......................................................................................420 Query menus...........................................................................................421 RCL control unit......................................................................................422 Menu-independent displays.............................................................................423 RCL – menus...........................................................................................424 Monitoring menu...................................................................................424 Lifting capacity tables menu......................................................................426 Datalogger menu...................................................................................427 Hand-held control.....................................................................................428 Outrigger control units...............................................................................429 Menu-independent buttons..........................................................................429 Outrigger menu....................................................................................430 Brief description of the operating elements...............................................................433 Definition of direction information...................................................................433 Basic rule........................................................................................433 General rules for buttons and symbols on the display..................................................434 Engine................................................................................................435 CCS display.......................................................................................435 Side panel........................................................................................435 AdBlue (DEF) system/Exhaust gas emission control system...............................................436 CCS display.......................................................................................436 Air intake inhibitor..................................................................................437 CCS display.......................................................................................437 Seat contact switch and dead man's switch.............................................................438 Crane control CCS.....................................................................................439 Outrigger – crane cab.................................................................................444 Control panels....................................................................................444 CCS display.......................................................................................445 Outrigger control units...............................................................................447 General information...............................................................................447 Outrigger menu....................................................................................448 Inclination indicators................................................................................450 Outrigger pressure displays...........................................................................451 Outrigger menu....................................................................................451 Outrigger control units...........................................................................451 Anemometer displays...................................................................................451 Counterweight menu....................................................................................452 CCS display.......................................................................................455 Main hoist............................................................................................456 Control panels....................................................................................456 CCS display.......................................................................................456 Auxiliary hoist.......................................................................................458 Control panels....................................................................................458 CCS display.......................................................................................458 Slewing gear..........................................................................................460 Control panels....................................................................................460 CCS display.......................................................................................461 Derricking gear.......................................................................................462 Control panels....................................................................................462 CCS display.......................................................................................463 Side panel........................................................................................463 Telescoping mechanism.................................................................................464 Control panels....................................................................................464 CCS display.......................................................................................465 Telescoping semi-automation menu..................................................................465 Manual telescoping menu...........................................................................467 Hydraulic system......................................................................................470 CCS display.......................................................................................470 Superstructure lock menu..............................................................................471 Turntable lock....................................................................................471 Houselock.........................................................................................473 CCS display.......................................................................................473 Remote control........................................................................................474 Rated capacity limiter (RCL)..........................................................................475 CCS display.......................................................................................475 RCL display.......................................................................................484 RCL override – version A..........................................................................485 RCL override – version B..........................................................................486 Electrical system.....................................................................................487 Lighting, windscreen wiper/washing system.............................................................488 Lighting..........................................................................................488 Windscreen wiper/ washing system..................................................................490 Horn..............................................................................................491 Hand-held control.....................................................................................492 Engine control panel..............................................................................492 Horn..............................................................................................492 Pre-select emergency operation....................................................................493 Windows and doors.....................................................................................494 Windows...........................................................................................494 Rear window.......................................................................................494 Crane cab door....................................................................................495 Diagnostics...........................................................................................496 Other.................................................................................................496 Short description of the operating elements – driving from the crane cab..................................497 Driving menu..........................................................................................497 Transmission..........................................................................................499 Final drive...........................................................................................501 Brakes................................................................................................502 CCS display.......................................................................................502 Side panel from above.............................................................................502 Steering..............................................................................................504 CCS display.......................................................................................504 Control panels....................................................................................507 10 Starting/switching off the engine – for crane operation....................................................509 When starting the engine for the first time in the day....................................................509 Starting the engine – from the crane cab..................................................................511 Checking the fuel level and AdBlue (DEF) level........................................................511 Fuel..............................................................................................511 AdBlue (DEF)......................................................................................511 Checks before starting the engine.....................................................................512 Checks on the carrier.............................................................................512 Checking the hand-held control....................................................................512 Switching on the ignition.............................................................................512 Control lever deflection query........................................................................513 Comparison of switching states........................................................................514 Display – setting the brightness......................................................................515 Starting the engine...................................................................................515 Checks after starting the engine......................................................................516 Setting idling speed..................................................................................517 Starting the engine – with the hand-held control..........................................................518 Switching off the engine..................................................................................518 When the hand-held control is connected...............................................................518 In the crane cab......................................................................................519 After switching off...............................................................................519 Using the emergency stop switches.....................................................................520 Resetting the emergency stop switch...............................................................520 11 Crane operation............................................................................................521 Before operating the crane................................................................................521 CHECKLIST: Checks before operating the crane..........................................................521 Checking the condition of the truck crane.............................................................525 Crane cab heater fuel tank........................................................................525 Visual inspection.................................................................................525 Checking the position of the hoist ropes..........................................................526 Checking the electrical system....................................................................527 Adjusting the crane cab seat and front control panel..................................................528 Crane cab seat....................................................................................528 Control panels....................................................................................529 Front control panel...............................................................................530 Checking the safety devices...........................................................................531 Rated capacity limiter............................................................................531 Lifting limit switch..............................................................................531 Emergency stop switch.............................................................................532 Seat contact switch...............................................................................533 Earthing the load.....................................................................................535 Locking/unlocking the turntable.......................................................................536 Locking points....................................................................................536 Locking the turntable.............................................................................537 Unlocking the turntable...........................................................................537 Switching the houselock on/off........................................................................538 Switching on the houselock........................................................................538 Switching off the houselock.......................................................................540 Setting the time......................................................................................541 Standard slewing range type...............................................................................543 Permissible slewing ranges and operating positions....................................................543 360° slewing range................................................................................543 Operating position 0° to the rear.................................................................543 180° to the front rigging position................................................................543 Free-on-wheels operating position.................................................................544 MAXbase slewing range type................................................................................545 Specifications in the lifting capacity tables.........................................................547 Enabled slewing ranges................................................................................548 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables....550 Operation of the rated capacity limiter...................................................................551 Switching on the RCL..................................................................................552 Switching on......................................................................................552 Entering the rigging mode.............................................................................554 Notes on Input....................................................................................554 Enter the slewing range type......................................................................555 Entering individual components....................................................................556 Entering the RCL code.............................................................................562 Pre-selecting telescoping.............................................................................562 Confirming the rigging mode and lifting capacity table................................................563 Slewing range type Standard.......................................................................563 Slewing range type MAXbase........................................................................565 Checks before operating the crane.....................................................................567 Monitoring menu...................................................................................567 Checking the rigging mode.........................................................................567 Hoist checking....................................................................................570 Displays during the crane operation...................................................................571 On the RCL display................................................................................571 On the CCS display................................................................................575 RCL early warning.....................................................................................579 RCL shutdown..........................................................................................579 Shutdown due to overload..........................................................................579 Displaying the lifting capacity tables................................................................581 Standard slewing range type.......................................................................581 Slewing range type MAXbase........................................................................583 RCL override – version A..............................................................................585 Overview status display...........................................................................585 When rigging......................................................................................586 To raise the boom.................................................................................587 In emergencies....................................................................................588 RCL override – version B..............................................................................589 Datalogger............................................................................................590 Export data.......................................................................................590 Display the data..................................................................................591 Crane operation with main boom............................................................................595 Checks during crane operation.........................................................................595 Horizontal alignment..............................................................................595 Safe distances....................................................................................595 Checking the wind speed...........................................................................596 Deformation of the main boom due to direct sunlight...............................................597 Main hoist............................................................................................599 Switching on the main hoist.......................................................................600 Lifting and lowering..............................................................................601 Maximum permissible hoist rope speed..............................................................602 Switching off the main hoist......................................................................602 Auxiliary hoist.......................................................................................603 Switching on the auxiliary hoist..................................................................603 Lifting and lowering..............................................................................604 Maximum permissible hoist rope speed..............................................................605 Switching off the auxiliary hoist.................................................................605 Lifting limit switch and lowering limit switch........................................................606 Lifting limit switch..............................................................................606 Lowering limit switch.............................................................................608 Derricking gear.......................................................................................609 Switching on the derricking gear..................................................................609 Raising and lowering..............................................................................610 Maximum derricking speed..........................................................................611 Re-enabling the raising function..................................................................611 Switching off the derricking gear.................................................................612 Lowering the main boom to a horizontal position...................................................612 Telescoping mechanism.................................................................................613 Overview..........................................................................................615 Telescoping process...............................................................................616 Assignment for display............................................................................618 Fixed length, intermediate length, telescoping length.............................................619 Telescoping.......................................................................................620 Telescoping sequence..............................................................................620 Checks before starting work.......................................................................621 Switching on the telescoping mechanism............................................................622 Function of the control lever.....................................................................622 Switching off the telescoping mechanism...........................................................624 Manual telescoping................................................................................625 Checking the initial position.....................................................................625 Unlocking the telescoping cylinder................................................................627 Extending/retracting the telescoping cylinder.....................................................629 Lock telescoping cylinder.........................................................................630 Unlocking the telescopic section..................................................................631 Telescoping the telescopic section................................................................632 Locking the telescopic section....................................................................633 Locking the telescopic section for on-road driving................................................634 Telescoping with semi-automation..................................................................634 Telescoping with pre-selection....................................................................636 High-speed mode.......................................................................................637 Derricking gear/ telescoping mechanism............................................................637 Hoists............................................................................................638 Slewing gear..........................................................................................639 Slewing gear brake................................................................................639 Switching on the slewing gear.....................................................................640 Releasing the slewing gear brake..................................................................640 Engaging the slewing gear brake...................................................................640 Slewing...........................................................................................641 Maximum slewing speed.............................................................................642 Braking the slewing movement......................................................................643 Slewing gear freewheel............................................................................643 Switching off the slewing gear....................................................................644 Slewing speed – Switching the reduction on and off....................................................645 Switching reduction off...........................................................................645 Possible movement combinations........................................................................646 Settings and displays for crane operation.................................................................647 Inclining the crane cab...............................................................................647 Setting idling speed..................................................................................648 Adjusting the wiper stroke interval of the windscreen wiper...........................................648 Limiting the power unit speeds........................................................................649 Switching the units of measure........................................................................650 Setting the characteristic curves for the control levers..............................................651 Using the slewable spotlights.........................................................................652 Displaying the operating hours........................................................................653 Working range limiter.....................................................................................655 viewing current settings..............................................................................656 On the RCL display................................................................................656 In the CCS Start menu.............................................................................657 Opening the working range limiter menu................................................................657 Enter limit values – for the overall height...........................................................658 Entering limit values – for the working radius........................................................660 Enter limit values – for the slewing range............................................................662 Enter limit values – for the hoist rope travel........................................................665 Shutdown by working range limiter.....................................................................667 Work break................................................................................................669 In case of short work breaks..........................................................................669 In case of work breaks longer than 8 hours............................................................670 To secure the truck crane.........................................................................670 Heating and air-conditioning system.......................................................................671 Heating system........................................................................................671 Switching on......................................................................................671 Heating...........................................................................................672 Air distribution..................................................................................673 Setting the day and time..........................................................................674 Storing the heating start.........................................................................675 Setting the heating period........................................................................676 Switching the heating start on and off............................................................676 Switching off.....................................................................................677 Setting the remaining time........................................................................677 Air-conditioning system...............................................................................678 Notes.............................................................................................678 Switching on......................................................................................678 Drying the air....................................................................................679 Switching off.....................................................................................679 CraneSTAR system..........................................................................................680 Overview..............................................................................................680 Position of the components............................................................................680 12 Rigging work...............................................................................................681 Rigging work checklists for crane operation with the main boom............................................681 CHECKLIST: Rigging....................................................................................681 CHECKLIST: Unrigging..................................................................................686 Selecting the suitable site...............................................................................689 Determining the required load-bearing area............................................................689 Safe distance from slopes and pits....................................................................692 Earthing the truck crane..............................................................................693 Safe distance from overhead power lines...............................................................694 Outriggers – Overview – Standard slewing range type.......................................................697 representation in the lifting capacity tables.........................................................697 Enabled outrigger spans...............................................................................698 Outriggers – Overview – MAXbase slewing range type........................................................699 Definitions...........................................................................................699 Representation in the lifting capacity tables.........................................................701 Enabled outrigger spans...............................................................................702 Operating the outriggers..................................................................................707 CHECKLIST: Extending the outriggers...................................................................707 CHECKLIST: Retracting the outriggers..................................................................709 Preparing the truck crane.............................................................................710 Setting the spans.....................................................................................711 For on-road driving...............................................................................712 Extending/retracting outrigger beams..................................................................713 From the control units............................................................................714 From the crane cab................................................................................715 Moving the outrigger pads into operating/driving position.............................................717 Enlarging the load-bearing area.......................................................................718 Extending/retracting supporting cylinders.............................................................719 From the control units............................................................................720 From the crane cab................................................................................721 Levelling the truck crane on outriggers horizontally..................................................723 Inclination indicators............................................................................723 Prerequisites.....................................................................................724 Manual alignment..................................................................................725 Automatic alignment...............................................................................726 Levelling the free-standing truck crane...............................................................727 Outrigger pressure display............................................................................728 Rigging/unrigging the counterweight.......................................................................731 Information on rigging................................................................................731 When rigging......................................................................................731 When unrigging....................................................................................732 Counterweight sections................................................................................733 Identification........................................................................................734 Slinging points on the counterweight sections.........................................................735 CHECKLIST: Rigging the counterweight..................................................................737 CHECKLIST: Unrigging the counterweight................................................................738 Assembling counterweight versions – on the turntable..................................................740 Assembling counterweight versions – on the counterweight platform.....................................741 Setting down the 1.0 t base plate.................................................................742 Counterweight hoist unit..............................................................................745 Counterweight menu................................................................................745 Extending/ retracting the lifting cylinders.......................................................746 Automatic rigging.................................................................................748 Automatic unrigging...............................................................................750 Cancelling automatic mode.........................................................................751 Removing/installing the counterweight on the turntable................................................752 Removing..........................................................................................752 Installing........................................................................................753 Setting down the counterweight for driving............................................................753 Slewing with rigged counterweight.....................................................................755 Installing/removing the auxiliary hoist/0.5 t section.....................................................757 Slinging the auxiliary hoist..........................................................................757 CHECKLIST: Installing the auxiliary hoist/removing the 0.5 t plate....................................758 CHECKLIST: Removing the auxiliary hoist/installing the 0.5 t plate....................................759 Establishing/disconnecting the connection between the auxiliary hoist and the turntable...............760 Establishing/disconnecting the hydraulic connection...................................................761 Establishing/disconnecting the electrical connection..................................................762 Establishing/disconnecting the connection to the central lubrication..................................763 Checking that the auxiliary hoist is functioning properly.............................................764 Slewing direction.................................................................................764 Slewing indicator.................................................................................764 Rigging the 0.5 t section.................................................................................765 Prerequisites.........................................................................................765 Slinging the 0.5 t section............................................................................765 Establishing/disconnecting the connection between the 0.5 t section and the turntable.................766 Transporting the auxiliary hoist/0.5 t section........................................................767 Rigging work on the main boom.............................................................................769 Hook block on the bumper..............................................................................769 Picking up the hook block.........................................................................769 Attaching the hook block..........................................................................770 Hook block on a separate vehicle......................................................................771 Picking up the hook block.........................................................................772 Setting down the hook block.......................................................................772 Reeving and unreeving the hoist rope..................................................................774 Reeving the hoist rope............................................................................776 Unreeving the hoist rope..........................................................................779 Possible reeving methods on the main boom.............................................................781 With 5 head sheaves...............................................................................781 With 6 head sheaves...............................................................................784 Installing/removing the lifting limit switch..........................................................787 Installing the lifting limit switch...............................................................787 Removing the lifting limit switch.................................................................790 Locking/unlocking the lifting limit switch............................................................792 Locking...........................................................................................792 Unlocking.........................................................................................792 Anemometer and air traffic control light..............................................................793 Installing........................................................................................793 Switching on/off..................................................................................794 Removing..........................................................................................795 Other rigging work........................................................................................797 Folding the mirrors in and out, and adjusting them....................................................797 Cameras for crane operation...........................................................................798 Camera on main boom...............................................................................798 Camera on the hoists..............................................................................801 Camera on the driver's cab........................................................................801 Operating the camera..............................................................................802 Step at the crane cab.................................................................................804 13 Driving with a rigged truck crane..........................................................................805 Driving route.............................................................................................805 Permissible rigging modes and axle loads..................................................................806 Axle load table.......................................................................................806 To drive without a load...............................................................................809 To drive with a load..................................................................................810 Axle loads............................................................................................810 Before driving the rigged truck crane.....................................................................811 Checking tyre pressure and wind speed.................................................................811 Secure the superstructure against slewing.............................................................811 Putting the truck crane on the wheels.................................................................812 Driving from the driver's cab.............................................................................815 Preparing to drive....................................................................................815 Transmission......................................................................................815 Switching on separate steering....................................................................815 Connections.......................................................................................816 While driving.........................................................................................816 After driving.........................................................................................817 Driving from the crane cab................................................................................819 Preparing to drive....................................................................................820 Opening/closing the Driving menu......................................................................821 Opening menu......................................................................................821 Selecting the operating mode......................................................................821 Crane's hydraulic system Driving mode.............................................................823 Closing menu......................................................................................823 Steering..............................................................................................824 Switching on......................................................................................824 Display and steering direction....................................................................824 Changing the steering direction...................................................................825 Displays when steering............................................................................825 Separate steering.................................................................................826 Normal steering...................................................................................829 Operating the transmission............................................................................830 Selecting the transmission mode...................................................................830 While driving.........................................................................................831 DM and RM transmission mode.......................................................................831 Transmission mode D...............................................................................831 Warning messages..................................................................................831 Possible connections..................................................................................832 Longitudinal/ transverse differential locks.......................................................832 After driving.........................................................................................834 14 Malfunctions during crane operation........................................................................835 Emergency stop switch.....................................................................................835 What to do when malfunctions occur during crane operation.................................................836 The load can be set down..............................................................................836 Load cannot be set down...............................................................................836 Warning and error messages................................................................................837 Program version.......................................................................................837 Warning messages on the CCS display...................................................................837 Error messages on the CCS display.....................................................................838 Warning messages on the RCL display...................................................................840 Troubleshooting...........................................................................................845 Engine malfunctions...................................................................................845 Malfunctions on the main hoist/auxiliary hoist........................................................845 Malfunctions in the hoist cameras.....................................................................847 Malfunctions in the main boom camera..................................................................847 Malfunctions in the derricking gear...................................................................848 Malfunctions in the telescoping mechanism.............................................................849 Malfunctions in the slewing gear......................................................................850 Malfunctions in the counterweight hoist unit..........................................................852 Malfunctions in the hydraulic system/hydraulic oil cooler.............................................852 Malfunctions when operating with the hand-held control................................................853 Malfunctions crane cab................................................................................853 Malfunctions on the outriggers........................................................................854 Malfunctions on the turntable lock....................................................................854 Malfunctions on the CCS/RCL control units.............................................................855 Malfunctions when driving from the crane cab..........................................................855 Malfunctions on the CraneSTAR system..................................................................856 Emergency operations and programs.........................................................................859 Mechanical emergency activation for retracting........................................................860 Checks before emergency activation................................................................860 Procedure.........................................................................................860 Mechanical emergency activation...................................................................861 Telescoping emergency program.........................................................................863 Opening telescoping emergency program menu........................................................863 Notes on the displays.............................................................................864 Checks in the emergency program...................................................................866 Retracting with emergency program.................................................................870 Tables for approaching the locking points.........................................................872 Entering the current telescoping......................................................................874 Emergency operation with the hand-held control........................................................876 Sockets...........................................................................................876 Connection........................................................................................877 Button combinations...............................................................................878 Emergency operation...............................................................................879 Notes on slewing in emergency operation...............................................................881 For the standard slewing range type...............................................................881 For the MAXbase slewing range type................................................................882 Slewing with an overridden slewing gear shutdown......................................................883 Hydraulic emergency operation with the hand pump..........................................................884 Connecting/disconnecting hoses........................................................................885 Establishing the required hydraulic circuits..........................................................886 Switching over valves.............................................................................886 For lifting/lowering the load.....................................................................887 Performing emergency activation.......................................................................888 After emergency activation............................................................................889 Hydraulic emergency operation as per DGUV.................................................................890 Applications and function.............................................................................890 CHECKLIST: Emergency operation........................................................................892 CHECKLIST: After emergency operation..................................................................893 For self-supply – connecting/disconnecting hoses......................................................894 For external supply – connecting/disconnecting the transformer........................................895 Establishing the required hydraulic circuits..........................................................896 Valves at the control panel.......................................................................896 For lifting/lowering..............................................................................897 For slewing.......................................................................................898 Performing emergency operation........................................................................899 Lifting/lowering..................................................................................899 Slewing...........................................................................................900 Derricking........................................................................................901 Emergency supply of another crane.....................................................................902 For emergency supply..............................................................................902 After emergency supply............................................................................902 Switching emergency operation on/off..................................................................903 Fuses in the crane cab....................................................................................904 Notes on changing fuses...............................................................................904 15 Index......................................................................................................911 A.........................................................................................................913 B.........................................................................................................913 C.........................................................................................................913 D.........................................................................................................916 E.........................................................................................................917 F.........................................................................................................918 H.........................................................................................................918 I.........................................................................................................919 L.........................................................................................................920 M.........................................................................................................920 O.........................................................................................................921 R.........................................................................................................922 S.........................................................................................................923 T.........................................................................................................924 W.........................................................................................................925
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